Fronius Fronius IG USA - LT-AC-SR2, LT-AC-SR-4 und IG-DC-DC Installation Instruction [EN, ES, FR]
/ Battery Charging Systems / Welding Technology / Solar Electronics
EN-US
ES
FR
LT-AC-SR2, LT-AC-SR4
IG-DC-DC
Installation instructions
Inverter for grid-connected photovoltaic systems
instrucciones de instalación
Inversores para instalaciones fotovoltaicas acopladas a la red
Instructions d'installation
Onduleur pour installations photovoltaïques connectées au réseau
42,0410,1854 003-06052013
0
Dear reader,
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarize yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features it has to offer. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.
EN-US
1
2
Contents
Safety rules ................................................................................................................................................ 5
Safety Rules Explanation...................................................................................................................... 5
General ................................................................................................................................................. 5
Utilization in Accordance with "Intended Purpose" ...............................................................................6
Environmental Conditions ..................................................................................................................... 6
Qualified Service Engineers.................................................................................................................. 6
Safety Measures at the Installation Location ........................................................................................ 6
EMC Device Classifications .................................................................................................................. 7
EMC Measures ..................................................................................................................................... 7
Electrical Installations ........................................................................................................................... 7
Protective Measures against ESD ........................................................................................................ 7
Safety Measures in Normal Operation.................................................................................................. 7
Safety Symbols ..................................................................................................................................... 8
Disposal ................................................................................................................................................ 8
Backup.................................................................................................................................................. 8
Copyright............................................................................................................................................... 8
General ...................................................................................................................................................... 9
Safety.................................................................................................................................................... 9
ESD Guidelines..................................................................................................................................... 9
General ................................................................................................................................................. 10
Required Tools And Materials............................................................................................................... 10
Open inverters and discharge capacitors .................................................................................................. 11
Opening the Inverter ............................................................................................................................. 11
Discharging the Capacitors................................................................................................................... 12
Replacing the LT-AC-SRx PC Board ......................................................................................................... 13
Removing the LT-AC-SRx PC Board.................................................................................................... 13
Replacing the LT-AC-SRx PC Board .................................................................................................... 13
Replacing the IG-DC-DC PC Board........................................................................................................... 15
Removing the IG-DC-DC PC Board...................................................................................................... 15
Installing the IG-DC-DC PC Board........................................................................................................ 16
Closing and turning on the inverter ............................................................................................................ 18
Closing the Inverter and Switching it on................................................................................................ 18
EN-US
3
4
Safety rules
EN-US
Safety Rules Explanation
General
DANGER! Indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING! Indicates a potentially hazardous situation which, if not avoided, will
result in death or serious injury.
CAUTION! Indicates a potentially harmful situation which, if not avoided, may result in minor and moderate injury or property damage.
NOTE! Indicates a risk of flawed results and possible damage to the equipment.
IMPORTANT! Indicates tips for correct operation and other particularly useful information.
It does not indicate a potentially damaging or dangerous situation.
If you see any of the symbols depicted in the "Safety rules," special care is required.
The device is manufactured using state-of-the-art technology and according
to recognized safety standards. If used incorrectly or misused, however, it can
cause
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operator,
- inefficient operation of the device
All persons involved in commissioning, maintaining and servicing the device
must
- be suitably qualified,
- have knowledge of and experience in dealing with electrical installations
and
- read and follow these operating instructions carefully
The operating instructions must always be at hand wherever the device is being used. In addition to the operating instructions, attention must also be paid
to any generally applicable and local regulations regarding accident prevention and environmental protection.
All safety and danger notices on the device
- must be kept in a legible state
- must not be damaged/marked
- must not be removed
- must not be covered, pasted or painted over
For the location of the safety and danger notices on the device, refer to the
section headed "General" in the operating instructions for the device.
Before switching on the device, remove any faults that could compromise
safety.
Your personal safety is at stake!
5
Utilization in Accordance with
"Intended Purpose"
The device is to be used exclusively for its intended purpose.
Utilization for any other purpose, or in any other manner, shall be deemed to
be "not in accordance with the intended purpose." The manufacturer shall not
be liable for any damage resulting from such improper use.
Utilization in accordance with the "intended purpose" also includes
- carefully reading and obeying all the instructions and all the safety and
danger notices in the operating instructions
- performing all stipulated inspection and servicing work
- installation as specified in the operating instructions
The following guidelines should also be applied where relevant:
- Regulations of the utility regarding energy fed into the grid
- Instructions from the solar module manufacturer
Environmental
Conditions
Qualified Service
Engineers
Operation or storage of the device outside the stipulated area will be deemed
as "not in accordance with the intended purpose." The manufacturer is not responsible for any damages resulting from unintended use.
For exact information on permitted environmental conditions, please refer to
the "Technical data" in the operating instructions.
The servicing information contained in these operating instructions is intended
only for the use of qualified service engineers. An electric shock can be fatal.
Do not perform any actions other than those described in the documentation.
This also applies to those who may be qualified.
All cables and leads must be secured, undamaged, insulated and adequately
dimensioned. Loose connections, scorched, damaged or inadequately dimensioned cables and leads must be immediately repaired by authorized personnel.
Maintenance and repair work must only be carried out by authorized personnel.
It is impossible to guarantee that externally procured parts are designed and
manufactured to meet the demands made on them, or that they satisfy safety
requirements. Use only original replacement parts (also applies to standard
parts).
Do not carry out any modifications, alterations, etc. without the manufacturer's
consent.
Components that are not in perfect condition must be changed immediately.
Safety Measures
at the Installation
Location
6
When installing devices with openings for cooling air, ensure that the cooling air can enter
and exit unhindered through the vents. Only operate the device in accordance with the degree of protection shown on the rating plate.
EMC Device Classifications
Devices in emission class A:
- Are only designed for use in industrial settings
- Can cause line-bound and radiated interference in other areas
Devices in emission class B:
- Satisfy the emissions criteria for residential and industrial areas.
This is also true for residential areas in which the energy is supplied from the public low-voltage grid.
EMC device classification as per the rating plate or technical data.
EN-US
EMC Measures
Electrical Installations
Protective Measures against
ESD
In certain cases, even though a device complies with the standard limit values
for emissions, it may affect the application area for which it was designed (e.g.,
when there is sensitive equipment at the same location, or if the site where the
device is installed is close to either radio or television receivers). If this is the
case, then the operator is obliged to take appropriate action to rectify the situation.
Electrical installations must only be carried out according to relevant national
and local standards and regulations.
Danger of damage to electrical components from electrical discharge. Suitable
measures should be taken to protect against ESD when replacing and installing components.
Safety Measures
in Normal Operation
Only operate the device when all protection devices are fully functional. If the
protection devices are not fully functional, there is a risk of
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operator,
- inefficient operation of the device
Any safety devices that are not functioning properly must be repaired by authorized personnel before the device is switched on.
Never bypass or disable protection devices.
7
Safety Symbols
Devices marked with the UL test mark satisfy the requirements of the relevant
standards for the USA.
Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada and the USA.
Disposal
Backup
Copyright
Do not dispose of this device with normal domestic waste! To comply with the
European Directive 2002/96/EC on Waste Electrical and Electronic Equipment and its implementation as national law, electrical equipment that has
reached the end of its life must be collected separately and returned to an approved recycling facility. Any device that you no longer require must be returned to your dealer, or you must locate the approved collection and recycling
facilities in your area. Ignoring this European Directive may have potentially
adverse affects on the environment and your health!
The user is responsible for backing up any changes made to the factory settings. The manufacturer accepts no liability for any deleted personal settings.
Copyright of these operating instructions remains with the manufacturer.
Text and illustrations are technically correct at the time of going to print. The
right to make modifications is reserved. The contents of the operating instructions shall not provide the basis for any claims whatsoever on the part of the
purchaser. If you have any suggestions for improvement, or can point out any
mistakes that you have found in the operating instructions, we will be most
grateful for your comments.
8
General
EN-US
Safety
WARNING! An electric shock can be fatal. Danger from grid voltage and DC volt-
age from solar modules.
- All electrical installations must be carried out in accordance with the National
Electrical Code, ANSI/NFPA 70, and any other codes and regulations applicable to the installation site.
- For installations in Canada, the installations must be carried out in accordance with applicable Canadian standards.
- The connection area should only be opened by an authorized electrician.
- The power stage set area should only be opened by Fronius-trained service
technicians.
Never work with live wires! Prior to all connection work, make sure that the AC
and DC wires are not charged.
WARNING! An electric shock can be fatal. Danger from residual voltage from capacitors.
You must wait until the capacitors have discharged. Discharging time lasts 5 minutes.
Using a suitable measurement device, ensure that the capacitors have fully discharged.
WARNING! Incorrect operation and work performed incorrectly can cause serious injury and damage! Only qualified staff are authorized to install your inverter
and only within the scope of the respective technical regulations. Do not start operation or carry out servicing and repair tasks before you have read the chapter
"Safety Instructions."
ESD Guidelines
NOTE! Observe ESD guidelines when handling electronic components and PC
boards. This primarily applies to ESD-compatible
- Packaging
- Work surfaces
-Floors
-Seating
- Grounding options
- Handling
No guarantee or warranty claims can be made in respect of any improperly handled electronic component or PC board.
9
General In these installation instructions, the replacement of PC boards LT-AC-SRx and IG-DC-DC
is described, as in order to replace the IG-DC-DC PC board, the LT-AC-SRx PC board
must also be removed.
LT-AC-SR2 PC Board LT-AC-SR4 PC Board
The LT-AC-SR4 PC board replaces the LT-AC-SR2 PC Board.
Required Tools
And Materials
10
IG-DC-DC PC Board
- TX20 Torx screwdriver
- TX25 Torx screwdriver
- Socket wrench size 8 mm (5/16 in).
- Socket wrench size 7 mm (9/32 in).
- Torx Allen wrench TX20 (or small ratchet with TX20 insert bit )
- Hand torque wrench
- TX20 and TX25 bit insert
- Socket wrench insert SW 7 mm (9/32 in) and SW 8 mm (5/16 in).
Open inverters and discharge capacitors
1
5
(6)(9)
EN-US
Opening the Inverter
WARNING! An electric shock can be fatal. Danger from grid voltage and DC volt-
age from solar modules. Never work with live wires! Prior to all work on the inverter, make sure that the AC and DC wires are not charged.
(1)(2)(3) (4) (5) (6) (7) (8)
If present, turn off the external AC and
DC disconnect.
Open the cover (1).
2
Switch the AC disconnect (4) and the
3
DC disconnect (5) to the "OFF" position.
Remove the four TX25 screws (2), (3),
4
(7), and (8).
Lift the cover with the display (6).
Unplug the ribbon cable (9) from the in-
6
verter.
Remove the cover with the display (6).
7
NOTE! The following three steps apply only if the AC or DC cables are routed into
the inverter from the side:
Separate the AC or DC cables from the inverter.
8
Disassemble the conduits from the inverter housing so that the inverter housing can
9
be removed.
Un-thread the AC or DC cables from the inverter.
10
CAUTION! An inadequate grounding conductor connection can cause serious injuries to persons and damage to (or loss of) property. The housing screws provide
an adequate grounding conductor connection for the housing ground and should
not be replaced under any circumstances by other screws that do not provide a
proper grounding conductor connection.
11
Remove the four TX25 screws (10) -
11
11
(13) on the underside of the inverter.
(10)
(11)
(14)
(12)
(13)
(15)
Remove the two TX25 screws (14) -
12
(15) on the top of the inverter.
Remove the rubber edge guards (16)
13
from the left and right sides.
Lift off the inverter housing.
14
Discharging the
Capacitors
(16)
WARNING! An electric shock can be fatal. Danger from residual voltage from capacitors. Only work on the LT-AC-SRx PC board when the capacitors are discharged.
Carry out the discharging of the capacitors
- on each power stage set,
and
- strictly in accordance with the following step.
On the LT-AC-SRx PC board, switch
1
the Jumper (1) from the "RUN" position
to the "SERVICE" (3) position.
(1)
(2)
The "SERVICE" LED (2) illuminates red for
approximately 5 seconds.
When the "SERVICE" LED (2) goes out, the
capacitors are discharged.
IMPORTANT! Pay attention to the warning
label at the capacitors as well as the information printed on the PC board.
(3)
12
Replacing the LT-AC-SRx PC Board
2
4
(1)
(2)
(3)
(4)
(5)
(6)
2
EN-US
Removing the LTAC-SRx PC Board
(1)
(2)
(3)
Unplug/remove all cables from the LT-
1
AC-SRx PC board.
Remove the 4 plastic spacers (1) - (4),
socket wrench, size 8 mm (5/16 in).
Remove the two TX20 screws (5) and
3
(6).
Withdraw the LT-AC-SRx PC board
upwards.
Replacing the LTAC-SRx PC Board
(4)
(5)
(6)
Insert the LT-AC-SRx PC board.
1
Tighten the four plastic spacers (3) (6), socket wrench, size 8 mm (5/16
in).
Tightening torque = 0.2 Nm (0.15 ft. lb).
Tighten the two TX20 screws (1) and
3
(2).
Tightening torque = 1.8 Nm (1.33 ft. lb).
13
(7)
(8)
(9)
(10)
(11)
(12) (13)
(14)
Plug in/connect the cables to the LT-
4
AC-PRx PC board:
IMPORTANT! Insert the choke con-
nections (7) correctly into the terminals
according to color.
- Plug in the ribbon cables (8) and
(9).
When connecting the ribbon
cables, ensure that all the cable
latches engage.
- Insert the 2-pin cable, white "+15
V sec" (14).
- Plug in the black transformer
cables (12) and (13) according to
cable length.
- Plug in the "L" gray (10) and "N"
blue (11) AC cables.
When connecting the cables, pay attention
to the information printed on the cables and
the PC board.
The jumper must be inserted at the "RUN"
position in order for the inverter to operate
normally.
(15)
(16)
If necessary, switch the jumper (15)
5
from the "SERVICE" position (16) to
the starting position "RUN" (15)
14
Replacing the IG-DC-DC PC Board
1
4
EN-US
Removing the IGDC-DC PC Board
(3)
(2)
(1)
(4)
(5)
(6)
Remove the LT-AC-SRx PC board
according to chapter “Replacing the
LT-AC-SRx PC Board“, section “Removing the LT-AC-SRx PC Board“.
For inverters with 2 power modules:
2
Also unplug the middle ribbon cable
(1) on the second power module and
un-thread it downwards if necessary.
NOTE! The TX25 screws (2) - (5)
are not magnetic. When removing
the screws, ensure that they do
not fall out or fall into the inverter.
Remove the four TX25 screws (2) - (5).
3
Remove the TX20 screws (7)
(e.g., Torx Allen wrench TX20 or small
ratchet with TX20 insert bit).
Remove the mounting plate (6).
5
(7)
(8)
(9)
(10)
(11)
(12)
Unplug/remove all cables from the IG-
6
DC-DC PC board.
Remove the three plastic spacers (8),
7
(9), and (11)
socket wrench, size 8 mm (5/16 in).
Remove the brass spacer (12)
8
socket wrench, size 7 mm (9/32 in).
Remove the IG-DC-DC PC board (10).
9
15
Installing the IG-
(1)(2)
4
DC-DC PC Board
180 °
NOTE! When inserting the IG-DCDC PC board, ensure that the cables are not trapped, kinked, or
damaged in any other way.
Insert the IG-DC-DC PC board (1).
1
Set the DIP switch (2) according to the
2
illustration.
For inverters with only one power module, the lower DIP switch setting applies.
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Plug in/connect the cables to the IG-
3
DC-DC PC board:
- Plug in the "-" gray (11) and "+" red
(13) DC cables.
- Plug in the white cable with the
marking "4" (3) and the white cable (4).
- Plug in the white cable (9) and the
white cable with the marking "1"
(10).
- Plug in the 2-pin fan cable (7).
Tighten the three plastic spacers (5),
(6), and (8),
socket wrench, size 8 mm (5/16 in).
Tightening torque = 0.2 Nm (0.15 ft. lb).
Tighten the brass separator (12),
5
socket wrench, size 7 mm (9/32 in).
Tightening torque = 1.0 Nm (0.74 ft. lb).
When connecting the cables, pay attention
to the information printed on the cables and
the PC board.
16
(15)
7
11
11
(14)
(16)
(17)
(18)
(19)
Plug in the ribbon cables (16) and (17)
6
.
NOTE! When inserting the mounting plate, ensure that the cables
are not trapped, kinked, or damaged in any other way.
(20)
(21)
Insert the mounting plate (20).
NOTE! The TX25 screws (14),
(15), (18), and (19) are not mag-
(16)
(17)
(21)
Tighten the four TX25 screws (14), (15), (18), and (19).
8
Tightening torque = 2.5 Nm (1.84 ft. lb).
Remove the TX20 screws (23)
9
(e.g., Torx Allen wrench TX20 or small ratchet with TX20 insert bit ).
Tightening torque = 1.8 Nm (1.33 ft. lb).
If necessary, thread in the middle ribbon cable (21);
10
plug the ribbon cable into the IG-DC-DC PC board (21).
For inverters with two power modules, pass the ribbon cable further up and also plug
it into the second power module.
When connecting the ribbon cables, ensure that all the cable latches engage.
Replace the LT-AC-SRx PC board according to chapter “Replacing the LT-AC-SRx
PC Board“, section “Replacing the LT-AC-SRx PC Board
(22)
(23)
netic. When replacing the screws,
ensure that they do not fall out or
fall into the inverter.
EN-US
17
Closing and turning on the inverter
1
3
(7)
4
7
Closing the Inverter and
Switching it on
(1)
(2)
(5)
CAUTION! An inadequate grounding conductor connection can cause serious injuries to persons and damage to (or loss of) property. The housing screws provide
an adequate grounding conductor connection for the housing ground and should
not be replaced under any circumstances by other screws that do not provide a
proper grounding conductor connection.
Replace the inverter housing from above.
Tighten the four TX25 screws (1) - (4)
(3)
(4)
(6)
2
on the underside of the inverter.
Tightening torque = 2.5 Nm (1.84 ft. lb).
Tighten the two TX25 screws (5) and
(6) on the top of the inverter.
Tightening torque = 2.5 Nm (1.84 ft. lb).
Replace the rubber edge guards (7)
onto the left and right sides
NOTE! The following three steps apply only if the AC and DC cables are routed
into the inverter from the side:
Insert AC and DC wires into the inverter.
5
Mount the conduits onto the inverter housing.
6
Connect the AC and DC cables to the inverter.
18
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