LG Electronics LGENBOX-01, LGxxxA1C-B3 User Manual

The Difference

Is in the Detail

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AC Module System Installation Instructions

LGxxxA1C-B3 / LGENBOX-01

* A minimum slope of 5 in/ft. for roof installations is required to meet fire class ratings.

The array frame must be grounded in accordance with NEC Article 250.

2

Table of Contents

1 Safety 3

1-1 Safety Symbols 3
1-2 Important Safety Instructions 3
1-3 FCC Guidelines 4
1-3 Circuit Symbols 4

2 Introduction 5

3 AC Module 6

3-1 Before Installation 6
3-2 Inspecting the Area of Installation 6
3-3 Inspecting Components of the AC Module 7
3-4 Measuring AC Voltage of the Utility 7
3-5 Wiring Diagram of AC Module System 8
3-6 Installing the AC Junction Box and PV Rack 9
3-7 Mounting the AC Module 9
3-8 Connecting AC Modules (Trunk Cable) 12
3-9 Grounding 16
3-10 Connecting AC Module Array to Distribution Panel

(General AC Cable, Transition Cable) –240VAC, 208VAC 18

3-11 Operation 22

3-12 Maintenance 22

4 EnerBox

4-1 Checking Components of the Communication Gateway 23
4-2 Connecting the Communication Gateway 24
4-3 Configuring the Installation App 25
4-4 Website 28

5 Accessories 29

6 Product Specifications 30

6-1 AC Module 30
6-2 EnerBox 32
6-3 Response to Abnormal Conditions 33
6-4 Dedicated Cables 34

7 Warranty 35

8 Transportation and Storage 35

9 Contact 35

TM

Communication Gateway 23

Revisions

Date Version Description of Change Remark

6/30/2014 1.0 (1

st

Edition)

3

1 Safety

Note and comply with the safety guidelines of this manual while handling AC modules. Failure to comply may result
in severe damage to the equipment and/or fatal injuries.

1-1 Safety Symbols

Safety symbols are used to minimize loss and injury during handling and operation of the equipment specified in this
manual.

DANGER

WARNING

CAUTION

Failure to comply with the instructions may cause fatal injuries or immediate death.

Failure to comply with the instructions may cause severe injuries or death.

Failure to comply with the instructions may cause injuries or damage to property.

Failure to comply with the instructions may cause severe injuries or immediate death
by overvoltage.

Failure to comply with the instructions may cause injuries or damage to property by fire.

1-2 Important Safety Instructions

DANGER

• To prevent the risk of electric shock, stay away from current-carrying terminals during operation. And, allow

several minutes after the circuit breaker has been turned off. It may be energized in the open position.

• To prevent the risk of overvoltage, do not disconnect the cable connector during operation.

WARNING

• To prevent the risk of burns, do not touch metal parts during operation.

• For safety, only qualified persons should service modules.

• To prevent the risk of electric shock, stay away from damaged module(s). Do not use module(s) with broken glass

or torn backsheets.

• Damaged modules must be handled with proper safety equipment. Failure to comply may result in serious bodily

injury or death.

• Micro inverter warranty void if cover removed. No serviceable parts inside. Refer servicing to qualified personnel.

• For proper operation, make sure to use exclusively cables, connectors and accessories provided by LG Electronics.

Parts that are not listed may cause critical danger.

• For proper operation, the AC module shall be connected only to a dedicated branch circuit.

• To prevent the risk of fire, do not connect any device between the AC module and circuit breaker. Circuit breaker

may not work properly.

• Before installation, make sure to check that the area of location meets the required environment specified in

Chapter 6. Product Specification (Voltage, frequency, temperature, number of AC modules, overcurrent device).

CAUTION

• Use proper equipment, connectors, wires and buttresses for the installation of the module. Failure to comply may

result in product damage, product failure and/or bodily injury.

• To reduce the risk of accidents, do not install during inclement weather.

• To prevent the risk of electric shock, do not touch the glass surface or frame of the solar module after installation.

• To prevent the risk of injury, do not apply pressure on the module (ex. placing heavy objects or stepping on the

module).

• To prevent the risk of injury, do not drop the module; modules must be gently handled and placed down.

• For proper operation, do not scratch the coating surface of the frame. It may increase the corrosion of the frame.

• For proper operation, do not concentrate sunlight on the module surface.

• Addition of holes in the frame or glass of the module may decrease the strength and integrity of the frame or glass.

• Do not remove warning labels.

• Store the module in its original package until installation.

4

1-3 FCC Guidelines

For Micro inverter & Communication Gateway

You are cautioned that changes or modifications to this unit not expressly approved by the party responsible for
compliance could void the user’s authority to operate this equipment.

This equipment has been tested and found to comply with the limits for a Class B Digital Device, pursuant to Part
15 of the FCC Rules. These limits are designed Part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference in a residential installation. This equipment generates, uses and
can radiate radio frequency energy and, if not installed and used in accordance with the instruction, may cause
harmful interference to radio communication. However, there is no guarantee that interference will not occur in a
particular installation. If this equipment does cause harmful interference to radio or television reception, which can
be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one
or more of the following measures:

- Reorient or relocate the receiving antenna.

- Increase the separation between the equipment and receiver.

- Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.

- Consult the dealer or an experienced radio/TV technician for help.

This device complies with part 15 of the FCC rules. Operation is subject to the following two conditions:(1) This
device may not cause harmful interference, and (2) This device must accept any interference received, including
interference that may cause undesired operation.

For Communication Gateway

Indoor use only

FCC Caution: For indoor use only; outdoor use or in any other environments not covered in this manual may

violate the FCC regulation and void the user’s authority to use the product.
Specially, within the 5.15-5.25 GHz band, U-NII device is restricted to indoor operations to reduce any potential for
harmful interference to co-channel MSS operations.

FCC RF Radiation Exposure Statement:
This equipment complies with FCC radiation exposure limits set forth for an uncontrolled environment.
This equipment should be installed and operated with a minimum distance of 8.87 inches (20 cm) between the
radiator and your body. End users must follow the specific operating instructions for satisfying RF exposure
compliance. This transmitter must not be co-located or operating in conjunction with any other antenna or
transmitter.

CAUTION: Regulations of the FCC and FAA prohibit airborne operation of radio-frequency wireless devices
because their signals could interfere with critical aircraft instruments.

1-4 Circuit Symbols

The following circuit symbols are used to describe the AC module circuit in this manual.

Circuit Symbol Description

DC (Direct Current) supply. Generated from PV module.

AC (Alternating Current) supply. Generated from utility and micro inverter. Used in
electric appliances.

Represents the phase of AC. The number in front of this symbol represents the
number of phases.

Terminal for EGC (Equipment Grounding Conductor) normally used to connect non–
current carrying metal parts of equipment together.

Terminal for GEC (Grounding Electrode Conductor) connecting EGCs and neutral
conductors to the ground for grounding.

Circuit breaker switch. l : ON, O : OFF.

/ PV module: Equipment that receives solar energy and generates DC power.
/ Inverter: Equipment that converts DC power into AC power.
/ Utility-Interactive inverter: Inverter connected in parallel with the grid to supply power.
/ Micro inverter: Inverter designed with minimal size to supply power to each PV module.

5

2 Introduction

LG AC module consists of PV(Photovoltaic) module and “Utility-Interactive” micro inverter. Without any additional

equipment, it converts the solar energy to AC power used in electric appliances and supplies to the utility.

The Advantages of AC Module System

• The AC module system, unlike a central inverter system, operates with module MPPT. The AC module does not

have any adverse effect on the other modules, allowing more power production in comparison to a central
inverter system.

• Eliminates installations related to DC voltage, reducing total installation and labor costs.

• Maintenance is easy as the system can be monitored in real time.

AC Module System

1. AC Module

Power
Communication

2. Communication
Gateway

Gird

Distribution

board

Meter

Smartphone
(Installation

App)

1. AC module

- Consists of PV module and micro inverter.

- Performs MPPT function, maximizing power generation.

2. Communication gateway

- Collects information about AC module system via AC cable.

- Stores data inside.

- Uses wireless connection to transmit data to smartphone or tablet.

Server

Router

3. Monitoring

PC

Smartphone

3. Monitoring

- Monitors and analyzes condition of the solar system.

- Transmits the condition of the system to the service center in case of a problem.

/ MPPT : Maximum Power Point Tracking.

6

3 AC Module

3-1 Before Installation

• LG AC module is “Utility-Interactive”, which requires approval from the corresponding authority prior to system

connection. Contact the applicable local government agencies and/or utility company.

• Installation, maintenance, and supervision may only be carried out by an approved installer for the safety of

workers and systems.

• Read and follow the installation guidelines specified in this manual. Installation in unapproved methods may
result in injuries includes fatal injuries and/or damage to the equipment. Consult with LG Solar for the approval of

the installation methods that are not specified in the installation manual. Failure to comply will void the warranty
and the module certificate.

• After receipt of LG AC module, check for possible damages from production or transportation. Any damaged
module must not be installed. Request an exchange by contacting LG Solar.

• If original modules (or parts) are replaced, check that the modified module works properly. The modified module

shall retain its model number.

• Store the AC module in its original packing until installation.

• Do not remove the dust cover from the connector in advance. Any particles in the cable may cause interference

to the current.

• Consider the weight of LG AC module before installation. The weight of LG AC module is 39.68lbs.

• Do not work alone. Install as a team unit with at least 2 persons working at a time.

• To prevent the risk of accidents, install with safety gear on at all times.

• Do not install in times of inclement weather. There is a risk of electric shock when it is raining or snowing.

• If installation location is high above ground, make sure to wear safety belt during the installation.

• Check that all parts used during the installation are certified for outdoor usage.

• During the module installation, do not let children near the module and the system.

• Carry out the installation according to the local electric code.

3-2 Inspecting the Area of Installation

Check that the location of installation meets the following requirements.

• Do not install near highly combustible structures or materials.

• Do not install where the maximum ambient temperature exceeds 149℉ (65°C).

• Do not install at a place with direct exposure to salt water or ammonia.

• Do not install at a place easily accessible to people.

• Do not install indoors or on a moving vehicle.

• In a place with frequent lightning storms, by installer, an auxiliary grounding may be connected directly from the

AC module system to the ground.

• If the target installation structure lies on an unleveled surface, do not forcefully modify the module to fit the

structure. Make sure that the installation structure has been set up to provide a flat surface. Unreliable structures
may cause damage to the product during and/or after installation.

7

3-3 Inspecting Components of the AC Module

After receiving the product, inspect all parts for possible deformity or malfunction.

3

7

9

2

6

8

1

1 PV module

Converts the solar energy to DC power.

2 Micro inverter

Converts DC power generated by each PV module to AC power.

3 PV frame

Protects and fixates AC module.

4 AC drop cable

Connects a micro inverter to trunk cable.

5 Trunk male connector

Junction connector between AC drop cable and trunk female connector.

6 Trunk female connector

Connects to trunk male connector of the next AC module in the array.

7 Bracket

Fixes trunk cable onto PV frame.

8 Dust cover

Prevents entry of foreign particles.

9 Cable holder

Prevents AC trunk cables from moving during transportation.

※ Warranty is void if it is broken after installed.

4

5

3-4 Measuring AC Voltage of the Utility

Measure the AC voltage of the utility at the distribution panel using a multi-meter. Refer to the table below to
determine the number of modules per array.

AC Voltage

Single phase 240V (per 1-array)

Three phase 208V

(per 3-array)

* For details, refer to Chapter 3-10. Connecting AC Module Array to the Distribution Panel.
* Factory setting of AC voltage of the AC modules is 240VAC. If you want to change the operating AC voltage range, you

need to set grid configuration directly. For details, refer to Chapter 4-3. Configuring the Installation App - Step 5.

Number of Maximum AC Modules

12 units

6 units ⅹ 3 (merge type)

11units ⅹ 3 (split type)

20A Circuit Breaker

2-pole ⅹ 1ea

3-pole ⅹ 1ea

2-pole ⅹ 3ea

8

3-5 Wiring Diagram of AC Module System

00000

NL1L2

G

Below is a sample diagram of the AC module system.

PV Rack AC Module Trunk Cable Transition Cable

Equipment
Grounding
Conductor

AC Junction Box

General AC
Cable

Meter

Installation App

Communication

Gateway

120VAC

Install in the following order. For details, please refer to each chapter.

Chapter 3-6. Installing the AC Junction Box and PV Rack

Install the AC junction box and PV rack at the installation site.

Chapter 3-7. Mounting the AC module

Mount AC modules on PV rack.

Chapter 3-8. Connecting AC Module (Trunk Cable)

Connect to AC modules by using trunk cables.

Chapter 3-9. Grounding

Connect the equipment grounding conductor to the distribution panel.

Distribution Panel

Chapter 3-10. Connecting Array of AC Modules-to-Distribution Panel (General AC Cable, Transition Cable) -

240VAC, 208VAC

Connect arrays of AC modules to the distribution panel by using transition cables and general AC
cables. (Wiring method depends on the voltage of the utility)

Chapter 4-2. Connecting the Communication Gateway

Connect the communication gateway to 120VAC outlet.

/ PV Rack: Structure used to fix AC modules on surfaces like roofs, empty plots, etc.
/ AC Junction Box: Container for electrical connections of AC cables, usually intended to conceal them from sight and prevent tampering.
/ General AC Cable : AC cable, not supplied by LG, used generally for outdoor electrical installation.
/ Distribution Panel : Component of an electricity supply system which divides an electrical power feed into subsidiary circuits in a common

enclosure that provides a protective fuse or circuit breaker for each circuit.

9

3-6 Installing the AC Junction Box and PV Rack

Before installing the AC junction box and PV rack, be aware of the following requirements:

NOTICE

• To allow ventilation through the backside of the AC module, it is recommended to install the PV rack allowing a

gap of at least 4 inches (100mm) between the back of the module and roof surface.

• Install AC junction box near the AC module.

• Install using the parts approved by the relevant local authority of installation site.

• Select appropriate angle for maximum exposure to sunlight.

Construct the over all frame of the solar system in the following order:

1. Install the PV rack according to the number of modules per array and the dimensions of the AC module. (refer to

Chapter 6. Product Specification)

2. Install the AC junction box near the PV rack. Select the size and type of AC junction box suitable for connection

type according to the output voltage. (Refer to Chapter 3-10. Connecting Array of AC Modules to Distribution

Panel)

3-7 Mounting the AC module

Before mounting AC module in the PV rack, be aware of the following requirements:

NOTICE

• Check that all parts of the product are intact and operational.

• Check that the cable connectors are well fixed.

• It is recommended to install the module at any angle with respect to the horizon, making it easier for dust to be

washed off by rain.

• When installed on a roof, the PV module must be mounted over a fire-resistant roof. The fire resistance of the PV
module is class C according to ANSI/UL790.

• For proper operation, do not remove PV frame or replace with another frame.

• Additional holes on the frame may weaken, the strength of the frame and cause damage.

• To avoid the tensile strain from the thermal expansion, it is recommended to install with a gap of between 0.236

inches (6mm) to 7.087 inches (180mm) between PV frames considering the length of the trunk cable. If gap
exceeds 7.087 inches, use the extension cable.

• Mount LG AC module to PV rack with 8~12N-mtorque.

• For reliable connection, do not place any foreign objects between PV frame and the PV rack.

• When installing modules in areas of heavy snow, special care should be taken to install the modules in a manner

that provides sufficient strength while meeting local code requirements.

PV Module Specification (conditions of 1000W/m2 irradiance and 77ºF (25°C) solar cell temperature)

Operation temperature

Maximum operation temperature: +194°F (90°C).
Minimum operation temperature: -40°F (-40°C).

Design strength

LGE solar modules are certified to basic loads of 50lb/ft

(about 2400 Pa)

Notes

- LG AC module can not be operated in locations of direct contact to salt water or ammonia.

- LG AC module is thin, so it may bend depending on the type of the PV rack.

- Reflection from snow, water or other weatherly variables may increase the output generated in the module.

- Colder temperatures may substantially increase voltage and power.

2

.

10

Fix AC module to the PV rack in the following order:

Serial No. K2xxxxxxxxxx

MAC Address : 48:D1:8E:40:00:90

Made in Korea

Step1. Peel adhesive label attached on the side of PV frame of AC modules and stick on a piece of paper mirroring

the array to map for monitoring.

Step 2. Place AC modules on the PV rack with a minimum gap of 0.236 inch (6mm) between each module. To

prevent the risk of slipping during installation, mount AC modules one by one. Connect trunk cables to each
mounted AC module. (Refer to Chapter 3-8. Connecting AC Modules)

Step 3. Fixate the PV module to the PV rack on the four mounting holes (marked by points below) with 4 M6

stainless bolts, 4 nuts, 4 spring washers, and 8 flat washers.
(To mount according to the different type of PV racks, refer to the next page under Mounting According to

the Different PV Racks)

WARNING

• To prevent the danger of the electric shock, make sure to turn off the circuit breaker prior to installation.

Connecting the PV Rack and PV Module

Module frame

Bolt

Flat washer

Flat washer

Spring washer

Nut

Support

11

1 2 12

1 2 12

Mounting According to the Type of PV rack

1 2 12

Minimum distance between module edge to PV rack is 10.236 inch (260mm).

Mounting Type Clamping Type (Long Side)

Use four mounting holes on two opposite sides.

Center ± 3.937 inch (100mm)

Clamping Range:

From module Edge

to 10.630 inch (270mm)

Center ± 3.937 inch (100mm)

11.811 inch
(300mm)

Use four clamps on the long frame.

Clamping Type (Short Side)

This method is not tested by IEC/UL.

Clamping Range

7.874 inch (200mm)

11.811 inch
(300mm)

Clamping Range:

From module Edge to

4.724 inch (120mm)

This installation is allowed in the following cases:

Use four clamps on the short frame and two

1. Slope roof: If module is installed parallel to the

clamps at the center of long frame.

2. Flat roof: If installed with an additional stand

※ Please check that PV rack does not interfere with a micro inverter.

Use four clamps on the short frame.

rooftop.

such as wind shield or deflector.