How it Works
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SolarMax 2000S, 6000S, 3000S, 4200S Instruction Manual

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TÜV
Rheinland
Product Safety
BAUART GEPRÜFT
TYPE APPROVED
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Introduction
Thank you for choosing a SolarMax solar inverter!
SolarMa x converts the direct current from your solar system into grid-compliant alternating current.
As a solar system operator you expect reliability and high yield from your system. With our SolarMax range we offer inverters that fully meet these requirements. The SolarMa x inverter range is characterised by high efficiency and high availability.
The inverters carry the CE mark as an indication of compliance with European Union Directives.
The “Type Approved” quality mark from TÜV Rheinland confirms compliance with all relevant safety standards.
The Management
Sputnik Engineering AG Höheweg 85 CH-2502 Biel/Bienne
E-Mail: sputnik@solarmax.com
SolarM ax string in verter: po werful, reli able, innovat ive.
Headqu arters of S putnik Engine ering AG in the f ormer Rolex buil ding in Biel, the Swi ss watch met ropolis.
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5 Troubleshooting 86
5.1 Introduction 86
5.2 Troubleshooting via the graphics display 87
5.3 Maintenance 90
6 Data communication 91
7 Technical description 93
7.1 Technical configuration SolarMax 2000S/3000S 93
7.2 Technical configuration SolarMax 4200S/6000S 93
7.3 Safety functions 94
7.4 Control functions 94
7.5 Technical data SolarMax 2000S/3000S 95
7.6 Technical data SolarMax 4200S/6000S 96
7.7 Glossary 97
7.8 Efficiency 98
8 Warranty 100
8.1 Warranty 100
8.2 Prolongation of guarantee 101
8.3 Limitation of liability and warranty 101
8.4 Applicable law 101
8.5 Place of jurisdiction 101
Contents
Introduction 54
1 Safety instructions 57
2 Installation 58
2.1 Installation 58
2.2 Electrical connection 61
2.3 Overvoltage protection 64
2.4 Switching on and off 65
2.5 Removal 65
2.6 Configurable limit values and operational settings 66
2.7 Heat sink temperature limit 67
2.8 Initial setup 67
2.9 Status signalling contact 68
3 Auto Test 70
3.1 Auto Test definition according to DK 5940 (Italy) 70
3.2 Start Auto Test 70
3.3 Procedure 71
4 Operation and fault display 73
4.1 Graphics display 73
4.2 LED display 73
4.3 Menu key symbols 74
4.4 Menu structure 75
4.5 Communication activity 82
4.6 Status messages 83
4.7 Alarm signals 85
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2 Installation
SolarMax inverters operate with high DC voltages. The complete system must therefore be installed with great diligence, following all relevant regulations. Contact with live parts can cause critical injuries or death. Only suitably qualified personnel may connect the SolarMax inverter to the mains. The installer must be approved by the relevant energy utility company.
The maximum solar generator output can be found in the data sheet.
Warning: The device may only be opened in de-energised state (AC and DC side). Wait for five minutes to allow the capacitors to discharge.
2.1 Installation
The device should be installed and connected with the cover closed. Sputnik Engineering has developed a mounting rail in order to simplif y the installation. Two zinc-plated wall screws (6 x 50 mm) and two wall plugs are included. First install the mounting rail on the wall. The SolarMax inverter can then be pushed onto the mounting rail. Fasten the inverter at the left and right of the mounting rail with two M6 x 12 screws.
1 Safety instructions
n Large arcs may be generated if connectors are disconnected on the DC side dur-
ing operation. The DC cable must therefore be disconnected before removing the MC connectors by means of the DC insulation switch on the left-hand side of the inverter.
n Caution: The discharge duration of the capacitors is 5 minutes. n Please follow the detailed installation instructions in Section 2. n Failure to observe the installation instructions will void any warranty and
liability.
n Disconnect your SolarMax inverter from the mains by disconnecting the AC feed
line before carrying out any maintenance and cleaning on the solar generator.
n Please follow the general local installation regulations.
n SolarMax inverters may be installed only by qualified electricians. n Please do not commission the device if the casing is damaged or you are
not sure whether the device is working properly! Immediately disconnect the device from the mains and from the solar generator!
n Before opening the SolarMax device, the DC and AC feed lines must be
disconnected.
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is made from cast aluminium, which ensures adequate cooling via convection and an additional fan.
Please note:
n The S olarMax may onl y be ope rated in an o vervoltage cat egor y II AC installati on!
If this is not the case, additional overvoltage-limiting elements (varistors) must be installed at the network connection point.
n If the SolarMax device is installed inside a building, the space should be well
ventilated.
n The inverter must be mounted on a solid surface. n For flammable surfaces an additional fireproof panel must be used, since the
heat sink may reach temperatures of up to 80 °C.
n Please refer to the technical data for the maximum permissible ambient tem-
perature.
n For optimum cooling the following distances should be adhered to: 0.5 m above,
0.5 m below, 0.3 m at the sides.
n Multiple devices should be installed above each other, if possible. For side-by-
side installation the minimum distance between devices should be 0.5 m. If different SolarMax models are used, they should be installed in the following order (top to bottom): SolarMax 2000S, SolarMax 3000S, SolarMax 4200S, SolarMa x 6000S.
n In external installations direct sunlight should be avoided. A protected installa-
tion location, for example under a canopy or a solar module, would be an advan­tage. The device should also be protected from splashing, for example rainwater dripping off roof or module edges.
n The inverters must not be installed in cabinets, enclosed recesses or similar
locations.
n Do not store flammable liquids near the inverter. Do not subject the inverter to
flammable gases or vapours.
n The inverter must be positioned out of reach of small children. n The inverter and the supply lines must be installed such that they are inaccess-
ible to pets (especially rodents).
n Due to noise emission it is advisable to avoid installation in living areas.
Graph ics display wi th operation DC insul ation switc h AC conn ector Stat us signalling co ntact DC conne ctor
The SolarMax housing meets the requirements of protection type IP 54 and is suit­able for outdoor installation. Protection rating IP 54 is only met if the enclosed AC connector and the solar generator are connected via the MC-4 connectors.
In order to maximise the energy yield it is important to position the inverter cor­rectly. The lower the ambient temperature, the more ef ficiently the inver ter will operate.
Notwithstanding the high efficiency of the SolarMax inverter, approx. 5 % of the power has to be dissipated in the form of heat. To this end the base of the device
545 mm
522 mm
290 mm
1
2
3
1
2
3
4
5
5
4
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Assembly of the AC cable socket
SM2000S/ 3000S/420 0S/60 00S:
Ensure that the cable is de-energised.
n Connect the AC cable socket with a flexible cable according to EN60309-2 /
VDE 0623. Strands with a max. cross-section of 4 mm
2
can be connected.
n Push the rear part of the socket over the cable.
n Press wire end sleeves onto the stripped strands. n Connect the individual wires with the insert in turn as follows
(Strand cross-section: see table on page 63)
Protective earth conductor PE with the screw terminal with earthing symbol Neutral conductor N on screw terminal with the label N
Phase L on screw terminal with the label L Tightening torque 0.8 – 1.0 Nm
n Ensure that the wires are connected properly. n Snap the rear part of the socket onto the socket insert. n Tighten the screwed cable gland.
Rear par t of socket
2.2 Electrical connection
Sputnik Engineering supplies the SolarMax inverters prewired and ready for con­nection. All connections are pluggable. The device therefore does not have to be opened.
The following connections are available:
n DC: 3 x 2 MC4 sockets (3 strings with MC4 connectors) n AC: Wieland flange connector n Communication: 2 x RJ45 (sealed with protective caps) n Status signalling contact M12 connector
Wiela nd flange conne ctor
AC feed li ne
3 x 2 pairs o f MC4 connect ors
DC feed li ne
2 x RJ45 so ckets
Data co mmunicatio n
Statu s signalling c ontact
SM2000S/3000S/4200S/6000S
Socket i nsert
Screwe d cable gland
If the RJ45 sockets are used and the inverter is exposed to the weather, please use products from the VARIOSUB-RJ45 range with IP67 protection from Phoenix Contact. This ensures that the installation meets the requirements of IP54.
n RJ45 connector, 8-pin, quick connector system (art. no. 1658493) n Pre-assembled Ethernet cable, 8-pin RJ45/IP67 on RJ45/IP67 (art. no.
1658480-)
Available from www.phoenixcontact.com.
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Back-up fuses and cable cross-sections
Follow the generally accepted state of the art. Start on the AC side.
AC side:
Each inverter must be protected separately! No consumers may be connected be­tween the fuse and the inverter!
Type 2000S 3000S 4200S 6000S
Back-up fuse (characteristic C)
10 A 13 A 20 A 25 A
Minimum cable cross-section (strand)
1.5 mm
2
1.5 mm22.5 mm22.5 mm
2
We recommend using larger conductor cross-sections in order to minimise line losses.
The flexible cable is connected to a junction box with a maximum length of one metre. From here the installation may be continued with a rigid TT cable.
DC side:
Select the cable cross-sections on the DC side to suit your system configuration and in accordance with the relevant installation regulations.
General in formation:
n When connecting several SolarMax devices, distribute the inverters over the
three mains phases.
n AC and DC cables must be suitable for the expected loads, currents and ambient
conditions (temperature, UV, etc.).
n The personal protection regulations must be followed when the inverter is con-
nected to the AC system.
n Ensure that the mains cable is de-energised before connecting the device. n Verify the polarity before installing the DC side. n Ensure short circuit- and earth-leakage-proof connection of the DC cables to the
MC terminals.
n Caution: Due to the earth-fault monitoring function, neither the minus nor the
plus terminal should be earthed. Otherwise the integrated insulation monitoring function would prevent grid feeding.
n Connect the DC side via the MC connectors.
> 600 V> 600 V
Large arcs may be generated if connectors are disconnected on the DC or the AC side during operation. The AC supply and the DC insulation switch must therefore be disconnected before removing the connectors.
Eart hing (second pr otective e arth conne ction)
Without a connection to the solar generator the stray current of the inverter is less than 3.5 mA on the AC side. However, during operation of the solar generator, the stray current at the inverter may far exceed the value of AC 3.5 mA. In this case a second, fixed protective earth connection according to EN 50178 is required. The cross-section of the second protective earth conductor should have at least the same cross-section as that of the main terminal. A second protective earth conduc­tor can be connected below the status signalling contact.
2.3 Overvoltage protection
SolarMax inverters feature integrated surge protectors at the input and output. On the DC side 2 surge arresters (varistors) for the plus and minus terminal to earth are installed. On the AC side a surge arrester (varistor) is installed between the phase and neutral. All surge arresters meet the requirements of class D according to VDE 0675-6 or Type 3 according to EN 61643-11.
Note the following if the overvoltage protection on the DC is to be increased:
n For inverters without galvanic isolation the DC terminals have a potential rela-
tive to earth that may be higher than the peak value of the mains voltage. For this reason, the response voltage of the surge arrester must be higher than 600 V
peak.
Solar ge nerator
The di agram on th e left sho ws the connec tion of additiona l surge arres­ters on t he DC side.
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2.4 Switching on and off
n All SolarMax inverters operate fully automatically and maintenance-free. The
isolating switches between the solar generator, the inverter and the 230 V mains supply remain on at all times. SolarMax will start and transfer power to the 230 V grid when the irradiance is high enough. Otherwise the device remains in standby mode and is thus available for grid feeding at all times. Overnight the electronic system is disconnected from the mains.
Voltage may only be applied on the DC and AC side of the SolarMax with the device closed.
Switching on:
n Switch on DC insulation switch.
The graphics display powers up. During the night or at times of insufficient irradiance the graphics display turns
itself off (no energy consumption).
n Switch on the AC isolating switch (may be fused).
Switching off:
n Switch off the AC insulation switch.
Large arcs may be generated if connectors are disconnected on the DC side during operation.
n Switch off the DC insulation switch.
Graphics display switched off.
2.5 Removal
n The device does not have to be opened for demounting. n The inverter must be de-energised. First disconnec t the device from the mains
on the AC side via the AC line protec tion breaker or the fuse. Then open the DC insulation switch in order to disconnect the inverter from the solar generator field. Now remove the connectors.
n Before releasing the screws ensure that the bottom of the device (heat sink) has
cooled suf ficiently to allow the device to be safely handled.
n Release the two locking screws on the left and right and remove the inver ter
from the mounting.
2.6 Configurable limit values and operational settings
In the Solar Max S series th e following par ameter s can be s et manually via the inter­face with the MaxTalk software. The settings are password-protected. A password application form can be ordered via the SolarMax hotline. The password is only made available to installers who sign the form. The password is not made available to private individuals or system operators.
Parameter Unit Regional settings Password-
protected
setting
DE/CH IT ES FR Other
Vac max
V 264 274 253 264 300
184…300
Vac min
V 184 186 196 196 184
f max
Hz 50.2 50.3 51 50.5 55
45…55
f min
Hz 47.5 49.7 48 49.5 45
df/dt max
Hz/s NA
0 (Inactive)
NA NA NA 0.1…1
Vac 10min max
V 253 0 (Inactive) 264 264 243…264
Ierr max
mA 300 300 300 300 300 50…300
Iac mean max
A 1 0.5% of
Iac rated*
1 1 1 0.05...1
Restart delay
s 0 0 180 0 0 0…600
Pac max SM2000S
W 1980 1980 1980 1980 1980 990…1980
Pac max SM3000S
W 2750 2750 2750 2750 2750 1375…2750
Pac max SM4200S
W 4180 4180 4180 4180 4180 2090…4180
Pac max SM6000S
W 5060 5060 5060 5060 5060 2530…5060
Iac max SM2000S
A 12 12 12 12 12 6…12
Iac max SM3000S
A 12 12 12 12 12 6…12
Iac max SM4200S
A 19 19 19 19 19 9…19
Iac max SM6000S
A 22 22 22 22 22 11…22
NA: not a vailable * Iac max = 1.1 x Iac rate d
The set values can be queried via the display in the main menu (see section 4.4).
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2.8 Initial setup
The “Initial Setup” starts automatically when the inverter is switched on for the first time. This procedure only has to be completed when the device is commis­sioned for the first time. To start with, English text appears inviting you to select the required language. The subsequent setup messages will then appear in the se­lected language. Then select the installation country. In the third step please check the date and the time and correct if necessary. The date set here is stored as the commissioning data and can be retrieved via the “Information” menu. All settings (apart from the country setting) can be modified later via the “Settings” menu.
The initial setup is still concluded with the
key.
Confirm the installation country with the
key.
Please note: After this confirmation, the selected country can no longer be changed!
Exit this menu with the
key. “Initial setup” will start again.
Important: The countr y must match the location of the inverter in order to ensure that the inverter operates within country-specific limit values.
Correct setting of the country ensures that the inverter operates within coun­try-specific limit values. If the selected country does not match the actual installation site the inverter will load incorrect limit values.
This may invalidate the ESC operating licence for the inverter.
2.7 Heat sink temperature limit
For safety reasons the temperature of the heat sink is limited to 80 °C. At ambient temperatures of more than 45 °C the heat sink temperature may reach 75 °C. In this event the maximum inver ter output is reduced temporarily. If the temperature rises above 80 °C the device switches off automatically in order to prevent thermal overload.
2.9 Status signalling contact
The status signalling contact is used for remote monitoring. The potential-free relay contact enables the status of the inverter to be monitored. The contact is located at the front of the unit between the DC and AC ports.
The functionality of the status signalling contact can be set in the Settings menu as follows:
Setting Function
Off The status signalling contacts are deactivated (remain in inactive
state).
Mains In mains mode the NO status signalling contact closes immedi-
ately and is opened again with the set delay as soon as the device is no longer in feed mode.
Error The NO status signalling contact closes after the set delay time
if a malfunction, fault or alarm occurs during this time. The relay opens immediately when the fault is no longer present.
The electronic monitoring system is supplied from the solar generator, i.e. the sta­tus signalling contact is open during the night and when the DC side is switched off.
The events that may trigger the status signalling contact are listed in Section 4.6 Status messages.
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3. Auto Test
The Auto Test function is required according to the Italian DK 5940 standard. It enables verification of the voltage and frequency monitoring function. The Auto Test option is only available in the main menu if “IT” (Italy) was selected as the installation location.
The Auto Test functionality and procedure is described below.
3.1 Auto Test definition according to DK 5940 (Italy)
During the Auto Test procedure in mains mode the trigger threshold for AC voltage and frequency monitoring is varied linearly with a ramp of ≤ 0.05Hz /s and ≤ 0.05 Vn/s (Vn = 230 Vac). At some point during the test the threshold will coincide with the current measured value, leading to triggering of the monitoring intervention. After each test step the values of the trigger thresholds, delay times, current meas­ured frequency and AC voltage values, and the standard threshold trigger value are displayed.
3.2 Start Auto Test
To start the Auto Test the inverter must be installed as described in Section 2. The Auto Test can be activated only if there is sufficient irradiance and the inverter is connected to the mains and is in feed mode.
1. Wait until the inver ter has connected itself to the mains.
2. Select Auto Test in the main menu.
3. Answer the question whether the Auto Test should be executed with YES.
4. The Auto Test now runs automatically.
Technical dat a of the status signalling contacts
U max I max
250 VAC 1 A
30 V
DC 1 A
A suitable mati ng c onnector for connec ting the s tatus signallin g conta ct can be order ed via the SolarM ax hotline.
Stat us signalling co ntact
Pin assignment:
Pin Contact:
1 NO 2 COM 3 NC
COMCOM
NC
NO NO
NC
Inactive state
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3. The trigger value, the delay time, the current value and the default voltage monitoring value (Vac min) are displayed.
Maximum frequency
1. The set frequency monitoring threshold f max is displayed.
2. The threshold value is decremented linearly until it reaches the current mains frequency value and mains monitoring is triggered.
3. The trigger value, the delay time, the current value and the default frequency monitoring value (f max) are displayed.
Minimum frequency
1. The set frequency monitoring threshold f min is displayed.
2. The threshold value is incremented linearly until it reaches the current mains frequency value and mains monitoring is triggered.
3. The trigger value, the delay time, the current value and the default frequency monitoring value (f min) are displayed.
After the Auto Test is complete the inverter returns to normal operation.
PLEA SE NOTE: if a fault occurs during the tests or the irradiance is too low the Auto Test is aborted and the message “Auto Test aborted” appears in the display together with an associated error message.
3.3 Procedure
Maximum voltage
1. The set voltage monitoring threshold Vac max is displayed.
2. The threshold value is decremented linearly until it reaches the current mains voltage value and mains monitoring is triggered.
3. The trigger value, the delay time, the current value and the default voltage monitoring value (Vac max) are displayed.
Minimum voltage
1. The set voltage monitoring threshold Vac min is displayed.
2. The threshold value is incremented linearly until it reaches the current mains voltage value and mains monitoring is triggered.
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4.3 Menu key symbols
Seven symbols are used for menu prompting:
Symbol Function / description
Scrolling upwards / increment number, or
next element scroll down or previous element
Back to higher-level menu
Select next number
Shows the required submenu or stores
any changes Starts edit mode for the selection
Cancel
4 Operation and fault display
4.1 Graphics display
The graphics display at the front is used to display system parameters, status information, and SolarMax fault messages, thereby offering the user convenient options for obtaining information about the device status.
The graphics display is backlit in order to improve readability under adverse light conditions. The backlight switches on whenever one of the three keys is pressed, and remains on for 180 seconds after the last key activity.
4.2 LED display
In addition to the graphics display, an LED display is available for indicating the device status (green, red or orange).
LED display Device status Description
Off Offline Device is switched off Flashing (green) Startup Device starting (initialisation,
restart delay) Green Mains operation Device feeding in Orange Malfunction Malfunction (e.g. mains
monitoring, overtemperature) Flashing (red) Error Device fault Green/red flashing Alarm Alarm messages see Section 4.7
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Overview
If none of the three keys is pressed for 120 seconds the display automatically switches to the Overview menu, which shows the three main parameters and the operating status.
➡ current inverter output ➡ yield today ➡ total yield since commissioning ➡ operating status
Measured Values
The following measurement readings can be displayed:
n Vdc ➡ current solar generator voltage n Idc ➡ current solar generator current n Vac ➡ current mains voltage n Iac ➡ current infeed current n Pac ➡ current inverter output n Frequency ➡ mains frequency n Temperature ➡ heat sink temperature n Fan (on/off) ➡ fan switched on or off
A maximum of four measured values can be displayed simultaneously. Use the arrow keys
and to switch to other values. Use the key to switch back
to the main menu.
4.4 Menu structure
The following submenus can be called up from the main menu:
n O v e r v i e w n Measured Values n Statistics
Days Months Years Total Reset
n Configuration n Settings
Language Time Date Device address Ethernet IP address Netmask TCP Port
n Auto Test* n Information
*Auto Test if regional setting is set to IT (see Section 3)
Use the arrow keys
and to select the required menu. Use the key to
switch to the selected menu.
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➡ monthly yield ➡ maximum power fed to the grid ➡ operating hours
Use the arrow keys
and to display the yields for the last 12 months. Use the
key to switch back to the Statistics menu.
➡ annual yield ➡ maximum power fed to the grid ➡ operating hours
Use the arrow keys
and to show the yields for the last ten years. Use the
key to switch back to the Statistics menu.
This screen shows the total yield and the operating hours of the inverter since it was commissioned. Use the
key to switch back to the Statistics menu.
➡ daily yield
➡ maximum power fed to the grid
➡ operating hours
Use the arrow keys
and to display the yields for the last 31 days. Use the
key to switch back to the Statistics menu.
Statistics
The following statistics can be displayed:
n Days n Months n Ye ars n To ta l n Reset
Use the arrow key
to select the required menu. Use the key to switch to the
selected menu. Use the
key to switch back to the main menu.
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Use the arrow keys and to display any value. Use the key to switch back to the main menu.
Settings
The following settings can be implemented via the graphics display:
Language Language selection: German, English, French, Italian or
Spanish Time Internal clock setting Date Current date setting Device address Enter a device address between 1 and 249. If several
inverters are connected to form a network, each device
must have a different address. Ethernet Switches the Ethernet interface on or off IP address Ethernet interface configuration (see section 6) Netmask Ethernet interface configuration (see section 6) TCP port Ethernet interface configuration (see section 6) Status relay Defines the function of the status signalling contact (see
Section 2.9) Status relay delay Delay time setting for the status signalling contact
Use the
key to confirm resetting of all statistics. Use the key to exit the
menu without resetting the statistics.
Configuration The following limit values and operating parameters cannot be modified via
the graphics display, because they are part of the country-specifi c settings (see
also section 2.6).
Country The installation country set during commissioning is
displayed here Vac min Minimum permissible mains voltage Vac max Maximum permissible mains voltage Vac 10min max Maximum permissible mean value of the mains voltage
over the last 10 minutes Iac max Maximum mains current Ierr max Maximum permissible fault current (rms value) on the
DC side Iac mean max Maximum permissible DC component of fed-in mains
current Pac max Maximum AC output that can be fed in f max Maximum permissible mains frequency f min Minimum permissible mains frequency Restart delay Grid feeding delay after disconnection from the mains df/dt max Maximum permissible mains frequency variation per
second
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In edit mode each digit is modified individually. Example: use the key to incre­ment the selected digit. Once the right value has been selected use the
key to
switch to the next digit and increment it with the
key. Once all digits have been
set, exit edit mode with the
key.
Information
This menu shows the following information:
n Device type (SM2000S, SM3000S, SM4200S, SM6000S) n Firmware version n Date of commissioning n Web address (www.solarmax.com)
Use the arrow key to select the required parameter. Use the key to switch to edit mode for the selected parameter. Use the
key to switch back to the main
menu.
Use the
key to switch back to the main menu.
4.5 Communication activity
If the symbol in the top line of the display is lit the inverter has received data.
Symbol Mode Function / description
No communication (no symbol is displayed)
Comm
Communication activity; this is displayed if the inverter has received data
(synonymous with the activity display of network cards)
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4.6 Status messages
The following table shows the possible status messages, subdivided into four ca­tegories:
Status message Cause
Startup
LED: Flashing (green)
Irradiance too low The solar irradiation is too low; feed
mode is not possible
Startup... In this state the inverter checks all
requirements that must be satisfied in order to enable secure feed mode
Restart in...s After a shutdown this value indicates
the number of seconds after which feed mode will resume
Mains operation
LED: Green
MPP operation The inverter has found the operating
point of the solar generator with the maximum inverter output
Maximum power The inverter limits the output to the
maximum power of the device (this may happen if the solar generator is oversized)
Mains operation The inverter is connected to the mains
and is operating in feed mode
Idc limitation The inverter limits the solar generator
current to the maximum permissible value (this may occur if the solar generator is designed such that the current at MPP exceeds the maxi­mum permissible input current of the inverter)
Iac limitation The inverter limits the mains current
to the maximum permissible value (this may occur in the event of strong irradiance fluctuations or if the solar generator is oversized)
Status message Cause
Malfunction
LED: Orange
Vdc too high The solar generator voltage is too
high
Iac asymmetric The DC component of the mains cur-
rent is too high
Ierr too high A fault current in excess of the
permissible limit value has occurred
on the solar generator side No mains No mains voltage Frequency too high The mains frequency is too high Frequency too low The mains frequency is too low Mains error A mains fault was detected Bad mains quality The 10-minutes mean value of
the mains voltage exceeds the
permissible limit value (according to
VDE0126-1-1) Vac too high The mains voltage is too high Vac too low The mains voltage is too low Temp. too high The inverter has interrupted the feed
mode because the heat sink tempera-
ture exceeds 80 °C
(see also section 2.7) Insulation fault An insulation fault was detected in
the solar generator or in the wiring of
the solar generator
Fault
LED: Flashing (red)
Device error An internal inverter fault has
occurred Overvoltage The DC link voltage of the inverter is
too high Overcurrent An overcurrent has occurred in the
inverter
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4.7 Alarm signals
The alarm messages are displayed in the graphics alternately with the status mes­sage. An alarm does not lead to shutdown, although loss of yield is to be expected. The LED display flashes green and red if an alarm is present. As long as the inverter does not operate in mains mode the alarm message is only displayed in the graph­ics display. In this case the LED display indicates the current device status.
The following table shows the possible alarm messages:
Alarm message Cause
Alarm LED: green/red flashing
Temp. limitation The inverter output is reduced
when the heat sink temperature reaches 75 °C (see also Section
2.7).
Failure fan 1 A failure of the internal fan has
been detected.
Failure fan 2 A failure of the external fan has
been detected.
Failure temp. sensor A failure of the temperature sensor
has been detected.
5 Troubleshooting
5.1 Introduction
Sputnik Engineering only supplies SolarMax inverters that have passed our exten­sive tests. Furthermore, for each device a long-term test under full-load conditions is carried out over several hours.
In the unlikely event of your PV system being affected by a fault we recommend the following procedure:
1. Ensure that the solar generator is correctly installed and connected to the mains. Check the connections and the procedure described in Section 2 (Installation).
2. The integrated graphics display facilitates troubleshooting. Further details are provided in the following subsection.
3. Contact our SolarMax hotline if you are unable to rectify the fault with the suggested measures.
SolarMax-Hotline
Calling from Germany: 0180 / 276 5 276 Calling from Austria: 0049 / 180 276 5 276 Calling from Switzerland: 032 / 346 56 06 Calling from other countries: 0041 / 32 346 56 06 Fax Hotline: 0041 / 32 346 56 26 E-mail: hotline@solarmax.com
www.solarmax.com
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5.2 Troubleshooting via the graphics display
Fault: No graphics display
Possible cause Remedy DC insulation switch switched off Switch on the DC insulation switch Irradiance too low Wait until irradiance is high enough Internal fault Notify SolarMax hotline Strings interrupted Rectify interruption
Malfunction: Graphic s display flashes periodically, or
Status message: Irradiance too low
Possible cause Remedy Irradiance too low Wait until irradiance is high enough
Malfunction: Overtemperature
Possible cause Remedy Ambient temperature too high Ensure air can circulate at the side of
the cooling fans
Insufficient air circulation Fan blocked Clean / replace fan
(see Section 5.3)
Malfunction: Iac asymmetric
Possible cause Remedy DC component of the mains current
is too large
First switch off AC side and then DC side for 20 seconds, then switch on again
For recurring faults contact the SolarMa x hotline
Malfunction: Ierr too high
Possible cause Remedy Fault current too large as level-change
or absolute value
Check solar generator and DC cabling
Earth leakage or insulation fault on the DC side
Equipotential bonding between inverter and module frame
Malfunction: Insulation fault
Possible cause Remedy Earth leakage or insulation fault on
the DC side
Check solar generator and DC cabling
Phase and neutral conductor inter­changed
Swap phase and neutral conductor in the AC coupling connector
Malfunction: No mains, frequency too high
or too low
Possible cause Remedy No grid or mains voltage interruption Check AC connection Mains frequency outside the tolerance Wait until the mains frequency is
within tolerance
Malfunction: Mains fault
Possible cause Remedy Stand-alone operation was detected For recurring faults contact the
SolarMa x hotline
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Malfunction: Vac too low or Vac too high
Possible cause Remedy Mains voltage too low / too high Check mains voltage
Malfunction: Vdc too high
Possible cause Remedy The solar generator voltage exceeds
the permissible value (see Technical data)
Immediately disconnect the DC insulation switch
Check module configuration
Alarm: Failure fan 1
Possible cause Remedy Internal temperature too high or
internal fan faulty
For recurring faults contact the SolarMa x hotline (A faulty fan leads to power reduction or even total shutdown.)
Alarm: Failure fan 2
Possible cause Remedy Internal temperature too high, or
external fan faulty
For recurring faults contact the SolarMa x hotline
Alarm: Failure temp. sensor
Possible cause Remedy Internal temperature too high or
temperature sensor faulty
For recurring faults contact the SolarMa x hotline
Alarm: Temp. limitation
Possible cause Remedy Internal temperature too high: device
reduces output. Check function of the external fan; check and clean the fan grille
For recurring faults contact the SolarMa x hotline
Fault: Device error
Possible cause Remedy Internal fault For recurring faults contact the
SolarMa x hotline
The following error messages can be displayed only during SolarMax initialisation. They indicate a device fault:
Error message Remedy
SUPPLY FAILURE For recurring faults contact the
SolarMa x hotline
ADC REFERENCE ERROR EEPROM ERROR CONFIGURATION ERROR IRRADIANCE TOO LOW Wait until irradiance is high enough
5.3 Maintenance
The SolarMax inverters generally operate maintenance-free. However, we recom­mend checking the AC output in the LC display during strong irradiance at regular intervals.
The cumulative operating and kilowatt hours provide additional information about the performance of your PV system.
A faulty external fan can be replaced without having to open the device: simply release the four fastening screws of the fan and open the cable plug.
Before changing the external fan disconnect the DC circuit breaker and the AC side!
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Other accessories
Product Function
MaxMeteo Logging of solar radiation and cell temperature MaxCount Logging of ESC meter readings MaxConnect plus Connection box with string monitoring MaxDisplay Control of large displays
To use the communication interface(s), enter the following parameters in the “Settings” menu:
Device address
If several inverters are connected to form a network (RS485), each device must have a different address. Addresses between 1 and 249 can be used. Please note that each device in the network must have a different address.
Ethernet (on / off)
To use the right-hand communication socket as Ethernet interface, enter “on”.
IP address
To access your inverter from the local network (LAN), enter a free IP address from your LAN network.
Netmask
Enter the associated subnet mask for your IP address.
TCP Por t
Enter the required TCP port for communication with the inverter. Please note that the TCP port must be greater than 1023, because this range is reserved for pre­defined applications (Well Known Services).
Further information on data communication can be found in the download area at www.solarmax.com
6 Data communication
Sputnik Engineering offers the MaxComm communication platform for solar sys­tems with SolarMax inverters. It offers a wide range of options for data recording and monitoring of your PV system. The following pages provide an overview of cur­rent products. Detailed information and product news can be found on our website at www.solarmax.com.
MaxTalk: for occasional communication or service technicians
The MaxTalk PC software is ideal for occasional inverter data queries or device set­tings. MaxTalk can be downloaded free of charge from our website.
MaxVisio: for smaller PV systems without remote monitoring
MaxVisio is the ideal stand-alone display for smaller PV systems without remote monitoring. MaxVisio displays and records the data for the whole system and for the individual devices. MaxVisio is operated via a convenient touchscreen display.
MaxWeb: the gateway to Internet e-based communication
MaxWeb is a data logger, monitoring unit and web server in one. MaxWeb is the ideal solution for reliable and professional monitoring of your SolarMax PV instal­lation. You can access your installation directly via an Internet connection in order to check current measured values or change your device settings. The data logger records operating parameters, yield values and events and automatically transfers them to the SolarMax web portal. In the event of a fault, MaxWeb sends alarm signals via e-mail or SMS.
SolarMax web portal: system data can be recalled at any time
The SolarMax web portal is the ideal complement to the MaxWeb data logger. The SolarMa x web portal offers access to the data of your PV system from any Internet access point. The SolarMax web portal offers a wide range of graphical and tabular data analysis options for your PV system.
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Block di agram SolarM ax 4200S /6000S
7.3 Safety functions
In order to ensure a high safety standard, SolarMax inverters feature integrated fault current monitoring on the DC side.
In the event of an earth fault current, the fault current monitoring system detects the differential current and interrupts the mains operation. In the event of accidental con­tact, the fault current monitoring system triggers a safety mechanism that switches the device off, thereby preventing electric shock.
7.4 Control functions
SolarMa x features state-of-the-art measuring and control electronics. A digital sig­nal processor (DSP) generates the PWM signals and offers the following inverter control functions:
n Automatic on/off-switching n Grid monitoring (overvoltage, undervoltage, mains frequency, detection of
stand-alone operation)
n Mains synchronisation and sinusoidal current control n Maximum power point tracking (MPPT, searching for the optimum operating
point)
n Output limitation for oversized solar generators n Input and output current limitation n Monitoring of the power electronics n Monitoring of the heat sink temperature n Control of the graphics display n External communication via RS485 and/or Ethernet
UDC
UDC
Step-up converter Bridge circuit Mains relay
EMC Filter
EMC Filter
Fault current
and earth
leakage
monitoring
Graphics display Monitor with digital signal processor PC interface
7 Technical description
A simple and robust design is typical for the SolarMax power unit.
7.1 Technical configuration SolarMax 2000S/3000S
The DC voltage of the solar generator is transferred to a DC bus voltage via a low­loss step-up converter (DC/DC converter). The IGBT bridge circuit generates the sinusoidal infeed current.
Block di agram SolarM ax 2000S/ 3000S
7.2 Technical configuration SolarMax 4200S/6000S
The DC voltage of the solar generator is transferred to a DC bus voltage via a low­loss step-up converter (DC/DC converter). The IGBT bridge circuit generates the sinusoidal infeed current.
The innovative MaxShare concept used in the SolarMax 6000C for the first time leads to a significant increase in efficiency in the partial load range. MaxShare switches the required power stages on or off according to the current output:
UDC
UDC
Graphics display Control unit with digital signal processor (DSP) PC interface
Step-up converter Bridge circuit Mains relay
Fault current
and earth-fault
monitoring
EMC filter
EMC filter
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7.5 Technical data SolarMax 2000S/3000S
SolarMax 2000S SolarMax 3000S
Input si de (DC)
Maximum generator output *) 2300 W
STC 3 300 WSTC
Regelbereich 100…550 VDC Maximum input voltag e 600 VDC Input curr ent 0...11 ADC 0...11 ADC
Output side (AC)
Rated ou tput 1800 W 250 0 W Maximum output 1980 VA 2750 VA Nominal m ains voltage / range 230 V
AC / 184...300 VAC
Power fac tor (PF) > 0.98 Nominal mains frequency/range 50 Hz / 45...55 Hz Harmonic distortion at rated output < 3 %
System data
Maximum efficienc y 97 % 97 % Europea n efficiency 95.4 % @ 40 0 V
DC
94.6 % @ 300 VDC
95.5 % @ 40 0 VDC
94.9 % @ 300 VDC Ambien t temperature –20 °C…+ 60 °C Rated ou tput up to ambient
temperature of
+ 45 °C Relati ve humidity 0…98 %, no condensation Protec tion type IP 54 Circuit t ype dig ital sine wave co ntroller, transformerless, t wo-stage
(no galvan ic isolation) Heat dis sipation convec tion / fan (fan exchangeable from outside) Display graphic LC d isplay 128 x 64 pixels , with backgroun d
illumina tion and status LED Operation three push buttons DC insula tion switch integrated DC insulation switch according to VDE 0100-712 CE-com pliant accordi ng to EN 50178, EN 61000 -6-2, EN 61000- 6-3, EN 61000-3 -2,
EN 61000- 3-3 Mains mon itoring VDE 0126-1-1 Fault cur rent monitorin g VDE 0 126-1-1 Mark of co nformity “Type a pproved” TÜV Rhe inland Additi onal standard s DK 5940, R D 661 Data logger data lo gger for energy yi eld, peak outpu t and operating
duration for the last 31 day s, 12 months and 10 years Data communication RS 485 / Et hernet Fault al arm contact M12 conne ctor with rela y as N/C contac t / N/O contact Dimensions (WxHxD) 545 x 290 x 185 mm Weight 13 kg 13 kg Casing aluminium , cover powder-coated
*) Recomme nded overdim ensioning15 % (ISE F raunhofer st udy) All rig hts, amendme nts and error s reserved .
7.6 Technical data SolarMax 4200S/6000S
SolarMax 4200S SolarMax 6000S
Input si de (DC)
Maximum generator output *) 5000 W
STC 6000 WSTC
Regelbereich 100...550 VDC Maximum input voltag e 600 VDC Input curr ent 0...22 ADC 0...22 ADC
Output side (AC)
Rated ou tput 3800 W 4600 W Maximum output 4180 VA 5060 VA Nominal m ains voltage / range 230 V
AC / 184...300 VAC
Power fac tor (PF) > 0.98 Nominal mains frequency/range 50 Hz / 45...55 Hz Harmonic distortion at rated output < 3 %
System data
Maximum efficienc y 97 % 97 % Europea n efficiency 95.8 % @ 400 V
DC
95.1 % @ 300 VDC
96.2 % @ 400 VDC
95.5 % @ 300 VDC Ambien t temperature –20 °C…+ 60 °C Rated ou tput up to ambient
temperature of
+ 45 °C Relati ve humidity 0…98 %, no condensation Protec tion type IP 54 Circuit t ype digital sine wave controller, transformerless, two-stage
(no galvanic isolation)
Heat dis sipation convection / fan (fan exchangeable from outside) Display graphic LC d isplay 128 x 64 pixels , with backgroun d
illumina tion and status LED Operation three push buttons DC insula tion switch integrated DC insulation switch according to VDE 0100-712 CE-com pliant accordi ng to EN 50178, EN 61000-6-2, EN 61000-6-3, EN 61000-3-12,
EN 61000-3-11 Mains mon itoring VDE 0126-1-1 Fault cur rent monitorin g VDE 0126-1-1 Mark of co nformity “Type approved” TÜV Rheinland Additi onal standard s DK 5940, RD 661 Data logger data logger for energy yield, peak output and operating dura-
tion for the last 31 days, 12 months and 10 years
Data communication RS 485 / Ethernet Fault al arm contact M12 connector with relay as N/C contact / N/O contact Dimensions (WxHxD) 545 x 290 x 185 mm Weight 15 kg 15 kg Casing aluminium, cover powder-coated
*) Recomme nded overdim ensioning15 % (ISE F raunhofer st udy) All rig hts, amendme nts and error s reserved .
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7.8 Efficiency
Efficiency SolarMax 2000S
PAC
[W]
Prelativ
[%]
η(250 VDC)
[%]
η
(300 VD C)
[%]
η
(400 VDC)
[%]
90 5 85.2 85.8 8 7.1 180 10 89.8 90.2 93.2 360 20 93.2 93.5 94.8 540 30 94.6 94.7 95.6 900 50 95.4 95.6 96 .1
180 0 100 95.2 95.4 96.0
European efficiency 94.4 94.6 95.4
Efficiency SolarMax 3000S
PAC
[W]
P
relat iv
[%]
η
(250 VDC )
[%]
η
(300 VD C)
[%]
η
(400 VDC)
[%]
125 5 8 7.0 87. 5 89.7 250 10 91.5 91.8 93.6 500 20 94.2 94.5 95.5 750 30 94.9 95.3 95.6
125 0 50 95.2 95.6 9 6.1 2500 100 94.4 9 5.1 95.5
European efficiency 94.4 94.9 95.5
Effici ency [%]
Output p ower relati ve to rated out put [%]
7.7 Glossary
Symbol Meaning
Frequency Mains frequency f max Maximum permissible mains frequency f min Minimum permissible mains frequency df/dt max Maximum permissible mains frequency variation per second Iac Output current, mains current Iac max Maximum permissible mains current Iac mean DC component of mains current (mains symmetry) Iac mean max Maximum permissible DC component of fed-in mains current Ierr Fault current, stray module current Ierr max Maximum permissible fault current (rms value) on the
DC side Restart delay Restart delay after a shutdown Pac Output Pac max Maximum output Pdc Input power, generator output Vac Output voltage, mains voltage Vac 10min Mean value of the mains voltage over the last 10 minutes Vac 10min max Maximum permissible mean value of the mains voltage over
the last 10 minutes Vac max Maximum permissible mains voltage Vac min Minimum permissible mains voltage Vdc Input voltage, generator voltage
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Efficiency SolarMax 4200S
PAC
[W]
P
relat iv
[%]
η
(250 VDC )
[%]
η
(300 VD C)
[%]
η
(400 VDC)
[%]
190 5 90.8 9 1.0 92.8 380 10 93.6 93.8 94.5 760 20 94.6 95 .1 95.8
1140 30 94.8 95.4 96 .1 1900 50 95.0 95.5 96.2 3800 100 94.4 95.0 95.6
European efficiency 94.6 9 5.1 9 5.8
Efficiency SolarMax 6000S
PAC
[W]
Prelativ
[%]
η
(250 VDC )
[%]
η
(300 VD C)
[%]
η
(400 VDC)
[%]
230 5 91. 0 9 2.1 93.4 460 10 94.1 94.5 95.5 920 20 9 5.1 95.7 96.2
138 0 30 95.2 95.8 96.4 2300 50 95.3 95.9 96.5 4600 100 94.5 95.2 96 .1
European efficiency 94.9 95.5 96.2
Legend:
P
AC output power [W]
P
relativ ratio of output power and rated output [%]
η
(VDC) efficiency at associated input voltage [%]
8 Warranty (Status: 12.11.2007)
8.1 Guarantee
Sputnik Engineering AG (hereafter: Sputnik) guarantees full function and lack of defects of its technical devices at the moment of shipment respectively in cases of sale of devices to natural persons for private use within the EU at the moment of their delivery to the consumer.
This guarantee applies only in case of malfunctions/defects which have been dis­covered within five years (for SolarMax 2000S-6000S) after shipment respectively delivery. The original invoice respectively the delivery receipt serve as proof for the relevant point of time. In all cases of guarantee, Sputnik must be notified of the inconformity clearly and in writing within this deadline.
In guarantee cases, the malfunctioning/defective device will be repaired or re­placed by Sputnik-service personnel within a reasonable time, in either case free of charge, unless this is impossible or disproportionate.
Replacement or repair shall be deemed to be disproportionate if it imposes costs on Sputnik which, in comparison with the alternative remedy, are unreasonable, taking into account:
n
the value the goods would have if there were no lack of conformity,
n
the significance of the lack of conformity, and
n
whether the alternative remedy could be completed without significant inconven­ience to the buyer.
“Free of charge”:
n
The guarantee covers only the costs for labour and materials used by Sputnik to bring the devices back to full function either in Sputnik’s factory or on-site by Sputnik service personnel. All other costs, especially shipping costs, travel and hotel expenses for on-site repairs by Sputnik-service personnel as well as costs of repairs by the buyer himself or other persons are not covered by the guarantee and go to the expense of the buyer or the distributor, unless other­wise specified in a written agreement.
n
In case of sale of devices to natural persons for private use within the EU and Switzerland, shipping costs as well as travel and hotel expenses for on-site repairs by Sputnik service personnel are also covered by the guarantee. How­ever, Sputnik covers only the shipping and travel expenses for the distance between Sputnik and the official Sputnik distributor from which the defective/ malfunctioning device was bought. Furthermore, Sputnik will not cover ship­ping costs, travel and hotel expenses if the sales point of this official Sputnik distributor is located in overseas territories of the EU or outside of the EU / outside of Switzerland.
In any case, Sputnik’s guarantee services are only free of charge if Sputnik has been contacted in advance and has agreed to the services to be provided.
In a guarantee case, the buyer may require an appropriate reduction of the price or have the contract rescinded:
n
if the buyer is entitled to neither repair nor replacement, or
n
if Sputnik has not completed the remedy within a reasonable time, or
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n
if Sputnik has not completed the remedy without significant inconvenience to the buyer.
The buyer is not entitled to have the contract rescinded if the lack of conformity is minor.
Especially in the following cases, this guarantee does not apply and any liability on the par t of Sputnik is excluded:
n
unauthorised technical intrusions, modification s or r epairs of the devices by the buyer himself;
n
us e of d evi ces f or pu rpo ses they are not i nte nded for, i nco rre ct or unr eason­able manipulation, incorrect or unreasonable installation, especially if the installation is made by non-authorised electricians;
n
influence of foreign substances/bodies or superior force (lightning strike, overvoltage, floods, etc.);
n
transport damage and other damage, which has occurred after the point of time in which the risk has passed to the buyer, as well as damage caused by incorrect packaging by the buyer.
This guarantee is compatible with the “Directive 1999/44/EC of the European Parlia­ment and of the Council of 25 May 1999 on certain aspects of the sale of consumer goods and associated guarantees ”. Any legal rights under applicable national leg-
islation within the personal, objective or geographic scope of this directive are not affected.
8.2 Prolongation of Services
Extended services beyond the scope of this guarantee will be provided by Sputnik upon request, according to the terms of a separate agreement on the prolongation of services.
8.3 Limitation of Liability and Warranty
To the maximum extent legally possible, any further liability of and/or alternative claims of warranty/guarantee against Sputnik are excluded. For commercial users, compensatory claims for loss of gain are also excluded.
8.4 Applicable Law
Unless explicitly agreed upon otherwise in writing, and as far as not in conflict with compulsory law, the material provisions of the UN Convention on Contracts for the International Sale of Goods (CISG) apply.
8.5 Place of Jurisdiction
Unless explicitly agreed upon otherwise in writing, and as far as not in conflict with compulsory law, the exclusive place of jurisdiction for all conflicts with Sputnik based on contractual, non-contractual and/or other types of claims lies in Biel, Switzerland.
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Certificate
Länderspezifische Zertifikate und Konformitäten können im Downloadbereich unter www.solarmax.com eingesehen werden
Country-specific certification and conformities can be found and downloa­ded at www.solarmax.com
Les certificats et déclarations de conformité spécifiques à chaque pays peuvent être consultés dans la zone de téléchargement, à l‘adresse www.solarmax.com
Certificados y documentos de conformidad específicos del país pueden verse en la zona de descarga en www.solarmax.com
I certificati e le dichiarazioni di conformità nazionali si possono consultare nella rubrica „Downloads“ del sito www.solarmax.com
Declaration of conformity
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