Sunleaf 3000TL, 5000TL, 3600TL, 4000TL Installation And Operator's Manual

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Solar Inverters

INSTALLATION AND OPERATOR'S

MANUAL

Model number: SUNLEAF xxxxTL series for Australia Rev. 1.0

REVISION TABLE

Document

Revision

Author Date Change Description

1.0 Falcon.Tang 07/04/2015 First release

SAVE THESE INSTRUCTIONS !

IMPORTANT SAFETY INSTRUCTIONS

: Reproduction and disclosure of the contents of this manual are strictly

forbidden without prior authorization .

Ge neral notes

The SUNLEAF is a transformerless solar inverter with two channels input of MPPT, and it converts the DC current of PV generator to AC current and feed it into the public grid.When you chose it, you have opted for reliable and powerful technology.With protection class IP65, the units are ready for use in all environmental conditions, and high efficiency meets your requirements.

GENERAL PREC AUTIONS

For your own safety and that of the unit, you must read and understand the instructions contained in this document before starting to work.

Keep these instructions in a place accessible to all the personnel who work with the unit so that these may be consulted.

Only professional technician may install and operate our units.

WARNING:

To avoid risk of electric shock from energy stored in capacitor, please wait for at least 5 minutes to access the conductor part of input or output terminals of the inverter after it is disconnected from the output of PV panel and AC grid.

There is a fuse in our units. For continued protection against risk of fire, replace only with same type and ratings of fuse. The replacement should be done by qualified service personnel.

 The installation of inverter must be performed in full compliance with the

National Wiring Rules of Standard AS/NZS 3000 and other relative local standards and regulations.

 No spare parts in package box. To avoid risk of electric shock, Do not remove

machine cover. No user serviceable parts inside. Refer servicing to qualified service personnel. Please contact your reseller if you need to know the nearest authorized repair center or qualified service personnel.

 As a qualified service personnel, you should know both ac and dc voltage

sources are terminated inside this units. Each circuit must be individually disconnected before servicing.

 Read and understand all the instructions contained in this manual and become

familiar with the safety symbols in the relevant paragraphs before you install and commission the equipment.

 The connection to the AC grid must be done only after receiving approval from

the administering authority as required by national and state interconnection regulations, and can be done only by qualified personnel.

 Keep the whole surface of the photovoltaic panel covered with material

opaque to solar radiation before connecting panel to equipment; this will ensure that no dangerous high voltage is present at the connection cables.

 This unit is designed to feed power to the public power grid (utility) only. Do

not connect this unit to an AC source or generator. Connecting Inverter to external devices could result in serious damage to your equipment. By the way, we have special types for these applications. If you are interested, please contact your local dealer.

 Although designed to meet all safety requirements, some parts and surfaces

of Inverter are still hot during operation. To reduce the risk of injury, do not touch the heat sink at the back of the solar inverter or nearby surfaces while Inverter is operating. By the way, keep it away from any flammable objects.

 This version

SUNLEAF inverters shall be used with

panels

connected in a “floating” way, i.e. with positive and negative terminal not connected to the ground.

The equipment is provided with several labels, some of them with a yellow background, which are related to safety issues. Make sure to read the labels and fully understand them before installing the equipment. The symbols are:

Equipment grounding conductor (Main grounding protective earth, PE)

Alternate Current (AC) value

Direct Current (DC) value

Phase

Grounding (Earth)

Caution: The temperature of metal enclosure may be high during operation.

CONTENT

1. OVERVIEW............................................................................................... 6

2. INSTALLATION....................................................................................... 8

2.1 Package inspection

......................................................................

2.2 Selecting the place of installation

..............................................

2.3 Fixed on the wall.............................................................................9

2.4 System diagram and connection label ...................................... 10

2.5 Connecting to the AC grid (utility)................................................12

2.6 Connecting to PV Panel (DC input) ........................................... 13

2.7 AC output protective device.......................................................... 14

3. CONTROL PANEL FUNCTIONS ..................................................... 14

3.1 Operate the Function Key ........................................................... 15

3.2 Ge n e r a l LC D D i s p l a y In f or mat i on .................................. 17

4. INVERTER START-UP AND OPERATION ...................................... 18

5. COM M UN I C ATION S ...................................................................... ..20

5.1 Data communications with RS232

...............................................

5.2 Data communications with RS485

.............................................

5.2.1 RS485 Serial Port..................................................................... 20

5.2.2 RJ45 Connectors...................................................................... 20

5.2.3 RS485 Daisy Chain................................................................... 21

5.3 Monitor Inverter............................................................................... 22

6. MAINTENANCE ..................................................................................... 22

7. TROUBLE SHOOTING ......................................................................... 23

8. SPECIFICATIONS ................................................................................. 25

1. OVERVIEW

1.1 Ma ch in e Ove rv ie w

Front View Bottom View

Fig.1 Overviews of inverter

display panel

PV input

RS232 outlet

AC terminals cover (AC terminals is inside)

RS485 inlet and outlet

Opening the package

After opening the package, please check the contents of the box. It should contain the following accessories:

Item Name Quantity

1. Solar inverter 1pcs

2. Mounting frame 1pcs

3. Mounting screws and blocks 6pcs

4. Safety-lock screws 2pcs

5. Socket head wrench 1pcs

6. DC socket assembly 2set

RS-485 sockets, one with 120 ohm terminal resistor

2pcs

8. Special RS-232 cable 1pcs

9. Instruction manual 1pcs

10. Monitor

software(

)1pcs

11. Warranty sheet 1pcs

SUNLEAF xxxxTL series include:

SUNLEAF 3000TL, SUNLEAF 3600TL，SUNLEAF 4000TL, SUNLEAF 5000TL

2. INSTALLATION

WARNING: The electrical installation of SUNLEAF inverter must be

performed in compliance with applicable local and national standards and

laws.

WARNING: The connection of SUNLEAF inverter to the AC grid must be

performed only after receiving authorization from the utility that operates

the grid.

2.1 Pa ckage Inspect io n

The customer is encouraged to perform the following checks:  Inspect the package box for apparent damage, such as holes, cracking or any

sign of possible damage to its contents.

 Describe any damage or shortage on the receiving documents and have the

carrier sign his/her full name.

 Open the package box and inspect the contents for internal damage. While

unpacking, be careful not to discard any equipment, parts or manuals. If any damage is detected, call the delivering carrier to determine the appropriate action. Save all shipping material for the event the carrier sends an inspector to verify damage!

 If the inspection reveals damage to the inverter, please call your local supplier

or the authorized distributor. They will determine if the equipment should be returned for repair. They will also provide instructions on how to get the equipment repaired;

 It is the customer’s responsibility to file a claim with the carrier. Failure to file a

claim with the carrier may void all warranty service rights for any damage;

 Carefully store the original packaging of SUNLEAF inverter since it shall be

used in case it is necessary to ship it for repair.

2.2 Se lecti ng th e place of instal lat i o n

Place of installation should be selected based on the following considerations:  SUNLEAF inverters shall be set at a suitable height from the ground to enable

easy readout view of the display and the LEDs.

 Select a well ventilated place sheltered from direct sun radiation. Choose a

place that allows fluent air flow around the unit.

 Allow sufficient room around the unit to enable easy installation and removal of

the object from its mounting surface.

The following figure shows the recommended minimum clearances around the inverter:

Fig.2 Installing minimum clearances around inverter

2. 3 Fi xe d on the wa l l

Step1: Drill 6 or 9 holes as illustrated in the Fig.3 Step2: Fix the mounting frame as illustrated in the Fig.4 by the screws, then, hang the inverter on the mounting frame. Step3: Fix safety-lock screws at left side and right side as illustrated in Fig.5 with the attached socket head wrench. Step4: Check the installation conditions.

For SUNLEAF 3000TLand SUNLEAF 3600TL

Fig.3 The size of mounting frame

For SUNLEAF 4000TL and SUNLEAF 5000TL

Fig.4 Hang inverter to mounting frame

Fig.5 Fix safety-lock screws

The customer is encouraged to perform the following checks:

 Do not install the solar inverter on a gradient surface.  Check the

upper

straps

solar inverter and ensureitto

fit

on to the bracket.

 Ensure safety-lock screws (M5 socket head cap screws) to insert into the

mounting frame through inverter’s heat sink.

 Check the secure mounting of the solar inverter by trying to raise it from the

bottom. The solar inverter should remain firmly attached.

 Choose a

strong

mounting

wall to

prevent

vibrations while inverter is

operating.

2. 4 Sy s tem Dia g ram an d Co n ne cti o n La be l

The SUNLEAF series are a single phase solar inverters with two channels input of MPPT. They are responsible for converting the direct current generated

by PV panels into single-phase 230Vac(or 240Vac) 50Hz alternating current for delivery into the AC grid.

The SUNLEAF series can be used in an on-grid PV system to produce electricity.

The installation of the SUNLEAF series and their connection to the AC grid shall be done in accordance with local regulations and may require the installation of adequate electricity consumption measuring devices.

The SUNLEAF series only operates when it is connected to the AC grid and can not operate as a stand-alone unit.

The simplified connection diagram of the inverter is as follows.

Fig.6 The PV system diagram

A. PV Panels: Provide DC power to inverter. B. Solar inverter: Converts DC (Direct Current) power from PV panel(s) to AC

(Alternating Current) power. Because Inverter is grid-connected it controls the current amplitude according to the PV Panel power supply. Inverter always tries to convert the maximum power from your PV panel(s).

C. DC Switch and AC Switch: “DC switch” is between PV Panels and solar

inverter while “AC Switch” is between AC Grid (Utility) and solar Inverter. They are be simplified in this diagram. In fact, they may consist of electrical breaker, fuse and connecting terminals. To comply with local safety standards and codes, the connection system should be designed and implemented by a qualified technician. also provides the solar inverter with an

integrated DC switch in Fig.6.

D. AC Grid (Utility): Referred to as “grid” in this manual, is the way your electric

power company provides power to your place. Please note that Inverter can only connect to low-voltage systems (namely, 230/240Vac, 50Hz).

Note: provides an integrated switch box that includes DC switch, AC switch, DC fuse, AC fuse, DC SPD and AC SPD devices as an option. Of course, you can get similar switch box from your local market.

Fig. 7 Connections available on inverter bottom and relevant marking

E. PV INPUT: Connected to PV Panels by MC4 terminals for each channels. F. RS232: Connected to monitoring computer by special RS232 cable

. G. RS485: daisy-chain communication for one or more inverters. H. AC TERMINAL (three blocks in right hand): Connected to AC Grid.

2. 5 Co nne c t i ng to th e AC Grid (Util ity)

A. Measure AC grid (utility) voltage and frequency. It should be 230VAC (or

240VAC), 50Hz and single phase. B. Open AC Switch between solar inverter and AC Grid (Utility). C. Open AC terminals cover and connect AC wires on AC terminals as follows:

Fig. 8 AC terminals under AC terminals cover

Re c o mm e n d ed AC wi re s

Mo d e l Di a m e t e r ( m m )

Cr o s s Ar e a ( mm²)

AW G No .

SUNLEAF 3000TL SUNLEAF 3600TL

2.05 3.31 12

SUNLEAF 4000TL SUNLEAF 5000TL

2.59 5.27 10

WARNING: HIGH LEAKAGE CURRENT! EARTH CONNECTION IS NECESSARY BEFORE CONNECTING PV PANEL.

Incorrect grounding can cause physical injury, death or equipment malfunction and increase electromagnetic interference. Make sure that grounding conductors are adequately sized as required by safety regulations. Do not connect the ground terminals of the unit in series in case of a multiple installation. This product can cause current with a d.c. component. Where a residual current operated protective device (RCD) or monitoring (RCM) device is used for protection in case of direct or indirect contact, only an RCD or RCM of Type B is allowed on the supply side of this product. A RCD with a residual current setting of 30mA, located between the inverter and the mains, shall be provided at the endue application!

2. 6 Con nec t in g to PV Pane l (DC in p ut )

A. Under

any

condition! Make sure the maximum open circuit voltage (Voc) of

each PV string is less than 500VDC for SUNLEAF 3000TL, SUNLEAF 4000TL and SUNLEAF 5000TL. The length of input wire must be less than 30m. By the way, generally, in the lowest ambient temperature of your installing field, the Voc of PV string is the highest.

B. Use MC4 (Multi-contact) connectors for PV array terminals.

To ensure maximum output power, we recommend to choose two groups of independent PV array for inverter DC input terminal.

C. Open DC Switch and Connect the positive and negative terminals from the

PV panel to DC switch, then to positive (+) terminals and negative (-) terminals on the solar inverter. Each DC terminal on inverter can withstand 20Adc.

D. When connecting PV panels to DC Switch, then, DC Switch to the terminals

of inverter, please make sure the polarity is correct.

Incorrect polarity connection could permanently damage the unit.

Please confirm short-circuit current of the PV string. The total short-circuit current of the PV string should be less than the inverter’s maximum DC input current.

E. High voltages exist when the PV panel is exposed to the sun. To reduce risk

of electric shock, avoid touching live components and treat connection terminals carefully.

F. To avoid the Electro Magnetic Interference of inverter to the surrounding

equipment, the following right connecting way be recommended.

Note: Ensure that photovoltaic field voltage polarity matches the “+” and “-” symbols. Before connecting SUNLEAF inverters with the photovoltaic field,

recommends to check, using a proper gauge, that the polarity value and

the voltage allowed value between positive and negative contacts are correct.

2. 7 AC ou t p u t prot ect i ve devic e

A. For model SUNLEAF 5000TL the AC output side should be in series an over current protective device which rated 32A, max rated breaking capacity 6KA. B. For model SUNLEAF 4000TL the AC output side should be in series an over current protective device which rated 25A, max rated breaking capacity 6KA. C. For model SUNLEAF 3000TL the AC output side should be in series an over current protective device which rated 20A, max rated breaking capacity 6KA.

3. CONTROL PANEL FUNCTIONS

There is a LCD screen, three LEDs and one function key on the front of the solar inverter. The LCD and LED provide you with details of the status of your Inverter. You also can use this Function key as a simple control.

Fig. 9 Control panel

A. LCD Screen: Display the current power, the today energy, the total energy

and the current time.

B. Display the operating data and situations, warning/error codes and

information.

C. Display the histogram of the power and the time.

D. POWER LED: Indicates the inverter is running normally.

E. ALARM LED: Indicates the alarm of inverter.

F. FAULT LED: Indicates the fault of inverter.

G. Function Key: Used to set different parameter and display language for the

inverter.

Description of inverter.

Note: To save power, the LCD display’s backlight automatically turns off after 10 seconds.

3.1 Op e r a te the Fu n c tio n Key

To view the operating data of the inverter, you can press the Function Key. Of course, the data also will automatically and periodically display. To set different display contrast and display language for the inverter, please carefully refer to the following chart.

To lockup or unlock display message as follows:

3.2 Ge n e ra l LCD Disp l ay In f ormatio n

State Message In LCD

STATE

DISPLAY CONTENT COMMENTS

Wait State

Standby PV input voltage low

Waiting Initial waiting

Connect in xxS System checking

Reconnect in xxS System checking

Inverter connection State

Connect OK Connect to Grid

Fault State

Exx System error code

Wxx System warning code

Auto Test State Auto Testing Protection auto test

Program State Flashing Update Software

Main Operating Messages In LCD

STATE

DISPLAY CONTENT COMMENTS

Normal Operation

SUNLEAF xxxxTL The inverter model Ver SW M1.00-S1.00 The software version Ver HW:J1.0 The hardware version

Vdc=xxx.x/xxx.xV The PV input voltage Idc=xx.x/xx.xA The PV input current Pdc=xxxx.x/xxxx.xW The PV input power

Vac = xxx.xV/Iac = xx.xA

The grid voltage and the output

current of inverter Fgrid = xx.xHz The grid frequency

Error History The history error message

English Current selected language AS4777 Comply with main standard

SN: xxxxxxxxxxxxx The Serial Number

20xxxxxx xx:xx Setting the current time

Buzzer setting Setting the buzzer

PF setting Setting the PF value

Power= xxxx.xW The current output power

Etoday = xx.xkWh The energy today Etotal = xxxxkW H The total energy in lifetime TIME 17:03PM The current time

4. INVERTER START-UP AND OPERATION

WARNING:

Do not place any items on SUNLEAF inverter during operation. When the inverter is operating, do not touch the heat sink since some

parts may become very hot.

Step 1: Ensure that the AC cable and DC cable is connected correctly, unused DC plugs and AC terminal cover are sealed. Step 2: Connect the DC and AC switches. The inverter starts up automatically when DC-power from the PV strings is sufficient. Once the solar inverter starts, it enters one of the following 3 states in turn:

Standby: The PV string can only provide just enough voltage to minimum requirements of the internal controller unit. Waiting: When the PV string DC voltage is greater than 100V, the inverter enters a “waiting” state and attempts to connect to the grid. Normal: When PV string DC voltage is greater than 150V, Inverter operates in the normal state. The Inverter will keep MPPT function and deliver power to AC Grid when it is in normal operation. Maybe it will stop under the situation of low input DC-power, don’t worry, it will automatically restart again when DC-power from the PV string is sufficient.

Error or Warning status

Inverter is designed to be user-friendly, therefore, the error or warning status of the Inverter can be easily understood by reading the information shown on the front panel display. All possible messages are shown in the following table.

DI SP LA Y COMM EN TS

Syst em fau lt

Auto Test Failed Auto Test does not pass W01 No grid No Utility, No Grid Connect W02 Vin overvoltage PV panel Voltage is too high E01 Isolation error Insulation Problem of PV panel E02 Ileak error GFCI Fault, leakage current is too high

E03 Grid fault Grid voltage/frequency is out of range

Inverter fault

E04 Coherence error Consistent Fault E05 Over temperature Internal temperature abnormal E06 Relay failure Output relay Fault E07 DCinj failure Output Current DC Offset too high E08 EEPROM failure EEPROM Fault E09 Com. failure Communication Fault E10 DC bus OV. DC Bus over-voltage E11 DC bus UV. DC Bus under-voltage E12 Vref error 2.5V Reference Voltage Fault E13 DC sensor fault DC current sensor fault E14 GFCI failure GFCI Device is damaged

5. COMMUNICATIONS

5.1 Data communication with RS232

Fig. 10 RS232 serial port and special RS232 cable

Open the cover of RS232 serial port, connect solar Inverter and computer by

special RS232 cable. By the way, the communication distance should be below 10m. If your computer doesn't have any RS232 port, only has USB ports, please buy a RS232-USB converter for the communication in the local market.

5.2 Data communication with RS485

5.2.1 RS485 Serial Port

The RS485 is used for several inverters’ communication. Ethernet cable is applied to connect each inverter herein. Only three cables in ethernet cable are applied: two signal ones and one for ground connection.

Fig. 11 The waterproof RJ45 socket and connectors for RS485 port

To help installation, the inverter features two RJ45 sockets to separate input ethernet cable from output ethernet cable.

5.2.2 RJ45 Connectors

The RS485 serial connection, whether single unit or several inverters as daisy chain, can be performed by means of the RJ45 connectors (See Fig.11).

It makes no difference if its sockets is no.1 or no.2 since they are connected in parallel, and signals are thus the same. One socket is for input ethernet cable with RJ45 connector, another socket is for output ethernet cable with RJ45 connector. The output ethernet cable reaches the following unit.

RS485 pin definition is as follows:

RJ45 connectors

Signal

Name

Description

1 RTN

Signal Return

Common reference for logical signals.

2 Not Used

3 Not Used

4 Not Used

5 Not Used

6 Not Used

7 -TR

- Data Line

Required for RS485 communication.

+TR

+ Data Line

Required for RS485 communication.

NOTE: You can buy T-568B standard Straight-Through ethernet cable to connect two adjacent inverters in local market. Of course, you can do it by yourself and remember the ethernet cable is Straight-Through.

5.2.3 RS485 Daisy Chain

RJ45 connectors may be used to connect a single SUNLEAF inverter or multiple SUNLEAF inverters daisy chained together. Up to 31 inverters can be daisy chained. Recommended maximum daisy chain length is 1000m. With multiple daisy-chained inverters, each unit will be automatically assigned a RS485 address with monitoring software. The RJ45 socket with120Ω terminal resistor should be installed at the last inverter in the chain. provides a special RJ45 socket with terminal resistor and a vacant RJ45 socket in the attached accessories. When the inverter is not the last one in the chain, please draw out the terminal resistor and use it as a vacant RJ45 socket. In order to ensure that the communication on the RS485 line is very safe, recommends connecting an isolating RS232-485 adapter between the first inverter in the daisy chain system and the computer. Of course, non-isolating RS232-485 adapter can also work.

The following diagram shows how to connect multiple inverters in a daisy chain configuration.

Fig.12 Multiple daisy-chain connection

NOTE: The RS485 link supports up to 31 inverters. NOTE: The RJ45 socket with120Ω terminal resistor should be installed at the last

inverter in the chain. Even if there is only one inverter, the 120Ω terminal resistor is also necessary.

5.3 Monitor Inverter

After RS232 or RS485 link is connected correctly, open monitoring software

communicator” that is installed from the attached CD, the user can monitor the inverters. The right side of the main interface is the detailed information of inverter. As to more detailed setting methods and other functions, please refer to “ communicator user’s manual” in the CD.

6. MAINTENANCE

The inverter is maintenance-free. Take it easy for its daily operation.

7. TROUBLE SHOOTING

In most situations, the Inverter requires very little service. However, if Inverter is not able to work perfectly, please refer to the following instructions before calling your local dealer or service personnel. If any problems arise, the “Alarm” LED on the front panel will be red and the LCD displays the relevant information. Please refer to the following table for a list of potential problems and their solution.

DISPLAY HOW TO DO ? No any display in LCD or LED

Check PV-input connections

W01 No grid

Check grid connection cables.

W02 Vin overvoltage

Check the Voc of PV string, see if it is

greater

than or too close to max. input DC voltage

relative inverter type.

E01 Isolation error

Check the impedance is between PV (+) &

(-) and the PV-Inverter is earthed.

The

impedance must be greater than 2MΩ

E02 Ileak error

The leakage current is too high. Unplug

the

inputs from the PV string and check

the

peripheral AC system.

E03 Grid fault

Make sure grid voltage and frequency meet

the

specifications

NO TE: During periods of little or no sunlight, the solar inverter may continuously start up and shut down. This is due to insufficient power generated to operate the control circuits, not a trouble.

If you ca n not solv e the tro ubl e wit h abo ve pr oce dure s, Pl ease contact your local dealer or service personnel.

Before contacting the authorized local dealer or service personnel, please find and keep at hand the following information:

Information of SUNLEAF inverter

1. Inverter Model

2. Serial Number

3. Week of manufacture

4. Which LED is red?

5. Which warning/error is displayed?

6. Do you notice whether warning/error can be repeated?

Information of the PV array

1. The model and manufacturer of the PV panels.

2. Number

strings

in the PV

array

and number

panels

per

string

Parameter

8. SPECIFICATIONS

Model

SUNLEAF 3000TL SUNLEAF 3600TL

Input Data

Max. DC power 330 0W 396 0W

Max. DC voltage 500V 500V

MPPT operating voltage rang e

100V-500 V 100V-500 V

Numbe r of para llel inpu t s

2 2

Number of MPP trackers

1 1

Max. input current

(total)

22.0A 22.0A

Output Data

Nominal AC output

power

3000W 3600W

Max. continous power 300 0W 3600W

Max. output current 15.0A 18 .0A

AC grid voltage range 206~270Vac 206~270Vac

AC grid frequency range

47~52Hz 47~52Hz

Power factor

(cosφ)

-0.9(l eadi ng)~0.9(la gging) -0.9(leading)~0.9(lagging)

THDI(at nominal output

power)

<3% <3%

AC connection Single phase Single phase

Max. efficiency 96.7% 96.7 %

Euro efficiency 96.2% 96.2%

MPPT efficiency 99.8% 99.8%

General Data

Dim ensions (W /D / H) in

358 /153/380 358/153 /380

Weight

15.5Kg 15.5Kg

Operating temperature range

–25 °C ~+60 ° C –25 °C ~+60 °C