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60000TL
User Manual
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ZUCCHETTI 50000TL, 60000TL, 70000TL User Manual

Identificazione: MD-AL-GI-00
Rev. 4.0 del 31.01.18 - Applicazione:
GID
Reg. Pile IT12110P00002965 - Capitale Sociale € 100.000,00 I.V. Reg. Impr. AR n.03225010481 - REA AR - 94189 Azienda Certificata ISO 9001 - Certificato n. 9151 - CNS0 - IT-17778
Grid-connected inverter
50K – 70K TL
User Manual
V1.1 (07-06-2019)
Identificazione: MD-AL-GI-00 Rev. 4.0 del 31.01.18 - Applicazione: GID
Manual of 07/06/2019 Rev. 1.1“User Manual for 50K-70K TL”
Table of Contents
1. Preliminary safety instructions………………………………………...…….…………………………………………………………….6
1.1. Safety instructions…..………………………………………………………..…………………………………………..………………..6
1.2. Symbols and icons……………………………………………………………….…………………………………………………………9
2. Product features……………….……………………………………………………….………….……………………………………………10
2.1. Product overview……….…………………………………………………...…………………………………….……………………..10
2.2. Description of functions……………………………………………………………………………………….……………………....15
2.3. Module protection………………………………………………………………..………………………………………………………18
2.4. Efficiency and derating curves.…………………………………………………………………………….……………………….18
3. Installation..………………………………………………………………………………………………………………………………………20
3.1. Installation procedure…………………………………………………………………...…………………….………………………21
3.2. Checks before installation…………………………………………………………………………………………………………….21
3.3. Installation tools…………………………………………………………………………….…………………………………………….22
3.4. Installation position………………………………………………………………………….….………………………………………24
3.5. Moving the 50K-70K TL inverter……….…………………………………………………….…………………………………….26
3.6. Installing the 50K-70K TL
inverter.………………………………………………………………………………………………..27
4. Electrical connections.……………..…………………………………………………………………..……………………….…………….28
4.1. Electrical connections.……………..…………………………………………………………………..……………………….………28
4.2. Connecting the PNGD ground cable……………..……………………………………………...………………………………..29
4.3. Connecting the DC input power cables………………………….…………..…………………….…………………………….30
4.4. Connecting the AC output power cables……………………...………………..……………………..………………………..34
4.5. Connecting the communication cables……………………...…………………………………………..………………………37
5. Commissioning the inverter……..………………………………………………………..…………………………….……………….....45
5.1. Safety inspection before commissioning………………………………………………………………………….…………….45
5.2. Starting the inverter……………………………………………………………………………………………………………………. 45
6. Operating interface..…………………………………………………………………………………………………………………………..46
6.1. Operating panel and display………………………………………………………………………………….…………..………….46
6.2. Main interface………………………………………………………………..…………………..…………………………………..…….47
6.3. Main menu………………………………………………………………………………………………………….…………………….....49
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7. Troubleshooting and maintenance………………………………………………………………………………………..………….....66
7.1. Troubleshooting…………………………………………………………………………………….…………………………………….66
7.2. Maintenance..…………………………………………………………………………………………...………………………………….74
8. Uninstalling…………………………………………………………………………………….……………...………………………………….75
8.1. Steps for uninstalling the inverter…………………………………………………………………………………………………75
8.2. Packaging…………………………………………………………………………………………………………………………………….75
8.3. Storage…..………………………………………………………………………………………………………………….………………...75
8.4. Disposal…….………………………………………………………………………..…………………………………….…………………75
9. Technical specifications.……………………………..………………………………………………………………………..……………..76
10. Warranty……………..………………………………………………………………………………………………………………..……………78
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Identificazione: MD-AL-GI-00 Rev. 4.0 del 31.01.18 - Applicazione: GID
Manual of 07/06/2019 Rev. 1.1“User Manual for 50K-70K TL”
General instructions
This manual contains important safety instructions that must be followed during installation and maintenance of the equipment.
Please keep these instructions!
This manual must be considered an integral part of the equipment and must always be available to everyone who interacts with this equipment. The manual must always accompany the equipment, even when it is transferred to another user or plant.
Copyright statement
The copyright of this manual belongs to Zucchetti Centro Sistemi S.p.A. No part of this manual may be copied (including the software), reproduced or distributed in any form or by any means without the permission of Zucchetti Centro Sistemi S.p.A. All rights reserved. ZCS reserves the right to final interpretation. This manual is subject to change based on feedback from users, installers or customers.
Please check our website at http://www.zcsazzurro.com for the latest version.
Zucchetti Centro Sistemi
Via Lungarno 305/A
52028, Terranuova Bracciolini (AR)
+39 055 91971
info@zcscompany.com
http://www.zcscompany.com
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Danger: indicates a hazardous situation which, if not resolved or avoided, could result in serious injury or death.
Danger
Warning: indicates a hazardous situation which, if not resolved or avoided, could result in serious injury or death.
Warning
Caution: indicates a hazardous situation which, if not resolved or avoided, could result in minor or moderate injury.
Caution
Attention: indicates a potentially hazardous situation which, if not resolved or avoided, could result in damage to the system, or other property.
Attention
Note: provides important tips on the correct and optimal operation of the product.
Preface
General information
Please read this manual carefully before installation, operation or maintenance. This manual contains important safety instructions that must be followed during installation and maintenance of the system.
Scope
This manual describes the assembly, installation, electrical connections, commissioning, maintenance and troubleshooting of the following inverters:
50000TL / 60000TL / 70000TL
Keep this manual so that it is accessible at all times.
Recipients
This manual is intended for qualified technical personnel (installers, technicians, electricians, technical support personnel or anyone who is qualified and certified to operate a photovoltaic system), who are responsible for installing and starting up the inverter in the photovoltaic energy system, and for operators of the photovoltaic system.
Symbols used
This manual provides information for safe operation and uses certain symbols to ensure the safety of personnel and materials, and for efficient use of the equipment during normal operation. It is important to understand this information in order to avoid injury and damage to property. Please take note of the following symbols used in this manual.
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If you have problems or questions regarding the reading and understanding of the following information, please contact Zucchetti Centro Sistemi S.p.A. through the appropriate channels.
Note
1. Preliminary safety instructions
General information in this chapter
Safety instructions
It mainly highlights the safety instructions to be followed during installation and use of the equipment.
Symbols and icons
Introduces the main safety symbols on the inverter.
1.1. Safety instructions
Before installing and using the equipment, make sure you read and understand the instructions in this manual and familiarise yourself with the relative safety symbols shown in this chapter.
Depending on national and local requirements, permission must be obtained from your local provider before connecting to the electrical grid, making sure that the connections are carried out by a qualified electrician.
Contact the nearest authorised service centre for any repairs or maintenance. Contact your distributor for information on the nearest authorised service centre. DO NOT carry out repairs yourself, as this may result in injury or damage.
Before installing and operating the equipment, the electrical circuit of the strings must be disconnected by opening the string circuit breaker to interrupt the high-voltage DC of the photovoltaic system. Failure to do so could result in serious injury.
Qualified personnel
Ensure that the operator has the necessary qualifications and training to operate the equipment. Personnel responsible for the use and maintenance of the equipment must be qualified and capable of performing the activities described, and must also have appropriate knowledge on how to correctly interpret the contents of this manual. For safety reasons, this inverter can only be installed by a qualified electrician with the necessary training and/or skills and knowledge. Zucchetti Centro Sistemi S.p.A. declines all responsibility for damage to property or personal injury caused by incorrect use of the device.
Installation requirements
Install and start the inverter according to the following instructions. Place the inverter on a suitable load­bearing support with sufficient load capacity (such as walls or photovoltaic racks) and make sure that the inverter is positioned vertically. Choose a suitable location for the installation of the electrical equipment. Make sure there is sufficient space for heat dispersion and to accommodate future maintenance. Maintain adequate ventilation and ensure that there is enough air circulation for cooling.
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Before connecting the mains power, be sure to disconnect the photovoltaic modules by disconnecting all the DC switches of the generator. When exposed to sunlight, the photovoltaic generator produces a voltage that can be dangerous!
Danger
All installation operations must be carried out by a professional electrician, who must:
be prepared. carefully read this manual and understand its contents.
Warning
Before connecting the inverter to the grid, make sure that all the necessary permits have been obtained from the local grid operator and that all the electrical connections are made by a professional electrician.
Attention
Do not remove the information label or open the inverter. Otherwise, ZCS will not provide any warranty or maintenance.
Note
Figure 1 – Do not lose or damage this manual
Transport requirements
If you have problems with the packaging that could damage the inverter or if you find any visible damage, report it immediately to the transport company. If necessary, request assistance from an installer of photovoltaic systems or from Zucchetti Centro Sistemi SpA. Transport of the equipment, especially by road, must be carried out with vehicles suitable to protect the components (in particular, electronic parts) against violent knocks, humidity, vibrations, etc.
Electrical connections
Please pay attention to the electrical regulations on accident prevention when dealing with photovoltaic inverters.
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Contact with the electrical grid or the terminal of the equipment may cause electrocution or fire!
•
Do not touch the terminal or the conductor connected to the electrical grid.
•
Follow all the instructions and safety requirements relating to the mains connection.
Danger
Some internal components reach very high temperatures when the inverter is in operation. Wear protective gloves!
Attention
Before carrying out any repairs, disconnect the inverter from the
mains network (AC side) and from the photovoltaic system (DC side).
After switching off the AC and DC switches, wait 5 minutes before
carrying out any repairs or maintenance on the inverter!
Danger
The inverter should start working again after any faults have been
fixed. For any repairs, contact your local authorised service centre;
Do not disassemble the internal components of the inverter
without permission. This will void the warranty. Zucchetti Centro Sistemi S.p.A. shall not be responsible for any damage or loss caused by these actions.
Attention
Operation
Maintenance and repair
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Pay attention to possible burns due to hot parts. Only touch the screen or press the keys while the inverter is in operation.
Caution
The PV strings should be connected to the ground in accordance with the local regulations!
• To ensure the safety of the system and people, the inverter and
photovoltaic strings must be securely connected to the ground.
Attention
Ensure the correct DC input voltage; which must be below the maximum allowable DC voltage. Overvoltage can cause permanent damage to the inverter or other faults which are not covered by the warranty!
Warning
Residual voltage may be present on the inverter! Before opening the inverter, wait 5 minutes to ensure that the capacitors are completely discharged.
Be careful of high voltage
Be careful of high temperatures
Complies with the European Standards (CE)
Grounding point
1.2. Symbols and icons
Safety symbols
Symbols on the inverter
Some safety symbols are located on the inverter. Read and understand the contents of the symbols before installing the inverter.
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Read this manual before installing the inverter.
Indication of the allowable temperature range
Degree of protection of the equipment according to the IEC 70-1 standard (EN 60529 June 1997).
Positive pole and negative pole of the input voltage (DC).
2. Product features
General information in this chapter Product overview
The field of use and overall dimensions of the 50K-70K TL inverters are indicated in this section.
Description of functions
It describes how the 50K-70K TL inverters and their internal operating modules work.
Efficiency curve
It describes the efficiency curves of the inverter.
2.1. Product overview
Field of use
The 50K-70K TL inverters are grid-connected photovoltaic inverters equipped with a dual-channel MPPT, capable of converting the direct current generated by the photovoltaic strings into three-phase sine wave alternating current and feeding the energy to the public electricity grid. An AC circuit breaker (see chapter 4.4) and DC circuit breaker must be used as disconnecting devices and must always be easily accessible.
Figure 2 – Grid-connected photovoltaic system
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The 50K-70K TL inverters can only be used with photovoltaic modules that do not require one of the poles to be grounded. The operating current and voltage during normal operation must not exceed the limits indicated in the technical specifications. Only photovoltaic modules can be connected to the input of the inverter (do not connect batteries or other power supply sources).
Intended networks
The 50K-70K TL inverters are compatible with network configurations TN-S, TN-C, TN-C-S, TT, IT. For a TT electrical grid, the voltage between neutral and ground should be less than 30V. The figure below shows the diagrams of these grids.
Figure 3 – Wiring diagrams of grid types on which the 50K-70K TL inverter can be installed
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Inverter components
Inverter models of the 50K-70K TL family are divided into three sizes according to their
maximum output power (50 kW, 60 kW, 70 kW).
Inverters with the same output power differ according to the characteristics of the wiring box.
Wiring box 2 can have two configurations, indicated by the letters SX (where X=4.5).
Figure 4 – Bottom view of the inverter
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S4
1. Communication board
2. AC output connectors
S5
1. AC surge arrester (II)
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The inverter model must be chosen by a qualified technician who knows the installation conditions, the
devices that will be installed outdoors and the possible integration with existing systems.
Optional components of the inverter should be chosen by a qualified technician who is familiar with the
installation conditions.
Identification of the type of inverter.
Overall dimensions: H x W x D = 737 mm x 713 mm x 297 mm
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Labels on the inverter
2.2. Description of functions
Figure 5 – Front, side and back view of the inverter and bracket
Figure 6 – Do not remove the label on the side of the inverter
The DC voltage generated by the PV modules is filtered through the input board before entering the power board. The input board also has the function of detecting the insulation impedance and the DC input voltage/current. The power board converts the DC power into AC power. The current converted in AC is filtered through the output board and is then fed into the grid. The output board also has the function of measuring the grid and GFCI voltage/current and acts as an output insulation relay. The control board provides the auxiliary power supply, controls the operating status of the inverter and shows it on the display. The display also shows the error codes when the inverter is not functioning properly. At the same time, the control board can activate the protection relay in order to protect the internal components.
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Operating principles
The control board of the strings measures the input current and voltage, analyses the functioning
state of each PV string, and if anomalies are found on the strings, alerts the user to perform the relative control and maintenance operations.
The DC switch disconnects the internal circuits from the DC input for maintenance purposes. DC surge arresters (category III, category II added on models S4 and S5) provide overvoltage
discharge on the DC side to protect the inverter’s internal circuits against excessive DC voltages.
Electromagnetic and filters (EMI) at the in-feed and out-feed allow filtering the electromagnetic
emissions of the inverters to ensure that they meet the electromagnetic compatibility requirements.
The input board measures the insulation impedance, voltage and current of the various strings; it
also manages the algorithm of the maximum power point algorithm (MPPT) in order to maximise the power generated by the photovoltaic strings.
The DC-AC conversion circuit converts the DC power into AC power and feeds it into the grid, in
compliance with the local requirements.
The insulation relay disconnects the inverter from the electrical network when the grid or the
inverter fails.
The LC filter filters the over-frequency components coming from the AC output of the inverters to
ensure that the energy fed into the grid meets the quality requirements of the grid itself.
AC surge arresters (category III, category II added on S5 models) provide overvoltage discharge to
the AC side in order to protect the internal circuits of the inverters against excessive AC voltages.
The communication board allows the inverter to communicate via RS485 and Wi-Fi (optional); the
user can access all operating data via a web portal from a PC and via APP.
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Figure 7 – Block diagram of the 50K-70K TL inverters
Inverter functions
A. Configurable relay
The inverter has a configurable switching relay that can be used in various operating conditions (set in the menu). For example, it can close normally open contacts when an alarm occurs.
B. Energy management unit
B.1 Remote power on/off
This control can be used to activate/deactivate the inverter via an external (remote) control.
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B.2 Feeding reactive power into the grid
The inverter is capable of generating reactive power and can then feed it into the grid by setting the Power Factor. The feed-in management can be controlled directly by the network operator via a dedicated RS485 serial interface.
B.3 Limiting the active power fed into the grid
If properly set, the inverter can limit the amount of active power fed into the grid at the desired value (expressed as a percentage). To achieve this limitation, it is necessary to use an external device (Anti­Reverse Power Controller) not supplied with the inverter.
B.4 Automatic power reduction when grid frequency exceeds the limit
When the grid frequency exceeds the limit set, the inverter reduces the power in order to ensure the stability of the grid.
B.5 Power reduction due to environmental conditions, input and output voltage
The power reduction value and temperature of the inverter at which it occurs depends on the ambient temperature and on many operating parameters, such as: input voltage, grid voltage and power available from the photovoltaic field. The inverter can therefore reduce the power at certain times of the day and depending on the value of these parameters.
C. Data transmission
The inverter (or a group of inverters) can be monitored remotely via an advanced communication system based on a RS485 interface or via Wi-Fi.
D. Software update
A microSD card is used to update the firmware.
E. Monitoring input strings The inverter monitors and displays the input voltage and current of each string. It also controls the status of the strings and in the event of a fault generates an alarm in the error list (visible from the display).
F. Overvoltage arrester monitoring (only for S4 and S5 versions)
The inverter monitors the status of the overvoltage arresters (both AC and DC), and in the event of a fault generates an alarm in the error list (visible from the display).
2.3. Module protection
A. Anti-islanding
The inverter is equipped with a protection system that automatically shuts down the system during power outages. This so-called “anti-islanding” system protects electrical workers when they are trying to repair lines on the grid according to the applicable national laws and regulations.
B. RCMU
The inverters are equipped with a redundancy on the reading of the ground leakage current, on both the direct and alternating current sides. The ground leakage current is measured simultaneously and independently by two different processors: it is sufficient for one of the two to detect a fault in order to trigger the protection, resulting in separation from the grid and shutdown of the operation.
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C. Grid monitoring
Continuous monitoring of the grid voltage to ensure that the voltage and frequency values stay within the operating limits.
D. Internal protection of the inverter device
The inverter has all kinds of internal protections to protect the device and internal components when abnormal situations occur on the grid or DC input line.
E. Ground fault protection
The inverter must be used with photovoltaic modules connected with “floating” connections, i.e. with positive
and negative terminals that are not grounded. An advanced ground fault protection circuit continuously monitors the ground connection and disconnects the inverter when a ground fault is detected. The ground fault condition is indicated by a red light on the front panel.
2.4. Efficiency and derating curves
Efficiency curve for an Azzurro ZCS 50K-70K TL inverter
Figure 1 – Efficiency curve for an Azzurro ZCS 50K-70 TL inverter
Input power (V) derating curve for an Azzurro ZCS 50K-70K TL inverter
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Figure 9 – Input power derating curve for an Azzurro ZCS 50K-70K TL inverter
Output power (V) derating curve for an Azzurro ZCS 50K-70K TL inverter
Figure 10 – Output power derating curve for an Azzurro ZCS 50K-70 TL inverter
3. Installation
General information in this chapter
This chapter describes how to install the 50K - 70K TL inverter.
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DO NOT install the 50K-70K TL inverter near flammable materials. DO NOT install the 50K-70K TL inverter in an area where flammable or explosive
materials are stored.
Danger
The housing and heat sink may become very hot while the inverter is running, DO NOT install the inverter in places where they may be touched inadvertently.
Warning
Consider the weight of the inverter when handling and transporting the inverter. Choose an appropriate mounting position and surface. Assign at least two people to install the inverter.
Attention
Installation notes:
3.1. Installation procedure
This section describes the procedure for installing the 50K-70K TL inverter
3.2. Checks before installation
This section describes the checks to carry out on the outer packaging, on the inverter and its components.
3.3. Installation tools
This section describes the tools needed to install the inverter and to make the electrical connections
3.4. Installation position
This section describes the characteristics of the installation site of the inverter.
3.5. Moving the inverter
This section describes how to move the inverter to the installation position
3.6. Installing the inverter This section describes the steps for installing the inverter on the wall
3.1. Installation procedure
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1 Photovoltaic inverter
1 mounting bracket
10 + input terminals
for 50K TL
12 + input terminals
for 60K TL & 70K TL
10 - input terminals
for 50K TL
12 - input terminals
for 60K TL & 70K TL
10 Metal terminals for +
DC power cables
(50K TL)
12 Metal terminals for +
DC power cables
(60K TL & 70K TL)
10 Metal terminals for -
DC power cables
(50K TL)
12 Metal terminals for -
DC power cables
(60K TL & 70K TL)
2 M6 hexagonal screws
1 M6 flat washer
Figure 11 – Installation steps
3.2. Checks before installation
Checking the outer packaging
The packaging materials and components may be damaged during transportation. Therefore, please check the materials of the outer packaging before installing the inverter. Check the surface of the box for external damage such as holes or tears. If any kind of damage is found, do not open the box containing the inverter and contact the supplier and transport company as soon as possible.
It is recommended to remove the packaged materials from the box 24 hours before installing the inverter.
Checking the product
After removing the inverter from its packaging, check that the product is intact and complete. If any damage is found or components are missing, contact the supplier and transport company.
Contents of the packaging
Carefully check the contents of the packaging before installation, making sure that no element inside the packaging is missing or damaged.
The package will contain the following components:
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8 M8x80 expansion plugs
1 user manual
1 warranty
1 certificate
10 A Stoppers for 50K TL 12 A Stoppers for 60K TL
& 70K TL
10 B Stoppers for 50K TL 12 B Stoppers for 60K TL
& 70K TL
No.
Tool
Function
1
Drill
Recommended drill bit: 8 mm
To drill holes in the wall for fixing
the bracket
2 Screwdriver (flat and star)
To screw and unscrew the screws
for the various connections (AC
power cables, removal of AC
connectors) 3
Wire stripper
To prepare the cables for wiring
4
Adjustable spanner (opening
greater than 32 mm)
To tighten the bolts
5 6 mm Allen key
To screw the inverter to the wall­mounting bracket and to open the
front cover of the inverter
6 Socket wrench
To screw the bolt for the grounding
connection
3.3. Installation tools
The following tools are required for installation of the inverter and electrical connections; therefore, they must be prepared before installation.
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7 RJ45 crimping tool
To crimp the RJ45 connectors for
the communication cables
8 Rubber hammer
To insert the expansion plugs into
the wall holes
9 MC4 removal tool
To remove the DC connectors from
the inverter
10 Diagonal pliers
To cut and tighten the cable ends
11 Wire stripping tool
To remove the outer sheath of the
wires
12 RJ45 terminal
RJ45 terminal
13 Cable cutter
To cut the power cables
14 Crimping tool
To crimp the power cables
15 Multi-meter
To check the voltage and current
values
16 Marking pen
To mark the wall for better fixing
precision
17 Measuring tape
To measure distances
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