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ZCS 3000TLM LITE, User Manual

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ZCS 3000TLM LITE User Manual Download Page 25

 

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Identificazione: MD-AL-GI-00 
Rev. 4.0 del 31.01.18 - Applicazione: GID 

Manual of 07/06/2019 Rev. 2.1 “User Manual for 3K-6KTLM LITE 

Cross-section of the cable (mm

2

)

 

 

Outer diameter of cable (mm)

 

Range

 

Recommended value

 

4.0-6.0

 

4.0

 

4. 5 - 7. 8

 

 

Table 1 – Recommended specifications for DC input cables

 

The DC input connectors (MC4) are classified into positive and negative connectors, as shown in the figures 

below.  

 

 

Figure 18 – Positive (1) and Negative (2) MC4 connectors

 

Note 

The  positive  and  negative  metal  terminals  are  packed  together  with  the  positive  and  negative  connectors 
respectively. Separate the positive and negative metal terminals after unpacking the inverter so as to avoid 

confusing the polarities. 

Procedure 

1)

 

Remove the cable glands from the positive and negative connectors. 

2)

 

Remove an appropriate length of the insulation layer from the positive and negative power cables by 
using a wire stripper, as shown in the figure. 

Summary of Contents for 3000TLM LITE

Page 1: ... REA AR 94189 Azienda Certificata ISO 9001 Certificato n 9151 CNS0 IT 17778 Zucchetti Centro Sistemi S p A Green Innovation Division Via Lungarno 248 52028 Terranuova Bracciolini Arezzo Italy tel 39 055 91971 fax 39 055 9197515 innovation zcscompany com zcs pec it www zcsazzurro com Grid connected inverter 3K 6K TLM LITE User Manual V2 1 07 06 2019 ...

Page 2: ...3 3 Installation tools 16 3 4 Installation position 18 3 5 Moving the ZCS 3 6 K TLM L inverter 19 3 6 Installing the ZCS 3 6 K TLM L inverter 20 4 Electrical connections 21 4 1 Electrical connections 22 4 2 PNGD cable connections 22 4 3 Connecting the DC input power cables 23 4 4 Connecting AC output power cables 27 4 5 Connecting the communication cables 31 5 Commissioning the inverter 37 5 1 Saf...

Page 3: ... 18 Applicazione GID Manual of 07 06 2019 Rev 2 1 User Manual for 3K 6KTLM LITE 7 2 Maintenance 62 8 Uninstalling 62 8 1 Steps for uninstalling the inverter 62 8 2 Packaging 62 8 3 Storage 62 8 4 Disposal 62 9 Technical specifications 63 10 Warranty 65 ...

Page 4: ...he 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 ...

Page 5: ...or 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 to avoid accidents and damage ...

Page 6: ...nd commissioning the equipment interrupt its operation by turning off the DC switch to disconnect the high voltage direct current of the photovoltaic system The high voltage direct current can also be interrupted by opening the switch of the photovoltaic panel Failure to do so could result in serious injury Qualified personnel Ensure that the operator has the necessary skills and training to opera...

Page 7: ...Please pay attention to the electrical regulations on accident prevention when dealing with photovoltaic inverters Before connecting the mains power be sure to disconnect the photovoltaic modules by disconnecting all the DC switches of the generator When exposed to the sun the photovoltaic generator produces a voltage that can be dangerous Danger All installation operations must be carried out by ...

Page 8: ...is in operation Wear protective gloves Attention Maintenance and repair 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...

Page 9: ...gs 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 Symbols on the inverter Some safety symbols are located on the inverter Read and understand the contents of the symbols before installing th...

Page 10: ...rters are indicated in this section Description of functions It describes how the 3K 6K TLM L inverters and their internal operating modules work Efficiency curve It describes the efficiency curves of the inverter 2 1 Product presentation Field of use The 3K 6K TLM L inverters are grid connected photovoltaic inverters equipped with a dual channel MPPT capable of converting the direct current gener...

Page 11: ...nd 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 Optional components of the inverter should be chosen by a qualified technician who is familiar with the installation conditions Overall dimensions H x W x D 478 mm x 344...

Page 12: ...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 disconnect the inverter from the grid Inverter functions A Feeding reactive power into the grid The inverter is able to produce reactive power and feed it into the grid through the setting of the Power Factor The feed in management can be...

Page 13: ...e GID Manual of 07 06 2019 Rev 2 1 User Manual for 3K 6KTLM LITE Wiring diagram Figure 5 Block diagram of the 3K 6K TLM L inverter 2 3 Efficiency curve Efficiency curve for a Azzurro ZCS 5000 TLM L model Figure 6 Efficiency curve for an Azzurro ZCS 5000 TLM L inverter ...

Page 14: ...ition and surface Assign at least two people to install the inverter Attention 3 1 Installation process Figure 7 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...

Page 15: ...he packaging is missing or damaged The package will contain the following components 1 Photovoltaic inverter 1 mounting bracket 2 input terminals 2 input terminals 2 Metal terminals for DC power cables 2 Metal terminals for DC power cables 2 M5 hexagonal screws 7 M6 flat washers 7 expansion plugs 2 spares 5 self tapping screws 1 user manual 1 warranty 1 certificate 1 AC output connector 1 Terminal...

Page 16: ...r fixing the bracket 2 Screwdriver To screw and unscrew screws for the various connections 3 Wire stripper To prepare the cables for wiring 4 Adjustable spanner opening greater than 32 mm To tighten the bolts 5 4 mm Allen key To screw the inverter to the wall mounting bracket and to open the front cover of the inverter 6 RJ45 crimping tool To crimp the RJ45 connectors for the communication cables ...

Page 17: ...es 11 Cable cutter To cut the power cables 12 Crimping tool To crimp the power cables 13 Multi meter To check the voltage and current values 14 Marking pen To mark the wall for better fixing precision 15 Measuring tape To measure distances 16 Level To make sure the bracket is level 17 ESD gloves Protective clothing 18 Safety goggles Protective clothing 19 Protection mask Protective clothing ...

Page 18: ...D Manual of 07 06 2019 Rev 2 1 User Manual for 3K 6KTLM LITE 3 4 Installation position Choose an appropriate installation location for the inverter Follow the requirements below to determine the installation position Figure 8 Requirements for installing a single inverter ...

Page 19: ...move the inverter from and to the ground if it is installed at a height of more than 180 cm from the ground Inverters installed at higher heights must be moved to the ground before they can be repaired or serviced 3 5 Moving the 3K 6K TLM L inverter This section describes how to move the inverter correctly 1 When opening the packaging insert your hands into the slots on both sides of the inverter ...

Page 20: ...tly position the mounting bracket on the wall using a level to ensure that it is straight mark the five holes using a suitable marker pen Keeping the hammer drill perpendicular to the wall and avoiding any sudden movements when drilling drill the five holes at the points marked on the wall using a 6 mm drill bit In case of errors during drilling it is necessary to reposition the holes 2 Insert the...

Page 21: ...al connections ensure that the DC circuit breaker is switched off Please note that the capacitors in the inverter may remain electrically charged after the DC circuit breaker has been switched off Therefore it is necessary to wait at least 5 minutes to allow the capacitor to discharge completely The inverter must be installed and serviced by professional technicians or electricians Attention The P...

Page 22: ... 4 2 Connecting PNGD cables grounding Connect the 3K 6K TLM L inverter to the ground electrode using ground protection cables PGND The inverter does not have a transformer therefore the positive pole and negative pole of the photovoltaic string does NOT need to be grounded Otherwise the inverter may fail All non current carrying metal parts such as the PV module frame PV rack housing of the combin...

Page 23: ... on the inverter heatsink as shown in the figure tighten the screw to a torque of 3 Nm using an Allen key Figure 16 Connecting the ground terminal 4 3 Connecting the DC input power cables Connect the 3K 6K TLM L inverter to the photovoltaic strings using DC input power cables Select the input mode the 3K 6K TLM L inverter has two MPPTs which can function either independently or in parallel dependi...

Page 24: ...PTs of the inverter Figure 17 Y branch connection cable for solar panels Make sure that the following information is observed Otherwise there is a risk of fire The modules connected in series in each string must have the same specifications The open circuit voltage for each string must be less than or equal to 600 VDC The output power for each PV string must be less than or equal to the maximum in...

Page 25: ... connectors as shown in the figures below Figure 18 Positive 1 and Negative 2 MC4 connectors Note The positive and negative metal terminals are packed together with the positive and negative connectors respectively Separate the positive and negative metal terminals after unpacking the inverter so as to avoid confusing the polarities Procedure 1 Remove the cable glands from the positive and negativ...

Page 26: ...and crimp them using a suitable tool Make sure that the cables are secured so that they cannot be pulled out with a force of less than 400 N as shown in Figure 20 Figure 20 Connecting the DC input power cables 2 5 Insert the crimped power cables into the corresponding seats until you hear a click sound At that point the power cables will be snapped into place 6 Replace the cable glands on the posi...

Page 27: ...figure below Before removing the positive and negative connectors make sure that the inverter s circuit breaker is switched off If not the direct current may cause an electric arc that could result in a fire Warning Figure 22 Removing the DC connector 4 4 Connecting the AC output power cables Connect the inverter to the AC power distribution network or power grid using AC power cables Do not use t...

Page 28: ...ectly sized cables otherwise the current may cause excessive heating or overloading which could result in a fire Figure 23 Do not connect loads between the inverter and circuit breaker Multi core copper cables The cross section of the power line must be sized in order to prevent unwanted disconnections of the inverter from the grid due to high impedance of the cable connecting the inverter to the ...

Page 29: ...with the local grid connection requirements and safety standards The inverters are equipped with AC output connectors with IP66 protection suitable for photovoltaic use customers must provide their own AC output cable connections the figure of the AC connector is shown below Figure 26 AC Output Connector Cable connection procedure 1 Identify the suitable cables as shown in table 2 and remove an ap...

Page 30: ...owing criteria Connect the yellow green wire to the hole labelled PE and tighten the wire with an Allen key Connect the brown wire to the hole labelled L and tighten the wire with an Allen key Connect the blue wire to the hole labelled N and tighten the wire with an Allen key Figure 29 Connecting the AC output cables 3 4 Secure the clamping cable gland by rotating it in a clockwise direction as sh...

Page 31: ...DRMS0 and CT input This chapter describes the steps to be followed for connecting the communication cables Communication port RS485 DRM0 CT cable cross section 0 5 1 5 mm2 0 5 1 5 mm2 0 5 1 5 mm2 Outer diameter 2 5 6 mm 2 5 6 mm 2 5 6 mm Table 3 Recommended specifications for AC output cables 1 Remove the central waterproof cover of the communication terminal block using a star screwdriver Figure ...

Page 32: ... be used DO NOT remove the unused connectors 3 Choose a suitable cable according to Table 4 2 and remove the outer insulating layer using a wire stripper the length of the conductor cable should be about 6 mm insert the cable through the cable gland and the waterproof cable gland as shown in the figure below Figure 33 Inserting the cables into the appropriate cable gland 4 Choose the terminal acco...

Page 33: ...al according to the printed label then tighten the screws to secure the waterproof cover turn the cable glands clockwise to tighten Figure 35 Closing the central door If multiple inverters need to be connected via the RS485 cable refer to the following The RS485 cables are connected in parallel so 4 cables are required to make the connection First connect the two 485 cables TX in parallel then con...

Page 34: ...tal ZCS AZZURRO app or your own monitoring system RS485 For a single inverter it is possible to connect the RS485 port to a terminal such as a PC using a special RS485 USB converter In this way it is possible to create a personal system for data acquisition and monitoring of the inverter upon request of the Modbus RTU proprietary protocol to ZCS S p A Alternatively the RS485 port can be connected ...

Page 35: ...reless signals such as routers Wi Fi modems and network extenders This allows the inverter data to be sent to the ZCS server and the inverter to be monitored remotely Figure 39 Connecting an inverter with Wi Fi For a group of inverters it is possible to connect the different wi fi cards to a single terminal router Wi Fi modem and network extenders This procedure does not require the setting of a p...

Page 36: ...the antenna terminal block and taking care when inserting the pins 3 Use the screws supplied to secure the Wi Fi GPRS module Figure 41 Removing the waterproof cover Figure 42 Installing the Wi Fi GPRS module For more information and instructions on how to configure the communication system refer to the relevant technical notes available at www azzurrozcs com or contact the ZCS service centre ...

Page 37: ...he grid Check that the voltage is within the correct range If possible measure the THD if there is too much distortion the inverter may not operate 5 2 Starting the inverter 1 Turn ON the DC switch both on the field panel and on the photovoltaic inverter if present wait for the screen to turn on 2 Turn ON the AC switch installed on the wall When the photovoltaic string generates enough direct curr...

Page 38: ... Figure 43 LCD display with buttons and LED indicators Main buttons Menu Back to go back or enter the main menu Up to go up or increase the value by 1 Down to go down or decrease the value by 1 OK Enter to confirm the selection and enter the menus Indicator lights Status light GREEN o Flashing wait or status check o Steady normal operation o Off temporary or permanent error Warning light RED o Ste...

Page 39: ...f 07 06 2019 Rev 2 1 User Manual for 3K 6KTLM LITE 6 2 Main interface The main LCD interface is used to display the statuses of the inverter information configuration of parameters etc When the power is turned on INITIALIZATION appears on the LCD screen as shown in the figure below ...

Page 40: ...ance relays and other safety parameters It also runs a self test to ensure that the software and hardware of the inverter are functional The inverter switches to the error state or permanent error state if errors occur Normal The inverter is functioning normally and is feeding power into the grid the inverter will go into a permanent error state if any errors are found Error inverter has encounter...

Page 41: ...nd time Select 1 Date and time and press OK to enter the menu for setting the date time First set the date and then the time using the Up and Down keys then press OK to move to the next character and confirm The date and time are expressed in the format 20YY MM DD HH MM SS The display will show OK if the setting is correct and Error in case of an error The date and time can be seen in the submenu ...

Page 42: ...K to enter the menu for setting the national grid connection regulations If Setting Disabled appears on the display go to step 6 Enable Country to enable this function After enabling the function repeat the steps described above and set the code for the desired country using the Up and Down keys confirming with OK the display will show OK if the setting is successful The current country code can b...

Page 43: ...ommunication address Use the Up and Down keys to select the number and OK to move to the next one and confirm After setting the address press OK The Modbus address indicates the address with which the inverter sends its data to the monitoring server Address 01 is used for single inverters if you want to extend the monitoring to multiple inverters progressive communication addresses will be used No...

Page 44: ...ess the Back key and enter the password again When the password has been entered correctly you can enter the menu The new protection voltage will now be loaded on the inverter automatically If the setting is successful OK will be displayed otherwise Error will be displayed Attention do not enter this menu if the microSD card is not inserted in the appropriate slot of the inverter or if the correct...

Page 45: ...1 using the Up and Down keys to select the number and OK to move to the next one and confirm If the display shows Incorrect try again press the Back key and enter the password again When the password has been entered correctly you can enter the menu With the Up and Down keys you can set the 1 Enable and 2 Disable option and select it with the OK key If the 1 Enable option is selected use the Up Do...

Page 46: ...l operation of the inverter press the Back key to enter the main menu 2 Press the OK key to enter the Settings menu 3 Press the Down key several times until 20 Fast Self test is displayed on the screen 4 Press OK to start the self test 5 The self test will now start automatically once completed press Down to display the self test results as shown in the figure ...

Page 47: ... 06 2019 Rev 2 1 User Manual for 3K 6KTLM LITE Standard Self test 1 During normal operation of the inverter press the Back key to enter the main menu 2 Press the OK key to enter the Settings menu 3 Press the Down key several times until 21 Standard Self Test is displayed on the screen ...

Page 48: ... 31 01 18 Applicazione GID Manual of 07 06 2019 Rev 2 1 User Manual for 3K 6KTLM LITE 4 Press OK to start the self test 5 The self test will now start automatically once completed press Down to display the self test results as shown in the figure ...

Page 49: ... P f and press OK to enter the relative menu from which you can change the active power according to the grid frequency required by the local regulations This function may be required by various regulations for grid connected inverters Use the Up Down and OK keys to set the time delay expressed in seconds s before the changed P active power will intervene ...

Page 50: ...y Command relating to item 6 Relay Command Relay test relating to item 15 Relay Test cannot be used on this model of inverter access to these submenus is not permitted either by the installer or by the end user ZCS S p A accepts no responsibility deriving from the activation of one of the settings described above B Press the OK key to enter the Event List menu The Event List menu is used to displa...

Page 51: ... Country menu Here you can see the country code that has been set Input Use the Up and Down keys in the System Info menu to move and the OK key to enter the 7 Input menu Here you can see the type of input of the photovoltaic strings Power factor Use the Up and Down keys in the System Info menu to move and the OK key to enter the 8 Power Factor menu Here you can see the value of the power factor P ...

Page 52: ...orrect try again press the Back key and enter the password again When the password has been entered correctly you can enter the menu and start updating the firmware Note You can check the firmware version currently installed on the inverter from the Service Code submenu found in the System Info menu IMPORTANT Do not perform any update operation if there is no microSD card inside the inverter or if...

Page 53: ...SENT the microSD card from its slot by pressing lightly on the card and pulling it out of the inverter Alternatively obtain the microSD card yourself Then insert it into the PC using the appropriate adapter 4 Open the microSD card drive and create a new folder with the name firmware making sure to match the lowercase and uppercase letters as indicated and checking that there are no spaces Now copy...

Page 54: ...nce the update has been successfully completed the country code must be changed press the Menu Back key to enter the Settings menu then scroll down to the Set Country item and enter the country code 22 Note if the inverter has been running for more than 24 hours this function must first be enabled from the Enable Country menu which corresponds to item 6 of the Settings menu Enter the password 0001...

Page 55: ...ed Follow the steps below to display the recorded alarms Press Menu Back to enter the main menu from the standard interface Select Event List in the menu screen then press OK to access the list of alarms and errors Information on event list Error code Error name Error description Possible solution ID01 GridOVP The grid voltage is too high If the alarms occurs occasionally the probable cause is tha...

Page 56: ...hin the input voltage range of the inverter The inverter automatically returns to its normal operating state after the string has been corrected ID10 IpvUnbalance The input current is not balanced Check the configuration of the input mode parallel mode independent mode of the inverter as indicated in Section 6 3 C 6 Input mode of this user manual if this setting is incorrect change it according to...

Page 57: ...ster chip fault ID22 HwAuxPowerFault Auxiliary voltage error ID23 BusVoltZeroFault Sampling error of bus voltage ID24 IacRmsUnbalance The output current is not balanced ID25 BusUVP The bus voltage is too low If the configuration of the PV string is correct no ID05 fault present the possible cause is that the solar radiation is too low The inverter automatically returns to its normal operating stat...

Page 58: ... by the inverter then check the input wiring if both are correct contact Technical Support ID49 ConsistentFault_VGrid The grid voltage sampling value between the master DSP and slave DSP is not suitable ID49 ID55 are internal faults of the inverter turn off the DC switch wait 5 minutes and then turn it back on again Check that the fault is no longer present If this is not the case contact Technica...

Page 59: ... high and has caused irreparable hardware failure ID65 ID70 are internal faults of the inverter turn off the DC switch wait 5 minutes and then turn it back on again Check that the fault is no longer present If this is not the case contact Technical Support ID66 UnrecoverBusOVP The bus voltage is too high and has caused an irreparable fault ID67 UnrecoverIacRmsUnbalance The grid current is not bala...

Page 60: ... because the grid current is too high The inverter automatically reduces the output power when the frequency of the electrical grid is too high ID83 RemoteDerating The inverter has been derated by remote control The inverter registers ID83 in case of remote derating operation Check the wiring of the remote input and the port of the output control signal on the communication board according to sect...

Page 61: ...at the heatsink for cooling the inverter has enough space to ensure adequate ventilation and that it is not obstructed by dust or other items Cleaning the inverter Use an air compressor a soft dry cloth or soft bristled brush to clean the inverter Do not use water corrosive chemical substances or aggressive detergents to clean the inverter Disconnect the AC and DC power to the inverter before clea...

Page 62: ... power for each MPPT 2000W 160V 520V 2400W 180V 520V 2600W 200V 520V 3000W 250V 520V 3000W 250V 520V 3500W 300V 520V Number of independent MPPTs 2 Number of DC inputs 1 for each MPPT Maximum DC input voltage 600V Input activation voltage 120V Rated DC input voltage 360V MPPT DC voltage range 90V 580V DC voltage range at full load 160V 520V 180V 520V 200V 520V 230V 520V 250V 520V 300V 520V Max inpu...

Page 63: ...s AC DC MOV Type III Standard Standard EMC EN 61000 6 1 2 3 4 Safety standard IEC 62116 IEC 61727 IEC 61683 IEC 60068 1 2 14 30 IEC 62109 1 2 Grid certificates NB T32004 2013 AS 4777 VDE 0126 1 1 VDE AR N 4105 EN50438 G83 2 G59 3 C10 11 CEI 0 21 RD1699 UTEC15 712 1 Communication Standard communication mode Wi Fi optional RS485 proprietary protocol microSD card optional Additional inputs or connect...

Page 64: ...ntees normal operation of the inverter If the inverter is defective or faulty during the warranty period contact your installer or supplier If the fault falls within the responsibility of the manufacturer Zucchetti Centro Sistemi S p A will provide service and maintenance free of charge Warranty exclusions Use of the 3K 6K TL L inverters for any other purpose than the intended one Defective or fau...

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