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ZCS 3PH 100KTL-HV, User Manual

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User’s Manual 3PH 100KTL-136KTL-HV 
Rev. 1.0 24/02/2021 

Identification: MD-AL-GI-00 
Rev. 1.0 of 24/02/2021 - Application: GID 

Dimensions description 

 

• Overall dimensions: H x W x D = 693.5 mm x 995.5 mm x 368 mm 

 

 

 

 

 

Figure 3 – Front, side and back view of the inverter and bracket 

• Labels on the inverter 

Summary of Contents for 3PH 100KTL-HV

Page 1: ... 03225010481 REA AR 94189 ISO 9001 Certified Company Certificate no 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 3PH 100KTL 136KTL HV User Manual ...

Page 2: ...8 3 3 Installation tools 20 3 4 Installation position 22 3 5 Moving the 3PH 100KTL 136KTL HV inverter 25 3 6 Installing the 3PH 100KTL 136KTL HV inverter 27 4 Electrical connections 32 4 1 Electrical connections 33 4 2 Terminal connector 33 4 3 Connecting PNGD cables grounding 34 4 4 Connecting the AC output power cables 36 4 5 Connecting the DC input power cables 41 4 6 Connecting the communicati...

Page 3: ...D AL GI 00 Rev 1 0 of 24 02 2021 Application GID 7 Troubleshooting and maintenance 58 7 1 Troubleshooting 58 7 2 Maintenance 64 8 Uninstalling 65 8 1 Uninstallation steps 65 8 2 Packaging 65 8 3 Storage 65 8 4 Disposal 65 9 Technical data 66 10 Warranty terms and conditions 67 ...

Page 4: ...plant Copyright statement Copyright of this manual belongs to Zucchetti Centro Sistemi S p A No part of this manual including the software etc may be copied 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 ins...

Page 5: ... inverter in the photovoltaic 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 to property Please take note of the foll...

Page 6: ... 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 skills and training to operate the equipment Personnel responsible f...

Page 7: ...s 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 panels produce a voltage that can be dangerous Danger All installation operations must be carried out by a ...

Page 8: ...art 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 EMC Noise Level Electromagnetic compatibility EMC refers to that on e...

Page 9: ...ons 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 Symbols on the inverter Some safety symbols are located...

Page 10: ...021 Application GID Ground connection point Read this manual before installing the inverter Indication of the allowable temperature range Positive and negative polarities of the input voltage DC RCM Regulatory Compliance Mark The product complies with the requirements of the applicable Australian standards ...

Page 11: ...d connected photovoltaic inverters equipped with 10 12 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 must be used as a disconnecting device and must always be easily accessible Figure 2 Grid connected photovoltaic system The 3PH 100KTL 136...

Page 12: ... 1 0 24 02 2021 Identification MD AL GI 00 Rev 1 0 of 24 02 2021 Application GID Dimensions description Overall dimensions H x W x D 693 5 mm x 995 5 mm x 368 mm Figure 3 Front side and back view of the inverter and bracket Labels on the inverter ...

Page 13: ...ut voltage current The power board converts the DC power into AC power The current converted into 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 sho...

Page 14: ...ctrical block diagram AZZURRO 3PH 100KTL 136KTL HV has 16 24 DC input strings 10 12 MPPT trackers that converters the direct current of PV array to grid compliant three phase current and feeds in into the utility grid Both DC and AC side has Surge Protection Device SPD Figure 5 Block diagram of the 3PH 100KTL 136KTL HV inverters ...

Page 15: ...loading is available 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 is called an anti islanding system This protects electrical workers when they are trying to repair lines on the grid in compliance with the applicable national laws and regulations B RCMU The inverters are equipped with a r...

Page 16: ...is indicated by a red LED on the front panel 2 4 Efficiency and derating curves Efficiency curve for an ZCS Azzurro model belonging to the 3PH 100KTL 136KTL HV family Figure 6 Efficiency curve for an ZCS Azzurro 3PH 100KTL 136KTL HV inverter 90 91 92 93 94 95 96 97 98 99 100 Efficiency Of Rated Output Power 125KTL HV Efficiency curve 600V 750V 850V 90 91 92 93 94 95 96 97 98 99 100 Efficiency Of R...

Page 17: ...f 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 A Installation process This section describes the process for installing the 3PH 100KTL 136KTL HV inverter B Checks before installation This section describes the checks to carry out on the outer packaging on the inverter and it...

Page 18: ...ter 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 pac...

Page 19: ...n GID 4 PV input connector 100KTL 20PCS 125KTL 20PCS 136KTL 24PCS 5 PV metal pin 100KTL 20PCS 125KTL 20PCS 136KTL 24PCS 6 PV metal pin 100KTL 20PCS 125KTL 20PCS 136KTL 24PCS 7 M10 90Hexagon screws 4 PCS 8 Auxiliary Handle 4 PCS 9 M6 30 Hexagon screws 2 PCS 10 Manual 1PCS 11 Warranty Card 1PCS 12 Quality Certificate 1PCS ...

Page 20: ...ill bit 10mm To drill holes in the wall for fixing the bracket 2 Screwdriver To screw and unscrew screws for the various connections 3 Wire stripper To prepare the cables for wiring 5 Adjustable spanner opening greater than 32 mm To tighten the bolts 6 4 mm Allen key 6 mm Allen key To screw the inverter to the wall mounting bracket and to open the front cover of the inverter 7 M5 socket wrench To ...

Page 21: ...nd tighten the cable ends 12 Wire stripping tool To remove the outer sheath of the cables 13 RJ45 2 pieces 14 Cable cutter To cut the power cables 15 Crimping tool To crimp the power cables 16 Multi meter To check the voltage and current values 17 Marker pen To mark the wall for better fixing precision 18 Measuring tape To measure distances 19 Level To make sure the bracket is level 20 ESD gloves ...

Page 22: ...AL GI 00 Rev 1 0 of 24 02 2021 Application GID 21 Safety goggles Protective clothing 22 Protection mask Protective clothing 3 4 Installation position Choose an appropriate installation location for the inverter Follow the requirements below to determine the installation position ...

Page 23: ...23 67 User s Manual 3PH 100KTL 136KTL HV Rev 1 0 24 02 2021 Identification MD AL GI 00 Rev 1 0 of 24 02 2021 Application GID Figure 8 Requirements for installing a single inverter ...

Page 24: ...alling multiple inverters Note For safety reasons ZCS S p A and or its partners may not carry out any technical repairs or maintenance work or 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 ...

Page 25: ...g of the inverter Figure 10 Removing the inverter from its packaging 2 Lift the inverter from its packing box and move it to the installation position To prevent damage and personal injury hold the inverter firmly when moving as it is a heavy piece of equipment Do not position the inverter with the input output terminals in contact with other surfaces as these are not designed to support the weigh...

Page 26: ...wo M12 rings into the inverter sides according to the instruction diagram below Note M12 rings need self preparation Figure 12 Installation of rings Fastened and tied the rope through two rings Lifting inverter 50 mm above ground by using lifting equipment check the tightening device of the hoisting ring and rope After confirming that the binding connection is secure lift the inverter to the desti...

Page 27: ...tion such as raining heavy fog winding Attention 3 6 Installing the 3PH 100KTL 136KTL HV inverter 1 Placed the rear panel on the mounting wall determine the mounting height of the bracket and mark the mounting poles accordingly Drilling holes by using Hammer Drill keep the hammer drill perpendicular to the wall and make sure the position of the holes should be suitable for the expansion bolts Figu...

Page 28: ...e expansion bolt vertically into the hole Figure 19 Screws into the holes 3 Align the rear panel with the hole positions fix the rear panels on the wall by tightening the expansion bolt with the nuts Figure 20 Install rear panel 4 Lift the inverter and hang it on the rear panel and fixing both side of inverter with M6 screw accessories ...

Page 29: ...GI 00 Rev 1 0 of 24 02 2021 Application GID Figure 21 Fix inverter 5 Use wall mount bracket ensure the pole position are in same level by using level rule and take a mark with maker Figure 22 Ensure hole position 6 Drilling hole by using Hammer Drill recommend to do a stain proofing ...

Page 30: ...ID Figure 23 Drilling holes 7 Use M10 screw and M10 flat washer to secure the wall bracket Note M10 50 screw and M10 flat washer need self preparation Figure 24 Fix wall bracket 8 Repeat step 4 Note if height between ground and bracket is less than 1 3m use auxiliary handle for installation Otherwise use lifting equipment ...

Page 31: ...31 67 User s Manual 3PH 100KTL 136KTL HV Rev 1 0 24 02 2021 Identification MD AL GI 00 Rev 1 0 of 24 02 2021 Application GID Figure 25 Installation position of auxiliary handle ...

Page 32: ...d be sure to disconnect the strings via the appropriate circuit breakers Danger The maximum open circuit voltage of the photovoltaic string must be less than 1100 V The 3PH 100KTL 136KTL HV has 10 or 12 independent input channels MPPT all the photovoltaic modules connected to them must be of the same model and brand and must be positioned with the same orientation solar azimuth and inclination ang...

Page 33: ...21 Application GID 4 7 Safety check Before operate inverter check the PV array inverter DC side safety connection and AC side safety connection 4 1 Electrical connections Figure 26 Flowchart for connecting cables to the inverter 4 2 Terminal connector Connector description as below take picture as reference ...

Page 34: ... HV inverter to the ground electrode using ground protection cables PGND The inverter does not have a transformer therefore the positive and negative polarities of the photovoltaic string do 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 combiner box and housing of the inverter in the PV power system m...

Page 35: ...wires protruding from the crimped part Note 2 The cavity formed after the conductor has been crimped must completely wrap the conductor wires The core of the wire must be in close contact with the terminal Figure 14 Preparing the ground cable 2 3 Remove the screw from the bottom side of inverter Shown as figure 5 4 connect the grounding cable to the grounding point and tighten the grouping screw T...

Page 36: ...ld connect a three phase circuit current to ensure inverter can be cut off with utility grid for abnormal condition The AC cable need to meet the requirement of local grid operator Cable connection procedure Open the wiring box Use M6 driver to unscrew the two screws on the wiring box Open wiring box cover Note Forbid to open then main board cover of inverter Before open the wiring box please ensu...

Page 37: ...cal grid company for help Inverter can only connect to grid after get the permission from local grid company Should not connect any loads between inverter and AC circuit breaker OT DT Requirement When use copper core cable please use copper terminal connector When use copper clad aluminum cable please use copper terminal connector When use aluminum core cable please use Copper and aluminum transit...

Page 38: ...cable size Name Type Area mm AC Cables Recommended Outdoor four core five core copper or aluminum wire Copper Wire 95 185 Aluminum Wire 120 240 PE Wire reference 5 3 1 Open the cover 2 Turn OFF the AC circuit breaker and secure against reconnection 3 Unscrew the nut of the AC terminal block and select the sealing ring according to the outer diameter of the cable Insert the nut sealing ring into th...

Page 39: ... 02 2021 Identification MD AL GI 00 Rev 1 0 of 24 02 2021 Application GID 5 Crimp the Terminal 6 Depending on the grid configuration connect L1 L2 L3 and N to the terminals according to the label and tighten the screw on the terminal using a screwdriver ...

Page 40: ...on GID Note Phase lines use M12 terminal connector PE line use M8 terminal connector The position of PE Line and N Line should not be opposite Opposite position may cause inverter permanently faulty As shown in the figure below for HV model the N wire does not need to be connected HV model 100KTL HV 125KTL HV 136KTL HV ...

Page 41: ...set to parallel mode Note Connecting PV strings into inverter must following the below procedure Otherwise any faulty cause by inappropriate operation will be including in the warranty case Ensure the maximum short circuit current of PV strings should less than the maximum inverter DC current input And three DC switch is in OFF position Otherwise it may cause high voltage and electric shock Ensure...

Page 42: ...ect the cable according below figure 1 Positive cable 2 negative cable Figure 35 DC cable connection 2 Crimp the PV metal contact pin to the striped cable using a proper crimping pliers 3 Insert wire into the connector cap nut and assemble into the back of male or female plug When you heard a click the pin tact assembly is seated correctly 3 Positive Connector 4 negative connector ...

Page 43: ... PV array positive pole and negative pole Dealing If need to remove the PV connector from inverter side please use the Removal Tool as below diagram move the connector gently Removal procedure To remove the positive and negative connectors from the inverter insert a removal tool in the bayonet coupling and press the tool with adequate force as shown in the figure below Before removing the positive...

Page 44: ...nnector 4 6 Connecting the communication cables Note When layout the wiring diagram please separate the communication wiring and power wiring in case the signal be affected USB Wifi Port Port Description USB WIFI port USB USB PORT Use for updating the software WIFI WIFI GPRS ETHERNET PORT Use for connect WiFi GPRS Ethernet for data transmission Procedure ...

Page 45: ...standards 3 core 4 8 0 25 1 Port Description PIN Define Function Note 1 RS485A RS485 signal Wire connection monitoring or multiple inverter monitoring 2 RS485A RS485 signal 3 RS485B RS485 signal 4 RS485B RS485 signal 5 Electric meter RS485A Electric meter RS485 signal Wire connection Electric meter 6 Electric meter RS485B Electric meter RS485 signal 7 GND S RS485 signal ground 8 DRM0 Remote shunt ...

Page 46: ...46 67 User s Manual 3PH 100KTL 136KTL HV Rev 1 0 24 02 2021 Identification MD AL GI 00 Rev 1 0 of 24 02 2021 Application GID ...

Page 47: ...if the minimum operating temperature allowable is reached should be less than 1100 V Make sure that all the photovoltaic strings are securely connected to the input of the inverter AC Connection Make sure that the AC switch of the inverter is off Check that the phases of the inverter are correctly connected to the grid R S T N PE Check that the type of AC grid in which the inverter is installed is...

Page 48: ... Application GID Zucchetti Centro Sistemi S p A shall not be held responsible for any consequences resulting from the incorrect selection of the country code If the inverter indicates the presence of any faults refer to section 7 1 of this manual or contact the Zucchetti Centro Sistemi S p A technical support ...

Page 49: ...H 100KTL 136KTL HV inverters 6 1 Operating panel and display Buttons and LED indicators Figure 19 LCD display with buttons and LED indicators Main buttons Short press UP button go up Long press UP button exit current interface Short press DOWN button go down Long press DOWN button enter current interface Indicator lights GFI Red light ON GFCI faulty Normal Green light flashing counting down or che...

Page 50: ... connection PV input current and voltage grid voltage current and frequency today generation total generation Inverter working status PV 1 12 PV input voltage and current Inverter working status PV generated power Inverter working status today generated electricity Inverter working status total generated electricity Inverter working status grid voltage and current Inverter working status grid volt...

Page 51: ... Application GID Inverter working status Wi Fi RS485 status Inverter faulty alarm When power turn on LCD interface displays INITIALIZING refer below picture When control board successfully connected with communication board the LCD display the current state of the inverter display as shown in the figure below ...

Page 52: ...sure inverter software and hardware are well functional Inverter will go to Fault State or Permanent State if any error or fault occurs Normal Inverter enter to Normal State it is feeding power to the grid inverter will go to Fault State or Permanent state if any error or fault occurs Fault Fault State Inverter has encountered recoverable error It should recover if the errors disappear If Fault St...

Page 53: ...temInfo 4 Display Time 5 Software Update A Enter setting Interface as below The Settings menu contains the following sub menu 1 Enter Setting Long press DOWN button 1 Set time 11 Logic Interface 2 Clear Energy 12 Set Power Ratio 3 Clear Events 4 Country Code 5 On Off Control 6 Set Energy 7 Set Address 8 Set Input mode 9 Set Language 10 MPPT Scan Long press the button to Enter the main interface of...

Page 54: ...save the specific file into USB and insert USB into inverter communication port On Off Control Inverter on off local control Set Energy Set the total power generation You can modify the total power generation through this option Set address Set the address when you need to monitor multiple inverters simultaneously Default 01 Set Input mode Azzurro 3PH 100KTL 136KTL HV has 10 12 MPPT these MPPTs ca...

Page 55: ...details of real time event records Event will be listed by the happening time and recent events will be listed in the front Please refer to below picture Long press the button and short press the button to turn the page in standard interface then enter into 2 Event List interface 2 Event List 1 Current event 2 History event Fault information 001 ID04 06150825 Display the event sequence number even...

Page 56: ...rovide the new update software called firmware for userif it is necessary The user needs to copy the upgrade file to the USB flash drive 6 4 Updating Inverter Software AZZURRO 3PH 100KTL 136KTL HV inverter offer software upgrade via USB flash drive to maximize inverter performance and avoid inverter operation error caused by software bugs 1 Turn off AC circuit breaker and DC switch remove the comm...

Page 57: ...d ARM in turns If main DSP update success the LCD will display Update DSP1 Success otherwise display Update DSP1 Fail If slave DSP update success the LCD will display Update DSP2 Success otherwise display UpdateDSP2 Fail 8 If Fail please turn off the DC switch wait for the LCD screen turn off then turn on the DC switch again then continue to update from step 5 9 After the update is completed turn ...

Page 58: ...roubleshooting methods and tips The process to check the event list can refers to Manual Even List ID Event List Name Even List Description Solution ID01 GridOVP The power grid voltage is too high If the alarm occurs occasionally the possible cause is that the electric grid is abnormal occasionally inverter automatically returns to normal operating status when the electric grid s back to normal If...

Page 59: ...too high 2 ID11 VGridLineFault Grid Line voltage Faulty ID12 InvOVP Inverter overvolatge ID17 HwADFaultIGrid The grid current sampling error ID17 ID24 are internal faults of inverter turn OFF the DC switch wait for 5 minutes then turn ON the DC switch Check whether the fault is rectified If no please contact technical support ID18 HwADFaultDCI The DCI sampling error ID19 HwADFaultVGrid DC Grid vol...

Page 60: ...gError Input mode incorrect ID45 Reserved ID47 Reserved ID49 Reserved Ensure the installation position and installation method meet the requirements of Section 4 4 of this user manual Check whether the ambient temperature of the installation position exceeds the upper limit If yes improve ventilation to decrease the temperature ID50 TempFault_HeatSink1 Heat sink1 over temperature protection ID51 T...

Page 61: ...ill work back normal ID69 PVOVP PV overvoltage ID70 Reserved ID71 BusOVP BUS overvoltage ID72 SwBusRmsOVP Inverter bus voltage overvoltage software ID73 SwBusInstantOVP Inverter bus voltage instantaneous value overvoltage software ID81 Reserved ID82 DciOCP Dci overcurrent faulty ID83 SwOCPInstant Output instantaneous current protection ID83 are internal faults of inverter turn OFF the DC switch wa...

Page 62: ...utes then turn ON the DC switch Check whether the fault is rectified If no please contact technical support ID130 unrecoverBusOVP Busovervoltagepermanent fault ID131 unrecoverHwBusOVP Busovervoltage hardware permanent fault ID133 Reserved ID134 unrecoverAcOCPInstan t Output transient overcurrent permanent fault ID135 unrecoverIacUnbalanc e Output current imbalance permanent fault ID138 unrecoverPV...

Page 63: ... shunt down ID165 RemoteDerating RemoteDerating Inverter shows ID83 when remote derating If no one operate this function please check the connection I O according to chapter 4 5 ID166 LogicInterfaceDerating Logical interface derating ID167 AlarmAntiRefluxing Anti Refluxing derating ID169 FanFault1 Fan 1 Alarm ID170 FanFault2 Fan 2 Alarm ID171 FanFault3 Fan 3 Alarm ID172 FanFault4 Fan 4 Alarm ID173...

Page 64: ... 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 performing any cleaning operations Cleaning the heatsink Use an air compressor a soft dry cloth or soft bristled brush to cle...

Page 65: ...sal Zucchetti Centro Sistemi S p A is not liable for the disposal of the equipment or parts thereof that does not take place according to the regulations and standards in force in the country of installation The symbol of the crossed out wheeled bin indicates that the equipment at the end of its useful life must be disposed of separately from household waste This product must be handed over to the...

Page 66: ...66 67 User s Manual 3PH 100KTL 136KTL HV Rev 1 0 24 02 2021 Identification MD AL GI 00 Rev 1 0 of 24 02 2021 Application GID 9 Technical data TECHNICAL DATA 100KTL HV 125KTL HV 136KTL HV ...

Page 67: ...1 Identification MD AL GI 00 Rev 1 0 of 24 02 2021 Application GID 10 Warranty terms and conditions To view the Warranty Terms and Conditions offered by ZCS Azzurro please refer to the documentation inside the product box and on the website www zcsazzurro com ...

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