Instruction manual - HQSOLhqsol.it/wp-content/uploads/2016/06/Solarmax_C... · SolarMax converts...

TÜVRheinland

Product Safety

BAUARTGEPRÜFT

TYPEAPPROVED

Instruction manual

The inverter for grid-connected PV installations

Always a sunbeam ahead

SolarMax 2000C/SolarMax 3000CSolarMax 4000C/SolarMax 4200C SolarMax 6000C

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1 IntroductionThank you for choosing a SolarMax solar inverter!

SolarMax converts the direct current from your solar system into grid-compliant alternating current.

As a solar system operator you expect reliability and high yield from your system. With our SolarMax range we offer inverters that fully meet these requirements. The SolarMax inverter range is characterised by high effi ciency and high availability.

The inverters carry the CE mark as a sign of compliance with European Union Direc-tives. The “Type Approved” quality mark from TÜV Rheinland confi rms compliance with all relevant safety standards.

The Management

Sputnik Engineering AGHöheweg 85CH-2502 Biel

E-Mail: [email protected]

SolarMax string inverter: powerful, reliable, innovative.

Headquarters of Sputnik Engineering AG in the former Rolex building in Biel, the Swiss watch metropolis.

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7 Technical description 28 7.1 Technical confi guration SolarMax 2000C/3000C 28 7.2 Technical confi guration SolarMax 4000C 28 7.3 Technical confi guration SolarMax 4200C/6000C 29 7.4 Safety functions 29 7.5 Control functions 30 7.6 Technical data SolarMax 2000C 31 7.7 Technical data SolarMax 3000C 32 7.8 Technical data SolarMax 4000C 33 7.9 Technical data SolarMax 4200C 34 7.10 Technical data SolarMax 6000C 35 7.11 Effi ciency 36

8 Guarantee for String Inverters 38 8.1 Guarantee 38 8.2 Prolongation of guarantee 39 8.3 Limitation of liability and warranty 39 8.4 Applicable law 39 8.5 Place of jurisdiction 39

9 Declaration of conformity 40

10 Clearance certifi cate 41

11 Mark of conformity 42

Contents 1 Introduction 2

2 Safety instructions 5

3 Installation 6 3.1 Installation 6 3.2 Electrical connection 9 3.3 Overvoltage protection 13 3.4 Switching on and off 14 3.5 Removal 14 3.6 Manually adjustable parameters 15 3.7 Heat sink temperature limit 15

4 Operation and fault display 16 4.1 LC-Display 16 4.2 Menu structure 16

5 Options 21 5.1 MaxComm data communication 21 5.2 Fault alarm contact 22

6 Troubleshooting 23 6.1 Introduction 23 6.2 Troubleshooting via the LC display 24 6.3 Maintenance 27

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3 InstallationSolarMax inverters operate with high DC voltages. The complete system must therefore be installed with great diligence, following all relevant regu-lations. Contact with live parts can cause critical injuries or death. Only

suitably qualifi ed personnel may connect the SolarMax inverter to the mains. The installer must be approved by the relevant energy utility company.The maximum solar generator output can be found in the data sheet (Section 6).

Warning: The device may only be opened in de-energised state (AC and DC side). Wait for fi ve minutes to allow the capacitors to discharge.

3.1 InstallationThe device should be installed and connected with the cover closed. Sputnik Engineering has developed a new installation set in order to simplify the installation. The set includes two galvanised hanger bolts (M6 x 120 mm) with nuts and two wall plugs. The hanger bolts are anchored in the wall. The SolarMax inverter can then be pushed over the two screws and fi xed with the nuts. Detailed assembly instruction are available in the form of a video fi lm on our website.

For maximum mounting security please refer to the following drawing:

Wall

Hanger bolt M6* 120 Torx T15

Nut M6 Inox

Washer M6

Wall plug 8 mm

Inverter

Hole in wall d= 8 mm I= 60 mm

2 Safety instructions

■ Large arcs may be generated if connectors are disconnected on the DC side during operation. The AC cable must therefore be disconnected before removing MC con-nectors. For this reason, unauthorised persons must be prevented from discon-necting connectors.

■ Caution: The discharge duration of the capacitors is 5 minutes.

■ Please follow the detailed installation instructions in Section 3.

■ Failure to observe the installation instructions will void any warranty and liability.

■ Disconnect your SolarMax inverter from the mains by disconnecting the AC feed line before carrying out any maintenance and cleaning on the solar generator.

■ Please follow the general local installation regulations.

■ SolarMax inverters may only be installed and opened by qualifi ed electri-cians.

■ Before opening the SolarMax device, the DC and AC feed lines must be dis-connected.

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Please note:■ The SolarMax device is installed inside a building, the space should be well venti-

lated.

■ The surface must be fi rm.

■ For fl ammable surfaces an additional fi reproof panel must be used, since the heat sink may reach temperatures of up to 75 °C.

■ Please refer to the technical data for the maximum ambient operating tempera-ture.

■ For optimum cooling the following distances should be adhered to: 1 m upwards, 0.8 m downwards, 0.2 m to the side.

■ If several devices are used, they should be installed side by side. If the devices have to be installed above each other due to space constraints, a minimum of 0.8 metres should be adhered to. If different SolarMax models are used, they should be installed in the following order (top to bottom): SolarMax 2000C, SolarMax 3000C, SolarMax 4000C, SolarMax 4200C, SolarMax 6000C.

■ In external installations direct insolation should be avoided. A protected instal-lation location, for example under a canopy or a solar module, would be an advan-tage. The device should also be protected from splashing, for example rainwater dripping off roof or module edges.

■ The inverters must not be installed in cabinets, enclosed recesses or similar locations.

■ Do not store fl ammable liquids near the inverter. Do not subject the inverter to fl ammable gases or vapours.

■ The inverter must be positioned out of reach of small children.

■ The inverter and the supply lines must be installed such that they are inaccessible forpets (especially rodents).

■ Due to noise emission it is advisable to avoid installation in living areas.

Menu button AC connector MC connector

The SolarMax housing meets the requirements of protection type IP 54 and is suit-able for outdoor installation.

Protection rating IP 54 is only met if the enclosed AC connector and the solar gene-rator are connected via the MC-4 connectors.

In order to maximise the energy yield it is important to position the inverter correctly. The lower the ambient temperature, the more effi ciently the inverter will operate.

Notwithstanding the high effi ciency of the SolarMax inverter, approx. 5 % of the power has to be dissipated in the form of heat. To this end the base of the device is made from cast aluminium, which ensures adequate cooling via convection and an additional fan (exception: SolarMax 2000C).

554 mm

522 mm

260

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196 mm

52 mm 1123

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Assembly of the AC cable socket SM2000C/3000C/4000C:

Ensure that the cable is de-energised.■ Connect the AC coupling connector with a fl exible cable according to

EN 60309-2 / VDE 0623.

■ Push the screwed cable gland with the threaded sleeve over the cable.

■ Press wire end sleeves onto the strands.

■ Connect the individual wires with the insert in turn as follows (strand cross-section: see Table p.12).

Protective earth conductor PE with the screw terminal with earthing symbol Neutral conductor N with screw terminal 1 Phase L with screw terminal 2 Screw terminal 3 remains unconnected

■ Ensure that the wires are connected properly.

■ Firmly screw the threaded sleeve onto the insert.

■ Screw the lower section into the threaded sleeve.

■ Insert the sealing insert and tighten the forcing nut.

Insert withthreaded ring

Threaded sleeve nut Lower section Sealing insert Lorcing

Screwed cable gland M20 x 1.5

3.2 Electrical connection Sputnik Engineering supplies the SolarMax inverters with internal connections estab-lished and with plug connectors/sockets installed. All connections are pluggable. The device therefore does not have to be opened.

The following connections are available:■ DC: 2 x 3 MC4 sockets (3 strings with MC4 plug connectors)■ AC: Binder fl ange connector■ Communication: 2 x RJ45 (sealed with protective caps)■ Fault relay: Blind plug -> can be replaced with a stuffi ng box (20 mm dia.)

SM2000C/3000C/4000C

SM4200C/6000C

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Back-up fuses and cable cross-sections

Follow the generally accepted state of the art. Start on the AC side.

AC side:

Type 2000C 3000C 4000C 4200C 6000C

Back-up fuse(characteristic C) 10 A 13 A 16 A 20 A 25 A

Recommended cable cross-section (strand) 1,5 mm

2 1,5 mm2 2,5 mm2 2,5 mm2 2,5 mm2

The fl exible cable is connected to a junction box with a maximum length of one metre. From here the installation may be continued with a rigid TT cable.

DC side:Select the cable cross-sections on the DC side to suit your system confi guration and in accordance with the relevant installation regulations.

■ When several SolarMax devices are connected, the inverters should be distributed to the three mains phases in order to avoid interference between the ENS monitor-ing units of the individual devices. Several SolarMax devices should only be con-nected to the same mains phase if the mains impedance is small (< 0.7 Ohm).

■ AC and DC cables must be suitable for the expected loads, currents and ambient conditions (temperature, UV, etc.).

■ The personal protection regulations must be followed when the inverter is con-nected to the AC system.

■ Ensure that the mains cable is de-energised before connecting the device.


■ Verify the polarity before installing the DC side.

■ Ensure short circuit- and earth-leakage-proof connection of the DC cables to the MC terminals.

■ Caution: Due to the earth-fault monitoring function, neither the minus nor the plus terminal should be earthed. Otherwise the integrated insulation monitoring func-tion would prevent grid feeding.

■ Connect the DC side via the MC connectors.

■ Caution: The maximum load for the MC connectors is 16 ADC. For higher input currents, 2 inputs have to be connected in parallel.

SM4200C/6000C:

■ Ensure that the cable is de-energised.

■ Connect the AC coupling connector with a fl exible cable according to EN 60309-2 / VDE 0623.

■ Push the screwed cable gland with the threaded sleeve over the cable.

■ Press wire end sleeves onto the strands.

■ Push the insert into the socket body until it engages.

■ Place the -ring over the insert.

■ Connect the individual wires with the insert in turn as follows (strand cross-section 2.5 mm2 / see Table p.12).

Protective earth conductor PE with the screw terminal with earthing symbol Neutral conductor N with screw terminal 1 Phase L with screw terminal 2 Screw terminals 3 and 4 remain unconnected


■ Firmly screw the threaded sleeve onto the socket body.

■ Screw the lower section into the threaded sleeve.

■ Insert the sealing insert and tighten the forcing nut.

If your system consits of more than three strings, we recommend consolidating the strings in a junction box. In this case the junction box should be connected to the SolarMax device.

-ring 21x1.5

Socket body

Insert

Coupling sleeve

Lower section

Sealing insert

Forcing nut

Screwed cable gland M20x1.5

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3.4 Switching on and off■ All SolarMax inverters operate fully automatically and maintenance-free. The

electrically isolating switches between the solar generator, the inverter and the 230 V grid always remain switched on. SolarMax will start and transfer power to the 230 V grid when the irradiance is high enough. Otherwise the device remains in standby mode and is thus available for grid feeding at all times. Over night the electronic system is disconnected from the mains.

Voltage may only be applied on the DC and AC side of the SolarMax with the device closed.

Switching on:■ Switch on the PV generator isolation device or connect the MC connector. The LC display switches on. During the night or at times of insuffi cient irradiance the LC display is off.

No energy is consumed.

■ Switch on the AC isolating switch (may be fused).

Switching off:■ Switch off the AC isolating switch. First switch off the AC isolating switch, particu-

larly in installations without DC switch.

Large arcs may be generated if connectors are disconnected on the DC side or the AC during operation.

■ Switch off the PV generator isolation device. The LC display switches off.

3.5 Removal■ The device does not have to be opened for demounting.■ The inverter must be de-energised. First disconnect the device from the mains

on the AC side via the AC line protection breaker or the fuse. Open then the PV generator isolation device or disconnect the MC connectors in order to disconnect the inverter from the solar generator fi eld.

■ Before releasing the mounting screws ensure that the bottom of the device (cast aluminium heat sink) has suffi ciently cooled so that the device can be touched for safely for demounting.

■ Release the two fi xing nuts from the hanger bolts and lift the inverter off the wall.

Large arcs may be generated if connectors are disconnected on the DC side or the AC during operation. The AC cable must therefore be discon-nected before removing the connectors.

Earthing (second protective earth connection)

Without a connection to the solar generator the stray current of the inverter is less than AC 3.5 mA. However, during operation of the solar generator, the stray current at inverter may far exceed the value of AC 3.5 mA. In this case a second, fi xed protective earth connection according to EN 50178 is required. The cross-section of the second protective earth conductor should have at least the same cross-section as that of the main terminal.

3.3 Overvoltage protectionThe SolarMax inverters feature integrated surge arresters at the input and output. On the DC side 2 surge arresters (varistors) for the plus and minus terminal to earth are installed. On the AC side a surge arrester (varistor) is installed between the phase and neutral. All surge arresters meet the requirements of class D according to VDE 0675-6 or Type 3 according to EN 61643-11.Note the following if the overvoltage protection on the DC is to be increased:

■ For inverters without galvanic isolation the DC terminals have a potential relative to earth that may be higher than the peak value of the mains voltage. For this reason the trip voltage of the surge arrester must be higher than 680 Vrms.

The diagram on the right shows the connection of additional surge arresters on the DC side.

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4 Operation and fault display4.1 LC-DisplayThe two-line LC display at the front is used to display system parameters, status information and fault reports for the SolarMax device, thereby offering the user con-venient options for obtaining information about the device status.

The Menu button is used for selecting different display options. ■ Pressing the button briefl y will show the current menu display positions.

■ Pressing the button longer (> 1.5 sec.) changes the menu (operating status - measurement readings – long-term measurement - confi guration).

The Menu button can also be used for setting the date and time, for selecting the language for the text displays (German, English, French, Italian or Spanish), for re-setting the long-term measurement readings (kWh, operating hours), and for setting the device address.

4.2 Menu structureThe display options are subdivided into four separate menus:

■ Operating status■ Measurement readings■ Long-term measurement■ Confi guration

3.6 Manually adjustable parametersIn the SolarMax C series the following parameters can be set manually via the inter-face with the MaxTalk software. The settings are password-protected. A password application form can be ordered via the SolarMax hotline. The password is only made available to installers who sign the form. The password is usually not made available to private individuals and system operators.

Parameter Factory setting Manual range Min./max. mains voltage 196 ... 253 V 196 ... 264 VMin./max. mains frequency 49.8 ... 50.2 Hz 45 ... 52 HzMax. frequency change/s 1 Hz 0.5 ... 5 HzENS (monitoring of step changes in mains impedance)

1 Ω 0.5 Ω, 1 Ω, inactive

Max. increase in fault current 25 mA 15 ... 30 mA

Max. DC current in AC current 1 A 0.6 … 1 A

Start delay after shutdown 10 sec. 10 … 600 sec.

Max. Pac SM2000C: 1980 WSM3000C: 2750 WSM4000C: 3800 WSM4200C: 4180 WSM6000C: 5060 W

SM2000C: 990…1980 WSM3000C: 1375…2750 WSM4000C: 1900…3800 WSM4200C: 2090…4180 WSM6000C: 2530…5060 W

Max. Iac SM2000C: 12 ASM3000C: 12 ASM4000C: 16 ASM4200C: 19 ASM6000C: 22 A

SM2000C: 6...12 ASM3000C: 6...12 ASM4000C: 8...16 ASM4200C 9...19 ASM6000C: 11...22 A

The set values can be queried via the display in the Confi guration menu (see section 4.2 Menu structure).

3.7 Heat sink temperature limitFor safety reasons the temperature of the heat sink is limited to 75 °C. Such a limi-tation may be required for ambient temperatures of more than 40 °C. In this case the power supplied is reduced such that the heat sink temperature does not exceed 75 °C. The device is switched off if the heat sink temperature continues to increase despite the power reduction.

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3. Active powerCumulative energy yield / day

4. Heat sink temperatureFan status (except SolarMax 2000C)

Display text Meaning

Fan running The fans (internal and external) are operating (SM300C only external)

Fan off The fans (internal and external) are switched off

Fan faulty Internal fan faulty

Long-term measurement menu:1. Cumulative energy yield / day

Cumulative energy yield / last operating day2. Cumulative energy yield / month

Cumulative energy yield / last operating month3. Cumulative energy yield / year

Cumulative energy yield / last year of operation 4. Cumulative energy yield overall

Total operating hours 5. First (i.e. current) fault entry6. Second fault entry7. Third fault entry

Explanation of error codesIn the long-term measurement menu the last three faults are displayed. In addition to the date and time (in the bottom line) an error code is displayed at the top right. These error codes correspond to the error messages described in Section 5.2. The following table provides an overview of the codes.

Code Error message

16385, 16386, 16388, 16392 System fault FI test

16400, 16416 System fault insulation fault

16448, 16512 System fault mains relay

16640,16896 Voltage incorrect Udc too high

17408, 18432 Stopped due to overvoltage or overcurrent

20480 Stopped due to asymmetric mains current

24576 Stopped due to fault current

32769, 32770, 32772 Grid monitoring, no grid available orfrequency too high, or frequency too low

32776 Grid monitoring, ENS shutdown

32784 Grid monitoring, RSS too strong

32896, 33024 Grid monitoring, Uac too high or too low

33280 Stopped due to overtemperature

Operating status menu:1. Operating statusThe following fault and operating status parameters can be displayed via the opera-ting status menu item:

LCD DISPLAY TEXT MEANING

Line 1 Line 2Operating status display

**** INFO **** Start-up.... The switch-on procedure is underway

**** INFO **** In operation.... SolarMax is in mains operation mode

**** INFO **** Operation at MPP Operation at optimum operating point

Operation at Rated output SolarMax feeds in the rated output

**** INFO **** DC current limitation The power is limited because the DC current is too high

**** INFO **** Temp. limitation The power is limited because the temperature is too highError messages

System fault FI test

Error messages, possible causes and measures are described in Section 5

(troubleshooting)

System fault Insulation fault

System fault Mains relay

Voltage incorrect Udc too high

Stopped due to Overvoltage

Stopped due to Overcurrent

Stopped due to Overtemperature

Stopped due to Asymmetric mains currrent

Stopped due to Fault current

Grid monitoring No grid available

Grid monitoring Frequency too high

Grid monitoring Frequency too low

Grid monitoring Impedance too high

Grid monitoring RSS too strong

Grid monitoring ENS shutdown

Grid monitoring Uac too low

Grid monitoring Uac too high

Too little Irradiance!

2. Date and time (format dd.mm.yy h:min)Measurement readings menu:

1. Solar generator voltageSolar generator current

2. Mains voltageMains current

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5. An exclamation mark ‚!’ starts fl ashing in the middle of the top line. The chan-ges are saved if the Menu button is pressed within 5 seconds. Otherwise the old settings are retained.

The display will return to the Measurement readings menu by pressing the key or automatically after 5 seconds.

Resetting the long-term measurement readingsResetting the long-term measurement readings will reset the kWh meters to zero. The long-term measurement readings are reset via the Menu button. Proceed as follows:

1. Keep the Menu button pressed until the text „Empty memory?“ appears. The display will run through the other menu titles.

2. Release the button. The text „Empty memory?“ starts fl ashing. The long-term measurement readings are deleted if the Menu button is pressed within 5 sec. Otherwise the current values are retained.

The display will return to the Measurement readings menu by pressing the key or automatically after 5 seconds.

Setting the network addressIn order to use the communication interfaces of your SolarMax inverter, you have to allocate a unique address for each device in the network. Addresses between 1 and 249 can be used, i.e. a maximum of 249 devices can be operated in a network. Proceed as follows for setting the SolarMax C network address:

1. Keep the Menu button pressed until the text „Address:“ appears.

2. Release the button. The current address is displayed, and the highest digit starts fl ashing.

3. For changing the value of this digit press the Menu button within 5 sec. Press the Menu button again once the required value is reached. The next digit starts fl ashing after 5 seconds. Please note: The highest available address is 249!

4. Repeat step 3. until the last digit has been reached.

5. An exclamation mark ‚!’ starts fl ashing to the right of the address. The changes are saved if the Menu button is pressed within 5 sec. Otherwise the old settings are retained.

Confi guration menu1. Device type / software version2. Device address3. Maximum AC output / maximum AC current4. Minimum mains voltage / maximum mains voltage5. Minimum mains frequency / maximum mains frequency6. Maximum frequency change per second / ENS setting7. Maximum fault current / maximum DC ratio in the AC current8. Start delay

Language selectionThe SolarMax can display text in German, English, French, Italian or Spanish. Select the language as follows:

1. Keep the Menu button pressed until the required language is displayed. The language display sequence depends on the current setting.

2. Release the button. The text switches between German, English, French, Italian and Spanish every second. Press the button at the required language in order to make your selection. The display will return to the Measurement readings menu.

If no language is selected within 30 seconds, the display will return to the Measurement readings menu.

The selected language is retained even when the device is switched off.

Setting the date and timeThe date and time is set via the Menu button. Proceed as follows:

1. Keep the Menu button pressed until the date/time display appears. The display will run through the other menu titles.

2. Release the button. The fi eld indicating the day starts fl ashing.

3. For changing the day press the Menu button within 5 sec. Press the Menu but-ton again once the required value has been reached.

If the entry is correct, do not press the Menu button. The fi eld will stop fl ashing after 5 sec.

4. The next fi eld starts fl ashing. Repeat steps 3. and 4. until the last fi eld (seconds) has been reached.

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5.2 Fault alarm contactSolarMax features a potential-free error message output with relay switching contact. This contact can be used for switching on a signal lamp switched or for transmit-ting an error signal to a building management system, for example. The fault alarm contact only works if the internal supply voltage is available. The correct function at times of low irradiance or in the event of a total inverter failure can therefore not be guaranteed. The fault alarm contact is triggered under the following conditions:

■ Mains fault (overvoltage, undervoltage, mains frequency deviations)

■ DC overvoltage, AC overcurrent

■ Overtemperature

■ DC fault current, earth leakage

■ Internal system error

Fault alarm contact in idle state

Technical data of the fault relay

Operation U I

NO contact 250 VAC 5 A

NC contact 250 VAC 2 A

NO contact 30 VDC 5 A

NC contact 30 VDC 1 A

Status: no error

COM NO NC

5 Options5.1 MaxComm data communication MaxComm is the communication system for all SolarMax inverters. In the C series the interface required for this system is integrated as standard. Communication is via RS-232 or RS-485. We recommend only using our tested and proven products for data visualisation and system monitoring. Third-party products may lead to compat-ibility problems, which may invalidate sections of the warranty. The following options illustrate the different capabilities. IP 54 versions of RJ45 connector are available for external installations.

PC-INT C: direct connection to an individual inverterIncluded: RJ-45 data cable for RS-232 (SUB-9) and “MaxTalk” CD. Functionality:

■ Visualisation of current inverter data■ Inverter parameterisation (voltage and frequency limit values, ENS, etc.)■ Reading of the device memory with the last 3 errors■ Utilisation of the notebook/PC hard disk as a data logger

This cable is ideally suitable for device parameterisation or troubleshooting by the installer. Due to its limited length (approx. 2.5 m) and the lack of data logger this cable is generally not suitable for long-term application.

MaxTalk Direct: Direct connection to several inverters Included: RS-485 to RS-232 converter and “MaxTalk“ CDFunctionality: see PC-INT CIn contrast to PC-INT C, MaxTalk Direct enables networking of several inverters (up to 200) and bridging of larger distances (approx. 300 m). It is therefore suitable as a stationary application and enables access to the PV system from an offi ce, for example. This converter has neither a display nor a data logger.

MaxWeb: MaxWeb is our Internet-capable data logger. It is operated via a conventional web browser. The data can be visualised in the SolarMax web portal. MaxWeb sends error messages via e-mail and SMS. MaxWeb can be connected to the Internet via an Ethernet, analog modem, ISDN or GPRS connection.

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6.2 Troubleshooting with the LC display

Fault: no LC display

Possible cause Measure

PV generator isolation device switchedoff

Switch on PV generator isolation device

Irradiance too low Wait until irradiance is high enough

Internal fault Notify SolarMax hotline

Strings interrupted Rectify interruption

Fault: Display fl ashes periodically, orError message: Irradiance too low


Irradiance too low Wait until irradiance is high enough

Error message: Stopped due to overtemperature


Ambient temperature too high Ensure that the top and bottom cooling fi ns are not obstructedInsuffi cient air circulation

Fan blocked Clean fan

Error message: Stopped due to asymmetric Iac


DC component of the mains current istoo large

Switch of AC side and then DC side for 20 seconds, then switch on again

For recurring faults contact the SolarMax hotline

6 Troubleshooting6.1 IntroductionSputnik Engineering only supplies SolarMax inverters that have passed our extensive tests. In addition, for each device a long-term test under full-load conditions is car-ried out over several hours.

In the unlikely event of your PV system being affected by a fault we recommend the following procedure:

1. Ensure that the solar generator is correctly installed and connected to the mains. Check the connections and the procedure described in Section 3 (Installation).

2. The integrated LCD display can be used for troubleshooting. Further details are provided in the following subsection.

3. Contact our SolarMax hotline if you are unable to rectify the fault with the sug-gested measures.

SolarMax hotlineCalling from Germany: 0180 / 276 5 276Calling from Austria: 0049 / 180 276 5 276Calling from Switzerland: 032 / 346 56 06Calling from other countries: 0041 / 32 346 56 06Fax hotline: 0041 / 32 346 56 26E-mail: [email protected]

www.solarmax.com

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Error message: Grid monitoring, no grid availabe, frequency too high, or frequency too low


No grid or mains voltage interruption Check AC connection

Error message: Grid monitoring, impedance too high


Mains impedance has reached switch-off criteria

For recurring faults please contact the SolarMax hotline

Error message: Grid monitoring, mains signalling too strong


Duration of mains signalling has ex-ceeded the maximum permitted time



Error message: Grid monitoring Uac too low or Uac too high


Mains voltage too low / too high Check compatibility of grid connection

Error message: Stopped due to fault current


Fault current (DC, AC component) too high as step or absolute value

Earth leakage or insulation fault on the DC side

Check solar generator

Equipotential bonding between inverter and module frame

Error message: System insulation fault


Earth leakage or insulation fault on the DC side

Check solar generator

Phase and neutral cond. interchanged Swap phase and neutral conductor in the AC coupling connector

Error message: System fault FI test


Fault current measurement self-test is outside the tolerance



Error message: System fault: mains relay


The mains relay self-test reveals a faulty switching contact



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7 Technical descriptionA simple and rugged design is typical for the SolarMax power unit.

7.1 Technical confi guration SolarMax 2000C / 3000CThe DC voltage of the solar generator is transferred to a DC bus voltage via a low-loss step-up converter (DC/DC converter). The IGBT bridge circuit generates the sinusoi-dal infeed current.

SolarMax 2000C/3000C block diagram

7.2 Technical confi guration SolarMax 4000CThe solar generator current is directly converted to sinusoidal mains current via the IGBT bridge circuit.

SolarMax 4000C block diagram

EMC filter

Fault current and earth leakage

monitoring

Step-up converter Bridge circuit Mains relay

EMC filter

LC display Control unit with digital signal processor (DSP) PC interface

EMC filter


monitoring

Step-up converter Mains relay

EMC filter


Error message: Voltage incorrect, Udc too high


The solar generator voltage exceeds the permissible value (see Technical data)

Disconnect DC side immediately Check module confi guration

Error message: Grid monitoring, ENS shutdown


The auxiliary processor has detected a fault



Error message: Stopped due to overvoltage or overcurrent


Irregular irradiance, voltage fl uctuations or short-term mains failure


Error message: Fan status (Measurement readings menue): Fan faulty

Possible cause Remedy

Internal temperature too high or internal fan faulty


6.3 MaintenanceThe SolarMax inverters generally operate maintenance-free. However, we recom-mend checking the AC output in the LC display during strong insolation at regular intervals.

The cumulative operating and kilowatt hours provide additional information about the performance of your PV system.

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Any insulation faults on the DC side (or earth leakage) are detected with two inde-pendent microprocessors before the SolarMax device is connected to the grid. Grid connection in the presence of insulation faults is thus prevented.All safety facilities meet the required single-fault tolerance, i.e. all critical functions are duplicated, thereby offering increased redundancy.

The safety circuits tested and approved by the German employers‘ liability insurance association for precision mechanics and electrical engineering.

7.5 Control functionsSolarMax features state of the art measuring and control electronics. A signal pro-cessors (DSP) generates the PWM signals and offers the following inverter control functions:

■ Automatic on/off-switching

■ Grid monitoring (overvoltage, undervoltage, mains frequency, islanding detec-tion)

■ Mains synchronisation and cosφ -control

■ Maximum power point tracking (MPPT, searching for the optimum operating point)

■ Output limitation for oversized solar generators

■ Input and output current limitation

■ Monitoring of the power electronics

■ Monitoring of the heat sink temperature

■ LC display control

■ Communication via serial RS232 / RS485 interface

7.3 Technical confi guration SolarMax 4200C / 6000CThe DC voltage of the solar generator is taken to a DC link via a low-loss step-up converter (DC/DC converter). The IGBT bridge circuit generates the sinusoidal infeed current.

The innovative MaxShare concept used in the SolarMax 6000C for the fi rst time leads to a signifi cant increase in effi ciency in the partial load range. MaxShare switches the required power stages on or off according to the current output:

SolarMax 4200C/6000C block diagram

7.4 Safety functions In order to ensure a high safety standard, the SolarMax inverters feature integrated fault current monitoring.

In the event of an earth fault current, the fault current monitoring system detects the differential current and interrupts the mains operation. In the event of accidental con-tact, the fault current monitoring system triggers a safety mechanism that switches the device off, thereby preventing electric shock.

EMC filter

Step-up converter Mains relayBridge circuit



monitoring EMC filter

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7.7 Technical data SolarMax 3000C

SolarMax 3000CInput side (DC)Max. input voltage**) 600 VDCMPP control range 90 ... 560 VDCMax. generator output*) 3300 WSTCMaximum current 11 ADC

Output side (AC)Rated output 2500 WMaximum output 2750 VAMains voltage 196 ... 253 VACPower factor >0.98Mains frequency 49.8 ... 50.2 HzHarmonic distortion < 3 %

System dataMaximum effi ciency 97 %European effi ciency 95.5 % (Udc: 400 V) / 94.9 % (Udc: 300 V)Night-time consumption 0 WAmbient op. temp. - 20 °C ... + 60 °CRel. humidity 0 ... 98 %, no condensation Heat dissipation convection, active cooling if required (fan)

Protection type IP 54Circuit type transformerless, two-stage (no galvanic isolation)

Grid monitoring ENS according to VDE 0126Fault current monitoring forpersonal and system protection

all-current-sensitive fault current monitoring according to VDE 0126

Display 2-line LC display with background illumination

Housing Heat sink and cover mad from cast aluminium Weight 12.7 kgDimensions (W*H*D) 554 x 260 x 190 mmCE-compliant according to EN 61000-6-3, EN 61000-6-1, EN 61000-3-2, EN 61000-3-3,

EN 50178Mark of conformity TÜV type approved

*) with recommended oversizing of 15 % (Fraunhofer ISE study)**) calculated at 1000 W/m2 and –10 °C (applies to central Europe). For systems in exposed locations temperatures 0.98Mains frequency 49.8 ... 50.2 HzHarmonic distortion < 3 %

System dataMaximum effi ciency 97 %European effi ciency 95.4 % (Udc: 400 V) / 94.6 % (Udc: 300 V)Night-time consumption 0 WAmbient op. temp. - 20 °C ... + 60 °CRel. humidity 0 ... 98 %, no condensation Heat dissipation convectionProtection type IP 54Circuit type transformerless, two-stage (no galvanic isolation)

Grid monitoring ENS according to VDE 0126Fault current monitoring forpersonal and system protection





*) with recommended oversizing of 15 % (Fraunhofer ISE study)**) calculated at 1000 W/m2 and –10 °C (applies to central Europe). For systems in exposed locations temperatures

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7.9 Technical data SolarMax 4200C

SolarMax 4200CInput side (DC)Max. input voltage**) 600 VDCMPP control range 90 ... 560 VDCMax. generator output*) 5000 WSTCMaximum current 22ADC, 16 ADC max. per input connector

Output side (AC)Rated output 3800 WMaximum output 4180 VAMains voltage 196 ... 253 VACPower factor >0.98Mains frequency 49.8 ... 50.2 HzHarmonic distortion < 3 %

System dataMaximum effi ciency 97 %European effi ciency 95.8 % (Udc: 400 V) / 95.1 % (Udc: 300 V)Night-time consumption 0 WAmbient op. temp. - 20 °C ... + 60 °CRel. humidity 0 ... 98 %, no condensationHeat dissipation convection, active cooling (fan) if required

Protection type IP 54Circuit type transformerless (no galvanic isolation) Mains monitoring ENS according to VDE 0126Fault current monitoring forpersonal and system protection





*) with recommended oversizing of 15 % (Fraunhofer ISE study))**) calculated at 1000 W/m2 and –10 °C (applies to central Europe). For systems in exposed locations temperatures 0.98Mains frequency 49.8 ... 50.2 HzHarmonic distortion < 3 %

System dataMaximum effi ciency 95 %European effi ciency 93.6 % (Udc: 400 V) / 92.3 % (Udc: 500 V)Night-time consumption 0 WAmbient op. temp. - 20 °C ... + 50 °CRel. humidity 0 ... 98 %, no condensation Heat dissipation convection, active cooling (fan) if required

Protection type IP 54Circuit type transformerless, two-stage (no galvanic isolation) Mains monitoring ENS according to VDE 0126Fault current monitoring forpersonal and system protection






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7.11 Effi ciency

Effi ciency SolarMax 2000CPAC [W]

Prelative [%]

η(250 VDC)[%]

η(300 VDC)[%]

η(400 VDC)[%]

90 5 85.2 85.8 87.1180 10 89.8 90.2 93.2360 20 93.2 93.5 94.8540 30 94.6 94.7 95.6900 50 95.4 95.6 96.1

1800 100 95.2 95.4 96.0Europ. effi ciency 94.4 94.6 95.4

Effi ciency SolarMax 3000C

PAC [W]

Prelative [%]

η(250 VDC)[%]

η(300 VDC)[%]

η(400 VDC)[%]

125 5 87.0 87.5 89.7250 10 91.5 91.8 93.6500 20 94.2 94.5 95.5750 30 94.9 95.3 95.61250 50 95.2 95.6 96.12500 100 94.4 95.1 95.5

Europ. effi ciency 94.4 94.9 95.5

Effi c

ienc

y [%

]

Output power relative to rated output [%]

Characteristic effi ciency of the SolarMax C series7.10 Technical data SolarMax 6000C

SolarMax 6000CInput side (DC)

Max. input voltage**) 600 VDCMPP control range 90 ... 560 VDCMax. generator output*) 6000 WSTCMaximum current 22 ADC, 16 ADC max. per input connector

Output side (AC)

Rated output 4600 WMaximum output 5060 VAMains voltage 196 ... 253 VACPower factor >0.98Mains frequency 49.8 ... 50.2 HzHarmonic distortion < 3 %

System data

Maximum effi ciency 97 %European effi ciency 96.2 % (Udc: 400 V) / 95.5 % (Udc: 300 V)Night-time consumption 0 WAmbient op. temp. - 20 °C ... + 50 °CRel. humidity 0 ... 98 %, no condensationHeat dissipation convection, active cooling (fan) if required Protection type IP 54Circuit type transformerless, two-stage (no galvanic isolation)

Mains monitoring ENS according to VDE 0126Fault current monitoring forpersonal and system protection


Display 2-line LC display with background illumination Housing Heat sink and cover mad from cast aluminium Weight 16.3 kgDimensions (W*H*D) 554 x 260 x 190 mmCE-compliant according to EN 61000-6-3, EN 61000-6-1, EN 61000-3-2, EN 61000-3-3,



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8 Guarantee for String Inverters (Status: 31.10.2005)

8.1 GuaranteeSputnik Engineering AG (hereafter: Sputnik) guarantees full function and lack of de-fects of its technical devices at the moment of shipment respectively in cases of sale of devices to natural persons for private use within the EU at the moment of their delivery to the consumer.

This guarantee applies only in case of malfunctions/defects which have been dis-covered within fi ve years (for SolarMax 2000C-6000C) after shipment respectively delivery. The original invoice respectively the delivery receipt serve as proof for the relevant point of time. In all cases of guarantee, Sputnik must be notifi ed of the in-conformity clearly and in writing within this deadline.

In guarantee cases, the malfunctioning/defective device will be repaired or replaced by Sputnik-service personnel within a reasonable time, in either case free of charge, unless this is impossible or disproportionate.

Replacement or repair shall be deemed to be disproportionate if it imposes costs on Sputnik which, in comparison with the alternative remedy, are unreasonable, taking into account:

■ the value the goods would have if there were no lack of conformity,■ the signifi cance of the lack of conformity, and■ whether the alternative remedy could be completed without signifi cant incon-

venience to the buyer.

“Free of charge”■ The guarantee covers only the costs for labor and materials used by Sputnik to

bring the devices back to full function either in Sputnik’s factory or on-site by Sputnik-service personnel. All other costs, especially shipping costs, travel and hotel expenses for on-site repairs by Sputnik-service personnel as well as costs of repairs by the buyer himself or other persons are not covered by the guarantee and go to the expense of the buyer or the distributor, unless otherwise specifi ed in a written agreement.

■ In case of sale of devices to natural persons for private use within the EU and Switzerland, shipping costs as well as travel and hotel expenses for on-site re-pairs by Sputnik-service personnel are also covered by the guarantee. However, Sputnik covers only the shipping and travel expenses for the distance between Sputnik and the offi cial Sputnik distributor, from which the defective/malfunc-tioning device was bought. Furthermore, Sputnik will not cover shipping costs, travel and hotel expense if the sales point of this offi cial Sputnik distributor is located in overseas territories of the EU or outside of the EU / outside of Switzer-land.

In any case, guarantee-services of Sputnik are only free of charge if Sputnik has been contacted in advance and has agreed to the services to be provided.

In a guarantee case, the buyer may require an appropriate reduction of the price or have the contract rescinded:


Prelative [%]

η(400 VDC)[%]

η(500 VDC)[%]

η(700 VDC)[%]

190 5 88.0 83.0 75.0380 10 91.7 89.0 85.0760 20 93.7 91.6 88.21140 30 94.5 92.8 90.41900 50 94.2 93.3 91.13800 100 93.2 92.5 90.5



Prelative [%]

η(250 VDC)[%]

η(300 VDC)[%]

η(400 VDC)[%]

190 5 90.8 91.0 92.8380 10 93.6 93.8 94.5760 20 94.6 95.1 95.81140 30 94.8 95.4 96.11900 50 95.0 95.5 96.23800 100 94.4 95.0 95.6



Prelative [%]

η(250 VDC)[%]

η(300 VDC)[%]

η(400 VDC)[%]

230 5 91.0 92.1 93.4460 10 94.1 94.5 95.5920 20 95.1 95.7 96.21380 30 95.2 95.8 96.42300 50 95.3 95.9 96.54600 100 94.5 95.2 96.1


Legend:PAC output power [W]Prelative ratio of output power and rated output [%]η(VDC) effi ciency at associated input voltage [%]

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9 Declaration of conformity■ if the buyer is entitled to neither repair nor replacement, or■ if Sputnik has not completed the remedy within a reasonable time, or■ if Sputnik has not completed the remedy without signifi cant inconvenience to

the buyer.The buyer is not entitled to have the contract rescinded if the lack of conformity is minor.

Especially in the following cases, this guarantee does not apply and any liability of Sputnik is excluded:

■ unauthorized technical intrusions, modifi cations or repairs of the devices by the buyer himself;

■ use of devices for purposes they are not intended for, incorrect or unreason-able manipulation, incorrect or unreasonable installation, especially if the installation is made by non-authorized electricians;

■ infl uence of foreign substances/bodies or superior force (lightning strike, ov-ervoltage, fl oods, etc.);

■ transport damage and other damage, which has occurred after the point of time in which the risk has passed to the buyer, as well as damage caused by incorrect packaging by the buyer.

This guarantee is compatible with the „Directive 1999/44/EC of the European Parlia-ment and of the Council of 25 May 1999 on certain aspects of the sale of consumer goods and associated guarantees“. Any legal rights under applicable national leg-islation within the personal, objective or geographic scope of this directive are not affected.

8.2 Prolongation of guarantee Through a supplemental agreement, the duration of the guarantee can be extended for a further 5 years, leading to a total duration of 10 years. Such a prolongation of the guarantee is only possible, if the respective supplemental agreement is concluded at the same time as a new device is bought.

8.3 Limitation of liability and warrantyTo the maximum extent legally possible, any further liability of and/or alternative claims of warranty/guarantee against Sputnik are excluded. For commercial users, compensatory claims for loss of gain are also excluded.

8.4 Applicable lawUnless explicitly agreed upon otherwise in writing, and as far as not in confl ict with compulsory law, the material provisions of the UN-Convention on Contracts for the International Sale of Goods (CISG) apply.

8.5 Place of jurisdictionUnless explicitly agreed upon otherwise in writing, and as far as not in confl ict with compulsory law, the exclusive place of jurisdiction for all confl icts with Sputnik based on contractual, non-contractual and/or other types of claims lies in Biel, Switzer-land.

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10 Clearance certifi cate 11 Mark of conformity

TÜVRheinland

Product Safety

BAUARTGEPRÜFT

TYPEAPPROVED

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