SG100KC Installation Manual
Contents
1. NOTE The installation location must be dry and should not contain any unexpected condensate water 4 4 Wiring Specification Cables in the SG100KC can be classified into either power cables or control data cables It is recommended that the power cable and control cables be installed on separate cable support arms Avoid long parallel runs of the two kinds of cables so as to decrease electromagnetic interference Where control cables must cross power cables make sure they are arranged at an angle as near to 90 as possible Do not run extra cables through the inverter The cable support arms must have good electrical bonding with each other and to the grounding electrodes Aluminum cable support arm systems can be used to improve local equalizing of potential Table 4 1 shows the recommended minimum distances between different parallel lengths shielded control cables and power cable Table 4 1 Min Distance between Control Cable and Power Cable Parallel length inch m Min Distances inch m 7874 inch 200m 12 inch 0 3m 11811 inch 300m 20 inch 0 5m 19685 inch 500m 48 inch 1 2m 24 Installation Design 4 4 5 Tightening Torques and Cable Protection 4 5 1 Tightening Torques for Power Cable Connections Tighten the cable with the proper torque shown in Table 4 2to prevent the loosening of cable lugs that may cause poor contact high contact resistance or even fire Table 4 2 Tightening Torques for P2. 1 Remove the wood side and top panels of the crate 2 Remove the barrier bag material from the inverter 3 Remove the anchor hardware which screws the inverter to the pallet Remove the front and rear base covers Unscrew the nuts under the wooden pallet Pull up the bolts SG100KC Nut Wooden Pallet Fig 6 5 Cross section View of the SG100KC Fastened on the Wooden Pallet 35 SG100KC installation Manual 6 2 2 Place the SG100KC To place the enclosure on the mounting surface 1 Make sure the mounting surface is level 2 Move the SG100KC into position 6 2 3 Fastening the SG100KC to Floor The SG100KC must be fastened to the floor as follows 1 Remove the front and rear base covers 2 Fasten the cabinet to the channel steels or floor with M12 bolts and nuts see Fig 6 6 Front SG100KC Bolt Floor Channel Steels Bolt Cable Trench Cable Trench Fig 6 6 Fastening the SG100KC 36 Electrical Connection About This Chapter This chapter describes the step by step procedure for electrical connection to complete the installation of the SG100KC 37 SG100KC installation Manual 7 1 Cable Specifications NOTE All wiring methods and processes should be in accordance with Local Electrical Codes The DC input cables including DC positive and DC negative must be chosen according to the recommended rating below Table 7 1 Recommen
3. J SUNGROU SUNGROUI LM SG100KC PV Grid Connected Inverter Installation Manual SG100KC IEN Ver13 201202 Version 1 3 About This Manual Thank you for purchasing the SG100KC from Sungrow Power Supply Co Ltd We hope you will be satisfied with this device along with your entire PV plant system Aim The aim of this manual is to give safety instructions and detailed setup information for the installation of SG100KC PV grid connected Inverter Target Readers This manual is provided to people who need to set up a system that includes the SG100KC grid connected inverter Installers must be qualified electricians only How to Use This Manual Read this manual and other documents before installation of the SG100KC This document must be stored near the installation and must be available at all times The contents of this manual will be periodically updated or revised when necessary However discrepancies cannot be excluded Please refer to the product or download the latest version of this manual via www sungrowpower com IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS Symbols Explanation Important instructions contained in this manual should be followed during installation of the inverter They will be shown by the following symbols DANGER DANGER indicates a hazard with a high level of risk which if not avoided will result in deadly or serious injury WARNING indicates a hazard with a m
4. A A UNE 15 Fig 3 6 Electrical Connections Interfaces of SG100KJC eese nennen nennen nnn nn nnns 16 Fig 4 1 The Solution from SUNGROW niteat orien tn Pt uerius lid 20 Fig 4 2 Clearance Space around the SG1D0KC ccc ccccecececcseseeeceesececseueeeceegeeecseaseeeseaeeeeseaseeessegeeesssaeeeeees 22 Fig 4 3 Sectional Drawing of Cable Treriebiae etos A A overs deuten us tidem de 23 Fig 4 4 Installation Process of the SG10OKC oe cecccccsescecceeseeeceeeeecseueeessaeeecseaseeeseaseeessageeesenseeesssgeeeeeas 26 Fig 6 1 Move the Packaged SG100KC cece ccccccecccccescecceseeeeceeseecceeaeeecsaaseesseaeeessaaeeeesaueeessageeessageessssgeeeesas 32 Fig 6 2 Move the SG100KC with the Wooden Pallet through a Forklift to ooocccccooccocococcnnononcnnnnos 33 Fig 6 3 Move the SG100KC through a FOFKIIfL 3 b is 33 Fig 6 4 Using Rail Steels or Crane to Move the SG100KC ooococcconccncococconoccnconcnnononcononcnnonaroncononcnnonannnnonnnnnnns 34 Fig 6 5 Cross section View of the SG100KC Fastened on the Wooden Pallet 35 Fig 6 6 Fastening thie 90100I amp G said Loo a rece cea o od 36 Fig 7 1 Power Cable Connection Terminal ccccccscccccssseecceeseeecesseecseeeeessageeecsegeeesseaseessageeesssseeessegeeeeess 39 Fig 4 2 Obenithie MallowWIUeHBS a ia tc idus ctetu ete oe vtae E DOv i e Detective o E cin uad iva 40 FOT SOPPEN the Eatolia sede
5. Mega ohmmeter or multimeter 28 Mechanical Installation About This Chapter This chapter describes the mechanical installation procedure of the SG100KC 29 SG100KC installation Manual 6 1 Transport and Shipping 6 1 1 Attentions The SG100KC inverter should be transported or installed as an integrated unit Never disassemble it without the permission of SUNGROW Always keep the SG100KC upright Avoid sudden force Only specific transport methods for the SG100KC are acceptable And note the heavy weight of the equipment and the non central center of gravity The SG100KC inverter weighs at least 1984 Ibs 900kg Please take this heavy weight into consideration during shipping and moving NOTE Lay the power cables before the mechanical installation of the SG100KC 30 Mechanical Installation 6 6 1 2 Moving the Packed SG100KC Pay attention to the symbols and data on the crate to make an informed choice on modes of transport and installation site see Table 6 1 Table 6 1 Symbol and Data Name on Crate THIS END UP KEEP UPRIGHT FRAGILE KEEP DRY CAUTION AGAINST WET 31 SG100KC installation Manual Use a forklift or crane to move the crated SG100KC tis recommended to transport the SG100KC using a forklift see Fig 6 1 A Insert the forks of the forklift to the bottom of wooden crate Elevate the SG100KC from beneath the wooden crate Useacrane to move the wooden crate se
6. Only operate SG100KC when it is safe to do so Only operate SG100KC when no damage is visibly apparent DANGER DC Voltage The PV array will provide DC voltage to the inverter when exposed to light which may cause an electrical shock during installation wiring or maintenance if not covered Limitations of Use The SG100KC PV grid connect inverter is not intended for use in connection with life support systems or other medical equipments or devices e Donot install on or over combustible surfaces e More than one live circuit see diagram For use in a controlled environment refer to manual for environmental conditions ESD Protection The SG100KC may be damaged irreversibly by electrostatic discharge ESD at its components During the operation of SG100KC please observe all the ESD related safety regulations Discharge any ESD by touching the grounded SG100KC conductor before contacting any electronic components Safety Instructions 1 A NOTICE Service Safety Thoroughly inspect the equipment prior to energizing Verify that no tools or equipment have inadvertently been left behind A NOTICE Never work alone when servicing this equipment Two persons are required until the equipment is properly de energized locked out and verified de energized with a meter NOTE Please keep this installation manual and other related documents in a handy place near the SG100KC These documents mu
7. solar power generation systems with a rating of 100kW The SG100KC inverter utilizes the advanced power conversion technology with the latest IGBT to convert the DC power from the photovoltaic array to stable three phase AC power and then feed the power to the utility grid through a filter and isolation transformer see Fig 3 1 3 oJ z RS An D 4 ss D pu ea 3 e I GH S O E x T S 2S Q o e c O BS s O Output Transformer 3 phase full bridge IGBT Breaker DC Circuit Fig 3 1 Simple Circuit Diagram of SG100KC 12 Introduction 3 Fig 3 2 shows the locations of basic controlling and information display elements that help users perform control and monitoring tasks SUNGROU POWER OPERATION FAULT EEE mE 000 200 900 D DC MAIN SWITCH ABB S E GRID MAIN SWITCH ABB ON Fig 3 2 External Appearance of SG100KC Power Operation and Fault B LCDandKeys 00000 Display data and perform control functions Shut down the inverter when pressed down D DC Main Switch DC side circuit breaker switch GRID Main Switch AC side circuit breaker switch 13 SG100KC installation Manual 3 2 Dimensions and Weight The SG100KC inverter s dimensions are 40inchx77inchx30inch 1020mmx1964mmx770mm
8. the commissioning of the SG100KC is completed The SG100KC does not need manual control in daily operation Keep the door closed and locked The door key must be kept by appointed personnel 54 Appendix About This Chapter This chapter gives technical data of the SG100KC exclusion of liability and the way to contact us 55 SG100KC installation Manual 10 1 Technical Data The following tables list the technical data of the SG100KC Basic production information and performance of the SG100KC are available from these tables 10 1 1 DC Parameters Parameter Max DC Voltage Start Voltage MPP Voltage Range Min DC Voltage Max DC Power Max Input Current Specification 600Vdc 320Vdc 300 600Vdc 300Vdc 105kWp 340A Recommend PV Array Open Circuit Voltage 450V 10 1 2 AC Parameters Parameter Rated Output Power Max AC Output Current Rated Grid Voltage Grid Voltage Range Rated Grid Frequency Grid Frequency Range Output Current THD Power Injection Power Factor cos o 56 Appendix 10 10 1 3 System Parameter Specification Max Efficiency 97 2 CEC Weight Efficiency 96 5 with transformer Protection Degree IP20 Indoor TYPE1 Operating Temperature 25 C 5b C 13 13 F Cooling Method Controlled force air cooling Relative Humidity 0 95 Non condensing Max Working Altitude 6667 ft 2000m 10 1 4 Display and Communication 10 1 5 Mechanical P
9. An Ethernet method and GPRS method can be extended optionally with specific device which can also be ordered from Sungrow 18 Installation Design About This Chapter This chapter provides the PV plant system solution with optional devices from SUNGROW information about how to design the installation environment how to arrange installation procedure Read this chapter to get information for installing the SG100KC 19 SG100KC installation Manual 4 1 The Solution with Optional Devices from SUNGROW The PV grid connected system configured with optional devices from SUNGROW is shown in Fig 4 1 Suninfo EM Environment Monitoring Device SunBox PVS PV Array Combiner Box SunBox PMD D DC Power Distribution Cabinet SunBox PMD A AC Power Distribution Cabinet Suninfo Logger Inverter Data Acquisition and Transmission Device Applied to PV power generation system to measure the wind speed wind direction and solar radiation By using PV array combiner box different strings of PV array can be converged into the PV array string box After that together with lightning arresters and circuit breakers it is connected to the inverter to reduce the system installation time and increase the system safety The DC distribution unit collects the DC current from PV arrays and feeds into the inverter which mainly contains DC input circuit breakers diodes and PV lightning protection device Th
10. Connection Optional The SG100KC supplies the RS485 interface to facilitate communication between inverter and a PC or a data logger There is also an RS485 RS232 converter needed to connect the SG100KC to a PC 1 Route the communication cables through the cable entry holes to the RS485 A B terminals see Fig 7 8 Route the RS485A cable to the RS485 232 converter TX or RX Route the RS485B cable to the RS485 232 converter TX or RX Secure the cables by tightening Connect the RS485 232 converter DB9 to the PC DB9 serial port see Fig 7 9 pup do fe i Fig 7 8 Serial Communication Cable Routing PIN3 TXD PIN2 RXD RS485A p TX RX RS485B RS485 232 SG100KC Converter PC RS232 Port Fig 7 9 Serial Communication Interface Connection If there are two or more inverters to be monitored install a communication system in series 47 SG100KC installation Manual NOTE e RS485 cable should be a shielded twisted pair for good communication RVVP 2 1 0 shielded twisted pair cable is recommended e Shielding layer of RS485 cable should be grounded by means of single point in t
11. Therefore it is needed to firmly attach PE copper bar to primary grounding system 43 SG100KC installation Manual 7 6 AC Grid Connections To reduce the risk of fire connect only to a circuit provided with a 340A maximum branch circuit over current protection NOTE When connecting external AC cables to the SG100KC you must follow the positive phasing sequence throughout the installation process The connection terminals are located in the lower right corner of the cabinet The connection process is as follows 1 Ensure that the AC grid cable has no electrical current 2 Route the Line Grid L1 L2 L3 and Neutral cables through the cable holes to the AC terminals see Fig 7 6 3 Connect the cables to terminals marked L1 L2 L3 and N respectively refer to Fig 7 1 4 Secure the AC Line cables to the terminal with screws AC Grid Terminals Fig 7 6 AC Output Cable Routing 44 Electrical Connection 7 NOTE Note that the AC grid connection is designed to fit the 3 phase grid which must be provided by the end user using a 3 phase 600 V system In a 3 phase 3 wir
12. WxHxD including the devices on the front panel The SG100KU inverter weighs approximately 1984 lbs 900 kg Please take this large dimensions and heavy weight into consideration during shipping moving and installation as Fig 3 3 Dimensions and Weight of SG100KC 14 Introduction 3 3 9 The Bottom and Top Views Cables and cooling air can come into the cabinet through the bottom panel see Fig 3 4 4x0 55in x0 79in N 3 l ES i P fe 11 8 in 11 8 in DC Cables 1 AC Cables Entry Hole 5 gt Exit Hole e CA 5 Cooling Air Inlets C dl LLL 4 I 11 31 5 in Unit inch Fig 3 4 Bottom View of SG100KC The Cooling air is fed in via the base inlet and shutters on the front and rear panels cooling air outlets are on the top of the SG100KC The consumption of the cooling fan is 240W and the outlet air flow is 60000ft h 1620m h see Fig 3 5 36 8 1n i _ 10 4 in 1133 in 10 4 in rt Outlet Air Flow 160000f h 9 lt Fans Power Conisumption 240W E Ko 00 O A BURONNQUQRBRBOUOUUOB LOTT 7 in il Unit inch Fig 3 5 Top View of SG100KC 15 SG100KC installation Manual 3 4 Electrical Connections Interface The
13. and is connected to the factory ground securely 52 Commissioning 9 9 2 4 Serial Communication Check Optional For external communication monitoring the data cables must be connected Make sure that the RS485 A and B cables are connected correctly and tightened to the RS485 232 converter Make sure the RS485 232 converter DB9 terminal is correctly connected to the PC DB9 serial port 9 2 5 Voltages Check AC Grid Voltage Check It must be verified that the inverter is connected to the correct grid type and that a right hand rotary field exists on L1 L2 L3 and Neutral The value of the AC line to line voltage should be about 600 V DC Voltage Check The DC connections are from the DC combiner boxes to the inverter The voltage on the individual DC cables should be substantially the same value and must never exceed the allowable maximum DC voltage Besides the voltage values the polarity of the DC inputs must also be verified All DC connections should be checked to ensure that they are mechanically tight The DC cables to be connected must be rated for a minimum of 600V 9 3 Start the Inverter If all tests and measurements are completed and all measured values are within the acceptable range the device can be switched on for the first time DANGER Before starting up the SG100KC ensure that e Nobody is working on the inverter e Cabinet doors are closed 53 SG100KC installation Manual To start the S
14. up Start up procedure Complete the commissioning Start Preparations Mechanical Installation Electrical Connection Installation Check Commissioning End Fig 4 4 Installation Process of the SG100KC 26 Preparations for Installation About This Chapter This chapter illustrates preparations for installation of the SG100KC including checking the unit and required tools 2 SG100KC installation Manual 5 1 Checking the Unit The first thing users must do after receiving the unit is to check the packaging and the device for any possible damages and verify the contents of the delivery with the delivery list Please contact Sungrow immediately in case you find any visible damage or loss of the delivery components that are supposed to be included in the package Check whether there are signs of damages Before installation and operation check the information on the crate to verify whether the product is the correct type Only an intact unit may be installed 5 2 Required tools The tools required for moving the unit to its final position fastening it to the floor and tightening the connections are listed below e Crane fork lift or pallet truck check load capacity rail steels jack and rollers e Torque wrench e Screwdrivers for the tightening of the frame screws e Setof wrenches and sockets e Wire stripper e Pliers Inner hexagon spanner e Alcohol blast burner or hot air blower e
15. 8 Table 7 2 Recommended Sizes for AC Cables cccccccsccccccsesseeeecsseeeeeecsseseeeecsseuseeeessueuseeesseaseeeeesseeanseeees 38 Table 7 3 Recommended Sizes for Ground Cables ooooooooonccccccccocccnconnnoccnncnonnnccnnnonnnncnnnnnnnnnrnnnconnnnrrnncnnnncnss 38 Table 7 4 Recommended Sizes for Communication Cables oo oooooccccccnocnccncccnnnccnnnnnnnncnnnononnnonnnnnnnnrnnnnnnnnarines 39 VIII oafety Instructions About This Chapter This chapter describes the appropriate usage and provides some important safety instructions about SG100KC SG100KC installation Manual 1 1 Appropriate Usage The grid connected PV system consists of PV modules grid connected inverters metering devices and a power distribution system as shown in Fig 1 1 Solar energy is converted into DC current by PV modules and is fed into the local power grid network by the grid connected inverter which synchronizes the frequency phase and pure sine waveform with the power network T dp dm d anm OR NY o i M lt A A D ROOK gt p X2 B C Fig 1 1 PV Generation System with SG100KC CON SETE Table 1 1 System Devices Type PV Arrays Monocrystalline Silicon Polycrystalline Silicon Amorphous Silicon Thin Film Cells Utility Grid TT TN C TN S TN C S IT Optional Devices Solar Info EM Environment Monitoring De
16. G100KC EL xe do Se i Verify 600 VAC voltage of the grid line to line voltage Close the door of the enclosure Turn the AC GRID main switch to the ON position Turn the DC main switch to the ON position It will take about 1 minute for the auto initialization of both the power conversion circuit and the LCD panel The POWER LED indicators both in the enclosure and in the LCD panel will be on the com LED indicator will flash every 2 or 3 seconds If the DC voltage is below the DC voltage start point Vpv lt 320V then the state of the LCD interface will always show Start up If the DC voltage exceeds the DC voltage start point Vpv gt 320V for 5 minutes the SG100KC will automatically change to Run state the OPERATION LED on the front door and the RUN LCD both will be on with the state of the LCD menu be changing to Run After the SG100KC entering normal operation set the time to local time via LCD control panel refer to the User Manual NOTE Desynchronized time between the inverter and upper PC in the communication system may result in data record failure 9 4 Complete the Commissioning If you perform all the start procedures check the operating condition of the SG100KC 1 2 3 4 Check whether there is abnormal noise heat generation smoke or smell Measure the grid connected voltage current and THD Check the ground of cabinet Check the LCD display and external communication So far
17. SG100KC provides multiple electrical terminals see Fig 3 6 CARA E f A 5 a 5 B z C L2 9 pome lu D Saa aaa o si aa om O L3 E A o DE e Oo O O O O O O O O O O O O O O O Oo NS Fig 3 6 Electrical Connections Interfaces of SG100KC AC Output Terminals To 3 phase Grid through AC main breaker Leave N Vacant in 3 phase 3 wire grid system Consult Local Distribution Company Ground Terminal Must be connected to protect operators from leakage current 16 Introduction 3 3 5 Data Acquisition 3 5 1 Data Display The inverter will display real time and logged running data of the inverter on the equipped LCD interface 3 5 2 Fault Indication The inverter can record the time and type of all faults in non volatile memory and inform the fault state to the customers through LCD and LED 3 5 3 Serial Data Access All the data and fault information can be accessed by a remote computer via serial port communication when necessary The inverter has a basic RS485 commu
18. The foundation must guarantee solid and safe positioning of the inverter It must be able to provide the load carrying capacity necessary to cope with the weight of the inverter The SG100KC is designed for indoor use only and must be placed on a level concrete floor or pad Any existing unevenness depressions or slope must be corrected prior to installation Prior to placing the inverter users should bear in mind that the cables should enter the inverter from underneath and through the cable entry holes 21 SG100KC installation Manual 4 3 2 Clearance Space Maintain a minimum of 24inch 600 mm clearance in back 48inch 1200mm in front and 24inch 600mm on top of the SG100KC for proper ventilation and installation operation NOTE The space from the top of the enclosure to the installation site ceiling must have enough clearance for ventilation and maintenance otherwise maintenance personnel cannot open the top panel Fig 4 2 Clearance Space around the SG100KC 4 3 3 Cable Trench The external cables of the SG100KC route into or out of the cabinet via the base Cable trenches or steel supports above the floor are recommended Refer to relevant design guides or standards A NOTICE Good electrical connection is needed between different cable trenches and GND terminals 22 Installation Design 4 Cable support arms can be used to support cables Signal cables should be separated from power cables wit
19. amages arising from the use of the SunInfo software This also applies to the provision or non provision of support activities Using the SunInfo software for commercial purposes is prohibited Decompiling decoding or destroying the original program including Sunlnfo software and the embedded software is prohibited 58 Appendix 10 10 3 About Us Sungrow power supply is a Chinese leading manufacturer of various power electronics products for renewable energy generation systems Our products include converters inverters battery chargers and other power supplies for distributable generation systems in both grid connected and stand alone applications The power rating of Sungrow products covers a range from several hundred watts to large mega watt systems Sungrow is dedicated to help our customers acquire stable and clean power with minimum cost maximum reliability and enhanced safety Contact Information If you have any questions about this product our hotline will be happy to assist you Please keep the following data when contacting Sungrow 59 SUNGROW Green and Effective Specifications subject to change without notice
20. arameters Dimensions WxHxD 40inchx77inchx30inch 1020mmx1964mmx770mm Weight 1984lbs 900kg 57 SG100KC installation Manual 10 2 Exclusion of Liability The contents of these documents are checked and revised periodically When necessary please call us or visit our website www sungrowpower com for the latest information However discrepancies cannot be excluded No guarantee is made for the completeness of these documents Please contact our company or distributors to get the latest version Guarantee or liability claims for damages of any kind are excluded if they are caused by one or more of the following Improper inappropriate use or installation of the product Installing or operating the product in an unintended environment Installing or operating the product when ignoring relevant safety regulations in the deployment location Ignoring safety warnings and instructions contained in all documents relevant to the product Installing or operating the product under incorrect safety or protection conditions Altering the product or supplied software without authorization The product malfunctions due to operating attached or neighboring devices beyond allowed limit values In case of unforeseen calamity or force majeure The use of supplied software produced by Sungrow Power Supply Co Ltd is subject to the following conditions Sungrow Power Supply Co Ltd rejects any liability for direct or indirect d
21. ch off the AC main switch turn the switch to the OFF position Switch off the DC main switch turn the switch to the OFF position Press in the handle to make it pop out from the lock hole and turn it to the right M a a I uos Now you can open the front door Delivery About This Chapter This chapter provides the scope of delivery of SG100KC nameplate and storage method SG100KC installation Manual 2 1 Scope of Delivery The following materials in Table 2 1 should be included in the crate Table 2 1 Scope of Delivery SG100KC PV Grid Connected Inverter Including key and parts for cabling En po CEEI p s CC p s CS NOTE User can download the latest version of this manual and the monitoring software via www sungrowpower com Delivery 2 2 2 Identify SG100KC You can identify the SG100KC from the nameplate There are two nameplates located on the back panel and inside the door as shown in Fig 2 1 A a l l a l 1 A SUNGROW lt GRID CONNECTED INVERTER Type S SG100KC S N 110223031 Date of manufacture 02 2011 min MPP voltage 300vde gt B max MPP voltage 600 Vdc max Input voltage 600 Vdc max Input current 340 Adc I Rated output power 100kW l Rated output voltage 3 phase 600 Vac Range of out
22. ded Sizes for DC Cables Cables and Bolt Requirements mm Requirements AWG DC cable At least 2 input cables with each 70 mm DC cable At least 2 input cables with each 70 mm M8 Bolt DC and DC Torque AWG 5 16N m The AC output cables including L1 L2 and L3 must be chosen according to the recommended sizes below Table 7 2 Recommended Sizes for AC Cables Cables and Bolt Requirements mm M8 Bolt L1 L2 L3 Torque 16N m The ground cables must be chosen according to the recommended sizes below Table 7 3 Recommended Sizes for Ground Cables Cables and Bolt Requirements mm Requirements AWG Ground cable Earthing resistance should be less than 10 Q or complies with the appropriate standard 38 Electrical Connection 7 The communication cables must be chosen according to the recommended sizes below Table 7 4 Recommended Sizes for Communication Cables Cable Requirements mm Requirements AWG Communication cable Shield cables are recommended Based on the above tables users should use proper cables for different terminals with different specifications 7 2 Parts for Cabling The parts for connecting power cables are provided on the copper bases The sequence of the parts is shown in Fig 7 1 DANGER Incorrect connection of power cables will cause fires Follow the sequence when connecting the power cables Copper Bus E D Power Cable Lug C v Locking Wash
23. e AC distribution unit is a distribution and protection interface between inverter and the utility network which contains grid side circuit breaker lightning protection devices and power meters Data acquisition device is used for processing the data from PV power plants which can be communicated with the PV grid connected inverter for PV power plants It is capable of monitoring one singular inverter and even up to 100 inverters 20 Installation Design 4 4 2 Basic Requirements The following requirements listed below should be met to ensure the normal operation of the SG100KC Avoid moisture and wet places e Install indoors and avoid sunlight and rain e Dontinstall the SG100KC in an unstable place e Install in a place where you can see the LED indicators or LCD display clearly e Ambient temperature range 13 F 131 F 25 C 55 C e Maintain spaces around the SG100KC for proper ventilation installation operation and passage escape route e Good ventilation and clean cooling air supply 4 3 Installation Environment Design 4 3 1 Floor A NOTICE There are air outlets on the top of the SG100KC Therefore at on site field air ducts must be installed to avoid foreign bodies entry The SG100KC should be installed in an electrical service room The floor wall clearances ventilation equipments and precaution devices should be designed by professional personnel and satisfy the following requirements
24. e Fig 6 1 B NOTE Flexible slings with lock catches on both ends are recommended You can buy the slings from SUNGROW A B Fig 6 1 Moving the Packaged SG100KC 32 Mechanical Installation 6 Move the SG100KC after Unpacking You can use a forklift rail steels or crane to move the SG100KC after unpacking e fthe unpacked SG100KC is far from the final position you can use the wooden pallet to move the SG100KC see Fig 6 2 Fig 6 2 Moving the SG100KC with the Wooden Pallet Using a Forklift to e To move the SG100KC using a forklift follow the procedures see Fig 6 3 1 Remove the front and rear base covers 2 Insert the forks of the forklift below the SG100KC at the points specified 3 Lift the SG100KC from beneath the enclosure Be sure to use a forklift with a sufficiently spaced fork span Fig 6 3 Moving the SG100KC Using a Forklift 33 SG100KC installation Manual Move the SG100KC in place with rail steels see Fig 6 4 A NOTE Lubricant can be sprayed on the surface of the rail steels to make moving the unit easier e lf you can move the SG100KC only using a crane you can order the angle irons and relevant parts free of charge see Fig 6 4 B A Fig 6 4 Moving the SG100KC Using Rail Steels or Crane 34 Mechanical Installation 6 6 2 Field Installation 6 2 1 Unpacking the Unit To unpack the SG100KC from the shipping crate
25. e sponge tapes on the sliding plats protect the cables from being scratched Do not remove 41 SG100KC Installation Manual 7 DC Connections The DC input copper bus is located in the lower left corner of the inverter there are 6 DC inputs in the DC copper bus with DT70 lugs Cables rated for a minimum of 600V are required for connecting the inputs of the inverter Because the maximum DC current may reach to 340A and the connection terminals are M8 lugs at least two AWG 1 0 70mm DC input cables for each DC pole are required for the large current The DC cables to be connected must be rated for a minimum of 600V Be careful not to connect the wrong DC input pole The voltage of the PV array must never exceed the maximum permissible inverter input voltage of 600V Ensure that the DC cables have no electric current Route the DC cables through the cable entry holes to the DC terminals see Fig 7 5 3 Connect the cables to DC and DC terminal on the DC circuit breaker respectively refer to Fig 7 1 4 Attach the DC cables to the terminals with the appropriate screws 42 Electrical Connection 7 DC Terminals DC Terminals O0 O O O O O O O_O OO O O O O O O O OOO Fig 7 5 DC Input Cable Routing NOTE DC grounding is required by contract The DC terminal in connected to the ground copper bus by leakage current sensor
26. e system the N terminal should be vacant Consult Local Distribution Company 7 Ground Connections It is crucial to connect all inverters to ground via appropriately sized conductors The PE copper bar has been firmly connected to the enclosure of inverter inside the SG100KC before the delivery Therefore it is necessary to firmly attach the PE copper bar to grounding electrode The cross sectional area of grounding cable is AWG 5 16mm The grid impedance must not exceed 100 or complies with the appropriate standard If there is another inverter in parallel connection a single core yellow green cable of at least AWG 5 16mm is needed to connect the enclosure of all inverters to make equipotential for them all This will avoid a current in the shielding layer of the communication cable due to different potentials Connect the factory ground to the ground terminal with a leaking current detector to measure the leaking current detection function See Fig 7 7 45 SG100KC Installation Manual 6 M QQ Q Q O Ld O O90 oo o o o o o o OO O O O O O G0 O Q Ground Terminal The ground copper bus bar This product can cause a DC current in the external protective earthing conductor A residual current operated protective RCD or monitoring RCM device is used for protection in case of direct or indirect contact Fig 7 7 Ground Cable Routing 46 Electrical Connection 7 7 8 Communication
27. edium level of risk which if not avoided could result in death or serious injury CAUTION indicates a hazard with a low level of risk which if not avoided could result in minor or moderate injury A NOTICE NOTICE indicates a situation which if not avoided could result in equipment malfunction or property damage NOTE NOTE indicates additional information emphasized contents or tips to help you solve problems or save time Contents I Safety Instr cDOD al T I ADDIODI Tate USdUe s sinis m Bote dn e M eai ee 2 1 2 Safety Inst UcllOlIS eS 3 tO ma plese 2 eVGA aro 6 PESO Matta 5 I Grid CAG Mal gt ire me 5 1 5 DC Maa WIECIY terete sets eontra e hood tate ai toa E 6 1 6 Open the Door of SC TOOK o 6 AS e E E E E O E PM eso Ol DOVO Y ai ae A AAA AA R 8 22 Identity SG10OKG oia Si 9 Z tU E ESE AAA ent ere erecta ore ecg mI uu uM EE 10 IIA AA de es eos ea esc TT 3 Basic Structure ald APpe aran a clas 12 32 DIMENSIONS AMG VVCIG IN s ois secu ts duse wlll aus tp aus cu t o AEN ULL KOUA 14 9 9 The Bottom angd TOD VIEWS averias nien e ect o dave diti secte t i 15 34 Electrical Connections MENICE uo il 16 30 Data ACQUIS MON a E A E cee oa 17 EARBIED NAY E EE E E 17 990 2 5 qu MACANO ES 17 3 9 9 Denal Dala Acc SS a anii elus ost aaa lil iii iaa 17 3 6 General Requirements 17 AAN ISedulletie llle s onec deu o drea e a e Lave tuuc o uu aio easi etus 17 3 6 2 Ventilation Requirements ccccccseccc
28. efore Start Up ooonccccoccccconnnocononocononononnnconononnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnrnnnnnnnnnnnnenananes 52 O21 PVA CHOCK qu PP EE ESOO E man E 52 ULA A li a a a 52 9 2 3 Ground Connection o 52 9 2 4 Serial Communication Check OptiONAl occooonccnccconcnccocconccnnccnnonononnnnnncononnanonononcnnnnnanonnos 53 D220 VO ages GASCO Id IURE A UEM UE 53 OS Start IMG giu 53 9 4 Complete the COMMISSIONING ccccsssceccseececcsesececceuseceeseeecseseeecseuseesseaseeeseaueeessadeeecsegeesssaeestenss 54 DOP CINK creson nn R E A N OO EO Tecni A eaa PO 56 O A E M dou tuU iu EUE 56 AC Pal mE A 56 Ncc 57 10 1 4 Display ana Comtnutii callo cd of 10 1 5 Mechanical Parameters socius rte tae io aa of tO Z gt or EL 6 quo dios ii ni Nada 58 TOS oos dB T DU o9 Figures Fig 1 1 PV Generation System with SG100KC seessssseeeseseeeeeeene nennen nnne nnn nnne nn nnsna nnns nna narrans 2 AN o oma ira e xxi nm uU Ua AN 9 Fig 3 1 Simple Circuit Diagram of SG100KOC ssssssssssssseseeeesene nennen nnne nnn nnn n annt nna nnns nn nnn 12 Fig 3 2 External Appearance of SG100KO ooocccoccnccococococonocococoncnnonocononnnnnnnnnonnnnnnnnnnonannnnnnnnnnnnnnnnnnnnnnannnenanenes 13 Fig 3 3 Dimensions and Weight of SG1OOKC sssesessssesesssseee nennen nennen nenne nnn sna nnns naar nsns 14 18 34 BOHOM VIEWOFSGTOOK ev 15 A RAEE EEO
29. er Fig 7 1 Power Cable Connection Terminal 39 SG100KC installation Manual 7 3 Start Electrical Connections 7 3 1 Open the Door The SG100KC is stopped and latched once shipping users must open the front door of the SG100KC for wiring 1 Switch off both the AC and DC main switches turn both switches counter clockwise GRID MAIN SWITCH GRID MAIN SWITCH OFF OFF OFF OFF ON Fig 7 2 Open the Main Switches 2 Press down the doorlock to release the latch handle and turn the handle clockwise Fig 7 3 Open the Latch 3 First open the left half door and then the right half door identify the 2 transparent plastic shields one in the upper position and one in the lower position 4 Itis necessary to take down the lower protective shield for wiring Note that there are 4 screws indicated by the blue circles to fix the shield Loosen and remove them all See Fig 7 4 40 Electrical Connection 7 GGG GGG O bu 90 00 O O O O O_O OO OO O O O O O Transparent Plastic Shields Fig 7 4 Remove the Protective Shield 7 4 Open the Cable Holes The external cables are routed into or out of the cabinet via the cable holes at the bottom the SG100KC The corresponding sliding plates should be removed for wiring 1 Turn the screws in the back of the sliding plate counter clockwise 2 Slide the plates backwards to open the holes The protectiv
30. g the Un ec M 28 AROGE OOOI presa aga SE cule eo dax uu adve e uui iet edd 28 6 Mechanical Installalt0D az oT Transport and SHIPPING usas lia dl teo 30 SE E E E A ENE A NT 30 6 1 2 Moving the Packed SG 100K C 0 A see ocu area aval e EN pnl 31 A A PPP a mM a aa a 35 0 2 Unpacking tne Uni m A E casas unautteetibumeads 35 62 2 Place the gt G100KC t detis De ee ee ee a ee ee 36 62 3 Fastening the sG 100KC TO FOO oic oret on o Pee inb quE uc Sea eens Sesces Ren Erato Basse dens 36 7 Electrical C OMMECELO Mg T EGNE SPECI Ca NOMS it 32e E 38 TANS TOL CADINING erc E Hr p 39 7 3 otdrt Electrical COMME CUOMS sas esses cobi a a ud ueDea Etpe t e ouai ooo 40 ALODE the DOOL cin oe nt roo mbi um Pu cM Id DEL IM IER IN DEM IM AU EDU 40 44 Open the Gable Holes reto A A 41 FONG o A cee 42 70 AS Grids CONNECCION S AME ME 44 EA GPOUNG CONNECCION S EE lo os ile 45 7 8 Communication Connection OptiONAl ooccccoonncncoconnonccnononcnnoncnonnncnnnonanonnononcnnonnnrnnonnarinnnnnnens 47 TO losedhed able ONG S 0 teer solidus ctn ee Sete ic can nee aes C epoca ales tcd Mu CE aeee 48 8 Installation Check list cccccsscsssscsssccsesccssccsssccsscccssccscccsescccsccssccesccssccseses AD I COMMISSIONING ior GER NI EI eit UII inima 9 1 Requirements of COMMISSIONING ccccesccccceseecccesseecceuseeecsaueecsaeeecseaseeessaseeessadeeeesegeesseaeeeetens 52 9 2 Inspection b
31. h enough distance to avoid interference For example Fig 4 3 Sectional Drawing of Cable Trench 4 3 4 Ventilation The heat generated exhaust hot air by the SG100KC must be dissipated out of the electrical service room efficiently in order to guarantee safe operation and high feed in power e High circulation of air is required e Plenty of fresh air should be available e Air should be pure and without dust classification 392 e Ventilation equipments are necessary e g fans blowers ventilation grilles e Exhaust fans are recommended to keep the air pressure balance e Directions of air inlet and outlet should be designed according to the local wind direction Measures for dust and rain proofing of air inlet and outlet are necessary e The sizes of air pipes should be designed by professional personnel according to the air quantity 4 3 5 Other Protections The SG100KC has the Ingress Protection 20 TYPE 1 and should be installed in dry clean industrial environment in accordance with EMC threshold and noise level 23 SG100KC installation Manual During operating the SG100KC will make some noise lt 80db install the SG100KC in industrial environment and avoid the vicinity to living area or office area After wiring the cable entry and exit holes should be covered by the slid plates And the remaining gaps should be filled by urethane foam so as to keep mice or other creatures from entering the cabinet
32. he site of the monitor terminal 9 Close the Cable Holes After all the electrical connections are completed the cable holes must be closed to protect the interior against dirt soil and creatures 1 Slide the plates forward until the flexible sponge seals are pressed against the cables 2 Turn the screws in the back of the sliding plate clockwise to fix the sliding plates 3 Seal the rest of the gaps with urethane foam 48 Installation Checklist About This Chapter This chapter describes the items needed to verify whether the installation for the SG100KC is correct 49 SG100KC installation Manual Check the mechanical and electrical installation of the inverter before commissioning Go through the checklist below with another person Mechanical Installation Check all the mechanical connections and make sure there are no damages scratches or abnormal parts The inverter has been fixed properly to the floor The clearance spaces around the inverter are proper The ambient operating conditions are within the allowed limits O ooling air circulates smoothly The protective enclosure seal is integral and reliable Electrical Installation The inverter is grounded properly The polarity of the PV input connections is correct The grid voltage matches the nominal input voltage of the inverter orar nn cc te cc cnn cgi NN Make sure all the bolts that fix the cables are tightened and secured The
33. nication method and can be extended to a variety of communication approaches which includes Ethernet Internet and GPRS by utilization of proper external adapters or modems 3 6 General Requirements 3 6 1 Grid Requirements The output of the SG100KC is designed to fit the 600V 3 phase 4 wire grid system which includes L1 L2 L3 Neutral and power ground 600V 3 phase 3 wire grid is acceptable In 3 phase 3 wire grid neutral terminal of SG100KC can be left vacant Consult Local Distribution Company 3 6 2 Ventilation Requirements Maintain a minimum of 24inch 600mm clearance in back 48inch 1200mm in front and 24inch 600mm on top of the SG100KC for proper ventilation and installation operation 3 6 3 Installation Requirements All installation practices on the SG100KC may only be performed when the device is safely de energized of all the DC and AC power sources and all the power switches are locked out SG100KC installation Manual The SG100KC is designed with some fans for cooling and ventilation Work on the fans may only be performed after all insulation measures have been taken 3 6 4 Personnel Requirements Only qualified technical personnel who are familiar with the installation of the system may undertake any such work 3 6 5 Communication Requirements The basic communication interface of the SG100KC is the RS485 serial communication which can be easily connected to a PC through a RS485 RS232 Converter
34. nt aoo oa 40 Fig 7 4 Remove the Protective Shield lessen nennen nennen nennen nnns sara n 41 FOO DC Input Gable ROA T T 43 FIG 7 56 OUTPUT Cable QUIN cu aas tonio papae hol Eug aoc Eee oet rote oe Cut Ua id ute eee ost epe uaa Ee clum ec eU e Ee AA 44 Fig 747 Ground Cable ROUUNG ia rtis ab Dn eO oda cbr Huc dod ne esac A ius pde Fig 7 8 Serial Communication Cable Routing ooccccccocnnccconcnnnnoncnnnnoncnnonnnconnononcnnnnoncnnnnnnrnnnnnnrnnnnnnrnnncnnannnns Fig 7 9 Serial Communication Interface Connection ooocccccconnnncccoccnconocononnnnononnnnonnononcnnonnnnnnnnnncnnonnnrnnnonaninnss VII Tables Table 1 1 System Devices Type cies mr to E Ge e a rc da 2 Table 2 t Scope of Delivery ias inedia alicia 8 Table 4 1 Min Distance between Control Cable and Power Cable cccccccccseeeeeeeeeeeeeeeeeeaeeeeeeeeeaneeeess 24 Table 4 2 Tightening Torques for Power Cable Connections occcooccccoccncccccnnoncncconcnonononononnnonannnonannnnnnnncnonens 25 Table 4 3 Installation Process DescriptiONS coooccocncconcconoconoconoconoconnoncnnnnonononononononanonnnnnnnnonnnnnnnnnnnnnninaninos 26 Table 6 1 Symbol and Data Name on Crate ooccccccncccccnccccnnccocnnncnnnnonanononannnonnnnonnnnnnnnnnonnnnnonannnnnnnnnnnnanenanenes 31 Table 7 1 Recommended Sizes for DC Cables eeeeeesseeeeeeeeeeee eene nnne nnn nnn nnne ennt nnns nnn nns 3
35. ower Cable Connections M5 28 in lbs 3 2 N m M6 62 in lbs 7 N m M8 142 in Ibs 16 N m M10 301 in Ibs 34 N m 4 5 2 Cable Protections eo Protection of communication cable Communication cables are thin and easily to be broken Lay power cables first then communication cables Communication cables should be laid in cable trench or cable support arms or tightened up by cable ties Avoid heating element and strong electric fields Protection of power cables Strong electric currents remain in the power cables Protect the insulating layer from sharp edges Bundle power cables together with insulated cable ties if necessary 4 6 Installation Process Fig 4 4 shows the installation process of the SG100KC And Table 4 3 gives a description about it 25 SG100KC installation Manual Table 4 3 Installation Process Descriptions Process Specification Reference Preparations before Checking the unit 5 Preparations for Installation Installation Required tools Mechanical Transport and shipping 6 Mechanical Installation Installation Field installation Electrical Connection Open the door 7 Electrical Connection DC connections AC grid connections Ground connection Communication connection Installation Check Check mechanical installation 8 Installation Checklist Check electrical connection Others Commissioning Check before commissioning 9 Commissioning Preparations before start
36. put voltage 528 to 650 Vac Rated output frequency 60Hz l Output frequency range 59 3Hz to 60 5Hz l Max Output current 105 Aac l Enclosure Type I Dperating ambient temperature 25C 55C c 0C l Cert to CSA C22 2 No 107 1 01 c l Intertek r SUNGROW CANADA INC 4 D WWW SUNGROW CA MADE IN CANADA k 2 Fig 2 1 Nameplate The picture is for reference only the actual item is standard SUNGROW Logo and product type CO 00 Marks of certification institutions of SG100KC ID Company name website and origin SG100KC installation Manual 2 3 Storage of SG100KC If there is a long time before installation or operation the SG100KC should be stored appropriately e Pack the SG100KC up in the crate e Keep the desiccant bags in the crate The SG100KC can only be stored when it is stopped and all the doors are closed in a dry room to protect the internal circuits against dust and moisture e Perform a routine check at least once a week e Unpack check and change desiccant bags every 6 months Keep the crate upright No stacking on top of the crate NOTE After long term storage a thorough test of the SG100KC is necessary 10 Introduction About This Chapter This chapter provides basic information about SG100KC SG100KC Installation Manual 3 1 Basic Structure and Appearance The SG100KC is an advanced and reliable three phase grid connected inverter for
37. re are no tools foreign objects or dust from drilling inside the inverter There is no condensate water or ice in the cabinet 50 Commissioning About This Chapter This chapter describes how to start the SG100KC for the first time including requirements for commissioning inspection before start up start up procedures and completion of the commissioning 51 SG100KC installation Manual 9 1 Requirements of Commissioning Before starting the device for the first time all operations related to the device should be checked carefully A NOTICE Check to make sure the voltages in both AC and DC meet the requirements of the SG100KC 9 2 Inspection before Start up 9 2 1 PV Array Check Before start up check the PV array Check open circuit voltage of each PV string matches the nominal input voltage Record the U I curve if possible Record the environmental parameters temperature radiation intensity Se P a Measure and record the resistance of cables if possible 9 2 2 SG100KC Check Before start up check the SG100KC 1 Ensure that the mechanical and electrical installation of the inverter has been checked according to 8 Installation Checklist 2 Ensure that the DC and AC GRID Main switches are in OFF position 3 Ensure that the Emergency Stop Button is released and works 9 2 3 Ground Connection Check Make sure that ground cable goes through the hole of the ground fault detection device
38. secccseeceseeceucecacecaueeseecsueeseueesaueesaeeesueeseaeessueeseeeseneesaas 17 9 5 2 INStallallOn FREGUINETIIGINS 53 2 deoa rosam oa e teo cs 17 0 54 Personnel Requirements ia 18 3 6 5 Communication Requirements esssesssssssssssssesee nennen nennen nn snn sese ases n nnns sna sess s nnns 18 A Installation Destinia LO 4 1 The Solution with Optional Devices from SUNGROW sesseesssesseeeen nennen nnn 20 4 2 Basic Requlrermerilts oe ore iR anbietet iii 21 4 3 Installation Environment Design cccccseeceeeeeeeeeeeceeeeseeeeeseeeeesaeeeseeeeseaeeeseeeesseneeeseseesseeessaeeeens 21 LEF gn En 21 2352 O o a eR 22 L6 KA 6 ono LEE 22 Lor pique n oad 23 430 Other Protections s editae i dentia viu destined D ud teni ad ead aaah ote aaa pace 23 laico e se je dol eee AE or ttum O mete ate terete E tema eer Me DERE D 24 4 5 Tightening Torques and Cable Protecti0D cooonccccocnconoconcnnccnanonnonononnononcnnonannnnonannnnonnnrnncnnancnnns 25 4 5 1 Tightening Torques for Power Cable Connections cccccoocccccccnconccnncncnnoncnnonnnnoncnnanennnnnnnnnnnos 25 45 2 Gable Proteell liS iun eto ores ee usate coast c uon apa ec Apta Ebo o toa usaba tampons ss dns ciE 25 Zodgnstallalon PIOCGSS A imus docu euro dias aar uten Sete desc Comes o ED etiara 25 D Preparations tor Installation ie ie eed rideo al o L Checkin
39. st be available to operators and maintenance personnel at all times 1 3 Emergency Stop Button The Emergency stop button will shutdown the inverter disconnects the AC contactor and stops the IGBT matrix immediately when it is punched pressed down The inverter must be started up manually through the LCD control menu if users want to recover the operation after the button is punched 1 4 Grid AC Main Switch The grid main switch is one of the primary disconnects for the inverter The inverter s doors cannot be opened until the switch of the grid main switch is in the OFF position When the AC main switch is in the OFF position all AC power is disconnected not live except the input side of the AC circuit breaker the utility grid To operate the inverter the AC circuit breaker switch must be in the ON position SG100KC installation Manual 1 5 DC Main Switch The DC main switch is also the primary disconnect for the inverter The inverter s doors cannot be opened until the switch of the DC circuit is in the OFF position When the DC main switch is in the OFF position all DC power is disconnected not live except in the DC input terminals if the PV array is connected and energized To operate the inverter the DC circuit breaker switch must be in the ON position 1 6 Open the Door of SG100KC Use the following procedure to shut down the SG100KC inverter before servicing Stop the inverter from the LCD control menu Swit
40. vice SunBox PVS PV Array Combiner Box SunBox PMD D DC Power Distribution Cabinet SunBox PMD A AC Power Distribution Cabinet Solar Info Logger Inverter Data Acquisition and Transmission Device Safety Instructions 1 1 2 Safety Instructions Pay attention to the following safety instructions DANGER Shock Hazard Death results from burns and electric shock upon touching the SG100KC live components e Do not touch the live components of the SG100KC e Observe all safety regulations DANGER Shock Hazard The enclosure of the SG100KC inverter may contain high voltage conductors The enclosure doors should be kept locked during operation except for maintenance or testing To avoid the risk of electric shock do not perform any action or operation which is not included in the operating instructions unless you are qualified to do so DANGER Shock Hazard The SG100KC inverter will immediately shutdown if users want to open the front door during operation Please check whether the unit is thoroughly shut down and isolated from the public grid and PV arrays before opening the front door To avoid the risk of electric shock a minimum of 5 minutes is needed for any stored potentials that are still left in the inverter after shut down to be discharged before opening the door SG100KC Installation Manual DANGER Lethal Voltage Damage to the SG100KC may result death by electric shock or fire
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