Orion SPG-360-2KO
Contents
1. COMMUNICATIONS amp FEATURES LCD Communication Interface Output Power AC Voltage Frequency MPP Voltage AC Current Total kWh Model F W Revision Operating state Contrast adjustment RS232 standard SNMP amp RS485 optional Page 22 Doc No SPG 1601A Rev07 07 Orion Manual Solar Energy Australia MECHANICAL WxDxH 350x300x135 mm Weight 11 3 kg Mounting Holes Holes for M5 bolts on 332 x 250 mm centres COMPLIANCES AS 3100 AS 4777 C Tick compliance N2581 NOTES 1 Test conditions Input Vpy 300VDC Output Vac 240 VAC 50Hz 2000W Temp 25 C unless otherwise stated O P Yo 125 Recommended ae epaaiinG range SS e ye 100 Permissable non operating only 75 50 D o o l 7 23 0 100 200 300 400 Op rating at reduced power DO NOT EXCEED 450VDC Figure 15 Output Power De rating Curve Doc No SPG 1601A Rev07 07 Orion Manual Page 23 Solar Energy Australia Appendix A Orion Solar Array Design Example Figure 16 Example Solar Array Configuration NOTES 1 Consult AS NZS 5033 for detailed regulations concerning protection wire sizes etc 2 The panels below are fictitious and are discussed purely to demonstrate the selection process 3 The specification is provided as a guide only consult your dealer installer for exact information SEA does not market or sell solar panels or mo2. How much power does one string of nine panels make 9 x the rated power from the datasheet or 9 x120 1080W in this example How much PV power do we need to obtain the full inverter output of 2000W Lets assume an overall efficiency of 90 including wiring and inverter losses so input power needs to be 2000 0 9 or 2222W for 2000W output How many strings of 9 panels do we need Divide the required input power by the power available from one string and take the nearest whole number of strings S0 2222 1080 2 05 gives two strings So two strings of 9 panels should be OK as long as the combined current available is less than the 20A specified for Orion and max voltage is less than 450VDC So check Check what is the worst case short circuit current per panel from the panel data sheet at high temperature typ 80 C for Sydney Each panel is 4 7A which is the same for each series string so total short circuit current is 2 x 4 7A 9 4A As this is less than 20A it s OK Check what is the worst case open circuit voltage from the panel data sheet at low temperature typ 0 C for Sydney Each panel is around 46V at 0 C when open circuit so PV array voltage will be 9 x 46V 414VDC at 0 C which is less than 450VDC which is also OK NOTE The maximum array temperature will be mainly dependent on the amount of cooling provided in any installation For best efficiency the panel temperature should be kept as low as p
3. in no way be held responsible for any losses incurred due to the malfunctioning or failure of a product Suitably qualified personnel MUST carry out wiring Failure to do so cannot justify a warranty claim Except for the foregoing expressed warranty Solar Energy Australia makes no other warranty expressed or implied including but not limited to the warranty of merchantability or fitness for a particular purpose If you have any questions about this warranty please do not hesitate to contact us NOTE Packing for service and transportation we recommend you keep the original packing in which your Orion was supplied This is the best way to protect your unit should shipping be required Solar Energy Australia cannot be held responsible for units damaged in transit Page 4 Doc No SPG 1601A Rev07 07 Orion Manual Solar Energy Australia 1 0 Important Safety Information Before commencing installation please read carefully and follow the recommended guidelines below for trouble free operation Only qualified and competent persons authorised by Solar Energy Australia are allowed to work on this inverter All aspects of these instructions for use and operation have to be known by persons working on this appliance Keep these instructions with your inverter for quick reference at all times In case of malfunction contact your supplier who should initiate the necessary steps for analysis and elimination of the problem Grid feeding
4. inverters convert the DC current derived from solar arrays into AC current that is fed into the LV low voltage electricity distribution grid NEVER connect an AC generator wind generator turbine or battery bank to the inverter severe damage will result Only PV panels may supply the unit AND FINALLY Please complete and return your warranty card This will enable us to efficiently handle any service enquiries you may have and keep you updated with any relevant important updates Thank you WARNING IMPORTANT Isolate the unit at both PV and grid isolating switches BEFORE commencing any installation or service work A licensed electrician must install the entire system including the PV array and associated wiring The installation of this inverter and the PV system supplying it MUST comply with the Australian New Zealand wiring rules laid down in AS NZS 3000 and to any requirements of the local electricity utility The Orion is a non isolated type grid feeding inverter and the unit should be considered live to low voltage LV at both the AC grid connection AND the photovoltaic PV DC connection When connected to the grid the PV panels will be at LV mains potential with respect to utility earth The PV panel frames must be bonded to an effective earth When disconnecting the PV connections the utility earth must remain connected to the Orion As a result the plug making the grid connection to the Orion should be connected firs
5. isolated type inverter the unit should be considered live to LV low voltage grid at both the AC grid connection AND the PV DC connection When disconnecting the PV connections the utility earth must remain connected to the Orion As a result the plug making the grid connection to the Orion should be connected first and disconnected last The connector provided is a permanently latching type requiring the use of tools to remove to avoid inadvertent disconnection When Orion is operating the PV panels will have DC and the LV AC grid voltages present internally with respect to earth The PV panel frames must be bonded to an effective earth As previously noted in most situations the Orion requires very little service other than to periodically check the black heatsink at the rear of the unit is not excessively dirty or choked with debris spider s webs etc In the event of a fault the unit will shut down and the RED LED will be illuminated In the event of a grid fault the converter disconnects automatically within 2 seconds The inverter reconnects automatically after 60 seconds in the event of an automatic disconnection Please keep the inverter in operating mode even if the LCD screen and indicator lights may be momentarily blank The unit may be in the process of reconnecting The LCD screen will also be blank at night and in conditions of low sunlight whenever the PV array voltage is approximately 90V or less as there may not be enough
6. its input current to a maximum of 10A when operating However under a fault condition the input current may rise and to prevent damage to the inverter we set a maximum current array short circuit current of 20A In any case the PV wiring must be protected by an external fuse or breaker typical rating 16A My Orion makes a quiet buzzing noise when running is that normal Yes quite normal At start up my Orion clicks loudly several times is that correct Yes the unit is testing its relays for grid connection My Orion gets warm when operating but cannot hear a fan running Is that normal The Orion does not require a cooling fan Check the heatsink at the rear of the unit is free from dust and debris Page 28 Doc No SPG 1601A Rev07 07 Orion Manual Solar Energy Australia NOTES Doc No SPG 1601A Rev07 07 Orion Manual Page 29 Solar Energy Australia Solar Energy Australia PTY LTD Sydney 4 Beaumont Road Mt Kuring Gai NSW 2080 Tel 02 9457 2277 Fax 02 9457 2255 Melbourne 1 15 Nicole Close North Bayswater VIC 3 153 Tel 03 9761 5877 Fax 03 9761 7789 Email sales solaraustralia com au Website www solaraustralia com au Page 30 Doc No SPG 1601A Rev07 07 Orion Manual
7. Array Design Example 24 A Quick Guide to the Maths 25 Appendix B Using Orion with an Oversized Array 26 FAQS Frequently Asked Questions 28 Page 2 Doc No SPG 1601A Rev07 07 Orion Manual Solar Energy Australia SEA Introduction and General Information Thank you for choosing to purchase another guality inverter from Solar Energy Australia This product has been developed to provide you with years of trouble free operation It is important to us that you get the best out of your inverter so please take a few minutes to read this manual carefully it could save you from frustration If you have any comments regarding our products and or service please do not hesitate to contact us to discuss your thoughts Remember As soon as your Solar Energy Australia product has been installed please complete and return your warranty card This will enable us to efficiently handle any service enquiries you may have and keep you updated with any relevant product updates FEATURES INCLUDE e Very high conversion efficiency gt 94 typical e RS232 communications with RS485 and network e Natural convection cooling quiet fan less design options e High reliability with dual micro controllers e Solar array earth leakage protection for your safety e Built in MPPT Maximum Power Point Tracker e Approved to AS NZS 4777 AS NZS 3100 and C Tick liant e High power density compact profile low weight complian i i e Stylish modern casin
8. Grid frequency Frequency xx XxHz Grid frequency in Hz ee PV array voltage Vdc xxx xV Input voltage Vpy from PV array VDC ee Grid feeding current AC Current xx xA Grid feed current in A RMS ee Accumulated energy information Total energy that has been fed to the grid since Energy XxxxxxkWh inverter installation System Fault ee No utility No utility The grid utility is not connected or is unavailable Inverter Fault The readings of the two microprocessors do not ee Consistent Failure Consistent failure agree this may indicate an internal fault Call service ee Temperature too high Over temperature eee is excessive check heatsink Inverter Information ee Model display Model xkW Inverter model xkW inverter ee LCD contrast setting Set Contrast Sets the display contrast ee LCD display lock Lock Hold the present message display ee Waiting for reconnect to grid Reconnect in xxx sec Estimated time to reconnect to grid ee Firmware version V XX XX F W version information for service ee Setting Language Set Language Set up the display language Figure 11 Orion condensed status message table Page 16 Doc No SPG 1601A Rev07 07 Orion Manual Solar Energy Australia Figure 12 LCD display seguence Display accuracy The figures present on the display are for user reference only They should not be used for checking or testing of the system Normally the accuracy is around 2 but can vary as much as 5 over temperatu
9. Orion Manual Solar Energy Australia Model XkW LI Waiting lI Checking XX ji Normal State JI Watt xxxx xW Figure 8 Orion display during start up Turn on the PV DC isolation switch If there is sufficient sunlight the Orion will display Waiting then after a few seconds No Utility and the RED LED will illuminate indicating a fault Now connect the grid After a few seconds Orion will indicate Grid Fault whilst it synchronises with the grid and then Checking 60S 59S 58S etc as it performs internal self tests and counts down preparing to connect with the grid At 0S the unit will click several times as the grid connect relays are tested Once both processors are satisfied all is in order the unit will connect and start supplying power to the grid the Green LED will illuminate and the LCD display will read Normal State followed by Watt xxxx xW where xxxx x indicates the power being fed to the grid The unit is now on line and feeding solar power to the grid If the unit fails to respond check that the array is providing sufficient voltage to start the unit approximately 150VDC is required at the PV input to attempt a connection Doc No SPG 1601A Rev07 07 Orion Manual Page 13 Solar Energy Australia 4 0 Operating the Orion Inverter Status LCD and LED displays Solar Energy Australia Figure 9 Orion LCD status display normal operating The Orion is de
10. ault LED The unit will disconnect from the grid if required Shutdown State During periods of little or no sunlight VPV lt 90V the Orion stops running In this mode the Orion takes no power from the grid and the front panel LCD and LEDs are turned off Page 14 Doc No SPG 1601A Rev07 07 Orion Manual Solar Energy Australia LCD Contrast setting If the LCD is hard to read as it may be in elevated temperatures adjust the contrast as follows Press the function key repeatedly until Contrast shows in the display Hold the function key down for longer than 2 seconds until Set Contrast and the small bar graph appears in the display Press the function key repeatedly until the display contrast is acceptable continual pressing cycles through from minimum to maximum contrast Release the key for at least 10 seconds and the display will revert to show Watt xxxx xW The contrast setting is complete Lighter Figure 10 Setting the Contrast Function Key The function key cycles through the various LCD parameters as follows once the unit is powered and operational as shown below Normal State gt Contrast gt Set Language gt Pac gt Vac gt Freq gt Vdc gt AC Current gt Energy gt Model gt Version gt Normal State LCD Display Backlight The LCD display backlight will operate whenever the function key is pressed LED Status indicators Two light emitting diode indicators are provided o
11. average efficiencies These must be configured so that the PV operating voltage is in the range of 150 360VDC ideally for full output in the range 240 360VDC see figure 15 and must never exceed 450VDC when open circuit even at low temperatures The worst case array short circuit current should be less than 20A Also at 2400W of solar power the PV operating voltage must be less that 360Vdc under any conditions See Appendix B Using Orion with an oversized array Generally the array will be north facing and inclined to suit the location s latitude It must be in full sun not shaded by plants or buildings Tracking is the most efficient option in terms of capturing sunlight but requires complex mechanics and additional expense for even a modest array such as required by Orion Strings of less than 8 x 24V panels are not recommended as the low voltage may result in the inverter connecting reconnecting unnecessarily in conditions of low light The low voltage will also reduce the available power output and the overall efficiency See de rating information refer to figure 15 in paragraph 8 6 Refer to Appendix A for one example of a typical solar array Page 6 Doc No SPG 1601A Rev07 07 Orion Manual Solar Energy Australia 3 0 Installation ALL WORKS MUST BE CARRIED OUT BY LICENSED AND QUALIFIED TRADES PERSONNEL Refer to important safety standards AS NZS 3000 AS NZS 4777 and AS NZS 5033 Refer to AS NZS 1768 for advice on l
12. bedded earth leakage protection and will disconnect or fail to operate if leakage current from PV or PV to protective earth is more than 30mA PV panel frames must be bonded to an effective earth A suitable double pole PV isolating switch and 16A fuse or MCB protection must be used in compliance with local regulations Page 10 Doc No SPG 1601A Rev07 07 Orion Manual Solar Energy Australia IMPORTANT Please ensure that the open circuit PV array voltage cannot exceed 450VDC under any conditions Refer to AS NZS 5033 for recommended wire sizes and protection Refer to AS NZS 1768 for regulations regarding lightning protection As the unit employs MPPT maximum power point tracking technology it can accept a very wide range of PV input voltages from approximately 90VDC to 450VDC However the nominal input voltage when operational must be kept to less than 360VDC and ideally in the range 240 to 360VDC for full output see section 8 figure 15 and paragraph on derating below The Orion is connected to the solar array by way of commonly available weather proof polarised solar panel connectors type Multi Contact Solarline 1 observing the polarity Multi Contact Solarline 1 Figure 6 Connecting the PV array Feeding more than one unit from a common PV array The Orion employs MPPT maximum power point tracking to ensure maximum power is generated by the solar array over temperature and light conditions However this functi
13. bility The maximum current must not exceed 20A under any conditions Doc No SPG 1601A Rev07 07 Orion Manual Page 9 Solar Energy Australia Isolating switches circuit breakers Make sure all isolating switches are of the double pole type and are off before attempting to install or service the unit Grid connection The Orion is suitable for connection only to a nominal 240VAC 50Hz grid A suitable 2 pole grid isolating switch and 16A fuse or MCB protection must be used in compliance with local regulations The AC connection to the Orion is made via the RST 2013 latching connector RST p n 96 031 4153 1 supplied We suggest using a minimum of 1 5mm sq 3 core cable AWG 16 Gland Completed Assembly P Figure 5 Wiring the grid feed connector Fit the shroud and cable gland over the cable Strip the cable Wire the plug as follows Active A Brown Neutral N Blue Earth E Yellow Green securely tightening the clamp screws Clip the shroud to the plug and tighten the cable gland securely Plug in the grid connection to the unit and make sure it latches positively If it is desired to remove the connector for example for service it can be removed by carefully depressing the grey latch tongue with a small screwdriver PV Connection WARNING Orion is a non isolated grid feeding inverter Grid voltages with respect to ground will be present on the PV inputs when operating For your safety Orion contains em
14. e User friendly LCD display showing complete status e E y installati 9 information asy Installation Doc No SPG 1601A Rev07 07 Orion Manual Page 3 Solar Energy Australia IMPORTANT YOU MUST REGISTER YOUR WARRANTY SOLAR ENERGY AUSTRALIA WARRANTY Terms and Conditions It is extremely important that all installation instructions contained within this manual are strictly adhered to Failure to do so will void your warranty If this unit is installed within 1km of the coast steps should be taken to prevent salt water or spray entering the unit Any corrosion related problems are not covered under the terms of this warranty A fully marinised version of this unit is not available Solar Energy Australia warrants this inverter against defects in material or workmanship for a period of five 5 years from the date of purchase when in normal use and service The warranty period will provide a total of five 5 years if a completed warranty card is received within 60 days of purchase No warranty will be provided on units which have not been paid for in full Some models may have the option of purchasing an extended warranty period see elsewhere in this manual for details This manufacturer s warranty is in addition to your consumer rights under local trade practices act This warranty does not extend to products which have been opened altered or repaired by persons other than those authorised by Solar Energy Australia or to products which b
15. ecome defective due to acts of God fire sabotage vandalism contaminated fluids negligence or failure to operate house and maintain the product in accordance with instructions provided in this manual This warranty does not cover repairs made necessary due to the product coming in contact with dirt abrasives moisture erosion corrosion varnish or other similar or failure due to poor quality of other system components Solar Energy Australia will repair or replace the defective product in accordance with its best judgment For service under warranty the buyer must contact Solar Energy Australia to obtain a Return Materials Advice RMA document and shipping instructions before returning the unit Products returned without prior authorisation may be delayed The buyer will pay all charges incurred in returning the product to the factory including any charges incurred for the uninstallation or reinstallation of the inverter and or its system components Solar Energy Australia will pay return freight charges if the product is found to be defective within the terms of this warranty Repair or replacement of any unit does not extend the original warranty terms in any way Solar Energy Australia reserves the right with some models to supply an accredited installer with replacement parts Aust only This may allow the unit to become operable much quicker This choice is at Solar Energy Australia s discretion Solar Energy Australia will
16. eve HIGH EFFICIENCY GRID FEED INVERTER JJ O Ooo Models SPG 360 2K0 OPERATION amp INSTALLATION MANUAL Serial No Model No SOLAR ENERGY AUSTRALIA Pty Ltd ACN 081 639 938 SYDNEY 4 BEAUMONT RD MT KURING GAI NSW 2080 TEL 02 9457 2277 FAX 02 9457 2255 MELBOURNE1 15NICOLE CLOSE BAYSWATER NTH VIC 3153 TEL 03 9761 5877 FAX 03 9761 7789 Email sales solaraustralia com au Web www solaraustralia com au Solar Energy Australia CONTENTS Introduction and General Information 3 1 0 Warranty Terms and Conditions 4 1 0 Important Safety Information 5 2 0 Product Description and System Design 6 3 0 Installation 7 Mounting the Inverter 7 Wiring the inverter 7 Compatibility Check 9 Solar Array Test 9 Isolating Switches Circuit Breakers 10 Grid Connection 10 PV Connection 10 Feeding more than one unit from a common PV array 11 Increasing Output power 11 De rating 11 Completing the Install 12 Operating The Orion 14 Inverter status LCD and LED displays 14 LCD Contrast setting 15 Function key 15 LCD Display Backlight 15 LED Status indicators 15 Message tables 16 Display Accuracy 17 Communications Options 18 RS232 Interface 18 RS485 Interface 18 6 0 Maintenance and Repair 19 7 0 Trouble Shooting Guide 20 Fault Codes 21 8 0 Specifications 22 Appendix A Orion Solar
17. ge 26 Doc No SPG 1601A Rev07 07 Orion Manual Solar Energy Australia If you know the panel characteristics from the manufacturer s data sheet and the number of series panels and parallel strings it is possible to determine if the array can be used by some simple maths For Orion the maximum current at 360V is given by the input power approximately 2400W taking into account average efficiencies divided by 360V or 2400 360 6 7A Next take 360V and divide by the number of panels in one string of your array 8 in the example above giving 45V per panel Next look up the current produced at 45V worst case i e min local ambient temperature against your panel manufacturers specification In this case it is 2 2A Next multiply that figure by the number of strings 3 in this case giving 6 6A Multiply this current times 360V 6 6 x 360V 2376W Ensure that this power is less than 2400W Thus in this example the array is right on the limit but OK to use As long as the current is less than 6 7A this is OK as any attempt by Orion to increase the current would lower the voltage away from 360VDC However if the current exceeds 6 7A then Orion will already be at its maximum power limit and the voltage will climb out of control above 360VDC with the unit operating which is not permitted Check the maximum open circuit voltage at worst case minimum ambient Using the manufacturers data when the current is zero the voltage is 48V We have eight ser
18. ies panels in the array so 48 x 8 is 384V which is less than 450V and is therefore OK Finally check the short circuit current at maximum ambient for a panel Multiply by the number of strings In the example above it is approximately 5 5A x 3 16 5A which is OK as it is less than the 20A specified for the Orion Doc No SPG 1601A Rev07 07 Orion Manual Page 27 Solar Energy Australia FAGS freguently asked guestions 0 A gt PD PL O gt DP oO FP D The Orion is a non isolated inverter is that dangerous No as long as the proper precautions are taken during install and subsequent use The Orion incorporates a built in residual current circuit breaker function for your protection The Orion must always have a secure ground connection as must the frames of the PV panels and associated metalwork Warning signs should be posted in accordance with AS NZS 5033 The Orion is rated at 2000W To gain maximum rebate wish to install a 1000W solar array Is this OK Yes as long as the array does not exceed the maximum current and input voltage its fine only bear in mind the output power available for grid feeding will also be reduced My existing array is rated at 4000W Can use it with the Orion which is only rated 2000W Yes probably Refer to Appendix B for details The array short circuit current must be less than 20A but the input current draw is quoted as 10A why the difference The Orion will always limit
19. ightning protection Note This unit classifies as a non isolated PCU as per AS NZS 5033 Mounting the Inverter Select a suitable site for mounting the inverter bearing in mind the inverter should be placed in a position which minimises the cable runs Choose a site which is dry free of salt or moisture laden air free of dust and not accessible to rodents Do not expose the unit to direct sunlight The unit is intended for wall mounting Inspection and operation may be more convenient when the unit is mounted approximately at head height There is also the reduced probability of flood damage depending on site LIE TP LI DIED LA LED 20cm space minimum 20cm space minimum TELL A EAE PEP Figure 1 Ventilation requirements We recommend the Orion be mounted in a location such as a garage or in a weatherproof box outside under an eave on a suitably solid vertical wall A cooling space of at least 200mm must be left at the top and bottom of the unit and ideally also at the sides to allow access to the safety screws The site should not be susceptible to temperatures exceeding 55 C or humidity in excess of 95 non condensing Refer to figure 1 Doc No SPG 1601A Rev07 07 Orion Manual Page 7 Solar Energy Australia Placing the inverter in a cupboard or small enclosure may reduce its output power and increase operating temperature reducing reliability Use the bracket as a template to drill the wall
20. iple inverters to share a common data bus over distances of up to 1 2Km Please consult your dealer for more information Page 18 Doc No SPG 1601A Rev07 07 Orion Manual Solar Energy Australia 6 0 Maintenance and Repair The appliance is considered to be maintenance free Itis advised from time to time to check the heat sink at the rear of the unitis free from obstruction to airflow Itis recommended a gualified person checks the installation annually for proper function and electrical connections You should also get the solar panels cleaned and their security checked at least every 12 months In the event of internal malfunction the unit will need to be returned to the manufacturer for repair The unit contains no user serviceable parts inside Note Removal of the cover will invalidate the warranty In the event of a problem please consult the Trouble Shooting guide section 7 before calling your supplier or returning the unit Doc No SPG 1601A Rev07 07 Orion Manual Page 19 Solar Energy Australia 7 0 Trouble Shooting Guide WARNING It is imperative that any fault location procedures or troubleshooting be carried out by qualified authorised personnel in accordance with the local utility suppliers regulations Make sure both PV and grid isolator switches are set to off before attempting any repair or service The Orion contains voltages of up to 450VDC inside the case In addition as the unit is a non
21. making sure it is level Figure 2 Orion Wall mounting options Do not over tighten the bracket to the wall as it may distort unless the wall is absolutely flat Hang the Orion unit on the bracket and insert the safety screws see figure 3 Page 8 Doc No SPG 1601A Rev07 07 Orion Manual Solar Energy Australia M4 13L Scr Figure 3 Fitting the safety screws IMPORTANT After hanging the unit make sure the safety screws are fitted and the unit cannot be lifted from the bracket Wiring the Inverter It is not necessary to remove the inverter cover for connection to the grid and or PV wiring The cover is secured using a tamperproof label Removal of the cover will invalidate the warranty inu Connection system 2 pole isolators fuse 16A w or MCB protection Figure 4 Orion typical installation diagram Before commencing please pay particular attention to the following Compatibility check Check for compatibility of local PV DC and AC grid voltage and frequency with that published on the compliance plate before making any connections The unit is suitable for connection to nominal 240VAC 50Hz grid systems only The maximum PV voltage must not exceed 450VDC Solar Array Test Before commencing wiring it is recommended that the solar arrays be tested to ensure correct polarity and voltage A full sun short circuit test must also be conducted to confirm maximum current capa
22. n the front panel and indicate the inverter status as follows Normal operation inverter in service GREEN LED ON RED LED OFF ee Fault detected inverter requires attention and or service GREEN LED OFF RED LED ON ee Refer to section 7 troubleshooting for more information If there is no display on the LCD panel and both the LEDs are off e e the PV voltage from the solar array is lt 90V so check there is sufficient sunlight and that the panels are correctly connected before calling service During periods of marginal sunlight the inverter may continually start up and shut down this is normal as there is insufficient power to operate the control circuits Doc No SPG 1601A Rev07 07 Orion Manual Page 15 Solar Energy Australia LEDS AND OPERATING STATUS MESSAGE DESCRIPTION Normal Working Status ee Power Off No display PV inverter shutdown Vpy 9OVDC ee Standby Standby 90V lt Input voltage 100V Input voltage range 100 150V during startup After ee nitialization and waiting Waiting PV voltage is above 100V inverter is waiting for feeding to grid ee Checking grid xxS shows UA When PV voltage gt 150V inverter is checking grid count down to connection g feeding conditions ee Feeding grid MPPT imel See Inverter is feeding power After 10 seconds of this display LCD will show wattage ee Instantaneous output power Pac xxxxW The real time output power in watts ee Grid voltage Vac Xxx xV Grid voltage in VAC RMS ee
23. on means that only one Orion unit can be supplied by any one PV array Increasing output power The Orion cannot be paralleled at the input due to the MPPT but may be parallel connected at the output with another similar unit or units consult your installer for more information Derating For PV voltages of less than approximately 240VDC the power available from the unit will be reduced in accordance with the de rating curve published in Section 8 figure 15 This is calculated in accordance with the maximum PV current draw being limited to 10A and taking into account the unit efficiency at low PV voltages For example at 150VDC PV input only around 1200W will be available to feed to the grid Doc No SPG 1601A Rev07 07 Orion Manual Page 11 Solar Energy Australia Completing the install Before finally turning on the Orion check the open circuit PV voltage is in the range of 150VDC to 450VDC and that 450VDC can never be exceeded for example in cold weather Failure to observe this instruction will damage the inverter Connect the RS232 cable or fit optional communications modules as required see section 5 0 Display information switch LCD Display Showing the inverter status Operation LED Green normal Utility AC connection Optional communications Operation LED slot RS485 amp other Red fault status Solar panel input RS232 cover Figure 7 Orion overview Page 12 Doc No SPG 1601A Rev07 07
24. ossible Doc No SPG 1601A Rev07 07 Orion Manual Page 25 Solar Energy Australia Appendix B Using Orion with an Oversized Array If you have an existing array or plan for future inverter upgrades by installing more panels than you need or wish to increase your yield in low light conditions then you might already have or wish to install more solar capability than the Orion can use The graphs below detail the issues involved Using the panel manufacturers curve for a single panel of the array at the minimum ambient temperature the curve is redrawn with new axis to represent the whole array So for example a notional 4kW array of 24 165W panels in three strings of eight would require the voltage axis to be multiplied by 8 and the current axis multiplied by 3 Fi ype Zl f Pinn manda li ary cba Tin PY A ay Tor cara amb d L E 5 E E 2 u u B qu BU Joie 1 a a s Figure 1 Figure 2 Figure 1 shows the data for a single panel figure 2 for the whole array of 3 strings of 8 panels 4kW maximum Also drawn on figure 2 is the current verses voltage for the Orion power limiting at 2400W taken from the derating curve The crucial point is where the curves intersect Is the voltage at that point greater than 360VDC No in the above example so although the array is over twice the size required it would be safe to connect to the Orion Fortunately it s not necessary to start drawing graphs Pa
25. ource only and generates a 240 VAC 50 Hz current output for direct connection to the LV low voltage power grid The unit operates with an input voltage between 100VDC and 360VDC The absolute maximum non operating input voltage is 450VDC The Orion employs a MPPT maximum power point tracker for efficient use with PV power systems and is supplied with built in PV earth leakage protection Trip current is 30mA The unit is designed for indoor use only The Orion is provided with a standard RS232 socket for connection to a PC for data acquisition There are optional components for communications via RS 485 and SNMP Contact your dealer for details The unit is compliant with AS NZS 4777 Grid Connection of Energy Systems Via Inverters and AS NZS 3100 2002 Approval and test specification General requirements for electrical equipment System Design This installation MUST be carried out by a licensed electrician However we have included some general information below as an initial guide The array must meet local requirements and the requirements of AS NZS 5033 for connection to a non isolated PCU Correctly sizing the solar array requires careful consideration of a number of complex factors Local area planning permits may be required and allowance must be made for the weight of the panels wind loading temperature cost and other variables To obtain full output approximately 20 25 sq m of PV panels will be required assuming
26. power available to run the internal circuitry During periods of reduced sunlight the inverter may continually start up and shut down This is normal as there is insufficient power to continuously operate the control circuits Page 20 Doc No SPG 1601A Rev07 07 Orion Manual Solar Energy Australia Fault codes Some possible faults and their solutions are given below see figure 14 FAULT RED LED ON ee System Fault Inverter Failure LCD Display Ground Fault Grid Fault No utility PV over voltage Over temperature Consistent Fault Relay Failure DC INJ High EEPROM failure SCI Failure High DC Bus Low DC Bus Ref 2 5V Fault DC Sensor Fault PV safety fault Possible Solutions 1 The ground current is too high 2 Unplug the inputs from the PV generator and check the peripheral AC system 3 After the cause is cleared replug the PV panel and check inverter status 4 If the problem persists call service 1 Wait for 5 minutes if the grid returns to normal the inverter will automatically restart 2 Make sure the grid voltage and frequency are to specification for location and inverter rating 240VAC 50Hz 1 The grid is not connected 2 Check connection cables switches etc 3 Check grid status 1 Check PV voltage is less than 450VDC 2 If less than 450VDC and the problem persists Call service 1 Check heatsink is clean and free from debris 2 Reduce ambient temperature 3 If not effec
27. re and tolerances The readings will vary up and down this is normal and caused by the MPPT maximum power point tracking feature Doc No SPG 1601A Rev07 07 Orion Manual Page 17 Solar Energy Australia 5 0 Communications Options The Orion supports powerful communications options RS232 is fitted as standard The unit also supports RS485 and IP Ethernet which are available as additional options at extra cost from your dealer RS232 interface A standard 9 pin female D type connector is provided for RS232 connection to an IBM format PC PIN No Function 1 2 3 5 7 NCO Note NC no connection Z O ZIZIZ OJOJOO Z O Figure 13 9 pin D connections Remove the two screws and hinge down the small panel in the centre of the unit between the PV and AC inputs to access the connector A standard 1 1 9 pin D type serial communications cable of a suitable length not supplied is required for the connection Lock the connectors using the jack screws on the cable Load the appropriate Orion software optional please contact your dealer Please select the correct COM port usually COM 1 or COM 2 If your PC does not have serial communications they may be available as an option Please contact your PC dealer or mother board manufacturer The default communications setting for Orion is 9600 baud 1 start 1stop bit no parity RS485 interface An optional RS485 interface card is available This allows mult
28. signed to be user friendly and the status of the inverter can be easily obtained by reading the liguid crystal display LCD and light emitting diodes LED s provided on the front panel display A single press button function key allows scrolling through menus and basic adjustments to Language and Contrast for example The Orion has 4 modes of operation 1 Waiting startup state If the PV voltage is between approximately 90 and 150VDC the inverter will enter a waiting state using only enough PV power to run its own internal circuitry The display and indicator LED s may be dark or operate intermittently Note in continuing conditions of poor light such as dawn dusk or heavy shading the Orion will attempt to minimise connections reconnections by incrementing the reconnect timer value in steps of 300 seconds up to a maximum of 999 seconds This behaviour is normal and does not indicate a fault When sufficient light becomes available Orion will reconnect and function normally Normal State In this mode the Orion works normally Whenever the supplied voltage from the solar panels is sufficient VPV gt 150VDC the Orion converts the power generated by the solar energy to the grid In the normal state the GREEN LED is ON Fault State The internal microprocessors continually monitor and adjust the system status If Orion finds any abnormal conditions such as a grid anomaly it will display the information on the LCD panel and light up the RED f
29. t making sure the grid is first isolated and disconnected last The connector provided is a permanently latching type requiring the use of tools for removal to avoid inadvertent disconnection Hazardous voltages can be present inside the converter even after disconnection Removal of the cover will invalidate the warranty and may result in injury The inverter is not designed for outdoor use Protect the unit against rain splashing water and salt spray Install it in a dry salt free atmosphere temperature range 55 C maximum humidity 95 non condensing Do not place any item on the inverter and allow a minimum of 200mm for ventilation all around the unit Keep black heatsink fins and inverter free of dust and obstructions to airflow Inadequate air circulation can lead to overheating and overload conditions Do not expose the unit to direct sunlight Hot Surfaces Although the unit is designed to meet all safety requirements some parts and surfaces will become hot during operation To reduce the risks of injury do not touch the black finned heat sink at the rear of the unit or nearby surfaces whilst the Orion is operating Doc No SPG 1601A Rev07 07 Orion Manual Page 5 Solar Energy Australia 2 0 Product Description and System Design Product Description The Orion is a highly efficient true sine wave DC AC Inverter designed for solar grid feeding applications The unit operates from a photovoltaic PV solar array DC power s
30. tive call service 1 Reset the inverter by disconnecting the PV supply 2 Wait for a few seconds 3 Reconnect the PV supply 4 If the problem persists call service Figure 14 Orion List of fault codes and possible solutions Doc No SPG 1601A Rev07 07 Orion Manual Page 21 Solar Energy Australia 8 0 Specifications ELECTRICAL Input Maximum DC voltage operating Maximum PV open circuit voltage MPPT range Activating Voltage Maximum array short circuit current Maximum inverter PV current draw 360 V dc 450 V dc 150 to 360 V dc 150 V de 20 A dc fault condition 10A limited by inverter Output Operating output voltage Operating Output Frequency Output Power Output Power Factor Conversion Efficiency Islanding Prevention Current Distortion THD Output Overvoltage Threshold Output Undervoltage Threshold Output Overfrequency Threshold Output Underfrequency Threshold ENVIRONMENT 240 V rms nominal 210 Vrms minimum 260 V rms maximum 50Hz 2000 W nominal 2200 W maximum Output Power Derating See Figure 15 gt 0 99 gt 94 Frequency drift with over under frequency trip over under voltage trip z5 263 V rms 207 V rms 50 75 Hz 49 25 Hz Protection Degree Operation Temperature range Humidity Heat Dissipation Standby Power Consumption Acoustic Noise IP43 20 to 50 C 0 to 95 non condensing Convection 7 W PV DC 90 to 150V lt 40 dBA
31. unting frames Example array specification typical figures Configuration Two parallel strings each comprising nine panels in series Panels Nominal 120W 24VDC Format each 6 x 12 Cells 72 total per panel Dimensions 1580 x 808 x 35 mm each panel HxWxD 3200 x 7300 x 35 mm minimum array not including mountings HxWxD Weight 15 5Kg each panel 280Kg array not including mountings Total Area 23 sq m approx Typical array voltage 9x33 297V open circuit max 440VDC at 0 C Typical array current 2 x 3 8A 7 6 short circuit current 9 4A Typical array power 2260W under standard 1kW sq meter insolation Estimated power to grid 2000W including wiring and efficiency losses Page 24 Doc No SPG 1601A Rev07 07 Orion Manual Solar Energy Australia A guick guide to the maths 1 Let us assume a target PV array voltage when operating of 300V Why This allows the full output of the inverter to be obtained at the best efficiency It s also below the maximum operating voltage of 360VDC For best efficiency the higher the PV voltage the better but the maximum MPPT voltage must never exceed 360VDC and the maximum open circuit voltage must never exceed 450VDC even when the array is cold What is the output voltage at max power point of our chosen panel from the data sheet 33V for the particular panels we have chosen So the nearest whole number of panels for our target voltage Is 300 33 9 09 or 9 panels
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