ZCS HYD 3000-ES User Manual
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ZCS HYD 3000-ES User Manual

Hybrid inverter
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ZCS HYD 3-6K ES hybrid inverter
User Manual
13 – 06 - 2019
V1.1 (for firmware version V1.40 or higher)

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Summary of Contents for ZCS HYD 3000-ES

  • Page 1 ZCS HYD 3-6K ES hybrid inverter User Manual 13 – 06 - 2019 V1.1 (for firmware version V1.40 or higher)

  • Page 2: Table Of Contents

    Table of Contents Introduction ................................6 Preliminary safety instructions ..........................7 2.1. Safety Notes ..............................7 2.2. Mounting and maintenance instructions ....................7 2.3. Symbols on the inverter ..........................9 Installation ................................10 3.1. Product overview ............................10 3.2. Contents of the packaging ........................11 3.3.
  • Page 3 Technical specifications ............................42 Troubleshooting ..............................44 Warranty ................................50 3/50 User Manual for HYD 3-6 kw ES Hybrid Inverter - Rev. 1.1 del 13/06/2019 Identificazione: MD-AL-GI-00 Rev. 4.0 del 31.01.18 - Applicazione: GID...
  • Page 4 (including the software), reproduced or distributed in any form or by any means without the permission of Zucchetti Centro Sistemi S.p.A. All rights reserved. ZCS reserves the right to final interpretation. This manual is subject to change based on feedback from users, installers or customers. Please check our website http://www.zcsazzuro.com...
  • Page 5 Preface General information Please read this manual carefully before installation, operation or maintenance. This manual contains important safety instructions that must be followed during installation and maintenance of the system.  Scope This manual describes the assembly, installation, electrical connections, commissioning, maintenance and troubleshooting of the HYD 3-6K ES hybrid inverter.

  • Page 6: Introduction

    1. Introduction The HYD-ES hybrid inverter is used in photovoltaic systems with battery storage. The energy produced by the photovoltaic system will be optimised for maximum self-consumption. The HYD-ES inverter can operate in automatic mode and in time-of-use charge, charge/discharge mode. In automatic mode, when the energy produced by the PV field is greater than that required by the utilities, the HYD-ES inverter charges the battery using the surplus photovoltaic energy, and when the photovoltaic energy is lower than that required, the inverter uses the energy stored in the battery to supply current to the local...

  • Page 7: Preliminary Safety Instructions

    2. Preliminary safety instructions Before installation, please read this manual carefully and make sure you fully understand its contents. The HYD-ES inverter fully complies with the safety regulations. During installation, operation and maintenance, all operators must follow the local safety guidelines. Improper operation may result in electric shock and/or damage to people and property.
  • Page 8  Battery maintenance workers must have the skills and knowledge required to carry out this activity.  All the batteries connected in parallel must be of the same model and have the same firmware version. This problem must be taken into consideration by the designer/installer, especially when replacing the batteries or when modifying the existing storage system.

  • Page 9: Symbols On The Inverter

    Be careful of hot surface. Comply with the European Conformity (EC) certification. Ground terminal. Read this manual before installing the ZCS HYD-ES inverter. This indicates the degree of protection of the equipment in accordance with the IEC 70-1 (EN 60529 June 1997) standard.

  • Page 10: Installation

    3. Installation 3.1. Product overview The HYD-ES inverter is subjected to strict controls and inspection before packaging and delivery. Do not turn the HYD-ES inverter upside down during delivery. Carefully check the packaging and product fittings before installation. Caution Figure 2 - Diagram of a system on which a HYD 3-6K ES hybrid is installed DC switch Current transformer port Battery input terminals...

  • Page 11: Contents Of The Packaging

    3.2. Contents of the packaging Carefully inspect the packaging and accessories before installation. It should contain the following accessories: 1 mounting bracket 6 AC terminals 2 M5 screws 2 battery terminals 8 M6 flat washers 2 TC terminals 4 terminal caps 8 expansion plugs 1 user manual 1 warranty...

  • Page 12: Installation Tools

    3.4. Installation tools Prepare the following tools before installation: Number Tool Model Function Percussion drill Used for drilling the wall Recommended diameter of 6mm Screwdriver Used for the wiring Cable stripper Used for stripping the wires Used for tightening the screws to 4mm Allen key connect the rear panel of the inverter...

  • Page 13: Wall Installation Position

    Dust mask Must be worn by operators 3.5. Wall installation position The HYD-ES inverter must be mounted vertically (to ensure rapid heat dissipation). Install the HYD-ES inverter in a location protected against direct sunlight and possible snow accumulation. Make sure that the installation position is well ventilated.
  • Page 14 Note: for safety reasons, ZCS Spa and/or its partners may not carry out any technical repairs or maintenance work, or move the inverter or battery pack from and to the ground if it is installed at a height of more than 180 cm from the ground.

  • Page 15: Electrical Connections

    Figure 5 – Instructions for installing the storage inverter and battery pack 4. Electrical connections High voltages in power conversion circuits. Danger of death by electrocution or serious burns. All work on the photovoltaic modules, inverters and battery systems must be carried out by qualified technicians.

  • Page 16: Connecting The Battery

    Figure 6 – Electrical Connections 4.1. Connecting the battery Figure 7 – Connecting the battery (measure polarity/voltage of the battery cables before connection) Step 1: Loosen the 4 screws (A) using a screwdriver (Fig. 6). Step 2: Remove the waterproof cover (B), loosen the cable gland (C), and then remove the cap (G). 16/50 User Manual for HYD 3-6 kw ES Hybrid Inverter - Rev.

  • Page 17: Photovoltaic Connection

    Step 3: Route the battery cables (F) through the cable gland, then connect the battery wires using the OT terminal (E). Step 4: Fasten the waterproof cover using the 4 screws. 4.2. Photovoltaic connection Recommended specifications for DC input cables Cross-sectional area (mm Outer diameter of cable (mm Range...
  • Page 18 the photovoltaic cables are correct. Insert the positive and negative connectors of the HYD-ES inverter until you hear a “click” sound, as show in Fig. 9. Figure 10 – Connecting the photovoltaic connectors Before removing the positive and negative PV connectors, make sure that the DC CIRCUIT BREAKER is OPEN.

  • Page 19: Ct / Can / Rs485 / Ntc - Pylontech Battery Connection

    Note Depending on the type of inverter, select the appropriate inverter accessories (cables, fuse holders, fuses, switches, etc). The open-circuit voltage of the photovoltaic system must be lower than the maximum DC input voltage of the inverter. The output voltage of the strings must be compatible with the MPPT voltage range. The positive and negative poles of the panel on the inverter must be connected separately.
  • Page 20 Figure 13 – CT connections Step 1: Refer to figure 12 for the correct position of the CTa. Wrap the CTa around the L wire of the mains power supply. Step 2: If necessary, network cables and terminal caps can be used to extend the CTa wires; the maximum length of the cable is 200m.

  • Page 21: Grid Connection

    485A----pin2& pin7 Step 7: Fasten the waterproof cover using the 4 screws. NOTE: If using batteries other than PYLOTECH batteries, please contact the ZCS service centre. 4.4. Grid connection Step 1: Loosen the 4 screws (A) using a screwdriver (Fig. 15).

  • Page 22: Critical Load Connection (Eps Function)

    Figure 15 – Connecting the grid and critical loads 4.5. Critical Load connection (EPS function) Critical Load: in the event of a power failure (or operation in Off-Grid mode), if the EPS function is enabled, the HYD-ES inverter will work in Emergency Power Supply (EPS) mode, using the energy stored in the battery to supply energy to critical loads via the LOAD connection port.
  • Page 23  If the HYD-Es inverter is faulty, manually move the switch to position 2. The grid will supply power to the critical load. Note: If the system is equipped with a production metre, take into account that the energy for the critical load is drawn before the meter and therefore this energy, even if produced by photovoltaic panels, is not counted as energy produced.

  • Page 24: Buttons And Indicator Lights

    5. Buttons and Indicator lights Figure 17 – Buttons and indicator lights 5.1. Buttons  Press “Back” to go back to the previous screen or to enter the main interface;  Press “Up” to enter the upper menu or to increase the value by 1; ...

  • Page 25: Operation

    6. Operation 6.1. Preliminary checks Before starting the system, please check that: The HYD-ES inverter is securely fixed to the mounting bracket; The PV+/PV- cables are securely connected, and the polarity and voltage are correct; The BAT+/BAT- cables are securely connected, and the polarity and voltage are correct; The GRID/LOAD cables are securely/correctly connected;...
  • Page 26 Figure 19 – Front view of a Tawaki Maui 4kWh battery In the case of Weco ReSU 4K4 batteries, press the POWER button for one second, making sure that the RUN light turns on. Figure 20 – Front view of a Weco ReSU 4K4 battery Close the AC switch between the AC port and the GRID port of the HYD-ES inverter and the grid.
  • Page 27 Make sure that you have selected the correct country code according to the local regulations. For this purpose, consult a professional electrician or qualified personnel from the electrical safety authorities. ZCS accepts no responsibility for consequences deriving from the selection of an incorrect country code. Caution 27/50 User Manual for HYD 3-6 kw ES Hybrid Inverter - Rev.
  • Page 28 PYLONTECH US2000 PLUS / US2000B 1.PYLON 2. DARFON DARFON 14S31P ESS 3.DEFAULT LEAD-ACID / LEAD-CRYSTAL / AQUION batteries All batteries that comply with ZCS’s BMS CAN communication protocol (Tawaki Maui 4. Lithium and Weco ReSU 4K4). 5. Alpha. ESS M48112-P / SMILE-BAT 6. SOLTARO SL-3KWH/ SL-1KWH Press “Up”...

  • Page 29: Commissioning

    6.3. Commissioning Main interface: Figure 21 – Main interface The default setting of the HYD-ES inverter is “Automatic Mode” so if the setting has not been changed, the operating mode will be as follows:  When “Photovoltaic Production” > “Home Consumption” If the battery is not fully charged, the HYD-ES inverter will charge the battery.

  • Page 30: Display Menu

    6.4. Display menu In the main interface, press the “Down” button to enter the page with the grid/battery settings: Main interface Press “down” 1.Grid(V) 2.Grid(A) 3.Frequency 4.Battery(V) 5.Charge current 5.Discharge current 7.Charge level 8.Battery cycles 9.Battery temp In the main interface, press the “Up” button to enter the page with the photovoltaic settings: Main interface Press “OK”...

  • Page 31: Basic Settings

    6.4.1. Basic settings: 1. Settings Press “OK” 1.Language 2.Date and time 3.Energy storage Mode “Up”↑ 4. PV input mode 5.EPS mode “Down” ↓ 6.Communication address 7.Self-Test 1. Set language Select “1. Language”, then press “OK”. Press “Up” or “Down” to select the language, then press “OK.” A quicker way: simultaneously press “Back”...
  • Page 32 Δ If PV production = LOAD consumption ( P < 100W) If PV production > LOAD consumption, the surplus power will be stored in the battery. the HYD-ES inverter will not charge or discharge the battery. If the battery is fully charged (or already at max If the PV production <...
  • Page 33 3. Photovoltaic Input Mode Photovoltaic Input Mode selection: The HYD-ES inverter has two MPPT channels. The two MPPTs can operate independently or in parallel. If the PV strings are connected in parallel, “parallel mode” must be selected before connecting to the inverter; otherwise the default configuration (independent mode) must be used. After changing the PV input mode, restart the HYD-ES inverter to validate this change.
  • Page 34 ↓ Wait Testing 27.S1... ↓ Wait Test 27.S1 OK! ↓ Wait Testing 27.S2... ↓ Wait Test 27.S2 OK! ↓ Wait Testing 81>S1... ↓ Wait Test 81>S1 OK! ↓ Wait Testing 81>S2… ↓ Wait Test 81>S2 OK! ↓ Wait Testing 81<S1... ↓...
  • Page 35 27.S1: 228V 408ms ↓ Press “Down” 27.S2 threshold 92V 200ms ↓ Press “Down” 27.S2: 227V 205ms ↓ Press “Down” 81>.S1 threshold 50.5Hz 100ms ↓ Press “Down” 81>.S1 49.9Hz 103ms ↓ Press “Down” 81>.S2 threshold 51.5Hz 100ms ↓ Press “Down” 81>.S2 49.9Hz 107ms ↓...

  • Page 36: Advanced Settings

    Press “Up” or “Down” to change the first digit, press “OK” to move to the next one. After changing all the digits, press “OK”. 5) Control 81.S1 Select “5. Control 81.S1” and press “OK.” Press “Up” or “Down” to “Enable 81.S1” or “Disable 81.S1”, press “OK.” 6.4.2.
  • Page 37 The user can enter the scan period or force an immediate scan. 7. Safety parameters (and other functions not previously described that appear in the user interface) Contact ZCS Technical Support for more information. 37/50 User Manual for HYD 3-6 kw ES Hybrid Inverter - Rev. 1.1 del 13/06/2019 Identificazione: MD-AL-GI-00 Rev.

  • Page 38: Event List

    6.4.3. Event list 3. Event list 1. List of current events “Up” ↑ 2.List of Historical events “Down” ↓ HYD-ES inverter event list, including the lists of current and historical events. 1) List of current events Select “1. List of Current Events”, press “OK” to check the current events. 2) List of historical events Select “2.

  • Page 39: Energy Statistics

    2)*Battery Capacity Depth of discharge Maximum charge (A) Battery Info (1) Over (V) Protection Maximum charge (V) Maximum discharge (A) Minimum discharge (V) 3.Safety Parameters Safety parameters (0) OVP 1 OVP 2 UVP 1 UVP 2 Safety parameters (1) OFP 1 OFP 2 UFP 1 UFP 2...
  • Page 40 Charge ***KWH Discharge ***KWH Select “5. Energy Statistics”, press “OK” to enter the Energy Statistics interface, which shows the energy production and consumption over a given period of time. Press “Up” or “Down” to check the daily, weekly, monthly, annually and total energy statistics . 40/50 User Manual for HYD 3-6 kw ES Hybrid Inverter - Rev.

  • Page 41: Software Update

    6.4.6. Software update If a software update is required, ask ZCS to send you the latest version of the available firmware. Copy the firmware folder to the main directory of the SD Card. Select “6. Software Update” and press “OK”; “Enter Password” appears on the screen. Enter the password “0715”, press “Up”...
  • Page 42 7. Technical specifications Model HYD 3000-ES HYD 4000-ES HYD 5000-ES HYD 6000-ES Battery parameters Lead-acid, lithium ion Battery type Battery rated voltage Battery voltage range 42-58V Recommended battery capacity 200Ah (100– 500 Ah optional) Maximum charge current 0 - 60A (programmable)
  • Page 43 AC Parameters Maximum output power 3000W 4000W 5000W 6000W 13.7A 18.2A 22.8A 27.3A Maximum output current Rated grid and frequency 230V, 47 – 53Hz or 57 – 63Hz voltage 150 – 275V (according to the local requirements) AC voltage range <3% Total harmonic current distortion 1 (adjustable +/-0.8)
  • Page 44 If the grid voltage/frequency is NOT within the acceptable range and the AC wiring is correct Grid frequency is too ID03 GridOFP but the alarm occurs repeatedly, contact ZCS high. Technical Support to change the grid overvoltage, undervoltage, overfrequency and Grid frequency is too...
  • Page 45 5 minutes protection and then switch it back on again. Check if the problem has been resolved. Grid current is too high If not, contact ZCS Technical Support. ID15 HwAcOCP and has triggered the hardware protection Check the settings of the HYD-ES inverter’s...
  • Page 46 Battery current is too If the fault occurs frequently, contact ZCS ID27 BatOCP high. Technical Support. ID28 DciOCP DCI is too high. ID28- ID31 are internal faults of the HYS-ES inverter; switch off the inverter, wait 5 minutes...
  • Page 47 Check if the SCI Communication is ID54 SciCommLose problem has been resolved. faulty If not, contact ZCS Technical Support. ID55 RecoverRelayFail Relay fault. Check the insulation resistance between the Insulation resistance is photovoltaic string and the ground. If there is...
  • Page 48 The battery voltage is low too low. In this case, the HYD-ES inverter will not discharge the battery to ensure a longer battery life. The software version is Contact ZCS Technical Support to update the ID94 unsuitable software. EEPROM ID95-ID96 are internal faults of the HYS-ES...
  • Page 49 Short-circuit discharge ID101 BatSCD protection If the fault occurs frequently, contact ZCS Technical Support. Battery overvoltage ID102 BatOV protection Battery undervoltage ID103 BatUV protection Battery overtemperature ID104 BatOTD Make sure that the battery is in a well- protection while ventilated place.
  • Page 50 9. Warranty Zucchetti Centro Sistemi SpA provides a 10-year product warranty, subject to registration on the website https://www.zcsazzurro.com/it/estensione-garanzia. In any case, the warranty cannot exceed 126 months from the date of delivery of the inverter. During the warranty period, Zucchetti Centro Sistemi S.p.A. guarantees normal operation of the inverter. If the inverter is defective or faulty during the warranty period, contact your installer or supplier.

This manual is also suitable for:

Hyd 4000-esHyd 5000-esHyd 6000-es

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