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AEC TOUGH Series Installation Manual

Single-phase grid-connected photovoltaic inverter
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Allis Electric Co., Ltd.
Installation Manual
Single-Phase Grid-Connected
Photovoltaic Inverter
TOUGH - Series

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  • Page 1 Allis Electric Co., Ltd. Installation Manual Single-Phase Grid-Connected Photovoltaic Inverter TOUGH - Series...
  • Page 3 All specifications are subject to change without prior notice. Ver. 1.1...
  • Page 4 These applied symbols are important for human safety. Violation of warnings may result in injury to persons or cause death. WARNING！ RISK OF ELECTRIC SHOCK WARNING！ RISK OF ELECTRIC SHOCK, ENERGY STORAGE TIMED DISCHARGE WARNING！ RISK OF DANGER WARNING！ HOT SURFACE REFER TO THIS OPERATIONAL MANUAL THIS MANUAL IS COPYRIGHT PROTECTED.
  • Page 5 Safety Notes General Cautions Read and follow all instructions in this manual. Failure to comply with the warnings in this manual may violate safety standards. The ！ manufacturer assumes no liability for the customer’s failure to comply with these requirements. Installation of the device must be in accordance with the relevant ！...
  • Page 6 Maintenance and Clean Each inverter is well calibrated before shipment and needs no additional maintenance during normal operation. Alterations are not to be made and no tampering with the assembly in the inverter without the manufacturer’s authorization unless ！ specified elsewhere in this manual. They may result in injury, electric shock, or fire and void the warranty.

  • Page 7: Table Of Contents

    Contents 1 INTRODUCTION ................1 1.1 G ..................1 ENERAL 1.2 S ................2 PECIFICATIONS 1.3 F ............7 UNCTIONS AND EATURES 1.4 A .................. 8 CCESSORIES 2 INSTALLATION ................9 2.1 P ................... 9 LACEMENT 2.2 M ................... 10 OUNTING 2.2.1 S .....................
  • Page 8 3.4.1 O ................28 PERATIONAL TATUS 3.4.2 C ................30 HECK RROR ESSAGE 3.4.3 S ..............31 ETTING BEFORE PERATION 3.4.4 I ....................33 NFORMATION 3.5 D ........... 34 ESCRIPTIONS OF RROR ESSAGES 3.6 T ..............38 ROUBLESHOOTING 4 TECHNICAL DOCUMENTATION ..........43 4.1 O ..............
  • Page 9 List of Figures Fig 1: Grid connected solar system overview ..........1 Fig 2: Accessories in the package ..............8 Fig 3: Hanging surface ..................10 Fig 4: Clearances required for installation ..........11 Fig 5: Fasten the mounting bracket ............. 12 Fig 6: Hook the inverter on the mounting bracket .........
  • Page 10 Fig 29: Euro. Efficiency of the TOUGH-5000 = 96.6% ......45 Fig 30: MPP Efficiency of the TOUGH-SERIES .......... 46 Fig 31: DC power curve of the TOUGH-3000 ..........47 Fig 32: DC power curve of the TOUGH-3300 ..........47 Fig 33: DC power curve of the TOUGH-4000 ..........

  • Page 11: Introduction

    Introduction General The grid-connected inverter converts DC power yielded from solar array into AC power for household consumption. Furthermore, the remaining AC power can be transmitted and sold back to the utilities company. The inverter operates intelligently under normal conditions and provides no backup power in case of power cut.

  • Page 12: Specifications

    Specifications Model TOUGH-3000 Output Data (AC) Maximum AC Output Power 3000 VA Maximum AC Output Current 14.5 a.c.A Nominal AC Voltage 230 a.c.V Grid AC Frequency 50 / 60 Hz, auto-selection Power Factor > 0.99 @ 20% load Reactive Power Factor 1 or adjustable from -0.9 to +0.9** Total Harmonic Distortion <...
  • Page 13 General Specification Dimensions (W x H x D) in mm 405 x 442 x 152 Weight 18 Kg Cooling Concept Free Convection Acoustic Noise Level < 35 dB(A) Maximum Operating Temperature -20 to +45 °C (without derating) Ambient Temperature Range -25 to +60 °C Storage / Transportation Condition Relative Humidity...
  • Page 14 Model TOUGH-3300 TOUGH-4000 TOUGH-5000 Output Data (AC) Maximum AC Output Power 3300 VA 4000 VA 5000 VA* Maximum AC Output Current 16.5 a.c.A 20 a.c.A 22 a.c.A* Nominal AC Voltage 230 a.c.V Grid AC Frequency 50 / 60 Hz, auto-selection Power Factor >...
  • Page 15 General Specification Dimensions (W x H x D) in mm 405 x 442 x 165 Weight 25.8 Kg Cooling Concept Free Convection Acoustic Noise Level < 35 dB(A) Maximum Operating Temperature -20 to +55 °C (without derating) Ambient Temperature Range -20 to +60 °C Storage / Transportation Condition Relative Humidity...
  • Page 16 Adjustable voltage, Frequency and Reconnection Settings VDE-AR-N 4105 Setting Range Default 50.05~51.50 51.5 Over-frequency (Hz) (60.05~61.50)* (61.5)* Over-frequency disconnection time (cycle) 1~10 47.50~49.95 47.50 Under-frequency (Hz) (57.50~59.95)* (57.50)* Under-frequency disconnection time (cycle) 1~10 Over-voltage (Vac) 235~264.5 264.5 Over-voltage disconnection time (cycle) 1~10 Under-voltage (Vac) 184~225...

  • Page 17: Functions And Features

    Functions and Features  DSP (Digital Signal Processor) makes use of the advanced digital control technology to enhance the conversion efficiency and the added functions. Conformity to the EMC, Low Voltage Directives and Standards, e.g.  2004/108/EC, 2006/95/EC, IEC/EN 62109-1/-2 and VDE-AR-N 4105. ...

  • Page 18: Accessories

    Accessories Please check the inverter and accessories in the package. If there is some part incomplete or any pages missing from the manual, please contact the authorized agent. Please check the following items in the box: Photovoltaic Inverter x 1 Mounting Bracket x 1 Female Cable Coupler Plus Key x 1 and Minus Key x 1 * For Dual MPPT：Plus Key x 2 and Minus Key x 2...

  • Page 19: Installation

    Installation 2.1 Placement Please take the following points into consideration when installing the inverter and selecting the installation location:  A solid and vertical wall is essential; not to hand it on a forward-tilting surface. The backward-tilting angle must be less than 30°. ...

  • Page 20: Mounting

    Fig 3: Hanging surface Mounting 2.2.1 Safety Notes Don’t remove the external cover of the inverter. No parts inside the inverter are to be maintained by the user. If necessary, only qualified maintenance staff can carry out; The solar panel exposed to sunlight supplies DC power.

  • Page 21: Install Inverter On Wall

    2.2.2 Install Inverter on Wall Select the appropriate space and the solid and vertical surfaces enough to support the inverter. The space surrounding the inverter must be appropriate so that heat can be dissipated easily and maintained conveniently, as shown below. Fig 4: Clearances required for installation...

  • Page 22: Fig 5: Fasten The Mounting Bracket

    The wall bracket is fixed on the wall by these 4～6 screws. The position of the fixing hole can be selected according to the wall condition. The construction can be referred in the following figure. Fig 5: Fasten the mounting bracket The four holes behind the inverter are simultaneously aligned with the four hooks on the bracket.

  • Page 23: Fig 7: Fasten The Screws

    Finally, the screws (see Appendix F in 1.4) are used to lock in the holes on the left and right sides of the support, so that the inverter can be fixed on the wall rack. Fig 7: Fasten the screws...

  • Page 24: Check Installation Status

    2.2.3 Check Installation Status Ensure the backward tilting angle of the installation wall should not exceed 30 , and the inverter can’t be installed on the walls which have forward-tilt. Ensure the inverter is correctly fixed on the hooks at the four corners of hanger.

  • Page 25: Wiring The Inverter

    Wiring the Inverter 2.3.1 Safety Notes Avoid static discharge damaging inverter. The parts inside the inverter could be damaged due to the ！ electric static discharge. Please take the grounding measures prior to touching any internal parts and terminals. 2.3.2 Introduction The inverter comprises DC input (connect to solar panel), AC output (connect to service entrance, utility power) and communication ports (monitor the inverter status).

  • Page 26: Dc Input Wiring

    2.3.3 DC Input Wiring 2.3.3.1 Safety Notes Touching the energized parts or the metal part of the connector may cause electric shock. The solar panel exposed to sunlight supplies hazardous DC voltage. The maximum DC input current of this inverter is 16 A and the DC connector rating is up to 25 A.

  • Page 27: Fig 9: Assemble Your Dc Terminals - Step 1

    2.3.3.2 Connect DC Connector 1. Take the DC connectors from the package, which includes 2 male connectors (positive and negative, see Appendix C in 1.4). 2. Peel the DC wires insulation about 8~10 mm and insert them into the metal terminals to the end. Then use a connector plier to press the terminals.

  • Page 28: Fig 11: Assemble Your Dc Terminals - Step 3

    4. Ensure both the DC disconnect switch and the external AC breaker are in OFF position. 5. Put the connecting fasteners (see Appendix D in 1.4) on the female connectors of the inverter. Pay attention to the installing direction and positions. Fig 11: Assemble your DC terminals - step 3 6.

  • Page 29: Com Line Connection

    2.3.4 COM Line Connection 2.3.4.1 Instruction The product is equipped with RS232 and RS485 interface. RS485 supports communication between multiple inverters in parallel so the two sets of RS485 pins are provided for this function. Please refer to the figure below as to the pins assignment. Fig 13: RS485 pins assignment Item Description...

  • Page 30: Fig 14: Remove The Rs485 Port Housing

    2.3.4.2 Connection Ensure both the DC disconnect switch and the external AC breaker are in OFF position; loosen the screws and remove the housing of COM port. Fig 14: Remove the RS485 port housing Counter-clockwise loosen the waterproof cable gland nut, remove waterproof plugs behind cable gland nut.

  • Page 31: Fig 16: Assemble The Communication Cable

    Loosen the rear nut on the gland and pass the communication cable through one of the rubber holes. Fig 16: Assemble the communication cable Connect each thread to the correct terminal contact (see 2.3.4.1) and lock the COM port housing back to the inverter. Fig 17: Lock the RS485 port housing Check the cable length and tightness.

  • Page 32: Fig 19: Multi-Inverter Wiring By Rs485

    2.3.4.3 Connection in Parallel by RS485 For more than one inverter in a system, RS485 provides this convenient communication functions. The inverter provides two RS485 contacts. Basically one (contact) is of connecting to your monitoring device (e.g. PC); and the other one is for connecting with adjacent inverter.

  • Page 33: Ac Output Wiring

    2.3.5 AC Output Wiring 2.3.5.1 Safety Notes Ensure both the DC disconnect switch and the external AC breaker are in OFF position. The maximum AC output current of this inverter is 14.5 A and the AC connector rating is up to 25 A. The diameter of the power wire shall be 12 AWG (4.0 mm ) at least.

  • Page 34: Fig 21: Check The Phase And Ground Terminals

    Fig 21: Check the phase and ground terminals Align two smooth gaps over the connector when jointing. Push the connector until the latch is positioned. Then, fasten the gland nut to keep the waterproof usage. Fig 22: Fasten the gland nut Insert AC connector to the socket on the inverter.

  • Page 35: Operation

    Operation 3.1 Overview The DC (PV) voltage reaches a certain minimum voltage if sufficient insolation is available, the inverter will enter “grid-feed” mode. If, as nightfall approaches, the voltage drops below the minimum voltage value, grid-feed mode ends and the inverter will shut down itself. Fig 24: Overview front panel of the inverter LCD Display LED Display (Green)

  • Page 36: Led Indication

    3.2 LED Indication The inverter is equipped with three LEDs that give information about the various operating statuses as follows: LED (red): System Fault The inverter was stopped when an unrecoverable failure occurred. (Refer to “error message table”) If the fault notification cannot be cleared, please contact your local service staff.

  • Page 37: Buttons On Panel

    3.3 Buttons on Panel By using the “UP,” “DOWN,” “OK,” and “ESC” buttons, users may be able to view which measured value is to be displayed. “ ”, ▼ ▲ “ ” key: Press “UP” or “DOWN” key to switch the various displays for measured values and data.

  • Page 38: Operational Status

    3.4.1 Operational Status The following paragraphs explain how the display works in each mode. 1. Illumination: Automatically the inverter shuts down in case of the low insolation. 2. Standby: The Inverter sets M o d e : S t a n d b y the initial values and it U g r i d : 2 3 0 .
  • Page 39 6. Sys. Lock: The inverter M o d e : S y s . L o c k stops if an unrecoverable U p v _ A : 5 0 0 . 0 V failure occurs; these some problem might be handled by technical service only.

  • Page 40: Check Error Message

    3.4.2 Check Error Message When error messages display, users could select the "Error message" by press the “Down” or “Up” key from the main menu and then press the "OK" key to confirm. For each page, there are recorded error events as shown in the following figure.

  • Page 41: Setting Before Operation

    3.4.3 Setting before Operation There are some parameters that can be re-configured from the panel. Users may select "Setting" from the main menu and press the "OK" key to enter system setting as shown below. Only the standard selection is password protected.
  • Page 42 S y s t e m S e t t i n g T i m e : 1 8 : 5 0 : 3 5 Press “DOWN / UP” key ↑↓ S y s t e m S e t t i n g S t a r t _ V : 5 0 0 V Press “DOWN / UP”...

  • Page 43: Information

    3.4.4 Information Users may select the "Information" from the main menu and press the "OK" key to enter system information as shown below. The screen will display information of your inverter including firmware and etc.  T/N: The model name of the inverter ...

  • Page 44: Descriptions Of Error Messages

    3.5 Descriptions of Error Messages In the event of a fault, the inverter will stop feeding the AC power to the utility grid and display the error message on the LCD. Qualified service staff shall do the analysis, measurement, and debug, if needed, according to the error message in order to resume normal conditions.
  • Page 45 FastEarthCurrent  The drastic change of the leakage current has exceeded the allowable value. Iac High  The AC current has exceeded the Iac Max. maximum permissible value. Idc-inj. Fault  The DC injection detection circuit failed. Idc-inj. High  The DC current injected into the utility grid side is too high.
  • Page 46 Offset Fault  Internal reference voltage detection circuit failed. PpvA High  The DC power has exceeded the PpvB High maximum permissible value. RCMU Fault  The residual current monitoring unit is abnormal. Relay Open  The output relay failed. Relay Short S1 (S2 or S3 or S4) Relay Fault Riso Low...
  • Page 47 System Error  The system is not working properly. Temp. High (Low)  The temperature inside the inverter exceeds the nominal operational range. Uac High  The AC voltage of utility grid is above the Fast Uac High upper limit. Uac Low ...

  • Page 48: Troubleshooting

    3.6 Troubleshooting The Inverter requires very little maintenance. When the inverter has encountered an event of fault, the error message will be displayed on the LCD and recorded in memory. If you encounter problems with the inverter, refer to the tables in this chapter for probable causes and recommended solutions, and then remove the fault condition(s) to have the inverter return to normal condition and continue to feed AC power to the utility.
  • Page 49 Error Message Possible Causes Disposal Measures Fan is stuck Try to remove any lint ■ ■ Fan malfunctions or dust that may be ■ Fan Lock stuck inside the fan Replace the fan ■ Cables or wires Make sure that the ■...
  • Page 50 Error Message Possible Causes Disposal Measures Calibration parameters Restart the inverter ■ ■ have deviated again if failed to restore MCUs diff.High Circuits inside inverter Inform professional ■ ■ are abnormal service staff to check the calibration parameters Default setting is wrong Inform the service staff ■...
  • Page 51 Error Message Possible Causes Disposal Measures AC output relay is Restart the inverter ■ ■ Relay Open abnormal. again; Inform Relay Short professional staff if you Relay Fault fail to restore Internal communication Restart the inverter ■ ■ is abnormal. again if the fault Circuits inside inverter continues...
  • Page 52 Error Message Possible Causes Disposal Measures Main voltage or Wait until the grid is ■ ■ frequency exceeds the back to stable. Uac High default settings Request the utility ■ Uac Low Main voltage or supplier to improve and ■ Fac High frequency is higher or then inform...

  • Page 53: Technical Documentation

    Technical Documentation Outline Drawing Fig 25: Outline drawing...

  • Page 54: Efficiency

    4.2 Efficiency The efficiency is shown below. Fig 26: Euro. Efficiency of the TOUGH-3000 = 95.83% Fig 27: Euro. Efficiency of the TOUGH-3300 = 96.1%...

  • Page 55: Fig 28: Euro. Efficiency Of The Tough-4000 = 96.5

    Fig 28: Euro. Efficiency of the TOUGH-4000 = 96.5% Fig 29: Euro. Efficiency of the TOUGH-5000 = 96.6%...

  • Page 56: Mpp Efficiency

    4.3 MPP Efficiency The MPP efficiency is shown below. Fig 30: MPP Efficiency of the TOUGH-SERIES...

  • Page 57: D E - Rating Operation

    4.4 De-rating Operation The inverter will limit the input power to ensure that the system safely operates as described in detail below. Fig 31: DC power curve of the TOUGH-3000 Fig 32: DC power curve of the TOUGH-3300...

  • Page 58: Fig 33: Dc Power Curve Of The Tough-4000

    Fig 33: DC power curve of the TOUGH-4000 Fig 344: DC power curve of the TOUGH-5000...

  • Page 59: Fig 35: Temperature De-Rating Curve Of The Tough-3000

    Fig 355: Temperature de-rating curve of the TOUGH-3000 Fig 366: Temperature de-rating curve of the TOUGH-3300...

  • Page 60: Fig 37: Temperature De-Rating Curve Of The Tough-4000

    Fig 377: Temperature de-rating curve of the TOUGH-4000 Fig 38: Temperature de-rating curve of the TOUGH-5000...
  • Page 61 ALLIS ELECTRIC CO., LTD. 12F NO. 19-11 SAN-CHUNG ROAD,NAN KANG DISTRICT TAIPEI, TAIWAN, R.O.C TEL:+886-2-2655-3456 FAX:+886-2-2655-2286...

This manual is also suitable for:

Tough-3000Tough-3300Tough-4000Tough-5000

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