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Voltacon Conversol MAX 11KW User Manual

Solar inverter / charger single phase 230vac
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User Manual
VOLTACON ENERGY SYSTEMS
Conversol MAX 11KW
SOLAR INVERTER / CHARGER
Single Phase 230VAC
Voltacon UK Limited | Burnsall Road | Industrial Estate | Coventry | CV5 6BU | England
Version: 1.0

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  • Page 1 User Manual VOLTACON ENERGY SYSTEMS Conversol MAX 11KW SOLAR INVERTER / CHARGER Single Phase 230VAC Voltacon UK Limited | Burnsall Road | Industrial Estate | Coventry | CV5 6BU | England Version: 1.0...

  • Page 2: Table Of Contents

    Table of Contents ABOUT THIS MANUAL ............................1 Purpose ................................1 Scope ................................1 SAFETY INSTRUCTIONS ........................... 1 INTRODUCTION ..............................2 Features ................................2 Basic System Architecture ..........................2 Product Overview ............................. 3 INSTALLATION ..............................4 Unpacking and Inspection ..........................4 Preparation ..............................

  • Page 3: About This Manual

    ABOUT THIS MANUAL Purpose This manual describes the assembly, installation, operation and troubleshooting of this unit. Please read this manual carefully before installations and operations. Keep this manual for future reference. Scope This manual provides safety and installation guidelines as well as information on tools and wiring. SAFETY INSTRUCTIONS WARNING: This chapter contains important safety and operating instructions.

  • Page 4: Introduction

    INTRODUCTION This is a multi-function inverter, combining functions of inverter, solar charger and battery charger to offer uninterruptible power support in a single package. The comprehensive LCD display offers user-configurable and easy-accessible button operations such as battery charging current, AC or solar charging priority, and acceptable input voltage based on different applications.

  • Page 5: Product Overview

    Product Overview Appendix I. NOTE: For parallel installation and operation, please check 1. LCD display 12. Current sharing port 2. Status indicator 13. Parallel communication port 3. Charging indicator 14. Dry contact 4. Fault indicator 15. USB port as USB communication port and USB function 5.

  • Page 6: Installation

    INSTALLATION Unpacking and Inspection Before installation, please inspect the unit. Be sure that nothing inside the package is damaged. You should have received the following items inside of package: Inverter unit Manual software CD RS-232 cable Parallel communication cable Current sharing cable DC Fuse Cable gland x 4 pcs PV connectors x 2 sets...

  • Page 7: Battery Connection

    Install the unit by screwing four screws. It’s recommended to use M4 or M5 screws. Battery Connection CAUTION: For safety operation and regulation compliance, it’s requested to install a separate DC over-current protector or disconnect device between battery and inverter. It may not be requested to have a disconnect device in some applications, however, it’s still requested to have over-current protection installed.

  • Page 8: Ac Input/Output Connection

    WARNING: Shock Hazard Installation must be performed with care due to high battery voltage in series. CAUTION!! Do not place anything between the flat part of the inverter terminal and the ring terminal. Otherwise, overheating may occur. CAUTION!! Do not apply anti-oxidant substance on the terminals before terminals are connected tightly.

  • Page 9: Pv Connection

    5. Then, insert AC output wires according to polarities indicated on terminal block and tighten terminal screws. Be sure to connect PE protective conductor ( ) first. →Ground (yellow-green) L→LINE (brown or black) N→Neutral (blue) 6. Make sure the wires are securely connected. CAUTION: Important Be sure to connect AC wires with correct polarity.
  • Page 10 Step 3: Assemble provided PV connectors with PV modules by the following steps. Components for PV connectors and Tools: Female connector housing Female terminal Male connector housing Male terminal Crimping tool and spanner Prepare the cable and follow the connector assembly process: Strip one cable 8 mm on both end sides and be careful NOT to nick conductors.
  • Page 11 Recommended Panel Configuration When selecting proper PV modules, please be sure to consider the following parameters: 1. Open circuit Voltage (Voc) of PV modules not to exceed maximum PV array open circuit voltage of the inverter. 2. Open circuit Voltage (Voc) of PV modules should be higher than the start-up voltage. 11KW INVERTER MODEL 11000W...

  • Page 12: Final Assembly

    Final Assembly After connecting all wirings, re-connect three cables and then put bottom cover back by screwing five screws as shown below. Remote Display Panel Installation The LCD module can be removable and installed in a remote location with an optional communication cable. Please take the follow steps to implement this remote panel installation.
  • Page 13 Step 2. Prepare your mounting holes in the marked locations as shown in the illustration below. The LCD module then can be securely mounted to your desired location. Ø 5-Ø 9 Note: Wall installation should be implemented with the proper screws to the right. Step 3.

  • Page 14: Communication Connection

    Communication Connection Serial Connection Please use the supplied serial cable to connect between the inverter and your PC. Install the monitoring software from the bundled CD and follow the on-screen instructions to complete your installation. For detailed software operation, refer to the software user manual on the bundled CD. Wi-Fi Connection This unit is equipped with a Wi-Fi transmitter.

  • Page 15: Operation

    OPERATION Power ON/OFF Once the unit has been properly installed and the batteries are connected well, simply press On/Off switch (located on the display panel) to turn on the unit. Inverter Turn-on After this inverter is turned on, WELCOME light show will be started with RGB LED BAR. It will slowly cycle through entire spectrum of nine colors (Green, Sky blue, Royal blue, Violet, Pink, Red, Honey, Yellow, Lime yellow) about 10-15 seconds.

  • Page 16: Lcd Display Icons

    Solid On Fault mode Flashing Warning mode Function Keys Function Key Description Exit the setting USB function setting Select USB OTG functions Timer setting for the Output source Setup the timer for prioritizing the output source priority Timer setting for the Charger source Setup the timer for prioritizing the charger source priority Press these two keys at the time to switch RGB LED bar...
  • Page 17 Indicates battery level by 0-24%, 25-49%, 50-74% and 75-100% in battery mode and charging status in line mode. When battery is charging, it will present battery charging status. Status Battery voltage LCD Display <2V/cell 4 bars will flash in turns. Bottom bar will be on and the other three bars Constant 2 ~ 2.083V/cell...

  • Page 18: Lcd Setting

    LCD Setting General Setting ” After pressing and holding “ button for 3 seconds, the unit will enter the Setup Mode. Press “ ” or “ ” button to select setting programs. Press “ ” button to confirm you selection or “ ”...
  • Page 19 Appliances (default) If selected, acceptable AC input voltage range will be within 90- 280VAC. AC input voltage range If selected, acceptable AC input voltage range will be within 170- 280VAC. AGM (default) Flooded User-Defined If “User-Defined” is selected, battery charge voltage and low DC cut-off voltage can be set up in program 26, 27 and 29.
  • Page 20 party Lithium battery If selected, programs of 02, 26, 27 and 29 will be automatically set up. No need for further setting. Please contact the battery supplier for installation procedure. Restart disable (default) Restart enable Auto restart when overload occurs Restart disable (default) Restart enable Auto restart when over...
  • Page 21 Battery fully charged 54V (default) Setting voltage point back to battery mode when selecting “SBU” (SBU priority) in program 01. Setting range is from 48V to 58V. Increment of each click is 1V. If this inverter/charger is working in Line, Standby or Fault mode, charger source can be programmed as below: Solar first Solar energy will charge battery...
  • Page 22 Stay at latest screen If selected, the display screen will stay at latest screen user finally switches. Backlight on (default) Backlight off Backlight control Alarm on (default) Alarm off Beeps while primary source is interrupted Bypass disable (default) Bypass enable Overload bypass: When enabled, the unit will transfer to line mode if...
  • Page 23 Single: This inverter is used Parallel: This inverter is operated in single phase application. in parallel system. When the inverter is operated in 3-phase application, set up inverter to be operated in specific phase. AC output mode L1 phase: L2 phase: *This setting is only available when the inverter is in standby mode (Switch...
  • Page 24 60min (default) Setting range is from 5min to 900min. Increment of each click is 5min. Battery equalized time 120min (default) Setting range is from 5min to 900 min. Increment of each click is 5 min. Battery equalized timeout 30days (default) Setting range is from 0 to 90 days.
  • Page 25 The setting range is from 30 A to 200 A. Increment of each click is 10A. If discharging current is higher than setting value, battery will stop discharging. At this time, if the utility is available, the inverter will operate in bypass mode.
  • Page 26 Scrolling Breathing RGB LED effects Solid on (Default) C01: (Default) C02: Color combination of RGB Violet-White-Sky blue White-Yellow-Green   LED to show energy source Pink-Honey Royal blue-Lime yellow   and battery charge/discharge status:  Grid-PV-Battery  Battery charge/discharge status Not reset (Default) Reset...
  • Page 27 For minute setting, the range is from 0 to 59. Time setting – Minute For hour setting, the range is from 0 to 23. Time setting – Hour For day setting, the range is from 1 to 31. Time setting– Day For month setting, the range is from 1 to 12.
  • Page 28 Step 3: Please select setting program by following the procedure. Program# Operation Procedure LCD Screen This function is to upgrade inverter firmware. If firmware upgrade is needed, please check with Upgrade your dealer or installer for detail instructions. firmware This function is to over-write all parameter settings (TEXT file) with settings in the On-The-Go USB disk from a previous setup or to duplicate inverter settings.
  • Page 29 Press “ ” button to set up Solar First Timer. Press “ ” button to select staring time. Press “ ” or “ ” button to adjust values and press “ ” to confirm. Press “ ” button to select end time. Press “ ”...

  • Page 30: Lcd Display

    LCD Display The LCD display information will be switched in turn by pressing the “UP” or “DOWN” button. The selectable information is switched as the following table in order. Selectable information LCD display Input Voltage=230V, output voltage=230V Input voltage/Output voltage (Default Display Screen) Input frequency=50Hz Input frequency...
  • Page 31 PV2 current = 2.5A PV1 power = 500W PV power PV2 power = 500W AC and PV charging current=50A PV charging current=50A Charging current AC charging current=50A...
  • Page 32 AC and PV charging power=500W PV charging power=500W Charging power AC charging power=500W Battery voltage=25.5V, output voltage=230V Battery voltage and output voltage Output frequency=50Hz Output frequency Load percent=70% Load percentage...
  • Page 33 When connected load is lower than 1kVA, load in VA will present xxxVA like below chart. Load in VA When load is larger than 1kVA (≧1KVA), load in VA will present x.xkVA like below chart. When load is lower than 1kW, load in W will present xxxW like below chart.
  • Page 34 This PV month energy = 388kWh, Load month energy= 988kWh. PV energy generated this month and Load output energy this month. This PV year energy = 3.88MWh, Load year energy = 9.88MWh. PV energy generated this year and Load output energy this year.

  • Page 35: Operating Mode Description

    Secondary CPU version 00012.03. Secondary CPU version checking. Secondary Wi-Fi version 00000.24. Secondary Wi-Fi version checking. Operating Mode Description Operation mode Description LCD display PV power and Grid is available. Grid is available. Standby mode Note: No charging at all no matter *Standby mode: The inverter if grid or PV power is is not turned on yet but at...
  • Page 36 Operation mode Description LCD display Fault mode Note: No charging. No charging at all no matter *Fault mode: Errors are if grid or PV power is caused by inside circuit error available. or external reasons such as over temperature, output short circuited and so on.
  • Page 37 Operation mode Description LCD display Power from battery and PV energy. PV energy will supply power to the loads and charge battery at the same time. No utility is available. The unit will provide output Battery Mode power from battery and/or PV power.

  • Page 38: Faults Reference Code

    Faults Reference Code Fault Code Fault Event Icon on Fan is locked when inverter is off. Over temperature Battery voltage is too high Battery voltage is too low Output short circuited. Output voltage is too high. Overload time out Bus voltage is too high Bus soft start failed PV over current PV over voltage...

  • Page 39: Warning Indicator

    Warning Indicator Warning Warning Event Audible Alarm Icon flashing Code Beep three times every Fan is locked when inverter is on. second Over temperature None Battery is over-charged Beep once every second Low battery Beep once every second Beep once every 0.5 Overload second Output power derating...

  • Page 40: Battery Equalization

    BATTERY EQUALIZATION Equalization function is added into charge controller. It reverses the buildup of negative chemical effects like stratification, a condition where acid concentration is greater at the bottom of the battery than at the top. Equalization also helps to remove sulfate crystals that might have built up on the plates. If left unchecked, this condition, called sulfation, will reduce the overall capacity of the battery.

  • Page 41: Specifications

    SPECIFICATIONS Table 1 Line Mode Specifications MODEL 11KW Input Voltage Waveform Sinusoidal (utility or generator) Nominal Input Voltage 230Vac 170Vac± 7V (UPS) Low Loss Voltage 90Vac± 7V (Appliances) 180Vac± 7V (UPS); Low Loss Return Voltage 100Vac± 7V (Appliances) High Loss Voltage 280Vac±...
  • Page 42 Table 2 Inverter Mode Specifications MODEL 11KW Rated Output Power 11000W Output Voltage Waveform Pure Sine Wave Output Voltage Regulation 230Vac± 5% Output Frequency 60Hz or 50Hz Peak Efficiency Overload Protection 100ms@≥180% load;5s@≥120% load; 10s@105%~120% load Surge Capacity 2* rated power for 5 seconds Low DC Warning Voltage @ load <...
  • Page 43 Table 3 Charge Mode Specifications Utility Charging Mode MODEL 11KW Charging Current (UPS) 150A @ Nominal Input Voltage Flooded 58.4Vdc Battery Bulk Charging Voltage AGM / Gel 56.4Vdc Battery Floating Charging Voltage 54Vdc Overcharge Protection 63Vdc Charging Algorithm 3-Step Battery Voltage, per cell Charging Current, % 2.43Vdc (2.35Vdc) Voltage...
  • Page 44 Table 4 General Specifications MODEL 11KW Safety Certification Operating Temperature Range -10°C to 50°C Storage temperature -15°C~ 60°C Humidity 5% to 95% Relative Humidity (Non-condensing) Dimension 147.4x 432.5 x 553.6 (D*W*H), mm Net Weight, kg 18.4 Table 5 Parallel Specifications Max parallel numbers Circulation Current under No Load Condition Max 2A...

  • Page 45: Trouble Shooting

    TROUBLE SHOOTING Problem LCD/LED/Buzzer Explanation / Possible cause What to do Unit shuts down LCD/LEDs and buzzer automatically will be active for 3 The battery voltage is too low 1. Re-charge battery. during startup seconds and then (<1.91V/Cell) 2. Replace battery. process.

  • Page 46: Appendix I: Parallel Function

    Appendix I: Parallel function 1. Introduction This inverter can be used in parallel with two different operation modes. 1. Parallel operation in single phase is with up to 6 units. The supported maximum output power is 66KW/66KVA. 2. Maximum six units work together to support three-phase equipment. Maximum four units support one phase.
  • Page 47 Recommended breaker specification of battery for each inverter: Model 1 unit* 11KW 250A/70VDC *If you want to use only one breaker at the battery side for the whole system, the rating of the breaker should be X times current of 1 unit. “X” indicates the number of inverters connected in parallel. Recommended breaker specification of AC input with single phase: 2 units 3 units...
  • Page 48 Three inverters in parallel: Power Connection Communication Connection Four inverters in parallel: Power Connection Communication Connection...
  • Page 49 Five inverters in parallel: Power Connection Communication Connection Six inverters in parallel: Power Connection Communication Connection...
  • Page 50 4-2. Support 3-phase equipment Two inverters in each phase: Power Connection Communication Connection Four inverters in one phase and one inverter for the other two phases: Power Connection Communication Connection...
  • Page 51 Three inverters in one phase, two inverters in second phase and one inverter for the third phase: Power Connection Communication Connection Three inverters in one phase and only one inverter for the remaining two phases: Power Connection Communication Connection...
  • Page 52 Two inverters in two phases and only one inverter for the remaining phase: Power Connection Communication Connection Two inverters in one phase and only one inverter for the remaining phases: Power Connection Communication Connection...
  • Page 53 One inverter in each phase: Power Connection Communication Connection WARNING: Do not connect the current sharing cable between the inverters which are in different phases. Otherwise, it may damage the inverters. 5. PV Connection Please refer to user manual of single unit for PV Connection. CAUTION: Each inverter should connect to PV modules separately.
  • Page 54 6. LCD Setting and Display Setting Program: Program Description Selectable option Single When the unit is operated alone, please select “SIG” in program 28. When the units are used in parallel Parallel for single phase application, please select “PAL” in program 28. Please refer to 5-1 for detailed information.
  • Page 55 Fault code display: Fault Code Fault Event Icon on Power feedback protection Firmware version inconsistent Current sharing fault CAN fault Host loss Synchronization loss Battery voltage detected different AC input voltage and frequency detected different AC output current unbalance AC output mode setting is different Code Reference: Code Description...
  • Page 56 the same time. If not, it will display fault 82 in following-order inverters. However, these inverters will automatically restart. If detecting AC connection, they will work normally. LCD display in Master unit LCD display in Slave unit Step 5: If there is no more fault alarm, the parallel system is completely installed. Step 6: Please switch on all breakers of Line wires in load side.
  • Page 57 8. Trouble shooting Situation Solution Fault Fault Event Code Description Restart the inverter. Check if L/N cables are not connected reversely in all inverters. For parallel system in single phase, make sure the sharing are Current feedback into connected in all inverters. the inverter is For supporting three-phase system, make sure the sharing cables are detected.

  • Page 58: Appendix Ii: Bms Communication Installation

    Appendix II: BMS Communication Installation 1. Introduction If connecting to lithium battery, it is recommended to purchase a custom-made RJ45 communication cable. Please check with your dealer or integrator for details. This custom-made RJ45 communication cable delivers information and signal between lithium battery and the inverter.
  • Page 59 PYLONTECH ①Dip Switch: There are 4 Dip Switches that sets different baud rate and battery group address. If switch position is turned to the “OFF” position, it means “0”. If switch position is turned to the “ON” position, it means “1”.
  • Page 60 Step 2: Use supplied RJ45 cable (from battery module package) to connect inverter and Lithium battery. * For multiple battery connection, please check battery manual for the details. Note for parallel system: 1. Only support common battery installation. 2. Use custom-made RJ45 cable to connect any inverter (no need to connect to a specific inverter) and Lithium battery.
  • Page 61 If communication between the inverter and battery is successful, the battery icon on LCD display will flash. Generally speaking, it will take longer than 1 minute to establish communication. PYLONTECH After configuration, please install LCD panel with inverter and Lithium battery with the following steps. Step 1.
  • Page 62 Step 4. Turn on the inverter. Step 5. Be sure to select battery type as “PYL” in LCD program 5. If communication between the inverter and battery is successful, the battery icon on LCD display will flash. Generally speaking, it will take longer than 1 minute to establish communication. Active Function This function is to activate lithium battery automatically while commissioning.
  • Page 63 5. Code Reference Related information code will be displayed on LCD screen. Please check inverter LCD screen for the operation. Code Description Action If battery status is not allowed to charge and discharge after the communication between the inverter and battery is successful, it will show code 60 to stop charging and discharging battery.

  • Page 64: Appendix Iii: The Wi-Fi Operation Guide In Remote Panel

    Appendix III: The Wi-Fi Operation Guide in Remote Panel 1. Introduction Wi-Fi module can enable wireless communication between off-grid inverters and monitoring platform. Users have complete and remote monitoring and controlling experience for inverters when combining Wi-Fi module with WatchPower APP, available for both iOS and Android based device. All data loggers and parameters are saved in iCloud.
  • Page 65 Then, a “Registration success” window will pop up. Tap “Go now” to continue setting local Wi-Fi network connection. Step 2: Local Wi-Fi Module Configuration Now, you are in “Wi-Fi Config” page. There are detailed setup procedure listed in “How to connect?” section and you may follow it to connect Wi-Fi.
  • Page 66 Step 3: Wi-Fi Network settings icon to select your local Wi-Fi router name (to access the internet) and enter password. Step 4: Tap “Confirm” to complete the Wi-Fi configuration between the Wi-Fi module and the Internet. If the connection fails, please repeat Step 2 and 3. Diagnose Function If the module is not monitoring properly, please tap “...
  • Page 67 2-3. Login and APP Main Function After finishing the registration and local Wi-Fi configuration, enter registered name and password to login. Note: Tick “Remember Me” for your login convenience afterwards. Overview After login is successfully, you can access “Overview” page to have overview of your monitoring devices, including overall operation situation and Energy information for Current power and Today power as below diagram.
  • Page 68 Devices Tap the icon (located on the bottom) to enter Device List page. You can review all devices here by adding or deleting Wi-Fi Module in this page. Add device Delete device icon on the top right corner and manually enter part number to add device. This part number label is pasted on the bottom of remote LCD panel.
  • Page 69 2-4. Device List In Device List page, you can pull down to refresh the device information and then tap any device you want to check up for its real-time status and related information as well as to change parameter settings. Please refer to the parameter setting list.
  • Page 70 【Battery Mode】Inverter will power the load from the batter with or without PV charging. Only PV source can charge battery. Device Alarm and Name Modification In this page, tap the icon on the top right corner to enter the device alarm page. Then, you can review alarm history and detailed information.
  • Page 71 【Rated Information】displays information of Nominal AC voltage, Nominal AC current, Rated battery voltage, Nominal output voltage, Nominal output frequency, Nominal output current, Nominal output apparent power and Nominal output active power. Please slide up to see more rated information. 【History】displays the record of unit information and setting timely. 【Wi-Fi Module Information】displays of Wi-Fi Module PN, status and firmware version.
  • Page 72 voltage discharge. Charger source To configure charger source priority. priority: Max. charging current It’s to set up battery charging parameters. The selectable values in Max. AC different inverter model may vary. charging current: Please see product manual for the details. Float charging voltage It’s to set up battery charging parameters.

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