Sofar 60KTLX-G3 Installation And Operating Manual
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Sofar 60KTLX-G3 Installation And Operating Manual

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SOFAR 60 ... 80KTLX-G3
Installation and
operating manual
Version 01 | March 2023
English
SOFAR 60KTLX-G3, 80KTLX-G3
1
SOFAR 60... 80KTLX-G3

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  • Page 1 SOFAR 60 … 80KTLX-G3 Installation and operating manual Version 01 | March 2023 English SOFAR 60KTLX-G3, 80KTLX-G3 SOFAR 60... 80KTLX-G3...

  • Page 2: Table Of Contents

    Target group Symbols used Basic safety information Safety information Symbols and signs Product features Product dimensions Power grid types Product dimensions Labelling on the device Functional features Efficiency curve Installation Installation information Installation procedure Examination before installation Connections SOFAR 60... 80KTLX-G3...
  • Page 3 Connecting the AC power cables Communication ports Energy meter connection System monitoring Commissioning the inverter Safety test before commissioning Starting the inverter Smartphone app SOFAR View Operation of the device Control panel and display field Standard display Status display Menu structure SOFAR 60... 80KTLX-G3...
  • Page 4 TABLE OF CONTENT Software update Troubleshooting handling Troubleshooting Maintenance Technical data SOFAR 60... 80KTLX-G3...

  • Page 5: About This Manual

    The current version was updated on 11/07/2023. Structure of the manual This manual contains important safety and installation instructions that must be observed during installation and maintenance of the device. SOFAR 60... 80KTLX-G3...

  • Page 6: Scope

    Scope This product manual describes the installation, electrical connection, commissioning, maintenance, and fault elimination procedures of the SOFAR 60... 80KTLX-G3 inverters. Target group This manual is intended for specialist electrical engineers who are responsible for the installation and commissioning of the inverter in the PV system, as well as the PV system operators.
  • Page 7 Follow the warnings in order to prevent injury! ATTENTION Non-observance may result in property damage! • Follow the warnings in order to prevent damage to or destruction of the product. NOTE • Provides tips essential to the optimal operation of the product. SOFAR 60... 80KTLX-G3...

  • Page 8: Basic Safety Information

    Before installing the device or carrying out maintenance on it, you must open the DC switch in order to interrupt the DC voltage of the PV generator. You can also switch off the DC voltage by opening the DC SOFAR 60... 80KTLX-G3...
  • Page 9 Choose a suitable place for the installation of electrical devices. Ensure that there is sufficient space for an emergency exit which is suitable for maintenance. Ensure sufficient ventilation in order to guarantee an air circulation for the cooling of the inverter. SOFAR 60... 80KTLX-G3...
  • Page 10 The labels must NOT be concealed by items and foreign objects (rags, boxes, devices, etc.); they must be regularly cleaned and kept clearly visible at all times. 2.1.5 Electrical connection Observe all applicable electrical regulations when working with the Solar inverter. SOFAR 60... 80KTLX-G3...
  • Page 11 Obtain authorisation from the local power grid operator before connecting the inverter to the public power grid. NOTE Voiding of guarantee • Do not open the inverter or remove any of the labels. Otherwise, SOFARSOLAR shall assume no guarantee. SOFAR 60... 80KTLX-G3...
  • Page 12 DC switch. • After switching off the AC circuit breaker and the DC switch, wait a minimum of 5 minutes before starting any maintenance or repair work. SOFAR 60... 80KTLX-G3...

  • Page 13: Symbols And Signs

    The PV generator must be earthed in accordance with the requirements of the local power grid operator! • For reasons of personal safety, we recommend that all PV module frames and inverters of the PV system are reliably earthed. WARNING SOFAR 60... 80KTLX-G3...
  • Page 14 Caution! Danger through electric shock Caution! Hot surface The product is compliant with EU guidelines Earthing point Please read the manual before installing the inverter SOFAR 60... 80KTLX-G3...
  • Page 15 The inverter must always be transported and stored with the arrows pointing upward The temperature range in which the inverter can operate RCM (Regulatory Compliance Mark) The product meets the requirements of the applicable Australian standards. SOFAR 60... 80KTLX-G3...

  • Page 16: Product Features

    This chapter describes the product features, dimensions and efficiency levels. Product dimensions The SOFAR 60... 80KTLX-G3 is a grid-coupled PV inverter with up to two MPPTs which converts the direct current generated by PV systems into a three-phase alternating current and feeds it into the public power grid.

  • Page 17: Power Grid Types

    PRODUCT FEATURES Power grid types SOFAR 60 ... 80KTLX-G3 are compatible with the following grid types: NOTE • For the TT grid, voltage between N and PE should be less than 30 V. Product dimensions All SOFAR 60 ... 80KTLX-G3 have the following dimensions: L ×...
  • Page 18 PRODUCT FEATURES front, side, back bottom view wall bracket SOFAR 60... 80KTLX-G3...

  • Page 19: Labelling On The Device

    An error code will appear on the display if the inverter is in an abnormal operating state. At the same time, the control board may trigger the relay in order to protect the internal components. SOFAR 60... 80KTLX-G3...
  • Page 20 Data transfer The inverter (or a group of inverters) can be monitored remotely via the RS485 communication bus or via WiFi/GPRS. Software update The device supports local updates via USB stick and remote updates via WiFi/GPRS. SOFAR 60... 80KTLX-G3...

  • Page 21: Efficiency Curve

    PRODUCT FEATURES 3.5.2 Electrical block diagram Efficiency curve Power efficiency curve (SOFAR 80KTLX-G3) SOFAR 60... 80KTLX-G3...

  • Page 22: Installation

    Choose a suitable installation location and -surface. • Commission a minimum of two persons with the installation of the inverter. • Do not set down the inverter upside-down. Installation procedure Mechanical installation is performed as follows: Examine the inverter before installation SOFAR 60... 80KTLX-G3...

  • Page 23: Examination Before Installation

    24 hours before installing the inverter. 4.3.2 Checking the delivery scope After unpacking the inverter, check that the delivery items are both intact and complete. In the event of any damage or missing components, contact the wholesaler. SOFAR 60... 80KTLX-G3...
  • Page 24 INSTALLATION Image Description Quantity Inverter SOFAR 60 ... 80KTLX-G3 Wall bracket AC waterproof cover M8*80 Hexagon screws PV+ metal pin PV- metal pin PV+ input terminal PV- input terminal M4 cross screw (for waterproof cover) M6*30 hexagon screw (for locking rear panel)

  • Page 25: Connections

    INSTALLATION COM terminal WiFi stick logger Manual Warranty card Product Certification Warranty registration form *) second Pcs. for SOFAR 40…50KTLX-G3 + SOFAR 50KTLX-G3-HV Tools Prepare the tools required for the installation and the electrical connection. No. Tool Model Function Hammer drill...
  • Page 26 Used to crimp power cables Multimeter Used to check the earthing Marker Used for marking Measuring tape Used to measure distances Spirit level Used to align the wall bracket ESD gloves for the installer Safety goggles for the installer SOFAR 60... 80KTLX-G3...

  • Page 27: Installation Location

    Anti-dust for the installer respiratory mask Socket wrench Used install expansion bolts Hammer Used install expansion bolts Installation location Choose a suitable position for the installation of the inverter. Ensure that the following requirements have been fulfilled: SOFAR 60... 80KTLX-G3...
  • Page 28 INSTALLATION Minimum distances for individual SOFAR 60 ... 80KTLX-G3 inverters: Minimum distances for several SOFAR 60 ... 80KTLX-G3 inverters: SOFAR 60... 80KTLX-G3...

  • Page 29: Unpacking The Inverter

    INSTALLATION Unpacking the inverter Open the packaging and have at least two people grip underneath the inverter at both sides. Lift the inverter out of the packaging and move it to its installation position horizontally. SOFAR 60... 80KTLX-G3...

  • Page 30: Installation Of The Inverter

    Installation of the inverter Hold the wall bracket in the desired place and mark the three holes. Put the wall bracket aside and drill the holes. SOFAR 60... 80KTLX-G3...
  • Page 31 INSTALLATION Fasten the rear panel to the wall using the M8*80 screws. Place the inverter in the wall bracket. Secure the inverter to the wall bracket using the Error! Reference source not found.. SOFAR 60... 80KTLX-G3...

  • Page 32: Electrical Connections

    ELECTRICAL CONNECTIONS Electrical connections Safety instructions This topic describes the electrical connections of the inverter SOFAR 60 ... 80KTLX-G3. Read this section thoroughly and carefully before connecting the cables. DANGER Electrical voltage at the DC connections • Ensure that the DC switch is OFF before establishing the electrical connection.

  • Page 33: Electrical Connection

    The connected PV modules must be compliant with IEC 61730 class A. Max. Max. AC output Model Panel ISC current SOFAR 60KTLX-G3 100 A 6*60 A SOFAR 80KTLX-G3 133.3 A Electrical connection The electrical connection is established as follows:...

  • Page 34: Connecting The Pe Cables

    As the inverter is transformerless, the plus and minus poles of the PV generator must NOT be earthed. Otherwise, the inverter will malfunction. In the PV system, not all live metal parts (e.g. PV module frames, PV frame, generator connection box housing, inverter housing) require earthing. SOFAR 60... 80KTLX-G3...
  • Page 35 Note: L2 is 2 to 3 mm longer than L1 Crimp the cable to the ring terminal. Recommended OT terminal: OT-M6. Tighten the crimped ring terminal with the M6 screw by using a torque wrench of 5 to 7 Nm: SOFAR 60... 80KTLX-G3...

  • Page 36: Connecting The Dc Cables

    • Cu cable cross section: 2.5 ... 6 mm • Cable outside diameter: 6 ... 9 mm Insert the positive and negative DC cables into the corresponding cable glands. ① Positive DC cable ② Negative DC cable SOFAR 60... 80KTLX-G3...
  • Page 37 Insert the crimped DC cables into the corresponding connector housing until you hear a “clicking” sound. ③ Positive ④ Negative Verify the voltage level of the DC input with a multimeter and ensure that the polarity is correct. SOFAR 60... 80KTLX-G3...

  • Page 38: Connecting The Ac Power Cables

    Connecting the AC power cables Connect the inverter to the AC power distributor or the power grid using AC power cables. SOFAR 60... 80KTLX-G3...
  • Page 39 The AC disconnecting device must be easily accessible. NOTE • The inverter SOFAR 60... 80KTLX-G3 has a built-in AFI (univ. sensitive residual current protection). If an external AFI is required, we recommend an AFI type A or B RCD featuring a residual current of 100 mA or higher.
  • Page 40 You need to use five core outdoor cables, the recommended AC cable and residual current device (RCD) can be used as below table: If a RCD is required under local regulations, SOFAR recommends a type A or B RCD with sensitivity of 100 mA or higher.
  • Page 41 The AC output terminal is equipped with a high-current 5-core terminal block and a customized waterproof cover (IP65). Please follow below steps to connect the AC cable. SOFAR 60... 80KTLX-G3...
  • Page 42 Select the suitable cable according to the table above. Remove the insulating layer of the AC output cable using a wire stripper and in accordance with the following illustration, and then guide the cables through the cable gland. SOFAR 60... 80KTLX-G3...
  • Page 43 (6 ... 10 Nm) and M6 screws (5 ... 7 Nm). Then tighten the AC cover screws (2 ... 3 Nm); NOTE • When an aluminum cable is used, a copper/aluminum conversion terminal is required. This is supplied together with the copper terminals. SOFAR 60... 80KTLX-G3...

  • Page 44: Communication Ports

    ELECTRICAL CONNECTIONS Communication ports The SOFAR 60 ... 80KTLX-G3 inverters come with one of the following two COM ports and one USB port. COM port type I COM port type II 5.7.1 USB port The USB port can be used to update the inverter's software version, or for connecting a WiFi-stick or Ethernet cable.
  • Page 45 ELECTRICAL CONNECTIONS 5.7.2 COM port Please follow below steps to install the COM cable according to the correct COM port : SOFAR 60... 80KTLX-G3...
  • Page 46 RS485 Signal + RS485 B2 RS485 Signal - Grounding GND.S Signal GND Logic interface for power DRM0 Remote shutdown control remote DRM1/5 Digital input 1 shutdown DRM2/6 Digital input 2 DRM3/7 Digital input 3 DRM4/8 Digital input 4 SOFAR 60... 80KTLX-G3...
  • Page 47 The inverter recognises all supported Demand Response commands and initiates the reaction within two seconds. The inverter remains in the reduced power mode as long as the input is closed. Supported DRM commands are pre-configured: DRM0, DRM5, DRM6, DRM7, DRM8: SOFAR 60... 80KTLX-G3...
  • Page 48 Definition Note Digital Input Grounding GND.S Signal GND DRMs/Logic DRM0 Remote shutdown Interface DRM1/5 0% power feed-in DI 5 DRM2/6 50% power feed-in DI 6 DRM3/7 75% power feed-in DI 7 DRM4/8 100% power feed-in DI 8 SOFAR 60... 80KTLX-G3...
  • Page 49 The inverter remains in the reduced power mode as long as the input is closed. Grid Protection Relais PIN: 9 10 11 12 PIN: 9 10 11 12 GND K0 GND 0 GND 0 kΩ K1 K2 K3 K4 Ripple Control Receiver SOFAR 60... 80KTLX-G3...
  • Page 50 Grounding GND.S Signal GND DRMs/Logic Interface DRM0 Remote shutdown DRM1/5 0% power NOTE • The Logic interface has to be activated in the LCD screen of the inverter, or with SOFAR View App: DRM0 active: Remote Shutdown SOFAR 60... 80KTLX-G3...

  • Page 51: Energy Meter Connection

    To use the feed-in limitation function, an external SmartMeter has to be connected to measure the power flow at the PCC: SOFAR Part Product Type Smart Meter (3-phase, 901.00000048-1 Chint DTSU666 1,5(6)A CT's) Smart Meter (3-phase 901.00000058-0 Chint DTSU666 5(80)A inline) SOFAR 60... 80KTLX-G3...
  • Page 52 When the Hard Feed-in Control is activated, the inverter shuts down whenever the setpoint is exceeded CTR Total Power Limit the power of the feeding-in phases to the setpoint. Ignore the phases where energy is bought from the grid (standard-setting) SOFAR 60... 80KTLX-G3...

  • Page 53: System Monitoring

    CTR Selling Power Limit the feed-in power of each phase to 1/3 of the setpoint System monitoring The SOFAR 60 ... 80KTLX-G3 inverters provide various communication methods for the system monitoring: RS485 or WiFi stick (standard), GPRS or Ethernet stick (optional). 5.9.1...
  • Page 54 When you have installed the stick logger, the inverters can directly upload your operating, energy and alarm data in the SolarMAN monitoring portal. NOTE • The Stick Loggers are using the outgoing TCP port 10000, which could be blocked in some internet routers SOFAR 60... 80KTLX-G3...
  • Page 55 Preparation: The WiFi stick is installed in accordance with the previous section and the SOFAR inverter must be in operation. Carry out the following steps in order to configure the WiFi stick: Connect your PC or smartphone with the WiFi network of the WiFi stick.
  • Page 56 Go to the newly created system in order to configure the stick logger (device/logger) Press the button on the WiFi stick for 1 second to activate the WPS mode of the stick so that the smartphone can be connected to the WiFi stick. SOFAR 60... 80KTLX-G3...
  • Page 57 Off: No connection to router Communication Flashing (1 sec.): Communication with with inverter inverter On: Logger connected to inverter Off: No connection to inverter READY Logger status Flashing (1 sec.): Normal status Flashing (0.1 sec.): Reset running Off: Error status SOFAR 60... 80KTLX-G3...
  • Page 58 The Ethernet stick is delivered with DHCP as standard, so it automatically gets an IP address from the router. If you wish to set up a fixed IP address, connect a PC to the Ethernet stick and open the configuration page via the web address 10.10.100.254. SOFAR 60... 80KTLX-G3...

  • Page 59: Commissioning The Inverter

    PV inverters. • Ensure that you have selected the correct country code according to regional authority requirements, and consult a qualified electrician or employees of electrical safety authorities. SOFAR 60... 80KTLX-G3...

  • Page 60: Smartphone App Sofar View

    The inverter continuously checks the set limits and, if required, disconnects the device from the grid. Smartphone app SOFAR View The app is available for Android and iOS systems and allows for easy initial setup as well as advanced configurations.

  • Page 61: Operation Of The Device

    OPERATION OF THE DEVICE Operation of the device This chapter describes the LCD and LED displays of the SOFAR 60 ... 80KTLX-G3 inverter. Control panel and display field 7.1.1 Buttons and display lights Buttons Button Name Description Short press: Select previous menu item...

  • Page 62: Standard Display

    “Error” or “Continuous” state. Normal The inverter goes into the “Normal” state, and feeds current into the grid Fault The inverter goes into the “Fault” state if an error fault occurs. normally reset automatically by the inverter. SOFAR 60... 80KTLX-G3...

  • Page 63: Menu Structure

    Deletes the total energy yield of the inverter 3. Clear events Deletes historical events recorded in the inverter 4. Country Code Sets the country and standard applicable to the current application conditions and requirements. Before setting this, ensure that SOFAR 60... 80KTLX-G3...
  • Page 64 13. PCC select Select either PCC Meter (default) or PCC ARPC. 14. Feed-in limit mode Select from below: (please refer to 5.8) Feed-in Control / Hard Feed-in Control CTR Total Power (default) CTR Phase Power CTR Selling Power SOFAR 60... 80KTLX-G3...
  • Page 65 The most recent events are listed at the top. 2. Event list 1. Current event 2. Event “History Fault information 001 ID04 06150825 (display of the event sequence number, event ID number and time that the event takes place) SOFAR 60... 80KTLX-G3...

  • Page 66: Software Update

    Insert the USB stick into the computer. SOFARSOLAR will send the firmware update to the user. Unzip the file and copy the original file to a USB stick. Attention: The firmware update file must be in the “firmware” subfolder! SOFAR 60... 80KTLX-G3...
  • Page 67 LCD screen goes out 11. Re-establish a watertight communication connection 12. Switch the DC and AC circuit breaker back on 13. You can check the current software version in item “3. Software version” of the SystemInfo menu. SOFAR 60... 80KTLX-G3...

  • Page 68: Troubleshooting Handling

    Please proceed as follows to display the recorded problems: Hold the button down to bring up the main menu of the standard interface. Select “2. Event list” and hold the button down to bring up the event list. Earth fault alarm SOFAR 60... 80KTLX-G3...
  • Page 69 AC circuit breaker and the AC cables of the inverter. If the alarm occurs repeatedly, contact technical support department in order to adjust the voltage and frequency limits after you have obtained the approval of the local power grid operator. SOFAR 60... 80KTLX-G3...
  • Page 70 If the error occurs frequently and lasts for a prolonged period, check whether the insulation resistance between the PV generator and earth (ground) is too low and examine the PV cable insulation. SOFAR 60... 80KTLX-G3...
  • Page 71 If not, GFCIDeviceF GFCI measurement error please contact the technical support ault department. MChip_Fault Master chip error HwAuxPower Auxiliary voltage error Fault BusVoltZeroF Bus voltage measurement ault error IacRmsUnbal The output current is not ance balanced SOFAR 60... 80KTLX-G3...
  • Page 72 If not, please contact the technical support department. SwBOCPInst The input current is too Check whether the input current is high higher than maximum permissible input current of the inverter, then check the input cables. If both are correct, please SOFAR 60... 80KTLX-G3...
  • Page 73 GFCI between the master department. DSP and the slave DSP is not consistent SpiCommLos The SPI communication between the master DSP and the slave DSP is faulty SciCommLos The SCI communication between the control board and communications board is faulty SOFAR 60... 80KTLX-G3...
  • Page 74 If not, UnrecoverBu The bus voltage is too high please contact the technical support sOVP caused department. unrectifiable error UnrecoverIac grid current RmsUnbalan unsymmetrical caused unrectifiable error UnrecoverIpv input current Unbalance unsymmetrical caused unrectifiable error SOFAR 60... 80KTLX-G3...
  • Page 75 Check whether the ambient temperature installation location exceeds the upper limit value. If so, improve the ventilation in order to reduce the temperature. SOFAR 60... 80KTLX-G3...
  • Page 76 Softwareversi The the control board and Contact technical support onisnotconsis communications board department in order to upgrade the tent software is not consistent software. SOFAR 60... 80KTLX-G3...

  • Page 77: Maintenance

    Check the heat sink for blockages (dust, snow etc.) and remove them if present. Please clean the heat sink using an air blower and a dry, soft cloth or a soft bristle brush. Do NOT clean the heat sink with water, corrosive chemicals, cleaning agents etc. SOFAR 60... 80KTLX-G3...
  • Page 78 Please follow below steps for maintenance: Check the connections to ensure all electric connections are turned off. Unscrew the six screws at the four corners of the fan housing: SOFAR 60... 80KTLX-G3...
  • Page 79 Use a soft brush to clean the fan. In case of damage, ensure to replace it in time. Reinstall the inverter according to the above steps. SOFAR 60... 80KTLX-G3...

  • Page 80: Technical Data

    50 Hz / 60 Hz Grid frequency range 45 – 55 Hz / 55 – 65 Hz (according to local standard) Active power adjustable range 0 – 100% THDi < 3% Power factor 1 default (adjustable +/-0.8) SOFAR 60... 80KTLX-G3...

  • Page 81: Sofar 60

    -30℃ – 60℃ Self-consumption at night (W) <2 Topology Transformerless Degree of protection IP66 Allowable relative humidity range 0 – 100% Max. operating altitude 4000 m Noise < 60 dB Weight (kg) Cooling Smart Fan Cooling Dimension (mm) 687*561*275 SOFAR 60... 80KTLX-G3...
  • Page 82 EN 61000-6-1, EN 61000-6-2, EN 61000-6-3, EN 61000-6-4 IEC 62109-1/2, IEC 62116, IEC 61727, IEC 61683, IEC Safety standards 60068(1,2,14,30), IEC 60255 VDE V 0124-100, V 0126-1-1, VDE-AR-N 4105, CEI 0-21/CEI 0-16, Grid standards UNE 206 007-1, EN 50549, G98/G99, EN 50530 SOFAR 60... 80KTLX-G3...
  • Page 83 TECHNICAL DATA SOFAR 60... 80KTLX-G3...
  • Page 84 Shenzhen SOFARSOLAR Co., Ltd. 11/F, Gaoxinqi Technology Building, District 67, XingDong Community, XinAn Street, Bao’An District, Shenzhen, China SOFARSOLAR GmbH Krämerstrasse 20 72764 Reutlingen Germany Email: service.uk@sofarsolar.com Web: www.sofarsolar.com SOFAR 60... 80KTLX-G3...

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