ZCS 4000TLM LITE User Manual
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ZCS 4000TLM LITE User Manual

Grid-connected inverter;
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Grid-connected inverter
3K – 6K TLM LITE
User Manual
V2.1 (07-06-2019)
Zucchetti Centro Sistemi S.p.A. - Green Innovation Division
Via Lungarno, 248 - 52028 Terranuova Bracciolini - Arezzo, Italy
tel. +39 055 91971 - fax. +39 055 9197515
innovation@zcscompany.com - zcs@pec.it – www.zcsazzurro.com
Reg. Pile IT12110P00002965 - Capitale Sociale € 100.000,00 I.V.
Reg. Impr. AR n.03225010481 - REA AR - 94189
Azienda Certificata ISO 9001 - Certificato n. 9151 - CNS0 - IT-17778

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  • Page 1 Via Lungarno, 248 - 52028 Terranuova Bracciolini - Arezzo, Italy tel. +39 055 91971 - fax. +39 055 9197515 innovation@zcscompany.com - zcs@pec.it – www.zcsazzurro.com Reg. Pile IT12110P00002965 - Capitale Sociale € 100.000,00 I.V. Reg. Impr. AR n.03225010481 - REA AR - 94189...

  • Page 2: Table Of Contents

    3.1. Installation process………………………………………………………………………...……………………………………………14 3.2. Checks before installation……………………………………………………………………………………………………………14 3.3. Installation tools…………………………………………………………………………….……………………………………………16 3.4. Installation position………………………………………………………………………….….………………………………………18 3.5. Moving the ZCS 3-6 K TLM L inverter……………………………………………………….……………………………………19 3.6. Installing the ZCS 3-6 K TLM L inverter.……….………………………………………………………..………………………20 4. Electrical connections.……………..…………………………………………………………………..……………………….…………….21 4.1. Electrical connections.……………..…………………………………………………………………..……………………….………22 4.2. PNGD cable connections.……………..…………………………………………………………………..……………………….…..22 4.3.
  • Page 3 7.2. Maintenance..…………………………………………………………………………………………...…………………………………62 8. Uninstalling…………………………………………………………………………………….……………...………………………………….62 8.1. Steps for uninstalling the inverter…………………………………………………………………………………………………62 8.2. Packaging…………………………………………………………………………………………………………………………………….62 8.3. Storage…..………………………………………………………………………………………………………………….………………...62 8.4. Disposal…….………………………………………………………………………..……………………………………….………………62 9. Technical specifications.……………………………………………………………………………………………………………………..63 10. Warranty……………..………………………………………………………………………………………………………………..……………65 3 / 64 Manual of 07/06/2019 Rev. 2.1 “User Manual for 3K-6KTLM LITE 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 at http://www.zcsazzurro.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 following inverters: 3000TLM LITE / 3680TLM LITE / 4000TLM LITE / 4600TLM LITE / 5000TLM LITE / 6000TLM LITE Keep this manual so that it is accessible at all times.

  • Page 6: Preliminary Safety Instructions

    1. Preliminary safety instructions If you have problems or questions regarding the reading and understanding of the following information, please contact Zucchetti Centro Sistemi S.p.A. through the appropriate channels. Note General information in this chapter Safety instructions It mainly highlights the safety instructions to be followed during installation and use of the equipment. Symbols and icons Introduces the main safety symbols on the inverter.
  • Page 7 Attention Do not remove the information label or open the inverter. Otherwise, ZCS will not provide any warranty or maintenance. Note 7 / 64 Manual of 07/06/2019 Rev. 2.1 “User Manual for 3K-6KTLM LITE Identificazione: MD-AL-GI-00 Rev.
  • Page 8 Operation Contact with the electrical grid or the terminal of the equipment may cause electrocution or fire! Do not touch the terminal or the conductor connected to the electrical • grid. Follow all the instructions and safety requirements relating to the mains •...

  • Page 9: Symbols And Icons

    1.2. Symbols and icons Safety signals Pay attention to possible burns due to hot parts. Only touch the screen or press the keys while the inverter is in operation. Caution The PV strings should be connected to the ground in accordance with the local regulations.

  • Page 10: Product Features

    Read this manual before installing the inverter. Indication of the allowable temperature range Degree of protection of the equipment according to the IEC 70-1 standard (EN 60529 June 1997). Positive pole and negative pole of the input voltage (DC). 2. Product features General information in this chapter Product presentation The field of use and overall dimensions of the 3K-6K TLM-L inverters are indicated in this section.
  • Page 11 The 3K-6K TLM inverters can only be used with photovoltaic modules that do not require one of the poles to be grounded. The operating current and voltage during normal operation must not exceed the limits indicated in the technical specifications. Only photovoltaic modules can be connected to the input of the inverter (do not connect batteries or other power supply sources).

  • Page 12: Description Of Functions

     Labels on the inverter Figure 4 – Do not remove the label on the side of the inverter 2.2. Description of functions The DC power generated by the PV modules is filtered through the input board before entering the power board.
  • Page 13 Figure 5 – Block diagram of the 3K-6K TLM-L inverter 2.3. Efficiency curve Efficiency curve for a Azzurro ZCS 5000 TLM-L model Figure 6 – Efficiency curve for an Azzurro ZCS 5000 TLM-L inverter 13 / 64 Manual of 07/06/2019 Rev. 2.1 “User Manual for 3K-6KTLM LITE Identificazione: MD-AL-GI-00 Rev.

  • Page 14: Installation

    3. Installation General information in this chapter This chapter describes how to install the 3K-6K TLM-L inverter. Installation notes:  DO NOT install 3K-6K TLM-L inverters near flammable materials.  DO NOT install 3K-6K TLM-L inverters in an area where flammable or explosive materials are stored.
  • Page 15 Carefully check the contents of the packaging before installation, making sure that no element inside the packaging is missing or damaged. The package will contain the following components: 1 Photovoltaic inverter 1 mounting bracket 2 + input terminals 2 - input terminals 2 Metal terminals for + 2 Metal terminals for - DC DC power cables...

  • Page 16: Installation Tools

    3.3. Installation tools The following tools are required for installation of the inverter and electrical connections; therefore, they must be prepared before installation. Tool Function Drill To drill holes in the wall for Recommended drill bit: 6 mm fixing the bracket To screw and unscrew screws for Screwdriver the various connections...
  • Page 17 To remove the outer sheath of Wire stripping tool the cables Cable cutter To cut the power cables Crimping tool To crimp the power cables To check the voltage and current Multi-meter values To mark the wall for better fixing Marking pen precision Measuring tape...

  • Page 18: Installation Position

    3.4. Installation position Choose an appropriate installation location for the inverter. Follow the requirements below to determine the installation position. Figure 8 – Requirements for installing a single inverter 18 / 64 Manual of 07/06/2019 Rev. 2.1 “User Manual for 3K-6KTLM LITE Identificazione: MD-AL-GI-00 Rev.

  • Page 19: Moving The Zcs 3-6 K Tlm L Inverter

    Figure 9 – Requirements for installing multiple inverters For safety reasons, ZCS Spa and/or its partners may not carry out any technical repairs or maintenance work, or move the inverter from and to the ground if it is installed at a height of more than 180 cm from the ground.

  • Page 20: Installing The Zcs 3-6 K Tlm L Inverter

    Figure 11 – Removing the inverter from its packaging 2) Lift the inverter from its packing box and move it to the installation position, then remove the polystyrene protections.  To prevent damage and personal injury, hold the inverter firmly when moving, as it is a heavy piece of equipment.

  • Page 21: Electrical Connections

    Figure 12 - Steps for installing the inverter on the wall 4. Electrical connections General information in this chapter This chapter describes the electrical connections of the 3K-6K TLM-L inverter. Carefully read this section before connecting the cables. NOTE: Before making any electrical connections, ensure that the DC circuit breaker is switched off. Please note that the capacitors in the inverter may remain electrically charged after the DC circuit breaker has been switched off.
  • Page 22 The maximum open-circuit voltage of the photovoltaic string must be less than 600 V. The 3K-6K TLM-L series has two Maximum Power Point Trackers (MPPT); all the photovoltaic modules connected to it must be of the same model so as to have the same rated electrical characteristics (Isc, Voc, Im, Vm, Pm and temperature coefficients) and be positioned in the same orientation (solar azimuth and inclination angle).

  • Page 23: Connecting The Dc Input Power Cables

    Note 1: L3 is the length between the insulation layer of the ground cable and the crimped part. L4 is the distance between the crimped part and the conductor wires protruding from the crimped part. Note 2: The cavity formed after the conductor has been crimped must completely wrap the conductor wires.
  • Page 24 Note Depending on the type of inverter, select the appropriate inverter accessories (cables, fuse holder, fuse, switch, 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 25 Cross-section of the cable (mm Outer diameter of cable (mm) Recommended value Range 4. 5 - 7. 8 4.0-6.0 Table 1 – Recommended specifications for DC input cables The DC input connectors (MC4) are classified into positive and negative connectors, as shown in the figures below.
  • Page 26 Figure 19 – Connecting the DC input power cables (1) L2 is approximately 2 or 3 mm longer than L1. Note: 3) Insert the positive and negative power cables in the corresponding cable glands. 4) Insert the stripped positive and negative power cables into the positive and negative metal terminals respectively, and crimp them using a suitable tool.

  • Page 27: Connecting Ac Output Power Cables

    Figure 21 – Connecting the DC input power cables (3) Insert the caps into the unused DC connectors. Note: Removal procedure To remove the positive and negative connectors from the inverter, insert a removal tool into the bayonet coupling and press the tool with adequate force, as shown in the figure below. Before removing the positive and negative connectors, make sure that the inverter’s circuit breaker is switched off.
  • Page 28 Context The AC power cables used for the inverter must be three-pole outdoor cables. For easier installation, use flexible cables. The table lists the recommended specifications for cables and circuit breakers. 3000TLM- 3600TLM- 4000TLM- 4600TLM- 5000TLM- 6000TLM Type Cable >4 >4 >4 >6...
  • Page 29 Figure 25 – Relationship between power loss, length and cable cross-section The 3K-6K TLM-L inverters are single-phase output inverters that fully comply with the local grid connection requirements and safety standards. The inverters are equipped with AC output connectors with IP66 protection suitable for photovoltaic use; customers must provide their own AC output cable connections;...
  • Page 30 Figure 27 – Connecting the AC output cables (1) 2) Disassemble the AC connector as shown in the figure below; insert the AC output cable (with its stripped insulation layers as shown in step 1) through the PG waterproof cable gland. Figure 28 –...

  • Page 31: Connecting The Communication Cables

    Figure 30 – Connecting the AC output cables (4) 4.5. Connecting the communication cables Connecting the communication port Note: The wiring procedure is the same for the RS485 input, DRMS0 and CT input. This chapter describes the steps to be followed for connecting the communication cables. Communication port RS485 DRM0...
  • Page 32 Figure 32 – Removing the cable glands and stoppers Note: The waterproof connectors refer respectively to (from left to right): RS485, CT, RS485. Remove the waterproof connectors according to the communication functions to be used. DO NOT remove the unused connectors.
  • Page 33 Type RS485 DRM0 Connector Label DRM0 Table 4 – Description of the communication terminals and their function Figure 34 – Tightening the terminals on the cables 5) Insert the terminal according to the printed label, then tighten the screws to secure the waterproof cover;...
  • Page 34 The 3-6K TL inverters are equipped with RS485 (standard) and Wi-Fi (optional) communication systems. These communication systems allow monitoring the main parameters of the inverter (energy generated, alarms, operating status) through various channels, such as the ZCS AZZURRO portal, ZCS AZZURRO app or your own monitoring system.
  • Page 35 For a single inverter, it is possible to connect the Wi-Fi adapter (sold separately) to a device capable of receiving wireless signals, such as routers, Wi-Fi modems and network extenders. This allows the inverter data to be sent to the ZCS server and the inverter to be monitored remotely. Figure 39 – Connecting an inverter with Wi-Fi For a group of inverters, it is possible to connect the different wi-fi cards to a single terminal (router, Wi-Fi modem and network extenders).
  • Page 36 For more information and instructions on how to configure the communication system, refer to the relevant technical notes available at www.azzurrozcs.com or contact the ZCS service centre. 36 / 64 Manual of 07/06/2019 Rev. 2.1 “User Manual for 3K-6KTLM LITE Identificazione: MD-AL-GI-00 Rev.

  • Page 37: Commissioning The Inverter

    5. Commissioning the inverter 5.1. Safety inspection before commissioning Make sure that the DC and AC voltages are within the range permitted by the inverter. Attention  Photovoltaic strings Before turning on the inverter, the photovoltaic string must be examined. Check the open-circuit voltage of each photovoltaic panel and compare it with the data in the technical datasheet.

  • Page 38: Operating Interface

    Operating interface General information in this chapter This section describes the display and its operation, as well as the buttons and LED indicators of the 3K-6K TLM-L inverters. 6.1. Operating panel and display Buttons and LED indicators Figure 43 – LCD display with buttons and LED indicators Main buttons: ...

  • Page 39: Main Interface

    6.2. Main interface The main LCD interface is used to display the statuses of the inverter, information, configuration of parameters, etc. When the power is turned on, INITIALIZATION…. appears on the LCD screen, as shown in the figure below 39 / 64 Manual of 07/06/2019 Rev.
  • Page 40 when the control board is correctly connected to the communication board, the LCD screen will display the current status of the inverter, as shown in the figure below. Inverter states include: Wait: inverter is waiting to Check the state at the end of the reconnection time. In this state, the PV voltage must be higher than 250 V, the grid voltage value must be between the minimum and maximum permissible limits, as should the other grid parameters;...

  • Page 41: Main Menu

    6.3. Main menu Press the “Menu/Back” button in the main interface screen to enter the main menu, which will appear as follows: Press the “OK” key to enter the “Settings” menu. The “Settings” menu contains the following sub-menu:  Date and time Select “1.
  • Page 42 the energy produced daily and in total, which is shown in the main interface. Press “OK” to start the procedure; the display will show “Enter PWD!”, press “OK” to enter the password. Enter the password “0001” using the “Up” and “Down” keys to select the number and “OK” to move to the next one, and confirm. If the display shows “Incorrect, try again,”...
  • Page 43  Enable country Select 7 “Enable country” and press “OK” to enter the menu for enabling the selection of the country code. The display will show “Enter PWD!”, press “OK” to enter the password. Enter the password “0001” using the “Up”...
  • Page 44  Initial parameters The user can change the start parameters directly from the LCD display. The user must first copy the TXT files to the SD card. These files can be requested from Zucchetti Centro Sistemi Spa technical support. Select 12 “InitParameters” and press “OK” to enter the menu for setting the start parameters. The display will show “Enter PWD!”, press “OK”...
  • Page 45 “Down” keys to select the number and “OK” to move to the next one, and confirm. If the display shows “Incorrect, try again!” press the “Back” key and enter the password again. When the password has been entered correctly, you can enter the menu. The new insulation resistance will now be loaded on the inverter automatically.
  • Page 46 Fast self-test  1) During normal operation of the inverter, press the “Back” key to enter the main menu. 2) Press the “OK” key to enter the “Settings” menu. 3) Press the “Down” key several times until “20. Fast Self-test” is displayed on the screen. 4) Press “OK”...
  • Page 47  Standard Self-test 1) During normal operation of the inverter, press the “Back” key to enter the main menu. 2) Press the “OK” key to enter the “Settings” menu. 3) Press the “Down” key several times until “21. Standard Self-Test” is displayed on the screen. 47 / 64 Manual of 07/06/2019 Rev.
  • Page 48 4) Press “OK” to start the self-test. 5) The self-test will now start automatically; once completed, press “Down” to display the self-test results, as shown in the figure. 48 / 64 Manual of 07/06/2019 Rev. 2.1 “User Manual for 3K-6KTLM LITE Identificazione: MD-AL-GI-00 Rev.
  • Page 49  P(f) Setting Select “22. Set P(f)” and press “OK” to enter the relative menu, from which you can change the active power according to the grid frequency required by the local regulations. This function may be required by various regulations for grid-connected inverters.
  • Page 50 ZCS S.p.A. accepts no responsibility deriving from the activation of one of the settings described above.
  • Page 51  Inverter type Use the “Up” and “Down” keys in the “System Info” menu to move, and the “OK” key to enter the “1. Inverter type” menu. Here you can see the power of the inverter model  Serial number Use the “Up”...
  • Page 52 Press the “OK” key to enter the “Date and Time” menu. Press the “Back” key in the main interface and the “Up” or “Down” keys to enter the submenu “4. Date and Time”, then press “OK” to display the current date and time set on the inverter. Press the “OK”...
  • Page 53 Firmware update procedure 1. Switch off the ZCS inverter by first disconnecting the AC power supply via the switch installed on the system, and then disconnecting the DC power supply via the switch located on the side of the inverter (if equipped) or switch off the system’s disconnecting switch. Wait for the display to turn off completely.
  • Page 54 “OK” key (fourth from the left) to enter the SOFTWARE UPDATE item. Enter the password 0715 and press “OK” again to start the update. 9. The update process will take about 3 minutes and will run automatically. The following indications will be followed: a.

  • Page 55: Troubleshooting And Maintenance

    7. Troubleshooting and maintenance 7.1. Troubleshooting This section contains information and procedures on how to troubleshoot any faults and errors that may occur during operation of the 3K-6K TLM-L inverter. If you have any problems with the inverter, please follow these steps. ...
  • Page 56 local grid operator. Check whether too few PV modules have been connected in series per string: therefore, the voltage (Vmp) of the PV string is lower than the minimum operating voltage of the inverter. In this case, adjust the The input voltage is PVUVP number of photovoltaic modules ID05...
  • Page 57 activated. contact Technical Support. The grid current is too high and has caused HwAcOCP the hardware ID15 protection to be activated. The grid current is too AcRmsOCP ID16 high. Sampling error of the HwADFaultIGrid ID17 grid current. HwADFaultDCI DCI sampling error. ID18 ID15-ID24 are internal faults of the Sampling error of the...
  • Page 58 user manual. If it is not correct, change it according to Section 6.3 (A) “10. Configuration of the Input Mode” of this manual. If the input mode is correct, turn off the “DC switch”, wait 5 minutes, and then turn it back on again.
  • Page 59 RelayTestFail Relay fault. ID55 Check the insulation resistance The insulation between the photovoltaic string and PvIsoFault ID56 resistance is too low. the ground, in the event of a short circuit, rectify the fault. The temperature of OverTempFault_Inv the inverter is too ID57 Make sure that the installation high.
  • Page 60 The input current is too high and has UnrecoverIPVInstant ID74 caused an irreparable fault. The EEPROM is ID74-ID77 are internal faults of the UnrecoverWRITEEEPROM ID75 unrecoverable. inverter; turn off the “DC switch”, wait 5 minutes, and then turn it back on again.

  • Page 61: Maintenance

    Check the configuration of the country, as indicated in Section 6.3 The country selected (C) 5 Country of this user manual; if it Invalid country ID97 in not valid. is not correct, change it according to Section 6.3(A) “4 Configuration of country code”...

  • Page 62: Packaging

     Unscrew the fixing bolt of the bracket and remove the inverter from the wall. 8.2. Packaging If possible, pack the inverter in its original packaging. 8.3. Storage Store the inverter in a dry place where the ambient temperature is between -25 and +60°C. 8.4.
  • Page 63 Power factor 1 (adjustable +/-0.8) Grid feed limit Feed adjustable from zero to nominal value Operating performance Maximum efficiency Weighted efficiency (EURO) 97.5% Consumption at night <1W MPPT efficiency >99.9% Protection Safety protection Anti-islanding, RCMU, Ground leakage monitoring Reverse polarity protection Overheating protection DC circuit breaker Optional...

  • Page 64: Warranty

    10. Warranty Zucchetti Centro Sistemi SpA provides a warranty of 10 years from the date of installation on the 3K-6K TLM-L inverter, subject to registration on the website https://www.zcsazzurro.com/it/estensione-garanzia. In any case, the warranty cannot exceed 66 months from the date of delivery of the inverter. During the warranty period, Zucchetti Centro Sistemi S.p.A.

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