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Aurora PVI-3600-OUTD-UK-F-W Installation And Operator's Manual

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AURORA
Inverters
INSTALLATION AND OPERATOR'S
MANUAL
Model number: PVI-3600-OUTD-UK-F-W
Rev. 1.0

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Summary of Contents for Aurora PVI-3600-OUTD-UK-F-W

  • Page 1  AURORA Inverters INSTALLATION AND OPERATOR’S MANUAL Model number: PVI-3600-OUTD-UK-F-W Rev. 1.0...

  • Page 2: Save These Instructions

    Installation and Operator’s Manual Page 2 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) REVISION TABLE Document Author Date Change Description Revision T. Melzl 5/1/2006 First release of the document T.Melzl 5/3/2006 Updated Anti-Inlanding reference SAVE THESE INSTRUCTIONS ! IMPORTANT SAFETY INSTRUCTIONS MAGNETEK: Reproduction and disclosure, even partially, of the contents of this manual are strictly forbidden without prior authorization of Magnetek.
  • Page 3 Installation and Operator’s Manual Page 3 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) IMPORTANT SAFETY INSTRUCTIONS This manual contains important safety and operational instructions that must be accurately understood and followed during the installation and maintenance of the equipment. To reduce the risk of electrical shock hazards, and to make sure the equipment is safely installed and commissioned, special safety symbols are used in this manual to highlight potential safety risks and important safety information.
  • Page 4 Safety Brake the wind turbine to prevent any possibility of high voltages appearing at the connecting cable terminations. The AC disconnecting means must be opened before working on the Aurora Wind inverters. GENERAL During inverter operation, some parts can be powered, some not properly insulated and, in some cases, some parts can move or rotate, or some surfaces can be hot.
  • Page 5 Installation and Operator’s Manual Page 5 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) In particular, during transport and handling, parts shall not be bent and/or the insulation distances shall not be changed. There should be no contact between electronic parts and connection terminals. Electrical parts must not be mechanically damaged or destroyed (potential health risk).
  • Page 6 Installation and Operator’s Manual Page 6 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) PVI-3600-OUTD-UK-F-W This document applies to the above-mentioned inverters, only. Fig. 1 - Product label information example The identification plate present on the inverter includes the following data: 1) Manufacturer Part Number 2) Model Number 3) Serial Number 4) Production Week/Year...

  • Page 7: Table Of Contents

    (PVI-3600-OUTD-UK-F-W Rev.: 1.0) CONTENTS: 1 FOREWORD 1.1 WIND ENERGY 2 SYSTEM DESCRIPTION 2.1 Main Elements of a Wind System: 2.2 Data Transmission and Check 2.3 AURORA Technical Description 2.4 Protective Devices 2.4.1 Anti-Islanding 2.4.2 Ground Fault 2.4.3 Further Protective Devices 2.5 System Design:...
  • Page 8 Installation and Operator’s Manual Page 8 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) 8.2 Output Values 8.3 Grid protection characteristics 8.4 General characteristics 8.5 Power Derating...

  • Page 9: Foreword

    SYSTEM DESCRIPTION AURORA inverter changes the wind energy into AC power which is fed to the electrical power distribution grid. AURORA does this conversion, also known as Dc to Ac inversion, in a very efficient way, without using rotating parts but just static power electronic devices.

  • Page 10: Main Elements Of A Wind System

    The diversion load is not a safety brake. The Aurora Wind inverter changes the rectified output of Wind Interface box into useable AC which is supplied to the grid at pre- determined nominal voltage and frequency. The Aurora Wind inverter is supplied with the Wind turbine manufacturer’s model...
  • Page 11 Installation and Operator’s Manual Page 11 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) The Aurora Wind Inverter is designed to accept only a single wind input. The current of this input is limited to 20 Amperes. Safety Wind Interface Brake Disconnect Diversion Load...

  • Page 12: Data Transmission And Check

    AURORA Technical Description Figure 4 shows a block diagram of AURORA. The main blocks are the input Dc- Dc converters (called boosters) and the output inverter. Both the Dc-Dc converters and the output inverter work at high switching frequency to minimize size and weight.
  • Page 13 Dc-Dc converters. The two Dc-Dc converters are controlled in parallel by the Wind maximum power point tracker control. Thanks to its high efficiency and large heat-sink, AURORA offers max. power operation over a wide ambient temperature range.

  • Page 14: Protective Devices

    AURORA in case a ground fault is detected and indicates the ground fault condition by means of a red LED on the front panel. AURORA is equipped with a (chassis) ground screw clamp, which shall be used for connection of the plant Protective Earth conductor (equipment grounding conductor).

  • Page 15: System Design

    This will allow the inverter to deliver the maximum output power for ambient temperatures up +40 ° C . The AURORA is designed for safe and reliable operation. This is made possible by the use of redundant control circuits.

  • Page 16: Package Inspection

    Save the AURORA original packaging, as it will have to be used in case the equipment has to be shipped out for repairs, or the responsible inspector...

  • Page 17: Package Check List

    Installation and Operator’s Manual Page 17 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) Package Check List Description Quantity (No.) Wind Inverter Bag with 4 screws, 4 blocks and 1 Tap wrench Torx TX20 One mounting reference drawing One copy of this manual One certificate of warranty CD-Rom with communication software...

  • Page 18: Choosing Installation Location

    Page 18 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) Choosing Installation Location The location for the installation of AURORA should be selected in accordance to the following recommendations: AURORA should be placed at a suitable height from ground to allow easy reading of the front display and the status LEDs.

  • Page 19: Wall Mounting

    Use the drawing to locate the holes on the wall. A set of standard expansion stainless steel screws is included in the package for use in mounting the AURORA to a masonry wall. In case of different materials make sure to select the proper mounting hardware.
  • Page 20 Install the expansion screws in the wall so that the head of the screws is about 4mm from the wall surface. Then hang AURORA on the wall by fitting the screw heads in the mounting slots as shown in Fig.7, and secure the screws.
  • Page 21 + 40 °C an output power de-rating may occur on the top units. RECOMMENDED ASSEMBLING Fig.8 Recommended multi Aurora mounting It is recommended that the unit be placed out of direct sunlight. WARNING: During operation, inverter surface can reach very high temperatures.

  • Page 22: Preliminaries To Electrical Connections

    WARNING: The electrical connections can be done only after AURORA is firmly mounted to the wall. WARNING: The connection of AURORA to the electrical distribution grid must be performed only by skilled operators and after having received authorization from the utility that operates the grid.
  • Page 23 Installation and Operator’s Manual Page 23 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) AURORA to the grid. Recommended ratings for the Ac over-current protection device is maximum 20A, 240V. Grid Diversion Load Disconnect Load Center Wind Wind Turbine Interface Safety Brake Switch...
  • Page 24 Minimum Ac wire size, 12AWG, 16 Amps. Maximum MPPT input wire and AC wire size is 10 AWG strand wire The AURORA must be installed using watertight wiring methods. This requires the use of UL listed watertight components and locknuts with the applicable wiring method.
  • Page 25 WARNING: Use listed watertight conduit connectors to maintain the enclosure rating of the AURORA inverter. To access the wiring terminal strip inside of the AURORA inverter remove the side panel as shown in Fig.12. Removing the panel allows you to access the screw terminal blocks and the conduit access holes.
  • Page 26 WARNING: When making the electrical connections follow this exact procedure to avoid exposure to dangerous voltages. Each step of the procedure is explained in the following paragraphs. To disconnect AURORA always open the breaker (AC and DC) prior to do any further operation.
  • Page 27 National Electric Code ANSI/FNPA 70 for proper equipment ground conductor sizing. The Protective Earth cable must be connected to the AURORA chassis ground connection as shown in Fig.14 using the screw provided. Tighten the screw to a torque of 0.6 Nm (5.3 in-lbs).
  • Page 28 Installation and Operator’s Manual Page 28 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) Step 5/7: Connect AURORA to the Ac disconnect switch or circuit breaker WARNING: Use proper, low impedance cables to connect AURORA to the Ac disconnect or circuit breaker, and between the disconnecting means to the grid.
  • Page 29 Wind MPPT connection: Follow this procedure for connecting the Wind Interface to the Aurora Wind Inverter. 1) Install the suitable wire method between AURORA Wind inverter and Wind Interface Box.
  • Page 30 Installation and Operator’s Manual Page 30 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) 2) Install suitable watertight connectors to the AURORA enclosure 3) Terminate the wires labeled + and – in the same input section terminal blocks of AURORA Input 1. 4) Connect the cable + to the terminal block labeled + 5) Connect the cable –...

  • Page 31: Start-Up

    50 V control power threshold the inverter will connect to the grid. 6) Then the AURORA will export to the grid and the green Power LED will be continuously lit (provided there is enough wind input power to feed power to the grid).

  • Page 32: Monitoring And Data Transmission

    The AURORA inverter usually works automatically and is maintenance-free. When the wind speed is not high enough to provide power for export to the grid AURORA disconnects automatically, and enters the stand-by mode, waiting to start working again. The operational cycle is automatically restored as soon as the wind speed is high enough.
  • Page 33 Installation and Operator’s Manual Page 33 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) Fig. 15 Data Transmission Options...

  • Page 34: Available Data

    Installation and Operator’s Manual Page 34 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) Available Data AURORA provides two sets of data that are accessed using AURORA interface software. 5.2.1 Real time data The real time operating data can be transmitted on request over the communication lines and is not recorded internally by the AURORA inverter.

  • Page 35: Led Indicators

    All data are available for transmission via the RS-485 link or PLM. In addition, the first two data of the list are displayed on the LCD. The AURORA Communicator software shall be used in order to download the internally stored data.
  • Page 36 485 communication. GFI (Red): NOTE: All inverter statuses signaled by the corresponding LED coming on or blinking, are also identified on AURORA LCD by a message relating to the operation being carried out or to the defect/fault found (see following sub-sections).
  • Page 37 What to do after an insulation defect has been found Whenever the red LED comes on, press the special multifunction push-button next to the LCD side to reset it. If this fault can be reset, the AURORA will continue working. If the fault cannot be...

  • Page 38: Messages And Error Codes

    Usually, when an error signal appears, an action is needed. This action will be managed as much as possible by AURORA or, in case this is not possible, AURORA will supply all the necessary information to assist the person...
  • Page 39 Installation and Operator’s Manual Page 39 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) Error Description Warning Message Type Type Wind Low W001 Input Voltage under threshold Input OC E001 Input overcurrent Wind Low W002 Wind Energy low Input OV E002 Input Overvoltage Internal Error E003 SW error...

  • Page 40: Lcd Display

    Data are shown cyclically, the screens change every 5 seconds. On the right of the display there is a button that when pressed freezes the screen. Pushing the button again unfreezes the screen. When AURORA is turned on the display shows the following screen for about 10 seconds: Initializing..
  • Page 41 ### Hz Fgrid ### Hz In range Out of range! After AURORA is connected to the grid the display starts showing cyclically the following information screens, each for 5 seconds: First screen: Type and Part Number Type #### Part N° ####...
  • Page 42 Installation and Operator’s Manual Page 42 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) Fourth screen: Output power and Voltage Input ## W ## V Fifth screen: Total energy exported to the grid and total operating time (that is time during which the unit was active). Both data are measured since the unit was first operated.
  • Page 43 Installation and Operator’s Manual Page 43 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) Sixth screen: Time during which the unit exported energy to the grid, and number of times that unit connected to the grid. Timegrid hh:mm:ss Numgrid ## Seventh screen: Daily energy and mode of operation of the inverter E-Today ## Wh ModeInverter OK In case the inverter is not working properly the Fault or Ground Fault LEDs will...
  • Page 44 Installation and Operator’s Manual Page 44 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) This screen shows the code of the error found, for further information refer to chapter 5.4. ERROR ############## These screens show the serial number and the firmware release number Model #### ####...
  • Page 45 Installation and Operator’s Manual Page 45 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) The sequence of the screens is summarized in the following figure: Grid fail Initializing... Please Wait Vgrid Fgrid Out of range Out of range Vgrid Fgrid In range In range Next Connection Regular cycle Regular cycle...
  • Page 46 E-Today Total energy exported to the grid today h-Total Total time since the unit was first operated Type Type of AURORA Serial Number Part N° Part Number Firmware Firmware release number Time during which the unit exported energy...

  • Page 47: Data Check And Communication

    The single AURORA has a default address is two (2) and the S1 dip switch is in the OFF position (pushed away from the side access panel). The RS-485 address does not have to be configured for the single AURORA inverter.
  • Page 48 Equivalent devices may also be used for the same purpose, but they have not been tested therefore Magnetek cannot grant the right functionalities. Please also note that ordinary commercial adapters may need additional impedance termination. Aurora PVI-RS232485 adapter DOES NOT. The following diagram shows how to connect multiple units on the same RS-485 bus.

  • Page 49: Power Line Modem (Plm)

    (PVI-3600-OUTD-UK-F-W Rev.: 1.0) Power Line Modem (PLM) A PLM modem card is an available option card for the Aurora. To collect the data transmitted over the PLM link two options are available: • Use the AURORA Easy Control data logger, model number PVI-AEC (*Check on availability in 2007).
  • Page 50 NOTE: the maximum number of inverters that can be connected via PLM is 63.NOTE It is not possible to have more than one receiving device such as AURORA Easy Control data logger or AURORA PLM/RS232 interface box connected to the same power line. Fig.20: Data transmission to AURORA Easy Control...

  • Page 51: Display Menù

    Use the following procedure to set the new address: 1) Press the key on the side of the LCD display button for at least 5 seconds. 2) AURORA disconnects from the grid, the yellow LED begins to blink and the display shows:...

  • Page 52: Automatic Setting

    Installation and Operator’s Manual Page 52 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) … AUTO 4) Confirm the choice by pressing once more the key for at least 5 seconds. NOTE When using RS-485 link there can be no more than 31 inverters connected on the same link.
  • Page 53 Installation and Operator’s Manual Page 53 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) 2) Verify that the inverter is set in mode Parallel: - SET IN MODE PARALLEL A short touch of the key allows to scroll the two options. In order to confirm the selection, press for longer than 5 sec. the same key. Press it for a shorter time to come back to the previous display.

  • Page 54: Measurement Accuracy

    Installation and Operator’s Manual Page 54 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) 6) Press the key for longer than 5 sec. to confirm the chosen BAUD RATE shown on the display. Press it for a shorter time to come back to the previous display. NOTE: Generally the standard speed to be chosen is 19200 Baud.
  • Page 55 Installation and Operator’s Manual Page 55 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) Resolution Data Accuracy Display Measurement 600mV Vin1 600mV Vin2 15mA Iin1 0.1A 15mA Iin2 0.1A E-Total E-Today h-Total TimeGrid...

  • Page 56: Troubleshooting

    Page 56 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) TROUBLESHOOTING AURORA inverters comply with standards set for grid-tied operation, safety and electromagnetic compatibility. Before being delivered by Magnetek, the product has been successfully subjected to several tests to check: operation, protective devices, performance and durability.
  • Page 57 Installation and Operator’s Manual Page 57 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) Before contacting the service center, keep the following information handy: INFO AURORA NOTE Information to be found directly on LCD AURORA model? Serial number? Week of production? LED flashing?

  • Page 58: Technical Features

    Installation and Operator’s Manual Page 58 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) TECHNICAL FEATURES Input Values WARNING: The Wind turbine maximum output voltage must be less than 600Vdc in under any condition. NOTE: The inverter has a linear power derating related to the input voltage, starting from 530 Vdc (100% output power) to 580 Vdc (0% output power)
  • Page 59 Single Wind MPPT , Power Curve is specific to MPPT configuration the Wind Turbine model As stated above, AURORA Wind performs MPPT on the programmed Wind turbine power curve and constantly researches the max. input Dc power point. This process is called MPPT (Maximum Power Point Tracking).

  • Page 60: Output Values

    Installation and Operator’s Manual Page 60 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) Output Values Value Description PVI-3600-OUTD-UK-F-W Nominal output power 3600 W Grid voltage, nominal operating values 230Vac Grid voltage, operating ranges 207 to 264Vac Grid frequency, maximum range 47 to 63 Hz Grid frequency, nominal 50 Hz Grid frequency, operating range...

  • Page 61: General Characteristics

    Installation and Operator’s Manual Page 61 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) General characteristics Value Description PVI-3600-OUTD-UK-F-W Maximum efficiency Internal consumption during stand-by < 8 W Internal consumption during night time < 0,30 W Operating ambient temperature -25°C to +60°C (-13°F to 140°F) Enclosure type Nema 4X Relative Humidity...

  • Page 62: Power Derating

    AURORA supplies the max output power for ambient temperatures ≤ 40°C, provided it is not exposed to sun radiation or other direct heat sources which may affect the internal thermal behavior.
  • Page 63 Installation and Operator’s Manual Page 63 of 63 (PVI-3600-OUTD-UK-F-W Rev.: 1.0) The above cases, originating a power derating, can also occur at the same time, but the power derating will always correspond to the lowest value read.

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