OPERATING INSTRUCTIONS PROTECT PV.510-KOR Indoor Solar Inverter EN AEG Power Solutions GmbH, Warstein-Belecke Department: PS AED Revision: Revision date: Released: 00 13.04.12 / Schenuit 13.04.12 / Gleitsmann Document no.
Operating instructions Protect PV.500 AEG Power Solutions GmbH, Warstein-Belecke Department: PS AED Revision: 00 Revision date: 13.04.12 / Schenuit Released: 13.04.12 / Gleitsmann Document no.
Protect PV.500 Operating Instructions AEG Power Solutions GmbH Emil-Siepmann-Strasse 32 59581 Warstein Germany Fax: e-mail: Internet: 2 of 73 +49 2902 763 100 +49 2902 763 645 service.aegpss@aegps.com http://www.aegps.
Protect PV.500 Operating Instructions Table of Contents 1 1.1 1.2 1.3 1.3.1 1.3.2 1.4 Information on How to Use these Instructions.............. 6 General Information........................................................... 6 Target Groups ................................................................... 7 Explanations of Target Groups .......................................... 7 Obligations of the Equipment Operator.............................. 7 Skilled Personnel Skills and Trainings .............
Protect PV.500 Operating Instructions 4 of 73 5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.1.6 5.1.7 5.1.8 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.3 5.3.1 5.3.2 Cells 5.3.3 5.3.4 5.3.5 5.4 5.5 5.5.1 5.5.2 5.5.3 5.5.4 5.5.5 5.6 5.6.1 Description of Sequence Control ..................................... 26 The “OFF” Status............................................................. 26 The “Waiting for Feed Conditions” Status ........................ 26 The “Operation” Status ...........................................
Protect PV.500 Operating Instructions 7.1 Communication Interface................................................. 47 7.1.1 General ........................................................................... 47 7.1.2 Technical Data ................................................................ 48 7.1.3 Structure of the MultiCom CCC Interface........................ 49 7.1.4 Configuration ................................................................... 53 7.1.4.1 Configuration Preparations ............
Protect PV.500 Operating Instructions 1 Information on How to Use these Instructions This chapter contains general information about these instructions and the people they are intended for. The Protect PV.500 with two control cabinets (+DCD/ACD, +INV) is referred to as 'equipment' in the rest of the instructions. The precise name (PV.500) cannot be avoided in some situations. In such cases the equipment is referred to as the PV.500 equipment or the individual control cabinets are mentioned. 1.
Protect PV.500 Operating Instructions Handling These instructions are structured so that all work necessary for operation can be performed by appropriately qualified skilled personnel. Illustrations are provided to clarify and facilitate certain steps. If danger to personnel and equipment cannot be ruled out in the case of certain work, it is highlighted accordingly by pictograms explained in Chapter 2, Safety Regulations. 1.
Protect PV.500 Operating Instructions Only operate the equipment in perfect working order and in accordance with good electrical engineering practice Arrange a fault detection check immediately if the equipment starts to behave differently Keep all safety signs and warning notices on the equipment in a complete and clearly legible condition Install fire extinguishers in the immediate vicinity of the equipment 1.3.
Protect PV.500 Operating Instructions Obligations of skilled personnel Observe the following safety instructions. 1. 2. 3. 4. 5. Work on and in electrical equipment is governed by strict rules in order to avoid electrical accidents. The rules are summarised in the five rules of safety. You must observe these rules: Disconnect safely. Secure the unit against being switched back on. Verify that all poles are de-energised. Earth and short-circuit the equipment.
Protect PV.500 Operating Instructions 2 Explanation of Symbols and Safety Instructions All of the symbols and abbreviations used in the text are described below. 2.1 Explanation of Symbols This section describes the symbols used in these instructions. Symbol Meaning Hazard symbols are triangular and feature a yellow background, black border and corresponding symbol. Signs containing orders are round and have a blue background with a white symbol. i Information is indicated by the letter i.
Protect PV.500 Operating Instructions 2.2 Safety Instructions All safety instructions have the following structure: SIGNAL WORD Type and source of hazard Consequence(s) of noncompliance Symbol Measure(s) to avoid hazard. Figure 1 2.2.1 Warning associated with operator action Signal Words Used Signal words at the start of safety instructions indicate the type and severity of the consequences if the measures for avoiding the hazard are not taken.
Protect PV.500 Operating Instructions Risk posed by corrosive vapours and liquids Risk posed by explosive material Table 3 – Hazard symbols 2.2.3 Signs Containing Orders for Personal Protective Equipment The following signs relate to the use of personal protective equipment. You are required to comply with them. Symbol Meaning for skilled personnel Wear a face shield. Wear an electrician's safety helmet. Wear insulating safety boots. Wear insulating overalls.
Protect PV.500 Operating Instructions 2.2.
Protect PV.500 Operating Instructions • All necessary operational measures must be initiated prior to deactivating any safety device in order to perform maintenance, repair or any other work on the unit. Safety awareness also entails informing colleagues of any unsuitable behaviour and reporting any faults detected to the appropriate authority or person.
Protect PV.500 Operating Instructions System stop switch The system stop switch is on the door of the equipment's DC/AC control cabinet. The system stop switch is not intended for switching off the equipment. It may only be used in an emergency. The DOU is used, amongst other things, to switch the equipment on and off. The system stop switch causes the - PV inputs - mains input and - mains 2 input to be separated. This interrupts the energy supply. It does not mean that the unit has been de-energised! 2.
Protect PV.500 Operating Instructions 2.7.2 Lockable Equipment Doors The equipment doors are fitted with a control cabinet lock. This prevents unauthorised personnel from accessing the equipment. The equipment door must be kept closed at all times. It may be opened for maintenance and repair work. i The space requirement for the opened equipment doors must be taken into account The equipment door must be closed again once maintenance and repair work is complete. 2.7.
Protect PV.500 Operating Instructions 2.8.1 Electrical Hazards DANGER Contact with voltage! Risk to life due to electric shock. Use dry insulating material to remove the victim from the live parts. Seek medical assistance and inform the control room. Disconnect the equipment safely. DANGER Electric shock after activating “System stop”! Parts of the equipment remain live after “System stop” has been activated (e.g. external voltage present at remote signal terminals). Risk to life due to electric shock.
Protect PV.500 Operating Instructions i Using residual-current-operated safety devices (FI) alone is not permitted. WARNING Water in electrical equipment! Risk to life due to electric shock. Do not use water to clean the cabinets. Do not place any vessels containing fluids on electrical equipment. 2.8.2 Risks Due to Moving Parts CAUTION Risk of injury due to rotating fans! The fans of the INV control cabinet are freely accessible. Never reach into rotating fans.
Protect PV.500 Operating Instructions 2.8.4 Risks due to Loss of Control ATTENTION Failure of remote signalling. If remote signalling fails or the signal lines are interrupted, the control room can no longer control the equipment. In such an event, faults can only be identified locally at the unit itself. Failure of external emergency switching device Disconnect the equipment safely. ATTENTION Failure of the display and operation unit.
Protect PV.500 Operating Instructions 3 Product Details The equipment has been designed for solar power plants and provides professional solutions for the use of installations covering large roofs or in open spaces. 3.1 Product Description The equipment is a solar inverter (INV) that feeds the electrical energy produced by the PV cells into a medium-voltage mains (e.g. 10 kV; 20 kV; 33 kV). The required mains transformer is not supplied with the unit and can be ordered as an extra if necessary.
Protect PV.500 Operating Instructions 3.2 Dimensions and Views Figure 3 3.3 Dimensions and views Appropriate Use Only operate the equipment with the maximum permissible connection values stated in the technical data sheet. Any other use or modification constitutes inappropriate use. Unauthorised repairs, manipulations or changes made to the equipment and its safety devices without the manufacturer's approval are not permitted.
Protect PV.500 Operating Instructions 3.4 Inappropriate Use No liability is accepted if the equipment is used for applications not intended by the manufacturer (= inappropriate use). Inappropriate use can cause serious or fatal personal injury. The responsibility for any measures necessary for the prevention of personal injury or damage to property is borne by the equipment operator or user. 3.5 Standards, Directives and CE Mark The equipment complies with currently applicable DIN and VDE regulations.
Protect PV.500 Operating Instructions Technology Due to the utilisation of high-performance electronic components, the equipment boasts a very high degree of operational reliability, is extremely efficient and is characterised by its versatility in communicating with other systems by means of interfaces. The entire control electronics system for the equipment is based on the use of microcomputer assemblies.
Protect PV.500 Operating Instructions The main assemblies of the inverter are: • DC load interrupter switch Q4 • Inverter stack, display and control unit with communication components • AC filter • Inverter output contactor K7 • Mains transformer (external) • Mains disconnector Q26 (external) The PV cells supply the inverter stack with DC voltage via DC load interrupter switch Q4. The inverter stack converts this DC voltage into a 3-phase AC voltage.
Protect PV.500 Operating Instructions 4 System Description This chapter describes the operating modes and functions of the equipment. 4.1 Operating Modes Two different operating modes may be used: • Individual operation • Partner operation 4.1.1 Individual Operation In individual operation, the inverter works independently and is not connected to any other inverters. The DC infeed from the PV cells and the link to the AC mains are only connected to this inverter.
Protect PV.500 Operating Instructions 5 System Function 5.1 Description of Sequence Control As soon as the equipment's control module is supplied with voltage, sequence control starts. Initially, load interrupter switch Q4 remains open. Once the initialisation phase is complete and if no deactivating faults are pending, load interrupter switch Q4 is closed. During subsequent operation, the switch is only opened by deactivating faults ( Chapter 6). Inverter output contactor K7 remains open initially.
Protect PV.500 Operating Instructions The set monitoring values are regularly checked. In this status, no power is fed into the mains. Possible change of status: If the DC voltage rises above a certain value for a certain time and the mains voltage and mains frequency are within a certain range, the unit switches to the “Operation” status. A start-up attempt is made, which involves switching on the inverter stack.
Protect PV.500 Operating Instructions If a deactivating or self-acknowledging fault is triggered, the equipment switches to the “Fault” status. The status can be switched from “Operation” to “OFF” using the “Off” control command. 5.1.5 The “Fault” Status If a deactivating or self-acknowledging fault is triggered ( ter 6), the equipment switches to the “Fault” status. The set monitoring values are regularly checked. In this status, no power is fed into the mains.
Protect PV.500 Operating Instructions If the DC voltage continues to increase due to the sun's rays getting stronger and the mains voltage and mains frequency are within acceptable limits, a start-up attempt is made. During a start-up attempt, the inverter stack is switched on, thereby drawing power from the DC voltage that is present. Inverter output contactor K7 is open during a start-up attempt.
Protect PV.500 Operating Instructions 5.1.8 Sequence Control Parameters Switch-on conditions Underfrequency, overfrequency, undervoltage, overvoltage: The equipment will only switch from the “Waiting for feed conditions” status to the “Operation” status if the feed conditions are met. These conditions include the mains voltage and the mains frequency. These values must be within certain limits described by the switch-on conditions.
Protect PV.500 Operating Instructions 5.2 Description of Fan Control 5.2.1 General The equipment features temperature-dependent fan control. The fans are either switched off, run on a fast or slow fan stage (cabinet fan only) or are gradually speeded up or slowed down (stack fan only). Fan control: • Extends the operating time of the fans • Minimises the noise generated by the fans • Improves the efficiency of the equipment by reducing its power consumption 5.2.
Protect PV.500 Operating Instructions 5.2.3 Cabinet Fan Control Parameters Unit exhaust air temperature limit value for switching on the fan: If the highest exhaust air temperature rises above this limit value, the fans which were switched off are switched to the fast fan stage. Unit exhaust air temperature limit value for switching off the fan: If the highest exhaust air temperature falls below this limit value, the fans which were running in the slow fan stage are switched off.
Protect PV.500 Operating Instructions Initialisation Maximum speed, minimum time! Minimum time elapsed IGBT temperature > limit value Variable speed depending on IGBT temperature IGBT temperature < limit value Fan switched off Figure 8 5.2.5 Fan control Parameters of Inverter Stack Fan Control IGBT temperature limit value for switching off the fan: If the highest IGBT temperature falls below this limit value, the fan is switched off.
Protect PV.500 Operating Instructions Sequence control behaviour differs depending on which solar cells are connected. The solar cells do not need to be earthed for operation with monocrystalline or polycrystalline solar cells. In this case, insulation measurement is always active. For operation with thin-film solar cells, the solar cells must be earthed. In this case, insulation measurement is not active during earthing. Insulation measurement sequence control features a “Maintenance mode”.
Protect PV.500 Operating Instructions 5.3.2 Operation With Monocrystalline or Polycrystalline Solar Cells General: This type of solar cell does not require active earthing. Sequence control: Insulation monitoring is always active. Maintenance mode: No action in the event of a “Maintenance mode” command. Starting the insulation test manually: No action, since the insulation test is always active. 5.3.3 Operation with Thin-Film Solar Cells General: This type of solar cell requires active earthing.
Protect PV.500 Operating Instructions The insulation test can only be started manually if an insulation test is not already running at the time. 5.3.4 Insulation Monitoring in Partner Operation In partner operation (see Chapter 5.5), both inverters are fitted with the isometer. Insulation measurement in single operation In single operation, the two inverters behave like two individual units. Insulation measurement is active in both inverters.
Protect PV.500 Operating Instructions 5.4 MPP Tracker In the “Operation” status (see Chapter 5.1.3), the inverter detects the maximum power point (MPP) of the PV cells. The MPP tracker detects the point at which the solar cells give off maximum power. This enables the system to achieve optimum efficiency. Figure 9 5.5 MPP performance curve Partner Operation In “partner operation”, the efficiency of a system with two inverters can be increased by connecting the two PV cells at less than full power.
Protect PV.500 Operating Instructions Figure 10 Linked operation in partner operating mode Change of status to separate operation: If capacity utilisation in the inverter which is switched on rises above a certain value, once a delay has elapsed, the two inverters are switched to separate operation. First, the inverter which is switched on is switched off. Then, the tie switch is opened. Once the tie switch is open, both inverters are switched on.
Protect PV.500 Operating Instructions If the faulty inverter has a self-acknowledging fault, the DC voltages of both inverters are compared. When the DC voltages are approximately identical, the tie switch is closed and the inverter which is not affected by the fault is then switched back on. If the DC voltages are still not the same once a set time has elapsed, the inverter which is not affected by the fault is switched back on.
Protect PV.500 Operating Instructions Later that morning: Insolation increases. As a result, the inverter feeding power into the mains works at increased capacity. If capacity utilisation rises above a certain value, the system switches to single operation. The tie switch opens and the inverter which is switched off logically is switched on. “Single operation” is active. Evening: Levels of insolation fall during the course of the day.
Protect PV.500 Operating Instructions The inverter is designed for a rated output power (sustained power) of 510 kW, see the technical data sheet. However, at low supply air temperatures, the inverter is capable of feeding in a higher power. When the function is activated, the maximum feed-in capacity at low supply air temperatures is increased according to a characteristic curve. If the temperature rises, the maximum feed-in capacity drops.
Protect PV.500 Operating Instructions 6 Monitoring Systems, Messages and Faults 6.1 General All monitoring systems only generate fault messages when the inverter is switched on; when it is switched off, the inverter is always reported as being free of faults. A distinction is made between deactivating, self-acknowledging and signalling faults. Deactivating faults switch the equipment off permanently once they have occurred a number of times. K7 and Q4 are opened.
Protect PV.500 Operating Instructions 6.
Protect PV.500 Operating Instructions CAN I/O monitoring systems Signalling DOU message Feedback signal DC load interrupter switch Q4.1 X Q4.x: !Switch feedback fault! Switch position Q4.1 X Q4.
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Protect PV.500 Operating Instructions 7 Interfaces PV power stations are usually monitored from a central location. Alongside the PV cells, the inverter is a key component of a power station, which is why various communication interfaces are available as standard. These include relay contacts and optocouplers, as well as various serial interfaces with protocols for integration into higher-level monitoring systems.
Protect PV.500 Operating Instructions 7.1.2 Technical Data MultiCom CCC hardware data (assembly A29.1) Connector : RS485 connection: Distance: Bus stations: Data line: Port 1 RS232 for configuration and COM server connection X2: 9-pin D-sub (socket; insulated) Port 2 RS232/RS485 for Modbus X5: 9-pin D-sub (socket; insulated) Twisted pair with Data+, Data-, shielded, shield attached on one side 1200 m max. at 9600 baud Max. 32 Shielded 1:1 data line (2 x 0.22; twisted pair), e.g.
Protect PV.500 Operating Instructions 7.1.3 Structure of the MultiCom CCC Interface RS485: RS232: 1 J1 J4 1 1 X1 J5 1 rt gn X5 LED X3 1 1 X4 B A B A 1 X2 S1 Modbus Figure 13 1 Configuration MultiCom CCC interface as a Modbus interface (top view) Connections: X1: Internal inverter bus and power supply X2: Potential-free RS232 serial interface X3: Triggering of “Remote signalling” X4: A remote panel can be connected to this potential-free CAN interface.
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Protect PV.500 Operating Instructions Figure 15 Serial D-sub connector X5 Port 2 (X5): RS485 pin assignment (default) Pin number Signal Description 3 B High data 8 A Low data Housing INV housing potential Please use a shielded fieldbus cable as the line, e.g. 2 x 0.22 twisted pair Lapp “UNITRONIC-BUS LD”. Please connect the RS485 bus line via the bus interface connector supplied. In an RS485 network, the ends of the bus must always be terminated.
Protect PV.500 Operating Instructions The X5 interface can be switched from RS485 to RS232 using jumpers J4 and J5. The factory setting is RS485, i.e. all jumpers are inserted at J4. You have the option of switching the interface to RS232 by reconnecting all jumpers to J5.
Protect PV.500 Operating Instructions Kabel/Cable 19,5 12 9,5 Figure 17 7.1.4 Shield connection Configuration The communication interface does not have to be configured in order to connect the PV inverter to the data logger system of the AEG “PV.LoG”. Once the bus cable has been installed and the system has been powered up, the configuration settings are made fully automatically.
Protect PV.500 Operating Instructions Figure 18 Main menu If the configuration does not start, you must wait for 10 seconds and then repeat the procedure. Make sure that no data is received via the X2/X5 interfaces during this time. Press the following key in the main menu: to save the set values, exit the configuration and activate the MultiCom interface. to cancel the configuration. <2> to access the X5 data transmission configuration. <4> to access the X5 data protocol configuration.
Protect PV.500 Operating Instructions 7.1.4.2 Configuring the Modbus Protocol To access the X5 data protocol configuration, you must press <4> in the main menu: Figure 19 Data protocol configuration Press one of the following keys in the “X5 Data Protocol” menu: to configure the Modbus protocol to accept the set values. The configuration is finished and the main menu is opened again. to cancel the configuration. This opens the main menu.
Protect PV.500 Operating Instructions 7.1.4.3 Configuring Modbus Data Transmission To access the X5 data transmission configuration, you must press <2> in the main menu: Figure 21 Modbus/JBus data transmission configuration Press one of the following keys in the “X5 Data Transmission” menu: • <1-7> to set the baud rate. • to set the parity. • <8,9> to set the number of stop bits. • to accept the set values. The configuration is finished and the main menu is opened again.
Protect PV.500 Operating Instructions 7.2 COM Server 7.2.1 General The COM server makes the PV inverter data available via an Ethernet network. A software application can communicate with the PV inverter via the network using a virtual COM port (this needs to be installed on a workstation). The COM server is installed as standard and is used by the AEG service department for remote maintenance purposes.
Protect PV.500 Operating Instructions Connections: CN1: Internal inverter bus and power supply MOD1: Ethernet connection CN5: Interface for firmware update Configuration jumpers: CN3: All closed (default) LED signals: Green LED (H1): The green LED on the assembly indicates the global status of the assembly.
Protect PV.500 Operating Instructions 7.2.5 Network Integration Configuration For network integration, you will need a free IP address for the COM server, the subnet mask plus the IP address for the gateway. This information can be obtained from your administrator if necessary. • Start the “Digi Device Discovery” tool. • The tool searches the network for Digi modules. The modules found are displayed. If several units are found, please select the unit to be configured using the MAC address.
Protect PV.500 Operating Instructions 7.3 Remote Signalling The remote signalling board is a contact interface for signalling PV messages and controlling PV units. It is supplied as an option for the AEG PV system and is intended for installation in the PV unit. The remote signalling master board consists of 5 potential-free signalling contacts and one control input. There is an independent 24 VDC power supply for the control input. The control signal is activated by bridging the relevant input.
Protect PV.500 Operating Instructions X7: S1: Connection to MultiCom interface Service switch X3: When a signal is received, the contact between the two contact points with the lower numbers is closed (normally open or “NO”). When a signal is received, the contact between the two contact points with the lowest numbers is open (normally closed or “NC”). The control signal is active when the input is bridged (normally open). The inverter is switched off.
Protect PV.500 Operating Instructions 8 Graphical Display and Operation Unit 8.1 General The graphical Display and Operation Unit (DOU) is integrated into the front of the solar inverter. It serves to signal and visualise unit data and to control the inverter system. The DOU consists of a display unit with 3 LEDs, a graphical LCD and an operating panel with 5 keys. The global unit status can be read from the LEDs (1). An acoustic signal generator stresses the urgency of critical system statuses.
Protect PV.500 Operating Instructions 8.1.1 Signalling LEDs: Red, permanently ON: Deactivating fault (must be acknowledged via the menu) Red, flashing: Self-acknowledging deactivating fault Yellow, flashing: Self-acknowledging message Green OFF: INV in sleep mode Green, flashing (1 Hz): INV waiting for feed conditions Green, flashing (0.
Protect PV.500 Operating Instructions Possible symbol keys and their function: Switch off inverter Switch on inverter Acknowledge acoustic signal generator Cursor up/Increase value/Scroll upwards Cursor down/Decrease value/Scroll downwards Cursor to the right Cursor to the left Status/Measured values menu System is blocked Acknowledge fault Select day/month/year curve Help menu No function Figure 24a 8.2 Keyboard symbols Start-up Following the power-up reset, the DOU performs a self-test.
Protect PV.500 Operating Instructions 8.3 Menu Structure 8.3.
Protect PV.500 Operating Instructions Additional submenus are displayed on the left-hand side. All selectable submenus are displayed in a frame. A black background indicates the current cursor position. The bottom line displays the current real time, which can be adjusted using the “Settings” menu. On the right-hand side, the current key function is represented as a symbol which is displayed in a small framed area. You can move the cursor using the “<” and “>” keys to select the corresponding submenu.
Protect PV.500 Operating Instructions At the top, a sun symbol indicates the current solar radiation trend. If the sun is black or a moon symbol is displayed, the PV voltage is so low that the inverter is in its idle state. An empty sun with no rays also indicates that the PV voltage is still too low, with the inverter in standby mode. The inverter is represented in the middle of the left-hand section. If a fault occurs or a message is present, the corresponding symbols flash on the inverter.
Protect PV.500 Operating Instructions Figure 31 Example of operating display Solar radiation is too low, the inverter is in standby mode. Figure 32 Example of operating display Solar radiation is too low, the inverter is in its idle state. The middle section displays the unit's most important infeed values in the form of digital values and a graph covering a certain period of time. The current daily data is shown as standard.
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Protect PV.500 Operating Instructions Figure 37 Example of yearly overview Yearly overview (t = year of start-up to current year) The right-hand side shows how the key is currently assigned. Figure 38 Operating display – Right-hand side Here you can switch the inverter on or off, depending on the unit status. If the operation has been blocked, this is indicated here via a key symbol. If a blank button is shown here, a fault is present.
Protect PV.500 Operating Instructions Use the bottom key with the measuring instrument symbol to call up menus with detailed information on the status and the measured values. This key flashes in the event of a fault in the unit, enabling you to access menus containing additional fault information directly. 8.3.4 Status/Measured Values You can call up the “Status/Measured values” menu from the operating display using the bottom key with the measuring instrument symbol.
Protect PV.500 Operating Instructions You can use the “Inverter” menu item to display the statuses and measured values for the inverter. You can toggle between the two menus using the “>” and “<” keys. In normal operation, the inverter can be switched on and off here, using the top key. In the event of a deactivating fault, you can call up a detailed description of the fault here. Once the fault has been rectified, you will need to acknowledge it using the top key.
Protect PV.500 Operating Instructions 8.3.5 Blocking You can call up the “Blocking” menu from the “Main menu”. After you have entered the current password, you can block operation of the inverter (switching ON/OFF and fault acknowledgement). The password must be entered digit by digit and then confirmed by pressing the ENTER key. The default password set by the factory is: 1201. In menus where switching operations are normally possible, blocking is indicated by a key. 8.3.
