FRONIUS IG 2000 / 3000 / 2500-LV FRONIUS IG 4000 / 5100 / 4500-LV 42,0410,1089 012005 US Operating instructions Grid-connected inverters for photovoltaic systems
Dear Reader Introduction Thank you for choosing Fronius - and congratulations on your new, technically highgrade Fronius product! This instruction manual will help you get to know your new machine. Read the manual carefully and you will soon be familiar with all the many great features of your new Fronius product. This really is the best way to get the most out of all the advantages that your machine has to offer.
Safety rules DANGER! WARNING! CAUTION! “DANGER!” indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word must be limited to the most extreme situations. This signal word is not used for hazards relating to property damage unless there is also a risk of personal injury appropriate to this level. “WARNING!” indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
General Remarks (continued) All the safety instructions and warning signs on the machine itself: - must be kept in a legible condition - must not be damaged - must not be removed - must not be covered, pasted or painted over For information about where the safety instructions and warning signs are located on the machine, please refer to the section of your machine’s instruction manual headed “General Remarks”.
Qualified Staff (continued) Maintenance and repair may only be carried out by an authorised specialist company. There is no guarantee in the case of parts sourced from other suppliers that these parts have been designed and manufactured to cope with the stresses and safety requirements that will be placed on them. Use only original spare parts (this also applies to standard parts).
Safety markings Equipment with the CE mark fulfils the basic requirements of the Guideline Governing Low-Voltage and Electromagnetic Compatibility. (More detailed information about this may be found in the Annex or in the section of your documentation headed “Technical Data”.
Table of Contents IMPORTANT SAFETY INSTRUCTIONS - SAVE THESE INSTRUCTIONS ................ 4 General ................................................................................................................ 4 Housing ............................................................................................................... 4 Galvanic isolation ................................................................................................ 5 Monitoring the grid ....................................
Display Modes ....................................................................................................... 20 Display mode outline ......................................................................................... 20 Display symbol key ............................................................................................ 21 Display mode "Now" .......................................................................................... 22 Display mode "Day / Year / Total" ...............
LocalNet ..................................................................................................................... 51 System upgrading / plug-in card system ............................................................ 51 Datalogger ......................................................................................................... 51 COM Card ......................................................................................................... 52 Insert plug-in cards ....................
IMPORTANT SAFETY INSTRUCTIONS - SAVE THESE INSTRUCTIONS General Warning! Incorrect operation and work performed incorrectly can cause serious injury & damage! Only qualified staff are authorized to install your FRONIUS IG and only within the scope of the respective technical regulations.
Galvanic isolation The design and function of the FRONIUS IG unit offers a maximum level of safety, both during installation as well as in operation. A complete galvanic isolation between the DC and AC sides is one such safety feature. The FRONIUS IG provides galvanic isolation and grid monitoring. The passive and active measures for the protection of persons and equipment help ensure safe installation and operation.
Solar modules (continued) The FRONIUS IG includes a ground fault detector interruptor (GFDI) according to UL 1741. This device measures the ground current of the PV array and prevents the inverter from feeding the grid in case of a ground fault. Grid connection Only appropriately licensed contractors are authorized to connect your FRONIUS IG to the grid. Consult your local authorities for specific requirements.
How a photovoltaic system works string mod. 2 mod. n mod. 1 - - mod. 2 string 3 string 2 string 1 mod. 1 + total string voltage module 1 module 2 + module 3 Power output and voltage are increased by combining a number of solar cells. If solar modules are connected in series like on a string, both the output power as well as the voltage will increase.
Operation manual The FRONIUS IG Unit in the PV System General information The FRONIUS IG is the latest generation of solar inverter. It is the highly complex link between solar modules and the grid. As such it is responsible for a number of high-level tasks. The following diagram gives a graphical overview as to where the FRONIUS IG is placed in the PV system.
Fully automatic operation management The FRONIUS IG is fully automatic. Starting at sunrise, as soon as the solar modules generate enough power, the automatic control unit starts monitoring voltage and frequency. As soon as there is a sufficient level of insolation, your solar inverter starts feeding energy to the grid. A few Watts of solar power output are sufficient to achieve this.
Monitoring the grid (continued) There are several ways the FRONIUS IG unit can identify a gridcutoff, by monitoring: - voltage - frequency - islanding conditions Display function and data communication The FRONIUS IG unit comes standard with a display that has been designed to enable quick and easy access to the most important data in your PV system. The FRONIUS IG is equipped with a basic logging function to monitor minimum and maximum data on a daily and a cumulative basis.
Product description The FRONIUS IG Unit How it functions The FRONIUS IG unit is designed for fully automatic operation. No manual control is necessary for feeding the power it generates into the grid. The FRONIUS IG unit starts operating automatically as soon as the power output of the solar modules is sufficient after sunrise. During its operation the FRONIUS IG unit optimizes the voltage of the solar modules for maximum power output.
Startup phase (continued) (2) TEST - self test of important components of the FRONIUS IG unit - The FRONIUS IG unit goes through a master check list for several seconds - the display says "TEST" and indicates the respective component which is being tested (for example "LED") (3) Synchronisation with grid - The screen displays "SYNCAC" - "WAITPS" is displayed: The FRONIUS IG is waiting for all power supplies in the network to be on stand-by. This procedure takes place dependent on the DCvoltage.
Overview for housing (1) Knockout for AC-cables (2) Knockout for DC-cables (3) Knockout for DatCom cable (4) LCD (5) LED for operating status (6) LED for GFDI status (7) Ventilator grill (1) (2) (3) (4) (5)(6) 13 (7)
Overview for housing (Continued) Warning! Hazard due to supply voltage and DC-voltage from the solar modules. Only qualified electrical professionals are authorized to open the connection area of the FRONIUS IG and only when it is not under voltage.
LED for operating status LED for GFDI status LED for operating status Depending on the operating status, the LED assumes different colors (1) LED lights up green: - a green light starts as soon as the FRONIUS IG unit has completed the startup phase, and stays green as long as the operation of feeding power into the grid continues - it indicates faultless operation of the photovoltaic equipment (2) LED flashes green: - as long as the photovoltaic equipment is operating without fault - an additional message
LED for operating status (continued) (4) LED flashes orange: - when a warning is displayed on the screen - or the FRONIUS IG unit has been set to standby operation in the setup menu (manual shutoff of operation) - the next day, operation will resume automatically - during the time the orange LED is flashing, the operation can be resumed manually at any time (see chapter "Setup Menu") (5) LED lights up red: - general status: the respective service code is displayed on the screen A list of all service codes,
Operating scheme The Display General information The FRONIUS IG unit is pre-configured to be ready for operation. Therefore it is not necessary to make any adjustments for it to operate and feed power into the grid.
Symbols (continued) (5) output bar ... indicates the power output fed into the grid at a given moment - independent from the display mode chosen. The screen displays % of the maximum possible output power of your solar inverter (6) ... appears with AC data readings that are directly related to the grid (7) ... appears with data readings that are directly related to the solar modules (8) ... appears with data readings that are related directly to the FRONIUS IG unit (9) ...
Menu level From the menu level you can enter the display mode or the setup menu. Access the top level menu by pressing the (C) key. (C) (C) Select display mode - the screen displays "Menu" - the display is operating in the top level menu (1) (2) (3) (4) (A) (A) (B) (D) (B) Select from the available modes: Instantaneous data, daily data, annual data, or total data over the life of the FRONIUS IG.
Scrolling between display functions (A) (B) (A) (A) (B) (B) - select the desired display mode (see above) - scroll between the display functions available with keys (A) or (B) Display Modes Display mode outline The following display modes are available: display mode "Now" ...shows present data display mode "Day" ... shows data for the current day display mode "Year" ...shows data for current calendar year - only available in combination with Datalogger display mode "Total" ...
Display symbol key The following table contains a brief list of the display readings available. Display readings without an asterisk are shown even if no Datalogger or Sensor box is connected to the FRONIUS IG.
Display mode "Now" Displays present readings - select display mode "Now" (see the chapter "The Display") - the first display reading of the display mode "Now" appears AC power supplied ...power supplied to grid at the particular moment (Watts) (A) - (B) - for the next item press key (B) to scroll back press key (A) AC grid voltage (Volts) AC current supplied .. current supplied to the grid at the particular moment (Amperes) grid frequency (Hertz) DC array voltage...
Display mode "Now" (continued) GFDI status ... if there is no ground fault in the system "OK GFDI" is displayed * power drawn from the grid ... present consumption (Watts; Sensor Box and load sensor required) * ambient temperature (°F; can also be set for °C in setup menu; this corresponds to temperature sensor No.2; Sensor Box and temperature sensor required) * irradiance ...
Display mode "Day / Year / Total" Display mode “Day“ ...
Display mode "Day / Year / Total" (continued) Energy supplied ... energy supplied during monitored period (kWh / MWh) (A) (B) Due to the variety of different monitoring systems, there can be deviations between the readings of other metering instruments as compared to the readings from the FRONIUS IG. For determining the energy supplied to the grid only the readings of the calibrated meter supplied by the electric utility company are relevant. - press (B) for next item to scroll back press (A) Yield ...
Display mode "Day / Year / Total" (continued) Minimum grid voltage... lowest reading of grid voltage (V) during observation period Maximum array voltage... highest reading of array voltage (V) during observation period * Energy consumption meter reading energy consumed during observation period (kWh / MWh; Sensor Box and consumption sensor required) * maximum module temperature ...
Display mode "Day / Year / Total" (continued) * minimum ambient temperature...lowest ambient temperature reading during observation period (°F; can also be set for °C in setup menu; temperature sensor No2; Sensor Box required) * maximum irradiance... highest irradiance during observation period (W/m²; Sensor Box and reference cell required) operating hours ... duration of operation of FRONIUS IG unit (HH:MM) Duration of operation is shown in hours and minutes up to 999 h and 59 min (display: "999:59").
The Setup Menu List of menu items The diagram below shows the menu of adjustable parameters Standby Contrast LightMode Cash IG-NR DatCom Time State_PS Version Enter 0 ... 7 AUTO currency ON OFF rate / kWh 00 ...
Display mode "Setup" The setup menu allows easy readjustment of the FRONIUS IG’s preset parameters to your needs.
Setting the menu items - "Standby" ...activate/deactivate the standby operation by pressing the “Enter“ key (D) The menu item "Standby" allows manual activation of the standby operation of the FRONIUS IG unit. The standby mode is helpful when troubleshooting or adding/removing system components. During standby operation the electronic system of the power stage is switched off. No power is fed into the grid. The LED flashes orange.
- "Contrast" ... set contrast on LCD display (C) (D) (D) - select from settings "0" to "7" - press key (A) or (B): - enter "Contrast": press "Enter" key (D) Since contrast depends on temperature, it may be necessary to adjust the menu item "Contrast" when ambient conditions change. Settings for minimum possible contrast (0) up to maximum possible contrast (7): (C) (D) ... (A) - maintain previous setting: press "Esc" key (C) (B) (C) - accept: press "Enter" key (D) (D) - "Menu Mode" ...
- "Light Mode" ... pre-setting of display illumination (C) - to enter "Light Mode": press "Enter" key (D) (D) (D) - To switch between settings Auto 1., On 2. and Off 3. - press keys (A) or (B): (C) 1.The display illumination will stop 30 seconds after the last time a key has been pressed - accept: press "Enter" key (D) - maintain previous setting: press "Esc" key (C) (D) (A) (B) (A) (C) 2.
The name of the currency units can be changed. For example, here you see the units changed from the default US Dollars (USD) to Canadian Dollars (CAD). 1 (D) 2 (A) (B) (C) (D) ... ... (A) (B) (C) (D) (D) 1.
(C) (D) (D) - "IG-NR" ...Setting the number (address) of the FRONIUS IG unit in a setup comprising more than one photovoltaic inverter linked with each other - enter "IG-NR" by pressing the "Enter" key (D) enter address (00 ...
(D) (C) (D) (C) (C) If a successful data link has been set up then "OKCOM" is displayed. 35 "Error" is displayed if DatCom is not installed or the data link is not functioning correctly.
Note! The menu item "Time" is only supported when the FRONIUS Datalogger is connected. (C) (D) - "Time" ... setting of date and time - enter "Time" by pressing "Enter" key (D) (D) (A) (B) (C) (D) (C) (D) (D) (A) (B) (D) (A) (B) (C) (D) (D) (A) (B) (C) (D) 36 1.Enter date (e.g.: 28.01.
- "STATE_PS" ... Status display of power stage sets - Press "Enter key" (D) - In this case for example the first power stage set (PS00) is on "Standby" - "Standby" means no electricity is being fed into the public mains - Press "Enter" key (D) (D) (D) (D) - Display of the most recently stored service code (e.g. "State 406") (D) Important! The most recently stored service code and the display "State Load" appear alternately.
- "Version" displays version number and serial number of the IG control unit and the power stage (D) - To switch between displays MAINCTRL1., PS00 2. - press key (A) or (B) (C) (D) display version number (A) - enter "Version" by pressing "Enter" key (D) 1.
Additional information Upgrading the system The FRONIUS IG unit is prepared for a whole series of system upgrades, such as: - Communication between FRONIUS IG and DatCom units - Dataloggers (for recording and managing your photovoltaic system data via personal computer), including Datalogger and modem connection - Sensors (temperature sensor / irradiance / electricity consumption meter / ...) Some system upgrades are offered as plug-in cards, similar to those on your personal computer.
Upgrading the system (continued) Please see further information in the chapter "LocalNet" of the installation and service manual.
Installation manual 41
Installation Installation instructions Safety General information These installation instructions serve as a manual for qualified electrical professionals and detail the installation, initial operation, status diagnosis and repair processes. It is in your interest to read the operating instructions carefully and to thoroughly observe the instructions it contains. In doing so you will avoid malfunctions resulting from incorrect operation.
Choosing the location general To get the most out of your FRONUS IG unit, observe the following rules: Choosing the location - during certain operation phases the FRONIUS IG unit may produce a slight noise. For this reason it should not be installed in an occupied living area - the FRONIUS IG unit is not to be set up in areas with large amounts of dust. If unavoidable, place the FRONIUS IG in an appropriately rated and ventilated box.
Preparing the wall mounting In the following it is described how the FRONIUS IG is mounted to the wall. As your FRONIUS IG is delivered, the mounting plate is fixed to the inverter by two screws on the bottom of the FRONIUS IG.
Connection Safety General Warning! Hazard due to supply voltage and DC-voltage from the solar modules. Only qualified electrical professionals are authorized to open the connection area of the FRONIUS IG and only provided that it is not under voltage. Warning! An electric shock can be fatal. Inadequately sized electrical components can cause serious injuries to persons and damage to (or loss of) property. - Electrical installations must be in accordance with the National Electrical Code, ANSI/NFPA 70.
Grid connection Your FRONIUS IG unit needs to be connected to two phases (L1, L2) of the grid and to equipment grounding Warning! In order to ensure the best possible operation of the grid monitoring system, it is important to make sure that there is minimal resistance in the lines to the connection point. The AC conductor resistance between the FRONIUS IG unit and the building’s distribution panel should not exceed 0.5 Ohm.
Connection - Fix the FRONIUS IG unit to the wall as shown in the "Installation" chapter. - Open the connection area as shown in the figure Warning! Hazard due to supply voltage and DC-voltage from the solar modules. Only qualified electrical professionals are authorized to open the connection area of the FRONIUS IG and only provided that it is not under voltage.
Connection (continued) - set the "AC" and "DC" disconnects (1) to the "OFF" position - remove the four screws (2) on the IGs baseplate as shown in the picture above - remove the LCD faceplate (3) covering the connection area - Insert a 3/4 in. conduit fitting in the knockouts labeled "AC" (4) and fasten it - Insert a 3/4 in. conduit fitting in the knockout labeled "DC" (5) and fasten it Note! Only use raintight conduits according to UL 514B for the AC, DC and the optional DatCom knockouts.
Note! Connecting the DC wiring with the wrong polarity may cause damage to the inverter. Connect the DC cables as described in the following instructions. Connect DC Important! To access the DC terminals, the white plastic divider needs to be bent upward or rotated out of the way. - Insert the DC cables through the DC conduit and connect them to the terminal block. - Connect the positive (+) cables to the "DC+" terminals, and the negative (-) cables to the "DC-" terminals.
Start up Operation Configuring your Inverter Factory preset configuration Your FRONIUS IG unit has been pre-configured in the factory and is ready for operation. After mounting the FRONIUS IG unit to the wall and connecting it to the solar modules (DC) and to the grid (AC), all you have to do is close the AC and DC circuit disconnects.
Ground fault indication General The FRONIUS IG is equipped with a ground-fault detection and interruption (GFDI) circuit as required by UL 1741 and the National Elelctrical code. If a ground fault occurs in the DC cabling the inverter disconnects from the grid. The fault is indicated by the red ground-fault LED and the service code "434" is shown on the display.
COM Card In order to connect the FRONIUS IG unit to the LocalNet, a COM Card is required - COM Card ......................... for exchanging data between your FRONIUS IG unit and the LocalNet. The COM Card has the following connection terminals: - 2 x RJ45 sockets labelled "IN" and "OUT" for connection of CAT 5 cables - Power supply socket for the connection of 12 V low voltage power pack (only necessary in certain cases as described in the FRONIUS IG DatCom manual).
Insert plug-in cards (continued) (2) Prefereably insert COM-Card into the left-most slot Configuration (3) (1) LocalNet automatically identifies different system upgrades (Datalogger Box, Sensor Box, ...). However it is not able to differentiate between several identical system upgrades. In order to define each FRONIUS IG unit in the LocalNet, the respective unit must have its own individual identification number.
Recording and filing of inverter and sensor data by means of Datalogger and Sensor Box. External communication (LocalNet) takes place via the COM Cards. Each COM Card has two RS-485 interfaces: one for input one for output. Connections are made using RJ45 plugs. PC IN IN OUT IN IN OUT GFDI COM Card GFDI COM Card The first FRONIUS IG unit with a COM Card can be located at a distance of up to 3300 ft. (1000 m) from the last FRONIUS IG unit with COM Card.
Status diagnosis and repair Service-Codes Displayed Service display Your FRONIUS IG unit is equipped with a self diagnostic system that automatically identifies a large number of possible operation issues by itself and displays them on the screen. Therefore it is possible to quickly isolate technical issues, and to distinguish between Service Codes related to the installation versus Service Codes which are internal to the inverter.
System failure Should the display remain dark for a longer period of time after sunrise, check the no-load voltage of the solar modules. Should the no-load voltage of the modules (at the terminals within the FRONIUS IG) not reach 160 V, it is possible that there is a problem on the DC side of the photovoltaic system (e.g. wrong module configuration).
Class 1 Definition of service class: First digit in code represents the category. Service codes of service class 1 are typically temporary. Their cause lies in the grid. The first reaction of your FRONIUS IG unit is to disconnect from the grid. Subsequently, the grid will be checked for the duration of the observation period stipulated. If after the end of this period no further defect is identified, your FRONIUS IG unit resumes operating and feeding power into the grid.
Class 3 Service class 3 comprises service codes that may appear during operation of feeding power supply, that do not cause a permanent interruption of the operation of feeding power into the grid. After automatic disconnection from the grid and waiting for its conditions to return to those stipulated, your FRONIUS IG unit will try to resume feed-in operation.
Class 4 Class 4 service codes may require the intervention of a trained Fronius service technician.
Class 4 (continued) Code Designation Description Repair 414 EEPROM faulty Memory deleted If service code persists, you should contact a Fronius trained service technician 416 Communication with IG-Ctrl not possible Orange LED lights up, then the FRONIUS IG attempts to restart If service code persists, contact a Fronius-trained service technician 417 Two power supplies have the same Print Number FRONIUS IG indicates a critical error If service code persists, contact a Fronius-trained service
Class 5 (continued) 506 EEPROM faulty Data from the "Total" menu is lost Automatic rectification 507 EEPROM faulty Data from the menu "Day" / "Year" is lost Automatic rectification 508 FRONIUS IG address is faulty Address for data communication is no longer saved Set address again 509 24h no feed e.g. solar module covered in snow e.g.
Annex Technical Data FRONIUS IG 2000 / 3000 / 2500-LV Input data Recommended PV power IG 2000 IG 3000 IG 2500-LV 1500-2500 Wp 2000-3300 Wp 1800-3000 Wp MPP-voltage range 150 - 400 V Max. input voltage (at 1000 W/m² / 14 °F in no-load operation) 500 V Nominal input voltage 270 V Nominal input current 7.2 A 10.0 A 8.6 A Maximum usable input current 13.6 A 18 A 16.9 A Max.
FRONIUS IG 2000 / 3000 / 2500-LV (continued) Protection devices Ground fault protection IG 2000 IG 2500-LV internal GFDI, in accordance with UL 1741 and NEC Art.
FRONIUS IG 4000 / 5100 / 4500-LV (continued) Protection devices Ground fault protection IG 4000 IG 5100 IG 4500-LV internal GFDI, in accordance with UL 1741 and NEC Art.
Policy and procedure for warranty returns and repairs To obtain service you must follow this policy and procedure for warranty returns and repairs: - All returned FRONIUS IG Solar Inverters require a Returned Merchandise Authorization Number (RMA) - A request for a RMA number requires the following information: - Proof-of-purchase in the form of the original invoice - Model Number of the FRONIUS IG Solar Inverter - Serial Number of the FRONIUS IG Solar Inverter - Description of the problem - Shipping addre
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Fronius Worldwide - www.fronius.com/addresses A Fronius International GmbH 4600 Wels-Thalheim, Günter-Fronius-Straße 1, Austria E-Mail: pv@fronius.com http://www.fronius.com USA Fronius USA LLC Solar Electronic Division 5266 Hollister Ave., #117, Santa Barbara, California 93111 E-Mail: pv-us@fronius.com http://www.fronius-usa.com Under http://www.fronius.
