ILUMEN PIDBOX Installation Manual

ILUMEN PIDBOX Utility INSTALLATION MANUAL Ilumen PIDbox utility – Version 1.0

TABLE OF CONTENT 1 Information on this manual ................................................................................................................................. 4 1.1 Validity ................................................................................................................................................................ 4 1.2 Target group ..................................................................................................................................................... 4 1.3 Additional information ................................................................................................................................. 4 1.4 Symbols ............................................................................................................................................................... 4 2 Safety ............................................................................................................................................................................. 4 2.1 Appropriate usage .......................................................................................................................................... 4 2.2 Qualifications of skilled persons............................................................................................................... 5 2.3 Safety precautions .......................................................................................................................................... 5 2.3.1 Electric shock .......................................................................................................................................... 5 2.3.2 Electrostatic discharge ........................................................................................................................ 5 3 Scope of delivery ....................................................................................................................................................... 5 4 Product description ................................................................................................................................................. 5 5 Mounting ...................................................................................................................................................................... 6 5.1 Mounting location requirements ............................................................................................................. 6 5.2 Mounting the Ilumen PIDbox utility using the mounting holes .................................................. 6 6 Electrical connections ............................................................................................................................................. 7 6.1 Earth connection ............................................................................................................................................. 7 6.2 Solar array and inverter connections ..................................................................................................... 8 6.3 Connection Diagrams .................................................................................................................................... 9 6.3.1 One DC-circuit breaker (1xMPPT, 1xInverter) ......................................................................... 9 6.3.2 Two DC-circuit breakers (2xMPPT, 1xInverter) ...................................................................... 9 6.3.3 Two DC-circuit breakers (2xMPPT, 2xInverter) ...................................................................... 9 6.4 Schematics ...................................................................................................................................................... 10 7 Commissioning ....................................................................................................................................................... 11 7.1 Check ................................................................................................................................................................. 11 7.2 Starting up the Ilumen PID utility ......................................................................................................... 11 7.3 Manually activate DC-circuit breakers ................................................................................................ 12 8 Installation summary ........................................................................................................................................... 13 9 Decommissioning the Ilumen PIDbox utility ............................................................................................. 13 9.1 Disassembling the PIDbox utility .......................................................................................................... 13 9.2 Packing the PIDbox utility ........................................................................................................................ 13

9.3 Disposing of the PIDbox utility............................................................................................................... 13 10 Troubleshooting ................................................................................................................................................ 14 10.1 Faults................................................................................................................................................................. 14 10.2 No good PID regeneration ........................................................................................................................ 14 10.3 Resetting the PIDbox utility .................................................................................................................... 14 10.4 Repairing the PIDbox utility .................................................................................................................... 15 11 Contact .................................................................................................................................................................. 15 12 Technical data .................................................................................................................................................... 16

1 INFORMATION ON THIS MANUAL This manual contains instructions on how to install the Ilumen PIDbox utility. 1.1 VALIDITY This manual applies to the Ilumen PIDbox utility v1.0. 1.2 TARGET GROUP This manual is intended for skilled persons. Only qualified persons with the appropriate skills are allowed to perform the tasks set forth in this manual. 1.3 ADDITIONAL INFORMATION Links to additional information can be found at www.ilumen.be  Ilumen PIDbox utility datasheet  What is PID?  PID checker 1.4 SYMBOLS Symbol Explanation Indicates a hazardous situation which, if not avoided, will result in property damage Indicates a hazardous situation which, if not avoided, will result in death or serious injury Information that is important for a specific topic or objective, but is not safety-relevant 2 SAFETY 2.1 APPROPRIATE USAGE The Ilumen PIDbox utility applies a voltage to PV modules in reference to earth. The device may only be switched on when the installation is executed as described in this manual. Before installing the Ilumen PIDbox utility, ensure that the permitted operating range of each component is maintained at all times. Before using the Ilumen PIDbox utility you have to obtain the appropriate approval from the manufacturer of the PV modules. Any applications other than those described here shall be considered contrary to the appropriate usage. Alternative use or modification of the Ilumen PIDbox utility will void warranty claims and operation permit.

2.2 QUALIFICATIONS OF SKILLED PERSONS The work described in this document must be performed by skilled personnel only. Skilled personnel must have the following qualifications:  Knowledge of how an inverter works and how it is operated  Training in how to deal with the dangers and risks involved in installing and operating electrical devices and plants  Training in the installation and commissioning of electrical devices and plants  Knowledge of all applicable standards and directives  Knowledge and observance of this document and all safety precautions 2.3 SAFETY PRECAUTIONS 2.3.1 ELECTRIC SHOCK When the Ilumen PIDbox utility is in operation, voltage will be present. Prior to maintenance work on the PV plant switch off the Ilumen PIDbox utility. When you want to change the arrangement of the Ilumen PIDbox utility you must switch off the Ilumen PIDbox utility 20 minutes prior to making any changes. 2.3.2 ELECTROSTATIC DISCHARGE Never operate the Ilumen PIDbox utility when not properly installed or when the components are not closed properly. Always make sure the grounding of the Ilumen PIDbox utility is done correctly. 3 SCOPE OF DELIVERY 1x Ilumen PIDbox utility Containing the following components a. iLumen PID controller b. PLC c. iLumen Energy meter d. Timer e. 1 or 2 automated DC-circuit breakers (according the ordering form) f. Installation manual 4 PRODUCT DESCRIPTION The Ilumen PIDbox utility is placed between the inverter and the solar array strings. The power of the strings goes through the PIDbox utility, entering on one side “PV in” and leaving on the other “Inv. out”. This means the Ilumen PIDbox utility is placed in series between the PV panels and the inverter. You can use one Ilumen PIDbox utility per 1 or 2 MPP trackers (when ordered with 1 or 2 DC-circuit breakers respectively).

5 MOUNTING 5.1 MOUNTING LOCATION REQUIREMENTS  The installation site must be freely and safely accessible at all times without the necessity for any auxiliary equipment.  The mounting location should be inside a well ventilated- and windproof location.  Do not place the Ilumen PIDbox utility in a dusty environment.  The ambient temperature must be between -10 and 35°C.  Normally the PIDbox utility is installed right next the inverter or close to the DC- combiner box. 5.2 MOUNTING THE ILUMEN PIDBOX UTILITY USING THE MOUNTING HOLES 1. Mark the 4 positions of the drill holes on the mounting surface 2. Drill the holes 3. Insert the wall plugs (if necessary) 4. Screw the Ilumen PID Utility to the mounting surface and make sure adequate washers are installed. 5. Check if mounted securely 1 2 3 4

When lifting the PIDbox utility, always ask a second person to assist or use special lifting equipment. One PIDbox utility weights around 90 kg. Be cautious for back injuries! 6 ELECTRICAL CONNECTIONS When installing the Ilumen PIDbox utility, the DC side of the PV plant must be switched off. After the installation is done, you can switch the DC switch back on. Also switch on the circuit breaker manually when needed inside the PIDbox utility. A standard 1 phase AC connection (230V AC) must be available on installation. This outlet should be on at all times. 6.1 EARTH CONNECTION To achieve the best result, the frames of the solar modules must be connected to the earth connector of the Ilumen PIDbox utility. For optimal result you must lay a cable (2.5-4mm2) to the mounting structure of the solar modules (make sure mounting structures and frames of the solar modules are electrically conducting). It is important that all frames of all solar modules are at the earth potential, if necessary you have to interconnect the mounting structures with additional cables. Connect the earth cable to the earth bar inside the PIDbox utility

6.2 SOLAR ARRAY AND INVERTER CONNECTIONS When installing the PIDbox utility between the PV array and inverter always switch off the DC switch of the inverter 1. Connect the positive DC cable coming from the first PV array. Connect it to the “PV in A+” position. 2. Connect the negative DC cable coming from the first PV array. Connect it to the “PV in A-” position. 3. Connect the positive DC cable coming from the second PV array (optional). Connect it to the “PV in B+” position. 4. Connect the negative DC cable coming from the second PV array (optional). Connect it to the “PV in B-” position. 5. Connect the “INV out A+” position to the positive side of the inverter of the first PV array 6. Connect the “INV out A-” position to the negative side of the inverter of the first PV array 7. Connect the “INV out B+” (optional) position to the positive side of the inverter of the second PV array 8. Connect the “INV out B-” (optional) position to the negative side of the inverter of the second PV array If you work with inverters with multiple MPPT’s you cannot mix the PV arrays from multiple MPPT’s. The maximum current that can pass through the Ilumen PIDbox utility per channel / MPPT is indicated on the DC circuit breaker and on the type plate on the side of the PIDbox utility. Make sure this is never exceeded. Make sure the PV arrays are connected to the “PV in A” and “PV in B” side of the Ilumen PIDbox utility, NEVER to the “INV out A” or “INV out B” side.

6.3 CONNECTION DIAGRAMS Several solutions are possible. Here you find the most common possible connections. 6.3.1 ONE DC-CIRCUIT BREAKER (1XMPPT, 1XINVERTER) 6.3.2 TWO DC-CIRCUIT BREAKERS (2XMPPT, 1XINVERTER) 6.3.3 TWO DC-CIRCUIT BREAKERS (2XMPPT, 2XINVERTER)

7 COMMISSIONING 7.1 CHECK Do a final check whether everything is properly mounted and connected (see chapter 5 and 6 for details):  The PV frames are all connected to the same earth as the earth pin of the Ilumen PIDbox utility  The PV and inverter DC cables are correctly connected  The AC connection is made properly If all these points are installed correctly you can start up the Ilumen PIDbox utility. 7.2 STARTING UP THE ILUMEN PID UTILITY The Ilumen PIDbox utility can only work in an automatic mode. To start up the Ilumen PIDbox utility, switch on the AC circuit breaker. Next see if the light on the Ilumen PIDbox utility starts burning. After checking the system it will be switched on automatically. When the Ilumen PIDbox utility is hooked up correctly to the inverter you will see the following status light readouts.  White: device is switched on  RED: DC circuit breakers are off. This light should burn during the night (starting from 22.30h)  GREEN:. DC circuit breakers are on. This light should burn during the day (starting from 04.30h)  BLUE: PID controller is switched on and cures the PV system. It takes a minute or so that the blue light will come on after the red light starts to light up. So there are 2 scenarios:  Daytime: white light and green light on  Nighttime: white light, red light and blue light on

7.3 MANUALLY ACTIVATE DC-CIRCUIT BREAKERS When it is necessary to manually activate the DC circuit breakers you can follow this guide below. You can manually activate it e.g. when the AC-power is not connected but you still want to use the PV-panels for your inverter. You can manually activate the DC circuit breakers by opening up the plastic see-trough cover and pressing the “I” button. If this doesn’t work you will have to charge up the circuit breaker. Pull the lever on the right side of the circuit breaker all the way down. Let go and repeat this until the words “charged” appear in the window. Press the “I” button again. This should only be done after all DC-connections are made. Make sure all connections are made properly before activating the DC-circuit breaker manually. lever ‘I’-button

8 INSTALLATION SUMMARY 1) Take the necessary safety precautions (DC switch of the inverter off). 2) Mount the Ilumen PIDbox utility correctly to a wall using the mounting holes. 3) Connect the Ilumen PIDbox utility earth bar to the frames of the PV modules and check the interconnections between the PV casings. 4) Disconnect the PV array cables from the inverter. 5) Mind the maximum allowed current through the DC circuit breakers of the PIDbox utility 6) Connect the PV array cables to the Ilumen PIDbox utility inputs (see 6.2 for details). 7) Connect the Ilumen PIDbox utility to the inverter (see 6.2 for details). 8) Connect the AC power 9) Switch on the AC circuit breaker 10) Turn the DC switch on inside the inverter or the DC combiner box 9 DECOMMISSIONING THE ILUMEN PIDBOX UTILITY 9.1 DISASSEMBLING THE PIDBOX UTILITY Switch off the Ilumen PIDbox utility by switching off the main AC circuit breaker. Switch off the DC power to the PIDbox utility inside the inverter or the DC combiner box. Disconnect the Ilumen PIDbox utility from the AC grid. Wait a minimum of 20 minutes. Disconnect the DC cables from the PIDbox utility. Disconnect all earth connections. When all electrical connections are disconnected you can dismount the Ilumen PIDbox utility. When doing any kind of work on the PIDbox utility, always switch off the DC power to the device inside the inverter or the DC combiner boxes. 9.2 PACKING THE PIDBOX UTILITY To pack the PIDbox utility use the original packaging or packaging suitable for the weight and dimensions of the PIDbox utility (see Section 12 "Technical Data"). 9.3 DISPOSING OF THE PIDBOX UTILITY Dispose of the PIDbox utility at the end of its service life in accordance with the disposal regulations for electronic waste currently applicable at the installation site.

10 TROUBLESHOOTING 10.1 FAULTS Lights readout Fault Corrective action No lights visible Product does not work Make sure the AC-power is connected and AC voltage is present. Also make sure that all the AC circuit breakers inside the PIDbox utility are switched on. No lights visible Product does work. The front panel lights can be defective Please contact iLumen technical service. Blue light does not burn during the night while the red and white lights are burning. Product does not cure the panels This can have 2 reasons:  It takes about 1 minute to activate the blue light after the red light has turned on.  Earth connection between PIDbox utility and the frame of the modules is interrupted. Alternating lights red and green. The PIDbox is not in automatic mode. The position of the DC-circuit breaker doesn’t correspond with the position it should be in. Check that the DC circuit breakers are in automatic mode. Please check that the plastic see-trough covers of the DC circuit breakers are closed properly. A black latch should click over the cover. Red light during the day when in automatic mode. The power to the inverter is interrupted during the day The DC switch has tripped. Reset the DC-switch. If the problem persists, please contact iLumen technical service. 10.2 NO GOOD PID REGENERATION If the modules are not regenerating or not regenerating fast enough you should check following things:  Check the grounding of the system. If necessary you should place additional interconnections between the frames of the modules.  Is the Ilumen PIDbox utility properly connected to the grid?  Is the AC power properly connected (is its indication light burning)?  Let an expert check if the problem you’re having with the yield is caused by PID 10.3 RESETTING THE PIDBOX UTILITY The PIDbox utility can simply be reset by switching off the AC-power. Wait 20 seconds and switch the AC-power back on. If resetting does not help fixing your problem, please consult chapter 10.1 of this manual.

10.4 REPAIRING THE PIDBOX UTILITY Do not try to repair the PIDbox utility by yourself without contacting iLumen. The warranty will be void. Always contact iLumen technical service if your PIDbox utility is broken. 11 CONTACT Ilumen bvba Ambachtsstraat 19 3980 Tessenderlo Belgium Tel: +32 13 30 61 77 [email protected] www.ilumen.be

12 TECHNICAL DATA Switch example PV array / inverter input Input PV voltage range 80 - 1000 V Output voltage to ground Up to 1250 V Maximum PV current / input V160 V200 V320 V400 V500 V800 160 A 200 A 320 A 400 A 500 A 800 A Number of independent DC inputs 1 or 2 (specify when ordering) Maximum output current in operation 20 mA GRID (AC) Nominal AC voltage 110 to 130 V or 220 to 250 V Nominal AC grid frequency 50 to 60 Hz Power consumption in standby operation < 10 W Typical power consumption in operation 50 W Maximum power consumption 80 W General data Dimensions IP44 (W x D x H) 800 x 400 x 1000 mm Dimensions IP65 (W x D x H) 1000x400x1000 mm Dimensions IP44 (W x D x H) model V800 1250 x 420 x 1250 mm Dimensions IP65 (W x D x H) model V800 1200x400x1000 mm Weight 95 kg Operating temperature range -25 to 60 °C (-13 to 140 °F) Environmental conditions IP44 – indoor use only IP65 – outdoor use (specify when ordering) Configuration Maximum one MPPT per DC-input None of the connected solar module poles may become grounded Communication Optional GPRS Various Warranty Up to 20 years Certificates www.ilumen.be Registration before use www.myilumen.be optional