Important - Advanced Energy
Advanced Energy® AE 500 Inverter
Installation and Operation
User Manual
March 2012 570-1001791-05A
Advanced Energy® AE 500 Inverter
Installation and Operation
User Manual
March 2012 570-1001791-05A
Advanced Energy
COPYRIGHT
This manual and the information contained herein are the proprietary property of Advanced
Energy Industries, Inc.
No part of this manual may be reproduced or copied without the express written permission of
Advanced Energy Industries, Inc. Any unauthorized use of this manual or its contents is
strictly prohibited. Copyright © 2012 Advanced Energy Industries, Inc. All Rights Reserved.
DISCLAIMER AND LIMITATION OF LIABILITY
The information contained in this manual is subject to change by Advanced Energy
Industries, Inc. without prior notice. Advanced Energy Industries, Inc. makes no warranty of
any kind whatsoever, either expressed or implied, with respect to the information contained
herein. Advanced Energy Industries, Inc. shall not be liable in damages, of whatever kind, as
a result of the reliance on or use of the information contained herein.
PRODUCT USAGE STATEMENT
WARNING :
Read this entire manual and all other publications pertaining to the work to
be performed before you install, operate, or maintain this equipment. Practice
all plant and product safety instructions and precautions. Failure to follow
instructions can cause personal injury and/or property damage. If the
equipment is used in a manner not specified by the manufacturer, the
protection provided by the equipment may be impaired. All personnel who
work with or who are exposed to this equipment must take precautions to
protect themselves against serious or possibly fatal bodily injury.
Advanced Energy Industries, Inc., (AE) provides information on its products
and associated hazards, but it assumes no responsibility for the after-sale
operation of the equipment or the safety practices of the owner or user.
NEVER DEFEAT INTERLOCKS OR GROUNDS.
Any use of the AE 500 unit that is not expressly authorized in this user
manual or associated documentation, including, without limitation, the use of
the AE 500 unit with incompatible photovoltaic panel technology, is expressly
prohibited by AE, and AE disclaims any responsibility or liability for such
prohibited use. The AE 500 unit should only be handled, installed, operated,
and maintained by trained personnel.
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AVERTISSEMENT :
Lire ce manuel au complet ainsi que toutes les autres publications portant
sur le travail à effectuer avant d’installer, d’utiliser ou d’entretenir cet
équipement. Pratiquer toutes les instructions et précautions de sécurité pour
l’usine et les produits. Tout manquement aux instructions suivantes peut
provoquer des blessures corporelles et/ou des dommages matériels. Si
l’équipement est utilisé de manière non spécifiée par le fabricant, la
protection fournie par l’équipement peut être compromise. Tous les membres
du personnel travaillant sur cet équipement ou qui y sont exposés doivent
observer les précautions pour se protéger contre des blessures graves, voire
mortelles.
Advanced Energy Industries, Inc. (AE) fournit des renseignements sur ses
produits et les dangers qui y sont liés, mais ne peut être tenue responsable
du fonctionnement après-vente de l’équipement ou des pratiques de sécurité
du propriétaire ou de l’utilisateur. NE JAMAIS DÉJOUER LES DISPOSITIFS
DE PROTECTION À VERROUILLAGE OU LES MISES À LA TERRE.
Toute utilisation de cette unité AE 500 qui n’est pas expressément autorisée
dans ce guide de l’utilisateur ou dans la documentation connexe, y compris,
sans s'y limiter, l’utilisation de l’unité AE 500 avec des technologies de
panneaux photovoltaïques incompatibles, est expressément interdite par AE,
et AE décline toute responsabilité découlant d’un tel usage interdit. L'unité
AE 500 doit seulement être manipulée, installée, utilisée et entretenue par un
personnel formé.
TRADEMARKS
is a registered trademark of Advanced Energy Industries, Inc.
PVPowered™ is a trademark of Advanced Energy Industries, Inc.
Power Factor Pro™ is a trademark of Advanced Energy Industries, Inc.
Advanced Power Controls™ is a trademark of Advanced Energy Industries, Inc.
Modbus® is a registered trademark of Gould, Inc.
Windows® is a registered trademark of the Microsoft Corporation.
CUSTOMER FEEDBACK
Advanced Energy’s technical writing staff has carefully developed this manual using
research-based document design principles. However, improvement is ongoing, and the
writing staff welcomes and appreciates customer feedback. Please send any comments on the
content, organization, or format of this user manual to:
• [email protected]
570-1001791-05A
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Advanced Energy
To order a manual, please contact AE Solar Energy Technical Support:
• [email protected]
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Table of Contents
Chapter 1. Safety and Product Compliance Guidelines
Important Safety Instructions ................................................................................ 1-1
Save These Instructions ........................................................................................ 1-1
Danger, Warning, and Caution Boxes in the Manual ............................................ 1-1
Safety Guidelines .................................................................................................. 1-2
Rules for Safe Installation and Operation ....................................................... 1-2
Personal Safety ..................................................................................................... 1-3
Medical and First Aid Treatment ..................................................................... 1-3
Safety Equipment Requirements .................................................................... 1-3
Interpreting Product Labels ................................................................................... 1-3
Product Compliance .............................................................................................. 1-4
Safety and EMC Directives and Standards .................................................... 1-5
Safety Directives and Standards .............................................................. 1-5
Electrical Safety .............................................................................................. 1-5
Disconnect Switch .................................................................................... 1-5
Wiring Requirements ...................................................................................... 1-6
Wiring Information .................................................................................... 1-6
Fire Prevention ............................................................................................... 1-8
Lockout and Tagout Requirements ....................................................................... 1-8
Acronyms and Frequently Used Terms ................................................................. 1-9
Chapter 2. Product Overview
General Description .............................................................................................. 2-1
Advanced Energy Inverter Models ................................................................. 2-1
Design Features ....................................................................................... 2-1
Product Features ................................................................................................... 2-2
Major Components and Functional Parts ............................................................. 2-3
Power Module Assembly ................................................................................ 2-4
Control Electronics ......................................................................................... 2-4
Data Monitoring Card Cage ............................................................................ 2-5
Communications Interface PCB ............................................................... 2-6
Operator Interface Controls ............................................................................ 2-6
Active Cooling System .................................................................................... 2-7
DC Combiner Sub Panel ................................................................................ 2-7
DC Sub Panel ................................................................................................. 2-7
AC Sub Panel ................................................................................................. 2-8
Housekeeping Transformer ............................................................................ 2-9
Magnetics Compartment ................................................................................ 2-9
Chapter 3. Planning
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General Requirements for Planning and Installation ............................................. 3-1
Handling the Inverter ............................................................................................. 3-1
Handling Options ............................................................................................ 3-2
Storage .................................................................................................................. 3-2
Location and Clearances ...................................................................................... 3-2
Location .......................................................................................................... 3-2
Noise .............................................................................................................. 3-2
Recommended Clearances ............................................................................ 3-2
Conduit and Conductors ....................................................................................... 3-3
Environmental Requirements ................................................................................ 3-4
Grounding and Neutral Requirements .................................................................. 3-4
PV Array Frame Grounding ............................................................................ 3-4
System Neutral ............................................................................................... 3-5
Utility Grid Interconnection .................................................................................... 3-6
Utility Connection Requirements .................................................................... 3-6
Contacting Your Local Utility .......................................................................... 3-6
Voltage Output ................................................................................................ 3-6
Inverter Monitoring ................................................................................................ 3-6
Calculating DC Input Voltage ................................................................................ 3-7
DC Combiner Sub Panel Options ......................................................................... 3-7
Breaker Protection for DC Input ..................................................................... 3-8
Chapter 4. Installing
Handling and Unpacking ....................................................................................... 4-1
Packaging Contents ....................................................................................... 4-1
Handling and Unpacking the Inverter ............................................................. 4-1
Installing the Air Intake Hoods ........................................................................ 4-2
Pre-Installation Inspection ..................................................................................... 4-5
Pre-Installation Inspection Tools .................................................................... 4-5
Step 1: External Inspection ............................................................................. 4-6
Step 2: Inspection of Rear Magnetics ............................................................. 4-6
Step 3: AC and DC Sub Panel Compartments ............................................... 4-7
Step 4: Power Module Compartment ............................................................. 4-8
Step 5: Upper Active Cooling Compartment ................................................... 4-9
Lifting and Mounting the Inverter ......................................................................... 4-10
Conduit Entry Points ........................................................................................... 4-12
Using Gland Plates for Cable Conduit Entry and Exit .................................. 4-12
Electrical Connections ......................................................................................... 4-15
AC Wiring ..................................................................................................... 4-16
Connecting to the Electrical Grid ........................................................... 4-18
DC Wiring ..................................................................................................... 4-21
Connecting to the PV Arrays .................................................................. 4-22
Using the Integrated Remote Disable Input .................................................. 4-25
Making the Remote Disable Connection ................................................ 4-26
24 V Power Supply ....................................................................................... 4-28
Wiring the 24 V Power Supply ............................................................... 4-29
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Chapter 5. Operation
System Startup Procedure .................................................................................... 5-1
Inverter Operating States ...................................................................................... 5-2
Display Screens and Operation ............................................................................ 5-4
To Operate the Display ................................................................................... 5-6
Ground Fault Interrupt Device ............................................................................... 5-6
To Respond to a Ground Fault ....................................................................... 5-7
To Shutdown the Inverter ...................................................................................... 5-8
De-energize/Isolation Procedures .................................................................. 5-9
Inverter Enable/Disable Controls .................................................................. 5-10
Chapter 6. Data Monitoring and Controls
Networking and Performance Monitoring .............................................................. 6-1
Ethernet Network Connection ......................................................................... 6-1
Connecting the Ethernet Cable ...................................................................... 6-2
To Establish an Internet Connection with the Inverter .................................... 6-3
To Verify Data Monitoring Connectivity .......................................................... 6-4
Modbus Overview ................................................................................................. 6-4
Modbus Communication Protocol ................................................................... 6-4
Networking Using the Modbus Option ................................................................... 6-4
Modbus TCP Installation ................................................................................ 6-5
Modbus TCP Network Configuration .............................................................. 6-6
Networking Using the Modbus RS-485 Option ..................................................... 6-6
Network Layout ............................................................................................... 6-7
Installing the Modbus RS-485 Cable .............................................................. 6-8
Setting the DIP Switches ................................................................................ 6-9
To Terminate the Inverter Network ........................................................ 6-10
To Set the Center Inverters for the Network .......................................... 6-11
To Set Network Biasing ......................................................................... 6-11
To Terminate the Network and Enable Biasing ..................................... 6-11
Setting the Modbus Address ........................................................................ 6-11
Modbus Commands ............................................................................................ 6-16
Modbus Command Format ........................................................................... 6-16
Return Slave ID ............................................................................................ 6-18
Modbus Data Types ............................................................................................ 6-19
Modbus Register Mapping ................................................................................. 6-19
Modbus Fixed Information Registers ............................................................ 6-19
Modbus Data Registers ................................................................................ 6-22
Modbus Status and Fault Code Registers .................................................... 6-23
Modbus Command Registers ....................................................................... 6-26
Chapter 7. Maintenance
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Visual Inspection ................................................................................................... 7-2
Maintenance Schedule .......................................................................................... 7-2
Replacement Parts ................................................................................................ 7-3
Checking and Replacing the Air Filters ................................................................. 7-4
Maintaining the Air Filters ............................................................................... 7-4
Maintaining the Card Cage Air Filter .............................................................. 7-6
Replacing the Battery on the Communications PCB ............................................. 7-6
Chapter 8. Troubleshooting and Solar Energy Technical
Support
Troubleshooting LAN Connectivity ........................................................................ 8-1
To Test the LAN Cable ................................................................................... 8-2
Troubleshooting Warnings and Faults .................................................................. 8-2
Troubleshooting Warnings .............................................................................. 8-3
System Warnings ..................................................................................... 8-3
Troubleshooting Inverter Faults ...................................................................... 8-4
AC Under Voltage Fault ........................................................................... 8-5
Ground Faults .......................................................................................... 8-5
To Resolve a Ground Fault ...................................................................... 8-6
Inverter Fault Codes ................................................................................ 8-8
PCB Status LEDs ................................................................................................ 8-13
Controller PCB Status LEDs ......................................................................... 8-13
Communication PCB Status LEDs ............................................................... 8-14
AE Solar Energy Technical Support .................................................................... 8-18
Appendix A. Specifications
Physical Specifications ......................................................................................... A-1
Electrical Specifications ....................................................................................... A-1
Efficiency Specifications ................................................................................ A-4
Efficiency Curves for the PVP500kW (480 VAC) Model ......................... A-4
Cooling Specifications .......................................................................................... A-4
Environmental Specifications ............................................................................... A-5
Appendix B. System and Mechanical Diagrams
System Diagram ................................................................................................... B-1
Mechanical Diagrams ........................................................................................... B-2
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List of Tables
Table 1-1. Branch breaker size recommendations ............................................... 1-6
Table 1-2. Acronyms and frequently used terms .................................................. 1-9
Table 3-1. Inverter clearances .............................................................................. 3-2
Table 3-2. Cooling and heat rejection rate requirements ...................................... 3-4
Table 4-1. Subcombiner wire sizing and torque values ...................................... 4-16
Table 4-2. Branch breaker size recommendations ............................................. 4-17
Table 4-3. Operational voltage ranges per electrical panel ................................. 4-18
Table 5-1. Inverter enable/disable ....................................................................... 5-10
Table 6-1. Maximum network length per Modbus bit rate ................................... 6-10
Table 6-2. Inverter address table ........................................................................ 6-13
Table 6-3. Modbus commands ............................................................................ 6-16
Table 6-4. Format for Read Holding Register command ................................... 6-16
Table 6-5. Response format for Read Holding Register command .................... 6-17
Table 6-6. Format for Write Single Register command ....................................... 6-17
Table 6-7. Response format for Write Single Register command ....................... 6-17
Table 6-8. Format for Return Slave ID ................................................................ 6-18
Table 6-9. Format for Return Slave ID command ............................................... 6-18
Table 6-10. Data types ........................................................................................ 6-19
Table 6-11. Modbus fixed information registers .................................................. 6-20
Table 6-12. Inverter model number ..................................................................... 6-21
Table 6-13. Bit mapping for inverter configuration register ................................. 6-21
Table 6-14. Modbus data registers ..................................................................... 6-22
Table 6-15. Modbus status and fault code registers ........................................... 6-23
Table 6-16. Modbus inverter operating status register values ............................ 6-24
Table 6-17. PVM status register status code values ........................................... 6-25
Table 6-18. Modbus command registers ............................................................. 6-26
Table 7-1. Maintenance checklist .......................................................................... 7-3
Table 7-2. Inverter replacement parts ................................................................... 7-4
Table 8-1. Inverter system warnings ..................................................................... 8-4
Table 8-2. Fault categories ................................................................................... 8-8
Table 8-3. Drive (DRV) faults ................................................................................ 8-9
Table 8-4. Voltage (VLT) faults ........................................................................... 8-10
Table 8-5. Grid (GRD) faults ............................................................................... 8-11
Table 8-6. Temperature (TMP) faults .................................................................. 8-12
Table 8-7. System (SYS) faults ........................................................................... 8-12
Table 8-8. Controller PCB LEDs ......................................................................... 8-13
Table 8-9. Link LED ............................................................................................ 8-15
Table 8-10. Activity LED ...................................................................................... 8-15
Table 8-11. Status LED ....................................................................................... 8-16
Table 8-12. Modbus LED .................................................................................... 8-17
Table 8-13. AE Solar Energy Technical Support 24 X 7 contact information ...... 8-18
Table A-1. Physical specifications ........................................................................ A-1
Table A-2. Electrical specifications ...................................................................... A-2
Table A-3. Utility interconnect voltage and frequency trip limits and times .......... A-3
Table A-4. Efficiency specifications for the PVP500kW (480 VAC) model .......... A-4
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Table A-5. Cooling specifications ......................................................................... A-4
Table A-6. Environmental specifications .............................................................. A-5
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List of Figures
Figure 2-1. Components of the AE 500 inverter .................................................... 2-3
Figure 2-2. Power module assembly ..................................................................... 2-4
Figure 2-3. Control electronics compartment ........................................................ 2-5
Figure 2-4. Data monitoring card cage assembly ................................................. 2-6
Figure 2-5. DC combiner sub panel ...................................................................... 2-7
Figure 2-6. DC sub panel ...................................................................................... 2-8
Figure 2-7. AC sub panel ...................................................................................... 2-8
Figure 3-1. Inverter clearances ............................................................................. 3-3
Figure 3-2. DC subcombiner options .................................................................... 3-8
Figure 4-1. Stacked air intake hoods ................................................................... 4-3
Figure 4-2. Placing the air intake hood on the inverter ......................................... 4-4
Figure 4-3. Hinge on the air intake hood - locked and open positions .................. 4-4
Figure 4-4. Attaching the hood's gas springs to the inverter ................................. 4-5
Figure 4-5. Inductor and transformer connections ................................................ 4-6
Figure 4-6. Bus bar connection inspection ............................................................ 4-7
Figure 4-7. Pull test of cable screw terminal connection ....................................... 4-8
Figure 4-8. Screen inspection ............................................................................... 4-8
Figure 4-9. Check the bus bar connections .......................................................... 4-9
Figure 4-10. Fan inspection .................................................................................. 4-9
Figure 4-11. Air filter check ................................................................................. 4-10
Figure 4-12. DC bottom entry gland plates ......................................................... 4-13
Figure 4-13. DC side entry gland plates .............................................................. 4-14
Figure 4-14. Installation of conduit hub ............................................................... 4-14
Figure 4-15. AC connections ............................................................................... 4-20
Figure 4-16. Bus bar connections ....................................................................... 4-20
Figure 4-17. DC connections .............................................................................. 4-22
Figure 4-18. DC subcombiner configurations ...................................................... 4-23
Figure 4-19. DC dead front ................................................................................. 4-24
Figure 4-20. DC inverter connections ................................................................. 4-25
Figure 4-21. Remote disable wiring diagram ...................................................... 4-27
Figure 4-22. Remote disable terminal block ........................................................ 4-28
Figure 4-23. 24 V power supply terminal location ............................................... 4-29
Figure 4-24. 24 V wiring example ....................................................................... 4-30
Figure 5-1. Inverter with AC disconnect power ON ............................................... 5-2
Figure 5-2. Inverter state diagram ......................................................................... 5-3
Figure 5-3. Initialize state screen .......................................................................... 5-5
Figure 5-4. Energy tracking state screens ............................................................ 5-5
Figure 5-5. Fault state screens ............................................................................. 5-5
Figure 5-6. Warning state screen .......................................................................... 5-6
Figure 5-7. Disabled state screen ......................................................................... 5-6
Figure 5-8. Inverter display and switch ................................................................. 5-6
Figure 5-9. Ground fault error message ................................................................ 5-7
Figure 5-10. AC disconnect power OFF ................................................................ 5-8
Figure 6-1. T-568B compliant Ethernet cable ....................................................... 6-2
Figure 6-2. Communication interface PCB Ethernet port location ........................ 6-3
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Figure 6-3. Communication interface PCB in the data monitoring section ............ 6-6
Figure 6-4. Daisy chain layout for RS-485 network: option A ............................... 6-7
Figure 6-5. Daisy chain layout for RS-485 network: option B ............................... 6-7
Figure 6-6. Daisy chain layout for RS-485 network: option C ............................... 6-7
Figure 6-7. Communications interface PCB with Modbus slave port location ....... 6-9
Figure 6-8. Termination switches on the user interface PCB .............................. 6-10
Figure 6-9. Setting the Modbus address ............................................................. 6-12
Figure 6-10. Example: Unit address switch set to address 25 ............................ 6-13
Figure 7-1. Air intake hoods .................................................................................. 7-5
Figure 7-2. Air intake hood in raised position ........................................................ 7-5
Figure 7-3. Card cage air filter .............................................................................. 7-6
Figure 8-1. Warning screen ................................................................................... 8-3
Figure 8-2. Screen sequence when an inverter faults ........................................... 8-5
Figure 8-3. Communication PCB with status LEDs ............................................. 8-14
Figure 8-4. Communication interface PCB with LEDs ........................................ 8-15
Figure A-1. Efficiency curves for the PVP500kW (480 VAC) model .................... A-4
Figure B-1. AE 500 system diagram .................................................................... B-1
Figure B-2. AE 500 mechanical diagram: View 1 ................................................. B-2
Figure B-3. AE 500 mechanical diagram: View 2 ................................................. B-3
Figure B-4. AE 500 mechanical diagram: View 3 ................................................. B-4
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List of Figures
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Chapter
1
Safety and Product Compliance
Guidelines
IMPORTANT SAFETY INSTRUCTIONS
To ensure safe installation and operation of the Advanced Energy AE 500 unit, read
and understand this manual before attempting to install and operate this inverter. At a
minimum, read and follow the safety guidelines, instructions, and practices.
SAVE THESE INSTRUCTIONS
This manual contains important instructions for the AE 500 unit that shall be
followed during installation and maintenance of the unit.
DANGER, WARNING, AND CAUTION BOXES
IN THE MANUAL
This symbol represents important notes concerning potential harm to people, this
unit, or associated equipment. Advanced Energy includes this symbol in Danger,
Warning, and Caution boxes to identify specific levels of hazard seriousness.
1027
DANGER:
DANGER indicates an imminently hazardous situation that, if not avoided,
will result in death or serious injury. DANGER is limited to the most extreme
situations.
DANGER:
DANGER indique une situation dangereuse imminente qui, si elle n’est pas
évitée, pourrait provoquer la mort ou des blessures graves. DANGER est
réservé aux situations les plus extrêmes.
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WARNING:
WARNING indicates a potentially hazardous situation that, if not avoided,
could result in death or serious injury, and/or property damage.
AVERTISSEMENT:
AVERTISSEMENT indique une situation potentiellement dangereuse qui, si
elle n’est pas évitée, pourrait provoquer la mort ou des blessures graves et/
ou des dommages matériels.
CAUTION:
CAUTION indicates a potentially hazardous situation that, if not avoided,
could result in minor or moderate injury, and/or property damage. CAUTION
is also used for property-damage-only accidents.
ATTENTION:
ATTENTION indique une situation potentiellement dangereuse qui, si elle
n’est pas évitée, pourrait provoquer des blessures mineures ou modérées et/
ou des dommages matériels. ATTENTION est également utilisé pour des
accidents causant uniquement des dommages matériels.
SAFETY GUIDELINES
Review the following information before attempting to install and operate the
product.
Rules for Safe Installation and Operation
Please note the following rules:
• Do not attempt to install or operate this equipment without proper training.
• Ensure that this unit is properly grounded.
• Ensure that all cables are properly connected.
• Verify that input line voltage and current capacity are within specifications
before turning on the power supplies.
• Use proper electrostatic discharge (ESD) precautions.
• Always be careful around this equipment.
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Safety and Product Compliance Guidelines
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PERSONAL SAFETY
Ensure any personnel entering a safety zone within a four foot area around any
operating inverter wear appropriate Personal Protective Equipment (PPE) as
mandated by national, state, and local authorities.
Medical and First Aid Treatment
Personnel working in and around operating power generation equipment should be
trained in Arc Flash Hazard, Fire Extinguisher selection and use, First Aid, Cardio
Pulmonary Resuscitation (CPR), and Automated External Defibrillator (AED) use (if
available).
Safety Equipment Requirements
Authorized service personnel performing operations on this unit should have the
following minimum safety equipment available:
• Consult NFPA 70E, or applicable local standards, for PPE requirements on
switch gear operating at less than 600 V
• Electrical hazard footwear (ANSI Z41/Z85 rated)
• Lock Out Tag Out (LOTO) Kit
• Appropriate meter to verify the circuits are safely de-energized (1000 VAC and
DC rated, minimum)
• Any other equipment as applicable to your operation as required by national,
state, and local regulations
INTERPRETING PRODUCT LABELS
The following labels may appear on your unit:
Earth ground
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Chassis ground
On or off
4588
4589
or
Phase
4590
Electrical fuse
1025
1026
4205
Alternating current
Direct current
Positive ground
Negative ground
PRODUCT COMPLIANCE
The following sections include information about unit compliance and certification,
including the conditions of use required to be in compliance with the standards and
directives.
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Safety and Product Compliance Guidelines
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Safety and EMC Directives and Standards
Certain options of this unit have been tested for and comply with the following
electromagnetic compatibility (EMC) and safety directives and standards and
industry guidelines.
☞ Important
This equipment must be installed and used in accordance with the Conditions
of Use described in this manual. If this equipment is expanded, modified, or
installed into a larger system, the user is responsible to guarantee the
compliance of the overall system. If this equipment is used with external
components, the user must ensure that the Safety and EMC requirements are
not violated.
SAFETY DIRECTIVES AND STANDARDS
• UL1741
Inverters, Converters, Controllers and Interconnection System Equipment for
Use With Distributed Energy Resources (2010)
◦ IEEE 1547
Standard for Interconnecting Distributed Resource with Electric Power
Systems
◦ IEEE 1547.1
Standard for Conformance Tests Procedures for Equipment Interconnecting
Distributed Resources with Electric Power Systems
• FCC Part 15 Class A conducted emissions
• CSA C22.2 No. 107.1-01
General use power supplies—industrial products
• National Electrical Code
Can be installed in compliance with National Electrical Code 2008 and 2011
Editions Article 690 Solar Photovoltaic Systems
Electrical Safety
DISCONNECT SWITCH
The inverter is equipped with an AC disconnect (power OFF) to stop power
conversion within the inverter. Before accessing the interior of the cabinet, this
disconnect must be in the OFF position. Since this disconnect only stops power
conversion within the inverter, both the external (or optional inverter integrated) DC
(photovoltaic array) and AC (utility grid) circuits must be isolated in order to fully
ensure the inverter is de-energized. Wait five minutes for the inverter to de-energize
before working on the inverter.
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AC/DC DISCONNECT DEVICE AND OTHER REQUIREMENTS
If the optional inverter integrated AC disconnect and inverter integrated DC
subcombiner breakers were not selected, then isolated disconnect devices must be
provided for both the PV array DC connection and for the AC utility grid connection
when installing an AE inverter.
AC DISCONNECT DEVICE, OVERCURRENT PROTECTION,
AND TRANSFORMER REQUIREMENTS
If the optional inverter integrated AC disconnect was not selected, then you must
install an AC disconnect and overcurrent protection device at the AE inverter that
complies with National Electric Code ANSI/NFPA 70 and local building code
requirements, whichever is more restrictive. The AC disconnect must be rated for
480 VAC at the maximum overcurrent protection setting, typically 1.25 * IAC
maximum. You must connect the inverter to a three-phase 480 VAC grounded wye
feeder or an 800 A service. Refer to the table below.
DC DISCONNECT DEVICE AND FUSE REQUIREMENTS
If the optional DC subcombiner circuit breakers were not selected, then you must
provide a DC disconnect and fusing for each section (or sub-array) of the PV array.
The disconnect must be rated for the voltage and the current rating of the
photovoltaic array connected to the inverter. The DC disconnect installation must
comply with your national and local electrical code.
Wiring Requirements
You must meet the following requirements when wiring the AE 500 inverter:
Table 1‑1. Branch breaker size recommendations
Model
AE 500
208 VAC
480 VAC
600 VAC
N/A
800 A
N/A
WIRING INFORMATION
☞ Important
You must use National Electrical Code (ANSI/NFPA 70) wiring methods.
DANGER:
Do not connect the PV negative or positive conductors to the ground bus
bars provided. The PV array is grounded through the integral GFDI.
Connecting the PV array positive or negative conductors to ground at any
other point in the system would defeat the ground fault protection circuit.
1‑6
Safety and Product Compliance Guidelines
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Advanced Energy® AE 500 Inverter
DANGER:
Ne pas brancher les conducteurs négatifs ou positifs du PV aux barres
omnibus mises à la terre fournies. Le panneau photovoltaïque est mis à la
terre au moyen du GFDI. La connexion des conducteurs positifs ou négatifs
du panneau photovoltaïque à la terre à tout autre point du système pourrait
déjouer le circuit de protection contre les défauts de terre.
• All wiring methods and materials shall be in accordance with the National
Electrical Code ANSI/NFPA 70 as well as all state and local code requirements.
• When sizing conductors and conduits for connection to the AE 500 inverter,
both shall be in accordance with the National Electrical Code ANSI/NFPA 70,
as well as state and local code requirements.
• The AC power conductor bus bar connections in the inverter should be
tightened to the torque value specified in the installation instructions. Each
conductor should be connected separately to the bus bar.
• The DC power conductor bus bar connections in the inverter should be
tightened to the torque value specified in the installation instructions. Each
conductor should be connected separately to the bus bar.
• AC overcurrent protection for the utility interconnect (grid-tie) must be
provided by the installers as part of the inverter installation.
• Installations in Canada should be in accordance with the Canadian Electrical
Code (CEC) or applicable local standards.
• Use only conductors with an insulation rating of 90°C minimum insulation
rating.
• This equipment is intended to be installed as part of a permanently grounded
electrical system per the NEC or local standards.
The inverter is electrically connected to the DC photovoltaic array in the DC
combiner sub panel which includes a positive, negative, and grounded bus bar. The
PV array is grounded internally by means of the GFDI.
The inverter can be ordered with an optional subcombiner with DC circuit breakers.
The subcombiners have individual input terminals for each circuit breaker. These
terminals require the use of a torque wrench to properly install the interface cables.
Use proper torque values of DC subcombiner box wire mounting hardware.
The inverter is factory configured for the appropriate three-phase output:
• AE 500 is 480 VAC
The inverter is electrically connected to the utility grid at the AC landing within the
AC section on the front right side of the inverter. These terminals require the use of a
UL-approved connector certified for use with the selected interface cables:
• Crimp-on type ring terminal
• Compression type lug
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Advanced Energy
Ensure phase cables run together through conduit and gland plates, which allows any
inductive currents produced to be cancelled out. Use proper torque values for
terminal lug mounting hardware.
A copper clad earth grounding electrode must be installed within three feet (one
meter) of the unit. The AC ground busbar located in the AC section, lower front
compartment, must be used as the single point connection to the earth grounding
electrode for the inverter system. For the convenience of installers, a DC ground bus
bar is provided. The DC and AC ground bus bars are solidly bonded together inside
the cabinet. If present, a DC Grounding Electrode Conductor (GEC) may be bonded
to the DC ground bar. Where permitted by NEC, a single conductor that meets all the
requirements of both DC GEC and AC equipment ground may be bonded to the AC
ground bar.
AC overcurrent protection for the utility interconnect (grid-tied) must be provided by
installers as part of the installation.
Fire Prevention
Care must be exercised when installing DC and AC connections within the inverter.
Follow all instructions in this manual to ensure proper and safe operation of this unit.
DANGER:
Risk of electrical shock. In the event of a fire, disconnect power to the
inverter and do not attempt to use a water based fire extinguisher. Utilize
only a Class C extinguisher rated for electrical fire.
DANGER:
Risque d’électrocution. Dans l’éventualité d’un incendie, débranchez
l’onduleur du secteur et n’utilisez pas d’extincteur à base aqueuse. Utilisez
uniquement les extincteurs de classe C conçus pour combattre les feux
électriques.
LOCKOUT AND TAGOUT REQUIREMENTS
To prepare the AE 500 unit for maintenance or troubleshooting, you must deenergize and isolate the AC and the DC interface energy sources before working on
the unit.
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Advanced Energy® AE 500 Inverter
ACRONYMS AND FREQUENTLY USED
TERMS
Table 1‑2. Acronyms and frequently used terms
Term
Description
Action delay
A predefined delay before a set point change.
A/D
Analog to digital conversion
ANSI
American National Standards Institute
BEMS
Building energy management system
CFM
Cubic feet per minute
Curtailment
A reduction of the power output level for scheduled capacity or
energy delivery. Allows limiting of system output power. Also
known as power throttling.
DHCP
Dynamic host configuration protocol
DNS
Domain name service
DSP
Digital signal processor
DVI
Digital video interface
EMI
Electromagnetic interference
ESD
Electro static discharge
GEC
Grounding electrode conductor
GFDI
Ground fault detector interruptor
IEEE
Institute of Electrical and Electronics Engineers
IGBT
Insulated gate bipolar transistor
Inverter
Also called the switching section or engine, this is the part of the
unit that inverts DC current to AC current.
IP
Internet protocol
Lagging
Current follows, or lags, voltage in an inductor. A source
producing power with a lagging power factor reduces the utility
grid voltage.
Leading
Current leads the voltage in a capacitor. A source producing
power with a leading power factor increases the grid voltage.
LOTO
Lockout Tagout
MCM
1000 circular mils utilized in wire sizing
MPPT
Maximum power point tracking
NEC
National Electric Code
NFPA
National Fire Protection Association
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Advanced Energy
Table 1‑2. Acronyms and frequently used terms (Continued)
Term
Description
NTP
Network time protocol
OEM mode
Original equipment manufacturer mode
PCB
Printed circuit board
PF
Power factor
PLL
Phase lock loop
PPE
Personal protective equipment
PV
Photovoltaic
PVM
PV monitoring
PVM Sync
Software application used to query inverters.
PWM
Pulse width modulation
Ramp rate
Changes in the inverter's power output at a controlled rate either
to increase or decrease power delivery.
Randomize
Allows a random delay before a set point change. The delay will
change every set point change.
Remote enable/ The inverter system can be remotely turned on or off. The
disable
inverter restarts after a five minute countdown.
1‑10
RMS
Root mean squared
SCADA
Supervisory control and data acquisition. A computer system that
monitors and controls infrastructure or facility-based processes.
Set point
Inverter is operating and delivering power at defined parameters.
SPF
Scheduled power factor
SVAr
Static volts-amps reactive
UL
Underwriter's Laboratory
UTC
Universal time coordinate. Also known as Greenwich mean time.
VAC
Voltage alternating current
VAr
Volts-amps reactive
VDC
Voltage direct current
VFD
Vacuum fluorescent display
Voc
Voltage open circuit
Safety and Product Compliance Guidelines
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Advanced Energy® AE 500 Inverter
Chapter
2
Product Overview
GENERAL DESCRIPTION
The Advanced Energy inverter is designed to act exclusively as a grid-tied inverter
for photovoltaic (PV) systems. The inverter converts direct current (DC) electricity
generated by the photovoltaic arrays into usable alternating current (AC) electricity.
This means the inverter must be tied to the utility grid and a photovoltaic system in
order to operate properly. Because the inverter is tied to a local utility source, if local
electrical load exceeds the power generated by the solar array, the grid automatically
supplies the additional electricity needed. Likewise, if the inverter produces more
power than is needed, it feeds the excess power back into the electrical grid.
Advanced Energy Inverter Models
This manual provides the information necessary to successfully install and operate
the applicable Advanced Energy inverter.
Within the AE product line some inverter models can be factory configured with
different three-phase outputs. See the specifications for more information.
For specific product characteristics, refer to the specifications in Appendix A.
DESIGN FEATURES
• Easy installation: The AE inverter is built for easy installation. To minimize
installation efforts, this inverter features an integrated isolation transformer and
optional integrated AC disconnect in a compact single cabinet. The inverter can
be ordered with a range of DC subcombiner designs for maximum adaptability
for the desired system operating scheme.
• Simple, innovative design: The AE inverter is a fully integrated solution with
standard integrated data monitoring available and an optional premium data
monitoring solution. This modular design enables rapid field service and
upgrades. The inverter can quickly and easily be installed in any location,
indoors or out.
• Adaptability: The PV Powered inverter has a standard DC Maximum Power
Point Tracking (MPPT) range from 310 V to 595 V.The maximum input
voltage is 600 VDC.
• Versatility: The AE inverter is designed for flexibility and can be used for a
range of commercial applications, accommodating most PV system
configurations.
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PRODUCT FEATURES
The design of the AE 500 inverter includes the following standard features.
• Equipped with redundant cooling system with variable speed fans and fault
detection. The built-in backup capabilities enables the inverter to deliver full
power at the maximum rated temperature even if one of the fans should fail.
Fan status is reported as a warning shown on the display and through remote
monitoring.
• Includes anti-islanding protection and monitoring functions to prevent the
inverter from feeding power to the utility grid in the event of a utility outage.
• Utilize EMI input and output filtration to prevent electromagnetic interference.
• Field-selectable voltage and frequency trip points constantly track the AC
current within the unit, limiting the inverter current output.
• Remote monitoring system using a standard Ethernet data reporting and
communications interface PCB. With a high speed connection, this interface
can provide PV system performance data in the following methods:
◦ Subscribe to the standard monitoring service on the secure AE website. This
recommended method allows the user to track the PV system and inverter
information online. The basic monitoring service is available to all registered
users.
◦ Provide data to incentive-based performance monitoring and reporting
programs for third parties.
• Inverter control through Modbus/TCP or Modbus/RTU for standard and
optional features:
◦ Power curtailment
◦ Power factor control
◦ Monitoring
◦ Remote disable
• Inverter remote disable for remote control by opening an external switch or set
of contacts.
2‑2
Product Overview
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Advanced Energy® AE 500 Inverter
MAJOR COMPONENTS AND FUNCTIONAL
PARTS
Data monitoring
Air intake hood
Power module assembly
Control electronics
Display
DC sub panel
AC sub panel
Ripple filter
DC landing
DC combiner sub panel
Figure 2‑1. Components of the AE 500 inverter
The modular design of the inverter makes them easy to access and service. As shown
in the preceding illustration the inverter is composed of two main sections:
• The upper compartments contains the power module assembly for the power
conversion electronics including:
◦ Power module assembly
◦ Control printed circuit boards (PCB)
◦ Power distribution PCB
◦ Power supply
◦ Active cooling system
◦ Dedicated data monitoring in the left compartment
• The lower and magnetics compartments house the following:
◦ DC combiner sub panel contains the optional DC breaker subcombiner,
optional subcombiner monitoring, and the positive, negative, and ground bars
◦ DC sub panel with the DC line filter, DC surge protection, and DC contactor
◦ AC sub panel with AC output filtering, surge protection, optional AC
disconnect, and AC connection points
◦ Magnetics compartment contains the isolation transformer and inductors
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Advanced Energy
Power Module Assembly
The inverter uses insulated gate bipolar transistors (IGBTs) for converting DC power
into three-phase AC power. The inverter is protected by over-current, over-voltage,
and over-temperature detection controls. If a protection system is activated, the
power module will cease power conversion and send an interrupt signal to the digital
signal processor (DSP).
Power module assembly
Figure 2‑2. Power module assembly
Control Electronics
The control electronics PCB is located in the upper right compartment. This PCB
includes the control electronics card cage and the ground fault detector interrupter
(GFDI) circuit. The purpose of the GFDI is to detect a ground fault (unintended
current flow from the solar panels to earth ground) and in the event of a ground fault,
stop AC power production.
The control electronics card cage houses the following PCBs:
• Power distribution PCB: Distributes the required logic level voltages for use
throughout the inverter.
• Controller PCB: Contains a powerful DSP that controls sine wave generation,
logic functions, and protection activities. All analog and digital inputs and
outputs are routed to the control PCB and fed to the DSP.
• Inverter interface PCB: Provides a central location for a range of input, output,
and control circuits.
2‑4
Product Overview
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Advanced Energy® AE 500 Inverter
Control electronics compartment
GFDI
Control electronics backplane
Control electronics card cage
Figure 2‑3. Control electronics compartment
WARNING:
Risk of electrical shock. The GFDI functions using a fuse to connect or bond
the solar array negative (or the solar array positive, if using a positively
grounded panel array) to earth ground.
AVERTISSEMENT:
Risque d'électrocution. Les fonctions GFDI utilisent un fusible pour connecter
ou lier le négatif du panneau solaire (ou le positif du panneau solaire, si l’on
utilise un panneau mis à la masse du positif) à la prise de terre.
If the ground fault current exceeds 5 A between the grounded array terminal and the
earth ground, the GFDI fuse will open and disconnect the solar panels from their
ground reference, interrupting the ground fault. In this situation, the inverter will
cease operation, display a fault message, and the LED on the inverter interface PCB
will illuminate red. If a GFDI current of 3 A to 5 A exists, the inverter will indicate a
ground fault warning.
Data Monitoring Card Cage
The data monitoring compartment in the upper left section of the inverter houses the
data monitoring and the communications interface PCBs along with the optional AE
premium data monitoring gateway.
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Product Overview
2‑5
Advanced Energy
The data monitoring card cage houses the following:
• Communications PCB: Provides serial, internet, and Modbus communications.
• Power distribution PCB: Distributes the required logic level voltages for use
throughout the inverter.
• User interface PCB: Provides accessible DIP switches for Modbus addressing
and termination.
The data monitoring card cage assembly in the following figure is designed to enable
fast and easy service and also acts as an EMI shield to ensure signal integrity on the
PCBs.
Data monitoring card cage
User interface PCB
DIP switches
Communications PCB
Power distribution PCB
Figure 2‑4. Data monitoring card cage assembly
COMMUNICATIONS INTERFACE PCB
The communications interface PCB is the backplane for the data monitoring card
cage assembly. This PCB contains the following:
• RJ45 Ethernet port that is used to connect the inverter to the internet
• Modbus/RTU connection
• Serial port is available for AE Solar Energy Technical Support use only
• Remote disable and inverter status connections
• 24 V auxiliary power supply connector
Operator Interface Controls
The vacuum fluorescent display (VFD) located on the front upper right of the inverter
cabinet includes both a digital display screen and two buttons. The display screen
shows the inverter's state, scrolling continuously through the screens. The Scroll/
Pause button controls the display screen and the ON/OFF switch enables or disables
the inverter.
2‑6
Product Overview
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Advanced Energy® AE 500 Inverter
Active Cooling System
The inverters come with fans which activate as needed to keep the internal
components within preset temperature limits. These fans are located on each side of
the inverter.
DC Combiner Sub Panel
The DC combiner sub panel compartment is where the inverter connections to the PV
source circuits are completed, including the positive, negative, and ground bus bars.
Optional DC circuit breaker subcombiner and subcombiner monitoring are also
located in the DC combiner sub panel if selected.
Ground bus bar
DC positive bus bar
Figure 2‑5. DC combiner sub panel
DC conductors from the array can enter through the side gland plate or through the
collared chase in the base of the inverter.
DC Sub Panel
This lower middle compartment for the DC sub panel houses the DC line filter, DC
contactor, DC surge protection, and DC voltage sense fusing.
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Advanced Energy
DC line filter
DC surge protection
DC contactor
DC current shunt
Figure 2‑6. DC sub panel
AC Sub Panel
The AC landing, AC surge protection, soft start contactor and ground reside in the
AC sub panel. The sub panel also includes the optional AC disconnect and revenue
meter.
Optional revenue meter
AC surge
Soft start contactor
Optional AC disconnect
AC landing
Ground
Figure 2‑7. AC sub panel
2‑8
Product Overview
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Advanced Energy® AE 500 Inverter
Housekeeping Transformer
The housekeeping transformer, located in the upper right in the control electronics
compartment, is a voltage conversion device that transforms 480 VAC to
120/160 VAC for use within the inverter.
Magnetics Compartment
The magnetics compartment contains the isolation transformer and the inductors.
• Isolation transformer: The inverter comes equipped with an integral isolation
transformer. The isolation transformer is designed for class-leading inverter
efficiency.
• Inductor: The inductor is used to filter the AC waveform generated by the
power module, effectively reducing high frequency noise.
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Advanced Energy
2‑10
Product Overview
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Advanced Energy® AE 500 Inverter
Chapter
3
Planning
GENERAL REQUIREMENTS FOR PLANNING
AND INSTALLATION
Planning for an installation of an AE inverter should only be performed by qualified
engineers with a thorough understanding of the processes involved for a successful
installation. Licensed and trained installers must comply with all local and national
code requirements for the installation of electrical power systems with AC and DC
voltages to 600 V.
The inverter must be anchored to a concrete mounting pad. The mounting pad must
meet local seismic requirements. Refer to the mechanical drawings in this manual for
optional seismic-rated concrete pad mounting requirements.
HANDLING THE INVERTER
WARNING:
Heavy equipment. AE 500 units weigh up to 4,140 kgs (9,100 lbs) with pallet
and packaging. If the unit is lifted incorrectly, it may result in death. In
addition, improper handling may result in serious damage to the unit and may
also void the warranty. Keep all doors securely closed while moving the unit.
Only use lifting equipment that is rated for the weight of the unit. Only use the
specified lifting points.
AVERTISSEMENT:
Équipement lourd. Les unités AE 500 pèsent jusqu’à 4,140 kgs (9,100 lbs)
avec palettes et emballage. Tout levage inadéquat de l’unité peut provoquer
la mort. De plus, toute manipulation inadéquate peut provoquer des
dommages graves à l’unité et pourrait aussi annuler la garantie. Garder
toutes les portes bien fermées lors du déplacement de l’unité. Utiliser
uniquement un équipement de levage d'une capacité nominale convenant au
poids de cette unité. Utiliser uniquement les points de levage spécifiés.
The inverter can weigh up to 4,140 kgs (9,100 lbs) with their pallet and packaging. If
the inverter is improperly handled, serious damage can occur and the warranty may
be voided. Only use lifting equipment that is rated for the weight of the inverter. Only
use the specified lifting points. Leave the inverter on its shipping pallet with the
protective plastic wrap in place until it is time to install.
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Planning
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Advanced Energy
☞ Important
Do not lift the inverter from the upper bolt points.
Handling Options
The AE 500 inverter may also be moved using lifting bars inserted through the front
to back fork slot openings.
☞ Important
Use only the front and rear fork slots. Do not use side slots to move the
inverter.
STORAGE
Prior to installation, the inverter should be stored in a non-condensing environment to
avoid potential rust and corrosion. Remove the transport bag when the inverter is
received. If the hood scoops are not installed, both hood scoops will need to be
installed immediately.
LOCATION AND CLEARANCES
Location
Select a suitable location to install the inverter. The inverter must be installed on a
flat, solid surface such as a concrete pad.
Noise
The inverter is capable of emitting audible switching noise and should be located
away from noise sensitive areas that are populated by people or animals.
Recommended Clearances
Working clearances must comply with your national and local electrical code.
Table 3‑1. Inverter clearances
Location
Front
3‑2
Distance
36″
Description
The front clearance is required to open and maintain the unit or as
required by local code.
Planning
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Advanced Energy® AE 500 Inverter
Table 3‑1. Inverter clearances (Continued)
Location
Distance
Description
Rear
24″
The rear clearance is required behind the inverter to allow room for full
opening of the air intake hoods.
Sides
36″
The minimum side clearances are 36″ in order open the side panels and
work on internal components when neessary.
Top
27.5″
The top clearance is required above the air intake hoods to maintain the
filters.
Clearances are shown in the figure below.
27.5”
36”
24”
36”
36”
Figure 3‑1. Inverter clearances
CONDUIT AND CONDUCTORS
All the external conduit and conductors are to be supplied by the installer. All
interconnect wiring and power conductors interfacing to the inverter must be in
accordance with national and local electrical code. All conductors shall be rated for
90°C (minimum).
Large gauge wire must conform to the minimum bend radius specified by applicable
national and local codes.
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External cable interfaces are through bottom or side gland plates. The gland plates
must be in place for operation of the inverter. Gland plate locations are included on
the mechanical drawings in the appendix.
ENVIRONMENTAL REQUIREMENTS
The unit may be installed either indoors or outdoors. If the installation of the inverter
is outdoors, all interconnect conduit and fittings must be rated NEMA 4 (same as the
inverter rating) as required by the NEC. For high temperature locations a shade
structure should be placed over the unit in order to reduce thermal stress and extend
the product's life.
Inverter power output will be de-rated for ambient temperatures in excess of 55°C/
131°F.
Table 3‑2. Cooling and heat rejection rate requirements
Requirement
Rate
Description
Cooling air flow rate
(maximum)
3,800 CFM
No external intake or
exhaust air ports are
required in the building if
air flow volume needs are
met.
Heat rejection rate
(maximum)
78,500 BTM/hr
n/a
GROUNDING AND NEUTRAL
REQUIREMENTS
PV Array Frame Grounding
DANGER:
Do not connect the PV negative or positive conductors to the ground bus
bars provided. The PV array is grounded through the integral GFDI.
Connecting the PV array positive or negative conductors to ground at any
other point in the system would defeat the ground fault protection circuit.
3‑4
Planning
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Advanced Energy® AE 500 Inverter
DANGER:
Ne pas brancher les conducteurs négatifs ou positifs du PV aux barres
omnibus mises à la terre fournies. Le panneau photovoltaïque est mis à la
terre au moyen du GFDI. La connexion des conducteurs positifs ou négatifs
du panneau photovoltaïque à la terre à tout autre point du système pourrait
déjouer le circuit de protection contre les défauts de terre.
CAUTION:
The inverter may be factory configured for either positive or negative ground.
It may NOT be field configured to a different grounding once it is shipped
from the factory. To identify if your inverter is configured for positive or
negative ground read the label next to the DC landing bus bar. Verify that the
grounding configuration matches your installation grounding plan. If you need
to reconfigure the ground, contact Advanced Energy for assistance. DO NOT
ground either DC lead at the time of installation. This will defeat the integral
GFDI circuit.
ATTENTION:
L’inverseur peut être configuré à l’usine pour une mise à la terre positive ou
négative. Il ne peut PAS être configuré sur le terrain à une mise à la terre
différente une fois qu’il a été expédié de l’usine. Pour savoir si votre
inverseur est configuré pour une mise à la terre positive ou négative, lire
l’étiquette près de la barre omnibus CC. Vérifier que la configuration de mise
à la terre correspond à votre plan de mise à la terre d’installation. Si on a
besoin de reconfigurer la mise à la terre, contacter Advanced Energy pour de
l’aide. NE PAS mettre à la terre le fil CC au moment de l’installation. Cela
déjouerait le circuit GFDI.
The inverter incorporates an integral GFDI device. The PV array safety ground
(frame ground) may be attached to the provided grounding bus bar. The grounding
bus bar is located in the DC combiner sub panel compartment. The PV array is
grounded internally by means of the GFDI.
The inverter is shipped preconfigured with positive or negative PV array grounding
based on the preference specified when the order is placed.
System Neutral
The inverter has been certified to national standards for installation without a neutral
conductor. Do not connect a neutral conductor from the AC service panel to the
inverter.
WARNING:
The AC output/neutral must not be bonded to ground within the equipment.
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Advanced Energy
AVERTISSEMENT:
La sortie et le neutre CA ne doivent pas être branchés à la masse à
l’intérieur du dispositif.
UTILITY GRID INTERCONNECTION
Utility Connection Requirements
Review all applicable national or local codes for specific requirements for the size of
the electrical service and the amount of current that is allowed to be fed into the panel
by the inverter.
Contacting Your Local Utility
Contact your electrical utility before connecting the inverter to ensure there are no
local restrictions or special requirements. Your local utility company may require
specific inspections, equipment, or other procedures not covered in this document.
Voltage Output
This inverter is designed to be connected to a three phase, grounded, wye
transformer. The AC output voltage is available on the inverter data plate for the
output voltage wye configuration. Do not change the output voltage of the inverter.
AC and DC power requirements are included in the specifications.
Related Links
• “Specifications” on page 9-1
INVERTER MONITORING
The inverter is equipped with a data monitoring module that can be used to monitor
the inverter through one of the following interfaces:
• Basic performance data can be accessed using a free web-based monitoring
service provided by AE.
• Locally through a third party monitoring system using Modbus/TCP or
Modbus/RTU.
3‑6
Planning
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Advanced Energy® AE 500 Inverter
Related Links
• “Data Monitoring and Controls” on page 6-1
CALCULATING DC INPUT VOLTAGE
To Calculate Maximum Open Circuit Voltage
• Calculate the maximum open circuit (no load) voltage for each series module
connection. Refer to the Advanced Energy Solar Energy web site and select the
String Calculator to calculate the input from the PV array.
Contact AE Solar Energy Technical Support if you require assistance
calculating the maximum DC input voltage for your array at your specific
location.
☞ Important
Each DC input connection must be wired to deliver the same input voltage.
☞ Important
For all temperature conditions, the open circuit voltage for each series
connection must be less than or equal to 600 VDC.
DC COMBINER SUB PANEL OPTIONS
The inverter comes with standard positive and negative bus bars for landing DC
inputs from the PV array.
An optional DC circuit breaker subcombiner can be factory installed. Standard
configurations include 8, 16, or 20 DC circuit breaker configurations are available as
shown in the figure below. Monitoring can be included on the 8 and 16 circuit
breaker configurations.
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Advanced Energy
8 circuit option
16 circuit option
8 circuit with
monitoring option
20 circuit option
16 circuit with
monitoring option
Figure 3‑2. DC subcombiner options
Breaker Protection for DC Input
The installer is responsible for providing proper over current protection for the DC
input circuit if the subcombiner circuit breaker option is not included.
3‑8
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Advanced Energy® AE 500 Inverter
Chapter
4
Installing
HANDLING AND UNPACKING
This section describes the required safe handling and unpacking procedures for the
AE inverter. Always follow the recommendations in this section to prevent accidental
damage or injury.
WARNING:
Heavy equipment. AE 500 units weigh up to 4,140 kgs (9,100 lbs) with pallet
and packaging. If the unit is lifted incorrectly, it may result in death. In
addition, improper handling may result in serious damage to the unit and may
also void the warranty. Keep all doors securely closed while moving the unit.
Only use lifting equipment that is rated for the weight of the unit. Only use the
specified lifting points.
AVERTISSEMENT:
Équipement lourd. Les unités AE 500 pèsent jusqu’à 4,140 kgs (9,100 lbs)
avec palettes et emballage. Tout levage inadéquat de l’unité peut provoquer
la mort. De plus, toute manipulation inadéquate peut provoquer des
dommages graves à l’unité et pourrait aussi annuler la garantie. Garder
toutes les portes bien fermées lors du déplacement de l’unité. Utiliser
uniquement un équipement de levage d'une capacité nominale convenant au
poids de cette unité. Utiliser uniquement les points de levage spécifiés.
Packaging Contents
The following items are included with the inverter when it is packaged for shipping:
• Manual
• Warranty card
• Final test report
• Keys for door handles
Handling and Unpacking the Inverter
TOOLS REQUIRED
• Two 3/4″ wrenches or one wrench and one 3/4″ socket wrench
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• Lifting device such as a forklift or pallet jack
• Utility knife
The inverter can be moved using a forklift or pallet jack that is rated to handle a
minimum of 4,140 kgs (9,100 lbs).
TO UNLOAD AND UNPACK THE INVERTER
1. Lift and move the inverter using the shipping pallet.
Do not penetrate the packaging or use the inverter base for unloading.
2. Remove the protective plastic wrap encasing the inverter.
If no damage is apparent, proceed with the next step. If you do see signs of
shipping damage, contact AE Solar Energy Technical Support and the carrier
immediately.
3. Using a 3/4″ wrench, loosen the bolts and nuts securing the inverter to the
pallet.
Installing the Air Intake Hoods
The air intake hoods may ship in separate packaging from the inverter. If the air
intake hoods are separate, both air intake hoods must be installed as soon as the
protective blue shipping wrap is removed from the inverter. The air intake hoods
prevent water and foreign objects from entering the inverter cabinet.
TOOLS REQUIRED
• Lifting device such as a forklift or overhead crane
• Lifting strap or chain
• Spreader bar
• Eyebolts
• Utility knife
• Flat head screwdriver
TO INSTALL THE AIR INTAKE HOODS
The air intake hoods are installed one at a time. After completing these steps for the
first hood, repeat the steps for the second hood.
1. Unstack the air intake hoods and set them side by side.
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Advanced Energy® AE 500 Inverter
Hood lifting point
Lifting point with eyebolt
Figure 4‑1. Stacked air intake hoods
2. Insert eyebolts through the lifting point holes on each end of one air intake
hood. Secure the eyebolts.
3. Connect a lifting strap securely to each eyebolt.
☞ Important
Use a spreader bar to prevent the lifting straps from crushing the air
intake hood.
4. Lift the air intake hood using the eyebolt as the lifting point.
☞ Important
Lift the air intake hood from the proper hoisting points only. Each hood
weighs 40 pounds.
As the air intake hood clears the ground, the hood rotates on the eyebolts,
settling into a correctly oriented position for installation. Carefully guide the
hood with your hands, if necessary, to prevent the hood from swinging.
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Rear hinges
Figure 4‑2. Placing the air intake hood on the inverter
5. Set the two back hinges on the rear edge of the air intake hood, on the rear top
edge of the inverter cabinet while aligning the hinge barrels.
6. Rotate the tab on each hinge to unlock the pin. Slide the pin into the cabinet
side of the hinge barrel and lock into place by rotating the tab. This secures the
back hinges.
Hinge in locked, open position
Hinge in locked, closed position
Figure 4‑3. Hinge on the air intake hood - locked and open positions
7. Remove the tape from the unattached end of the gas springs.
The other end of the gas springs are factory installed to the air intake hood.
8. Lower the loose end of the gas springs to the cabinet and snap into place on the
ball on the inside of the inverter cabinet.
Once the gas springs are attached to the cabinet, they will hold the hood open.
4‑4
Installing
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Advanced Energy® AE 500 Inverter
Gas spring
Ball
Figure 4‑4. Attaching the hood's gas springs to the inverter
9. Remove the lifting strap and the eyebolts from the installed air intake hood.
10. Close the air intake hood.
11. Using a slotted screw driver, engage all three latches, by rotating clockwise, to
secure the front edge of the air intake hoods. Align the two dimples on the latch
bezel to ensure a tight seal.
☞ Important
The first air intake hood must be securely latched and the eyebolts
removed before installing the second hood.
PRE-INSTALLATION INSPECTION
Before placing and installing the inverter, the inverter should be inspected to identify
possible external and internal shipping damage. If a problem is identified during any
of these inspection steps contact AE Solar Energy Technical Support.
Pre-Installation Inspection Tools
The following tools are needed to perform the pre-installation inspection of the
inverter:
• Large flat blade (common) screwdriver
• Access door entry key
• Hex wrench
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Step 1: External Inspection
1. Inspect the shipping materials and the inverter for any cosmetic or structural
damage. Specifically look for any structural damage or crushing of the base or
doors.
2. Confirm all doors open freely and easily.
The front doors on the main compartments of the inverter have a rotating hand
latch with integral key lock to secure the main compartment doors. All other
access doors on the inverter require that a flat blade screwdriver latch be
released in order to open the doors.
☞ Important
If the DC circuit breaker option is included, the DC sub panel
compartment will not have a locking door.
Step 2: Inspection of Rear Magnetics
1. Using a hex wrench remove the large cover plates on the back of the inverter to
access the magnetics.
2. Inspect all nine connections including the following:
a. Three into the inductors
b. Three from the inductors to the transformer
For each connection check the integrity of the bus bar connections and
terminals.
Inspection locations
Figure 4‑5. Inductor and transformer connections
4‑6
Installing
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Advanced Energy® AE 500 Inverter
3. Check the screens at the bottom of the compartment for damage or debris.
4. Replace the cover plates. Make sure the gaskets are not damaged during
replacement of the plates. Do not overtighten the screws.
Step 3: AC and DC Sub Panel Compartments
1. Check the integrity of the bus bar connections and terminals for each bus bar
landing in the AC and DC compartments.
Connection inspection
Figure 4‑6. Bus bar connection inspection
2. Ensure the cable connections are plugged in and fully seated.
3. Inspect and pull test all cable screw terminal connections.
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Cable screw terminals
Figure 4‑7. Pull test of cable screw terminal connection
4. Inspect the screens at the bottom of the compartment for damage or debris.
DC bottom entry gland plate
4686
Figure 4‑8. Screen inspection
If any loose wires are found during the inspections, and the correct location of
the connection is unknown, contact AE Solar Energy Technical Support.
Step 4: Power Module Compartment
• Check the integrity of the bus bars and their connections in the upper power
module compartment.
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4678
Bus bar connections
Figure 4‑9. Check the bus bar connections
Step 5: Upper Active Cooling Compartment
1. Ensure the fans spin freely.
Screws
Check connections
Check connections
Figure 4‑10. Fan inspection
2. Ensure all air filters are fully seated.
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Air filters
4680
Figure 4‑11. Air filter check
This completes the pre-installation inspections.
LIFTING AND MOUNTING THE INVERTER
The inverter base is designed to allow a properly rated forklift to lift it from the front
or back using the fork slots.
☞ Important
Before installing the inverter, make sure the pre-installation inspection steps
have been completed and no issues have been identified.
Mounting Requirements
When mounting the inverter, consider the following requirements:
• Mount the unit on a flat surface in an upright position.
• The mounting surface must comply with all national and local standards for
weight, seismic, and wind sheer requirements.
• The mounting surface must be prepared according to the site specific structural
drawing.
Required Tools
• Lifting device such as forklift or a crane may be used to lift and position the
inverter. Lifting devices must be rated for 4,140 kgs (9,100 lbs). Proper lifting
methods may include:
◦ Using a crane with a strap rated for the weight of the inverter
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Installing
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Advanced Energy® AE 500 Inverter
◦ Using lifting beams, spreader bars, or similar equipment rated for the weight
of the inverter
To Lift and Mount the Unit
WARNING:
Do not attempt to lift the full weight of the unit from the left or right sides only.
Attempting to lift from just the left or right sides only will result in an unstable
and unsafe condition.
AVERTISSEMENT:
Ne pas tenter de soulever l’unité uniquement à partir du côté gauche ou
droit. Toute tentative de soulever l’unité par le côté gauche ou droit pourrait
occasionner une situation d’instabilité dangereuse.
CAUTION:
Care MUST be taken to protect the inverter from compressive stresses or
forces which may dent or deform the cabinet or cause damage to the
inverter. Damage caused by improper handling may void the warranty. Safe
handling, operating, and installation practices are the responsibility of the
installer.
ATTENTION:
Redoubler de vigilance pour protéger l’inverseur des contraintes ou forces en
compression qui peuvent endommager ou déformer l’armoire ou
endommager l’inverseur. Les dommages causés par la manipulation
inadéquate peuvent annuler la garantie. Les pratiques sécuritaires de
manipulation, de fonctionnement et d’installation incombent à l’installateur.
☞ Important
Damage caused by improper handling can void the warranty. Safe operating,
handling, and installation practices are the responsibility of the installer.
1. Prepare the mounting surface according to the site specific structural drawing.
2. Remove the plates covering the fork slots.
3. Lift the inverter off the pallet using the forklift slots on the front or back.
The front and back of the inverter base each have two fork slots that are 8.5"
wide and 34" apart on center.
☞ Important
The center of gravity is toward the back, lower third of the inverter and
centered side to side. Refer to the mechanical drawings to view the
center of gravity location.
4. Position the inverter in the selected location.
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Alternate methods of lifting and positioning the inverter may be used. Proper
methods may include the use of a crane with a strap rated for the weight of the
inverter; however, care MUST be taken to protect the inverter from
compressive stresses or forces which may dent or deform the cabinet or cause
damage to the inverter. Use of lifting beams, spreader bars, or similar
equipment rated for the weight of the inverter can be employed for this purpose.
5. Secure the inverter to the mounting surface by setting the anchoring hardware
through each of the six holes in the external mounting flange on the base of the
unit.
Refer to the mechanical drawings in the Appendix to review the anchoring
locations.
6. Replace the cover plates over the fork slots.
CONDUIT ENTRY POINTS
The inverter is shipped from the factory with side and bottom gland plates that allow
for conduit entry.
☞ Important
All penetrations in the inverter cabinet must be through the specified gland
plates which are for the sole purpose of providing a safe and convenient way to
route wiring in to and out of the inverter. Penetrating the inverter housing in
any other location besides the gland plates voids the warranty.
☞ Important
Do not block the cabinet's side access with conduit.
☞ Important
Do not attach conduit support structure to the cabinet.
The bottom of the inverter has collared entry conductor chases available in the DC
and AC landing compartments. The bottom left side gland plates can be removed to
expose the chases as an alternative to the gland plates.
Using Gland Plates for Cable Conduit Entry and Exit
All power cabling and communications wiring must enter and exit via the inverter
cabinet’s gland plates. There are gland plates on the AC and DC sides of the inverter
for bottom and side entry. In addition, there is a gland plate on the upper left side for
data monitoring wiring. Each gland plate location is selected to ensure safe
installation, proper airflow and prevention of dust, debris, moisture, insect, and
animal incursion. Do not penetrate the cabinet at any other location. All gland plates
except those covering the bottom entry chases need to be installed for proper
operation of the inverter.
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Installing
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Advanced Energy® AE 500 Inverter
The bottom chases are located beneath the bottom DC and AC gland plates. If the
bottom side chase is used, the bottom DC and AC gland plates are not needed and
can be removed from the cabinet. The gland plates should not be left loose in the
compartment.
☞ Important
The gland plate on the front of the inverter, next to the DC combiner sub panel
door, is intended for service access only and should not be used for conductor
entry.
TOOLS REQUIRED
• 5/32″ hex wrench
• NEMA 4 conduit hubs
• Knockout punch
TO USE THE GLAND PLATES
☞ Important
All penetrations in the inverter cabinet must be through the gland plates which
are provided for the sole purpose of a safe and convenient way to route wiring
in to and out of the inverter. Penetrating the inverter cabinet in any other
location besides the gland plates voids the warranty.
☞ Important
Remove all metal shavings and wire scraps from the inverter prior to replacing
the gland plates.
1. Select the size(s) and location(s) of the hole(s) that need to be punched.
DC bottom entry gland plate
4686
Figure 4‑12. DC bottom entry gland plates
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Cover for fan compartment
Service access only
Side entry gland plates
Figure 4‑13. DC side entry gland plates
2. Remove the gland plate while taking care not to damage the weatherproof
gasket material on the back side of the plate.
3. Punch holes as needed in the gland plate.
4. Attach watertight NEMA 4 conduit hubs in each hole.
The inverter is a NEMA 4 enclosure. Use only rain-tight or wet-location
conduit hubs and install these hubs as shown in the following figure.
Lower cabinet gland plate
2 inch straight metal conduit connector
4348
Figure 4‑14. Installation of conduit hub
CAUTION:
For outdoor installations make liquid-tight connections to the unit.
ATTENTION:
Pour les installations extérieures, effectuer des connexions étanches
à l’unité.
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Advanced Energy® AE 500 Inverter
5. Replace the gland plate taking care to evenly seat the gasket material against
the cabinet.
6. Tighten until the gland plate is snug. Do not overtighten.
ELECTRICAL CONNECTIONS
DANGER:
Electrical connections must comply with national and local standards.
Voltage drop and other considerations may dictate that larger wire sizes be
used.
DANGER:
Les connexions électriques doivent être conformes aux normes nationales et
locales. Des chutes de tension et autres facteurs peuvent imposer l’usage de
fils de plus gros calibre.
DANGER:
RISK OF DEATH OR BODILY INJURY. Disconnect and lockout/tagout all
sources of input power before working on this unit or anything connected to
it.
DANGER:
RISQUE DE MORT OU DE BLESSURES CORPORELLES. Débrancher et
verrouiller/étiqueter toutes les sources de puissance d’entrée avant de
travailler sur cette unité ou sur tout élément qui y est raccordé.
After the inverter is properly secured to the mounting pad and the conduit hubs have
been installed the electrical connections can be completed. Terminal connections for
the inverter are located inside the inverter. When facing the inverter the connections
are located in the following areas:
• DC terminals are on the left side
• AC terminals are on the right side
Both AC and DC bus bars accept standard terminal lug-crimped wires mounted to the
bus bar fittings with standard grade 8, 3/8″ mounting hardware.
For the optional DC circuit breaker subcombiners, the conductor is connected to the
bus bar provided for each breaker or inserted directly into the DC circuit breaker
frame depending on the configuration. The following table lists the accepted wire
sizing for each subcombiner lug option.
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Table 4‑1. Subcombiner wire sizing and torque values
Maximum Wire Size
Breaker
Frame
Maximum
Amperage
Required
Torque
Terminal
Temp.
Rating
8 x 400
Direct to bus bar. No wire size limit.
Attach lug to bus bar with grade 8, 3/8″
hardware.
40 ft-lbs
90°C
16 x 225
Direct to bus bar. No wire size limit.
Attach lug to bus bar with grade 8, 3/8″
hardware.
40 ft-lbs
90°C
20 x 225
4/0 max, #4 min Cu/AL
10 ft-lbs
75°C
No DC
breakers
Direct to bus bar. No wire size limit.
Attach lug to bus bar with grade 8, 3/8″
hardware.
40 ft-lbs
75°C
AC Wiring
WARNING:
Follow the order listed in this section to wire the inverter. Failure to do so
may result in hazardous voltages or disconnection of contacts.
AVERTISSEMENT:
Pour câbler l’onduleur, suivez les ordres décrits dans cette section. Tout
manquement au suivi scrupuleux des instructions est susceptible d’entrainer
des tensions anormales ou le débranchement de contacts.
CAUTION:
To reduce the risk of fire, connect only to a branch circuit with overcurrent
protection appropriately rated in accordance with your national and local
electrical codes.
ATTENTION:
Pour réduire le risque d'incendie, brancher seulement à un circuit de
dérivation avec une protection de surintensité d'une capacité nominale
conforme aux codes d’électricité nationaux et locaux.
4‑16
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Advanced Energy® AE 500 Inverter
CAUTION:
The input and output circuits are isolated from the enclosure. System
grounding, when required by national and local electrical code, is the
responsibility of the installer.
ATTENTION:
Les circuits d’entrée et de sortie sont isolés de l’enceinte. La mise à la terre
du système, lorsqu’elle est exigée par le code d’électricité national ou local,
est la responsabilité de l’installateur.
WARNING:
The AC output/neutral must not be bonded to ground within the equipment.
AVERTISSEMENT:
La sortie et le neutre CA ne doivent pas être branchés à la masse à
l’intérieur du dispositif.
☞ Important
The inverter is certified for installation without a neutral conductor. Do NOT
pull a neutral conductor from the AC service panel to the inverter.
The inverter is designed for use with the following grounded wye, three-phase power
grids.
• 480 VAC
☞ Important
The inverter must be connected to a grounded wye configuration.
The voltage output is not selectable on AE inverters. Do not attempt to change the
AC output voltage once it is set at the factory.
Use the applicable national and local electrical code to select the appropriate AC wire
sizing for your application. Correct wire sizing requires, at a minimum,
considerations for ampacity, temperature, and conduit. In addition, wire should be
sized to minimize voltage drop. Install the inverter on a dedicated branch circuit with
a recommended circuit breaker rating as specified in the following table.
Table 4‑2. Branch breaker size recommendations
Model
AE 500
208 VAC
480 VAC
600 VAC
N/A
800 A
N/A
The inverter does not have internal AC fusing so it is important to size the branch
circuit protection appropriately.
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When an inverter is installed on an electrical panel the AC operating voltage range of
the inverter should be considered. Voltages outside this range will cause the inverter
to fault. See the specifications section of this manual for AC operating voltage
ranges.
Table 4‑3. Operational voltage ranges per electrical panel
Electrical Panel
480 VAC
Operational Voltage Range
422 VAC – 528 VAC
Related Links
• “Electrical Specifications” on page 9-1
CONNECTING TO THE ELECTRICAL GRID
DANGER:
Risk of electrical shock. High voltages are present in the inverter cabinet.
Both AC and DC disconnects must be in the OFF position when working on
the unit. Wait five minutes to discharge high voltage before opening the front
panels of the inverter.
DANGER:
Risque d’électrocution. L’intérieur de l’onduleur est soumis à des hautes
tensions. Les interrupteurs de courant alternatif et continu doivent être mis
HORS TENSION durant les travaux sur l’unité. Attendez cinq minutes afin de
permettre la décharge du courant haute tension avant de démonter les
panneaux avant de l’onduleur.
CAUTION:
To avoid an increase in AC voltage to unacceptable values while the inverter
is connected, the grid impedance value at the connection point should be as
low as possible. By keeping the grid impedance value low, the system will
achieve higher efficiency.
ATTENTION:
Afin d’éviter des surtensions inacceptables de CA lorsque l’onduleur est
branché, assurez-vous que la valeur de l’impédance aux points de connexion
au réseau public est la plus basse possible. Une faible valeur d’impédance
permet un fonctionnement plus efficace de l’appareil.
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Advanced Energy® AE 500 Inverter
WARNING:
Do not connect a neutral wire to the WYE point of the isolation transformer.
Doing so will cause the inverter to malfunction and will void the warranty.
AVERTISSEMENT:
Ne branchez pas de câble neutre au point WYE du transformateur
d’isolation. Un tel branchement causerait un fonctionnement défectueux de
l’onduleur et annulerait la garantie.
The inverter is connected to the electrical grid using four wires:
• Phase A voltage
• Phase B voltage
• Phase C voltage
• Ground
☞ Important
Do NOT connect a neutral wire to the wye point of the isolation transformer.
The four AC termination bus bars for phases A, B, C, and ground are located in the
lower section of the AC panel. The phase and ground bus bars are vertically
mounted. Each bus bar has eight holes per phase of 3/8″ diameter holes, spaced
1.625″ apart vertically.
The AC connections must be made through conduit installed in the bottom or side
entry gland plates.
Tools Required
• 5/32″ Allen wrenches (Allen wrench adaptor for a socket wrench
recommended)
• 7/16″ open-end wrench or socket wrench and a 6″ extender
• Torque wrench
To Connect the AC Wiring
1. Remove the protective plastic cover with a 7/16″ socket wrench.
2. Run the conduit from the main breaker panel to the desired gland plate on the
inverter.
3. Insert a conduit fitting in the gland plate and fasten with a locking nut.
4. Feed the PHASE A, PHASE B, PHASE C, and GROUND wires through the
conduit and into the right side conduit opening of the inverter.
5. Connect the wires to the appropriate AC landings as follows:
a. GROUND wire to the marked EARTH GROUND landing inside the
inverter.
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b. Phase A, B, and C to the AC landings inside the inverter.
☞ Important
The inverter auto phases and will auto detect phase rotation.
Optional revenue meter
AC surge
Soft start contactor
Optional AC disconnect
AC landing
Ground
Figure 4‑15. AC connections
Bus bar
Crimp connector
Washer, 3/8 high strength
Screw, hex cap, 3/8 - 16 x 1, Grade 8
Washer, Belleville, 3/8, 6500 lb flat load
4618
Nut, hex, 3/8 - 16, Grade 8
Figure 4‑16. Bus bar connections
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Advanced Energy® AE 500 Inverter
Use grade 8, 3/8″ hardware to secure the lugs of the outgoing AC cables to the
bus bars.
6. Ensure all connections are wired correctly and properly torqued. Tighten the
AC terminal screws to 40 ft-lbs.
7. Reinstall the protective plastic cover.
DC Wiring
DANGER:
Before proceeding with the DC wiring, confirm that the PV array has been
disconnected from the inverter using the external DC disconnect.
DANGER:
Avant d’effectuer les branchements CC, assurez-vous que les piles PV sont
déconnectées de l’onduleur en utilisant le connecteur CC externe.
DANGER:
Make sure the PV array polarity and voltage between the positive and
negative cables are correct before connecting the PV array cables to the DC
terminal block.
DANGER:
Assurez-vous que la polarité et le voltage des câbles positifs et négatifs des
piles PV sont corrects avant de brancher les câbles des piles PV aux bornes
CC.
The DC negative and ground bus bars are located in the lower left compartment, the
DC landing to the left of the DC combiner sub panel. The DC positive and optional
DC circuit breaker subcombiner are located in the DC combiner sub panel. The
positive, negative, and ground bus bars are vertically mounted. The positive and
negative bus bars have 18 rows of two 3/8″ diameter holes spaced 1.75″ apart and
four individual holes spaced 1.5 apart″ vertically. The ground bar has 24 rows of two
3/8″ diameter holes spaced 1.25″ apart.
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Ground bus bar
DC+ bus bar
DC- bus bar
Figure 4‑17. DC connections
CONNECTING TO THE PV ARRAYS
DANGER:
Risk of electrical shock. When exposed to light, PV arrays create electrical
energy that could cause a hazardous condition.
DANGER:
Risque d’électrocution. Lorsqu’elles sont exposées à la lumière, les piles
photovoltaïques génèrent un courant électrique susceptible de causer des
conditions dangereuses.
Follow these steps to wire the DC inputs from the PV panels to the inverter. These
instructions are for a negatively grounded array. For a positively grounded array, use
the opposite terminals.
Tools Required
• 5/32″ Allen wrenches (Allen wrench adaptor for a socket wrench
recommended)
• Open-end wrench or socket wrench
• Torque wrench
• Voltmeter
4‑22
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To Connect the DC Wiring
8 circuit option
16 circuit option
8 circuit with
monitoring option
20 circuit option
16 circuit with
monitoring option
Figure 4‑18. DC subcombiner configurations
1. Disconnect power to the DC wiring by disconnecting the PV array outside the
inverter before starting the DC wiring.
2. Clearly mark the array positive and negative leads.
3. Route the PV array leads through the conduit to the desired entry gland plate
on the DC side of the inverter.
☞ Important
The front left access cover can be removed for better access to the DC
wiring.
4. If using the DC circuit breaker option, remove the dead front panel to access
the breaker landings.
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Breakers
DC+ bus bar
Dead front
Figure 4‑19. DC dead front
5. Connect the PV frame ground wire(s) to the ground lug on the point marked
in the lower left side of the cabinet.
6. Connect positive DC cables(s) to the terminals located on the positive bus bar
or the breaker by inserting the cable directly into the breaker frame terminal
depending on the configuration. Use grade 8, 3/8″ hardware to secure the lugs
of the incoming DC cables to the bus bar. The DC landing torque specification
is 40 ft-lbs.
7. Connect negative DC lead(s) directly to the terminals located on the negative
DC bus bar as shown in the following figure. Use grade 8, 3/8″ hardware to
secure the lugs of the incoming DC cables to the bus bar. The DC landing
torque specification is 40 ft-lbs.
4‑24
Installing
570-1001791-05A
Advanced Energy® AE 500 Inverter
Bus bar
Crimp connector
Washer, 3/8 high strength
Screw, hex cap, 3/8 - 16 x 1, Grade 8
Washer, Belleville, 3/8, 6500 lb flat load
4618
Nut, hex, 3/8 - 16, Grade 8
Figure 4‑20. DC inverter connections
8. Re-install the DC dead front if the circuit breaker option is used.
9. Energize the DC cables.
10. Using a voltmeter, check the PV array positive leads and confirm the voltage is
positive when referenced to the negative leads. The reading should not exceed
your calculated series Voc or the 600 VDC maximum inverter input
specification.
11. De-energize the DC cables.
12. Re-install the front left access cover.
Using the Integrated Remote Disable Input
There are two remote disable inputs available to the installer in the inverter. The
inputs are located on the communications interface PCB which is located in the data
monitoring compartment.
The remote disable inputs consist of two pairs of screw terminals to which a user can
connect separate remote switches or contacts. Using the remote disable input allows
the inverter to be shut down remotely by opening a switch or set of contacts. This
feature would typically be used in conjunction with a fire alarm panel or a generator
output signal. The contacts need to be normally closed for the inverter to operate. The
customer will need to provide a 5 V, 5 mA tolerant relay, switch, or set of contacts.
570-1001791-05A
Installing
4‑25
Advanced Energy
☞ Important
Termination switches are located on the communications PCB terminal to
allow normal operation. Do not move the switches unless you intend to use this
feature.
☞ Important
Closing the remote disable contact with the inverter ON/OFF switch in the ON
position will re-start the inverter.
MAKING THE REMOTE DISABLE CONNECTION
Parts or Tools Required
You need the following parts and/or tools to make the remote disable connection:
• Control wire, 14-22 awg
• Wire stripper
• Small screwdriver
☞ Important
Thin stranded wire is recommended.
The Remote Disable and Other On-Site Power Sources
The following information describes how to make the remote disable connection on
the AE 500 inverter. The remote disable circuit requires a normally-closed contact
capable of switching a 5 V, 5 mA signal. One or two remote disable connections can
be made to the unit.
☞ Important
The AE 500 inverter cannot operate with this remote disable open. If the
remote disable feature is not used, the remote disable termination switches
must be left in place for the inverter to operate.
You are required to establish this external remote disable connection if an additional
power source exists at your installation site that could be damaged if the PV system
continues to run when the power source turns on. For example, if you have an on-site
generator that supplies power when an electrical outage occurs, you should make the
remote disable connection from the inverter to the on-site generator to ensure the PV
system shuts downs when the generator turns on.
4‑26
Installing
570-1001791-05A
Advanced Energy® AE 500 Inverter
Closed Remote Contacts = Inverter Enabled
Inverter Remote
Disable Terminals
Remote Contacts
Control Wire
Open Remote Contacts = Inverter Disabled
Inverter Remote
Disable Terminals
Remote Contacts
Control Wire
Figure 4‑21. Remote disable wiring diagram
To Make the Remote Disable Connection
DANGER:
Risk of electrical shock. High voltages are present in the inverter cabinet.
Both AC and DC disconnects must be in the OFF position when working on
the unit. Wait five minutes to discharge high voltage before opening the front
panels of the inverter.
DANGER:
Risque d’électrocution. L’intérieur de l’onduleur est soumis à des hautes
tensions. Les interrupteurs de courant alternatif et continu doivent être mis
HORS TENSION durant les travaux sur l’unité. Attendez cinq minutes afin de
permettre la décharge du courant haute tension avant de démonter les
panneaux avant de l’onduleur.
☞ Important
This procedure is written for a single remote disable connection. If two remote
disables are used, follow the same steps for each remote disable connection.
1. Disconnect the power to the inverter before starting the installation.
2. Remove the data monitoring gland plate on the upper left side of the inverter.
570-1001791-05A
Installing
4‑27
Advanced Energy
The data monitoring gland plate is a small, flat piece of metal covering the side
entry port to the inverter’s data monitoring compartment.
3. Drill or punch a hole in the desired location to allow access for the remote
disable control wires.
4. Install a water-tight conduit hub connection.
5. Replace the gland plate.
6. Route the remote disable control wires from the remote device.
7. Locate the remote disable terminal block located on the communications
interface PCB in the monitoring compartment.
8. Locate and remove one jumper from the remote disable terminal block shown
in the following illustration.
Data montioring card cage
Ethernet port
Remote disable terminal block
Figure 4‑22. Remote disable terminal block
9. Strip approximately 1/4″ (6 mm) of insulation from each conductor of the
control wire.
10. Insert the stripped wires in the remote disable terminal block and tighten the
screws.
24 V Power Supply
The AE 500 inverter has an integrated 24 V power supply option. The 24 VDC
power supply is sized to handle most common loads in the field. The optional power
supply can provide power for various balance-of-system components such as string
combiner monitoring, weather stations, cell routers, and other monitoring options.
If a 24 V power supply option was not included when the inverter was ordered, the
power supply will not be factory installed and the inverter's field terminals will not
have power available. In an installation situation requiring additional power and the
4‑28
Installing
570-1001791-05A
Advanced Energy® AE 500 Inverter
24 V power supply is not installed, an additional power supply will need to be
provided by the installer. The additional power supply will need to be installed
external to the inverter.
The integrated 24 V power supply meets the following specifications:
• Output voltage: 24 VDC
• Output current: 10 A
• Output wattage: 240 W
• Fuse size: 10 A
When sizing a power supply it is recommended the load not exceed 80% of name
plate capacity to prolong the life of the power supply and avoid nuisance trips caused
by inrush current. For example, if the total load capacity of all the field devices
powered by the 24 VDC power supply exceeds 80% of the rating, a second power
supply is recommended. If a second power supply is used it must be provided by the
installer and mounted external to the inverter. For this configuration, the loads must
be separated and the 24 VDC supplies isolated from each other.
24 V power supply terminals
Figure 4‑23. 24 V power supply terminal location
WIRING THE 24 V POWER SUPPLY
The data monitoring compartment on the upper left side of the inverter contains the
communications interface PCB. The 24 VDC terminals are located on the
communications interface PCB.
Parts or Tools Required
You need the following parts and/or tools to make the remote disable connection:
• Control voltage wire (size depends on calculated voltage drop)
• Wire stripper
570-1001791-05A
Installing
4‑29
Advanced Energy
• Small flat head screwdriver
• Voltage meter
To Make the 24 V Terminal Connections
The following information describes how to make the 24 V power supply connection
on the AE 500 inverter. The 24 V terminal block contains three sets of terminals to
run control power wiring to the field. These terminals are electrically connected
together and pull power from the same power supply.
☞ Important
Load calculations determining the total load for the terminal block should be
completed prior to wiring the terminal connections.
1. Disconnect the power to the inverter before wiring the terminal connections.
2. Remove the data monitoring compartment plate on the upper left front of the
inverter.
3. Locate the 24 V power supply terminal block located on the communications
interface PCB in the data monitoring compartment.
To cellular modem
To String Monitoring
hardware
+
-
+
-
+
-
External 24vdc Out
Communications Interface PCB
Figure 4‑24. 24 V wiring example
4. Strip approximately 1/4″ (6 mm) of insulation from each conductor coming
from the 24 V power supply.
5. Insert the stripped wires in the 24 V power supply terminal block and tighten
the screws.
4‑30
Installing
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Advanced Energy® AE 500 Inverter
Chapter
5
Operation
SYSTEM STARTUP PROCEDURE
WARNING:
Before turning on the inverter, ensure that the front panels are closed
properly.
AVERTISSEMENT:
Assurez-vous de la bonne fermeture des panneaux antérieurs avant de
mettre l’onduleur en route.
To Start the Inverter
1. Turn the ON/OFF switch to the OFF position.
The ON/OFF switch is located next to the display screen.
2. Open the door to the DC combiner sub panel.
3. Check the polarity of the DC positive and negative connectors to ensure they
are wired correctly.
4. Confirm the PV panel open circuit voltage is at or below 600 VDC.
5. Turn all DC breakers to the ON position.
6. Close all upper and lower cabinet doors.
7. Turn on the external AC connection to the inverter.
8. Turn on the external DC disconnect to provide DC power to the inverter.
9. Turn the inverter's AC disconnect (if equipped) to the power ON position.
Pause/scroll button
On/Off button
4684
570-1001791-05A
Operation
5‑1
Advanced Energy
10. Turn the ON/OFF switch to the ON position.
After five minutes, the inverter starts to produce power into the AC grid if all
necessary operating conditions are met.
Display
Disconnect in power on position
4685
Figure 5‑1. Inverter with AC disconnect power ON
If the unit fails to power on, use the troubleshooting information provided in
this manual. If those steps do not resolve the problem, contact your service
provider or AE Solar Energy Technical Support.
INVERTER OPERATING STATES
The AE 500 inverter has ten operating states. The inverter will transition from one
state to another only as shown in the following figure. Each operating state is
described below.
5‑2
Operation
570-1001791-05A
Advanced Energy® AE 500 Inverter
Initialize
Disabled
Sleep
Startup
Delay
Fault
DC
Precharge
Cool Down
AC
Precharge
Power
Track
(auto
mode)
Idle
Figure 5‑2. Inverter state diagram
• Initialize: The inverter enters this state after a power cycle. Variables and
devices are initialized and I/O ports set. When initialization is complete, the
inverter enters the sleep state.
• Disabled: The inverter enters this state when the front-panel switch is in the
OFF position or when a disable command is received over the Modbus
connection. If a fault condition occurs, the inverter switches to the fault state.
When the fault is cleared and the condition no longer exists, the inverter returns
to the disabled state. The inverter displays a message on the screen indicating
the inverter is disabled. When an enable command is received or the front-panel
switch is changed to the ON position, the inverter switches to the sleep state.
The inverter will also enter the disabled state when the remote disable input
feature is applied.
• Fault: The inverter enters this state when any fault condition occurs. The
inverter can enter this state from any other state except initialize. Unless the
fault is latching, the inverter clears the fault when the fault condition subsides.
The inverter displays the fault codes and messages indicating the current fault
conditions. If the fault is latching, the inverter switches to the latched fault state.
The inverter enters this state when a latching fault condition occurs. The
inverter displays fault codes and messages indicating the current fault
conditions. When the fault is cleared, the inverter switches to the sleep state.
Descriptions of the inverter faults are included in the Troubleshooting chapter.
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Operation
5‑3
Advanced Energy
• Sleep: In this state, the inverter is enabled but the DC voltage is below the
minimum operating window. When the PV input voltage rises above the
starting voltage, the inverter switches to the startup delay state.
• Startup Delay: In this state, the inverter delays a specified time and then enters
the DC precharge state. The delay depends on the conditions prior to the sleep
state and the time taken to reach this state from the previous shutdown. If a grid
interactive fault occurred on the previous shutdown, the inverter will remain in
this state for five minutes.
• DC Precharge: In this state, the inverter closes the DC precharge-contactor,
which limits inrush current into the DC bus capacitors. When the DC bus
voltage reaches the PV input voltage and is greater than the DC start voltage,
the inverter switches to the AC precharge state.
• AC Precharge: In this state, the inverter closes the main DC contactor and the
AC precharge-contactor, which limits inrush current into the transformer. Once
the transformer is magnetized, the main AC contactor is closed and the AC precharge contactor is opened. After a short delay the inverter switches to the idle
state.
• Idle: In this state, the inverter stops energy conversion and displays a message
indicating that the inverter is idle. The inverter switches to the power tracking
state when the DC voltage is above the DC start voltage. If a fault condition
occurs, the inverter switches to the fault state. If the DC voltage drops below the
minimum, the inverter switches to the sleep state.
• Cool Down: In this state, the inverter opens the main DC contactor but leaves
the main AC contactor closed to run the cooling fans. The inverter remains in
this state until the inverter temperatures are below the shutdown threshold. If
the PV input voltage rises above the start threshold, the inverter will transition
from this state to the DC precharge state.
• Power Track: In this state, the inverter operates in voltage control mode using
the maximum power point tracking (MPPT) function. If a fault occurs, the
inverter switches to the fault state.
Related Links
• “Troubleshooting and Solar Energy Technical Support” on page 8-1
DISPLAY SCREENS AND OPERATION
The digital display located on the front of the AE inverter includes both a scrolling
display screen and buttons for operating. The display provides the unit operator with
information about the current state of the inverter.
There are five sets of screens that may display depending on the state of the inverter.
The five sets are:
5‑4
Operation
570-1001791-05A
Advanced Energy® AE 500 Inverter
• Initialize: The initialize state is displayed on the screen when the inverter is first
turned on.
• Energy tracking: These are the normal power production states of idle, run, and
AC and DC precharge. Following the startup delay, the inverter goes to energy
tracking which starts with the DC and AC precharge and then goes to idle and
run.
• Fault
• Warning
• Disabled
The display screens for each state are shown in the following figures. When there is a
series of display screens associated with the inverter state then the inverter will
continuously scroll through these screens.
PVP 500KW
STARTUP DELAY
Starting In
234 seconds
Figure 5‑3. Initialize state screen
Advanced Energy
Industries, Inc.
PVP 500KW
POWER TRACKING
DC
Volts 352
Amps 267
www.aei.com
Screen 1: Product
AC
Volts
Amps
L1
278
185
Screen 2: Power tracking
L2
281
181
Screen 4: AC values
L3
279
183
P
Q
-Q
S
84.4
0.1
4.8
78.4
MWh
MVArh
MVARh
MVAh
Screen 5: Power controls
Screen 3: DC values
Power Out
352 kW
Total
56.2 MWH
Screen 6: Power values
Figure 5‑4. Energy tracking state screens
☞ Important
The DC current display is not a precise measurement.
Fault Codes
SYS 0020 DRV 0000
VLT 0000 TMP 0000
GRD 0000
Screen 1: Fault code(s)
Fault
AC FAST UNDERVOLT A
GFDI FAULT
Screen 2: Fault text
Advanced Energy
phone: (877)312-3832
email:
[email protected]
aei.com
Screen 3: Contact information
Figure 5‑5. Fault state screens
570-1001791-05A
Operation
5‑5
Advanced Energy
4654
Figure 5‑6. Warning state screen
4651
Figure 5‑7. Disabled state screen
To Operate the Display
The inverter display scrolls through a series of display screens based on the current
state of the inverter. To operate the display:
• Press the Pause/Scroll button to pause the display on a specific screen
• Press the Pause/Scroll button again to resume the scroll function
Pause/scroll button
On/Off button
4684
Figure 5‑8. Inverter display and switch
☞ Important
The ON/OFF switch disables the inverter, turning off inverter output power.
GROUND FAULT INTERRUPT DEVICE
The inverter is equipped with a ground fault detector interrupter (GFDI). The purpose
of the GFDI is to detect a ground fault (unintended current flow from the solar panels
to earth ground) and in this event, disable the inverter.
5‑6
Operation
570-1001791-05A
Advanced Energy® AE 500 Inverter
WARNING:
For the GFDI circuit to function as designed, the solar array safety ground
must not be connected to the PV array positive or negative leads. Bonding
the safety ground to the grounded leg of the array anywhere but through the
inverter will cause the GFDI circuit to be bypassed. This would defeat the
operation of the GFDI and potentially create an unsafe operating condition.
AVERTISSEMENT:
Pour que le circuit GFDI fonctionne normalement, la prise de terre de
sécurité du système PV ne doit pas être branché aux câbles positifs ou
négatifs des piles PV. Brancher la prise de terre de sécurité au pied des piles
ou à toute autre partie que l’onduleur causerait une mise hors circuit du
GFDI. Ceci ne empêcherait le fonctionnement normale du circuit GFDI et
créerait des conditions de fonctionnement potentiellement dangereuses.
The GFDI functions using a 5 A fuse to connect or bond the solar array negative (or
the solar array positive, if using a positively grounded panel array) to earth ground.
If the ground fault current exceeds 5 A between the grounded array terminal and the
earth ground, the fuse will open and disconnect the solar panels from their ground
reference, interrupting the ground fault. In this situation, the inverter will cease
operation and display a ground fault message.
To Respond to a Ground Fault
• If the inverter displays a ground fault as shown in the following figure turn off
the AC and DC to the inverter and refer to the inverter maintenance and
troubleshooting information.
The following figure shows the inverter ground fault error message.
4652
Figure 5‑9. Ground fault error message
570-1001791-05A
Operation
5‑7
Advanced Energy
TO SHUTDOWN THE INVERTER
DANGER:
This unit contains energy storage devices that take up to 5 minutes to
discharge. Verify the high energy capacitors are completely discharged
before working on this unit.
DANGER:
Cette unité contient des dispositifs de stockage d’énergie qui prennent
jusqu’à 5 minutes pour se décharger. Vérifier que les condensateurs à haute
énergie sont complètement déchargés avant de travailler sur l’unité.
1. Turn the ON/OFF switch on the display to OFF position.
2. Turn the AC disconnect (if equipped) to the power OFF position by rotating the
AC power lever to the position shown in the following figure.
The display on the upper front panel should be inactive.
AC disconnect in power off position
Figure 5‑10. AC disconnect power OFF
3. Open the utility connection circuit breaker.
4. Disconnect the PV array connection to the inverter using the external PV
disconnect.
5‑8
Operation
570-1001791-05A
Advanced Energy® AE 500 Inverter
De-energize/Isolation Procedures
DANGER:
Risk of electrical shock. When exposed to light, PV arrays create electrical
energy that could cause a hazardous condition.
DANGER:
Risque d’électrocution. L’autorisation officielle de votre compagnie locale
d’électricité est requise avant de brancher l’onduleur sur le réseau public.
Seul le personnel qualifié est autorisé à brancher le dispositif sur le réseau
public d’électricité.
DANGER:
This unit contains energy storage devices that take up to 5 minutes to
discharge. Verify the high energy capacitors are completely discharged
before working on this unit.
DANGER:
Cette unité contient des dispositifs de stockage d’énergie qui prennent
jusqu’à 5 minutes pour se décharger. Vérifier que les condensateurs à haute
énergie sont complètement déchargés avant de travailler sur l’unité.
The following procedure should be followed to de-energize the inverter for
maintenance.
TO DE-ENERGIZE THE INVERTER
1. Turn the inverter’s ON/OFF switch to the OFF position.
2. Disconnect the PV array connection to the inverter using the external PV
disconnect
3. Turn the AC disconnect (if equipped) to the power OFF position by rotating the
AC power lever to the off position.
The display on the upper front panel should be inactive.
4. Open the utility connection circuit breaker or the overcurrent protection device,
a breaker or disconnect.
5. Install LOTO devices on the equipment as necessary to comply with LOTO
requirements.
570-1001791-05A
Operation
5‑9
Advanced Energy
Inverter Enable/Disable Controls
The table below shows the interaction of the inverter on/off controls. Cells containing
an x can be in either state.
Table 5‑1. Inverter enable/disable
Inverter Enable/
Disable Switch
Inverter
Disconnect
Switches
On
Closed
Enabled
Enabled
Enabled
Off
x
x
x
Disabled
x
Open
x
x
Disabled
x
x
Disabled
x
Disabled
x
x
x
Disabled
Disabled
5‑10
Remote Enable/
Modbus
Disable
Enable/Disable
Operation
Inverter Status
570-1001791-05A
Advanced Energy® AE 500 Inverter
Chapter
6
Data Monitoring and Controls
NETWORKING AND PERFORMANCE
MONITORING
The inverter has an integrated data monitoring module located in the dedicated data
monitoring compartment. The data monitoring module enables access to the inverter
performance data using the following methods:
• Basic performance data can be accessed using a free web-based monitoring
service provided by AE.
• The data monitoring module can deliver data to a third party monitoring system
through a Modbus/TCP over an Ethernet network, or Modbus/RTU over an
RS-485 network.
Ethernet Network Connection
An Ethernet connection can be used to connect the unit to the internet, or to a local
Modbus/TCP network not connected to the internet. AE offers a free basic
monitoring service through the solarenergy.advanced-energy.com website. Internet
service must be set up at the installation site before the inverter can be accessed
online. The data monitoring module supports only hard-wired CAT5 solutions to the
inverter. The module does NOT support wireless configurations. To access the data
monitoring information, customers need to provide a broadband Ethernet connection
to the inverter, based on the following specifications:
• Provide a DHCP-enabled, or static IP based broadband internet connection that
is always ON. This can be cable internet, a DSL line, or equivalent.
• Provide a hard-wired, Ethernet connection between the communications
interface PCB in the inverter and the closest site LAN connection.
◦ If multiple inverters are commissioned to a single site, an Ethernet hub can be
located in an outdoor-rated enclosure to distribute the LAN to the inverters.
☞ Important
The data monitoring module does not support dial-up modem connectivity.
☞ Important
Some complex networks may require a system administrator to add the inverter
to the network, or to configure the unit to a static IP address.
All AE commercial inverters come standard with an Ethernet port that is intended to
be connected to the Internet or to a local area network for Modbus/TCP. The
commercial inverter operates as an Internet appliance. The inverter communicates
570-1001791-05A
Data Monitoring and Controls
6‑1
Advanced Energy
with the AE data center using https (port 443). Communications is one way – the
inverter only communicates externally to the AE data center. Typically the inverter
posts approximately 50 kB of data to the data center every 15 minutes. The inverter
may post data more frequently for a short period of time if there is an inverter fault.
Connecting the Ethernet Cable
PARTS OR TOOLS REQUIRED
You need the following parts and/or tools to make the Ethernet cable connection:
• Ethernet LAN cable (Category 5 or above)
• RJ45 modular connector plugs
• Appropriate conduit fitting
• Ethernet hub, switch or router to provide network connectivity
• Cable tester
TO MAKE THE INVERTER'S ETHERNET CONNECTION
Use the following steps to complete the connection of the Ethernet cable to the
inverter's communication interface PCB:
1. Route the Ethernet (CAT5) cable from the Internet-enabled router, at the gland
plate location on the upper left side of the inverter, using the proper conduit
and hub connectors.
☞ Important
The Ethernet cable must comply with T-568B standards as shown in the
following figure. This is the only configuration supported by the data
monitoring module. Other wiring configurations will not work.
Front
Bottom
Figure 6‑1. T-568B compliant Ethernet cable
6‑2
Data Monitoring and Controls
570-1001791-05A
Advanced Energy® AE 500 Inverter
2. Plug the Ethernet cable into the Ethernet port on the communication interface
PCB located in the data monitoring section of the inverter. Refer to the
following figure for the port location.
Ethernet port
Figure 6‑2. Communication interface PCB Ethernet port location
Related Links
• “Conduit Entry Points” on page 4-12
To Establish an Internet Connection with the Inverter
Below is a list of requirements to establish inverter communications with the AE data
center. Connectivity must be established before registration on the site is attempted.
1. Connect the inverter’s Ethernet port to a hub or router using an Ethernet cable.
Ethernet cables must meet the T-568B wiring standard and must be less than
320 feet in length. If a longer cable is needed additional networking hardware
may be required.
2. Provide DHCP server access to the inverter and provide a path to the Internet
for https (port 443) from the inverter.
As shipped, the inverter requires DHCP to establish its IP address. Contact AE
Solar Energy Technical Support if a fixed IP address is required for your
network.
3. Locate the inverter's MAC address on the label on the communications
interface PCB.
The communications interface PCB must be removed from the card cage
assembly to see the MAC address.
When the Internet connection is established, go to the AE web site and navigate to
the PVP Commercial Monitoring page to register the inverter and begin using the
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Data Monitoring and Controls
6‑3
Advanced Energy
monitoring tools. Contact AE Solar Energy Technical Support if additional
information is needed on how to use the online tool.
To Verify Data Monitoring Connectivity
Verify connectivity using the following information:
1. Check the status light located on the front of the communication PCB in the
card cage on the right side of the upper compartment in the data monitoring
section.
If the green status light is in a solid on state, the data monitoring connection is
established. If the status light is not solid, troubleshoot the connection.
2. Register the inverter at the AE Solar Energy web site to complete the setup for
monitoring the inverter.
Related Links
• “Troubleshooting and Solar Energy Technical Support” on page 8-1
MODBUS OVERVIEW
The AE 500 inverter can communicate via Modbus/TCP or Modbus/RTU.This
chapter is written for PV installers, electricians, controls contractors, and Modbus
network programmers.
Modbus Communication Protocol
Modbus is a serial communications protocol and is the most commonly used means
of monitoring and communicating between devices in the PV industry. The Modbus
protocol allows for communication between a Modbus master device and multiple
Modbus slave devices connected to the same network. The physical layer for
Modbus/TCP is a CAT5 Ethernet network. Modbus/RTU uses a twisted pair shielded
conductor RS-485 network.
NETWORKING USING THE MODBUS OPTION
The following steps are required to set up a Modbus TCP network for your AE
inverter:
• Field installation : This step can be completed onsite by a PV installer or an
electrician that does not have working knowledge of a Modbus network
6‑4
Data Monitoring and Controls
570-1001791-05A
Advanced Energy® AE 500 Inverter
◦ Consult the facility IT administrator for network device installation support
and coordination
◦ Install the Modbus network communications cabling
• Modbus network configuration: This step can be done onsite or remotely and
should be completed by the Modbus network programmer
◦ Set the IP address assigned to the inverter and port 502 for Modbus TCP
◦ Configure the point maps for the slave devices
Modbus TCP Installation
Disconnect the power to the inverter before starting the installation.
DANGER:
Risk of electrical shock. High voltages are present in the inverter cabinet.
Both AC and DC disconnects must be in the OFF position when working on
the unit. Wait five minutes to discharge high voltage before opening the front
panels of the inverter.
DANGER:
Risque d’électrocution. L’intérieur de l’onduleur est soumis à des hautes
tensions. Les interrupteurs de courant alternatif et continu doivent être mis
HORS TENSION durant les travaux sur l’unité. Attendez cinq minutes afin de
permettre la décharge du courant haute tension avant de démonter les
panneaux avant de l’onduleur.
TO INSTALL THE MODBUS TCP CABLE
1. Remove the data monitoring gland plate on the left side of the inverter.
The data monitoring gland plate is a flat piece of metal covering the side entry
port to the inverter’s data monitoring compartment.
2. Cut a hole in the desired location to allow access for the cable.
3. Install a water-tight conduit hub connection.
4. Replace the gland plate.
5. Route an Ethernet cable from a network port in the facility that has been
approved by the network administrator through the conduit hub.
6. Connect the Ethernet cable to the Ethernet port on the communication interface
PCB.
The communication interface PCB is located in the data monitoring section in
the left upper compartment of the inverter.
570-1001791-05A
Data Monitoring and Controls
6‑5
Advanced Energy
Communication interface PCB
4687
Figure 6‑3. Communication interface PCB in the data monitoring section
Modbus TCP Network Configuration
TO ASSIGN THE IP ADDRESS AND PORT ID
1. Contact the facility’s IT Network Administrator (or person with similar
responsibilities) to assign an IP address to each inverter. Advanced users can
assign a static IP address.
Contact AE Solar Energy Technical Support for assistance.
2. Set the Modbus master to communicate through port 502.
NETWORKING USING THE MODBUS RS-485
OPTION
The following steps are required to set up a Modbus RS-485 network for the AE
inverter:
• Field installation : This step can be completed onsite by a PV installer or an
electrician that does not have working knowledge of a Modbus network
◦ Installing the Modbus network wiring
◦ Configuring end-of-line termination and network biasing
◦ Setting the Modbus address for each slave inverter
6‑6
Data Monitoring and Controls
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Advanced Energy® AE 500 Inverter
☞ Important
The contractor responsible for network programming will need to
provide the slave addresses prior to setting the Modbus address for each
slave inverter.
The final part of the RS-485 installation process is the Modbus network
configuration. These steps should be completed by the Modbus network programmer.
The last two steps are:
• Setting the device addresses so the Modbus master program will accept the
Modbus addresses assigned during the field installation
• Configuring point maps for slave devices
Network Layout
When multiple inverters or other Modbus slave devices are connected to a single
Modbus master device, the multiple devices need to be connected in one of the three
daisy chain layouts shown in the following figure.
4646
Figure 6‑4. Daisy chain layout for RS-485 network: option A
4647
Figure 6‑5. Daisy chain layout for RS-485 network: option B
4648
Figure 6‑6. Daisy chain layout for RS-485 network: option C
☞ Important
When multiple devices are wired to the network, the network shield must be
terminated to earth ground at one point on the network, typically at the
beginning or the end. For device connections the shield must be rewired to
provide a continuous shield and isolated from ground.
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Data Monitoring and Controls
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Advanced Energy
Installing the Modbus RS-485 Cable
MODBUS RS-485 WIRING REQUIREMENTS
The Modbus RTU connections are made using shielded, insulated, 18-24 gauge
twisted-pair communication cable that has a characteristic impedance of 120 ohms. If
the RS-485 network will not pass through any high voltage (> 300 V) areas, then
300 V rated cable may be used in the low voltage data monitoring compartment of
the inverter. Check with your local inspector or project engineer if you need
assistance in determining this requirement. Some appropriate 300 V data cables
include:
• Belden 3105A (1P22AWG shielded)
• Belden 3082A (1P15AWG + 1P18AWG shielded)
Belden 7897A (1P15AWG + 1P18AWG shielded) is an example of a 600 V rated
cable that may also be used; others exist as well.
TO INSTALL THE MODBUS RS-485 CABLE
DANGER:
Risk of electrical shock. High voltages are present in the inverter cabinet.
Both AC and DC disconnects must be in the OFF position when working on
the unit. Wait five minutes to discharge high voltage before opening the front
panels of the inverter.
DANGER:
Risque d’électrocution. L’intérieur de l’onduleur est soumis à des hautes
tensions. Les interrupteurs de courant alternatif et continu doivent être mis
HORS TENSION durant les travaux sur l’unité. Attendez cinq minutes afin de
permettre la décharge du courant haute tension avant de démonter les
panneaux avant de l’onduleur.
1. Disconnect the power to the inverter before starting the installation.
2. Remove the data monitoring gland plate on the upper left side of the inverter.
The data monitoring gland plate is a flat piece of metal covering the side entry
port to the inverter’s data monitoring compartment.
3. Punch or drill a hole in the desired location to allow access for the cable.
4. Install a water-tight conduit hub connection.
5. Replace the gland plate.
6. Route a RS-485 cable from the master device on the Modbus network port in
the facility that has been approved by the network administrator through the
conduit hub.
6‑8
Data Monitoring and Controls
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Advanced Energy® AE 500 Inverter
7. Connect each Modbus cable to a slave port terminal block on the
communications interface PCB. Connect the plus (+) cables to plus (+)
connections and the minus (-) cables to minus (-) connections so they
correspond throughout the network.
Note: Two slave port terminal blocks, wired in parallel, are available to
simplify wiring in a daisy-chain network.
Modbus slave port terminals
Figure 6‑7. Communications interface PCB with Modbus slave port location
8. Connect a ground reference line to the terminal labeled S on the Modbus slave
terminal block.
The shield of a communications cable may be used for this reference as long as
the shield is connected to earth ground at one point only. AE recommends that
all AE inverters have connected grounds when possible.
☞ Important
Some Modbus devices do not have a shield or reference input. In these
cases the device most often uses the DC power supply (-) as the RS-485
reference. It may be necessary to place an RS-485 isolator on these
devices or power them from a common DC supply that has its DC (-)
referenced to earth ground at the same point where the network cable
shield is earthed.
Setting the DIP Switches
By default, the termination uses three switches that are set in the disabled position
when the inverter is shipped. The location of the switches can determine the
following settings for an inverter:
• Terminate the network
• Determine the center inverter(s) on the network
• Turn on biasing
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Data Monitoring and Controls
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Advanced Energy
Termination DIP switches
Figure 6‑8. Termination switches on the user interface PCB
The performance of your Modbus network may require each end of the network to be
terminated using 120 Ω termination resistors. When the network is long, relative to
the RS-485 bit rate in use, bus terminations must be installed. The network length is
determined by the total backbone cable length and not necessarily the line-of-sight
between the two furthest apart devices.
Table 6‑1. Maximum network length per Modbus bit rate
RS-485/Modbus Bit
Rate
Maximum Network
Length Without
Termination in Feet
(Meters)
Maximum Network
Length With Termination
in Feet (Meters)
9600 bps
1000 (305)
4000 (1200)
19,200 bps
500 (152)
4000 (1200)
38,400 bps
250 (76)
4000 (1200)
57,600 bps
150 (46)
4000 (1200)
TO TERMINATE THE INVERTER NETWORK
If bus termination is desired and the inverter is on the end of the Modbus network,
you need to set the termination.
On the front of the user interface PCB, using the Modbus Termination switches:
• Place the Line switch in the On position.
6‑10
Data Monitoring and Controls
570-1001791-05A
Advanced Energy® AE 500 Inverter
TO SET THE CENTER INVERTERS FOR THE NETWORK
On the front of the user interface PCB, using the Modbus Termination switches:
1. Place the Low switch in the OFF position.
2. Place the Line switch in the OFF position.
3. Place the High switch in the OFF position.
TO SET NETWORK BIASING
Biasing sets the voltage levels on the data lines of an inactive or idle network. At
least one device on the network must provide biasing. On shorter networks with
fewer installed devices, biasing may only be needed on the device furthest away from
the master. Longer networks that are terminated on both ends may require two
devices to have their biasing enabled.
To Set the Jumpers to Use the Inverter’s Built-in Biasing
On the front of the user interface PCB, using the Modbus Termination switches:
1. Place the Low switch in the ON position.
2. Place the Line switch in the OFF position.
3. Place the High switch in the ON position.
TO TERMINATE THE NETWORK AND ENABLE BIASING
As an alternative, an end inverter on the network can require both termination and
biasing to be enabled. On the front of the user interface PCB, set the following
switches to configure the inverter for both settings.
1. Place the Low switch in the ON position.
2. Place the Line switch in the ON position.
3. Place the High switch in the ON position.
Setting the Modbus Address
A Modbus network containing slave devices requires a unique address for each slave.
These unique addresses allow the master device to identify and communicate with
each slave. The Modbus network administrator must assign a unique Modbus address
to each AE inverter.
The Modbus Address switches are located on the user interface PCB in the card
cage in the data monitoring compartment.
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Advanced Energy
Modbus DIP switches
Figure 6‑9. Setting the Modbus address
TO SET THE MODBUS ADDRESS
1. Determine each slave address.
2. Set the address on each slave device.
The slave address is set using the Modbus Address switches on the front of
the user interface PCB.
☞ Important
0 is not an allowed address.
☞ Important
Some Modbus master devices do not allow addresses above the decimal
value of 126. AE recommends keeping the number of slave devices
between 2 and 100.
Device Addressing Example
Each inverter must be set to a unique address specified by the site monitoring
contractor. The address is set using a binary code on the address DIP switch.
To set an inverter to an address of 25:
1. Find the desired address in the left hand column of the table below labeled
“Unit Address”.
2. Identify which switches, by switch number, must be set to the ON position.
For example, an address of 25 requires switch numbers 1, 4, and 5 to ON.
3. Once the switches are set in the ON position, the switch should look like the
figure below.
6‑12
Data Monitoring and Controls
570-1001791-05A
Advanced Energy® AE 500 Inverter
ON
Addr 1
2
4
8
16
32
64
128
Addr 1
2
3
4
5
6
7
8
4670
Figure 6‑10. Example: Unit address switch set to address 25
If you need more device addresses than the 80 provided in the following table, refer
to a complete digital to binary conversion table.
Table 6‑2. Inverter address table
Switch Number
Unit
Address
(decima
l)
1
2
3
4
5
6
7
8
32
64
128
Switch Address
1
2
4
8
16
1
ON
Off
Off
Off
Off
Off
Off
Off
2
Off
ON
Off
Off
Off
Off
Off
Off
3
ON
ON
Off
Off
Off
Off
Off
Off
4
Off
Off
ON
Off
Off
Off
Off
Off
5
ON
Off
ON
Off
Off
Off
Off
Off
6
Off
ON
ON
Off
Off
Off
Off
Off
7
ON
ON
ON
Off
Off
Off
Off
Off
8
Off
Off
Off
ON
Off
Off
Off
Off
9
ON
Off
Off
ON
Off
Off
Off
Off
10
Off
ON
Off
ON
Off
Off
Off
Off
11
ON
ON
Off
ON
Off
Off
Off
Off
12
Off
Off
ON
ON
Off
Off
Off
Off
13
ON
Off
ON
ON
Off
Off
Off
Off
14
Off
ON
ON
ON
Off
Off
Off
Off
15
ON
ON
ON
ON
Off
Off
Off
Off
16
Off
Off
Off
Off
ON
Off
Off
Off
17
ON
Off
Off
Off
ON
Off
Off
Off
18
Off
ON
Off
Off
ON
Off
Off
Off
19
ON
ON
Off
Off
ON
Off
Off
Off
20
Off
Off
ON
Off
ON
Off
Off
Off
21
ON
Off
ON
Off
ON
Off
Off
Off
22
Off
ON
ON
Off
ON
Off
Off
Off
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Data Monitoring and Controls
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Advanced Energy
Table 6‑2. Inverter address table (Continued)
Switch Number
Unit
Address
(decima
l)
1
2
3
4
5
6
7
8
32
64
128
Switch Address
1
2
4
8
16
23
ON
ON
ON
Off
ON
Off
Off
Off
24
Off
Off
Off
ON
ON
Off
Off
Off
25
ON
Off
Off
ON
ON
Off
Off
Off
26
Off
ON
Off
ON
ON
Off
Off
Off
27
ON
ON
Off
ON
ON
Off
Off
Off
28
Off
Off
ON
ON
ON
Off
Off
Off
29
ON
Off
ON
ON
ON
Off
Off
Off
30
Off
ON
ON
ON
ON
Off
Off
Off
31
ON
ON
ON
ON
ON
Off
Off
Off
32
Off
Off
Off
Off
Off
ON
Off
Off
33
ON
Off
Off
Off
Off
ON
Off
Off
34
Off
ON
Off
Off
Off
ON
Off
Off
35
ON
ON
Off
Off
Off
ON
Off
Off
36
Off
Off
ON
Off
Off
ON
Off
Off
37
ON
Off
ON
Off
Off
ON
Off
Off
38
Off
ON
ON
Off
Off
ON
Off
Off
39
ON
ON
ON
Off
Off
ON
Off
Off
40
Off
Off
Off
ON
Off
ON
Off
Off
41
ON
Off
Off
ON
Off
ON
Off
Off
42
Off
ON
Off
ON
Off
ON
Off
Off
43
ON
ON
Off
ON
Off
ON
Off
Off
44
Off
Off
ON
ON
Off
ON
Off
Off
45
ON
Off
ON
ON
Off
ON
Off
Off
46
Off
ON
ON
ON
Off
ON
Off
Off
47
ON
ON
ON
ON
Off
ON
Off
Off
48
Off
Off
Off
Off
ON
ON
Off
Off
49
ON
Off
Off
Off
ON
ON
Off
Off
50
Off
ON
Off
Off
ON
ON
Off
Off
51
ON
ON
Off
Off
ON
ON
Off
Off
52
Off
Off
ON
Off
ON
ON
Off
Off
6‑14
Data Monitoring and Controls
570-1001791-05A
Advanced Energy® AE 500 Inverter
Table 6‑2. Inverter address table (Continued)
Switch Number
Unit
Address
(decima
l)
1
2
3
4
5
6
7
8
32
64
128
Switch Address
1
2
4
8
16
53
ON
Off
ON
Off
ON
ON
Off
Off
54
Off
ON
ON
Off
ON
ON
Off
Off
55
ON
ON
ON
Off
ON
ON
Off
Off
56
Off
Off
Off
ON
ON
ON
Off
Off
57
ON
Off
Off
ON
ON
ON
Off
Off
58
Off
ON
Off
ON
ON
ON
Off
Off
59
ON
ON
Off
ON
ON
ON
Off
Off
60
Off
Off
ON
ON
ON
ON
Off
Off
61
ON
Off
ON
ON
ON
ON
Off
Off
62
Off
ON
ON
ON
ON
ON
Off
Off
63
ON
ON
ON
ON
ON
ON
Off
Off
64
Off
Off
Off
Off
Off
Off
ON
Off
65
ON
Off
Off
Off
Off
Off
ON
Off
66
Off
ON
Off
Off
Off
Off
ON
Off
67
ON
ON
Off
Off
Off
Off
ON
Off
78
Off
Off
ON
Off
Off
Off
ON
Off
69
ON
Off
ON
Off
Off
Off
ON
Off
70
Off
ON
ON
Off
Off
Off
ON
Off
71
ON
ON
ON
Off
Off
Off
ON
Off
72
Off
Off
Off
ON
Off
Off
ON
Off
73
ON
Off
Off
ON
Off
Off
ON
Off
74
Off
ON
Off
ON
Off
Off
ON
Off
75
ON
ON
Off
ON
Off
Off
ON
Off
76
Off
Off
ON
ON
Off
Off
ON
Off
77
ON
Off
ON
ON
Off
Off
ON
Off
78
Off
ON
ON
ON
Off
Off
ON
Off
79
ON
ON
ON
ON
Off
Off
ON
Off
80
Off
Off
Off
Off
ON
Off
ON
Off
570-1001791-05A
Data Monitoring and Controls
6‑15
Advanced Energy
MODBUS COMMANDS
All AE commercial inverters support basic Modbus commands. The commands in
the following table are used to read and write (set) inverter operating parameters or
obtain the unit's identifying information.
Table 6‑3. Modbus commands
Command Name
Command
Number
Description
Read Holding Register
03
Read value from the register
Write (preset) Single
Register
06
Write value to the register
Return Slave ID
17
Returns a text string containing the ID
number of the inverter.
The format of the ID returned is
dependent on the version of the
inverter.
• "PVP Inverter
IDxxxxxxxxxxxxxx" on older
models
• "xxPVP Inverter
IDxxxxxxxxxxxxxx" for newer
models
Modbus Command Format
The Read Holding Register command is used to read values from Modbus registers.
Table 6‑4. Format for Read Holding Register command
Command Information
6‑16
Command Layout
Modbus address
nn
Command number
03
First register MSB
xx
First register LSB
xx
Data MSB
xx
Data LSB
xx
CRC LSB
xx
Data Monitoring and Controls
570-1001791-05A
Advanced Energy® AE 500 Inverter
Table 6‑4. Format for Read Holding Register command (Continued)
Command Information
Command Layout
CRC MSB
xx
Table 6‑5. Response format for Read Holding Register command
Response Information
Response Layout
Modbus address
nn
Command number
03
Number of bytes of data
n
First register MSB
xx
First register LSB
xx
Second register MSB
xx
Second register LSB
xx
Nth register MSB
xx
Nth register LSB
xx
CRC LSB
xx
CRC MSB
xx
The Write Single Register command is used to write data to a register.
Table 6‑6. Format for Write Single Register command
Command Information
Command Layout
Modbus address
nn
Command number
06
First register MSB
xx
First register LSB
xx
Data MSB
xx
Data LSB
xx
CRC LSB
xx
CRC MSB
xx
Table 6‑7. Response format for Write Single Register command
Response Information
Response Layout
Modbus address
nn
Command number
06
570-1001791-05A
Data Monitoring and Controls
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Advanced Energy
Table 6‑7. Response format for Write Single Register command (Continued)
Response Information
Response Layout
Number of bytes of data
n
First register MSB
xx
First register LSB
xx
Data MSB
xx
Data LSB
xx
CRC LSB
xx
CRC MSB
xx
Return Slave ID
The Return Slave ID command is used to read a text string containing the ID
number of the inverter.
Table 6‑8. Format for Return Slave ID
Command Information
Command Layout
Modbus slave address
Command number
nn (1-126)
11h
The Return Slave ID command returns the ASCII string "xxPVP Inverter IDxxxxx".
for example "0x50,0xFF,PVP Inverter ID02860910080321". The first "xx" represents
two non-ASCII bytes, representing the following information:
• Byte 1:0x50 - An identifier byte for the AE inverter
• Byte 2:0x00 - If communication with the inverter is down
0xFF - If communication with the inverter is okay
• Byte 3 through byte n: Contains "PVP Inverter IDxxxxx"
Table 6‑9. Format for Return Slave ID command
Response Information
Modbus slave address
6‑18
Response Layout
11h
Command number
n
Number of bytes of data
xx
Data 1
xx
Data 2
xx
Data n
xx
Data Monitoring and Controls
570-1001791-05A
Advanced Energy® AE 500 Inverter
Table 6‑9. Format for Return Slave ID command (Continued)
Response Information
Response Layout
CRC LSB
xx
CRC MSB
xx
MODBUS DATA TYPES
Modbus data types used with the AE 500 unit are shown in the following table.
Table 6‑10. Data types
Data Type
ASCII
Description
Two ASCII characters per register
For a text string the left-most character is the lowest register
number.
UINT16
Unsigned integer, 16 bits
Range: 0 to 65,536
SINT16
Signed integer, 16 bits
Range: –32,767 to +32,767
UINT 32
(requires two
registers)
Unsigned integer, 32 bits
SINT32
(requires two
registers)
Signed integer, 32 bits
FLOAT
(requires two
registers)
IEEE 754 standard 32-bit floating point number
Range: 0 to 4,294,967,295
Range: –2,147,483,647 to +2,147,483,647
High order 16 bits in the first of the two registers. Low order 16
bits in the second register. (Big Endian)
MODBUS REGISTER MAPPING
The following tables list the Modbus registers with their location and a description of
the data stored in the register.
Modbus Fixed Information Registers
570-1001791-05A
Data Monitoring and Controls
6‑19
Advanced Energy
Table 6‑11. Modbus fixed information registers
Description
Start
Register
End
Register
No. of
Modbus
Registers Address
Data
Type
Notes
Modbus base address = 0
Inverter ID
number
0
7
8
40001
ASCII
The ID number
is a 16-character
number that is
unique for each
inverter.
Inverter model
number
1
2
2
40002
ASCII
The model
number is
extracted from
four digits of the
inverter ID
number.
Table 6-12
Firmware
version
8
11
4
40009
ASCII
This register can
contain up to 8
characters.
Example: V1.9
Map version
13
13
1
40014
UINT16
The range is 1
through 4.
This number
Increments
sequentially as
the map changes.
All versions are
backwards
compatible.
Inverter
configuration
14
14
1
40015
UINT16
See Table 6-13
on page 6-21.
Inverter serial
number
15
24
10
40016
ASCII
This register
contains the
serial number of
the inverter
(which is also on
the product
label). Up to 20
characters are
available.
Rated power
25
25
1
40026
UINT16
kW
6‑20
Data Monitoring and Controls
570-1001791-05A
Advanced Energy® AE 500 Inverter
Table 6‑12. Inverter model number
Inverter Model
Modbus Model Number
PVP30kW
0272, 0273, 0274, 0288, 0289, 0290
PVP35kW
0300, 0301, 0302, 0303
PVP50kW
0304, 0305, 0306, 0307
PVP75kW
0276, 0277, 0278, 0279
PVP100kW
0280, 0281, 0282, 0283
PVP250kW
0312, 0313, 0314, 0315, 0316, 0317, 0318, 0319
PVP260kW
0312, 0313, 0314, 0315, 0316, 0317, 0318, 0319
PVP500kW
0386, 0387
Table 6‑13. Bit mapping for inverter configuration register
Inverter Configuration
Bit Mapping
AC volts = 208
0x0001
AC volts = 240
0x0002
AC volts = 480
0x0004
AC volts = 600
0x0200
Transformer tap position
0x0008
Instructions
This bit is:
• Set if the tap is at 265 V
• Clear if the tap is 295 V
The default is 295 V.
Transformer wiring
configuration
0x0010
This bit is:
• Set if the inverter is wired
as delta
• Clear if the inverter is
wired as wye
The default is wye.
Utility meter installation
flag
0x0100
This bit is:
• Set if the meter is installed
• Clear if the meter is not
installed
The default is not installed.
570-1001791-05A
Data Monitoring and Controls
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Advanced Energy
Table 6‑13. Bit mapping for inverter configuration register (Continued)
Inverter Configuration
Bit Mapping
Positive ground
Instructions
0x0400
This bit is:
• Set if the inverter is
configured for positive
ground
• Clear if the inverter is
configured for negative
ground
Factory configured
AC disconnect
0x0800
This bit is:
• Set if an AC disconnect is
installed
• Clear if an AC disconnect
is not installed
Factory configured
Modbus Data Registers
Table 6‑14. Modbus data registers
Description
Start
Register
End
Register
No. of
Modbus
Registers Address
Data
Type
Notes
Modbus base address = 1000
VoltsA L-N
1000
1001
2
41001
FLOAT ± 32 bit IEEE 754
VoltsB L-N
1002
1003
2
41003
FLOAT ± 32 bit IEEE 754
VoltsC L-N
1004
1005
2
41005
FLOAT ± 32 bit IEEE 754
Current A
1006
1007
2
41007
FLOAT ± 32 bit IEEE 754
Current B
1008
1009
2
41009
FLOAT ± 32 bit IEEE 754
Current C
1010
1011
2
41011
FLOAT ± 32 bit IEEE 754
DC input
voltage
1012
1013
2
41013
FLOAT ± 32 bit IEEE 754
DC input
current (see
note)
1014
1015
2
41015
FLOAT ± 32 bit IEEE 754
Line
frequency
1016
1017
2
41017
FLOAT ± 32 bit IEEE 754
Line kW
1018
1019
2
41019
FLOAT ± 32 bit IEEE 754
6‑22
Data Monitoring and Controls
570-1001791-05A
Advanced Energy® AE 500 Inverter
Table 6‑14. Modbus data registers (Continued)
Description
Start
Register
End
Register
No. of
Modbus
Registers Address
Data
Type
Notes
Modbus base address = 1000
Total kWh
delivered
1020
1021
2
41021
UINT32 0 to 4.29e9
PV input
voltage
1022
1023
2
41023
FLOAT ± 32 bit IEEE 754
DC kW
(calculated)
1024
1025
2
41025
FLOAT ± 32 bit IEEE 754
Time since
epoch
1026
1027
2
41027
FLOAT Seconds since
01/01/1970
Total kWh
1028
1029
2
41029
UINT32 ± 32 bit IEEE 754
Modbus Status and Fault Code Registers
The following table provides information about the registers that are used to report
status and fault codes. Each of these registers provides information about a group of
status codes or faults. For more information on the specific faults that can be reported
for each of the fault registers, see the troubleshooting information for the inverter.
For more information about the status codes, see Table 6-16 on page 6-24 and
Table 6-17 on page 6-25.
Table 6‑15. Modbus status and fault code registers
Description
Start
Register
End
Register
No. of
Registers
Modbus
Address
Data
Type
Notes
Modbus base address = 2000
Inverter
operating
status (state)
2100
2100
1
42101
UINT16 See Table 6-16 on
page 6-24.
Main fault
2101
2101
1
42102
UINT16 See the fault
codes descriptions
in the inverter
troubleshooting
information.
Drive fault
2102
2102
1
42103
UINT16 See the fault
codes descriptions
in the inverter
troubleshooting
information.
570-1001791-05A
Data Monitoring and Controls
6‑23
Advanced Energy
Table 6‑15. Modbus status and fault code registers (Continued)
Description
Start
Register
End
Register
No. of
Registers
Modbus
Address
Data
Type
Notes
Modbus base address = 2000
Voltage fault
2103
2103
1
42104
UINT16 See the fault
codes descriptions
in the inverter
troubleshooting
information.
Grid fault
2104
2104
1
42105
UINT16 See the fault
codes descriptions
in the inverter
troubleshooting
information.
Temperature
fault
2105
2105
1
42106
UINT16 See the fault
codes descriptions
in the inverter
troubleshooting
information.
System fault
2106
2106
1
42107
UINT16 See the fault
codes descriptions
in the inverter
troubleshooting
information.
System
warnings
2107
2107
1
42108
UINT16 See the fault
codes descriptions
in the inverter
troubleshooting
information.
PVM (PV
Monitoring)
status codes
2108
2108
1
42109
UINT16 See Table 6-17 on
page 6-25.
The following table contains the bitmap information for the inverter operating status
register. The response values for this command are shown in the bale as both hex and
decimal values.
Table 6‑16. Modbus inverter operating status register values
Description
Hex Value
Decimal Value
Modbus register number = 42101
6‑24
Sleep state
0
0
Startup delay state
1
1
AC precharge state
2
2
Data Monitoring and Controls
570-1001791-05A
Advanced Energy® AE 500 Inverter
Table 6‑16. Modbus inverter operating status register values (Continued)
Description
Hex Value
Decimal Value
Modbus register number = 42101
DC precharge state
3
3
Idle state
4
4
Power track state
5
5
Reserved
6
6
Reserved
7
7
Reserved
8
8
Fault state
9
9
Initialization state
A
10
Disabled state
B
11
Latching fault state
C
12
Cool down state
D
13
The following table contains the bitmap information for the PVM status register . The
response values for this command are shown in the table as both hex and decimal
values. When multiple codes are set, the resulting status word value will be a sum of
the individual code values.
Table 6‑17. PVM status register status code values
Description
Hex Value
Decimal Value
Notes
Modbus register number = 42005
OK
0
0
Rebooting
1
1
Inverter
communication fault
2
2
Web post fault
4
4
DNS server fault
8
8
Real time clock error
10
16
570-1001791-05A
Data Monitoring and Controls
Results in return value
of zero for reads of
data registers listed in
Table 6-14 on
page 6-22.
The battery is dead or
cannot synchronize
with the network time
server.
6‑25
Advanced Energy
Table 6‑17. PVM status register status code values (Continued)
Description
Hex Value
Decimal Value
Notes
Modbus register number = 42005
Wrong
communications
firmware
20
32
Incompatible or
incorrect revision of
communications
firmware.
Modbus address error
40
64
Failed reading the
Modbus address
switches.
Modbus Command Registers
Table 6‑18. Modbus command registers
Description
Start
Register
End
Register
No. of
Modbus
Registers Address
Data
Type
Notes
Modbus base address = 3000
Clear fault
command
3000
Disable
inverter
3001
3000
1
43001
UINT16 Range = CF hex
Write this value to
clear faults and try
a restart.
3001
1
43002
UINT16 Write values:
• 0xDD to
disable
• 0xEE to
enable
Reading this
register returns:
• 0 after
bootup
• 0xDD after a
disable
• 0xEE after an
enable
command is
sent
6‑26
Data Monitoring and Controls
570-1001791-05A
Advanced Energy® AE 500 Inverter
Table 6‑18. Modbus command registers (Continued)
Description
Start
Register
End
Register
No. of
Modbus
Registers Address
Data
Type
Notes
Modbus base address = 3000
Enable
inverter
3002
3002
1
43003
UINT16 Write values:
• 0xDD to
disable
• 0xEE to
enable
Reset data
3003
comm section
3003
1
43004
UINT16 Write 0x99 to this
register to reset
the
communication
interface PCB.
Related Links
• “Troubleshooting Warnings and Faults” on page 8-2
570-1001791-05A
Data Monitoring and Controls
6‑27
Advanced Energy
6‑28
Data Monitoring and Controls
570-1001791-05A
Advanced Energy® AE 500 Inverter
Chapter
7
Maintenance
WARNING:
These servicing instructions are for use by qualified personnel only. To
reduce the risk of electric shock, do not perform any servicing other than that
specified in the operating instructions.
AVERTISSEMENT:
Ces instructions d’entretien sont destinées uniquement à un personnel
qualifié. Pour réduire le risque d'électrocution, ne pas effectuer un entretien
autre que celui spécifié dans les instructions de fonctionnement.
WARNING:
Maintenance personnel must receive proper training before installing,
troubleshooting, or maintaining high-energy electrical equipment. Potentially
lethal voltages could cause death, serious personal injury, or damage to the
equipment. Ensure that all appropriate safety precautions are taken.
AVERTISSEMENT:
Le personnel d’entretien doit recevoir une formation appropriée avant
d’installer, de dépanner ou d’entretenir un équipement électrique à haute
énergie. Des tensions potentiellement mortelles pourraient provoquer la
mort, des blessures graves ou des dommages à l’équipement. S’assurer que
toutes les consignes de sécurité appropriées ont été respectées.
Routine maintenance of the AE inverter should be performed according the
maintenance schedule in this manual in order to maintain the overall performance of
the unit. Some maintenance procedures are required every five, ten, fifteen, and
twenty years from point of installation.
The user manual includes maintenance procedures that you can perform without
specialized equipment.
570-1001791-05A
Maintenance
7‑1
Advanced Energy
VISUAL INSPECTION
DANGER:
Risk of electrical shock. High voltages are present in the inverter cabinet.
Both AC and DC disconnects must be in the OFF position when working on
the unit. Wait five minutes to discharge high voltage before opening the front
panels of the inverter.
DANGER:
Risque d’électrocution. L’intérieur de l’onduleur est soumis à des hautes
tensions. Les interrupteurs de courant alternatif et continu doivent être mis
HORS TENSION durant les travaux sur l’unité. Attendez cinq minutes afin de
permettre la décharge du courant haute tension avant de démonter les
panneaux avant de l’onduleur.
DANGER:
RISK OF DEATH OR BODILY INJURY. Disconnect and lockout/tagout all
sources of input power before working on this unit or anything connected to
it.
DANGER:
RISQUE DE MORT OU DE BLESSURES CORPORELLES. Débrancher et
verrouiller/étiqueter toutes les sources de puissance d’entrée avant de
travailler sur cette unité ou sur tout élément qui y est raccordé.
AE recommends visually inspecting the inverter every time it is serviced. Start by
observing the front, back, and sides of the inverter for damage, foreign objects, or
dust and debris that may have accumulated around the inverter. Remove dirt and
debris from the area around the inverter at least every six months.
MAINTENANCE SCHEDULE
The following maintenance should be performed annually by a qualified service
person. Please refer to AE's Terms and Conditions of Sale for warranty-related items.
Complete the maintenance checklist below save the information for your records.
7‑2
Maintenance
570-1001791-05A
Advanced Energy® AE 500 Inverter
Table 7‑1. Maintenance checklist
Item #
Check or Procedure
Annual
Maintenance
A
General inspection and cleaning
1
Record general site conditions.
X
2
Record inverter performance data from inverter display.
X
3
Record environmental conditions.
X
4
Remove dirt and debris from underneath the inverter.
X
5
Inspect and clean interior of inverter.
X
6
Inspect air filter and clean or replace.
X
7
Confirm presence of product documentation.
X
B
Connections and wiring
8
Complete visual inspection of electrical connections and wiring.
X
9
Complete mechanical inspection of connections and wiring.
X
10
Measure torque of all electrical connections and re-torque as
needed.
X
11
Complete thermal scan of inverter connections, wiring and
electronics.
X
C
Testing
12
Confirm the inverter operating modes including standby, startup
and on.
X
13
Check operation of protective circuits and alarms.
X
14
Validate display data accuracy.
X
D
Repair or replace
15
Repair or replace items that have been determined to be near the
end of their useful life.
E
Reporting
16
Complete preventative maintenance report and recommendation.
X
X
REPLACEMENT PARTS
Contact Solar Energy Technical Support for information on obtaining replacement
parts.
570-1001791-05A
Maintenance
7‑3
Advanced Energy
Table 7‑2. Inverter replacement parts
Part
Replacement Schedule
Door seal gaskets
5 years
Battery (CR1216)
When a Real Time Clock error occurs in
Modbus PVM status register 42005.
Air filters
As needed
Card cage filter
As needed
CHECKING AND REPLACING THE AIR
FILTERS
As part of preventative maintenance, every 12 months you should perform regular
checks of the self-contained cooling system to determine if the air filters need to be
replaced. Cleaning may be required more often depending on the location of the
inverter or the air filters might need to be replaced.
Maintaining the Air Filters
TOOLS REQUIRED
• Flat-head screwdriver
• 5/32″ Allen wrench
TO MAINTAIN THE AIR FILTERS
The air intake hoods are mounted on gas shocks. The hoods must be in the open
position to clean the filters.
1. Shutdown the inverter prior to starting this procedure and wait five minutes.
2. Using a flat-head screwdriver, turn each of the six retainer tabs a three-quarter
turn. The air intake hoods can now be lifted to the open position.
7‑4
Maintenance
570-1001791-05A
Advanced Energy® AE 500 Inverter
Air filters
4680
Figure 7‑1. Air intake hoods
3. Remove the filters using a 5/32″ Allen wrench.
4. Clean the filters by vacuuming or blowing out using an air hose with a diffuser.
If there is significant accumulation of dust or particulate matter within the filter
fabric, areas of visible blockage to air flow, or physical damage, replace the
affected filters.
Hood in closed position
Raised hood
Figure 7‑2. Air intake hood in raised position
5. Inspect the filter frames for damage.
Contact AE Solar Energy Technical Support if you wish to replace the filters or
frames.
6. Close and secure the hoods before resuming normal operation of the unit.
570-1001791-05A
Maintenance
7‑5
Advanced Energy
Maintaining the Card Cage Air Filter
TO MAINTAIN THE CARD CAGE FILTER
The card cage features a secondary air filter to ensure long PCB life. The card cage
air filter is located under the intake air shroud above the card cage located in the
upper right compartment.
Use the following instructions to access the secondary air filter for the card cage.
1. Shutdown the inverter and wait five minutes prior to starting this maintenance
procedure.
2. Remove the air intake shroud next to the power supplies. This will expose the
air filter.
Shroud
Air filter for control
electronics compartment
Note: Power supplies are removed
Figure 7‑3. Card cage air filter
3. Remove the four screws on the card cage air filter.
4. Remove the filter.
5. Clean the filter with compressed air.
6. Replace the filter and secure with the screws.
If the filter needs to be replaced, contact AE Solar Energy Technical Support.
7. Replace the shroud.
REPLACING THE BATTERY ON THE
COMMUNICATIONS PCB
Parts Required
• Battery: Part number CR1216
7‑6
Maintenance
570-1001791-05A
Advanced Energy® AE 500 Inverter
To Replace the Battery
Use the following instructions to access the battery.
1. Shutdown the inverter and wait five minutes before starting.
2. Remove the communications PCB from the card cage in the data monitoring
compartment.
3. Remove the battery located in the lower right section of the PCB by pushing
the battery up from the lower right corner of the battery.
4. Insert a new battery with the positive side facing out.
5. Reinsert the communications PCB in the card cage.
6. Close and secure the door on the data monitoring compartment.
570-1001791-05A
Maintenance
7‑7
Advanced Energy
7‑8
Maintenance
570-1001791-05A
Advanced Energy® AE 500 Inverter
Chapter
8
Troubleshooting and Solar
Energy Technical Support
WARNING:
Maintenance personnel must receive proper training before installing,
troubleshooting, or maintaining high-energy electrical equipment. Potentially
lethal voltages could cause death, serious personal injury, or damage to the
equipment. Ensure that all appropriate safety precautions are taken.
AVERTISSEMENT:
Le personnel d’entretien doit recevoir une formation appropriée avant
d’installer, de dépanner ou d’entretenir un équipement électrique à haute
énergie. Des tensions potentiellement mortelles pourraient provoquer la
mort, des blessures graves ou des dommages à l’équipement. S’assurer que
toutes les consignes de sécurité appropriées ont été respectées.
Before calling AE Solar Energy Technical Support, perform recommended checks
and troubleshooting procedures. If you are still unable to resolve faults or warnings
and resume normal operation after following these checks and procedures, contact
AE Solar Energy Technical Support.
TROUBLESHOOTING LAN CONNECTIVITY
Most connectivity problems relate to wiring issues or corporate security settings
blocking the inverter from accessing the Internet.
Wiring problems are usually caused by the following:
• Result of a poor crimp
• Wire that exceeds 320 ft. as specified in the installation of the inverter
• Pinched wires somewhere between the inverter and the hub or router
Corporate network problems will require support from your corporate IT department
where the inverter is installed. The most common problem is the inverter has not
been provided with DHCP server access using port 443 or the static IP address has
not been set.
Troubleshooting communications issues can also be accomplished using the four
LED lights on the communications PCB.
570-1001791-05A
Troubleshooting and Solar Energy Technical Support
8‑1
Advanced Energy
To Test the LAN Cable
AE recommends using pre-made cables whenever possible. If a cable must be handcrimped, we recommend:
• Test the cable with a cable tester such as a Fluke LinkRunner™ Pro Network
Multimeter (LPRO1000).
• Verify the cable’s integrity by connecting a laptop to the cable at the inverter
and verify it has access to the Internet.
• Verify the inverter’s MAC address has been assigned an IP address by the
network.
TROUBLESHOOTING WARNINGS AND
FAULTS
WARNING:
Maintenance personnel must receive proper training before installing,
troubleshooting, or maintaining high-energy electrical equipment. Potentially
lethal voltages could cause death, serious personal injury, or damage to the
equipment. Ensure that all appropriate safety precautions are taken.
AVERTISSEMENT:
Le personnel d’entretien doit recevoir une formation appropriée avant
d’installer, de dépanner ou d’entretenir un équipement électrique à haute
énergie. Des tensions potentiellement mortelles pourraient provoquer la
mort, des blessures graves ou des dommages à l’équipement. S’assurer que
toutes les consignes de sécurité appropriées ont été respectées.
DANGER:
This unit contains energy storage devices that take up to 5 minutes to
discharge. Verify the high energy capacitors are completely discharged
before working on this unit.
DANGER:
Cette unité contient des dispositifs de stockage d’énergie qui prennent
jusqu’à 5 minutes pour se décharger. Vérifier que les condensateurs à haute
énergie sont complètement déchargés avant de travailler sur l’unité.
The inverter's display screen is the primary indicator of a possible problem with the
inverter. The inverter can detect and display inverter warnings and faults.
8‑2
Troubleshooting and Solar Energy Technical Support
570-1001791-05A
Advanced Energy® AE 500 Inverter
Before performing advanced troubleshooting, the inverter must be de-energized.
Prior to conducting the following troubleshooting steps, perform a visual inspection
to check for the following:
• Loose or disconnected wires
• Fuses
• Other connections
• Hardware issues
If the visual inspection reveals potentially unsafe conditions, discontinue
troubleshooting and contact AE Solar Energy Technical Support or email
[email protected] prior to proceeding.
Troubleshooting Warnings
Warnings are displayed if a condition is detected that does not require the inverter to
shut down but may require attention. The following screen is a sample warning
screen.
4654
Figure 8‑1. Warning screen
SYSTEM WARNINGS
The following table lists the system warnings.
570-1001791-05A
Troubleshooting and Solar Energy Technical Support
8‑3
Advanced Energy
Table 8‑1. Inverter system warnings
Hexadecimal
Value
Display String
Description
0001
FAN 1 WARNING
Fan 1 warning
0002
FAN 2 WARNING
Fan 2 warning
0008
MAG HITEMP
WARNING
Magnetics high
temperature warning
0010
HI TEMP PWR
LIMIT
Power foldback warning
0020
DELTA TEMP
WARNING
Heatsink delta
temperature warning
0080
GFDI CURRENT
WARNING
GFDI current warning
0100
AC SURGE
WARNING
AC surge warning
0200
DC SURGE
WARNING
DC surge warning
0400
DC CURRENT
WARNING
Negative DC current
warning
0800
IPM CURRENT
WARNING
IPM current warning
1000
PS 24V WARNING
24 V power supply
warning
2000
DC BLEED
WARNING
DC bleed circuit warning
Action
Contact Solar Energy
Technical Support
Troubleshooting Inverter Faults
If a fault has occurred the inverter will cease power production until the fault is
cleared. A fault may be a latching or non-latching fault.
• Non-latching: Automatically clears if the fault condition is resolved and the
inverter automatically restarts after completing its startup sequence.
• Latching: Requires manual intervention to restart the inverter.
If the inverter has faulted, the display screen will show the corresponding fault
information in a series of three or more screens. The display will then cycle back
through the three screens.
• First screen: Displays the fault category followed by the hexidecimal fault
code(s) value.
• Second screen: Displays a text description of the fault code(s).
• Third screen: Displays Solar Energy Technical Support contact information.
8‑4
Troubleshooting and Solar Energy Technical Support
570-1001791-05A
Advanced Energy® AE 500 Inverter
In the following example, a system fault, SYS returned a code, indicating too many
fault restarts occurred. The 0000 indicates no fault occurred in the other fault
groups.
Fault Codes
SYS 0020 DRV 0000
VLT 0000 TMP 0000
GRD 0000
Screen 1: Fault code(s)
Fault
AC FAST UNDERVOLT A
GFDI FAULT
Screen 2: Fault text
Advanced Energy
phone: (877)312-3832
email:
[email protected]
aei.com
Screen 3: Contact information
Figure 8‑2. Screen sequence when an inverter faults
AC UNDER VOLTAGE FAULT
To Identify an AC Under Voltage Fault
If the inverter displays an AC Under Voltage fault and all the voltages going
into the inverter are within the tolerances provided in the specifications, continue
with the following troubleshooting tips.
1. Check the main branch circuit breaker.
a. If the breaker is not tripped:
Check the small fuses located on the AC panel. If one or more of these fuses
have opened, replace them with like parts (600 VAC, 7.5 A as required)
2. If any of the fuses are open, visually inspect the wiring. Look for the following:
a. Frayed wires or carbon marks indicating a short
b. Burned traces on the PCBs
If any of these conditions are present, DO NOT START THE INVERTER.
Contact AE Solar Energy Technical Support for replacement parts or service.
GROUND FAULTS
The inverter is equipped with a Ground Fault Detector Interrupter (GFDI). The
purpose of the GFDI is to detect a ground fault (unintended current flow from the
solar panels to earth ground) and in this event, disable the inverter.
WARNING:
For the GFDI circuit to function as designed, the solar array safety ground
must not be connected to the PV array positive or negative leads. Bonding
the safety ground to the grounded leg of the array anywhere but through the
inverter will cause the GFDI circuit to be bypassed. This would defeat the
operation of the GFDI and potentially create an unsafe operating condition.
570-1001791-05A
Troubleshooting and Solar Energy Technical Support
8‑5
Advanced Energy
AVERTISSEMENT:
Pour que le circuit GFDI fonctionne normalement, la prise de terre de
sécurité du système PV ne doit pas être branché aux câbles positifs ou
négatifs des piles PV. Brancher la prise de terre de sécurité au pied des piles
ou à toute autre partie que l’onduleur causerait une mise hors circuit du
GFDI. Ceci ne empêcherait le fonctionnement normale du circuit GFDI et
créerait des conditions de fonctionnement potentiellement dangereuses.
The GFDI functions using a 5 A fuse to connect or bond the solar array negative (or
the solar array positive, if using a positively grounded panel array) to earth ground
on the DC subcombiner panel. If the ground fault current exceeds 5 A between the
grounded array terminal and the earth ground, the GFDI fuse will open and
disconnect the solar panels from their ground reference, interrupting the ground fault.
In this situation, the inverter will cease operation and show a ground fault message on
the inverter display.
To Identify the Cause of a Ground Fault
1. Turn the ON/OFF switch on the display to the OFF position.
2. Turn the AC disconnect to the power OFF position.
The display on the upper front panel should be inactive.
3. Identify the cause of the ground fault by checking the following items:
a. A configuration error during commissioning.
b. Switching the grounded conductor in the DC disconnect.
▪ For a negatively grounded system, the positive leg should be broken in the
DC disconnect.
▪ For a positively grounded system, the negative leg should be broken in the
DC disconnect.
c. A pinched wire in the installation connecting some part of the array or DC
wiring to earth ground.
d. Mismatched array strings in a multiple inverter installation.
TO RESOLVE A GROUND FAULT
DANGER:
This unit contains energy storage devices that take up to 5 minutes to
discharge. Verify the high energy capacitors are completely discharged
before working on this unit.
8‑6
Troubleshooting and Solar Energy Technical Support
570-1001791-05A
Advanced Energy® AE 500 Inverter
DANGER:
Cette unité contient des dispositifs de stockage d’énergie qui prennent
jusqu’à 5 minutes pour se décharger. Vérifier que les condensateurs à haute
énergie sont complètement déchargés avant de travailler sur l’unité.
DANGER:
Verify that no shock hazard exists between both fuse terminals and earth
ground before removing the fuse. A 600 V rated fuse pulling device is
required.
DANGER:
Vérifier qu’il n’y a aucun risque d’électrocution entre les deux bornes de
fusible et la prise de terre avant de retirer le fusible. Un arrache-fusible d’une
capacité de 600 V est requis.
1. Open the control electronics compartment and locate the GFDI fuse on the
backplane PCB.
2. Inspect the 5 A GFDI fuse for continuity using a multimeter.
◦ If the fuse is not open, continue troubleshooting using the steps below.
◦ If the fuse is open, a ground fault exists outside the inverter. Refer to the
instructions for resolving an external ground fault.
3. Remove the GFDI fuse.
4. Check for continuity (ohms) across the GFDI fuse.
If the meter indicates no continuity then a ground fault likely exists.
◦ Check the DC voltage between the grounded terminal of the array and earth
ground. The voltage should be less than 30 volts with the GFDI fuse
removed. If the voltage is higher than 30 volts, a ground fault likely still
exists. Check the array wiring. For the best results, perform this test with the
DC disconnect in both the ON and OFF positions.
◦ Make sure the grounded leg of the solar array is not disconnected inside the
DC disconnect compartment.
5. Once the ground fault condition has been eliminated, verify the voltage
between earth ground and the grounded side of the PV array is less than 30
volts.
6. Ensure the DC disconnect is in the OFF position and install the new GFDI fuse.
7. Restart the inverter.
Related Links
• “System Startup Procedure” on page 5-1
570-1001791-05A
Troubleshooting and Solar Energy Technical Support
8‑7
Advanced Energy
INVERTER FAULT CODES
The inverter display screen provides fault information. In addition, the inverter
firmware utilizes a Modbus variable to indicate a fault condition. Each bit in this fault
variable represents a fault type, the same fault type displayed on the screen. The
Modbus information for the bit assignments and specific fault variables for the fault
categories are as follows:
Table 8‑2. Fault categories
Description
Screen
Display
Category
Bit Number
Hex Value
Decimal Value
Modbus register number = 42102
Drive fault
DRV
0
1
1
Voltage fault
VLT
1
2
2
Grid fault
GRD
2
4
4
Temperature fault
TMP
3
8
8
System fault
SYS
4
10
16
15
8000
32768
Latching fault
For each fault category, another fault variable provides detailed information on which
fault has occurred within this category. The following tables list the possible faults
within each category and related information:
• Hexidecimal value: Value displayed following the category
• Screen display text: Text displayed on the second screen
• Description: Describes the fault
• Action: Necessary steps to resolve the fault
Drive Faults
The following table lists the drive protection faults.
8‑8
Troubleshooting and Solar Energy Technical Support
570-1001791-05A
Advanced Energy® AE 500 Inverter
Table 8‑3. Drive (DRV) faults
Display
Screen Hex
Value
Display Screen Text
Description
0001
DRIVE A LOW
Drive protection fault,
phase A low
0002
DRIVE A HIGH
Drive protection fault,
phase B high
0004
DRIVE B LOW
Drive protection fault,
phase C low
0008
DRIVE B HIGH
Drive protection fault,
phase A high
0010
DRIVE C LOW
Drive protection fault,
phase B low
0020
DRIVE C HIGH
Drive protection fault,
phase C high
0040
HW OVERCURRENT A
Peak over-current,
phase A
0080
HW OVERCURRENT B
Peak over-current,
phase B
0100
HW OVERCURRENT C
Peak over-current,
phase C
0200
RMS OVERCURRENT A RMS over-current,
phase A
0400
RMS OVERCURRENT B RMS over-current,
phase B
0800
RMS OVERCURRENT C RMS over-current,
phase C
1000
DC OVERVOLTAGE
DC volts over range
2000
DC UNDERVOLTAGE
DC volts under range
Action
Contact Solar Energy
Technical Support
Voltage Faults
The following table lists the voltage faults, including VAC sense, VDC, and power
supply faults.
570-1001791-05A
Troubleshooting and Solar Energy Technical Support
8‑9
Advanced Energy
Table 8‑4. Voltage (VLT) faults
Display
Screen Hex
Value
Display Screen Text
Description
0001
VAC OVER PEAK A
Peak AC voltage high,
phase A
0002
VAC OVER PEAK B
Peak AC voltage high,
phase A
0004
VAC OVER PEAK C
Peak AC voltage high,
phase A
0008
PLL FAULT
Control PLL fault
0010
AC UNBALANCED
FAULT
AC voltages unbalanced
0020
DC OVER VOLTAGE
DC voltage high
0040
POWER SUPPLY P5
5 V power supply fault
0080
POWER SUPPLY P15
15 V power supply fault
0100
POWER SUPPLY M15
-15 V power supply
fault
0200
POWER SUPPLY 10
10 V power supply fault
0400
POWER SUPPLY 24
24 V power supply fault
1000
DC PRECHARGE
DC precharge fault
2000
PV-DC DELTA
PV input and DC bus
voltage delta
Action
Contact AE Solar
Energy Technical
Support.
Grid Faults
The grid faults in the following table include grid interactive voltage and frequency
faults.
8‑10
Troubleshooting and Solar Energy Technical Support
570-1001791-05A
Advanced Energy® AE 500 Inverter
Table 8‑5. Grid (GRD) faults
Display
Screen Hex
Value
Display Screen Text
Description
0001
AC FAST UNDERVOLT Fast AC voltage low,
A
phase A
0002
AC FAST UNDERVOLT Fast AC voltage low,
B
phase B
0004
AC FAST UNDERVOLT Fast AC voltage low,
C
phase C
0008
AC SLOW
UNDERVOLT A
Slow AC voltage low,
phase A
0010
AC SLOW
UNDERVOLT B
Slow AC voltage low,
phase B
0020
AC SLOW
UNDERVOLT C
Slow AC voltage low,
phase C
0040
AC FAST OVERVOLT A Fast AC voltage high,
phase A
0080
AC FAST OVERVOLT B Fast AC voltage high,
phase B
0100
AC FAST OVERVOLT C Fast AC voltage high,
phase C
0200
AC SLOW OVERVOLT
A
Slow AC voltage high,
phase A
0400
AC SLOW OVERVOLT
B
Slow AC voltage high,
phase B
0800
AC SLOW OVERVOLT
C
Slow AC voltage high,
phase C
1000
AC UNDER FREQ
Low frequency fault
2000
AC OVER FREQ
High frequency fault
Action
Wait for the grid to
stabilize. The inverter
cannot operate correctly
when the grid voltage is
out of range limitations
or is unstable.
Temperature Faults
The following table lists the temperature faults.
570-1001791-05A
Troubleshooting and Solar Energy Technical Support
8‑11
Advanced Energy
Table 8‑6. Temperature (TMP) faults
Display
Screen Hex
Value
Display Screen Text
Description
0001
HEATSINK TEMP A1
Module heat-sink A1
temperature high
0002
HEATSINK TEMP A2
Module heat-sink A2
temperature high
0004
HEATSINK TEMP B1
Module heat-sink B1
temperature high
0008
HEATSINK TEMP B2
Module heat-sink B2
temperature high
0010
HEATSINK TEMP C1
Module heat-sink C1
temperature high
0020
HEATSINK TEMP C2
Module heat-sink C2
temperature high
0040
BOARD TEMP HI
Control board
temperature high
0080
DRIVE TEMP LOW
Drive temperature low
0100
MAGNETICS TEMP HI
Magnetics temperature
high
0200
AMBIENT TEMP LOW
Ambient temperature
low
0400
MAG TEMP LOW
Magnetics temperature
low
0800
IPM TEMP HIGH
IPM temperature high
Action
Clean all filters. Make
sure air vents aren't
blocked and sufficient
space is provided
around all air vents.
If the filters are clean
and air flow is
insufficient, contact AE
Solar Energy Technical
Support.
System Faults
The following table lists the miscellaneous system faults.
Table 8‑7. System (SYS) faults
Display
Screen Hex
Value
8‑12
Display Screen Text
Description
0001
GROUND FAULT
Ground fault
0002
AC CONTACTOR
AC contactor fault
0004
DC CONTACTOR
DC contactor fault
Troubleshooting and Solar Energy Technical Support
Action
Check the PV array
field wiring.
570-1001791-05A
Advanced Energy® AE 500 Inverter
Table 8‑7. System (SYS) faults (Continued)
Display
Screen Hex
Value
Display Screen Text
Description
0008
WD TIMER
Watchdog fault
0010
CPU LOAD
CPU load fault
0020
RESTART LIMIT
Too many fault restarts
0040
CONFIGURATION
Configuration fault
0080
CURRENT
IMBALANCE
AC current imbalance
0100
AC VOLTAGE SENSE
No AC voltage detected
0800
DISCONNECT OPEN
Disconnect open
1000
DC MISWIRE
DC mis-wired for
configured grounding
Action
Contact AE Solar
Energy Technical
Support for service.
Check the DC wiring.
PCB STATUS LEDS
The AE commercial inverter includes status LEDs to help troubleshoot system
operation. The status LEDs are located on the following PCBs:
• Controller PCB
• Communications interface PCB
Controller PCB Status LEDs
There are two LEDs on the front of the controller PCB, a green and a red LED.
Table 8‑8. Controller PCB LEDs
LED
Color
Green
Flash
Code
Solid
570-1001791-05A
LED Sequence / Unit
Status
Inverter is on and ready to
produce power.
Action
None
Troubleshooting and Solar Energy Technical Support
8‑13
Advanced Energy
Table 8‑8. Controller PCB LEDs (Continued)
LED
Color
Flash
Code
Solid
LED Sequence / Unit
Status
The inverter is in a faulted
condition.
Action
• Check the fault code on the display
screen
• Clear the fault condition
• Inverter will auto reset
Red
Flashing A latching fault has occurred.
• Check the fault code on the display
screen
• Manually clear the fault condition
• Restart the inverter
Communication PCB Status LEDs
The communication PCB includes four status LEDs.
• Link: Indicates presence of a hardware Ethernet connection
• Activity (or ACT): Indicates internet traffic
• Status: Indicates the communication status
• Modbus: Indicates activity on the Modbus network
The four LEDs primary location is on the face of the communication PCB in the data
monitoring card cage on the left side of the power module assembly as shown in the
following figure.
Status LED lights
Figure 8‑3. Communication PCB with status LEDs
8‑14
Troubleshooting and Solar Energy Technical Support
570-1001791-05A
Advanced Energy® AE 500 Inverter
The other set of LEDs are on the communication interface PCB located in the data
monitoring section in the front upper left of the inverter. These four LEDs are surface
mount LEDs located near the Ethernet and Modbus connector as shown in the
following figure. These LEDs are redundant and are synchronized with
communication PCB.
Status LEDs
Figure 8‑4. Communication interface PCB with LEDs
Table 8‑9. Link LED
LED
Color
Amber
Flash Code
Unit Status / Description
Action
On
Hardware Ethernet connection is found
None
Off
No hardware Ethernet connection available None
Table 8‑10. Activity LED
LED
Color
Green
Flash Code
Unit Status / Description
Action
Flashes
Continuous flash to indicate the presence of None
internet traffic
Solid
May be solid in the presence of heavy
internet traffic
570-1001791-05A
None
Troubleshooting and Solar Energy Technical Support
8‑15
Advanced Energy
Table 8‑11. Status LED
LED
Color
Green
Flash Code
On
Unit Status / Description
Serial communication is established.
Inverter communications are operating
normally.
Action
None
• On solid for a few seconds
• Followed by quick flashes for several
seconds while the communications
device looks for an Internet
connection
• After a few seconds flashes more
slowly while serial communication is
established with the inverter’s main
processor
• Remains on unless a fault occurs
Short-longshort
Serial communication fault. The
None
communication PCB is communicating
with the inverter’s main processor via serial
communication. If the communication PCB
cannot establish communication with the
main processor, the serial communication
fault code will flash. It is normal for this
status code to flash for a few seconds
during startup.
Long-shortshort
DNS failure. The inverter attempts to post
data once every 15 minutes to the AE
database using Domain Name Service
(DNS) server to resolve the IP address. The
DNS failure code will flash when:
• Verify the IP
address is valid.
• DNS server cannot be found
• Invalid IP address returned
If this post succeeds, the LED returns to
normal operation until the next post
attempts to connect to the DNS server.
8‑16
Troubleshooting and Solar Energy Technical Support
570-1001791-05A
Advanced Energy® AE 500 Inverter
Table 8‑11. Status LED (Continued)
LED
Color
Flash Code
Short-ShortLong
Unit Status / Description
Action
Network connection fault. The inverter
cannot post data to the AE database server.
The status LED may indicate normal
operation before this occurs. This can
happen in the following circumstances:
• Verify network
cable is
connected.
• Verify the IP
address is valid.
• Network cable is not connected
• Network does not have a DHCP server
or the DHCP server did not provide a
valid IP address to the inverter
• AE server is down for maintenance
• Any other network problem that does
not allow data to post to the AE server
Table 8‑12. Modbus LED
LED
Color
Green
Flash Code
Short (1/8
sec.)
Unit Status / Description
Enables the installer to troubleshoot the
system by verifying that communications
are occurring on the network, indicating the
following:
• If the inverter is connected as a slave
device, the LED flashes quickly
whenever there is activity on the
network
• Modbus network commands occurring
but are not addressed to this specific
inverter
Long (1/2
sec.)
• Check the Modbus
address switches
and make sure
they correspond to
the address
programmed into
the Modbus
master.
• Confirm that the
baud rate and
other
communication
parameters of the
Modbus master
are set correctly.
Inverter sees and responds to a Modbus
None
master request message that is addressed to
this specific inverter.
Short and long Communication occurring on a Modbus
network that contains multiple Modbus
slave devices.
570-1001791-05A
Action
None
Troubleshooting and Solar Energy Technical Support
8‑17
Advanced Energy
AE SOLAR ENERGY TECHNICAL SUPPORT
Please contact AE Solar Energy Technical Support if you have questions or problems
that cannot be resolved by working through the provided troubleshooting. When you
call Solar Energy Technical Support, make sure to have the unit serial number and
part number. These numbers are available on unit labels.
Table 8‑13. AE Solar Energy Technical Support 24 X 7 contact information
Office
AE Solar Energy Technical Support
Contact
Phone (24 hrs/day, 7 days/week):
20720 Brinson Blvd
Inside the U.S., call 877.312.3832 or
Bend, OR 97701
Outside the U.S., call
+1.541.323.4143
USA
☞ Important
For returns and repairs, please
call Solar Energy Technical
Support to request an RMA
and obtain the correct shipping
address.
Email: (We will respond to email by the
next business day.)
[email protected]
If you would prefer to contact a local or regional sales or service office, visit the
Advanced Energy web site for current contact information (click on Sales and
Support):
• http://www.advanced-energy.com
8‑18
Troubleshooting and Solar Energy Technical Support
570-1001791-05A
Advanced Energy® AE 500 Inverter
Appendix
A
Specifications
PHYSICAL SPECIFICATIONS
Table 9‑1. Physical specifications
Description
Specification
General physical specifications
Enclosure rating
NEMA 4
Construction
Powder-coated steel with hot-dipped zinc base
Size
2520 mm x 3043 mm x 1240 mm
99.2″ x 119.8″ x 48.8″
Maximum weight
8,800 lbs
Clearance
Front: 36″
Rear: 24″
Sides: 36″ and 36″
Top: 27.5″
User Interface and Communications Protocol
Display
VFD 4 rows x 20 characters
RS-485
Screw terminal block
Ethernet
IP over Ethernet
ELECTRICAL SPECIFICATIONS
The table lists electrical specs for the following inverter models:
• PVP500kW (480 VAC)
Note the following limits:
• Accuracy limit of voltage and energy production measurements: ± 5%
• Accuracy limit of frequency measurement: ± 0.1 Hz
570-1001791-05A
Specifications
A‑1
Advanced Energy
Table 9‑2. Electrical specifications
Description
Specification
AC Characteristics
Continuous AC power
PVP500kW: 500 kW
Grid type
Three phase, four wire wye (not compatible with delta service)
Nominal AC voltage
(VAC)
480 VAC models: 480 wye
Maximum output fault
PVP500kW: 891.4 A rms at 480 VAC, 3.32 ms
current and duration (also
known as the maximum
fault current contribution)
Maximum utility
backfeed current
PVP500kW: 3782.0 A rms at 480 VAC, 32 ms
AC maximum continuous PVP500kW: 480 VAC: 608A
current
CEC efficiency
PVP500kW: 480 VAC: 97.0%
Peak efficiency
PVP500kW: 480 VAC: 97.8%
Frequency range
59.3 Hz to 60.5 Hz
AC voltage range set
points (default)
(–12% to +10%)
AC operating range
480 VAC models: 423 VAC to 528 VAC
Power factor at full power > 0.99
Total Harmonic
Distortion
< 3%
Standby losses
PVP500kW: < 80 W
DC Characteristics
DC input bus bar rating
3500 A
Maximum operating input PVP500kW: 1600 A
current
MPPT rangenote 1
310 V to 595 V
Maximum voltage at open 600 VOC
circuit
Startup voltage
330 V
Startup power
PVP500kW: 1100 W
note 1
A‑2
At unity power factor and nominal AC voltage.
Specifications
570-1001791-05A
Advanced Energy® AE 500 Inverter
Table 9‑3. Utility interconnect voltage and frequency trip limits and times
Voltage Trip Limits and Times
The default trip limits and times meet UL1741 anti-islanding requirements.
Voltage trip limit field adjustment range as a percentage of nominal: –12% to +10%
Accessible range of trip times: 0.16 s to 300 s
(The accuracy limit of time measurement is ± 0.1 s.)
480 VAC Configurations
Condition
Factory setting (VAC) Range (VAC)
Default Trip Time
(seconds)
Voltage phase high
304.8
304.8 to 332.5
1.0
Voltage phase low
243.9
216.1 to 243.9
2.0
Voltage phase fast
high
332.5
332.5
0.16
Voltage phase fast low 138.6
138.6
0.16
Frequency Trip Limits and Times
Condition
Factory setting (Hz)
Range (Hz)
Maximum Trip Time
(seconds)
Line frequency low
59.3
57.5 to 59.8
0.16
Line frequency high
60.5
60.5
0.16
570-1001791-05A
Specifications
A‑3
Advanced Energy
Efficiency Specifications
EFFICIENCY CURVES FOR THE PVP500KW (480 VAC)
MODEL
CEC Efficiency = 97%
100 100
95 95
Efficiency, %
90 90
85 85
80 80
310 Vdc
75
353 Vdc
480 Vdc
70
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
% of Rated Outpu t Power
Figure 9‑1. Efficiency curves for the PVP500kW (480 VAC) model
Table 9‑4. Efficiency specifications for the PVP500kW (480 VAC) model
Input Voltage
(VDC)
Power Level in Percent and kW
10%
20%
30%
50%
75%
100%
50.00
100.00
150.00
250.00
375.00
500.00
Weighted
VMIN
310
97.5
97.8
97.8
97.7
97.2
96.7
97.4
VNOM
353
96.7
97.5
97.6
97.4
97.0
96.5
97.2
VMAX
480
95.7
96.8
97.0
96.8
96.5
96.0
96.6
COOLING SPECIFICATIONS
Table 9‑5. Cooling specifications
Description
Specification
Cooling method
Forced convection
Maximum heat rejection
rate
78,500 BTU/hr
A‑4
Specifications
570-1001791-05A
Advanced Energy® AE 500 Inverter
Table 9‑5. Cooling specifications (Continued)
Description
Specification
Maximum fan air flow
rate
1800 liters per second (3800 CFM)
ENVIRONMENTAL SPECIFICATIONS
Table 9‑6. Environmental specifications
Equipment
Status
Operating
Temperature
–30°C to +55°C
–22°C /-7.6°F to
+131°F
Standby/Storage –40°C to +60°C
–40°F to +140°F
570-1001791-05A
Relative Humidity
0% to 95% noncondensing
Air Pressure
Minimum air pressure =
81.2 kPa (812 mbar)
Equivalent altitude = 1829 m
(6000′)
0% to 95% noncondensing
Specifications
A‑5
Advanced Energy
A‑6
Specifications
570-1001791-05A
Advanced Energy® AE 500 Inverter
Appendix
B
System and Mechanical Diagrams
SYSTEM DIAGRAM
MAIN COMPARTMENT
DC CONTACTOR
Load-Break Rated
2
POS_I N
POS_OUT
NEG_I N
NEG_OUT
Bulk
3
4
DC-
Line
LINE
AC Disc Status
3 PHASE
CONTACTOR P OWER
GROUND
3 x 600VAC, 7.5A
AC Cont GFI
ISOLATION XFMR
Y:Y
480, 600V
INSTALLER
LANDINGS
480/600Vac
3 Phase, 60Hz
500kW to Grid/Utility
CONTACTOR P OWER
Adjacent Phase
DC Cont Ctrl
AC DISCONNECT
Load Rated
LOAD
3 x 600VAC, 10A
Array Current Measure
Neg/Pos Gnd Select By Assy
AC Cont Status
SWITCHING INDUCTORS
DC+
Shunt
DC HOT
CONTACTOR P OWER
Snubber
PW M
V DC
IA C
Temp
Error
1
AC CONTACTOR
Load Rated
AC FILTER
IPM
DC FILTER
DC Cont Status
MAIN COMPARTMENT
MAGNETICS COMPARTMENT
DC COLD
1 ph HK Xfmr
AC Precharge Ctrl
160V
CTRL +
Bleeder
CTRL -
AC SURGE
CTRL +
CTRL -
Bleeder Disable
600V
Phase A
Phase B
120V
480V
600VAC, 3A
CTRL +
Precharge
DC Precharge Ctrl
LVRT
CTRL -
7.5A
CONTACTOR P OWER
L1
L2
3A
GND
GFDI
DC Surge Status
24V SUPPLY
24V Power Supply
PV Voltage Measure
DC SURGE
L1
AC Cont Ctrl
DC+
DC-
UL508A Panel Power
Power Good
Power Status 1
24V Power Supply
GFDI Status
600VDC, 5A
AC Surge Status
INVERTER BACKPLANE
AC Cont GFI
L2
3A
GND
Revenue Grade Meter,
Input Power
3x600VAC, 0.1A
DC+
DCPower Good
Revenue Grade Meter,
Line Voltage Measurement
Power Status 2
GF Current Measure
Utility Volts Measure
Utility Current Measure
INVERTER BACKPLANE
INVERTER BACKPLANE
ELECTRONICS COMPARTMENTS
DISABLE
DC COLD
AC Disc Status
DC NEG
DC COLD CKT1
PW M
Co n tr o ller
REVERSED IN + GND SYSTEMS
2
4
2
24VTO IPMs (3)
COMBINER OPTIONS
Power Status 1
OPTION 3
20 X 225A BREAKERS NOT MONITORED
AC Cont Ctrl
DC Cont Ctrl
AC Precharge Ctrl
DC Precharge Ctrl
SW1
LINK
Blower
Remote Disable Fast
Remote Disable Slow
3 x 600VAC 3A
5V
Blower
48V
3 x 600VAC 3A
24V
ACT
48V
10V
250V, 5A
1
3 Ph Auto
Po w er Dis t.
OPTION 2
8 X 400A BREAKERS MONITORED
GFDI Status
ON-
2
Modbus Address, 8-pole DIP
Modbus Termination, 4-pole DIP
3 x 600VAC, 7.5A
Power Status 2
GROUND
SW2
Modbus 3-2
24V
DC Surge Status
Bleeder Disable
3
ON+
Output Flag 1, Running
Output Flag 2, Fault
AC Surge Status
DC COLD CKTn
250V, 0.2A
OPTIONAL
REVENUE-GRADE
POWER METER
Modbus 3
Modbus Meter
120V Power In
MBUS
10V
STAT
5V
Modbus UL508
Modbus 1-2
RJ45
POST
3 Phase Current Sense
250V, 3A (3)
Service Com Port
AC Cont Status
DC Cont Status
24V USER
120V Power In
FAULT
24V CONTROL
250V, 3A
3 Phase V oltage Sense
PAUSE / SCROLL
250V, 3A
Us er In ter fac e
OK
DC HOT CKTn
OPTION 1
16 X 225A BREAKERS MONITORED
24V SUPPLY
Po w er Dis t.
VFD, 4x20 Character
USER BACKPLANE
TA CH
PW M
Circuit Breakers
See Tables
In v er ter In ter fac e
DC PO S
DC HOT CKT1
INVERTER BACKPLANE
Co m m
DC HOT
TA CH
PW M
INSTALLER
LANDINGS
295-595Vdc, 600Vmax
3500A Max Array Short Circuit Current
RJ45
OPTIONAL
UL508A PANEL
Modbus 1
Modbus IN
FROM PREVIOUS INVERTER
Modbus OUT
TO NEXT INVERTER
Figure 10‑1. AE 500 system diagram
570-1001791-05A
System and Mechanical Diagrams
B‑1
Advanced Energy
MECHANICAL DIAGRAMS
Figure 10‑2. AE 500 mechanical diagram: View 1
B‑2
System and Mechanical Diagrams
570-1001791-05A
Advanced Energy® AE 500 Inverter
Figure 10‑3. AE 500 mechanical diagram: View 2
570-1001791-05A
System and Mechanical Diagrams
B‑3
Advanced Energy
Figure 10‑4. AE 500 mechanical diagram: View 3
B‑4
System and Mechanical Diagrams
570-1001791-05A
Advanced Energy® AE 500 Inverter
Index
A
AC
sub panel 2‑8
AC/DC interface
understanding the 4‑16
acronyms 1‑9
address
binary conversion table 6‑11
air filters
inspecting 7‑6
maintenance 7‑4
air intake hood 2‑7
position 7‑4
air intake hoods
installing 4‑2
alert boxes in user manual 1‑1
amperage
wire sizing 4‑15
B
battery
replacing 7‑3, 7‑6
bus bar
connections 4‑6, 4‑7, 4‑8, 4‑15
DC inputs 3‑7
grounding 3‑4
standard 3‑7
buttons
inverter 2‑6
C
cable
backbone 6‑9
card cage
control electronics 2‑4
inspecting the air filters 7‑6
PCBs 2‑5
categories 8‑8
checklist for maintenance 7‑2
circuit breaker
options 3‑7
commands
Modbus 6‑16
communications interface PCB
Ethernet connection 6‑2
location of 6‑5
port 6‑8
570-1001791-05A
remote disable 4‑25
status lights 6‑4
communications PCB
connectivity 8‑1
replacing the battery 7‑6
compartment
main enclosure 2‑3
compliance
directives and standards 1‑5
unit 1‑4
conductor
neutral 3‑4
conductors
external 3‑3
rating 3‑3
conduit
entry location 4‑18
entry locations 4‑22
entry points 4‑12
external 3‑3
configuring
Modbus network 6‑6
connections
bus bar 4‑6, 4‑7, 4‑8, 4‑15
conduit hubs 4‑12
electrical 4‑15
network cable 6‑8
connectivity
communications PCB 8‑1
DHCP server access 8‑1
IP address 8‑2
contact information 8‑18
control electronics
card cage 2‑4
controls
operator interface 2‑6
cooling
inspecting the fan filters 7‑4
specifications 9‑4
customer support 8‑18
D
damage
in shipping 4‑5
data
types of data, Modbus 6‑19
data monitoring
card cage 2‑5
Index
i
Advanced Energy
DC
inverter 3‑6
module 6‑1
combiner sub panel 2‑7
landing 2‑7
sub panel 2‑7
DC input voltage
calculating 3‑7
DC interface
understanding the 4‑21
de-energize
procedure 5‑9
definitions 1‑9
DHCP server access
connectivity issues 8‑1
diagrams
mechanical 10‑2
system 10‑1
DIP switches
remote disable 5‑10
directives 1‑5
disconnect
safety 1‑5
display
operation of 5‑6
door
locking handles 4‑6
on inverter 4‑6
door gaskets
replacing 7‑3
E
electrical connections
AC/DC terminals 4‑15
electrical specifications 9‑1
electromagnetic compatibility
directives and standards 1‑5
environmental
cooling requirements 3‑4
corrosion 3‑4
heat rejection rate 3‑4
environmental specifications 9‑5
Ethernet
cable 6‑2
cables 6‑3
connection 6‑1
F
fan filters
inspecting 7‑4
fans
activation of 2‑7
ii
fault codes 8‑8
drive 8‑8
grid 8‑10
system 8‑12
temperature 8‑11
voltage 8‑9
fire
prevention 1‑8
G
GFDI
handling of ground fault 5‑6
gland plates
conduit entry 4‑12
location 3‑3
ground fault
identifying 8‑5
resolving 8‑6
response to 5‑7
ground fault interrupt device
see GFDI
grounding
bus bar 3‑4
positive or negative 3‑4
requirements 3‑4
guidelines
safety 1‑2
I
icons
in user manual 1‑1
on unit 1‑3
inductor 2‑9
industry guidelines, compliance with 1‑5
inspecting
inverter 7‑2
inspection
connections 4‑7, 4‑8
fan 4‑9
filters 4‑9
screen 4‑6, 4‑7
terminal 4‑6, 4‑7
troubleshooting 8‑2
installation
AC/DC interface 4‑16
clearance 3‑2
conduit 4‑12
conduit entry locations 4‑18, 4‑22
DC interface 4‑21
hoods 4‑2
lifting and moving 4‑1
lifting and positioning 4‑10
location 3‑2
Index
570-1001791-05A
Advanced Energy® AE 500 Inverter
Modbus TCP cable 6‑5
planning 3‑1
requirements 3‑1
weight 3‑1
internet
connection 6‑1
inverter
AC and DC sub panel compartments 4‑7
address 6‑11
air intake hoods 4‑2
clearance 3‑2
communications 6‑4
communications interface 2‑5
components 2‑3
connectivity 6‑4
control electronics 2‑4
cooling compartment 4‑9
data monitoring 3‑6
DC combiner sub panel 2‑7
DC landing 2‑7
DC sub panel 2‑7
de-energize procedure 5‑9
diagram of 2‑3
display 2‑6, 5‑4, 8‑2
display operation 5‑6
door 4‑6
faults 8‑4
features 2‑2
gaskets 7‑3
general description 2‑1
ground fault 5‑7
inductor 2‑9
inspection 4‑6
lifting and moving 4‑1
lifting and positioning 4‑10
magnetics compartment 4‑6
maximum power point tracking range 2‑1
models 2‑1
mounting 4‑10
operating states 5‑2
power module compartment 4‑8
protection system 2‑4
registering 6‑4
shutdown procedure 5‑8
storing 3‑2
sub panel 2‑8
transformer 2‑9
transformers 2‑9
troubleshooting 8‑8
weight 3‑1
inverterinspection 7‑2
IP address 6‑3
assigning 6‑6
connectivity issues 8‑2
570-1001791-05A
J
jumpers
remote disable 4‑25
L
labels on unit 1‑3
LEDs
status 8‑13
lifting
methods 4‑10
lockout and tagout
requirement 1‑8
M
MAC address
location of 6‑3
maintenance
air filters 7‑4
checklist 7‑2
overview 7‑1
replacement parts 7‑3
maximum power point tracking
range 2‑1
mechanical
diagrams 10‑2
Modbus
address 6‑11
commands 6‑16
data types 6‑19
network biasing 6‑11
network cable 6‑8
network settings 6‑11
network setup 6‑6
network termination 6‑10, 6‑11
protocol 6‑4
register mapping assignment 6‑19
TCP cable installation 6‑5
TCP network setup 6‑4
monitoring 2‑2
basic service 6‑1
remote 2‑2
mounting
requirements 4‑10
N
network
address 6‑11
biasing 6‑11
central inverter settings 6‑11
configuration 6‑6
connection 6‑2
connectivity issues 8‑1, 8‑13
Index
iii
Advanced Energy
daisy chain layout 6‑7
length of 6‑9
Modbus termination 6‑9
options 3‑6
shield 6‑7
termination 6‑9, 6‑10, 6‑11
networkModbus TCP 6‑4
neutral
grounding 3‑4
O
operating states
of inverter 5‑2
operation
normal 5‑1
starting up the unit 5‑1
P
parts
replacements 7‑3
PCB
battery replacement 7‑3
communications interface 2‑5, 8‑13
control electronics 2‑4
controller 8‑13
DC distribution 8‑5
status LEDs 8‑13
physical specifications 9‑1
port
address 6‑3
communications interface PCB 6‑8
ID 6‑6
power supply
optional 4‑28
optional 24 V 4‑29
preventative maintenance
checklist 7‑2
product
compliance 1‑4
labels 1‑3
protection system
detection controls 2‑4
PV array
input 3‑4
R
register
Modbus mapping assignment 6‑19
registering
inverter 6‑4
remote disable
communications interface PCB 4‑25
making the connection 4‑26
iv
protecting other power sources 4‑26
user interface PCB 5‑10
S
safety
directives and standards 1‑5
electrical 1‑5
equipment requirements 1‑3
fire prevention 1‑8
first aid 1‑3
guidelines 1‑2
unit lockout and tagout 1‑8
zone 1‑3
seismic
requirements 3‑1
shutdown
procedure 5‑8
specifications
cooling 9‑4
efficiency 9‑4
electrical 9‑1
environmental 9‑5
physical 9‑1
standards 1‑5
start the unit 5‑1
status lights
on communications interface PCB 6‑4
storage
of inverter 3‑2
string calculator
input voltage calculation 3‑4
sub panel
AC 2‑8
DC 2‑7
subcombiner
connections 4‑15
monitoring 3‑7
options 3‑7
wire sizing 4‑15
support information 8‑18
symbols
in user manual 1‑1
on unit 1‑3
system
diagram 10‑1
T
technical support 8‑18
terminal blocks
options 4‑18, 4‑21
torque requirements 4‑18, 4‑21
Index
570-1001791-05A
Advanced Energy® AE 500 Inverter
terms frequently used 1‑9
transformer
housekeeping 2‑9
isolation 2‑9
troubleshooting
connectivity 8‑1, 8‑13
faults 8‑4, 8‑5
inspection 8‑2
inverter 8‑2
warnings 8‑3
turn on the unit 5‑1
U
unit
icons and symbols used 1‑3
lockout and tagout requirements 1‑8
startup 5‑1
turning on 5‑1
user interface PCB
remote disable 5‑10
switch settings 6‑10, 6‑11
switches 6‑11
user manual
alert boxes in 1‑1
570-1001791-05A
symbols and icons used 1‑1
utility
requirements 3‑6
V
voltage
calculating DC input 3‑7
output 3‑6
W
warning in user manual 1‑1
website 2‑2
for monitoring 2‑2
weight
of inverter 3‑1
wire sizing
for amperage 4‑15
wiring
requirements 1‑6
sizing 1‑6
wye
configuration 3‑6
Index
v
Advanced Energy
vi
Index
570-1001791-05A
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