SolarVu

TM

Installation Guide for Fronius IG Plus V ModBus Inverters

Introduction

SolarVu TM is an energy portal that enables remote monitoring of renewable energy generation sites over the internet. It requires the installation of a K135 gateway which continuously transfers data from the inverters to the remote

SolarVu servers. This guide explains how to connect the K135 gateway to

Fronius IG Plus V 3.0 - 12.0 inverters with the ModBus communication option card. Several steps are required:

1) Connect the K135 gateway to the inverters

2) Connect the K135 gateway to the building LAN for internet access

3) Enter the communications settings into each inverter

4) Access SolarVu from a browser and configure the energy portal

Site Preparation

To access SolarVu from a browser, the inverters communicate serially with a

Cachelan K135 gateway connected to the site network as shown in fig 1. Each inverter requires an optional ModBus 485 comms card, Fronius #4,240,021,Z that must be purchased from Fronius and plugged in to the inverter. Each comms card has screw terminals for 485 serial connection. The K135 connects to inverters over RS485 using twisted pair wire, typically using Cat5e cables, daisy chained for multiple inverters. The LAN must have high speed internet service to an ISP to provide access to the internet. The K135 RJ45 ethernet jack plugs into an RJ45 LAN jack connected to the building router using a standard

Cat5e patch cable. Alternatively, SolarVu can be ordered with a 3G cellular modem for wireless internet connection. A source of 120VAC for control power needs to be connected to the SolarVu enclosure.

K135 Installation

Mount the SolarVu enclosure containing the K135 gateway in a suitable location, typically in the electrical room near the inverters. The NEMA4 enclosure can also be mounted outdoors if preferred. The RS485 serial cable can run long distances, over 1000 feet, if necessary.

Fig 1 Internet Connection for single 10kW inverter

10kW

RS485

Modbus

#1

DB9

10kW

Fronius IG Plus V

K135

GATEWAY

#N

SolarVu

SERVERS

RJ45

Ethernet

CABLE/DSL

MODEM

FIREWALL

ROUTER

CORPORATE

ETHERNET

LAN

LOCAL

ACCESS

Fig 2 SolarVu enclosure wiring

Inverter ModBus address (ID) assignment in SolarVu configuration form and K135 label

3 Connect ethernet cable

to building LAN here

SMART GRID ENERGY

ISP

MOBILE

BROWSER

ACCESS

INTERNET

GE810

4 Connect 485 Cat5e cable

to first inverter here

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Power Supply: Source the 120VAC supply from a 15 amp breaker electrical circuit suitable for control power and connect to the internal junction box as shown in fig 2. Refasten the reusable dongle tie wrap after wiring to prevent it becoming loose over time.

RS485 Serial: Connect the RS485 serial cat5e cable to the K135 terminal board as shown in fig 3 being careful to match the correct wire colours to the terminals.

Recommended cable type is Cat5e, 8 wire, UTP, #24 solid. Twisted pair must be used for the RS485 serial data wires. Use a tie wrap to provide strain relief for the cat5e cable. The ground wire is internally connected to terminal 4 to provide a path for transient protection. Connect the other end of the serial cable to the first inverter as shown in fig 4. Over 1000 feet of wire can be used for reliable serial communications.

Mount NEMA4 enclosure inside or outside 1 Drill holes and

attach conduit

Fig 3 K135 Gateway connection

K135 Gateway

Ethernet: Use a standard ethernet patch cable with RJ45 plug on each end of the appropriate length to connect from the RJ45 ethernet jack on the K135 gateway to the network ethernet at a RJ45 wall jack or router/switch. The network router must be configured to match the K135 IP settings. This is usually auto

IP assignment using DHCP for small sites but a larger commercial organization may require static IP settings specified by the IT system administrator. This should be specified at time of order. Settings as shipped can be verified from the SolarVu configuration sheet included in the enclosure document pouch.

Alternatively, SolarVu can be ordered with a 3G cellular modem/router installed for wireless connection. This requires installation of a customer supplied SIM card with an active telco account for service.

To 5V power dongle

4 Connect to building LAN

GE812

3

Inverter ModBus Address (IDs) shown on label

& SolarVu configuration form

2

GE813

Loosen reusable tiewrap.

Remove dongle and cover.

Connect 120VAC control power to junction box.

Replace cover, dongle and tighten retainer tie wrap.

1 Tie wrap cat5e wire from inverter for strain relief

Transient

protection components

2 Connect 485 wire from first inverter

1 D+ Blue

2 D- Blue-white

3 COM GreenTie

4 GND Green #14(transient ground)

SolarVu Installation Guide for Satcon PowerGate Plus Inverters

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Inverter Connection

An optional ModBus communication card Fronius part #4,240,021,Z must be ordered for each inverter. It has to be configured and installed for communications to work. See fig 4 for layout and setup steps. Verify that the terminator plugs that ship with the board are installed in the IN and OUT jacks. Consult the SolarVu configuration form or K135 gateway label for the required inverter ModBus addresses (IDs) usually 1,2... Each inverter requires a unique ModBus ID which matches the address sent by the K135 gateway. Set the first inverter to the lowest address using the 2 rotary switches. Set each subsequent inverter to the next highest address. Communication between SolarVu and the inverters will not work if an address is duplicated or does not match the SolarVu specified values.

Install the communication jumpers for 2 wire RS485, no termination. The baud rate is fixed at 9600 and does not require setup. Route the RS485 cat5e cable from the K135 gateway into the first inverter and make a daisy chain connection to the next inverter. Avoid a star connection between inverters or data integrity may be compromised. Be careful to match the colours and terminals at each connection point. When the serial connector wiring is complete, plug the ModBus com card into the motherboard connector as shown in fig 5.

Replace the board retaining cover. For futher details see the Fronius ModBus Card installation manual part #42,0410,1867 that ships with the ModBus card.

The final step is to apply DC power to each inverter and verify using the front panel display that the protocol is set to DATcom.

Fig 4 Fronius ModBus card setup and 485 connection

3

Install jumpers for

2 wire RS485, with no termination

(baud rate fixed at 9600)

Last inverter only termination

(optional)

All Inverters except last one

4 Connect cat5e 4 pair wire

Cut unused wires

Match colours

From K135 Gateway

To next inverter

Green

Blue

Blue-White

C

TXD1

TXD0

RXD0

RXD1

V

Top

2 Set Modbus slave address (ID) to match SolarVu settings.

See SolarVu configuration form

or K135 gateway label

Photo setting is Modbus ID = 02

Upper Lower

E

0 2

E

0 2

A

68

A

68

Modbus Communications Card

Fronius #4,240,021,Z

Front

SMART GRID ENERGY

Status

Indicators

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6 Plug in

Connector

1 Install terminator plugs in IN & OUT jacks

Daisy Chain Connection

5

Plug card into motherboard

Install metal retaining cover

SolarVu

K135

Gateway

485

Inverter #1

Address=1

E

0 2

E

0 2

Inverter #2

Address=2

E

0 2

E

0 2

Daisy chain 485 connections.

Do not star connect.

Inverter #n

Address=n

E

0 2

E

0 2

Optional termination last inverter only

See Fronius Modbus Communications

Manual #42,0410,1867 for more details

GE809

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Fig 5 Installing ModBus card in inverter

1 Install Modbus card in motherboard socket

3 Replace metal retaining cover

(not shown)

4 With DC input power applied

POWER LED should be on.

COMM LED flashes when module receives valid Modbus command

Cat5e wire from K135 gateway

Cat5e wire to next inverter

Inverter Protocol Setting

Each inverter must be configured with a unique ModBus address (ID) using the address switches on the ModBus comm card. The correct protocol must be selected for each inverter using the front panel keys and display.

Access Code: 22742

Interface Protocol: DATcom

Baud Rate: Fixed at 9600-8-N-1

Protocol Setting To access the front panel display, DC power must be applied to the inverter. With the display active follow the steps in fig 6 to reach the protocol selection screen. Use the Up/Down keys to select DATcom protocol, necessary for ModBus communications. After clicking Enter, with MODE displayed, access the protocol screen again and verify that DATcom was saved.

Wtih the inverters and SolarVu enclosure powered on, the COM LED on the bottom of the Modbus card (fig 4) should periodically flash to indicate the card is being addressed by the K135 gateway. It should now be possible to view all the inverters in SolarVu.

2

GE811

Plug in wired connector

Fig 6 See Fronius IG Inverter manual for communications settings programming instructions

1.

2.

Switch to the menu level (press the

‘Menu’ key)

Select the ‘Setup’ (1) mode using the

‘Left’ or ‘Right’ keys

SMART GRID ENERGY

3.

Press the ‘Enter’ key

- ‘Stand by

’ is displayed

4.

Immediately press the ‘Menu’ key five times

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- „00000

CODE

’ is displayed

5.

Use the ‘Up’ and ‘Down’ keys to change the flashing number

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6.

7.

8.

9.

Confirm the number using the ‘Enter’ key

Enter code 22742

After entering all numbers, press the

-

‘Enter’ key

Display flashes

-

Press the ‘Enter’ key again

‘MIX

Mode

’ is displayed

Important ‘DC

Mode

’ is displayed for inverters with only one power module.

10. Use the ‘Up’ and ‘Down’ keys to select

‘COMM’

11. Confirm using the ‘Enter’ key

‘MODE’ is displayed

12. Confirm using the ‘Enter’ key

SMART GRID ENERGY

-

13. Use the ‘Up’ and ‘Down’ keys to select

‘Dat com (do not select IFP)

14. Confirm using the ‘Enter’ key

-

The protocol type has been changed

‘MODE’ is displayed

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Testing the System

At this point the installation should be complete ready for testing. It is helpful to have access to a PC that is connected to the internet for viewing SolarVu screens. Using the URL supplied for the system. The K135 is preconfigured to automatically send inverter data to the

SolarVu servers. To do this it must first establish an internet connection. Then it will collect data from the inverters and periodically transmit it.

Verifying correct operation is described in the sections that follow. Indicator lights and actual values accessible from the SolarVu Analyzer

> Inverter Status screen figure 7 are useful for determining the status of the system.

Fig 7 Use the ANALYZER > Inverter Status screen to check system status

To access the inverter status screen, enter the SolarVu URL in your browser

Click ANALYZER

Inverter Status

Time of last update received from the K135 gateway

Inverter identification

Measured values from the inverter

SMART GRID ENERGY

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Alarms and status reported by inverter

GE738

Light is green if K135 is reading valid data from the inverter over RS485.

K135 must be connected to the internet.

Light goes green if K135 is connected to the internet

Time of last communication.

K135 sends an update every

15 minutes

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Network Setup

It automatic IP assignment is used, on power up, the K135 looks for a DHCP server to provide it a dynamic IP address. If a PC connected to the network can automatically connect to the internet through a browser then the network is already configured to accept the K135. Otherwise consult the IT systems administrator for assistance. If a dedicated IP address, subnet mask and DNS server address are required, this needs to be entered into the K135 before shipment. Once the K135 receives its IP address it acts as a client. It will automatically try to connect to the SolarVu TM server and begin transferring data from the inverter to the server.

K135 indicators and connections

Factory Reset

Connect to RJ45 LAN

(see IP settings)

RJ45

ETHERNET

10/100 Base-T

Connect to 120VAC power supply

5Vdc

POWER

5.0V

K135 Status Indicator Interpretation

LED

POWER

INDICATOR STATUS

NORMAL STATUS

OFF- no power

ON

ON-power OK

READY

SERIAL

100Base

ON

RED FLASH

GREEN FLASH

ON IP address valid

OFF No DHCP or static IP address.

OFF Check K135 to inverter connection, inverter address

& baud rate. No AC/DC to Inverter.

RED flash=K135 Transmit data, Green flash=Receive data

ON

ON- 100Base

OFF- 10Base or no ethernet

Link ON

ON - ethernet network connection OK

OFF No ethernet connection

Activity

SHORT

FLASH

FLASH - data traffic activity

Power

Ready

Serial Rx/Tx

100Base

Link IP

Serial

TROUBLESHOOTING CHECKLIST

Obtain IP by DHCP or set static IP.

Network configured to recognize K135

Check serial cable between inverter & K135

Correct inverter communications settings.

Inverter Inverter has AC and DC power on.

Serial Port Data/Console

Internet

Internet connection from ISP to LAN is operating normally

RS232

SERIAL PORT

COMMUNICATION

MODE SWITCH

Connect to inverter

Data mode - left

Testing

Ensure the inverters and K135 are powered on, the ethernet cable is plugged into a network jack and the RS485 cable is connected between the K135 and the inverter(s). The Power and Ready lights should be on if the power supply is plugged in. The Link light on indicates the ethernet connection is working.

100Base will only be on for high speed connections; for 10Base it is off. The

Act light will periodically flash showing network activity. The Serial Rx/Tx flashes when the inverter is polled by the K135 but most of the time the light is off.

Internet Connection

Power on the K135 and allow at least 2 minutes for communication to be established. From any internet connected computer, open the browser and type in the SolarVu site address assigned for your account. This will be found on the account label shipped with the K135 and on the front panel of the K135. It is in the format www.mysitename.solarvu.net

K135

Support

SMART GRID ENERGY

K135 in data mode (red switch set to left viewed from top)

Technical support: [email protected]

[email protected]

K135 GATEWAY

URL : mysite.solarvu.net

USER: myusername

PASSWORD: mypassword

IP: DHCP

MAC: 00-01-95-06-E8-33

ID: SS100 070300075 v1.4.1

TYPE:

Check ANALYSER > INVERTER STATUS for communication

Screen shots may vary by inverter type

All rights reserved

Once the SolarVu energy portal is reached, the opening screen is the SITE view. Click ANALYZER > INVERTER STATUS. If there is a connection from the site, the Last Communication light will be green. The K135 gateway does not need to be connected to the inverter for this light to be green. If this indicator is red, it indicates no internet connection has been established. Check internet connections at the site by trying to browse the internet at the site with a PC connected to the network.

LIVE - for valid data, green status light and time received

On a new system, the K135 gateway will search for the address of each connected inverter. When found, the Last Data Updated indicator will be green and inverter data will appear. If this indicator is red but the Last Communication indicator is green, check the RS485 serial connection to the inverter and that unique slave IDs have been entered. When both lights are green the gages on the SITE screen will display live data and graphs will begin recording site energy output. Contact Cachelan Technical Support for assistance if you cannot get a connection.

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SolarVu Installation Guide for Satcon PowerGate Plus Inverters

Video Tour

For an overview of available features, visit www.solarvu.net and play the What is SolarVu video. Each screen has a HELP button that explains how all the features work. An online help guide is available for printing under SETUP >

DOWNLOADS > PRINTED HELP .

Visit www.solarvu.net for a features video

Help guide

Site Screen

For a summary of information about the site, click the SITE menu button. On the upper left, the current charging status of the solar panels, total power being generated now and in the last 30 days is displayed. Underneath, the carbon footprint of energy equivalents is displayed since startup. Links to other websites can be left as defaults or changed in SETUP to personal preferences. The local weather is preset. Email [email protected] to have it changed. For viewing on a widescreen TV suitable for display in a public place, click the WIDE PAGE button.

On the right is a slideshow for public viewing. Content can be personalized using uploaded graphics in SETUP.

Site Summary Screen

Select wide screen view for public display on an HDTV

Live Data

Click the LIVE menu button to display current power being generated in the array.

Actual power and energy generated today are shown on the meter dial. For a normally operating system, the status indicator should be green with the last update time less than 15 minutes ago. Lifetime energy and revenue are shown digitally. For correct revenue display, the sell price per kWh must be entered in

SETUP. If connection to the site is lost, or if an alarm is detected, the status indicator will be red. Click the Listen button with sound on for more information.

Trends are shown for the lifetime of the system using the graphs on the right.

Select either an Energy or Revenue view using the button. Click the desired time period under the graph. Scroll over a data point with the mouse for more detailed information about that day. The carbon footprint pulldown gives energy equivalents for the solar power generated for the selected time period.

Analyzer - Performance

Click the ANALYZER menu button and select a category in the pulldown menu and a time period under the graph. The carbon footprint will compute the energy equivalents to the solar energy generated over the selected time period. This helps visitors get a practical feel for the benefits available. To find the carbon equivalent for an arbitrary value, override the actual solar amount by entering a kWh value and selecting a category, then click the Calculator button. Other views including buy/sell energy use, performance and payback can be selected with in the pulldown menu. The screen will return to the last value selected on return.

LIVE view shows current conditions

SMART GRID ENERGY

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ANALYSER - select performance views from pulldown

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Analyzer - Troubleshooting

When problems occur with the system or to check inverter operation, click

ANALYZER > INVERTER STATUS. Each inverter connected to the system with a K135 gateway will have its own display panel showing actual values sent. Remotely located technical personnel can assist in interpreting what the values are conveying. If no communication has been received from the device for more than 2 hours a No Data Available message will be shown.

For detailed analysis, it may be helpful to download all readings for the time period of interest into a spreadsheet for further analysis using SETUP >

DOWNLOAD.

Click ANALYZER > INVERTER STATUS for troubleshooting

Download printable HELP guide or actual readings for any time period

Setup

For entering settings to configure your site, click the SETUP menu button.

Enter your unique username and password from the account label.

The setup screen appears showing communication status and current preference settings. Check the last communication time Π. It should show a time within the last 15 minutes if communication between the site and

SolarVu

TM

server is working normally.

For the payback and revenue calculators to work properly, correct parameters for energy sell rate, capacity, average insolation etc should be entered. Account > Equipment Setup is for factory use. All changes take immediate effect. The Site Setup tab is used to customize the banner, links, slideshow and system description. Click the Help  button for each section for a description of the effect for each entry. For further analysis, individual energy readings for any time period can be downloaded into a spreadsheet from the DOWNLOAD section.

Enter the email address Ž for each individual that wants a regular status report sent to them and select the frequency. This report will include energy and revenues for different time periods and indicate if there are any alarms. In the Password tab, include an email address to receive the Setup login password if this is forgotten.

See K135 label for SETUP login myusername mypassword

Configure site settings in SETUP

SMART GRID ENERGY

K135 GATEWAY

URL : mysite.solarvu.net

USER: myusername

PASSWORD: mypassword

IP: DHCP

MAC: 00-01-95-06-E8-33

ID: SS100 070300075 v1.4.1

TYPE:

DATE: Feb 2009

SUPPORT: cachelan.com

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Support

See the What is SolarVu? video at www.solarvu.net for a feature overview.

Each screen has a HELP button with details for the items on that view. A printable HELP guide can be downloaded in SETUP > DOWNLOAD.

For additional technical support, send an email to [email protected] or dial our support line in Toronto, Canada at 905.470.8400

Cachelan Technical Support

[email protected]

905.470.8400 x228

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