SOFAR HYD 5-20KTL-3PH (01) PDF MANUAL

This manual describes the installation, electrical connection, commissioning, maintenance, and fault elimination for the HYD 5-20KTL-3PH series of inverters. Please adhere to the following guidelines:

▶ Carefully read this manual before use and retain it for future reference.

▶ Treat this manual as an integral component of the device.

▶ Keep this manual in close proximity to the device, including when it is handed over to another user or moved to a different location.

▶ Read and observe all given safety information contained within the manual.

Warnings are presented using symbols and signal words to ensure the safety of persons and property. They are structured to provide clear information on the type of danger and how to avoid it.

Warnsymbol:

The general danger symbol warns of a risk of serious injury when used with the signal words CAUTION, WARNING, and DANGER.

Signalwords:

Sectional Warnings:

These warnings refer to a complete section and are structured to show the type and source of danger, consequences for non-observance, and how to avoid the danger.

Embedded Warnings:

These warnings are part of an action sequence and are placed right before the dangerous step. They combine the type/source of danger, consequences, and avoidance instructions.

Action steps and notes are presented in a specific format to guide you through procedures.

Note:

Notes are presented in a grey bar and provide tips essential to the optimal operation of the product.

Qualified Personnel:

Only a qualified electrician who has received training on occupational safety, is familiar with local laws and regulations, and understands the manual should install, operate, and maintain the inverter.

Electrical Connection Safety:

▶ Dangerous DC voltage: Before establishing the electrical connection, cover the PV modules with opaque material or disconnect the PV generator. Solar radiation generates dangerous voltage.

▶ All installations and electrical connections may only be carried out by trained electricians.

▶ Obtain authorization from the local power grid operator before connecting the inverter to the public power grid.

▶ Do not open the inverter or remove any labels, as this will void the guarantee.

Operation Safety:

▶ Electric shock: Contact with the electrical grid or the device’s terminals can result in electric shock or fire. Do not touch terminals or conductors connected to the grid.

▶ Burning due to hot housing: During operation, internal components become very hot. Wear protective gloves and keep children away from the device.

Repair and Maintenance Safety:

▶ Dangerous voltage: Before any repair work, switch off the AC circuit breaker and the DC switch. Wait a minimum of 5 minutes before starting maintenance to allow capacitors to discharge.

▶ Unauthorised repairs: Do not open internal components without authorization. Contact a local authorized service center for any required repairs.

General Cautions:

▶ Hot housing: While the inverter is in operation, only touch the display and the buttons, as the housing can become hot.

▶ Implement earthing: The PV generator must be earthed according to local requirements. It is recommended that all PV module frames and inverters are reliably earthed.

▶ Damage due to overvoltage: Ensure that the input voltage does not exceed the maximum permissible voltage to avoid damage not covered by the warranty.

The HYD 5-20KTL-3PH is a grid-coupled PV and energy storing inverter that can also supply energy in stand-alone operation. The DC output from the PV generator can be used for both grid feed-in and battery charging. The battery can supply energy to the grid or the consumer. Key features include:

▶ Two MPP trackers with 1.5-fold DC overload.

▶ Flexible switching between on-grid operation and energy storage operation.

▶ Maximum efficiency when charging and discharging the battery (97.8%).

▶ Up to 2 battery strings with a combined maximum charging and discharging current of 50 A.

▶ Wide battery input voltage range (180–800 V).

▶ The EPS (emergency power supply) output can be connected to unbalanced loads, with a switchover time of less than 10 milliseconds and a temporary overload of up to 10%.

▶ Up to 6 inverters can operate in parallel at the EPS connection and AC connection.

▶ Monitoring via RS485 and WiFi, optionally via Bluetooth.

The inverter supports several application configurations:

Typical energy storage system: A standard setup with PV panels, battery unit(s), and a connection to the grid.

System without PV connection: In this configuration, there are no PV panels connected. The battery is charged through the grid connection.

System without battery: A configuration where the system operates with PV panels and a grid connection, but the battery unit(s) can be added later.

Back-up mode (off-grid): When there is no grid connection, the PV panels and the battery provide electricity to the critical load.

System with multiple inverters (5–20 kW): Up to 6 inverters can be connected in parallel to the grid and EPS connections, allowing for an EPS output of up to 200 kVA. In this setup, all inverters should be the same model, and the energy meter is connected to the Master inverter.

AC retrofit system: This configuration adds the hybrid system to an existing PV system. A second smart meter is installed to measure the PV production from the existing solar inverter, which is then used for charging the battery.

Unbalanced load: By enabling the “Unbalanced load” option, the inverter can compensate for unbalanced loads in either EPS (off-grid) or on-grid mode.

Connecting GTX 3000-H batteries (AMASS)

The HYD 5-8KTL-3PH models have one battery input (max. 25 A), while the HYD 10-20KTL-3PH models have two (max. 25 A / 25 A).

▶ If a battery input is unused, set it to “Not Used” in the inverter’s system settings (System Settings -> Input Channel Config -> Bat Channel2 -> Not Used).

▶ Configure the battery setup only when the inverter is in standby mode.

▶ Turn the inverter off via Advanced Settings -> 10. Switch on / off -> Switch Off before making changes.

▶ The battery inputs of different inverters should not be connected in parallel.

▶ Each battery tower needs a unique battery address (configurable from 00–15 or not used).

Connecting BTS 5K batteries

The HYD 5-8KTL-3PH models have one battery input (max. 25 A), and the HYD 10-20KTL-3PH models have two (max. 25 A / 25 A).

▶ Configuration of the battery setup should only be done when the inverter is in standby mode.

▶ Turn the inverter off via Advanced Settings -> 10. Switch on / off -> Switch Off before making changes.

▶ If a battery input is unused, set it to “Not Used”.

▶ The battery inputs of different inverters should not be connected in parallel.

▶ Each battery tower corresponds to a unique battery address. The “Auto Config. Address” feature will automatically detect the number and addresses of connected batteries within 2-3 minutes.

▶ For certain regions like Australia, safety regulations require the neutral cables on the grid-connected side and EPS side to be connected together. Otherwise, the EPS function cannot be used.

Delivery Scope:

After unpacking, check that all items are intact and complete. The delivery scope includes the inverter, wall bracket, various terminals and connectors, screws, communication cables, smart meter, WiFi stick, and documentation.

Tools Required:

1. Fulfill Environment and Location Requirements:

▶ Choose a dry, clean, and tidy place.

▶ Ambient temperature range: -30–60°C.

▶ Relative humidity: 0–100% (non-condensed).

▶ Install in a well-ventilated place, away from flammable or explosive materials.

▶ Maximum altitude: 4000m.

▶ Ensure minimum clearances around the inverter for ventilation: 50 cm above and below, 30 cm on the sides.

2. Unpack and Move the Inverter:

1. Open the packaging and grip underneath the inverter at the sides with both hands.

2. Lift the inverter out of the packaging and move it to its installation position. The inverter is very heavy; ensure it is kept balanced. Do not place it on its connections.

3. Install the Wall Bracket and Inverter:

1. Hold the wall bracket in the desired place, use a spirit level to ensure it’s straight, and mark the four holes. Drill the holes.

2. Guide the M8*80 expansion screws into the holes.

3. Align the wall bracket with the holes and fasten it by tightening the nuts on the expansion screws.

4. Place the inverter onto the wall bracket and fasten it with the M6 hexagon screw.

5. You can secure the inverter to the wall bracket using a lock for added security.

Safety First: Wear rubber gloves and protective clothing. Ensure the DC switch is OFF and wait at least 5 minutes before working on connections. Cover PV modules to prevent voltage generation.

1. Connect the Protective Earth (PE) Cable:

1. Remove the insulation of the PE cable (≥ 4mm² recommended). L2 should be 2 to 3mm longer than L1.

2. Crimp the cable to the ring terminal.

3. Install the crimped ring terminal and washer with the M6 screw and tighten to a torque of 3 Nm using an Allen key.

2. Connect the DC Lines (PV and Battery):

The connection steps are the same for battery and PV, but the terminal colors are different (blue for battery, black for PV). If only one battery set is used, connect it to the BAT1 port.

1. Use the correct cable (4.0–6.0 mm² cross-section, 4.5–7.8 mm outer diameter).

2. Remove insulation from the cables (L2 is 2-3 mm longer than L1).

3. Insert the DC cables into the corresponding cable glands.

4. Crimp the DC cables. The crimped connection must withstand 400 Nm.

5. Insert the crimped DC cables into the corresponding connector housing until you hear a “click”. Ensure polarity is correct.

6. Re-screw the cable glands to the connector housing.

7. Insert the positive and negative connectors into the corresponding DC input terminals on the inverter until they click into place. Insert protective caps into any unused DC connections.

3. Connect the AC Power Cables:

Ensure the grid is switched off before connecting.

1. Select a suitable cable and remove the outer insulation (A = 30-50 mm) and inner insulation (B = 3-5 mm).

2. Disassemble the AC connector and guide the AC cable through the cable gland.

3. Connect the wires to the correct terminals (L1, L2, L3, N, PE) and tighten with an Allen key.

4. Assemble the connector housing and screw the cable gland tight.

5. Connect the AC connector to the AC connection of the inverter by turning it clockwise until it locks.

6. Attach the connector accessories to the connector and fasten them with a cross screwdriver.

The inverter has several communication interfaces for monitoring and control:

Smart Meter Connection (for energy management):

Connect the inverter to the smart meter via RS485. The inverter’s COM port Pin 5 (RS485+) connects to the meter’s Pin 24, and Pin 6 (RS485-) connects to the meter’s Pin 25. Use a shielded twisted pair cable and keep it away from power cables.

WiFi/Ethernet Stick Installation and Configuration:

1. Remove the protective cap from the USB interface on the inverter.

2. Install the WiFi/Ethernet stick.

3. Tighten the connecting nut.

WiFi Stick Configuration (Web Browser):

1. Connect your PC or smartphone to the WiFi network of the stick (Name: “AP” + serial number). The password (PWD) is on the stick’s label.

2. Open a web browser and go to the address 10.10.100.254.

3. Log in with username “admin” and password “admin”.

4. Click on the “Wizard” to configure the stick for your local internet access.

DRMs/Logic Interface (for grid control):

This RJ45 interface controls feed-in power based on external signals from grid operators. The pin assignments and logic depend on local standards (e.g., AS/NZS, VDE, EN50549). Follow the installation steps to press wire terminals, route the cable through the gland, and lock the connector.

Link Port (for parallel operation):

In systems with multiple inverters, connect the devices in a Master/Slave configuration using the Link Port. The first and last inverters in the chain need to be connected with the 8-Pin connection terminals. This allows a single energy meter on the Master inverter to control the whole system.

1. Double Check Before Starting:

Ensure all of the following are true:

• Inverter is firmly fastened to the wall.

• PV+/PV- and BAT+/BAT- wires are firmly connected with correct polarity and voltage.

• DC isolator between battery and inverter is correctly connected and OFF.

• GRID / LOAD cables are firmly and correctly connected.

• AC circuit breakers for GRID and LOAD are correctly connected and OFF.

• Communication cables (Lithium battery BMS or Lead-acid NTC wire) are correctly connected.

2. Starting the Inverter:

1. Make sure there’s no power generation in the inverter from the grid.

2. Turn ON the inverter’s DC switch.

3. Switch ON the battery and the DC isolator between the battery & inverter.

4. Turn ON the AC circuit breaker between the inverter GRID port & GRID.

5. Turn ON the AC circuit breaker between the inverter LOAD port & critical load.

6. The inverter should start to operate.

3. Initial Setup:

The following parameters must be set before the inverter starts normal operation:

1. Language setting: The default is English.

2. System time setting: This is set automatically if connected to a server or app.

3. Safety parameter import: Select the correct country code. This can be done from a USB drive or using the “Sofar View” app.

4. Set the input channel: Configure which inputs (PV, Bat Channel1, Bat Channel2) are being used.

5. Set battery parameters: Set battery type, max charging/discharging current, and discharge depth according to your battery specifications.

Buttons:

LEDs:

Standard Display Navigation:

The main screen shows an overview of PV Production, Battery Power, Grid Power, and Home Consumption.

▶ Press the Up button repeatedly to cycle through detailed information screens for:

• PV Information (voltage, power, frequency)

• Grid Output Information (voltage, power, frequency)

• Grid Information (power and IMPORT PF)

• Load Information (Load Power)

• Battery Information (BAT1) (current, power, state of charge, etc.)

• Battery Information (BAT2) (current, power, state of charge, etc.)

The inverter has several integrated energy management modes:

Self-use (Default Mode): The inverter automatically charges and discharges the battery to maximize self-consumption. PV power first supplies the load, then charges the battery, and any excess is exported to the grid. If PV power is insufficient, the battery discharges to support the load. If both are insufficient, power is imported from the grid. Priority for power supply is PV > battery > grid. Priority for consumption is Loads > Battery > Grid.

Time-of-Use: Set up to 4 rules to charge the battery during specific time intervals, on specific dates or weekdays, based on the battery’s State of Charge (SOC). This is useful for charging from the grid during off-peak hours. If no rule is active, the system reverts to Self-use mode.

Timing: Define up to 4 rules with fixed times of the day to charge or discharge the battery with a specific power. Each rule can be enabled or disabled, and charging/discharging periods can be set separately.

Passive: Used in systems with an external energy management controller. The inverter’s operation is controlled by the external device via the Modbus RTU protocol.

Peak Shaving: Limits the maximum power purchased from the grid. When the load power exceeds the set limit, the battery starts discharging to stabilize the system power at the set value. This is useful for managing electricity costs and in areas with a weak grid.

Off-grid: When the battery SOC is sufficient, the system prioritizes using the battery to power the off-grid load, even if the grid is available. If the battery is depleted, it will switch to the grid or a generator to power the load and recharge the battery.

Manual Genset: Activates manual recharging of the battery from a power generator connected to the AC GRID input, typically in the event of a grid failure.

Feed-in Priority: The PV system prioritizes supplying a pre-set amount of power to the grid after local loads are satisfied. The battery will only be charged once this grid supply target has been met.

Press the “Back” button to bring up the main menu. Navigate with the Up/Down arrows and select with the “Enter” button. Some advanced settings require the password “0001”.

Main Menu

1. System Settings: Basic settings needed to operate the device.

• Language Settings: Sets the display language.

• Time: Sets the system time.

• Safety Param.: Sets the country and grid code.

• Energy Storage Mode: Select between Self-use, time-of-use, timing, passive mode.

• Input Channel Config: Define if PV and/or batteries are connected.

• EPS Mode: Enable/Disable the emergency power supply (EPS).

• Communication Addr.: Set the Modbus address (default: 01).

2. Advanced Settings (Password: 0001):

• Battery Parameter: Set detailed parameters for Battery 1 and 2 (Capacity, Voltage, Current limits, DOD, etc.).

• Set Feed-in Limit: Activate and set the maximum feed-in power.

• IV Curve Scan: Enable/disable cyclical scanning of the IV curve for shaded generators.

• Logic interface: Activate/deactivate logical interfaces.

• Restore Factory Settings: Reset stored data.

• Parallel setting: Configure for parallel inverter operation (Master/Slave).

• CT Calibration: Correct the direction and phase assignment of connected CTs.

• Switch On / Off: Switch the inverter on/off or to standby.

• Unbalanced Support: Enable support for unbalanced loads.

• Dry Contact Control: Configure the function of the dry contact relay.

3. Energy Statistics: View daily, monthly, yearly, and lifetime energy data (PV, Load, Export, Import, Charge, Discharge).

4. System information: View detailed information about the inverter, battery, and safety parameters.

5. Event list: Display real-time and historical event/fault recordings.

6. Software update: Update firmware via USB.

7. Battery real-time Info: (Only with BTS battery system).

Note: To perform a firmware update, the inverter must have PV input or grid status. The update will fail if only the battery is connected.

1. Insert the USB stick containing the firmware into a computer.

2. Unzip the firmware file and copy the original file to the USB stick. The file must be placed in a subfolder named “firmware”.

3. Safely shut down the inverter. Go to the main menu, select “2. Advanced Settings -> Switch On/Off -> Switch Off”.

4. Insert the USB flash drive into the USB interface of the inverter.

5. Go to menu item “6. Software update” on the LCD display.

6. Enter the password “0715” and then select “Software Upgrade (PCS)”.

7. The system will successively update the main DSP, auxiliary DSP, and ARM processors. Monitor the display during the process.

8. If an error occurs, try the update again. If it fails repeatedly, contact technical support.

9. After the update is complete, go to “Advanced Settings -> Switch On/Off -> Switch On” to restart the inverter.

10. You can check the new software version in “1. Inverter Info (2)” of the System Info menu (password: 0715).

Initial Troubleshooting Steps:

First, check for any warnings, error messages, or error codes on the inverter’s screen. If no information is displayed, check the following:

▶ Is the inverter in a clean, dry, well-ventilated area?

▶ Is the DC switch set to ON?

▶ Are all cables sufficiently dimensioned and in good condition?

▶ Are all configuration settings for the installation correct?

To view recorded problems, go to the main menu and select “Event List”.

Shutdown Procedure for Inspection:

1. Use the menu to shut down the inverter: Advanced Settings -> Switch On/Off -> Switch Off.

2. Disconnect the AC circuit breaker for the grid port.

3. Disconnect the AC breaker for the load port.

4. Disconnect the PV side DC switch.

5. Turn off the battery and disconnect the DC switch between the battery and the inverter.

6. Wait for 5 minutes before checking the inverter.

Inverter Error List:

Battery Error List:

Inverters do not generally require daily or routine maintenance. Before carrying out any cleaning, ensure the inverter is fully shut down (DC switch and AC circuit breakers are OFF) and wait at least 5 minutes.

Cleaning the inverter:

Clean the inverter housing using an air blower and a dry, soft cloth or a soft bristle brush. Do NOT use water, corrosive chemicals, or other cleaning agents.

Cleaning the heat sink:

To ensure correct long-term operation, check the heat sink for blockages (from dust, snow, etc.) and remove them if present. Clean the heat sink using an air blower and a dry, soft cloth or a soft bristle brush. Do NOT use water, corrosive chemicals, or other cleaning agents.