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Passionately Powered

Plugreen Solar Micro-Inverter Systems

PGM-200P-230

PGM-230P-230

PGM-260P-230

Plugreen Corporation,

Laattakatu 13, 08150 Lohja, Finland

Phone : +358 40 1525086

www.plugreen.com

[email protected]

Installation and Operations Manual

Contact Information

1

Please read this very carefully 1

Safety Instructions 1

2

How the solar micro-inverter works 2

Plugreen solar micro-inverter models 2

3

Parts required to install micro inverter 3

Installation Procedure 4

Step 1 - Install the AC Branch Circuit Junction Box 5

Step 2 - Mount the Plugreen Solar micro-inverters on the rack 5

Step 3 - Lay the AC common cable along the rack using mounting hooks 5

Step 4 - Connect the individual micro inverter on the common cable 5

Step 5 - Ground the system using suitable copper wire 5

Step 6 - Completing the Plugreen Installation Map and Connecting the PV Modules 6

4

5

Ground Fault 8

Other Faults 8

Troubleshooting an Inoperable Solar micro-inverter 8

Disconnecting the Plugreen Solar micro-inverter from the PV Module 9

6

Technical Considerations 10

Technical Specifications 10

Plugreen Solar micro-inverter Operating Parameters 10

Voltage and Frequency Limits for Utility Interaction 11

7

Plugreen Corporation Warranty 12

Plugreen Installation Map 15

Important Safety Information 1

Plugreen Solar micro-inverter System 2

Plugreen Solar micro-inverter Installation 3

Commissioning 7

Troubleshooting 8

Technical Data 10

Appendix 12

Table of Contents

1 Important Safety Information

Important Safety Information

The following safety symbols indicates the safety hazard conditions, this needs to be taken care to

reduce the risk of electrical shock and to ensure the safe installation and operation of the Plugreen

Solar micro-inverter.

: This indicates a situation where failure to follow instructions may cause a serious

hardware failure if not applied appropriately. Use extreme caution when performing this task.

: This indicates information particularly important for optimal system operation. Follow these

instructions closely.

Read this very carefully

WARNING

NOTE

Safety Instructions

Perform all electrical installations in accordance with all local electrical codes and the National

Electrical Code (IEC).

Be aware that only qualified personnel should install and/or replace Plugreen Solar micro-inverters.

Do not attempt to repair the Plugreen Solar micro-inverter; it contains no user-serviceable parts. If it

fails, please contact Plugreen customer service to obtain an RMA number and start the replacement

process. Tampering with or opening the Plugreen Solar micro-inverter will void the warranty.

Before installing or using the Plugreen Solar micro-inverter, please read all instructions and cautionary

markings in the technical description and on the Plugreen Solar micro-inverter system and the PV-

array.

Connect the Plugreen Solar micro-inverter to the electrical utility grid only after receiving prior approval

from the utility company.

Be aware that the body of the Plugreen Solar micro-inverter is the heat sink and can reach a

temperature of 80 C. To reduce risk of burns, do not touch.

Do NOT disconnect the PV module from the Plugreen Solar micro-inverter without first removing AC

power.

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NOTE: For Plugreen Solar micro-inverter Warranty Terms and Conditions, see the Appendix of this

manual.

Copyright Plugreen Corporation. 2011 1-00001 REV 1 1

>

The Plugreen Solar micro-inverter system is a technologically advanced power conversion system for use

in utility-interactive applications. This manual details the safe installation and operation of the Plugreen

Solar micro-inverter.

consists of the following:

Plugreen Solar micro-inverter

Plugreen Common AC cabling system

Plugreen Communication Gateway Unit

Plugreen web-based monitoring software “Insight”

Plugreen Solar micro-inverter System

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2 Plugreen Solar micro-inverter System

The Plugreen Solar micro-inverter extracts maximum energy from individual photovoltaic (PV) panels.

Each Plugreen Solar micro-inverter is connected to individual PV module. This enables unique intelligent

Maximum Peak Power Point Tracker (iMPPT) of each PV module. By doing so, the single point of failure can

be avoided compared to a string inverter system.

Communication Gateway Unit can be plugged into any two pin standard outlet. The power supply to this unit

is universal so it works from 85 to 265VAC. This unit needs to be installed indoors. Once you connect the

AC power, connect Ethernet cable between the units and your broadband router or modem. Once you

install the Communication Gateway unit, it automatically starts communicating with the centralized web

server. Please log in to the data monitoring web server though Plugreen webpage to understand the data

logging systems and displays.

This integrated system maximizes energy harvest, increases system

reliability, and simplifies design, installation and management.

2Copyright Plugreen Corporation. 2011 1-00001 REV 1

How the Micro-Inverter Works>

>

Plugreen Solar micro-inverters

Broadband

router

AC power cord

PC displaying

data from Insight

Application

Photovoltaicmodules

Ethernet cable

Power LinesPower Lines

Plugreen

communication

Gateway

Plugreen Solar micro-inverter Models

The Plugreen PGM200/PGM230/PGM260 Solar micro-inverters operate with most 60 and 72-cell PV

module configurations. In case of technical enquiries, please contact our Customer support at

[email protected].

1 Plugreen Solar micro-inverter SystemPV systems using Plugreen Solar micro-inverters are simple to install. Each Solar micro-inverter quickly

mounts on the PV racking, directly beneath each PV module. Low voltage DC wires connect from the PV

module directly to the co-located solar micro-inverter, thus eliminating the risk of personnel exposure to

lethal 600Vdc power.

3 Plugreen Solar micro-inverter Installation

WARNING:

WARNING:

WARNING:

WARNING:

WARNING:

Before installing the Plugreen Solar micro-inverter, read all instructions and

cautionary markings in the user manual, on the Plugreen Solar micro-inverter, and on the

photovoltaic array.

Perform all electrical installations in accordance with all local electrical codes and the

National Electrical Code (IEC).

Connect the Plugreen Solar micro-inverter to the electrical utility grid only after

receiving prior approval from the utility company.

Be aware that only qualified personnel should connect the Plugreen Solar micro-

inverter to the electrical utility grid.

Be aware that installation of this equipment includes risk of electric shock. Normally

grounded conductors may be ungrounded and energized when a ground fault is indicated.

Parts required for installing the micro-inverter system

Adapter plate

Junction box

Plugreen AC Common Cable

Mounting hooks for AC Common Cable

Grounding conductor

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Installation Procedure

Installing the Plugreen Solar micro-inverter system involves the following steps:

Installing the AC branch circuit junction box

Mount the Plugreen Solar micro-inverters on the rack

Lay the AC common cable along the rack using mounting hooks

Connect the individual micro inverter on the common cable

Ground the system using suitable copper wire

Connect the PV modules to solar micro-inverters

STEP 1

STEP 2

STEP 3

STEP 4

STEP 5

STEP 6

Refer the installation diagram below for better understanding

Do not connect Plugreen Solar micro-inverters to the utility grid or energize the AC

circuit(s) until you have completed all of the installation procedures as described in the following

sections

WARNING:


WARNING: Do not connect Plugreen Solar Micro Inverter to a off grid like Inverter, UPS or

Generator



Mount the Junction box plate at a suitable location on the PV racking system (typically at the

end of a row of modules).

Install an appropriate junction box with adapter plate.

: Use electrical system components approved for wet locations only.

Connect the open wire end of the Plugreen AC Common Cable into the junction box using an

appropriate gland or strain relief fitting.

Route the continuous Grounding Electrode Conductor (GEC) through the grounding clamp of

each solar micro-inverter. Check the standards applicable for each country

Installing the AC branch circuit junction box

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§

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§

WARNING

STEP 1

Mark the approximate centre of each PV module on the racking system. Typically the location should be

aligning with the PV module junction box.

: Please use the mounting rack in such a way that it allows a minimum of 20mm

between the top of the roof and the bottom of the solar micro-inverter and 25mm between the

back of the PV module and the top of the Micro inverter.

WARNING

Mount the Plugreen Solar micro-inverters on the rack STEP 2STEP 2

Connect the individual micro inverter on the common cable

Each Solar micro-inverter comes with one 3 pin Circular AC connector with a wire length of 60cms.

Connect these AC connectors with the respective female connectors on the AC Common Cable. Unused

connectors on the AC Common Cable should be plugged with the Cap provided.

: AC Common Cable wiring is as: Red – Phase, black- neutral, green – earth/ground

: Make sure protective end caps have been installed on all unused AC connectors.

Unused AC Solar micro-inverter wire harness connectors may be live when the system is

energized by the utility system.

Make sure that size of AC wire gauge is appropriate to take into account of voltage drop

between the AC branch circuit junction box

WARNING

WARNING

NOTE:

STEP 4

Ground the system using suitable copper wire

Each Plugreen Solar micro-inverter comes with a ground clip that can accommodate a 6-10 AWG

conductor. Route a continuous GEC through each of the solar micro-inverters to the NEC approved AC

grounding electrode. The racking and module could be grounded to this conductor using a crimp

connection. An alternative method would be to connect the solar micro-inverter to the grounded racking

using a grounding washer approved for the racking.

STEP 5

STEP 3 Lay the AC common cable along the rack using mounting hooks

WARNING : Ensure that common AC Cable does not hang loose.


STEP 6 Connect the PV modules to solar micro-inverters

The Plugreen Installation Map is a diagrammatic representation of the physical location of each Plugreen

Solar micro-inverter in your PV installation. Plugreen creates this map from information that you provide in

a system map. You can use the blank map in the Appendix to record solar micro-inverter placement for

your system. When your map is complete, send it to Plugreen as described below. Plugreen then uses this

information to provide you with detailed information about the performance of your PV system and to allow

you to see a graphic representation of your PV system on the Plugreen ‘Insight’, a web-based monitoring

and analysis. Feel free to provide your own layout if a larger or more intricate installation map is required.

To complete your map

Each Plugreen Solar micro-inverter has a removable serial number label located on the top cover. Peel

the removable serial number label from each Plugreen Solar micro-inverter and affix it to the respective

location on the Plugreen installation map.

Send the installation map to Plugreen at [email protected] after completion. You can also download

installation maps and examples from www.plugreen.com.

After Plugreen creates a graphical representation of your PV system on the website, use the Plugreen

website “Insight” application link to view detailed performance information for your PV system. Please

go to www.plugreen.com for more information on the Plugreen Insight web-based monitoring and

analysis.

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To connect your PV modules:

: Completely install all solar micro-inverters and all system inter-wiring connections prior to

installing the PV modules.

Best Practice: Test AC first. Before you rack-mount the PV, pull and terminate all AC wiring, energize the

branches, and power up the solar micro-inverters to make sure that they all report into the

Communication Gateway unit and are operating correctly.

Mount the PV modules above their corresponding solar micro-inverters. Each solar micro-inverter

comes with two oppositely sexed MC4 multi-contact connectors.

First connect the positive DC wire from the PV module to the negatively marked DC connector (female

socket) of the solar micro-inverter. Then connect the negative DC wire from the PV module to the

positively marked DC connector (male socket) of the solar micro-inverter. Repeat for all remaining PV

modules using one solar micro-inverter for each module.

NOTE

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: The AC output neutral is not bonded to ground inside the solar micro-inverter. NOTE

4 Commissioning

WARNING:

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§

§

Connect the Plugreen Solar micro-inverter to the electrical utility grid only after receiving prior

approval from the utility company.

Only qualified personnel must connect the Plugreen Solar micro-inverters to the Utility grid

Ensure that all AC and DC wiring is correct and none of them are damaged

Ensure that all junction boxes are closed properly

Procedure for Commissioning the Plugreen Solar micro-inverter PV system:

Switch on the main circuit breaker on each Plugreen solar micro-inverter branches.

Switch on the main utility-grid AC circuit breaker. The system will start producing power after 3

minutes of System configuration them.

: Since Plugreen solar micro-inverters are powered by PV panels, make sure that sufficient

sun light is available during this process.

The Plugreen solar micro-inverters will start to send performance data over Power Line (PLC)

to the Communication Gateway unit. The time required for all the solar micro-inverters in the

system to report to the Communication Gateway unit will vary with the number of solar micro-

inverters in the system. The first units should be detected within 10 minutes but the entire

system could take hours to detect. Please refer to the Communication Gateway unit Installation

and Operation Manual.

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§

Note


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5 Troubleshooting

Adhere to all the safety measures described throughout this manual. Qualified personnel can use the

following troubleshooting steps if the PV system does not operate correctly:

: Do not attempt to repair the Plugreen Solar micro-inverter; it contains no user-

serviceable parts. If it fails, please contact Plugreen customer service to obtain an RMA number

and start the replacement process.

WARNING

Solar micro-inverter Error Reporting

Please connect the Communication Gateway Unit to the same utility phase on which the solar micro-inverters are connected

Check the status of each solar micro-inverter.

: Please refer the Communication Gateway unit user manual.

Ground Fault:

Please check the Grid Earth and Neutral voltage; it should be as per the standard.

Other Faults:

Please refer the Communication Gateway unit Operations manual.

Note

WARNING

WARNING

WARNING

WARNING

: Be aware that only qualified personnel should troubleshoot the PV array or the

Plugreen Solar micro-inverter.

: Never disconnect the PV wire connectors under load. Please cover the PV module

using an opaque covering sheet prior to disconnecting the module.

: Always disconnect AC power before disconnecting the PV module wires from the

Plugreen Solar micro-inverter. The AC connector of the first solar micro-inverter in a branch circuit

is suitable as a disconnecting means once the AC branch circuit breaker in the load centre has

been opened.

: The Plugreen Solar micro-inverters are powered by DC power from the PV modules.

Troubleshooting an Inoperable Solar micro-inverter

To troubleshoot an Inoperable Solar micro-inverter, follow the steps in the order shown:

Check the connection to the utility grid. Verify that the utility voltage and frequency are within

allowable ranges shown in the Technical Data section on page 10 of this manual. Verify utility

power is present at the inverter in question by removing AC, then DC power. Never disconnect

the DC wires while the solar micro-inverter is producing power.

Check the AC branch circuit interconnection harness between all the solar micro-inverters.

Verify each inverter is energized by the utility grid as described in the previous step.

STEP 1

STEP 2


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5 Troubleshooting

Make sure that any AC disconnects are functioning properly and are closed.

Verify the PV module DC voltage is within the allowable range shown in the Technical Data

section on page 10 of this manual.

Check the DC connections between the solar micro-inverter and the PV module.

If the problem persists, please call to customer support at Plugreen.

STEP 3

STEP 1

STEP 2

STEP 3

STEP 4

STEP 5

STEP 6

STEP 7

STEP 4

STEP 5

STEP 6

WARNING: Do not attempt to repair the Plugreen Solar micro-inverter; it contains no user-

serviceable parts. If troubleshooting methods fail, please return the solar micro-inverter to your

distributor for maintenance.

Disconnecting the Plugreen Solar micro-inverter from the PV Module

To ensure that the solar micro-inverter is not disconnected from the PV modules under load, adhere to

the following disconnection steps in the order shown:

Disconnect the AC by opening the branch circuit breaker.

Disconnect the first AC connector in the branch circuit.

Cover the module with an opaque cover.

Using a DC current probe, verify there is no current flowing in the DC wires between the PV

module and the solar micro-inverter.

Care should be taken when measuring DC currents, most clamp-on meters must be zeroed

first and tend to drift with time.

Disconnect the PV module wire connectors from the Solar micro-inverter

Remove the Solar micro-inverter from the PV array racking.


>

6 Technical Data

Technical Considerations

The Plugreen PGM200/230/260 Solar micro-inverters are designed to operate with most 60 and 72-

cell PV module configurations. Be sure to verify the voltage and current specifications of your PV module

match with those of the solar micro-inverter. For more information, refer to the Plugreen website

(www.Plugreen.com) for a list of approved PV module racking systems and PV modules.

WARNING

WARNING

WARNING

: The panel voltage range should match with the solar micro-inverter input ratings.

: Make sure that the maximum open circuit voltage is within the specs of solar micro-

inverter units.

: Make sure that the maximum short circuit current of PV panels should be less or

equal to the solar micro-inverter specs.

Note: PV module output voltage and current depends on the size and temperature of the PV cells,

also the solar irradiation falling over the panels.

A list of compatible PV modules is maintained on the Plugreen website (www.Plugreen.com).

Technical Specifications

Plugreen Solar micro-inverter - DC Operating Parameters

Parameter/Model Unit Min Typical Max

MPPT voltage range

PGM200/230/260

PGM200/230/260

Maximum DC input voltage

Maximum DC input short circuit current

Maximum DC input current

PGM200/230/260

PGM200/230/260

V

V

A

A

24 38

45

10/11/12

12


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6 Technical Data

Plugreen Solar micro-inverter - AC Operating Parameters

Parameter/Model Unit

Unit

Min

Min

Typical

Typical

Max

Max

PGM200/230/260

PGM200/230/260

200/230/260

PGM200/230/260

Output power factor

Maximum AC output Power (-40 to +65 Deg C)

Nominal AC output voltage range

Maximum AC output current

Nominal AC output frequency range

Extended AC output frequency range

High AC Voltage trip limit accuracy

Low AC Voltage trip limit accuracy

Frequency trip limit accuracy

W

Vrms

A

Hz

Hz

%

%

Hz

0.95

211

49.4

49.2

2.5

4

±0.1

0.99

230

.85/1/1.1

50

60

1

264

50.41

50.6

Miscellaneous Operating Parameters

Peak inverter efficiency

CEC weighted efficiency

Nominal MPP tracking efficiency

Total Harmonic Distortion

Operating temperature range

Storage temperature range

%

%

%

%

Deg C

Deg C

- 40

- 40

95

92

>99

5

+ 65

+ 65

Plug Green Micro Inverter Operating Parameters

Dimensions

Weight

Enclosure environmental rating

Cooling

Communication

Standard warranty term

Compliance applicable*

160X138X32mm

1.6Kgs

IP65/NEMA6

Convection

Power Line

15 Years

UL, CE, VDE


Note: Specifications are subjected change without notice. *Certifications pending

7 Appendix

Plugreen Corporation Warranty

Plugreen Corporation ("Plugreen") has developed a highly reliable Micro-inverter that is designed to

withstand normal operating conditions when used for its originally intended purpose in compliance with

the Plugreen User Manual supplied with the originally shipped system. The Plugreen limited warranty

("Limited Warranty") covers defects in workmanship and materials of the Plugreen Solar Micro-inverter

("Defective Product") for a period of fifteen (15) years from the date of original purchase of such Micro-

inverter at point of sale to the originally-installed end user location (the "Warranty Period").

During the Warranty Period, the warranty is transferable to a different owner as long as the Micro-

inverter remains installed at the originally-installed end user location. During the Warranty Period,

Plugreen will, at its option, repair or replace the Defective Product free of charge, provided that Plugreen

through inspection establishes the existence of a defect that is covered by the Limited Warranty. Plugreen

will, at its option, use new or reconditioned parts in repairing or replacing the Defective Product. Plugreen

reserves the right to use parts or products of original or improved design in the repair or replacement of

Defective Product. If Plugreen repairs or replaces a Defective Product, the Limited Warranty continues on

the repaired or replacement product for the remainder of the original Warranty Period or ninety (90) days

from the date of Plugreen’s return shipment of the repaired or replacement product, whichever is later.

The Limited Warranty covers both parts and labor necessary to repair the Defective Product, but does not

include labor costs related to un-installing the Defective Product or re-installing the repaired or

replacement product. The Limited Warranty also covers the costs of shipping repaired or replacement

product from Plugreen, via a non-expedited freight carrier selected by Plugreen.

The Limited Warranty does not cover, and Plugreen will not be responsible for, shipping damage or

damage caused by mishandling by the freight carrier and any such damage is the responsibility of the

freight carrier. To obtain repair or replacement service under this Limited Warranty, the customer must

comply with the following policy and procedure:

§ All Defective Products must be returned with a Return Merchandise Authorization Number (RMA)

which customer must request from Plugreen. Before requesting the RMA, however, the customer

should contact Plugreen technical support representative to evaluate and troubleshoot the problem

while the Plugreen Solar Micro-inverter is in the field, since many problems can be solved in the field.


7 Appendix

§ Proof-of-purchase of the Defective Product in the form of

(1) the dated purchase receipt from the original purchase, or

(2) the dated dealer invoice or,

(3) purchase receipt from original equipment manufacturer (OEM), or

(4) the dated receipt showing the product was exchanged under warranty.

§ Model number of the Defective Product.

§ Serial number of the Defective Product.

§ Detailed description of the defect.

§ Shipping address for return of the repaired or replacement product.

§ If in-field troubleshooting does not solve the problem, Customer may request the RMA number, which

request must include the following information:

§

§

All Defective Products authorized for return must be returned in the original shipping container or

other packaging that is equally protective of the product.

The returned Defective Product must not have been disassembled or modified without the prior written

authorization of Plugreen.

Plugreen Solar Micro-inverters are designed to withstand normal operating conditions and typical wear

and tear when used for their original intent and in compliance with the installation and operating

instructions supplied with the original equipment. The Limited Warranty does not apply to, and Plugreen

will not be responsible for, any defect in or damage to any Plugreen Solar Micro-inverter: (1) that has been

misused, neglected, tampered with, altered, or otherwise damaged, either internally or externally; (2) that

has been improperly installed, operated, handled or used, including use under conditions for which the

product was not designed, use in an unsuitable environment, or use in a manner contrary to the Plugreen

User Manual or applicable laws or regulations; (3) that has been subjected to fire, water, generalized

corrosion, biological infestations, acts of God, or input voltage that creates operating conditions beyond

the maximum or minimum limits listed in the Plugreen Solar Micro-inverter specifications, including high

input voltage from generators or lightning strikes; (4) that has been subjected to incidental or

consequential damage caused by defects of other components of the solar system; or (5) if the original

identification markings (including trademark or serial number) of such Micro-inverter have been defaced,

altered, or removed.

The Limited Warranty does not cover costs related to the removal, installation or troubleshooting of the

customer's electrical systems. The Limited Warranty does not extend beyond the original cost of the

Plugreen Solar Micro-inverter.


The Limited Warranty is the sole and exclusive warranty given by Plugreen and where permitted by law, is

made expressly in lieu of all other warranties, express or implied, statutory or otherwise, including, without

limitation, warranties of title, quality, merchantability, fitness for a particular purpose or non-infringement

or warranties as to accuracy, sufficiency or suitability of any technical or other information provided in

manuals or other documentation. In no event will Plugreen be liable for any special, direct, indirect,

incidental or consequential damages, losses, cost or expenses however arising, whether in contract or

tort, including without limitation any economic losses of any kind, any losses or damage to property or any

personal injury.

To the extent any implied warranties are required under applicable law to apply to the Plugreen Solar

Micro-inverter, such implied warranties shall be limited in duration to the Warranty Period, to the extent

permitted by applicable law. Some countries, states or provinces do not allow limitations or exclusions on

implied warranties or on the duration of an implied warranty or on the limitation or exclusion of incidental

or consequential damages, so the above limitation(s) or exclusion(s) may not apply. This Limited Warranty

gives the customer specific legal rights, and the customer may have other rights that may vary from

country to country, state to or province to province.

7 Appendix


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Plugreen Corporation,

Laattakatu 13, 08150 Lohja, Finland

Phone : +358 40 1525086

www.plugreen.com

[email protected]

Contact Information

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