Sungrow COM100D/COM100E Smart Communication Box User Manual

1 About This Manual

This manual is valid for the smart communication box researched and manufactured by Sungrow Power Supply Co., Ltd.

• COM100D
• COM100E

The COM100D and COM100E are referred to as the "COM100" for short unless otherwise specified.

1.1 Validity

This manual is valid for the smart communication box researched and manufactured by Sungrow Power Supply Co., Ltd.

1.2 Type Description

1.3 Intended Use

This manual is intended to provide the reader with detailed information on the COM 100 and describe how to install and operate the device.

1.4 Target Group

This manual is intended for technically qualified persons who need to install, operate, and maintain the COM100 and users who need to perform daily operations.

1.5 How to Use This Manual

Read this manual carefully before performing operation on the device. Keep the manual in a convenient place for future reference. All rights reserved including the pictures, symbols, and markings used in this manual. Any reproduction or disclosure, even partially, of the contents of this manual is strictly prohibited without prior written authorization of Sungrow. The content of the manual will be periodically updated or revised as per the product development. It is probable that there are changes in manuals for the subsequent module edition. If there any inconsistency, the actual product shall prevail.

1.6 Symbol Explanation

This manual contains important safety and operational instructions that must be accurately understood and respected during the installation and maintenance of the equipment. To ensure the optimum use of this manual, note the following explanations of the symbols used.

DANGER indicates a hazard with a high level of risk which, if not avoided, will result in death or serious injury.

WARNING indicates a hazard with a medium level of risk which, if not avoided, could result in death or serious injury.

CAUTION indicates a hazard with a low level of risk which, if not avoided, could result in minor or moderate injury.

NOTICE indicates a situation which, if not avoided, could result in equipment or property damage.

NOTE indicates additional information, emphasized contents or tips to help you solve problems or save time.

2 Safety Instruction

This chapter mainly introduces safety instructions that need to be respected during the operation of the COM100. The COM100 has been designed and tested strictly according to international safety regulations. As electrical and electronic equipment, the COM100 must be installed, commissioned, operated, and maintained in strict accordance with related safety instructions. Incorrect operation or misuse of the device may cause:

• personal injury of the operators or the third party
• device damage of the operators or the third party

Therefore, the following safety instructions must be read and always kept in mind prior to any work. All detailed work-related safety warnings and notes will be specified at the critical points in corresponding chapter.

WARNING All operation and electrical work must only be performed by qualified personnel.

Before Installation

NOTICE COM100 complies with FCC/IC RSS-102 radiation exposure limits set forth for an uncontrolled environment. COM100 should be installed and operated with minimum distance 20cm between the radiator & user's body.

NOTICE After receiving the device, check if there is damage caused during transport. Contact Sungrow or the forwarding company once any problem is detected. The related operators must be familiar with the safety instructions in this manual and other safety regulations about the installation, operation and maintenance of the COM100. Correct moving, transport, installation, operation and maintenance are important for the long-term operation of the Logger1000.

During Installation

NOTICE The COM100 can only be used as described in this manual. Alter the product without authorization or use spare parts not sold or recommended by Sungrow may lead to fire, electric shock or other damages.

NOTICE Disconnect all electrical connections and the upstream input switch to make sure the COM100 is voltage-free during installation.

Maintenance and Replacement

WARNING The maintenance of the COM100 can only be performed by qualified personnel from service dept. of Sungrow or other qualified personnel. User can never maintain or replace the modules and other parts. Serious personal injury or property loss may follow if otherwise.

NOTICE Never replace the internal components of the COM100 without authorization. Sungrow shall not be held liable for any possible damage caused by ignorance of this warning.

3 Product Introduction

3.1 Function Description

3.1.1 Brief Introduction

With a data logger integrated inside, the COM100 is featured with flexible networking, auxiliary maintenance, and easy operation.

Flexible networking

• Support of RS485, Ethernet, and WiFi communication
• Support of access by various environment sensors, energy meters, and Meteo Stations

Auxiliary maintenance

• Support of batch inverter parameter setting and software upgrading
• Support of remote desktop function, lower maintenance costs
• Support of automatic search and allocation of inverter address, easier onsite debugging
• Support of grid control instruction and power factor control
• Support of local real-time monitoring, unnecessary to connect the Internet

Easy operation

• Equipped with lighting device for ease of night maintenance
• Plastic enclosure, lighter weight and easier installation

3.1.2 Networking Application

The COM100 can monitor running information of the PV system in real time and transfer the information to the background. As shown in the figure below, the COM100 communicates with iSolarCloud via a switch.

Diagram showing the COM100 connected to iSolarCloud via a router, SCADA system, Insight, Switch, Meteo Station, Energy Meter, PV module, Inverter, Transformer, and Grid. A second diagram shows connection via WiFi or 4G network.

3.2 Appearance

The COM100 unit has a mounting ear (A) and a waterproof terminal (B) on its side.

3.3 Dimensions

The dimensions of the COM100 are as follows:

• Width (W): 460mm
• Height (H): 315mm
• Depth (D): 130mm

4 Installation Flow

The overall installation flow of the COM100 is as follows:

1. Unpacking and inspection
2. Location selection
3. Mechanical installation
4. Electrical installation
5. Check before commissioning
6. Running steps

5 Mechanical Installation

5.1 Unpacking and Inspection

Check the scope of delivery for completeness according to the packing list. The following items should be included:

• A COM100
• B Documents: Quick user manual, delivery inspection report, packing list, warranty card, and certificate
• C Cable tie: 12, used for binding the cables
• D Hexagon bolt assembly: 4, M6 x 45, used for wall-mounting to fasten the device on the metal surface
• E Expansion bolt: 4, M6 x 60, used for wall-mounting to fasten the device on the concrete wall
• F Terminal resistor: 6x120Ω. Note: If there are more than 15 devices connected on the RS485 bus, it is recommended to connect a 120Ω terminal resistor in parallel on the A and B lines at the head (or tail end) of the bus.
• G OT terminal: M5x10, used for grounding connection

5.2 Location Requirements

Environment Requirements

• With the ingress of protection IP66, the COM100 can be installed both indoors and outdoors (more often).
• Ambient temperature: -30°C to +60°C; and ambient humidity: ≤ 95%. If otherwise, the internal components will be damaged.
• Take anti-moisture and anti-corrosion measures.

5.3 Installation Tools

Installation tools include but are not limited to the following recommended ones. If necessary, use other auxiliary tools on site.

• General tools: Utility knife, Marker, Measuring tape, Protective gloves, Dust mask, Goggles, Vacuum cleaner.
• Installation tools: Hammer drill, Electric screwdriver, Wire stripper, Wire clipper, Phillips screwdriver, Rubber mallet, Crimping tool, RJ45 crimping tool.

5.4 Installation Method

The COM100 can be installed in wall-mounting manner or pole-mounting manner.

WARNING Be aware of the weight of the COM100 throughout the installation process! Tip over or fall of the device due to inappropriate operation can cause personal injury!

5.4.1 Wall-Mounting

Mount the COM100 onto the concrete wall or metal surface according to onsite conditions.

DANGER Avoid drilling holes in the utility pipes and/or cables attached to back of the wall!

NOTICE Operation personnel should wear goggles and dust mask throughout the drilling process to avoid dust inhalation or contact with eyes.

For Concrete Wall:

1. Select an appropriate installation surface.
2. Mark positions for drilling holes with a marker.
3. Drill the holes with a drill according to the marks made before.
4. Secure all the expansion bolts into the holes with a rubber hammer.
5. Fix the COM100 onto the installation surface with the enclosed fasteners.

For Metal Surface:

1. Select an appropriate installation surface.
2. Mark positions for drilling holes with a marker.
3. Drill the holes with a drill according to the marks made before.
4. Fix the COM100 onto the installation surface with the enclosed fasteners.
5. Check and ensure that the COM100 is firmly in place.

5.4.2 Pole-Mounting (Optional)

The COM100 can be installed in the pole-mounting manner which should be specified when you place an order. Sungrow will design according to actual installation conditions. Accessories supplied with the COM100 include matching screw assembly, nuts, brackets, clamps, etc.

The installation procedure is as follows:

1. Anchor the COM100 to the mounting-brackets by using the screw assembly via the mounting ears.
2. Fix the mounting-brackets with the clamps by using the nuts.

5.5 Antenna Connection (Optional)

The COM100 comes standard with an antenna. If the COM100 is to be installed in a container, purchase a sucker antenna.

1. Release the 4 screws on the front side of the COM100 and open the front cover of the cabinet.
2. Loosen the "RF" waterproof terminal on the bottom of the COM100.
3. Lead the antenna through the "RF" waterproof terminal, and secure clockwise the nut at the end of the antenna to the corresponding terminal on the bottom of the Logger1000.
4. Place the sucker antenna base on a metal surface outside the container. (Ensure the metal enclosure is correctly positioned for signal reception, indicated by a checkmark, not an 'X'.)

6 Electrical Connection

6.1 Waterproof Terminal Description

The waterproof terminals on the bottom of the COM100 are described as follows:

6.2 Internal Structure

The internal structure of the COM100 is shown in the following figure:

• A Logger1000A or Logger1000B
• B Switch-mode power supply and surge protection device, 24Vdc power supply
• C Micro circuit breaker, used to connect/disconnect the external 220Vac power supply
• D Lighting device, turns on the light before opening the front cover of the cabinet for ease of night maintenance
• E Antenna
• F Cable tie buckle, used for binding cables
• G Grounding terminal

6.3 Preparation Before Cable Connection

1. Release the 4 screws on the front side of the COM100 and open the front cover of the cabinet.
2. Turn the internal power switch of the COM100 to the "OFF" position to ensure the COM100 is voltage-free.

6.4 Grounding

1. Strip the insulation cover of the grounding cable and crimp the stripped cable to the OT terminal.
2. Fasten the grounding cable in the sequence of cross recessed fastener assembly (A), OT terminal (D), and grounding hole.

6.5 RS485 Port

6.5.1 Connect to the Device with RS485 Port

RS485 communication terminals inside the COM100 are located at the bottom of the Logger, including A1B1, A2B2, and A3B3.

Communication cable specification: RS485 cable (Outdoor ultraviolet protection shielded twisted pair - STP)

1. Loosen the "RS485-1/2/3" waterproof terminal on the bottom of the COM100.
2. Lead the RS485 cable through the "RS485-1/2/3" waterproof terminal. Strip the cable jacket and insulation layer of the communication cable with a wire stripper respectively. (Ensure stripping lengths are approximately 8-10mm for jacket and 15mm for insulation).
3. Connect the stripped cable to the RS485 ports of the Logger1000. Note: RS485A is connected to port A while RS485B is connected to port B.
4. Fasten the "RS485-1/2/3" waterproof terminal.

6.5.2 Connect to the Device with RJ45 Port

Communication cable specification: ETH communication cable (Outdoor STP Ethernet cable)

1. Loosen the "RS485-1/2/3" waterproof terminal on the bottom of the COM100.
2. Lead the Ethernet cable through the "RS485-1/2/3" waterproof terminal. Strip the insulation layer of the communication cable with an Ethernet wire stripper.
3. Insert the stripped communication cable into the RJ45 connector in the correct order, and crimp it with a crimping tool. The wire color to pin correspondence is:
   • Pin 1: White-and-orange
   • Pin 2: Orange
   • Pin 3: White-and-green
   • Pin 4: Blue
   • Pin 5: White-and-blue
   • Pin 6: Green
   • Pin 7: White-and-brown
   • Pin 8: Brown
4. Insert the RJ45 connector of the Ethernet communication cable into the "ETH" port of the Logger1000.
5. Fasten the "RS485-1/2/3" waterproof terminal.

6.6 Ethernet Port

The COM100 can be connected to the background of the PV system via the Ethernet port, and the communication protocol is standard Modbus TCP or IEC104.

1. Prepare a suitable length of Ethernet cable.
2. Insert one end of the cable into the port of the Ethernet switch and the other end to the "ETH" port of the Logger1000 inside the COM100.
3. Set IP address of the ETH port to be within the same network segment as that of the background monitoring system. (Default IP of the "ETH": 12.12.12.12).

6.7 External AC Power Supply Cable

External AC power supply ports are provided on the bottom of the external power supply circuit breaker inside the COM100.

Power cable specification: Power cable (Outdoor ultraviolet protection cable)

1. Loosen the "AC (100~277V)" waterproof terminal, and insert the external power supply cable through the waterproof terminal into the corresponding terminal of the micro circuit breaker inside the COM100.
2. Strip and connect the cable to the corresponding terminal inside the COM100.
3. Fasten the "AC (100~277V)" waterproof terminal.

6.8 External DC Power Supply Cable

The 24Vdc power supply port inside the COM100 is the "24V IN" and "24V OUT" port on the bottom of the Logger. The rated power is 10W and the max. power is 12W. The COM100 can supply the connected external device with 24Vdc power.

DC cable specification: DC cable (Outdoor ultraviolet protection STP)

1. Loosen an unused waterproof terminal on the bottom of the COM100.
2. Lead the DC cable through the waterproof terminal. Strip the cable jacket and insulation layer of the DC cable by appropriate length with a wire stripper.
3. Insert the stripped DC cable into the port "24V IN" and "24V OUTHere is the JSON requested:
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