Xantrex PV-100208 User Guide

OPERATION and MAINTENANCE

MANUAL

for

MODEL PV-100208

100 kW Grid-Tied Photovoltaic Inverter

Document #151700

Revision B October 13, 2003

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS - THIS MANUAL CONTAINS IMPORTANT INSTRUCTIONS

FOR XANTREX TECHNOLOGY MODEL PV-100208 GRID TIED PHOTOVOLTAIC INVERTER THAT SHALL BE FOLLOWED DURING INSTALLATION AND MAINTENANCE OF THE PV-

100208.

Xantrex Technology Inc.

161-G SOUTH VASCO ROAD

Livermore, CA 94550

(925) 245-5400

Table of Contents

Product Description ................................................ Section 1

Introduction ............................................................................. 1-1

Major Components ................................................................. 1-1

Control Components ............................................................... 1-2

Interconnection Standards Compliance .....................................1-3

Specifications .......................................................................... 1-4

Equipment Symbol ................................................................... 1-4

Safety ............................................................................. Section 2

Safety Features ........................................................................2-1

Isolation Procedure ..................................................................2-2

Installation And Initial Turn-On ....................... Section 3

Isolation Transformer Requirements .......................................... 3-1

Torque and Wire Gauge Specifications .....................................3-2

Installation Instructions ............................................................. 3-2

Interconnection Wiring .............................................................3-4

Initial Turn On Procedure .........................................................3-6

Operation ................................................................... Section 4

Description of System Operation ..............................................4-1

Operation Features .................................................................. 4-2

Operator Interface ................................................................... 4-3

Manual State Transitions .......................................................... 4-5

Automatic State Transitions ......................................................4-6

Auto-Restart Feature ............................................................... 4-7

Isolation Procedure ..................................................................4-7

Turn-On Procedure ................................................................. 4-7

Troubleshooting ....................................................... Section 5

General ................................................................................... 5-1

Alarms and Fault Conditions ....................................................5-1

Preventative Maintenance .................................. Section 6

Periodic Maintenance .............................................................. 6-1

Isolation Procedure ..................................................................6-2

Turn-On Procedure ................................................................. 6-2

Appendix ...................................................................... Section 7

Fault Codes .............................................................................7-1

Read/Write Parameter Menu.................................................... 7-1

Warranty and Certifications ...................................................... 7-4

Drawings List .......................................................................... 7-5

SECTION 1 PRODUCT DESCRIPTION

INTRODUCTION

The Xantrex Technology Model PV-100208 is a current following grid tied photovoltaic inverter, utilizing state-of-the-art IPM (Intelligent Power Module), insulated gate bi-polar transistors (IGBT’s) and gate drive circuits to allow interface of a photovoltaic array with a utility grid. The PV-100208 consists of an inverter bridge, photovoltaic controller, and associated control electronics. The PV100208 control software provides for complete overall system control with a variety of protection and safety features.

MAJOR COMPONENTS

The major components of the PV-100208 are identified in Figure 1-1. Control components are identified in Figure 1-2. For specific control components see Drawing No. 151702 located in Section 7 (Appendix).

Main Enclosure

This enclosure is NEMA-3R rated. The PV-100208 main enclosure contains the power electronic inverter bridge, electrical and electromechanical control components, power supplies, system sensing circuits, and the PV-100208 embedded control unit. Also found within the main enclosure are some of the system protection devices (sense and control power fuses).

DOCUMENT: 151700

Figure 1-1

PV-100208 Photovoltaic Inverter

Operation and Maintenance Manual

1-1

SECTION 1 PRODUCT DESCRIPTION

AC Interface Enclosure

This enclosure is NEMA-3R rated. The AC Interface serves as the connection between the isolation transformer/utility and the PV-100208. This enclosure is where the AC line fuses and AC disconnect switch reside. For specific control components see Drawing No. 151703 in Section 7 (Appendix).

DC Interface Enclosure

This enclosure is NEMA-3R rated. The DC Interface serves as the connection interface between the PV array and the PV-100208. This enclosure is where the DC disconnect switch and DC contactor reside. For specific control components see Drawing No. 151704 in Section 7 (Appendix).

CAUTION

The fuses within the PV-100208 are intended for protecting the PV-100208 control circuitry only. They are not intended to provide protection for the PV array or external cabling.

Power Electronics Matrix

The power electronics converter is located at the top of the PV-100208 Main Enclosure. The matrix is comprised of switching transistors (IGBTs), transistor gate drive electronics, a laminated power bus, DC capacitor bank, and an aluminum extrusion heat sink with a cooling fan. The fan is located above the matrix heatsink.

The PV array is tied logically to the matrix DC bus via the DC interface enclosure. The embedded control unit manages the transfer of power between the DC bus and the utility grid.

Operator Interface

The operator interface is located on the front door of the PV-100208 main enclosure. It consists of an On/Off switch and a keypad with liquid crystal display for control and monitoring purposes. All interface components are NEMA-3R rated. Refer to Section 4 for detailed operation instructions.

Inductor Enclosure

This enclosure is NEMA-3R rated. It contains the necessary filter components to insure the PV-100208 line currents and voltages meet IEEE-519 and UL1741 harmonic distortion requirements. Mounted on the right side of the lower enclosure is an inductor fan to allow cooling of the line filter components within. This enclosure also serves as the mounting base for the PV-100208 main enclosure.

CONTROL COMPONENTS

The following assemblies are contained within the PV-100208 main enclosure as shown in Figure 1-2 (see Appendix in Section 7).

Power Distribution Panel

This panel contains many of the Electro-mechanical, protective, and control power components necessary to support the operation of the PV-100208.

DOCUMENT: 151700

PV-100208 Photovoltaic Inverter

Operation and Maintenance Manual

1-2

SECTION 1 PRODUCT DESCRIPTION

Power Control Unit (PCU)

The PCU is a Digital Signal Processor (DSP) based control board that performs numerous control and diagnostic functions associated with PV-100208 operation. Its most significant tasks are control of PV100208 electromechanical components and power electronics converters, signal conditioning for high voltage signal inputs and communication with the operator interface panel and system sensors. The

PCU also contains the necessary DC power supplies to support its operation.

INTERCONNECTION STANDARDS COMPLIANCE

The PV-100208 has been tested and listed by Underwriters Laboratories to be in compliance with UL1741 Static Inverters And Charge Controllers For Use In Photovoltaic Power Systems, as well as IEEE-929-2000 Recommended Practice For Utility Interface Of Photovoltaic (PV) Systems.

IEEE-929-2000 provides guidance regarding equipment and functions necessary to ensure compatible operation of photovoltaic systems which are connected in parallel with the electric utility. UL1741 is the standard applied by Underwriters Laboratory to the PV-100208 to verify it meets the recommendations of IEEE-929-2000. Refer to both documents for details of these recommendations and test proce-

dures.

DOCUMENT: 151700

C-C

Figure 1-2

PV-100208 Photovoltaic Inverter

Operation and Maintenance Manual

D-D

1-3

SECTION 1 PRODUCT DESCRIPTION

SPECIFICATIONS

The PV-100208 has been designed for photovoltaic power systems, which operate within the following specifications. Application of the PV-100208 in a manner inconsistent with these specifications may cause damage to the PV-100208 and other system components, and is a violation of the terms of the warranty.

egatloVeniLCAlanimoN%21-%01+,CAV802

tnerruCeniLCAmumixaM )egatlovenilwolta(SMRA803

ycneuqerFeniLlanimoNzH7.0-5.0+,zH06

rewoPtuptuOCAsuounitnoC esahP3CAV802@Wk0.001

egatloVmumixaMVPCDV006

wodniWgnikcarTrewoPkaePCDV006-*033

egatloVgnikcarTrewoPkaePmuminiMVPCDV033

tnerruCmumixaMVPCDA913

noitarugifnoCVP dednuorgevitagenraloponoM

erutarepmeTgnitarepOC°05ot02-**

erutarepmeTegarotSC°05ot04-

gnitaRerutarepmeTtneibmAmumixaMC°05

ytidimuHevitaleRgnisnednoc-noN,%59oT

noitavelEteef006,6evobadetareD

)sehcnini(snoisnemiD02X5.67X38

thgieW.sbl0051.xorppA

epyTerusolcnER3AMEN

eliFgnitsiLLU653991E-eliF

*Dependent on actual AC line voltage. Refer to Section 4 for detail on the minimum power tracking voltage. **If ambient temperature is between -20 to 0° C, the unit must be powered up in standby for at least one hour prior to going on-line.

EQUIPMENT SYMBOL

Chassis ground – Customer supplied system ground connection point. This symbol may be found near a stud within the main enclosure. It is provided as a location to bond the electrical system equipment ground.

DOCUMENT: 151700

PV-100208 Photovoltaic Inverter

1-4

Operation and Maintenance Manual

SECTION 2 SAFETY

SAFETY FEATURES

WARNING

The PV-100208 enclosure contains exposed high voltage conductors. The enclosure doors should remain locked, except during maintenance or testing. 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 unless you are qualified to do so. Do not open the cabinet doors if extreme moisture is present (rain or heavy dew).

On/Off Switch

The PV-100208 incorporates a maintained position on/off switch located on the front door of the main enclosure. Under normal conditions, the on/off switch is in the on position. Turning the switch to the off position will initiate a controlled shutdown of the PV-100208 and open the A/C contactor within the unit. The A/C contactor cannot be closed unless the switch is in the on position. The PV-100208 is prevented from being restarted until the on/off switch is turned back to the on position. Cycling the on/ off switch will reset the PV-100208 and attempt to clear any system fault.

Main Enclosure Door Interlock Switch

The front door of the PV-100208 main enclosure is equipped with an interlock switch to preclude operation in the event of the front door being opened. It is required that the PV-100208 main enclosure door handle be padlocked during normal operation.

WARNING

The PV-100208 will immediately shutdown if the front door is opened during operation. It is required that the PV-100208 main enclosure door handle be padlocked during normal operations. Please make sure the unit is powered down, and isolated from the utility grid and PV panels, prior to opening the front door. Allow 5 minutes for any stored potentials to be discharged, prior to opening the unit.

Disconnect Switches

Both AC & DC switches are equipped with lockout hasps for personnel safety. The switch enclosure door will not open while the PV-100208 is running. In addition, the switch handle and shaft provide a door interlock. The door cannot be opened when the switch is in the “on” position. The PV disconnect switch is equipped with an auxiliary contact block which enables the switch to be used as a load break PV disconnect. In the event a disconnect switch is opened while the PV-100208 is processing power from the PV array, the contact block will signal the PCU to stop processing power before the switch opens.

Fault Reporting

Any fault conditions are reported to the operator interface. The LCD will display a text description of the fault. Refer to Section 5, Troubleshooting, for detailed descriptions of system fault conditions.

PV Ground Fault Detection

The PV-100208 is equipped with ground fault detection circuitry (see section 3, installation and section 7, system schematic for further detail). Upon detection of 10 amps of ground fault current, the PV100208 executes an orderly shutdown, and annunciates a ground fault at the operator interface. The

DOCUMENT: 151700

PV-100208 Photovoltaic Inverter

Operation and Maintenance Manual

2-1

SECTION 2 SAFETY

PV-100208 will remain faulted until the ground fault is remedied and cleared at the operator interface (see section 5, troubleshooting).

Over/Under Voltage and Frequency The over/under frequency and voltage detection setpoints have been chosen to be in compliance with IEEE-929 and UL1741.

noitidnoCtluaF

)lanimoNfo%(

%05<CAVCAV<401selcyC6

%05< %88<CAVCAV<401<381sdnoceS2

%88<CAV< %011CAV<381<822noitarepOlamroN

%731<CAV<%011582<CAV<822sdnoceS2

%731<CAV582< CAVselcyC2

7.0-detar<f3.95<fselcyC6

5.0+detar>f5.06>fselcyC6

egnaRegatloVemiTpirT

Anti Island Protection

A digital phase-shift-loop (PSL) circuit is implemented in the DSP inverter controller to prevent “Islanding” of the PV-100208.

The DSP continuously makes minor adjustments to the power factor phase angle above and below unity. In the event of a utility outage, these adjustments destabilize the feedback between the inverter and the remaining load, resulting in an over/under frequency or voltage condition. The PV-100208 then performs an orderly shutdown. The fault condition will remain until the utility voltage and frequency have returned to normal for 5 minutes.

This method has been extensively tested and proven to exceed the requirements of UL 1741.

ISOLATION PROCEDURE

The following procedure should be followed to de-energize the PV-100208 for maintenance:

WARNING

The terminals of the PV input may be energized if the arrays are energized. In addition, allow 5 minutes for all capacitors within the enclosure to discharge after disconnecting the PV-100208 from AC and DC sources.

1. Turn the on/off switch to the off position.

2. Open the PV array disconnect switch.

3. Open the AC interface disconnect switch.

4. Open the isolation transformer circuit breaker.

5. Install lockout devices on the isolation transformer circuit breaker and PV disconnect switch.

DOCUMENT: 151700

PV-100208 Photovoltaic Inverter

Operation and Maintenance Manual

2-2

SECTION 3 INSTALLATION AND INITIAL TURN-ON

ISOLATION TRANSFORMER REQUIREMENTS

The PV-100208 UL1741 certification requires the 100 kVA WYE/WYE isolation transformer be wired between the inverter AC output and the utility interconnection. This custom 100 kVA isolation transformer is included with any PV-100208 that requires UL1741 certification (see Appendix in Section 7 for transformer dimensions and specifications). If UL1741 and NEC690 is not a requirement of your PV installation, you may use any standard dry-type isolation transformer as long as the inverter side is rated for a minimum of 100 kVA, 208 VAC continuous duty. Contact Xantrex Technology if you have any questions.

WARNING

Check with the local utility of jurisdiction when selecting the winding configuration of the isolation transformer. Individual utilities may have unique requirements related to isolation transformer wiring. Some winding configurations may keep the PV-100208 from detecting a loss of phase condition on the utility system which may allow potentially lethal voltage to be present on the open phase wirings.

WARNING

Xantrex Technology requires installing an isolation transformer between the PV100208 inverter and the point of utility interconnection. Failure to do so could result in catastrophic damage to the PV-100208 as well as the utility distribution system and will void the product warranty.

Inverter Side Isolation Transformer Requirements The inverter side transformer windings may be configured either DELTA or WYE, and must be rated for 208 VAC. If a WYE wound transformer is used to interface with the PV-100208, and the PV array is grounded, the neutral (X0) must be left floating. If the neutral is tied to ground, the inverter will suffer irreparable damage.

Utility Side Isolation Transformer Requirements The utility side isolation transformer windings may be configured either DELTA or WYE, and must be rated for the utility voltage at the point of utility inter-connection. Check with the utility of jurisdiction when selecting an isolation transformer configuration. If a WYE wound transformer is used to interface with the utility, it is not necessary to connect the neutral (X0) to ground. The PV-100208 is a balanced, three phase, current sourcing inverter, and only operates with the presence of a stable utility voltage. Single phase grounded loads which may be present between the transformer and utility, will maintain their existing ground reference at the utility distribution transformer. Grounding the neutral of a WYE wound transformer may create an “open delta” condition, depending on the utility configuration. This

condition may keep the PV-100208 from detecting a loss of phase condition on the utility system, which may allow potentially lethal voltage to be present on the open phase wiring.

Contact your Xantrex Technology distributor if you have any questions regarding isolation transformer requirements.

DOCUMENT: 151700

PV-100208 Photovoltaic Inverter

3-1

Operation and Maintenance Manual

SECTION 3 INSTALLATION AND INITIAL TURN-ON

TORQUE AND WIRE GAUGE SPECIFICATIONS

The following torque specifications are to be used on all electrical interfaces made during installation of the PV-100208.

Torque Table

eziStloBrokcolBlanimreTgnitteSeuqroT

)CA(tloB61-8/3mN2.82/.sblni052

,-CD,+CD(kcolBlanimreT

)lartueNCD&

mN1.13/sblni572

The following table shows acceptable wire gauges to be connected to the PV-100208 AC and DC inputs.

Wire Gauge Table

noitanimreTGWAegnaReriW

)CA(hctiwStcennocsiD)nim(MCM052

-CD,+CD(kcolBlanimreT

)lartueNCD&

4#-MCM005

INSTALLATION INSTRUCTIONS

CAUTION

All wiring methods shall be in accordance with the National Electrical Code ANSI/ NFPA 70. All power conductors interfacing to the PV-100208 should be sized in accordance with the National Electric Code ANSI/NFPA 70 and local codes. Large gauge wire must have a minimum bend radius dependent upon the wire gauge (refer to the National Electric Code, Article 373-6B). Take care to keep the wire bundles away from any sharp edges which may damage wire insulation over time. Xantrex Technology recommends using 250 MCM, 105 degrees C, minimum, copper wire for all connections to the PV-100208.

Ventilation Considerations

Maintain a minimum of 6” clearance in back and minimum of 12” in front and both sides of the PV100208 for proper cooling fan operation.

Installation

1. Move the PV-100208 into place. Lift the PV-100208 from beneath the lower enclosure with a forklift as shown in Figure 3-1. (See following page.)

2. Anchor the lower enclosure feet to the floor with a 1/2” anchor bolts.

3. Install all conduits needed for cable entry in the shaded areas of both AC and DC interface enclosures as shown in Figure 3-2. (See following page).

DOCUMENT: 151700

PV-100208 Photovoltaic Inverter

3-2

Operation and Maintenance Manual

SECTION 3 INSTALLATION AND INITIAL TURN-ON

Lift Here

Figure 3-1

Cable Entry Area

Figure 3-2

Array Grounding

NEC 690-41/42 requires the PV array to be earth grounded. The PV-100208 chassis is also bonded to the PV safety ground terminal block. Refer to the system schematic in the appendix for further wiring configuration.

DOCUMENT: 151700

PV-100208 Photovoltaic Inverter

Operation and Maintenance Manual

3-3

SECTION 3 INSTALLATION AND INITIAL TURN-ON

Ground Fault Detection

The PV-100208 is equipped with a ground fault detection circuit and current transducer. This circuit is active when the PV array is grounded as described in the previous section. In the event of a greater than 10 amp ground fault, the PV100208 will execute an orderly shutdown and annunciates a ground fault at the operator interface. The PV-100208 will remain faulted until the ground fault is remedied and cleared at the operator interface (see section 5, Troubleshooting).

CAUTION

The input and output circuits are isolated from the enclosure and that system grounding, if required by sections 690-41 and 690-42 of the National Electric Code, ANSI/NFPA 70, is the responsibility of the installer.

INTERCONNECTION WIRING

CT1

CAUTION

To reduce the risk of fire, connect only to a circuit provided with 450 amperes maximum branch circuit overcurrent protection in accordance with the National Electrical Code, ANSI/NFPA 70.

The following wires for connecting the PV-100208 to external devices are not provided by Xantrex Technology: (See installation diagram on pages 3-5.)

• Connect 3-Phase 208 VAC inverter output (AC Disconnect switch) to terminals of the 208 VAC

inverter side of isolation transformer. If the inverter side of the isolation transformer is con-

figured WYE, the neutral must be left floating. If the inverter side neutral is tied to ground, the inverter will not function properly. Also, insure that the neutral is not bonded to the isolation transformer frame. Be sure to maintain proper phasing as shown in the system sche-

matic found in Section 7.

• Connect Isolation transformer grid side terminals 1, 2, and 3 to line circuit breaker. Be sure to

maintain proper phasing as shown in the system schematic found in Section 7.

• PV frame ground to ground terminal block (TB3).

• Connect PV+, PV-, and PV Safety ground to the DC interface enclosure’s designated termina-

tions. See Section 7 for further detail .

CAUTION

When connecting external AC wires to the PV-100208, positive phasing sequence must be maintained throughout the installation process. Refer to the System Schematic in Section 7 of this manual for proper phasing convention.

Install all wires listed above. Refer to the Appendix in Section 7 for layout of the AC and DC interface enclosures. Refer to the system schematic in Section 7 for more detailed terminal locations.

DOCUMENT: 151700

PV-100208 Photovoltaic Inverter

Operation and Maintenance Manual

3-4

SECTION 3 INSTALLATION AND INITIAL TURN-ON

PV Array

Frame Ground

GND

PV-

PV+

Circuit

DOCUMENT: 151700

Breaker

AC Interface DC Interface

A B C

To Single Point

Electrical

Distribution

System Ground

PV-100208 Photovoltaic Inverter

Operation and Maintenance Manual

H3 X3

X2H2

H1 X1

Inverter

PV-100208

3-5

Wiring Diagram

Gnd

Chassis

Isolation Transformer

SECTION 3 INSTALLATION AND INITIAL TURN-ON

INITIAL TURN ON PROCEDURE

The following must be performed by an approved Technician:

The following procedures are intended to verify correct installation and proper operation of the PV-

100208. These steps are to be followed sequentially. Do not continue if any of the steps or results are

unclear. Refer to Section 4 for a detailed description of system operation. Refer to Section 5 for fault condition descriptions and troubleshooting. Refer to Section 7 for detailed system schematics.

Visual Inspection, Isolation Transformer WYE/WYE

• Verify the isolation transformer circuit breaker is open.

• If a phase rotation meter is available, verify proper phase rotation at the line side of the isolation

transformer circuit breaker.

• Insure the neutral on the inverter side is left floating. If the inverter side neutral is tied to ground,

the inverter will not function properly. Also, insure that the neutral is not bonded to the isolation transformer frame.

• Verify the inverter 208 VAC conductors are connected to the isolation transformer.

• If the wires are marked, verify they follow the sequence on the line side of the isolation transformer

and circuit breaker.

• Verify the utility conductors are properly connected to the isolation transformer.

Visual Inspection, PV-100208

• Insure AC and DC disconnect switches are opened.

• Remove the front cover from the inductor enclosure, open the door of the main enclosure, and

disconnect enclosures and inspect.

• Verify all wire connections are tight.

• Inspect the fiber optic cables between the PCU and the matrix driver boards. All fibers should be

snap-locked into their respective receivers/transmitters.

• Insure all connector jack screws on the PCU and matrix driver board are tight.

• Verify AC phase connections landed at the AC interface enclosure.

Visual Inspection, PV Array Wiring

• Verify the PV+, PV-, and PV safety ground are isolated from each other. The safety ground must not

be tied to PV-.

• Verify all PV fuses are installed.

Initial Power

• Turn the On/Off switch, located on the front door to Off.

• With the DC disconnect switch opened, close one of the PV array string disconnect switches.

• Carefully measure VDC across the PV +/- terminal block. The value should be the same as at the

PV array string disconnect switch. It should also be positive.

• Close the PV disconnect switch.

• Carefully measure VDC between the DC contactor negative (-) terminal and the DC switch positive

DOCUMENT: 151700

PV-100208 Photovoltaic Inverter

Operation and Maintenance Manual

3-6

+ 32 hidden pages

Xantrex PV-100208 User Guide

Specifications and Main Features

Frequently Asked Questions

User Manual