Xantrex PV100S-HE Installation Guide

PV100S 100 kW Grid-Tied Photovoltaic Inverter
PV100S-208-HE PV100S-480-HE
Planning and Installation Manual
PV100S 100 kW Grid-Tied Photovoltaic Inverter
Planning and Installation Manual
About Xantrex
Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with products from 50 watt mobile units to 2.5 MW utility-scale systems for wind, solar, batteries, fuel cells, microturbines, and backup power applications in both grid-connected and stand-alone systems. Xantrex products inclu de inverters, batt ery chargers, programmable power supplies, and variable speed drives that convert, supply, control, clean, and distribute electrical power.
Trademarks
PV100S 100 kW Grid-Tied Photovoltaic Inverter is a trademark of Xantrex International. Xantrex is a registered trademark of Xantrex International.
Other trademarks, registered trademarks, and product names are the property of their respective owners and are used herein for identification purposes only.
Notice of Copyright
PV100S 100 kW Grid-Tied Photovoltaic Inverter: PV100S-208-HE and PV100S-480-HE Planning and Installation Manual© May 2006 Xantrex International. All rights reserved.
Exclusion for Documentation
UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX TECHNOLOGY INC. (“XANTREX”) (
A) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER
INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION.
(
B) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES, WHETHER SPECIAL,
DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION.
THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USERS RISK; AND (C) REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH, ALTHOUGH STEPS HAVE BEEN
TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION, THE ACCURACY CANNOT BE GUARANTEED. APPROVED
XANTREX CONTENT IS CONTAINED WITH THE ENGLISH LANGUAGE VERSION WHICH IS POSTED AT
WWW.XANTREX.COM.
Date and Revision
May 2006 Revision A
Part Number
152973 Rev A
Product Number (FGA)
PV100S-208-HE 1-152797-01 PV100S-480-HE 1-152798-01
Contact Information
T elephone: 1 800 670 0707 (toll free North America)
1 360 925 5097 (direct) Fax: 1 360 925 5143 (direct) Email: customerservice@xantrex.com Web: www.xantrex.com
About This Manual
Purpose
The purpose of this Planning and Installation Manual is to provide explanations and procedures for planning and installing the PV100S 100 kW Grid-Tied Photovoltaic Inverter. For operation and maintenance of the PV100S, refer to the
PV100S 100 kW Grid-tied Photovoltaic Inverter Operation and Maintenance Manual.
Scope
The Manual provides safety guidelines, detailed planning and setup information, and procedures for installing the inverter.
Audience
The Manual is intended for use by anyone who plans to construct or install a system involving the PV100S 100 kW Grid-Tied Photovoltaic Inverter. Installers must meet all local and state code requirements for licensing and training for the installation of Electrical Power Systems with AC and DC voltage to 600 volts.
Organization
This Manual is organized into four chapters and one appendix: Chapter 1, “Introduction” provides information about the features and functions
of the PV100S 100 kW Grid-Tied Photovoltaic Inverter. Chapter 2, “Planning” provides information to help you plan the installation of the
PV100S 100 kW Grid-Tied Photovoltaic Inverter. Chapter 3, “Installation” describes the procedures to install the PV100S 100 kW
Grid-Tied Photovoltaic Inverter. This chapter includes unpacking and moving instructions, mounting instructions, and cabling instructions.
Chapter 4, “Verification” provides a checklist to ensure the installation of the PV100S is correct and complete.
Appendix A contains the system schematics to aid with installation.
152973 Rev A iii
About This Manual
Conventions Used
The following conventions are used in this guide.
WARNING
W arnings identify conditions or practices that could result in personal injury or loss of life.
CAUTION
Cautions identify conditions or practices that could result in damage to the unit or other equipment.
Important:
serious as a caution or warning.
This Manual contains information for two models of the PV100S 100 kW Grid­Tied Photovoltaic Inverter. One model is designed to operate with a 208 Vac utility input, and the other model is designed to operate with a 480 Vac utility input.
The model PV100S-208-HE 100kW Grid-Tied Photovoltaic Inverter (208 Vac input) will be referred to as the PV100S-208-HE when it is being referenced individually.
The model PV100S-480-HE 100kW Grid-Tied Photovoltaic Inverter (480 Vac input) will be referred to as the PV100S-480-HE when it is being referenced individually.
When the both models are being referenced together, they will be referred to as the PV100S.
These notes describe things which are important for you to know, but not as
iv 152973 Rev A
Abbreviations and Acronyms
ANSI American National Standards Institute CCU2 Converter Control Unit 2 CFM Cubic Feet per Minute CW Clockwise DSP Digital Signal Processor FPGA Field Programmable Gate Array GUI Graphical User Interface IEEE Institute of Electrical and Electronics Engineers IGBT Insulated Gate Bipolar Transistor IPM Intelligent Power Module KCMIL 1000 circular mils LAN Local Area Network
About This Manual
LCD Liquid Crystal Display NEC National Electrical Code NFPA National Fire Protection Association PBX Private Branch Exchange PSL Phase-Shift Loop POTS Plain Old Telephone Service PV Photovoltaic UFCU Universal Front Panel Control Unit
Related Information
Other part numbers which are referred to in the Manual include:
AC Sense Harness Assembly, Part number 1-152403-01
RS232/FO Converter Kit, Part number 1-152624-01 For related information on the PV100S, refer to the:
PV100S 100 kW Grid-Tied Photovoltaic Inverter: PV100S-208-HE and PV100S-480-HE Operation and Maintenance Manual (Part number 152977)
You can find more information about Xantrex Technology Inc. as well as its products and services at www.xantrex.com.
152973 Rev A v
vi
Important Safety Instructions
SAVE THESE INSTRUCTIONS — DO NOT DISCARD
This Manual contains important safety instructions for the PV100S that shall be followed during installation and maintenance procedures.
WARNING: Shock Hazard
Read and keep this Planning and Installation Manual for future reference. Before installing PV100S (either model), read all instructions, cautionary markings, and all other appropriate sections of this Manual. Failure to adhere to these warnings could result in severe shock or possible death. Exercise extreme caution at all times to prevent accidents.
WARNING: Shock Hazard
The PV100S enclosures contain exposed high-voltage conductors. The enclosure doors should remain closed with the latches tightened, except during installation, maintenance or testing. These servicing instructions are for use by qualified personnel who meet all local and state code requirements for licensing and training for the installation of Electrical Power Systems with AC and DC voltage to 600 volts. To reduce the risk of electric shock, do not perform any servicing other than that specified in the installation instructions unless you are qualified to do so. Do not open the cabinet doors if extreme moisture is present (rain or heavy dew).
WARNING: Lethal Voltage
In order to remove all sources of voltage from the PV100S, the incoming power must be de-energized at the source. This may be done at the main utility circuit breaker and by opening the AC Disconnect and the DC Disconnect Switches on the PV100S. Review the system configuration to determine all of the possible sources of energy. In addition, allow 5 minutes for the DC bus capacitors, located on the ceiling of the cabinet, to discharge after removing power.
WARNING: Limitations on Use
The PV100S 100 kW Grid-Tied Photovoltaic Inverter is not intended for use in connection with life support systems or other medical equipment or devices.
152973 Rev A vii
Safety
General Safety Precautions
1. When installing the PV100S, use only components recommended or sold by Xantrex®. Doing otherwise may result in a risk of fire, electric shock, injury to persons, and will void the warranty.
2. Do not attempt to operate the PV100S if it has been dropped, or received more than cosmetic damage during transport or shipping. If the PV100S is damaged, or suspected to be damaged, see the Warranty for this unit in the
PV100S 100 kW Grid-Tied Photovoltaic Inverter: PV100S-208-HE and PV100S-480-HE Operation and Maintenance Manual.
3. T o reduce the risk of electrical shock, lock out and tag out t he PV100S before attempting any maintenance, service, or cleaning.
Personal Safety
Follow these instructions to ensure your safety while working with the PV100S.
Safety Equipment
Authorized service personnel must be equipped with standard safety equipment which include the following:
Safety glasses
Ear protection
Steel-toed safety boots
Safety hard hats
Padlocks and tags
Appropriate meter to verify that the circuits are de-energized (600 Vac and DC rated, minimum)
Check local safety regulations for other requirements.
Wiring Requirements
1. All wiring methods and materials shall be in accordance with the National Electrical Code ANSI/NFPA 70. When sizing conductors and conduits interfacing to the PV100S, both shall be in accordance with the National Electrical Code ANSI/NFPA 70, as well as all state and local code requirements.
2. Use copper conductors only with insulation rated for 90 °C.
3. The PV100S has a three-phase output. It is marked with this symbol:
4. The AC power conductor wiring interfacing with the AC terminals in the Transformer Enclosure are located at T6-X1, T6-X2, and T6-X3. These terminals should be tightened to a torque value of 250 in-lbs (28.2 Nm) for both models of the PV100S. Conductors terminated to these terminals must use a crimp-on type ring terminal or compression-type lug. The terminals are one bolt per pole. See Figure 3-14 on page 3–16 for the location of these terminals.
viii 152973 Rev A
Safety
5. The AC power conductor wiring interfacing with the AC terminals in the Main Inverter Enclosure are located at TB4-A, TB4-B, and TB4- C. These terminals are to be tightened to a torque value of 275 in-lbs (31 Nm) for both models of the PV100S. The terminals will accept a conductor size of 350 KCMIL. See Figure 3-15 on page 3–17 for the location of these terminals.
6. The AC power conductor wiring interfacing with the AC terminals in the AC Interface Enclosure are located at S1-2T1, S1-4T2, and S1-6T3. These terminals should be tightened to a torque value of 480 in-lbs (54.2 Nm) for model PV100S-208-HE and to a torque value of 250 in-lbs (28.2 Nm) for model PV100S-480-HE. See Figure 3-17 on page 3–18 for the location of
these terminals and the Caution on page 3–19.
7. The AC neutral conductor from the utility is terminated in the AC Interface Enclosure at the TB6-Neutral terminal. This terminal requires the use of a crimp-on type ring terminal or compression-type lug and should be tightened to a torque value of 250 in-lbs (28.2 Nm) for both models of the PV100S.
See Figure 3-18 on page 3–20 for the location of these terminals.
8. The DC power conductor wiring interfacing with the DC terminals at TB3-1, TB3-2, and TB3-3 are to be tightened to a torque value of 500 in-lbs (56.5 Nm) for both models of the PV100S. These terminals will accept a conductor size of 500 KCMIL. Keep these cables together as much as possible and ensure that all cables pass through the same knockout and conduit fittings, thus allowing any inductive currents to cancel.
See Figure 3-19 on page 3–21 for the location of these terminals.
9. This product is intended to be installed as part of a permanently grounded electrical system per the National Electrical Code ANSI/NFPA 70. A copper ground rod must be installed within three feet of the PV100S enclosure. This is the single point earth ground for the inverter system. The single point ground for the system is to be made at the AC ground bus bar (TB2) in the AC Interface Enclosure. This terminal requires the use of a crimp on type ring terminal or compression-type lug and should be tightened to a torque value of 420 in-lbs (47.1 Nm) for both models of the PV100S.
10. The equipment grounds on the PV100S are marked with this symbol: .
11. AC over-current protection for the utility interconnect (Grid-tie) must be provided by the installers as part of the PV100S installation.
WARNING: Shock or Fire Hazard
In accordance with the National Electrical Code, ANSI/NFPA 70,
Connect only to a circuit provided with 400 amperes maximum branch circuit over-current protection for model PV100S-208-HE, and
Connect only to a circuit provided with 200 amperes maximum branch circuit over-current protection for model PV100S-480-HE.
152973 Rev A ix
Safety
Operational Safety Procedures
Never work alone when servicing this equipment. A team of two is required until the equipment is properly de-energized, locked out and tagged out, and verified de-energized with a meter.
Thoroughly inspect the equipment prior to energizing. Verify that no tools or equipment have inadvertently been left behind.
Lockout and Tagout Procedure
Safety requirements mandate that this equipment not be serviced while energized. Power sources for the PV100S must be locked out and tagged out prior to servicing. A padlock and tagout device should be installed on each energy source prior to servicing.
WARNING: Shock Hazard
Review the system schematics for the installation in Appendix A, “Schematics” to verify that all available energy sources are de-energized. DC bus voltage may also be present. Be sure to wait the full 5 minutes to allow the capacitors to discharge completely.
The PV100S can be energized from both the AC source and the DC source. To ensure that the inverter is de-energized prior to servicing, lock out and tag out the PV100S using the following procedure:
1. Open, lock out, and tag out the incoming power at the utility main circuit breaker.
2. Open, lock out, and tag out the AC Disconnect Switch (S1) on the AC Interface Enclosure. See Figure 1-4 on page 1–9 for the location of the AC Disconnect Switch.
3. Open, lock out, and tag out the DC Disconnect Switch (S2) on the DC Interface Enclosure. See Figure 1-4 on page 1–9 for the location of the DC Disconnect Switch.
4. Using a confirmed, accurate meter, verify all power to the inverter is de­energized. A confirmed, accurate meter must be verified on a known voltage before use. Ensure that all incoming energy sources are de-energized by checking the following locations.
a) Inverter Terminals: TB4-A, TB4-B, TB4-C (Phase A, B, C)
See Figure 3-15 on page 3–17.
b) Utility Terminals: Bottom of S1-2T1, S1-4T2, S1-6T3
See Figure 3-17 on page 3–18.
c) PV Terminals: Bottom of TB3-1, TB3-2, TB3-3 (PV+, PV-, GND)
See Figure 3-19 on page 3–21.
x 152973 Rev A
De-Energize/Isolation Procedure
The following procedure should be followed to de-energize the PV100S for maintenance.
WARNING: Shock Hazard
The terminals of the DC input may be energized if the PV arrays are energized. In addition, allow 5 minutes for all capacitors within the main enclosure to discharge after disconnecting the PV100S from AC and DC sources.
To isolate the PV100S:
Safety
1. Turn the
2. Open the DC Disconnect Switch on the DC Interface Enclosure.
3. Open the AC Disconnect Switch on the AC Interface Enclosure.
4. Open the utility connection circuit breaker.
5. Install lockout devices on the utility connection circuit breaker and DC Disconnect Switch.
ON/OFF switch to the OFF position.
Interconnection Standards Compliance
The PV100S has been tested and listed by Underwriters Laboratories to be in compliance with UL 1741 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.
UL 1741 is the standard applied by Underwriters Laboratory to the PV100S to verify it meets the recommendations of IEEE-929-2000.
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.
Refer to both documents for details of these recommendations and test procedures.
152973 Rev A xi
xii
Contents
Important Safety Instructions 1
Introduction
Description of the PV100S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 System Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4
Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4
Voltage and Frequency Ranges - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4 System Ground Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5 System Neutral Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5
Utility Side Isolation Transformer Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5 Environmental Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6 Regulatory Approvals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6
Operator Interface Controls- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–7
Main Enclosure Door Interlock Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–7 ON/OFF Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8 AC and DC Disconnect Switches - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–9
Communication Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–9
System Status and Fault Reporting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–10 Data Logging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–10
Communication Methods - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–11
Universal Front Panel Control Unit (UFCU) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–11 PC Connection Methods - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–12
POTS Access - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–13
Wireless Access - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–13
Ethernet LAN Access - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–14
Direct Access - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–14
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -vii
2
Planning
Overview of PV100S Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2 PV Planning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3 Ventilation and Serviceability Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3 Ground Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4 System Neutral Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4 Communication Requirements- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4 Utility Side Isolation Transformer Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4 Electrical Diagrams and Schematics- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5 Layout Options - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6 Conduit Penetration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8 Conductor and Conduit Sizing- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11 Anchoring the PV100S- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13
152973 Rev A xiii
Contents
3
Installation
Equipment Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2 Unloading - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
Moving the PV100S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3 Unpacking the PV100S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3
Removing the Pallet and Moving the PV100S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4 Mounting and Anchoring the Units - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5 Opening or Closing Access Doors- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–6 Conduit Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9 Wiring — General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–10
Over-Current Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–11
Conductor Termination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–11
Wire Gauge and Torque Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–12
Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–12
System Neutral Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–14
Utility Side Isolation Transformer Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–14 Wiring — Specific - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–15
AC Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–15
PV Array Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–20 PC Communications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–22
PC Connection Methods - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–22
Establishing a POTS Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–23 Establishing Wireless Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–24 Establishing an Ethernet LAN Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–24 Direct Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–25
4
Verification
Verification Procedure Summary - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2 Visual Inspection of Mechanical Connections- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3 Visual Inspection of Electrical Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3 Visual Inspection, Isolation Transformer Wye:Wye - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4 Corrective Action- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4
A
Schematics
Index
xiv 152973 Rev A
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - IX–1
Figures
Figure 1-1 PV100S Dimensions (Not to scale) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3 Figure 1-2 PV100S Operator Interface Components- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–7 Figure 1-3 ON/OFF Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8 Figure 1-4 AC and DC Disconnect Switches- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–9 Figure 1-5 LCD Display and UFCU Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–11 Figure 1-6 PC Connections in the Communication Enclosure - - - - - - - - - - - - - - - - - - - - - - - - - 1–12 Figure 1-7 POTS Access - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–13 Figure 1-8 Wireless Access - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–13 Figure 1-9 Ethernet LAN Access - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–14 Figure 1-10 Direct Access - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–14 Figure 2-1 PV100S Layout Option A- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–6 Figure 2-2 PV100S Layout Option B- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–7 Figure 2-3 Conduit Entry Figure Reference - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8 Figure 2-4 Inductor Enclosure Conduit Entry, Left Side - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9 Figure 2-5 Transformer Enclosure Conduit Entry, Right Side - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9 Figure 2-6 AC Interface Enclosure Conduit Entry, Left Side - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10 Figure 2-7 DC Interface Enclosure Conduit Entry, Bottom Side- - - - - - - - - - - - - - - - - - - - - - - - 2–10 Figure 2-8 Communication Enclosure Conduit Entry, Bottom Side - - - - - - - - - - - - - - - - - - - - - 2–10 Figure 2-9 Main Inverter Enclosure Anchor Bolt Pattern (Not to scale)- - - - - - - - - - - - - - - - - - - 2–13 Figure 2-10 AC Interface Enclosure/Transformer Enclosure Anchor Bolt Pattern (Not to Scale)- - - 2–14 Figure 3-1 Moving the Crated PV100S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3 Figure 3-2 Forklift Lifting Locations - Underneath Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4 Figure 3-3 Mounting Hole Locations- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5 Figure 3-4 Main Inverter Enclosure Access Doors- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–6 Figure 3-5 AC Interface Enclosure Access Door - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7 Figure 3-6 DC Interface Enclosure Access Door - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7 Figure 3-7 Transformer Access Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8 Figure 3-8 Inductor Access Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8 Figure 3-9 Conduit Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9 Figure 3-10 Single-point Ground (TB2) Ground Bar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–13 Figure 3-11 Chassis Ground Bar (TB1) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–13 Figure 3-12 Route AC Cables through the Conduit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–15 Figure 3-13 Tie-wraps on the AC Sense Harness- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–15 Figure 3-14 AC Terminal Connections in the AC Interface Enclosure/Transformer Assembly - - - - 3–16 Figure 3-15 AC Terminal Connections in the Main Inverter Enclosure - - - - - - - - - - - - - - - - - - - - 3–17 Figure 3-16 Connecting the AC Sense Harness - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–17 Figure 3-17 AC Terminal Connections in the AC Interface Enclosure - - - - - - - - - - - - - - - - - - - - 3–18
152973 Rev A xv
Figures
Figure 3-18 AC Terminal Connections from the Utility- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–20 Figure 3-19 PV Array Cable Routing and Terminations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–21 Figure 3-20 Telephone Cable Routing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–23 Figure 3-21 RS232/FO Converter Kit Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–26 Figure 3-22 Direct Connect Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–26 Figure A-1 Electrical Diagram (sample)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–3 Figure A-2 PPV100S-480-HE Schematic for Main Power Distribution (152846 B1)- - - - - - - - - - - A–4 Figure A-3 PV100S-480-HE Schematic for Control Power Distribution (152846 B2) - - - - - - - - - - A–5 Figure A-4 PV100S-480-HE Schematic for Converter Control Unit (152846 B3)- - - - - - - - - - - - - A–6 Figure A-5 PV100S-208-HE Schematic Main Power Distribution (152847 B1) - - - - - - - - - - - - - - A–7 Figure A-6 PV100S-208-HE Schematic for Control Power Distribution (152847 B2) - - - - - - - - - - A–8 Figure A-7 PV100S-208-HE Schematic for Converter Control Unit (152847 B3)- - - - - - - - - - - - - A–9
xvi 152973 Rev A
Tables
Table 1-1 Electrical Specifications- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4 Table 1-2 Over/Under Voltage and Over/Under Frequency Ranges- - - - - - - - - - - - - - - - - - - - - - 1–4 Table 1-3 Environmental Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6 Table 3-1 AC Terminal Wire Gauge, Bolt Size, and Torque Values - - - - - - - - - - - - - - - - - - - - 3–12 Table 3-2 DC Terminal Wire Gauge, Bolt Size, and Torque Values - - - - - - - - - - - - - - - - - - - - 3–12
152973 Rev A xvii
xviii
1
Introduction
Chapter 1, “Introduction” provides information about the features and functions of the PV100S 100 kW Grid-Tied Photovoltaic Inverter.
Introduction
Description of the PV100S
The PV100S 100 kW Grid-Tied Photovoltaic Inverter is a UL 1741 listed, utility interactive, three-phase power conversion system for grid-connected photovoltaic arrays with a power rating of 100 kW. Designed to be easy to install and operate, the PV100S automates start-up, shutdown, and fault detection scenarios. With user-definable power tracking that matches the inverter to the PVarray and adjustable delay periods, users are able to customize start up and shut down sequences. Multiple PV100S inverters are easily paralleled for larger power installations.
The PV100S power conversion system consists of a pulse-width modulated (PWM) inverter, switch gear for isolation and protection of the connected AC and DC power sources, and a high efficiency custom Wye:Wye isolation transformer. Housed in a rugged NEMA 3R rated, galvanized steel enclosure, the PV100S incorporates sophisticated Intellimod (IGBTs) as the main power switching devices. An advanced, field-proven, Maximum Peak Power Tracker (MPPT) integrated within the PV100S control firmware ensures the optimum power throughput for harvesting energy from the photovoltaic array.
The advanced design of the PV100S includes an EMI output filter and the main AC contactor located electrically on the utility side of the isolation transformer. The location of the main AC contactor, and the ability to de-energize the isolation transformer during times of non-operation, greatly reduces the night-time tare losses consumed by an idle isolation transformer. An integrated soft-start circuit precludes nuisance utility-tie circuit breaker trips as the result of isolation transformer inrush current.
®
(IPM) Insulated Gate Bipolar Transistors
Additionally, the PV100S integrated controller contains self-protection features including over and under voltage and frequency safeguards. An integral anti-island protection scheme prevents the inverter from feeding power to the grid in the event of a utility outage. The PV100S includes a local user interface comprised of an O user-friendly, Graphic User Interface (GUI) provides a remote interface for operator interrogation of PV100S system status, control, metering/data logging and protective functions within the PV100S. The status, control, and lo gging features are also supported by the choice of three communication mediums, allowing the information to be accessed or commanded remotely.
The PV100S comes in two modules comprised of six enclosures to house the electronics described above. The first module includes the Main Inverter Enclosure, Inductor Enclosure, DC Interface Enclosure, and Communication Enclosure. The second module includes the Transformer Enclosure and AC Interface Enclosure. These components are identified in Figure 1-1 on page 1–3. Figure 1-1 also shows the dimensions and locations of the various enclosures that comprise the PV100S.
See “Layout Options” on page 2–6 for information on configuration options.
1–2 152973 Rev A
N/OFF switch, keypad, and 4-line, 80 character LCD display. A
Front View
44.0"
44.0"
(110 cm)
(110 cm)
AC
Interface
Enclosure
Communication Enclosure
49 7/8"
49 7/8"
(124.8 cm)
(124.8 cm)
Transformer
Enclosure
Description of the PV100S
60 ¼"
60¼"
(150.5 cm)
(150.5 cm)
4
DC Interface
Enclosure
PV
DISCONNECT
59 ¼"
(148 cm)
(148 cm)
29 ¼"
29 ¼"
(73 cm)
(73 cm)
59 ¼"
THIS UNIT EMPLOYS FIELD ADJUSTABL E VO LTAGE AND FREQUENC Y SETPOINTS AND TIME DELAYS. THEY ARE FACTORY SET IN COMPLIANCE WITH UL1741 AND MAY ONLY BE CHANGED BY TRAINED SERVICE TECHNICIANS WITH APPROVAL BY BOTH THE LOCAL UTILITY AND
EQUIPMENT OWNER.
REFER TO THE OPERATO R’S
MANUAL FOR FURTHER DETAIL.
TYPE 3R
U L
®
61CN
Mfg - Arl
LISTED UTILITY INTERACTIVE PHASE INVERTER
Max. system DC
Max. input
AC
DC
current 3A
Voltage 600V
Max. operating
Oper. Volt. Range
AC
183-229 L-L
DC
current 319A
Oper. Freq. range
Range of oper.
AC
59.3 - 60.5
Volts. 330-480V
DC
Normal output frequency
Max. array abort
60 Hz
AC
circuit current
DC
Enclosure
480A
Max. output overcurrent
Nominal output
AC
protection
voltage 208V
DC
400A
Maximum utility
Maximum output
feedback current
fault current
DC
AC
178A
323 A
Max. continuous
Max continuous
output current
output power
AC
DC
278A
100 kVA
Maximum operating ambient 50 °C
MANUFACTURED
MODEL NUMBER:
JAN
04
MAY
SEP
PV100S-208
FEB
JUN
05
OCT
SERIAL NUMBER:
06
APR
JUL
NOV
XXXX
07
MAR
AUG
DEC
L-152462 Rev A
Inductor
Enclosure
987 F1
^
^
F2654
F3MENU
32
.
-10
F4ENTER
0
I
This is a class A product. In a domestic environment this
product may cause radio interferenc es, in which case, the user may be requ ired to take adequate measures.
Main
Inverter
WARNING
RISK OF ELECTRICAL SHOCK
WARNING:
DO NOT REMOVE COVER, NO USER SERVICEABLE
PARTS INSIDE, STORED ENERGY IN CAPACITOR. ALLOW AT LEAST 5 MINUTES AFTER DISCONNECTING ALL SOURCES OF SUPPLY.
REFER SERVICING TO QUALIFIED SERVICE
PERSONNEL.
BOTH AC AND DC VOLTRAGE SOURC ES ARE
TERMINAED INSIDE THIS EQUIPMENT. EACH CIRCUIT MUST BE VIDUAL DISCONNECTED
INDI BEFORE SERVICING.
WHEN THE PHOTOVOLTAIC ARRAY
IS EXPOSED TO LIGHT, IT SUPPLIES A DC VOLTAGE TO THIS EQUIPMENT.
21 2/8"
21 3/8"
(53.5 cm)
(53.5 cm)
Back Front
AC Interface Enclosure
AC
DISCONNECT
33 ½"
33 ½"
(53.5 cm)
(83.75 cm)
AC Side View
Figure 1-1
PV100S Dimensions (Not to scale)
Communication Enclosure
Front
DC Interface Enclosure
83"
83"
(205.7 cm)
(205.7 c m)
DC Side View
Inductor
Enclosure
Back
59 ¼"
59 ¼"
(148 cm)
(148 cm)
152973 Rev A 1–3
Introduction
System Specifications
The PV100S has been designed for photovoltaic power systems, which operate within the following specifications.
CAUTION: Equipment Damage
Operation of the PV100S in a manner other than specified in this Manual may cause damage to the PV100S and other system components and will void the terms of the warranty.
Electrical Specifications
Table 1-1 provides the AC and DC specifications for the PV100S.
Table 1-1
Specification PV100S-208-HE PV100S-480-HE
Nominal AC Input Voltage (+10% to -12% acceptable range)
Maximum AC Output Current 278 A Nominal AC Input Frequency
(+0.5 to -0.7 Hz acceptable range) Output Power 100.0 kW 100.0 kW Peak Power Tracking Window 300 to 600 Vdc 300 to 600 Vdc Maximum Open Circuit Voltage 600 Vdc 600 Vdc Maximum DC Input Current 357 amps 357 amps
Electrical Specifications
208 Vac (183 to 228 Vac)
rms
60 Hz (59.3 to 60.5 Hz)
480 Vac (422 to 528 Vac)
121 A
rms
60 Hz (59.3 to 60.5 Hz)
Voltage and Frequency Ranges
Table 1-2 provides the over-voltage, under-voltage, over-frequency, and under-frequency detection limits for the PV100S. These detection limits have been factory tested and deemed to be in compliance with IEEE-292 and UL 1741 requirements for utility interaction.
Table 1-2
Vac Condition (% of Nominal)
Vac < 50% Vac < 104 6 cycles Vac < 240 6 cycles 50% < 88% < Vac < 110% < Vac < 137% 228 < Vac < 285 2 seconds 528 < Vac < 657 2 seconds 137% < f < rated -0.7 f < 59.3 6 cycles f < 59.3 6 cycles f > rated +0.5 f > 60.5 6 cycles f > 60.5 6 cycles
Over/Under Voltage and Over/Under Frequency Ranges
PV100S-208-HE PV100S-480-HE
Voltage Range Trip Time Voltage Range Trip Time
Vac < 88% 104 < Vac < 183 2 seconds 240 < Vac < 422 2 seconds
110% 183 < Vac < 228 normal operation 422 < Vac < 528 normal operation
Vac 285 < Vac 2 cycles 657 < Vac 2 cycles
1–4 152973 Rev A
System Ground Requirements
This product is intended to be installed as part of a permanently grounded electrical system per the National Electrical Code ANSI/NFPA 70. A copper ground rod must be installed within three feet of the PV100S enclosures and connected to the unit as described in “System Grounding” on page 3–12. The single-point ground for the system is to be made at the AC ground bus bar (TB2) in the AC Interface Enclosure.
System Neutral Requirements
The PV100S is designed to be installed as a 4-wire system. As required by the UL 1741 listing, a neutral conductor from the utility-interconnect must be terminated at TB6 within the AC Interface Enclosure to ensure that the AC voltage sensing circuit can perform an individual phase voltage (line-to-neutral) measurement. The function of the neutral connection is to provide a point of reference for measurement purposes that is essentially at ground potential. No power will flow through the neutral conductor.
Utility Side Isolation Transformer Requirements
The PV100S is supplied with a high-efficiency custom Wye:Wye isolation transformer as part of the AC Interface/Transformer assembly. The utility side windings of the isolation transformer are configured Wye and must match the voltage at the utility inter-tie. The PV100S is a balanced, three-phase, current-sourcing inverter and only operates with the presence of a stable utility voltage. The transformer is also supplied with a neutral connection on the utility interconnect. Connection of this utility-side neutral does not affect the operation of the inverter; however, connection of the neutral on the inverter -side does af fect the operation and must be left floating or disconnected. Single-phase, grounded loads, which may be present between the transformer and utility, will maintain their existing ground reference at the utility distribution transformer.
System Specifications
CAUTION: Equipment Damage
If the Isolation Transformer (T6-X0) neutral terminal is tied to ground, it will cause irreparable damage to the PV100S. Check local regulations for their requirements regarding the connection of the neutral.
WARNING: Lethal Voltage
Grounding the neutral of a Wye-wound transformer may create an “open delta” condition, depending on the utility configuration. This condition may keep the PV100S 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.
152973 Rev A 1–5
Introduction
Environmental Specifications
The following environmental specifications are the same for both models of the PV100S 100 kW Grid-Tied Photovoltaic Inverter.
Table 1-3
Specification Value
Dimensions
Weight
Allowable Ambient Temperature
Relative Humidity To 95%, Non-condensing Elevation Power Derated above 6600 ft Clearance (ventilation and
serviceability)
Environmental Specifications
Inverter and DC Interface
Transformer and AC Interface
Overall System Footprint:
Layout Option A
Layout Option B
Inverter and DC Interface Transformer and AC Interface Overall Weight
Operating Storage
82 in H × 60 1/4 in W × 22 in D (208 cm H × 153 cm W× 56 cm D)
44 in H × 50 in W × 34 in D (112 cm H × 127 cm W × 86 cm D)
12 ft W × 6 ft L (approximate) (3.6 m × 1.8 m)
9 ft W × 7 ft L (approximate) (2.7 m W × 2.1 m L)
1000 lbs (approximate) 1400 lbs (approximate) 2400 lbs (approximate)
-20 °C to 50 °C Maximum
-40 °C to 50 °C Maximum
In front of access doors: 36 in (91 cm) In front of access panels: 36 in (91 cm) Sides: 12 in (30 cm) Back: 6 in (15 cm)
Maximum Distance between Main Inverter Enclosure and AC Interface/Transformer Enclosure
15 ft (4.5 m)
Regulatory Approvals
The PV100S is certified to UL 1741 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. For more
information, see “Interconnection Standards Compliance” on page xi.
1–6 152973 Rev A
Operator Interface Controls
Operator interface controls are located on the front door of the main Inverter Enclosure. These controls include an ON/OFF Switch, 4-line LCD display and a keypad called the Universal Front Panel Control Unit (UFCU). Additionally , there is an AC Disconnect Switch on the AC Interface Enclosure and a DC Disconnect Switch on the DC Interface Enclosure.
Communication
Enclosure
AC Disconnect
Switch
Display
Universal Front Panel Control (UFCP)
LCD
Operator Interface Controls
DC Disconnect
Switch
ON/OFF
Switch
AC Interface Enclosure
(AC Side View)
Figure 1-2
PV100S Operator Interface Components
Main Enclosure Door Interlock Switch
WARNING: Shock Hazard
Disengaging the main enclosure door interlock switch does NOT remove all hazardous voltages from inside the inverter. Before attempting to service the PV100S, follow the de-energize Lockout and Tagout procedure on page x.
The front door of the PV100S main enclosure is equipped with an interlock switch to prevent operation while the front door is open. Opening the door of the Main Inverter Enclosure will initiate an immediate controlled shutdown of the PV100S and opens both the main AC and DC contactors. The main AC and DC contactors
DC Interface
Enclosure
Main Inverter Enclosure
(Front View)
152973 Rev A 1–7
Introduction
ON/OFF Switch
cannot be closed unless the door interlock switch is in the engaged position. The PV100S is prevented from being restarted until the door is again closed and the interlock switch is in the engaged position.
It is required that the PV100S main enclosure door must be locked during normal operation. The door interlock switch does NOT remove all hazardous voltages from inside the inverter. Before attempting to service the PV100S, follow the de-energize Lockout and Tagout procedure on page x.
The PV100S incorporates a maintained position ON/OFF switch located on the front door of the main enclosure. Under normal conditions, the
ON position. Turning the switch to the OFF position will initiate an immediate
the
ON/OFF switch is in
controlled shutdown of the PV100S and opens both the main AC and DC contactors within the unit. The main AC and DC contactors cannot be closed unless the being restarted until the
ON/OFF switch is in the ON position. The PV100S is prevented from
ON/OFF switch is turned back to the ON position.
WARNING: Shock Hazard
Turning the ON/OFF switch to the OFF position does NOT remove all hazardous voltages from inside the inverter. Before attempting to service the PV100S, follow the de-energize Lockout and Tagout procedure on page x.
Figure 1-3
1–8 152973 Rev A
ON/OFF Switch
AC and DC Disconnect Switches
Both AC and DC Interface Enclosures are equipped with lockout hasps for personnel safety. The enclosure doors should not be opened while the PV100S is operating.
The switch handles and shafts provide a door interlock for both the AC and DC Interface Enclosures. The doors cannot be opened when the switch is in the position.
The DC Disconnect Switch is equipped with an auxiliary contact block which enables the switch to be used as a load break DC disconnect. In the event the DC Disconnect Switch is opened while the PV100S is processing power from the PV array, the early-break contact block will signal the CCU2 (Converter Control Unit 2) to stop processing power prior to opening the DC Disconnect switch.
Additionally, opening the DC Disconnect Switch will cause the PV100S to execute an immediate orderly shutdown, open both the main AC and DC contactors, and report a PV disconnect fault on the LCD of the UFCU.
Communication Features
ON
AC Disconnect Switch
AC Interface Enclosure
Figure 1-4
AC and DC Disconnect Switches
Communication Features
The PV100S provides two types of information to the user:
system status and/or fault information
data logging information. System status and/or fault information can be accessed using the Universal Front
Panel Control Unit (UFCU) or a PC using the Xantrex Solar GUI software. Data logging requires the use of a PC using the GUI software.
DC Disconnect Switch
DC Interface Enclosure
152973 Rev A 1–9
Loading...
+ 65 hidden pages