Xantrex PV225S Installation Guide

PV225S 225 kW
Grid-Tied
Photovoltaic
Inverter

PV225S-480

Planning and Installation Manual

PV225S 225 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 1.5 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 include inverters, battery
chargers, programmable power supplies, and variable speed drives that convert, supply, control, clean, and distribute
electrical power.

Trademarks

PV225S 225 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

PV225S 225 kW Grid-Tied Photovoltaic Inverter Planning and Installation Manual© April 2005 Xantrex
International. All rights reserved.

Disclaimer

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 LOSS OR DAMAGE, WHETHER 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 USER’S RISK.

Date and Revision

April 2005 Revision A

Part Number

152606 Rev A

Contact Information

Telephone: [phone] (toll free North America)

1 360 925 5097 (direct)

Fax: [phone] (toll free North America)

1 360 925 5143 (direct)

Email: [e-mail]

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 PV225S 225 kW Grid-Tied
Photovoltaic Inverter.

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 PV225S 225 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:

Chapter 1, “Introduction” provides information about the features and functions
of the PV225S 225 kW Grid-Tied Photovoltaic Inverter.

Chapter 2, “Planning” provides information to help plan the installation of the
PV225S 225 kW Grid-Tied Photovoltaic Inverter.

Chapter 3, “Installation” describes the procedures needed to install the PV225S
225 kW Grid-Tied Photovoltaic Inverter. This section includes unpacking and
moving instructions, mounting instructions, and cabling instructions.

Chapter 4, “Verification” provides a checklist to ensure the installation of the
PV225S is correct and complete.

152606 Rev A iii

About This Manual

Conventions Used

The following conventions are used in this guide.

WARNING

Warnings 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.

These notes describe things which are important for you to know, but not as

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

LCD Liquid Crystal Display

NFPA National Fire Protection Association

PBX Private Branch Exchange

PSL Phase-Shift Loop

POTS Plain Old Telephone Service

PV Photovoltaic

UFCU Universal Frontpanel Control Unit

Related Information

You can find more information about Xantrex Technology Inc. as well as its
products and services at www.xantrex.com.

iv 152606 Rev A

Important Safety Instructions

SAVE THESE INSTRUCTIONS - DO NOT DISCARD

This manual contains important safety instructions for the PV225S 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 the PV225S, 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 PV225S 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 PV225S, 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 PV225S. 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.

152606 Rev A v

Safety

General Safety Precautions

1. When installing the PV225S 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 PV225S if it has been dropped, or received more
than cosmetic damage during transport or shipping. If the PV225S is
damaged, or suspected to be damaged, see the Warranty for this unit in the
PV225S 225 kW Grid-Tied Photovoltaic Inverter Operation and Maintenance
Manual.

3. To reduce the risk of electrical shock, lock-out and tag the PV225S before
attempting any maintenance, service, or cleaning.

Personal Safety

Follow these instructions to ensure your safety while working with the PV225S.

Safety Equipment

Authorized service personnel must be equipped with standard safety equipment
including 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 PV225S, both shall be in accordance with the National
Electric 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 PV225S 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 420 in-lbs (47.5 Nm).
Conductors terminated to these terminals must use a crimp-on type ring

vi 152606 Rev A

Safety

terminal or compression-type lug. The terminals can accommodate up to two
conductors per phase. See Figure 3-14 on page 3–15 for the location of these
terminals.

5. The AC power conductor wiring interfacing with the AC terminals in the
Main Inverter Enclosure are located at TB5, TB6, and TB7. These terminals
are to be tightened to a torque value of 375 in-lbs (42.4 Nm). The terminals
will accept a conductor size of 350 kcmil and can accommodate up to six
conductors per phase. See Figure 3-15 on page 3–16 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 310 in-lbs (35.0 Nm). See

Figure 3-16 on page 3–16 for the location of these terminals.

7. The AC neutral conductor from the utility is terminated in the AC Interface
Enclosure at the TB11 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 228 in-lbs (25.7 Nm). See Figure 3-18 on page 3–18 for the

location of these terminals.

8. The DC power conductor wiring interfacing with the DC terminals at S2-6,
K2-6T3, and TB4 are to be tightened to a torque value of 600 in-lbs
(67.8 Nm). These terminals will accept a conductor size of 600 kcmil and can
accommodate up to four conductors per pole at S2-6 and K2-6T3 and up to
two conductors at TB4. 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 3–19

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 Electric Code ANSI/NFPA 70. A copper
ground rod must be installed within three feet of the PV225S 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 (TB12) 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-lb (47.5 Nm).

10. The equipment grounds on the PV225S are marked with this symbol:

11. AC overcurrent protection for the utility interconnect (Grid-tie) must be
provided by the installers as part of the PV225S installation.

CAUTION: Fire Hazard

In accordance with the National Electrical Code, ANSI/NFPA 70, connect only to a circuit
provided with 400 amperes maximum branch circuit overcurrent protection for the
PV225S-480.

152606 Rev A vii

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, and verified de­energized with a meter.

Thoroughly inspect the equipment prior to energizing. Verify that no tools or
equipment have inadvertently been left behind.

Lockout and Tag

Safety requirements mandate that this equipment not be serviced while energized.
Power sources for the PV225S must be locked-out and tagged prior to servicing.

A padlock and tag should be installed on each energy source prior to
servicing.

WARNING: Shock Hazard

Review the system schematic for the installation 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 PV225S can be energized from both the AC source and the DC source. To
ensure that the inverter is de-energized prior to servicing, lockout and tag the
PV225S using the following procedure.

1. Open, lockout, and tag the incoming power at the utility main circuit breaker.

2. Open, lockout, and tag 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, lockout, and tag 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: TB5, TB6, TB7 (Phase A, B, C)

See Figure 3-15 on page 3–16.

b) Utility Terminals: Bottom of S1-2T1, S1-4T2, S1-6T3

See Figure 3-16 on page 3–16.

c) PV Terminals: Bottom of S2-6, K2-6T3, TB4 (PV+, PV-, GND)

See Figure 3-19 on page 3–19.

viii 152606 Rev A

De-Energize/Isolation Procedure

The following procedure should be followed to de-energize the PV225S for
maintenance.

WARNING

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 PV225S from AC and DC sources.

To isolate the PV225S:

Safety

1. Turn the O

2. Open the DC Disconnect Switch.

3. Open the AC Disconnect Switch.

4. Open the utility connection circuit breaker.

5. Install lockout devices on the utility connection circuit breaker and DC
Disconnect Switch.

N/OFF switch to the OFF position.

Interconnection Standards Compliance

The PV225S 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 PV225S to
verify it meets the recommendations of IEEE-929-2000.

Refer to both documents for details of these recommendations and test
procedures.

152606 Rev A ix

x

Contents

Important Safety Instructions

1

Introduction

Description of the PV225S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2
System Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4

Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4

Over Voltage, Under 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

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

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -v

2

Planning

Overview of PV225S 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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5
Electrical Diagrams and Schematics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5
Layout Options - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6
Conduit Penetration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8
Conductor and Conduit Sizing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11
Anchoring the PV225S- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13

152606 Rev A xi

Contents

3

Installation

Equipment Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2
Unloading - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2

Moving the PV225S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3
Unpacking the PV225S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3

Removing the Pallet and Moving the PV225S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4
Mounting and Anchoring the Units - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5
Opening or Closing Access Doors- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–6
Conduit Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9
Wiring - General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–10

Overcurrent Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–11

Conductor Termination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–11

Wire Gauge and Torque Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–12

Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–12

System Neutral Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–13

Utility Side Isolation Transformer Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–13
Wiring - Specific - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–14

AC Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–14

PV Array Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–19
PC Communications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–20

PC Connection Methods - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–20

Establishing a POTS Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–21
Establishing Wireless Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–22
Establishing an Ethernet LAN Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–22
Direct Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–23

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

xii 152606 Rev A

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - IX–1

Figures

Figure 1-1 Dimensions (Not to scale) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3
Figure 1-2 PV225S Operator Interface Components- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–7
Figure 1-3 On/Off Switch (S3) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8
Figure 1-4 AC and DC Disconnect Switches (S1 and S2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–9
Figure 1-5 LCD Display and UFCU Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–11
Figure 1-6 PC Connections in the Communications 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 PV225S Layout Option A- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6
Figure 2-2 PV225S 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, Bottom Side - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10
Figure 2-8 Communications Enclosure Conduit Entry, Bottom Side- - - - - - - - - - - - - - - - - - - - - 2–10
Figure 2-9 Main Inverter Anchor Bolt Pattern (Not to scale) - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13
Figure 2-10 AC Interface/Transformer Anchor Bolt Pattern (Not to Scale) - - - - - - - - - - - - - - - - - 2–14
Figure 3-1 Moving the crated PV225S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3
Figure 3-2 Forklift Lifting Locations - Underneath Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4
Figure 3-3 Mounting Hole Locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5
Figure 3-4 Inverter Enclosure Access Doors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–6
Figure 3-5 AC Interface Access Door - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7
Figure 3-6 DC Interface Access Door - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7
Figure 3-7 Transformer Access Panels- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8
Figure 3-8 Inductor Access Panels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8
Figure 3-9 Conduit Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9
Figure 3-10 Single-point Ground (TB12) Ground Bar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–12
Figure 3-11 Chassis Ground Bar (TB1) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–13
Figure 3-12 Route AC Cables through the Conduit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–14
Figure 3-13 Tie-wraps on the AC Sense Harness- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–15
Figure 3-14 AC Terminal Connections in the AC Interface/Transformer Enclosure - - - - - - - - - - - 3–15
Figure 3-15 AC Terminal Connections in the Main Inverter Enclosure - - - - - - - - - - - - - - - - - - - - 3–16
Figure 3-16 AC Terminal Connections in the AC Interface Enclosure - - - - - - - - - - - - - - - - - - - - 3–16
Figure 3-17 Connecting the AC Sense Harness - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–17

152606 Rev A xiii

Figures

Figure 3-18 AC Terminal Connections from the Utility- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–18
Figure 3-19 PV Array Cable Routing and Terminations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–19
Figure 3-20 Telephone Cable Routing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–21
Figure 3-21 RS232/FO Converter Kit Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–23
Figure 3-22 Direct Connect Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–24
Figure A-1 Electrical Diagram (sample)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–3
Figure A-2 PV225S-480 Schematic for Main Power Distribution (152291 B1) - - - - - - - - - - - - - - A–4
Figure A-3 PV225S-480 Schematic for Control Power Distribution (152291 B2) - - - - - - - - - - - - - A–5
Figure A-4 PV225S-480 Schematic for Converter Control Unit (152291 B3)- - - - - - - - - - - - - - - - A–6

xiv 152606 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

152606 Rev A xv

xvi

1

Introduction

Chapter 1, “Introduction” provides information about the features and

functions of the PV225S 225 kW Grid-Tied Photovoltaic Inverter.

Introduction

Description of the PV225S

The PV225S 225 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 225 kW. Designed to be easy to install and operate,
the PV225S automates start-up, shutdown, and fault detection scenarios. With
user-definable power tracking that matches the inverter to the array and adjustable
delay periods, users are able to customize start up and shut down sequences.
Multiple PV225S inverters are easily paralleled for larger power installations.

The PV225S 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 custom Wye/Wye isolation transformer. Housed in a
rugged NEMA-3R rated, powder-coated steel enclosure, the PV225S incorporates
sophisticated Intellimod
the main power switching devices. An advanced, field-proven, Maximum Peak
Power Tracker (MPPT) integrated within the PV225S control firmware ensures
the optimum power throughput for harvesting energy from the photovoltaic array.

The advanced design of the PV225S 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 (IGBTs) as

Additionally, the PV225S 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 PV225S includes a local user interface
comprised of an O
user-friendly, Graphic User Interface (GUI) provides a remote interface for
operator interrogation of PV225S system status, control, metering/data logging
and protective functions within the PV225S. The status, control, and logging
features are also supported by the data modem (included) and can be accessed
remotely.

The PV225S 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 Communications
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 PV225S.

See “Layout Options” on page 2–6 for information on configuration options.

N/OFF switch, keypad, and 4-line, 80 character LCD display. A

1–2 152606 Rev A

Front View

AC

Interface

Enclosure

Communications
Enclosure

Transformer

Enclosure

Main

Inverter

Enclosure

Inductor

Enclosure

Description of the PV225S

DC Interface

Enclosure

Back

Figure 1-1

Front

AC Interface
Enclosure

AC Side View

Dimensions (Not to scale)

Communications
Enclosure

Front

DC Interface
Enclosure

Back

Inductor

Enclosure

DC Side View

152606 Rev A 1–3

Introduction

System Specifications

The PV225S has been designed for photovoltaic power systems, which operate
within the following specifications.

CAUTION: Equipment Damage

Operation of the PV225S in a manner other than specified in this manual may cause
damage to the PV225S 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 PV225S.

Table 1-1

Specification PV225S-480

Nominal AC Input Voltage
(+10% to -12% acceptable range)

Maximum AC Output Current 271 A

Nominal AC Input Frequency
(+0.5 to -0.7 Hz acceptable range)

Output Power 225 kW

Peak Power Tracking Window 330 to 600 Vdc

Maximum Open Circuit Voltage 600 Vdc

Maximum DC Input Current 710 amps

Electrical Specifications

Over Voltage, Under Voltage and Frequency Ranges

Table 1-2 provides the over voltage, under voltage, over-frequency, and
under-frequency detection limits for the PV225S. 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 < 240 6 cycles

50% <

88% < Vac <

110% < Vac < 137% 528 < Vac < 657 2 seconds

137% <

f < rated -0.7 f < 59.3 6 cycles

f > rated +0.5 f > 60.5 6 cycles

Over/Under Voltage and Over/Under Frequency Ranges

Voltage Range Trip Time

Va c < 88% 240 < Vac < 422 2 seconds

110% 422 < Vac < 528 normal operation

Vac 657 < Vac 2 cycles

480 Vac
(422 to 528 Vac)

rms

60 Hz
(59.3 to 60.5 Hz)

PV225S-480

1–4 152606 Rev A

System Ground Requirements

This product is intended to be installed as part of a permanently grounded
electrical system per the National Electric Code ANSI/NFPA 70. A copper ground
rod must be installed within three feet of the PV225S 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 (TB12) in the AC
Interface Enclosure.

System Neutral Requirements

The PV225S 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 TB11 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 PV225S is supplied with a custom, high-efficiency, 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 PV225S 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 affect 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 PV225S. 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 PV225S 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.

152606 Rev A 1–5

Introduction

Environmental Specifications

The following environmental specifications are the same for both models of the
PV225S 225 kW Grid-Tied Photovoltaic Inverter.

Table 1-3

Specification Value

Environmental Specifications

Dimensions

Inverter and DC Interface

88.5 in H x 80 in W x 32 in D
(225 cm H x 203 cm W x 81 cm)

Transformer and AC Interface

49.5 in H x 61.5 in W x 35.5 in D
(126 cm H x 156 cm W x 90 cm D)

Overall System Footprint:

Layout Option A

14 ft W x 5 ft L (approximate)
(4.3 m x 1.5 m)

Layout Option B

10 ft W x 9 ft L (approximate)
(3 m W x 2.7 m L)

Weig ht

Inverter and DC Interface
Transformer and AC Interface
Overall Weight

2300 lbs (approximate)
2350 lbs (approximate)
4650 lbs (approximate)

Allowable Ambient Temperature

Operating
Storage

-20 °C to 50 °C Maximum

-40 °C to 50 °C Maximum

Relative Humidity To 95%, Non-condensing

Elevation Power Derated above 6600 ft

Clearance (ventilation and
serviceability)

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

15 ft (4.5 m)
Inverter Enclosure and AC
Interface/Transformer Enclosure

1–6 152606 Rev A

Operator Interface Controls

Operator interface controls are located on the front door of the main inverter
enclosure. These controls include an O
keypad called the Universal Frontpanel Control Unit (UFCU). Additionally there
is an AC and DC Disconnect on the AC Interface Enclosure and the DC Interface
Enclosure Doors.

Communication

Enclosure

Operator Interface Controls

N/OFF Switch, 4-line LCD display and

DC Disconnect

Switch (S2)

AC
Disconnect
Switch (S1)

Figure 1-2

AC Interface Enclosure

(AC Side View)

PV225S Operator Interface Components

LCD

Display

Universal
Frontpanel
Control
(UFCP)

ON/OFF

Switch

(S3)

Main Enclosure Door Interlock Switch

The front door of the PV225S main enclosure is equipped with an interlock switch
to preclude operation while the front door is open. Opening the door of the main
inverter enclosure will initiate an immediate controlled shutdown of the PV225S
and opens both the main AC and DC contactors. The main AC and DC contactors
cannot be closed unless the door’s interlock is in the engaged position. The
PV225S is prevented from being restarted until the door is again closed and the
switch is in the engaged position.

DC Interface

Enclosure

Main Inverter Enclosure

(Front View)

It is required that the PV225S 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 PV225S, follow the
de-energize Lockout and Tag procedure on

152606 Rev A 1–7

page viii.

Introduction

On/Off 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 PV225S, follow the
de-energize Lockout and Tag procedure on page viii.

The PV225S incorporates a maintained position ON/OFF switch (S3) located on
the front door of the main enclosure. Under normal conditions, the O
is in the O

N position. Turning the switch to the OFF position will initiate an

N/OFF switch

immediate controlled shutdown of the PV225S and opens both the main AC and
DC contactors within the unit. The main AC and DC contactors cannot be closed
unless the switch is in the
restarted until the O

ON position. The PV225S is prevented from being

N/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 PV225S, follow the de-energize
Lockout and Tag procedure on page viii.

Figure 1-3

ON/OFF Switch
(S3)

On/Off Switch (S3)

1–8 152606 Rev A