Xantrex PV 45208 User Guide

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Page 1

OPERATION and MAINTENANCE

MANUAL

for

MODEL PV-45208

45 kW Grid-Tied Photovoltaic Inverter

Document #151710

Revision F January 24, 2005

IMPORT ANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS - THIS MANUAL CONT AINS IMPOR T ANT INSTRUCTIONS

FOR XANTREX TECHNOLOGY MODEL PV -45208 GRID TIED PHOTOVOL T AIC INVER TER THA T SHALL BE FOLLOWED DURING INST ALLATION AND MAINTENANCE OF THE PV -

45208.

Xantrex Technology Inc.

161-G SOUTH VASCO ROAD

Livermore, CA 94551

(925) 245-5400

Page 2

T able of Contents

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

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

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

Interconnection Standards Compliance.....................................1-2

Specifications ..........................................................................1-3

Equipment Symbol...................................................................1-3

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

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

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

Installation And Initial T urn-On ....................... Section 3

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

T orque and Wire Gauge Specifications .....................................3-1

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

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

Initial Turn On Procedure.........................................................3-7

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

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

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

Operator Interface (LCD)........................................................4-5

Example of Normal System Operation .....................................4-6

System Operating Parameters ..................................................4-7

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

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

Fault Conditions ......................................................................5-1

Fault Descriptions and Troubleshooting ....................................5-2

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

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

Isolation Procedure..................................................................6-1

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

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

Drawings List ..........................................................................7-1

W arranty and Certifications ......................................................7-1

Optional Accessories ...............................................................7-1

Page 3

SECTION 1 PRODUCT DESCRIPTION

INTRODUCTION

The Xantrex Technology Model PV-45208 is a 45kW Grid Tied Photovoltaic Inverter. It utilizes advanced power electronics to allow the interface of a photovoltaic array with an utility grid. The PV45208 is a highly integrated assembly, consisting of an inverter bridge and associated control electronics. The PV-45208 control software provides for complete overall system control with the required protective and safety features.

MAJOR COMPONENTS

The major components of the PV-45208 are identified in Drawing No. 151712.

Main Enclosure

The enclosure (shown in Figure 1-1) is NEMA-3R rated. The PV-45208 enclosure contains the solar control bus board, output line filter (insuring that the PV-45208 line currents meet IEEE-519 harmonic distortion requirements), control power transformers, and A/C contactor. The upper enclosure contains the operator interface panel ( LCD and an on/off switch).

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Figure 1-1

Figure 1-2

PV-45208 Photovoltaic Inverter

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SECTION 1 PRODUCT DESCRIPTION

CAUTION

The fuses within the PV-45208 are intended for protecting the PV-45208 control circuitry only. They are not intended to provide protection for the PV array or external cabling.

Matrix Bus Board The PV-45208 design makes use of a fully integrated matrix bus board as shown in Figure 1-2. The bus board assembly is mounted to an aluminum extrusion heatsink, which is mounted between the upper and lower enclosures. The power electronics is comprised of a three, dual pack IGBT devices, mounted to the heatsink. The bus board is mounted on top of the IGBT dual pack devices, which is supported through a series of standoffs attached to the heat sink.

Solar Control Unit (SCU) The SCU consists of an integrated modulator board and a DSP control board. The modulator board contains isolated closed loop IGBT PWM drive circuits, A/C and D/C high voltage measurement circuits, A/C, D/C and ground current regulation and measurement circuits, A/C contactor controls, and binary I/O circuitry.

DSP The DSP board interfaces to the modulator board through a PC104 interface bus. The DSP board is designed to the industry standard PC-104 specification, and is used to perform the majority of the calculations needed to control the bus board. The most significant tasks are: control of PV45208 electromechanical components and power electronics converters, signal conditioning (digital filtering and transformations), and communication with the operator interface panel and system sensors.

SCU & DSP

INTERCONNECTION STANDARDS COMPLIANCE

The PV-45208 has been tested and certified 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 test procedure performed by Underwriters Laboratory on the PV-45208 to verify it meets the recommendations of IEEE-929-2000. Refer to both documents for details of these recommendations and

test procedures.

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SECTION 1 PRODUCT DESCRIPTION

SPECIFICATIONS

The PV-45208 has been designed for photovoltaic power systems, which operate within the following specifications. Application of the PV-45208 in a manner inconsistent with these specifications may cause damage to the PV-45208 and other system components, and is a violation of the terms of the warranty.

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*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.

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SECTION 2 SAFETY

SAFETY FEATURES

WARNING

The PV-45208 enclosure contains exposed high voltage conductors. The upper enclosure access panel should remain closed, 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 remove the front access panel if extreme moisture is present (rain or heavy dew).

On/Off Switch

The PV-45208 incorporates a maintained position on/off switch located on the upper 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-45208 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-45208 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-45208 and attempt to clear any system fault.

Enclosure Front Access Panel

The front access panel of the PV-45208 upper enclosure is fastened with twelve M6 stainless steel hex nuts. It is required that the PV-45208 enclosure front panel be securely fastened during normal opera-

tion.

WARNING

The PV-45208 does not incorporate a door interlock switch. Please make sure the unit is powered down, and isolated from the utility grid and PV panels, prior to opening the front access panel. Allow 5 minutes for any stored potentials to be discharged, prior to opening the unit. The front access panel of the PV-45208 upper enclosure must be securely fastened during normal operation.

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-45208 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 PV45208 executes an orderly shutdown, and annunciates a ground fault at the operator interface. The PV45208 will remain faulted until the ground fault is remedied and cleared at the operator interface (see section 5, troubleshooting). To enable this feature for monopolar pv array configuration, a jumper is installed between TBDC- and TB NEUT on the PV input terminal block. This must be the only point of PV conductor ground. Monopolar pv array configuration is enabled by default (for a detailed description of bipolar and monopolar pv array configurations, see Section 4 Operation Features).

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SECTION 2 SAFETY

Anti Island Protection

A digital phase-shift-loop (PSL) circuit is implemented in the DSP inverter controller to prevent “Islanding” of the PV-45208.

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-45208 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-45208 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-45208 from AC and DC sources.

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

2. Open the PV array disconnect switch (if present).

3. Open the AC interface disconnect (if present).

4. Open the isolation transformer circuit breaker.

5. Install lockout devices on the isolation transformer circuit breaker and PV disconnect switch (if present).

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SECTION 3 INSTALLATION AND INITIAL TURN-ON

ISOLATION TRANSFORMER REQUIREMENTS

The PV -45208 UL1741 certification requires the use of a Xantrex T echnology specified 45 kVA WYE/ WYE isolation transformer between the inverter AC output and the utility interconnection (see Appendix in Section 7 for transformer dimensions and specifications). This custom 45 kVA isolation transformer is not part of the 45kVA inverter, but can be ordered as a separate item. If maintaining the listing to UL1741 is not a requirement for your application, contact Xantrex Technology for a fact sheet describing the installation options and precautions for installing this inverter in a photovoltaic system that does not require UL1741 compliance.

WARNING

Xantrex Technology requires installing an isolation transformer between the PV 45208 inverter and the point of utility interconnection. Failure to do so could result in catastrophic damage to the PV-45208 as well as the utility distribution system and will void the product warranty.

Inverter Side Isolation Transformer Requirements The inverter side of the isolation transformer is configured as a WYE, and is rated for 208 VAC. The neutral connection on the inverter side must be left floating. If the neutral is tied to ground, the inverter will be damaged internally at power-up.

Utility Side Isolation Transformer Requirements The utility-side windings of the isolation transformer are configured WYE and must match the voltage at the utility inter-tie. Verify that the transformer supplied matches the voltage requirement. Also, the transformer is supplied with a neutral connection on the utility side. Connection of this utility-side neutral does not affect the operation of the inverter. Check the local utility of jurisdiction for their requirements regarding the connection of this neutral.

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

TORQUE AND WIRE GAUGE SPECIFICATIONS

The following torque specifications are to be used on all electrical interfaces made during installation of the PV-45208.

T orque Table

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SECTION 3 INSTALLATION AND INITIAL TURN-ON

The following table shows acceptable wire gauges to be connected to the PV-45208 AC and DC inputs.

Wire Gauge Table

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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-45208 should be sized in accordance with the National Electric Code ANSI/NFP A 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 No. 1/0 AWG, 105 degrees C, minimum, copper wire for all connections with the PV-45208.

Ventilation Considerations

Check with applicable installation standards for additional clearance requirements.

Installation

The PV-45208 is designed to be both floor mounted, or wall mounted. The following procedures describes mounting instructions for both mounting methods.

Floor Mounted

1. Move the PV-45208 into place. Lift the PV-45208 from beneath the lower enclosure with a forklift as shown in Figure 3-2. (See following page.)

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

Wall Mounted

1. Screw two 3/8” x 3-1/2” long lag bolts into existing studs in the wall (16-inch mounting center) at lower mounting level on PV-45208. Lag bolts should be horizontally level with each other . Leave a minimum of 1” of bolt protruding from the wall.

2. Place the PV-45208 bottom mounting ears, shown in Figure 3-1 and Figur e 3-2 onto installed lag bolts. (See following page.)

3. Hold the unit against the wall and install the upper lag bolts (3/8” x 3-1/2”). Tighten the bolts firmly.

4. Tighten the lower lag bolts while the unit is held in place.

5. Two access panels on the lower enclosure are provided for cable entry, shown in Figure 3-3. (See following page.)

6. Local building codes may require additional support/reinforcement when wall mounting the PV-

45208. Check with local authorities for further detail.

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SECTION 3 INSTALLATION AND INITIAL TURN-ON

Figure 3-1

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Figure 3-2

PV-45208 Photovoltaic Inverter

Operation and Maintenance Manual

Lift Here

Cable Entry Access Panel (Both Sides)

Figure 3-3

3-3

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SECTION 3

CT1

INSTALLATION AND INITIAL TURN-ON

Array Grounding

NEC 690-41/42 requires the PV array be earth grounded. The PV-45208 is shipped with a ground bond for installation between the PV negative terminal block to the PV safety ground terminal block. The PV-45208 chassis is also bonded to the PV safety ground terminal block. This ground bond is clearly marked with a warning label which must be read before installation. For floating PV array configurations, the factory installed PV negative ground bond must not be installed. Installation of this ground bond will cause irreparable damage to the PV-45208. For bipolar PV array configurations, the installer must move the ground bond between the PV array midpoint and the safety ground terminal block. Refer to the system schematic in the appendix for further wiring configuration.

Ground Fault Detection

The PV-45208 is equipped with a ground fault detection circuit and current transducer (CT1 in illustration). This circuit is active when the PV array is grounded as described in the previous section. In the event of a greater than 10 amps ground fault, the PV-45208 will execute an orderly shutdown and annunciates a ground fault at the operator interface. The PV-45208 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 the system grounding, if requir ed by sections 690-41, 690-42 and 690-43 of the National Elec-

CT1

trical Code, ANSI/NFP A 70, is the responsibility of the installer.

Phase-Sequencing The PV-45208 is equipped with an automatic sequence-phase-detection control algorithm. This allows the utility interface conductors to be connected in any sequence convenient at the time of installation. Upon system initialization at power-up, the PV-45208 determines the phase sequence of the utility connection and configures the modulator drivers accordingly .

INTERCONNECTION WIRING

CAUTION

To reduce the risk of fire, connect only to a circuit provided with 175 amperes @208VAC, or 75 amperes @480VAC maximum branch circuit overcurrent protection in accordance with the National Electrical Code, ANSI/NFPA 70.

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SECTION 3 INSTALLATION AND INITIAL TURN-ON

The following wires for connecting the PV-45208 to external devices are not provided by Xantrex T echnology: (See wiring diagram on page 3-6.)

• 3-Phase 208 VAC inverter output to terminals of the 208 VAC primary side of isolation transformer. The neutral must be left floating. Ground loops will exist when the inverter starts

switching, which will cause the inverter to shut down due to phase over-currents and will result in damage to the PV-45208. Also, insure that this neutral is not bonded to the isolation transformer frame.

• System electrical ground to the isolation transformer chassis ground.

• Isolation transformer grid side terminals to line circuit breaker (or the AC disconnect switch if

present).

• PV frame ground to PV-45208 enclosure chassis ground stud.

• PV-45208 enclosure chassis ground stud to the electrical distribution system ground.

• PV+ to the inverter enclosure terminal block TBDC+.

• PV- to the inverter enclosure terminal block TBDC-.

• PV neutral if connecting a bipolar PV array.

Install all wires listed above. Refer to the following wiring diagram and the system schematics in Section 7 for more detailed terminal locations.

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SECTION 3 INSTALLATION AND INITIAL TURN-ON

PV Array

Frame

Ground

Optional PV Conductor

Ground Jumper

PV+

PV-

Box

(Optional)

Xantrex Combiner

GND

Inverter

PV-45208

GND

H3 X3

H2 X0

H1 X2 X1

(Optional)

Wiring Diagram

Isolation Transformer

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To Single Point Electrical

Distribution System Ground

Breaker

Line Circuit

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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-

45208. 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.

• Remove the isolation transformer access panel.

• Insure the neutral on the inverter side of the isolation transformer 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.

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

Visual Inspection, PV-45208

• Insure AC and DC disconnect switches are opened (if present).

• Insure PV array string disconnect switches are opened (if present).

• Open the upper and lower enclosure access panels.

• Verify all wire connections are tight.

• Inspect the cables between the lower enclosure terminal blocks and the upper enclosure matrix and

driver board. All wire harnesses should be snap-locked into their respective PCB headers.

Visual Inspection, PV Array Wiring

• Verify the PV+, PV-, PV neutral (if array is bipolar), and PV safety ground are isolated from each other. Refer to system schematic in Section 7.

• Verify PV array is properly grounded. Refer to previous section on PV array grounding.

• Verify all PV fuses are installed (if present).

• Verify PV string diodes are wired properly (if present).

• Verify proper PV voltage polarity at the PV string discon-

nect/combiner boxes.

Initial Power

• Close the isolation transformer circuit breaker.

• Verify 208 VAC voltage across the AC disconnect.

• Close the AC disconnect (if present).

• With the DC disconnect switch open (if present), close one

of the PV array string disconnect devices.

• Carefully measure VDC at the PV disconnect switch. The value should be the same as at the PV array string disconnect

DC TERMINAL

device. It should also be positive.

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SECTION 3 INSTALLATION AND INITIAL TURN-ON

• Close the PV disconnect switch (if present).

• Carefully measure VDC across TBDC+ and TBDC- (PV +/-) terminal block. The value should be

the same as at the PV array string disconnect device. It should also be positive.

• Open the PV disconnect switch. The matrix capacitor bank voltage should slowly degrade to near zero over a 5-minute period.

• Open all PV string disconnect switches.

System Verification

• Ensure the on/off switch is disabled.

• Upon applying 208 VAC power to the PV -45208, observe the LCD display on the upper enclosure.

The LCD should display ‘init-FCU Version’, followed by the model number and software revision before briefly going blank. The LCD may be difficult to see depending on external light conditions. After approximately 15 seconds the panel should finish initialization. Upon completion, line 1 (system status) of the LCD should read ‘Shutdown’.

• Remedy any faults reported. If the fault indicator does not change, the fault condition is still present (see Section 5). Cycling the on/off switch will reset the PV-45208 and attempt to clear any system faults. Once all faults are cleared, line 1 of the LCD will read ‘Shutdown’ indicating the PV-45208 is idle.

• Close all PV array string disconnect switches (if present).

• Close the main PV disconnect switch (if present).

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

• If the PV voltage is above the PV Start Voltage setpoint, and the PV Start T ime is exceeded, the PV-

45208 should transition to “Power Tracking” (see Section 4, Operation).

• Depending upon solar conditions, the PV-45208 may not operate at full power. If the PV array is not experiencing full sun, the PV maximum power tracker will regulate the PV voltage to maintain maximum PV power output. (See section 4 for further description of the peak power tracker).

• The PV-45208 is now fully operational.

Fine Tuning

• All PV-45208 operating parameters have been set at the factory, based upon prior experience with various PV arrays. Contact your Xantrex Technology distributor for further information.

• It is recommended that the PV -45208 be watched during Wake-Up and Sleep T est. If the PV-45208 cycles between operating and sleeping at either of these times, the operating setpoints may not be set properly. (Refer to Section 4 for a detailed description of PV-45208 operating states). The PV45208 should not cycle if the setpoints are set properly.

NOTE

Some field adjustable parameters are password protected and may only be changed by trained service technicians. In particular are parameters relating to utility protection setpoints. These have been set in the factory to the limits mandated by UL1741. Any changes to these setpoints should be agr eed upon by the local utility and the equipment owner.

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SECTION 4 OPERATION

DESCRIPTION OF SYSTEM OPERATION

Overview

The PV-45208 is a fully automated grid-tied photovoltaic inverter. Manual interaction or control of the inverter is necessary only in the event of a system fault. The following conditions govern PV-45208 operation:

• Stable utility voltage and frequency must be present for all states of operation.

• Fault states are automatic from any state of operation. A fault will cause the PV-45208 to immedi-

ately stop processing all power. The fault condition will be reported to the operator interface.

• The on/off switch, located on the upper enclosure of the PV-45208, must be switched to the on position for all operating states.

• Cycling the on/off switch attempts to clear any system faults and return the PV-45208 to normal operation.

Operating States

Control software governs the operation of the PV-45208. There are six main operating states. The following descriptions depict the LCD interface. Line 1 (system status) of the LCD will indicate operating states on the display.

• Initializing: The LCD displays ‘Initializing’. The PCU monitors the status of the PV array and utility grid, waiting until the PV array voltage is sufficient to export power to the utility.

• Wake-Up: The LCD displays ‘Wake Up Test’. Once the PV voltage is sufficient to export power to the utility grid, the PV-45208 will wait 5 minutes before starting. This insures the PV voltage is not transient in nature and keeps the system from cycling during unstable irradiance conditions.

• Power Tracking: The LCD displays ‘Power Tracking’ while the PV-45208 delivers power to the utility. This is the standard operating state of the PV-45208. The PV-45208 maximum power tracker will optimize power output from the PV array. If available, PV power is above the maximum power rating of the PV-45208, the inverter will current limit, which will cause the PV voltage to rise above the array peak power voltage. The minimum operating voltage of the PV-45208 is typically around 300 VDC. The power tracker will not track voltage below this point, regardless of the actual peak power voltage of the PV array.

• Sleep Test: The LCD displays ‘Sleep Test’ while the control system begins a 5 minute sleep test. This normally indicates the PV irradiance is declining as the sun sets. If the output power remains below 200 watts during the 5 minute sleep test, the system will transition to standby. The time delay allows the inverter to ride through any temporary irradiance reductions.

• Fault: The PV-45208 has encountered a fault condition. When this happens, regardless of the PV- 45208 state-of-operation, the PV-45208 will stop processing all power and execute an orderly system shutdown. Line 2 will display the fault description with the fault code displaying on line 3.

• Shutdown: The LCD displays ‘Shutdown’. The PV array does not have enough power capacity to maintain the inverter operating losses or the line contactor is open and the devices are not switching.

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SECTION 4 OPERATION

OPERATION FEATURES

Automatic Phase Sequence Detection

During system power-up, the PV-45208 detects the phase rotation of the three-phase utility voltage as seen at the inverter output terminals. The control software then determines the proper switching sequence for the output power stage. It is not necessary to maintain a particular phase sequence convention between the inverter and the utility point of interconnection.

Fixed Unity Power Factor Operation

The Xantrex PV Series grid tied PV inverters maintain unity power factor during operation. The control software constantly senses utility voltage, and constructs the output current waveform to match the utility voltage. The PV line of inverters are not capable of operation without the presence of normal utility voltage, nor are they capable of varying the output power factor off unity.

Variable Minimum DC Input Voltage Level

The minimum DC input voltage limit for the PV-45208 is a function of the utility AC line voltage. The PV-45208 control software periodically changes the minimum allowable DC input voltage based upon the actual line voltage during operation.

For monopolar PV array configurations: Minimum DC voltage will vary between 282 and 320Vdc for line voltage fluctuations between factory set minimum and maximum line voltage limits. For example: At the factory set high line voltage limit of 220.5, the minimum required DC input voltage is approximately 320Vdc. At the factory set low line voltage limit of 196Vac, the minimum required DC input voltage is approximately 282Vdc. At nominal 208Vac, the minimum DC input voltage is 300Vdc.

For bipolar array configurations: Minimum DC voltage will vary between approximately 340 and 380Vdc.

Utility Voltage/Frequency Fault Automatic Reset

In the event of a utility voltage or frequency excursion outside of preset limits, the PV-45208 will stop operation and annunciate a fault at the operator interface. Once the utility voltage has stabilized within acceptable limits for a period of at least five minutes, the PV-45208 will automatically clear the fault and resume normal operation. Voltage and frequency fault setpoints are detailed later in this section.

Active Island Detection

Much concern has been given to the possibility of an inverter causing a ‘utility island’ condition during a utility power outage. An island condition is defined as grid tied inverter maintaining operation and supporting a load that has been isolated from the utility power source. This requires the load to be closely balanced to the output power of the inverter as well as having a resonant frequency close to 60Hz. Needless to say, this is an extremely remote possibility. To insure this condition does not occur, the PV-45208 control software contains an active phase-shift-loop algorithm, which destabilizes a balanced load, which may otherwise be capable of maintaining inverter operation in the absence of utility voltage. This feature has been extensively tested and proven to exceed the safety requirements of UL-1741 and IEEE-929-2000.

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SECTION 4 OPERATION

Ground Fault Detection

The PV-45208 is capable of detecting PV array ground fault current. To enable this feature, a wire must be installed between ground and the desired ground reference point on the PV array. For bipolar PV array configurations, the ground wire must be connected between the PV array neutral point and TB-NEUT terminal block. For grounded monopolar PV array configurations, the ground wire must be connected between TBDC- and TB NEUT terminal blocks (see the following diagram for clarification and the system schematic in Section 7). This feature is enabled for grounded monopolar PV array configuration at the time of shipment. For bipolar PV array configuration, the jumper wire must be removed between TBDC- and TB NEUT.

To upper enclosure

PV-45208 DC

Input Terminal

Block

Inverter

Chassis

DOCUMENT: 151710

Diagram Of Bipolar Ground Fault Detection Configuration

Jumper Wire

For PV Ground

To upper

Fault Detection

enclosure

PV-45208 DC

Input Terminal

Diagram Of Monopolar Configuration

PV-45208 Photovoltaic Inverter

Operation and Maintenance Manual

Block

Inverter

Chassis

4-3

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SECTION 4 OPERATION

Current Imbalance Detection

In the event of phase-to-phase current imbalance of greater than 20% between phases, the inverter will execute an orderly shutdown, and annunciate a fault at the operator interface. See Section 5, Troubleshooting, for further information on this fault condition.

DC Overvoltage Detection

In the event of DC voltage greater than 600Vdc, the PV-45208 will execute an orderly shutdown and annunciate a fault to the operator interface. If DC voltage remains greater than 600Vdc, the PV-45208 may be irreparably damaged. See Section 5, troubleshooting for further information on this fault condition.

Peak Power Tracking

The PV-45208 control software employs an active PV peak power tracker, designed to maintain maximum power output from the PV array at all times of operation. The peak power voltage point varies primarily depending upon the temperature of the PV cells. The PV-45208 constantly seeks the optimum voltage and current operating points of the PV array to maintain maximum PV power output.

Automatic Wake Up PV Voltage Optimization

Every day the PV-45208 wakes up and starts producing power, the control software determines if it is necessary to make adjustments to the start voltage setpoint. If the PV-45208 wakes up and determines that there is insufficient PV array power to support inverter operation, the start voltage setpoint is shifted slightly higher. This assumes that once the voltage on the array has risen, there will be greater PV power as the PV array is exposed to higher irradiance. Conversely, if the PV-45208 wakes up and determines that there is more power than is necessary to support inverter operation, the PV start voltage setpoint is lowered. The PV start voltage setpoint will usually be optimized over the period of one week. This value may be manually adjusted via the graphical user interface program to expedite the optimization process. There is also a user settable timer that determines the time required for the PV start voltage to exceed the start voltage setpoint. This timer may also be manually adjusted via the graphical user interface to help compensate for poorly placed PV arrays. The default wake-up time delay is factory set at five minutes.

Automatic Sleep Test

Toward the end of every solar day, the PV-45208 automatically determines when to stop producing power dependent upon the output power of the inverter. As the net output power of the PV-45208 nears zero, a timer is started to allow the inverter to ride through any brief irradiance reductions. The default sleep time delay is factory set at five minutes.

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SECTION 4 OPERATION

OPERATOR INTERFACE

The PV-45208 is equipped with a Liquid Crystal Display. The display consists of 4 text lines containing the following information:

• Line 1: System Status - The current operating state of the inverter.

• Line 2: DC Current or Fault Descriptions - This line reports the DC current (amps). If the PV-

45208 is faulted, this line will report a description of the fault condition.

• Line 3: Bus Voltage or Fault Code - This line reports the Bus Voltage, in volts. If the PV-45208 is faulted, this line will report a code for the fault condition.

• Line 4: Inverter Output Power or Countdown Timer - During normal operation, this line will report the inverter real time output power. During initialization or start-up, this line displays the countdown timer.

The on/off switch is used to enable or disable system operation. The on/off switch is also used to reset the inverter and clear any system faults.

The following is a typical display of the LCD during the six main operating states and an on/off switch.

System Starting

DOCUMENT: 151710

Initializing

Operation and Maintenance Manual

PV-45208 Photovoltaic Inverter

Power Tracking

System Wake Up Test

4-5

Page 21

SECTION 4 OPERATION

System Fault

System Sleep Test

EXAMPLE OF NORMAL SYSTEM OPERATION

System Stop

System Shutdown

Upon initial application of AC voltage, the LCD located on upper enclosure will display ‘Shutdown’ for approximately 15 seconds. Once the system has finished initializing, the PV-45208 will remain in standby until adequate PV voltage is available. 5 minutes after the PV start voltage has been reached, the PV-45208 will synchronize to the utility grid and begin peak power tracking the PV array. The time delay protects the inverter from excessive on/off cycling.

The PV-45208 will continue to process power until the AC output power approaches the operating losses of the inverter for a period of 5 minutes. The time delay protects the inverter from excessive on/ off cycling.

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Page 22

SECTION 4 OPERATION

SYSTEM OPERATING PARAMETERS

The PV-45208 contains a number of system operating parameters which may be field adjusted using an optional graphical user interface program (contact Xantrex Technology for further information). All operating parameters have been set at the factory during system test based upon prior experience with various PV arrays, or to be in compliance with UL1741. In general, the factory default settings allow for stable, efficient operation of the PV -45208 connected with any PV array configured for a 330-600 VDC peak power voltage point.

On the following page is a list of the PV-45208 operating parameters, showing valid ranges and the factory default settings. Many of these parameters are specific to domestic or European operation. Changing parameters not applicable to the region of operation will not affect inverter performance. Some field adjustable parameters are password protected and may only be changed by trained service technicians, specifically parameters relating to utility protection setpoints. These have been set in the factory to the limits mandated by UL1741. Any changes to these setpoints should be agreed upon by the local utility and the equipment owner. The ability to adjust the voltage and frequency setpoints across the actual utility voltage and frequency has been provided as a simulation tool to verify the PV45208 accurately detects and responds to a utility excursion. This test should only be performed by a trained service technician. It is possible to adjust the setpoints in a manner that will prevent the PV45208 from functioning.

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SECTION 4 OPERATION

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Operation and Maintenance Manual

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SECTION 4 OPERATION

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Operation and Maintenance Manual

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Page 25

SECTION 5 TROUBLESHOOTING

GENERAL

In the event of a fault, the PV-45208 will annunciate the condition at the operator interface. The PV45208 will execute an orderly shutdown and remain faulted until the fault is cleared (manually or automatically).

In general, the operator should respond to any PV-45208 fault as follows:

1. The source of the fault should be sought by referring to the following chart.

2. Rectify the fault condition and attempt to clear the fault by cycling the on/off switch.

3. If the problem cannot be corrected, note and write down the fault code and description, then contact your Xantrex Technology distributor for assistance or service.

FAULT CONDITIONS

LCD Fault Annunciation

The LCD interface reports fault conditions on Line 2 and 3. The fault code number will follow a text description. The fault description will remain displayed until the fault has been corrected and cleared. Each fault is described on the following page.

Fault Clearing

Faults may be cleared automatically by the PV-45208 or manually by the operator depending upon the type of fault. The utility protection faults (over/under AC line voltage and frequency) are self-clearing fault conditions. Once the utility voltage and frequency returns within allowable operating ranges, for a period of five minutes, the PV-45208 will clear the fault and resume normal operation.

Latching faults must be cleared manually by the system operator. Once the cause of the fault condition has been corrected, the fault may be cleared with the on/off switch. First turn the switch to the off position and then back to the on position in order to reset the inverter . If a fault is sustained, the inverter will not reset, and will continue to report the fault. If the fault has been corrected, the LCD will return to the normal display , and the PV-45208 will resume normal operation.

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LCD Display and On/Off Switch

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SECTION 5 TROUBLESHOOTING

FAULT DESCRIPTIONS AND TROUBLESHOOTING

F AULT DESCRIPTIONS

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(1) IPM Device Fault (0x0001 Through 0x0020)

Both over current and over temperature condition can cause IPM device faults. The fault code for both conditions is the same for each device, while there is a unique fault code for each device.

Possible causes for over current condition:

• Short circuit in output AC line.

• Low supply voltage to IPM control circuit.

• Shorted isolation transformer.

Possible causes for over temperature condition:

• External cooling fan inoperable.

• Airflow on heatsink impeded due to accumulation of debris.

• Operation above rated ambient temperature for an extended period of time.

• Auxiliary contact block on contactor K1 inoperable. This is only possible if the fan does not operate

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SECTION 5 TROUBLESHOOTING

when the contactor closes. Carefully check voltage at the K1-N.O. aux. contact to the ground bus when the contactor is closed. (See schematic in Section 7).

(2) AC Line Voltage Low Fault (0x0100) The utility AC voltage fell below the minimum programmed limit. There are two levels of response to low line voltage conditions. The first level of response is set to 183.0 VAC with a time delay of less than 2 seconds. By default, the second level is set to 104 VAC with a time delay of less than 0.1 seconds. Voltage setpoints may be modified via the operator interface program. Utility protection setpoints may only be adjusted by trained personnel with approval by both the local utility and the equipment owner.

Possible causes:

• The utility voltage fell below the allowable limit (183.0 VAC by default). V erify the utility voltage is stable and within allowable operating limits.

• There is a problem with one or more of the AC sense wires (see system schematic in Section 7).

This fault is auto-resetting. The unit will automatically restart after line has stabilized within normal limits for 5 minutes.

(3) AC Line Voltage High Fault (0x0200)

The utility AC voltage exceeded the maximum-programmed limit. There are two levels of response to high line voltage conditions. The first level of response is set to 228.8 VAC with a time delay of less than 2 seconds. By default, the second level is set to 285.0 VAC with a time delay of less than 2 cycles, and is not field adjustable. Voltage setpoints may be modified via the operator interface program. Utility protection setpoints may only be adjusted by trained personnel with approval by both the local utility and the equipment owner.

Possible causes:

• The utility voltage exceeded the allowable limit (228.8 VAC by default). V erify the utility voltage is stable and within allowable operating limits.

• There is a problem with one or more of the AC sense wires (see system schematic in Section 7).

The fault is auto-resetting. The unit will automatically restart after line has stabilized within normal limits for 5 minutes.

(4) AC Line Under Frequency Fault (0x0400)

The AC utility frequency fell below the minimum programmed limit. This limit is set to 59.5 Hz and the system response time limit is set to less than 0.1 seconds to insure the PV-45208 disconnects from the utility within the time allowed by UL1741. Frequency setpoints may be modified via the operator interface program. Utility protection setpoints may only be adjusted by trained personnel with approval by both the local utility and the equipment owner.

Possible causes:

• The utility frequency fell below the allowable limit (59.5 Hz by default). Verify the utility frequency is stable and within allowable operating limits.

• There is a problem with one or more of the AC sense wires (see system schematic in Section 7).

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SECTION 5 TROUBLESHOOTING

This fault is auto-resetting. The unit will automatically restart after line has stabilized within normal limits for 5 minutes. Frequency setpoints may be modified via the operator interface program. Utility protection setpoints may only be adjusted by trained personnel with approval by both the local utility and the equipment owner.

(5) AC Line Over Frequency Fault (0x0800) The AC frequency exceeded the maximum-programmed limit. This limit is set to 60.5 Hz and the system response time limit is set to less than 0.1 seconds to insure the PV-45208 disconnects from the utility within the time allowed by UL1741.

Possible causes:

• The utility frequency exceeded the allowable limit (60.5 Hz by default). Verify the utility frequency is stable and within allowable operating limits.

• There is a problem with one or more of the AC sense wires (see system schematic in Section 7).

This fault is auto-resetting. The unit will automatically restart after line has stabilized within normal limits for 5 minutes.

(6) Ground Current Fault (0x8000)

The earth safety ground current has exceeded the maximum-programmed value.

Possible causes:

• The negative wire from the PV array has been passed through CT1. Verify PV ground jumper is installed between TBDC- and TBNEUT.

• Inspect the PV array for actual ground faults.

• The PV array has been grounded in more than one location. If the PV array is grounded through

CT1, it must not be grounded at any other location.

• CT1 defective: Contact your Xantrex Technology distributor for assistance or service.

(7) DC Bus Over Voltage Fault (0x4000) The DC bus voltage has exceeded the maximum limit.

This is also the PV input voltage sense point. Check the PV input voltage at the PV disconnect switch. If the voltage is below 600 VDC and agrees with the voltage displayed on the LCD, cycle the on/off switch and restart the PV-45208.

Possible causes:

• The PV array open circuit voltage exceeded 600 VDC.

• There is a problem with the PV voltage sense wiring (see system schematic in Section 7).

(8) CT Offset Fault (0x80000)

Upon system startup, the PV-45208 has determined that the CT offset current is too large to be calibrated. This is caused by the control system detecting current, when no current is commanded.

• Observe individual phase currents with the operator interface program. Generally , a CT offset fault with show high currents on one phase while the system is in Standby , with zero actual current being

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processed.

• Check +/- VDC power supply outputs.

• Check control wire harness integrity (Refer to the system schematic in Section 7).

• Check CT harness for damage.

• Check CT harness +/-15VDC at CT.

• Check CT output voltage (mV) with reference to ground.

• Replace CT showing high output voltage offset.

(9) Current Imbalance Fault (0x10000) The PV-45208 has determined that there is an excessive phase-to-phase current imbalance, while the system is operating.

• Observe individual phase currents during operation with the operator interface program and with a true RMS oscilloscope. Verify waveforms are sinusoidal and maintain proper phase relationships.

• Determine which phase is imbalanced.

• Verify phase conductor wiring integrity (Refer to the system schematic in Section 7).

• Check CT control wire harness integrity (Refer to the system schematic in Section 7).

• Replace CT on the phase exhibiting the current imbalance.

Stop Switch Fault

The on/off switch, located on the upper enclosure, is disabled. The contact block on the back of the switch must be open for the PV-45208 to report this message.

If the switch is in the on position and the LCD reads ‘Stop Switch’:

• Isolate the PV-45208 from external power (Refer to Section 2).

• Verify continuity across the switch contact block while the switch is turned to the on position.

• Verify continuity between J9-1 and J9-2 while the switch is enabled.

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SECTION 6 PREVENTATIVE MAINTENANCE

PERIODIC MAINTENANCE

Xantrex Technology recommends that the following preventative maintenance be carried out on the PV-45208:

Monthly intervals or as required:

Aluminum Extrusion Heatsink

Accumulation of dirt and debris on the aluminum extrusion heatsink and fan shroud will decrease the ability to transfer heat, which can cause the PV-45208 to shutdown on over-temperature alarms. Inspect the aluminum extrusion heatsink and fan shroud for accumulation of dirt and debris. Remove enclosure panels and clean if debris is present.

Fan Operation

Verify proper operation of the heatsink cooling fan, located within the lower enclosure. The fan operates when the K1 contactor is closed. Remove any debris from the fan and finger guard.

Six month intervals:

(See Isolation Procedure and perform prior to the following)

Enclosure Seals

Inspect the enclosure access panel seal. If damaged, replace with equivalent closed cell foam gasket. Call your Xantrex Technology distributor for factory replacements or specifications.

Electrical Connections

Inspect the condition of all wiring within the PV-45208. Inspect all wire crimps and connections for damage caused from high temperature. Check for corrosion. Replace any damaged wires. Verify all mechanical connections are sufficiently tightened. Verify all conduction surfaces are clean and free of corrosion.

Mechanical electrical connections will loosen over time. This is caused primarily by thermal cycling during normal operation. As connections loosen, electrical impedance will increase at the connection, eventually leading to fire and component damage. It is critical to check all electrical connections every six months.

Enclosure

Access the enclosure and remove any accumulated dirt and debris. Vacuum enclosure whenever dust or dirt is present.

ISOLATION PROCEDURE

The following procedure should be followed to de-energize the PV-45208 for maintenance:

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SECTION 6 PREVENTATIVE 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 shutting down the PV-45208.

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

2. Open the PV array disconnect switch (if present).

3. Open the AC disconnect (if present).

4. Open the isolation transformer circuit breaker.

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

TURN-ON PROCEDURE

Refer to Section 3 for a detailed first-time turn on procedure.

1. Remove any lockout devices from the isolation transformer circuit breaker and PV disconnect switch.

2. Close the isolation transformer circuit breaker.

3. Close the AC disconnect (if present).

4. Close the PV array disconnect switch (if present).

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

After a 15 second initialization period and a 5 minute wake up period, the PV-45208 will automatically begin power tracking, given the PV voltage is greater than the PV start voltage setpoint.

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SECTION 7 APPENDIX

DRAWINGS LIST

151718 : Schematic, System, Grid Tied Inverter, PV-45208

151711 : Envelope Drawing, Grid Tied Inverter, PV-45208

151712 : Assembly, Main Enclosure, Control Components, 45 kVA, PV-45208

151717 : Transformer, 45 kVA, 3-Pole, 60 Hz, 98% Efficient, 208Y/120 or 480Y/277

WARRANTY AND CERTIFICATIONS

Xantrex Inverter Warranty Registration

Underwriters Laboratories Compliance Of Standard UL1741

OPTIONAL ACCESSORIES

For details and specifications on Xantrex Technology 10 and 12 Pole, 600 VDC Combiner Boxes, contact your Xantrex Technology distributor.

For details and specifications on 45 kVA 3-Pole, 208 Delta/208-120 WYE and 480-277 WYE Transformers, contact your Xantrex Technology distributor.

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Xantrex Technology Inc. PV-45208

Photovoltaic Inverter

Major Parts List

Assembly Description: Main Enclosure, Control Components, PV-45208 Xantrex Technology Inc. Assembly # 151712

Item # Qty Reference Designator Xantrex Technology Part # Description

1 1 - 1-160070-01 Enclosure, Upper 2 1 - 1-160051-01 Enclosure, Lower 3 1 - 1-151435-01 Heatsink, PV-45208 4 1 T1 1-160015-01 Transformer, 175VA, 24V 5 1 LF1 1-150684-01 Filter, EMI, 115/250 VAC, 2 Amp 6 1 K1 1-160131-01 Contactor, 3P, 24VDC Coil, 115A 7 1 TB-DC 1-160012-01 Block, Power Distribution, Inter, 3P 8 1 B1 1-160125-01 Fan, 230V, 50/60Hz, 73dba, 10"

9 1 L1 1-151219-01 Reactor, Line, 3Ph, 158uH, 139 Arms 10 3 C1-3 1-150403-02 Capacitor, NP, 4uF, 600VAC, 6% 11 3 L2-4 1-151225-01 Reactor, PWM, 1 Ph, 400uH, 139 ARMS 12 1 - 1-150378-02 Assy, PCB, DSP 13 1 PS1 1-160044-01 PCB, 24VDC, 100W 14 1 PS2 1-160006-01 Power Supply, Single Out, +15VDC 15 1 PS3 1-160030-01 Power Supply, Triple Out, +5, +/-15VDC 16 1 - 1-160052-01 Assy, LCD Display 17 1 - 1-160128-01 Assy, Bus, 600V, 100A 18 3 F1-3 1-151719-01 Fuse, 250V, 175A 19 3 - 1-151720-01 Fuse Holder, Semi-Conductor Fuse 20 1 - 1-151656-03 Assy, PCB, SCU-UL, 45kW 21 2 CT1,CT5 1-150296-01 CT, Hall Effect, 200A:1mA 22 1 T2 1-151843-01 Transformer, Iso, 230/115:230/115, 200A 23 3 - 1-160094-01 Fuse Holder, 30A, 600V, 2Pole 24 6 F4-F9 1-160092-01 Fuse, Time Delay, 250VAC 25 3 - 1-151241-01 Terminal Block, 1 Pole, 24-8 AWG 26 1 - 1-151242-01 Barrier Block, 24-18 AWG

151712 Sheet 2 of 2

Page 39

Page 40

Xantrex Technology, Inc.

Distributed Power Markets

161G South Vasco Road

Livermore, CA 94550 USA

Phone +1 925.245.5400

Fax +1 925.245.1022

XANTREX PV SERIES LIMITED WARRANTY AND REGISTRATION

Xantrex Technology warrants all equipment supplied to Customer under this purchase order against defects in workmanship and material for a period of (12) twelve months from delivery, provided that the equipment has been operated and maintained in accordance with the service manual provided with the equipment. Should Customer give Xantrex written notice of any such defects within the warranty period, and Xantrex’s inspection confirms the existence of such defects, Xantrex shall correct the defects, either by repair or replacement, at its sole option.

For wall-mounted products (generally, below 30 kW in rating), defective products must be returned to Xantrex or it Authorized Service Center in the original or equivalent packaging. The cost of transportation and insurance on items returned for service is at the Customer’s expense. Return transportation and insurance expense shall be borne by Xantrex.

For floor mounted inverter products (generally, 30 kW in rating and above), warranty repairs or replacements are performed at the installation site. Xantrex’s material, labor, freight and travel/living expenses associated with such repair or replacement shall be borne by Xantrex.

In either case, Customer’s labor and travel/living expense shall be borne by Customer. Xantrex will assume no expense, liability or responsibility for repairs made by or for Customer without written authority from Xantrex. Xantrex shall not be responsible for any consequential, incidental or similar damages.

THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

Project Name ______________________ Customer PO # ______________________ Inverter Serial # ______________________ Delivery Date ______________________

Xantrex Authorized Signature: Customer Authorized Signature:

________________________ ________________________

________________________ ________________________ Date Date

Page 41

Xantrex PV 45208 User Guide

Specifications and Main Features

Frequently Asked Questions

User Manual