Xantrex Technology PV-225208 User Manual

OPERATION and MAINTENANCE

MANUAL

for

MODEL PV-225208

225 kW Grid-Tied Photovoltaic Inverter

Document #151811

Revision C November 26, 2003

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS - THIS MANUAL CONTAINS IMPORTANT INSTRUC-

TIONS FOR XANTREX TECHNOLOGY MODEL PV-225208 GRID TIED PHOTOVOLTAIC INVERTER THAT SHALL BE FOLLOWED DURING INSTALLATION AND MAINTENANCE OF THE PV-225208.

Xantrex Technology Inc.

161-G SOUTH VASCO ROAD

Livermore, CA 94550

(925) 245-5400

Table of Contents

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

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

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

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

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

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

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

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

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

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

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

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

Torque and Wire Gauge Specifications................................. 3-1

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Drawings List ........................................................................ 7-4

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

SECTION 1 PRODUCT DESCRIPTION

INTRODUCTION

The Xantrex Technology Model PV-225208 is a current following grid tied photovoltaic inverter, utilizing state-of-the-art IPM (Intelligent Power Module), insulated gate bi-polar transistors (IGBT’s) and gate drive circuits to allow interface of a photovoltaic array with a utility grid. The PV-225208 consists of an inverter bridge, photovoltaic controller, and associated control electronics. The PV-225208 control software provides for complete overall system control with a variety of protection and safety features.

MAJOR COMPONENTS

The major components of the PV-225208 are identified in Figure 1-1. Control components are identified in Figure 1-2. For specific control components see Drawing No. 151808 located in Section 7 (Appendix).

Main Enclosure

This enclosure is NEMA-3R rated. The PV-225208 main enclosure contains the power electronic inverter bridge, electrical and electromechanical control components, power supplies, system sensing circuits, and the PV-225208 embedded control unit. Also found within the main enclosure are some of the system protection devices (sense and control power fuses).

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Figure 1-1

PV-225208 Photovoltaic Inverter

Operation and Maintenance Manual

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SECTION 1 PRODUCT DESCRIPTION

AC Interface Enclosure

This enclosure is NEMA-3R rated. The AC Interface serves as the connection between the isolation transformer/utility and the PV-225208. This enclosure is where the AC line fuses and AC disconnect switch reside. For specific control components see Drawing No. 151809 in Section 7 (Appendix).

DC Interface Enclosure

This enclosure is NEMA-3R rated. The DC Interface serves as the connection interface between the PV array and the PV-225208. This enclosure is where the DC disconnect switch and DC contactor reside. For specific control components see Drawing No. 151810 in Section 7 (Appendix).

CAUTION

The fuses within the PV-225208 are intended for protecting the PV-225208 control circuitry only. They are not intended to provide protection for the PV array or external cabling.

Power Electronics Matrix

The power electronics converters are located at the top of the PV-225208 Main Enclosure. Each matrix is comprised of switching transistors (IGBTs), transistor gate drive electronics, a laminated power bus, DC capacitor bank, and an aluminum extrusion heat sink with a cooling fan. A fan is located above each matrix heatsink.

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

Operator Interface

The operator interface is located on the front door of the PV-225208 main enclosure. It consists of an On/Off switch and a keypad with liquid crystal display for control and monitoring purposes. All interface components are NEMA-3R rated. Refer to Section 4 for detailed operation instructions.

Inductor Enclosure

This enclosure is NEMA-3R rated. It contains the necessary filter components to insure the PV-225208 line currents and voltages meet IEEE-519 and UL1741 harmonic distortion requirements. Mounted on the right and left side of the lower enclosure are inductor fans to allow cooling of the line filter components within. This enclosure also serves as the mounting base for the PV-225208 main enclosure.

CONTROL COMPONENTS

The following assemblies are contained within the PV-225208 main enclosure as shown in Figure 1-2. For specific control components see Drawing No. 151808 in Section 7 ( Appendix).

Power Distribution Panel

This panel contains many of the Electro-mechanical, protective, and control power components necessary to support the operation of the PV-225208.

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SECTION 1 PRODUCT DESCRIPTION

Power Control Unit (PCU)

The PCU is a Digital Signal Processor (DSP) based control board that performs numerous control and diagnostic functions associated with PV-225208 operation. Its most significant tasks are control of PV-225208 electromechanical components and power electronics converters, signal conditioning for high voltage signal inputs and communication with the operator interface panel and system sensors. The PCU also contains the

necessary DC power supplies to support its operation.

INTERCONNECTION STANDARDS COMPLIANCE

The PV-225208 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 IEEE929-2000 Recommended Practice For Utility Interface Of Photovoltaic (PV) Systems.

IEEE-929-2000 provides guidance regarding equipment and functions necessary to ensure compatible operation of photovoltaic systems which are connected in parallel with the electric utility. UL1741 is the standard applied by Underwriters Laboratory to the PV-225208 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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Figure 1-2

PV-225208 Photovoltaic Inverter

Operation and Maintenance Manual

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SECTION 1 PRODUCT DESCRIPTION

SPECIFICATIONS

The PV -225208 has been designed for photovoltaic power systems, which operate within the following specifications. Application of the PV -225208 in a manner inconsistent with these specifications may cause damage to the PV -225208 and other system components, and is a violation of the terms of the warranty .

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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-225208 enclosure contains exposed high voltage conductors. The enclosure doors should remain locked, except during maintenance or testing. These servicing instructions are for use by qualified personnel only. To reduce the risk of electric shock, do not perform any servicing other than that specified in the operating instructions unless you are qualified to do so. Do not open the cabinet doors if extreme moisture is present (rain or heavy dew).

On/Off Switch

The PV-225208 incorporates a maintained position on/off switch located on the front door of the main enclosure. Under normal conditions, the on/off switch is in the on position. Turning the switch to the off position will initiate a controlled shutdown of the PV-225208 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-225208 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-225208 and attempt to clear any system fault.

Main Enclosure Door Interlock Switch

The front door of the PV-225208 main enclosure is equipped with an interlock switch to preclude operation in the event of the front door being opened. It is required that the PV-225208 main enclosure door handle be padlocked during normal operation.

WARNING

The PV-225208 will immediately shutdown if the front door is opened during operation. It is required that the PV-225208 main enclosure door handle be padlocked during normal operations. Please make sure the unit is powered down, and isolated from the utility grid and PV panels, prior to opening the front door. Allow 5 minutes for any stored potentials to be discharged, prior to opening the unit.

Disconnect Switches

Both AC & DC switches are equipped with lockout hasps for personnel safety. The switch enclosure door will not open while the PV-225208 is running. In addition, the switch handle and shaft provide a door interlock. The door cannot be opened when the switch is in the “on” position. The PV disconnect switch is equipped with an auxiliary contact block which enables the switch to be used as a load break PV disconnect. In the event a disconnect switch is opened while the PV-225208 is processing power from the PV array, the contact block will signal the PCU to stop processing power before the switch opens.

Fault Reporting

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

PV Ground Fault Detection

The PV-225208 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 PV-225208 executes an orderly shutdown, and annunciates a ground fault at the operator interface. The PV-225208 will remain faulted until the ground fault is remedied and cleared at the operator interface (see section 5, troubleshooting).

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SECTION 2 SAFETY

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

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Anti Island Protection

A digital phase-shift-loop (PSL) circuit is implemented in the DSP inverter controller to prevent “Islanding” of the PV-225208.

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-225208 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-225208 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 main enclosure to discharge after disconnecting the PV-225208 from AC and DC sources.

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

2. Open the DC interface (PV array) disconnect switch.

3. Open the AC interface disconnect switch.

4. Open the isolation transformer circuit breaker.

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

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SECTION 3

Torque Table

INSTALLATION AND INITIAL TURN-ON

ISOLA TION TRANSFORMER REQUIREMENTS

The PV-225208 UL1741 certification requires the use of a Xantrex Technology specified 225 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 225 kVA isolation transformer is not part of the 225 kVA 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 PV225208 inverter and the point of utility interconnection. Failure to do so could result in catastrophic damage to the PV-225208 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 (X0) 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 local jurisdiction for their requirements regarding the connection of this neutral.

Contact your Xantrex Technology 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-225208.

Terminal Block or Bolt Size Torque Setting

3/8-16 Bolt (AC) 250 in lbs./28.2 Nm

Terminal Block (DC+, DC-,

& DC Neutral)

275 in lbs/31.1 Nm

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SECTION 3

Wire Gauge Table

INSTALLATION AND INITIAL TURN-ON

The following table shows acceptable wire gauges to be connected to the PV-225208 AC and DC inputs.

Termination Wire Range AWG

Compression Lug (AC)

Compression Lug (DC+ and

DC-)

Terminal Block (DC Neutral)

INSTALLATION INSTRUCTIONS

All wiring methods shall be in accordance with the National Electrical Code ANSI/ NFPA 70. All power conductors interfacing to the PV-225208 should be sized in accordance with the National Electric Code ANSI/NFPA 70 and local codes. Large gauge wire must have a minimum bend radius dependent upon the wire gauge (refer to the National Electric Code, Article 373-6B). Take care to keep the wire bundles away from any sharp edges which may damage wire insulation over time. Xantrex Technology recommends using 250 MCM, 105 degrees C, minimum, copper wire for all connections to the PV-225208.

Up to 4 600MCM-#2

Conductors Per Phase

Up to 8 600MCM-#2

Conductors for each (+) and

(-)

Up to 2 350MCM-#6

Conductors

CAUTION

Ventilation Considerations

Maintain a minimum of 12” clearance in back , front and both sides of the PV-225208 for proper cooling fan operation.

Installation

1. Move the PV-225208 into place. Lift the PV-225208 from beneath the lower enclosure with a forklift as

shown in Figure 3-1. (See following page.)

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

3. Install all conduits needed for cable entry in the shaded areas of both AC and DC interface enclo-

sures as shown in Figure 3-2. (See following page).

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PV-225208 Photovoltaic Inverter

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Operation and Maintenance Manual

SECTION 3 INSTALLATION AND INITIAL TURN-ON

Lift Here

Figure 3-1

Cable Entry Area

Figure 3-2

Array Grounding

NEC 690-41/42 requires the PV array to be earth grounded. The PV-225208 chassis is also bonded to the PV safety ground terminal block. Refer to the system schematic in the appendix for further wiring configuration.

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SECTION 3 INSTALLATION AND INITIAL TURN-ON

Ground Fault Detection

The PV-225208 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 amp ground fault, the PV-225208 will execute an orderly shutdown and annunciates a ground fault at the operator interface. The PV-225208 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 required by sections 690-41, 690-42 and 690-43 of the National Electric Code, ANSI/NFPA 70, is the responsibility of the installer.

INTERCONNECTION WIRING

CT1

CAUTION

To reduce the risk of fire, connect only to a circuit provided with 800 amperes @208VAC, or 400 amperes @480VAC maximum branch circuit overcurrent protection in accordance with the National Electrical Code, ANSI/NFPA 70.

The following wires for connecting the PV-225208 to external devices are not provided by Xantrex Technology: (See installation diagram on pages 3-5.)

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

inverter side of isolation transformer. The neutral on the inverter side of the isolation transformer

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-225208. Also, insure that this neutral is not bonded to the isolation transformer frame. Be

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

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

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

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

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

tions. See Section 7 for further detail .

CAUTION

When connecting external AC wires to the PV-225208, positive phasing sequence must be maintained throughout the installation process. Refer to the System Schematic in Section 7 of this manual for proper phasing convention.

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

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SECTION 3 INSTALLATION AND INITIAL TURN-ON

PV+

PV-

PV Array

Frame Ground

DC Interface

AC Interface

A B C

GND

Inverter

PV-225208

Wiring Diagram

Chassis Gnd

Circuit

Breaker

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A B C

To Single Point Electrical

Distribution System Ground

PV-225208 Photovoltaic Inverter

Operation and Maintenance Manual

X2 H2H3X3

Isolation

Transformer

3-5

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-225208. These steps are to be followed sequentially. Do not continue if any of the steps or results are unclear. Refer to Section 4 for a detailed description of system operation. Refer to Section 5 for fault condition descriptions and troubleshooting. Refer to Section 7 for detailed system schematics.

Visual Inspection, Isolation Transformer WYE/WYE

• Verify the isolation transformer circuit breaker is open.

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

transformer circuit breaker.

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

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

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

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

and circuit breaker.

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

Visual Inspection, PV-225208

• Insure AC and DC disconnect switches are opened.

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

disconnect enclosures and inspect.

• Verify all wire connections are tight.

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

snap-locked into their respective receivers/transmitters.

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

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

Visual Inspection, PV Array Wiring

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

be tied to PV-.

• Verify all PV fuses are installed.

Initial Power

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

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

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

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

• Close the PV disconnect switch.

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

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SECTION 3 INSTALLATION AND INITIAL TURN-ON

(+) terminal. The value should be the same as at the PV array string disconnect switch. It should also be positive.

• Open all PV string disconnect switches.

• Close the isolation transformer circuit breaker.

• Verify 208 VAC voltage across the AC disconnect switch. If a phase rotation meter is available,

verify proper phase rotation at the AC disconnect switch.

• Close the AC disconnect switch.

• Verify 208 VAC voltage across the AC line fuses F1-3.

System Verification

• Upon applying 208 VAC power to the PV-225208, observe the operator interface panel. After approxi-

mately 15 seconds, the panel should finish initialization and will probably report a fault condition.

• Remedy any faults reported. To clear a fault condition, press the <ENTER> key twice. If the fault message

does not change, the fault condition is still present. Most likely, any faults seen at this point will be related to PV-225208 safety switches. To disable the door interlock switch with the main enclosure door opened, pull the switch shaft out. It will lock in its ‘maintenance’ position. Once all faults are cleared the system will read ‘Sleeping’ or ‘Keyswitch Disable’ depending on the position of the On/Off switch. To re-enable interlock, push the shaft in and close the door.

• Scroll up the menu until ‘Enter Read Parameter:’ is displayed.

• Press <Enter>, then <19>. This is line voltage frequency being read by the PCU. It should read 60.0

+0.5, -0.7.

• Verify the On/Off switch is in the ‘Off’ position.

• Close the PV array string disconnect switches.

• Close the PV-225208 DC disconnect switch.

• Press <F2> on the operator interface panel. If the PV voltage is above the PV Start Voltage setpoint,

the second line should read ‘Waking Up’. Once the PV Start Time is exceeded, the PV-225208 should transition to ‘Power Tracking’.

• The power tracker was previously limited to 25% of PV-225208 rated power. Once the PV-225208 has

stabilized operation (approximately 20 seconds), scroll through the main operator interface panel menu. Verify all phase voltages and currents are closely balanced.

• Scroll to ‘Enter Read Parameter:’ Press <ENTER> then <17> <ENTER> to view ground fault

current value. This value should be equal to or very close to zero. Continue to monitor this value as the PV-225208 is commanded to higher power levels.

• Enter the write parameter menu and increase the ‘I PPT Max %’ to 50. Exit the write parameter

menu and verify all operating values are proper.

• Continue to increment ‘I PPT Max %’ to 100. Depending upon solar conditions, the PV-225208 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. To determine if the PV-225208 has reached it’s maximum power output, enter <20> at the ‘Enter Read Parameter:’ ‘0’ means the PV-225208 has not reached maximum power, contrarily, ‘1’ means the PV-225208 has reached maximum power and executed the modified peak power tracker to limit output power.

• The PV-225208 is now fully operational.

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