Xantrex Technology PV-30208 User Manual

OPERATION and MAINTENANCE

MANUAL

for

MODEL PV-30208

30 kW Grid-Tied Photovoltaic Inverter

Document #151315

Revision E November 17, 2003

IMPORT ANT SAFETY INSTRUCTIONS

SA VE THESE INSTRUCTIONS - THIS MANUAL CONT AINS IMPOR T ANT INSTRUCTIONS

FOR XANTREX TECHNOLOGY MODEL PV -30208 GRID TIED PHOTOVOL T AIC INVER TER THA T SHALL BE FOLLOWED DURING INST ALLATION AND MAINTENANCE OF THE PV -

30208.

Xantrex Technology Inc.

161-G SOUTH VASCO ROAD

Livermore, CA 94551

(925) 245-5400

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 Panel (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

SECTION 1 PRODUCT DESCRIPTION

INTRODUCTION

The Xantrex Technology Model PV-30208 is a 30 kW Grid Tied Photovoltaic Inverter. It utilizes advanced power electronics to allow the interface of a photovoltaic array with an utility grid. The PV30208 is a highly integrated assembly, consisting of an inverter bridge and associated control electronics. The PV-30208 control software provides for complete overall system control with the required protective and safety features.

MAJOR COMPONENTS

The major components of the PV-30208 are identified in Drawing No. 151317.

Main Enclosure

The enclosure (shown in Figure 1-1) is NEMA-3R rated. The PV-30208 enclosure contains the solar control bus board, output line filter (insuring that the PV-30208 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).

DOCUMENT: 151315

Figure 1-1

Operation and Maintenance Manual

PV-30208 Photovoltaic Inverter

Figure 1-2

1-1

SECTION 1 PRODUCT DESCRIPTION

CAUTION

The fuses within the PV-30208 are intended for protecting the PV-30208 control circuitry only. They are not intended to provide protection for the PV array or external cabling.

Matrix Bus Board The PV-30208 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 heatsink.

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 PV30208 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-30208 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-30208 to verify it meets the recommendations of IEEE-929-2000. Refer to both documents for details of these recommendations and

test procedures.

DOCUMENT: 151315

PV-30208 Photovoltaic Inverter

Operation and Maintenance Manual

1-2

SECTION 1 PRODUCT DESCRIPTION

SPECIFICATIONS

The PV-30208 has been designed for photovoltaic power systems, which operate within the following specifications. Application of the PV-30208 in a manner inconsistent with these specifications may cause damage to the PV-30208 and other system components, and is a violation of the terms of the warranty.

egatloVeniLCAlanimoN%21-%01+,CAV802

tnerruCeniLCAmumixaM )egatlovenilwolta(SMRA49

ycneuqerFeniLlanimoNzH7.

rewoPtuptuOCAsuounitnoC esahP3CAV802@WK0.03

egatloVmumixaMVPCDV006

wodniWgnikcarTrewoPkaePCDV

egatloVgnikcarTrewoPkaePmuminiMVP033

tnerruCmumixaMVPCDA001

tnerruCtiucriCtrohSyarrAmumixaMVPCDA83

noitarugifnoCVP

erutarepmeTgnitarepOC°05ot02-**

erutar

epmeTegarotSC°05ot04-

gnitaRerutarepmeTtneibmAmumixaMC°05

ytidimuHevitaleRgnisnednoc-noN,%59oT

noitavelEteef

)sehcnini(snoisnemiD91X6.53X5.45

thgieW.sbl062.xorppA

epyTerusolcnER3AMEN

006-*033

0-zH5.0+,zH06

dnuorglartuen

ralop-ibro,dednuorgevitagenraloponoM

006,6evobadetareD

eliFgnitsiLLU6539

91E-eliF

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

EQUIPMENT SYMBOL

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

DOCUMENT: 151315

PV-30208 Photovoltaic Inverter

Operation and Maintenance Manual

1-3

SECTION 2 SAFETY

SAFETY FEATURES

WARNING

The PV-30208 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-30208 incorporates a maintained position on/off switch located on the upper enclosure. Under normal conditions, the on/off switch in the on position. Turning the switch to the off position will initiate a controlled shutdown of the PV-30208 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-30208 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-30208 and attempt to clear any system fault.

Enclosure Front Access Panel

The front access panel of the PV-30208 upper enclosure is fastened with twelve M6 stainless steel hex nuts. It is required that the PV-30208 enclosure front panel be securely fastened during normal opera-

tion.

WARNING

The PV-30208 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-30208 upper enclosure must be securely fastened during normal operation.

Fault Reporting

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-30208 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 PV30208 executes an orderly shutdown, and annunciates a ground fault at the operator interface. The PV30208 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).

DOCUMENT: 151315

PV-30208 Photovoltaic Inverter

Operation and Maintenance Manual

2-1

SECTION 2 SAFETY

ISOLATION PROCEDURE

Anti Island Protection

A digital phase-shift-loop (PSL) circuit is implemented in the DSP inverter controller to prevent “Islanding” of the PV-30208.

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-30208 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 UL1741. The following procedure should be followed to de-energize the PV-30208 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-30208 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).

DOCUMENT: 151315

PV-30208 Photovoltaic Inverter

Operation and Maintenance Manual

2-2

SECTION 3 INSTALLATION AND INITIAL TURN-ON

ISOLATION TRANSFORMER REQUIREMENTS

The PV -30208 UL1741 certification requires the use of a Xantrex T echnology specified 30 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 30 kVA isolation transformer is not part of the 30 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 PV 30208 inverter and the point of utility interconnection. Failure to do so could result in catastrophic damage to the PV-30208 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-30208.

T orque Table

eziStloBrokcolBlanimreTgnitteSeuqroT

guLreppoC61-5mN9.5/.sblni25

DOCUMENT: 151315

slanimreTCDdnaCAmN1.13/sblni572

PV-30208 Photovoltaic Inverter

Operation and Maintenance Manual

3-1

SECTION 3 INSTALLATION AND INITIAL TURN-ON

The following table shows acceptable wire gauges to be connected to the PV-30208 AC and DC inputs.

Wire Gauge Table

noitanimreTGWAegnaReriW

)CA(kcolBnoitubirtsiD2#-0/2 )CD(kcolBnoitubirtsiD2#-0/2

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-30208 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. 2 AWG, 105 degrees C, minimum, copper wire for all connections with the PV-30208.

Ventilation Considerations

Check with applicable installation standards for additional clearance requirements.

Installation

The PV-30208 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-30208 into place. Lift the PV-30208 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-30208. Lag bolts should be horizontally level with each other . Leave a minimum of 1” of bolt protruding from the wall.

2. Place the PV-30208 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-

30208. Check with local authorities for further detail.

DOCUMENT: 151315

PV-30208 Photovoltaic Inverter

Operation and Maintenance Manual

3-2

SECTION 3 INSTALLATION AND INITIAL TURN-ON

Figure 3-1

DOCUMENT: 151315

Figure 3-2

PV-30208 Photovoltaic Inverter

Operation and Maintenance Manual

Lift Here

Cable Entry Access Panel (Both Sides)

Figure 3-3

3-3

SECTION 3

CT1

INSTALLATION AND INITIAL TURN-ON

Array Grounding

NEC 690-41/42 requires the PV array to be earth grounded. The PV-30208 is shipped with a ground bond for installation between the pv negative terminal block to the pv safety ground terminal block. The PV-30208 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-30208. 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 Section 7, Appendix for further wiring configuration.

Ground Fault Detection

The PV-30208 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-30208 will execute an orderly shutdown and annunciates a ground fault at the operator interface. The PV-30208 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-30208 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-30208 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 125 amperes @208VAC, or 50 amperes @480V AC maximum branch circuit over current protection in accordance with the National Electrical Code, ANSI/NFPA 70.

DOCUMENT: 151315

PV-30208 Photovoltaic Inverter

Operation and Maintenance Manual

3-4

SECTION 3 INSTALLATION AND INITIAL TURN-ON

The following wires for connecting the PV-30208 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-30208. 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-30208 enclosure chassis ground stud.

• PV-30208 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.

DOCUMENT: 151315

PV-30208 Photovoltaic Inverter

Operation and Maintenance Manual

3-5

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-30208

GND

H3 X3

H2 X0

H1 X2 X1

(Optional)

Wiring Diagram

Isolation Transformer

DOCUMENT: 151315

PV-30208 Photovoltaic Inverter

Operation and Maintenance Manual

To Single Point Electrical

Distribution System Ground

Breaker

Line Circuit

3-6

+ 28 hidden pages