Home

Xantrex PV100S-480 User's Manual

1. 8 7 5 4 5 2 1 NOTES MAIN POWER DISTRIBUTION ALL CONTROL WIRE 600v CLASS UNLESS OTHERWISE SPECIFIED 1 WIRE PASS THROUGH ALL CT S AC DISCONNECT ENCLOSURE TRANSFORMER ENCLOSURE MAIN CONVERTER ENCLOSURE PV DISCONNECT ENCLOSURE 51 EMI T6 L1 Se D SN DA OSEE Ae CONTACTOR ww 4004 xi 184 ssov 400 En e dk 32 F1 4 m PIE vip gos a 2 H X 2 F2 He 3 PRSE ltra LAS B 4 913 F3 SYSTEM c 6 5 erat 5 CUSTDMER ES a SUPPLIED a ps mo 5000 555 MATRIX i 55 s 5 e SH fo SNUBBER 2 Ly T T l SUPPLIED e EN SHT 3B4 C 24 5 CCU2 P amp 4 l n PV SENSE F25 5 SHT 303 ccUa pg 1 2 PV PV GND
2. 4 4 Corrective 4 4 Schematics jq RR a aa IX 1 xiv 152315 Rev C Tables Table 1 1 Electrical Specifications 1 4 Table 1 2 Over Under Voltage and Over Under Frequency Ranges 1 4 Table 1 3 Environmental Specifications 1 6 Table 3 1 AC Terminal Wire Gauge Bolt Size and Torque Values 3 12 Table 3 2 DC Terminal Wire Gauge Bolt Size and Torque Values 3 12 152315 Rev C XV xvi Figures Figure 1 1 Figure 1 2 Figure 1 3 Figure 1 4 Figure 1 5 Figure 1 6 Figure 1 7 Figure 1 8 Figure 1 9 Figure 1 10 Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Figure 2 6 Figure 2 7 Figure 2 8 Figure 2 9 Figure 2 10 Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 3 6 Figure 3 7 Figure 3 8 Figure 3 9 Figure 3 10 Figure 3 11 Figure 3 12 Figure 3 13 Figure 3 14 Figure 3 15 Figure 3 16 Figure 3 17 152315 Rev C Dimensions Not to scale 1 3 PV100S Operator Interface Components 1 7 On Off Switch 1 8 AC and DC Disconnect Switches
3. MAIN INVERTER ENCLOSURE DC INTERFACE ENCLOSURE CBI CIRCUIT BREAKER TOMER SUPPLIED 16 52 1 LF1 K 480 or 208Y 208Y 100KVA DC CONTAC OR dC DISCONNI C MS MATRIX 1 C CO JC SCC C AC DISCONNECT SWITCH FILTER AC CONTACTOR ISOLATION TRANSFORMER 4 SWITCH gt A 3 4 o e REL B B3 C T m oe 4 N oe 4 H ro CND Soma SOFT START 4 GND H T oe 2 ODE TO UTILITY 60HZ DISTRIBUTION SYSTEM SINGLE POINT TO LOCAL EARTH GROUND Figure A 1 Electrical Diagram sample TELEPHONE SERVICE 152315 Rev C A 3 Schematics Appendix A 8 7 6 5 4 5 2 1 a ES REVISION NOTES MAIN POWER DISTRIBUTION ALL CONTROL WIRE 600V CLASS UNLESS OTHERWISE SPECIFIED 1 WIRE PASS THROUGH ALL CT S AC DISCONNE
4. 3 10 Overcurrent Protection 3 11 Conductor Termination 3 11 Wire Gauge and Torque Requirements 3 12 Grounding 3 12 System Neutral Requirements 3 13 Utility Side Isolation Transformer Requirements 3 13 Wiring Specific 3 14 Connections 3 14 PV Array Connections 3 19 PC Communications 3 20 PC Connection Methods 3 20 Establishing a POTS Connection 3 2 Establishing Wireless Connection 55 5 5 5 5 5 3 22 Establishing an Ethernet LAN Connection 3 22 Direct Connection 3 23 4 Verification Verification Procedure Summary 4 2 Visual Inspection of Mechanical Connections 4 3 Visual Inspection of Electrical Connections 4 3 Visual Inspection Isolation Transformer
5. CERRO FERIIS IR t EH ER ST eres su SSS SS SINGLE POINT TO F15 10 bi FAN EARTH GROUND 2 1 PAB 7 CONTACTOR CONTROL SHT TB8 2 SHT 245 TB8 4 T2 X2 SHT 2 SHT 207 LINE SENSE 277 10 this T3 CU2 P1001 6 2 1001 2 p SHT 3 1 CCU2 P1001 4 A 4 T3 4 AND 5 PIN OUT 15 5e CU2 P7 4 AGND SHT 304 DIMENSIONS IN INCHES DATE Sacr mew aL sem ex DRAWN 12 08 02 v Beccles SCHEMATIC E pd mame BERT SYSTEM PV100S 208 1 mue sr BY Sa San BY 8 7 5 4 3 2 Figure 5 PV100S 208 Schematic Main Power Distribution 152376 C1 152315 Rev C A 7 Schematics Appendix A 8 7 6 5 4 5 2 1 NOTES CONTROL POWER DISTRIBUTION 25 1 CONTROL POWER SHT 185 J Wl e 595 208V 24V 150 e o CCU2 P5 4 2 2 CCU2 P5 1 SHT 3A6 gt n PS1 CIN 15VDC DRIVER BOARD P1 1 8g SHT 3D5 DC INTERFACE ENCLOSURE
6. LHS 212 9 Y lt 1 24 L r 20 E MINIS El E M ASi OL OL AGI 6 6 5 vOIOM 8 8 AGI 2 2 _AGI 9 9 lal IHS 181 28 5 sna OL 8 et NIS WANNI 2 2 A pac IHS gr d INHAN guvog WHO 81 I gt 22 155 SYL LHS 8 61 T NIS 3NTL zm 9 9 anav TH S D e 6 6 8 Eee m OL OL 1 O o e hg x Sg o v zx ou 8 1 a Don 8 gt N 8 11 6 8 _ 5 LT 555 138vdS 0L OF c 5 46 6 6 B z N ai 3uvdS 2 a 5 bl 9 9 2 OLH H S a JOONAS t 3008 wwASt t 48 1 uk oF er a m 52 giu 110 1389495 zi zi Ino Laevas 920 ITNT OL 0L nnn 1955 Een 6 20 91405 8 15 8 8 HIE S Hoane a Hass men 2 8 220 8 8 lt 30191400 50 72 LHS Ano THS
7. 1 9 LCD Display and Location 1 11 PC Connections the Communications Enclosure 1 12 POTS Access 1 13 Wireless Access 1 13 Ethernet LAN Access 1 14 Direct 8 1 14 PV100S Layout Option 2 6 PV100S Layout Option 2 7 Conduit Entry Figure Reference 2 8 Inductor Enclosure Conduit Entry Left Side 2 9 Transformer Enclosure Conduit Entry Right Side 2 9 AC Interface Enclosure Conduit Entry Left Side 2 10 DC Interface Enclosure Bottom Side 2 10 Communications Enclosure Conduit Entry Bottom Side 2 10 Main Inverter Anchor Bolt Pattern Not to scale 2 13 AC Interface Transformer Anchor Bolt Pattern Not to Scale 2 14 Moving the crated 1005 3 3 Forklift Lifting Locations Underneath Unit 3 4 Mounting Hole Locations
8. AGND DRIVER 1 5 D 2 B 0 dg MAIN ENCLOSURE DOOR 208V 120V L1 H 250 THERMAL d 3 ANP T 25 SWITCH RU ON OFF J1077 CONTACTOR 53 CONTROL c J10 8 185 F2 3 2 MAIN ENCLOSURE lt gt GROUND STRAP TB1 SHT 181 TB7 4 SHT 1B3 TB7 5 xantrex Dl NONE 152376 J sm 2 3 8 7 6 25 4 5 2 1 Figure 6 PV100S 208 Schematic for Control Power Distribution 152376 C2 A 8 152315 Rev C Schematics Appendix A DI 152376 i A 9 NES kola 29 te 6 8 14 0100 o a 5 N 28 01 14 2100 amp in n LZ 4 5 14 2100 19 d 926 HS Meck 4 A UE N 9 H 5 5 5 x Q g E P Dus X M N z o m Ole E i om lt zl 5 24 d i auov o o s8IVIS Nas aan Z Z 00 20014 1N3204010 m 5 5 9 91 1 24 20 SL
9. 3 5 Inverter Enclosure Access Doors 3 6 AC Interface Access Door 3 7 DC Interface Access Door 3 7 Transformer Access Panels 3 8 Inductor Access Panels 3 8 Conduit Installation 3 9 Single point Ground TB2 Ground Bar 3 12 Chassis Ground 1 3 13 Route AC Cables through the Conduit 3 14 Tie wraps on the AC Sense 3 15 AC Terminal Connections in the AC Interface Transformer Enclosure 3 15 AC Terminal Connections in the Main Inverter Enclosure 3 16 AC Terminal Connections in the AC Interface Enclosure 3 16 Connecting the AC Sense Harness 3 17 xvii Figures Figure 3 18 Figure 3 19 Figure 3 20 Figure 3 21 Figure 3 22 Figure 1 Figure A 2 Figure 3 Figure 4 Figure A 5 Figure A 6 Figure 7 xviii AC Terminal Connections from the Utility 3 18 PV Array Cable Routing and Terminations 3 19
10. 110 cm Y 7 21 3 8 53 5 Back ac Back Front Front 83 205 7 cm DC Interface T Communications Enclosure a 4 Interface Enclosure 59 4 148 Inductor Enclosure Y cC 33 83 75 DC Side View AC Side View Figure 1 1 Dimensions Not to scale 152315 Rev C 1 3 Introduction System Specifications The PV100S has been designed for photovoltaic power systems which operate within the following specifications CAUTION Equipment Damage Operation of the PV100S in a manner other than specified in this manual may cause damage to the PV100S and other system components and will void the terms of the warranty Electrical Specifications Table 1 1 provides the AC and DC specifications for the PV100S Table 1 1 Electrical Specifications Specification 1005 208 1005 480 Nominal AC Input Voltage 208 Vac 480 Vac 10 to 12 acceptable range 183 to 228 Vac 422 to 528 Vac Maximum AC Output Current 278 Aims 121 Anns Nominal AC Input Frequency 60 Hz 60 Hz 0 5 to 0 7 Hz acceptable range 59 3 to 60 5 Hz 59 3 to 60 5 Hz Output Power 100 0 kW 100 0 kW Peak Power Tracking Window 330 to 600 Vdc 330 to 600 Vdc Maximum Open Circuit Voltage 600 600 Vdc Maximum DC Input Current 319 amps 319 amps Over Voltage Under Voltage and Frequency Ranges Table 1 2 provides the over voltage under voltage
11. 152315 Rev C Communication Methods Communication Methods The PV100S communicates system status information to the user using the following methods Front Panel Control Unit UFCU Display Connection Direct or Remote Xantrex Solar Graphic User Interface GUI Software required Communication with a PC requires the selection of one of the following options e Remote Connection This method has three options available One of these options will be field installed prior to commissioning POTS Plain Old Telephone Service Connection Wireless Connection Ethernet LAN Connection Direct Connection This method is most commonly used by field technicians for local connection and troubleshooting purposes Important The customer is responsible for providing the appropriate support service to support a PC connection 1 making arrangements for an analog phone line wireless service or local area network Universal Front Panel Control Unit UFCU The UFCU keypad is located on the front of the Main Inverter Enclosure to manipulate and view system operation and status The keypad is comprised of 20 touch sensitive keys that provide a means to navigate through the menus and alter user changeable settings Communications Enclosure LCD Display P Ht Universal Front Panel Control Unit UFCU Figure 1 5 LCD Display and UFCU Location See the PV100S 1
12. Given the flexibility to co locate the AC interface enclosure transformer assembly to fit a desired system layout the conduits and conductors are to be supplied by the installer See Conduit Penetration on page 2 8 for recommendations on enclosure penetration locations and conduit routing See Conductor and Conduit Sizing on page 2 11 for information on sizing the conductors and conduits interconnect wiring and power conductors interfacing to the PV100S must be in accordance with the National Electric Code ANSI NFPA 70 and any applicable local codes 152315 Rev C PV Planning PV Planning Large gauge wire must conform to the minimum bend radius specified in the NEC Article 373 6B Ninth Edition Take care to keep the wire bundles away from any sharp edges which may damage wire insulation over time conductors should be made of copper and rated for 90 minimum If the installation of the PV100S is to be outdoors all interconnect conduit and fitings must be NEMA 4 rated as required by the NEC To determine the number of photovoltaic panels that are required for the PV power plant please use the PV planning tool from the Xantrex website http www xantrex com support pvsizing disclaimer asp Ventilation and Serviceability Requirements Ventilation Maintenance and Serviceability Indoor Temperature Control 152315 Rev The following environmental conditions must be established and maintain
13. Ground Requirements 1 5 GUI v IEEE v IGBT v Indoor Temperature Control 2 3 IPM v Isolation Transformer 2 4 3 13 K v L LCD v Location 2 2 M Main Enclosure Door Interlock Switch 1 7 Maintenance and Serviceability 2 3 Mounting and Anchoring 3 5 Moving 3 3 Moving the 1005 3 4 On Off Switch 1 8 Operational Safety x Over Voltage Under Voltage and Frequency Ranges 1 4 Overcurrent Protection 3 11 Overview 2 2 PC Connection Methods 3 20 PC Connections Direct Connect 2 4 LAN Connection 3 22 Wireless Remote Connect 2 4 Wireless Remote Connection 3 22 PersonalSafety Planning 2 2 PSL v v PV Array Connections 3 19 PV Planning 2 3 Index R Removing the Pallet 3 4 S Safety T Torque and Wire Gauge Specifications 3 12 U UFCU v Unloading 3 2 Unpacking 3 3 Utility Side Isolation Transformer Requirements 1 5 V Verification Procedure Summary 4 2 Visual Inspection of Electrical Connections 4 3 Visual Inspection of Mechanical Connections 4 3 Visual Inspection Isolation Transformer Wye Wye 4 4 Wireless Remote Access 1 13 Wiring Requirements viii X Xantrex website v IX 2 152315 Rev Xantrex Technology Inc 1 800 670 0707 Tel toll free NA 1 360 925 5097 Tel direct 1 360 925 5143 Fax direct customerserviceQ xantrex com www xantrex com 152315 Rev C Printed in
14. L 28 q LIONE n qvas ozn oinowg 14 2 a 25 y 1 m Bin IP sinaino PE OB uU 425 5 e 5 gt 5 SS 8 255 exeo ES BEER 5 5 ON 00 e 5 t i gt 5 zn 2 Ew 42 Mo 84 28 amp 48 p T 4 y B MES E lt TUE Lu geo 2 8 O 5 Le 27 5 C O en lt Figure 7 PV100S 208 Schematic for Converter Control Unit 152376 C3 152315 Rev C Schematics Appendix A This page was intentionally left blank A 10 152315 Rev C Index A Abbreviations and Acronyms v Access Doors 3 6 Anchoring 2 13 Array Grounding 3 13 C CCU2 v CFM v Chassis Grounds 3 13 Clearance 2 2 Communication 2 4 Communications 3 20 Components 2 2 Conductor and Conduit Sizing 2 11 Conduit Installation 3 9 Conduit Penetration 2 8 Conduits and Conductors 2 2 Controls 1 7 Conventions Used iv Corrective Action 4 4 D Data Logging 1 10 DC terminals TB3 1 TB3 2 amp TB3 3 3 11 Direct Access 1 14 Disconnect Switches 1 9 DSP v E Electrical Diagrams 2 5 Electrical Specifications 1 4 Environmental Specifications 1 6 Equipment 3 2 F Fault Reporting and Logging 1 10 G General Safety viii Ground 3 13
15. A copper ground rod must be installed within three feet of the PV100S enclosure This 15 the single point earth ground for the inverter system The single point ground for the system is to be made at the AC ground bus bar TB2 in the AC Interface Enclosure System Neutral Requirements The PV100S is designed to be installed as a 4 wire system As required by the UL 1741 listing a neutral conductor from the utility interconnect must be terminated at TB6 within the AC Interface Enclosure to ensure that the AC voltage sensing circuit can perform an individual phase voltage line to neutral measurement The function of the neutral connection is to provide a point of reference for measurement purposes that is essentially at ground potential No power will flow through the neutral conductor Communication Requirements The PV100S can accommodate any one of the following options for PC Communication POTS Connect Kit uses a MultiTech 56K Modem RS232 Fiber Optic Converter configured for ethernet and SA2 Surge Arrestor A direct analog phone line to the local phone service is required to use this feature The phone line used for PV100S communication cannot be routed through a Private Branch Exchange PBX unless an analog PBX card is used e Wireless Connect uses a GSM Wireless Modem Ethernet LAN Connect uses a data communication device to enable the unit to connect to a local area network e Direct Connect uses RS
16. fork span fork span Figure 3 2 Forklift Lifting Locations Underneath Unit 3 4 152315 Rev C Mounting and Anchoring the Units Important Before proceeding with the installation determine the location and layout of the components conduit penetration locations conductor and conduit sizing and method for anchoring the unit Ensure adequate space is provided for clearance for ventilation and serviceability Review Chapter 2 Planning if necessary before proceeding Mounting and Anchoring the Units To mount and anchor the PV100S 1 Predrill the floor or pad to accept 1 2 diameter masonry anchors ensure it has pre installed anchoring bolts that will fit the 5 8 mounting holes Lift the main inverter from beneath the lower enclosure with a forklift or pallet jack as shown in Figure 3 2 on page 3 4 Move the Main Inverter Enclosure into place Lift the AC interface transformer assembly from beneath the enclosure with a forklift or pallet Jack as shown in Figure 3 2 on page 3 4 Move the AC interface transformer assembly into place Secure the Main Inverter Enclosure feet to the floor with a 1 2 diameter anchor bolts Secure the AC interface transformer assembly enclosure feet to the floor with 1 2 diameter anchor bolts Mounting Holes for securing and anchoring the units Figure 3 3 Mounting Hole Locations 152315 Rev C 3 5 Installation Opening or Closing Access Doors To lock or unlo
17. of 275 in lb 31 Nm Connect the ground conductor to the terminal on the ground bar on the left side of the enclosure Torque this connection to 420 in Ibs 47 5 Nm Enlargement of Terminal Connectors in the AC Interface Enclosure S1 2T1 S1 6T3 AC Interface Enclosure A phase C phase 1 4T2 B phase Figure 3 16 AC Terminal Connections in the AC Interface Enclosure 3 16 152315 Rev 152315 Rev C Wiring Specific 6 The AC Sense Harness is pre terminated within the AC interface transformer assembly and the opposite end is mated with its 9 pin plug to the corresponding 9 pin jack within the Main Inverter Enclosure See Figure 3 17 Figure 3 17 Connecting the AC Sense Harness 7 Replace the access panels on the front of both the main inverter Inductor Enclosure and the Transformer Enclosure Additionally close the front door to the Main Inverter Enclosure To connect the utility service to AC Interface Enclosure 1 Remove the door clamps and open the door to the AC Interface Enclosure 2 Route the AC power conductors A B C phase neutral and a neutral ground cable through the conduit from the utility service to the AC Interface Enclosure See Figure 3 18 for the location of these terminals 3 Connect the AC power conductors at the S1 2T1 A phase 51 4 2 B phase and S1 6T3 C phase terminals using the M8 PV100S 480 or M10 PV100S 208 hardware Cables to
18. 271 5 x 12596 347 A required ampacity Step 2 Determine the conduit length between inverter and transformer Ifthe conduit length between the inverter and the transformer is less than 24 inches then the cable can be sized using the NEC Table 310 16 in Raceway Ninth Edition e Ifthe conduit length is greater than 24 inches then the cable must be sized using NEC Table 310 16 in Raceway Ninth Edition and by using the adjustment factors in NEC TAble 310 15 b 2 a Planning Step 3 Size the cable This example assumes that the conduit length is less than 24 inches NEC Table 310 16 Ninth Edition indicates the Temperature Correction Factor for 90 THHN cable in a 50 ambient is 0 82 With a required ampacity from Step 1 above of 347 amps it can be calculated that the required cable ampacity at 50 C in this application is 423 amps 347 divided by 0 82 In this example two cables per phase termination are used so from NEC Table 310 16 Ninth Edition it is apparent that the 90 THHN cable must be 3 0 AWG or larger Two each 3 0 AWG conductors at 50 C have an allowable ampacity of 450 amps 225 multiplied by 2 Step 4 Size the conduit In this step the cross sectional area of all the individual cables is first calculated Once calculated the total cross sectional area of the cables is determined by summing their values In this example 3 0 AWG 2000 V cable is selected for the AC Phase connection
19. AC Interface Enclosure and Transformer Enclosure from beneath their shipping crates Figure 3 1 Moving the crated PV100S Unpacking the PV100S To unpack the main inverter and the AC Interface Enclosure and transformer assembly from their shipping crates 1 Using a claw hammer or pry bar remove the crate s wood top and side panels 2 Remove the main inverter s anchor hardware that attaches it to the shipping pallet 3 Remove the AC Interface Enclosure and transformer assembly anchor hardware that attaches them to their shipping pallet 152315 Rev C 3 3 Installation Removing the Pallet and Moving the PV100S CAUTION Equipment Damage To move the PV100S use a forklift that has a sufficient lift capacity and a 26 fork span To move the PV100S using a forklift 1 Place the forks of the forklift below the unit at the points specified in Figure 3 2 2 Liftthe PV100S from beneath the respective enclosures Be sure to use a forklift with a 26 fork span Remove the pallet from beneath the unit 4 Once the pallets are removed from the units use the same lifting locations to lift the units into the place where they are to be permanently located Communications Enclosure xantrex Inverter DC Interface Enclosure Enclosure AC Transformer 5 Interface Enclosure Enclosure Inductor Enclosure i 2 i Lift Here 27 Lift Here E 26 66 cm 26 66 cm
20. Main Inverter Enclosure TB4 A TB4 B and TB4 C Enclosure have two openings per pole These terminals do not require the use of crimp on type ring terminals or compression lugs See Figure 3 15 on page 3 16 for the location of these terminals AC Interface The AC line terminals in the AC Interface Enclosure S1 2T1 S1 4T2 and Enclosure 51 6 3 are one bolt per pole These terminals require the use of crimp on type ring terminals or compression lugs See Figure 3 16 on page 3 16 for the location of these terminals The AC neutral terminal in the AC Interface Enclosure TB6 has one bolt per pole and requires the use of crimp on type ring terminals or compression lugs See Figure 3 18 on page 3 18 for the location of this terminal DC Interface The DC terminals in the DC Interface Enclosure TB3 1 TB3 2 and TB3 3 Enclosure have two openings per pole These terminals do not require the use of crimp on type ring terminals or compression lugs See Figure 3 19 on page 3 19 for the location of these terminals Important Keep these cables together as much as possible and ensure that all cables pass through the same knockout and conduit fittings thus allowing any inductive currents to cancel 152315 Rev C 3 11 Installation Wire Gauge and Torque Requirements Table 3 1 provides acceptable wire gauges bolt sizes and torque values for AC terminal connections Table 3 1 AC Terminal Wire Gauge Bolt Size and Torque Val
21. Telephone Cable Routing 3 21 RS232 FO Converter Kit Installation 3 23 Direct Connect Installation 3 24 Electrical Diagram sample 3 PV100S 480 Schematic for Main Power Distribution 152316 El 4 1005 480 Schematic for Control Power Distribution 152316 2 5 PV100S 480 Schematic for Converter Control Unit 152316 6 PV100S 208 Schematic Main Power Distribution 152376 7 1005 208 Schematic for Control Power Distribution 152376 2 8 PV100S 208 Schematic for Converter Control Unit 152376 3 9 152315 Introduction Chapter 1 Introduction provides information about the features and functions of the PV100S 100 kW Grid Tied Photovoltaic Inverter Introduction Description of the PV100S 1 2 1005 100 kW Grid Tied Photovoltaic Inverter is UL 1741 listed utility interactive three phase power conversion system for grid connected photovoltaic arrays with a power rating of 100 kW Designed to be easy to install and operate the PV100S automates start up shutdown and fault detection scenarios With user definable power tracking that matches the inverter to the array and adjustable delay periods users are able
22. over frequency and under frequency detection limits for the PV100S These detection limits have been factory tested and deemed to be in compliance with IEEE 929 and UL 1741 requirements for utility interaction Table 1 2 Over Under Voltage and Over Under Frequency Ranges PV100S 208 PV100S 480 Vac Condition of Nominal Voltage Range Time Voltage Range Trip Time Vac lt 50 Vac lt 104 6 cycles Vac lt 240 6 cycles 50 lt Vac lt 88 104 lt Vac lt 183 2 seconds 240 lt lt 422 2 seconds 88 lt Vac lt 110 183 lt Vac lt 228 normal operation 422 lt Vac lt 528 normal operation 11094 Vac 13796 228 lt Vac 285 2 seconds 528 Vac 657 2 seconds 137 lt Vac 285 lt Vac 2 cycles 657 lt Vac 2 cycles f lt rated 0 7 lt 59 3 6 cycles f lt 59 3 6 cycles f gt rated 0 5 f 60 5 6 cycles f 60 5 6 cycles 1 4 152315 Rev C System Specifications System Ground Requirements This product is intended to be installed as part of a permanently grounded electrical system per the National Electric Code ANSI NFPA 70 copper ground rod must be installed within three feet of the PV100S enclosures and connected to the unit as described in System Grounding on page 3 12 The single point ground for the system is to be made at the AC ground bus bar TB2 in the AC Interface Enclosure System Neutral Requirements The PV100S is designed to be installed as a 4
23. wire system As required by the UL 1741 listing a neutral conductor from the utility interconnect must be terminated at TB6 within the AC Interface Enclosure to ensure that the AC voltage sensing circuit can perform an individual phase voltage line to neutral measurement The function of the neutral connection is to provide a point of reference for measurement purposes that is essentially at ground potential No power will flow through the neutral conductor Utility Side Isolation Transformer Requirements 152315 Rev C The PV100S is supplied with a custom high efficiency isolation transformer as part of the AC Interface Transformer assembly The utility side windings of the isolation transformer are configured Wye and must match the voltage at the utility inter tie The PV100S is a balanced three phase current sourcing inverter and only operates with the presence of a stable utility voltage The transformer is also supplied with a neutral connection on the utility interconnect Connection of this utility side neutral does not affect the operation of the inverter however connection of the neutral on the inverter side does affect the operation and must be left floating or disconnected Single phase grounded loads which may be present between the transformer and utility will maintain their existing ground reference at the utility distribution transformer CAUTION Equipment Damage If the Isolation Transformer T6 X0 neutral terminal i
24. 0 5 2 T GROUND STRAP MAIN ENCLOSURE Ji TB SHT 181 TB7 4 SHT 183 T87 5 xantrex NONE 152316 F SHT 2 OF 3 8 7 6 5 4 5 2 1 Figure A 3 PV100S 480 Schematic for Control Power Distribution 152316 152315 Rev C A 5 lt X 5 8 d lt 152316 7 20 E 2 S z2 L m 5 a Ho i 5 nu 922 LHS A UE 9 2 z je 5 T m Ho 3 gt 5 P evra at 41 QB 2 2 85 D g zz 5 QN gt gt gt 2 3 o Nis Nis Z Z Nas 0014 51 134319 galar 5 1 23 00 91 S 21 LHS zz 2 1 i L 624 I Bi 3 5 35 201041 m 6 6 8 ile 4 99 IHS 181 J 5 S OL lt 53 t V NISTYANNTI 2 z 88 IHS amp indNI Z 81 FH 41 gt e z NOV Misi GVL 8 9 NV NaS 9 9 lt gt lt Z NaS 2 2 2 5 555 8 6 ONI_Xn 8 A 01 01 INxnv n O 4 m e E gt E SA 5 fr 5 o SE
25. 00 kW Grid tied Photovoltaic Inverter Operation and Maintenance Manual for details 152315 Rev C 1 11 Introduction PC Connection Methods Communications Enclosure Personal computers can be used to access the system status and programming features of the PV100S A computer can be connected either directly or remotely Remote Connect uses one of the three kits below POTS Kit uses a MultiTech 56K Modem RS232 Fiber Optic Converter configured for ethernet and SA2 Surge Arrestor e Wireless Kit uses a GSM Wireless Modem Ethernet LAN Kit uses a data communication device to enable the unit to connect to a local area network 2 Direct Connect This method is used for troubleshooting It uses a RS232 Fiber Optic Converter configured for a PC a DB25 to DB25 gender changer and a DB25 to DB9 Serial Cable Software is included to provide a graphic user interface that relates important system information This software is called Xantrex Solar Graphic Interface GUI See Computer Communications with the PV100S in the PV100S 100 kW Grid tied Photovoltaic Inverter Operation and Maintenance Manual for additional information The GUI can dial up the inverter and receive fault report calls from it through a standard Hayes compatible landline modem When the GUI initiates a call through the modem at the GUI computer the inverter s modem answers the call and initiates a 9600 baud serial connection effectively as i
26. 2 Minimum Clearance 152315 Rev C Layout Options Minimum Dimension of Base Approximately 9 ft by 7 ft 2 7 m x 2 1 m BASE Concrete Floor or Pad Approximately 9 ft by 7 ft 2 1 m x 2 7 m 36 Minimum Clearance 9 ft 2 7 m 12 Minimum Clearance AC Interface Enclosure Transformer Enclosure Conduit not to exceed 15 T 12 Communications Minimum Enclosure Clearance THU DC Interface Enclosure 12 Minimum Clearance s 361 m TE nverter Minimum Clearance Clearance Enclosure 36 Minimum Clearance lt 7ft 21 m Figure 2 2 1005 Layout Option 152315 Rev C 2 7 Planning Conduit Penetration The following illustrations show the recommended locations for electrical conduit entry into the PV100S enclosures These drawings are to be used for system planning purposes such that the shaded areas are representative of the maximum allowable area and location in which electrical conduit may penetrate the enclosures of the PV100S see Figure 2 3 through Figure 2 8 Xantrex recommends a standard trade size conduit knock out set for cutting punching the PV100S enclosures and panels for conduit entry Communications Encl
27. 232 Fiber Optic Converter configured for a PC a DB25 to DB25 gender changer and DB25 to DB9 Serial Cable Determine which communications options are required for the installation and procure the appropriate service or phone access The personal computer to be used with this unit must have the appropriate hardware as well such as a 56K modem for dial up connection or a Network Interface Card NIC for a LAN connection Utility Side Isolation Transformer Requirements The PV100S is supplied with a custom high efficiency isolation transformer as part of the AC interface transformer assembly The utility side windings of the isolation transformer are configured Wye and must match the voltage at the utility inter tie The PV100S is a balanced three phase current sourcing inverter and only operates with the presence of a stable utility voltage The transformer is also supplied with a neutral connection on the utility interconnect Connection of this 2 4 152315 Rev C Electrical Diagrams and Schematics utility side neutral does not affect the operation of the inverter however connection of the neutral on the inverter side does affect the operation and must be left floating or disconnected Single phase grounded loads which may be present between the transformer and utility will maintain their existing ground reference at the utility distribution transformer CAUTION Equipment Damage If the Isolation Transformer T6 X0 neutral te
28. 32 Fiber Optic Converter configured for ethernet and SA2 Surge Arrestor and requires access to a local analog phone line Plain Old Telephone Service POTS Wireless Kit uses a GSM Wireless Modem to access wireless phone service e Ethernet LAN Kit uses a data communication device to enable the unit to connect to a local area network 2 Direct Connect This method is used for troubleshooting It uses a RS232 Fiber Optic Converter configured for a PC a DB25 to DB25 gender changer and a DB25 to DB9 Serial Cable Software is included to provide a graphic user interface that relates important system information This software 15 called Xantrex Solar Graphic Interface GUI See Computer Communications with the PV100S in the PV100S 100 kW Grid tied Photovoltaic Inverter Operation and Maintenance Manual for additional information The GUI can dial up the inverter and receive fault report calls from it through a standard Hayes compatible landline modem When the GUI initiates a call through the modem at the GUI computer the inverter s modem answers the call and initiates a 9600 baud serial connection effectively as if the GUI was connected directly Or if the inverter experiences a fault it will initiate a call to the GUI and report the fault details PC Connection Methods The personal computer can be connected to the PV100S the following ways Important Ensure the appropriate service has been established before proceed
29. 5 Rev C Communication Features AC and DC Disconnect Switches Both AC and DC Interface Enclosures are equipped with lockout hasps for personnel safety The enclosure doors should not be opened while the PV100S is operating The switch handles and shafts provide a door interlock for both the AC and DC interface enclosures The doors cannot be opened when the switch is in the ON position The DC Disconnect switch 18 equipped with an auxiliary contact block which enables the switch to be used as a load break DC disconnect In the event the DC Disconnect switch is opened while the PV100S is processing power from the PV array the early break contact block will signal the CCU2 Converter Control Unit 2 to stop processing power prior to the opening DC Disconnect switch Additionally opening the DC Disconnect switch will cause the PV100S to execute an immediate orderly shutdown open both the main AC and DC contactors and report a PV disconnect fault on the LCD of the UFCU 4 DC Disconnect AC Disconnect Switch Switch DC Interface Enclosure AC Interface Enclosure Figure 1 4 AC and DC Disconnect Switches Communication Features 152315 Rev C The PV100S provides two types of information to the user system status and or fault information and data logging information System status and fault information can be accessed using the Universal Front Panel Control Unit UFCU or a personal computer usin
30. CT ENCLOSURE TRANSFORMER ENCLOSURE MAIN CONVERTER ENCLOSURE PV DISCONNECT ENCLOSURE E 200A w sw w 175A Fuses AC CONTACTOR 130uH 350A DEVICES 200 LC1F115 1754 H1 x TB4 690V 400A 1574 gt 52 F4 E 1 480 24 e H ui sra scs Lef 2 VOLTS AC La 8 He 3 PHASE 2 76 4 SYSTEM c ls al brr ile JA 6 H3 lt CUSTOMER y SUPPLIED wu 15000 lt lt IPM M ss 13 c3 H ate SH 5 MATRIX GND NETS NU SNUBBER 4 NS lu ate toe 9 CUSTOMER l a a SUPPLIED u 8 AT EN SHT 3B4 480V 208V 400VA _ 24 5 CCU2 P amp 4 l n PV SENSE F25 5 AMP ju SHT 353 1 1 2 PV PV PV GND zr eoim i or xe RUNE SNC 4 mS SINGLE POINT TO F15 10 EARTH GROUND 2 1 C9 MA E TB8 4 CONTACTOR CONTROL 1 SHT 282 246 CONTROL SHT 207 LINE SENSE 277 10 Aje 13 CU2 P1001 6 2 1001 2 gt SHT 3 1 CCU2 P1001 4 A VE ENSION
31. L OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION b ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE WHETHER DIRECT INDIRECT CONSEQUENTIAL OR INCIDENTAL WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER S RISK Date and Revision May 2005 Revision C Part Number 152315 Rev C Contact Information Telephone 1 800 670 0707 toll free North America 1 360 925 5097 direct Fax 1360 925 5143 direct Email customerservice xantrex com Web www xantrex com About This Manual Purpose The purpose of this Planning and Installation Manual is to provide explanations and procedures for planning and installing the PV100S 100 kW Grid Tied Photovoltaic Inverter Scope The Manual provides safety guidelines detailed planning and setup information and procedures for installing the inverter Audience The Manual is intended for use by anyone who plans to construct or install a system involving the PV100S 100 kW Grid Tied Photovoltaic Inverter Installers must meet all local and state code requirements for licensing and training for the installation of Electrical Power Systems with AC and DC voltage to 600 volts Organization This Manual is organized into four chapters Chapter 1 Introduction provides information about the features and functions of the 1005 100 kW Grid Tied Photovoltaic Inverter Chapter 2 Planning pr
32. S xantrex s Eccles T3 T4 AND T5 PIN OUT v ENGR BY BEccles SCHEMATIC APPLICATION S iin 37 SYSTEM 1005 480 WEDSe BY 8 7 6 5 4 3 2 Figure A 2 PV100S 480 Schematic for Main Power Distribution 152316 E1 A 4 152315 Rev C Appendix A Schematics 91625 4 8 7 6 5 4 5 2 1 NOTES CONTROL POWER DISTRIBUTION UPPER SS SS SS Mee MITTERE ee eS ee CONTROL POWER SHT 185 S dn tare ME 208V 24N 150 2 H xt CCU2 P5 4 F18 2 E MHIL Se Zinet oe CCU2 P5 1 SHT N n 51 15 0 DRIVER 1 1 88 SHT 305 DC INTERFACE ENCLOSURE IN 3 AGND BoaRD P1 5 JO E K2 COIL 120VAC ad m gt a OS SE 4 5 MAIN ENCLOSURE DOOR c2 E noa 3r XE laps SWITCH 1 HL o L ON OFF 10 7 AC CONTACTOR 5 INDUCTOR CONTROL M 185 n m x2 F2
33. Smart choice for power a ntrex 1005 208 1005 480 Planning and Installation Manual PV100S 100 kW Grid Tied Photovoltaic Inverter www xantrex com Smart choice for power xa ntrex PV100S 100 kW Grid Tied Photovoltaic Inverter Planning and Installation Manual About Xantrex Xantrex Technology Inc is a world leading supplier of advanced power electronics and controls with products from 50 watt mobile units to 1 5 MW utility scale systems for wind solar batteries fuel cells microturbines and backup power applications in both grid connected and stand alone systems Xantrex products include inverters battery chargers programmable power supplies and variable speed drives that convert supply control clean and distribute electrical power Trademarks PV100S 100 kW Grid Tied Photovoltaic Inverter is a trademark of Xantrex International Xantrex 15 a registered trademark of Xantrex International Other trademarks registered trademarks and product names are the property of their respective owners and are used herein for identification purposes only Notice of Copyright PV100S 100 kW Grid Tied Photovoltaic Inverter Planning and Installation ManualO May 2005 Xantrex International All rights reserved Disclaimer UNLESS SPECIFICALLY AGREED TO IN WRITING XANTREX TECHNOLOGY INC MAKES NO WARRANTY AS TO THE ACCURACY SUFFICIENCY OR SUITABILITY OF ANY TECHNICA
34. USA
35. ant Outdoor installations require that all conduit fittings interfacing with the 1005 be NEMA 4 rated To install the conduits 1 Determine the conduit penetration locations in the Main Inverter Enclosure and the AC interface transformer assembly See Figure 2 3 on page 2 8 through Figure 2 5 on page 2 9 2 Install appropriately sized conduit based upon system layout and required codes between the main inverter and the AC interface transformer assembly For ease of conduit installation the access panels on both the main inverter and the AC interface transformer assembly can be removed 3 Determine all remaining conduit penetration locations in the AC Interface enclosure DC Interface Enclosure and Communication Enclosure See Figure 2 3 on page 2 8 through Figure 2 8 on page 2 10 4 Install all remaining appropriately sized conduit interfacing for the AC Interface Enclosure DC Interface Enclosure and Communication Enclosure based upon system layout and required codes Conduit Figure 3 9 Conduit Installation 152315 Rev C 3 9 Installation Wiring General wiring methods and materials shall be in accordance with the National Electrical Code ANSI NFPA 70 When sizing conductors and conduits interfacing to the 1008 both shall be in accordance with the National Electric Code ANSI NFPA 70 as well as all state and local code requirements WARNING Shock Hazard The PV100S enclosures contain exp
36. ay result in a risk of fire electric shock injury to persons and will void the warranty Do not attempt to operate the 1005 if it has been dropped or received more than cosmetic damage during transport or shipping If the PV100S is damaged or suspected to be damaged see the Warranty for this unit in the PV100S 100 kW Grid Tied Photovoltaic Inverter Operation and Maintenance Manual To reduce the risk of electrical shock lock out and tag the PV100S before attempting any maintenance service or cleaning Follow these instructions to ensure your safety while working with the PV100S Safety Equipment Authorized service personnel must be equipped with standard safety equipment including the following Safety glasses Ear protection Steel toed safety boots Safety hard hats Padlocks and tags Appropriate meter to verify that the circuits are de energized 600 Vac and DC rated minimum Check local safety regulations for other requirements Wiring Requirements viii 1 wiring methods and materials shall be in accordance with the National Electrical Code ANSI NFPA 70 When sizing conductors and conduits interfacing to the 1005 both shall be in accordance with the National Electric Code ANSI NFPA 70 as well as all state and local code requirements Use copper conductors only with insulation rated for 90 C The 1005 has three phase output It is marked with this symbol 2j The AC power conduct
37. ck local regulations for their requirements regarding the connection of these neutrals WARNING Lethal Voltage Grounding the neutral of a Wye wound transformer may create an open delta condition depending on the utility configuration This condition may keep the PV100S from detecting a loss of phase condition on the utility system which may allow potentially lethal voltage to be present on the open phase wiring Wiring Specific This section provides information for connecting the AC and DC conductors ground conductors and AC Sense Harness AC Connections To connect the main inverter to AC interface transformer assembly 1 Remove the access panels from the front of both the Main Inverter Enclosure and the Transformer Enclosure Additionally open the front door to the Main Inverter Enclosure 2 Routethe AC power conductors A B C phase cables and ground conductor through the conduit between the main inverter to the AC interface transformer assembly T6 Route the AC cables from the Inverter Enclosure through the conduit to the 1 Lo Transformer Enclosure Inductor Enclosure AC Sense Harness partially hidden below AC Cables Figure 3 12 Route AC Cables through the Conduit Transformer Enclosure 3 14 152315 Rev C Wiring Specific 3 Inaddition to the power conductors route the AC Sense Harness assembly Xantrex P N 1 152403 01 between the main inverter to the AC inter
38. ck the front door on the main inverter 1 Usethe 7 mm triangle key provided with the unit a Insert the key in the lock and turn counterclockwise to open clockwise to lock b Pull front door open from the right side Main Inverter Front Door Lock Main Inverter Front Door Lock Figure 3 4 Inverter Enclosure Access Doors 3 6 152315 Rev C 4 E Figure 3 5 AC Interface Access Door Door Latches m 4 Figure 3 6 DC Interface Access Door 152315 Rev C Door Latches Opening or Closing Access Doors To Open Access Door 1 Confirm that the AC Disconnect Switch handle is placed in the OFF Open position prior to opening the door Loosen the bolts on door latches and slide away from the door Pull open from right side To Close Access Door l Confirm that the AC Disconnect Switch handle is placed in the OFF Open position prior to closing the door Close the door and slide the latches back over the edge of the door Tighten the bolts on door latches To Open Access Door l Confirm that the DC Disconnect Switch handle is placed in the OFF Open position prior to opening the door Loosen the bolts on door latches and slide away from the door Pull open from the left side To Close Access Door l Confirm that the DC Disconnect Switch handle is placed in the OFF Open position prior to closing the door Close the door and slid
39. drill and masonry bits e Trade size conduit knock out set The PV100S is shipped partially assembled in two separate shipping crates and one cardboard box C One crate is the main inverter and is marked 1 152311 01 1 The other crate is the AC Interface Enclosure and transformer assembly and 15 marked 1 152378 01 208 Vac or 1 152324 01 480 Vac The cardboard box contains one of the three remote connection kits POTS Connection 1 152674 01 e Wireless Connection 1 152659 01 Ethernet Connection 1 152658 01 WARNING Heavy Equipment The main inverter weighs approximately 1000 Ibs Both versions 208 Vac and 480 Vac of the AC Interface Enclosure and transformer assembly weigh approximately 1400 Ibs Attempting to lift the equipment by other than the recommended lifting points may damage the equipment or present a personnel safety hazard and void the warranty Keep all the doors closed and latched when moving the enclosures Leaving the door latches unsecured may result in damage to the unit and void the warranty 3 2 152315 Rev C Unloading Moving the PV100S CAUTION Equipment Damage To move the PV100S use a forklift that has a sufficient lift capacity and has a 26 fork span To move the PV100S while it is still inside the shipping crates 1 Place the forks of the forklift below the shipping crate at the points specified on the shipping crate 2 Liftthe main inverter and the
40. e door is again closed and the switch is in the engaged position It is required that the PV100S main enclosure door must be locked during normal operation The door interlock switch does NOT remove all hazardous voltages from inside the inverter Before attempting to service the PV100S follow the de energize Lockout and Tag procedure on page x 152315 Rev C 1 7 Introduction WARNING Shock Hazard Disengaging the main enclosure door interlock switch does NOT remove all hazardous voltages from inside the inverter Before attempting to service the PV100S follow the de energize Lockout and Tag procedure on page x On Off Switch The PV100S 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 an immediate controlled shutdown of the PV100S and opens both the main AC and DC contactors within the unit The main AC and DC contactors cannot be closed unless the switch is in the ON position The PV100S is prevented from being restarted until the ON OFF switch is turned back to the ON position WARNING Shock Hazard Turning the ON OFF switch to the OFF position does NOT remove all hazardous voltages from inside the inverter Before attempting to service the 1005 follow the de energize Lockout and Tag procedure on page x Figure 1 3 On Off Switch 15231
41. e feet of the PV100S enclosures per the National Electric Code ANSI NFPA 70 The single point ground for the system 1s to be made at the AC ground bar TB2 in the AC Interface Enclosure System Grounding r AC Ground Bar TB2 to be used for the Single Point Ground P EE AC Interface Enclosure Figure 3 10 Single point Ground TB2 Ground Bar 152315 Rev C Chassis Ground Array Grounding Wiring General The chassis ground is a copper bus bar in the Main Inverter Enclosure and has 3 8 16 bolts for terminating the AC ground The ground conductor size depends on the size of the main circuit breaker NEC Table 250 122 Ninth Edition requires that the ground conductor be at least 3 AWG for a 400 A circuit breaker and 6 AWG for a 200 A circuit breaker Torque connections to ground bar in the Main Inverter Enclosure as follows e PVI100S 208 420 1 16 47 5 Nm e PV100S 480 420 in Ibs 47 5 Nm The equipment ground on the PV100S is marked with this symbol AC Ground Bar TB1 to be used for the Chassis Ground Main Inverter Enclosure Figure 3 11 Chassis Ground Bar TB1 NEC Article 690 41 42 Ninth Edition requires the PV array to be earth grounded The PV100S chassis is also bonded to the PV safety ground terminal block System Neutral Requirements The PV100S is designed to be installed as a 4 wire system As required by the UL 1741 listing a neutral conductor from the utility int
42. e the latches back over the edge of the door Tighten the bolts on door latches 3 7 Installation Transformer Access Panel To Remove the Access Panel Loosen and remove the 1 4 self tapping sheet metal screws x6 To Replace the Access Panel Replace and tighten the 1 4 self tapping sheet metal screws Inductor Access Panel To Remove the Access Panel Use a Phillips screwdriver to loosen and remove the 1 4 20 Phillips round head bolts x8 To Replace the Access Panel Replace and tighten the 1 4 20 Phillips round head bolts Figure 3 8 Inductor Access Panels 3 8 152315 Rev C Conduit Installation Conduit Installation Given the flexible nature of the system conduit installation will be dependent upon the final configuration of the system Procurement and installation of the conduit therefore is the responsibility of the installer Since the layout will be dependent upon the location available for the installation and the size of the conductors used specific conduit size and type must be pre determined by the installer before the actual installation See Conductor and Conduit Sizing on page 2 11 for instructions on how to determine the size of the conductors and conduits to be used Once the size of the conductors and conduits has been determined follow the instructions below for installing the conduits Be sure to consult the NEC Handbook and any local codes to ensure code compliance Import
43. ed to ensure the safe and efficient operation and servicing of the PV100S Adequate space must be provided around the unit for ventilation and access during servicing If locating the unit indoors ambient air temperature cannot exceed the maximum temperature for which the unit is rated Maintain a minimum clearance of 12 inches on both sides and 6 inches behind the Main Inverter Enclosure and the AC Interface Enclosure for proper cooling fan operation Maintain a minimum clearance of 36 inches in front of the main inverter access door the Transformer Enclosure access panel and the AC interface access door for maintenance and serviceability See Figure 2 1 on page 2 6 and Figure 2 2 on page 2 7 for illustrations of these clearance requirements Ifthe PV100S is to be installed indoors and external air is used for ventilation the required cubic feet per minute CFM rate must be no less than 1000 CFM This assumes the temperature inside the building 15 allowed to rise only 10 above the outside temperature Therefore the maximum allowable outside ambient temperature is 50 50 minus 10 equals 40 Maximum Ambient Temperature If air conditioning 15 planned for an indoor installation the heat load of the PV100S is 1800 BTU Hour at full load 2 3 Planning Ground Requirements This product is intended to be installed as part of a permanently grounded electrical system per National Electric Code ANSI NFPA 70
44. eing referenced individually e When the both models are being referenced together they will be referred to as the PV100S 152315 Rev C About This Manual Abbreviations and Acronyms ANSI CCU2 CFM CW DSP FPGA GUI IEEE IGBT IPM kemil LAN LCD NFPA PBX PSL POTS PV UFCU Related Information American National Standards Institute Converter Control Unit 2 Cubic Feet per Minute Clockwise Digital Signal Processor Field Programmable Gate Array Graphical User Interface Institute of Electrical and Electronics Engineers Insulated Gate Bipolar Transistor Intelligent Power Module 1000 circular mils Local Area Network Liquid Crystal Display National Fire Protection Association Private Branch Exchange Phase Shift Loop Plain Old Telephone Service Photovoltaic Universal Frontpanel Control Unit You can find more information about Xantrex Technology Inc as well as its products and services at www xantrex com 152315 Rev vi Important Safety Instructions SAVE THESE INSTRUCTIONS DO NOT DISCARD This manual contains important safety instructions for the PV 1005 that shall be followed during installation and maintenance procedures N WARNING Shock Hazard Read and keep this Planning and Installation Manual for future reference Before installing PV100S either model read all instructions cautionary markings and all other appropriate sections of this manual Failure to adhere to these warnings c
45. en the utility connection circuit breaker 3 Install lockout devices on the utility connection circuit breaker and DC disconnect switch Interconnection Standards Compliance 152315 Rev C The PV100S has been tested and listed by Underwriters Laboratories to be in compliance with UL1741 Static Inverters And Charge Controllers For Use In Photovoltaic Power Systems as well as IEEE 929 2000 Recommended Practice For Utility Interface of Photovoltaic PV Systems IEEE 929 2000 provides guidance regarding equipment and functions necessary to ensure compatible operation of photovoltaic systems which are connected in parallel with the electric utility UL1741 is the standard applied by Underwriters Laboratory to the PV100S to verify it meets the recommendations of IEEE 929 2000 Refer to both documents for details of these recommendations and test procedures xi xii Contents Important Safety Instructions vii 1 Introduction Description of the PVIOOS 1 2 System Specifications 1 4 Electrical Specifications 1 4 Over Voltage Under Voltage and Frequency Ranges 1 4 System Ground Requirements 1 5 System Neutral Requirements 1 5 Utility Side Iso
46. erconnect must be terminated at TB6 within the AC Interface Enclosure to ensure that the AC voltage sensing circuit can perform an individual phase voltage line to neutral measurement The function of the neutral connection is to provide a point of reference for measurement purposes that is essentially at ground potential No power will flow through the neutral conductor Utility Side Isolation Transformer Requirements 152315 Rev C The PV100S is supplied with a custom high efficiency isolation transformer as part of the AC interface transformer assembly The utility side windings of the isolation transformer are configured Wye and must match the voltage at the utility Installation inter tie The PV100S is a balanced three phase current sourcing inverter and only operates with the presence of a stable utility voltage The transformer 1s also supplied with a neutral connection on the utility interconnect Connection of this utility side neutral does not affect the operation of the inverter however connection of the neutral on the inverter side does affect the operation and must be left floating or disconnected Single phase grounded loads which may be present between the transformer and utility will maintain their existing ground reference at the utility distribution transformer CAUTION Equipment Damage If the Isolation Transformer T6 X0 neutral terminal is tied to ground it will cause irreparable damage to the PV100S Che
47. erface transformer assembly 5 8 1 5 cm 29 73 7 cm x4 Figure 2 9 Main Inverter Anchor Bolt Pattern Not to scale 152315 Rev 2 13 Planning 29 E 17 f 73 7 cm 44 cm 25 63 5 cm 34 1 9 x6 Figure 2 10 AC Interface Transformer Anchor Bolt Pattern Not to Scale The floor or pad should either be pre drilled to accept masonry anchors or have pre installed anchoring bolts 2 14 152315 Rev Installation Chapter 3 Installation describes the procedures needed to install the 1005 100 kW Grid Tied Photovoltaic Inverter This section includes unpacking and moving instructions mounting instructions and cabling instructions Installation Equipment Required Unloading The following is a list of required tools and equipment to aid in the installation of the PV100S This list is not a comprehensive list but is intended to help identify the minimum recommended tools and equipment used during the installation e Forklift 26 minimum fork span and or pallet jack Claw hammer or pry bar Standard and metric socket set Standard and metric wrench set Standard Allen Hex wrenches 5 16 and 7 16 Large slip joint pliers e Standard and Phillips screwdrivers e Torque wrench with 0 600 in Ibs minimum range e Appropriate voltage meter 600 Vac and DC rated minimum Phase rotation meter 600 Vac rated minimum Hammer
48. f the GUI was connected directly Or if the inverter experiences a fault it will initiate a call to the GUI and report the fault details Communications Enclosure Enlargement RS232 FO Converter MultiTech 56K Modem 5 2 Surge Arrestor POTS connection option shown Figure 1 6 PC Connections in the Communications Enclosure 1 12 152315 Rev C Communication Methods POTS Access Figure 1 7 illustrates the PV100S connected remotely to a personal computer Outlet Phone Line Outlet 5 Figure 1 7 POTS Access Wireless Access Figure 1 8 illustrates the PV100S connected remotely to a personal computer using a wireless network Figure 1 8 Wireless Access 152315 Rev C 1 13 Introduction Ethernet LAN Access The 1005 can be remotely accessed through a local area network LAN Outlet LAN Outlet Router or Hub Figure 1 9 Ethernet LAN Access Direct Access Figure 1 10 illustrates the PV100S connected directly to a personal computer Figure 1 10 Direct Access 1 14 152315 Rev C Planning Chapter 2 Planning provides information to help plan the installation of the PV100S 100 kW Grid Tied Photovoltaic Inverter Planning Overview of 1005 Installation Planning Definition Components Location Clearance Conduits and Conductors 2 2 WARNING Shock Hazard Installations of th
49. face transformer assembly Prior to completing the installation of the AC Sense Harness secure the harness to the AC power conductors with nylon tie wraps so it does not touch the surfaces ofthe L1 inductor Failure to secure the AC Sense Harness away from these surfaces may cause deformation of the harness insulation and possibly damage due to the excessive heat generated by the L1 inductor Prior to completing the installation of the AC Sense Harness secure the harness to the AC power conductors with nylon tie wraps Figure 3 13 Tie wraps on the AC Sense Harness 4 Connect AC power conductors in the Transformer Enclosure at the T6 X1 A phase T6 X2 B phase and T6 X3 C phase bus bars using 3 8 16 hardware Connect the ground conductor in the AC Interface Transformer Enclosure at TB2 Cables to these terminals must use a crimp on type ring terminal or compression type lug Tighten these connections to a torque value of 420 in Ibs 47 5 Nm Ground Cable from T6 X3 6 2 T6 X1 Main Inverter Enclosure r TB2 Ground Bar AC Interface Enclosure Transformer Enclosure Figure 3 14 AC Terminal Connections in the AC Interface Transformer Enclosure 152315 Rev C 3 15 Installation 5 Connect the AC power conductors in the Main Inverter Enclosure at TB4 A A phase 4 B phase and TB4 C C phase with a box connector using a 5 16 Hex screw This hardware should be tightened to a torque value
50. g 152315 Rev C wiring methods and materials shall be in accordance with the National Electrical Code ANSI NFPA 70 When sizing conductors and conduits interfacing to the PV100S both shall be in accordance with the National Electric Code ANSI NFPA 70 as well as all state and local code requirements Large gauge wire must conform to the minimum bend radius dependent upon the wire gauge refer to the National Electric Code Article 373 6B Ninth Edition CAUTION Equipment Damage Be careful to keep the wire bundles away from any sharp edges which may damage wire insulation over time The following provides information on sizing the conductors and conduits for the system To calculate the proper conduit size 1 Determine the required cable ampacity 2 Determine the conduit length between the inverter and the transformer 3 Determine the proper size for the cable according to the allowable ampacities indicated by NEC Table 310 16 Ninth Edition 4 Determine the proper size for the conduit The following is an example of the steps outlined above Assumptions were made in this example which may not match your application and the resulting design may not comply with all code requirements Consult a licensed electrician on recommendations for specific installations Step 1 Determine the required cable ampacity AC Phase Cables from Inverter to Transformer 100 kW 208 1 732 277 5 Arms full load current
51. g the Xantrex Solar Graphic User Interface GUI software Data logging requires the use of a PC using the GUI software Introduction System Status and Fault Reporting Data Logging Basic system status and all fault conditions rising from within the PV100S are reported to the UFCU The unit stores the time and details of all faults in non volatile memory The 4 line LCD will display a hexadecimal value and a brief text description of the fault This information can also be accessed using a personal computer using the GUI software either directly or remotely Alternatively the fault reporting can be accomplished using the optional Fax Modem Types of status information include Current Operating State or Goal State Fault Code if applicable Inverter State Line Voltage and Current Inverter Matrix Temperature Inverter Power State PV Voltage and Current PV Power Grid Frequency e Peak Power Tracker Enabled The inverter stores data values and software metrics for debugging These values are stored within the CCU2 controller board in non volatile memory Data logging requires the use of a PC connection using the Xantrex Solar Graphic User Interface GUI software The data logging features include the following e Operational Values Internal Metrics Data Log Acquisition e Graphic Data Analysis Fault Log Acquisition e Software Upgrade e Accumulated Values e Configurable Parameters
52. g the incoming power at the utility main circuit breaker 2 Open lockout and tag the AC Disconnect Switch S1 on the AC Interface Enclosure See Figure 1 4 on page 1 9 for the location of the AC Disconnect Switch 3 Open lockout and tag the DC Disconnect Switch S2 on the DC Interface Enclosure See Figure 1 4 on page 1 9 for the location of the DC Disconnect Switch 4 Usinga confirmed accurate meter verify all power to the inverter is de energized A confirmed accurate meter must be verified on a known voltage before use Ensure that all incoming energy sources are de energized by checking the following locations a Inverter Terminals TB4 A TB4 B TB4 C Phase A B C See Figure 3 15 on page 3 16 b Utility Terminals Bottom of S1 2T1 S1 4T2 S1 6T3 See Figure 3 16 on page 3 16 c Terminals Bottom of TB3 1 TB3 2 TB3 3 PV GND See Figure 3 19 on page 3 19 152315 Rev C Safety De Energize Isolation Procedure The following procedure should be followed to de energize the PV100S for maintenance AN WARNING The terminals of the DC input may be energized if the PV arrays are energized In addition allow 5 minutes for all capacitors within the main enclosure to discharge after disconnecting the PV100S from AC and DC sources To isolate the PV100S 1 Turn the ON OFF switch to the OFF position 2 Open the DC interface disconnect switch 3 Open the AC interface disconnect switch 4 Op
53. has the appropriate hardware installed to support this feature 1 e Network Interface Card NIC 2 Open the Communications Enclosure and plug the LAN cable 5 cable into the RJ45 Port of the SA2 Surge Arrestor marked UNPROTECTED 3 Install the GUI Software following the instructions in the PV100S 100 kW Grid tied Photovoltaic Inverter Operation and Maintenance Manual 4 Usethe GUI to setup the connection information a From the GUI Main page click on the inverter icon for the inverter to be setup b Click on lt COMMUNICATION gt c Select CONNECT TO IP ADDRESS in the drop down menu d Fill m the IP address provided by the Internet Service Provider e Click on the CONNECT button f Click on the lt gt button g Repeat this procedure for each unit to be added to local area network 152315 Rev C Direct Connection PC Communications The direct connection provides the means to use the features of the GUI by connecting a PC directly to the CCU2 This allows field personnel to monitor and control the inverter from a nearby laptop computer directly connected by a serial cable The computer connects to the inverter directly through one of its serial COM ports running at 9600 baud The installed RS232 FO Converter will have to be removed and minor re wiring will be required The RS232 FO Converter kit Xantrex p n 1 152624 01 1s required for this connection to change the communication protocol from ethe
54. hown in this photo Figure 3 18 AC Terminal Connections from the Utility 3 18 152315 Rev C Wiring Specific PV Array Connections To make the connections from the PV Array combiner to DC Interface enclosure Remove the door clamps and open the door to the DC Interface Enclosure 2 Route the PV Array cables conductors POSitive NEGative PV and PV GND through the conduit to the DC Interface Enclosure entering on the underside 3 DC power conductor terminations are made at the TB3 1 POS DC and TB3 2 NEG DC and TB3 3 PV Gnd locations See Figure 3 19 4 Terminations for the POSitive NEGative and GND conductors within the DC Interface enclosure at the TB3 locations are made with box connector using a 7 16 Hex Allen screw The hardware should be tightened to a torque value of 500 56 5 Nm for both the PV100S 480 and PV100S 208 systems 5 Close the door to the DC Interface Enclosure and replace the door clamps GrouND TB3 3 PV NEGative Cable TB3 2 PV POSitive Cable TB3 1 Conduit entry from PV Array Figure 3 19 PV Array Cable Routing and Terminations 152315 Rev C Installation PC Communications Personal computers can be used to access the system status and programming features of the PV100S A computer can be connected either directly or remotely 1 Remote Connect uses one of the three kits below POTS Kit uses a MultiTech 56K Modem RS2
55. ing Also ensure the personal computer to be used has the appropriate hardware to support the installed feature such as a phone line wireless phone service or local area network POTS Connection e Wireless Connection e Ethernet LAN Connection Direct Connection 3 20 152315 PC Communications Establishing a POTS Connection 152315 Rev C Important A direct analog phone line to the local phone service is required to use this feature The phone line used for PV100S communication cannot be routed through a Private Branch Exchange PBX unless an analog PBX card is used To connect a personal computer using the POTS Connection 1 2 3 Ensure the personal computer to be used has 56K modem installed Open the Communications Enclosure Plug the local phone line into the RJ11 port on the SA2 Surge Arrestor marked UNPROTECTED SA2 Surge Arrestor MultiTech 56K Modem Figure 3 20 Telephone Cable Routing 4 Install the GUI Software following the instructions in the PV100S 100 kW Grid tied Photovoltaic Inverter Operation and Maintenance Manual Use a Terminal Emulation program on the PC to access the modem See the GUI Help Menu Communication by Modem for instructions on setting up the Terminal Emulation program on the computer See also Connect to Telephone Number and Connect to Remote Inverter by Modem for additional information Use the GUI to setup the connection informat
56. ion a From the GUI Main page click on TOOLS b Click on the inverter icon for the inverter to be setup c Click on the INVERTER DATA gt d Click on the CONNECTION tab e Fill out the information required on the lt GENERAL gt page the TELEPHONE FAULT CONFIGURATION gt page and the TELEPHONE CONFIGURATION page Installation Establishing Wireless Connection Important Ensure the Wireless service has been established with the local service provider before proceeding To connect a personal computer using the GSM Wireless modem 1 Ensure the personal computer has the appropriate hardware installed to support this feature 2 Install the GUI Software following the instructions in the PV100S 100 kW Grid tied Photovoltaic Inverter Operation and Maintenance Manual 3 Usethe GUI to setup the connection information a From the GUI Main page click on lt TOOLS gt b Click on the inverter icon for the inverter to be setup c Click on the INVERTER DATA gt d Click on the CONNECTION tab e Fill out the information required on lt GENERAL gt page the TELEPHONE FAULT CONFIGURATION gt page and the TELEPHONE CONFIGURATION gt page Establishing an Ethernet LAN Connection Important Ensure the local area network has been established with the local service provider before proceeding To connect a personal computer using the Ethernet LAN Connection 1 Ensure the personal computer
57. is equipment should only be performed by qualified technicians Installers must meet all local and state code requirements for licensing and training for the installation of Electrical Power Systems with AC and DC voltage to 600 volts Planning for a system requires complete understanding of all the components that are involved to successfully install the PV100S to meet the required national state and local codes A power system such as the PV100S is a collection of devices designed to supply AC power to the utility grid from a solar energy PV source All types of grid tied inverter installations residential or industrial share common components This chapter describes each component and suggests the minimum requirements for a safe installation The PV100S 100 kW Grid Tied Photovoltaic Inverter is designed to be installed in either an indoor or outdoor location The PV100S must be anchored to a level concrete floor or pad Ideally the AC interface enclosure transformer assembly is placed on the left side of the Main Inverter Enclosure The AC interface enclosure transformer assembly may be co located adjacent to the left side of the Main Inverter Enclosure up to but not exceeding 15 feet away Adequate ventilation and service access must be taken into consideration when installing the PV100S See Ventilation and Serviceability Requirements on page 2 3 for specific clearance requirements and ambient temperature requirements
58. lanning Layout Options The PV100S is shipped as two separate assemblies and can be arranged as shown in Figure 2 1 or Figure 2 2 The PV100S can be arranged in a number of different system layout options to fit specific site requirements The AC interface transformer assembly may be co located adjacent to the left side of or behind the Main Inverter Enclosure up to and not exceeding 15 feet away Given the flexibility to co locate the AC interface transformer assembly to fit a desired system layout the interconnect AC power conductors and conduit between the Main Inverter Enclosure and the AC interface transformer assembly are to be supplied by the installer See Figure 2 1 and Figure 2 2 depicting two options for locating the AC interface transformer assembly adjacent to the main inverter Minimum Dimension of Base Approximately 12 ft by 6 ft 3 6 m x 1 8 m Communications BASE Concrete Floor or Pad Enclosure Approximately 12 ft by 6 ft 3 6 m x 1 8 m 1 8 6 Minimum Clearance AC DC Interface Interface Transformer Enclosure Enclosure Enclosure 36 Minimum Clearance Inverter Enclosure Minimum Clearance 15 Max Distance from Inverter Minimum Clearance 0 Figure 2 1 PV100S Layout Option A 2 6 36 Minimum learance 1
59. lation Transformer Requirements 1 5 Environmental Specifications 1 6 Operator Interface Controls 1 7 Main Enclosure Door Interlock Switch 1 7 On Off Switch 1 8 AC and DC Disconnect Switches 1 9 Communication Features 1 9 System Status and Fault Reporting 1 10 Data Logging 1 10 Communication Methods 1 11 Universal Front Panel Control Unit UFCU 1 11 PC Connection Methods 1 12 POTS Access 1 13 Wireless Access 1 13 Ethernet LAN Access 1 14 Direct Access 1 14 2 Planning Overview of PV100S Installation 2 2 PV Planning 2 3 Ventilation and Serviceability Requirements 2 3 Ground Req
60. ming the following verification steps on the PV100S review all safety requirements and procedures outlined in this manual and on any cautionary markings on the components within the system Inspect the following items prior to completion of the installation 1 Visually inspect all the mechanical connections This would include both electrical conduit fittings as well as enclosure anchoring and seismic bracing if required 2 Visually inspect the electrical connections and verify proper tightness of all terminations 3 Visually inspect the Isolation Transformer Wye Wye connections and ensure the T6 X0 neutral connection is left disconnected or floating 4 Perform corrective actions if required 152315 Rev C Visual Inspection of Mechanical Connections Visual Inspection of Mechanical Connections To perform a visual inspection of the PV100S mechanical connections 1 Ensure that the AC and DC Disconnect Switches well as any utility interconnect circuit breakers or main disconnect switches are opened Ensure all anchor bolts and any required seismic bracing is properly tightened and in place Remove the wiring access panels and front covers from the AC Interface Transformer assembly and Main Inverter Inductor Enclosure Remove the latches and open the doors of the Main Inverter Enclosure the AC and DC Interface Enclosures and Communication Enclosure and inspect Verify all wire conduit fittings and connections a
61. mpression type lug and should be tightened to a torque value of 228 in lbs 25 7 Nm for model PV100S 208 and model PV100S 480 See Figure 3 18 on page 3 18 for the location of these terminals The DC power conductor wiring interfacing with the DC terminals at TB3 1 TB3 2 and TB3 3 to be tightened to a torque value of 500 in lbs 56 5 Nm for model PV100S 208 and model PV100S 480 These terminals will accept a conductor size of 500 kcmil Keep these cables together as much as possible and ensure that all cables pass through the same knockout and conduit fittings thus allowing any inductive currents to cancel See Figure 3 19 on page 3 19 for the location of these terminals This product is intended to be installed as part of a permanently grounded electrical system per the National Electric Code ANSI NFPA 70 A copper ground rod must be installed within three feet of the PV100S enclosure This is the single point earth ground for the inverter system The single point ground for the system 1s to be made at the AC ground bus bar TB2 in the AC Interface Enclosure This terminal requires the use of a crimp on type ring terminal or compression type lug and should be tightened to a torque value of 420 in lbs 47 5 Nm for model PV100S 208 and model PV100S 480 The equipment grounds on the PV100S are marked with this symbol AC overcurrent protection for the utility interconnect Grid tie must be provided by the installers as
62. or wiring interfacing with the AC terminals in the Transformer Enclosure are located at T6 X1 T6 X2 and T6 X3 These terminals should be tightened to a torque value of 420 in lbs 47 5 Nm for model PV100S 208 and model PV100S 480 Conductors terminated to these 152315 Rev C 152315 Rev C Safety terminals must use a crimp on type ring terminal or compression type lug The terminals are one bolt per pole See Figure 3 14 on page 3 15 for the location of these terminals The AC power conductor wiring interfacing with the AC terminals in the Main Inverter Enclosure are located at 4 4 and 4 C These terminals are to be tightened to a torque value of 275 in lbs 31 1 Nm for model PV100S 208 and model PV100S 480 The terminals will accept a conductor size of 350 kcmil See Figure 3 15 on page 3 16 for the location of these terminals The AC power conductor wiring interfacing with the AC terminals in the AC Interface Enclosure are located at S1 2T1 S1 4T2 and S1 6T3 These terminals should be tightened to a torque value of 310 in Ibs 35 0 Nm for model PV100S 208 and to a torque value of 115 in lbs 13 0 Nm for model PV100S 480 See Figure 3 16 on page 3 16 for the location of these terminals and the cautionary note on page 3 17 The AC neutral conductor from the utility 1s terminated in the AC Interface Enclosure at the TB6 Neutral terminal This terminal requires the use of a crimp on type ring terminal or co
63. orrect and complete Verification Verification Procedure Summary WARNING Electrocution Hazard This chapter describes specific steps to ensure the installation of the PV100S 100 kW Grid Tied Photovoltaic Inverter is correct and complete Failure to adhere to these warnings could result in severe shock or possible death Exercise extreme caution at all times to prevent accidents These installation instructions are for use by those familiar and skilled with high voltage procedures WARNING Shock Hazard The PV100S enclosures contain exposed high voltage conductors The enclosure doors should remain closed with the latches tightened except during installation maintenance or testing To reduce the risk of electric shock do not perform any servicing other than that specified in the installation instructions unless you are qualified to do so WARNING Lethal Voltage In order to remove all sources of voltage from the PV100S the incoming power must be de energized at the source This may be done at the utility main circuit breaker and by opening the AC disconnect and the DC disconnect switches on the PV100S Review the system configuration to determine all of the possible sources of energy In addition allow 5 minutes for the DC bus capacitors located on the ceiling of the cabinet to discharge after removing power The following procedures are intended to verify correct installation and proper wiring of the PV100S Prior to perfor
64. orrect torque value For specific torque values see Table 3 1 Terminal Wire Gauge Bolt Size and Torque Values on page 3 12 and Table 3 2 Terminal Wire Gauge Bolt Size and Torque Values on page 3 12 3 Verify the AC power conductors terminated at T6 X1 T6 X2 T6 X3 within the Transformer Enclosure are terminated correctly and properly sequenced 4 Ensure the neutral on the inverter side T6 X0 is left floating If the inverter side neutral is to ground the inverter will not function properly Also ensure that the neutral is not bonded to the isolation transformer frame Date Checks Completed Corrective Action Perform after initial inspection if required 1 Correct any necessary repairs pertaining to the previous inspection steps 2 Replace the wiring access panels to the AC interface transformer assembly and Main Inverter Enclosure 3 Replace the latches and close the doors of the Main Inverter Enclosure the AC and DC Interface Enclosures and communication enclosure 4 Ensure that the AC and DC Disconnect Switches as well as any utility interconnect circuit breaker or main disconnect circuit breaker are left open 4 4 152315 Rev C Schematics Appendix A contains useful schematics to aid with installation Schematics This page intentionally left blank A 2 152315 Rev C Appendix A Schematics AC INTERFACE ENCLOSURE TRANSFORMER ENCLOSURE
65. osed high voltage conductors The enclosure doors should remain closed with the latches tightened except during installation maintenance or testing These servicing instructions are for use by qualified personnel who meet all local and state code requirements for licensing and training for the installation of Electrical Power Systems with AC and DC voltage to 600 volts To reduce the risk of electric shock do not perform any servicing other than that specified in the installation instructions unless you are qualified to so Do not open the cabinet doors if extreme moisture is present rain or heavy dew WARNING Lethal Voltage In order to remove all sources of voltage from the PV100S the incoming power must be de energized at the source This may be done at the main utility circuit breaker and by opening the AC Disconnect and the DC Disconnect Switches on the PV100S Review the system configuration to determine all of the possible sources of energy In addition allow 5 minutes for the DC bus capacitors located on the ceiling of the cabinet to discharge after removing power CAUTION Equipment Damage When connecting external AC wires to the PV100S positive phasing sequence must be maintained throughout the installation process Refer to the system schematics in Appendix of this manual for proper phasing convention Important Take care to keep the wire bundles away from any sharp edges which may damage wire insula
66. osure xantrex AC Interface DC Interface Enclosure Enclosure AC Transformer d j Interface Enclosure A Enclosure Inductor 2 4 B Enclosure a j AC side view 3 of 1005 Front view of PV100S Figure 2 4 2 9 Figure 2 5 on page 2 9 Figure 2 6 2 10 D Figure 2 7 on page 2 10 E Figure 2 8 on page 2 10 Figure 2 3 Conduit Entry Figure Reference 152315 Rev C Conduit Penetration 6 15 cm h 2 5 cm 30 cm 1 s G 6 15 cm Figure 2 4 Inductor Enclosure Conduit Entry Left Side 2 5 cm e 15 12 30 4 j e 15 ii Figure 2 5 Transformer Enclosure Conduit Entry Right Side 152315 Rev C 2 9 Planning Backside of Transformer Enclosure partial view AC Disconnect Switch S1 1 2 5 8 20 cm 5 13 Figure 2 6 AC Interface Enclosure Conduit Entry Left Side 8 20 2 5 8 20 cm 2 5 Figure 2 7 DC Interface Enclosure Bottom Side 3 8 cm 1 2 5 10 5 27 5 t 1 2 5 cm Figure 2 8 Communications Enclosure Conduit Entry Bottom Side 152315 Rev C Conductor and Conduit Sizing Conductor and Conduit Sizin
67. ould result in severe shock or possible death Exercise extreme caution at all times to prevent accidents WARNING Shock Hazard The PV100S enclosures contain exposed high voltage conductors The enclosure doors should remain closed with the latches tightened except during installation maintenance or testing These servicing instructions are for use by qualified personnel who meet all local and state code requirements for licensing and training for the installation of Electrical Power Systems with AC and DC voltage to 600 volts To reduce the risk of electric shock do not perform any servicing other than that specified in the installation instructions unless you are qualified to do so Do not open the cabinet doors if extreme moisture 1 present rain or heavy dew WARNING Lethal Voltage In order to remove all sources of voltage from PV100S the incoming power must de energized at the source This may be done at the main utility circuit breaker and by opening the AC Disconnect and the DC Disconnect Switches on the PV100S Review the system configuration to determine all of the possible sources of energy In addition allow 5 minutes for the DC bus capacitors located on the ceiling of the cabinet to discharge after removing power 152315 Rev C vii Safety General Safety Precautions Personal Safety 1 When installing the PV100S use only components recommended sold by Xantrex Doing otherwise m
68. ovides information to help plan the installation of the PV100S 100 kW Grid Tied Photovoltaic Inverter Chapter 3 Installation describes the procedures needed to install the PV100S 100 kW Grid Tied Photovoltaic Inverter This section includes unpacking and moving instructions mounting instructions and cabling instructions Chapter 4 Verification provides a checklist to ensure the installation of the 1006 is correct and complete 152315 Rev C iii About This Manual Conventions Used The following conventions are used in this guide AN WARNING Warnings identify conditions or practices that could result in personal injury or loss of life AN CAUTION Cautions identify conditions or practices that could result in damage to the unit or other equipment Important These notes describe things which are important for you to know but not as serious as a caution or warning This Manual contains information for two models of the PV100S 100 kW Grid Tied Photovoltaic Inverter One model is designed to operate with a 208 Vac utility input and the other model is designed to operate with a 480 Vac utility input The model PV100S 208 100kW Grid Tied Photovoltaic Inverter 208 Vac input will be referred to as the PV100S 208 when it is being referenced individually model 1005 480 100kW Grid Tied Photovoltaic Inverter 480 Vac input will be referred to as the PV100S 480 when it is b
69. part of the PV100S installation CAUTION Fire Hazard In accordance with the National Electrical Code ANSI NFPA 70 connect only to a circuit provided with 400 amperes maximum branch circuit overcurrent protection for model 1005 208 and only to a circuit provided with 200 amperes maximum branch circuit overcurrent protection for model PV100S 480 Safety Operational Safety Procedures Never work alone when servicing this equipment A team of two 1 required until the equipment is properly de energized locked out and tagged and verified de energized with a meter Thoroughly inspect the equipment prior to energizing Verify that no tools or equipment have inadvertently been left behind Lockout and Tag Safety requirements mandate that this equipment not be serviced while energized Power sources for the PV100S must be locked out and tagged prior to servicing A padlock and tag should be installed on each energy source prior to servicing AN WARNING Shock Hazard Review the system schematic for the installation to verify that all available energy sources are de energized DC bus voltage may also be present Be sure to wait the full 5 minutes to allow the capacitors to discharge completely The 1005 can be energized from both the AC source and DC source To ensure that the inverter is de energized prior to servicing lockout and tag the PV100S using the following procedure 1 Open lockout and ta
70. re properly tightened Visual Inspection of Electrical Connections To perform a visual inspection of the PV100S electrical connections 1 152315 Rev C Ensure that the AC and DC disconnect switches as well as any utility interconnect circuit breakers or main disconnect switches are opened Ensure all conductors and wiring connections interfacing with the PV100S tightened to the correct torque value For specific torque values see Table 3 1 Terminal Wire Gauge Bolt Size and Torque Values on page 3 12 and Table 3 2 DC Terminal Wire Gauge Bolt Size and Torque Values on page 3 12 Verify AC power conductors terminated at TB4 A TB4 C within the Main Inverter Enclosure are terminated correctly and properly sequenced Verify the AC power conductors terminated at S1 2T1 51 4 2 S1 6T3 within the AC Interface Enclosure are terminated correctly and properly sequenced Verify DC power conductors terminated at TB3 1 TB3 2 TB3 3 within the DC Interface Enclosure are terminated correctly and properly polarized 4 3 Verification Visual Inspection Isolation Transformer Wye Wye To perform a visual inspection of the Isolation Transformer Wye Wye 1 Ensure that the AC and DC Disconnect Switches as well as any utility O Interconnect circuit breakers or main disconnect switches are open 2 Verify all conductor and wiring connections interfacing with the PV100S tightened to the c
71. rminal is tied to ground it will cause irreparable damage to the PV100S Check local regulations for their requirements regarding the connection of these neutrals WARNING Lethal Voltage Grounding the neutral of a Wye wound transformer may create an open delta condition depending on the utility configuration This condition may keep the PV100S from detecting a loss of phase condition on the utility system which may allow potentially lethal voltage to be present on the open phase wiring Electrical Diagrams and Schematics 152315 Rev C Since installations vary widely a sample electrical diagram of the PV100S is provided in Figure 1 on page A 3 This diagram 1 to be used for system planning purposes only For more detailed information refer to the schematic illustrations for model specific electrical schematics Model PV100S 480 Figure 2 1005 480 Schematic for Main Power Distribution 152316 E1 on page A 4 Figure A 3 PV100S 480 Schematic for Control Power Distribution 152316 E2 on page 5 Figure A 4 PV100S 480 Schematic for Converter Control Unit 152316 E3 on page A 6 Model PV100S 208 Figure 5 PV100S 208 Schematic Main Power Distribution 152376 on page 7 Figure A 6 1005 208 Schematic for Control Power Distribution 152376 C2 on page A 8 e Figure A 7 PV100S 208 Schematic for Converter Control Unit 152376 on page 9 2 5 P
72. rnet to serial in the Communications Enclosure A DB25 to DB25 gender changer adapter and DB9 DB25 serial cable are provided with the RS232 FO Converter kit to complete the connection If connecting the PC directly to the inverter 1 Openthe Communications Enclosure 2 Disconnect the TX transmit orange and RX Receive blue wires from the installed RS232 FO Converter in the Communications Enclosure 3 Disconnect the power plug from the installed converter and plug it into the new RS232 FO Converter Remove the installed converter Replace with the new RS232 FO Converter Reconnect the TX transmit orange and RX Receive blue wires to the new Converter in the Communications Enclosure 6 Plug the DB25 to DB25 Gender changer Adapter into the Serial Communications Port on the RS232 FO Converter Step not shown 7 Plugthe DB25 connector on the serial cable into the gender adapter and the DB9 connector of the serial cable into the serial port on the computer Step not shown 4 4 Modem Power Cord Do not Remove MultiTech 56K Modem Figure 3 21 RS232 FO Converter Kit Installation 152315 Rev C Installation RE232 FO Converter DB25 to DB25 Gender Changer Adapter DB25 DB9 Serial Cable Figure 3 22 Direct Connect Installation 3 24 152315 Rev C Verification Chapter 4 Verification provides a checklist to ensure the installation of the 1005 is c
73. s DLO 3 0 AWG Cable 3 0 AWG DLO 2000 90 per Phase 3 0 AWG has an O D of 0 789 0 789 x 0 789 x 6x 0 7854 2 93 Ground Cable 1 Each Z2 AWG per NEC Table 250 122 Ninth Edition using 400 A Breaker 2 AWG has an O D of 0 384 for THHN and 0 565 for DLO 0 565 x 0 565 x 0 7854 0 250 in Sense Control Wires 8 Each 16 AWG UL1015 THHN Hook up Wire 16 AWG has an O D of 0 096 0 096 x 0 096 x 8 x 0 7854 0 058 in Total 2 93 0 250 0 058 3 238 Using the Over 2 Wires column per NEC Chapter 9 Table 4 Ninth Edition indicates that the following minimum permitted conduit trade size 15 acceptable for the 15 wires in this exercise EMT 3 Trade size IMC 3 5 Trade size RMC 3 5 Trade size 152315 Rev C Anchoring the PV100S Anchoring the PV100S The PV100S is designed to be installed in either an indoor or outdoor location It must be placed on and anchored to a level concrete floor or pad The concrete floor or pad upon which the PV100S is anchored must be structurally designed to meet any local state or national requirements for weight seismic and wind sheer if applicable Four 5 8 holes are provided in the feet of the main inverter and six 5 8 holes are provided in the feet of the AC interface transformer assembly for anchoring to the floor or pad Figure 2 9 and Figure 2 10 depict the layout patterns of the anchoring holes for both the PV100S main inverter and the AC int
74. s tied to ground it will cause irreparable damage to the PV100S Check local regulations for their requirements regarding the connection of the neutral WARNING Lethal Voltage Grounding the neutral of a Wye wound transformer may create an open delta condition depending on the utility configuration This condition may keep the PV100S from detecting a loss of phase condition on the utility system which may allow potentially lethal voltage to be present on the open phase wiring Environmental Specifications The following environmental specifications are the same for both models of the PV100S 100 kW Grid Tied Photovoltaic Inverter Table 1 3 Environmental Specifications Specification Value Dimensions Inverter and DC Interface Transformer and AC Interface Overall System Footprint 82 in H x 60 1 4 in W x 22inD 208 cm H x 153 cm W x 56 cm 44 in Hx 50 Wx 34inD 112 cm H x 127 cm W x 86 cm D Layout Option A 12 ft W x 6 ft L approximate 3 6 mx 1 8 m Layout Option B 9 ft W x 7 ft L approximate 2 7 m W x 2 1 mL Weight Inverter and DC Interface Transformer and AC Interface Overall Weight 1000 Ibs approximate 1400 Ibs approximate 2400 Ibs approximate Allowable Ambient Temperature Operating Storage 20 to 50 Maximum 40 to 50 Maximum Relative Humidity To 95 Non condensing Elevation Power Derated above 6600 ft Clearance ven
75. these terminals must use crimp on type ring terminal or compression type lug Torque these connections to 115 in Ibs 13 0 Nm for the M8 PV100S 480 and 310 in Ibs 35 0 Nm for the 10 PV100S 208 See Figure 3 18 for the location of these terminals CAUTION Equipment Damage The termination points of the AC power conductors at S1 include a captive nut and plastic insulator between the terminals and the panel Ensure the length of the connection hardware used to attach the AC power conductors at S1 2T1 S1 4T2 S1 6T3 does not bottom out to the plastic insulator The depth of hole at terminals of S1 is from top of the tab Failure to observe this may result in failure of the plastic insulator and may cause a direct short to ground Installation 4 Connectthe neutral conductor at TB6 Connect the ground conductor at TB2 Terminations for the neutral and ground conductors within the AC Interface Enclosure at the TB6 and TB2 locations are made with 3 8 16 hardware Cables to these terminals must use a crimp on type ring terminal or compression type lug and should be tightened to a torque value of 228 in Ibs 25 7 Nm for TB6 and 420 in lbs 47 5 Nm for TB2 for both the PV100S 480 and PV100S 208 systems See Figure 3 18 for the location of these terminals 5 Close the door to the AC Interface Enclosure and replace the door clamps TB6 Neutral Conduit entry from utility Ground TB2 Note PV100S 208 s
76. tilation and serviceability In front of access doors 36 1n 91 cm In front of access panels 36 in 91 cm Sides 12 in 30 cm Back 6in 15 cm Maximum Distance between Main Inverter Enclosure and AC Interface Transformer Enclosure 15 ft 4 5 m 152315 Rev C Operator Interface Controls Operator Interface Controls Operator interface controls are located on the front door of the main inverter enclosure These controls include an ON OFF Switch 4 line LCD display and keypad called the Universal Frontpanel Control Unit UFCU Additionally there 15 an AC and DC Disconnect on the AC Interface Enclosure and the DC Interface Enclosure Doors ___ Communication Enclosure LCD _ DC Disconnect Display AC Disconnect Switch Universal Frontpanel Control UFCP ON OFF Switch Enclosure AC Interface Enclosure Inverter Enclosure AC Side View Front View Figure 1 2 PV100S Operator Interface Components Main Enclosure Door Interlock Switch The front door of the PV100S main enclosure is equipped with an interlock switch to preclude operation while the front door is open Opening the door of the main inverter enclosure will initiate an immediate controlled shutdown of the PV100S and opens both the main AC and DC contactors The main AC and DC contactors cannot be closed unless the door s interlock is in the engaged position The PV100S is prevented from being restarted until th
77. tion over time Consult the NEC ANSI NFPA 70 Code Book to ensure code compliance The model PV100S has a three phase output It is marked with this symbol e Conductor size should have been pre determined when the conduit was installed Prepare the appropriate length conductors for each connection 152315 Rev C Wiring General Overcurrent Protection AC overcurrent protection for the Utility Interconnect Grid tie must be provided by the installer as part of the PV100S installation CAUTION Equipment Damage In accordance with the NEC ANSI NFPA 70 Ninth Edition the following branch circuit overcurrent protection must be provided 400A maximum for PV100S 208 200A maximum for PV100S 480 Conductor Termination The PV100S has terminals and bus bars for making all wiring connections required for the installation All terminals used for making AC and DC connections require the use of copper conductors with an insulation rating of 90 or higher For wire gauge bolt size and torque values for the AC terminals see Table 3 1 For wire gauge bolt size and torque values for the DC terminals see Table 3 2 Transformer The AC terminals in the Transformer Enclosure T6 X1 T6 X2 and T6 X3 Enclosure require the use of crimp on type ring terminals or compression lugs The terminals are one bolt per pole See Figure 3 14 on page 3 15 for the location of these terminals Main Inverter The AC terminals in the
78. to customize start up and shut down sequences Multiple PV100S inverters are easily paralleled for larger power installations The PV100S power conversion system consists of a pulse width modulated inverter switch gear for isolation and protection of the connected AC and DC power sources and a custom Wye Wye isolation transformer Housed in a rugged NEMA 3R rated powder coated steel enclosure the PV100S incorporates sophisticated Intellimod IPM Insulated Gate Bipolar Transistors IGBTs as the main power switching devices An advanced field proven Maximum Peak Power Tracker MPPT integrated within the PV100S control firmware ensures the optimum power throughput for harvesting energy from the photovoltaic array The advanced design of the PV100S includes an EMI output filter and the main AC contactor located electrically on the utility side of the isolation transformer The location of the main AC contactor and the ability to de energize the isolation transformer during times of non operation greatly reduces the night time tare losses consumed by an idle isolation transformer An integrated soft start circuit precludes nuisance utility tie circuit breaker trips as the result of isolation transformer inrush current Additionally the PV100S integrated controller contains self protection features including over and under voltage and frequency safeguards An integral anti island protection scheme prevents the inverter from feeding po
79. ues AC Terminal Acceptable Wire Size Bolt Hardware Size Torque Requirements Connections Range both models PV100S 208 PV100S 480 1005 208 PV100S 480 1 500MCM to 4 AWG 3 8 16 3 8 16 420 in Ib 420 in Ib Chassis Ground 1 stud per pole 47 5 Nm 47 5 Nm TB2 500MCM to 4 AWG 3 8 16 3 8 16 420 in Ib 420 in Ib System Ground 1 stud per pole 47 5 Nm 47 5 Nm TB6 Neutral 500MCM to 4 AWG 3 8 16 3 8 16 228 in Ib 228 in Ib 1 stud per pole 25 7 Nm 25 7 Nm 81 2 51 472 350MCM to 6 AWG M10 See Caution 8 See Caution 310 in Ib 115 in Ib S1 6T3 1 stud per pole on page 3 17 on page 3 17 35 0 Nm 13 0 Nm T6 X1 T6 X2 350MCM to 6 AWG 3 8 16 3 8 16 420 in Ib 420 in Ib T6 X3 1 stud per pole 47 5 Nm 47 5 Nm 4 4 350MCM to 4 AWG 5 16 Hex 5 16 Hex 275 in Ib 275 in Ib TB4 C 2 openings per pole 31 Nm 31 Nm Table 3 2 provides acceptable wire gauges bolt sizes and torque values to be connected to the PV100S DC terminal connections Table 3 2 DC Terminal Wire Gauge Bolt Size and Torque Values DC Terminal Acceptable Wire Size Bolt Hardware Size Torque Requirements Connections Range both models PV100S 208 PV100S 480 1005 208 PV100S 480 TB3 1 TB3 2 500MCM to Z4 AWG 7 16 Hex 7 16 Hex 500 in Ib 500 in Ib TB3 3 2 openings per pole 56 5 Nm 56 5 Nm Grounding Install a copper ground rod within thre
80. uirements 2 4 System Neutral Requirements 2 4 Communication Requirements 2 4 Utility Side Isolation Transformer Requirements 2 4 Electrical Diagrams and Schematics 2 5 Layout Options 2 6 Conduit Penetration 2 8 Conductor and Conduit Sizing 2 11 Anchoring the 10058 2 13 152315 Rev C xiii Contents 3 Installation Equipment 3 2 3 2 Moving the PVIOOS 3 3 Unpacking the 1005 3 3 Removing the Pallet and Moving the 1008 3 4 Mounting and Anchoring the Units 3 5 Opening or Closing Access Doors 3 6 Conduit Installation 3 9 Wiring General
81. wer to the grid in the event of a utility outage The PV100S includes a local user interface comprised of an ON OFF switch keypad and 4 line 80 character LCD display A user friendly Graphic User Interface GUI provides a remote interface for operator interrogation of PV100S system status control metering data logging and protective functions within the PV100S The status control and logging features are also supported by the data modem included and can be accessed remotely The PV100S comes in two modules comprised of six enclosures to house the electronics described above The first module includes the Main Inverter Enclosure Inductor Enclosure DC Interface Enclosure and Communications Enclosure The second module includes the Transformer Enclosure and AC Interface Enclosure These components are identified in Figure 1 1 on page 1 3 Figure 1 1 also shows the dimensions and locations of the various enclosures that comprise the PV100S See Layout Options on page 2 6 for information on configuration options 152315 Rev C Description of the PV100S 60 Front View 150 5 cm Communications Enclosure 49 7 8 124 8 DC Interface 4 Enclosure 59 14 148 Inverter Interface Enclosure Enclosure A Transformer Inductor 29 44 0 Enclosure 73 cm
82. z9 B 524 p mom lt 8 gt lt Be B 1 S5 E 2 P 5 E 1344454 6 6 Ej 5 N xwds 8 8 a N lt 2 ai 99 28 2 3dON 3w S v 300N WAS H2 ale BE ab n m Au 1 0 1 zn Zen 218 9 Lin 24 920 9 55 fein fen 6 2 NOlV IS 6 9 61 t 8 8 L s les e 9 2 CNGIEINOCJ 3d Maius 6 2455 E wa Len 0 ds L amp n B a INO 3wds ein ae tL ud ex n L y nY tL PE 2 uz 22 ero 25 5 262 E ao a n 2 5 9 2 amp co Schematics NOTES SHT 3D4 152315 Rev C E 152316 SHT 5 OF 3 xantrex D 5 Figure A 4 PV100S 480 Schematic for Converter Control Unit 152316 E3 A 6 Appendix A Schematics

Xantrex PV100S-480 User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents