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PV Powered PVP260kW, Installation & Operation Manual

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18

Tools Required

The following tools are required to complete the installation of the inverter:

• 

9/16 inch socket wrench

• 

9/16 inch open-ended wrench

• 

3/8 inch, 3/16 inch, 5/16 inch and 5/32 inch Allen wrenches (Allen wrench adaptor 
for a socket wrench recommended)

• 

Digital multimeter (1000V rated)

• 

1/4 inch flat blade (common) screwdriver

• 

#1 and #2 Phillips screwdriver

• 

Wire strippers

• 

Utility knife

• 

0-120 inch/pound torque wrench

• 

0-50 foot/pound torque wrench

• 

600 volt rated fuse puller/pliers

• 

Tools for installing anchor bolts

• 

RJ45 crimping tool (if making a custom CAT5 cable)

3.6  Grid Interconnection

Utility Connection Requirements

Review all NEC 690, local codes and utility requirements before installing the inverter. 
NEC 690 has specific requirements for the size of the electrical service and the amount of 
current that is allowed to be fed into the panel by the inverter.

Contact your Local Utility

Contact your electrical utility before connecting the inverter to ensure there are no local 
restrictions or special requirements. Your local utility company may require specific 
inspections, equipment, or other procedures not covered in this document.

Voltage Outputs 

This inverter was designed to be connected to three phase power. The AC output voltage 
will be for a 480VAC in 

Y

 (WYE) configuration. Do not attempt to change the output 

voltage of the inverter.

AC and DC power requirements are shown in 

Appendix C - Mechanical Drawings

.

3.7  Monitoring

The inverter is equipped with a Data Monitoring Module that can be used to post data 
to the internet via a broadband Ethernet connection or by connecting to a local modbus 
network via RS-485. To use the modbus communications option refer to 

Chapter 5, 

Modbus Network Installation

. To connect the Data Monitoring Module to the site’s 

LAN, refer to section 

4.6 Performance Monitoring and Networking

. For instructions 

on installing and using the Data Monitoring Module, or if your site does not have a 

Summary of Contents for PVP260kW

Page 1: ...97 600100 24 B02 PVP260kW Inverter INSTALLATION OPERATION MANUAL ...

Page 2: ......

Page 3: ... easiest to install and most reliable solar inverters in the industry Our innovative approach to performance monitoring provides secure and easy access to system performance and inverter status over the Internet Contact Information PV Powered Inc 20720 Brinson Blvd PO Box 7348 Bend OR 97708 Tel 541 312 3832 Technical Support 1 877 312 3832 Fax 541 312 3840 www pvpowered com email support pvpowered...

Page 4: ...ii ...

Page 5: ...iring the utmost attention Failure to heed this warning will result in serious injury or death to personnel and destruction of equipment WARNING The Warning statement is used to inform the installer operator of a situation requiring serious attention Failure to heed this warning may result in serious injury or death to personnel and destruction of equipment CAUTION The Caution statement is used to...

Page 6: ...iv ...

Page 7: ...Detector Interruptor IEEE Institute of Electrical and Electronics Engineers IGBT Insulated Gate Bipolar Transistor IP Internet Protocol LOTO Lockout Tagout MCM 1000 circular mils utilized in wire sizing MPPT Maximum Power Point Tracking NEC National Electric Code NFPA National Fire Protection Association PCB Printed Circuit Board PLL Phase Lock Loop PPE Personal Protective Equipment PV Photovoltai...

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Page 9: ... Environmental Requirements 16 3 5 Grounding and Neutral Requirements 17 3 6 Grid Interconnection 18 3 7 Monitoring 18 3 8 DC Subcombiner Optional 19 3 9 PV Array Input 20 4 Installation 21 4 1 Handling and Unpacking 21 4 2 Pre Installation Inspection Steps 22 4 3 Conduit Entry 26 4 4 Setting and Anchoring 27 4 5 Electrical Connections 27 4 6 Performance Monitoring and Networking 33 5 Modbus Netwo...

Page 10: ...6 Communication PCB Status Light Operation 67 7 7 Controller PCB Status Light Operation 70 Appendix A Specifications 71 Appendix B Wiring Diagram 73 Appendix C Mechanical Drawings 75 Appendix D Limits and Fault Codes 77 Appendix E Annual Maintenance Requirements Checklist 83 Appendix F Efficiency Curves 85 F 1 PVP260kW Efficiency Curves 85 F 2 PVP260kW LV Efficiency Curves 86 Limited Warranty 87 I...

Page 11: ...ide 26 Figure 4 12 Side Entry Gland Plates DC Side 26 Figure 4 13 Conduit Hub Installation 28 Figure 4 14 Inverter Connections 30 Figure 4 15 DC Subcombiner Configurations 32 Figure 4 16 T 568B Compliant Ethernet Cable 33 Figure 4 17 Comm X Ethernet Port Location 34 Figure 5 1 AC Distribution and the Comm X PCBs 38 Figure 5 2 Close up View of Comm X PCB 39 Figure 5 3 Daisy Chain Layout for RS 485 ...

Page 12: ...mple of the Fault Display Screens 63 Figure 7 5 Fault Example Screen 63 Figure 7 6 Infrared Inspection Port 66 Figure 7 7 Status LED Lights 67 Figure 7 8 Comm X PCB Lights 68 Table 7 1 Status LED Flash Codes 69 Table A 1 Product Specifications Data 72 Figure B 1 Wiring Diagram 73 Figure C 1 Mechanical Drawings 75 Figure C 2 Mechanical Drawings 76 Table D 1 Voltage and Frequency Limits 77 Table D 2...

Page 13: ...to the PVP260kW except that it is configured for low voltage 265 VDC input Throughout the remainder of this manual the two models are referred to as the PVP260kW All information applies to both models unless stated otherwise Easy Installation The PVP260kW Inverter is built for easy installation To minimize installation efforts this inverter features an integrated isolation transformer and integrat...

Page 14: ...ding power to the utility grid in the event of a utility outage EMI Output Filters The PVP260kW Inverter utilizes EMI output filters to prevent electromagnetic interference AC Overcurrent Protection The PVP260kW Inverter current monitoring system constantly monitors the AC current within the unit limiting the inverter current output Remote Monitoring All PV Powered commercial inverters come with a...

Page 15: ...d the positive negative and ground bars DC Sub Panel with integrated DC ground fault detector interrupter PCB and DC disconnects AC Sub Panel with AC output filtering surge protection and AC connection points Magnetics Compartment contains the isolation transformer and inductors Power Module Assembly The inverter uses Insulated Gate Bipolar Transistors IGBTs for converting DC power into three phas...

Page 16: ...ications 2 Power Distribution PCB Distributes the required logic level voltages for use throughout the inverter 3 Controller PCB Contains a powerful DSP that controls sine wave generation logic functions and protection activities All analog and digital inputs and outputs are routed to the Control PCB and fed to the DSP 4 I O PCB Provides a central location for a range of input output and control c...

Page 17: ... transforms 480VAC to 120VAC for use within the inverter Isolation Transformer The inverter comes equipped with an integral isolation transformer Figure 1 1 Rear View The isolation transformer is designed for class leading inverter efficiency Inductor The inductor Figure 1 1 Rear View is used to filter the AC waveform generated by the power module effectively reducing high frequency noise AC Sub P...

Page 18: ...bution PCB Comm X PCB The Comm X PCB Figure 1 6 is located in the AC sub panel just below the AC Distribution PCB The Comm X PCB includes the RJ45 Ethernet port that is used to connect the inverter to the internet The Comm X PCB also includes a modbus master port not enabled a modbus slave port and a DVI port that is used to connect the Comm X PCB to the main Communications PCB A serial port is av...

Page 19: ... three Jumpers Installed Figure 1 6 Comm X PCB DC Sub Panel This panel houses the DC disconnect DC distribution PCB fuses and integrated fused subcombiner box Figure 1 7 DC Combiner Sub Panel Shown With 16 Circuit Monitoring Subcombiner DC Disconnect DC Line Filter DC Positive Busbar DC Contactor Analog to Digital Converter for Sub Array Monitoring optional Fused Subcombiner Optional DC Negative B...

Page 20: ...G Risk of Electrical Shock The GFDI functions using a 5A fuse to connect or bond the solar array Negative or the solar array Positive if using a positively grounded panel array to earth ground on the DC Distribution PCB If the ground fault current exceeds 5A between the grounded array terminal and the earth ground the fuse will open and disconnect the solar panels from their ground reference inter...

Page 21: ...RUCTIONS This manual contains important instructions for the PVP260kW Inverter that must be followed during installation and maintenance of the inverter DANGER Risk of Electrical Shock High voltages are present within the inverter cabinet Both AC and DC disconnects must be in the OFF position when working on the unit Wait five minutes to discharge high voltage before opening the front panels of th...

Page 22: ...nance of the inverter in accordance with NEC ANSI NFPA 70 as well as all state and local code requirements Follow all national and state accident prevention regulations WARNING Crush Hazard The inverters have a specific balance point that correlates to their Center of Gravity While the units meet UL1741 Stability tests they should not be tipped beyond 10o of tilt as the unit could topple over and ...

Page 23: ...aker and PV array inputs are disconnected DANGER Risk of Electrical Shock Allow five 5 minutes for internal power to dissipate prior to entering the enclosure cabinet Ensure all terminals are voltage free with the use of a multimeter 2 3 Personal Safety Safety Zone Ensure any personnel entering a safety zone within a four foot area around any operating inverter wear appropriate Personal Protective...

Page 24: ...C minimum The inverter has a three phase 480VAC output The inverter is interfaced with the utility grid at the AC landing within the AC section on the front right side of the inverter These terminals require the use of a UL approved crimp on type ring terminal or a UL approved compression type lug certified for use with the chosen interface cables Ensure similar cables run together in conduit runs...

Page 25: ...ion for the utility interconnect grid tied must be provided by installers as part of the installation 2 5 De energize Isolation Procedures De energize The following procedure should be followed to de energize the inverter for maintenance DANGER AC and DC voltages will still be present at the inverter AC and DC landing points unless utility connection circuit breaker and PV array inputs are disconn...

Page 26: ...14 Figure 2 1 Inverter in the De energized State DC Disconnect in Power OFF Position AC Disconnect in Power OFF Position ON OFF Switch in OFF Position ...

Page 27: ...state and national codes 3 2 Location and Clearances Location Select a suitable location to install the inverter The inverter must be installed on a flat solid surface such as a concrete pad The inverter should be located as close to the array as possible to minimize the DC wire length Left and Right Sides PV Powered recommends providing a minimum of 12 inches of clearance on each side of the inve...

Page 28: ...Edition All conductors shall be rated for 90o C minimum External Cable Interfaces Entry through bottom side or top gland plates See Appendix C Mechanical Drawings for details 3 4 Environmental Requirements The unit may be installed either indoors or outdoors If the installation of the inverter is outdoors all interconnect conduit and fittings must be rated NEMA 4 same as inverter rating as require...

Page 29: ...d at any other point in the system would defeat the ground fault protection circuit The inverter is shipped pre configured with positive or negative PV array grounding based on the preference provided at the time of order CAUTION The inverter may be factory configured for either positive or negative ground It may NOT be field configured to a different grounding once it is shipped from the factory ...

Page 30: ...er Contact your Local Utility Contact your electrical utility before connecting the inverter to ensure there are no local restrictions or special requirements Your local utility company may require specific inspections equipment or other procedures not covered in this document Voltage Outputs This inverter was designed to be connected to three phase power The AC output voltage will be for a 480VAC...

Page 31: ...tandard positive and negative busbars for landing DC inputs from the PV array Optional eight 16 and 20 circuit internal subcombiner boxes are available as shown in the figure below In addition the eight and 16 circuit subcombiners can be ordered with monitoring on each input circuit 8 Circuit Option 16 Circuit Option 20 Circuit Option 8 Circuit with Monitoring Option 16 Circuit with Monitoring Opt...

Page 32: ...t if an optional fused subcombiner is not selected 3 9 PV Array Input The PV array open circuit voltage should never exceed 600 volts The PV Powered web site at http www pvpowered com installation_support php includes a string calculator Contact your system installer or PV Powered if you require additional assistance ...

Page 33: ...e inverter base for unloading Leave the inverter on its shipping pallet with its protective plastic wrap in place to alleviate any UV concerns if it is stored outside until it is time to install When the inverter is ready to be placed in its mounting location complete the following steps 1 Remove the protective plastic wrap 2 Remove all bolts that anchor the inverter to the pallet 3 Plan for a saf...

Page 34: ...structural damage Specifically look for any structural damage or crushing of the base and doors Confirm all doors open freely and easily Step 2 Rear Magnetics Compartment 1 Remove the large cover plates on the back of the inverter accessing the magnetics 2 Inspect all nine connections including the following Three connections into the inductor Three from the inductor to the transformer Three exiti...

Page 35: ...re not damaged during replacement of the plates Do not over tighten the screws Step 3 AC DC Sub Panel Compartments 1 For each busbar landing in the AC and DC compartments check the integrity of the busbar connections and terminals Figure 4 4 Busbars and Busbar Connection Inspection 2 Ensure the cable connections are plugged in and fully seated Figure 4 5 Inspection of Cable Connections ...

Page 36: ...r damage or debris Figure 4 7 Screen Inspection If any lose wires are found during the inspections and the location of the connection is unknown contact PV Powered s Customer Service and Technical Support Step 4 Upper Electronics Compartment 1 Check the integrity of the busbars and their connections in the upper electronics compartment Figure 4 8 Checking the Busbar Connections ...

Page 37: ...re that the fans spin freely Figure 4 9 Fan Inspection 2 Ensure all air filters are fully seated Figure 4 10 Air Filter Check This completes the pre installation inspection WARNING Before installing the inverter make sure the pre installation steps have been completed and no issues have been identified ...

Page 38: ...sides of the inverter for top bottom and side entry totalling six locations Each gland plate location is selected to ensure safe installation proper airflow and prevention of dust debris moisture insect and animal incursion Do not penetrate the cabinet at any other location All gland plated need to be installed for proper operation of the inverter To use a gland plate 1 Select the size s and locat...

Page 39: ...er to the concrete base by setting the anchoring hardware through each of the six holes in the external mounting flange as shown in sheet two of Appen dix C Mechanical Drawings The flanged inverter base allows the unit to be anchored after positioning 4 5 Electrical Connections Proceed with making the electrical connections of the inverter once it has been properly secured to the concrete slab Ter...

Page 40: ... should be switched ON only after all wiring has been properly connected and inspected AC Wiring WARNING Follow the order listed in this section to wire the inverter Failure to do so may result in hazardous voltages or disconnection of contacts CAUTION The National Electrical Code NEC requires that the inverter be connected to a dedicated circuit with no other outlets or devices connected to the s...

Page 41: ... sized to minimize voltage drop Install the inverter on a dedicated branch circuit with a maximum 400A circuit breaker The inverter does not have internal AC fusing so it is important to size the branch circuit protection appropriately When an inverter is installed on a 480VAC electrical panel the operational voltage range is 422 VAC 528 VAC for the inverter Voltages outside this range will cause ...

Page 42: ...dure 1 Remove the protective plastic cover with a 5 32 Allen wrench 2 Run the conduit from the main breaker panel to the desired gland plate on the in verter and insert the fitting in the gland plate and fasten with a locking nut 3 Feed the PHASE A PHASE B PHASE C and GROUND wires through the conduit and into the right side conduit opening of the inverter 4 Connect the GROUND wire to the terminal ...

Page 43: ...ay cables to the DC terminal block DC Input Voltage Calculate the maximum open circuit no load voltage for each series module connection FOR ALL TEMPERATURE CONDITIONS THE OPEN CIRCUIT VOLTAGE FOR EACH SERIES CONNECTION MUST BE LESS THAN OR EQUAL TO 600 VDC Contact PV Powered if you require assistance calculating the maximum DC input voltage for your array at your specific location DC Inputs Each ...

Page 44: ...lbs 6 Connect the PV frame ground wire s to the ground lug on the point marked in the lower DC cabinet 8 Circuit Option 16 Circuit Option 20 Circuit Option 8 Circuit with Monitoring Option 16 Circuit with Monitoring Option Subcombiner with no Circuits Figure 4 15 DC Subcombiner Configurations 7 Energize the DC cables 8 Using a voltmeter check the PV array positive leads and confirm the voltage is ...

Page 45: ...nection to the inverter based on the following specifications Provide a DHCP enabled broadband internet connection that is always ON This can be cable internet a DSL line or equivalent Requires a hard wired Ethernet enabled connection available at the inverter location Internet service should be connected using one of the following preferred methods Hard wire an outdoor rated shielded CAT5 Etherne...

Page 46: ...ing All PV Powered commercial inverters come standard with an Ethernet port that is intended to be connected to the Internet The PV Powered commercial inverter operates as an Internet appliance The inverter communicates with the PV Powered Data Center using https port 443 Communications is one way the inverter only communicates externally to the PV Powered Data Center Typically the inverter will p...

Page 47: ...lly the result of a poor crimp wire that exceeds 320 ft or pinched wires somewhere between the inverter and the hub or router PV Powered recommends using pre made cables whenever possible If a cable must be hand crimped we recommend testing the cable with a cable tester such as a Fluke LinkRunner Pro Network Multimeter LPRO1000 Verify the cable s integrity by connecting a laptop to the cable at th...

Page 48: ...36 ...

Page 49: ...unication between a modbus master and multiple slave devices connected to the same network RS 485 is the protocol standard used by PV Powered as the hardware s serial interface while modbus is the communication protocol that runs on the PV Powered inverters 5 3 Networking Using the Modbus Option The following steps can be performed by a qualified installer to set up a modbus network These steps ar...

Page 50: ...ble rated for outdoor operation at 600V such as Belden 9341 The gland plate is a flat piece of metal covering the holes in the side of the inverter Remove the gland plate and cut a hole in the desired location to allow access for the cable Replace the gland plate Figure 5 1 AC Distribution and the Comm X PCBs 2 Connect the modbus cable The end of the modbus cable connects to the modbus slave conne...

Page 51: ...d devices have connected grounds when possible The ref line r connector in the figure below shows the ground connection This is the top or GND connection of the MODBUS Slave connector This is the J5 connection of the MODBUS Slave connector Note If your modbus device does not have a ground connection it is not required to connect it to a ground cable Figure 5 3 Daisy Chain Layout for RS 485 Network...

Page 52: ...one and three and leave the jumper on the middle pair of pins of J7 for a network with only one slave device or for the device on the end of a network 2 Set the slave devices Remove the three jumpers from all the J7 pins for any device in the middle of your network Only devices at the end of the modbus network should have the middle jumper installed 3 Set the biasing Biasing sets the voltage level...

Page 53: ... Move right to the Switch column to find the converted address value of this slave device Note 0 is not an allowed address Address Switch Address Switch Address Switch Address Switch Address Switch 1 2 1 2 1 2 1 2 1 2 1 0 1 21 1 5 41 2 9 61 3 D 81 5 1 2 0 2 22 1 6 42 2 A 62 3 E 82 5 2 3 0 3 23 1 7 43 2 B 63 3 F 83 5 3 4 0 4 24 1 8 44 2 C 64 4 0 84 5 4 5 0 5 25 1 9 45 2 D 65 4 1 85 5 5 6 0 6 26 1 A...

Page 54: ...2 Figure 5 5 Rotary Switches for Setting the Inverter Number The switches are located near the center of the Comm X PCB and are labeled SW1 and SW2 as they appear in Figure 5 5 If you need more device addresses than the 100 listed in the above table refer to a complete digital to hexadecimal conversion table Note Some modbus master devices do not allow addresses above the decimal value of 126 PV P...

Page 55: ... the following command sections contain two tables The first table describes the format of a modbus command request while the second table contains the format of the command s response Then the next section Modbus Register Maps provides additional information about these commands and their valid registers Read Holding Register The Read Holding Register command is used frequently Typically the modb...

Page 56: ...and is used to write to one of the command registers found in Table 5 14 Using this command does not change the inverter s data in registers described in Tables 5 10 5 12 or 5 13 Command Information Command Layout Modbus slave address nn 1 126 Command number 06 First register MSB xx First register LSB xx Data MSB xx Data LSB xx CRC LSB xx CRC MSB xx Table 5 6 Format for Write Single Register comma...

Page 57: ... Inverter IDxxxxx for example 0x50 0xFF PVP Inverter ID02860910080321 The first xx represents two non ASCII bytes representing the following information Byte 1 0x50 An identifier byte for PVP inverters Byte 2 0x00 If communication with the inverter is down 0xFF If communication with the inverter is okay Byte 3 through byte n Contains PVP Inverter IDxxxxx Response Information Response Layout Modbus...

Page 58: ...xed information registers Inverter Configuration Bit Mapping Instructions AC Volts 208 0x0001 AC Volts 240 0x0002 AC Volts 480 0x0004 Transformer tap position 0x0008 Set if Tap at 265V Clear if Tap at 295V Default 295V Transformer wiring configuration 0x0010 Set if wired as Delta Clear if wired as Wye Default Wye Utilitimeter installation flag 0x0100 Set if meter is installed Clear if not installe...

Page 59: ... 16 Bit mapped See Table D 4 Voltage fault 2103 2103 1 42104 UINT 16 Bit mapped See Table D 5 Grid fault 2104 2104 1 42105 UINT 16 Bit mapped See Table D 6 Temperature fault 2105 2105 1 42106 UINT 16 Bit mapped See Table D 7 System fault 2106 2106 1 42107 UINT 16 Bit mapped See Table D 8 System warnings 2107 2107 1 42108 UINT 16 Bit mapped See Table D 9 PVM status codes 2108 2108 1 42109 UINT 16 B...

Page 60: ...tatus and fault code register in Table 5 12 The command s response values are returned as hexadecimal values which you need to convert to the decimal value in order to understand the returned information Description Hex Value Decimal Value Modbus register number 42101 Sleep state 0 0 Startup delay state 1 1 AC precharge state 2 2 DC precharge state 3 3 Idle state 4 4 Power track state 5 5 Reserved...

Page 61: ...ter number UINT16 Unsigned integer 16 bits Range 0 to 65535 SINT16 Signed integer 16 bits Range 32767 to 32767 UINT 32 requires two registers Unsigned integer 32 bits Range 0 to 4 294 967 295 SINT 32 requires two registers Signed integer 32 bits Range 2 147 483 647 to 2 147 483 647 FLOAT requires two registers IEEE 754 standard 32 bit floating point number Table 5 17 Data formats for registers Inf...

Page 62: ...50 ...

Page 63: ...nal panel doors 3 Turn on the external AC connection to the inverter 4 Turn on the external DC disconnect to provide DC power to the inverter 5 Turn the ON OFF switch to the OFF position 6 Turn the inverter s AC disconnect to the power ON position Refer to Figure 6 1 The display on the upper front panel should now be active The display is shown in Figure 6 3 7 Turn the inverter s DC disconnect to ...

Page 64: ...rter Operating States The PVP260kW has nine operating states The inverter will transition from one state to another only as shown in Figure 6 2 Each operating state is described below DC Disconnect in Power ON Position AC Disconnect in Power ON Position ...

Page 65: ... OFF position or when a disable command is received over the serial port If a fault condition occurs the inverter switches to the Fault state When the fault is cleared and the condition no longer exists the inverter returns to the disabled state The inverter displays a message on the screen indicating the inverter is disabled When an enable command is received or the front panel switch is changed ...

Page 66: ...utdown If a grid interactive fault occurred on the previous shutdown the inverter will remain in this state for 5 minutes DC Precharge In this state the inverter closes the DC precharge contactor which limits inrush current into the DC bus capacitors When the DC bus voltage reaches the PV input voltage and is greater than the DC start voltage the inverter switches to the AC precharge state AC Prec...

Page 67: ...ed Each of the display screens for each state are shown in Figures 6 4 through 6 8 If there is a series of display screens associated with the inverter state then the inverter will continuously scroll through these screens If a fault occurs the display also provides a fault code that corresponds to a set of pre defined fault descriptions as detailed in Appendix D Limits Descriptions Fault Codes an...

Page 68: ...e Screen Figure 6 8 Disabled State Screen Display Operation The inverter display normally scrolls through a series of display screens based on the current state of the inverter To pause the display on a specific screen press the Pause Scroll button on the dis play To resume the scroll function press the Pause Scroll button again ...

Page 69: ...ceeds 5A between the grounded array terminal and the earth ground the fuse will open and disconnect the solar panels from their ground reference interrupting the ground fault In this situation the inverter will cease operation and display a fault message see Appendix D Limits and Fault Codes Additionally the LED on the DC Distribution PCB will illuminate Figure 6 9 Ground Fault Error Message If th...

Page 70: ...al Shock Allow five 5 minutes for internal power to dissipate prior to entering the enclosure cabinet Ensure all terminals are voltage free with the use of a multimeter DC Disconnect in Power OFF Position AC Disconnect in Power OFF Position ON OFF Switch in OFF Position ...

Page 71: ...lowing maintenance should be performed annually by a qualified service person See Appendix E Annual Maintenance Requirements Checklist for a checklist of these required maintenance items A General Inspection Cleaning 1 Record general site conditions 2 Record inverter performance data from inverter display 3 Record environmental conditions 4 Remove dirt and debris from underneath the inverter 5 Ins...

Page 72: ...nual Preventative Maintenance Checklist Complete the maintenance checklist included in Appendix E and save the information for your records This checklist is also available on the www pvpowered com web site Maintaining the Blower Intake Filters PV Powered recommends an annual inspection and cleaning of the blower intake filters Cleaning may be required more often depending on the location of the i...

Page 73: ...rd Cage Air Filter The card cage features a secondary air filter to ensure long PCB life The card cage air filter is located under the intake air shroud above the card cage which is located on the right side of the power module assembly in the upper cabinet Use the following instructions to access the secondary air filter and refer to Figure 7 3 1 Remove the air intake shroud above the card cage T...

Page 74: ... latching fault requires manual intervention to restart the inverter If the inverter has faulted the display screen will show the corresponding fault information in a series of three or more screens The first screen displays the fault code s The second screen displays a text description of the fault s The third screen displays technical support contact information The display will then cycle back ...

Page 75: ...mple of the Fault Display Screens In addition the inverter can also detect and display inverter warnings Warnings are displayed if a condition is detected that does not require the inverter to shut down but may require attention A sample warning screen is shown below in Figure 7 5 A complete list of warnings can be found in Appendix D Limits Descriptions Fault Codes and Torque Values Figure 7 5 Fa...

Page 76: ...erances specified in Appendix A Specifications refer to the troubleshooting tips below 1 If the main branch circuit breaker is not tripped check the small fuses located on the AC distribution PCB there are nine in three sets of three If one or more of these fuses have opened replace them with like parts 600VAC 10A or 20A as required 2 If any of the fuses were open visually inspect the wiring Look ...

Page 77: ...should be broken in the DC disconnect 3 A pinched wire in the installation connecting some part of the array or DC wiring to earth ground 4 In the case of a multiple inverter installation mismatched array strings Repairing a Ground Fault DANGER Risk of Electrical Shock Allow five 5 minutes for internal power to dissipate prior to entering the enclosure cabinet Ensure all terminals are voltage free...

Page 78: ...d Technical Support at 1 877 312 3832 or email support pvpowered com Infrared Inspection Ports Infrared inspection of the isolation transformer and inductors can be performed by utilizing the port at the top of the DC sub panel shown in Figure 7 6 The inverter must be shutdown before accessing the port 1 Shutdown the inverter 2 Remove the infrared inspection port cover plate by removing the four 5...

Page 79: ...ication PCB LED Lights The communication PCB s four LED lights can be found in two locations Communication card The primary location is on the face of the communication card which resides in the card cage in the right side of the upper cabinet Refer to Figure 7 7 Comm X PCB The additional set of LED lights are on the Comm X PCB located in the lower section of the AC distribution cabinet inside the...

Page 80: ...id for a few seconds then flashes quickly for several seconds while the communications device looks for an Internet connection After a few seconds the Status LED flashes more slowly while serial communication is established with the inverter s main processor Once serial communication is established the Status LED should remain on unless a fault occurs The Status LED will flash status codes if any ...

Page 81: ...f this post succeeds the LED will go back to normal operation until the next post again tries to connect to the DNS server Network Connection Fault This status code flashes when the inverter cannot post data to the PV Powered database server The Network Connection Fault status code starts flashing only after the inverter has tried to post data to the PV Powered server The Status LED may indicate n...

Page 82: ...ix E Annual Maintenance Requirements Checklist 7 7 Controller PCB Status Light Operation There are two lights on the front of the Controller PCB a green and a red light If the green light is on The inverter is on and ready to produce power If the red light is on Solid red the inverter is in a faulted condition that will be auto reset by the inverter if the fault condition is cleared Flashing red t...

Page 83: ... 10 12 to 10 AC Operating Range V 422VAC 528VAC 422VAC 528VAC Power Factor at full power 99 99 THD 3 3 Cooling Forced Convection Forced Convection Temperature range C 30 to 50 30 to 50 Max ambient at Pnom C 50 50 Standby losses W 67 67 Startup voltage 330 300 Maximum continuous power W 500 500 Utility interconnect voltage trip limits and times See Appendix D See Appendix D Utility Frequency Trip L...

Page 84: ...ogram Yes Yes Extended warranty 20 Year Yes Yes Range of integrated fused sub array combiners and subcombiner monitoring Yes Yes Table A 1 Product Specifications Data Notes 1 The PVP260kW Inverter complies with FCC Part 15 Class A conducted requirements Radiated will be tested at a later date and will be tested to CISPR not FCC 2 The PVP260kW Inverter is designed to meet or exceed NEC Article 690 ...

Page 85: ...CONTACT POWER 48V CONTACT POWER USER INPUT 1 USER INPUT 2 VFD Data INTERFACE DISPLAY 48V CONTROL POWER 5A GND THRESHOLD DETECT DC MEASURE PV MEASURE PRECHARGE GFDI TO CONTROL 1 2 3 4 5 6 7 PLC COIL INTERFACE CONTROL CENTER DC IN 3 PHASE AC OUT DC DC A B C RIPPLE CAPS 48V CONTACT POWER GND 1 2 AUX NO AUX NO Controller OK FAULT PWM I O Ext 10V 5V 3 3V Power Dist 15V 15V 5V Comm ACT Modbus Status RES...

Page 86: ...74 ...

Page 87: ...75 Appendix C Mechanical Drawings Figure C 1 Mechanical Drawings APPENDIX C ...

Page 88: ...76 Figure C 2 Mechanical Drawings ...

Page 89: ...1 Hz Adjustable low trip 57 5 59 8 High trip fixed at 60 5 Accessible range of Trip Times Limits of Accuracy Time Measurement 0 1 sec 16 to 300 seconds Table D 2 Adjustable Voltage and Frequency Limits 260kW Faults and Warnings Fault Variables The 260kW firmware will utilize one 16 bit variable fault to indicate a fault condition Each bit in this fault variable represents the fault type or categor...

Page 90: ...Peak over current phase C 0200 RMS OVERCURRENT A RMS over current phase A 0400 RMS OVERCURRENT B RMS over current phase B 0800 RMS OVERCURRENT C RMS over current phase C Table D 4 Drive Faults The following table lists the voltage faults including VAC sense VDC and power supply faults Hexadecimal Value Display String Description 0001 VAC OVER PEAK A Peak AC voltage high phase A 0002 VAC OVER PEAK ...

Page 91: ...C voltage high phase A 0400 AC SLOW OVERVOLT B Slow AC voltage high phase B 0800 AC SLOW OVERVOLT C Slow AC voltage high phase C 1000 AC UNDER FREQ Low frequency fault 2000 AC OVER FREQ High frequency fault Table D 6 Grid Fault GRD The following table lists the temperature faults Hexadecimal Value Display String Description 0001 HEATSINK TEMP A1 Module heat sink A1 temperature high 0002 HEATSINK T...

Page 92: ...SENSE No AC voltage detected Table D 8 System Faults SYS The following table lists the system warnings Hexadecimal Value Display String Description 0001 FAN 1 WARNING Fan 1 warning 0002 FAN 2 WARNING Fan 2 warning 0004 FAN 3 WARNING Fan 3 warning 0008 MAG HITEMP WARNING Magnetics high temperature warning 0010 HI TEMP PWR LIMIT Power foldback warning 0020 DELTA TEMP WARNING Heatsink delta temperatu...

Page 93: ...il 4 Direct to busbar 43 ft lbs 75 C 400 Qty two 2 Al Cu 350kcmil 4 Direct to busbar 43 ft lbs 75 C 200 Al Cu 350kcmil 6 31 ft lbs 75 C 100 Al Cu 2 0 6 10 ft lbs 75 C Table D 10 Subcombiner Wire Sizing and Torque Values AC DC Bus Landing Hardware The following diagram details the installation of the input wiring to the busbars Nut Torque to 43 ft lbs Lock washer Flat washer Crimp connector Bolt 3 ...

Page 94: ...82 ...

Page 95: ...al connections and wiring 10 Complete mechanical inspection of connections and wiring 11 Measure torque of all electrical connections and re torque as needed 12 Complete thermal scan of inverter connections wiring and electronics C Testing 13 Confirm inverter operating modes including standby startup and on 14 Check operation of protective circuits and alarms 15 Check operation of relays and conta...

Page 96: ...84 ...

Page 97: ...er Level kW 10 20 30 50 75 100 Input Voltage Vdc 26 00 52 00 78 00 130 00 195 00 260 00 Wtd Vmin 295 96 0 97 5 97 7 97 6 97 1 96 4 97 2 Vnom 341 95 6 97 3 97 5 97 4 97 0 96 4 97 0 Vmax 480 94 4 96 5 96 9 97 0 96 6 96 1 96 6 CEC Efficiency 97 0 295 Vdc 341 Vdc 480 Vdc 70 75 80 85 90 95 100 0 10 20 30 40 50 60 70 80 90 100 Efficiency of Rated Output Power 295 Vdc 341 Vdc 480 Vdc Figure F 1 PVP260kW ...

Page 98: ...0 30 50 75 100 Input Voltage Vdc 26 00 52 00 78 00 130 00 195 00 260 00 Wtd Vmin 265 96 1 97 6 97 8 97 5 96 9 96 0 97 1 Vnom 319 95 6 97 3 97 5 97 3 96 7 95 9 96 9 Vmax 480 94 0 96 2 96 7 96 8 96 2 95 5 96 3 CEC Efficiency 96 5 265 Vdc 319 Vdc 480 Vdc 70 75 80 85 90 95 100 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 Efficiency of Rated Output Power 265 Vdc 319 Vdc 480 Vdc Figure F 2 PVP260kW LV Effici...

Page 99: ...r Warranty PV Powered will at its discretion repair or replace the defective component s free of charge as long as PV Powered is notified of the defect during the warranty period PV Powered reserves the right to inspect the faulty component s and determine if the defect is due to material or manufacturing flaws PV Powered also reserves the right to charge for service time expended if the defect is...

Page 100: ...ARRANTIES THAT MAY HAVE ARISEN FROM COURSE OF DEALING OR USAGE OF TRADE TO THE MAXIMUM EXTENT PERMITTED BY LAW PV POWERED S AGGREGATE MONETARY LIABILITY TO YOU FOR ANY REASON AND FOR ANY AND ALL CAUSES OF ACTION WHETHER IN CONTRACT TORT OR OTHERWISE WILL NOT EXCEED THE AMOUNT PAID TO PV POWERED FOR THE PV POWERED INVERTER S COVERED BY THIS 10 YEAR WARRANTY PV POWERED WILL NOT BE LIABLE UNDER ANY C...

Page 101: ...Holding Register 43 Return Slave ID 45 Write Single Register 44 communications parameters 42 Comm X PCB 6 components major 3 conductors 16 conduit 16 hub installation 28 contact information i contacting local utility 18 cooling 5 cooling requirements 17 25 D data monitoring module 33 49 DC inputs 31 input voltage 31 wiring 31 DC Combiner sub panel 8 DC Distribution PCB 8 DC Subcombiner PCB options...

Page 102: ...y screens 55 efficiency 85 electrical grid connections 30 enclosure type 27 fan intake screen 60 flash codes 69 handling 21 inspecting 22 louver plate 61 main enclosure 3 major components 3 models 1 monitoring 18 33 38 operating states 52 packaging 21 power distribution PCB 4 power module 3 rotary switches 42 shutdown 57 starting 51 status lights 67 69 70 versatility of 1 islanding prevention 10 i...

Page 103: ... values 48 status and fault codes 47 rotary switches 42 RS 485 35 39 S safety 9 conventions iii designation of danger warning and caution iii equipment 11 islanding prevention 10 labels 11 zone 11 screens faults 63 service 10 shutdown procedure 57 slave device 37 38 address conversion table 41 setting address 41 specifications 2 start up procedure 51 status lights 67 69 70 status values 48 subcomb...

Page 104: ...92 Notes ...

Page 105: ......

Page 106: ...PO Box 7348 Bend OR 97708 P 541 312 3832 www pvpowered com ...

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