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TBEA TC500K3US-O, Installation Manual

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TC500K3US-O Installation Instructions

 

39 

5.5.2 Cable Protection 

The  protection  for  cables  includes  the  communication  cables  and  power 

cables protection. The protective methods are as follows:   

 

Protection for communication cables

 

Since the communication cables are weak, they are easy to be broken by 

the  tension  or  fall  off  from  the  terminals  in  construction,  then  they  shall  be 

connected  after  the  power  circuits  are  all  connected,  and  also,  they  shall  be 

aligned  along  the  trenches  in  connection,  if  no  cable  trenches,  they  shall  be 

fastened  by  ribbons,  besides,  you  shall  avoid  heating  elements  and  circuit 

cables of high field when aligning the cables. 

 

Protection for power cables 

Due  to  the  strong  current  in  the  power  circuit  cables  which  may  lead  to 

short circuit, you shall avoid any scratches or damages on the insulation skins 

of the cables when installing and connecting the cables. Also, the power cables 

must be secured properly. 

5.6 Installation Process 

The  total  installation  process  of  the  TC500K3US-O  inverter  is  as  shown 

in Figure 5-7, and the installation process description is shown in Table 5-2. 

 

Summary of Contents for TC500K3US-O

Page 1: ......

Page 2: ...ions 7 2 1 Safety Precautions 7 2 2 Notes on Operation 11 2 2 1 Live Line Measurement 11 2 2 2 Opening the Plant 11 2 2 3 Requirements Prior to Connecting the Switches on AC and DC Sides 12 2 2 4 Notes on Shutdown 13 3 Product Delivery 14 3 1 Scope of Delivery 14 3 2 Nameplate of TC500K3US O 15 3 3 Storage 16 3 4 Transportation 18 ...

Page 3: ...27 5 2 Installation Environment 28 5 2 1 Ground Requirements 28 5 2 2 Requirements of the Minimum Space for Outdoor Uses 29 5 2 3 Requirements of the Minimum Space for Indoor Uses 32 5 3 Requirements of the Alignment of Wires Ventilation and Others 33 5 3 1 Requirements of Cable Trenches 33 5 3 2 Ventilation Requirements 34 5 3 3 Other Requirements 36 5 4 Wiring Specifications 37 5 5 Fixation and ...

Page 4: ...portation 43 7 1 1 Precautions 43 7 1 2 Packaging and Logos 44 7 1 3 Transportation Packaged 46 7 1 4 Transportation without Packaging 47 7 2 Field Installation 49 8 Electrical Connection 54 8 1 Precautions 54 8 2 Input and Output Requirements 55 8 3 Cable Requirements 56 8 4 Wiring Components 58 8 5 Preparations for Electrical Wiring 62 8 6 DC Side Wiring 63 8 7 AC Side Wiring 69 8 8 Ground Conne...

Page 5: ... 1 Commissioning Requirements 84 10 2 Check before Commissioning 85 10 2 1 Check the PV Array 85 10 2 2 Check the Inverter 85 10 2 3 Check the Parameters of the Inverter Grid 85 10 3 Preparing before Power on 87 10 4 Power on 88 10 5 Completion of the Test Run 88 11 Appendixes 89 11 1 Technical Data 89 11 1 1 Electrical Part 89 11 1 2 Mechanical Part 91 11 1 3 System Data 91 11 1 4 Transformer Par...

Page 6: ...V 11 2 Warranty Statement 92 11 2 1 Normal Warranty 92 11 2 2 Extended Warranty 94 11 2 3 Contact Us 94 ...

Page 7: ...ain precautions must be observed when installing and or operating the product To reduce the risk of personal injury and to ensure the safe installation and operation of the product you must carefully read and follow all instructions cautions and warnings in this manual Warnings in this Document DANGER indicates a high degree of potential hazards if not avoided which will lead to death or serious i...

Page 8: ...sses to property DISCRIPTION is the additional information of the manual the emphasis and supplement of the contents which may also provide product optimization tips or skills that can help you solve certain problems or save your time Warnings on this product Please note the identification labels on the engine body including the following Warning electric shock This symbol indicates that the inver...

Page 9: ...ange so please do not touch arbitrarily to avoid personal injuries PE This symbol indicates that it is the PE port and solid grounding is needed to ensure the safety of the operating personnel ON This symbol is the ON position schematic diagram of AC and DC circuit breakers OFF This symbol is the OFF position schematic diagram of AC and DC circuit breakers ...

Page 10: ...expect you to put forward more views on the performance and the function of this product We continue to improve the quality of this product 1 2 Introduction This manual applies to TC500K3US O PV inverter hereinafter referred to as inverter this manual contains the followings contents Safety instructions This manual introduces safety signs during operation and precautions of dangers warnings and ca...

Page 11: ...s of the inverter during test commissioning and the operational process of the inverters Others This manual introduces the technical data of the inverter warranty clauses and the contact information of our company 1 3 Applicable Scope This manual is for the staff working on installing and operating of the inverter Staff for installation and maintenance shall be equipped with certain expertise in e...

Page 12: ...s etc used in this manual are owned by TBEA Xi an Electrical Technology Co Ltd No part of this document can be reproduced by unauthorized persons without the prior written permission of our company Manual content will be constantly updated and corrected but it is inevitable that there are slight discrepancies from material objects or errors in this manual Users will be subject to the purchased act...

Page 13: ...present in the live components of the inverter Touching live components results in death or serious injury due to electric shock When working in a high contact risk environment wear personal protective equipment Do not touch live components Follow the instructions precisely Observe all the safety messages on the product and in the documentation Before any work on the inverter is performed always d...

Page 14: ...rsonal protective equipment for all work on the inverter Prior to connecting the DC cables ensure that the DC cables are voltage free Unauthorized modification or damaged device can lead to danger to life due to electric shock or fire hazard It is forbidden to refit the equipment and no unauthorized person can use the equipment Initially and visually check whether the equipment is damaged or has o...

Page 15: ...ure that unauthorized persons do not have access to the PV plant Danger to life due to blocked escape routes In hazardous situations blocked escape routes can lead to death or serious injury It is imperative that the escape route is freely accessible at all times An escape route of at least 3 ft 915 mm width must be available at all times Make sure the minimum passage width of the route meets loca...

Page 16: ...n must comply with local electrical installation standards Improper contacts or operations of printed circuit boards or other static sensitive components will cause damages to the device Avoid unnecessary contacts with the circuit board Comply with the electrostatic protection specification wear antistatic wrist straps During the overhaul of the plant and routine maintenance turn the breakers on A...

Page 17: ...ic shock Prior to live line measurement it is imperative to wear suitable personal protective equipment and instruments such as wearing insulated gloves etc 2 2 2 Opening the Plant Even if all connections to the inverter have been disconnected lethal voltage may still be present in the capacitor of the inverter After disconnecting the inverter from voltage sources wait at least 5 minutes for the c...

Page 18: ...he installation manual and schematics Protective earthing connection has been done with power grid transmission and internal power supply Confirm that the inverter has been closed and locked Emergency stop switch is in loose status It shall be confirmed that the rated voltage frequency and phase sequence of the connection terminals on AC side are in line with requirements It shall be confirmed tha...

Page 19: ...o OFF 2 Observe the LCD display until the rate of work of the display is shown as 0 3 Turn both AC and DC circuit breakers to OFF 4 Disconnect the front and rear breakers of the inverter When fault or emergency occurring Shutdown procedure 1 Press down the emergency stop button then turn the key switch to OFF 2 Turn both AC and DC circuit breakers to OFF and then disconnect the preamplifier breake...

Page 20: ...ny doubt contact the TBEA Company The packing case of TC500K3US O contains the following items Table 3 1 Supply scope of TC500K3US O Items Name Quantity Remarks 1 TC500K3US O PV Grid Connected Inverters 1 Including cabinet keys and accessories 2 TC500K3US O Installation Manual 1 3 TC500K3US O Operation Manual 1 4 Warranty Card 1 5 Certificate 1 6 Test Report 1 TC500K3US O has been rigorously teste...

Page 21: ...s of the damage we will provide the fastest and best service If you have special needs users can log in the website of TBEA Co Ltd To freely download the latest version of the manual or directly contact with TBEA Xi an Electric Technology Co Ltd 3 2 Nameplate of TC500K3US O The nameplate is affixed on the top of the left side of TC500K3US O cabinet TBEA LOGO product name Product parameter data Pro...

Page 22: ...n of the delivery and the acceptance work if the device cannot be immediately installed and operated on site but needs to be stored the following aspects shall be paid attention to Prevent damage to the device due to moisture If the inverter is stored improperly in moist environment moisture will penetrate the attachment and cause internal electrical damage Keep the original closed state of the pa...

Page 23: ...and moisture will penetrate into the inverter and may damage the electrical part The building ground must be suitable for the weight of 2300kg 5077lbs Unevenness of the ground must be less than 0 25 Long term storage without packaging is prohibited Outdoor storage or storage in direct sunlight environment is prohibited Chassis tilting or overlapping placement is prohibited Regular inspection gener...

Page 24: ...ng term storage the cabinet door shall first be opened for inspection so as to confirm whether the device is intact and a professional test is necessary 3 4 Transportation The inverter shall only be transported complying with the transportation method described in 7 1 of the installation manual During the transportation always pay attention to its center of gravity position which has been marked o...

Page 25: ... system PV grid generated system consists of PV array PV grid connected inverters metering devices and the powder distribution system Solar energy is converted to DC power through PV array and becomes sine wave current synchronous with the grid through the PV grid connected inverter and is then fed into the grid TC500K3US O is an outdoor type grid inverter and rather flexible to use It can be inst...

Page 26: ...ystem components of TC500K3US O are as shown in Table 4 2 Table 4 2 List of the system components Name Type PV arrays Thin Film Cells Public grid IT Combiner box 600V 80A I 160A If the inverter isn t installed according to the document description or privately installed or reconstructed without authorization accidents or device damage is likely to occur If losses are caused by these reasons TBEA w...

Page 27: ...ng status of inverters LCD display Displaying the information of operating data Key switch Switches inverter Emergency stop button Shut down the inverter immediately when press it down DC main switch DC side circuit breaker switch Door lock To close the front door of the inverter use the matching key to lock the door AC main switch AC side circuit breaker switch DC input cabinet Inverter cabinet A...

Page 28: ...cription 4 3 1 Dimensions Maximum dimensions of TC500K3US O 2370mm 93 3inch 2140mm 84 3inch 910mm 35 9inch W H D Weighs approximately 2300kg 5077Ibs The mechanical and external dimensions are as shown in Figure 4 3 Figure 4 3 Dimensions of the complete machine ...

Page 29: ...ipped with a removable dustproof net and insect net which need to be cleaned regularly Figure 4 4 Ventilation schematic of TC500K3US O 4 4 Circuit Introduction Direct current generated by PV array is converted to alternating current through inversion in the inverting module of TC500K3US O and then becomes sine wave through the filter and is then fed to the grid via the isolation and step up of an ...

Page 30: ...in Figure 4 5 External communication unit 3 Controller AC Breaker Fuses DC Breaker inverter 320V 580V Auxillary unit HMI unuit RS 232 RS 485 DC 24V A B C DC SPD AC SPD E M C filt e r E M C filt er GFDI AC Fliter AC 200 Gab Gbc Gca AC Contactor Figure 4 5 The main circuit of TC500K3US O ...

Page 31: ...tc Its internal terminals are as shown in Figure 4 6 Figure 4 6 Schematic figure of terminals Items Name A PV array positive input terminals DC B PV array negative input connecting copper bars DC C Connect AC output connecting copper bars with L1 L2 and L3 three phase grids respectively D Grounding copper bars E RS485 communication interfaces and external power supply interfaces ...

Page 32: ...TC500K3US O Installation Instructions 26 RS485 RS232 converter is needed for communication with the upper computer ...

Page 33: ...ll not be placed in areas of high humidity in long term Avoid direct sunlight otherwise the excess temperature causes equipment derating which may affect power generation We recommend installation in the shade or shading devices installation Enough space around the unit for good ventilation convenient installation and maintenance as well as escape in emergency Installation environment clean As it ...

Page 34: ...and either sunken or inclined situations on the floor are prohibited Accuracy requirements of foundation slabs Levelness the base length tolerance shall be controlled within 1mm 1000mm Parallelism the base length tolerance shall be controlled within 1mm 1000mm Height difference between the front base and rear base shall be controlled within 1mm 1000mm A solid safe and reliable foundation must be p...

Page 35: ...pe routes must meet the American minimum requirements of 915mm in order to satisfy the minimum requirements for a single person to go through freely and also enough spatial distance will provide good conditions for the equipment and cables to release the heat avoiding the shutdown and even fire and other dangerous situations caused by overheating Minimum installation space for single TC500K3US O T...

Page 36: ...scription A 1700 70inch Minimum distance in front meeting the normal opening and closing of the front door user operations safe evacuation and other requirements B 1300 52inch Minimum distance rear C 600 24inch Minimum distance above D 600 24inch Minimum distance at right side 600mm 24inch is the distance from the closed wall E 600 24inch Minimum distance at left side The minimum space of installa...

Page 37: ...etails are shown in Figure 5 3 Figure 5 3 Requirements of back to back installation space for two TC500K3US O Second way face to face Details are shown in Figure 5 4 Figure 5 4 Requirements of face to face installation space for two TC500K3US O ...

Page 38: ...eously to avoid blocking the escape routes and preventing the people from failing to flee the scene immediately in case of failures Both the front and back doors of TC500K3US O can be opened and the maximum size of the door slabs is of about 750mm 5 2 3 Requirements of the Minimum Space for Indoor Uses If you need to install indoors the ground space cable trenches ducts ventilation equipment and v...

Page 39: ...00K3US O are led in and out below and the cables connecting the TC500K3US O inverter and the outside are suggested being aligned along the cable trenches for easy installation and maintenance Concrete cable trenches shall be preset at the installation location or steel supports shall be installed on the ground mounting surface shall be raised and cables shall be laid out at overhead places See the...

Page 40: ...ication control and power cables shall be separated when laying the cables and DC circuits and AC circuits shall be laid separately In this way the installation and maintenance will be easier and interference of power circuits to communication and control signal lines will be reduced Figure 5 6 Sectional view of cable trenches 5 3 2 Ventilation Requirements A lot of heat will be generated when TC5...

Page 41: ... TC500K3US O at places with bad ventilation and low air flow Enough fresh air shall be supplied at the air inlet of the inverter The air inlet shall be cleaned regularly to prevent being blocked by sediments and others when the cabinet is installed outdoors Ventilation equipment In order to ensure efficient and reliable operation of the equipment the ambient temperature for the equipment in runnin...

Page 42: ...the actual situation of the local wind direction Fans shall be overhauled every two years as recommended to ensure the equipment is running well 5 3 3 Other Requirements According to NEMA 3R protection class the TC500K3US O outdoor inverter is suitable for outdoor installation And the control areas are packaged and sealed According to EMC requirements and noise levels the inverter shall be install...

Page 43: ...p the shortest length as far as possible and keep a certain distance from the power cables The power cables power lines and data lines shall placed in separate cable trenches in order to avoid that the power cables and other cables are aligned parallelly for a long distance and reduce the electromagnetic interference caused by the output voltage transient The distance between the power cables powe...

Page 44: ...rface or supports as far as possible such as support beams steel tanks metal rails and so on 5 5 Fixation and Protection of Connection Cables 5 5 1 Fixation of Cables In order to prevent poor contact caused by loose wring cooper terminals by forces or heat or even fires caused by increased contact resistance the following requirements of torques shall be met when fastening the screws on the wiring...

Page 45: ... aligned along the trenches in connection if no cable trenches they shall be fastened by ribbons besides you shall avoid heating elements and circuit cables of high field when aligning the cables Protection for power cables Due to the strong current in the power circuit cables which may lead to short circuit you shall avoid any scratches or damages on the insulation skins of the cables when instal...

Page 46: ...TC500K3US O Installation Instructions 40 Figure 5 7 Installation process ...

Page 47: ...ve the inverter 2 Install and fix the inverter 7 Mechanical installation Electrical connection Electrical connection includes 1 Open the front door and remove the protective cover 2 DC side wiring 3 AC side wiring 4 Ground connection Communication cable connection 8Electrical connection Inspection after the installation The inspected items include 1 Mechanical installation inspection 2 Electrical ...

Page 48: ...e complete according to the packing list Items Name Quantity 1 TC500K3US O inverter 1 2 Anti theft screw wrench 2 3 Key 2 4 Certificate 1 5 Warranty card 1 6 Product support manual 1 7 Factory inspection report 1 6 2 Installation Tools and Parts The tools and parts required in installation are as follows Crane forklift or fork lift truck with sufficient carrying capacity Torque wrench Screwdriver ...

Page 49: ...ired during the course of transporting or handling the inverter 7 1 1 Precautions The links mentioned in the following contents are required to be noted during the transportation of the inverter all the time avoiding any hazards and accidents that may occur during the transportation All staff must wear proper safety protection equipment The minimum load bearing requirements of at least 2300kg must...

Page 50: ...face that does not meet the requirements for any deformation of the inverter as a result The forklift is used to move the inverter by the user as far as possible according to the recommendation and the weight and size of the machine shall be always noted Cables of DC input and AC main power are proposed to be laid out before the inverter cabinet is moved to the predetermined position Because the c...

Page 51: ...avity center logo Lifting logo Right side up prohibit to placing inverters horizontally in an inclined way or upside down Handle with care to avoid damages to inverters caused by too intense frictions and collisions in transportation environments Prohibit to placing in a multilayer stacking form Pay attention to moisture and prevent inverters from rain or moisture ...

Page 52: ... package are required to note when moving the inverter The equipment shall be provided with a sufficient carrying capacity and a reasonable lay out support or lifting point is required The forklift transportation a standard transportation method is shown in Figure 7 1A The center of gravity on the box shall fall onto the middle of the two forks of the forklift during the transportation A greater s...

Page 53: ...ithout packaging is usually used near the final installation location and the inverter with package removed can be moved by forklifts hoists sliding rails or cranes If the place to remove the package is farther from the final installation location the inverter with a wood pallet at the base can be transported by the forklift as shown in Figure 7 2 ...

Page 54: ...igure 7 3 The cover plates at the front and back bases are required to move The forklift shall be closer enough to take the inverter and then inserted in depth into the bottom of the inverter to lift it Lift it at the center of gravity The lifting process is required to keep slow to avoid any accidents Figure 7 3 Inverter is moved by using a forklift ...

Page 55: ...m the front and back sides Use lifting cables to fix and to ensure that four corners are all connected and fastened sufficiently Figure 7 4 Lifting party When lifting switch on the DC and AC circuit breakers making the handle of circuit breaker perpendicular to the ground separating lifting handles from damage due to wrapping and colliding with cables 7 2 Field Installation ...

Page 56: ...move the cushioning materials outside the inverters Step3Remove the anchor parts fixed on the transport board of the inverter a Remove the front and back cover boards of the base b Spin the self tapping bolt on the bottom of the wooden pellet c Remove the self tapping bolt to separate the inverter and the transport wooden pallet Figure 7 5 Fixed on wooden pallets Items Name A Inverter B Pallet C S...

Page 57: ...dering method is not recommended to fix the inverter The inverter needs to be fixed on the channel or ground installation steps are as follows Step 1 Remove the front and back cover plates of the bottom of the cabinet Step 2 M12 bolts are used to fix the inverter on the channel or ground through the waist holes in the base Figure 7 6 Fixed dimensions for bottom installation ...

Page 58: ...xation methods of the inverter Items Name A Inverter B Foundation C M12 anchor bolt D Cable trench E Channel steel F M12 bolts nuts spring washers flat washers combination Figure 7 8 Sketch of the connection between the base of the inverter and the channel ...

Page 59: ...TC500K3US O Installation Instructions 53 Items Name A Inverter base B M12 bolt C Flat washer D Spring washer E M12 nut F Channel steel ...

Page 60: ...onnections are conducted after the installation and fixation of the inverter and note the requirements of connections and precautions of this chapter in the electrical connections The DC side voltage of TC500K3US O DC is up to 600Vdc AC side voltage reaches 200Vac Do not touch any live parts Make sure that AC and DC sides are uncharged before installation and maintenance As the temperature of TC50...

Page 61: ...e open circuit voltage of PV array shall not exceed 600Vdc otherwise the inverter may be damaged The maximum power of PV array of TC500K3US O can be configured to 500kW Public grid TC500K3US O will continue to detect whether the power grid meet grid connected conditions To meet the grid limits of grid connected conditions the three phase power grid is used Meanwhile the grid connected inverter is ...

Page 62: ...as follows AWG 90 copper is recommended to use The current is proposed to be not greater than 3A through 1mm wire The wires of same sizes and types shall be selected for the same side of the cable The diameter of the single wire is avoided to be too large Cables shall be crimped with wire terminals with UL certification and the sizes of wire terminals shall be according to the actual installation ...

Page 63: ...y DC Φ11 67 4 196 22N m 2 0 AWG PV array DC Φ11 67 4 196 22N m 2 0AWG Grounding cable power cabinet Φ13 85 346 39N m 3 0 AWG Grounding cable AC side Φ13 85 346 39N m 3 0 AWG Grounding cable DC side Φ13 85 346 39N m 3 0 AWG Communication lines Φ5 0 75 27 3N m 17AWG L1 phase grid Φ18 6 253 1064 120N m 500Kcmil 6 L2 phase grid Φ18 6 253 1064 120N m 500Kcmil 6 L3 phase grid Φ18 6 253 1064 120N m 500Kc...

Page 64: ...t to the actual products that you have purchased 8 4 Wiring Components The installation of TC500K3US O sees Figure 8 1 Incorrect wiring order may cause a fire Note the order of the wiring Ensure that the connection pieces are tight when connecting If the connection is not sufficient or the contact surface is oxidized then the excessive heat may cause a fire Figure 8 1 Installation order of termina...

Page 65: ...pper and aluminum transition pieces are required when aluminum wires are used to connect wiring connections are shown in the figure below Figure 8 2 Connecting of copper and aluminum transition pieces Items Name A Copper bar with riveted nuts B Copper bar without riveted nuts C Bolt D Spring washer E Flat washer F Line terminal aluminum G Cooper aluminum transition sheet H Nut ...

Page 66: ... terminal then a whole piece of copper and aluminum transition piece is used as shown in Figure 8 2 The bottom of TC500K3US O has inlet line board as shown in the Figure through which the external lines can be threaded into the inverter going through the inlet line board The Figure 8 3 shows the hole making positions of the inlet line board making holes according to the Figure as shown is advisabl...

Page 67: ...on Instructions 61 Items Name A DC cabinet inlet line board B Power cabinet inlet line board C AC cabinet inlet line board 1 Inlet line board of DC cabinet 2 Inlet line board of power cabinet 3 Inlet line board of AC cabinet ...

Page 68: ...t holes of grounding cables H Inlet holes of communication lines 8 5 Preparations for Electrical Wiring Before wiring the door shall be opened to make the cables insert the seal threading plate Users need to open the front door of TC500K3US O before wiring specific steps are as follows Figure 8 4 Open the front door Step 1 The front door can be opened through the door lock handle Lock schematic is...

Page 69: ...onverged by the combiner box and then connected to the DC side of the TC500K3US O inverter The positive DC side of the TC500K3US O inverter is connected to the bottom of the fuse The fuse has 3 groups group A has 8 fuses located inside the DC groups B and C are located in the power cabinet each group has 6 fuses totally 20 fuses The upper positives shall be connected each to each with the lower ne...

Page 70: ...hall be checked the material of the external terminal connecting point if the copper and aluminum materials are interconnected a special copper and aluminum connector is needed don t directly connected Copper and aluminum connectors can be ordered from TBEA or quality products may be purchased by the client DC side wiring shall ensure that the copper cable specifications of each copper bar be cons...

Page 71: ...can be accessed make 2 fuses idle Access 120A for each way 6 ways can be accessed Access 120A for each way 6 ways can be accessed 1 Scheme 1 and Scheme 2 DC input cable connection TC500K3US O DC side of the inverter is of the maximum input current of 1600A in order to meet the maximum DC input current requirements and cooling needs the positive and negative poles each shall be connected with 20 wa...

Page 72: ... ways of positive cables with 2 cables for spare groups B and C of fuses in the power cabinet are all wired The negative is also connected with 18 negative cables and the upper positives shall be connected each to each with the lower negatives right DC input cable connection in Scheme 3 see Figure 8 6 Figure 8 6 Option Three DC input wiring ...

Page 73: ...verter to ensure the DC side wiring is not charged Step 2 Measured with a multimeter to ensure that the open circuit voltage of the PV array does not exceed 600Vdc Step 3 Use a multimeter to confirm the positive and negative Step 4 Strip the insulation of the cable end 5mm longer as the wiring hole The DC input terminal of the TC500K3US O is connected only 1 copper cable to each of the positive an...

Page 74: ...cable to the combiner box or the positive of PV array 1 Connect the wiring terminal to the lower fuse of positive input the fuse has nuts spring washers and flat washers which can be directly fastened with tools the installation detailed in the Figure 8 1 8 2 8 5 8 6 8 7 2 Tighten the nut using a torque wrench Step 8 Connect DC cable to combiner box or PV array negative 1 Select a bolt matching th...

Page 75: ...AC side inverter shall be cut off making the contact terminal uncharged The connecting of grid shall comply with the requirements of the relevant departments as well as all the concerned safety regulations Step 1 Cut off the AC side inverter and use multimeter to check if the terminal is free of charge Step 2 Check AC wiring phase sequence Strip the insulation from the cable end each phase of the ...

Page 76: ... burner or hot hair dryer to make heat shrink tubing tightened Step 5 Connect L1 cable to output wiring A U phase copper bar with identifier A as shown in the figure Connect L2 cable to output wiring B V phase copper bar with identifier B as shown in the figure Connect L3 cable to output wiring C W phase copper bar with identifier C as shown in the figure 1 Select bolt M16 nut M16 spring washer an...

Page 77: ... and if the wiring terminal and copper bar connections are clamped with some heat shrink tubing it shall be removed if clamped otherwise it could lead to poor contact or even damage to the inverter Three terminals are reserved for users on the AC power of TC500K3US O shown in Figure 8 8 Figure 8 8 AC power terminals Items Name A AC cabinet connecting copper bars B M16 bolts spring washers and flat...

Page 78: ...tening torque table Output terminals of cable connects to the transformer low voltage winding so the N line is dangling and does not connect with others and with good insulation protection Three phase cable A B C of the alternative current output shall respectively add yellow green and red hot shrink bushing in order to distinguish the phase sequences Step 7 Make sure the wiring is firm and fasten...

Page 79: ...e electric control room and must be in good connection with 3 grounding lines of 3 0AWG 85mm cable and the contact resistance shall not exceed 4Ω All leading in boards of each cabinet have leading in holes for ground wire Grounding bar is threaded together through the entire cabinet And Grounding bars of each cabinet shall have a ground wire when connected to the cabinet There shall be marked GND ...

Page 80: ...ue of 39 N m E Grounding cable 3 0AWG 85mm F Marks of grounding cable mounting holes To ensure safety make sure the potential of the cabinets that weren t connected by bolts is equal if multiple inverters are in parallel Use at least 16mm 5 AWG thick single yellow green cable to fix the inverters to the frame of the cabinet s shell with cable lugs and bolts which will prevent current turned up on ...

Page 81: ...RS485 serial communication Terminals have been reserved inside of inverter The position of the communication terminals are shown in Figure 8 10 Figure 8 10 Schematic diagram of communications wiring Items Name A Connection port of external power supply B Connection port of 485 communication line Apply a shielded twisted cable for RS485 communication cable The RS485 connector is located on the bott...

Page 82: ...d with A on the outside are the external power supply with AC200V B is labeled RS485 terminals on the terminal block Terminals marked with B are RS485 terminals 8 10 Power Supply The power supply mode of control source of TC500K3US O is divided into two modes One is a self powered mode and the other is the external power supply mode The machine defaults in the internal power supply Users can set a...

Page 83: ...lf powered mode of the inverter has been set up when delivery Directly use no other wiring 8 10 2 External Power Supply Modes If the user selects the external power supply mode the user shall adjust the machine as the following figure Figure 8 12 External power supply wiring ...

Page 84: ...er to prevent short circuiting of air flow inside and outside the cabinet and to ensure the tightness of the cabinet as a whole there is a need to seal the threaded hole at the bottom with fire clay After the cabinet wiring is completed there will be some certain gap between the cable and leading in hole which will cause a short circuit inside and outside the cabinet air flue resulting in an adver...

Page 85: ... C Fireproofing mud There is a scupper at the bottom of the cabinet There are two scuppers at the front and back of each cabinet as shown in Figure 8 14 which are located near the door Pay attention to whether the scupper is smooth to prevent fire clay or other debris block the scupper when seal the wiring and cabinet ...

Page 86: ...TC500K3US O Installation Instructions 80 A C B D F E G I H J L K Figure 8 14 Schematic diagrams of scupper ...

Page 87: ...right back of the DC cabinet E Scupper at the left front of the power cabinet F Scupper at the right front of the power cabinet G Scupper at the left back of the power cabinet H Scupper at the right back of the power cabinet I Scupper at the left front of the AC cabinet J Scupper at the right front of the AC cabinet K Scupper at the left back of the AC cabinet L Scupper at the right back of the AC...

Page 88: ... temperature humidity and ventilation conditions of the environment the inverter is exposed meet the requirements Cooling air flows smoothly The seal protection of the cabinet is complete and reliable Inspection of electrical installation The inverter is grounded completely and firmly Grid voltage matches with the rated input voltage of the inverter unit The grid connecting phase sequence is corre...

Page 89: ...ve parts shall be fastened with insulating tapes No tools parts and conductive dusts or other foreign matters generated by drilling are left in the cabinet No condensed moisture or icing is inside the cabinet The door is locked and the keys are kept by a specially assigned person ...

Page 90: ... of the device shall be checked thoroughly before commissioning Especially check whether the voltage of DC and AC terminals meets the requirements and whether the polarity and phase sequence is correct Check whether the connection of the system comply with the requirements of the relevant standards And the system is properly grounded Grounding resistance of decisive has a great significance for th...

Page 91: ... the PV array work and conduct the test when the PV array run stable Record the environmental parameters including voltage temperature and light intensity Measure the cable resistance with OHM meter that is megohm range between the junction box and inverter Accurate records all values 10 2 2 Check the Inverter A series of checks shall be conducted before power on Step 1 Check the installation and ...

Page 92: ... range with a multimeter and records all phases and comparative voltage PE value in details Parameter description Reference value V Grid voltage 208 A B 208 A C 208 B C 208 A PE 120 B PE 120 C PE 120 If the deviation of the voltage is too large the transmission ratio of the transformer needs to be adjusted If possible measure THD of the phase total harmonic distortion and check the curve If the di...

Page 93: ...oltage TC500K3US O DC voltage shall not exceed 600Vdc Very high DC voltage will damage the inverter 10 3 Preparing before Power on Ready to power on when all the items have been checked and all has been confirmed to meet the requirements Step 1 Make sure the grid line voltage is 200Vac again Step 2 Make sure that no person is operating the inverter inside and outside cabinet Step 3 Install all the...

Page 94: ...ltage current and THD situation are stable Step 3 Check whether the inverter enclosure is grounded properly Step 4 Operate LCD control panel to check whether they are normal and accurate So far TC500K3US O commissioning has been completed you can enter the daily operation and maintenance procedures Once the normal operation of the inverter only when maintenance and troubleshooting there is a need ...

Page 95: ... source 3180 A peak 85 33 ms Output data grid side Parameter description Reference value Rated output power kW 500 Normal output voltage Vac 200 defalt setting value Allowable grid voltage range three phase 12 10 i e 176Vac 220Vac Normal output frequency Hz 60 defalt setting value Operating frequency Hz 59 8 this operating point is adjustable 60 5 Maximum continuous output current A 1443 ac Maximu...

Page 96: ... Utility interconnection voltage trip limits and trip times Max V Min V Clearing times s L L L N L L L N Max Min Overvoltage Fast 250 N A 236 N A 1 0 16 Overvoltage Slow 228 N A 216 N A 10 1 Undervoltage Slow 180 N A 140 N A 20 2 Undervoltage Fast 120 N A 80 N A 2 0 16 Parameter description Reference value Adjustable LIMITS Utility interconnection frequency trip limits and trip times Magnitude ran...

Page 97: ...e consumption W 100 Normal operation temperature range 25 60 full power operating ambient temperature 25 50 Maximum continuous output power 55 C kW 350 Maximum continuous output power 60 C kW 350 Cooling method Air cooling Permissible relative humidity 0 95 without condensation 11 1 4 Transformer Parameters A External Transformer was Used in TC500K3US O Anti Islanding Test Transformer parameters a...

Page 98: ...11 2 Warranty Statement 11 2 1 Normal Warranty 1 Evidence During the warranty period customers claiming to quality assurance are required to present invoice to purchased products meanwhile trademark on the products shall be clearly visible otherwise our company reserves the right not to conduct quality assurance 2 Warranty clause The products with malfunction replaced are disposed by our company R...

Page 99: ...l Machine malfunction or damage caused by installing repairing altering or disassembling by unauthorized services and staff Machine malfunction or damage caused by using non standard or those components or software not offered by Sunny Central Any installation or usage not in accordance with provisions of relevant international standards Damage caused by unexpected disaster If customers ask for qu...

Page 100: ...any questions please contact us about this product contact details are as follows Company name TBEA Xi an Electric Technology Co Ltd Address Xi an TBEA New Energy Industrial Park No 70 fourth Shanglinyuan Road High tech Zone Xi an Zip code 710119 Hotline 400 606 6029 E mail tbeapower tbea com cn Fax 029 68760500 042http www tbeapower com ...

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