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Xantrex PV225S-480-P, Operation And Maintenance Manual

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4

Troubleshooting

Chapter 4, “Troubleshooting” contains information and procedures 
for troubleshooting the PV225S 225 kW Grid-Tied Photovoltaic 
Inverter. It provides descriptions of common situations and errors that 
may occur and provides possible solutions for resolving fault 
conditions. It also provides instructions for clearing faults manually, if 
required.

Summary of Contents for PV225S-480-P

Page 1: ...PV225S 225 kW Grid Tied Photovoltaic Inverter PV225S 480 P Operation and Maintenance Manual...

Page 2: ......

Page 3: ...PV225S 225 kW Grid Tied Photovoltaic Inverter Operation and Maintenance Manual...

Page 4: ...are used herein for identification purposes only Notice of Copyright PV225S 225 kW Grid Tied Photovoltaic Inverter Operation and Maintenance Manual August 2005 Xantrex International All rights reserv...

Page 5: ...nized into five chapters and one appendix Chapter 1 Introduction contains information about the features and functions of the PV225S 225 kW Grid Tied Photovoltaic Inverter Chapter 2 Operation contains...

Page 6: ...he manual it will be referred to as the PV225S unless otherwise noted WARNING Warnings identify conditions or practices that could result in personal injury or loss of life CAUTION Cautions identify c...

Page 7: ...IEEE Institute of Electrical and Electronics Engineers IGBT Insulated Gate Bipolar Transistor IPM Intelligent Power Module kcmil 1000 circular mils LAN Local Area Network POTS Plain Old Telephone Ser...

Page 8: ...vi...

Page 9: ...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 w...

Page 10: ...ding 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...

Page 11: ...cation of these terminals 8 The DC power conductor wiring interfacing with the DC terminals at S2 6 K2 6T3 and TB4 are to be tightened to a torque value of 600 in lbs 67 8 Nm These terminals will acce...

Page 12: ...the utility main circuit breaker 2 Open lockout and tag the AC Disconnect Switch S1 on AC interface assembly See Figure 1 8 on page 1 12 for the location of the AC Disconnect Switch 3 Open lockout an...

Page 13: ...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...

Page 14: ...xii...

Page 15: ...1 7 Converter Control Unit CCU2 1 7 Power Electronics Matrices 1 7 Inductor Enclosure 1 7 DC Interface Enclosure 1 8 Transformer Enclosure 1 8 AC Interface Enclosure 1 8 Communications Enclosure 1 9 O...

Page 16: ...Changes 2 20 Setting the Date and Time 2 21 Manual State Transitions 2 22 Automatic State Transitions 2 22 Auto restart Feature 2 23 Energize Procedure Startup 2 24 Computer Communications with the P...

Page 17: ...or Interlock Functions 3 6 Matrix Test 3 6 Operate Inverter 3 7 Completed Commissioning 3 7 4 Troubleshooting Faults and Fault Codes 4 2 General Troubleshooting 4 2 Clearing Faults Manually 4 3 Fault...

Page 18: ...ons System Specifications A 2 Environmental Specifications A 2 Electrical Specifications A 3 Over Voltage Under Voltage and Frequency Ranges A 3 Wire Gauge and Torque Requirements A 4 Warranty and Pro...

Page 19: ...ation Screens 2 7 Figure 2 4 Operator Interface Menu Diagram 2 8 Figure 2 5 Scrolling through the Read Menu 2 10 Figure 2 6 Read by ID Feature 2 13 Figure 2 7 State Transition Diagram 2 20 Figure 2 8...

Page 20: ...re 4 1 LCD showing Fault Code 4 3 Figure 5 1 Inverter AC Terminal Locations in the Main Inverter Enclosure 5 4 Figure 5 2 Utility AC Terminal Connections in the AC Interface Enclosure 5 4 Figure 5 3 P...

Page 21: ...lues Menu 2 14 Table 2 5 Write Menu Parameters 2 16 Table 4 1 Fault Codes 4 4 Table A 1 Environmental Specifications A 2 Table A 2 Electrical Specifications A 3 Table A 3 Over Under Voltage and Over U...

Page 22: ...xx...

Page 23: ...1 Introduction Chapter 1 Introduction contains information about the features and functions of the PV225S 225 kW Grid Tied Photovoltaic Inverter...

Page 24: ...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 consum...

Page 25: ...sabled the PV225S will regulate the DC Bus at the PPT V Ref setpoint Regulating the DC bus means drawing more or less current out of the PV array to maintain this desired voltage With the PPT Enable s...

Page 26: ...put current waveform Given a nominal input voltage of 208 Vac the minimum DC input voltage threshold is 300 Vdc On a transient basis the PV225S does have the ability to adjust the minimum DC input vol...

Page 27: ...ain latched until the utility voltage and frequency have returned to normal for at least 5 minutes This method has been extensively tested and proven to exceed the requirements of IEEE 929 Recommended...

Page 28: ...nclosure Inductor Enclosure DC Interface Enclosure and Communications Enclosure The second module includes the Transformer Enclosure and AC Interface Enclosure These components are identified in Figur...

Page 29: ...tronics Matrices The power electronics converters are located at the top of the PV225S main inverter enclosure Both the left and right matrices are comprised of six switching transistors IGBTs transis...

Page 30: ...rmer Enclosure from the AC Interface Enclosure to the Main Inverter Enclosure AC Interface Enclosure The AC Interface Enclosure is NEMA 3R rated The AC interface serves as the connection between the u...

Page 31: ...e could include a POTS Connect Kit a Wireless Connect Kit or an Ethernet LAN kit or a Direct Connect Kit Figure 1 4 AC Interface Enclosure and Transformer Enclosure AC Disconnect Switch Transformer En...

Page 32: ...tdown of the PV225S 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 PV225S is prevented from bein...

Page 33: ...ess the switch is in the ON position The PV225S is prevented from being restarted until the ON OFF switch is turned back to the ON position WARNING Shock Hazard Disengaging the main enclosure door int...

Page 34: ...will signal the CCU2 Converter Control Unit 2 to stop processing power prior to opening the DC Disconnect Switch Additionally opening the DC Disconnect Switch will cause the PV225S to execute an immed...

Page 35: ...Goal State Fault Code if applicable Inverter State Line Voltage and Current Inverter Matrix Temperature Inverter Power PV State PV Voltage and Current PV Power Grid Frequency Peak Power Tracker Enable...

Page 36: ...hod is most commonly used by field technicians for commissioning and troubleshooting purposes Universal Front Panel Control Unit UFCU The UFCU keypad is located on the front of the Main Inverter Enclo...

Page 37: ...tion 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 gend...

Page 38: ...e 1 11 illustrates the PV225S connected remotely to a personal computer Wireless Access Figure 1 12 illustrates the PV225S connected remotely to a personal computer using a wireless network Figure 1 1...

Page 39: ...1 17 Ethernet LAN Access The PV225S can be remotely accessed through a local area network Direct Access Figure 1 14 illustrates the PV225S connected directly to a personal computer Figure 1 13 LAN Acc...

Page 40: ...quisition The inverter maintains a data log in non volatile memory for up to 30 days after which the oldest data is overwritten The GUI reads this data and updates a local file that can be imported to...

Page 41: ...2 Operation Chapter 2 Operation contains information on the basic operation of the PV225S 225 kW Grid Tied Photovoltaic Inverter...

Page 42: ...aged position Both the AC and DC Disconnect switches must be in the ON or closed position Fault conditions must not be present Faults Fault states are automatic from any state of operation In the even...

Page 43: ...ltage 440V PV V Start PV Voltage 440V PV V START K1 Settle for 5 seconds ON LINE PV Power 1 0kW PV P STOP PV Power 1 0kW PV P STOP PV Voltage 300V Min Oper TEST for 5 0 min PV T STOP PV Voltage 300V M...

Page 44: ...ndition will be reported to the operator interface LCD Most PV225S faults are latching and must be cleared at the operator interface keypad before transitioning to another operating state The ON OFF s...

Page 45: ...ng PV array V I characteristics The PV controller regulates a constant amount of PV current as commanded by the user from the operator interface keypad up to the PV current limit of the PV225S If the...

Page 46: ...lear faults In the WRITE Menu it jumps to set Goal F2 While in the READ Menu this key jumps to display INV A Volts While in the WRITE Menu this key jumps to display Max AC Volts F3 While in the READ M...

Page 47: ...wing information First Line System Status ID 1 Second Line Inverter Status ID 4 Third Line PV Status ID 13 Fourth Line Goal State ID 2 Figure 2 3 Initialization Screens Initialising Front Panel v5 0 S...

Page 48: ...ccurs at the LCD above the Universal Front Panel Control Unit UFCU and if used at the computer running the GUI monitoring program Making changes to the parameters within the WRITE Menu is done with th...

Page 49: ...he operator interface keypad to scroll through the READ Menu The fourth line of the display will change to display the appropriate information See Table 2 1 The key will scroll downward through the me...

Page 50: ...it ENTER or Value by ID System PWR Tracking Inv Online PV Online INV A Volts 480 From the Standard Display 1 Press the button once 2 Fourth line displays CCU version and Front Panel version software 3...

Page 51: ...llowing Shut Down 0 PWR Tracking 1 Manual Current 2 Matrix Test 3 2 N A Fault code See Fault Code Descriptions on page 4 4 for a detailed list of Fault Codes 3 N A Inverter State Displays as INV where...

Page 52: ...line 3 Sleep test 4 13 N A PV Voltage Displays as PV Volt xxx PV Voltage 14 Vdc PV Current Displays as PV amps xxx PV Current 15 Adc PV Power Displays as PV kW xxx PV Power 16 kW Grid Frequency Displ...

Page 53: ...ENTER to enter the Read by ID feature 3 Use the keypad to enter the ID number of the Data Log Configuration or Accumulated Value ID number and press ENTER See Table 2 2 for a list of READ Menu items...

Page 54: ...cumulated Values Menu ID Usage 600 Accumulated Operating Hours on actual day 601 Accumulated Operating Hours in actual week 602 Accumulated Operating Hours in actual month 603 Accumulated Operating Ho...

Page 55: ...his month 633 Peak Power monitored this year 634 Peak Power monitored since Commissioning 635 639 Not available 640 Peak Power Sold for a day 641 Peak Power Sold for a week 642 Peak Power Sold for a m...

Page 56: ...r the desired value and press ENTER If the value entered is outside the acceptable range for the parameter the original value will remain c To leave the WRITE Menu and return to the READ Menu press th...

Page 57: ...requirements 35 Hertz 59 5 59 5 60 5 Maximum Ground Fault Current Displays as Max Gnd Flt I This parameter sets the trigger point value for Ground Over Current 0033 fault Once the current through the...

Page 58: ...er expires 40 Seconds 300 1200 0 PV Output Power to Enter Sleep Test Mode Displays as PV P Stop This is the output power trigger point for the inverter to transition into sleep test mode When the outp...

Page 59: ...For example if the value of this parameter is 0 5 then every half a second the power tracker will increase or decrease the voltage reference point to check if more power can be produced at the new le...

Page 60: ...al State menu will show on the LCD display 4 Scroll through the goal state menu with the or keys until the desired goal state is displayed on the fourth line of the display 5 Press ENTER The LCD will...

Page 61: ...in a six digit format For example a The date is entered month day year mmddyy April 28 2005 is entered 042805 ENTER b The time is entered in military hours minutes seconds i e 24 hour clock 4 30 pm is...

Page 62: ...ater current than the capacity of the PV array If this causes the PV voltage to drop below the minimum operating voltage 300 Vdc the PV225S will transition to Shutdown 3 To exit the Manual Current mod...

Page 63: ...the fault condition if possible and attempt to clear the fault by pressing F1 2 The ability to clear the fault can only be done from the READ Menu If a fault occurs while accessing the WRITE Menu pres...

Page 64: ...han the PV V Start set point De Energize Isolation Procedure Shutdown The following procedure should be followed to de energize the PV225S for maintenance To isolate the PV225S 1 Turn the ON OFF switc...

Page 65: ...s metering and data logging capabilities and controls protective functions If multiple inverters are networked together the software is capable of tracking up to 50 inverters on the same network Deter...

Page 66: ...n must be enabled on your CDROM drive Manual Start assumes that Autorun is not enabled on your CDROM drive Use a Command prompt to initiate the installation program Starting the Setup Program Using Au...

Page 67: ...o your CDROM and the name of the installation program as shown in Figure 2 10 4 Click OK The splash screen shown in Figure 2 11 will appear 5 Proceed to the Model Specific Software Installation sectio...

Page 68: ...can continue To continue with the GUI software installation 1 After the GUI Setup Splash Screen appears Figure 2 11 click on the button INSTALL PV225S GUI The GUI Setup Welcome Window will appear next...

Page 69: ...is acceptable for the installation proceed to Step 4 If not click on the CHANGE DIRECTORY button and provide a new name for the desired destination directory 3 Click on the picture of the computer to...

Page 70: ...program group to be used The following setup progress indication window will appear 5 When completed you will see this 6 Click OK The GUI is now installed on the computer Figure 2 15 GUI Setup Progres...

Page 71: ...mputer and click the following menu items in the order shown below 1 Window s START button 2 PROGRAMS 3 XANTREX_SOLAR 4 XANTREX SOLAR GUI Remote LAN Connection If no inverter is connected to the COM1...

Page 72: ...152607 Direct Connection If the serial communication port of the inverter is connected to the COM1 serial port of the computer the following screen will appear Figure 2 18 GUI Interface Screen if Conn...

Page 73: ...cordingly follow the directions provided below To configure the inverters in the GUI 1 With the GUI Main Menu open Right click on the Inverter 1 icon 2 Click on the tabs to display each page and fill...

Page 74: ...out Operational Limits Information requested b Click on the PV Sub menu to continue c Fill out PV Information requested d Click on the Power Tracker Sub menu to continue Figure 2 21 Operational Config...

Page 75: ...Connection General Information in the form in Figure 2 24 7 Click on the Telephone Fault Configuration sub menu to continue Figure 2 23 Operational Configuration Screen Power Tracker Fill out all the...

Page 76: ...n Figure 2 26 11 Once the information is complete click the OK button to accept the changes and return to the GUI main menu Figure 2 25 Connection Configuration Screen Telephone Fault Configuration Fo...

Page 77: ...sections Getting Started IMPORTANT Read this first Setup Tutorial for setting up the GUI and configuring an inverter Windows Description of each window of the GUI Menu Commands Description of each GU...

Page 78: ...2 38...

Page 79: ...Computer Communications with the PV225S 152607 2 39...

Page 80: ...Operation 2 40 152607...

Page 81: ...3 Commissioning Chapter 3 Commissioning contains information on safely commissioning the PV225S 225 kW Grid Tied Photovoltaic Inverter...

Page 82: ...nications with the GUI h Confirm Operational Parameters AC DC and Power Tracker i Verify Door Interlock Functions j Perform the Matrix Test k Operate Inverter 3 Submit the Test report and warranty for...

Page 83: ...ure The Commissioning Test procedure must cease at this point Do not attempt to continue the test until each step can be checked and verified a If grid voltage is not available and the Commissioning T...

Page 84: ...nergize the control power circuits 3 Look listen and smell for signs of defects 4 Record any defects found 5 Once you finish applying the grid voltage go back to the GUI Commissioning Procedure and cl...

Page 85: ...ablished close the connection b While at the Inverter create a fault This could be done by opening the DC Disconnect Switch S2 c Verify the Inverter calls the End User and reports the fault The fault...

Page 86: ...ch by pulling it out into the service position 3 Clear the fault 4 Once you finish these tasks go back to the GUI Commissioning Procedure and click on the check box to indicate the task is complete Go...

Page 87: ...lete Go to the next step by clicking on the NEXT button Completed Commissioning 1 Once you have successfully completed all the commissioning steps save the test report to a file 2 Email the completed...

Page 88: ...3 8...

Page 89: ...s for troubleshooting the PV225S 225 kW Grid Tied Photovoltaic Inverter It provides descriptions of common situations and errors that may occur and provides possible solutions for resolving fault cond...

Page 90: ...the cause of the fault has been identified and corrected and it is determined to be safe to proceed PV225S faults may be manually cleared from the UFCU keypad or using the remote GUI See Clearing Fau...

Page 91: ...ocedure describes how to manually clear a fault message from the LCD To clear the fault 1 Determine the source of the fault using Table 4 1 Fault Codes on page 4 4 Correct the fault condition 2 Ensure...

Page 92: ...tes that the Utility grid frequency is above or rose above the maximum allowed value of 60 5Hz for greater than 6 cycles This fault is auto clearing Once the Utility grid frequency has recovered withi...

Page 93: ...nnection of the PV225S to the grid has failed K1 was opened while the PV225S was processing power K1 is inoperable K3 is inoperable SSR1 is inoperable TS1 or TS2 is open 0015 Grid Disconnection S This...

Page 94: ...hat the PV225S has detected that the DC bus voltage has exceeded the maximum allowed value of 925 Vdc PV system wiring short Lightning strike on PV system wiring XX31 Left Matrix Over Current S This f...

Page 95: ...Supply is defective P3 on CCU2 is loose or disconnected AC system wiring short 0033 Ground Over Current S This fault indicates that the PV225S has detected that the ground fault current has exceeded t...

Page 96: ...mory S This fault indicates that the PV225S has detected that one of the two non volatile memory banks on the CCU2 controller board has failed The CCU2 performs a series of tests to confirm the validi...

Page 97: ...individual IPM devices of the IGBT matrix also generates a gate fault as the result of either short circuit over current over temperature or an under voltage condition The first two digits of the fau...

Page 98: ...one IGBT faults simultaneously the two first digits are added in hexadecimal form to indicate that the gate drive fault has occurred in more than one phase thus the error code will contain the summati...

Page 99: ...ve Interlock switch is inoperable P2 or P3 on CCU2 is loose or disconnected CCU2 15Vdc Power Supply is defective 0071 PV Switch Open H This fault indicates that the PV225S has detected that the DC Dis...

Page 100: ...Software acknowledge bit not accepted FPGA inoperable 0084 Left Matrix Not OFF S This fault indicates that the PV225S has detected that the left IGBT matrix FPGA was not disabled after having sent a c...

Page 101: ...ftware for the PV225S must be downloaded into the CCU2 controller board F100 Software Restarted S This fault indicates that the PV225S has detected that the system software has been re booted This is...

Page 102: ...4 14...

Page 103: ...5 Preventative Maintenance Chapter 5 Preventative Maintenance contains information and procedures for performing preventative maintenance on the PV225S 225 kW Grid Tied Photovoltaic Inverter...

Page 104: ...e PV225S for maintenance To isolate the PV225S 1 Turn the ON OFF switch to the OFF position 2 Open the DC Disconnect Switch 3 Open the AC Disconnect Switch 4 Open the utility connection circuit breake...

Page 105: ...Disconnect Switch 3 Open lockout and tag the DC Disconnect Switch S2 on DC interface assembly See Figure 1 8 on page 1 12 for the location of the DC Disconnect Switch 4 Using a confirmed accurate mete...

Page 106: ...re Figure 5 2 Utility AC Terminal Connections in the AC Interface Enclosure AC Ground Bar TB1 to be used for the Chassis Ground TB6 TB5 TB7 AC Interface Enclosure Enlargement of Terminal Connectors in...

Page 107: ...Maintenance Safety 152607 5 5 Figure 5 3 PV Terminal Locations PV NEGative K2 6T3 PV POSitive S2 6 PV GrouND TB4...

Page 108: ...sfer heat which may cause the PV225S to enter a fault state based upon an over temperature alarm Remove and clean if debris is present Fan Operation Verify proper operation of the external cooling fan...

Page 109: ...found to be or are suspected to be unacceptable contact your Xantrex Technology distributor for factory replacements or recommendations Replacement of any damaged wires will be necessary Verify all me...

Page 110: ...5 8...

Page 111: ...A Specifications Appendix A provides the environmental and electrical specifications for the PV225S 225 kW Grid Tied Photovoltaic Inverter...

Page 112: ...face Overall System Footprint Layout Option A Layout Option B 88 5 in H x 80 in W x 32 in D 225 cm H x 203 cm W x 81 cm 49 5 in H x 61 5 in W x 35 5 in D 126 cm H x 156 cm W x 90 cm D 14 ft W x 5 ft L...

Page 113: ...tion PV225S 480 P Nominal AC Input Voltage 10 to 12 acceptable range 480 Vac 422 to 528 Vac Maximum AC Output Current 271 Arms Nominal AC Input Frequency 0 5 to 0 7 Hz acceptable range 60 Hz 59 3 to 6...

Page 114: ...M to 4 AWG 1 stud per pole 3 8 16 420 in lb 47 5 Nm TB12 System Ground 500 MCM to 4 AWG 1 stud per pole 3 8 16 420 in lb 47 5 Nm TB11 Neutral 500 MCM to 4 AWG 1 stud per pole 3 8 16 228 in lb 25 7 Nm...

Page 115: ...Appendix A Schematics 152607 A 5 Figure A 1 Electrical Diagram sample...

Page 116: ...LL NOT BE REPRODUCED COPIED OR USED AS THE BASIS FOR THE MANUFACTURE OR SALE OF EQUIPMENT WITHOUT THE EXPRESS WRITTEN PERMISSION OF XANTREX TECHNOLOGY INC 2 D ANGLES AUT X XX X XXX SIZE TITLE CONFIDEN...

Page 117: ...for Control Power Distribution 152812 A2 REVISIONS SEE SHEET 1 6 B A 5 C D 4 3 DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SHOWN 2 TITLE 6 PROJECTION 3RD ANGLE 5 4 3 2 1 DWG No TM D SCALE SIZE SHT OF R...

Page 118: ...ic for Converter Control Unit 152812 A3 REVISIONS SEE SHEET 1 6 B A 5 C D 4 3 DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SHOWN 2 TITLE 6 PROJECTION 3RD ANGLE 5 4 3 2 1 DWG No TM D SCALE SIZE SHT OF REV...

Page 119: ...the property of Xantrex Xantrex covers both parts and labor necessary to repair the product and return shipment to the customer via a Xantrex selected non expedited surface freight within the contiguo...

Page 120: ...sion of implied warranties To the extent you are entitled to implied warranties under federal law to the extent permitted by applicable law they are limited to the duration of this Limited Warranty So...

Page 121: ...ort xantrex com Customer Company Name __________________________________ Project Name __________________________________ System Location Information Street __________________________________ City ____...

Page 122: ...WA 4...

Page 123: ...tware Setup Program 2 26 System Requirements 2 26 I Inductor Enclosure 1 7 Installation 2 28 integrated controller 1 2 Internal Metrics 1 18 Isolation Procedure 5 2 L Lockout and Tag 5 3 M Main Enclos...

Page 124: ...1 18 Remote LAN Connection 2 31 Running the GUI 2 31 S Self protection features 1 2 Shutdown 2 24 Specifications A 2 Electrical A 3 Environmental A 2 Over Voltage Under Voltage and Frequency Ranges A...

Page 125: ......

Page 126: ...rex Technology Inc 1 800 670 0707 Tel toll free NA 1 360 925 5097 Tel direct 1 800 994 7828 Fax toll free NA 1 360 925 5143 Fax direct customerservice xantrex com www xantrex com 152607 PC Printed in...

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