ABB PVI-3.0-TL-OUTD-S-US Product Manual Download

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ABB solar inverters

Product manual

PVI-3.0-3.6-3.8-4.2-TL-OUTD-S-US (-A)

(3.0 to 4.2 kW)

Summary of Contents for PVI-3.0-TL-OUTD-S-US

Page 1: ...ABB solar inverters Product manual PVI 3 0 3 6 3 8 4 2 TL OUTD S US A 3 0 to 4 2 kW ...

Page 2: ... 2 3001CV List of related manuals UNO manuals and guides Code English PVI 3 0 3 6 3 8 4 2 TL OUTD US A Quick Installation Guide BCM 00161 1 ...

Page 3: ...ponsible party could void the user authority to operate the equipment FCC REMARKS The equipment has been tested and found to comply with the limits for a Class B digital device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radiate radio frequency energy...

Page 4: ... inverters 1 Introduction and safety 2 Installation location 3 Mounting and wiring 4 Operations 5 Troubleshooting 6 Maintenance 7 Appendix PVI 3 0 3 6 3 8 4 2 TL OUTD S US A Product manual BCG 00681 1_AA NA Rev 1 0 Copyright 2014 ABB All Rights Reserved ...

Page 5: ...tation and handling 13 Lifting 13 Incoming inspection 13 Select the installation location 14 Environmental check 14 Installation position 15 Mounting and wiring 17 Wall mounting 17 Wiring details 19 Wiring box components 19 Wiring connections 22 DC array connections 23 Independent or parallel configuration of inputs 24 Setting the input mode switch S1 25 Parallel mode front switch wiring box S ver...

Page 6: ...lectric parameter monitoring 48 Troubleshooting 49 Arc fault detection self test errors 49 Obtaining the service level password 50 Display messages and error codes 50 Making a service call 61 Maintenance 63 Routine maintenance 63 Recommended system maintenance 64 Preventative maintenance 64 Storage and dismantling 65 Appendix 67 System description 67 Protective devices within the inverter 68 Topog...

Page 7: ... with all prevailing codes and regulations associated with high voltages HOT TEMPERATURE Some surfaces may become hot do not touch the product while it is in operation UL1741 Standard for Safety for Inverters Converters Controllers and Interconnection System Equipment for use with Distributed Energy Resources CSA C22 2 No 107 1 01 General Use Power Supplies Equipment safety warnings In addition to...

Page 8: ...ation or operation may lead to serious safety and shock hazards and or equipment damage Electrical connection warnings This grid tied inverter system operates only when properly connected to the AC utility grid Before connecting the inverter to the AC utility grid contact the local power distribution company to receive the appropriate approvals This connection must be made only by qualified techni...

Page 9: ...y do not replace the safety regulations enforced in the country of installation Maintenance operations must be carried out according to the maintenance section 6 of this manual Do not use the equipment if any operating anomalies are found Liabilities arising from commercial components are delegated to their respective manufacturers Thermal and voltage hazard WARNING Depending upon ambient temperat...

Page 10: ...g parameters stated in this manual and adherence to the National Electric Code See environmental conditions below and environmental checks in section 2 Conditions of Use WARNING This inverter utilizes a transformerless design and requires connect ed array s to be floating with respect to ground it can be used only with photovol taic modules that do not require one of the terminals to be grounded T...

Page 11: ... is commonly referred to as a DC Arc Fault Current Interruption The ABB DC ARC FAULT DETECTOR and INTERRUPTOR AFDI solution is based on Digital Signal Processor DSP technology TheAFDI module has two independent channels designed to accommodate the two independent MPPT channels associated with all ABB String inverters and has two current sensors and associated circuitry to identify the presence of ...

Page 12: ... Adjustable parameters UL 1741 CSA C22 2 No 107 1 01 C US Country of Origin Italy www abb com solar SOLAR UTILITY INTERACTIVE TRANSFORMERLESS INVERTER MODEL PVI 3 0 OUTD S US This device complies with Part 15 of the FCC Rules Operation is subject to the following two 2 this device must accept any interference received including interference that may cause undesidered operation Nominal Input Operat...

Page 13: ... or where there is a provision eyebolts or handles can be inserted and used as lifting points Do not lift several units or parts of the equipment at the same time unless otherwise indicated Incoming inspection It is the customer s responsibility to examine the condition of the unit Upon receipt of the inverter please check the following Inspect the shipping container for any external damage Invent...

Page 14: ...alling the inverter where operating temperatures exceed the specifications will result in power limiting It is recommended the inverter be installed within the specified temperature range Exposure to direct sunlight will increase the operational temperature of the inverter and may cause output power limiting ABB recommends using a sun shade minimizing direct sunlight when the ambient air temperatu...

Page 15: ...Ds can be easily seen Ensure sufficient working area in front of the inverter to allow removal of the covers and easy access for servicing the inverter When planning the installation maintain clearance distances shown to allow normal control functions and easy maintenance operations For multiple inverter installations position the inverters side by side maintaining minimum clearances If the space ...

Page 16: ... 16 3005CC2 2 Installation location ...

Page 17: ...r If the installation is done on a concrete wall the wall plugs provided should be used and the mounting holes in the wall should have a 10mm diameter and 75mm depth When the wall is made of a different material other than concrete the installation should be done using adequate mounting material ABB recommends always using stainless steel screws Components included in mounting kit XAK 00060 0 1 Wa...

Page 18: ...t the bracket such that the hooks in position C face outward and upward Hang the inverter on the mounted bracket by lifting the unit up and over the mounting plate Guide the inverter and switchbox brackets engaging the brackets C D and E F on the back of the inverter Secure chassis bottom using the machine screw and washer provided through center hole H on the inverter and engaging in the bracket ...

Page 19: ...ing box components Table 3 1 switchbox external components Ref Description A DC conduit entry KO s trade size 1 1 1 4 B AC conduit entry KOs trade size 1 1 1 4 C DC disconnect switch D Signal conduit entry with plastic threaded plug trade size E AC conduit entry with plastic threaded plug trade size 1 1 1 4 F DC conduit entry with plastic threaded plug trade size 1 1 1 4 G Silkscreen ON OFF legend...

Page 20: ...of the installer to provide external disconnect switches and Overcurrent Protection Devices OCPD as re quired by National Electric Codes and other prevailing regulations To access the wiring terminals in the inverter and switchbox the inverter cover and switchbox cover must be removed To remove the front cover of the inverter compartment loosen the four captive screws indicated using the Torx scre...

Page 21: ...pe These terminals accept 16 6 AWG wire Front switch model AC output terminals are spring pressure type These terminals ac cept 14 4 AWG wire Bottom switch model array wiring and AC output terminals use a standard terminal block The wire range accepted is 18 4 AWG wire There is a copper ground bus bar provided which accepts 14 6 AWG wire 2 Ground terminals for the front switch model are spring pre...

Page 22: ...Listed PV wire per NEC 690 35 PV output conductors must consist of sheathed jacketed multi conductor cables or installed in an approved raceway and must be isolated from the enclosure and system grounding as required by NEC 690 35 and is the responsibility of the installer The maximum allowable input short circuit current limit of the photovoltaic array for each MPPT input channel is is 20Adc for ...

Page 23: ...FF position and locked out When connecting the DC conductors verify polarity prior to terminating Failure to perform these checks may cause arcing and potential fire The array equipment grounding must be installed per the requirements of the NEC and is the responsibility of the installer Connect array to String 1 and String 2 input positions shown below running separate wires for POS and NEG for e...

Page 24: ...e independent of each other one for each input channel In the independent mode the arrays can differ from each other in installation conditions type and number of photovoltaic modules connected in series Single MPPT configuration parallel mode In the parallel mode the two channels are connected in parallel and strings of photovoltaic modules having the same type and number of modules in series can...

Page 25: ...eed of external combiner fusing To operate the inverter in the parallel MPPT mode place S1 switch UP in the PAR position Note that only two strings can be directly connected to the inverter in this mode If more than two strings are required all strings must be combined in an external fused combiner box or the IND mode must be used Use the following instructions to electrically connect the input ch...

Page 26: ...urrent protection is not provided with the inverter it is the responsibility of the end user to provide overcurrent protection for the AC output circuit The default AC grid connection 240VRMS 3W Split Phase requires the neutral terminal to be connected to the grid neutral conductor for proper operation Before connecting the inverter to the grid the grid type must be selected if it differs from the...

Page 27: ... grid standard table below shows AC wiring connections according to the AC grid type Connect wiring to the numbered terminals as shown in the table Size conductors per NEC Article 310 use only 75 C or 90 C copper wire Terminal block accommodates conductor type shown and wire size range per table 3 2 If several inverters are installed to a three phase AC GRID always distribute the inverters between...

Page 28: ...duit is used run the appropriate raceway and terminate it to the wiring box chassis using a conduit connector that matches the raceway The conduit must be terminated at one of the two openings show in table 3 1 Route the cables through the switchbox and into the inverter keeping close to right wall of the switchbox chassis For versions with a front facing switch route the cables through the plasti...

Page 29: ...t for low noise on the line this is particularly so for large plants with multiple inverters For best results the shield must be tied to ground at only one point on the line typically at one end or the other The shield wiring must be continuous as it passes from one inverter to the next on a daisy chain but must not be tied to ground at these junctions Daisy chain multi unit configuration The RS 4...

Page 30: ...e the termination resistance for the communication line by moving the S2 switch item T in table 3 3 down into the ON position All other inverters in the daisy chain will have the S2 switch placed up in the OFF position Addressing each inverter When multiple inverters are connected on a single RS 485 bus it is necessary to assign a different RS 485 address to each unit The address on the inverter i...

Page 31: ... is disabled the inverter automatically switches on and off in re sponse to appropriate conditions If the remote control function is enabled from the menu the switching on of the inverter also depends on the state of the R_ON OFF terminal compared to the GND terminal present on the terminal labeled Q in table 3 3 If the function is enabled as noted above With the R and R terminals open floating th...

Page 32: ... 32 3007CC3 3 Mounting and wiring ...

Page 33: ...provides two types of data which are accessed through the appropriate interface software and or the LCD Real time operating data Real time operating data can be transmitted on request through the communication lines and are not recorded in the inverter For data transmission to a computer download the free Aurora Manager Lite software from the website Internally stored data The inverter internally ...

Page 34: ...lt on the DC side of the PV array When this fault is detected the inverter immediately disconnects from the grid and the rel evant error warning appears in the display area b7 Keypad button Description ESC button Use the ESC button to access the main menus exit a mode or go back UP button Use the UP button to read the data on the display by scrolling upwards or to increase the set value during dat...

Page 35: ...w red Inverter is initializing loading settings and performing grid check Transition status while operating conditions are checked 3 green yellow red Inverter is powering the grid Normal operation 4 green yellow red Inverter is shut down because of a GFI fault Ground fault has been detected 5 green yellow red Inverter detected a fault The fault can be inside or outside the inverter See the alarm c...

Page 36: ...increasing or decreasing the settable values The ENTER button is used to open the menu choices make a selection and confirm a change in adjustable values During regular operation the display will cycle through general information shown at right Cycling is indicated by two arrows in the top right corner of display area b7 Scrolling can be stopped by pressing the ENTER button until the padlock symbo...

Page 37: ...ed To reset all the counters of this submenu press the ENTER button and hold for 3 seconds until a beep is heard Today Displays the daily statistics E day Daily energy produced PPeak Daily peak power value Val Daily production value calculated with the currency and conversion coefficient set in the relevant section of the SETTINGS CO2 Amount of CO2 saved today Last 7 days Last month Last 30 days L...

Page 38: ...ds four zeroes into the display and opens the submenus outlined below Settings Address Display Set Service New PW Password 0000 Cash Time Language Vstart Alarm Remote Control UV Prot T MPPT Scan EN DIS Scan Interval Alarm Message Set Vgrid Advanced Password New Address xxx Contrast XXXX four digits Light Power Graph Name Val kwH 00 50 Time Date English Vstart1 Vstart 2 Production Fault Enable Disa...

Page 39: ...This section of the menu is reserved for installers and it is necessary to have a dedicated password See Troubleshooting section 5 for instructions to obtain the service level password The Service menu can be used to adjust the Voltage and Frequency Trip Limit and Trip Time Parameters according to the grid requirements of the installation locale This inverter has been factory programmed to automat...

Page 40: ...e the average grid voltage overcomes the threshold value 305V 110 of Nominal line to neutral Voltage 110 x VLN to 115 x VLN SET U Indicates the value of the intermediate under voltage set point below which the inverter disconnects from the grid 88 of Nominal line to neutral Voltage 88 of Nominal line to neutral Voltage Fixed SET F Indicates the value of the intermediate over frequency set point be...

Page 41: ...ediate Under Voltage setpoint U 2 sec 0 16 sec to 5 sec SET TIME F Indicates the value of the countdown timer associated with the Intermediate Over Frequency setpoint F 0 16 sec 0 16 sec to 300 sec SET TIME F Indicates the value of the countdown timer associated with the Intermediate Under Frequency setpoint F 0 16 sec 0 16 sec to 300 sec SET TIME Conn 1 Indicates the time the inverter takes to co...

Page 42: ...e the password for accessing the SETTINGS menu The default password is 0000 and can be changed using the display keyboard Use ENTER to scroll the digits from left to right Use ESC to return to the previous digit from right to left Press ESC several times to return to the previous menus Use DOWN to progressively scroll the numerical scale downwards from 9 to 0 Be careful to memorize the new passwor...

Page 43: ...ching occurs when there is a Warning When N O or N C contact is chosen it will stay open or closed until the inverter reports an error once an error is reported the relay switches state and closes or opens The contact remains switched from its rest condition until normal operation is restored Alarm configurable the relay switches when there is an alarm Error or Warning which has been selected by t...

Page 44: ...this parameter to establish the optimal working point There are three settings to choose from LOW MEDIUM and HIGH The default setting is MEDIUM Multi max scan by setting this parameter the user can enable disable the scan decide the frequency with which the scan is carried out and override it manually a Enable Disable Enables Disables the scan for identifying the maximum power point of the system ...

Page 45: ...access to modify the country standard for grid connection Part No Displays the inverter part number Serial No Displays the inverter serial number and the week from 1 to 52 and year of manufacture Firmware Displays the revision of the firmware installed in the equipment INFO Part No Serial No Firmware ...

Page 46: ...ed to specified values within outside range c Grid frequency value and status compared to specified values within outside range 4 When the connection sequence is completed the inverter starts operating Normal operation is indicated by a warning sound and the green LED staying permanently ON sunlight is sufficient to export power to the grid If the check routine gives a negative result the inverter...

Page 47: ...and frequency parameters the grid connection sequence starts and the inverter displays the following screens 3 Time seconds to complete output voltage and frequency check It takes from 30 seconds to several minutes to complete the operation Next connections 2 secs 4 Shows instant output voltage value and within outside range status Vgrid 223 8V In range 5 Shows instant output frequency value and w...

Page 48: ... Iin1 Instant input current value 10A Pin Measured instant input power 11A Riso Measured insulation resistance Unlike the parameters discussed above this is not an instant value but a measurement taken one time during inverter start up 12A When all items described above test OK the inverter shows a corresponding message in the display top line along with date and time in the bottom line Clock malf...

Page 49: ...asured and analyzed If a DC arc fault is detected during operation the inverter is disconnected from theAC grid and an error will be shown on the inverter display Press and hold the ESC key for three seconds to clear the error which will start the self test If self test results are OK the inverter will reconnect to the AC grid If the DC arc fault is still present the self test will result in error...

Page 50: ...through the steady or intermittent lighting of the relevant LED a message that identifies the operation it is carrying out or the detected fault anomaly is also indicated in the two line display Messages identify the current status of the inverter and do not relate to a fault When a W with a number after it appears in the display it indicates a Warning Code and is usually cleared through an orderl...

Page 51: ...reaching the absolute threshold beyond which the inverter will be damaged When the inverter input voltage exceeds the Over Voltage thresh old the inverter will generate the alarm and not start Measure the input voltage in the inverter with a voltmeter If it is higher than the maximum voltage of the oper ating interval the alarm is real Check the configu ration of the PV array If it is lower than t...

Page 52: ...ow Bulk Voltage Voltage at a specific part of in verter input circuit is not sufficient for grid connection The alarm can be triggered by causes external to the inverter a low inverter input voltage just above the activation voltage that is not accompanied by sufficient availability of power from the pho tovoltaic array typical condition of periods of insufficient sunlight If the error warning app...

Page 53: ... return within operating range and for the inverter to cool down If the problem persists once the ambient temperature has returned within the range contact customer service Remember to wait for the time necessary to allow the inverter to cool down E015 Bulk Cap Fail Bulk capacitor fail ure Error inside the inverter regarding a problem in the bulk capacitors Error inside the inverter that cannot be...

Page 54: ...d value and the known value during the test is not within the allowed tol erance This is an error inside the inverter that cannot be checked externally If the problem persists after switching the inverter off and then on again con tact customer service By its nature the alarm ap pears only before connection to the grid E020 Self Test Error 1 Booster relay self test fail Before connecting to the gr...

Page 55: ...e current supplied to the grid exceeds the threshold of 0 5 of the rated op erating current The error does not stop the in verter instead tries to connect to the grid again Sporadic repetition of the error is a sign of large grid distortions or sudden changes in sunlight whereas systematic rep etition of the error warning will be a sign of an inverter fault If the grid voltage is strongly distorte...

Page 56: ...an installer to identify and eliminate the problem If the measured value is greater than 1 mega ohm and the error warning continues to be present contact customer service Damp increases leakage and can therefore be the cause of a reduction in insulation resistance E026 Vref Error Bad internal reference voltage Wrong measurement of the ref erence voltage inside the equip ment Internal error that ca...

Page 57: ...utput relay out of range There is too great a difference in voltage between the input and the output of the output relay that can be caused by grid voltage instability Check the grid conditions for instabilities caused by switch of heavy loads or reactive loads like motors welding machines etc If the problem appears re peatedly contact customer service E032 Error Read I Wrong I Measure Measurement...

Page 58: ...abled only in inverters equipped with ground ing kit and is used to monitor the voltage at the ends of the ground ing resistor The error appears when the voltage at the ends of the resistor connected between ground and pole of the photovol taic array exceeds 30V for more than 30 minutes or 120V for more than one second Check for the presence and correct contacting of the two terminals of the groun...

Page 59: ...n figuration of the PV array or a configuration at the limit as re gards the minimum input voltage of the inverter Check the inverter input voltage If it does not exceed the Vstart check that there is sufficient sunlight and that the composition of the system is correct If it exceeds the Vstart contact customer service W002 Input UV Low input voltage during switch off Insufficient sunlight Wrong c...

Page 60: ...nal time of the microproces sors and indicates clock circuit malfunctioning This is an error inside the inverter that cannot be resolved with external operations If the alarm is persistently repeated contact customer service W017 Jbox fail Fuse control board fail DC string fail Fuse s on the fuse boards is are damaged Using a multimeter check the condition of the fus es situated on the fuse boards...

Page 61: ...ata stored in the EEPROM Reset of the energy data saved in the inverter this operation can be handled through the display or advanced configuration software Notification of change that is saved in the historical log of inverter events The notice may also occur on substitution of the Memory Card where the statistical production data is saved Making a service call The following information is necess...

Page 62: ... 62 C011C5 5 Troubleshooting ...

Page 63: ...tion to promptly report any anomalies Always use the personal protective equipment provided by the employer and comply with the safety conditions in section 1 of this manual ABB accepts no liability if the periodic checks and maintenance cycles indicated in this manual and in the attached documentation are not complied with correctly or if maintenance is entrusted to unqualified staff Routine main...

Page 64: ...t to determine hot spots Check torque value for any connection indicated Annually Check AC pressure connectors Annually Check torque of screws on chassis access covers to insure NEMA4X compatibility Annually Check all connections terminals for discoloration or signs of high temp current 1 year Remove and replace the memory back up battery see instructions in this section ABB recommends checking th...

Page 65: ...se of these substances which are potentially harmful to the environment in accordance with the regulations in force in the country of installation If the equipment is dismantled follow the regulations in force in the country of destination and avoid causing any kind of pollution upon disposal Use dumps suitable for disposal of the various types of materials listed below COMPONENT MATERIAL OF CONST...

Page 66: ... 66 C012C6 6 Maintenance ...

Page 67: ...load requirement i e an excess of energy is produced it is sent directly into the public network becoming available to other users Depending on prevailing codes and regulations of the installation area the energy produced can be sold to the utility or credited against future consumption producing energy savings STRINGS AND ARRAYS A photovoltaic panel consists of many photovoltaic cells mounted on ...

Page 68: ...pped with additional protective devices to guarantee safe operation in any circumstance These protective devices include Continuous monitoring of the grid voltage to ensure the voltage and frequency values stay within operating limits Control of internal temperatures to automatically limit the power if necessary to ensure the unit does not overheat derating Topographic diagram of the equipment The...

Page 69: ... standards and regulations TheInverteroperatingsystem program communicateswithallofthesub systemswithintheinverterperforming necessary data processing calculations to guarantee optimal performance levels of the system and high power harvesting in all installation and load conditions while maintaining full compliance with prevailing safety directives laws and regulations IN1 IN2 S VERSION IN1 1 IN1...

Page 70: ...on standards to avoid waste and unnecessary leakage Graphs of the efficiency curves of the inverters are shown below The efficiency curves are affected by technical parameters that are continually being developed and improved and should be considered approximate PVI 3 0 OUTD US 240V PVI 4 2 OUTD US 240V ...

Page 71: ...age grid voltage and power available from the photovoltaic arrays The inverter may reduce its output power during the day according to the value of these parameters The following graphs show the automatic reduction in output power in relation to ambient temperature In any case the inverter ensures top power up to 40 C ambient temperature when it is not directly exposed to the sun Power reduction d...

Page 72: ... 72 C013C7 7 Appendix Output power with one DC section operating ...

Page 73: ...ﬂoating arrays Output protection devices Anti islanding protection Meets UL 1741 IEEE1547 requirements Over voltage protection type Varistor 2 L1 L2 L1 G Maximum AC OCPD Rating 20ARMS 20ARMS 15ARMS 25ARMS 20ARMS 20ARMS 20ARMS 20ARMS 20ARMS 25ARMS 25ARMS 25ARMS Efﬁciency Maximum efﬁciency 96 9 97 97 97 CEC efﬁciency 96 Operating performance Night time consumption 0 6WRMS Stand by consumption 8WRMS ...

Page 74: ...Further information For more information onABB products and services for solar applications navigate to www abb com solarinverters ...

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