Xantrex PV100S-208, Operation And Maintenance Manual

Page 1: ...PV100S 100 kW Grid Tied Photovoltaic Inverter Operation and Maintenance Manual PV100S 208 PV100S 480...

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Page 3: ...s PV100S 100 kW Grid Tied Photovoltaic Inverter Operation and Maintenance Manual...

Page 4: ...spective owners and are used herein for identification purposes only Notice of Copyright PV100S 100 kW Grid Tied Photovoltaic Inverter Operation and Maintenance Manual May 2005 Xantrex International A...

Page 5: ...rganized into five chapters and one appendix Chapter 1 Introduction contains information about the features and functions of the PV100S 100 kW Grid Tied Photovoltaic Inverter Chapter 2 Operation conta...

Page 6: ...as the PV100S 208 when it is being referenced individually The model PV100S 480 100kW Grid Tied Photovoltaic Inverter 480 Vac input will be referred to as the PV100S 480 when it is being referenced i...

Page 7: ...inute CW Clockwise DSP Digital Signal Processor FPGA Field Programmable Gate Array GUI Graphical User Interface IEEE Institute of Electrical and Electronics Engineers IGBT Insulated Gate Bipolar Trans...

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Page 9: ...ntenance 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 S...

Page 10: ...ar protection Steel toed safety boots Safety hard hats Padlocks and tags Appropriate meter to verify that the circuits are de energized 600 Vac and DC rated minimum Check local safety regulations for...

Page 11: ...f these terminals 8 The DC power conductor wiring interfacing with the DC terminals at TB3 1 TB3 2 and TB3 3 are to be tightened to a torque value of 500 in lbs 56 5 Nm for model PV100S 208 and model...

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 and...

Page 13: ...s And Charge Controllers For Use In Photovoltaic Power Systems as well as IEEE 929 2000 Recommended Practice For Utility Interface of Photovoltaic PV Systems IEEE 929 2000 provides guidance regarding...

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Page 15: ...trol Unit CCU2 1 7 Power Electronics Matrix 1 7 Inductor Enclosure 1 7 DC Interface Enclosure 1 8 Transformer Enclosure 1 8 AC Interface Enclosure 1 8 Communications Enclosure 1 9 Operator Interface C...

Page 16: ...ate 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 th...

Page 17: ...y Door 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 Fa...

Page 18: ...ations 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...

Page 19: ...tialization 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 Figur...

Page 20: ...ty AC Terminal Connections in the AC Interface Enclosure 5 4 Figure 5 3 PV Terminal Locations 5 5 Figure A 1 Electrical Diagram sample A 5 Figure A 2 PV100S 480 Schematic for Main Power Distribution 1...

Page 21: ...Write Menu Parameters 2 16 Table 4 1 Fault Codes 4 4 Table A 1 Environmental Specifications A 2 Table A 2 Electrical Specifications for the PV100S 100 kW Grid Tied Photovoltaic Inverter A 3 Table A 3...

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Page 23: ...1 Introduction Chapter 1 Introduction contains information about the features and functions of the PV100S 100 kW Grid Tied Photovoltaic Inverter...

Page 24: ...the utility side of the isolation transformer The location of the main AC contactor and the ability to de energize the isolation transformer during times of non operation greatly reduces the night tim...

Page 25: ...disabled the PV100S will regulate the DC Bus at the PPT V Ref set point Regulating the DC bus means drawing more or less current out of the PV array to maintain this desired voltage With the PPT Enabl...

Page 26: ...Automatic Reset In the event of a utility voltage or frequency excursion outside of preset limits the PV100S will stop operation and display a fault at the operator interface Once the utility voltage...

Page 27: ...remain 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 Recommen...

Page 28: ...C A C A C M ax con t i nuo us ou t p ut cu r ren t 278A M ax cont i n uous ou t put p ow er 100 kV A M ax im u m operating a m bient 5 0 C M O DEL N UM BE R PV100S 208 SE RIAL N UM BE R XXX X L 152 4...

Page 29: ...ns the necessary DC power supplies to support its operation Power Electronics Matrix The power electronics converter is located at the top of the PV100S main inverter enclosure The matrix is comprised...

Page 30: ...sformer 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 th...

Page 31: ...d 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 Enclosur...

Page 32: ...shutdown of the PV100S and opens both the main AC and DC contactors The main AC and DC contactors cannot be closed unless the door s interlock is in the engaged position The PV100S is prevented from b...

Page 33: ...unless the switch is in the ON position The PV100S is prevented from being restarted until the ON OFF switch is turned back to the ON position WARNING Shock Hazard Disengaging the main enclosure door...

Page 34: ...block 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 PV100S to execute an...

Page 35: ...tate 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 Enabled Data...

Page 36: ...t 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 Enclosure to ma...

Page 37: ...nable the unit to connect to a local area network 2 Direct Connect This method is used for troubleshooting It uses a RS232 Fiber Optic Converter configured for a PC a DB25 to DB25 gender changer and a...

Page 38: ...gure 1 11 illustrates the PV100S connected remotely to a personal computer Wireless Access Figure 1 12 illustrates the PV100S connected remotely to a personal computer using a wireless network Figure...

Page 39: ...17 Ethernet LAN Access The PV100S can be remotely accessed through a local area network Direct Access Figure 1 14 illustrates the PV100S connected directly to a personal computer Figure 1 13 Ethernet...

Page 40: ...e that can be imported to a spreadsheet Graphic Data Analysis Graphical charts of any operational values from the data log of an inverter can be displayed remotely Fault Log Acquisition The inverter m...

Page 41: ...2 Operation Chapter 2 Operation contains information on the basic operation of the PV100S 100 kW Grid Tied Photovoltaic Inverter...

Page 42: ...engaged 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 e...

Page 43: ...Voltage 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 300...

Page 44: ...condition will be reported to the operator interface LCD Most PV100S faults are latching and must be cleared at the operator interface keypad before transitioning to another operating state The ON OF...

Page 45: ...existing 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 PV100S...

Page 46: ...o clear 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 REA...

Page 47: ...llowing 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...

Page 48: ...nu occurs 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 wit...

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: ...e Hit ENTER or Value by ID System PWR Tracking Inv Online PV Online INV A Volts 208 From the Standard Display 1 Press the button once 2 Fourth line displays CCU version and Front Panel version softwar...

Page 51: ...ng 1 Manual Current 2 Matrix Test 3 2 N A Fault code See Faults and Fault Codes on page 4 2 for a detailed list of Fault Codes 3 N A Inverter State Displays as INV where can be any one of the states l...

Page 52: ...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 Displays as Grid Freq Grid Frequenc...

Page 53: ...ess 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 ite...

Page 54: ...Accumulated 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...

Page 55: ...d this 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...

Page 56: ...nter 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...

Page 57: ...UL 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 t...

Page 58: ...timer 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 o...

Page 59: ...ion 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...

Page 60: ...Goal 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 wil...

Page 61: ...me 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...

Page 62: ...greater current than the capacity of the PV array If this causes the PV voltage to drop below the minimum operating voltage 300 Vdc the PV100S will transition to Shutdown 3 To exit the Manual Current...

Page 63: ...ct 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 p...

Page 64: ...he PV V Start set point De Energize Isolation Procedure Shutdown The following procedure should be followed to de energize the PV100S for maintenance To isolate the PV100S 1 Turn the ON OFF switch to...

Page 65: ...sses 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 De...

Page 66: ...orun 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...

Page 67: ...d to 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 sec...

Page 68: ...re 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 PV100S GUI The GUI Setup Welcome Window will appear n...

Page 69: ...ow 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...

Page 70: ...he 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 Prog...

Page 71: ...computer 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 CO...

Page 72: ...379 Rev C 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 C...

Page 73: ...accordingly 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 fi...

Page 74: ...ll 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 Con...

Page 75: ...the 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...

Page 76: ...n in 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...

Page 77: ...to the following 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 Descri...

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Page 79: ...3 Commissioning Chapter 3 Commissioning contains information on safely commissioning the PV100S 100 kW Grid Tied Photovoltaic Inverter...

Page 80: ...mmunications 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...

Page 81: ...If grid voltage is not available to the unit open the AC Disconnect Switch S1 and lock the AC Interface Enclosure The Commissioning Test procedure must cease at this point Do not attempt to continue t...

Page 82: ...by clicking on the NEXT button Apply Grid Voltage 1 Verify all enclosure doors are closed and locked 2 Close the AC Disconnect S1 Switch This will energize the control power circuits 3 Look listen and...

Page 83: ...on the modem show activity Once communica tions are established 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 Inver...

Page 84: ...ED 2 Bypass the switch 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...

Page 85: ...plete 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...

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Page 87: ...s for troubleshooting the PV100S 100 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 88: ...nce the cause of the fault has been identified and corrected and it is determined to be safe to proceed PV100S faults may be manually cleared from the UFCU keypad or using the remote GUI See Clearing...

Page 89: ...procedure 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 Ens...

Page 90: ...indicates 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...

Page 91: ...K3 is inoperable SSR1 is inoperable TS1 is open 0015 Grid Disconnection S This fault indicates that the PV100S has detected a sudden AC voltage increase of greater than 40 of the nominal peak to peak...

Page 92: ...phase A 0230 Matrix over current in phase B 0430 Matrix over current in phase C If more than one phase faults simultaneously the two first digits are added in hexadecimal form to indicate an over curr...

Page 93: ...ernal ROM error CPU error 0043 Serial EEPROM Timeout S This fault indicates that the PV100S has detected that when writing data to the serial EEPROM a confirmation timer of 300mS has expired Internal...

Page 94: ...ate drive fault has occurred An internal protection circuit within the individual IPM devices of the IGBT matrix also generates a gate fault as the result of either short circuit over current over tem...

Page 95: ...ctive 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 PV100S has detected that the DC...

Page 96: ...0S has detected that the IGBT matrix FPGA was not disabled after having sent a command for it to turn off The CCU2 sends an acknowledge bit to confirm the command is received This fault is primarily a...

Page 97: ...5 Preventative Maintenance Chapter 5 Preventative Maintenance contains information and procedures for performing preventative maintenance on the PV100S 100 kW Grid Tied Photovoltaic Inverter...

Page 98: ...S for maintenance To isolate the PV100S 1 Turn the ON OFF switch to the OFF position 2 Open the DC interface disconnect switch 3 Open the AC interface disconnect switch 4 Open the utility connection c...

Page 99: ...e AC 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...

Page 100: ...in the Main Inverter Enclosure Figure 5 2 Utility AC Terminal Connections in the AC Interface Enclosure TB4 A TB4 B TB4 C TB1 Ground Bar AC Interface Enclosure Enlargement of Terminal Connectors in t...

Page 101: ...Maintenance Safety 152379 Rev C 5 5 Figure 5 3 PV Terminal Locations PV POSitive Cable TB3 1 PV NEGative Cable TB3 2 Conduit entry from PV Array GrouND TB3 3...

Page 102: ...ability to transfer heat which may cause the PV100S 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 exte...

Page 103: ...re 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...

Page 104: ...5 8...

Page 105: ...A Specifications Appendix A provides the environmental and electrical specifications for the PV100S 100 kW Grid Tied Photovoltaic Inverter...

Page 106: ...rface Overall System Footprint Layout Option A Layout Option B 82 in H x 60 1 4 in W x 22 in D 208 cm H x 153 cm W x 56 cm D 44 in H x 50 in W x 34 in D 112 cm H x 127 cm W x 86 cm D 12 ft W x 6 ft L...

Page 107: ...422 to 528 Vac Maximum AC Output Current 278 Arms 121 Arms Nominal AC Input Frequency 0 5 to 0 7 Hz acceptable range 60 Hz 59 3 to 60 5 Hz 60 Hz 59 3 to 60 5 Hz Output Power 100 0 kW 100 0 kW Peak Pow...

Page 108: ...d per pole 3 8 16 3 8 16 420 in lb 47 5 Nm 420 in lb 47 5 Nm TB2 System Ground 500MCM to 4 AWG 1 stud per pole 3 8 16 3 8 16 420 in lb 47 5 Nm 420 in lb 47 5 Nm TB6 Neutral 500MCM to 4 AWG 1 stud per...

Page 109: ...Appendix A Schematics 152379 Rev C A 5 Figure A 1 Electrical Diagram sample...

Page 110: ...Schematics Appendix A A 6 152379 Rev C Figure A 2 PV100S 480 Schematic for Main Power Distribution 152316 E1...

Page 111: ...Appendix A Schematics 152379 Rev C A 7 Figure A 3 PV100S 480 Schematic for Control Power Distribution 152316 E2...

Page 112: ...Schematics Appendix A A 8 152379 Rev C Figure A 4 PV100S 480 Schematic for Converter Control Unit 152316 E3...

Page 113: ...Appendix A Schematics 152379 Rev C A 9 Figure A 5 PV100S 208 Schematic Main Power Distribution 152376 C1...

Page 114: ...Schematics Appendix A A 10 152379 Rev C Figure A 6 PV100S 208 Schematic for Control Power Distribution 152376 C2...

Page 115: ...Appendix A Schematics 152379 Rev C A 11 Figure A 7 PV100S 208 Schematic for Converter Control Unit 152376 C3...

Page 116: ...Schematics Appendix A A 12 152379 Rev C This page intentionally left blank...

Page 117: ...me 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 conti...

Page 118: ...clusion 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...

Page 119: ...mer Company Name __________________________________ Project Name __________________________________ System Location Information Street __________________________________ City _________________________...

Page 120: ...Warranty and Return WA 4 152379 Rev C...

Page 121: ...Software Starting the Software 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...

Page 122: ...ures 1 18 Remote LAN Connection 2 31 Running the GUI 2 31 S Self protection features 1 2 Shutdown 2 24 Software Upgrade 1 18 Specifications A 2 Electrical A 3 Environmental A 2 Over Voltage Under Volt...

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Page 124: ...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 152379 Rev C PC Printed...