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About Xantrex Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with products from 50 watt mobile units to 1.5 MW utility-scale systems for wind, solar, batteries, fuel cells, microturbines, and backup power applications in both grid-connected and stand-alone systems. Xantrex products include inverters, battery chargers, programmable power supplies, and variable speed drives that convert, supply, control, clean, and distribute electrical power.
About This Manual Purpose The purpose of this Planning and Installation Manual is to provide explanations and procedures for planning and installing the PV100S 100 kW Grid-Tied Photovoltaic Inverter. Scope The Manual provides safety guidelines, detailed planning and setup information, and procedures for installing the inverter.
• 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 individually. • When the both models are being referenced together, they will be referred to as the PV100S.
IGBT kcmil NFPA POTS UFCU Related Information You can find more information about Xantrex Technology Inc. as well as its products and services at www.xantrex.com. 152315 Rev C American National Standards Institute Converter Control Unit 2 Cubic Feet per Minute...
Important Safety Instructions SAVE THESE INSTRUCTIONS - DO NOT DISCARD This manual contains important safety instructions for the PV100S that shall be followed during installation and maintenance procedures. WARNING: Shock Hazard Read and keep this Planning and Installation Manual for future reference. Before installing PV100S (either model), read all instructions, cautionary markings, and all other appropriate sections of this manual.
4. The AC power conductor wiring interfacing with the AC terminals in the Transformer Enclosure are located at T6-X1, T6-X2, and T6-X3. These terminals should be tightened to a torque value of 420 in-lbs (47.5 Nm) for model PV100S-208 and model PV100S-480. Conductors terminated to these viii 152315 Rev C...
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310 in-lbs (35.0 Nm) for model PV100S-208 and to a torque value of 115 in-lbs (13.0 Nm) for model PV100S-480. See Figure 3-16 on page 3–16 for the location of these terminals and the cautionary note on page 3–17.
Safety Operational Safety Procedures Never work alone when servicing this equipment. A team of two is required until the equipment is properly de-energized, locked-out and tagged, and verified de- energized with a meter. Thoroughly inspect the equipment prior to energizing. Verify that no tools or equipment have inadvertently been left behind.
De-Energize/Isolation Procedure The following procedure should be followed to de-energize the PV100S for maintenance. WARNING The terminals of the DC input may be energized if the PV arrays are energized. In addition, allow 5 minutes for all capacitors within the main enclosure to discharge after disconnecting the PV100S from AC and DC sources.
Introduction Description of the PV100S The PV100S 100 kW Grid-Tied Photovoltaic Inverter is a UL 1741 listed, utility interactive, three-phase power conversion system for grid-connected photovoltaic arrays with a power rating of 100 kW. Designed to be easy to install and operate, the PV100S automates start-up, shutdown, and fault detection scenarios.
Front View Communications Enclosure 49 7/8" (124.8 cm) Interface Enclosure Transformer 44.0" (110 cm) 21 3/8" (53.5 cm) Back AC Interface Enclosure DISCONNECT 33 ½" (83.75 cm) AC Side View Figure 1-1 Dimensions (Not to scale) 152315 Rev C TH I S U N I T EM P L O Y S FI E L D A D JU S T AB LE V O LT A G E A N D FR E Q U E N C Y S E T POI N T S A N D T I M E D E L AY S.
System Ground Requirements This product is intended to be installed as part of a permanently grounded electrical system per the National Electric Code ANSI/NFPA 70. A copper ground rod must be installed within three feet of the PV100S enclosures and connected to the unit as described in “System Grounding”...
Introduction Environmental Specifications The following environmental specifications are the same for both models of the PV100S 100 kW Grid-Tied Photovoltaic Inverter. Table 1-3 Environmental Specifications Specification Dimensions Inverter and DC Interface Transformer and AC Interface Overall System Footprint: Weight Inverter and DC Interface Transformer and AC Interface Overall Weight Allowable Ambient Temperature...
Operator Interface Controls Operator interface controls are located on the front door of the main inverter enclosure. These controls include an ON/OFF Switch, 4-line LCD display and keypad called the Universal Frontpanel Control Unit (UFCU). Additionally there is an AC and DC Disconnect on the AC Interface Enclosure and the DC Interface Enclosure Doors.
Introduction WARNING: Shock Hazard Disengaging the main enclosure door interlock switch does NOT remove all hazardous voltages from inside the inverter. Before attempting to service the PV100S, follow the de-energize Lockout and Tag procedure on page x. On/Off Switch The PV100S incorporates a maintained position front door of the main enclosure.
AC and DC Disconnect Switches Both AC and DC Interface Enclosures are equipped with lockout hasps for personnel safety. The enclosure doors should not be opened while the PV100S is operating. The switch handles and shafts provide a door interlock for both the AC and DC interface enclosures.
Introduction System Status and Fault Reporting Basic system status and all fault conditions rising from within the PV100S are reported to the UFCU. The unit stores the time and details of all faults in non-volatile memory. The 4-line LCD will display a hexadecimal value and a brief text description of the fault.
Communication Methods The PV100S communicates system status information to the user using the following methods. • The Front Panel Control Unit (UFCU) Display • PC Connection (Direct or Remote) - Xantrex Solar Graphic User Interface (GUI) Software required. Communication with a PC requires the selection of one of the following options.
Introduction PC Connection Methods Personal computers can be used to access the system status and programming features of the PV100S. A computer can be connected either directly or remotely. 1. Remote Connect - uses one of the three kits below. •...
POTS Access Figure 1-7 illustrates the PV100S connected remotely to a personal computer. Figure 1-7 POTS Access Wireless Access Figure 1-8 illustrates the PV100S connected remotely to a personal computer using a wireless network. Figure 1-8 Wireless Access 152315 Rev C Communication Methods 1–13...
Introduction Ethernet LAN Access The PV100S can be remotely accessed through a local area network. Figure 1-9 Ethernet LAN Access Direct Access Figure 1-10 illustrates the PV100S connected directly to a personal computer. Figure 1-10 Direct Access 1–14 152315 Rev C...
Planning Overview of PV100S Installation WARNING: Shock Hazard Installations of this equipment should only be performed by qualified technicians. Installers must meet all local and state code requirements for licensing and training for the installation of Electrical Power Systems with AC and DC voltage to 600 volts.
Large gauge wire must conform to the minimum bend radius specified in the NEC, Article 373-6B, Ninth Edition. Take care to keep the wire bundles away from any sharp edges which may damage wire insulation over time. All conductors should be made of copper and rated for 90 °C (minimum). If the installation of the PV100S is to be outdoors, all interconnect conduit and fittings must be NEMA 4 rated as required by the NEC.
Planning Ground Requirements This product is intended to be installed as part of a permanently grounded electrical system per National Electric Code ANSI/NFPA 70. A copper ground rod must be installed within three feet of the PV100S enclosure. This is the single point earth ground for the inverter system.
For more detailed information, refer to the schematic illustrations for model-specific electrical schematics. Model PV100S-480: • Figure A-2, “PV100S-480 Schematic for Main Power Distribution (152316 E1)” on page A–4 • Figure A-3, “PV100S-480 Schematic for Control Power Distribution (152316 E2)” on page A–5 •...
Planning Layout Options The PV100S is shipped as two separate assemblies and can be arranged as shown in Figure 2-1 or Figure 2-2. The PV100S can be arranged in a number of different system layout options to fit specific site requirements. The AC interface/transformer assembly may be co-located adjacent to the left side of (or behind) the Main Inverter Enclosure up to, and not exceeding, 15 feet away.
Minimum Dimension of Base: Approximately 9 ft by 7 ft (2.7 m x 2.1 m) 12" Minimum Clearance Conduit (not to exceed 15') Communications 12" Minimum Clearance Figure 2-2 PV100S Layout Option B 152315 Rev C BASE: Concrete Floor or Pad 36"...
Planning Conduit Penetration The following illustrations show the recommended locations for electrical conduit entry into the PV100S enclosures. These drawings are to be used for system planning purposes, such that the shaded areas are representative of the maximum allowable area and location in which electrical conduit may penetrate the enclosures of the PV100S, see Figure 2-3 through Figure 2-8.
Conductor and Conduit Sizing All wiring methods and materials shall be in accordance with the National Electrical Code ANSI/NFPA 70. When sizing conductors and conduits interfacing to the PV100S, both shall be in accordance with the National Electric Code ANSI/NFPA 70, as well as all state and local code requirements. Large gauge wire must conform to the minimum bend radius dependent upon the wire gauge (refer to the National Electric Code, Article 373-6B (Ninth Edition).
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Planning Step 3. Size the cable. This example assumes that the conduit length is less than 24 inches. NEC Table 310.16 (Ninth Edition) indicates the Temperature Correction Factor for 90 °C THHN cable in a 50 °C ambient is 0.82. With a required ampacity from Step 1 above of 347 amps, it can be calculated that the required cable ampacity at 50 °C in this application is 423 amps.
Anchoring the PV100S The PV100S is designed to be installed in either an indoor or outdoor location. It must be placed on and anchored to a level concrete floor or pad. The concrete floor or pad, upon which the PV100S is anchored, must be structurally designed to meet any local, state, or national requirements for weight, seismic, and wind sheer if applicable.
Planning 17 ½" (44 cm) 25" (63.5 cm) Figure 2-10 AC Interface/Transformer Anchor Bolt Pattern (Not to Scale) The floor or pad should either be pre-drilled to accept masonry anchors or have pre-installed anchoring bolts. 2–14 29" (73.7 cm) ¾" (1.9 cm) (x6) 152315 Rev C...
Installation Chapter 3, “Installation” describes the procedures needed to install the PV100S 100 kW Grid-Tied Photovoltaic Inverter. This section includes unpacking and moving instructions, mounting instructions, and cabling instructions.
Installation Equipment Required The following is a list of required tools and equipment to aid in the installation of the PV100S. This list is not a comprehensive list, but is intended to help identify the minimum recommended tools and equipment used during the installation. •...
Moving the PV100S CAUTION: Equipment Damage To move the PV100S, use a forklift that has a sufficient lift capacity and has a 26" fork span. To move the PV100S while it is still inside the shipping crates: 1. Place the forks of the forklift below the shipping crate at the points specified on the shipping crate.
Installation Removing the Pallet and Moving the PV100S CAUTION: Equipment Damage To move the PV100S, use a forklift that has a sufficient lift capacity and a 26" fork span. To move the PV100S using a forklift: 1. Place the forks of the forklift below the unit at the points specified in Figure 3-2.
Important: of the components, conduit penetration locations, conductor and conduit sizing, and method for anchoring the unit. Ensure adequate space is provided for clearance for ventilation and serviceability. Review Chapter 2, “Planning” if necessary before proceeding. Mounting and Anchoring the Units To mount and anchor the PV100S: 1.
Installation Opening or Closing Access Doors To lock or unlock the front door on the main inverter: 1. Use the 7 mm triangle key provided with the unit. a) Insert the key in the lock and turn counterclockwise to open; b) Pull front door open from the right side.
Figure 3-5 AC Interface Access Door Figure 3-6 DC Interface Access Door 152315 Rev C To Open Access Door: 1. Confirm that the AC Disconnect Switch handle is placed in the OFF (Open) position prior to opening the door. 2. Loosen the bolts on door latches and slide away from the door.
Installation Figure 3-7 Transformer Access Panels Figure 3-8 Inductor Access Panels 3–8 Transformer Access Panel To Remove the Access Panel: Loosen and remove the 1/4" self-tapping sheet metal screws (x6). To Replace the Access Panel: Replace and tighten the 1/4" self-tapping sheet metal screws.
Conduit Installation Given the flexible nature of the system, conduit installation will be dependent upon the final configuration of the system. Procurement and installation of the conduit, therefore, is the responsibility of the installer. Since the layout will be dependent upon the location available for the installation and the size of the conductors used, specific conduit size and type must be pre-determined by the installer before the actual installation.
Installation Wiring - General All wiring methods and materials shall be in accordance with the National Electrical Code ANSI/NFPA 70. When sizing conductors and conduits interfacing to the PV100S, both shall be in accordance with the National Electric Code ANSI/NFPA 70, as well as all state and local code requirements. WARNING: Shock Hazard The PV100S enclosures contain exposed high-voltage conductors.
• 400A maximum for PV100S-208 • 200A maximum for PV100S-480 Conductor Termination The PV100S has terminals and bus bars for making all wiring connections required for the installation. All terminals used for making AC and DC connections require the use of copper conductors with an insulation rating of 90 °C (or higher).
National Electric Code ANSI/NFPA 70. The single-point ground for the system is to be made at the AC ground bar (TB2) in the AC Interface Enclosure. AC Interface Enclosure Figure 3-10 Single-point Ground (TB2) Ground Bar 3–12 Bolt (Hardware) Size PV100S-208 PV100S-480 3/8-16 3/8-16 3/8-16 3/8-16 3/8-16 3/8-16...
Torque connections to ground bar in the Main Inverter Enclosure as follows: • PV100S-208 - 420 in-lbs (47.5 Nm) • PV100S-480 - 420 in-lbs (47.5 Nm) The equipment ground on the PV100S is marked with this symbol: AC Ground Bar (TB1) to be used...
Installation inter-tie. The PV100S is a balanced, three-phase, current-sourcing inverter and only operates with the presence of a stable utility voltage. The transformer is also supplied with a neutral connection on the utility interconnect. Connection of this utility-side neutral does not affect the operation of the inverter, however connection of the neutral on the inverter-side does affect the operation and must be left floating or disconnected.
3. In addition to the power conductors, route the AC Sense Harness assembly (Xantrex P/N 1-152403-01) between the main inverter to the AC interface/transformer assembly. Prior to completing the installation of the AC Sense Harness, secure the harness to the AC power conductors with nylon tie-wraps so it does not touch the surfaces of the L1 inductor.
Installation 5. Connect the AC power conductors in the Main Inverter Enclosure at TB4-A (A phase), TB4-B (B phase), and TB4-C (C phase) with a box connector using a 5/16" Hex screw. This hardware should be tightened to a torque value of 275 in-lb (31 Nm).
M10 (PV100S-208) hardware. Cables to these terminals must use a crimp-on type ring terminal or compression-type lug. Torque these connections to 115 in-lbs (13.0 Nm) for the M8 (PV100S-480), and 310 in-lbs (35.0 Nm) for the M10 (PV100S-208). See Figure 3-18 for the location of these terminals.
228 in-lbs (25.7 Nm) for TB6, and 420 in-lbs (47.5 Nm) for TB2 for both the PV100S-480 and PV100S-208 systems. See Figure 3-18 for the location of these terminals.
DC Interface enclosure at the TB3 locations are made with box connector using a 7/16" Hex Allen screw. The hardware should be tightened to a torque value of 500 in-lbs. (56.5 Nm) for both the PV100S-480 and PV100S-208 systems. 5. Close the door to the DC Interface Enclosure and replace the door clamps.
Installation PC Communications Personal computers can be used to access the system status and programming features of the PV100S. A computer can be connected either directly or remotely. 1. Remote Connect - uses one of the three kits below. • •...
Establishing a POTS Connection Important: feature. The phone line used for PV100S communication cannot be routed through a Private Branch Exchange (PBX) unless an analog PBX card is used. To connect a personal computer using the POTS Connection: 1. Ensure the personal computer to be used has a 56K modem installed. 2.
Installation Establishing Wireless Connection Important: provider before proceeding. To connect a personal computer using the GSM Wireless modem: 1. Ensure the personal computer has the appropriate hardware installed to support this feature. 2. Install the GUI Software following the instructions in the PV100S 100 kW Grid-tied Photovoltaic Inverter Operation and Maintenance Manual.
Direct Connection The direct connection provides the means to use the features of the GUI by connecting a PC directly to the CCU2. This allows field personnel to monitor and control the inverter from a nearby laptop computer directly connected by a serial cable.
Verification Verification Procedure Summary WARNING: Electrocution Hazard This chapter describes specific steps to ensure the installation of the PV100S 100 kW Grid-Tied Photovoltaic Inverter is correct and complete. Failure to adhere to these warnings could result in severe shock or possible death. Exercise extreme caution at all times to prevent accidents.
Visual Inspection of Mechanical Connections To perform a visual inspection of the PV100S mechanical connections: 1. Ensure that the AC and DC Disconnect Switches, as well as any utility interconnect circuit breakers or main disconnect switches, are opened. 2. Ensure all anchor bolts and any required seismic bracing is properly tightened and in place.
Verification Visual Inspection, Isolation Transformer Wye/Wye To perform a visual inspection of the Isolation Transformer Wye/Wye: 1. Ensure that the AC and DC Disconnect Switches, as well as any utility Interconnect circuit breakers or main disconnect switches, are open. 2. Verify all conductor and wiring connections interfacing with the PV100S are tightened to the correct torque value.
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Index 3 – 4 Removing the Pallet Safety Torque and Wire Gauge Specifications UFCU 3 – 2 Unloading 3 – 3 Unpacking Utility Side Isolation Transformer Requirements Verification Procedure Summary Visual Inspection of Electrical Connections Visual Inspection of Mechanical Connections Visual Inspection, Isolation Transformer Wye/Wye 4 –...
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Xantrex Technology Inc. 1 800 670 0707 Tel toll free NA 1 360 925 5097 Tel direct 1 360 925 5143 Fax direct customerservice@xantrex.com www.xantrex.com 152315 Rev C Printed in USA...
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