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PV Powered PVP260kW Installation & Operation Manual

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PVP260kW Inverter
INSTALLATION & OPERATION MANUAL
97-600100-24-B02

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Summary of Contents for PV Powered PVP260kW

  • Page 1 PVP260kW Inverter INSTALLATION & OPERATION MANUAL 97-600100-24-B02...

  • Page 3: Preface

    Preface PV Powered PV Powered designs, manufactures and markets the solar power industry’s most reliable photovoltaic solar inverter solutions. We’ve assembled a highly experienced solar power electronics design team. Our vision is to spur the widespread adoption and success of solar power, by assisting our distributors, dealers and installers in this dynamic market while ensuring that our products are the best supported, easiest to install and most reliable solar inverters in the industry.
  • Page 5 Revisions and Certification For applicability of technical information with your specific product, contact PV Powered Customer Service and Technical Support at support@pvpowered.com. Safety Information and Conventions Designation of Danger, Warning and Caution DANGER The Danger statement is used to inform the installer/operator of a situation requiring the utmost attention.

  • Page 7: Acronyms.and.abbreviations

    PVP260kW Inverter Installation and Operation Manual Acronyms and Abbreviations Analog to Digital Conversion ANSI American National Standards Institute Cubic Feet per Minute DHCP Dynamic Host Configuration Protocol Domain Name Service Digital Signal Processor Digital Video Interface Electromagnetic Interference Electro Static Discharge...

  • Page 9: Table Of Contents

    Table of Contents Preface...........................i Safety.Information.and.Conventions.................. iii Acronyms.and.Abbreviations....................v 1..Introduction........................1 1.1..Design.Features......................1 1.2..Product.Characteristics.....................2 1.3..Product.Features.......................2 1.4..Major.Components.and.Functional.Parts.Descriptions..........3 2..Safety..........................9 2.1..General.Safety......................9 2.2..Electrical.Safety.....................10 2.3..Personal.Safety.......................11 2.4..Wiring.Requirement....................12 2.5..De-energize/Isolation.Procedures................13 3..Planning..........................15 3.1..General.Requirements....................15 3.2..Location.and.Clearances..................15 3.3..Conduits.and.Conductors..................16 3.4..Environmental.Requirements.................16 3.5..Grounding.and.Neutral.Requirements..............17 3.6..Grid.Interconnection....................18 3.7..Monitoring.
  • Page 10 7..Maintenance.&.Troubleshooting..................59 7.1..Visual.Inspection....................59 7.2..Annual.Preventative.Maintenance................59 7.3..Maintaining.the.Card.Cage.Air.Filter..............61 7.4..Faults.and.Warnings....................62 7.5..Troubleshooting.Faults...................64 7.6..Communication.PCB.Status.Light.Operation............67 7.7..Controller.PCB.Status.Light.Operation..............70 Appendix.A.-.Specifications....................71 Appendix.B.-.Wiring.Diagram....................73 Appendix.C.-.Mechanical.Drawings..................75 Appendix.D.-.Limits.and.Fault.Codes................77 Appendix.E.-.Annual.Maintenance.Requirements.Checklist..........83 Appendix.F.-.Efficiency.Curves..................85 F.1..PVP260kW.-.Efficiency.Curves................85 F.2..PVP260kW-LV.-.Efficiency.Curves...............86 Limited.Warranty........................87 Index...........................89 viii...
  • Page 11 PVP260kW Inverter Installation and Operation Manual List of Figures and Tables Figure.1-1. PVP260kW.Inverter..................3 Figure.1-2. Power.Module.Assembly.................4 Figure.1-3. Card.Cage.Assembly..................4 Figure.1-4. AC.Sub.Panel....................5 Figure.1-5. AC.Distribution.PCB..................6 Figure.1-6. Comm.X.PCB....................7 Figure.1-7. DC.Combiner.Sub.Panel.Shown.With.16-Circuit.Monitoring.Subcombiner..7 Figure.1-8. DC.Distribution.PCB..................8 Table.2-1. Inverter.Symbols....................9 Figure.2-1. Inverter.in.the.De-energized.State..............14 Figure.3-1. Inverter.Clearances..................16 Figure.3-2.
  • Page 12 Table.D-3. Main.Fault.Categories..................77 Table.D-4. Drive.Faults....................78 Table.D-5. Voltage.Fault.(VLT)..................78 Table.D-6. Grid.Fault.(GRD)...................79 Table.D-7. Temperature.Fault.(TMP)................79 Table.D-8. System.Faults.(SYS)..................80 Table.D-9. System.Warnings....................80 Table.D-10. Subcombiner.Wire.Sizing.and.Torque.Values..........81 Figure.D-1. AC.and.DC.Bus.Landing.Hardware.with.Torque.Values......81 Table.E-1. Annual.Maintenance.Requirements.Checklist..........83 Figure.F-1. PVP260kW.Efficiency.Curves...............85 Figure.F-2. PVP260kW-LV.Efficiency.Curves..............86...

  • Page 13: Introduction

    295VDC to 500VDC standard, with an optional 265 VDC input on the LV model. The maximum input voltage is 600VDC. Versatility The PVP260kW Inverter is designed for flexibility. It can be used for a range of commercial applications and it can accommodate most PV system configurations.

  • Page 14: Product.characteristics

    •. Remote.monitoring Redundant Cooling System The PVP260kW Inverter is equipped with a redundant cooling system. The variable speed blowers with built-in backup capabilities enable the unit to remain fully ventilated even if one of the blowers should fail. Blower status is reported as a warning shown on the display and through remote monitoring.

  • Page 15: Major.components.and.functional.parts.descriptions

    Panel AC Ripple Filter Front View Rear View Figure 1-1 PVP260kW Inverter Main Enclosure The modular design of the inverter makes it easy to access and service. The main enclosure (Figure 1-1) is comprised of two main sections: 1.. The.upper.compartment.contains.the.power.conversion.electronics,.control.Printed.

  • Page 16: Figure.1-2. Power.module.assembly

    Card Cage Assembly Figure 1-2 Power Module Assembly Controller PCB I/O PCB Power Distribution PCB Communications PCB Figure 1-3 Card Cage Assembly The Card Cage Assembly (Figure 1-3) is designed to enable fast and easy service and also acts as an EMI shield to ensure signal integrity on the following four PCBs: 1..

  • Page 17: Figure.1-4. Ac.sub.panel

    PVP260kW Inverter Installation and Operation Manual The DSP is very efficient at computing control and signal processing tasks. The DSP also has built-in on-chip peripherals that include a Pulse Width Modulation (PWM) driver, Analog to Digital (A/D) converters and other related features.

  • Page 18: Figure.1-5. Ac.distribution.pcb

    The Comm X PCB also includes a modbus master port (not enabled), a modbus slave port and a DVI port that is used to connect the Comm X PCB to the main Communications PCB. A serial port is available for PV Powered service use only.

  • Page 19: Figure.1-6. Comm.x.pcb

    PVP260kW Inverter Installation and Operation Manual Modbus Address Switch 1 (upper) Modbus Address Switch 2 (lower) Master Jumpers with no Jumpers Installed Slave Jumpers with three Jumpers Installed Ethernet Port Modbus Output (master) (Not enabled) Modbus Output (slave) Figure 1-6 Comm X PCB...

  • Page 20: Figure.1-8. Dc.distribution.pcb

    DC Combiner Sub Panel The inputs from the PV array are landed in the DC Combiner sub panel. This sub panel includes the positive, negative and ground busbars. Optional fused subcombiner and subcombiner monitoring are also located in the DC Combiner Sub Panel if selected. DC Distribution PCB The DC Distribution PCB is located on the DC sub panel.

  • Page 21: Safety

    On or Off Table 2-1 Inverter Symbols SAVE THESE INSTRUCTIONS: This manual contains important instructions for the PVP260kW Inverter that must be followed during installation and maintenance of the inverter. DANGER Risk of Electrical Shock. High voltages are present within the inverter cabinet.

  • Page 22: Electrical.safety

    CAUTION Risk of Electrical Shock. All electrical installations should be accomplished in accordance with local electrical codes and the National Electrical Code (NEC), ANSI/NFPA 70. 2.2 Electrical Safety Islanding Prevention - Electrical Safety Features The inverter is designed for safety, reliability and efficiency. Power for the inverter control circuitry is drawn from the utility grid.

  • Page 23: Personal.safety

    PVP260kW Inverter Installation and Operation Manual Equipment Precaution/ Warning Labels Observe all warning decals, placards and symbols posted within the inverter for safe operation. Disconnect Switches The unit is equipped with both AC and DC Disconnect (power OFF) switches to stop power conversion within the inverter unit.

  • Page 24: Wiring.requirement

    •. Appropriate.meter.to.verify.the.circuits.are.safely.de-energized.(1000VAC.and.DC. rated,.minimum) •. Any.other.equipment.as.applicable.to.your.operation.as.required.by.national,.state. and.local.regulations 2.4 Wiring Requirement WARNING In accordance with the NEC, ANSI/NFPA70, connect only to a circuit provided with a 400 amp maximum branch circuit overcurrent protection. Fire and Explosion Prevention Care must be exercised when installing DC and AC hookups within the inverter. Follow all instructions in this manual to ensure proper and safe operation of this unit.

  • Page 25: De-Energize/Isolation.procedures

    PVP260kW Inverter Installation and Operation Manual 3/8” holes for lug connections. The fused subcombiners have individual input terminals for each fuse block. These terminals require the use of a torque wrench to properly install the chosen interface cables. For proper torque values of DC subcombiner box wire mounting hardware, see Appendix D - Limits and Fault Codes .

  • Page 26: Figure.2-1. Inverter.in.the.de-Energized.state

    ON/OFF Switch in OFF Position DC Disconnect AC Disconnect in Power OFF in Power OFF Position Position Figure 2-1 Inverter in the De-energized State...

  • Page 27: Planning

    DC wire length. Left and Right Sides PV Powered recommends providing a minimum of 12 inches of clearance on each side of the inverter (working clearances must also comply with NEC 110.26) to allow access to the external mounting flanges.

  • Page 28: Conduits.and.conductors

    Clearances are shown in the figure below. 18 inches 2 inches Clearance Required Behind Unit 3 feet 12 inches 12 inches Figure 3-1 Inverter Clearances 3.3 Conduits and Conductors All the external conduits and conductors are to be supplied by the installer. See Appendix C - Mechanical Drawings for inverter gland plate locations.

  • Page 29: Grounding.and.neutral.requirements

    DC landing busbar. Verify that the grounding configuration matches your installation grounding plan. If you need to reconfigure the ground, contact PV Powered for assistance. DO NOT ground either DC lead at the time of installation. This will defeat the integral GFDI circuit.

  • Page 30: Grid.interconnection

    Tools Required The following tools are required to complete the installation of the inverter: • 9/16 inch socket wrench • 9/16 inch open-ended wrench • 3/8 inch, 3/16 inch, 5/16 inch and 5/32 inch Allen wrenches (Allen wrench adaptor for a socket wrench recommended) •...

  • Page 31: Dc.subcombiner.(Optional)

    PVP260kW Inverter Installation and Operation Manual broadband Ethernet connection available, contact PV Powered Customer Service and Technical Support at 1-877-312-3832 for assistance. 3.8 DC Subcombiner (Optional) The inverter comes with standard positive and negative busbars for landing DC inputs from the PV array. Optional eight, 16 and 20 circuit internal subcombiner boxes are available as shown in the figure below.

  • Page 32: Pv.array.input

    3.9 PV Array Input The PV array open circuit voltage should never exceed 600 volts. The PV Powered web site at http://www.pvpowered.com/installation_support.php includes a string calculator. Contact your system installer or PV Powered if you require additional assistance.

  • Page 33: Installation

    4. Installation 4.1 Handling and Unpacking This section describes the required safe handling and unpacking procedures for the PVP260kW Inverter. Always follow the recommendations in this section to prevent accidental damage or injury. WARNING Heavy Equipment. PVP260kW Inverters weigh up to 5,000 pounds with pallet and packaging.

  • Page 34: Pre-Installation.inspection.steps

    Before placing and installing the inverter, it should be inspected to identify possible external and internal shipping damage. If a problem is identified during any of these inspection steps please contact PV Powered’s Customer Service and Technical Support at 1-877-312-3832, or email support@pvpowered.com.

  • Page 35: Figure.4-3. Air.deflector.check

    PVP260kW Inverter Installation and Operation Manual 4.. Ensure.the.air.deflector.is.held.firmly.in.place.. Figure 4-3 Air Deflector Check 5.. Replace.the.cover.plates..Make.sure.the.gaskets.are.not.damaged.during.replacement. of.the.plates..Do.not.over.tighten.the.screws. Step 3: AC/DC Sub Panel Compartments 1.. For.each.busbar.landing.in.the.AC.and.DC.compartments,.check.the.integrity.of.the. busbar.connections.and.terminals.. Figure 4-4 Busbars and Busbar Connection Inspection 2.. Ensure.the.cable.connections.are.plugged.in.and.fully.seated. Figure 4-5 Inspection of Cable Connections...

  • Page 36: Figure.4-6. Pull.test.of.cable.screw.terminal.connection

    Figure 4-6 Pull Test of Cable Screw Terminal Connection 4.. Inspect.the.screens.at.the.bottom.of.this.compartment.for.damage.or.debris. Figure 4-7 Screen Inspection If any lose wires are found during the inspections, and the location of the connection is unknown, contact PV Powered’s Customer Service and Technical Support. Step 4: Upper Electronics Compartment 1.. Check.the.integrity.of.the.busbars.and.their.connections.in.the.upper.electronics. compartment.

  • Page 37: Figure.4-9. Fan.inspection

    PVP260kW Inverter Installation and Operation Manual Step 5: Upper Active Cooling Compartment 1.. Ensure.that.the.fans.spin.freely. Figure 4-9 Fan Inspection 2. Ensure all air filters are fully seated. Figure 4-10 Air Filter Check This completes the pre-installation inspection. WARNING Before installing the inverter, make sure the pre-installation steps have been...

  • Page 38: Conduit.entry

    4.3 Conduit Entry AC and DC cables can be brought into the inverter through the top, bottom or side gland plates as shown in Appendix C - Mechanical Drawings . WARNING All penetrations in the inverter cabinet must be through the six gland plates which are provided for the sole purpose of providing a safe and convenient way to bring wiring in to and out of the inverter.

  • Page 39: Setting.and.anchoring

    PVP260kW Inverter Installation and Operation Manual 4.4 Setting and Anchoring The inverter base is designed to allow a properly rated forklift to lift it from the front or back. Fork slots are also provided on the left and right sides to enable small adjustments.

  • Page 40: Figure.4-13. Conduit.hub.installation

    Lower cabinet gland plate 2 inch straight metal conduit connector Figure 4-13 Conduit Hub Installation IMPORTANT: Use rain-tight or wet-location conduit hubs that comply with the requirements in the Standard for Fittings for Conduit and Outlet Boxes, UL 514B. DANGER Electrical connections must comply with local electrical codes, the National Electric Code (NEC) and ANSI/NFPA 70.
  • Page 41 PVP260kW Inverter Installation and Operation Manual CAUTION The input and output circuits are isolated from the enclosure. System grounding, when required by Sections 690-41, 690-42 and 690-43 of the National Electric Code (NEC), ANSI/NFPA 70-1999, is the responsibility of the installer.

  • Page 42: Figure.4-14. Inverter.connections

    The inverter is connected to the electrical grid using four wires: •. Phase.A.voltage •. Phase.B.voltage •. Phase.C.voltage •. Ground Do NOT connect a neutral wire to the WYE point of the isolation transformer. The AC termination busbars in the inverter are terminated in the AC disconnect located within the lower enclosure on the right side.
  • Page 43 FOR ALL TEMPERATURE CONDITIONS, THE OPEN CIRCUIT VOLTAGE FOR EACH SERIES CONNECTION MUST BE LESS THAN OR EQUAL TO 600 VDC. Contact PV Powered if you require assistance calculating the maximum DC input voltage for your array at your specific location.

  • Page 44: Figure.4-15. Dc.subcombiner.configurations

    4.. Connect.positive.DC.lead(s).to.the.positive.terminals.located.on.the.busbar.or.fuse. holder.as.applicable..Refer.to.Figure.4-15..The.DC.landing.torque.spec.is.43.ft-lbs. 5.. Connect.negative.DC.lead(s).directly.to.the.negative.terminals.located.on.the.busbar. or.fusing.as.shown.in.Figure.4-15..The.DC.landing.torque.specification.is.43.ft-lbs. 6.. Connect.the.PV.frame.ground.wire(s).to.the.ground.lug.on.the.point.marked. .in. the.lower.DC.cabinet. 8 Circuit Option 16 Circuit Option 20 Circuit Option 8 Circuit with 16 Circuit with Subcombiner with no Circuits Monitoring Option Monitoring Option Figure 4-15 DC Subcombiner Configurations 7.. Energize.the.DC.cables. 8..

  • Page 45: Performance.monitoring.and.networking

    First, basic performance data can be accessed using a free web-based monitoring service provided by PV Powered. Second, the Data Monitoring Module can deliver data to a third party monitoring system over a modbus RS485 network.

  • Page 46: Figure.4-17. Comm.x.ethernet.port.location

    (port 443). Communications is one way – the inverter only communicates externally to the PV Powered Data Center. Typically the inverter will post 1Kb to 2Kb of data via web service call to the data center every 15 minutes. If there is an inverter fault, the inverter may post data more frequently for a short period of time.
  • Page 47 320 ft., or pinched wires somewhere between the inverter and the hub or router. PV Powered recommends using pre-made cables whenever possible. If a cable must be hand-crimped, we recommend testing the cable with a cable tester such as a Fluke LinkRunner™...

  • Page 49: Modbus.network.installation

    PV Powered inverters. Modbus also allows for communication between a modbus master and multiple slave devices connected to the same network. RS-485 is the protocol standard used by PV Powered as the hardware’s serial interface while modbus is the communication protocol that runs on the PV Powered inverters.

  • Page 50: Figure.5-1. Ac.distribution.and.the.comm.x.pcbs

    A. Installation Process Before you start, disconnect the power to the inverter. DANGER AC and DC voltages will still be present at the inverter AC and DC landing points unless utility connection circuit breaker and PV array inputs are disconnected. 1.

  • Page 51: Figure.5-2. Close-Up.view.of.comm.x.pcb

    PVP260kW Inverter Installation and Operation Manual Connect the plus (+) cable to all plus (+) connections and the minus (-) cable to all other minus (-) connections so they correspond throughout the network. Note: The ‘MODBUS Master’ connections are not enabled at this time.

  • Page 52: Figure.5-4. J7.Pins.with.jumper.terminators

    2. Using jumpers to set the pins By default, the termination pins have all three slave jumpers installed when the inverter is shipped. By modifying the location of the jumpers on the termination pins you can make the following settings to an inverter: •.

  • Page 53: Table.5-1. Inverter.address.conversion.for.switches.1.And.2

    A modbus network containing slave devices requires a unique address for each slave. This allows the master device to identify and communicate with each slave. The modbus network administrator must assign an unique modbus address to each PV Powered inverter.

  • Page 54: Figure.5-5. Rotary.switches.for.setting.the.inverter.number

    2.. Set.the.switch.address.on.each.slave.device. The slave address for each PV Powered inverter is set using two rotary switches. Each switch is hexadecimal, containing 0 through 9, followed by A through F. Set the switches using the following guideline: •. The.first.switch.is.always.set.to.the.value.in.the.“1”.column.below.the.“Switch”. heading •. The.second.switch.is.always.set.to.the.value.in.the.“2”.column.below.the.

  • Page 55: Table.5-3. Supported.modbus.commands

    PVP260kW Inverter Installation and Operation Manual 2. Using modbus commands PV Powered inverters provide basic modbus commands. The supported commands are listed in the following table. Command Command Name Description Number Read Holding Register Retrieves the voltage, power and energy values from the inverter.

  • Page 56: Table.5-5. Format.for.read.holding.register,.Response.to.command.03

    Response Response Information Layout Modbus slave address nn (1-126) Command number Number of bytes of data Fist register MSB First register LSB Second register MSB Second register LSB Nth register MSB Nth register LSB CRC LSB CRC MSB Table 5-5 Format for Read Holding Register, response to command 03 Write Single Register Write Single Register command is used to write to one of the command registers...

  • Page 57: Table.5-7. Format.for.write.single.register,.Response.to.command.06

    PVP260kW Inverter Installation and Operation Manual Response Response Information Layout CRC LSB CRC MSB Table 5-7 Format for Write Single Register, response to command 06 Return Slave ID Command Command Information Layout Modbus slave address nn (1-126) Command number Table 5-8 Format for Return Slave ID, command 11h xxPVP Inverter IDxxxxx The Slave ID command returns the ASCII string “...

  • Page 58: Table.5-10. Fixed.information.registers

    Modbus Register Maps The following tables list the modbus registers with their location and a description of the data stored in the register. For more information describing the data format contained in column six, the “Format” column of each table, see Table 5-17 at the end of this chapter. Start Nbr.

  • Page 59: Table.5-12. Data.registers

    PVP260kW Inverter Installation and Operation Manual Start Nbr. of Description Format Range Register Register Registers Address Modbus base address = 1000 Line frequency 1016 1017 41017 FLOAT +/- 32bit IEEE754 Line kW 1018 1019 41019 FLOAT +/- 32bit IEEE754 Total kWH...

  • Page 60: Table.5-14. Command.registers

    Start Nbr. of Description MB Address Format Range Notes Register Register Registers Modbus base address = 3000 Enable inverter 3002 3002 43003 UINT 16 EE hex Write 0xDD to disable Write 0xEE to enable Reset data comm 3003 3003 43004 UINT 16 99 hex Write 99 hex to this...

  • Page 61: Table.5-16. Inverter.data.comm.status.word

    IEEE 754 standard 32-bit floating point number Table 5-17 Data formats for registers Information about the Data Monitoring Module For additional information on how to use the modbus Data Monitoring Module, contact PV Powered Customer Service and Technical Support at 1-877-312-3832.

  • Page 63: Operation

    6. Operation 6.1 Start Up Procedure WARNING Before turning on the inverter, ensure that the front panels are closed properly. To start the inverter, complete the following steps in order: 1.. Prior.to.engaging.the.disconnect.switches,.check.the.polarity.of.the.DC.positive.and. negative.connectors.to.ensure.they.are.wired.correctly.and.confirm.the.PV.panel. open.circuit.voltage.is.at.or.below.600.VDC. 2.. Close.the.external.panel.doors. 3.. Turn.on.the.external.AC.connection.to.the.inverter. 4.. Turn.on.the.external.DC.disconnect.to.provide.DC.power.to.the.inverter. 5..

  • Page 64: Inverter.operating.states

    Position Figure 6-1 AC and DC Disconnect Power ON 6.2 Inverter Operating States The PVP260kW has nine operating states. The inverter will transition from one state to another only as shown in Figure 6-2. Each operating state is described below.

  • Page 65: Figure.6-2. Inverter.state.diagram

    PVP260kW Inverter Installation and Operation Manual Initialize Disabled Sleep Startup Delay Fault Precharge Precharge Power Track (auto Idle mode) Figure 6-2 Inverter State Diagram Initialize The inverter enters this state after a reset or power cycle. Variables and devices are initialized and I/O ports set.
  • Page 66 Fault The inverter enters this state when any fault condition occurs. The inverter can enter this state from any other state except initialize. Unless the fault is latching, the inverter clears the fault when the fault condition subsides. The inverter displays the fault codes and messages indicating the current fault conditions.

  • Page 67: Display.screens.and.display.operation

    PVP260kW Inverter Installation and Operation Manual 6.3 Display Screens and Display Operation Display Screens The inverter display provides the operator with information about the current state of the inverter. There are five sets of screens that may display depending on the state of the inverter.

  • Page 68: Figure.6-6. Fault.state.screens

    Screen 1: Fault Code(s) Screen 2: Fault Text Screen 3: Contact Information Figure 6-6 Fault State Screens Figure 6-7 Warning State Screen Figure 6-8 Disabled State Screen Display Operation The inverter display normally scrolls through a series of display screens based on the current state of the inverter.

  • Page 69: Ground.fault.interrupt.device

    PVP260kW Inverter Installation and Operation Manual 6.4 Ground Fault Interrupt Device The inverter is equipped with a GFDI (Ground Fault Detector/Interrupter). The purpose of the GFDI is to detect a ground fault (unintended current flow from the solar panels to earth ground) and in this event, disable the inverter.

  • Page 70: Figure.6-10. Ac.and.dc.disconnect.power.off

    ON/OFF Switch in OFF Position DC Disconnect AC Disconnect in Power OFF in Power OFF Position Position Figure 6-10 AC and DC Disconnect Power OFF DANGER Risk of Electrical Shock. Allow five (5) minutes for internal power to dissipate prior to entering the enclosure cabinet. Ensure all terminals are voltage free with the use of a multimeter.

  • Page 71: Maintenance.&.Troubleshooting

    7.1 Visual Inspection PV Powered recommends visually inspecting the inverter every time it is serviced. Start by observing the front, back and sides of the inverter for damage, foreign objects, or dust and debris that may have accumulated around the inverter. Remove dirt and debris from the area around the inverter at least every six months.

  • Page 72: Figure.7-1. Air.intake.hood

    Maintaining the Blower Intake Filters PV Powered recommends an annual inspection and cleaning of the blower intake filters. Cleaning may be required more often depending on the location of the inverter. The air intake hood is mounted on gas shocks. It must be in the open position to clean the filters.

  • Page 73: Maintaining.the.card.cage.air.filter

    Use the following instructions to access the secondary air filter and refer to Figure 7-3. 1.. Remove.the.air.intake.shroud.above.the.card.cage..This.will.expose.the.air.filter.. 2.. Remove.the.four.screws.on.the.card.cage.air.filter. 3.. Clean.the.filter.with.compressed.air.. 4.. Once.the.filter.is.cleaned,.replace.the.filter.and.shroud. If the filter needs to be replaced, call PV Powered Technical Support at 1-877-312-3832,. or.email.support@pvpowered.com.

  • Page 74: Faults.and.warnings

    Card Cage Air Shroud Retainer Screws Card Cage Air Filter Figure 7-3 Card Cage Air Filter 7.4 Faults and Warnings The display screen is the primary indicator of a possible problem with the inverter. If a fault has occurred the inverter will cease power production until the fault is cleared. A fault may be a latching or non-latching fault.

  • Page 75: Figure.7-4. Example.of.the.fault.display.screens

    PVP260kW Inverter Installation and Operation Manual Identifying the Inverter’s Fault Codes Startup Upon startup, the inverter will automatically scroll between the startup screens shown in Figure 7-4. Figure 7-4 Example of the Fault Display Screens In addition, the inverter can also detect and display inverter warnings. Warnings are displayed if a condition is detected that does not require the inverter to shut down but may require attention.

  • Page 76: Troubleshooting.faults

    If the visual inspection reveals potentially unsafe conditions, discontinue troubleshooting and contact PV Powered Technical Support at 1-877-312-3832, or email support@ pvpowered.com prior to proceeding. AC Under Voltage Fault...
  • Page 77 PVP260kW Inverter Installation and Operation Manual The GFDI functions using a 5A fuse to connect or bond the solar array Negative (or the solar array Positive, if using a positively grounded panel array) to earth ground on the DC Distribution PCB.

  • Page 78: Figure.7-6. Infrared.inspection.port

    2.. Once.the.ground.fault.condition.has.been.eliminated,.verify.the.voltage.between.earth. ground.and.the.grounded.side.of.the.PV.array.is.less.than.30.volts. 3.. Ensure.the.DC.disconnect.is.in.the.OFF.position.and.install.the.new.GFDI.fuse. 4.. Follow.section. 6.1.Start.Up.Procedure .to.restart.the.inverter. If the ground fault cannot be eliminated, contact PV Powered Technical Support at 1-877-312-3832, or email support@pvpowered.com. Infrared Inspection Ports Infrared inspection of the isolation transformer and inductors can be performed by utilizing the port at the top of the DC sub panel (shown in Figure 7-6).

  • Page 79: Communication.pcb.status.light.operation

    Installation and Operation Manual 7.6 Communication PCB Status Light Operation Communication PCB LED Lights All PV Powered commercial inverters include four status LED lights to help troubleshoot system operation: Link – Indicates presence of a hardware Ethernet connection Activity (or ACT) – Indicates internet traffic Status –...

  • Page 80: Figure.7-8. Comm.x.pcb.lights

    Link Light Activity Light Status Light Figure 7-8 Comm X PCB Lights Link LED Operation and Signaling •. The.Link.LED.remains.on.if.a.hardware.Ethernet.connection.is.found. •. The.LED.is.off.if.there.is.no.hardware.Ethernet.connection. •. There.are.no.flash.codes.for.the.Link.LED. Activity LED Operation and Signaling •. The.Activity.LED.(called.ACT.on.some.circuit.PCBs).flashes.to.indicate.the.presence. of.internet.traffic. •. There.are.no.flash.codes.for.the.Activity.LED. Status LED Operation and Signaling •. During.the.startup.sequence.the.Status.LED.is.on.solid.for.a.few.seconds,.then.flashes. quickly.for.several.seconds.while.the.communications.device.looks.for.an.Internet.

  • Page 81: Table.7-1. Status.led.flash.codes

    The inverter uses a DNS (Domain Name Service) server to resolve the IP address of the PV Powered database when it posts the data, once every 15 minutes. If the DNS server cannot be found, or does not return a valid IP address, the DNS Failure code will flash for a minute or so while the inverter is trying to post.

  • Page 82: Controller.pcb.status.light.operation

    Periodic short and long flashes will be seen when communications occur on a modbus network that contains multiple modbus slave devices. If only short flashes are seen: •. Check.the.inverter.modbus.address.switches.and.make.sure.they.correspond.to.the. address.programmed.into.the.modbus.master. •. Confirm.that.the.baud.rate.and.other.communication.parameters.of.the.modbus.mas- ter.are.set.correctly. For further modbus network configuration details see Appendix E - Annual Maintenance Requirements Checklist .

  • Page 83: Appendix.a.-.Specifications

    Appendix A - Specifications Model PVP260kW PVP260kW-LV Electrical Characteristics Continuous Power (AC) 260kW 260kW 480VAC 480VAC Grid Type 3 phase, 4 wire Y 3 phase, 4 wire Y Maximum array short circuit current (DC) 1600A 1600A Maximum output fault current and duration...

  • Page 84: Table.a-1. Product.specifications.data

    Table A-1 Product Specifications Data Notes: 1. The PVP260kW Inverter complies with FCC Part 15 Class A conducted requirements. Radiated will be tested at a later date and will be tested to CISPR, not FCC. 2. The PVP260kW Inverter is designed to meet or exceed NEC Article 690 and UL1741-2005 Static Inverters and Charge Control- lers for use in Photovoltaic Power Systems, which includes testing for IEEE 1547.1-2005, IEEE 929-2000 and IEEE519-2000.

  • Page 85: Appendix.b.-.Wiring.diagram

    Appendix B - Wiring Diagram Figure B-1 Wiring Diagram...

  • Page 87: Appendix.c.-.Mechanical.drawings

    Appendix C - Mechanical Drawings Figure C-1 Mechanical Drawings...

  • Page 88: Figure.c-2. Mechanical.drawings

    Figure C-2 Mechanical Drawings...

  • Page 89: Appendix.d.-.Limits.and.fault.codes

    Appendix D - Limits and Fault Codes Factory setting Maximum Condition Range (VAC) (VAC) or (Hz) Trip Time (s) 304.8 304.8 – 332.5 Voltage phase high Voltage phase low 243.9 216.1 – 243.9 Voltage phase fast high 332.5 332.5 – 360.2 0.16 Voltage phase fast low 138.6...

  • Page 90: Table.d-4. Drive.faults

    For each fault category, another fault variable further specifies which fault has occurred within this category. The following tables list the faults for each category (variable). The following table lists the drive protection faults, gate or current. Hexadecimal Display String Description Value 0001...

  • Page 91: Table.d-6. Grid.fault.(Grd)

    PVP260kW Inverter Installation and Operation Manual The grid faults in the following table include grid interactive voltage and frequency faults. Hexadecimal Display String Description Value 0001 AC FAST UNDERVOLT A Fast AC voltage low, phase A 0002 AC FAST UNDERVOLT B...

  • Page 92: Table.d-8. System.faults.(Sys)

    The following table lists the miscellaneous system faults. Hexadecimal Display String Description Value 0001 GROUND FAULT Ground fault 0002 AC CONTACTOR AC contactor fault 0004 DC CONTACTOR DC contactor fault 0008 WD TIMER Watchdog fault 0010 CPU LOAD CPU load fault 0020 RESTART LIMIT Too many fault restarts...

  • Page 93: Table.d-10. Subcombiner.wire.sizing.and.torque.values

    PVP260kW Inverter Installation and Operation Manual DC Subcombiner Inputs The following table reflects proper DC wire sizing and torque values per subcombiner application: Fuse Block Required Terminal Temp. Maximum Maximum Wire Size Torque Rating Amperage Qty. two (2) - Al/Cu 500kcmil-#4/Direct to busbar 43 ft-lbs 75°C...

  • Page 95: Appendix.e.-.Annual.maintenance.requirements.checklist

    Appendix E - Annual Maintenance Requirements Checklist Item # Requirement General Inspection & Cleaning Record general site conditions Record inverter performance data from inverter display Record environmental conditions Remove dirt and debris from underneath inverter Inspect and clean interior of inverter Inspect air filter and replace or clean Confirm presence of required site-specific safety equipment Confirm presence of product documentation...

  • Page 97: Appendix.f.-.Efficiency.curves

    Appendix F - Efficiency Curves Manufacturer: PV Powered LLC Model #: PVP 260kW 295V Rated Maximum Continuous Output Power: 260.00 kW Night Tare Loss: 67.00 W F.1 PVP260kW - Efficiency Curves Vmin: 295 Vdc Vnom: 341 Vdc Vmax: 480 Vdc Power Level (%;...

  • Page 98: F.2

    Manufacturer: PV Powered LLC Model #: PV 260kW Rated Maximum Continuous Output Power: 260.00 kW Night Tare Loss: 67.00 W F.2 PVP260kW-LV - Efficiency Curves Vmin: 265 Vdc Vnom: 319 Vdc Vmax: 480 Vdc Power Level (%; kW) 100% Input Voltage (Vdc) 26.00...

  • Page 99: Limited.warranty

    The 10-Year Warranty may be transferred to subsequent owners, except that the 10- Year Warranty shall be void if, without prior approval of PV Powered, either (i) the PV Powered commercial inverter is moved from its original installation location or (ii) the overall PV system design is altered.
  • Page 100 All replaced products and all parts removed from repaired products become the property of PV Powered. PV Powered covers the parts, travel and labor necessary to repair the product within the United States and Canada. If your product requires troubleshooting or warranty service, contact your installer or dealer.

  • Page 101: Index

    Index conduit 16 hub installation 28 abbreviations v contact information i contacting output voltage local utility 18 changing 29 cooling 5 over-current protection 2, 13 cooling requirements 17, 25 under voltage fault 64 wiring 30 AC Distribution PCB 6 data monitoring module 33, 49 acronyms v AC sub panel 5 inputs 31...
  • Page 102 louver plate 61 main enclosure 3 major components 3 inspecting 25 models 1 intake screen 60 monitoring 18, 33, 38 fault codes 63, 77 operating states 52 AC under voltage 64 packaging 21 startup 63 power distribution PCB 4 fire and explosion prevention 12 power module 3 first aid 11 rotary switches 42...
  • Page 103 PVP260kW Inverter Installation and Operation Manual service 10 shutdown procedure 57 NEMA 4 27 slave device 37, 38 networking 39 address conversion table 41 communication parameters 42 setting address 41 modbus set up 37 specifications 2 terminating 40 start up procedure 51...
  • Page 104 Notes...
  • Page 106 PO Box 7348 • Bend, OR 97708 • P: 541-312-3832 • www.pvpowered.com...

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