PVP250kW & PVP260kW Inverter INSTALLATION & OPERATION MANUAL 97-600100-28-C
Preface PV Powered Contact Information PV Powered, Inc. 20720 Brinson Blvd. PO Box 7348 Bend, OR 97708 Tel: 541-312-3832 Technical Support: 1-877-312-3832 Fax: 541-312-3840 www.pvpowered.com email: support@pvpowered.com Document Copyright PV Powered PVP250kW & PVP260kW Inverter Installation and Operation Manual ©2011 PV Powered. All rights reserved. This manual may not be reproduced or distributed without written permission from PV Powered.
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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. Failure to heed this warning will result in serious injury or death to personnel and destruction of equipment.
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PVP250kW & PVP260kW Inverter Installation & Operation Manual Acronyms and Abbreviations A/D Analog to Digital Conversion ANSI American National Standards Institute CFM Cubic Feet per Minute DHCP Dynamic Host Configuration Protocol DNS Domain Name Service DSP Digital Signal Processor DVI Digital Video Interface EMI Electromagnetic Interference ESD Electro Static Discharge GFDI Ground Fault Detector Interruptor IEEE Institute of Electrical and Electronics Engineers IGBT Insulated Gate Bipolar
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Table of Contents Preface...................................................................................................................................i Safety Information and Conventions.................................................................................. iii Acronyms and Abbreviations................................................................................................v 1. Introduction..............................................................................................
6. Operation........................................................................................................................63 6.1 Start Up Procedure..................................................................................................63 6.2 Inverter Operating States........................................................................................64 6.3 Display Screens and Display Operation.................................................................67 6.
PVP250kW & PVP260kW Inverter Installation & Operation Manual List of Tables Table 2-1 Table 2-2 Table 4-1 Table 4-2 Table 5-1 Table 5-2 Table 5-3 Table 5-4 Table 5-5 Table 5-6 Table 5-7 Table 5-8 Table 5-9 Table 5-10 Table 5-11 Table 5-12 Table 5-13 Table 5-14 Table 5-15 Table 5-16 Table 5-17 Table 5-18 Table 5-19 Table 5-20 Table 5-21 Table 5-22 Table 7-1 Table A-1 Table D-1 Table D-2 Table D-3 Table D-4 Table D-5 Table D-6 Table D-7 Table D-8 Table D-9 Table D-10 Table E-1 Inverter Symbols..............
List of Figures Figure 1-1 Figure 1-2 Figure 1-3 Figure 1-4 Figure 1-5 Figure 1-6 Figure 1-7 Figure 1-8 Figure 2-1 Figure 3-1 Figure 3-2 Figure 4-1 Figure 4-2 Figure 4-3 Figure 4-4 Figure 4-5 Figure 4-6 Figure 4-7 Figure 4-8 Figure 4-9 Figure 4-10 Figure 4-11 Figure 4-12 Figure 4-13 Figure 4-14 Figure 4-15 Figure 4-16 Figure 4-17 Figure 4-18 Figure 5-1 Figure 5-2 Figure 5-3 Figure 5-4 Figure 5-5 Figure 6-1 Figure 6-2 Figure 6-3 Figure 6-4 Figure 6-5 Figure 6-6 Figure 6-7 Figure 6-8 Figure 6-9 Figure 6-10 Fi
PVP250kW & PVP260kW Inverter Installation & Operation Manual Figure 7-5 Figure 7-6 Figure 7-7 Figure C-1 Figure C-2 Figure C-3 Figure C-4 Figure D-1 Figure F-1 Figure F-2 Figure F-3 Figure F-4 Fault Example Screen....................................................................................75 Communications Card with Status LED Lights............................................79 Comm X PCB Lights.....................................................................................
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1. Introduction 1.1 Design Features The PVP250kW, PVP260kW and PVP260kW-LV Inverters are designed to act exclusively as a grid-tied inverter for photovoltaic (PV) systems. This means the inverter must be tied to the utility grid and a photovoltaic system in order to operate properly and it is not suitable for any other applications (such as a battery back-up or wind powered systems). The inverter contains everything needed to convert the DC voltage generated by a solar array into AC electrical power.
Versatility The PVP250kW and PVP260kW Inverters are designed for flexibility. They can be used for a range of commercial applications and they can accommodate most PV system configurations. 1.2 Product Characteristics See Appendix A - Specifications for the product specifications information. 1.
PVP250kW & PVP260kW Inverter Installation & Operation Manual 1.4 Major Components and Functional Parts Descriptions Air Intake Hood Power Module Assembly } Display Data Monitoring Section Revenue Grade Meter (optional feature) DC Sub Panel DC Combiner Sub Panel AC Sub Panel Figure 1-1 PVP250kW and PVP260kW Inverters Main Enclosure The modular design of the inverters makes them easy to access and service. The main enclosure (Figure 1-1) is comprised of two main sections: 1.
} 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. Communications PCB – Provides serial, internet and Modbus communications. 2. Power Distribution PCB – Distributes the required logic level voltages for use throughout the inverter. 3.
PVP250kW & PVP260kW Inverter Installation & 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. Active Cooling The inverters come with blowers which activate as needed to keep the internal components within preset temperature limits. These blowers are located under the air intake hood of the inverter.
AC Distribution PCB The AC Distribution PCB (Figure 1-5) is located on the AC sub panel.
PVP250kW & PVP260kW Inverter Installation & Operation Manual Modbus Address Switch 1 (upper) Modbus Address Switch 2 (lower) Factory Use Only Master Jumpers Ethernet Port Slave Jumpers Modbus Output (slave) Modbus Output (master) (Not enabled) Figure 1-6 Comm X PCB DC Sub Panel This panel houses the DC disconnect, DC distribution PCB, fuses and integrated fused subcombiner box.
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. It includes the DC voltage sensing and DC soft start circuit. The DC Distribution PCB also houses the GFDI (Ground Fault Detector/Interrupter) circuit.
PVP250kW & PVP260kW Inverter Installation & Operation Manual Operator Interface Controls/Vacuum Fluorescent Display The Vacuum Fluorescent Display (VFD) provides multiple information screens to the user. Views and Basic Block Diagram of the Inverter See “Appendix C - Mechanical Drawings” for multiple views of the inverter.
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2. Safety 2.1 General Safety IMPORTANT SAFETY INSTRUCTIONS: This product has been engineered and manufactured to ensure your personal safety. Improper use may result in potential electrical shock or burns. Read and follow all instructions for installation, use and servicing of this product. Read all safety warnings before installing or operating the inverter. CONSIGNES IMPORTANTES DE SÉCURITÉ : Ce produit a été conçu et fabriqué pour garantir la sécurité maximale des personnes.
Handling, Service and Maintenance Only qualified personnel should perform the transportation, installation and initial operation and maintenance of the inverters in accordance with NEC ANSI/NFPA 70, as well as all state and local code requirements. Follow all national and state accident prevention regulations. ! ! ! ! WARNING Crush Hazard. The inverter has a specific balance point that correlates to their Center of Gravity. While the units meet UL1741 and CSA 107.1-1.
PVP250kW & PVP260kW Inverter Installation & Operation Manual ! ! ! ! ! ! ! ! DANGER Risque d’électrocution. L’intérieur de l’onduleur est soumis à des hautes tensions. Les interrupteurs de courant alternatif et continu doivent être mis HORS TENSION durant les travaux sur l’unité. Attendez cinq minutes afin de permettre la décharge du courant haute tension avant de démonter les panneaux avant de l’onduleur. DANGER Risk of Electrical Shock.
! ! ! AVERTISSEMENT Risque de brulure. Certaines parties de l’onduleur peuvent atteindre des températures considérables durant une exploitation normale. Soyez prudent durant les travaux autour du puits thermique. WARNING Risk of Damage to Equipment. The inverter contains Electro Static Discharge (ESD) sensitive circuitry. Discharge any static charge potential, by touching bare skin to earth ground, prior to contacting any internal components. AVERTISSEMENT Risque d’endommagement matériel.
PVP250kW & PVP260kW Inverter Installation & Operation Manual 2.3 Personal Safety Safety Zone Ensure any personnel entering a safety zone within a four foot area around any operating inverter wear appropriate Personal Protective Equipment (PPE) as mandated by national, state and local authorities.
! AVERTISSEMENT Conformément au code national de l’électricité et à la norme ANSI/NFPA70, ou au code électrique canadien applicable, l’installation électrique ne doit se faire que sur un circuit équipé d’un circuit de dérivation de protection contre les surintensités calibré correctement.
PVP250kW & PVP260kW Inverter Installation & Operation Manual ! DANGER Ne branchez pas les conducteurs photovoltaïques positifs ou négatifs à la barre omnibus de mise à la terre fournie. Les piles PV sont mises à la terre grâce au GFDI intégral. Mettre les conducteurs positifs ou négatifs à la terre à tout autre point du système ne permettrait pas au circuit de protection contre les mises à la masse défectueuses de fonctionner normalement.
480VAC 600VAC PVP250kW Model 400A 350A PVP260kW 400A N/A PVP260kW-LV 400A N/A Table 2-2 Branch Breaker Size Recommendations 2.5 De-energize/Isolation Procedures ! ! ! ! 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.
PVP250kW & PVP260kW Inverter Installation & Operation Manual ON/OFF Switch in OFF Position DC Disconnect in Power OFF Position AC Disconnect in Power OFF Position Figure 2-1 Inverter in the De-energized State 19
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3. Planning 3.1 General Requirements Installation 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 voltages to 600 volts. The inverter must be anchored to a concrete pad. The mounting pad must meet local seismic requirements. See Appendix C - Mechanical Drawings for concrete pad mounting specifications.
Front – A front clearance of three (3) feet is required to open and maintain the unit per NEC 110.26 or applicable Canadian Electrical Code. Top – A top clearance of 18 inches above the air intake hood is required to maintain the filters and blowers. Clearances are shown in the figure below. 2 inches Clearance Required Behind Unit 18 inches 12 or 36 inches 12 or 36 inches 3 feet 1. Only one side, right or left, is recommended to have the full 36”clearance while the remaining side must have 12”.
PVP250kW & PVP260kW Inverter Installation & Operation Manual 3.5 Environmental Requirements The unit may be installed either indoors or outdoors. If the installation of the inverter is outdoors, all interconnect conduit and fittings must be rated NEMA 4 (same as inverter rating) as required by the NEC. For hot locations a shade structure should be placed over the unit in order to reduce thermal stress and extend the product’s life.
! ! CAUTION The inverter may be factory configured for either positive or negative ground. It may NOT be field configured to a different grounding once it is shipped from the factory. To identify if your inverter is configured for positive or negative ground read the label next to the 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.
PVP250kW & PVP260kW Inverter Installation & Operation Manual • #1 and #2 Phillips screwdriver • Wire strippers • Utility knife • 0-120 inch/pound torque wrench • 0-50 foot/pound torque wrench • 600 volt rated fuse puller/pliers • Tools for installing anchor bolts • RJ45 crimping tool (if making a custom CAT5 cable) 3.7 Grid Interconnection Utility Connection Requirements Review all NEC 690 or applicable state or local standards.
8 Circuit Option 16 Circuit Option 8 Circuit with Monitoring Option 20 Circuit Option 16 Circuit with Monitoring Option Figure 3-2 DC Subcombiner Box Options No Fuse Option It is the responsibility of the installer to provide proper fuse protection for the DC input circuit if an optional fused subcombiner is not selected. 3.10 PV Array Input The PV array open circuit voltage should never exceed 600 volts. The PV Powered web site at renewables.advanced-energy.com/StringCalculator.
4. Installation This section describes the required safe handling and unpacking procedures for the PVP250kW and PVP260kW Inverters. Always follow the recommendations in this section to prevent accidental damage or injury. WARNING ! Heavy Equipment. PVP250kW and PVP260kW Inverters weigh up to 5,200 pounds with pallet and packaging. If the inverter is lifted incorrectly, it may result in death. In addition, improper handling may result in serious damage to the inverter and may also void the warranty.
4. Lift the inverter off the pallet using the forklift slots on the front or back. The left and right fork slots are not designed for lifting the inverter and may only be used for fine adjustments where the inverter’s full weight will not be lifted from a single side. The front and back of the inverter base each have two fork slots that are 7.5” wide and 26.5” apart on center. The left and right sides of the inverter base each have two fork slots that are 7.5” wide and 21” apart on center. 4.
PVP250kW & PVP260kW Inverter Installation & Operation Manual Figure 4-2 Screen Check 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.
2. Ensure the cable connections are plugged in and fully seated. Figure 4-5 Inspection of Cable Connections 3. Inspect and pull test all cable screw terminal connections. 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.
PVP250kW & PVP260kW Inverter Installation & Operation Manual Step 4: Upper Electronics Compartment 1. Check the integrity of the busbars and their connections in the upper electronics compartment. Figure 4-8 Checking the Busbar Connections 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 completed and no issues have been identified. AVERTISSEMENT Avant de procéder à l’installation de l’onduleur, assurez-vous d’avoir effectué toutes les étapes correctement et qu’aucun problème ne subsiste. 4.3 Setting and Anchoring ! ! WARNING Do not attempt to lift the full weight of the inverter from the left or right sides only.
PVP250kW & PVP260kW Inverter Installation & Operation Manual 2. Position the inverter to the preferred location. Alternate methods of lifting and positioning the inverter may be used. Proper methods may include the use of a crane with a strap rated for the weight of the inverter; however, care MUST be taken to protect the inverter from compressive stresses or forces which may dent or deform the cabinet or cause damage to the inverter.
3. Punch holes as needed. 4. Attach watertight NEMA 4 hubs to the holes. 5. Replace the gland plate taking care to evenly seat the gasket material against the cabinet. 6. Tighten screws until snug. Do not overtighten. Figure 4-11 Bottom Entry Gland Plates - DC Side Figure 4-12 Side Entry Gland Plates - AC Side 4.5 Electrical Connections Proceed with making the electrical connections of the inverter once it has been properly secured to the concrete slab.
PVP250kW & PVP260kW Inverter Installation & Operation Manual 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 the NEC and ANSI/NFPA 70 or applicable state or local standards.
4.6 AC Wiring ! ! ! ! ! WARNING Follow the order listed in this section to wire the inverter. Failure to do so may result in hazardous voltages or disconnection of contacts. AVERTISSEMENT Pour câbler l’onduleur, suivez les ordres décrits dans cette section. Tout manquement au suivi scrupuleux des instructions est susceptible d’entrainer des tensions anormales ou le débranchement de contacts.
PVP250kW & PVP260kW Inverter Installation & Operation Manual ! PRUDENCE Afin de prévenir les risques d’incendie, les calibres de protection contre les surtensions des circuits de dérivation suivants sont recommandés: 480VAC 600VAC PVP250kW Model 400A 350A PVP260kW 400A N/A PVP260kW-LV 400A N/A La taille du circuit de dérivation de protection contre les surintensités doit être conforme au code national de l’électricité et à la norme ANSI/NFPA 70, ou au code électrique canadien.
ampacity, temperature and conduit. In addition wire should be sized to minimize voltage drop. Install the inverter on a dedicated branch circuit with a recommended circuit breaker rating as specified in the following table. Refer to Table D-10 in Appendix D for more information.
PVP250kW & PVP260kW Inverter Installation & Operation Manual PRUDENCE ! Afin d’éviter des surtensions inacceptables de CA lorsque l’onduleur est branché, assurez-vous que la valeur de l’impédance aux points de connexion au réseau public est la plus basse possible. Une faible valeur d’impédance permet un fonctionnement plus efficace de l’appareil.
Busbar Note: Grade 8 hardware required. Crimp Connector/Lug Figure 4-15 Busbar Connections ! ! WARNING Do not connect a neutral wire to the WYE point of the isolation transformer. Doing so will cause the inverter to malfunction and will void the warranty. AVERTISSEMENT Ne branchez pas de câble neutre au point WYE du transformateur d’isolation. Un tel branchement causerait un fonctionnement défectueux de l’onduleur et annulerait la garantie. AC Wiring Procedure 1.
PVP250kW & PVP260kW Inverter Installation & Operation Manual Adjustable Voltage Range The inverter is factory calibrated to the voltage and frequency limits detailed in Appendix D - Limits, Fault Codes, Torque Values, and Wire Sizes. These limits are adjustable and can be set by PV Powered field technicians. 4.7 DC Wiring ! ! ! ! DANGER Before proceeding with the DC wiring, confirm that the PV array has been disconnected from the inverter using the external DC disconnect.
DC Wiring Procedure Follow these steps to wire the DC inputs from the PV panels to the inverter. These instructions are for a negatively grounded array. For a positively grounded array, use the opposite terminals. Refer to Figure 4-14. ! ! DANGER Risk of Electrical Shock. When exposed to light, PV arrays create electrical energy that could cause a hazardous condition. DANGER Risque d’électrocution.
PVP250kW & PVP260kW Inverter Installation & Operation Manual 8 Circuit Option 16 Circuit Option 20 Circuit Option 8 Circuit with Monitoring Option 16 Circuit with Monitoring Option Subcombiner with no Circuits Figure 4-16 DC Subcombiner Configurations 9. Using a voltmeter, check the PV array positive leads and confirm the voltage is positive when referenced to the negative leads. The reading should not exceed your calculated series Voc total. 10. De-energize the DC cables. 11.
4.8 Performance Monitoring and Networking The inverter has an integrated Data Monitoring Module located in a dedicated Data Monitoring section. The Data Monitoring Module enables access to the inverter performance data in two ways. 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 RS-485 network.
PVP250kW & PVP260kW Inverter Installation & Operation Manual Connecting the Ethernet Cable to the Internet Use the following steps to complete the connection of the Data Monitoring Module: 1. Route the Ethernet (CAT5) cable from the Internet-enabled router, at the gland plate location on the upper right side of the inverter, using the proper conduit and hub connectors. Refer to section 4.4 Conduit Entry for instructions on how to properly use gland plates. 2.
• Connect the inverter’s Ethernet port to a hub or router. Ethernet cables must meet the T-568B wiring standard and must be less than 300 feet in length. • Provide DHCP server access to the inverter. The inverter requires DHCP to establish its IP address. • Provide a path to the Internet for https (port 443) from the inverter. The MAC address for the inverter can be found on the side of the communications PCB. To see the MAC address the communications PCB must be removed from the card cage assembly.
5. Modbus Network Installation 5.1 Overview PV Powered commercial inverters can communicate via Modbus RS-485 and Modbus TCP/IP. This chapter explains how to communicate with a PV Powered commercial inverter on a Modbus network through either RS-485 or TCP/IP. This chapter is written for PV installers, electricians, controls contractors and Modbus network programmers. 5.2 Modbus Communication Protocol 5.
! DANGER Les voltages alternatifs et continus seront toujours présents aux points de contact CA et CC de l’onduleur à moins que les disjoncteurs du réseau public et que les alimentations des piles PV ne soient débranchés. Step 1: Installing the Modbus Cable for TCP/IP A.
PVP250kW & PVP260kW Inverter Installation & Operation Manual The final part of the RS-485 installation process is the Modbus network configuration. These steps should be completed by the Modbus network programmer. The last two steps are: • Setting the device addresses. • Configuring point maps for slave devices. 5.7 Modbus RS-485 Installation Process Disconnect the power to the inverter before starting the installation.
Comm X PCB Figure 5-1 Comm X PCB in the Data Monitoring Section Switch 1 Switch 2 Factory Use Only Master jumpers with no jumpers installed Ethernet Port Slave jumpers with no jumpers installed Modbus Master (inactive) Modbus Slave Port Figure 5-2 Comm X PCB with Modbus Slave Port Location C. Connect the Modbus cable. The end of the Modbus cable connects to the Modbus slave port connector on the Comm X PCB. See Figure 5-2 for the location of the Modbus slave port.
PVP250kW & PVP260kW Inverter Installation & Operation Manual Note: The Modbus master connections are not enabled at this time. D. Connect a ground reference line to the terminal labeled “GND” on the Modbus slave connector. The shield of a communications cable may be used for this reference as long as the shield is connected to earth ground at one point only. It is recommended that PV Powered devices have connected grounds when possible. Note: Some Modbus devices do not have a shield or reference input.
Step 2: Using Jumpers to Set the Pins for RS-485 Installation By default, the termination pins have three slave jumpers installed in the J6/Master positions and three jumpers in the J7/Slave positions when the inverter is shipped. The location of the jumpers can determine the following settings to an inverter: • Terminate the network • Set jumpers for the center inverter(s) on the network • Turn on biasing Jumper setting options A. Terminate the network.
PVP250kW & PVP260kW Inverter Installation & Operation Manual B. Set the jumpers for the center inverters on the network. • J7 - remove all three jumpers from the J7 pins for any inverter in the middle of the network, and place the jumpers in the J16 neutral position. J6 J16 High X Line X Low X J7 Table 5-3 No Biasing or Termination (Default Setting) C. Set the biasing. Biasing sets the voltage levels on the data lines of an inactive or idle network.
First pair of pins, J6 - Master Second pair of pins, J16 - NC Third pair of pins, J7 - Slave Figure 5-4 Location of Jumpers J6, J16 and J7 on the Comm X PCB Step 3: Setting the Modbus Address for Each Slave Device 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. To set the address: A.
PVP250kW & PVP260kW Inverter Installation & Operation Manual Address Switch 1 2 10 0 A 11 0 12 Address Switch 1 2 30 1 E B 31 1 0 C 32 13 0 D 14 0 E 15 0 16 Address Switch 1 2 50 3 2 F 51 3 2 0 52 33 2 1 34 2 2 F 35 2 1 0 36 17 1 1 18 1 19 20 Address Switch 1 2 70 4 6 3 71 4 3 4 72 4 53 3 5 73 54 3 6 74 3 55 3 7 2 4 56 3 37 2 5 57 2 38 2 6 1 3 39 2 1 4 40 2 Address Switch 1 2 90 5 A 7 91 5 B 8
The switches are located near the center of the Comm X PCB and are labeled SW1 and SW2 as they appear in Figure 5-5. If you need more device addresses than the 100 listed in Table 5-6, refer to a complete digital to hexadecimal conversion table. Note: Some Modbus master devices do not allow addresses above the decimal value of 126. PV Powered recommends keeping the number of slave devices between 2 and 100.
PVP250kW & PVP260kW Inverter Installation & Operation Manual these commands and their valid registers. Read Holding Register The Read Holding Register command is used frequently. Typically the Modbus master continually reads the values from registers containing the desired information.
Command Information Modbus slave address Command Layout nn (1-126) Command number 06 First register MSB xx First register LSB xx Data MSB xx Data LSB xx CRC LSB xx CRC MSB xx Table 5-11 Format for Write Single Register, command 06 Response Information Modbus slave address Response Layout nn (1-126) Command number 06 Number of bytes of data n First register MSB xx First register LSB xx Data MSB xx Data LSB xx CRC LSB xx CRC MSB xx Table 5-12 Format for Write Single Register
PVP250kW & PVP260kW Inverter Installation & Operation Manual Response Information Modbus slave address Response Layout nn (1-126) Command number 11h Number of bytes of data n Data 1 xx Data 2 xx Data n xx CRC LSB xx CRC MSB xx Table 5-14 Format for Return Slave ID, response to command 11h Modbus Register Maps The following tables list the Modbus registers with their location and a description of the data stored in the register.
Description Start Register End Register Nbr.
PVP250kW & PVP260kW Inverter Installation & Operation Manual Description Start Register End Nbr. of MB Address Format Range Register Registers Notes Modbus base address = 3000 Clear fault command 3000 3000 1 43001 UINT 16 CF hex Write this value to clear faults and try a restart.
When multiple errors are set, the resulting status word value will be a sum of the individual fault and/or error values listed in the following table. Hex Value Description Decimal Value Notes Modbus register number = 42005 OK 0 0 Rebooting 1 1 Inverter communication fault 2 2 Web post fault 4 4 DNS server fault 8 8 Real time clock error 10 16 Battery is dead or cannot synchronize with the network time server.
6. Operation 6.1 Start Up Procedure ! ! WARNING Before turning on the inverter, ensure that the front panels are closed properly. AVERTISSEMENT Assurez-vous de la bonne fermeture des panneaux antérieurs avant de mettre l’onduleur en route. To start the inverter, complete the following steps in order: 1.
ON/OFF Switch DC Disconnect in Power ON Position AC Disconnect in Power ON Position Figure 6-1 AC and DC Disconnect Power ON 6.2 Inverter Operating States The PVP250kW and PVP260kW Inverters have nine operating states. The inverters will transition from one state to another only as shown in Figure 6-2. Each operating state is described below.
PVP250kW & PVP260kW Inverter Installation & Operation Manual Initialize Disabled Sleep Startup Delay Fault DC Precharge AC Precharge Power Track (auto mode) Idle 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. When initialization is complete, the inverter enters the Sleep state.
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. If the fault is latching, the inverter switches to the latched fault state. The inverter enters this state when a latching fault condition occurs.
PVP250kW & PVP260kW Inverter Installation & 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. The five states are: Startup, Power Track (normal power production state), Fault, Warning and Disabled. Each of the display screens for each state are shown in Figures 6-4 through 6-8.
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. • To pause the display on a specific screen press the “Pause/Scroll” button on the display. • To resume the scroll function press the “Pause/Scroll” button again.
PVP250kW & PVP260kW Inverter Installation & Operation Manual 6.4 Ground Fault Interrupt Device The inverter is equipped with a Ground Fault Detector Interrupter (GFDI). 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. ! WARNING For the GFDI circuit to function as designed, the solar array safety ground must not be connected to the PV array positive or negative leads.
6.5 Shutdown Procedure To shutdown the inverter, complete the following steps in order: 1. Turn the inverter’s ON/OFF switch to the OFF position. 2. Turn the AC disconnect to the power OFF position by rotating the AC power lever to the position shown in Figure 2-1. The display on the upper front panel should be inactive. 3. Turn the DC disconnect to the power OFF position by rotating the DC power lever to the OFF position shown in Figure 6-10. 4. Open the utility connection circuit breaker. 5.
7. Maintenance & Troubleshooting 7.1 Visual Inspection ! ! ! ! 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. DANGER Les voltages alternatifs et continus seront toujours présents aux points de contact CA et CC de l’onduleur à moins que les disjoncteurs du réseau public et que les alimentations des piles PV ne soient débranchés.
B. Connections and Wiring 8. Complete visual inspection of electrical connections and wiring. 9. Complete mechanical inspection of connections and wiring. 10. Measure torque of all electrical connections and re-torque as needed. 11. Complete thermal scan of inverter connections, wiring and electronics. C. Testing 12. Confirm the inverter operating modes including standby, startup and on. 13. Check operation of protective circuits and alarms. 14. Validate display data accuracy. D. Repair or Replace 15.
PVP250kW & PVP260kW Inverter Installation & Operation Manual Figure 7-1 Air Intake Hood 2. Remove the four filters by loosening the wing nuts on the filter brackets. 3. Clean the filters by vacuuming or blowing out using an air hose with a diffuser. 4. After cleaning, inspect the filters for damage to the filters or frames. Contact PV Powered if you wish to replace the filters or frames. 5. Reinsert the filters and close the air intake hood.
7.4 Maintaining the Card Cage Air Filter The card cage features a secondary air filter to ensure long PCB life. The card cage air filter is located under the intake air shroud above the card cage which is located on the right side of the power module assembly in the upper cabinet. 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.
PVP250kW & PVP260kW Inverter Installation & Operation Manual The display will then cycle back to the first screen. A sample series of screens is shown in Figure 7-4 below. The complete list of fault codes are provided in Appendix D - Limits, Fault Codes, Torque Values, and Wire Sizes as a guide. Identifying the Inverter’s Fault Codes Startup Upon startup, the inverter will automatically scroll between the startup screens shown in Figure 7-4.
7.6 Troubleshooting Faults ! ! WARNING These servicing instructions are for use by qualified personnel only. To reduce the risk of electric shock, do not perform any servicing other than that specified in the operating instructions for someone of your qualifications. AVERTISSEMENT Ces instructions de maintenance sont destinées à être utilisées exclusivement par du personnel qualifié.
PVP250kW & PVP260kW Inverter Installation & Operation Manual Ground Fault 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. ! WARNING For the GFDI circuit to function as designed, the solar array safety ground must not be connected to the PV array positive or negative leads.
Repairing a Ground Fault 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. DANGER ! Risque d’électrocution. Laissez passer cinq (5) minutes afin de permettre la dissipation du courant interne avant d’ouvrir les panneaux du dispositif. Utilisez un multimètre sur toutes les bornes afin de confirmer l’absence de courant.
PVP250kW & PVP260kW Inverter Installation & Operation Manual 7.
Link Light Activity Light Status Light Figure 7-7 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.
PVP250kW & PVP260kW Inverter Installation & Operation Manual The following list provides the status codes and their meaning. Status Flash Code Normal Operation On steady, no flashing Serial Communication Fault Short-Long-Short DNS Failure Long-Short-Short Network Connection Fault Short-Short-Long Table 7-1 Status LED Flash Codes Status LED Code Descriptions Normal Operation: Inverter communications are operating normally.
to it, the flashes will be longer in duration. A series of longer (slower) flashes indicates the inverter is responding to the Modbus master request. 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.
Appendix A - Specifications Characteristic PVP250kW (600VAC) PVP250kW (480VAC) PVP260kW (480VAC) PVP260kW-LV (480VAC) AC Characteristics Continuous power (AC) 249.5kW 3 phase, 4 wire Y Grid type Nominal AC voltages (VAC) 260kW (not compatible with delta service) 600 Y 480 Y Maximum output fault current and duration 1200A/29 ms (Also called maximum fault current contribution) Maximum utility backfeed current (A) 593 AC maximum continuous current (A) 243 304 CEC efficiency (%) 96.5 96.
PVP250kW (600VAC) Characteristic Limits of accuracy time measurement PVP250kW (480VAC) PVP260kW (480VAC) PVP260kW-LV (480VAC) +/- 0.
Appendix B - Wiring Diagram Refer to the following pages for the PVP250kW and PVP260kW wiring diagram.
2 3 4 5 6 PROPRIETARY INFORMATION PV Powered, Inc. CONFIDENTIAL & 7 8 Revision Record PV Powered, Inc.
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Appendix C - Mechanical Drawings Refer to the following pages for mechanical drawings of the PVP250kW and PVP260kW inverters.
Figure C-1 PVP250kW/PVP260kW Mechanical Drawing - View 1 88 A B C D 1. 2. 3. 4. 5. 34 " 7 9 1 /4 " 9 3" 4 LEFT S I D E V I E W 33 1 /8 " 4 1 3 /8 " 6 1 /2 " 1 8 7 /8 " 3 F RO N T V I E W 104" 9 4 3 /4 " 3 TH IS D R AW IN G IS TH E P R O P E R TY O F P V PO W E R E D AN D M U S T N O T B E L O AN E D , C O PIE D IN W H O L E O R IN P AR T, O R U S E D F O R M AN U F AC TU R IN G O R TE N D E R IN G P U R P O S E S W ITH O U T W R ITTE N C O N S E N T.
Figure C-2 PVP250kW/PVP260kW Mechanical Drawing - View 2 89 A B C D 4 4 3 2" DC G LAND PLATE CLEAR OPENI NG, 21" X 7" 3 4 5 /8 " BOTTOM VI EW 100" 3 TH IS D R AW IN G IS TH E P R O P E R TY O F P V PO W E R E D AN D M U S T N O T B E L O AN E D , C O PIE D IN W H O L E O R IN P AR T, O R U S E D F O R M AN U F AC TUR IN G O R TE N D E R IN G P U R P O S E S W ITH O U T W R ITTE N C O N S E N T. IT M U ST B E R E TU R N E D O N D E M AN D .
Figure C-3 PVP250kW/PVP260kW Mechanical Drawing - View 3 90 A B C D 4 4 1 08 5/ 8" C AC G LAN D P LATE, C UTO UT OPENING 21" X 7" TO P V I E W D O O RS O P E N 3 20" 7 1 /2 " AN G LES ± 2° F IN IS H T R E AT M E N T D O N O T S C A LE D R AW IN G D EC IM ALS . X X ± .0 3 .X X X ± .0 1 0 U N L E S S O TH E R W IS E S PE C IF IE D D I M E N S IO N S A R E IN I N C H E S .
Figure C-4 PVP250kW/PVP260kW Mechanical Drawing - View 4 91 A B C D 4 3 2 3" C L R 3 AN G LES ± 2° F IN IS H T R E AT M E N T D O N O T S C A LE D R AW IN G D EC IM ALS . X X ± .0 3 .X X X ± .0 1 0 U N L E S S O TH E R W IS E S PE C IF IE D D I M E N S IO N S A R E IN I N C H E S . TO L E R A N C E S AR E : SEI SM IC ANCHORAG E REQ UI REM ENTS 2007 CBC - BASED O N ASCE 7-05 AE O AE O 2 RO R E L E A SE T O P R O D .
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Appendix D - Limits, Fault Codes, Torque Values, and Wire Sizes Factory setting (VAC or Hz) Range (VAC) Maximum Trip Time(s) Voltage phase high 304.8 304.8 – 332.5 1.0 Voltage phase low 243.9 216.1 – 243.9 2.0 Voltage phase fast high 332.5 332.5 0.16 Voltage phase fast low 138.6 138.6 0.16 Voltage phase high 381.1 381.1 – 415.7 1.0 Voltage phase low 304.8 270.2 – 314.8 2.0 Voltage phase fast high 415.7 415.7 0.16 Voltage phase fast low 173.2 173.2 0.
PVP250kW and PVP260kW Faults and Warnings Fault Variables The PVP250kW and PVP260kW firmware utilizes one, 16-bit variable (fault) to indicate a fault condition. Each bit in this fault variable represents the fault type or category. The bit assignments and specific fault variables for the fault categories are as follows: Bit Nbr.
PVP250kW & PVP260kW Inverter Installation & Operation Manual The following table lists the voltage faults, including VAC sense, VDC and power supply faults.
Hexadecimal Value Display String Description 0001 HEATSINK TEMP A1 Module heat-sink A1 temperature high 0002 HEATSINK TEMP A2 Module heat-sink A2 temperature high 0004 HEATSINK TEMP B1 Module heat-sink B1 temperature high 0008 HEATSINK TEMP B2 Module heat-sink B2 temperature high 0010 HEATSINK TEMP C1 Module heat-sink C1 temperature high 0020 HEATSINK TEMP C2 Module heat-sink C2 temperature high 0040 BOARD TEMP HI Control board temperature high 0080 DRIVE TEMP LOW Drive temperature
PVP250kW & PVP260kW Inverter Installation & Operation Manual The following table lists the system warnings.
AC & DC Bus Landing Hardware The following diagram details the installation of the input wiring to the busbars. Note: Grade 8 hardware required.
Appendix E - Annual Maintenance Requirements Checklist Item # Requirement A General Inspection & Cleaning 1 Record general site conditions 2 Record inverter performance data from inverter display 3 Record environmental conditions 4 Remove dirt and debris from underneath inverter Inspect and clean interior of inverter 6 Inspect air filter and replace or clean 7 Confirm presence of product documentation B Connections and Wiring 8 Complete visual inspection of electrical connections and wiri
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Appendix F - Efficiency Curves F.1 PVP250kW (600VAC) - Efficiency Curves Input Voltage (Vdc) Vmin 295 Vnom 341 Vmax 480 Power Level (%; kW) 10% 20% 30% 50% 75% 100% 24.95 49.90 74.85 124.75 187.13 249.50 95.2 96.8 97.1 97.1 96.8 96.4 94.8 96.5 96.8 96.9 96.6 96.3 93.4 95.6 96.1 96.2 96.0 95.7 Wtd 96.8 96.6 95.9 CEC Efficiency = 96.
F.2 PVP250kW (480VAC) - Efficiency Curves Input Voltage (Vdc) Vmin 295 Vnom 341 Vmax 480 Power Level (%; kW) 10% 20% 30% 50% 75% 100% 24.95 49.90 74.85 124.75 187.13 249.50 96.0 97.0 96.9 96.9 96.6 96.1 95.6 96.6 96.7 96.8 96.4 96.0 94.7 95.8 96.2 96.2 95.9 95.4 Wtd 96.7 96.5 95.9 CEC Efficiency = 96.
PVP250kW & PVP260kW Inverter Installation & Operation Manual F.3 PVP260kW (480VAC) - Efficiency Curves Input Voltage (Vdc) Vmin 295 Vnom 341 Vmax 480 10% 26.00 96.0 95.6 94.4 20% 52.00 97.5 97.3 96.5 Power Level (%; kW) 30% 50% 78.00 130.00 97.7 97.6 97.5 97.4 96.9 97.0 75% 195.00 97.1 97.0 96.6 100% 260.00 96.4 96.4 96.1 Wtd 97.2 97.0 96.6 CEC Efficiency = 97.0% 100 95 295 Vdc 341 Vdc 480 Vdc Efficiency, % 90 85 80 295 Vdc 75 341 Vdc 480 Vdc 70 0 0.1 0.2 0.3 0.4 0.5 0.6 0.
F.4 PVP260kW-LV (480VAC) - Efficiency Curves Input Voltage (Vdc) Vmin 265 Vnom 319 Vmax 480 10% 26.00 96.1 95.6 94.0 20% 52.00 97.6 97.3 96.2 Power Level (%; kW) 30% 50% 78.00 130.00 97.8 97.5 97.5 97.3 96.7 96.8 75% 195.00 96.9 96.7 96.2 100% 260.00 96.0 95.9 95.5 Wtd 97.1 96.9 96.3 CEC Efficiency = 96.5% 100 95 265 Vdc 319 Vdc 480 Vdc Efficiency, % 90 85 80 265 Vdc 75 319 Vdc 480 Vdc 70 0 0.1 0.2 0.3 0.4 0.5 0.6 0.
Index A abbreviations v AC output voltage changing 37 over-current protection 2, 17 under voltage fault 76 wiring 40 AC Distribution PCB 6 acronyms v AC sub panel 5 ACT LED.
flash codes 81 fuse 69 rotary switches 55 shutdown 70 starting 63 status lights 79, 81, 82 versatility of 1 IP address 47 assigning to inverter 48 islanding prevention 12 isolation procedure 18 isolation transformer 5 G GFDI 23, 69, 77.
PVP250kW & PVP260kW Inverter Installation & Operation Manual O status lights 79, 81, 82 status values 61 subcombiners 34 switches 55 for disconnect 14 symbols 11 operating states 64 operator interface controls 9 overcurrent protection 2 P T packaging 27 PCB, descriptions of 4 port ID 47 power distribution PCB 4 powering down 70 power module 3 power module assembly 4 power supply transformer 5 product specifications data sheet 84 pull test 30 PV Powered how to contact i monitoring service 44 terminati
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Limited Warranty The 10-Year Warranty may be transferred to subsequent owners, except that the 10Year 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.
PV Powered will, at its discretion, use new and/or reconditioned parts in performing warranty repair and in building replacement products. PV Powered reserves the right to use parts or products of original or improved design in the repair or replacement. If PV Powered repairs or replaces a product, PV Powered’s warranty continues for the remaining portion of the original warranty period or 90 days from the date of repair, whichever period expires later.
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PO Box 7348 • Bend, OR 97708 • P: 541-312-3832 • www.pvpowered.
