Grid-Tied Residential Inverters Installation and Operation Manual PV Powered Grid-Tied Residential Inverters INSTALLATION & OPERATION MANUAL 80801.3.
Preface Grid-Tied Residential Inverters Installation and Operation Manual PV Powered Contact Information PV Powered, Inc. 150 SW Scalehouse Loop Bend, OR 97702 Tel: 541-312-3832 Customer Service and Technical Support: 1-877-312-3832 Fax: 541-383-2348 www.pvpowered.com email: support@pvpowered.com i PREFACE PV Powered designs, manufactures, and markets the solar power industry’s most reliable photovoltaic solar inverter solutions.
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.
Grid-Tied Residential Inverters Installation and Operation Manual Acronyms and Abbreviations A/D Analog to Digital Converter ANSI American National Standards Institute CFM Cubic Feet per Minute DSP Digital Signal Processor EMI Electromagnetic Interference ESD Electro Static Discharge GFDI Ground Fault Detector Interruptor IEEE Institute of Electrical and Electronics Engineers IGBT Insulated Gate Bipolar Transistor LOTO Lockout Tagout MCM 1000 circular mils utilized in wire sizing MPP
Document Copyright Grid Tied Residential Inverter Installation and Operations Manual (Models 1100, 2000, 2500, 2800, 3000, 3500, 4600, 4800, 5200) ©2008 PV Powered. All rights reserved. This manual may not be reproduced or distributed without written permission from PV Powered.
Grid-Tied Residential Inverters Installation and Operation Manual Table of Contents 1. Introduction and Safety.................................................................................................1 1.1 General Safety................................................................................................................1 1.2 FCC Compliance............................................................................................................2 2. Planning .............................
List of Figures and Tables Danger Symbol ................................................................................................................... ii Warning Symbol ................................................................................................................. ii Caution Symbol .................................................................................................................. ii Figure 3-1 V-shaped Mounting Bracket..................................................
Grid-Tied Residential Inverters Installation and Operation Manual 1. Introduction and Safety The PV Powered Grid Tied Residential Inverters is a utility interactive inverter for photovoltaic (PV) systems. The inverter is tied to an electrical source provided by the local utility company as well as to the PV system. The inverter contains everything needed to convert the DC voltage generated by the PV arrays into the AC voltage required to power a house.
1.2 FCC Compliance The Grid Tied Residential Inverters have been tested and found to pass FCC Class B radio interference standards with proper installation of the inverter. This is not a guarantee that there will be no interference at every installation. If you notice interference at your installation, try the following potential solutions: ! • Move or re-orient the affected device. • Increase the distance between the devices. • Connect the device to a different AC circuit.
2. Planning Grid-Tied Residential Inverters Installation and Operation Manual 2.1 Select a Location for the Inverter When choosing a location for the inverter, consider the following criteria: • The inverter is suitable for both indoor and outdoor installation; the inverter enclosure has a NEMA 3R rating. • The optimum location of the inverter is outside, shielded from direct exposure to sunlight (i.e. not on the south facing side of the building).
2.2 Mounting the Inverter The inverter should be mounted vertically to a flat, solid surface such as wallboard, concrete, or wood siding. It should be located near the PV arrays to minimize the DC wire length. The bracket provided makes mounting the inverter quick and simple. The two screw holes at either end of the top of the bracket are 16 inches apart and are designed to match standard stud locations. Anchor the bracket to the wall studs once you have located them.
3. Installation Grid-Tied Residential Inverters Installation and Operation Manual 3.1 Mounting and Anchoring Models PVP4600, PVP4800 and PVP5200 1. Locate the wall studs in the desired location and align the mounting bracket over the studs. Mark the mounting holes. Ensure that locations A and B (see Figure 3-1) are aligned over the wall studs. 2. VERIFY THE BRACKET IS LEVEL. Ensure points A and B are aligned with the wall studs. Drill 1/8” pilot holes for the screws.
Models PVP1100, PVP1100EVR, PVP2000, PVP2000EVR, PVP2500, PVP2800, PVP3000, PVP3500 1. Locate the wall studs in the desired location and align the mounting bracket over a single stud. Mark the mounting holes ensuring holes C, D, E and F are directly over the single stud (see Figure 3-2). 2. VERIFY THE BRACKET IS LEVEL. Ensure points C through F are aligned with the wall studs. Drill 1/8” pilot holes for the screws. Use heavy-duty 1/4” x 2” coarse thread lag screws to secure points C through F to the wall.
Grid-Tied Residential Inverters Installation and Operation Manual Figure 3-4 Inverter with Mounting Bracket in Place NOTE: Leave the inverter cover off to allow for electrical connection described in 3.2 Electrical Connections. 3.2 Electrical Connections CAUTION ! The National Electrical Code (NEC) requires that the inverter be connected to a dedicated circuit with no other outlets or devices connected to the same circuit. See NEC Section 690-64(b)(1).
Inverter Model Circuit Breaker Required 1 pole 15A PVP1100 PVP2000 PVP2500 PVP2800 PVP3000 PVP3500 PVP4600 PVP4800 PVP5200 2 pole 15A 2 pole 20A 2 pole 20A 2 pole 20A 2 pole 20A 2 pole 30A 2 pole 30A 2 pole 30A Table 3-1 Required Branch Circuit Protection Inverter Voltage and Frequency Limits The inverter is factory-calibrated to the voltage and frequency limits specified in Table 3-2. This adjustable range can be set by PV Powered field technicians.
Grid-Tied Residential Inverters Installation and Operation Manual Do not proceed with the electrical connection of the inverter until it has been properly mounted. WARNING ! Electrical connections must be completed in accordance with local electrical codes and the National Electrical Code (NEC), ANSI/NFPA 70. Use 10 AWG, minimum 90oC (194oF), copper wire for all inverter electrical connections. Voltage drop as well as other considerations may dictate using larger wire sizes.
Separation of Circuits The lower part of the inverter circuit board is divided into three sections: 1. The left side is dedicated to the low voltage DC communications. 2. The center is dedicated to the AC. 3. The right side is dedicated to the DC. Each section has two to three knockouts. UL 1741 standard requires a straight run of wire, with no loops or crossover to the other circuits (sections) and low voltage versus high voltage in each section. 1.
Grid-Tied Residential Inverters Installation and Operation Manual Figure 3-6 is a schematic representation of the PV Powered single-point grounding. The front cover is grounded through the cover mounting screws.
If the inverter displays “Ground Fault”, turn OFF the AC and DC to the inverter and refer to the fault examples in this manual. PV Ground Figure 3-8 AC and PV Grounding Connecting the Inverter to the Electrical Grid Two circuit boards are located inside the inverter: 1. The Control Board (at the top of the inverter). 2. The Power Distribution Board (at the bottom of the inverter) with the following terminals: The AC connection terminal. The DC connection terminal.
Grid-Tied Residential Inverters Installation and Operation Manual WARNING ! Ensure the main 240V (or 208V for the PVP2800 and PVP4600 or 120 for PVP1100 or PVP1100EVR) breaker at the circuit breaker panel is switched OFF before connecting to the AC terminal block. To wire the inverter to the main utility grid, follow these steps and refer to Figure 3-9: 1. Run the conduit from the main breaker panel to the bottom of the inverter.
Connecting DC Wires/PV Panels WARNING ! Before proceeding with the DC wiring, completely cover the surface of all PV panels with dark material to avoid the production of electrical current. WARNING ! Make sure the polarity and the PV panel voltage between the positive and the negative cable connectors of the PV panels are correct before connecting the panels to the DC terminal block on the power distribution board.
Grid-Tied Residential Inverters Installation and Operation Manual NOTE: For all temperature conditions, the Voc for each series connection must total less than the VDC indicated in Table 3-4 for all residential inverter models. Review the PV panel’s data sheet for operating temperature ranges. 2. Keep track of the array positive and negative leads and mark them clearly. 3. Route the PV array leads through the far right opening in the inverter. 4.
GFI Jumper (J3) Fuse Clips PV Negative PV Positive Figure 3-11 Power Board Connections 9. Confirm that the DC disconnect is turned OFF and remove the material from the array. 10. With a voltmeter, check the PV array positive leads in the DC disconnect and confirm that the voltage is positive when referenced to the negative leads. The reading should match your series Voc total. 11. Measure the DC voltage potential between the two fuse clips (see Figure 3-11) for the 1A fuse. 12.
4. Operations Grid-Tied Residential Inverters Installation and Operation Manual ! Before turning on the inverter, ensure that the front panel is closed properly. WARNING ! The heat sink can reach temperatures in excess of 158ºF (70ºC). Do not touch the heat sink when in use, and do not place anything on top of the heat sink. 4.1 Start up Procedures To start up the inverter, complete the following steps in the order indicated: 1. Turn the AC breaker ON. 2. Verify that the RED LED light is illuminated.
4.2 Inverter Front Panel Status Indicators The inverter has two LED indicator lights visible through the upper left corner of the front panel. These lights indicate the inverter’s status. • If the inverter’s operating environment is safe to export power into the AC grid, the GREEN LED is illuminated. • If the operating environment moves outside the safe operating limits governed by UL 1741, IEEE 1547, and IEEE 519, the RED LED indicator is illuminated. The inverter continuously monitors: 1.
Grid-Tied Residential Inverters Installation and Operation Manual If the RED LED continues to illuminate when there is sufficient sunlight for operation, verify that no wiring connections are loose. If the wiring is tight, see 5. Maintenance and Troubleshooting for additional information. The vacuum fluorescent display (VFD) indicates the inverter’s status and real-time power output into the AC Grid. This display provides the following information: • Inverter model number.
Normal Display Cycle The display will change screens every two seconds to show a different set of information as shown in Figures 4-1 and 4-2. PVP 3500 Start in 269 sec 0 Watts 3212 kWh 240 VAC 297 VDC Screen 1 Screen 2 Screen 3 Figure 4-1 Normal Startup Screens PVP 3500 1245 Watts 3212 kWh 241 VAC 255 VDC Screen 1 Screen 2 Screen 3 Figure 4-2 Running Screens If a fault occurs, the display also provides a corresponding fault code. Refer to 5.
Grid-Tied Residential Inverters Installation and Operation Manual 5. Maintenance & Troubleshooting The inverter provides two indicator lights that help troubleshoot problems: 1. The light on the left is a RED LED. The RED LED illuminates any time the DC voltage is below the inverters startup DC voltage, such as at night. The RED LED blinks if the inverter has had a fault condition, and the vacuum fluorescent display (VFD) displays a fault code. Possible faults are listed in Table 5-1. 2.
3. Check for continuity (ohms). It should be zero or 1-2 ohms. If the meter indicates no continuity, then a ground fault likely exists. 4. If the fuse is blown, replace it with a like fuse rated at 600VDC and 1A. DO NOT insert the new fuse until there is no ground fault present. 5. Check the DC voltage between the grounded terminal of the array and earth ground. The voltage should be less than 25 volts with the GFI fuse removed.
Grid-Tied Residential Inverters Installation and Operation Manual NOTE: In this case the fault refers to the last fault detected. If the inverter is in a faulted state, the RED LED blinks and the VFD scrolls through the screens shown in the faulted example above. The text of the fault describes the specific fault condition that the inverter experienced. If the inverter is no longer experiencing the condition that caused it to fault (e.g.
Fault Codes Fault Code VFD Text Fault Description 8000 0000 Power Module Generated by the power electronics to protect the module. 4000 0000 Power Module Generated by the power electronics to protect the module. 1000 0800 PLL Fault The inverter was unable to match the grid frequency. This is usually caused by an unstable power grid. 1000 0400 AC Voltage High The grid voltage exceeded the limits in Table 3-2. 1000 0200 AC Voltage Low The grid voltage dipped below the AC limits in Table 3-2.
Grid-Tied Residential Inverters Installation and Operation Manual 6. Limited Warranty PV Powered, Inc. provides a limited warranty for your residential or commercial inverter and optional data monitoring module for defects caused by material or manufacturing flaws. The inverter and the data monitoring module must be installed and maintained by a qualified installer in order for the warranty to be valid. 6.
6.3 What is Not Covered PV Powered does not warrant its products from any and all defects or damage caused by: • Normal wear and tear. • Shipping or transportation damages. • Improper installation. • Improper maintenance. • Excessive voltage or current conditions from the electrical grid or PV panels. • Exposure to unsuitable environmental conditions (including but not limited to damage due to lightning strikes, storm, fire, flood, etc.).
Grid-Tied Residential Inverters Installation and Operation Manual IF THIS PRODUCT IS A CONSUMER PRODUCT, FEDERAL LAW DOES NOT ALLOW AN EXCLUSION OF IMPLIED WARRANTIES. TO THE EXTENT YOU ARE ENTITLED TO IMPLIED WARRANTIES UNDER FEDERAL LAW, TO THE EXTENT PERMITTED BY APPLICABLE LAW THEY ARE LIMITED TO THE DURATION OF THIS LIMITED WARRANTY.
6.6 Miscellaneous Provisions This limited warranty will be governed and interpreted exclusively in accordance with the laws of the state of Oregon, without reference to provisions concerning conflicts of laws. If any provision of this limited warranty is found by any court or arbitrator to be invalid, illegal or unenforceable, the validity, legality and enforceability of the remaining provisions will not be affected thereby.
Grid-Tied Residential Inverters Installation and Operation Manual 7. Return Procedure Before returning the product directly to PV Powered, you must first obtain a Return Materials Authorization Number (RMA) from PV Powered. You must also pre-pay for shipping. When you contact a PV Powered representative, please have the following information ready: 1. The serial number of the product 2. The reason for the return 3.
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Grid-Tied Residential Inverters Installation and Operation Manual Appendix A - Specifications The specifications detailed below are expected operational parameters, and should be used in designing your PV system in accordance with the NEC.
Specifications PVP3000 PVP3500 Maximum DC Input Voltage (VOC) PVP4600 PVP4800 PVP5200 500VDC DC Voltage Operating Range (V) 170VDC-450VDC 200VDC450VDC 205VDC450VDC 200VDC450VDC 240VDC450VDC DC MPPT Range (V) 170VDC-380VDC 200VDC380VDC 205VDC380VDC 200VDC380VDC 240VDC380VDC 18A 18A 25A 26A 25A 183V229V 211V264V 211V264V 240V 240V DC Imp Maximum Current (A) DC Isc Maximum Current (A) AC Operating Range (V) 26A 26A 211V264V 211V264V 240V 240V AC Frequency Range (Hz) 48A 59
Index Grid-Tied Residential Inverters Installation and Operation Manual A Acronyms and Abbreviations iii INDEX C Connecting DC Wires/PV Panels 14 DC Connections 14 Open Circuit Calculations 14 Connecting the Inverter to the Electrical Grid 12 Contact Information i F Fault Codes 24 G GFI Circuit 11 Grounding 10 I Islanding Prevention- Electrical Safety Features 2 L LED Indicator Lights 18 Location and Clearances 3 M Multiple Faults 23 R Revisions and Certification ii S Safety Information and Conventions i
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150 SW Scalehouse Loop U Bend, OR 97702 U P: 541-312-3832 U www.pvpowered.
