Xantrex™ GT500 480, Xantrex GT500 480 PG, Xantrex GT500 600 & Xantrex GT500 600 PG 500 kW Grid-Tied Photovoltaic Inverters Planning and Installation Manual www.schneider-electric.
Xantrex GT500 480, Xantrex GT500 480 PG, Xantrex GT500 600 & Xantrex GT500 600 PG 500 kW Grid-Tied Photovoltaic Inverters Planning and Installation Manual www.schneider-electric.
Trademarks Schneider Electric, the Schneider Electric logo, and Xantrex are trademarks or registered trademarks of the Schneider Electric group of companies. Other trademarks, registered trademarks, and product names are the property of their respective owners and are used herein for identification purposes only. Notice of Copyright Copyright © 2012, 2011 Schneider Electric SA.
About This Manual Purpose The purpose of this Planning and Installation Manual is to provide explanations and procedures for planning and installing Schneider Electric Xantrex GT500 480, Xantrex GT500 480 PG, Xantrex GT500 600, and Xantrex GT500 600 PG 500 kW Grid-Tied Photovoltaic Inverters. Scope The Manual provides safety guidelines, detailed planning and setup information, and installation procedures.
About This Manual Naming Conventions Used This Manual contains information for four models of the Xantrex GT500 Grid-Tied Photovoltaic Inverter. When all models are being referenced together, they will be referred to as the Xantrex GT500. When the models are being referenced individually, they will be referred to by their model number, as shown in the table below.
About This Manual CAUTION CAUTION without the exclamation symbol indicates a potentially hazardous situation, which, if not avoided, can result in equipment damage. NOTICE NOTICE indicates important information that you need to read carefully. Acronyms This Manual uses the following abbreviations and acronyms.
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Safety Important Safety Instructions READ AND SAVE THESE INSTRUCTIONS. DO NOT DISCARD. This Manual contains important safety instructions for the Xantrex GT500 that must be followed during planning, installation, and maintenance procedures. DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, AND ARC FLASH • Read all instructions, cautionary markings, and all other appropriate sections of this Manual and all labels on the product before installing, operating, troubleshooting, or maintaining the Xantrex GT500.
Safety WARNING HAZARD OF ELECTRIC SHOCK, EXPLOSION, FIRE, AND ARC FLASH. HAZARD OF EQUIPMENT DAMAGE. Unsafe conditions and damage to the Xantrex GT500 could result if the instructions and the electrical, physical, and environmental installation specifications in this Manual are not obeyed. Failure to follow these instructions can result in death, serious injury, or equipment damage.
Safety WARNING HAZARD OF AMPUTATION The Xantrex GT500 has exposed fans under a cover at the rear of the inverter assembly. Do not remove the rear fan inlet cover unless all sources to the inverter have been de-energized, locked out, and tagged out. Make sure the fans are not operating before working near them or replacing them. Failure to follow these instructions can result in death or serious injury.
Safety CAUTION HAZARD OF EQUIPMENT DAMAGE Sensitive electronics inside the Xantrex GT500 can be destroyed when touched if you are electrostatically charged. Discharge to earth potential using wrist ground straps before touching internal components on the Xantrex GT500. Failure to follow these instructions can result in equipment damage. Personal Protection Follow these instructions to help protect yourself while working with the Xantrex GT500.
Safety Lock-out and Tag-out Procedure Lock out refers to the practice of preventing de-energized circuits from being reenergized by putting locks on the disconnecting devices, holding them open. Tag out refers to the practice of attaching a tag to the disconnect device locks warning others not to operate the disconnect device and containing information relating to the lock out, such as the person responsible, the reason, and the date and time.
Safety NOTICE To open the AC circuit breaker (CB1) access door on the transformer assembly, turn the thumb latch. To open the transformer assembly (AC) doors: • Using a flat head screwdriver, turn the slot on the latch 90 degrees clockwise. • Pull on the handle upwards, and then rotate the handle counterclockwise to open. To open the DC switch (S1) access door on the inverter assembly, use a flat head screwdriver to turn the latch.
Safety 8. Open, lock out, and tag out the AC output (grid) circuit at its external disconnect switch provided by the installer as part of the installation. 9. Open, lock out, and tag out the external auxiliary AC source (if used) at its external disconnect means provided by the installer as part of the installation. PUSH TO OPEN PUSH TO CLOSE button button Indicates open or closed status Figure i AC circuit breaker 10.
Safety 12. Open the inverter assembly’s right door only. 13. Wearing appropriate personal protective equipment and using a voltmeter with minimum ratings of 1000 volts AC and DC that has been tested on a known AC voltage source and a known DC voltage source before use, measure DC voltage from line to line and from line to ground (see Figure ii): • Between the PV+ bus bar and the PV- bus bar and to ground to make sure the inverter side of the DC switch is de-energized.
Safety 14. Open the transformer assembly’s center and right doors. 15. Wearing appropriate personal protective equipment and using a voltmeter with minimum ratings of 1000 volts AC and DC that has been tested on a known AC voltage source and a known DC voltage source before use, measure AC voltage between each line and from each line to ground (see Figure iii): • At TB19-1 and TB19-3. • At TB38-2, 4, and 6.
Safety 16. After all measurements have been verified as 0 VAC: a) Open, lock out, and tag out the CB3 control power circuit breaker. b) Open, lock out, and tag out the CB4 auxiliary control power circuit breaker (if external auxiliary AC power is installed).
Contents Important Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -vii 1 Introduction Description of the Xantrex GT500- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 Power Conversion System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 Advanced Design Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Contents Moving the Inverter Assembly with a Sling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8 Moving the Transformer Assembly with a Sling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9 Mounting and Anchoring the Xantrex GT500 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–11 Installing and Wiring the Throat Connection Kit- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–12 Opening or Closing Access Door
Contents Verify Display and Keypad Operation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Verify AC, DC, and Power Tracking Operational Parameters - - - - - - - - - - - - - - - - - - - - - - - - Operate Inverter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Perform Automatic Disconnection Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Revise Protection Settings (If Requ
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 1-9 Figure 1-10 Figure 1-11 Figure 2-1 Figure 2-2 Figure 2-3 Figure 3-1 Figure 3-2 Figure 3-3 Figure 3-4 Figure 3-5 Figure 3-6 Figure 3-7 Figure 3-8 Figure 3-9 Figure 3-10 Figure 3-11 Figure 3-12 Figure 3-13 Figure 3-14 Figure 3-15 Figure 3-16 Figure 3-17 Figure 3-18 Figure 3-19 Figure 3-20 Figure 4-1 Figure A-1 Figure B-1 Figure B-2 Xantrex GT500 - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Figures xxii 975-0601-01-01 Revision B This manual is for use by qualified personnel only.
Tables Table 3-1 Table A-1 Table A-2 Table A-3 Table A-4 Table A-5 Table A-6 Table A-7 Table A-8 Table A-9 DC terminal polarity - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–26 Environmental specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–2 Electrical specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–3 Over/under voltage and over/under frequency ran
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1 Introduction Chapter 1 provides information about features and functions. 975-0601-01-01 Revision B This manual is for use by qualified personnel only.
Introduction Description of the Xantrex GT500 The Xantrex GT500 is a utility interactive, three-phase power conversion system for grid-connected photovoltaic arrays with a power rating of 500 kW. An isolation transformer is provided with the Xantrex GT500. Designed to be easy to install and operate, the Xantrex GT500 automates startup, shutdown, and fault detection scenarios.
Physical Characteristics Local Display The Xantrex GT500 includes a local user interface comprised of an ENABLE/ switch, keypad, and four-line, 80-character display. DISABLE The Xantrex RS485/Modbus Communications Kit provides remote plant monitoring, offering a remote interface for operator interrogation of the Xantrex GT500’s system status, control, and metering/data logging as well as protective functions within the Xantrex GT500.
Introduction Transformer assembly Inverter assembly Control panel access door Door locks Door locks DC switch S1 access door AC breaker access door (CB1) Throat connection kit ENABLE/DISABLE switch (S3) (behind the door) Keypad and display Figure 1-1 Xantrex GT500 1–4 975-0601-01-01 Revision B This manual is for use by qualified personnel only.
Physical Characteristics Transformer assembly CB4 (AUX control power CB) CB3 (control power CB) Ground bus TB2 CB1 TB1–C TB1–B TB1–A Figure 1-2 Transformer assembly: AC interface (shown with barriers removed) 975-0601-01-01 Revision B This manual is for use by qualified personnel only.
Introduction Transformer assembly CB3 & CB4 TB38 LF1 line filter (behind middle cabinet door) CB1 Isolation transformer (behind middle and right cabinet doors) Heaters 4 & 5 Heater 3 Figure 1-3 Transformer assembly: heaters (shown with barriers removed) 1–6 975-0601-01-01 Revision B This manual is for use by qualified personnel only.
Physical Characteristics Inverter assembly TB4 TB3 TB5 PV ground See Table 3-1 on page 3–26 for the DC terminal polarity of each Xantrex GT500 model. Figure 1-4 Inverter assembly: DC interface (shown with barriers removed) 975-0601-01-01 Revision B This manual is for use by qualified personnel only.
Power electronics magnified Heater H6 Heater H2 GFI For service Heater H1 Power electronics Inverter assembly Introduction Figure 1-5 Inverter assembly: power electronics and heaters (shown with barriers removed) 1–8 975-0601-01-01 Revision B This manual is for use by qualified personnel only.
Physical Characteristics AC Interface The AC interface (Figure 1-2 on page 1–5) is located on the left side of the transformer assembly and serves as the connection for the utility. This section houses the AC output terminals (TB1–A, TB1–B, and TB1–C), AC circuit breaker, control power transformer, optional line filter, optional circuit breakers, and AC sensing circuitry. Each TB1 terminal provides six M10 clearance holes with space for three cables (see Table A-6 on page A–6 for torque requirements).
Introduction The PV generator is tied to the DC bus via the DC interface section. The embedded control card manages the transfer of power between the PV generator and the utility grid. Heater Fans The heater fans provide supplementary heat to Xantrex GT500 units installed in particularly cold areas.
Operator Interface Controls DC Interface The DC interface (see Figure 1-4 on page 1–7) is located on the right side of the inverter assembly and serves as the connection interface between the PV array and the Xantrex GT500. This section houses the PV input terminals (TB3, TB4, and TB5), DC switch S1, PV ground fault detection circuitry, DC surge arrestor, solid-state relays, and 48 VDC power supply.
Introduction AC Circuit Breaker (CB1) Operation The internal AC circuit breaker can be opened by accessing the small door on the transformer assembly as shown in Figure 1-1 on page 1–4. The PUSH TO OPEN button (see Figure 1-9) will open the internal AC circuit breaker and interrupt the main AC grid connection to the inverter. The PUSH TO CLOSE button is not the preferred method for energization of AC to the inverter. Perform a controlled shutdown or energization by using the ENABLE/DISABLE switch.
Communication Features and Methods Figure 1-10 DC switch (S1) Communication Features and Methods The Xantrex GT500 provides three types of information: • System status and fault detection information • Data logging information • Oscillography The Xantrex GT500 communicates information to the user using the following methods: • Display above the keypad • External monitoring via the included Xantrex RS485/Modbus Communications Kit for remote plant monitoring 975-0601-01-01 Revision B This manual i
Introduction System Status and Fault Detection Reporting Basic system status and all fault detection conditions arising from within the Xantrex GT500 are reported. The four-line display shows a hexadecimal value and a brief description of the detected fault. Additionally, the control card stores the time and details of all detected faults in non-volatile memory for later retrieval.
Communication Features and Methods Data Logging The Xantrex GT500 stores data values and software metrics for debugging. The firmware maintains a data log located in the control card’s non-volatile memory. The Xantrex GT500 records the 17 parameters listed below and logs them into a circular buffer, such that the earliest records are overwritten once the capacity of the buffer is exceeded. The log capacity is 1292 records.
Introduction Oscillography The Xantrex GT500 includes a graphic data analysis tool known as oscillography. The inverter’s firmware continuously records, in the control card’s non-volatile memory, 500 samples of data at 1 millisecond intervals. Of these, 250 samples are taken right before a fault detection occurs and 250 samples are taken after the fault detection. Once a fault detection occurs and the 250 samples are logged, the log stops and goes into DONE status.
2 Planning Chapter 2 provides information to help plan the installation. WARNING HAZARD OF ELECTRIC SHOCK, FIRE, EXPLOSION, OR ARC FLASH • Xantrex GT500 installation must only be planned and performed by qualified personnel in accordance with all applicable installation codes. See “Audience” on page iii for the definition of qualified personnel. • The Xantrex GT500 must be mounted over a non-combustible surface in accordance with the instructions in “Location” on page 2–3.
Planning Array Sizing To determine the number of photovoltaic panels required for the PV power plant, use the PV planning tool on the Schneider Electric Web site: 1. Go to www.schneider-electric.com/renewable-energies. 2. Navigate to your specific product page. 3. Click Sizing Tools. External Disconnects and Overcurrent Protection In all installations, the installer must provide disconnecting means for the PV input, AC output, and external auxiliary AC source input (if used) wiring.
Environmental and Site Requirements Xantrex GT500 to reduce power production. If the heat exposure is excessive, it could also trigger an over-temperature fault detection and cease operation. It is recommended that in high ambient conditions, the inverter be shaded as much as possible by using either a shading structure or placing the inverter on the side of the building that gets the least amount of direct sunlight.
Planning Equipment Grounding Requirements The equipment safety ground connection point for grounding the Xantrex GT500 enclosures is the ground terminal TB2 in the transformer assembly. That point must be connected to ground in the installation in accordance with applicable installation codes. A ground connection point TB5 (PV GND) is provided in the inverter assembly for the PV array frame grounding conductors.
Conductors, Conduit, and Wiring Methods Transformer assembly Inverter assembly AC interface conduit entry 30.5 cm x 30.5 cm (12.0 in. x 12.0 in.) DC interface conduit entry 30.5 cm x 30.5 cm (12.0 in. x 12.0 in.) B A: 11.4 cm (4.5 in.) B: 17.8 cm (7.0 in.) A C D C: 19.1 cm (7.5 in.) D: 15.9 cm (6.25 in.) Figure 2-1 Conduit entry from the sides 975-0601-01-01 Revision B This manual is for use by qualified personnel only.
2–6 513 mm (20.2 in.) 105 mm (4.1 in.) 51 mm (2.0 in.) Front of transformer assembly Back of transformer assembly 520 mm (20.5 in.) AC cable entry area 310 mm (12.2 in.) Back of inverter assembly Front of inverter assembly PV cable entry area 50 mm (2.0 in.) 500 mm (19.7 in.) 165 mm (6.5 in.) Planning Figure 2-2 Conduit entry (bottom view) 975-0601-01-01 Revision B This manual is for use by qualified personnel only.
Anchoring the Xantrex GT500 Anchoring the Xantrex GT500 Four 19 mm (0.75 in.) holes are provided in the feet of the assembly for anchoring to the floor or pad. The floor or pad can be pre-drilled to accept masonry anchors or have pre-installed anchoring bolts. DANGER HAZARD OF ELECTRIC SHOCK, FIRE, EXPLOSION, OR ARC FLASH The throat assembly is a critical part of the safety enclosure of the Xantrex GT500.
Figure 2-3 Anchor bolt pattern (bottom view) 2–8 749±6.4 mm (29.5±.25 in.) 42 mm (1.7 in.) 305±12.7 mm (12.0±.5 in.) Spacing panel to panel Back of inverter assembly Front of inverter assembly Front of transformer assembly Back of transformer assembly 2094±6.4 mm (82.4±.25 in.) 1930±6.4 mm (76.0±.25 in.) 383±12.7 mm (15.1±.5 in.) Front of inverter assembly frame and Transformer assembly colinear 125 mm (4.9 in.) 350±6.4 mm (13.8±.25 in.) 129 mm (5.1 in.
3 Installation Chapter 3 describes the installation procedures, including unpacking, moving, mounting, and cabling instructions. DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, AND ARC FLASH • Read all instructions, cautionary markings, and all other appropriate sections of this Manual and all labels on the product before installing, operating, troubleshooting, or maintaining the Xantrex GT500.
Installation Unloading and Moving the Xantrex GT500 WARNING HAZARD OF CRUSH INJURY AND EQUIPMENT DAMAGE • The inverter assembly weighs approximately 2700 lbs (1225 kg). The transformer assembly weighs approximately 4140 lbs (1878 kg). Do not lift the equipment other than at the recommended lifting points. • Keep all the doors closed and latched when moving the assemblies. • Use appropriately rated lifting equipment.
Unloading and Moving the Xantrex GT500 Unpacking the Xantrex GT500 To unpack the Xantrex GT500 (see Figure 3-1 on page 3–4): 1. Remove the wood cap from the inverter assembly, and remove the plastic wrapping material surrounding both assemblies. 2. Remove and save the throat connection kit and hardware located in the box behind the inverter assembly.
Installation Wood cap (inverter assembly only) Anchor hardware (rear hardware not visible in drawing) Throat connection kit and hardware Anchor hardware Shipping pallet Figure 3-1 Unpacking the Xantrex GT500 (inverter assembly shown) Cable gland plates Figure 3-2 Inverter assembly: cable gland plates (DC barrier removed) 3–4 975-0601-01-01 Revision B This manual is for use by qualified personnel only.
Unloading and Moving the Xantrex GT500 959 mm (37.8 in.) Cg Forklift lifting points 1085 mm (42.7 in.) 647 mm (25.5 in.) 610 mm (24.0 in.) Figure 3-3 Lifting points and center of gravity: inverter assembly 975-0601-01-01 Revision B This manual is for use by qualified personnel only.
Installation 2175 mm (85.6 in.) 699 mm (27.5 in.) 875 mm (34.4 in.) 2134 mm (84.0 in.) Forklift lifting points (distance between center of lifting points is 610 mm (24 in.)) Figure 3-4 Lifting points and center of gravity: transformer assembly 3–6 975-0601-01-01 Revision B This manual is for use by qualified personnel only.
Unloading and Moving the Xantrex GT500 Moving the Assemblies with a Forklift WARNING HAZARD OF CRUSH INJURY • The inverter and transformer assemblies are top heavy and could become unbalanced. • Verify that the capacity of the handling equipment is adequate for each assembly’s weight (see Table A-1 on page A–2). • Stabilize the assemblies with a safety strap to reduce the possibility of tipping. • Keep all unnecessary personnel away while handling and moving the assemblies.
Installation Moving the Inverter Assembly with a Sling WARNING HAZARD OF CRUSH INJURY • Verify that the capacity of the handling equipment is adequate for the inverter assembly’s weight (see Table A-1 on page A–2). • Keep all unnecessary personnel away while handling and moving the assemblies. Failure to follow these instructions can result in death or serious injury. To move the inverter assembly using a sling: 1. Use a sling at the locations indicated in Figure 3-6.
Unloading and Moving the Xantrex GT500 Use a spreader bar to help prevent damage to the inverter assembly. Use slings rated appropriately for the inverter assembly’s weight. Pin locations on base frame Figure 3-6 Moving with a sling: inverter assembly Moving the Transformer Assembly with a Sling WARNING HAZARD OF CRUSH INJURY • Verify that the capacity of the handling equipment is adequate for the transformer assembly’s weight (see Table A-1 on page A–2).
Installation To move the transformer assembly using a sling: 1. Use a sling at the locations indicated in Figure 3-7. Use slings with pin inserts for the frame, and use a spreader bar when hoisting to help prevent damage to the transformer assembly (see Figure 3-7). Hoisting equipment is not provided. 2. Select or adjust the rigging lengths to compensate for any unequal weight distribution of load and to keep the transformer assembly in an upright position. 3.
Mounting and Anchoring the Xantrex GT500 Mounting and Anchoring the Xantrex GT500 Follow the procedure below to mount and anchor the Xantrex GT500. To mount and anchor the Xantrex GT500: 1. If the Xantrex GT500 will be installed on a combustible surface, install a metal barrier completely covering the bottom of both the inverter and transformer assemblies. 2.
Installation Installing and Wiring the Throat Connection Kit After the inverter and transformer assemblies have been secured, install the throat connection kit (see Figure 3-8 on page 3–13 through Figure 3-14 on page 3–16). To install the throat connection kit: 1. Install the three-phase and ground bus bars provided in the throat connection kit to the inverter and transformer assemblies using the provided M10 fastening hardware and cover plates.
Installing and Wiring the Throat Connection Kit Figure 3-8 Throat connection kit: installed bus bars and cables Figure 3-9 Throat connection kit: connector clamps 975-0601-01-01 Revision B This manual is for use by qualified personnel only.
Installation Engaging the tabs on the bottom throat cover Sliding the top throat cover down over the flanges Figure 3-10 Throat connection kit: installing top cover and bottom cover TB13 TB13 TB14 TB14 Install the two 120 VAC 8 AWG power cables (labelled TB13-12 and TB14-12) onto the upper right-most screw terminal of the distribution blocks TB13 and TB14.
Installing and Wiring the Throat Connection Kit F (not visible; behind item E) Items required for throat connection: A: M10 bolt B: M10 nut C: Belleville washer D: Bus bar cap plate E: Flexible bus bar F: Bus bar D E C C B A Items A–E are included in the throat connection kit. Item F is part of the inverter assembly.
Installation Top throat cover (front side) Bottom throat cover Ground cable Top throat cover (back side) Ground stud Installed throat connection Figure 3-13 Throat connection kit: assembly and installation Ground bus bar Ground stud Figure 3-14 Throat connection kit: connecting the ground cable 3–16 975-0601-01-01 Revision B This manual is for use by qualified personnel only.
Opening or Closing Access Doors Opening or Closing Access Doors DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, AND ARC FLASH • Do not open any doors or covers unless you are qualified personnel and the Xantrex GT500 has been completely de-energized following the “Lockout and Tag-out Procedure” on page xi. • Do not open the cabinet doors if rain, heavy dew, or condensation is present. Failure to follow these instructions will result in death or serious injury.
Installation Transformer assembly Inverter assembly Control panel access door Door locks Door locks DC switch S1 access door AC breaker access door ENABLE/DISABLE switch (S3) (behind the door) Keypad and display Figure 3-15 Opening or closing the access door 3–18 975-0601-01-01 Revision B This manual is for use by qualified personnel only.
General Wiring Requirements General Wiring Requirements DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, AND ARC FLASH • Read all instructions, cautionary markings, and all other appropriate sections of this Manual and all labels on the product before installing, operating, troubleshooting, or maintaining the Xantrex GT500.
Installation through the same knockout and conduit fittings, allowing any inductive currents to cancel. For torque values, see Table A-6 on page A–6. For the location of these terminals, see Figure 1-2 on page 1–5. The Xantrex GT500 includes the ability to auto-sense and correct for a misphased connection at the AC interface terminals.
General Wiring Requirements The auxiliary power interface terminals (TB6-1 and TB6-3) are NEMA type boxlug terminals that require the use of solid or stranded copper wire only. See Figure 3-18 on page 3–24 for the location of these terminals. DC Interface The DC terminals (TB3, TB4, and TB5 [PV GND]) in the inverter assembly are provided with sixteen holes for bolts for securing conductors terminated with crimp-on type ring-terminals or compression-type lugs.
Installation Transformer assembly CB4 (AUX control power CB) CB3 (control power CB) GND BUS TB2 CB1 TB1-C TB1-B TB1-A Figure 3-16 Single-point ground; ground bar and AC utility terminals Connecting the Conductors This section provides information for connecting the AC and DC conductors and the ground conductors. Table A-6 and Table A-5 show the specifications of the AC and DC wiring.
Connecting the Conductors To remove the AC barriers: 1. Open the transformer assembly’s left door. 2. Remove all four screws shown circled on the left side of Figure 3-17, and then slide out the barrier. 3. Open the transformer assembly’s right door. 4. Remove all six screws shown circled on the right side of Figure 3-17, and then slide out the barrier. Figure 3-17 Removing the AC barriers Connecting the AC Output To connect the Xantrex GT500 AC output to the AC utility: 1.
Installation 4. If you are sourcing AC auxiliary power externally, proceed to “Connecting AC Auxiliary Power (Optional)” on page 3–24. If not, close the transformer assembly’s door, and then proceed to “DC Wiring” on page 3–24. The AC barrier will be re-installed in a later step. Connecting AC Auxiliary Power (Optional) The Xantrex GT500 is factory-configured to take its AC auxiliary power from the AC output. To source the control power from an external source instead (see Figure 3-18): 1.
Connecting the Conductors To remove the DC barrier: 1. Open the inverter assembly’s door. 2. Remove all four screws as shown in Figure 3-19, and then slide out the barrier. Note that the two top screws are not visible in the photograph. They are on top of the barrier, in line with the screws on the bottom. Figure 3-19 Removing the DC barrier Connecting the PV Input To make the connections from the PV array to the Xantrex GT500: 1. Make sure the DC barrier has been removed. 2.
Installation Inverter assembly TB4 TB3 TB5 PV ground Figure 3-20 PV array cable routing and terminations Table 3-1 DC terminal polarity Model TB3 TB4 TB5 Xantrex GT500 480 PV+ PV- PV ground Xantrex GT500 480 PG PV- PV+ PV ground Remote Communications The Xantrex GT500 has the ability to provide remote communications and plant monitoring using the included Xantrex RS485/Modbus Communications Kit.
4 Commissioning Chapter 4 contains information on commissioning. DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, AND ARC FLASH • Read all instructions, cautionary markings, and all other appropriate sections of this Manual and all labels on the product before installing, operating, troubleshooting, or maintaining the Xantrex GT500.
Commissioning Commissioning Procedure This section provides the procedure necessary to safely and correctly commission the Xantrex GT500. NOTICE It is important to record any issues encountered while following this procedure. To commission the Xantrex GT500, complete the Xantrex GT500 commissioning procedure as summarized below. Commissioning Step See Record the serial number and location. “Starting the Commissioning Test” on page 4–3. Inspect the Xantrex GT500.
Starting the Commissioning Test Starting the Commissioning Test Enter all the information required under “Step 1. Record and Document Serial Number and Inverter Location” on page C–3 on the form in Appendix C, “Commissioning Test Record”. The serial number is located on a label placed on the lower-left front of the inverter assembly’s door. Inspect the Xantrex GT500 1. Perform the “Lock-out and Tag-out Procedure” on page xi. 2.
Commissioning Auxiliary power not provided externally 1. When auxiliary power is not provided externally, verify the jumpers on terminal block TB6 (located on internal left wall of the transformer assembly) are located from TB6-4 to TB6-5 and TB6-7 to TB6-8. 2. Check the torque of the terminals at TB6 (see Table A-7 on page A–6). Tighten as necessary. Verify Throat Connection Kit Wiring After verifying the throat connection kit wiring, complete “Step 3.
Verify Voltages Verify DC Wiring After verifying the DC wiring, complete “Step 2. Installation and Cable Check” on page C–3 on the form in Appendix C. To verify DC wiring: 1. Verify that the array frame grounding wires are connected to TB5 (PV ground). 2. For a negative-grounded system, verify that PV+ is connected to TB3 and PV- is connected to TB4. 3. For a positive-grounded system, verify that PV- is connected to TB3, and PV+ is connected to TB4. 4.
Commissioning DANGER HAZARD OF ELECTRIC SHOCK Hazardous voltages will now be present on AC terminals TB1-A, B, and C, terminal block TB6 (see Figure 3-18 on page 3–24), and on circuits and parts throughout the Xantrex GT500. Do not proceed without appropriate PPE. Failure to follow these instructions will result in death or serious injury. 4. Wearing appropriate PPE, open the transformer assembly doors to access the AC compartment. 5.
Verify Voltages 6. If results are within the correct range, continue with the commissioning procedure steps. 7. Confirm all measurement equipment, meters, and probes are removed safely from the inverter and immediate work area. 8. De-energize the Xantrex GT500 by following the “Lock-out and Tag-out Procedure” on page xi. 9. Slide the AC barrier from the left side of the transformer assembly back into place, and then secure it with the four screws as shown on the left side of Figure 3-17 on page 3–23. 10.
Commissioning 5. With an appropriate voltmeter, use the positive (+, red) voltmeter probe on TB3 and the negative (-, black) voltmeter probe on TB5 ground. Measuring the correct polarity is important. • On a negative grounded system the voltage should read between +300 VDC and +600 VDC. • On a positive grounded system the voltage should read between -300 VDC and -600 VDC. 6.
System Startup System Startup DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH • Thoroughly inspect the installed equipment, and verify that all tools, loose parts, and installation equipment have been removed from the Xantrex GT500 before energizing. • Make sure all barriers have been properly replaced before energizing any circuits. • Make sure all doors on the Xantrex GT500 are closed and latched before proceeding. • Do not energize the Xantrex GT500 if any barriers are missing or damaged.
Commissioning You might hear a whirring sound that is the motor drive to charge the spring mechanism of the AC circuit breaker. This is normal and should stop within 10 seconds. Starting the System To start the system: 1. Make sure the transformer and inverter assembly doors are closed and all latches are tightened. 2. Make sure the ENABLE/DISABLE switch is in the DISABLE position. 3. Apply AC grid voltage by switching on the external AC grid disconnect device. 4.
Verify AC, DC, and Power Tracking Operational Parameters Verify AC, DC, and Power Tracking Operational Parameters For each of the following parameters, readings are shown on the display. Access the WRITE menu parameter list by pressing the MENU key, and then entering the password 594. Using the \/ key, scroll down in the WRITE menu and record the parameter settings here and in “Step 8. Confirm Write Menu Parameters for AC Limits” through “Step 10.
Commissioning Operate Inverter To operate the inverter: 1. Make sure all transformer and inverter assembly doors are closed and locked. 2. Energize PV input to the Xantrex GT500. PV voltage must be above the starting voltage for the Xantrex GT500 to proceed. 3. Using the front panel or the GUI, set the I PPT Max percent to 10%. 4. Place the ENABLE/DISABLE switch in the ENABLE position.
Perform Automatic Disconnection Test Perform Automatic Disconnection Test The automatic disconnection test can be run at any convenient power level. To perform the automatic disconnect test: 1. With the Xantrex GT500 running, open the external disconnect switch (if load-break rated) on the AC output circuit, or in some other manner deenergize the AC grid. 2. Check the front panel display to verify that the inverter ceases to energize its output terminals. After a convenient period, re-close the disconnect.
Commissioning To configure the Xantrex GT500’s Modbus address: 1. If the display has reset to its default, press MENU, type in the password 594, and then press ENTER. 2. Using the arrow keys, scroll to the Modbus Address option, and then press ENTER. 3. Type in the new address, and then press ENTER. Figure 4-1 Xantrex RS485/Modbus Communications Kit Complete Commissioning To complete commissioning: 1.
A Specifications Appendix A provides specifications. 975-0601-01-01 Revision B This manual is for use by qualified personnel only.
Specifications The Xantrex GT500 has been designed for photovoltaic power systems that operate within the following specifications. WARNING HAZARD OF ELECTRIC SHOCK, EXPLOSION, FIRE, AND ARC FLASH. HAZARD OF EQUIPMENT DAMAGE. Unsafe conditions and damage to the Xantrex GT500 could result if the instructions and the electrical, physical, and environmental installation specifications in this Manual are not obeyed. Failure to follow these instructions can result in death, serious injury, or equipment damage.
Electrical Specifications Electrical Specifications Table A-2 provides the AC and DC specifications for the Xantrex GT500. Table A-2 Electrical specifications Specification Xantrex GT500 480 and Xantrex GT500 480 PG Xantrex GT500 600 and Xantrex GT500 600 PG Nominal AC Output Voltage 480 VAC 600 VAC (+10% to -12% default range) (422 to 528 VAC) (528 to 660 VAC) Maximum Continuous AC Output Current 610 Arms 490 Arms Nominal AC Input Frequency 60 Hz 60 Hz (+0.5 to -0.7 Hz default range) (59.
Specifications Regulatory Specifications Certified by CSA International to the applicable requirements of the following regulatory standards: • UL 1741 — Inverters, Converters, Controllers, and Interconnection System Equipment for use with Distributed Energy Resources (includes IEEE 1547, 1547.1) • CAN/CSA-C22.2 No. 107.
Hardware Sizing and Torque Requirements Table A-4 Over/under voltage and over/under frequency ranges (Xantrex GT500 600 and Xantrex GT500 600 PG models only) VAC Condition (% of Nominal) Xantrex GT500 Voltage Range Trip Time VAC < 50% Fast Under-voltage VAC < 300 10 cycles (0.
Specifications Table A-6 provides acceptable bolt sizes, conductor range, and torque values for AC output terminal connections. Table A-6 AC output terminal bolt size and torque values AC Terminal Connections Max. # of Conductors per Terminal Maximum Bolt Size TB2 GND (Enclosure Ground) 2 M10 49.3 Nm (36.4 ft-lb) Maximum based on Standard stainless hardware (Class 5.8) TB1-A, TB1-B, and TB1-C 3 M10 49.3 Nm (36.4 ft-lb) Maximum based on Standard stainless hardware (Class 5.
Dimensions Dimensions Top view Side view A A: 890.0 mm (35.0 in.) B B: 1088.0 mm (42.8 in.) 609 mm (24.0 in.) 925 mm (36.4 in.) Front view 2240.0 mm (88.2 in.) 2133.0 mm (84.0 in.) 2200.0 mm (86.6 in.) 4638.0 mm (182.6 in.) Figure A-1 Xantrex GT500 dimensions 975-0601-01-01 Revision B This manual is for use by qualified personnel only.
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B Circuit Diagram Appendix B provides the circuit diagram. 975-0601-01-01 Revision B This manual is for use by qualified personnel only.
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Appendix B - Circuit Diagram Circuit Diagram for Xantrex GT500 480, Xantrex GT500 480 PG, Xantrex GT500 600, and Xantrex GT500 600 PG 500 kW Grid-Tied Photovoltaic Inverters A sample electrical diagram of the Xantrex GT500 480 and Xantrex GT500 480 PG is provided in Figure B-1. Since installations vary widely, use this diagram for system planning purposes only.
Appendix B - Circuit Diagram A sample electrical diagram of the Xantrex GT500 600 and Xantrex GT500 600 PG is provided in Figure B-1. Since installations vary widely, use this diagram for system planning purposes only. Grounding, overcurrent protection, and disconnecting means shown are not intended to be complete and vary by system design and installation location. Consult applicable local codes.
C Commissioning Test Record Appendix C contains the Commissioning Test Record. 975-0601-01-01 Revision B This manual is for use by qualified personnel only.
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Commissioning Test Record Commissioning Test Record Step 1. Record and Document Serial Number and Inverter Location Date and Time of Commissioning: Transformer Assembly Serial Number: Xantrex GT500 Serial Number: CCU Board Serial Number: Installation Name: Technician Name: Inverter Location (Site ID): Company Name: Address: Contact Email: City: State: Zip: Country: Step 2. Installation and Cable Check Power Conductors installed correctly: Yes Terminations are properly torqued: Yes Step 3.
Commissioning Test Record Step 10. Confirm Write Menu Parameters for Power Tracker Configuration PPT V Ref: I PPT Max %: PPT Enable: PPT Rate: PPT V Rate: Notes: Step 11.
Index A C AC auxiliary connections, torque values A–6 AC barrier re-installing 4–7 removing 3–23 AC circuit breaker (CB1) 1–12 AC interface auxiliary control power 1–9 communications circuit 1–9 overview 1–9 transformer assembly 1–5 AC power connections, torque values A–6 AC terminal bolt size and torque values A–6 AC voltages, verify for commissioning 4–5 AC wiring 3–23 auxiliary power 3–24 auxiliary power, commissioning verification 4–3 commissioning verification 4–3 acronyms v activating Modbus kits 4–
Index verify AC wiring 4–3 verify auxiliary power wiring 4–3 verify DC voltages 4–7 verify DC wiring 4–5 verify display 4–10 verify keypad 4–10 verify operational parameters 4–11 verify throat connection kit wiring 4–4 communications circuit 1–9 communications, remote 3–26 conductor requirements 2–4 conductor termination wiring 20 conduits bottom entry 2–6 entry 2–4 requirements 2–4 side entry 2–4, 2–5 configuring Modbus addresses 4–14 control card 1–9 control, remote 1–9 controls, operator interface 1–11 c
Index I IEEE (Institute of Electrical and Electronics Engineers) v IGBT (insulated gate bipolar transistor) v inspection for commissioning 4–3 installation AC (auxiliary power) wiring 3–24 AC barrier, re-installing 4–7 AC barrier, removing 3–23 AC wiring connecting 3–23 anchoring 2–7 anchoring bolt pattern 2–8 auxiliary power wiring 3–24 bottom entry 2–6 cable entry 2–4 center of graviy, inverter assembly 3–5 center of graviy, transformer assembly 3–6 chassis ground 3–21 clearance requirements 2–2 conducto
Index O S opening inverter assembly doors 3–17 transformer assembly doors 3–17 operational parameters, verification during commissioning 4–11 oscillography 1–16 overcurrent protection 2–2 S1 (DC switch) 1–12 safety conventions iv equipment x limitations on use viii screw sizes throat connection kit connections A–6 self-protection, Xantrex GT500 1–2 sending commissioning test record 4–14 sending test record 4–14 serial number for commissioning 4–3 shading, installation in high ambient temperatures 2–3 sh
Index torque values AC auxiliary connections A–6 AC power connections A–6 AC terminal A–6 DC terminal A–5 throat connection kit A–6 throat connection kit connections A–6 transformer assembly AC interface 1–5 center of gravity 3–6 closing the doors 3–17 definition iv heaters 1–6 installation 3–11 opening the doors 3–17 transformer, isolation 3, 2–4 re-installing AC barrier 4–7 re-installing DC barrier 4–8 removing AC barrier 3–23 removing DC barrier 3–25 requirements 3–19 throat connection kit 3–12 throat c
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