PV225S-480-P Operation and Maintenance Manual PV225S 225 kW Grid-Tied Photovoltaic Inverter
PV225S 225 kW Grid-Tied Photovoltaic Inverter Operation and Maintenance Manual
About Xantrex Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with products from 50 watt mobile units to one MW utility-scale systems for wind, solar, batteries, fuel cells, microturbines, and backup power applications in both grid-connected and stand-alone systems. Xantrex products include inverters, battery chargers, programmable power supplies, and variable speed drives that convert, supply, control, clean, and distribute electrical power.
About This Manual Purpose The purpose of this Operation and Maintenance Manual is to provide explanations and procedures for operating, maintaining, and troubleshooting the PV225S 225 kW Grid-Tied Photovoltaic Inverter. Installation instructions are available in the PV225S 225 kW Grid-tied Photovoltaic Inverter Planning and Installation Manual. Scope This Manual provides safety guidelines and information about operating and troubleshooting the unit.
About This Manual Conventions Used The following conventions are used in this guide. WARNING Warnings identify conditions or practices that could result in personal injury or loss of life. CAUTION Cautions identify conditions or practices that could result in damage to the unit or other equipment. Important: These notes describe things which are important for you to know, but not as serious as a caution or warning.
About This Manual Abbreviations and Acronyms CCU2 Converter Control Unit 2 CFM Cubic Feet per Minute CW Clockwise DSP Digital Signal Processor FPGA Field Programmable Gate Array GUI Graphical User Interface IEEE Institute of Electrical and Electronics Engineers IGBT Insulated Gate Bipolar Transistor IPM Intelligent Power Module kcmil 1000 circular mils LAN Local Area Network POTS Plain Old Telephone Service PSL Phase-Shift Loop PV Photovoltaic UFCU Universal Frontpanel Control
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Important Safety Instructions SAVE THESE INSTRUCTIONS - DO NOT DISCARD This manual contains important safety instructions for the PV225S that must be followed during installation and maintenance procedures. WARNING: Shock Hazard Read and keep this Operation and Maintenance Manual for future reference. Before installing the PV225S, read all instructions, cautionary markings, and all other appropriate sections of this manual. Failure to adhere to these warnings could result in severe shock or possible death.
Safety General Safety Precautions 1. When installing the PV225S use only components recommended or sold by Xantrex. Doing otherwise may result in a risk of fire, electric shock, injury to persons, and will void the warranty. 2. Do not attempt to operate the PV225S if it has been dropped, or received more than cosmetic damage during transport or shipping. If the PV225S is damaged, or suspected to be damaged, see the Warranty section of this manual. 3.
Safety terminal or compression lug. The terminals can accommodate up to two conductors per phase. See the PV225S 225 kW Grid-tied Photovoltaic Inverter Planning and Installation Manual for the location of these terminals. 5. The AC power conductor wiring interfacing with the AC terminals in the Main Inverter Enclosure are located at TB5, TB6, and TB7. These terminals are to be tightened to a torque value of 375 in-lb (42.4 Nm).
Safety Operational Safety Procedures Never work alone when servicing this equipment. A team of two is required until the equipment is properly de-energized, locked-out and tagged, and verified deenergized with a meter. Thoroughly inspect the equipment prior to energizing. Verify that no tools or equipment have inadvertently been left behind. Lockout and Tag Safety requirements mandate that this equipment not be serviced while energized.
Safety De-Energize/Isolation Procedure The following procedure should be followed to de-energize the PV225S for maintenance. WARNING The terminals of the DC input may be energized if the PV arrays are energized. In addition, allow 5 minutes for all capacitors within the main enclosure to discharge after disconnecting the PV225S from AC and DC sources. To isolate the PV225S: 1. Turn the ON/OFF switch to the OFF position. 2. Open the DC Disconnect Switch. 3. Open the AC Disconnect Switch. 4.
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Contents Important Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - vii 1 Introduction Operation Features- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 Fixed Unity Power Factor Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 Peak Power Tracking - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–
Contents 2 Operation Description of System Operation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2 Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2 Faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2 Operating States - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Contents 3 Commissioning Commissioning Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2 Starting the Commissioning Test File - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2 Serial Number - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3 Verify AC Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Contents A Specifications System Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Environmental Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Over Voltage, Under Voltage and Frequency Ranges - - - - - - - - - - - - - - - - - - - - - - - - - - Wire Gauge and Torque Requirem
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 1-12 Figure 1-13 Figure 1-14 Figure 2-1 Figure 2-2 Figure 2-3 Figure 2-4 Figure 2-5 Figure 2-6 Figure 2-7 Figure 2-8 Figure 2-9 Figure 2-10 Figure 2-11 Figure 2-12 Figure 2-13 Figure 2-14 Figure 2-15 Figure 2-16 Figure 2-17 Figure 2-18 Figure 2-19 Figure 2-20 Figure 2-21 Figure 2-22 Figure 2-23 152607 Maximum Peak Power Tracking - - - - - - - - - - - - - - - - - - - - -
Figures Figure 2-24 Figure 2-25 Figure 2-26 Figure 2-27 Figure 4-1 Figure 5-1 Figure 5-2 Figure 5-3 Figure A-1 Figure A-2 Figure A-3 Figure A-4 xviii Connection Configuration Screen - General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–35 Connection Configuration Screen - Telephone Fault Configuration - - - - - - - - - - - - - -2–36 Connection Configuration Screen - General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2–36 GUI Interface Screen if Connected Directly - - - -
Tables Table 2-1 Table 2-2 Table 2-3 Table 2-4 Table 2-5 Table 4-1 Table A-1 Table A-2 Table A-3 Table A-4 Table A-5 152607 Scrolling through the Read Menu Parameters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9 Read Menu Descriptions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11 Data Logging Menu- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–14 Accumulated Values Menu - - - - - - - - - - - - - - - -
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1 Introduction Chapter 1, “Introduction” contains information about the features and functions of the PV225S 225 kW Grid-Tied Photovoltaic Inverter.
Introduction Operation Features The PV225S 225 kW Grid-Tied Photovoltaic Inverter is a UL 1741 listed, utility interactive, three-phase power conversion system for grid-connected photovoltaic arrays with a power rating of 225 kW. Designed to be easy to install and operate, the PV225S automates start-up, shutdown, and fault detection scenarios. With user-definable power tracking that matches the inverter to the array and adjustable delay periods, users are able to customize startup and shutdown sequences.
Operation Features Peak Power Tracking An advanced, field-proven, Maximum Peak Power Tracker (MPPT) algorithm integrated within the PV225S control software ensures the optimum power throughput for harvesting energy from the photovoltaic array. The peak power voltage point of a PV array can vary, primarily depending upon solar irradiance and surface temperature of the PV panels. This peak power voltage point is somewhat volatile, and can easily move along the I-V curve of the PV array every few seconds.
Introduction Optimization of the PV225S MPPT will result in an increase in energy production. The user is encouraged to study the PV array’s I-V curves and to adjust the MPPT user settable parameters accordingly. Figure 1-1 Maximum Peak Power Tracking Dynamic DC Minimum Operating Voltage The PV225S employs a unique approach to the minimum DC input voltage for operation.
Safety Features Safety Features Anti-Island Protection A condition referred to as "Islanding" occurs when a distributed generation source (such as the PV225S Grid-tied Photovoltaic Inverter) continues to energize a portion of the utility grid after the utility experiences an interruption in service. This type of condition may compromise personnel safety, restoration of service, and equipment reliability. The PV225S employs a method for detecting the islanding condition using a Phase-Shift-Loop (PSL).
Introduction Physical Characteristics The PV225S comes in two modules comprised of six enclosures to house the electronics described above. The first module includes the Main Inverter Enclosure, Inductor Enclosure, DC Interface Enclosure, and Communications Enclosure. The second module includes the Transformer Enclosure and AC Interface Enclosure. These components are identified in Figure 1-2.
Physical Characteristics Main Inverter Enclosure The PV225S Main Inverter Enclosure is NEMA-3R rated and contains the power distribution panel, the converter control unit (CCU2), and the power electronics matrices. Also found within the Main Inverter Enclosure are some of the system protection devices (such as the sense and control power fuses).
Introduction DC Interface Enclosure The DC Interface Enclosure is NEMA-3R rated. The DC interface serves as the connection interface between the PV array and the PV225S. This enclosure is where the DC Disconnect Switch and DC contactor reside. CAUTION: Equipment Damage The fuses within the PV225S are intended for protecting the PV225S control circuitry only. They are not intended to provide protection for the PV array or external cabling.
Physical Characteristics AC Interface Enclosure AC Disconnect Switch Transformer Enclosure Figure 1-4 AC Interface Enclosure and Transformer Enclosure Communications Enclosure The Communications Enclosure is NEMA-4 rated. It contains the hardware to enable a personal computer to connect to the unit, either directly or remotely. Hardware could include a POTS Connect Kit, a Wireless Connect Kit, or an Ethernet LAN kit, or a Direct Connect Kit.
Introduction Operator Interface Controls Operator interface controls are located on the front door of the main inverter enclosure. These controls include an ON/OFF Switch, 4-line LCD display and keypad called the Universal Frontpanel Control Unit (UFCU). Additionally there is an AC and DC Disconnect on the AC Interface Enclosure and the DC Interface Enclosure Doors.
Operator Interface Controls WARNING: Shock Hazard Disengaging the main enclosure door interlock switch does NOT remove all hazardous voltages from inside the inverter. Before attempting to service the PV225S, follow the de-energize Lockout and Tag procedure on page 5–3. On/Off Switch The PV225S incorporates a maintained position ON/OFF Switch (S3) located on the front door of the main enclosure. Under normal conditions, the ON/OFF switch is in the ON position.
Introduction AC and DC Disconnect Switches Both AC and DC interface enclosures are equipped with lockout hasps for personnel safety. The enclosure doors should not be opened while the PV225S is operating. The switch handles and shafts provide a door interlock for both the AC and DC interface enclosures. The doors cannot be opened when the switch is in the ON position. The DC Disconnect Switch (S2) is equipped with an auxiliary contact block which enables the switch to be used as a load break DC disconnect.
Communication Features System Status and Fault Reporting Basic system status and all fault conditions rising from within the PV225S are reported to the UFCU. The unit stores the time and details of all faults in non-volatile memory. The 4-line LCD will display a hexadecimal value and a brief text description of the fault. This information can also be accessed using a personal computer using the GUI software either directly or remotely.
Introduction Communication Methods The PV225S communicates system status information to the user using the following methods. • • The Front Panel Control Unit (UFCU) Display PC Connection (Direct or Remote) - Xantrex Solar Graphic User Interface (GUI) Software required. Communication with a PC requires the selection of one of the following options. • Remote Connection -- This method has three options available. One of these options will be field-installed prior to commissioning.
Communication Methods PC Connection Methods Personal computers can be used to access the system status and programming features of the PV225S. A computer can be connected either directly or remotely. 1. Remote Connect - uses one of the three kits below. • • • POTS Kit - uses a MultiTech® 56K Modem, RS232/Fiber Optic Converter (configured for ethernet) and SA2 Surge Arrestor. Wireless Kit - uses a GSM Wireless Modem.
Introduction POTS Access Figure 1-11 illustrates the PV225S connected remotely to a personal computer. Figure 1-11 POTS Access Wireless Access Figure 1-12 illustrates the PV225S connected remotely to a personal computer using a wireless network.
Communication Methods Ethernet LAN Access The PV225S can be remotely accessed through a local area network. Figure 1-13 LAN Access Direct Access Figure 1-14 illustrates the PV225S connected directly to a personal computer.
Introduction GUI Software Features Read-only Menu Write-Menu The GUI software provides access to the following “Read-only Menu” information. See Table 2-2, “Read Menu Descriptions” on page 2–11 for a specific list of available parameters. • Operational Values • Internal Metrics The GUI software provides control of the following system parameters. These parameters are in the Write Menu. • Data Logging User-Configurable Parameters.
2 Operation Chapter 2, “Operation” contains information on the basic operation of the PV225S 225 kW Grid-Tied Photovoltaic Inverter.
Operation Description of System Operation Overview The PV225S is a fully automated grid-interactive photovoltaic inverter. System startup, system shutdown, PV power tracking, and fault detection scenarios are all governed and monitored by the CCU2 controller within the PV225S. Manual interaction or control of the inverter is necessary only in the event of a system fault. Additionally, the following conditions govern operation of the PV225S.
Description of System Operation POWER UP INITIALIZING PV contactor opened. Inverter matrix off. Grid contactor open. Green LED on. Red off. System State: Key Disable Inverter State: Standby PV State: Sleep KEY DISABLE PV contactor open. Inverter matrix off. Grid contactor open. Enable Key Inverter matrix off.
Operation Operating States A state machine implemented within the CCU2 control software governs the operation of the PV225S with clearly defined transitions between its operating states. There are five steady-state operating states and numerous intermediate transition states. • • • • • • • Power Tracking Transition Shutdown Fault Manual Current Matrix Test Automatic Sleep Test Power Tracking This is the standard operating state of the PV225S.
Operating States Shutdown The line interface controller is idle. The CCU2 monitors the status of the PV array and utility grid, waiting in standby until the PV array is available to produce power to the grid. Fault The PV225S has encountered a fault condition. When this happens, regardless of the PV225S state of operation, the PV225S will stop processing all power and execute an orderly system shutdown. A description of the fault and fault code will appear on the operator interface LCD.
Operation Operator Interface The purpose of the operator interface is to provide a means of communicating critical operational information to and from the unit. This communication occurs between the operator and the UFCU Keypad and LCD display or between the operator and a personal computer running the Xantrex Solar GUI software. UFCU Keypad Operation and LCD Display The UFCU keypad is located on the front of the Main Inverter Enclosure to manipulate and view system operation and status.
Operator Interface LCD Display - Initialization Screen Any time AC power is applied to the unit, the LCD display will cycle through the following displays while the system initializes. Once it’s done with this process, the standard display will appear. Front Panel Initialization - Screen 1 Initialising... Front Panel Initialization - Screen 2 Front Panel v5.0 SW Build: 012805 Model: PV225S XANTREX TECHNOLOGY www.xantrex.
Operation Menu Structure The operator interface consists of three levels: • • • READ Menu - operation information provided to the user from the PV225S. The READ Menu consists of all operational values, the date and time. These can be viewed any time the PV225S has control power. WRITE Menu - operational parameters provided to the PV225S from the user. The WRITE Menu consists of a goal state sub-menu, and all system configurable parameters.
Operator Interface READ Menu The READ Menu includes the following information: • • • • • • • • • • • Current Operating State or Goal State Fault Code (if applicable) Inverter State Line Voltage and Current Inverter Matrix Temperature Inverter Power PV State PV Voltage and Current PV Power Grid Frequency Peak Power Tracker Enabled Table 2-1 shows how the third and fourth line of the LCD will change as the operator continues scrolling through the Menu.
Operation Standard Display System: PWR Tracking Inv: Online Pv: Online Goal : PWR Tracking From the Standard Display: 1. Press the \/ button once. System: PWR Tracking Inv: Online Pv: Online CCU Vx.xx FP Vx.x 2. Fourth line displays CCU version and Front Panel version software. System: PWR Tracking Inv: Online Pv: Online Feb-14-2005 10:01:55 3. Press the \/ button again. 4. Text on Fourth line displays the Date and Time. System: PWR Tracking Inv: Online Hit ENTER or "." "-" Value by ID# 5.
Operator Interface Table 2-2 READ Menu Descriptions Operational Parameter Description ID Units Current Operating State Current system states include the following. 1 N/A 2 N/A Displays as: System: * where * can be any one of the states listed in the description for this parameter. System Goal State Displays as: Goal: * where * can be any one of the states listed in the description for this parameter.
Operation Table 2-2 READ Menu Descriptions Operational Parameter Description ID Units Phase C current Phase C current 10 Arms Inverter Real Power 11 kW Temperature of the Inverter IGBT matrix heatsink 12 °C PV States include the following. 13 N/A PV Voltage 14 Vdc PV Current 15 Adc PV Power 16 kW Grid Frequency 17 Hz Indication as to whether the PPT is enabled or disabled.
Operator Interface READ-by-ID The Read-by-ID feature supports the ability of the user to view any Read or Write parameter available within the menu structure. It also provides a means to view data logging and accumulated values information. See Table 2-2 for a list of the Read Menu parameters. See Table 2-3 for a list of data logging menu parameters. See Table 2-4 for a list of accumulated values parameters. To use the Read-by-ID Feature: 1.
Operation Table 2-3 provides a list of the Data Logging Menu parameters. Table 2-3 Data Logging Menu ID# Usage 300 Data Log Daily Rate in Minutes 301 ID# of 1st parameter to be logged 302 ID# of 2nd parameter to be logged 303 ID# of 3rd parameter to be logged 304 through 390 ID#s of the 4th through the 90th parameter to be logged.
Operator Interface Table 2-4 Accumulated Values Menu ID# Usage 631 Peak Power monitored this week 632 Peak Power monitored this month 633 Peak Power monitored this year 634 Peak Power monitored since Commissioning 635-639 Not available 640 Peak Power Sold for a day 641 Peak Power Sold for a week 642 Peak Power Sold for a month 643 Peak Power Sold for a year WRITE Menu Important: Specific grid-interface parameters within the WRITE Menu have been set in the factory to the limits mandated
Operation Changing and Displaying WRITE Menu Parameter Values Follow the procedure below to change WRITE Menu parameters. To change WRITE Menu parameters: 1. From the standard display or anywhere in the READ Menu, you may access the WRITE menu parameters by pressing the
Operator Interface Table 2-5 Write Menu Parameters Default Maximum Minimum Value Value Value Parameter Description ID Units Minimum Grid Voltage This parameter sets the trigger point value for “AC voltage low” (0012) fault. If the grid voltage is below this parameter’s value, the fault is triggered. The lower limit of this parameter is restricted by UL requirements. 33 Percentage 88 of Nominal voltage 95 88 This parameter sets the trigger point value for “AC frequency high” (0011) fault.
Operation Table 2-5 Write Menu Parameters Units Default Maximum Minimum Value Value Value Time delay to transition from PV 39 wake up state to PV On-line state. Once the inverter is in PV Wake Up mode, it waits for the amount of time determine by this parameter before transitioning into PV on-line mode. During this time the inverter checks that the PV voltage is no less than the PV wake voltage, otherwise it goes into PV Sleep mode.
Operator Interface Table 2-5 Write Menu Parameters Default Maximum Minimum Value Value Value Parameter Description ID Units Enable Peak Power Tracker This parameter switches on and off the Power Tracker function. When the Power Tracker is on, the inverter will regulate the bus voltage to optimize output power. When the Power Tracker is off, the inverter will regulate the bus voltage to maintain it at “PPT V Ref” volts.
Operation Commanding Goal State Changes To change the Goal State: 1. From the standard display press the
Operator Interface Setting the Date and Time Follow the procedure below to change the date and time. To change the Date and Time: 1. From the standard display, press the
Operation Manual State Transitions State conditions can also be transitioned manually. Refer to “Commanding Goal State Changes” on page 2–20 for instructions on commanding PV225S goal states for manual transitions. Shutdown → Matrix Test → Shutdown 1. Turn the ON/OFF switch to the OFF position. 2. Command the PV225S to the Matrix Test. 3. After completing the Matrix Test, command the PV225S to Shutdown.
Auto-restart Feature Any State → Fault If the PV225S encounters a fault, regardless of operating state, it will transition to the Fault state. The PV225S will remain in this state until the fault condition has been remedied and cleared. The Fault Code number will appear on the first line of the LCD. A description of the fault will show on the second line. The third line of the LCD will read “F1 to Clear Fault?”. The fourth line shows the goal state.
Operation Energize Procedure (Startup) To start up the PV225S: 1. Remove any lockout devices from the Utility connection circuit breaker and PV disconnect switch. 2. Close the Utility connection circuit breaker. 3. Close the AC Disconnect Switch. 4. Close DC Disconnect Switch. 5. Turn the ON/OFF switch to the ON position. After a 15 second initialization period, the PV225S will automatically transition to ‘Waking Up’, given the PV voltage is greater than the PV V Start set point.
Computer Communications with the PV225S Computer Communications with the PV225S The PV225S provides multiple options for communicating system status or data logging through a personal computer using the Xantrex Solar Graphic User Interface (GUI) software. The Xantrex Solar Graphic User Interface (GUI) software is a Windows™-based program that: • • • • displays system status, accesses inverter controls, accesses metering and data logging capabilities, and controls protective functions.
Operation Installing the Graphic User Interface (GUI) Software The following section outlines the minimum system requirements for using the GUI software and instructions for installing, configuring, and using the software. Close all programs running on the computer before proceeding with the installation. Minimum System Requirements The following lists the minimum requirements for using the Xantrex Solar Graphic User Interface (GUI) Software.
Computer Communications with the PV225S Starting Setup From a Command Prompt To start the program from a command prompt: 1. Insert the XANTREX SOLAR INVERTER GUI – INSTALLATION CD into your CDROM drive. 2. Click on START and select “RUN”. 3. Enter the drive letter assigned to your CDROM and the name of the installation program as shown in Figure 2-10. Figure 2-10 Staring Setup from a Command Prompt Important: The drive letter assigned to your CDROM may be different from the one shown in Figure 2-10.
Operation Model Specific Software Installation Once the Setup program has been started, installation of the GUI software can continue. To continue with the GUI software installation: 1. After the GUI Setup Splash Screen appears (Figure 2-11), click on the button INSTALL PV225S GUI. The GUI Setup Welcome Window will appear next (Figure 2-12).
Computer Communications with the PV225S 2. Click OK and the following window will appear: Figure 2-13 GUI Setup Start Window If the directory provided in this window is acceptable for the installation, proceed to Step 4. If not, click on the CHANGE DIRECTORY button and provide a new name for the desired destination directory. 3. Click on the picture of the computer to continue with the installation.
Operation 4. Click CONTINUE to confirm the program group to be used. The following setup progress indication window will appear. Figure 2-15 GUI Setup Progress Indicator Window 5. When completed, you will see this: Figure 2-16 GUI Setup Start Window 6. Click OK. The GUI is now installed on the computer.
Computer Communications with the PV225S Running the GUI To run the GUI software program, log onto the computer and click the following menu items in the order shown below. 1. Window’s START button 2. PROGRAMS 3. XANTREX_SOLAR 4.
Operation Direct Connection If the serial communication port of the inverter is connected to the COM1 serial port of the computer, the following screen will appear.
Computer Communications with the PV225S GUI Configuration - Adding Inverters Once the GUI has started, you will need to configure each Inverter icon to reflect the appropriate operational parameters for each inverter that is connected to the system. The software automatically defaults to one inverter. To program that inverter accordingly, follow the directions provided below. To configure the inverters in the GUI: 1. With the GUI Main Menu open, Right-click on the “Inverter 1” icon. 2.
Operation 5. Fill out the Operational Configurations Information in the form shown in Figure 2-21 through Figure 2-23. This section has four sub-menu pages to cover the following parameters. a) Fill out Operational Limits Information requested. b) Click on the PV Sub-menu to continue. Form Tab Fill out all the required information on this form. Sub-menu Figure 2-21 Operational Configuration Screen - Limits c) Fill out PV Information requested. d) Click on the Power Tracker Sub-menu to continue.
Computer Communications with the PV225S e) Fill out the Power Tracking Information requested. f) Click on the Connections Form Tab to continue. Form Tab Fill out all the required information on this form. Figure 2-23 Operational Configuration Screen - Power Tracker 6. Fill out the Connection - General Information in the form in Figure 2-24. 7. Click on the Telephone Fault Configuration sub-menu to continue. Form Tab Fill out all the required information on this form.
Operation 8. Fill out the Connection - Telephone Fault Configuration Information in the form shown in Figure 2-25. 9. Click on the Telephone Configuration sub-menu to continue. Form Tab Fill out all the required information on this form. Sub-menus Figure 2-25 Connection Configuration Screen - Telephone Fault Configuration 10. Fill out the Connection - Telephone Configuration Information in the form shown in Figure 2-26.
Computer Communications with the PV225S GUI Help The GUI software program has a built-in help program. Once the program is started, click on the HELP menu item to start the Help program. The Help interface is divided into the following sections. • • • • • • • • Getting Started - IMPORTANT: Read this first Setup - Tutorial for setting up the GUI and configuring an inverter Windows - Description of each window of the GUI Menu Commands - Description of each GUI Menu command How to...
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Computer Communications with the PV225S 152607 2–39
Operation 2–40 152607
3 Commissioning Chapter 3, “Commissioning” contains information on safely commissioning the PV225S 225 kW Grid-Tied Photovoltaic Inverter.
Commissioning Commissioning Procedure This section provides the procedure necessary to safely and correctly commission a PV225S inverter. Important: It is important to record any issues encountered while following this procedure. Summary To commission the PV225S: 1. Ensure the Verification Tests have been completed and have passed successfully. See the PV225S 225 kW Grid-tied Photovoltaic Inverter Planning and Installation Manual, Section 4. 2.
Starting the Commissioning Test File Serial Number 1. Enter the information required by GUI in the white text boxes on the form that appears next. The converter serial number is located on a label placed on the lower-left front of the Main Inverter Enclosure door. 2. Once you finish recording the required information, click on the check box to indicate the task is complete. Go to the next step by clicking on the "NEXT" button. Verify AC Voltage 1.
Commissioning 6. Once you finish verifying PV DC voltages, go back to the GUI Commissioning Procedure and click on the check box to indicate that the task is complete. Go to the next step by clicking on the "NEXT" button. Inspect Inductor Enclosure 1. Remove the back and side access panels to the Inductor Enclosure and inspect the connections. 2. Check for loose cables, rubbing, or interference. 3.
Starting the Commissioning Test File 7. Once you finish checking the Front Panel Display, go back to the GUI Commissioning procedure and click on the check box to indicate the task is complete. Go to the next step by clicking on the "NEXT" button. Establish Communications with the GUI 1. Verify that the appropriate hardware has been installed for the desired communications connection–Remote or Direct Connect.
Commissioning Confirm DC Operational Parameters 1. Verify the Inverters PV Settings. 2. Make any necessary changes. 3. Record these values. 4. Once you finish these tasks, go back to the GUI Commissioning Procedure and click on the check box to indicate the task is complete. Go to the next step by clicking on the "NEXT" button. Confirm Power Tracker Configuration Operational Parameters 1. Verify the inverter’s Power Tracker Configuration. 2. Make any necessary changes. 3. Record these values. 4.
Starting the Commissioning Test File Operate Inverter 1. Make sure all doors are closed and locked. 2. Using the Front Panel or the GUI, set the I PPT Max percent to 25%. 3. Place the ON/OFF Switch (S3) in the ON position. If the PV voltage is above PV Start voltage threshold, followed by a 5-minute delay period, the PV contactor (K2) will close, followed by the Main AC contactor (K1). The inverter will begin to produce power up to 25% of rated power. 4. Look, listen and smell for any defects.
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4 Troubleshooting Chapter 4, “Troubleshooting” contains information and procedures for troubleshooting the PV225S 225 kW Grid-Tied Photovoltaic Inverter. It provides descriptions of common situations and errors that may occur and provides possible solutions for resolving fault conditions. It also provides instructions for clearing faults manually, if required.
Troubleshooting Faults and Fault Codes Fault states are automatic from any state of operation. In the event of a fault condition, the PV225S will immediately stop processing power and execute an immediate orderly shutdown, open both the main AC and DC contactors, and remain in a faulted state until the fault is remedied and cleared (manually or automatically).
Clearing Faults Manually Clearing Faults Manually Faults associated with a grid disturbance clear automatically. These faults include: • • • • 0010 (AC Frequency Low), 0011 (AC Frequency High), 0012 AC Voltage Low), and 0013 (AC Voltage High) only. Once the AC voltage and frequency return to within the acceptable range, the PV225S will clear the fault and automatically restart after a 5-minute delay. All other faults associated with the PV225S must be circumvented and cleared manually using the UFCU.
Troubleshooting Fault Code Descriptions Table 4-1 provides a complete description of all the fault conditions that may occur on the PV225S. Table 4-1 Fault Codes Error Code Fault Type Fault Source(s) H=Hardware S=Software Fault Description Possible Causes 0000 No Faults N/A N/A N/A 0010 AC Frequency Low S This fault indicates that the Utility grid frequency is below or fell below the minimum allowed value of 59.3 Hz for greater than 6 cycles. This fault is auto-clearing.
Fault Code Descriptions Table 4-1 Fault Codes Fault Type Error Code Fault Source(s) H=Hardware S=Software 0013 AC Voltage High 0014 Fault Description Possible Causes S This fault indicates that the utility grid voltage is above or rose above the maximum allowed value of 110% of nominal Vac for greater than 2 seconds, or 137% of nominal Vac for greater than 2 cycles. This fault is auto-clearing.
Troubleshooting Table 4-1 Fault Codes Fault Type Error Code Fault Source(s) H=Hardware S=Software 0017 Phase Error 0020 PV Over-Current Fault Description Possible Causes S This fault indicates that the PV225S has detected an incorrect phase rotation of the incoming AC grid voltage. This condition is indicative of a power conductor termination error, resulting in improper phasing sequence. • AC power conductors terminated at S1-2T1, S1-4T2, and S1-6T3 are improperly phased.
Fault Code Descriptions Table 4-1 Fault Codes Error Code XX32 Fault Type Fault Source(s) Right Matrix Over Current H=Hardware S=Software S Fault Description Possible Causes This fault indicates that the PV225S has detected that the AC current on one or more phases of the inverter output has exceeded the maximum allowed value of 712 Arms.
Troubleshooting Table 4-1 Fault Codes Fault Type Error Code Fault Source(s) H=Hardware S=Software 0041 State Invalid 0042 Fault Description Possible Causes S The state machine implemented within the CCU2 system software governs the operation of the PV225S. This fault indicates that the PV225S has detected an unknown system variable and has encountered an invalid state.
Fault Code Descriptions Table 4-1 Fault Codes Fault Type Error Code Fault Source(s) H=Hardware S=Software 0048 Bad Memory XX50 Left Matrix Gate Fault Description Possible Causes S This fault indicates that the PV225S has detected that the SRAM DIMM on the CCU2 controller board has failed. The CCU2 performs a series of tests to confirm the validity of the SRAM and the memory module has produced errors.
Troubleshooting Table 4-1 Fault Codes Fault Type Error Code Fault Source(s) H=Hardware S=Software XX51 Right Matrix Gate S Fault Description Possible Causes The CCU2 controller sends digitized timing signals for gating the IGBT’s via the IPM driver board and bidirectional fiber optic communication. This fault indicates that the PV225S has detected that an IGBT gate drive fault has occurred in the right matrix.
Fault Code Descriptions Table 4-1 Fault Codes Error Code XX61 Fault Type Fault Source(s) Right Matrix Temperature H=Hardware S=Software S Fault Description Possible Causes This fault indicates that the PV225S has detected that the temperature of the right IGBT matrix aluminum heatsink has exceeded the maximum allowed value of 95 °C.
Troubleshooting Table 4-1 Fault Codes Fault Type Error Code Fault Source(s) H=Hardware S=Software 0080 Left Matrix Not ON S 0081 0084 0085 4–12 Right Matrix Not ON S Left Matrix Not OFF S Right Matrix Not OFF S Fault Description Possible Causes This fault indicates that the PV225S has detected that the left IGBT matrix (FPGA) was not enabled after having sent a command for it to turn on. The CCU2 sends an acknowledge bit to confirm the command is received.
Fault Code Descriptions Table 4-1 Fault Codes Fault Type Error Code Fault Source(s) H=Hardware S=Software F000 Shipping Software S This fault indicates that the PV225S has detected that the CCU2 controller board has shipping software installed. This software is not operational software. The correct system software for the PV225S must be downloaded into the CCU2 controller board.
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5 Preventative Maintenance Chapter 5, “Preventative Maintenance” contains information and procedures for performing preventative maintenance on the PV225S 225 kW Grid-Tied Photovoltaic Inverter.
Preventative Maintenance Maintenance Safety Prior to following any Maintenance Procedures, follow the System Shutdown and Lock-out and Tag procedure. Operational Safety Procedures Never work alone when servicing this equipment. A team of two is required until the equipment is properly de-energized, locked-out and tagged, and verified deenergized with a meter. Thoroughly inspect the equipment prior to energizing. Verify that no tools or equipment have inadvertently been left behind.
Maintenance Safety Lockout and Tag Safety requirements mandate that this equipment not be serviced while energized. Power sources for the PV225S must be locked-out and tagged prior to servicing. Each energy source should have a padlock and tag installed on each energy source prior to servicing. WARNING: Shock Hazard Review the system schematic for the installation to verify that all available energy sources are de-energized. DC bus voltage may also be present.
Preventative Maintenance AC Ground Bar (TB1) to be used for the Chassis Ground TB7 TB6 TB5 Figure 5-1 Inverter AC Terminal Locations in the Main Inverter Enclosure AC Interface Enclosure Enlargement of Terminal Connectors in the AC Interface Enclosure TB11 S1-2T1 (A phase) TB12 S1-6T3 (C phase) S1-4T2 (B phase) AC Interface Enclosure Figure 5-2 Utility AC Terminal Connections in the AC Interface Enclosure 5–4 152607
Maintenance Safety PV POSitive (S2-6) PV NEGative (K2-6T3) PV GrouND (TB4) Figure 5-3 PV Terminal Locations 152607 5–5
Preventative Maintenance Periodic Maintenance Xantrex Technology recommends that the following preventative maintenance procedures be carried out on the PV225S. Monthly Intervals or As Required Perform the following preventative maintenance tasks on a monthly basis or as required. Aluminum Extrusion Heatsinks ❐ Inspect the aluminum extrusion heatsinks and external cooling fans for accumulation of dirt and debris.
Periodic Maintenance Six-month Intervals Perform the following preventative maintenance tasks on a six-month basis or as required. Enclosure Seals ❐ Inspect the enclosure access panel seal. If damaged, replace with equivalent closed cell foam gasket. Call your Xantrex Technology distributor for factory replacements or specifications. Electrical Connections ❐ Inspect the condition of all wiring within and interfacing to the PV225S.
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A Specifications Appendix A provides the environmental and electrical specifications for the PV225S 225 kW Grid-Tied Photovoltaic Inverter.
Specifications System Specifications The PV225S has been designed for photovoltaic power systems, which operate within the following specifications. CAUTION: Equipment Damage Operation of the PV225S in a manner other than specified in this manual may cause damage to the PV225S and other system components and will void the terms of the warranty. Environmental Specifications The following environmental specifications are the same for both models of the PV225S 225 kW Grid-Tied Photovoltaic Inverter.
System Specifications Electrical Specifications Table A-2 provides the AC and DC specifications for the PV225S. Table A-2 Electrical Specifications Specification PV225S-480-P Nominal AC Input Voltage (+10% to -12% acceptable range) 480 Vac (422 to 528 Vac) Maximum AC Output Current 271 Arms Nominal AC Input Frequency 60 Hz (+0.5 to -0.7 Hz acceptable range) (59.3 to 60.
Specifications Wire Gauge and Torque Requirements Table A-4 provides acceptable wire gauges, bolt sizes, and torque values for AC terminal connections. Table A-4 AC Terminal Wire Gauge, Bolt Size, and Torque Values AC Terminal Connections Acceptable Wire Size Range (both models) Bolt (Hardware) Size Torque Requirements TB1 (Chassis Ground) 500 MCM to #4 AWG (1 stud per pole) 3/8-16 420 in-lb (47.5 Nm) TB12 (System Ground) 500 MCM to #4 AWG (1 stud per pole) 3/8-16 420 in-lb (47.
Appendix A Schematics Figure A-1 Electrical Diagram (sample) 152607 A-5
Schematics Appendix A 6 5 4 3 2 1 REVISIONS 3RD ANGLE PROJECTION D D C C B B A A CONFIDENTIAL INFORMATION OF XANTREX TECHNOLOGY INC. COPYRIGHT 2004 XANTREX TECHNOLOGY INC.. THIS DOCUMENT IS THE PROPERTY OF XANTREX TECHNOLOGY INC., AND SHALL NOT BE REPRODUCED, COPIED, OR USED AS THE BASIS FOR THE MANUFACTURE OR SALE OF EQUIPMENT, WITHOUT THE EXPRESS WRITTEN PERMISSION OF: XANTREX TECHNOLOGY INC. TOLERANCES: (UNLESS OTHERWISE SHOWN) X.XX X.XXX ANGLES ± .02 ± .005 ± 1.
Appendix A Schematics 6 5 4 3 1 2 REVISIONS: SEE SHEET 1 3RD ANGLE PROJECTION D D C C B B A A TITLE: SCHEMATIC, SYSTEM, PV225S-480-P SIZE DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SHOWN 6 5 4 3 2 REV. DWG No.
Schematics Appendix A 6 5 4 3 2 1 REVISIONS: SEE SHEET 1 3RD ANGLE PROJECTION D D C C B B A A TITLE: SCHEMATIC, SYSTEM, PV225S-480-P SIZE DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SHOWN 6 5 4 3 2 REV. DWG No.
Warranty and Product Information Xantrex Limited Warranty PV225S GRID TIE INVERTER (PV SERIES INVERTER) 1. What does this warranty cover and how long does it last? This Limited Warranty is provided by Xantrex Technology Inc. (“Xantrex”) and covers defects in workmanship and materials in your PV Series Inverter. This warranty lasts for a Warranty Period of 5 years from the date of purchase at point of sale to you, the original end user customer. 2.
Warranty and Return 4.
Warranty and Return PRODUCT REGISTRATION To ensure the fastest possible service, please ensure your system information submitted to Xantrex. Please fill the required information in and send a copy of this page to Xantrex Technology Inc. along with a copy of the GUI Commissioning File. Fax number: 925 455 0382 Mail to: Xantrex Technology Inc.
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Index A I AC Interface Enclosure 1–8 Accumulated Values 1–18 Anti-Island Protection 1–5 Auto-restart Feature 2–23 Autorun 2–26 Inductor Enclosure 1–7 Installation 2–28 integrated controller 1–2 Internal Metrics 1–18 Isolation Procedure 5–2 C L Clearing Faults Manually 4–3 Command Prompt 2–27 Commissioning 3–2 Communication Enclosure 1–9 Communications 2–25 Configurable Parameters 1–18 Controls 1–10 Converter Control Unit (CCU2) 1–7 Lockout and Tag 5–3 D On/Off Switch 1–11 Operating States 2–4 Fault
Index Power Distribution Panel 1–7 Power Electronics Matrix 1–7 PV Ground Fault Detection 1–5 R Remote Monitor and Control Features 1–18 Remote/LAN Connection 2–31 Running the GUI 2–31 S Self-protection features 1–2 Shutdown 2–24 Specifications A–2 Electrical A–3 Environmental A–2 Over Voltage, Under Voltage and Frequency Ranges A–3 Startup 2–24 System Operation 2–2 T Three-phase power conversion system 1–2 Torque and Wire Gauge Specifications A–4 Transformer Enclosure 1–8 IX–2 152607
Xantrex Technology Inc. 1 800 670 0707 Tel toll free NA 1 360 925 5097 Tel direct 1 800 994 7828 Fax toll free NA 1 360 925 5143 Fax direct customerservice@xantrex.com www.xantrex.
