Eaton Power Xpert Solar 1500 Instruction Manual

Power Xpert Solar 1500/1670 kW Inverter
Utility-Scale Photovoltaic Inverter
Installation and Operation
User Manual
Effective October 2014
New Information

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Disclaimer of Warranties and Limitation of Liability
The information, recommendations, descriptions and safety notations in this document are
based on Eaton Corporation’s (“Eaton’s”) experience and judgment and may not cover all
contingencies. If further information is required, an Eaton sales office should be consulted.
Sale of the product shown in this literature is subject to the terms and conditions outlined in
appropriate Eaton selling policies or other contractual agreement between Eaton and the
purchaser.
THERE ARE NO UNDERSTANDINGS, AGREEMENTS, WARRANTIES, EXPRESSED OR
IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR
MERCHANTABILITY, OTHER THAN THOSE SPECIFICALLY SET OUT IN ANY EXISTING
CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE
OBLIGATION OF EATON. THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME
PART OF OR MODIFY ANY CONTRACT BETWEEN THE PARTIES.
In no event will Eaton be responsible to the purchaser or user in contract, in tort (including
negligence), strict liability or otherwise for any special, indirect, incidental or consequential
damage or loss whatsoever, including but not limited to damage or loss of use of equipment,
plant or power system, cost of capital, loss of power, additional expenses in the use of
existing power facilities, or claims against the purchaser or user by its customers resulting
from the use of the information, recommendations and descriptions contained herein. The
information contained in this manual is subject to change without notice.
Cover Photo: Power Xpert®Solar 1500/1670 kW Inverter

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Scope of the Manual
Target Audience
This manual describes the installation, operation, and maintenance of the Eaton Power Xpert
Solar 1500/1670 kW Inverters. This manual is intended for professionals working in the
photovoltaic industry. The information provided will enable Architects, Consultants,
Contractors, Engineers, Solar Integrators, and Utilities to successfully specify, order,
design-in, install, commission, operate, and maintain the inverter.
This equipment, its installation, operation, and maintenance is intended for qualified
personnel who are licensed and trained for electrical-power systems ranging to 35 kV volts
AC, and 1000 volts DC. This manual addresses the inverter specific input DC and output
AC voltages.
Product Usage
Eaton Power Xpert Solar 1500/1670 kW Inverter is intended for conversion of
photovoltaic-module energy into alternating-current for grid-tie applications. Usage
other than as intended is prohibited, voiding the warranty and certification.

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Support Services
The goal of Eaton is to ensure your greatest possible satisfaction with the operation of our
products. We are dedicated to providing fast, friendly, and accurate assistance. That is why
we offer you so many ways to get the support you need. Whether it’s by phone, fax, or email,
you can access Eaton’s support information 24 hours a day, seven days a week. Our wide
range of services is listed below.
Please contact your local distributor or sales representative for product specification,
availability pricing, and ordering. Product-application assistance is available through these
channels.
Website
Use the Eaton website to find product information, directly. You can also find information on
local distributors or Eaton’s sales offices.
Product Website
www.eaton.com/powerxpertsolar
●Photovoltaic Inverters
www.eaton.com/solar
●Photovoltaic Balance of System Products
EatonCare Customer Support Center
Call the EatonCare Support Center if you need assistance with placing an order, stock
availability or proof of shipment, expediting an existing order, emergency shipments, product
price information, returns other than warranty returns, and information on local distributors or
sales offices.
Voice: 855-ETN-SOLR (386-7657)
(8:00 a.m.–6:00 p.m. EST)
FAX: [phone]
After-Hours Emergency: 800-543-7038
(6:00 p.m.–8:00 a.m. EST)
Technical Resource Center
Voice: 877-ETN-CARE (386-2273)
(8:00 a.m.–5:00 p.m. EST)
FAX: [phone]
email: [email protected]
Photovoltaic-Inverter Specific Contact Information
Eaton
901 S 12th Street
Watertown, WI 53094
United States

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Table of Contents
DEFINITIONS, SAFETY, AND LIMITATIONS
Read these Instructions FIRST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Save These Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Definitions and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
POWER XPERT SOLAR 1500/1670 KW INVERTER
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product Information and Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inverter Overview and Highlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Major Components and Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION INSTRUCTIONS
Delivery Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Unloading and Moving Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Anchoring Requirements—Concrete Pad and Seismic . . . . . . . . . . . . . . . . . . . 16
DC Input Fuse Options—Re-Combiner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ELECTRICAL CONNECTIONS
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DC Circuit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Inverter AC Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Neutral and Equipment Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Phase Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Grounding Conductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Grounding Electrode Terminal and Conductor . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Positive-Ground Photovoltaic Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INVERTER OPERATION
Pre-Commission Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Energize and Operation Procedure: Automatic Operation . . . . . . . . . . . . . . . . . 30
De-Energize Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Interactive Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Operational States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
MAINTENANCE
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
TROUBLESHOOTING
Identifying Inverter Faults and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Inverter Response to Faults and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Troubleshooting Ground-Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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Table of Contents, continued
GLOSSARY
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
APPENDIX A
Power Xpert Solar Electrical, Mechanical and Equipment Specifications . . . . . 65
APPENDIX B
Flex Bus Kit: Throat Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
APPENDIX C
Step-Up Transformer Sensor Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
APPENDIX D
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
APPENDIX E
Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
APPENDIX F
Enclosure Lifting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
APPENDIX G
Customer External Load-Power Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . 76
APPENDIX H
Maintenance Schedule Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
APPENDIX J
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

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List of Figures
Figure 1. Symbols and Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 2. DANGER—WARNING—CAUTION—NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 3. Power Xpert Solar Inverter Rating Label (Typical) . . . . . . . . . . . . . . . . . . . . . . 5
Figure 4. Power Xpert Solar 1500/1670 kW Inverter Diagram . . . . . . . . . . . . . . . . . . . . 6
Figure 5. Major Components Diagram: Inverter and Step-Up Transformer . . . . . . . . . . 8
Figure 6. Power Xpert Solar Inverter with Step-Up Transformer . . . . . . . . . . . . . . . . . . 8
Figure 7. Power Xpert Solar: Inverter Power Module and Power Stacks . . . . . . . . . . . . 11
Figure 8. Schematic of the Ventilation-Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 9. Mounting of Lifting Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 10. Mounting of Cover Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 11. Inverter Transport by Lift Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 12. Inverter Transport by Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 13. Inverter Cabinet Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 14. Anchoring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 15. Inverter Conductor Entry-Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 16. Inverter and Transformer Conductor Entry Locations . . . . . . . . . . . . . . . . . . 18
Figure 17. Electrical Connections, Power Xpert Solar 1500/1670 kW Inverter . . . . . . . . 20
Figure 18. PV Conductor Terminations (Typical)—Positive and Negative Connections . 21
Figure 19. Typical Mounting with MV Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 20. Phase Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 21. AC Output Phase Connections: Throat Connection Details . . . . . . . . . . . . . 24
Figure 22. DC Section: 24 Input-Circuit options, Illustrated PV Input Connections . . . . 26
Figure 23. DC Section Grounding Bus and Grounding Electrode Terminal . . . . . . . . . . 26
Figure 24. AC Section Equipment Grounding Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 25. Accessory Power Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 26. Inverter AC Cabinet Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 27. HMI Menu Display Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 28. Power Xpert Solar Machine-State Transition Diagram . . . . . . . . . . . . . . . . . 46
Figure 29. The GFDI Connection Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 30. Flex Bus Kit: 84-37413-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Figure 31. Example of Available Step-Up Transformer Monitoring . . . . . . . . . . . . . . . . . 70
Figure 32. Enclosure Lifting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 33. Location of CB4 in the Electrical Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

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List of Tables
Table 1. Word Meanings: “shall,” “may,” “must,” and “should” . . . . . . . . . . . . . . . . . . 1
Table 2. Standard Inverter Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Table 3. DC Input Fuse Re-Combiner Options:
Power Xpert Solar 1500/1670 kW Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Table 4. Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Table 5. Inverter Minimum and Required Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Table 6. Re-Combiner Input Options: Power Xpert Solar 1500/1670 kW Inverter . . . . . 17
Table 7. Fasteners and Sequence for Conductor Termination . . . . . . . . . . . . . . . . . . . . . 21
Table 8. 3-Wire Connection—Inverter Point-of-Common Coupling Interface . . . . . . . . . 24
Table 9. 30-Day, 6-Month and Annual Inspection and Maintenance . . . . . . . . . . . . . . . 40
Table 10. Fault and Warning Types: Actions and Resolution . . . . . . . . . . . . . . . . . . . . . . 44
Table 11. Critical Faults: CRITICAL FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Table 12. Non-Critical Faults: FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Table 13. Warnings That Become Faults: WARNING RFAULT . . . . . . . . . . . . . . . . . . . 49
Table 14. Warnings That Cannot Become Faults: FAULT R. . . . . . . . . . . . . . . . . . . . . 54
Table 16. Inverter Inhibit Status: INHIBIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Table 15. Alerts That Signal Inverter Service Is Required: NOTIFY . . . . . . . . . . . . . . . . 55
Table 17. Power Xpert Solar Electrical,
Mechanical and Equipment Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Table 18. Grid-Tie Settings: Protection Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Table 19. Step-Up Transformer Sensor Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Table 20. DC Section Electrical Connection Torque Values . . . . . . . . . . . . . . . . . . . . . . 71
Table 21. AC Section Electrical Connection Torque Values . . . . . . . . . . . . . . . . . . . . . . . 71
Table 22. Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Table 23. Inverter Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Table 24. Maintenance Schedule Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

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