PV Powered 1100 User manual

Grid-Tied Residential Inverters
Installation and Operation Manual
PV Powered Grid-Tied Residential Inverters
INSTALLATION & OPERATION MANUAL
80801.3.0

Grid-Tied Residential Inverters
Installation and Operation Manual
i
PREFACE
Preface
PV Powered
PV Powered designs, manufactures, and markets the solar power industry’s most
reliable photovoltaic solar inverter solutions. We’ve assembled a highly experienced
solar power electronics design team. Our vision is to spur the widespread adoption and
success of solar power, by assisting our distributors, dealers and installers in this dynamic
market while ensuring that our products are the best supported, easiest to install, and
most reliable solar inverters in the industry. Our innovative approach to performance
monitoring provides secure and easy access to system performance and inverter status
over the Internet.
Contact Information
PV Powered, Inc.
150 SW Scalehouse Loop
Bend, OR 97702
Tel: [phone]
Customer Service and Technical Support: 1-877-312-3832
Fax: [phone]
www.pvpowered.com
email: [email protected]

ii
DANGER
The Danger statement is used to inform the installer/operator of a situation requiring
the utmost attention. Failure to heed this warning will result in serious injury or death to
personnel and destruction of equipment.
!
WARNING
The Warning statement is used to inform the installer/operator of a situation requiring seri-
ous attention. Failure to heed this warning may result in serious injury or death to person-
nel and destruction of equipment.
!
CAUTION
The Caution statement is used to inform the installer/operator of a situation requiring atten-
tion. Failure to heed this Caution may result in injury to personnel and damage
to equipment.
!
Revisions and Certification
For applicability of technical information with your specific product, contact PV
Powered Customer Service and Technical Support at [email protected].
Safety Information and Conventions
Designation of Danger, Warning and Caution

Grid-Tied Residential Inverters
Installation and Operation Manual
iii
Acronyms and Abbreviations
A/D Analog to Digital Converter
ANSI American National Standards Institute
CFM Cubic Feet per Minute
DSP Digital Signal Processor
EMI Electromagnetic Interference
ESD Electro Static Discharge
GFDI Ground Fault Detector Interruptor
IEEE Institute of Electrical and Electronics Engineers
IGBT Insulated Gate Bipolar Transistor
LOTO Lockout Tagout
MCM 1000 circular mils utilized in wire sizing
MPPT Maximum Power Point Tracking
NEC National Electric Code
NFPA National Fire Protection Association
PCB Printed Circuit Board
PLL Phase Lock Loop
PPE Personal Protective Equipment
PV Photovoltaic
PWM Pulse Width Modulation
VFD Vacuum Fluorescent Display

iv
Document Copyright
Grid Tied Residential Inverter Installation and Operations Manual (Models 1100, 2000,
2500, 2800, 3000, 3500, 4600, 4800, 5200) ©2008 PV Powered. All rights reserved.
This manual may not be reproduced or distributed without written permission from PV
Powered.

Grid-Tied Residential Inverters
Installation and Operation Manual
v
TABLE
of CONTENTS
Table of Contents
1. Introduction and Safety.................................................................................................1
1.1 General Safety................................................................................................................1
1.2 FCC Compliance............................................................................................................2
2. Planning ..........................................................................................................................3
2.1 Select a Location for the Inverter ..................................................................................3
2.2 Mounting the Inverter ...................................................................................................4
3. Installation......................................................................................................................5
3.1 Mounting and Anchoring ...............................................................................................5
3.2 Electrical Connections ...................................................................................................7
4. Operations ....................................................................................................................17
4.1 Start Up Procedures .....................................................................................................17
4.2 Inverter Front Panel Status Indicators ........................................................................18
5. Maintenance and Troubleshooting.............................................................................21
5.1 Red and Green LED Lights ON ..................................................................................21
5.2 Ground Fault ................................................................................................................21
5.3 Displayed Fault Codes .................................................................................................22
6. Limited Warranty ........................................................................................................25
6.1 Term of Coverage ........................................................................................................25
6.2 Coverage ......................................................................................................................25
6.3 What is Not Covered....................................................................................................26
6.4 Disclaimer and Limitation of Liability ........................................................................26
6.5 Arbitration....................................................................................................................27
6.6 Miscellaneous Provisions ............................................................................................28
7. Return Procedure.........................................................................................................29
7.1 Information about Your System ...................................................................................29
Appendix A- Specifications ...............................................................................................31
Index ..................................................................................................................................33

vi
Danger Symbol ................................................................................................................... ii
Warning Symbol .................................................................................................................ii
Caution Symbol .................................................................................................................. ii
Figure 3-1 V-shaped Mounting Bracket..............................................................................5
Figure 3-2 T-shaped Mounting Bracket ..............................................................................6
Figure 3-3 Inside Screw (below the power board) .............................................................6
Figure 3-4 Inverter with Mounting Bracket in Place..........................................................7
Figure 3-5 Communications, AC and DC Ports .................................................................9
Figure 3-6 System Block Diagram Showing Single-Point Ground..................................11
Figure 3-7 Example Ground Fault Message .....................................................................11
Figure 3-8 AC and PV Grounding ....................................................................................12
Figure 3-9 AC Wiring for the Line 1, Line 2 and Ground Wires......................................13
Figure 3-10 Positive and Negative Jumpers .....................................................................15
Figure 3-11 Power Board Connections.............................................................................16
Figure 4-1 Normal Startup Screens .................................................................................20
Figure 4-2 Running Screens .............................................................................................20
Figure 5-1 Faulted.............................................................................................................22
Figure 5-2 Starting Up From a Faulted State....................................................................22
Figure 5-3 AC Voltage High/DC Voltage Low Fault........................................................23
Figure 5-4 Power Low Fault.............................................................................................23
Table 3-1 Required Branch Circuit Protection....................................................................8
Table 3-2 Inverter Voltage Frequency Limits .....................................................................8
Table 3-3 Grounding Electrode Sizing .............................................................................10
Table 3-4 PV Open Circuit Voltages.................................................................................14
Table 5-1 Fault Codes .......................................................................................................24
Table A-1 Specifications ............................................................................................. 31-32
Table A-2 Abnormal Specifications ..................................................................................32
List of Figures and Tables

Grid-Tied Residential Inverters
Installation and Operation Manual
1
1. Introduction and Safety
1. INTRODUCTION
& SAFETY
CAUTION
All electrical installations should be done in accordance with local electrical•
codes and the National Electrical Code (NEC), ANSI/NFPA 70.
Before connecting the inverter to the electrical utility grid, your utility•
company must grant approval. Only qualified electricians should make the
connection.
When exposed to light, photovoltaic (PV) arrays create electrical energy that•
could cause a hazardous condition. To avoid this, completely cover the surface
of all PV arrays with opaque (dark) material before wiring them.
The inverter contains no user-serviceable parts. Refer maintenance to qualified•
service personnel.
Do not touch the heat sink located at the top of the inverter, temperatures can•
exceed 158°F (70oC).
!
The PV Powered Grid Tied Residential Inverters is a utility interactive inverter for
photovoltaic (PV) systems.
The inverter is tied to an electrical source provided by the local utility company as well
as to the PV system. The inverter contains everything needed to convert the DC voltage
generated by the PV arrays into the AC voltage required to power a house.
This manual provides information necessary for the successful installation and use of the
PV Powered Grid Tied Residential Inverters.
1.1 General Safety
IMPORTANT SAFETY INSTRUCTIONS: This product has been engineered and manu-
factured to ensure your personal safety. Improper use may result in potential electrical
shock or burns. Read and follow all instructions for installation, use and servicing of
this product. Read all safety warnings before installing or operating the inverter.
NOTE: A locking tab has been designed into Grid Tied Residential Inverters
It is the sole responsibility of the end user to provide a locking
mechanism that utilizes the tab and secures the cover on the
inverter.
SAVE THESE INSTRUCTIONS: This manual contains important instructions
for the Grid Tied Residential Inverters that must be followed during installation
and maintenance of the Grid Tied Residential Inverters.

2
CAUTION
Read all safety warnings and instructions before installing or operating the inverter.
!
1.2 FCC Compliance
The Grid Tied Residential Inverters have been tested and found to pass FCC Class B
radio interference standards with proper installation of the inverter. This is not a guarantee
that there will be no interference at every installation. If you notice interference at your
installation, try the following potential solutions:
Move or re-orient the affected device.•
Increase the distance between the devices.•
Connect the device to a different AC circuit.•

Grid-Tied Residential Inverters
Installation and Operation Manual
3
2. PLANNING
2. Planning
2.1 Select a Location for the Inverter
When choosing a location for the inverter, consider the following criteria:
The inverter is suitable for both indoor and outdoor installation; the inverter•
enclosure has a NEMA 3R rating.
The optimum location of the inverter is outside, shielded from direct expo-•
sure to sunlight (i.e. not on the south facing side of the building).
The heat sink temperatures can exceed 158°F (70• oC). The inverter must be
installed so that people will not touch the top of the unit.
The inverter is designed to handle the temperature extremes of most climates.•
The operating and non-operating environmental ambient temperature range
is -15°F to 105°F (-25oC to 40oC).
Location and Clearances
The following clearances are recommend for proper placement of the inverter:
A minimum of 36 inches between the bottom of the inverter box and the•
ground.
A minimum of 12 inches above the heat sink.•
Visibility of the operating LEDs and display located at the top front of the
inverter box should also be considered.
If the inverter is installed in an enclosed space, adequate ventilation must be
provided.

44
WARNING
Before drilling holes to mount the inverter, verify that there are no electrical wires or
plumbing in the area
!
2.2 Mounting the Inverter
The inverter should be mounted vertically to a flat, solid surface such as wallboard,
concrete, or wood siding. It should be located near the PV arrays to minimize the DC
wire length.
The bracket provided makes mounting the inverter quick and simple. The two screw
holes at either end of the top of the bracket are 16 inches apart and are designed to
match standard stud locations. Anchor the bracket to the wall studs once you have
located them.

Grid-Tied Residential Inverters
Installation and Operation Manual
5
3. INSTALLATION
3. Installation
3.1 Mounting and Anchoring
Models PVP4600, PVP4800 and PVP5200
Locate the wall studs in the desired location and align the mounting bracket over the1.
studs. Mark the mounting holes. Ensure that locations A and B (see Figure 3-1) are
aligned over the wall studs.
VERIFY THE BRACKET IS LEVEL.2. Ensure points A and B are aligned with the wall
studs. Drill 1/8” pilot holes for the screws.
Use heavy-duty 1/4 inch x 2 inch coarse thread lag screws to secure points A and
B to the wall.
Use an 1/8” screw to secure point C (see Figure 3-1).
AB
C
Figure 3-1 V-shaped Mounting Bracket
Carefully hang the inverter on the upper part of the bracket. The hooks located at the3.
rear of the inverter should hang over the bracket.
Verify inverter is level.4.
For the PVP4600, PVP4800, or PVP5200 models, remove the four screws on the lower5.
lid to access the electrical connections.
There are no user serviceable parts in the upper portion of the inverter.
Locate the two inverter mounting holes below the power board (see Figure 3-2).6.
Insert the two mounting screws through the inverter and tighten securely.

6
Models PVP1100, PVP1100EVR, PVP2000, PVP2000EVR, PVP2500, PVP2800, PVP3000, PVP3500
Locate the wall studs in the desired location and align the mounting bracket over a single1.
stud. Mark the mounting holes ensuring holes C, D, E and F are directly over the single
stud (see Figure 3-2).
VERIFY THE BRACKET IS LEVEL. Ensure points C through F are aligned with the2.
wall studs. Drill 1/8” pilot holes for the screws.
Use heavy-duty 1/4” x 2” coarse thread lag screws to secure points C through F to
the wall.
Use an 1/8” screw to secure points A and B (See Figure 3-2).
A
E
D
CB
F
Mounting Hole
Figure 3-2 Mounting Bracket
Carefully hang the inverter on the upper part of the bracket. The hooks located at the rear3.
of the inverter should hang over the bracket.
Verify inverter is level.4.
Remove the front cover of the inverter by unscrewing the four cover screws located5.
around the front perimeter of the inverter.
Locate the inverter mounting hole below the power board (see Figure 3-3). Insert the6.
mounting screw through the inverter and tighten securely.
Figure 3-3 Inside Screw (below the power board)

Grid-Tied Residential Inverters
Installation and Operation Manual
7
CAUTION
The National Electrical Code (NEC) requires that the inverter be connected to a
dedicated circuit with no other outlets or devices connected to the same circuit.
See NEC Section 690-64(b)(1). The NEC also places limitations on the size of the
inverter and the manner in which it is connected to the utility grid. See NEC Section
690-64(b)(2).
To reduce the risk of fire, connect the inverter to the appropriate size breaker (See
Table 3-1 for required branch circuit protection). Maximum branch-circuit over-
current protection calculated in accordance with the National Electrical Code (NEC),
ANSI/NFPA 70.
!
Figure 3-4 Inverter with Mounting Bracket in Place
NOTE: Leave the inverter cover off to allow for electrical connection
described in 3.2 Electrical Connections.
3.2 Electrical Connections

8
Inverter Model Circuit Breaker Required
PVP1100 1 pole 15A
PVP2000 2 pole 15A
PVP2500 2 pole 20A
PVP2800 2 pole 20A
PVP3000 2 pole 20A
PVP3500 2 pole 20A
PVP4600 2 pole 30A
PVP4800 2 pole 30A
PVP5200 2 pole 30A
Table 3-1 Required Branch Circuit Protection
Inverter Voltage and Frequency Limits
The inverter is factory-calibrated to the voltage and frequency limits specified in Table
3-2. This adjustable range can be set by PV Powered field technicians.
Condition Factory
Setting
Adjustable Range
(VAC) Models 2500,
3500, 4600, 4800, 5200
Adjustable Range
(VAC) Models 1100,
2000, 2800, 3000
Maximum
Trip Time(s)
Voltage phase high 132.0 132.0 - 138.0 132.0 - 142.0 < 1 second
Voltage phase low 105.6 99.6 - 105.6 95.6 - 105.6 < 2 seconds
Voltage phase fast high 144.0 144.0 - 150.0 144.0 - 156.0 < 160ms
Voltage phase fast low 60.0 54.0 - 60.0 < 60.0 < 160ms
Voltage high line to line
(240V inverters)
264.0
Voltage low line to line
(240V inverters)
211.0
Voltage high line to line
(208V inverters)
228.8
Voltage low line to line
(208V inverters)
183.0
Line frequency low 59.3 Hz n/a < 160ms
Line frequency high 60.5 Hz n/a < 160ms
Table 3-2 Inverter Voltage Frequency Limits

Grid-Tied Residential Inverters
Installation and Operation Manual
9
Figure 3-5 Communications, AC and DC Ports
WARNING
Electrical connections must be completed in accordance with local electrical codes
and the National Electrical Code (NEC), ANSI/NFPA 70. Use 10 AWG, minimum
90oC (194oF), copper wire for all inverter electrical connections. Voltage drop as well
as other considerations may dictate using larger wire sizes.
!
WARNING
Make sure the main breaker in the main utility breaker box is switched OFF before
wiring the inverter. This breaker should be switched ON only after all wiring has been
completed as described in this manual.
!
WARNING
Follow the order listed below to wire the inverter. Failure to do so may result in
hazardous voltages or disconnection of contacts.
!
CAUTION
The input and output circuits are isolated from the enclosure. System grounding,
when required by Sections 690-41, 690-42, and 690-43 of the National Electric Code
(NEC), ANSI/NFPA 70-1999, is the responsibility of the installer.
!
NOTE: PV Powered recommends sizing wire of one percent voltage drop for
AC and one percent voltage drop for DC.
IMPORTANT: When mounting the inverter outside, use rain-tight or wet-location conduit
hubs that comply with the requirements in the Standard for Fittings for Conduit and Outlet
Boxes, UL 514B.
Terminal connections for the inverter are located inside the inverter on the circuit board at
the bottom of the cabinet. The AC and DC terminals accept wires up to 6 AWG.
Do not proceed with the electrical connection of the inverter until it has been properly
mounted.

10
Separation of Circuits
The lower part of the inverter circuit board is divided into three sections:
The left side is dedicated to the low voltage DC communications.1.
The center is dedicated to the AC.2.
The right side is dedicated to the DC.3.
Each section has two to three knockouts. UL 1741 standard requires a straight run of
wire, with no loops or crossover to the other circuits (sections) and low voltage versus
high voltage in each section.
Left knockouts (up to the divider) are for low voltage communications only1.
(PVM1010 Data Monitoring Module).
Center knockouts are for AC.2.
Right knockouts are for DC.3.
Grounding
A single-point ground connection is located in the lower right-hand side of the inverter
cabinet. This is where the PV array grounding wire is terminated. The AC ground
connection is terminated next to the Line 1 and Line 2 connections on the circuit board.
The PV ground connector is attached to the cabinet with a 10-32 bolt. This ground lug is
provided to allow for the PV safety ground to be bonded to the cabinet. This is the only
place the PV ground should be connected to the inverter.
Do not tie the safety ground to the PV array positive or negative. That would defeat•
the PV ground fault protection circuit. Refer to Figure 3-8 for additional information.
See Table 3-3 for appropriate sizing of the grounding electrode. Use the maximum•
current AC or DC - whichever is larger - and multiply it by 1.25 to get the maximum
current rating per NEC 690.
Maximum
Current Rating
Minimum Size of Grounding
Electrode Conductor AWG
Copper Aluminum
Copper Clad
15 8 6
20 8 6
30 8 6
40 8 6
60 8 6
Table 3-3 Grounding Electrode Sizing

Grid-Tied Residential Inverters
Installation and Operation Manual
11
Line
Filter
Control pcb Power Distribution PCB
DC
Power
Supply
L1
L2
GND
PV GND
20 A SB
System Block Diagram
120/240 VAC
60Hz
PV
DC input
PVP3500 & PVP2500
+
GND
1A
GF Detect Circuit
-
Figure 3-6 System Block Diagram Showing Single-Point Ground
GFI Circuit
The purpose of the Ground Fault Interrupter (GFI) circuit is to detect a ground fault
(unintended current flow from the PV arrays to earth ground).
For the GFI circuit to function as designed, the PV array safety ground must be con-•
nected only at the ground terminals provided.
Bonding the safety ground to the grounded leg of the array anywhere but through the•
inverter will bypass the GFI circuit. This creates an unsafe operating condition.
The GFI works by using a fuse to connect or bond the PV array negative (or the PV•
array positive if using a positively grounded array) to earth ground through the 1A
fuse.
If current is greater than 1A between the grounded array terminal and the earth•
ground, the fuse will “blow”. A “blown” or open fuse will disconnect the PV arrays
from their ground reference and interrupt the ground fault current. In this situation,
the inverter will cease operation and display a fault message as shown in Figure 3-7.
Fault 0400 0000
Ground Fault
Figure 3-7 Ground Fault Message
Figure 3-6 is a schematic representation of the PV Powered single-point grounding. The
front cover is grounded through the cover mounting screws.

If the inverter displays “Ground Fault”, turn OFF the AC and DC to the inverter and refer to
the fault examples in this manual.
PV Ground
Figure 3-8 AC and PV Grounding
Connecting the Inverter to the Electrical Grid
Two circuit boards are located inside the inverter:
The Control Board (at the top of the inverter).1.
The Power Distribution Board (at the bottom of the inverter) with the following2.
terminals:
The AC connection terminal.
The DC connection terminal.
The internal Ground Fault Interrupt fuse.
WARNING: Replace the GFI fuse with the same type and rating of
fuse. The inverter uses only Littelfuse KLKD001 1A/600V.
The inverter is connected to the electrical grid using 3 wires - LINE 1, LINE 2 and
GROUND.
NOTE: To avoid an increase in AC voltage to unacceptable values while the
inverter is exporting power, the grid impedance value at the connection
point should be as low as possible. By keeping the grid impedance
value low, the inverter will achieve higher system efficiency and avoid
nuisance shutdowns. The total impedance of the grid plus the
interconnecting AC wires should be less than 1.25 Ohm.
12
WARNING
Replace the GFI fuse with the same type and rating of fuse. The inverter uses only
Littelfuse KLKD001 1A/600V.
!

Grid-Tied Residential Inverters
Installation and Operation Manual
13
WARNING
Ensure the main 240V (or 208V for the PVP2800 and PVP4600 or 120 for PVP1100
or PVP1100EVR) breaker at the circuit breaker panel is switched OFF before con-
necting to the AC terminal block.
!
To wire the inverter to the main utility grid, follow these steps and refer to Figure 3-9:
Run the conduit from the main breaker panel to the bottom of the inverter. Insert the1.
fitting in the center opening of the inverter and fasten it with a locking nut.
Feed the LINE 1, LINE 2 and GROUND wires through the conduit and into a center2.
opening of the inverter.
Connect the GROUND wire to the terminal marked “earth ground” inside the3.
inverter.
Connect the LINE 2 wire to the terminal marked “line 2” inside the inverter.4.
Connect the LINE 1 wire to the terminal marked “line” inside the inverter.5.
Ensure all connections are wired correctly and properly torqued. Tighten the termi-6.
nal block screws to 0.5 Nm (0.37 ft/lb).
Figure 3-9 AC Wiring for the Line 1, Line 2 and Ground Wires
NOTE: In the PVP1100 units. Line 1 wire is the only phase voltage wire.
LINE 2 is neutral and LINE 3 is the AC GROUND.