PV Powered PVP260kW User manual
97-600100-24-B02
PVP260kW Inverter
INSTALLATION & OPERATION MANUAL
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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.
20720 Brinson Blvd.
PO Box 7348
Bend, OR 97708
Tel: 541-312-3832
Technical Support: 1-877-312-3832
Fax: 541-312-3840
www.pvpowered.com
email: support@pvpowered.com
Document Copyright
PV Powered PVP260kW Inverter Installation and Operation Manual ©2010 PV Powered.
All rights reserved. This manual may not be reproduced or distributed without written
permission from PV Powered.
PREFACE
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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
!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 serious attention. Failure to heed this warning may result in serious
injury or death to personnel and destruction of equipment.
!CAUTION
The Caution statement is used to inform the installer/operator of a situation
requiring attention. Failure to heed this Caution may result in injury to
personnel and damage to equipment.
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PVP260kW Inverter
Installation and Operation Manual
Acronyms and Abbreviations
A/D Analog to Digital Conversion
ANSI American National Standards Institute
CFM Cubic Feet per Minute
DHCP Dynamic Host Configuration Protocol
DNS Domain Name Service
DSP Digital Signal Processor
DVI Digital Video Interface
EMI Electromagnetic Interference
ESD Electro Static Discharge
GFDI Ground Fault Detector Interruptor
IEEE Institute of Electrical and Electronics Engineers
IGBT Insulated Gate Bipolar Transistor
IP Internet Protocol
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
PVM PV Monitoring
PWM Pulse Width Modulation
RMS Root Mean Squared
UL Underwriter’s Laboratory
VAC Voltage Alternating Current
VDC Voltage Direct Current
VFD Vacuum Fluorescent Display
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Table of Contents
CONTENTS
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PVP260kW Inverter
Installation and Operation Manual
List of Figures and Tables
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1. Introduction
1.1 Design Features
The PVP260kW and PVP260kW-LV Inverters are designed to act exclusively as a grid-
tied inverter for photovoltaic (PV) systems. This means the inverter must be tied to the
utility grid and a photovoltaic system in order to operate properly and it is not suitable for
any other applications (such as a battery back-up or wind powered systems). The inverter
contains everything needed to convert the DC voltage generated by a solar array into AC
electrical power. Because the inverter is tied to a local utility source, if local electrical
load exceeds the power generated by the solar array, the grid automatically supplies
the additional electricity needed. Likewise, if the inverter produces more power than is
needed, it feeds the excess power back into the electrical grid.
This manual provides all the information necessary to successfully install and operate the
PVP260kW Inverter.
PVP260kW Models
Two models of the PVP260kW are available: the PVP260 and the PVP260-LV. The
PVP260-LV is identical to the PVP260kW except that it is configured for low voltage
265 VDC input.
Throughout the remainder of this manual, the two models are referred to as the
PVP260kW. All information applies to both models unless stated otherwise.
Easy Installation
The PVP260kW Inverter is built for easy installation. To minimize installation efforts,
this inverter features an integrated isolation transformer and integrated AC and DC
disconnects in a compact single cabinet. The unit can be ordered with a range of DC
subcombiner designs for maximum adaptability for the desired system operating scheme.
Simple, Innovative Design
The PVP260kW Inverter is a fully integrated solution with standard integrated data
monitoring. The modular design enables rapid field service and upgrades. The inverter
can quickly and easily be installed in any preferred location, indoors or out.
Adaptability
The PVP260kW Inverter’s DC Maximum Power Point Tracking (MPPT) range is
295VDC to 500VDC standard, with an optional 265 VDC input on the LV model. The
maximum input voltage is 600VDC.
Versatility
The PVP260kW Inverter is designed for flexibility. It can be used for a range of
commercial applications and it can accommodate most PV system configurations.
INTRODUCTION
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1.2 Product Characteristics
See Appendix A - Specifications for the product specifications information.
1.3 Product Features
The design of the PVP260kW Inverter includes:
Redundant Cooling System
The PVP260kW Inverter is equipped with a redundant cooling system. The variable
speed blowers with built-in backup capabilities enable the unit to remain fully ventilated
even if one of the blowers should fail. Blower status is reported as a warning shown on
the display and through remote monitoring.
Anti-islanding Protection
An advanced anti-islanding monitoring function prevents the inverters from feeding
power to the utility grid in the event of a utility outage.
EMI Output Filters
The PVP260kW Inverter utilizes EMI output filters to prevent electromagnetic
interference.
AC Overcurrent Protection
The PVP260kW Inverter current monitoring system constantly monitors the AC current
within the unit, limiting the inverter current output.
Remote Monitoring
All PV Powered commercial inverters come with a standard Ethernet data acquisition
and communications interface module. With a high speed connection, this module can
provide PV system performance data in the following ways:
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PVP260kW Inverter
Installation and Operation Manual
1.4 Major Components and Functional Parts Descriptions
Front View Rear View
Figure 1-1 PVP260kW Inverter
Main Enclosure
The modular design of the inverter makes it easy to access and service. The main
enclosure (Figure 1-1) is comprised of two main sections:
• AC Sub Panel with AC output filtering, surge protection and AC connection
points.
• Magnetics Compartment contains the isolation transformer and inductors.
Power Module Assembly
The inverter uses Insulated Gate Bipolar Transistors (IGBTs) for converting DC power
into three-phase AC power. The inverter is protected by over-current, over-voltage and
over-temperature detection controls. If a protection system is activated, the power module
will cease power conversion and send an interrupt signal to the Digital Signal Processor
(DSP).
Air Intake
Hood
Power
Module
Assembly
DC
Combiner
Sub Panel
Display
AC Sub
Panel
Revenue
Grade Meter
(optional
feature)
DC Sub
Panel
Isolation
Transformer Inductor
AC Ripple Filter
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Figure 1-2 Power Module Assembly
Figure 1-3 Card Cage Assembly
The Card Cage Assembly (Figure 1-3) is designed to enable fast and easy service and
also acts as an EMI shield to ensure signal integrity on the following four PCBs:
Communications PCB – Provides serial, internet and modbus communications.
2. Power Distribution PCB – Distributes the required logic level voltages for use
throughout the inverter.
3. Controller PCB – Contains a powerful DSP that controls sine wave generation, logic
functions and protection activities. All analog and digital inputs and outputs are
routed to the Control PCB and fed to the DSP.
4. I/O PCB – Provides a central location for a range of input, output and control cir-
cuits.
}Card Cage Assembly
Controller PCB
I/O PCB
Power Distribution PCB
Communications PCB
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PVP260kW Inverter
Installation and Operation Manual
The DSP is very efficient at computing control and signal processing tasks. The DSP also
has built-in on-chip peripherals that include a Pulse Width Modulation (PWM) driver,
Analog to Digital (A/D) converters and other related features.
Active Cooling
The inverters come with blowers which activate as needed to keep the internal
components within preset temperature limits. These blowers are located under the air
intake hood of the inverter.
Housekeeping Transformer
The housekeeping transformer, located in the bottom left of the AC sub panel, is a voltage
conversion device that transforms 480VAC to 120VAC for use within the inverter.
Isolation Transformer
The inverter comes equipped with an integral isolation transformer (Figure 1-1, Rear
View). The isolation transformer is designed for class-leading inverter efficiency.
Inductor
The inductor (Figure 1-1, Rear View) is used to filter the AC waveform generated by the
power module, effectively reducing high frequency noise.
AC Sub Panel
The AC landing, filtering and sense fusing takes place in the AC sub panel (Figure
1-4). The AC sub panel also includes the main load-rated transformer contactors, AC
disconnect, surge modules and the soft-start circuit.
Figure 1-4 AC Sub Panel
AC Disconnect
AC Surge Modules
Soft Start Contactor
AC Line Filter
Comm X PCB
Soft Start Resistors
Main Contactor
Soft Start and AC Sense Fuses
AC Landing Busbars (3)
AC Distribution PCB
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AC Distribution PCB
The AC Distribution PCB (Figure 1-5) is located on the AC sub panel. The AC
Distribution PCB contains:
• Fusing for the AC Sense Circuit and 48 VDC power supply
• Fusing for the optional 24 VDC balance of system power supply
Figure 1-5 AC Distribution PCB
Comm X PCB
The Comm X PCB (Figure 1-6) is located in the AC sub panel just below the AC
Distribution PCB. The Comm X PCB includes the RJ45 Ethernet port that is used to
connect the inverter to the internet. The Comm X PCB also includes a modbus master
port (not enabled), a modbus slave port and a DVI port that is used to connect the Comm
X PCB to the main Communications PCB. A serial port is available for PV Powered
service use only.
AC Sense & DC Power
Supply Fuses
Power Supply Fuses (optional)
Soft Start Fuses
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PVP260kW Inverter
Installation and Operation Manual
Modbus Output (master)
(Not enabled)
Modbus Address
Switch 1 (upper)
Modbus Output (slave)
Ethernet Port
Modbus Address
Switch 2 (lower)
Master Jumpers
with no Jumpers
Installed
Slave Jumpers with
three Jumpers
Installed
Figure 1-6 Comm X PCB
DC Sub Panel
This panel houses the DC disconnect, DC distribution PCB, fuses and integrated fused
subcombiner box.
Figure 1-7 DC Combiner Sub Panel Shown With
16-Circuit Monitoring Subcombiner
DC Disconnect
DC Line Filter
DC Positive Busbar
DC Contactor
Analog to Digital
Converter for Sub
Array Monitoring
(optional)
Fused Subcombiner
(Optional)
DC Negative Busbar
CT for Sub Array
Monitoring
(Optional)
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DC Combiner Sub Panel
The inputs from the PV array are landed in the DC Combiner sub panel. This sub panel
includes the positive, negative and ground busbars. Optional fused subcombiner and
subcombiner monitoring are also located in the DC Combiner Sub Panel if selected.
DC Distribution PCB
The DC Distribution PCB is located on the DC sub panel. It includes the DC voltage
sensing and DC soft start circuit. The DC Distribution PCB also houses the GFDI
(Ground Fault Detector/Interrupter) circuit. The purpose of the GFDI is to detect a ground
fault (unintended current flow from the solar panels to earth ground) and in the event of a
ground fault, stop AC power production.
Figure 1-8 DC Distribution PCB
!WARNING
Risk of Electrical Shock. The GFDI functions using a 5A fuse to connect or
bond the solar array Negative (or the solar array Positive, if using a positively
grounded panel array) to earth ground on the DC Distribution PCB.
If the ground fault current exceeds 5A between the grounded array terminal and the earth
ground, the fuse will open and disconnect the solar panels from their ground reference,
interrupting the ground fault. In this situation, the inverter will cease operation, display a
fault message and the LED on the DC Distribution PCB will illuminate red. If a ground
fault current of 3-5A exists, the inverter will indicate a ground fault warning.
Operator Interface Controls/Vacuum Fluorescent Display
The Vacuum Fluorescent Display (VFD) provides multiple information screens to the
user.
Views and Basic Block Diagram of the Inverter
See
Appendix C - Mechanical Drawings
for multiple views of the inverter.
Table of contents
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