PV Powered StarInverter PVP1100 User manual

PV Powered LLC 11-18-28-704
PVP1100, PVP1800, PVP2800
Installation and Operation Manual
PV Powered
Delivering Tomorrow’s Solar Technology . . . Today

PV Powered LLC 1 11-18-28-704
StarInverter
PVP1100, PVP1800 and PVP2800
Table of Contents
IMPORTANT SAFETY INSTRUCTIONS 2
1.0 INTRODUCTION 3
2.0 INSTALLATION 5
2.1 SELECTING A LOCATION FOR THE STARINVERTER 5
2.2 MOUNTING THE STARINVERTER 6
2.2.A STEPS TO MOUNT THE STARINVERTER 6
2.2.B ATTACHING THE OPTIONAL AC DC DISCONNECT BOX 8
2.3 ELECTRICAL CONNECTION 9
2.3.A GROUNDING 10
2.3.B CONNECTING THE STARINVERTER TO THE ELECTRICAL GRID 11
2.3.C CONNECTING DC WIRES/PV PANELS 13
2.3.D CONNECTING THROUGH THE OPTIONAL AC DC DISCONNECT BOX 15
2.3.E CONNECTING COMMUNICATIONS 16
3.0 OPERATION 17
3.1 START UP PROCEDURES FOR THE STARINVERTER 17
3.2 LED INDICATOR LIGHTS/VACUUM FLUORESCENT DISPLAY 18
3.2.A LED INDICATOR LIGHTS (MODEL PVP1100) 18
3.2.B LED INDICATOR LIGHTS/VACUUM FLUORESCENT DISPLAY (MODELS PVP1800 AND
PVP2800) 19
3.3 PVP COMMAND CENTER 21
3.3.A DATA LOGGING WITH THE PVP COMMAND CENTER 23
4.0 TROUBLESHOOTING 24
5.0 SPECIFICATIONS 26
6.0 LIMITED WARRANTY 27

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IMPORTANT SAFETY INSTRUCTIONS
This product has been engineered and manufactured to ensure your personal
safety. Improper use may result in potential electrical shock or burns. Please
read and follow all instructions for installation, use and servicing of this product.
SAVE THESE INSTRUCTIONS – This manual contains important
instructions for the StarInverter model numbers PVP1100, PVP1800 and
PVP2800 that must be followed during installation and maintenance of the
StarInverter.
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 StarInverter to the electrical utility grid, approval must be
granted by your utility company. Only qualified electricians should make the
connection.
♦ When exposed to light, 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 StarInverter contains no user-serviceable parts. Refer servicing to qualified
service personnel.
♦ Do not touch the heat sink located at the top of the StarInverter. Temperatures
can exceed 158 degrees (70°C).
Please read all safety warnings and instructions before
beginning the installation or operation of the
StarInverter.
SAVE THESE INSTRUCTIONS

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1.0 INTRODUCTION
The PV Powered StarInverter is a utility interactive inverter for photovoltaic (PV) systems.
The StarInverter is tied to an electrical source provided by the local utility company (i.e.
on-grid), as well as to the photovoltaic system. The StarInverter contains everything
needed to convert the DC voltage generated by the solar arrays into the AC voltage
required to power a house. Because the inverter is tied to a local utility source, if a
house’s electrical needs exceed the power generated by the solar arrays, the house
automatically taps into its local power supply for that additional electricity. Likewise, if a
house does not utilize all the power generated by the solar panels, the inverter actually
reverses the flow of electricity (i.e. electricity is fed back into the grid). Think of it as
accumulating credits of electricity with the utility for future use.
The information contained within this manual will provide all the information necessary for
successful installation and use of the StarInverter.
Product Features
Command Center Software
Revolutionary software developed by
PV Powered establishes a new industry
standard for ease of use. Monitor the
status and efficiency of energy
generated by the PV system on screen
and in real time.
Easy Installation
The custom designed mounting
brackets and easy-to-follow
instructions make installation simple
and quick.
Figure 1: PVP Command Center
Simple, Innovative Design
Everything needed to power up the StarInverter is contained within the inverter
box, including AC and DC connections and circuits. Low part count keeps costs
down and simplifies the installation and troubleshooting processes.
Safety Features
The StarInverter is designed for safety. Control power comes from the utility grid,
ensuring that power can never be generated during a utility grid failure. The
output stage transformer guarantees isolation of the utility grid and PV modules.
Expandability
The StarInverter is designed with growth in mind, from residential to commercial
use. Most PV system configurations can be accommodated.
System Flexibility
There are three connection options available with the StarInverter. These options
vary depending on your model. See Figures 2 and 3. Refer to your local utility
provider for specific connection requirements per regulations.

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PVP1100
Option 1 Use the optional PV Powered AC DC Disconnect.
Option 2 Use the optional PV Powered AC DC Disconnect with a utility grade
meter.
Option 3 Use a second party AC and DC Disconnect.
Figure 2: StarInverter PVP1100 Connection Options
PVP1800 and PVP2800
Option 1 Use the DC/GFI Circuit Breakers located inside the inverter.
Option 2 Use the DC/GFI Circuit Breakers inside the inverter with a utility
grade meter.
Option 3 Use a second party AC and DC Disconnect.
Figure 3: StarInverter PVP1800 & PVP2800 Connection Options
Solar Panel
Solar Panel
Solar Panel
Solar Panels
PVP1100
Solar Panel
Solar Panel
Solar Panel
Solar Panels
Solar Panel
Solar Panel
Solar Panel
Solar Panels
AC Load Center
Utility Grid
AC
Disconnect
Connection Option #3
DC
Disconnect
Connection Option #1
PVP1100
AC/DC
Disconnect
Connection Option #2
PVP1100
AC/DC
Disconnect
Solar Panel
Solar Panel
Solar Panel
Solar Panels
PVP1800/2800
Solar Panel
Solar Panel
Solar Panel
Solar Panels
Solar Panel
Solar Panel
Solar Panel
Solar Panels
AC Load Center
Utility Grid
AC
Disconnect
Connection Option #3
DC
Disconnect
Connection Option #1
PVP1800/2800
Connection Option #2
PVP1800/2800

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2.0 INSTALLATION
2.1 Selecting a Location for the StarInverter
In choosing a location for the StarInverter, consideration should be given to the following
criteria:
♦ The heat sink temperatures can exceed 158 degrees (70°C). The StarInverter
must be installed so that the top of the unit is not expected to be contacted by
persons.
♦ The StarInverter is suitable for installation both indoors and outdoors and the
enclosure has been given a NEMA 3R rating.
♦ When the StarInverter is installed outdoors, it should be shielded from rain and
direct sunlight, if possible.
♦ The StarInverter is designed to handle the temperature extremes of most
climates. The operating and non-operating ambient temperature range is from
-25°C to 40°C.
♦ The following clearances are recommended for proper placement of the
StarInverter:
• A minimum 36″clearance between the bottom of the inverter box and
the ground.
• A minimum 12″clearance above the inverter box for ventilation.
• A minimum 8” clearance around the side of the inverter box so that all
Warning and Caution labels are clearly visible and able to be easily
read.
• Visibility of the operating LED’s and display located at the top front of
the inverter box should also be considered.
♦ If the StarInverter is to be installed in an enclosed cabinet or closet, external
ventilation must be provided to allow for sufficient heat dissipation.
♦ At all times, air circulation around the inverter box must be sufficient.

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2.2 Mounting the StarInverter
The StarInverter should be mounted vertically to a flat, solid surface such as wallboard,
concrete or wood siding. The inverter should be located in close proximity to the solar
panels to minimize the DC wire length.
The two mounting brackets provided make mounting the StarInverter quick and simple.
There is one bracket for the top and one for the bottom. The two screw holes in each
bracket are 16 inches apart. Once the wall studs are located, anchoring the brackets
becomes an easy task.
WARNING: Prior to drilling holes to mount the StarInverter in the location
selected, ensure there are no electrical wires or plumbing in the area.
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).
CAUTION:
To reduce the risk of fire, connect the PVP1800 or PVP2800 only to a circuit with 20 amps
maximum branch-circuit overcurrent protection in accordance with the National Electrical
Code (NEC), ANSI/NFPA 70. The PVP1100 must be connected to a circuit with 15 amps
maximum branch-circuit overcurrent protection in accordance with the National Electrical
Codde (NEC), ANSI/NFPA 70.
2.2.a Steps to Mount the StarInverter
1. Locate the wall studs in the desired location and mark upper mounting bracket
screw holes.
2. MAKE SURE BRACKET IS LEVEL. Drill holes for the screws through the holes
on the bracket. Use heavy-duty molly bolts or anchors if mounting into drywall
only. See Figure 4.
Figure 4: Upper Mounting Bracket

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3. Remove the front cover of the StarInverter by unscrewing the two cover screws
located on the bottom of the inverter. (The PVP2800 will have four cover
screws located on the front and bottom of the inverter.)
4. Attach the lower mounting bracket, being careful not to damage the heat sink
cooling fins. See Figure 5.
Figure 5: Underside of StarInverter and Lower Mounting Bracket
5. Carefully bring the inverter right side up and hang it on the upper bracket.
6. Verify inverter is level. Seal the upper mounting holes on the inverter with
RTV.
7. Mark the locations of the lower mounting bracket holes. Drill holes into studs
or install wallboard anchors as necessary.
8. Screw in the bottom screws of the bottom bracket to anchor the bracket to the
wall. Refer to Figure 6.
Figure 6: Mounted StarInverter with Mounting Brackets in place.

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If installing the PVP1100 with the optional AC DC Disconnect Box, see step 2.2.b. If
installing the PVP1100 without the AC DC Disconnect Box or if installing the PVP1800 or
PVP2800, please proceed to section 2.3 Electrical Connection.
PLEASE NOTE: Leave the inverter cover off to allow for electrical
connection in section 2.3.
2.2.b Attaching the OPTIONAL AC DC Disconnect Box*
*NOTE: Certain utility companies require this equipment per regulations. If
you are unsure of these regulations, contact the utility provider. If the
Disconnect Box is not required, proceed to section 2.3.
1. Attach the optional StarInverter AC DC Disconnect Box as depicted in Figures 7
through 9. Holes are threaded for four 10-32 screws at the top of the AC DC
Disconnect Box. Place the screws through the holes in the bottom of the
PVP1100 and into the top of the Disconnect Box.
2. Tighten the four screws to a torque value between 2.0 and 2.5 Nm.
Figure 7: AC DC Disconnect Box Figure 8: Location of screw holes for AC DC
Disconnect Box
Figure 9: Installed AC DC Disconnect Box

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2.3 Electrical Connection
Do not proceed with the electrical connection of the StarInverter until it has been properly
mounted.
WARNING: Electrical connections must be done in accordance with local
electrical codes and the National Electrical Code (NEC), ANSI/NFPA 70. Use 10
AWG, minimum 90°(194°F), copper wire for all PVP1800 and PVP2800
connections. Use 14 AWG, minimum 90°(194°F), copper wire for all PVP1100
connections. Voltage drop as well as other considerations may dictate that
larger wire sizes be used.
WARNING: Make sure the main 120/208/240 volt breaker in the main
utility breaker box is switched OFF before wiring the StarInverter. This breaker
should be switched ON only after all wiring has been completed as set forth in
this manual.
WARNING: Follow the order listed below in wiring the StarInverter. Failure
to do so may result in hazardous voltages or disconnection of contacts.
Terminal connections for the StarInverter are located inside the inverter on the circuit
board at the bottom of the box. Solid wires up to 8 AWG (6mm²) and flexible wires up to
10 AWG (4mm²) are accepted by the AC terminals. Wires up to 6 AWG are accepted by
the DC terminals.
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.
Figure 10: Communications, AC and DC ports.

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2.3.a Grounding
♦ A single point ground connection is located in the lower right hand side of the
StarInverter cabinet. The PV panel grounding wire is terminated there. The AC
ground connection is terminated next to the Line and Line 2/Neutral connections
on the circuit board. The PV ground is bolted to the cabinet with a ¼-20 bolt.
(Refer to Figure 12.)
♦ Figure 11 includes schematic representations of the PVP1100, PVP1800, and
PVP2800 single point grounding. The front cover is grounded through the two
cover mounting screws.
Figure 11: System Block Diagram showing single point ground point
PVP1100
Line
Filter
Control pcb Power Distribution PCB
DC
Power
Supply
L
N
GND
PV GND
+
-
15 A SB
System Block Diagram
120 VAC
60Hz
90-180 VDC
To dedicated
AC circuit
PV
DC input
Line
Filter
Control pcb Power Distribution PCB
DC
Power
Supply
L1
L2
GND
PV GND
15 A SB
System Block Diagram
208/240 VAC
60Hz
240:200-450 VDC
208:180-450 VDC
PV
DC input
PVP 2800
1A
15A
-
+
GND
Line
Filter
Control pcb Power Distribution PCB
DC
Power
Supply
L1
N
GND
PV GND
20 A SB
System Block Diagram
120 VAC
60Hz
120-360 VDC
PV
DC input
PVP 1800
-
+
GND
15A 1A

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Figure 12: AC and PV Grounding
2.3.b Connecting the StarInverter to the Electrical Grid
Inside the StarInverter are two circuit boards:
♦ The Control Board
♦ The Power Distribution Board with a D-sub socket or an optional terminal block
for communications to a personal computer and:
• The AC connection terminal
• The DC connection terminal
• The Internal AC grid fuse(s)
WARNING: For continued protection against risk of fire, replace only with
same type and ratings of fuse. For models PVP1800 and PVP2800 use only
Littelfuse 326020 20 AMP 250V AC. For model PVP1100 use only Littelfuse
326015 15 AMP 250V AC.
PV Powered provides overcurrent protection on the Power Distribution Board with two 20
AMP fuses for models PVP1800 and PVP2800 and with one 15 AMP fuse for model
PVP1100. (See warning above). Overcurrent protection is also provided with the optional
AC DC Disconnect Box available with the PVP1100 and with the included DC/GFI circuit
breakers on the PVP1800 and PVP2800. Additional overcurrent protection for the
inverter’s AC output is provided by circuit breakers at the breaker panel.
The StarInverter is connected to the electrical grid using 3 wires - the LINE, LINE
2/NEUTRAL and GROUND.
Please Note: To avoid an increase in AC voltage to unacceptable values while the
StarInverter is connected, the grid impedance value at the connection point should
be as low as possible. By keeping the grid impedance value low, higher system
efficiency will be achieved.

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The total impedance of the grid plus the interconnecting AC wires should be less
than 1.25 Ohm.
WARNING: Make sure the main 120/208/240 V breaker at the circuit
breaker panel is switched off before you connect the AC terminal block.
To wire the StarInverter to the main utility grid, follow the steps outlined below (refer to
Figure 13):
1. Run the conduit from the main breaker panel to the bottom of the StarInverter
and insert the fitting in the center opening of the StarInverter, fastening with a
locking nut.
2. Feed the LINE, LINE 2/NEUTRAL and GROUND wires through the conduit and
into the center opening of the StarInverter.
3. Connect the GROUND wire to the terminal marked ‘earth ground’ inside the
StarInverter.
4. Connect the LINE 2/NEUTRAL wire to the terminal marked ‘line 2/neutral’ inside
the StarInverter.
5. Connect the LINE wire to the terminal marked ‘line’ inside the StarInverter.
6. Ensure all connections are wired correctly and properly torqued. Tighten the
terminal block screws to 0.5 Nm.
Figure 13: AC wiring for the line, line 2/neutral and ground wires.

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2.3.c Connecting DC Wires/PV Panels
WARNING: Before proceeding with the DC wiring, completely cover the
surface of all PV-arrays with dark material to avoid the production of electrical
current.
WARNING: Make sure the polarity and the PV panel voltage between the +
and the – cable connectors of the PV panels are correct. Then connect the
panels to the DC terminal block on the power distribution board.
The PV panel open circuit voltage should be at or below the listed voltages in Figure 14
under all circumstances. Each DC input to the DC terminal block must be less than the
voltages listed in Figure 14.
Figure 14: PV open circuit voltages.
To wire the DC inputs from the PV panels to the StarInverter (refer Figure 15):
Note: Each DC input connection must carry the same input voltage. The StarInverter
allows up to three connections for both the + and the – pole.
1. Calculate the maximum open circuit (no load) for each series panel connection.
FOR ALL TEMPERATURE CONDITIONS, THE OPEN CIRCUIT VOLTAGE
FOR EACH SERIES CONNECTION MUST TOTAL LESS THAN THE OPEN
CIRCUIT VOLTAGE INDICATED IN FIGURE 14 FOR THE
CORRESPONDING STARINVERTER MODEL. Review your panel’s data sheet
for operating temperature ranges.
2. Keep track of the array positive and negative leads and mark them clearly.
3. Route the PV array leads through the far right opening in the StarInverter.
4. Connect each series positive DC lead to the positive terminals of the power
distribution board.
StarInverter
Model
PV Panel Open Circuit
Voltage
DC Input to DC
Terminal Block
PVP1100 180VDC 180VDC
PVP1800 360VDC 360VDC
PVP2800 450VDC 450VDC

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5. Connect negative DC leads directly to the negative terminal on the power
distribution board.
6. Connect the ground wire(s) to the ground lug.
7. Confirm that the DC disconnect is turned off and remove the material from the
array. With a voltmeter, check the PV array positive leads and confirm that the
voltage is positive when referenced to the negative leads. The reading should
match your series Voc total.
Figure 15: DC Wiring

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2.3.d Connecting Through the Optional AC DC Disconnect Box
(PVP1100 Model Only)
Refer to Figure 16 for a diagram of the AC and DC wiring when using the optional PV
Powered AC DC Disconnect Box. Ensure all connections are wired correctly and properly
torqued. The nominal value of tightening torque to be applied to the clamping screws for
the breakers is 2.0 – 2.5 Nm (18-22 LB-IN).
Figure 16: AC and DC wiring with the AC DC Disconnect Box
Figure 17: Views of the AC DC Disconnect Box
Line
Filter
Control pcb Power Distribution PCB
DC
Power
Supply
L
N
GND
PV GND
+
-
15 A SB
System Block Diagram
120 VAC
60Hz
90-180 VDC
To dedicated
AC circuit
PV
DC input
15 A DC Breaker
&GFI
1A
15A 15A 15 A
AC Breaker
GND LN
PVP 1100
PV Positive Negative Ground
AC DC
Disconnect

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2.3.e Connecting Communications (Optional Step)
To connect the communications and load the software follow the steps outlined below
(Refer to Figures 18 and 19):
1. Hardwire the communications cable to the communication terminal, or plug in the
D-sub cable to the serial port.
Figure 18: Communications located on the Power Distribution Board
Serial Connection Table
Figure 19: Hardwiring the serial connection
2. Replace the front cover of the StarInverter and tighten the two or four screws
located on the cover.
5 Pin Screw
Terminal
Connector
Serial Cable Serial Function
1 7 Request to Send (RTS)
2 2 Receive Data (Rx)
3 4 Data Terminal Ready (DTR)
4 3 Transmit Data (Tx)
5 5 Signal Ground (SG)

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3.0 OPERATION
3.1 Start Up Procedures for the StarInverter
WARNING: Before turning on the StarInverter ensure that the front panel
is closed properly.
WARNING: The heat sink can reach temperatures in excess of 158º (70ºC).
Care must be taken to not touch the heat sink when in use. Nothing should be
placed on top of the heat sink.
Starting up the StarInverter requires the following steps in the order indicated below:
1. Turn the AC breaker ON.
2. Verify that a red LED light is illuminated.
3. Verify that communication is established with the PVP Command Center
(software on PC). This is an optional step.
4. Remove the dark cover from the PV panels.
5. Check the polarity to make sure the + and – are wired correctly and confirm
that the PV panel open circuit voltage is at or below the level specified in Figure
14.
6. Turn the DC breaker ON.
7. IT IS RECOMMENDED THAT YOU ATTACH A PADLOCK AT THIS TIME TO
PREVENT UNAUTHORIZED ACCESS OR DAMAGE TO THE INVERTER.
8. After 5 minutes, the StarInverter will start to produce power into the AC grid if
all necessary operating conditions are met.

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3.2 LED Indicator Lights/Vacuum Fluorescent Display
3.2.a LED Indicator Lights (Model PVP1100)
The StarInverter PVP1100 displays 7 LED indicator lights visible through the upper left
corner of the front panel. Refer to Figure 20.
These lights will indicate the PVP1100’s status and real-time output power into the AC
Grid.
If the PVP1100’s operating environment is safe to produce power into the AC grid, the
“OK” (Green) LED is illuminated.
If at any moment the operating environment moves outside the safe operating limits,
governed by UL 1741, IEEE 519, and NEC 690, the “FAULT” (Red) LED indicator will be
illuminated.
The StarInverter is continuously monitoring:
1. The AC grid connection to ensure the AC voltage and frequency levels are within
safe operating limits (per UL and NEC specifications).
2. The DC PV panel input(s) to ensure safe operating conditions (per UL and NEC
specifications).
3. The PVP1100 itself to ensure only safe operating conditions exist within the
PVP1100’s operating environment.
If all 3 conditions are met the inverter will illuminate the “OK” (Green) LED.
If any one of the operating conditions is not met there is a fault and the PVP1100 will
illuminate the “FAULT” (Red) LED.
The “FAULT” (Red) LED will illuminate when the PV panel voltage is not within safe
operating limits. This will occur at sunset, when the inverter will turn off for the night. It
may also occur when clouds reduce the amount of sunlight, or when the panels are
covered with snow. Anytime the level of sunlight is too low to produce 90 volts of DC
input (the low end of the PVP1100’s operating range) the inverter will turn off. This
ensures only safe and clean (low distortion) power is being generated. When the panels
are once again exposed to enough sunlight, the PVP1100’s auto-start feature will begin,
and after 5 minutes, the “OK “ (Green) LED should illuminate.
If the “FAULT” (Red) LED continues to illuminate when there is sufficient sunlight for
operation, verify all wiring connections are solid. See Section 4.0 Troubleshooting. If the
PVP1100 Command Center is communicating with the inverter, the exact operating
conditions can be determined in real-time.

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Figure 20: LED Indicator Lights
3.2.b LED Indicator Lights/Vacuum Fluorescent Display (Models
PVP1800 and PVP2800)
LED INDICATOR LIGHTS
The StarInverter PVP1800 and PVP2800 displays 2 LED indicator lights visible through the
upper left corner of the front panel. These lights will indicate the StarInverter’s status.
If the StarInverter’s operating environment is safe to produce power into the AC grid, the
“OK” (Green) LED is illuminated.
If at any moment the operating environment moves outside the safe operating limits,
governed by UL 1741, IEEE 519, and NEC 690, the “STAND BY” (Red) LED indicator will
be illuminated.
The StarInverter is continuously monitoring:
4. The AC grid connection to ensure the AC voltage and frequency levels are within
safe operating limits (per UL and NEC specifications).
5. The DC PV panel input(s) to ensure safe operating conditions (per UL and NEC
specifications).
6. The StarInverter itself to ensure only safe operating conditions exist within the
operating environment.
If all 3 conditions are met the inverter will illuminate the “OK” (Green) LED.
•••••••
PV Powered LLC
www.pvpowered.com
Utility Interactive Photovoltaic Inverter
100w
300w
500w
700w
900w
OK
Fault
PVP1100
Listed 20RP
patent pending