PV Powered StarInverter PVP1100 User manual

97-600100-02-A01
PV Grid-tied Residential Inverter and
Integrated AC/DC Disconnect
INSTALLATION & OPERATION MANUAL

i
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.
PO Box 7348
Bend, OR 97708
Tel: [phone]
Technical Support: 1-877-312-3832
Fax: [phone]
www.pvpowered.com
email: [email protected]
Document Copyright
PV Grid-tied Residential Inverter and Integrated AC/DC Disconnect
Installation and Operation Manual
©2009 PV Powered. All rights reserved. This manual may not be
reproduced or distributed without written permission from PV Powered.
PREFACE

ii

PV Grid-tied Residential Inverter and Integrated AC/DC Disconnect
Installation and Operation Manual
iii
Safety Information and Conventions
SAVE THESE INSTRUCTIONS: This manual contains important
instructions for the PV Grid-tied Residential Inverter and Integrated
AC/DC Disconnect that shall be followed during installation and
maintenance of the inverter.
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.
!DANGER
L’alerte de sécurité Danger est employée pour informer
l’installateur ou l’opérateur d’une situation exigeant la plus
grande attention. Le non-respect de cet avertissement en-
traînera des blessures graves ou la mort et la destruction de
l’équipement.
!AVERTISSEMENT
L’alerte de sécurité Avertissement est employée pour informer
l’installateur ou l’opérateur d’une situation exigeant une at-
tention sérieuse. Le non-respect de cet avertissement peut
entraîner des blessures graves ou la mort et la destruction de
l’équipement.
!ATTENTION
L’alerte de sécurité Attention est employée pour informer
l’installateur ou l’opérateur d’une situation exigeant l’attention.
Le non-respect de cet avertissement peut entraîner des blessures
et endommager l’équipement.

iv
For applicability of technical information with your specic product,
contact PV Powered Customer Service and Technical Support at
[email protected].
Certifications
UL 1741
IEEE 1547
FCC Class A & B
CEC Efciency Testing
CSA 22.2 107.1
UL 98

PV Grid-tied Residential Inverter and Integrated AC/DC Disconnect
Installation and Operation Manual
v
Acronyms and Abbreviations
AC Alternating Current
ANSI American National Standards Institute
AWG American Wire Gage
CEC California Energy Commission (US)/Canadian Electrical Code
CSA Canadian Standards Association
CPU Controlled Processing Unit
DC Direct Current
EGC Equipment Grounding Conductor
FCC Federal Communications Commission (US)
GEC Grounding Electrode Conductor
GFI Ground Fault Interrupt
IEEE Institute of Electrical and Electronics Engineers
LED Light-Emitting Diode
LOTO Lockout Tagout
LP Low Power
MPPT Maximum Power Point Tracking
NEC National Electric Code
NEMA National Electrical Manufacturers Association
NFPA National Fire Protection Association
Nm A unit of torque
PLL Phase Lock Loop
PPE Personal Protective Equipment
PV Photovoltaic
STC Standard Test Condition
UL Underwriters Laboratory
VAC Voltage Alternating Current
VDC Voltage Direct Current
VFD Vacuum Fluorescent Display
VOC Voltage Open Circuit
VOC_TC Voltage Open Circuit, Temperature Coefcient

vi

vii
Preface ................................................................................................................. i
Safety Information and Conventions ................................................................. iii
Acronyms and Abbreviations ..............................................................................v
1. Introduction and Safety ...................................................................................1
1.1 Introduction ..............................................................................................1
1.2 General Safety ..........................................................................................1
1.3 FCC Compliance ......................................................................................2
2. Planning ...........................................................................................................5
2.1 Selecting a Location for the Inverter and
Integrated AC/DC Disconnect ...............................................................5
2.2 Guidelines for Mounting the Inverter and
Integrated AC/DC Disconnect ..............................................................5
3. Installation .......................................................................................................7
3.1 Mounting and Anchoring the Inverter and Integrated
AC/DC Disconnect ................................................................................7
4. Wiring Requirements .....................................................................................11
4.1 Electrical Connections ............................................................................11
4.2 Supported Voltages and Grid Types .......................................................12
4.3 Wiring Information .................................................................................13
4.4 AC Circuit Breaker Requirements ..........................................................14
4.5 Inverter Voltage and Frequency Limits ..................................................14
4.6 Circuit Separation ...................................................................................16
4.7 Single-point Grounding ..........................................................................17
4.8 Wiring a Single Inverter with an Integrated AC/DC Disconnect ...........21
4.9 Wiring Multiple Inverters with Integrated AC/DC Disconnects ............26
5. Operation .......................................................................................................29
5.1 Start Up Procedures ................................................................................29
5.2 Inverter Front Panel Status Indicators ....................................................30
6. Troubleshooting .............................................................................................33
6.1 LED Status ..............................................................................................33
6.2 Displayed Fault Codes ............................................................................34
6.3 Fault Code Lists ......................................................................................36
7. Service and Replacement ..............................................................................39
7.1 Accessing the Wiring Terminals .............................................................39
7.2 Removing the Inverter ............................................................................40
7.3 Replacing the Inverter ............................................................................41
7.4 Finishing the Replacement .....................................................................42
Table of Contents
TABLE OF
CONTENTS

viii
Appendix A - Specications ...............................................................................43
A.1 Inverter Specications ............................................................................43
A.2 Integrated AC/DC Disconnect Specications ........................................45
A.3 Circuit Breaker Requirements ................................................................46
A.4 Abnormal Specications ........................................................................46
Appendix B - Ground Conguration .................................................................47
B.1 Field Conguration of an Inverter for Use with
Positively Grounded PV Arrays ...........................................................47
Appendix C - Cabinet Dimensions ....................................................................51
C.1 Schematics for Inverter-only ..................................................................51
C.2 Schematics for Inverter with Integrated AC/DC Disconnect .................55
Limited Warranty ...............................................................................................59
Return Procedure ...............................................................................................63
Index ..................................................................................................................65

PV Grid-tied Residential Inverter and Integrated AC/DC Disconnect
Installation and Operation Manual
ix
List of Figures and Tables
Figure 2-1 Interior Components of the Inverter/Disconnect Unit ...............6
Figure 3-1 Small Mounting Bracket ...........................................................7
Figure 3-2 Large Mounting Bracket ...........................................................8
Figure 3-3 Inverter’s Inside Screw Below the Power Board ......................9
Figure 3-4 Inverter and Integrated AC/DC
Disconnect with Mounting Bracket ...........................................9
Table 4-1 Inverter Compatibility with Voltage and Grid .........................13
Figure 4-1 Supported Utility Voltage Congurations ...............................13
Table 4-2 Recommended Branch Circuit Protection ...............................14
Table 4-3 Inverter Voltage and Frequency Limits ...................................15
Figure 4-2 Knockouts on AC/DC Disconnect - Bottom View ..................17
Table 4-4 Grounding Electrode Conductor Sizing ..................................18
Figure 4-3 System Block Diagram of Single-point System Ground .......19
Figure 4-4 Grounding of the Inverter and Integrated AC/DC Disconnect 20
Figure 4-5 Ground Fault Message ............................................................21
Figure 4-6 AC and PV Grounding in Integrated
AC/DC Disconnect Cabinet ....................................................21
Table 4-5 Conductor Use By Inverter Model ..........................................22
Figure 4-7 Disconnect’s AC Conductor Connections:
EGC, Line 1 and Line 2 ..........................................................24
Figure 4-8 Wiring Multiple Arrays with Inverter/Disconnect Units .........28
Figure 5-1 Normal Startup Screens ...........................................................31
Figure 5-2 Running Screens ......................................................................32
Figure 6-1 Faulted .....................................................................................34
Figure 6-2 Starting Up From a Faulted State ............................................35
Figure 6-3 AC Voltage High/DC Voltage Low Fault ................................35
Figure 6-4 Power Low Fault .....................................................................36
Table 6-1 Fault Codes ..............................................................................37
Table 6-2 Normal Fault Codes ................................................................38
Table 6-3 Fault Codes Requiring Service ................................................38
Figure 7-1 Connections between the Inverter and Integrated AC/DC
Disconnect ...............................................................................40
Figure 7-2 Reconnecting the Inverter’s Conductors .................................42

x
Table A-1 Inverter PVP1100 through PVP2800 Specications ...............43
Table A-2 Integrated AC/DC Disconnect Technical Specications .........45
Table A-3 Circuit Breaker Requirements .................................................46
Table A-4 Abnormal Specications .........................................................46
Figure B-1 Inverter’s Power Board Terminals...........................................47
Figure B-2 Conductors Reversed on Power Board Terminals ...................48
Figure B-3 New Label for DC Terminal Circuit Board .............................48
Figure B-4 New Label for Exterior of AC/DC Disconnect .......................48
Figure B-5 GFI Negative Jumper in J10 Port ............................................49
Figure B-6 Negative and Positive GFI Jumpers ........................................49
Figure B-7 PV Terminals in the Inverter ...................................................50
Figure B-8 Negative and Positive GFI Jumpers ........................................50
Figure C-1 Side and Front Views of the PVP1100, PVP2000, PVP2500,
PVP2800, PVP3000 and PVP3500 Inverter-only Cabinet ......51
Figure C-2 Back and Bottom Views of PVP1100, PVP2000, PVP2500,
PVP2800, PVP3000 and PVP3500 Inverter-only Cabinet ......52
Figure C-3 Side and Front Views of the PVP4600, PVP4800 and
PVP5200 Inverter-only Cabinet ..............................................53
Figure C-4 Back and Bottom Views of PVP4600, PVP4800 and
PVP5200 Inverter-only Cabinet Inverter-only Cabinet ...........54
Figure C-5 Side and Front Views of the PVP1100, PVP2000, PVP2500,
PVP2800, PVP3000 and PVP3500 Inverter
with Integrated AC/DC Disconnect Cabinet ...........................55
Figure C-6 Back and Bottom Views of the PVP1100, PVP2000, PVP2500,
PVP2800, PVP3000 and PVP3500 Inverter
with Integrated AC/DC Disconnect Cabinet ...........................56
Figure C-7 Side and Front Views of the PVP4600, PVP4800 and
PVP5200 Inverter with Integrated
AC/DC Disconnect Cabinet ....................................................57
Figure C-8 Back and Bottom Views of PVP4600, PVP4800 and
PVP5200 Inverter with Integrated
AC/DC Disconnect Cabinet ....................................................58

1
1. Introduction and Safety
1.1 Introduction
The PV Grid-tied Residential Inverter and Integrated AC/DC Disconnect
is a utility interactive inverter for photovoltaic (PV) systems. The inverter
and disconnect are integrated, requiring installation as a single unit.
The integrated inverter and disconnect are tied to an electrical source
provided by the local utility company as well as the PV system. The
inverter contains everything needed to convert the DC energy generated by
the PV array(s) into AC energy required to power a house. The Integrated
AC/DC Disconnect provides the disconnect switch for DC and AC
connections for the PV array and the utility grid using a single switch.
This manual provides information necessary for the successful installation
and operation of the PV Grid-tied Residential Inverter and Integrated
AC/DC Disconnect.
1.2 General Safety
IMPORTANT SAFETY INSTRUCTIONS: This product has been
engineered and manufactured to ensure your personal safety. Improper
installation and operation 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 and disconnect.
The disconnect has a locking on/off switch. When the switch is in the off
position, a lock can be inserted through the switch so it cannot be opened.
Locking the unit is the responsibility of the end user. The lid should be
secured to prevent unauthorized access or damage to the unit.
SAVE THESE INSTRUCTIONS: This manual contains important
instructions for the PV Grid-tied Residential Inverter and Integrated
AC/DC Disconnect that must be followed during installation, operation
and maintenance.
INSTRUCTIONS IMPORTANTES CONCERNANT LA SECURITÉ
CONSERVER CES INSTRUCTIONS. CETTE NOTICE CONTIENT
DES INSTRUCTIONS IMPORTANTES CONCERNANT LA
SÉCURITÉ.
INTRODUCTION
& SAFETY

2
!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 qualied
electricians should make the connection.
• When exposed to light, PV arrays form electrical energy
that creates a potentially hazardous condition. To avoid this,
completely cover the surface of all PV arrays with opaque
material before wiring them.
• The inverter contains no user-serviceable parts. Refer
maintenance to qualied service personnel.
!ATTENTION
• Toutes les installations électriques devraient être faites
selon les codes de l’électricité locaux et le Code national de
l’électricité (NEC), ANSI/NFPA 70.
• Avant de connecter l’onduleur au réseau électrique du
service public, votre entreprise de service public doit en
accorder l’autorisation. Seuls les électriciens qualiés
devraient faire la connexion.
• Lorsqu’exposés à la lumière, les générateurs PV produisent
de l’énergie électrique qui crée une situation susceptible
d’être dangereuse. Pour éviter ceci, couvrir entièrement
la surface de tous les générateur PV d’un matériel opaque
avant de les connecter.
• L’onduleur ne contient aucune pièce réparable par
l’utilisateur. Coner la maintenance au personnel d’entretien
qualié.
1.3 FCC Compliance
The PV Grid-tied Residential Inverter and Integrated AC/DC Disconnect
have been tested and found to pass FCC Class B radio interference
standards with proper installation of the unit. 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.

PV Grid-tied Residential Inverter and Integrated AC/DC Disconnect
Installation and Operation Manual
3
!CAUTION
Read all safety warnings and instructions before installing or
operating the inverter/disconnect unit.
!ATTENTION
Lire toutes les alertes de sécurité et les instructions avant
d’installer ou d’utiliser l’onduleur ou le dispositif de
déconnexion.

4

5
2.1 Selecting a Location for the Inverter and
Integrated AC/DC Disconnect
When choosing a location for the inverter/disconnect unit, consider the
following criteria:
• The unit is suitable for both indoor and outdoor installation; the in-
verter and disconnect enclosures have a NEMA 3R rating.
• The optimum location of the unit is outside, shielded from direct expo-
sure to sunlight (i.e. not on the south facing side of the building).
• The heat sink temperature can exceed 158°F (70°C). The unit should
be installed so people cannot touch the top of the inverter.
• The inverter is designed and tested to produce maximum continuous
output power within the ambient temperature range of -15°F to 105°F
(-25°C to 40°C).
Location and Clearances
The following clearances are recommended for proper placement of the
unit:
• A minimum of 36” (91.5 cm) between the bottom of the Integrated
AC/DC Disconnect box and the ground.
• A minimum of 12” (30.5 cm) above the heat sink.
• Approximately .5” (1.25 cm) of width clearance on the right and left
sides of the unit’s cabinet.
Visibility of the operating LEDs and display located at the top front of the
inverter box should also be considered. Refer to Figure 2-1 for the location
of the LED and display.
If the unit is installed in an enclosed space, adequate ventilation must be
provided.
2.2 Guidelines for Mounting the Inverter and
Integrated AC/DC Disconnect
The inverter/disconnect unit should be mounted vertically to a at, solid
surface such as strut, concrete, or wood siding. It should be located near
the PV arrays to minimize the DC conductor length.
The provided bracket and paper mounting template make mounting the
unit quick and simple.
The small bracket:
• Has a vertical row of screw holes down the center and is designed for a
single-stud mount. Refer to Figure 3-1.
2. Planning
PLANNING

6
The large bracket:
• Has two top screw holes at either end of the large bracket, 16”
(40.6 cm) apart which are designed to match standard stud spacing.
Refer to Figure 3-2.
The inverter also has an internal mounting screw. Refer to Figure 2-1 for
the location of this screw.
!WARNING
Before drilling holes to mount the inverter, verify that there are
no electrical wires or plumbing in the area.
!AVERTISSEMENT
Avant de percer des trous pour installer l’onduleur, vérier qu’il
n’y a aucun l électrique ou plomberie dans le secteur.
Figure 2-1 Interior Components of the Inverter/Disconnect Unit
Control Board
with LED Lights
Transformer
Inductor
Power Board
Display
GFI Fuse Port
Mounting Screw
Inverter
Disconnect
AC Wiring
Connections
DC Wiring
Connections
GFI Fuse Terminals

7
3.1 Mounting and Anchoring the Inverter and Integrated
AC/DC Disconnect
After you have determined a suitable location for the inverter/disconnect
unit, the next step is anchoring the bracket to the wall stud(s).
Models PVP1100, PVP2000, PVP2500, PVP2800, PVP3000
and PVP3500
1. Locate a wall stud in the desired location and align the mounting
bracket or paper mounting template with the vertical row of screw
holes over it for a single-stud mount. Mark the mounting holes
ensuring holes A through D are directly over the single stud.
2. VERIFY THE BRACKET IS LEVEL. Align points A through D with
the wall stud. Drill 1/8” (.32 cm) pilot holes for the screws.
• Use heavy-duty 1/4” x 2” (.635 cm x 5 cm) (coarse thread lag
screws to secure points A, B and D.
• Use an 1/8” (.32 cm) screw (and anchor if necessary) to secure
point C. Refer to the following gure.
Figure 3-1 Small Mounting Bracket
3. Carefully hang the inverter/disconnect unit on the upper part of the
bracket. The hooks located at the rear of the inverter should hang over
the bracket.
4. Verify the inverter/disconnect unit is level.
5. Remove the front lid of the inverter by unscrewing the two cover
screws located at the bottom perimeter of the inverter.
A
B
C
D
3. Installation
INSTALLATION

8
6. Locate the inverter mounting hole below the power board (see Figure
3-3). Insert the mounting screw through the inverter and tighten
securely.
Models PVP4600, PVP4800 and PVP5200
1. Locate the wall studs in the desired location and align the mounting
bracket or paper mounting template over the studs. Mark the mounting
holes. Ensure that locations A and B in the following gure are aligned
over two wall studs.
2. VERIFY THE BRACKET IS LEVEL. Ensure points A and B are
aligned with the wall studs. Drill 1/8” pilot holes for the screws.
• Use heavy-duty 1/4” x 2” (.635 cm 5 cm) coarse thread lag screws
to secure points A and B to the wall.
• Use an 1/8” (.32 cm) screw (and anchor if necessary) to secure
point C.
Figure 3-2 Large Mounting Bracket
3. Carefully hang the inverter/disconnect unit on the upper part of the
bracket. The hooks located at the rear of the inverter should hang over
the bracket.
4. Verify the inverter/disconnect unit is level.
5. Remove the front lid of the inverter by unscrewing the four screws
located around the front perimeter of the inverter.
6. Locate the inverter mounting hole below the power board (see Figure
3-3). Insert the mounting screw through the inverter and tighten
securely.
B
A
C