YASKAWA PVS-500 User manual

PVS-500 DC-COUPLED
STORAGE SYSTEM
User’s Manual

Yaskawa Solectria Solar DOCR-071069 Page 2of 24
Contents
1. IMPORTANT SAFETY INSTRUCTIONS........................................................................... 3
2. SYSTEM OVERVIEW......................................................................................................... 4
3. INSTALATION .................................................................................................................... 5
3.1 Delivery ........................................................................................................................ 5
3.2 Placement and Anchoring ............................................................................................ 5
3.3 AC Wiring..................................................................................................................... 6
3.4 DC Wiring................................................................................................................... 11
3.5 Communications......................................................................................................... 20
4. System Operation ............................................................................................................. 21
4.1 Initial Comissioning Procedure................................................................................... 21
4.2 System OFF Procedure.............................................................................................. 22
4.3 System ON Procedure................................................................................................ 22
4.4 Replacement Fuses.................................................................................................... 23
5. WARRANTY & RMA INSTRUCTIONS ............................................................................. 24
6. APPENDICES................................................................................................................... 24

Yaskawa Solectria Solar DOCR-071069 Page 3of 24
1. IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
The SOLECTRIA PVS 500 DC-Coupled Storage System comprises a factory-
integrated set of US-manufactured and factory-integrated components that form the
core of the system: DCR-500 DC Re-Combiner, XGI 1500 Inverters, ACC-500 AC
Combiner, and the Plant Master Controller. The storage system is complete with the
addition five PV subarrays, five CR1500-400 PV Combiners, the DynaPower DC/DC
Converter and the customer-selected battery system complete with enclosure, safety
elements and controls.
This manual provides instructions for operation of the PVS-500 DC Coupled Storage
System. In addition, please read all instructions and warnings for the associated
component equipment in their respective manuals.
This manual contains important instructions for operation of the PVS-500 DC-Coupled
Storage System. To reduce the risk of electrical shock and to ensure the safe operation
of the system, the following safety symbols are used to indicate dangerous conditions
and important safety instructions.
WARNING
Could Injure
Personnel or
Damage Equipment
Instructions
for Qualified
Personnel Only
Positive
Connection
Point Symbol
Negative
Connection
Point Symbol
Ground
Connection
Point Symbol
DC Electrical
Connection
Point Symbol
WARNING: Never operate the system with fewer than 4 PV Circuits connected.

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2. SYSTEM OVERVIEW
DC RE-COMBINER
AC COMBINER
3 XGI 1500 INVERTERS

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3.INSTALATION
3.1 Delivery
Check for Damage: Yaskawa Solectria Solar thoroughly inspects and rigorously tests all rack-
mounted components in the PVS-500 DC-Coupled Storage System -- before shipment. On
rare occasions damage may occur during shipping. Upon receipt of the PVS-500 system,
check for the following:
Inspect the AC Combiner as received, pre-mounted and pre-wired on the PVS-
500 rack.
If damage is observed, take digital photos to document the damage and
immediately report the damage to the shipping company.
If the recipient has any question about the potential shipping damage, contact
Yaskawa Solectria Solar (see Section 6 for contact information).
If Yaskawa Solectria Solar determines that the AC Combiner must be returned,
obtain an RMA number from Yaskawa Solectria Solar and instructions for
returning the unit.
3.2 Placement and Anchoring
To anchor the PVS-500 to a concrete pad, secure anchor bolts at each of the four anchoring
provisions located at each end of the horizontal support bars. These anchor points have an
internal diameter opening of 1”.

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3.3 AC Wiring
All AC Wiring is completed within the ACC-1500-500 that is premounted to the PVS-500 rack.
The ACC1500-50 AC Combiner enclosure is rated Type 3R and will maintain this rating when
the user follows appropriate installation methods.
STEP 1: Confirm that all wiring and associated components are de-energized
Confirm that the AC switch on the AC Combiner is in the “Off” position.
Confirm that the AC switch on the XGI 1500 inverters (on the rack with other
equipment in the PVS-500 DC-Coupled Storage system) are in the “off” position (Fig
4.1).
Confirm there is no voltage at the terminals for the XGI 1500 inverters’ AC output
conductors in the ACC1500-500 AC Combiner.
Rotate the XGI 1500 Inverter AC Disconnect to the “Off” position
STEP 2: Prepare the Enclosure for Conduits
Note the target area for conduit connections for the combined AC Output Circuit, on
the bottom face of the ACC1500-500 AC Combiner, as shown in Figure 4.2. Only
the shaded areas indicated should be used.
Add the holes for the conduit and fittings. The AC Combiner provides adequate
space for 2” – 3” conduits for the 3-phase 600VAC conductors.
Remove all metal shavings and debris from the inside of the AC Combiner.
Remove all metal shavings and debris from the inside of the ACC1500-500
AC Combiner enclosure.

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Interior of the ACC1500-500 AC Combiner
Bottom of the ACC1500-500 AC Combiner Showing
Areas Available (shaded) for Conduit
10.25 in.
(260mm)
14.2 in.
(360mm)
11.6 in.
(295mm)
1.18 in.
(30 mm)
1.18 in.
(30 mm)
6.3 in.
(160mm)
0.78 in.
(20mm)
0.78 in.
(20mm)
200A 600VAC FUSES,
TYPE J, for ΦA, Φb, Φc,
from 3 INVERTERS
600A, 600VAC 3-POLE
DISCONNECT SWITCH
600A 600VAC FUSES, TYPE
J, for ΦA, Φb, Φc, COMBINED
OUTPUT from 3 INVERTERS
DUAL BARREL LUGS for
FIELD-WIRED OUTPUT,
3-PH 600VAC
BUSBARS
ϕ
A
ϕ
B
ϕ
C
EQUIPMENT GROUND
TERMINAL
HINGED
COVER
AUX POWER, 3A FUSES
346 VAC

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Conduit Connections
Follow these instructions and best practices when securing conduits to the ACC1500-
500 AC Combiner.
1. Use UL514B certified water-tight conduit fittings and proper installation methods
to provide a water-tight connection that will maintain the Type 3R rating of the
enclosure.
2. Use an appropriately-rated sealant and seal the conduits fully to prevent the
exchange of air between the conduit and the enclosure. Sealing the conduit will
help prevent condensation in the enclosure.
STEP 3: AC Output Circuit Connections
See NEC Articles 310 and 690 for proper conductor sizing. The phase lugs are shown in
Figure 4.3 and their specifications in Table 4.1.
Phase Lugs (one per phase)
Conduits connected to an outdoor enclosure can introduce water vapor into
the enclosure and lead to the formation of condensation inside. Failure to
follow these guidelines can result in water intrusion into the unit through the
conduit connections and may void the warranty.
Do not attempt to make connections to the ACC1500-500 AC Combiner if not
qualified for electrical work.

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Phase Lugs Specifications
Conductor Compatibility
6AWG –350kcmil
Copper and Aluminum
Conductor Type
2-Barrel
Temperature Rating
90C
Torque
350kcmil to > 2 AWG: 375 in-lb
6 AWG to ≤2 AWG: 275 in-lb
Phase Lug Specifications
Follow these steps when making conductor connections in the AC Combiner:
Verify absence of voltage on all conductors.
Run the AC Output Circuit conductors into the AC Combiner through appropriate
conduit and fittings.
Connect the phase conductors to the lugs and apply torque per the specifications in
Table 4.1.
Connect equipment ground conductors to the equipment ground terminals.
Aluminum Conductors
When using aluminum conductors, follow these steps to prepare the conductors.
1. Prepare one wire at a time.
2. Remove the appropriate insulation from the wire.
3. Using a wire brush, remove the oxidized outer layer from the aluminum
conductors.
4. Immediately apply a neutral dielectric grease, such as Ideal NOALOX®anti-
oxidant compound, and connect the aluminum cable to the terminal.
5. If the connection is not made within 30 seconds of applying the compound,
repeat this process, as an oxidized layer may have formed on the conductor.
Aluminum oxidizes quickly when exposed to the atmosphere. An oxidized
layer is a poor conductor that could lead to thermal issues, production loss,
or damage to the Re-Combiner.

Yaskawa Solectria Solar DOCR-071069 Page 10 of 24
STEP 4: Equipment Ground Wire Connections
Terminals are provided in the Combiner for all Equipment Grounding Conductors
(EGCs). Torque each EGC per the specifications in Table 4.2 below.
Equipment Ground Bar
Ground Bar Specifications
Final Steps
Verify that all connections meet the requirements of this User’s Manual.
Secure the ACC1500-500 AC Combiner cover, ensuring that all ¼-turn fasteners are
secured.
Consult the startup and commissioning procedures for the PVS-500 DC-Coupled
Energy Storage system before energizing.
Ground Bar Specifications
Positions
12
Conductor Compatibility
12 (Al) / 14 (Cu) AWG –4 AWG
Temperature Rating
90C
Torque
20 in-lb, flat-head screwdriver
Verify the proper polarity of each conductor. Polarity reversal can lead to
dangerous conditions capable of harming personnel and damaging equipment.
Check the AC Combiner for tools and debris; ensure that the unit is clean and
orderly.

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Switch Handle Positions for OFF (left) and ON (right)
The ACC1500-500 AC Combiner contains a user-operable AC disconnect switch. When this
disconnect switch handle is in the OFF position, the circuit is open between the input Inverter
AC Output Circuit conductors and the combined AC Output Circuit conductors. The disconnect
handle can be locked in the OFF position with user supplied safety locks. The plastic tab on
the face of the disconnect handle can be lifted to reveal the locking provisions.
The disconnect switch is rated for 600A, is fully load-break rated and can be safely operated
under normal operating conditions when installation is per this User’s Manual and all warnings
and ratings are observed.
3.4 DC Wiring
All DC wiring is completed within the DCR-1500 Re-Combiner. The DCR-1500 Re-Combiner
functions as the DC bus in the SOLECTRIA PVS-500 DC-Coupled Energy Storage System,
coupling 5 PV inputs, 3 Inverter inputs, and one DC/DC converter input. The DCR-1500 Re-
Combiner provides overcurrent protection for the PV and DC/DC Converters and also ground
fault sensing for the PV inputs.
WARNING: Disconnect all PV modules or completely cover the surface of all PV
modules with opaque (dark) material before wiring. PV arrays produce dc voltage when
exposed to light and could create a hazardous condition. Always verify the absence of
voltage before performing work on the Re-Combiner.
WARNING: Connecting PV output circuits to the input of the Re-Combiner and making
the connection to the Dynapower DC/DC Converter (DPS-500, DPS-375, or DPS-250)
and battery subsystem, must only be done after receiving approval from the utility
company and AHJ, and should only be performed by qualified persons.
90
°
ON
OFF
Do not operate the disconnect handle switch with the AC Combiner door open.
OF
F
ON

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The DCR-1500 DC Re-Combiner Components
PV OUTPUT CIRCUIT
400A DC DISCONNECT
SWITCHES 5x
5x
400A FUSE
5x
250A FUSE
3x
630A* FUSE
(2 x 315A
fuses
in parallel)
COMMS
PCBA
IMI SENSORS
5x
PV CIRCUIT
EQUIPMENT
GROUND 5x
INVERTERS &
DC/DC
EQUIPMENT
GROUND
TERMINALS
ALL CONNECTIONS IN THIS SECTION
COMPLETED IN THE FACTORY
(*400A fuse used with DPS-375, DPS-250)
400A DC DISCONNECT SWITCHES
FOR PV OUTPUT CIRCUITS

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Figure 5.1 –Specs for Field Wiring to the DCR-1500 Re-Combiner
STEP 1: Disconnect all Equipment Before Wiring to the Re-Combiner
BEFORE removing the Re-Combiner’s covers:
Open all five DC switches on the Re-Combiner, and
Open the DC switch between the Dynapower DC/DC Converter and the
Battery Subsystem, to disconnect the batteries from the system.
STEP 2: De-Energize the PV Conductors
PV arrays can create hazardous DC voltages. Do not attempt to connect
the PV circuits to the Re-Combiner until all PV conductors are confirmed
to be de-energized.
1. Use a multi-meter to check for DC voltage and confirm that the PV Output Circuit
conductors, coming from the CR1500-26-20S-400 PV Source Circuit Combiners in
the array field, are de-energized.
2. If DC voltage is present, locate the PV Source Circuit Combiners and open all DC
disconnect switches, then re-measure.
3. DO NOT PROCEED until the conductors are confirmed to be de-energized.
FACTORY PRE-WIRED
To XGI 1500 inverters
4/0 AWG Cu conductors
EGC: 4 AWG Cu
FIELD-WIRED
From DPS-500 (-375 or -250)
Max 500 kcmil Cu conductors
2 per pole
EGC: 1/0 AWG Cu
FIELD-WIRED
From PV Source Circuit Combiners
Max: 2 cond x 500 kcmil per pole, Cu or Alum or
1 cond x 750 kcmil per pole, Cu or Alum
EGC: 3 AWG Cu, or 1 AWG Alum
FACTORY PRE-WIRED
Comms wiring harness
to XGI 1500 inverters

Yaskawa Solectria Solar DOCR-071069 Page 14 of 24
STEP 3: Prepare the Enclosure for Conduits
1. Remove the left-side cover from the Re-Combiner; save all fasteners for later re-
installation.
2. Note the target area for conduit connections for the PV circuits on the bottom face of
the Re-Combiner, as shown in Figure 5.2.
3. Add the necessary holes for the conduits for PV Output Circuit entries. The Re-
Combiner accepts up to 5 separate PV Output Circuits.
4. Be sure to remove any metal shavings and debris from the inside of the Re-
Combiner.
Recombiner Conduit Entry Locations
This section used for
factory-wired connections
This section used for
field-wired connections

Yaskawa Solectria Solar DOCR-071069 Page 15 of 24
SPECIAL INSTRUCTIONS
PRECAUTIONS FOR ALUMINUM WIRE AND CONDUIT SEALING
Aluminum Conductors
When using aluminum conductors, follow these steps to prepare the conductors.
6. Prepare one wire at a time.
7. Remove the appropriate insulation from the wire.
8. Using a wire brush, remove the oxidized outer layer from the aluminum
conductors.
9. Immediately apply a neutral dielectric grease, such as Ideal NOALOX®anti-
oxidant compound, and connect the aluminum cable to the terminal.
10.If the connection is not made within 30 seconds of applying the compound,
repeat this process, as an oxidized layer may have formed on the conductor.
Conduit Connections
Follow these instructions and best practices when securing conduits to the Re-
Combiner.
3. Use UL514B certified water-tight conduit fittings and proper installation methods
to provide a water-tight connection that will maintain the Type 3R rating of the
enclosure.
4. Use an appropriately-rated sealant and seal the conduits fully to prevent the
exchange of air between the conduit and the enclosure. Sealing the conduit will
help prevent condensation in the enclosure.
Aluminum oxidizes quickly when exposed to the atmosphere. An oxidized
layer is a poor conductor that could lead to thermal issues, production loss,
or damage to the Re-Combiner.
Conduits connected to an outdoor enclosure can introduce water vapor into
the enclosure and lead to the formation of condensation inside. Failure to
follow these guidelines can result in water intrusion into the unit through the
conduit connections and may void the warranty.

Yaskawa Solectria Solar DOCR-071069 Page 16 of 24
STEP 4: PV Output Circuit Wiring Terminations in the Re-Combiner
The PV Output Circuit conductors terminate on tabs extending from the DC switch. The
tabs are factory-supplied with dual studs to maintain conductor alignment. Figure 5.3
illustrates the terminations and the sections below identify the relevant specifications.
Note that users must supply the Crimp Lug and Fasteners as defined.
PV Output Circuit Conductors Terminations
Lugs Compression lugs are NOT provided with the Re-Combiner. The lugs must
conform to the specifications given in the table below:
Conductors
Conductor Termination
Single and Dual Conductor Terminations
Lug Type
Plating &
Material
Max. Tongue
Width
Hole Size
Temp
Rating
Two-Hole
Tin Plated Cu
1.95 in
for M8 stud
90C
Max distance from hole center to end of lug
14 mm
Max Allowable Conductor Size
Cu or Alum, 90C temp rating
1 or 2 cond at 500 kcmil
1 cond at 750 kcmil
Fasteners
(Supplied)
A: 8mm flanged nut, SS
Torque: 90 in-lb (10 Nm)
Dual Conductors
Crimp Lugs
Single
Conductor Crimp
Lug
A
Positive polarity conductors (red wires in Fig 5.3) connect to a fuse.
Confirm polarity and fuse connection for positive conductors.
A

Yaskawa Solectria Solar DOCR-071069 Page 17 of 24
STEP 5: DynaPower DC/DC Converter Conductor Termination
The Re-Combiner is supplied with 20-foot pigtail conductors for the wiring to the
Dynapower DC/DC Converter. These conductors are pre-terminated inside the Re-
Combiner; the pigtail conductors are provided looped and secured temporarily outside
of the unit. The user is responsible to route, secure and properly terminate these
conductors to the Dynapower DC/DC Converter.
Conductors
Factory Pre-Wired DynaPower DC/DC Converter Terminations inside the Re-Combiner
Max Output
Current
DPS-500: 500 A
DPS-375/250: 312.5A
DC Re-
Combiner No.
of Terminals
2 per pole (2 pos, 2 neg)
Supplied
Conductors
350kcmil, 90C rated
2 per Pole (as in Fig. 5.5)
+
_
See the DynaPower DC/DC Converter Installation User Manual for making
connections to that unit. No field-wiring inside the Re-Combiner is required
for the Dynapower DC/DC Converter.

Yaskawa Solectria Solar DOCR-071069 Page 18 of 24
STEP 6: Equipment Ground Wiring
Terminals are provided in the Re-Combiner for all Equipment Grounding Conductors
(EGCs) associated with the PV Source Circuits, DynaPower DC/DC Converter and XGI
1500 inverters. NOTE: the Re-Combiner comes from the factory with the XGI 1500
inverters and Dynapower DC/DC Converter Equipment Ground Conductors pre-wired to
ground lugs. Torque each EGC for the PV Source Circuits per the specifications below.
PV Equipment Ground Lugs (5x)
14 AWG –2 AWG
Torque to 20 in-lb, Slotted Screw
Cu or Al Conductors
Final Steps
Verify the proper polarity of each conductor. Polarity reversal can lead to dangerous
conditions capable of harming personnel and equipment.
Check the Re-Combiner for tools and debris; ensure that the unit is clean and orderly.
1. Verify that all connections meet the requirements of this User’s Manual.
2. Secure the Re-Combiner cover, ensuring that all fasteners are in place.
3. Consult the startup and commissioning procedures for the PVS-500 before energizing.

Yaskawa Solectria Solar DOCR-071069 Page 19 of 24
Re-Combiner Switches On/Off Positions
The Re-Combiner contains five user-operable disconnect switches for the PV Output
Circuit inputs (see Fig. 6.1). When the disconnect switch handle is in the OFF position, the
circuit is open between the PV Output Circuit and the DC bus in the Re-Combiner.
Conversely, when the disconnect switch is in the ON position, the circuit is closed between
the PV Output Circuit and the DC Bus in the Re-Combiner.
The disconnect switch is rated for 400A, is fully load-break rated and can be safely
operated under normal operating conditions when installation is per this User’s Manual
and all warnings and ratings are observed.
All Disconnect Switches must be OFF before working on the Re-Combiner.
90
°
OF
F
ON

Yaskawa Solectria Solar DOCR-071069 Page 20 of 24
3.5 Communications
The inverter MODBUS TCP network and Heila Edge controller are prewired to the network
switch inside the Heila control cabinet. Install two separate Cat 6 Ethernet cables with internet
access to the network switch inside this cabinet.
Heila Control Cabinet Components
Supply (2) Cat 6
Ethernet cables to
network switch.
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