TL Inverter

Contents
1 About this Manual......................................................................................... 4
1.1 Preface.................................................................................................. 4
1.2 Introduction .......................................................................................... 4
1.3 Applicable Scope.................................................................................. 5
1.4 Manual Instruction ............................................................................... 6
2 Safety Precautions ......................................................................................... 7
2.1 Safety Precautions ................................................................................ 7
2.2 Notes on Operation ............................................................................ 11
2.2.1 Live Line Measurement .......................................................... 11
2.2.2 Opening the Plant .................................................................... 11
2.2.3 Requirements Prior to Connecting the Switches on AC and DC
Sides ................................................................................................. 12
2.2.4 Notes on Shutdown ................................................................. 13
3 Product Delivery ......................................................................................... 14
3.1 Scope of Delivery............................................................................... 14
3.2 Nameplate of TC500K3US-O ............................................................ 15
3.3 Storage ............................................................................................... 16
3.4 Transportation .................................................................................... 18
I
4 Product Description .................................................................................... 19
4.1 Grid-connected System ...................................................................... 19
4.2 Appearance ......................................................................................... 21
4.3 Appearance Description ..................................................................... 22
4.3.1 Dimensions.............................................................................. 22
4.3.2 Ventilation Design ................................................................... 23
4.4 Circuit Introduction ............................................................................ 23
4.5 Terminals ............................................................................................ 25
5 Product Installation .................................................................................... 27
5.1 Basic Installation Pequirements ......................................................... 27
5.2 Installation Environment .................................................................... 28
5.2.1 Ground Requirements ............................................................. 28
5.2.2 Requirements of the Minimum Space for Outdoor Uses ........ 29
5.2.3 Requirements of the Minimum Space for Indoor Uses ........... 32
5.3 Requirements of the Alignment of Wires, Ventilation and Others ..... 33
5.3.1 Requirements of Cable Trenches ............................................ 33
5.3.2 Ventilation Requirements ........................................................ 34
5.3.3 Other Requirements ................................................................ 36
5.4 Wiring Specifications ......................................................................... 37
5.5 Fixation and Protection of Connection Cables ................................... 38
5.5.1 Fixation of Cables ................................................................... 38
II
5.5.2 Cable Protection ...................................................................... 39
5.6 Installation Process ............................................................................ 39
6 Installation Preparations ............................................................................ 42
6.1 Pre-Installation Inspection ................................................................. 42
6.2 Installation Tools and Parts ................................................................ 42
7 Equipment Installation ............................................................................... 43
7.1 Equipment Transportation .................................................................. 43
7.1.1 Precautions .............................................................................. 43
7.1.2 Packaging and Logos .............................................................. 44
7.1.3 Transportation Packaged ......................................................... 46
7.1.4 Transportation without Packaging........................................... 47
7.2 Field Installation ................................................................................ 49
8 Electrical Connection.................................................................................. 54
8.1 Precautions ......................................................................................... 54
8.2 Input and Output Requirements ......................................................... 55
8.3 Cable Requirements ........................................................................... 56
8.4 Wiring Components ........................................................................... 58
8.5 Preparations for Electrical Wiring ...................................................... 62
8.6 DC Side Wiring .................................................................................. 63
8.7 AC Side Wiring .................................................................................. 69
8.8 Ground Connection ............................................................................ 73
III
8.9 Communication Wiring ...................................................................... 75
8.10 Power Supply ................................................................................... 76
8.10.1 Self-Powered Mode............................................................... 76
8.10.2 External Power Supply Modes .............................................. 77
8.11 Seal at the Bottom of Cabinet .......................................................... 78
9 Installation Inspections ............................................................................... 82
10 Commissioning .......................................................................................... 84
10.1 Commissioning Requirements ......................................................... 84
10.2 Check before Commissioning .......................................................... 85
10.2.1 Check the PV Array .............................................................. 85
10.2.2 Check the Inverter ................................................................. 85
10.2.3 Check the Parameters of the Inverter Grid ............................ 85
10.3 Preparing before Power on ............................................................... 87
10.4 Power on .......................................................................................... 88
10.5 Completion of the Test Run ............................................................. 88
11 Appendixes ................................................................................................. 89
11.1 Technical Data .................................................................................. 89
11.1.1 Electrical Part ........................................................................ 89
11.1.2 Mechanical Part ..................................................................... 91
11.1.3 System Data .......................................................................... 91
11.1.4 Transformer Parameters ........................................................ 91
IV
11.2 Warranty Statement .......................................................................... 92
11.2.1 Normal Warranty ................................................................... 92
11.2.2 Extended Warranty ................................................................ 94
11.2.3 Contact Us ............................................................................. 94
V
TC500K3US-O Installation Instructions
Important Safety Instructions
Save These Instructions
This manual contains important instructions for the following product:
 TC500K3US-O
The product is designed and tested in accordance with international safety
requirements, but as with all electrical and electronic equipment, certain
precautions must be observed when installing and/or operating the product. To
reduce the risk of personal injury and to ensure the safe installation and
operation of the product, you must carefully read and follow all instructions,
cautions and warnings in this manual.
Warnings in this Document
“DANGER” indicates a high degree of potential hazards, if not

avoided, which will lead to death or serious injury.
“WARNING” indicates a moderate degree of potential hazards, if not

avoided, which may result in death or serious injury.
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“CAUTION” indicates a low level of risks, if not avoided, which may

result in moderate or minor injuries to personnel.
“NOTICE” indicates potential hazards, if not avoided, which may

cause the result that the equipment cannot work properly or cause losses to
property.
“DISCRIPTION” is the additional information of the manual, the

emphasis and supplement of the contents, which may also provide product
optimization tips or skills that can help you solve certain problems or save
your time.
Warnings on this product
Please note the identification labels on the engine body, including the
following:
Warning electric shock

This symbol indicates that the inverter interior contains high voltage,
and an electric shock may be caused when touching.
2
Warning hot surface

This symbol indicates that the temperature here is higher than that
within the body acceptable range, so please do not touch arbitrarily to avoid
personal injuries.
PE
This symbol indicates that it is the PE port, and solid grounding is
needed to ensure the safety of the operating personnel.
ON
This symbol is the “ON” position schematic diagram of AC and DC
circuit breakers.
OFF
This symbol is the “OFF” position schematic diagram of AC and DC
circuit breakers.
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1 About this Manual
This chapter introduces the main contents, facing readers, notice for use
and explanations to symbols to help users have a better understanding and
using of this manual.
1.1 Preface
Dear customers, appreciating for using TC500K3US-O PV grid-connected
inverters developed by TBEA. We sincerely hope this product will meet your
needs and expect you to put forward more views on the performance and the
function of this product. We continue to improve the quality of this product.
1.2 Introduction
This manual applies to TC500K3US-O PV inverter (hereinafter referred
to as ‘inverter’),this manual contains the followings contents.
 Safety instructions
This manual introduces safety signs during operation and precautions of
dangers, warnings and cautions during installation.
 System Introduction
This manual introduces the scope of delivery of inverters, identification
methods, storage and structure, electrical modality principle of inverters.
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 Installation design
This manual introduces the system design, installation environment, and
electrical wiring design as well as installation process of inverter.
 Installation and inspection
This manual introduces mechanical installation, electrical installation, and
communication connections of the inverter, and the inspection methods after
installation.
 Commissioning guidance
This manual introduces precautions of the inverter during test
commissioning and the operational process of the inverters.
 Others
This manual introduces the technical data of the inverter, warranty clauses
and the contact information of our company.
1.3 Applicable Scope

This manual is for the staff working on installing and operating of the
inverter. Staff for installation and maintenance shall be equipped with certain
expertise in electrical, wiring and mechanical fields, familiar with electrical,
mechanical schematics and features of electronic components. It is also
required for the staff to be familiar with the content of the document and to
comply with the safety regulations.
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1.4 Manual Instruction
Please read this manual carefully before installing the product. Please
keep this manual on hand for quick reference. In addition to this installation
manual, the following documents can also be used:
 TC500K3US-O Operation Manual
The images, logos, symbols, etc. used in this manual are owned by TBEA
Xi'an Electrical Technology Co., Ltd.. No part of this document can be
reproduced by unauthorized persons without the prior written permission of
our company.
Manual content will be constantly updated and corrected, but it is
inevitable that there are slight discrepancies from material objects or errors in
this manual. Users will be subject to the purchased actual products and can
download latest version of the manual at http://www.tbeapower.com or from
other sales channels.
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2 Safety Precautions
This chapter introduces the overview of safe use of TC500K3US-O PV
inverters and safety precautions needed to be followed during installation and
operation.
2.1 Safety Precautions
 Danger to life from electric shock due to live voltage.
High voltages are present in the live components of the inverter. Touching
live components results in death or serious injury due to electric shock.
When working in a high contact-risk environment, wear personal
protective equipment.
Do not touch live components.
Follow the instructions precisely.
Observe all the safety messages on the product and in the documentation.
Before any work on the inverter is performed, always disconnect all
external voltage sources of the plant.
(1) Grid voltage

(2) External power supply
(3) DC voltage of PV array
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Ensure that no disconnected components can be reconnected.
After disconnecting the inverter from the voltage sources, wait at least 5
minutes for the capacitors of the inverter to discharge completely.
DC cables connected to PV modules that are exposed to sunlight are live.
Touching live components results in death or serious injury.
 Wear suitable personal protective equipment for all work on the
inverter.
 Prior to connecting the DC cables, ensure that the DC cables are
voltage-free.
 Unauthorized modification or damaged device can lead to danger to
life due to electric shock or fire hazard.
It is forbidden to refit the equipment and no unauthorized person can use
the equipment.
Initially and visually check whether the equipment is damaged or has
other dangerous conditions before operating.
Check whether other external equipments or circuit connections are in
safe states.
Confirm that this equipment is in a safe state, and then operate.
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 Danger to life when the inverter is not locked
If the inverter is not locked, this means that unauthorized persons have
access to components carrying lethal voltage. Touching live components can
result in death or serious personal injury due to electric shock.
Always keep the inverter locked.
Remove the keys from the door locks and from the key switch.
Keep the keys in a safe place.
Ensure that unauthorized persons do not have access to the PV plant.
 Danger to life due to blocked escape routes
In hazardous situations, blocked escape routes can lead to death or serious
injury. It is imperative that the escape route is freely accessible at all times.
An escape route of at least 3 ft. (915 mm) width must be available at all
times. Make sure the minimum passage width of the route meets local
standards.
Remove all tripping hazards from the escape routes.
Do not place any objects in the escape route area.
If two inverters have been installed facing each other, never open the
doors of the both inverters simultaneously.
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 Only professional electricians or persons are allowed to work on the
product.
It must ensure that at least 2 personnel are working in the field until the
equipment is safely de-energized and discharged completely during
maintenance.
Only after getting permission of local power company and completing
installation by qualified persons, can the inverter be connected with the grid.
Electrical installation must comply with local electrical installation
standards.
 Improper contacts or operations of printed circuit boards or other
static-sensitive components will cause damages to the device.
Avoid unnecessary contacts with the circuit board.
Comply with the electrostatic protection specification, wear antistatic

wrist straps.
During the overhaul of the plant and routine maintenance, turn the
breakers on AC and DC sides to “OFF” position to avoid irrelevant personnel
from approaching or meeting with accident. It is recommended to erect
warning labels or set up barrier tape.
This manual cannot cover all possible cases in transportation, installation,
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commissioning. If encountering some cases not described in the manual, please

contact TBEA Co.,Ltd..
2.2 Notes on Operation
2.2.1 Live Line Measurement
High voltage is present in the plant. Touching by accident may result in
death or personal injury due to electric shock. Prior to live line measurement, it
is imperative to wear suitable personal protective equipment and instruments
(such as wearing insulated gloves, etc.).
2.2.2 Opening the Plant
Even if all connections to the inverter have been disconnected, lethal

voltage may still be present in the capacitor of the inverter. After disconnecting
the inverter from voltage sources, wait at least 5 minutes for the capacitor of
the inverter to discharge completely before maintenance and overhaul or other
operation.
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2.2.3 Requirements Prior to Connecting the Switches on AC and

DC Sides
 Breakers on AC, DC sides shall be disconnected and the protective panel
against accidental touch shall be installed or protective measures be taken.
 All connections must be carried out in accordance with the installation
manual and schematics.
 Protective earthing connection has been done with power grid
transmission and internal power supply.
 Confirm that the inverter has been closed and locked.
 Emergency stop switch is in loose status.
 It shall be confirmed that the rated voltage, frequency and phase sequence
of the connection terminals on AC side are in line with requirements.
 It shall be confirmed that the voltage polarity on DC side is correctly
connected.
 Check PV array by insulation test to ensure no ground fault.
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2.2.4 Notes on Shutdown
There are two cases for shutdown, in normal maintenance and in fault
occurring. The procedures for respective shutdown are as follows:
 Normal maintenance and overhaul
Shutdown procedure:
(1) Turn the key switch to “OFF”.
(2) Observe the LCD display until the rate of work of the display is
shown as “0”.
(3) Turn both AC and DC circuit breakers to “OFF”.
(4) Disconnect the front and rear breakers of the inverter.
 When fault or emergency occurring
Shutdown procedure:
(1) Press down the emergency stop button then turn the key switch to
“OFF”.
(2) Turn both AC and DC circuit breakers to “OFF”, and then
disconnect the preamplifier breaker and after stage amplifier circuit
breaker.
(3) Turn the key switch to “OFF”.
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3 Product Delivery
This chapter describes the scope of delivery of TC500K3US-O, the name
plate recognition and storage methods of inverter.
3.1 Scope of Delivery
TC500K3US-O is delivered with wooden case packaging. During
transportation, transportation requirements described in the manual must be
followed. If there is any doubt, contact the TBEA Company.
The packing case of TC500K3US-O contains the following items:
Table 3-1 Supply scope of TC500K3US-O
Items Name Quantity Remarks

TC500K3US-O PV Including cabinet keys
1 1
Grid-Connected Inverters and accessories
2 TC500K3US-O Installation Manual 1
3 TC500K3US-O Operation Manual 1
4 Warranty Card 1
5 Certificate 1
6 Test Report 1
TC500K3US-O has been rigorously tested and inspected in the

factory before transportation, but collisions, dumping and other
unforeseen circumstances may still occur during transportation. Therefore,
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you must conduct the detailed acceptance of the packaging, appearance

and other aspects after receiving the inverter. If any damage detected,
please contact the transportation company or directly contact with TBEA
Co., Ltd., (see "Appendix" for the contact details) and provide photos of
the damage, we will provide the fastest and best service.
If you have special needs, users can log in the website of TBEA Co.,
Ltd. To freely download the latest version of the manual or directly
contact with TBEA Xi'an Electric Technology Co.,Ltd..
3.2 Nameplate of TC500K3US-O
The nameplate is affixed on the top of the left side of TC500K3US-O
cabinet.
TBEA LOGO, product name
Product parameter data
Product serial number
Product certification LOGO
Company name
Figure 3-1 Schematic figure of nameplate of TC500K3US-O
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The nameplate which contains important parameter information

related to the inverter shall always be protected during the transportation,
installation, maintenance, repair and other operations.
3.3 Storage
This section provides you with a variety of information about the storage
of TBEA’s North American inverter. This information will help you to prevent
damages to the device itself due to improper storage.
Upon completion of the delivery and the acceptance work, if the device
cannot be immediately installed and operated on site, but needs to be stored,
the following aspects shall be paid attention to:
Prevent damage to the device due to moisture.
If the inverter is stored improperly, in moist environment, moisture will
penetrate the attachment and cause internal electrical damage.
 Keep the original closed state of the packaging.
 Keep the desiccant in the package, and it shall not be abandoned.
 If the inverter needs to be kept six months or more, it must be placed in a
dry area, and the desiccant shall be regularly replaced.
 When storing the device, pay attention to the ventilation and
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moisture-proof work, water is strictly prohibited in the storage
environment.
 Storage temperature: -30℃ ~ +70℃ (-22°F ~ +158°F), relative humidity
is less than 95%.
Avoid damage to the device due to uneven building ground.
If the inverter is stored on uneven ground, the external structure of the
device may be damaged.
Dust and moisture will penetrate into the inverter and may damage the
electrical part.
 The building ground must be suitable for the weight of 2300kg (5077lbs).
 Unevenness of the ground must be less than 0.25%.
 Long-term storage without packaging is prohibited!
 Outdoor storage or storage in direct sunlight environment is

prohibited!
 Chassis tilting or overlapping placement is prohibited!
 Regular inspection, generally not less than once a week, check

whether the packaging is intact, avoid pest moth bite, if found
damaged, the device shall be replaced immediately.
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 Pay attention to response to the surrounding harsh environment, such

as quenching, shock heating, collision, etc., so as to avoid damage to
the inverter;
When working on the device after long-term storage, the cabinet door
shall first be opened for inspection, so as to confirm whether the device is
intact and a professional test is necessary.
3.4 Transportation
The inverter shall only be transported complying with the transportation
method described in 7.1 of the installation manual. During the transportation,
always pay attention to its center-of-gravity position, which has been marked
on the outer packing case.
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4 Product Description
This chapter describes the product information of the TC500K3US-O.
4.1 Grid-connected System
TC500K3US-O, produced by TBEA Xi'an Electric Technology Co., Ltd.,
is a power-plant PV grid-connected inverter with a transformer inside, suitable
for indoor or outdoor installation. It converts direct current generated by PV
array to alternating current, being an important part of the PV grid-generation
system.
PV grid-generated system consists of PV array, PV grid-connected
inverters, metering devices and the powder distribution system. Solar energy is
converted to DC power through PV array, and becomes sine wave current
synchronous with the grid through the PV grid-connected inverter and is then
fed into the grid. TC500K3US-O is an outdoor type grid inverter and rather
flexible to use. It can be installed outdoors and can also be installed in the
operating room. According to different grid connection modes, they can be
divided into low-voltage grid and medium-voltage grid. The PV grid-generated
system equipped with TC500K3US-O is as shown in Figure 4-1.
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A B C D E
Figure 4-1 PV grid-generated system of TC500K3US-O
Table 4-1 Parts list
Items Name
A PV array
B Combiner box
C TC500K3US-O
D Step-up isolation transformer
E Public grid
Adaptable system components of TC500K3US-O are as shown in Table
4-2.
Table 4-2 List of the system components
Name Type
PV arrays Thin Film Cells
Public grid IT
Combiner box 600V（80A≤I≤160A）
If the inverter isn't installed according to the document description,

or privately installed or reconstructed without authorization, accidents or
device damage is likely to occur. If losses are caused by these reasons,
TBEA will not assume any responsibility.
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4.2 Appearance
The appearance of TC500K3US-O is as shown in Figure 4-2.
Figure 4-2 Appearance of TC500K3US-O

Items Device name Description
① Panel lights Displaying the operating status of inverters
② LCD display Displaying the information of operating data
③ Key switch Switches inverter
④ Shut down the inverter immediately when press it

Emergency-stop button
down
⑤ DC main switch DC side circuit breaker switch
⑥ To close the front door of the inverter, use the

Door lock
matching key to lock the door
⑦ AC main switch AC side circuit breaker switch
⑧ DC input cabinet
⑨ Inverter cabinet
⑩ AC output cabinet
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4.3 Appearance Description
4.3.1 Dimensions
Maximum dimensions of TC500K3US-O: 2370mm (93.3inch) ×
2140mm(84.3inch) ×910mm (35.9inch) (W × H ×D)
Weighs: approximately 2300kg (5077Ibs)

The mechanical and external dimensions are as shown in Figure 4-3.
Figure 4-3 Dimensions of the complete machine
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4.3.2 Ventilation Design
The upper part of TC500K3US-O is the air inlet for cooling air to go into
and the lower is the air outlet to discharge hot air.
The air inlet of the head cover is equipped with a removable

dustproof net and insect net, which need to be cleaned regularly.
Figure 4-4 Ventilation schematic of TC500K3US-O
4.4 Circuit Introduction
Direct current generated by PV array is converted to alternating current

through inversion in the inverting module of TC500K3US-O, and then
becomes sine wave through the filter and is then fed to the grid via the isolation
and step-up of an internal three-phase transformer.
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AC Fliter AC Contactor AC Breaker
Fuses+DC Breaker inverter
+ A
＝
+ B
E M C filt e r
E M C filt er
- C
3～
320V－580V
DC
AC
SPD SPD
24
GFDI Gab
Controller Gbc
Gca
RS232 RS 485 DC- 24V
Figure 4-5 The main circuit of TC500K3US-O

External communication unit Auxillary
HMI unuit AC - 200
unit
The main circuit of TC500K3US-O is as shown in Figure 4-5.
4.5 Terminals
TC500K3US-O provides multiple terminals which can be connected to

multiple DC input, two AC output and PC for communication, etc. Its internal
terminals are as shown in Figure 4-6.
Figure 4-6 Schematic figure of terminals
Items Name
A PV array positive input terminals (DC +)
B PV array negative input connecting copper bars (DC-)
Connect AC output connecting copper bars with L1, L2 and L3 three-phase grids
C
respectively.
D Grounding copper bars
E RS485 communication interfaces and external power supply interfaces
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RS485/RS232 converter is needed for communication with the upper

computer.
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5 Product Installation
This chapter describes the detailed installation requirements and process
of TC500K3US-O.
5.1 Basic Installation Pequirements
To ensure the machine to work properly, the installation environment and
requirements are as follows:
 TC500K3US-O’s waterproof rating is NEMA 3R; it can be installed
outdoors and indoors; as electronic device, it shall not be placed in areas
of high humidity in long term;
 Avoid direct sunlight, otherwise the excess temperature causes equipment
derating which may affect power generation. We recommend installation
in the shade or shading devices installation;
 Enough space around the unit for good ventilation, convenient installation
and maintenance as well as escape in emergency;
 Installation environment clean;
 As it produces noises in operation, try to mount away from living areas;
 Ensure flat and sufficient carrying capacity of the assembling floor;
 Installation location shall be convenient observation of LCD display;
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 Ambient temperature: -25°C ~ 50°C (-13°F ~ +130°F). Relative humidity:
0 ~ 95% (non-condensing);
5.2 Installation Environment
TC500K3US-O inverters can be installed both indoors and outdoors.
5.2.1 Ground Requirements
TC500K3US-O is required to be installed on a flat slab with a concrete
foundation and a surface covered with flame-resistant materials, and either
sunken or inclined situations on the floor are prohibited.
Accuracy requirements of foundation slabs:
 Levelness: the base length tolerance shall be controlled within
1mm/1000mm;
 Parallelism: the base length tolerance shall be controlled within
1mm/1000mm;
 Height difference between the front base and rear base shall be
controlled within 1mm/1000mm.
A solid, safe and reliable foundation must be provided. The foundation
must be capable of bearing 2300 kg of the inverter weight. And the weight
must be always taken into consideration when selecting the installation
location.
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Figure 5-1 Requirements of ground for TC500K3US-O installation
5.2.2 Requirements of the Minimum Space for Outdoor Uses
The inverter and the surrounding objects must have the minimum distance
when installing the inverter, to meet the requirements in maintenance, escape
and ventilation. The escape routes must meet the American minimum
requirements of 915mm in order to satisfy the minimum requirements for a
single person to go through freely, and also, enough spatial distance will
provide good conditions for the equipment and cables to release the heat,
avoiding the shutdown and even fire and other dangerous situations caused by
overheating.
 Minimum installation space for single TC500K3US-O
The space of 1800mm shall be provided in front and over 1800mm
(32inch) to the back, and over 600mm (24inch) to the top for easy installation,
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cooling, maintenance and enough space to escape in emergency.
Details are shown in Figure 5-2:
Figure 5-2 Requirements of installation space for a single set of TC500K3US-O
Items Recommended minimum

Description
distance (mm)
Minimum distance in front meeting the
normal opening and closing of the front door,
A 1700(70inch)
user operations, safe evacuation and other
requirements
B 1300(52inch) Minimum distance rear

C 600(24inch) Minimum distance above
Minimum distance at right side, 600mm
D 600(24inch)
(24inch) is the distance from the closed wall
E 600(24inch) Minimum distance at left side
 The minimum space of installation space for two TC500K3US-O.
First way: back to back
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Figure 5-3 Requirements of back-to-back installation space for two TC500K3US-O
Second way: face to face
Figure 5-4 Requirements of face-to-face installation space for two TC500K3US-O
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Third way: front to back
Figure 5-5 Requirements of front-to-back installation space for two TC500K3US-O
 The doors between the two inverters are prohibited to open

simultaneously, to avoid blocking the escape routes and preventing
the people from failing to flee the scene immediately in case of
failures.
 Both the front and back doors of TC500K3US-O can be opened, and
the maximum size of the door slabs is of about 750mm.
5.2.3 Requirements of the Minimum Space for Indoor Uses
If you need to install indoors, the ground, space, cable trenches, ducts,
ventilation equipment and various protective measures in the control room
32
need rigorous designs, please contact TBEA for confirmation.
A space of at least 915mm must be kept for the tunnel escape at the
emergency exit when the TC500K3US-O is installed indoors, and obstacles
blocking the tunnel escape shall be removed to keep the tunnel escape
unobstructed.
5.3 Requirements of the Alignment of Wires, Ventilation and

Others
5.3.1 Requirements of Cable Trenches
The wires of TC500K3US-O are led in and out below, and the cables
connecting the TC500K3US-O inverter and the outside are suggested being
aligned along the cable trenches, for easy installation and maintenance.
Concrete cable trenches shall be preset at the installation location; or steel
supports shall be installed on the ground, mounting surface shall be raised, and
cables shall be laid out at overhead places. (See the relevant design standard
specifications for details)
The cable trenches are often designed and constructed by the construction
party in accordance with the relevant standards, taking the weight and size of
the equipment into full consideration.
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Reliable electrical connections between cable trenches as well as cable
trenches and ground electrodes are required.
Section of cable trenches is shown in Figure 5-6, the user can determine
the number of cable brackets according to the requirements, and the
communication, control and power cables shall be separated when laying the
cables, and DC circuits and AC circuits shall be laid separately. In this way, the
installation and maintenance will be easier, and interference of power circuits
to communication and control signal lines will be reduced.
Figure 5-6 Sectional view of cable trenches
5.3.2 Ventilation Requirements
A lot of heat will be generated when TC500K3US-O is running, so the
electrical performance of the equipment will be affected when its temperature
34
is too high, and even the equipment will be damaged, consequently, the release
of these heat is required to be taken into full account when selecting the
installation environment, in order to ensure a proper and efficient operation of
the equipment.
 Ventilation environment
To meet the ventilation requirements of TC500K3US-O, its installation
environment must meet the following conditions:
 You shall avoid installing TC500K3US-O at places with bad
ventilation and low air flow.
 Enough fresh air shall be supplied at the air inlet of the inverter.
 The air inlet shall be cleaned regularly to prevent being blocked by
sediments and others when the cabinet is installed outdoors.
 Ventilation equipment
In order to ensure efficient and reliable operation of the equipment, the
ambient temperature for the equipment in running must be controlled within
the allowable range.
 The air is let in from the upper part in the design of the ducts for the
outdoor TC500K3US-O, and the waste heat is discharged out through
the bed plate at the base. Therefore, according to the requirements of
35
the maintenance chapter in the user manual, the appropriate air vents
must be kept clear and clean.
 Avoid direct sunlight, otherwise the excess temperature causes
equipment derating which may affect power generation. We
recommend installation in the shade or shading devices installation;
 The air inlet shall face towards the direction selected according to the
actual situation of the local wind direction.
 Fans shall be overhauled every two years as recommended, to ensure
the equipment is running well.
5.3.3 Other Requirements
According to NEMA 3R protection class, the TC500K3US-O outdoor
inverter is suitable for outdoor installation. And the control areas are packaged
and sealed.
According to EMC requirements and noise levels, the inverter shall be
installed in an industrial environment or outdoors.
After wiring is completed, the inlet and outlet line boards on the machine
shall be installed and fastened to meet waterproof and windproof requirements.
36
TC500K3US-O shall avoid direct sunlight; otherwise, the higher

temperature will affect the generation.
5.4 Wiring Specifications
Cables used for the system can generally be divided into power cables,
power lines and data lines.
When laying the communication cables, you need to stay away from the
power cables, and the cables at the intersections need to keep a right angle. The
communication cables shall keep the shortest length as far as possible, and
keep a certain distance from the power cables.
The power cables, power lines and data lines shall placed in separate cable
trenches, in order to avoid that the power cables and other cables are aligned
parallelly for a long distance, and reduce the electromagnetic interference
caused by the output voltage transient.
The distance between the power cables, power lines and data lines shall be
greater than 0.2m. In case of the cross-distribution of wires, the crossing angle
shall be of 90 degrees, but the distance can be reduced appropriately.
The corresponding relation of the minimum distance recommended
37
between the paralleled shielded data lines and power cables and the line length
can be seen in Table 5-1.
Table 5-1 Space between signal lines and power cable wirings
Length of parallel lines(inch) Minimum space distance(inch)
7874(200m) 12(0.3m)
11811(300m) 20(0.5m)
19685(500m) 48(1.2m)
The data line shall be aligned close to the earth surface or supports as far
as possible, such as support beams, steel tanks, metal rails and so on.
5.5 Fixation and Protection of Connection Cables
5.5.1 Fixation of Cables
In order to prevent poor contact caused by loose wring cooper terminals
by forces, or heat or even fires caused by increased contact resistance, the
following requirements of torques shall be met when fastening the screws on
the wiring cooper terminal:
Screw size Torque(in-lbs)

M4 18in-lbs (2N·m)
M5 27in-lbs (3N·m)
M6 40in-lbs (4.5N·m)
M8 98in-lbs (11N·m)
M10 196in-lbs(22N·m)
M12 346in-lbs(39N·m)
M16 1064in-lbs(120N·m)
38
5.5.2 Cable Protection
The protection for cables includes the communication cables and power
cables protection. The protective methods are as follows:
 Protection for communication cables
Since the communication cables are weak, they are easy to be broken by
the tension or fall off from the terminals in construction, then they shall be
connected after the power circuits are all connected, and also, they shall be
aligned along the trenches in connection, if no cable trenches, they shall be
fastened by ribbons, besides, you shall avoid heating elements and circuit
cables of high field when aligning the cables.
 Protection for power cables
Due to the strong current in the power circuit cables which may lead to
short circuit, you shall avoid any scratches or damages on the insulation skins
of the cables when installing and connecting the cables. Also, the power cables
must be secured properly.
5.6 Installation Process
The total installation process of the TC500K3US-O inverter is as shown
in Figure 5-7, and the installation process description is shown in Table 5-2.
39
Figure 5-7 Installation process
40
Table 5-2 Installation process description
Reference
Installation steps Installation instructions
sections
Preparations need to be done before 6 Installation

the installation of TC500K3US-O: preparations
1. Whether the product accessories
Pre-installation preparations
are complete
2. Whether the installation tools and
parts are complete
Mechanical installation includes: 7 Mechanical
Mechanical installation 1. Move the inverter installation
2. Install and fix the inverter
Electrical connection includes: 8Electrical connection
1. Open the front door and remove
the protective cover
Electrical connection 2. DC side wiring
3. AC side wiring
4. Ground connection
Communication cable connection
The inspected items include: 9Installation checklist
1.Mechanical installation inspection
Inspection after the installation
2. Electrical installation inspection
3. Others
Commissioning includes: 10 Commissioning
1. Pre-commissioning inspection
Power-on, commissioning 2. Preparations before starting up
3. Initial operating steps
4. Completion of commissioning
41
6 Installation Preparations
This chapter describes the preparatory work before installing

TC500K3US-O, including checking accessories are complete and preparing the
tools and parts required in installation.
6.1 Pre-Installation Inspection
Check all the accessories delivered are complete according to the packing
list;
Items Name Quantity

1 TC500K3US-O inverter 1
2 Anti-theft screw wrench 2
3 Key 2
4 Certificate 1
5 Warranty card 1
6 Product support manual 1
7 Factory inspection report 1
6.2 Installation Tools and Parts

The tools and parts required in installation are as follows:
 Crane, forklift or fork lift truck (with sufficient carrying capacity)
 Torque wrench
 Screwdriver
 Wire stripper
 Alcohol blast burner (hot hair dryer)
 Internal hexagonal wrench for fixing terminals
 Megger and multimeter
42
7 Equipment Installation
This chapter describes the process of installing the TC500K3US-O
inverter, including the method of transportation, demolition of the package on
the site and fixation.
7.1 Equipment Transportation
This section describes the preparatory work and basic requirements
needed in the transportation of the equipment, also includes the precautions
required during the course of transporting or handling the inverter.
7.1.1 Precautions
The links mentioned in the following contents are required to be noted
during the transportation of the inverter all the time, avoiding any hazards and
accidents that may occur during the transportation.
 All staff must wear proper safety protection equipment.
 The minimum load-bearing requirements of at least 2300kg must be

provided for all transporting and handling ways.
 Enough space distance shall be always kept during the

transportation.
 The equipment shall be close to the ground as far as possible during

the transportation.
43
 As a whole, the inverter must not be disassembled either in

transportation or in installation. Any failure caused by the
modification without any authorization from TBEA is not covered
within the warranty scope.
 The inverter cannot tilt, shake violently or bear force suddenly, such
as a sudden lay-down or uplift during the moving process.
 Parameters marked shall be read carefully, in order to select the

appropriate means of transport and storage sites.
 You must strictly avoid storing the inverter on the surface that does
not meet the requirements for any deformation of the inverter as a
result.
 The forklift is used to move the inverter by the user as far as possible
according to the recommendation, and the weight and size of the
machine shall be always noted.
 Cables of DC input and AC main power are proposed to be laid out

before the inverter cabinet is moved to the predetermined position.
Because the cables are thick, as soon as the inverter cabinet is
installed, the cable wiring is very difficult to carry out.
7.1.2 Packaging and Logos
An integrated package is required for the inverter during the
transportation, ensuring to provide good protection for the inverter, and the
operation shall strictly follow the various indications on the package. The
44
packaging logos are illustrated as follows:
Icon Sign
Gravity center logo
Lifting logo
Right side up, prohibit to placing inverters

horizontally, in an inclined way or upside down
Handle with care to avoid damages to inverters

caused by too intense frictions and collisions in
transportation environments
Prohibit to placing in a multilayer stacking form
Pay attention to moisture, and prevent inverters

from rain or moisture
Besides, several important parameters are marked on the packaging box:
45
Name Description
MODEL NO.: Inverter model
SIZE: Out packing size
N.W: Inverter net weight
G. W.: Gross weight, inverter including the out packing case
7.1.3 Transportation Packaged
The inverter with the package can be moved by use of forklifts, forks of
hoists or cranes. The transportation is shown in Figure 7-1.
The weight of the inverter, the position of the center of gravity and lifting
logo on the package are required to note when moving the inverter. The
equipment shall be provided with a sufficient carrying capacity and a
reasonable lay-out support or lifting point is required.
The forklift transportation (a standard transportation method) is shown in
Figure 7-1A.
 The center of gravity on the box shall fall onto the middle of the two
forks of the forklift during the transportation.
 A greater size of the inverter may block the driver’s line of sight, so
supporting staff is required.
 Hoist transportation packaged shown in Figure 7-1B.
 Rings must be used and the lifting point must be designed according
to the signs on the package.
46
A B
Figure 7-1 Inverter transportation with packaging
7.1.4 Transportation without Packaging
The handling without packaging is usually used near the final installation
location, and the inverter with package removed can be moved by forklifts,
hoists, sliding rails or cranes.
If the place to remove the package is farther from the final installation
location, the inverter with a wood pallet at the base can be transported by the
forklift,as shown in Figure 7-2.
47
Figure 7-2 Forklift transportation of inverters with wood pallets
The moving way of forklifts is as shown in Figure 7-3.

 The cover plates at the front and back bases are required to move;
 The forklift shall be closer enough to take the inverter and then
inserted in-depth into the bottom of the inverter to lift it;
 Lift it at the center of gravity;
 The lifting process is required to keep slow, to avoid any accidents.
Figure 7-3 Inverter is moved by using a forklift
48
The lifting method is shown in Figure 7-4.

 Remove cover plates of the front and back base seats;
 Lifting round steels are drawn out from the front and back sides.
 Use lifting cables to fix, and to ensure that four corners are all
connected and fastened sufficiently.
Figure 7-4 Lifting party
When lifting, switch on the DC and AC circuit breakers, making the

handle of circuit breaker perpendicular to the ground separating lifting
handles from damage due to wrapping and colliding with cables.
7.2 Field Installation
49
Unpacking
Unpack the shipping cases of the TC500K3US-O inverter in accordance
with the following procedures.
Step1 Unpack the wooden sides and roofs of packing cases.
Step2 Remove the cushioning materials outside the inverters.
Step3Remove the anchor parts fixed on the transport board of the inverter.
a. Remove the front and back cover boards of the base;
b. Spin the self-tapping bolt on the bottom of the wooden pellet;
c. Remove the self-tapping bolt to separate the inverter and the transport
wooden pallet.
Figure 7-5 Fixed on wooden pallets

Items Name
A Inverter
B Pallet
C Self-tapping bolt
50
The TC500K3US-O is packed according to the reverse procedures.

Note that the shielding material and drier are reserved when packing.
Soldering method is not recommended to fix the inverter.
The inverter needs to be fixed on the channel or ground, installation steps
are as follows:
Step 1 Remove the front and back cover plates of the bottom of the
cabinet.
Step 2 M12 bolts are used to fix the inverter on the channel or ground
through the waist holes in the base.
Figure 7-6 Fixed dimensions for bottom installation
51
Figure 7-7 Fixation methods of the inverter
Items Name
A Inverter
B Foundation
C M12 anchor bolt
D Cable trench
E Channel steel
F M12 bolts, nuts, spring washers, flat washers combination
Figure 7-8 Sketch of the connection between the base of the inverter and the channel
52
Items Name
A Inverter base
B M12 bolt
C Flat washer
D Spring washer
E M12 nut
F Channel steel
53
8 Electrical Connection
This chapter introduces the methods and precautions of the electrical
connection of TC500K3US-O. The installer shall use National Electrical Code,
ANSI/NFPA 70 wiring methods all the field wiring.
8.1 Precautions
The electrical connections are conducted after the installation and fixation
of the inverter, and note the requirements of connections and precautions of
this chapter in the electrical connections.
The DC side voltage of TC500K3US-O DC is up to 600Vdc, AC side

voltage reaches 200Vac.
Do not touch any live parts!
 Make sure that AC and DC sides are uncharged before installation

and maintenance.
 As the temperature of TC500K3US-O is partly high, TC500K3US-O

and flammables and explosives shall not be piled together.
54
 The inverter can be connected to the grid only when the local power
company permits.
 Electrical installation must comply with local electrical installation

standards.
 Only qualified electricians or personnel with professional

qualification can carry out the electrical installation of the product.
8.2 Input and Output Requirements
 PV array
The open circuit voltage of PV array shall not exceed 600Vdc; otherwise
the inverter may be damaged. The maximum power of PV array of
TC500K3US-O can be configured to 500kW.
 Public grid
TC500K3US-O will continue to detect whether the power grid meet

grid-connected conditions. To meet the grid limits of grid-connected conditions,
the three-phase power grid is used. Meanwhile, the grid-connected inverter is
installed after getting the permission of the local power sector.
Table 8-1 Grid requirements

Parameter name Parameter requirements
Grid voltage(Vac) 176~220
Grid frequency(Hz) 59.8~60.5
55
The DC input and AC output circuits are isolated from the enclosure. The
PV system grounding shall be installed per the requirements of section 690.41
through 690.47 of national electrical code, ANSI/NFPA 70, PV system
grounding installation is the responsibility of the installer.
8.3 Cable Requirements
Requirements for selecting the cable are as follows:
 AWG 90℃ copper is recommended to use.
 The current is proposed to be not greater than 3A through 1mm²
wire.
 The wires of same sizes and types shall be selected for the same side of
the cable.
 The diameter of the single wire is avoided to be too large.
Cables shall be crimped with wire terminals with UL certification, and the
sizes of wire terminals shall be according to the actual installation situations.
The maximum current of DC side of the inverter is 1600A, and the
maximum current of AC side is 1443A. The recommended specifications of
connection cable are shown in Table 8-2.
56
Table 8-2 Comparison table of connection cables
Wire diameter Wire diameter

Connection Torque
Cables requirements requirements
bore diameter ( in-lbs)
(mm²) (ANSI)
196
PV array DC + Φ11 67.4 2/0 AWG
(22N·m)
196
PV array DC- Φ11 67.4 2/0AWG
(22N·m)
Grounding cable - 346

Φ13 85 3/0 AWG
power cabinet (39N·m)

Φ13 85 3/0 AWG
AC side (39N·m)

Φ13 85 3/0 AWG
DC side (39N·m)
Communication
Φ5 0.75 27 (3N·m) 17AWG
lines
1064
L1 phase grid Φ18 6×253 500Kcmil×6
(120N·m)
1064
(120N·m)
1064
(120N·m)
57
The specifications in the "Instructions" are the standard of the

inverter. If you have special requirements, please explain to TBEA staff
when ordering. Specific parameters are subject to the actual products that
you have purchased.
8.4 Wiring Components
The installation of TC500K3US-O sees Figure 8-1.
Incorrect wiring order may cause a fire. Note the order of the wiring.
Ensure that the connection pieces are tight when connecting. If the
connection is not sufficient, or the contact surface is oxidized, then the
excessive heat may cause a fire.
Figure 8-1 Installation order of terminals and mounting bolts
58
Items Name
A Copper bar (with riveted nuts)
B Copper bar (without riveted nuts)
C Bolt
D Spring washer
E Flat washer
F Line terminal
G Nut
Copper and aluminum transition pieces are required when aluminum
wires are used to connect, wiring connections are shown in the figure below:
Figure 8-2 Connecting of copper and aluminum transition pieces

Items Name
A Copper bar (with riveted nuts)
B Copper bar (without riveted nuts)
C Bolt
D Spring washer
E Flat washer
F Line terminal (aluminum)
G Cooper - aluminum transition sheet
H Nut
59
Note the direction of copper and aluminum transition pieces when
connecting, namely: the copper sides and copper busbars are fitted, and the
aluminum sides and aluminum terminals are fitted.
If one connection bus bar has more than one terminal, then a whole piece
of copper and aluminum transition piece is used, as shown in Figure 8-2:
The bottom of TC500K3US-O has inlet line board as shown in the Figure,
through which the external lines can be threaded into the inverter going
through the inlet line board. The Figure 8-3 shows the hole-making-positions
of the inlet line board; making holes according to the Figure as shown is
advisable, which can facilitate the wiring.
Figure 8-3 Inlet line board of cabinet
60
Items Name
A DC cabinet inlet line board
B Power cabinet inlet line board
C AC cabinet inlet line board
(1) Inlet line board of DC cabinet
(2) Inlet line board of power cabinet
(3) Inlet line board of AC cabinet
61
Items Name
A Positive inlet holes of DC inlet lines
B Negative inlet holes of DC inlet lines
C Inlet holes of combiner box grounding cables
D A -phase outlet hole of AC output
E B -phase outlet hole of AC output
F C -phase outlet hole of AC output
G Inlet holes of grounding cables
H Inlet holes of communication lines
8.5 Preparations for Electrical Wiring
Before wiring, the door shall be opened, to make the cables insert the seal
threading plate.
Users need to open the front door of TC500K3US-O before wiring,
specific steps are as follows:
Figure 8-4 Open the front door
Step 1 The front door can be opened through the door lock handle. Lock
schematic is shown in Figure 8-4.
Step 2 Cables are inserted to the threading plate from the bottom of the
62
machine, and tightened with the corresponding line bank.
Step 3 Fireproofing mud is used to block up the gaps of threading board,
and check the leakproofness of the bottom of the inverter.
8.6 DC Side Wiring
The PV array is converged by the combiner box, and then connected to
the DC side of the TC500K3US-O inverter. The positive DC side of the
TC500K3US-O inverter is connected to the bottom of the fuse. The fuse has 3
groups: group A has 8 fuses located inside the DC, groups B and C are located
in the power cabinet; each group has 6 fuses, totally 20 fuses. The upper
positives shall be connected each to each with the lower negatives right. As
shown in Figure 8-5.
Figure 8-5 DC input wiring
63
Items Name
A Group A fuses (a total of 8 in DC cabinet)
B Group B fuses (a total of 6 in power cabinet)
C Group B fuses (a total of 6 in power cabinet)
D Fuse
M10 nuts, spring washers and flat washers combination
E
(with fuses, tightening torque of 22 N • m)
F DC positive cables
G DC negative connection bars
M10 bolts, spring washers and flat washers combination
H
(tightening torque of 22 N • m)
I DC negative cables
It shall be checked the material of the external terminal connecting

point, if the copper and aluminum materials are interconnected, a special
copper and aluminum connector is needed, don’t directly connected!
(Copper and aluminum connectors can be ordered from TBEA or quality
products may be purchased by the client).
DC side wiring shall ensure that the copper cable specifications of

each copper bar be consistent. Our company will not assume any
responsibility if the user fails to connect as required causing the DC circuit
breaker burned.
DC combiner box according to different rated output current, the inverter

may have 3 wiring schemes as shown in Table.
64
Current of the
Access
combiner Group A Group B Group C
scheme
box(A)
Access 80A for Access 80A for Access 80A for
each way of fuses, each way of each way of
Scheme 1 80
with a total of 8 fuses, with a fuses, with a
ways total of 6 ways total of 6 ways
Access 100A for Access 100A Access 100A for
each way of fuses, for each way of each way of
Scheme 2 100
with a total of 8 fuses, with a fuses, with a
ways total of 6 ways total of 6 ways
Access 120A for Access 120A Access 120A for
each way, 6 ways for each way, 6 each way, 6
Scheme 3 120
can be accessed, ways can be ways can be
make 2 fuses idle accessed accessed
(1) Scheme 1 and Scheme 2 DC input cable connection
TC500K3US-O DC side of the inverter is of the maximum input current
of 1600A, in order to meet the maximum DC input current requirements and
cooling needs, the positive (+) and negative (-) poles each shall be connected
with 20 ways of 2/0AWG (67.4mm²) input lines; the upper positives shall be
connected each to each with the lower negatives right. All the 20 positive fuses
shall be connected. The wiring of the DC input in Scheme 1 and Scheme 2 see
the figure.
(2) Scheme 3 DC input cable connection
The positive (+) and negative (-) poles of DC incoming lines are
65
connected each with 18 ways of 2/0AWG (67.4mm²) input lines. Group A’s 8
fuses are connected only with 6 ways of positive cables, with 2 cables for spare;
groups B and C of fuses in the power cabinet are all wired. The negative is also
connected with 18 negative cables, and the upper positives shall be connected
each to each with the lower negatives right. DC input cable connection in
Scheme 3 see Figure 8-6.
Figure 8-6 Option Three DC input wiring
66
When other connecting schemes are selected, please contact with

TBEA professionals. If the customer selects other connecting schemes
arbitrarily, and thus influence the product installation and application,
TBEA shall not assume any responsibility.
Steps of DC side wiring are as follows:
Step 1 Disconnect the DC side of the power distribution inverter to ensure
the DC side wiring is not charged.
Step 2 Measured with a multimeter to ensure that the open circuit voltage
of the PV array does not exceed 600Vdc.
Step 3 Use a multimeter to confirm the positive and negative.
Step 4 Strip the insulation of the cable end 5mm longer as the wiring hole.
The DC input terminal of the TC500K3US-O is connected only 1 copper cable
to each of the positive and negative corresponding to the DT wiring terminal of
which the diameter shall be greater than 11mm.
Step 5 Wire the DT - wiring terminal.
(1) Insert the bare copper wire into the wring hole.
67
(2) Tighten the wiring terminal in two or more ways.
Step 6 Install heat shrinking tubing.
(1) Select heat shrinking tubing corresponding to the cable size, with the
length of about 5cm;
(2) Put the heat shrink tubing onto the wiring terminal completely.
(3) Use an alcohol burner or hot hair dryer to make heat shrink tubing
tightened.
Step 7 Connect "DC +" cable to the combiner box or the positive of PV
array.
(1) Connect the wiring terminal to the lower fuse of positive input; the
fuse has nuts, spring washers and flat washers which can be directly
fastened with tools, the installation detailed in the Figure 8-1、8-2、
8-5、8-6、8-7.
(2) Tighten the nut using a torque wrench.
Step 8 Connect "DC-" cable to combiner box or PV array negative.
(1) Select a bolt matching the wiring terminal (M10). Connect the
terminal onto the DC negative input copper bar which has screw
holes for direct fastening. The installation detailed see the Figure
8-1、8-2、8-5、8-6、8-7.
68
(2) Tighten the nut using a torque wrench.
Step 9 Check if the wiring is firmly tightened as required.
8.7 AC Side Wiring
The output voltage of the AC side of TC500K3US-O inverter is 200Vac, it
can be connected via high-voltage or medium-voltage transformer to
high-voltage or medium voltage grid. The wiring of AC side of the inverter and
the grid is as follows.
When connected to AC grid, the AC side inverter shall be cut off,

making the contact terminal uncharged.
The connecting of grid shall comply with the requirements of the

relevant departments as well as all the concerned safety regulations.
Step 1 Cut off the AC side inverter and use multimeter to check if the
terminal is free of charge.
Step 2 Check AC wiring phase sequence.
Strip the insulation from the cable end, each phase of the TC500K3US-O
AC output terminal shall use 6 ways of 500 Kcmil (253mm²) copper wires
corresponding to the DT wiring terminal of which the installation hole
diameter shall be greater than 17mm. The pealed length of the terminal shall be
69
5mm longer as the wiring hole depth.
Step 3 Connect DT- wiring terminal
(1) Insert the bare copper wire into the wring hole.
(2) Tighten the wiring terminal in two or more ways.
Step 4 Install heat shrinking tubing
(1) Select heat shrinking tubing corresponding to the cable size, with the
length of about 5cm;
(2) Put the heat shrink tubing onto the wiring terminal completely.
(3) Use an alcohol burner or hot hair dryer to make heat shrink tubing
tightened.
Step 5 Connect "L1" cable to output wiring A (U) phase copper bar with
identifier "A" as shown in the figure;Connect "L2" cable to output wiring B (V)
phase copper bar with identifier "B" as shown in the figure; Connect "L3"
cable to output wiring C (W) phase copper bar with identifier "C" as shown in
the figure
(1) Select bolt (M16), nut (M16), spring washer and flat washer
coincident with the wiring terminal. Connect the wiring terminal to
the AC input copper bar (hole specifications Φ18), the installation
detailed see the Figure 8-1、8-2、8-8.

(2) Tighten the bolt using a torque wrench.
70
The screw length shall be appropriate, it shall come out to the

mounting holes slightly, it may affect device insulation if exposed too long,
or even cause a short circuit, it is recommended to use M16 * 50 screws.
Check whether the installation is complete and if the wiring terminal

and copper bar connections are clamped with some heat shrink tubing, it
shall be removed if clamped, otherwise it could lead to poor contact, or
even damage to the inverter.
Three terminals are reserved for users on the AC power of TC500K3US-O,

shown in Figure 8-8.
Figure 8-8 AC power terminals

Items Name
A AC cabinet connecting copper bars
B
C AC cables
D AC connecting copper bar logo
71
Step 6 Connecting respectively the other side of AC output cable "L1"
"L2" "L3" to the corresponding terminal of the step-up transformer low voltage
200V, choose the right screw, crimp the wiring copper nose on the
transformer copper busbar, then use a wrench to tighten the screw referring to
the section 5.5.1 fastening torque table.
Output terminals of cable connects to the transformer low voltage
winding, so the N line is dangling and does not connect with others, and
with good insulation protection.
Three-phase cable A, B, C of the alternative current output shall
respectively add yellow, green and red hot shrink bushing, in order to
distinguish the phase sequences.
Step 7 Make sure the wiring is firm and fastening torque meets the
requirements.
If the winding of the step-up transformer has an N-line tap, then do

not have to connect the N-line but insulate it.
72
8.8 Ground Connection
To ensure safety, all inverters need to be grounded through a conductor.
The PE copper bar in the TC500K3US-O cabinet has been reliably
connected with the shell of the inverter. And the PE copper bar in each cabinet
has been connected with each other through the entire cabinet. PE ground
copper bars need to be connected with the installation site or an equipotential
connecting device in the electric control room, and must be in good connection
with 3 grounding lines of 3/0AWG (85mm²) cable, and the contact resistance
shall not exceed 4Ω.
All leading-in boards of each cabinet have leading-in holes for ground
wire. Grounding bar is threaded together through the entire cabinet. And
Grounding bars of each cabinet shall have a ground wire when connected to the
cabinet. There shall be marked “GND” on the top of installation hole of the
ground wire for identifying. M12 bolt shall be used between the grounding
wire and grounding bar with the fastening torque of 39 N • m. The connection
type is shown in the figure. Ground copper bars shown in Figure 8-9.
73
Figure 8-9 Schematic diagram of grounding copper bars
Items Name
A DC cabinet grounding bars
B Power cabinet grounding bars
C AC cabinet grounding bars
D
E Grounding cable 3/0AWG (85mm²)
F Marks of grounding cable mounting holes
To ensure safety, make sure the potential of the cabinets that weren’ t
connected by bolts is equal if multiple inverters are in parallel. Use at least
16mm²(5 AWG) thick single yellow-green cable to fix the inverters to the
frame of the cabinet’s shell (with cable lugs and bolts), which will prevent
current turned up on the shielding layer because of unequal potential of the
inverters.
74
The Photovoltaic System Grounding shall be installed per the
requirements of Sections 690.41 through 690.47 of the National Electrical
Code, ANSI/NFPA 70 and is the responsibility of the installer.
8.9 Communication Wiring
TC500K3US-O inverters in parallel apply RS485 serial communication.
Terminals have been reserved inside of inverter. The position of the
communication terminals are shown in Figure 8-10.
Figure 8-10 Schematic diagram of communications wiring
Items Name
A Connection port of external power supply
B Connection port of 485 communication line
 Apply a shielded twisted cable for RS485 communication cable;
 The RS485 connector is located on the bottom of the AC inverter cabinets.
Use the shielded twisted wire leads communication cable from the outside
75
of RS485 and connect directly to the RS485 trunk of the monitoring
system (if the user has a protocol converter, connect directly to the
protocol converter);
 After connected with shielded cable of shielding layer, apply a single

point of protocol at the monitoring terminal;
 Terminals marked with A on the outside are the external power supply
with AC200V.
 B is labeled RS485 terminals on the terminal block. Terminals marked
with B are RS485 terminals.
8.10 Power Supply
The power supply mode of control source of TC500K3US-O is divided
into two modes. One is a self-powered mode, and the other is the external
power supply mode. The machine defaults in the internal power supply. Users
can set and choose the power supply mode through the following switch.
8.10.1 Self-Powered Mode
Self-powered mode is shown in Figure 8-11:
76
Figure 8-11 Self-powered modes
Self-powered mode of the inverter has been set up when delivery. Directly
use, no other wiring.
8.10.2 External Power Supply Modes
If the user selects the external power supply mode, the user shall adjust
the machine as the following figure.
Figure 8-12 External power supply wiring
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The diameter of cable for external power supply shall be not less than
2.5mm²(13AWG).
Hot-line work may result in the risk of fatal electric shock, so make
sure it is uncharged when connects with external power supply and in the
case of setting the power supply mode.
8.11 Seal at the Bottom of Cabinet
In order to prevent short-circuiting of air flow inside and outside the

cabinet and to ensure the tightness of the cabinet as a whole, there is a need to
seal the threaded hole at the bottom with fire clay.
After the cabinet wiring is completed, there will be some certain gap
between the cable and leading-in hole, which will cause a short circuit inside
and outside the cabinet air flue, resulting in an adverse effect on the cooling
rack. Therefore, the gap between the leading-in hole and cable shall be sealed
to ensure tightness of the cabinet as a whole.
78
Figure 8-13 Schematic diagrams of seal

Items Name
A Cables
B Inlet line board
C Fireproofing mud
There is a scupper at the bottom of the cabinet. There are two

scuppers at the front and back of each cabinet, as shown in Figure 8-14,
which are located near the door. Pay attention to whether the scupper is
smooth to prevent fire clay or other debris block the scupper when seal the
wiring and cabinet.
79
A B C
D E F
G H I
J K L
Figure 8-14 Schematic diagrams of scupper
80
Items Name
A Scupper at the left front of the DC cabinet
B Scupper at the right front of the DC cabinet
C Scupper at the left back of the DC cabinet
D Scupper at the right back of the DC cabinet
E Scupper at the left front of the power cabinet
F Scupper at the right front of the power cabinet
G Scupper at the left back of the power cabinet
H Scupper at the right back of the power cabinet
I Scupper at the left front of the AC cabinet
J Scupper at the right front of the AC cabinet
K Scupper at the left back of the AC cabinet
L Scupper at the right back of the AC cabinet
81
9 Installation Inspections
This chapter gives a checklist which needs to be filled in after the
installation of TC500K3US-O inverters.
Before the inverter is put into operation, the installation of the inverter
shall be checked by at least two staff members according to the following table
to ensure validity of the installation of the inverter.
Inspected items of mechanical installation

□ Inverter enclosure is without deformation and damage conditions
□ The bottom of the inverter is fixed and supported stably and reliably
□ The inverter has enough spaces around
□ The temperature, humidity and ventilation conditions of the environment the
inverter is exposed meet the requirements
□ Cooling air flows smoothly
□ The seal protection of the cabinet is complete and reliable
Inspection of electrical installation

□ The inverter is grounded completely and firmly
□ Grid voltage matches with the rated input voltage of the inverter unit
□ The grid-connecting phase sequence is correct, and the tightening torque meets the
requirements
□ DC input connects with the positive and negative poles correctly, and the tightening
torque meets the requirements
□ Communication wiring is correct, and maintains a certain distance from other cables
□ The wire size of cables is marked properly and clearly
□ Insulation protective cover is complete and reliable, and the danger warning labels
are clear and firm
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Other inspections
□ All useless conductive parts shall be fastened with insulating tapes
□ No tools, parts and conductive dusts or other foreign matters generated by drilling
are left in the cabinet
□ No condensed moisture or icing is inside the cabinet
□ The door is locked and the keys are kept by a specially-assigned person
83
10 Commissioning
This chapter describes the process of the first run of the TC500K3US-O
inverter after the installation is completed, including the inspections of the
photovoltaic array, each check each wiring end of the cable before
commissioning, commissioning requirements, preparatory work before starting
and power on, etc..
10.1 Commissioning Requirements
The installation of the device shall be checked thoroughly before
commissioning. Especially check whether the voltage of DC and AC terminals
meets the requirements, and whether the polarity and phase sequence is correct.
Check whether the connection of the system comply with the requirements of
the relevant standards. And the system is properly grounded. Grounding
resistance of decisive has a great significance for the security of the entire
system, so it must be determined whether grounding resistance meets the
requirements before the first commissioning.
Before commissioning make sure all switches of the AC side, DC side

are off.
84
10.2 Check before Commissioning
10.2.1 Check the PV Array
Check the PV array before parallel. Check whether the open circuit
voltage of each column meets the requirements.
Ensure conditions of weather stable, as the voltage will change with the
temperature of the solar cell panel. Apply the UI recorder to record the PV
array work, and conduct the test when the PV array run stable.
 Record the environmental parameters, including voltage,
temperature and light intensity.
 Measure the cable resistance with OHM meter that is megohm range
(between the junction box and inverter). Accurate records all values.
10.2.2 Check the Inverter
A series of checks shall be conducted before power on:
Step 1 Check the installation and wiring in accordance with 9 inverters
checklist.
Step 2 Make sure the AC and DC circuit breakers are OFF.
10.2.3 Check the Parameters of the Inverter Grid
85
 Check the grid voltage
Check whether the three-phase of the inverter is connected correctly to the
three-phase sequence of the grid.
Check whether the phase voltage and line voltage are within a
predetermined range with a multimeter, and records all phases and comparative
voltage PE value in details.
Parameter description Reference value(V)
Grid voltage 208

A- B 208
A- C 208
B–C 208
A - PE 120
B- PE 120
C - PE 120
If the deviation of the voltage is too large, the transmission ratio of

the transformer needs to be adjusted.
 If possible, measure THD of the phase (total harmonic distortion),

and check the curve. If the distortion is very serious, the inverter may
not run.
86
 Check the DC voltage
DC shall connect combiner box to the inverter DC input terminals.
 Ensure the DC input polarity is correct.
 Measure and record the voltage of each DC (open circuit). The voltage
value of each phase shall be almost the same, and do not exceed the
allowable maximum DC voltage.
TC500K3US-O DC voltage shall not exceed 600Vdc. Very high DC

voltage will damage the inverter.
10.3 Preparing before Power on
Ready to power on when all the items have been checked and all has been
confirmed to meet the requirements.
Step 1 Make sure the grid line voltage is 200Vac again.
Step 2 Make sure that no person is operating the inverter inside and
outside cabinet.
Step 3 Install all the screws to its original position which are removed
when wiring, and then shut the front door of the cabinet, and lock the door.
87
10.4 Power on
10.5 Completion of the Test Run
Conduct test run as following steps after the inverter has been through the
network operation:
Step 1 Check whether the inverter is abnormal, such as excessive noise,
excessive heat, and abnormal smell or smoke.
Step2 Measure whether the inverter grid voltage, current and THD
situation are stable.
Step 3 Check whether the inverter enclosure is grounded properly.
Step 4 Operate LCD control panel to check whether they are normal and
accurate.
So far, TC500K3US-O commissioning has been completed; you can enter
the daily operation and maintenance procedures.
Once the normal operation of the inverter, only when maintenance

and troubleshooting, there is a need to open the cabinet door. When
operating normally, the door shall be locked, keys kept by hand, and the
door shall be opened by professionals.
88
11 Appendixes
11.1 Technical Data
11.1.1 Electrical Part
 Input data (DC side)
Parameter description Reference value

Maximum DC voltage (Vdc) 600
PV grounding mode PV-grounding (ANSI requirements)
MPPT voltage range of DC input (V) DC320 ~ DC580 (full load)
Maximum PV array input power (kW) 550
Maximum input current (A) 1600
Maximum input short circuit current (A) 2500
Maximum input source backfeed current to
3180 A peak/ 85.33 ms
input source
 Output data (grid side)

Rated output power(kW) 500
Normal output voltage(Vac) 200(defalt setting value)
Allowable grid voltage range (three-phase) -12% ~ +10 %, i.e. 176Vac ~ 220Vac
Normal output frequency(Hz) 60(defalt setting value)
59.8(this operating point is
Operating frequency(Hz)
adjustable) ~60.5
Maximum continuous output current (A) 1443(ac)
Maximum output fault current (A) / duration (ms) 1270 rms/997, 6600 peak/ 997
Maximum output overcurrent protection (A) 2000 (internal circuit breaker)
Maximum continuous output power(kW) 500
Type 2/ 26.4 A rms, 65.0 A peak, 19.3
Synchronization in-rush current
ms
89

Trip limit and trip time accuracy 2V/20ms 0.1Hz/20ms
Limits of accuracy of frequency measurement (Hz) 0.1
Limits of accuracy of Voltage measurement (V) 2
Total current waveform distortion factor(%) <3 (rated power)
Control of power factor 0.9 (leading) ~ 0.9 (lagging)
Adjustable LIMITS - Utility Clearing times

Max(V) Min(V)
interconnection voltage trip limits (s)
and trip times:

L-L L-N L-L L-N Max Min
Overvoltage/Fast 250 N/A 236 N/A 1 0.16

Overvoltage/Slow 228 N/A 216 N/A 10 1
Undervoltage/Slow 180 N/A 140 N/A 20 2
Undervoltage/Fast 120 N/A 80 N/A 2 0.16

Adjustable LIMITS- Utility
interconnection frequency trip limits Magnitude range (V) Time range (s)
and trip times:
Overfrequency-Lower Range 60.5 0.16
Underfrequency-Upper Range 59.8 0.16 to 300
Underfrequency-Lower Range > 57.0 0.16 to 300
Underfrequency – Extended Low Range < 57.0 0.16 Sec
90
11.1.2 Mechanical Part

Actual size (W×H ×D) mm 2370 ×2140 ×910
Weight(kg) 2300
11.1.3 System Data

Maximum efficiency(%) 97.7 (without transformers)
CEC efficiency(%) 97.5 (without transformers)
Protection grade 3R
Night time consumption(W) <100
Normal operation temperature range(℃) -25~+60
full power operating ambient temperature(℃) -25~+50
Maximum continuous output power @ 55 C (kW) 350
Maximum continuous output power @ 60 C (kW) 350
Cooling method Air-cooling
Permissible relative humidity(%) 0 ~ 95 (without condensation)
11.1.4 Transformer Parameters
A External Transformer was Used in TC500K3US-O Anti-Islanding Test,
Transformer parameters are as Below:
No. Item Primary Secondary Comments
1 Power rating (kVA) 750
2 Frequency (Hz) 50/60
3 Number of Phases 3
4 Coupling Y D
91
No. Item Primary Secondary Comments
5 Rated Voltage (V) 400 200/315/400
6 Rated Current (A) 1082.5 2165/1374.7/1082.5
7 Cooling Air Temp.(℃) -25 ～ 55
8 Insulation level(MΩ) ≥100 ( DC1000V@60S )

Short-circuit
9 Impedance(%,75℃) 4.5
10 Protection Level IP00
11.2 Warranty Statement
11.2.1 Normal Warranty
(1) Evidence
During the warranty period, customers claiming to quality assurance are
required to present invoice to purchased products meanwhile trademark on the
products shall be clearly visible, otherwise our company reserves the right not
to conduct quality assurance.
(2) Warranty clause
The products with malfunction replaced are disposed by our company.
Reasonable time shall be provided to our company for repair work.
(3) Disclaimer
92
 In the following cases, our company reserves the right not to conduct
quality assurance:
 Complete appliance, components are out of warranty.
 Damages caused during transportation
 Improper installation, alteration or use
 Operating in harsh environment that doesn’t conform to the specifications
of the manual
 Machine malfunction or damage caused by installing, repairing, altering
or disassembling by unauthorized services and staff.
 Machine malfunction or damage caused by using non-standard or those
components or software not offered by Sunny Central
 Any installation or usage not in accordance with provisions of relevant
international standards
 Damage caused by unexpected disaster
 If customers ask for quality assurance to dispose the faults caused in the
above cases, we can provide paid service after technical diagnosis by our
company’s services.
93
11.2.2 Extended Warranty
For specific questions, please contact us.
11.2.3 Contact Us
If you have any questions, please contact us about this product, contact
details are as follows:
Company name: TBEA Xi'an Electric Technology Co., Ltd.
Address: Xi'an TBEA New Energy Industrial Park, No. 70, fourth
Shanglinyuan Road, High-tech Zone, Xi’ an
Zip code: 710119
Hotline: 400-606-6029
E-mail: tbeapower@tbea.com.cn
Fax: 029-68760500-042http: //www.tbeapower.com
94

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Contents

1 About this Manual......................................................................................... 4

1.2 Introduction .......................................................................................... 4

1.3 Applicable Scope.................................................................................. 5

1.4 Manual Instruction ............................................................................... 6

2 Safety Precautions ......................................................................................... 7

2.1 Safety Precautions ................................................................................ 7

2.2 Notes on Operation ............................................................................ 11

2.2.1 Live Line Measurement .......................................................... 11

2.2.2 Opening the Plant .................................................................... 11

2.2.3 Requirements Prior to Connecting the Switches on AC and DC

2.2.4 Notes on Shutdown ................................................................. 13

3 Product Delivery ......................................................................................... 14

3.1 Scope of Delivery............................................................................... 14

3.2 Nameplate of TC500K3US-O ............................................................ 15

3.3 Storage ............................................................................................... 16

3.4 Transportation .................................................................................... 18

4.1 Grid-connected System ...................................................................... 19

4.2 Appearance ......................................................................................... 21

4.3 Appearance Description ..................................................................... 22

4.3.2 Ventilation Design ................................................................... 23

4.4 Circuit Introduction ............................................................................ 23

4.5 Terminals ............................................................................................ 25

5 Product Installation .................................................................................... 27

5.1 Basic Installation Pequirements ......................................................... 27

5.2 Installation Environment .................................................................... 28

5.2.1 Ground Requirements ............................................................. 28

5.2.2 Requirements of the Minimum Space for Outdoor Uses ........ 29

5.2.3 Requirements of the Minimum Space for Indoor Uses ........... 32

5.3 Requirements of the Alignment of Wires, Ventilation and Others ..... 33

5.3.1 Requirements of Cable Trenches ............................................ 33

5.3.2 Ventilation Requirements ........................................................ 34

5.3.3 Other Requirements ................................................................ 36

5.4 Wiring Specifications ......................................................................... 37

5.5 Fixation and Protection of Connection Cables ................................... 38

5.5.1 Fixation of Cables ................................................................... 38

5.6 Installation Process ............................................................................ 39

6 Installation Preparations ............................................................................ 42

6.1 Pre-Installation Inspection ................................................................. 42

6.2 Installation Tools and Parts ................................................................ 42

7 Equipment Installation ............................................................................... 43

7.1 Equipment Transportation .................................................................. 43

7.1.1 Precautions .............................................................................. 43

7.1.2 Packaging and Logos .............................................................. 44

7.1.3 Transportation Packaged ......................................................... 46

7.1.4 Transportation without Packaging........................................... 47

7.2 Field Installation ................................................................................ 49

8.1 Precautions ......................................................................................... 54

8.2 Input and Output Requirements ......................................................... 55

8.3 Cable Requirements ........................................................................... 56

8.4 Wiring Components ........................................................................... 58

8.5 Preparations for Electrical Wiring ...................................................... 62

8.6 DC Side Wiring .................................................................................. 63

8.7 AC Side Wiring .................................................................................. 69

8.8 Ground Connection ............................................................................ 73

8.10 Power Supply ................................................................................... 76

8.10.1 Self-Powered Mode............................................................... 76

8.10.2 External Power Supply Modes .............................................. 77

8.11 Seal at the Bottom of Cabinet .......................................................... 78

9 Installation Inspections ............................................................................... 82

10.1 Commissioning Requirements ......................................................... 84

10.2 Check before Commissioning .......................................................... 85

10.2.1 Check the PV Array .............................................................. 85

10.2.2 Check the Inverter ................................................................. 85