Operation and Maintenance Manual

GT500E 500 kW Grid-Tied Photovoltaic Inverter

GT500E 500 kW Grid-Tied Photovoltaic Inverter

Operation and Maintenance Manual

About Xantrex
Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with products from 50 watt mobile units to 2.5 MW utility-scale systems for wind, solar, batteries, fuel cells, microturbines, and backup power applications in both grid-connected and stand-alone systems. Xantrex products include inverters, battery chargers, programmable power supplies, and variable speed drives that convert, supply, control, clean, and distribute electrical power.

Trademarks
GT500E 500 kW Grid-Tied Photovoltaic Inverter is a trademark of Xantrex International. Xantrex is a registered trademark of Xantrex International. Other trademarks, registered trademarks, and product names are the property of their respective owners and are used herein for identification purposes only.

Notice of Copyright
GT500E 500 kW Grid-Tied Photovoltaic Inverter Operation and Maintenance Manual March 2007 Xantrex International. All rights reserved.

Exclusion for Documentation

UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX TECHNOLOGY INC. (XANTREX) (A) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION. (B) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES, WHETHER SPECIAL, DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER S RISK; AND (C) REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH, ALTHOUGH STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION, THE ACCURACY CANNOT BE GUARANTEED. APPROVED XANTREX CONTENT IS CONTAINED WITH THE ENGLISH LANGUAGE VERSION WHICH IS POSTED AT WWW.XANTREX.COM.

Date and Revision

March 2007 Revision B

Part Number
152670

Contact Information
Telephone: 1 360 925 5097 (North America) 49 0180 2240400 (Germany) 34 935 560 976 (Spain) 1 360 925 5143 (North America) 49 (0) 7531 8199868 (Germany) 34 934 736 093 (Spain) customerservice@xantrex.com GTsupport.Germany@xantrex.com GTsupport.Spain@xantrex.com www.xantrex.com

Fax:

Email:

Web:

About This Manual

Purpose
The purpose of this Operation and Maintenance Manual is to provide explanations and procedures for operating, maintaining, and troubleshooting the GT500E 500 kW Grid-Tied Photovoltaic Inverter. Installation instructions are available in the GT500E Grid-Tied Photovoltaic Inverter Planning and Installation Manual (Part #:152669).

Scope
This Manual provides safety guidelines and information about operating and troubleshooting the unit.

Audience
This Manual is intended for anyone who needs to operate the GT500E 500 kW Grid-Tied Photovoltaic Inverter. Operators must be familiar with all the safety regulations pertaining to operating high-voltage equipment as dictated by local code. Operators must also have a complete understanding of this equipments features and functions.

Organization
This Manual is organized into five chapters and one appendix. Chapter 1, Introduction contains information about the features and functions of the GT500E 500 kW Grid-Tied Photovoltaic Inverter. Chapter 2, Operation contains information on the basic operation of the GT500E 500 kW Grid-Tied Photovoltaic Inverter. Chapter 3, Commissioning contains information on safely commissioning the GT500E 500 kW Grid-Tied Photovoltaic Inverter. Chapter 3, Troubleshooting contains information and procedures for troubleshooting the GT500E 500 kW Grid-Tied Photovoltaic Inverter. It provides descriptions of common situations and errors that may occur and provides possible solutions for resolving fault conditions. It also provides instructions for clearing faults manually, if required. Chapter 4, Preventative Maintenance contains information and procedures for performing preventative maintenance on the GT500E 500 kW Grid-Tied Photovoltaic Inverter. Appendix A provides the environmental and electrical specifications for the GT500E 500 kW Grid-Tied Photovoltaic Inverter.

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About This Manual

Conventions Used
The following conventions are used in this guide.

WARNING
Warnings identify conditions or practices that could result in personal injury or loss of life.

CAUTION
Cautions identify conditions or practices that could result in damage to the unit or other equipment.

Important: These notes describe things which are important for you to know, but not as
serious as a caution or warning.

Abbreviations and Acronyms

ANSI CCU2 CFM CW DSP FPGA GUI IEEE IGBT IPM kcmil NFPA PBX PSL PV UFCU American National Standards Institute Converter Control Unit 2 Cubic Feet per Minute Clockwise Digital Signal Processor Field Programmable Gate Array Graphical User Interface Institute of Electrical and Electronics Engineers Insulated Gate Bipolar Transistor Intelligent Power Module 1000 circular mils National Fire Protection Association Private Branch Exchange Phase-Shift Loop Photovoltaic Universal Frontpanel Control Unit

Related Information
You can find more information about Xantrex Technology Inc. as well as its products and services at www.xantrex.com.

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Important Safety Instructions

SAVE THESE INSTRUCTIONS - DO NOT DISCARD
This manual contains important safety instructions for the GT500E that must be followed during installation and maintenance procedures.

WARNING: Shock Hazard

Read and keep this Operation and Maintenance Manual for future reference. Before installing GT500E, read all instructions, cautionary markings, and all other appropriate sections of this manual. Failure to adhere to these warnings could result in severe shock or possible death. Exercise extreme caution at all times to prevent accidents.

WARNING: Shock Hazard

The GT500E Inverter Enclosures contain exposed high voltage conductors. The Inverter Enclosure doors should remain closed with the latches tightened, except during maintenance or testing. These servicing instructions are for use by qualified personnel who meet all local and governmental code requirements for licensing and training for the installation of Electrical Power Systems with AC and DC voltage to 1000 volts. To reduce the risk of electric shock, do not perform any servicing other than that specified in the installation instructions unless you are qualified to do so. Do not open the cabinet doors if extreme moisture is present (rain or heavy dew).

WARNING: Lethal Voltage

In order to remove all sources of voltage from the GT500E, the incoming power must be de-energized at the source. This may be done at the main utility circuit breaker and by opening the AC Disconnect and the DC Disconnect Switches on the GT500E. Review the system configuration to determine all of the possible sources of energy. In addition, allow 20 minutes for the DC bus capacitors to discharge after removing power.

Safety

Risks
WARNING: Shock hazard
Parts of the condenser charge will still be energized for a maximum of 20 minutes after being disconnected. Open device cover plates or doors only after the device is disconnected and discharged. Check whether the device is no longer live (DC voltage) including terminals PV+ and PV-.

WARNING: Explosion hazard

The IGBT module may explode in the event of a major malfunction. Do not operate larger devices while the pivoting part is opened.

WARNING: Crush hazard

The inverters have a very high balance point and can easily topple down. Only move while exercising care. Pay attention to the balance point sticker during transport.

WARNING: Amputation hazard

The inverters contain integrated ventilators including rotating ventilator wheels. Do not place fingers in ventilator.

WARNING: Burn hazard

Inverters contain components that become hot during normal operation. Do not touch.

CAUTION
The inverters have a supply air and exhaust air area, which must remain unobstructed. The device can overheat and be destroyed if the installation signs are not adhered to. Disassemble the tracks required for transportation located at the top for operating the cabinet devices.

CAUTION
Inverter electronics can be destroyed when touched and when electrostatically charged. Discharge via earth potential before touching and wear appropriate protective gear.

CAUTION
No connections or disconnections are allowed at the terminal strips or internal connectors during operation. Turn device off before performing terminal work; wait 5 to 20 minutes (condenser charge) and recheck to ensure device is no longer live.

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Safety

General Safety Precautions

1. When installing the GT500E use only components recommended or sold by Xantrex. Doing otherwise may result in a risk of fire, electric shock, injury to persons, and will void the warranty. 2. Do not attempt to operate the GT500E if it has been dropped, or received more than cosmetic damage during transport or shipping. If the GT500E is damaged, or suspected to be damaged, see the Warranty section of this manual. 3. To reduce the risk of electrical shock, lock-out and tag the GT500E before attempting any maintenance, service, or cleaning.

Personal Safety
Follow these instructions to ensure your safety while working with the GT500E.

Qualified Personnel
Only qualified personnel should perform the transportation, installation and initial operation and maintenance of the GT500E and have an understanding of IEC 364 or CENELEC HD 384 or DIN VDE 0100 and IEC 664 or DIN VDE 0110. Follow all national accident prevention regulations. Qualified personnel, within the meaning of these basic safety regulations, will be people who are familiar with the installation, assembly, start-up and operation of the GT500E and have the appropriate qualifications with respect to their functions.

Safety Equipment
Authorized service personnel must be equipped with standard safety equipment including the following: Safety glasses Ear protection Steel-toed safety boots Safety hard hats Padlocks and tags Appropriate meter to verify that the circuits are de-energized (1000 Vac and DC rated, minimum)

Check local safety regulations for other requirements.

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Safety

Wiring Requirements
1. All wiring methods and materials shall be in accordance with the National Electrical Code ANSI/NFPA 70, European Requirements, as well as all state and local code requirements (for example, DIN / VDE). 2. The GT500E has a three-phase output. 3. The AC power conductor wiring interfacing with the AC terminals in the AC Interface Enclosure (-H0) are located at L1, L2, L3. These terminals requires the use of a crimp-on type ring terminal or compression-type lug. Keep these cables together as much as possible and ensure that all cables pass through the same knockout and conduit fittings, allowing any inductive currents to cancel. For torque values, see Table A-5 on page A5. See Figure 4-1 on page 44 for the location of these terminals. 4. The AC Control Voltage wiring interfacing with the Control Voltage terminals in the AC Interface Enclosure are located at -X2 L1and L2. For torque values, see Table A-5 on page A5. See Figure 4-2 on page 44 for the location of these terminals. 5. The DC power conductor wiring interfacing with the DC terminals is terminated in the DC Interface Enclosure (-H2). These terminals requires the use of a crimp-on type ring terminal or compression-type lug. Keep these cables together as much as possible and ensure that all cables pass through the same knockout and conduit fittings, allowing any inductive currents to cancel. For torque values, see Table A-6 on page A5. See Figure 4-3 on page 45 for the location of these terminals. 6. This product is intended to be installed as part of a permanently grounded electrical system as per the National Electric Code ANSI/NFPA70 and EU requirements, as well as all state and local code requirements (for example, DIN/VDE). The single point ground for the system is to be made at the ground bus bar in the AC Interface Enclosure. 7. The equipment grounds on the GT500E are marked with PE. See Figure 4-1 on page 44 for the location of this terminal. 8. AC overcurrent protection for the utility interconnect equipment (Grid-tie transformer) must be provided by the installers as part of the GT500E installation.

CAUTION: Fire Hazard

In accordance with the National Electrical Code, ANSI/NFPA 70, connect only to a circuit provided with 1200 A maximum branch circuit overcurrent protection.

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Safety

Operational Safety Procedures

Never work alone when servicing this equipment. A team of two is required until the equipment is properly de-energized, locked-out and tagged, and verified deenergized with a meter. Thoroughly inspect the equipment prior to energizing. Verify that no tools or equipment have inadvertently been left behind.

Lockout and Tag

Safety requirements mandate that this equipment not be serviced while energized. Power sources for the GT500E must be locked-out and tagged prior to servicing. A padlock and tag should be installed on each energy source prior to servicing.

WARNING: Shock Hazard

Review the system schematic for the installation to verify that all available energy sources are de-energized. DC bus voltage may also be present. Be sure to wait the full 20 minutes to allow the capacitors to discharge completely. Schematics are located inside the front door of the unit.

The GT500E can be energized from both the AC source and the DC source. To ensure that the inverter is de-energized prior to servicing, lockout and tag the GT500E using the following procedure. 1. Open, lockout, and tag the incoming power at the utility disconnect. 2. Open, lockout, and tag the AC Disconnect Switch (-Q1) on the AC Interface Enclosure (-H0). See Figure 1-9 on page 111 for the location of the AC Disconnect Switch. 3. Open, lockout, and tag the DC Disconnect Switch (-Q11) on DC Interface Enclosure (-H2). See Figure 1-9 on page 111 for the location of the DC Disconnect Switch. 4. Using appropriate means, open, lockout, and tag incoming PV circuits. 5. Using a confirmed, accurate meter, verify all power to the inverter is deenergized. A confirmed, accurate meter must be verified on a known voltage before use. Ensure that all incoming energy sources are de-energized by checking the following locations. a) AC Utility Terminals: (Bottom of L1, L2, L3 and PE) See Figure 4-1 on page 44 and Figure 4-2 on page 44 for the location of these terminals. b) PV Terminals: (PV+ and PV-) See Figure 4-3 on page 45 for the location of these terminals. c) Auxiliary Control Power (X2-L1, X2-L2) See Figure 4-2 on page 44 for the location of these terminals.

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De-Energize/Isolation Procedure
The following procedure should be followed to de-energize the GT500E for maintenance.

WARNING
The terminals of the DC input may be energized if the PV arrays are energized. In addition, allow 20 minutes for all capacitors within the Inverter Enclosure to discharge after disconnecting the GT500E from AC and DC sources.

To isolate the GT500E: 1. Turn the ON/OFF switch to the OFF position. 2. Open the DC interface disconnect switch (-Q11). 3. Open the AC interface disconnect switch (-Q1). 4. Open the utility connection circuit breaker. 5. Open the Auxiliary Control Power disconnect to de-energize the Auxiliary Control Power. 6. Install lockout devices on the utility connection circuit breaker, AC and DC disconnect switches. Install a lockout device on the Auxiliary Control Power disconnect.

Interconnection Standards Compliance

The GT500E complies with the German grid protection requirements of VDEW and the Spanish RD 1663/2000. The GT500E is designed to meet UL 1741 Static Inverters And Charge Controllers For Use In Photovoltaic Power Systems, as well as IEEE-519. Refer to both documents for details of these recommendations and test procedures.

Intended Use
The GT500E may only be used in connection with PV modules. It is not suitable for any other application areas. An initial operation (e.g. starting the intended operation) will only be allowed when observing the EMC guideline (89/336/EWG). The GT500E complies with the 73/23/EWG low voltage directive requirements. The harmonized standards of the series EN 50178/DIN VDE 0160 in connection with EN 60439-1/DIN VDE 0660 part 500 and EN 60146/DIN VDE 0558 will be used for the inverters.

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Safety

Moving the GT500E

You can move the GT500E by either using a crane or a forklift.

WARNING: Equipment is heavy

If lifted incorrectly, the GT500E could overbalance and cause personal injury.

Use the figure below to locate the balance point or center of gravity( symbol). For specific instructions on how to move your GT500E, reference your GT500E Grid-Tied Photovoltaic Inverter Planning and Installation Manual (Part #:152669)
Center of Gravity

Side view

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Safety

Moving using a crane

Ensure you dismantle the top for transport.

Moving using a forklift

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Contents
Important Safety Instructions 1 Introduction
Description of the GT500E - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -12 Physical Characteristics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -13 AC Interface Enclosure (-H0) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -14 AC Utility Terminal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -14 AC Control Terminal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -14 Inverter Enclosure (-H1) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -15 Power Distribution Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -15 Converter Control Unit (CCU2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -15 Power Electronics Matrix - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -15 DC Interface Enclosure (-H2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -16 DC Terminal Room - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -16 Circuit Diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -17 Operator Interface Controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -18 On/Off Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -19 Emergency Stop (E-STOP) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 110 AC and DC Disconnect Switches - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 111 Operation Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 112 Fixed Unity Power Factor Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 112 Peak Power Tracking - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 112 Utility Voltage/Frequency Fault Automatic Reset - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 113 Safety Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 114 Anti-Island Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 114 PV Ground Insulation Detection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 114 DC Over-voltage Detection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 115 Ground Fault Monitoring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 115 Lightning Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 116 Communication Features and Methods - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 117 System Status and Fault Reporting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 117 Data Logging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 118 PC Connection Methods - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 119 Direct Access Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 119 Remote Access Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 119 Optional Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 120 RS232 Converter Kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 120 ------------------------------------------ v

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2 Operation
Description of System Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22 Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22 Faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22 Operating States - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24 Power Tracking - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24 Transition - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24 Shutdown - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25 Fault - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25 Manual Current - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25 Matrix Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25 Automatic Sleep Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25 Operator Interface - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26 UFCU Keypad Operation and Display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26 Display - Initialization Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27 Standard Display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27 Menu Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27 Read Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29 Write Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 215 Commanding Goal State Changes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 221 Setting the Date and Time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 222 Manual State Transitions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 223 Automatic State Transitions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 223 Auto-restart Feature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 225 Energize Procedure (Startup) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 225 Wiring Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 226 Insulation Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 226

3 Troubleshooting
Faults and Fault Codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 32 General Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 32 Clearing Faults Manually - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33 Fault Code Descriptions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 34 CCU2 Disconnect Errors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 310 Matrix Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 312

4 Preventative Maintenance
Maintenance Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operational Safety Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - De-Energize/Isolation Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Lockout and Tag - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Maintenance Intervals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Maintenance Interval Determined by Environmental Pollution - - - - - - - - - - - - - - - - - - - - Maintenance Package on a 10 year basis - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - xiv

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Contents

Specifications
System Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Environmental Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Regulatory Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Over Voltage, Under Voltage and Frequency Ranges - - - - - - - - - - - - - - - - - - - - - - - - - - Bolt Sizes and Torque Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A2 A2 A3 A3 A4 A5 A6

Warranty and Product Information

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Figures
Figure 1-1 Figure 1-2 Figure 1-3 Figure 1-4 Figure 1-5 Figure 1-6 Figure 1-7 Figure 1-8 Figure 1-9 Figure 1-10 Figure 1-11 Figure 1-12 Figure 1-13 Figure 1-14 Figure 1-15 Figure 1-16 Figure 2-1 Figure 2-2 Figure 2-3 Figure 2-4 Figure 2-5 Figure 2-6 Figure 2-7 Figure 3-1 Figure 4-1 Figure 4-2 Figure 4-3 Figure 4-4 Figure 4-5 Figure 4-6 Figure A-1 GT500E Major Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13 AC Terminal Room - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14 AC Control Voltage Terminal Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14 DC Terminal Room - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16 GT500E Circuit Diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17 GT500E Operator Interface Components- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18 On/Off Switch- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19 E-STOP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 110 AC and DC Disconnect Switches - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 111 Maximum Peak Power Tracking - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 113 Bender Relay Display- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 114 GT500E Current Transducers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 115 AC Lightning Protection- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 116 DC Lightning Protection- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 116 Display and UFCU Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 117 RS232/FO Converter Kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 120 Operating States Flow Chart - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23 The Universal Front Panel Control Unit (UFCU) and Display- - - - - - - - - - - - - - - - - - 26 Initialization Screens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27 Operator Interface Menu Diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28 Read-by-ID Feature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 213 State Transition Diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 221 Display Showing Fault Code - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 224 Display Showing Fault Code - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33 AC Terminal Connections from the Utility - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 44 AC Control Voltage Terminal Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 44 PV Terminal Locations- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45 Ventilation Fan Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 46 Power Fuses - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47 Control Transformer Fuses - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47 GT500E Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A6

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Tables
Table 2-1 Table 2-2 Table 2-3 Table 2-4 Table 2-5 Table 3-1 Table A-1 Table A-2 Table A-3 Table A-4 Table A-5 Table A-6 Scrolling through the Read Menu Parameters - - - - - - - - - - - - - - - - - - - - - - - - - - - - 210 Read Menu Descriptions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 211 Data Logging Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 214 Accumulated Values Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 214 Write Menu Parameters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 216 Fault Codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 34 Environmental Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A2 Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A3 Regulatory Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A3 Over/Under Voltage and Over/Under Frequency Ranges - - - - - - - - - - - - - - - - - - - - - A4 AC Terminal Bolt Size, and Torque Values - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A5 DC Terminal Bolt Size, and Torque Values - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A5

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Introduction

Chapter 1, Introduction contains information about the features and functions of the GT500E 500 kW Grid-Tied Photovoltaic Inverter.

Introduction

Description of the GT500E

The GT500E 500 kW Grid-Tied Photovoltaic Inverter is a utility interactive, three-phase power conversion system for grid-connected photovoltaic arrays with a power rating of 500 kW. Designed to be easy to install and operate, the GT500E automates start-up, shutdown, and fault detection scenarios. With user-definable power tracking that matches the inverter to the array and adjustable delay periods, users are able to customize startup and shutdown sequences. Multiple GT500E inverters are easily paralleled for larger power installations. The GT500E power conversion system consists of a pulse-width modulated (PWM) inverter, switch gear for isolation and protection of the connected AC and DC power sources. Housed in a rugged IP21 rated, galvanized steel enclosure, the GT500E incorporates sophisticated Intellimod (IPM) Insulated Gate Bipolar Transistors (IGBTs) as the main power switching devices. An advanced, fieldproven, Maximum Peak Power Tracker (MPPT) integrated within the GT500E control firmware ensures the optimum power throughput for harvesting energy from the photovoltaic array. The advanced design of the GT500E includes an EMI output filter and the main AC contactor located electrically on the inverter side of the isolation transformer. Additionally, the GT500E integrated controller contains self-protection features including over and under voltage and frequency safeguards. An integral antiisland protection scheme prevents the inverter from feeding power to the grid in the event of a utility outage. The GT500E includes a local user interface comprised of an ON/OFF switch, keypad, and 4-line, 80 character display. An available user-friendly Graphic User Interface (GUI) can provide an interface for Operator Interrogation of GT500E system status, control, metering/data logging and protective functions. These features can be accessed remotely using an optional data modem. The GT500E comes in a set of three Enclosures to house the Electronics described above. The left one-door section is the AC Interface Enclosure (-H0). The center two-door section is the Main Inverter Enclosure (-H1). The right one-door section is the DC Interface Enclosure (-H2). The three Enclosures are constructed and delivered as one complete assembly. These components are identified in Figure 11 on page 13 and the dimensions are identified in Figure A-1 on page A6.

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Physical Characteristics
The GT500E comes in a set of 3 enclosures to house the Electronics described above. The left 1-door section is the AC Interface Enclosure (-H0). The center 2door section is the Inverter Enclosure (-H1). The right 1-door section is the DC Interface Enclosure (-H2). The 3 enclosures are constructed and delivered as one complete assembly. The GT500E is IP21 rated. These components are identified in Figure 1-1.

AC Interface Enclosure -HO

Main Inverter Enclosure (Front View) -H1

DC Interface Enclosure -H2

Figure 1-1 GT500E Major Components

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AC Interface Enclosure (-H0)

The AC Interface serves as the connection for the utility (see Figure 1-1 to locate the AC Interface Enclosure). This enclosure is where the AC line fuses and AC disconnect switch reside. The terminals for the AC Control Voltage and the main AC contactor are also located in this enclosure.

AC Utility Terminal

Figure 1-2 AC Terminal Room Terminal L1 is located on the left side. Terminal L2 is located in the center. Terminal L3 is located on the right side. It provides space for 6 cables with a M12 bore diameter (see Table A-5 on page A5 max. torque).

AC Control Terminal

AC Control Voltage Terminals (-X2-L1, -X2-L2)

Figure 1-3 AC Control Voltage Terminal Connections

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Inverter Enclosure (-H1)

The GT500E Inverter Enclosure is IP21 rated and contains the power distribution panel, the converter control unit (CCU2), and power electronics matrix. Also found within the Main Inverter Enclosure are some of the system protection devices (such as the sense and control power fuses).

Power Distribution Panel

Located in the middle right side of the Inverter Enclosure, this power distribution panel contains many of the Electromechanical, protective, and control power components necessary to support the operation of the GT500E.

Converter Control Unit (CCU2)

The CCU2 is a Digital Signal Processor (DSP) based control board that performs numerous control and diagnostic functions associated with GT500E operation. Its most significant tasks are control of GT500E electromechanical components and power electronics converters and communication with the Universal Front Panel Control Unit, and system sensors. The CCU2 also contains the necessary DC power supplies to support its operation.

Power Electronics Matrix

The power electronics converter is located behind the inner doors of the Main Inverter Enclosure. The matrix consists of switching transistors (IGBTs), transistor gate drive electronics, laminated bus structure, DC capacitors and an aluminium extrusion heatsink with cooling fans. The fans are located below the heatsink. The PV array is tied logically to the matrix DC bus within the DC interface Enclosure. The embedded CCU2 control unit manages the transfer of power between the DC bus and the utility grid.

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DC Interface Enclosure (-H2)

The DC interface serves as the connection interface between the PV array and the GT500E (see Figure 1-1 on page 13 to locate the AC Interface). This enclosure is where the DC Disconnect Switch and DC contactors reside.

CAUTION: Equipment Damage

The fuses within the GT500E are intended for protecting the GT500E control circuitry only. They are not intended to provide protection for the PV array or external cabling.

DC Terminal Room

Figure 1-4 DC Terminal Room The plus (positive) terminal is located on the left. The minus (negative) terminal is located on the right side. The terminal room provides space for 8 cables with a M12 bore diameter (see Table A-6 on page A5 for max. torque). The grounding connection is located to the far left side M12 (see Table A-6 on page A5 for max. torque).

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Circuit Diagram
S olar inverter G 500E T

S inus F ilter
high voltage transform er 315V L1 grid L2 L3 A C sw itch line choke inverter choke
lig tn g h in p tectio ro n E V M F ilter

IG T m B atrix
line contactor D C IN U P T D C sw itch

D -link C

lig tn h ing pro tectio n

E V M F ilter

D C contactor

230/400 V L1 auxillary control pow L2 er

Figure 1-5 GT500E Circuit Diagram

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Operator Interface Controls

Operator interface controls are located on the front door of the Inverter Enclosure. These controls include an ON/OFF Switch, Emergency Stop (E-STOP) pushbutton, 4-line display and keypad called the Universal Frontpanel Control Unit (UFCU). Additionally there is an AC and DC Disconnect on the AC Interface Enclosure and the DC Interface Enclosure Doors.

AC Interface Enclosure

DC Interface Enclosure Display

Universal Frontpanel Control (UFCP) On/Off Switch E-STOP Push button AC Disconnect Switch (-Q1)

DC Disconnect Switch (-Q11)

Main Inverter Enclosure (Front View)

Figure 1-6 GT500E Operator Interface Components

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On/Off Switch
The GT500E incorporates a maintained position ON/OFF switch located on the front door of the Inverter Enclosure. Under normal conditions, the ON/OFF switch is in the ON position. Turning the switch to the OFF position will initiate an immediate controlled shutdown of the GT500E and open both the main AC and DC contactors within the unit. The main AC and DC contactors cannot be closed unless the switch is in the ON position. The GT500E is prevented from being restarted until the ON/OFF switch is turned back to the ON position.

WARNING: Shock Hazard

Turning the ON/OFF switch to the OFF position does NOT remove all hazardous voltages from inside the inverter. Before attempting to service the GT500E, follow the de-energize Lockout and Tag procedure on page 43.

Figure 1-7 On/Off Switch

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Emergency Stop (E-STOP)

The GT500E incorporates a maintained position E-STOP pushbutton located on the Inverter Enclosure. Under normal conditions, the E-STOP pushbutton is in the CLOSED (extended) position. Pushing the pushbutton to the OPEN (depressed) position will initiate an immediate controlled shutdown of the GT500E and open both the main AC and DC contactors within the unit. The main AC and DC contactors cannot be closed unless the pushbutton is in the CLOSED (extended) position. The GT500E is prevented from being restarted until the E-STOP pushbutton is in the CLOSED (extended) position. Provisions are supplied for adding a remote emergency stop circuit.

Figure 1-8 E-STOP

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AC and DC Disconnect Switches

Both AC and DC Interface Enclosures are equipped with lockout hasps for personnel safety. The Enclosure doors should not be opened while the GT500E is operating. The switch handles and shafts provide a door interlock for both the AC and DC Interface Enclosures. The doors cannot be opened when the switch is in the ON position. The DC Disconnect switch is equipped with an auxiliary contact block which enables the switch to be used as a load break DC disconnect. In the event the DC Disconnect switch is opened while the GT500E is processing power from the PV array, the early-break contact block will signal the CCU2 (Converter Control Unit) to stop processing power prior to opening the DC Disconnect switch. Additionally, opening the DC Disconnect switch will cause the GT500E to execute an immediate orderly shutdown, open both the main AC and DC contactors, and report a PV disconnect fault on the display of the UFCU. All GT500E Inverter Enclosure doors must be locked during normal operation.

WARNING: Shock Hazard

Disengaging the Inverter Enclosure door interlock switch does NOT remove all hazardous voltages from inside the inverter. Before attempting to service the GT500E, follow the deenergize Lockout and Tag procedure on page 43.

AC Disconnect Switch (-Q1)

DC Disconnect Switch (-Q11)

AC Interface Enclosure

DC Interface Enclosure

Figure 1-9 AC and DC Disconnect Switches

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Operation Features
The GT500E has the following operation features.

Fixed Unity Power Factor Operation

The GT500E maintains unity power factor during operation. The control software constantly senses utility voltage, and constructs the output current waveform to match the utility voltage. The GT500E is not capable of operation without the presence of normal utility voltage, nor is it capable of varying the output power factor off unity.

Peak Power Tracking

An advanced, field-proven, Maximum Peak Power Tracker (MPPT) algorithm integrated within the GT500E control software ensures the optimum power throughput for harvesting energy from the photovoltaic array. The peak power voltage point of a PV array can vary, primarily depending upon solar irradiance and surface temperature of the PV panels. This peak power voltage point is somewhat volatile, and can easily move along the I-V curve of the PV array every few seconds. The MPPT algorithm allows the GT500E to constantly seek the optimum voltage and current operating points of the PV array, and maintain the maximum peak PV output power. Accessible via the UFCU, there are five user settable parameters that control the behavior of the maximum peak power tracker within the GT500E. As show in Figure 1-10 on page 113, user settable parameters include: PPT V Ref (ID# 37), I PPT Max (ID#42), PPT Enable (ID# 44), PPT Rate (ID# 45), and PPT V Step (ID# 46).

Upon entering the Power Tracking mode, it takes approximately 20 seconds for the GT500E to ramp the PV voltage to the PPT V Ref setpoint regardless of the actual PV voltage. With the PPT Enable set to 0 (power tracker disabled), the GT500E will regulate the DC Bus at the PPT V Ref setpoint. Regulating the DC bus means drawing more or less current out of the PV array to maintain this desired voltage. With the PPT Enable set to 1 (power tracker enabled), followed by the expiration of the PPT Rate (MPPT decision frequency), the MPPT will reduce the reference voltage by an amount equal to the PPT V Step value. At this point the MPPT will compare the amount of AC output power produced to the previous amount of AC power produced by the GT500E. If the output power has increased, the next change made (after PPT Rate has again expired) to the reference voltage, will be in the same direction.

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Conversely, if the power comparison proves undesirable, the power tracker will reverse the direction of the change to the PPT_V Step. The MPPT algorithm within the GT500E will then continue this ongoing process of stepping and comparing in order to seek the maximum power throughput from the PV array. The changes made by the MPPT to the reference voltage are restricted to 20% of PPT V Ref and by the maximum and minimum PV input voltage (800 and 450 V respectively). Also, the MPPT will not attempt to produce power greater than that allowed by the I PPT Max setpoint. If available PV power is above the maximum allowable power level of the GT500E, the MPPT will increase voltage as needed to maintain output power below rated maximum. Optimization of the GT500E MPPT will result in an increase in energy production. The user is encouraged to study the PV arrays I-V curves and to adjust the MPPT user settable parameters accordingly.

Figure 1-10 Maximum Peak Power Tracking

Utility Voltage/Frequency Fault Automatic Reset

In the event of a utility voltage or frequency excursion outside of preset limits, the GT500E will stop operation and display a fault at the operator interface. Once the utility voltage has stabilized within acceptable limits for a period of at least 5 minutes, the GT500E will automatically clear the fault and resume normal operation. Voltage and frequency fault setpoints are detailed later in this section.

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Safety Features
Anti-Island Protection
A condition referred to as "Islanding" occurs when a distributed generation source (such as the GT500E Grid-tied Photovoltaic Inverter) continues to energize a portion of the utility grid after the utility experiences an interruption in service. This type of condition may compromise personnel safety, restoration of service, and equipment reliability. The GT500E employs a method for detecting the islanding condition using a Phase-Shift-Loop (PSL). This method is implemented in the CCU2 to prevent islanding of the GT500E. The CCU2 continuously makes minor adjustments to the power factor phase angle above and below unity. In the event of a utility interruption or outage, these adjustments destabilize the feedback between the inverter and the remaining load, resulting in an over/under frequency or voltage condition. Upon detection of such a condition, the GT500E then performs an immediate orderly shutdown and opens both the main AC and DC contactors. The fault condition will remain latched until the utility voltage and frequency have returned to normal for at least 5 minutes. This method has been extensively tested and proven to exceed the requirements of IEEE-929 (Recommended Practices for Utility Interface of Photovoltaic [PV] Systems) and UL 1741 (Static Inverters and Converters for use in Independent Power Systems).

PV Ground Insulation Detection

The GT500E is equipped with a PV Ground Insulation Detection circuit (Bender Relay). The circuit measures the impedance between the PV+ circuit and ground and between the PV- circuit and ground. If the impedance drops below a preset value, the GT500E will execute an immediate orderly shutdown, open both the AC and DC contactors and report a PV Ground Insulation Fault on the display of the UFCU. The GT500E will remain faulted until the fault is remedied and the advisory is cleared at the operator interface. No parallel switching of the bender relays is allowed.

Figure 1-11 Bender Relay Display

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The inverter disconnects itself in the event of a ground fault.

WARNING: High voltage

The resulting capacitive earth current is rather large due to a floating inverter and PV module assembly.

DC Over-voltage Detection
In the event of DC voltage greater than 850 Vdc (optional 880 Vdc), the GT500E will execute an orderly shutdown and will report a fault to the operator interface. If DC voltage remains greater than 850 Vdc (optional 880 Vdc), the GT500E may be irreparably damaged. See Chapter 3, Troubleshooting for further information on this fault condition.

Ground Fault Monitoring

The GT500E is equipped with a ground fault detection circuit by means of Hall Effect current transducers (+T14) (-T13) installed in the DC+ and DC- circuits. This circuit is active when the PV array is properly grounded. The current flowing in the PV+ and PV- circuits should be the same magnitude but opposite polarity. Any difference is considered ground current. In the event this imbalanced current exceed a predetermined value; the GT500E will execute an immediate orderly shutdown, open both the AC and DC contactors, and report a ground fault on the display of the UFCU. The GT500E will remain faulted until the ground fault is remedied and the advisory is cleared at the operator interface.

Current Transducers (+T14) and (-T13)

Figure 1-12 GT500E Current Transducers

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Lightning Protection
Antenna fuses were incorporated to obtain maximum protection. The control voltage is secured against over voltages by means of (3) DBM 1 440 SN 15000 (F31, -F32, -F33) located in the AC interface enclosure and the DC input using a DGY PV 1000 (-F34) located in the DC interface enclosure. The antenna fuses are equipped with an indicator. A green light on the indicator states that the antenna fuse is OK; a red light on the indicator means that the antenna fuse must be replaced. If a DBM 1 440 SN 1500 needs to be replaced, the back-up fuses (-F35) must be checked as well.

Backup Fuses (-F35)

DBM 1 440 SN 1500 (-F31) (-F32) (F33)

Figure 1-13 AC Lightning Protection

DGY PV 1000 (-F34)

Figure 1-14 DC Lightning Protection

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Communication Features and Methods

The GT500E provides two types of information to the user: system status and/or fault information, and data logging information.

System status and fault information can be accessed using the Universal Front Panel Control Unit (UFCU) or a personal computer using the Graphic User Interface (GUI) software. Data logging requires the use of a PC using the GUI software. The GT500E communicates system status information to the user using the following methods. The Front Panel Control Unit (UFCU) Display PC Connection (Direct and/or Remote) - Graphic User Interface (GUI) Software required (may require additional hardware) External Analog Monitoring - (Optional) (e.g., Irradiance, PV temp, ambient temp, wind speed) (requires additional hardware)

System Status and Fault Reporting

Basic system status and all fault conditions rising from within the GT500E are reported to the UFCU. The unit stores the time and details of all faults in nonvolatile memory. The 4-line display will show a hexadecimal value and a brief text description of the fault. The fault value is also made available to the Graphic User Interface (GUI). The GUI has a more extensive description of the fault. The UFCU keypad is located on the right center door to manipulate and view system operation and status. The keypad is comprised of 20 touch-sensitive keys that provide a means to navigate through the menus and alter user-changeable settings.
Display

Universal Front Panel Control Unit (UFCU)

Figure 1-15 Display and UFCU Location

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See the GT500E 500 kW Grid-Tied Photovoltaic Inverter Planning and Installation Manual (Part #: 152669) for details. This information can also be accessed using a personal computer using the GUI software either directly or remotely. Alternatively, the fault reporting can be accomplished using optional communication systems such as a Fax modem. Types of status information include: Current Operating State or Goal State Fault Code (if applicable) Inverter State Line Voltage and Current Inverter Matrix Temperature Inverter Power PV State PV Voltage and Current PV Power Grid Frequency Peak Power Tracker Enabled

Data Logging
The inverter stores data values and software metrics for debugging. These values are stored within the CCU2 controller board in non-volatile memory. Data logging requires the use of a PC connection using the Xantrex Solar Graphic User Interface (GUI) software. The Data Logging features include: Operational Values Internal Metrics Data Log Acquisition Graphic Data Analysis Fault Log Acquisition Software Upgrade Accumulated Values Configurable Parameters

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PC Connection Methods
Personal computers can be used to access the system status, control and programming features of the GT500E. Computers can be connected either directly or remotely using the appropriate optional hardware and software. Software is available to provide a graphic user interface that relates important system information. This software is called the Graphic User Interface (GUI).

Direct Access Connection

The GT500E can be directly accessed by a computer. This connection requires using the optional RS232 Converter kit (Xantrex Part #: 1-152624-01 KIT, COMM, DIRECT, PC TO CCU). The kit contains an RS232/FO converter configured for PC use with an adaptor, a DB9/DB25 serial cable and a fiber optic harness.

Remote Access Connection

The GT500E can be remotely accessed through several methods such as a telephone connection or Local Area Network (LAN). Optional hardware and software is needed for these features.

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Optional Equipment
The following options are available for purchase for use with the GT500E to enhance its communications capability. The additional GT500E options can be field installed. Contact a Xantrex distributor for further information on installation options.

RS232 Converter Kit

RS232 Converter kit (Xantrex Part #: 1-152624-01 KIT, COMM, DIRECT, PC TO CCU) contains a RS232/Fiber Optic Converter configured for PC use with an adaptor, a DB9/DB25 serial cable and a fiber optic harness (not shown).

RS232/FO Converter Kit (Part #: 1-152624-01)

DB25 Adapter on Serial Cable

DB25-DB25 Gender Changer Adapter DB9 Adapter on Serial Cable RS232 Converter

Figure 1-16 RS232/FO Converter Kit

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Operation

Chapter 2, Operation contains information on the basic operation of the GT500E 500 kW Grid-Tied Photovoltaic Inverter.

Operation

Description of System Operation

Overview
The GT500E is a fully automated grid-interactive photovoltaic inverter. System startup, system shutdown, PV power tracking, and fault detection scenarios are all governed and monitored by the CCU2 controller within the GT500E. Manual interaction or control of the inverter is necessary only in the event of a system fault. Additionally, the following conditions govern operation of the GT500E. Stable utility AC voltage and frequency as specified in Table A-4 must be present for all states of operation. PV voltage as specified in Table A-4 must be present. With the exception of the Matrix Test state, the ON/OFF switch, located on the front door of the GT500E Inverter Enclosure, must be switched to the ON position for all operating states. Both the AC and DC Disconnect switches must be in the ON or closed position. Fault conditions must not be present.

Faults
Fault states are automatic from any state of operation. In the event of a fault condition, the GT500E will immediately stop processing power and execute an immediate orderly shutdown, open both the main AC and DC contactors, and remain in a faulted state until the fault is remedied and cleared (manually or automatically). Most faults are latching, and only those faults associated with grid disturbances are auto-clearing and thus enable the GT500E to restart after a 5 minute delay period. All fault conditions arising from within the GT500E are reported to the UFCU (Universal Frontpanel Control Unit). The 4-line display on the UFCU will display a hexadecimal value (fault code) and a brief text description of the fault. Once the cause of the fault has been identified and corrected, and it is determined to be safe to proceed, GT500E faults may be cleared from the UFCU keypad or via the remote GUI. See Clearing Faults Manually on page 33 for instructions on this procedure.

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POWER UP
INITIALIZING PV contactor opened. Inverter matrix off. Grid contactor open. Green LED on. Red off.

System State: Key Disable Inverter State: Standby PV State: Sleep

KEY DISABLE PV contactor open. Inverter matrix off. Grid contactor open.

Enable Key
Inverter matrix off. Line contactor open

System State: Shutdown Inverter State: Standby PV State: Sleep

SLEEP for at least 10 seconds

PV Voltage > 300V Close K2

PV Contactor Closed

PV Voltage < 50V (300V - 250V margin)

PV Contactor Open

PV Voltage > 440V (PV V START)

System State: Shutdown Inverter State: Standby PV State: Wake Up

WAKE UP for 5.0 min. (PV T START)

PV Voltage < 440V (PV V Start)

Grid Contactor K1 Close

System State: Shutdown Inverter State: Main Settling PV State: Wake Up

K1 Settle for .5 seconds

Inverter Matrix On

PV Voltage < 300V (Min. Oper.)

PV Voltage < 300V (Min. Oper.) System State: Power Tracking Inverter State: On Line PV State: On Line

ON LINE

PV Power < 1.0kW (PV P STOP) PV Power > 1.0kW (PV P STOP)

TEST for 5.0 min. (PV T STOP)

5 minutes elapsed

System State: Power Tracking Inverter State: On Line PV State: Sleep Test FAULT PV contactor opened. Inverter matrix off. Grid contactor open. Red LED on. Green off.

Fault from any State

Fault Cleared

Bold - constant value Italic - User settable. Underline - Default value.

Figure 2-1 Operating States Flow Chart

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Return to SleepState Retrun to Sleep State

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Operating States
A state machine implemented within the CCU2 control software governs the operation of the GT500E with clearly defined transitions between its operating states. There are five steady-state operating states and numerous intermediate transition states. Power Tracking Transition Shutdown Fault Manual Current Matrix Test Automatic Sleep Test

Power Tracking
This is the standard operating state of the GT500E. The GT500E maximum power tracker will demand maximum power from the PV array, given sufficient PV irradiance. The user should be aware of the following conditions governing GT500E state transitions: Qualified utility voltage must be present for all states of operation. Fault states are automatic from any state of operation. A fault will cause the GT500E to immediately stop processing all power. The fault condition will be reported to the operator interface display. Most GT500E faults are latching and must be cleared at the operator interface keypad before transitioning to another operating state. The ON/OFF switch, located on the front door of the GT500E, must be in the ON position for all operating states except Matrix Test, in which case it must be in the OFF position.

Transition
The intermediate transition states provide an orderly progression from one operating state to the next. The user has the ability to manually transition the GT500E between operating states via the operator interface keypad or remotely using the GUI software. Manual transitions are initiated by entering a Goal State, where the goal state is the desired operating state. Given all applicable system parameters are within acceptable limits, and the request is valid within the state machine, the GT500E will initiate the proper sequence of operations necessary to progress to the requested goal state. Refer to Figure 2-1 on page 23 for an illustration of valid state transitions.

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Shutdown
The line interface controller is idle. The CCU2 monitors the status of the PV array and utility grid, waiting in standby until the PV array is available to produce power to the grid.

Fault
The GT500E has encountered a fault condition. When this happens, regardless of the GT500E state of operation, the GT500E will stop processing all power and execute an orderly system shutdown. A description of the fault and fault code will appear on the operator interface display. The Fault state may be cleared from the keypad once the cause of the fault has been corrected. See Chapter 3, Troubleshooting for a complete description of all fault codes.

Manual Current
This operating state is provided to evaluate the existing PV array V-I characteristics. The PV controller regulates a constant amount of PV current as commanded by the user from the operator interface keypad, up to the PV current limit of the GT500E. If the user commands more PV current than is available, the DC bus voltage will drop below the minimum bus voltage level and the GT500E will enter Shutdown mode.

Matrix Test
This operating state is provided to verify proper operation of the matrix and associated control electronics. There is no power transfer between the PV and utility in this mode. The ON/OFF switch must be in the OFF position for the GT500E to enter this state.

Automatic Sleep Test

Toward the end of every solar day, the GT500E automatically determines when to stop producing power dependent upon the output power of the inverter. As the net output power of the GT500E nears zero, a timer is started to allow the inverter to ride through any brief irradiance reductions.

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Operator Interface
The purpose of the operator interface is to provide a means of communicating critical operational information to and from the unit. This communication occurs between the operator and the UFCU Keypad and display or between the operator and a personal computer running the GUI software.

UFCU Keypad Operation and Display

The UFCU keypad is located on the front of the Main Inverter Enclosure to manipulate and view system operation and status. The keypad is comprised of 20 touch-sensitive keys that provide a means to navigate through the menus and alter user-changeable settings. Four function keys are available. F1 - When in the READ Menu, this key is used to clear Faults. If there is no fault it jumps to display "INV A Volts:". In the WRITE Menu, it jumps to display "Goal:". F2 - When in the READ Menu, this key jumps to display "INV kW:". In the WRITE Menu, it jumps to display "PPT V Ref:". F3 - When in the READ Menu, this key jumps display to "PV kW:". In the WRITE Menu, it jumps to display "PPT Enable:". F4 - When in the READ Menu, this key jumps to display "kWH:". In the WRITE Menu, it jumps to display "Role 0=SA 1=M 2=S:". Two Navigation keys are available. \/ or /\ moves forward or backward within the menu structure. Upon reaching the end of the menu, it will roll-over to the beginning of the same menu. Ten numeric keys (0 through 9), two symbol keys (. and -), and an ENTER key are available for entering user-settable parameters. The MENU key allows you to enter the password-protected Write parameters.

System: PWR Tracking Inv: Online Pv: Online INV kW:

Display

UFCU Keypad

Standard Display

Figure 2-2 The Universal Front Panel Control Unit (UFCU) and Display

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Display - Initialization Screen

Any time AC power is applied to the unit, the display will cycle through the following displays while the system initializes. Once its done with this process, the standard display will appear.
Front Panel Initialization - Screen 1
GT500E XANTREX TECHNOLOGY www.xantrex.com <FP Software Version>

Standard Display
System: PWR Tracking Inv: Online Pv: Online INV kW:

Figure 2-3 Initialization Screens

Standard Display
The Standard Display provides the following information: First Line - System Status (ID 1) Second Line - Inverter Status (ID 4) Third Line - PV Status (ID 13) Fourth Line - INV kW: (ID 11)

Menu Structure
The operator interface consists of three levels: READ Menu - operation information provided to the user from the GT500E. The Read Menu consists of all operational values, the date and time. These can be viewed any time the GT500E has control power. WRITE Menu - operational parameters provided to the GT500E from the user. The Write Menu consists of a goal state sub-menu, and all system configurable parameters. The Write Menu is password protected and may only be changed by trained service technicians. In particular are parameters relating to utility protection setpoints. Data Logging - the collection of specific parameters values over a period of time. The data logging feature is only available if using the GUI. However, the user does have the ability to view a snapshot of specific data using the Read by ID feature. See Table 2-3 and Table 2-4 on page 214.
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Information reported back to the user (READ Menu) occurs at the display above the Universal Front Panel Control Unit (UFCU) and (if used) at the computer running the GUI monitoring program. Making changes to the parameters within the Write Menu is done with the UFCU keypad or the GUI software program and requires a password.

Important: Specific grid-interface parameters within the WRITE Menu have been set in
the factory to the limits mandated by the utility. Any changes to these setpoints should be agreed upon by the local utility and the equipment owner.

Upon system powerup, the operator interface display will show the system operating state on the first line. The inverters state of operation will be reported on the second line. The PV Arrays state of operation will be reported on the third line. The Inverter kW will be reported on the fourth line.

Important: While in the WRITE Menu, the operator interface display will reset itself to
the standard display if there is no input for more than 2 minutes.

System: PWR Tracking Inverter: Online PV: Online INV kW:

Standard Display Password

READ Menu

Enter Goal State WRITE Menu

Set Date/Time Change Parameters

Figure 2-4 Operator Interface Menu Diagram

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READ Menu
The READ Menu includes the following information: Current Operating State or Goal State Fault Code Front Panel Software Version CCU2 Software Version Inverter Model Date & Time Goal State Read by ID# Inverter Voltage and current Inverter Power Inverter Temperature PV Voltage and Current PV Power Grid Frequency PV PPT Enable Ground Current Accumulated Power

Table 2-1 shows how the third and fourth line of the display will change as the operator continues scrolling through the Menu. Table 2-2 on page 211 provides a detailed description of READ Menu operational values that are shown on the display.

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To Display Any Operational Value in the READ Menu From the Standard Display, use the /\ or \/ keys on the operator interface keypad to scroll through the READ Menu. The fourth line of the display will change to display the appropriate information. See Table 2-1. The \/ key will scroll downward through the menu. The /\ key will scroll upward through the menu.

Table 2-1 Scrolling through the Read Menu Parameters

Read Menu Value Front Panel Software Version CCU2 Software Version Inverter Model Date & Time European format Goal State Read by ID# Inverter L1-L2 Volt Inverter L2-L3 Volt Inverter L3-L1 Volt Inverter L1-L2 Current Inverter L2-L3 Current Inverter L3-L1 Current Inverter Power Inverter Temperature PV Voltage PV Current PV Power Grid Frequency PV PPT Enable Ground Current Accumulated Power Fourth Line of the Display FP 151-0407-nn-nn CCU 151-0125-nn-nn GT500E DD-MMM-YYYY HH:MM:SS Goal: Value by ID# INV A Volts: INV B Volts: INV C Volts: INV A Amps: INV B Amps: INV C Amps: INV kW: INV Temp: PV Volts: PV Amps: PV kW: Grid Freq: PV PPT: Ground I: KWH

Upon reaching the end of the menu, it will go back to the beginning of the menu.

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Table 2-2 Read Menu Descriptions

Operational Parameter Current Operating State Displays as: System: * where * can be any one of the states listed in the description for this parameter. Description Current system states include the following.
Initializing (0) Key-disabled (1) Shutdown (2) Starting (3) PWR Tracking (4) Manual Current (5) Matrix Test (6) Faulted (7)

ID 1

Units N/A

System Goal State Displays as: Goal: * where * can be any one of the states listed in the description for this parameter. Fault code Inverter State Displays as: Inverter: * where * can be any one of the states listed in the description for this parameter. PV State Displays as: PV: * where * can be any one of the states listed in the description for this parameter. Front Panel Software Version CCU2 Software Version Inverter Model Line L1L2 voltage Displays as: INV A volts: xxx Line L2L3 voltage Displays as: INV B volts: xxx Line L3L1 voltage Displays as: INV C volts: xxx

Goal States include the following.

0: Shut Down (0) 1: PWR Tracking (0) 2: Manual Current (0) 3: Matrix Test (0)

N/A

See Faults and Fault Codes on page 32 for a detailed list of Fault Codes. Inverter States includes the following.
Shut Down (0) Stand-by (1) Starting (2) Main-Setting (3) On-Line (4)

3 4

N/A N/A

PV States include the following.

Shut Down (0) Sleep (1) Wakeup (2) On-line (3) Sleep-test (4)

N/A

In form FP 151-0407-nn-nn In form CCU 151-0125-nn-nn GT500E Line to line voltage

N/A N/A N/A 6

N/A N/A N/A Vrms

Line to line voltage

Vrms

Line to line voltage

Vrms

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Table 2-2 Read Menu Descriptions

Operational Parameter Phase L1 current Displays as: INV A amps: xxx Phase L2 current Displays as: INV B amps: xxx Phase L3 current Displays as: INV C amps: xxx Inverter Real Power Displays as: INV KW: Inverter Matrix Temperature Displays as: INV Temp: PV Voltage Displays as: PV Volts: xxx PV Current Displays as: PV amps: xxx PV Power Displays as: PV kW: xxx Grid Frequency Displays as: Grid Freq: Peak Power Tracker Enable Displays as: PV PPT: * where * can be any one of the states listed in the description for this parameter. Ground Current Displays as: Ground I: kW Accumulated Displays as: kWH: kW Accumulated 20 N/A Ground Current 19 N/A Indication as to whether the PPT is enabled or disabled.
Off (0) On (1)

Description Phase L1 current

ID 9

Units Arms

Phase L2 current

10

Arms

Phase L3 current

11

Arms

Inverter Real Power

12

kW

Temperature of the Inverter IGBT matrix heatsink

13

PV Voltage

14

Vdc

PV Current

15

Adc

PV Power

16

kW

Grid Frequency

17

Hz

18

N/A

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READ-by-ID The Read-by-ID feature supports the ability of the user to view any Read or Write parameter available within the menu structure. It also provides a means to view data logging and accumulated values information. See Table 2-2 for a list of the Read Menu parameters. See Table 2-3 for a list of data logging menu parameters. See Table 2-4 for a list of accumulated values parameters. To use the Read-by-ID Feature: 1. From the Standard Display, press the /\ key seven times to scroll upward through the menu to the Read-by-ID Menu item. Stop when the 3rd and 4th line of the display change as shown in Figure 2-5. 2. Press <ENTER> to enter the Read-by-ID feature. 3. Use the keypad to enter the ID number of the Data Log Configuration or Accumulated Value ID number and press <ENTER>. See Table 2-2 for a list of READ Menu items and their ID numbers. a) Press the . button to move upward in the Menu structure. b) Press the - to move backward in the menu structure. These keys only function in the Read-by-ID feature.
System: Shutdown Inv: Standby Hit ENTER or . or Value by ID#

Press <ENTER> when this screen appears to access the Read-by-ID feature.

System: Shutdown Inv: Standby Hit ENTER or . or Read ID# xxx: xxx

Use the keypad to enter the desired ID number and press <ENTER>. The display will change as shown and will show the requested value. where: xxx = any Menu ID xxx = operational value of Menu ID Use the . and - buttons to scroll backward and forward within the Read-by-ID menu.

Figure 2-5 Read-by-ID Feature

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Table 2-3 provides a list of the Data Logging Menu parameters. Table 2-3 Data Logging Menu
ID# 300 301 302 303 304 through 390 391 392 393 394 395 396 397 398 299 Usage Data Log Daily Rate in Minutes ID# of 1st parameter to be logged ID# of 2nd parameter to be logged ID# of 3rd parameter to be logged ID#s of the 4th through the 90th parameter to be logged. Not available Data Log Nightly Rate in Minutes First Daytime Hour First Night-time Hour Size of Data Log in Words Words per record Count of parameters per record Offset from Data Log or next log record Address of the Data Log

Table 2-4 provides a list of the Accumulated Values Menu parameters. Table 2-4 Accumulated Values Menu
ID# 600 601 602 603 604 605 606 607 608 609 610-619 620 621 622 623 624 625 626-629 630 631 632 214 Usage Accumulated Operating Hours on actual day Accumulated Operating Hours in actual week Accumulated Operating Hours in actual month Accumulated Operating Hours in actual year Accumulated Operating Hours since Commissioning Accumulated Sell Mode Hours on Actual Day Accumulated Sell Mode Hours in actual week Accumulated Sell Mode Hours in actual month Accumulated Sell Mode Hours in actual year Accumulated Sell Mode Hours since Commissioning Not available Accumulated Power Sold Hours on actual day Accumulated Power Sold Hours in actual week Accumulated Power Sold Hours in actual month Accumulated Power Sold Hours in actual year Accumulated Power Sold Hours since Commissioning Accumulated Power Sold Hours since last reset Not available Peak Power monitored today Peak Power monitored this week Peak Power monitored this month 152670

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Table 2-4 Accumulated Values Menu

ID# 633 634 635-639 640 641 642 643 Usage Peak Power monitored this year Peak Power monitored since Commissioning Not available Peak Power Sold for a day Peak Power Sold for a week Peak Power Sold for a month Peak Power Sold for a year

WRITE Menu
Important: Specific grid-interface parameters within the WRITE Menu have been set in the factory to the limits mandated by the local utility. Any changes to these setpoints should be agreed upon by the local utility and the equipment owner.
The WRITE Menu includes the following parameters: Ground Current Max PPT Voltage Reference PV Voltage Start PV Time (Start and Stop) PV Power Stop PPT Current Max % Manual Current % PPT Enable PPT Update Rate and Voltage Step

Important: WRITE parameters require a password to access and should only be changed
by authorized personnel.

Table 2-5 provides a detailed description of WRITE parameters that are shown on the display. Table 2-5 shows additional WRITE Menu parameters that may be available depending upon the configuration of the system.

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Changing and Displaying WRITE Menu Parameter Values Follow the procedure below to change WRITE Menu parameters. To change WRITE Menu parameters: 1. From the standard display or anywhere in the READ Menu, you may access the WRITE menu parameters by pressing the <MENU> key. This will ask for a password. 2. Enter the password <5><9><4> and press the <ENTER> button. a) If the wrong password is entered, the display will again prompt the user for the password. b) If a mistake is made while keying in the password, the /\ or \/ keys may be used as a backspace key. 3. Once within the Write Menu, the first item is the Set Goal State. Use the /\ or \/ key on the operator interface keypad to scroll through the WRITE Menu parameters. a) To change the displayed parameter, press the <ENTER> button. b) Enter the desired value and press <ENTER>. If the value entered is outside the acceptable range for the parameter, the original value will remain. c) To leave the WRITE Menu and return to the READ Menu, press the <MENU> button once and the standard information will reappear on the display. Table 2-5 Write Menu Parameters
Parameter Set Goal State Displays as:
Hit ENTER to set Goal:

Description Commands a Goal State.

ID

Units

Default Value

Maximum Value

Minimum Value

Set Date Displays as:

ddmmyy

The date is entered month-dayyear (ddmmyy): April 28, 2005 is entered 280405. The time is entered in military hours-minutes-seconds (i.e., 24-hour clock): 4:30 pm is entered 163000. This parameter sets the trigger point value for AC voltage High (0013) fault. If the grid voltage is over this parameters value, the fault is triggered. The upper limit of this parameter is restricted by UL requirements. 32 Percentage 110 of Nominal voltage 112 97

Set Time: Displays as: 163000 Maximum Grid Voltage Displays as:
Max AC Volts %:

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Table 2-5 Write Menu Parameters

Parameter Description ID 33 Units Default Value Maximum Value 105 Minimum Value 88

Minimum Grid Voltage This parameter sets the trigger point value for AC voltage low Displays as: (0012) fault. If the grid voltage is Min AC Volts%: below this parameters value, the fault is triggered. The lower limit of this parameter is restricted by UL requirements. Maximum Grid Frequency Displays as:
Max AC Freq:

Percentage 90 of Nominal voltage

This parameter sets the trigger point value for AC frequency high (0011) fault. If the grid frequency is over this parameters value, the fault is triggered. The upper limit of this parameter is restricted by UL requirements. This parameter sets the trigger point value for AC frequency low (0010) fault. If the grid frequency is below this parameters value, the fault is triggered. The lower limit of this parameter is restricted by UL requirements. This parameter sets the trigger point value for Ground Over Current (0033) fault. Once the current through the ground cable is greater than the value of this parameter, the fault is triggered. This is the initial PV voltage the inverter is going to try to keep as it goes into on line mode. If the power tracker is off, the inverter will draw current from the PV array to maintain this reference voltage. If the power tracker is on, this is the reference voltage from which the inverter start exploring voltages that produce more power. This is the trigger point that transitions the inverter from PV Sleep state to PV Wake Up state. When the PV voltage reaches the value of this parameter the inverter transitions into PV Wake Up mode.

34

Hertz

51.0

52.0

49.5

Minimum Grid Frequency Displays as:

Min AC Freq:

35

Hertz

49.0

50.5

48.0

Maximum Ground Fault Current Displays as:

Max Gnd Flt I:

36

Amps

10

20

Peak Power Tracker Reference Voltage Displays as:

PPT V Ref:

37

Volts

600

800

450

PV Wakeup Voltage Displays as:

PV V Start:

38

Volts

650

800

450

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Table 2-5 Write Menu Parameters

Parameter Time Delay for PV Wake up Displays as:
PV T Start:

Description

ID

Units Seconds

Default Value 300

Maximum Value 1200

Minimum Value 0

Time delay to transition from PV 39 wake up state to PV On-line state. Once the inverter is in PV Wake Up mode, it waits for the amount of time determine by this parameter before transitioning into PV on-line mode. During this time the inverter checks that the PV voltage is no less than the PV wake voltage, otherwise it goes into PV Sleep mode. This is the amount of time the inverter will be in Sleep Test mode if the output power continues to be below PV P Stop. The inverter will exit Sleep Test mode towards on-line mode is the power is over PV P Stop or towards Shutdown mode is the PV T Stop timer expires. This is the output power trigger point for the inverter to transition into sleep test mode. When the output power is below the value of this parameter the inverter enters sleep test mode. This parameter sets the percentage of maximum rated power the inverter will produce when in power tracker mode. For example, a 500 kW system with this parameter set to 50 will not attempt to produce more than 250 kW. 40

Time delay for PV Sleep Test Displays as:

PV T Stop:

Seconds

300

1200

PV Output Power to Enter Sleep Test Mode Displays as:

PV P Stop:

41

KW

10.0

0.1

Power Tracker Maximum Output Power Displays as:

I PPT Max:

42

Percentage 100 of maximum output power.

110

Manual Current Output This parameter sets the percentage of maximum out current the Displays as: inverter will attempt to produce I Manual%: while in manual current mode.

43

Percentage 25 of maximum output current.

110

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Table 2-5 Write Menu Parameters

Parameter Enable Peak Power Tracker Displays as:
PPT Enable:

Description

ID

Units 0 = Off 1 = On

Default Value 1

Maximum Value 1

Minimum Value 0

44 This parameter switches on and off the Power Tracker function. When the Power Tracker is on, the inverter will regulate the bus voltage to optimize output power. When the Power Tracker is off, the inverter will regulate the bus voltage to maintain it at PPT V Ref volts. This parameter sets the rate at which the Power Tracker function makes changes to the voltage reference point as it tries to find the optimal position. For example, if the value of this parameter is 0.5, then every half a second the power tracker will increase or decrease the voltage reference point to check if more power can be produced at the new level. This parameter sets the size of the change the Power Tracker will make to the voltage reference point as it tries to find the optimal position. For example, if the value of this parameter is set to 1, the Power Tracker will increase or decrease the voltage reference point by one volt at a speed of PPT Rate to check if more power can be produced at the new level. This parameter sets the language used to display messages. 45

Power Tracker Rate Displays as:

PPT Rate:

Seconds

0.5

10.0

0.1

Power Tracker Step Displays as:

PPT V Step:

46

Volts

10.0

0.1

Language Selection Displays as:

Language Code:

48

0 = English 10 = German 20 = Spanish

20

Role Reversal Displays as:

Role 0=SA 1=M 2=S:

This parameter sets the Master/ Slave default state of the Unit. If Stand Alone is selected; there is no Master/Slave operation. This parameter sets the power level where the master unit will disconnect from the full array and enable the slave unit to operate.

50

0= Standalone 1 = Master 2 = Slave

Master/Slave High Power Displays as:

MS High kW:

51

kW

400

500

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Table 2-5 Write Menu Parameters

Parameter Master/Slave Low Power Displays as:
MS Low kW:

Description This parameter sets the power level where the master unit will disable the slave unit and reconnect to the full array. This Parameter Sets The Condition Of The Role Reversal function:

ID 52

Units kW

Default Value 100

Maximum Value 500

Minimum Value 0

Role Reversal Displays as:

0=OFF 1=ROLE REV:

54

0 = OFF 1 = ON

Master/Slave transition This parameter sets the time the power level must remain above time the MS High kW level before the Master will disconnect from the Displays as: MS Trans Secs: full array and enable the slave unit to operate. This parameter also sets the time the power level must remain below the MS Low kW level before the Master will disable the slave unit and re-connect to the full array. Reset kWH Displays as:
Reset kWH:

53

Seconds

30

1000

The parameter allows the operator to reset the accumulated power reading to Zero. Press the ENTER to reset to Zero. Hit F4 to confirm will appear. The parameter allows the operator to reset all the settable parameters back to the Factory Default settings: Press the ENTER to reset to Factory Default. Hit F4 to confirm will appear.

N/A

kWh

N/A

N/A

N/A

Factory Default Displays as:

Factory Default:

N/A

N/A

N/A

N/A

N/A

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Commanding Goal State Changes

To change the Goal State: 1. From the standard display press the <MENU> key. This will prompt the user for a password. The display will change the third line to Type and Hit ENTER and fourth line of the display to Password:. 2. Enter the password <5><9><4> and press the <ENTER> button. The display will change the third line to Hit ENTER to set and fourth line of the display to Goal:. 3. Press <ENTER> again. The Goal State menu will show on the display. 4. Scroll through the goal state menu with the /\ or \/ keys until the desired goal state is displayed on the fourth line of the display. 5. Press <ENTER>. The display will then prompt the user by showing the following text on the third line: Press F4 to Confirm. 6. Press <F4> and the GT500E will transition to this goal state. If the goal state requested violates the conditions of the state machine, the GT500E will remain in the previous state of operation.

SHUTDOWN Manual Inverter = Disabled FAULT Automatic

MATRIX TEST Inverter = Idle

POWER TRACKING Inverter = PV Power

Manual

MANUAL CURRENT Inverter = PV Current

Figure 2-6 State Transition Diagram

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Setting the Date and Time

Follow the procedure below to change the date and time. To change the Date and Time: 1. From the standard display, press the <MENU> key. This will prompt the user for the password. The display will change the third and fourth lines as follows: Type and Hit ENTER Password:. 2. Enter the password <5><9><4> and press the <ENTER> button. 3. Scroll down with the \/ key until date or time parameters are reached. a) If youre changing the date, the third and fourth lines of the display will show as follows: Type and hit ENTER Set Date: DDMMYY b) If youre changing the time, the third and fourth lines of the display will show as follows: Type and hit ENTER Set Time: HHMMSS 4. Press <ENTER>. Enter the proper date or time in a six digit format. For example: a) The date is entered day-month-year (ddmmyy): April 28, 2005 is entered 280405 <ENTER>. b) The time is entered in military hours-minutes-seconds (i.e., 24-hour clock): 4:30 pm is entered 163000 <ENTER>. If a mistake is made while entering the date or time, the /\ and \/ keys may be used as a backspace key. Any two-digit year YY may be entered for the date, but regardless of the keyed entry, the maximum Day-Month DDMM that the UFCU will accept is a 3112 or Dec. 31st. The maximum allowable time entry the UFCU will accept is 235959. 5. Once the entry is accepted, the third and fourth lines of the display will revert back to the following: a) If youre changing the date, the third and fourth lines of the display will show as follows: Hit ENTER to set Set Date: b) If youre changing the time, the third and fourth lines of the display will show as follows: Hit ENTER to set Set Time: 6. Pressing the <MENU> key will return the user to the standard display.

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Operator Interface

Manual State Transitions

State conditions can also be transitioned manually. Refer to Commanding Goal State Changes on page 221 for instructions on commanding GT500E goal states for manual transitions. Shutdown Matrix Test Shutdown 1. Turn the ON/OFF switch to the OFF position. 2. Command the GT500E to the Matrix Test. 3. After completing the Matrix Test, command the GT500E to Shutdown. If the ON/OFF switch is turned to ON while the GT500E is in the Matrix Test state, the GT500E will transition to Shutdown. Power Tracking Manual Current Power Tracking or Shutdown 1. Verify the PV manual current parameter (I Manual %) is set to the desired percent of rated. 2. Command the GT500E to Manual Current mode from the operator interface keypad. While in the manual current mode, the user may change the PV manual current parameter. However, the user may demand greater current than the capacity of the PV array. If this causes the PV voltage to drop below the minimum operating voltage (445 Vdc), the GT500E will transition to Shutdown. 3. To exit the Manual Current mode, the user must manually command the GT500E to Power Tracking.

Automatic State Transitions

State conditions can also be transitioned automatically. Refer to Commanding Goal State Changes on page 221 for instructions on commanding GT500E goal states. Shutdown Power Tracking Shutdown 1. The ON/OFF switch must be turned to the ON position. 2. Once the PV voltage exceeds the PV voltage start set point (PV V Start) the GT500E will start a wake-up timer (PV T Start). a) If the PV voltage remains above the PV start voltage set point for the duration of the wake-up timer, the GT500E will transition to Power Tracking. b) If the PV power drops below the PV power stop set point, (PV P Stop) the GT500E will start a PV sleep timer (PV T Stop). c) If the PV voltage and power remain below their respective setpoints for the duration of the sleep timer, the GT500E will transition to Shutdown.

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Operation

Any State Fault If the GT500E encounters a fault, regardless of operating state, it will transition to the Fault state. The GT500E will remain in this state until the fault condition has been remedied and cleared. The Fault Code number will appear on the first line of the display. A description of the fault will show on the second line. The third line of the display will read F1 to Clear Fault?. The fourth line shows the goal state.
Fault: 0070 INTERLOCK ACTIVATED F1 to Clear Fault INV kW:

Display Showing Fault Code

UFCU Keypad

Figure 2-7 Display Showing Fault Code To clear the fault: 1. See Table 3-1, Fault Codes on page 34 for a complete listing of Fault Codes and possible remedies. Correct the fault condition if possible and attempt to clear the fault by pressing F1. 2. The ability to clear the fault can only be done from the READ Menu. If a fault occurs while accessing the WRITE Menu, pressing <MENU> once will return to the Read Menu, and F1 to Clear Fault will appear on the third line of the display.

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Auto-restart Feature

Auto-restart Feature
In the event of a utility voltage or frequency excursion outside of those specified in Table A-4 on page A4, the GT500E will automatically transition to a Fault condition. Once the Utility recovers for a period of five minutes, the GT500E will automatically clear the fault, then resume normal operation.

Energize Procedure (Startup)

To start up the GT500E: 1. Remove any lockout devices from the Utility connection circuit breaker and PV disconnect switch. 2. Remove any lockout devices from the Auxiliary Control Power disconnect and energize the Auxiliary Control Power. 3. Close the Utility connection circuit breaker. 4. Close the AC Disconnect Switch. 5. Close the DC Disconnect Switch. 6. Verify the E-STOP pushbutton is in the CLOSED (extended) position. 7. If a remote E-STOP pushbutton is installed; Verify it is in the CLOSED (extended) position. 8. Turn the ON/OFF switch to the ON position. After a 15 second initialization period, the GT500E will automatically transition to Waking Up, given the PV voltage is greater than the PV V Start set point.

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Operation

Wiring Check
WARNING
Please adhere to all general safety instructions when gauging the device.

WARNING
Beware right rotating field L1, L2, L3 upon initial operation.

WARNING: Shock hazard

Disconnecting only the main control switch at the AC and DC side will be insufficient when working on the facility.

WARNING: Shock hazard

The inverter may also be supplied by external power.

CAUTION
The emergency OFF switch should only be used in emergencies as load breaking excessively stresses the component parts. Always use the ON/OFF switch for controlled breaks of the GT500E.

Verify the following items in order to check the wiring: 1. Mechanical control of torque. 2. Control voltage can be supplied externally or internally. 3. Gauge internal control voltage; must be within the 230V10% range (see schematic diagrams) 4. Transformers off-load voltage gauged at approximately 300V10V 5. Gauge PV+ and PV- voltage. Should be equal to the PV voltage.

Insulation Check
For GT500Es, an insulation check in accordance with VDE 0160 / EN50178 can be performed for the entire inverter including activation levels and the power supply unit. Insulation checks of the control electronics are neither possible nor required as they are grounded. The connections to the control electronics must be disconnected while the insulation check is performed as resistors are used for sensing the direct current link voltage, AC voltage and the PV array voltage. To avoid overheating the Y-connected capacitors, the test must not exceed 2000 V or last more than one minute.

WARNING: Shock hazard

The inverter must be discharged upon a successful insulation gauge. Plug all plugs back in or secure them.

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Insulation Check

The following actions must be taken before an insulation check: The GT500E will be checked using 2 kV DC for 1 minute. Output will be checked against earth. 1. Lightning Protection Remove lightning protection on AC side (-F31, -F32, -F33) Remove lightning protection on DC side (-F34) Verify Grid potential is removed from AC main control switch (-Q1) Verify PV potential is removed from DC main control switch (-Q11) Verify auxiliary power is removed from -F6 and -F7 Bridge all three phases of AC contactor (-K1) and bridge line side to load side Bridge line side to load side of DC contactors (-K11) and (-K12) Close AC and DC main control switches (-Q1) and (-Q11) Unplug J1000 from the CCU2 board (-A1) Unplug J1001 from the CCU2 board (-A1)

2. Remove all power potentials

3. Short circuiting all power potentials

4. Remove Xantrex Board (A1) connections

5. Remove connections from the central circuit board survey (-A3) Unplug X20 from the central circuit board (-A3) Unplug X21 from the central circuit board (-A3) To perform an insulation check: 1. Remove and tape the PV+ and PV- sense wires from the Bender relay coupling unit (-R15). Perform insulation check (2000V 1 minute maximum) After the insulation check, ensure that you remove all the bridges, reinstall the connections and return the converter to original condition.

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Operation

De-Energize/Isolation Procedure (Shutdown)

The following procedure should be followed to de-energize the GT500E for maintenance:

WARNING
The terminals of the DC input may be energized if the PV arrays are energized. In addition, allow 20 minutes for all capacitors within the Inverter Enclosure to discharge after disconnecting the GT500E from AC and DC sources.

To isolate the GT500E: 1. Turn the ON/OFF switch to the OFF position. 2. Open the DC interface disconnect switch (-Q11). 3. Open the AC interface disconnect switch (-Q1). 4. Open the utility connection circuit breaker. 5. Open the Auxiliary Control Power disconnect to de-energize the Auxiliary Control Power. 6. Install lockout devices on the utility connection circuit breaker, AC and DC disconnect switches. Install a lockout device on the Auxiliary Control Power disconnect.

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Troubleshooting

Chapter 3, Troubleshooting contains information and procedures for troubleshooting the GT500E 500 kW Grid-Tied Photovoltaic Inverter. It provides descriptions of common situations and errors that may occur and provides possible solutions for resolving fault conditions. It also provides instructions for clearing faults manually, if required.

Troubleshooting

Faults and Fault Codes

Fault states are automatic from any state of operation. In the event of a fault condition, the GT500E will immediately stop processing power and execute an immediate orderly shutdown, open both the main AC and DC contactors, and remain in a faulted state until the fault is remedied and cleared (manually or automatically). In the event of an alarm or fault condition, the GT500E will execute an immediate, orderly shutdown and remain in a faulted state until the alarm or fault is remedied and cleared (manually or automatically). Faults associated with a grid disturbance clear automatically. The GT500E will automatically re-start after a 5-minute delay. All other faults must be cleared manually.

All fault conditions arising from within the GT500E are reported to the UFCU (Universal Frontpanel Control Unit). The 4-line display will show a hexadecimal value (fault code) and a brief text description of the fault. Most faults are latching and only those faults associated with grid disturbances are auto-clearing and thus enable the GT500E to restart after a 5 minute delay period. Once the cause of the fault has been identified and corrected, and it is determined to be safe to proceed, GT500E faults may be manually cleared from the UFCU keypad or using the remote GUI. See Clearing Faults Manually on page 33 for instructions on this procedure.

General Troubleshooting
Respond to any GT500E alarm or fault as follows: 1. Note and document the alarm or fault code and brief text description. 2. Determine the source of the alarm or fault by referring to Table 3-1, Fault Codes on page 34. 3. Rectify the alarm or fault condition and attempt to clear the fault from the display. See Clearing Faults Manually on page 33 for instructions on this procedure. 4. If the condition is sustained and cannot be corrected, again note and document the fault code and description, and contact either your Distributor / Reseller, or Xantrex Customer Service.

WARNING: Lethal Voltage

In order to remove all sources of voltage from the GT500E, the incoming power must be de-energized at the source. This may be done at the Utility main circuit breaker, and by opening the AC disconnect and the DC disconnect switches on the GT500E. Review the system configuration to determine all of the possible sources of energy. In addition, allow 20 minutes for the DC bus capacitors, located on the ceiling of the cabinet, to discharge after removing power.

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Clearing Faults Manually

Clearing Faults Manually

Faults associated with a grid disturbance clear automatically. These faults include: 0010 (AC Frequency Low), 0011 (AC Frequency High), 0012 AC Voltage Low), and 0013 (AC Voltage High) only.

Once the AC voltage and frequency return to within the acceptable range, the GT500E will clear the fault and automatically restart after a 5-minute delay. All other faults associated with the GT500E must be identified, corrected and then cleared manually using the UFCU or GUI. The following procedure describes how to manually clear a fault message from the display. To clear the fault: 1. Determine the source of the fault using Table 3-1, Fault Codes on page 34. Correct the fault condition. 2. Ensure the fault code and Clear Fault? message is shown in the display. a) If the Clear Fault? message is not shown on the second line of the display, scroll through the read parameter menu with the /\ or \/ keys until the message appears. 3. To clear the fault, press <ENTER>. The GT500E will transition to Sleeping mode.

0071 PV SWITCH OPEN F1 to Clear Fault? INV kW:

Display Showing Fault Code

UFCU Keypad

Figure 3-1 Display Showing Fault Code

Important: If the fault does not clear, the fault condition has not been corrected.

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Fault Code Descriptions

Table 3-1 provides a complete description of all the fault conditions that may occur on the GT500E. Default values are show, but some limits are useradjustable. Table 3-1 Fault Codes
Error Code 0000 0010 Fault Type H=Hardware S=Software Fault Description N/A S N/A This fault indicates that the Utility grid frequency is below or fell below the setting of Min AC Freq: for greater than 6 cycles. This fault is auto-clearing. Once the Utility grid frequency has recovered within the acceptable operating range, the GT500E will qualify the value and automatically clear this fault and resume normal operation after 5 minute delay period. This fault indicates that the Utility grid frequency is above or rose above the setting of Max AC Freq: for greater than 6 cycles. This fault is auto-clearing. Once the Utility grid frequency has recovered within the acceptable operating range, the GT500E will qualify the value and automatically clear this fault and resume normal operation after 5 minute delay period. This fault indicates that the utility grid voltage is below or fell below the setting of Min AC Volt%: of nominal Vac for greater than 2 seconds, or 50% of nominal VAC for greater than 6 cycles. This fault is auto-clearing. Once the Utility grid voltage has recovered within the acceptable operating range, the GT500E will qualify the value and automatically clear this fault and resume normal operation after 5 minute delay period.

Fault Source(s) No Faults AC Frequency Low

Possible Causes N/A Utility grid frequency fell below the allowable limit

0011

AC Frequency High

Utility grid frequency rose above the allowable limit

0012

AC Voltage Low

Utility grid voltage fell below the allowable limit Fuses -F1.1, -F1.2, -F2.1, -F2.2, -F3.1, -F3.2 blown P1001 on CCU2 is loose or disconnected

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Fault Code Descriptions

Table 3-1 Fault Codes

Error Code 0013 Fault Type H=Hardware S=Software Fault Description S This fault indicates that the utility grid voltage is above or rose above the setting of Max AC Volt%: of nominal Vac for greater than 2 seconds, or 137% of nominal Vac for greater than 2 cycles. This fault is auto-clearing. Once the Utility grid voltage has recovered within the acceptable operating range, the GT500E will qualify the value and automatically clear this fault and resume normal operation after 5 minute delay period. This fault indicates that the GT500E has detected a sudden AC voltage increase of greater than 40% of the nominal peak-to-peak value. This normally is the result of a sudden disconnection from the Utility grid while the GT500E was processing power. This fault indicates that upon entering the Power Tracking State, the GT500E has detected that the PV voltage has remained above the PV Start Voltage threshold even after commanding the DC contactor to close. This condition is indicative of a DC contactor circuit failure. The calculated frequency is negative indicating the phase rotation of the grid is incorrect. The correct rotation is L1, L2, L3 This fault indicates that the GT500E has detected a DC current in the Positive connection to the Unit greater than the maximum allowed of 2490 amps This fault indicates that the GT500E has detected a DC current in the negative connection to the Unit greater than the maximum allowed of 2490 amps.

Fault Source(s) AC Voltage High

Possible Causes Utility grid voltage rose above the allowable limit

0015

Grid Disconnection

-Q1 was opened while the GT500E was processing power

0016

DC Contactor Circuit

-K11 or -K12 is inoperable -K31 or -K32 is inoperable

0017

Phase Error

Phase Rotation of the incoming grid connections is wrong. -T13 is inoperable P3 on CCU2 is loose or disconnected PV system wiring short -T14 is inoperable P3 on CCU2 is loose or disconnected PV system wiring short

0019

PV Over I Positive

0020

PV Over I Negative

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Troubleshooting

Table 3-1 Fault Codes

Error Code 0021 Fault Type H=Hardware S=Software Fault Description S This fault indicates that the GT500E has detected a DC input voltage of greater than the maximum allowed value of 1200 Vdc. This fault indicates that the GT500E has detected that the DC bus voltage has exceeded the maximum allowed value of 925 Vdc. This fault indicates that the GT500E has detected that the AC current on one or more phases of the inverter output has exceeded the maximum allowed value of 2500Apk. The first two digits of the fault code indicate the particular phase where the over current occurred as follow: 0130 - Matrix over current in phase A 0230 - Matrix over current in phase B 0430 - Matrix over current in phase C If more than one phase faults simultaneously, the two first digits are added in hexadecimal form to indicate an over current condition in more than one phase, thus the error code will contain the summation of the faulted phases. This fault indicates that the GT500E has detected that the ground fault current has exceeded the setting of Max Gnd Flt I:. This fault indicates that the GT500E has detected a current in unused inputs to the Unit greater than the maximum allowed of 2490 amps. The Bender relay has detected the impedance between ground and the positive or negative PV array has dropped below the setting of the Bender relay.

Fault Source(s) PV Over-Voltage

Possible Causes PV system wiring short Lightning strike on PV system wiring PV system wiring short Lightning strike on PV system wiring P3 on CCU2 is loose or disconnected AC system wiring short

0023

Bus Voltage High

XX30

Matrix Over Current

0033

Ground Over Current

P3 on CCU2 is loose or disconnected Ground -to-AC or DC-to-System wiring short

XX34

Unused Matrix Over I

This indicates a problem on the CCU2 board.

0035

PV Ground Insulation

Ground in the array.

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Fault Code Descriptions

Table 3-1 Fault Codes

Error Code 0040 Fault Type H=Hardware S=Software Fault Description S This code indicates that the GT500E has detected that the system is in Programming mode. This fault does not indicate any malfunction with the GT500E, but is merely an indication that the system software is in the process of being downloaded into the EEPROMs of the CCU2. The state machine implemented within the CCU2 system software governs the operation of the GT500E. This fault indicates that the GT500E has detected an unknown system variable and has encountered an invalid state. This fault indicates that the GT500E has detected a serial EEPROM write error. The CCU2 controller board performs a verification check of data written to ROM compared to what is read back. This fault indicates that the GT500E has detected that when writing data to the serial EEPROM, a confirmation timer of 300mS has expired. Internal RAM error CPU error

Fault Source(s) Programming Software

Possible Causes

0041

State Invalid

0042

Serial EEPROM Write Error

Internal ROM error CPU error

0043

Serial EEPROM Timeout

Internal ROM error CPU error

0044

Bad NOVRAM Memory

This fault indicates that the GT500E has detected that one of the two nonvolatile memory banks on the CCU2 controller board has failed. The CCU2 performs a series of tests to confirm the validity of the NOVRAM, and one of the two banks has produced errors. This fault indicates that the GT500E has detected that an interrupt 2 timeout has occurred. The CCU2 controller board performs a conversion validation of analog-todigital data within the A to D converters. If validation of the conversion is not performed within 500mS, an interrupt 2 timeout fault will occur.

Internal NOVRAM error CPU error

0045

Interrupt 2 Timeout

Internal A to D converter error CPU error

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Troubleshooting

Table 3-1 Fault Codes

Error Code 0047 Fault Type H=Hardware S=Software Fault Description S This fault indicates that the GT500E has detected that a software test fault has occurred. This is a simulated fault used for debugging purposes. This fault indicates that the GT500E has detected that the SRAM DIMM on the CCU2 controller board has failed. The CCU2 performs a series of tests to confirm the validity of the SRAM, and the memory module has produced errors. This fault indicates that the GT500E has detected that the temperature of the IGBT matrix aluminium heatsink has exceeded the maximum allowed value of 95 C. Internal SRAM error CPU error

Fault Source(s) Software Test

Possible Causes

0048

Bad Memory

0062

Matrix Temperature

External cooling fan inoperable Air flow on heat sink impeded due to accumulation of debris Operation above rated ambient temperature for an extended period of time

0072 0073 0074

Local E-Stop Remote E-Stop Fused PV Contactor

S S S

CCU2 has detected a loss of 15 VDC at terminal J2-1. CCU2 has detected a loss of 15 VDC at terminal J2-5. This fault indicates that the GT500E has detected that upon system shutdown, the DC bus voltage has remained within 5% of the DC input voltage for more than 10 seconds. This condition is indicative of a fused PV contactor (-K11 or -K12). This fault indicates that the GT500E has detected that the system was commanded via the GUI to transition to the Shutdown State. This fault is not indicative of a failure or malfunction, but primarily used to disable the system remotely.

Local E-Stop pushbutton is depressed. Remote E-Stop pushbutton is depressed. -K11 or -K12 is inoperable -K31 or -K32is inoperable

0075

Shutdown Remotely

Remote Shutdown command via the GUI

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Fault Code Descriptions

Table 3-1 Fault Codes

Error Code 0082 Fault Type H=Hardware S=Software Fault Description S

Fault Source(s) Matrix Not ON

Possible Causes Software acknowledge bit not accepted FPGA inoperable

This fault indicates that the GT500E has detected that the IGBT matrix (FPGA) was not enabled after having sent a command for it to turn on. The CCU2 sends an acknowledge bit to confirm the command is received. This fault is primarily a watch-dog between software and hardware to ensure control of the IGBT matrix (FPGA). This fault indicates that the GT500E has detected that the IGBT matrix (FPGA) was not disabled after having sent a command for it to turn off. The CCU2 sends an acknowledge bit to confirm the command is received. This fault is primarily a watch-dog between software and hardware to ensure control of the IGBT matrix (FPGA).

0083

Matrix Not OFF

Software acknowledge bit not accepted FPGA inoperable

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Troubleshooting

CCU2 Disconnect Errors

These errors cause the device to disconnect. They will be reported to the CCU2 Board. Fault 0152 IGBT Overcurrent Cause: An over current will be created if the current exceeds 1130 Arms. Remedy: Checking of grid (voltage, frequency, rotational direction) Checking for short circuit in grid

Fault 0252 Switch Fault Cause: Switch Error will be displayed if an IGBT was activated and if no feedback signal is given that it is actually activated. Remedy: Optical wave guide check.

Fault 0452 Overtemperature Cause: The cooling elements temperature of the alternating current converter will be measured. The error Excess Temperature will be displayed if it exceeds 80C. The temperature will be displayed in the display. Remedy: Cooling element ventilator failed Air intake apertures plugged Temperature switch defective Air intake temperature too high

Fault 0852 Overvoltage DC Bus Cause: The error Over voltage Intermediate Circuit will be displayed in the event that the intermediate circuit voltage exceeds 850V. Remedy: Check PV modules circuit Check right rotating field grid

Fault 1052 Earth Fault Since the PV array is ungrounded, this fault has been disabled.

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Fault Code Descriptions

Fault 2052 Undervoltage 24V Converter Cause: Error Under voltage 24 V Supply will be displayed if the power semiconductors control voltage is below 20 V. Remedy: Check internal control voltage 24VDC.

Fault 0153 DC Overcurrent Cause: An overcurrent will be created if the DC bus current exceeds 1255 A average. Remedy: Check PV Modules circuits.

Fault 0853 Too Cold or Internal Voltage not in Range Causes: A temperature sensor is located inside, which displays this error in the event of temperature below 0C. Or one of the electronics supply voltage is defective Or optical wave grid CLK is missing on the circuit board Central Evaluation. Check interior thermostat and service cabinet heater Check LWL for damage or pulled plugs Check circuit board for correctly plugged in plugs

Remedy:

These errors are all alternating current converter errors. Please contact the service department in the event that these errors occur repeatedly.

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Troubleshooting

Matrix Test
Under certain conditions the Matrix test can be helpful in troubleshooting. The DC bus must be charged in order to perform a matrix test. When the bus is discharged during a Matrix test, a Switch Fault will occur when the bus voltage drops to a low level. This fault is normal and can be reset. 1. Confirm that the ON/OFF Switch (-S2) in the OFF position. 2. Verify the DC bus voltage is about 50 VDC. 3. From the GUI or front panel, select Matrix test from the Goal State menu. 4. Listen for a smooth hum from the converter and verify that the DC bus voltage slowly drops to zero and a Switch Fault occurs when the voltage gets too low. 5. If the hum is very loud or the bus voltage drops rapidly, refer to the Matrix Gate Faults listed on page 39. 6. To stop the test, select Goal state from the GUI or Front Panel and choose Shutdown.

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Preventative Maintenance

Chapter 4, Preventative Maintenance contains information and procedures for performing preventative maintenance on the GT500E 500 kW Grid-Tied Photovoltaic Inverter.

Preventative Maintenance

Maintenance Safety
Prior to following any Maintenance Procedures, follow the System Shutdown and Lock-out and Tag procedure.

Operational Safety Procedures

Never work alone when servicing this equipment. A team of two is required until the equipment is properly de-energized, locked-out and tagged, and verified deenergized with a meter. Thoroughly inspect the equipment prior to energizing. Verify that no tools or equipment have inadvertently been left behind.

WARNING: Shock Hazard

Review the system schematic for the installation to verify that all available energy sources are de-energized. DC bus voltage may also be present. Be sure to wait the full 20 minutes to allow the capacitors to discharge completely.

De-Energize/Isolation Procedure
The following procedure should be followed to de-energize the GT500E for maintenance:

WARNING: Shock Hazard

The terminals of the DC input may be energized if the PV arrays are energized. In addition, allow 20 minutes for all capacitors within the Inverter Enclosure to discharge after disconnecting the GT500E from AC and DC sources.

To isolate the GT500E: 1. Turn the ON/OFF switch to the OFF position. 2. Open the DC interface disconnect switch (-Q11). 3. Open the AC interface disconnect switch (-Q1). 4. Open the utility connection circuit breaker. 5. Open the Auxiliary Control Power disconnect to de-energize the Auxiliary Control Power. 6. Install lockout devices on the utility connection circuit breaker, AC and DC disconnect switches. Install a lockout device on the Auxiliary Control Power disconnect.

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Maintenance Safety

Lockout and Tag

Safety requirements mandate that this equipment not be serviced while energized. Power sources for the GT500E must be locked-out and tagged prior to servicing. Each energy source should have a padlock and tag installed on each energy source prior to servicing.

WARNING: Shock Hazard

Review the system schematic for the installation to verify that all available energy sources are de-energized. DC bus voltage may also be present. Be sure to wait the full 20 minutes to allow the capacitors to discharge completely.

The GT500E can be energized from both the AC source and the DC source. To ensure that the inverter is de-energized prior to servicing, lock out and tag the GT500E using the following procedure. 1. Open, lockout, and tag the incoming power at the utility main circuit breaker. 2. Open, lockout, and tag the AC Disconnect Switch (-Q1) on AC interface assembly. See Figure 1-9 on page 111 for the location of the AC Disconnect Switch. 3. Open, lockout, and tag the DC Disconnect Switch (-Q11) on DC interface assembly. See Figure 1-9 on page 111 for the location of the DC Disconnect Switch. 4. Using a confirmed, accurate meter, verify all power to the inverter is deenergized. A confirmed, accurate meter must be verified on a known voltage before use. Ensure that all incoming energy sources are de-energized by checking the following locations. a) AC Utility Terminals: (Bottom of L1, L2, L3 and PE) See Figure 4-1 on page 44 and Figure 4-2 on page 44 for the location of these terminals. b) PV Terminals: (PV+ and PV-) See Figure 4-3 on page 45 for the location of these terminals. c) Auxiliary Control Power (X2-L1, X2-L2) See Figure 4-2 on page 44 for the location of these terminals.

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Preventative Maintenance

L1 Phase terminal

L3 Phase terminal L2 Phase terminal

TB1 Ground Bar

Figure 4-1 AC Terminal Connections from the Utility

AC Control Voltage Terminals (-X2-L1, -X2-L2)

Figure 4-2 AC Control Voltage Terminal Connections

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Maintenance Safety

PV NEGative (PV-)

PV POSitive (PV+)

Ground (PE)

Conduit entry from PV Array

Figure 4-3 PV Terminal Locations The maintenance intervals must be adhered to in order to warrant a safe and precise operation. The requirement for these maintenance intervals is an assembly at an average annual temperature of +20 C, whereby the maximum cooling air must be within the +45 C to -10 C range. The filter air degree of pollution may not exceed the rate of pollution according to DIN EN 50178 2.

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Preventative Maintenance

Maintenance Intervals
In principle, customers choose between two types of maintenance intervals: Maintenance interval determined by the environmental degree of pollution Maintenance interval determined by facilitys operating time

Maintenance Interval Determined by Environmental Pollution

In principle, facilities will be maintained on an annual basis. For this purpose, all control cabinet ventilators and power element ventilators are checked for proper functioning. The ventilator fans and filter pads will be cleaned. The cabinets interior will be checked for dust deposits and subsequently cleaned. Special attention is paid to corrosion and any water that might have penetrated the cabinet. The lightning protection is checked for functional efficiency.

Maintenance Package on a 10 year basis

In principle, facilities will be maintained after ten years. For this purpose, the power element ventilator and the interiors ventilator are replaced. Only trained personnel may perform maintenance work. The power connections are retightened and all electrical parts are visually checked. The air regulators, cable lugs, compensators, etc. are checked for discoloration due to excessive temperatures. The control cabinets will be cleaned. Ventilation The ventilation fans are located at the top of the enclosure: AC Interface Enclosure: 1 piece Main Inverter Enclosure: 3 pieces DC Interface Enclosure: 1 piece

Fan

Graphic shows the DC Inverter Enclosure fan. Fans in other Enclosures are in a similar location.

Figure 4-4 Ventilation Fan Location The ventilation fans will only be replaced as a whole.

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Maintenance Intervals

Power Fuses

The power fuses are located in the AC cabinet. (Max.torque 40 Nm)

Figure 4-5 Power Fuses Control Transformer Fuses The control transformer fuses are located in the inverters pivoting part.

Figure 4-6 Control Transformer Fuses Power Element Ventilator The power element ventilators are located in the service cabinet. The ventilators will only be replaced as a whole.

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48

Specifications

Appendix A provides the environmental and electrical specifications for the GT500E 500 kW Grid-Tied Photovoltaic Inverter.

Specifications

System Specifications
The GT500E has been designed for photovoltaic power systems, which operate within the following specifications.

CAUTION: Equipment Damage

Operation of the GT500E in a manner other than specified in this manual may cause damage to the GT500E and other system components and will void the terms of the warranty.

Environmental Specifications CAUTION

The GT500E will be destroyed if stored outside. Only store in dry areas.

Table A-1 Environmental Specifications

Specification Dimensions Weight Allowable Ambient Temperature Operating Storage Relative Humidity Elevation Storage Air Pressure Protection Class Cooling Air Power Element Interior Cooling Air Clearance (ventilation and serviceability) Top Front Value 2112 mm H x 2406 mm W x 605 mm D (83 in. H x 94 in. W x 24 in. D) 1770 kg (3902 lbs) -10 C to 45 C Maximum (14 F to 113 F) -25 C to 55 C Maximum (-13 F to 131 F) EN60721 temperature 1K1 humidity 1K3 1500 m 700 to 1060 mbar IP21 2700 m3/h starting temperature 68 C 2700 m3/h starting temperature 40/45 C

100 mm 600 mm (door clearance) plus local safety standards

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Electrical Specifications
Table A-2 provides the AC and DC specifications for the GT500E. Table A-2 Electrical Specifications
Specification Suggested PV Array Power Nominal AC Input Voltage (+10% to -12% acceptable range) Maximum AC Output Current Nominal AC Input Frequency (+0.5 to -0.7 Hz acceptable range) Output Power Peak Power Tracking Window Maximum Open Circuit Voltage Maximum DC Input Current DC Input MPP Range AC Output Voltage Line Power Factor AC Current Distortion Rated Current AC Output Clock Frequency Efficiency without Transformer External Control Voltage Inverters Couple Capacity Against Earth Value 560 kWp 20 kVac three phase 315 Vac (without transformer) (other voltages on request) 920 Arms 50 Hz 500.0 kW 450 to 800 Vdc 850 Vdc (880 Vdc optional) 1120 A 450 to 850 Vdc 450 to 800 V 315 V 5% approximately 1 (above 20% rated power) < 3% THD at rated power 920 A 4.5 kHz 700 Vdc 315 Vac 500 kW 97.3% control voltage supplied externally 230/400 V (other voltages on request) approx. 15 F

External Control Voltages max. Power Output 2500 W

Regulatory Specifications
Table A-3 provides the regulatory specifications for the GT500E. Table A-3 Regulatory Specifications
Standard General Standards Regulation Met EN50178 VDEW CE EN61000-6-4 EN61000-6-2

Emitted Interference Interference Resistance

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Specifications

Over Voltage, Under Voltage and Frequency Ranges

Table A-4 provides the over voltage, under voltage, over-frequency, and underfrequency detection limits for the GT500E. These detection limits have been factory tested and deemed to be in compliance with requirements for utility interaction. Table A-4 Over/Under Voltage and Over/Under Frequency Ranges
Vac Condition (% of Nominal) Low Range 87% < Vac < 103% Low Default 90% < Vac High Range 97% < Vac < 113% High Default 110% < Vac 50 Hz Low Range -2.0 < f < 0.5 50 Hz Low Default -1.0 < f 50 Hz High Range -0.5 < f < 2.0 50 Hz High Default 1.0 < f 60 Hz Low Range -0.5 < f < 0.5 60 Hz Low Default -0.5 < f 60 Hz High Range -0.5 < f < 0.5 60 Hz High Default -0.5 < f a.Adjustable, password protected Voltage Range 50Hza 275 < Vac < 325 Voltage Range 60Hza 275 < Vac < 325 Trip Time 100 ms

283.5 < Vac 305 Vac <355

283.5 < Vac 305 Vac <355

100 ms 100 ms

346.5 < Vac 48.0 < f < 50.5 49.0 < f 49.5 < f < 52.0 51.0 < f

346.5 < Vac

100 ms 2 cycles 2 cycles 2 cycles 2 cycles

59.5 < f < 60.5 59.5 < f 59.5 < f < 60.5 60.5 < f

2 cycles 2 cycles 2 cycles 2 cycles

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Bolt Sizes and Torque Requirements

Table A-5 provides acceptable bolt sizes, and torque values for AC terminal connections. Table A-5 AC Terminal Bolt Size, and Torque Values
AC Terminal Connections PE (Enclosure Ground) L1, L2, L3 -X2-L1, -X2-L2, -X2-PE Max. # of Conductors per Terminal 2 6 1 Bolt Torque (Hardware) Size Requirements 1/M12 3/M12 M3 75 Nm (55 lb ft) 75 Nm (55 lb ft) 0.6 0.8 Nm (5.3 7 lb ft)

Table A-6 provides acceptable bolt sizes, and torque values to be connected to the GT500E DC terminal connections. Table A-6 DC Terminal Bolt Size, and Torque Values
AC Terminal Connections PV+, PVMax. # of Conductors Bolt Torque per Terminal (Hardware) Size Requirements 8 4/M12 75 Nm (55 lb ft)

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Specifications

Dimensions
Dimensions in mm
110

597

1197 2406

597

568 605

Figure A-1 GT500E Dimensions

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Warranty and Product Information

Limited Warranty
1.1 What does this warranty cover and how long does it last?
This Limited Warranty is provided by Xantrex Technology Inc. ("Xantrex") and covers defects in quality in workmanship and materials ("Defects") in your GT500E 500 kW Grid-Tied Photovoltaic Inverter. This warranty lasts for a period of 2 years (the "Warranty Period") from the date of commissioning indicated on the product warranty registration form submitted to Xantrex.

1.2 What will Xantrex do?

If there is a Defect, Xantrex will repair or replace the defective product free of charge, provided that: a. you have followed the procedure at 1.3 and not been able to get a remedy from the system integrator of the product; b) you notify Xantrex, without undue delay, of the Defect within the Warranty Period; and c) Xantrex, through inspection, troubleshooting, or other means establishes the existence of a Defect that it is covered by this Limited Warranty. Xantrex will, at its option, use new and/or reconditioned parts in performing warranty repair and building replacement products. Xantrex reserves the right to use parts or products of original or improved design in the repair or replacement. If Xantrex repairs or replaces a product, the warranty is suspended during the repair or replacement and continues for the remaining portion of the original Warranty Period or 90 days from the date of the completed repair activity, whichever is greater. All replaced products and all parts removed from repaired products become the property of Xantrex. Xantrex covers both parts and labour necessary to repair the product. If the product was sold in Spain, Xantrex will cover costs via a Xantrex-selected non-expedited surface freight and packing.

1.3 How do you get service?

If you are unable to contact your system integrator. If the system integrator is unable to provide service, contact Xantrex directly at the following numbers: GERMANY Telephone: Fax: Email 49 0180 2240400 49 (0) 7531 8199868 GTsupport.Germany@xantrex.com SPAIN Telephone: Fax: Email 34 935 560 976 34 934 736 093 GTsupport.Spain@xantrex.com

1.4 What does this warranty not cover?

This Limited Warranty does not cover normal wear and tear of the product or costs associated with replacing consumable items such as like air filter, fuses, arrestors etc. A shorter than normal life during the Warranty Period caused by excessive use, or incorrect use not considered a Defect. Please consult your Operation and Maintenance Manual to determine the proper use of the product. This warranty does not apply to and Xantrex will not be responsible for any damage to the product: a. if it has not been used in accordance with the Operation and Maintenance Manual supplied with the product, if it has been damaged during shipping, mishandled, neglected, improperly installed, physically damaged or altered (either internally or externally) or damaged from improper use or use in an unsuitable environment; b) if it has been subjected to fire, water, generalized corrosion, biological infestations, or input voltage that creates operating conditions beyond the maximum or minimum limits listed in the Xantrex product specifications including high input voltage from generators and lightning strikes; c) if repairs have been done to it other than by Xantrex or an Authorized Service Center; d) if it is used as a component part of a product expressly warranted by another manufacturer; and e) if its original identification (trade-mark, serial number) markings have been defaced, altered, or removed. 152670 WA1

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1.5 Exclusions
This Limited Warranty is the sole and exclusive warranty provided by Xantrex in connection with your Xantrex product and is, where permitted by law, in lieu of all other warranties, conditions, guarantees, representations, obligations and liabilities, express or implied, statutory or otherwise in connection with the product, however arising (whether by contract, tort, negligence, principles of manufacturer's liability, operation of law, conduct, statement or otherwise) including without restriction any implied warranty or condition of quality, merchantability or fitness for a particular purpose. Any implied warranty of merchantability or fitness for a particular purpose to the extent required under applicable law to apply to the product shall, where permitted by law, be limited in duration to the period stipulated under this Limited Warranty. In no event will Xantrex be liable for any special, indirect, incidental or consequential damages, losses, costs or expenses however arising whether in contract or tort including, without restriction, any economic losses of any kind, any loss or damage to property, or any damage or injury arising from or as a result of misuse or abuse or the incorrect installation, integration or operation of the product.

1.6 Limitations on Exclusions

This Limited Warranty does not affect your rights as prescribed by law and as established in the Law on Warranties for Consumer Goods (Spain) or the German Civil Code ("BGB"). In Germany, the legal provisions regarding suspension or expiration ("Ablaufhemmung"), suspension ("Hemmung") and recommencement of limitation periods remains unaffected. Some countries do not allow limitations or exclusions on implied warranties or on the duration of an implied warranty or on the limitation or exclusion of incidental or consequential damages, so the above limitation(s) or exclusion(s) may not apply to you. For example, in Germany, the exclusion at 1.5 shall not apply in the case of mandatory liability, i.e. under the German Product Liability Act ("Produkthaftungsgesetz") or in the case of intent, gross negligence, and injury of life, body or health, or breach of a condition which goes to the root of the contract ("wesentliche Vertragspflichten"). However, claims for damages arising from a breach of a condition which goes to the root of the contract shall be limited to the foreseeable damage which is intrinsic to the contract, unless caused by intent or gross negligence or based on liability for injury of life, body or health. The exclusion at 1.5 in Germany also does not imply a change in the burden of proof to your detriment.

1.8 WARNING: LIMITATIONS ON USE

Please refer to your Operation and Maintenance Manual for limitations on uses of the product. Specifically, please note that the GT500E 500 kW Grid-Tied Photovoltaic Inverter is not intended for use in connection with life support systems or other medical equipment or devices and Xantrex makes no representation or warranty in connection with any use of the product for such purposes. Xantrex Technology Inc. 8999 Nelson Way Burnaby, British Columbia Canada V5A 4B5

Out of Warranty Service

If the warranty period for your GT500E 500 kW Grid-Tied Photovoltaic Inverter has expired, if the unit was damaged by misuse or incorrect installation, if other conditions of the warranty have not been met, or if no dated proof of purchase is available, your unit may be serviced, repaired or replaced for applicable charges.

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Product Registration
To ensure the fastest possible service, please ensure your system information submitted to Xantrex. Please fill the required information in and send a copy of this page to Xantrex Technology Inc. Fax number: 925 455 0382

Mail to:

Xantrex Technology Inc. 161-G South Vasco Road Livermore, CA 94551 Attention: Customer Service USA

Customer Company Name: Project Name:

__________________________________ __________________________________

System Location Information: Street City Country __________________________________ __________________________________ __________________________________

Xantrex Inverter Model: Serial Number of Inverter: Name of Distributor (if applicable):

__________________________________ __________________________________ __________________________________

__________________________________________ Xantrex Authorized Signature Date:

__________________________________________ Customer Authorized Signature Date:

Note: Please email the GT500E Commissioning Report File to: pvcommissioningreport@xantrex.com.

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Xantrex Technology Inc.

1 360 925 5097 (North America) + 49 0180 2240400 (Germany) + 34 935 560 976 (Spain) 1 360 925 5143 (North America) + 49 (0) 7531 8199868 (Germany) + 34 934 736 093 (Spain) customerservice@xantrex.com GTsupport.Germany@xantrex.com GTsupport.Spain@xantrex.com www.xantrex.com

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Printed in Canada