Attachment 2_ Solar O _ M.pdf

N O A A L a J o l l a L a b o r a t o r y R e p l a c e m e n t P r o j e c t

G i b b e n s D r a k e S c o t t G o u l d E v a n s T r a n S y s t e m s H D R A | D W R B

Submittal Review Transmittal | 4041 Mill Street, Kansas City, Missouri 64111 t 816.931.6655 f 816.931.9640

Project: LaJolla Laboratory Replacement

Specification Description:

Solar PV O&M Manual Resubmittal Specification No. 004-16800-1

To: NOAA Western Acquisition Division Date Received: 2/22/2013

7600 Sand Point Way NE Date Returned: 3/5/2013 Seattle, WA 98115

GDS Project No:

201066.04

Contract For: NOAA Attention: Mark Eberling, COTR Contract Number: AB1330-10-CN-0114

To: Rudolph & Sletten

10955 Vista Sorrento Pkwy, #100 San Diego, CA 92130

Attention: Mike Samudio

Corrections or comments made relative to submittals during this review do not relieve the contractor from compliance with the drawings and specifications. This check is only for review of general conformance with the design concept of the project and general compliance with the information given in the contract document. The contractor is responsible for confirming and correcting all quantities and dimensions; selecting fabrication processes and techniques of construction; coordinating his work with that of other trades and performing his work in a safe and satisfactory manner.

Comments:

Proceed with Final O&M Submission

Spec No: Section Description: Action

004-16800-1 Solar PV O&M Manual Resubmittal I/O

AAP Approved AAN Approved as Noted ANR Approved as Noted-Resubmit DIS Disapproved I/O Information Only

Cc:

Gould Evans Gibbens Drake Scott TranSystems HDR ADWRB

Submittal Packages Detailed with Items and Reviewers

Solar PV O&M Manual004-16800-1

Author Company Contact Author Package # Trade Importance

Rudolph and Sletten Dustin Matteson Sound and Video Normal

Items

Item No. Register No. Rev. Description Type Action Logged By Returned Closed

¨ ¨001 16800.09 1 Solar Photovoltaic System - Operation & Maintenance Data

O&M Manuals In Review Dustin Matteson

Reviewers

From Company To Company Sent Date DueDate Received Date +/- Action Sent For

Rudolph and Sletten - Dustin Matteson U.S. Department of Commerce, NOAA, Western Acquisition Division - NOAA Designer

2/22/2013 3/8/2013 In Review Review

Package Notes Reviewer General Comments

As-builts will be submitted as soon as PV build-out is complete.

[6/7/2012 12:03 PM U.S. Department of Commerce, NOAA, Western Acquisition Division - NOAA Designer]

1) General - Requirements of specification 01782 paragraph 2.1 have not been met with this submittal; including but not limited to Organization, Title page, Table of contents, File names and Bookmarks, etc.

2) Page 2 of the 228 page pdf - The size indicated on the cover , 201,600 W DC, does not match the size submitted in the shop drawing submittals 002-16800-0, which indicated a value of 200,690 W DC. R&S indicated that this is due to the fact that 240 watt modules were installed in lieu of the 235 watt modules that were approved in subsequent submittals. Need to provide revised shop drawings to accurately indicate the installed system. PV watts AC Energy & Cost Savings calculation pages as provided with submittal 002-16800-0 should be revised and resubmitted.

3) Page 150 of the 228 page pdf - The 240 watt PV module submitted in the O&M does not match the approved 235 watt PV module provided with submittal of 002-16800-0. Have these modules been approved? Have the associated structural calculations been provided for these revised panels?

4) Page 162 of the 228 page pdf - The standard anemometer was not submitted in any of the previous submittals. Has this device been approved?

5) Page 170 of the 228 page pdf - The Aurora Environmental Appliance from Power One was not submitted in any of the previous submittals. Has this device been approved?

6) Page 182 of the 228 page pdf - The pyranometer was not submitted in any of the previous submittals.

Has this device been approved?

7) General - In submittal 002-16800-0 an Energy Recommerce device, RECtrack 3, was submitted for approval. Was this device approved and being installed? If it is, information needs to be provided in this O&M manual.

8) General - Submittal 002-16800-0 included information for the Circuit Breaker Panelboard. Is this panelboard(s) being provided under this contract? If it is, information needs to be provided in this O&M manual.

Prolog Converge Printed On: 2/22/2013 Page 2 of 2

Sullivan Solar Power of California, Inc.

Leading the Solar Energy Revolution

8949 Kenamar Dr., Suite 101

San Diego, CA 92121

858-271-7758

C10-839077

O+M Manual

For

NOAA La Jolla Laboratory Replacement Project

8901 La Jolla Shores Drive

La Jolla, CA 92037

Solar Photovoltaic System

Size: 198,240 WDC

Dustin.Matteson Revised

Dustin.Matteson

8949 Kenamar Dr Ste 101, San Diego, CA 92121, C-10 839077, (858) 271-7758

Table of Contents

Description Pages

Cover Sheet 1

Table of Contents 2

1. Sullivan Documents

1.1 LOTO Procedures 3-4

1.2 Cleaning Instructions 5

1.3 System Warranty 6

2. Inverter Spec Sheets 7-10

3. Inverter Manual 11-132

4. Inverter Warranty 133-136

5. Combiner Box Spec Sheets 137-138

6. Combiner Box Manual 139-148

7. Combiner Box Warranty 149

8. Module Spec Sheets 150-151

9. Module Installation and User Manual 152-159

10. Module Warranty 160-161

11. Data Acquisition System 162-189

12. Sunlink Racking Information 190-224

13. Maintenance Log 225

14. Cleaning Log 226

15. Service Log 227

16. Replace Part Parts Matrix 228

17. Training Sign In Sheet 229

18. Commissioning Report 230-245

19. As-Build Plan Set 246-253

Photovoltaic System Operation, Shut down and LOTO (Lock Out Tag Out) Procedures:

1.0 Safely Disconnecting the Photovoltaic System from the Grid:

1. Read through instructions found in section 6 under tab 3 “Inverter Manual”. These procedures should be used when a scheduled shut down or maintenance of the Inverter is required.

In case of an emergency follow the below procedure:

2. Place the handle of the Main Photovoltaic Utility Disconnect in the off position. The main disconnect is located in the electrical room on the first floor.

a. The AC feeders from the Photovoltaic Inverter(s) to the load side of the Utility

Disconnect switch will now be de-energized.

b. If work is to be performed inside the disconnect proper PPE should be worn as the line side of the disconnect may still be energized.

c. This Disconnect provides a LOTO point. Follow all standard LOTO procedures if work is to be performed downstream of this disconnect.

Note: Before performing any work on potentially live equipment it is always safe practice to assume it is live until tested dead. Follow all NFPA 70E guidelines, Owner requirements or

Safety Administrator protocols that may be in place.

WARNING! PV system is connected to the load side of the main breaker! The first point of connection is the line side of the fused pullout and will be hot unless the PV breaker is switched to the off position.

2.0 Safely Disconnecting the Photovoltaic Feeders from the combiner boxes to the Inverter:

Danger! PV DC Circuits will always be energized while the solar modules are exposed to light, this includes moon light. Always ensure proper PPE is worn when handling Photovoltaic Source

Circuits. Consult with your safety administrator if you are unsure of on-site policy. At a minimum proper PPE would be: Hardhat, Safety Glasses, ANSI rated boots, cotton clothes, fiberglass ladder and voltage rated gloves.

1. Place the DC disconnect handles (located on the 12 combiner boxes on the roof) in the off position. Capacitors can take up to 8 minutes to discharge. Consider both the line and load side of all DC disconnects hot after it has been opened until the capacitors have fully discharged and verified dead.

a. DC Voltage on the line side of this disconnect will ALWAYS be energized when the Photovoltaic modules are exposed to light. Extreme caution should be taken when working on DC circuits.

2.1 Safely Disconnecting the Photovoltaic Source Circuits from the array to the Combiner

Boxes:

Note: This should only be done after all DC disconnects have been verified open and dead per the above section.

There are (6) combiner boxes feeding the each of the two inverters for a total of (12) combiners.

Identify the combiner boxes that work is to be performed on. These are all marked on the as-built drawings.

1. Use a DC clamp on meter to verify there is no current passing through the source circuits feeding into the fuse blocks.

2. Once verified there is no current passing through the fuse blocks, open the fuse holders.

3. Verify with a 600VDC rated volt meter that there is no voltage present.

4. Close the combiner box lid and install a LOTO kit on the latch

2.1A If work is performed on the Photovoltaic Source Circuits these precautions shall be followed:

1. Follow instructions in section 2.0 above before disconnecting any PV Source Circuits.

2. Identify the modules that are connected to the PV Source Circuit.

3. Locate the positive and negative home runs for the PV source circuits work is to be performed on and break the connection at the module via the Multi Contact Connector.

a) These are identified on the as-built drawings.

This document is informational and all work (outside of standard cleanings) on the Photovoltaic system is to be performed by Sullivan Solar Power or its authorized representatives for (10) ten years from date of commissioning.

Cleaning Methods:

Dos:

Light Cleaning:

o Soft tail brush to remove light dust at the bottom of the module

Medium Cleaning (most common):

o Spray the modules down with water (no chemicals) then use a squeegee to remove dirt and grime

Heavy Cleaning:

o Spray the modules down with water, use a soft car washing brush or window washing brush to scrub the panels lightly then follow up with a quick rinse and squeegee to pull off any remaining dirt

Paint removal:

o Apply Isopropyl Rubbing Alcohol to a cotton rag and clean off any light overspray o If the IPA does not remove paint, a razor blade used carefully at an appropriate angle can be used to remove heavy overspray

Don’ts:

Use a pressure washer

Use any type of cleansers

Use any products that will leave a film or residue on the glass module once dried

When to Clean:

1. When the modules are noticeably dusty and a layer of dirt has built up at the bottom

(lower end) covering up a portion of the Photovoltaic cells.

2. Modules should be cleaned in the morning or late afternoons when the temperature of the panel surface is at its lowest.

3. Suggested Cleaning Schedule:

o Beginning of: March, May, July and September o Note: If there has been a hard rain within the past two weeks and the modules visibly look only slightly dusty hold off the cleaning until condition (1) has occurred or the next cleaning cycle.

A cleaning crew of two people, one rinsing and one with a squeegee is the most efficient method for cleaning the arrays. Crew must maintain a 6’ clearance from roof edge when cleaning array.

Consult with your safety manager prior to performing any work.

WARRANTY

System Information

This warranty applies to the following 198,240WDC

Project Title: NOAA La Jolla Laboratory Replacement Project

Located at: 8901 La Jolla Shores Drive La Jolla, CA 92037

Coverage

This ten year warranty is subject to the terms below

All components of the generating system AND the system’s installation. Said warrantor shall bear full cost of diagnosis, repair and replacement of any system or system component, at no cost to the customer. This ten year warranty is for the major system components, including solar modules and inverters.

General Terms

This warranty extends to the original purchaser and to any subsequent purchasers or owners at the same location during the warranty period. This warranty is effective from the date of completion.

Exclusions

This warranty does not apply to:

Damage, malfunction, or degradation of electrical output caused by failure to properly operate or maintain the system in accordance with the printed instructions provided with the system.

Damage, malfunction, or degradation of electrical output caused by any repair or replacement of a part or service not provided or authorized in writing by the warrantor.

Damage, malfunction, or degradation of electrical output resulting from purchaser or third party abuse, accident, alteration, improper use, negligence or vandalism, or from earthquake, fire, flood, flying objects or other acts of God.

Obtaining Warranty Service

Contact the following warrantor for service or instructions:

Name: Daniel Sullivan - President Phone: 858-271-7758

Company: Sullivan Solar Power Fax: 858-271-7759

Address: 8949 Kenamar Dr., Suite 101, San Diego, CA 92121

Signature: ___________________________ Date: ___________

PowerGate Plus 100 kW UL

PVS-100-UL

PV Inverters

Satcon PowerGate Plus PV inverters are the world’s most widely deployed solutions, powering many of the largest commercial and utility-scale solar installations.

Advanced Performance

With their advanced system intelligence, next-generation EDGE® MPPT technology, and industrial-grade engineering, PowerGate® Plus inverters maximize system uptime and power production, even in cloudy conditions.

Utility-Ready Features compatible with virtually any third-party monitoring system and easily integrated into SCADA systems allowing fast communications

EDGE MPPT

boosts PV plant kilowatt yield all photovoltaic cell technologies

Printed Circuit Board Durability humidity and air-pollution levels

Profitable PV Power

The Satcon® PowerGate® intelligence, next-generation EDGE® MPPT technology and industrial-grade engineering, the PowerGate Plus 100 kW inverters maximize system uptime and power production, even in the harshest environments.

Advanced, Rugged, and Reliable

Engineered from the ground up to meet the demands of large-scale installations, Satcon PV inverters feature an outdoor-rated enclosure, advanced monitoring and control capabilities and EDGE, Satcon’s next-generation MPPT solution.

Proven Performance

The proven leader in solar PV inverter solutions for commercial installations, Increased PV Plant Yield

At the heart of PowerGate Plus is EDGE, Satcon’s next-generation power optimization solution. With rapid and accurate MPPT control, EDGE increases

PV plant kWh yield by extending the production window of arrays, enabling them to operate at optimal voltage and current levels for longer periods of enabling you to get the most from your investment.

PowerGate Plus 100 kW UL

Streamlined Design

With all components encased in a single, space-saving enclosure, PowerGate Plus PV inverters are easy to install, operate and maintain.

Rugged Construction

-4° F to +122° F (-20° C to +50° C) without derating enclosure dissipate solar radiation, reduce heat buildup

Easy Maintenance gland plates make installation of DC and AC cables easy switch isolates the inverter, with the from the photovoltaic power system to allow inspection and maintenance

Proven Reliability

PV inverters are engineered from the ground up to meet the demands of large-scale installations.

Safety switches power connections

Output Transformer inverter to the grid

PowerGate Plus 100 kW Specifications UL/CSA

Input Parameters

315-600 VDC

600 VDC

1 331 ADC

Negative

Ground

Positive

Ground

DC Input Combiner Options

5 x 110A

6 x 100A

Transformer

2 Yes

Efficiency

Maximum3 96.6% 96.5% 96.7% 96.6%

CEC 96%

Output Parameters

Nominal Power 100 kW

208 VAC 240 VAC 480 VAC 600 VAC

183-229

VAC

211-264

VAC

422-526

VAC

528-660

VAC

278 A 241 A 121 A 96 A

Standby Consumptions (tare losses including control power and aux.)

62 W 62 W 66 W 65 W

60 Hz

Maximum Harmonic Distortion <3% THD

>99%

Dynamic Power Factor Control

Power Curtailment 0-100%, 1% steps

Environment

(Nominal Power)

-4º F to +122º F (-20º C to +50º C)

º C to +50º C)

-22º F to +158º F (-30º C to +70º C)

Cooling Forced Air up to 90%

PowerGate Plus 100 kW UL Specifications

PowerGate Plus 100 kW Specifications UL/CSA

Enclosure

Dimensions (H x W x D) 80 x 57 x 31 in. (203 x 145 x 78 cm)

Weight4 2,350 lbs. (1068 kg)

Finish

Warranty and Services

Five Year Warranty

Extended Warranty

(1 and 5 year increments)

Preventative Maintenance Agreement

Design Services

APEX Project Management

Communication Interface

Monitoring

PV View Plus

Third-Party Compatibility

Regulations and Standards Conformity

1 Calculated at nominal power and minimum DC voltage.

2 The 20% boost tap on the isolation transformer increases the AC voltage output range for applications where the solar array DC operating voltage is at or near the lower end of the DC input range. This boost allows for continued inverter operation at lower DC voltage input levels.

3 Calculated with auxiliary power.

4 Dependent on options selected.

Power Efficiency

Power Level Efficiency*

10% 93.2%

20% 96.1%

30% 95.5%

50% 96.7%

75% 96.5%

100% 96.1%

* 480V model

Output Options

PowerGate Plus 100 kW

Energy Equity Protection (EEP)

Satcon provides a wide range of optional value-added services to protect your investment across the entire lifecycle of your project.

Design Services

Satcon’s Design Services organization can guide you through all phases of project development using our broad experience and engineering skills.

APEX Project Management

Satcon APEX™ Project Management ensure that your project comes in on time and on budget.

Warranty and Services

PowerGate Plus Options

CCM Gateway www.Satcon.com for additional tools and product

– Articles, white papers and case studies

© 2012 Satcon Technology Corporation. All rights reserved. Satcon is a registered trademark of Satcon Technology Corporation.

All other trademarks are the property of their respective owners.

Satcon Corporate 25 Drydock Avenue, 7th Floor

Satcon West

Fremont, CA 94538

Satcon Canada 835 Harrington Court

Canada

Satcon Germany An der Welle 4 60322 Frankfurt Main Germany

Satcon International s.r.o.

170 00 Praha 7

Satcon Greece

Patima Halandriou – 152 38 Greece

Satcon Shenzhen China

Shenzhen 518057, China

Satcon Shanghai China

City Center of Shanghai, Shanghai 200051, China www.Satcon.com

PowerGate® Plus Inverter

Installation, Operation and Maintenance

Guide

PVS-75 (208, 240, 480) and PVS-100 (208, 240, 480, 600)

75kW and 100kW with Integrated Isolation Transformer

(Internal) - UL

PM00437 Revision 7

Satcon Technology Corporation

835 Harrington Court, Burlington, Ontario, Canada, L7N 3P3 Tel: 905.639.4692 I Fax: 905.639.0961 I www.satcon.com http://www.satcon.com/

Contents i

Table of Contents

About This Guide ................................................................................................................................................................................... viii

Purpose ................................................................................................................................................................................................ viii

Who Should Read this Manual ............................................................................................................................................................. viii

How the Manual is Organized .............................................................................................................................................................. viii

Section 1: .................................................................................................................................................................................. viii

Section 2: .................................................................................................................................................................................. viii

Reference Manuals ............................................................................................................................................................................... ix

IMPORTANT SAFETY INSTRUCTIONS .................................................................................................................................................. xi

General Safety Precautions .................................................................................................................................................................. xii

Electrical Safety Precautions and Practices ......................................................................................................................................... xiii

Safe Practices ................................................................................................................................................................................. xiii

Shock Prevention ............................................................................................................................................................................ xiii

Service and Maintenance ................................................................................................................................................................ xiv

Fire and Explosion Prevention ........................................................................................................................................................ xiv

Bodily Injury Prevention .................................................................................................................................................................. xiv

Medical and First Aid Treatment ..................................................................................................................................................... xiv

Equipment Precautionary/Warning Labels ...................................................................................................................................... xiv

Potential Equipment Damage ......................................................................................................................................................... xiv

Integrated Electrical Safety Features .............................................................................................................................................. xv

Handling Safety .................................................................................................................................................................................... xv

Special Symbols ................................................................................................................................................................................... xvi

Chapter 1 Product Information

About this Chapter

Overview

Regulatory Standards

Technologies and Design Features

Isolation Transformer

Operational Features

Maximum Power Point Tracking

Unity Power Factor

Remote Monitoring Option

Safety Features

Enclosure Door Interlock Switch

DC Disconnect Switch

AC Disconnect Switch or Breaker

ON/OFF Switch

Over Voltage and Over Current Detection

Front Matter ii

Ground-Fault Detection and Interruption

Anti-Islanding Protection

Inverter Options

Communication Configurations

Standard Configuration (Modbus RS485 Protocol)

Remote Monitoring Options (TCP/IP Protocol)

System Options

Ratings and Specifications

Physical Description

Access Doors

DC Power Input Section

AC Power Output Section

Enclosure Safety Ground

Human Machine Interface (HMI)

Logic Processing Box

Enclosure Cooling Components

Cable Entry and Exit

Mounting Lugs

Dimensions and Weights

Human Machine Interface (HMI)

ON/OFF Switch

Run Enable/Disable

Power Generation Indicator

Keypad and Display

Display

Keypad

Chapter 2 Installation Information

About this Chapter

Step 1- Before Starting Installation

Step 2 - Planning for Installation

Ventilation and Serviceability Requirements

Ventilation Requirements

Serviceability Access Requirements

Enclosure Anchoring Requirements

Mounting Pad Requirements

Planning Cable Entries

AC and DC Cables

Customer Control and Communications Wiring

Underground Conduit or Raceway iii

Conduit Punch Tools

Step 3 – Preparing for Installation

Handling Inverter Enclosure

Unloading Inverter Enclosure

Moving Inverter Unit

Unpacking and Inspecting Inverter Unit

Inspecting and Reporting Shipping Damage

Step 4 – Mounting and Anchoring Inverter Enclosure

Step 5 – Installing Conduits

Cable Gland Thickness

Preferred Practices

Step 6 – Connecting DC and AC Power and Grounding Conductors

Identifying Conductor and Wiring Locations

Wiring and Cabling Data

Connecting Enclosure Safety Ground

Connecting DC System Equipment Grounding Conductors

Connecting AC Grounding Conductor

Connecting DC Input Power

Connecting AC Output Power

Step 7- Installing Communication Wiring

Before You Begin

Modbus RS485 Serial Communication

Modbus TCP/IP Communication

Communication Controller Module

General Guidelines for Wiring RS485 Links

Step 7A - Wiring Inverter RS485SS Connector

Step 7B - Wiring for ModbusTCP/IP Networks

Step 8 – Install Customer Control Wiring (TBC)

Step 9-Verify Installation

Mechanical Checks

Electrical Checks

Step 10 – Verify Input and Output Power Requirements

Step 11-Commission Unit

Chapter 3 Operations Information

About this Chapter

Overview of Operations

Operating States

Inverter Control

Inverter Run Enabled or Disabled iv

Inverter Startup Conditions

Inverter Stop Conditions

Inverter Fault Shutdown

Inverter ON/OFF Control

Inverter Reset

Maximum Power Point Tracking

Local and Remote Control

Modbus Communication

AC Output Reactive Power Control

Fan Control

About the Keypad and Display

Keypad

HMI Display

About the Menu Structure

Using Keypad and Display

How to Move to Lower Level

How to Move Up One Level

How to Enter and Save Data (Operation Sub Menus Only)

How to Clear Faults

How to View Faults

Navigating Through the Menu Hierarchies

Menu Descriptions

Monitoring Menu Descriptions

Status Submenu Descriptions

Firmware Sub Menu Descriptions

Metering Sub Menu Descriptions

Energy Production Sub Menus

System Information Sub Menus

Status and Faults Menu

Operations Menu

Control Submenus

Settings Submenus

Field Adjustment Set Points

Fault and Warning Messages

General Faults

DPCB Faults

Hardware Faults

Inverter Faults

Temperature faults v

Warning Messages

Shutdown Procedures

Fast Shutdown Procedure (ON/OFF Switch)

Controlled Shutdown Procedure (HMI)

Chapter 4 Maintenance Information

About this Chapter

About Warranty and Preventive Maintenance

Warranty Packages

Standard Warranty

Extended Warranty

Preventive Maintenance Plans

Preventive Maintenance under Standard Warranty

Scheduled Maintenance

Semi-Annual Intervals

Annual Intervals

Preventive Maintenance Guidelines for Customers

Customer Responsibilities

Guidelines for Cleaning and General Inspection

Guidelines for Cable Maintenance

Guidelines for Power Component Maintenance

Guidelines for Printed Circuit Board Maintenance

Guidelines for Blower Fan Maintenance

Guidelines for Air Filter Maintenance

General Maintenance Workmanship

Chapter 5 Commissioning Procedures

About this Chapter

Connecting AC and DC Power Cables

Initial Power Up

Appendix vi

List of Figures

Figure 1 PV View Plus

Remote Monitoring Option Figure 2 PVS-75 and PVS-100 Models Figure 3 Enclosure Door Latch Figure 4 Human Machine Interface (HMI) Figure 5 Enclosure Corner Mounting Lugs Figure 6 Enclosure Mounting Dimensions (PVS-75 and PVS-100 Models) Figure 7 Planning for Cable and Wiring Entries (PVS-75 andPVS-100 Models) Figure 8 Bottom Gland Plate Dimensions (PVS-75 and PVS-100 Models) Figure 9 Ground to Gland Plate Clearance (PVS-75 and PVS-100 Models) Figure 10 Shipping Pallet Forklift Locations Figure 11 Corner Mounting Lugs Figure 12 Enclosure Internal Locations (PVS-75 and PVS-100 Models) Figure 13 Enclosure Safety Ground (PVS-75 and PVS-100 Models) Figure 14 DC Ground (PVS-75 and PVS-100 Models) Figure 15 AC Ground (PVS-75 and PVS-100 Models) Figure 16 DC Input Connections PVS-75 and PVS-100 Models (No Combiner Option) Figure 17 DC Input Connections PVS-75 and PVS-100 Models (Combiner Option) Figure 18 AC Output Connections (PVS-75 and PVS-100 Models) Figure 19 Communication Connectors Figure 20 Communication Controller Module Figure 21 Two-Wire Plus Common and Shield RS485 Connection Figure 22 RS485 Daisy Chain Connection Figure 23 Incorrect Configuration (T-Connection) Figure 24 Incorrect Configuration (Star Connection) Figure 25 RS485SS Pin-Out Information Figure 26 Remote Monitoring Option Wiring Figure 27 Inverter Remote Control Wiring Terminal Block (TBC) Figure 28 Terminal Block TBC Terminations Diagrammatic Representation Figure 29 Automatic Startup State Diagram Figure 30 State Diagram for Inverter Shutdown Figure 31 AC Output Reactive Power Control, PVS-75 Model Figure 32 AC Reactive Power Control, PVS-100 Model Figure 33 HMI Display Figure 34 HMI Menu Hierarchy Figure 35 Using Keypad Figure 36 Monitoring Menu Hierarchy Figure 37 Status and Faults Menu Hierarchy Figure 38 Operations Menu Hierarchy vii

List of Tables

Table 1 Inverter Options Table 2 Remote Monitoring Option Components Table 3 Ratings and Specifications for PVS-75 Model (1 of 2) Table 4 Ratings and Specifications for PVS-100 Model (1 of 2) Table 5 Physical Data for PVS-75 and PVS-100 Models Table 6 Enclosure Anchoring Hardware Table 7 Wire and Cable Connection Details for PVS-75 Model Table 8 Wire and Cable Connection Details for PVS-100 Model Table 9 Terminal Block TBC Details Table 10 Inverter Operating States Table 11 Local and Remote Control Functions Table 12 Menu Summary Table 13 Status Submenu Descriptions Table 14 Firmware Submenu Descriptions Table 15 Metering Submenu Descriptions (1 of 2) Table 16 Energy Production Submenu Descriptions Table 17 System Information Submenu Descriptions Table 18 Status and Faults Submenu Descriptions Table 19 Control Submenu Descriptions (1 of 5) Table 20 Settings Submenu Descriptions (1 of 2) Table 21 Default Voltage and Current Trip Level and Time Settings Table 22 Default Voltage and Frequency Trip Level and Time Settings Table 23 General Faults Table 24 DPCB Faults Table 25 Hardware Faults Table 26 Inverter Faults Table 27 Temperature Faults Table 28 Warning Messages Table 29 Semi-Annual Maintenance Service Tasks Table 30 Annual Maintenance Service Tasks viii

About This Guide

Purpose

This manual provides information about installing, operating, maintaining, and troubleshooting the PVS-75 and PVS-100 PowerGate ® Plus inverters. It describes the following models:

208/240VAC

480VAC

600VAC

Who Should Read this Manual

This manual should be read by anyone who needs to:

Understand the product

Plan the installation

Install the product

Commission the product

Operate the product

Maintain the product, if necessary

How the Manual is Organized

This manual is divided into two primary sections: front matter (section 1) and five chapters (second section).

Section 1:

Front Matter: This section contains important safety information, together with information about the conventions used in this manual as well as a listing of the symbols used in the equipment.

Section 2:

Chapter 1 Product Information: This chapter provides general information about PowerGate ® Plus Inverters, including their important features, ratings and specifications, physical descriptions, and user controls.

Chapter 2 Installation Information: This chapter provides information to help plan the installation, how the enclosure should be mounted, and how it should be connected electrically.

Chapter 3 Operations Information: This chapter provides information about the inverter operations, including its different operating states and how the user can interact with the unit.

Chapter 4 Preventive Maintenance: This chapter provides information about scheduled and periodic maintenance.

Chapter 5 Commissioning Procedures: Explains how to start up the inverter after installation ix

Reference Manuals

If you need additional information about the PowerGate® Plus options or communication interfaces, refer to the following user manuals:

PM00488 -Communication Interface Reference Guide (required)

PM00490 - Communication Control Module User Guide (option)

PM00468 - Smart SubCombiner Installation Manual (option)

PM00440 - PV View® Plus User Guide (option)

PM00447 - PV View® Plus Weather Station (option) x

Conventions Used

WARNING

Warnings tell you about conditions ar actions that could result in personal injury or death. A qualifier (e.g. Hazardous Voltage) may follow the warning title.

CAUTION

Cautions tell you about conditions or actions that could result in damage to the inverter or other equipment. A qualifier (e.g. Inverter Damage) may follow the warning title.

NOTE

Notes tell you about things which are important for you to know but not as serious as cautions or warnings.

xi

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

This manual contains important instructions for the PVS-50 that shall be followed during installation and maintenance of the inverter.

The PowerGate ® PLUS Inverter system presents a SHOCK HAZARD. Read and keep this Operation and Maintenance Guide for future reference. Before installing the PVS-50, read all instructions, cautionary markings and other appropriate sections of this guide.

Failure to follow these warnings could result in severe shock or even death. Exercise extreme caution at all times to prevent possible accidents.

These instructions are not meant to cover every safety eventuality nor to replace any local or site specific safety procedures. The information in this section is intended as a supplement to local or site specific procedures. Satcon does not assume responsibility for the compliance or noncompliance to any code, national, local or otherwise for the proper installation of the PowerGate ® PLUS Inverter or associated equipment supplied.

A potential for personal injury and/or equipment damage exists if electrical codes and these instructions are not followed.

DANGER

This PowerGate® PLUS Inverter contains LETHAL VOLTAGES. Authorized service personnel only should perform all repairs and service. There are no user serviceable parts inside this inverter.

xii

General Safety Precautions

Only qualified personnel familiar with the PowerGate ® PLUS Inverter design should plan or implement the installation, start-up and subsequent maintenance of the system.

Failure to comply may result with personal injury and or equipment damage.

An incorrectly installed PowerGate ® PLUS Inverter may result in equipment damage or a reduction in product life. Incorrect wire sizing, inadequate supply, or excessive ambient temperatures may result in system malfunction.

This PowerGate ® PLUs Inverter contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this unit. Board component damage may result if proper ESD measures are not followed.

To avoid an electric shock, verify that the voltage on the bus capacitors has discharged before performing any work on the PowerGate ® Plus Inverter. Measure the voltage across CF (wires 14 and 15) in the inverter; this voltage must be zero to be fully discharged.

The enclosure contains exposed high voltage conductors. The enclosure door should remain locked, except during maintenance or testing by trained service personnel. Do not open the cabinet doors if extreme moisture is present (rain, snow or heavy dew).

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Electrical Safety Precautions and Practices

ELECTRIC SHOCK can KILL. Do not touch live electrical parts. ELECTRIC ARC FLASH can injure eyes, burn skin, cause equipment damage and ignite combustible material. DO NOT disconnect load power by disconnecting power cables. Prevent tools from causing short circuits.

Be aware that you do not have to physically touch high-voltage parts to receive an electrical shock; high-voltage can jump across gaps seeking objects of lower potential (i.e. body parts, tools, or equipment).

Safe Practices Equipment that supplies electrical power can cause serious injury or death, or damage to other equipment or property. The operator must strictly observe all safety rules and take precautionary actions. Safe practices have been developed from past experience in the use of power source equipment.

Shock Prevention Bare conductors, terminals in the output circuit or ungrounded, electrically live equipment can fatally shock a person. Be sure to follow the following guidelines:

Have a certified electrician verify that the equipment is adequately installed and grounded.

Only authorized and properly trained personnel should maintain or troubleshoot the PowerGate ® PLUS Inverter.

Use proper safety clothing, procedures and test equipment.

The electrical resistance of the body is decreased when wet, permitting dangerous currents to flow through it. While inspecting or servicing equipment, do not work in damp areas.

Stand on a dry rubber mat or dry wood, and use insulating gloves when dampness or sweat cannot be avoided and never work alone.

The equipment must be installed and maintained in accordance with the National Electrical Code NFPA 70, or other applicable codes.

Inspect cables frequently for damage to the insulation and the connectors.

Replace or repair cracked or worn cables immediately.

Do not overload cables.

Do not touch output terminal while equipment is energized.

DC input terminals and output terminals remain energized when internal disconnects and breakers are open. .

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Service and Maintenance This equipment must be maintained in good electrical condition to avoid hazards stemming from disrepair. Report any equipment defect or safety hazard to the supervisor and discontinue use of the equipment until its safety has been assured. Only qualified personnel should make repairs to the inverter.

Before servicing, disconnect AC and DC sources to the inverter.

The PowerGate ® Plus Inverter contains high-voltage DC capacitors. Allow five (5) minutes for all capacitors within the enclosure to discharge after disconnecting the inverter from AC and DC sources.

Fire and Explosion Prevention Fire and explosion are caused by electrical short circuits, combustible material near the equipment, or unsafe operating conditions. Overloaded or shorted equipment can become hot enough to cause fires by self-destruction or by causing nearby combustibles to ignite. Provide primary input protection to remove short circuited or heavily overloaded equipment from the line.

Bodily Injury Prevention Serious injury can result from contact with live circuit components inside this equipment, Shut down this equipment for inspection and routine maintenance in accordance with Chapter 3, Section 6. When equipment is in operation, use extreme care in doing necessary troubleshooting and adjustment.

Medical and First Aid Treatment First aid procedures need to be in place in accordance with local and site health and safety procedures. Electric shock victims should be checked by a physician and taken to hospital immediately if any abnormal signs are observed.

Equipment Precautionary/Warning Labels Inspect all precautionary, warning labels on the equipment monthly. Order and replace all labels that cannot be easily read or are worn out. Labels can be ordered by email at pv.service@SatCon.com.

Potential Equipment Damage Improper phase connection, paralleling, or use can damage the equipment. Maintenance personnel should become familiar with the layout and be aware of the basic system parameters. Only qualified trained personnel should be allowed to work with this equipment under competent supervision. The DC input voltage present for the solar array can be as high as 660VDC (maximum). The AC output voltage can be as high as 600VAC depending on output configuration and utility voltage.

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Integrated Electrical Safety Features PowerGate ® Plus Inverters contain the following integrated electrical safety features:

Software protection controls (described in Chapter 3, Operating).

Enclosure Door Interlock Switches (described in Chapter 1 and Chapter 3)

ON/OFF switch (described in Chapter 1 and Chapter 3)

DC Disconnect Switch (described in Chapter 1 and Chapter 3)

AC Breaker (described in Chapter 1 and Chapter 3)

Anti-islanding protection (described in Chapter 1)

Be sure to understand these features.

Handling Safety

When moving the enclosure, handle with care and caution.

Do not use the hold-down brackets for lifting. Unit must be lifted from the bottom. Unit must be supported on all four sides when lifting due to its narrow width and depth.

Ensure that the load rating of the lifting device is sufficient to safely lift the electrical unit.

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Special Symbols

The following special symbols are used within the PowerGate® Plus Inverter enclosure

GROUND – Symbol used throughout the enclosure to designate a connection point to ground.

DC Positive – Symbol used throughout the enclosure designate a connection point to the DC Positive of the Solar Photovoltaic Array.

DC Negative – Symbol used throughout the enclosure to designate a connection point to the DC Negative of the Solar Phortovoltaic Array.

AC Circuit – Symbol used throughout the enclosure to designate that a circuit is an AC, 60Hz circuit.

Number of Phases– Symbol used throughout the enclosure to indicate the number of the phases in the circuit

ON position– Symbol used throughout the enclosure to indicate the ON position of switches and breakers.

OFF position– Symbol used throughout the enclosure to indicate the OFF position for switches and breakers.

DC Circuit – Symbol used throughout the enclosure to designate that the circuit is intended to be connected to a DC circuit.

Chapter 1 Product Information

PM00437 Revision 7 Confidential and Proprietary Information 1

Chapter 1 Product Information

About this Chapter

This chapter introduces the PVS-75 and PVS-100 PowerGate® Plus Inverters. Topics include:

Technologies and design features

Operational features

Safety features

Ratings and specifications

Physical description

Operator controls

2 Confidential and Proprietary Information PM00437 Revision 7

Overview

The PVS-75 and PVS-100 PowerGate ® Plus Inverters are power conversion systems that are designed to be used in grid-connected photovoltaic systems. These types of systems represent one of the most important configurations of distributed energy resources (DER).

The PVS-75 model has a power rating of 75kW and the PVS-100 is rated at 100kW. These units are easy to install, easy to operate, and incorporate the latest technologies.

Regulatory Standards

The PVS-75 and PVS-100 PowerGate ® Plus Inverters are fully certified to the following standards:

“Standard for Inverters, Converters, Controllers and Interconnection System Equipment for Use With Distributed Energy Resources,” UL1741, including revisions through and including November , 2005

“General Use Power Supplies,” CSA 107.1

PowerGate ® Plus Inverters also comply with IEEE 1547, including testing to IEEE 1547.1 and IEEE C62.45.

Technologies and Design Features

PowerGate® Plus Inverters convert the DC outputs of photovoltaic arrays into three phase AC power using reliable, high efficiency Insulated Gate Bipolar Transistors (IBGT) as the primary switching devices. These devices are rated for 1200V and operate at very high switching frequencies. The inverter itself makes use of a snuberless design, meaning that there are no resistive-capacitive (RC) circuits that can reduce efficiency as well as reliability.

Design features include:

The unit is designed solely for connection to the grid, namely “Line Linkage Mode” (Grid Export Mode), where it exports power to the grid when the DC output from solar photovoltaic array is available.

The power is exported to the grid (Grid Export Mode) by the inverter in AC Current Control mode whereby the current in each phase of the three phase inverter is precisely controlled by the inverter regulator.

The three phases output voltages and currents are sinusoidal with low total harmonic distortion to meet the UL1741 and IEEE 519-1992 harmonic requirements.

The control circuit uses a digital control board named “Digital Power Control Board” (DPCB) using digital signal processor (DSP) and Field Programmable Gate Array (FPGA) chips for control, system monitoring and protection.

Many areas and components sensitive to over-temperature conditions are monitored with thermal detectors. Extensive electronic fault detection schemes, with fuses are employed to ensure safety of critical circuits.

Isolation Transformer All PowerGate® Plus Inverters include a high-efficiency Delta/Wye isolation transformer that has very low coil and core losses. This transformer is mounted within the inverter enclosure where it performs two functions:

Operational Features

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First, it provides galvanic isolation when the solar array is grounded.

Second, it allows the inverter to match the voltage of the utility grid. The utility side windings of the inverter are configured Wye and must match the voltage at the utility inter-tie during installation.

The isolation transformer also has a tap on the low voltage side to enable the inverter to operate when the incoming PV array voltage drops below 305VDC.

The isolation transformer is a dry type transformer wound with high-temperature insulation. The unit is vacuum pressure impregnated (VPI) with polyester resin for durability and protection against the environment. The transformer is forced air cooled by ambient air and designed with a 1.10 service factor for long life. The unit includes over-temperature switches for protection and indication on the panel display of the PowerGate® Plus Inverter.

Operational Features

Maximum Power Point Tracking The PV array has a unique operating point (voltage-current curve) at which it can supply maximum power. This point is called the maximum power point (MPP). However this point changes continuously with the unpredictable variations in solar irradiance and cell temperatures.

Maximum Power Point Tracking (MPPT) is a method to operate the PV array in a way that allows it to deliver its maximum power more efficiently at every instant.

To do this, the PowerGate® Plus Inverters use a sophisticated algorithm to continuously seek the optimum voltage and current operating points of the PV array. The optimum settings are controlled through the Human Machine Interface (HMI) parameters entered through the keypad and display.

Unity Power Factor The PowerGate® Plus Inverter continuously senses the utility voltage and frequency and adjusts its output current waveform to match the utility voltage.

Remote Monitoring Option The PowerGate® PLUS inverter may be equipped with either the Satcon PV View™ Plus option or other third-party web-enabled data monitoring option.

With the remote monitoring option, the PowerGate ® Plus inverter allows parameters (DC voltage and current, AC voltage and current, and power) to be transmitted over a Modbus communication link to a Gateway so that these parameters can be viewed in real-time via the internet (website). Data can then be accessed through secure servers by various State and/or Utility photovoltaic programs.

Refer to the Satcon PV View® Plus or third-party web-enabled data monitoring option manual for more information.

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Safety Features

The PowerGate® Plus Inverter has both hardware and software safety features to suit different purposes and actions.

Enclosure Door Interlock Switch The door interlock switch is provided to prevent operation while the front door is opened (for maintenance and servicing). When a door is opened, the PowerGate® Plus Inverter immediately starts a controlled shutdown of the unit (opens the main AC and DC contactors in a controlled sequence). These contactors cannot be closed until the door interlock switch is in the engaged position.

The door interlock switch turns off power being delivered by the inverter. However, live power will exist in both the DC and AC sections within the enclosure. Exercise extreme care when servicing or maintaining the equipment.

DC Disconnect Switch To make maintenance work safer, all PowerGate® Plus inverters have a DC switch (DS1) that isolates both poles of the solar array panels from the inverter. This switch, which includes an electrical interlock, is also used as a no-load disconnecting device.

NOTE

Local electrical code may require a full load disconnect switch be accessible at all times for the user. In some cases, an additional DC disconnect switch may be required externally for compliance to some local codes. Consult local load authorities for more information.

AC Disconnect Switch or Breaker The PVS-75 and PVS-100 models are equipped with an AC circuit breaker to isolate the inverter from the grid. Protection on the grid side should be provided by an additional fused disconnect switch or circuit breaker.

ON/OFF Switch The PVS-75 and PVS-100 models have an ON/OFF switch, located on the operator interface panel on the main door. When this switch is turned to its OFF position, the inverter immediately shuts down.

Safety Features

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The ON/OFF switch turns off power being delivered by the inverter. However, live power will exist in both the DC and AC sections within the enclosure

Over Voltage and Over Current Detection Over voltage and over current are controlled by internal control electronics and associated software. If the trip set points are exceeded, the inverter will shutdown in an orderly manner.

Ground-Fault Detection and Interruption The PowerGate® Plus Inverter is equipped with a fuse ground-fault detection and circuit interruption (GFDI).

Ground fault protection is provided by a fuse (FUGFDI). A current sensor is also provided to measure operating ground current. The auxiliary contact of the ground fuse is monitored. If a ground fault occurs and the fuse opens, the PowerGate ® Plus inverter shuts down immediately by opening all AC and DC contactors. This in turn isolates the inverter from the grid. The GDFI configuration complies with NEC 690.5.

Anti-Islanding Protection PowerGate® Plus Inverters meet the stringent requirements of UL 1741 “Inverters, Converters, Controllers and Interconnection System Equipment for Use with Distributed Energy Resources”. UL 1741 is a standard that specifies the anti-islanding protection criteria for all distributed generation solutions.

Electrical system islanding occurs when the utility grid is removed but local energy sources, such as photovoltaic inverters, continue to operate and supply power to local loads.

Unintentional islanding is an unwanted condition that…