Xantrex Technology Power Supply PV100S 208 User Manual
PV100S-208  
PV100S-480  
Planning and Installation Manual  
PV100S 100 kW  
Grid-Tied  
Photovoltaic  
Inverter  
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PV100S 100 kW Grid-Tied  
Photovoltaic Inverter  
Planning and Installation Manual  
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About Xantrex  
Xantrex Technology Inc. is a world-leading supplier of advanced power electronics and controls with products from  
50 watt mobile units to 1.5 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  
PV100S 100 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  
PV100S 100 kW Grid-Tied Photovoltaic Inverter Planning and Installation Manual© May 2005 Xantrex  
International. All rights reserved.  
Disclaimer  
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 LOSS OR DAMAGE, WHETHER 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.  
Date and Revision  
May 2005 Revision C  
Part Number  
152315 Rev C  
Contact Information  
Telephone:  
1 800 670 0707 (toll free North America)  
1 360 925 5097 (direct)  
Fax:  
1 360 925 5143 (direct)  
[email protected]  
www.xantrex.com  
Email:  
Web:  
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About This Manual  
Purpose  
The purpose of this Planning and Installation Manual is to provide explanations  
and procedures for planning and installing the PV100S 100 kW Grid-Tied  
Photovoltaic Inverter.  
Scope  
The Manual provides safety guidelines, detailed planning and setup information,  
and procedures for installing the inverter.  
Audience  
The Manual is intended for use by anyone who plans to construct or install a  
system involving the PV100S 100 kW Grid-Tied Photovoltaic Inverter. Installers  
must meet all local and state code requirements for licensing and training for the  
installation of Electrical Power Systems with AC and DC voltage to 600 volts.  
Organization  
This Manual is organized into four chapters:  
Chapter 1, “Introduction” provides information about the features and functions  
of the PV100S 100 kW Grid-Tied Photovoltaic Inverter.  
Chapter 2, “Planning” provides information to help plan the installation of the  
PV100S 100 kW Grid-Tied Photovoltaic Inverter.  
Chapter 3, “Installation” describes the procedures needed to install the PV100S  
100 kW Grid-Tied Photovoltaic Inverter. This section includes unpacking and  
moving instructions, mounting instructions, and cabling instructions.  
Chapter 4, “Verification” provides a checklist to ensure the installation of the  
PV100S is correct and complete.  
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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.  
This Manual contains information for two models of the PV100S 100 kW Grid-  
Tied Photovoltaic Inverter. One model is designed to operate with a 208 Vac  
utility input, and the other model is designed to operate with a 480 Vac utility  
input.  
•
•
•
The model PV100S-208 100kW Grid-Tied Photovoltaic Inverter  
(208 Vac input) will be referred to as the PV100S-208 when it is being  
referenced individually.  
The model PV100S-480 100kW Grid-Tied Photovoltaic Inverter  
(480 Vac input) will be referred to as the PV100S-480 when it is being  
referenced individually.  
When the both models are being referenced together, they will be referred to  
as the PV100S.  
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About This Manual  
Abbreviations and Acronyms  
ANSI  
CCU2  
CFM  
CW  
American National Standards Institute  
Converter Control Unit 2  
Cubic Feet per Minute  
Clockwise  
DSP  
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  
FPGA  
GUI  
IEEE  
IGBT  
IPM  
kcmil  
LAN  
LCD  
NFPA  
PBX  
PSL  
Local Area Network  
Liquid Crystal Display  
National Fire Protection Association  
Private Branch Exchange  
Phase-Shift Loop  
POTS  
PV  
Plain Old Telephone Service  
Photovoltaic  
UFCU  
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 PV100S that shall be  
followed during installation and maintenance procedures.  
WARNING: Shock Hazard  
Read and keep this Planning and Installation Manual for future reference. Before  
installing PV100S (either model), 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 PV100S enclosures contain exposed high-voltage conductors. The enclosure doors  
should remain closed with the latches tightened, except during installation, maintenance  
or testing. These servicing instructions are for use by qualified personnel who meet all  
local and state code requirements for licensing and training for the installation of  
Electrical Power Systems with AC and DC voltage to 600 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 PV100S, 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 PV100S. Review the  
system configuration to determine all of the possible sources of energy. In addition, allow  
5 minutes for the DC bus capacitors, located on the ceiling of the cabinet, to discharge  
after removing power.  
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Safety  
General Safety Precautions  
1. When installing the PV100S 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 PV100S if it has been dropped, or received more  
than cosmetic damage during transport or shipping. If the PV100S is  
damaged, or suspected to be damaged, see the Warranty for this unit in the  
PV100S 100 kW Grid-Tied Photovoltaic Inverter Operation and Maintenance  
Manual.  
3. To reduce the risk of electrical shock, lock-out and tag the PV100S before  
attempting any maintenance, service, or cleaning.  
Personal Safety  
Follow these instructions to ensure your safety while working with the PV100S.  
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  
(600 Vac and DC rated, minimum)  
Check local safety regulations for other requirements.  
Wiring Requirements  
1. All wiring methods and materials shall be in accordance with the National  
Electrical Code ANSI/NFPA 70. When sizing conductors and conduits  
interfacing to the PV100S, both shall be in accordance with the National  
Electric Code ANSI/NFPA 70, as well as all state and local code  
requirements.  
2. Use copper conductors only with insulation rated for 90 °C.  
3. The PV100S has a three-phase output. It is marked with this symbol:  
4. The AC power conductor wiring interfacing with the AC terminals in the  
Transformer Enclosure are located at T6-X1, T6-X2, and T6-X3. These  
terminals should be tightened to a torque value of 420 in-lbs (47.5 Nm) for  
model PV100S-208 and model PV100S-480. Conductors terminated to these  
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Safety  
terminals must use a crimp-on type ring terminal or compression-type lug.  
The terminals are one bolt per pole. See Figure 3-14 on page 3–15 for the  
location of these terminals.  
5. The AC power conductor wiring interfacing with the AC terminals in the  
Main Inverter Enclosure are located at TB4-A, TB4-B, and TB4- C. These  
terminals are to be tightened to a torque value of 275 in-lbs (31.1 Nm) for  
model PV100S-208 and model PV100S-480. The terminals will accept a  
conductor size of 350 kcmil. See Figure 3-15 on page 3–16 for the location of  
these terminals.  
6. The AC power conductor wiring interfacing with the AC terminals in the  
AC Interface Enclosure are located at S1-2T1, S1-4T2, and S1-6T3. These  
terminals should be tightened to a torque value of 310 in-lbs (35.0 Nm) for  
model PV100S-208 and to a torque value of 115 in-lbs (13.0 Nm) for model  
PV100S-480. See Figure 3-16 on page 3–16 for the location of these  
terminals and the cautionary note on page 3–17.  
7. The AC neutral conductor from the utility is terminated in the AC Interface  
Enclosure at the TB6-Neutral terminal. This terminal requires the use of a  
crimp-on type ring terminal or compression-type lug and should be tightened  
to a torque value of 228 in-lbs (25.7 Nm) for model PV100S-208 and model  
PV100S-480. See Figure 3-18 on page 3–18 for the location of these  
terminals.  
8. The DC power conductor wiring interfacing with the DC terminals at TB3-1,  
TB3-2, and TB3-3 are to be tightened to a torque value of 500 in-lbs  
(56.5 Nm) for model PV100S-208 and model PV100S-480. These terminals  
will accept a conductor size of 500 kcmil. Keep these cables together as much  
as possible and ensure that all cables pass through the same knockout and  
conduit fittings, thus allowing any inductive currents to cancel. See Figure 3-  
19 on page 3–19 for the location of these terminals.  
9. This product is intended to be installed as part of a permanently grounded  
electrical system per the National Electric Code ANSI/NFPA 70. A copper  
ground rod must be installed within three feet of the PV100S enclosure. This  
is the single point earth ground for the inverter system. The single point  
ground for the system is to be made at the AC ground bus bar (TB2) in the AC  
Interface Enclosure. This terminal requires the use of a crimp on type ring  
terminal or compression-type lug and should be tightened to a torque value of  
420 in-lbs (47.5 Nm) for model PV100S-208 and model PV100S-480.  
10. The equipment grounds on the PV100S are marked with this symbol:  
11. AC overcurrent protection for the utility interconnect (Grid-tie) must be  
provided by the installers as part of the PV100S installation.  
CAUTION: Fire Hazard  
In accordance with the National Electrical Code, ANSI/NFPA 70, connect only to a circuit  
provided with 400 amperes maximum branch circuit overcurrent protection for model  
PV100S-208 and only to a circuit provided with 200 amperes maximum branch circuit  
overcurrent protection for model PV100S-480.  
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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 de-  
energized 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 PV100S 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 5 minutes to  
allow the capacitors to discharge completely.  
The PV100S 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  
PV100S 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 (S1) on the AC Interface  
Enclosure. See Figure 1-4 on page 1–9 for the location of the AC Disconnect  
Switch.  
3. Open, lockout, and tag the DC Disconnect Switch (S2) on the DC Interface  
Enclosure. See Figure 1-4 on page 1–9 for the location of the DC Disconnect  
Switch.  
4. Using a confirmed, accurate meter, verify all power to the inverter is de-  
energized. 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) Inverter Terminals: TB4-A, TB4-B, TB4-C (Phase A, B, C)  
See Figure 3-15 on page 3–16.  
b) Utility Terminals: Bottom of S1-2T1, S1-4T2, S1-6T3  
See Figure 3-16 on page 3–16.  
c) PV Terminals: Bottom of TB3-1, TB3-2, TB3-3 (PV+, PV-, GND)  
See Figure 3-19 on page 3–19.  
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Safety  
De-Energize/Isolation Procedure  
The following procedure should be followed to de-energize the PV100S for  
maintenance.  
WARNING  
The terminals of the DC input may be energized if the PV arrays are energized. In  
addition, allow 5 minutes for all capacitors within the main enclosure to discharge after  
disconnecting the PV100S from AC and DC sources.  
To isolate the PV100S:  
1. Turn the ON/OFF switch to the OFF position.  
2. Open the DC interface disconnect switch.  
3. Open the AC interface disconnect switch.  
4. Open the utility connection circuit breaker.  
5. Install lockout devices on the utility connection circuit breaker and DC  
disconnect switch.  
Interconnection Standards Compliance  
The PV100S has been tested and listed by Underwriters Laboratories to be in  
compliance with UL1741 Static Inverters And Charge Controllers For Use In  
Photovoltaic Power Systems, as well as IEEE-929-2000 Recommended Practice  
For Utility Interface of Photovoltaic (PV) Systems.  
IEEE-929-2000 provides guidance regarding equipment and functions necessary  
to ensure compatible operation of photovoltaic systems which are connected in  
parallel with the electric utility.  
UL1741 is the standard applied by Underwriters Laboratory to the PV100S to  
verify it meets the recommendations of IEEE-929-2000.  
Refer to both documents for details of these recommendations and test  
procedures.  
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Contents  
Important Safety Instructions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -vii  
1
Introduction  
Description of the PV100S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2  
System Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4  
Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4  
Over Voltage, Under Voltage and Frequency Ranges - - - - - - - - - - - - - - - - - - - - - - - - - 1–4  
System Ground Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5  
System Neutral Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5  
Utility Side Isolation Transformer Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5  
Environmental Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6  
Operator Interface Controls- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–7  
Main Enclosure Door Interlock Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–7  
On/Off Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8  
AC and DC Disconnect Switches - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–9  
Communication Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–9  
System Status and Fault Reporting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–10  
Data Logging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–10  
Communication Methods - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–11  
Universal Front Panel Control Unit (UFCU) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–11  
PC Connection Methods - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–12  
POTS Access - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–13  
Wireless Access - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–13  
Ethernet LAN Access - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–14  
Direct Access - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–14  
2
Planning  
Overview of PV100S Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2  
PV Planning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3  
Ventilation and Serviceability Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3  
Ground Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4  
System Neutral Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4  
Communication Requirements- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4  
Utility Side Isolation Transformer Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4  
Electrical Diagrams and Schematics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5  
Layout Options - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6  
Conduit Penetration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8  
Conductor and Conduit Sizing- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11  
Anchoring the PV100S- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13  
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Contents  
3
Installation  
Equipment Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2  
Unloading - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2  
Moving the PV100S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3  
Unpacking the PV100S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3  
Removing the Pallet and Moving the PV100S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4  
Mounting and Anchoring the Units - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5  
Opening or Closing Access Doors- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–6  
Conduit Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9  
Wiring - General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–10  
Overcurrent Protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–11  
Conductor Termination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–11  
Wire Gauge and Torque Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–12  
Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–12  
System Neutral Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–13  
Utility Side Isolation Transformer Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–13  
Wiring - Specific - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–14  
AC Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–14  
PV Array Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–19  
PC Communications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–20  
PC Connection Methods - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–20  
Establishing a POTS Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–21  
Establishing Wireless Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–22  
Establishing an Ethernet LAN Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–22  
Direct Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–23  
4
Verification  
Verification Procedure Summary - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2  
Visual Inspection of Mechanical Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3  
Visual Inspection of Electrical Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3  
Visual Inspection, Isolation Transformer Wye/Wye - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4  
Corrective Action - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4  
A
Schematics  
Index - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - IX–1  
xiv  
152315 Rev C  
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Tables  
Table 1-1  
Table 1-2  
Table 1-3  
Table 3-1  
Table 3-2  
Electrical Specifications- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4  
Over/Under Voltage and Over/Under Frequency Ranges- - - - - - - - - - - - - - - - - - - - - - 1–4  
Environmental Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6  
AC Terminal Wire Gauge, Bolt Size, and Torque Values - - - - - - - - - - - - - - - - - - - - 3–12  
DC Terminal Wire Gauge, Bolt Size, and Torque Values - - - - - - - - - - - - - - - - - - - - 3–12  
152315 Rev C  
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Figures  
Figure 1-1 Dimensions (Not to scale) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3  
Figure 1-2 PV100S Operator Interface Components- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–7  
Figure 1-3 On/Off Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8  
Figure 1-4 AC and DC Disconnect Switches- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–9  
Figure 1-5 LCD Display and UFCU Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–11  
Figure 1-6 PC Connections in the Communications Enclosure- - - - - - - - - - - - - - - - - - - - - - - - - 1–12  
Figure 1-7 POTS Access - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–13  
Figure 1-8 Wireless Access - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–13  
Figure 1-9 Ethernet LAN Access - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–14  
Figure 1-10 Direct Access - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–14  
Figure 2-1 PV100S Layout Option A- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6  
Figure 2-2 PV100S Layout Option B- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–7  
Figure 2-3 Conduit Entry Figure Reference - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8  
Figure 2-4 Inductor Enclosure Conduit Entry, Left Side - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9  
Figure 2-5 Transformer Enclosure Conduit Entry, Right Side - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9  
Figure 2-6 AC Interface Enclosure Conduit Entry, Left Side - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10  
Figure 2-7 DC Interface Enclosure, Bottom Side - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–10  
Figure 2-8 Communications Enclosure Conduit Entry, Bottom Side - - - - - - - - - - - - - - - - - - - - - 2–10  
Figure 2-9 Main Inverter Anchor Bolt Pattern (Not to scale) - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13  
Figure 2-10 AC Interface/Transformer Anchor Bolt Pattern (Not to Scale) - - - - - - - - - - - - - - - - - 2–14  
Figure 3-1 Moving the crated PV100S- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3  
Figure 3-2 Forklift Lifting Locations - Underneath Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4  
Figure 3-3 Mounting Hole Locations- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5  
Figure 3-4 Inverter Enclosure Access Doors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–6  
Figure 3-5 AC Interface Access Door - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7  
Figure 3-6 DC Interface Access Door - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7  
Figure 3-7 Transformer Access Panels- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8  
Figure 3-8 Inductor Access Panels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8  
Figure 3-9 Conduit Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9  
Figure 3-10 Single-point Ground (TB2) Ground Bar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–12  
Figure 3-11 Chassis Ground Bar (TB1) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–13  
Figure 3-12 Route AC Cables through the Conduit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–14  
Figure 3-13 Tie-wraps on the AC Sense Harness- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–15  
Figure 3-14 AC Terminal Connections in the AC Interface/Transformer Enclosure - - - - - - - - - - - 3–15  
Figure 3-15 AC Terminal Connections in the Main Inverter Enclosure - - - - - - - - - - - - - - - - - - - - 3–16  
Figure 3-16 AC Terminal Connections in the AC Interface Enclosure - - - - - - - - - - - - - - - - - - - - 3–16  
Figure 3-17 Connecting the AC Sense Harness - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–17  
152315 Rev C  
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Figures  
Figure 3-18 AC Terminal Connections from the Utility- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–18  
Figure 3-19 PV Array Cable Routing and Terminations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–19  
Figure 3-20 Telephone Cable Routing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–21  
Figure 3-21 RS232/FO Converter Kit Installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–23  
Figure 3-22 Direct Connect Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–24  
Figure A-1 Electrical Diagram (sample)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–3  
Figure A-2 PV100S-480 Schematic for Main Power Distribution (152316 E1) - - - - - - - - - - - - - - A–4  
Figure A-3 PV100S-480 Schematic for Control Power Distribution (152316 E2) - - - - - - - - - - - - - A–5  
Figure A-4 PV100S-480 Schematic for Converter Control Unit (152316 E3)- - - - - - - - - - - - - - - - A–6  
Figure A-5 PV100S-208 Schematic Main Power Distribution (152376 C1) - - - - - - - - - - - - - - - - - A–7  
Figure A-6 PV100S-208 Schematic for Control Power Distribution (152376 C2)- - - - - - - - - - - - - A–8  
Figure A-7 PV100S-208 Schematic for Converter Control Unit (152376 C3)- - - - - - - - - - - - - - - - A–9  
xviii  
152315 Rev C  
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Introduction  
1
Chapter 1, “Introduction” provides information about the features and  
functions of the PV100S 100 kW Grid-Tied Photovoltaic Inverter.  
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Introduction  
Description of the PV100S  
The PV100S 100 kW Grid-Tied Photovoltaic Inverter is a UL 1741 listed, utility  
interactive, three-phase power conversion system for grid-connected photovoltaic  
arrays with a power rating of 100 kW. Designed to be easy to install and operate,  
the PV100S 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 start up and shut down sequences.  
Multiple PV100S inverters are easily paralleled for larger power installations.  
The PV100S 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, and a custom Wye/Wye isolation transformer. Housed in a  
rugged NEMA 3R rated, powder-coated steel enclosure, the PV100S incorporates  
sophisticated Intellimod (IPM) Insulated Gate Bipolar Transistors (IGBTs) as  
the main power switching devices. An advanced, field-proven, Maximum Peak  
Power Tracker (MPPT) integrated within the PV100S control firmware ensures  
the optimum power throughput for harvesting energy from the photovoltaic array.  
The advanced design of the PV100S includes an EMI output filter and the main  
AC contactor located electrically on the utility side of the isolation transformer.  
The location of the main AC contactor, and the ability to de-energize the isolation  
transformer during times of non-operation, greatly reduces the night-time tare  
losses consumed by an idle isolation transformer. An integrated soft-start circuit  
precludes nuisance utility-tie circuit breaker trips as the result of isolation  
transformer inrush current.  
Additionally, the PV100S integrated controller contains self-protection features  
including over and under voltage and frequency safeguards. An integral  
anti-island protection scheme prevents the inverter from feeding power to the grid  
in the event of a utility outage. The PV100S includes a local user interface  
comprised of an ON/OFF switch, keypad, and 4-line, 80 character LCD display. A  
user-friendly, Graphic User Interface (GUI) provides a remote interface for  
operator interrogation of PV100S system status, control, metering/data logging  
and protective functions within the PV100S. The status, control, and logging  
features are also supported by the data modem (included) and can be accessed  
remotely.  
The PV100S comes in two modules comprised of six enclosures to house the  
electronics described above. The first module includes the Main Inverter  
Enclosure, Inductor Enclosure, DC Interface Enclosure, and Communications  
Enclosure. The second module includes the Transformer Enclosure and AC  
Interface Enclosure. These components are identified in Figure 1-1 on page 1–3.  
Figure 1-1 also shows the dimensions and locations of the various enclosures that  
comprise the PV100S.  
See “Layout Options” on page 2–6 for information on configuration options.  
1–2  
152315 Rev C  
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Description of the PV100S  
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UFACTURED  
AY SE  
U N  
CT  
NO  
AUG DEC  
O
DE  
L
N
UMBE R:  
0S-20  
PV1  
0
8
J
A
N
M
P
0
4
F
EB  
J
O
0
5
S
E
R
I
A
L
N
UMBE R:  
X
XXX  
APR  
V
0
6
M
A
R
0
7
L
-
1
5
2
4
6
2
R
e
v
A
Transformer  
Enclosure  
Inductor  
Enclosure  
29 ¼"  
(73 cm)  
44.0"  
(110 cm)  
21 3/8"  
(53.5 cm)  
Back  
Front  
Back  
Front  
83"  
(205.7 cm)  
DC Interface  
Enclosure  
Communications  
Enclosure  
AC Interface  
Enclosure  
59 ¼"  
(148 cm)  
AC  
D
I
S
C
O
N
N
ECT  
Inductor  
Enclosure  
33 ½"  
(83.75 cm)  
DC Side View  
AC Side View  
Figure 1-1 Dimensions (Not to scale)  
152315 Rev C  
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Introduction  
System Specifications  
The PV100S has been designed for photovoltaic power systems, which operate  
within the following specifications.  
CAUTION: Equipment Damage  
Operation of the PV100S in a manner other than specified in this manual may cause  
damage to the PV100S and other system components and will void the terms of the  
warranty.  
Electrical Specifications  
Table 1-1 provides the AC and DC specifications for the PV100S.  
Table 1-1 Electrical Specifications  
Specification  
PV100S-208  
PV100S-480  
Nominal AC Input Voltage  
208 Vac  
480 Vac  
(+10% to -12% acceptable range) (183 to 228 Vac)  
(422 to 528 Vac)  
Maximum AC Output Current  
278 A  
121 A  
rms  
rms  
Nominal AC Input Frequency  
60 Hz  
60 Hz  
(+0.5 to -0.7 Hz acceptable range) (59.3 to 60.5 Hz)  
(59.3 to 60.5 Hz)  
100.0 kW  
Output Power  
100.0 kW  
Peak Power Tracking Window  
Maximum Open Circuit Voltage  
Maximum DC Input Current  
330 to 600 Vdc  
600 Vdc  
330 to 600 Vdc  
600 Vdc  
319 amps  
319 amps  
Over Voltage, Under Voltage and Frequency Ranges  
Table 1-2 provides the over voltage, under voltage, over-frequency, and  
under-frequency detection limits for the PV100S. These detection limits have  
been factory tested and deemed to be in compliance with IEEE-929 and UL 1741  
requirements for utility interaction.  
Table 1-2 Over/Under Voltage and Over/Under Frequency Ranges  
PV100S-208  
PV100S-480  
Trip Time  
Vac Condition  
(% of Nominal)  
Voltage Range  
Trip Time  
Voltage Range  
Vac < 240  
Vac < 50%  
Vac < 104  
6 cycles  
6 cycles  
50% < Vac < 88%  
88% < Vac < 110%  
110% < Vac < 137%  
137% < Vac  
104 < Vac < 183 2 seconds  
183 < Vac < 228 normal operation  
228 < Vac < 285 2 seconds  
240 < Vac < 422  
422 < Vac < 528  
528 < Vac < 657  
657 < Vac  
2 seconds  
normal operation  
2 seconds  
2 cycles  
285 < Vac  
f < 59.3  
f > 60.5  
2 cycles  
6 cycles  
6 cycles  
f < rated -0.7  
f < 59.3  
6 cycles  
f > rated +0.5  
f > 60.5  
6 cycles  
1–4  
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System Specifications  
System Ground Requirements  
This product is intended to be installed as part of a permanently grounded  
electrical system per the National Electric Code ANSI/NFPA 70. A copper ground  
rod must be installed within three feet of the PV100S enclosures and connected to  
the unit as described in “System Grounding” on page 3–12. The single-point  
ground for the system is to be made at the AC ground bus bar (TB2) in the AC  
Interface Enclosure.  
System Neutral Requirements  
The PV100S is designed to be installed as a 4-wire system. As required by the  
UL 1741 listing, a neutral conductor from the utility-interconnect must be  
terminated at TB6 within the AC Interface Enclosure to ensure that the AC  
voltage sensing circuit can perform an individual phase voltage (line-to-neutral)  
measurement. The function of the neutral connection is to provide a point of  
reference for measurement purposes that is essentially at ground potential. No  
power will flow through the neutral conductor.  
Utility Side Isolation Transformer Requirements  
The PV100S is supplied with a custom, high-efficiency, isolation transformer as  
part of the AC Interface/Transformer assembly. The utility side windings of the  
isolation transformer are configured Wye and must match the voltage at the utility  
inter-tie. The PV100S is a balanced, three-phase, current-sourcing inverter and  
only operates with the presence of a stable utility voltage. The transformer is also  
supplied with a neutral connection on the utility interconnect. Connection of this  
utility-side neutral does not affect the operation of the inverter, however  
connection of the neutral on the inverter-side does affect the operation and must  
be left floating or disconnected. Single-phase, grounded loads which may be  
present between the transformer and utility, will maintain their existing ground  
reference at the utility distribution transformer.  
CAUTION: Equipment Damage  
If the Isolation Transformer (T6-X0) neutral terminal is tied to ground, it will cause  
irreparable damage to the PV100S. Check local regulations for their requirements  
regarding the connection of the neutral.  
WARNING: Lethal Voltage  
Grounding the neutral of a Wye-wound transformer may create an “open delta” condition,  
depending on the utility configuration. This condition may keep the PV100S from  
detecting a loss of phase condition on the utility system, which may allow potentially  
lethal voltage to be present on the open-phase wiring.  
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Introduction  
Environmental Specifications  
The following environmental specifications are the same for both models of the  
PV100S 100 kW Grid-Tied Photovoltaic Inverter.  
Table 1-3 Environmental Specifications  
Specification  
Value  
Dimensions  
Inverter and DC Interface  
82 in H x 60 1/4 in W x 22 in D  
(208 cm H x 153 cm W x 56 cm)  
Transformer and AC Interface  
44 in H x 50 in W x 34 in D  
(112 cm H x 127 cm W x 86 cm D)  
Overall System Footprint:  
Layout Option A  
12 ft W x 6 ft L (approximate)  
(3.6 m x 1.8 m)  
9 ft W x 7 ft L (approximate)  
(2.7 m W x 2.1 m L)  
Layout Option B  
Weight  
Inverter and DC Interface  
Transformer and AC Interface  
Overall Weight  
1000 lbs (approximate)  
1400 lbs (approximate)  
2400 lbs (approximate)  
Allowable Ambient Temperature  
Operating  
Storage  
-20 °C to 50 °C Maximum  
-40 °C to 50 °C Maximum  
Relative Humidity  
Elevation  
To 95%, Non-condensing  
Power Derated above 6600 ft  
In front of access doors: 36 in (91 cm)  
In front of access panels: 36 in (91 cm)  
Sides: 12 in (30 cm)  
Clearance (ventilation and  
serviceability)  
Back: 6 in (15 cm)  
Maximum Distance between Main 15 ft (4.5 m)  
Inverter Enclosure and AC  
Interface/Transformer Enclosure  
1–6  
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Operator Interface Controls  
Operator Interface Controls  
Operator interface controls are located on the front door of the main inverter  
enclosure. These controls include an ON/OFF Switch, 4-line LCD 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.  
Communication  
Enclosure  
DCDisconnect  
LCD  
Display  
Switch  
AC Disconnect  
Switch  
Universal  
Frontpanel  
Control  
(UFCP)  
ON/OFF  
Switch  
DC Interface  
Enclosure  
AC Interface Enclosure  
(AC Side View)  
Main Inverter Enclosure  
(Front View)  
Figure 1-2 PV100S Operator Interface Components  
Main Enclosure Door Interlock Switch  
The front door of the PV100S main enclosure is equipped with an interlock switch  
to preclude operation while the front door is open. Opening the door of the main  
inverter enclosure will initiate an immediate controlled shutdown of the PV100S  
and opens both the main AC and DC contactors. The main AC and DC contactors  
cannot be closed unless the door’s interlock is in the engaged position. The  
PV100S is prevented from being restarted until the door is again closed and the  
switch is in the engaged position.  
It is required that the PV100S main enclosure door must be locked during normal  
operation. The door interlock switch does NOT remove all hazardous voltages  
from inside the inverter. Before attempting to service the PV100S, follow the  
de-energize Lockout and Tag procedure on page x.  
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Introduction  
WARNING: Shock Hazard  
Disengaging the main enclosure door interlock switch does NOT remove all hazardous  
voltages from inside the inverter. Before attempting to service the PV100S, follow the  
de-energize Lockout and Tag procedure on page x.  
On/Off Switch  
The PV100S incorporates a maintained position ON/OFF switch located on the  
front door of the main 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 PV100S and opens 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 PV100S 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 PV100S, follow the de-energize  
Lockout and Tag procedure on page x.  
Figure 1-3 On/Off Switch  
1–8  
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Communication Features  
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 PV100S 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 PV100S is processing power from the PV  
array, the early-break contact block will signal the CCU2 (Converter Control  
Unit 2) to stop processing power prior to the opening DC Disconnect switch.  
Additionally, opening the DC Disconnect switch will cause the PV100S to  
execute an immediate orderly shutdown, open both the main AC and DC  
contactors, and report a PV disconnect fault on the LCD of the UFCU.  
DC Disconnect  
Switch  
AC Disconnect  
Switch  
DC Interface Enclosure  
AC Interface Enclosure  
Figure 1-4 AC and DC Disconnect Switches  
Communication Features  
The PV100S 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 Xantrex Solar  
Graphic User Interface (GUI) software. Data logging requires the use of a PC  
using the GUI software.  
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Introduction  
System Status and Fault Reporting  
Basic system status and all fault conditions rising from within the PV100S are  
reported to the UFCU. The unit stores the time and details of all faults in  
non-volatile memory. The 4-line LCD will display a hexadecimal value and a  
brief text description of the fault.  
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 the optional 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 the following.  
•
•
•
•
•
•
•
•
Operational Values  
Internal Metrics  
Data Log Acquisition  
Graphic Data Analysis  
Fault Log Acquisition  
Software Upgrade  
Accumulated Values  
Configurable Parameters  
1–10  
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Communication Methods  
Communication Methods  
The PV100S communicates system status information to the user using the  
following methods.  
•
•
The Front Panel Control Unit (UFCU) Display  
PC Connection (Direct or Remote) - Xantrex Solar Graphic User Interface  
(GUI) Software required. Communication with a PC requires the selection of  
one of the following options.  
•
Remote Connection -- This method has three options available. One of  
these options will be field-installed prior to commissioning.  
•
•
•
POTS (Plain Old Telephone Service) Connection  
Wireless Connection  
Ethernet LAN Connection  
•
Direct Connection -- This method is most commonly used by field  
technicians for local connection and troubleshooting purposes.  
Important: The customer is responsible for providing the appropriate support service  
to support a PC connection. (i.e., making arrangements for an analog phone line, wireless  
service or local area network.)  
Universal Front Panel Control Unit (UFCU)  
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.  
Communications  
Enclosure  
LCD Display  
Universal Front Panel  
Control Unit (UFCU)  
Figure 1-5 LCD Display and UFCU Location  
See the PV100S 100 kW Grid-tied Photovoltaic Inverter Operation and  
Maintenance Manual for details.  
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Introduction  
PC Connection Methods  
Personal computers can be used to access the system status and programming  
features of the PV100S. A computer can be connected either directly or remotely.  
1. Remote Connect - uses one of the three kits below.  
•
POTS Kit - uses a MultiTech® 56K Modem, RS232/Fiber Optic  
Converter (configured for ethernet) and SA2 Surge Arrestor.  
•
•
Wireless Kit - uses a GSM Wireless Modem.  
Ethernet LAN Kit - uses a data communication device to enable the unit  
to connect to a local area network.  
2. Direct Connect - This method is used for troubleshooting. It uses a  
RS232/Fiber Optic Converter (configured for a PC), a DB25-to-DB25 gender  
changer, and a DB25-to-DB9 Serial Cable.  
Software is included to provide a graphic user interface that relates important  
system information. This software is called Xantrex Solar Graphic Interface  
(GUI). See "Computer Communications with the PV100S" in the PV100S 100  
kW Grid-tied Photovoltaic Inverter Operation and Maintenance Manual for  
additional information.  
The GUI can dial up the inverter and receive fault report calls from it through a  
standard Hayes-compatible, landline modem. When the GUI initiates a call  
through the modem at the GUI computer, the inverter’s modem answers the call  
and initiates a 9600 baud serial connection, effectively as if the GUI was  
connected directly. Or, if the inverter experiences a fault, it will initiate a call to  
the GUI and report the fault details.  
Communications Enclosure  
Enlargement  
Communications  
Enclosure  
RS232/FO Converter  
®
MultiTech 56K Modem  
SA2 Surge Arrestor  
POTS connection option shown.  
Figure 1-6 PC Connections in the Communications Enclosure  
1–12  
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Communication Methods  
POTS Access  
Figure 1-7 illustrates the PV100S connected remotely to a personal computer.  
Figure 1-7 POTS Access  
Wireless Access  
Figure 1-8 illustrates the PV100S connected remotely to a personal computer  
using a wireless network.  
Figure 1-8 Wireless Access  
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Introduction  
Ethernet LAN Access  
The PV100S can be remotely accessed through a local area network.  
Figure 1-9 Ethernet LAN Access  
Direct Access  
Figure 1-10 illustrates the PV100S connected directly to a personal computer.  
Figure 1-10 Direct Access  
1–14  
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Planning  
2
Chapter 2, “Planning” provides information to help plan the installation of  
the PV100S 100 kW Grid-Tied Photovoltaic Inverter.  
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Planning  
Overview of PV100S Installation  
WARNING: Shock Hazard  
Installations of this equipment should only be performed by qualified technicians.  
Installers must meet all local and state code requirements for licensing and  
training for the installation of Electrical Power Systems with AC and DC voltage  
to 600 volts.  
Planning  
Planning for a system requires complete understanding of all the components that  
are involved to successfully install the PV100S to meet the required national,  
state, and local codes.  
Definition  
A power system (such as the PV100S) is a collection of devices designed to  
supply AC power to the utility grid from a solar energy (PV) source.  
Components  
All types of grid-tied inverter installations, residential or industrial, share common  
components. This chapter describes each component and suggests the minimum  
requirements for a safe installation.  
Location  
The PV100S 100 kW Grid-Tied Photovoltaic Inverter is designed to be installed  
in either an indoor or outdoor location. The PV100S must be anchored to a level,  
concrete floor or pad.  
Ideally the AC interface enclosure/transformer assembly is placed on the left side  
of the Main Inverter Enclosure. The AC interface enclosure/transformer assembly  
may be co-located adjacent to the left side of the Main Inverter Enclosure up to,  
but not exceeding, 15 feet away.  
Clearance  
Adequate ventilation and service access must be taken into consideration when  
installing the PV100S. See “Ventilation and Serviceability Requirements” on  
page 2–3 for specific clearance requirements and ambient temperature  
requirements.  
Conduits and  
Conductors  
Given the flexibility to co-locate the AC interface enclosure/transformer assembly  
to fit a desired system layout, the conduits and conductors are to be supplied by  
the installer.  
See “Conduit Penetration” on page 2–8 for recommendations on enclosure  
penetration locations and conduit routing.  
See “Conductor and Conduit Sizing” on page 2–11 for information on sizing the  
conductors and conduits.  
All interconnect wiring and power conductors interfacing to the PV100S must be  
in accordance with the National Electric Code ANSI/NFPA 70 and any applicable  
local codes.  
2–2  
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PV Planning  
Large gauge wire must conform to the minimum bend radius specified in the  
NEC, Article 373-6B, Ninth Edition.  
Take care to keep the wire bundles away from any sharp edges which may damage  
wire insulation over time.  
All conductors should be made of copper and rated for 90 °C (minimum).  
If the installation of the PV100S is to be outdoors, all interconnect conduit and  
fittings must be NEMA 4 rated as required by the NEC.  
PV Planning  
To determine the number of photovoltaic panels that are required for the PV  
power plant, please use the PV planning tool from the Xantrex website:  
http://www.xantrex.com/support/pvsizing/disclaimer.asp  
Ventilation and Serviceability Requirements  
The following environmental conditions must be established and maintained to  
ensure the safe and efficient operation and servicing of the PV100S. Adequate  
space must be provided around the unit for ventilation and access during  
servicing. If locating the unit indoors, ambient air temperature cannot exceed the  
maximum temperature for which the unit is rated.  
Ventilation  
Maintain a minimum clearance of 12 inches on both sides and 6 inches behind the  
Main Inverter Enclosure and the AC Interface Enclosure for proper cooling fan  
operation.  
Maintenance and  
Serviceability  
Maintain a minimum clearance of 36 inches in front of the main inverter access  
door, the Transformer Enclosure access panel, and the AC interface access door  
for maintenance and serviceability.  
See Figure 2-1 on page 2–6 and Figure 2-2 on page 2–7 for illustrations of these  
clearance requirements.  
Indoor Temperature  
Control  
If the PV100S is to be installed indoors and external air is used for ventilation, the  
required cubic feet per minute (CFM) rate must be no less than 1000 CFM. This  
assumes the temperature inside the building is allowed to rise only 10 °C above  
the outside temperature. Therefore, the maximum allowable outside ambient  
temperature is 50 °C (50 °C minus 10 °C equals 40 °C Maximum Ambient  
Temperature).  
If air conditioning is planned for an indoor installation, the heat load of the  
PV100S is 1800 BTU/Hour at full load.  
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Planning  
Ground Requirements  
This product is intended to be installed as part of a permanently grounded  
electrical system per National Electric Code ANSI/NFPA 70. A copper ground  
rod must be installed within three feet of the PV100S enclosure. This is the single  
point earth ground for the inverter system. The single point ground for the system  
is to be made at the AC ground bus bar (TB2) in the AC Interface Enclosure.  
System Neutral Requirements  
The PV100S is designed to be installed as a 4-wire system. As required by the  
UL 1741 listing, a neutral conductor from the utility-interconnect must be  
terminated at TB6 within the AC Interface Enclosure to ensure that the AC  
voltage sensing circuit can perform an individual phase voltage (line-to-neutral)  
measurement. The function of the neutral connection is to provide a point of  
reference for measurement purposes that is essentially at ground potential. No  
power will flow through the neutral conductor.  
Communication Requirements  
The PV100S can accommodate any one of the following options for PC  
Communication:  
•
POTS Connect Kit - uses a MultiTech® 56K Modem, RS232/Fiber Optic  
Converter (configured for ethernet) and SA2 Surge Arrestor. A direct analog  
phone line to the local phone service is required to use this feature. The phone  
line used for PV100S communication cannot be routed through a Private  
Branch Exchange (PBX) unless an analog PBX card is used.  
•
•
Wireless Connect - uses a GSM Wireless Modem.  
Ethernet LAN Connect - uses a data communication device to enable the  
unit to connect to a local area network.  
•
Direct Connect Kit - uses a RS232/Fiber Optic Converter (configured for a  
PC), a DB25-to-DB25 gender changer, and a DB25-to-DB9 Serial Cable.  
Determine which communications options are required for the installation and  
procure the appropriate service or phone access. The personal computer to be used  
with this unit must have the appropriate hardware as well, such as a 56K modem  
for dial up connection or a Network Interface Card (NIC) for a LAN connection.  
Utility Side Isolation Transformer Requirements  
The PV100S is supplied with a custom, high-efficiency, isolation transformer as  
part of the AC interface/transformer assembly. The utility side windings of the  
isolation transformer are configured Wye and must match the voltage at the utility  
inter-tie. The PV100S is a balanced, three-phase, current-sourcing inverter and  
only operates with the presence of a stable utility voltage. The transformer is also  
supplied with a neutral connection on the utility interconnect. Connection of this  
2–4  
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Electrical Diagrams and Schematics  
utility-side neutral does not affect the operation of the inverter, however  
connection of the neutral on the inverter-side does affect the operation and must  
be left floating or disconnected. Single-phase, grounded loads which may be  
present between the transformer and utility, will maintain their existing ground  
reference at the utility distribution transformer.  
CAUTION: Equipment Damage  
If the Isolation Transformer (T6-X0) neutral terminal is tied to ground, it will cause  
irreparable damage to the PV100S. Check local regulations for their requirements  
regarding the connection of these neutrals.  
WARNING: Lethal Voltage  
Grounding the neutral of a Wye-wound transformer may create an “open delta” condition,  
depending on the utility configuration. This condition may keep the PV100S from  
detecting a loss of phase condition on the utility system, which may allow potentially  
lethal voltage to be present on the open-phase wiring.  
Electrical Diagrams and Schematics  
Since installations vary widely, a sample electrical diagram of the PV100S is  
provided in Figure A-1 on page A–3. This diagram is to be used for system  
planning purposes only.  
For more detailed information, refer to the schematic illustrations for  
model-specific electrical schematics.  
Model PV100S-480:  
•
•
•
Figure A-2, “PV100S-480 Schematic for Main Power  
Distribution (152316 E1)” on page A–4  
Figure A-3, “PV100S-480 Schematic for Control Power  
Distribution (152316 E2)” on page A–5  
Figure A-4, “PV100S-480 Schematic for Converter Control  
Unit (152316 E3)” on page A–6  
Model PV100S-208:  
•
•
•
Figure A-5, “PV100S-208 Schematic Main Power Distribution (152376 C1)”  
on page A–7  
Figure A-6, “PV100S-208 Schematic for Control Power  
Distribution (152376 C2)” on page A–8  
Figure A-7, “PV100S-208 Schematic for Converter Control  
Unit (152376 C3)” on page A–9  
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Planning  
Layout Options  
The PV100S is shipped as two separate assemblies and can be arranged as shown  
in Figure 2-1 or Figure 2-2.  
The PV100S can be arranged in a number of different system layout options to fit  
specific site requirements. The AC interface/transformer assembly may be  
co-located adjacent to the left side of (or behind) the Main Inverter Enclosure up  
to, and not exceeding, 15 feet away.  
Given the flexibility to co-locate the AC interface/transformer assembly to fit a  
desired system layout, the interconnect AC power conductors and conduit  
between the Main Inverter Enclosure and the AC interface/transformer assembly  
are to be supplied by the installer. See Figure 2-1 and Figure 2-2, depicting two  
options for locating the AC interface/transformer assembly adjacent to the main  
inverter.  
Minimum Dimension of Base:  
Approximately 12 ft. by 6 ft. (3.6 m x 1.8 m)  
12' (3.6 m)  
BASE: Concrete Floor or Pad  
Approximately 12 ft by 6 ft  
(3.6 m x 1.8 m)  
Communications  
Enclosure  
12"  
Minimum  
Clearance  
6'  
(1.8 m)  
6" Minimum Clearance  
DC Interface  
Enclosure  
AC  
Interface  
Enclosure  
12"  
Minimum  
Clearance  
Transformer  
Enclosure  
36"  
Minimum  
Clearance  
Conduit  
12"  
36"  
Minimum  
Clearance  
Inverter  
Enclosure  
Minimum  
Clearance*  
(15' Max. Distance  
from Inverter)  
36"  
Minimum  
36"  
Minimum  
Clearance  
Clearance  
Figure 2-1 PV100S Layout Option A  
2–6  
152315 Rev C  
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Layout Options  
Minimum Dimension of Base:  
Approximately 9 ft by 7 ft (2.7 m x 2.1 m)  
36"  
Minimum  
Clearance  
BASE: Concrete Floor or Pad  
Approximately 9 ft by 7 ft  
(2.1 m x 2.7 m)  
9 ft  
(2.7 m)  
12"  
Minimum  
Clearance  
36"  
Minimum  
Clearance  
AC  
Transformer  
Enclosure  
Interface  
Enclosure  
Conduit  
(not to exceed 15')  
12"  
Minimum  
Clearance  
Communications  
Enclosure  
DC Interface  
Enclosure  
12"  
Minimum  
Clearance  
36"  
Minimum  
Clearance  
12"  
Minimum  
Clearance  
Inverter  
Enclosure  
36"  
Minimum  
Clearance  
7 ft (2.1 m)  
Figure 2-2 PV100S Layout Option B  
152315 Rev C  
2–7  
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Planning  
Conduit Penetration  
The following illustrations show the recommended locations for electrical conduit  
entry into the PV100S enclosures. These drawings are to be used for system  
planning purposes, such that the shaded areas are representative of the maximum  
allowable area and location in which electrical conduit may penetrate the  
enclosures of the PV100S, see Figure 2-3 through Figure 2-8. Xantrex  
recommends a standard trade-size conduit knock-out set for cutting/punching the  
PV100S enclosures and panels for conduit entry.  
Communications  
Enclosure  
E
Inverter  
DC Interface  
Enclosure  
AC Interface  
Enclosure  
Enclosure  
AC  
Interface  
Enclosure  
Transformer  
Enclosure  
AC  
D
Inductor  
B
Enclosure  
C
A
AC side view  
of PV100S  
Front view of PV100S  
Figure 2-4 on page 2–9  
A
B
C
Figure 2-5 on page 2–9  
Figure 2-6 on page 2–10  
D Figure 2-7 on page 2–10  
E
Figure 2-8 on page 2–10  
Figure 2-3 Conduit Entry Figure Reference  
2–8  
152315 Rev C  
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Conduit Penetration  
6" (15 cm)  
2" (5 cm)  
12" (30 cm)  
6" (15 cm)  
6"  
Figure 2-4 Inductor Enclosure Conduit Entry, Left Side  
2" (5 cm)  
6" (15 cm)  
12" (30 cm)  
6" (15 cm)  
Figure 2-5 Transformer Enclosure Conduit Entry, Right Side  
152315 Rev C  
2–9  
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Planning  
Backside of  
Transformer  
Enclosure  
AC Disconnect Switch (S1)  
(partial view)  
1" (2.5 cm)  
8" (20 cm)  
5" (13 cm)  
Figure 2-6 AC Interface Enclosure Conduit Entry, Left Side  
8"  
(20 cm)  
2" (5 cm)  
8" (20 cm)  
2" (5 cm)  
Figure 2-7 DC Interface Enclosure, Bottom Side  
3" (8 cm)  
1" (2.5 cm)  
10.5" (27 cm)  
1" (2.5 cm)  
Figure 2-8 Communications Enclosure Conduit Entry, Bottom Side  
2–10  
152315 Rev C  
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Conductor and Conduit Sizing  
Conductor and Conduit Sizing  
All wiring methods and materials shall be in accordance with the National  
Electrical Code ANSI/NFPA 70. When sizing conductors and conduits interfacing  
to the PV100S, both shall be in accordance with the National Electric Code  
ANSI/NFPA 70, as well as all state and local code requirements.  
Large gauge wire must conform to the minimum bend radius dependent upon the  
wire gauge (refer to the National Electric Code, Article 373-6B (Ninth Edition).  
CAUTION: Equipment Damage  
Be careful to keep the wire bundles away from any sharp edges which may damage wire  
insulation over time.  
The following provides information on sizing the conductors and conduits for the  
system.  
To calculate the proper conduit size:  
1. Determine the required cable ampacity.  
2. Determine the conduit length between the inverter and the transformer.  
3. Determine the proper size for the cable according to the allowable ampacities  
indicated by NEC Table 310.16 (Ninth Edition).  
4. Determine the proper size for the conduit.  
The following is an example of the steps outlined above. Assumptions were made  
in this example which may not match your application, and the resulting design  
may not comply with all code requirements. Consult a licensed electrician on  
recommendations for specific installations.  
Step 1. Determine the required cable ampacity.  
AC Phase Cables from Inverter to Transformer:  
100 kW / 208 Vac / 1.732 = 277.5 Arms (full load current)  
277.5 x 125% = 347 A (required ampacity)  
Step 2. Determine the conduit length between inverter and transformer.  
•
If the conduit length between the inverter and the transformer is less than  
24 inches, then the cable can be sized using the NEC Table 310.16  
(in Raceway) (Ninth Edition).  
•
If the conduit length is greater than 24 inches, then the cable must be sized  
using NEC Table 310.16 (in Raceway) (Ninth Edition) and by using the  
adjustment factors in NEC TAble 310-15(b)(2)(a).  
152315 Rev C  
2–11  
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Planning  
Step 3. Size the cable.  
This example assumes that the conduit length is less than 24 inches. NEC  
Table 310.16 (Ninth Edition) indicates the Temperature Correction Factor for  
90 °C THHN cable in a 50 °C ambient is 0.82. With a required ampacity from  
Step 1 above of 347 amps, it can be calculated that the required cable ampacity at  
50 °C in this application is 423 amps. (347 divided by 0.82)  
In this example, two cables per phase termination are used, so from NEC  
Table 310.16 (Ninth Edition) it is apparent that the 90 °C THHN cable must be  
3/0 AWG or larger. Two each 3/0 AWG conductors at 50°C have an allowable  
ampacity of 450 amps (225 multiplied by 2).  
Step 4. Size the conduit.  
In this step, the cross sectional area of all the individual cables is first calculated.  
Once calculated, the total cross sectional area of the cables is determined by  
summing their values. In this example, 3/0 AWG, 2000 V cable is selected for the  
AC Phase connections:  
DLO 3/0 AWG Cable:  
3/0 AWG DLO, 2000V, 90 °C per Phase  
3/0 AWG has an O.D. of 0.789  
0.789 x 0.789 x 6 x 0.7854 = 2.93 in²  
Ground Cable:  
1 Each #2 AWG (per NEC Table 250.122(Ninth Edition),  
using 400 A Breaker)  
#2 AWG has an O.D. of 0.384 for THHN and 0.565 for DLO  
0.565 x 0.565 x 0.7854 = 0.250 in²  
Sense/Control Wires:  
8 Each #16 AWG, UL1015, THHN, Hook-up Wire  
#16 AWG has an O.D. of 0.096  
0.096 x 0.096 x 8 x 0.7854 = 0.058 in²  
Total:  
2.93 + 0.250 + 0.058 = 3.238 in²  
Using the "Over 2 Wires" column per NEC Chapter 9, Table 4, (Ninth Edition)  
indicates that the following minimum permitted conduit trade size is acceptable  
for the 15 wires in this exercise:  
EMT = 3" Trade size  
IMC = 3.5" Trade size  
RMC = 3.5" Trade size  
2–12  
152315 Rev C  
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Anchoring the PV100S  
Anchoring the PV100S  
The PV100S is designed to be installed in either an indoor or outdoor location. It  
must be placed on and anchored to a level concrete floor or pad. The concrete  
floor or pad, upon which the PV100S is anchored, must be structurally designed to  
meet any local, state, or national requirements for weight, seismic, and wind sheer  
if applicable.  
Four 5/8" holes are provided in the feet of the main inverter, and six 5/8" holes are  
provided in the feet of the AC interface/transformer assembly for anchoring to the  
floor or pad.  
Figure 2-9 and Figure 2-10 depict the layout patterns of the anchoring holes for  
both the PV100S main inverter and the AC interface/transformer assembly.  
5/8"  
(1.5 cm)  
29" (73.7 cm)  
(x4)  
16 ¼"  
(40.6 cm)  
Figure 2-9 Main Inverter Anchor Bolt Pattern (Not to scale)  
152315 Rev C  
2–13  
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Planning  
29"  
(73.7 cm)  
17 ½"  
(44 cm)  
25"  
(63.5 cm)  
¾" (1.9 cm)  
(x6)  
Figure 2-10 AC Interface/Transformer Anchor Bolt Pattern (Not to Scale)  
The floor or pad should either be pre-drilled to accept masonry anchors or have  
pre-installed anchoring bolts.  
2–14  
152315 Rev C  
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Installation  
3
Chapter 3, “Installation” describes the procedures needed to install  
the PV100S 100 kW Grid-Tied Photovoltaic Inverter. This section  
includes unpacking and moving instructions, mounting instructions,  
and cabling instructions.  
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Installation  
Equipment Required  
The following is a list of required tools and equipment to aid in the installation of  
the PV100S. This list is not a comprehensive list, but is intended to help identify  
the minimum recommended tools and equipment used during the installation.  
•
•
•
•
Forklift (26" minimum fork span) and/or pallet jack  
Claw hammer or pry bar  
Standard and metric socket set  
Standard and metric wrench set  
•
•
•
•
•
•
•
•
Standard Allen® Hex wrenches (5/16 and 7/16)  
Large slip-joint pliers  
Standard and Phillips screwdrivers  
Torque wrench with 0 - 600 in-lbs minimum range  
Appropriate voltage meter (600 Vac and DC rated, minimum)  
Phase rotation meter (600 Vac rated, minimum)  
Hammer drill and masonry bits  
Trade-size conduit knock-out set  
Unloading  
The PV100S is shipped partially assembled in two separate shipping crates and  
one cardboard box.  
❐ One crate is the main inverter and is marked "1-152311-01".  
❐ The other crate is the AC Interface Enclosure and transformer assembly and is  
marked "1-152378-01" (208 Vac) or "1-152324-01" (480 Vac).  
❐ The cardboard box contains one of the three remote connection kits:  
•
•
•
POTS Connection 1-152674-01,  
Wireless Connection 1-152659-01, or  
Ethernet Connection 1-152658-01.  
WARNING: Heavy Equipment  
The main inverter weighs approximately 1000 lbs. Both versions (208 Vac and 480 Vac)  
of the AC Interface Enclosure and transformer assembly weigh approximately 1400 lbs.  
Attempting to lift the equipment by other than the recommended lifting points may  
damage the equipment or present a personnel safety hazard and void the warranty. Keep  
all the doors closed and latched when moving the enclosures. Leaving the door latches  
unsecured may result in damage to the unit and void the warranty.  
3–2  
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Unloading  
Moving the PV100S  
CAUTION: Equipment Damage  
To move the PV100S, use a forklift that has a sufficient lift capacity and has a 26" fork  
span.  
c
To move the PV100S while it is still inside the shipping crates:  
1. Place the forks of the forklift below the shipping crate at the points specified  
on the shipping crate.  
2. Lift the main inverter and the AC Interface Enclosure and Transformer  
Enclosure from beneath their shipping crates.  
Figure 3-1 Moving the crated PV100S  
Unpacking the PV100S  
To unpack the main inverter and the AC Interface Enclosure and  
transformer assembly from their shipping crates:  
1. Using a claw hammer or pry bar, remove the crate’s wood top and side panels.  
2. Remove the main inverter’s anchor hardware that attaches it to the shipping  
pallet.  
3. Remove the AC Interface Enclosure and transformer assembly anchor  
hardware that attaches them to their shipping pallet.  
152315 Rev C  
3–3  
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Installation  
Removing the Pallet and Moving the PV100S  
CAUTION: Equipment Damage  
To move the PV100S, use a forklift that has a sufficient lift capacity and a 26" fork span.  
c
To move the PV100S using a forklift:  
1. Place the forks of the forklift below the unit at the points specified in  
Figure 3-2.  
2. Lift the PV100S from beneath the respective enclosures.  
Be sure to use a forklift with a 26" fork span.  
3. Remove the pallet from beneath the unit.  
4. Once the pallets are removed from the units, use the same lifting locations to  
lift the units into the place where they are to be permanently located.  
Communications  
Enclosure  
7
4
8
5
2
9
6
3
F1  
F2  
F3  
F4  
^
^
1
MEN  
U
.
0
-
ENTE  
R
P
V
D
IS  
C
ON  
N
EC  
T
0
I
Inverter  
Enclosure  
DC Interface  
Enclosure  
AC  
Interface  
Enclosure  
Transformer  
Enclosure  
Inductor  
Enclosure  
Lift Here  
26" (66 cm)  
fork span  
Lift Here  
26" (66 cm)  
fork span  
Figure 3-2 Forklift Lifting Locations - Underneath Unit  
3–4  
152315 Rev C  
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Mounting and Anchoring the Units  
Important: Before proceeding with the installation, determine the location and layout  
of the components, conduit penetration locations, conductor and conduit sizing, and  
method for anchoring the unit. Ensure adequate space is provided for clearance for  
ventilation and serviceability. Review Chapter 2, “Planning” if necessary before  
proceeding.  
Mounting and Anchoring the Units  
To mount and anchor the PV100S:  
1. Predrill the floor or pad to accept 1/2" diameter masonry anchors or ensure it  
has pre-installed anchoring bolts that will fit the 5/8" mounting holes.  
2. Lift the main inverter from beneath the lower enclosure with a forklift or  
pallet jack as shown in Figure 3-2 on page 3–4. Move the Main Inverter  
Enclosure into place.  
3. Lift the AC interface/transformer assembly from beneath the enclosure with a  
forklift or pallet jack as shown in Figure 3-2 on page 3–4. Move the AC  
interface/transformer assembly into place.  
4. Secure the Main Inverter Enclosure feet to the floor with a 1/2" diameter  
anchor bolts.  
5. Secure the AC interface/transformer assembly enclosure feet to the floor with  
1/2" diameter anchor bolts.  
Mounting Holes for  
securing and anchoring  
the units.  
Figure 3-3 Mounting Hole Locations  
152315 Rev C  
3–5  
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Installation  
Opening or Closing Access Doors  
To lock or unlock the front door on the main inverter:  
1. Use the 7 mm triangle key provided with the unit.  
a) Insert the key in the lock and turn counterclockwise to open;  
clockwise to lock.  
b) Pull front door open from the right side.  
Main Inverter Front Door Lock  
Main Inverter Front Door Lock  
Figure 3-4 Inverter Enclosure Access Doors  
3–6  
152315 Rev C  
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Opening or Closing Access Doors  
To Open Access Door:  
1. Confirm that the AC Disconnect Switch  
handle is placed in the OFF (Open)  
position prior to opening the door.  
2. Loosen the bolts on door latches and  
slide away from the door.  
3. Pull open from right side.  
Door Latches  
To Close Access Door:  
1. Confirm that the AC Disconnect Switch  
handle is placed in the OFF (Open)  
position prior to closing the door.  
2. Close the door and slide the latches  
back over the edge of the door.  
3. Tighten the bolts on door latches.  
Figure 3-5 AC Interface Access Door  
To Open Access Door:  
1. Confirm that the DC Disconnect Switch  
handle is placed in the OFF (Open)  
position prior to opening the door.  
2. Loosen the bolts on door latches and  
slide away from the door.  
3. Pull open from the left side.  
To Close Access Door:  
1. Confirm that the DC Disconnect Switch  
handle is placed in the OFF (Open)  
position prior to closing the door.  
2. Close the door and slide the latches  
back over the edge of the door.  
3. Tighten the bolts on door latches.  
Door Latches  
Figure 3-6 DC Interface Access Door  
152315 Rev C  
3–7  
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Installation  
Transformer Access Panel  
To Remove the Access Panel:  
Loosen and remove the 1/4"  
self-tapping sheet metal screws  
(x6).  
To Replace the Access Panel:  
Replace and tighten the 1/4"  
self-tapping sheet metal screws.  
Figure 3-7 Transformer Access Panels  
Inductor Access Panel  
To Remove the Access Panel:  
Use a Phillips screwdriver to loosen  
and remove the 1/4-20 Phillips  
round-head bolts (x8).  
To Replace the Access Panel:  
Replace and tighten the 1/4-20  
Phillips round-head bolts.  
Figure 3-8 Inductor Access Panels  
3–8  
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Conduit Installation  
Conduit Installation  
Given the flexible nature of the system, conduit installation will be dependent  
upon the final configuration of the system. Procurement and installation of the  
conduit, therefore, is the responsibility of the installer. Since the layout will be  
dependent upon the location available for the installation and the size of the  
conductors used, specific conduit size and type must be pre-determined by the  
installer before the actual installation. See “Conductor and Conduit Sizing” on  
page 2–11 for instructions on how to determine the size of the conductors and  
conduits to be used. Once the size of the conductors and conduits has been  
determined, follow the instructions below for installing the conduits. Be sure to  
consult the NEC Handbook and any local codes to ensure code compliance.  
Important: Outdoor installations require that all conduit fittings interfacing with the  
PV100S be NEMA 4 rated.  
To install the conduits:  
1. Determine the conduit penetration locations in the Main Inverter Enclosure  
and the AC interface/transformer assembly. See Figure 2-3 on page 2–8  
through Figure 2-5 on page 2–9.  
2. Install appropriately sized conduit based upon system layout and required  
codes between the main inverter and the AC interface/transformer assembly.  
For ease of conduit installation, the access panels on both the main inverter  
and the AC interface/transformer assembly can be removed.  
3. Determine all remaining conduit penetration locations in the AC Interface  
enclosure, DC Interface Enclosure, and Communication Enclosure. See  
Figure 2-3 on page 2–8 through Figure 2-8 on page 2–10.  
4. Install all remaining appropriately sized conduit interfacing for the AC  
Interface Enclosure, DC Interface Enclosure, and Communication Enclosure  
based upon system layout and required codes.  
Conduit  
Figure 3-9 Conduit Installation  
152315 Rev C  
3–9  
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Installation  
Wiring - General  
All wiring methods and materials shall be in accordance with the National  
Electrical Code ANSI/NFPA 70. When sizing conductors and conduits interfacing  
to the PV100S, both shall be in accordance with the National Electric Code  
ANSI/NFPA 70, as well as all state and local code requirements.  
WARNING: Shock Hazard  
The PV100S enclosures contain exposed high-voltage conductors. The enclosure doors  
should remain closed with the latches tightened, except during installation, maintenance  
or testing. These servicing instructions are for use by qualified personnel who meet all  
local and state code requirements for licensing and training for the installation of  
Electrical Power Systems with AC and DC voltage to 600 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 PV100S, 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 PV100S. Review the  
system configuration to determine all of the possible sources of energy. In addition, allow  
5 minutes for the DC bus capacitors, located on the ceiling of the cabinet, to discharge  
after removing power.  
CAUTION: Equipment Damage  
When connecting external AC wires to the PV100S, positive phasing sequence must be  
maintained throughout the installation process. Refer to the system schematics in  
Appendix A of this manual for proper phasing convention.  
Important: Take care to keep the wire bundles away from any sharp edges which may  
damage wire insulation over time. Consult the NEC ANSI/NFPA 70 Code Book to ensure  
code compliance.  
The model PV100S has a three-phase output. It is marked with this symbol:  
Conductor size should have been pre-determined when the conduit was installed.  
Prepare the appropriate length conductors for each connection.  
3–10  
152315 Rev C  
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Wiring - General  
Overcurrent Protection  
AC overcurrent protection for the Utility Interconnect (Grid-tie) must be provided  
by the installer as part of the PV100S installation.  
CAUTION: Equipment Damage  
In accordance with the NEC, ANSI/NFPA 70 (Ninth Edition) the following branch-circuit  
overcurrent protection must be provided:  
•
•
400A maximum for PV100S-208  
200A maximum for PV100S-480  
Conductor Termination  
The PV100S has terminals and bus bars for making all wiring connections  
required for the installation. All terminals used for making AC and DC  
connections require the use of copper conductors with an insulation rating of  
90 °C (or higher). For wire gauge, bolt size, and torque values for the AC  
terminals, see Table 3-1. For wire gauge, bolt size, and torque values for the DC  
terminals, see Table 3-2.  
Transformer  
Enclosure  
The AC terminals in the Transformer Enclosure (T6-X1, T6-X2, and T6-X3)  
require the use of crimp-on type ring terminals or compression lugs. The terminals  
are one bolt per pole.  
See Figure 3-14 on page 3–15 for the location of these terminals.  
Main Inverter  
Enclosure  
The AC terminals in the Main Inverter Enclosure (TB4-A, TB4-B, and TB4-C)  
have two openings per pole. These terminals do not require the use of crimp-on  
type ring terminals or compression lugs.  
See Figure 3-15 on page 3–16 for the location of these terminals.  
AC Interface  
Enclosure  
The AC line terminals in the AC Interface Enclosure (S1-2T1, S1-4T2, and  
S1-6T3) are one bolt per pole. These terminals require the use of crimp-on type  
ring terminals or compression lugs.  
See Figure 3-16 on page 3–16 for the location of these terminals.  
The AC neutral terminal in the AC Interface Enclosure (TB6) has one bolt per  
pole and requires the use of crimp-on type ring terminals or compression lugs.  
See Figure 3-18 on page 3–18 for the location of this terminal.  
DC Interface  
Enclosure  
The DC terminals in the DC Interface Enclosure (TB3-1, TB3-2, and TB3-3)  
have two openings per pole. These terminals do not require the use of crimp-on  
type ring terminals or compression lugs.  
See Figure 3-19 on page 3–19 for the location of these terminals.  
Important: Keep these cables together as much as possible, and ensure that all cables  
pass through the same knockout and conduit fittings, thus allowing any inductive currents  
to cancel.  
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Installation  
Wire Gauge and Torque Requirements  
Table 3-1 provides acceptable wire gauges, bolt sizes, and torque values for AC  
terminal connections.  
Table 3-1 AC Terminal Wire Gauge, Bolt Size, and Torque Values  
Bolt (Hardware) Size  
Torque Requirements  
AC Terminal  
Connections  
Acceptable Wire Size  
Range (both models) PV100S-208 PV100S-480 PV100S-208 PV100S-480  
TB1  
(Chassis Ground)  
500MCM to #4 AWG  
(1 stud per pole)  
3/8-16  
3/8-16  
3/8-16  
3/8-16  
3/8-16  
3/8-16  
420 in-lb  
(47.5 Nm)  
420 in-lb  
(47.5 Nm)  
TB2  
(System Ground)  
500MCM to #4 AWG  
(1 stud per pole)  
420 in-lb  
(47.5 Nm)  
420 in-lb  
(47.5 Nm)  
TB6 (Neutral)  
500MCM to #4 AWG  
(1 stud per pole)  
228 in-lb  
(25.7 Nm)  
228 in-lb  
(25.7 Nm)  
S1-2T1, S1-4T2,  
S1-6T3  
350MCM to #6 AWG M10 (See Caution M8 (See Caution  
310 in-lb  
(35.0 Nm)  
115 in-lb  
(13.0 Nm)  
on page 3–17)  
on page 3–17)  
(1 stud per pole)  
T6-X1, T6-X2,  
T6-X3  
350MCM to #6 AWG  
(1 stud per pole)  
3/8-16  
3/8-16  
420 in-lb  
(47.5 Nm)  
420 in-lb  
(47.5 Nm)  
TB4-A, TB4-B,  
TB4-C  
350MCM to #4 AWG  
(2 openings per pole)  
5/16 Hex  
5/16 Hex  
275 in-lb  
(31 Nm)  
275 in-lb  
(31 Nm)  
Table 3-2 provides acceptable wire gauges, bolt sizes, and torque values to be  
connected to the PV100S DC terminal connections.  
Table 3-2 DC Terminal Wire Gauge, Bolt Size, and Torque Values  
Bolt (Hardware) Size  
Torque Requirements  
DC Terminal  
Connections  
Acceptable Wire Size  
Range (both models) PV100S-208 PV100S-480 PV100S-208 PV100S-480  
TB3-1, TB3-2,  
TB3-3  
500MCM to #4 AWG  
(2 openings per pole)  
7/16 Hex  
7/16 Hex  
500 in-lb  
(56.5 Nm)  
500 in-lb  
(56.5 Nm)  
Grounding  
System Grounding  
Install a copper ground rod within three feet of the PV100S enclosures per the  
National Electric Code ANSI/NFPA 70. The single-point ground for the system is  
to be made at the AC ground bar (TB2) in the AC Interface Enclosure.  
AC Ground Bar  
(TB2) to be used  
for the Single Point  
Ground  
AC Interface Enclosure  
Figure 3-10 Single-point Ground (TB2) Ground Bar  
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Wiring - General  
Chassis Ground  
The chassis ground is a copper bus bar in the Main Inverter Enclosure and has  
3/8-16" bolts for terminating the AC ground. The ground conductor size depends  
on the size of the main circuit breaker.  
NEC Table 250.122 (Ninth Edition) requires that the ground conductor be at least  
#3 AWG for a 400 A circuit breaker and #6 AWG for a 200 A circuit breaker.  
Torque connections to ground bar in the Main Inverter Enclosure as follows:  
•
•
PV100S-208 - 420 in-lbs (47.5 Nm)  
PV100S-480 - 420 in-lbs (47.5 Nm)  
The equipment ground on the PV100S is marked with this symbol:  
AC Ground Bar  
(TB1) to be used  
for the Chassis  
Ground  
Main Inverter Enclosure  
Figure 3-11 Chassis Ground Bar (TB1)  
Array Grounding  
NEC Article 690-41/42 (Ninth Edition) requires the PV array to be earth  
grounded. The PV100S chassis is also bonded to the PV safety ground terminal  
block.  
System Neutral Requirements  
The PV100S is designed to be installed as a 4-wire system. As required by the  
UL 1741 listing, a neutral conductor from the utility-interconnect must be  
terminated at TB6 within the AC Interface Enclosure to ensure that the AC  
voltage sensing circuit can perform an individual phase voltage (line-to-neutral)  
measurement. The function of the neutral connection is to provide a point of  
reference for measurement purposes that is essentially at ground potential. No  
power will flow through the neutral conductor.  
Utility Side Isolation Transformer Requirements  
The PV100S is supplied with a custom, high-efficiency, isolation transformer as  
part of the AC interface/transformer assembly. The utility side windings of the  
isolation transformer are configured Wye and must match the voltage at the utility  
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Installation  
inter-tie. The PV100S is a balanced, three-phase, current-sourcing inverter and  
only operates with the presence of a stable utility voltage. The transformer is also  
supplied with a neutral connection on the utility interconnect. Connection of this  
utility-side neutral does not affect the operation of the inverter, however  
connection of the neutral on the inverter-side does affect the operation and must  
be left floating or disconnected. Single-phase, grounded loads, which may be  
present between the transformer and utility, will maintain their existing ground  
reference at the utility distribution transformer.  
CAUTION: Equipment Damage  
If the Isolation Transformer (T6-X0) neutral terminal is tied to ground, it will cause  
irreparable damage to the PV100S. Check local regulations for their requirements  
regarding the connection of these neutrals.  
WARNING: Lethal Voltage  
Grounding the neutral of a Wye-wound transformer may create an “open delta” condition,  
depending on the utility configuration. This condition may keep the PV100S from  
detecting a loss of phase condition on the utility system, which may allow potentially  
lethal voltage to be present on the open phase wiring.  
Wiring - Specific  
This section provides information for connecting the AC and DC conductors,  
ground conductors, and AC Sense Harness.  
AC Connections  
To connect the main inverter to AC interface/transformer assembly:  
1. Remove the access panels from the front of both the Main Inverter Enclosure  
and the Transformer Enclosure. Additionally, open the front door to the Main  
Inverter Enclosure.  
2. Route the AC power conductors A, B, C phase cables and ground conductor  
through the conduit between the main inverter to the AC interface/transformer  
assembly (T6).  
Route the AC cables from the Inverter  
Enclosure through the conduit to the  
Transformer Enclosure.  
Inductor Enclosure  
AC Sense Harness (partially  
hidden below AC Cables)  
Transformer Enclosure  
Figure 3-12 Route AC Cables through the Conduit  
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Wiring - Specific  
3. In addition to the power conductors, route the AC Sense Harness assembly  
(Xantrex P/N 1-152403-01) between the main inverter to the AC  
interface/transformer assembly. Prior to completing the installation of the AC  
Sense Harness, secure the harness to the AC power conductors with nylon  
tie-wraps so it does not touch the surfaces of the L1 inductor. Failure to secure  
the AC Sense Harness away from these surfaces may cause deformation of  
the harness insulation and possibly damage due to the excessive heat  
generated by the L1 inductor.  
Prior to completing the installation  
of the AC Sense Harness, secure  
the harness to the AC power  
conductors with nylon tie-wraps.  
Figure 3-13 Tie-wraps on the AC Sense Harness  
4. Connect the AC power conductors in the Transformer Enclosure at the T6-X1  
(A phase), T6-X2 (B phase), and T6-X3 (C phase) bus bars using  
3/8-16" hardware. Connect the ground conductor in the AC  
Interface/Transformer Enclosure at TB2. Cables to these terminals must use a  
crimp-on type ring terminal or compression-type lug. Tighten these  
connections to a torque value of 420 in-lbs (47.5 Nm).  
Ground Cable from  
T6-X2  
T6-X1  
T6-X3  
Main Inverter  
Enclosure  
TB2 Ground Bar  
AC Interface Enclosure  
Transformer Enclosure  
Figure 3-14 AC Terminal Connections in the AC Interface/Transformer Enclosure  
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Installation  
5. Connect the AC power conductors in the Main Inverter Enclosure at TB4-A  
(A phase), TB4-B (B phase), and TB4-C (C phase) with a box connector  
using a 5/16" Hex screw. This hardware should be tightened to a torque value  
of 275 in-lb (31 Nm). Connect the ground conductor to the TB1 terminal on  
the ground bar on the left side of the enclosure. Torque this connection to  
420 in-lbs (47.5 Nm).  
TB4-A  
TB4-B  
TB4-C  
TB1 Ground Bar  
Figure 3-15 AC Terminal Connections in the Main Inverter Enclosure  
Enlargement of  
Terminal Connectors  
in the AC Interface  
Enclosure  
S1-6T3  
(C phase)  
S1-2T1  
AC Interface Enclosure  
(A phase)  
S1-4T2  
(B phase)  
Figure 3-16 AC Terminal Connections in the AC Interface Enclosure  
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Wiring - Specific  
6. The AC Sense Harness is pre-terminated within the AC interface/transformer  
assembly and the opposite end is mated with its 9-pin plug to the  
corresponding 9-pin jack within the Main Inverter Enclosure. See Figure  
3-17.  
Figure 3-17 Connecting the AC Sense Harness  
7. Replace the access panels on the front of both the main inverter Inductor  
Enclosure and the Transformer Enclosure. Additionally, close the front door  
to the Main Inverter Enclosure.  
To connect the utility service to AC Interface Enclosure:  
1. Remove the door clamps and open the door to the AC Interface Enclosure.  
2. Route the AC power conductors A, B, C phase, neutral, and a neutral ground  
cable through the conduit from the utility service to the AC Interface  
Enclosure. See Figure 3-18 for the location of these terminals.  
3. Connect the AC power conductors at the S1-2T1 (A phase), S1-4T2  
(B phase), and S1-6T3 (C phase) terminals using the M8 (PV100S-480) or  
M10 (PV100S-208) hardware. Cables to these terminals must use a crimp-on  
type ring terminal or compression-type lug. Torque these connections to  
115 in-lbs (13.0 Nm) for the M8 (PV100S-480), and 310 in-lbs (35.0 Nm) for  
the M10 (PV100S-208). See Figure 3-18 for the location of these terminals.  
CAUTION: Equipment Damage  
The termination points of the AC power conductors at S1 include a captive nut and plastic  
insulator between the terminals and the panel. Ensure the length of the connection  
hardware used to attach the AC power conductors at S1-2T1, S1- 4T2, S1-6T3, does not  
bottom out to the plastic insulator. The depth of the hole at terminals of S1 is ½" from top  
of the tab. Failure to observe this may result in failure of the plastic insulator and may  
cause a direct short to ground.  
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Installation  
4. Connect the neutral conductor at TB6. Connect the ground conductor at TB2.  
Terminations for the neutral and ground conductors within the AC Interface  
Enclosure at the TB6 and TB2 locations are made with 3/8-16" hardware.  
Cables to these terminals must use a crimp-on type ring terminal or  
compression-type lug and should be tightened to a torque value of 228 in-lbs  
(25.7 Nm) for TB6, and 420 in-lbs (47.5 Nm) for TB2 for both the  
PV100S-480 and PV100S-208 systems. See Figure 3-18 for the location of  
these terminals.  
5. Close the door to the AC Interface Enclosure and replace the door clamps.  
S1-6T3  
S1-2T1  
(C Phase terminal)  
(A Phase terminal)  
S1-4T2  
(B Phase terminal)  
TB6 Neutral  
Conduit entry  
from utility  
Ground TB2  
Note: PV100S-208 shown in this photo.  
Figure 3-18 AC Terminal Connections from the Utility  
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Wiring - Specific  
PV Array Connections  
To make the connections from the PV Array/combiner to DC Interface  
enclosure:  
1. Remove the door clamps and open the door to the DC Interface Enclosure.  
2. Route the PV Array cables conductors POSitive (PV+), NEGative (PV-), and  
PV GND through the conduit to the DC Interface Enclosure, entering on the  
underside.  
3. The DC power conductor terminations are made at the TB3-1 (POS/DC+),  
and TB3-2 (NEG/DC-) and TB3-3 (PV Gnd) locations. See Figure 3-19.  
4. Terminations for the POSitive, NEGative, and GND conductors within the  
DC Interface enclosure at the TB3 locations are made with box connector  
using a 7/16" Hex Allen screw. The hardware should be tightened to a torque  
value of 500 in-lbs. (56.5 Nm) for both the PV100S-480 and PV100S-208  
systems.  
5. Close the door to the DC Interface Enclosure and replace the door clamps.  
GrouND (TB3-3)  
PV NEGative Cable (TB3-2)  
PV POSitive Cable (TB3-1)  
Conduit entry from PV Array  
Figure 3-19 PV Array Cable Routing and Terminations  
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Installation  
PC Communications  
Personal computers can be used to access the system status and programming  
features of the PV100S. A computer can be connected either directly or remotely.  
1. Remote Connect - uses one of the three kits below.  
•
POTS Kit - uses a MultiTech® 56K Modem, RS232/Fiber Optic  
Converter (configured for ethernet) and SA2 Surge Arrestor and requires  
access to a local analog phone line (Plain Old Telephone Service-POTS).  
•
•
Wireless Kit - uses a GSM Wireless Modem to access wireless phone  
service.  
Ethernet LAN Kit - uses a data communication device to enable the unit  
to connect to a local area network.  
2. Direct Connect - This method is used for troubleshooting. It uses a  
RS232/Fiber Optic Converter (configured for a PC), a DB25-to-DB25 gender  
changer, and a DB25-to-DB9 Serial Cable.  
Software is included to provide a graphic user interface that relates important  
system information. This software is called Xantrex Solar Graphic Interface  
(GUI). See "Computer Communications with the PV100S" in the PV100S 100  
kW Grid-tied Photovoltaic Inverter Operation and Maintenance Manual for  
additional information.  
The GUI can dial up the inverter and receive fault report calls from it through a  
standard Hayes-compatible, landline modem. When the GUI initiates a call  
through the modem at the GUI computer, the inverter’s modem answers the call  
and initiates a 9600 baud serial connection, effectively as if the GUI was  
connected directly. Or, if the inverter experiences a fault, it will initiate a call to  
the GUI and report the fault details.  
PC Connection Methods  
The personal computer can be connected to the PV100S the following ways.  
Important: Ensure the appropriate service has been established before proceeding.  
Also ensure the personal computer to be used has the appropriate hardware to support the  
installed feature, such as a phone line, wireless phone service, or local area network.  
•
•
•
•
POTS Connection  
Wireless Connection  
Ethernet LAN Connection  
Direct Connection  
3–20  
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PC Communications  
Establishing a POTS Connection  
Important: A direct analog phone line to the local phone service is required to use this  
feature. The phone line used for PV100S communication cannot be routed through a  
Private Branch Exchange (PBX) unless an analog PBX card is used.  
To connect a personal computer using the POTS Connection:  
1. Ensure the personal computer to be used has a 56K modem installed.  
2. Open the Communications Enclosure.  
3. Plug the local phone line into the RJ11 port on the SA2 Surge Arrestor  
marked "UNPROTECTED".  
SA2 Surge Arrestor  
MultiTech 56K  
Modem  
Figure 3-20 Telephone Cable Routing  
4. Install the GUI Software following the instructions in the PV100S 100 kW  
Grid-tied Photovoltaic Inverter Operation and Maintenance Manual.  
5. Use a Terminal Emulation program on the PC to access the modem.  
See the GUI Help Menu "Communication by Modem" for instructions on  
setting up the Terminal Emulation program on the computer. See also,  
"Connect to Telephone Number" and "Connect to Remote Inverter by  
Modem" for additional information.  
6. Use the GUI to setup the connection information.  
a) From the GUI Main page, click on <TOOLS>  
b) Click on the inverter icon for the inverter to be setup.  
c) Click on the <INVERTER DATA>  
d) Click on the <CONNECTION> tab.  
e) Fill out the information required on the <GENERAL> page, the  
<TELEPHONE FAULT CONFIGURATION> page, and the <TELEPHONE  
CONFIGURATION> page.  
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Installation  
Establishing Wireless Connection  
Important: Ensure the Wireless service has been established with the local service  
provider before proceeding.  
To connect a personal computer using the GSM Wireless modem:  
1. Ensure the personal computer has the appropriate hardware installed to  
support this feature.  
2. Install the GUI Software following the instructions in the PV100S 100 kW  
Grid-tied Photovoltaic Inverter Operation and Maintenance Manual.  
3. Use the GUI to setup the connection information.  
a) From the GUI Main page, click on <TOOLS>  
b) Click on the inverter icon for the inverter to be setup.  
c) Click on the <INVERTER DATA>  
d) Click on the <CONNECTION> tab.  
e) Fill out the information required on the <GENERAL> page, the  
<TELEPHONE FAULT CONFIGURATION> page, and the <TELEPHONE  
CONFIGURATION> page.  
Establishing an Ethernet LAN Connection  
Important: Ensure the local area network has been established with the local service  
provider before proceeding.  
To connect a personal computer using the Ethernet LAN Connection:  
1. Ensure the personal computer has the appropriate hardware installed to  
support this feature (i.e., Network Interface Card [NIC]).  
2. Open the Communications Enclosure and plug the LAN cable (CAT5 cable)  
into the RJ45 Port of the SA2 Surge Arrestor marked "UNPROTECTED".  
3. Install the GUI Software following the instructions in the PV100S 100 kW  
Grid-tied Photovoltaic Inverter Operation and Maintenance Manual.  
4. Use the GUI to setup the connection information.  
a) From the GUI Main page, click on the inverter icon for the inverter to be  
setup.  
b) Click on <COMMUNICATION>.  
c) Select "CONNECT TO IP ADDRESS" in the drop-down menu.  
d) Fill in the IP address provided by the Internet Service Provider.  
e) Click on the <CONNECT> button.  
f) Click on the <OK> button.  
g) Repeat this procedure for each unit to be added to local area network.  
3–22  
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PC Communications  
Direct Connection  
The direct connection provides the means to use the features of the GUI by  
connecting a PC directly to the CCU2. This allows field personnel to monitor and  
control the inverter from a nearby laptop computer directly connected by a serial  
cable. The computer connects to the inverter directly through one of its serial  
COM ports running at 9600 baud.  
The installed RS232/FO Converter will have to be removed and minor re-wiring  
will be required.  
The RS232/FO Converter kit (Xantrex p/n 1-152624-01) is required for this  
connection to change the communication protocol from ethernet to serial in the  
Communications Enclosure. A DB25-to-DB25 gender-changer adapter and  
DB9/DB25 serial cable are provided with the RS232/FO Converter kit to  
complete the connection.  
If connecting the PC directly to the inverter:  
1. Open the Communications Enclosure.  
2. Disconnect the TX (transmit-orange) and RX (Receive-blue) wires from the  
installed RS232/FO Converter in the Communications Enclosure.  
3. Disconnect the power plug from the installed converter and plug it into the  
new RS232/FO Converter.  
4. Remove the installed converter. Replace with the new RS232/FO Converter.  
5. Reconnect the TX (transmit-orange) and RX (Receive-blue) wires to the new  
Converter in the Communications Enclosure.  
6. Plug the DB25-to-DB25 Gender-changer Adapter into the Serial  
Communications Port on the RS232/FO Converter. (Step not shown.)  
7. Plug the DB25 connector on the serial cable into the gender-adapter and the  
DB9 connector of the serial cable into the serial port on the computer. (Step  
not shown.)  
2
3
4
Modem Power Cord  
(Do not Remove)  
SA2 Surge Arrestor  
MultiTech 56K Modem  
Figure 3-21 RS232/FO Converter Kit Installation  
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Installation  
5
3
RE232/FO Converter  
DB25-to-DB25 Gender Changer  
Adapter  
DB25/DB9 Serial Cable  
Figure 3-22 Direct Connect Installation  
3–24  
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Verification  
4
Chapter 4, “Verification” provides a checklist to ensure the  
installation of the PV100S is correct and complete.  
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Verification  
Verification Procedure Summary  
WARNING: Electrocution Hazard  
This chapter describes specific steps to ensure the installation of the PV100S 100 kW  
Grid-Tied Photovoltaic Inverter is correct and complete. Failure to adhere to these  
warnings could result in severe shock or possible death. Exercise extreme caution at all  
times to prevent accidents. These installation instructions are for use by those familiar  
and skilled with high voltage procedures.  
WARNING: Shock Hazard  
The PV100S enclosures contain exposed high-voltage conductors. The enclosure doors  
should remain closed with the latches tightened, except during installation, maintenance  
or testing. 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.  
WARNING: Lethal Voltage  
In order to remove all sources of voltage from the PV100S, 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 PV100S. Review the  
system configuration to determine all of the possible sources of energy. In addition, allow  
5 minutes for the DC bus capacitors, located on the ceiling of the cabinet, to discharge  
after removing power.  
The following procedures are intended to verify correct installation and proper  
wiring of the PV100S. Prior to performing the following verification steps on the  
PV100S, review all safety requirements and procedures outlined in this manual  
and on any cautionary markings on the components within the system.  
Inspect the following items prior to completion of the installation:  
1. Visually inspect all the mechanical connections. This would include both  
electrical conduit fittings, as well as enclosure anchoring and seismic bracing  
if required.  
2. Visually inspect the electrical connections and verify proper tightness of all  
terminations.  
3. Visually inspect the Isolation Transformer Wye/Wye connections and ensure  
the T6-X0 neutral connection is left disconnected or floating.  
4. Perform corrective actions if required.  
4–2  
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Visual Inspection of Mechanical Connections  
Visual Inspection of Mechanical Connections  
To perform a visual inspection of the PV100S mechanical connections:  
1. Ensure that the AC and DC Disconnect Switches, as well as any utility  
interconnect circuit breakers or main disconnect switches, are opened.  
❐
❐
❐
❐
2. Ensure all anchor bolts and any required seismic bracing is properly  
tightened and in place.  
3. Remove the wiring access panels and front covers from the AC  
Interface/Transformer assembly and Main Inverter Inductor Enclosure.  
4. Remove the latches and open the doors of the Main Inverter Enclosure,  
the AC and DC Interface Enclosures, and Communication Enclosure  
and inspect.  
5. Verify all wire conduit fittings and connections are properly tightened.  
❐
Visual Inspection of Electrical Connections  
To perform a visual inspection of the PV100S electrical connections:  
1. Ensure that the AC and DC disconnect switches, as well as any utility  
interconnect circuit breakers or main disconnect switches, are opened.  
❐
❐
2. Ensure all conductors and wiring connections interfacing with the  
PV100S are tightened to the correct torque value.  
For specific torque values, see Table 3-1, “AC Terminal Wire Gauge,  
Bolt Size, and Torque Values” on page 3–12 and Table 3-2, “DC  
Terminal Wire Gauge, Bolt Size, and Torque Values” on page 3–12.  
3. Verify AC power conductors terminated at TB4-A, TB4-B, TB4-C  
within the Main Inverter Enclosure are terminated correctly and  
properly sequenced.  
❐
❐
❐
4. Verify the AC power conductors terminated at S1-2T1, S1-4T2, S1-6T3  
within the AC Interface Enclosure are terminated correctly and properly  
sequenced.  
5. Verify DC power conductors terminated at TB3-1, TB3-2, TB3-3 within  
the DC Interface Enclosure are terminated correctly and properly  
polarized.  
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Verification  
Visual Inspection, Isolation Transformer Wye/Wye  
To perform a visual inspection of the Isolation Transformer Wye/Wye:  
1. Ensure that the AC and DC Disconnect Switches, as well as any utility  
Interconnect circuit breakers or main disconnect switches, are open.  
❐
❐
2. Verify all conductor and wiring connections interfacing with the  
PV100S are tightened to the correct torque value.  
For specific torque values, see Table 3-1, “AC Terminal Wire Gauge,  
Bolt Size, and Torque Values” on page 3–12 and Table 3-2, “DC  
Terminal Wire Gauge, Bolt Size, and Torque Values” on page 3–12.  
3. Verify the AC power conductors terminated at T6-X1, T6-X2, T6-X3  
within the Transformer Enclosure are terminated correctly and properly  
sequenced.  
❐
❐
4. Ensure the neutral on the inverter side (T6-X0) is left floating. If the  
inverter side neutral is tied to ground, the inverter will not function  
properly. Also, ensure that the neutral is not bonded to the isolation  
transformer frame.  
Date  
Checks Completed  
Corrective Action  
Perform after initial inspection (if required):  
1. Correct any necessary repairs pertaining to the previous inspection steps.  
2. Replace the wiring access panels to the AC interface/transformer assembly  
and Main Inverter Enclosure.  
3. Replace the latches and close the doors of the Main Inverter Enclosure, the  
AC and DC Interface Enclosures, and communication enclosure.  
4. Ensure that the AC and DC Disconnect Switches, as well as any utility  
interconnect circuit breaker or main disconnect circuit breaker, are left open.  
4–4  
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Schematics  
A
Appendix A contains useful schematics to aid with installation.  
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Schematics  
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A–2  
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Appendix A  
Schematics  
Figure A-1 Electrical Diagram (sample)  
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Schematics  
Appendix A  
Figure A-2 PV100S-480 Schematic for Main Power Distribution (152316 E1)  
A-4  
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Appendix A  
Schematics  
Figure A-3 PV100S-480 Schematic for Control Power Distribution (152316 E2)  
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Schematics  
Appendix A  
Figure A-4 PV100S-480 Schematic for Converter Control Unit (152316 E3)  
A-6  
152315 Rev C  
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Appendix A  
Schematics  
Figure A-5 PV100S-208 Schematic Main Power Distribution (152376 C1)  
152315 Rev C  
A-7  
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Schematics  
Appendix A  
Figure A-6 PV100S-208 Schematic for Control Power Distribution (152376 C2)  
A-8  
152315 Rev C  
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Appendix A  
Schematics  
Figure A-7 PV100S-208 Schematic for Converter Control Unit (152376 C3)  
152315 Rev C  
A-9  
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Schematics  
Appendix A  
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A-10  
152315 Rev C  
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Index  
A
I
Abbreviations and Acronyms  
Access Doors 3 – 6  
Anchoring 2 – 13  
Array Grounding 3 – 13  
v
IEEE  
IGBT  
v
v
Indoor Temperature Control 2 – 3  
IPM  
v
Isolation Transformer 2 – 4, 3 – 13  
C
K
CCU2  
CFM  
v
v
kcmil  
v
Chassis Grounds 3 – 13  
Clearance 2 – 2  
Communication 2 – 4  
Communications 3 – 20  
Components 2 – 2  
L
LCD  
v
Location 2 – 2  
Conductor and Conduit Sizing 2 – 11  
Conduit Installation 3 – 9  
Conduit Penetration 2 – 8  
Conduits and Conductors 2 – 2  
Controls 1 – 7  
Conventions Used iv  
Corrective Action 4 – 4  
M
Main Enclosure Door Interlock Switch 1 – 7  
Maintenance and Serviceability 2 – 3  
Mounting and Anchoring 3 – 5  
Moving 3 – 3  
Moving the PV100S 3 – 4  
D
O
Data Logging 1 – 10  
DC terminals TB3-1, TB3-2 &TB3-3 3 – 11  
Direct Access 1 – 14  
Disconnect Switches 1 – 9  
On/Off Switch 1 – 8  
Operational Safety  
Over Voltage, Under Voltage and Frequency Ranges  
x
1 – 4  
DSP  
v
Overcurrent Protection 3 – 11  
Overview 2 – 2  
E
Electrical Diagrams 2 – 5  
Electrical Specifications 1 – 4  
Environmental Specifications 1 – 6  
Equipment 3 – 2  
P
PC Connection Methods 3 – 20  
PC Connections  
Direct Connect 2 – 4  
LAN Connection 3 – 22  
Wireless Remote Connect 2 – 4  
Wireless Remote Connection 3 – 22  
Personal Safety viii  
Planning 2 – 2  
F
Fault Reporting and Logging 1 – 10  
G
PSL  
PV  
v
v
General Safety viii  
Ground 3 – 13  
Ground Requirements 1 – 5  
PV Array Connections 3 – 19  
PV Planning 2 – 3  
GUI  
v
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Index  
R
Removing the Pallet 3 – 4  
S
Safety vii  
T
Torque and Wire Gauge Specifications 3 – 12  
U
UFCU  
v
Unloading 3 – 2  
Unpacking 3 – 3  
Utility Side Isolation Transformer Requirements 1 – 5  
V
Verification Procedure Summary 4 – 2  
Visual Inspection of Electrical Connections 4 – 3  
Visual Inspection of Mechanical Connections 4 – 3  
Visual Inspection, Isolation Transformer Wye/Wye  
4 – 4  
W
Wireless Remote Access 1 – 13  
Wiring Requirements viii  
X
Xantrex  
web site  
v
IX–2  
152315 Rev C  
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Xantrex Technology Inc.  
1 800 670 0707 Tel toll free NA  
1 360 925 5097 Tel direct  
1 360 925 5143 Fax direct  
[email protected]  
www.xantrex.com  
Printed in USA  
152315 Rev C  
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