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Eaton PV240 User Manual

Manual is about: Eaton Grid-Tied PV Inverter User Manual

Summary of PV240

  • Page 1

    Eaton grid-tied pv inverter user manual ver. 1.1.

  • Page 2

    Eaton corporation page 2 ver 1.1 index important safety notification --------------------------------------------- 3 1. Introduction ------------------------------------------------------------------ 5 2. Limited warranty ----------------------------------------------------------- 6 3. Features over...

  • Page 3

    Eaton corporation page 3 ver 1.1 important safety notification general this user manual contains important instructions and notifications for the eaton grid-tie pv inverter which must be followed during installation and maintenance for of the inverters. The eaton grid-tie pv inverter is designed and...

  • Page 4

    Eaton corporation page 4 ver 1.1 safety symbols electrical shock electrical shock indicates a potential for an electrical shock if not avoided. Warning warning indicates a potentially hazardous situation that could result in death or serious injury if not avoided. Caution caution indicates a hazardo...

  • Page 5: 1. Introduction

    Eaton corporation page 5 ver 1.1 1. Introduction this manual describes all the information needed to install and operate an eaton pv240, pv250, pv260 and pv270 grid-tie pv inverter (“pv inverter”). Important in order to avoid problems during the install procedure, it is recommended to read the entir...

  • Page 6: 2. Limited Warranty

    Eaton corporation page 6 ver 1.1 2. Limited warranty eaton grid-tie pv inverter comes with a 10-year warranty. This warranty covers all defects due to design, manufacturing and components. This warranty does not cover damages resulting from: seal on the product is broken improper transportation and ...

  • Page 7: 4. Product Overview

    Eaton corporation page 7 ver 1.1 4. Product overview 4.1 introducing the grid pv system the grid-connected pv system is mainly composed of four parts: the pv-modules, the gird-tied pv inverter, the ac-connection unit (the connection interface) and a connection to the public utility. When a pv-panel ...

  • Page 8

    Eaton corporation page 8 ver 1.1 4.2 introducing eaton grid-connected pv inverter eaton grid-tied pv inverter converts direct current (dc) power generated by a pv panel into alternating current (ac), which is compatible with the local electrical distribution network; also called the public utility, ...

  • Page 9: 4.3 Dimensions And Weight

    Eaton corporation page 9 ver 1.1 4.3 dimensions and weight measuring weights: model pv238 pv240 pv250 pv260 pv270 net weight (lbs) 86 86 90.4 101.4 101.4 17.1 in. 33.4 in. 8.4 in. Figure 4.3: dimension and weight of pv inverter.

  • Page 10

    Eaton corporation page 10 ver 1.1 4.4 control and display overview figure 4.4: overview of eaton pv inverter a. Lcd display lcd screen displays all measured values and parameters. B. Led indicators there are three indicators used to indicate the operating status. C. Control keys they are three contr...

  • Page 11: 4.5 Led Indicators

    Eaton corporation page 11 ver 1.1 4.5 led indicators eaton grid-connected pv inverter has three built-in led indicators which will provide information of the operational status: figure 4.5: led indicators a) power-on led indicator it is a green led indicator which will light up in green when the fee...

  • Page 12

    Eaton corporation page 12 ver 1.1 4.6 control keys and lcd displays eaton grid-connected pv inverters are equipped with three control keys which could be used to switch between each display menus. Figure 4.6: control keys and lcd displays a) upper arrow control key arrow control key is used to advan...

  • Page 13

    Eaton corporation page 13 ver 1.1 4.7 night backlight button figure 4.7: the location of night backlight button eaton grid-connected pv inverter will switch-off during the evening as nightfall approaches. During the switch-off period, the lcd no longer displays any information since there is not fee...

  • Page 14: 5.1 Open The Packing

    Eaton corporation page 14 ver 1.1 5. Installation of eaton grid-tied pv inverter 5.1 open the packing a. 1 x eaton gird-connected pv inverter b. 1 x mounting bracket c. 1 x accessories box i. 1 x user manual ii. 6 x m4 mounting screws iii. 6 x mounting anchors iv. 2 x m4 safety-lock screws v. 1 x fe...

  • Page 15

    Eaton corporation page 15 ver 1.1 5.3 identify the eaton grid-tied pv inverter the structure of the eaton grid-tied pv inverter can be divided into two parts, main housing and wiring box shown in figure 5.3.1. The main housing contains the electrical components that are used for power conversion and...

  • Page 16

    Eaton corporation page 16 ver 1.1 an additional electrical name plate is attached in the bottom plate of the wiring box as shown in figure 5.3.3. Important for the pv240 model, the user will be able to use the manual function of a dip switch in order to down power the pv240 model into 3800w output. ...

  • Page 17

    Eaton corporation page 17 ver 1.1 a warning label plate is located in the left-hand side of pv inverter as indicated in figure 5.3.4. This warning label is used to indicate all important notices that shall be known. When you are dealing with the general utility system and dc generator, read and foll...

  • Page 18: 5.4 Mounting Inverter

    Eaton corporation page 18 ver 1.1 5.4 mounting inverter figure 5.4.1: required dimension a) select a dry location, out of direct sunlight with ambient temperature between -20 and 45°c. Important it is important to not install the eaton grid-tied pv inverter under direct sunlight. This is because the...

  • Page 19

    Eaton corporation page 19 ver 1.1 important the nec requires that the dc disconnect should be mounted between 3 ft ~ 6.5 ft from the ground if the pv inverter will be used as the standard disconnect. D) installing position selecting a proper installation position for the pv inverter is very importan...

  • Page 20

    Eaton corporation page 20 ver 1.1 caution do not to install pv inverter horizontally and tilt-forward direction as illustrated above. The pv inverter is designed only for the vertical installation position. Do not place any obstacles on the top of pv inverter. Moreover, pv inverter may make noise du...

  • Page 21

    Eaton corporation page 21 ver 1.1 ii) there are 2 types of handling modes to install the mounting bracket on a wall. The user can use the different screwing points as appropriate. The corner screwing points or the central screwing point as illustrated in the figures, below. To secure the mounting br...

  • Page 22

    Eaton corporation page 22 ver 1.1 warning it is important to ensure the drilling locations are not located on any electrical wiring within the wall. F. Mount the pv inverter into the mounting bracket as illustrated below. I) hook up the pv inverter by aligning the opening of rear-side enclosure and ...

  • Page 23

    Eaton corporation page 23 ver 1.1 ii) secure the edge point of mounting bracket in order to avoid the wiring box swaying due to weather, the safety screws for the wiring box must be tightening. There will be two pieces of the m4 size screws found within accessories box. The tightening location of mo...

  • Page 24

    Eaton corporation page 24 ver 1.1 iv) unfasten 4 m5 screws from the top cover of wring box as illustrated below: figure 5.4.10: remove the screws of dc/ac wiring box screwdriver a m5 hexagon head screwdriver is required for the procedure. V) remove the top cover of disconnect box and then find the h...

  • Page 25: 6. Wiring Box Overview

    Eaton corporation page 25 ver 1.1 6. Wiring box overview 6.1 hardware structures figure 6.1: wiring box structures a. Protection mov for dc input side b. Dc bypass terminal c. Fault signal terminal d. Dc/ac disconnect e. 2 fuse holder for ac output side (shipped with dummy fuses) f. Super rs485 inte...

  • Page 26: 6.2 Hardware Functioning

    Eaton corporation page 26 ver 1.1 6.2 hardware functioning a. Protection mov for dc input side it is the surge protection that is equipped and used to protect input circuit against excessive voltage on the dc connections. B. Bypass terminal block for dc input side it is the bypass terminal block for...

  • Page 27

    Eaton corporation page 27 ver 1.1 d. Fault signal terminal the eaton grid-tied pv inverter has a built-in fault signal terminal, which can be connected simultaneously with an error indicator besides the lcd screen. A female connector is included within the accessories box. System installers or servi...

  • Page 28

    Eaton corporation page 28 ver 1.1 figure 6.2.3: failure operating mode.

  • Page 29

    Eaton corporation page 29 ver 1.1 e. Ac protection i) if an external ac breaker or fuse protector is installed, it is not necessary to implement ac protection fuses within the wiring box. The specification of external breakers or fuses shall meet the recommended ratings listed in the following table...

  • Page 30

    Eaton corporation page 30 ver 1.1 f. Super rs485 card the rs485 interface card is located in the right-hand side position of the wiring box and integrated and shipped with the pv inverter. Figure 6.2.4: integrated rs485 interface card a) link led indicator: when an ethernet cable is inserted in any ...

  • Page 31

    Eaton corporation page 31 ver 1.1 d) update led indicator: it indicates when the firmware is uploading from super-485 card to the inverter; the led will light up in red. E) definition of rj-45 poe ports warning power on socket pin 7 & pin 8 are dc powered. Do not connect other devices to this port a...

  • Page 32

    Eaton corporation page 32 ver 1.1 figure 6.2.6: terminal switch on model figure 6.2.6 illustrates the proper connection model that used for the 5 eaton gird-connected pv inverters with ez logger lite. For inverter 1, 2, 3, 4, set dip switch “off”; for last inverter (inverter 5), press pin 1 and pin ...

  • Page 33

    Eaton corporation page 33 ver 1.1 h) multiple connections: usage of ethernet cable ethernet cable can be used to connect either port to another super-485 card. The cable must be a “straight through cable” as shown in figure 6.2.8. And it is important to ensure the pin position of ethernet cable is c...

  • Page 34

    Eaton corporation page 34 ver 1.1 figure 6.2.10: mixed connecting mode j) multiple connections: terminal block usage the terminal block that designed for the super rs485 card is used with twisted wire pairs to establish the connection between each pv inverter as shown in figure 6.2.11. Figure 6.2.11...

  • Page 35

    Eaton corporation page 35 ver 1.1 figure 6.2.12: connecting mode for data logger l) connect to pc via super-485 to rs-232 converter when wiring super-485 card from inverter to super-485 to rs-232 converter, connect opposite pins of super-485 (receive pin to transmit pin, and transmit pin to receive ...

  • Page 36

    Eaton corporation page 36 ver 1.1 g. Dc protection this is the over current and over voltage protection that is used for the direct current (dc) side. According the nec 690.15-18, fuse holders can be used to disconnect the pv modules for serving. The eaton grid-tied pv inverter is shipped with dummy...

  • Page 37

    Eaton corporation page 37 ver 1.1 the standard formula for dc fuse selection: nominal voltage of fuse must be 600v dc rating and the fuse should be selected between 1.56 x isc n assume the maximum short circuit current (isc) of the solar module used is 4.85a. The rating of the selected fuse must hav...

  • Page 38

    Eaton corporation page 38 ver 1.1 h. Dc input terminal block it is the terminal block that used to connect the dc cables from the pv modules. In order to have a trouble free connection, it is recommended to connect pv modules of the same type, same quantity, with an identical configuration of string...

  • Page 39

    Eaton corporation page 39 ver 1.1 k. Utility configuration dip switch it is a utility configuration dip switch that is embedded within dc/ac wiring box. This dip switch allows the user to do different configurations of the pv inverter in order to let it connect to the different public grid systems u...

  • Page 40

    Eaton corporation page 40 ver 1.1 pin signal assignment 1 n.C. 2 txd 3 rxd 4 n.C. 5 common 6 n.C. 7 n.C. 8 n.C. 9 n.C. L. Rs232 interface (for service purpose) the eaton gird-tied pv inverter is equipped with a versatile communications interface and can be used with a stand-alone monitoring software...

  • Page 41

    Eaton corporation page 41 ver 1.1 6.3 maximum ac short-circuit current according to requirements for safety protection, pv inverters shall have a short circuit test on the ac output circuit. The following table describes the test result of the ac short-circuit current that the pv inverter had. Maxim...

  • Page 42

    Eaton corporation page 42 ver 1.1 figure 6.4.2: dimension of knockouts direction diameter quantity underside combo 1-1/4 in. & 1 in. 4 combo 3/4 in. & 1/2 in. 4 back side combo 1-1/4 in. & 1 in. 4 combo 3/4 in. & 1/2 in. 4 let-hand side combo 1-1/4 in. & 1 in. 3 combo 3/4 in. & 1/2 in. 1 right-hand ...

  • Page 43

    Eaton corporation page 43 ver 1.1 figure 6.4.3: levels area and the size of knockouts figure 6.4.4: knocking points of inner level figure 6.4.5: knocking points of outer level tools a m4 size slotted screwdriver and hammer are required for the opening procedure of knockouts. Inner level area outer l...

  • Page 44

    Eaton corporation page 44 ver 1.1 in order to utilize an opening hole in the inner level area, it is necessary to use the required tools such as a slotted screwdriver with a hammer to knock at the certain point repeatedly as figure 6.4.6 indicated: figure 6.4.6: knocking point of inner level in orde...

  • Page 45: 7.1 Dc Wiring Connections

    Eaton corporation page 45 ver 1.1 7. Connecting the pv inverter 7.1 dc wiring connections since the wiring box has been opened during mounting procedures, please use the proper tools to knockout an opening hole in the desired location from wiring box for ac cables and then inserted a conduit and fix...

  • Page 46

    Eaton corporation page 46 ver 1.1 iv. Use multi-meter to confirm the total input power of pv strings in order to ensure the input power from pv string will not be exceed the permission setting 600v dc as the maximum operating voltage according to electrical specification of pv inverter and the maxim...

  • Page 47

    Eaton corporation page 47 ver 1.1 c) connecting dc cables of pv strings to the dc terminal by following the steps below: figure 7.1.4: dc terminal for pv inverter i. Select the proper rating for the string fuse by following the calculation that had been mentioned in section g. Dc protection of chapt...

  • Page 48

    Eaton corporation page 48 ver 1.1 warning do not mix the connection with the wrong polarity. This may cause damage to the pv inverter; therefore, it is very important to do the polarity check before connecting the dc power to the wiring box. Do not startup the pv inverter while the fuse cover is rem...

  • Page 49: 7.2 Ac Wiring Connections

    Eaton corporation page 49 ver 1.1 7.2 ac wiring connections configuration of utility grid eaton grid-connected pv inverter can be installed with the following type of utility grid systems by 2 wire or 3 wire ac cables, and with a ground cables as illustrated in the table below. Acceptable grid syste...

  • Page 50

    Eaton corporation page 50 ver 1.1 warning configuration of utility grid connections is required and to be completed by a licensed engineer or electrical contractor ensure the correct sized ac cables is used. Danger alternating current (ac) is terminated in pv inverter. All connections between public...

  • Page 51

    Eaton corporation page 51 ver 1.1 utility configuration description ac terminal lcd display dip switch setting 1 2 3 pin 1 pin 2 pin 3 dip switch on off off 208 delta: corner grounded l1 l2 － g pv2xx 1 208 delta: corner grounded on off on 240 delta: corner grounded l1 l2 － g pv2xx 240 delta: corner ...

  • Page 52

    Eaton corporation page 52 ver 1.1 configuration for the ac wiring: a) after the dc wiring connection is finished, start to dash an opening hole for the ac cabling, and insert the conduit and tighten with the pipe end fitting. Figure 7.2.2.1: install a conduit on an open hole b) ensure the ac utility...

  • Page 53

    Eaton corporation page 53 ver 1.1 c) use a multi-meter to measure the ac voltage from the combiner box for ac utility. It is important to confirm the ac voltage that being used is matching with the correct configuration of utility configuration dip switch used. D) refer to the information from the t...

  • Page 54

    Eaton corporation page 54 ver 1.1 f) for the ac cables, the terminal connectors are recommended to be used with ac cables in order to ensure the quality of conducting between ac cables and ac terminal is good as shown in figure 7.2.2.3. Figure 7.2.2.3: terminal connectors are required for ac cables ...

  • Page 55

    Eaton corporation page 55 ver 1.1 h) and then please check the condition of the conduits again in order to ensure all conduits are tightly locked and secure for the protection against rain before top cover reinstalled with the wiring box. I) last, reinstall the top cover of wiring box by tightens 4 ...

  • Page 56

    Eaton corporation page 56 ver 1.1 8. Lcd displays function tree 8.1 first level display menu operation status output power model name grid system definition of level 1 display menu operating and output power status display the operation status and the instant-output power of the unit. Model name and...

  • Page 57

    Eaton corporation page 57 ver 1.1 8.2 second level display menu 8.2.1 daily, weekly and monthly energy display menu e-day display menu it is a menu that will display the output energy for the past 30 days. E-week display menu it is a menu that will display the output energy for the past 52 weeks. E-...

  • Page 58

    Eaton corporation page 58 ver 1.1 8.2.2 date and hour display menu important the enter key is the control key that used to enter into subdirectory for the configurations and the direction arrow control keys are used to rotate between each menu. Date adjusting menu it is the date and hour setting men...

  • Page 59: 9. Maintenance

    Eaton corporation page 59 ver 1.1 9. Maintenance 9.1 external cooling fan replacement for pv240 and pv250 models, there is no cooling fan designed for the external housing, but an internal fan designed within pv inverter for the thermal management. Therefore, “fan lock” is the only failures message ...

  • Page 60

    Eaton corporation page 60 ver 1.1 if the cooling fan is dirty, a vacuum cleaner can be used to clean from the top of the pv inverter. If the cleaning procedure does not fixed the problem, service personnel can determine the status of the cooling fan and make a replacement. The following procedures d...

  • Page 61

    Eaton corporation page 61 ver 1.1 c) after cooling fan is already lifted out, disconnect the power cable of the cooling fan as shown in figure 9.1.3. Figure 9.1.3: disconnects the power cables of the cooling fan d) install a new cooling fan by connecting its power cable to pv inverter. Then re-tight...

  • Page 62

    Eaton corporation page 62 ver 1.1 9.2 cleaning the lcd display if the screen of the lcd display and the led indicators are dusty and not readable, please use a piece of damp cloth to clean the surface. 9.3 install or replace the dc/ac fuse insulation protection an insulation glove should be worn dur...

  • Page 63

    Eaton corporation page 63 ver 1.1 b) next, take off the broken fuse or dummy fuse from the fuse cover as shown in figure 9.3.2: figure 9.3.2: take off the broken fuse c) insert a new fuse into the fuse cover. Ensure the fuse is selected from the recommended list of brands and rating as discussed in ...

  • Page 64: 10. Specifications

    Eaton corporation page 64 ver 1.1 10. Specifications model pv238 pv240 pv250 pv260 pv270 input (dc) nominal dc voltage 360v max. Pv open voltage 600v start-up voltage 150v shutdown voltage typical 80v working voltage range 100 ~ 515 v full rating voltage range 225 ~ 500v 200 ~ 500 v mppt working ran...

  • Page 65

    Eaton corporation page 65 ver 1.1 model pv238 pv240 pv250 pv260 pv270 output (ac) nominal ac current @ 208v 18.3a 18.3a 22.1a 28.9a 33.7a nominal ac current @ 240v 15.8a 16.7a 20.8a 25a 29.2a nominal ac current @ 277v 13.7a 14.4a 18.1a 21.7a 25.3a max. Ac current @ 208v 18.3a 18.5a 22.5a 30a 35a max...

  • Page 66

    Eaton corporation page 66 ver 1.1 model pv238 pv240 pv250 pv260 pp270 general ac surge protection 6kv grid interface regulation ieee1547 (2003), ieee1547.1(2005) safety ul1741 (2010), csa c22.2 no.107.1-01 emc fcc part 15 class b iec 61000-6-2 iec 61000-6-3 mechanical wall mounted yes dimension w x ...

  • Page 67: 11. Trouble Shooting

    Eaton corporation page 67 ver 1.1 11. Trouble shooting 11.1 display message table it is important to understand all operational and error messages that could appear on the lcd display. The error messages that appear are especially important because service personnel will need this information report...

  • Page 68

    Eaton corporation page 68 ver 1.1 iii) system information messages operation condition messages descriptions model display pv2xx inverter model lcd display lock lock hold the present display message waiting for reconnect to the grid reconnect in xxx s the time for reconnect to the grid iv) system fa...

  • Page 69

    Eaton corporation page 69 ver 1.1 operation condition messages descriptions communication failure between microprocessors sci failure communication between mcu inside is abnormal dc bus voltage is too high high dc bus the dc bus inside is higher than expected gfci detection abnormal gfci failure the...

  • Page 70

    Eaton corporation page 70 ver 1.1 c) no utility conditions: utility is not available. This can occur if the ac fuse is broken, no ac connections from utility system, or broken ac cables. Corrective actions: check the utility system and the ac connections of the pv inverter check the ac fuses of the ...

  • Page 71

    Eaton corporation page 71 ver 1.1 trouble shooting actions for inverter faults messages a) consistent fault conditions: the readings between two microprocessors of control board are not consistent. It could be caused by the dsp and/or other circuits not functioning properly. Corrective actions: rest...

  • Page 72

    Eaton corporation page 72 ver 1.1 e) dc inj. High fault conditions: input dc injection too high. Corrective actions: check the connection of the dc input. Restart the pv inverter. If fault remains, disconnect the pv inverter and contact the system installer. F) eeprom failures conditions: eeprom ins...

  • Page 73

    Eaton corporation page 73 ver 1.1 i) gfci failure conditions: the gfci detection circuit is abnormal. Corrective actions: check the pv string grounding cable from the pv inverter restart the pv inverter. If fault remains, contact the system installer to check the grounding of the pv inverter. If the...