PV-Inverter SunPower SPR-5000m / SPR-6000m / SPR-7000m / SPR-8000m

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1 PV-Inverter SunPower SPR-5000m / SPR-6000m / SPR-7000m / SPR-8000m Installation Guide SPR50-80m-IUS TB-SPR50_60_70M DMS# Rev *E US

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3 Copyright 2010 SunPower, Corp. All rights reserved. SunPower Corporation 3939N. First Street San Jose, California 95134, USA Tel SUN-0123 Fax Installation Guide SPR50-80m-IUS

4 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions that shall be followed during installation and maintenance of the follwing types of SunPower inverters: SPR 5000m SPR 6000m SPR 7000m SPR 8000m The inverter is designed and tested according to international safety requirements, but as with all electrical and electronic equipment, certain precautions must be observed when installing and/or operating the inverter. To reduce the risk of personal injury and to ensure the safe installation and operation of the inverter, you must carefully read and follow all instructions, cautions and warnings in this Installation Guide. Warnings A Warning describes a hazard to equipment or personnel. It calls attention to a procedure or practice, which, if not correctly performed or adhered to, could result in damage to or destruction of part or all of the SunPower equipment and/or other equipment connected to the SunPower equipment or personal injury. DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE NOTICE is used to address practices not related to personal injury. 4 SPR50-80m-IUS Installation Guide

5 Other symbols In addition to the safety and hazard symbols described on the previous pages, the following symbol is also used in this Installation Guide: This symbol accompanies notes that call attention to supplementary information that you should know and use to ensure optimal operation of the system. Markings on this product The following symbols are used as markings on this product with the following meanings. Warning regarding dangerous voltage The product works with high voltages. All work on the product may only be done as described in its documentation. Beware of hot surface The product can become hot during operation. Do not touch the product during operation. Observe the operating instructions Read the product s documentation before working on it. Follow all safety precautions and instructions as described in the documentation. AC current DC current Earth Ground This inverter is evaluated to UL 1741, which includes assessment to all of the requirements of IEEE1547 and IEEE1547.1, which are an outgrowth and further development of the IEEE recommended practices and guidelines contained in IEEE Std IEEE provides recommendations regarding the proper equipment and functionality necessary to ensure compatible operation when power generation is connected to the utility grid. Installation Guide SPR50-80m-IUS

6 General warnings General Warnings All electrical installations must be done in accordance with the local and National Electrical Code ANSI/NFPA 70. The inverter contains no user-serviceable parts except for the fans on the bottom of the enclosure and the handle covers on the sides of the unit. For all repair and maintenance always return the unit to an authorized SunPower Service Center. Before installing or using the inverter, read all of the instructions, cautions, and warnings on the inverter, the PV array, in this Installation Guide. Before connecting the inverter to the electrical utility grid, contact the local utility company. This connection must be made only by qualified personnel. PV arrays produce electrical energy when exposed to light and thus can create an electrical shock hazard. Wiring of the PV-arrays should only be performed by qualified personnel. 6 SPR50-80m-IUS Installation Guide

7 Warranty All SunPower inverters sold in the USA have a ten-year warranty, as indicated on the warranty card included in the SunPower shipping container. For warranty coverage, or if you have questions about the SunPower warranty, contact SunPower at the address, telephone number or Web site listed on page 3 (to send , see the Contact section of the SunPower Web site). SUNPOWER LIMITED WARRANTY FOR PV INVERTERS SPR-5000m, SPR-6000m, SPR-7000m, SPR-8000m 1. Limited Product Warranty and exclusions SunPower Corporation with offices at 3939 North First Street, San Jose CA ( SunPower ) provides a limited warranty that covers defects of your SPR-3000m, SPR-4000m, SPR-5000m, SPR- 6000m, SPR-7000m or SPR-8000m inverter (each, the Inverter ) caused by material or manufacturing faults. The warranty period is for 10 years and begins on the date of purchase by the original end user. Warranty claims may only be made by, or on the behalf of, the original end customer or a person to whom title has been transferred for the home or premises on which the solar inverter were originally installed. SunPower will, at its option, repair or replace the defective component(s) free of charge, provided that SunPower is notified of the defect during the warranty period and a dated proof of purchase is furnished. SunPower reserves the right to inspect the faulty component(s) and determine if the defect is due to material or manufacturing flaws. SunPower also reserves the right to charge for service time expended if the defect is not due to material or manufacturing flaws or is not for some other reason subject to this limited warranty. SunPower does not warrant inverters from any and all defects or damage caused by: a) Normal wear and tear b) Shipping or transportation damages c) Improper installation d) Exposure to unsuitable environmental conditions (including but not limited to damage due to lightning strikes) e) Unauthorized or abnormal use or operation f) Negligence or accidents g) Material or workmanship not provided by SunPower or its authorized service centers h) This warranty does not cover costs related to the removal, installation, or troubleshooting of your electrical systems Installation Guide SPR50-80m-IUS

8 SunPower will, at its option, use new and/or reconditioned parts in performing warranty repair and in building replacement products. SunPower reserves the right to use parts or products of original or improved design in the repair or replacement. If SunPower repairs or replaces a product, its warranty continues for the remaining portion of the original warranty period or 90 days from the date of the return shipment to the customer, whichever period expires later. All replaced products and all parts removed from repaired products become the property of SunPower. SunPower covers both parts and labor necessary to repair the product and return shipment to the customer, via a SunPower selected non-expedited surface freight carrier within the United States and Canada. The warranty does not cover any cost associated with installation, removal or re-installation of the Inverter. 2. Limitation of Warranty Scope EXCEPT FOR THIS EXPRESS LIMITED WARRANTY, SUNPOWER EXPRESSLY EXCLUDES ALL WARRANTIES WITH RESPECT TO THE INVERTER, EXPRESS AND IMPLIED, INCLUDING BUT NOT LIMITED TO THE WARRANTY OF MERCHANTABILITY, THE WARRANTY OF FITNESS FOR PARTICULAR PURPOSE, AND ANY WARRANTIES THAT MAY HAVE ARISEN FROM COURSE OF DEALING OR USAGE OF TRADE. TO THE MAXIMUM EXTENT PERMITTED BY LAW, SUNPOWER S AGGREGATE MONETARY LIABILITY TO THE CUSTOMER FOR ANY REASON AND FOR ANY AND ALL CAUSES OF ACTION, WHETHER IN CONTRACT, TORT OR OTHERWISE, WILL NOT EXCEED THE AMOUNT PAID TO SUNPOWER FOR THE INVERTER. SUNPOWER WILL NOT BE LIABLE TO YOU UNDER ANY CAUSE OF ACTION, WHETHER IN CONTRACT, TORT OR OTHERWISE, FOR ANY INDIRECT, SPECIAL, INCIDENTAL, CONSEQUENTIAL, OR PUNITIVE DAMAGES. THE PRICE FOR THE INVERTER AND SUNPOWER S OBLIGATIONS UNDER THIS EXPRESS LIMITED WARRANTY ARE CONSIDERATION FOR LIMITING SUNPOWER S LIABILITY. IF THIS PRODUCT IS A CONSUMER PRODUCT, FEDERAL LAW DOES NOT ALLOW AN EXCLUSION OF IMPLIED WARRANTIES. TO THE EXTENT YOU ARE ENTITLED TO IMPLIED WARRANTIES UNDER FEDERAL LAW, TO THE EXTENT PERMITTED BY APPLICABLE LAW THEY ARE LIMITED TO THE DURATION OF THIS LIMITED WARRANTY. SOME STATES AND PROVINCES DO NOT ALLOW LIMITATIONS OR EXCLUSIONS ON IMPLIED WARRANTIES OR ON THE DURATION OF AN IMPLIED WARRANTY OR ON THE LIMITATION OR EXCLUSION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION(S) OR EXCLUSION(S) MAY NOT APPLY TO YOU. THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS. YOU MAY HAVE OTHER RIGHTS WHICH MAY VARY FROM STATE TO STATE OR PROVINCE TO PROVINCE. 3. Obtaining Warranty Performance If you feel you have a justified claim covered by this Limited Warranty, please notify the solar installer, from whom you purchased the Inverter. 8 SPR50-80m-IUS Installation Guide

9 Table of Contents Table of Contents 1 Introduction Target group Product overview Safety Installation overview Unpacking and inspection Scope of delivery AC voltage configuration Opening the inverter Locating internal components Configuring the AC voltage Utility configuration jumpers Mounting Choosing a mounting location Selection of the mounting location Ambient conditions Position Dimensions and required clearances Mounting procedure Mounting the wall-mounting bracket Mounting the DC-disconnect (if applicable) Mounting the inverter Wiring the inverter Sequence of connecting Wiring without DC-disconnect Wiring with DC-disconnect Bottom view and dimensions Installation Guide SPR50-80m-IUS

10 Table of Contents 5.3 Opening the inverter Opening the DC-disconnect (if applicable) Wiring the AC output AC connection requirements AC wiring without DC-disconnect AC wiring with DC-disconnect Wiring the DC input DC connection requirements DC input grounding Connecting the DC wires DC wiring without DC-disconnect DC wiring with DC-disconnect DC connection with additional DC distribution Communication wiring RS232 communication RS485 communication Closing the inverter Closing the DC-disconnect (if applicable) Commissioning Displays and messages LED operation indicators All LEDs are off All LEDs are on Green LED blinks three times per second Green LED blinks once per second Green LED is on Green LED is shortly off once per second LED fault indicators Red and yellow LEDs are on Red LED is on Installation Guide SPR50-80m-IUS

11 7.2.3 Yellow LED is on Yellow LED is blinking 2 times Yellow LED is blinking 4 times Yellow LED is blinking 5 times Status messages on the LCD Display LCD display language selection Measuring channels and parameters Measuring channels Operating mode Inverter operating parameters Troubleshooting General Error messages Maintenance Cleaning the fans Cleaning the handle covers Testing the fans Exchanging the fuses Exchanging the GFDI fuse within the inverter Exchanging the PV string fuses within the DC-disconnect Technical specifications FCC compliance information Wiring diagrams Without DC-disconnect With DC-disconnect Specifications SPR-5000m SPR-6000m SPR-7000m Installation Guide SPR50-80m-IUS

12 10.7 SPR-8000m DC-disconnect Trip limits/trip times Torque values and wire sizes SPR50-80m-IUS Installation Guide

13 Introduction 1 Introduction This installation guide provides all the information needed to install, commission and operate SunPower grid-tied photovoltaic (PV) inverters of the following types: SPR-5000m SPR-6000m SPR-7000m SPR-8000m To help avoid problems during the installation, familiarize yourself with the installation process by reading the entire Installation Guide before starting the installation. 1.1 Target group This manual is for qualified personnel. Qualified personnel has received training and has demonstrated skills and knowledge in the construction and operation of the device. Qualified personnel is trained to deal with the dangers and hazards involved in installing electric devices. WARNING Lethal voltages are present at various points in a PV system. For safety reasons only qualified personnel may install and operate this equipment. Installation Guide SPR50-80m-IUS

14 Introduction SunPower 1.2 Product overview The SunPower SPR-5000m/SPR-6000m/SPR-7000m/SPR-8000m is a DC to AC grid-tied utility interactive inverter for use with photovoltaic (PV), fuel cell, wind turbine and other sources of DC power. For the use with a wind turbine In general, the inverter takes power from a DC source (PV modules) and converts it to AC power for the utility grid. This power is delivered first to local loads (household appliances, lights, motor loads, etc.), with any excess power fed to the utility. The power consumed by the local loads reduces the power needed from the utility. Excess power may actually spin the utility meter backwards depending on the type of meter in your system. This power may also be recorded as power credits by the utility company depending on the interconnection agreement. An example of basic system components is shown in figure below. Position A B C D E Description PV array Inverter with DC-Disconnect Local loads Meter Utility grid Policies vary from one utility company to another. Consult with a representative of the local utility company before designing and installing a PV system. 14 SPR50-80m-IUS Installation Guide

15 Introduction 1.3 Safety Anti-islanding protection Islanding is a condition that can occur if the utility grid is disconnected while the inverter is operating and the remaining load is resonant at 60 Hz and matches the output of the inverter perfectly. This condition is highly unlikely and had never been witnessed outside of a controlled laboratory. Nevertheless, the inverter incorporates an advanced active islanding protection algorithm to ensure that the system will not export power into a balanced 60 Hz resonant load while the utility is disconnected. The inverter periodically injects both leading and lagging reactive current into the utility grid. This method has been proven by Underwriters Laboratories to effectively destabilize and disconnect from a balanced island condition. PV ground fault detection and interruption The inverter is equipped with a ground fault detection device. If a ground fault current greater than 1 A is detected, the inverter will shut down and display the fault condition on the user interface display. Once the ground fault is located and corrected, the ground fault error will need to be manually cleared and the inverter will then resume normal operation. PV series fusing Series fusing may be required depending on the type of PV module used in the system. See NEC Interconnection code compliance The inverter has been tested and listed by Underwriters Laboratories to meet the requirements of UL1741 Static Inverters and Charge Controllers for use in Photovoltaic Power Systems and UL1998 Software in Programmable Components, as well as IEEE Recommended Practice for Utility Interface of Photovoltaic Systems and IEEE 1547 Standard for Interconnecting Distributed Resources with Electric Power Systems. The inverter is cul listed to CSA standard No. c Contact the local utility and/or the authority having jurisdiction prior to connecting the inverter to the utility grid. FCC compliance The SunPower SPR-5000m/SPR-6000m/SPR-7000m/SPR-8000m has been tested and certified by a nationally recognized testing laboratory and conforms to all FCC Part 15 A & B EMI/EMC emissions regulations. Installation Guide SPR50-80m-IUS

16 Introduction SunPower Feature overview Over twenty years of inverter manufacturing experience has gone into the design of the SunPower SPR-5000m/SPR-6000m/SPR-7000m/SPR-8000m PV inverter. As a result, the inverter represents state-of-the-art technology, high reliability and over all ease of use - all the qualities you ve come to expect from SunPower. Some of the features included are: High efficiency Auto line voltage detection and configuration Temperature regulated fan cooling with simplified fan replacement Advanced communication options LCD Display Powder coated die-cast enclosure Compatible with all SunPower inverter products Quiet operation Simple installation Operating temperature The inverter has been designed to maintain full power output at ambient temperatures as high as +113 F (+45 C). Fan cooling allows this level of output power to be achieved even in enclosed spaces. The inverter will continue to operate well beyond +113 F (+45 C) and de-rates as needed to maintain a safe internal component temperature. 16 SPR50-80m-IUS Installation Guide

17 Introduction 1.4 Installation overview This section provides a high-level overview of the installation process so you have an idea what to expect as you proceed through the rest of the installation guide. The installation process is broken down into the following tasks: Section 2: Unpacking and inspection This section provides instructions and information for unpacking the inverter and inspecting it for shipping damage. Section 3: AC voltage configuration This section includes information on removing the lid, locating primary components within the inverter and selecting the appropriate voltage configuration for the installation. Section 4: Mounting This section includes guidelines to help you select the best mounting location, suggestions to insure optimum performance, cautions and warnings that you should follow to avoid injury and/or equipment damage and step-by-step instructions for mounting the inverter. Section 5: Wiring the inverter This section includes guidelines for selecting the correct wire sizes, cautions and warnings that you should follow to avoid injury and/or equipment damage and step-by-step instructions for wiring the inverter to a PV array, household electrical circuits and the utility grid. Procedures are also included for connecting optional data-communication cables. Section 6: Commissioning Commissioning involves applying DC input power to the inverter, observing the LED and LCD indicators on the front lid, and resolving any problems that occur. Section 7: Displays and messages This section provides troubleshooting tips and procedures for resolving problems that may occur during installation and operation. Section 8: Troubleshooting This section provides troubleshooting tips and procedures for resolving problems that may occur during installation and operation. Section 9: Maintenance This section includes maintenance and cleaning of the inverter and cautions and warnings you should follow to avoid injury and/or equipment damage. Section 10: Technical specifications This section includes technical data for the inverter, connection diagrams and torque specifications for the connection of cables and the screws of the inverter. Installation Guide SPR50-80m-IUS

18 Unpacking and inspection SunPower 2 Unpacking and inspection All inverters are thoroughly tested and inspected before they are packed and shipped. Although they are shipped in sturdy, recyclable packaging; damage can still occur during shipping. It is important to carefully inspect the shipping container prior to beginning the installation. If any external damage to the packaging makes you suspect the inverter itself could be damaged, or if you find that the inverter is damaged after unpacking it, report the damage immediately to your SunPower dealer and to the shipping company that delivered the inverter. If it becomes necessary to return the inverter, use the original packaging in which it was delivered. WARNING The inverter weighs 148 lbs. (67 kg). To avoid injury, be sure to use proper lifting techniques and secure the help of someone to assist in the unpacking and installation of the inverter. If you need assistance with a damaged inverter, contact your SunPower dealer or SunPower. Contact information for SunPower is provided below. SunPower Corp. 3939N. First Street San Jose, California 95134, USA Tel SUN-0123 Fax SPR50-80m-IUS Installation Guide

19 Unpacking and inspection 2.1 Scope of delivery SunPower SPR-5000m/SPR-6000m/SPR-7000m/SPR-8000m PV inverter: Position Number Description A 1 Inverter B 1 Wall-mounting bracket C 3 1 Spare screw and washer for closing the inverter lid. 2 screws and washers for fastening the inverter to the wallmounting bracket. D 2 Spare jumpers for the fan test and for the grid configuration. E 2 Handle covers for left and right side. DC-Disconnect (if applicable): Position Number Description F 1 DC-Disconnect G 3 1 screw and one washer for closing the DC-Disconnect lid. 2 screws and washers for fastening the DC-Disconnect to the wallmounting bracket. Installation Guide SPR50-80m-IUS

20 AC voltage configuration SunPower 3 AC voltage configuration 3.1 Opening the inverter 1. Remove the 6 screws and lock washers from the enclosure lid and pull the lid forward smoothly. 2. Place the lid, screws, and lock washers aside where they will be out of your way while you are connecting wires and cables to the inverter. CAUTION Be careful not to misplace the screws or the lock washers, as all six screws and lock washers are required to ensure that the lid is grounded properly and is fully sealed to the case. Handle the lid carefully, as even minor damage to the lid could result in an inadequate seal between the lid and the case, thus allowing moisture to enter the case and damage the sensitive electronic components. NOTICE Do not install the inverter during periods of precipitation or high humidity (>95 %). Moisture trapped within the enclosure may cause corrosion and damage to the electronic components. 20 SPR50-80m-IUS Installation Guide

21 AC voltage configuration 3.2 Locating internal components The figure below illustrates the locations of the major internal components of the inverter. Refer to this illustration as needed to locate particular components. Position A B C D Description Sockets for communication Piggy-Back Display Status LEDs Voltage Configuration Jumpers Installation Guide SPR50-80m-IUS

22 AC voltage configuration SunPower Position Description E Voltage Configuration Terminal Blocks F Ground Terminal (PE) G Output AC Line Terminals (N, L1 and L2) H PV Grounding + DC Grounding electrode conductor I Output AC Line Terminals (L1, L2, N and PE) K PV GROUNDED Terminal (input from PV array) L PV UNGROUNDED Terminal (input from PV array) M Combined UNGROUNDED Terminal N DC Terminal (input from PV array) O DC+ Terminal (input from PV array) P Flat connection for grounding the cable shield for communication Q Terminal for communication 22 SPR50-80m-IUS Installation Guide

23 AC voltage configuration Configuring the AC voltage The SPR-8000m may not be connected to a 208 V grid. The inverter may be easily configured for the different grid types commonly found in the U.S. The inverter is compatible with: 208 V AC output (except for SPR-8000m) 240 V AC output 277 V AC output The inverter comes from the factory pre-configured for utility interconnection at 240 V AC. The inverter may be reconfigured for other voltages by following the steps below and referring to figure to the right. There are four wires coming into the main cabinet through a grommet. Each wire is labeled with its corresponding voltage and is connected to one of the two large terminal blocks located just below the grommet. Refer to the figure on the right and follow the instructions below: 1. The input voltage setting is determined by the jumper that is connected to the left terminal block (A). If the system is 240 V, no adjustment is necessary. 2. If adjustment is necessary, choose the wire with the correct voltage for your application from the right terminal block (C). Connect it to the left side of the left terminal block (A). Tighten all wires on the left terminal block. Torques for left AC configuration terminal block: Grey Terminal Blocks (Weidmüller) 10 6 AWG (6 mm² 16 mm²): 18 in lbs. (2 Nm) Green Terminal Blocks (Phoenix) 8 6 AWG (10 mm² 16 mm²): 40 in lbs. (4.5 Nm) 10 AWG (8 mm²): 22 in lbs. (2.5 Nm) 3. Do not remove the wire in the left terminal block labeled 0 V (B). It remains connected to the right side of the left terminal block in all configurations. 4. Connect all unused wires to the right terminal block (C) and tighten them. Torques for right AC configuration terminal block (unused wires): Grey Terminal Blocks (Weidmüller) 11 in lbs. (1.2 Nm) Green Terminal Blocks (Phoenix) 15 in lbs. (1.7 Nm) Installation Guide SPR50-80m-IUS

24 AC voltage configuration SunPower If the inverter is configured for the incorrect transformer voltage, (e.g. the inverter is configured for 240 V and then connected to a 208 V grid), the inverter will display the following error message: If this error message is encountered, recheck the input voltage configuration and confirm that it is set properly. Automatic grid voltage detection The inverter s software is designed to automatically detect which grid voltage it is feeding. Depending upon the voltage and phase angle between L1-N and L2-N, the inverter will determine if it is connected to a 208 V, 240 V or 277 V grid. If the inverter is configured for the incorrect transformer voltage (e. g. the inverter is configured for 240 V and then connected to a 208 V grid) the inverter will display an error message. Table below lists the voltage limits for the AC connection with a frequency range of 59.3 Hz 60.5 Hz. AC Connection Type Voltage Range 208 V nominal, line to line (except SPR-8000m) 183 V 229 V 240 V nominal, line to line 211 V 264 V 277 V nominal, line to neutral 244 V 305 V If the utility system has a neutral, the local Authority Having Jurisdiction (AHJ) may require that the neutral be connected to the inverter. Follow the procedure in chapter 3.3 Utility configuration jumpers (page 26) and chapter AC wiring without DC-disconnect (page 49) to set the configuration jumpers and connect a neutral conductor to the inverter. 24 SPR50-80m-IUS Installation Guide

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