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Contents
1.2 Introduction of the Manual................................................................... 1
1.4 Functions of the Manual ...................................................................... 3
2.2.1 Live Line Measurement .......................................................... 10
2.2.2 Opening Plant .......................................................................... 10
2.2.3 Requirements Prior to Connecting the Switches on AC and DC
2.2.4 Notes on Shutdown ................................................................. 12
3.1 Start up under the Case of Internal Power Supply of Control Power . 13
3.1.1 Preparations before Startup ..................................................... 14
3.1.2 Startup Steps ............................................................................ 15
3.2 Startup in the Case of External Power Supply of Control Power ....... 17
3.4 Emergency Shutdown ........................................................................ 23
I
3.5 Precautions for Maintenance and Overhauling .................................. 23
4.1 PV Grid-Connected Power Generation System ................................. 26
4.2 Communication Mode ........................................................................ 27
4.2.1 GE 485 Communication .......................................................... 27
4.2.2 Ethernet Communication ........................................................ 27
4.3.1 Circuit Topology ..................................................................... 27
4.3.2 Appearance Description .......................................................... 29
5.2 Running Mode Swapping ................................................................... 40
6 Operation Introduction for LCD Display ................................................. 42
6.1 Logical Architecture of LCD Display ................................................ 42
6.2 LCD Display Instructions .................................................................. 42
8 Fault Analysis and Troubleshooting .......................................................... 54
8.2 Fault Diagnosis and Troubleshooting ................................................. 55
II
9.1.1 Electrical Part .......................................................................... 57
9.1.2 Mechanical Part ....................................................................... 57
9.1.3 System Data ............................................................................ 58
9.2.1 Standard Warranty ................................................................... 58
9.2.2 Extended Warranty .................................................................. 59
9.2.3 Contact Us ............................................................................... 60
III
1 About this Manual
1.1 Introduction
TC500K3US-O User Manual
Dear customer, thank you for using TC500K3US-O PV grid-connected inverters independently developed and manufactured by TBEA Xi’ an Electric
Technology Co., Ltd.. We sincerely hope that this product will meet your needs and hope that you can put your valuable views on the design and performance of the product. Customers’ comments will be the energy for our progresses.
1.2 Introduction of the Manual
This manual is applicable to TC500K3US-O PV grid-connected inverter products (hereinafter referred to as ’inverters’). The main contents of this manual are:
Safety instructions
It introduces the safety precautions and warning labels noted during the operation and maintenance of inverters.
Startup and shutdown procedures
Pre-inspections and detailed steps.
Product description
Power generation system topology applied as well as functions of inverters.
1
Operating mode
TC500K3US-O User Manual
Various operating statuses.
Operation introduction for LCD display
Applications and operations of LCD display.
Routine maintenance
Routine maintenance cycles and methods.
Fault analysis and problem solving
Possible faults and processing methods.
Appendix
It introduces the technical parameters, quality clause and the contact information.
1.3 Application Scope
This manual is for the staff working on installing and operating of the inverter. Staff for installation and maintenance shall be equipped with certain expertise in electrical, wiring and mechanical fields, familiar with electrical, mechanical schematics and features of electronic components. It is also required for the staff to be familiar with the content of the document and to comply with the safety regulations.
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1.4 Functions of the Manual
TC500K3US-O User Manual
Please read this manual carefully before installing the product. Please keep this manual on hand for quick reference. In addition to this installation manual, the following documents can also be used.
1.5 Description of Symbols
In order to ensure the personal and property safety, the manual provides the relevant information and uses appropriate symbols to emphasize and highlight, so as to help customers using the product more efficiently. The symbols used in the manual are listed below, please read carefully.
“DANGER” indicates a high degree of potential hazards, if not avoided, which will lead to death or serious injury.
“WARNING” indicates a moderate degree of potential hazards, if not avoided, which may result in death or serious injury.
“CAUTION” indicates a low level of risks, if not avoided, which may result in moderate or minor injuries to personnel.
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TC500K3US-O User Manual
“NOTICE” indicates potential hazards, if not avoided, which may cause the result that equipment cannot work properly or cause losses to property.
“DISCRIPTION” is the additional information of the manual, the emphasis and supplement of the contents, which may also provide product optimization tips or tricks can help you solve certain problem or save your time.
Warning electric shock
This logo indicates that the inverter interior contains high voltage, and an electric shock may be caused when touching.
Warning hot surface
This symbol indicates that the temperature here is higher than that within the body acceptable range, so please do not touch arbitrarily to avoid personal injuries.
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TC500K3US-O User Manual
PE
This symbol indicates that it is the PE port, and solid grounding is needed to ensure the safety of operating personnel.
ON
This symbol is the “ON” position schematic diagram of AC and DC circuit breakers.
OFF
This symbol is the “OFF” position schematic diagram of AC and DC circuit breakers.
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2 Safety Precautions
TC500K3US-O User Manual
This chapter introduces the overview of safe use of TC500K3US-O PV inverters and safety precautions to be followed during installation and operation.
2.1 Safety Precautions
Danger to life from electric shock due to live voltage.
High voltages are present in the live components of the inverter. Touching live components results in death or serious injury due to electric shock.
When working in a high contact-risk environment, wear personal protective equipment.
Do not touch live components.
Follow the instructions precisely.
Observe all safety messages on the product and in the documentation.
Before any work on the inverter is performed, always disconnect all external voltage sources of the plant.
(1) Grid voltage
(2) External power supply
(3) DC voltage of PV array
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TC500K3US-O User Manual
Ensure that no disconnected components can be reconnected.
After disconnecting the inverter from voltage sources, wait at least 5 minutes for the capacitors of the inverter to discharge completely.
DC cables connected to PV modules that are exposed to sunlight are live. Touching live components results in death or serious injury.
Wear suitable personal protective equipment for all work on the inverter.
Prior to connecting the DC cables, ensure that the DC cables are voltage-free.
Unauthorized modification or damaged device can lead to danger to life due to electric shock or fire hazard.
It is forbidden to refit the equipment and no unauthorized person can use the equipment.
Initially and visually check whether the equipment is damaged or has other dangerous conditions before operating.
Check whether other external equipments or circuit connections are in safe states.
Confirm that this equipment is in a safe state, and then operate.
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TC500K3US-O User Manual
Danger to life when the inverter is not locked.
If the inverter is not locked, this means that unauthorized persons have access to components carrying lethal voltage. Touching live components can result in death or serious personal injury due to electric shock.
(1) Always keep the inverter locked.
(2) Remove the keys from the door locks and from the key switch.
(3) Keep the keys in a safe place.
(4) Ensure that unauthorized persons do not have access to the PV plant.
Danger to life due to blocked escape routes.
In hazardous situations, blocked escape routes can lead to death or serious injury. It is imperative that the escape route is freely accessible at all times.
(1) An escape route of at least 3 ft. (915 mm) width must be available at all times. Make sure the minimum passage width of the route meets local standards.
(2) Remove all tripping hazards from the escape routes.
(3) Do not place any objects in the escape route area.
(4) If two inverters have been installed facing each other, never open the doors of both inverters simultaneously.
Only qualified electricians or persons are allowed to work on the product.
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TC500K3US-O User Manual
(1) It must ensure that at least 2 personnel are working in the field until the equipment is safely de-energized and discharged completely during maintenance.
(2) Only after getting permission of local power company and completing installation by qualified persons, can the inverter be connected with the grid.
(3) Electrical installation must comply with local electrical installation standards.
Improper contacts or operations of printed circuit boards or other static-sensitive components will cause damages to the device.
(1) Avoid unnecessary contacts with the circuit board.
(2) Comply with the electrostatic protection specification, wear antistatic wrist straps.
During the overhaul of the plant and routine maintenance, turn the breakers on AC and DC sides to “OFF” to avoid irrelevant personnel from approaching or meeting with accident. It is recommended to erect warning labels or set up barrier tape.
This manual cannot cover all the possible cases in transportation, installation, commissioning. If encountering some cases not described in the manual, please contact TBEA Co., Ltd..
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2.2 Notes on Operation
2.2.1 Live Line Measurement
TC500K3US-O User Manual
High voltage is present in the plant. Touching by accident may result in death or personal injury due to electric shock. Prior to live line measurement, it is imperative to wear suitable personal protective equipment and instruments (such as wearing insulated gloves, etc.).
2.2.2 Opening Plant
Even if all connections to the inverter have been disconnected, lethal voltage may still be present in the capacitor of the inverter. After disconnecting the inverter from voltage sources, wait at least 5 minutes for the capacitor of the inverter to discharge completely before maintenance and overhaul or other operations.
2.2.3 Requirements Prior to Connecting the Switches on AC and
DC Sides
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TC500K3US-O User Manual
Breakers on AC, DC sides shall be disconnected and the protective panel against accidental touch shall be installed or protective measures be taken.
All connections must be carried out in accordance with the installation manual and schematics.
Protective earthing connection has been done with power grid transmission and internal power supply.
Confirm that the inverter has been closed and locked.
Emergency stop switch is in loose.
It shall be confirmed that the rated voltage, frequency and phase sequence of the connection terminals on AC side are in line with requirements.
It shall be confirmed that the voltage polarity on DC side is correctly
connected.
Check PV array by insulation test to ensure there is no ground fault.
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2.2.4 Notes on Shutdown
TC500K3US-O User Manual
There are two cases for shutdown, in normal maintenance and in fault occurring. The procedures for respective shutdown are as follows:
Normal maintenance and overhaul
Shutdown procedure:
(1) Turn the key switch to “OFF”.
(2) Observe the LCD display until the rate of work of the display is shown as “0”.
(3) Turn both AC and DC circuit breakers to “OFF”.
(4) Disconnect the front and rear breakers of the inverter.
When fault or emergency occurring
Shutdown procedure:
(1) Press down the emergency stop button then turn the key switch to
“OFF”.
(2) Turn both AC and DC circuit breakers to “OFF”, and then disconnect the preamplifier breaker and after stage amplifier circuit breaker.
(3) Turn the key switch to “OFF”.
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3 Startup and Shutdown Steps
TC500K3US-O User Manual
3.1 Start up under the Case of Internal Power Supply of Control
Power
The power control of TC500K3US-O PV is divided into 2 operating conditions, internal power supply and external power supply:
Internal power supply
The AC voltage source (applicable to the range of 176V AC -220V AC) required by the inverter control system shall get electricity from the lines between Phase A and Phase B upside the AC circuit breaker. When the grid voltage is normal, and after the AC circuit breaker is closed, the grid can provide control power to the system.
See details for accessing control power for internal power supply in the control power system in the installation manual of TC500K3US-O PV grid-connected inverters, and the energizing air-switch position of internal control power is as shown in Figure 3-1.
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TC500K3US-O User Manual
Figure 3-1 Air-switch of internal power supply
3.1.1 Preparations before Startup
(1) All connections are carried out in accordance with the installation manual and circuit diagrams.
(2) Ensure the inverter has made protective grounding connections for the strong current at AC and DC sides and the system control power supply.
(3) The startup key is at the “OFF” position.
(4) The emergency stop button is pressed.
(5) The AC and DC circuit breakers are at the “OFF” position, and installed with protective covers.
(6) Check the lines, and make sure the connecting cables are correct.
(7) Measure with a multimeter and make sure that the grid voltage is
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TC500K3US-O User Manual normal.
(8) Check PV modules VIA insulation tests to ensure there is no ground fault.
If conditions permit, use oscilloscopes and other related equipments to check whether the grid voltage frequency and the phase sequence at the connecting side of the grid and the inverter are normal as far as possible
(the frequency is within the range of 59.8Hz-60.5Hz), otherwise, it will lead to failure of the inverter startup.
3.1.2 Startup Steps
When the above meets the normal startup requirements, carry out the following operations:
Step 1
Close the inverter door at the AC side, then turn the AC side circuit breaker from “OFF” to “ON”, the closing of AC side circuit breaker is completed.
Step 2
Check whether the air-switch of internal control power of DC side door is closed, if not, please close the air-switches of the control power.
Step 3
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TC500K3US-O User Manual
After the AC side circuit breaker is closed, the energizing process of the internal power supply of control power is completed, and LCD display is started, if everything is normal, the control power is energized successfully, enter into Step 4.
Step 4
Close the combiner boxes of all lines in sequence, and check whether combiner boxes operate properly, if normal, enter into Step 5.
Step 5
Close the inverter door at DC side, and turn the circuit breaker at DC side from “OFF” to “ON”, the closing of DC side circuit breaker is completed.
Step 6
Observe whether the voltage at AC and DC sides on LCD display is normal again, if the voltage at both sides is within the normal startup voltage range, then screw on the emergency stop button. It can be observed that the panel LED lights change from the flashing yellow light to the constantly on green light immediately (the display status and logic of LED lights on the panel refer to the description contents of LED lights in Chapter 4). If the LED light on the panel is not the constantly on green light, it proves that the inverter has faults, please check the fault records on the LCD display or the fault records on the background monitoring interface immediately, and then refer to Chapter 8
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Fault handling to clear the faults.
Step 7
TC500K3US-O User Manual
In the case that the green light is on constantly, turn the key switch on the inverter panel from “OFF” to “ON”, the inverter will automatically enter the grid-connected working state. LED light immediately turns into the constantly on red light after grid connection is completed (when the red light is on constantly, it indicates that the grid-connected power generation of the inverter is successful). See the description of LED lights in Chapter 4 for details.
Once the inverter runs normally, no man-made interferences and controls are needed. It is necessary to open the inverter door only in case of maintenance and troubleshooting. Lock the inverter door with keys properly during normal operations. Keys shall be kept by a specially-assigned person, and the inverter door shall be opened by professional staff.
3.2 Startup in the Case of External Power Supply of Control
Power
The control power of TC500K3US-O PV grid-controlled inverter is divided into 2 operating conditions, internal power supply and external power supply:
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External power supply
TC500K3US-O User Manual
The AC voltage source (applicable to the range of 176V AC -220V AC) required by the inverter control system shall be provided from the external power supply of the inverter. See details for accessing control power for external power supply in the control power system in the installation manual of
TC500K3US-O PV grid-connected inverters. The energizing air-switch position of external control power is as shown in Figure 3-2.
Figure 3-2 Energizing air-switch of external power supply
(1) All connections are carried out in accordance with the installation manual and circuit diagrams.
(2) Ensure that the inverter has made protective grounding connections for the strong current at AC and DC sides and the system control power supply.
(3) The startup key is at the “OFF” position.
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(4) The emergency stop button is pressed.
TC500K3US-O User Manual
(5) The AC and DC circuit breakers are at the “OFF” position, and installed with protective covers.
(6) Check the lines, and make sure the connecting cables are correct.
(7) Measure with a multimeter and make sure that the grid voltage is normal.
(8) Check PV modules VIA insulation tests to ensure there is no ground fault.
If conditions permit, use oscilloscopes and other related equipments to check whether the grid voltage frequency and the phase sequence at the connecting side of the grid and the inverter are normal as far as possible
(the frequency is within the range of 59.8Hz-60.5Hz), otherwise, it will lead to failure of the inverter startup.
When the above meets the normal startup requirements, carry out the following operations:
Step 1
Check whether the air-switch of external control power of DC side inverter door is closed, if not, please close the air-switch of control power. And use a multimeter to measure whether the input voltage of AC control power is
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TC500K3US-O User Manual normal (within the range of 176V-220V). If not, please adjust the output voltage of the external power supply voltage source to the normal range
(176V-220V). After the external control power is normal, enter Step 2.
Step 2
After the energizing process of the external power supply of control power is completed, immediately check whether LCD display is started normally, if everything is normal, the control power is energized successfully, then enter into Step 3.
Step 3
Close the inverter door at the inverter AC side, and turn the circuit breaker of the inverter at AC side from “OFF” to “ON”, the closing of AC side circuit breaker is completed. Observe whether the AC side voltage displayed on LCD display is normal, if not normal, please refer to Chapter 8 Grid overvoltage or under-voltage fault handling.
Step 4
Close the combiner boxes of all lines in sequence, and check whether combiner boxes operate properly, if normal, then enter into Step 5.
Step 5
Close the inverter door at the inverter DC side, and turn the circuit breaker of the inverter at DC side from “OFF” to “ON”, the closing of DC side circuit
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TC500K3US-O User Manual breaker is completed. Observe whether the DC side voltage on LCD display is normal. If not, please refer to Chapter 8 DC side overvoltage and under-voltage faults handling.
Step 6
Observe whether the voltage at AC and DC sides on LCD display is normal again, if the voltage at both sides is within the normal startup voltage range, then screw on the emergency stop button. It can be observed that the panel LED lights change from the flashing yellow light to the constantly on green light immediately (the display status and logic of LED lights on the panel refer to the description contents of LED lights in Chapter 4). If the LED light on the panel is not the constantly on green light, it proves that the inverter has faults, please check the fault records on the LCD display or the fault records on the background monitoring interface immediately, and then refer to Chapter 8
Fault handling to clear the faults.
Step 7
In the case that the green light is on constantly, turn the key switch on the inverter panel from “OFF” to “ON”, the inverter will automatically enter the grid-connected working state. LED light immediately turns into the constantly on red light after grid connection is completed (when the red light is on constantly, it indicates that the grid-connected power generation of the inverter is successful). See the description of LED lights in Chapter 4 for details.
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3.3 Normal Shutdown
TC500K3US-O User Manual
Shutdown of inverters is usually divided into 2 cases, i.e. normal shutdown when the machine is normal in case of normal maintenances, the emergency shutdown in case of faults.
Step 1
Turn the key switch on the inverter panel from “OFF” to “ON”, and then press the emergency stop button.
Step 2
Disconnect the circuit breaker at AC side, and then disconnect the DC circuit breaker.
In case of maintenances or inspections, if the inverter door of the inverter needs to be opened. It is noteworthy that even if all connections of the inverter have been disconnected, the capacitor of the inverter may still have lethal high voltage causing the risk of death. After the inverter is closed, please wait at least 5 minutes to discharge the power of the capacitor. Carry out maintenance, overhauling and other operations when the voltage value at DC side is reduced to a safe range by measuring with a multimeter.
When the machine is working properly, prohibit directly disconnecting the circuit breakers at AC and DC sides to avoid the risk of
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TC500K3US-O User Manual
damages to the breaker causing by arcing. Severely, it may also cause damages to the inverter.
3.4 Emergency Shutdown
Step 1
First press the emergency stop button on the inverter panel quickly.
Disconnect the circuit breaker at AC side, and then disconnect the DC circuit breaker.
Step 2
Then turn the key switch on the inverter panel to “OFF”.
In case of maintenances or inspections, if the door of inverter needs to be opened, it is noteworthy that even if all connections of the inverter have been disconnected, the capacitor of the inverter may still have lethal high voltage causing the risk of death. After the inverter is closed, please wait at least 5 minutes to discharge the power of the capacitor. Carry out maintenance, overhauling and other operations when the voltage value at
DC side is reduced to a safe range by measuring with a multimeter.
3.5 Precautions for Maintenance and Overhauling
Before carrying out maintenance and overhauling of equipments, first refer to Section 3.4 for the correct shutdown of inverters, meanwhile, the
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following points shall also be noted:
TC500K3US-O User Manual
Ensure that at least 2 operating staff shall be involved during overhauling.
Carefully view the operation manual before overhauling.
Carry the essential tools for inverter overhauling, and it is required to wear insulating gloves during overhauling operations.
First disconnect the power supply at DC and AC sides (grid air-switch).
Then the control power must be accessed from the external power supply.
After the inverter stops operating, be sure to wait at least 5 minutes, carry out maintenance, overhauling and other operations for the inverter after checked that the bus is fully discharged by measuring with a multimeter.
Conduct necessary grounding and short circuit connections.
Use cloths of insulating materials to conduct insulating covering for the parts of operation parts which may be near live parts.
In the whole maintenance and overhauling process, it is required to ensure that the tunnel escape is smooth.
General considerations include the following:
Since inverters are basically installed in a place far away from the urban areas, relevant first aid and emergency response measures shall be available at the inverter using places.
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TC500K3US-O User Manual
With related auxiliary facilities to ensure the safety of personnel and equipments, for example, when carrying out maintenance, overhauling and other operations for equipments, relevant personnel shall take appropriate protective measures as required, such as wearing earplugs, insulating shoes, anti-scald gloves, etc.
All operations for the inverter are required to comply with the relevant standards of the installation location.
This manual does not cover the actual situations and problems encountered in all field operation processes. Therefore, when encountering problems cannot be explained or solved by the manual, please timely contact TBEA Xi’ an Electric Technology Co., Ltd..
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4 Product Description
TC500K3US-O User Manual
4.1 PV Grid-Connected Power Generation System
PV grid-connected power generation system is as shown in Figure 4-1, which is composed by PV array, combiner box, grid-connected inverter and data acquisition system. Solar energy is converted into direct current via PV modules, and then the combiner box shall reasonably allocate the power transmitted by PV arrays. Then the direct current shall be converted into the sine-wave current with the same frequency as the grid and the controllable phase amplitude via TC500K3US-O PV grid-connected inverters, and finally fed into the grid through a transformer matching grid voltage.
PV array Combiner box PV inverter Transformer
Grid
Monitoring and scheduling unit
Figure 4-1 PV grid-connected power generation system
TC500K3US-O PV grid-connected inverter independently developed by
TBEA Xi’ an Electric Technology Co., Ltd. is a station inverter without transformers inside. It is applicable to harsh outdoor environments, and is an important part of PV power generation system.
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4.2 Communication Mode
TC500K3US-O User Manual
4.2.1 GE 485 Communication
The inverter adopts the standard RS485 serial communication mode.
Single or multiple inverters can communicate with the host PC via
RS485/RS232 converter, and comprehensive monitoring and control operations are carried out via the PC background monitoring software. Or first use the standard RS485 serial port to connect to the communication management machine, and communicate with the PC background via RS485/RS232 converter.
4.2.2 Ethernet Communication
In addition to GE 485 communication, TC500K3US-O inverter hardware is also set up with the Ethernet communication module, users can choose to configure the Ethernet communications when needed. If users need to configure the Ethernet communications, please contact us. Please refer to
Chapter 9 for the contact information of our company.
4.3 Hardware Structure
4.3.1 Circuit Topology
Figure 4-2 is the circuit topology structure of TC500K3US-O PV grid-connected inverter. The inverter converts DC input by PV arrays into AC via the three-phase full -bridge inverter, filters will filter it into sine-wave current, and finally it will be connected to the grid for power generation after
27
matched by the transformer.
TC500K3US-O User Manual
-2 er ilt C f EM er ilt C f EM
320V－580V
Figure 4-2 Inverter structure
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4.3.2 Appearance Description
TC500K3US-O User Manual
The appearance of TC500K3US-O inverter is as shown in Figure 4-3.
Figure 4-3 Inverter appearance
The main components of TC500K3US-O appearance external view is as described in Table 4-1, the main function of the various components in the table are described below:
Table 4-1 Main components of inverter
Items Device name
①
Panel lights
②
③
LCD display
Key switch
④
⑤
Description
Displaying the operating status of inverters
Displaying the information of operating data
Controlling inverter switches
Emergency stop button
When users need an emergency stop, the emergency stop can be achieved through this button
DC circuit breaker Disconnecting the inverter and the DC source
⑥
⑦
Door lock
To close the front door of the inverter, use the matching key to lock the door
AC circuit breaker
Disconnecting the inverter and the AC source
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Items Device name
⑧
⑨
DC input cabinet
Inverter cabinet
⑩
AC output cabinet
(1) Panel lights
TC500K3US-O User Manual
Description
There are 3 LED display lights (yellow, green and red) on TC500K3US-O inverter panel. The 3 LED indicator lights will only be lit at the same time. It is described as follows for different situations:
Green light is on constantly
The green light is on constantly only when all circumstances meet the startup conditions.
Green light is flashing
When the system enters into self-test status, the green light is flashing.
Red light is on constantly
Red light is on constantly when equipments operate in connected grids.
Yellow light is on constantly
When the inverter has an internal fault, the yellow light is on constantly.
Yellow light is flashing
When the inverter has an external fault, the yellow light is flashing.
(2) LCD display
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TC500K3US-O User Manual
Users can check monitor message via LCD display to carry out some specific monitor functions which are as follows:
Displaying startup steps
Displaying real-time operating data
Displaying fault information
To check historical events recorded
(3) Key switch
Panel key switch is used to control the inverter to be on or off. When external conditions are met, turn the key switch to “ON” so that the inverter starts up. During normal startup or operation, turn the key switch to "OFF" so that the inverter shuts down.
(4) Emergency stop button
When the plant is in need of emergency shutdown during operation or startup, quickly push the emergency stop button, by which the inverter is turned off immediately. At this point, LED yellow lights on the inverter panel come to flash.
When the emergency stop button is once pushed and restarting the plant is required, it shall be done to switch the emergence stop button upward and reset the key switch.
(5) DC circuit breaker
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TC500K3US-O User Manual
Three DC circuit breakers are configurations for DC input, which are inside of the DC inverter on the left side of the inverter. Three-circuit parallel breakers, the main breaker component of the inverter, are used to control make-break of the DC main circuit, and they can carry out the function that hardware module exerts disconnecting protection to DC current with overcurrent or overheat. When the three DC circuit breakers are on “OFF” position, the power supply to photovoltaic DC source leading to the inverter is cut off.
(6) Door lock
Before the normal startup of the inverter, lock shall be used to lock the inverter door, which serves to protect staff and the device itself. The key to the lock shall be safe kept by specialized personnel; non-staff can readily open the inverter door.
(7) AC circuit breaker
AC circuit breaker, inside of AC output inverter on the right side of the inverter, is the main breaker component of the inverter and used to control make-break of the AC circuit. It can carry out the function that hardware module exerts disconnecting power grid from the inverter when its output side is with overcurrent and overheat. When the AC circuit breaker is on the "OFF", all AC power supply are cut off.
4.4 Functions of Inverter
Besides offering application functions to users as shown in Table 4-2, one
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TC500K3US-O User Manual function of TC500K3US-O inverter is grid-generation, and on the other hand the inverter has a perfect protection feature as shown in Table 4-3.
Function
Output power regulation
Adjustable power factor
MPPT
Table 4-2 Applications of inverter
Description
Users can achieve the adjustment of active and reactive powers from 5% to
100 % by using the background monitoring software
The power factor of
TC500K3US-O inverter can be adjusted continuously in the range of 0.9 (leading) ~
0.9 (lagging)
TC500K3US-O inverter has the maximum power output function during the normal operation process
Remarks
Inverters need to reduce powers to achieve their own protection under special circumstances
Achieve the grid security management scheduling
Participate in the adjustment of the grid voltage, improve the voltage level of the power system, and improve the power quality
None
Excellent conversion efficiency
Peak efficiency of 97.7% None
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TC500K3US-O User Manual
GFDI protection
Table 4-3 Self-protection function of inverter
Protection function
DC overvoltage protection
DC under-voltage protection
Reverse polarity protection
Description
When the voltage at DC side exceeds a certain range, the inverter will shut down to implement the protective operation, and report the type of fault to LCD display
When the voltage at DC side is below a certain range, the inverter will shut down to implement the protective operation, and report the type of fault to LCD display
When the positive and negative polarities at DC input are reversed, the inverter will shut down to implement the protective operation, and report the type of fault to LCD display
TC500K3US-O is equipped with the hardware protection-oriented and the software detection protection assisted dual protection method, which has achieved the redundancy protection, and is safe and reliable. When GFDI has a fault, it can effectively protect the
Remarks
None
None
None
None
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Protection function
AC overvoltage protection
AC under-voltage protection
AC over-frequency protection
AC under-frequency protection
Description
TC500K3US-O User Manual
Remarks
inverter, and report the type of fault to LCD display
When the voltage at AC side exceeds a certain range, the inverter will shut down to implement the protective operation, and report the type of fault to LCD display
When the voltage at AC side is below a certain range, the inverter will shut down to implement the protective operation, and report the type of fault to LCD display
When the frequency at AC side exceeds a certain range, the inverter will shut down to implement the protective operation, and report the type of fault to LCD display
When the frequency at AC side is below a certain range, the inverter will shut down to implement the protective operation, and report the type of fault to LCD display
None
None
None
None
35
Protection function
Overload protection
PV under- power protection
Over-current protection
Environmental over-temperature protection
IGBT over-temperature protection
Description
TC500K3US-O User Manual
Remarks
When the input power at DC side is too large, after the output power of the inverter overloads 2 hours, the inverter system will implement the protective operation to limit the output power within the safe range
When the input power at PV side is too low, the inverter will implement the shutdown protective operation
When the inverter output current exceeds a certain range, the inverter will implement the shutdown protective operation
None
None
None
In the case that the ambient temperature exceeds 50°, the inverter will implement output power derating; in the case that the ambient temperature exceeds
60°, the inverter will implement the shutdown operation protective
When the temperature of IGBT power module in the inverter exceeds a certain range, the inverter will implement the protective operation
None
None
36
Protection function
Islanding protection
Description
TC500K3US-O User Manual
Remarks
“Island Effect” refers to the phenomenon that when the grid is de-energized, if the resonant frequency of a partial load at the
TC500K3US-O inverter system frequency of the grid, can automatically implement the inverter output side is equal to the rated the inverter will shutdown protective operation in case of “islanding” continue to work, and the power generation equipment will supply power for the load as an isolated power.
“Island Effect” has significant risks to the safety of equipments and personnel
37
5 Running Mode
5.1 Running Mode
TC500K3US-O User Manual
The operating status of TC500K3US-O inverter are basically “starting up”,
“system standby”, “grid-connected operation”, “manual shutdown”, “fault shutdown”, “emergency shutdown”, which are respectively explained as follows:
Starting up
The key switch shall not be switched to “ON” until the inverter has been installed and DC input and AC output cables are properly connected, in addition to breakers are closed and all preparation for powering on are completed.
System standby
When the system detects conditions for starting up AC and DC are normal and detects no serious fault, the photovoltaic power generation system shifts to standby mode.
Grid-connected operation
During the standby, the photovoltaic power generation system comes to self-test and after it detects that all operating conditions for starting up the plant are normal the system will control the contactor on AC side to be closed. Then the system shifts to grid-connected operation status and transfers energy on DC
38
side to the grid in the form of alternating current.
TC500K3US-O User Manual
If any fault occurs or not all conditions for starting up the plant are met during the system shifting from standby mode to grid-connected operation mode, the system will not shift to grid-connected operation.
Fault shutdown
When the photovoltaic power generation system is under grid-connected operation and any internal or external fault occurs, the inverter will stop running and shift to failure state, and then failure causes will be displayed on
LCD display for users. By this time, the system continues to monitor whether the fault is eliminated or not, if the fault is not eliminated the system remains failure state; if the fault is eliminated and conditions for starting up the plant are met, the system will automatically start up in five minutes later and eventually turn to grid-connected operation mode again.
Manual shutdown
Manual shutdown refers to artificially switching the key switch on the inverter panel to “OFF” to make the inverter turn to shutdown mode. It is worth noting that when a serious fault shutdown happens to the system the key switch shall be restarted by first switching the key switch to “OFF” and then to
“ON” (to realize a reset to the key switch).
39
Emergency shutdown
TC500K3US-O User Manual
When the inverter system goes into any above emergency status, press down the scram button on the panel to stop the inverter.
As emergency shutdown is the shutdown caused by serious fault, it is also required to once reset the key switch after the shutdown.
5.2 Running Mode Swapping
The grid-generation of TC500K3US-O grid-connected inverter is operated automatically, without human interference and control. It can detect whether the AC grid is met with conditions for grid-generation and whether PV array has enough energy; after all conditions are met it will go into grid-generation mode. The figure for operating mode swapping of the inverter is as shown in
Figure 5-1.
40
Wiring is completed, check the line, power it
TC500K3US-O User Manual
Boot
AC and DC systems to meet the start up conditions
Occurred during the start up of AC and DC conditions not met means the internal system failure
System standby
System self-test is completed, the inverter is free of trouble
Emergency shutdown
In an emergency, press the emergency stop button for system shutdown
Gridded operation
In case of serious failure, must restart key switch, first "OFF" and then back to
"ON"
Human shutdown
1. Fault clear;
2. Start up conditions met;
3. Loosen the emergency stop button to restore the system
During operation, the control system can be turned off via the key switch, turn the key switch to "OFF"
Troubleshooting ended, start up system operating conditions are met, the system waits for 5MINS from starting
Failure shutdown
Its own module fault of inverter occurs as well as the external AC and DC fault can be subjective to observations displayed via the LCD
Figure 5-1 Figure of operating mode swapping
41
TC500K3US-O User Manual
6 Operation Introduction for LCD Display
6.1 Logical Architecture of LCD Display
LCD display is on the observe side of the inverter, parallel to human eyes to facilitate users to check data and conduct related operations. Figure 6-1 shows the massive structure of the menu on LCD display interface.
Instant Power Daily Monthly Annual Events Lauguage
Home
Info Default Clear Backup Contrast Comm.
Time
Figure 6-1 Logical architecture of LCD display
6.2 LCD Display Instructions
Interface display Description
Start page: when the inverter is energized, LCD display will start automatically and simultaneously display the start page.
After the start-up process ends, LCD will automatically enter the main interface.
42
Instant
Upv
Uab
Ubc
Uca f
Home
521.0V
297.0A
Power :
Day :
152.1kW
2950.0kWh
Total : 9481.0kWh
Status: Running
Info
P
2013-10-01 18:26:00
315.0V 281.5A
315.1V 281.4A
314.8V 281.6A
TC500K3US-O User Manual
Main interface: the main interface includes input parameters, output parameters, generated power and energy, operating state, power trend charts and other information, and displays the current date and time.
Instant t
Home
521.0V
315.0V
315.1V
314.8V
50.00Hz
2013-10-01 18:26:00
Ipv 297.0A
Ia
Ib
Ic
λ
281.5A
281.4A
281.6A
0.99
1/2
Power
Operating data:
select
“operating data” in the navigation bar to enter the operating data interface, this interface displays the detailed data parameters of inverters in
2 pages, the left figure group shows the operating steps, and press the page-switching key to view.
Instant
Pin p
154.9kW
152.1kW
Day Time 503Min
24h
Sum Time
CO2 Sub.
Inverter temp.
9452.5kg
43.6℃
Q
S
2013-10-01 18:26:00
-0.1kVar
152.3kVA
2/2
Home Power
43
Power
600 kW
8
Instant
Power
600 kW
14
2013-10-01
Daily
20 h
2013-09-30
TC500K3US-O User Manual
Power curve: select “power curve” in the navigation bar to enter the power curve interface, this interface displays the power curve of the inverter output of the day, the horizontal axis is time, and the vertical axis is power.
Users can view the measured power curve as required. The left figure group shows the operating steps, it is described as follows:
(1) Press the page-turning key to “turn up” or “turn down” the date and view the historical data;
(2) Press the cancel key to restore to the current time data viewing.
Note: it can save 2 months data at most.
8
Instant
Daily
6 MWh
1
Power
14
15
Daily
20 h
2013-10
Generated energy: select the
“daily energy output”, the
“monthly energy output” and the “annual energy output” in the navigation bar to view the corresponding information of generated energy; view historical data, and the operation is as that of power curves.
30 d
Monthly
44
Monthly
150 MWh
2013
TC500K3US-O User Manual
1
Daily
Annual
2000 MWh
6 12 m
Annual
2013-10-01 12:00:00
2011
Monthly
2036 y
Events
Events 2013-10-01 12:00:00
2013-08-29 09:57:16 COM. Error
2013-08-21 14:03:20 DC Over-Voltage
2013-08-04 17:13:28 AC voltage high
2013-07-15 10:11:02 Frequency low
2013-07-02 12:38:41 L1Overheat Warn
2013-06-20 08:13:52 Grid phase
Event log: select “event log” in the navigation bar to enter the event log interface, this interface can view detailed event information. When the event information is more than
1 page, view historical events, press the page-turning key, and the operation is as that of power curves.
Annual
1/10
Language
45
Language
Events
Language
Select：
Chinese
Select:
Chinese
2013-10-01 12:00:00
Time
2013-10-01 12:00:00
TC500K3US-O User Manual
Language
setting: select
“language setting” in the navigation bar to enter into language setting. The left figure group shows the operating steps, it is described as follows:
(1) Press the edit key to enter into the operation interface of language setting;
(2) Press the “-” or “+” key to switch languages;
(3) Press the cursor moving key to carry out language
“Confirmation” or “Cancel” operation;
(4) Press the “Confirmation” operation, operation prompt will appear, such as
“successful operation” etc.; press the “Cancel” operation, restore to the original state of language setting;
Enter Cancle
Events Time
2013-10-01 12:00:00 Language
Events
Select: Chinese
Enter Cancle
Sucessful
Time
46
Time
Date：
2013
/10/01
Time： 12:10:00
2013-10-01 12:00:00
TC500K3US-O User Manual
Time setting: select “time setting” in the navigation bar, enter the time setting interface to set the display time of the system; the operation is as that of language setting.
Language
Comm.
Comm.
2013-10-01 12:00:00
BaudRate： 9600
Communication setting:
select “communication setting in the navigation bar, and enter the communication setting interface to conduct corresponding settings for the address and the baud rate of the system; the operation is as that of language setting.
Time
Contrast
Contrast
2013-10-01 12:00:00
Contrast
setting: select
“contrast setting” in the navigation bar, and enter the contrast setting interface to set the LCD contrast; the operation is as that of language setting.
Comm.
Backup
47
Backup
Contrast
Backup
Input USB
Input filename：
0 0
2013-10-01 12:00:00
Clear
2013-10-01 12:00:00
USB Connected
TC500K3US-O User Manual
Backup data: select “backup data” in the navigation bar to backup data. The left figure group shows the operating steps, it is described as follows:
(1) Insert U disk into the USB port of LCD, display the prompt “USB is connected”, and display the default file name “00”;
(2) Press the edit key to enter the file name modification modify, press “-” or “+” key to operate;
(3) Press the cursor moving key to move the cursor position;
(4) Press the “Confirmation” operation to backup data, operating prompts will appear, such as “Downloading”, etc.
Note: when it prompts
“Downloading”, do not remove the U disk.
Contrast
Clear
Backup 2013-10-01 12:00:00
Input filename：
0 0
Contrast
Enter Cancle
USB Connected
Clear
48
Backup 2013-10-01 12:00:00
TC500K3US-O User Manual
Input filename：
0 0
Contrast
Backup
Enter Cancle
USB Connected
Clear
2013-10-01 12:00:00
Input filename：
0 0
Loading...
Contrast
Clear
Clear
Password：
* * *
2013-10-01 12:00:00
Event clear: select “event clear” in the navigation bar to enter the event clear interface, the historical events of the system log can be cleared.
Backup Default
49
Clear 2013-10-01 12:00:00
TC500K3US-O User Manual
Password： * * *
Enter Cancle
Sucessful
Backup
Default
Default
Password：
* * *
2013-10-01 12:00:00
Factory reset: select “factory reset” in the navigation bar to enter the factory reset setting interface, the historical data and the setup parameters of the system can be cleared.
Default
Clear Info
2013-10-01 12:00:00
Password： * * *
Clear
Enter Cancle
Handling...
Info
50
Info 2013-10-01 12:00:00
Model :TC500K3US-O
Company :TBEA Xi'an Elec-Tech Co.LTD
Tel :400-606-6029
Website :http://www.tbeapower.com
S/N :0000000000000000
SoftVer. :V02B00D00(M) V01B04D00(F)
V01B02D00(T) V02B00D00(V) V01B00D06(L)
Default Home
TC500K3US-O User Manual
Product information: select
“product information” in the navigation bar, the display interface will display the relevant information of the inverter product.
51
7 Routine Maintenance
TC500K3US-O User Manual
All maintenance work on the equipment shall be performed by professional electricians.
Regular maintenance is required, including:
(1) Regularly inspect the connecting cables inside equipment, replace them when necessary;
(2) Regularly test on the functions of components;
(3) Regularly inspect contact joints;
(4) If necessary, regularly clean the inside of the chassis.
Table 7-1 shows the regular maintenance on TC500K3US-O inverter in general environment, when in a dusty environment the maintenance time shall be correspondingly shortened.
52
TC500K3US-O User Manual
Table 7-1 Regular maintenance on the inverter
Maintenance work
Maintenance intervals
Regularly clean inverter surfaces
Regularly replace dust meshes
12 months
6 - 12 months
Check whether the connections of all cables are loose, if loose, carry out necessary fastening; check whether the connection terminals and insulations have discoloration or shedding, replace the damaged or corroded connection terminals
Testing of cooling fan functions: check the functions and running noises of all fans, and fans can control its starting according to the temperature regulator during operations
Check whether the affixed warning labels are firm or clear, replace if necessary
Regularly replace fans
Testing of protection equipment functions includes: circuit breakers, power switch
12 months
12 months
12 months
5 years
12 months
53
8 Fault Analysis and Troubleshooting
TC500K3US-O User Manual
8.1 Troubleshooting
When the inverter cannot output current or abnormal change happens to generated energy, causes to system fault are generally as follows:
Connection failure on external power grid (e.g.: A, B, C lines are not properly connected, or phase sequence is connected wrong);
PV array exceeds the range of operating voltage;
Network voltage is lower than the normal operating voltage of the inverter;
Grid voltage is higher than the normal operating voltage of the inverter;
Grid frequency is lower than the normal operating frequency of the inverter;
Grid frequency is higher than the normal operating frequency of the inverter;
Output short circuit;
IGBT module failure.
54
TC500K3US-O User Manual
First, find out whether the general power outage occurs and whether the inverter output cable is disconnected.
If not finding any other fault, professional and technical personnel shall check the connection between the inverter and the transmission grid.
8.2 Fault Diagnosis and Troubleshooting
Any fault happens to the inverter can be checked through LCD display and background software. For various faults occurring in system operation, the corresponding fault diagnosis and troubleshooting are as shown in Table 8-1:
Fault type
PV1 Reverse
PV2 Reverse
PV3 Reverse
PV Over-Voltage
Grid phase fault
AC voltage high
Table 8-1 Troubleshooting chart
Fault cause
PV array positive and negative reverse connection
PV array positive and negative reverse connection
PV array positive and negative reverse connection
PV array voltage Above
600V
Three-phase AC lines
Connection error
Processing mode Remarks
Check the PV array line connections
Check the PV array line connections
Check the PV array line connections
Reduce the number of arrays in series
Check connections line
None
None
None
None
None
Grid voltage exceeds the range of 88% -110%
Check the grid
Automatically restart after the grid is recovered
55
Fault type
AC voltage low
Frequency high
Frequency low
LCD display communication failure
DC SPD
AC SPD
Fault cause
TC500K3US-O User Manual
Processing mode Remarks
Grid voltage exceeds the range of 88% -110%
Grid frequency exceeds the range of 59.8Hz-60.5Hz
Grid frequency exceeds the range of 59.8Hz-60.5Hz
Check the grid
Check the grid
Check the grid
Automatically restart after the grid is recovered
Automatically restart after the grid is recovered
Automatically restart after the grid is recovered
Communication failure between LCD display and inverter
Contact after-sales
SPD protection module at
DC side has a fault
SPD protection module at
AC side has a fault our
Please replace the
SPD protection modules of the same type, if the fault persists, contact the manufacturer
Please replace the
SPD protection modules of the same type, if the fault persists, contact the manufacturer
None
Restart after replacement
Restart after replacement
56
9 Appendixes
9.1 Technical Parameters
9.1.1 Electrical Part
TC500K3US-O User Manual
Input data (DC side)
Parameter description
Maximum DC voltage(Vdc)
PV grounding mode
MPPT voltage range of DC input(V)
Maximum PV array input power(kW)
Maximum input current(A)
Output data (grid side)
Reference value
600
PV-grounding (ANSI requirements)
DC320 ~ DC580V(full load)
550
1600
Parameter description
Rated output power(kW) 500
Reference value
Rated grid voltage(Vac)
Allowable grid voltage range (three-phase)
Rated grid frequency(Hz)
Allowable grid frequency(Hz)
200
-12% ~ +10 %, i.e. 176Vac ~ 220Vac
60
59.8 (this operating point is adjustable) -60.5
Total current waveform distortion factor(%) <3 (rated power)
Control of power factor 0.9 (leading) ~ 0.9 (lagging)
9.1.2 Mechanical Part
Parameter description
Actual size (W × H × D) mm
Weight(kg)
Reference value
2370×2140×910
2300
57
Protection function
TC500K3US-O User Manual
Over / under voltage protection (Yes / No)
Over / under frequency protection (Yes / No)
Anti- islanding protection (Yes / No)
Over-current protection (Yes / No)
Yes
Yes
Yes
Yes
9.1.3 System Data
Parameter description
Maximum efficiency(%)
CEC efficiency(%)
Reference value
97.7 (without transformers)
97.5 (without transformers)
Protection grade
Night time consumption(W)
NEMA 3R
<100
Permissible operating ambient temperature(℃) -25~+50
Cooling method Air-cooling
Permissible relative humidity(%) 0 ~ 95 (without condensation)
9.2 Warranty Statement
9.2.1 Standard Warranty
(1) Evidence
During the warranty period, customers claiming to quality assurance are required to present invoice to purchased products meanwhile trademark on the products shall be clearly visible, otherwise our company reserves the right not to conduct quality assurance.
(2) Warranty clause
The products with malfunction replaced are disposed by our company.
Reasonable time shall be provided to our company for repair work.
(3) Disclaimer
58
TC500K3US-O User Manual
In the following cases, our company reserves the right not to conduct quality assurance.
Complete appliance, components are out of warranty.
Damages caused during transportation.
Improper installation, alteration or use.
Operating in harsh environment that doesn’t conform to specifications of the manual.
Machine malfunction or damage caused by installing, repairing, altering or disassembling by unauthorized services and staff.
Machine malfunction or damage caused by using non-standard or those components or software not offered by Sunny Central.
Any installation or usage not in accordance with provisions of relevant international standards.
Damage caused by unexpected disaster.
If customers ask for quality assurance to dispose the faults caused in the above cases, we can provide paid service after technical diagnosis by our company’s services.
9.2.2 Extended Warranty
For specific questions, please contact us.
59
TC500K3US-O User Manual
9.2.3 Contact Us
If you have any question concerning this product, please contact us.
Contact details are as follows:
Company name: TBEA Xi'an Electric Technology Co., Ltd.
Address: Xi'an TBEA New Energy Industrial Park, No. 70, fourth
Shanglinyuan Road, High-tech Zone, Xi’ an
Zip code: 710119
Hotline: 400-606-6029
E-mail: [email protected]
Fax: 029-68760500-042 http: //www.tbeapower.com
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