POWER PLANT CONTROLLER
Contents
1. 28 6 1 MAINTENANCE SHEE T E nre pd un PUnR MU TEE UM UM 28 6 2 CHECK THE EXTERNAL INTERNAL CONDITIONS OF THE CABINET 29 6 9 AIR FILTER MAINTENANG E S 30 6 4 CHECKING THE SEALS LOCKS AND 0000004 31 c 31 6 6 CHECKING CONTROL AND AUXILIARY VOLTAGES 24 VDC 230 VAO 32 6 7 CHECKING THE RELAYS AND SWITCHES eee 32 6 8 CHECKING THE TIGHTENING TORQUE eee 33 DESGRHIETIOBNOE TAE FIII eee eee eee ree eee ee one mE MI 34 NAVIGA HON BAR E 34 gd ove te 35 7 3 DESCRIPTION OF THE HMI 36 73A ALARMS AND VVARNIBISIS edunt capac guemremcusnemtnuertarscppimamientac SE E 37 Tie PLANT DATA T 40 n 41 T34 SER 42 1 p pec 43 GE 44 8 DATA TRANSFER VIA MODBUS TCP IP 45 Rev 00 17 04 2014 3 45 POWER PLANT 9p CONTROLLER A SANTERNO User Manual CARRARO GROUP 1 GENERAL INFORMATION ON THE PRODUCT WARNING For a correct and risk free use of the equipment make2. A Hot exhaust air B Fresh air intake 26 45 Rev 00 17 04 2014 User Manual 9p SANTERNO POWER PLANT A CARRARO GROUP CONTROLLER 5 12 Commands on the Cabinet Front The following commands are located on the cabinet door AA SANER 1 Master switch or disconnect switch 10Q1 for the Power Plant Controller It is always provided with padlocks in open position preventing the switch from closing The locking slot may house maximum padlocks 7 mm not supplied 2 Touch panel 12 touch panel on model SANTERNO PPC 15 9 touch panel on model SANTERNO PPC 180 The touch panel enables setting up and manually controlling the PPC The HMI is described in section INSTALLATION 3 Power Meter if fitted This device allows adjusting the power values based on the desired power output 4 White indicator light If on this means that the cabinet is powered 5 indicator light If on this means that an alarm tripped Rev 00 17 04 2014 27 45 POWER PLANT 9p CONTROLLER A SANTERNO User Manual CARRARO GROUP 6 MAINTENANCE Adequate maintenance ensures that performance and reliability is maintained over time This heading describes all the activities required to keep the cabinet parts which are subject to wear and deterioration and or components which are essential for guaranteeing safety and optimum performance in good condition Access to products for the purpose of maintenance modifications and
3. Buffer Alarms Press this button to access the page showing the alarm history Buffer Warnings Press this button to access the page showing the warning history The table below details the alarm messages that may appear Alarm Alarm message Alarm message Possible Cause Possible solution Lui Regulators Disabled PPC has just been When the PPC is powered on it started disables the regulators for the first 60 seconds so that all devices may start up The regulators are enabled when this initialization stage is over Enable the regulators from the The regulators have Regulation Data page local mode just been disabled by or from the remote interface the user This alarm trips if the number of inverters in emergency condition is Communications failure over the Inverter Offline in too many inverters parameter Check the value set for this parameter Rev 00 17 04 2014 37 45 POWER PLANT CONTROLLER 002 003 004 005 006 38 45 Antiwind up Regulator active Antiwind up Regulator active Regulator P Saturation ON Regulator Q Saturation ON Antiwind up Regulator active The regulator cannot reach the preset active power set point The active power regulator 15 in saturation mode The regulator cannot reach the preset reactive power set point The reactive power regulator 15 in saturation mode The regulator output is higher or lower than the
4. ALL129 fino al ALL 143 Inverter IP Address ALL241 fino al ALL426 Alarm communication inverter Rev 00 17 04 2014 2 The regulator output is higher or lower than the threshold set in the Regulation Data page Some inverters are off due to bad weather conditions The calculated Kpc is out of the allowable range set in the Limits page The calculated Kfc is out of the allowable range set in the Limits page No communication between the PLC and the Power Meter When powered on the PPC creates the communications channels to the inverters This alarm indicates that the PPC cannot communicate with the inverter indicated No communication between the PLC and the inverter indicated SANTERNO CARRARO GROUP POWER PLANT CONTROLLER From the Trend page check if the reactive power set point ranges within the allowable range set by the parameters on the Regulation Data page Check the operating conditions of the inverters Check the value of the regulator parameters influencing the Kpc Check the limits set for the Kpc Check the value of the regulator parameters influencing the Kfc Check the limits set for the Kfc Check if the Power Meter is properly power supplied Check the correct wiring of the network cable between the PLC and the Power Meter Check if communications parameter settings Mask in the Power Meter are correct Check if the addresses of the in
5. Upto 1000 m as Installation site Operating ambient humidity 2 to 95 1g m to 25g m without condensation or ice formation class 3k3 according to EN 50178 Ambient humidity in storage 5 to 95 19 m to 25g m without condensation or ice formation environment class 1K3 according to EN 50178 Ambient humidity during Maximum 95 up to 60g m condensation may appear when the transport equipment is off class 2k3 according to EN 50178 Atmospheric pressure for operation and storage 86 to 106 kPa class and class 1k4 according to EN 50178 Atmospheric pressure during transport 70 to 106 kPa class 2k3 according to EN 50178 3 2 Electrical Specifications of the Cabinet Electrical Specifications Supply voltage 230Vac Rev 00 17 04 2014 13 45 POWER PLANT 9p CONTROLLER A SANTERNO User Manual CARRARO GROUP 3 3 Mechanical Specifications of the Cabinet Mechanical Specifications 600 x 800 x 400 model SANTERNO 15 600 x 1000 x 400 model SANTERNO 180 45Kg model SANTERNO 15 Weight k eight kg 55Kg model SANTERNO 180 Degree of protection 1 44 RAL7035 orange peel Colour Phosphate conversion coating followed by epoxy polyester powder coating Dimensions WxHxD mm 3 4 Electric and Communications Interface Electric and Communications Interface Power Meter interface 3 Voltage transformers and 2 Current transformers Commun
6. it is to be considered safe in the sense of what is described above 18 45 Rev 00 17 04 2014 User Manual 9p SANTERNO POWER PLANT A CARRARO GROUP CONTROLLER 5 3 Grounding N DANGER ALWAYS GROUND THE EQUIPMENT Connect the cabinet to the equipotential bonding A ground collector bar is provided inside the cabinet collecting all the equipotential bonding connection The ground collector bar is in the lowest part of the cabinet 5 4 Positions of the Terminal Boards for the Connection of the Incomin Cables The figure below shows the positions of the terminal boards for the connection of the incoming cables Terminal boards are marked with an X followed by a digit for example X4 this identifier is located on the cabinet on the top part of the terminal board 40 100 13F1 13F2 1 40 100 Barra di terra Rev 00 17 04 2014 19 45 POWER PLANT 2 SANTERNO User Manual CONTROLLER CARRARO GROUP 5 5 Cable Entry The cabinet bottom panel may be removed by loosening the screws on its sides Before wiring the cables drill the panel where cable entry is required The cabinet bottom is shown in the figure below nne ui m mmm n d p p 20 45 Rev 00 17 04 2014 User Manual 5 6 Cable Cross sections SANTERNO PPC 15 Cabinet X1 N 2 terminals for 0 5 4mm flex cable X2 N 10 terminals for 0
7. threshold set in the Regulation Data page The available power in the PV plant does not allow achieving the power set point The regulator output is higher or lower than the threshold set in the Regulation Data page Some inverters are off due to bad weather conditions The regulator cannot achieve the voltage set point The voltage regulator is in saturation mode SANTERNO CARRARO GROUP User Manual Check if the set point ranges within the allowable range set by the parameters on the Regulation Data page Check the operating conditions of the inverters Check if the set point ranges within the allowable range set by the parameters on the Regulation Data page Check the operating conditions of the inverters Check if the set point ranges within the allowable range set by the parameters on the Regulation Data page Check the operating conditions of the inverters Check if the set point ranges within the allowable range set by the parameters on the Regulation Data page Check the operating conditions of the inverters From the Trend page check if the reactive power set point ranges within the allowable range set by the parameters on the Regulation Data page Check the operating conditions of the inverters Rev 00 17 04 2014 User Manual 007 Regulator U Saturation ON 009 Kpc out of range ALLO10 Kfc out of range 033 Power meter communication error
8. Equipment Wiring has been made in order to identify the operating voltages of the circuit sections based on the colours of the isolating sheath of the cables CES tie AC DC power wiring gt 120V or for cables other than those mentioned in this table BLUE 24 Vdc auxiliary circuit wiring Wiring of the circuits supplied by external power supply sources and not cut off from the master switch YELLOW Oo EN Wiring of the safety equipotential circuit 16 45 00 17 04 2014 User Manual SANTE RNO 5 2 Description of the Cabinet The cabinet may be accessed from its front side only Its main function is to adjust the active power and reactive power at the point of interconnection POI by interacting with the inverters on the field Disconnector 10Q1 is located on the front panel It delivers power supply to the whole cabinet or cuts off power supplied when required ORANGE cables may be live even when switch 10Q1 is open A switch inside the cabinet controls power distribution to all LV devices PLC comms board and HMI The pictures below show the front view of the SANTERNO 15 cabinet Rev 00 17 04 2014 17 45 POWER PLANT 9p CONTROLLER A SANTERNO User Manual CARRARO GROUP The cabinet components are grouped to form functional areas The lower part houses the power supply terminals The middle part houses the fuses SANTERNO PPC 15 cabinet only relays switches and the Modbus TCP IP communication
9. GROUP Terminal X3 is for the PLC inputs and outputs and the voltage free contacts of the auxiliary relay X3 Terminal Board Terminal Description Potential Digital Input E0 0 PLC free Digital input EO 1 PLC free Digital input E0 2 PLC free Digital input 0 3 PLC free Digital input E0 4 PLC free Digital input E0 5 PLC free Digital input 0 6 PLC free 10 11 12 Digital input E1 3 PLC free 13 Digital input E1 4 PLC free 17 Digital output AO 1 PLC free N 14 15 16 Digital output A0 4 PLC free Digital output A0 5 PLC free 22 Digital output 0 6 PLC free 24 Digital output A1 0 PLC free 28 Digital output A1 4 PLC free 32 N C voltage reecontact39KA1 33 voltage free contact 39KA1 o Too ooo 34 __ N O voltage free contact Terminal X4 is the for the cabinet cooling fan Cooling Fan Terminals Potential 230Vac 50Hz output 210141 18 19 20 21 25 26 27 29 30 31 230 50Hz output 22 45 00 17 04 2014 User Manual 9p SANTERNO POWER PLANT CONTROLLER CARRARO GROUP 5 8 Terminal Functions for SANTERNO 180 The terminal lists given in this section describe the full functionality of the Power Plant Controller Check the optionals fitted in the substation and the relevant connections Terminal board X1 is for the connection of the supply voltage to the cabinet Line input terminals inal Description
10. PLC free Digital input E3 6 PLC free BEEN Digital input E3 7 PLC free 33 Digital output A0 1 PLC free 34 Digital output A0 2 PLC free CT 395 Digital output AO 3PLC free Digital output 0 4 PLC free DJ 37 jDigtalouput A0 5 PLC free j 22 00 17 04 2014 23 45 POWER PLANT 9p CONTROLLER A SANTERNO User Manual CARRARO GROUP 38 Digital output 0 6 PLC free 39 Digital output A1 0 PLC free 40 Digital output A1 1 PLC free Digital output A1 2 PLC free 42 Digital output A1 3 PLC free 48 Digital output A1 4 PLC free Digital output A1 5 PLC free 45 Digital output A1 6 PLC free Digital output A1 7 PLC free Digital output A2 0 PLC free 50 DigitaloutputA23PLC free 51 Digital output A2 4 PLC free CT CCS 52 Digital output A2 5 PLC free 53 Digital output A2 6 PLC free O 54 Digital output A2 7 PLC free 55 Digital output AS PLC free O o Digital output A3 1 PLC free 57 Digital output A3 2 PLC free 58 Digital output A3 3 PLC free CT y 59 Digital output A3 4 PLC free 60 Digital output A3 5 PLC free 61 Digital output A3 6 PLC free CT Cs 62 Digital output A3 7 PLC free 63 contact CT CS 64 voltage free contact 65 contact 41KA
11. Potential 230Vac 50Hz Line input Terminal is for the PLC inputs and outputs and the voltage free contacts of the auxiliary relay inal otential 1 Digital EOOPLC free 0000 Digital input E0 1 PLC free 00 00 S3 Digital input E0 2 PLC free 4 Digital input E0 8 PLC free 5 Digital input E0 4 PLC free 6 Digital input E0 5 PLC free O 8 Digital input E0 7 PLC free O Z 9 Digitalinput E1 0 PLC free o 10 Digital input E1 1 PLC free CT 11 j DigtalnputET2PLC free 312 Digital input E1 3 PLC free O 198 DigtalinptE14PLC free 14 Digitalinput E1 5 PLC free 15 jDigtalinptEt 6PLC free O Z o 16 DigtalinptE17PLC free O 17 Digital input E2 0 PLC free CT Cid 18 DigtalinputE2 1 PLC free 19 DigitalinputE22PLC free 20 DigitalinputE23PLC free CT Cid 21 Digital input E2 4 PLC free 22 jDigtalnputE25PLC free O 293 Digital input E2 6 PLC free O 4 input E2 7 PLC free CST Cis 25 DigitalinputE3 0PLC free 2222 26 DigitalinputE3 1PLC free O Z o 27 DigtalinputES 2PLC free CY Cid 28 DigitalinputE3 3PLC free 29 Digital input E3 4 PLC free CT Cs 30 Digital input E3 5
12. indicated in the cross reference if the reference of the component appears in the same sheet Only the column number is therefore indicated Le 11 ud c E re mi alf i8kni 46 i sui disg tutela i propri diritt 11 1 All 18KB3 18KHM1 Bz 1250 Ri tronica t 1613 15 9 54 locui X E47 LA 18 Bur AW IX a 5 8 he i 4 iz 15 8 13X 14 12 6 21 22M 19 9 ig 14 a Hn 2 e i H E Lontactor Farallel 5 closure contactor enable sianal i E l E ri E 4 pprimgts pe 180 a F Example if the sheet number is not included in the cross reference this means that a secondary element of the component is shown on the same sheet Since the cabinet is to be integrated into a system composed of multiple elements each one accomplishing a specific function the numbering scheme of some of the components or conductors connected to the cabinet may differ from the one above since such components conductors may be related to another part of the system 8 45 Rev 00 17 04 2014 User Manual 9 SANTERNO POWER PLANT A CARRARO GROUP CONTROLLER 1 8 Test Certificate The Test Certificate is prepared by the technicians of Elettronica Santerno while testing the Power Plant Controller cabinet It contains al
13. management involves all persons responsible for production and maintenance It must be carried out in observance of the health and safety regulations described in section Execution of Work The minimum maintenance interval is indicated in the Maintenance Sheet Equipment installed in an environment where there is a high concentration of dust requires more frequent maintenance than generally indicated WARNING Failure to observe maintenance prescriptions may result in the product warranty conditions being nullified NOTE In the event of any fault please contact the CUSTOMER SERVICE of Elettronica Santerno SpA for instructions on the necessary corrective actions to be taken 6 1 Maintenance Sheet Check the external internal conditions of the electrical cabinet Air filler maintenance Check locks and hinges Check control and auxiliary voltages 230 V and 24 V Check relays and modular switches Check cable tightening Check product labels nameplates and warning signs The frequency of scheduled maintenance may need to be increased depending on the location in which the equipment is installed and the relative ambient conditions 28 45 00 17 04 2014 User Manual 2 SANTERNO POWERPLANT CARRARO GROUP 6 2 Check the External Internal Conditions of the Cabinet N DANGER Death from electrocution and burns due to contact with live components Make sure that no voltage is applied to the equipment Power must be cut
14. off Before accessing the cabinet follow the instructions given in section Accessing the Equipment Safety Procedure Dot not touch any components other than those mentioned in this instruction manual To check the external internal conditions of the electrical cabinet proceed as follows OVERALL CONDITION OF THE CABINET Check external condition of the cabinet Check state of the insulating sheaths on the conductors Check that there no signs of overheating on the power conductors especially near the connection points on the equipment e Check that there are no signs of cable gnawing caused by rodents e Check the state of all the signs nameplates affixed to the equipment Signs must always be in good condition and legible GENERAL CABINET CLEANING Check the interior of the cabinet for the build up of dust dirt humidity and infiltration of water from the outside e Check that the ventilation ducts on the inductors and transformers are clear Should it be necessary to clean the cabinet always adopt adequate measures Rev 00 17 04 2014 29 45 POWER PLANT 9p CONTROLLER A SANTERNO User Manual CARRARO GROUP 6 3 Air Filter Maintenance N DANGER Death from electrocution and burns due to contact with live components Make sure that no voltage is applied to the equipment Power must be cut off Before accessing the cabinet follow the instructions given in section Accessing the E
15. starting the equipment DANGER ALWAYS EARTH THE EQUIPMENT CAUTION The Power Plant Controller cabinet is to be used only as described in this manual Any use other than that described in this manual is to be considered inappropriate and therefore improper gt DANGER ELECTRIC SHOCK HAZARD Avoid touching electrical parts when the equipment is powered on Never work on the equipment when powered on EXPLOSION AND FIRE RISKS The risk of explosion or fire may exist if the equipment is installed in a room containing flammable vapours Do not install the equipment where there is a risk of explosion or fire 10 45 00 17 04 2014 User Manual CAUTION Do not connect supply voltages which exceed the rated voltage If voltage exceeding the rated value is applied the internal circuits may be damaged 9p SANTERNO POWER PLANT A CARRARO GROUP CONTROLLER Do not carry out isolation tests between the power terminals or between the control terminals Make sure that the screws on the connection terminal board have been tightened correctly Observe the ambient conditions for installation The electronic boards contain components which are sensitive to electrostatic charges Do not touch the boards unless absolutely necessary Should this be the case take all the necessary precautions to prevent damages caused by electrostatic charges 2 1 Intended Use The Power Plant Controller cabinet must on
16. the 24 Vdc power supply proceed as follows Open the cabinet door Check the presence of 24 Vdc control voltage on the terminals on switch 24Q2 Close the cabinet door To check the 230 Vac power supply proceed as follows Open the cabinet door Check the presence of 230 Vac control voltage on the terminals on switch 10Q2 Close the cabinet door 6 7 Checking the Relays and Switches DANGER Death from electrocution and burns due to contact with live components of the grid Make sure that no voltage is applied to the equipment Power must be cut off Before accessing the cabinet follow the instructions given in section Accessing the Equipment Safety Procedure This section refers to all relays and switches located inside the cabinet Visually inspect the installed fuses making sure that they are correctly inserted into their holders Check the presence of the fixing springs on the fuse holder socket e Visually inspect the modular switches installed Check their mechanical and electrical functionality 32 45 Rev 00 17 04 2014 User Manual 9p SANTERNO POWER PLANT A CARRARO GROUP CONTROLLER 6 8 Checking the Tightening Torque DANGER Death from electrocution and burns due to contact with live components Make sure that no voltage is applied to the equipment Power must be cut off Before accessing the cabinet follow the instructions given in section Accessing the Equipment Safety Proc
17. 1 y y Terminal X4 is the for the cabinet cooling fan Cooling Fan Terminals BENE pi 1 8 9 0 41 2 3 5 8 3 3 4 4 4 4 4 otential 1 230 50Hz output 5 9 Switches Installed on the Power Plant Controller The PPC switches and their functionality are given in the table below Rated Current A Description of the Function Characteristic soar 3P 25A _ 230Vac 50Hz Line input master switch 24 45 Rev 00 17 04 2014 User Manual 2 SANTERNO POWERPLANT CARRARO GROUP 5 10 Ethernet TCP IP Communications Interface Wirin The Power Plant Controller wiring to the Ethernet network is to be made using only one network cable The incoming Ethernet cable may be connected to the internal switch 35A1 in the wiring diagram Failure to do so can lead to serious communications failures severely affecting the functionality of the Power Plant Controller Rev 00 17 04 2014 25 45 POWER PLANT 7 SANTERNO User Manual CONTROLLER CARRARO GROUP 5 11 Cabinet Ventilation The cabinet is equipped with a cooling fan located on the right side of the enclosure as well as with an air suction filter located on the left side of the enclosure Keep areas close to the air filter and the cooling fan free from obstacles to allow for free circulation of air The fan flow rate is 41m h The figure below shows the air cooling system of the cabinet RUFFO CARRARO A GANKERNG
18. 5 2 5mm flex cable X3 N 34 terminals for 0 5 2 5mm flex cable X4 2 terminals for 0 5 4mm flex cable SANTERNO PPC 180 Cabinet X1 N 2 terminals for 0 5 4mm2 flex cable X3 65 terminals for 0 5 2 5mm flex cable X4 N 2 terminals for 0 5 4mm flex cable 5 7 Terminal Functions for SANTERNO PPC 15 9 SANTERNO POWER PLANT A CARRARO GROUP CONTROLLER The terminal lists given in this section describe the full functionality of the Power Plant Controller Check the optionals fitted in the substation and the relevant connections Terminal board X1 is for the connection of the supply voltage to the cabinet Line Input Terminals Potential 1 inal 230Vac 50Hz Line input Terminal X2 is for the power supply of the CTs the 5 and the Power Meter CTs VTs and Power Meter mE Potential Voltage transformer L1 2 Voltage transformer L2 Voltage transformer L3 Neutral of the star centre of the Voltage transformer L1 L2 and L3 C NENNEN 3 2 5 Cumenttransormerseconday S1 phase Li 6 Current transformer secondary S2 phase L1 lt 7 Cumenttransormerseconday S1 phase L2 8 Current transformer secondary S2 phase L2 lt 9 Cumenttransormerseconday S1 3 10 Current transformer secondary S2 phase L3 2 inal 1 3 4 5 7 10 00 17 04 2014 21 45 POWER PLANT 9p CONTROLLER A SANTERNO User Manual CARRARO
19. 7 Electrical and Mechanical Schematic The editing technique is described hereafter This description will allow the reader to fully understand the electrical and mechanical schematic and to easily identify the equipment components The pages of the electrical schematic are distinguished by three different numbers in the bottom right hand corner 82 000006 Continued Proprieta Field indicates the location of the components 4 Q1 Inside the electrical cabinet Q1F On the front of the electrical cabinet EXT External device Sheet indicates the progressive number of each sheet in the electrical schematic Continued indicates the number of the following sheet The ID code for each component and conductor relates to the first page in which the component or conductor appears usually based on the direction of energy flow followed by a progressive number 18KA2 82 9000008 Ri 18 18kM1 110Va R2 1250 i Example of component ID 16L 3 i 3 i 3 4 84 6 e 13X 148 21X JN 22 13 14 21 22 Parallel Parallel contactor contactor command relay Cross references are provided in the electrical schematic for conductors and components which appear on more than one page The cross reference format is Sheet Column Rev 00 17 04 2014 7 45 POWER PLANT 9p CONTROLLER A SANTERNO User Manual CARRARO GROUP The sheet number is not
20. COMMUNICATIONS 00 14 A HANDLING AND MOUNTING Ero be 15 4 1 HANDLING 15 4 2 HANDLING USING A JACK OR FORKLIFT 15 IIN TACCA HON 16 5 1 IDENTIFYING THE FUNCTIONAL VOLTAGE OF THE CIRCUITS INTERNAL TO OUR MEN Tos ee 16 5 2 DESCRIPTION OF THE 17 29 GROUNDING 19 5 4 POSITIONS OF THE TERMINAL BOARDS FOR THE CONNECTION OF THE INCOMING CABLE 19 20 5 6 CABLE 55 21 5 7 TERMINAL FUNCTIONS FOR SANTERNO PPC 15 21 5 8 TERMINAL FUNCTIONS FOR SANTERNO PPC 180 23 5 9 SWITCHES INSTALLED ON THE POWER PLANT CONTROLLER 24 2 45 00 17 04 2014 User Manual 9p SANTERNO POWER PLANT A CARRARO GROUP CONTROLLER 5 10 ETHERNET TCP IP COMMUNICATIONS INTERFACE WIRING 25 Su b CABINET Eu RUM 26 5 12 COMMANDS ON THE CABINET FRONT eeaeeeeeeeaaeeeeeaas 2 6
21. LLER A SANTERNO User Manual CARRARO GROUP TABLE OF CONTENTS 1 GENERAL INFORMATION ON THE PRODUCT eere 4 1 1 CABINET IDENTIFICATION AND 4 1 2 MAIN FUNCTIONS STANDARDLY 5 15 NAMEPLATE ees E E E 5 1 4 FOR WHOM THIS MANUAL 6 1 5 ATTACHED mener nnne nnne 6 1 6 PRESERVATION OF THE DOCUMENTATION eene 6 1 7 ELECTRICAL AND MECHANICAL 7 10 9 1 9 SYMBOLS USED IN THIS 9 T10 DERINITION Se 9 2 CAUTION STATENVIEIN TS 10 12 INTENDED U E 11 2 2 QUALIFIED TECHNICAL nens 11 eo EXECUTION OFW ORE 11 2 4 ACCESSING THE EQUIPMENT SAFETY 12 TE TING 13 3 1 ENVIRONMENTAL REQUIREMENTS FOR INSTALLATION AND STORAGE 13 3 2 ELECTRICAL SPECIFICATIONS OF THE 13 3 3 MECHANICAL SPECIFICATIONS OF THE CABINET 14 3 4 ELECTRIC AND
22. POWER PLANT CONTROLLER USER MANUAL Issued on 17 04 2014 nev 00 English This manual is integrant and essential to the product Carefully read the instructions contained herein as they provide important hints for use and maintenance safety This product is to be used only for the purposes it has been designed to Other uses should be considered improper and dangerous The manufacturer is not responsible for possible damages caused by improper erroneous and irrational uses e Elettronica Santerno is responsible for the product in its original setting Any changes to the structure or operating cycle of the product must be performed or authorized by Elettronica Santerno Elettronica Santerno assumes no responsibility for the consequences resulting by the use of non original spare parts Elettronica Santerno reserves the right to make any technical changes to this manual and to the product without prior notice If printing errors or similar are detected the corrections will be included in the new releases of the manual e The information contained herein is the property of Elettronica Santerno and cannot be reproduced Elettronica Santerno enforces its rights on the drawings and catalogues according to the law SANTERNO CARRARO GROUP Elettronica Santerno S p A Via della Concia 7 40023 Castel Guelfo BO Tel 39 0542 489711 Fax 39 0542 489722 santerno com sales santerno com POWER PLANT 9p CONTRO
23. edure Check the tightness of all the terminal clamps for connecting the power wiring and tighten if necessary Pay particular attention to any colour variations or anomalies concerning the insulation and the terminals The minimum tightening torques to be used can be gathered from the Manufacturer s technical notes Rev 00 17 04 2014 33 45 POWER PLANT CONTROLLER Z SANTE RNO User Manual CARRARO GROUP 7 DESCRIPTION OF THE HMI 7 1 Navigation Bar A navigation bar is available at the bottom of each page of the HMI Navigation bar example n 5 point been em Description Goes to the Trend page Goes to the Limits page where the limit thresholds may be set for certain parameters The red lock indicates that the level 3 password administrator level is required Goes to the Set point page The yellow lock indicates that the level 2 password supervisor level is required This button enables or disables the regulators operation The red lock indicates that the level 3 password administrator level is required GB Er Disab Regulator This button is to be found on all the pages of the HMI Press this button from any page to go back to the Main Page Goes to the next page or the upper level page Goes to the previous page or the lower level page 34 45 Rev 00 17 04 2014 User Manual 9p SANTERNO POWER PLANT A CARRARO GROUP CONTROLLER 7 2 Password If a
24. evel of responsibility concerning operation of the electrical system required some of his her tasks may be delegated to others Person in charge of working activities Works Supervisor Person with the highest level of responsibility concerning the execution of work If required some of his her tasks may be delegated to others The Works Supervisor must give all persons involved in the execution of work activities the relative instructions concerning reasonably foreseeable dangers which may not be immediately apparent 00 17 04 2014 9 45 POWER PLANT 9p CONTROLLER A SANTERNO User Manual CARRARO GROUP Skilled electrician Someone who has been trained and has enough technical knowledge or experience to enable him her to avoid the dangers which may be generated by electricity Instructed person Someone who has been adequately advised or supervised by a skilled person to enable him her to avoid the dangers which may be generated by electricity 2 CAUTION STATEMENTS This section covers safety statements The non observance of the safety instructions below may cause serious injury or death and equipment failure Carefully read the instructions below before installing starting and operating the equipment Only competent personnel must carry out the equipment installation SAFETY RECOMMENDATIONS TO FOLLOW DURING USE AND INSTALLATION OF THE EQUIPMENT NOTE Always read this instruction manual thoroughly before
25. ications interface 10 100 Ethernet RJ 45 Modbus TCP IP WARNING Environmental conditions significantly affect the life expectancy of the product consequently DO NOT install the product in a location which does not meet the required specifications 14 45 00 17 04 2014 User Manual Z SANTERNO 4 HANDLING AND MOUNTING 4 1 Handling Conditions Use a forklift truck to handle the equipment Refer to section Mechanical Specifications of the Cabinet WARNING POWER PLANT CONTROLLER For safety reasons and to ensure correct operation it is strictly PROHIBITED to tilt the cabinet forwards or backwards 4 2 Handling Using a Pallet Jack or Forklift Truck If the cabinet is to be lifted from underneath a forklift truck must be used Position the fork tines in the spaces along the base which must be opened up beforehand by removing the central base panels 8100005 Rev 00 17 04 2014 15 45 POWER PLANT 9p CONTROLLER A SANTERNO User Manual CARRARO GROUP 5 INSTALLATION The Power Plant Controller is part of a system so no particular installation instructions are given However it is necessary to take all possible measures to avoid exposing the equipment to direct sunlight in order to keep the internal temperature ranging within the allowable limit values this applies to force ventilated cabinets 5 1 Identifying the Functional Voltage of the Circuits Internal to the
26. in the PV plant Use port 502 defined by the ModBus to establish a connection rn l Register Unit of Line frequency INT32 1000 Hz Measured active power INT32 1000 KW Line voltage INT32 Regulators status INT16 1 3 5 1 1 Reactive power set point selection 0 gt Reactive power set point INT16 1 1 Power factor index set point 1 3 3 3 5 7 8 oet point source Local Remote 3 5 7 1 1 1 Active power set point INT32 31 00 00 0 Measured reactive power INT32 EM Power factor index set point wm 3 o o RW Register bitmapping Regulators status register address 17 Bit Bit Bit Bit 71884444 2 ma 0 Regulators 0 Voltage 0 Reactive power 0 Active power disabled regulator linear regulator linear regulator linear pattern pattern pattern 1 Regulators enabled 1 Voltage 1 Reactive power 1 Active power regulator regulator regulator saturation saturation saturation Register bitmapping Local Remote set points register address 19 O Local set point control O Local parameter regulators control 1 Remote set point control 1 Remote parameter regulators control Rev 00 17 04 2014 45 45
27. is suggested that talc be used to stop the seals from sticking to the sheet metal of the cabinet over time Check correct operation of the cabinet locks by locking and unlocking the doors Check if the door hinges operate smoothly opray all movable parts and parts subject to wear with water free lubricant 6 5 Check the Fan DANGER Death from electrocution and burns due to contact with live components Dot not touch any components other than those mentioned in this instruction manual Check operation and noisiness of the fan installed on the left side of the cabinet If required open the cabinet door to force fan operation The fan can be started up by thermostat 14B1 installed inside the cabinet and by setting a lower temperature than the ambient temperature At the end of inspection Restore the thermostat to the initial temperature value e Close the electrical cabinet doors Rev 00 17 04 2014 31 45 POWER PLANT CONTROLLER Z SANTE RNO User Manual CARRARO GROUP 6 6 Checking Control and Auxiliary Voltages 24 Vdc 230 Vac DANGER Death from electrocution and burns due to contact with live components of the grid Dot not touch any components other than those mentioned in this instruction manual To check the cabinet control and auxiliary voltages follow the instructions provided below The exact position of the control points can be seen on the Electrical and Mechanical Schematic To check
28. l the information related to the execution and the results of the Production Tests 1 9 Symbols Used in this Manual KEY N DANGER Indicates an operating procedure which if not carried out correctly may lead to injuries or even death caused by electric shock o CAUTION Indicates an operating procedure which if not carried out correctly may cause serious damage to the equipment i NOTE Indicates important information concerning use of the equipment 1 10 Definitions Installer Technician responsible for setting up positioning and installing the equipment in compliance with the system diagram and in accordance with first class professional criteria Operator Worker who has been suitably trained and informed on the risks and relative safety procedures to be adopted The operator can carry out routine maintenance on the equipment Plant manager Person who co ordinates or manages system management activities and is responsible for ensuring health and safety standards are adhered to Technical room Place used for housing the technological systems such as the wiring plumbing heating air conditioning lifting and telecommunications systems It is equipped with suitable forced air ventilation and or air conditioning and is also fitted with appropriate safety devices governing access maintenance and fire prevention Person in charge of running the electrical system System Manager Person with the highest l
29. livered by the plant and measured by the Power Meter Blue track Trend of the reactive power set point Trend of the reactive power delivered by the plant and measured by the Power Meter The values percent for the delivered active power reactive power and their set points are displayed at the bottom of the page Those values relate to the point in the graph indicated by the upright marker Use the two buttons in the bottom right corner to change the marker position The Trend graph is very helpful when tuning the regulators as it helps check the regulation efficiency and the presence of overshoots if any when the reference of the reactive power active power varies Rev 00 17 04 2014 41 45 POWER PLANT CONTROLLER Z SANTERNO User Manual CARRARO GROUP 7 3 4 Configuration Menu This page allows accessing the Power Plant Controller configuration pages The administrator password level 3 is required to open the Inverter Power Meter Regulator Parameter and Plant Data pages All pages protected by a level 3 password can be accessed by the Santerno Service personnel only The Set Point page may be accessed by entering the supervisor password level 2 Inverter Press this button to configure and enable the inverters in the plant Net Analyzer Goes to the Power Meter configuration page Regulator Goes to the page including all the regulators parameters of the PPC Parameters Plant Data Goes to the page allowing configu
30. ly be used as described in this manual Any use other than that described in this manual is to be considered improper and therefore non compliant 2 2 Qualified Technical Personnel All work on the cabinets must be carried out by skilled technical personnel only By skilled personnel it is intended persons who have been suitably trained to carry out the work in question To commission and use the self power supply cabinet personnel must know and understand the instructions for installation and use In particular all safety warnings must be strictly observed 2 3 Execution of Work Maintenance configuration modifications and management operations require the involvement of all production and maintenance personnel These activities must be carried out in observance of health and safety regulations The Standards and Laws governing this aspect vary depending on the personnel involved methods of access and or the tasks which may be carried out on the product and envisage constructive measures aimed at guaranteeing adequate levels of safety otandard EN 50110 1 second edition identifies the people who are granted access to the product e Person in charge of running the electrical system System Manager e Person in charge of work activities Works Supervisor e Skilled electrician e Instructed person Please refer to section Definitions Standard EN 50110 1 governs the way work in a plant is carried out and the relationship between
31. ord level Current page number oet point sent locally Delivered active power Delivered reactive power remotely TSO DO SCADA Parameters from local or remote SANTERNO SCADA SANTERNO A CARRARO GROUP Data Alarms Plant Trend Configuration Service The buttons at the bottom of each page allow navigating among the pages of the HMI From the Main Page the following pages may be accessed Description Goes to the pages related to the alarms diagnostic messages and history data Goes to the page displaying the Plant Data variables of the PV plant Goes to the graphs displaying the power output and the plant set points Data Configuration Goes to the Power Plant Controller configuration pages Service Goes to the Service page where you can set the system clock log out ant shut down the HMI 36 45 Rev 00 17 04 2014 User Manual 9p SANTERNO POWER PLANT A CARRARO GROUP CONTROLLER 7 3 1 Alarms and Warnings This page displays alarms messages and history data A ores oJ Alarms and warnings PEST o JS n SetPoint fo Param Alarms Wami Buffer Buffer Pp z AME Alarms Warnings n At the bottom of each page there are 4 buttons allowing accessing the following pages Buon 0000 Press this button to display pop up page showing the alarms tripped Press this button to display a pop up page showing the events fired
32. ower of the PV plant Full scale value of the active and reactive power percent Rated voltage Rated voltage of the PV plant at the connection point of the Power Meter Plant resistance Rsk Line equivalent resistance Used by the voltage regulator available Plant reactance Xsk Line equivalent reactance Used by the voltage regulator only regulator not always available Actual active power Active power measured by the Power Meter Active power reference Active power set point 10096 equals the Rated active power Actual reactive power Reactive power measured by the Power Meter Reactive power set point pe PFI reference Power factor index set point The reactive power regulator may operate with reactive power reference or PFI section 7 3 5 Actual voltage Voltage measured by the Power Meter at the connection point 40 45 Rev 00 17 04 2014 User Manual 9 SANTERNO POWER PLANT A CARRARO GROUP CONTROLLER 7 3 3 Trend This page displays the trends of the set points and the active and reactive power measures P Power 0 kW Q Power Trend 15 10 2013 08 32 53 100 95 90 85 80 75 70 65 60 55 50 45 40 35 9 25 20 15 10 5 0 amp e 177 Eal 467 Tag connection Value TE value SetPoint P SetP Actual 50 Actual P 50 SetPoint_Q Actual_Q QA nos ulation set Point Parameters Ta Black track Trend of the active power set point Red track Trend of the active power de
33. p of the Plant Data page Reactive power reference The first drop down menu allows Enter the Local mode to choosing the reactive reference Q or change the reference type the PFI reference The side box shows the type of reference that is currently activated The Q ref box sets the reactive power Q set point ref box sets the PFI set point Voltage reference Sets the voltage set point The voltage regulator is not always available Rev 00 17 04 2014 43 45 POWER PLANT CONTROLLER Z SANTERNO User Manual CARRARO GROUP 7 3 6 Service The Service page allows doing the following suspend the panel runtime set date and time log out 21 10 2013 09 49 28 30 07 2013 11 15 09 The correct date and time setting is required for the trip logs and history data This button shuts down the touch panel The level 3 administrator password Santerno service personnel only is required Once the date and time are set in the Modify box press Set time to update them The green lock indicates that the level 1 password operator is required Press this button to log out 44 45 Rev 00 17 04 2014 User Manual 9p SANTERNO POWER PLANT A CARRARO GROUP CONTROLLER 8 DATA TRANSFER VIA MODBUS TCP IP PROTOCOL The PPC displays the following data accessible via ModBus TCP IP protocol by establishing a connection to an address from the address list including all the addresses of the devices
34. password is required the window below will automatically appear along with a virtual keyboard Enter the username and password and press OK Press CANCEL to close the window without logging in Connessione Utente Password OK Annulla car 2131456 7 i s fig hj k toa om 2 lt v b njm 2 wo 4 8 FC 8 eu 4 gt Three password levels are provided for the HMI to access the configuration parameters of the Power Plant Controller The data or pages that are password protected are marked by different pictograms red yellow green lock as shown below evene cic Level 3 password administrator The administrator may execute all level operations level 1 level 2 level 3 The administrator pages are for Santerno s service personnel Level 2 password supervisor The supervisor may execute also level 1 operations Level 1 password operator Rev 00 17 04 2014 35 45 POWER PLANT Z SANTE RNO User Manual CARRARO GROUP CONTROLLER 7 3 Description of the HMI Pages The Main Page appears when the touch panel is turned on The following information is given on all pages Ee P Power 20 kW M O20 08 31 A In P PW level 0 3 N pag 1 Power 0 age SetPoint Param Values readout from the Power Meter Active passw
35. quipment Safety Procedure The cabinet is equipped with air intake grilles fitted with felt filters efficiency class EN 779 G2 Maintenance activities consist of replacing the felt filters The front air intake grille can be removed by inserting a screwdriver in the point indicated and gently levering it out The felt is held in a cavity in the air intake grille which is securely fastened to the cabinet door The type of felt filters used must be suitable for the application The spare felts may be purchased from Elettronica Santerno NOTE In the event of fault please contact the CUSTOMER SERVICE of Elettronica Santerno SpA for instructions on the necessary corrective actions to be taken The figure shows how to replace the filter felt 10005 30 45 00 17 04 2014 User Manual 9p 6 POWER PLANT A CARRARO GROUP CONTROLLER 6 4 Checking the Seals Locks and Hinges DANGER Death from electrocution and burns due to contact with live components Make sure that no voltage is applied to the equipment Power must be cut off Before accessing the cabinet follow the instructions given in section Accessing the Equipment Safety Procedure To check the cabinet door seals locks and hinges proceed as follows Visually inspect the cabinet seals for any signs of cracking or damage Any seals showing signs damage in the areas of door contact must be completely replaced It
36. ring the plant data Set Point Goes to the page allowing controlling the active power set point the reactive power set point and the voltage set point 42 45 Rev 00 17 04 2014 User Manual 2 7 3 5 Set Point SANTERNO CARRARO GROUP POWER PLANT CONTROLLER This page allows setting the active power set point the reactive power set point and the voltage set point the voltage reference is not always displayed P Power 0 kw S t t 15 10 2013 08 43 04 et poin PW level 3 13 A 0 SetPoint 2771 Param ACTIVE POWER REFERENCE REACTIVE POWER REFERENCE LOCAL REMOTE ACTUAL LOCAL ACTUAL 2000 3000 3000 Reactive Power ref E Reactive Power ref 84 00 IW LOCAL REMOTE ACTUAL iis ref 0 00 0 00 0 00 VOLTAGE REFERENCE EE 40204 LOCAL REMOTE ACTUAL PFI ref 0 900 1 700 1 700 100 00 96 90 00 90 00 kVAr ulation Trend i a The LOCAL REMOTE and CURRENT values of the set points are given for each regulator The set points may be set up directly from the touch panel only if the Local set point mode is activated To do so press the Local Remote button at the bottom of the page supervisor password level 2 required Section Desemipion Lc NENNEN power reference Loco setting the active power set point 10096 M the rated power of the PV plant displayed on to
37. sure that all the parameters provided by the manufacturer are respected and that all the check procedures and test procedures are carried out according to the instructions provided 1 1 Cabinet Identification and Ratings SANTERNO PPC 15 cabinet May control up to 15 inverters y 800 800 800 gt 25 1 em 13A1 4 25H1 5 39H1 0 0 145 310380 450 600 SANTERNO PPC 180 cabinet May control up to 192 inverters 250 125 120 0 0 1 1001 1900 a T 1000 875 ve SM Ap io 2 25A1 2 i 4 25H1 iz 1 5 41 1 i 250 i e 125 e 0 0 240 360 ann The cabinet is provided with a hinged door allowing 120 opening 4 45 Rev 00 17 04 2014 User Manual 9p SANTERNO POWER PLANT A CARRARO GROUP CONTROLLER 1 2 Main Functions Standardly Included e Auxiliary services power supply and low voltage distribution e Interface point for the connection to the external network for the remote monitoring services e Equipment control via PLC e HMI touch panel 1 3 Nameplate The cabinet nameplate provides all the technical and identification data Part Number assigned to the equipment by Elettronica Santerno mark and list of the Regulations applicable to the construction of the equipment CE is collective registered mark Serial Number of the equipment Cabinet specs The nameplate is silver coloured and measures 100
38. switch The upper part houses the PLC with the relevant communications board The 12 touch panel is located on the front door of the SANTERNO PPC 15 cabinet The 9 touch panel is located on the front door of the SANTERNO PPC 180 cabinet IMPORTANT In any case absolute safety does not exist as stated in the CEI 11 15 standard paragraph 1 1 02 quoted below Omissis No regulation notwithstanding its degree of accuracy is able to guarantee absolute immunity to people and goods against the dangers of electricity The implementation of the prescriptions contained in these standards can reduce hazard exposure but cannot avoid a condition in which accidental events may determine a dangerous situation for people and goods As a matter of facts stands as a synonym for compliant with state of the art practices Such practices represent a set of rules that allow implementing a safety level which is considered to be acceptable by the community on the basis of current technical and technological knowledge and economical resources The state of the art continually evolves and the standards describe its evolution over time In particular according to the Italian law No 186 of March 1 1968 a product compliant with CEI Comitato Elettrotecnico Italiano standards means a product constructed in compliance with state of the art practices The equipment described in this manual is compliant with CEI standards and therefore
39. the aforementioned persons who may work on the plant to maintain the electrical safety conditions stipulated by European Directives Rev 00 17 04 2014 11 45 POWER PLANT 9p CONTROLLER A SANTERNO User Manual CARRARO GROUP 2 4 Accessing the Equipment Safety Procedure N DANGER Circuits may be live even when the master switch is in open position Always put the equipment in safety conditions before carrying out any operation inside the automatic power supply cabinet To do this follow the instructions below Cut off direct line master switch 1001 The upstream circuit is energized even after master switch 1001 is open Cut off the external switch so that voltage is removed from the upstream circuit as well ORANGE cables are live even when switch 1001 is open SRUPPO CARRARO 12 45 00 17 04 2014 User Manual 9p SANTERNO POWER PLANT A CARRARO GROUP CONTROLLER 3 TECHNICAL DATA 3 1 Environmental Requirements for Installation and Storage Required Conditions Operating ambient temperature 0 40 Ambient temperature in storage and transport 15 C to 460 C environment Pollution degree 2 or better Do not install the equipment in direct sunlight and in areas which may be subject to conductive powders corrosive gases vibrations and water jets and leaking in case the IP rating does not provide for suitable protection Do not install in saline environments Atitude
40. verter in an emergency are properly set up Check if the 15 properly connected to the inverters in an emergency Check the conditions inverter operating Check the correct wiring of the network cable between the PLC and the Power Meter Check if communications parameter settings lp Mask in the Power Meter are correct 39 45 POWER PLANT CONTROLLER Z SANTE RNO User Manual CARRARO GROUP The table below shows the messages that may appear Message Message text Description MSG001 Password E Santerno active Indicates that someone has password becomes logged in typing the invalid after 5 minutes SANTERNO password inactivity MSGO002 Password TSO DO active Indicates that someone has password becomes logged in typing the TSO DO invalid after 5 minutes password inactivity 7 3 2 Plant Data This page displays the power set points and some plant variables measures by the Power Meter 21 10 2013 09 48 00 Plant Data Pu level 5 200 SetPoint 5 1 Param 22 Rated active power kW Plant resistance Rsk Rated voltage 20 kV Plant reactance Xsk 0 01000 Actual Active Power 0 00 0 00 Active Power Reference 1500 00 kW 30 00 96 Actual Reactive Power 0 00 Reactive Power Reference 3000 kVAr PFI Reference 1700 Actual Voltage 20 895 gt Rated active power Rated active p
41. x70mm Example of a nameplate r ELETTRONICA SANTERNO S p A MADE IN ITALY www elettronicasanterno it CODE ZZEJQCN047 Vin 230 V 50 Hz in 15A Icu 4 9 SERIAL NUMBER 2 i 1301273 ELETTRONICA SANTERNO Rev 00 17 04 2014 5 45 POWER PLANT 9p CONTROLLER A SANTERNO User Manual CARRARO GROUP 1 4 For Whom This Manual is Intended This manual is intended for e Installers e Operators e Person in Charge for the management of a PV plant See section Definitions 1 5 Attached Documentation The following documents are always provided with the Power Plant Controller This guide Any information related to the transport assembly Installation Guide installation and maintenance of the product is described herein mice ical and Mechanical onem This document contains detailed information related to the internal layout and the electrical schematic of the cabinet Test Certificate This document contains information on the execution and the results of the Production Test Conformity Declaration Conformity Declaration to the applicable Regulations 1 6 Preservation of the Documentation All the documents related to the Power Plant Controller cabinet shall be preserved for the entire service life of the product along with the PV installation documentation and shall always be easily accessible 6 45 Rev 00 17 04 2014 User Manual 2 SANTERNO POWERPLANT CARRARO GROUP 1
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