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ZBB 200kW PCS

1. 4 v 1 2 X GENERATOR PHASES OUTPUT POWER V HEHHE A PV INPUT DC LINK 1 OUT_KVA KVA V IHHHHEA 1 VOLTAGE V 1 VOLTAGE V 2 OUT_KVAR KVR V HEHEHHE 2 CURRENT A 21 GND 3 OUT KW KW GEN FREQUENCY 3 POWER KW FREQ HZ 2 3 4 LINE PHASES INVERTER TEMPERATURE BATTERY INPUT V A A A 1 BATTERY 1 VOLTAGE V B3HHHHE V 2 CABINET 2 CURRENT A V HHH C HHHH 3 POWER 4KW LINE PHASES INVERTER FREQUENCY BATTERY INPUT V HHH A 1 CURRENT1 A B HHH V A FREQ HZ 2 CURRENT2 A V HEHEH A 3 3 v GEN POWER 1 GEN KVA 2 GEN_KVAR KVR GEN KW 4KW SPS JOB NO 95093 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 3 17 PCS CONTROL SUBMENU 1 CONTROL SETTINGS 2 SAVE PARAMETERS 3 DIAGNOSTICS 4 STATUS FLAGS 2 1 NOT READY CAUSE 2 LOCAL COMMAND 3 OPERATING MODE 4 OPERATING SEQUENCE v SAVE PARAMETERS 1 READ PARAMETERS 2 SAVE PARAMETERS 3 SAVE KWHr METER 3t of Faults Alarms THHHHE FLTLL CURL SYNC 2 VRG PDN BBBBBBBB BBBBBBBB SAVE PARAMETERS 4 INITIALIZE PARA 5 CLEAR PCS KWHr 6 CLEAR GEN KWHr
2. FAULTS SCREEN 3 CBLD GEN BAT DIS OPERATING MODE 1 INVERTER 2 GENERATOR 3 HYBRID Enter 2 4 PCS COMMAND 1 START 2 STOP 5 LOCAL 6 REMOTE 8 RESET OPERATING SEQUENCE OPER SEQ SPS JOB NO 95093 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 3 18 SETPOINTS SUBMENU 1 AC BUS SETTING 2 GENERATOR SETTING 3 BATTERY SETTING 4 PV SETTING 1 2 3 4 DC SETTING EQUALIZE SETTINGS GENERATOR SETTING AC SETPOINT 1 VDCMAN V VOLTAGE VDC 1 SEC 1 VLINE SET V 2 VDCLOW SET V DURATION MINS 2 GEN COOL SEC VDCHI SET PERIOD DAY GEN KVA MPPT SETTINGS ABSORBTION SETTING LINE OVER VOLTAGE MPPT ENABLE HHEHE VOLTAGE 1 TRIP STEP MIN STEP MAX DURATION MIN FLOATV SEC MPPT SETTINGS SEARCH TIMEJHHHHEIMS MIN POWERJHEHHEL IE BATTERY SETTING 1 VBAT LOW VDC 2 TBAT LOW SEC 3 MAX BAT A PV OVER CURRENT 1 TRIP A 2 DELAY MS BATTERY SETTING TOTAL mv C TEMPERATURE COEFFICENT GROUND OVER CURRENT 1 TRIP 2 DELAY MS Battery temperature compensation range Tmax C Tmin C
3. 1 TRIP 2 DELAY MS BATTERY OVER VOLTAGE 1 TRIP A 2 DELAY MS BATTERY OVER CURRENT BATTERY OVER TEMP 1 TRIP C 2 DELAY MS 2DELAY LINE UNDER VOLTAGE 1 TRIP 2 DELAY 5 OVER FREQUENCY TRIP HZ 2 DELAY MS UNDER FREQUENCY TRIP HZ 2 DELAY MS zx PRODUCT INFO SUBMENU 1 HELP MESSAGE 2 SOFTWARE VERSION 3 CHECKSUM 4 SLAVEID 1 2 3 PRESS THE SUBMENU TOGO THE UP MENU PRESS THE MENU TO GO THE MAIN MENU FPGA AAAAAAAAAAAA F240 AAAAAAAAAAAA F206 AAAAAAAAAAAA OIT SF PC350 AAA v CHECKSUM PROGRAM F240 ACTUAL F240 SET H SLAVEID ENTER HHH PRESS THE SERVICES MENU TO GO THE TRIP LEVEL AND PARAMETERS SETTINGS WHEN A FAULT APPEARSPRESS THE SUBMENU KEY TO GO TO THE RESET SCREEN CHECKSUM PARAMETERS F240 SET F240 ACTUAL CHECKSUM KWHr METER F240 SET F240 ACTUAL SPS JOB NO 95093 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 3 19 FAULT SCREENS SPARE CODE CHECKSUM WRONG DC BUS OVER VOLTAGE DC BUS PRECHARGING FAULT Fault 00 Fault 16 Fault 32 Fault 48 LINE OVER VOLTAGE PARAMETER CHEC
4. MASK 4 MASK UNDER FREQUENCY 1 TRIP HZ 2 DELAY 5 2 INVERTER PI SETTING KP INV 1 KLINV INVERTER SETTINGS KP INV V KLINV V dHHHE 3 4 5 Remote Operating Procedures This section describes the remote operating procedures of the PCS The PCS operates in remote control from a PLC sending commands through RS485 communication link 3 4 5 1 Data Flow Arrangement Between PLC and PCS DPCB The following tables summarize the status and data interchange signals between the PLC and the PCS DPCB The data communication uses Mod bus protocol Table 3 4 1 shows a summary of the Mod bus registers used for communication from PCS and the analog data sent from PCS DPCB to PLC together with the conversion factors Table 3 4 2 shows data sent from PLC to PCS DPCB Commands For the SET points the conversion SPS JOB NO 95093 INSTALLATION AND OPERATION MANUAL 3 21 The information of this document is proprietary and not to be reproduced without permission factors are marked in the right column Tables 3 4 3 3 4 9 show the detailed information Faults Alarms Status signals transmitted by PCS SatCon PCS operates in remote control from the remote controller or the host controller commands and provides PCS information through RS485 communication link The communication protocol is MODBUS RTU having the following configuratio
5. Parallel operation mode 3 This mode of operation is similar to the Inverter only mode except that when needed the generator will be used to charge the battery Whenever the generator and PCS are running in parallel the PCS tries to supply the loads VARs and the unbalanced component of the load current negative sequence 2 Inall modes local and remote the PCS will not start until the ON OFF switch is in the ON position and a start command is given For all modes of operation the PCS will shutdown when the ON OFF switch is set to the off position For a local start the PC command must be set to to start the unit The PCS will set the PC Command back to zero to acknowledge the start For Mode 1 and Mode 3 starts 3 PCS will close the charging contactor CRCH and the Pre charge action will take place If the DC link voltage does not reach pre charge value within 30sec unit will fault out as a Pre charge fault 4 After the DC link voltage is charged to the battery voltage the battery contactor is closed The PCS will use the chopper to boost the DC link voltage up to the PV voltage and then close the PV contactor Note if the PV disconnect switch is in the OFF position the DC link voltage is not boosted and the PC contactor remains open 5 The inverter ramps the its output voltage up to the ac voltage setpoint and closes AC Contactor CR2A For Mode 2 starts 3 PCS will close the generator start command contact and wait ti
6. S LOCAL 6 BBBBBBBBBBBBBBBB E RESET FLTLL CURL SYNC PRE SYNC2 VRG BEBBEBBE Y GENERATOR SETTING 1 GEN 8 SEC OPERATING MODE 1INVERTER 2 GENERATOR HYBRID Enter OPERATING SEQUENCE OPER SEQ titii The information of this document is proprietary and not to be reproduced without permiss SPS JOB NO 95093 INSTALLATION AND OPERATION MANUAL 2 GEN SEC 3 GEN KVA BATTERY OVER VOLTAGE 1 TRIP titii V 2 DELAY MS ion BATTERY OVER CURRENT 1 TRIP Hit A 2 DELAY MS BATTERY OVER TEMP 1 TRIP 2 DELAY MS 3 16 GROUND OVER CURRENT METERING SUBMENU 1 AC OUTPUT 3 DC INPUT 4 ENERGY 2 BATTERY STATUS 2 1 OUTPUT POWER 2 LINE PHASES 3 GEN POWER 4 GEN VOLT amp CURRENT v BATTERY INPUT 1 VOLTAGE V 2 CURRENT A 3 POWER KW TIME TILL EQUALIZE THHHHE Hrs TIME SINCE EQUALIZE THHHHE HRS TEMPERATURE COMPENSATION V TABSORB CHARGING MODE ABSORBTION B FLOAT B EQUALIZE B d 1 PCS IN ENERGY 2 PCS OUT ENERGY 3 GEN OUT ENERGY 3 v 1 PV INPUT 2 BATTERY INPUT 3 DC LINK 4 TEMPERATURE
7. F206 OIT SF PC350 AAA CHECKSUM PROGRAM SLAVEID F240 ACTUAL F240 ENTER SET iiit OUTPUT POWER GENERATOR PHASES PRESS THE SERVICES MENU TO GO THE TRIP LEVEL AND PARAMETERS CHECKSUM PARAMETER F240 SET Hiit F240 ACTUAL CHECKSUM KWHr METER F240 SET Hii F240 ACTUAL 1 OUT_KVA KVA cate V IH SETTINGS 2 OUT_KVAR i KVR WHEN A FAULT a OUT KW HKW V inti A BATTERY INPUT BVINBUT APPEARSPRESS THE o GEN FREQUENCY 1 V 1 8 V RESETECREEN 2 CURRENT A 2 CURRENT FREQ HZ B POWER ii KW a POWER iitit tW BATTERY INPUT i ERA 1 CURRENT 1 LINE PHASES 2 CURRENT2 8 A Hat A CURRENTS BUS SETTING MH PHA 2 GENERATOR SETTING 3 BATTERY SETTING cue V INVERTER FREQUENCY CPV SETTING LINE PHASES V DC LINK TEMPERATURE Banene V anit 1 VOLTAGE 888 V 1 BATTERY i 8C cue V AH BL HEHA 2 CABINET HC SETPOINT 1VUNESET V H GEN POWER BATTERY INPUT 1 1 VOLTAGE V LINE OVER VOLTAGE 2 GEN_KVAR KVR 2 CURRENT JHHRE A s d 5 POWER T CONTROL SETTINGS a GEN KW AW 2
8. PV OVER CURRENT Timed PV over current Fault 34 3 PV INST OVER CURRENT Instantaneous 1ms PV over current Fault 35 4 BATTERY OVER TEMP Timed battery over temperature Fault 36 5 BATT INST OVER VOLT Instantaneous 1ms battery over voltage Fault 37 6 DC BUS INST UNDER VOLTAGE Instantaneous 1ms DC link under voltage Fault 38 7 DC BUS INST OVER VOLTAGE Instantaneous 1ms DC link over voltage Fault 39 8 PV FUSE FAULT The PV fuse has opened Fault 40 9 PV DIODE OVER TEMP The thermoswitch on the diode heatsink has Fault 41 opened 10 NVRAM INITIALIZED The NVRAM codes forces the PCS to Fault 442 initialize the database to factory default values 11 BATTERY CONNECTION The battery has been connected backwards Fault 43 REVERSED or the battery voltage feedback is open circuited 12 BATTERY OVER VOLTAGE Timed battery over voltage Fault 44 13 BATTERY UNDER VOLTAGE Timed battery under voltage Fault 45 14 BATTERY OVER CURRENT Timed battery over current Fault 46 15 BATTERY INST OVER Instantaneous 1ms battery over current Fault 47 CURRENT SPS JOB NO 95093 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 3 27 Table 3 4 6 STATUS4 Fault4 Modbus Register 30073 Bit Acronym Description Fault 0 DC BUS PRECHARGING The dc link could not be precharged through
9. 3 1 3 2 3 1 3 Ventilation Considerations ERR Roe PERI 3 2 EQUIPMENT MARKINGS RATINGS 3 3 INPUT OUTPUT INTERCONNECTIONS 3 6 OPERATING INSTRUCTIONS 3 41 General erroe E RR en aedi Hee perdere 3 4 2 PCS Stdtes consc eee cree e ee tede 34 3 PCS BID eret 3 4 3 1 Sequence of events when Starting the 3 11 3 4 3 2 Sequence of events when Stopping the PCS 3 13 3 4 3 3 Sequence of events during Fault Shutdown of the PCS 3 13 3 4 3 4 Sequence of events during E Stop of the 3 13 3 4 3 5 Low Battery Current eese eim 3 13 3 4 3 6 Battery Protections ncesi eneee nennen nennen 3 14 3 4 4 Local Operating Procedures 3 14 3 4 4 1 Local Control Panel amp System Diagnostic LED Description 3 14 3AA2 Description emo Ure be REIHE 3 15 3 4 5 Remote Operating Procedures nennen 3 36 3 4 5 1 Data Flow Arrangement Between PLC and 3 36 3 4 5 2 Protection for Losing Remote Communication 3 44 TRIP POINTS i eem HD oe den cs RETE DUE ere een 3 45 PREVENTATIVE MAINTENANGE tmn ret ror UU 3 49 3 6 1 Power Compo
10. 6 Isolation Operators Metering amp System Status Via LCD Display OIT SPS JOB NO 95093 INSTALLATION AND OPERATION MANUAL Input DC disconnect switch on PV input Input DC disconnect switch on Battery input Input DC Fuses on each Buck Boost Chopper PV input fuse Inverter Fuses AC Breakers for Generator AC Breaker for Load Start Stop Selector Switch Audible Alarm Enable Disable Switch Emergency Push button RD ESTOP Located on the outside of PCS Output AC Voltage 3 Phases Output Current All 3 Phases Generator Current All 3 Phases Real Output Power kW Reactive Output Power Real Inverter Power kW Reactive Inverter Power k VAR Battery DC Voltage Battery DC Current DC Bus Voltage Stop Run Status Fault No Fault Status Modes of operation 3 5 The information of this document is proprietary and not to be reproduced without permission 3 3 Screen Information is available on the LCD display which is backlit LCD 5 X 7 dot matrix with cursor 4 lines of 20 characters It interfaces with the digital control board through an RS 232 port and provides the operator with parameter set up diagnostics information and input output metering information INPUT OUTPUT INTERCONNECTIONS Before connecting the input cables to the power supply service check voltage amperage and phase ratings of the generator and the output Make certain that the capacity of the generator is adequate
11. INV TSW Inverter heatsink over temperature thermoswitch N C 8 LAC TSW Line reactor over temperature thermoswitch N C 9 TX TSW Main transformer over temperature thermoswitch N C 10 AC FUSE Inverter AC fuse status N C 11 CR OUT PCS output contactor CR2A status N O 12 CR NEUR PCS neutral resistor CRG status N O 13 CR GEN Generator contactor CR2B status N O 14 GEN Generator circuit break status N C 15 CB LD Load circuit break status N C SPS JOB NO 95093 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 3 29 Table 3 4 9 STATUS7 Digital Inputs 17 32 Modbus Register 30076 Bit Acronym Description 0 DIODE TSW PV diode heat sink over temperature thermoswitch N C 1 ESTOP Emergency stop switch N C 2 PV FUSE The PV fuse status N C 3 START Run Stop front panel switch N O 4 SPARE Spare 5 SPARE Spare 6 SPARE Spare 7 SPARE Spare 8 SPARE Spare 9 SPARE Spare 10 SPARE Spare 11 SPARE Spare 12 SPARE Spare 13 SPARE Spare 14 SPARE Spare 15 SPARE Spare 3 4 5 2 Protection for Losing Remote Communication When PCS is in remote control mode there is a watchdog timer for protecting the unit when the remote communication is lost The remote controller PLC should keep sending different data 0 or not 0 to Modbus re
12. L L Frequency Range 56Hz 64Hz Nominal Voltage 480V AC L L Nominal Frequency 60 Hz Current Maximum 120A per phase Power Maximum 100kVA SPS JOB NO 95093 3 3 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission Output Parameters Number of Phases Output Voltage Range Output Frequency Range Output Nominal Voltage Output Nominal Frequency Output Current Maximum Output Power Maximum Operational range of line linkage frequency Efficiency of power conversion Power factor at reduced load Output current harmonics Over load capability Environment Operating Ambient Temperature Relative Humidity Physical Location Enclosure Dimension Weight Cooling Signal Transfer Modbus Protocol SPS JOB NO 95093 INSTALLATION AND OPERATION MANUAL 3 432V 528V AC L L 59 5Hz 60 5Hz 480V AC L L 60 Hz 120A per phase 100 Rated frequency 1 gt 93 4 0 2 lead to 0 2 lag THD lt 3 Each lt 2 Meeting or exceeding IEEE 519 110 continuous 30 C to 50 C 15 95 Non condensing Outdoor NEMA 3R 84 H X 82 W X 30 D maximum excluding eye bolts removable air intake plenum enclosure amp breaker handles etc 4700 Lbs approximately Forced air with 2 backward curved AC Impeller Fans 3 4 The information of this document is proprietary and not to be reproduced without permission
13. Timed PCS output under frequency Fault 06 7 LINE OVER CURRENT Timed PCS output over current Fault 07 8 OUTPUT CONTACTOR STATUS The status of CR2A does not match the Fault 08 command 9 GENERATOR CONTACTOR The status of CR2B does not match the Fault 09 STATUS command 10 NEUTRAL RESISTOR The status of CRG does not match the Fault 10 CONTACTOR STATUS command 11 INVERTER HEATSINK OVER The inverter heatsink thermoswitch has Fault 11 TEMPERATURE opened 12 CHOPPER HEATSINK OVER The chopper heatsink thermoswitch has Fault 12 TEMPERATURE opened 13 DOOR OPEN The PCS front door is opened Fault 13 14 NEUTRAL OVER CURRENT Timed PCS transformer neutral over current Fault 14 15 GROUND OVER CURRENT Timed PV ground over current Fault 15 SPS JOB NO 95093 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 3 25 Table 3 4 4 STATUS2 Fault2 Modbus Register 30071 Bit Acronym Description Fault 0 CODE CHECKSUM WRONG The CRC checksum of the PCS software did Fault 16 not match the expected value Power up only 1 DATA CHECKSUM WRONG The CRC checksum of the PCS did Fault 17 not match the expected value Power up only 2 OUTPUT PHASE SEQUENCE The Generator phase sequence is reversed Fault 18 WRONG 3 TEST MODE The unit is in test mode illegally Fault 19 4 GENE
14. are CSA and UL listed or recognized Capacitors Capacitors are applied at values well below their continuous design rating The capacitor chosen in this application is medium power film capacitor which uses a dry wound non oil filled segmented metallized polypropylene or polyester dielectric which features the controlled self heating process specially treated to have a very high dielectric strength in operating conditions up to 85 degree C These capacitors can with stand much higher levels of surge voltage very high rms currents and longer lifetime than their electrolytic counterparts Resistors Satcon standard resistor margins are normally twice the power rating of the application hence very reliable Breakers amp Contactors The circuit breakers and contactors are applied at values well below their continuous design rating generally around 75 of the rating Higher ambient temperature and frequency de rating factors are applied on the circuit breakers and contactors to ensure a reliable design and long lasting product The circuit breakers are rated for interrupt rating as specified in the customer specifications IGBTS The isolated gate bipolar transistors IGBTs are selected to operate well within the Safe Operating Area SOA of the device specification for 100 load and any specified overloads Laminated bus bars are used in the inverter and chopper assemblies to reduce the inductance on the side and hence the switching l
15. are used at the output of the power conditioning system before the output AC interconnection breaker CB1 and CB2 These surge suppressors have formidable surge handling capability and fast clamp response SPS JOB NO 95093 1 8 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 1 3 15 Logic Control and Protection The logic control and protection consists of the following printed circuit boards and modules All the printed circuit boards are conformal coated optional not provided with this system for reliability and outdoor environment 1 2 3 4 5 Voltage Current Scaling Board VCSB 4VI The main function of this board is to receive the input voltage and current signals from the sensors and scale down to the required level to be used by the digital power control board DPCB Digital Power Control Board DPCB The DPCB uses the DSP and FPGA Field Programmable Gate Array to generate PWM gating signals for the chopper and inverter control and regulation start stop sequence diagnostics and protection System diagnostics and status are displayed on the front Operator Interface Terminal OIT Programmable software used for overall system control allows for system flexibility without the need for hardware change This provides our customers with rapid response to their changing needs Gate Driver Board DFOD These boards are the g
16. for the power requirements of the unit being connected to it The cables must be rated for insulation level of 600V AC or higher for AC side 600VDC 1000VDC for DC side and 300V 600V for control connections Check all connections and ensure they are tight Always connect the grounding lead to the grounded switch box or building ground Ensure that the current capacity of the grounding lead will be adequate for the worst fault current situation Refer to ANSI NFPA 70 for details CAUTION Ensure all the barriers and guards are put in place after the field connections are made DC CONNECTIONS 1 Battery A battery stack rated at 210 325VDC 400A max should be connected to the 100kV A PCS battery input The input set of cables from battery stack must be rated for 400A continuous The input cables from the battery stack connect to the and DC bus bars on the DC Input section i e Left Side in the PCS The customer comes with adequate number of cables as recommended in section 2 3 3 from cable entry cut out as indicated on EL00372 01 drawing i e Left side wall of the PCS CAUTION The lugs should be installed as per lug manufacturer s specifications and recommended instructions WARNING Make sure the DC and DC polarities are followed correctly while hooking up the DC input cables from the Battery to the Power conditioning system CAUTION The polarity of the connection on the Battery is important since the power for contr
17. for voltage matching to 480 VAC line voltage application The output transformer has Delta Wye configuration and is rated at 115KVA amp 170 480V ratio This PCS can provide 480V at 60Hz The transformer chosen is high efficiency design The isolation transformer is a dry type transformer wound with class 220 insulation The unit is vacuum pressure impregnated VPI with polyester resin for durability and protection against the environment The transformer is forced air cooled by ambient air and designed with a 1 10 service factor for long life The unit includes over temperature switches for protection and indication on the panel display of the PCS Output Breakers for short circuit protection The AC breakers are used mechanical isolation and over current protection The interconnection breakers are equipped with auxiliary contacts position indicators for control monitoring The current rating and trip setting of the breakers are as follows Nom Over f current Power current current Breaker limit KVA A i rating A A 100 Pre charge Circuitry to limit current inrush to specified levels The pre charge circuitry is used to limit the inrush current to a specified level during a start and to charge the bus to the required level This circuit consists of a charging module CRCH and charging resistors RCH1 4 This circuit is also protected by dc charging fuse FCH1 Surge Suppressor SS1 2 Two surge suppressor modules
18. generator output the inverter will synchronize to the generator voltage and close the generator contactor CR2B The inverter immediately changes its mode of operation from voltage to current control mode At this time the PCS carries the full load current The balanced unity power factor component of the load current is smoothly transferred to the generator The PCS limits at this stage are 10 voltage and 4 Hz frequency The inverter then starts importing as much power as possible from the generator to charge the battery Limits are placed on the battery charging current and voltage and generator current While charging off the generator the maximum available power from the PV is used Depending on available PV power and load conditions this means the generator may not run at full power Once the batteries are charged the PCS smoothly reverses its power flow until the generator current is zero At this time the generator contactor is opened and the generator is allowed to run it cooling cycle The PCS can charge or discharge the battery By convention the charge mode means the battery current is negative and the discharge mode means the battery current is positive The AC output real power is defined as SPS JOB NO 95093 3 10 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission positive when the power is flowing out of the unit 3 4 2 PCS States The PC
19. impeller fans provide the cooling of the whole PCS The air intake for the PCS is from the front top air intake plenum through filtered openings as shown in the drawings and the air exhaust is though the louver on the front door of the enclosure at the bottom The louver is designed to meet NEMA 3R requirements and to prevent any entry of water as prescribed by NEMA standards Any obstructions in the airflow path will degrade the performance of the power conditioning system and can result in the nuisance tripping of the unit SPS JOB NO 95093 3 2 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 3 2 EQUIPMENT MARKINGS RATINGS This section specifically deals with the equipment markings including symbols controls and the applicable ratings of the PCS The power conditioning system does not use any symbols to mark the DC AC frequency and phases All the information is provided in words 100KVA PCS RATINGS SPECIFICATIONS Electrical PV Input Parameters Input Voltage Maximum 600Vdc Input Voltage Range 330Vdc 600Vdc Input Current Maximum 319Adc Input Current Range 0 to 319Adc Battery Input Parameters Input Voltage Maximum 325Vdc Input Voltage Range 210V DC 325Vdc Input Current Maximum 400Adc Input Current Range 0 to 400Adc Input Current Ripple 2 RMS Generator input Parameters Number of Phases 3 Voltage Range 432V AC 528V AC
20. the Fault 48 FAULT precharge contactor and resistor 1_ PV DISCONNECT OPEN The PV disconnect switch is in the open position Fault 49 2 BATTERY DISCONNECT The Battery disconnect switch is in the open Fault 50 OPEN position 3 GENERATOR START The generator failed to start after the specified Fault 51 FAULT number of attempts 4 SPARE Unused bit Fault 52 5 GENERATOR UNDER Timed generator under voltage Fault 53 VOLTAGE 6 GENERATOR OVER Timed generator over voltage Fault 54 VOLTAGE 7 GENERATOR OVER Timed generator over frequency due to over Fault 55 FREQUENCY speed 8 GENERATOR UNDER Timed generator under frequency due to stall Fault 56 FREQUENCY 9 GENERATOR INST Instantaneous 1 cycle generator under voltage Fault 57 UNDER VOLTAGE 10 GENERATOR INST OVER Instantaneous 1 cycle generator over voltage Fault 58 VOLTAGE 11 Fault 59 12 Fault 60 13 Fault 61 14 GENERATOR CIRCUIT The generator circuit break has tripped Fault 62 BREAKER OPEN 15 LOAD CIRCUIT BREAKER The load circuit breaker has tripped Fault 63 OPEN SPS JOB NO 95093 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 3 28 Table 3 4 7 STATUSS Digital Outputs Modbus Register 30074 Bit Acronym Description 0 CR_BAT Command to close the battery contactor CRIA 1 CR_PV Command to clos
21. 2 9641 Jan 29 2010 HK KS 3 9641 Jan 29 2010 KS CHAPTER 1 CHAPTER 2 2 1 2 2 2 3 Table of Contents Bebe te bete OE SHARE etta 1 1 INTRODUCTION ge E 1 1 DESIGN FEATURES tta eet RE nU UD eee ute 1 2 DESIGN CONSIDERATIONS 1 3 SYSTEM QUTLINE nne nere depen DIR pP 1 5 1 3 1 DC disconnect switches for PV and Battery inputs eese 1 5 1 3 2 DC load break contactors for PV and Battery inputs esses 1 5 1 3 3 Battery and PV current and voltage sensing esee 1 5 1 3 4 DC fuses for chopper inputs and PV 1 sese 1 6 1 3 5 DGimreactors ee eere p REC Re Petre eb Ye p OS 1 6 1 3 6 Buck Boost Choppers 1 6 1 3 7 capacitors eee em ettet e eR e Ue ESS 1 7 1 3 8 Three phase inverter module 1 7 1 3 9 Output AC filter reactor and AC filter capacitor oo 1 7 1 3 10 Output contactors rite etre rhe eer 1 7 1 3 11 Isolation transformer esee nennen nennen nennen rennes 1 8 1 3 12 Output breakers for load and generator for short circuit protection 1 8 1 3 13 Pre charge circuitry to limit current inrush to specified levels 1 8 1 3 14 Surge SUppreSSOTS hee cie P eae nct eiie tee e ee es 1
22. 2 FAULT MASKS 3 DAC TP 4 TEST MODES d 3 HEATER ON PLL LOCK 1 TRIP DEG 2 DELAY MS DAC TEST POINT DATA DAC1 DAC 2 DACS3 DAC 4 DACS DAC 6 NEUTRAL CONTACTOR PV INST d V yee 0 OPEN BAT INST O C A V amp l SCALING 1 SWITCHED BAT INST O V V KVOLT_OUT 2 CLOSED 4 L ON INST 3HHHHE V KCURR OUT HHHHE NEGATIVE SEQ REG EN Y LUN INST V KCURR INV Hn 0 DISABLE TEST CODE 3HHHHE INV CURR LIMIT 1 1 ENABLE TEST DC VOLTAGE SCALING 11 SPECIAL 1 GATE 2 INV OL NEUTRAL OVER CURRENT KVOLT_DC HHH 8 DIGOUT 9 CHP OL 1 TRIP KVOLT_DCB 1 3 GATE TEST 2 DELAY MS KVOLT DC PV INVA HHEH DC CURRENT SCALING DC PI SETTINGS v PLL PI SETTING INVB HHE LINE OVER CURRENT KCURR_DC KP IDCREG KP PLL 997 INVC KCURR DCB IDCREG KI_PLL_F HEHHE DIGOUT TEST HHHH 1TRIP KCURR OPENLOOP TEST DUTY 2 DELAY MS OVER FREQUENCY 1 TRIP HZ 2 DELAY 5 DC PI SETTINGS K VDC VDC HHHHE PLL PI SETTING KP_PLL_S KL PLL S CHOPPER INVERTER DC PI SETTINGS KP VDCB KI VDCB 2 v FAULT1 MASK FAULT2 MASK FAULTS
23. 3 15 Logic Control and Protection IMPORTANT SAFETY INSTRUCTIONS GENERAL eterne eit tet mn no rt etii or p a tei p m rt ede eet 2 11 IPrecautionsz uc e rcr eoi oer 2 1 2 Electrical Safety cesses one one DURER ne EPE EE ERES 2 12 1 Generali coo RR RO ERA EH 2 1 2 2 Shock Prevention oc mee tertie rer eee pe Ue xvn 2 1 2 3 Service and Maintenance siisii n a e 2 3 2 1 2 4 Fire and Explosion Prevention 2 3 2 1 2 5 Bodily Injury Prevention sese 2 3 2 1 2 6 Medical and First Aid Treatment essere 2 3 2 1 2 7 Equipment Precautionary Warning Labels sess 2 3 ELECTRICAL SAFETY FEATURES eneeeeeeeeen nennen enne enne nennen tenente nennt 2 4 2 2 1 Enclosure Door Interlock Switches eese 2 4 22 2 EcStop Button eon oer d eo er e t tens 2 4 HANDLING amp INSTALLATION nennen enne 2 4 2 331 General is rS HERBES 2 5 2 3 2 Over current Protection AC amp DC Circuit ssssssseee 2 5 2 3 3 Wire Sizes for cust interface Torque Specifications amp Special Symbols 2 6 3 4 3 2 3 3 3 4 3 5 3 6 3 1 INSTALLATION amp OPERATING INSTRUCTIONS eee 3 1 INSTALLATION 3 1 3 1 1 Assembly a
24. 353kW 250kW Max AC Output Reactive Power not for battery 0 250kVAR 250kVAR Note that these settings are different from trip settings that are for the unit shutdown Local Operating Procedures This section describes the local operating procedures of the PCS Local control operation is controlled from the Operator Interface Terminal OIT Local Control Panel and System Diagnostic LED Description The local control panel of the PCS is located on the right side of the PCS enclosure and comprises the following 1 Operator Interface Terminal OIT Display monitored PCS voltage current and power Provides detailed description of faults Operator defined settings such as power settings timer settings etc Switching between Local and Remote control Described in detail in section 3 4 4 2 2 Push Buttons Start It starts the PCS inverter only Stop It stops everything in a controlled mode Reset It resets the PCS E Stop It stops everything in emergency situation SPS JOB NO 95093 3 14 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 3 Selector Switches Audible Alarm On Off Enables or disables audible alarm 4 System Diagnostics LEDs DC Input If the outside DC contactors are closed and the DC input voltage is within acceptable range LED will be flashing or constant ON When the absol
25. C link capacitor is divided into three banks The first capacitor bank is on the inverter assembly comprised of Film capacitors the second capacitor bank is on the chopper assembly also comprised of film capacitors which use dry wound non oil filled segmented metallized polypropylene or polyester dielectric The third capacitor bank consists of electrolytic capacitors and is connected between the buck boost choppers and inverter to supply transient energy to the inverter Three Phase Inverter Module The inverter is utilising IGBT s with a high degree of voltage margin The inverter converts the DC voltage from the DC bus to the desired AC output voltage The AC output voltage is controlled by pulse width modulation PWM of the IGBT s as signalled by the DPCB The pulse width modulation is done at a frequency 5 0kHz that minimises switching losses and to provide the required performance The module IGBT s are mounted on air cooled heat sinks and uses laminated bus bar construction for interconnection to further reduce switching losses and provide a high degree of power circuit integrity and reliability Like the chopper module the inverter modules are designed for easy replacement by bolted electrical connections to the laminated bus and connectors for gating and controls The inverter module gate driver boards DFOD utilises fibre optic gating and includes protection circuitry for over current amp gating fault protection and indication o
26. DELAY 888 2 SAVE PARAMETERS TIME TILL EQUALIZE seer Hrs STATUS FLAG LINE UNDER VOLTAGE TIME SINCE EQUALIZE PES TATUS FEARS HRS 2 tr MS TEMPERATURE 84 COMPENSATION it V OVER FREQUENCY TABSORB MHkMin SAVE PARAMETERS Y 1TRIP HZ 1 READ PARAMETERS F of Faults 7 Alarms 2 DELAY 888 MS CHARGING MODE 2 SAVE PARAMETERS ABSORBTION TNOT READY CAUSE 3 SAVE KWHr METER UNDER FTIEGUENOY FLOAT 5 2 LOCAL COMMAND SAVE PARAMETERS 1TRIP Mh HZ EQUALIZE B 3 OPERATING MODE 4 OPERATING SEQUENCE 4 INITIALIZE PARA 5 CLEAR PCS KWHr 6 CLEAR GEN KWHr 2 DELAY MS Y EQUALIZE SETTINGS DC SETTING VOLTAGE VDC 1 5 V DURATION MINS 2 VDCLOW SET ttt V PERIOD DAY VDCHI SET ABSORBTION SETTING MPPT SETTINGS VOLTAGE VDC MPPT DURATION MIN ISTEP MIN MV FLOATV SEC ISTEP MAX titt MV BATTERY SETTING MPPT SETTINGS 1 VBAT LOW VDC ISEARCH 2 TBAT LOW SEC MIN_POWER H 3 MAX BAT A BATTERY SETTING OVER CURRENT TOTAL Mff mviC TRIP 8888 A TEMPERATURE 2 DELAY MS COEFFICENT Battery temperature compensation range Tmax Tmin 4c M TRIP 8800 6 2 DELAY MS CB LD PCS COMMAND AF ICBGEN BATDIS 1 START 2 STOP
27. GISED AIR FILTERS Clean the air filters provided with the blowers at regular intervals To maintain a uniform airflow through the power module heatsink the air filter must be in place at all times during the operation of the Power Conditioning System PCS Aside from proper airflow the air filter helps provide clean air for circulation Standard filters furnished with the fans are permanent recleanable type The recommended maximum filter load for efficient performance is 0 40 AFI dust per net sq ft of filter area To clean standard filters remove and flush the filter with a stream of water After flushing allow filter to drain DO NOT USE CAUSTICS IN CLEANING WATER For maximum filter efficiency coat the filters with a filter coat adhesive after cleaning SPS JOB NO 95093 3 36 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 3 6 4 Workmanship Perform all repairs in accordance with good electrical repair practices interconnecting lead connections to components must be made with proper wire terminations Route all leads neatly and secure with wire ties cable clamps etc When reassembling parts on PCS use only the same size hardware as what is originally fastened to the part The preferred hardware for this unit is metric however some of the purchased components such as contactors switches transformers may have standard sizes S A E Use only met
28. KSUM DC BUS UNDER VOLTAGE PV DISCONNECT OPEN Fault 01 Fault 17 Fault 33 Fault 49 LINE UNDER VOLTAGE PHASE SEQUENCE WRONG PV OVER CURRENT BATTERY DISCONNECT OPEN Fault 02 Fault 18 Fault 34 Fault 50 LINE INST TEST MODE PV INST OVER CURRENT GENERATOR START FLT OVER VOLTAGE Fault 03 Fault 19 Fault 35 Fault 51 LINE INST UNDER GEN OVER CURRENT BATTERY OVER TEMP INVERTER CURRENT VOLTAGE LIMIT EXCEEDED Fault 04 Fault 20 Fault 36 Fault 52 LINE OVER FREQUENCY Fault 05 BATTERY FUSE Fault 21 BATT INST OVER VOLT Fault 37 GENERATOR UNDER VOLTAGE Fault 53 LINE UNDER FREQUENCY Fault 06 INVERTER FUSE Fault 22 DC BUS INST UNDER VOLTAGE Fault 38 GENERATOR OVER VOLTAGE Fault 54 LINE OVER CURRENT Fault 07 DC CHOKE OVER TEMP Fault 23 DC BUS INST OVER VOLTAGE Fault 39 GENERATOR OVER FREQUENCY Fault 55 INVERTER CONTACTOR LINE REACTOR OVER PV FUSE FAULT GENERATOR UNDER STATUS TEMPERATURE FREQUENCY Fault 08 Fault 24 Fault 40 Fault 56 GENERATOR CONTACTOR TRANSFORMER OVER PV DIODE OVER TEMP GENERATOR INST STATUS TEMPERATURE UNDER VOLTAGE Fault 09 Fault 25 Fault 41 Fault 57 NEUTRAL RESISTOR CONTACTOR STATUS Fault 10 FPGA WATCH DOG Fault 26 NVRAM INITIALIZED Fault 42 GENERATOR INST OVER VOLTAGE Fault 58 INVERTER HEAT SINK POWER SU
29. LTAGE 660 100 14 DC BUS UNDER VOLTAGE 270 100 15 DC BUS INST UNDER VOLTAGE 200 1 16 DC BUS INST OVER VOLTAGE 700 1 17 OVER CURRENT 380 100 18 PV INST OVER CURRENT 400 1 19 BATTERY OVER TEMP 50 0 1000 20 BATT INST OVER VOLT 390 1 21 BATTERY OVER VOLTAGE 310 1000 22 BATTERY UNDER VOLTAGE 216 1000 23 BATTERY OVER CURRENT 450 100 24 BATTERY INST OVER CURRENT 800 25 GENERATOR OVER VOLTAGE Same as 1 26 GENERATOR UNDER VOLTAGE Same as 2 27 GENERATOR INST OVER VOLTAGE Same as 3 28 GENERATOR INST UNDER VOLTAGE Same as 4 29 GENERATOR OVER FREQUENCY Same as 5 30 GENERATOR UNDER FREQUENCY Same as 6 31 GENERATOR OVER CURRENT 100 SPS JOB NO 95093 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission Other important settings Table 3 5 PV Setpoints VB HEX Parameter Setting name Description Default Modbus setting 0xC033 ABSORBTION V Absorption voltage used for constant voltage 294Vdc 40260 charging Bulk voltage 0xC039 ABSORBTION T The duration the battery is charged at constant 3Hours 40266 voltage in a normal charging cycle 0xC030 EQUALIZE V Absorption voltage used during an equalizing 306Vdc 40257 charge cycle OxC03A EQUALIZE T The duration the battery is charged at constant 4Hours 40267 voltage in a equalizing charging cycle 0xC031 FLOAT V Absorption voltag
30. Letsk 100kW 100kVA BATTERY POWER CONDITIONING SYSTEM PCS INSTALLATION amp OPERATION USER MANUAL IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions for hybrid Power Conditioning System PCS that shall be followed during installation and maintenance of the inverter for Battery applications Please read all instructions before operating the equipment and save this manual for future reference MANUAL NO PM00419 REVISION NO 3 DATE Jan 2010 SATG en Power Systems SATCON POWER SYSTEMS CANADA LTD 835 HARRINGTON COURT BURLINGTON ONTARIO CANADA L7N 3P3 TELEPHONE 905 639 4692 FAX 905 639 0961 2007 2010 Satcon This document is the confidential and proprietary information of Satcon No part of this document may be photocopied reproduced stored in a retrieval system or transmitted in any form or by any means whether electronic mechanical or otherwise without prior written permission Satcon reserves the right to change details in this publication without notice PowerGate Plus and PV View Plus are the registered trademarks of Satcon Edge is a trademark of Satcon Other product names and or organization names mentioned may be trademarks and or registered trademarks of their respective companies Publication Number Date and Revision REV ECO DATE AUTHOR APPR COMMENT 0 9641 Jan 29 2010 HK KS 1 9641 Jan 29 2010 HK KS
31. Logic Control and Protection The following sections describe these major components of the power circuit in detail DC DISCONNECT SWITCHES FOR PV AND BATTERY INPUTS DS1 AND DS2 DC disconnect switches are used to isolate the PV and Battery inputs from the inverter for maintenance purposes These switches are equipped with auxiliary NO and NC contacts for control system monitoring It is not recommended to open the disconnect switches under load condition In emergency situations operate Emergency stop Button or Start Stop switch to stop PCS before opening the disconnect switches DC LOAD BREAK CONTACTORS FOR PV AND BATTERY INPUTS DC Contactors are used to isolate the battery and PV inputs to the PCS during the off and overload condition Two single pole contactors are used to isolate battery and PV circuits one each is used in PV circuit and CRIB is used in Battery circuit Battery and PV Current amp Voltage Sensing LEM1 LEMDC1 3 amp RDC1 2 AND DCVS a DC current sensor is used to measure the dc current from the solar array LEMDC1 3 are used to measure the three currents flowing in between the choppers and the battery bank The current sensors chosen are highly immune to external interference and have wide frequency bandwidth SPS JOB NO 95093 1 5 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission These current sensors provide the cu
32. PPLY FAULT BATTERY CONNECTION MODBUS COMM FAULT OVER TEMPERATURE REVERSED Fault 11 Fault 27 Fault 43 Fault 59 CHOPPER HEAT SINK HW DC OVER VOLTAGE BATTERY OVER VOLTAGE OVER TEMPERATURE KWHr METER CHECKSUM Fault 12 Fault 28 Fault 44 Fault 60 DOOR OPEN HW CHOPPER OVER BATTERY UNDER EMERGENCY STOP CURRENT VOLTAGE Fault 13 Fault 29 Fault 45 Fault 61 NEUTRAL OVER CURRENT HW INVERTER OVER BATTERY OVER CURRENT GENERATOR CIRCUIT CURRENT BREAKER OPEN Fault 14 Fault 30 Fault 46 Fault 62 GROUND OVER CURRENT Fault 15 GATE DRIVER FAULT Fault 31 BATTERY INS OVER CURRENT Fault 47 LOAD CIRCUIT BREAKER OPEN Fault 63 SPS JOB NO 95093 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 3 20 SERVICE ACCESS MENU 1 PROTECTION 2 SCALING 3 REGULATOR 4 SETTINGS OPTIONS DC BUS OVER VOLTAGE 1 DC SCALING 1 DC PI SETTING 1 SETTINGS 1 TRIP 2 DELAY 5 DC BUS UNDER VOLTAGE 1 TRIP V 2 DELAY MS 3 INST 4HHHHEV HARDWARE TRIP LEVELS linv3HHEA INST O C A 2 AC SCALING 3 TEMP SCALING 2 PLL PI SETTING 3 INVERTER PI SET TEMPERATURE SCALING _ _
33. R OPEN LOOP Factory use only TEST DUTY 0xC691 INVA GATE TEST Factory use only 0xC692 INVB GATE TEST Factory use only 0xC693 INVC GATE TEST Factory use only 0xC694 CHPA GATE TEST Factory use only 0xC695 CHPB GATE TEST Factory use only 0xC696 CHPC GATE TEST Factory use only SPS JOB NO 95093 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 3 6 3 6 1 PREVENTATIVE MAINTENANCE General housekeeping is the key to maintaining power electronic and electrical equipment They are to be kept as dust free as possible A scheduled program of inspection will reduce the possibility of problems Field maintenance of the PCS should be done by qualified service personnel and should be limited to cleaning and inspection of the unit and its components and replacement of fuses and lamps All servicing repair work including testing and calibration should be referred to the supplier of PCS or qualified trained electronic technicians Turn off input power and de energize all live sources in the PCS before any scheduled maintenance procedure is carried out Make sure that the power cannot be inadvertently turned back on Carefully clean dust from the interior of the PCS by blowing low pressure compressed air into the interior from the bottom of the unit first and then from the top The equipment must be maintained in good electrical condition to avoid hazards st
34. RATOR OVER CURRENT Timed Generator over current Fault 420 5 CHOPPER FUSE One or more of the chopper fuses has opened Fault 21 6 INVERTER FUSE One or more of the inverter fuses has opened Fault 22 7 DC CHOKE OVER One or more of the chopper DC choke Fault 23 TEMPERATURE thermoswitches has opened 8 LINE REACTOR OVER The line reactor thermoswitch has opened Fault 24 TEMPERATURE 9 TRANSFORMER OVER The transformer thermoswitch has opened Fault 25 TEMPERATURE 10 WATCHDOG The DSP stopped reporting to the FPGA Fault 26 11 HW POWER SUPPLY FAULT The dc power supply to the DPCB has failed Fault 27 12 HW DC BUS OVER VOLTAGE Instantaneous hardware detected dc bus over Fault 28 voltage 13 HW CHOPPER OVER CURRENT Instantaneous hardware detected chopper Fault 29 over current 14 HW INVERTER OVER Instantaneous hardware detected inverter Fault 30 CURRENT over current 15 GATE DRIVER FAULT One of the gate drivers has faulted due to a Fault 431 power supply failure or an IGBT fault SPS JOB NO 95093 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 3 26 Table 3 4 5 STATUS3 Fault3 Modbus Register 30072 Bit Acronym Description Fault 0 DC BUS OVER VOLTAGE Timed DC link over voltage Fault 32 1 DC BUS UNDER VOLTAGE Timed DC link under voltage Fault 33 2
35. S 3 4 3 1 Sequence of events when Starting the PCS The PCS will only start if following conditions are met No faults in the unit The FAULT LED on the PCS panel is OFF The battery disconnect is closed and the output and generator circuit breakers are closed SPS JOB NO 95093 3 11 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission The battery is connected and it s voltage is higher than Minimum Battery Voltage set point To start the PCS 1 Select the operating mode from the OIT Operator Interface Terminal Inverter only mode 1 In this mode the inverter will start up from the battery and PV and supply power to the load This mode should be chosen if the batteries are already charged and capable of supplying the load If the generator is already running when the unit is started in this mode the PCS will synchronize to the generator and ramp its output current to zero before shutting it off In this mode the generator will not be used to charge the battery If the battery is discharged below the minimum value the unit will shutdown Generator only mode 2 In this mode the PCS will close the generator start command and wait for the generator to start After the warm up time is elapsed and voltage and frequency of the generator were in the defined range Generator contactor CR2B will be closed by control and generator will power the load
36. S has the following operating states a b 9 5 h OFF Unit is stopped contactors are open no fault Pre charge Unit is pre charging DC link with the battery Boost charge Unit is boosting the DC voltage to match the PV voltage Inverter mode The PCS inverter is supplying the load Parallel mode PCS is sharing the load with generator The PCS supplies the VARs and negative sequence Transition mode The inverter is synchronizing to the generator and then either loading or unloading the generator Generator PCS has the generator supplying the load Constant Voltage Charge PCS is charging the batteries off of the PV or generator at constant voltage Fault Unit has critical faults PCS will shutdown and can only be reset manually The PCS operating sequence can be controlled from a b PCS Local Control Panel Operator Interface Terminal OIT Remote Control PLC through Mod bus and RS485 communication 3 43 PCS Control The PCS can be operated from the local operator panel or from the remote controller through the RS485 communication link using Mod bus protocol The default during powering up of the logic can be set to either local or remote control mode Switching the PCS to local or remote control mode can be done from the local operator panel OIT when the unit is not running The following sections describe the sequence of events during local control or remote control of the PC
37. Use of two DSP with a dual port SRAM architecture provides parallel processing capability 9 Most of the components selected in the power conditioning system are CE CSA or UL listed or recognized to equivalent approval agency DESIGN CONSIDERATIONS The power conditioning system for the 100kV A Battery PV System is designed using customer specifications international standards such as IEEE CSA UL IEC etc and sound engineering practices to develop a rugged product capable of providing years of service The components used in the Power conditioning system are UL or CSA or CE listed or recognized where applicable The general design features of Satcon products include the following Enclosures Rugged heavy gauge metal with enamel coated paint on all surfaces NEMA standards are followed to ensure a good design All removable internal panels are 11 gauge galvanized surfaces are painted 2 coats of rust inhibiting primer and painted The enclosure meets the NEMA 3R rating Assembly All components are secured by mechanical means independent of electrical connections The robust design ensures that the unit can withstand all transportation shock and vibration Layout of the electrical panels minimizes overlaying of the components and replacement components are easily accessible to the service personnel Special care is taken in the design so that Mean time to Repair is kept minimum All the adhesives silicone sealant acoustic fo
38. am glastic insulators wire way bushings etc used in the power conditioning system are chosen from UL listed or recognized component list Wiring Wiring used in the PCS is a high temperature TEW 90C or Tefzel 105C wires which has a minimum insulation level of 300Volts for control circuits and 600V or 1000V for the power circuit as applicable Bundled conductor ampacity is reduced according to CSA and National Electrical Code de rating factors Minimum of 12 gauge wiring for the power conductors is used in the PCS system UL1741 standard guidelines are followed in terms of wire routing spacing and bending radius etc SPS JOB NO 95093 1 3 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission Magnetics Transformers and reactors are designed at the rated load and for continuous duty plus the specified overload Higher ambient temperatures are also taken in to account while spec ing out the magnetic Flux densities are maintained with margin for specified over voltages The temperature class of insulation is Class 220 Class R independent of designed temperature rise The magnetics are vacuum pressure impregnated VPI with polyester resin for durability and protection against the environment The transformer and reactors are forced air cooled by ambient air and designed with a 1 10 service factor for long life All the magnetic used in this power conditioning system
39. and the cables must be rated to handle 120Aac at 60Hz The output cables from the generator connect to the Breaker For Ground and Neutral connection from the generator there is a two pole terminal block located beside 1 This terminal block is marked and for Neutral and Ground connection respectively For proper cable size please refer to section 2 3 3 of the manual AC OUTPUT LOAD CONNECTION The A B C N amp G from the generator are connected to the 480V AC load input CB2 and the cables must be rated to handle 120Aac at 60Hz The output cables from the load connect to the Breaker CB2 For Ground and Neutral connection from the load side there is a two pole terminal block located beside CB2 This terminal block is marked N and G for Neutral and Ground connection respectively For proper cable size please refer to section 2 3 3 of the manual GROUND CONNECTION Both generator input and output load connections to the inverter have to have ground connections The grounding terminal blocks are internally connected to the main ground bus bar inside the PCS See EL00373 01 for more details on the grounding connections CUSTOMER TERMINAL BLOCK CONNECTIONS The customer needs to connect the control wiring before starting the PCS There is customer control wiring cut out provided on the left side wall of the PCS as indicated on EL00309 drawing The customer wires connect to TBC1 located on the left hand side panel i
40. areas Stand on a dry rubber mat or dry wood and use insulating gloves when dampness or sweat cannot be avoided and never work alone The equipment must be installed and maintained with the National Electrical Code ANSI NFPA 70 or other applicable codes Inspect cables frequently for damage to the insulation and the connectors Replace or repair cracked or worn cables immediately Do not overload cables Do not touch output terminal while equipment is energized SPS JOB NO 95093 2 2 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 2 1 2 3 2 1 2 4 2 1 2 5 2 1 2 6 2 1 2 7 Service and Maintenance This equipment must be maintained in good electrical condition to avoid hazards stemming from disrepair Report any equipment defect or safety hazard to the supervisor and discontinue use of the equipment until its safety has been assured Qualified personnel should make repairs only Make sure all the power is off and capacitors de energized before doing any repairs Fire and Explosion Prevention Fire and explosion are caused by electrical short circuits combustible material near the equipment or unsafe operating conditions Overloaded or shorted equipment can become hot enough to cause fires by self destruction or by causing nearby combustibles to ignite Provide primary input protection to remove short circuited or heavily overloaded equipment from t
41. ate drivers for the IGBTs of chopper and inverter modules In addition to the drive and isolation of the chopper Inverter gating signals they also provide shoot through fault protection and detection The gate driver boards are connected to the Digital Power Control Board DPCB through fibre optic links LEM and Current Transformers 1 and LEMDCs 1 3 are used to sense the DC currents of the PV input and buck boost choppers respectively and LEMs are used to sense inverter currents for control and protection purposes Current transformers CT1A amp CTIC are used to monitor line current and CT2A CT2B amp CT2C are used to monitor generator current for control and protection purposes Voltage Sensing Transformers TRLS1 3 voltage sensing transformers are used to sense the 3 phase output AC voltage for the control and protection logic Voltage sensing transformers TRGS1 3 are used to sense the generator voltage for the control and protection logic SPS JOB NO 95093 1 9 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 2 2 IMPORTANT SAFETY INSTRUCTIONS This chapter lists all the safety instructions that need to be followed while installing and operating the Power Conditioning System The following is merely a guide for proper installation Satcon Technology Corporation cannot assume responsibility for the com
42. cal unit produce definite heat dissipation depending on the unit size For the air cooled PCS attention must be given to airflow to ensure that the supply and exhaust are unobstructed and adequate cool air is available The area of the electrical unit should be free of radio frequency interference such as encountered with some welding units This may cause erroneous fault conditions and shutdown of the power supply system WARNING All connecting cables interfacing to the PCS shall conform to the requirements of the local electrical code the national electrical code ANSI NFPA 70 or other national codes as applicable Large gauge wire must have a minimum bend radius dependent upon the wire gauge Take care to keep wire bundles away from any sharp edges which may damage the wire insulation over time Observe proper wiring practices for Level 1 2 and 3 wiring Qualified persons shall do all installation wiring and machine reconnection CAUTION Ensure all the barriers and guards are put in place in the power conditioning system after the field connections are made Over current Protection AC amp DC Circuit Breakers provide the over current protections for the ac output circuits The over current protection on the battery and PV side are provided through FUDC1 4 SPS JOB NO 95093 2 5 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 2 3 3 Wire Si
43. dge 44 40213 Initialize params Set to force PCS to set Must set Get params for default database to factory default values to take effect Should set Save params to keep default values 45 40214 Clear pcs meters Clears PCS kWH meters Set to 1 PCS will clear to acknowledge 46 40215 Clear gen meters Clears Generator kWH Set to PCS will clear to meters acknowledge 47 40216 modbus watchdog Flag to check for loss of Toggle high low every scan communication for modbus comm timeout 40226 Slaveid Slave modbus I D 1 to 255 1 is default value 40361 operating mode dp Determines whether the PCS 1 PCS only Generator or both are allowed to run 2 Generator only 3 Hybrid normal mode SPS JOB NO 95093 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 3 24 Table 3 4 3 STATUS1 Fault1 Modbus Register 30070 Bit Acronym Description Fault 0 SPARE Unused fault bit Fault 0 1 LINE OVER VOLTAGE Timed PCS output over voltage Fault 401 2 LINE UNDER VOLTAGE Timed PCS output under voltage Fault 402 3 LINE INST OVER VOLTAGE Instantaneous 1 cycle PCS output over Fault 03 voltage 4 LINEUNDER INST VOLTAGE Instantaneous 1 cycle PCS output over Fault 04 voltage 5 LINE OVER FREQUENCY Timed PCS output over frequency Fault 05 6 LINE UNDER FREQUENCY
44. e the PV contactor CRIA 2 CR_PRE Command to close the DC bus precharge circuit contactor 3 CR OPEN DIS Command to open the normally closed DC bus discharge 4 CR GEN Command to close the generator contactor CR2B 5 CR OUT Command to close the PCS output contactor CR2A 6 CR FAN Command to close the inverter and chopper cooling fan relay 7 CR NEU Command to close the PCS neutral contactor CRG 8 GEN STRT Command to close the generator start command contacts 9 HEATER Command to close the PCS heater relay when the unit is cold 10 ALARM Command to close the alarm buzzer relay 11 FAULT LIGHT Turns on the Fault light on the front panel 12 GEN LIGHT Turns on the Generator on light on the front panel 13 BAT LIGHT Turns on the Battery light on the front panel 14 PV LIGHT Turns on the PV light on the front panel 15 G D RESET Sends a reset command to the gate driver boards Table 3 4 8 STATUS6 Digital input 1 16 Modbus Register 30075 Bit Acronym Description 0 DSW_OR_ES Input from the door switch estop chain N C 1 PV_DS PV disconnect status N C 2 BAT_DS Battery disconnect status N O 3 BAT FUSE Choppers fuse status N C 4 LDC TSW Chopper choke over temperature thermoswitch status N C 5 FAN TSW Chopper or Inverter heatsink fan run thermoswitch N C 6 CHP_TSW Chopper heatsink over temperature thermoswitch N C 7
45. e used during indefinite 280Vdc 40258 maintenance charging from the PV 0xCO3B EQUALIZE PERIOD The number of days that must elapse before the 15 days 40268 battery is charged with an equalizing cycle 0xC036 IMAX BAT Maximum battery charge current 400Adc 40263 0xC032 Discharged battery voltage to start generator 228Vdc 20259 0 038 T BAT LO The time the battery must maintain its voltage in 10sec 40265 order for the generator to start and charge the battery 0xC03C BATTERY TEMPCO The total battery temperature co efficient in mV C 660mV C 40269 for all the cells combined Example 5 5mv Cx120cells 660mV C Table 3 5 2 PV Setpoints VB HEX Parameter Setting name Description Default Modbus setting OxC02F VDCLOW SET Minimum dc link voltage setpoint 40256 0xCO2C VDCHI SET DC link voltage range high setting 600 600 40253 OxC02E VDCMAN SET Manual control dc link setpoint 400 40255 OxC03F MPPT ENABLE Set to one for automatic maximum PV power 1 enabled 40272 point tracking Set to zero to use manual dc voltage control OxC04B STEP MAX The maximum dc bus voltage step taken every 2000mV 40284 search interval OxC04C STEP MIN The minimum dc bus voltage step taken every 100mV 40285 search interval 0xCO4D SEARCH TIME The search interval time whereby the dc bus 500mS 40286 voltage is changed to find the maximum power point OxC04E MIN POWER The minimum that the PV power must change by 1 0 40287 to consider a change in t
46. ecommended 2 X 4 O or 4X Maximum 4 X 4 O Recommended 2 X 4 O or 4X Plus the connections from Battery if required Maximum 4 X 4 O Recommended 4 X 2 0 or 3X 4 O Maximum 4 X 4 O Recommended 4 X 2 O or 3X 4 O 1X4 O PER POLE TOTAL OF 3 X 4 O 1X4 O 1X 6AWG 1X 4 0 PER POLE TOTAL OF 3 X 4 0 1X4 O 1X 6AWG 2 22AWG 2 14AWG or 1 10 SPS JOB NO 95093 M10 Clearance Hole 17mm Wrench M10 Clearance Hole 17mm Wrench M10 Clearance Hole 17mm Wrench M10 Clearance Hole 17mm Wrench M10 Clearance Hole 17mm Wrench LUG kit 5 16 Allen Key Terminal Block 5 16 Allen Key Terminal Block 5 16 Allen Key LUG kit 5 16 Allen Key Terminal Block 5 16 Allen Key Terminal Block 5 16 Allen Key Screw Driver INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 37 8 50 5 Nm OR 334 5 447 Ibf in 37 8 50 5 Nm OR 334 5 447 Ibf in 37 8 50 5 Nm OR 334 5 447 Ibf in 37 8 50 5 Nm OR 334 5 447 Ibf in 37 8 50 5 Nm OR 334 5 447 Ibf in 23Nm OR 204 Ibf in 275 Ibf in 275 Ibf in 23Nm OR 204 Ibf in 23Nm OR 204 Ibf in 23Nm OR 204 Ibf in 4 4 7 1 Ibf in 2 6 Special Symbols NT 60Hz GROUND Symbol throughout the enclosure designates connection point to ground DC Positive Symbol throughout the enclosure designates con
47. emming from disrepair Report any equipment defect or safety hazard and discontinue use of the equipment until its safety has been assured Inspect cables frequently for damage to the insulation and the connectors Replace or repair cracked or worn cables immediately Do not overload cables Do not touch the output terminal while equipment is energised Power Components Power components should be kept clean and free of dirt and obstructions This will avoid tracking and heat build up thereby increasing the life of the device Clean air intake filters using compressed air or a soft brush Inspect terminal blocks for evidence of overheating due to loose electrical connections Inspect electrical and mechanical connections for tightness inspect closely all compression type connectors Inspect all wiring leads and cables Inspect for cuts abrasions and signs of deterioration and overheating Inspect leads for broken strands at terminals Inspect the hinges on the doors if present If these hinges stick and difficult to operate spray hinges with a good silicone spray lubricant Due to thermal expansion and vibration during operation it is recommended that after three 3 months of operation all clamps power bolt on connections logic screw on connections and rectifier diode Insulated gate bipolar transistor IGBT mounting torque to be checked Make sure the recommended torque specs for the device is followed This should be repeated six 6 mon
48. gister 40208 WatchDog PCS will copy the received data to Modbus register 30074 for the PLC reading back If the data of the Modbus register 40208 WatchDog in PCS keeps at 0 or not 0 for longer than the watchdog timer PCS will shutdown and fault out as a WATCHDOG Remote communication watchdog fault The watchdog timer can be set from OIT main menu Manufacturer will set the timer to 5 seconds If the watchdog timer is set to O this protection function will be disabled Note that the function does not work when the inverter of PCS is not running or PCS is in local control mode SPS JOB NO 95093 3 30 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 3 5 TRIP POINTS This section informs the user of the trip level settings Table 3 5 1 Faults Trip Level Settings No Fault Description Trip Setting Trip Time ms rms degC Oz non adjustable 1 LINE OVER VOLTAGE 530 500 2 LINE UNDER VOLTAGE 430 500 3 LINE INST OVER VOLTAGE 580 17 4 LINE INST UNDER VOLTAGE 400 17 5 LINE OVER FREQUENCY 63 0 30 6 LINE UNDER FREQUENCY 57 0 30 7 LINE OVER CURRENT 138 100 8 NEUTRAL OVER CURRENT 5 0 100 9 GROUND OVER CURRENT 10 0 1000 10 HW DC BUS OVER VOLTAGE 800 0 11 HW CHOPPER OVER CURRENT 600 0 12 HW INVERTER OVER CURRENT 800 0 13 DC BUS OVER VO
49. hase 21 30090 VACOUTC Power converter voltage phase C to N Amps AC 22 30091 IACOUTA Power converter current phase A Amps AC 23 30092 IACOUTB Power converter current phase A Amps AC 24 30093 IACOUTC Power converter current phase A Amps AC 25 30094 KVARGEN Generator apparent power KVARxIO 26 30095 KWGEN Generator real power kWx10 27 30096 KVAGEN Generator reactive power kVAx10 28 30097 VACGENA Generator voltage phase A to N Volts AC phase 29 30098 VACGENB Generator voltage phase B to N Volts AC phase 30 30099 VACGENC Generator voltage phase C to N Volts AC phase 31 30100 IACGENA Generator current phase A Amps AC 32 30101 IACGENB Generator current phase A Amps AC 33 30102 IACGENC Generator current phase A Amps AC SPS JOB NO 95093 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 3 23 Table 3 4 2 Data Input Commands from Modbus Function code 16 Item Modbus Name Description Comment Register 40 40209 R_command Operation commands START 1 STOP 2 RESET 4 ESTOP 8 LOCAL 16 REMOTE 32 41 40210 Get params Command PCS to load Set to PCS will clear to newest parameters from acknowledge database 42 40211 Save params Command PCS to save Set to PCS will clear to newest database to NVRAM acknowledge 43 40212 Save meters Command PCS to savekWH Set PCS will clear to meters to NVRAM acknowle
50. he line Bodily Injury Prevention Serious injury can result from contact with live circuit components inside this equipment SHUT down this equipment for inspection and routine maintenance When equipment is in operation use extreme care in doing necessary troubleshooting and adjustment Medical and First Aid Treatment First aid facilities and a qualified first aid person should be available for immediate treatment of all injury victims Electric shock victims should be checked by a physician and taken to hospital immediately if any abnormal signs are observed Equipment Precautionary Warning Labels Inspect all precautionary warning labels on the equipment monthly Order and replace all labels that cannot be easily read or are worn out IMPROPER PHASE CONNECTION PARALLELING OR USE can damage the equipment The Maintenance Technician should become familiar with the layout and be aware of the basic system parameters Only qualified trained technicians should be allowed to work with this equipment under competent supervision The input to the power supply can go up to 320Vdc maximum from the battery The Power supply is connected to 480Vac on the utility side The bus on the PCS can be as high as 660Vdc The unit has a high voltage DC Capacitor The operator and service personnel must strictly observe all safety rules and precautionary actions WARNING Risk of Electric Shock from energy stored in capacitor Do not open doors until 5 mi
51. he search direction SPS JOB NO 95093 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission Table 3 5 3 Generator Parameters VB HEX Parameter Setting name Description Default Modbus setting 0 035 Rated generator 100 40262 0xC037 MAX STARTS The maximum number of time the PCS will 3 40264 attempt to start the generator before quitting 0xCO4A T RESTART The time the PCS waits before restarting the 10 sec 40283 generator after a failed start 0xC034 T START The time the PCS waits before checking the 45sec 40261 generator voltage after starting the generator 0xCO3D GEN WARM The time the generator is run without load to 120sec 40270 warm up the engine OxC03E GEN COOL The time the generator is run without load to cool 120sec 40271 down the engine Table 3 5 4 Other settings VB HEX Parameter Setting name Description Default Modbus setting 0xCO2D VLINE SET Desired line to line output voltage 480 40254 0xC60C STATUS FLAGS Bits Read only 0 CHECK DONE 1 SYNCHRONIZE TO GENERATOR 2 SYNCHRONIZED 3 INVERTER LINE LINKED 4 CONSTANT VOLTAGE CHARGE 5 PRECHARGE DC LINK 6 IN CURRENT LIMIT 7 FAULT 0xC60D NOT READY CODE SPS JOB NO 95093 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary a
52. ing Remove and retain these braces in an event the unit has to be moved in the future to another location SPS JOB NO 95093 3 1 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 3 1 2 Grounding Means A DC ground Bus Bar is provided to allow connections of the Battery and Solar Array Equipment Frame grounding cables Two terminal blocks are provided in the AC output section for customer connection for ground connection on the generator and load side DC GROUND There is a DC Ground Bus bar provided in the DC compartment of the inverter to allow connections of the Solar Array and Battery Equipment Frame grounding cables and in order to comply with sections 690 41 and 690 42 of the NEC Note All the exposed non current carrying metal parts of inverter are grounded in order to comply with section 690 43 of the NEC Ventilation Considerations The 100kVA PCS unit unit uses filtered forced air cooling for all the magnetic components overall system and all the power electronic modules The 3 phase inverter and chopper assemblies are mounted on air cooled heat sink ensuring sufficient cooling for the semiconductors The magnetics are cooled by the overall airflow through the enclosure The magnetic are designed to require minimum airflow to stay within temperature specifications The power conditioning system is provided with two blowers These backward curved AC
53. ithout permission HYBRID OPERATOR INTERFACE TERMINAL TOP LEVEL SATCON POWER SYSTEMS PHOTOVOLTAIC POWER CONDITIONING SYSTEM 1 METERING 2 PCS CONTROL 3 SETPOINTS 4 PRODUCT INFO 3 4 1 2 Y 1 OUTPUT 1 CONTROL SETTINGS 1 AC BUS SETTING 1 HELP MESSAGE 2 BATTERY STATUS 2 SAVE PARAMETERS 2 GENERATOR SETTING 2 SOFTWARE VERSION 3 DC INPUT 3 DIAGNOSTICS 3 BATTERY SETTING 3 CHECKSUM 4 ENERGY 4 STATUS FLAGS 4 PV SETTING 4 SLAVEID p 1 OUTPUT POWER 1 PV INPUT 1 NOT READY CAUSE 2 LINE PHASES 2 BATTERY INPUT 2 LOCAL COMMAND 3 GEN POWER 3 DC LINK 3 OPERATING MODE 4 GEN VOLT amp CURRENT 4 TEMPERATURE 4 OPERATING SEQUENCE WHOLE MENU SATCON POWER SYSTEMS PHOTOVOLTAIC POWER CONDITIONING SYSTEM i TMETERING 2 PCS CONTROL a SETPOINTS j4 PRODUCT INFO i OUTPUT BATTERY STATUS DC INPUT ENERGY Y 1 OUTPUT POWER 2 LINE PHASES 3 GEN POWER 4 GEN VOLT amp CURRENT Y Y 1 HELP MESSAGE 2 SOFTWARE VERSION 3 CHECKSUM 4 SLAVEID I i i PV INPUT BATTERY INPUT DC LINK TEMPERATURE 1 5 IN ENERGY 2 OUT ENERGY I3 GEN OUT ENERGY PRESS THE SUBMENU TOGO THE UP MENU PRESS THE MENU TO GO THE MAIN MENU Y FPGA AAAAAAAAAAAA F240
54. l during logic power up to local control mode General The power conditioning system supplies power from the Battery and PV inputs to the load in voltage control mode delivering 100 power with a performance of 2 of rated voltage and 0 1 of rated frequency In this mode the inverter supplies the load until the battery is discharged below an acceptable level In this mode all available power from the PV array is used Any net surplus is used top charge the battery Any net shortage is made for with the battery The battery current direction can change at any time depending on the load and PV state This means the battery will cycle between discharging and constant current charging with the load and PV conditions Charging in constant current mode will stop when the battery voltage reaches the absorption set point at which the battery enters constant voltage charging mode It should be noted that when the battery is being charged in constant voltage mode it may not be possible to use all available PV power since the load and battery requirements are more or less fixed In stand alone mode no generator the unit will quit constant voltage charging if the PV is unable to support the load Constant voltage absorption charging is followed by float charging in stand alone mode only When the battery is discharged below the V battery lo set point the PCS will start the generator Once the generator is warmed up and voltage is detected on the
55. me specified by generator wait time for the generator to start After the warm up time is elapsed and voltage and frequency of SPS JOB NO 95093 3 12 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 3 4 3 2 3 4 3 3 3 4 3 4 3 4 3 5 the generator were in the defined range Generator contactor 2 will be closed by control and generator will power the load If the generator fails to start the PCS will open the generator start command contact and wait time specified by generator restart time before attempting to restart After the specified number of restart attempts has failed the PCS will fault Sequence of events when stopping the PCS 1 PCS disables gating to the choppers and inverter and opens all contactors AC and DC contactors including the generator contactor and start command contact After stopping the unit will be in the OFF state Sequence of events during Fault Shutdown of the PCS Most faults alarms will put the PCS in a FAULT state Some faults are used as alarm messages in cases where the PCS could continue to run Note that all the faults are latched and can be reset from the local or remote control command The following describes the sequence of events during fault shutdown 1 The PCS stops in the same manner as a normal stop 2 PCS is in FAULT state 3 The PCS faults are displayed in the OIT Main Me
56. n Baud Rate 19200 Word Length 8 Parity None Stop bits 1 Slave ID is 1 or can be set at OIT SPS JOB NO 95093 3 22 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission Table 3 4 1 Data Output from PCS via Modbus Function code 4 Item Modbus Name Description Comment or Register Ratio 1 30070 STATUSI Fault word 1 Unsigned bitwise 2 30071 STATUS2 Fault word 2 Unsigned bitwise 3 30072 STATUS3 Fault word 3 Unsigned bitwise 4 30073 STATUS4 Fault word 4 Unsigned bitwise 5 30074 STATUS5 Digital outputs 1 16 Unsigned bitwise 6 30075 STATUS6 Digital inputs 1 16 Unsigned bitwise 7 30076 STATUS7 Digital inputs 17 32 Unsigned bitwise 8 30077 PCS_STATE Current operating state of PCS 9 30078 KWBATT Battery power kW x10 10 30079 KWPV PV power kW x10 11 30080 VPV PV voltage Volts DC 12 30081 IPV PV current Amps DC 13 30082 VDCLK DC link voltage Volts DC 14 30083 BATVDC Battery voltage Volts DC 15 30084 BATIDC Battery current Amps DC 16 30085 KVAROUT Power converter apparent power KVARxIO 17 30086 KWOUT Power converter real power kWx10 18 30087 KVAOUT Power converter reactive power kVAx10 19 30088 VACOUTA Power converter voltage phase A to N Volts AC phase 20 30089 VACOUTB Power converter voltage phase B to N Volts AC p
57. n active state HANDLING amp INSTALLATION SAFETY This section details all the safety features that shall be followed while handling and installing the power conditioning system PCS This section also identifies the wire size torque specifications types of field or customer wiring connections CAUTION Attempting to lift the equipment other than the recommended lifting point may damage the equipment or present a personal safety hazard CAUTION Ensure that the load rating of the lifting device is sufficient to safely raise the electrical unit Refer to the packing slip enclosed with shipment for shipping weights SPS JOB NO 95093 2 4 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 2 3 1 2 3 2 General When selecting the installation location the following conditions should be considered A The standard operating ambient temperature of the power conditioning system PCS must be between 30C and 50 degree centigrade The magnetics and the power electronics are air cooled in this PCS Make sure that the air intake and air exhaust openings are not blocked at any time The equipment must be kept clean Dust build up inside the enclosure inhibits proper cooling and decreases the system reliability Only persons familiar with the function of the electrical unit should have access to the equipment The losses in the electri
58. n the panel display of the PCS The inverter has AC Fuses FUAC1 2 3 700Vac at the output for over current protection These AC fuses are equipped with fuse indicators and this information is fed back to the control logic Output AC Filter Reactor LO amp AC Filter Capacitor CO The output 3 phase AC filter reactor LO filters the inverter s output voltage to eliminate any switching transients and is required for inverter energy storage It is a high efficiency design optimized for the switching frequency of the inverter The AC Choke is iron core The output filter capacitor CO is connected in delta and is on the primary side of the transformer and the capacitor selected is heavy duty capacitor rated at 1000Volts AC This L C filter reduces the output current harmonics below 3 under steady state conditions Output AC Contactors CR2A amp CR2B The 3 pole AC output contactors are used to isolate the power supply from the generator and load in a stop state and during the Power Conditioning System pre charge starting period The output contactors are equipped with DC coils for control and 1NO INC auxiliary contacts for monitoring SPS JOB NO 95093 1 7 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 1 3 11 1 3 12 1 3 13 1 3 14 Isolation Transformer TRO The output isolation transformer is required for grounded battery applications and is used
59. nd easy accessibility of major components Design engineering and manufacturing of all inverter systems under a strictly implemented Quality Assurance Program has led to similarly designed equipment being delivered with long MTBF Mean Time Between Failure Chapter 2 provides the important installation safety instructions that must be followed while installing the power conditioning system Chapter 3 describes the installation handling grounding means ventilation considerations equipment markings input output interconnections operating instructions field adjustable trip point procedures and preventative maintenance Chapter 4 includes the list of drawings for the power conditioning system user DESIGN FEATURES SPS JOB NO 95093 1 1 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission The basic design features of the 100 power conditioning system for battery application are as follows 1 The unit is designed according to the customer s specification of 100 power conditioning system The unit has three modes of operation namely inverter mode in which power is exported to the load from the batteries and photovoltaic cells Generator mode where the power is used from the generator to supply the load and also charge the batteries and Parallel mode which happens for a short period of time while the PCS is transfer
60. nd not to be reproduced without permission Table 3 5 5 Service access parameters VB HEX Parameter Setting name Description Default Modbus setting OxCO5C NEUTRAL CONTACTOR 0 OPEN 1 SWITCHED ON TRANSITIONS 1 40301 2 0N 0xC040 NEG SEQ REG EN 0 DISABLE 1 1 l special 11 40273 0xCO2B T HEATER ON Cabinet temperature where heater must be run 4 0 40252 x10 scale OxC06D PLL LOCK ANGLE The maximum allowable angle between the PCS 5 degrees 40318 and the generator to be considered locked OxC06E PLL LOCK DELAY The time the PCS and generator angle difference 50ms 40319 must be low to be considered locked 0xC076 DACI For displaying real time variables 0 077 DAC2 For displaying real time variables 0xC078 DAC3 For displaying real time variables 0 079 DAC4 For displaying real time variables 0xCO7A DAC5 For displaying real time variables 0xCO7B DAC6 For displaying real time variables 0xC090 FAULT1 MASK Factory use only 65535 0xC090 FAULT2 MASK Factory use only 65535 0xC090 FAULT3 MASK Factory use only 65535 0xC090 FAULT4 MASK Factory use only 65535 0xCO9B DIGOUT TEST Code represents desired output state determined 0 to 65535 by adding binary values of the output ports 1 to 16 For example out1 1 16 32768 0xC682 TEST CODE Factory use only 0xC683 TEST MODE Factory use only 0xC689 CHOPPER OPEN LOOP Factory use only TEST DUTY 0xC690 INVERTE
61. nection point to Battery DC Positive DC Negative Symbol throughout the enclosure designates connection point to Battery DC Negative DC Circuit Symbol throughout the enclosure designates the circuit intended to be connected to a DC circuit AC Circuit Symbol throughout the enclosure designates the circuit intended to be connected to an AC circuit including frequency in Hz Number of Phases Symbol throughout the enclosure indicates number of the phases in the circuit ON position Symbol throughout the enclosure indicates where the switches or breakers are in ON position OFF position Symbol throughout the enclosure indicates where the switches or breakers are in OFF position SPS JOB NO 95093 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 2 7 3 0 3 1 3 1 1 3 CHAPTER 3 INSTALLATION amp OPERATING INSTRUCTIONS This chapter specifies the necessary installation operating instructions amp maintenance for the 100 PCS Section 3 1 describes the installation assembly amp mounting grounding means and ventilation considerations Section 3 2 describes the equipment markings and ratings of the PCS Section 3 3 describes the input output inter connections of the PCS Section 3 4 states the operating instructions of the PCS Section 3 5 describes the field adjustable trip points and ranges for voltage and frequency for the use
62. nents nee mette rr 3 49 3 6 2 Control Components 3 50 3 6 3 Fans Blower amp Air Filter Maintenance seen 3 50 3 644 Workmanship iive Der Ie ed SR etie ees 3 51 1 0 1 1 1 CHAPTER 1 INTRODUCTION Satcon Technology Corporation has experience in numerous inverter applications for grid connected and independent three phase loads as well as a number of distributed resource application inverters alternative energy The 100kVA PCS for battery PV application is designed to interface with the dc power from the battery and Photovoltaic Array output and supply the power to the load The PCS at the same time has a Generator as a backup power in case the battery and PV power were under the power required by the load The power conditioning system is designed for three phase output connection of 480Vac at 60 Hz operation with an output transformer for North American application The solid state technology used in the design is of proven reliability and is based upon a number of commercial products number of circuit implementation techniques used are novel in nature and lead to basic design features common to the PWM series of inverters The basic design philosophy emphasises the isolation of single component failures such that multiple component failures do not occur This leads to a low MTTR Mean Time To Repair due to extensive fault diagnostic circuits a
63. nside the PCS as per wiring drawing WD01202 The customer modbus connection via fibre optics communication link is also available on FOSTCDR located above TBC1 on the left side panel in the PCS Refer to general arrangement drawing GA00307 HIELD SHOULD BE GROUNDED TO THE PANEL CLOSEST POINT TO THE TERMINAL 95093 3 8 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission CUSTOMER REMOTE amp COMMUNICATION CONNECTIONS TBC amp TBR m GROUND AND NEUTRAL CONNECTIONS FROM GENERATOR PHASE A B amp C CONNECTION FROM GENERATOR GROUND AND NEUTRAL CONNECTIONS TO LOAD PHASE A amp C CONNECTIONS TO LOAD SPS JOB NO 95093 3 9 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 3 4 OPERATING INSTRUCTIONS This section describes the operating instructions and the sequence of events of PCS operation The PCS can be operated in local mode from the local control panel OIT or in remote mode from the remote controller PLC through RS485 Modbus communication between the PLC and the PCS Digital Control Board Changing between the Local and Remote control can be done from the local control panel when unit is not running Manufacturer sets the default mode of contro
64. nu Diagnostic screen or in the PC Fault Alarm window Sequence of events during E Stop of the PCS The Emergency Stop can be generated from the local E Stop push button on the door of the PCS The following describes the sequence of events during E Stop 1 The e stop is treated the same as a stop command The exception is that the e stop is fail safe and will open all contactors Low Battery Voltage There is a setting LOW BATTERY GENSET START for low battery voltage which can be set from OIT service menu It is set to 228A by manufacturer When the battery voltage drops to this level of voltage the PCS will send a command to start the Generator SPS JOB NO 95093 3 13 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 3 4 3 6 Battery Protection 3 4 4 3 4 4 1 There are some limit settings for protecting batteries which are used to limit total battery current voltage and AC output power The settings are positive values but they are used for both discharging and charging battery these settings can be set from OIT service menu Limits for Battery Protection Item Adjustable Range Set Value Max Battery Voltage for charge 200 320V 320V Min Battery Voltage for discharge 150 250V 225V Max Total Battery Current for discharge charge 600 1200A 1200A Max AC Output Real Power for discharge charge 0
65. nutes after disconnecting all sources of supply SPS JOB NO 95093 2 3 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 2 2 ELECTRICAL SAFETY FEATURES The PCS contains a number of safety features in the design Much of the safety features are software oriented and are described in the Operation section Some of the hardware safety features and anti islanding protection are explained as follows Enclosure Door Interlock Switches There are door switches located on all doors in the PCS Opening any of these doors during operation will trigger a Safety Trip of the PCS for safety purposes Please note that opening the door will cause the PCS to trip and there may be live parts in the PCS with hazardous voltages the access should be allowed only to trained service personnel When maintenance and servicing is not required it is required that all doors are locked and the access is only available to the trained service personnel E Stop Button The PCS unit comes equipped with E Stop Button located on the operator interface panel on the right side door of the PCS Triggering of the E Stop will result in immediate shutdown of the PCS unit Please note that E Stop will only cause the PCS inverter shutdown there will still be live parts in the AC output section of the PCS The E Stop button is also equipped with a Twist to Release to reinstate the button back to the no
66. ol logic of the inverter in powered from the battery side SPS JOB NO 95093 3 6 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 2 Photovoltaic Installer should connect a photovoltaic array rated at 330 600 VDC 319A max to 100 PCS input The input set of cables from Photovoltaic array must be rated for 319A continuous The input cables from the array connect to the and DC and GND bus bars on the DC Input section i e Left Side in the PCS The customer comes with adequate number of cables as recommended in section 2 3 3 from cable entry cut out as indicated on EL00372 01 drawing i e Left side wall of the PCS CAUTION The lugs should be installed as per lug manufacturer s specifications and recommended instructions WARNING Make sure the DC and DC polarities are followed correctly while hooking up the DC input cables from the Battery to the Power conditioning system POSITIVE POSITIVE CONNECTIONS BATTERY FROM SOLAR CONNECTIONS ARRAY NEGATIVE CONNECTIONS FROM SOLAR ARRAY NEGATIVE BATTERY CONNECTIONS GND CONNECTIONS FROM SOLAR ARRAY AND OR BATTERY SPS JOB NO 95093 3 7 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission AC GENERATOR CONNECTION The A B C N amp G from the generator are connected to the 480VAC Generator input CB1
67. osses and overshoot on the devices These state of the art power electronic assemblies use minimal snubber circuits which results in fewer parts count hence increasing the reliability of the PCS and efficiency Printed Circuit Boards All the printed circuit boards used in the PCS system are conformally coated optional not supplied with this system for longevity and adverse weather amp site conditions All printed circuit boards are manufactured as per IPC A 610 class 3 standards SPS JOB NO 95093 1 4 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 1 3 1 3 1 1 3 2 1 3 3 1 3 4 1 3 5 1 3 6 1 3 7 1 3 8 1 3 9 1 3 10 1 3 11 1 3 12 1 3 13 1 3 14 SYSTEM OUTLINE The one line diagram used to illustrate the circuit topology of the unit is shown in Drawing SD00142 The 100 power conditioning unit consists of the following major components DC disconnect switches for PV and Battery inputs DC load break contactors for PV and Battery inputs Battery and PV Current amp Voltage Sensing DC Fuses for Chopper inputs and PV input DC Reactors Buck Boost Choppers DC Link Capacitor Three Phase Inverter Module Output AC Filter Reactor amp AC Filter Capacitor Output AC Contactors Isolation Transformer Output breakers for load and generator for short circuit protection Pre charge circuitry to limit current inrush to specified levels
68. pliance or noncompliance to any code national local or otherwise for the proper installation of this Power Conditioning System or associated equipment A hazard of personal injury and or equipment damage exists if electrical codes are ignored during installation N N gt gt 1 GENERAL 1 1 Precautions DANGER This PCS contains LETHAL VOLTAGES Authorized service personnel only should perform all repairs and service There are no user serviceable parts inside the PCS WARNING Only qualified personnel familiar with the PCS design should plan or implement the installation start up and subsequent maintenance of the system Failure to comply may result with personal injury and or equipment damage WARNING An incorrectly installed PCS may result in equipment damage or a reduction in product life Incorrect wire sizing inadequate supply or excessive ambient temperatures may result in system malfunction CAUTION This PCS contains ESD Electrostatic Discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing this unit Board component damage may result if proper ESD measures are not followed SPS JOB NO 95093 2 1 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 2 1 2 2 1 2 1 2 1 2 2 WARNING avoid an electric shock verify that the voltage on the bus capacitor
69. r Section 3 6 describes the preventative maintenance procedures for the PCS CAUTION Read understand and follow all instructions in the Operation Maintenance manual before installing operating or servicing the equipment Keep the manual available for future use by all operators INSTALLATION This section describes the PCS installation assembly and mounting as required grounding means ventilation considerations WARNING The method of installation conductor size and over current protection shall conform to the requirements of the local electrical code the national electrical code ANSI NFPA 70 or other national codes as applicable Qualified persons shall do all installation wiring and machine reconnection Assembly amp Mounting Inspect the PCS for any shipping damage If damage is found notify the carrier immediately Do not attempt to repair Notify the contractor to determine the best way to correct the problem Remove the packing material from the unit All mechanical connections are sealed with lock tight thread sealer Refer to Enclosure Layout drawing EL00372 01 for input and output gland plate locations and mounting configuration The centre of gravity and weight is also shown on the enclosure layout drawing Please refer to our standard handling manual which is shipped with the unit for standard handling practices for our products There may be temporary shipping braces in the unit to eliminate vibrations during shipp
70. rature switches for protection and indication on the panel display of the PCS Buck Boost Choppers The buck boost choppers x 3 are comprised of IGBT modules for boosting the voltage from the battery to the DC voltage required by the inverter or decreasing the voltage while charging the batteries off the DC link voltage The power flow is bi directional i e the batteries can be discharged or charged via these choppers The amount of boost is controlled by pulse width modulating PWM of the IGBT as signalled by the DPCB control logic There are three buck boost choppers in the PCS The pulse width modulation is done at a frequency 2 5kHz that minimises switching losses and to provide the required performance The IGBT s are mounted on air cooled heat sinks The modules use laminated bus bar construction for interconnection to further reduce switching losses and provide a high degree of power circuit integrity and reliability The module is designed for easy replacement by bolted electrical connections to the laminated bus and connectors for gating and controls The chopper module gate driver boards DFOD utilises fibre optic gating and protection circuitry for over current amp gating fault protection and indication on the panel display of the PCS SPS JOB NO 95093 1 6 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 1 3 11 DC Link Capacitor CF The D
71. ric tools to loosen or tighten metric hardware and as well use only standard size tools to loosen and tighten standard size hardware These fundamental practices will help to avoid insufficient tightening and rounding off corners SPS JOB NO 95093 3 37 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 4 CHAPTER 4 4 0 APPLICABLE DOCUMENTS AND DRAWINGS The following drawings are included in the manual INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission No Drawing Title Drawing No Included 1 SD00142 One Line System Block Diagram 100kV A Hybrid PCS 4 2 SC00565 Power Schematic 100kVA Hybrid PCS 4 3 EL00372 01 Enclosure Layout 100kVA Hybrid PCS 4 4 GA00459 General Arrangement 100kVA Hybrid PCS 4 6 WD01626 DPCB Wiring 100kVA Hybrid PCS 4 7 WD01627 120VAC 24VDC Control Wiring Diagram 100kVA Hybrid PCS 4 8 WD01625 Logic Interconnection Diagram 100kV A Hybrid PCS 4 SPS JOB NO 95093 4 1
72. ring the load from inverter to generator or ViseVersa The control for inverter mode is AC Voltage control for generator mode depending on the stage of charging switches from Current control to voltage control on the chopper and for parallel mode is AC Current control The three phase output voltages and currents are sinusoidal with low total harmonic distortion meeting the Harmonic specification required 006 0619 The inverter and chopper use 1200V rated IGBT s for fast switching high switching frequency and high efficiency The state of the art inverter and chopper stack with sandwiched bus bar design are used increasing the efficiency and reliability of the system The control circuit uses Digital Power Control Board DPCB using DSP Digital Signal Processor and FPGA Field Programmable Gate Array for control system monitoring and protection All areas sensitive to over temperature conditions are monitored with thermal detectors Extensive electronic fault detection schemes with fuses are employed to ensure safety of critical circuits SPS JOB NO 95093 1 2 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission 1 2 8 Use of DSP based control allows for advanced control strategies such as field oriented control D Q Frame control and predictive control resulting in improved system dynamic response stability and accuracy
73. rrent information for controls to digital board The sensing board DCVS is an accurate voltage sensor used to measure Battery voltage Voltage divider networks and RDC2 provide voltage information from PV and DC Link to the digital board for control purposes DC Fuses FUDC1 4 The DC fuses FUDC1 3 are provided for backup protection and current limiting There are 3 buck boost choppers in total and each Chopper s DC branch is fused The choppers are fused only in the positive leg since the batteries are grounded at the negative terminal FUDC4 provides over current protection for the PV input to the PCS These DC fuses are equipped with fuse indicators and this information is fed back to the control logic for monitoring DC Reactors LF1 3 The DC input reactor is used for energy storage in the buck boost chopper and to limit the rms ripple current to less than 2 of the current It is a high efficiency design optimized for the switching frequency of the chopper A DC reactor is used per buck boost chopper hence total of 3 de reactors in the PCS The switching is 120 degree shifted on each chopper to reduce the ripple The reactor is dry type wound with class 220 insulation The unit is vacuum pressure impregnated VPI with polyester resin for durability and protection against the environment The reactors are forced air cooled by ambient air and designed with a 1 10 service factor for long life The reactors include over tempe
74. s has discharged before performing any work on the PCS Measure the voltage across CF in PCS it must be zero to be fully discharged WARNING The enclosure contains exposed high voltage conductors The enclosure door should remain locked except during maintenance or testing by trained service personnel Do not open the cabinet doors if extreme moisture is present rain snow or heavy dew Electrical Safety WARNING ELECTRIC SHOCK can KILL Do not touch live electrical parts ELECTRIC ARC FLASH can injure eyes burn skin cause equipment damage and ignite combustible material DO NOT use power cables to break load and prevent tools from causing short circuits General Equipment that supplies electrical power can cause serious injury or death or damage to other equipment or property The operator must strictly observe all safety rules and take precautionary actions Safe practices have been developed from past experience in the use of power source equipment Shock Prevention Bare conductors terminals in the output circuit or ungrounded electrically live equipment can fatally shock a person Have a certified electrician verify that the equipment is adequately grounded and learn what terminals are electrically HOT Use proper safety clothing procedures and test equipment The electrical resistance of the body is decreased when wet permitting dangerous currents to flow through it When inspecting or servicing equipment do not work in damp
75. ths later and then every year thereafter SPS JOB NO 95093 3 35 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced without permission Control Components Electronic The printed circuit boards are to be kept clean and free of any accumulations of dirt and foreign materials Static materials should never be allowed near circuit boards while in the PCS unit or in the stores Caution should be used when near or handling circuit boards proper Electro static Discharge ESD measures must be taken to avoid PCB failures There are no requirements other than housekeeping standards that the maintenance program requires on the logic control components Note All the above items are subject to thermal degradation Good housekeeping is the prime method of maintaining original design parameters and increasing the MTBF of the unit Fans Blower amp Filter Maintenance Physical rotation and observation of any noise or binding on the fans will reduce failures during operation There are two blowers backward curved impellers in the system that are mounted on the back side of the PCS The entire backward curved impeller should be cleaned as necessary to remove accumulated dust dirt and other foreign particles which may collect on the blades or other parts Refer to fan manufacturer data sheet for maintenance instructions in details CAUTION THIS TEST IS TO BE DONE WHEN PCS IS DE ENER
76. ute value of DC input current is lower than the low battery current setting 40A the DC INPUT LED on the PCS panel will be flashing otherwise constant ON Stand By When PCS is in Standby state LED is ON otherwise OFF Inverter Operation If inverter gating is enabled LED is Line Linkage Operation It is not used Stand Alone Operation It is not used Output If the line voltage is okay LED is ON Line Fault If a line fault OV UV OF UF is detected this LED will be ON Fault System fault LED will be ON PCS in shutdown state 3 4 4 2 OIT Description The Operator Interface Terminal OIT provides an easy and convenient way to control the unit in Local Mode The OIT keypad layout is shown in the following figure It has a Main Menu key and a Service Menu key for selecting two menus respectively Pressing the corresponding number in the menu allows the operator to access each submenu The screens in each submenu can be accessed using the Page Up or Page Down keys In a setting screen use 7 or 8 key to select a setting data press CLEAR key then use number keys to input data press ENTER key to apply the data A Bg SPS JOB NO 95093 3 15 INSTALLATION AND OPERATION MANUAL The information of this document is proprietary and not to be reproduced w
77. zes for Customer Interface Torque Specifications amp Special Symbols The following table gives the wire gauges recommended lug crimping tool and torque values for connections of all the cables that customer must use for field connections to the various points in the PCS MAXIMUM CABLE DC Input from Solar Cell Panels Positive Connections DC Input from Solar Cell Panels Negative Connections DC Input from Solar Cell panels And Battery if required Ground Connections DC Input from Battery Bank Positive Connections DC Input from Battery Bank Negative Connections 3PH 480VAC Generator Note The cables must be sized not to exceed 75c at the connection point Use 75c column of conductor sizing tables from NEC Neutral Generator Ground Generator 3PH 480VAC Load Note The cables must be sized not to exceed 75c at The Connection point Use 75c column of conductor sizing tables from NEC Ground Load Customer Control Wiring TBC amp TBR Terminal Block TOP or Bottom Cable Entry TOP or Bottom Cable Entry TOP or Bottom Cable Entry TOP or Bottom Cable Entry TOP or Bottom Cable Entry TOP or Bottom Cable Entry TOP or Bottom Cable Entry TOP or Bottom Cable Entry TOP or Bottom Cable Entry TOP or Bottom Cable Entry TOP or Bottom Cable Entry TOP or Bottom Cable Entry Maximum 4 X 4 O Recommended 2 X 4 O or 4X Maximum 4 X 4 O R

ZBB 200kW PCS

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