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EN / PVS800-57 central inverters (100 to 630 kW) hardware manual

1. 94 Maintenance Replacing the cooling fan of the inverter module R8i 2 A WARNING Follow the safety instructions page 77 Ignoring the instructions can cause physical injury or death or damage to the equipment 1 seven steps safety precautions page 12 Stop the inverter and disconnect it from the AC and DC power lines Wait for five minutes to let the inverter DC capacitors discharge before opening the cabinet door Ensure by measuring with a multimeter impedance at least 1 Mohm that there is no voltage present Open the inverter cubicle door Disconnect the fan wiring plug a Remove the locking screws b Pull the fan out along its sliding rails c Install new fan in reverse order pr Qu e gt
2. Required free space for door opening see chapter Dimension drawings Losses cooling data and noise The inverter is cooled by an internal fan flow direction from front to top 4 _ 78 L9 789 789 L3 S89 W 4 10 10 20 20 PVS800 57 0630kW B 205000 for dimensioning the ventilation of the electric equipment room cooling air flow for a cabinet with one DC input cubicle only at partial power typically 65 dB with speed controlled fans 104 Technical data Filter material in the inlet door grating airTex G150 288 mm x 292 mm 688 mm x 521 mm Terminal and lead through data for the DC input power cable Inverter type No of cable lead throughs 060 mm 2 36 Units with fuse protected DC input Units with MCB protected connections DC input connections Standard 4H382 8H382 12H382 377 E 67777 ec peus 7 ____ _____ The DC input power cable terminal data is given in the table below Units with fuse protected DC input connections PDE busbars busbars PE busbar Inverter type Pcs ee Bolt Tightening Bolt Tightening PVS800 57 Standard 4H382 8H382 12H382 Size torque size torque a f m
3. 108 Constant voltage output 108 Auxiliary power output 108 108 DONANO 108 eeren reana 109 DDCS fiber optic link 109 24 V DC power input 109 eee een 111 Degrees of protection 112 ace 2 378 9 3 23 9 v 6 RE 113 264s teas 114 Auxiliary circuit power consumption 114 marking 115 Compliance with the European Low Voltage Directive 115 Compliance with the European EMC directive 115 Compliance with EMC standards EN 61000 6 2 2005 and EN 61000 6 4 2007 115 Applicable standards and requirements 115 Medium voltage network 116 Low voltage network 116 MAKING a set suse RnB E pu ERE re ES 116 VDE MAKING
4. y8 611 705 dy 775 91 2 699 ve 92 699 09 pel SE 92 I vel ITEL OLS 8119 616 G pP e Ii 6v 676 IVNING IN ION IOSO NOC Li 690555590000005500000001005990000000009650000000990000950500000090000000099559000000659000 51914 ve p 6 SS 007 14 i 60 vc 019 Dimension drawings 129 R8i Top view of fastening points 2 I gt oO lt gt LC NI e lt lt D lt gt 4 A lt gt ien gt lt gt lt gt GG lt gt Oo a oO BC gt oo xS CO YD E ex MD CY LC Tc UC cx ret ON CQ a Y uen el ux 2 L 1 1 Eo Bae T 1 LC LO gt C CX LC ca o e 1 SES E i YYTETTUT KENNT 00000000000000000000000000000000000000000000000000000006000006000000000000000000000009 o ES O 4 294 29 13 04 76 6 0 S LO ex c ro E E gt E cu gt c E co gt XR lt DOD lt gt 5 gt lt gt gt c oo lt co cb CE SS 65 ub gt CO LD r ceo OO
5. N o o 09 69 61 lt i o 005 A lt gt lt gt lt gt ER EUM 21 12 S C 2 6 6 o ap E LC Y 2n usu 865 49 2 36 gt 0 64 JOY SIGNAL CABLES 2 x R8i Twelve DC inputs option 12 382 132 Dimension drawings 9 0600000VnV Se ee 9270 090 31902 5 09D S m lt i nm LE La Coa x c P a i 1 S aon N V UNA CO ONIXIJ IVNS3INI lt TES 403 SINIOd 58 16 801 uodo Joo 29 2 62 Sp 29 T 009 01 ead em Co lt gt lt S qu jar gt ene CO pO lt lt E Cole Co no CE co lt gt c n lt gt E E lt lt gt e5 c ee 20 e lt gt em A x n co Dimension drawings 133 2 x AC output terminals eed 3AUA0000090765 i i amr 1 I Li Li 1 o o o sS o LC Coco
6. ONT LAL 019 Dimension drawings 127 DC terminals of units with four DC inputs option 49382 91 0600000VnV PO Go co PO PO Qr E ee E EM ED S 565 35 E 5 ES Sui L2 qe 5s ns lt gt 1 uw c a 00 I L T 4 117 167 81 78 61 pos cp 14 EUR cs 60 7296 699 69 62 791 MESE T Hi 1917 618 8 9 616 VA gt NO J E Sry 01 4 67 672 E 5 4 0000000000000000000000000000000000090 omm m jjj QE EET A Y AT 5474 ONT LST c0 yc 019 R8i DC terminals of units with eight DC inputs option 8H382 128 Dimension drawings 910600000 9 M CoO gt lt lt p Go lt lt pm Co pm CO Go MO mo Co DX Ro DO gt cn c em oem ees ee Po Po Po rd CAS CO J o MS lt gt Co 4 p DO Do no Jj lt gt J gt lt lt gt Cr Qo 1 81S Bike
7. 11 Use of warnings 11 Safety in installation and maintenance 12 General seven step safety precautions 12 Electrical Salely amen oet 13 Grounding 14 General safety 15 board ened Ge REG tan ees 17 Fiber optic 17 Start up and operation 18 2 Introduction to the manual What this chapter contains 19 ET 19 Contents of the manual 19 Related documents 20 Categorization by frame size and option code 20 Quick installation commissioning and operation flowchart 20 Terms and abbreviations 21 3 Operation principle and hardware description What this Chapter contains 23 RE CU REIR UOS
8. Maintenance 95 Replacing the inverter module frames 2 x f WARNING Follow the safety instructions page 77 Ignoring the instructions can cause physical injury or death or damage to the equipment or damage to the equipment WARNING Ignoring the following instructions can cause physical injury or death Use extreme caution when manoeuvering the inverter module Extend the support legs of the module when it is removed from the cabinet Do not tilt the module The module is heavy and has a high center of gravity It topples over easily if handled carelessly Lift the module by the upper part only using the lifting hole s at the top Do not use the ramp with plinth heights over 50 mm The ramp supplied with the inverter is designed for a plinth height of 50 mm the standard plinth height of ABB cabinets Tighten the four fastening bolts of the ramp carefully Extracting the module from the cubicle Repeat the seven steps safety precautions page 12 Stop the inverter and disconnect it from the AC and DC power lines Wait for five minutes to let the inverter DC capacitors discharge before opening the cabinet door Ensure by measuring with a multimeter impedance at least 1 that there is no voltage present Open the cubicle door Remove any shrouds that protect the busbars and cable entries Open the transparent cover on the front of th
9. O 10 20 30 40 50 60 70 80 90 100 96 O 10 20 30 40 50 60 70 80 90 100 P Py 96 Q Reactive power in percentage of nominal active power Relative active power Current Overvoltage category IEC 62109 Harmonic distortion See section Ratings 3 With option F263 the category is 1 THD current lt 3 at nominal load DC input connection data Maximum DC power Py Maximum DC current Imax pc Maximum DC voltage Umax pc Operational DC voltage range Umppt DC Voltage ripple Overvoltage category IEC 62109 See section Ratings See section Ratings 1000 V DC Types 0100kW A 0250kW A and 0500kW A 450 825 V DC Types 0315kW B and 0630kW B 525 825 V DC lt 3 2 Auxiliary power connection data Voltage Frequency Allowed electrical system 230 V AC 115 V AC optional 50 60 Hz TN S grounded system If IT ungrounded system contact ABB for instructions 108 Technical data Overvoltage category 2 IEC 62109 Control unit RDCU RMIO connection data Analog inputs RDCU A43 PVS800 master control program one programmable differential current input 0 mA 4 20 mA Ri 100 ohm RDCU A41 PVS800 inverter control program two programmable differential current input 0 mA 4 20 mA Rin 100 ohm and one programmable differential voltage input 10 V 10 V Rin 200 kohm The analog inputs are galvanically isolated
10. appropriate inverter manuals and optional module manuals delivery documents Check that there are no signs of damage Manuals and other loose parts are delivered inside the inverter Before attempting installation and operation check the information on the type designation label of the inverter to verify that the delivery is of the correct type See sections Type designation labels on page 39 and Type designation key on page 40 Mechanical installation 45 Moving the unit Move the unit by crane A fork lift or pallet truck B or on rollers C as shown below Use the steel lifting bars attached to the top of the cabinet Insert the lifting ropes or slings into the holes of the lifting bars The lifting bars can be removed not mandatory once the cabinet is in its final position If the lifting bars are removed the bolts must be refastened to retain the degree of protection of the cabinet The unit is to be moved only in the upright position The centre of gravity is high Be therefore careful when transporting the unit Avoid tilting the cabinet If using a pallet truck check its load capacity before attempting to move the unit If the cabinet needs to be laid on its back it must be supported from below beside the cubicle seams as shown below a support b cabinet back panel Note Transportation of a
11. Ge og dees 117 Golden Sun marking 117 12 Dimension drawings What this chapter contains 119 IRC 4 DOTT 120 POMC IROL othe eee ee G 123 Frame 2 x cnc cen aewcadaeeben bee Renew 130 Further information Safety instructions 11 Safety instructions What this chapter contains This chapter contains the safety instructions which you must follow when installing operating and servicing the inverters If ignored physical injury or death may follow or damage may occur to the inverter photovoltaic generator or adjoining equipment Read the safety instructions before you work on the unit Use of warnings Warnings caution you about conditions which can result in serious injury or death and or damage to the equipment They also tell you how to avoid the danger Notes draw attention to a particular condition or fact or give information on a subject The warning symbols are used as follows Electricity warning warns of hazards from electricity which can cause AN physical injury and or damage to the equipment General warning warns about conditions other than those caused by electricity which can result in physical injury and or damage to the equipment Electrostatic sensitive devices warning warns of electrostatic discharge which
12. L 00000000000 CD NIO yj i 100 c2 NYC LY gt gt 62 ce More M ANC 2212 s pee cou o SOC A 65 oA 3AUA0000090765 pep e oo x SF mr CO LY wT lt lt 2 R8i Top view of fastening points 16 501 VEC 00 001 RESET 0092 00 001 0750 AT OO 9 06 06 060 96 78 S6 78 0 1 99 76799 069 069 09 09 9709 0 16 2v 162v 060 060 101 UE 0 6 0 6 62 61 62 61 067 067 E 1 6 61 Ore Ore 75 pup 06 06 1007 ECL 00 0 0 p d 01 1 Pr o9 D 59 10 P OSG 0 zi e E 5 Dt C c S 2 2 LIS 069 075 16 271 060 10 LE 076 Dimension drawings 137 0000090765 M16 24 pcs aan OO 1 1 Twelve DC inputs option 12H382 138 Dimension drawings Further information More information about ABB products for solar applications on the Internet www abb com solar Contact us www abb com solar 3AUA0000053689 Rev E EN 2012 04 13 Power and productivity LIP for a better world PF
13. Operation principle and hardware description 31 Symbol Terminal Description Operation Component F1 1 AC fuses F1 4 F1 20 Circuit breakers Circuit breakers for overvoltage protection devices F50 and F51 Overvoltage Devices for overvoltage protection against for example climatic protection devices overvoltages caused by lightning strikes F50 is optional F263 Grounding contactor The inverter software controls the disconnection of the positive with options F282 negative pole grounding and F283 Grounding board Provides fuse protection and current monitoring with options F282 and F283 AC main switch Hand operated switch which connects the inverter to the electrical power system The switch includes AC main fuses The AC main switch can be operated at all times If it is operated during operation the inverter will trip as the grid disappears Auxiliary control Hand operated switch which connects the auxiliary control voltage to voltage switch the inverter filter Optional filter 2216 for low voltage distribution networks Electrical power network supervision function The inverter control program includes an electrical power network supervision function The inverter monitors for example the electrical power system overvoltage undervoltage overfrequency underfrequency and frequency change rate The function is used for disconnecting the inverter from the power system in power syste
14. 6 40 ROT 122 Dimension drawings 8ZLE800000VNVE 1415 le vl 716 7 sjndui 9q Jno4 pou euo Dimension drawings 123 Frame R8i Two DC inputs as standard four DC inputs with option 4H382 e 25 v o e e 3 8 O e rue e lt e D ne lt lt gt l0 Ee C 4 lt lt En o gt L OG AN ae 1 _ Oz pem Q lt gt 2 Z 09 lt gt Cy Me OFS VC xis e ASI Ec Uu ld TZ m o 20 20 lo lo Hy oa 9 lt gt D LL co Top om x lt lt lt x 18871 69 14 pv fV gt lt 66 I 18 e Sa Yun 7 8S 117 p 124 Dimension drawings R8i Eight DC inputs option 8H382 24 44 oor open max pec CREER 0000090163 LC lt gt ce lt gt 1 lt gt T gt lt
15. 19 50 60 Coda S UADOO0 118285 E 202 G6100 6410 J401 K458 K4644K479 095 1409 DL IEEE Serial number The first digit of the serial number refers to the manufacturing plant The next four digits refer to the units manufacturing year and week respectively The remaining digits complete the serial number so that there are no two units with the same number Type designation see section Type designation key below Valid markings Ratings of inverter Inverter module label The type designation label of the inverter module includes the ratings valid markings a type code and a serial number The module label is attached to the front panel of the module 40 Operation principle and hardware description An example type designation label of the inverter module is shown below uo EU INVERTER U DC 450 900 850 UL vl Oy Imax DC 700A Output U AC 3 230 325 V M 600 A 3 __ _1 __ __ 58 632 _ __ UL open t 2 Code iu 1 PySa00 104 0250KW A UO wl T E m Serno k 04 2 61 LIE ME Serial number The first digit of the serial number refers to the manufacturing plant The next four digits refer to the units manufacturing year and week respectively The remaining digits complete the serial number so that there are no two modules with the same number Type designation Valid markings Ratings of inverter module Type desi
16. 24 Block diagram of solar generator system 25 Main circuit diagram of the inverter system 26 Electrical power network supervision function 31 Positive or negative pole grounding options F282 and F283 31 Cabinet layout of frame 32 Cabinet layout of frame 33 Cabinet layout of frame 2 x 34 Doordevices 35 Inverter module 35 Inverter module R8i 35 Connections and interfaces overview 37 CDP 312R Control 38 1622 39 Type designation labels 39 39 Inverter module label 39 Type designation key 40 4 Mechanical installation What this chapter contains 43 Checking the installation site
17. 3 5e lt gt LO LC Terminals of PVS800 57 0100kW A Terminals of PVS800 57 0250kW A 0315kW B 0500kW A and 0630kW B Units with MCB protected DC input connections option H377 Inverter type Photovoltaic switches PE PEbusbar PVS800 57 Max wire size Tightening Bolt BE mm torque size torque 0100kW A 6 50 stranded cable 30 44 Nm 6 70 solid cable 22 92 101 Technical data 105 Terminal and lead through data for the AC output power cable AC busbars PE busbar a M12 70 N m M10 30 44 7 50 5 3 8 2 32 lb ft GNI Terminals of PVS800 57 0100kW A Terminals of PVS800 57 0250kW A 0315kW B 0500kW A and 0630kW B 106 Technical data AC output connection specification Voltage Allowed electrical system type Transformer Short circuit withstand strength IEC 60439 1 Frequency Imbalance Voltage dips Fundamental power factor cos phi4 Types 0100kW A 0250kW A and 0500kW A 300 V AC 3 phase 10 Types 0315kW B and 0630kW B 350 V AC 3 phase 10 3 phase IT ungrounded system Galvanic isolation for each inverter is needed The transformer must be suitable for GBT based inverter use with high du dt values against the ground Dedicated low voltage winding is needed for each inverter Static screen between windings with proper dimensioning is needed For detai
18. T c NS E CER ere po D e poa lt gt gt wu Of 4 EE 22 09 INI 0 Q SS 87 L 22 11 t s 2 U c L 2 59000000000000000000009 006600560005665000000069000000000000000000000000606000000000696000000000000000000000609 0000000000000000000000 d Dimension drawings 125 R8i AC output terminals 0000090163 6 Ex LL LC Sat lt gt NI if O alo c n rd lt gt M ce a Y 1 1 a oF Lu 67S 09 27 280 DC terminals of units with two DC inputs standard 126 Dimension drawings 910600000VnV no Co eo CO Co PO AT d WT 2 lt gt Con c c D CoO lt gt o 0 0 SE i m b oS NO o o 0 0 69 62 791 ey Weds FOL 19 7E 6 8 ee 9 66 S S 051 2 60 692 5 E ON FONAO
19. 16 AC output grid connection terminals behind the fan swing out frame with connecting knobs for temporary grounding for work Cabinet fans AC output cable lead throughs behind the fan swing out frame Grid monitoring relay options 0969 and 0974 115 230 V auxiliary control voltage connection terminals and switch Heating resistor option G300 The output cubicle heating resistor is behind the fan swing out frame Junction box power supply option G410 Operation principle and hardware description 35 Door devices As standard the cabinet door is equipped with an inverter control panel and AC and DC main switch operating handles Optionally the door can also be equipped with emergency stop push and reset buttons and ground fault monitoring indication and reset buttons Inverter module 71 The cooling fan at the base of the inverter module is fed from the auxiliary voltage supply 5 0 mes o es B EE DC input connections Output busbars Ex Cooling fan Power connection for cooling fan X41 Fiber optic connectors
20. Note Some grid related functions like the low voltage ride through and grid monitoring will start to work only after the inverter has been started and stopped once Stop the inverter by pressing the control panel key Q 80 Start up Set parameter 98 08 AUTO LINE ID RUN to NO This parameter setting prevents an unneccessary ID run in case of auxiliary power loss of the control board Note If the phase order changes set 99 07 LINE SIDE ID RUN to YES to run the ID run once See the firmware manual SETTING THE INVERTER MASTER CONTROL PROGRAM PARAMETERS Set the wake up and sleep levels in parameter group 31 and Correct settings minimise the start other start up parameters ups in the morning and shut downs in the evening It is useful to follow the operation for a few days and nights It may be needed to adjust the settings according to the season See PVS800 central inverters firmware manual 3AUA0000058422 English Set the remote or automatic reset and start functions Note Ensure that local regulations and site specific requirements allow the remote or automatic reset and Start after faults SETTING UP FIELDBUS CONTROL remote control mode Set the fieldbus parameters of the inverter control programs See PVS800 central inverters firmware manual 3AUA0000058422 English and the appropriate fieldbus adapter module manual Check that you can read the signals Check that you can start and stop th
21. lt _ cos Le 30 85 184 30 Pat i P 9 14 _ Oo exe p p 134 Dimension drawings 2 x R8i DC terminals of units with four DC input terminals standard ONS ex LC AR zc O epo md 9 gt ES lt gt lt gt IS Cy i oy QOO gt 9 E gt 02 2 X eo SS lt lt C 2 C Cr gt gt OC c CN m mE oo SP coco LOLO Li QZ CI L oA 3AUA0000090765 19 ire ek Si m Lr E SO 1 sc CY Ra Wut CETERI ET EE gt i zy n eum gt LC CD Ld ae ec lt gt Lus Le EI Y eo NI ec eS Y 726 18 067 y 90d i BARS MT LC eI E ERN 10 24 G 952 2 Hm CAAA Cpe Dimension drawings 135 2 x R8i DC terminals of units with eight DC input terminals 8H382 3AUA0000090765 CO 2 EC CO COGO Ico E o M zm c C S Ure EE d
22. 399 _ 19 m DC fuses for 12 DC input connections option 12H382 Inverter type NO NO Fuse information Rated current A PVS800 57 0500RW A 57 0500kW A 166 170M4388 PC71UD13C160TF PVS800 57 0630kW B 170M4388 PC71UD13C160TF m Miniature DC circuit breakers option 377 Inverter type Breaker information PVS800 57 0100kW A S804PV S80 PVS800 57 0250kW A S804PV S100 PVS800 57 0500kW A S804PV S100 m Miniature circuit breakers for options G300 and G410 Owo Bee Inverter type G300 S 202 K6 DS201 C6A30 Technical 103 Dimensions weights and free space requirements Dimensions and weights of the standard cabinet are given below 290 ess 455 eo 237 60 36 door equipment such as switches and air inlet gratings excluded Widths and weights of the cabinets with options are given below Width mm Weight kg 700 260 __ me 3x9 gt 35 zum 399 3m zum 399 Required free space around the unit for cooling
23. 43 Required toolS counted 44 Checking the delivery 44 MOWING MGC UNT s _ eet poe 45 Placing Ihe UDI aoc esac teed bya 46 Overview of the installation process 46 Fastening the cabinet the floor 47 Alternative 1 Clamping 47 Alternative 2 Using the holes inside the cabinet 48 Miscellaneous 49 Preventing the recirculation of hot air 49 Ventilation duct at the air outlet of the cabinet 49 Calculating the required static pressure difference 50 Cable duct the floor below the cabinet 51 5 Planning the electrical installation What this chapter contains 53 Selecting the 1 53 Requirements for the transformer 54 Selecting the grid disconnecting 55 Selecting the DC input disconnecting 55 Checking the compatibility of the solar generato
24. 599 a _ Rs 45 C 50 65 35 38 OSA R8 40 C 965 m 30 so 80 _ 00592517 Continuous AC output current Type A inverters No overloadability at 40 C Type B inverters No overloadability at 45 1096 overloadability at 25 PN AC Continuous AC output power Type A inverters No overloadability at 40 C Type B inverters No overloadability at 45 C 10 overloadability at 25 Imax DC Maximum input current at nominal output power and ambient temperature UN AC Nominal output voltage Poy Recommended maximum input power to ensure full output power at normal radiation conditions Inverter limits the power to a safe level Temp Nominal ambient temperature The values apply to this temperature 100 Technical data Derating The load capacity current and power decreases if the installation site altitude exceeds 1000 metres 3300 ft or if the ambient temperature exceeds the nominal ambient temperature Temperature derating of types 0100kW A 0250kW A and 0500kW A In the temperature range 40 C 104 F to 50 C 122 F the rated output current is decreased as shown below 100 INN 40 50 104 122 Temperature derating of types 0315kW B and 0630kW B In the temperature range 45 113 F to 55 131 F the rated output current is decreased as shown below 110 rated current is allowed
25. This chapter contains preventive maintenance instructions of the inverter Maintenance intervals If installed in an appropriate environment the inverter requires very little maintenance The table below lists the routine maintenance intervals recommended by ABB The recommended maintenance intervals and component replacements are based on specified operational and environmental conditions ABB recommends annual inverter inspections to ensure the highest reliability and optimum performance Consult your local ABB Service representative for more details on the maintenance On the Internet go to http www abb com drivesservices tne M Capacitor reforming Every year when stored See Reforming the capacitors Depending on the dustiness of the environment every 6 to 12 See Cleaning the heatsink months Cabinet air filter replacement See Replacing the air filters Frame inverter modules Check and cleaning of power Every 3 years connections LCL filter fan change Every 6 years Cabinet door fan change Every 6 years Cabinet roof fan change Every 6 years Heatsink temperature check and cleaning See Checking and cleaning the power connections 2 x 86 Maintenance Inverter module fan change Every 6 years Capacitor change Every 20 years See Capacitors 4FPS1000027105 Cleaning the interior of the cabinet WARNING Follow the safety instructions page 11 Ignoring the AN N instructions can
26. UVD Front view with cooling fan removed Inverter module R8i The modules run on wheels which along with the quick connector at the AC output enable quick replacement of a module for maintenance The inverter module is equipped with a speed controlled cooling fan involving a power supply board and a fan inverter board that outputs a frequency in the range of 25 to 55 Hz to the fan The fan is regulated according to the temperature of the output stage of the module Through inverter parameters other operating modes such as constant speed 36 Operation principle and hardware description may also be available see the firmware manual The power to the fan is supplied from the intermediate DC circuit e O DC input connections Operation principle and hardware description 37 Connections and interfaces overview The diagram below shows the power connections and control interfaces of the inverter CDP312R 24 V DC ExtPower AINT AINT 230 N PEO PE x21 oe 1 ___ 8 2 3C 1 Monitoring and or controlling of the inverter 2 Grid monitoring relay option Q969 or Q974 3 See page 74 Ground fault monitoring option Q954 9 Remote monitoring default connection For ring topology see the firmware manual for the
27. 120 V control Not allowed unless the 24 V cable is cables in separate ducts inside the insulated for 230 V 120 V or insulated cabinet with an insulation sleeving for 230 V 120 V Implementing short circuit and thermal overload protection W Protecting the inverter and AC output cable in short circuit situations The inverter is equipped with internal AC fuses which restrict inverter damage in case of a short circuit inside the inverter Install external protection such as fuses according to local regulations appropriate AC line voltage and the rated current of the inverter to protect the AC output cable Protecting the photovoltaic generator and DC input cable in short circuit situations The input DC fuses or optional DC input miniature circuit breakers option H377 protect the inverter DC circuit and the DC input cables in a short circuit situation when the cable is dimensioned according to inverter nominal DC current and fuse and breaker ratings See section Fuses on page 101 for the fuse and breaker ratings To protect inverters delivered without input DC fuses option 0 291 follow the instructions in section nstructions for inverters delivered without input DC fuses option 0 291 on page 62 Note The inverter does not protect the photovoltaic generator Install adequate protection devices to for example each string Protecting the inverter and the AC output cable against thermal overload The inver
28. 77 PRIMARY CHECKS EU he ES 77 FIRST START local control mode 78 SETTING THE INVERTER MASTER CONTROL PROGRAM PARAMETERS 80 SETTING UP FIELDBUS CONTROL remote control mode 80 SETTING UP THE INSULATION MONITORING DEVICE option 0954 80 SETTING UP THE CABINET HEATER option 6300 80 Connecting DriveWindow 81 Configuring the NETA 01 Ethernet Adapter Module 02 9 Fault tracing What this chapter contains 83 83 Warning and fault messages displayed by the CDP 312R Control Panel 84 Fault Same ID numbers 84 Fault tracing of the insulation monitoring device option 954 84 10 Maintenance What this chapter contains 85 Maintenance intervals 85 Cleaning the interior of the cabinet 86 Replacing air filters 86 Inlet GOOF 86 Cleaning the heatsink 87 Checking and cleaning the power connections 2 87 88 Replaci
29. Only qualified electricians are allowed to carry out the work described Ignoring the safety instructions can cause injury or death Checking the insulation of the assembly Inverter Every inverter module has been tested for insulation between the main circuit and the chassis 2700 V rms 50 Hz for 1 second at the factory Therefore do not make any voltage tolerance or insulation resistance tests eg hi pot or megger on any part of the inverter AC output cable Check the insulation of the AC output cable according to local regulations before connecting it to the inverter DC input cable s Check the insulation of the DC input cable s according to local regulations before connecting it to the inverter 66 Electrical installation Photovoltaic generator Ensure that the insulation of the solar generator has been checked according to manufacturer s instructions The solar generator must be disconnected from the inverter during the insulation check Checking the compatibility with IT ungrounded systems The EMC filter option E216 is not suitable for use in an IT ungrounded system Check that the low voltage network is of the TN grounded type If not please contact ABB ungrounded power system or a high resistance grounded over 30 ohm power system the system will be connected to earth potential through the EMC filter capacitors This may cause danger or damage the equipment in the network WARNING
30. program version GSXR7340 and later Terminal block size cables 0 3 to 3 3 mm 22 to 12 AWG Tightening torque 0 2 to 0 4 0 2 to 0 3 Ibf ft 1 Can be configured for Start Stop or other use with parameter settings 2 Total maximum current shared between this output and the optional modules installed on the board 3 Can be configured with parameter settings for resetting the emergency stop circuit with the emergency stop reset button on the cabinet door option 0951 4 Used only with options F282 and F283 RMIO VREF Reference voltage 10 V DC 1 kohm lt AGND lt 10 kohm gt VREF Reference voltage 10 V DC 1 kohm R lt AGND 10 kohm DC current measurement Grounding current measurement 4 20 mA Rin 100 ohm Solar generator DC voltage measurement AI3 _ 0 4 20 mA Rin 100 ohm AO1 By default not in use 0 4 20 mA lt Toon By default not in use 0 4 20 mA R lt 700 ohm X22 By default not in use 1 AC and DC overvoltage protection 4 DC cable overcurrent protection DI5 Transformer trip MWS Emergency stop option Q951 24VD 24 V DC max 100 mA 24VD DGND1 Digital ground DGND2 Digital ground DIIL DC grounding acknowledgement Auxiliary voltage output and input non isolated 24 V DC 250 mA 2 Relay output 1 By default not in use With option Q951 reserved A 5 7 1
31. ABB cabinets Tighten the four fastening bolts of the ramp carefully Safety instructions 17 e Beware of the cooling fan blades The fans may continue to rotate for a while after the disconnection of the electrical supply Beware of hot surfaces Some parts inside the inverter cabinet such as heatsinks of power semiconductors remain hot for a while after the disconnection of the electrical supply e sure that borings and grindings do not enter the inverter when installing Electrically conductive dust inside the unit may cause damage or lead to malfunction e Fastening the cabinet by riveting or welding is not recommended However if welding is necessary ensure the return wire is properly connected close to the weld in order not to damage the electronic equipment in the cabinet Also ensure that welding fumes are not inhaled Printed circuit boards Ignoring the following instructions can cause equipment malfunction and damage to the equipment WARNING The printed circuit boards contain components sensitive to 4 electrostatic discharge Wear a grounding wrist band when handling the boards Do not touch the boards unnecessarily Fiber optic cables Ignoring the following instructions can cause equipment malfunction and damage to the equipment cables always grab the connector not the cable itself Do not touch the ends of the fibers with bare hands as the fiber is extremely sensiti
32. K19 or K19 1 control Relay output 2 Ground fault reset with option Q954 m Relay output 3 Main AC contactor control 72 Electrical installation Default I O connections RDIO on A41 The default connections of the RDIO 01 Digital Extension Modules inserted on the inverter control unit are shown below Digital input output RDIO Description terminal RDIO 01 no 1 on Slot 2 A412 Digital input 1 X11 DI1 DC contactor K2 status 1 DC contactor K2 1 status 1 closed closed Digital input 2 X12 DI2 DC contactor K2 2 status 1 closed Digital input 3 12 013 Grid monitoring relay status 0 monitoring relay status 0 tripped tripped Digital output 1 X21 R1 DC contactor K2 close DC contactor K2 1 close command command Digital output 2 X22 R2 DC contactor K2 2 close command RDIO 01 no 2 on Slot 1 A411 Digital input 4 X11 DH DENN AC contactor K1 2 supervision Digital output 3 X21 R1 AC contactor K1 2 close command Digital output 4 X22 R2 Charging contactor K19 2 close command Connection procedure Making 360 degrees grounding at the cabinet lead through for the control cables 1 Loosen the EMI conductive cushions 2 Cutadequate holes to the rubber grommets in the lead through plate and lead the cables through the grommets and the cushions into the cabinet 3 Strip off the cable plastic sheath above the lead through plate just enough to ensur
33. L brackets not included in the delivery Use the lifting bar fastening holes and bolts M16 20 aie 10 Slot detail front view dimensions millimetres Cubicle Distance between slots width p 250 mm 9 85 600 mm 450 mm 17 7 800 mm 650 mm 25 6 Ec Fastening the cabinet at the top with L brackets side view Clamp dimensions in millimetres The a L bracket dotted line denotes the cabinet frame b Cabinet roof 48 Mechanical installation Alternative 2 Using the holes inside the cabinet The cabinet can be fastened to the floor using the fastening holes inside the cabinet if they are accessible The recommended maximum distance between the fastening points is 800 mm 31 5 If the back fastening holes are not accessible fasten the top of the cabinet to the wall with L brackets not included in the delivery Use the lifting bar fastening holes and bolts M16 Fastening the cabinet at the top with L brackets side view a L bracket b Cabinet roof 25 mm 0 985 Fastening holes inside the cabinet Added width a Cubicle width Side panels of the cabinet 15 mm 0 67 Back panel of the cabinet 10 mm 0 4 Gap between cubicles mm b Distance between fastening holes Outer hole diameter 31 mm 1 22 Bo
34. Operation principle of the measuring circuit 61 Safely INTOMMAUON daw dees 61 Customer WINING 61 Boe ee ee 61 62 Implementing positive or negative pole grounding options F282 and F283 62 Limiting the conducted disturbances with the EMC filter option E216 in low voltage TN grounded networks 62 Instructions for inverters delivered without input DC fuses option 02291 62 Mechanical installation of the input DC fuses 63 6 Electrical installation What this chapter contains 65 AAOS 44 2 yne 65 Checking the insulation of the 65 nuni PTT 65 2 5 ered ee ee 65 65 Photovoltaic generator 66 Checking the compatibility with IT ungrounded systems 66 Connecting the power cables 66 CONNECIONCIAGIAN aus RE 66 DC input cable connection procedure 67 AC output cable connecti
35. PM M cor O cor lt gt 2 7 m eo ere MIG m m ice lt on 29 gt DD J On sto L ES 33 tl ex Ve Cer m m 88 3 855 5 jd 1 IG ial _ 669 I ivl EIC uo 0 lt lt gt o NI NI gt vC 18 790 T az lesu HE 2 ee e M C1 C ME G Sv c 25 69 61 GPe 52 C ale 8S 1 575 a EE n CS 11 136 Dimension drawings 2 x R8i DC terminals of units with twelve DC input terminals 12H382 O D gt r 1 1 1 1 ar 1 i CO cogo lt gt E oO Ako cor EC IC po 90 B P cor o gt lt gt 2 i mn gt gt e OLY Or LLL Giek NI gt e 1 r c D 1 n Cx LO E Co FERMINALSIN 1 Q R ee B LIFTING L Ooooooo00000 0000000000 00000000000
36. R7i with option H377 DC input terminals of frame R8i with option four miniature circuit breakers for two DC input 4H382 and frame 2 x four fuse connections protected DC input connections a Cable lead throughs a Cable lead throughs b Cable support b Cable support b DC input miniature circuit breakers 68 Electrical installation ACoutput cable connection procedure 1 Frames and Remove the shroud covering the output power terminals Frame 2 x R8i Undo the three fastening screws of the cabinet fan swing out frame covering the output power terminals and open the swing out frame 2 Lead the cable s into the inside of the cabinet If shielded cable is used make the 360 grounding arrangements at the cabinet entry as shown below and connect the twisted shield of the AC output cable s to the cabinet PE ground busbar with a cable lug 3 Connect the phase conductors to terminals L1 L2 and L3 Connect the separate PE grounding conductor if present to the cabinet PE ground busbar 4 Refit the shroud onto the output power terminals 21 sl POSS AC output terminals of PVS800 57 0630kW 360 degrees grounding a 360 degrees EMC lead throughs b Cable support Electrical installation 69 Connecting the external power supply cable for the auxiliary circuit Connect the external power supply cable
37. a 1E
38. and disconnect it from the AC and DC power lines Wait for five minutes to let the inverter DC capacitors discharge before opening the cabinet door Ensure by measuring with a multimeter impedance at least 1 Mohm that there is no voltage present Open the LCL filter cubicle door Disconnect the wire plug Remove the two screws holding the fan unit Pull the fan unit out Install new fan in reverse order e w I9 i E PF fal de 7 le zi n pe n i Maintenance 89 Replacing the LCL filter cooling fan 2 x R8i cause physical injury or death or damage to the equipment f WARNING Follow the safety instructions page 77 Ignoring the instructions can E a Repeat the seven steps safety precautions page 12 Stop the inverter and disconnect it from the AC and DC power lines Wait for five minutes to let the inverter DC capacitors discharge before opening the cabinet door Ensure by measuring with a multimeter impedance at least 1 that there is no voltage present Open the LCL filter cubicle door Disconnect the fan wiring plug Undo the screw of the fan fastening clip Pull the fan out Install a new fan in reverse order 90 Maintenance Replacing the incoming cubicle door fans frames R8i and 2 x and the output cubicle door fan frame R8i A WARNING Follow the safety instructions page 77 Ignoring the instr
39. can damage the equipment 12 Safety instructions Safety in installation and maintenance General seven step safety precautions These precautions are intended for all who work on the inverter its input and output cables the transformer or photovoltaic generator WARNING Before any work repeat the seven steps safety precautions AN described below 1 Clearly identify the work location Read the safety instructions of the work area and the component you are working on See the subsections below and component specific manuals 2 Disconnect and secure against reconnection Disconnect all possible power supplies Lock the disconnectors to open position and attach a warning notice to them After disconnection of the inverters always wait for 5 minutes to let the intermediate circuit capacitors to discharge uU 3 Protect against any other live parts o 4 Take special precautions when close to bare conductors 5 Check that the installation is dead Always ensure by measuring that there is no power connected 6 Apply temporary grounding for work Connect the AC and am T ii DC busbars to the PE W W connecting knob is using an appropriate 25 mm temporary grounding tool View of AC busbars grounding 0 7 Issue permit to work Safety instructions 13 Electrical safety These warnings are intended for all who work on the inverter its input and output cables the transformer or pho
40. cause physical injury or death or damage to the equipment WARNING Use a vacuum cleaner with an antistatic hose and nozzle Using a T 4 normal vacuum cleaner creates static discharges which can damage circuit boards 1 seven steps safety precautions page 12 Stop the inverter and disconnect it from the AC and DC power lines Wait for five minutes to let the inverter DC capacitors discharge before opening the cabinet door Ensure by measuring with a multimeter impedance at least 1 Mohm that there is no voltage present 2 When necessary clean the interior of the cabinet with a soft brush and a vacuum cleaner 3 Clean the air inlets and outlets of the fans Check the air inlet filters of the cabinet Replace when necessary see section Replacing the air filters below Replacing the air filters Check the air filters and replace if necessary see section Losses cooling data and noise on page 103 for the correct filter types m Inlet door filters Remove the fasteners at the top of the grating Lift the grating and pull it away from the door 1 2 3 Replace the air filter mat 4 Install the grating in reverse order Maintenance 87 Cleaning the heatsink The inverter module heatsink fins pick up dust from the cooling air Check the cleanliness of the heatsink regularly The inverter runs into overtemperature warnings and fa
41. cooling fan s and contactor control circuits Transformer The transformer connects the inverter AC side to the low voltage or medium voltage distribution network Junction box power The inverter supplies power to the junction box through terminal X21 supply option Max 6 A Fault current protected G410 C11 EMC filter capacitor Reduces electromagnetic interference C16 C18 F3 x Input DC fuses Protect the DC input connections The exact number of the fuses depends on the number of the DC input connections Note These fuses are not used with option H377 Q2 DC main switch Hand operated switch which connects the inverter to the solar generator The switch is interlocked with the DC contactor so that it will not open unless the DC contactor is open If there is no auxiliary power in the inverter the switch cannot be operated at all It will remain in the position where it already is DC contactors The inverter controls the DC contactor according to the operational state The solar generator is disconnected from the inverter when needed Inverter DC fuses Protect the inverter module Inverter module Converts the DC voltage to AC voltage The operation is controlled by switching the IGBTs LCL filter Smooths the current and voltage waveform U4 AC contactors The inverter controls the AC contactor according to the operational K1 2 state Charging circuit The inverter controls the charging contactors after receiving a start command
42. ft see page 100 110 Technical data Isolation and grounding diagram Test voltage 500 V AC gt X NO e N lt gt Common mode voltage between channels 15 V B 8 oa NO 012 DI3 014 s ponor s pe s ravo 1 DIIL X23 X25 Test voltage 4 kV AC Ground Jumper J1 settings digital inputs share a common ground This is the default setting Grounds of input groups j a 8 DI1 DI4 and DI5 DI6 DIIL are separate insulation voltage 50 V Technical data 111 Efficiency All values below are without auxiliary power consumption The inverter complies with efficiency standards IEC 61683 and EN 50530 Maximum efficiency emm ae PVSSCSTOIRMA wooo 968 PVS800 57 0250KW A 980 ova 969 European EURO eta PVS800 57 0100kW A efficiency 5096 P P PVS800 57 0250kW A efficiency 50 rom PVS800 57 0500kW A efficiency 50 112 Technical data Maximum efficiency DC voltage 525 V 675 V 825 V PVS800 57 0BTEKWB PVS800 57 0630KW B European EURO eta efficiency PVS800 57 0315kW B efficiency PVS800 57 0630kW B efficiency 5096 nom 76 Degrees of p
43. generator is able to feed power to the inverter This enables verifying that the inverter functions properly Parameter settings can be done during the dark hours Also the inverter modulation can be tested without input power from the photovoltaic arrays Check that the polarity and voltage of each connected DC solar Note There should be a record string is correct document stating that the polarity Remove the inverter DC fuses and voltage of each solar string is OK The resistance value should be available for setting up the optional insulation monitoring device Measure that the plus pole is connected to the plus terminal and the minus pole to the minus terminal and the voltage is correct Replace the DC fuses Verify the expected DC voltage Check that the open circuit DC Note The expected DC voltage can voltage from the solar generator lies within the allowed range of be estimated by using the open the inverter eg 450 1000 V DC circuit voltage of the solar modules and the number of modules in a string FIRST START local control mode Measure and record the DC voltage Note The expected and measured Units with optional miniature circuit breakers 377 Open the DC voltages should be roughly miniature circuit breakers Measure and record all DC inputs equal Units with optional miniature circuit breakers 377 Close the miniature circuit breakers Switch on the auxiliary power The co
44. is not a personnel safety or fire protection feature Customer wiring The insulation monitoring device can be connected to external systems See the circuit diagrams delivered with the inverter Start up See chapter Start up 62 Planning the electrical installation More information e Circuit diagrams delivered with the inverter e Manufacturer s operating manual of the insulation monitoring device Implementing positive or negative pole grounding options F282 and F283 Some solar module types require positive or negative grounding Make sure that the optional positive F282 or negative F283 grounding method is suitable for the solar modules that you are using Ground the panels during long maintenance breaks if the panel type requires it Limiting the conducted disturbances with the EMC filter option E216 in low voltage TN grounded networks The optional EMC filter E216 can be installed at the network side of the low voltage transformer to limit the conducted disturbances to other equipment connected to the network The filter has capacitors connected to ground and is not suitable for IT ungrounded networks Ensure that the network owner and operator allows the installation of this kind of a filter The filter must always be installed according to local regulations Instructions for inverters delivered without input DC fuses option 0F291 If the standard input DC fuses are not suitable for the customer app
45. of the inverter system An example main circuit diagram of the 100 kW 250 kW and 315 kW inverter systems is shown below Auxiliary power supply 11 52 T PVS800 57 1xR7i PVS800 5 1xR8i Option E216 Grid Operation principle and hardware description 27 Symbol Terminal Description Operation Component DC input terminals The solar generator is connected to the inverter DC input terminals with busbars and fuse links or through miniature circuit breakers option H377 AC output The AC output terminals connect the inverter to the low voltage AC power system Auxiliary control The customer supplies 230 V AC 1 phase auxiliary control voltage to voltage input the inverter circuit boards cooling fan s and contactor control circuits Transformer The transformer connects the inverter AC side to the low voltage or medium voltage distribution network Junction box power The inverter supplies power to the junction box through terminal X21 supply option Max 6 A Fault current protected G410 EMC filter capacitor Reduces electromagnetic interference C16 only in 250 kW units C16 C21 Input DC fuses Protect the DC input connections The exact number of the fuses depends on the number of the DC input connections Note These fuses are not used with option H377 F1 20 Circuit breakers Circuit breakers for overvoltage protection devices F50 and F51 F41 Q2 DC main switch Hand operat
46. often used in reference to a group of components that share a similar mechanical construction To determine the frame size of a component refer to the rating tables in chapter Technical data IGBT Insulated gate bipolar transistor a voltage controlled semiconductor type widely used in inverters due to its easy controllability and high switching frequency Inverter A cabinet built entity containing all inverter modules together with their control electronics and and auxiliary components The inverter module converts the DC voltage to AC voltage Its operation is controlled by switching the IGBTs Miniature circuit breaker 0 circuit breaker Maximum power point tracking Inverter menee function that automatically operates the photovoltaic generator at its maximum power point NAMU Auxiliary measuring unit 5 0 measuring Auxiliary measuring unit 0 Ethernet adapter module Photovoltaic cell In this manual solar power system components based on photovoltaic effect are generator module called solar cell solar module solar array solar string and solar array junction box as string array and defined below array junction box PGND Grounding monitoring board PLC Programmable logic controller PPCS Power plate communication system a protocol used in the optical fiber link that controls the output semiconductors of an inverter module Group of parallel c
47. or ground it indirectly via a few nanofarads high frequency capacitor eg 3 3 nF 630 V The shield can also be grounded directly at both ends if they are in the same ground line with no significant voltage drop between the end points Tighten the screws to secure the connection Note Keep any signal wire pairs twisted as close to the terminals as possible Twisting the wire with its return wire reduces disturbances caused by inductive coupling Connecting a PC For connecting a PC to the inverter during the start up procedure see chapter Start up For normal use connect the PC through a fiber optic link to CH3 of the RDCO module inserted in the master control unit A43 Installing optional modules Mechanical installation Optional modules such as fieldbus adapters and extensions are inserted in the optional module slot on the RDCU Control Unit at the factory The module is fastened with a screw oee page 3 for the available slots Note Correct installation of the screw is essential for fulfilling the EMC requirements and for proper operation of the module Wiring the modules See the appropriate optional module manual for specific installation and wiring instructions Installation checklist 75 Installation checklist What this chapter contains This chapter contains a list for checking the mechanical and electrical installation of the inverter Checklist Go through the checks below with another person F
48. required parameter settings 6 APBU branching unit and two AINT boards only in frames 2 x 8 In other frames the fiber optic cables from A41 are connected directly to AINT See the next page for other descriptions See chapter Electrical installation for the wiring instructions and section Control unit RDCU RMIO connection data on page 108 for the control unit specifications For more information on the connections see the circuit diagrams delivered with the inverter 38 Operation principle and hardware description RDCU Master control unit equipped with the RMIO board containing the PVS800 solar A43 inverter master control program Terminal block Terminal block Analog inputs 3 pcs and outputs 2 pcs 24 V DC External power input ExtPower Rxxx 0x Fieldbus adapter module RETA 01 RETA 02 RPBA 01 or 01 RXxx Ox Reserved for string monitoring option 479 DDCS RDCO 0x DDCS communication adapter module For using the inverter PC tools NETA Ox Ethernet adapter module for Internet browser based remote monitoring of the inverter RDCU Inverter control unit equipped with the RMIO board containing the PVS800 solar inverter control program Terminal block X20 X21 Reference voltage 24 V DC X21 Analog inputs and outputs 5 pcs Reserved Contact ABB if need to be used X22 Digital inputs 7 pcs one input reserved for the optional ground fault monitoring Auxiliary voltage output and input 24 V DC X25 t
49. safety and performance criteria and tests for solar inverters 118 Technical data Dimension drawings 119 Dimension drawings What this chapter contains This chapter contains example dimension drawings of the inverter 120 Dimension drawings Frame 7 ge eS uc 6 pee lt gt gt o gt B DX EM gt u o o o o o o o o o o o o lt CX LC lt lt Cry NS E NI Ys C LC SD E752 Li gt o es c co e 97 9 ZS ii 791 98 8 ttl p E 97 058 75 06 open max Door __ RUN 12 558 as ro lt La ae D zc FE CO 5 lt lt lt lt __ E RTRA IG 00 gt d NI B ool RE g A col 66 005 RS E 6 89 OGLI eo He dub 4 0000083128 Dimension drawings 121 AC output 0000083128 TA cl is
50. weights and free space requirements on page 103 for requirements for free space around the unit The floor that the unit is installed on must be of non flammable material as smooth as possible and strong enough to support the weight of the unit The floor flatness must be checked with a spirit level before the installation of the cabinets into their final position The maximum allowed deviation from the surface level is 5 mm in every 3 metres The installation site should be levelled if necessary as the cabinet is not equipped with adjustable feet 44 Mechanical installation Note For easy maintenance do not install the inverter on a higher level than the floor in front of it If the inverter is placed higher the ramp supplied with the inverter cannot be used when replacing an inverter module The wall behind the unit must be of non flammable material Required tools The tools required for moving the unit to its final position fastening it to the floor and tightening the connections are listed below e crane fork lift or pallet truck check load capacity iron bar jack and rollers e Pozidrive and Torx 2 5 6 mm screwdrivers for the tightening of the frame screws e torque wrench e set of wrenches and sockets Checking the delivery The inverter delivery contains e inverter cabinet line up e optional modules if ordered installed onto the control units e ramp for the inverter module replacement
51. with 16 A gG fuses See the circuit diagrams delivered with the inverter Technical data 115 Applicable standards and requirements The inverter complies with the standards below IEC EN 62109 1 2010 Safety of power converters for use in photovoltaic power systems Part 1 General requirements EN 50530 2010 Overall efficiency of photovoltaic inverters IEC EN 60529 1992 Degrees of protection provided by enclosures IP code IEC EN 61000 6 2 2005 Electromagnetic compatibility EMC Part 6 2 Generic standards Immunity for industrial environments IEC EN 61000 6 4 2007 Electromagnetic compatibility EMC Part 6 4 Generic standards Emission standard for industrial environments NEMA 250 2003 Enclosures for Electrical Equipment 1000 Volts Maximum IEC 61683 1999 Photovoltaic systems Power conditioners Procedure for measuring efficiency IEC 62116 2008 Test procedure of islanding prevention measures for utility interconnected photovoltaic inverters BDEW 2008 Technical guideline Generating plants connected to the medium voltage network French Order 2008 French Ministerial Order for electrical energy generating facilities NOR DEVE08088815A VDE 0126 1 1 Automatic disconnection device between a generator and the public low voltage grid CE marking A CE mark is attached to the inverter to verify that the unit follows the provisions of the European Low Voltage and EMC Directives Compliance with the E
52. with a hand operated disconnecting device Optionally it can be equipped with miniature DC input circuit breakers option H377 The breakers do not however isolate the inverter DC input conductors and terminals from the input voltage Therefore the junction boxes must be equipped with breakers for the isolation Checking the compatibility of the solar generator and inverter Check that e generator current and voltage match the rated values of the inverter e generator open circuit voltage does not exceed the maximum allowed DC voltage of the inverter e generator operating range lies between the limits of the maximum power point tracking MPPT function of the inverter control program e generator grounding requirements match with the inverter Selecting the power cables General rules Dimension the DC input power and AC output power cables according to local regulations e Dimension the cable to carry the inverter load current See chapter Technical data for the rated currents e Select a cable rated for at least 70 C maximum permissible temperature of conductor in continuous use e The inductance and impedance of the PE conductor cable grounding wire must rated according to permissible touch voltage appearing under fault conditions so that the fault point voltage will not rise excessively when a ground fault occurs Select an AC output cable rated for at least 600 V AC A two conductor system is allowed
53. 0 11 gt lt 23 1 2 X25 Relay output 2 Fault 1 Relay output 3 Grounding switch control 2 Electrical installation 71 Default I O connection diagram 41 The external control cable connections to the RMIO board for the PVS800 solar inverter control program with default settings are shown below program version ISXR7340 and later Terminal block size cables 0 3 to 3 3 mm 22 to 12 AWG Tightening torque 0 2 to 0 4 0 2 to 0 3 Ibf ft 1 Total maximum current shared between this output and the optional modules installed on the board RMIO X20 lt 10 kohm X21 VREF By default not in use 10 V DC 1 lt AGND lt 10 kohm By default not in use 10 10 V Rin 200 Output inverter R7i cubicle temperature 6 Al2 measurement 4 20 mA 30 80 Incoming cubicle temperature 8 AI measurement 4 20 mA 30 80 1 By default not in use 0 4 20 mA lt 700 ohm By default not in use 0 4 20 R lt 700 ohm X22 cal 555555 A RE supervision 2 102 Inverter Inverter start stop 3 _ 08 __ AC contactor K1 K1 1 supervision 6 DI6 __ By default notin use 24 V DC max 100 mA 8 24VD 9 DGND1 Digital ground X23 1 424V Auxiliary voltage output and input non 2 GND isolated 24 V DC 250 mA X25 Relay output 1 Charging contactor
54. 230 V AC signals in the same cable 58 Planning the electrical installation Signals allowed to be run in the same cable Relay controlled signals providing their voltage does not exceed 48 V can be run in the same cables as digital input signals It is recommended that the relay controlled signals be run as twisted pairs Relay cable type The cable type with braided metallic screen eg OLFLEX by LAPPKABEL Germany has been tested and approved by ABB Routing the cables It is recommended that the input DC power cable output AC power cable and control cables be installed on separate trays Where control cables must cross power cables ensure they are arranged at an angle as near to 90 degrees as possible Do not run extra cables through the inverter The cable trays must have good electrical bonding to each other and to the grounding electrodes Aluminium tray systems can be used to improve local equalizing of potential If four conductor AC cabling is used place the three output phase cables symmetrically and close to each other Asymmmetrical installation may induce current to grounding cables and metal structures A diagram of the cable routing is shown below Inverter DC input cable AC output power cable min 500 mm 8in 90 ES Control cables Planning the electrical installation 59 Separate control cable ducts 230 V 230 V 24V 120 V 24V 120 V Lead 24 V and 230 V
55. ABB solar inverters PVS800 5 7 central inverters 100 to 630 kW nl 111 M BIET IM M TAI i T 1317 IM hl iili M Tl MT i TI HEAT BAT II 1915 Ia II AA 1 Hil AAI WA ITI nl 1h 1 ul Wil Power and productivity dp Lp for a better world PF B B9 List of related manuals Inverter hardware manual Code English PVS800 57 hardware manual 3AUA0000053689 Inverter firmware manual PVS800 central inverters firmware manual 3AUA0000058422 and adaptive program application guide 3AUA0000091276 Option manuals and quides PVS JB 8 M junction box with monitoring for PVS800 central 3AUA0000087106 inverters user s manual 1 Delivered as printed copy with the inverter 2 Delivered as a printed copy with the option Hardware manual PVS800 5 central inverters 100 to 630 kW 1 Safety instructions 4 Mechanical installation 6 Electrical installation 8 Start up Or 2012 ABB Oy All Rights Reserved 3AUA0000053689 Rev E EN EFFECTIVE 2012 04 13 Table of contents List of related manuals 2 1 Safety instructions What this chapter contains
56. C input cables or terminals from the DC voltage supplied by the photovoltaic generator Before working inside the inverter cabinet switch off or isolate the auxiliary voltage supply from the inverter Before working on the unit apply temporary grounding for work See page 12 Do not work on the control cables when power is applied to the inverter or to the external control circuits Externally supplied control circuits may cause dangerous voltages inside the inverter even when the main power on the inverter is switched off Live parts inside the cubicle are protected against direct contact when all protective plastic covers and metallic shrouds are in place Pay special attention when handling sharp metallic shrouds Do not make any insulation or voltage withstand tests on the inverter or inverter modules Note The DC connection terminals UDC UDC L and L carry a dangerous DC voltage up to 1000 V Depending on the external and internal wiring dangerous voltages 115 V or 230 V may be present at different terminals in the auxiliary connection unit With options F282 and F283 one of the poles of the photovoltaic generator is grounded and therefore the other pole has full voltage against ground up to 1000 V When the photovoltaic generator cells are exposed to light even if it is dim the generator supplies DC voltage to the inverter 14 Safety instructions Grounding These warnings are intended for al
57. Fuses Data for the factory installed fuses are given in the tables below Fuses from other manufacturers can be used if they meet the given ratings m Maincircuit AC fuses Fuse information 3 400 170M5808D PIENA 7 3 roa SRKDPVOR FVSSU STOSISRWS 3 1000 3084 SSURDSPVIOD FVSSUUSTOSURWA __ 6 tooo 68URDSSTTFIQU0 6 10 omena 590 000 Inverter DC fuses Inverter type Fuse information Rated current PVS800 57 0100kW A 5 0100kW A 170M6303 7 2 8 TURDISPAIUD 4 1 TURDISPAIBUD 4 7 TURDISPAIUD NO NO 102 Technical data DC fuses for standard DC input connections Fuse information DC input connections Qty Rated current PNSNOSTONOWA 31 9 Pesos 4 49 TES POTD TCA 2 4 50 5 PCTUDTICSTE 4 8 49 _ PCTTUDTACAOOTE Pvsssroowvs 4 8 50 PCTUDTICSTF DC fuses for 4 DC input connections option 4H382 Qty Rated current Lad PVS800 57 0250kW A 8 250 170M4390 PC71UD13C250TF PVS800 57 0315kW B 1 170M4390 PC71UD13C250TF DC fuses for 8 DC input connections option 8H382 Rated current t 6
58. If the optional EMC filter E216 is installed on an IT system an Connecting the power cables Connection diagram PVS800 57 us NN 1 Solar array junction box 2 One DC line needs to be grounded for certain thin film photovoltaic module types and if required by country specific regulations 3 360 degrees grounding is recommended at the cabinet entry if shielded cable is used Ground the other end of the input cable shield or PE conductor at the transformer 4 5 If shielded cable is used not required but recommended and the conductivity of the shield is lt 50 of the conductivity of the phase conductor use a separate PE cable 5 or a cable with a grounding conductor 4 Electrical installation 67 DC input cable connection procedure Remove the shroud covering the input power terminals Lead the cable s into the inside of the cabinet If shielded cable is used connect the shield to the cabinet grounding busbar with a cable lug Connect the DC conductor to terminal L and the DC conductor to terminal L Note In the R8i and 2 x frame sizes with fuse protected DC input connections the location of the and terminals varies depending on the number of the DC input connections See chapter Dimension drawings If a separate PE conductor is used connect it to the cabinet grounding terminal Refit the shroud onto the input power terminals DC input terminals of frame
59. as a group Insulation test voltage 500 V AC 1 min Max common mode voltage 15 VDC between the channels Common mode rejection ratio gt 60 dB at 50 Hz Resolution 0 025 12 bit for the 10 V 10 V input 0 5 11 bit for the 0 10 V and 0 20 mA inputs Inaccuracy 0 596 Full Scale Range at 25 77 F Temperature coefficient 100 ppm C 56 ppm F max Constant voltage output Voltage 10 V DC 0 10 V DC x 0 5 Full Scale Range at 25 C 77 F Temperature coefficient 100 ppm C x56 ppm F Maximum load 10 mA Applicable potentiometer 1 kohm to 10 kohm Auxiliary power output Voltage 24 V DC x 10 short circuit proof Maximum current 250 mA shared between this output and optional modules installed on the RMIO Analog outputs Two programmable current outputs 0 4 to 20 mA lt 700 ohm Resolution 0 196 10 bit Inaccuracy 1 Full Scale Range at 25 77 F Temperature coefficient 200 ppm C 111 ppm F max Digital inputs RDCU A43 PVS800 master control program two programmable digital inputs common ground 24 V DC 15 to 2096 and a start interlock input Group isolated can be divided in two isolated groups see Isolation and grounding diagram below RDCU A41 PVS800 inverter control program one programmable digital input common ground 24 V DC 15 to 20 and a start interlock input Group isolated can be divided in two isolated groups see I
60. as follows 1 A transformer with static screening between the primary and secondary windings is used to ensure that no excessive emission is propagated to neighboring low voltage networks The low voltage network is of the TN type grounded The EMC filter option E216 is installed on network side of the low voltage transformer 4 inverter is installed according to the instructions given in the hardware manual QN Low voltage network Equipment PVS800 option E216 C tick marking C tick marking is required in Australia and New Zealand A C tick mark is attached to the inverter to verify compliance with the relevant standards IEC EN 61000 6 2 2005 and IEC EN 61000 6 4 2007 mandated by the Trans Tasman Electromagnetic Compatibility Scheme For fulfilling the requirements of the standard see section Compliance with the European EMC directive on page 115 Technical data 117 VDE marking A VDE mark is attached to the inverters with option C178 The VDE mark verifies that the unit follows the provisions of the German VDE 0126 1 1 standard that specifies the grid connection parameters and safety functions for German low voltage network Golden Sun marking A Golde Sun mark is attached to the inverters with option 177 The Golden Sun mark verifies that the solar inverter is allowed to be connected to a Chinese electricity network The Golden Sun certification program specifies
61. below 25 77 F 5 15 25 35 45 55 T 41 F 59 F 77 F 95 F 113 F 131 F Altitude derating In altitudes from 1000 to 2000 m 3300 to 6562 ft above sea level the derating is 1 for every 100 m 328 ft If the installation site is higher than 2000 m 6600 ft above sea level contact your local ABB distributor or office for further information Combined derating Because altitude affects the maximum temperature it is possible to compensate for the altitude derating value with a limited maximum ambient temperature Each degree of maximum ambient temperature below the nominal ambient temperature gives a 1 compensation to the altitude derating Technical data 101 Note Maximum altitude is still limited to 2000 m 6562 ft Note Use temperature compensation only for altitude derating Nominal power must not be exceeded Example If the maximum ambient temperature of an inverter installed at 1800 m 5906 ft is limited to 35 95 F the derating factor is 100 8 5 97 or 0 97 Type equivalence table Inverter type Inverter module s used LCL filter s used size PVS800 57 0100kW A PVS800 104 0105kW A _ 104 0105kW A 8 05 PVS800 57 0250kW A PVS800 104 0250kW A 15 PVS800 57 0315kW B PVS800 104 0315kW B SLCL 16 PVS800 57 0500kW A 2xPVS800 104 0250kW A 2xSLCL 15 PVS800 57 0630kW B 2xPVS800 104 0315kW B 2xSLCL 16
62. checklist contains a list for checking the mechanical and electrical installation of the inverter Start up describes the start up procedure of the inverter Fault tracing describes the fault tracing possibilities of the inverter Maintenance contains preventive maintenance instructions of the inverter Technical data contains the technical data for the inverter Dimension drawings contains example dimension drawings of the inverter Related documents See the inside of the front cover Categorization by frame size and option code Some instructions technical data dimensions and weights which concern only certain inverter frame sizes are marked with the symbol of the frame size such as R8i The frame size is not marked on the inverter designation label To identify the frame size of your unit see the rating tables in chapter Technical data The instructions and technical data which concern only certain optional selections are marked with option codes eg Q951 The options included in the inverter can be identified from the option codes visible on the type designation label The option selections are listed in section designation key on page 40 Quick installation commissioning and operation flowchart Task See Plan the installation Technical data Check the ambient conditions ratings required cooling Planning the electrical installation air flow input and output power connection compatibility Option manual
63. conductors to the terminals of auxiliary control voltage switch Q10 as shown below For the location of the switch inside the cabinet see the cabinet layout photos in chapter Operation principle and hardware description 010 230 E 52 e 6 PE oPE Maximum fuse 16 A Note concerning power supply from IT ungrounded systems Contact ABB for instructions Equip the power supply for the auxiliary circuit with fault current circuit breakers for ground fault indication and tripping If the overvoltage protection device of the auxiliary control voltage input causes unnecessary ground fault trippings the type of the device must be changed Connecting the junction box power supply option G410 800 57 PVS JB 8 M PVS JB 8 M pm 070 00 60 230 V Connecting the EMC filter option E216 Connect the EMC filter on the network side of the low voltage transformer PVS800 57 300 V 400 V EMC filter Connecting the control cables External control cable connections to the RMIO board terminals of the inverter are shown below For more information see the firmware manual 70 Electrical installation Default connection diagram 43 The external control cable connections to the RMIO board for the PVS800 solar inverter master control program with default settings are shown below
64. de derating 100 Combined derating 100 Type equivalence table 101 FUSOS Pr 101 Main circUIt 101 Inverter 1 5 5 101 DC fuses for standard DC input connections 102 DC fuses for 4 DC input connections option 49382 102 DC fuses for 8 DC input connections option 8H382 102 DC fuses for 12 DC input connections option 129382 102 Miniature DC circuit breakers option 77 102 Miniature circuit breakers for options G300 and 6410 102 Dimensions weights and free space requirements 103 Losses cooling data and noise 103 Terminal and lead through data for the DC input power cable 104 Terminal and lead through data for the AC output power cable 105 AC output connection specification 106 DC input connection data 107 Auxiliary power connection data 107 Control unit RDCU RMIO connection data 108 Analog inputs
65. e proper connection of the bare shield and the EMI conductive cushions 4 Tighten the EMI conductive cushions around the bare shield Electrical installation 73 p tttm onum ni r x r E d 1 ET _ Side view of the cable lead through Control cable routing Auxiliary a Grommet control cubicle of PVS800 57 b EMI conductive cushion Lead through plate Note If the outer surface of the shield is non conductive e shield at the midpoint of the bare part Be careful not to cut the conductors or the grounding wire if present e Turn the shield inside out to expose its conductive surface e Cover the turned shield and the stripped cable with copper foil to keep the shielding continuous a Cable shield b Grounding wire c Shielded twisted pair d Copper foil 4 Electrical installation Connecting the cables to the terminals Connect the conductors to the appropriate detachable terminals of the RMIO board see pages 0 and 71 At the terminal block use shrink tubing or insulating tape to contain any stray strands The shield especially in case of multiple shields can also be terminated with a lug and fastened with a screw at nearest grounding clamp Leave the other end of the shield unconnected
66. e connections at the junction box option 479 and their tightening torques are OK The EMC filter option E216 is correctly installed if present There are no tools foreign objects or dust from drilling inside the modules or the cabinet All shrouds and covers are in place Start up 77 Start up What this chapter contains This chapter describes the start up procedure of the inverter It also gives some advice for operation Start up procedure The functioning of the inverter is first tested in the local control mode with the control panel CDP312R Thereafter the control program parameters are set The start up procedure is described step by step in the table below SAFETY WARNING Follow the safety instructions during the N iran and start up procedure See chapter Safety instructions Only qualified electricians are allowed to install and start up the inverter PRIMARY CHECKS Check that the mechanical and electrical installation of the inverter is OK See chapter nstallation checklist Check that insulation of the assembly is OK See section Note If the insulation is not OK the Checking the insulation of the assembly page 65 optional insulation resistance monitoring 0954 cannot be tuned properly 8 Start up Check that it is light enough for the inverter to be able to feed Note There must be enough light so power to the AC power system grid once it is operating that the solar
67. e inverter Check that the inverter can be seen from the PLC Test control and actual values SETTING UP THE INSULATION MONITORING DEVICE option Q954 Check that there is only one insulation monitoring device for all inverters in the same galvanically connected IT system Adjust the settings of the insulation monitoring device to suit the More information installation Circuit diagrams delivered with the inverter Insulation monitoring device manufacturer s operating manual In case the insulation monitoring device trips while the inverter is Note Ensure that local regulations running but shows acceptable values before starting disable the and site specific requirements allow measuring during operation the disabling of the monitoring SETTING UP THE CABINET HEATER option G300 m Set the maximum temperature with the T65 thermostat default NENNT 10 Choose the control mode by connecting the heater power supply wire to one of the three terminals listed below 5 3 Heating is switched off by the T65 thermostat and when the inverter is modulating e 5 4 Heating is controlled by the K65 customer control relay 24 V DC control signal and by the T65 thermostat X5 5 Heating is only controlled by the T65 thermostat Start up 81 The optional cabinet heater has three control modes see circuit diagram sheets 64 and 65 delivered with the inverter The control mode can be selected by c
68. e inverter module the rightmost module and disconnect the fiber optic cables Move the cables aside Remove the L shaped DC busbars on top of the module Disconnect the terminal block X50 next to the DC busbars Remove the two module fastening screws 7a at the top At the base of the module loosen the two fastening bolts 7b but leave them in place lift the bracket 7c and fasten it into the up position carefully 96 Maintenance 8 Insert the module pull out ramp under the two bolts at the base of the module and tighten the bolts carefully 9 Pull the module carefully out of the cubicle along the ramp Make sure the wires do not catch While pulling on the handle keep a constant pressure with one foot on the base of the module to prevent the module from tipping over Use safety shoes with metal toe cap to avoid foot injury 10 Extend the support legs of the module Keep the legs extended until the module is about to be inserted back into the cubicle Maintenance 97 inserting the module into the cubicle 1 Move the new inverter module close to the ramp then retract the support legs of the module 2 Push the module up the ramp back into the cubicle Keep your fingers away from the edge of the module front plate to avoid pinching them between the module and the cubicle Also keep a constant pressure with one foot on the base of the module to stabilize
69. ed switch which connects the inverter to the solar generator The switch is interlocked with the DC contactor so that it will not open unless the DC contactor is open If there is no auxiliary power in the inverter the switch cannot be operated at all It will remain in the position where it already is K2 DC contactor The inverter controls the DC contactor according to the operational state The solar generator is disconnected from the inverter when needed Inverter DC fuses Protect the inverter module Z1 1 3 Common mode filter Reduces common mode voltages and currents in the solar generator and inverter main circuit and AC output Overvoltage Devices for overvoltage protection against for example climatic F51 protection devices overvoltages caused by lightning strikes F52 F50 is optional F263 Inverter module Converts the DC voltage to AC voltage The operation is controlled by switching the IGBTs LCL filter Smooths the current and voltage waveform AC contactor The inverter controls the AC contactor according to the operational state 28 Operation principle and hardware description Symbol Terminal Description Operation Component Charging circuit The inverter controls the charging contactor after receiving a start command Grounding contactor The inverter software controls the disconnection of the positive with options F282 negative pole grounding and F283 Grounding board Provides fuse protectio
70. eed 450 mm The cabinet weight lies on the 100 mm wide section in front and 50 mm wide section on the back which the floor must carry Prevent the cooling air flow from the cable duct to the cabinet by bottom plates To ensure the degree of protection for the cabinet use the original bottom plates delivered with the unit With user defined cable entries take care of the degree of protection fire protection and EMC compliance 50 mm 100 mm Allowed area for cable duct view from Minimum widths for the floor support side above a Cabinet front The shaded view a Cabinet front area can be used for a cable duct CO 7 7777727747 OO a Preventing cooling air flow 1 Cables 2 Bottom plates 52 Mechanical installation Planning the electrical installation 53 Planning the electrical installation What this chapter contains This chapter contains the instructions that you must follow when selecting the cables transformer protections cable routing and way of operation for the inverter system Note The installation must always be designed and made according to applicable local laws and regulations ABB does not assume any liability whatsoever for any installation which breaches the local laws and or other regulations Furthermore if the recommendations given by ABB are not fol
71. f not press the control panel key 1 L gt 654 0 V STATE STAND BY AC POWER 0 0 kW AC CURR1 Start the inverter by pressing the control panel key lt Description the events a normal starting procedure After reveiving the start command the inverter goes to the SLEEP mode 1 L gt 598 0 V I STATE SLEEP AC POWER 0 0 kW AC 1 If there is enough DC voltage available the inverter starts with the START ISU mode after a delay defined by parameter group 31 1 L gt 617 0 V I STATE START ISU AC POWER 0 0 kW AC CURR1 In this mode the inverter charges the DC capacitors from the AC output synchronises to the grid The DC contactor closes The inverter goes to the MPPT mode and starts to produce power to the AC output 1L 570 0 V STATE MPPT AC POWER 20 0 kW AC 1 39 When there is not enough DC voltage and or power available the inverter goes back to the SLEEP mode after a delay defined by parameter group 31 It may be useful to shorten the delays during the start up temporarily Wake up and sleep levels should match the available DC voltage Check that the inverter operates properly from the following Example display actual value parameters 01 34 PV MODULE DC MEAS 01 11 Iu ES TENET POWER 96 and 01 07 AC CURRENT L1 The DC voltage FM M STATE MPPT should have dropped from the earlier measured open circuit AC POWER 102 0 kW voltage and the power should match the current AC CURR1 197 A
72. for the DC input cabling but a shielded cable can also be used Shield ere 56 Planning the electrical installation oymmetrical shielded cable is recommended for the AC output cabling see section Recommended AC output power cable types below Compared to a four conductor system the use of symmetrical shielded cable reduces electromagnetic emission of the whole inverter system Note When continuous metal conduit is employed shielded cable is not required The conduit must have bonding at both ends as with cable shield To operate as a protective conductor the shield conductivity requirements according to IEC 61439 1 are shown below when the protective conductor is made of the same metal as the phase conductors Cross sectional area of Minimum cross sectional the phase conductors area of the corresponding protective conductor S mm S mm 16 lt 8 535 s To effectively suppress radiated and conducted radio frequency emissions the cable shield conductivity must be at least 1 10 of the phase conductor conductivity The requirements are easily met with a copper or aluminum shield The minimum requirement of the cable shield is shown below It consists of a concentric layer of copper wires with an open helix of copper tape or copper wire The better and tighter the shield the lower the emission level and bearing currents Insulation jacket Planning the electrical installation 57 m Recommended AC outpu
73. ge 103 Note The ventilation system must keep the static pressure in the air outlet duct sufficiently below the pressure of the room where the inverter is located in order that the cabinet fans can produce the required air flow through the cabinet Ensure that no dirty or moist air is able to flow backward to the inverter in any case even during off time or while servicing the inverter or the ventilation system 50 Mechanical installation Calculating the required static pressure difference The required static pressure difference between the exit air duct and the inverter installation room can be calculated as follows pg 1 5 2 pg where 0 5 P Vm q dynamic pressure p air density kg m Vm average air velocity in the exit duct s m s 2 rated air flow of the inverter m s cross sectional area of the exit duct s m Example The cabinet has 3 exit openings of 315 mm diameter The rated air flow of the cabinet is 3760 m h 1 0 m s 3 0 3152 1 4 0 234 m Vm q A 1 0 0 234 4 3 mis 0 5 p Vm 0 5 1 1 4 32 10 Pa The required pressure in the exit air duct is then 1 5 2 10 Pa 15 20 Pa below the pressure in the room More information Contact ABB Mechanical installation 51 Cable duct in the floor below the cabinet A cable duct can be constructed below the middle part of the cabinet The duct width may not exc
74. gnation key The type designation contains information on the specifications and configuration of the inverter The first digits from left express the basic configuration eg PV8800 57 250kW A The optional selections are given thereafter separated by plus signs eg Q951 The main selections are described below Not all selections are available for all types For more information refer to PVS800 5 ordering information 8AXD 10000021367 available on request Selection Altematves PVS800 product series ABB central inverters Type 57 Cabinet built central inverter When no options are selected IP42 UL Type 2 AC contactor aR fuses fuse switch 100 kW 250 kW and 315 kW AC side switch disconnector 500 kW and 630 kW terminals for 230 V AC external control voltage CDP312 Control Panel RDIO for internal control RDCO 03 module for optical communication EMC filtering common mode filter PVS800 solar inverter control programs bottom entry and exit of cables coated boards maximum DC voltage 1000 V DC ungrounded DC input IT ungrounded AC output DC input overvoltage and surge protection AC output overvoltage protection with varistors AC grounding terminals on output busbars DC input busbars 1 x DC input connections for 100 kW units 2 x DC input connections for 250 kW and 315 kW units 4 x DC input connections for 500 kW and 630 kW units DC contactor and main switch DC grounding terminals on input busbars electrical power
75. h inverter is approximately 6 1 withstands low voltage side current DC components of at least 0 5 of the nominal rated current preferably without using an air gap withstands the 3 total harmonic distortion generated by the inverter However we recommend dimensioning the transformer for at least 5 total harmonic distortion to withstand possible outside interference from the network ABB recommends that the transformer is equipped with an off load tap changer for voltage regulation on the high voltage side of the winding with two 2 5 step points to the plus and minus directions The inverter does not require any specific transformer notation ABB recommends using traditional notations such as Dy11d0 Dy11y11 etc Do not ground the neutral star point of the transformer or connect it to the neutral points of other windings Planning the electrical installation 55 Selecting the grid disconnecting device The inverter is equipped with a hand operated disconnecting device which isolates the inverter and the solar generator from the electrical power system The disconnecting device does not however isolate the inverter AC output busbars from the power system Therefore during installation and maintenance work on the inverter the AC output cables and busbars must be isolated from the electrical power system with a disconnector at the transformer Selecting the DC input disconnecting device As standard the inverter is equipped
76. hanging the heater power supply wire in the auxiliary control cabinet More information Circuit diagrams delivered with the Connecting DriveWindow inverter If the DriveWindow PC tool is used in the start up procedure proceed as follows Start the DriveWindow program and connect to the inverter by choosing ABB SMP OPC server Connect the PC to the inverter in a ring as shown below RDCU A43 0 12 Note If all connected control units are not seen through the optical ring check that the node address of each RMIO board is set properly Connect optical fibers to channel CH3 in each RMIO board and change parameter 70 15 CH3 NODE ADDR accordingly Note The new node address becomes valid only after the next power up of the RMIO board Open the parameter window from the DriveWindow program 82 Start up Configuring the NETA 01 Ethernet Adapter Module See the NETA 01 Ethernet Adapter Module User s Manual 3AFE64605062 English Fault tracing 83 Fault tracing What this chapter contains This chapter describes the fault tracing possibilities of the inverter LEDs This table describes LEDs of the inverter ____ OSS Mounting piaiarm Green The main 24 V power supply for the control panel and the RMIO board is OK AINT board V204 green 5 V
77. if optional equipment is included with the solar generator and other technical data Select the cables Unpack and check the units Moving the unit page 45 Check that all necessary optional modules and If the converter has been non operational for more equipment are present and correct than one year the converter DC link capacitors Only intact units may be started up need to be reformed See Capacitor reforming instructions 3BFE64059629 English Check the installation site Checking the installation site page 43 Technical data Route the cables Routing the cables page 58 Introduction to the manual 21 Task See Install the inverter Connect the power cables Connect Mechanical installation page 43 Electrical the control and the auxiliary control cables installation page 65 Check the installation Installation checklist page 75 Commission the inverter Start up page 77 PVS800 central inverters firmware manual 3AUA0000058422 English Terms and abbreviations Term Explanation Abbreviation APBU Optical branching unit for fiber links that use the PPCS protocol The unit is used for connecting parallel connected inverter modules to the RDCU DDCS Distributed drives communication system a protocol used in optical fiber communication inside and between ABB drives and inverters Electromagnetic compatibility Frame size Relates to the construction type of the component in question The term is
78. imeter impedance at least 1 that there is no voltage present 2 Open the inverter cubicle door 3 Extract one inverter module from the cabinet as described in section Replacing the inverter module frames 2 4 Check the tightness of the cable connections at the quick connector Use the tightening torque tables in chapter Technical data 5 Clean all contact surfaces of the quick connector and apply a layer of suitable joint compound eg lsoflex Topas NB 52 from Kluber Lubrication onto them 6 Re insert the inverter module 7 Repeat steps 4 to 7 for all remaining R8i inverter modules 88 Maintenance Fans The cooling fan lifespan depends on the inverter usage and ambient temperature See the firmware manual for an actual signal which indicates the hours of usage of the fan Fan failure can be predicted by the increasing noise from fan bearings and the gradual rise in the heatsink temperature in spite of heatsink cleaning If the inverter is operated in a critical part of a process fan replacement is recommended once these symptoms start appearing Replacement fans are available from ABB Do not use other than ABB specified spare parts Replacing the LCL filter cooling fan 71 WARNING Follow the safety instructions page 77 Ignoring the instructions can AN cause physical injury or death or damage to the equipment 1 Repeat the seven steps safety precautions page 12 Stop the inverter
79. l who are responsible for the grounding of the inverter WARNING Ignoring the following instructions can cause physical injury or death increased electromagnetic interference and equipment malfunction e Ground the inverter and adjoining equipment to ensure personnel safety in all circumstances and to reduce electromagnetic emission and interference e sure that grounding conductors are adequately sized as required by safety regulations e namultiple inverter installation connect each inverter separately to protective earth PE e When shielded AC power cables are used make a 360 high frequency grounding of cable entries at the cabinet lead through in order to suppress electromagnetic disturbances In addition connect the cable shields to protective earth PE in order to meet safety regulations EMC filters are not allowed at the AC output of the inverter Donotinstall the inverter on a TN grounded system Do not install the EMC filter option E216 for the network side of the low voltage transformer on an ungrounded system Note Power cable shields are suitable for equipment grounding conductors only when adequately sized to meet safety regulations Asthe touch current of the inverter is higher than 3 5 mA AC or 10 mA DC a fixed protective earth connection is required by IEC EN 621089 5 2 5 Safety instructions 15 General safety These instructions are intended for all who in
80. lication the inverter can be delivered without input DC fuses option 02 291 In this case install appropriate DC fuses to protect the inverter DC circuit and the DC input cables in a short circuit situation Protect the positive and negative poles of an input with separate fuses The power loss of a fuse may never exceed 25 W The table below shows the rated DC current for selecting the input DC fuses see the next table as per the number of the DC input connections to the solar generator 49A 8 CdS 8 9A 5A S5A _ 8 A 29A 3 294 000 880 Planning the electrical installation 63 The table below shows the recommended input DC fuse types Smaller fuses can also be used Rated DC fuse Recommended input DC fuses current of the inverter Dimensions of the recommended fuses mm 1 mm 0 0394 in we Wem OTe TF 6 wm mw mW _ m Mechanical installation of the input DC fuses Use 8 bolts and nuts to connect the fuses to the busbars 64 Planning the electrical installation Electrical installation 65 Electrical installation What this chapter contains This chapter describes the electrical installation process of the inverter Warnings in this chapter Follow the Safety instructions on the first pages of this manual WARNING
81. lid particles Class Solid particles Class Solid particles Class 392 153 252 Atmospheric pressure 70 to 106 kPa 70 to 106 kPa 60 to 106 kPa 0 7 to 1 05 atmospheres 0 7 to 1 05 atmospheres 0 6 to 1 05 atmospheres Vibration IEC 60068 2 Max 1 mm 0 04 in Max 1 mm 0 04 in Max 3 5 mm 0 14 in 5 to 13 2 Hz 5 to 13 2 Hz 2 to 9 Hz max 7 m s 23 ft s max 7 m s 23 52 max 15 m s 49 ft s 13 2 to 100 Hz 13 2 to 100 Hz 9 to 200 Hz sinusoidal sinusoidal sinusoidal Shock IEC 60068 2 27 Not allowed Max 100 m s 330 ft 100 m s 330 ft s 11 ms 52 11 ms Not allowed 100 mm 4 in for weight 100 mm 4 in for weight over 100 kg 220 Ib over 100 kg 220 Ib 114 Technical data Materials Cabinet Busbars Fire safety of materials IEC 60332 1 Package Disposal Hot dip zinc coated thickness approximately 20 micrometers steel sheet thickness 1 5 mm with polyester thermosetting powder coating thickness approximately 80 micrometers on visible surfaces except back panel Color RAL 7035 light beige semigloss Tin or silver plated copper Insulating materials and non metallic items mostly self extinctive Frame Wood or plywood Plastic wrapping PE LD Bands PP or steel The inverter contains raw materials that should be recycled to preserve energy and natural resources The package materials are environmentally compatible and recyclable All metal parts can be rec
82. lowed the inverter may experience problems that the warranty does not cover Selecting the transformer Transformers designed for photovoltaic applications are available from ABB Each inverter must be galvanically isolated from other inverters by a dedicated transformer or winding If you intend to connect inverters in parallel please contact ABB for more information ABB recommends a transformer designed for the environment where it will be installed compliance with power transformer standard IEC 60076 and testing according to converter transformer standard for industrial applications IEC 61378 1 Country specific requirements must always be fulfilled 54 Planning the electrical installation Requirements for the transformer suitable for the network and inverter AC voltage current and power suitable for use with IGBT inverters degree of protection temperature limits and lifetime are appropriate for the environment equipped with a static grounded screen between the high and low voltage windings voltage withstand level of the low voltage winding is at least 1 6 kV against ground A typical voltage waveform against ground is shown below Uac grid V SD A p A CTI BLU ALI BRI EM G00 800 t ms voltage rise time withstand level du dt of the low voltage winding is at least 1000 V per microsecond against ground rated short circuit impedance for eac
83. ls on selecting the transformer see Selecting the transformer on page 53 Type 0100kW A Maximum allowable prospective short circuit current is 10 when protected by fuses given in fuse tables Types 0250kW A 0500kW A 0315kW B and 0630kW B Maximum allowable prospective short circuit current is 50 when protected by fuses given in fuse tables When temporary grounding for work is applied the grounding cables are connected to the connecting knobs of the AC and DC busbars and PE of the inverter the maximum allowable prospective short circuit current is decreased to 25 kA 1 s If the connected grounding cables and clamps are not equivalent to the prospective short circuit rating of the inverter the total rating will be lower 48 to 63 Hz withstand with normal dimensioning grid compliance may require disconnection at smaller values Maximum rate of change 17 5 Max 3 of nominal phase to phase AC line voltage Max 2596 Note If the inverter is expected to survive voltage dips low voltage ride through auxiliary power supply must be ensured for example by an uninterruptible power supply 1 Power factor cos phi4 adjustment range Technical data 107 0 1 capacitive or inductive depending on the dimensioning Types 0250kW A and 0500kW A Types 0315kW B and 0630kW B Qmax V 10 000 Pag Qmax 0 9 10 000 Pag
84. lt size M16 42 Mu 250 mm 9 85 0 5 600 450 mm 17 7 ad 650 mm 25 6 Mechanical installation 49 Miscellaneous Preventing the recirculation of hot air Prevent hot air circulation outside the inverter by leading the outcoming hot air away from the area where the inlet air to the inverter is taken Also ensure that the hot air from the inverter module cubicle cannot enter the adjacent cubicles KIN ON 6900000000000006000060066 00525 poononoonoooooorononoooaa 1 4 y Fo X E e o o e o o o o o Ventilation duct at the air outlet of the cabinet A ventilation duct can be constructed at the air outlet of the inverter cabinet If an exhaust fan is used ensure that the capacity is sufficient See Losses cooling data and noise on pa
85. m fault situations The disconnecting times and frequency limits depend on the owner of the power system and local legislation The inverter also provides the electrical power network supervision function with certified monitoring relays options 0969 and Q974 Positive or negative pole grounding options F282 and F283 The positive and negative pole grounding options can be used when solar modules require grounding of inverter DC poles The grounding of the poles complies with standard IEC 62109 2 The grounding is always connected when auxiliary power is connected except when the automatic photovoltaic generator insulation check is done before the inverter starts The grounding wire is protected by a fuse on the PGND 02 board Due to personnel protection reasons the grounding is disconnected when sudden level changes are monitored from the grounding wire current The grounding resistance can be adjusted by the user during the start up 32 Operation principle and hardware description Cabinet layout of frame R7i A cabinet of frame R7i is shown below with doors open and shrouds removed PEPPER EERE JBesWpion E A cubicle Inverter module cubicle DC cable lead throughs Photovoltaic generator connection terminals 3 Auxiliary control voltage connection terminals and switch Ground fault monitoring device option 0954 5 Grid monitoring relay options 0969 and 0974 6 DC contact
86. manual What this chapter contains This chapter describes the intended audience and contents of the manual It contains a flowchart of steps in checking the delivery installing and commissioning the inverter The flowchart refers to chapters sections in this manual and other manuals Target audience This manual is intended for people who plan the installation install commission use and service the inverter Read the manual before working on the inverter You are expected to know the fundamentals of electricity wiring electrical components and electrical schematic symbols The manual is written for readers worldwide Both SI and imperial units are shown Contents of the manual The chapters of the manual are briefly described below Safety instructions give safety instructions for the installation commissioning operation and maintenance of the inverter Introduction to the manual introduces the manual Operation principle and hardware description describes the operation principle and construction of the inverter in short Mechanical installation describes the mechanical installation procedure of the inverter Planning the electrical installation contains the instructions that you must follow when selecting the cables protections cable routing and way of operation for the inverter system 20 Introduction to the manual Electrical installation describes the electrical installation process of the inverter Installation
87. n and current monitoring with options F282 and F283 AC main switch Hand operated switch which connects the inverter to the electrical power system The switch includes AC main fuses The AC main switch can be operated at all times If it is operated during operation the inverter will trip as the grid disappears Auxiliary control Hand operated switch which connects the auxiliary control voltage to voltage switch the inverter filter Optional filter 2216 for low voltage distribution networks Operation principle and hardware description 29 An example main circuit diagram of the 500 kW and 630 kW inverter systems is shown below 1 A M EE PERS ER U 5 4 2 1 41 20 F51 20 2 2 F2 3 PE Auxiliary power supply F11 F52 7 Grid 30 Operation principle and hardware description Symbol Terminal Description Operation Component DC input terminals The solar generator is connected to the inverter DC input terminals with busbars and fuse links or through miniature circuit breakers option H377 AC output The AC output terminals connect the inverter to the low voltage AC power system Auxiliary control The customer supplies 230 V AC 1 phase auxiliary control voltage to voltage input the inverter circuit boards
88. network supervision function electrical power network support functions a set of manuals warranty 12 24 months Nominal AC power Refer to the rating tables page 99 Voltage 300 V AC operational MPPT DC voltage range 450 825 V DC B 350VAC operational MPPT DC voltage range 525 825 V DC Filters E216 EMC RFI filter for the network side of the transformer TN grounded low voltage networks options Operation principle and hardware description 41 Selection Cabinet and construction options Line options Cabling MCB protected DC input connections 4 miniature circuit breakers for 100 kW units 8 miniature circuit breakers for 250 kW units 16 x miniature circuit breakers for 500 kW units 8H382 8 x fuse protected DC input connections for 250 kW 315 kW 500 kW ul MM Fieldbus K467 02 Ethernet PROFINET IO and Modbus TCP IP adapter module K479 01 Modbus adapter module for PVS JB 8 M Junction box interface Slot 2 Specialis Safely Ground fault monitoring in IT ungrounded systems Documentation anguage 42 Operation principle and hardware description Mechanical installation 43 Mechanical installation What this chapter contains This chapter describes the mechanical installation procedure of the inverter Checking the installation site oee section Ambient conditions on page 113 for allowable operating conditions and section Dimensions
89. ng the LCL filter cooling fan 88 Replacing the LCL filter cooling fan 2 x Rai 89 Replacing the incoming cubicle door fans frames R8i and 2 x R8i and the output cubicle door fan frame R8i 90 Replacing the output cubicle swing out frame fans frame 2 x 91 Replacing the cabinet roof fans frames R8i and 2 x R8i with option H377 92 Replacing the cooling fan of the inverter module R7i 93 Replacing the cooling fan of the inverter module 2 R8i 94 Replacing the inverter module frames 2 95 Extracting the module from the cubicle 95 Inserting the module into the 97 Replacing the LCL filter 97 Capacitors 97 Reforming the capacitors 98 11 Technical data What this chapter contains 99 RatingS wad beet 99 eee ea eed eee ee ene 100 Temperature derating of types 0100kW A 0250kW A and 0500kW A 100 Temperature derating of types 0315kW B and 0630kW B 100 Altitu
90. ntrol boards should wake up The inverter is in the stand by mode if no faults are active Then the control panel shows STAND BY For descriptions of the inverter modes refer to the firmware manual 1 gt 654 0 V STATE STAND BY AC POWER 0 0 kW AC 1 Note There may be fault and warning indications flashing on the display They will be reset during the next steps Ensure that the control panel is controlling the master control unit See the firmware manual A43 by checking the node number from the display Units with optional emergency stop function 0951 Release the emergency stop button and reset the emergency stop Units with optional positive negative grounding 282 283 the firmware manual Configure the grounding option Reset all faults on both control boards If there are no faults or only the grid monitoring fault close the AC main switch Note The grid monitoring fault cannot be reset before the AC voltage is connected Wait for the grid monitoring relay to reset before resetting the fault from the control panel Start up 79 The DC voltage should match the value of 01 34 PV MODULE Note If the DC voltage differs from DC MEAS in the Master control program the parameter value do not try to start the inverter Contact ABB Check that the inverter is in local control mode ie letter L is at the top row of the control panel display I
91. o X27 Relay outputs 3 pcs 24 V DC External power input ExtPower SLOT 1 This slot is reserved in 2xR8i units SLOT 2 RDIO 01 Reserved for inverter control and grid monitoring relay signals DDCS RDCO 01 DDCS communication adapter module CDP 312R Control Panel The CDP 312R is the user interface of the inverter unit providing the essential controls such as Start Stop Reset Reference and the parameter settings for the inverter control programs The control panel is connected to the RDCU units For how to use the control panel refer to the firmware manual Operation principle and hardware description 39 Circuit boards The inverter contains the following printed circuit boards as standard e main circuit board AINT e control and I O board RMIO inside the RDCU Control Unit power supply board APOW gate driver control board AGDR diagnostics and panel interface board ADPI e measuring board Type designation labels Inverter label The type designation label of the inverter includes an IEC rating CE and other markings a type designation and a serial number which allow individual recognition of each unit The type designation label is located on the front cover of the inverter cabinet An example label is shown below pz EN 77 input 525 825 V IP42 Dnm h 4 Umax pc 1000 V y ABE Oy ImazxDC 1200 C Output 530 kW HFJ
92. o y vb 4 gp E La m o Og va Esp cg tj CY ts Cx p LC Oo S LOY CX LED o o o C OT ELM aes ONDE iB CEELEN EE ELLEELLE ELELEE LELLE LEELLE LELEL LLELLE EELEE LELEL LLELLE nmn AL G cS e e 227 ELI LET e Ee 0000090163 1 Two DC inputs standard four DC inputs option 4H382 eight DC inputs with miniature circuit breakers option H377 2 Eight DC inputs option 8H382 Lo 130 Dimension drawings Frame 2 x R8I 2 x Four DC inputs standard 0 Door open max Co mI TE sme co LL co f sie gt NI lt r a CO ei pd NI Fees lt gt OES ules Ce x ce p ai 4 S ME Control panel NOV lt gt 2 gt c gt ra i a 13 Ha 9 PR C cum 3 en c ex co eo CO Ge pel SESS S 59 3AUA0000090765 Dimension drawings 131 2 x Eight DC inputs option 8H382 0000090765 E gt lt
93. ollow the Safety instructions given on the first pages of this manual Check that MECHANICAL INSTALLATION O There is sufficient free space around the unit See page 703 Ol The ambient operating conditions are allowed See page 113 O unit is properly fastened to the floor and wall See Mechanical installation O cooling air is able to flow freely ELECTRICAL INSTALLATION See Electrical installation O capacitors are reformed if stored over one year refer to Capacitor reforming instructions 3BFE64059629 English O Theinverter is grounded properly TheAC line voltage matches the nominal output voltage of the inverter O Ihe AC transformer is suitable for use with the inverter See section Selecting the transformer page 53 76 Installation checklist Check that The insulation of the assembly is sufficient See Checking the insulation of the assembly page 65 That the AC power system is an IT ungrounded system The AC power cable connections at L1 L2 and L3 and their tightening torques are OK The DC power cable connections at UDC and UDC and their tightening torques are OK The power cables are routed away from other cables See section Routing the cables page 58 The auxiliary power supply cable connections at Q10 and their tightening torques are OK The external control connections to the inverter are OK including emergency stop fieldbus etc The cabl
94. on 23 Operation principle and hardware description What this chapter contains This chapter describes the operation principle and construction of the inverter in short 24 Operation principle and hardware description Product overview The PVS800 5 is a central inverter for converting adjusting and conveying power generated by a solar generator to the electrical power system The inverter is built in an air cooled cabinet for indoor use Cooling air is let in through the gratings at the lower part of the cabinet door The air outlet is at the cabinet roof PVS800 57 0100kW PVS800 57 0250kW and PVS800 57 0315kW m M MITTIT PVS800 57 0500kW and PVS800 57 0630kW As standard the solar generator is connected to the DC input terminals of the inverter with busbars and fuse links Option H377 provides miniature circuit breakers for connecting solar array junction boxes Operation principle and hardware description 25 Block diagram of solar generator system A block diagram of a solar generator system where the solar module string arrays are connected to the electrical power system through an inverter is shown below Solar module photovoltaic module Solar string Solar array Solar generator Solar array junction box N gt Inverter 26 Operation principle and hardware description Main circuit diagram
95. on procedure 68 Connecting the external power supply cable for the auxiliary circuit 69 Connecting the junction box power supply option 6410 69 Connecting the EMC filter option 2216 69 Connecting the control 69 Default I O connection diagram A43 70 Default I O connection diagram A41 71 Default I O connections RDIO on RDCU 41 72 Connection procedure 72 Making 360 degrees grounding at the cabinet lead through for the control cables 72 Connecting the cables to the I O terminals 74 Conhecida PO 74 Installing optional modules 74 Mechanical installation 74 Wiring the modules 74 7 Installation checklist What this chapter contains 75 iced 75 8 Start up What this chapter contains 77 Start up procedure 77 BARELY fas gue as 229
96. onnected solar stings 00 Group of parallel connected solar stings 00 parallel connected solar strings Solar array junction Device that connects outputs of multiple solar source circuits strings into a box combined output circuit or circuits 22 Introduction to the manual Term Explanation Abbreviation Solarcel cell Device that converts Device that converts light directly into electricity by the photovoltaic effect directly into electricity by the photovoltaic Device that converts light directly into electricity by the photovoltaic effect EN generator The total of all solar strings of a solar power supply system which are electrically interconnected solar module Packaged interconnected assembly of solar cells Solrsting Solrsting Circuitofseries connectedsolarmodues of Circuitofseries connectedsolarmodues connected solar modules RDCO DDCS communication module that can be snapped on the RMIO board to add the available fibre optic channels RDCU Control unit The is a separate unit consisting of an RMIO board in a plastic housing Radio frequency interference RMIO Control and I O board Contains the principal inputs and outputs of the inverter USB DDCS adapter for connecting the DriveWindow PC tool to the inverter The adapter is connected to the USB port of the PC and to the fiber optic channel of the RDCO Total harmonic distortion Operation principle and hardware descripti
97. or Inverter DC fuses Inverter module 3 inverter module cooing External control interfaces behind the swing out frame RDCU Control Unit A41 inverter control unit RDCU Control Unit A43 master control unit Operation principle and hardware description 33 Cabinet layout of frame R8I A cabinet of frame R8i is shown below with doors open and shrouds removed Cubicles Auxiliary control cubicle B Output cubicle Inverter module cubicle D Incoming cubicle External control interfaces 22 Control Unit A41 inverter control unit 23 Control Unit A43 master control unit Description 5 6 Ground fault monitoring device option 095 S 7 Inverter DC fuses InverterDC fuses 9 Inverter module S AC output cable lead throughs 34 Operation principle and hardware description Cabinet layout of frame 2 x R8I A cabinet of frame 2 x R8i is shown below with doors open shrouds removed and cabinet fan swing out frame opened A Auxiliary control cubicle Output cubicle C Inverter module cubicle D Incoming cubicle External control interfaces 23 RDCU Control Unit A41 inverter control unit RDCU Control Unit A43 master control unit 25 APBU Branching Unit 8 Ground faut monitoring device SSS 3 aches fuses AC main switch
98. r and inverter 55 Selecting the power cables 55 General TUES 04604 recreare Soo X CREE a OR a do ER ae e eden 55 Recommended AC output power cable 57 Not allowed power cabletypes 57 Selecting the control cables 57 General icd 57 Signals separate cables 57 Signals allowed to be run the same cable 58 Relay cable type 58 Routing the cables 58 Separate control cable 59 Implementing short circuit and thermal overload protection 59 Protecting the inverter and AC output cable in short circuit situations o9 Protecting the photovoltaic generator and DC input cable in short circuit situations 59 Protecting the inverter and the AC output cable against thermal overload 59 Supplying power for the auxiliary 60 Supplying circuits from the AC output of the inverter 60 Implementing ground fault monitoring in IT ungrounded systems 60 Insulation monitoring device option 0954 60
99. resistance of the solar generator correctly according to the settings when the inverter is not operating During operation the inverter may disturb the measuring For disabling the monitoring device during the inverter operation contact ABB Operation principle of the measuring circuit The insulation monitoring device superimposes a pulsating measuring voltage on the system The measuring pulse consists of positive and negative pulses of the same amplitude The period depends on the respective leakage capacitances and the insulation resistance of the system to be monitored The monitoring device can be adapted to different photovoltaic module types with parameter settings See the user s manual of the device Safety information The insulation monitoring device is constructed according to state of the art and recognized technical safety rules Nevertheless when the device is used hazards may occur to the life and limb of the user or of third parties or there may be adverse effects on the monitoring device or on other valuable property The monitoring device must only be used for the purpose for which it is intended e when it is in perfect technical condition as far as safety is concerned Only one insulation monitoring device may be used in each interconnected IT system When insulation or voltage test is to be carried out the device is to be isolated from the system for the test period The ground fault monitoring function 0954
100. ring the instructions can AN cause physical injury or death or damage to the equipment 1 Repeat the seven steps safety precautions page 12 Stop the inverter and disconnect it from the AC and DC power lines Wait for five minutes to let the inverter DC capacitors discharge before opening the cabinet door Ensure by measuring with a multimeter impedance at least 1 Mohm that there is no voltage present 2 Undo the four fastening screws of the fan assembly plate 3 Disconnect the fan wiring plug 4 Undo the fan fastening screws 5 Disconnect power supply and PE wires 6 Install a new fan in reverse order Maintenance 93 Replacing the cooling fan of the inverter module 71 f WARNING Follow the safety instructions page 77 Ignoring the instructions can POT a cause physical injury or death or damage to the equipment Repeat the seven steps safety precautions page 12 Stop the inverter and disconnect it from the AC and DC power lines Wait for five minutes to let the inverter DC capacitors discharge before opening the cabinet door Ensure by measuring with a multimeter impedance at least 1 that there is no voltage present Open the inverter cubicle door Disconnect the wire plug a Remove the two screws holding the fan unit b To free the fan pull it slightly outwards then downwards c Install new fan in reverse order
101. rotection IP 42 UL type 2 Technical 113 Ambient conditions Environmental limits for the inverter are given below The inverter is to be used in a heated indoor controlled environment Note If the installation has ventilation ducts directly to outdoors eg a container installation back flow of moist and dusty air must be prevented See section Ventilation duct at the air outlet of the cabinet on page 49 Operation Storage Transportation installed for stationary in the protective in the protective use package package Installation site altitude to 2000 m 6562 ft above sea level above 1000 m 281 ft see section Derating Air temperature Types 0100kW A 40 to 70 C 40 to 40 to 70 C 40 to 0250kW A 0500kW A 158 F 158 F 15 to 50 C 5 to 122 F Types 0315kW B and O630kW B 15 to 55 C 5 to 131 F No frost allowed See section Derating Relative humidity 5 to 95 Max 95 Max 95 No condensation allowed Maximum allowed relative humidity is 60 in the presence of corrosive gases Environmental category Indoor conditioned N NN Wet conditions Not to be used in wet location The installation location must be dry tee Pollution degree 2 Normally only non conductive pollution is allowed Contamination levels No conductive dust allowed IEC 60721 3 3 IEC 60721 3 Chemical gases Class Chemical gases Class Chemical gases Class 2 IEC 60721 3 1 3C1 1C2 2C2 So
102. solation and grounding diagram below Internal supply for digital inputs 24 V DC short circuit proof An external 24 V DC supply can be used instead of the internal supply Insulation test voltage 500 V AC 1 min Logical thresholds 8VDC 0 gt 12 1 Input current to DI 5 10 mA 016 5 mA Filtering time constant 1 ms Relay outputs Switching capacity Minimum continuous current Maximum continuous current Insulation test voltage DDCS fiber optic link 24 V DC power input Voltage Typical current consumption without optional modules Maximum current consumption Technical data 109 RDCU A43 PVS800 master control program two programmable relay outputs or with option 0951 one programmable relay output RDCU A41 PVS800 inverter control program without option Q954 one programmable relay output 8 A at 24 V DC or 250 V AC 0 4 A at 120 V DC 5 mA rms at 24 V DC 2 Arms 4 kV AC 1 minute With optional communication adapter module RDCO Protocol DDCS ABB Distributed Drives Communication System 24 V DC 10 250 mA 1200 mA with optional modules inserted The terminals on the RMIO board as well as on the optional modules attachable to the board fulfil the Protective Extra Low Voltage PELV requirements stated in EN 50178 provided that the external circuits connected to the terminals also fulfil the requirements and the installation site is below 2000 m 6562 ft Above 2000 m 6562
103. stall and service the inverter WARNING Ignoring the following instructions can cause physical injury or death N or damage to the equipment Use extreme caution when manoeuvering an inverter or LCL filter module that runs on wheels Extend the support legs of the module when it is removed from the cabinet Do not tilt the module The modules are heavy and have a high center of gravity They topple over easily if handled carelessly Lift the module by the upper part only using the lifting hole s at the top 16 Safety instructions When removing a module which is equipped with wheels pull the module carefully out of the cubicle along the ramp Make sure the wires do not catch While pulling on the handle keep a constant pressure with one foot on the base of the module to prevent the module from tipping over Use safety shoes with metal toe cap to avoid foot injury When replacing a module which is equipped with wheels push the module up the ramp into the cubicle Keep your fingers away from the edge of the module front plate to avoid pinching them between the module and the cubicle Also keep a constant pressure with one foot on the base of the module to stabilize the movement Do not use the ramp with plinth heights over 50 mm The ramp supplied with the inverter is designed for a plinth height of 50 mm the standard plinth height of
104. t power cable types The power cable types that can be used for the inverter AC output are represented below Symmetrical shielded cable with three phase conductors and a concentric PE conductor as shield The shield must meet the requirements of IEC 61439 1 see above Check with local state country electrical codes for allowance Symmetrical shielded cable with three phase conductors and a concentric PE conductor as shield A separate PE conductor is required if the shield does not meet the requirements of IEC 61439 1 see above Symmetrical shielded cable with three phase conductors and symmetrically constructed PE conductor and a shield The PE conductor must meet the requirements of IEC 61439 1 Symmetrical shielded cable with individual shields for each phase conductor is not allowed on any cable size for input and motor cabling Selecting the control cables General rules All control cables must be shielded Use a double shielded twisted pair cable for analog signals Employ one individually shielded pair for each signal Do not use common return for different analog signals A double shielded cable is the best alternative for low voltage digital signals but single shielded twisted pair cable Figure b is also usable A double shielded twisted pair cable A single shielded twisted pair cable Signals in separate cables Run analog and digital signals in separate shielded cables Never mix 24 V DC and 115
105. ter protects itself and the AC output cable against thermal overload when the cable is dimensioned according to the nominal current of the inverter No additional thermal protection devices are needed 60 Planning the electrical installation Supplying power for the auxiliary circuits the inverter with rated auxiliary voltage Protect the supply according to local regulations with eg fuses and or fault current breakers Do not connect any additional appliances to the inverter without consulting with ABB Supplying circuits from the AC output of the inverter If the AC output of the inverter is used for supplying any circuits provide galvanic isolation as shown in the diagram below A denotes other equipment and B supplying auxiliary circuit of the inverter See also Connecting the external power supply cable for the auxiliary circuit on page 69 For instructions on selecting the transformer see section Selecting the transformer on page 53 High voltage Low voltage Implementing ground fault monitoring in IT ungrounded systems The internal current sum measurement based ground fault monitoring of the inverter detects ground faults in some cases in IT ungrounded systems However often the ground fault leakage current does not exceed the trip level and the inverter remains is operation The inverter can be equipped with insulation monitoring device option Q954 or the IT system must be monitored otherwise wi
106. th a monitoring device suitable for use with inverters Because of the leakage currents of inverters many ground fault monitoring devices do not work properly with them Insulation monitoring device option Q954 The option includes an insulation monitoring device with coupling device which enables monitoring the insulation resistance before the inverter is started Planning the electrical installation 61 The insulation monitoring device measures insulation resistance between the DC busbars and protective earth PE When the inverter modulates the insulation monitoring device measures also instantaneously the AC line resistance against ground The device reacts to all ground faults in IT systems which are galvanically connected to each other The ground fault detection is not based on system imbalance but the device detects symmetrical and unsymmetrical ground faults as well If the insulation resistance between the conductors and the ground falls below set response values the insulation monitoring device alarm relay is switched and the indication LED lights up The inverter is tripped or an alarm is given depending on the parameter settings When auxiliary power to the insulation monitoring device is switched off its alarm relays are switched to the fault position The response values and parameters of the insulation monitoring device are set with its function keys Note The insulation monitoring device measures the insulation
107. the movement 3 Refasten the module fixing screws at the top and reconnect the DC busbars The tightening torque is 70 N m for M12 screws 4 Reconnect the cables X50 fiber optic cables 5 Loosen the module fastening bolts at the base of the module and remove the pull out ramp Flip the module fastening bracket into the down position and tighten the screws 6 Close the cubicle door 3 Replacing the LCL filter Contact ABB Capacitors The inverter intermediate circuit employs several electrolytic capacitors Their lifespan depends on the inverter loading and ambient temperature Capacitor life can be prolonged by lowering the ambient temperature Capacitor life shortens in high ambient temperatures and under heavy loading It is not possible to predict a capacitor failure Capacitor failure is usually followed by a mains fuse failure or a fault trip Contact ABB if capacitor failure is suspected Replacements are available from ABB Do not use other than ABB specified spare parts 98 Maintenance m Reforming the capacitors Reform re age spare part capacitors once a year according to Capacitor reforming instructions 3BFE64059629 English Technical 99 Technical data What this chapter contains This chapter contains the technical data for the inverters Ratings The inverter ratings are given below Inverter type Temp Nominal Low IRSE NN osos ns aes 599
108. tovoltaic generator or damage to the equipment f WARNING Ignoring the following instructions can cause physical injury or death Only qualified electricians are allowed to install and maintain the inverter Never work on the photovoltaic generator or the inverter or its input or output cables when the inverter is connected to electrical power system or to the photovoltaic generator After disconnecting the inverter from the electrical power system and the DC input always wait for 5 min to let the intermediate circuit capacitors discharge before you start working on the inverter its input and output cables or the photovoltaic generator Always ensure by measuring with a multimeter impedance at least 1 Mohm that 1 Voltage between inverter phases L1 L2 L3 and the frame is close to O V 2 Voltage between the inverter module terminals UDC and UDC and inverter DC input terminals L and L and the frame is close to 0 V Before working inside the inverter cabinet isolate the AC line cables and busbars from the electrical power system with the disconnector of the power system transformer Also isolate the inverter from the photovoltaic generator with the safety switch of the generator or by other means The grid disconnecting device disconnecting means of the inverter does not isolate the AC output cables and terminals from the electrical power system The DC main switch switches or DC input circuit breakers do not isolate the D
109. uctions can cause physical injury or death or damage to the equipment 1 seven steps safety precautions page 12 Stop the inverter and disconnect it from the AC and DC power lines Wait for five minutes to let the inverter DC capacitors discharge before opening the cabinet door Ensure by measuring with a multimeter impedance at least 1 Mohm that there is no voltage present Open the cubicle door Disconnect the fan supply wires Undo the fan fastening screws Install a new fan in reverse order pL em Maintenance 91 Replacing the output cubicle swing out frame fans frame 2 x R8i WARNING Follow the safety instructions page 77 Ignoring the instructions can cause physical injury or death or damage to the equipment 1 Repeatthe seven steps safety precautions page 12 Stop the inverter and disconnect it from the AC and DC power lines Wait for five minutes to let the inverter DC capacitors discharge before opening the cabinet door Ensure by measuring with a multimeter impedance at least 1 that there is no voltage present Open the output cubicle door Undo the three fastening screws of the cubicle fan swing out frame Open the swing out frame Disconnect the fan wiring plug Undo the fan fastening screws oe ae Gel 92 Maintenance Replacing the cabinet roof fans frames R8i and 2 x R8i with option H377 WARNING Follow the safety instructions page 77 Igno
110. ults if the heatsink is not clean When necessary clean the heatsink as follows WARNING Follow the safety instructions page 11 Ignoring the instructions can AN cause physical injury or death or damage to the equipment 1 Repeat the seven steps safety precautions page 12 Stop the inverter and disconnect it from the AC and DC power lines Wait for five minutes to let the inverter DC capacitors discharge before opening the cabinet door Ensure by measuring with a multimeter impedance at least 1 Mohm that there is no voltage present 2 Open the inverter cubicle door 3 Extract the inverter module from the cabinet as described in section Replacing the inverter module frames R8i 2 x 4 Remove the module cooling fan as described in section Fans below 5 Blow clean dry compressed air not humid from bottom to top and simultaneously use a vacuum cleaner at the air outlet to trap the dust Note Prevent the dust from entering adjoining equipment 6 Refit the cooling fan Checking and cleaning the power connections 2 R8i A WARNING Follow the safety instructions page 77 Ignoring the instructions can cause physical injury or death or damage to the equipment 1 Repeatthe seven steps safety precautions page 12 Stop the inverter and disconnect it from the AC and DC power lines Wait for five minutes to let the inverter DC capacitors discharge before opening the cabinet door Ensure by measuring with a mult
111. unit on its back is only allowed if the unit is equipped for such transportation at the factory 46 Mechanical installation Placing the unit Move the cabinet into its final position with an iron bar and a piece of wood at the bottom edge of the cabinet Place the wooden piece properly in order not to damage the cabinet frame Overview of the installation process The unit must be installed in an upright vertical position It can be installed with its back against a wall or back to back with another unit and side by side Fasten the cabinet to the floor and roof as described under Fastening the cabinet to the floor page 47 Note 1 Leave required free space around the unit See page 103 Note 2 Height adjustment can be done by using metal shims between the bottom frame and floor Mechanical installation 47 Fastening the cabinet to the floor The cabinet must be fastened to the floor by using clamps along the edge of the cabinet bottom or by bolting the cabinet to the floor through the holes inside Alternative 1 Clamping Insert the clamps into the twin slots along the front and rear edges of the cabinet frame body and fasten them to the floor with a bolt The recommended maximum distance between the clamps is 800 mm 31 5 If there is not enough working space behind the cabinet for mounting fasten the top of the cabinet to the wall with
112. uropean Low Voltage Directive The compliance with the European Low Voltage Directive has been verified according to standard EN 62109 Compliance with the European directive The EMC Directive defines the requirements for immunity and emissions of electrical equipment used within the European Union EMC standards EN 61000 6 2 2005 and EN 61000 6 4 2007 cover requirements stated for electrical and electronic apparatus intended for use in industrial environments Compliance with EMC standards EN 61000 6 2 2005 and EN 61000 6 4 2007 EMC stands for Electromagnetic Compatibility It is the ability of electrical electronic equipment to operate without problems within an electromagnetic environment Likewise the equipment must not disturb or interfere with any other product or system within its locality 116 Technical data Medium voltage network The requirements of the EMC Directive can be met as follows 1 A transformer with static screening between the primary and secondary windings is used to ensure that no excessive emission is propagated to neighboring low voltage networks 2 inverter is installed to an IT ungrounded system according to the instructions given in the hardware manual Medium voltage network Neighboring network Static screen Low voltage network PVS800 Equipment Equipment Low voltage network The requirements of the EMC Directive can be met
113. ve to dirt The minimum allowed bend radius is 35 mm 1 4 in f WARNING Handle the fiber optic cables with care When unplugging optic 18 Safety instructions Start up and operation These warnings are intended for all who commission plan the operation or operate the inverter WARNING Ignoring the following instructions can cause physical injury or death or damage to the equipment e Close the inverter AC main switch and miniature DC circuit breakers option 377 before start Do not open the DC main switch when the inverter is running e Do not open the inverter AC main switch or and miniature DC circuit breakers option H377 when the inverter is running WARNING Ignoring the following instructions can cause physical injury or death or damage to the equipment Before adjusting the inverter and putting it into service make sure that all equipment are suitable for operation PAN e he maximum allowed number of power ups by applying power is five in ten minutes Note e external source for start command is selected and it is ON the inverter will start immediately after fault reset When the control location is not set to Local L not shown in the status row of the display the stop key on the control panel will not stop the inverter To stop the inverter using the control panel press the LOC REM key and then the stop key Q Introduction to the manual 19 Introduction to the
114. voltage of the board is OK V308 re V310 green IGBT control signal transmission to the gate driver control boards is enabled 84 Fault tracing Warning and fault messages displayed by the CDP 312R Control Panel The control panel displays the warnings and faults of the inverter control unit that it is currently controlling Flashing messages WARNING ID 2 or FAULT ID 2 on the control panel display indicate a warning or fault at the other control unit To display the warning or fault identification text shift the control panel to view the other control unit See PVS800 central inverters firmware manual 3AUA0000058422 English for the descriptions causes and remedies of the warning and fault messages Fault Same ID numbers If the ID numbers of the two control units are set equal the control panel stops functioning To clear the situation e Disconnect the panel cable from the master control unit RMIO board A43 e Set the ID number of the inverter control unit RMIO board A41 to 2 For the setting procedure see the PVS800 central inverters firmware manual 34UA0000058422 English e Connect the disconnected cable to the board of the master control unit A43 again and set its ID number to 1 Fault tracing of the insulation monitoring device option Q954 Refer to section mplementing ground fault monitoring in IT ungrounded systems page 60 Maintenance 85 Maintenance What this chapter contains
115. ycled The plastic parts can either be recycled or burned under controlled circumstances according to local regulations Most recyclable parts are marked with recycling marks If recycling is not feasible all parts excluding electrolytic capacitors and printed circuit boards can be landfilled The DC capacitors C1 1 to C 1 x contain electrolyte and the printed circuit boards contain lead both of which are classified as hazardous waste within the EU They must be removed and handled according to local regulations For further information on environmental aspects and more detailed recycling instructions please contact your local ABB distributor Auxiliary circuit power consumption The auxiliary circuit must be supplied by the customer galvanically separated from inverter output Inverter type Total in running Total in stand by W W Notes The values above do not include the cooling fans of the inverter modules Their power is taken from the solar generator Every additional incoming cubicle increases the auxiliary power consumption by 50 W The actual consumption depends on the options installed Option G300 PVS800 57 0100kW A max 150 W PVS800 57 0250kW A and PVS800 57 0315kW B max 250 W PVS800 57 0500kW A 350 W PVS800 57 0630kW B max 400 W The actual power consumption depends on temperature Option G410 Maximum power consumption 20 W per junction box The auxiliary circuit has to be protected

EN / PVS800-57 central inverters (100 to 630 kW) hardware manual

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