AEG TKS-CS Saw User Manual
Contents
1. 5 safety rules 1 Disconnect safely Secure the equipment against being switched back on 2 3 Verify that all poles are de energised 4 Earth the equipment close the earthing switch and short circuit the equipment Provide protection in the form of covers or barriers for any neighbouring live parts A safe disconnection certificate or a release certificate according to DIN VDE 0105 100 EN 50110 must be presented prior to all maintenance and repair work The owner must draw up a safe disconnection procedure and brief personnel on this Page 26 of 39 8000043213 BAL Compact Station TKS CS Operating Instructions AE G POWER SOLUTIONS The owner is responsible for correct servicing of the systems and the equipment This also applies to system components that fall within the responsibility of the grid operator In order to ensure uninterrupted availability of the equipment preventive servicing work should be carried out based on the maintenance schedule Regular maintenance reduces the risk of breakdowns and disruption due to technical faults To maintain the validity of the warranty e Regular maintenance must be carried out and documented according to the maintenance schedule e Only original AEG PS spare parts or spare parts purchased from AEG PS may be used For further details please refer to the provisions of the individual contracts The owner must define work instructions for carrying out servi2. 8000043213 BAL Page 15 of 39 AEG POWER SOLUTIONS 5 Functional Description PV IcX PV SuN max 1 to8 optional PV IcX max 1 to 8 PV LoG MH PV 500 MH FA PV 500 MH PV IcX PV SuN max 1 to 8 optional Monitoring Transformer Transformer Transformer Monitoring PV 500 MH mA Figure 10 Equipment diagram example TKS CS 1000 Compact Station TKS CS Operating Instructions Transfer station Radio and ripple control power utility interface 3 Switchgear PV ControL Internet connection CAN bus max 2 x 500 m FO ring max 4 km Modbus RS485 max 2 x 500 m Ethernet COM server max 80 m Power cable sennenennn ne RS485 current voltage transformer The station equipment is configured in accordance with the required nominal output One or two Protect PV inverters can be connected to a compact station TKS CS The PV Control or Skycontrol unit is adapted to the power station capacity and the local feed conditions Further functional information can be found in the Protect PV Inverter Operating Instructions BAL Page 16 of 39 8000043213 BAL Compact Station TKS CS Operating Instructions AE G Transport POWER SOLUTIONS DANGER Suspended loads during transport Possibility of death or crushing gt Select lifting gear according to the total weight to be transported gt Do not step under sus
3. MV system User pra Q 8 rif E OF e ease EE AA d Sy a 2 1 Disconnect the equipment safely 2 Remove all connections from the transformer and secure the equipment 8000043213 BAL Page 31 of 39 AE G Compact Station TKS CS Operating Instructions vr d POWER SOLUTIONS 1 Figure 19 Station roof 1 Roof structure 3 Station frame 2 Screw connection J The roof structure weighs around 130 kg Comply with Directive 90 269 EEC handling of loads 3 Open all doors and unscrew the 6 roof structure screw connections Completely remove the roof structure from the compact station TKS CS gt roof removal Bosecker 1 2 Figure 20 Replacing the transformer 2 example 1 Low voltage box 3 Transformer compartment 2 Transformer 4 Attach the transformer to the transport eyelets and carefully lift it using lifting gear Page 32 of 39 8000043213 BAL Compact Station TKS CS Operating Instructions AE G POWER SOLUTIONS 5 Place a new transformer in the compact station s trough and establish the connections Finally replace and align the roof structure and establish the screw connections gt transformer operating instructions 10 3 2 2 Replacing the MV Switchgear 3 4 Figure 21 Partial top view TKS CS example 1 Transformer compartment 3 Medium voltage compartment 2 Low voltage box 4 MV switchgear 1 Disconnect the equipment s
4. electrical and mechanical screw connections They do not apply to floor attachment with dynamic stress applied 8000043213 BAL Page 23 of 39 AE G Compact Station TKS CS Operating Instructions POWER SOLUTIONS 8 Start up DANGER Working with voltages up to 1 kV Risk to life due to electric shock gt Comply with BGV A3 DIN VDE 0105 100 EN 50110 IEC 61243 gt Skilled personnel with a Working with Live Current certificate Special AEG Power Solutions software and hardware tools must be used for initial start up Only skilled personnel trained by AEG PS are in a position to use these tools correctly and to perform initial start up Once the equipment has been fully installed the following aspects must be checked e Screw connections properly tightened e Cable connections properly established e Tools removed e Protective covers properly installed 9 Operation The system is operated as a result of power emerging from the Protect PV inverter this is determined by the power plant control system Page 24 of 39 8000043213 BAL Compact Station TKS CS Operating Instructions AE G POWER SOLUTIONS 10 Servicing DANGER Contact with voltage Risk to life due to electric shock gt Press emergency off gt Move the victim away from live parts using dry insulating material gt Get medical help and inform the control room gt Disconnect the equipment safely DANGER Working with voltages up to 1 kV Risk
5. suitable locking systems should be installed by the owner on all exterior doors of the compact station 2 1 Installation Location The equipment is intended for use outdoors as an enclosed electrical unit e Environmental conditions gt technical data in accordance with DIN EN 60721 3 4 e Freely accessible air vents for heat dissipation e Ground pressure min 250 kN m gt excavation plan Refer to the technical data for additional criteria When selecting the installation location regional regulations governing noise emissions must be taken into account Do not install the equipment in areas subject to flooding or those with a high groundwater level 2 2 Lightning Protection The connection to the potential equalisation system of the foundation provides the equipment with effective protection against lightning strikes The manufacturer s specifications must be implemented effectively in order to provide the photovoltaic system with suitable lightning protection measures Further safety information can be found in the Protect PV Inverter Operating Instructions BAL 8000043213 BAL Page 7 of 39 AE G Compact Station TKS CS Operating Instructions POWER SOLUTIONS 3 Scope of Delivery Check that the following components have been delivered with the equipment e 1x compact station TKS CS inc Transformer corresponding to nominal output Medium voltage system corresponding to nominal output Low voltage b
6. Earth the equipment close the earthing switch and short circuit the equipment Provide protection in the form of covers or barriers for any neighbouring live parts The owner must draw up a safe disconnection procedure and brief personnel on this 11 1 Removing Connection Cables e Disconnect power terminals e Disconnect the power supply and auxiliary power supply e Disconnect all external control cables e Disconnect the earthing line clips from the central earthing system 11 2 Dismantling DANGER Suspended loads during transport Possibility of death or crushing gt Select lifting gear according to the total weight to be transported gt Do not step under suspended loads gt Secure the danger zone gt Wear personal protective equipment Page 36 of 39 8000043213 BAL Compact Station TKS CS Operating Instructions AE G POWER SOLUTIONS DANGER Toppling of cargo during transport by industrial trucks Possibility of death or crushing gt Lift cargo under its centre of gravity gt Secure the cargo and danger zone gt Wear personal protective equipment gt f necessary secure the transformer to prevent it slipping gt Attach suitable load carrying equipment to the compact station using the transport eyelets on the concrete base gt Lift the equipment carefully and remove cables 11 3 Disposal 11 3 1 Statutory Provisions Equipment at the end of its life is el
7. OPERATING INSTRUCTIONS TKS CS Compact Station for Connecting the Solar Inverter to Medium Voltage AEG Power Solutions GmbH Warstein Belecke Department PS AE Revision 01 Revision date 15 10 2012 Hagelstein Released 15 10 2012 Songur Document no 8000043213 BAL en AEG POWER SOLUTIONS AEG POWER SOLUTIONS Page 2 of 39 Compact Station TKS CS Operating Instructions Revision Service Status Revision Date Name 00 07 08 2012 Hagelstein 01 Corrections pages 6 15 21 15 10 2012 Hagelstein 8000043213 BAL Compact Station TKS CS Operating Instructions AE G POWER SOLUTIONS Table of Contents 1 General Information scsicvesiescctsewteseressesecesuecsveceuevedinevecsut 6 1 1 Ur 6 1 2 Appropriate Use ccccccssccceeeceeeceeeeceueeceeesausesseesaees 6 1 3 List Of Abbreviations rrrrrrrnrrnnrrrnrrnrrnarenanrnanenanennnennne 6 2 gt YY EEE EE EE ES 7 2 1 IISTANAUION LOCAL ON Lae 7 2 2 Lightning ProteCtiON cccccccecceecceeseeceeeceeeeeeceeeaeeeees 7 3 Scope of Delivery ccccccccssscceeeecseseeceneeceneeseeneseeees 8 4 Equipment SpecificationsS anxxrnnnnennnnonnnnnnnnnennnnnennn 9 4 1 TUE 5 sarsaeicearereasvwedaaeanarcunsesonseninzanirsinrriciemeipnaanassasned 9 4 2 DIMENSIONS arrarrnnrnnnrvarnnnrnarnnnnnernannnernnnnnnennnnnnnnnsnneen 10 4 3 Low Voltage BOX rrrnrrnnnrnnnrnnnrnnnrnnnnnnnnnnrnnnnnnnn
8. afely 2 Remove all connections from the MV switchgear and secure the equipment 3 Unscrew the screws of the MV switchgear and remove it from the compact station using an industrial truck gt MV switchgear BAL 8000043213 BAL Page 33 of 39 AE G Compact Station TKS CS Operating Instructions POWER SOLUTIONS 10 4 Maintenance Schedule The maintenance schedule does not release the owner from his obligation to create his own maintenance and operating instructions for the location and to document them fully as quickly as possible Maintenance instructions supplied by component manufacturers must be included in the detailed specifications relating to the scope of maintenance work For recurrent measurements and measurements after repair work as per BGV A3 compliance with the DIN VDE 0105 100 inspection intervals is mandatory Ongoing Check the measured results of the equipment for plausibility Replace defective measuring instrumentation at the end of production Data bus Ongoing functional testing in operation Monthly Test lamps and replace diodes if required Check the function of the system s internal measuring instrumentation by comparing the values during operation with the values displayed Check the function of the measuring instruments and accessory systems required for operation and servicing Check the interior area and equipment for moisture and if necessary establish the cause and dry the eq
9. alidity These instructions relate to the technical specifications of the equipment at the time of publication These instructions are a component part of the system Legal claims arising from this contractual relationship shall only be recognised by AEG Power Solutions GmbH subject to the terms agreed under the warranty obligation in the main contract Appropriate Use The compact station TKS CS is designed for use in solar power stations with one or two Protect PV inverters in accordance with IEC 62271 202 The compact station is intended for outdoor installation An output related transformer for electrical isolation and output dependent medium voltage switchgear for feeding into the local medium voltage mains are installed in the compact station The equipment may only be used for this purpose Any other use constitutes misuse and can endanger personal safety List of Abbreviations Abbreviation Meaning CS Compact Station MH Metal Housing Further information can be found in the Protect PV Inverter Operating Instructions BAL 8000043213 BAL Compact Station TKS CS Operating Instructions AE G POWER SOLUTIONS 2 Safety The qualified skilled personnel are responsible for safety The member of personnel who Is responsible for the equipment must ensure that only suitably qualified persons are allowed access to the equipment To ensure safety in the electrical operating areas these areas should be lockable i e
10. aner must be completed before and after cleaning work Circuit and installation markings should be noted before cleaning so that if a marking is damaged or falls off this can be rectified 10 2 3 Functional Test J Always perform a functional test after completing any servicing work and before starting operation Electrical equipment must only be started up if it is in perfect working order and must be kept in this condition Following repair replacement or modification work a functional test must be performed in accordance with the commissioning log For repeat tests functional testing of the equipment or its components need only be carried out to an extent that verifies the safety of the equipment 10 2 4 Testing Measuring The aim of testing measuring is to verify that the electrical equipment complies with the installation standards In the case of recurrent tests all measurements must be taken in accordance with the initial start up and DIN VDE 0105100 and compliance with all values limits must be verified All measuring and monitoring devices used for testing must comply with the standards DIN VDE 0413 EN 61557 and DIN 0404 and must be tested and calibrated regularly in accordance with ISO 9001 2000 The equipment has various diagnostic functions some of which are optional which can significantly reduce the time required for maintenance work and troubleshooting Self diagnosis This is activated when the
11. ccordance with the manufacturer s installation instructions located in the system Insert the branch cable into the compact station from below 8000043213 BAL Page 21 of 39 AEG POWER SOLUTIONS Compact Station TKS CS Operating Instructions 7 2 6 Medium Voltage Transformer Page 22 of 39 gt h Figure 16 Transformer example 1 Earth connection 4 MV elbow connector Transformer cover 5 Voltage tap changer 2 LV connection with 6 Retaining plate with cable clips porcelain isolator 3 MV porcelain isolator The oil transformer is preinstalled and wired in the compact station TKS CS The LV connections are established in accordance with DIN EN 50386 Transformer and MV connections with porcelain isolators comply with DIN EN 504180 During replacement work establish the electrical cabling connections as normal and connect the three earthing terminals gt manufacturer s technical operating documentation 8000043213 BAL Compact Station TKS CS Operating Instructions AE G POWER SOLUTIONS 7 3 Tightening Torques for Screw Connections Mechanical connection Electrical Thread Connection crewatrengtn aeie an category hosdserem category 5 8 8 8 DIN 84 Nm Nm Nm Nm M4 1 2 1 3 2 0 1 2 M5 2 0 2 65 4 0 2 0 M6 3 0 4 4 7 0 2 5 M8 6 0 10 5 17 0 3 5 M10 10 0 33 0 4 0 M12 15 5 56 0 M16 30 0 140 0 M20 52 0 260 0 M24 80 0 445 0 Table 5 Tightening torques These values apply to
12. cing work giving details of Ambient conditions Tools equipment means of protection and auxiliary equipment Suitable personal protective equipment and organisational safety measures Servicing work must be carried out in accordance with BGV A3 DIN VDE 0100 VDE 0105 and DIN 31051 DIN EN 13306 AEG PS will rescind all obligations such as warranty agreements service contracts etc entered into by AEG PS or its representatives without prior notice in the event of anything other than original AEG PS spare parts being used 10 1 Obligation to Keep a Written Record Inspection results and details of any servicing work carried out must be recorded in writing Experience has shown that the best way to document inspection results is in the form of a test report The following information must be recorded e Maintenance schedule e Date of the measure carried out e Work performed e Any special notes on the work performed e Persons who carried out the work e Signatures of the persons who carried out the work e Signature of the person responsible supervisor 8000043213 BAL Page 27 of 39 AEG POWER SOLUTIONS Compact Station TKS CS Operating Instructions A correct test report completed in full is important for technicians as evidence of exoneration in case of later complaints or for investigations in case of damage For this reason test reports should be retained for a long time around 10 years 10 2 Maintena
13. e F21 16 A Socket outlet with earthing contact F22 16 Door contacts and lighting F23 6A Medium voltage tripping F24 16 A Power supply PV LoG MH F25 6A Axial fan F26 16A optional F27 16 A optional FO 20 Sub distribution supply F1 25A Auxiliary transformer F10 Overvoltage protection Table 2 Fuses Page 12 of 39 8000043213 BAL Compact Station TKS CS Operating Instructions AE G POWER SOLUTIONS 4 3 3 Communications Cabinet PV LoG MH 1 5 2 6 7 3 8 3 9 4 Figure 6 PV LoG MH example 1 Data logger 5 Ethernet coupler 2 Fuses 6 Data acquisition boards 3 UPS 24 V DC 7 CAN overvoltage protection 4 Short circuit and 8 Terminal strip The compact station TKS CS features the PV LoG MH and a variety of interfaces for monitoring and control Data exchange between the PV LoG MH and the MH station control systems the PV IcX and the transfer station takes place via Ethernet modbus CAN bus and FO cables For further information refer to the PV LoG MH Operating Instructions 4 3 4 Central Earthing System i mw a N 11 RAO ND Figure 7 Central earthing system example 8000043213 BAL Page 13 of 39 AE G Compact Station TKS CS Operating Instructions POWER SOLUTIONS No HO7V K Name mm 1 70 Low voltage box 2 95 Cable entry 3 70 Station housing 4 16 Sub distribution 5 16 Communications cabinet PV LoG MH 6 70 Medium voltage system 7 70 Transformer Table 3 Potential equalisin
14. ectrical scrap In commercial contexts the manufacturer is responsible for the disposal of electrical scrap unless otherwise agreed Electrical scrap must always be disposed of by an expert Electrical and electronic scrap may only be disposed of in compliance with local legislation and regulations German Electrical and Electronic Equipment Act 2002 96 EC WEEE and the Basel Convention Electronic scrap consists of valuable materials which can be reclaimed as secondary raw materials but it also contains environmentally harmful substances Commercial disposal companies have information on the best way to recycle material e g in the form of a Recycling Handbook For example it is possible to recycle e PCBs and circuit boards e Electronic components EPROMs ICs and relays e Chips processors hard disks and drives e Batteries 11 3 2 Chemical System Components AEG PS complies with the restrictions on the use of hazardous substances in electrical and electronic units according to the German Electric and Electronic Equipment Act Section 5 2002 95 EC 8000043213 BAL Page 37 of 39 AE G Compact Station TKS CS Operating Instructions POWER SOLUTIONS Do not dispose of old batteries with refuse They contain environmentally harmful materials Hg Cd or Pb Ensure compliance with local legislation and regulations governing the storage handling and disposal of batteries Components such as plastics and insulat
15. enaes 29 VS EN 30 VET MANN 30 10 2 5 2 Replacing the Axial Ventilator rrrrrrrnnrvrnrrnnnrrnnrennn 30 8000043213 BAL Page 3 of 39 AEG POWER SOLUTIONS Page 4 of 39 Compact Station TKS CS Operating Instructions 10 3 g SE E E T apes 31 10 3 1 Testing after Repairs Lusanerken nmenerv menn 31 10 3 2 Replacement Work rrnnrnnnnnnnnnnnnnnnnnnnennnennnennnrnnnennee 31 10 3 2 1 Replacing the Transformer rrrvnnrrnnnrrnnnrernrennvrnnnrenn 31 10 3 2 2 Replacing the MV Switchgear arrnnnnennnrrvarrnnnrnnnnennn 33 10 4 Maintenance SChHedUule ccccccccseeeceeeeceeeesseeeeseeees 34 10 5 Storing Spare PA save 35 11 Decommissioning and Dismantling anurnnvrnnvvnnuvnn 36 11 1 Removing Connection Cables ccccccesseeeeseeeeeeees 36 11 2 BIE ape Ta 0 ER 36 11 3 ISD OS al EE EE ME 37 11 3 1 Statutory Provisions surrer 37 11 3 2 Chemical System Components ernnrrvnrnnrvennnvrennnvnen 37 List of TAN 39 ke 0 E rac ceuaes 39 8000043213 BAL Compact Station TKS CS Operating Instructions AE G POWER SOLUTIONS AEG Power Solutions GmbH Emil Siepmann Strasse 32 59581 Warstein Germany a 49 2902 763 100 Fax 49 2902 763 645 E mail service aegoss aegps com Internet http www aegps com 8000043213 BAL Page 5 of 39 AEG POWER SOLUTIONS 1 1 1 1 2 1 3 Page 6 of 39 Compact Station TKS CS Operating Instructions General Information V
16. equipment is switched on Internal auxiliary programs monitor the bus system the control PCBs and the sensors amongst other things and signal any faults that occur Data logger Measured data parameters and fault indications are saved continuously Measured data and performance data as well as fault histories can be read out and evaluated as required J The operating instructions describe how to output performance and fault histories 8000043213 BAL Page 29 of 39 AEG POWER SOLUTIONS 10 2 5 Care 10 2 5 1 Lubrication Compact Station TKS CS Operating Instructions BGV A2 requires the owner to perform repeat tests at stipulated times in order to verify that the electrical equipment is in perfect working order At stipulated times the owner must check that the fault current differential current and fault voltage protection devices are functioning properly Carry out manual insulation testing Carry out the following care measures for the station e Lubricate hinges rods and guide rails after cleaning e Lubricate the ball bearings in the axial ventilator after around 20 000 operating hours or a maximum of 4 years according to the manufacturer s specifications 10 2 5 2 Replacing the Axial Ventilator Page 30 of 39 Rotating parts Injury to fingers and hands possible gt Do not reach into rotating parts gt De energise fans 1 2 3 4 5 Figure 17 Replacing the axial ventilator 1 Hou
17. g strip The central earthing system is preinstalled on the potential equalising strip in the compact station 4 4 Medium Voltage System Figure 8 MV switchgear example The installed MV switchgear example is an interior system with cable branch line K and transformer branch line T modules Further information on the MV switchgear is available in the installation and operating instructions included in the scope of delivery Page 14 of 39 8000043213 BAL Compact Station TKS CS Operating Instructions AE G POWER SOLUTIONS 4 5 Transformer 1 2 3 4 J am A Cte AT AT AT T AN Y Y VER N TONT WE Par AA ALAA ANA S Vett etee SY a a a a a oe EP 8 H A oe vi N Hr TREE AA AR Figure 9 Transformer example 1 Temperature 5 LV connection to LV box sensor indication 6 Oil fill level valve 2 Earth terminal 7 Transport securing device 3 MV porcelain isolator 8 Cooling fins 4 MV connection to MV system All internal connections to and from the transformer are preinstalled in the compact station The transformer is on vibration dampers and is secured for transport The transport securing device does not need to be removed for operation The transformer is equipped with temperature and oil level monitoring equipment which is connected to the PV LoG MH and emits a warning if abnormal values occur For further information refer to the transformer documentation
18. igure 9 Transformer example rrrrnnnrrrnnnnnrerrnnnnenrnnnnrrnnnnnrennnnenennnnn 15 Figure 10 Equipment diagram example rrrrrnnnnrnvvnrnnnnrrvrnnnnnnrrrennnnnn 16 Figure 11 Crane TENSPO arenaen medan 17 Figure 12 Setting the compact station in place rrrrrrnnnnrnvvrnnnnvrrernnnnn 18 FIS UNN 19 Figure 14 ISO small distribution box example rrrrrnnnrrrvvrrnnnvrrvrnnnnnn 20 Figure 15 Medium voltage system example rrrrrrnnnrnrrnrnnnnnnvnnnnnnn 21 Figure 16 Transformer CxAMple ccccsescecccseececeeeseecceeseeeseenseesseees 22 Figure 17 Replacing the axial ventilator rrrrrrnnrrrrrrrnnnrrrvrnrnnnnrrrrnnnnn 30 Figure 18 Replacing the transformer 1 example rrrrrrrnnnnrrrrvnnnnnn 31 Fig re 19 ST NON FOOT sanne ddandehapinepadade 32 Figure 20 Replacing the transformer 2 example rrrrrrrrnnnrrrvrnnnnnn 32 Figure 21 Partial top view TKS CS example merrrrnnnnrrnrvrnnrrrnnnnnnnn 33 8000043213 BAL Page 39 of 39
19. ing materials should be disposed of as industrial waste and should be recycled Page 38 of 39 8000043213 BAL Compact Station TKS CS Operating Instructions AE G POWER SOLUTIONS List of Tables Table 1 Dimensions rrrnnrrrvvnrnnnnnrvnnrnnnnnrvnnnnnnnnsrnnnnnnnnsennnnnnsnsennnnnnsnssnn 10 Table 2 FUSES ssicecaziscsetecctesasdescstatdedchaessissstnte2g dtaatiee dsaataeiebtadientesateloaneasce 12 Table 3 Potential equalising Strip rrrrrrrrnnnnnrrrrrnnnnrrrnrrnnnnnrennnnnnnnvenn 14 Table 4 LV box connections rrrrrrrrnnnnnrrnnrnnnnnrrnnrnnnnnrrnnnnnnnsennnnnnsnsenn 19 Table 5 Tightening tOrques cccccsceeeceeceeeeeeeeeeeeeeeeeeeeseeeeeeeeeseaneeeeeneas 23 List of Figures Figure 1 Compact station TKS CS rrrrnrrrnnnrnnnnnnnnrrnnnrrnnnnnnnnvrnnnnrnnnnnnnnee 9 Figure 2 Compact station side VICWS ccccccceeecesseseeeeeeeeeeaaeeeeeeeeess 10 Figure 3 Low voltage box example rrrrrnrrrvrrrnnnrrrrvrrnnnrrrrnvrnnnnrrrnnnnnn 10 Figure 4 Low voltage boxes example rrrrrrrnnnnnrvvrnnnnnnrrnnrnnnnnennnnnnn 11 Figure 5 ISO small distribution box example cccceeeeeeesseeeeeeeeees 12 Figure 6 PV LOG MH example ccceccceecseeeseeeeceeeeeeeeeseeeeeeeeeeaaaees 13 Figure 7 Central earthing system example rrrrrnnrnnnnrrvrnrnnnrrrrrnnnnnn 13 Figure 8 MV switchgear example rrrrrrnnnnrrvrrnnnnerrnnnnrrrnnnnrervnnnnennnnn 14 F
20. nce and Inspection 10 2 1 Visual Inspection 10 2 2 Cleaning Page 28 of 39 Visual inspections should be carried out in accordance with DIN EN 13018 Inspections must involve careful checks for the following in the equipment e Mechanical damage e Corrosion thermal changes to and tightness of the electrical connections e Moisture e Accumulation of conductive dirt or dust e Defective fuses e Foreign bodies e Fans dirty or damaged M2 and M3 when the waste air duct is open e Filter mat dirty or damaged Safety devices and warning notices should be checked for damage and legibility If there is condensation in the equipment the internal heating device should be checked to determine whether it is working properly Only equipment tested in accordance with DIN VDE 0680 may be used for cleaning If there is condensation in the equipment parts that are to be cleaned cleaning must not be carried out The cleaning procedure used must comply with the relevant regulations and provisions of the accident prevention regulation VBG 4 Elektrische Anlagen und Betriebsmittel Electrical installations and equipment and DIN VDE 0105 100 Operation of electrical installations Only specially trained electricians may carry out cleaning work when the equipment is live 8000043213 BAL Compact Station TKS CS Operating Instructions AE G POWER SOLUTIONS The log for dry cleaning low voltage installations using a vacuum cle
21. ng Instructions AE G POWER SOLUTIONS 7 2 Installation Hinge side of the door when closing Fingers or hands may be crushed gt Do not hold the hinge side of the door gt Take care while closing the cabinet door Observe the bending radius of the supply lines With one bend bending radius 10 x diameter of supply line 7 2 1 Low Voltage Box Figure 13 LV box 1 LV box protective cover 4 Cable lug 2 Load interrupter NH4 1250 A 5 Protective cover 3 Connection panel NH4 Cu busbars Connection Design Torque Nm L1 3 U V W max 3x240 mmf M12 2 15 5 PE max 3x120 mmf M12 2 15 5 2 cable lug connection Table 4 LV box connections 1 Remove the protective cover from the connection panel The order of the conductors L1 L2 L3 must be adhered to 8000043213 BAL Page 19 of 39 AEG POWER SOLUTIONS Compact Station TKS CS Operating Instructions 2 Establish the AC power connections and PE connections using the cable lug in accordance with the circuit diagram and using the relevant tightening torque 3 Remove any cable debris and tools from the equipment and replace the protective cover on the connection panel 7 2 2 ISO Small Distribution Box Figure 14 ISO small distribution box example 1 Residual current operated circuit 5 Screw connections breaker 6 Miniature circuit breakers 2 Back up fuse sub distribution 7 Fuses max 25 A 3 Terminal strips 8 Ove
22. nnnnnnnnnnn 10 4 3 1 AG ENN 11 4 3 2 ISO Small Distribution BOX rrrarernnrornrrrranenanennanennnnnn 12 4 3 3 Communications Cabinet PV LoG MH 008 13 4 3 4 Central Earthing System rrrnrnnrnnnnnennnnrnnnnennnnnnnnnnen 13 4 4 Medium Voltage System ranrrnnanrrrnnnrnnnnrnnanennnnnnnnnne 14 4 5 TAN 15 5 Functional Description ranrnanvnnnnnnnnnnnvnnunnnunnnunnnuenn 16 6 TNS OO 2 17 7 ASSEMPN uer 18 7 1 Se Aa E EE E 18 1 2 S PAN eg EE 19 7 2 1 Low Voltage BOX rrnnrrnnrrnnnrnnnnnnnrnnnnnnnnnnrnnnnnnnrnnnnnnnnnnn 19 7 2 2 ISO Small Distribution BOX rrrarernnrornrrrranenanennanennnnnn 20 7 2 3 Communication Interface PV LoG MH rrrnnrrnnnnennnner 20 7 2 4 Central Earthing System rrrnranrnnnnnnennanrnnnnennnnrnnnnnen 21 7 2 5 Medium Voltage System rannrnnnnrnrnnnennnnrnranennnnnnnnnne 21 7 2 6 Medium Voltage Transformer arrrrnnennnnnrnnrnnnrnnnnennn 22 7 3 Tightening Torques for Screw Connections 23 8 SOU NUD EE EE 24 9 PAN 24 10 SEMINAR seendv 25 10 1 Obligation to Keep a Written Record rrarrnnnrnnnnrnnnre 27 10 2 Maintenance and Inspection rrrnrrrrnrrrnrrernvrnnvrnnnrennn 28 10 2 1 Visual Inspection rrrnrnnnrrnnrnnnrnnnrvnrevnrennrennrennrennsennne 28 1022 Me 28 1023 Funcional TSi cticis sea ccdedecteccsinedesnccdaseeaecbnceseciaseeceds 29 10 2 4 Testing M Suring ccccccscccseeceecceeccesceseceeeeees
23. ompact station side views Dimension mm Height of metal housing with roof 1686 5 Height of concrete base 780 MH depth roof 1750 1804 MH width roof 2900 2954 Table 1 Dimensions 4 3 Low Voltage Box oe er TILT T y e i I A 1 2 3 4 5 6 7 Figure 3 Low voltage box example 1 Central earthing system 5 ISO small distribution 2 Communications cabinet PV LoG MH box 3 Load interrupter switch 3 pin 6 Battery cabinet 4 LV connections with protective cover 7 Socket outlet with earthing contact Page 10 of 39 8000043213 BAL Compact Station TKS CS Operating Instructions AE G POWER SOLUTIONS The low voltage box must remain closed during operation 4 3 1 AC Connections 1 2 3 Figure 4 Low voltage boxes example 1 LV box for an MH 4 LV box for two MH 2 AC connection 1Q0 with steel 5 AG connection 1Q0 2Q0 with sheet protective cover Makrolon protective cover 3 Load interrupter switch 8000043213 BAL Page 11 of 39 AE G Compact Station TKS CS Operating Instructions POWER SOLUTIONS 4 3 2 ISO Small Distribution Box 5 6 Figure 5 ISO small distribution box example 1 Cable duct internal 6 FO fuse max 20 A 2 F20 Fl switch 25 A Sub distribution 3 F21 27 miniature circuit 7 F1 fuses max 25 A breakers Auxiliary transformer 4 4Q0 motor protection switch 8 F10 overvoltage protection Fan 5 3Q0 motor protection switch Auxiliary transformer Fus
24. ox Power supply and auxiliary power supply e Technical documents comprising Technical data Installation and operating instructions Drawings circuit diagrams Available to order AEG Service can also provide the following documents e Spare parts list e Service book To place an order please contact E AEG Power Solutions GmbH Emil Siepmann Strasse 32 59581 Warstein Germany T 49 2902 763 100 Fax 49 2902 763 645 E mail service aegpss aeg com Internet http www aegps com Page 8 of 39 8000043213 BAL Compact Station TKS CS Operating Instructions AE G POWER SOLUTIONS 4 Equipment Specifications 4 1 Structure The compact station TKS CS consists of a metal housing with a detachable roof structure and a concrete base The concrete base comprises a warp resistant foundation with an oil and water tight trough in the transformer compartment Figure 1 Compact station TKS CS 1 Transformer compartment 6 Wall structure 2 Roof structure 7 Concrete base 3 ISO small distribution box 8 AC feed from MH PV LoG 9 Low voltage box 4 MV branch feed 5 MV switchgear The wall and door structures are designed with double walls and forced ventilation An additional axial ventilator is installed in the door of the transformer compartment for ventilation purposes 8000043213 BAL Page 9 of 39 AE G Compact Station TKS CS Operating Instructions POWER SOLUTIONS 4 2 Dimensions 1750 Figure 2 C
25. pended loads gt Secure the danger zone gt Wear personal protective equipment Figure 11 Crane transport The station may only be lifted using the crane rings on the longitudinal sides The crane rings on the face sides are only intended for transport securing purposes and for dragging towing the stations while they are raised Raising the stations using the crane rings on the face sides is not permitted The load carrying equipment used ropes belts must have a sufficient carrying capacity The weight of the station is dependent on the equipment configuration please see the technical data The load must be evenly distributed between all four ropes belts Lifting at one side is not permitted No people or objects may be on the platforms in front of the station doors during lifting 8000043213 BAL Page 17 of 39 AE G Compact Station TKS CS Operating Instructions POWER SOLUTIONS 7 Assembly 7 1 Setting in Place The compact station TKS CS does not need a foundation The concrete base serves as its foundation 3 5 Figure 12 Setting the compact station in place 1 Ground 4 Transport eyelets 2 Concrete base 5 Transport rod 3 Metal housing Using the construction pit pin create a construction pit on clear ground The system may only be installed by crane gt Chapter 6 Transport Remove the transport rod after the system has been installed Page 18 of 39 8000043213 BAL Compact Station TKS CS Operati
26. rvoltage protection 4 Motor protection switch Auxiliary transformer The ISO small distribution box is preinstalled in the compact station To open the ISO small distribution box unscrew the four screw connections The cover can then be pulled out towards the front Establish the connections in accordance with the circuit diagram 7 2 3 Communication Interface PV LoG MH Page 20 of 39 The communications cabinet PV LoG MH includes batteries which are installed in the cabinet or in a separate box Install the communications cabinet PV LoG MH in accordance with the PV LoG installation instructions Wiring is carried out in accordance with the circuit diagram Data is exchanged between the PV IcX combiner boxes or the PV ControL and the PV LoG MH via CAN bus gt USP and operating instructions for PV LoG and PV ControL 8000043213 BAL Compact Station TKS CS Operating Instructions AE G POWER SOLUTIONS 7 2 4 Central Earthing System Connect the active earthing to the potential equalising strip according to the circuit diagram 7 2 5 Medium Voltage System 1 2 Figure 15 Medium voltage system example 1 Cable branch line L1 L2 L3 left flap external AC connections 2 Transformer branch line right flap internal AC connections from transformer to load interrupter switch The MV system is preinstalled in the compact station Use the power cables supplied for the system AG connections and connect in a
27. sing plate with M9 4 Connection cable with seal 2 Protective screen 5 Drive motor 3 Impeller 6 Weather proof cover The axial ventilator must be replaced if it is defective or runs out of round As a precaution it should be changed every 4 years when bearing lubrication is due Remove the axial ventilator in accordance with the manufacturer s specifications and send it to the manufacturer for maintenance 8000043213 BAL AEG Compact Station TKS CS Operating Instructions POWER SOLUTIONS 10 3 Repairs Only AEG PS skilled personnel may carry out repairs and modifications on the compact station CS xx lf you want other personnel to carry out this work this will need to be authorised by means of written approval from AEG PS Only original AEG PS spare parts or spare parts purchased from AEG PS may be used Testing after Repairs Each time the equipment is repaired or modified all recurrent tests measurements are to be carried out and documented in 10 3 1 accordance with DIN VDE 0105 initial start up log once the work is complete 10 3 2 Replacement Work 10 3 2 1 Replacing the Transformer The transformer can be accessed via the detachable roof or a door It can only be replaced when the roof structure has been removed 4 ET j CO 3 1 2 Figure 18 Replacing the transformer 1 example 3 Internal connections from 1 Temperature sensor 2 Internal connections to low voltage box
28. stems and repair them if required Clean the equipment to minimise creepage currents do not use water Comply with BGV A3 DIN VDE 0105 100 during this process Check that the safety signs are complete and legible and replace if required Must be checked by an expert every 2 years Check the function of the lighting in the compact station and replace if necessary Every 2 years Check of the safety signs in the operating area and in the equipment by an expert Every 4 years Replace the axial ventilator and clean the weather proof cover 10 5 Storing Spare Parts When ordering spare parts you must provide the component l designation installation location and component number as well as the unit number of the component The AEG PS customer service department will be happy to send you a spare parts list on request 8000043213 BAL Page 35 of 39 AE G Compact Station TKS CS Operating Instructions POWER SOLUTIONS 11 Decommissioning and Dismantling The compact station TKS CS can be decommissioned or dismantled for the purposes of changing its location or disposal Before beginning any work on the equipment it must be de energised For this purpose the five safety rules of electrical engineering in accordance with DIN VDE 0105 EN 50110 must be observed 5 safety rules 1 Disconnect safely Secure the equipment against being switched back on 2 3 Verify that all poles are de energised 4
29. to life due to electric shock gt Comply with BGV A3 DIN VDE 0105 100 EN 50110 IEC 61243 gt Skilled personnel with a Working with Live Current certificate DANGER Residual voltage from capacitors Risk to life due to electric shock gt Observe discharge time gt Disconnect the equipment safely Keep the equipment clean to minimise leakage currents DANGER Contact with leakage current Risk to life due to electric shock gt Disconnect the equipment safely DANGER Toppling of cargo during transport by industrial trucks Possibility of death or crushing gt Lift cargo under its centre of gravity gt Secure the cargo and danger zone gt Wear personal protective equipment 8000043213 BAL Page 25 of 39 AE G Compact Station TKS CS Operating Instructions POWER SOLUTIONS Insufficient ventilation of equipment Equipment may overheat gt Keep air vents clear gt Ensure the equipment is sufficiently ventilated Heat generation in resistors Risk of burning gt Do not touch hot components Hinge side of the door when closing Fingers or hands may be crushed gt Do not hold the hinge side of the door gt Take care while closing the cabinet door Entry of water into electrical equipment Risk to life due to electric shock Do not use water to clean the cabinets gt Do not place any vessels containing fluids beverage cups for example on electrical equipment
30. uipment Clean the interior areas of the compact station operating area Every 6 months Check the fastenings and function of the electrical connections of all components in the compact station Check the function of the fault current differential current and fault voltage protective circuits Carry out recurrent measurements in accordance with DIN VDE 0105 Check the axial ventilator for damage and whether it is working correcily rotation and repair or replace if necessary Check the axial ventilator and weather proof cover for dirt and clean if necessary Check the function of the overtemperature warning system by opening the sensor path Page 34 of 39 8000043213 BAL Compact Station TKS CS Operating Instructions AE G POWER SOLUTIONS Annually Measuring and monitoring devices must comply with the VDE 0413 standard Check and calibrate all measuring instruments Check that the equipment as a whole is in perfect working order Check housing and roof structure for damage Check line connections for dirt and corrosion Check protective covers for damage and check their fastenings Check all input monitoring and output values in the equipment and also in interaction with the external control system Check the control behaviour of the equipment and readjust correct or change the limit values if required Check the function of the peripheral connections i e all connections of the various accessory sy
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