OPERATING INSTRUCTIONS PROTECT PV.xxx-MH Solar Inverter with Metal Housing Medium Voltage AEG Power Solutions GmbH, Warstein-Belecke Department: PS AE Revision: 04 Revision date: 15/11/2013 / Hagelstein Released: 15/11/2013 / Langer Document no.
Protect PV.500/630-MH - Operating Instructions Revision Service Page 2 of 45 Status Revision Date Name 01 New edition 31/07/2012 Hagelstein 02 Corrections (pages 7, 10, 13) 15/10/2012 Hagelstein 03 Correction (pages 37/38) 30/10/2012 Hagelstein 04 supplementing PV.
Protect PV.500/630-MH - Operating Instructions Table of Contents 1 1.1 1.2 1.3 General Information .................................................... 5 Validity .......................................................................... 5 Appropriate Use ............................................................ 5 List of Abbreviations ...................................................... 5 2 2.1 2.2 Safety ...........................................................................
Protect PV.500/630-MH - Operating Instructions 10.3 10.3.1 10.3.2 10.3.2.1 10.3.2.2 10.3.2.3 10.3.2.4 10.4 10.5 Repairs........................................................................ 34 Testing after Repairs ................................................... 35 Exchanging Work ........................................................ 35 Exchanging the Door Stops ......................................... 35 Exchanging the LVMD Service Flap Opener ............... 36 Exchanging the Waste Air Duct ..
Protect PV.500/630-MH - Operating Instructions 1 General Information 1.1 Validity 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. 1.2 Appropriate Use The Protect PV.
Protect PV.500/630-MH - Operating Instructions 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. suitable locking systems should be installed by the owner in all MH stations. 2.
Protect PV.500/630-MH - Operating Instructions 3 Scope of Delivery Check that the following components have been delivered with the equipment: • 1x Protect PV.500/630-MH consisting of: − Metal housing with built-in Protect PV.
Protect PV.500/630-MH - Operating Instructions 4 Equipment Specifications 4.1 Type Designation Protect PV.690-MH-Vx-GER-x x = option GER = state/region/standard Vx = version (optional) MH = with metal housing 690 kW = nominal AC output PV = photovoltaik series Protect = AEG family Table 1 - Type designation in accordance (example) The type designation of the inverter can be found in the BAL Protect PV.500 or PV.6x0/8x0. 4.2 Design The Protect PV.
Protect PV.500/630-MH - Operating Instructions 4.3 Dimensions 2 1 3 4 5 Figure 2 - Metal housing top view Item Dimension MH height with roof [mm] 2791.0 1 MH depth (roof) 1114.0 (1301.3) 2 MH width (roof) 3000.0 (3178.5) 3 DC cable feed-through 600 x 100 4 AC cable feed-through 440 x 100 5 Total depth when door is open 2570.0 Weather protection grid depth 76.0 Table 2 - Dimensions 4.
Protect PV.500/630-MH - Operating Instructions 4.5 Low-Voltage Main Distributor The low-voltage main distributor (LVMD) is located on the righthand side of the metal housing. 1 2 3 4 5 6 7 Figure 3 - Low-voltage main distributor PV.630-MH 1 Ethernet connection 2 Power supplies 3 Additional emergency shutdown equipment 4 Modbus connection 5 Load interrupter switch Q26.n 6 AC connections to transformer 7 PE conductor The LVMD must always be kept closed during operation.
Protect PV.500/630-MH - Operating Instructions Functional Description PV.IcX PV.SuN max. 1 to 8 optional TKS-CS.1000 PV.LoG-MH PV.IcX Transformer TransformerMonitoring max. 1 to 8 PV.500-MH = ~ PV.500-MH = PV.IcX PV.SuN max. 1 to 8 optional Transfer station Radio and ripple control / power utility interface ~ TKS-CS.500 4 x relay Energy meter Switchgear PV.ControL PV.LoG-MH Transformer Internet connection TransformerMonitoring 5 CAN bus, max. 2 x 500 m FO, ring max.
Protect PV.500/630-MH - Operating Instructions 6. Transport The Protect PV.xxx-MH consists of a compact housing which can be transported by a forklift truck or crane and suitable loadcarrying equipment (traverse cross bars or crane grabs). Select lifting gear and load-carrying equipment according to the weight of the equipment ( Technical Data). 6.1 Transport Securing Device i Never lift the equipment by the transport securing device.
Protect PV.500/630-MH - Operating Instructions 6.2 Crane Transport DANGER Suspended loads during transport Possibility of death or crushing. Select lifting gear according to the total weight to be transported. Do not step under suspended loads. Secure the danger zone. Wear personal protective equipment. Figure 6 - Crane transport with special traverse cross bar Special traverse cross bars are used for transporting the Protect PV.xxx-MH by crane.
Protect PV.500/630-MH - Operating Instructions 6.3 Transport by Industrial Trucks DANGER Toppling of cargo during transport by industrial trucks Possibility of death or crushing. Lift cargo under its centre of gravity. Secure the cargo and danger zone. Wear personal protective equipment. Figure 7 - Transport by industrial trucks The base structure includes openings for loading forks; these match up with the MH station's centre of gravity.
Protect PV.500/630-MH - Operating Instructions 7 Assembly DANGER Suspended loads during transport Possibility of death or crushing. Select lifting gear according to the total weight to be transported. Do not step under suspended loads. Secure the danger zone. Wear personal protective equipment. 7.1 Foundation The Protect PV.xxx-MH requires a frost-proof foundation with a min. depth of 80 cm.
Protect PV.500/630-MH - Operating Instructions 7.2 MH Station Before assembling the MH station, lead the cables to the installation location on the DC and AC sides and position them within the foundation so that they are ready to enter the station. 1 2 3 4 Figure 9 - Cable feed-throughs 1 Base structure 2 MH floor 3 DC cable feed-through 4 AC cable feed-through When setting down the MH station, feed in the cables and avoid crushing them under the base structure.
Protect PV.500/630-MH - Operating Instructions Unscrew and remove the screws that are already there, position the assembly brackets so that they are flush and screw them in place using the relevant tightening torque. Figure 11 - Hole for heavy-duty dowel Drill the holes for the heavy-duty dowels in the completed foundation. The distance between the holes and the edge is specified by the manufacturer of the heavy-duty dowels.
Protect PV.500/630-MH - Operating Instructions 7.3 Installation WARNING Hinge side of the door when closing Fingers or hands may be crushed. Do not hold the hinge side of the door. Take care while closing the cabinet door. i 7.3.1 Observe the bending radius of the supply lines. With one bend: bending radius = 10 x diameter of supply line. DC Connections Establish the combiner boxes (PV.IcX/ArrayGuard) DC connections in the Protect PV.500/630 DC/AC cabinet ( Operating Instructions Protect PV.500 or PV.
Protect PV.500/630-MH - Operating Instructions The opening lever for the LV main distributor is accessible when the door to the inverter is open. Insert the AC power connections from below and screw them to the cable lug using the relevant tightening torque. 1 2 3 4 5 6 1 2 3 4 Figure 13 - PV.630-MH low-voltage connections 1 Connection L1 - X26:U 2 Connection L2 - X26:V 3 Connection L3 - X26:W i 4 Connection - X26:PE 5 Load interrupter switch Q26.
Protect PV.500/630-MH - Operating Instructions 7.3.3 Power Supply 1 2 Figure 14 - Power supply 1 X11:L, N, PE - 230 V AC power supply 2 X13:L, N, PE - Auxiliary power supply max. 400 W The Protect PV.xxx-MH has a power supply for supplying internal loads (fans) and an auxiliary power supply for the control unit. Power is supplied from a second circuit or internally via the X3 connection (grid).
Protect PV.500/630-MH - Operating Instructions 7.3.4 Communication Interfaces The Protect PV.xxx-MH has a variety of interfaces for monitoring and control. Data is exchanged with the PV.LoG via the Ethernet/COM server and Modbus/RS485.
Protect PV.500/630-MH - Operating Instructions 7.4 Tightening Torques for Screw Connections Mechanical connection Electrical connection Cheese head screw, strength category 5.8 Hexagon screw, strength category 8.8 [Nm] [Nm] [Nm] Slotted cheese head screw DIN 84 with slot [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.
Protect PV.500/630-MH - Operating Instructions 8 Start-up DANGER Working with voltages up to 1 kV Risk to life due to electric shock. Comply with BGV A3, DIN VDE 0105-100 (EN 50110, IEC 61243). Skilled personnel with a Working with Live Current certificate. i The electrical equipment must not be started up/operated if there are any traces of condensation. Starting up the Protect PV.
Protect PV.500/630-MH - Operating Instructions 10 Maintenance DANGER Contact with voltage Risk to life due to electric shock. Press emergency off. Move the victim away from live parts using dry insulating material. Get medical help and inform the control room. Disconnect the equipment safely. DANGER Working with voltages up to 1 kV Risk to life due to electric shock. Comply with BGV A3, DIN VDE 0105-100 (EN 50110, IEC 61243). Skilled personnel with a Working with Live Current certificate.
Protect PV.500/630-MH - Operating Instructions CAUTION Insufficient ventilation of equipment Equipment may overheat. Keep air vents clear. Ensure the equipment is sufficiently ventilated. WARNING Heat generation in resistors Risk of burning. Do not touch hot components. WARNING Hinge side of the door when closing Fingers or hands may be crushed. Do not hold the hinge side of the door. Take care while closing the cabinet door.
Protect PV.500/630-MH - Operating Instructions The owner is responsible for correct maintenance 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 maintenance work should be carried out based on the maintenance schedule. Regular maintenance reduces the risk of breakdowns and disruption due to technical faults.
Protect PV.500/630-MH - 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 Service work and Inspection 10.2.1 Visual Inspection Visual inspections should be carried out in accordance with DIN EN 13018.
Protect PV.500/630-MH - Operating Instructions The log for dry-cleaning low-voltage installations using a vacuum cleaner 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. Cleaning the heat sink 1 2 2 3 4 4 3 Figure 16 - Protect PV.
Protect PV.500/630-MH - Operating Instructions 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.
Protect PV.500/630-MH - Operating Instructions 10.2.5 Care 10.2.5.1 Lubrication Carry out the following care measures for the station: • Lubricate hinges, rods and guide rails after cleaning. • After cleaning rubber door seals, rub lightly with a rubber care product such as deer tallow. • Clean weather protection grid seals and rub with a rubber care product. When dismantling the weather protection grid, carry out care measures for the entire seal. 10.2.5.2 Replacing Filter Mats (PV.
Protect PV.500/630-MH - Operating Instructions 10.2.5.3 Replacing Filter Mats (MH) 1 2 3 3 4 Figure 18 - Filter mat in MH station 1 Filter mat insert 2 Filter mat 3 Screw fastening M5 x 12 Clean and replace air filter mats according to the pollution degree; however, this must be done at least one a year in accordance with DIN EN 779. 1. Unscrew the filter mat insert from the inside. 2. Remove the old filter mat and screw in the new one. 3. Screw the filter mat insert back on. 10.2.5.
Protect PV.500/630-MH - Operating Instructions Sealing profile 1 Selected material for sealing profile Sponge rubber (EPDM) black (rubber section EPDM 65° ± 5 Shore A) Sponge rubber (NBR) black (rubber section NBR 60° ± 5 Shore A) Sealing profile 2 Selected material for sealing profile Sponge rubber (EPDM) black (rubber section EPDM 65° ± 5 Shore A) 10.2.5.
Protect PV.500/630-MH - Operating Instructions 1. Unscrew screw connections and lift out the service flap by the handles. 2. Remove the old sealing profile. Clean the area and insert the new profile. Starting halfway up, attach sealing profile 2 all the way round. 3. Reattach the service flap. 10.2.5.6 Replacing the Battery (PV.xxx) The 3 V Li-battery on PCB A17 should be replaced as a precaution after around 10 years, as it is exposed to thermal loads. 10.2.5.7 Replacing Radial Ventilators/Fans (PV.
Protect PV.500/630-MH - Operating Instructions 7. Disconnect and remove the connection cables from the ventilator. 8. Clean the inside of the ventilation duct. Clean the cooling fins of the IGBT inverter stacks with compressed air. Installation is the same procedure in reverse. Switch on the equipment and test whether the ventilator is working. Removing and installing radial fans M2 and M3/4: Fans M2 and M3/4, and their corresponding connectors, are located on the INV cabinet roof. 1.
Protect PV.500/630-MH - Operating Instructions 10.3.1 Testing after Repairs Each time the equipment is repaired or modified, all recurrent tests/measurements are to be carried out and documented in accordance with DIN VDE 0105 once the work is complete. 10.3.2 Exchanging Work 10.3.2.
Protect PV.500/630-MH - Operating Instructions 10.3.2.2 Exchanging the LVMD Service Flap Opener 1 2 3 4 Figure 23 - LVMD opener 1 Opening lever 2 Screw connection 3 LVMD service flap 4 Release mechanism The LVMD service flap opening lever reduces the frame width by about 42 mm. For this reason, the lever should be dismantled as a precaution when replacing the PV.xxx. To do this, the two M5 x 20 countersunk screws and the lever must be removed. Installation is the same procedure in reverse. 10.3.2.
Protect PV.500/630-MH - Operating Instructions 1. Open the service flap from the rear. 2. Remove the air baffle by unscrewing all M5 x 12 hexagon screws from the waste air duct (on the side) and the INV control cabinet (rear wall) and removing the plate. 1 2 3 4 Figure 25 - Waste air duct from the front 1 Detailed view of connection from front 2 Screw connection M16 x 40 3 Waste air duct 4 Service opening 3. Unscrew the M16 x 40 hexagon screws from the PV.
Protect PV.500/630-MH - Operating Instructions 3. Remove DC connections and PE cables. 4. Remove PV.xxx-ID AC connections and PE cables in the lowvoltage main distribution (top). 5. Disconnect and remove the power supply, emergency shutdown and communication connections from the PV.xxx-ID. 6. Secure the cables in the equipment. 1 2 3 Figure 27 - Dismantling the Protect PV.
Protect PV.500/630-MH - Operating Instructions 10.4 Period Schedule The period 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. i 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.
Protect PV.500/630-MH - Operating Instructions Every 6 months Clean radial ventilators/fans. (Do not use any cleaning products containing acids, bases or solvents or water jets/pressure washers when cleaning). Check the function of the heating devices (BG20) in the DC/AC and INV control cabinet, especially before cold spells. No condensation may be present in the equipment during operation. Check the function of the overtemperature warning system by opening the sensor path.
Protect PV.500/630-MH - Operating Instructions 10.5 Storing Spare Parts i When ordering spare parts, you must provide the component designation, installation location and component number as well as the unit number of the Protect PV.xxx-ID. AEG PS recommends that you have the following spare parts available: Item Component F41.x DC input fuses, l.v. h.b.c. fuse L2-2 1200 V A12, A13 (optional) Remote signalling P8 - CCC A91.
Protect PV.500/630-MH - Operating Instructions 11 Decommissioning and Dismantling The Protect PV-xxx-MH can be decommissioned or dismantled for the purposes of changing its location or disposal. Before beginning any work on the equipment, it must be deenergised. 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. 2. Secure the equipment against being switched back on. 3.
Protect PV.500/630-MH - Operating Instructions DANGER Toppling of cargo during transport by industrial trucks Possibility of death or crushing. Lift cargo under its centre of gravity. Secure the cargo and danger zone. Wear personal protective equipment. Attach suitable load-carrying equipment to the Protect PV.xxxMH. Disconnect the housing assembly brackets from the foundation. Lift the equipment carefully and remove cables. 11.3 Disposal 11.3.
Protect PV.500/630-MH - Operating Instructions 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 insulating materials should be disposed of as industrial waste and should be recycled.
Protect PV.500/630-MH - Operating Instructions List of Tables Table 1 - Type designation in accordance (example) ............................... 8 Table 2 - Dimensions ................................................................................. 9 Table 3 - Connection terminals, MH (example) ....................................... 10 Table 4 - Tightening torques .................................................................... 22 Table 5 - Plugs for fan monitoring ...................................
