Energized by AEG Power Solutions Solarinverter Protect PV.
Operating Instructions Maintenance and Servicing Installation Instructions and Start-Up Single-line Diagram Outline Drawing Connection Diagram Technical Data Sheet
Operating Instructions Protect PV.500 AEG Power Solutions GmbH, Warstein-Belecke Department: PS AE Revision: 01 Revision date: 28.06.2011/Schenuit Approved: 30.06.2011/Gleitsmann Document no.
Protect PV.500 Operating Instructions Fax: e-mail: Internet: 2 of 70 AEG Power Solutions GmbH Emil-Siepmann-Strasse 32 59581 Warstein Germany +49 2902 763 100 +49 2902 763 645 service.aegpss@aegps.com http://www.aegps.
Protect PV.500 Operating Instructions Table of Contents 1 1.1 1.2 1.3 1.3.1 1.3.2 1.4 Information on How to Use these Instructions...............6 General Information.............................................................6 Target Groups .....................................................................7 Explanations of Target Groups............................................7 Obligations of the Equipment Operator ...............................7 Skilled Personnel Skills and Training ............
Protect PV.500 Operating Instructions 5 5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.1.6 5.1.7 5.1.8 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.3 5.3.1 5.3.2 4 of 70 5.3.3 5.3.4 5.3.5 5.4 5.5 5.5.1 5.5.2 5.5.3 5.5.4 5.5.5 System Function .............................................................26 Description of Sequence Control.......................................26 The "OFF" Status ..............................................................26 The "Waiting for Feed Conditions" Status .........................
Protect PV.500 Operating Instructions 7 Interfaces .........................................................................44 7.1 Communication Interface ..................................................44 7.1.1 General..............................................................................44 7.1.2 Technical Data ..................................................................45 7.1.3 Structure of the MultiCom CCC Interface ..........................46 7.1.4 Configuration ........................
Protect PV.500 Operating Instructions 1 Information on How to Use these Instructions This chapter contains general information about these instructions and the people they are intended for. The Protect PV.500 with two control cabinets (+DCD/ACD, +INV) is referred to as 'equipment' in the rest of the instructions. The precise name (PV.500) cannot be avoided in some situations and here the equipment is referred to as the PV.500 equipment or the individual control cabinets are mentioned. 1.
Protect PV.500 Operating Instructions Handling These instructions are structured so that all work necessary for operation can be performed by appropriately qualified personnel. Illustrations are provided to clarify and facilitate certain steps. If danger to personnel and equipment cannot be ruled out in the case of certain work, it is highlighted accordingly by pictograms explained in chapter 2, Safety Regulations. 1.
Protect PV.500 Operating Instructions To ensure the safety of the equipment, the equipment operator must: Î Only operate the equipment in perfect working order and in accordance with good electrical engineering practice Î Arrange a fault detection check immediately if the equipment starts to behave differently Î Keep all safety signs and warning notices on the equipment in a complete and clearly legible condition Î Install fire extinguishers in the immediate vicinity of the equipment 1.3.
Protect PV.500 Operating Instructions Obligations of skilled personnel Observe the following safety instructions. Î Work on and in electrical equipment is governed by strict rules in order to avoid electrical accidents. The rules are summarised in the five rules of safety. You must observe these rules: 1. Disconnect safely. 2. Secure the unit against being switched back on. 3. Verify that all poles are de-energised. 4. Earth and short-circuit the equipment. 5.
Protect PV.500 Operating Instructions 2 Explanation of Symbols and Safety Instructions All of the symbols and abbreviations used in the text are described below. 2.1 Explanation of Symbols This section describes the symbols used in these instructions. Symbol Meaning Hazard symbols are triangular and feature a yellow background, black border and corresponding symbol. Signs containing orders are round and have a blue background with a white symbol. i Information is indicated by the letter i.
Protect PV.500 Operating Instructions 2.2 Safety Instructions All safety instructions have the following structure: SIGNAL WORD Type and source of hazard Consequence(s) of noncompliance Symbol Figure 1 2.2.1 Î Measure(s) to avoid hazard. Warning associated with operator action Signal Words Used Signal words at the start of safety instructions indicate the type and severity of the consequences if the measures for avoiding the hazard are not taken.
Protect PV.500 Operating Instructions 2.2.3 Signs Containing Orders for Personal Protective Equipment The following signs relate to the use of personal protective equipment. You are required to comply with them. Symbol Meaning for skilled personnel Wear a face shield. Wear an electrician's safety helmet. Wear insulating safety boots. Wear insulating overalls. Wear insulating gloves with long sleeves Wear hearing protection when operating the equipment.
Protect PV.500 Operating Instructions 2.2.
Protect PV.500 Operating Instructions All necessary operational measures must be initiated prior to deactivating any safety device in order to perform maintenance, repair or any other work on the unit. Safety awareness also entails informing colleagues of any unsuitable behaviour and reporting any faults detected to the appropriate authority or person.
Protect PV.500 Operating Instructions System stop switch The system stop switch is on the door of the equipment's DC/AC control cabinet. The system stop switch is not intended for switching off the equipment. It may only be used in an emergency. The DOU is used, amongst other things, to switch the equipment on and off. The system stop switch causes the - PV inputs - mains input and - mains 2 input to be separated. This interrupts the energy supply. It does not mean that the unit has been de-energised! 2.
Protect PV.500 Operating Instructions 2.7.2 Lockable Equipment Doors The equipment doors are fitted with a control cabinet lock. This prevents unauthorised personnel from accessing the equipment. Equipment doors must be kept locked at all times. It may be opened for maintenance and repair work. i The space requirement for the opened equipment doors must be taken into account Equipment doors must be locked again once maintenance and repair work is complete. 2.7.
Protect PV.500 Operating Instructions 2.8.1 Electrical Hazards DANGER Contact with voltage! Risk to life due to electric shock. Î Use dry insulating material to remove the victim from the live parts. Î Seek medical assistance and inform the control room. Î Disconnect the equipment safely. DANGER Electric shock after activating "System stop"! Parts of the equipment remain live after "System stop" has been activated (e.g. external voltage present at remote signal terminals).
Protect PV.500 Operating Instructions i Using residual-current-operated safety devices alone is not permitted. Water in electrical equipment! Risk to life due to electric shock! Î Do not use water to clean the cubicles Î Do not place any vessels containing fluids on electrical equipment 2.8.2 Risks Due to Movable Components CAUTION Risk of injury due to rotating fans! The fans of the INV control cabinet are freely accessible. Î Never reach into rotating fans.
Protect PV.500 Operating Instructions ATTENTION Failure of the display and operation unit If the display and operation unit fails, the skilled personnel will no longer be able to control the equipment. In such an event, malfunctions will no longer be displayed. Î Inform the control room. 2.8.5 Risks from Maintenance and Repair Work i Only trained and qualified skilled personnel (as described above) may work on or around the equipment while strictly observing the safety regulations.
Protect PV.500 Operating Instructions 3 Product Details The equipment has been designed for solar power plants and provides professional solutions for the use of installations covering large roofs or in open spaces. 3.1 Product Description The equipment is a solar inverter (INV) that feeds the electrical energy produced by the PV cells into a medium-voltage mains (e.g. 10 kV; 20 kV; 33 kV). The required mains transformer is not supplied with the unit and can be ordered as an extra if necessary.
Protect PV.500 Operating Instructions 3.2 Dimensions and Views 2070 2700 11,5 1200 925 660 625 600 1500 600 Figure 3 3.3 Dimensions and views Appropriate Use Only operate the equipment with the maximum permissible connection values stated in the technical data sheet. Any other use or modification constitutes inappropriate use. Unauthorised repairs, manipulations or changes made to the equipment and its safety devices without the manufacturer's approval are not permitted.
Protect PV.500 Operating Instructions 3.4 Inappropriate Use No liability is accepted if the equipment is used for applications not intended by the manufacturer (= inappropriate use). Inappropriate use can cause serious or fatal personal injury. The responsibility for any measures necessary for the prevention of personal injury or damage to property is borne by the equipment operator or user. 3.5 Standards, Directives and CE Mark The equipment complies with currently applicable DIN and VDE regulations.
Protect PV.500 Operating Instructions Technology Due to the utilisation of high-performance electronic components, the equipment boasts a very high degree of operational reliability, is extremely efficient and is characterised by its versatility in communicating with other systems by means of interfaces. The entire control electronics system for the equipment is based on the use of microcomputer assemblies.
Protect PV.500 Operating Instructions The main assemblies of the inverter are: • DC load interrupter switch Q4 • Inverter stack, display and control unit with communication components • AC filter • Inverter output contactor K7 • Mains transformer (external) • Mains disconnector Q26 (external) The PV cells supply the INV stack with DC voltage via DC load interrupter switch Q4. The INV stack converts this DC voltage into a 3-phase AC voltage.
Protect PV.500 Operating Instructions 4 System Description This chapter describes the operating modes and functions of the equipment. 4.1 Operating Modes Two different operating modes may be used: • Individual operation • Compain operation 4.1.1 Individual Operation In individual operation, the inverter works independently and is not connected to any other inverters. The DC infeed from the PV cells and the link to the AC mains are only connected to this inverter.
Protect PV.500 Operating Instructions 5 System Function 5.1 Description of Sequence Control As soon as the equipment's control module is supplied with voltage, sequence control starts. Initially, the load interrupter switch Q4 remains open. Once the initialisation phase is complete and if no deactivating faults are pending, the load interrupter switch Q4 is closed. During subsequent operation, the switch is only opened by deactivating faults (Æ chapter 6).
Protect PV.500 Operating Instructions In this status, no power is fed into the mains. Possible change of status: If the DC voltage rises above a certain value for a certain time and the mains voltage and mains frequency are within a certain range, the unit switches to the "Operation" status. An attempt to start up is made which involves switching on the inverter stack.
Protect PV.500 Operating Instructions The status can be switched from "Operation" to "OFF" using the "Off" control command. 5.1.5 The "Fault" Status If a deactivating or self-acknowledging fault is triggered (Æ chapter 6), the equipment switches to the "Fault" status. The monitoring parameters values are checked regularly. In this status, no power is fed into the mains.
Protect PV.500 Operating Instructions If the DC voltage continues to increase due to the sun's rays getting stronger and the mains voltage and mains frequency are within acceptable limits, a start-up attempt is made. During a startup attempt, the inverter stack is switched on, thereby drawing power from the DC voltage that is present. The inverter output contactor K7 is open during a start-up attempt.
Protect PV.500 Operating Instructions 5.1.8 Sequence Control Parameters Switch-on conditions: Underfrequency, overfrequency, undervoltage, overvoltage: The equipment will only switch from the "Waiting for feed conditions" status to the "Operation" status if the feed conditions are met. These conditions include the mains voltage and the mains frequency. These values must be within certain limits described by the switch-on conditions.
Protect PV.500 Operating Instructions 5.2 Description of Fan Control 5.2.1 General The equipment features temperature-dependent fan control. The fans are either switched off, run on a fast or slow fan stage (cabinet fan only) or are gradually speeded up or slowed down (stack fan only). Fan control: • Extends the operating time of the fans • Minimises the noise generated by the fans • Improves the efficiency of the equipment by reducing its power consumption 5.2.
Protect PV.500 Operating Instructions 5.2.3 Cabinet Fan Control Parameters Unit exhaust air temperature limit value for switching on the fan: If the highest exhaust air temperature rises above this limit value, the fans which were switched off are switched to the fast fan stage. Unit exhaust air temperature limit value for switching off the fan: If the highest exhaust air temperature falls below this limit value, the fans which were running in the slow fan stage are switched off.
Protect PV.500 Operating Instructions Initialisation Maximum speed, minimum time! Minimum time elapsed Variable speed depending on IGBT temperature IGBT temperature > limit value IGBT temperature < limit value Fan switched off Figure 8 5.2.5 Fan control Parameters of INV Stack Fan Control IGBT temperature limit value for switching off the fan: If the highest IGBT temperature falls below this limit value, the fan is switched off.
Protect PV.500 Operating Instructions Sequence control behaviour differs depending on which solar cells are connected. The solar cells do not need to be earthed for operation with monocrystalline or polycrystalline solar cells. In this case, insulation measurement is always active. For operation with thin-film solar cells, the solar cells have to be earthed. In this case, insulation measurement is not active during earthing. Insulation measurement sequence control features a "Maintenance mode".
Protect PV.500 Operating Instructions Maintenance mode: Maintenance mode can be triggered either via a command or by means of remote signalling. Active earthing switches off immediately when maintenance mode is activated. However, the digital and analogue signals from the isometer continue to be ignored. Active earthing is switched on again the next time a switch is made to the "Operation" status. However, the unit remains in maintenance mode for at least a certain time; i.e.
Protect PV.500 Operating Instructions 5.4 MPP Tracker In the "Operation" status (see chapter 5.1.3), the inverter detects the maximum power point (MPP) of the PV cells. The MPP tracker detects the point at which the solar cells give off maximum power. This enables the equipment to achieve optimum efficiency. Figure 9 5.5 MPP performance curve Compain Operation In "compain operation", the efficiency of a system with two inverters can be increased by connecting the two PV panels at less than full power.
Protect PV.500 Operating Instructions Change of status to single operation: If capacity utilisation in the inverter which is switched on rises above a certain value, once a delay has elapsed, the two inverters are switched to single operation. First, the inverter which is switched on is switched off. Then, the tie switch is opened. Once the tie switch is open, both inverters are switched on.
Protect PV.500 Operating Instructions First, the inverter which is not affected by the fault is also switched off. The DC voltage is then checked. When the DC voltages are approximately identical, the tie switch is closed and the inverter which is not affected by the fault is then switched back on. If the DC voltages are still not the same once a certain time has elapsed, the inverter which is not affected by the fault is switched back on.
Protect PV.500 Operating Instructions Evening: Levels of insolation fall during the course of the day. The capacity utilisation at which the two inverters are working drops as a result. If the capacity utilisation of the two inverters falls below a certain value, the system switches to linked operation. The tie switch is closed and one inverter is switched off logically. "Linked operation" is active. Later in the evening: Levels of insolation fall further. Capacity utilisation drops as a result.
Protect PV.500 Operating Instructions 6 Monitoring Systems, Messages and Faults 6.1 General All monitoring systems only generate fault messages when the inverter is switched on; when it is switched off, the inverter is always reported as being free of faults. A distinction is made between deactivating, self-acknowledging and signalling faults. Deactivating faults switch the equipment off permanently. K7 and Q4 are opened. The fault can be acknowledged manually or by switching the unit off and on.
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Protect PV.500 Operating Instructions 7 Interfaces PV power stations are usually monitored from a central location. Alongside the PV cells, the inverter is a key component of a power station, which is why several communication interfaces are available as standard. These include relay contacts and optocouplers, as well as various serial interfaces with protocols for integration into higher-level monitoring systems.
Protect PV.500 Operating Instructions 7.1.2 Technical Data MultiCom CCC hardware data (assembly A29.1) Connector : RS485 connection: Distance: Bus stations: Data line: Port 1 RS232 for configuration and COM server connection X2: 9-pin D-sub (socket; insulated) Port 2 RS232/RS485 for Modbus X5: 9-pin D-sub (socket; insulated) Twisted pair with Data+, Data-, shielded, shield attached on one side 1200 m max. at 9600 baud Max. 32 Shielded 1:1 data line (2 x 0.22; twisted pair), e.g.
Protect PV.500 Operating Instructions 7.1.3 Structure of the MultiCom CCC Interface RS485: RS232: 1 J1 J4 1 1 X1 J5 X5 1 rt gn LED X3 1 1 B A B A X4 1 S1 X2 1 Modbus Configuration Figure 13 MultiCom CCC interface as a Modbus interface (top view) Connections: X1: Internal inverter bus and power supply X2: Potential-free RS232 serial interface X3: Triggering of "Remote signalling" X4: A remote panel can be connected to this potential-free CAN interface.
Protect PV.
Protect PV.500 Operating Instructions Pin number Signal Description 3 B High data 8 A Low data Housing INV housing potential Please use a shielded fieldbus cable as the line, e.g. 2 x 0.22 twisted pair Lapp "UNITRONIC-BUS LD". Please connect the RS485 bus line via the bus interface connector supplied. In an RS485 network, the ends of the bus must always be terminated. If necessary, insert the 120 Ohm resistor supplied between connections A and B.
Protect PV.500 Operating Instructions The X5 interface can be switched from RS485 to RS232 using jumpers J4 and J5. The factory setting is RS485, i.e. all jumpers are inserted at J4. You have the option of switching the interface to RS232 by reconnecting all jumpers to J5.
Protect PV.500 Operating Instructions Kabel/Cable 19,5 12 9,5 Figure 17 Shield connection 7.1.4 Configuration The communication interface does not have to be configured in order to connect the PV inverter to the data logger system of the AEG "PV.LoG". Once the bus cable has been installed and the system has been powered up, the configuration settings are made fully automatically.
Protect PV.500 Operating Instructions Figure 18 Main menu If the configuration does not start, you must wait for 10 seconds and then repeat the procedure. Make sure that no data is received via the X2/X5 interfaces during this time. Press one of the following keys in the main menu: • to save all settings, finish the configuration and activate the MultiCom interface.
Protect PV.500 Operating Instructions 7.1.4.2 Configuring the Modbus Protocol To access the X5 data protocol configuration, you must press <4>in the main menu: Figure 19 Data protocol configuration menu Press one of the following keys in the "X5 Data Protocol" menu: • to configure the Modbus protocol • to apply all settings. The configuration is finished and the main menu is opened again. • to cancel the configuration. This opens the main menu.
Protect PV.500 Operating Instructions 7.1.4.3 Configuring Modbus Data Transmission To access the X5 data transmission configuration, you must press <2> in the main menu: Figure 21 Modbus/JBus data transmission configuration menu Press one of the following keys in the "X5 Data Transmission" menu: • <1-7> to set the baud rate • to set the parity • <8,9> to set the number of stop bits • to apply the settings. The configuration is finished and the main menu is opened again.
Protect PV.500 Operating Instructions 7.2 COM Server 7.2.1 General The COM server makes the PV inverter data available via an Ethernet network. A software application can communicate with the PV inverter via the network using a virtual COM port (this needs to be installed on a workstation). The COM server is installed as standard and is used by the AEG service department for remote maintenance purposes.
Protect PV.500 Operating Instructions Connections: CN1: Internal inverter bus and power supply MOD1: Ethernet connection CN5: Interface for firmware update Configuration jumpers: CN3: All closed (default) LED signals: Green LED (H1): The green LED on the assembly indicates the global status of the assembly.
Protect PV.500 Operating Instructions 7.2.5 Network Integration Configuration For network integration, you will need free IP address for the COM server, the subnet mask plus the IP address for the gateway. This information can be obtained from your administrator if necessary. • Start the "Digi Device Discovery" tool. • The tool searches the network for Digi modules. The modules found are displayed. If several units are found, please select the unit to be configured using the MAC address.
Protect PV.500 Operating Instructions 7.3 Remote Signalling The remote signalling board is a contact interface for signalling PV messages and controlling PV units. It is supplied as an option for the AEG PV system and is intended for installation in the PV unit. The remote signalling master board consists of 5 potential-free signalling contacts and one control input. There is an independent 24 VDC power supply for the control input. The control signal is activated by bridging the relevant input.
Protect PV.500 Operating Instructions X3: When a signal is received, the contact between the two contact points with the lower numbers is closed (normally open or "NO"). X4: When a signal is received, the contact between the two contact points with the lower numbers is opened (normally closed or "NC"). X5: The control signal is active when the input is bridged (normally open). The inverter is switched off. The following default signals are used for remote signalling: X3.1-2 3 Inverter feed operation X3.
Protect PV.500 Operating Instructions 8 Graphical Display and Operation Unit 8.1 General The graphical Display and Operation Unit (DOU) is integrated into the front of the solar inverter. It is used to signal and visualise unit data and to control the inverter system. The DOU consists of a display unit with 3 LEDs, a graphical LCD and an operating panel with 5 keys. The global unit status can be read from the 3 LEDs. An acoustic signal generator stresses the urgency of critical equipment statuses.
Protect PV.500 Operating Instructions 8.1.1 Signalling LEDs: Red, permanently ON: Deactivating fault (must be acknowledged via the menu) Red, flashing: Self-acknowledging deactivating fault Yellow, flashing: Self-acknowledging messages Green OFF: INV in sleep mode Green, flashing (1 Hz): INV waiting for feed conditions Green, flashing (0.
Protect PV.500 Operating Instructions Possible keyboard symbols and their function: Switch off inverter Switch on inverter Acknowledge acoustic signal generator Cursor up/Increase value/Scroll upwards Cursor down/Decrease value/Scroll downwards Cursor to the right Cursor to the left Status/Measured values menu System is blocked Acknowledge fault Select day/month/year curve Help menu No function Figure 24a 8.2 Keyboard symbols Start-up Following the power-up reset, the DOU performs a self-test.
Protect PV.500 Operating Instructions 8.3 Menu Structure 8.3.
Protect PV.500 Operating Instructions The "main menu" has the typical menu structure. Additional submenus are displayed on the left-hand side. All selectable submenus are shown in a frame. A black background indicates the current cursor position. The bottom line displays the current real time, which can be adjusted in the "Settings" menu. On the right-hand side, the current key function is represented as a symbol inside a small framed area.
Protect PV.500 Operating Instructions At the top, a sun symbol indicates the current solar radiation trend. If the sun is black or a moon symbol is displayed, the PV voltage is so low that the inverter is in its idle state. An empty sun with no rays also indicates that the PV voltage is still too low, with the inverter in standby mode. The inverter is represented in the middle of the left-hand section. If a fault occurs or a message is present, the corresponding symbols flash on the inverter.
Protect PV.500 Operating Instructions Figure 31 Solar radiation is too low, the inverter is in standby mode. Figure 32 Solar radiation is too low, the inverter is in its idle state. The middle section displays the unit's most important infeed values in the form of digital values and a graph covering a certain period of time. The current daily data is shown as standard. This display appears automatically if no keys have been pressed for 1 minute.
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Protect PV.500 Operating Instructions Figure 37 Yearly overview (t = year of start-up to current year) The right-hand side shows how the key is currently assigned. Figure 38 Operating display – Right-hand side Here you can switch the inverter on or off, depending on the unit status. If the operation has been blocked, this is indicated here via a key symbol. If a blank button is shown here, a fault is present.
Protect PV.500 Operating Instructions 8.3.4 Status/Measured Values You can call up the "Status/Measured values" menu from the operating display using the bottom key with the measuring instrument symbol. Here you can use the "<", ">", "^" and ENTER keys to open the submenus containing the statuses and measured values for the individual unit components. Press the ENTER key to return to the Status/Measured values menu.
Protect PV.500 Operating Instructions -- Iverter-Status -Grid operation MPP -- Inverter-data -UL12-31.[V]: 270 270 270 IL1-3..[A]: 587 587 587 P....[kW]: 261 S...[kVA]: 275 Q..[kvar]: 14 cos(phi).: 275 F....[Hz]: 50.0 E...[kWh]: 937 T1...[°C]: 25.0 T2 ...[°C]: 28.0 E..[kWh]: 2089336 t ....[h]: 1262 Figure 42 Menu: Inverter The voltage and current of the three phases are displayed as measured values. The power values P, S, Q and cos-phi appear underneath these voltages and currents.
Protect PV.500 Operating Instructions 8.3.5 Blocking You can call up the "Blocking" menu from the "main menu". After you have entered the current password, you can block operation of the inverter (switching on/off and fault acknowledgement). The password must be entered digit by digit and then confirmed by pressing the ENTER key. The default password is: 1201. In menus where switching operations are normally possible, blocking is indicated by a key. 8.3.
Maintenance and Servicing Protect PV.500 AEG Power Solutions GmbH, Warstein-Belecke Department: PS AE Revision: 01 Revision date: 28/06/2011/Schenuit Approved: 30.06.2011/Gleitsmann Document no.
Protect PV.500 Maintenance and Servicing Fax: e-mail: Internet: 2 of 14 AEG Power Solutions GmbH Emil-Siepmann-Strasse 32 59581 Warstein Germany +49 2902 763 100 +49 2902 763 645 service.aegpss@aegps.com http://www.aegps.
Protect PV.500 Maintenance and Servicing Table of Contents 1 General Information ..........................................................4 2 Safety..................................................................................4 3 Product Details ..................................................................4 4 4.1 4.2 4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.4 4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.5 4.5.1 4.5.2 4.6 4.6.1 4.6.2 Maintenance and Repair ...................................................
Protect PV.500 Maintenance and Servicing 1 General Information These instructions relate to the technical specifications of the equipment at the time of publication. The contents of these instructions do not constitute subject matter of a contract, but are for information purposes only. AEG Power Solutions GmbH reserves the right to make modifications to the content and technical data in these instructions without prior notice.
Protect PV.500 Maintenance and Servicing 4 Maintenance and Repair 4.1 General Information The installed AEG Power Solutions system contains high-quality, durable parts and components, which are coordinated with one another in order to provide the best possible conditions for system operation.
Protect PV.500 Maintenance and Servicing 4.3 Inspection The system is inspected to establish its current condition; the actual content of the inspection and the intervals at which it is to be performed must be defined on the basis of the relevant installation site and operating conditions. DANGER Contact with voltage! Inspection work must sometimes be performed when the system is connected to the power supply. Risk to life due to electric shock.
Protect PV.500 Maintenance and Servicing 4.3.
Protect PV.500 Maintenance and Servicing 4.3.2 Diagnostic Functions The comprehensive diagnostic functions implemented in the system not only increase its operational reliability considerably, but also reduce the time required for maintenance work and troubleshooting to a minimum. The system is equipped with the following diagnostic functions, some of which are optional: Self-diagnosis: This is activated when the system is switched on.
Protect PV.500 Maintenance and Servicing 4.4 Functional Test i Always perform a functional test after completing any servicing work and before starting operation. Perform the functional test in accordance with the start-up procedure and check the report. 4.4.1 Isolating Solar Inverters The following are required: z Multimeter z Two-pin voltage detector z Circuit diagram DANGER Contact with voltage! Risk to life due to electric shock.
Protect PV.500 Maintenance and Servicing 4.4.2 Cleaning and Checking the Protection Devices Î Clean or replace the filter mats. Î Clean the heat sink in the solar inverter power section. Î Check the clamping joints for thermal stress and ensure they are secure. Î Check the fuses and isolators. 4.4.3 Checking the Monitoring System Î Check insulation monitors. Î Check Q26 triggering. Î Test the function of the anti-condensation heater (option).
Protect PV.500 Maintenance and Servicing 4.5.
Protect PV.500 Maintenance and Servicing 4.6.1 Removing and Installing the Fans CAUTION Risk of injury due to rotating fans! The fans of the INV control cabinet are freely accessible. Î Never reach into rotating fans. Î When setting up any system, ensure that the fans cannot be touched. When fans are replaced, the starting capacitors must be replaced too. Removing the fan: i The fans switch on and off depending on the temperature.
Protect PV.500 Maintenance and Servicing Cabinet fans M2 and M3 are located on the INV cabinet roof. Fans are replaced as described below: Î Disconnect the cable clip from the hexagon-head bolt. Î Detach fan connectors X91.1 and X91.2. Î Unscrew the 4 fixing bolts on the fan's mounting plate and remove the fan from the cabinet. Î Unscrew the fan from its mounting plate and remove it. Installing the fan: Î Install the fan by repeating these steps in reverse order. Î Switch on the system.
Protect PV.500 Maintenance and Servicing 5 Fault Messages Refer to the Protect PV.500 operating instructions for a detailed description of fault messages. Some faults can be located and eliminated quickly with the help of this table. 6 Spare Parts and Customer Service Although this system uses non-wearing components, we recommend stocking the spare parts listed in the table below. This will help to ensure your system is always available. Item Component A91.
Installation and Start-up Protect PV.500 AEG Power Solutions GmbH, Warstein-Belecke Department: PS AE Revision: 01 Revision date: 28.06.2011/Schenuit Approved: 30.06.2011/Gleitsmann Document no.
Protect PV.500 Installation and Start-up Fax: e-mail: Internet: 2 of 20 AEG Power Solutions GmbH Emil-Siepmann-Strasse 32 59581 Warstein Germany +49 2902 763 100 +49 2902 763 645 service.aegpss@aegps.com http://www.aegps.
Protect PV.500 Installation and Start-up Table of Contents 1 General Information...............................................................4 2 Safety ......................................................................................4 3 Product Details ......................................................................4 4 4.1 4.2 4.3 4.4 4.5 4.6 Transport, Storage and Installation .....................................5 Packing ...............................................................
Protect PV.500 Installation and Start-up 1 General Information These instructions relate to the technical specifications of the equipment at the time of publication. The contents of these instructions do not constitute subject matter of a contract, but are for information purposes only. AEG Power Solutions GmbH reserves the right to make modifications to the content and technical data in these instructions without prior notice.
Protect PV.500 Installation and Start-up 4 Transport, Storage and Installation 4.1 Packing The system or the individual control cabinets are fastened to transport pallets and packed at the factory to withstand both rail and road transport. The system or the individual control cabinets are packed in plastic film to prevent any damage to the surface paint and to protect against moisture. 4.
Protect PV.500 Installation and Start-up The required air is drawn in through the control cabinet doors and the ventilation slots at the base, and let out through the roof or the back panel.
Protect PV.500 Installation and Start-up Compliance with the requirements of IEC 60364-7-729 is mandatory when installing the system. i Make sure that there is a space of at least 500 mm in front of the system (ensure compliance with national requirements, which may be different) when its doors are open to ensure an escape route. There must be a minimum clearance of 400 mm above the system to allow air to escape.
Protect PV.500 Installation and Start-up Transporting the system Î Unscrew the fan cover (optional). Î Remove the fixing bolts from the transport pallet. Î Insert the two transport rails (1) (optional) and use the screws provided to screw them into the threaded bores (2) provided on top of the cabinet at the front and back. Î Attach the ropes to the transport eyelets (3) and to the crane. Î Check that the transport eyelets and ropes are fastened tight.
Protect PV.500 Installation and Start-up 4.5 Using a Forklift or Lowlift Truck to Transport the System WARNING Risk of accident due to transport with industrial trucks! Possibility of death or very serious injury. Î Only use industrial trucks if it is not possible to use a crane. Î Only trained personnel working specifically in the area of transport may transport the system. Î Secure the danger zone. Î Wear personal protective equipment.
Protect PV.500 Installation and Start-up Figure 4 i Transporting a system using industrial truck BL2933 Observe the centre of gravity! The lifting arms must be - sufficiently long and - sufficiently far apart Transport the system as follows: Î Insert the lifting arms underneath the transport pallet. Î Carefully lift the system or the individual control cabinets and transport them to the intended installation site. Î Lower the system or the individual control cabinets carefully without jolting them.
Protect PV.500 Installation and Start-up 4.6 Installation and Assembly in the Event of Control Cabinets Being Supplied Separately ATTENTION Inadequately qualified and untrained skilled personnel can damage the system! This can cause considerable damage to equipment. Î Only qualified skilled personnel trained by the manufacturer may install and assemble the individual control cabinets (if they are supplied separately).
Protect PV.500 Installation and Start-up 4.8 Tightening Torque Values for Screw Connections These values apply to the electrical and mechanical connections. They do not apply to the floor attachment of the system or the individual control cabinets where the floor is subject to dynamic force. Thread Electrical connection Mechanical connection Cheese head screw strength category 5.
Protect PV.500 Installation and Start-up 5 Connection Work Figure 6 System without control cabinet doors ATTENTION If the polarity of the lines is incorrect, this can damage the system! This can cause considerable damage to equipment. Î Ensure the correct polarity is observed when connecting the lines. i The image above may not always be strictly accurate, depending on which options have been selected.. A distinction is made between internal and external connections/cabling.
Protect PV.500 Installation and Start-up 5.1 External Connections i Establish the connections in accordance with the circuit diagram provided. The mains connection line for the independent power supply must be protected by the circuit breaker specified in the technical data sheet. See the circuit diagram and the technical data sheet for possible connection cross-sections. DANGER System not installed correctly! Risk to life due to electric shock.
Protect PV.500 Installation and Start-up 5.2 Internal Connections in the Event of Control Cabinets Being Supplied Separately ATTENTION Inadequately qualified and untrained skilled personnel can damage the system! This can cause considerable damage to equipment. Î Only qualified skilled personnel trained by the manufacturer may establish the internal connections of the individual control cabinets (if they are supplied separately).
Protect PV.500 Installation and Start-up Î Remove any cable debris, tools, bolts, etc. from the connection panel. Î Replace the partition plates in the floor of the cabinet. Î Reattach the connection cover. Connection of the control and signal lines The control and signal lines for remote signalling are connected using a 3 mm screwdriver. Shielded control and signal lines may be advantageous in terms of EMC. Î For this purpose, connect the shield of the lines to the terminal unit.
Protect PV.500 Installation and Start-up Start-up Preparations The following are required: z 3-pin phase-rotation indicator z Multimeter z Two-pin voltage detector z Circuit diagram Prerequisites: z All miniature circuit breakers are switched on, except F60. z All circuit breakers and load interrupters are switched off. Protect PV.500 -Q4.
Protect PV.500 Installation and Start-up 6.2 Connection of AC Voltage i An insulation test must be performed before the mains voltage is connected. Connect the medium-voltage switchgear. Voltage is present at the external mains isolating point. Medium voltage: DANGER Switchgear not connected correctly! Risk to life due to electric shock. Î Only qualified and trained skilled personnel who are authorised to work with switchgear and have experience of doing so may connect the switchgear.
Protect PV.500 Installation and Start-up 6.3 Connection of DC Voltage GCB Grid DOU Generator connection box Power utility mains (supplying mains) Display and operation unit After connecting the DC voltage: Î Switch off GCBs (external). Î Check that there is no voltage. Î Insert all F41 fuses (DC/AC control cabinet). Î Check the polarity in the system's DC/AC control cabinet. Î Check the polarity of the DC at every GCB. Connect all GCBs. Î Switch on the system via the DOU.
Protect PV.500 Installation and Start-up 7 Isolating Solar Inverters The following are required: z Multimeter z Two-pin voltage detector z Circuit diagram 7.1 Isolation Procedure DANGER Contact with voltage! Risk to life due to electric shock. The capacitors can continue to carry voltage for quite some time; terminal X11 (AC control cabinet) will also remain live.
Single line Diagram Protect PV.500 AEG Power Solutions GmbH, Warstein-Belecke Abteilung: PS AE Revision: 00 Revisionsdatum: 23.03.2011 / Songur Freigabe: 23.03.2011 / Langer Dokumenten-Nr.
This document is property of AEG Power Solutions and must not be displayed or duplicated to any third party without the concent of the company CAE EPLAN Electric P8 Stat Alteration 1000002145_ref 1 Date Name 3 3 3 3 Basisplan DC Input 3 -A2 -L5 3 3 -A1 3 -L4 23.03.2011 Date Editor Songur Checked Gleitsmann/Langer Norm -INV Protect PV.500 max. 185mm² -Q4.1 -K7 -DC/AC -X11 U,N,PE 1-8 2 -X33 1;2 -X41 -F41.1....F41.
Outline Drawing Protect PV.500 AEG Power Solutions GmbH, Warstein-Belecke Abteilung: PS AE Revision: 00 Revisionsdatum: 18.01.2011 / Bornkessel Freigabe: 20.05.2011 / Trandafir Dokumenten-Nr.
ohne BG. 50 without BG.
Connection Diagram Protect PV.500 AEG Power Solutions GmbH, Warstein-Belecke Abteilung: PS AE Revision: 00 Revisionsdatum: 10.05.2011 / Songur Freigabe: 10.05.2011 / Langer Dokumenten-Nr.
This document is property of AEG Power Solutions and must not be displayed or duplicated to any third party without the concent of the company CAE EPLAN Electric P8 Stat Alteration 1000002145_ref 1 Date Name A12-X5:1;2 MVSTBR A12-X3:10-12 MVSTBR MVSTBR MVSTBR MVSTBR A13-X4:3;4 A13-X3:1-3 A13-X3:4-6 A13-X3:7-9 Input 3 Output 6 Output 7 Output 8 Connection diagram MVSTBR A13-X4:1;2 Input 2 Basisplan MVSTBR A12-X3:7-9 Fault AC Distribution Grid-fault Power Solutions Protect PV.
This document is property of AEG Power Solutions and must not be displayed or duplicated to any third party without the concent of the company CAE EPLAN Electric P8 Stat Alteration 1000002145_ref T7D PV -Q4 Name D2 -F41.4 2L+ 2 1 D1 U< 2 2L- 2 1 4 3 3L+ 2 Basisplan -F41.5 3L- 2 -F41.7 1 -F41.8 1 -F41.9 1 -F41.10 -K21 10A -F21 BK 2.5 mm² L- -F41.11 -2T1 +1L1 1L- 1 4 3 BK 2.5 mm² 2 1 -R21 1 6 5 CU60x10 mm BK 2.5 mm² 2 1 E BK 2.5 mm² -F41.13 BK 2.
This document is property of AEG Power Solutions and must not be displayed or duplicated to any third party without the concent of the company CAE EPLAN Electric P8 Stat Alteration 1000002145_ref 1 Date Name External Date 10.05.2011 Songur Editor Checked Gleitsmann/Langer Norm PV Inverter Output Basisplan PV.LvS Low voltage main distribution 2 3 X3 V W PE CU40x5 mm 5 Control -X26 Connection diagram Protect PV.500 H07V-K GN/YE 2x95mm² PE_INV Protect PV.
This document is property of AEG Power Solutions and must not be displayed or duplicated to any third party without the concent of the company CAE EPLAN Electric P8 Stat Alteration 1000002145_ref 1 Date -X11 U Name U PE 12 14 11 N Basisplan BK BK BK 2,5 mm² 2,5 mm² 2,5 mm² L1 Date 10.05.
This document is property of AEG Power Solutions and must not be displayed or duplicated to any third party without the concent of the company CAE EPLAN Electric P8 Stat Alteration 1000002145_ref -A12 Date Remote signaling 8000022187 Name -X1 -X6 24V -X7 + 1-16 - -X5 - 1 + + 2 -X2 Remote voltage monitoring Off Date 10.05.
Technical Data Sheet Protect PV.500 AEG Power Solutions GmbH, Warstein-Belecke Department: PS AE Revision: 00 Revision date: 25.07.2011 / Schenuit Approved: 29.07.2011 / Linke Documenten-No.
Protect PV.500 Technical Data Sheet Technical Data (general) General Unit Data Type: G660 D283/1040 N3srefg-P510püx Ambient temperature .................................. -10 °C to +45 °C in acc. with EN 62040-1 … with derating ...................................... +45 °C to +55 °C in acc. with EN 62040-1 Relative air humidity rH ............................... 0 ... 95%, non-condensing Cooling type ................................................ F in acc.
Protect PV.500 Technical Data Sheet Electrical Unit Data DC Input Parameters Max. PV power (recommended) ............................... 500 – 580 kWp DC voltage range ...................................................... 400 – 1000 V DC voltage range, MPPT .......................................... 500 – 820 V Max. permissible DC current..................................... 1060 A Number of DC inputs ................................................
Protect PV.500 Technical Data Sheet Communication Interfaces FalseEthernet ComServer......................................... A27 Telecommunications A29.......................................... No Equipment/Safety Equipment Graphical display ...................................................... Yes DC-side earth fault detection..................................... Yes DC-side load interrupter switch ................................. Q4 / With motor drive AC-side load interrupter switch .................
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