AEG PV.500-MH User Manual
Operating Instructions
Protect PV.500-MH
AEG Power Solutions GmbH, Warstein-Belecke
Department: PS AED
Revision: 00
Revision date: 25.04.2012 / Schenuit
Released: 25.04.2012 / Aranda
Document no. 8000043212 BAL, en
Protect PV.500-MH Operating Instructions
AEG Power Solutions GmbH
Emil-Siepmann-Strasse 32
59581 Warstein
Germany
+49 2902 763 100
Fax: +49 2902 763 645
E-mail: service.aegpss@aegps.com
Internet: http://www.aegps.com
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Table of Contents
1 Information on How to Use these Instructions ............... 6
1.1 General Information ............................................................. 6
1.2 Target Groups ..................................................................... 7
1.3 Explanations of Target Groups ............................................ 7
1.3.1 Obligations of the Equipment Operator ............................... 7
1.3.2 Skilled Personnel Skills and Training .................................. 8
1.4 Storing Instructions .............................................................. 9
2 Explanation of Symbols and Safety Instructions ......... 10
2.1 Explanation of Symbols ..................................................... 10
2.2 Safety Instructions ............................................................. 11
2.2.1 Signal Words Used ............................................................ 11
2.2.2 Hazard Symbols Used ....................................................... 11
2.2.3 Signs Containing Orders for Personal Protective Equipment12
2.2.4 Abbreviations ..................................................................... 13
2.3 Emergency Procedure (e.g. in the Event of a Fire) ........... 13
2.4 Safety Awareness ............................................................. 13
2.5 Particular Dangers associated with Photovoltaic Systems 14
2.6 Safety Signs and Warning Notices on the Equipment ....... 15
2.7 Safety and Protection Devices for the Equipment ............. 15
2.7.1 Protective Covers .............................................................. 15
2.7.2 Lockable Equipment Doors ............................................... 16
2.7.3 Guard ................................................................................ 16
2.8 Residual Hazards .............................................................. 16
2.8.1 Electrical Hazards ............................................................. 17
2.8.2 Risks Due to Moving Parts ................................................ 18
2.8.3 Fire-Related Risks ............................................................. 18
2.8.4 Risks due to Loss of Control ............................................. 19
2.8.5 Risks from Maintenance and Repair Work ........................ 19
3 Product Details ................................................................ 20
3.1 Product Description ........................................................... 20
3.2 Dimensions and Views ...................................................... 21
3.3 Appropriate Use ................................................................ 21
3.4 Inappropriate Use .............................................................. 21
3.5 Standards, Directives and CE Mark .................................. 22
3.6 Nameplate ......................................................................... 22
3.7 Technology ........................................................................ 23
3.8 Operating Elements ........................................................... 24
4 System Description ......................................................... 25
4.1 Individual Operation .......................................................... 25
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5 System Function ............................................................. 26
5.1 Description of Sequence Control ....................................... 26
5.1.1 The "OFF" Status .............................................................. 26
5.1.2 The "Waiting for Feed Conditions" Status ......................... 26
5.1.3 The "Operation" Status ...................................................... 27
5.1.4 The "Waiting" Status.......................................................... 27
5.1.5 The "Fault" Status.............................................................. 28
5.1.6 The "Night" Status ............................................................. 28
5.1.7 Sequence Control During the Course of the Day .............. 28
5.1.8 Sequence Control Parameters .......................................... 30
5.2 Description of Fan Control ................................................. 31
5.2.1 General .............................................................................. 31
5.2.2 Fan Control, Cabinet Fan .................................................. 31
5.2.3 Cabinet Fan Control Parameters ....................................... 32
5.2.4 Fan Control, Inverter Stack Fan ........................................ 32
5.2.5 Parameters of Inverter Stack Fan Control ......................... 33
5.3 Insulation Monitoring and Earthing of PV Cells ................. 33
5.3.1 General .............................................................................. 33
5.3.2 Operation With Monocrystalline or Polycrystalline Solar
Cells 35
5.3.3 Operation with Thin-Film Solar Cells ................................. 35
5.3.4 Insulation Monitoring Parameters ...................................... 36
5.4 MPP Tracker ..................................................................... 36
6 Monitoring Systems, Messages and Faults .................. 37
6.1 General Information ........................................................... 37
6.2 Table of Faults ................................................................... 38
7 Interfaces ......................................................................... 42
7.1 Communication Interface .................................................. 42
7.1.1 General .............................................................................. 42
7.1.2 Technical Data .................................................................. 43
7.1.3 Structure of the MultiCom CCC Interface ......................... 44
7.1.4 Configuration ..................................................................... 47
7.1.4.1 Configuration Preparations ................................................ 48
7.1.4.2 Configuring the Modbus Protocol ...................................... 50
7.1.4.3 Configuring Modbus Data Transmission ........................... 51
7.2 COM Server ...................................................................... 52
7.2.1 General .............................................................................. 52
7.2.2 Network Connection .......................................................... 52
7.2.3 Structure of the COM Server (internally wired to A93) ...... 52
7.2.4 Installation of the COM Server .......................................... 53
7.2.5 Network Integration Configuration ..................................... 54
7.2.6 Configuration of the Virtual COM Port ............................... 54
7.3 Remote Signalling ............................................................. 55
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8 Graphical Display and Operation Unit ........................... 57
8.1 General Information ........................................................... 57
8.1.1 Signalling ........................................................................... 58
8.1.2 Keyboard Operation .......................................................... 58
8.2 Start-up .............................................................................. 59
8.3 Menu Structure .................................................................. 60
8.3.1 Menu Tree ......................................................................... 60
8.3.2 Main Menu ......................................................................... 60
8.3.3 Operating Display .............................................................. 61
8.3.4 Status/Measured Values ................................................... 66
8.3.5 Blocking ............................................................................. 67
8.3.6 Fault History ...................................................................... 68
8.3.7 Settings ............................................................................. 68
8.3.8 Information ........................................................................ 68
8.3.9 Service .............................................................................. 68
8.3.10 Help ................................................................................... 68
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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. In such
cases the equipment is referred to as the PV.500 equipment or the
individual control cabinets are mentioned.
1.1 General Information
Validity
These instructions correspond to the technical specifications of the
equipment at the time of publication. The contents of these instructions do not constitute a subject matter of the 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. AEG Power Solutions GmbH cannot be held liable for
any inaccuracies or inapplicable information in these instructions,
which came about as a result of changes to the content or technology applied after this equipment was supplied, as there is no
obligation to continuously update the data and maintain its validity.
Warranty
Our goods and services are subject to the general conditions of
supply for products in the electrical industry, and our general sales
conditions. We reserve the right to alter any specifications given in
these instructions, especially with regard to technical data, operation, dimensions and weights. AEG Power Solutions GmbH will rescind all obligations such as warranty agreements, service contracts, etc. entered into by AEG Power Solutions GmbH or its representatives without prior notice in the event of maintenance and
repair work being carried out with anything other than original AEG
Power Solutions GmbH spare parts or spare parts purchased from
AEG Power Solutions GmbH.
Complaints
In the event of complaints, please contact us within eight days of
receipt of goods and provide the following details:
Type designation
Serial number
Nature of complaint
Period of use
Ambient conditions
Any claims submitted after this point cannot be considered.
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Handling
These instructions are structured so that all work necessary for
operation can be performed by appropriately qualified skilled 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.
1.2 Target Groups
This document explains which groups these instructions are intended for and the obligations of these groups. Definitions of staff
requirements are also provided.
Every care has been taken in drafting these instructions. Should
you notice any errors, please contact the manufacturer immediately.
So that the instructions remain up to date, please remember to insert any supplements received from AEG Power Solutions GmbH.
1.3 Explanations of Target Groups
These instructions are intended for various target groups:
The equipment operator or the person appointed by him (the
party responsible for the equipment)
The skilled personnel responsible for using the equipment
1.3.1 Obligations of the Equipment Operator
The equipment operator or the person appointed by him/her (the
party responsible for the equipment) is responsible for the safety of
personnel and for the safety, function and availability of the equipment. These factors depend on compliance with the safety instructions. Compliance with the safety instructions is required at all
times.
To ensure the safety of personnel, the equipment operator
must:
Select skilled personnel on the basis of skills and training (
Chapter 1.3.2)
Make skilled personnel aware of the need for compliance with
regulations ( Chapter 1.3.2)
Provide skilled personnel with personal protective equipment,
user information and instructions
Provide skilled personnel with regular briefings about all safety
measures and keep a record of such briefings
Inform skilled personnel of where fire extinguishers are located
and how to use them
To ensure the safety of the equipment, the equipment operator must:
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Only operate the equipment in perfect working order and in ac-
cordance with good electrical engineering practice
Arrange a fault detection check immediately if the equipment
starts to behave differently
Keep all safety signs and warning notices on the equipment in a
complete and clearly legible condition
Install fire extinguishers in the immediate vicinity of the equip-
ment
1.3.2 Skilled Personnel Skills and Training
Only trained and qualified skilled personnel may perform the work
described, using tools, equipment and test equipment intended for
the purpose and in perfect working order.
All work is coordinated and monitored by the person responsible
for work. The person responsible for work is directly responsible
for the execution of the work. Before work commences, the person
responsible for work must inform the person responsible for the
equipment and agree on a work schedule with him. The persons
responsible for the work and equipment must be trained and qualified skilled personnel and may be one and the same person.
"Trained skilled personnel" means electricians who as a result of
their specialist training:
Have knowledge and experience of the relevant standards,
regulations, requirements and accident prevention regulations
Have been instructed in the mode of operation and operating
conditions of the equipment
Have the ability to assess the effect of any intended work on
the safe operation of this particular equipment
Can assess the work and recognise and avoid potential risks
Compliance with the safety instructions described is essential for
the protection of skilled personnel and the equipment. Skilled personnel must be aware of and follow these safety instructions.
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Obligations of skilled personnel
Observe the following safety instructions.
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. Provide protection in the form of covers or barriers for any
neighbouring live parts.
Once work is complete, reverse the five safety rules starting at
number 5 and working back to number 1.
Read these instructions. Memorise the safety instructions.
( Chapter 2)
Ensure compliance with the following regulations:
Accident prevention regulations of the respective country of
destination and the generally valid safety regulations according
to IEC 364.
BGV A1 (Prevention principles)
BGV A3 (Electrical systems and equipment)
BGV A8 (Safety and health protection warnings in the work-
place)
Report damage to the equipment and electrical installations to
the equipment operator.
Only use spare parts approved by the manufacturer for mainte-
nance
and repair work.
Use personal protective equipment (PPE) as intended.
Check that PPE is in perfect working order and report any de-
fects you notice to the equipment operator.
Wear a hair net if you have long hair. Do not wear loose cloth-
ing or jewellery.
Reinstate protection devices (including covers) on completion
of all work on or with the equipment.
Keep the instructions in the pull-out document pocket.
1.4 Storing Instructions
Store these instructions in an appropriate place. A pull-out document pocket is located on the inside of the door. These instructions
must be stored together with the equipment.
Should the equipment change hands, include these instructions
when handing it over to the new operator.
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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.
Information is indicated by the letter i. These
i
Table 1 Instruction and warning symbols in these operating
instructions
Other symbols and their meanings
Typograph-
ical element Meaning
This symbol is used for action instructions.
1.
2.
3.
sections contain important information about the
phases of the equipment's service life.
Instructions relating to the environment are
identified by a wheelie bin. Instructions relating
to the environment make reference to mandatory requirements set out by regional or national
authorities which are of particular relevance
when disposing of materials used during operation, for example.
Numbers are used for action instructions that
need to be followed in a specific order.
This symbol is used for bulleted lists.
Table 2 – Other symbols
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References to figures, chapters or tables are
shown using the symbol on the left.
Protect PV.500_MH Operating Instructions
2.2 Safety Instructions
All safety instructions have the following structure:
SIGNAL WORD
Type and source of hazard
Figure 1 Warning associated with operator action
2.2.1 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.
Warning colour Consequences
Symbol
DANGER
WARNING
CAUTION
Consequence(s) of noncompliance
Measure(s) to avoid hazard.
Warns of a situation posing an immediate
hazard which will lead to death or serious
injury.
Warns of a situation posing a possible hazard which may lead to death or serious injury.
Warns of a situation posing a possible hazard which may lead to minor injury.
ATTENTION
2.2.2 Hazard Symbols Used
The following hazard symbols are used to illustrate hazards in the
safety instructions.
Symbol Meaning for skilled personnel
warns of possible damage to property and
the environment which could interrupt operation.
General hazard source
Electrical hazard
Risk of falling loads
Risk posed by flammable material
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Risk posed by corrosive vapours and liquids
Risk posed by explosive material
Table 3 – Hazard symbols
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.
Table 4 Signs containing orders for PPE
Check that personal protective equipment is in perfect working order and report any defects you notice to the equipment operator.
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2.2.4 Abbreviations
Protect PV.500_MH Operating Instructions
The following abbreviations are used in these operating instructions:
DOU Display and operation unit
AC
Alternating current
BGV Regulation set out by Employer's Liability Insurance
Association (Germany)
CAN Controller Area Network
CNF Manufacturing order number
DC
Direct current
DCD/ACD DC/AC control cabinet
DCS Distributed control system
DIN German Standards Institute
EPO Emergency power off (system off)
GCB Generator connection box
Grid Power utility mains (power utility company's mains)
IEC International Electrotechnical Commission
IGBT Insulated gate bipolar transistor
INV Inverter cabinet
PE conductor Protective earth conductor, earthing
PV Photovoltaics
VDE Verband der Elektrotechnik Elektronik Informations-
technik e. V. (German Association for Electrical,
Electronic & Information Technologies)
INV Inverter
2.3 Emergency Procedure (e.g. in the Event of a Fire)
Never put your own life at risk. Your own safety is paramount.
Call the fire brigade.
Call the emergency doctor, if necessary.
Shut down the equipment using the system stop switch (ensur-
ing your own safety).
2.4 Safety Awareness
The qualified skilled personnel defined in Chapter 1.3.2 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 or permitted within its vicinity.
The following points must be observed:
All such working procedures which are detrimental to the safe-
ty of persons and the operation of the equipment in any way
are prohibited.
The equipment may only be operated when in perfect working
order.
Never remove or render inoperable any safety devices.
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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.
The member of personnel responsible for the equipment must
ensure that:
The safety instructions and operating instructions are readily
available and are complied with
The operating conditions and technical data are observed
Safety devices are used
The prescribed maintenance work is performed
Maintenance personnel are informed without delay or the
equipment is shut down immediately in the event of abnormal
voltages or noise, high temperatures, vibrations or any similar
phenomena, so that the cause of this can be determined
2.5 Particular Dangers associated with Photovoltaic Systems
Here you will find information about the additional dangers associated with photovoltaic systems.
An active power source is connected. Depending on the operating
status, the PV cells and the equipment may be live.
Crystalline silicon cells
Crystalline PV cells (silicon cells) usually have an IT system
configuration, i.e. a non-earthed system that will be inadvertently
earthed in the event of an earth fault.
A generator with a complex branched structure can only be shut
down with a great deal of difficulty (in the event of a short circuit,
for example).
DANGER
Contact with voltage! Extremely high DC voltages of
up to 1000 VDC are present.
Risk to life due to electric shock.
Do not touch live parts.
Wear personal protective equipment ( Chapter
2.2.3).
Thin-film cells
To prevent corrosion, thin-film cells must be earthed.
Lightning protection
The desired level of protection can only be achieved if a lightning
protection zone concept has been implemented for the building
where the unit is to be installed, in accordance with DIN VDE
0185-4.
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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!
2.6 Safety Signs and Warning Notices on the Equipment
Safety signs and warning notices are located in the vicinity of danger spots. They provide information about electrical hazards and
residual hazards associated with working on and with the equipment.
Safety signs and warning notices must always be in perfect condition and clearly legible. You must comply with safety signs and
warning notices whenever you are working on or with the equipment.
2.7 Safety and Protection Devices for the Equipment
This section describes all safety and protection devices. Safety
and protection devices protect personnel against hazards which
cannot be countered by safe design.
Safety and protection devices must always be in perfect working
order.
2.7.1 Protective Covers
The equipment is designed so that the live components in the operating area are secured with protective covers wherever possible.
The protective covers provide protection against accidental contact
with live parts.
Such protection may only be removed for start-up and for maintenance or repair work.
The covers must be replaced immediately on completion of such
work and checked to ensure that they are in perfect working order.
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2.7.2 Lockable Equipment Doors
The equipment doors are fitted with a control cabinet lock. This
prevents unauthorised personnel from accessing the equipment.
The equipment door must be kept closed at all times.
It may be opened for maintenance and repair work.
The space requirement for the opened equipment doors
i
The equipment door must be closed again once maintenance and
repair work is complete.
2.7.3 Guard
The guard forms the equipment's housing. It protects against unintended contact with live parts and electromagnetic rays.
It may be removed for maintenance and repair work.
must be taken into account
i
The guard must be put back in place once maintenance and repair
work is complete.
2.8 Residual Hazards
This section describes residual hazards. Despite the measures
taken to ensure safety and protection, the equipment poses residual hazards which cannot be countered by design.
Observe warnings at all times while you are working.
The area around the equipment must be made secure
when the guard is removed.
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2.8.1 Electrical Hazards
DANGER
Contact with voltage!
Risk to life due to electric shock.
Use dry insulating material to remove the victim from
the live parts.
Seek medical assistance and inform the control room.
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).
Risk to life due to electric shock.
Disconnect the equipment safely.
DANGER
Electric shock caused by inverter.
Parts of the equipment remain live after the inverter has
been shut down.
Risk to life due to electric shock.
Disconnect the equipment safely.
DANGER
Electric shock caused by back feeding.
The input terminals of the equipment may remain live
after the incoming power supply has been interrupted.
Risk to life due to electric shock.
Disconnect the equipment safely.
Install back feeding protection (a disconnector) in the
load circuit.
DANGER
Electric shock caused by leakage currents.
The capacitors generate high leakage currents in the
equipment. Conductive parts may be live in the event of
connection errors.
Risk to life due to electric shock.
Establish a PE conductor connection prior to start-up.
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i
2.8.2 Risks Due to Moving Parts
Using residual-current-operated safety devices (FI) alone
is not permitted.
WARNING
Water in electrical equipment!
Risk to life due to electric shock.
Do not use water to clean the cabinets.
Do not place any vessels containing fluids on electrical
equipment.
2.8.3 Fire-Related Risks
Installation of fireproof enclosures (EN 60950-1)
A built-in floor plate ensures that, in the event of a fire, no molten
or burning material can fall out of the equipment.
We recommend having a separate supply/exhaust air connection
for the PV.500 in order to prevent smoke spreading in the event of
a fire.
CAUTION
Risk of injury due to rotating fans!
The fans of the INV control cabinet are freely accessible.
Never reach into rotating fans.
When setting up any system, ensure that the fans
cannot be touched.
WARNING
Spread of smoke in electrical operating areas.
If smoke is detected or a fire breaks out, immediately
disconnect the equipment from the power supply and
inform the maintenance personnel.
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2.8.4 Risks due to Loss of Control
ATTENTION
Failure of remote signalling.
If remote signalling fails or the signal lines are interrupted,
the control room can no longer control the equipment.
In such an event, faults can only be identified locally at the
unit itself.
Failure of external emergency switching device
Disconnect the equipment safely.
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, faults will no longer be displayed.
Inform the control room.
2.8.5 Risks from Maintenance and Repair Work
Only trained and qualified skilled personnel (as de-
i
scribed above) may work on or around the equipment
while strictly observing the safety regulations.
DANGER
Risk to life due to electric shock.
Potentially fatal voltages are present in the equipment.
Disconnect safely.
Secure the unit against being switched back on.
Verify that all poles are de-energised.
Earth and short-circuit the equipment.
Provide protection in the form of covers or barriers for
any neighbouring live parts.
ATTENTION
Damage to property.
Only use original spare parts.
Do not intervene in the equipment without authorisa-
tion to do so.
Observe the safety regulations.
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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. It is possible to combine
two Protect PV.500 units to create a 1 MW system. A joint isolating
transformer can be used, with an electrically isolated low-voltage
connection for each Protect PV.500. 1 MW systems can be made
to support "partner operation" to increase their efficiency.
The rating plate, featuring all the relevant data, is located on the
inside of the door.
Figure 2 PV.500 equipment
Important information about equipment documentation
i
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Further descriptions and unit diagrams are included in the
document folder.
Protect PV.500_MH Operating Instructions
3.2 Dimensions and Views
Figure 3 Dimensions and views
3.3 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. The manufacturer cannot be held liable
for damage resulting from such repairs, manipulations or changes.
Safety
The equipment will operate reliably and safely subject to compliance with the instructions, the operating and equipment specifications and regulations set out by the Employer's Liability Insurance
Association.
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.
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