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PV.630
User Manual
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AEG PV.630 User Manual

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PROTECT PV.630
Solarinverter
EN
Operating instructions
Installation and Start-up
Maintenance and Servicing
Single-line Diagram
Outline Drawing
Connection Diagram
Technical Data Sheet
Operating instructions
Protect PV.630
AEG Power Solutions GmbH, Warstein-Belecke Department: PS AED Revision: 00 Revision date: 23.01.2013 / Schenuit Released: 23.01.2013 / Wäsche
Document no. 8000047961 BAL, en
Protect PV.630 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
1.3.1Obligations of the Equipment Operator ............................... 7
1.3.2Skilled Personnel Skills and Trainings ................................ 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
2.2.1Signal Words Used ............................................................ 11
2.2.2Hazard Symbols Used ....................................................... 11
2.2.3Signs Containing Orders for Personal Protective
2.2.4Abbreviations ..................................................................... 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
2.7.1Protective Covers .............................................................. 15
2.7.2
2.7.3Guard ................................................................................ 16
2.8 Residual Hazards .............................................................. 16
2.8.1Electrical Hazards ............................................................. 17
2.8.2Risks Due to Moving Parts ................................................ 18
2.8.3Fire-Related Risks ............................................................. 18
2.8.4Risks due to Loss of Control ............................................. 19
2.8.5Risks from Maintenance and Repair Work ........................ 19
Equipment ......................................................................... 12
Lockable Equipment Doors ............................................... 16
3 Product Details ................................................................ 20
3.1 Product Description ........................................................... 20
3.2 Dimensions and Views ...................................................... 21
3.3 Appropriate Use ................................................................ 21
3.4 Inappropriate Use .............................................................. 22
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 Operating Modes ............................................................... 25
4.1.1Individual Operation .......................................................... 25
4.1.2
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Partner Operation .............................................................. 25
Protect PV.630 Operating Instructions
5 System Function ............................................................. 26
5.1 Description of Sequence Control ....................................... 26
5.1.1The “OFF” Status .............................................................. 26
5.1.2The “Waiting for Feed Conditions” Status ......................... 26
5.1.3The “Operation” Status ...................................................... 27
5.1.4The “Waiting” Status .......................................................... 27
5.1.5The “Fault” Status .............................................................. 28
5.1.6The “Night” Status ............................................................. 28
5.1.7Sequence Control During the Course of the Day .............. 28
5.1.8Sequence Control Parameters .......................................... 30
5.2 Description of Fan Control ................................................. 31
5.2.1General .............................................................................. 31
5.2.2Fan Control, Cabinet Fan .................................................. 31
5.2.3Cabinet Fan Control Parameters ....................................... 32
5.2.4Fan 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
5.3.1General .............................................................................. 33
5.3.2Operation With Monocrystalline or Polycrystalline Solar
Cells .................................................................................. 34
5.3.3Operation with Thin-Film Solar Cells ................................. 34
5.3.4Insulation Monitoring in Partner Operation ........................ 35
5.3.5Insulation Monitoring Parameters ...................................... 35
5.4 MPP Tracker ..................................................................... 36
5.5 Partner Operation .............................................................. 36
5.5.1Linked Operation ............................................................... 36
5.5.2Single Operation ................................................................ 37
5.5.3Linked Operation in the Event of a Fault ........................... 38
5.5.4Partner Operation During the Course of the Day .............. 38
5.5.5Partner Operation Parameters .......................................... 39
5.6 “Extended” operating mode ............................................... 39
5.6.1Parameters of the “Extended” operating mode ................. 40
6 Monitoring Systems, Messages and Faults .................. 40
6.1 General .............................................................................. 40
6.2 Table of Faults ................................................................... 42
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7 Interfaces ......................................................................... 46
7.1 Communication Interface .................................................. 46
7.1.1General .............................................................................. 46
7.1.2Technical Data .................................................................. 47
7.1.3Structure of the MultiCom CCC Interface ......................... 48
7.1.4Configuration ..................................................................... 52
7.1.4.1Configuration Preparations ................................................ 52
7.1.4.2Configuring the Modbus Protocol ...................................... 54
7.1.4.3Configuring Modbus Data Transmission ........................... 55
7.2 COM Server ...................................................................... 56
7.2.1General .............................................................................. 56
7.2.2Network Connection .......................................................... 56
7.2.3Structure of the COM Server ............................................. 56
7.2.4Installation of the COM Server .......................................... 57
7.2.5Network Integration Configuration ..................................... 58
7.2.6Configuration of the Virtual COM Port ............................... 58
7.3 Remote Signalling ............................................................. 59
8 Graphical Display and Operation Unit ........................... 61
8.1 General .............................................................................. 61
8.1.1Signalling ........................................................................... 62
8.1.2
Keyboard Operation .......................................................... 62
8.2 Start-up .............................................................................. 63
8.3 Menu Structure .................................................................. 64
8.3.1Menu Tree ......................................................................... 64
8.3.2 Main Menu ......................................................................... 64
8.3.3Operating Display .............................................................. 65
8.3.4Status/Measured Values ................................................... 70
8.3.5Blocking ............................................................................. 71
8.3.6 Fault History ......................................................................... 72
8.3.7Settings ............................................................................. 72
8.3.8Information ........................................................................ 72
8.3.9Service .............................................................................. 72
8.3.10Help ................................................................................... 72
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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.630 with two control cabinets (+DCD/ACD, +INV) is referred to as 'equipment' in the rest of the instructions. The pre­cise name (PV.630) cannot be avoided in some situations. In such cases the equipment is referred to as the PV.630 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 Trainings
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.630 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.630 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.630 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.630 units to create a 1.26 kW system. A joint isolat­ing transformer can be used, with an electrically isolated low­voltage connection for each Protect PV.630. 1.26 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.
A B
Figure 2 PV.630 equipment
Item Designation
3
1
2
1 Display and operation unit (DOU) 2 System stop 3 Fan assembly (fan cover optional) A INV control cabinet +INV B DC/AC control cabinet +DCD/ACD
Important information about equipment documenta­tion
i
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Further descriptions and unit diagrams are included in the document folder.
Protect PV.630 Operating Instructions
3.2 Dimensions and Views
0
7
0
2
2700
660
925
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.
1500 1200
60011,5
600
625
75
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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. The requirements of BGVA3 are met on the basis of compliance with EN 50274/VDE 0660-51.
The requirements of VDE 0100, Part 410, IEC 60364-4-41, “Func­tional extra-low voltage with safe isolation” and IEC 62109, “Safety of power converters for use in photovoltaic power systems” have been complied with where applicable.
The CE mark on the unit confirms compliance with the EC frame­work directives for 2006/95/EC (Low Voltage) and for 2004/108/EC (Electromagnetic Compatibility), provided that the actions outlined in the instructions are observed.
3.6 Nameplate
The following information appears on the nameplate:
Figure 4 Rating plate (example)
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3.7 Technology
Protect PV.630 Operating Instructions
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. The fact that the various assemblies are logically integrated and linked into the overall sys­tem means that unit properties can be defined by making unit­specific parameter settings in the software.
Information is exchanged between the individual modules using the CAN bus (Controller Area Network). This CAN bus features high interference immunity and is used in a wide variety of indus­trial applications.
The figure below illustrates the principle of the equipment.
DC
(PV-modules)
Protect PV.500
Q4
=
K7
Q26
Display
~
~
~
Communication
M
Control unit
Control unit
supply
AC mains 2
Medium-voltage mains
Figure 5 Functional principle of the equipment for connection to a low-
voltage mains
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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 inverter stack with DC voltage via DC load interrupter switch Q4. The inverter stack converts this DC voltage into a 3-phase AC voltage. A sinusoidal current is fed into the mains via the AC filter, inverter output contactor K7 and the mains transformer.
DANGER
Risk to life due to electric shock.
Mains disconnector Q26 (external) and the isolator in the genera­tor connection box (GCB) are there to isolate the inverter in the event of unit faults or when maintenance needs to be performed on the unit.
The control unit is supplied with power from the AC mains or, op­tionally, from a second AC mains.
3.8 Operating Elements
For details of how the internal operating elements are arranged, please refer to the documents included in the unit.
Potentially fatal voltages are present at the terminals on
the equipment.
Do not touch live parts.
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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 Partner 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. Switching operations, control commands and modifications to set­ting parameters are only performed by the unit concerned.
4.1.2 Partner Operation
In partner operation, two inverters are connected via a CAN bus. The DC voltage infeeds of both units can be linked using a cou­pling breaker. Levels of efficiency can be increased in this operat­ing mode by running one inverter on two connected PV cells at less than full power. It is the inverter itself that connects and dis­connects the DC voltage; it is also responsible for switching the units on and off. This operating mode is described in detail in Chapter 5.5.
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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, load interrupter switch Q4 remains open. Once the initiali­sation phase is complete and if no deactivating faults are pending, load interrupter switch Q4 is closed. During subsequent operation, the switch is only opened by deactivating faults ( Chapter 6).
Inverter output contactor K7 remains open initially. The contactor is switched by the sequence control.
The figure below provides a graphical illustration of the sequence control statuses.
5.1.1 The “OFF” Status
OFF command OFF command
Feed-in
conditions met
Delay complete
ON command
Waiting for feed
Fault
Operation
Fault
Operating conditions no longer met
Waiting
Fault
Figure 6 Sequence control
OFF
conditions
Fault
OFF command
OFF command
Daytime detection
Night-time detection
Fault acknowledgement
Fault
Night
The equipment has been switched off logically via the DOU or the master control unit.
The equipment is running without faults, the monitoring systems are not activated.
In this status, no power is fed into the mains. Possible change of status:
The status can be switched from “OFF” to “Waiting for feed condi­tions” by switching the equipment on via the DOU and the master control unit.
5.1.2 The “Waiting for Feed Conditions” Status
The values of the DC voltage on the PV cells, the mains voltage and the mains frequency are monitored by the equipment.
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The set monitoring values are regularly checked. 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. A start-up attempt is made, which involves switching on the inverter stack. If the DC voltage collapses too dramatically during this start-up attempt, the inverter stack is switched off again and there is a delay before at­tempting to start up again. The equipment will not switch to the “Operation” status until any dip in the DC voltage that occurs dur­ing a start-up attempt is within acceptable limits.
If the DC voltage falls below a certain value for a certain time, the equipment switches to the “Night” status. If a deactivating or self-acknowledging fault is triggered, the equipment switches to the “Fault” status. The status can be switched from “Waiting for feed conditions” to “OFF” using the “Off” control command.
5.1.3 The “Operation” Status
The equipment has met all conditions for operation and no deac­tivating or self-acknowledging faults are present.
The set monitoring values are regularly checked. In this status, power is fed into the mains and inverter output con-
tactor K7 is closed.
Possible change of status:
If the generated power falls below a certain value for a certain time, the operating conditions are no longer met. The equipment then switches to the “Waiting” status.
If a deactivating or self-acknowledging fault is triggered, the equipment switches to the “Fault” status.
The status can be switched from “Operation” to “OFF” using the “Off” control command.
5.1.4 The “Waiting” Status
If the power fed in falls below a certain value when the equipment is in “Operation”, it switches to the “Waiting” status. Although the incoming power is low, the DC voltage of the PV cell could still be high enough and even stable enough to meet the feed conditions in the “Waiting for feed conditions” status. So that the inverter does not switch back on again immediately, thereby subjecting inverter output contactor K7 to unnecessary strain due to frequent switch­ing, after the “Operation” status the unit initially switches to the “Waiting” status. It remains in this status for a certain time, only switching to the “Waiting for feed conditions” status once this time has elapsed.
The set monitoring values are regularly checked.
Possible change of status:
Once the delay has elapsed, the unit switches to the “Waiting for feed conditions” status.
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If a deactivating or self-acknowledging fault is triggered, the equipment switches to the “Fault” status.
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 ( Chap­ter 6), the equipment switches to the “Fault” status.
The set monitoring values are regularly checked. In this status, no power is fed into the mains.
Possible change of status:
If a self-acknowledging fault has been triggered and this fault does indeed acknowledge itself, the unit switches to the “Waiting for feed conditions” status.
If a deactivating fault has been triggered, the “Acknowledge fault” control command can be used to switch back to the “Waiting” sta­tus. The status can be switched from “Fault” to “OFF” using the “Off” control command. In the “OFF” status, the unit is always free of faults.
5.1.6 The “Night” Status
If the DC voltage falls below a certain value for a certain time, the equipment switches to the “Night” status.
The set monitoring values are regularly checked. In this status, no power is fed into the mains.
Possible change of status:
If, the following morning, the DC voltage rises above a certain val­ue for a certain time, the equipment switches to the “Waiting for feed conditions” status.
If a deactivating or self-acknowledging fault is triggered, the equipment switches to the “Fault” status.
The status can be switched from “Operation” to “OFF” using the “Off” control command.
5.1.7 Sequence Control During the Course of the Day
Early morning:
The equipment is in the “Night” status. The sun's rays increase the DC voltage generated by the PV cells. If this voltage stays above a certain value for a certain time, the unit switches to the “Waiting for feed conditions” status.
The DC voltage continues to be monitored in this status. In order for a start-up attempt to be made, it must remain above a certain value for a certain time. The mains voltage and mains frequency are also checked. These values must be within certain limits.
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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 start-up attempt, the inverter stack is switched on, thereby drawing power from the DC voltage that is present. Inverter output contactor K7 is open during a start-up attempt. If the load on the DC voltage caus­es it to collapse too dramatically during this start-up attempt, the inverter stack is switched off again and there is a delay until the next start-up attempt is made. If the DC voltage does not dip too significantly, inverter output contactor K7 closes and power is fed into the mains. The inverter is now in the “Operation” status.
Day:
During the course of the day, the inverter will remain in the “Opera­tion” status if the sun's rays are strong enough and no faults occur. Power is fed into the mains and inverter output contactor K7 is closed.
Evening:
As the sun goes down, the power fed into the mains decreases. If this power falls below a certain value for a certain time, the operat­ing conditions are no longer met. The inverter stack is switched off, inverter output contactor K7 opens and the unit switches to the “Waiting” status.
Once the “Waiting” status delay has elapsed, the unit switches back to “Waiting for feed conditions”. Although the sun's rays are not as strong, the DC voltage might still be high enough for a suc­cessful start-up attempt with the inverter stack and inverter output contactor K7 being switched on again. However, because the sun's rays are not as strong, it is unlikely that the operating condi­tions will still be met in the “Operation” status. As a result, the equipment will switch back to the “Waiting” status once a delay has elapsed.
When the unit switches back to this status, the delay is extended until the unit switches back to the “Waiting for feed conditions” sta­tus.
The cyclic changes of status “Operation” -> “Waiting” -> “Waiting for feed conditions” -> “Operation” can take place several times depending on insolation, the time of year, location and other condi­tions (e.g. snow on the PV cells). So that inverter output contactor K7 is not overloaded by this cycle of changes, the “Waiting” status delay is extended every time the unit switches to this status.
This has very little effect on the energy fed in, because the low levels of insolation mean that hardly any energy is being generat­ed.
Later in the evening:
Levels of insolation continue to fall. As a result, the DC voltage drops again. If the DC voltage drops below a certain value for a certain time, no more start-up attempts are made. If the DC volt­age continues to drop, the unit switches to the “Night” status.
Night:
The equipment shuts down all possible loads so that as little ener­gy as possible is being consumed. The equipment remains in the “Night” status until the following morning.
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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.
Voltage limit value for night detection, delay time for night detection:
If the DC voltage falls below the voltage limit value for longer than the delay time, the unit switches to the “Night” status.
Voltage limit value for day detection, delay time for day detection:
If the DC voltage rises above the voltage limit value for longer than the delay time, the equipment switches to the “Waiting for feed conditions” status.
Inverter stack switch-on time:
The time for which the inverter stack is switched on during a start­up attempt
Permissible voltage dip after switching on the stack:
Prior to the start-up attempt, a limit value is calculated from the present DC voltage and the permissible voltage dip.
If the start-up attempt causes the DC voltage to fall below this cal­culated limit value, this start-up attempt will fail.
Delay until the next start-up attempt following failure on ac­count of excess voltage dip:
After the failure of a start-up attempt, this delay must elapse before the next start-up attempt is made.
Power limit value for shutdown, delay time for shutdown:
If the power fed into the mains remains below the limit value for longer than the delay time, the unit switches to the “Waiting” sta­tus.
Standard delay for a renewed start-up attempt following shut­down, offset delay added to the standard delay after shutdown, maximum number of times the offset delay can be added to the standard delay:
Variable delay in the “Waiting” status Chapter 5.1.4.
Minimum DC voltage, fill factor (PV system parameter):
If the DC voltage rises above a value resulting from the minimum DC voltage divided by the fill factor, a start-up attempt is made.
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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
5.2.2 Fan Control, Cabinet Fan
As soon as the equipment's control module is supplied with volt­age, fan control always starts with the fast fan stage. The control can be restarted to check whether the fans are working correctly. For example, after maintenance work, it is not necessary to wait for the fans to reach the temperature criterion to switch on the fast fan stage.
The fast fan stage is always active for at least a certain time. The unit exhaust air temperatures are checked after this time. If the highest temperature from the two sensors is below a certain value, the fan control switches to the slow fan stage.
The unit exhaust air temperatures are also checked in the slow fan stage. If the highest temperature from the two sensors is below a certain value, the fans are switched off. If the highest temperature rises again during operation with the lower fan stage, fan control switches to the fast fan stage.
If, when the fans are switched off, the highest temperature from the two sensors rises above a certain value, fan control switches to the fast fan stage.
Initialisation
Fast fan stage, minimum time!
Unit exhaust air
temperature > limit
value
Unit exhaust
air temperature
> limit value
Figure 7 Fan control
Slow fan stage
Fan switched off
Unit exhaust air temperature < limit value
Unit exhaust air temperature < limit value
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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.
Unit exhaust air temperature limit value for switching to the fast fan stage:
If the highest exhaust air temperature rises above this limit value, the fans which were running in the slow fan stage are switched to the fast fan stage.
Unit exhaust air temperature limit value for switching to the slow fan stage, minimum time in the fast fan stage:
If the highest exhaust air temperature falls below this limit value, the fans which were running in the fast fan stage are switched to the slow fan stage if the minimum time in the fast fan stage has elapsed.
5.2.4 Fan Control, Inverter Stack Fan
As soon as the equipment's control module is supplied with volt­age, fan control always starts with the maximum fan speed. This means that the control can be restarted to check whether the fan is working correctly. For example, after maintenance work, it is not necessary to wait for the fan to reach the temperature criterion to switch on the maximum fan speed.
The maximum fan speed is always active for at least a certain time. The IGBT temperatures are checked after this time. The fan speed is then determined using the highest of these temperatures. If the highest temperature from the two sensors is below a certain value, the fan is switched off completely.
If, when the fans are switched off, the highest temperature from the two sensors rises above a certain value, the fan is again oper­ated at the maximum speed for a certain time.
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Initialisation
Maximum speed,
minimum time!
Minimum time elapsed
IGBT temperature
> limit value
Figure 8 Fan control
Variable speed
depending on IGBT
temperature
Fan switched off
5.2.5 Parameters of Inverter 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.
IGBT temperature limits and fan speeds, x-y coordinates for determining variable speed:
The variable fan speed is determined by a linear x-y characteristic on the basis of these values.
IGBT temperature limit: If the IGBT temperature rises above the lower limit value, the fan that was previously switched off is run at maximum speed for the minimum time.
Minimum time, maximum speed: If the minimum time has elapsed, the fan is controlled variably us­ing the measured IGBT temperature.
IGBT temperature < limit value
5.3 Insulation Monitoring and Earthing of PV Cells
5.3.1 General
Insulation measurements and tests are carried out with an inte­grated isometer. This device detects and checks the insulation re­sistance.
The insulation resistance detected is compared with two limit val­ues stored in the isometer. If the insulation resistance is below one of the limit values, the unit generates a signal. If the limit value is below the other limit value, the device generates a second signal. The limit values can be modified on the isometer.
The two signals are sent to the equipment control. Signalling faults are generated from the two isometer signals ( Chapter 6).
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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 must be earthed. In this case, insulation measurement is not active during earthing.
Insulation measurement sequence control features a “Maintenance mode”. This mode can only be activated for thin-film solar cells. Activating this mode disconnects earthing. This can be useful when mowing areas where solar panels are installed, for example.
5.3.2 Operation With Monocrystalline or Polycrystalline Solar Cells
General:
This type of solar cell does not require active earthing.
Sequence control:
Insulation monitoring is always active.
Maintenance mode:
No action in the event of a “Maintenance mode” command.
Starting the insulation test manually:
No action, since the insulation test is always active.
5.3.3 Operation with Thin-Film Solar Cells
General:
This type of solar cell requires active earthing. Active earthing is switched on during the day and switches off at
night. An insulation test is carried out at night. When active earthing is switched on, the digital signals from the
isometer are ignored. Once active earthing is switched off, a certain time is allowed to
elapse before the digital signals from the isometer are evaluated.
Sequence control:
When the equipment sequence control switches to the “Night” sta­tus (see Chapter 5.1.6), active earthing is switched off once a cer­tain time has elapsed.
The insulation test starts with a delay. Once a certain test time has elapsed, the insulation test finishes and active earthing is switched on again. If the sequence control switches to “Operation” status before the test time has elapsed, the timer control is ignored, the insulation test is terminated and active earthing is switched back on.
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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 signals from the isometer continue to be ignored. Active earthing is switched on again the next time a switch is made to “Operation” status. However, the unit remains in maintenance mode for at least a certain time; i.e. even if the unit is switched over to the “Opera­tion” status, maintenance mode is not terminated until this time has elapsed.
Starting the insulation test manually:
The insulation test can be started manually for maintenance work. Active earthing is switched off when the insulation test is started
and the test actually commences once a delay has elapsed. When the test time has elapsed, the insulation test ends and active earth­ing is switched on again.
The insulation test can only be started manually if an insulation test is not already running at the time.
5.3.4 Insulation Monitoring in Partner Operation
In partner operation (see Chapter 5.5), both inverters are fitted with the isometer.
Insulation measurement in single operation
In single operation, the two inverters behave like two individual units. Insulation measurement is active in both inverters.
Insulation measurement in linked operation
In linked operation, the inverters are connected on the DC voltage side. If both inverter isometers were to be active in this operating mode, this would distort the measurement of the insulation re­sistance. Therefore, in linked operation, the isometer of the invert­er which is not active is switched off and its sensors are discon­nected from the DC voltage. Now only one isometer is active and the measurement of the insulation resistance is correct.
5.3.5 Insulation Monitoring Parameters
All parameters are only relevant for operation with thin-film solar cells.
Insulation test time:
The analogue and digital signals from the isometer are evaluated during this time.
Delay for insulation test following shutdown of K21 (earthing of PV cells):
Once the earthing has been disconnected, this time must elapse before insulation measurement can start.
Delay for shutdown of K21 in night operation:
Once sequence control has switched to the “Night” status, this time must elapse before earthing is removed with contactor K21.
Minimum time in maintenance mode:
If maintenance mode has been activated, the earthing is discon­nected and remains so for at least this time.
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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 system to achieve optimum efficiency.
Figure 9 MPP performance curve
5.5 Partner Operation
In “partner operation”, the efficiency of a system with two inverters can be increased by connecting the two PV cells at less than full power.
If insolation levels fall, the PV cells are connected and only one in­verter is in operation.
If insolation levels rise, the connection is terminated. Now both in­verters are in operation. Each inverter is supplied with power by its associated PV panel.
5.5.1 Linked Operation
One inverter is switched on and is feeding power into the mains. The other inverter is logically switched off. The tie switch is closed.
The inverter which is active in linked operation changes daily. This operating mode is active when insolation levels are low.
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Figure 10 Linked operation in partner operating mode
Change of status to separate 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 separate 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.
Change of status to linked operation in the event of a fault: In the event of a deactivating or self-acknowledging fault in the in­verter which is switched on, the system switches to linked opera­tion.
The inverter which is switched off is switched on. The faulty invert­er is shut down due to the fault.
5.5.2 Single Operation
Both inverters are switched on and are feeding power into the mains. The tie switch is open.
This operating mode is active when insolation levels are high.
Figure 11 Single operation in partner operating mode
Change of status to linked operation:
If the capacity utilisation of the two inverters falls below a certain value, the system switches to linked operation once a set delay has elapsed.
The MPP tracker is switched off in both inverters and an attempt is made to regulate the two inverters to a uniform DC voltage. When the DC voltages are approximately identical, the tie switch is closed and one inverter is switched off. If the DC voltages cannot be regulated to the same value in a certain time, the two MPP trackers switch back on. Once a delay has elapsed, the MPP trackers are switched back off again and the next attempt to match the DC voltage is started.
Change of status to linked operation in the event of a fault:
In the event of a deactivating or self-acknowledging fault in one in­verter, the two inverters are switched to linked operation. First, the inverter which is not affected by the fault is also switched off.
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If the faulty inverter has a self-acknowledging fault, the DC voltag­es of both inverters are compared. 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 set time has elapsed, the invert­er which is not affected by the fault is switched back on. After a de­lay, a new attempt is made to exit single operation and switch to linked operation in the event of a fault.
If the faulty inverter has been permanently deactivated by a deac­tivating fault, the DC voltages cannot be compared because the faulty inverter is disconnected from the DC voltage via switch Q4. In such a case, there is no possibility of equalising currents being generated when the tie switch is closed. The tie switch is therefore closed and the inverter which does not have a fault is switched back on again.
5.5.3 Linked Operation in the Event of a Fault
One inverter is switched on and is feeding power into the mains. The other inverter has been shut down due to a fault. The tie switch is closed.
This operating mode is active when one inverter is affected by a fault.
Figure 12 Linked operation in the event of a fault in partner operating mode
Change of status to linked operation:
The system switches to linked operation when the fault message is acknowledged in the inverter affected by the fault. The inverter af­fected by the fault is switched off logically once the fault has been acknowledged.
5.5.4 Partner Operation During the Course of the Day
Early morning:
The tie switch is closed from the previous day. Overnight, a deci­sion has been made as to which inverter will be switched on logi­cally in linked operation on this day and which will be switched off logically. If the sequence control (see Chapter 4.1) of both invert­ers now switches from the “Night” status to the “Waiting” status, one inverter is switched off logically. The other inverter is switched on logically and feeds power into the mains if the sun's rays are strong enough. “Linked operation” is active.
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Later that morning:
Insolation increases. As a result, the inverter feeding power into the mains works at increased capacity. If capacity utilisation rises above a certain value, the system switches to single operation. The tie switch opens and the inverter which is switched off logically is switched on. “Single operation” is active.
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. If capacity utilisation falls below a certain value, sequence control on both inverters switches to the “Night” status. Power stops being fed into the mains. “Linked operation” is active.
Night:
Overnight, a decision is made as to which inverter is to be active in linked operation the next day. So that both inverters are operated for approximately the same amount of time, the inverters are oper­ated alternately.
5.5.5 Partner Operation Parameters
Load threshold for terminating the INV connection:
If capacity utilisation in linked operation rises above the parameter value, the system switches to single operation.
Load threshold for connecting the INV:
If capacity utilisation in single operation falls below the parameter value, the system switches to linked operation.
Maximum DC voltage difference for connecting the INV:
When the system switches from single operation to linked opera­tion, the MPP trackers in both inverters are switched off and an at­tempt is made to match the DC voltages. The system only switch­es to linked operation if the difference is less than the parameter value.
5.6 “Extended” operating mode
The “Extended” operating mode is an optional operating mode. Its parameters are set in the factory. The technical data sheet indi­cates whether the function is active or not. If the operating mode is active, the inverter can feed a higher power under certain condi­tions. The transformer must be designed for this increased feed-in capacity.
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The inverter is designed for a rated output power (sustained pow­er) of 630 kW, see the technical data sheet. However, at low sup­ply air temperatures, the inverter is capable of feeding in a higher power. When the function is activated, the maximum feed-in ca­pacity at low supply air temperatures is increased according to a characteristic curve. If the temperature rises, the maximum feed-in capacity drops. If the temperature rises above a certain value, the device can only continue outputting the rated output power. The relationship between the possible feed-in capacity and the temper­ature is shown in Figure 13a.
Figure 13 a Extended operating mode
5.6.1 Parameters of the “Extended” operating mode
Temperature value at which the rated output power can be fed:
If the supply air temperature rises above this value, it is only pos­sible to continue feeding the rated output power.
Temperature value at which the maximum excess power can be fed:
If the supply air temperature drops below this value, it is possible to output the maximum excess power.
Power rating for normal feed-in capacity:
If the supply air temperature rises above the value, it is possible to feed this power as the maximum. This value corresponds to the rated output power.
Power rating for increased feed-in capacity:
If the supply air temperature drops below a value, it is possible to feed this power as the maximum.
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.
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A distinction is made between deactivating, self-acknowledging and signalling faults.
Deactivating faults switch the equipment off permanently once they have occurred a number of times. K7 and Q4 are opened.
When a fault first occurs, it is acknowledged after a certain time has elapsed and the inverter makes a start-up attempt. This start­up attempt is only made if the DC voltage did not drop too dramati­cally during the fault. If the cause of the fault is still present after the start-up attempt, the inverter is switched off again.
A maximum of 3 start-up attempts are made. Each time the inverter is switched off, K7 and Q4 are opened. After a successful start-up attempt and once a certain operating
time has elapsed, the counter for start-up attempts is reset again. If the third start-up attempt is also unsuccessful, the inverter is
switched off permanently. The fault is then no longer self­acknowledging. It can be acknowledged by switching the equip­ment off and on or by manually acknowledging the fault. However, if the cause of the fault is still present following manual acknowl­edgement, another deactivating fault will be generated.
Self-acknowledging faults switch the equipment off. K7 is opened, Q4 remains closed.
The equipment starts up again when the cause of the fault is no longer present. The fault can also be acknowledged manually or by switching the equipment off and on. However, if the cause of the fault is still present following manual acknowledgement, anoth­er self-acknowledging fault will be generated.
Signalling faults do not have any effect on the equipment's se­quence control. K7 and Q4 remain closed.
A signalling fault acknowledges itself automatically when the cause of the fault is no longer present. The fault can also be acknowl­edged manually or by switching the equipment off and on. Howev­er, if the cause of the fault is still present following manual acknowledgement, another signalling fault will be generated.
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6.2 Table of Faults
The monitoring systems listed below will cause the inverter to switch off, are self­acknowledging or signalling and are shown on the DOU with corresponding plain text:
Temperature monitoring systems
Fault/Message
Deac-
tivat-ing
IGBT 1 stack temperature warning X !Equipment temperature fault!
IGBT 2 stack temperature warning X !Equipment temperature fault!
IGBT 1 stack temperature fault X #Equipment temperature fault#
IGBT 2 stack temperature fault X #Equipment temperature fault#
IGBT supply air undertemperature X !Ambient temperature fault!
Self-
acknow-led
ging
Signalling
DOU message
IGBT supply air temperature
X !Ambient temperature fault!
warning
IGBT supply air temperature fault X #Ambient temperature fault#
Unit exhaust air 1
X !Equipment temperature fault!
temperature warning
Unit exhaust air 2
X !Equipment temperature fault!
temperature warning
Unit exhaust air 1
X #Equipment temperature fault#
temperature fault
Unit exhaust air 2
X #Equipment temperature fault#
temperature fault
Equipment supply air under-
X !Ambient temperature fault!
temperature
Unit supply air temperature warn-
X !Ambient temperature fault!
ing
Unit supply air temperature fault X #Ambient temperature fault#
Temperature sensor fault
X #Temperature sensor fault#
IGBT 1 stack
Temperature sensor fault
X #Temperature sensor fault#
IGBT 2 stack
Temperature sensor fault
X #Temperature sensor fault#
IGBT supply air temperature
Temperature sensor fault
X #Temperature sensor fault#
unit exhaust air 1 temperature
Temperature sensor fault
X #Temperature sensor fault#
unit exhaust air 2 temperature
Temperature sensor fault unit
X #Temperature sensor fault#
supply air temperature
IGBT difference current deviation X !Difference current deviation!
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CAN I/O monitoring systems
Fault/Message
Protect PV.630 Operating Instructions
Deac-
tivat-ing
Self-
acknow-led
ging
Signalling
DOU message
Feedback signal
X Q4.x: !Switch feedback fault!
DC load interrupter switch Q4.1
Switch position Q4.1
X Q4.x: Switch open
Feedback signal
X K21: !Switch feedback fault!
K21 earthing PV cells
Monitoring
X !Miniature circuit breaker tripped!
F21 earthing circuit breaker
Monitoring
X !Overvoltage protection tripped! F81 surge voltage arrester DC input
Monitoring
X !Insulation monitor warning! insulation monitor level 1
Monitoring
X !Insulation monitor alarm! insulation monitor level 2
Monitoring F83/F84 surge voltage arrester AC
X F83/84: !Miniature circuit breaker
tripped!
– anti-condensation heater
Monitoring F60 auxiliary power supply mains 2
Monitoring F61 independent power supply mains 1
Monitoring Q26 AC mains disconnector
Monitoring unit cabinet door
Monitoring communication CAN I/O AC cabinet
Monitoring communication CAN I/O DC cabinet
Monitoring CAN I/O parameters
X F60: !Miniature circuit breaker
tripped!
X F61: !Miniature circuit breaker
tripped!
X Q26: Switch open
X !Unit cabinet door open!
X !Communication fault with I/O
control!
X !Communication fault with I/O
control!
X #I/O parameter error#
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Unit Monitoring Systems
Fault/Message
Protect PV.630 Operating Instructions
Deac-
tivat-ing
Self-
acknow-led
ging
Signalling
DOU message
Monitoring fan fault cabinet fan
Monitoring fan fault stack fans
Monitoring K91 feedback signal fan contactor
Monitoring K7 feedback signal INV
output contactor
Monitoring parameter limits
Monitoring PCB ID
Monitoring EEPROM
Monitoring serial EEPROM
Monitoring Watchdog
X !Fan failure!
X !Fan failure!
X K91: !Switch feedback fault!
X #Fault K7 feedback signal#
X !Parameter limit fault!
X #Self-test fault#
X #EEPROM fault#
X !System fault!
X #Watchdog#
Monitoring 15 V supply voltage
Monitoring IGBT stack
Monitoring short-circuit/overload
Monitoring load current transformer
Monitoring stack current transformer
Monitoring
inverter output voltage
Monitoring stack overcurrent
Monitoring mains synchronisation
Monitoring parallel CAN communication
X #15 V supply voltage fault#
X #Stack fault#
X #Short circuit#
X #Load current transformer fault#
X #Stack current transformer –
fault#
X #AC voltage deviation#
X #Stack overcurrent#
X #Synchronisation fault#
X !Communication fault parallel
CAN!
Monitoring
X !Remote monitoring fault! remote monitoring communication
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DC voltage monitoring systems
Fault/Message
Deac-
tivat-ing
acknow-led
Self-
ging
Signalling
DOU message
Monitoring
X #DC voltage deviation# DC overvoltage
Grid monitoring systems
Fault/Message
Deac-
tivat-ing
Self-
acknow-led
ging
Signalling
DOU message
Field rotation or phase fault X #Field rotation fault#
Monitoring
X #Mains frequency deviation# grid overfrequency
Monitoring
X #Mains frequency deviation# grid underfrequency
Monitoring
X #Mains voltage deviation# grid overvoltage
Monitoring
X #Mains voltage deviation# grid undervoltage
Monitoring
X #Mains symmetry fault# symmetric fault
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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 various 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.
To facilitate PV power station monitoring, AEG also offers relevant additional components that are adapted for use with inverters and PV generators. This enables the client to monitor an entire PV power station from a central location easily and reliably.
7.1 Communication Interface
The photovoltaic inverter is equipped with a central communication unit, a “MultiCom CCC interface”.
As well as performing various other functions, this unit facilitates communication between PV inverters and higher-level monitoring systems.
A special system of central monitoring via the Internet can be real­ised using AEG monitoring components such as “PV.LoG”. The connection between the inverter and PV-LoG has been optimally adapted for monitoring and management purposes and is estab­lished via the Modbus protocol. If you have any further questions, please contact your supplier.
7.1.1 General
Two separate potential-free serial interfaces are provided as standard for the purpose of establishing communication connec­tions. One interface – port X2 – is assigned the AEG-specific pro­tocol CBSER and is used both locally and remotely for correspond­ing service tools. The other one – port X5 – supports the Modbus protocol and enables the PV inverter to be integrated into higher­level monitoring and control systems with ease. This port can be switched over from RS232 to RS485.
An external CAN bus provides a further connection option, which can be used for monitoring via a remote panel.
The MultiCom CCC interface can be found on the pivot inside the DC/AC cabinet (item A29.1; see the assembly diagram).
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Protect PV.630 Operating Instructions
MultiCom CCC hardware data (assembly A29.1)
Connector : 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) RS485 connection: Twisted pair with Data+, Data-, shielded, shield attached on one side Distance: 1200 m max. at 9600 baud Bus stations: Max. 32 Data line: Shielded 1:1 data line
(2 x 0.22; twisted pair), e.g. Lapp “UNITRONIC-BUS LD”
Port 3 CAN bus for remote panel X4: 3-pin Combicon connector
Communication data port 1 (X2)
Protocol: CBSER Transmission rate: 1200 - 57,600 baud (adjustable)
Transmission parameters: 9600 baud, 8, E, 1 (default) Configuration mode: 9600 baud, 8, N, 1
Communication data port 2 (X5)
Protocol: Modbus Transmission mode: Half-duplex Transmission code: RTU Transmission rate: 1200 - 57,600 baud (variable) 19,200 baud (default) Start bits: 1 Data bits: 8 Parity: none, even, odd (variable) Stop bits: 2 with no parity, 1 with parity Function code: 03 (read register)
06 (write register) 16 (write multiple registers)
Min. response time of slave: 0-99 ms variable (0 ms default) Modbus slave address: 01-99 (adjustable) (01 default)
Communication data port 3 (X4)
Protocol: Proprietary CAN bus Transmission rate: 50 kbaud
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7.1.3 Structure of the MultiCom CCC Interface
RS232:RS485:
1
J4
1
J5
X5
1
J1
1
X1
1
rt
LED
gn
X3
1
B A B A
X4
S1
1
1
X2
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 con-
nected to this potential-free CAN interface.
X5: Potential-free RS485/RS232 serial interface
Configuration jumpers: J1: 1-2: Firmware update; 2-3: (default) J4: All closed: RS485 (default) J5: All closed: RS232
The transmission topology of the Modbus interface (connector X5) is set by means of the two configuration jumper blocks (J4/J5). The factory setting is RS485.
In order to be able to use the Modbus interface as a point-to-point connection via RS232, you must remove all jumpers from block J4 and plug them in on block J5.
Button: S1: Button for initiating the configuration via connector X2
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LED signals: Green/red flashes: Configuration can be selected via the ter-
minal (up to 30 seconds after restarting)
Green on: Operating status; no external communica-
tion via X2 and X5
Green flashes: Data transmission on the serial interfaces
(X2 or X5)
Red on: Fault
Description of serial interfaces:
Port 1: Serial interface X2
The potential-free RS232 serial interface at connector X2 supports the AEG-specific CBSER protocol for parameter setting and moni­toring purposes. Special service tools can be used to monitor and manage the equipment locally and (with the aid of the COM serv­er) remotely via a network. This is also the port used for configur­ing the assembly's interfaces.
5
9
Figure 14 Serial D-sub connector X2
Port 1 (X2): RS232 pin assignment
Pin number Signal Description
2 RxD PC receiving data from the MCC 3 TxD PC sending data to the MCC 5 GND Interface reference potential
Housing INV housing potential
Please use a 1:1 data cable for configuration purposes.
Port 2: Serial interface X5
The potential-free RS485 interface at connector X5 supports the Modbus protocol for integration into higher-level monitoring sys­tems.
1
6
5
9
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Figure 15 Serial D-sub connector X5
Port 2 (X5): RS485 pin assignment (default)
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.
Shield connection of the RS485 bus line: Shielding is a means of weakening (attenuating) magnetic, elec-
trical or electromagnetic interference fields. Interference currents on line shields are dissipated to earth by means of the shield busbar that has a conductive connection to the housing. A low-impedance connection to the PE conductor is es­pecially important to prevent these interference currents from themselves becoming a source of interference.
If possible, only use lines with a braided shield. The shield cover­age should be at least 80%. Avoid using lines with a foil shield be­cause tensile and compressive stresses applied when fastening the line can easily damage the foil, resulting in a reduction in the shielding effect.
Please bear the following points in mind when handling the screen: Use cable clips or shield terminal blocks made of metal to se-
cure the braided shield. The clips must surround the shield and make good contact with it over a large area.
Attach the shield to a shield busbar right after the line enters
the cabinet. Run the shield right up to the assembly; however, ensure that it does not make contact there!
When used in PV applications, the shield of the RS485 bus line should only be earthed on one side so that no equalising or inter­ference currents can flow through the shielding. However, if sever­al bus stations are present, you must make sure that the shield is never interrupted.
Always attach the shield of the RS485 bus line to earth on the qui­escent side, i.e. only one side of the shield is attached to the earth potential on the master or data logger side.
In the PV inverter, the shield must not be connected to the housing in any way.
Insert the RS485 bus cable into the equipment until it reaches the MultiCom interface, shorten it accordingly and attach both wires to terminals A and B.
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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.
Port 2 (X5): RS232 pin assignment
Pin number Signal Description
2 RxD PC receiving data 3 TxD PC sending data 5 GND Interface reference potential 7 RTS Handshake 8 CTS Handshake
Housing INV housing potential
If the RS232 version is used for this port, please use a 1:1 data line.
Controller Area Network (CAN) at X4
Up to four remote panels can also be connected to the potential­free CAN interface for central signalling and display.
1
Figure 16 Connector X4
Port 3 (X4): CAN pin assignment
Pin number Designation Cable colour coding
1 GND White + brown 2 Data_L Yellow 3 Data_H Green
Please use a shielded CAN bus cable as the line, e.g. 2 x 0.22 twisted pair Lapp “UNITRONIC-BUS LD”.
Route the CAN bus line from the PV inverter to the remote panel. In a CAN bus network, the ends of the bus must always be termi­nated. A 120 ohm terminating resistor is pre-installed at connector X4 of the CAN bus connection as standard.
Connect the line shield to the housing potential of the INV unit via shield terminal blocks. Openings are provided in the plate of the PV inverter for installing the shield in the connection room area. Remove approx. 20 mm of the sheath at this point.
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7.1.4 Configuration
9,5
Figure 17 Shield connection
Kabel/Cable
19,5
12
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.
If you are using a different/in-house monitoring system, you can adjust the transmission parameters and the slave address of the Modbus interface to suit your requirements via port 1 (X2). We would be happy to provide you with the Modbus unit profile on re­quest.
7.1.4.1 Configuration Preparations
You will need a 1:1 data line and a PC. For this configuration, you must connect the PC to the MultiCom
interface (X2) via the data line and start a terminal program, e.g. Hyperterminal, on the PC.
Setting the terminal program:
Data transmission: COMx, 9600 baud/8 data bits/1 stop bit No parity/no protocol Terminal emulation: VT100 You can then start the configuration by pressing the “S1” button on
the MultiCom interface. Ensure that no communication has taken place via interfaces X2/X5 for at least 10 seconds before doing so.
Initiation of the configuration is displayed by the two LEDs flashing on the MultiCom interface and the following display on the termi­nal:
“PRESS <CR> FOR CONFIGURATION WHILE LED IS FLASHING”
The configuration starts provided you press the <ENTER> key (<CR>) within 30 seconds. The configuration main menu opens:
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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 the following key in the main menu: <CR> to save the set values, exit the configuration and activate
the MultiCom interface. <ESC> to cancel the configuration. <2> to access the X5 data transmission configuration. <4> to access the X5 data protocol configuration. The possible keyboard actions are shown in the menu in “< >”.
The following special keys can be used in the menus: <CR>: Carriage return () or ENTER key <ESC>: Escape key <TAB>: Tabulator () key <BS>: Backspace () or Rubout key < >: Space bar
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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
Press one of the following keys in the “X5 Data Protocol” menu: <TAB> to configure the Modbus protocol <CR> to accept the set values. The configuration is finished and
the main menu is opened again. <ESC> to cancel the configuration. This opens the main menu.
Figure 20 Modbus protocol configuration
Press one of the following keys in the “X5 Data Protocol – Mod­bus/JBusV2” menu:
<!> to load the factory setting. <1> to configure the Modbus slave address. <2> to configure the delay time between a request from the
master and the response from the slave.
<CR> to accept the set values. The configuration is finished
and the main menu is opened again.
<ESC> to cancel the configuration. This opens the main menu.
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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
Press one of the following keys in the “X5 Data Transmission” menu:
<1-7> to set the baud rate. <n,e,o> to set the parity. <8,9> to set the number of stop bits. <CR> to accept the set values. The configuration is finished
and the main menu is opened again. <ESC> to cancel the configuration. This opens the main menu. The Modbus factory setting is: 19200 8 E 1.
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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. This calls for an appropriate Ether­net network with an Internet connection plus a fixed IP address as­signment.
The COM server is located at position A27.
7.2.2 Network Connection
This COM server has an IEEE 802.3-compatible network connec­tion on a shielded RJ45 plug connector. Its assignment corre­sponds to that of an MDI interface, which means the connection to the hub or switch is made using a 1:1 wired patch cable.
Ex-works, the COM server operates in an autonegotiation mode on the network side. This means the data transmission speed and the duplex process are automatically negotiated with the connected switch or hub and are set accordingly.
7.2.3 Structure of the COM Server
gn
CN5
1
CN1
Figure 22 COM server interface (top view)
H1
MOD1
gn
Digi Connect ME
ye
1
CN3
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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. The following signals are possible:
LED Jumper Meaning
Flashing CN3 Start-up/error
On CN3 Ready
Flickering CN3 Ethernet  CAN communication
Green network LED (MOD1):
The green LED indicates communication on the network.
Yellow network LED (MOD1):
The yellow LED remains on permanently if an Ethernet network is connected.
7.2.4 Installation of the COM Server
The COM server uses a communication module from Digi (“Digi Connect ME”). In order to communicate via the COM server, it must be integrated into the network and a virtual COM port must be set up on a computer. The “Digi Device Discovery” tool and a Digi RealPort driver are required for this purpose. You can find these tools at www.digi.com/support or at www.aegps.com.
Network factory settings for the COM server:
IP address: 10.10.10.0 Subnet mask: 255.255.0.0 Default gateway: 0.0.0.0
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7.2.5 Network Integration Configuration
For network integration, you will need a 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. This can be
found on the Digi module sticker on the COM server. If no
modules are detected, check your network and your firewall
settings. Run the search again using “Refresh view”. Select the required unit. You can enter the necessary network
parameters using the right mouse button + “Configure network
settings”. Use “Save” and “Reboot” to apply the settings and complete
the installation.
Exit the “Digi Device Discovery” tool. You can use the “ping” command to test whether the COM
server can be reached on the network.
7.2.6 Configuration of the Virtual COM Port
Communication with the COM server takes place via a virtual COM port, which is implemented by means of a RealPort driver. In order to do this, the RealPort driver needs to be installed and configured.
Start the RealPort driver installation process. For this purpose,
the COM server must be connected to the network and the
network parameters must be set. The installation program searches the network for Digi mod-
ules. The modules found are displayed along with the config-
ured IP address and MAC address. If several units are found,
please select the unit to be configured using the MAC address
and select “Next”. The MAC address can be found on the Digi
module sticker on the COM server. If no modules are detected,
check your network and your firewall settings. Run the search
again using “Refresh view”. In the “Describe the Device” window, you can make RealPort
settings. This is where you need to select the COM port via
which the application is to communicate later. All other settings
can be left as per the factory settings. Select “Finish” to complete the installation. The application can communicate via the set COMx port with a
baud rate of 115.2 kB as standard. 9600 kB is also possible as an alternative. Between these two transmission rates, the COM server has an autobaud detection function.
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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. There is no need for an additional auxiliary power supply.
The signals are assigned as standard or can be configured on a customer-specific basis. An integrated service switch enables maintenance work on the unit to be signalled.
Technical data:
The maximum load for the signalling contacts (X3/X4) is 500 V/8 A AC or 50 V/2 A DC.
If the specified power has been applied to the relay con­tacts once, those contacts can no longer reliably switch
I
an extra-low voltage (evaporation of the gold alloy)!
The control input (X5) has an independent 24 VDC power supply. The input is activated via a bridge.
Structure:
2
1
3 2 1
12 11 10
9
8
7 6
5 4
3 2 1
1
1
X7
X1
1
X2
X2
S1
1
1
X6
1
OPT1
K25
K24
K23
K22
K21
X5
X4
X3
1
1
1
Figure 23 Remote signalling master module A12 (top view)
X1: Power supply connection X2: Connection for remote signalling expansion boards X3/X4: Remote signalling outputs with relay changeover
switches
X5: Remote signalling input via optocoupler with independ-
ent power supply
X6: Service plug
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X7: Connection to MultiCom interface S1: Service switch
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 lowest numbers is open (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 (NO) X3.4-5 6 DC distribution signal* (NO) X3.7-8 9 AC distribution signal* (NO) X3.10-11 12 Incoming mains fault (NO) X4.1 2-3 Inverter fault* (NC) X5.1-2 Inverter remote switch-off (NO)
*): Collective signals that contain all messages and faults
Figure 23 shows the normally closed contact in the state that ap­plies when the signal is not active (normally open) or the voltage is zero.
The service switch enables maintenance work on the unit to be signalled to the MultiCom interface using various protocols.
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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 serves 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 LEDs (1). An acoustic signal generator stresses the urgency of critical system statuses.
The graphical LCD shows equipment statuses and measured val­ues using symbols and plain text. You can control and parametrise the unit using menus which are protected by a password.
The DOU is operated using 4 display keys, to which alternating functions are assigned, and one ENTER key. The key functions that are currently active are shown on the LCD in the form of sym­bols.
Figure 24 DOU
1 LEDs: Red, yellow, green (from top to bottom) 2 Graphical display (LCD) 3 4 general function keys 4 ENTER key
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8.1.1 Signalling
LEDs:
Red, permanently ON: Deactivating fault
Red, flashing: Self-acknowledging deactivating fault Yellow, flashing: Self-acknowledging message Green OFF: INV in sleep mode Green, flashing (1 Hz): INV waiting for feed conditions Green, flashing (0.5Hz): INV feeding into mains with derating Green, permanently ON: INV feeding into mains
Acoustic signal generator:
Signal generator ON: Urgent message and equipment fault
8.1.2 Keyboard Operation
You can use the ENTER key to open and close submenus and to acknowledge control functions and parameters.
The 4 display keys are assigned to different functions. The key functions that are currently active are represented as symbols which can be found in a small framed area on the right-hand side of the LCD.
In the “Operating display” and “Inverter” menus, you can switch the inverter on and off using the general keys. The keyboard symbols in the menu indicate the control function which is currently availa­ble. If a switch-off procedure has been initiated, you must confirm it by means of a security prompt in order to avoid inadvertent switch­ing off. The general control system of the inverter can be blocked and protected with a password.
If a unit fault occurs, refer to the “Inverter” menu, where the cause is specified. After eliminating the cause, acknowledge the fault in the menu. You can then switch the individual converters back on again.
You can acknowledge the acoustic signal generator using the key­board. On the LCD operating display you will find a special acknowledgement key represented by a loudspeaker symbol. In all other menus, you can press any key (even a key to which no func­tions have been assigned) to acknowledge the generator. If the number of messages or faults increases, the acknowledgement is cancelled. You can impose a general block that inhibits the acous­tic signal generator in the event of a fault and inhibits the clicking sound when you press a key.
(must be acknowledged via the menu)
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Possible symbol keys 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
8.2 Start-up
Status/Measured values menu
System is blocked
Acknowledge fault
Select day/month/year curve
Help menu
No function
Figure 24a Keyboard symbols
Following the power-up reset, the DOU performs a self-test. Data is read from the inverter once the test has been completed suc­cessfully. The LEDs light up in sequence during this phase. A start screen appears on the LCD and a status bar indicates the duration of the start-up process.
When you start up the DOU for the first time (commissioning), select the menu language using the general keys “<” and “>”. The languages are indicated using the country-specific abbreviation (number plate). The language that is currently selected is dis­played on a black background. Once you have confirmed the se­lected language by pressing the ENTER key, the next menu opens. In order to comply with international requirements, all of the displays up to the one for language selection are displayed in Eng­lish.
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8.3 Menu Structure
8.3.1 Menu Tree
Power ON
Start-up
Main menu
Operating
display
Status/
Measured
Values
Photo-
voltaics
Incoming
mains
Inverter
COM -
interface
AUX
signals
Blocking
(password-
protected)
Figure 25 Menu tree
Fault
history
Settings
Contrast
Language
Real time
Acoustic
signal
generator
Information Help
Service
(password-
protected)
Password
From all menus the system automatically returns to the operating display after a certain period of time if no keys are pressed on the DOU
8.3.2 Main Menu
Operating displ
Fault history
Information
Mon 05 Jan 2009
Figure 26 Main menu
After start-up, the “Main menu” represents the highest menu level, which means that you can open further submenus from here, and you can always return to this level.
The “Main menu” has the typical menu structure.
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Blocking
Settings
Service
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Protect PV.630 Operating Instructions
Additional submenus are displayed on the left-hand side. All se­lectable submenus are displayed in a frame. A black background indicates the current cursor position. The bottom line displays the current real time, which can be adjusted using the “Settings” menu.
On the right-hand side, the current key function is represented as a symbol which is displayed in a small framed area. You can move the cursor using the “<” and “>” keys to select the corresponding submenu. Use the ENTER key to activate a selected submenu. Using the “?” key, you can call up the “Help” menu, which de­scribes the various keyboard symbols.
8.3.3 Operating Display
You can call up the “Operating display” from the main menu. If the DOU has not been used for some time, the system automatically switches back to the operating display, no matter which menu it is in.
The LCD background illumination is switched off if no further oper­ations are carried out and the system is not in an abnormal status. In the event of a unit fault, the background illumination remains switched on until the fault is acknowledged. If the inverter is in night mode, the content of the LCD is cleared and “Sleep mode” is displayed instead. The background illumination is also switched off.
You can reactivate the DOU by pressing any key.
Figure 27 Operating display – Normal operation
The “Operating display” consists of 3 parts: The left-hand side shows the current global unit status:
Figure 28 Operating display – Left-hand side
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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. The bar on the left shows the PV voltage as a symbol and a digital value. If the bar is completely filled in, this in­dicates that sufficient PV voltage is present. The bar on the right shows the inverter status. If the inverter is feeding power into the mains, the bar is filled in.
The total energy fed in is shown at the bottom of the display.
Examples of possible displays:
Figure 29 Example of operating display
The equipment is in its normal state, the inverter is feeding power into the mains.
Figure 30 Example of operating display
Solar radiation is sufficient, the inverter is switched off. If the sine symbol on the inverter is flashing, the inverter has been switched off due to a fault or it is currently in the synchronisation phase.
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Figure 31 Example of operating display
Solar radiation is too low, the inverter is in standby mode.
Figure 32 Example of operating display
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.
Figure 33 Operating display – Central section
You can use the double arrow key to select the infeed periods be­low.
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Figure 34 Example of daily data
Daily data for the current day, previous day (t = 00:00 – 04:00, 15 minute intervals)
Figure 35 Example of monthly data
Monthly data (t = day 1 – 31) for the last 12 months
Figure 36 Example of yearly data
Current yearly data (t = month 1 – 12)
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Figure 37 Example of yearly overview
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. The flashing measured values menu then takes you to the inverter menu, where detailed information can be found on the fault and where you have to acknowledge it.
You can use the double arrow key to select the different display types for the energy data logger. Current day (default) -> Previous day -> Monthly overview -> Cur­rent yearly overview -> Yearly overview
If messages have been output or faults have occurred, you can acknowledge the acoustic signal generator here; otherwise, this key is not assigned.
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Use the bottom key with the measuring instrument symbol to call up menus with detailed information on the status and the meas­ured values. This key flashes in the event of a fault in the unit, en­abling you to access menus containing additional fault information directly.
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.
-- Status/data --
Photovoltaic
Inverter
AUX signals
Figure 39 Menu: Status/Measured values
You can use the “Photovoltaics” menu item to display the meas­ured values for the panels. Any faults in the DC distribution are shown here too.
Grid side
COM interface
Menu
-- Photovoltaic --
UDC.[V]: 600 R-ISO[kOhm]: 100
IDC.[A]: 481
PDC[kW]: 289
Figure 40 Photovoltaics menu
You can use the “Incoming mains” menu item to display the meas­ured values for the incoming mains. Any mains faults or faults in the AC distribution are shown here too.
-- Grid side --
U
I
.[V]: 270 270 270
L12-31
..[A]: 587 587 587
L1-3
F....[Hz]: 50.0 Failures: 2
Figure 41 Menu: Incoming mains
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You can use the “Inverter” menu item to display the statuses and measured values for the inverter. You can toggle between the two menus using the “>” and “<” keys. In normal operation, the inverter can be switched on and off here, using the top key. In the event of a deactivating fault, you can call up a detailed description of the fault here. Once the fault has been rectified, you will need to acknowledge it using the top key. A high­voltage symbol “V” will then appear on the top key.
-- Iverter-Status --
Grid operation MPP
-- Inverter-data --
U
I
.[V]: 270 270 270
L12-31
..[A]: 587 587 587
L1-3
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
....[h]: 1262
t
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.
These are then followed by the frequency F and the daily energy E.
The ambient temperature of cabinet T1 and the supply air temper­ature of inverter stack T2 are shown as the temperatures.
Next come the total energy counter ∑E and the inverter operating hours counter ∑t.
You can scroll through the measured values using the “v” and “^” keys.
You can use the “COM interface” menu item to look up the status­es of the communication PCBs.
You can use the “AUX signals” menu item to look up the status of optional general signals on the remote signalling board.
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.
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8.3.6 Fault History
8.3.7 Settings
8.3.8 Information
Protect PV.630 Operating Instructions
The default password set by the factory is: 1201. In menus where switching operations are normally possible, block-
ing is indicated by a key.
You can call up the “Fault history” menu from the “Main menu”. A data logger that records the inverter's fault history is integrated in the inverter unit. You can display the 20 most recent faults as of the current date or as of a specific date.
You can call up the “Settings” menu from the “Main menu”. Here you can set the following parameters in the submenus: LCD contrast, Language, Real time and Acoustic signal gener­ator for indicating faults and keyboard operation
You can call up the “Information” menu from the “Main menu”. Us­ing this menu, you can call up information about the unit type, the firmware versions and the available communication options.
8.3.9 Service
8.3.10 Help
You can call up the password-protected “Service” menu from the “Main menu”. The password must be entered digit by digit and then confirmed by pressing the ENTER key.
The default password set by the factory is: 1201. Once the current password has been entered, you can select a
submenu where you can change the DOU password. In the “Password” menu, you can set the password for block-
ing operation and for setting parameters. A range of 0000 to
9999 is possible.
Keep the password secure.
I
You can call up the “Help” menu from the “Main menu” using the “?” key. This enables you to look up the meaning of the keyboard symbols.
If you have forgotten the password, the DOU will need to be reset at the customer's expense!
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Protect PV.630
AEG Power Solutions GmbH, Warstein-Belecke Department: PS AED Revision: 00 Revision date: 23.01.2013/Schenuit Released: 23.01.2013/Wäsche
Document no. 8000047963 BAL, en
Protect PV.630 Installation and Start-up
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 General Information ............................................................... 4
2 Safety ...................................................................................... 4
3 Product Details ...................................................................... 4
4 Transport, Storage and Installation ..................................... 5
4.1 Packaging ................................................................................ 5
4.2 Storage .................................................................................... 5
4.3 Installation Site Requirements, Operating Area ....................... 5
4.4 Using a Crane to Transport and Install the System ................. 7
4.5 Using a Forklift or Lowlift Truck to Transport the System ........ 9
4.6 Installation and Assembly in the Event of Control Cabinets
4.7 Installing, Aligning, Attaching ................................................. 11
4.8 Tightening Torque Values for Screw Connections ................ 12
5 Connection Work ................................................................. 13
5.1 External Connections ............................................................. 14
5.2 Internal Connections in the Event of Control Cabinets Being
Being Supplied Separately .................................................... 11
Supplied Separately ............................................................... 15
6 Start-up ................................................................................. 16
6.1 Start-up Preparations ............................................................. 17
6.2 Connection of AC Voltage ..................................................... 18
6.3 Connection of DC Voltage ..................................................... 20
7 Isolating Solar Inverters ...................................................... 21
7.1 Isolation Procedure ................................................................ 21
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1 General Information
These instructions correspond to the technical specifications of the equipment at the time of publication. The contents of these instruc­tions do not constitute the 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.
Please refer to the respective operating instructions for all other general information.
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 or permitted within its vicinity.
Please refer to the respective operating instructions for all other safety information.
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.
Please refer to the respective operating instructions for all other information relating to this topic.
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4 Transport, Storage and Installation
4.1 Packaging
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.
4.2 Storage
Only store the system or the individual control cabinets for a max­imum period of six months in the original packaging in dry, venti­lated rooms with a permanent roof. The permissible ambient tem­perature range is between -35°C and +70°C with a relative humidi­ty of 85%.
If the system or the individual control cabinets are stored for longer than six months, they must first be packed with standard desic­cants and then sealed in airtight plastic film.
To prevent damage, only remove the protective film from
i
the system or the individual control cabinets immediately prior to installation.
4.3 Installation Site Requirements, Operating Area
The system is intended for installation in areas which are difficult to access.
The system is intended for operation in a station (container) by de­fault. The system must be installed in such a way that the supply air and exhaust air ducts can ensure sufficient cooling of the INV control cabinet. Access must facilitate replacement of the fans and opening of the cleaning flap.
If the system is not operated in a wall-mounted station, additional measures must be taken to ensure that there is sufficient cooling of the INV control cabinet in particular and that the exhaust air cannot get back in through the supply air openings.
Suitable floor surfaces for installation of the system are: Double floors
Above cable ducts or Directly on a level surface
Ensure that the weight of the system does not exceed the max-
imum floor bearing capacity.
Observe the applicable fire protection requirements.
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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.
2700
2
0
7
0
2
1
1
1
1500
660
925
Figure 1 Air vents on the system (1=supply air, 2=exhaust air)
1200
600
625
Additional installation site requirements:
- It must be free from conductive dust
- It must be free from corrosive acid vapours
- The maximum system supply air temperature must not be
exceeded
- The air vents on the system must not be obstructed, includ-
ing by the structural conditions or features of the installation site.
CAUTION
Risk of injury due to rotating fans!
60011,5
75
The fans of the INV control cabinet are freely accessible.
Never reach into rotating fans.
When setting up any system, ensure that the fans can-
not be touched.
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Compliance with the requirements of IEC 60364-7-729 is mandatory when installing the system.
Make sure that there is a space of at least 500 mm in front of the system (ensure compliance with national re-
i
quirements, 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.
ATTENTION
Insufficient dissipation of waste heat can damage the system!
Dissipate the waste heat in accordance with the manu-
facturer's specifications.
4.4 Using a Crane to Transport and Install the System
Preparations
Please note the following before transport: During crane transport, only use the transport rails (1) (optional)
intended for this purpose.
Only use ropes which allow an angle of at least 45° between
rope and cabinet roof.
Do not exceed the permissible load-bearing capacity of each
rope. The load-bearing capacity must be dimensioned as fol­lows:
WARNING
Risk of accident due to suspended loads!
Possibility of death or very serious injury.
Only trained personnel working specifically in the area
of transport may transport the system.
Secure the danger zone.
Never stand under suspended loads.
Make sure that nobody stands under suspended loads.
Wear personal protective equipment.
Load-bearing capacity per rope ≥ 0.5 x total weight of sys-
tem or of individual components
The total weight of the system or of the individual components
is specified in the technical data sheet.
Do not exceed the permissible weight that can be carried by the
crane.
Use one rope per transport eyelet. Be aware of the equipment's centre of gravity.
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Transporting the Equipment
Unscrew the fan cover (optional).
Remove the fixing bolts from the transport pallet.
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.
Attach the ropes to the transport eyelets (3) and to the crane.
Check that the transport eyelets and ropes are fastened tight.
Carefully lift the system and transport it to its installation site.
Lower the system carefully without jolting it.
Check that the system is stable.
Remove the ropes and transport eyelets.
Reattach the fan cover (optional).
3
2
1290
2 2
3
1
2
1
Figure 2 Using a crane to transport an assembled system with transport
rails
1
300
900
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4.5 Using a Forklift or Lowlift Truck to Transport the System
Please note the following before transport: Do not exceed the permissible weight that can be carried by the
industrial truck or lowlift truck. The total weight of the equipment is specified in the technical data sheet.
Be aware of the equipment's centre of gravity. The centre of
gravity is indicated on the figure above.
Use industrial trucks or lowlift trucks with lifting arms which are
long enough and far enough apart.
WARNING
Risk of accident due to transport with industrial trucks!
Possibility of death or very serious injury.
Only use industrial trucks if it is not possible to use a
crane.
Only trained personnel working specifically in the area
of transport may transport the system.
Secure the danger zone.
Wear personal protective equipment.
Transport with an industrial truck or lowlift truck should be
i
Preparation:
Leave the individual control cabinets on the transport pallets. If individual units are to be transported, the pallet can only be lifted
from the front or back. If units which are supplied already screwed together to form a single system are to be transported, the pallet can only be lifted from the sides.
avoided in particular on construction sites and/or uneven ground unless absolutely necessary.
Figure 3 Transporting individual control cabinets
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Figure 4 Transporting a system using industrial truck
Observe the centre of gravity! The lifting arms must be
i
Transport the system as follows:
Insert the lifting arms underneath the transport pallet.
Carefully lift the system or the individual control cabinets and
transport them to the intended installation site.
Lower the system or the individual control cabinets carefully
without jolting them.
Move the forklift or lowlift truck backwards.
Unscrew the fan grilles from the system or the individual control
cabinets.
Remove the four fixing bolts from the transport pallet, lift the
system or the individual control cabinets from the pallet and set them down at the final installation site.
Attach the fan grilles to the system or the individual control cab-
inets
- sufficiently long and
- sufficiently far apart.
.
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4.6 Installation and Assembly in the Event of Control Cabinets Being Supplied Separately
Inadequately qualified and untrained skilled person­nel can damage the system!
This can cause considerable damage to equipment.
Only qualified skilled personnel trained by the manu-
If the control cabinets are supplied separately, the sealing strip provided must be stuck in place between them (run-
i
ning all the way around) before the system is installed. The control cabinets must also be bolted together at the appropriate points.
4.7 Installing, Aligning, Attaching
Four holes are provided for the fixing bolts in the frame of each control cabinet.
The spacings and diameters of the holes can be found in the draw­ing below.
ATTENTION
facturer may install and assemble the individual control cabinets (if they are supplied separately).
925
Align the system vertically and compensate for any uneven-
ness.
Attach the system to the floor.
Bolt individual cabinets at the appropriate points (through the
frame at the top and at the vertical posts at the front and back).
1500 1200
660
600
625
Figure 5 Bottom attachment
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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 indi-
vidual control cabinets where the floor is subject to dynamic force. The specified torque information for the built-in units must be ob-
served.
Required torques of the electrical screw connections
Connection of devises in general Copper-rails connections
Nominal torque [Nm]
Screw size
strength class 5.8
acc. N57 2205
slotted-head
hex-head
strength class 8.8
Nominal torque [Nm]
acc. N57 2201
hex-head (min)
strength class 8.8
min. max.
M2,5
M3
M3,5
M4 M5 M6
M8 M10 M12 M16 M20
0,21 - 0,42 0,37 - 0,74 0,57 - 1,15
0,85 - 1,7
1,75 - 2,65
2,95 - 4,4 7,0 - 14,0
0,33 - 0,65
0,58 - 1,2 0,9 - 1,85 1,35 - 2,7
2,8 - 5,5 4,7 - 9,3
11,5 - 22,5
22 – 44 38 – 75
90 – 180
174 - 347
2 3
5,5
15 30 60
120
Table 1 Tightening torque values for screw connections
2,7 5,5 9,3
22,5
44 75
180
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A
A
A
2
028
A
A
A
3
5 Connection Work
S100
C12
C13
M
R17.3
A17
A91.1
K91
X100-X500 X101,X103 X121,X201 X202,X286 X300,X500
29.1 A27
A12 A13
A20
F93 F94 A31 F91 X11-X33 F83
S200
115.1
115.2
R17.4
F86
F86.1
38.1
38.2
51
K62
F101
F84 F61
F60 F22
F13
M2
A1
1800 228
F17 F31 F38 F51 F81
F41.1 - F41.8
M1
1500 1200
L5.1-L5.3A86.3L4.1-L4.3 A86.2
2700
Figure 6 Installation 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.
Ensure the correct polarity is observed when connect-
ing the lines.
The image above may not always be strictly accurate,
i
depending on which options have been selected.
A distinction is made between internal and external connec­tions/cabling.
X3.W
X3.V
X3.U
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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.
Only trained and qualified skilled personnel who are
authorised to install medium-voltage systems may con­nect such equipment.
Wear personal protective equipment.
Power terminals
-X41:1L+, 1L­ to
-X41:8L+, 8L-
-X3:U, V, W Mains connection Maximum 3x150 mm²/phase
PE Earth connection Maximum 2x120 mm²
X6:1, 2 Partner master Maximum 4x95 mm²/pole
X6:3, 4 Partner slave Maximum 4x95 mm²/pole
Control/Monitoring terminals
-E1:1, PE, 2 Auxiliary power supply 2-phase 230 VAC
-X13:U, N, PE 230 V output ±20% maximum 400 VA
-X26:1, 2, 3, 4 Input Q26 external
DC connection Maximum 185 mm²
-X33:1, 2 Signals (NC contact of S1, system stop)
-A12-X3, X4, X5 Remote signalling
-A13-X3, X4 Remote signalling
-A20-X3:1, 2, 3 Partner mode (optional)
Designated cable:
See cable diagram
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5.2 Internal Connections in the Event of Control Cabinets Being Supplied Separately
All the cables for establishing electrical connections between the individual control cabinets feature end-of-wire markings. This means that they can be connected safely to the correct terminals.
The cables may only be connected at the designated connection points.
Where possible, coded connectors ensure that plug connections cannot be reversed.
The power lines must be tightened with the required torque to es­tablish a reliable electrical connection (Table 1).
ATTENTION
Inadequately qualified and untrained skilled personnel can damage the system!
This can cause considerable damage to equipment.
Only qualified skilled personnel trained by the manu-
facturer may establish the internal connections of the individual control cabinets (if they are supplied sepa­rately).
ATTENTION
Unconnected protective earth conductors (PE) can damage the system!
This can cause considerable damage to equipment.
Connect the protective earth conductor (PE) of the AC
control cabinet to the earth bar.
The cables are connected as follows:
Open the control cabinet door.
Remove the connection cover from the connection terminals.
Open the partition plates in the floor of the cabinet.
Insert the cables to be connected from below.
Fix the cables to the respective connections by securing the
cable lugs using an open-ended spanner.
Secure the protective earth conductors (PE) to the designated
unit frames.
Secure the cables on the cable clamp rail to provide strain re-
lief.
Check to ensure that the cables are secured correctly and
tighten the fixing bolts if necessary.
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Check the cables to ensure the polarity and phase sequence
are correct.
Remove any cable debris, tools, bolts, etc. from the connection
panel.
Replace the partition plates in the floor of the cabinet.
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.
For this purpose, connect the shield of the lines to the terminal
unit. Additionally, the shield can be connected to the PE con­nection provided on the control unit pivot plate.
Correct routing of the PE conductor acc. to IEC 60364-5-54.
6 Start-up
The cable clamp rail is located 130 mm above the floor.
i
Special AEG Power Solutions software and hardware tools must be used for initial start-up. Only skilled personnel trained by AEG Power Solutions are in a position to use these tools correctly and to perform initial start-up.
Once the system has been fully installed, the following aspects must be checked:
Screw connections properly tightened Connection cables correct Tool removed Terminal space covers attached
Read the operating instructions prior to start-up.
Observe the bending radius! (With one bend: radius = 10 x diameter)
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6.1 Start-up Preparations
The following are required:
3-pin phase-rotation indicator Multimeter Two-pin voltage detector Circuit diagram
Prerequisites:
All miniature circuit breakers are switched on. All circuit breakers and load interrupters are switched off.
Protect PV.
+DCD/ACD
+NSHV
-Q4.1
-F41
DC (PV-Modul)
-F38,
-F81
Figure 7 - Functional principle, with miniature circuit breakers shown
+INV
-A1
Control
-K7
Com
-Q26
-L26
-F13,
-F22,
-F60,
-F61,
-F101
Isolating points Q1 and Q26 are designed on a system-
i
specific basis and do not form part of the PV.630.
Before connecting the AC voltage, check:
Auxiliary power supply circuit selection circuit 1/circuit 2 Select the auxiliary power supply circuit by positioning the bridge
block on terminal X14.
-Q1
12
Mains
EVU-Netz
1
1
11223 3445566778899
X14
12
Figure 8 – Auxiliary power supply circuit selection 1 left bridge block:
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1
0
1
2
X14
1 0
1
1
1
2
Protect PV.630 Installation and Start-up
Auxiliary power supply via external circuit 2 (E1:L/N/PE;AC230V); F60.
2 right bridge block:
Auxiliary power supply via internally generated circuit 1; F61. (As delivered)
The bridge block must not be disconnected in "Operation" status.
i
F60, F61 switched off (DC/AC control cabinet). F14 switched off (DC/AC control cabinet). Q4.1 switched off (DC/AC control cabinet). Q26 switched off (external). F41 not engaged (DC/AC control cabinet).
The inverter cannot be switched on without a bridge block.
F22, F13, F101 switched on (DC/AC control cabinet).
i
6.2 Connection of AC Voltage
i
Connect the medium-voltage switchgear. Voltage is present at
the external mains isolating point.
Medium voltage:
The low-voltage winding of the mains transformer must not be connected to earth.
An insulation test must be performed before the mains voltage is connected.
DANGER
Switchgear not connected correctly!
Risk to life due to electric shock.
Only qualified and trained skilled personnel who are
authorised to work with switchgear and have experience of doing so may connect the switchgear.
Wear personal protective equipment.
Skilled personnel are appointed by the system operator.
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After connecting the AC voltage:
Auxiliary power supply via internally generated circuit 1
Switch on Q1 (external).
Switch on Q26 (external).
Measure the clockwise rotating field at X3 (AC control cabinet).
Measure the voltage at F61 (DC/AC control cabinet).
Switch on F61
The control unit and the DOU are now working. Q4.1 (DC/AC control cabinet) switches on automatically after a few
seconds.
Auxiliary power supply via external circuit 2
Switch on Q1 (external).
Switch on Q26 (external).
Measure the clockwise rotating field at X3 (AC control cabinet).
Connect the external power supply/auxiliary voltage at E1.
Measure the external voltage at E1.
Switch on F60 (DC/AC control cabinet)
The control unit and the DOU are now working. Q4.1 (DC/AC control cabinet) switches on automatically after a few
seconds.
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Protect PV.630 Installation and Start-up
6.3 Connection of DC Voltage
GCB Generator connection box Grid Power utility mains (supplying mains) DOU Display and operation unit
After connecting the DC voltage:
Switch off GCBs (external).
Check that there is no voltage.
Insert all F41 fuses (DC/AC control cabinet).
Check the polarity in the system's DC/AC control cabinet.
Check the polarity of the DC at every GCB.
Connect all GCBs.
Switch on the system via the DOU. The INV contactor K7 switches on automatically after a few sec-
onds and power is fed into the power utility mains. If the INV contactor K7 does not switch on, check the following:
“Field rotation fault” fault message Check the INV control cabinet and DC/AC control cabinet connec­tion lines to ensure they have a clockwise rotating field.
Isolate the system to do this.
Other fault indications See “Monitoring Systems, Messages and Faults” in the operat­ing instructions.
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7 Isolating Solar Inverters
The following are required:
Multimeter Two-pin voltage detector 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. Switching off Q26 (external) and Q4 does not isolate the system entirely from the voltage! The remote signalling lines may still be live even after the mains and DC have been disconnected!
Only trained skilled personnel may isolate the system.
Do not touch any live parts.
To isolate the system from the voltage, you must dis­connect the supply lines.
Wear personal protective equipment.
Switch the PV solar inverter off via the DOU.
Switch off Q26 (external).
Switch off F60, F61 (DC/AC control cabinet).
Switch off GCBs (external).
Remove all F41 fuses (DC/AC control cabinet).
Check that there is no voltage at X41 and X3 (DC/AC control
cabinet).
Observe the "five rules of safety", i.e. "earth and short-circuit"
the AC and DC supplies if necessary.
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Maintenance and Servicing
Protect PV.630
AEG Power Solutions GmbH, Warstein-Belecke Department: PS AED Revision: 00 Revision date: 23.01.2013 / Schenuit Released: 23.01.2013 / Wäsche
Document no. 8000047962 BAL, en
Protect PV.630 Maintenance and Servicing
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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Protect PV.630 Maintenance and Servicing
Table of Contents
1 General Information .......................................................... 4
2 Safety .................................................................................. 4
3 Product Details .................................................................. 4
4 Maintenance and Repair ................................................... 5
4.1 General Information ............................................................. 5
4.2 Scope of the Recommended Measures .............................. 5
4.3 Inspection ............................................................................ 6
4.3.1 Visual Inspection ................................................................. 7
4.3.2 Diagnostic Functions ........................................................... 8
4.3.3 Reading Out the Memory .................................................... 8
4.3.4 Removing Accumulated Dust .............................................. 8
4.3.5 Obligation to Keep a Written Record ................................... 8
4.4 Functional Test .................................................................... 9
4.4.1 Isolating Solar Inverters ....................................................... 9
4.4.2 Cleaning and Checking the Protection Devices ................ 10
4.4.3 Checking the Monitoring System ....................................... 10
4.4.4 System Stop ...................................................................... 10
4.4.5 Documentation .................................................................. 10
4.5 Maintenance ...................................................................... 10
4.5.1 Additional Work ................................................................. 11
4.5.2 Documentation .................................................................. 11
4.6 Repair ................................................................................ 11
4.6.1 Removing and Installing the Fans ..................................... 12
4.6.2 Power Section ................................................................... 13
5 Fault Messages ................................................................ 14
6 Spare Parts and Customer Service ............................... 14
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