ABB Fimer PVS980-58-4348kVA-I Commissioning And Maintenance Manual Download Page 5

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Table of contents

Use of warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation and maintenance safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Electrical safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Electrical safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Safe start-up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2. Introduction to the manual

Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Categorization and option code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Generic disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Cybersecurity disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Terms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3. Electrical commissioning

Checking the settings of the auxiliary voltage transformer (G415) . . . . . . . . . . . 20

1-phase power output (G410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3-phase power output (G415+G398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3-phase power output (G430) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Connecting temporary external 230/115 V AC supply for control system during commission

ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Smoke detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Installing fieldbus adapter modules (K458, +K475) . . . . . . . . . . . . . . . . . . . . . . 22

Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4. Start-up and operation

Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Primary and ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Set up the insulation monitoring device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Set-up the current transducers (G417) for all DC inputs . . . . . . . . . . . . . . . 26

Hints on using the assistant control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Parameter settings before the first start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

First start (local control mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Set up fieldbus control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Register the inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Starting and stopping the inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Inverter control with parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Inverter control with Start/Stop switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Inverter control with SCADA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Summary of Contents for Fimer PVS980-58-4348kVA-I

Page 1: ...Central inverter PVS980 58 From 4348 to 5000 kVA Commissioning and maintenance manual ...

Page 2: ...tral inverters firmware manual 3AXD10001146386 Option manuals and guides ACS AP x Assistant control panels user s manual 3AUA0000085685 Start up and maintenance PC tool Drive composer user s manual 3AUA0000094606 FENA 01 11 21 Ethernet adapter module user s manual 3AUA0000093568 FSCA 01 RS 485 adapter module user s manual 3AUA0000109533 NETA 21 Remote monitoring tool user s manual 3AUA0000096939 C...

Page 4: ...2 ...

Page 5: ...utput option G415 G398 20 3 phase power output option G430 20 Connecting temporary external 230 115 V AC supply for control system during commission ing 20 Smoke detector 21 Installing fieldbus adapter modules option K458 K475 22 Connecting a PC 23 4 Start up and operation Start up procedure 25 Safety 25 Primary and ambient conditions 25 Set up the insulation monitoring device 26 Set up the curren...

Page 6: ...operation after a firmware update 36 Troubleshooting 36 Cabinet 37 Cleaning the cabinet 37 Cleaning the cooling air intake grilles 37 Filters 38 Replacing the main cooling filters 38 Replacing the control section air filters 39 Cleaning the power module heat exchanger 41 Fans 42 Replacing the main cooling fans 42 Replacing the power module cooling fans 44 Replacing the control section cooling fan ...

Page 7: ...ll you about conditions which can cause injury or death or damage to the equipment They also tell you how to prevent the danger The manual uses these warning symbols Electricity warning Electrical hazards which can cause injury or death or damage to the equipment General warning Conditions other than those caused by electricity which can cause injury or death or damage to the equipment Electrostat...

Page 8: ... or the inverter or its input or output cables when the inverter is connected to an electrical power system or to the PV generator Before you do work in the AC DC LCL or power section of the inverter isolate the AC busbars from the electrical power system with the disconnector of the power system transformer Also isolate the inverter from the PV generator with the safety switch of the PV generator...

Page 9: ...alified electricians are permitted to do grounding work Always ground the inverter and adjoining equipment Correct grounding also decreases electromagnetic emissions and interference Follow the site s policy on disconnecting the inverter from AC and DC The cross sectional area of protective bonding conductors for connection to the main earthing terminal need not exceed 25 mm2 Cu or an equivalent c...

Page 10: ... the inverter from the AC supply normally a disconnector or a breaker on the HV side of the main transformer because the optional AC breaker of the inverter does not remove the voltage from the AC output of the inverter a Disconnect the inverter from the DC power supply usually the DC switches of the solar array junction boxes or the DC combiner box b Make sure that reconnection is not possible Lo...

Page 11: ... the site when you do the measurements do not measure in wet conditions Do not use a multimeter Verify that the voltage between the AC busbars and the grounding PE busbar is close to 0 V Make sure that the voltage between the inverter AC output terminals L1 L2 L3 i and the grounding PE busbar ii is close to 0 V Measure every phase to phase and phase to ground voltage L1 L2 L1 L3 L2 L3 L1 GND L2 GN...

Page 12: ...rk must be done outside the inverter 6 Protect any other energized parts in the work location against contact Take special precautions when you work near bare conductors 7 Ask the person in charge of work for a permit to work After you finish the work make sure that the inverter is clean from inside and that all the tools have been removed from inside the inverter remove the temporary grounding an...

Page 13: ... fingers or other objects into the fans Be aware of hot surfaces Some parts in the inverter cabinet such as the heat exchangers are hot after you disconnect the electrical supply Make sure that the debris from the installation work does not go into the inverter Electrically conductive debris in the unit can cause damage Do not open the doors of the inverter when it is raining or when sand or dust ...

Page 14: ...to the equipment Handle the fiber optic cables with care When you disconnect the cables hold the connector not the cable Do not touch the ends of the fibers with bare hands as the ends are extremely sensitive to dirt Do not bend the fiber optic cables too tightly The minimum permitted bend radius is 35 mm 1 4 in ...

Page 15: ...iary power disconnector Q64 If the inverter is supplied from external auxiliary power connect it and close the disconnector Q64 Before you put the inverter make sure that all of the equipment is suitable for operation Do not use the inverter in a manner not specified in this manual Note for UL installations To reduce the risk of fire connect the inverter only to a circuit provided with branch circ...

Page 16: ...14 Safety instructions ...

Page 17: ... inverters that follow PVS980 58 4348kVA I PVS980 58 4456kVA J PVS980 58 4782kVA K PVS980 58 5000kVA L Target audience This manual is intended for FIMER trained and certified persons who commission and service the inverter Read the manual before you do work on the inverter You are expected to know the fundamentals of electricity wiring electrical components and electrical schematic symbols ...

Page 18: ...use negligence or accident iii has been used in a manner contrary to the Manufacturer s instructions or iv has failed as a result of ordinary wear and tear All material in this manual is subject to change without a further notice The manual is intended as a non contractual document Cybersecurity disclaimer This product is designed to be connected to and to communicate information and data via a ne...

Page 19: ...rollability and high switching frequency Inverter A cabinet built device containing all inverter modules together with their control electronics and I O and auxiliary components The inverter module converts the DC voltage to AC voltage Its operation is controlled by switching the IGBTs I O Input Output MCB Miniature circuit breaker MGND Solar array functional grounding unit MIRU Solar array insula...

Page 20: ...18 Introduction to the manual ...

Page 21: ...Electrical commissioning 19 3 Electrical commissioning This chapter describes the electrical commissioning of the inverter ...

Page 22: ...rminal X62 and the service outlet Voltage selection 230 or 400 V AC Maximum power 10 kVA Can be connected to grounded systems TN 3 phase power output option G430 The inverter has a 3 phase power output for an auxiliary power transformer when option G430 is selected Voltage Same as inverter output Supplied fuse 63 A 60 A IEC UL Can be connected only to IT ungrounded systems Connecting temporary ext...

Page 23: ...ral wire to terminal X11 3 Connect line wire to terminal X12 4 You can limit the power consumption by opening the 48 V PSU feeding circuit breakers Close only F12 to activate the control boards and communication modules Smoke detector The inverter is equipped with a smoke detector in the DC section as standard For more information refer to the Firmware manual Remove the protective cap from the smo...

Page 24: ... disconnecting device and measure to make sure that there is no voltage present Refer to Installation and maintenance safety on page 6 2 Switch off any potentially dangerous control voltages coming to the inverter 3 Install the module into slot 1 of the control unit see details on the Hardware manual page 104 4 Push the retaining clip on top of the module to lock it 5 Tighten the mounting screw of...

Page 25: ...trol panel does not support Ethernet communication 2 Open the USB connector cover on the front of the control panel 3 Connect a USB cable Type A to Type Mini B between the USB connector on the control panel 3a and a free USB port on the PC 3b 4 The panel will display an indication when the connection is active Refer to the documentation of the PC tool for setup instructions Refer to ACS AP x assis...

Page 26: ...24 Electrical commissioning ...

Page 27: ...e inverter is correct Refer to section Installation checklist in the Hardware manual Make sure that the insulation of the assembly is sufficient Refer to section Checking the settings of the auxiliary voltage transformer option G415 on page 20 Make sure that the ambient conditions for start up temperature humidity altitude etc are within the limits Refer to the technical data in the Hardware manua...

Page 28: ...arameter settings needed before the first start according to the firmware manual Refer to the start up section of the firmware manual First start local control mode Disable the external communications for example for the data logger plant controller or SCADA system Release the fast power off switch Make sure that the DC voltage of the solar generator matches the value of the 208 01 DC Input Voltag...

Page 29: ...connecting state after the delay set in parameter 213 13 Make sure that the inverter operates properly from the following actual value parameters 101 01 DC Voltage 101 12 Power 174 31 to 174 94 where the active input parameters depend on the DC input options G417 The DC voltage should decrease from the open circuit voltage and the active power should match the line current and the AC voltage Set u...

Page 30: ... value directly in the parameter group 189 Inverter Control with the control panel or with a computer through USB or SCADA Inverter control with Start Stop switch To enable the inverter operation turn the Start Stop switch to 1 RUN To disable the inverter operation turn the Start Stop switch to 0 STOP Inverter control with SCADA For more information refer to the Firmware manual for the parameter 1...

Page 31: ...r Operating Green The inverter operates normally Warning Orange There is an active warning in the inverter Fault Red There is an active fault in the inverter Heating Blue The internal heater is on Control panel ACS AP I Status LED Green continuous The inverter operates normally and the control unit is on Green flickering Data is transferred between the PC tool and the inverter via USB Green blinki...

Page 32: ...Red An error or warning detected by the AC500 firmware MIRU 01 POWER Green The MIRU 01 unit is powered ERROR Red An error detected by the MIRU 01 firmware STATUS Green The status of the insulation resistance measurement Slow flash once every 5 seconds Measurement ready Rapid flash 5 times per second Measurement not ready DISABLE Red Insulation resistance measurement is disabled MGND 01 POWER Green...

Page 33: ... a suitable environment it requires little maintenance The tables list the routine maintenance intervals recommended by FIMER The recommended maintenance and component replacement intervals are based on the specified operational and environmental conditions For more information on inverter maintenance contact your local FIMER Service representative Descriptions of symbols Action Description I Visu...

Page 34: ...an may void the warranty In addition if the plan is not followed the inverter may experience problems that the warranty does not cover Note Perform the maintenance actions listed below more often in case the inverter is installed out of the specified operational and environmental conditions Refer to the Hardware manual Pay special extra attention during the first year after commissioning Target ta...

Page 35: ...its output power to keep each operating power section below its maximum output power limit The capability of the inverter is reduced linearly along with the amount of disabled power sections To activate reduced run 1 Stop inverter operation with the Start Stop switch or with the parameter 189 01 Inverter operation 2 To access the reduced run control parameters enter an engineer level passcode to p...

Page 36: ...because any modified parameter settings such as option codes Modbus node ID and so on need to be restored after the SW upload On the control panel Open the Main menu Select Backups Select Create backup 6 Disable the inverter with the Start Stop switch On the control panel Open the Main menu Select Parameters and Complete list Scroll to 189 Inverter control and press Select Return to the start view...

Page 37: ...ate the firmware update process Click OK to acknowledge the warning message about not disturbing the load process The progress bar indicates remaining time of the load process WARNING Do not unplug the USB cable while uploading the firmware Also make sure the PC has enough battery life or is connected to power mains If the upload is interrupted the Flash memory stick might have to be replaced 5 Cl...

Page 38: ...arameter 196 08 to reload the correct parameter names 4 Disconnect the USB cable from the control panel and close the door Firmware update is now completed Troubleshooting The firmware upload fails with error code 10 Upload terminates prematurely with error code 10 This happens when inverter operation was not disabled before the firmware upload Disable the inverter and retry The firmware upload fa...

Page 39: ... 5 If you ignore the instructions physical injury or death or damage to the equipment can occur WARNING Use a vacuum cleaner with an antistatic hose and nozzle Using a normal vacuum cleaner creates static discharges which can damage the sensitive components 1 Stop the inverter and do the steps in Electrical safety on page 6 before you start the work 2 Clean the interior of the cabinet with a soft ...

Page 40: ...ooling filters The approved filter types are Camfil Ecopleat M5 size 592 x 592 x 96 mm Camfil type code 2355500 1 Remove the cover fastening screws 2 Remove the cover 3 Remove the filter fastening screws and brackets 4 Remove the filter 1 2 3 3 ...

Page 41: ...l type code CM355 WARNING Obey the safety instructions on page 5 If you ignore the instructions physical injury or death or damage to the equipment can occur 1 Before you start stop the inverter and do the steps in Electrical safety on page 6 2 Open the DC section door on the front side of the inverter 3 Remove the bottom touch protection shroud 4 Remove half of the fixing screws of the control se...

Page 42: ...heet to the correct dimensions 9 Reassemble the control section filter assembly Make sure that the new filter sheet is properly aligned to the frame Tightening torque for the screws is 4 N m 10 Push the control section filter assembly back into place and install the fixing screws Tightening torque for the screws is 9 N m 11 Reattach the bottom touch protection shroud Tightening torque for the scre...

Page 43: ... to the equipment can occur WARNING Use a vacuum cleaner with an antistatic hose and nozzle Using a normal vacuum cleaner creates static discharges which can damage circuit boards WARNING Be careful when you clean the heat exchanger to prevent damage to it Obey the safety instructions starting on page 50 for further details To clean the heat exchanger 1 Before you start stop the inverter and do th...

Page 44: ...ry or death or damage to the equipment can occur 1 Before you start stop the inverter and do the steps in Installation and maintenance safety on page 6 2 Remove the front cover plate or open the front door of the section being worked on 3 Disconnect the fan connectors from the terminal block 4 Remove the fixing screws of the fan cassette 2 3 4 ...

Page 45: ...nnect the cable connectors of the cooling fans 7 Loosen the locking screws of the fan assembly plates 8 Carefully lift the fan assembly plates out of the fan cassette using the keyholes in the fan assembly plates 9 Replace the cooling fans Make sure that the air flow directions is correct towards the roof of the inverter when the fans are installed Tightening torque for the nuts is 6 N m 5 6 7 7 8...

Page 46: ... of each fan group from parameter group 202 Fan control Replacing the power module cooling fans WARNING Obey the safety instructions on page 5 If you ignore the instructions physical injury or death or damage to the equipment can occur The power module cooling fans are located under each power module of the inverter 1 Before you start stop the inverter and do the steps in Electrical safety on page...

Page 47: ...plate screws is 9 N m 7 Close the cover plate of the power section 8 After the inverter starts make sure that there are no fan failure warnings You can read the status of each fan from parameter group 202 Fan control Replacing the control section cooling fan The control section cooling fan is located at the top of the control section WARNING Obey the safety instructions on page 5 If you ignore the...

Page 48: ...t the air flow directions is correct through the hole in the back wall of the control section 7 Reinstall the fan finger protection guard to the new fan Tightening torque for the screws is 2 N m 8 Reinstall the fan assembly plate Tightening torque for the fan assembly plate screws is 9 N m 9 Connect the fan connector 10 Close the doors of the control section 11 After the inverter starts make sure ...

Page 49: ...cur 1 Before you start stop the inverter and do the steps in Electrical safety on page 6 2 Use wind hooks on the doors 3 If the inverter has fuse status detection option remove and disconnect the cables related to it on the fuse 4 Grease the fuse rails 5 Replace the blade fuses using the supplied fuse handle 6 Make sure that the new fuse is properly pushed to the slot 5 ...

Page 50: ...ment can occur 1 Before you start stop the inverter and do the steps in Electrical safety on page 6 2 Disconnect the cables of the power supply buffer 3 The power supply and buffer are rail mounted devices Pull on the bottom part and lift up to remove them 4 Attach the new power supply buffer and make sure they are properly fastened 5 Connect the cables of the power supply buffer 3 2 ...

Page 51: ...rol unit you can move the memory unit to the new control unit to keep the firmware and parameter settings WARNING Do not remove or insert the memory unit when the control unit is powered To remove the memory unit open the fastening screws 1 and pull the memory unit 2 out 2 1 ...

Page 52: ...o is authorized by FIMER WARNING When the module is out of the enclosure do not go under it Required tools Socket wrench set Socket driver Power driver Torx 30 bit 70 mm and a 100 mm extension Torque wrench 5 N m to 16 N m Small power screwdriver Make sure that you hold the fixing hardware to prevent it from falling ...

Page 53: ...er module 1 Open the quarter locks that attach the power module air filter unit 2 Remove the power module air filter unit 3 Remove the screws that attach the brackets to the module 4 Slide a pallet next to the module opening 1 2 2 3 4 ...

Page 54: ...e brackets between the module and the pallet to bridge the gap 6 Remove the fixing bolts that attach the power module to the frame 7 Remove the two rubber covers from the power module 8 Loosen the extraction bolts evenly 5 6 7 8 ...

Page 55: ...ule in reverse order Note the following After the module is pushed into the frame tighten the two extraction bolts Alternate between the bolts by turning them a maximum of ten turns at a time Tighten the extraction bolts to 16 N m Install the fixing bolts on the sides of the module and tighten them to 16 N m Reattach the brackets Install the rubber covers over the extraction bolts Make sure that t...

Page 56: ...54 Maintenance ...

Page 57: ...Further information For more information on FIMER products and services for solar applications visit fimer com ...

Page 58: ...tsoever for potential errors or possible lack of information in this document For more information please contact your local FIMER representative or visit fimer com We reserve all rights in this document and in the subject matter and illustrations contained therein Any reproduction disclosure to third parties or utilization of its contents in whole or in parts is forbidden without prior written co...

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