ABB PVS800-57B Maintenance Manual Download Page 7

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Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Descriptions of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Recommended annual maintenance actions by the user . . . . . . . . . . . . . . . . . . . . . . 60
Recommended maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Examining the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Cleaning the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Replacing the cabinet door air filters and cleaning the grilles . . . . . . . . . . . . . . . . . . 62

Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Replacing the inverter power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Storing spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
DC circuit capacitors reforming, spare modules, and spare capacitors . . . . . . . . . . . 75

Further information

Summary of Contents for PVS800-57B

Page 1: ...ABB SOLAR INVERTERS PVS800 57B central inverters Commissioning and maintenance manual...

Page 2: ...XD50000048331 Firmware manuals and guides PVS800 57B central inverters firmware manual 3AXD50000048332 Option manuals and guides ACS AP x Assistant control panels user s manual 3AUA0000085685 Start up...

Page 3: ...manual PVS800 57B central inverters 3AXD50000048331 Rev A EN EFFECTIVE 2018 06 25 2018 ABB Oy All Rights Reserved 1 Safety instructions 4 Mechanical installation Table of contents 5 Electrical install...

Page 4: ......

Page 5: ...19 Terms and abbreviations 20 3 Storing lifting and transporting Contents of this chapter 23 Moving the inverter 23 Storing the inverter 24 Lifting the inverter in the shipping package 25 With a crane...

Page 6: ...6 Default I O connection diagram 46 Connection procedure 46 Fast power off circuit 47 Startup after FPO 47 Connecting a PC 48 Installing fieldbus adapter modules 49 6 Installation checklist Contents o...

Page 7: ...the power module cooling fans 63 Replacing the power module board compartment fan 64 Replacing the LCL filter cooling fans 65 Replacing the AUX cabinet cooling fan 66 Replacing the DC cabinet cooling...

Page 8: ...8...

Page 9: ...an 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...

Page 10: ...aic generator with the safety switch of the generator or by other means The optional AC disconnectors or optional breakers do not isolate the AC output cables and terminals of the inverter from the el...

Page 11: ...installation connect each inverter separately to the protective earth PE busbar of the switch board or the transformer Avoid grounding loops and keep grounding cables at least 0 5 m away from the AC...

Page 12: ...of all the power sections Q10 the optional 3 phase output switch F13 If the inverter is supplied from an external auxiliary power disconnect also that For auxiliary power switches note the following...

Page 13: ...hort circuit current can cause the temporary grounding cables to move hazardously 7 Ask the person in control of the electrical installation work for a permit to work 8 After you finish the work make...

Page 14: ...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...

Page 15: ...fuse switch F10 AC Q2 and DC Q1 Note the point on page 12 about auxiliary power supply When the inverter operates do not open the AC or DC disconnectors Before you adjust the inverter and put it into...

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

Page 17: ...erter The flowchart refers to sections in this manual and in other manuals Applicability This manual is applicable to PVS800 57B central inverters Target audience This manual is intended for persons w...

Page 18: ...d the operation of the inverter Hardware status The fault tracing possibilities of the inverter Maintenance The preventive maintenance instructions of the inverter Related documents Refer to the inner...

Page 19: ...rs hardware manual 3AXD50000048300 EN Option manual if optional equipment is included Unpack and examine the units for damage Make sure that all of the optional modules and equipment are present and c...

Page 20: ...gate bipolar transistor a voltage controlled semiconductor type widely used in inverters due to its easy controllability and high switching frequency Inverter A cabinet built device containing all inv...

Page 21: ...into a combined output circuit or circuits Solar cell Device that converts light directly into electricity by the photovoltaic effect Solar generator The total of all solar strings of a solar power s...

Page 22: ...22 Introduction to the manual...

Page 23: ...ng beams on the roof or with a fork lift from the base of the inverter Always move the inverter in the upright position WARNING Obey these instructions to prevent physical injury or death or damage to...

Page 24: ...or example for four weeks of storage use 800 g of desiccant bags Replace the bags with fresh bags every four weeks and do not open the doors unnecessarily during the storage period Examples of suitabl...

Page 25: ...nd dents Make sure that the slings have sufficient loading capacity The minimum length of each sling is 1 8 m Adjust the lengths of the lifting slings to make sure that the inverter does not tilt Atta...

Page 26: ...the inverter from the lifting holes on the base of the inverter Make sure that the forklift truck has sufficient loading capacity Always lift the inverter so that its center of mass is centered on th...

Page 27: ...Storing lifting and transporting 27 Moving the crate with a forklift...

Page 28: ...damage to the inverter frame To prevent damage to the inverter do not put cargo straps over the inverter when it is not in the shipping package Do not throw hooks over the roof This can damage the pai...

Page 29: ...e tools required to move the inverter fasten it to the foundation and tighten the connections Crane fork lift or pallet truck with sufficient load capacity and iron bar jack and rollers Pozidriv and T...

Page 30: ...efer to PVS800 57B central inverters hardware manual 3AXD50000048300 EN Record possible deviations carefully and contact the local ABB representative immediately Examining the installation site Refer...

Page 31: ...ove the lifting beams seal their mounting holes to retain the degree of protection The distance between the lifting holes in the lifting beam is 2150 mm 7 The minimum length of the lifting slings is 1...

Page 32: ...he cabinet from below alongside the cubicle seams Final placement of the cabinet Move the cabinet into its final position with a slate bar spud bar Put a piece of wood between the edge of the cabinet...

Page 33: ...upright vertical position You can install the cabinet with its back against a wall a or back to back with another unit b To adjust the height of the cabinet use metal shims between the cabinet bottom...

Page 34: ...s along the front and rear edges of the cabinet frame body and fasten them to the floor with a M12 bolt The recommended maximum distance between the clamps in the front edge is 800 mm 31 5 Wall clampi...

Page 35: ...that were delivered with the unit With user defined cable entries take care of the degree of protection fire protection and EMC compliance Ventilation The air inlets of the installation space must su...

Page 36: ...he required air flow through the cabinet Make sure that no dirty or moist air flows back to the inverter even during off time or when you do maintenance on the inverter Calculating the required static...

Page 37: ...Mechanical installation 37 pd 0 5 vm 2 0 5 1 1 5 52 17 Pa The required pressure in the exit air duct is then 1 5 2 17 Pa 26 34 Pa below the pressure in the room For more information Contact ABB...

Page 38: ...38 Mechanical installation...

Page 39: ...rm voltage tolerance or insulation resistance tests on any part of the inverter AC output cables Make sure that the insulation of the AC output cable obeys the local regulations before you connect it...

Page 40: ...ch other and to the ground Make sure that there is 500 mm 20 in of separation between the power cables and the control cables If the control cables cross the power cables set them at angle as close to...

Page 41: ...he cabinet entry Ground the other end of the input cable shield or PE conductor at the transformer 3 4 If you use shielded cable which is recommended and the conductivity of the shield is 50 of the co...

Page 42: ...tion that is as equal as possible Connect single core cables without concentric protective shielding armor as shown WARNING Ground all conductive cable supports cable clamps and individual conductive...

Page 43: ...Put the cable s into the inside of the cabinet 3 If it is a shielded cable connect the shield to the cabinet grounding busbar with a cable lug 4 Connect the DC conductor to terminal DC and the DC cond...

Page 44: ...t is a shielded cable prepare the cable ends and do the 360 grounding at the cabinet entry Connect the twisted shield of the AC output cable s to the cabinet PE ground busbar with a cable lug 4 Connec...

Page 45: ...er has a 3 phase power output for an auxiliary power transformer when option G429 is selected Voltage Same as inverter output Can be connected only to IT ungrounded systems 1U5 173V 1U4 200V 1U3 350V...

Page 46: ...ensure proper connection of the bare shield Note If the outer surface of the shield is non conductive Cut the shield at the midpoint of the bare part Do not cut the conductors or the grounding wire i...

Page 47: ...ith its return wire reduces disturbances caused by inductive coupling Fast power off circuit The FPO circuit is powered from the 24 V DC circuit which is connected directly to the Fast Power Off switc...

Page 48: ...panel ethernet connector of the inverter 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...

Page 49: ...re by measuring that the I O terminals of the control unit especially the relay output terminals are safe 3 Insert the module into a free option module slot on the control unit 4 Fasten the mounting s...

Page 50: ...50 Electrical installation...

Page 51: ...of this chapter This chapter contains a list for checking the mechanical and electrical installation of the inverter Warnings WARNING Obey the instructions in chapter Safety instructions If you ignor...

Page 52: ...PVS800 57B central inverters hardware manual 3AXD50000048300 EN The insulation of the assembly is sufficient refer to Insulation test on page 39 The AC power system is an IT ungrounded system The AC p...

Page 53: ...electrical installation of the inverter is correct Refer to section Installation checklist on page 51 Make sure that the insulation of the assembly is sufficient Refer to section Insulation test on p...

Page 54: ...adjusted to 30 kohm at the factory Refer to the PVS800 57B central inverters firmware manual 3AXD50000048332 EN More information Circuit diagrams delivered with the inverter Set up the current transdu...

Page 55: ...e If the DC voltage is different from the parameter value do not start the inverter Contact ABB Enable the inverter operation from parameter 189 1 Make sure that the inverter operates properly from th...

Page 56: ...56 Start up and operation...

Page 57: ...olor and meaning of the LED indicators in the inverter Where LED Color Indication Control panel Status LED Green cont The inverter operates normally The control unit is powered and 24 V is supplied to...

Page 58: ...een The AC500 program is running ERR 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 G...

Page 59: ...formance For more detailed maintenance information refer to the maintenance instructions product manuals and the ABB website www abb com solarinverters Inverter s designed life time is 25 years If the...

Page 60: ...iness corrosion and temperature inside the cabinet Cleaning if needed I Overall cleanliness of inverter e g cabinet door sealings function of cooling fans main circuit terminals I Other Air circuit br...

Page 61: ...y fastened to the installation surface Make sure that the doors are closed Cleaning the cabinet WARNING Obey the safety instructions page 9 If you ignore the instructions physical injury or death or d...

Page 62: ...r 1 Stop the inverter and do the steps in Performing electrical work on page 12 before you start the work 2 Remove the grille fasteners 3 Remove the grilles one by one 4 Remove the dirty air filters f...

Page 63: ...top the inverter and do the steps in Performing electrical work on page 12 2 Open the cover plates of the ISU cabinet 3 Remove the screws that hold the cover plate of the fan unit 4 Lift the cover pla...

Page 64: ...cal work on page 12 2 Open the cover plates of the ISU cabinet 3 Remove the two M4 12 T20 screws that lock the fan holder 4 Pull the fan holder out of the module 5 Disconnect the fan cable 6 Remove th...

Page 65: ...orming electrical work on page 12 2 Open the ISU cabinet cover plates 3 Disconnect the power and control cables of the LCL cooling fans 4 Loosen the locking screws of the LCL cooling fan 5 Pull the fa...

Page 66: ...rter and do the steps in Performing electrical work on page 12 2 Open the AUX cabinet door 3 Disconnect the power connector of the cooling fan 4 Remove the 2 screws that hold the cooling fan and finge...

Page 67: ...jury or death or damage to the equipment can occur 1 Before you start stop the inverter and do the steps in Performing electrical work on page 12 2 Open the DC cabinet door 3 Disconnect the power conn...

Page 68: ...power connector of the cooling fans 4 Remove the cover of the cable tray above the fan assembly and take out the cables 5 Remove the 8 screws that hold the fan assembly 6 Disconnect the fan wiring 7 R...

Page 69: ...he terminals on the front of the module including fiber optic cabling Move the disconnected wiring aside 7 Attach the module extraction installation ramp included to the base of the cabinet so that th...

Page 70: ...70 Maintenance 5 6 4 3...

Page 71: ...Maintenance 71 7 8 8...

Page 72: ...72 Maintenance 9 10...

Page 73: ...sure with one foot on the base of the module to prevent the module from falling on its back 4 Secure the top front of the module with two screws Tighten to 22 N m 16 lbf ft 5 Secure the bottom front o...

Page 74: ...n the fastening screw and remove the battery 2 Install the new BR2032 battery 3 Dispose of the old battery according to local disposal rules or applicable laws 4 Set the real time clock Replacing the...

Page 75: ...acitors reforming spare modules and spare capacitors If there are spare modules or separate spare DC circuit capacitors ABB recommends that you reform the capacitors annually See separate instructions...

Page 76: ...76 Maintenance...

Page 77: ...Further information For more information on ABB products and services for solar applications navigate to www abb com solarinverters...

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