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ABB PVS800-IS Hardware Manual Download Page 41

Start-up

Contents of this chapter

This chapter provides instructions for start-up of the PVS800-IS inverter station.

WARNING!

Only an authorized electrician is allowed to install, start up and maintain the inverter
station. Follow the

Safety instructions (page 9)

and the local safety regulations.

If ignored, physical injury or death may follow, or damage may occur to the
equipment.

Tools needed

•

Computer with the Drive composer PC tool installed (for the inverter diagnostics and
settings)

•

Multimeter

Start-up tasks

Note:

These instructions are valid for a typical system (solar plant, inverter station and MV
substation) such as the one presented in the example

Main circuit diagram (page 17)

. The

symbols in square brackets, for example [U1], refer to the device designations used in the
circuit diagrams.

Additional information

Task

Pre-checking the switchgear (voltage not connected)

See the switchgear manufacturer’s instructions.

8

Start-up 41

Summary of Contents for PVS800-IS

Page 1: ... ABB CENTRAL INVERTERS PVS800 IS inverter stations 1 645 to 4 156 MW Hardware manual ...

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Page 3: ...00 IS inverter stations 1 645 to 4 156 MW Table of contents 1 Safety instructions 5 Mechanical installation 7 Electrical installation 8 Start up 2018 ABB Oy All Rights Reserved 3AXD50000255818 Rev A EN EFFECTIVE 2018 06 04 ...

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Page 5: ...rview 16 Layout drawing 17 Main circuit diagram 17 Inverter 18 Type designation label 19 Type designation key 4 Storing lifting and transporting 21 Contents of this chapter 21 Storing 22 Lifting 23 Transporting 23 Incoming inspection at arrival 5 Mechanical installation 25 Contents of this chapter 25 General guidelines 25 Constructing the foundation for the inverter station 27 Preparation of the g...

Page 6: ...om inverter station to MV substation 40 Connecting the control cabling 8 Start up 41 Contents of this chapter 41 Tools needed 41 Start up tasks 9 Maintenance 45 Contents of this chapter 45 General 46 Maintenance intervals 46 Cleaning the inverter compartment 47 Replacing the intake air filters and cleaning the sandboxes 48 Cleaning the exterior surfaces of the inverter station 48 Materials 48 Proc...

Page 7: ... Combined derating 56 Derating Example 11 Drawings 57 Contents of this chapter 58 Dimensions and layout 59 Transportation drawing 60 Lifting drawing 61 Foundation and external cabling layout 63 Cable entry system example Further information Table of contents 7 ...

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Page 9: ...ch can result in serious injury or death and or damage to the equipment and advise on how to avoid the danger The following warning symbols are used in this manual WARNING Electricity warning warns of hazards from electricity which can cause physical injury and or damage to the equipment WARNING General warning warns about conditions other than those caused by electricity which can result in physi...

Page 10: ... only be energized and de energized by an authorized person who has task specific instructions for the operation of an MV substation and permission from the on site foreperson in charge of electrical work If other people must be in the vicinity while the door is open warn them and if required provide supervision and guidance General safety instructions WARNING Before any work perform the safety pr...

Page 11: ...tchgear Lock and add a warning notice e Turn the disconnector switch if any at the transformer side of the switchgear to open position Lock and add a warning notice f Disconnect all inverter DC supplies The DC disconnectors are usually located in the junction boxes on the solar field Lock and add warning notices 3 Check that all shrouds and screens are in place A shroud or screen may only be remov...

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Page 13: ...w the fundamentals of electricity wiring electrical components and electrical schematic symbols The manual is written for readers worldwide Contents of the manual Safety instructions gives safety instructions for the installation start up operation and maintenance of the inverter station Introduction to this manual provides information about the contents of this manual Hardware description describ...

Page 14: ...rter firmware manuals and guides Inverters 3AXD50000048332 PVS800 57B central inverters firmware manual Other Inverters 3AXD50000048331 PVS800 57B commissioning and maintenance manual Whole inverter station Main circuit diagram of the inverter station Whole inverter station Main circuit diagrams of the inverters Whole inverter station Commissioning checklist Inverters PVS800 57B test report Access...

Page 15: ... equipment required to connect a solar power generator DC to medium voltage substation equipment AC and ultimately to the MV power grid The rugged inverter station consists of a modified and insulated 20 foot high cube HC sea container housing one or two inverters with comprehensive protection control and monitoring functions air filtration system auxiliary power system 3 Hardware description 15 ...

Page 16: ...on boxes 3 Air outlets with weather protection hoods 4 Local power enclosure see Local power enclosure page 39 5 Auxiliary voltage transformer option G344 6 Installation area for post assembled components for example monitoring 500 x 1200 7 Note Components must not block the air inlet area Main earthing bar MEB 8 Container doors 9 16 Hardware description ...

Page 17: ...B EAB Auxiliary power Customer s TN S grid Option Auxiliary power from LV busbar PVS1 PVS1 PVS1 PVS2 PVS2 PVS2 MV switchgear compartment of MV substation A MV transformer compartment of MV substation B PVS800 IS inverter station C DC input 1 Inverters 2 MV transformer 3 MV switchgear 4 Power grid AC connection and to parallel inverter stations if there are any 5 External auxiliary power supply sta...

Page 18: ...em Serial number Each inverter station has a unique serial number For example CG201341001 CG ABB factory identification code 2013 Manufacturing year 41 Manufacturing week 001 Manufacturing unit number Serial no Type designation key For example PVS800 IS 3464kW C G344 PVS800 Product series IS Construction inverter station 3464kW Nominal AC power C Nominal AC voltage G344 Option plus code For more i...

Page 19: ...uction IS Inverter station Steel frame container built IP54 inverter compartment C4 corrosion class double staged air filtering G4 filter class 2 x PVS800 57B central inverters G300 cabinet heater 20H382 20x fuse protected DC input connections optionally 24H382 24x fuse protected DC inputs 7 9 Nominal AC power xxxxkW See chapter Technical data page 53 10 16 Nominal AC voltage C 380 VAC C 400 VAC 1...

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Page 21: ... more than two weeks without using electric heaters Hang fresh desiccant bags about 1 m above the floor Use 500 g desiccant per week of storage to ensure dry conditions inside the inverter station during storage For example for four weeks of storage use 2 kg of desiccant bags Replace the bags with fresh bags every four weeks and avoid opening the doors unnecessarily during the storage period Examp...

Page 22: ... the inverter station does not tilt during the lifting Do not allow lifting slings to scratch the walls or roof Damaged paint can lead to corrosion Use a guide wire attached to a lower corner of the inverter station to prevent rotation WARNING Ignoring the following instructions can cause physical injury or death or damage to the equipment Use only authorized lifting equipment and personnel Preven...

Page 23: ...e maximum thickness of the mat is 3 cm Fasten the inverter station firmly onto the chassis with heavy duty transport straps WARNING Transport the inverter station on an open heavy duty chassis Do not use an enclosed trailer because the inverter station could easily get scratched if it comes into contact with the walls of the trailer Keep the transportation height as low as possible Make sure that ...

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Page 25: ...f the surrounding ground at least 5 cm per meter This ensures that surface water flows away from the inverter station properly The height of the column foundations used with the station should be at least 80 cm but may need to be taller to secure a frost proof depth In the completed installation there must be 15 cm gap between the ground and the bottom of the container Consider local conditions su...

Page 26: ...e water does not cause harm Construct proper support for the inverter station On sandy soil Gravel is usually enough below the column foundations Fill the foundation hole with gravel according to normal construction practices Use geotextile to prevent mixing of fill gravel with the surrounding soil Start by filling with crushed stone or coarse gravel and continue with finer material Compress the f...

Page 27: ...el with surrounding soil 3 Put coarse gravel at the bottom of the hole and fine gravel at the top 4 Compress the gravel and soil below the foundation area 5 1 2 3 4 Fine gravel on top 1 Coarse gravel 2 Geotextile 3 Compressed area minimum 7500 x 4000 mm 4 Maximum 560 mm after compression 5 Mechanical installation 27 ...

Page 28: ...ing ground around the foundation Make sure that you obey the rules in section Constructing the foundation for the inverter station page 25 Do not place the inverter station too low Adding gravel around a inverter station which is placed too high is much easier than reinstalling the inverter station 2 Check that the foundation is level Maximum inclination of the foundation below the inverter statio...

Page 29: ...for local frost conditions add insulation around the column foundations 2 Fill the hole with fine gravel with a 5 cm m tilting angle Leave a 15 cm air gap underneath the inverter station 3 To minimise growth of grass the use of fiber around the station is recommended Put the fiber 20 cm below the station and about 80 cm around the station 4 Construct two rows of 500 x 500 mm concrete tiles around ...

Page 30: ...t the planting compost base is at least one meter from the inverter station housing and that fully grown bushes will not prevent maintenance access to the inverter station Ensure that the plantation does not discharge dust or seeds that could hinder the cooling air flow Adding weather protecting hoods 1 2 1 Remove the temporary protectors 1 1 Add weather protection hoods 2 2 30 Mechanical installa...

Page 31: ...ion Follow the Safety instructions page 9 and the local safety regulations If ignored physical injury or death may follow or damage may occur to the equipment Checking that the installation is clean and undamaged Clean the inverter station of all dirt Repair any damage caused to the exterior painting during installation See section Checking and repairing painted surfaces page 50 6 Checking the ins...

Page 32: ...or tools from the station They can cause shortcircuit faults or other damage Check that the station is clean Mud on painted surfaces will increase the risk of corrosion See chapter Maintenance page 45 Check the main circuit clearance distances cable terminations and connections against the main circuit diagram Check that all connections have been tightened Check that all necessary warning labels h...

Page 33: ...y occur to the equipment Routing the cables Route the input DC power cables AC power cables and control cables in separate paths The minimum distance between control cables and DC or AC power cables is 500 mm when run in parallel Do not install the control cables in the same cable trenches with DC cables Where control cables must cross power cables ensure they are arranged at an angle as near to 9...

Page 34: ...the wall near the exit door Check that the inverter station is properly connected to earth MV SUBSTATION PVS800 IS MEB MEB LV TR MV PE PE PE PE Frame Frame Frame HEA M12 70 T1 Transformer H1 H3 Switchgear H3 Transf breaker PVS1 Inverter PVS2 Inverter AC Main Switch AC Main Switch EAB Aux power box H07 V K 120mm2 H07 V K 120mm2 H07 V K 16mm2 120mm2 H07 V K Earthing electrode Measuring the insulatio...

Page 35: ...emove the cable supports and lead throughs in the bottom of the inverter cabinets to enable cabling 4 Connect the cables to the appropriate terminals in the inverters see sections DC input cable connection procedure page 36 and AC output cable connection procedure page 37 Tighten the connections to the torques specified in the inverter manual 5 Fill the cable trenches WARNING Make sure that unused...

Page 36: ...of the cabinet 4 If it is a shielded cable connect the shield to the cabinet grounding busbar with a cable lug 5 Connect the DC conductor to terminal DC and the DC conductor to terminal DC 6 If there is a separate PE conductor connect it to the cabinet grounding terminal 7 Refit the shroud onto the input power terminals a DC DC a DC DC DC input terminals DC DC Cable lead throughs a 36 Electrical i...

Page 37: ... 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 5 Connect the phase conductors to terminals L1 L2 and L3 6 If it is present connect the separate PE grounding conductor to the cabinet PE ground busbar 7 Install the shroud on to the output power terminals a L1 L2 L3 AC output terminals L1 L...

Page 38: ... the inverter station through a cable lead through located in the bottom of the inverter station next to the exit door Tighten the cable gland Make sure that unused holes and glands will be covered 4 Connect the cables to the appropriate terminals in the local power enclosure cabinet 5 Fill the cable trenches Note A ready made PVS800 IS application program template is part of the delivery The prog...

Page 39: ...als to connect auxiliary power supply from PVS800 IS to MV substation 2 Terminals to connection transformer IO alarm and trip signals from MV substation 3 Terminals to connect 3 phase 400 VAC to inverter s aux power supplies 4 Note The locations of switches and terminals may vary by delivery Check details from the circuit diagrams delivered with the PVS800 IS unit Electrical installation 39 ...

Page 40: ...MV substation The cable lead through for the power supply is located in the bottom of the container next to the exit door See the sections Main circuit diagram page 17 Technical data page 53 and Foundation and external cabling layout page 61 for further information Also see the PVS800 IS circuit drawings delivered within the unit Connecting the control cabling See section Foundation and external c...

Page 41: ...he equipment Tools needed Computer with the Drive composer PC tool installed for the inverter diagnostics and settings Multimeter Start up tasks Note These instructions are valid for a typical system solar plant inverter station and MV substation such as the one presented in the example Main circuit diagram page 17 The symbols in square brackets for example U1 refer to the device designations used...

Page 42: ... transformer faults unpowered and en sure that the inverters detect the fault indications and trip accordingly Turn the earthing switch at the grid side of the switchgear to the not earthed position Ask the power grid owner to connect the inverter station to the power grid Wait until the inverter station has been connected to the power grid before proceeding Turn the disconnecting switch at the gr...

Page 43: ...to wait inverter s first start This can be done by setting start up delay to inverter paramet ers See PVS800 57B hardware manual 3AXD50000048300 English Perform the rest of the inverter commissioning tasks if any Close the AC disconnector Q2 of the second in verter PVS2 to be commissioned Repeat the commissioning tasks if any for the second inverter Start up 43 ...

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Page 45: ...lacements are based on specified operational and environmental conditions ABB recommends annual inspections to ensure the highest reliability and optimum performance Consult your local ABB Service representative for more details on the maintenance WARNING Only an authorized electrician is allowed to service the inverter station Follow the Safety instructions page 9 and the local safety regulations...

Page 46: ...fter commissioning then every 5 years Cleaning the external surfaces See section Lubricating external hinges locks and seals page 49 Every 2 years Lubricating hinges and locks See section Checking and cleaning the grounding bars and points page 52 Every 5 years General condition check checking grounding bar See drawing Foundation and extern al cabling layout page 61 for max imum recommended tiltin...

Page 47: ...e filters are easily damaged if handled carelessly WARNING While cleaning sand collection boxes make sure that you do not touch or damage the filters 1 Turn off the inverters PVS1 PVS2 2 Loosen the screws on the filter supports on 2 sides 3 Remove the filter support frame 4 Replace the air filter 5 Reinstall the filter support frame and tighten the screws 6 Check and clean the sand collection boxe...

Page 48: ...ve stubborn dirt Rinse the detergent off with water The inverter station is IP54 protected A pressure washer can be used on the roof but must not be used near air inlets or outlets Wash air inlets with a gentle low pressure water flow Use a mop to gently wash the air outlet louvres inside the weather protection hoods Note The design of air inlet may vary from the picture on the right Consult ABB f...

Page 49: ...ay 0893 051 or similar spray Door seal lubricant Würth Rubber Care 0890 110 or similar silicone free spray Note Do not use lubricants containing silicone Silicone may react with repaired paint Procedure Oil the hinges and locks Wipe off excess lubricant with towels Spray door seals with rubber conditioning spray Wipe off excess lubricant with towels Maintenance 49 ...

Page 50: ...with clean water 3 Let the surface dry completely and keep it clean 4 Coat the area with zinc primer 5 Cover the damaged area with finishing paint 50 Maintenance Checking and repairing painted surfaces Materials Sandpaper or steel wire brush Cleaning towels Detergents Würth Pro Clean 0893 140 or similar Zinc primer Hempel zinc primer 16490 or Würth Rost Stop 0890 191 or similar Finishing paint Hem...

Page 51: ...erfect can be used to speed up the work and to provide a smoother surface appearance Maintenance 51 Checking and repairing unpainted zinc coated surfaces Materials Sandpaper Cleaning towels and liquids Zinc coating on non painted surfaces Würth Zinc 300 0892 200 with brush or Zinc Spray Perfect 0893 114 113 or similar Note Obey the instructions given by the material manufacturers Procedure WARNING...

Page 52: ...tween the grounding bar and cable terminal joint surfaces 2 Change the spring lock washers Tighten the cables to the nominal torque values torque for a M12 bolt is 50 Nm Note Check the main earthing bar in the MV substation as well to ensure a proper earthing grid Follow instructions and guidelines from the supplier of the MV substation 10 11 12 1 2 3 4 5 6 7 9 8 Earthing to container earthing poi...

Page 53: ...Technical data Contents of this chapter This chapter contains the technical data of the PVS800 IS inverter station 10 Technical data 53 ...

Page 54: ...equency 3 3 3 3 Harmonic distortion current 4 Yes Yes Yes Yes Power factor compensation Efficiency 5 98 5 98 4 98 3 98 5 Maximum 98 4 98 3 98 4 98 3 Euro eta Power consumption 3600 W 1800 W Own consumption in operation 6 120 W 60 W Standby operation consumption 6 500 W 500 W Additional maximum heating power 7 Environmental limits IP54 IP54 Degree of protection 8 20 C 45 C 20 C 45 C Ambient tempera...

Page 55: ...ace for MV substation 2 5 mm2 terminal size pre wired to inverters for example temper ature oil level alarm status optional derating 1 pcs I O signals NC types in alarm situation 0 Trip signal interface for MV substation 2 5 mm2 terminal size Inverter fuses See the PVS800 57B hardware manual Fuse ratings See chapter Drawings Cable lead through data See the PVS800 57B hardware manual Inverters DC a...

Page 56: ...vailable inverter power account for the different ratios of P per C at different inverter operating temperatures see section Temperature derating page 56 Combined derating Because altitude affects the maximum temperature it is possible to compensate for the altitude derating value with a limited maximum ambient temperature Each degree of maximum ambient temperature below the nominal ambient temper...

Page 57: ...Drawings Contents of this chapter This chapter contains the additional drawings of the PVS800 IS inverter station 11 Drawings 57 ...

Page 58: ... G G K K 2900 2438 6058 2999 844 2457 644 1169 5 1287 5 165 533 1676 0 2067 5 2467 5 4882 5 3AXD50000249831 Cable tunnel G G Space reservation for post installations K K Space reservation for post installations 58 Drawings ...

Page 59: ...ation drawing 1380 2900 1380 1219 2438 2900 6058 2260 5855 Center of gravity Exit door Center of gravity Container doors Exit door 20 HC High Cube container 20 HC High Cube container 3AXD50000245185 Drawings 59 ...

Page 60: ...ING CHAINS WITH MINIMUM CAPACITY OF 5000KG CHAIN USE LIFTING CHAINS WITH MINIMUM LENGTH OF 5000MM Exit door Length 5000mm Length 5000mm IF NEED FOR PRECISE ALIGNMENT WITHOUT TILTING USE 400MM LONGER LIFTING CHAIN ON THIS SIDE Container doors Exit door max max 60 Drawings ...

Page 61: ...tation IS after installation 1mm meter total 6mm in lengthwise total 2 5 mm sidewise Note Frost conditions and local regulations may require deeper trenches In these cases use taller column foundations MV station Earthing grid Earthing cable 120mm2 IO and PSU cables PVS1 PVS2 Note The control cables must not be installed into same pit with DC cables Follow minimum distances between control and DC ...

Page 62: ...800 IS MALVA CABLING ASSEM 0 Based on Prepared J Viljasalo 23 Mar 18 Title LAYOUT DRAWING Doc des Scale Form Customer Check P Kärki 23 Mar 18 EXTERNAL CABLING LAYOUT DRAWING 11 1000 A3 Appr K Pokela 23 Mar 18 PVS800 57B IS Resp dept Rev ind 0 Lang EN Cust Doc No Project name Doc No 3AXD50000250325 Sheet 2 DMS Number 3AXD10000707879 Weight kg Total 2 A Initial Approval 23 Mar 18 J Viljasalo EAB ETS...

Page 63: ...Cable entry system example Cable entries for earthing PSU IO and AUX cables DC cables PVS1 AC cables PVS1 DC cables PVS2 AC cables PVS2 Drawings 63 ...

Page 64: ...by navigating to www abb com searchchannels Product training For information on ABB product training navigate to new abb com service training Providing feedback on ABB manuals Your comments on our manuals are welcome Navigate to new abb com drives manuals feedback form Document library on the Internet You can find manuals and other product documents in PDF format on the Internet at www abb com dri...

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Page 68: ...www abb com solarinverters 3AXD50000255818A Copyright 2018 ABB All rights reserved Specifications subject to change without notice 3AXD50000255818 Rev A EN EFFECTIVE 2018 06 04 ...

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