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Safety instructions

Contents of this chapter

This chapter presents the use of warnings in the manual and gives instructions for safe
installation, start-up, use and maintenance of the PVS980-CS compact skid.

Use of warnings

Warnings caution you about conditions which 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 physical injury and/or damage to the equipment.

WARNING!

General warning warns about weather conditions, prohibited maintenance
operations during a typhoon, thunderstorm, snow, rain and electrical storm.
Maintenance in such conditions can result in physical injury and/or damage to the
equipment.

WARNING!

General warning warns about maintenance work on the roof which should always
be done from the outer perimeter, considering the local safety regulations.

1

Safety instructions 9

Summary of Contents for PVS980-CS

Page 1: ... ABB SOLAR INVERTERS PVS980 CS compact skid Hardware manual ...

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Page 3: ...kid Hardware manual Table of contents 1 Safety instructions 5 Mechanical installation 6 Electrical installation 8 Start up and operation 2019 ABB Oy All Rights Reserved 3AES PVS980 CS 00 MA01 Rev A EN EFFECTIVE 2019 10 31 ...

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Page 5: ...sources 14 Disconnecting the MV switchgear V module 14 Safety instructions for the auxiliary service board 14 Safe operation 2 Introduction to this manual 17 Contents of this chapter 17 Applicability 17 Target audience 17 Related documents 18 Terms and abbreviations 3 Hardware description 19 Contents of this chapter 19 Product overview 19 External dimensions 20 Layout drawing 20 Working areas and ...

Page 6: ...tallation 41 Contents of this chapter 42 Routing the cables 42 Earthing 43 Protective earthing grounding inside the compact skid 43 Measuring the insulation resistance of the cabling 43 Connecting DC cable from solar generator to inverters 43 Connecting the communication and auxiliary cabling Optional 44 Connecting the power grid cabling to the MV switchgear 7 Finalizing the installation 45 Conten...

Page 7: ...nting the damaged surface visible rust 58 Maintenance of Zinc coated surfaces 58 Coating the scratched areas 58 Tools and materials 58 Coating the damaged surface 59 Maintenance of grounding bars and points 59 Tools 59 Procedure 11 Maintenance of external hinges and locks 61 Tools 61 Lubricating the external hinges and locks 61 Procedure 12 Technical data 63 Contents of this chapter 64 Technical d...

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Page 9: ...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 physical injury and or damage to the equipment WARNING General warning warns about weather conditions prohibited maintenance operations during a typhoon thunderstorm snow rain and electrical storm Maintenan...

Page 10: ... equipment Only authorized electricians are allowed to install start up and maintain the compact skid Working methods tools components etc must follow the IEC regulations Obey all local safety regulations concerning electrical stations The compact skid should be energized and de energized only by an authorized person who has the task specific instructions for the operation of an MV substation and ...

Page 11: ...r and or MV transformer area Ignoring the instructions can cause physical injury or death or damage to the equipment 1 Identify the MV switchgear and read its safety instructions 2 Check the operation of the capacitive voltage indicators in all MV switchgear bays all phase LEDs are switched on when a voltage is connected 3 Disconnect the MV switchgear from all possible power supplies external auxi...

Page 12: ...e 8 Turn the disconnecting switch of the MV transformer side of the MV switchgear to open position Lock and add a warning notice 9 Disconnect the MV switchgear from the MV network all possible external power supplies grid and parallel stations See the User s manual of the MV switchgear Lock and add warning notices Earthing the MV switchgear and AC cabinet 1 Turn the earthing switches of the MV swi...

Page 13: ... 1 or inverter 2 AC and DC sides Connect the AC and DC busbars in both DC sections to PE with a temporary grounding tool 13 Issue a work permit Disconnecting the inverter from all possible sources To disconnect the inverter from all possible sources such as AC DC supply external auxiliary power etc follow below steps 1 Disconnect the inverter from the AC supply normally a disconnector or a breaker...

Page 14: ...nsformer Lock and tag 2 Open the secondary circuit breaker of the auxiliary service transformer Lock and tag 3 Open all switches breakers and connectors of the auxiliary service board Lock and tag 4 Make sure you are not near to any live parts while working Disconnect the live circuits or protect them with shrouds screens 5 Check the status of the voltage indicators in the auxiliary service board ...

Page 15: ...the Drive composer PC tool with a communication cable of sufficient length when you monitor or adjust inverter parameters during operation If the Start switch is in ON position and the Start command is active the inverter starts immediately after a fault reset For more information see PVS980 central inverters firmware manual 3AXD50000026271 EN Use the start delay when you start the PVS980 CS for t...

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Page 17: ...king on the compact skid You are expected to know the fundamentals of electricity wiring electrical components and electrical schematic symbols Related documents Code English Document Hardware manuals and guides 3AXD50000026013 PVS980 central inverter hardware manual 3AXD50000046782 PVS980 central inverters commissioning and maintenance manual Firmware manuals and guides 3AXD50000026271 PVS980 cen...

Page 18: ...954400 1 Oil type MV transformer Operation and maintenance manual of distribution MV transformers to do not available in library Terms and abbreviations Description Term Abbreviation Alternating current AC Construction of ABB SafeRing MV switchgear CCV Compact skid CS Construction of MV switchgear CV Direct current DC Low voltage 50 1000 V AC LV Low voltage ride through LVRT Medium voltage 1 35 kV...

Page 19: ...the power flow monitor and protect the power generator Oil immersed MV transformer transforms low voltage from the inverters into a medium voltage for the power grid MV switchgear is the connection point to the power grid It is also the main protection switching breaking and disconnecting equipment on the medium voltage side of the solar power plant Auxiliary service board contains auxiliary servi...

Page 20: ... components A B D C MV switchgear area For more information see section MV switchgear page 24 A AC auxiliary area For more information see section Auxiliary service board page 22 B Inverter area For more information see section Working areas and main components page 20 C MV transformer area For more information see section MV transformer page 25 D 20 Hardware description ...

Page 21: ...t the end of MV switchgear area 2 Cooling air inlet 3 Cooling air outlet 4 B Lead through holes for DC cabling from solar generator Terminal for the external DC earthing 5 C Lead through holes for AC cabling from inverters to MV transformer 6 Lead through holes for cabling from MV transformer to MV switchgear 7 D Hardware description 21 ...

Page 22: ...w describes the components of a standard auxiliary service board Additional components and customization are included in the project specific documentation Note Technical drawings are delivered with the unit only if you requested Auxiliary service transformer 1 Surge arrester protection for the auxiliary service board 2 Upstream on load fuse switch for auxiliary service transformer protection 3 22...

Page 23: ...uit breaker for auxiliary service transformer protection 4 Torch light and charger 5 Auxiliary service board circuit breakers and differential protections 6 Grounding busbar 7 Terminals block 8 Hardware description 23 ...

Page 24: ...e below 2 The connection of other parallel connected substations V is the Vacuum circuit breaker module equipped with the Self power relay REJ 603 as a standard MV switchgear circuit The diagrams below show the standard CV MV switchgear and optional CCV MV switchgear Both the switchgears can be upgraded to V module motorized and REF615 protection relay by adding combisensors for metering purpose F...

Page 25: ...er For information on the inverter see PVS980 central inverter hardware manual 3AXD50000026013 EN PVS980 central inverters commissioning and maintenance manual 3AXD50000046782 EN PVS980 central inverters firmware manual 3AXD50000026271 EN Hardware description 25 ...

Page 26: ...line configuration See also single line diagram 3AES PVS980 CS 01 DW01 List of technical drawings page 67 1 Inverters 2 MV transformer 3 MV switchgear 4 Auxiliary power supply 5 AC cabinet fan 6 AC cabinet heating 7 Power socket 8 Lightning 9 AC Cabinet control system 10 Inverter 1 power supply 11 Inventer 1 power supply 12 CS Control equipment 13 Spare 1 14 Spare 2 26 Hardware description ...

Page 27: ... Description Compact Skid Type Designation PVS980 CS XXXX Y options MADE IN SPAIN MANUFACTURED IN 20XX B A C D E F G H I J Serial number Each unit has a unique serial number A Description of the unit Medium Voltage Compact Skid B Type designation key For more information see Type designation key page 28 C See item description in Type designation key page 28 D H Manufacturing country name I Manufac...

Page 28: ...follow the basic code Each option code starts with an identifying letter common for the whole Product Series followed by descriptive digits The option codes are separated by plus signs The following table describes the fields of the basic code and the option code Refer to the items of figure in Type designation label Example PVS980 CS XXXX Y Options Description Item PVS980 Inverter mode D CS Compa...

Page 29: ...ings or any general poor condition WARNING Ignoring the following instructions can cause physical injury or death or damage to the equipment Use only authorized lifting equipment and personnel Prevent anybody getting under the load Do not stand on the roof while fastening the lifting slings or while lifting Do not throw slings or hooks onto the roof WARNING Use original silica gel bags only during...

Page 30: ...and vegetation free The ground must support the station evenly from below and there should not be any twisting or stress Do not place the compact skid directly onto the bare ground because this could damage the paint and cause corrosion Place the compact skid on wooden support beams Locate the beams under the four corners and the middle points Conditions for using desiccant bags Hang the desiccant...

Page 31: ...rs is five meters Adjust the length of lifting sling or chains so that the compact skid does not tilt during lifting Do not allow the 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 compact skid to prevent rotation Tools used for lifting Two 30 tons cranes Two spreaders 17 tons of 2 10 meters 6 89 ft to do should th...

Page 32: ...cross the compact skid See locations marked in below figure 2 Attach the sling or chains to the base structure fastening point 3 Connect the slings to the spreaders as shown in the below figures 4 Use the two cranes 32 Storing lifting and transporting ...

Page 33: ...red unpacked from the factory as standard The compact skid is built to fit inside an ISO 40 HC 1AAA according to ISO 3874 type shipping container It can be transported on a dedicated sea container trailer using the standard container attachment system Incoming inspection at arrival Visually check for any potential transportation damage s If any damages found mark and record them and immediately in...

Page 34: ...chains of 9 5 tons Two slings of eight tons Minimum five meters Pre requisite Follow the below instructions before you start unloading the PVS980 CS received in a 40 ft HC container 1 Protect the corners of the compact skid against shock 2 Make sure that the terrain is level and sturdy Consider that the compact skid has an approximate weight of 15 tons 3 Unload the standard container carrying the ...

Page 35: ...e wheels trajectory 2 Make sure that the guide platforms are leveled to the container floor 3 Connect the belly chains to the fastening points in the skid profile 4 Connect the slings to the belly chains and to the forklift Storing lifting and transporting 35 ...

Page 36: ... forklift must be perfectly aligned to the compact skid so that the station does not touch the container walls Optional Pull the compact skid until connection with spreader and crane is possible Then follow the lifting procedure to place the compact skid 36 Storing lifting and transporting ...

Page 37: ...ons Safety See Safety instructions page 9 Before you move the compact skid see instructions in chapter Storing lifting and transporting page 29 Tools Use the following tools to move the compact skid to fasten the compact skid foundation and to tighten the connections Crane forklift or pallet truck with sufficient load capacity Pozidriv and Torx 2 5 6 mm screwdrivers with short and long heads or bi...

Page 38: ...e work can be difficult The entire perimeter of the compact skid must rest on the foundation The compact skid must be above ground level To support the station use concrete or steel columns of at least 450 mm of height anchored to the attachment points marked in the drawing 3AES PVS980 CS 4600 30 DW02 Note The columns or concrete pad foundations are not part of the delivery Check the load carrying...

Page 39: ...se bolts and washers in each connection point not provided Mechanical installation 39 10 To fasten the compact skid to the foundation use the supplied attachment brackets see figure below Use bolts and washers in each connection point not provided Follow the local regulations and applicable standards to calculate the mechanical and structural properties of the connector Always consider the site co...

Page 40: ...m the outside Provide a permanent or portable platform for comfortable operation of the compact skid switching devices as the foundation can be higher than the surrounding ground For platform design and construction follow local rules and standards 4 Do not plant trees near the compact skid If bushes are planted make sure that the planting compost base is at least one meter 40 in away from the sta...

Page 41: ...ly an authorized electrician is allowed to install the cabling to the compact skid Obey the Safety instructions page 9 and the local safety regulations If ignored physical injury or death may follow or damage to the equipment may occur WARNING Do not do any electrical installation work during a thunderstorm WARNING Make sure that all external cable entries are fully sealed to prevent entry of fore...

Page 42: ...le Medium voltage cabling 1 Control and low voltage cabling 2 DC cabling lead through holes 3 Enclosure grounding terminals 4 Earthing Construct an earthing electrode for the compact skid Follow local regulations Connect the earthing electrode to the terminal located at the base of the compact skid See drawing 3AES PVS980 CS 02 DW02 Use joint lubricant to protect the connection point against corro...

Page 43: ...l 3AXD50000026013 EN and the wiring diagrams delivered with the compact skid To connect the DC cable from solar generator to inverters 1 Remove the covers of the cable entries 2 Lead the cables into the compact skid and seal the entry with the gland plates that is delivered with the inverter 3 Connect the cables to correct terminals of the inverters Tighten the connections to the torque values giv...

Page 44: ...ructions Connect the cables to the MV switchgear The standard cable termination see figure below installed in MV switchgear is of interface type C with bolted type 400 series Interface C with M16 x 2 metric threads 400 series In 630 A This termination is standard on all modules and for side connections 4 Fill the cable trenches and seal the cable entries For more information see chapter Finalizing...

Page 45: ...rical installation work during a thunderstorm WARNING Make sure that all external cable entries are fully sealed to prevent entry of foreign elements such as animals and insects Finalizing the installation 1 Clean the compact skid of all dirt 2 Repair any damages to the paint surface See section Maintenance of painted surfaces page 57 3 Install the external hood for the fan if apply See Mechanical...

Page 46: ...ng grounding of the compact skid and its components and make sure that it obeys the earthing grounding schematic Pull the earthing wires at the terminals to ensure that the connections are tight Remove any foreign objects such as loose fastenings and tools from the compact skid This can cause short circuit faults or other damages Make sure that the compact skid is clean Contaminated surfaces can i...

Page 47: ...the local safety regulations If ignored physical injury or death or damage to the equipment may occur WARNING Do not do electrical installation work during a thunderstorm Tools needed PC with Drive composer PC tool and applicable communication cables for the inverter diagnostics and settings Voltage detector Insulation resistance meter For more information see section Measuring the insulation resi...

Page 48: ...es specified in this section does not replace the instructions given by the product manuals of each component Additional information Task Check that there is no voltage Pre check the MV switchgear Visually examine the gas level of the SF6 tank from the gauge See SF6 Insulated Main Unit and Compact MV Switchgear Installation and Operating Instructions Operate all mechanical devices twice to do link...

Page 49: ...he local regulations applicable laws and standards required by the local power grid are met Applicable for C module MV switchgear Turn the earthing switch on the grid side of the MV switchgear to the not earthed position Contact your local grid and MV authority Only authorized personnel are permitted to make the connections Ask the power grid owner to connect the station to the power grid Wait unt...

Page 50: ...intenance manual 3AXD50000046782 EN Follow the inverter commissioning procedure If any other optional equipment is integrated into the compact skid such as UPS communication equipment and others then check the applicable documentation of the equipment before executing the start up procedure 50 Start up and operation ...

Page 51: ...iary service transformer Energize the MV transformer Voltage level depends on the inverter type 600 630 660 690 V Check that the incoming voltage level is equal to inverter voltage AC output Close Auxiliary service transformer primary breaker Check that voltage is 400 230 V 10 Check that the Auxiliary service transformer sec ondary winding voltage level is 400 230 V Close Auxiliary service transfo...

Page 52: ... the inverter manual to do correct manual link See PVS980 commissioning and maintenance manual 3AXD50000046782 EN Follow the inverter commissioning procedure If any other optional equipment is integrated into the compact skid such as UPS communication equipment and others then check applicable documentation of the equipment before executing the start up procedure 52 Auxiliary service board start u...

Page 53: ...ectrician is permitted to do maintenance work on the compact skid Obey the Safety instructions page 9 and follow the local safety regulations If ignored physical injury or death or damage to the equipment may occur WARNING Do not do electrical work during a thunderstorm Tools list Torx drivers Philips screwdrivers PoziDriv Torque wrench Set of wrenches and sockets Cable and wire strippers Crimping...

Page 54: ...70 A4 70 8 8 N m 0 9 M3 2 3 M4 4 5 M5 5 0 8 0 M6 12 20 M8 25 40 M10 40 70 M12 60 110 M14 90 170 M16 120 240 M18 Mechanical connection 1 Torque Bolt and nuts A2 70 A4 70 Quality 8 8 0 85 1 21 M3 0 80 2 78 M4 1 60 5 5 M5 2 80 9 5 M6 6 8 23 M8 14 46 M10 24 79 M12 37 127 M14 56 198 M16 81 283 M18 114 402 M20 1 Not applicable to threaded inserts 54 Maintenance ...

Page 55: ...enance contact your local ABB service representative Maintenance activities Perform the following inspections at least once in every six months Task Action Check the operating environment surroundings and conditions I Check the availability of spare parts I Check for any dust corrosion etc inside and outside the compact skid I Check and clean the inlet and outlet grills filters I Check the sealing...

Page 56: ...eaning procedure This section contains the minimum requirements for cleaning the PVS980 CS Perform the inspections at least twice a year Make sure that a sufficient high frequency according to specific site conditions or as recommended by ABB is used WARNING Obey the Safety instructions page 9 and the local safety regulations If ignored physical injury or death or damage to the equipment may occur...

Page 57: ...r support frames and tighten the screws Cleaning the fans Avoid the circuit breaker from turning on accident ally Turn OFF OPEN the circuit breaker for fan Measure to make sure that it is not energized Disconnect the supply and signal cabling Use compressed air to clean the fans Cleaning the MV switchgear area If necessary use a duster or pressurized air to clean locations you cannot reach with th...

Page 58: ...ply first layer of paint to the damaged area Let it dry thoroughly for at least 12 hours 6 Apply second layer of paint to the damaged area 7 Apply final layer e g Aliphatic Polyurethane coating Maintenance of Zinc coated surfaces WARNING Obey the Safety instructions page 9 and the local safety regulations If ignored physical injury or death or damage to the equipment may occur WARNING Obey the Saf...

Page 59: ...ools Steel wool Ensto SR1 joint compound or equivalent 42839 Würth protective wax or equivalent Procedure 1 Examine the condition of the grounding bar and grounding cables in the MV switchgear area If there is any visible corrosion remove the cables and remove the corrosion with steel wool Apply joint compound between the grounding bar and the joint surfaces of the cable terminal 2 Change the spri...

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Page 61: ...hinges and locks 1 Lubricate the external hinges and locks 2 Wipe off the excess lubricant Procedure 1 Examine the condition of the grounding bar and grounding cables in the MV switchgear area If there is any visible corrosion remove the cables and remove the corrosion with steel wool Apply joint compound between the grounding bar and the joint surfaces of the cable terminal 2 Change the spring lo...

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Page 63: ...Technical data Contents of this chapter This chapter contains the technical data of the PVS980 CS compact skid 12 Technical data 63 ...

Page 64: ...power at 50 C in kVA 2 2 2 2 1 1 1 1 Number of secondary windings 690 V 660 V 630 V 600 V 690 V 660 V 630 V 600 V Low voltage level 36 kV Medium voltage level range 50 Hz or 60 Hz Rated frequency Mineral vegetable optional Oil type 2 x 2 5 Tap changer AI AI Winding material primary secondary Yes Eco efficiency optional MV switchgear ABB SafePlus SF6 insulated Switchgear type 630 A Rated current Si...

Page 65: ...ton Environmental 20 C 50 C Operating temperature range 2000 m Operating altitude range 95 Relative humidity non condensing IP 54 IP 66 for inverter Environmental protection rat ing C4 C5M optimal Painting corrosion protection Product compliance IEC 60364 IEC 61936 1 IEC 60502 1 Conformity Reactive power compensation also at night power reduction LVRT HVRT FqRT Grid support Technical data 65 ...

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Page 67: ...tion Drawing code Product Series Single Line Diagram 3AES PVS980 CS 01 DW01 Product Series Electrical Layout 3AES PVS980 CS 02 DW01 Product Series Grounding Layout 3AES PVS980 CS 02 DW02 3AES SH CS4600 14 SP01 A Auxiliary Cabinet Project Specific Product Series Dimensional Layout 3AES PVS980 CS 30 DW01 Product Series Footprint 3AES PVS980 CS 30 DW02 Project Specific if applicable Auxiliary Service...

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Page 69: ...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...

Page 70: ...www abb com solarinverters 3AES PVS980 CS 00 MA01A 2019 ABB Oy All Rights Reserved Specifications subject to change without notice 3AES PVS980 CS 00 MA01 Rev A EN EFFECTIVE 2019 10 31 ...

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