ABB PVS980-CS User manual

—
ABB SOLAR INVERTERS
PVS980-CS compact skid
Hardware manual

PVS980-CS compact skid
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

Table of contents
1 Safety instructions
9Contents of this chapter ..........................................................................
9Use of warnings ...................................................................................
10Allowed usage .....................................................................................
10Safe installation, start-up and maintenance ..................................................
10General safety instructions ...................................................................
11Working areas .................................................................................
11Personal protective equipment (PPE) ......................................................
11PPE safety equipment ....................................................................
11Safety instructions for MV switchgear and MV transformer area .......................
12Disconnecting the MV switchgear from power supply ................................
12Earthing the MV switchgear and AC cabinet ..........................................
12Safety instructions for the Inverter area ....................................................
13Disconnecting the inverter from all possible sources .................................
14Disconnecting the MV switchgear (V-module) .........................................
14Safety instructions for the auxiliary service board ........................................
14Safe operation .................................................................................
2 Introduction to this manual
17Contents of this chapter ..........................................................................
17Applicability ........................................................................................
17Target audience ...................................................................................
17Related documents ...............................................................................
18Terms and abbreviations .........................................................................
3 Hardware description
19Contents of this chapter ..........................................................................
19Product overview ..................................................................................
19External dimensions ..............................................................................
20Layout drawing ....................................................................................
20Working areas and main components .........................................................
21Main components .............................................................................
22AC cabinet components ......................................................................
22Auxiliary service board .......................................................................
24MV switchgear .................................................................................
24MV switchgear circuit ......................................................................
25MV transformer ................................................................................
25Inverter ..........................................................................................
26Main circuit diagram ..............................................................................
27Type designation label ...........................................................................
28Type designation key .............................................................................
4 Storing, lifting and transporting
29Contents of this chapter ..........................................................................
Table of contents 5

30Storing ..............................................................................................
30Conditions for using desiccant bags ........................................................
31Lifting ...............................................................................................
31Tools used for lifting ...........................................................................
32Lifting instructions .............................................................................
33Transporting .......................................................................................
33Incoming inspection at arrival ...............................................................
34Unloading ..........................................................................................
34Tools used for unloading .....................................................................
34Pre-requisite ...................................................................................
35Unloading instructions ........................................................................
5 Mechanical installation
37Contents of this chapter ..........................................................................
37Safety ...............................................................................................
37Tools ................................................................................................
38Foundation guidelines ............................................................................
38Placing the compact skid on the foundation ..................................................
39Fastening the compact skid .....................................................................
39Constructing earthing electrode and earthing ................................................
39Filling the pit and finalizing the surroundings .................................................
39Unpacking ......................................................................................
6 Electrical installation
41Contents of this chapter ..........................................................................
42Routing the cables ................................................................................
42Earthing ............................................................................................
43Protective earthing (grounding) inside the compact skid ....................................
43Measuring the insulation resistance of the cabling ..........................................
43Connecting DC cable from solar generator to inverters .....................................
43Connecting the communication and auxiliary cabling (Optional) ..........................
44Connecting the power grid cabling to the MV switchgear ...................................
7 Finalizing the installation
45Contents of this chapter ..........................................................................
45Finalizing the installation .........................................................................
46Landscaping the station ..........................................................................
46Checking the installation of compact skid .....................................................
8 Start-up and operation
47Contents of this chapter ..........................................................................
47Tools needed ......................................................................................
48Prerequisite ........................................................................................
48Start-up procedure ................................................................................
9 Auxiliary service board start-up (Optional)
10 Maintenance
53Contents of this chapter ..........................................................................
53Tools list ............................................................................................
6 Table of contents

54Tightening torque .................................................................................
55Maintenance intervals ............................................................................
55Maintenance activities ........................................................................
56Component maintenance intervals .........................................................
56Removing the technical floor .............................................................
56Inverter maintenance ......................................................................
56Cleaning procedure ...............................................................................
57Maintenance of painted surfaces ...............................................................
57Repainting the scratched areas .............................................................
57Tools and materials ........................................................................
58Painting the damaged surface (no visible rust) .......................................
58Painting the damaged surface (visible rust) ...........................................
58Maintenance of Zinc coated surfaces ..........................................................
58Coating the scratched areas .................................................................
58Tools and materials ........................................................................
58Coating the damaged surface ............................................................
59Maintenance of grounding bars and points ...................................................
59Tools .............................................................................................
59Procedure ......................................................................................
11 Maintenance of external hinges and locks
61Tools ................................................................................................
61Lubricating the external hinges and locks .................................................
61Procedure ..........................................................................................
12 Technical data
63Contents of this chapter ..........................................................................
64Technical data and types: PVS980-CS ........................................................
13 Drawings
67Contents of this chapter ..........................................................................
67List of technical drawings ........................................................................
Further information
Table of contents 7

8

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

Allowed usage
• The PVS980-CS is a compact skid containing: two outdoor 1500 VDC ABB central
inverters, an ABB oil immersed MV transformer, MV switchgear, a monitoring system
and DC connections. The skid connects a PV power plant to a medium voltage grid.
Use the skid only at its permissible input/output ratings and ambient conditions. Make
sure this compliance is satisfied before commissioning.
• The operation and maintenance of the compact skid must be carried out by certified
technicians that fulfill all local skill set and safety requirements. Any unqualified personnel
must maintain a safe distance from the compact skid. All activities must be in accordance
with the criteria described in the ABB technical documents and local regulations.
• Make changes to the compact skid only with the direct authorization of ABB. Any
alterations done outside ABB approval will invalid the warranty for the product. ABB is
not liable for any damages caused by these changes.
Safe installation, start-up and maintenance
This section contains the safety instructions which you must follow when installing,
commissioning and maintaining the compact skid. If ignored, physical injury or death may
follow, or damage may occur to the 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
permission from the on-site foreperson in charge of electrical work.
￭General safety instructions
WARNING!
Before you perform any work in the compact skid, obey the following safety
precautions.
1. Clearly identify the work location.
2. Read the safety instructions of the work area and the component you are working on.
See the subsections below and the component-specific manuals.
3. Disconnect and secure against reconnection.
4. Disconnect all possible power supplies (external, auxiliary and inverters) and open all
base fuse switches. Lock the disconnectors in the open position and attach a warning
notice to them. After disconnecting power to the inverters, always wait until the stored
energy of the inverters is discharged. See also, inverters manual.
5. Use protection against any live parts.
6. Take special precautions when you work close to exposed conductors.
7. Measure to ensure that there is no voltage connected.
8. Carry out earthing (grounding) and short circuiting.
9. Issue a permit to work.
10 Safety instructions
3

￭Working areas
• MV Transformer Area
• MV Switchgear Area
• Inverter Area
• Auxiliary Service Area
Each work area has separate safety instructions.
￭Personal protective equipment (PPE)
• Perform any operation on the equipment with suitable work clothes and instruments.
See PPE safety equipment (page 11).
• When choosing a personnel protective equipment, consider environmental conditions
such as humidity, noise, etc. and local regulations.
• Make sure the work clothes and accessories are not prone to generate electrostatic
charges, fires or any other condition that compromises personnel safety.
PPE safety equipment
The minimum required safety equipment is as follows:
• Safety shoes
• Safety gloves
• Safety glasses
• Head protection
• Hearing protection
• Work clothes
￭Safety instructions for MV switchgear and MV transformer area
WARNING!
Perform the below instructions before you start working inside the MV switchgear
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, auxiliary, and
inverters as well as any parallel connection stations), and secure by locking and tagging.
See instructions in section, Disconnecting the MV switchgear from power
supply (page 12).
4. Check that all shrouds/screens are in place.
5. Check that you are not near to any live parts while working. All live circuits must be
protected with shrouds/screens.
6. Make sure that the MV switchgear is dead.
• Check the status of voltage indicators in all MV switchgear bays. Note that all phase
LEDs which were switched on AC cabinet at are now switched off).
7. Earth the MV switchgear and the AC cabinet. See instructions in section, Earthing the
MV switchgear and AC cabinet (page 12).
Safety instructions 11

8. Check that the MV transformer is dead (high voltage terminals, low voltage terminals,
any auxiliary power, and instrumentation). Use an appropriate high voltage tester only
for the high voltage side, and a voltage detector with suitable testing heads for the low
voltage side.
9. Issue a work permit.
Disconnecting the MV switchgear from power supply
To disconnect the MV switchgear from all possible power supplies (external, auxiliary, and
inverters as well as any parallel connection stations), follow the below steps:
1. Stop the string inverters outside the compact skid.
2. Open the DC disconnecting switches in each inverter unit and add warning notices. If
applicable, open the AC disconnecting switches in each inverter unit, lock and add
warning notices (applicable only when inverter includes the options +F296 and +F253).
3. Open all fuse base switches of the inverter inputs, lock and add warning notices.
4. Open all auxiliary breakers, switches and fuses in the auxiliary service board, lock and
add warning notices.
5. Open the main circuit breaker in the auxiliary service transformer, lock and add warning
notices.
6. Set the inverter auxiliary power off (if applicable).
7. Turn the vacuum circuit breaker of the MV switchgear to open position. Lock and add
warning notice.
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 switchgear to “earthed” position, lock (remove the
MV switchgear Ronnis key of the V module) and add warning notices.
2. If the compact skid is connected to parallel skids, make sure that you also turn the
appropriate earthing switches of the parallel skids to “earthed” position.
3. Temporarily, ground the MV switchgear terminals at all possible external power supplies
(grid and parallel skids). See the User's manual of the MV switchgear. Lock and add
warning notices.
4. Ground the inverter AC sides with appropriate temporary grounding set.
￭Safety instructions for the Inverter area
WARNING!
Perform the below instructions before you start working on the inverters. Ignoring
the instructions can cause physical injury or death, or damage to the equipment.
You must be a qualified electrician to do installation and service work.
1. Identify the inverter and read its safety instructions. See PVS980 central inverters
hardware manual (3AXD50000026013 [EN]).
2. Clearly identify the work location. Make sure that there is an escape route in case of an
emergency.
12 Safety instructions
3

3. Disconnect and isolate. (Not all disconnectors provide sufficient isolation against voltage
surges.). See instructions in section, Disconnecting the inverter from all possible
sources (page 13).
4. Protect any other energized parts in the work location against contact.
5. Open the breaker and switches of the auxiliary service board.
6. Open the main circuit breaker of the auxiliary service transformer, lock and add warning
notices.
7. Disconnect the MV switchgear (V-module). See instructions in section Disconnecting
the MV switchgear (V-module) (page 14).
8. Check that the inverter is dead. Make sure the voltage between the following terminals
and the grounding (PE) busbar is close to 0 V.
• inverter AC output terminals (L1, L2, L3)
• inverter power module UDC+ and UDC- terminals
• DC input terminals DC+ and DC-
9. After you disconnect the inverter, wait for at least five minutes to let the intermediate
circuit capacitors discharge before you continue.
10. Check that all shrouds/screens are in place except the one that prevents access to the
parts that you must work on currently.
11. Make sure you are not near to any live parts while working. Disconnect the live circuits
or protect with shrouds/screens.
12. Temporarily ground inverter 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 on
the HV side of the main transformer), because the optional AC disconnectors or breakers
of the inverter do not remove the voltage from the AC outside busbars of the inverter.
2. Disconnect the inverter from the DC power supply (usually the DC circuit breakers of
the solar array junction boxes or the DC combiner box), because the optional DC
disconnectors do not remove the voltage from the inverter input busbars or fuses.
3. Disconnect the following optional devices:
Option codeDevices
1Q4 , 2Q4AC main disconnection devices (AC breakers or AC switch disconnectors) of
all power units
1Q1, 2Q1DC disconnectors of all the power sections
1Q10, 2Q10Auxiliary power disconnectors of all the power sections
0Q123-phase output disconnector
0F11, 0F13)1-phase output circuit breakers
If the inverter is supplied from external auxiliary power, disconnect also that.
4. Make sure that reconnection is not possible. Lock all disconnectors in the open position
and attach warning notices. Lock and tag.
Safety instructions 13

5. After disconnecting the inverter, wait for at least five minutes to let the capacitors
discharge.
Disconnecting the MV switchgear (V-module)
To disconnect the MV switchgear (V-module), follow the below steps:
1. Open the V-module breaker, lock and add warning notices.
2. Set the disconnecting switch on the V-module to open position, lock and add warning
notices. See MV switchgear user's manual.
3. Make sure that the V-module is dead: check that the voltage indicators in all V-module
bays (all phase LEDs) are switched off.
4. Measure to confirm that the installation is not energized. Also, test the performance of
the voltage measurement device by measuring a live voltage.
5. Make sure that the V-module is earthed. Turn the earthing switches to “earthed” position,
lock (remove the V-module key) and add warning notices. If the station is connected to
parallel stations, turn the applicable earthing switches to “earthed” position.
￭Safety instructions for the auxiliary service board
1. Open the main circuit breaker or main switch of the auxiliary service transformer. 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.
6. Check that the auxiliary service board is dead.
7. Issue a work permit.
￭Safe operation
WARNING!
Obey these instructions to prevent injury, death, or damage to the equipment.
WARNING!
Keep all doors locked while the compact skid is operating. Allow access to only
authorized personnel.
1. Keep all doors of the compact skid closed during operation. Give the keys only to
authorized personnel.
2. Before you start the inverter, close the following devices:
• two AC and two DC main switches
• auxiliary measurement unit switch 1F3.4
• internal auxiliary MV transformer fuse switches
• overload protection switches 1Q10, 1Q11, 2Q10 and 2Q11.
3. Do not open the AC base fuse switches when the compact skid is operating.
4. Before you adjust the group of inverters and set them into service, make sure that all
of them are suitable for operation.
14 Safety instructions
3

5. Do not use the inverters in a manner not specified in the manual.
6. The maximum allowed number of power-ups by applying power is five in ten minutes.
Note:
• Spend as little time as possible near the inverters or the compact skid.
• Use a personal computer and 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 the first time to let you move
away.
Safety instructions 15

16

Introduction to this manual
Contents of this chapter
This chapter provides information about the manual such as applicability, target audience
and contents. It also lists the related documents.
Applicability
This manual is applicable to PVS980-CS (compact skid).
Target audience
This manual is intended for persons who transport, store, plan the installation, install,
commission and maintain the compact skid.
Read this manual before working 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
3AXD50000026013PVS980 central inverter hardware manual
3AXD50000046782PVS980 central inverters commissioning and maintenance manual
Firmware manuals and guides
3AXD50000026271PVS980 central inverters firmware manual
Option manuals and guides
3AUA0000085685ACS-AP-x Assistant control panels user’s manual
3AUA0000094606Start-up and maintenance PC tool Drive composer user’s manual
2
Introduction to this manual 17

Code (English)Document
3AUA0000093568FENA-01/-11/-21 Ethernet adapter module user’s manual
3AUA0000109533FSCA-01 RS-485 adapter module user’s manual
3AUA0000096939NETA-21 Remote monitoring tool user’s manual
1VDD005976SafeRing/SafePlus 12–24 kV installation and operating instructions
1VDD006116SafeRing/SafePlus 36 kV installation and operating instructions
to do: not available in library
1LTR954400-1Oil-type MV transformer: Operation and maintenance manual of distribution
MV transformers to do: not available in library
Terms and abbreviations
DescriptionTerm/
Abbreviation
Alternating currentAC
Construction of ABB SafeRing MV switchgearCCV
Compact skidCS
Construction of MV switchgearCV
Direct currentDC
Low voltage (50...1000 V AC)LV
Low voltage ride-throughLVRT
Medium voltage (1...35 kV)MV
Personal protective equipmentPPE
Sulfur hexafluoride (this gas type is used in MV switchgear).SF6
SwitchgearSWG
Total harmonic distortionTHD
Earthed networkTN-S
18 Introduction to this manual

Hardware description
Contents of this chapter
This chapter provides an overview of the PVS980-CS (compact skid). It also includes layout,
type designation label and type designation information.
Product overview
The PVS980-CS is a skid-based solution that connects a PV power plant to a medium
voltage power grid. The solution is constructed around a skid house that contains:
•Central inverters—converts direct current (DC) and voltage from the solar generator
into alternating current (AC) and voltage for the power grid. The inverters also control
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 services for the autonomous operation of
the compact skid as well as space for optional UPS and communication bard.
External dimensions
The compact skid is constructed over a skid suitable for transportation inside a 40 HC
container with,
• External dimension (length, width, height) = 11850 x 2150 x 2340 mm
• Total weight = < 22 ton.
3
Hardware description 19

Layout drawing
This section describes the working areas and main components of the PVS980-CS. For
more information, see drawing, 3AES-PVS980-CS-30-DW01.
Working areas and main components
ABDC
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