ABB PVS800-IS User manual

—
ABB CENTRAL INVERTERS
PVS800-IS inverter stations (1.645 to 4.156
MW)
Hardware manual

Hardware manual
PVS800-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

Table of contents
1 Safety instructions
9Contents of this chapter ...........................................................................
9Use of warnings ....................................................................................
10Safe installation, start-up and maintenance ....................................................
10General safety instructions ....................................................................
11Safety instructions for the inverter compartment ..........................................
11Safe operation ......................................................................................
2 Introduction to this manual
13Contents of this chapter ...........................................................................
13Applicability .........................................................................................
13Target audience ....................................................................................
13Contents of the manual ...........................................................................
14Related documents ................................................................................
14Terms and abbreviations ..........................................................................
3 Hardware description
15Contents of this chapter ...........................................................................
15Overview ............................................................................................
16Layout drawing .....................................................................................
17Main circuit diagram ...............................................................................
17Inverter ..............................................................................................
18Type designation label ............................................................................
19Type designation key ..............................................................................
4 Storing, lifting and transporting
21Contents of this chapter ...........................................................................
21Storing ...............................................................................................
22Lifting ................................................................................................
23Transporting ........................................................................................
23Incoming inspection at arrival ....................................................................
5 Mechanical installation
25Contents of this chapter ...........................................................................
25General guidelines .................................................................................
25Constructing the foundation for the inverter station .......................................
27Preparation of the ground .................................................................
28Adding column foundations ...............................................................
28Placing the inverter station on the foundation ..............................................
29Constructing earthing electrode and earthing ..............................................
29Adding the cables ..............................................................................
29Filling the pit and finalizing the surroundings ...............................................
30Adding weather protecting hoods ............................................................
Table of contents 5

6 Checking the installation
31Contents of this chapter ...........................................................................
31Checking that the installation is clean and undamaged ......................................
32Checking the installation of the inverter station ...............................................
7 Electrical installation
33Contents of this chapter ...........................................................................
33Routing the cables .................................................................................
33Locations of the cable entries ....................................................................
34Earthing .............................................................................................
34Measuring the insulation resistance of the cabling ...........................................
35Connecting AC and DC cabling ..................................................................
36DC input cable connection procedure .......................................................
37AC output cable connection procedure .....................................................
38Connecting alarm and trip signals from MV substation to inverter station .................
39Local power enclosure .........................................................................
40Connecting auxiliary power supply from inverter station to MV substation ................
40Connecting the control cabling ...................................................................
8 Start-up
41Contents of this chapter ...........................................................................
41Tools needed .......................................................................................
41Start-up tasks .......................................................................................
9 Maintenance
45Contents of this chapter ...........................................................................
45General ..............................................................................................
46Maintenance intervals .............................................................................
46Cleaning the inverter compartment ..............................................................
47Replacing the intake air filters and cleaning the sandboxes .................................
48Cleaning the exterior surfaces of the inverter station .........................................
48Materials .........................................................................................
48Procedure .......................................................................................
49Lubricating external hinges, locks and seals ...................................................
49Materials .........................................................................................
49Procedure .......................................................................................
50Checking and repairing painted surfaces ......................................................
50Materials .........................................................................................
50Procedure .......................................................................................
51Checking and repairing unpainted, zinc coated surfaces ....................................
51Materials .........................................................................................
51Procedure .......................................................................................
52Checking and cleaning the grounding bars and points .......................................
52Materials .........................................................................................
52Procedure .......................................................................................
10 Technical data
53Contents of this chapter ...........................................................................
54Technical data ......................................................................................
6 Table of contents

56Derating .............................................................................................
56Temperature derating ..........................................................................
56Altitude derating ................................................................................
56Combined derating .............................................................................
56Derating Example ...........................................................................
11 Drawings
57Contents of this chapter ...........................................................................
58Dimensions and layout ............................................................................
59Transportation drawing ............................................................................
60Lifting drawing ......................................................................................
61Foundation and external cabling layout ........................................................
63Cable entry system example .....................................................................
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 PVS800-IS inverter stations.
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.
1
Safety instructions 9

Safe installation, start-up and maintenance
This section contains the safety instructions which you must follow when installing,
commissioning and maintaining the inverter station. 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 inverter station.
Working methods, tools, components etc. must follow the IEC regulations.
Obey all installation safety standards. This can require, among other things, the use of
personal protection equipment (PPE), such as arc-proof clothing, arc-proof masks, protective
footwear, protective gloves, eye protection and hearing protection. High power inverter
installations have high fault currents. Select appropriate arc-proof clothing. Always follow
the local safety regulations concerning the inverter stations.
PVS800-IS is a low voltage (LV) device which is connected via a step-up transformer to the
medium voltage (MV) grid. The PVS800-IS inverter station may 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 precautions steps described below.
1. Clearly identify the work location.
Read the safety instructions of the work area and the component you are working on.
See the subsections below and component-specific manuals.
2. Disconnect and secure against reconnection.
Disconnect all possible power supplies. Lock the disconnectors in the open position
and attach a warning notice to them. After disconnection of the inverters, always wait
for 5 minutes to let the intermediate circuit capacitors discharge.
3. Protect against any other live parts.
4. Take special precautions when close to exposed conductors.
5. Check that the installation is dead.
Always measure to ensure that there is no voltage connected.
6. Carry out earthing (grounding) and short circuiting.
7. Issue a permit to work.
10 Safety instructions

￭Safety instructions for the inverter compartment
WARNING!
Perform the procedure below before starting work on the inverters. Ignoring the
instructions can cause physical injury or death, or damage to the equipment.
1. Identify the inverter which you need to work on. Read the inverter safety instructions.
See section Related documents (page 14).
2. Disconnect both inverters from all power supplies (PV generator, transformer and AUX),
and secure by locking and tagging.
a. Stop the inverters. Open the DC disconnecting switches [Q1] of both inverter units
([PVS1] and [PVS2]), lock and add warning notices.
b. Open the AC breakers [Q2] of both inverter units ([PVS1] and [PVS2]), lock and
add warning notices. After disconnection of the inverters, always wait for 5 minutes
to let the intermediate circuit capacitors to discharge.
c. Switch off auxiliary power to both inverters from the auxiliary cabinet. If the auxiliary
system requires work, switch off the power supply for the auxiliary cabinet. Lock
and add warning notices.
d. Open the MV breaker or switch fuse combination at the transformer side of the
switchgear. 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
removed if it is a requirement to reach the parts which you are currently working on.
4. Check that you will not be near to any live parts while working. Disconnect live circuits
or protect with shrouds/screens.
5. Check that the circuit is dead at AC and DC terminals of the inverters and other
accessible parts in the main circuit. Use a multimeter with suitable testing heads.
6. Temporarily ground both inverters’ ([PVS1] and [PVS2]) AC and DC sides with an
appropriate temporary grounding set.
7. Issue a work permit.
Safe operation
This section contains the safety instructions which you must follow when operating the
inverter station. If ignored, physical injury or death may follow, or damage may occur to the
equipment.
WARNING!
Keep the door of the inverter station locked while the inverter station is operating.
Allow access to the keys to authorized personnel only.
Safety instructions 11

12

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 PVS800-IS inverter stations.
Target audience
This manual is intended for persons who transport, store, plan the installation, install,
commission and maintain PVS800-IS inverter stations.
Read this manual before working on the inverter station. You are expected to know 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 describes the operation principle and construction of the inverter
station.
Storing, lifting and transporting provides instructions for storing, lifting and transporting the
inverter station.
Mechanical installation describes how to install the inverter station mechanically.
2
Introduction to this manual 13

Electrical installation gives instructions on wiring the inverter station.
Checking the installation describes how to check the installation of the inverter station.
Start-up describes the start-up procedure of the inverter station.
Maintenance contains preventive maintenance instructions of the inverter station.
Technical data contains the technical specifications of the inverter station.
Drawings contains the additional drawings of the inverter station.
Related documents
ApplicabilityCode (English)Document
Inverter hardware manuals and guides
Whole inverter station3AXD50000009549
PVS800-IS inverter station hardware manual
Inverters3AXD50000048300
PVS800-57B hardware manual
Inverter firmware manuals and guides
Inverters3AXD50000048332
PVS800-57B central inverters firmware manual
Other
Inverters3AXD50000048331
PVS800-57B commissioning and maintenance manual
Whole inverter stationMain circuit diagram of the inverter station
Whole inverter stationMain circuit diagrams of the inverters
Whole inverter stationCommissioning checklist
InvertersPVS800-57B test report
AccessoryAccessory documents
Terms and abbreviations
DescriptionTerm/
Abbreviation
Electromagnetic compatibilityEMC
Maximum power point. The current and voltage values of the solar module, string or array
which will produce the highest power output under the prevailing operating conditions. See
also MPPT.
MPP
Maximum power point tracking. This is a function which automatically operates the solar
generator, array, string or module at its maximum power point.
MPPT
14 Introduction to this manual

Hardware description
Contents of this chapter
This chapter provides an introduction to the PVS800-IS inverter station.
Overview
The PVS800-IS inverter station provides the DC to AC power conversion 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

Layout drawing
4
5
6
8
3
1
2
4
3
3
9
3
2
7
600
Main components:
Exit door1
Inverters, PVS1 and PVS22
Air intakes with filtering systems with sand collection boxes3
Air outlets with weather protection hoods4
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 12007
Note:
Components must not block the air inlet area.
Main earthing bar, MEB8
Container doors9
16 Hardware description

Main circuit diagram
The diagram below shows the main circuit of the PVS800-IS inverter station and an example
MV substation with medium voltage switchgear and transformer. It also shows the alternative
auxiliary power supplies for the inverter station.
1
2
3
5
6
4
C
BA
7
+H1 +H2 +H3
=MV SUBSTATION
=MV =LV =LV
MV grid
=TR
+T1
=PVS800-IS
+EAB
DC input 1
DC input 2
Aux.
power box Aux.
power box
+EAB+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 substationA
MV transformer compartment of MV substationB
PVS800-IS inverter stationC
DC input1
Inverters2
MV transformer3
MV switchgear4
Power grid (AC) connection (and to parallel inverter stations if there are any)5
External auxiliary power supply (standard)6
Internal auxiliary power supply / transformer (option +G344)7
Inverter
See the inverter manuals for information on the inverters. See Related documents (page 14).
Hardware description 17

Type designation label
The figure below shows an example of the type designation label. The label contains the
basic data of the inverter station. It is located inside the inverter compartment door.
Serial nr: xxxxxxxxxxx
Type: PVS800-IS-xxxxkW-x+xxxx
Order no: xxxxxxxxxx
Manufactured
by ABB
DescriptionItem
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 information, see section Type designation key (page 19).
Type
Order numberOrder no.
18 Hardware description

Type designation key
The type designation describes the composition of the inverter station. The type designation
is visible on the type designation label which is attached to the inverter station. The complete
type designation is divided into sub codes:
• The first 1…18 digits form the basic code which describes the basic construction of the
inverter station. The fields in the basic code are separated by hyphens.
•The option codes 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.
DescriptionDigit no.
PVS800 product series1...6
Construction. -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
17...18
The following table describes the option codes.
DescriptionCode
Container options
Upgrade to corrosion class C5 and filtering class F7. Required for near coastal installation locations
(site located more than 1 km and up to 10 km distance from medium to high saline coastal line).
G312
6 kVA auxiliary power transformer supplied from main AC side of an inverter (external auxiliary
power supply connection is not needed)
G344
Container specialities
Customized (see the project-specific documentation)P902
Hardware description 19

20