Operating manual HS80/HS100/HS120

Transcription

1 HELIOS SYSTEMS HS 100 Operating manual HS80/HS100/HS120 Helios Systems S.L. Eckernförder Landstrasse Flensburg Tel.: +49-(0) Fax: +49-(0) Mail: All rights reserved. Full or partial reproduction is only permitted with the consent of Helios Systems. Creation date: 10. September 2010 Translation of original operating manual Version 1.0

2 Table of contents 1 Introduction Designated purpose Intended use Non-intended use Standards and directives About this operating manual Safety Safety instructions Basic safety instructions Obligations of the owner Obligations of the qualified electrician Obligations of the crane operator Obligations of the industrial truck operator Safety instructions on the central inverter Identification of the central inverter Technical description Delivery Included in the delivery Functional description Principle of the central inverter Exterior view Display Operating Manual HS80/HS100/HS120, Helios Systems

3 Table of contents Emergency stop switch AC main switch Interior view Optional heating elements Technical data Technical data of the HS Technical data of the HS Technical data of the HS Transport and the necessary conditions at the installation site Packaging Transport General instructions Crane transport Industrial truck support Securing the central inverter for transport Installation site prerequisites Grid Connections Foundation Distances Ventilation Ambient variables Operating Manual HS80/HS100/HS120, Helios Systems

4 Table of contents 5 Installation Mounting switch knob Q Connect the solar generator (DC) Connecting solar generator without string option Connecting the solar generator to power switch (Option with power switches, up to 5 solar generator strings) Connecting to the grid (AC) Suitable cable lugs Connection area power switch Q Connecting the auxiliary power supply Internal power supply External power supply (optional) Connect the monitoring system Commissioning Preparing for the commissioning process Commissioning Operating states Standby Start up MPP mode Shutdown Stop Operating Manual HS80/HS100/HS120, Helios Systems

5 Table of contents 8 De-commissioning Emergency stop switch AC main switch Switching off the control voltage Maintenance Executing maintenance tasks Taking measurements Disposal Disposal of the electrolytic capacitors Errors Appendix Spare Parts List Operating Manual HS80/HS100/HS120, Helios Systems

6 Introduction 1 Introduction 1.1 Designated purpose The central inverters from Helios Systems have been specially developed for photovoltaic systems. They convert the DC voltage that is given off by the solar generators into gridconformant alternating current and feed it into the power grid, three-phase. 1.2 Intended use The central inverters from Helios Systems should only be operated in photovoltaic systems. In photovoltaic systems central inverters are used exclusively for converting direct current into DC voltage. Intended use also includes reading the operating manual, as well as complying with all instructions contained in the operating manual, particularly the safety instructions. All maintenance tasks should be executed exclusively by qualified electricians who have been trained and authorized, at the specified intervals. Central inverters should only be set up within the ambient conditions cited in section Technical data" on page Non-intended use Any use other than the use specified under section Intended use" on page 5 is considered non-intended use. The following uses of the central inverter are considered non-intended use: in wind turbines, in uninterruptible power supplies (UPS), in powered vehicles, as a component of a frequency converter. Safe operation is not ensured if the central inverter is not used as intended. Do not make any changes to the central inverter. 1.4 Standards and directives The central inverter complies with the standards and directives cited in the Declaration of Conformity. Operating Manual HS80/HS100/HS120, Helios Systems 5

7 Introduction 1.5 About this operating manual This operating manual contains information on safety, function, transport, installation, commissioning, de-commissioning, maintenance, disposal and errors of the central inverters from Helios Systems. This operating manual has been prepared exclusively for qualified electricians who have been trained and authorized. In addition special qualifications are required for the following activities: Activity Transport Set-up Commissioning Instruction Error correction Maintenance/service Cleaning Repair De-commissioning Qualification/should only be executed by Authorized and trained specialists Qualified electricians who have been trained and authorized Qualified electricians who have been trained and authorized Employees of Helios Systems Qualified electricians who have been trained and authorized Qualified electricians who have been trained and authorized Qualified electricians who have been trained and authorized Employees of Helios Systems Qualified electricians who have been trained and authorized Operating Manual HS80/HS100/HS120, Helios Systems 6

8 Safety 2 Safety 2.1 Safety instructions Safety instructions must be strictly complied with! The safety instructions are classified according to the following risk levels: Identifies a serious risk situation. Serious, irreversible injuries or fatal injuries will occur if this safety instruction is not complied with. WARNING! Identifies a serious risk situation. Serious, irreversible injuries or fatal injuries can occur if this safety instruction is not complied with. CAUTION! Identifies a risk situation. Minor or moderate injuries can occur if this safety instruction is not complied with. NOTICE! Identifies risk of material damage. Material damage can occur if this safety instructions is not complied with. Operating Manual HS80/HS100/HS120, Helios Systems 7

9 Safety 2.2 Basic safety instructions Life-threatening danger due to high voltage. During operation the doors of the central inverter must remain closed! Life-threatening danger due to residual voltage. Strictly maintain a minimum wait time of 30 minutes after switching off and prior to opening the central inverter. Life-threatening danger due to high voltage. For all tasks in the vicinity of the central inverter: Maintain the safety distance to the central inverter that must be complied with in accordance with BGV A3 (see Table 4/BGV A3 "Safety distances for non-electrical work, depending on the rated voltage )! Comply with the sequence of protective measures: 1. Disconnect, 2. Safeguard from being switched on again, 3. Ensure that equipment is de-energized, 4. Ground and short circuit, 5. Cover or shield adjacent live components. Have the work area marked before starting work (responsible party according to BGI 758). Operating Manual HS80/HS100/HS120, Helios Systems 8

10 Safety Life-threatening danger due to high voltage. Ensure that only qualified electricians who have been trained and authorized work on the central inverter. In addition special qualifications are required for some activities (see About this operating manual" on page 6). Prior to starting all tasks on the central inverter: Ensure that the central inverter is disconnected from the grid. Ensure that the intermediate circuit of the central inverter is discharged. Safeguard the central inverter from switching on again spontaneously. Prior to performing tasks on the central inverter use a suitable tool to ensure that residual voltage is not present. Use suitable tools with appropriate markings and PPE for working on live parts (VDE 0680/VDE 0682). Life-threatening danger due to a lack of help. If there is an accident a second person must provide help. Always work with a second person near you! NOTICE! Warning - damage to the central inverter. The control cabinet door can only be opened when the AC main switch has manually been placed in the OFF position. NOTICE! Warning - damage to the central inverter. Improper repair work can cause damage to the central inverter. All repair tasks should be performed by employees of Helios Systems. Operating Manual HS80/HS100/HS120, Helios Systems 9

11 Safety Life-threatening danger due to failure to comply with the safety instructions. Comply with the information and safety instructions affixed to the device and in this operating manual. Ensure that the operating manual is kept on hand in the vicinity of the central inverter. Cut wounds due to hand tools. WARNING! Only use suitable tools to cut and strip. Only use knives with a covered handle and cable measurement handles with a circular protrusion to prevent fingers from sliding in the direction of the blade. Wear protective gloves when using knives with a fixed blade. Do not keep a knife with open blade in work clothes or in the tool belt. Danger of falling and injury when working on ladders. Check whether the tasks that must be executed can be safely executed from ladders. If this is not the case use work platforms or scaffolds. Select a suitable ladder and use it as intended (e.g. do not use a step ladder as an extension ladder). Ensure that the set-up site is safe (capable of bearing a load, level, and that the ladder cannot slip). Wear safety footwear. Operating Manual HS80/HS100/HS120, Helios Systems 10

12 Safety WARNING! Warning - harmful to health. The electrolytic capacitors contain ethylene glycol that is considered to be an irritant and harmful to health. Wear protective goggles. Wear suitable protective clothing. If there is contact seek medical attention immediately. If there is eye contact rinse eyes with water for at least 10 minutes. If swallowed drink plenty of water. Only have the person affected vomit if the person affected is fully conscious. Immediately taken off contaminated clothing and remove it safely. If there is skin contact wash off immediately with plenty of water. Life-threatening danger due to flammable or explosive gasses. Ensure that the ambient air is free of flammable or explosive gasses. Life-threatening danger due to corrosive substances. Ensure that the ambient air is free of corrosive substances. Danger of injury due to inadequate protective clothing. Wear safety footwear for all tasks performed on the central inverter. Operating Manual HS80/HS100/HS120, Helios Systems 11

13 Safety 2.3 Obligations of the owner Life-threatening danger due to high voltage. Ensure that only qualified electricians who have been trained and authorized work on the central inverter. In addition special qualifications are required for some activities (see About this operating manual" on page 6). For tasks performed on the central inverter it must remain in a de-energized state to the extent possible for the entire duration of the tasks. This is achieved via the following five safety rules: 1. Disconnect - provide suitable devices for activating the switch elements. 2. Safeguard against restart - make suitable devices available to safeguard against restart. 3. Ensure de-energized status - provide suitable voltage detectors (to 1000 V rated voltage, two-pole). 4. Ground and short circuit. 5. Cover or shield adjacent live parts - provide suitable covering material appropriate for the activity that will be executed. The release for work should only be given after the person responsible for the work executes and checks the five safety rules. Ensure that the central inverter is operated in accordance with the applicable statutory regulations and in accordance with the safety instructions on the device and in this operating manual, all safety instructions cited in this manual and affixed to the central inverter are complied with, understood, and followed, all safety devices are always in faultless and functional operating status, (e.g. emergency stop switch), the prescribed intervals or intervals specified in the operating manual for maintenance tasks are complied with, maintenance tasks are executed only by qualified electricians who have been trained and authorized, repair tasks are only executed by employees of Helios Systems. Operating Manual HS80/HS100/HS120, Helios Systems 12

14 Safety 2.4 Obligations of the qualified electrician Life-threatening danger due to residual voltage. The central inverter should only be installed, maintained, commissioned, and de-commissioned by qualified electricians who have been trained and authorized. Ensure that a second instructed person, who can help in an emergency, is always present for all tasks performed on electrical equipment. If there is an accident the second person must switch off the power supply and provide help. Strictly maintain a minimum wait time of 30 minutes after switching off and prior to opening the central inverter. Prior to performing tasks on the central inverter use a suitable tool to ensure that residual voltage is not present. On the display, read out the DC voltage that is applied. Never open the central inverter during operation. Comply with the operating instructions and safety instructions in this operating manual. Comply with the safety instructions affixed on the central inverter. Only operate the central inverter in TN networks. 2.5 Obligations of the crane operator Danger of injury during crane operation. Defects that occur during crane operation can result in severe or fatal injuries. The crane should only be operated by authorized specialists who have been trained in the area of crane operation. Ensure that the guidelines specified in BGV D6: Cranes, are satisfied. The angle between the ropes or chains of the crane and the top side of the central inverter must be at least 60 o or greater (see "Crane transport" on page 30). Operating Manual HS80/HS100/HS120, Helios Systems 13

15 Safety 2.6 Obligations of the industrial truck operator Danger of injury during transport. Defects that occur during transport can cause severe or fatal injuries. The industrial truck should only be operated by authorized specialists who have been trained to handle industrial trucks. Ensure that the guidelines specified in BGV D27: Industrial trucks, are satisfied. Operating Manual HS80/HS100/HS120, Helios Systems 14

16 Safety 2.7 Safety instructions on the central inverter CAUTION! Device damage due to loose power line. ALUMINUM CONDUCTORS Recommendation! Comply with the following when using aluminum conductors: 1. Remove the oxide layer of the conductor (wire) with a wire brush. 2. Grease the aluminum conductor (wire) with acid-free grease (e.g. Vaseline or terminal grease). 3. The conductor should be checked after approx. 4 weeks with a torque wrench (Nm), thereafter it should be checked yearly. 4. Only one conductor (wire) should be connected in one terminal. Life-threatening danger due to high voltage. You must wait at least 30 minutes until the intermediate circuit has discharged. Life-threatening danger due to high voltage. Ensure that only qualified electricians who have been trained and authorized work on the central inverter. Operating Manual HS80/HS100/HS120, Helios Systems 15

17 Safety 2.8 Identification of the central inverter The type plates are on the inside of the door, on the outside of the door, and on the mounting plate. Operating Manual HS80/HS100/HS120, Helios Systems 16

18 Technical description 3 Technical description 3.1 Delivery Check the delivery for completeness. If the delivery is not complete, please contact Helios Systems. Check the central inverter for transport damage. If you determine that there is transport damage, immediately contact the freight forwarder Included in the delivery Central inverter Control cabinet key Operating manual Test log - final test Test protocol - insulation monitor 3.2 Functional description The central inverter from Helios Systems has been specially developed for use in photovoltaic systems, and it has been equipped with state-of-the-art, efficiency-optimized technology. The central inverter converts the DC voltage that is given off by the solar generators into gridconformant alternating current and feeds it into the public power grid, three-phase. The central inverter has an integrated transformer and is intended for connection to the TN network. Operating Manual HS80/HS100/HS120, Helios Systems 17

19 Technical description 3.3 Principle of the central inverter A8 9 A1 8 A Fig. 3-1 Principle circuit diagram of the central inverter 1 EMC filter (interference suppression filter) 6 Power supply 2 Intermediate circuit 7 A3 - communication PCB 3 IGBT bridge 8 A1 - control card V - grid 9 A8 - insulation monitor V from external The HS80/HS100/HS120 is a three-phase central inverter for grid-coupled photovoltaic systems. The solar generator is connected on the left side on the optional DC fuses or on the power switches. Via the DC switch disconnector Q1 and an interference suppression filter (1) the DC voltage gets to the intermediate circuit (2). The intermediate circuit (2) supplies the IGBT bridge (3). Downstream of the IGBT bridge (3) there is the transformer T4 for galvanic separation, an interference suppression filter (1) and the grid contactor K1. In series there is the power switch Q2, which is manually operated from the front side of the central inverter. The station service supply for the controller can be executed internally (bridges set on terminal block X1) or can be supplied from outside (bridges on terminal block X1removed) (5) (see "Connecting the auxiliary power supply" on page 45). Operating Manual HS80/HS100/HS120, Helios Systems 18

20 Technical description 3.4 Exterior view HELIOS SYSTEMS HS Fig. 3-2 Exterior view 1 Display 2 Emergency stop switch 3 AC main switch Operating Manual HS80/HS100/HS120, Helios Systems 19

21 Technical description Display The display is used to show status data, to reset error messages, and to switch the central inverter on and off. The device is operated via the display Emergency stop switch Life-threatening danger due to residual voltage. Strictly maintain a minimum wait time of 30 minutes after switching off, and prior to opening the central inverter! Prior to performing tasks on the central inverter use a suitable tool to ensure that residual voltage is not present. In an emergency the central inverter can be immediately disconnected from the grid (AC) and from the solar generator (DC) (see "Emergency stop switch" on page 53) AC main switch The central inverter is disconnected from the grid by activating the AC main switch (Position off ) or connected to the grid (position on ). If the central inverter is switched off automatically due to excess AC voltage the position of the AC main switch changes to tripped. In this case the central inverter is disconnected from the grid. To be again switched on the central inverter must first be taken out of service (see "Decommissioning" on page 53) and placed in service again (see "Commissioning" on page 48). Operating Manual HS80/HS100/HS120, Helios Systems 20

22 Technical description 3.5 Interior view Fig. 3-3 Interior view Operating Manual HS80/HS100/HS120, Helios Systems 21

23 Technical description 1 Communication board 9 DC switch disconnector Q1 2 Intermediate circuit 10 DC power switch ( string option ) 3 IGBT bridge 11 Insulation monitor 4 Measuring transducer AC current 12 Overvoltage protector DC 5 Contactor K1 13 DC EMC filter 6 Overvoltage protector AC 14 Measuring transducer DC current 7 Terminal strip X1/X V power unit 8 AC power switch Q2 16 Control card Optional heating elements NOTICE! Warning - damage to the central inverter. The values of the thermostats and of the hygrostats should not be adjusted. Optionally two heating elements can be installed on the inside of the door. In addition there are two thermostats and one hygrostat on the inside of the door. The values are set in the factory: -BT1-5 C, -BT2 5 C, -BT3 > 90 % relative humidity. The heating elements switch themselves on if the temperature drops below 5 C or if the humidity increases above 90 %. If the temperature drops below -5 C the central inverter switches off. The heating elements remain switched on. If the temperature increases above -5 C the central inverter will be switched on again automatically. Operating Manual HS80/HS100/HS120, Helios Systems 22

24 Technical description 3.6 Technical data Technical data of the HS80 General data Description Value/unit More detailed description Dimensions 1000 mm x 1900 mm x 850 mm W x D x H Weight < Approx kg Maximum set-up altitude 2000 m above sea level without power loss Humidity < 95 % Non-condensing Ambient temperature 0 o C to 50 o C other on request Protection class IP20 Type of cooling Forced convection cooling 1500 m 3 /h Min. air quality Class 3S2 in accordance with EN Cabinet color RAL7035 other on request EMC satisfies EN , EN Low-voltage directive satisfies EN Test Grid monitor CE conformity TÜV in accordance with VDEW guidelines satisfied Electrical data Description Value/unit More detailed description Rated output power 80 kw at +/-10 % of the rated grid voltage Rated output power 88 kw at rated voltage Rated grid voltage 400 V, 3~, 50 Hz, clockwise TN network, other forms of networks, voltages, and frequencies on request Maximum grid short-circuit current Maximum output current 36 ka other on request 128 A Power factor (cos?) > 0,99 from 20 % rated power Distortion factor (THD) < 3 % at rated power Rated PV power 84 kw within +/-10 % rated grid voltage Operating Manual HS80/HS100/HS120, Helios Systems 23

25 Technical description Electrical data Description Value/unit More detailed description Max. PV power 92 kw at rated voltage Max. PV power 205 A Maximum PV off-load voltage 900 V= MPP range 450 V= to 820 V= at rated PV power Regulating procedure MPP tracking Efficiency (94,6/96,9/96,9/96,7/96,3) % at (10/30/50/75/100) % power EC efficiency 96,5 % incl. transformer losses, excl. station service EC efficiency 96,3 % incl. transformer losses and station service Infeed from Loss in standby/at night Maximum station service 450 W < 30 W < 250 W Equipment/components Buffer amplifier Three-phase current power switch (AC power switch Q2) Emergency stop switch Display Ground fault monitor Overvoltage protector Load disconnect switch with motor drive Power switch with activation from outside present Touch screen with numeric and graphic output Insulation monitor with adjustable limit value monitored overvoltage protector - DC current side three-phase current side Options - DC current fuses or DC current power switches to protect up to 5 inputs - Measurement and monitoring of the individual input currents - Cabinet heater Operating Manual HS80/HS100/HS120, Helios Systems 24

26 Technical description Technical data of the HS100 General data Description Value/unit More detailed description Dimensions 1000 mm x 1900 mm x 850 mm W x D x H Weight < Approx kg Maximum set-up altitude 2000 m above sea level without power loss Humidity < 95 % Non-condensing Ambient temperature 0 o C to 50 o C other on request Protection class IP20 Type of cooling Forced convection cooling 1500 m 3 /h Min. air quality Class 3S2 in accordance with EN Cabinet color RAL7035 other on request EMC satisfies EN , EN Low-voltage directive satisfies EN Test Grid monitor CE conformity TÜV in accordance with VDEW guidelines satisfied Electrical data Description Value/unit More detailed description Rated output power 100 kw at +/-10 % of the rated grid voltage Rated output power 110 kw at rated voltage Rated grid voltage 400 V, 3~, 50 Hz, clockwise TN network, other forms of networks, voltages, and frequencies on request Maximum grid short-circuit current Maximum output current 36 ka other on request 160 A Power factor (cos?) > 0,99 from 20 % rated power Distortion factor (THD) < 3 % at rated power Rated PV power 104 kw Within +/-10 % rated grid voltage Max. PV power 115 kw at rated voltage Max. PV power 250 A Operating Manual HS80/HS100/HS120, Helios Systems 25

27 Technical description Electrical data Description Value/unit More detailed description Maximum PV off-load voltage 900 V= MPP range 450 V= to 820 V= at rated PV power Regulating procedure MPP tracking Efficiency (93,9/96,9/97,1/97,0 /96,7) % at (10/30/50/75/100) % power EC efficiency 96,5 % incl. transformer losses, excl. station service EC efficiency 96,3 % incl. transformer losses and station service Infeed from Loss in standby/at night Maximum station service 560 W < 30 W < 250 W Equipment/components Buffer amplifier Three-phase current power switch (AC power switch Q2) Emergency stop switch Display Ground fault monitor Overvoltage protector Load disconnect switch with motor drive Power switch with activation from outside present Touch screen with numeric and graphic output Insulation monitor with adjustable limit value monitored overvoltage protector - DC current side three-phase current side Options - DC current fuses or DC current power switches to protect up to 5 inputs - Measurement and monitoring of the individual input currents - Cabinet heater Operating Manual HS80/HS100/HS120, Helios Systems 26

28 Technical description Technical data of the HS120 General data Description Value/unit More detailed description Dimensions 1000 mm x 1900 mm x 850 mm W x D x H Weight < Approx kg Maximum set-up altitude 2000 m above sea level without power loss Humidity < 95 % Non-condensing Ambient temperature 0 o C to 50 o C other on request Protection class IP20 Type of cooling Forced convection cooling 1500 m 3 /h Min. air quality Class 3S2 in accordance with EN Cabinet color RAL7035 other on request EMC satisfies EN , EN Low-voltage directive satisfies EN Test Grid monitor CE conformity TÜV in accordance with VDEW guidelines satisfied Electrical data Description Value/unit More detailed description Rated output power 120 kw at +/-10 % of the rated grid voltage Rated output power 132 kw at rated voltage Rated grid voltage 400 V, 3~, 50 Hz, clockwise TN network, other forms of networks, voltages, and frequencies on request Maximum grid short-circuit current Maximum output current 36 ka other on request 190 A Power factor (cos?) > 0,99 from 20 % rated power Distortion factor (THD) < 3 % at rated power Rated PV power 125 kw Within +/-10 % rated grid voltage Max. PV power 137 kw at rated voltage Max. PV power 260 A Operating Manual HS80/HS100/HS120, Helios Systems 27

29 Technical description Electrical data Description Value/unit More detailed description Maximum PV off-load voltage 900 V= MPP range 450 V= to 820 V= at rated PV power Regulating procedure MPP tracking Efficiency (94,0/97,0/97,1/96,9 /96,5) % at (10/30/50/75/100) % power EC efficiency 96,5 % incl. transformer losses, excl. station service EC efficiency 96,3 % incl. transformer losses and station service Infeed from Loss in standby/at night Maximum station service 560 W < 30 W < 250 W Equipment/components Buffer amplifier Three-phase current power switch (AC power switch Q2) Emergency stop switch Display Ground fault monitor Overvoltage protector Load disconnect switch with motor drive Power switch with activation from outside present Touch screen with numeric and graphic output Insulation monitor with adjustable limit value monitored overvoltage protector - DC current side three-phase current side Options - DC current fuses or DC current power switches to protect up to 5 inputs - Measurement and monitoring of the individual input currents - Cabinet heater Operating Manual HS80/HS100/HS120, Helios Systems 28

30 Transport and the necessary conditions at the installation site 4 Transport and the necessary conditions at the installation site 4.1 Packaging Unless otherwise agreed, the packaging satisfies the HPE packaging guidelines that have been specified by the German Associations for Wooden Materials, Pallets, Export Packaging (Bundesverband Holzmittel, Paletten, Exportverpackung e.v). 4.2 Transport Life-threatening danger due to the central inverter tipping. Only transport the central inverter with cranes and industrial trucks that have sufficient load-bearing capacity. The central inverter should only be transported by authorized personnel who have been trained to operate industrial trucks. NOTICE! Improper transport can damage the device. To avoid damage, only transport the central inverter in a vertical position General instructions Check the delivery immediately after it arrives for completeness and possible transport damage. If the delivery is incomplete contact Helios Systems. Use suitable transport equipment appropriate for the local conditions. Comply with the information in sections Obligations of the crane operator" on page 13 and Obligations of the industrial truck operator" on page 14 in this regard. Only remove the transport safeguards when the central inverter is standing vertically at the intended installation site. Operating Manual HS80/HS100/HS120, Helios Systems 29

31 Transport and the necessary conditions at the installation site Crane transport Life-threatening danger due to falling loads. Falling loads can cause fatal injuries. Only use the permissible lifting devices to lift loads. Ensure that no one is in the danger zone of the suspended load. Wear appropriate protective work clothing. Life-threatening danger if the wrong lifting devices are used. Use of the wrong lifting devices can cause severe or fatal injuries. Only use the permissible lifting devices to lift the central inverter (weight of the central inverter: See "Technical data" on page 23). Fasten the crane tackle on the transport eyes so that it cannot slip. Lashing eyes as specified in DIN 580 are provided of the roof of the control cabinet, for loading the central inverter. The following permissible total loads apply for systematic load: At 60 cable angle N At 90 cable angle N Fig. 4-1 Crane transport Operating Manual HS80/HS100/HS120, Helios Systems 30

32 Transport and the necessary conditions at the installation site Industrial truck support NOTICE! Warning - damage due to use of a lifting device (e.g. fork lift). Due to the lifting device components and connections on the underside of the floor of the central inverter can be damaged. When lifting the central inverter ensure that components and connections on the floor of the unit are not damaged. When lifting the central inverter ensure that the stress or load is only applied in the area of the pedestal feet. Fig. 4-2 Fork lift transport Operating Manual HS80/HS100/HS120, Helios Systems 31

33 Transport and the necessary conditions at the installation site Securing the central inverter for transport NOTICE! Warning - do not use improper transport safeguards. Improper transport safeguards can damage the central inverter. For transport on a truck or trailer the central inverter must be properly lashed. The truck or trailer must have lashing eyes. Trained, specialized personnel that meet the requirements specified in regulations VDI 2700 and VDI 2703 must load the central inverter. The correct dimensioning and implementation of load securing measures must be specified on a case-by-case basis. To lash the central inverter, fasten the ratchet strap on the lashing eyes and on the lashing eyes of the landing surface. Tighten the ratchet strap with the tensioning device. 4.3 Installation site prerequisites Grid NOTICE! Ensure that the rotary field is correct. The rotary field must be clockwise. If this is not the case the central inverter will not establish a connection to the public grid. The standard version of the central inverter is configured for the TN network 400 V, 3~, 50 Hz, clockwise. Central inverters for other grid forms, voltages and frequencies on request. Operating Manual HS80/HS100/HS120, Helios Systems 32

34 Transport and the necessary conditions at the installation site Connections The connection cables must be present, prepared, and secured: Solar generator connection, Grid connection, Auxiliary voltage connection, Communication connection. Life-threatening danger due to high voltage. Protect cables and lines against mechanical influences. Route the cables and lines that go to the central inverter through a highly flexible plastic protective hose. Offload the plastic protective hose on both ends with catching clamps to relieve the hose from pull and pressure. Fit a marked pull-in aid (not metal) on each plastic protective hose. Ensure that the cables and lines are introduced into the central inverter from below. In this regard at least protection class IP54 must be ensured. The pull and pressure relief at the introduction point must be executed via a C-profile rail in accordance with EN Life-threatening danger due to defective lines and cable. Comply with the specified bend radii. Offload the plastic protective hose on both ends to relieve the hose from pull and pressure. Only route one cable through each cable gland. Ensure that the diameter of the cables and lines match the diameters of the cable glands and threaded unions. Operating Manual HS80/HS100/HS120, Helios Systems 33

35 Transport and the necessary conditions at the installation site 4.4 Foundation Ensure that the foundation can bear the weight of the central inverter and of the transport device (See "Technical data" on page 23). The foundation must be level, stable, slip-resistant, and fire resistant. 4.5 Distances The central inverter must be easily accessible for operation and maintenance. In this regard the following distances must be maintained: Front: Minimum 500 mm with the door open Top: Minimum 200 mm The central inverter does not require a defined distance or clearance to sides and to the rear. Fig. 4-3 Distance upward (left)/distance to the front with the door open (right) Operating Manual HS80/HS100/HS120, Helios Systems 34

36 Transport and the necessary conditions at the installation site 4.6 Ventilation Life-threatening danger due to flammable or explosive gasses. Ensure that the ambient air is free of flammable or explosive gasses. Life-threatening danger due to corrosive substances. Ensure that the ambient air is free of corrosive substances. NOTICE! Warning - damage or overheating of the central inverter. Insufficient cooling air for the central inverter can cause damage or overheating. Ensure that sufficient cooling air is available at the installation site. The central inverter must be set up on a foundation that ensures that sufficient air can be suctioned in. The intake air is distributed in the interior of the central inverter through two radial fans that are attached below the cover. The air is suctioned in from below and blown out on the top side of the central inverter. The air volume that is displaced is 1500 m 3 /h. The central inverter generates a maximum of 5 kw power loss that must be dissipated via the ventilation. 4.7 Ambient variables The protection class must meet the specifications in section Technical data" on page 23. Operating Manual HS80/HS100/HS120, Helios Systems 35

37 Installation 5 Installation Life-threatening danger due to high voltage. Only only qualified electricians who have been trained and authorized are allowed to install the central inverter. Comply with the safety instructions affixed to the central inverter and in this operating manual. Cover the live copper rails with a Plexiglas cover. Check the cable feeds for damage. Prior to performing tasks on the central inverter use a suitable tool to ensure that the central inverter is switched off and de-energized. NOTICE! Material damage due to the wrong torque. If the cable lugs are tightened too tightly damage can occur. If the cable lugs are tightened too loosely the cables and lines can loosen. NOTICE! Material damage due to improper connection. Ensure that the oxide layer of the aluminum conductor has been removed with a wire brush, the aluminum conductor (wire) has been greased with acid-free grease (e.g. Vaseline or terminal grease), the connection of the aluminum conductor is checked after approx. 4 weeks, with a torque wrench, thereafter it must be checked yearly, only one aluminum conductor is connected per terminal. Operating Manual HS80/HS100/HS120, Helios Systems 36

38 Installation 5.1 Mounting switch knob Q2 NOTICE! Material damage due to an incorrect AC main switch position. Ensure that prior to connecting the control cabinet door the control element and the AC main switch in the interior of the control cabinet are in the OFF position. The control element and the actuating rod for the AC main switch Q2 are delivered in dismounted status. You will find the parts of the AC main switch Q2 in the interior of the central inverter on the sliding floor plate. Fig. 5-1 Dismounted AC main switch Q2 1. Unscrew the fastening screws for the actuating rod on the AC main switch Q2. 2. Insert the actuating rod. In this process pay attention to the alignment of the actuating rod. Fig. 5-2 Insert the actuating rod in the AC main switch Q2 Operating Manual HS80/HS100/HS120, Helios Systems 37

39 Installation 3. Fasten the actuating rod in the AC main switch Q2 with the screws. Fig. 5-3 Fasten the actuating rod on the AC main switch Q2. 4. Remove the screws from the control element. 5. Insert the control element into the intended opening in the control cabinet door from the outside. In this process pay attention to the alignment of the control element. Fig. 5-4 Insert the control element of the AC master switch Q2 6. Screw fasten the control element from the inside with the previously removed screws. Fig. 5-5 Fasten the control element onto the control cabinet door Operating Manual HS80/HS100/HS120, Helios Systems 38

40 Installation 5.2 Connect the solar generator (DC) There are two different ways to connect the solar generator (DC). One connection type is without string option (See "Connecting solar generator without string option" on page 39). The second connection type is executed with power switches and offers the possibility of connecting up to 5 solar generators (See "Connecting the solar generator to power switch (Option with power switches, up to 5 solar generator strings)" on page 40) Connecting solar generator without string option Life-threatening danger due to high voltage. The installation should be executed only by qualified electricians who have been trained and authorized. 1. Open the front door. 2. Unscrew the threaded unions of the Plexiglas cover. 3. Take off the Plexiglas cover. 4. Remove the sliding floor plate. 5. Route the cable to the connection area from below. 6. Check the cable feeds for damage. Fig. 5-6 Copper rails with (left) and without (right) Plexiglas cover Operating Manual HS80/HS100/HS120, Helios Systems 39

41 Installation 7. The cable lugs must be configured for fastening with M8 screws. Route the cable lugs to the correct copper rail. Ensure correct polarity. 8. Fasten the cable lugs (tightening torque: 20 Nm). 9. Screw on the Plexiglas cover. 10. Fix the cables in place on the cable catch strip with aluminum cable clamps. 11. If no other cables will be connected reinstall the sliding door Connecting the solar generator to power switch (Option with power switches, up to 5 solar generator strings) Life-threatening danger due to high voltage. The installation should be executed only by qualified electricians who have been trained and authorized. 1. Open the front door. 2. Unscrew the threaded unions of the lower Plexiglas cover. 3. Take off the Plexiglas cover. 4. Remove the sliding floor plate. 5. Route the cable to the connection area from below. 6. Check the cable feeds for damage. Fig. 5-7 Connect the solar generators to the power switches Operating Manual HS80/HS100/HS120, Helios Systems 40

42 Installation 7. Route the cable that is fitted with wire end sleeves, coming from below to the appropriate power switches. The polarity is marked on the mounting plate under the power switches. The sequence is as follows, from left to right: String 1 - plus String 1 - minus String 2 - plus String 2 - minus String 3 - plus String 3 - minus String 4 - plus String 4 - minus String 5 - plus String 5 - minus The short red-marked bridge cable in the middle between the lower plus and minus connection terminal of a string are connected in the factory. 8. Fasten the cable lugs (tightening torque: 3-4 Nm). The maximum cable cross section is 50 mm Screw on the lower Plexiglas cover. 10. Fix the cables in place on the cable catch strip with aluminum cable clamps. 11. If no other cables will be connected reinstall the sliding door. Operating Manual HS80/HS100/HS120, Helios Systems 41

43 Installation 5.3 Connecting to the grid (AC) NOTICE! Ensure that the rotary field is correct. The rotary field must be clockwise. If this is not the case the central inverter will not establish a connection to the public grid. 1. Open the front door. 2. Pull off the contact protection via the cable inlets of the AC power switch Q2. 3. Remove the sliding floor plate. 4. Route the cable to the connection area from below. 5. Check the cable feeds of the grid connection for damage. Fig. 5-8 AC power switch Q2 6. The cable lugs must be configured for fastening with M8 screws. Route the cable lugs to the AC power switch inputs. The color sequence is as follows, from left to right (tightening torque: 8 Nm): - L1 left/brown - L2 center/black - L3 right/gray Ensure that the underlying measurement lines are correctly connected for the grid power supply. Operating Manual HS80/HS100/HS120, Helios Systems 42

44 Installation Life-threatening danger due to defective and inadequate grounding. In the central inverter there are interference suppression filters with increased work currents to ground. Ensure that the PE conductor has at least half the cross section of the phase conductor. 7. Connect the PE conductor. The cable shoe must be configured for M8 screws (tightening torque: 23 Nm). 8. Fit the N conductor with a wire end sleeve and connect the N-conductor (tightening torque: 3.2 Nm Nm). The maximum N-conductor cross section is 35 mm 2. The N-conductor should only be connected for the internal power supply (see Internal power supply" on page 45). Fig. 5-9 PE (green-yellow) and N-conductor (blue) 9. Slide the contact protection back on. 10. Fix the cables in place on the cable catch strip with aluminum cable clamps. 11. If no other cables will be connected reinstall the sliding door. Operating Manual HS80/HS100/HS120, Helios Systems 43

45 Installation Suitable cable lugs Suitable cable lugs for connecting the grid (AC) are available from the company FeCon or from the company Elpress. FeCon item number Elpress catalog number Suitable for cable cross section KRFS mm KRFS mm KRFS mm KRFS mm KRFS mm Connection area power switch Q2 The cable lugs for connecting the grid should be a maximum of 24 mm wide, so that they fit in the connection area of the power switch Q2. max. 24 mm max. 9,5 mm Fig Power switch Q2 Operating Manual HS80/HS100/HS120, Helios Systems 44

46 Installation 5.4 Connecting the auxiliary power supply The central inverter is delivered with an internal power supply. Optionally an external power supply is possible Internal power supply 1. Open the front door. 2. Connect the N-conductor to the blue screw-type terminal next to the AC power switch Q2. 3. Switch the miniature circuit breaker F32 (1) to the on position. 1 Fig Miniature circuit breaker F32 Operating Manual HS80/HS100/HS120, Helios Systems 45

47 Installation External power supply (optional) 1. Open the front door. 2. Switch the miniature circuit breaker F32 to the off position. 3. Remove the two bridges from X1.1 to X1.3 and from X1.2 to X1.5 Use a suitable flat-head screwdriver with a blade width of 3.5 mm. Fig Remove the bridges 4. Fit each cable with a wire end sleeve (cross section: 0.75 mm mm 2 ) and connect the cables as follows: L-conductor to X1-3, N-conductor to X1-5 (blue), PE-conductor to X1-8 (green-yellow). Fig External power supply Operating Manual HS80/HS100/HS120, Helios Systems 46

48 Installation 5.5 Connect the monitoring system Data communication is executed via Ethernet. Fig Connect the Ethernet cable: NOTICE! Warning - damage to the central inverter. Ensure that lightning protection is present if the Ethernet cable of the central inverter exits the building. 1. Connect the network cable (1) to the communication PCB. 2. Route the cable downward on the right inside of the central inverter. 3. Fix the network cable in place with cable ties. Operating Manual HS80/HS100/HS120, Helios Systems 47

49 Commissioning 6 Commissioning Life-threatening danger due to high voltage. Comply with the safety instructions affixed to the central inverter and in this operating manual. The central inverter should only be commissioned by qualified electricians who have been trained and authorized. 6.1 Preparing for the commissioning process Life-threatening danger due to high voltage. Ensure that the central inverter is de-energized, the slide switch on the DC switch disconnector Q1 is in position Auto, the AC main switch and the AC power switch Q2 are in the off position, the emergency stop switch is unlocked, all power switches for the string option with power switches are switched off, the fuse switch F31 is switched on, the miniature circuit breaker F32 for internal power supply is switched on, or for external power supply is switched off, all cables and lines are undamaged, correctly connected and in faultless condition, the threaded unions on all connection rails and terminal strips have the correct tightening torque. Operating Manual HS80/HS100/HS120, Helios Systems 48

50 Commissioning Commissioning 1. The central inverter must be connected on the DC main supply. 2. The central inverter must be connected on the AC main supply. Life-threatening danger due to high voltage. Only take measurements with appropriate measurement devices. 3. For the option solar generator without string option (Page 39) measure the DC voltage from plus to minus. The polarity must correspond to the plus/minus markings, and the measured values must be within the tolerances (see section Technical data" on page 23). Life-threatening danger due to high voltage. When taking the measurements all DC power switches must be switched off. 4. For the option solar generator with string option (Page 40) measure the DC voltage of each individual string from plus to minus. The polarity must correspond to the plus/minus markings, and the measured values must be within the tolerances (see section Technical data" on page 23). 5. Switch on all DC power switches. 6. Measure the grid voltage AC: - Phase to phase - Phase to N - Phase to PE The measured values must be within the tolerances (see section Technical data" on page 23). Operating Manual HS80/HS100/HS120, Helios Systems 49

51 Commissioning WARNING! Danger of pinching when closing the front door. When closing the front door, ensure that bodily extremities (hands, fingers) do not get in the closing edges. 7. Close the front door. 8. Touch the display. The display shows the operating status of the central inverter. 9. Set the AC main switch to the "on" position. This automatically activates the DC switch disconnector Q1 in the interior of the central inverter. After approximately 90 seconds, the central inverter starts up. Operating Manual HS80/HS100/HS120, Helios Systems 50

52 Operating states 7 Operating states After commissioning, the central inverter runs through operating states described below. The parameters that cause the central inverter to change to a certain operating state are prescribed. 7.1 Standby If the solar generator voltage is over 480 V, the central inverter changes to the Standby operating status. The central inverter is connected to the grid via the grid contactor K Start up If the solar generator voltage increases above 500 V, the infeed operation is started. If the solar generator current drops below 2 A, the infeed operation is switched off for 30 seconds. When the solar generator voltage again climbs above 500 V, the infeed mode is switched on again. If the solar generator current is continuously over 2 A the central inverter is in normal mode and infeed is continuous. 7.3 MPP mode Thanks to the Maximum Power Point Tracker (MPPT) the solar power of the solar generator is optimally used. The MPPT is comprised of the continuous MPPT and the cyclical MPPT. The continuous MPPT varies the solar generator voltage in small increments, and determines the solar generator power after each increment. In this process the continuous MPPT always the tracks the path of optimal solar generator power. Cyclic MPPT is active every 20 seconds and scans a defined voltage range in larger increments (normally +/- 5 % of the applied solar generator voltage). If the cyclic MPPT has found the solar generator voltage with the greatest solar generator power, the continuous MPPT takes over this solar generator voltage for further tracking. 7.4 Shutdown If the solar generator current drops below 2 A, initially only the infeed operation is switched off. If the solar generator voltage drops below 460 V the central inverter is disconnected from the grid by opening the grid contactor K1. Operating Manual HS80/HS100/HS120, Helios Systems 51

53 Operating states 7.5 Stop Error monitoring is active in each operating state. If a error occurs, all functions of the central inverter will be stopped automatically. A error message will be shown on the display. If the cause of the error is eliminated, the central inverter resumes operation in Standby mode after approximately one minute. Operating Manual HS80/HS100/HS120, Helios Systems 52

54 De-commissioning 8 De-commissioning Life-threatening danger due to residual voltage. Strictly maintain a minimum wait time of 30 minutes after switching off and prior to opening the central inverter! Prior to performing tasks on the central inverter use a suitable tool to ensure that residual voltage is not present. 8.1 Emergency stop switch NOTICE! Only activate the emergency stop switch in an emergency. In an emergency the emergency stop switch immediately disconnects the central inverter from the power supply (AC) and from the solar generator (DC). Only when the dangerous situation has been resolved, and possible errors have been corrected, should the emergency stop switch be unlocked by pulling it out. Press the emergency stop button to shut down the central inverter in an emergency. After unlocking the emergency stop switch the central inverter wills resume operation after a wait time of one minute. 8.2 AC main switch By switching the AC main switch to the off position, the central inverter will be disconnected from the grid on the AC side by the power switch Q2. The DC-side disconnect via the switch disconnector Q1 occurs in the interior of the central inverter. 8.3 Switching off the control voltage If there is an internal power supply the control voltage must be switched off on the miniature circuit breaker F32. If there is an external power supply the control voltage must be switched off outside of the central inverter. Operating Manual HS80/HS100/HS120, Helios Systems 53

55 Maintenance 9 Maintenance Life-threatening danger due to high voltage. The central inverter should only be maintained by qualified electricians who have been trained and authorized. Prior to performing tasks on the central inverter use a suitable tool to ensure that the central inverter is switched off and de-energized. Always work with a second person near you. NOTICE! Warning - damage to the central inverter. Improper repair work can cause damage to the central inverter. All repair tasks should be performed by employees of Helios Systems. 9.1 Executing maintenance tasks 1. Shut down the central inverter (see section De-commissioning" on page 53). Life-threatening danger due to residual voltage when performing maintenance tasks on the outer area. For all tasks in the vicinity of the central inverter: Maintain the safe distance to the central inverter that must be complied with in accordance with BGV A3 (see Table 4/BGV A3 "Safety distances for non-electrical work depending on the rated voltage"). Operating Manual HS80/HS100/HS120, Helios Systems 54

56 Maintenance Life-threatening danger due to residual voltage when performing maintenance tasks in the interior. Strictly maintain a minimum wait time of 30 minutes after switching off and prior to opening the central inverter! Prior to performing tasks on the central inverter use a suitable tool to ensure that residual voltage is not present. The maintenance tasks described must be executed within the specified intervals, starting with the installation date. Maintenance tasks Every 12 months Every 24 months Check the housing and interior area for discoloration, corrosion, fouling, significant dust and water accumulation, and damage. Check all fans and their filters, if present. Check whether foreign objects on the central inverter hinder air circulation. Check the function of the DC load switch (Q1). Check the status of the copper rails. Check the status of all cables and lines. X X X X X Check all fuses for damage. Check the AC and DC overvoltage protection for damage. Check the function of the internal 24 V power supply. Check the accuracy of the AC measured values (See "Taking measurements" on page 56). Check the function of the emergency stop switch. Check the status of the capacitors. X X X X X X Operating Manual HS80/HS100/HS120, Helios Systems 55

57 Maintenance Taking measurements Life-threatening danger due to residual voltage. Maintain a minimum wait time of 30 minutes after switching off and prior to opening the central inverter. Prior to performing tasks on the central inverter use a suitable tool to ensure that residual voltage is not present. Only take measurements with appropriate measurement devices. 1. Use a multimeter. Check the output voltage of the internal 24 V power supply. The DC output voltage of the 24 V power supply unit should be 24 V +/- 0.5 V. 2. Check the accuracy of the AC measured values. In the display the AC voltages of phase L1, L2, and L3 are shown. Compare these display values with the values measured by the voltmeter. The accuracy should be +/-2.5 %. WARNING! Danger of pinching when closing the front door. When closing the front door, ensure that bodily extremities (hands, fingers) do not get in the closing edges. 3. Close the front door. 4. Switch on the central inverter (See "Commissioning" on page 48). Operating Manual HS80/HS100/HS120, Helios Systems 56

58 Disposal 10 Disposal Life-threatening danger due to residual voltage. The central inverter should only be dismantled and disposed of by qualified electricians who have been trained and authorized. The central inverter contains electrical components and metal. Final and professional disposal of the central inverter must be executed under the applicable statutory regulations of the user country. Particularly comply with the special regulations for electronics and electrical equipment. The central inverter has been manufactured in accordance with the applicable EC Directive 2002/95/EC on the Restriction of the use of certain Hazardous Substances in Electrical and Electronic Equipment (RoHS). No solder points contain lead, thus there are no hazardous substances. Separate disposal is not necessary. The waste management company is responsible for the correct coding and description of its waste. Operating Manual HS80/HS100/HS120, Helios Systems 57

59 Disposal 10.1 Disposal of the electrolytic capacitors Warning - harmful to health. WARNING! The electrolytic capacitors contain ethylene glycol that is considered to be an irritant and harmful to health. Wear protective goggles. Wear suitable protective clothing. If there is contact seek medical attention immediately. If there is eye contact rinse eyes with water for at least 10 minutes. If swallowed drink plenty of water. Only have the person affected vomit if the person affected is fully conscious. Immediately taken off contaminated clothing and remove it safely. If there is skin contact wash off immediately with plenty of water. CAUTION! Environmental damage is possible because ethylene glycol poses a slight hazard to water. The ethylene glycol from the electrolytic capacitors should not get into soil or ground water. Electrolytic capacitors are in the intermediate circuit, in the 24 V power supply unit and in other electronic components. Particularly comply with the regulations for disposal of special waste. The regulations issued by government agencies apply, particularly the regulations associated with the European Waste Catalogue. Operating Manual HS80/HS100/HS120, Helios Systems 58