PV.MH (English)

PV.MH (English)
Operating Instructions
Protect PV.500-MH
AEG Power Solutions GmbH, Warstein-Belecke
Department:
PS AED
Revision:
00
Revision date:
25.04.2012 / Schenuit
Released:
25.04.2012 / Aranda
Document no.
8000043212 BAL, en
Protect PV.500-MH Operating Instructions
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
AEG Power Solutions GmbH
Emil-Siepmann-Strasse 32
59581 Warstein
Germany

Fax:
E-mail:
Internet:
+49 2902 763 100
+49 2902 763 645
[email protected]
http://www.aegps.com
80000043212 BAL
Protect PV.500_MH Operating Instructions
Table of Contents
1
1.1
1.2
1.3
1.3.1
1.3.2
1.4
Information on How to Use these Instructions ...............6
General Information .............................................................6
Target Groups .....................................................................7
Explanations of Target Groups ............................................7
Obligations of the Equipment Operator ...............................7
Skilled Personnel Skills and Training ..................................8
Storing Instructions ..............................................................9
2
2.1
2.2
2.2.1
2.2.2
2.2.3
2.2.4
2.3
2.4
2.5
2.6
2.7
2.7.1
2.7.2
2.7.3
2.8
2.8.1
2.8.2
2.8.3
2.8.4
2.8.5
Explanation of Symbols and Safety Instructions .........10
Explanation of Symbols .....................................................10
Safety Instructions .............................................................11
Signal Words Used ............................................................11
Hazard Symbols Used .......................................................11
Signs Containing Orders for Personal Protective Equipment12
Abbreviations .....................................................................13
Emergency Procedure (e.g. in the Event of a Fire) ...........13
Safety Awareness .............................................................13
Particular Dangers associated with Photovoltaic Systems 14
Safety Signs and Warning Notices on the Equipment .......15
Safety and Protection Devices for the Equipment .............15
Protective Covers ..............................................................15
Lockable Equipment Doors ...............................................16
Guard ................................................................................16
Residual Hazards ..............................................................16
Electrical Hazards .............................................................17
Risks Due to Moving Parts ................................................18
Fire-Related Risks .............................................................18
Risks due to Loss of Control .............................................19
Risks from Maintenance and Repair Work ........................19
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
Product Details ................................................................20
Product Description ...........................................................20
Dimensions and Views ......................................................21
Appropriate Use ................................................................21
Inappropriate Use ..............................................................21
Standards, Directives and CE Mark ..................................22
Nameplate .........................................................................22
Technology ........................................................................23
Operating Elements ...........................................................24
4
4.1
System Description .........................................................25
Individual Operation ..........................................................25
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5
5.1
5.1.1
5.1.2
5.1.3
5.1.4
5.1.5
5.1.6
5.1.7
5.1.8
5.2
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.3
5.3.1
5.3.2
Cells
5.3.3
5.3.4
5.4
System Function .............................................................26
Description of Sequence Control .......................................26
The "OFF" Status ..............................................................26
The "Waiting for Feed Conditions" Status .........................26
The "Operation" Status ......................................................27
The "Waiting" Status..........................................................27
The "Fault" Status..............................................................28
The "Night" Status .............................................................28
Sequence Control During the Course of the Day ..............28
Sequence Control Parameters ..........................................30
Description of Fan Control .................................................31
General ..............................................................................31
Fan Control, Cabinet Fan ..................................................31
Cabinet Fan Control Parameters .......................................32
Fan Control, Inverter Stack Fan ........................................32
Parameters of Inverter Stack Fan Control .........................33
Insulation Monitoring and Earthing of PV Cells .................33
General ..............................................................................33
Operation With Monocrystalline or Polycrystalline Solar
35
Operation with Thin-Film Solar Cells .................................35
Insulation Monitoring Parameters ......................................36
MPP Tracker .....................................................................36
6
6.1
6.2
Monitoring Systems, Messages and Faults ..................37
General Information ...........................................................37
Table of Faults ...................................................................38
7
Interfaces .........................................................................42
7.1
Communication Interface ..................................................42
7.1.1 General ..............................................................................42
7.1.2 Technical Data ..................................................................43
7.1.3 Structure of the MultiCom CCC Interface .........................44
7.1.4 Configuration .....................................................................47
7.1.4.1 Configuration Preparations ................................................48
7.1.4.2 Configuring the Modbus Protocol ......................................50
7.1.4.3 Configuring Modbus Data Transmission ...........................51
7.2
COM Server ......................................................................52
7.2.1 General ..............................................................................52
7.2.2 Network Connection ..........................................................52
7.2.3 Structure of the COM Server (internally wired to A93) ......52
7.2.4 Installation of the COM Server ..........................................53
7.2.5 Network Integration Configuration .....................................54
7.2.6 Configuration of the Virtual COM Port ...............................54
7.3
Remote Signalling .............................................................55
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8.1
8.1.1
8.1.2
8.2
8.3
8.3.1
8.3.2
8.3.3
8.3.4
8.3.5
8.3.6
8.3.7
8.3.8
8.3.9
8.3.10
Graphical Display and Operation Unit ...........................57
General Information ...........................................................57
Signalling ...........................................................................58
Keyboard Operation ..........................................................58
Start-up ..............................................................................59
Menu Structure ..................................................................60
Menu Tree .........................................................................60
Main Menu .........................................................................60
Operating Display ..............................................................61
Status/Measured Values ...................................................66
Blocking .............................................................................67
Fault History ......................................................................68
Settings .............................................................................68
Information ........................................................................68
Service ..............................................................................68
Help ...................................................................................68
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1
Information on How to Use these Instructions
This chapter contains general information about these instructions
and the people they are intended for.
The Protect PV.500 with two control cabinets (+DCD/ACD, +INV)
is referred to as 'equipment' in the rest of the instructions. The precise name (PV.500) cannot be avoided in some situations. In such
cases the equipment is referred to as the PV.500 equipment or the
individual control cabinets are mentioned.
1.1
General Information
Validity
These instructions correspond to the technical specifications of the
equipment at the time of publication. The contents of these instructions do not constitute a subject matter of the contract, but are for
information purposes only.
AEG Power Solutions GmbH reserves the right to make modifications to the content and technical data in these instructions without
prior notice. AEG Power Solutions GmbH cannot be held liable for
any inaccuracies or inapplicable information in these instructions,
which came about as a result of changes to the content or technology applied after this equipment was supplied, as there is no
obligation to continuously update the data and maintain its validity.
Warranty
Our goods and services are subject to the general conditions of
supply for products in the electrical industry, and our general sales
conditions. We reserve the right to alter any specifications given in
these instructions, especially with regard to technical data, operation, dimensions and weights. AEG Power Solutions GmbH will rescind all obligations such as warranty agreements, service contracts, etc. entered into by AEG Power Solutions GmbH or its representatives without prior notice in the event of maintenance and
repair work being carried out with anything other than original AEG
Power Solutions GmbH spare parts or spare parts purchased from
AEG Power Solutions GmbH.
Complaints
In the event of complaints, please contact us within eight days of
receipt of goods and provide the following details:
Type designation
Serial number
Nature of complaint
Period of use
Ambient conditions
Any claims submitted after this point cannot be considered.
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Handling
These instructions are structured so that all work necessary for
operation can be performed by appropriately qualified skilled personnel.
Illustrations are provided to clarify and facilitate certain steps.
If danger to personnel and equipment cannot be ruled out in the
case of certain work, it is highlighted accordingly by pictograms
explained in Chapter 2, Safety Regulations.
1.2
Target Groups
This document explains which groups these instructions are intended for and the obligations of these groups. Definitions of staff
requirements are also provided.
Every care has been taken in drafting these instructions. Should
you notice any errors, please contact the manufacturer immediately.
So that the instructions remain up to date, please remember to insert any supplements received from AEG Power Solutions GmbH.
1.3
Explanations of Target Groups
These instructions are intended for various target groups:


1.3.1
The equipment operator or the person appointed by him (the
party responsible for the equipment)
The skilled personnel responsible for using the equipment
Obligations of the Equipment Operator
The equipment operator or the person appointed by him/her (the
party responsible for the equipment) is responsible for the safety of
personnel and for the safety, function and availability of the equipment. These factors depend on compliance with the safety instructions. Compliance with the safety instructions is required at all
times.
To ensure the safety of personnel, the equipment operator
must:
 Select skilled personnel on the basis of skills and training (
Chapter 1.3.2)
 Make skilled personnel aware of the need for compliance with
regulations ( Chapter 1.3.2)
 Provide skilled personnel with personal protective equipment,
user information and instructions
 Provide skilled personnel with regular briefings about all safety
measures and keep a record of such briefings
 Inform skilled personnel of where fire extinguishers are located
and how to use them
To ensure the safety of the equipment, the equipment operator must:
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 Only operate the equipment in perfect working order and in accordance with good electrical engineering practice
 Arrange a fault detection check immediately if the equipment
starts to behave differently
 Keep all safety signs and warning notices on the equipment in a
complete and clearly legible condition
 Install fire extinguishers in the immediate vicinity of the equipment
1.3.2
Skilled Personnel Skills and Training
Only trained and qualified skilled personnel may perform the work
described, using tools, equipment and test equipment intended for
the purpose and in perfect working order.
All work is coordinated and monitored by the person responsible
for work. The person responsible for work is directly responsible
for the execution of the work. Before work commences, the person
responsible for work must inform the person responsible for the
equipment and agree on a work schedule with him. The persons
responsible for the work and equipment must be trained and qualified skilled personnel and may be one and the same person.
"Trained skilled personnel" means electricians who as a result of
their specialist training:
 Have knowledge and experience of the relevant standards,
regulations, requirements and accident prevention regulations
 Have been instructed in the mode of operation and operating
conditions of the equipment
 Have the ability to assess the effect of any intended work on
the safe operation of this particular equipment
 Can assess the work and recognise and avoid potential risks
Compliance with the safety instructions described is essential for
the protection of skilled personnel and the equipment. Skilled personnel must be aware of and follow these safety instructions.
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Obligations of skilled personnel
Observe the following safety instructions.
 Work on and in electrical equipment is governed by strict rules
in order to avoid electrical accidents. The rules are summarised
in the five rules of safety. You must observe these rules:
1. Disconnect safely.
2. Secure the unit against being switched back on.
3. Verify that all poles are de-energised.
4. Earth and short-circuit the equipment.
5. Provide protection in the form of covers or barriers for any
neighbouring live parts.
 Once work is complete, reverse the five safety rules starting at
number 5 and working back to number 1.
 Read these instructions. Memorise the safety instructions.
( Chapter 2)
 Ensure compliance with the following regulations:
 Accident prevention regulations of the respective country of
destination and the generally valid safety regulations according
to IEC 364.
 BGV A1 (Prevention principles)
 BGV A3 (Electrical systems and equipment)
 BGV A8 (Safety and health protection warnings in the workplace)
 Report damage to the equipment and electrical installations to
the equipment operator.
 Only use spare parts approved by the manufacturer for maintenance
and repair work.
 Use personal protective equipment (PPE) as intended.
 Check that PPE is in perfect working order and report any defects you notice to the equipment operator.
 Wear a hair net if you have long hair. Do not wear loose clothing or jewellery.
 Reinstate protection devices (including covers) on completion
of all work on or with the equipment.
 Keep the instructions in the pull-out document pocket.
1.4
Storing Instructions
Store these instructions in an appropriate place. A pull-out document pocket is located on the inside of the door. These instructions
must be stored together with the equipment.
Should the equipment change hands, include these instructions
when handing it over to the new operator.
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2
Explanation of Symbols and Safety Instructions
All of the symbols and abbreviations used in the text are described
below.
2.1
Explanation of Symbols
This section describes the symbols used in these instructions.
Symbol
Meaning
Hazard symbols are triangular and feature a
yellow background, black border and corresponding symbol.
Signs containing orders are round and have a
blue background with a white symbol.
i
Information is indicated by the letter i. These
sections contain important information about the
phases of the equipment's service life.
Instructions relating to the environment are
identified by a wheelie bin. Instructions relating
to the environment make reference to mandatory requirements set out by regional or national
authorities which are of particular relevance
when disposing of materials used during operation, for example.
Table 1
instructions
Instruction and warning symbols in these operating
Other symbols and their meanings
Typographical element Meaning

This symbol is used for action instructions.
1.
2.
3.
Numbers are used for action instructions that
need to be followed in a specific order.

This symbol is used for bulleted lists.

References to figures, chapters or tables are
shown using the symbol on the left.
Table 2 – Other symbols
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2.2
Safety Instructions
All safety instructions have the following structure:
SIGNAL WORD
Type and source of hazard
Consequence(s) of noncompliance
Symbol
 Measure(s) to avoid hazard.
Figure 1
2.2.1
Warning associated with operator action
Signal Words Used
Signal words at the start of safety instructions indicate the type and
severity of the consequences if the measures for avoiding the hazard are not taken.
Warning colour
DANGER
Warns of a situation posing an immediate
hazard which will lead to death or serious
injury.
WARNING
Warns of a situation posing a possible hazard which may lead to death or serious injury.
CAUTION
Warns of a situation posing a possible hazard which may lead to minor injury.
ATTENTION
2.2.2
Consequences
warns of possible damage to property and
the environment which could interrupt operation.
Hazard Symbols Used
The following hazard symbols are used to illustrate hazards in the
safety instructions.
Symbol
Meaning for skilled personnel
General hazard source
Electrical hazard
Risk of falling loads
Risk posed by flammable material
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Risk posed by corrosive vapours and liquids
Risk posed by explosive material
Table 3 – Hazard symbols
2.2.3
Signs Containing Orders for Personal Protective Equipment
The following signs relate to the use of personal protective equipment. You are required to comply with them.
Symbol
Meaning for skilled personnel
Wear a face shield.
Wear an electrician's safety helmet.
Wear insulating safety boots.
Wear insulating overalls.
Wear insulating gloves with long sleeves.
Wear hearing protection when operating the
equipment.
Table 4
Signs containing orders for PPE
Check that personal protective equipment is in perfect working order and report any defects you notice to the equipment operator.
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2.2.4
Abbreviations
The following abbreviations are used in these operating instructions:
DOU
Display and operation unit
AC
Alternating current
BGV
Regulation set out by Employer's Liability Insurance
Association (Germany)
CAN
Controller Area Network
CNF
Manufacturing order number
DC
Direct current
DCD/ACD DC/AC control cabinet
DCS
Distributed control system
DIN
German Standards Institute
EPO
Emergency power off (system off)
GCB
Generator connection box
Grid
Power utility mains (power utility company's mains)
IEC
International Electrotechnical Commission
IGBT
Insulated gate bipolar transistor
INV
Inverter cabinet
PE conductor Protective earth conductor, earthing
PV
Photovoltaics
VDE
Verband der Elektrotechnik Elektronik Informationstechnik e. V. (German Association for Electrical,
Electronic & Information Technologies)
INV
Inverter
2.3
Emergency Procedure (e.g. in the Event of a Fire)
 Never put your own life at risk. Your own safety is paramount.
 Call the fire brigade.
 Call the emergency doctor, if necessary.
 Shut down the equipment using the system stop switch (ensuring your own safety).
2.4
Safety Awareness
The qualified skilled personnel defined in Chapter 1.3.2 are responsible for safety. The member of personnel who is responsible
for the equipment must ensure that only suitably qualified persons
are allowed access to the equipment or permitted within its vicinity.
The following points must be observed:
 All such working procedures which are detrimental to the safety of persons and the operation of the equipment in any way
are prohibited.
 The equipment may only be operated when in perfect working
order.
 Never remove or render inoperable any safety devices.
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
All necessary operational measures must be initiated prior to
deactivating any safety device in order to perform maintenance, repair or any other work on the unit.
Safety awareness also entails informing colleagues of any unsuitable behaviour and reporting any faults detected to the appropriate
authority or person.
The member of personnel responsible for the equipment must
ensure that:
 The safety instructions and operating instructions are readily
available and are complied with
 The operating conditions and technical data are observed
 Safety devices are used
 The prescribed maintenance work is performed
 Maintenance personnel are informed without delay or the
equipment is shut down immediately in the event of abnormal
voltages or noise, high temperatures, vibrations or any similar
phenomena, so that the cause of this can be determined
2.5
Particular Dangers associated with Photovoltaic Systems
Here you will find information about the additional dangers associated with photovoltaic systems.
An active power source is connected. Depending on the operating
status, the PV cells and the equipment may be live.
DANGER
Contact with voltage! Extremely high DC voltages of
up to 1000 VDC are present.
Risk to life due to electric shock.
 Do not touch live parts.
 Wear personal protective equipment ( Chapter
2.2.3).
Crystalline silicon cells
Crystalline PV cells (silicon cells) usually have an IT system
configuration, i.e. a non-earthed system that will be inadvertently
earthed in the event of an earth fault.
A generator with a complex branched structure can only be shut
down with a great deal of difficulty (in the event of a short circuit,
for example).
Thin-film cells
To prevent corrosion, thin-film cells must be earthed.
Lightning protection
The desired level of protection can only be achieved if a lightning
protection zone concept has been implemented for the building
where the unit is to be installed, in accordance with DIN VDE
0185-4.
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System stop switch
The system stop switch is on the door of the equipment's DC/AC
control cabinet.
The system stop switch is not intended for switching off the equipment. It may only be used in an emergency.
The DOU is used, amongst other things, to switch the equipment
on and off.
The system stop switch causes the
- PV inputs
- mains input and
- mains 2 input
to be separated. This interrupts the energy supply.
It does not mean that the unit has been de-energised!
2.6
Safety Signs and Warning Notices on the Equipment
Safety signs and warning notices are located in the vicinity of danger spots. They provide information about electrical hazards and
residual hazards associated with working on and with the equipment.
Safety signs and warning notices must always be in perfect condition and clearly legible. You must comply with safety signs and
warning notices whenever you are working on or with the equipment.
2.7
Safety and Protection Devices for the Equipment
This section describes all safety and protection devices. Safety
and protection devices protect personnel against hazards which
cannot be countered by safe design.
Safety and protection devices must always be in perfect working
order.
2.7.1
Protective Covers
The equipment is designed so that the live components in the operating area are secured with protective covers wherever possible.
The protective covers provide protection against accidental contact
with live parts.
Such protection may only be removed for start-up and for maintenance or repair work.
The covers must be replaced immediately on completion of such
work and checked to ensure that they are in perfect working order.
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2.7.2
Lockable Equipment Doors
The equipment doors are fitted with a control cabinet lock. This
prevents unauthorised personnel from accessing the equipment.
The equipment door must be kept closed at all times.
It may be opened for maintenance and repair work.
i
The space requirement for the opened equipment doors
must be taken into account
The equipment door must be closed again once maintenance and
repair work is complete.
2.7.3
Guard
The guard forms the equipment's housing. It protects against unintended contact with live parts and electromagnetic rays.
It may be removed for maintenance and repair work.
i
The area around the equipment must be made secure
when the guard is removed.
The guard must be put back in place once maintenance and repair
work is complete.
2.8
Residual Hazards
This section describes residual hazards. Despite the measures
taken to ensure safety and protection, the equipment poses residual hazards which cannot be countered by design.
Observe warnings at all times while you are working.
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2.8.1
Electrical Hazards
DANGER
Contact with voltage!
Risk to life due to electric shock.
 Use dry insulating material to remove the victim from
the live parts.
 Seek medical assistance and inform the control room.
 Disconnect the equipment safely.
DANGER
Electric shock after activating "System stop"!
Parts of the equipment remain live after "System stop"
has been activated (e.g. external voltage present at remote signal terminals).
Risk to life due to electric shock.
 Disconnect the equipment safely.
DANGER
Electric shock caused by inverter.
Parts of the equipment remain live after the inverter has
been shut down.
Risk to life due to electric shock.
 Disconnect the equipment safely.
DANGER
Electric shock caused by back feeding.
The input terminals of the equipment may remain live
after the incoming power supply has been interrupted.
Risk to life due to electric shock.
 Disconnect the equipment safely.
 Install back feeding protection (a disconnector) in the
load circuit.
DANGER
Electric shock caused by leakage currents.
The capacitors generate high leakage currents in the
equipment. Conductive parts may be live in the event of
connection errors.
Risk to life due to electric shock.
 Establish a PE conductor connection prior to start-up.
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i
Using residual-current-operated safety devices (FI) alone
is not permitted.
WARNING
Water in electrical equipment!
Risk to life due to electric shock.
 Do not use water to clean the cabinets.
 Do not place any vessels containing fluids on electrical
equipment.
2.8.2
Risks Due to Moving Parts
CAUTION
Risk of injury due to rotating fans!
The fans of the INV control cabinet are freely accessible.
 Never reach into rotating fans.
 When setting up any system, ensure that the fans
cannot be touched.
2.8.3
Fire-Related Risks
Installation of fireproof enclosures (EN 60950-1)
A built-in floor plate ensures that, in the event of a fire, no molten
or burning material can fall out of the equipment.
We recommend having a separate supply/exhaust air connection
for the PV.500 in order to prevent smoke spreading in the event of
a fire.
WARNING
Spread of smoke in electrical operating areas.
 If smoke is detected or a fire breaks out, immediately
disconnect the equipment from the power supply and
inform the maintenance personnel.
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2.8.4
Risks due to Loss of Control
ATTENTION
Failure of remote signalling.
If remote signalling fails or the signal lines are interrupted,
the control room can no longer control the equipment.
In such an event, faults can only be identified locally at the
unit itself.
Failure of external emergency switching device
 Disconnect the equipment safely.
ATTENTION
Failure of the display and operation unit.
If the display and operation unit fails, the skilled personnel
will no longer be able to control the equipment.
In such an event, faults will no longer be displayed.
 Inform the control room.
2.8.5
Risks from Maintenance and Repair Work
i
Only trained and qualified skilled personnel (as described above) may work on or around the equipment
while strictly observing the safety regulations.
DANGER
Risk to life due to electric shock.
Potentially fatal voltages are present in the equipment.
 Disconnect safely.
 Secure the unit against being switched back on.
 Verify that all poles are de-energised.
 Earth and short-circuit the equipment.
 Provide protection in the form of covers or barriers for
any neighbouring live parts.
ATTENTION
Damage to property.
 Only use original spare parts.
 Do not intervene in the equipment without authorisation to do so.
 Observe the safety regulations.
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3
Product Details
The equipment has been designed for solar power plants and provides professional solutions for the use of installations covering
large roofs or in open spaces.
3.1
Product Description
The equipment is a solar inverter (INV) that feeds the electrical
energy produced by the PV cells into a medium-voltage mains
(e.g. 10 kV; 20 kV; 33 kV).
The required mains transformer is not supplied with the unit and
can be ordered as an extra if necessary. It is possible to combine
two Protect PV.500 units to create a 1 MW system. A joint isolating
transformer can be used, with an electrically isolated low-voltage
connection for each Protect PV.500. 1 MW systems can be made
to support "partner operation" to increase their efficiency.
The rating plate, featuring all the relevant data, is located on the
inside of the door.
Figure 2
i
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PV.500 equipment
Important information about equipment documentation
Further descriptions and unit diagrams are included in the
document folder.
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3.2
Dimensions and Views
Figure 3
3.3
Dimensions and views
Appropriate Use
Only operate the equipment with the maximum permissible connection values stated in the technical data sheet. Any other use or
modification constitutes inappropriate use.
Unauthorised repairs, manipulations or changes made to the
equipment and its safety devices without the manufacturer's approval are not permitted. The manufacturer cannot be held liable
for damage resulting from such repairs, manipulations or changes.
Safety
The equipment will operate reliably and safely subject to compliance with the instructions, the operating and equipment specifications and regulations set out by the Employer's Liability Insurance
Association.
3.4
Inappropriate Use
No liability is accepted if the equipment is used for applications not
intended by the manufacturer (= inappropriate use). Inappropriate
use can cause serious or fatal personal injury. The responsibility
for any measures necessary for the prevention of personal injury
or damage to property is borne by the equipment operator or user.
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3.5
Standards, Directives and CE Mark
The equipment complies with currently applicable DIN and VDE
regulations. The requirements of BGVA3 are met on the basis of
compliance with EN 50274/VDE 0660-51.
The requirements of VDE 0100, Part 410, IEC 60364-4-41, "Functional extra-low voltage with safe isolation" and IEC 62109, "Safety
of power converters for use in photovoltaic power systems" have
been complied with where applicable.
The CE mark on the unit confirms compliance with the EC framework directives for 2006/95/EC (Low Voltage) and for 2004/108/EC
(Electromagnetic Compatibility), provided that the actions outlined
in the instructions are observed.
3.6
Nameplate
The following information appears on the nameplate:
Figure 4
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Rating plate (example)
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Technology
Due to the utilisation of high-performance electronic components,
the equipment boasts a very high degree of operational reliability,
is extremely efficient and is characterised by its versatility in communicating with other systems by means of interfaces.
The entire control electronics system for the equipment is based
on the use of microcomputer assemblies. The fact that the various
assemblies are logically integrated and linked into the overall system means that unit properties can be defined by making unitspecific parameter settings in the software.
Information is exchanged between the individual modules using
the CAN bus (Controller Area Network). This CAN bus features
high interference immunity and is used in a wide variety of industrial applications.
The figure below illustrates the principle of the equipment.
DC
(PV-Module)
Protect PV.500
Q4
Display
=
Kommunikation
~
~
~
Steuergerät
3.7
M
Steuergerätversorgung
K7
Q26
Mittelspannungs-Netz
Figure 5
Functional principle of the equipment for connection to a lowvoltage mains
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The main assemblies of the inverter are:
 DC load interrupter switch Q4
 Inverter stack, display and control unit with communication
components
 AC filter
 Inverter output contactor K7
 Mains transformer (external)
 Mains disconnector Q26
The PV cells supply the inverter stack with DC voltage via DC load
interrupter switch Q4. The inverter stack converts this DC voltage
into a 3-phase AC voltage. A sinusoidal current is fed into the
mains via the AC filter, inverter output contactor K7 and the mains
transformer.
DANGER
Risk to life due to electric shock.
Potentially fatal voltages are present at the terminals on
the equipment.
 Do not touch live parts.
Mains disconnector Q26 and the isolator in the generator connection box (GCB) are there to isolate the inverter in the event of unit
faults or when maintenance needs to be performed on the unit.
The control unit is supplied with power from the AC mains or, optionally, from a second AC mains.
3.8
Operating Elements
For details of how the internal operating elements are arranged,
please refer to the documents included in the unit.
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4
System Description
This chapter describes the individual operation operating mode
and functions of the equipment.
4.1
Individual Operation
In individual operation, the inverter works independently and is not
connected to any other inverters. The DC infeed from the PV cells
and the link to the AC mains are only connected to this inverter.
Switching operations, control commands and modifications to setting parameters are only performed by the unit concerned.
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5
System Function
5.1
Description of Sequence Control
As soon as the equipment's control module is supplied with voltage, sequence control starts.
Initially, load interrupter switch Q4 remains open. Once the initialisation phase is complete and if no deactivating faults are pending,
load interrupter switch Q4 is closed. During subsequent operation,
the switch is only opened by deactivating faults ( Chapter 6).
Inverter output contactor K7 remains open initially. The contactor is
switched by the sequence control.
The figure below provides a graphical illustration of the sequence
control statuses.
OFF command
Operation
OFF command
OFF
ON command
OFF command
Feed-in
conditions met
Daytime detection
Waiting for feed
conditions
Operating
conditions
no longer
met
Night
Night-time detection
Delay
complete
Fault
Waiting
Fault
acknowledgement
Fault
Fault
Fault
Fault
OFF command
Figure 6
5.1.1
Sequence control
The "OFF" Status
The equipment has been switched off logically via the DOU or the
master control unit.
The equipment is running without faults, the monitoring systems
are not activated.
In this status, no power is fed into the mains.
Possible change of status:
The status can be switched from "OFF" to "Waiting for feed conditions" by switching the equipment on via the DOU and the master
control unit.
5.1.2
The "Waiting for Feed Conditions" Status
The values of the DC voltage on the PV cells, the mains voltage
and the mains frequency are monitored by the equipment.
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The set monitoring values are regularly checked.
In this status, no power is fed into the mains.
Possible change of status:
If the DC voltage rises above a certain value for a certain time and
the mains voltage and mains frequency are within a certain range,
the unit switches to the "Operation" status. A start-up attempt is
made, which involves switching on the inverter stack. If the DC
voltage collapses too dramatically during this start-up attempt, the
inverter stack is switched off again and there is a delay before attempting to start up again. The equipment will not switch to the
"Operation" status until any dip in the DC voltage that occurs during a start-up attempt is within acceptable limits.
If the DC voltage falls below a certain value for a certain time, the
equipment switches to the "Night" status.
If a deactivating or self-acknowledging fault is triggered, the
equipment switches to the "Fault" status.
The status can be switched from "Waiting for feed conditions" to
"OFF" using the "Off" control command.
5.1.3
The "Operation" Status
The equipment has met all conditions for operation and no deactivating or self-acknowledging faults are present.
The set monitoring values are regularly checked.
In this status, power is fed into the mains and inverter output contactor K7 is closed.
Possible change of status:
If the generated power falls below a certain value for a certain
time, the operating conditions are no longer met. The equipment
then switches to the "Waiting" status.
If a deactivating or self-acknowledging fault is triggered, the
equipment switches to the "Fault" status.
The status can be switched from "Operation" to "OFF" using the
"Off" control command.
5.1.4
The "Waiting" Status
If the power fed in falls below a certain value when the equipment
is in "Operation", it switches to the "Waiting" status. Although the
incoming power is low, the DC voltage of the PV cell could still be
high enough and even stable enough to meet the feed conditions
in the "Waiting for feed conditions" status. So that the inverter does
not switch back on again immediately, thereby subjecting inverter
output contactor K7 to unnecessary strain due to frequent switching, after the "Operation" status the unit initially switches to the
"Waiting" status. It remains in this status for a certain time, only
switching to the "Waiting for feed conditions" status once this time
has elapsed.
The set monitoring values are regularly checked.
Possible change of status:
Once the delay has elapsed, the unit switches to the "Waiting for
feed conditions" status.
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If a deactivating or self-acknowledging fault is triggered, the
equipment switches to the "Fault" status.
The status can be switched from "Operation" to "OFF" using the
"Off" control command.
5.1.5
The "Fault" Status
If a deactivating or self-acknowledging fault is triggered ( Chapter 6), the equipment switches to the "Fault" status.
The set monitoring values are regularly checked.
In this status, no power is fed into the mains.
Possible change of status:
If a self-acknowledging fault has been triggered and this fault does
indeed acknowledge itself, the unit switches to the "Waiting for
feed conditions" status.
If a deactivating fault has been triggered, the "Acknowledge fault"
control command can be used to switch back to the "Waiting" status.
The status can be switched from "Fault" to "OFF" using the "Off"
control command. In the "OFF" status, the unit is always free of
faults.
5.1.6
The "Night" Status
If the DC voltage falls below a certain value for a certain time, the
equipment switches to the "Night" status.
The set monitoring values are regularly checked.
In this status, no power is fed into the mains.
Possible change of status:
If, the following morning, the DC voltage rises above a certain value for a certain time, the equipment switches to the "Waiting for
feed conditions" status.
If a deactivating or self-acknowledging fault is triggered, the
equipment switches to the "Fault" status.
The status can be switched from "Operation" to "OFF" using the
"Off" control command.
5.1.7
Sequence Control During the Course of the Day
Early morning:
The equipment is in the "Night" status. The sun's rays increase the
DC voltage generated by the PV cells. If this voltage stays above a
certain value for a certain time, the unit switches to the "Waiting for
feed conditions" status.
The DC voltage continues to be monitored in this status. In order
for a start-up attempt to be made, it must remain above a certain
value for a certain time. The mains voltage and mains frequency
are also checked. These values must be within certain limits.
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If the DC voltage continues to increase due to the sun's rays getting stronger and the mains voltage and mains frequency are within acceptable limits, a start-up attempt is made. During a start-up
attempt, the inverter stack is switched on, thereby drawing power
from the DC voltage that is present. Inverter output contactor K7 is
open during a start-up attempt. If the load on the DC voltage causes it to collapse too dramatically during this start-up attempt, the
inverter stack is switched off again and there is a delay until the
next start-up attempt is made. If the DC voltage does not dip too
significantly, inverter output contactor K7 closes and power is fed
into the mains. The inverter is now in the "Operation" status.
Day:
During the course of the day, the inverter will remain in the "Operation" status if the sun's rays are strong enough and no faults occur.
Power is fed into the mains and inverter output contactor K7 is
closed.
Evening:
As the sun goes down, the power fed into the mains decreases. If
this power falls below a certain value for a certain time, the operating conditions are no longer met. The inverter stack is switched off,
inverter output contactor K7 opens and the unit switches to the
"Waiting" status.
Once the "Waiting" status delay has elapsed, the unit switches
back to "Waiting for feed conditions". Although the sun's rays are
not as strong, the DC voltage might still be high enough for a successful start-up attempt with the inverter stack and inverter output
contactor K7 being switched on again. However, because the
sun's rays are not as strong, it is unlikely that the operating conditions will still be met in the "Operation" status. As a result, the
equipment will switch back to the "Waiting" status once a delay
has elapsed.
When the unit switches back to this status, the delay is extended
until the unit switches back to the "Waiting for feed conditions" status.
The cyclic changes of status "Operation" -> "Waiting" -> "Waiting
for feed conditions" -> "Operation" can take place several times
depending on insolation, the time of year, location and other conditions (e.g. snow on the PV cells). So that inverter output contactor
K7 is not overloaded by this cycle of changes, the "Waiting" status
delay is extended every time the unit switches to this status.
This has very little effect on the energy fed in, because the low
levels of insolation mean that hardly any energy is being generated.
Later in the evening:
Levels of insolation continue to fall. As a result, the DC voltage
drops again. If the DC voltage drops below a certain value for a
certain time, no more start-up attempts are made. If the DC voltage continues to drop, the unit switches to the "Night" status.
Night:
The equipment shuts down all possible loads so that as little energy as possible is being consumed. The equipment remains in the
"Night" status until the following morning.
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5.1.8
Sequence Control Parameters
Switch-on conditions
Underfrequency, overfrequency, undervoltage, overvoltage:
The equipment will only switch from the "Waiting for feed conditions" status to the "Operation" status if the feed conditions are
met. These conditions include the mains voltage and the mains
frequency. These values must be within certain limits described by
the switch-on conditions.
Voltage limit value for night detection,
delay time for night detection:
If the DC voltage falls below the voltage limit value for longer than
the delay time, the unit switches to the "Night" status.
Voltage limit value for day detection,
delay time for day detection:
If the DC voltage rises above the voltage limit value for longer than
the delay time, the equipment switches to the "Waiting for feed
conditions" status.
Inverter stack switch-on time:
The time for which the inverter stack is switched on during a startup attempt
Permissible voltage dip after switching on the stack:
Prior to the start-up attempt, a limit value is calculated from the
present DC voltage and the permissible voltage dip.
If the start-up attempt causes the DC voltage to fall below this calculated limit value, this start-up attempt will fail.
Delay until the next start-up attempt following failure on account of excess voltage dip:
After the failure of a start-up attempt, this delay must elapse before
the next start-up attempt is made.
Power limit value for shutdown,
delay time for shutdown:
If the power fed into the mains remains below the limit value for
longer than the delay time, the unit switches to the "Waiting" status.
Standard delay for a renewed start-up attempt following shutdown,
offset delay added to the standard delay after shutdown,
maximum number of times the offset delay can be added to
the standard delay:
Variable delay in the "Waiting" status  Chapter 5.1.4.
Minimum DC voltage,
fill factor (PV system parameter):
If the DC voltage rises above a value resulting from the minimum
DC voltage divided by the fill factor, a start-up attempt is made.
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5.2
Description of Fan Control
5.2.1
General
The equipment features temperature-dependent fan control. The
fans are either switched off, run on a fast or slow fan stage (cabinet fan only) or are gradually speeded up or slowed down (stack
fan only).
Fan control:
 Extends the operating time of the fans
 Minimises the noise generated by the fans
 Improves the efficiency of the equipment by reducing its power
consumption
5.2.2
Fan Control, Cabinet Fan
As soon as the equipment's control module is supplied with voltage, fan control always starts with the fast fan stage. The control
can be restarted to check whether the fans are working correctly.
For example, after maintenance work, it is not necessary to wait
for the fans to reach the temperature criterion to switch on the fast
fan stage.
The fast fan stage is always active for at least a certain time. The
unit exhaust air temperatures are checked after this time. If the
highest temperature from the two sensors is below a certain value,
the fan control switches to the slow fan stage.
The unit exhaust air temperatures are also checked in the slow fan
stage. If the highest temperature from the two sensors is below a
certain value, the fans are switched off. If the highest temperature
rises again during operation with the lower fan stage, fan control
switches to the fast fan stage.
If, when the fans are switched off, the highest temperature from
the two sensors rises above a certain value, fan control switches to
the fast fan stage.
Initialisation
Fast fan stage,
minimum time!
Unit exhaust air
temperature > limit
value
Unit exhaust
air temperature
> limit value
Unit exhaust air
temperature < limit
value
Slow fan stage
Unit exhaust air
temperature < limit
value
Fan switched off
Figure 7
Fan control
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5.2.3
Cabinet Fan Control Parameters
Unit exhaust air temperature limit value for switching on the
fan:
If the highest exhaust air temperature rises above this limit value,
the fans which were switched off are switched to the fast fan stage.
Unit exhaust air temperature limit value for switching off the
fan:
If the highest exhaust air temperature falls below this limit value,
the fans which were running in the slow fan stage are switched off.
Unit exhaust air temperature limit value for switching to the
fast fan stage:
If the highest exhaust air temperature rises above this limit value,
the fans which were running in the slow fan stage are switched to
the fast fan stage.
Unit exhaust air temperature limit value for switching to the
slow fan stage,
minimum time in the fast fan stage:
If the highest exhaust air temperature falls below this limit value,
the fans which were running in the fast fan stage are switched to
the slow fan stage if the minimum time in the fast fan stage has
elapsed.
5.2.4
Fan Control, Inverter Stack Fan
As soon as the equipment's control module is supplied with voltage, fan control always starts with the maximum fan speed. This
means that the control can be restarted to check whether the fan is
working correctly. For example, after maintenance work, it is not
necessary to wait for the fan to reach the temperature criterion to
switch on the maximum fan speed.
The maximum fan speed is always active for at least a certain
time. The IGBT temperatures are checked after this time. The fan
speed is then determined using the highest of these temperatures.
If the highest temperature from the two sensors is below a certain
value, the fan is switched off completely.
If, when the fans are switched off, the highest temperature from
the two sensors rises above a certain value, the fan is again operated at the maximum speed for a certain time.
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Initialisation
Maximum speed,
minimum time!
Minimum time elapsed
IGBT temperature
> limit value
Variable speed
depending on IGBT
temperature
IGBT temperature
< limit value
Fan switched off
Figure 8
5.2.5
Fan control
Parameters of Inverter Stack Fan Control
IGBT temperature limit value for switching off the fan:
If the highest IGBT temperature falls below this limit value, the fan
is switched off.
IGBT temperature limits and fan speeds, x-y coordinates for
determining variable speed:
The variable fan speed is determined by a linear x-y characteristic
on the basis of these values.
IGBT temperature limit:
If the IGBT temperature rises above the lower limit value, the fan
that was previously switched off is run at maximum speed for the
minimum time.
Minimum time, maximum speed:
If the minimum time has elapsed, the fan is controlled variably using the measured IGBT temperature.
5.3
Insulation Monitoring and Earthing of PV Cells
5.3.1
General
Insulation measurements and tests are carried out with an integrated isometer. This unit detects and checks the insulation resistance.
The insulation resistance detected is compared with two limit values stored in the isometer. If the insulation resistance is below one
of the limit values, the unit generates a signal. If the limit value is
below the other limit value, the device generates a second signal.
The limit values can be displayed and even modified on the isometer.
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The insulation resistance detected and the two signals are sent to
the equipment control. The insulation resistance is displayed as a
measured value. Signalling faults are generated from the two
isometer signals ( Chapter 6).
Sequence control behaviour differs depending on which solar cells
are connected. The solar cells do not need to be earthed for operation with monocrystalline or polycrystalline solar cells. In this
case, insulation measurement is always active.
For operation with thin-film solar cells, the solar cells must be
earthed. In this case, insulation measurement is not active during
earthing.
Insulation measurement sequence control features a "Maintenance mode". This mode can only be activated for thin-film solar
cells. Activating this mode disconnects earthing. This can be useful
when mowing areas where solar panels are installed, for example.
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5.3.2
Operation With Monocrystalline or Polycrystalline Solar Cells
General:
This type of solar cell does not require active earthing.
Sequence control:
Insulation monitoring is always active.
Maintenance mode:
No action in the event of a "Maintenance mode" command.
Starting the insulation test manually:
No action, since the insulation test is always active.
5.3.3
Operation with Thin-Film Solar Cells
General:
This type of solar cell requires active earthing.
Active earthing is switched on during the day and switches off at
night. An insulation test is carried out at night.
When active earthing is switched on, the digital signals and analogue signal from the isometer are ignored.
Once active earthing is switched off, a certain time is allowed to
elapse before the digital signals from the isometer are evaluated
and the analogue measured value is output.
Sequence control:
When the equipment sequence control switches to the "Night" status (see Chapter 5.1.6), active earthing is switched off once a certain time has elapsed.
The insulation test starts with a delay. Once a certain test time has
elapsed, the insulation test finishes and active earthing is switched
on again. If the sequence control switches to "Operation" status
before the test time has elapsed, the timer control is ignored, the
insulation test is terminated and active earthing is switched back
on.
Maintenance mode:
Maintenance mode can be triggered either via a command or by
means of remote signalling. Active earthing switches off immediately when maintenance mode is activated. However, the digital
and analogue signals from the isometer continue to be ignored.
Active earthing is switched on again the next time a switch is made
to "Operation" status. However, the unit remains in maintenance
mode for at least a certain time; i.e. even if the unit is switched
over to the "Operation" status, maintenance mode is not terminated until this time has elapsed.
Starting the insulation test manually:
The insulation test can be started manually for maintenance work.
Active earthing is switched off when the insulation test is started
and the test actually commences once a delay has elapsed. When
the test time has elapsed, the insulation test ends and active earthing is switched on again.
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The insulation test can only be started manually if an insulation
test is not already running at the time.
5.3.4
Insulation Monitoring Parameters
All parameters are only relevant for operation with thin-film solar
cells.
Insulation test time:
The analogue and digital signals from the isometer are evaluated
during this time.
Delay for insulation test following shutdown of K21 (earthing
of PV cells):
Once the earthing has been disconnected, this time must elapse
before insulation measurement can start.
Delay for shutdown of K21 in night operation:
Once sequence control has switched to the "Night" status, this
time must elapse before earthing is removed with contactor K21.
Minimum time in maintenance mode:
If maintenance mode has been activated, the earthing is disconnected and remains so for at least this time.
5.4
MPP Tracker
In the "Operation" status (see Chapter 5.1.3), the inverter detects
the maximum power point (MPP) of the PV cells.
The MPP tracker detects the point at which the solar cells give off
maximum power.
This enables the system to achieve optimum efficiency.
Figure 9
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MPP performance curve
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6
Monitoring Systems, Messages and Faults
6.1
General Information
All monitoring systems only generate fault messages when the inverter is switched on; when it is switched off, the inverter is always
reported as being free of faults.
A distinction is made between deactivating, self-acknowledging
and signalling faults.
Deactivating faults switch the equipment off permanently once
they have occurred a number of times. K7 and Q4 are opened.
When a fault first occurs, it is acknowledged after a certain time
has elapsed and the inverter makes a start-up attempt. This startup attempt is only made if the DC voltage did not drop too dramatically during the fault. If the cause of the fault is still present after
the start-up attempt, the inverter is switched off again.
A maximum of 3 start-up attempts are made.
Each time the inverter is switched off, K7 and Q4 are opened.
After a successful start-up attempt and once a certain operating
time has elapsed, the counter for start-up attempts is reset again.
If the third start-up attempt is also unsuccessful, the inverter is
switched off permanently. The fault is then no longer selfacknowledging. It can be acknowledged by switching the equipment off and on or by manually acknowledging the fault. However,
if the cause of the fault is still present following manual acknowledgement, another deactivating fault will be generated.
Self-acknowledging faults switch the equipment off. K7 is
opened, Q4 remains closed.
The equipment starts up again when the cause of the fault is no
longer present. The fault can also be acknowledged manually or
by switching the equipment off and on. However, if the cause of
the fault is still present following manual acknowledgement, another self-acknowledging fault will be generated.
Signalling faults do not have any effect on the equipment's sequence control. K7 and Q4 remain closed.
A signalling fault acknowledges itself automatically when the cause
of the fault is no longer present. The fault can also be acknowledged manually or by switching the equipment off and on. However, if the cause of the fault is still present following manual
acknowledgement, another signalling fault will be generated.
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6.2
Table of Faults
The monitoring systems listed below will cause the inverter to switch off, are selfacknowledging or signalling and are shown on the DOU with corresponding plain text:
Temperature monitoring systems
Deactivating
Selfacknow-led
ging
Signalling
DOU message
IGBT 1 stack temperature warning
X
!Equipment temperature fault!
IGBT 2 stack temperature warning
X
!Equipment temperature fault!
Fault/Message
IGBT 1 stack temperature fault
X
#Equipment temperature fault#
IGBT 2 stack temperature fault
X
#Equipment temperature fault#
IGBT supply air undertemperature
X
!Ambient temperature fault!
IGBT supply air temperature warning
X
!Ambient temperature fault!
IGBT supply air temperature fault
X
#Ambient temperature fault#
Unit exhaust air 1
temperature warning
X
!Equipment temperature fault!
Unit exhaust air 2
temperature warning
X
!Equipment temperature fault!
Unit exhaust air 1
temperature fault
X
#Equipment temperature fault#
Unit exhaust air 2
temperature fault
X
#Equipment temperature fault#
Equipment supply air undertemperature
X
!Ambient temperature fault!
Unit supply air temperature warning
X
!Ambient temperature fault!
Unit supply air temperature fault
X
#Ambient temperature fault#
Temperature sensor fault
IGBT 1 stack
X
#Temperature sensor fault#
Temperature sensor fault
IGBT 2 stack
X
#Temperature sensor fault#
Temperature sensor fault
IGBT supply air temperature
X
#Temperature sensor fault#
Temperature sensor fault
unit exhaust air 1 temperature
X
#Temperature sensor fault#
Temperature sensor fault
unit exhaust air 2 temperature
X
#Temperature sensor fault#
Temperature sensor fault unit supply
air temperature
X
#Temperature sensor fault#
IGBT difference temperature
deviation
X
#IGBT difference temperature
dev.#
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CAN I/O monitoring systems
Deactivat-ing
Selfacknow-led
ging
Signalling
DOU message
Feedback signal
DC load interrupter switch Q4.1
X
Q4.x: !Switch feedback fault!
Switch position Q4.1
X
Q4.x: Switch open
Feedback signal
K21 earthing PV cells
X
K21: !Switch feedback fault!
Monitoring
F21 earthing circuit breaker
X
!Miniature circuit breaker tripped!
Monitoring
F81 surge voltage arrester DC
input
X
!Overvoltage protection tripped!
Monitoring
insulation monitor level 1
X
!Insulation monitor warning!
Monitoring
insulation monitor level 2
X
!Insulation monitor alarm!
Monitoring mains voltage
auxiliary power supply mains 2
X
!Auxiliary power supply – mains
failed!
Monitoring
F83/F84 surge voltage arrester AC
– anti-condensation heater
X
F83/84: !Miniature circuit breaker
tripped!
Monitoring
F60 auxiliary power supply mains 2
X
F60: !Miniature circuit breaker
tripped!
Monitoring
F61 independent power supply
mains 1
X
F61: !Miniature circuit breaker
tripped!
Monitoring
Q26 AC mains disconnector
X
Q26: Switch open
Monitoring
unit cabinet door
X
!Unit cabinet door open!
Monitoring communication CAN
I/O AC cabinet
X
!Communication fault with I/O
control!
Monitoring communication CAN
I/O DC cabinet
X
!Communication fault with I/O
control!
Fault/Message
Monitoring
CAN I/O parameters
X
#I/O parameter error#
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Unit Monitoring Systems
Signalling
DOU message
Monitoring
fan fault cabinet fan
X
!Fan failure!
Monitoring
fan fault stack fans
X
!Fan failure!
Monitoring K91
feedback signal fan contactor
X
K91: !Switch feedback fault!
Fault/Message
Monitoring K7
feedback signal INV output contactor
Deactivat-ing
Selfacknow-led
ging
X
#Fault K7 feedback signal#
Monitoring
parameter limits
X
!Parameter limit fault!
Monitoring
PCB ID
X
#Self-test fault#
Monitoring
EEPROM
X
#EEPROM fault#
Monitoring
serial EEPROM
X
!System fault!
Monitoring
Watchdog
X
#Watchdog#
Monitoring
15 V supply voltage
X
#15 V supply voltage fault#
Monitoring
IGBT stack
X
#Stack fault#
Monitoring
short-circuit/overload
X
#Short circuit#
Monitoring
load current transformer
X
#Load current transformer fault#
Monitoring
stack current transformer
X
#Stack current transformer –
fault#
Monitoring
X
#AC voltage deviation#
X
#Stack overcurrent#
inverter output voltage
Monitoring
stack overcurrent
Monitoring
mains synchronisation
X
#Synchronisation fault#
Monitoring
parallel CAN communication
X
!Communication fault parallel
CAN!
Monitoring
remote monitoring communication
X
!Remote monitoring fault!
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DC voltage monitoring systems
Fault/Message
Deactivat-ing
Monitoring
DC overvoltage
Selfacknow-led
ging
Signalling
X
DOU message
#DC voltage deviation#
Grid monitoring systems
Fault/Message
Deactivat-ing
Selfacknow-led
ging
Signalling
DOU message
Field rotation or phase fault
X
#Field rotation fault#
Monitoring
grid overfrequency
X
#Mains frequency deviation#
Monitoring
grid underfrequency
X
#Mains frequency deviation#
Monitoring
grid overvoltage
X
#Mains voltage deviation#
Monitoring
grid undervoltage
X
#Mains voltage deviation#
Monitoring
symmetric fault
X
#Mains symmetry fault#
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7
Interfaces
PV power stations are usually monitored from a central location.
Alongside the PV cells, the inverter is a key component of a power
station, which is why various communication interfaces are available as standard.
These include relay contacts and optocouplers, as well as various
serial interfaces with protocols for integration into higher-level
monitoring systems.
To facilitate PV power station monitoring, AEG also offers relevant
additional components that are adapted for use with inverters and
PV generators. This enables the client to monitor an entire PV
power station from a central location easily and reliably.
7.1
Communication Interface
The photovoltaic inverter is equipped with a central communication
unit, a "MultiCom CCC interface".
As well as performing various other functions, this unit facilitates
communication between PV inverters and higher-level monitoring
systems.
A special system of central monitoring via the Internet can be realised using AEG monitoring components such as "PV.LoG". The
connection between the inverter and PV-LoG has been optimally
adapted for monitoring and management purposes and is established via the Modbus protocol. If you have any further questions,
please contact your supplier.
7.1.1
General
Two separate potential-free serial interfaces are provided as
standard for the purpose of establishing communication connections. One interface – port X2 – is assigned the AEG-specific protocol CBSER and is used both locally and remotely for corresponding service tools. The other one – port X5 – supports the Modbus
protocol and enables the PV inverter to be integrated into higherlevel monitoring and control systems with ease. This port can be
switched over from RS232 to RS485.
An external CAN bus provides a further connection option, which
can be used for monitoring via a remote panel.
The MultiCom CCC interface can be found on the pivot inside the
DC/AC cabinet (item A29.1; see the assembly diagram).
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7.1.2
Technical Data
MultiCom CCC hardware data (assembly A29.1)
Connector
:
RS485 connection:
Distance:
Bus stations:
Data line:
Port 1 RS232 for configuration
and COM server connection
X2: 9-pin D-sub (socket; insulated)
Port 2 RS232/RS485 for Modbus
X5: 9-pin D-sub (socket; insulated)
Twisted pair with Data+, Data-,
shielded, shield attached on one side
1200 m max. at 9600 baud
Max. 32
Shielded 1:1 data line
(2 x 0.22; twisted pair),
e.g. Lapp "UNITRONIC-BUS LD"
Port 3 CAN bus for remote panel
X4: 3-pin Combicon connector
Communication data port 1 (X2)
Protocol:
CBSER
Transmission rate:
1200 - 57,600 baud (adjustable)
Transmission parameters: 9600 baud, 8, E, 1 (default)
Configuration mode: 9600 baud, 8, N, 1
Communication data port 2 (X5)
Protocol:
Transmission mode:
Transmission code:
Transmission rate:
Modbus
Half-duplex
RTU
1200 - 57,600 baud (variable)
19,200 baud (default)
Start bits:
1
Data bits:
8
Parity:
none, even, odd (variable)
Stop bits:
2 with no parity, 1 with parity
Function code:
03 (read register)
06 (write register)
16 (write multiple registers)
Min. response time of slave: 0-99 ms variable (0 ms default)
Modbus slave address:
01-99 (adjustable) (01 default)
Communication data port 3 (X4)
Protocol:
Transmission rate:
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7.1.3
Structure of the MultiCom CCC Interface
RS485:
RS232:
1
J1
J4
1
1
X1
J5
1
rt
gn
X5
LED
X3
1
1
B A B A
X4
1
X2
S1
Modbus
Figure 13
1
Configuration
MultiCom CCC interface as a Modbus interface (top view)
Connections:
X1: Internal inverter bus and power supply
X2:
Potential-free RS232 serial interface
X3:
Triggering of "Remote signalling"
X4:
A remote panel can be connected to this potential-free CAN
interface.
X5:
Potential-free RS485/RS232 serial interface internally wired
to X91
Configuration jumpers:
J1:
1-2: Firmware update;
2-3: (default)
J4:
All closed:
RS485 (default)
J5:
All closed:
RS232
The transmission topology of the Modbus interface (connector X5)
is set by means of the two configuration jumper blocks (J4/J5). The
factory setting is RS485.
In order to be able to use the Modbus interface as a point-to-point
connection via RS232, you must remove all jumpers from block J4
and plug them in on block J5.
Button:
S1: Button for initiating the configuration via connector X2
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LED signals:
Green/red flashes:
Configuration can be selected via the terminal
(up to 30 seconds after restarting)
Operating status; no external communication via X2 and X5
Data transmission on the serial interfaces
(X2 or X5)
Fault
Green on:
Green flashes:
Red on:
Description of serial interfaces:
Port 1: Serial interface X2
The potential-free RS232 serial interface at connector X2 supports
the AEG-specific CBSER protocol for parameter setting and monitoring purposes. Special service tools can be used to monitor and
manage the equipment locally and (with the aid of the COM server) remotely via a network. This is also the port used for configuring the assembly's interfaces.
5
1
9
Figure 14
6
Serial D-sub connector X2
Port 1 (X2): RS232 pin assignment
Pin number
Signal Description
2
RxD
PC receiving data from the MCC
3
TxD
PC sending data to the MCC
5
GND
Interface reference potential
Housing
INV housing potential
Please use a 1:1 data cable for configuration purposes.
Port 2: Serial interface X5 (internally wired to X91)
The potential-free RS485 interface at connector X5 supports the
Modbus protocol for integration into higher-level monitoring systems.
5
9
1
6
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Figure 15
Serial D-sub connector X5
Port 2 (X5): RS485 pin assignment (default)
Pin number
Signal Description
3
B
High data
8
A
Low data
Housing
INV housing potential
Please use a shielded fieldbus cable as the line,
e.g. 2 x 0.22 twisted pair Lapp "UNITRONIC-BUS LD".
Please connect the RS485 bus line via the bus interface connector
supplied. In an RS485 network, the ends of the bus must always
be terminated. If necessary, insert the 120 ohm resistor supplied
between connections A and B.
Shield connection of the RS485 bus line:
Shielding is a means of weakening (attenuating) magnetic, electrical or electromagnetic interference fields.
Interference currents on line shields are dissipated to earth by
means of the shield busbar that has a conductive connection to the
housing. A low-impedance connection to the PE conductor is especially important to prevent these interference currents from
themselves becoming a source of interference.
If possible, only use lines with a braided shield. The shield coverage should be at least 80%. Avoid using lines with a foil shield because tensile and compressive stresses applied when fastening
the line can easily damage the foil, resulting in a reduction in the
shielding effect.
Please bear the following points in mind when handling the screen:
 Use cable clips or shield terminal blocks made of metal to secure the braided shield. The clips must surround the shield and
make good contact with it over a large area.
 Attach the shield to a shield busbar right after the line enters
the cabinet. Run the shield right up to the assembly; however,
ensure that it does not make contact there!
When used in PV applications, the shield of the RS485 bus line
should only be earthed on one side so that no equalising or interference currents can flow through the shielding. However, if several bus stations are present, you must make sure that the shield is
never interrupted.
Always attach the shield of the RS485 bus line to earth on the quiescent side, i.e. only one side of the shield is attached to the earth
potential on the master or data logger side.
In the PV inverter, the shield must not be connected to the housing
in any way.
Insert the RS485 bus cable into the equipment until it reaches the
MultiCom interface, shorten it accordingly and attach both wires to
terminals A and B.
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The X5 interface can be switched from RS485 to RS232 using
jumpers J4 and J5. The factory setting is RS485, i.e. all jumpers
are inserted at J4. You have the option of switching the interface to
RS232 by reconnecting all jumpers to J5.
Port 2 (X5): RS232 pin assignment
Pin number
Signal Description
2
RxD
PC receiving data
3
TxD
PC sending data
5
GND
Interface reference potential
7
RTS
Handshake
8
CTS
Handshake
Housing
INV housing potential
If the RS232 version is used for this port, please use a 1:1 data
line.
Controller Area Network (CAN) at X4
Up to four remote panels can also be connected to the potentialfree CAN interface for central signalling and display.
1
Figure 16
Connector X4
Port 3 (X4): CAN pin assignment
Pin number
Designation
Cable colour coding
1
GND
White + brown
2
Data_L
Yellow
3
Data_H
Green
Please use a shielded CAN bus cable as the line,
e.g. 2 x 0.22 twisted pair Lapp "UNITRONIC-BUS LD".
Route the CAN bus line from the PV inverter to the remote panel.
In a CAN bus network, the ends of the bus must always be terminated. A 120 ohm terminating resistor is pre-installed at connector
X4 of the CAN bus connection as standard.
7.1.4
Configuration
The communication interface does not have to be configured in order to connect the PV inverter to the data logger system of the
AEG "PV.LoG". Once the bus cable has been installed and the
system has been powered up, the configuration settings are made
fully automatically.
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If you are using a different/in-house monitoring system, you can
adjust the transmission parameters and the slave address of the
Modbus interface to suit your requirements via port 1 (X2). We
would be happy to provide you with the Modbus unit profile on request.
7.1.4.1 Configuration Preparations
You will need a 1:1 data line and a PC.
For this configuration, you must connect the PC to the MultiCom
interface (X2) via the data line and start a terminal program, e.g.
Hyperterminal, on the PC.
Setting the terminal program:
Data transmission:
COMx, 9600 baud/8 data bits/1 stop bit
No parity/no protocol
Terminal emulation:
VT100
You can then start the configuration by pressing the “S1” button on
the MultiCom interface. Ensure that no communication has taken
place via interfaces X2/X5 for at least 10 seconds before doing so.
Initiation of the configuration is displayed by the two LEDs flashing
on the MultiCom interface and the following display on the terminal:
“PRESS <CR> FOR CONFIGURATION WHILE LED IS
FLASHING”
The configuration starts provided you press the <ENTER> key
(<CR>) within 30 seconds. The configuration main menu opens:
Figure 18
Main menu
If the configuration does not start, you must wait for 10 seconds
and then repeat the procedure. Make sure that no data is received
via the X2/X5 interfaces during this time.
Press the following key in the main menu:
<CR> to save the set values, exit the configuration and activate
the MultiCom interface.
<ESC> to cancel the configuration.
<2> to access the X5 data transmission configuration.
<4> to access the X5 data protocol configuration.
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The possible keyboard actions are shown in the menu in “< >”.
The following special keys can be used in the menus:
<CR>:
<ESC>:
Carriage return () or ENTER key
Escape key
<TAB>:
Tabulator () key
<BS>:
< >:
Backspace () or Rubout key
Space bar
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7.1.4.2 Configuring the Modbus Protocol
To access the X5 data protocol configuration, you must press <4>
in the main menu:
Figure 19
Data protocol configuration
Press one of the following keys in the “X5 Data Protocol” menu:
<TAB> to configure the Modbus protocol
<CR> to accept the set values. The configuration is finished and
the main menu is opened again.
<ESC> to cancel the configuration. This opens the main menu.
Figure 20
Modbus protocol configuration
Press one of the following keys in the “X5 Data Protocol – Modbus/JBusV2” menu:
 <!> to load the factory setting.
 <1> to configure the Modbus slave address.
 <2> to configure the delay time between a request from the
master and the response from the slave.
 <CR> to accept the set values. The configuration is finished
and the main menu is opened again.
 <ESC> to cancel the configuration. This opens the main menu.
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7.1.4.3 Configuring Modbus Data Transmission
To access the X5 data transmission configuration, you must press
<2> in the main menu:
Figure 21
Modbus/JBus data transmission configuration
Press one of the following keys in the “X5 Data Transmission”
menu:
 <1-7> to set the baud rate.
 <n,e,o> to set the parity.
 <8,9> to set the number of stop bits.
 <CR> to accept the set values. The configuration is finished
and the main menu is opened again.
 <ESC> to cancel the configuration. This opens the main menu.
The Modbus factory setting is: 19200 8 E 1.
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7.2
COM Server
7.2.1
General
The COM server makes the PV inverter data available via an
Ethernet network. A software application can communicate with
the PV inverter via the network using a virtual COM port (this
needs to be installed on a workstation). The COM server is installed as standard and is used by the AEG service department for
remote maintenance purposes. This calls for an appropriate Ethernet network with an Internet connection plus a fixed IP address assignment.
The COM server is located at position A27.
7.2.2
Network Connection
This COM server has an IEEE 802.3-compatible network connection on a shielded RJ45 plug connector. Its assignment corresponds to that of an MDI interface, which means the connection to
the hub or switch is made using a 1:1 wired patch cable.
Ex-works, the COM server operates in an autonegotiation mode on
the network side. This means the data transmission speed and the
duplex process are automatically negotiated with the connected
switch or hub and are set accordingly.
Structure of the COM Server (internally wired to A93)
gn
CN5
MOD1
7.2.3
H1
Digi
Connect ME
gn
ye
CN3
CN1
1
1
Figure 22
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COM server interface (top view)
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Connections:
CN1:
Internal inverter bus and power supply
MOD1: Ethernet connection
CN5:
Interface for firmware update
Configuration jumpers:
CN3:
All closed (default)
LED signals:
Green LED (H1):
The green LED on the assembly indicates the global status of the
assembly. The following signals are possible:
LED
Jumper
Meaning
Flashing
CN3
Start-up/error
On
CN3
Ready
Flickering
CN3
Ethernet  CAN communication
Green network LED (MOD1):
The green LED indicates communication on the network.
Yellow network LED (MOD1):
The yellow LED remains on permanently if an Ethernet network is
connected.
7.2.4
Installation of the COM Server
The COM server uses a communication module from Digi ("Digi
Connect ME"). In order to communicate via the COM server, it
must be integrated into the network and a virtual COM port must
be set up on a computer. The "Digi Device Discovery" tool and a
Digi RealPort driver are required for this purpose. You can find
these tools at www.digi.com/support or at www.aegps.com.
Network factory settings for the COM server:
IP address:
10.10.10.0
Subnet mask:
255.255.0.0
Default gateway:
0.0.0.0
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7.2.5
Network Integration Configuration
For network integration, you will need a free IP address for the
COM server, the subnet mask plus the IP address for the gateway.
This information can be obtained from your administrator if necessary.
 Start the "Digi Device Discovery" tool.
 The tool searches the network for Digi modules. The modules
found are displayed. If several units are found, please select
the unit to be configured using the MAC address. This can be
found on the Digi module sticker on the COM server. If no
modules are detected, check your network and your firewall
settings. Run the search again using "Refresh view".
 Select the required unit. You can enter the necessary network
parameters using the right mouse button + "Configure network
settings".
 Use "Save" and "Reboot" to apply the settings and complete
the installation.
 Exit the "Digi Device Discovery" tool.
 You can use the "ping" command to test whether the COM
server can be reached on the network.
7.2.6
Configuration of the Virtual COM Port
Communication with the COM server takes place via a virtual COM
port, which is implemented by means of a RealPort driver. In order
to do this, the RealPort driver needs to be installed and configured.
 Start the RealPort driver installation process. For this purpose,
the COM server must be connected to the network and the
network parameters must be set.
 The installation program searches the network for Digi modules. The modules found are displayed along with the configured IP address and MAC address. If several units are found,
please select the unit to be configured using the MAC address
and select "Next". The MAC address can be found on the Digi
module sticker on the COM server. If no modules are detected,
check your network and your firewall settings. Run the search
again using "Refresh view".
 In the "Describe the Device" window, you can make RealPort
settings. This is where you need to select the COM port via
which the application is to communicate later. All other settings
can be left as per the factory settings.
 Select "Finish" to complete the installation.
The application can communicate via the set COMx port with a
baud rate of 115.2 kB as standard. 9600 kB is also possible as an
alternative. Between these two transmission rates, the COM server
has an autobaud detection function.
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7.3
Remote Signalling
The remote signalling board is a contact interface for signalling PV
messages and controlling PV units. It is supplied as an option for
the AEG PV system and is intended for installation in the PV unit.
The remote signalling master board consists of 5 potential-free
signalling contacts and one control input.
There is an independent 24 VDC power supply for the control input. The control signal is activated by bridging the relevant input.
There is no need for an additional auxiliary power supply.
The signals are assigned as standard or can be configured on a
customer-specific basis. An integrated service switch enables
maintenance work on the unit to be signalled.
Technical data:
The maximum load for the signalling contacts (X3/X4) is 500 V/8 A
AC or 50 V/2 A DC.
i
If the specified power has been applied to the relay contacts once, those contacts can no longer reliably switch
an extra-low voltage (evaporation of the gold alloy)!
The control input (X5) has an independent 24 VDC power supply.
The input is activated via a bridge.
Structure:
X2
X2
S1
1
OPT1 X5
1
2
1
X4
3
2
1
K25
1
1
K24
X7
1
K23
1
1
K22
X1
1
Figure 23
X1:
X2:
X3/X4:
X5:
X6:
X3
X6
K21
1
12
11
10
9
8
7
6
5
4
3
2
1
Remote signalling master module A12 (top view)
Power supply connection
Connection for remote signalling expansion boards
Remote signalling outputs with relay changeover
switches
Remote signalling input via optocoupler with independent power supply
Service plug
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X7:
S1:
Connection to MultiCom interface
Service switch
X3:
When a signal is received, the contact between the two
contact points with the lower numbers is closed (normally open or "NO").
When a signal is received, the contact between the two
contact points with the lowest numbers is open (normally
closed or "NC").
The control signal is active when the input is bridged
(normally open). The inverter is switched off.
X4:
X5:
The following default signals are used for remote signalling:
X3.1-2 3
Inverter feed operation
(NO)
X3.4-5 6
DC distribution signal*
(NO)
X3.7-8 9
AC distribution signal*
(NO)
X3.10-11 12 Incoming mains fault
(NO)
X4.1 2-3
Inverter fault*
(NC)
X5.1-2
Inverter remote switch-off
(NO)
*): Collective signals that contain all messages and faults
Figure 23 shows the normally closed contact in the state that applies when the signal is not active (normally open) or the voltage is
zero.
The service switch enables maintenance work on the unit to be
signalled to the MultiCom interface using various protocols.
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8
Graphical Display and Operation Unit
8.1
General Information
The graphical Display and Operation Unit (DOU) is integrated into
the front of the solar inverter. It serves to signal and visualise unit
data and to control the inverter system. The DOU consists of a
display unit with 3 LEDs, a graphical LCD and an operating panel
with 5 keys.
The global unit status can be read from the LEDs (1). An acoustic
signal generator stresses the urgency of critical system statuses.
The graphical LCD shows equipment statuses and measured values using symbols and plain text. You can control and parametrise
the unit using menus which are protected by a password.
The DOU is operated using 4 display keys, to which alternating
functions are assigned, and one ENTER key. The key functions
that are currently active are shown on the LCD in the form of symbols.
Figure 24
1
2
3
4
DOU
LEDs: Red, yellow, green (from top to bottom)
Graphical display (LCD)
4 general function keys
ENTER key
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8.1.1
Signalling
LEDs:
Red, permanently ON:
Deactivating fault
(must be acknowledged via the menu)
Red, flashing:
Self-acknowledging deactivating fault
Yellow, flashing:
Self-acknowledging message
Green OFF:
INV in sleep mode
Green, flashing (1Hz): INV waiting for feed conditions
Green, flashing (0.5 Hz): INV feeding into mains with derating
Green, permanently ON:
INV feeding into mains
Acoustic signal generator:
Signal generator ON: Urgent message and equipment fault
8.1.2
Keyboard Operation
You can use the ENTER key to open and close submenus and to
acknowledge control functions and parameters.
The 4 display keys are assigned to different functions. The key
functions that are currently active are represented as symbols
which can be found in a small framed area on the right-hand side
of the LCD.
In the "Operating display" and "Inverter" menus, you can switch
the inverter on and off using the general keys. The keyboard symbols in the menu indicate the control function which is currently
available. If a switch-off procedure has been initiated, you must
confirm it by means of a security prompt in order to avoid inadvertent switching off. The general control system of the inverter can be
blocked and protected with a password.
If a unit fault occurs, refer to the "Inverter" menu, where the cause
is specified. After eliminating the cause, acknowledge the fault in
the menu. You can then switch the individual converters back on
again.
You can acknowledge the acoustic signal generator using the keyboard. On the LCD operating display you will find a special
acknowledgement key represented by a loudspeaker symbol. In all
other menus, you can press any key (even a key to which no functions have been assigned) to acknowledge the generator. If the
number of messages or faults increases, the acknowledgement is
cancelled. You can impose a general block that inhibits the acoustic signal generator in the event of a fault and inhibits the clicking
sound when you press a key.
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Possible symbol keys and their function:
Switch off inverter
Switch on inverter
Acknowledge acoustic signal generator
Cursor up/Increase value/Scroll upwards
Cursor down/Decrease value/Scroll downwards
Cursor to the right
Cursor to the left
Status/Measured values menu
System is blocked
Acknowledge fault
Select day/month/year curve
Help menu
No function
Figure 24a
8.2
Keyboard symbols
Start-up
Following the power-up reset, the DOU performs a self-test. Data
is read from the inverter once the test has been completed successfully. The LEDs light up in sequence during this phase. A start
screen appears on the LCD and a status bar indicates the duration
of the start-up process.
When you start up the DOU for the first time (commissioning),
select the menu language using the general keys "<" and ">". The
languages are indicated using the country-specific abbreviation
(number plate). The language that is currently selected is displayed on a black background. Once you have confirmed the selected language by pressing the ENTER key, the next menu
opens. In order to comply with international requirements, all of the
displays up to the one for language selection are displayed in English.
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8.3
Menu Structure
8.3.1
Menu Tree
Power ON
Start-up
Main menu
Operating
display
Blocking
(passwordprotected)
Fault
history
Status/
Measured
Values
Settings
Service
(passwordprotected)
Information
Contrast
Photovoltaics
Language
Incoming
mains
Real time
Acoustic
signal
generator
Inverter
Help
Password
From all menus the system automatically
returns to the operating display after
a certain period of time if no keys are
pressed on the DOU
COM interface
AUX
signals
Figure 25
8.3.2
Menu tree
Main Menu
Figure 26
Operating displ
Blocking
Fault history
Settings
Information
Service
Mon 05 Jan 2009
07:00
Main menu
After start-up, the "Main menu" represents the highest menu level,
which means that you can open further submenus from here, and
you can always return to this level.
The "Main menu" has the typical menu structure.
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Additional submenus are displayed on the left-hand side. All selectable submenus are displayed in a frame. A black background
indicates the current cursor position. The bottom line displays the
current real time, which can be adjusted using the "Settings"
menu.
On the right-hand side, the current key function is represented as a
symbol which is displayed in a small framed area. You can move
the cursor using the "<" and ">" keys to select the corresponding
submenu. Use the ENTER key to activate a selected submenu.
Using the "?" key, you can call up the "Help" menu, which describes all the various keyboard symbols.
8.3.3
Operating Display
You can call up the "Operating display" from the main menu. If the
DOU has not been used for some time, the system automatically
switches back to the operating display, no matter which menu it is
in.
The LCD background illumination is switched off if no further operations are carried out and the system is not in an abnormal status.
In the event of a unit fault, the background illumination remains
switched on until the fault is acknowledged. If the inverter is in
night mode, the content of the LCD is cleared and "Sleep mode" is
displayed instead. The background illumination is also switched
off.
You can reactivate the DOU by pressing any key.
Figure 27
Operating display – Normal operation
The "Operating display" consists of 3 parts:
The left-hand side shows the current global unit status:
Figure 28
Operating display – Left-hand side
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At the top, a sun symbol indicates the current solar radiation trend.
If the sun is black or a moon symbol is displayed, the PV voltage is
so low that the inverter is in its idle state. An empty sun with no
rays also indicates that the PV voltage is still too low, with the inverter in standby mode.
The inverter is represented in the middle of the left-hand section. If
a fault occurs or a message is present, the corresponding symbols
flash on the inverter. The bar on the left shows the PV voltage as a
symbol and a digital value. If the bar is completely filled in, this indicates that sufficient PV voltage is present. The bar on the right
shows the inverter status. If the inverter is feeding power into the
mains, the bar is filled in.
The total energy fed in is shown at the bottom of the display.
Examples of possible displays:
Figure 29
Example of operating display
The equipment is in its normal state, the inverter is feeding power
into the mains.
Figure 30
Example of operating display
Solar radiation is sufficient, the inverter is switched off. If the sine
symbol on the inverter is flashing, the inverter has been switched
off due to a fault or it is currently in the synchronisation phase.
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Figure 31
Example of operating display
Solar radiation is too low, the inverter is in standby mode.
Figure 32
Example of operating display
Solar radiation is too low, the inverter is in its idle state.
The middle section displays the unit's most important infeed values
in the form of digital values and a graph covering a certain period
of time. The current daily data is shown as standard. This display
appears automatically if no keys have been pressed for 1 minute.
Figure 33
Operating display – Central section
You can use the double arrow key to select the infeed periods below.
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Figure 34
Example of daily data
Daily data for the current day, previous day
(t = 00:00 – 04:00, 15 minute intervals)
Figure 35
Example of monthly data
Monthly data (t = day 1 – 31) for the last 12 months
Figure 36
Example of yearly data
Current yearly data (t = month 1 – 12)
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Figure 37
Example of yearly overview
Yearly overview
(t = year of start-up to current year)
The right-hand side shows how the key is currently assigned.
Figure 38
Operating display – Right-hand side
Here you can switch the inverter on or off, depending on the unit
status. If the operation has been blocked, this is indicated here via
a key symbol. If a blank button is shown here, a fault is present.
The flashing measured values menu then takes you to the inverter
menu, where detailed information can be found on the fault and
where you have to acknowledge it.
You can use the double arrow key to select the different display
types for the energy data logger.
Current day (default) -> Previous day -> Monthly overview -> Current yearly overview -> Yearly overview
If messages have been output or faults have occurred, you can
acknowledge the acoustic signal generator here; otherwise, this
key is not assigned.
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Use the bottom key with the measuring instrument symbol to call
up menus with detailed information on the status and the measured values. This key flashes in the event of a fault in the unit, enabling you to access menus containing additional fault information
directly.
8.3.4
Status/Measured Values
You can call up the "Status/Measured values" menu from the operating display
using the bottom key with the measuring instrument symbol.
Here you can use the "<", ">", "^" and ENTER keys to open the
submenus containing the statuses and measured values for the
individual unit components.
Press the ENTER key to return to the Status/Measured values
menu.
-- Status/data -Photovoltaic
Grid side
Inverter
COM interface
AUX signals
Menu
Figure 39
Menu: Status/Measured values
You can use the "Photovoltaics" menu item to display the measured values for the panels. Any faults in the DC distribution are
shown here too.
UDC.[V]:
-- Photovoltaic -[kohm] 100
600
R-ISO[kOhm]:
IDC.[A]:
481
PDC[kW]:
289
Figure 40
Photovoltaics menu (example)
You can use the "Incoming mains" menu item to display the measured values for the incoming mains. Any mains faults or faults in
the AC distribution are shown here too.
-- Grid side -UL12-31.[V]:
270
270
270
IL1-3..[A]:
587
587
587
F....[Hz]:
50.0
Figure 41
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Failures: 2
Menu: Incoming mains (example)
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You can use the "Inverter" menu item to display the statuses and
measured values for the inverter. You can toggle between the two
menus using the ">" and "<" keys.
In normal operation, the inverter can be switched on and off here,
using the top key. In the event of a deactivating fault, you can call
up a detailed description of the fault here. Once the fault has been
rectified, you will need to acknowledge it using the top key. A highvoltage symbol "V" will then appear on the top key.
-- Iverter-Status -Grid operation MPP
-- Inverter-data -UL12-31.[V]:
270
270
270
IL1-3..[A]:
587
587
587
P....[kW]:
261
S...[kVA]: 275
Q..[kvar]:
14
cos(phi).: 275
F....[Hz]: 50.0
E...[kWh]: 937
T1...[°C]: 25.0
T2 ...[°C]: 28.0
E..[kWh]: 2089336
t ....[h]: 1262
Figure 42
Menu: Inverter (example)
The voltage and current of the three phases are displayed as
measured values. The power values P, S, Q and cos-phi appear
underneath these voltages and currents.
These are then followed by the frequency F and the daily energy
E.
The ambient temperature of cabinet T1 and the supply air temperature of inverter stack T2 are shown as the temperatures.
Next come the total energy counter ∑E and the inverter operating
hours counter ∑t.
You can scroll through the measured values using the "v" and "^"
keys.
You can use the "COM interface" menu item to look up the statuses of the communication PCBs.
You can use the "AUX signals" menu item to look up the status of
optional general signals on the remote signalling board.
8.3.5
Blocking
You can call up the "Blocking" menu from the "Main menu". After
you have entered the current password, you can block operation of
the inverter (switching ON/OFF and fault acknowledgement). The
password must be entered digit by digit and then confirmed by
pressing the ENTER key.
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The default password set by the factory is: 1201.
In menus where switching operations are normally possible, blocking is indicated by a key.
8.3.6
Fault History
You can call up the "Fault history" menu from the "Main menu". A
data logger that records the inverter's fault history is integrated in
the inverter unit. You can display the 20 most recent faults as of
the current date or as of a specific date.
8.3.7
Settings
You can call up the "Settings" menu from the "Main menu". Here
you can set the following parameters in the submenus:
LCD contrast, Language, Real time and Acoustic signal generator for indicating faults and keyboard operation
8.3.8
Information
You can call up the "Information" menu from the "Main menu". Using this menu, you can call up information about the unit type, the
firmware versions and the available communication options.
8.3.9
Service
You can call up the password-protected "Service" menu from the
"Main menu". The password must be entered digit by digit and
then confirmed by pressing the ENTER key.
The default password set by the factory is: 1201.
Once the current password has been entered, you can select a
submenu where you can change the DOU password.
 In the "Password" menu, you can set the password for blocking operation and for setting parameters. A range of 0000 to
9999 is possible.
i
Keep the password secure.
If you have forgotten the password, the DOU will need to
be reset at the customer's expense!
8.3.10 Help
You can call up the "Help" menu from the "Main menu" using the
"?" key. This enables you to look up the meaning of the keyboard
symbols.
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80000043212 BAL
Installation and Start-up
Protect PV.500-MH
AEG Power Solutions GmbH, Warstein-Belecke
Department:
PS AED
Revision:
00
Revision date:
25.04.2012 / Schenuit
Released:
25.04.2012 / Aranda
Document no.
8000043213 BAL, en
Protect PV.500-MH Installation and Start-up
2 of 22

AEG Power Solutions GmbH
Emil-Siepmann-Strasse 32
59581 Warstein
Germany

Fax:
E-mail:
Internet:
+49 2902 763 100
+49 2902 763 645
[email protected]
http://www.aegps.com
80000043213 BAL
Protect PV.500-MH Installation and Start-up
Table of Contents
1
General Information............................................................... 4
2
Safety ...................................................................................... 4
3
Product Details ...................................................................... 4
4
Transport and Set-up ............................................................ 5
4.1
Transport Notes ....................................................................... 5
4.2
Forklift Transport...................................................................... 6
4.3
Crane Transport....................................................................... 7
4.4
Installation Instructions ............................................................ 8
4.5
Installation of PV.500 Inverter.................................................. 9
4.5.1 Removal of the Door Stops...................................................... 9
4.5.2 Removal of the Ventilation and Filter Mat Inserts .................. 10
4.5.3 Removal of the Opener Lever of the Right Service Flap ....... 11
4.5.4 Attachment of the PV.500 on the Socle of the Inverter
Station 11
4.6
Installation of the Waste Air Duct ........................................... 12
4.7
Tightening Torque Values for Screw Connections ................ 15
5
5.1
Connection Work ................................................................. 16
External Connections............................................................. 17
6
6.1
6.2
6.3
Start-up ................................................................................. 18
Start-up Preparations............................................................. 19
Connection of AC Voltage ..................................................... 20
Connection of DC Voltage ..................................................... 21
7
7.1
Isolating Solar Inverters ..................................................... 22
Isolation Procedure ................................................................ 22
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1
General Information
These instructions correspond to the technical specifications of the
equipment at the time of publication. The contents of these instructions do not constitute a subject matter of the contract, but are for
information purposes only.
AEG Power Solutions GmbH reserves the right to make modifications to the content and technical data in these instructions without
prior notice. AEG Power Solutions GmbH cannot be held liable for
any inaccuracies or inapplicable information in these instructions,
which came about as a result of changes to the content or technology applied after this equipment was supplied, as there is no
obligation to continuously update the data and maintain its validity.
Please refer to the respective operating instructions for all
other general information.
2
Safety
The qualified skilled personnel are responsible for safety. The
member of personnel who is responsible for the equipment must
ensure that only suitably qualified persons are allowed access to
the equipment or permitted within its vicinity.
Please refer to the respective operating instructions for all
other safety information.
3
Product Details
The equipment has been designed for solar power plants and provides professional solutions for the use of installations covering
large roofs or in open spaces.
Please refer to the respective operating instructions for all
other information relating to this topic.
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4
Transport and Set-up
4.1
Transport Notes
The inverter station consists of a compact housing that can be
transported by a forklift or a crane with suitable crane gear (crossmembers or crane grabs).
Please note that the selected lifting tackle must have a safe working load of 1100 kg for the weight of the inverter station without the
PV.500 installed, or 3000 kg with the PV.500 installed.
The sturdy socle design permits transport without a wooden pallet.
This means a truck with a 3 m loading height is sufficient for
transport.
Figure 1
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4.2
Forklift Transport
On the front and rear of the inverter station, there are openings for
forklift tines thus allowing transport from either side.
Figure 2
Due to the uneven weight distribution following installation of the
PV.500, and the associated shift in the centre of gravity, the forklift
tines are positioned off-centre. Refer to the following illustration for
the dimensions of the openings:
Figure 3
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4.3
Crane Transport
Specially produced crossmembers also suitable for transport with
the PV.500 installed can be provided on request.
Figure 4
ATTENTION: Due to the danger of tipping, make sure to
transport in the upright position!
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4.4
Installation Instructions
For installation of the PV.500 in the inverter station.
Figure 5
Figure 6
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4.5
Installation of PV.500 Inverter
The opening clearance in the door frame is 2730 mm (Figure 7).
This means when the PV.500 is inserted, there are gaps to the left
and right of max. 15 mm each between the PV.500 (width 2700
mm) and the door frame of the inverter station. This limitation
means that care must be taken to ensure that the PV.500 is upright when lifted with the forklift. In addition, when inserting make
sure that the PV.500 is lifted and inserted on the left and right via
the earthing bushes (Figure 7).
Figure 7
Before the PV.500 can be inserted into the inverter station, it is also necessary for the door stops, the opener lever of the right service flap and the ventilation/filter mat inserts of the doors to be removed. The following sections 5.1 to 5.3 provide assistance in this.
4.5.1
Removal of the Door Stops
As standard, each of the doors can be opened by a maximum of
95°. The opening clearance between the doors is then about 2670
mm (Figure 8), meaning that the PV.500 could not be inserted.
Therefore, the door stops on the left and right must be removed,
so that the door panels can be opened beyond the standard angle
of 95°.
Figure 8
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In order to remove the door stops, remove the M8x20 hexagon
bolts (Figure 9) that are screwed into the frame. This means the
door stops are now only connected to the door panels, and the
doors can be opened sufficiently.
Figure 9
4.5.2
Removal of the Ventilation and Filter Mat Inserts
To increase the open passage between the doors, it is also possible to remove the ventilation and filter mat inserts. To do this, remove all the M5x12 hexagon bolts.
Figure 10
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4.5.3
Removal of the Opener Lever of the Right Service Flap
The lever of the release mechanism that is used for opening the
right service flap reduces the frame width by about 42 mm (Figure
11). For this reason, the lever must be removed temporarily before
the PV.500 is inserted. For this purpose, the two M5x20 countersunk screws must be removed, followed by the lever.
Figure 11
4.5.4
Attachment of the PV.500 on the Socle of the Inverter Station
To allow insertion and positioning of the PV.500 to be coordinated
from the rear as well, the service flap on the rear wall of the inverter station should be opened first.
Figure 12
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Following this, the PV.500 can be placed on the pre-installed rails
on the socle, aligned and attached to the socle using the supplied
M12x30 bolts and A12 washers.
Figure 13
4.6
Installation of the Waste Air Duct
CAUTION
Risk of injury due to rotating fans!
The fans of the INV control cabinet are freely accessible.
 Never reach into rotating fans.
 When setting up any system, ensure that the fans cannot be touched.
Compliance with the requirements of IEC 60364-7-729 is
mandatory when installing the system.
i
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Make sure that there is a space of at least 500 mm in
front of the system (ensure compliance with national requirements, which may be different) when its doors are
open to ensure an escape route.
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ATTENTION
Insufficient dissipation of waste heat can damage the
system!
 Dissipate the waste heat in accordance with the manufacturer's specifications.
The dimensions of the waste air duct and the height of the inverter
mean that the duct must be built around the fans step by step once
the PV.500 has already been inserted into the inverter station.
First of all, the bottom and left air baffles must be placed on the
PV.500 and bolted together using M5x12 hexagon bolts (Figure
13). The M16x40 hexagon bolts should initially only be used for
securing to the PV.500.
Figure 14
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Following this, the air baffles at the top and right should be installed.
Figure 15
Finally, the complete duct can be pushed flush with the rear wall of
the inverter station, and secured to the PV.500 by the M16x40
hexagon bolts.
Figure 16
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4.7
Tightening Torque Values for Screw Connections
These values apply to the electrical and mechanical connections.
They do not apply to the floor attachment of the system or the individual control cabinets where the floor is subject to dynamic force.
Thread
Electrical
connection
Mechanical connection
Cheese head
screw
strength category
5.8
[Nm]
Hexagon screw
strength category
8.8
Slotted
cheese head
screw DIN 84
[Nm]
[Nm]
[Nm]
M4
1.2
1.3
2.0
1.2
M5
2.0
2.65
4.0
2.0
M6
3.0
4.4
7.0
2.5
M8
6.0
10.5
17.0
3.5
M10
10.0
-
33.0
4.0
M12
15.5
-
56.0
-
M16
30.0
-
140.0
-
M20
52.0
-
260.0
-
M24
80.0
-
445.0
-
Table 1
Tightening torque values for screw connections
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5
Connection Work
Figure 17
Installation without control cabinet doors
ATTENTION
If the polarity of the lines is incorrect, this can damage the system!
This can cause considerable damage to equipment.
 Ensure the correct polarity is observed when connecting the lines.
i
The image above may not always be strictly accurate,
depending on which options have been selected.
A distinction is made between internal and external connections/cabling.
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5.1
External Connections
i
Establish the connections in accordance with the circuit
diagram provided. The mains connection line for the independent power supply must be protected by the circuit
breaker specified in the technical data sheet. See the circuit diagram and the technical data sheet for possible
connection cross-sections.
The inverter station must be earthed according to the
applicable regulations.
DANGER
System not installed correctly!
Risk to life due to electric shock.
 Only trained and qualified skilled personnel who are
authorised to install medium-voltage systems may connect such equipment.
 Wear personal protective equipment.
Power terminals
-X41:1L+, 1Lto
-X41:8L+, 8L-
DC connection
(on PV.500)
Maximum 185 mm²
-X26:U, V, W
Mains connection
(on side of MH)
Maximum 3x150 mm²/phase
PE
Earth connection
(on side of MH)
Maximum 2x120 mm²
Control/Monitoring terminals
-X11:L, N, PE
Electrical power supply AC 230V (on side of MH)
-X13:L, N, PE
Auxiliary power supply AC 230V (on side of MH)
-X33:1, 2
Signals (NC contact from S1,
1-2 system off, 3-4 emergency off) (on side of
MH)
-A12-X3, X4, X5
Remote signalling (on PV.500)
-A13-X3, X4
Remote signalling (on PV.500)
-X91:1-5
CAN communication controller (on side of MH)
-A93:1-8
COM server (on side of MH)
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6
Start-up
Special AEG Power Solutions software and hardware tools must
be used for initial start-up. Only skilled personnel trained by AEG
Power Solutions are in a position to use these tools correctly and
to perform initial start-up.
Once the system has been fully installed, the following aspects
must be checked:
 Screw connections properly tightened
 Connection cables correct
 Tool removed
 Terminal space covers attached
Read the operating instructions prior to start-up.
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Start-up Preparations
The following are required:
 3-pin phase-rotation indicator
 Multimeter
 Two-pin voltage detector
 Circuit diagram
Prerequisites:
 All miniature circuit breakers are switched on, except F60.
 All circuit breakers and load interrupters are switched off.
Protect PV.500
-Q4.1
+INV
+NSHV
-K7
-L26
-F41
Control
-F38,
-F81
Figure 18
i
-Q26
-A1
Com
-Q1
2
1
-F13,
-F22,
-F60,
-F61,
-F101
Functional principle, with miniature circuit breakers shown
Isolating points Q1 are designed on a system-specific
basis and do not form part of the PV.500.
Before connecting the AC voltage, check:
 F60 switched off (DC/AC control cabinet)
 F14 switched off (DC/AC control cabinet)
 Q4.1 switched off (DC/AC control cabinet)
 Q26 switched off
 F41 not engaged (DC/AC control cabinet)
 F22, F13, F61, F101 switched on (DC/AC control cabinet)
i
The low-voltage winding of the mains transformer must
not be connected to earth.
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EVU-Netz
Mains
+DCD/ACD
DC (PV-Modul)
6.1
Protect PV.500-MH Installation and Start-up
6.2
Connection of AC Voltage
i
An insulation test must be performed before the mains
voltage is connected.
 Connect the medium-voltage switchgear. Voltage is present at
the external mains isolating point.
Medium voltage:
DANGER
Switchgear not connected correctly!
Risk to life due to electric shock.
 Only qualified and trained skilled personnel who are
authorised to work with switchgear and have experience
of doing so may connect the switchgear.
 Wear personal protective equipment.
Skilled personnel are appointed by the system operator.
After connecting the AC voltage:
 Switch on Q1 (external).
 Switch on Q26.
 Measure the clockwise rotating field at X3 (AC control cabinet).
 Connect the external power supply/auxiliary voltage at X11.
 Measure the external voltage at X11.
 Switch on F60 (DC/AC control cabinet).
The control unit and the DOU are now working.
Q4.1 (DC/AC control cabinet) switches on automatically after a few
seconds.
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6.3
Connection of DC Voltage
GCB
Grid
DOU
Generator connection box
Power utility mains (supplying mains)
Display and operation unit
After connecting the DC voltage:
 Switch off GCBs (external).
 Check that there is no voltage.
 Insert all F41 fuses (DC/AC control cabinet).
 Check the polarity in the system's DC/AC control cabinet.
 Check the polarity of the DC at every GCB.
Connect all GCBs.
 Switch on the system via the DOU.
The INV contactor K7 switches on automatically after a few seconds and power is fed into the power utility mains.
If the INV contactor K7 does not switch on, check the following:
"Synchronisation fault" fault message
Check the INV control cabinet and DC/AC control cabinet connection lines to ensure they have a clockwise rotating field.
 Isolate the system to do this.
The DC voltage is very low
There is insufficient sunlight.
Other fault indications
 See "Monitoring Systems, Messages and Faults" in the operating instructions.
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7
Isolating Solar Inverters
The following are required:
 Multimeter
 Two-pin voltage detector
 Circuit diagram
7.1
Isolation Procedure
DANGER
Contact with voltage.
Risk to life due to electric shock.
The capacitors can continue to carry voltage for quite
some time; terminal X11 (AC control cabinet) will also remain live.
Switching off Q26 and Q4 does not isolate the system entirely from the voltage!
The remote signalling lines may still be live even after the
mains and DC have been disconnected!
 Only trained skilled personnel may isolate the system.
 Do not touch any live parts.
 To isolate the system from the voltage, you must dis-
connect the supply lines.
 Wear personal protective equipment.
 Switch the PV solar inverter off via the DOU.
 Switch off Q26 (external).
 Switch off F60 (DC/AC control cabinet).
 Switch off GCBs (external).
 Remove all F41 fuses (DC/AC control cabinet).
 Check that there is no voltage at X41 and X3 (DC/AC control
cabinet).
 Observe the "five rules of safety", i.e. "earth and short-circuit"
the AC and DC supplies if necessary.
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Maintenance and Servicing
Protect PV.500-MH
AEG Power Solutions GmbH, Warstein-Belecke
Department:
PS AED
Revision:
00
Revision date:
25.04.2012 / Schenuit
Released:
25.04.2012 / Aranda
Document no.
8000043214 BAL, en
Protect PV.500-MH Maintenance and Servicing
2 of 14

AEG Power Solutions GmbH
Emil-Siepmann-Strasse 32
59581 Warstein
Germany

Fax:
E-mail:
Internet:
+49 2902 763 100
+49 2902 763 645
[email protected]
http://www.aegps.com
80000043214 BAL
Protect PV.500-MH Maintenance and Servicing
Table of Contents
1
General Information ..........................................................4
2
Safety ..................................................................................4
3
Product Details ..................................................................4
4
4.1
4.2
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.4
4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
4.5
4.5.1
4.5.2
4.6
4.6.1
4.6.2
Maintenance and Repair ...................................................5
General Information .............................................................5
Scope of the Recommended Measures ..............................5
Inspection ............................................................................6
Visual Inspection .................................................................7
Diagnostic Functions ...........................................................8
Reading Out the Memory ....................................................8
Removing Accumulated Dust ..............................................8
Obligation to Keep a Written Record ...................................8
Functional Test ....................................................................9
Isolating Solar Inverters .......................................................9
Cleaning and Checking the Protection Devices ................10
Checking the Monitoring System .......................................10
System Stop ......................................................................10
Documentation ..................................................................10
Maintenance ......................................................................10
Additional Work .................................................................11
Documentation ..................................................................11
Repair ................................................................................11
Removing and Installing the Fans .....................................12
Power Section ...................................................................13
5
Fault Messages ................................................................14
6
Spare Parts and Customer Service ...............................14
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Protect PV.500-MH Maintenance and Servicing
1
General Information
These instructions correspond to the technical specifications of the
equipment at the time of publication. The contents of these instructions do not constitute a subject matter of the contract, but are for
information purposes only.
AEG Power Solutions GmbH reserves the right to make modifications to the content and technical data in these instructions without
prior notice. AEG Power Solutions GmbH cannot be held liable for
any inaccuracies or inapplicable information in these instructions,
which came about as a result of changes to the content or technology applied after this equipment was supplied, as there is no
obligation to continuously update the data and maintain its validity.
Please refer to the respective operating instructions for all
other general information.
2
Safety
The qualified skilled personnel are responsible for safety. The
member of personnel who is responsible for the equipment must
ensure that only suitably qualified persons are allowed access to
the equipment or permitted within its vicinity.
Please refer to the respective operating instructions for all
other safety information.
3
Product Details
The equipment has been designed for solar power plants and provides professional solutions for the use of installations covering
large roofs or in open spaces.
Please refer to the respective operating instructions for all
other information relating to this topic.
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4
Maintenance and Repair
4.1
General Information
The installed AEG Power Solutions system contains high-quality,
durable parts and components, which are coordinated with one
another in order to provide the best possible conditions for system
operation. To maintain the functional reliability of the system and to
make sure it continues to deliver optimum energy yields, the following steps need to be performed on a regular basis:
 Regular inspection of system operation
 Annual system maintenance
 Servicing according to the duration of operation
 Observe the applicable country-specific standards and directives.
i
The operator or their designated representative is responsible for the system whilst maintenance work is being carried out; he or she also coordinates the work itself.
The person appointed to maintain the system is responsible for the work carried out on the system section assigned to him or her.
DANGER
Contact with voltage! Extremely high DC voltages of
up to 1000 VDC are present.
Risk to life due to electric shock.
 Do not touch live parts.
 Wear personal protective equipment.
4.2
Scope of the Recommended Measures
We recommend carrying out the following work:
Task
Interval
Inspection
1 - 3 months, depending on installation site
Function Test
6 months
Maintenance
12 months
Servicing
According to number of operating hours worked
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Protect PV.500-MH Maintenance and Servicing
4.3
Inspection
The system is inspected to establish its current condition; the actual content of the inspection and the intervals at which it is to be
performed must be defined on the basis of the relevant installation
site and operating conditions.
DANGER
Contact with voltage.
Inspection work must sometimes be performed when the
system is connected to the power supply.
Risk to life due to electric shock.
 Only trained skilled personnel may carry out work on
the system.
 Do not touch any live parts.
 Secure the work area.
 Observe the safety regulations.
 Observe the Technical Rules for Plant Safety (TRBS =
Technische Regeln für Betriebssicherheit).
 Wear personal protective equipment.
i
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With all relevant precautionary measures in place, the
measuring lines must be routed to the live measuring
points in order to record measured data.
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Protect PV.500-MH Maintenance and Servicing
4.3.1
Visual Inspection
When visually inspecting the system, check:
 There is any mechanical damage or if foreign bodies can be
found in the system
 Whether any corrosion is present
 Whether any moisture is present in the system
 Whether excessive thermal stress can be detected at cables or
components
 Whether any conductive dirt or dust has accumulated in the
system
 Whether any accumulation of dust affects heat dissipation
 Whether the fans are dirty or damaged
 Whether the air filters are dirty or damaged
 Whether the supply and exhaust air system (in the case of a
station installation) is dirty or damaged
The intervals at which visual inspections should be performed are
largely determined by the site conditions.
Figure 1 View of the cabinet
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Protect PV.500-MH Maintenance and Servicing
4.3.2
Diagnostic Functions
The comprehensive diagnostic functions implemented in the system not only increase its operational reliability considerably, but also reduce the time required for maintenance work and troubleshooting to a minimum.
The system is equipped with the following diagnostic functions,
some of which are optional:
Self-diagnosis:
This is activated when the system is switched on. Internal auxiliary
programs monitor and signal faults, including those from the bus
system, the control PCBs or the sensors.
Data logger:
Specified measured data and parameters are saved for every fault
that occurs. This data is read out and evaluated as required.
4.3.3
Reading Out the Memory
i
4.3.4
The fault memory is described in the operating instructions.
Removing Accumulated Dust
If large quantities of dust have accumulated, the system should, as
a precaution, be cleaned with dry compressed air in order to ensure adequate heat dissipation.
4.3.5
Obligation to Keep a Written Record
Inspection results and details of any maintenance work carried out
must be recorded in writing. Experience has shown that the best
way to document inspection results is in the form of a test report.
The following information must be recorded:
 Maintenance schedule
 Date of the measure carried out
 Work performed
 Any special notes on the work performed
 Persons who carried out the work
 Signatures of the persons who carried out the work
 Signature of the person responsible (supervisor)
A correct test report, completed in full, is important for technicians
as evidence of exoneration in case of later complaints or for investigations in case of damage. For this reason, test reports should be
retained for a long time (around 10 years).
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4.4
Functional Test
i
Always perform a functional test after completing any
maintenance work and before starting operation.
Perform the functional test in accordance with the start-up procedure and check the report.
4.4.1
Isolating Solar Inverters
The following are required:
 Multimeter
 Two-pin voltage detector
 Circuit diagram
DANGER
Contact with voltage.
Risk to life due to electric shock.
The capacitors can continue to carry voltage for quite
some time; terminal X11 will also remain live.
Switching off Q4 and Q26 does not isolate the system
entirely from the voltage!
The remote signalling lines may still be live even after the
mains and DC have been disconnected!
 Only trained skilled personnel may isolate the system.
 Do not touch any live parts.
 To isolate the system from the voltage, you must dis-
connect the supply lines.
 Wear personal protective equipment.
 Switch the PV solar inverter off via the DOU.
 Switch off Q26.
 Switch off F60 (DC/AC control cabinet).
 Q4.1 (DC/AC control cabinet) switches off automatically after a
few seconds.
 Switch off GCBs (external).
 Remove all F41 fuses (DC/AC control cabinet).
 Check that there is no voltage at X41 (DC/AC control cabinet)
and X3 (DC/AC control cabinet).
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Protect PV.500-MH Maintenance and Servicing
4.4.2
Cleaning and Checking the Protection Devices
 Clean or replace the filter mats.
 Clean the heat sink in the solar inverter power section.
 Check the clamping joints for thermal stress and ensure they
are secure.
 Check the fuses and isolators.
4.4.3
Checking the Monitoring System
 Check insulation monitors.
 Check Q26 triggering.
 Test the function of the anti-condensation heater.
Inverter start-up
Solar inverter start-up – see start-up information for the Protect
PV.500.
 Check the LEDs on the DOU.
 Check that the solar inverter starts up correctly.
4.4.4
System Stop
Test the function of the installed system shutdown equipment.
 Test the internal system stop switch (DC/AC control cabinet).
4.4.5
Documentation
The functional test procedure followed and the results obtained
must be recorded.
4.5
Maintenance
The measures described under points 4.3 and 4.4 form part of the
maintenance activities.
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Protect PV.500-MH Maintenance and Servicing
4.5.1
Additional Work
The following work must also be carried out, observing the safety
regulations that have been described:
 Perform the following voltage tests:
 AC mains at X3 or X26
 DC voltage with solar inverter switched off
 MPP voltage with solar inverter switched on
 Check the following auxiliary voltages:
-
X11: power supply mains 230 V
X13: auxiliary power supply 230 V
 Perform an insulation test:
 Individual measurement via mega-ohmmeter
 Check measured values of the integrated ISO measuring instrument
Starting the insulation test manually:
Active earthing can be switched off manually using PV tools in order to perform maintenance work. This option is only available on
systems for thin-film cells.
The insulation test is started with a delay. When the test time has
elapsed, the insulation test ends and active earthing is switched on
again.
The insulation test can only be started manually if an insulation
test is not already running at the time.
 Check remote signalling contacts:
 Check remote signals
 Check the DOU
 Check the earth connectors:
 Check earthing connections
 Check contact resistance
4.5.2
Documentation
The maintenance procedure followed and the results obtained
must be recorded.
4.6
Repair
Repairs may only be carried out on the installation by AEG Power
Solutions skilled personnel.
If you want other personnel to carry out repairs, this will need to be
authorised by means of written approval from AEG Power Solutions. Only original AEG Power Solutions spare parts (or spare
parts purchased from AEG Power Solutions) may be used.
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Protect PV.500-MH Maintenance and Servicing
4.6.1
Removing and Installing the Fans
CAUTION
Risk of injury due to rotating fans!
The fans of the INV control cabinet are freely accessible.
 Never reach into rotating fans.
 When setting up any system, ensure that the fans cannot be touched.
When fans are replaced, the starting capacitors must be replaced
too.
Removing the fan:
i
The fans switch on and off depending on the temperature.
Even after the system has been switched off the fans may
continue to run until the unit temperature drops. Do not
remove connectors under load, i.e. when the fans are
running.
The power supply to the motors must be isolated before
any work is carried out on the fans!
 Disconnect the corresponding connectors on the "fan monitoring" assemblies.
INV control cabinet
M1 / X 201 Stack fan
M2 / A91.1 X1 Cabinet fan
M3 / A91.1 X2 Cabinet fan
Stack fan M1 is located in the air duct of the INV power section at
the bottom of the cabinet.
Fans are replaced as described below:
 Unscrew the cover from the air duct.
 Disconnect the temperature sensor.
 Unscrew the 6 fixing bolts on the fan holder and remove the
2 nuts from the fan assembly.
 Pull the fan assembly out of the air duct towards you and set
it down.
 Detach the fan connections and disconnect the cables.
Installing the fan:
 Install the fan by repeating these steps in reverse order.
 Switch on the system.
 Check that the fan is functioning correctly.
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Protect PV.500-MH Maintenance and Servicing
Cabinet fans M2 and M3 are located on the INV cabinet roof in
the waste air duct.
Fans are replaced as described below:
 Unscrew the service flap from the waste air duct.
 Disconnect the cable clip from the hexagon-head bolt.
 Detach fan connectors X91.1 and X91.2.
 Unscrew the 4 fixing bolts on the fan's mounting plate and
remove the fan from the cabinet.
 Unscrew the fan from its mounting plate and remove it.
Installing the fan:
 Install the fan by repeating these steps in reverse order.
 Switch on the system.
 Check that the fan is functioning correctly.
4.6.2
Power Section
When components have reached the end of their service life they
must be replaced in order to maintain the functional reliability of
the system.
Replacement of the capacitors in the inverter's DC and AC circuits
is recommended after around 100,000 hours of operation.
The output contactor on the inverter (K7) reaches the end of its
service life when it has completed the specified number of switching operations. These operations are recorded in the memory; the
contactor then has to be replaced in accordance with its particular
technical data.
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Protect PV.500-MH Maintenance and Servicing
5
Fault Messages
Refer to the Protect PV.500 operating instructions for a detailed
description of fault messages.
Some faults can be located and eliminated quickly with the help of
this table.
6
Spare Parts and Customer Service
Although this system uses non-wearing components, we recommend stocking the spare parts listed in the table below. This will
help to ensure your system is always available.
Item
Component
A91.1
Fan monitoring
A12, A13
Remote signalling
F41
DC input fuse
M1
Stack fan for INV control cabinet
M2, M3
Cabinet fan for INV control cabinet
i
When ordering spare parts, please quote the designation
(item/component) and the unit number.
We would like to draw your attention to the fact that spare parts not
supplied by us have neither been tested nor approved.
Installing spare parts of this kind can therefore have a detrimental
effect on the functional capability and passive safety of the system.
We do not accept any warranty claims/liability for any resulting
damage.
Our customer service department will be happy to send you a
complete spare parts list for your system on request.
Please contact the address already specified for help in this matter
or if you have any further questions or suggestions.
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2
3
4
5
6
7
8
CAE EPLAN Electric P8
1
PV.500/630-MH
Station
PV.LoG
NYM-J 3x1,5mm²
-X11
external Supply
-X33
NYM-J 3x1,5mm²
1-4
UNITRONIC BUS LD
2x2x0,22mm²
communication
Cat-5
Ethernet
NYM-J 3x1,5mm²
Auxiliary supply Output
-F91 8;10;12;4
7;9;11;3
-F93 1-8
1-8
UNITRONIC BUS LD
2x2x0,22mm²
Cat-5
230 VAC
PE
PE
CU
60x10
-Q26
-X26
-Q4.1
NSGAFOEU 3x3x1x150mm²
n
n
n
1
n
n
n
CAN
1
2
2
2
8
Silflex-N 2x1,5mm²
1L1-1L3
2L1-2L3
X26:U;V;W
CU
60x10
3
11
12
C12
C11
-A20-X3
1
2
Silflex-N 2x1,5mm²
CU
60x10
1-3
PV.IcX.1.1.2
-X41 -F41.8
CAN
-F41.2
n
3
-X41
n
1
2
3
4
3
-X41 -F41.1
n
1-8
U,N,PE
H07V-K 120mm²
U;V;W
1
-A93 1-8
-X13
Modbus/RS485
COM server
-A27 1-8
-PE
-X3
3
1-5
-X13
-K7
PV.IcX.1.1.1
-X91
L;N;PE
-A29-X5 1-9
-DC/AC
-INV
-X33 1;2
U,N,PE
INV
-E1
PV.500/630
System Off
Auxiliary voltage
Li2YCYv 8x2x0,5mm²
This document is property of AEG Power Solutions and must not be
displayed or duplicated to any third party without the concent of the company
CAN
L;N;PE
max. 185mm²
max. 185mm²
PV.IcX.1.1.m
max. 185mm²
1000002928
CAN
01
X26:U;V;W
Stat Alteration
Next page
+STR/1
02.05.2012 Songur
Date
Name
Date
02.05.2012
Editor
Songur
Checked Langer
Norm
Protect PV.500/630-MH
Basisplan
POWER SOLUTIONS
Single line diagram
= PV.500/630-MH
+ SLD
1000002928 USP
en
sheet
sheets
1
1
1
2
F93
F91
3
5
4
A
2570
331
Cabling DC
DC Kabeldurchführung
Cabling AC
AC Kabeldurchführung
X91
100
PE
DETAIL A
440
X13
X33
8
Bottom View
X11
B
7
PE
A93
A
6
B
600
121
U,V,W
100
Side View
Side View
Front View
1301,3
3178,5
C
C
A
2791
630
Observe protection note to DIN 34.
1114
76
D
D
80
829
192
908
80
134,5
134,5
1110
3000
E
E
Free size tolerances Surfaces
DIN ISO
2768 m
Name
Date
Editor 26.04.2012 d.aranda
Check 27.04.2012 b.adams
Norm.
F
1
2
3
4
01 CU1Schiene
Stat. Alteration
24.05.2012 ARA
Date
Name Origin:
Scale
1:50
Mass: ca. 2800 kg
PV.5001MH
PV.6301MH
1000002928_01_AP
repl.for:
repl.by:
A3
en
Page
1
1 Pa.
1
2
3
4
CAE EPLAN Electric P8
This document is property of AEG Power Solutions and must not be
displayed or duplicated to any third party without the concent of the company
2L1
2L2
CU
7
Input
Output
Power supply
Auxiliary supply
Netz 2 AC 230V
230V / 400W max.
X11
L
N
PE
X13
L
N
PE
L
N
PE
8
60x10
CU
PE
W
60x10
V
60x10
CU
1000002928
6
PV.500-MH
X26:U
01
X26:U;V;W
Stat Alteration
5
2L3
2
4
6
12 14
1
3
5
11
-Q26.1
U>
CU
1L3
CU
CU
60x10
CU
1L2
60x10
1L1
60x10
C11
60x10
C12
PE
-W1
-W2
-W3
-W4
-W5
-W6
Silflex-N
NSGAFÖU
Silflex-N
H07V-K
NYM-J
NYM-J
2x1,5 mm²
3x2x1x240 mm²
2x1,5 mm²
1x120 mm²
3x1,5 mm²
3x1,5 mm²
Protect PV.500
X26
3
4
X3
U
V
W
X26
1
2
PE
E1
1(L)
2(N) PE
Power supply
Mains 2
AC 230V
02.05.2012 Songur
Date
Name
Date
02.05.2012
Editor
Songur
Checked Langer
Norm
Protect PV.500/630-MH
Basisplan
POWER SOLUTIONS
Circuit diagram
X13
Auxiliary supply
Output
230V / 400W max.
Next page
2
= PV.500/630-MH
+ STR
1000002928 STR
en
sheet
sheets
1
2
1
2
3
4
5
7
8
CAE EPLAN Electric P8
PV.500-MH
Ethernet RJ-45
System Off
Emergency shut-down
10/100 Base T
RS 485/ Modbus
PV LOG via CAT7 4x2x0,5mm² Erdkabel (Max. 80m)
X33
2
3
X91
4
This document is property of AEG Power Solutions and must not be
displayed or duplicated to any third party without the concent of the company
1
1
2
3
4
-A93
5
Mini Patch Panel
FL-PP-RJ45_SCC
8000040414
1 2 3 4 5 6 7 8
1-8
-W10
-W12
Unitronic Bus LD
CAT-5
2x2x0,22 mm²
YE
-F91
Overvoltage arrester
8000023185+
8000023186
L
H
7
Patch Cable
BN/
WH
GN
(-)
11
9
IN
-F93
Overvoltage arrester
MJ8-CAT5E (72853)
8000040413
3
13
1-8
IN
13
PE
8
L
-W7
-W8
Silflex
Silflex
2x1,5 mm²
2x1,5 mm²
H
1000002928
OUT
12
10
(-)
PE
OUT
4
1-8
-W9
-W11
Unitronic Bus LD
CAT-5
2x2x0,22 mm²
Patch Cable
YE
Stat Alteration
6
BN/
WH
GN
Protect PV.500
-X33
1
2
3
System Off
Date
Name
Date
02.05.2012
Editor
Songur
Checked Langer
Norm
4
Emergency
shut-down
-A29.1
Multicom CCC
8000012654 STR
-X5
8
3
-A27
5
-MOD1
1-8
COM-Server
8000036639
Next page
Protect PV.500/630-MH
Basisplan
POWER SOLUTIONS
Circuit diagram
= PV.500/630-MH
+ STR
1000002928 STR
en
sheet
sheets
2
2
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