PVS800-MWS Megawatt Stations: Hardware Manual
PVS800-MWS Megawatt Stations: Hardware Manual
PVS800-MWS Megawatt Stations: Hardware Manual
Hardware manual
PVS800-MWS megawatt stations
Hardware manual
PVS800-MWS megawatt stations
Table of contents
1. Safety instructions
5. Mechanical installation
6. Electrical installation
8. Start-up
Table of contents
1. Safety instructions
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Use of warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safe installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Working areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Safety instructions for the switchgear compartment . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety instructions for the transformer compartment . . . . . . . . . . . . . . . . . . . . . . . . . 12
Safety instructions for the inverter compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3. Hardware description
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Layout drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Main circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Switchgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5. Mechanical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
General guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Place the substation higher than the surroundings . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Construct a sturdy foundation for the substation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Construct an earthing electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Finalize the surroundings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Foundation option 1 Supporting the substation with gravel . . . . . . . . . . . . . . . . . . . . . 31
6
6. Electrical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Locations of the cable entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Earthing (grounding) the substation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Protective earthing (grounding) inside the substation . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Measuring the insulation resistances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Connecting the cabling from the solar generator to the inverters . . . . . . . . . . . . . . . . . 37
Connecting the control cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Connecting the power grid cabling to the switchgear . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8. Start-up
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Tools needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Start-up tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Pre-checking the switchgear (voltage not connected) . . . . . . . . . . . . . . . . . . . . . . . 42
Pre-checking the transformer (voltage not connected) . . . . . . . . . . . . . . . . . . . . . . . 42
Pre-checking the inverters (voltage not connected) . . . . . . . . . . . . . . . . . . . . . . . . . 42
Connecting the substation to the solar power generator and commissioning the inverters
42
Connecting the substation to the power grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Connecting the inverters to AC supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9. Maintenance
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Inverter compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Cleaning the inverter compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Replacing the intake air filters of the inverter compartment . . . . . . . . . . . . . . . . . . . 47
Replacing the stirrer fan in the inverter compartment . . . . . . . . . . . . . . . . . . . . . . . . 48
Replacing the UPS battery (option +G413) in the inverter compartment . . . . . . . . . 48
Transformer and switchgear compartments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Cleaning the transformer and switchgear compartments . . . . . . . . . . . . . . . . . . . . . 49
Cleaning the intake air filters on the doors of transformer compartment . . . . . . . . . 49
Replacing the intake air filters on the doors of transformer compartment . . . . . . . . . 50
Replacing the cooling fan in the switchgear compartment . . . . . . . . . . . . . . . . . . . . 51
Substation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Checking and repairing the painted surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Checking and repairing the non-painted, zinc coated surfaces . . . . . . . . . . . . . . . . . 53
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Checking and cleaning the grounding bars and points . . . . . . . . . . . . . . . . . . . . . . . . 54
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
11. Drawings
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Dimensions, layout, transportation details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Lifting drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Location of cable entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Further information
8
Safety instructions 9
1
Safety instructions
Use of warnings
Warnings caution you about conditions which can result in serious injury or death and/or
damage to the equipment, and advise on how to avoid the danger. The following warning
symbols are used in this manual:
Electricity warning warns of hazards from electricity which can cause physical
injury and/or damage to the equipment.
General warning warns about conditions, other than those caused by electricity
which can result in physical injury and/or damage to the equipment.
10 Safety instructions
WARNING! Before any work, repeat the seven steps safety precautions
described below.
Working areas
The substation is divided in to three working areas based on the precautions needed for
safe working: switchgear compartment, transformer compartment and inverter
compartment. There are separate safety instructions for each of these compartments.
Safety instructions 11
WARNING! Perform the procedure below before starting the work on the
switchgear. Ignoring the instructions can cause physical injury or death, or
damage to the equipment.
1. Identify the switchgear and read its safety instructions.
Check the operation of the capacitive voltage indicators in all switchgear bays (all
phase LEDs are switched on when voltage is connected).
2. Disconnect the switchgear from all possible power supplies (grid, solar generator and
parallel connected substations), and secure by locking and tagging.
i. Stop the inverters. Open the DC disconnecting switches [Q2] in both inverter units
([PVS1] and [PVS2]), lock and add a warning notices.
ii. Open the AC disconnecting switches [Q1] in both inverters units ([PVS1] and
[PVS2]), lock and add a warning notices.
iii. Switch off auxiliary power to both inverters.
iv. Open the breaker or fuse switch on the transformer side of the switchgear.
v. Turn the disconnecting switch on the transformer side of the switchgear (if any) to
open position. Lock and add warning notice.
vi. Disconnect the switchgear terminals from all possible external power supplies
(grid and parallel substations). See the user's manual of the feeding device. Lock
and add warning notices.
3. Check that all shrouds/screens are on place.
4. Check that you will not be near any live parts while working. Disconnect the live
circuits or protect with shrouds/screens.
5. Check that the switchgear is dead.
i. Check the status of the voltage indicators in all switchgear bays (all phase LEDs
which were on at step 1 are now switched off).
6. Earth the switchgear and inverters.
i. Turn the earthing switches of the switchgear to earthed position, lock and add
warning notices. If the substation is connected to parallel substations, make sure
that you also turn the appropriate earthing switches to earthed position.
ii. Temporary ground the switchgear terminals at all possible external power supplies
(grid and parallel substations). See the user's manual of the feeding device. Lock
and add warning notices.
iii. Temporary ground the inverter ([PVS1] and [PVS2]) AC sides with appropriate
temporary grounding set.
7. Issue a work permit.
12 Safety instructions
WARNING! Perform the procedure below before starting the work on the
transformer. Ignoring the instructions can cause physical injury or death, or
damage to the equipment.
1. Identify the transformer and read its safety instructions.
2. Disconnect the transformer from both possible power supplies (switchgear and solar
generator), and secure by locking, earthing and tagging.
i. Stop the inverters. Open the DC disconnecting switches [Q2] in both inverters
units ([PVS1] and [PVS2]), lock and add a warning notices.
ii. Open the AC disconnecting switches [Q1] in both inverters units ([PVS1] and
[PVS2]), lock and add a warning notices.
iii. Switch off auxiliary power to both inverters.
iv. Open the breaker on the transformer side of the switchgear.
v. Turn the disconnecting switch on the transformer side of the switchgear (if any) to
open position. Lock and add warning notice.
3. Check that all shrouds/screens are on place.
4. Check that you will not be near any live parts while working. Disconnect the live
circuits or protect with shrouds/screens.
5. Check that the transformer is dead (high voltage terminals, low voltage terminals, any
auxiliary power and instrumentation). Use an appropriate high voltage tester only for
the high voltage side, and multimeter with suitable testing heads for the low voltage
side.
6. Earth the transformer side of the switchgear and inverters.
i. Temporary ground the inverter ([PVS1] and [PVS2]) AC sides with appropriate
temporary grounding set.
ii. Turn the earthing switch on the transformer side of the switchgear to earthed
position, lock and equip it with a warning notice.
7. Issue a work permit.
Safety instructions 13
WARNING! Perform the procedure below before starting the work on the
inverters. Ignoring the instructions can cause physical injury or death, or damage
to the equipment.
1. Identify the inverter which you need to work on. Read the inverter safety instructions.
2. Disconnect the inverter from both possible power supplies (transformer and solar
generator), and secure by locking and tagging.
i. Stop the inverters. Open the DC disconnecting switches [Q2] in both inverters
units ([PVS1] and [PVS2]), lock and add a warning notices.
ii. Open the AC disconnecting switch [Q1] of the appropriate inverter unit ([PVS1] or
[PVS2]), lock and add a warning notice. After disconnection of the inverter, always
wait for 5 minutes to let the intermediate circuit capacitors to discharge.
iii. Switch off auxiliary power to both inverters.
iv. Open the breaker on the transformer side of the switchgear.
v. Turn the disconnecting switch at the transformer side of the switchgear (if any) to
open position. Lock and add warning notice.
vi. Disconnect all inverter DC supplies. The DC disconnectors are usually located in
the junction boxes on the solar field. Lock and add warning notices.
3. Check that all shrouds/screens are on place except the one that prevent access to the
parts that you must work on currently.
4. Check that you will not be near any live parts while working. Disconnect the live
circuits or protect with shrouds/screens.
5. Check that the circuit is dead: AC and DC terminals of the inverters and other
accessible parts in the main circuit. Use a multimeter with suitable testing heads.
6. Temporary ground the inverter.
i. Temporary ground the inverter ([PVS1] or [PVS2]) AC and DC sides with
appropriate temporary grounding set.
7. Issue a work permit.
14 Safety instructions
Safe operation
This section contains the safety instructions which you must follow when operating the
substation. If ignored, physical injury or death may follow, or damage may occur to the
equipment.
WARNING! Keep all doors of the substation locked while the substation is
operating. Allow access to the keys of each compartment to the authorized
personnel only.
Introduction to this manual 15
2
Introduction to this manual
Applicability
The manual is applicable with the PVS800-MWS substations.
Target audience
This manual is intended for persons who transport, store, plan the installation, install,
commission and maintain the PVS800-MWS substation.
Read the manual before working on the substation. You are expected to know the
fundamentals of electricity, wiring, electrical components and electrical schematic
symbols.
The manual is written for readers worldwide.
Start-up
Finalizing and checking the installation
Maintenance
Technical data
Drawings
Related documents
Document Applicability
Manuals
AC Alternating current
CCF Construction of ABB Safering switchgear. See subsection Switchgear on page 22.
CCV Construction of ABB Safering switchgear. See subsection Switchgear on page 22.
DC Direct current
DeF Construction of ABB Safering switchgear. See subsection Switchgear on page 22.
DeV Construction of ABB Safering switchgear. See subsection Switchgear on page 22.
mppt Maximum power point tracker. MPPT is a technique that solar inverters use to get the maxi-
mum possible power from solar panels.
SWG Switchgear
3
Hardware description
Overview
PVS800-MWS substation includes the equipment needed for the connection of a solar
power generator to the medium voltage power grid. The substation is built inside a
container. The main components are:
inverters which invert the direct current (DC) and voltage from the solar generator to
alternating current (AC) and voltage for the power grid. Inverters also control the
power flow, monitor and protect the power generator.
transformer which transforms low voltage from inverters to medium voltage for the
power grid.
switchgear which is the connection point to the power grid. It is also the main
protecting, switching, breaking and disconnecting equipment of the medium-voltage
side of the solar power plant.
20 Hardware description
Layout drawing
C
A B 7
1 3 4
2 9 5 9 8
Compartments:
A Switchgear compartment
B Transformer compartment
C Inverter compartment
Main components:
A 1 Switchgear
2 Lead-through holes for power grid cabling, and the terminal for the external earthing electrode
(in base plate, at end of switchgear compartment)
B 3 Transformer
C 4 Inverters
5 Lead-through holes for cabling from solar generator (on both sides of the substation)
8 Concrete base
A B C
6
Aux. voltage
Local power
transformer
enclosure
(option +G344)
3
4
2 1
No. Description
A Switchgear compartment
B Transformer compartment
C Inverter compartment
1 DC input
2 Inverters
3 Transformer
4 Switchgear
Switchgear
Substation is always equipped with ABB SafeRing switchgear. Type DeV is used as
standard but other types are also available:
DeV consists of two modules:
De is the grid-side module equipped with power cable terminals and an earthing
switch.
V is the transformer-side module equipped with the circuit breaker and an earthing
switch.
CCV consists of three modules:
C is the grid-side module with the grid cable terminals, and a disconnecting and
earthing switch.
The other C module is the grid connection point of the parallel-connected
substation.
V is the transformer-side module, equipped with the circuit breaker, and an
earthing switch.
DeF or CCF type switchgears are also possible. F stands for a switch-fuse
disconnector and an earthing switch. See the switchgear manual for more information.
The diagram below illustrates the alternative switchgear types with the types and the
option codes in a container delivery.
Transformer
See the transformer manual for information on the transformer.
Inverter
See the inverter manuals for information on the inverters.
Hardware description 23
IEC 62271-202
Serial nr: xxxxxxxxxxx
Type: PVS800-MWS-xxxxkW-zz +yyyy +yyyy
Prodyear: 2012-50
Order no: xxxxxxxxxx
AS ABB
ESTONIA
Item Description
4
Storing, lifting and transporting
Storing
To avoid any condensation inside the substation, store it indoor in a dry (heated)
warehouse. If that is not possible, supply and switch on the internal heaters to keep
the inside temperature above the temperature outside.
Place the substation on a solid, flat, dry, and vegetation-free ground. The ground must
support the substation evenly from below, ie, there must be no twisting or stress.
Place the substation on wooden support beams. Locate the beams under the lifting
points and at the middle.
Protect the interior of the substation from rain water and dust. At the minimum, cover
the air inlet and outlet gratings.
26 Storing, lifting and transporting
Lifting
Obey these instructions and the additional information given in section Lifting drawing on
page 63:
Protect the corners of the substation against shock.
Lift the substation from the lifting eyes (a). Use ring clutches TPA-R1 10.0.
Protect concrete base and substation with wooden support below the ring clutches
during lifting (b).
Use long enough spreaders (c) to avoid damage to the substation. The lifting slings
may not scratch the walls.
Adjust the lengths of the lifting slings so that the substation does not tilt during the
lifting.
WARNING! Ignoring the following instructions can cause physical injury or death,
or damage to the equipment:
a
Storing, lifting and transporting 27
Transporting
Obey these instructions and the additional information given in section Dimensions, layout,
transportation details on page 60:
Protect the substation with wooden corners, plastic film, etc. The substation is
delivered unpacked from the factory as standard.
Protect the interior of the substation from rain water and dust. At the minimum, cover
the air inlet and outlet gratings (a).
Lay the substation directly on the transportation chassis to prevent sliding and to keep
the height as low as possible. We recommend to use friction enhancement mats
(rubber) below the substation. The maximum thickness of the mat is 2 cm.
Fasten the substation firmly onto the chassis with heavy-duty transport straps. Fasten
the straps to the lifting eyes (b) with ring clutches of type TPA-R1 10.0. Alternative
fastening points (c) are on the short sides of the substation: there are Rd36 threaded
holes in which you can install suitable anchors bolts.
Warning!
Transport the substation on an open heavy-duty chassis. Do not use a closed-top
trailer. The substation always moves somewhat during the transportation, and it
might get scratched to the walls of the trailer.
Keep the transportation height as low as possible. Do not use wooden beams below the
substation during transportation. Make sure that the total height of the transportation is not
above the maximum allowed height for the planned route.
Do not throw hooks over the roof.
c b
28 Storing, lifting and transporting
Mechanical installation 29
5
Mechanical installation
General guidelines
Place the substation higher than the surroundings
Place the substation a little higher than the surroundings to prevent corrosion caused by
surface water collecting against the substation.
Tilt the surface of the surrounding ground min. 3 cm per meter. This makes sure that
there is a proper flow of the surface water away from the substation.
Height of the concrete base is 39 cm. Bury it mostly into the ground but do not allow
the ground level to reach the metal walls. The concrete base must be about 8 cm
visible.
Consider the local conditions such as frost, rain (humidity) and drought.
30 Mechanical installation
30 mm
Note:
Tilt the surface of the surrounding ground min. 3 cm per meter.
Leave the concrete base 8 cm visible.
Consider the local conditions such as frost, rain (humidity) and drought.
32 Mechanical installation
1000 mm
80 mm
30 mm
min. 200 mm
2330 mm
min. 6830 mm
Note:
Tilt the surface of the surrounding ground min. 3 cm per meter.
Leave the concrete base 8 cm visible.
Consider the local conditions such as frost, rain (humidity) and drought.
Mechanical installation 33
1000 mm
80 mm
30 mm
150 200 400
min. 1100 mm
min. 370 mm
2330 mm
Note:
Tilt the surface of the surrounding ground min. 3 cm per meter.
Leave the concrete base 8 cm visible.
Consider the local conditions such as frost, rain (humidity) and drought.
34 Mechanical installation
6
Electrical installation
Rev B
Electrical installation 37
7
Finalizing and checking the
installation
Check the earthing (grounding) of the substation and its components against the earthing
(grounding) schematic. Pull the earthing wires at the terminals to ensure that the connections are
tight.
Remove all foreign objects such as loose screws, nuts or tools from all compartments. They can
cause a short-circuit faults.
If there is sand or dirt inside the inverter, transformer or switchgear compartments, clean them. See
chapter Maintenance.
Check the main circuit clearance distances, cable terminations and connections against the main
circuit diagram. Check also that the connections have been tightened.
If there is a measuring cubicle in the switchgear, check that the instrument transformer ratios are
correct.
Check that all necessary warning labels have been attached to the substation.
Check that the insulation resistances of the external power cables have been measured.
Perform the installation checks detailed in the device specific manuals. See subsection Related
documents on page 16 for a list of manuals.
8
Start-up
Tools needed
Computer with Drive window PC tool installed (for the inverter diagnostics and
settings)
Multimeter
Current injection device (for the testing of the protection relay of the switchgear)
Insulation resistance measurement device. See section Measuring the insulation
resistances on page 37 for the measuring voltages and resistance values.
42 Start-up
Start-up tasks
Task Additional information
Operate all devices once. SF6 Insulated Ring Main Unit and Compact
Switchgear Installation and Operating
Instructions (6- 24 kV) (1VDD005976 GB)
Check the settings of protection relay are Tune the settings according to local utility grid
according to the factory test report. and the transformer type in use. Follow the
instructions in the product manual of the relay.
Protection relay REJ603: Check the condition of Self-Powered Feeder Protection REJ603 users
current transformers with multimeter. and technical manual (1MDB07208-YN).
Protection relay REJ603: Test the relay tripping. Current injection test described in the manual.
Check the insulation resistance of the transformer Measuring the insulation resistances on page 37
and its cabling if they have not been done on site
recently.
Connecting the substation to the solar power generator and commissioning the inverters
Measure the DC supply voltage level at each input
terminal of inverter [PVS1].
Ensure that all checkings required by the local Consult the local power grid owner.
power grid owner have been done.
Start-up 43
Ask the power grid owner to connect the substation Only authorized personnel is allowed to perform
to the power grid. the connection.
Wait unit the substation has been connected to the
power grid before proceeding.
Check that the voltage level on the low voltage Transformer monitoring relay and AC busbars of
side of the transformer is correct. Adjust the the inverters.
transformer tap settings if needed.
Run the transformer with no load for several hours If the ambient temperature is:
before proceeding to the tasks under the 10 C or above, run 3 hours.
subsection Connecting the inverters to AC supply.
below 10 C, run 6 hours.
Perform the rest of the inverter commissioning See PVS800-57 hardware manual
tasks (if any). (3AUA0000053689 [English]).
9
Maintenance
General
The recommended maintenance intervals and component replacements are based on
specified operational and environmental conditions. ABB recommends annual inspections
to ensure the highest reliability and optimum performance. Consult your local ABB Service
representative for more details on the maintenance.
Maintenance intervals
The table below lists the routine maintenance intervals recommended by ABB.
Maintenance task Interval Instructions
Cleaning the inverter Every 2 years See section Cleaning the inverter
compartment (First check after commission) compartment on page 47.
Replacing intake air filters on the Every 2 years See section Replacing the intake
wall and on the door of inverter (yearly check) air filters of the inverter
compartment compartment on page 47.
Replacing stirrer fan in the Every 10 years See section Replacing the stirrer
inverter compartment (yearly check) fan in the inverter compartment
on page 48.
Replacing UPS battery (option Every 5 years See section Replacing the UPS
+G413) in the inverter battery (option +G413) in the
compartment inverter compartment on page
48.
Cleaning intake air filter on the Every 2 years See section Cleaning the intake
door of transformer compartment (yearly check) air filters on the doors of
transformer compartment on
page 49.
Replacing intake air filter on the Every 5 years See section Replacing the intake
door of transformer compartment (yearly check) air filters on the doors of
transformer compartment on
page 50.
Replacing cooling fan in the Every 10 years See section Replacing the
switchgear compartment (yearly check) cooling fan in the switchgear
compartment on page 51.
General condition check, After 2 years of installation, and See the dimensional layout
checking tilting of solar station after 10 years of installation. drawing for reference
(1VPD000012X0036).
The main components of the substation have their own routine maintenance schedules in
addition to the tasks listed in the table above. See the appropriate manuals listed in
section Related documents on page 16.
Maintenance 47
Inverter compartment
Cleaning the inverter compartment
WARNING! Do the steps given in section Safety instructions for the inverter
compartment on page 13. Ignoring the instructions can cause physical injury or
death, or damage to the equipment.
WARNING! Do the steps given in section Safety instructions for the inverter
compartment on page 13. Ignoring the instructions can cause physical injury or
death, or damage to the equipment.
1. Switch off the main switch of the Local power enclosure [EAB] to cut the supply for the
inverters and their UPS battery (option +G413).
2. Open the door of the auxiliary control cubicle of the inverter cabinet. The UPS battery
(option +G413) is located on the floor.
3. Ensure by measuring that no voltage is connected to the USP battery.
4. Replace the battery by following its users guide.
Maintenance 49
WARNING! Do the steps given in section Safety instructions for the switchgear
compartment on page 11 and Safety instructions for the transformer compartment
on page 12. Use safety glasses and respiratory protector if using compressed air.
Ignoring the instructions can cause physical injury or death, or damage to the equipment.
1. Ensure that the transformer has cooled down before you proceed.
2. Use a vacuum cleaner to clean floor, doors, and interior metal beams on concrete
base. If necessary use duster or pressured air as help around corners with no proper
access with vacuum cleaner.
3. Clean the surface of the transformer with a duster. In case of lot of dust, use
compressed air for cleaning the transformer.
4. Clean the insulators of the transformer with ethanol.
1. Blow compressed air gently from inside to outside through the filter until the dust will
come off.
50 Maintenance
WARNING! Do the steps given in section Safety instructions for the transformer
compartment on page 12. Ignoring the instructions can cause physical injury or
death, or damage to the equipment.
WARNING! Do the steps given in section Safety instructions for the switchgear
compartment on page 11. Ignoring the instructions can cause physical injury or
death, or damage to the equipment.
1. Switch off the circuit breaker supplying power supply for the cooling fan in the
switchgear compartment. The circuit breaker is located in the local power enclosure
[EAB] in the inverter compartment. Prevent the accidental switch-on of the breaker
during the maintenance procedure.
2. Check by measuring that no voltage is connected to the fan.
3. Replace the fan and power it up.
4. Check that fan blows air to right direction. Use temperature controller of the
transformer [ETT] to start the fan temporarily (enable the fan relay test). The fan
rotates to right direction if air flows out from the switchgear compartment. Change the
direction of the fan when necessary.
52 Maintenance
Substation
Checking and repairing the painted surfaces
Materials
Sand paper
Cleaning towels and liquids
Primer below paint on rusted or/and scratched surfaces: Hempel zinc primer 16490 or
Wrth Rost Stop 0890 191 (or similar)
Finishing paint: Hempel Hempathane HS 55610 two-component polyurethane paint
(or similar)
Paint colors: See Paint colors on page 56.
Note! Obey the instructions given by the material manufacturers.
Procedure
WARNING! Do the steps given in section Safety instructions for the switchgear
compartment on page 11. Ignoring the instructions can cause physical injury or
death, or damage to the equipment.
If there is lost finishing paint but no damage to the metal beneath or no rust visible:
1. Clean the damaged area with suitable detergent followed by a water clean.
2. Let the surface dry completely and keep it clean.
3. Cover the damaged area with the finishing paint.
If there are scratches and bare metal or rust visible (see a in figure below):
1. Remove rust gently with sand paper.
2. Clean the damaged area and its surrounding.
3. Coat the damaged area with primer. Let it dry thoroughly.
4. Add top paint on the damaged area.
Lost paint but no damage beneath it Scratch to the metal and rust
a
Maintenance 53
Procedure
WARNING! Do the steps given in section Safety instructions for the switchgear
compartment on page 11. Ignoring the instructions can cause physical injury or
death, or damage to the equipment.
Pay special attention on doors and lower parts of the walls. Those areas have potentially
corrosive elements like dust and humidity.
1. If there is rust, remove the rust gently with sand paper.
2. Clean the damaged area and its surrounding.
3. Coat the damaged area with zinc coat. Wrth Zinc 300 preferred due to thicker coat.
On larger areas Wrth Zinc Spray Perfect can be used to speed up the work and to do
even better looking surface.
54 Maintenance
Procedure
WARNING! Do the steps given in section Safety instructions for the switchgear
compartment on page 11 and Safety instructions for the transformer compartment
on page 12. Ignoring the instructions can cause physical injury or death, or
damage to the equipment.
10
Technical data
Technical data
PVS800-MWS-1000kW-20 PVS800-MWS-1250kW-20
Central inverter type PVS800-57-500kW-A PVS800-57-630kW-B
Ratings: Input data (DC)
Temp 40 C 40 C
PPV, MAX [kWp] 2 600 2 750
UDC, mpp [V DC] 450825 525825
UDC, max [V DC] 1000 1000
IDC, max [A DC] 2 1145 2 1230
UPV, ripple [%] <3 <3
Number of inputs 2 8 (+/-) 2 8 (+/-)
Number of mppt trackers 2 2
Ratings: Output data (AC)
Temp 40 C 40 C
PAC, N [kW] 1000 1250
IAC, N [A AC] 28.9 36.1
UAC, N [V AC] 20000 20000
fN [Hz] 50/60 50/60
Harmonic distortion [%] <3 <3
56 Technical data
PVS800-MWS-1000kW-20 PVS800-MWS-1250kW-20
Auxiliary power
Allowed electrical system type 400 V 3-phase TN-S 400 V 3-phase TN-S
Terminal size (per conductor) [mm2] 16 16
Aux power, running (without options) [W] <1140 <1140
Aux power, standby (without options)) [W] <150 <150
Additional max. heating power [W] 2200 2200
Efficiency
hmax [%] 97.8 97.8
heuro [%] 97.1 97.3
(at minimum mppt DC voltage, standard transformer,
no auxiliary power included)
Cooling
Inverter compartment cooling air flow [m3/h] 6720 6720
Inverter cooling method Forced air cooling Forced air cooling
Transformer and switchgear cooling method Natural cooling Natural cooling
Dimensions and weight
Width / Height / Depth [mm] 6930 / 3070 / 2430 6930 / 3070 / 2430
Weight [tons] approx. 20 approx. 21
Power cable lead-through and
terminals
Switchgear compartment See Drawings on page 59. See Drawings on page 59.
Inverter compartment See Drawings on page 59 See Drawings on page 59
and the inverter hardware and the inverter hardware
manual. manual.
Cable lead-through type HSI-150 system covers. HSI-150 system covers.
See Dimensions, layout, See Dimensions, layout,
transportation details on transportation details on
page 60. page 60.
Paint colors
Walls RAL 7035 (light beige, RAL 7035 (light beige,
semigloss) semigloss)
Roof RAL 7012 RAL 7012
Degree of protection and ambient
conditions
Degree of protection IP54 (inverter compart.) / IP54 (inverter compart.) /
IP23d (other compart.) IP23d (other compart.)
Ambient temperature range (max.) [C] -1540 (50) no frost -1540 (50) no frost
allowed. See Derating allowed. See Derating
below. below.
Relative humidity [%] 15 to 95%, no condensation 15 to 95%, no condensation
allowed allowed
Highest altitude (max.) [m] 1000 (2000). See Derating 1000 (2000). See Derating
below. below.
Corrosivity category of environment C4 (EN ISO 12944-2) C4 (EN ISO 12944-2)
Fuses and protection relays
Main circuit AC protection relay REJ603-CT2 REJ603-CT2
Inverter DC fuses (option+8H382) See inverter manual See inverter manual
Technical data 57
PVS800-MWS-1000kW-20 PVS800-MWS-1250kW-20
Applicable standards
Sub-station IEC 62271-202 High-voltage/low-voltage prefabricated
substation
Transformer IEC 60076-11 Power Transformers, DIN EN 60076-11,
VDE 0532-76-11
Switchgear IEC 60694 Common specifications for high-voltage
switchgear and controlgear standards,
IEC 62271-100 High-voltage switchgear and controlgear -
Part 100: High-voltage alternating-current circuit-s,
IEC 62271-102 High-voltage switchgear and controlgear -
Part 102: Alternating current disconnectors and earthing
switches,
IEC 62271-105 High-voltage switchgear and controlgear -
Part 105: Alternating current switch-fuse combinations,
IEC 62271-200 High-voltage switchgear and controlgear -
Part 200: A.C. metal-enclosed switchgear and controlgear
for rated voltages above 1 kV and up to and including 52
kV,
IEC 60265-1 High-voltage switches- Part 1: Switches for
rated voltages above 1 kV and less than 52 kV,
IEC 60529 Degrees of protection provided by enclosures
(IP code)
Inverter See PVS800-57 hardware manual (3AUA0000053689
[English]).
Product compliance
Safety and EMC CE conformity According to LV and EMC directives
Grid compliance According to country requirements
Cable lead-through data See chapter Drawings.
Derating
In altitude from 1000 to 2000 m (3300 to 6600 ft) above sea level, the derating is 1% for every 100 m (328 ft).
If the installation site is above 2000 m (6600 ft) above sea level, contact your ABB distributor or office for
further information.
In temperature range +40 C (+104 F) to +50 C (+122 F), the nominal output current must be derated 2% for
every additional 1 C (1.8 F). The output current is calculated by multiplying the nominal current by the
derating factor.
Example: If the ambient temperature is +50 C (+122 F), the derating factor is 100% - 2%/C 10 C = 80%
or 0.80. The actual output current is then 0.80 Nominal output current.
110
Derated output current
100
(% nominal value)
90
80
70
25 30 35 40 45 50
Temperature C
58 Technical data
Drawings 59
11
Drawings
60 Drawings
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Max 60
Min 3200mm
Max 4200mm
Lifting drawing
1165mm
45,9in
3412mm
134,3in
33,5in
850mm
33,5in
850mm
Note:
- The center of gravity of the lifted station shall be exactly below the hook of the crane. This is done by adjusting the individual
lengths of the lifting chains accordingly. Total weight: 20000kg*
- Lifting equipment Frimeda Transport Anchor System from HALFEN is to be used. Valid only with ABB DTE 1000 or DTE 1250
The lifting equipment is fastened to the lifting eyes by means of ring clutches type TPA-R1 10.0 valid only with ABB DTE 1250 transformer installed
*transformers
- In order to avoid any unnecessary stress and twisting of the enclosure it is very important that all four lifting chains
engage the load at the same time.
Name / Material Length Width Consumpt Item no. Weight
- The length of the lifting chains is to be adjusted so that the substation does not tilt more than 3 during lifting. Surface Scale Basic tolerances
Control Department
- Lifting equipment shall match, and fulfil needs for total lifting weight. 1:25 ISO 2768-m
Drawn Responsible Department Title
29.11.2011 ROION LAKE
POWER IT, CSS
Approved Revision New Department
7.22 x 2114 Country Code
- Important: Ensure personnel safety during lifting by using authorized lifting equipment and preventing anybody getting MWS Lifting Instruction
Drawings 63
EE
Changed Pages
under the load. Draw. no / Doc. no.
1
Page no.
ABB Technology Ltd 1VPD000008 1
We reserve the rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden. Copyright 2005 ABB
64 Drawings
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