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VC WL series EU type Operating manual Instrucciones de servicio Manuale di servizio Manuel de service Table of contents 1 1.1 1.2 1.3 1.4 1.5 2 2.1 2.2 2.3 2.4 2.5 3 3.1 3.2 3.2.1 3.2.2 3.3 3.3.1 3.3.2 3.3.3 3.4 3.5 3.5.1 3.5.2 3.6 3.6.1 3.6.2 DO_BA_2009_1ENG_DVo 02.10.2009 4 4.1 4.2 4.3 4.4 4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.4.6 4.4.7 4.5 4.6 Introduction 3 Brief description Intended use Standards and directives About this manual Environmental information 3 3 3 4 4 Safety 5 Responsibilities of the operator Responsibilities of the electrician Responsibilities of the crane driver Responsibilities of the industrial truck driver Basic safety instructions 5 6 7 8 9 Technical description 13 Scope of supply Block diagram Voltwerk VC WL 110–280 Voltwerk VC WL 300 Interior view Voltwerk VC WL 110 Voltwerk VC WL 280 Voltwerk VC WL 300 Surge voltage protection Control cabinet Sine card AC cards Front door Integrated On/Off switch LED indicators 13 13 13 14 14 15 16 18 19 19 21 22 22 22 23 Installation location 25 Operating area Foundation Ventilation Electrics DC-side Auxiliary power supply AC-side Disconnecting devices Residual current protection (RCD) Medium voltage transformer for Voltwerk VC WL 300 Grid characteristic Lightning protection plan Notes on transport 25 27 28 31 32 32 32 33 34 34 35 38 38 Voltwerk VC WL series EU model Operating manual ENGLISH Table of contents 1 Table of contents 5 ENGLISH 5.1 5.2 5.3 5.3.1 5.3.2 5.4 5.5 5.6 5.7 5.8 6 6.1 6.2 7 7.1 7.2 7.3 7.4 8 8.1 8.2 8.3 8.4 8.5 8.6 9 41 41 41 43 43 45 48 48 49 49 52 Commissioning 55 Filling out the commissioning report Putting the device into operation 55 56 Maintenance 59 Maintenance interval Safety instructions Check the device when disconnected Measurements 59 59 61 66 Troubleshooting 69 Fault report LED indicators on the front door LED indicators for sine card LED indicators for AC cards Delays Manufacturer's service centre 69 70 72 72 73 74 Repairs 75 Safety information Fuse replacement LV HRC fuses Surge voltage protection device Glass cartridge fuse 75 76 76 76 77 Commissioning report 79 Specifications 85 Efficiency curves with various input voltages 88 DO_BA_2009_1ENG_DVo 02.10.2009 9.1 9.2 9.2.1 9.2.2 9.2.3 Installation Requirements Connecting the solar generator Connecting the grid Voltwerk VC WL 110–280 Voltwerk VC WL 300 Connecting the auxiliary power supply Fitting cable strain relief Connecting the monitoring system Changing grid characteristics using DIP switches (optional) Measurements 2 Operating manual Voltwerk VC WL series EU model 1 Introduction Introduction 1.1 ENGLISH 1 Brief description Voltwerk VC WL series EU model central inverters convert the direct voltage output from solar generators into grid-compliant alternating voltage and feed it as three-phase current into the public power grid. Voltwerk VC WL series EU model central inverters can be combined in order to generate a high power output. Voltwerk VC WL 110–280 Voltwerk VC WL 110–280 central inverters are equipped with transformers which transmit the energy produced. Voltwerk VC WL 300 The Voltwerk VC WL 300 is a transformerless central inverter. This results in a divergent voltage of 270 V, unlike the Voltwerk VC WL 110–280 central inverters. Monitoring, communication 1.2 The SmartControl monitoring unit is connected to the device's internal interface via a CAN converter. Operating data and system messages are communicated to the internet via ethernet, telephone line or GSM connection. The data can be viewed and analysed either on the Voltweb online portal or on the ControlCenter. For details, see the website of the manufacturer (www.voltwerk.com). Intended use Voltwerk VC WL series EU model central inverters are designed exclusively for converting direct current into alternating current in photovoltaic systems. Any other use shall be deemed not to be as intended. The inverter may only be installed and operated in accordance with the operating conditions and requirements (see chapter 4, page 31). Unauthorised modifications to the device which have not been tested and approved by the manufacturer are not permitted. DO_BA_2009_1ENG_DVo 02.10.2009 Intended use also includes compliance with the specifications of this Operating manual. Voltwerk VC WL series EEG model central inverters are approved for use exclusively in the Federal Republic of Germany. The technical documentation for this device is supplied solely in German. 1.3 Standards and directives The enclosed EC declaration of conformity lists the EU standards and directives satisfied by the device. Information on country-specific standards and directives complied with is published on the manufacturer's website (www.voltwerk.com). Voltwerk VC WL series EU model Operating manual 3 1 Introduction 1.4 About this manual ENGLISH Please provide us with feedback if you have any questions, comments or criticisms regarding this manual. Contact details can be found on the back of the manual. Subject of this manual This manual covers the transport, assembly, installation, commissioning and repair of the Voltwerk VC WL series EU model. User group This operating manual is intended to be used by Electrician appointed by the operator. Aid to orientation The following aids will assist you in finding your way around this manual: Text formatting Descriptions for LED indicators in the text appear in bold. Item numbers appear as (1), (2), (3). Symbols Denotes the start of a procedure with a description of its objective. This is followed by individually numbered steps, which may be interspersed with background information, illustrations, or warning instructions. Denotes important background information for operational procedures. 1.5 Environmental information DO_BA_2009_1ENG_DVo 07.01.2010 Voltwerk VC WL series EU model products consist of materials which can be recycled to recover the raw materials. The device, its accessories, and its packaging should therefore be recycled in an environmentally responsible manner. 4 Operating manual Voltwerk VC WL series EU model 2 Safety Safety 2.1 ENGLISH 2 Responsibilities of the operator DO_BA_2009_1ENG_DVo 02.10.2009 The operator must ensure that: | applicable industrial safety regulations, professional association regulations and technical regulations are complied with; | the specified photovoltaic system safety equipment is fully functional; | a second person is present during all work on the electrical system. In the event of an unforeseen electrical accident, that person must be able to switch off the power supply and provide assistance; | any work involving the transport, assembly, installation, commissioning and repair of the device is carried out only by an authorised specialist; | persons commissioned to perform the work can evaluate their assigned tasks and recognise possible risks; | warning instructions on the device which have become illegible are replaced as soon as possible; | the device is installed and operated in an enclosed area, identified with the appropriate warning and safety symbols; | access to the operating area is only granted to persons authorised by the operator; | the operating area is kept free of combustible or explosive materials and aggressive, caustic or corrosive gases; | a device is not used if it is defective; | no unauthorised changes are made to the device; | the specifications (see Chapter Specifications, page 85) and operating conditions (see chapter 4, page 25) are adhered to; | only qualified crane operators are allowed to lift the device by crane; | only qualified drivers are allowed to transport the device on an industrial truck; | in accordance with its weight, the device is only transported or lifted using an industrial truck or crane; | any routes along which the device will be transported are able to bear the weight of the device and of the industrial truck or crane; | modifications and servicing on the device are only carried out by employees from the manufacturer or by personnel authorised by the manufacturer; | maintenance work, including fan replacement, is performed on a regular basis; | an adequate residual current protection system (e.g. an RCD), which is suited to the location, is in place and is used; | an adequate lightning protection plan, which is suited to the location, is in place and is used; Voltwerk VC WL series EU model Operating manual 5 ENGLISH 2 Safety 2.2 | the device is always switched off before a medium voltage transformer is switched off; | the instruction manual and, in particular, the safety instructions are read and understood by any persons commissioned to perform tasks; | the instruction manual is available during transport, assembly, installation, commissioning and repair; | the instruction manual is kept in the immediate vicinity of the device; | the required grid configuration is ensured (see chapter 4.4, page 31); | the grid characteristics are set correctly, in accordance with locationspecific requirements (see chapter 5.7, page 49); | changes to the grid characteristics are discussed with the energy supplier in question. Unauthorised changes to the settings may lead to malfunctions, losses in yield or to loss of feed-in licence. Responsibilities of the electrician 6 the general information, step-by-step instructions and, in particular, the safety instructions regarding assembly and installation are read in their entirety before commissioning and before closing the disconnectors, and are followed at all times; | the Voltwerk VC WL 110–280 is only operated in Terre Neutre (TN) networks or Terre Terre (TT) networks; | the Voltwerk VC WL 300 is only operated in Isolé Terre (IT) networks. This involves ensuring that the IT network is an unearthed network and is earthed if an earth fault occurs; | the external low-voltage distribution board is capable of switching off the combined currents of all central inverters which have been connected; | the device is never opened during operation; | all plexiglass covers are fitted. The plexiglass covers serve the dual purposes of safety and ventilation. They guide the air into and distribute it around the device; | the safety devices and warning instructions on the device are used/ observed; | before any electrical work is performed, suitable measuring equipment is used to ensure that the device is fully deengergised, both in the DC and AC settings, in accordance with applicable directives. N.B. On photovoltaic systems, the power source is always active during the hours of daylight; | no safety devices are removed or disabled; | inserted connecting cables are adequately secured by cable strain relief (attached to a cable mounting rail). Connecting cables which are not strain-relieved may be damaged or completely pulled out, causing considerable material damage to persons or property; | measurements are only taken with suitable measuring equipment which conform with applicable standards and directives. Before carrying out the measurement, read the operating manual for the measuring equipment; Operating manual Voltwerk VC WL series EU model DO_BA_2009_1ENG_DVo | 02.10.2009 The electrician must ensure that: 2 Safety the device is secured by means of a built-in lock and may only be opened using the key supplied with the device; | all external and internal disconnectors are opened before commencing work on the device. ENGLISH 2.3 | Responsibilities of the crane driver The crane operator must ensure that: | crane operation is halted if: | the load cannot be securely held and safely removed due to the influence of the wind; | faults occur which compromise operational safety; all emergency limit switches and brakes have been tested before operating the crane; | only crane hooks which have a safety catch are used and that these have been regularly tested; | crane cables have been maintained and checked for damage; | the crane has been securely set up; | the weight and centre of gravity have been determined before the load is attached (rated capacity limiter must not be used as a balance); | the load is not picked up by retracting the boom after the rated capacity limiter has been activated; | persons to give instructions have been posted if the crane driver does not have a clear view of the load. predetermined hand signals or a radio are used for communication between operator and instructor(s); | loads which have been attached by hand are not raised until a hand signal is given; | long loads which may become caught on other objects during transportation are controlled with guide cables; | loads are not allowed to tilt or swing backwards and forwards; | loads which are trapped are not pulled free by the crane; | no persons are carried together with the load or with the load lifting gear; | the danger area of the crane is clearly identified; | loads are not left hanging on an unmanned crane; | loads are not lifted over the heads of other workers. DO_BA_2009_1ENG_DVo 02.10.2009 | Voltwerk VC WL series EU model Operating manual 7 2 Safety 2.4 Responsibilities of the industrial truck driver The driver must ensure that: transport is halted if: | the load cannot be securely held due to the influence of the wind; | faults occur which endanger operational safety; | all emergency limit switches and brakes have been tested before transport; | the industrial truck has no faults; | fork arms used for lifting are at the same height; | the lifting chains are equally tensioned; | restraint systems are used where available; | the industrial truck is loaded in such a way that the driver has a clear view of the route ahead; | the industrial truck is not overloaded; | the industrial truck is loaded in such a way that loads cannot fall off or shift; | the industrial truck is only driven with the lifting boom inclined backwards; | when travelling on slopes and inclines the load is carried facing the gradient; | persons have been posted to give instructions if the driver does not have a clear view of the route ahead or the load; predetermined hand signals or a radio are used for communication between operator and instructor(s); | vehicles are only loaded or unloaded by the industrial truck if they have been secured against rolling and tilting; | no persons are endangered when the industrial truck is in motion; | loads are not deposited in traffic routes and escape paths or in front of safety equipment and operating equipment which must remain accessible at all times; | no persons are carried together with the load or with the industrial truck; | loads are not transported over the heads of other workers; | a protective beam has been fitted to the fork arms when the truck is travelling unloaded; | if necessary, the base panel of the device is removed during transport. DO_BA_2009_1ENG_DVo 02.10.2009 ENGLISH | 8 Operating manual Voltwerk VC WL series EU model 2 Safety 2.5 Basic safety instructions Risk of fatal injury due to high voltages | Cover or shield any adjacent live components. N.B. On photovoltaic systems, the power source is always active during the hours of daylight. | Before starting any work on electrical systems: | Disconnect the system | Ensure that it is secured against being switched back on | Verify that the system is fully deenergised | Earth and short-circuit the system Risk of fatal injury due to residual voltages Residual voltages inside the device can result in fatal surges. Capacitors may be charged even after the device is switched off. When Voltwerk VC WL series EU model central inverters are disconnected via the On/Off switch, voltage is still present at the AC and DC connections. The On/Off switch is not a DC disconnector. | Open all external and internal disconnectors and secure them against being switched back on. | After switching off the device, always wait for a period of 8 minutes before touching. | A suitable measuring instrument should be used to verify that the device is deenergised, in accordance with applicable guidelines. Risk of fatal injury from arcing and short circuit currents Very high DC voltages (no zero point) may exist in photovoltaic systems, which could cause arcing in the event of faults or if components such as fuses or plugs are not used in the specified manner. The short circuit current of the solar generator is only slightly higher than the maximum operating current and is always dependant on current irradiation levels. This means that, where short circuits occur, there is no definite guarantee that circuit breakers will be tripped. | Use components in the correct manner. DO_BA_2009_1ENG_DVo 02.10.2009 Risk of fatal injury from magnetic and electromagnetic fields Magnetic and electromagnetic fields may result in serious damage to health for persons wearing a pacemaker, with metallic implants or who use a hearing aid. | Persons wearing a pacemaker, with metallic implants or who use a hearing aid are forbidden to enter the operating area. Risk of fatal injury through disregard of safety instructions If the sequence of steps for installation and the safety instructions are not followed, the device may be permanently damaged and electrical accidents may occur with serious health consequences. Voltwerk VC WL series EU model Operating manual 9 ENGLISH Death or serious injury could result when working on high-voltage and high-current electrical systems and live parts. 2 Safety | Observe the sequence of procedure steps for installation and follow the safety instructions. Risk of fatal injury due to lack of assistance ENGLISH In the event of an accident a second person can lend assistance. | Only carry out work if a second person is present. Risk of injury due to high temperatures The components of the product may reach temperatures of up to 150 °C, which can cause serious burns. | After switching off the product, wait for an appropriate period before touching. | Do not touch hot components. Material damage due to foreign objects Foreign objects such as film, plastic bags and pieces of paper may be sucked in by the fans, putting the product at risk. Foreign objects stored in the operating area may obstruct the ventilation equipment, putting the product at risk. This may lead to losses in yield and damage to the device. | Keep the operating area dry, clean and free of foreign objects. | Keep the operating area free of combustible or explosive materials and aggressive or corrosive gases. Material damage due to differing specifications The product is designed exclusively for operation in line with the specifications. Use under other conditions may cause damage to the product and may lead to losses in electricity fed into the grid. | Observe the specifications. Material damage due to loose screw connections Before commissioning, check that all screw connections are tightened to the correct torque and retighten where necessary. | Do not treat nuts and bolts, either with grease or in any other way. Warning instructions Warning instructions identify information relating to safety. They consist of the following: 10 | Warning symbol (pictogram), | Indicator word to denote the level of risk, | Details of the nature and source of the risk | Details of the possible consequences if warning instructions are disregarded, Operating manual Voltwerk VC WL series EU model DO_BA_2009_1ENG_DVo | 02.10.2009 If the specified tightening torques are not observed, the screws may become loose as a consequence of vibration in the terminal blocks. Loosened screw connections change the resistance and the conductivity at the connection. Operation of the central inverter can be adversely affected and it may suffer damage. 2 Safety | Measures for averting the risk and preventing injury or material damage. The warning instructions are classified according to the following levels of risk: WARNING Denotes an extraordinarily hazardous situation. Disregard of this instruction will lead to serious, irreversible injury or death. ENGLISH DANGER Denotes an extraordinarily hazardous situation. Disregard of this instruction may lead to serious, irreversible injury or death. Denotes a hazardous situation. Disregard of this instruction may lead to slight or moderate injury. NOTICE Denotes a risk of material damage. Disregard of this instruction may lead to material damage. DO_BA_2009_1ENG_DVo 02.10.2009 CAUTION Voltwerk VC WL series EU model Operating manual 11 DO_BA_2009_1ENG_DVo 02.10.2009 ENGLISH 2 Safety 12 Operating manual Voltwerk VC WL series EU model 3 Technical description Technical description 3.1 ENGLISH 3 Scope of supply | Central inverter | Terminating resistor 120 !"#0.25 W | 2 bus plugs in the housing | Energy supplier's signal cable (pre-assembled), length = 10 m | Control cabinet key | Operating manual | Manufacturing test certificate | EC declaration of conformity Completeness Check the scope of supply for completeness immediately on receipt. If the scope of supply is incomplete, contact the manufacturer (contact details on the back of the manual). Transportation damage If you discover damage which has occurred during transportation, contact the manufacturer (contact details on the back of the manual). All electrical screw connections were marked during manufacturing. This makes it easy to recognise if one of these connections has become lose. If any of the device's screw connections are loose, contact the manufacturer (contact details on the back of the manual). Storage Packaging material 3.2 Take the packaging material to an environmentally-friendly recycling facility. Block diagram Voltwerk VC WL 110–280 Voltwerk VC WL 110–280 central inverters are equipped with an integrated transformer to transmit the energy produced. Voltwerk VC WL 110–280 central inverters are designed to be connected to TN (Terre Neutre) networks and TT (Terre Terre) networks. DO_BA_2009_1ENG_DVo 02.10.2009 3.2.1 The device should be stored at an ambient temperature between –20 and +50 °C. The device packaging is not weatherproof. Only store the packaged device in enclosed spaces, which are free of aggressive or corrosive gases, vapours or dust. Voltwerk VC WL series EU model Operating manual 13 3 Technical description 1~ 230V DC 493 – 965V DC Filter ȝ& >f / <f / >U /<U ENGLISH MPP / >U / >I U 3~ + N 400V AC Filter DC ISO U U Filter 3.1: 3.2.2 Voltwerk VC WL 110–280: Block diagram Voltwerk VC WL 300 The Voltwerk VC WL 300 central inverter is an inverter without an integrated transformer which means there is no galvanic isolation between the solar generator and the electricity grid. In this case, galvanic isolation is provided exclusively by the medium voltage transformer. The interlinked output voltage is 270 V (156 V phase conductor to neutral conductor). Voltwerk VC WL 300 central inverters are designed for grid connection to a medium voltage transformer and may only be operated in IT (Isolé Terre) networks. 1~ 230V DC 530 – 965V DC Filter ȝ& >f / <f / >U /<U MPP / >U / >I U 3~ + N 270V AC Filter DC ISO U U 3.3 Voltwerk VC WL 300: Block diagram Interior view Depending on the revision status of the inverter in question, the interior structure may differ from that shown in the following diagrams. The arrangement of the components is basically the same. 14 Operating manual Voltwerk VC WL series EU model DO_BA_2009_1ENG_DVo 3.2: 02.10.2009 Filter 3 Technical description Voltwerk VC WL 110 ENGLISH 3.3.1 (1) (12) (2) (3) (4) (5) (11) (6) (10) (7) (9) DO_BA_2009_1ENG_DVo 02.10.2009 3.3: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (8) Voltwerk VC WL 110 interior view LV HRC disconnector for surge voltage protection LV HRC disconnector AC output Auxiliary power supply connections L, N, PE Surge voltage protection arrester, type II AC connection bar L3 AC connection bar L2 AC N connection bar AC connection bar L1 AC PE connection bar DC – connection bar DC + connection bar DC power circuit breaker Voltwerk VC WL series EU model Operating manual 15 3 Technical description Voltwerk VC WL 280 ENGLISH 3.3.2 (1) (2) (3) (4) (5) (11) (12) (8) (10) 3.4: (1) 16 (9) Voltwerk VC WL 280 interior view LV HRC disconnector for surge voltage protection Operating manual Voltwerk VC WL series EU model DO_BA_2009_1ENG_DVo (7) 02.10.2009 (6) 3 Technical description ENGLISH LV HRC disconnector AC output DC power circuit breaker Surge voltage protection arrester, type II Auxiliary power supply connections L, N, PE DC + connection bar DC – connection bar AC PE connection bar AC connection bar L3 AC connection bar L2 AC connection bar L1 AC N connection bar DO_BA_2009_1ENG_DVo 02.10.2009 (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) Voltwerk VC WL series EU model Operating manual 17 3 Technical description Voltwerk VC WL 300 ENGLISH 3.3.3 (1) (2) (3) (6) (10) (8) (11) (9) 3.5: 18 (7) Voltwerk VC WL 300 interior view Operating manual Voltwerk VC WL series EU model DO_BA_2009_1ENG_DVo (5) 02.10.2009 (4) 3 Technical description 3.4 LV HRC disconnector for surge voltage protection DC power circuit breaker Surge voltage protection arrester, type II Auxiliary power supply connections L, N, PE DC + connection bar DC – connection bar AC PE connection bar AC connection bar L3 AC connection bar L2 AC connection bar L1 AC N connection bar ENGLISH (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) Surge voltage protection Protection range Surge voltage protection AC side Type II Auxiliary power supply Type II DC side Basic protection Depending on the local lightning protection situation, the main low voltage distribution board and the DC connection may need to be fitted with type I or type II arresters (see chapter 4.5, page 38). 3.5 Control cabinet DO_BA_2009_1ENG_DVo 02.10.2009 Depending on the revision status of the inverter in question, the interior structure of the control cabinet may differ from that shown in the following diagram. The layout is basically the same. The number of components (e.g the coupling relay) is determined by the power class of the inverter. Voltwerk VC WL series EU model Operating manual 19 3 Technical description ENGLISH (12) (1) (11) (2) (10) (9) (3) (4) (5) (6) (7) (8) 20 Coupling relay (number dependent on power class) Isolation amplifier (only on Voltwerk VC WL series EEG model) Frequency transducer (only on Voltwerk VC WL series EEG model) DC card AC card 1 AC card 2 AC card 3 Sine card LOGO PLC (only on Voltwerk VC WL series EEG model) Power supply unit T3 Power supply unit T4 Fuse clips for grid monitoring and auxiliary power supply Operating manual Voltwerk VC WL series EU model 02.10.2009 (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) Control cabinet DO_BA_2009_1ENG_DVo 3.6: 3 Technical description Circuit board Description and roles Reverse wiring# (not pictured) | | DC card | | Regulates the intermediate circuit voltage Analyses DC surge voltage events AC cards 1 to 3 | Each of the three cards is responsible for one phase. They work independently of each other. Regulate AC voltages and AC currents. | CPU card # (not pictured) | | Processes all values and information Regulates and controls individual components Sine card | Checks the direction of the supply network's rotary field Measures the frequency and compares it with the specified reference frequency Checks frequency tolerances If all the measured values are within specifications, issues approval for connection to the grid | | | 3.5.1 Acts as an interface between hardware and software, and as a holder for additional circuit boards All input and output signals are routed via this circuit board. Interface card # (not pictured) | Acts as a connection to external systems (e.g. monitoring unit, Service laptop) Power supply unit T3 | Supplies the electronic equipment, current sensors, LED indicators (front door) and the relay Power supply unit T4 | Supplies the electronic equipment, output stage, if applicable LOGO PLC, frequency transducer Sine card Top LED Centre LED Grid synchronous Phase sequence (rotary Voltage field) Response from the AC cards DO_BA_2009_1ENG_DVo 02.10.2009 Three LED indicators are visible on the right of the sine card circuit board. They light up when the inverter is in feed-in mode. Voltwerk VC WL series EU model Operating manual Bottom LED 21 ENGLISH Roles of the different circuit boards 3 Technical description 3.5.2 AC cards Numbering from left to right LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED colour Yellow Yellow Yellow Green Red Green Meaning if LED lit Overcurren AC surge voltt age, primary side AC surge voltage, secondary side Min. AC Fault voltage in normal operation 3.6 3.6.1 Normal grid operation Front door Integrated On/Off switch The On/Off switch integrated into the front door disconnects the central inverter in question from the auxiliary power supply (AC grid). In the process, activation of the central inverter is interrupted. The central inverter is disconnected from the AC grid. Display Meaning 0 Device disconnected from the auxiliary power supply I Device ready for operation Risk of fatal injury due to residual voltage | Open all external and internal disconnectors and secure them against being switched back on. | A suitable measuring instrument should be used to verify that the device is deenergised, in accordance with applicable guidelines. The option also exists to install an additional external On/Off switch outside of the operating area. This switch is integrated into the external auxiliary power supply. The external On/Off switch disconnects the central inverter from the auxiliary power supply (AC grid). In the process, activation of the central inverter is interrupted. The central inverter is disconnected from the AC grid. 22 Operating manual Voltwerk VC WL series EU model 02.10.2009 When Voltwerk VC WL series EU model central inverters are disconnected via the On/Off switch, voltage is still present at the AC and DC connections. N.B.: The On/Off switch is not a DC disconnector. DO_BA_2009_1ENG_DVo ENGLISH Six LED indicators are visible on each of the three identical AC cards. These are numbered from left to right. During normal operation LEDs 4 and 6 light up. 3 Technical description 3.6.2 LED indicators ENGLISH Each device has four LED indicators on its front door. These may light up or flash. For information on the LED indicators' various flashing codes, (see chapter 6, page 55 and chapter 8.2, page 70. Indicator Meaning Status of mains voltage SG Status of solar generator voltage and output Grid Status of grid connection Fault Malfunction indicator DO_BA_2009_1ENG_DVo 02.10.2009 On Voltwerk VC WL series EU model Operating manual 23 DO_BA_2009_1ENG_DVo 02.10.2009 ENGLISH 3 Technical description 24 Operating manual Voltwerk VC WL series EU model 4 Installation location Installation location ENGLISH 4 When selecting an installation location, note the following: 4.1 | Transient emissions (acc. to DIN EN 61000-6-4:2007-09) | Interference resistance (acc. to DIN EN 61000-6-2:2006-03) | Noise emissions from the device (< 75 dB or < 85 dB) | Required grid quality (acc. to DIN EN 61000-3-11:2001-04 and DIN EN 61000-3-12:2005-09) Operating area Voltwerk VC WL series EU model central inverters may only be installed in enclosed operating areas. Requirements | Dry | Flat | Flame retardant | Non-slip | Clean | Free of foreign objects Foreign objects such as film, plastic bags and pieces of paper may be sucked in by the fans, putting the device at risk. | Free of combustible and explosive materials | Lockable and only accessible to persons authorised by the operator | Raised floor for ventilation or base fitted with a grille to prevent access | Cooling system fitted DO_BA_2009_1ENG_DVo 02.10.2009 Please note that heat is released both by the central inverter and by devices such as transformers, fuse distributors and system monitoring components (e.g. PC, server). Distances | Designed to bear the weight of the device (see Chapter Specifications, page 85) and of the transport vehicle | Designed to match the device footprint (see Chapter Specifications, page 85) When selecting the installation location, the following distances must be complied with: | 100 mm to the side | 40 mm from the wall | 300 mm above No item should be stored above the device. Voltwerk VC WL series EU model Operating manual 25 4 Installation location When ensuring this, please note the device dimensions. 40 mm ENGLISH 1,210 mm 100 m 100 mm m 1,700 mm Voltwerk VC WL 110 from above with the doors open DO_BA_2009_1ENG_DVo 02.10.2009 4.1: 26 Operating manual Voltwerk VC WL series EU model 4 Installation location 40 mm ENGLISH 2,010 mm 1,700 mm 100 mm 100 mm 4.2: Ambient temperatures DO_BA_2009_1ENG_DVo 02.10.2009 4.2 Voltwerk VC WL 280–300K from above with the doors open Ensure that the space complies with the acceptable ambient temperatures both during installation and operation: Voltwerk VC WL 110 –20 °C to +45 °C Voltwerk VC WL 280–300K –20 °C to +40 °C Foundation Ensure that the foundation can bear the weight of the device model in question, as well as the weight of the transport vehicle. The foundation must: | be level, | be flame retardant, | be non-slip, | be of an adequately solid construction to bear the weight of the device (see Chapter Specifications, page 85) and the transport vehicle, Please note: under-engineered foundations may collapse thus creating a life-threatening situation. | be designed to match the device footprint (see Chapter Specifications, page 85) Voltwerk VC WL series EU model Operating manual 27 4 Installation location 4.3 Ventilation Material damage due to foreign objects ENGLISH Foreign objects such as film, plastic bags and pieces of paper may be sucked in by the fans, putting the product at risk. Foreign objects stored in the operating area may obstruct the ventilation equipment, putting the product at risk. This may lead to losses in yield and damage to the device. | Keep the operating area dry, clean and free of foreign objects. | Keep the operating area free of combustible or explosive materials and aggressive or corrosive gases. Material damage due to inadequate ventilation If, owing to insufficient ventilation capacity or blocked air passageways, individual components of the device are unable to achieve sufficient cooling, these components may age prematurely. The components may be irreparably damaged. The circulation of air is only possible if all plexiglass covers are fitted and the inverter is closed. | Provide sufficient ventilation in the operating area. | Fit all plexiglass covers. | Do not operate the inverter except in its closed state. DO_BA_2009_1ENG_DVo 02.10.2009 Voltwerk VC WL series EU model central inverters must be installed on a raised floor or base. The raised floor or base will ensure that air can be sufficiently filtered and drawn in through the inlet opening in the base of the inverter. 28 Operating manual Voltwerk VC WL series EU model 4 Installation location Air flow ENGLISH Hot air 1,500 m3/h 4.3: Cold air Air flow for the Voltwerk VC WL 110 1,500 m³/h DO_BA_2009_1ENG_DVo 02.10.2009 Required flow rate Voltwerk VC WL series EU model Operating manual 29 4 Installation location ENGLISH Hot air 1,750 m3/h 1,750 m3/h Cold air 4.4: Air flow for the Voltwerk VC WL 280–300K Required flow rate 3,500 m³/h (2 x 1,750 m³/h) Please note that the Voltwerk VC WL 280 and Voltwerk VC WL 300 central inverters both consist of two separate cabinets. A flow rate of 1,750 m³/h is required for each cabinet. 30 To filter the inlet air at the base, use a G3 or G4 class filter (EN 779). | The cooling air of the inverter and the ambient air must be free of combustible and explosive gases. | The cooling air of the inverter and the ambient air must be free of aggressive, caustic and corrosive gases (e.g. ammonia, sulphurous gases). | The cooling air of the inverter and ambient air must be free of corrosive gases (such as salt-laden air). | In order to prevent a 'short circuit' between the two different air flows, fresh air and exhaust air must be structurally separated. Operating manual Voltwerk VC WL series EU model DO_BA_2009_1ENG_DVo | 02.10.2009 Requirements for the air in the operating area | The size of the air inlet and air outlet must be determined in line with the design and the required flow rate. | The maximum permissible humidity of the cooling and ambient air is 95%. | At the flow rate required for the device (cool air quantity), the total pressure loss caused by flow resistance must be less than 70 Pa. If the pressure is higher than this, use external fans. When calculating the pressure loss, consider: | pressure losses from components such as air baffles, air filters, blades, air ducts | increase in pressure loss due to dirt on components | that the inverter can be disregarded when calculating the pressure loss. Using external fans The ventilation system can be supported by an external fan. If the fan is thermostat-controlled: | install it in the exhaust air duct, | install it centrally over the inverter, | with the Voltwerk VC WL 110 set to +45 °C, | with the Voltwerk VC WL 280–300K set to +40 °C. A timed relay ensures that the fan runs on for 5 to 10 minutes. This reduces the switching frequency. If you do not have any experience of planning and implementing ventilation systems, contact an expert for help. 4.4 Electrics The following must be present on site: Cable leads for the connection in the right length and size. | A fuse switch with a gG-type fusible cut-out or a power circuit breaker with an isolating function The connection cross-sectional area for all Voltwerk VC WL series EU model central inverters depends on the desired voltage drop, the fuse rating and on the laying system. Comply with the local regulations. Solar generator (DC) Grid (AC) Unlimited maximum cross section, connection via M12 cable lugs Auxiliary power supply (230 V) AC) 1.5–2.5 mm² DO_BA_2009_1ENG_DVo 02.10.2009 Connection cross-sectional area | Voltwerk VC WL series EU model Operating manual 31 ENGLISH 4 Installation location 4 Installation location 4.4.1 DC-side Possible earthing of solar modules When using some thin-film modules as well as special solar modules with contacts on the rear, it may be necessary to earth the solar generator. Please contact the manufacturer of the solar module to check whether this is required. If the manufacturer requires that the solar generator is earthed, the DC earth must be protected with a fuse approved for DC currents. Also ensure applicable safety regulations, standards and local regulations are observed. Risk of fatal injury due to earthed solar generator. A fault in the DC cabling can cause a short circuit or arcing. If there is an insulation fault in the solar generator, touching the solar generator can cause death. The risk of fatal injury is increased in an earthed solar generator. Service engineers must be advised of the earthing so that they can operate accordingly in the event of malfunction. | Use a DC disconnect switch for earthing. | Clearly mark earthed solar generators. When using central inverters from the Voltwerk VC WL series EU model, it is possible to earth the solar module on both poles. If the inverter is connected to an earthed solar generator, the SG LED indicator on the front door will flash continuously. This warning is visible throughout the entire operating time and cannot be deactivated for safety reasons. Voltwerk VC WL 300 4.4.3 Auxiliary power supply | Cable lead, single-phase, 230 V ± 20%, 56–63 Hz | TN network | Series fuse 16 A, type B or comparable | If necessary, use a separate transformer with an output of 2.5 kVA to supply the central inverter with 230 V. AC-side Fuse the AC connecting cable with the rated current specified on the type plate. If the specified rated current differs from the rated current for the fuse inserts, use a fuse insert with the next highest rated current. Two cables can be connected per phase. Maximum fuse values 32 For information on this, consult the local regulations. Level of performance Fuse rating Fuse type Voltwerk VC WL 110 160 A LV HRC1 Voltwerk VC WL 280 400 A LV HRC3 Voltwerk VC WL 300 630 A LV HRC3 Operating manual Voltwerk VC WL series EU model 02.10.2009 4.4.2 DO_BA_2009_1ENG_DVo ENGLISH There are two to eight cable leads, as up to four positive terminal strings and four negative terminal strings can be connected. 4 Installation location When using a circuit breaker, set it to the rated current of the device. Voltwerk VC WL series EU model central inverters only switch on with a clockwise rotary field. The incorrect rotary field will prevent the device from connecting to the public grid. ENGLISH Rotary field L1 L3 L2 4.5: Clockwise rotary field Voltwerk VC WL 300 The AC output voltage is 270 Veff (phase to phase). Please note that the lower output voltage (270 V) creates higher currents (577 A). This calls for larger cable sections than for devices with 400 V output voltage. The cable section depends on the length of the cable, the fuse rating, the laying system and, if applicable, on local regulations. Requirements The following requirements must be fulfilled: | 4.4.4 DO_BA_2009_1ENG_DVo 02.10.2009 DC-side The AC cables for connection to the Voltwerk VC WL series EEG model must: | be protected against earth faults, | be protected against short circuit, | have a voltage resistance of at least 1,000 V. | No consumer may be connected to the AC output voltage of the device. | Use aluminium cable clips to act as cable strain relief. | A medium voltage transformer or a shared transformer with galvanically isolated low-voltage windings must be used for each device. Disconnecting devices An external DC disconnecting device must be connected upstream of the Voltwerk VC WL series EU model central inverters, so that if damage occurs or for the purposes of inspecting the solar generator, the central inverters can be disconnected on the DC side. The manufacturer recommends that a surge voltage protection device should also be provided. Material damage due to short circuit A fault such as a short circuit in a cable or generator junction box (GAK) may damage the central inverter. | Fuse each cable between the GAK and the central inverter to protect against overload. # The fuse value depends on which cables have been used, the cable length, the laying system and the GAK. Voltwerk VC WL series EU model Operating manual 33 4 Installation location ENGLISH AC-side 4.4.5 An external AC disconnecting device must be connected upstream of the Voltwerk VC WL series EU model central inverters, so that the central inverter may be fully deenergised during maintenance, for instance. The external disconnecting device must be able to be secured to prevent it being switched back on. Disconnecting devices must comply with international regulations IEC 60364-7-712. Residual current protection (RCD) Risk of fatal injury due to residual voltage If a high-impedance connection is made in an electricity grid between a phase conductor and earth, a residual current will flow, which will not be disconnected by an upstream fuse. Residual currents can cause fatal injuries, fires and material damage. | Different grid configurations Use RCDs (Residual Current Devices). An RCD must be used In Terre Terre (TT) networks. In Terre Neutre Combiné (TN-C) networks, RCDs must not be used. In other grid configurations, checks should be made on a project-by-project basis, as to whether an RCD is required due to the specifications of the energy supplier, insurance company or building regulation authorities, as well as standards and technical directives (e.g. DIN VDE 0100-410 (IEC 60364-441:2005)). Please note that, for technical reasons, the central inverters have a leakage current (300 mA). 4.4.6 Medium voltage transformer for Voltwerk VC WL 300 Medium voltage side In accordance with the specifications of the energy supplier Low voltage side Interlinked voltage Rated power 34 Operating manual 270 Veff (3 phases, N) 270 kVA Voltwerk VC WL series EU model DO_BA_2009_1ENG_DVo Specifications of the transformer required when using a Voltwerk VC WL 300: 02.10.2009 The Voltwerk VC WL 300 central inverter is an inverter without an integrated transformer which means there is no galvanic isolation between the solar generator and the electricity grid. A medium voltage transformer with galvanic isolation is required to connect a Voltwerk VC WL 300 inverter to the electricity grid. A medium voltage transformer must be provided for each central inverter, or the medium voltage transformer must have a galvanically isolated winding for each device. Combining the Voltwerk VC WL 300 with other Voltwerk VC WL series EU model devices is only then possible if appropriate medium voltage transformers are used. Except for the missing transformer, the basic design and operation correspond to the Voltwerk VC WL 280. When designing the fuses and cables to the transformer, however, account must be taken of the higher output and lower output voltage of the Voltwerk VC WL 300. 4 Installation location Low voltage side 4.4.7 Dyn5 or Dyn11 <= 6 % ENGLISH Vector group Short circuit voltage Grid characteristic TN or TT networks Voltwerk VC WL 110–280 central inverters are designed to be connected to TN (Terre Neutre) networks and TT (Terre Terre) networks. In TN and TT networks, the transformer which is feeding in is earthed. TN networks Circuits in TN networks L1 L2 L3 PEN N PE 4.6: TN-C (Terre Neutre Combiné) network L1 L2 L3 N PEN 4.7: PE TN-C-S (Terre Neutre Combiné Separé) network DO_BA_2009_1ENG_DVo 02.10.2009 L1 L2 L3 N PE 4.8: TN-S (Terre Neutre Separé) network Voltwerk VC WL series EU model Operating manual 35 4 Installation location TT network L1 L2 ENGLISH L3 N PE 4.9: TT (Terre Terre) network In contrast to a TT system, in a TN system, a zeroing of the transformer is performed. Example circuit 230V / 50Hz / L1, N, PE Control PE PE L2 AC Filter DC: U< / U> / I< / I> MPP L1 L3 AC: f> / f< / U> / U< N N PEN 230V / 50Hz / L1, N, PE L1 L2 L3 N Control PE PE L2 AC Filter L3 AC: f> / f< / U> / U< 4.10: Voltwerk VC WL 110–280: Example circuit Multiple Voltwerk VC WL 110–280 central inverters can be operated on one medium voltage transformer with a shared winding. IT network Voltwerk VC WL 300 36 Voltwerk VC WL 300 central inverters are designed for grid connection to a medium voltage transformer and may only be operated in IT (Isolé Terre) networks. Please note: Operating manual Voltwerk VC WL series EU model 02.10.2009 N DO_BA_2009_1ENG_DVo DC: U< / U> / I< / I> MPP L1 4 Installation location | An IT network is an unearthed network. | In the event of an earth fault the network is earthed. Therefore: | earth the inverter housing with low resistance. | ENGLISH the surge voltage protection device and inverter filter units are only functional when the device is earthed. do not earth the neutral point of the medium voltage transformer. L1 L2 L3 N PE 4.11: IT (Isolé Terre) network Example of circuit with two inverters 230V / 50Hz / L1, N, PE Control AC Filter DC: U< / U> / I< / I> MPP L1 AC: f> / f< / U> / U< L2 L3 N L1 L2 L3 Control L1 AC Filter DC: U< / U> / I< / I> MPP DO_BA_2009_1ENG_DVo 02.10.2009 230V / 50Hz / L1, N, PE AC: f> / f< / U> / U< L2 L3 N 4.12: Voltwerk VC WL 300: Example circuit Voltwerk VC WL series EU model Operating manual 37 4 Installation location One medium voltage transformer must be provided per central inverter. 4.5 Lightning protection plan ENGLISH Material damage due to lightning strike A lightning strike in the vicinity of or directly to the photovoltaic system may damage the system components. | Create a lightning protection plan for all system components (solar modules, inverters, monitoring system, etc.). | Put the lightning protection plan into action. The risk of surge voltage events and lightning strikes will differ depending on the location and composition of the photovoltaic system. Please note: | Risk assessment acc. to DIN EN 62305-2 | Statutory and local regulations | Requirements of the insurer of the photovoltaic system Each location and differing system topology (module types, rated voltage, cable routing, etc.) places different demands on a lightning protection plan. The manufacturer is not able to produce any universally applicable specifications to guarantee total protection. Each photovoltaic system must be evaluated in its own right. If you do not have any experience of planning and implementing such systems, contact an expert for help. The manufacturer recommends, that all cables connected to the inverter be protected with a Type II surge voltage arrester acc. to EN 61643-11 /12. Particularly the DC input must be protected against impermissible surge voltages, which can be transmitted through the cables of the solar generator. Depending on system topology, risk and composition, either a Type II arrester acc. to EN 61643-11/-12 or a Type I arrester is used. Please note that this recommendation will not guarantee complete protection of the device under all circumstances. 4.6 Notes on transport Material damage due to incorrect transportation. 38 Avoid the effects produced by impact when using an industrial truck or crane. | Transport the device in an upright position only. | Ensure the transportation method produces low levels of vibration. | If an industrial truck is used, only raise the central inverter from the rear. | Remove the base panel when using an industrial truck. | Transport the device in a full assembled state. Operating manual Voltwerk VC WL series EU model DO_BA_2009_1ENG_DVo | 02.10.2009 Material damage may be caused if the central inverters are improperly transported. ENGLISH 4 Installation location (1) 4.13: Transport using an industrial truck (1) Marking on the device showing centre of gravity Risk of injury due to incorrect attachment Material damage or personal injuries may be caused if the central inverters are incorrectly attached when lifted. The central inverters have a high, eccentric centre of gravity (1). If this centre of gravity is not taken into account, the load can tip over during lifting and transport. This can result in personal injuries or material damage. Only attach the central inverter to the transport forks. | Check the centre of gravity (1) for the device, paying attention to the marking on the packaging. | Use a steel cable > 1,500 m. Use steel cables of lengths which suit the type of device. | For the hanger assembly, only use standardised steel cables which have been approved for transporting the tension load specific to the device. DO_BA_2009_1ENG_DVo 02.10.2009 | Voltwerk VC WL series EU model Operating manual 39 4 Installation location ENGLISH > 1,500 mm ??????????? (1) 4.14: Transportation by crane (1) Marking on the device showing centre of gravity Material damage due to condensate If the device is moved from a cold environment to an operating area, condensate may form, causing damage to the electronic equipment. | Before commissioning, the device must be absolutely dry. | During transportation, do not subject the device to high temperature fluctuations or particularly high levels of air humidity. | Observe a minimum waiting time of 2 hours between installation at the operating site and commissioning. Material damage due to temperature fluctuations Transport the unit at a constant temperature and at low humidity. Material damage due to impact When slewing and depositing the load, electronic equipment can be damaged by the force of impact. | 40 Ensure the unit does not suffer impact during transportation. Operating manual Voltwerk VC WL series EU model DO_BA_2009_1ENG_DVo | 02.10.2009 During transportation, electronic equipment can be damaged by temperature fluctuations and air humidity. 5 Installation Installation DO_BA_2009_1ENG_DVo 02.10.2009 5.1 5.2 ENGLISH 5 Requirements | Before commissioning, Voltwerk VC WL series EU model central inverters must be prepared to suit local conditions and adjusted according to national regulations and technical connection conditions. | Make sure that the grid voltage stays within the specified limit (see Chapter Specifications, page 85). | Before starting any work: | Disconnect the inverter and secure it against switching back on. | Ensure that the inverter is fully deenergised. | Ensure that the connections are fully deengergised. N.B. On photovoltaic systems, the power source is always active during the hours of daylight. | The base panels must be fitted. | The transport rails must be fitted. | Cable leads for the connections are provided on site by the operator in the right length and size. Replace the leads if they are damaged. | The fuse rating and fuse type of the external series fuse must be observed. | A fuse switch with a gG-type fusible cut-out or a power circuit breaker with an isolating function must be used. | Auxiliary power supply: Series fuse 16 A, type B or comparable must be used. | Voltwerk VC WL 300: A fuse must be connected between the device and the medium voltage transformer, since no fuse has been integrated into the device. | The grid connection cable with the specified rated current must be fused (see chapter 4.4.3, page 32). Connecting the solar generator Tools required | Torque wrench 17 mm | Cable stripping knife, insulation removal tool | M12 cable lug# cable lugs must be of the correct size for the cable sections used. | Approved tool for crimping cable lugs Voltwerk VC WL series EU model Operating manual 41 5 Installation ENGLISH Requirements | Disconnect the inverter and secure it against being switched back on. | Verify that the inverter is fully deenergised. N.B. On photovoltaic systems, the power source is always active during the hours of daylight. | Switch off the auxiliary power supply. | 2 to a maximum of 8 cable leads must be available on site, as up to four positive terminal strings and four negative terminal strings may be connected. Connecting the solar generator 1. Remove the lower plexiglass cover. 2. Check the cable leads of the solar generator. (1) (2) 5.1: (1) (2) Voltwerk VC WL 110 DC + connection bar DC – connection bar (1) (1) (2) 42 Voltwerk VC WL 280–300K DC + connection bar DC – connection bar 3. Loosen the securing nuts on the threaded studs inserted through the connection bars. 4. Remove the retaining washer and flat washer from each of the threaded studs. Operating manual Voltwerk VC WL series EU model DO_BA_2009_1ENG_DVo 5.2: 02.10.2009 (2) 5 Installation Material damage due to unsuitable cable lugs NOTICE Cable lugs may come undone, thereby interrupting the flow of current and causing material damage. 5. | the device's connection bar and | the diameter of the bolt. Install the mounting elements on the threaded bolt in the following order:# a) Cable lug# b) Washer# c) Retaining washer# d) Securing nut Material damage due to loose screw connections NOTICE If the specified tightening torques are not observed, the screws may become loose as a consequence of vibration in the terminal blocks. Loosened screw connections change the resistance and the conductivity at the connection. Operation of the central inverter can be adversely affected and it may suffer damage. Result 02.10.2009 the chosen cable diameter, Do not use aluminium cable lugs. | DO_BA_2009_1ENG_DVo | ENGLISH Use cable lugs of the correct size, ensuring that the cable lugs match: | 5.3 5.3.1 | Before commissioning, check that all screw connections are tightened to the correct torque and retighten where necessary. | Do not treat nuts and bolts, either with grease or in any other way. Thread size Tightening torque (Nm) M10 54 M12 93 6. Tighten the securing nuts. 7. Fit the plexiglass cover and screw into place. 8. Label the cables. The solar generator is connected. Connecting the grid Voltwerk VC WL 110–280 Requirements | Disconnect the inverter and secure it against being switched back on. | Verify that the inverter is fully deenergised. N.B. On photovoltaic systems, the power source is always active during the hours of daylight. | Switch off the auxiliary power supply. Voltwerk VC WL series EU model Operating manual 43 5 Installation | Ensure that the AC cables are fully deengergised. | TN or TT network must be present. ENGLISH Voltwerk VC WL 110–280 central inverters are designed to be connected to TN (Terre Neutre) networks and TT (Terre Terre) networks. Connecting to the grid 1. Remove the lower plexiglass cover. 2. Check the AC cable leads. Voltwerk VC WL series EU model central inverters only switch on with a clockwise rotary field. The incorrect rotary field will prevent the device from connecting to the public grid. Check the direction of the rotary field. | (1) (2) (3) (5) 5.3: (4) Grid connectionsVoltwerk VC WL 110 (1) (2) 5.4: (1) (2) (3) (4) (5) 6. 44 (5) Grid connectionsVoltwerk VC WL 280 AC AC AC AC AC connection bar L3 connection bar L2 connection bar L1 N connection bar PE connection bar Fit the cable connections L1, L2, L3, N, and PE. Operating manual Voltwerk VC WL series EU model DO_BA_2009_1ENG_DVo (4) 02.10.2009 (3) 5 Installation NOTICE | Retaining washers | Washers Use cable lugs of the correct size, ensuring that the cable lugs match: | the chosen cable diameter, | the device's connection bar and | the diameter of the bolt. Do not use aluminium cable lugs. 8. 02.10.2009 Securing nuts Cable lugs may come undone, thereby interrupting the flow of current and causing material damage. | DO_BA_2009_1ENG_DVo | Material damage due to unsuitable cable lugs | NOTICE Remove the following components from the threaded bolt of the connection bars: ENGLISH 7. Install the mounting elements on the threaded bolt in the following order:# a) Cable lug# b) Washer# c) Retaining washer# d) Securing nut Material damage due to loose screw connections If the specified tightening torques are not observed, the screws may become loose as a consequence of vibration in the terminal blocks. Loosened screw connections change the resistance and the conductivity at the connection. Operation of the central inverter can be adversely affected and it may suffer damage. | Before commissioning, check that all screw connections are tightened to the correct torque and retighten where necessary. | Do not treat nuts and bolts, either with grease or in any other way. Thread size Tightening torque (Nm) M10 54 M12 93 9. Tighten the securing nut. 10. Label the cables. 11. Fit the plexiglass cover and screw into place. Result 5.3.2 Voltwerk VC WL 110–280: The grid is connected. Voltwerk VC WL 300 Requirements | Disconnect the inverter and secure it against being switched back on. Voltwerk VC WL series EU model Operating manual 45 ENGLISH 5 Installation | Verify that the inverter is fully deenergised. N.B. On photovoltaic systems, the power source is always active during the hours of daylight. | Switch off the auxiliary power supply. | Ensure that the AC cables are fully deengergised. | The IT network must be present. Voltwerk VC WL 300 central inverters are designed for grid connection to a medium voltage transformer and may only be operated in IT (Isolé Terre) networks. | | A medium voltage transformer or a shared transformer with galvanically isolated low-voltage windings must be provided for each device. Please note that: | Voltwerk VC WL 300 is a device which does not have galvanic isolation. | The N conductor connection of the device must be connected straight to the unearthed, low-voltage side neutral point of the medium voltage transformer. An AC fuse rated at 630 A must be present. No AC fuse is integrated into the inverter. Connecting to the grid 1. Remove the lower plexiglass cover. 2. Check the AC cable leads. Voltwerk VC WL series EU model central inverters only switch on with a clockwise rotary field. The incorrect rotary field will prevent the device from connecting to the public grid. | Check the direction of the rotary field. (1) (2) (4) 5.5: (1) (2) (3) (4) 46 (5) Grid connectionsVoltwerk VC WL 300 AC AC AC AC connection bar L3 connection bar L2 connection bar L1 N connection bar Operating manual Voltwerk VC WL series EU model DO_BA_2009_1ENG_DVo 02.10.2009 (3) 5 Installation (5) NOTICE 7. The following components are removed from the threaded bolt of the connection bars: Retaining washers | Washers Cable lugs may come undone, thereby interrupting the flow of current and causing material damage. Use cable lugs of the correct size, ensuring that the cable lugs match: | the chosen cable diameter, | the device's connection bar and | the diameter of the bolt. Do not use aluminium cable lugs. 8. 02.10.2009 Securing nuts | Material damage due to unsuitable cable lugs | DO_BA_2009_1ENG_DVo | Install the mounting elements on the threaded bolt in the following order:# a) Cable lug# b) Washer# c) Retaining washer# d) Securing nut Material damage due to loose screw connections If the specified tightening torques are not observed, the screws may become loose as a consequence of vibration in the terminal blocks. Loosened screw connections change the resistance and the conductivity at the connection. Operation of the central inverter can be adversely affected and it may suffer damage. | Before commissioning, check that all screw connections are tightened to the correct torque and retighten where necessary. | Do not treat nuts and bolts, either with grease or in any other way. Thread size Tightening torque (Nm) M10 54 M12 93 9. Tighten the securing nut. 10. Label the cables. 11. Fit the plexiglass cover and screw into place. Result Voltwerk VC WL 300: The grid is connected. Voltwerk VC WL series EU model Operating manual 47 ENGLISH Fit the cable connections L1, L2, L3, N, and PE. Ensure that: the N conductor connection is connected straight to the unearthed, low voltage side neutral point of the medium voltage transformer. | NOTICE AC PE connection bar 6. 5 Installation 5.4 Connecting the auxiliary power supply ENGLISH Requirements Voltwerk VC WL 300 | Disconnect the inverter and secure it against being switched back on. | Verify that the inverter is fully deenergised. N.B. On photovoltaic systems, the power source is always active during the hours of daylight. | Switch off the auxiliary power supply. | Cable lead, single-phase, 230 V ± 20%, 56–63 Hz | TN network | Series fuse 16 A, type B or comparable | If necessary, use a separate transformer with an output of 2.5 kVA to supply the central inverter with 230 V. N PE 1 X2 1 Connecting the auxiliary power supply 1. Result 5.5 Connect the wires L, N and PE to the connection terminal, ensuring that the cables are correctly allocated to the terminals. Auxiliary power supply is connected. Fitting cable strain relief Risk of injury due to damaged cable leads Cable leads for the connections are provided on site by the operator in the right length and size. | Fit the cable strain relief on site. | Adequately secure connecting cables entering the device by a cable strain relief (cable mounting rail). | Only use aluminium cable clips for cable strain relief on the cables. Check all cable leads before connecting the cabling. Fitting cable strain relief 1. 48 Fasten the cable lead to a cable mounting rail. Operating manual Voltwerk VC WL series EU model DO_BA_2009_1ENG_DVo | 02.10.2009 Connecting cables which are not strain-relieved may be damaged or severed. This can result in serious personal injury or material damage. 5 Installation Cable strain relief must be provided on site and must only be carried out using components which are approved for the purpose. 5.6 Cable strain relief has been fitted. ENGLISH Result Connecting the monitoring system The SmartControl monitoring system is connected to the device communication hub via the CAN converter. The remaining second interface must be terminated using the resistor provided. When routing the cables, please note that routing signal cables and power-carrying cables together can cause interruptions to the signal. Signal cables should therefore be routed separately from these other cables. More detailed information can be found in the SmartControl Operating manual. 5.7 Changing grid characteristics using DIP switches (optional) On delivery, the grid characteristics of the Voltwerk VC WL series EEG model are set in accordance with the requirements laid down by the BDEW (German Federal Association for the Energy and Water Industries) in chapter 2.5.3 of the Technical Directive “Generation systems on medium voltage grids”, June 2008 edition. Other inverters in the Voltwerk VC WL series EU model are delivered with their grid characteristics set in accordance with VDE0126-1-1. If the setting is not suitable for the power characteristics of your grid connection, you can modify the setting to meet location-specific requirements. Please note the country-specific standards and directives. You can obtain the approved values from your energy supplier. Material damage due to incorrect grid characteristics Using the wrong grid characteristics may significantly impair operating performance and lead to malfunctions and permanent damage to the device. DO_BA_2009_1ENG_DVo 02.10.2009 If the grid characteristics are not set to the same values on the three AC cards, this may significantly impair operating performance and lead to malfunctions and permanent damage to the device. | Discuss the grid characteristics with your energy supplier. | Set the grid characteristics on all three AC cards to the same value. Requirements | Disconnect the inverter and secure it against being switched back on. | Verify that the inverter is fully deenergised. N.B. On photovoltaic systems, the power source is always active during the hours of daylight. | Switch off the auxiliary power supply. Voltwerk VC WL series EU model Operating manual 49 5 Installation Required tools and materials | Insulated tool with a fine point of approx. 1 mm in diameter | Magnifying glass (where required) ENGLISH Changing grid characteristics NOTICE 1. Open the control cabinet. 2. Remove the plexiglass cover. Material damage due to damaged DIP switches DIP switches are particularly sensitive to mechanical stress and must be set with the aid of a special tool or an object with a stable, filigree tip. Only use suitable tools. | (1) (2) (3) (4) (1) to (3) AC cards [4] Sine card 3. Set the DIP switches on the three AC cards (1) to (3) as per the information in the following tables. Mains voltage (phase to N) S1 S2 S3 S4 grid undervoltage 221 VAC –a –a off off 197 VAC –a –a off on a a on off –a on on a –a grid surge voltage 208 V AC – 186 VAC –a – 235 VAC off off – 253 VAC off on –a –a a –a –a 245 VAC on off – 264 VAC on on –a a) The status of the DIP switch is not analysed. 50 Operating manual Voltwerk VC WL series EU model DO_BA_2009_1ENG_DVo Comment 02.10.2009 Voltwerk VC WL 110–280 5 Installation Comment Mains voltage (phase to N) S1 S2 S3 S4 Grid undervoltage 150 VAC –a –a off off 134 VAC – a a off on 141 VAC –a –a on off 126 VAC – a a on on 159 VAC off off –a –a 172 VAC off on –a –a a –a –a Grid surge voltage – – 166 VAC on off – 179 VAC on on –a ENGLISH Voltwerk VC WL 300 a) The status of the DIP switch is not analysed. If the values which can be set using the DIP switches do not meet the specifications, the next lower value must be selected for the surge voltage shutdown (e.g. specified: 248 V, selected: 245 V). If this is the case for the undervoltage shutdown, the next higher value must be selected (e.g. specified: 205 V, selected: 208 V). 4. Repeat this procedure for all three AC cards. 5. Set the DIP switches on the sine card (4) according to the specifications in the following tables. Please note the requirements laid down by the BDEW (German Federal Association for the Energy and Water Industries) in chapter 2.5.3 of the Technical Directive “Generation systems on medium voltage grids”, June 2008 edition, are applicable for the Voltwerk VC WL series EEG model. DO_BA_2009_1ENG_DVo 02.10.2009 Basic frequency 50 Hz Lower shutdown Upper shutdown S1 S2 S3 S4 47.5 Hz 50.2 Hz off off off off 49.5 Hz 50.5 Hz off off off on 47 Hz 51 Hz off off on off 47.5 Hz 51 Hz off off on on 48 Hz 51 Hz off on off off 49 Hz 51 Hz off on off on 47.5 Hz 51.5 Hz off on on off 47.5 Hz 52 Hz off on on on Basic frequency 60 Hz Lower cut-out Upper cut-out S1 S2 S3 S4 59.8 Hz 60.2 Hz on –a off off on – a on off a off on on on 59.5 Hz 60.5 Hz 59 Hz 61 Hz on – 57 Hz 60.2 Hz on –a a) The status of the DIP switch is not analysed. Voltwerk VC WL series EU model Operating manual 51 5 Installation Material damage due to foreign objects NOTICE When open, the control cabinet may become dirty. ENGLISH | Result 5.8 The control cabinet should be immediately closed and locked after any work. 6. Fit the plexiglass cover, screw into place and seal. 7. Close the control cabinet and seal it. Grid characteristics have been changed. Measurements To complete the installation, make the measurements and record the results as well as the measuring equipment used. The results must comply with the requirements of the applicable standards and directives, as well as the device specifications (see Chapter Specifications, page 85). Safety instructions | Use any safety devices fitted to the device and follow any safety instructions shown on the device. | Take note of safety guidelines for conducting measurements on live system and device components. | Standards for measurements taken from the solar generator (DC) and of the mains voltage (AC) must be carefully adhered to. | Before carrying out the measurement, read the Operating manual for the measuring equipment, and observe it while performing such tasks. Tools required | The appropriate, tested equipment. N.B. Due to faulty connections, voltages > 1,000 VDC may also be present. | Insulated measuring equipment acc. to DIN EN 61557-2 | Earth-resistance measuring equipment acc. to DIN EN 61557-9 | Faulted circuit-impedance measuring equipment acc. to DIN EN 61557-3 Open external disconnecting devices (solar generator, grid connection and auxiliary power supply) and secure them against being switched on again. 2. Verify that the system is fully deenergised. DO_BA_2009_1ENG_DVo 1. 02.10.2009 Carrying out the measurements 52 Operating manual Voltwerk VC WL series EU model 5 Installation Risk of fatal injury due to residual voltages Residual voltages inside the device can result in fatal surges. Capacitors may be charged even after the device is switched off. When Voltwerk VC WL series EU model central inverters are disconnected via the On/Off switch, voltage is still present at the AC and DC connections. The On/Off switch is not a DC disconnector. | Open all external and internal disconnectors and secure them against being switched back on. | After switching off the device, always wait for a period of 8 minutes before touching. | A suitable measuring instrument should be used to verify that the device is deenergised, in accordance with applicable guidelines. 3. Open internal disconnectors (DC power circuit breakers, LV HRC disconnectors for AC output and LV HRC disconnectors for surge voltage protection). 4. Remove the plexiglass cover. Risk of fatal injury through disregard of the Operating manual DANGER Certain measuring equipment can be used when the power supply is connected. There is a risk of fatal injury if measuring equipment is not used in the prescribed manner. | Check the instructions in the measuring equipment operating manual. | Follow the instructions in the Operating manual. 5. Connect the measuring equipment. 6. Cover adjacent live device parts. 7. Close the external disconnect facilities for the solar generator and the grid connection. 8. Measure the grid voltage (AC), i.e. phase to phase as well as phase to N and phase to PE. The measured voltage must be within the parameters given in the specifications (see Chapter Specifications, page 85). DO_BA_2009_1ENG_DVo 02.10.2009 Measure the rotary field of the grid voltage (AC). Ensure that: Voltwerk VC WL series EU model central inverters only switch on with a clockwise rotary field. The incorrect rotary field will prevent the device from connecting to the public grid. Measure the solar generator voltage (DC) and polarity, observing permissible tolerances: | Voltwerk VC WL 110–280: 493–965 V | Voltwerk VC WL 300: 530–965 V The faulted circuit impedance is the resistance of the current loop (device, conductor, protective earth) in the event of a frame fault (a conductive connection between the phase conductor and the protective earth). The value of the faulted circuit impedance determines the size of the short circuit current. The latter must not exceed the value specified by DIN VDE 0100, to ensure that the system's protective equipment (fuse, circuit breaker) will trip out/blow reliably. Voltwerk VC WL series EU model Operating manual 53 ENGLISH DANGER 5 Installation 9. Measure the faulted circuit impedance. Ensure that: | the faulted circuit impedance is measured between all three conductors (L1, L2 and L3) and the protective earth (PE). ENGLISH The earthing resistance is the electrical resistance between the protective earth connection and the reference potential of the ground. Earthing resistance is measured by running an alternating current over the earthing conductor, the earth electrode and the earth-spreading resistor. It can be measured either directly or indirectly. For direct measurement, an earth probe is required. For indirect measurement, the approximate earthing resistance is determined using an 'earth-electrode loop resistance measurement', without the use of a probe. R A $ UL/IF R A Earthing resistance (protective earth) U L Contact voltage I F Residual current 10. Measure the earthing resistance. To do this, follow the instructions in the measuring equipment operating manual. The insulation resistance is the electrical resistance among the various conductors and between the conductors and the protective earth (PE). 11. Measure the insulation resistance. To do this, follow the instructions in the measuring equipment operating manual. 12. Voltwerk VC WL series EEG model: measure the energy supplier's signal at the inverter and adjust to the supplier's requirements. 13. Carry out other measurements as required by standards. 14. Measure the auxiliary power supply. Ensure that the voltage is within the specified parameters (see chapter 4.4.2, page 32). 15. Put the plexiglass cover in place. 16. Close the LV HRC disconnector for surge voltage protection. Ensure that: the disconnector clamp is tilted upwards with one hand and firmly pressed on. 17. Close all disconnectors (DC power circuit breakers and LV HRC disconnectors for AC output). 18. Screw the plexiglass cover into place. The measurements have been completed. DO_BA_2009_1ENG_DVo Result 02.10.2009 19. Close the front door. 54 Operating manual Voltwerk VC WL series EU model 6 Commissioning Commissioning 6.1 ENGLISH 6 Filling out the commissioning report Before commissioning, inspect the installation. To do this, consult | safety devices and safety instructions on the device, | safety guidelines for conducting measurements on live system and device components, | the operating manual for the measuring equipment. Before commissioning, inspect the configuration of the system and the cable routing. If the necessary documents are missing, contact the operator of the photovoltaic system. Risk of fatal injury due to residual voltages Residual voltages inside the device can result in fatal surges. Capacitors may be charged even after the device is switched off. When Voltwerk VC WL series EU model central inverters are disconnected via the On/Off switch, voltage is still present at the AC and DC connections. The On/Off switch is not a DC disconnector. | Open all external and internal disconnectors and secure them against being switched back on. | After switching off the device, always wait for a period of 8 minutes before touching. | A suitable measuring instrument should be used to verify that the device is deenergised, in accordance with applicable guidelines. Tools required | The appropriate, tested equipment. N.B. Due to faulty connections, voltages U > 1,000 VDC may also be present. DO_BA_2009_1ENG_DVo 02.10.2009 Filling out the report 1. Fill out the Commissioning report, page 79 ff. Measured data must comply with the requirements of the applicable standards and directives, as well as the device specifications (see chapter Specifications, page 85). Voltwerk VC WL series EU model Operating manual 55 6 Commissioning 6.2 Putting the device into operation Before putting the device into operation, all the LED indicators on the front door are switched off. ENGLISH Putting the device into operation 1. Fit and close all safety covers. 2. Close all disconnectors and switch on the DC power circuit breaker in the device. 3. Close and lock cabinet doors. 4. Set the On/Off switch on the front door to 0. 5. Close the external DC disconnection device 6. Close the external AC disconnection device. 7. Switch on the auxiliary power supply. 8. Set the On/Off switch on the front door to I. Device is ready for operation. Once the AC and DC grids have been switched on, the inverter activates the LED indicators on the front door. ON SG GRID FAULT Meaning Device has just been switched on. Self-test for about 5 seconds. Grid connection mode | Solar generator voltage/output too low | No power fed to the grid If the solar generator voltage is sufficient, the device will wait 2–5 minutes before it starts to feed power to the grid. Grid feed-in mode Inverter operating normally LED is constantly lit LED is off The operating frequency of central inverters lies within a clearly audible range. The noises which are perceived as a type of screeching, hissing or squeaking are typical of the device and represent no impairment to operation. 56 Operating manual Voltwerk VC WL series EU model DO_BA_2009_1ENG_DVo 02.10.2009 LED is flashing 6 Commissioning Voltwerk VC WL series EEG model central inverters can only feed in to the grid at full output if | fGrid = 47.5–50.05 Hz and | the mains voltage is at least 95% of the rated mains voltage (see chapter Specifications, page 85) ENGLISH there is no output reduction due to the presence of an external signal, Device is in operation. DO_BA_2009_1ENG_DVo 02.10.2009 Result | Voltwerk VC WL series EU model Operating manual 57 DO_BA_2009_1ENG_DVo 02.10.2009 ENGLISH 6 Commissioning 58 Operating manual Voltwerk VC WL series EU model 7 Maintenance Maintenance 7.1 ENGLISH 7 Maintenance interval Central inverter Maintenance interval 2 years This period may be shortened owing to local conditions. Reasons for a shortened maintenance interval are: | High level of stress caused by deposits of dirt or dust, e.g. on farms | Vibration e.g. if the device is sited in direct proximity to railway lines or arterial roads | High number of nominal load hours e.g. in tracked systems | Constantly high or sharply fluctuating ambient temperatures e.g. desert or steppe locations. A proper inspection will uncover faults such as a defective protective earth, missing sections of shielding, damaged supply cables, parasitic voltages on the housing. Replace any defective components and wear parts. Filters The maintenance interval is dependent on the location (cleanness of the air) and on the ventilation plan for the operating area. Remove deposits of dirt regularly, in order to avoid a reduction in the amount of cooling air or impermissible counterpressure. Carry out regular maintenance on the filters as well as the supply and exhaust air passages and any openings in the operating area. 7.2 Safety instructions DO_BA_2009_1ENG_DVo 02.10.2009 Risk of fatal injury due to high voltages Death or serious injury could result when working on high-voltage and high-current electrical systems and live parts. | Cover or shield any adjacent live components. N.B. On photovoltaic systems, the power source is always active during the hours of daylight. | Before starting any work on electrical systems: | Disconnect the system | Ensure that it is secured against being switched back on | Verify that the system is fully deenergised | Earth and short-circuit the system Voltwerk VC WL series EU model Operating manual 59 7 Maintenance Risk of fatal injury due to residual voltages Residual voltages inside the device can result in fatal surges. Capacitors may be charged even after the device is switched off. ENGLISH When Voltwerk VC WL series EU model central inverters are disconnected via the On/Off switch, voltage is still present at the AC and DC connections. The On/Off switch is not a DC disconnector. | Open all external and internal disconnectors and secure them against being switched back on. | After switching off the device, always wait for a period of 8 minutes before touching. | A suitable measuring instrument should be used to verify that the device is deenergised, in accordance with applicable guidelines. Risk of fatal injury from arcing and short circuit currents Very high DC voltages (no zero point) may exist in photovoltaic systems, which could cause arcing in the event of faults or if components such as fuses or plugs are not used in the specified manner. The short circuit current of the solar generator is only slightly higher than the maximum operating current and is always dependant on current irradiation levels. This means that, where short circuits occur, there is no definite guarantee that circuit breakers will be tripped. | Use components in the correct manner. Risk of fatal injury due to lack of assistance In the event of an accident a second person can lend assistance. | Only carry out work if a second person is present. Risk of fatal injury through disregard of safety instructions If the sequence of steps for installation and the safety instructions are not followed, the device may be permanently damaged and electrical accidents may occur with serious health consequences. | Observe the sequence of procedure steps for installation and follow the safety instructions. Risk of injury due to high temperatures After switching off the product, wait for an appropriate period before touching. | Do not touch hot components. Material damage due to foreign objects Foreign objects such as film, plastic bags and pieces of paper may be sucked in by the fans, putting the product at risk. Foreign objects stored in the operating area may obstruct the ventilation equipment, putting the product at risk. This may lead to losses in yield and damage to the device. | 60 Keep the operating area dry, clean and free of foreign objects. Operating manual Voltwerk VC WL series EU model DO_BA_2009_1ENG_DVo | 02.10.2009 The components of the product may reach temperatures of up to 150 °C, which can cause serious burns. 7 Maintenance | Keep the operating area free of combustible or explosive materials and aggressive or corrosive gases. Required tools and measuring instruments Appropriate screwdriver | Torque wrench | Vacuum cleaner | Brush | Cloth | Control cabinet key | Measuring equipment for determining the flow rate, e.g. anemometer | Clip-on ammeter for direct current | Insulated measuring equipment acc. to DIN EN 61557-2 | Earth-resistance measuring equipment acc. to DIN EN 61557-9 | Faulted circuit-impedance measuring equipment acc. to DIN EN 615573 | Voltmeter, measuring range 0–1,000 VDC; 0–500 VAC. N.B. Due to faulty connections, voltages > 1,000 VDC may also be present. | Protective earth test device ENGLISH | Please note, that measuring equipment and all cables should be certified to protection class CAT II (1,000 V), in accordance with EN 61010-1. 7.3 Check the device when disconnected Requirements Auxiliary power supply switched off. | External and internal disconnectors open and secured against being switched back on. | Delay of 8 minutes observed. | Deenergised state of the device verified using a suitable measuring instrument, in accordance with applicable guidelines. | DC power circuit breaker in the device open. DO_BA_2009_1ENG_DVo 02.10.2009 | Voltwerk VC WL series EU model Operating manual 61 7 Maintenance Checking the operating area ENGLISH NOTICE Material damage due to foreign objects Foreign objects such as film, plastic bags and pieces of paper may be sucked in by the fans, putting the product at risk. Foreign objects stored in the operating area may obstruct the ventilation equipment, putting the product at risk. This may lead to losses in yield and damage to the device. | Keep the operating area dry, clean and free of foreign objects. | Keep the operating area free of combustible or explosive materials and aggressive or corrosive gases. 1. 2. Make sure there is air circulation at the fan vents. Please note: | The top of the device must remain unobstructed, to allow air to escape. | Exhaust air from the inverter must be able escape unimpeded. | The cooling air intake is on the bottom of the device; so it must be set up to take account of this. The central inverter must not draw in any dirt. | Clean dust and sand from the floor. | Clean or, if necessary, replace the air filter in the base of the device. Check the supply air to the operating area. Ensure that: | 3. only G3 or G4 class filters (EN 779) are used. the quantity of air is checked for each device. Ensure that: central inverters must be set up on a raised floor or base to ensure that air can be sufficiently filtered and drawn in through the inlet opening in the base of the central inverter. Required volume of air Voltwerk VC WL 110 1,500 m 3/h Voltwerk VC WL 280–300K 3,500 m³/h DO_BA_2009_1ENG_DVo 02.10.2009 Level of performance 62 Operating manual Voltwerk VC WL series EU model 7 Maintenance Result Checking the operating area. Please note: | The operating area must be dry, clean and free of foreign objects. Foreign objects such as film, plastic bags and pieces of paper may be sucked in by the fans, putting the device at risk. | The operating area must be free of combustible or explosive materials. | The cooling and ambient air of the inverter must be free of combustible or explosive gases. | The cooling air of the inverter and the ambient air must be free of aggressive, caustic and corrosive gases (e.g. ammonia, sulphurous gases and similar). | The cooling and ambient air of the inverter must be free of corrosive gases (such as salt-laden air). | In order to prevent a 'short circuit' between the two different air flows, fresh air and exhaust air must be structurally separated. | The maximum humidity of the cooling and ambient air is < 95 %. ENGLISH 4. The operating area has been checked. Checking the external area Result 1. Check the locking mechanisms on the device and the interconnected control cabinets or supply units. 2. Examine the housing for discolouration. 3. Clean the grilles over the inverter fans. 4. Check the cross-section, routing, connection and identification of protective earths and earthing conductors. 5. Inspect the external AC and DC terminal boxes according to the manufacturer's specifications. 6. Inspect the AC and DC connection cables to the central inverter. To do this, check | the insulation for damage, | the fastening and routing of the cables, | Crushing and overheating of the cables. The external area has been inspected. DO_BA_2009_1ENG_DVo 02.10.2009 Checking the internal area 1. Check the plexiglass covers. 2. Check cable connections for firm jointing.# Replace damaged lines or cables. 3. Check the tightening torques of the screw connections on the AC and DC connection bars and the PE connection bar. Voltwerk VC WL series EU model Operating manual 63 7 Maintenance ENGLISH Tightening torques Thread size Tightening torque (Nm) M10 54 M12 93 4. Check screw connections. Please note that, bolts and nuts are not treated (greased). 5. Check the copper rails for discolouration and corrosion. 6. Check the device for visible damage, areas of discolouration or signs of scorched or overheated cables and cable connections. 7. Check the device for deposits of dirt and areas of damage caused by animals (e.g. gnawing damage caused by rodents). 8. Check for areas of noticeable discolouration inside the interior and on components. 9. Check the surge voltage protection devices. Please note: | If the indicator is red, replace the surge voltage protection devices (see chapter 9.2.2, page 76). | Inspect the LV HRC circuit breaker (base and cover), ensuring that it does not exhibit signs of damage or scorch marks. | Inspect the base of the surge voltage protection device, ensuring that it does not exhibit signs of damage or scorch marks. | Check the fuse clip for continuity, ensuring that it does not exhibit signs of damage or scorch marks. 10. Check the fuse indicators on varistors and fuses. Please note that the fuses must be replaced every 6 years. Fuses older than this may blow prematurely, leading to loss of yield. 11. Check all fuses for corrosion or erosion on the contact plates. 12. Check for dust deposits and water traces.# Clean the capacitors with a brush. Clean the device with a vacuum cleaner. Please note: Result | Do not damage any components, cables or other fixtures. | If a compressor is used, maintain a minimum distance of 30 cm. The interior area has been checked. Open the control cabinet. 2. Remove the plexiglass cover. Risk of fatal injury due to high voltages DANGER Death or serious injury could result when working on high-voltage and high-current electrical systems and live parts. | 3. 64 Cover or shield any adjacent live components. Switch on the auxiliary power supply. Operating manual Voltwerk VC WL series EU model DO_BA_2009_1ENG_DVo 1. 02.10.2009 Check the device fan 7 Maintenance Material damage due to contact erosion The contacts of the contactor are only closed while the actuating mechanism is powered. A contactor which is not fully, or which is only belatedly actuated may be damaged, causing a contact erosion. | Actuate contactor K91 quickly and with adequate force. ENGLISH NOTICE (1) 7.1: 4. Contactor K91 (1) on the upper top-hat rail in the control cabinet Actuate contactor K91 rapidly with a solid and fully insulated object (diameter approx. 0.5 cm). All fans come on. Note any noises from the fan. Result 5. Switch off the auxiliary power supply. 6. In the event of unusual fan noises, determine which fan is causing these and replace it. If you require help, contact the manufacturer (contact details on the back of the manual). 7. Fit the plexiglass cover, screw into place and seal. 8. Close the control cabinet and seal it. The device fans have been checked. DO_BA_2009_1ENG_DVo 02.10.2009 Checking the control cabinet 1. Open the control cabinet. 2. Check the control cabinet for visible damage, areas of discolouration or signs of scorched or overheated cables and cable connections. 3. Remove the plexiglass cover. 4. Check card sets for water traces and dust deposits. 5. Gently press down on the card sets on the front. This ensures that the card sets are in contact. 6. Inspect the control cabinet for deposits of dirt caused by animals and damage due to gnawing. 7. Check the level of erosion on the auxiliary relay, determine the cause and replace if necessary. 8. Check the DIP switch settings. For information on this, consult the energy supplier's specifications. 9. Fit the plexiglass cover, screw into place and seal. 10. Close the control cabinet and seal it. Result The control cabinet has been inspected. Voltwerk VC WL series EU model Operating manual 65 7 Maintenance 7.4 Measurements ENGLISH Requirements | Disconnect the inverter and secure it against being switched back on. | Verify that the inverter is fully deenergised. N.B. On photovoltaic systems, the power source is always active during the hours of daylight. | Switch off the auxiliary power supply. | Safety covers closed. | On/Off switch on the front door set to 0. | All disconnectors as well as the DC power circuit breaker inside the device are open. Risk of fatal injury due to residual voltages Residual voltages inside the device can result in fatal surges. Capacitors may be charged even after the device is switched off. When Voltwerk VC WL series EU model central inverters are disconnected via the On/Off switch, voltage is still present at the AC and DC connections. The On/Off switch is not a DC disconnector. | Open all external and internal disconnectors and secure them against being switched back on. | After switching off the device, always wait for a period of 8 minutes before touching. | A suitable measuring instrument should be used to verify that the device is deenergised, in accordance with applicable guidelines. Risk of fatal injury through disregard of the Operating manual Certain measuring equipment can be used when the power supply is connected. There is a risk of fatal injury if measuring equipment is not used in the prescribed manner. | Check the instructions in the measuring equipment operating manual. | Follow the instructions in the Operating manual. 1. Measure the faulted circuit impedance. Ensure that: | 66 The faulted circuit impedance is measured between all three conductors (L1, L2 and L3) and the protective earth (PE). Operating manual Voltwerk VC WL series EU model DO_BA_2009_1ENG_DVo The faulted circuit impedance is the resistance of the current loop (device, conductor, protective earth) in the event of a frame fault (a conductive connection between the phase conductor and the protective earth). The value of the faulted circuit impedance determines the size of the short circuit current. The latter must not exceed the value specified by DIN VDE 0100, to ensure that the system's protective equipment (fuse, circuit breaker) will trip/blow reliably. 02.10.2009 Measuring The earthing resistance is the electrical resistance between the protective earth connection and the reference potential of the earth. Earthing resistance is measured by running an alternating current over the earthing conductor, the earth electrode and the earth-spreading resistor. It can be measured either directly or indirectly. For direct measurement, an earth probe is required. For indirect measurement, the approximate earthing resistance is determined using an 'earth-electrode loop resistance measurement', without the use of a probe. R A $ U L/I F R A Earthing resistance (protective earth) U L Contact voltage I F Residual current 2. Measure the earthing resistance. To do this, follow the instructions in the measuring equipment operating manual. The insulation resistance is the electrical resistance among the various conductors and between the conductors and the protective earth (PE). 3. Measure the insulation resistance. To do this, follow the instructions in the measuring equipment operating manual. 4. Close the LV HRC disconnectors. 5. Remove the surge voltage protection. 6. Measure the device's insulation resistance. To do this: 7. Result | measure L1 against PE, | measure L2 against PE, | measure L3 against PE, | measure N against PE, | follow the instructions in the measuring equipment operating manual. Check the resistance of the On/Off switch on the front door. The measurements have been completed. DO_BA_2009_1ENG_DVo 02.10.2009 The device may be operated again (see chapter 6, page 55). Voltwerk VC WL series EU model Operating manual 67 ENGLISH 7 Maintenance DO_BA_2009_1ENG_DVo 02.10.2009 ENGLISH 7 Maintenance 68 Operating manual Voltwerk VC WL series EU model 8 Troubleshooting Troubleshooting Voltwerk VC WL series EU model central inverters work automatically. If a fault occurs with the inverter, the most recent fault message is displayed on the LED indicators on the front door. 8.1 Fault report In the event of a fault, the actual condition of the central inverter must be recorded. Reporting a fault 1. First, leave the central inverter as you find it.# Do not switch the central inverter off. 2. Record the status of the LED indicators on the front door. Use the terms: “flashing”, “on”, “off” 3. Record traces of water and smoke residue. 4. Record the actual condition with images. Risk of fatal injury due to high voltages DANGER Death or serious injury could result when working on high-voltage and high-current electrical systems and live parts. DO_BA_2009_1ENG_DVo 02.10.2009 | Cover or shield any adjacent live components. N.B. On photovoltaic systems, the power source is always active during the hours of daylight. 5. Open the front door. 6. Carry out a visual inspection. 7. Record the actual condition # (loose, faulty parts, surge voltage protection, etc.). 8. Open the control cabinet. 9. Record the actual condition. 10. Record the status of the sine card LED indicators. Use the terms: “flashing”, “on”, “off” Three LED indicators are visible on the right of the sine card. 11. Record the status of the LED indicators on the AC card. Use the terms: “flashing”, “on”, “off” Six LED indicators are visible on each of the three identical AC cards. These are numbered from left to right. 12. Voltwerk VC WL series EEG model: Record the values on the display for the LOGO PLC. 13. Voltwerk VC WL series EEG model: Record the values on the display for the frequency transducer. Voltwerk VC WL series EU model Operating manual 69 ENGLISH 8 8 Troubleshooting 14. Close and lock the control cabinet and front door. Result ENGLISH 8.2 The fault has been recorded. LED indicators on the front door The Fault LED indicator may light up or flash. | The Fault LED indicator is lit. Inverter detects a fault which is probably irreversible and switches off. | The Fault LED indicator is flashing. Inverter probably detects a reversible, temporary fault and switches off temporarily. It normally switches back on automatically once the fault has been cleared. SG GRID FAULT Possible cause Action Grid fault | Grid fuse faulty | Series fuse for the surge voltage protection device faulty | Grid cabling to the central inverter faulty | Wrong rotary field | Disconnector at the grid feed-in point is faulty | Grid voltage or frequency outside tolerance range | Grid synchronisation faulty due to faults in the grid voltage | Grid impedance too high Internal fault | Fault after completion of self-test | Fault when connecting to grid | Defective grid contactor | Defective output stage | Power stage does not connect | | | | | | | | | | | | | | Restart using the On/Off switch of the front door. Observe a delay of at least 20 seconds before restarting. If the fault is still present after a restart, contact the manufacturer's Service department. Check the grid contactor. If the grid contactor is defective, contact the manufacturer's Service department. If the cause of the fault has been overcome, the device will switch back on. DO_BA_2009_1ENG_DVo | Check mains voltage. Check grid fuse. Check the series fuse for the surge voltage protection device. Check the grid wiring. Check the installation and DC grid. Change the rotary field. Check the disconnector. Observe a delay of 180 seconds. Voltwerk VC WL series EEG model: observe a delay of 30 seconds. If the cause of the fault has been overcome, the device will switch back on. 02.10.2009 ON 70 Operating manual Voltwerk VC WL series EU model 8 Troubleshooting SG GRID FAULT Possible cause Action Surge voltage, overheating | Surge voltage on the solar generator The device automatically disconnects from the grid in the event of surge voltage (on the DC side) by opening the DC disconnector. Check the sizing of the solar generator. Ambient temperature too high (see chapter 4.1, page 25) | Lower the ambient temperature. | Check whether, due to space considerations, a 'short circuit' is likely to occur between the inlet and exhaust air flows, i.e. the inverter sucks in its | Overheating in the device own exhaust air. The device automatically | Check the ventilation of the operating disconnects from the grid in the area (see chapter 4.3, page 28). event of considerable If the cause of the fault has been rectified, overheating of the reactors or the DC disconnector must be manually of the transformer by opening reset. the DC disconnector. The device does not automatically switch back on after this particular fault has occurred. Insulation resistance fault on the solar generator | | | | | Check the insulation resistance. Establish and rectify the cause of the insulation resistance fault. If, owing to the type of module used, the solar generator has been consciously earthed, the SG LED indicator flashes permanently for safety reasons. LED is constantly lit LED is flashing LED is off DO_BA_2009_1ENG_DVo 02.10.2009 The status of this LED indicator has no significance for the information currently displayed. Voltwerk VC WL series EU model Operating manual 71 ENGLISH ON 8 Troubleshooting 8.3 LED indicators for sine card LED status indicator Possible cause Action LED (1) off Grid synchronisation has not yet occurred. | Wait 2–5 minutes. Sine card faulty | Contact the manufacturer's Service department; the sine card must be replaced. LED (2) off Phase sequence reversed | Change rotary field (clockwise rotary field). LED (3) off An AC card is not reporting “Voltage OK” | Check mains voltage Ribbon connection cable ST1 defective | Replace ribbon connection cable ST1.# The cable connects the sine card to the CPU card. Sine card faulty | Contact the manufacturer's Service department; the sine card must be replaced. 8.4 LED indicators for AC cards The three AC cards work independently. Six LED indicators are visible on each of the three identical AC cards. These are numbered from left to right. LED status indicator Possible cause Action LED (1) on Current limitation active Card set faulty | | | Check activation. Restart the device. If the fault persists after a restart, contact the manufacturer's Service department; the card set must be replaced. LED (2) on Output stage switches off Fault in the control technology Card set faulty Output stage faulty Surge voltage on the transformer's primary side | | | Check activation. Restart the device. If the fault persists after a restart, contact the manufacturer's Service department; the card set must be replaced. LED (3) on AC surge voltage DIP switches wrongly set (different national limitations) | Check the DIP switches (note the specifications of the energy supplier). 72 Operating manual Voltwerk VC WL series EU model 02.10.2009 If one or more LED indicators on the AC cards are flickering, this does not indicate a fault. DO_BA_2009_1ENG_DVo ENGLISH Three LED indicators are visible on the right of the sine card. LED status indicator Possible cause Action LED (4) off AC voltage too low Grid fault The DIP switches are set incorrectly | | Check mains voltage Check the voltage in the potentiometer card (assembly F4.1 to F4.3). The DIP switches are set incorrectly | Check the DIP switches (note the specifications of the energy supplier). LED (5) on Output stage faulty Short circuit Defect in the activation cable Card set fault | LED (6) off Minimum voltage not achieved or Maximum voltage exceeded | | Remove the activation cable from the reverse wiring. If the fault persists: | Check the connection of the card set to the reverse wiring. If the fault persists: | replace the card set, | plug the connector back in If the fault persists: | Replace activation lines. If the fault persists, contact the manufacturer's Service department. Check mains voltage Check the DIP switches (note the specifications of the energy supplier). If faults occur, the AC cards can be swapped around to assist in localising the fault. If the cause of the fault is on a particular card, it will recur in the card's new location. In such a case, contact the manufacturer's Service department; the AC card must be replaced. 8.5 Delays When analysing a fault, note the switch-on delay of the inverter. DO_BA_2009_1ENG_DVo 02.10.2009 Voltwerk VC WL series EU model central inverters automatically adjust their switch-on delay to account for the current situation. This prevents ineffective attempts to connect to the grid (e.g. at sunset). A waiting time of a few minutes is observed when switching on after grid malfunctions. If the device is switched off due to insufficient power input and the solar generator voltage then rises back above the switch-on threshold, the switch-on delay will be about four minutes. If the inverter is not feeding in or is only feeding in at a reduced level, and the following requirements have been met: | good irradiation, | solar generator correctly connected and switched on, | LED indicators indicate that the inverter is ready for operation, then | check the installation of the solar generator and the AC grid. If the fault persists, contact the manufacturer's Service department. Voltwerk VC WL series EU model Operating manual 73 ENGLISH 8 Troubleshooting 8 Troubleshooting | Voltwerk VC WL series EEG model central inverters: check the energy supplier's signal. The signal received by the energy supplier's interface on the inverter must meet the energy supplier's requirements. ENGLISH Voltwerk VC WL series EEG model central inverters can only feed in to the grid at full output if: 8.6 | there is no output reduction due to the presence of an external signal, | fGrid = 47.5–50.05 Hz and | the mains voltage is at least 95% of the rated mains voltage (see chapter Specifications, page 85) Manufacturer's service centre In the event of faults, contact the manufacturer's Service department (contact details can be found on the back of the manual). To allow the manufacturer to respond quickly and appropriately, please provide the following details: | Invoice number (delivery note if applicable) | Serial number of the inverter | A brief description of the fault and a fault report What does the LED indicators' fault report look like? Is the fault reproducible? | Was the inverter working properly before the fault? | Information about the PV system such as solar module type, circuitry, solar generator voltage | How long is the mains cable and what is the cable cross-section? | What are the irradiation conditions? | Voltwerk VC WL series EU model central inverters: what is shown on the display of the LOGO PLC? DO_BA_2009_1ENG_DVo 02.10.2009 | | 74 Operating manual Voltwerk VC WL series EU model 9 Repairs Repairs 9.1 ENGLISH 9 Safety information Risk of fatal injury from arcing and short circuit currents Very high DC voltages (no zero point) may exist in photovoltaic systems, which could cause arcing in the event of faults or if components such as fuses or plugs are not used in the specified manner. The short circuit current of the solar generator is only slightly higher than the maximum operating current and is always dependant on current irradiation levels. This means that, where short circuits occur, there is no definite guarantee that circuit breakers will be tripped. | Use components in the correct manner. Risk of fatal injury due to high voltages Death or serious injury could result when working on high-voltage and high-current electrical systems and live parts. | Cover or shield any adjacent live components. N.B. On photovoltaic systems, the power source is always active during the hours of daylight. | Before starting any work on electrical systems: | Disconnect the system | Ensure that it is secured against being switched back on | Verify that the system is fully deenergised | Earth and short-circuit the system Risk of fatal injury due to residual voltages Residual voltages inside the device can result in fatal surges. Capacitors may be charged even after the device is switched off. DO_BA_2009_1ENG_DVo 02.10.2009 When Voltwerk VC WL series EU model central inverters are disconnected via the On/Off switch, voltage is still present at the AC and DC connections. The On/Off switch is not a DC disconnector. | Open all external and internal disconnectors and secure them against being switched back on. | After switching off the device, always wait for a period of 8 minutes before touching. | A suitable measuring instrument should be used to verify that the device is deenergised, in accordance with applicable guidelines. Risk of fatal injury due to lack of assistance In the event of an accident a second person can lend assistance. | Only carry out work if a second person is present. Voltwerk VC WL series EU model Operating manual 75 9 Repairs 9.2 9.2.1 Fuse replacement LV HRC fuses ENGLISH Requirements | Disconnect the inverter and secure it against being switched back on. | Verify that the inverter is fully deenergised. N.B. On photovoltaic systems, the power source is always active during the hours of daylight. | Switch off the auxiliary power supply. Replacing LV HRC fuses 1. Quickly open the LV HRC disconnector. 2. Remove the fuses. 3. Inspect the LV HRC disconnector (base and cover), ensuring that it does not exhibit signs of damage or scorch marks. 4. Replace the fuses. Ensure that: 5. Result 9.2.2 | you always replace the complete set. This prevents incipient damage from becoming a problem. | the same type of fuse is used: # Voltwerk VC WL 110: LV HRC1 160 A; 690 V# Voltwerk VC WL 280: LV HRC1 400 A; 690 V# Voltwerk VC WL series EU model series fuse for surge voltage protection: LV HRC00 125 A; 500 V# Depending on the revision status of the inverter in question, the fuse type may differ from the type specified here. Quickly close the LV HRC disconnector. Ensure that: | closing requires some force. | the LV HRC disconnector is fully closed. The fuses have been replaced. The device may be operated again (see chapter 6, page 55). Surge voltage protection device The indicator for the surge voltage protection device in the inspection window is red. Requirements | Disconnect the inverter and secure it against being switched back on. | Verify that the inverter is fully deenergised. N.B. On photovoltaic systems, the power source is always active during the hours of daylight. | Switch off the auxiliary power supply. Replacing the surge voltage protection device 1. 76 Pull the faulty surge voltage protection device out of the holder. Operating manual Voltwerk VC WL series EU model DO_BA_2009_1ENG_DVo | 02.10.2009 Note 2. Inspect the base of the surge voltage protection device, ensuring that it does not exhibit signs of damage or scorch marks. 3. Replace the surge voltage protection device. Ensure that: | you always replace the complete set. This prevents incipient damage from becoming a problem. | the same type of fuse is used: # A5.2 = VAL-MS 400ST# A5.4 = VAL-MS 230ST# Depending on the revision status of the inverter in question, the fuse type may differ from the type specified here. | you pay attention to orientation. If a surge voltage protection device is faulty, the series fuse may also be faulty or have suffered incipient damage. If a series fuse is faulty, a grid fault is displayed. The device switches off. Always inspect the series fuse and, if necessary, replace it. | Result 9.2.3 The surge voltage protection device has been replaced. The device may be operated again (see chapter 6, page 55). Glass cartridge fuse The glass cartridge fuse safeguards the grid monitoring and auxiliary power supply for the device controller. Requirements | Disconnect the inverter and secure it against being switched back on. | Verify that the inverter is fully deenergised. N.B. On photovoltaic systems, the power source is always active during the hours of daylight. | Switch off the auxiliary power supply. Replacing the glass cartridge fuse DO_BA_2009_1ENG_DVo 02.10.2009 (1) 1. Remove the fuse insert from the fuse clip (1). 2. Remove the fuse from the fuse insert. 3. Check the fuse clip for continuity. ensuring that it does not exhibit signs of damage or scorch marks. Voltwerk VC WL series EU model Operating manual 77 ENGLISH 9 Repairs 9 Repairs ENGLISH 4. | you always replace the complete set. This prevents incipient damage from becoming a problem. | the same type of fuse with the same fuse rating is used: # F4.1–4.3 = T1 L250V# F4.4 = T10 L250V# Depending on the revision status of the inverter in question, the fuse type may differ from the type specified here. 5. Place the fuse into the fuse insert. 6. Place the fuse insert containing the new fuse into the fuse clip. The fuse has been changed. The device can be operated again (see chapter 6, page 55). DO_BA_2009_1ENG_DVo 02.10.2009 Result Replace the fuse Ensure that: 78 Operating manual Voltwerk VC WL series EU model Commissioning report ENGLISH Commissioning report Before commissioning, inspect the installation. | Use any safety devices fitted to the device and follow any safety instructions shown on the device. | Take note of safety guidelines for conducting measurements on live system and device components. | Before carrying out measurement, read the Operating manual for the measuring equipment. Risk of fatal injury due to residual voltages Residual voltages inside the device can result in fatal surges. Capacitors may be charged even after the device is switched off. When Voltwerk VC WL series EU model central inverters are disconnected via the On/Off switch, voltage is still present at the AC and DC connections. The On/Off switch is not a DC disconnector. | Open all external and internal disconnectors and secure them against being switched back on. | After switching off the device, always wait for a period of 8 minutes before touching. | A suitable measuring instrument should be used to verify that the device is deenergised, in accordance with applicable guidelines. Tools required The appropriate, tested equipment. N.B. Due to faulty connections, voltages > 1,000 VDC may also be present. | Anemometer Procedures Desired result 1. Inspect the foundation that the device is sited on. Device standing on a raised floor or base Ground bears the weight of the device. | Change the positioning of the device. # Cooling air is taken in from underneath (see chapter 4.3, page 28). 2. Inspect the operating Operating area, including area, including the raised floor, is free of raised floor. foreign objects and dampness. | Clean the operating area. Remove sand, water and other dirt. 02.10.2009 DO_BA_2009_1ENG_DVo | Voltwerk VC WL series EU model Actual result Operating manual Action in case of noncompliance 79 Commissioning report Actual result Action in case of noncompliance 3. Inspect the transport Transport rails removed rails. | Remove the transport rails. 4. Measure the temperature in the operating area. Voltwerk VC WL 110: +45 to –20 °C Voltwerk VC WL 280– 300K: +40 to –20 °C | Set the temperature of the operating area so that the temperature of air supplied to the device is within tolerances. 5. Measure the inverter cooling air quantity. Voltwerk VC WL 110: 1,500 m³/h Voltwerk VC WL 280– 300K: 2 x 1,750 m³/h | | Extend the supply and exhaust openings. Use external fans. 6. Inspect the air filter on the air inlet at the base. Filter clean Class G3 or G4 filter used | | Clean the air filter. Replace the air filter. 7. Measure the size of the air inlet in the operating area per device. Compare with the ventilation design. In order to prevent a 'short circuit' between the two different air flows, fresh air and exhaust air must be structurally separated. | Expand the air inlet. 8. Measure the size of the air outlet in the operating area per device. Compare with the ventilation design. In order to prevent a 'short circuit' between the two different air flows, fresh air and exhaust air must be structurally separated. | Expand the air outlet. 9. Check the pressure loss. The sum of the pressure loss caused by flow resistance must be less than 70 Pa. | Modify the operating area.# Exhaust air must be able escape unimpeded from the device. If necessary, install external fans. | 10. Measure the At least 300 mm distance between the device and the ceiling or obstacles such as cable guides or lights. 80 Operating manual | Change the positioning of the device.# The top of the device must remain unobstructed, to allow air to escape. Voltwerk VC WL series EU model 02.10.2009 Desired result DO_BA_2009_1ENG_DVo ENGLISH Procedures Commissioning report Desired result Actual result Action in case of noncompliance 11. Inspect the top of the No foreign objects on the device. device | Remove foreign objects.# The top of the device must remain unobstructed, to allow air to escape. 12. Inspect the cable strain relief. All connecting cables must be secured using a cable strain relief (cable mounting rail). | Secure all connecting cables with a cable strain relief. 13. Remove any foreign objects from inside the device. Device does not contain any foreign objects such as an earthing harness, jumpers, tools or measuring equipment | Remove foreign objects. 14. Check the markings During manufacturing, all (locking paint) on the the electrical screw screw connections. connections were marked to make it easy to recognise if one had become loose. | If screw connections in the device have become loose, contact the manufacturer (contact details on the back of the manual). # Do not operate the device. 15. Check the electrical connections for firm jointing. | With spring-loaded terminals, ensure that the cables are fully inserted. Only handle cable lugs with approved press or crimp tools. Cables and lines are connected tightly DO_BA_2009_1ENG_DVo 02.10.2009 | 16. Check the tightening M10 = 54 Nm torque of the terminal M12 = 93 Nm blocks. | Correct the tightening torque. 17. Check the series fuse for the auxiliary power supply. 16 A, type B or comparable | Replace series fuses. 18. Check the external fuse for the power connection. Voltwerk VC WL 110: # 160 A, LV HRC1 Voltwerk VC WL 280: 400 A, LV HRC3 Voltwerk VC WL 300: 630 A, LV HRC3 | | Replace the fuses. When using a circuit breaker, set it to the rated current of the device. 19. Inspect the contact for the card sets in the control cabinet. All card sets are in contact | Securely click the cards into place (press on the front of the card). 20. Inspect the coupling relays. The coupling relays are engaged | Engage the coupling relays. Voltwerk VC WL series EU model Operating manual 81 ENGLISH Procedures Commissioning report Desired result Actual result Action in case of noncompliance 21. Measure the AC (see voltage, i.e. measure chapter Specifications, phase to phase, page 85 phase to N, and phase to PE. | 22. Measure the auxiliary 230 V ± 20% 56–63 Hz power supply. | | | 23. Measuring the rotary Clockwise rotary field field of the grid voltage (AC). | 24. Measure the solar generator voltage (DC). | Voltwerk VC WL 110– 280: 493 V–965 V Voltwerk VC WL 300: 530 V–965 V 25. Check the polarity of the DC connection. | | | | | Inspect the installation. Check the AC grid. Change the rotary field. Inspect the installation. Check the solar generator. Inspect the installation. Check the solar generator. | | | Check the AC grid. Inspect the AC cable. Contact the energy supplier. 27. Measure the earthing RA < 2 ! resistance. To do RA $ U L/I F this, follow the instructions in the measuring equipment operating manual. | Check the earth. 28. Measure the In accordance with DIN insulation resistance. EN 60204-1 To do this, follow the RISO %#1.0 M! instructions in the measuring equipment operating manual. | Inspect the cabling. 29. Check the grid characteristics. | Change the grid characteristics appropriately. 82 Compliant with DIN VDE 0100 Inspect the installation. Check the AC grid. Grid characteristics meet the energy supplier's specifications Operating manual 02.10.2009 26. Measure the faulted circuit impedance. Please note:# The faulted circuit impedance is measured between all three conductors (L1, L2 and L3) and the protective earth (PE). Inspect the installation. Check the AC grid. Voltwerk VC WL series EU model DO_BA_2009_1ENG_DVo ENGLISH Procedures Commissioning report Desired result Actual result Action in case of noncompliance 30. Voltwerk VC WL serie Data meets the energy s EEG model: supplier's specifications measure the energy supplier's signal on the device. | Check the installation of the cable for the energy supplier signal cable. 31. Check all plexiglass covers. | Fit plexiglass covers and screw into place. DO_BA_2009_1ENG_DVo 02.10.2009 All plexiglass covers are fitted and screwed into place. Voltwerk VC WL series EU model Operating manual 83 ENGLISH Procedures DO_BA_2009_1ENG_DVo 02.10.2009 ENGLISH 84 Operating manual Voltwerk VC WL series EU model Specifications All Voltwerk VC WL series EU model central inverters have the following characteristics: | Protection type against environmental influences: IP 20 acc. to IEC 60529 | Maximum permissible air humidity 95%, non-condensing | Switches on automatically if there is sufficient solar generator power | In the event of overload, adjusts the operating point to the solar generator characteristic curve | Maximum Power Point tracking (%#99% accuracy) | Earth fault monitoring | High performance varistors to act as surge voltage protection | Power factor Cos & %#0.99 | Grid characteristics (voltage and frequency) can be adjusted to meet country-specific standards and the specifications of the energy supplier (see chapter 5.7, page 49) | Auxiliary power supply, single-phase, 230 V ± 20 % 56–63 Hz, TN network | Transient emissions (acc. to DIN EN 61000-6-4:2007-09) | Interference resistance (acc. to DIN EN 61000-6-2:2006-03) Connections present of Voltwerk VC WL series EU model central inverters: | 4 DC input connections L1, L2, L3, N, DC +, DC – and PE: M12 connection bolt Auxiliary power supply: 1.5–2.5 mm² terminals DO_BA_2009_1ENG_DVo 02.10.2009 | | Voltwerk VC WL series EU model Operating manual 85 ENGLISH Specifications Specifications Installation and location data VC WL 110 VC WL 280 VC WL 300 ENGLISH External dimensionsa (H x W x 1,800 x 1,21 1,800 x 2,01 1,800 x 2,01 D) [mm] 0 x 800 0 x 800 0 x 800 Weight [kg] 1,220 2,400 1,540 Ambient temperature [°C] –20 to +45 –20 to +40 –20 to +40 Min. fan flow rate per device [m³/h ] 1,500 3,500 3,500 Noise emissions [dB] < 75 < 85 < 85 a) To account for transport packaging, add 200 mm to the depth and 100 mm to the length and width of the devices. DC input data VC WL 110 VC WL 280 VC WL 300 Input voltage range [VDC] Start-up input voltage [VDC] 965–493 965–493 965–530 515 515 550 Rated input voltage [VDC] MPP voltage range [V DC] 510 510 540 493–780 493–780 530–780 Max. input current [ADC] 223 568 566 Input fuses (internal, thermal) [A] 250 630 630 Efficiency levela VC WL 110 VC WL 280 VC WL 300 Maximum efficiency factor 97.6 % 97.5 % 98.8 % European efficiency factor 97.0 % 96.8 % 98.2 % VC WL 110 VC WL 280 VC WL 300 Max. output [W] 290 770 770 Recommended series fuse [A] 16 A model B 16 A model B 16 A model B Power consumption in 55 standby mode, night mode [W] 60 60 Power consumption during operationa [W] 60–770 60–770 4.2 4.1 55–290 Energy requirements for 8 hrs, 1.7 25 °Cb [kW/h] a) The fans in the devices are temperature regulated. b) Values are for information only. There may be other requirements depending on the system, region and installation location. 86 Operating manual Voltwerk VC WL series EU model DO_BA_2009_1ENG_DVo Auxiliary power supply 02.10.2009 a) At DC and AC rated voltage without including the auxiliary power supply.# Depending on the revision status of the inverter in question, the values may differ from those specified here. Specifications AC output data a Mains voltage range [V] VC WL 280 VC WL 300 457–322 457–322 310–218 400 400 270 Maximum output current [A] 145 361 577 Rated power [kW] 100 250 270 Maximum output power [kW] 100 250 270 Rated frequency [Hz] 50 (60) 50 (60) 50 (60) Frequency range [Hz] 47–52 (57–61) 47–52 (57–61) 47–52 (57–61) Required grid configuration All TN All TN IT network networks, TT networks, TT network network Distortion factor <2% <2% ENGLISH Rated mains voltage [V] a VC WL 110 <3% DO_BA_2009_1ENG_DVo 02.10.2009 a) Voltage between phases; the measurement in the device is between phase and neutral Voltwerk VC WL series EU model Operating manual 87 Efficiency curves with various input voltages ENGLISH Efficiency curves with various input voltages1 Voltwerk VC WL 110 98,00% 96,00% 94,00% 92,00% (1) 90,00% (2) 88,00% (3) 86,00% 0% 9.1: 20% 30% 40% 50% 60% 70% 80% 90% 100% Efficiency level measured against percent of rated AC capacity Voltwerk VC WL 110: U = 540 Voltwerk VC WL 110: U = 635 Voltwerk VC WL 110: U = 700 VDC VDC VDC 1) Depending on the revision status of the inverter in question, the efficiency levels may differ from those specified here. 88 Operating manual Voltwerk VC WL series EU model DO_BA_2009_1ENG_DVo 02.10.2009 (1) (2) (3) 10% Efficiency curves with various input voltages Voltwerk VC WL 280 98,00% ENGLISH 97,00% 96,00% 95,00% 94,00% (1) 93,00% 92,00% 91,00% (2) 90,00% (3) 89,00% 0% 9.2: (1) (2) (3) 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Efficiency level measured against percent of rated AC capacity Voltwerk VC WL 280: U = 540 VDC Voltwerk VC WL 280: U = 640 VDC Voltwerk VC WL 280: U = 700 VDC Voltwerk VC WL 300 100,00% 99,00% 98,00% 97,00% 96,00% 95,00% DO_BA_2009_1ENG_DVo 02.10.2009 94,00% 93,00% (1) (2) (3) 92,00% 0% 9.3: (1) (2) (3) 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Efficiency level measured against percent of rated AC capacity Voltwerk VC WL 300: U = 540 VDC Voltwerk VC WL 300: U = 640 VDC Voltwerk VC WL 300: U = 740 VDC Voltwerk VC WL series EU model Operating manual 89