Operation Manual HSI500 HSI640 HS1000 HSI1250 V31 Eng

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250
Helios Systems Eckernfrder Landstrasse 78 24941 Flensburg Germany Tel.: +49-(0)461-318011-70 Fax: +49-(0)461-318011-71 Mail: info@fe-con.com
All rights reserved. Full or partial reproduction is only permitted with the consent of Helios Systems. Creation date: 25. November 2010
Translation of original operating manual
Version 1.0
Table of contens
1
1.1 1.2 1.3 1.4 1.5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Designated purpose .................................................................................................... 1 Intended use ............................................................................................................... 1 Improper use ............................................................................................................... 1 Standards and directives ............................................................................................ 2 About this operating manual ....................................................................................... 2
2
2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety instructions ....................................................................................................... 3 Basic safety instructions ............................................................................................. 4 Obligations of the owner ............................................................................................. 8 Obligations of the qualified electrician ...................................................................... 10 Obligations of the crane operator .............................................................................. 10 Obligations of the industrial truck operator ............................................................... 11 Safety instructions on the central inverter ................................................................. 12 Identification of the HSI500 / HSI640 / HSI1000 / HSI1250 ...................................... 13
3
3.1
Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Delivery ..................................................................................................................... 14
Included in the delivery ......................................................................................................... 14
3.1.1
3.2 3.3
3.3.1 3.3.2
Functional description ............................................................................................... 15 Principle of the systems ............................................................................................ 16

Principle of the HSI500 / HSI640 .......................................................................................... 16 Principle of the HSI1000 / HSI1250 ...................................................................................... 17
3.4
3.4.1 3.4.2
Exterior views ............................................................................................................ 18

HSI500 / HSI640 exterior view .............................................................................................. 18 HSI1000 / HSI1250 external view ......................................................................................... 19
Table of contens 3.4.3 3.4.4 Display (optional) .................................................................................................................. 20 Emergency stop switch ......................................................................................................... 20
3.5
3.5.1 3.5.2 3.5.3 3.5.4
Interior views ............................................................................................................. 21

Central inverter interior view ................................................................................................. 21 HSI500 / HSI640 control cabinet interior view ...................................................................... 22 HSI1000 / HSI1250 control cabinet interior view .................................................................. 23 Optional heating elements .................................................................................................... 24
3.6
3.6.1 3.6.2 3.6.3 3.6.4
Technical data ........................................................................................................... 25

Technical data of the HSI500 ............................................................................................... 25 Technical data of the HSI640 ............................................................................................... 27 Technical data of the HSI1000 ............................................................................................. 29 Technical data of the HSI1250 ............................................................................................. 31
4
4.1 4.2
Transport and the necessary conditions at the installation site . . . . . . . . . . . . 33

Packaging ................................................................................................................. 33 Transport ................................................................................................................... 33
General instructions .............................................................................................................. 33 Crane transport .................................................................................................................... 34 Industrial truck support ........................................................................................................ 35 Securing for transport ........................................................................................................... 36
4.2.1 4.2.2 4.2.3 4.2.4
4.3
4.3.1 4.3.2
Installation site prerequisites ..................................................................................... 37

Grid ....................................................................................................................................... 37 Connections .......................................................................................................................... 38
4.4 4.5 4.6

4.6.1 4.6.2
Foundation ................................................................................................................ 38 Distances .................................................................................................................. 39 Ventilation ................................................................................................................. 40

Ventilation of the central inverter .......................................................................................... 40 Ventilation of the control cabinet ........................................................................................... 41
4.7
Ambient variables ..................................................................................................... 41
ii
Table of contens
5
5.1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Installation of the central inverter .............................................................................. 43
Connect the solar generator (DC) ......................................................................................... 43 Connecting to the grid (AC) .................................................................................................. 44
5.1.1 5.1.2
5.2 5.3
5.3.1 5.3.2
Cable connections in the control cabinet .................................................................. 46 Installation of the control cabinet .............................................................................. 47
Internal connections between central inverter and control cabinet ....................................... 48 External connections of the control cabinet .......................................................................... 49
6 7
7.1 7.2 7.3 7.4 7.5
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Operating states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Standby ..................................................................................................................... 54 Start up ..................................................................................................................... 54 MPP mode ................................................................................................................ 54 Shutdown .................................................................................................................. 54 Stop ........................................................................................................................... 55
8
8.1 8.2
De-commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Emergency stop switch ............................................................................................. 56 Switching off the control voltage ............................................................................... 56
9
9.1 9.2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Executing maintenance tasks ................................................................................... 57 Taking measurements .............................................................................................. 59
10 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
10.1 Disposal of the electrolytic capacitors ....................................................................... 61
iii
Table of contens
11 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 12 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
12.1 Spare parts list for the HSI500 / HSI640 control cabinet .......................................... 65 12.2 Spare parts list for the HSI1000 / HSI1250 control cabinet ...................................... 67 12.3 Spare parts list for the inverter cabinet ..................................................................... 69
iv
Introduction
1 Introduction
1.1 Designated purpose

The HSI500 / HSI640 / HSI1000 / HSI1250 from Helios Systems has been specially developed for use in photovoltaic systems. The HSI500 / HSI640 / HSI1000 / HSI1250 converts the DC voltage that is given off by the solar generators into gridconformant alternating current and feeds it into the power grid. The HSI500 and HSI640 are each comprised of a central inverter and a control cabinet. Three cabinets are supplied with the product groups HSI1000 and HSI1250 two central inverters and a control cabinet.
1.2 Intended use

The HSI500 / HSI640 / HSI1000 / HSI1250 may only be operated in photovoltaic systems and serves exclusively for the conversion of direct current into alternating current. It may only be operated in IT networks. Intended use also includes reading the operating manual, as well as complying with all instructions contained in the operating manual, particularly the safety instructions. The operating manual must be kept for the entire service life of the product. Maintenance work of any type may only be performed by employees of Helios Systems. Observe all prescribed time intervals. The HSI500 / HSI640 / HSI1000 / HSI1250 may only be set up within the ambient conditions specified in section Technical data" on page 25.
1.3 Improper use

Any use other than the use specified under section Intended use" on page 1 is considered improper use. The following uses of the HSI500 / HSI640 / HSI1000 / HSI1250 are included under improper use: in uninterruptible power supplies (UPS), in powered vehicles or as a component of a frequency converter. In the case of improper use of the HSI500 / HSI640 / HSI1000 / HSI1250, safe operation is not guaranteed. Any modifications of the HSI500 / HSI640 / HSI1000 / HSI1250 are prohibited.
Introduction
1.4 Standards and directives

The HSI500 / HSI640 / HSI1000 / HSI1250 conforms to the standards and the declaration of conformity.
1.5 About this operating manual

This operating manual provides information about safety, function, transport, installation (including commissioning and decommissioning), disposal, faults and maintenance of the HSI500 / HSI640 / HSI1000 / HSI1250 from Helios Systems. This operating manual is only intended for expert personnel authorised by the operator and trained in electrical engineering. The respective competences of the electrician must be clearly established by the operator. In addition, special qualifications are required for the following activities:
Activity Transport Set-up Commissioning Instruction Fault remedy Maintenance/service Cleaning Repair Decommissioning Qualification/may only be performed by Authorised and trained specialists Qualified electricians who have been trained and authorized Qualified electricians who have been trained and authorized Employees of Helios Systems Qualified electricians who have been trained and authorized Qualified electricians who have been trained and authorized Authorised and trained specialists Employees of Helios Systems Qualified electricians who have been trained and authorized
Safety
2 Safety
2.1 Safety instructions

Safety instructions must be strictly complied with! The safety instructions are classified according to the following risk levels: DANGER! Identifies a serious risk situation. Serious, irreversible injuries or fatal injuries will occur if this safety instruction is not complied with.
WARNING! Identifies a serious risk situation. Severe, irreversible injury or death can occur if this safety instruction is not complied with.
CAUTION! Identifies a risk situation. Minor or moderate injuries can occur if this safety instruction is not complied with.
NOTICE! Identifies a risk of material damage. Material damage can occur if this safety instruction is not complied with.
Safety
2.2 Basic safety instructions

DANGER! Life-threatening danger due to high voltage. During operation the doors of the central inverter must remain closed!
DANGER! Life-threatening danger due to residual voltage. After switching off the central inverter, observe a minimum wait time of 30 minutes before opening, without fail!
DANGER! Life-threatening danger due to high voltage. For all tasks in the vicinity of the central inverter: Maintain the safety distance to the central inverter that must be complied with in accordance with BGV A3 (see Table 4/BGV A3 "Safety distances for non-electrical work, depending on the rated voltage")! Comply with the sequence of protective measures: 1. Disconnect, 2. Safeguard from being switched on again, 3. Ensure that equipment is de-energized, 4. Ground and short circuit, 5. Cover or shield adjacent live components. Have the work area marked before starting work (responsible party according to BGI 758).
Safety
DANGER! Life-threatening danger due to high voltage. Make sure that only authorized and trained electricians work on the central inverter. The respective competences of the qualified electrician must be clearly established. In addition, special qualifications are required for the following activities: (see section About this operating manual" on page 2). Prior to starting all tasks on the central inverter: Ensure that the central inverter is disconnected from the grid. Ensure that the intermediate circuit of the central inverter has discharged. Safeguard the central inverter from switching on again spontaneously. Prior to performing tasks on the central inverter use a suitable tool to ensure that residual voltage is not present. Use suitable tools with appropriate markings and PPE for working on live parts (VDE 0680/VDE 0682). DANGER! Life-threatening danger due to a lack of help. If there is an accident a second person must provide help. Always work with a second person near you! NOTICE! Warning against damage to the HSI500 / HSI640 / HSI1000 / HSI1250. Improper repair work can cause damage to the central inverter. All repair tasks should be performed by employees of Helios Systems. DANGER! Life-threatening danger due to failure to comply with the safety instructions. Comply with the information and safety instructions affixed to the device and in this operating manual. Make sure that the operating manual is kept near the HSI500 / HSI640 / HSI1000 / HSI1250.
Safety
WARNING! Cut wounds due to hand tools. Only use suitable tools to cut and strip. Only use knives with a covered handle and cable measurement handles with a circular protrusion to prevent fingers from sliding in the direction of the blade. Wear protective gloves when using knives with a fixed blade. Do not keep a knife with open blade in work clothes or in the tool belt. DANGER! Danger of falling and injury when working on ladders. Check whether the tasks that must be performed can be safely performed from ladders. Otherwise, use work platforms or scaffolds. Select a suitable ladder and use it as intended e. g. do not use a step ladder as an extension ladder). Ensure that the set-up site is safe (capable of bearing a load, level, and that the ladder cannot slip). Wear safety footwear. WARNING! Warning - harmful to health. The electrolytic capacitors contain ethylene glycol that is considered to be an irritant and harmful to health. Wear protective goggles. Wear suitable protective clothing. In the case of contact, immediately seek a doctor. If there is eye contact rinse the eyes with water for at least 10 minutes. If swallowed drink plenty of water. Only induce vomiting if the affected person is fully conscious. Take off contaminated clothing immediately and remove it safely. If the case of skin contact wash off immediately with plenty of water.
Safety
DANGER! Life-threatening danger due to flammable or explosive gasses. Ensure that the ambient air is free of flammable or explosive gasses.
DANGER! Life-threatening danger due to corrosive substances. Ensure that the ambient air is free of corrosive substances.
DANGER! Danger of injury due to inadequate protective clothing. Always wear safety shoes when working on the HSI500 / HSI640 / HSI1000 / HSI1250.
Safety
2.3 Obligations of the owner

DANGER! Life-threatening danger due to high voltage. Make sure that only authorized and trained electricians work on the central inverter. The respective competences of the qualified electrician must be clearly established. In addition, special qualifications are required for the following activities: (see section About this operating manual" on page 2). For tasks performed on the central inverter it must remain in a deenergised state to the extent possible for the entire duration of the tasks. This is achieved via the following five safety rules: 1. Disconnect provide suitable devices for activating the switch elements. 2. Safeguard against restarting provide suitable devices to safeguard against restarting. 3. Ensure de-energised state provide suitable voltage detectors (up to 1000 V rated voltage, two-pole). 4. Ground and short circuit. 5. Cover or shield adjacent live components provide suitable covering material appropriate for the activity to be performed. The release for work should only be given after the person responsible for the work executes and checks the five safety rules.
Safety
DANGER! Life-threatening danger due to high voltage. Ensure that the operation of the HSI500 / HSI640 / HSI1000 / HSI1250 takes place in accordance with the valid legal provisions and the applicable safety instructions for the equipment in this operating manual, all safety instructions cited in this manual and affixed to the HSI500 / HSI640 / HSI1000 / HSI1250 are complied with, understood, and followed, all safety devices are always in faultless and functional operating status, (e. g. emergency stop switch on the control cabinet), the prescribed intervals or intervals specified in the operating manual for maintenance tasks are complied with, maintenance work may only be performed by authorized and trained, qualified electricians, repair tasks are only executed by employees of Helios Systems.
Safety
2.4 Obligations of the qualified electrician

DANGER! Life-threatening danger due to residual voltage. The HSI500 / HSI640 / HSI1000 / HSI1250 may only be installed, maintained, commissioned and de-commissioned by qualified electricians who have been trained and authorized. Ensure that a second instructed person, who can help in an emergency, is always present for all tasks performed on electrical equipment. If there is an accident the second person must switch off the power supply and provide help. After switching off the central inverter, observe a minimum wait time of 30 minutes prior to opening, without fail! Prior to performing tasks on the central inverter use a suitable tool to ensure that residual voltage is not present. On the display (optional), read out the DC voltage that is applied. Never open the central inverter during operation. Observe the operating manual, and especially the safety instructions, without fail. Observe the safety instructions affixed to the HSI500 / HSI640 / HSI1000 / HSI1250. Only operate the HSI500 / HSI640 / HSI1000 / HSI1250 in IT networks.
2.5 Obligations of the crane operator

DANGER! Danger of injury during crane operation. Deficiencies emerging during crane operation can result in severe or fatal injuries. The crane should only be operated by authorized specialists who have been trained in the area of crane operation. Ensure that the guidelines specified in BGV D6: Cranes, are satisfied. The angle between the ropes or chains of the crane and the top side of the HSI500 / HSI640 / HSI1000 / HSI1250 must be at least 45 (see section Crane transport" on page 34).
10
Safety
2.6 Obligations of the industrial truck operator

DANGER! Danger of injury during transport. Deficiencies emerging during transport can result in severe or fatal injuries. The industrial truck may only be operated by authorized, qualified personnel who are trained in the use of industrial trucks. Ensure that the guidelines specified in BGV D27: Industrial trucks, are satisfied.
11
Safety
2.7 Safety instructions on the central inverter

DANGER! Life-threatening danger due to high voltage. You must wait at least 30 minutes until the intermediate circuit has discharged.
DANGER! Life-threatening danger due to high voltage. Ensure that only qualified electricians who have been trained and authorized work on the central inverter.
CAUTION! Device damage due to loose power line. ALUMINUM CONDUCTORS Recommendation! Observe the following when using aluminum conductors: 1. Remove the oxide layer of the conductor (wire) with a wire brush. 2. Grease the aluminum conductor (wire) with acid-free grease (e. g. Vaseline or terminal grease). 3. The conductor should be checked after approx. 4 weeks with a torque wrench (Nm), thereafter it should be checked yearly. 4. Only one conductor (wire) should be connected in one terminal.
12
Safety
2.8 Identification of the HSI500 / HSI640 / HSI1000 / HSI1250

The type plates of the inverter and the control cabinet are located at the bottom on the outside of the door, at the top on the inside of the door and on the respective mounting plates. The type plate includes the following information: Serial Number Name Type Power Voltage Frequency Short Circuit Level Year of Manufacture Examples of the respective type plates are shown in the following: HSI500 power element HSI640 power element
HSI500 / HSI640 control cabinet
HSI1000 / HSI1250 control cabinet
13
Technical description
3 Technical description
3.1 Delivery
Check the delivery for completeness. If the delivery is not complete, please contact Helios Systems. Check the HSI500 / HSI640 / HSI1000 / HSI1250 for transport damage. If you determine that there is transport damage, immediately contact the freight forwarder. 3.1.1 Included in the delivery The scope of delivery varies, depending on whether you are using the HSI500, HSI640, HSI1000 or HSI1250: HSI500 / HSI640: 1x central inverter 1x control cabinet Control cabinet key for central inverter and control cabinet Operating manual Test log - final test Test protocol - insulation monitor HSI1000 / HSI1250: 2x central inverter 1x control cabinet Control cabinet key for central inverter and control cabinet Operating manual Test log - final test Test protocol - insulation monitor
14
3.2 Functional description

The HSI500 / HSI640 / HSI1000 / HSI1250 from Helios Systems has been specially developed for use in photovoltaic systems and equipped with the state-of-the-art, efficiency-optimised technology. It converts the DC voltage that is given off by the solar generators into grid-conformant alternating current and feeds it into the public power grid, three-phase. The HSI500 / HSI640 is comprised of a 500 kW / 640 kW central inverter and a control cabinet. The HSI1000 and HSI1250 are comprised of two 500 kW / 640 kW central inverters and a control cabinet. The central inverter is only intended for connection to the IT network.
Description HSI500 HSI640 HSI1000 HSI1250
Components 1x 500 kW power element and 1x control cabinet 1x 640 kW power element and 1x control cabinet 2x 500 kW power element and 1x control cabinet 2x 640 kW power element and 1x control cabinet
15
3.3 Principle of the systems

3.3.1 Principle of the HSI500 / HSI640
HSI500
Fig.3-1 HSI500 / HSI640 principle circuit diagram
The HSI500 / HSI640 is a three-phase central inverter for grid-coupled photovoltaic systems. The HSI500 / HSI640 is comprised of two cabinets, a central inverter and a control cabinet. From left to right: DC switch disconnector Q1, interference suppression filter (EMC), DC connection with IGBT bridge, interference suppression filter and the grid contactor K1.
16
3.3.2 Principle of the HSI1000 / HSI1250

HSI1000
Fig.3-2 HSI1000 / HSI1250 principle circuit diagram
The HSI1000 / HSI1250 is a three-phase central inverter for grid-coupled photovoltaic systems. The HSI1000 / HSI1250 is comprised of three cabinets, two central inverters and a control cabinet. From left to right: DC switch disconnector Q1, interference suppression filter (EMC), IGBT bridge, interference suppression filter and the grid contactor K1.
17
3.4 Exterior views

3.4.1 HSI500 / HSI640 exterior view
5
Fig.3-3 HSI500 / HSI640 exterior view
1 2 3 4 5
Air guide boxes Display (optional) (See "Display (optional)" on page 20) Emergency stop switch (See "Emergency stop switch" on page 20) Control cabinet Central inverter
18
3.4.2 HSI1000 / HSI1250 external view
Fig.3-4 HSI1000 / HSI1250 external view
1 2 3 4 5 6
Air guide boxes of the respective central inverters Display (optional) for the left central inverter (See "Display (optional)" on page 20) Emergency stop switch (See "Emergency stop switch" on page 20) Display (optional) for the right central inverter (See "Display (optional)" on page 20) Central inverter Control cabinet
19
3.4.3 Display (optional) The display is used to show status data, to reset error messages, and to switch the central inverter on and off. The display and control functions of the display run parallel to the software interface. 3.4.4 Emergency stop switch DANGER! Life-threatening danger due to residual voltage. Strictly maintain a minimum wait time of 30 minutes after switching off and prior to opening the central inverter! Prior to performing tasks on the central inverter use a suitable tool to ensure that residual voltage is not present. In an emergency the central inverter can be immediately disconnected from the grid (AC) and from the solar generator (DC) (See "Emergency stop switch" on page 56).
20
3.5 Interior views

3.5.1 Central inverter interior view
1 2
4 5 6 7
Fig.3-5 Central inverter interior view
1 2 3 4
Intermediate circuit IGBT bridge, L1, L2, L3 Measuring transducer DC current Measuring transducer AC current
5 6 7
DC switch disconnector Q1 HF-Filter Contactor K1
21
3.5.2 HSI500 / HSI640 control cabinet interior view
2 3
Fig.3-6 HSI500 / HSI640 control cabinet interior view
1 2 3 4
Communication board Control card Thermostats (only present if the heating option was selected) Hygrostat (only present if the heating option was selected)
5 6 7
Insulation monitor 3x 24 V power supply unit Transformer for the internal power supply (optional)
22
3.5.3 HSI1000 / HSI1250 control cabinet interior view
4 3 5
Fig.3-7 HSI1000 / HSI1250 control cabinet interior view
1 2 3 4
Communication board Control card Thermostats (only present if the heating option was selected) Insulation monitor
5 6 7
Hygrostat (only present if the heating option was selected) 3x 24 V power supply unit Transformer for the internal power supply (optional)
23
3.5.4 Optional heating elements NOTICE! Warning against damage to the HSI500 / HSI640 / HSI1000 / HSI1250. The values of the thermostats and of the hygrostats should not be adjusted.
Fig.3-8 Heating elements (left HSI500 / HSI640; right HSI1000 / HSI 1250, with and without the display option)
Optionally, two heating elements can be installed on the inside of the door. In addition, there are two thermostats and a hygrostat in the control cabinet. The values are set at the factory and may not be changed: -BT1 -5 C, -BT2 +5 C, -BT3 > 90 % relative humidity. The heating elements switch on automatically as soon as the temperature falls below 5 or C the relative humidity exceeds 90 %. If the temperature falls below -5 the power supply of the C control card is switched off. The heating elements remain switched on. If the temperature exceeds -5 the power supply of the control card is automatically switched on again. C,
24
3.6 Technical data

3.6.1 Technical data of the HSI500 Electrical data
Rated output power Rated output power 500 kW 560 kW at +/-10 % of the rated grid voltage at rated voltage only IT network, other frequencies on request
Grid voltage and frequency range 270 V +/-10 %, 3~, 50 Hz +/-2 Hz Maximum output current Power factor (cos ?) Distortion factor (THD) Rated PV power Maximum PV power Maximum PV power Maximum PV off-load voltage MPP range Regulating procedure Efficiency EC efficiency Infeed from Loss in standby/at night Maximum station service 1199 A > 0,98 <3% 510 kW 575 kW 1230 A 900 V= 450 V= to 820 V= MPP tracking
from 20 % rated output at rated power within +/-10 % rated grid voltage at rated voltage
at rated PV power
(97,0 | 98,0 | 98,0 | 97,9 | 97,8) % at (10 | 30 | 50 | 75 | 100) % power 97,8 % 700 W < 30 W < 1000 W excl. station service
25
General data
Ambient temperature Humidity Set-up altitude Type of cooling Minimum air quality Protection class Dimensions (H x W x D) Weight Cabinet colour EMC Low-voltage directive Grid monitor CE conformity 0 to 50 C C < 95 % up to 2000 m above sea level Forced convection cooling Class 3S2 IP20 2100 mm x 1800 mm x 850 mm 1600 kg RAL7035 fulfils EN61000-6-2, EN61000-6-4 fulfils EN50178 in accordance with VDEW guidelines Satisfied Inverter + Control cabinet Inverter cabinet + Control cabinet other on request other on request Non-condensing without power loss 3600 m3/h in accordance with EN60721-3-3
Equipment/components
Buffer amplifier AC contactor Emergency stop switch Display Ground fault monitor Overvoltage protector Present Touch screen with numeric and graphic output Insulation monitor Monitored overvoltage protector - DC current side three-phase current side Load disconnect switch with motor drive
Options
- Cabinet heater - Display
Accessories
- DC distribution with up to 60 inputs (individually secured with switch disconnectors) - String Monitoring System
26

Rated output power Rated output power 640 kW 680 kW at rated voltage at rated voltage only IT network, other frequencies on request
Grid voltage and frequency range 300 V +/-10 %, 3~, 50 Hz +/-2 Hz Maximum output current Power factor (cos ?) Distortion factor (THD) Rated PV power Maximum PV power Maximum PV power Maximum PV off-load voltage MPP range Regulating procedure Efficiency EC efficiency Infeed from Loss in standby/at night Maximum station service 1244 A > 0,98 <3% 654 kW 695 kW 1308 A 900 V= 500 V= to 820 V= MPP tracking (97,5 | 98,3 | 98,3 | 98,2 | 98,0) % 98,1 % 700 W < 30 W < 1000 W
from 20 % rated output at rated power at rated voltage at rated voltage
at rated PV power
at (10 | 30 | 50 | 75 | 100) % power excl. station service
General data
Ambient temperature Humidity Set-up altitude Type of cooling Minimum air quality Protection class Dimensions (H x W x D) Weight Cabinet colour EMC Low-voltage directive Grid monitor CE conformity 0 to 50 C C < 95 % up to 2000 m above sea level Forced convection cooling Class 3S2 IP20 2100 mm x 1800 mm x 850 mm 1700 kg RAL7035 fulfils EN61000-6-2, EN61000-6-4 fulfils EN50178 in accordance with VDEW guidelines Satisfied Inverter + Control cabinet Inverter + Control cabinet other on request other on request Non-condensing without power loss 3600 ml/h in accordance with EN60721-3-3
27
Options
Accessories
28

Rated output power Rated output power Grid voltage range and grid frequency Maximum output current Power factor (cos ?) Distortion factor (THD) Rated PV power Maximum PV power Maximum PV power Maximum PV off-load voltage MPP range Regulating procedure Efficiency EC efficiency Infeed from Loss in standby/at night Maximum station service 1000 kW 1100 kW 270 V +/-10 %, 3~, 50 Hz/60 Hz +/- 2 Hz 2376 A > 0,98 <3% 2 x 511 kW 2 x 562 kW 2 x 1249 A 900 V= 2x (450 V= to 820 V=) MPP tracking (97,0 | 98,0 | 98,0 | 97,9 | 97,8) % at (10 | 30 | 50 | 75 | 100) % power 97,8 % 700 W < 80 W < 2000 W excl. station service per MPP tracker at rated PV power from 20 % rated output at rated power within +/-10 % rated grid voltage at rated voltage at +/-10 % of the rated grid voltage at rated voltage only IT network other frequencies on request
General data
Ambient temperature Humidity Set-up altitude Type of cooling Min. air quality Protection class Dimensions (H x W x D) Weight Cabinet colour EMC Low-voltage directive Grid monitor CE conformity 0 to 50 C C < 95 % up to 2000 m above sea level Forced convection cooling Class 3S2 IP20 2100 mm x 3000 mm x 850 mm 3000 kg RAL7035 fulfils EN61000-6-2, EN61000-6-4 fulfils EN50178 in accordance with VDEW guidelines Satisfied Inverter + Control cabinet Inverter + Control cabinet other on request other on request Non-condensing without power loss 3600 ml/h in accordance with EN60721-3-3
29
Options
Accessories
30

Rated output power Rated output power Grid voltage range and grid frequency Maximum output current Power factor (cos ?) Distortion factor (THD) Rated PV power Maximum PV power Maximum PV power Maximum PV off-load voltage MPP range Regulating procedure Efficiency EC efficiency Infeed from Loss in standby/at night Maximum station service 1280 kW 1360 kW 300 V +/-10 %, 3 ~ 50 Hz/60 Hz +/-2 Hz 2488 A > 0,98 <3% 2 x 654 kW 2 x 695 kW 2 x 1,308 A 900 V= 2 x (500 V= to 820 V=) MPP tracking (97,5 | 98,3 | 98,3 | 98,2 | 98,0) % 98,1 % 700 W < 80 W < 2000 W at (10 | 30 | 50 | 75 | 100) % power excl. station service per MPP tracker at rated PV power from 20 % rated output at rated power at rated voltage at rated voltage at rated voltage only IT network other frequencies on request
General data
Ambient temperature Humidity Set-up altitude Type of cooling Min. air quality Protection class Dimensions (H x W x D) Weight Cabinet colour EMC Low-voltage directive Grid monitor CE conformity 0 to 50 C C < 95 % up to 2000 m above sea level Forced convection cooling Class 3S2 IP20 2100 mm x 3000 mm x 850 mm 3200 kg RAL7035 fulfils EN61000-6-2, EN61000-6-4 fulfils EN50178 in accordance with VDEW guidelines Satisfied Inverter + Control cabinet Inverter + Control cabinet other on request other on request Non-condensing without power loss 3600 ml/h in accordance with EN60721-3-3
31
Options
Accessories
32
Transport and the necessary conditions at the installation site
4 Transport and the necessary conditions at the installation site
4.1 Packaging
Unless otherwise agreed, the packaging satisfies the HPE packaging guidelines that have been specified by the German Associations for Wooden Materials, Pallets, Export Packaging (Bundesverband Holzmittel, Paletten, Exportverpackung e. V).
4.2 Transport
DANGER! Life-threatening danger due to the HSI500 / HSI640 / HSI1000 / HSI1250 tipping over. Only transport the inverter cabinet of the HSI500 / HSI640 / HSI1000 / HSI1250 using an industrial truck with sufficient loadbearing capacity. Only transport the control cabinet of the HSI500 / HSI640 / HSI1000 / HSI1250 using a crane or industrial truck with sufficient load-bearing capacity. The HSI500 / HSI640 / HSI1000 / HSI1250 may only be transported by authorized, qualified personnel trained in the operation of industrial trucks and cranes. NOTICE! Improper transport can damage the device. Only transport the devices HSI500 / HSI640 / HSI1000 / HSI1250 in an upright position in order to prevent damage.
4.2.1 General instructions Check the delivery immediately after it arrives for completeness and possible transport damage. If the delivery is incomplete contact Helios Systems. Only transport the inverter cabinet with an industrial truck. The control cabinet is supplied with transport eyes and can be transported using a crane or an industrial truck. Use suitable transport equipment appropriate for the local conditions. Comply with the information in sections Obligations of the crane operator" on page 10 and Obligations of the industrial truck operator" on page 11 in this regard.
33
Only remove the transport safeguards when the HSI500 / HSI640 / HSI1000 / HSI1250 is standing vertically at the intended installation site. 4.2.2 Crane transport DANGER! Life-threatening danger due to falling loads. Falling loads can cause fatal injuries. Only use the permissible lifting devices to lift loads. Ensure that no one is in the danger zone of the suspended load. Wear appropriate protective work clothing. DANGER! Life-threatening danger if the wrong lifting devices are used. Use of the wrong lifting devices can cause severe or fatal injuries. When lifting the control cabinet of the HSI500 / HSI640 / HSI1000 / HSI1250, only use the permissible lifting devices (weight of the respective device: See "Technical data" on page 25). Transport eyes in accordance with DIN 580 are provided for loading the control cabinet of the HSI500 / HSI640 / HSI1000 / HSI1250. The following permissible total loads apply for systematic load: At 45 cable angle 4800 N At 60 cable angle 6400 N At 90 cable angle 13600 N
34
4.2.3 Industrial truck support NOTICE! Warning against use of the lifting device (e. g. forklift). Components and connections on the underside of the base of the HSI500 / HSI640 / HSI1000 / HSI1250 can be damaged by the lifting device. When lifting the HSI500 / HSI640 / HSI1000 / HSI1250 equipment, ensure that components and connections on the base of the unit are not damaged. When lifting the HSI500 / HSI640 / HSI1000 / HSI1250 ensure that the stress or load is only applied in the area of the pedestal feet.
Fig.4-1 Industrial truck transport of the HSI1000 / HSI1250
35
4.2.4 Securing for transport NOTICE! Warning against damage from improper transport safeguards. Improper transport safeguarding can result in damage to the HSI500 / HSI640 / HSI1000 / HSI1250. For transport on a truck or trailer the HSI500 / HSI640 / HSI1000 / HSI1250 must be properly lashed. The truck or trailer must have lashing eyes. Trained, specialised personnel that meet the requirements specified in regulations VDI 2700 and VDI 2703 must load the central inverter. The correct dimensioning and implementation of load securing measures must be specified on a case-by-case basis. To lash the HSI500 / HSI640 / HSI1000 / HSI1250, fasten the ratchet strap on the lashing eyes of the equipment and the lashing eyes of the landing surface. Tighten the ratchet strap with the tensioning device.
36
4.3 Installation site prerequisites

4.3.1 Grid NOTICE! Ensure that the rotary field is correct. The rotary field must be clockwise. If this is not the case the central inverter will not establish a connection to the public grid.
The HSI500 / HSI640 / HSI1000 / HSI1250 may only be operated in an IT network. The connection of two or more inverters to an IT network is not permitted.
37
4.3.2 Connections The following connection cables must be present, prepared, and secured: Solar generator connection, Grid connection, Auxiliary voltage connection, Communication connection. DANGER! Life-threatening danger due to high voltage. Protect cables and lines against mechanical influences. All cables and lines must be protected by a highly flexible plastic protective hose. Offload the plastic protective hose on both ends with catching clamps to relieve the hose from pull and pressure. Fit a marked pull-in aid (not metal) on each plastic protective hose. Ensure that the cables and lines are introduced into the central inverter and control cabinet from below. In this regard at least protection class IP20 must be ensured. DANGER! Life-threatening danger due to defective lines and cable. Comply with the specified bend radii. Offload the plastic protective hose on both ends to relieve the hose from pull and pressure. Only route one cable through each cable gland. Ensure that the diameter of the cables and lines match the diameters of the cable glands and threaded unions.
4.4 Foundation
The foundation must be able to support the weight of the HSI500 / HSI640 / HSI1000 / HSI1250 and the transport device. The foundation must be level, stable, slip-resistant, and fire resistant.
38
4.5 Distances
The HSI500 / HSI640 / HSI1000 / HSI1250 must be easily accessible for operation and maintenance. In this regard the following distances must be maintained: Front: 500 mm minimum with open door. The HSI500 / HSI640 / HSI1000 / HSI1250 requires a minimum distance of 50 mm to the side and rear.
HSI1000 / HSI1250
min 50 mm
HSI500 / HSI650
min 50 mm min 50 mm min 50 mm
min 50 mm
min 50 mm
min 500 mm min 500 mm
Fig.4-2 Distances with open door (left HSI1000 / HSI1250; right HSI500 / HSI640)
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4.6 Ventilation
DANGER! Life-threatening danger due to flammable or explosive gasses. Ensure that the ambient air is free of flammable or explosive gasses.
DANGER! Life-threatening danger due to corrosive substances. Ensure that the ambient air is free of corrosive substances.
NOTICE! Warning - damage or overheating of the HSI500 / HSI640 / HSI1000 / HSI1250. Insufficient cooling air for the HSI500 / HSI640 / HSI1000 / HSI1250 can lead to damage or overheating. Ensure that sufficient cooling air is available at the installation site.
4.6.1 Ventilation of the central inverter The central inverter must be set up on a foundation that ensures that sufficient air can be suctioned in. The suctioned air is distributed in the interior of the central inverter by fans. The central inverter circulates the air with three small fans in the doors and two large radial fans in the cover. The air is suctioned in from below and blown out on the top side of the central inverter. The required air quantity, the air quality and the protection class must fulfil the requirements in section Technical data" on page 25.
40
4.6.2 Ventilation of the control cabinet The control cabinet must be set up on a foundation that ensures that sufficient air can be suctioned in. The suctioned air is distributed in the interior of the control cabinet by fans. The control cabinet circulates the air with fans in the cover. The air is suctioned in from below and blown out on the top side of the control cabinet. The required air quantity, the air quality and the protection class must fulfil the requirements in section Technical data" on page 25.
4.7 Ambient variables

The protection class must meet the specifications in section Technical data" on page 25.
41
Installation
5 Installation
DANGER! Life-threatening danger due to high voltage. The installation of the inverter and the control cabinet may only be performed by trained, qualified personnel authorized by the operator. Observe the safety instructions affixed to the HSI500 / HSI640 / HSI1000 / HSI1250 and in this operating manual. Check the cable feeds for damage. NOTICE! Material damage due to the incorrect torque. If the cable lugs are tightened too tightly damage can occur. If the cable lugs are tightened too loosely the cables and lines can loosen.
NOTICE! Material damage due to improper connection. Ensure that the oxide layer of the aluminum conductor has been removed with a wire brush, the aluminum conductor (wire) has been greased with acid-free grease (e. g. Vaseline or terminal grease), the connection of the aluminum conductor is checked after approx. 4 weeks, with a torque wrench, thereafter it must be checked yearly, only one aluminum conductor is connected per terminal.
42
Installation
5.1 Installation of the central inverter

5.1.1 Connect the solar generator (DC) DANGER! Life-threatening danger due to high voltage. The installation may only be carried out by qualified electricians who have been trained and authorized.
1. Open the front door. 2. Remove the sliding floor plate. 3. Route the cable to the connection area from below. 4. Check the cable feeds for damage.
Fig.5-1 Copper rails for the connection of the solar generator
5. The cable lugs must be configured for fastening with M10 screws. Route the cable lugs to the correct copper rail. Ensure correct polarity. 6. Fasten the cable lugs (torque of 45 Nm). 7. If no other cables will be connected reinstall the sliding door.
43
Installation
5.1.2 Connecting to the grid (AC) NOTICE! Ensure that the rotary field is correct. The rotary field must be clockwise. Otherwise, the inverter will not establish a connection to the public grid.
1. Open the front door. 2. Remove the sliding floor plate. 3. Route the cable to the connection area from below. 4. Check the cable feeds of the grid connection for damage.
Fig.5-2 AC power switch Q2
5. The cable lugs must be configured for fastening with M12 screws. Route the cable lugs to the correct contactor inputs. The colour sequence is as follows, from left to right (tightening torque: 80 Nm). - (1) L1 left/brown - (2) L2 centre/black - (3) L3 right/gray
44
Installation
6. Connect the PE conductor. The cable lug for the PE conductor must be configured for M8 screws (torque: 23 Nm).
Fig.5-3 PE conductor (green-yellow)
7. If no other cables will be connected reinstall the sliding door.
45
Installation
5.2 Cable connections in the control cabinet

The inverter cabinet is positioned to the left of the control cabinet. An additional converter cabinet is positioned to the right of the control cabinet for the HSI1000 / HSI1250. The left half of the control cabinet contains the following cable connections for the HSI500 / HSI640 / HSI1000 / HSI1250: HSI500 / HSI640 / HSI1000 / HSI1250 X1A DC voltage for insulation monitor AC voltage L1, L2 and L3 for AC voltage measurement Supply voltage for roof fan Q1 and K1 feedback Overvoltage protection Control signal for roof fan Control for intermediate circuit fans in the door and/or rear wall Q1 and K1 control 230 V supply voltage for the optional heating elements. Screw the green-yellow PE cable on the mounting plate with 8 Nm. Drive cable DC measurement line For the HSI1000 / HSI1250 the right half of the control cabinet contains the following additional cable connections: HSI1000 / HSI1250 X1B DC voltage for insulation monitor AC voltage L1, L2 and L3 for AC voltage measurement Supply voltage for roof fan Q1 and K1 feedback Overvoltage protection Control signal for roof fan Control for intermediate circuit fans in the door and/or rear wall Q1 and K1 control 230 V supply voltage for the optional heating elements. Screw the green-yellow PE cable on the mounting plate with 8 Nm. Drive cable Measurement loc
X3A
X5A X20A X13A PE
X3B
X5B X20B X13B PE
46
Installation
5.3 Installation of the control cabinet

All connections between the inverter and the control cabinet were disconnected for transport. In the following an explanation on the basis of a control cabinet for the HSI1000 and 1250 is provided for which cables must be connected in order to ensure correct operation. The respective connections are only provided once in the control cabinet of the HSI500 or HSI640.
1
1
Ethernet connection D-SUB plug connector Plug connectors for periphery Potential equalisation screws Auxiliary transformer -T1 Terminal strip X9
2 3 4 5 6
Points 1 to 4 are provided twice. The left inverter is connected to the left and the right inverter is connected to the right.
5 6
Fig. 5-4 Control cabinet connections
47
Installation
5.3.1 Internal connections between central inverter and control cabinet
Fig.5-5 View of control cabinet with connected connections
1. Guide the cable through the provided opening from the inverter to the control cabinet. 2. Connect the D-SUB plug connections to the connections (2, see page 47) and screw them onto the control card. The D-SUB plug connections serve for the control of the power elements and, therefore, are of considerable importance for the correct operation of the inverter. The D-SUB plug connectors X104 to X105 serve for the control of the power stages. The plug X103 includes the Idc input current. 3. Then connect the five plug connectors for the periphery to the connections (3, see page 47) by plugging the respective plug connector into the terminal strip. 4. Fasten the green-yellow PE wire to the potential equalisation using the screw (4, see page 47).
48
Installation
5.3.2 External connections of the control cabinet DANGER! Life-threatening danger from missing overload / lightning protection. No lightning / overvoltage protection is installed for the communication lines. If the lines should leave the building in which the HSI500 / HSI640 / HSI1000 / HSI1250 is located, appropriate lightning protection must be installed by an authorized electrician. NOTICE! Material damage from improper routeing of cable. Use the available wiring conduit to route the cable within the control cabinet.
The supply, feedback and communication lines are connected to the control cabinet as external connections. 1. There are two different possibilities for connecting the external voltage supply. Both possibilities are achieve through the terminal strip X9 (6, see page 47). The inverter is supplied directly from the 270 / 300 V IT network. For this purpose, the connection takes place at terminals 1 and 2 of the terminal strip X9. The voltage is converted to 230 V TN using the auxiliary transformer -T1 (5, see page 47). The inverter is operated directly with a supply voltage of 230 V TN. Connect the supply to the terminals 6 to 8 of the terminal strip X9 (6, see page 47).
Fig.5-6 Terminal configuration of the connection X9.
49
Installation
2. The data communication between the inverter and the monitoring system takes place through the Ethernet interface of the control cabinet (HSI500 / HSI640 each have one and the HSI1000 / HSI1250 each have two Ethernet connections). Connect the Ethernet cable to the Ethernet connection (1, see page 47). For further information about the monitoring system, the latest version is available for download at www.helios-systems.net. 3. Every inverter has zero potential signal and control contacts which can be used as necessary. "Inverter ready" changeover contact, connection X2A, terminals 1 to 3. Connection for external emergency stop switch, connection X2A, terminals 4 to 5. "Insulation monitor" changeover contact, connection X2A, terminals 6 to 7.
external customer contact "Unit A ready" Emergency stop costumer Insulation monitor
from 230V or 24V
to 230V or 24V to 230V or 24V
X2A
21
-S2
22
Fig.5-7 Zero potential signal and control contacts
50
Installation
4. In addition, external consumers can also be connected to the various outgoing supply voltage lines, such as for lighting or outlets for stations.
2a.6 / 2.1 / 2a.6 /
L N
L / 2a.2 N / 2.6 PE / 2a.2
PE
-F8
/2.1 B6A 2
-F9
/2.2 B6A 2
-F10
/2.2 B6A 2
-F11
/2.3 B6A 2
-X14
10
11
12
Power Supply Light and Sockets
Power Supply Light and Sockets
Fig.5-8 Outgoing supply voltage lines for external consumers
51
Commissioning
6 Commissioning
DANGER! Life-threatening danger due to high voltage. Observe the safety instructions affixed to the HSI500 / HSI640 / HSI1000 / HSI1250 and in this operating manual. The HSI500 / HSI640 / HSI1000 / HSI1250 may only be commissioned by qualified electricians who have been trained and authorized. DANGER! Life-threatening danger due to high voltage. Ensure that the central inverter is de-energized, the slide switch on the DC switch disconnector Q1 is in position Auto, the emergency stop switch is pressed, all cables and lines are undamaged, correctly connected and in faultless condition, the threaded unions on all connection rails and terminal strips have the correct tightening torque.
1. The central inverter must be connected on the DC main supply. 2. The central inverter must be connected on the AC main supply. DANGER! Life-threatening danger due to high voltage. Only take measurements with appropriate measurement devices.
3. Measure the DC voltage. The polarity must correspond to the plus/minus markings, and the measured values must be within the tolerances (see section Technical data" on page 25). 4. Switch on all DC power switches. 5. Measure the grid voltage AC from phase to phase. The measured values must be within the tolerances (see section Technical data" on page 25).
52
Commissioning
WARNING! Danger of pinching when closing the front door. When closing the front door, ensure that bodily extremities (hands, fingers) do not get caught in the closing edges. 6. Close the front door. 7. Unlock the emergency stop switch. After a short wait time, the central inverter starts up.
53
Operating states
7 Operating states
After commissioning, the central inverter runs through operating states described below. The parameters that cause the central inverter to change to a certain operating state are prescribed.
7.1 Standby
If the solar generator voltage is below Umpp min, the central inverter switches to "Standby" mode. The central inverter is connected to the grid via the grid contactor K1.
7.2 Start up
If the solar generator voltage increases to 50 V above Umpp min, infeed mode is started. If the solar generator current falls below the minimum value, infeed mode switches off for 30 seconds. If the solar generator voltage increases to 50 V above Umpp min, infeed mode is switched on again. If the solar generator current is continuously above the minimum value, the central inverter is in normal mode and infeed is continuous. Start-up can require various attempts; if necessary, a pause of a few minutes must be observed after several attempts.
7.3 MPP mode

Thanks to the Maximum Power Point Tracker (MPPT) the solar power of the solar generator is optimally used. The MPPT is comprised of the continuous MPPT and the cyclical MPPT. The continuous MPPT varies the solar generator voltage in small increments, and determines the solar generator power after each increment. In this process the continuous MPPT always the tracks the path of optimal solar generator power. The cyclic MPPT scans a defined voltage range in large increments. This takes place several time each day. If the cyclic MPPT has found the solar generator voltage with the greatest solar generator power, the continuous MPPT takes over this solar generator voltage for further tracking.
7.4 Shutdown
If the solar generator current drops below the minimum value, initially only the infeed operation is switched off. If the solar generator voltage drops below Umpp min, the central inverter is disconnected from the grid by opening the grid contactor K1.
54
Operating states
7.5 Stop
Fault monitoring is active in each operating state. If a fault occurs, all functions of the central inverter will be stopped automatically. An error message will be shown on the display. If the cause of the fault is eliminated, the central inverter returns to "Standby" mode after a wait time.
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De-commissioning
8 De-commissioning
DANGER! Life-threatening danger due to residual voltage. Strictly maintain a minimum wait time of 30 minutes after switching off and prior to opening the central inverter! Prior to performing tasks on the central inverter use a suitable tool to ensure that residual voltage is not present.
8.1 Emergency stop switch

NOTICE! Only activate the emergency stop switch in an emergency. In an emergency the emergency stop switch immediately disconnects the central inverter from the power supply (AC) and from the solar generator (DC). Only once the dangerous situation has passed and potential faults have been eliminated may the emergency stop switch be unlocked by pulling it out again. Press the emergency stop switch to shut down the central inverter in an emergency. After unlocking the emergency stop switch the central inverter will resume operation after a brief wait time.
8.2 Switching off the control voltage

If there is an internal power supply the control voltage must be switched off on the automatic circuit breaker F7. If there is an external power supply the control voltage must be switched off outside of the central inverter.
56
Maintenance
9 Maintenance
DANGER! Life-threatening danger due to high voltage. The HSI500 / HSI640 / HSI1000 / HSI1250 may only be maintained by qualified electricians who have been trained and authorized. Using suitable tools, ensure that the HSI500 / HSI640 / HSI1000 / HSI1250 has been switched off and de-energised. Always work with a second person near you. NOTICE! Warning - damage to the central inverter. Improper repair work can cause damage to the central inverter. All repair tasks should be performed by employees of Helios Systems.
9.1 Executing maintenance tasks

1. Switch off the HSI500 / HSI640 / HSI1000 / HSI1250 (see section De-commissioning" on page 56). DANGER! Life-threatening danger due to residual voltage when performing maintenance tasks on the outer area. For all work near the HSI500 / HSI640 / HSI1000 / HSI1250 Maintain the safe distance to the HSI500 / HSI640 / HSI1000 / HSI1250 that must be complied with in accordance with BGV A3 (see Table 4/BGV A3 "Safety distances for non-electrical work depending on the rated voltage")! DANGER! Life-threatening danger due to residual voltage when performing maintenance tasks in the interior. After switching off the central inverter, observe a minimum wait time of 30 minutes before opening, without fail! Prior to opening the central inverter use a suitable tool to ensure that residual voltage is not present.
57
Maintenance
The maintenance tasks described must be executed within the specified intervals, starting with the installation date.
Maintenance tasks Check the housing and interior area for discolouration, corrosion, fouling, significant dust and water accumulation, and damage. Check all fans and their filters, if present. Check whether foreign objects on the central inverter hinder air circulation. Check the function of the DC load switch (Q1). Check the status of the copper rails. Check the status of all cables and lines. Check all fuses for damage. Check the AC and DC overvoltage protection for damage. Check the function of the internal 24 V power supply. Check the accuracy of the AC measured values (See "Taking measurements" on page 59). Check the function of the emergency stop switch. Check the status of the capacitors. Every 12 months X X X X X X X X X X X Every 24 months
58
Maintenance
9.2 Taking measurements

DANGER! Life-threatening danger due to residual voltage. After switching off the central inverter, observe a minimum wait time of 30 minutes before opening. Prior to opening the central inverter use a suitable tool to ensure that residual voltage is not present. Only take measurements with measurement devices intended for this purpose. 1. Check the output voltage of the internal 24 V power supply. The DC output voltage of the 24 V power supply unit should be 24 V +/- 0.5 V. Use a multimeter. 2. Check the accuracy of the AC measured values. The alternating current of phases L1, L2 and L3 are shown on the display. Compare these display values with the values measured by the voltmeter. The accuracy should be +/-2.5 %. WARNING! Danger of pinching when closing the front door. When closing the front door, ensure that bodily extremities (hands, fingers) do not get caught in the closing edges. 3. Close the front door. 4. Switch on the HSI500 / HSI640 / HSI1000 / HSI1250 (See "Commissioning" on page 52).
59
Disposal
10 Disposal
DANGER! Life-threatening danger due to residual voltage. The HSI500 / HSI640 / HSI1000 / HSI1250 may only be disassembled and disposed of by qualified electricians who have been trained and authorized.
The HSI500 / HSI640 / HSI1000 / HSI1250 contains electrical components and metal. Final and professional decommissioning and/or disposal of the HSI500 / HSI640 / HSI1000 / HSI1250 must be executed under the applicable statutory regulations of the country of use. Please observe the special regulations for electronics and electrical equipment, in particular. The HSI500 / HSI640 / HSI1000 / HSI1250 has been manufactured in accordance with the applicable EC Directive 2002/95/EC on the Restriction of the use of certain Hazardous Substances in Electrical and Electronic Equipment (RoHS). No solder points contain lead, thus there are no hazardous substances. Separate disposal is not necessary. The waste management company is responsible for the correct coding and description of its waste.
60
Disposal
10.1 Disposal of the electrolytic capacitors

WARNING! Warning - harmful to health. The electrolytic capacitors contain ethylene glycol that is considered to be an irritant and harmful to health. Wear protective goggles. Wear suitable protective clothing. If there is contact seek medical attention immediately. If there is eye contact rinse eyes with water for at least 10 minutes. If swallowed drink plenty of water. Only induce vomiting if the affected person is fully conscious. Take off contaminated clothing immediately and remove it safely. If the case of skin contact wash off immediately with plenty of water. CAUTION! Environmental damage is possible because ethylene glycol poses a slight hazard to water. The ethylene glycol from the electrolytic capacitors should not get into soil or ground water.
Electrolytic capacitors are in the intermediate circuit, in the 24 V power supply unit and in other electronic components. Comply with the regulations for disposal of special waste, in particular. The regulations issued by government agencies apply, particularly the regulations associated with the European Waste Catalogue.
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Faults
11 Faults
DANGER! Life-threatening danger due to high voltage. Faults on the HSI500 / HSI640 / HSI1000 / HSI1250 may only be corrected by qualified electricians who have been trained and authorized.
If a fault occurs during operation, the HSI500 / HSI640 / HSI1000 / HSI1250 goes into the Stop mode (see section Operating states" on page 54). An error code and its description in English will appear on the display.
Error code Description Possible cause
Temperature A high ambient temperature can increase the temperature in the interior of the HSI500 / HSI640 / HSI1000 / HSI1250 and impair normal operation. Keep the ambient variables of the HSI500 / HSI640 / HSI1000 / HSI1250 in the range of the data cited in section Technical data" on page 25. 11 12 13 14 15 16 18 21 Overvoltage 31 32 33 34 35 36 Overcurrent inverter phase L1, HW driver Overcurrent inverter phase L1, HW control card Overcurrent inverter phase L1, software Overcurrent phase L1, software Overcurrent inverter phase L2, HW driver Overcurrent inverter phase L2, HW control card Excessive phase current Excessive phase current Phase current L1 > 400 A Grid current L1 > 180 A Excessive phase current Excessive phase current Temperature inverter phase L1, HW driver Temperature inverter phase L1, software Temperature inverter phase L2, HW driver Temperature inverter phase L2, software Temperature inverter phase L3, HW driver Temperature inverter phase L3, software Temperature, ambient Temperature, control card Temperature IGBT L3 > 90 ventilation C, ok? Ambient temperature > 50 C Ambient temperature > 50 C Temperature IGBT L2 > 90 ventilation C, ok? Temperature IGBT L1 > 90 ventilation C, ok?
62
Faults
Error code 37 38 39 40 41 42 43 44 45 Overvoltage 70 75 80 81 82 Undervoltage 120 125 130
Description Overcurrent inverter phase L2, software Overcurrent phase L2, software Overcurrent inverter phase L3, HW driver Overcurrent inverter phase L3, HW control card Overcurrent inverter phase L3, software Overcurrent phase L3, software Overcurrent I_DC, HW control card Overcurrent I_DC, software Unsymmetric inverter currents
Possible cause Phase current L2 > 400 A Grid current L2 > 180 A Excessive phase current Excessive phase current Phase current L3 > 400 A Grid current L3 > 180 A IDC too high IDC > 280 A
Overvoltage grid phase L1, stage 5 Overvoltage grid phase L2, stage 5 Overvoltage grid phase L3, stage 5 Overvoltage DC link, HW control card Overvoltage DC link, software
Grid voltage > 110 % or setting error Grid voltage > 110 % or setting error Grid voltage > 110 % or setting error DC voltage > 900 V or setting error DC voltage > 900 V or setting error
Undervoltage grid phase L1, stage 5 Undervoltage grid phase L2, stage 5 Undervoltage grid phase L3, stage 5
Grid voltage < 90 % Grid voltage < 90 % Grid voltage < 90 %
Power switch Check whether the power switches are switched on: AC power switch Q2, DC switch disconnector Q1. 151 Q1 tripped - DC switch disconnector Q1 in tripped position. - Is the emergency stop switch unlocked? AC switch disconnector Q2 in tripped position AC switch disconnector in tripped position
152 155
Q2 tripped K1 tripped
63
Faults
Error code
Description
Possible cause
Hardware Hardware faults indicate damage. Contact the authorized service staff. 161 162 163 164 166 167 168 Grid 171 174 Grid rotation Grid frequency Check whether the rotary field is clockwise (L1, L2, L3) Check the grid frequency Inverter phase L1 Inverter phase L2 Inverter phase L3 Error_X103 Short-circuit DC link Insulation error Overvoltage protection Problem with the insulation of the solar field relative to PE (ground error) Change the IGBT driver Change the IGBT driver Change the IGBT driver Check the cable to the IDC sensor
Software An internal error counter outputs a "Service Request" as soon as a certain number of errors has occurred. If too many errors have occurred, the HSI500 / HSI640 / HSI1000 / HSI1250 switches to "Stop" mode (Errorcounter overrun). Contact the authorized service staff. 181 183 184 Wrong system parameters Error counter overrun (x errors/hour) User switched off inverter via display or Ethernet
64
Appendix
12 Appendix
12.1 Spare parts list for the HSI500 / HSI640 control cabinet
Type without adapter plate AST3211-A1-D24 Web server EMERGENCY STOP MPMP3-10R Contact block MCBH-02 FAC3X/900/C Auxiliary switch block CEL 18-10 PLC-RSP-230UC/21-21AU TRIO-PS/1AC/24VDC/5A PLC-RSP-230UC/21-21 Type FZK +5...+60? Type FZK -20...+30? -K1 -K12A -G1 -K11A -BT1 -BT3 -M1 S201-K8A -F6A, -F7 -A8 -S1 -S1 -A3 -H1 -A1 1 1 1 1 1 1 1 1 3 1 1 1 1 2 Location Quantity Helios item number 810021 540006 110003 500008 500130 540009 500006 520001 580002 520010 550002 550003 650004 510047
Item
Control card
Display
Web server
Emergency stop
Contact block
Insulation tester
Auxiliary contact
Relay
Power supply
Interface relay
Thermostat
Thermostat
Fan
Circuit Breaker
65
Appendix
Type S201-B6A PLC-RSP-230UC/21HC MTDN 3000 VA CHM2D 1000V/440mA fuse 10x38 CHM3D 1000V/440mA fuse 10x38 MFR 012 -BT2 -F1A 2 1 3 1 -F12A 1 -T1 1 -K13 1 -F3-F5, -F7-F11,-F13 9 Location Quantity Helios item number 510011 520010 640011 500033 500032 500025 500032 550004
Item
Circuit Breaker
Interface relay
Isolating transformer
Fuse Holder
440 mA DC fuse
Fuse Holder
440 mA DC fuse
Hygrostat
66
Appendix
12.2 Spare parts list for the HSI1000 / HSI1250 control cabinet
Type without adapter plate AST3211-A1-D24 Web server EMERGENCY STOP MPMP3-10R Contact block MCBH-02 FAC3X/900/C Auxiliary switch block CEL 18-10 PLC-RSP-230UC/21-21AU TRIO-PS/1AC/24VDC/5A PLC-RSP-230UC/21-21 Type FZK +5...+60? Type FZK -20...+30? -G1 -K11A, -K11B -BT1 -BT3 -M1 S201-K8A S201-B6A PLC-RSP-230UC/21HC MTDN 3000 VA -F6A, -F6B, -F7 -F3-F5, -F7-F11,-F13 -K13 -T1 -K12A, -K12B -K1 -A8 -S1 -S1 1 1 2 1 2 3 2 1 1 1 3 9 1 1 -A3 2 -H1 2 -A1 2 Location Quantity Helios item number 810021 540006 110003 500008 500130 540009 500006 520001 580002 520010 550002 550003 650004 510047 510011 520010 640011
Item
Control card
Display
Web server
Emergency stop
Contact block
Insulation tester
Auxiliary contact
Relay
Power supply
Interface relay
Thermostat
Thermostat
Fan
Circuit Breaker
Circuit Breaker
Interface relay
Isolating transformer
67
Appendix
Type CHM2D 1000V/440mA fuse 10x38 CHM3D 1000V/440mA fuse 10x38 MFR 012 -BT2 1 6 -F1A, -F1B 2 4 -F12A, -F12B 2 Location Quantity Helios item number 500033 500032 500025 500032 550004
Item
Fuse Holder
440 mA DC fuse
Fuse Holder
440 mA DC fuse
Hygrostat
68
Appendix
12.3 Spare parts list for the inverter cabinet

Type R3G310-AN43-73 T7D1600M T7 Gear Motor 230VAC 230VAC SCR 230VAC T7 auxiliary contact On/Off Contactor AF 1650-30-22 100-250VAC Metal isolator 10x38 1000V/440mA fuse 10x38 E92 2-pole 1000V/440mA fuse 10x38 2-conductor ECM filter 1600A 760V 440V PMB 2123470KSP Semix553GB128Ds Part No. 016 Part No. 020 Semix driver V054 -F1 -F1 -C1 C70..C96 -V11-V39 A11A33 -A14-A34 -A15-A35 -F2 -F2 -K1 -Q1 -Q1 -Q1 1 1 1 1 1 2 1 2 1 27 27 9 3 3 520032 500025 500032 500129 500032 670005 220003 610001 120006 120007 120002 -Q1 1 -Q1 1 -M1A/-M1B 2 Location Quantity Helios item number 650009 510067
Item
Radial fan
Circuit breaker
Gear motor
Undervoltage circuit breaker
Closing release
Auxiliary contact
Contactor
Fuse holder for DC fuses
440 mA DC fuse
Fuse holder for DC fuses
440 mA DC fuse
DC- EMC input filter
Capacitor 0.47 F 1200VDC
Semix IGBT
SEMIX adapter 3 pole 500 kW V0.2
SEMIX accumulator 3 pole 500 kW
Semix driver V054
69
Appendix
Type Current converter 2000A ES2000 3x0,15mH 1070A MKP 3x55,7F 3x300KOhm/ Umax=760V DG 1000 FM XLP 00 Sz.000 RNO 29.165 RB50/6 33kOhm 1% CDE425 P1 FXR 3.000F 500V 64x155 -M3-M8 Type FZK 0-60 C MFR 012 -BT1 -BT2 R10-R27 -R1-R6 -F3 -F3 -F4-F6 3 1 3 6 18 9 54 6 1 1 -C2 1 -C2 1 -L1 1 -T9-T12 4 Location Quantity Helios item No. 530005 640016 660014 660013 570008 500056 500067 660009 660001 350019 660012 650008 550002 550004
Item
Current converter
3-phase 3-current throttle
Power capacitor
Discharge module
OVERVOLTAGE DIVERTER
Disconnector
Fuse insert 40 A 690 V
Power resistor 240 W 0.2 Ohm 10 %
Resistor
Busbar
Capacitor
Fan
Thermostat
Hygrostat
70
Appendix
71

Operation Manual HSI500 HSI640 HS1000 HSI1250 V31 Eng

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Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250

Translation of original operating manual

Functional description ............................................................................................... 15 Principle of the systems ............................................................................................ 16

Exterior views ............................................................................................................ 18

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250

Interior views ............................................................................................................. 21

Technical data ........................................................................................................... 25

Transport and the necessary conditions at the installation site . . . . . . . . . . . . 33

4.2.1 4.2.2 4.2.3 4.2.4

Installation site prerequisites ..................................................................................... 37

4.4 4.5 4.6

Ambient variables ..................................................................................................... 41

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Operating states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250

1.1 Designated purpose

1.2 Intended use

1.3 Improper use

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250

1.4 Standards and directives

1.5 About this operating manual

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250

2.1 Safety instructions

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250

2.2 Basic safety instructions

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250

2.3 Obligations of the owner

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250

2.4 Obligations of the qualified electrician

2.5 Obligations of the crane operator

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250

2.6 Obligations of the industrial truck operator

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250

2.7 Safety instructions on the central inverter

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250

2.8 Identification of the HSI500 / HSI640 / HSI1000 / HSI1250

HSI500 / HSI640 control cabinet

HSI1000 / HSI1250 control cabinet

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250

3.2 Functional description

Description HSI500 HSI640 HSI1000 HSI1250

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250

3.3 Principle of the systems

Fig.3-1 HSI500 / HSI640 principle circuit diagram

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250

3.3.2 Principle of the HSI1000 / HSI1250

Fig.3-2 HSI1000 / HSI1250 principle circuit diagram

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250

3.4 Exterior views

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250

3.4.2 HSI1000 / HSI1250 external view

Fig.3-4 HSI1000 / HSI1250 external view

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250

3.5 Interior views

Fig.3-5 Central inverter interior view

DC switch disconnector Q1 HF-Filter Contactor K1

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250