SG3125HV Turnkey Station System Manual. SG3125HV-V11-SEN-Ver

Transcription

1 SG3125HV Turnkey Station System Manual SG3125HV-V11-SEN-Ver

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3 Contents 1 About This Manual Foreword Validity Content Target Group Symbols Explanation How to Use this Manual Terminology Safety Instructions Intended Use Important Safety Instructions General Safety Rules Manual Storage PV Arrays Hazards Ground Fault Protection Live Line Measurement Measuring Instrument Voltage-free Operations ESD Protection LCD Parameter Setting Sand and Moisture Protection Symbols on the Device Body Safety Warning Signs Daily Operation and Maintenance Disposal of Waste Manual Description Product Description Overall Design of the Turnkey Station Turnkey Station Views Mechanical Parameter Ventilation Design Interior Design of the Turnkey Station I

4 3.2.1 Internal Components Cable Entry Design Internal Devices of the Turnkey Station Operations on the DC and AC circuit breakers Operations on the Protection Fuse inside the PMD Delivery Scope of Delivery Identifying the Turnkey Station Checking for Transport Damages Storage of the Turnkey Station Removing Sealing Tapes Mechanical Installation Transport Hoisting the Turnkey Station Safety Precautions Hoisting Fastening of Connectors Foundation Selection of Installation Site Foundation Requirements Recommended foundation construction plan Other Precautions Clearance Requirement Electrical Installation Safety Instructions Generals rules Five Safety Rules Preparation before Electrical Connections Installation Tools Cable crimping Parts for Cabling Opening the Turnkey Station door Checking the Cables During Connection Turnkey Station Circuit Diagram and Cable Connection Circuit Diagram Cable Specifications II

5 6.4 DC Connection Checking before Connection DC Cable Connection AC Connection Safety Notices AC Cable Connection Ground Connection Communication Connection RS485 communication solution Ethernet Communication Solution Power Supply Mode of the intelligent PMD External Power Supply Mode Internal Power Supply Mode Finishing Electrical Connection Commissioning Safety Instructions Requirements for Commissioning Checking before Commissioning Checking the Cable Connection Checking the Turnkey Station Switches Checking PV Array Checking Grid Voltage Preparation before Starting Starting the Device LCD Parameter Setting Completing Commissioning Starting/Stopping Starting Inspection before starting Start Steps Stopping Normal Stop Turnkey Station Stops when A Fault Occurs LCD Menu Operation LCD Touchscreen Default Screen Initialization III

6 9.2.2 Default Screen Introduction Backlight and Screensaver Overview of LCD Menu and Icon Overview of Submenu and Icon Layout of the submenus Entering Password Language Setting Conventional Way Shortcut Date and Time Setting Running Information Checking History Information Checking History Event Checking History Data Checking History Fault Checking History Alarm Checking Present Fault Information Checking Starting/Stopping Load Default Firmware Version Checking Parameters of LCD Communication Parameters Running Parameters Protection Parameter Turnkey Station Functions Operation Mode Mode Change Operation Mode Description Active Power Limitation Introduction to Active Power Limitation How to Realize Power Limitation Reactive Power Adjustment LVRT High Voltage Ride Through (HVRT) Temperature Derating Altitude Derating Curve MPPT IV

7 10.9 Intelligent Temperature-Control Technology Insulation Monitoring Function Introduction Simple Troubleshooting Protection Function DC over-voltage protection AC over/under-voltage protection Frequency anomaly protection Islanding protection Reverse polarity protection Overload protection Ground protection Module over-temperature protection Internal over-temperature protection Firefighting Troubleshooting Safety Instructions Fault Checking Fault and Troubleshooting on the LCD screen LCD Display Alarm Information and Troubleshooting Other Faults Routine Maintenance Safety Instructions Safety Instructions Five Safety Rules Maintenance Introduction Maintenance Interval Cleaning the Turnkey Station Introduction Cleaning Interval Cleaning the Internal Dust Cleaning the Foundation Filter checking and cleaning Cleaning the Surface of the Turnkey Station Checking the Lock and Hinge Checking the Sealing Strip V

8 12.4 On-site painting make-up measures Replacement of the electrical components Replace DC fuses Appendix Turnkey Station System Parameter Input data (DC side) Output data (Grid side) Mechanical parameters System data Tightening Torques Exclusion of Liability Contact Information VI

9 1 About This Manual 1.1 Foreword Thank you for purchasing the Turnkey Station from Sungrow Power Supply Co., Ltd.. We hope that the device will meet your satisfaction. Your commands and feedbacks on the performance and function of the device are important for our further improvement. 1.2 Validity This manual is applicable to the Turnkey Station product of SG3125HV (hereinafter it will be referred to as "Turnkey Station" unless otherwise specified). 1.3 Content This manual contains the following information: Content Safety instruction Product Description Delivery Installation Commissioning Start/Stop Operation on LCD Display Functions Troubleshooting Daily operation Description Safety instructions on the installation, operation, maintenance, and troubleshooting of the Turnkey Station The appearance and internal components of the Turnkey Station Delivery and inspection after receiving the Turnkey Station Mechanical transport, installation, and electrical connection of the Turnkey Station Safety notices and commissioning process when the Turnkey Station is powered on for the first time Steps of starting and stopping the Turnkey Station internal devices during normal maintenance or troubleshooting Function and use of the Turnkey Station user interface Descriptions of the Turnkey Station main functions Simple troubleshooting of the Turnkey Station Instructions on and guides to the daily operation of the Turnkey Station 1.4 Target Group This manual is for technical personnel who are responsible for the transport, installation and other operations on the Turnkey Station. Only qualified personnel can perform the installation, maintenance, and troubleshooting. Unauthorized persons should not perform any operation to the Turnkey Station and should be away from the Turnkey Station to avoid potential hazards. Qualified personnel are: Equipped with certain electrical wiring and mechanical knowledge and familiar with electrical and mechanical principle diagram Familiar with the construction and working principle of the PV grid-connected power generation system; and familiar with the construction and working principle of the Turnkey Station upstream and downstream equipment Trained especially in the installation and commissioning of electrical devices 1

10 1 About This Manual System Manual Capable of coping with the dangerous and emergency situations during the installation and commissioning Familiar with the country/regional standards and specifications Familiar with this manual 1.5 Symbols Explanation This manual contains important safety and operational instructions that must be accurately understood and respected during the installation and maintenance of the equipment. To ensure the optimum use of this manual, note the following explanations of the symbols used. DANGER indicates a hazard with a high level of risk which, if not avoided, will result in death or serious injury. WARNING indicates a hazard with a medium level of risk which, if not avoided, could result in death or serious injury. CAUTION indicates a hazard with a low level of risk which, if not avoided, could result in minor or moderate injury. NOTICE indicates a situation which, if not avoided, could result in equipment or property damage. NOTE indicates additional information, emphasized contents, or tips to help you solve problems or save time. The symbols below may be pasted on the electrical parts of the Turnkey Station or its internal device. Make sure to read the following symbols and fully understand them before installing the equipment. Symbol Explanation Lethal voltage inside! Do not touch! Hot surface! Do not touch the hot surface of the device. Protective earth. Earthing securely to ensure personal safety. 2

11 System Manual 1 About This Manual 1.6 How to Use this Manual Read this manual and other related documents before transporting and installing the Turnkey Station. Documents must be stored at hand and available at all times. All rights reserved including the pictures, markings, and symbols used. Any reproduction or disclosure, even partially, of the contents of this manual is strictly prohibited without prior written authorization of Sungrow. The contents of the manual will be periodically updated or revised as per the product development. It is probably that there are changes of manual in the subsequent module edition. The latest manual can be acquired via visiting the website at Please read this manual and other related manuals before installing and operating the devices inside the Turnkey Station. 1.7 Terminology Name For short Turnkey Station Turnkey Station Module unit/ Inverter unit Unit Intelligent power distribution cabinet Intelligent PMD or PMD The foregoing devices are expressed in the abbreviation form in this document unless otherwise specified. 3

12 2 Safety Instructions 2.1 Intended Use The Turnkey Station, researched, developed, and manufactured by Sungrow, is mainly applied to large-and-medium PV power station. The Turnkey Station can meet the modular design and quick installation requirements of the large-and-medium PV power station and can ensure the long-term, reliable, and safe power generation compliant with the grid. The PV power generation system with the Turnkey Station is shown in the following figure. A B C D E Fig. 2-1 Application of Turnkey Station to the PV Power System No. A B C D E Name PV Array PV Array Combiner Box Turnkey Station Transformer Utility Grid Installation of the Turnkey Station not in compliance with the description in this manual or installation or modification of the device without authorization from Sungrow may lead to personal injuries or device damages and may void pertinent warranty claims from Sungrow. 2.2 Important Safety Instructions Read the safety instructions carefully before installing the Turnkey Station. Refer to corresponding manuals for the safety instructions on the internal devices General Safety Rules Touching the terminals or contactors connected to the grid may lead to electric shock! Do not touch the terminals or conductors connected to the grid. Respect all safety instructions on the grid connection. 4

13 System Manual 2 Safety Instructions Lethal voltages are present inside the device! Pay attention to and follow the warning signs on the device. Respect all safety instructions in this manual and other pertinent documents. Electric shock or fire may occur due to device damage or system fault. Visually inspect the Turnkey Station for device damages or other hazards. Check if the external devices and circuit connections are safe. Only operate the device when it is safe to do so. All installations and operations on the Turnkey Station must be in full accordance with the national and local regulations and standards Manual Storage Product manuals are an indispensable part of the product. Important information about the transport, installation, maintenance, and troubleshooting of the Turnkey Station is included in this manual. All the descriptions in this manual, especially those safety-related items, must be complied with. Please read all the instructions thoroughly prior to performing any operation work on the Turnkey Station. Transport, install, maintain, and service the Turnkey Station strictly following the descriptions in this manual. Device damage, personal injury, or property loss may follow if otherwise. This manual and relevant documents should be available for relevant persons at all times PV Arrays Hazards DC high voltage! Electric shock hazards! When exposed to sunlight, PV array will produce voltage, which is very high in large-scale power Turnkey Station. Death from burning and electric shock due to touching the PV array. During installation, maintenance, and troubleshooting of the device, please ensure that: The Turnkey Station is disconnected from the PV array. Necessary warning signs are in place to prevent inadvertent reconnection. 5

14 2 Safety Instructions System Manual Ground Fault Protection If a ground fault occurs in the PV system, some parts that are supposedly voltage-free may carry lethal voltage. Accidental touch may cause serious damage. Make sure there is no system ground fault before performing operation and take proper protective measures Live Line Measurement High voltages are present inside the device. Death can result from burning and electric shock due to touching the live components of the Turnkey Station. During live line measurement, use suitable protective equipment, for example, dielectric gloves, and accompanied by other persons Measuring Instrument The instrument for measuring the electrical parameters should meet the following requirements: The instrument for measuring the electrical parameters should be a high-quality instrument with sufficient measuring range. Make sure the connection and use of the instrument are correct to avoid arc and other dangerous situations. Use suitable protective equipment, for example, dielectric gloves during live line measurement Voltage-free Operations Perform operations on the Turnkey Station only when all devices inside the Turnkey Station are completely voltage-free. Avoid any inadvertent re-connections. Verify that no voltage or current is present with appropriate testing devices. Ground and short-circuit whenever necessary. Cover possible live parts to avoid inadvertent touch. Ensure sufficient escape room. After the Turnkey Station stops, wait at least 10 minutes before operating it. Ensure that the Turnkey Station is completely voltage-free. 6

15 System Manual 2 Safety Instructions ESD Protection Devices may be damaged irreversibly by electrostatic discharge (ESD). Avoid unnecessary touching of the PCB. Observe all the ESD-related safety instructions. Wear proper personal protective equipment (PPE) such as wrist strap LCD Parameter Setting Certain LCD settable parameters are closely related to the operations of the Turnkey Station and internal devices, therefore these parameters can only be set with reliable evaluation of the system. Improper parameter setting may impair the functionality of the device. Only qualified personnel can set the parameters Sand and Moisture Protection Do not open doors of the Turnkey Station on sandstorm, thunderstorm, strong wind or hail days or when the ambient humidity is above 95% Symbols on the Device Body Symbols on the device contain important information on safe operations of the Turnkey Station and its internal devices. Do not tear or damage them! Do not damage or tear the symbols. All symbols on the device body must be clearly legible. Replace the symbols once any damage or illegibility is detected Safety Warning Signs During transport, installation, maintenance, and troubleshooting of the Turnkey Station, keep unauthorized persons away. Post warning signs near the Turnkey Station upstream and downstream switches to prevent inadvertent connection. Place necessary warning signs or barriers near the on-site operation areas Daily Operation and Maintenance Make sure the doors of the Turnkey Station are closed and locked during daily operation to prevent internal devices from damages caused by rain or rodents. Regularly check and maintain the Turnkey Station and internal devices to ensure long-term and reliable operation of the Turnkey Station. 7

16 2 Safety Instructions System Manual Make proper insulation protection during live line operation. At least two persons are required until the operation is done. Proper filed rescue facilities are necessary since locations of most PV Turnkey Stations are far away from the urban areas. Take the followings into consideration during daily operation and maintenance: The nameplate is pasted on the Turnkey Station body. It contains important parameter information of the devices. Protect the nameplate during all operations. Heating components may exist inside the Turnkey Station. When the device stops, the heating components may be still hot. Wear proper gloves when working on them. Maintain the cooling fans inside the Turnkey Station only when the fans stop rotating. Wear proper PPE, such safety glasses, safety footwear, and safety gloves, if necessary. All necessary auxiliary measures are advisable to ensure personal and device safety Disposal of Waste When the Turnkey Station has come to the end of its service life, it cannot be disposed of together with household wastes. Some inside components can be recycled while some components can cause environmental pollution. Please contact the local authorized collection point Manual Description For user convenience, there are a large number of pictures in this manual. These pictures are indicative only. For details about the device, please refer to the actual product you receive. Keep this manual at a convenient place near the device for future reference during installation, operation, maintenance, and troubleshooting of the device. All the descriptions in this manual are for the standard Turnkey Station. Please inform us in the purchase order if you have specific requirements. The actual product you receive may differ. This manual may not cover all possible situations. Should a specific problem not explained in this manual occur, please contact Sungrow. 8

17 3 Product Description 3.1 Overall Design of the Turnkey Station Turnkey Station Views View Description Front view. Front of the Turnkey Station; a pair of doors are equipped. Back view. Back of the Turnkey Station; a pair of doors are equipped. Left view Left of the Turnkey Station; a pair of doors are equipped. 9

18 3 Product Description System Manual View Description Right view Right side of the Turnkey Station. Control and Monitoring Window The Control and Monitoring window is located at the front door of the Turnkey Station. At the upper part are LED indicators; at the middle part is the color liquid crystal touchscreen; and at the lower part are the emergency stop button and maintenance interface. Please refer to the figure below. LCD EMERGENCY STOP MAINTENANCE INTERFACE Fig. 3-1 Control and Monitoring window There are three LED indicators at the upper part of the Control and Monitoring Window: POWER indicates the power is on; OPERATION indicates the proper operation of the Turnkey Station; FAULT indicates a fault. The working status of the Turnkey Station can be acquired through these LEDs. LED Color Description POWER Green The control circuit power supply is supplying power. White The Turnkey Station is in stop mode. OPERATION Green The Turnkey Station is in grid-connected run mode. Yellow The Turnkey Station is in alarm run mode. FAULT Red A fault occurs and has not been removed. The LED will be off when the fault is cleared. EMERGENCY STOP button When an emergency occurs, the DC and AC circuit breakers are disconnected automatically after pressing the emergency stop button. The MAINTENANCE INTERFACE The MAINTENANCE interface is the standard Ethernet port for maintenance only. 10

19 5309mm System Manual 3 Product Description The cover plate of the LCD can only be opened by using a specific key. Please remove the key and store it properly after the operation to the LCD Mechanical Parameter Dimensions External dimensions (without the flashings) are shown in the figure below. Front view Side view Height Width Depth Fig. 3-2 Appearance and dimensions of the Turnkey Station Width Height Depth 2991mm 2591mm 2438mm Weight Approx. 6,000kg (with internal devices). Clearance spaces The clearance spaces around the Turnkey Station should be sufficient for at least the doors when they are all open. 5601mm Fig. 3-3 The diagram of the required space when the door is opened for 90 11

20 3 Product Description System Manual Ventilation Design The ventilation system is designed as the cool air is drawn from the bottom of the Turnkey Station and hot air is exhausted from the top of the Turnkey Station. Fig. 3-4 Air inlets and outlets of the Turnkey Station 3.2 Interior Design of the Turnkey Station Internal Components The figure below shows the top view of the major electrical components inside the Turnkey Station: B A C D Devices in the above figure are: Fig. 3-5 Turnkey Station internal devices layout Item Device Description A DC cabinet That includes fuses and DC switches. Cooper bars at the bottom of the DC cabinet are used for DC-side cable connections. B Module cabinet It converts the DC current into the AC current. C AC cabinet That includes AC contactors and AC switches. Cooper bars at the bottom of the AC cabinet are used for AC-side cable connections. The upper part of the cabinet integrates monitor function and D Intelligent PMD the lower part of the cabinet integrates AC power distribution function. 12

21 System Manual 3 Product Description Cable Entry Design For ease of cable connection in the field, all cables among the Turnkey Station internal devices are connected before delivery. All cables between the Turnkey Station and the external devices are routed through the bottom of the Turnkey Station. All cables coming into or out of the Turnkey Station should be protected properly, for example, using cable pipes to prevent damage from rodents. After cable connection, all cable entries except for cable glands should be sealed with fireproof mud or other appropriate materials. The cable entries at the bottom of the Turnkey Station are shown below. Hole-1 Hole-1 Hole-1 Hole-2 Hole-3 Fig. 3-6 Cable entries of the Turnkey Station The function of each opening is shown below: Item Name Note Hole-1 DC cable inlets DC cables are connected to the DC cabinet through these 3 holes. Hole-2 AC cable outlet AC cables are connected to the grid through this hole. Hole-3 Communication & power distribution Communication & power distribution cables come inside the Turnkey Station cable entry through this hole. Dimensions of the holes Unit: mm 13

22 3 Product Description System Manual Internal Devices of the Turnkey Station The Turnkey Station contains the DC cabinet, the module cabinet, the AC cabinet, and the PMD. The DC cabinet, the AC cabinet, and the PMD are all equipped with wiring terminals and operation switches DC cabinet A B Item Name Description A DC switches Control the connection/disconnection on the DC side of the Turnkey Station B The upper part of the copper bar is for positive cable DC cable connection area while the lower part is for negative cable connection area connection AC cabinet A B Item Name Description A AC switch Controls the connection/disconnection on the AC side B AC cable Three phases. Connect to L1 phase, L2 phase, and L3 phase connection area from bottom to top 14

23 DISCHARGED SPRING System Manual 3 Product Description PMD A B C D E Item Name A Electricity meter B RS485 communication port C Ethernet port D* Micro circuit breaker and corresponding wiring terminal E Protection fuse Note: * The operation switch in the figure is for reference only and may differ from the actual product Operations on the DC and AC circuit breakers This Turnkey Station is equipped with electrically-controlled air circuit breakers on the DC and AC sides. The appearance of the circuit breaker panels are shown in the figure below. D E C B A A CLOSED B C Push OFF Push ON D E DC side Fig. 3-7 DC and AC circuit breakers AC side Item Name Description A Manual energy storage When the circuit breaker has no energy, you can handle manually store energy through this button. B Circuit breaker state Display the present state of the circuit breaker, OPEN or indicator CLOSED C Push OFF button The breaker is switched off when this button is pressed D Push ON button The breaker is switched on when this button is pressed E Energy storage state Display the present energy storage state, CHARGED indicator SPRING or DISCHARGE SPRING 15

24 DISCHARGED SPRING CHARGED SPRING 3 Product Description System Manual The DC Switch can be used together with a micro-motor. When there is the power supply on the Turnkey Station AC side, the energy can be stored to the breaker through this motor; when there is no power supply on the Turnkey Station AC side, you need to store the energy through the manual energy storage handle. The operation steps are briefly described by taking the DC switch as an example. Switch on Press the Push ON button on the breaker panel to switch on the breaker. Before switching on the breaker, you need to check if the energy storage state displayed on the panel is CHARGED SPRING. If the state is DISCHARGED SPRING, you need to store the energy manually by turning the manual energy storage handle down until the breaker panel displays CHARGED SPRING. After the breaker is switched on, the breaker panel displays CLOSED. Switch off Press the Push OFF button on the breaker panel to switch off the breaker. After the breaker is switched off, the breaker panel displays OPEN Operations on the Protection Fuse inside the PMD Identify fuses states The fuse inside the PMD is in closing or opening state. (a) (b) (c) Figure (a) shows the closing state Figure (b) shows the opening state The fuse is in the closing state by default. 16

25 4 Delivery 4.1 Scope of Delivery The scope of delivery of the Turnkey Station is shown in the following table: A B C D E F G H I J No. Device Quantity Note A Turnkey Station 1 - B Enclosed System manual, delivery inspection report, 1 documents certification, and warranty card C Door keys of Turnkey Station 1 - Keys to monitor window 1 - D Bolt 85 M M8 25 E Flat washer 170 φ16 F Spring washer 85 M16 85 M16 G Nut 12 M8 5 M6 H Washer 24 M8 10 M6 I Disc springs 12 M8 J 10 M5 16 Cross recessed 60 M6 20 hexagon bolt 12 M

26 4.Delivery System Manual Note: The foregoing components and their quantities are based on the standard Turnkey Station, and those of the actual product may differ. 4.2 Identifying the Turnkey Station Identify the Turnkey Station from its nameplate. The nameplate contains the following information: Turnkey Station model, major technical parameters, marks of certification institutes, origins, and serial number. Nameplate Very important technical parameters and Turnkey Station-related parameters are displayed on the nameplate. Protect the nameplate at all times! 4.3 Checking for Transport Damages The Turnkey Station has been strictly inspected and tested before delivery. Despite robust packaging, the container or inside devices may be damaged during transport. Therefore, once you receive the Turnkey Station, a detailed inspection is necessary. If any damage is detected, contact the forwarding company or Sungrow immediately. A relevant photo is desired. We will provide you with the fast and best service. Examine the contents of the shipment to check the scope of delivery described in 4.1 Scope of Delivery for completeness. Check to make sure the Turnkey Station and inner devices are of the same models as those in your order; Check thoroughly the Turnkey Station and inner devices for any possible damages during transport. Install and commission the Turnkey Station only when it is technically faultless! Make sure before installing the Turnkey Station that the Turnkey Station is intact without any damage; and all devices inside the Turnkey Station are intact without any damages. Before commissioning of the Turnkey Station, make sure all the sealing tapes are removed from the air inlets and outlets. Otherwise, there may not be sufficient fresh air for the normal operation of the devices inside the Turnkey Station. 18

27 System Manual 4.Delivery 4.4 Storage of the Turnkey Station If the Turnkey Station is not to be installed immediately after delivery, store it appropriately: Store the Turnkey Station indoors, for example, large warehouse or workshop, to prevent possible condensation or damp. If the Turnkey Station has to be stored outdoors, elevate the Turnkey Station base according to the geological and ambient conditions. When the ambient temperature is too low, heat the Turnkey Station internal devices. Temperature: -40 C~+70 C Relative humidity: 0 to 95%, and non-condensation Store the Turnkey Station on a dry, clean, and solid ground with sufficient load-bearing capacity. The ground should be flat without water, bumps, or plantings. Lock the Turnkey Station internal devices and the Turnkey Station during storage. Take proper protective method to prevent the water and dust penetrating into the Turnkey Station. Protect the Turnkey Station air inlets and outlets at least. Regularly, once every half a month at least, check the Turnkey Station and internal devices. 4.5 Removing Sealing Tapes To prevent sea-water or moisture penetrating into the Turnkey Station during ship transport, the air inlets and outlets of the Turnkey Station are all sealed with sealing tapes. The positions of the sealing tapes are shown by "A" in the following figure. A A A A A A Front view Left view A A A A A A A A Back view Fig. 4-1 Location of the sealing tapes 19

28 5 Mechanical Installation Respect all local standards and requirements during mechanical installation. 5.1 Transport All devices are installed inside the Turnkey Station before delivery. The Turnkey Station should be transported as a whole. Transport the Turnkey Station by a crane with sufficient load capacity. The Turnkey Station is delivered to the user by the forwarding company. After unloading, the Turnkey Station will be transported to the installation site by the plant staff. Local standards and regulations on the transport and loading & unloading of the container, especially those safety instructions, should be observed at all times. All the accessory appliances used during transport should be maintained beforehand. The Turnkey Station must be transported by qualified personnel. Qualified personnel are those who have relevant training experience, especially safety-related experience. Keep in mind the dimensions and total weight of the Turnkey Station at all times! Ensure that the following requirements are met: All the doors are locked. Choose the appropriate crane or hoist to transport the Turnkey Station. The crane or hoist must be sufficiently capable of bearing the Turnkey Station weight. An additional traction vehicle may be required when the road has a gradient. Anything, which may hinder the transport, like trees, cables (or the like), should be removed. If possible, transport the Turnkey Station on fine weather days. Warning signs or barriers must be posted near the transport areas to avoid accidental injuries. Additionally, the following requirements should be met when the Turnkey Station is placed on the ground: Place the Turnkey Station carefully and gently. Do not pull or push the Turnkey Station on any surface. The place should be firm and flat with good drainage and no obstacles or outshoots. The Turnkey Station should be supported by the four feet. 20

29 System Manual 5 Mechanical Installation 5.2 Hoisting the Turnkey Station Safety Precautions Observe the safety operating rules of the crane at all times. Standing within 5 to 10 meters away from the hoisting areas is strictly prohibited! Anybody standing under the boom or Turnkey Station is strictly prohibited in the whole hoisting process. The hoisting work must be stopped on violent weather days. For example, in strong wind, heavy rain, or thick fog conditions. Please observe the following items: All safety requirements must be met. A professional instructor is required in the whole hoisting process. All the used slings must have the load-bearing capacity of at least 10t. The crane should have sufficient arm length and radius of gyration. All the connection point must be firmly connected. The length of the slings can be adjusted appropriately according to on-site conditions. Transport the Turnkey Station in a level, smooth, and steady way. Transport the Turnkey Station by connecting the four top corner fittings. Some accessories may be required to ensure the safety during hoisting. The following figure illustrates the hoisting operations. Circle A describes the work areas of the crane. Anybody standing inside the circle B is prohibited for safety considerations. B A Inverter Inverter Crane Fig. 5-1 Hoisting the Turnkey Station 21

30 5 Mechanical Installation System Manual Hoisting During the whole hoisting process, please observe the following rules: Hoist the Turnkey Station in a vertical manner. Do not drag or drop the Turnkey Station on any surface. When the Turnkey Station has been hoisted for about 300mm away from the ground, stop to check if all the connections are still firm. After confirmation, continue hoisting the Turnkey Station. When transported to the final location, the Turnkey Station should be put down slowly and steadily. The final location should be firm, level, and well-drained. The Turnkey Station is supported by four bottom fittings on the ground. The Turnkey Station should be hoisted by four top corner fittings as shown in the following figure. Fig. 5-2 Hoisting from top fittings Fastening of Connectors Use slings with hooks or U-hooks to hoist the Turnkey Station. The lifting devices should be correctly connected to the Turnkey Station. 22

31 System Manual 5 Mechanical Installation Lifting device Hook U-hook Connections Notice Insert the hook from inside to outside. Lateral pin of the U-hook should be tightened. National and local safety rules should be observed at all times. Violating relevant safety rules may void pertinent warranty claims from Sungrow. 5.3 Foundation Selection of Installation Site When selecting the installation site, consider the following requirements at least: Ambient and geological conditions, such as stress wave emissions, the level of underground water table and etc. should be taken into account. The ambient environment should be dry, well ventilated, and far away from inflammable materials. The ground at the installation site must be compacted enough. Relative compaction of the ground should be equal to or greater than 98%. Otherwise, take proper methods to strengthen the ground Foundation Requirements Pay attention to the high weight of the Turnkey Station. Check thoroughly the conditions on the installation site (mainly the geographical and environmental conditions) before designing and constructing the foundation. Improper foundation construction may affect the placement of the Turnkey Station, open & close of the door, and future maintenance. Therefore, the foundation must be designed and constructed according to the related standard. The dimensions and weight of the Turnkey Station, the cable route, and the future maintenance should be considered at all times. The following conditions must be met: The bottom of the foundation should be firm enough. 23

32 5 Mechanical Installation System Manual The foundation should be at least 820mm higher than the ground level on site to prevent the rain from damaging the base or penetrating into the Turnkey Station. Sufficient cross-sectional area and depth of the foundation should be maintained. The depth is designed according to local soil conditions. Cable route should be taken into account. According to the cable design of Turnkey Station and for easy electrical connection, please establish cable trenches on the bottom of the Turnkey Station, i.e. reserve the cable trenches inside the foundation and pre-bury the wire pipes. The dirt dug out should be cleared immediately Recommended foundation construction plan The foundation construction plan includes concrete foundation plan and strip foundation plan. Plan 1: Concrete foundation The foundation plan described in this chapter is for reference only. Please consult on-site professional project personnel before construction. This section clearly specifies the foundation construction plan for reference as shown below (unit: mm). For details, refer to the final civil drawing issued by the design institute. The recommended foundation construction plan is described as follows: Channel steel preembedding A maintenance platform should be built for the convenience of maintenance and repair work. The position of cable inlets and outlets are at the bottom of the Turnkey Station. In the construction of the foundation, adequate space is reserved for AC/DC side cable trench 24

33 System Manual 5 Mechanical Installation and perforating pipes are pre-embedded. The specification and quantity of the perforating pipes are determined according to the cable model and cable quantity. 20# channel steel is pre-embedded on the front and back side of the foundation surface so that the foundation of the Turnkey Station can be welded with the foundation after the mechanical installation. The pre-embedded channel steel must be level with the rest part of foundation upper surface; and the pre-embedded steel sheet must be firm and reliable. According to the on-site actual conditions, drainage system is designed and constructed at the bottom of the foundation to avoid water immersion. In the construction of the foundation, the grounding body is pre-embedded. One end of the grounding body is welded with the main grounding network of power plant while the other end is welded with the pre-embedded channel steel in the foundation to ensure firm welding quality. The embedded grounding pole must be in accordance with the installation codes. The maintenance entry is designed on the foundation; if necessary, the operators can enter the foundation to perform required operations. It is recommended to build up steps at the inlet of the Turnkey Station for convenient access. The step width and level are appropriately selected according to the actual on-site conditions. For convenience of future maintenance and repair work, a proper maintenance area is constructed around the foundation according to the actual on-site conditions. The maintenance area has an adequate bearing capacity and levelness and complies with the local standard/code. Both ends of all the pre-embedded pipes are temporarily blocked to prevent impurities. Otherwise, it is inconvenient to lay cables in the future. Upon connection of all the electrical cables, the cable inlet, outlet, and joint are sealed by refractory mud or other appropriate materials to prevent pests and mice from entry. For the rest recommended dimensions, please refer to the mentioned drawing and other related drawings. Pre-bury grounding units according to relevant standards of the country/region where the project is issued. Fixing the Turnkey Station Check to ensure that the foundation construction has met all the local standards and other relevant requirements. Hoist the Turnkey Station onto the foundation after the foundation is dry enough. 25

34 5 Mechanical Installation System Manual Foundation Inverter bottom Plan 2: Concrete pillar The following conditions must be fulfilled: The bottom of the foundation should be firm enough. The foundations must be suitable for the weight of the Turnkey Station. The foundation should be at least 100mm higher than the pea gravel ground on site to prevent the rain from damaging the base or penetrating into the Turnkey Station. Each foundation has the following width: 500mm to 600mm. The length of each foundation must be at least 200 mm longer than the width of Turnkey Station on each side. Sufficient cross-sectional area and depth of the foundation should be maintained. The depth is designed according to local soil conditions. Cable route should be taken into account. Overall construction effect of Plan 2 is shown below. Front view Left view A B C A A B A 26

35 System Manual 5 Mechanical Installation No A B C Name Foundation Pea gravel ground Solid ground, e.g. gravel Other Precautions A drainage system should be designed on the installation site to prevent the Turnkey Station from being immersed in water during heavy rainfalls. Do not plant any trees near the Turnkey Station installation site to prevent the damage of the Turnkey Station caused by tree leaves or stems. 5.4 Clearance Requirement On site, if two Turnkey Stations are placed side by side, the minimum reserved clearances around the Turnkey Stations are shown in the following figure. C B D A Fig. 5-3 Requirements for clearances around the Turnkey Station A* B* C* D* 4000mm 4000mm 4000mm 4000mm Note: A is the minimum distance away from the front doors. * The distance illustrated in this table is the minimum values. More space is recommended for better ventilation and higher conversion efficiency of the Turnkey Station. 27

36 6 Electrical Installation 6.1 Safety Instructions Generals rules High voltage! Electrical hazards! Do not touch the live components of the device. Make sure the AC and DC sides are voltage-free before installation. Never put flammable materials in the vicinity of the Turnkey Station. If a ground fault occurs to the PV system, some parts that were voltage-free before may contain lethal voltage. Accidental touch may cause serious damage. Make sure there is no system ground fault before operation and take proper protective measures. Observe all the country-specific standards and regulations. Connect the Turnkey Station to public grid only after receiving authorization from the local network operator. Only professional electricians can perform the operations described in this chapter. Observe all the instructions to connect the wires. Disconnect all AC and DC Switches before electrical connection. Sand and moisture penetration may affect the performance of electric devices inside the Turnkey Station! Do not perform electrical connection in sandy season or when the ambient relative humidity is above 95%. Perform electrical connection on fine weather days. 28

37 System Manual 6 Electrical Installation Improper torque used may cause a fire to the connection point! Fix the bolts by strictly following the torque requirements in this manual during electrical connection. Too small bending radius or excessive intertwine may damage the fiber! When selecting fiber as the communication cable, please follow the related requirements of the fiber manufacturer about the min. allowable bending radius. Only professional electricians can perform the electrical connection. Professional electricians should meet the related requirements listed in 2 Safety Instructions in this manual. Sungrow should hold no liability for any personal injury or property loss caused by ignorance of the safety instructions. Ensure the electrical insulation is satisfied before laying the cables. Follow the EMC regulation and lay the power cable and communication cable in different layers. Provide support and protection to the cables to reduce the stress of the cables when necessary. Strictly follow all the instructions when connecting the cables. The installation and design of the Turnkey Station must fulfill national and local standards and regulations. Sungrow should hold no liability for the Turnkey Station or system fault caused by ignorance of the description in this manual. Select optical fibers as the external communication cable to lower the signal interference Five Safety Rules During electrical connections and other operations on the inside device, observe the following Five Safety Rules: Disconnect all the external connections and disconnect the Turnkey Station internal power supply Avoid any inadvertent re-connections. Verify that no voltage or current is present with appropriate testing devices. 29

38 6 Electrical Installation System Manual Ground and short-circuit whenever necessary. Cover possible live parts to avoid inadvertent touch. 6.2 Preparation before Electrical Connections Cables inside the Turnkey Station have been connected before delivery. You need to connect the cables of the Turnkey Station to the external devices, i.e. the DC input cable connection, the AC output copper bus connection, the communication connection, and the communication cabinet cable connection Installation Tools Prepare the following tools before installation: Torque wrench Screwdriver Wire stripper Terminal crimping device Alcohol blast burner (or hot air blower) Allen wrench Meg-ohmmeter or multimeter Other auxiliary tools or spare parts Cable crimping You need to crimp the cables as follows before the electrical connection. Step 1 Strip off the insulation cover of the cable with a stripped length of 5mm longer than the depth of the cable lug; L=D+5mm D Cable lug Step 2 Crimp the cable lug. 1. Insert the stripped cable into the cable lug; 2. Tighten the cable lug with relevant tools. The crimping number should be more than two. 30

39 System Manual 6 Electrical Installation Step 3 Insert the heat-shrinkable tubing; 1. A tubing with a length of 2cm longer than the depth of the cable lug is recommended; 2. Insert the heat-shrinkable tubing into the cable lug; 3. Shrink the tubing with a hot air blower. Cable protectors are advisable in the cable crosses if the multi-core cables are used Parts for Cabling Incorrect connection of power cables will cause fires. Follow the sequence when connecting the power cables. Ensure the fastness of the connection parts. Poor contact or oxidation of the contact surface may cause a fire. NOTICE Long bolts may impair the insulation and may cause a short circuit. Remove the heat-shrinkable tubing between the cable lug and the copper bar if necessary. Poor contact or over-heating may follow if otherwise. Clean the connection terminals before cable connection. Do not touch the terminal after cleaning. The spare parts required for connecting power cables, such as the screws, are within the scope of delivery. Please respect the description in this chapter during connection. 31

40 6 Electrical Installation System Manual Copper Wire Connection If copper wires are used, connect the spare parts as described below: A E D F E D C B Fig. 6-1 Copper wire terminal connection sequence of single-hole cable connection A B C D E F Copper Bus Cable Lug Bolt Spring washer Flat washer Nut Aluminum Wire Connection When the aluminum wire is selected, a copper-aluminum composite terminal is needed as shown below: A E D F E D C B Fig. 6-2 Copper-aluminum composite terminal of single-hole cable connection A B C D E F Copper copper-aluminum composite Bolt Spring Flat Nut Bus terminal washer washer Opening the Turnkey Station door All the Turnkey Station doors are standard container doors. Open the doors before cable connection Checking the Cables Check to ensure the intactness and insulation of all cables before electrical connection. Poor insulation or damages of the cables may cause potential hazards. Replace them if necessary. 32

41 System Manual 6 Electrical Installation During Connection Make sure the polarities of the DC cables and AC cables and the phase sequence of the AC cables are correct before connection. Do not pull the cables hard during electrical connection. Make sure there is enough wire bending space for all connection cables. Take proper methods to reduce the stress of cables. Check carefully for the correctness and fastness of the connections. 6.3 Turnkey Station Circuit Diagram and Cable Connection Circuit Diagram Turnkey Station A E = F 3~ G B C D K Devices in the above figure are: Item A B C D E F G K Cable Specifications Fig. 6-3 Turnkey Station main circuit diagram Name DC input AC output External communication port External 3-phase power supply port DC cabinet Module cabinet AC cabinet Intelligent PMD Choose cables according to the rules below: All the cables must have sufficient ampacity. The ampacity of the conductor can be influenced by environmental conditions, conductor insulation materials, laying, wire materials, cross-sectional areas and etc. 33

42 6 Electrical Installation System Manual All the cables must be chosen according to the maximum current on the AC and DC sides of the Turnkey Station, and enough allowance is required. Cables for one side should be of the same type and specification. Flame-retardant and fire-resistant cables are recommended. Overloading operation of cables is strictly prohibited. 6.4 DC Connection Checking before Connection Check the following items before cable connections. Check the open-circuit voltage of the PV array to ensure the open-circuit voltage is within the max. DC voltage of the Turnkey Station. Mark the negative and positive polarity of the cable. Check the PV array for possible ground fault. Open-circuit voltage of the PV array should not exceed the max. DC voltage of the Turnkey Station. The Turnkey Station may be damaged if otherwise. If the ground fault is found, it must be removed before any DC connection. Strictly follow all the instructions when connecting the cables. Observe all the safety rules required by the PV array manufacture. Start the DC connection only when all checks and measurements meet requirements. 34

43 System Manual 6 Electrical Installation DC Cable Connection 50 Φ (6*70) (6*70) (6*70) DC+ DC- 80 Front view of the left- door side of the inverter Dimensions of copper bar Top view of the left- door side of the inverter Fig. 6-4 The location and size (in mm) of the wiring copper bar on the DC side Item A B Description DC positive cable connection area DC negative cable connection area Cable requirements: 21 input cables can be connected to the DC side The maximum cross-sectional area of the aluminum/copper cable is 400mm 2 Recommended copper lug mode: DT-400 or BL Fasten the wiring terminal with the bolts of M16 55 in the scope of delivery The fastening torque is 119~140N m Cable connection steps Step 1 Make sure the switch upstream of the combiner box is in the OFF position. Step 2 Strip off the insulation cover of the cable with a stripped length of 5mm longer than the depth of the cable lug. Step 3 Crimp the cable lug. 1. Insert the stripped cable into the cable lug. 2. Tighten the cable lug with relevant tools. The crimping number should be more than two. Step 4 Insert the heat-shrinkable tubing. 1. A tubing with length of 2cm longer than the depth of the cable lug is recommended. 2. Insert the heat-shrinkable tubing into the cable lug. 35

44 6 Electrical Installation System Manual 3. Shrink the tubing with a hot air blower. Step 5 Connect the cable. Cable protectors are recommended in the cable crosses if the multi-core cables are used. 1. Select bolts matching with the cable lug. 2. Attach the cable lug to the DC connection copper bar following the sequence in the following figure. 3. Fasten the bolts with a screwdriver or spanner. Incorrect connection sequence may cause a fire. Please pay much attention to the connection sequence. Ensure the firmness of the cable connection. Poor connection or oxidation of the surface may cause over-heating or a fire. NOTICE Long bolts may impair the insulation and may cause a short circuit. Remove the heat-shrinkable tubing between the cable lug and the copper bar if necessary. Poor contact or over-heating may follow if otherwise. Step 6 Confirm that all cable connections are secure. Connect the DC cables according to the above steps. 6.5 AC Connection Safety Notices Incorrect AC connection may cause damages to the Turnkey Station. Electrical hazards! Do not touch the live components. Disconnect the AC switches and ensure all terminals are voltage-free. The connection to the public grid must be carried out only after receiving approval from the distribution utility as required by national and state interconnection regulations. Strictly follow all the instructions when connecting the cables. 36

45 System Manual 6 Electrical Installation Strictly follow all instructions on the device when closing/opening the AC switches AC Cable Connection Φ17 700(10*70) L3 L2 L1 70 Dimensions of copper bar Inverter front side-front view Inverter front side-top view Fig. 6-5 The location and size (in mm) of the wiring copper bar on the AC side Cable requirements: A maximum of 11 three-phase cables can be connected to the AC side The maximum cross-sectional area of the aluminum/copper cable is 400mm 2 Recommended copper lug mode: DT-400 or BL Fasten the wiring terminal with the bolts of M16 55 in the scope of delivery The fastening torque is 119~140N m Cable connection steps Step 1 Disconnect the downstream grid-side switches of the Turnkey Station. Step 2 Check to ensure the AC connection sequence is correct. Step 3 Strip off the insulation cover of the cable with a stripped length of 5mm longer than the depth of the cable lug. Use cable lug based on the cable specification. Step 4 Crimp the copper cable lug. 1. Insert the stripped cables into the cable lug. 2. Tighten the cable lug with proper tools. The crimping number should be more than two. Step 5 Install the heat-shrinkable tubing. 1. Select tubing with dimensions matching with the cables. Tubing length should be 2cm longer than the cable lug. 2. Insert the heat-shrinkable tubing into the cable lug. 3. Shrink the tubing with a hot air blower. 37

46 6 Electrical Installation System Manual If multi-core cable is used, install cable protection stall at the forks. Step 6 Connect the cable. 1. Select bolts matching with the cable lug. 2. Crimp the cable lug into the AC copper bar. 3. Fasten the bolts with screwdriver or spanner Incorrect connection sequence may cause a fire. Please pay much attention to the connection sequence. Ensure the firmness of the cable connection. Poor connection or oxidation of the surface may cause over-heating or fire. NOTICE Long bolts may impair the insulation and may cause a short circuit. Remove the heat-shrinkable tubing between the cable lug and the copper bar if necessary. Poor contact or over-heating may follow if otherwise. Step 7 Check to ensure the connection is secure. Connect the AC cables according to the above steps. 6.6 Ground Connection Brief Introduction Generally, the ground connection includes equipotential connection of internal devices and external grounding. C A B D Item A B C D Description DC cabinet AC cabinet Module cabinet Intelligent PMD Front door side Equipotential connection of Turnkey Station internal devices The grounding copper bar inside the Turnkey Station is located at the right side of the Turnkey Station, as shown in the following figure A. 38

47 System Manual 6 Electrical Installation A The main internal electrical devices have been connected to the ground copper bar before delivery. External grounding Two external grounding points are located at the bottoms on the left side and right side of the Turnkey Station. Illustrations Description Left-side view of the Turnkey Station. The external grounding point is located at B in the figure. B Right-side view of the Turnkey Station. The external grounding point is located at B in the figure. B The external grounding points of the Turnkey Station can be grounded in the following two manners: Connect the grounding cable to the external grounding points with M10 bolts, where the recommended cable is of 50 mm 2 to 95 mm 2. Weld the grounding steel flat onto the external grounding point, after which anti-corrosion processing needs to be performed. It is recommended that two points of the Turnkey Station should be connected to the ground system of the PV plant. 39

48 6 Electrical Installation System Manual The Turnkey Station needs to be grounded on site. The following operations should also be conducted on site: Measure the electrical conductivity between the device ground terminals and the total equipotential connection copper bar to ensure the effectiveness of the internal ground connection. Perform the external grounding according to on-site situation and instructions of the plant staff. The grounding resistance should be no more than 4Ω. The grounding resistance should be determined according to local standards and regulations. The country-specific regulations and standards must be observed at all times! If you have any doubts during the ground cable connection, please contact the related technical personnel in time. Any installations not following the standards or the installation and alternation without permission may lead to safety incidents or damage to the devices. Sungrow shall hold no liability for the damages caused. 6.7 Communication Connection All communications between the Turnkey Station and the external devices are based on the intelligent PMD inside the Turnkey Station. As shown in the following figure, the RS485 port and the Ethernet port are designed in the intelligent PMD. A B Item A B Description RS485 communication port Ethernet port 40

49 System Manual 6 Electrical Installation RS485 communication solution The A5B5 port is connected to the PC. A6B6 to A9B9 are standby ports and can be connected to the detection and control device of the transformer, the combiner box, the environmental detector, and the like. For details, refer to the actual configuration. Inverter PIN3:TXD PIN2:RXD PC A5B5 RS485A RS485B TX+/RX+ TX-/RX RS485/232 converter PC RS232 Connection steps Step 1 Strip off the insulation covers at the ends of two cables that need to be connected to the same terminal. Step 2 Insert the bare copper wires into the cold-pressed terminal and crimp them with the crimping tool. Step 3 Connect the cold-pressed terminal to the communication terminal. Step 4 Twist shield layers of the two cables into one and insert it into the cold-pressed terminal after heat shrink via heat-shrinkable tubing A B FG Fig. 6-6 Schematic diagram of terminal crimping To ensure communication quality, the RS485 communication connection cable should be the shielded twisted pair. (Recommended: the shielded twisted pair of RVVP-2*1.0.) After the shield layers of the shielded cable is connected, single point grounding is adopted at the monitoring terminal Ethernet Communication Solution Connect the Ethernet port inside the PMD to the PC by using the network cable (EIA/TIA568B) 41

50 6 Electrical Installation System Manual PC Ethernet port 6.8 Power Supply Mode of the intelligent PMD The power supply mode includes internal power supply mode (default) and external power supply mode. Internal power supply mode: powered by the AC current that is output from the AC cabinet inside the Turnkey Station, where cables for the internal power supply have been connected before delivery. External power supply mode: connect the external auxiliary power port and the external three-phase power supply to supply power External Power Supply Mode The power distribution area, including the wiring terminal and the micro circuit breaker, is located at the bottom of the PMD. The internal power distribution area of the PMD is shown in the following figure. C D 42

51 System Manual 6 Electrical Installation The external auxiliary power supply needs to be the three-phase 380V AC current, and the cross-sectional area of the connected cable is 6.6mm 2. The maximum distribution power of the PMD is 15kW. Item Description Description C Port of the external three-phase power supply Corresponding micro circuit breaker is Q2 D Protection fuse - Operation before cable connection Disconnect the protection fuse at the bottom of the PMD before closing the external power supply switch Q2. For details, refer to the section "3.2.5 Operations on the Protection Fuse inside the PMD" Internal Power Supply Mode Cables for the internal power supply have been connected before delivery. During normal operation of the Turnkey Station, the control switch of the internal power supply mode automatically connects and disconnects without manual operations. In the internal power supply mode, close the protection fuse at the bottom of the PMD. For details, refer to the section "3.2.5 Operations on the Protection Fuse inside the PMD". 6.9 Finishing Electrical Connection After the electrical connection, check the connection of all cables. Make sure all the connections are correct and firm. After ensuring that all connections are correct and firm, Check the bottom of the Turnkey Station and seal the gaps between the cables with fireproof mud. If cable glands are used, make sure they are tightened. Seal the unused terminal. Reassemble the protective grid removed. Water-proof processing should be done on the foundation of the Turnkey Station. 43

52 7 Commissioning 7.1 Safety Instructions High voltage! Electric shock! Wear proper protective equipment before performing any operations on the device. Do not touch the live terminals or conductors. Respect all safety instructions inside the device and in this manual. Respect all safety instructions prescribed by the manufacturer of devices connected to the Turnkey Station. Grid-connection of the Turnkey Station can only be done by qualified persons after receiving approval from the local utility grid company. When the Turnkey Station is operating, make sure there are no flammable materials within at least 5m around the installation site. Local/national standards about the min. electric clearance around the Turnkey Station should be respected. Make sure the installation is correct and no spare parts or tools are left inside the device. Close the doors of the Turnkey Station and the internal devices if the commissioning process is stopped. 7.2 Requirements for Commissioning Before commissioning, installation of the DC cabinet and AC cabinet inside the Turnkey Station should be checked thoroughly. Ensure all cable connections are secure and all bolts are fixed properly. Ensure DC side voltage meets the Turnkey Station requirements and the polarity is correct. 44

53 System Manual 7 Commissioning Ensure AC side voltage meets the Turnkey Station requirements. Ensure all cable connections meets related standards and requirements. Ensure the system is properly grounded. Ground resistance is so important for the whole system that before the commissioning, make sure the ground resistance is less than 4Ω NOTICE All operations during the commissioning must be performed by qualified personnel only. Commission the device when it is sunny and the environmental conditions are stable to ensure successful commissioning. 7.3 Checking before Commissioning Checking the Cable Connection Check cables for any possible damages or cracks. Check that all cables are connected securely according to the cable connection diagram. Adjust the cable connection if necessary. Ensure all cable connections are firmly enough. Fix the bolts if necessary. Check the PE equipotential connection. Ensure PE ground point of the internal devices has been connected to the equipotential connection point in the Turnkey Station and properly grounded. The ground resistance should be no more than 4Ω Checking the Turnkey Station Switches Ensure that all DC, AC, and micro switches in the Turnkey Station are in the OFF position. Ensure that the emergency stop button is released. Check and ensure the Turnkey Station and switches upstream and downstream meet the requirements and flexible enough Checking PV Array Ensure the measuring devices are connected and used correctly. Otherwise, there will be an electric arc. DC side voltage should be no more than the Turnkey Station max. input DC voltage. Too high DC voltage may damage the Turnkey Station even cause safety incident. 45

54 7 Commissioning System Manual To ensure the system reliability and device operation, the Turnkey Station DC side should employ PV cells of the same manufacturer and numbers of PV cells in each string should be the same. Check the PV arrays before grid-connection. The voltage of each DC main cables should be the same and no more than the max. allowable DC voltage. Check carefully the polarity of each DC main cable. Once the polarity in one DC main cable is incorrect, the PV arrays may be damaged. Make sure the environmental condition is stable since the voltage of PV array may change with the solar radiation and the temperature of the PV cells. Use the U-I curve to record the PV array situation. Commission the device when the PV array output situation is stable. The PV field circuit fault (module fault or module numbers deviation in certain array), cable damages or connection looseness may cause the voltage deviation exceeding 3% at stable environmental conditions. Record the environmental parameters (temperature and radiation, etc.). Measure the resistance of cables (between the terminal box and the Turnkey Station). Record accurately all the measured data Checking Grid Voltage Measure accurately the grid 3-phase line-to-line voltage: L1-L2, L1-L3, and L2-L3. Measured data should not exceed the grid permissible voltage and the three phases are balanced. Adjust the transfer ratio of the transformer by qualified personnel if the grid voltage deviation is large. Measure and record the grid frequency. Measured data should not exceed the grid permissible frequency. Measure the THD and check the curve if possible. The Turnkey Station will stop running if the THD is serious. Record accurately all the measured data. 7.4 Preparation before Starting Place the disassembled protection grills to their original positions and ensure the connection is secure. Clean the device site. Make sure the position is clean without flammable or explosive materials. Ensure the ventilation of the installation place. Recheck to ensure the Turnkey Station and switches upstream and downstream meet the requirements and are flexible enough. 7.5 Starting the Device If all tests and measurements have been performed, and all measured values lie within the acceptable range, the device can be switched on for the first time. Proceed as follows to start the Turnkey Station: 46

55 System Manual 7 Commissioning Step 1 Check again for the polarity on the internal DC side of the Turnkey Station. Step 2 Close the upstream and downstream switches of the Turnkey Station. Step 3 Manually close the auxiliary power supply switch inside the Turnkey Station and wait the touchscreen to be powered on. Step 4 Stop the Turnkey Station through the touchscreen. Step 5 Turn off Trip Enable and Door-protect enable through the touchscreen. Step 6 Set output power limitation to 5% through the touchscreen. Step 7 Manually close all AC switches inside the Turnkey Station. Step 8 Manually close all DC switches inside the Turnkey Station. Step 9 Perform the start operation through the touchscreen, and the Turnkey Station starts grid-connected operation. Step 10 Increase output power limitation gradually to the maximum value. To ensure the Turnkey Station normal operation for the first time, please measure the Turnkey Station DC input voltage beforehand. When the DC side voltage meets the start-up requirement, i.e. DC voltage is steadily higher than DC start-up voltage. Start the Turnkey Station for the first time. 7.6 LCD Parameter Setting When the LCD is on, set the LCD display language, data and time, communication parameters, and active power limitation etc. according to Chapter 9: LCD Operation in this manual. You can also view the Turnkey Station running information and perform pertinent operation. 7.7 Completing Commissioning If all the start-up procedures have been performed, check the operating condition of the Turnkey Station. Check whether there are anomalies of the Turnkey Station: abnormal noise, overheating, smoking, or unusual odor. Check the Turnkey Station grid-connected voltage, current, and THD for unstableness. Check the grounding of the Turnkey Station enclosure. Check the functionality of the LCD display. Record accurately the Turnkey Station operation data during commissioning. The duration of commissioning depends on the plant scale, plant location, on-site environmental conditions, and on the like. Usually, if on-site condition is stable, the commissioning can last for 1 week, i.e. 168 hours. The commissioning of the Turnkey Station is completed. The Turnkey Station operates normally. After commissioning, plant starts power generation and enters daily maintenance process. 47

56 7 Commissioning System Manual When the Turnkey Station is operating, make sure there are no flammable materials or other materials within at least 5 meters around the installation site. Local/national standards about the min. electric clearance around the Turnkey Station should be respected. The Turnkey Station needs no manual control in daily operation. Open the cabinet door only for maintenance or troubleshooting and by qualified personnel only. Keep the door closed and locked and store the keys of the door by appointed personnel during normal operation. 48

57 8 Starting/Stopping 8.1 Starting Inspection before starting After the maintenance or service work, you may start the Turnkey Station. Inspect the following requirement before starting the Turnkey Station: All connections are done by strictly following the relevant manual and circuit diagram. The coverings of the internal devices are fixed and secured. The emergency stop button is released. Make sure, via suitable instruments, that there is no ground fault of the PV array. Measure the DC and AC voltage with multi-meter to check if they meet the Turnkey Station startup conditions and ensure that there is no overvoltage hazard. Measure the DC voltage with multi-meter, and check if the polarity is correct. If the Turnkey Station has been stored for more than half a year in the required storage environment, a thorough and careful inspection is necessary before the Turnkey Station is powered on Start Steps When the foregoing conditions are met, proceed as follows to start the Turnkey Station: Step 1 Close the upstream and downstream switches of the Turnkey Station. Step 2 Manually close the auxiliary power supply switch inside the Turnkey Station and wait the touchscreen to be powered on. Step 3 Stop the Turnkey Station through the touchscreen. Step 4 Turn off Trip Enable and Door-protect enable through the touchscreen. Step 5 Manually close all AC switches inside the Turnkey Station. Step 6 Manually close all DC switches inside the Turnkey Station. Step 7 Perform the start operation through the touchscreen, and the Turnkey Station starts grid-connected operation. After startup, the Turnkey Station will automatically check if parameters of the DC and AC side meet the grid-connection requirements. If the requirements are met, and the set time has been reached, the Turnkey Station will turn to the OPERATION mode and feed the generated AC current to the grid. The Turnkey Station needs no manual control in daily operation. Open the cabinet door only for maintenance or troubleshooting and by qualified personnel only. Keep the door closed and locked and store the keys of the door by appointed personnel during normal operation. 49

58 9 Starting/Stopping System Manual 8.2 Stopping Turnkey Station stops during normal maintenance and service work or when a fault occurs Normal Stop Proceed as follows to stop the Turnkey Station during normal maintenance and service work: Step 1 Stop the Turnkey Station through the stop operation on the LCD panel. Step 2 Disconnect the DC, AC, and Auxiliary power supply switches. Step 3 Disconnect the Turnkey Station downstream switches. Step 4 Disconnect the Turnkey Station upstream switches. Step 5 The Turnkey Station stops. During normal operation, disconnection of AC or DC switch is strictly prohibited. Otherwise, the switch can be damaged and the Turnkey Station may also be damaged Turnkey Station Stops when A Fault Occurs Proceed as follows to stop the Turnkey Station when a fault or an emergency occurs: Step 1 Press the emergency stop button. Step 2 Disconnect the DC, AC, and Auxiliary power supply switches. Step 3 Disconnect the Turnkey Station downstream switches. Step 4 Disconnect the Turnkey Station upstream switches. Step 5 The Turnkey Station stops. Use the emergency stop button only when an emergency or a fault occurs. Under normal conditions, stop the Turnkey Station by performing the stop command in the LCD panel. Press the emergency stop button directly in case of crisis to ensure a timely response. The emergency stop button will stay in lock state once you press it. Use a key to unlock the button. 50

59 9 LCD Menu Operation 9.1 LCD Touchscreen The LCD touchscreen, located at the eye-level inside the monitoring window on the front side of the Turnkey Station is used for viewing the data and related set parameters by the user. For user convenience, there are a large number of pictures about the LCD interface in this chapter. The parameters and other details in those pictures are indicative only. The actual product you receive may differ. If the time shown on the LCD panel is different from the actual local time after time calibration, please check the button cells on the back of the LCD panel and replace them if necessary. 9.2 Default Screen Initialization The LCD is initialized and then enters into the starting menu. The initialization screen appears every time the Turnkey Station is powered on. After initialization, the default screen follows Default Screen Introduction G H Item Description B Yield data. The first line from the top is the A present active power; and the work state A C D is the transient state of the Turnkey Station. Today s active power curve indicating the B power percentage (power value/the E F Turnkey Station nominal power value). DC side voltage and current of the C Turnkey Station AC side line-to-line voltage and phase D current E Language selection button. Click it to change languages among English, Chinese, French, and Italian. F Present date and time The success rate of the Turnkey Station G internal communication The success rate of communication H between the Turnkey Station and PC Accessing to submenus mentioned below starts from the default menu. 51

60 9 LCD Menu Operation System Manual LCD screen contains lots of parameters pertinent to the Turnkey Station operation. All parameters must be set by appointed personnel. Do not modify any parameters before you fully understand this manual or consult the staff from Sungrow Backlight and Screensaver If there is no operation on the screen for more than 5 minutes, the backlight will be off. Activate the backlight by tapping the screen and the screen will r display the menu operated previously. 9.3 Overview of LCD Menu and Icon Overview of Submenu and Icon There are three buttons on the lower left side of the touch panel for the user to operate Start/Stop, Home,, Function. The logical structures of these menus are shown below: Main Menu First sub-menu Second sub-menu Third sub-menu Start/Stop Start - - Stop - - Home Function Run-information Real-Time Data - Power curve - E-histogram - History-information Layout of the submenus His-event His-fault - His-data - His-alarm Start/Stop Start - Stop - Set-parameter Sys-parameter Language & Firmware Ver. Time Remote/Local control Load default Run-parameter - Pro-parameter - Com-parameter Serial port param. Network param. The layout of submenus is the same as that shown below except for the default menu. 52

61 System Manual 9 LCD Menu Operation A B Item Description Title bar The first line from the top is the present success rate of communication. A The left side of the second line is the name of the present page, while the right side is the present date and time. B Data display or parameter configuration. From left to right: the three main icons; the return button to return to the previous C menu by tapping it. For convenience, the operations on the menus are referred to as the menu name with C quotation marks. For example, the menu will be referred to as Set-parameter. 9.4 Entering Password Turnkey Station parameters are protected by the password. The user can enter the Set-parameter sub-menu only after entering the correct password. Proceed as follows to enter the password: Step 1 Tap Function on the default menu; Step 2 Tap Set-parameter, and the password entering window pops out; Step 3 Tap the white edit box, and a keypad pops out. Step 4 Enter the password through the keypad. Button Clr Esc Enter Max./Min. Function backspace key, delete the digit input clear the digitals input escape and close the keypad confirm the password input the maximum and minimum value that can be entered; digital beyond this range is invalid 53

62 9 LCD Menu Operation System Manual If the entered password is 1111, the user can enter the normal parameter setting page and set system parameters, running parameters, protection parameters, and communication parameters. Step 5 Press Enter to confirm the entered password. Step 6 If the entered password is incorrect, an Error password window will appear. Tap Enter and re-enter the password. 9.5 Language Setting The user can set the language by either of the following two ways: Conventional Way Step 1 Tap Function on the default menu; Step 2 Tap Set-parameter ; Step 3 Tap Sys-parameter after entering the correct password; Step 4 Tap Language & Firmware Ver. and enter the language and firmware version sub-menu; Step 5 Select the target language Shortcut The language setting shortcut (A) is at the lower right side of the Home menu. Select either language by tapping the language button. By tapping the button, the language can be switched among English, Chinese, French, and Italian. The language on the button is the present language on the display. 54

63 System Manual 9 LCD Menu Operation A 9.6 Date and Time Setting Step 1 Tap Function on the default menu; Step 2 Tap Set-parameter ; Step 3 Tap Sys-parameter after entering the correct password; Step 4 Tap Time and enter the date and time setting sub-menu; Step 5 Set the Year, Month, Date, Hour, Minute and Second. Tap the corresponding cell and the keypad will appear; Step 6 Set the time and date by tapping the keypad and confirm the setting by tapping Enter. 9.7 Running Information Checking Running information contains all data pertinent to the Turnkey Station operation: Real-time data The real-time running information can be checked. The output power, DC voltage & current, power factor, reactive power, efficiency, daily/monthly/annual power yields, internal temperature, positive/negative insulation resistance to the ground, running time, amount of CO 2 reduction, grid frequency, AC phase/line voltage, module temperature, AC & DC switches states, bypass switches/fuse state, power supply mode are included. Power curve The output power curve shows the percentage of the power yield to the nominal power on that particular day. The data are updated every several seconds and the total diagram data will be cleared at the beginning of a new day. 55

64 9 LCD Menu Operation System Manual E-histogram The power yields of the present day in the histogram. Proceed as follow to view the running information: Step 1 Tap Function on the default menu; Step 2 Tap Run-information and switch among Real Time Data, Power curve and E-histogram. The default display is Real Time Data ; Step 3 Tap Power curve and enter the power curve sub-menu; Step 4 Tap E-histogram and enter the electricity histogram sub-menu. The display value is directive only and must not be used as a basis for charging. 9.8 History Information Checking There are four kinds of history information: History event, history fault, history data, and history alarm History Event Checking Step 1 Tap Function on the default menu. Step 2 Tap History-information and enter the history information sub-menu. 56

65 System Manual 9 LCD Menu Operation Step 3 Tap His-event and enter the history event sub-menu. A maximum ofa maximum of 200 history events can be viewed via this sub-menu, and a maximum ofa maximum of 5 records can be displayed on one page. The upper left side of the event table is the total number of the current event records. Tap Prev or Next to turn pages up or down History Data Checking The system can record the Turnkey Station running information of the latest 90 days with the records updated every 15 minutes per day. History data displays the data related to the power yields and the electric quantity of the Turnkey Station. Proceed as follows to check the history information: Step 1 Tap Function on the default menu. Step 2 Tap History-information and enter the history information sub-menu. Step 3 Tap His-data and enter the history data sub-menu. Tap Prev or Next to turn pages up or down History Fault Checking When a fault occurs in the Turnkey Station, the user can view the present fault via the LCD screen and the history fault records as follows: Step 1 Tap Function on the default menu. Step 2 Tap History-information and enter the history information sub-menu. Step 3 Tap His-fault and enter the history fault sub-menu. 57

66 9 LCD Menu Operation System Manual A maximum of 200 history faults can be viewed from this sub-menu, with a maximum of 5 records can be shown on one page. The upper left side of the event table is the total number of the current fault records. Tap Prev or Next to turn pages up or down History Alarm Checking Proceed as follows to check the history warn information: Step 1 Tap Function on the default menu. Step 2 Tap History-information and enter the history information sub-menu. Step 3 Tap his-alarm and enter the history alarm sub-menu. A maximum of 200 history alarms can be viewed from this sub-menu, with a maximum of 5 records can be shown on one page. The upper left side of the event table is the total numbers of the current warn records. Tap Prev or Next to turn pages up or down. 9.9 Present Fault Information Checking The module cabinet inside the Turnkey Station includes three module units(inverter unit). There may be one or more faults occur in the inverter units inside the Turnkey Station at the same time, and the fault can be viewed on the LCD screen. Follow the description in this chapter to view the fault information when the faults occur. Fault If there is a fault, the Work State will show Fault. Tap the Fault cell. 58

67 System Manual 9 LCD Menu Operation The state column of the module unit that has fault will display Fault". As shown in the left figure, a fault occurs to inverter unit 1. Tap the fault cell of inverter unit 1 to check the present fault. The fault interface of inverter unit 1 will appear with the fault item in red Starting/Stopping Usually, the Turnkey Station will start automatically when the grid-connected requirements are met. Follow either of the two ways below to start/stop the Turnkey Station through the LCD screen: Tap Start/Stop on the default menu. Tap Start/Stop from the Function menu. Start or stop the Turnkey Station by tapping the start/stop button on the screen. A confirm operation interface will appear after tapping the corresponding buttons. The instruction is effective after confirmation; and cancel the operation by tapping Cancel Load Default Proceed as follows to perform the load default: Step 1 Tap Function on the default menu. Step 2 Tap Set-parameter. Step 3 Tap Sys-parameter after entering the correct password. Step 4 Tap Load default and the password inputting window appears. 59

68 9 LCD Menu Operation System Manual The password is The system will be reset after entering the password Firmware Version Checking The user can view the firmware version of the LCD and DSP as follows: Step 1 Tap Function on the default menu. Step 2 Tap Set-parameter. Step 3 Tap Sys-parameter after entering the correct password. Step 4 Tap Language & Firmware Ver. and enter the language and firmware version sub-menu. Step 5 The firmware version of LCD and DSP is displayed at the bottom of the page Parameters of LCD Communication Parameters Improper communication parameter configuration may lead to communication failure! Follow strictly the instructions of the plant staff to configure the communication parameters. There are RS485 communication and Network communication. The user can set the communication address and protocol through the LCD screen when the hardware connection is complete and the device is energized. Proceed as follows to set the communication parameters: Step 1 Tap Function on the default menu. Step 2 Tap Set-parameter. Step 3 Tap Com-parameter after entering the correct password. 60

69 System Manual 9 LCD Menu Operation Set parameter from the Serial Port Parameter interface for RS485 serial communication. Set parameter from the Network Parameter interface for Network communication Serial Port Parameter Setting Click Serial port param to enter the following interface. Two parameters pertinent to RS485 serial port communication can be set according to the parameter range shown on the display. Address is prescribed by the plant staff and the address for each device must be unique when there is more than one device. Baud is selected according to the communication method adopted on site. Network Parameter Setting Click Network Parameter to enter the following interface. Six parameters pertinent to the Network communication can be set. DNS address 1 and DNS address 2 can be set to the default value. Other parameters are assigned by plant staff. Set parameter via the pop-up keypad. 61

70 9 LCD Menu Operation System Manual Running Parameters Setting Running Parameters Step 1 Tap Function on the default menu. Step 2 Tap Set-parameter. Step 3 Tap Run-parameter after entering the correct password. Step 4 Set the running parameter by tapping the pop-up keypad and tap ENTER to confirm the setting. Tap Prev or Next to turn pages up or down. Description of Running Parameters Parameter Description Vmppt-max (V) Maximum MPPT voltage Vmppt-min (V) Minimum MPPT voltage T-start-wait (s) The time from the AC/DC parameters meet the grid-connection conditions to the Turnkey Station begins to generate power. T-stop-delay (s) The time from the LCD display or upper computer sends stop command to Turnkey Station performs the stop command stop slope (%/s) Active power decline rate from the time at which Turnkey Station performs stop command to the time at which Turnkey Station stops start slope (%/s) Active power rise rate from the time at which the Turnkey Station performs the start command to the time at which the Turnkey Station completes the startup Limit Power (%) Percentage that the active power output accounted for the nominal output power (%) Pf cosφ Q-limit (%) Percentage that the reactive power rise accounted for the nominal power (%) Q-adjust switch - Power-off saved (Pf) If the power factor setting can be saved when the LCD screen is powered off Power-off saved (P-limited) If the limit power(%) setting can be saved when the LCD screen is powered off SVG switch If the reactive power compensation is activated or deactivated T-recover (s) Automatic recovery time when fault occurs P-rise rate (%/s) Rate of rise of the active power P-decline rate (%/s) Rate of decline of the active power Q-rise rate (%/s) Rate of rise of the reactive power Q-decline rate (%/s) Rate of decline of the reactive power Trip Enable Trip the DC main switches of two modules FW func enable To enable/disable the FW function FW output change base The standard of active power change caused by frequency change 62

71 System Manual 9 LCD Menu Operation Parameter 50Hz OF decrease start(hz) 50Hz OF decrease end(hz) 60Hz OF decrease start(hz) 60Hz OF decrease end(hz) OF decrease slope OF decrease limit (%) FW input type FW enable power(%) 50Hz UF increase start(hz) 50Hz UF increase end(hz) 60Hz UF increase start(hz) 60Hz UF increase end(hz) UF increase slope UF increase limit(%) QU enable power(%) QU operation mode QU input type QU ind var limit (%) QU cap var limit (%) QU PF limit (%) QU volt rise start(%) QU volt rise end(%) QU volt drop start(%) QU volt drop end(%) V auto-adj ref(%) Description For 50Hz grid type, refer to f1i in Fig.9-1 The relation curve between the active power and the frequency For 50Hz grid type, refer to f2i in Fig.9-1 The relation curve between the active power and the frequency For 60Hz grid type, refer to f1i in Fig.9-1 The relation curve between the active power and the frequency For 60Hz grid type, refer to f2i in Fig.9-1 The relation curve between the active power and the frequency Refer to K1 in Fig.9-1 The relation curve between the active power and the frequency Refer to ΔP1 in Fig.9-1 The relation curve between the active power and the frequency The input frequency type of the FW function. The max./min value of the real-time frequency or during frequency change After the FW function is enabled, the FW function is started when the percentage of the actual output active power is bigger than the set value For 50Hz grid type, refer to f1s in Fig.9-1 The relation curve between the active power and the frequency For 50Hz grid type, refer to f2s in Fig.9-1 The relation curve between the active power and the frequency For 60Hz grid type, refer to f1s in Fig.9-1 The relation curve between the active power and the frequency For 60Hz grid type, refer to f2s in Fig.9-1 The relation curve between the active power and the frequency Refer to K2 in Fig.9-1 The relation curve between the active power and the frequency Refer to ΔP2 in Fig.9-1 The relation curve between the active power and the frequency In QU mode, the QU function will be enabled when the actual output active power percentage is bigger than the set value In QU reactive power mode, the method to set the reactive power value QU function input voltage type; the max./min value of the real-time grid voltage or during grid voltage change Refer to Qmax in Fig.9-2 The relation curve between the reactive power and the voltage Refer to Qmin in Fig.9-2 The relation curve between the reactive power and the voltage The Turnkey Station compensation power factor min. and max. value caused by grid voltage change; setting is available when the QU operation mode is TanPhiadj or CosPhiadj Refer to U1i in Fig.9-2 The relation curve between the reactive power and the voltage. Refer to U2i in Fig.9-2 The relation curve between the reactive power and the voltage. Refer to U1s in Fig.9-2 The relation curve between the reactive power and the voltage Refer to U2s in Fig.9-2 The relation curve between the reactive power and the voltage When the reactive regulation switch is V auto-adj, the grid regulation reference is set according to the percentage of nominal voltage 63

72 9 LCD Menu Operation System Manual Parameter V auto-adj hysteresis(%) Q(P) upper PF Q(P) lower PF Q(P) upper power(%) Q(P) lower power(%) Description When the reactive regulation switch is V auto-adj, the allowable plus or minus error of the regulation voltage and it is set according to the percentage of nominal voltage Power factor of point P1 in Fig. 9-3 Q(P) mode curve Power factor of point P2 in Fig. 9-3 Q(P) mode curve Output power of point P2 in Fig. 9-3 Q(P) mode curve Output power of point P1 in Fig. 9-3 Q(P) mode curve The relation curve between the active power and the frequency is shown in the figure below. P/kW Pn P2 k2 P0 P1 k1 f/hz f2s f1s fn f1i f2i Fig. 9-1 The relation curve between the active power and the frequency The relation curve between the reactive power and the voltage is shown in the figure below. Q Qmax U2s U1s U1i U2i U Qmin Fig. 9-2 The relation curve between the reactive power and the voltage 64

73 System Manual 9 LCD Menu Operation Q(P) mode curve is shown in following figure. Upper PF Cap P1 Lower Power Upper Power P/Pn Lower PF Ind P2 Fig. 9-3 Q(P) mode curve Running parameter range and default value are shown in the following table. Parameter Range Default Vmppt-max (V) 875~ Vmppt-min (V) 875~ T-start-wait (s) 0~ T-stop-delay (s) 0~600 0 Stop slope (%/s) 0.1~ Start slope (%/s) 0.01~ Limit Power (%) 0~ Pf -0.8~-1/0.8~1 1 Q-limit (%) -100~100 0 Q-adjust switch Close/Pf/Q-limit/QU mode/ Pf V auto-adj/qp mode Power-off saved (Pf) Save/Not save Save Power-off saved (P-limited) Save/Not save Not save SVG switch Enable/Disable Disable T-recover (s) 20~ P-rise rate (%/s) 0.01~ P-decline rate (%/s) 0.01~ Q-rise rate (%/s) 0.01~ Q-decline rate (%/s) 0.01~ Trip Enable Enable/Disable Disable FW func enable Enable/Disable Disable FW output change base Rated-P/Pre-derate-P Pre-derate-P 50Hz OF decrease start(hz) 50~ Hz OF decrease end(hz) 50~ Hz OF decrease start(hz) 60~ Hz OF decrease end(hz) 60~ OF decrease slope 0~2 0.4 OF decrease limit (%) 0~ FW input type RT-F/Record-F Record-F FW enable power(%) 0~ Hz UF increase start(hz) 45~ Hz UF increase end(hz) 45~ Hz UF increase start(hz) 55~ Hz UF increase end(hz) 55~ UF increase slope 0~2 0.4 UF increase limit(%) 0~ QU enable power(%) 0~

74 9 LCD Menu Operation System Manual Parameter Range Default QU operation mode Var PCT adj/ Var PCT adj TanPhi adj/ CosPhi.adj QU input type RT volt/record volt RT volt QU ind var limit (%) 0~ QU cap var limit (%) 0~ QU PF limit (%) 0.8~1 0.9 QU volt rise start(%) 100~ QU volt rise end(%) 100~ QU volt drop start(%) 90~ QU volt drop end(%) 90~ V auto-adj ref(%) 90~ V auto-adj hysteresis(%) 0~10 1 Q(P) upper PF 0.9~1 1 Q(P) lower PF 0.9~1 0.9 Q(P) upper power(%) 50~ Q(P) lower power(%) 0~50 50 Note: * non-settable ** at night when the Turnkey Station enters standby mode (but does not enter the deeper standby mode with lower power consumption), the SVG function needs to be activated: first, stop the Turnkey Station by the LCD button, and then start; set the SVG switch to Enable. The SVG is an optional function of this Turnkey Station. Please refer to the LCD screen for the specific setting ranges of these parameters Protection Parameter Setting Protection Parameter Step 1 Tap Function on the default menu; Step 2 Tap Set-parameter ; Step 3 Tap Pro-parameter after entering the correct password. Set the protection parameter by tapping the pop-up keypad and tap ENTER to confirm the the setting. Tap Prev or Next to turn pages up or down. Description of Protection Parameters Parameter Ⅰ_Vgrid-max(%) Ⅱ_Vgrid-max(%) Description Set the grid over-voltage protection Ⅰ value. Protection is activated when voltage exceeds this value. Set the grid over-voltage protection Ⅱ value. Protection is activated when voltage exceeds this value. 66

75 System Manual 9 LCD Menu Operation Parameter Ⅲ_Vgrid-max(%) Ⅳ_Vgrid-max(%) Ⅴ_Vgrid-max(%) Recover_Vgrid-max(%) Ⅰ_T-Vhigh trip(ms) Ⅱ_T-Vhigh trip(ms) Ⅲ_T-Vhigh trip(ms) Ⅳ_T-Vhigh trip(ms) Ⅴ_T-Vhigh trip(ms) Ⅰ_Vgrid-min(%) Ⅱ_Vgrid-min(%) Ⅲ_Vgrid-min(%) Ⅳ_Vgrid-min(%) Ⅴ_Vgrid-min(%) Recover_Vgrid-min(%) Ⅰ_T-Vlow trip(ms) Ⅱ_T- Vlow trip(ms) Ⅲ_T- Vlow trip(ms) Ⅳ_T- Vlow trip(ms) Ⅴ_T- Vlow trip(ms) Ⅰ_Fgrid-max(Hz) Ⅱ_Fgrid-max(Hz) Ⅲ_Fgrid-max(Hz) Ⅳ_Fgrid-max(Hz) Ⅴ_Fgrid-max(Hz) Recover_Fgrid-max(Hz) Ⅰ_T-Fhigh trip(ms) Ⅱ_T-Fhigh trip (ms) Ⅲ_T-Fhigh trip(ms) Ⅳ_T-Fhigh trip (ms) Ⅴ_T-Fhigh trip(ms) Description Set the grid over-voltage protection Ⅲ value. Protection is activated when voltage exceeds this value. Set the grid over-voltage protection Ⅳ value. Protection is activated when voltage exceeds this value. Set the grid over-voltage protection Ⅴ value. Protection is activated when voltage exceeds this value. The Turnkey Station recovers normal operation when grid voltage is below this value Grid over-voltage protection Ⅰ trip time Grid over-voltage protection Ⅱ trip time Grid over-voltage protection Ⅲ trip time Grid over-voltage protection Ⅳ trip time Grid over-voltage protection Ⅴ trip time Set the grid under-voltage protection Ⅰ value. Protection is activated when voltage is below this value. Set the grid under-voltage protection Ⅱ value. Protection is activated when voltage is below this value. Set the grid under-voltage protection Ⅲ value. Protection is activated when voltage is below this value. Set the grid under-voltage protection Ⅳ value. Protection is activated when voltage is below this value. Set the grid under-voltage protection Ⅴ value. Protection is activated when voltage is below this value. The Turnkey Station recovers normal operation when grid voltage is above this value Grid under-voltage protection Ⅰ trip time Grid under-voltage protection Ⅱ trip time Grid under-voltage protection Ⅲ trip time Grid under-voltage protection Ⅳ trip time Grid under-voltage protection Ⅴ trip time Set the grid over-frequency protection I value. Protection is activated when frequency exceeds this value Set the grid over-frequency protection II value. Protection is activated when frequency exceeds this value Set the grid over-frequency protection Ⅲ value. Protection is activated when frequency exceeds this value Set the grid over-frequency protection Ⅳ value. Protection is activated when frequency exceeds this value Set the grid over-frequency protection Ⅴ value. Protection is activated when frequency exceeds this value The Turnkey Station recovers normal operation when grid frequency is below this value Set the grid over-frequency I tripping time Set the grid over-frequency II tripping time Set the grid over-frequency Ⅲ tripping time Set the grid over-frequency Ⅳ tripping time Set the grid over-frequencyⅤ tripping time 67

76 9 LCD Menu Operation System Manual Parameter Ⅰ_Fgrid-min(Hz) Ⅱ_Fgrid-min(Hz) Ⅲ_Fgrid-min(Hz) Ⅳ_Fgrid-min(Hz) Ⅴ_Fgrid-min(Hz) Recover_Fgrid-min(Hz) Ⅰ_T-Flow trip(ms) Ⅱ_T-Flow trip (ms) Ⅲ_T-Flow trip(ms) Ⅳ_T-Flow trip (ms) Ⅴ_T-Flow trip (ms) LVRT switch LVRT T1(ms) LVRT T2(ms) LVRT voltage1(%) LVRT voltage2(%) LVRT dynamic Var Kf factor HVRT switch HVRT T1(ms) HVRT T2(ms) HVRT voltage1(%) HVRT voltage2(%) Recover T-grid(s) Active Islanding I leakage-pro(a) Door-protect enable Fault manual restart Negative Vgrid protect value(v) Grid_V-unbalanced protect value(%) Grid_V-unbalanced protect time(s) Anti-PID mode Ins monitor measure time(s) Ins monitor protect threshold(k) Ins monitor Vdc-start(V) Description Set the grid under-frequency protection I value. Protection is activated when frequency exceeds this value Set the grid under-frequency protection II value. Protection is activated when frequency exceeds this value Set the grid under-frequency protection Ⅲ value. Protection is activated when frequency exceeds this value Set the grid under-frequency protection Ⅳ value. Protection is activated when frequency exceeds this value Set the grid under-frequency protection Ⅴ value. Protection is activated when frequency exceeds this value The Turnkey Station recovers normal operation when grid frequency is above this value Set the grid under-frequency I tripping time Set the grid under-frequency II tripping time Set the grid under-frequency Ⅲ tripping time Set the grid under-frequency Ⅳ tripping time Set the grid under-frequency Ⅴtripping time Enable or disable the LVRT switch Refer to T1 in Fig Lower voltage withstand requirements Refer to T2 in Fig Lower voltage withstand requirements Refer to U1 in Fig Lower voltage withstand requirements Refer to U2 in Fig Lower voltage withstand requirements Ratio of reactive power compensation and voltage dropping depth during LVRT Enable or disable the HVRT switch Refer to T1 in Fig High voltage withstand requirements Refer to T2 in Fig High voltage withstand requirements Refer to U1 in Fig High voltage withstand requirements Refer to U2 in Fig High voltage withstand requirements The grid under-/over-voltage and under-/over-frequency protection is enabled. When the grid turns normal and the set time is reached, the fault will be removed. Enable or disable the islanding protection function Leakage current protection setting value Enable or disable the door control protection Manual fault restart. If this function is enabled, the Turnkey Station can reconnect to the grid only after the fault is removed manually. Protection value of negative voltage to ground 3-phase grid voltage unbalance protection threshold value 3-phase grid voltage unbalance time reaches to the set value. Protection is activated If Anti-PID mode is enabled, you may set the Anti-PID mode (Invalid, Suppression and Repair) Insulation monitoring time Insulation monitoring protection threshold value Insulation monitoring startup voltage. When the DC voltage reaches to this set value, the insulation monitoring enables. 68

77 System Manual 9 LCD Menu Operation Protection parameter range and default value are shown in the following table. Parameter Range Default Ⅰ_Vgrid-max(%) 105~ Ⅱ_Vgrid-max(%) 105~ Ⅲ_Vgrid-max(%) 105~ Ⅳ_Vgrid-max(%) 105~ Ⅴ_Vgrid-max(%) 105~ Recover_Vgrid-max(%) 105~ Ⅰ_T-Vhigh trip(ms) 40~ Ⅱ_T-Vhigh trip(ms) 40~ Ⅲ_T-Vhigh trip(ms) 40~ Ⅳ_T-Vhigh trip(ms) 40~ Ⅴ_T-Vhigh trip(ms) 40~ Ⅰ_Vgrid-min(%) 10~95 80 Ⅱ_Vgrid-min(%) 10~95 50 Ⅲ_Vgrid-min(%) 10~95 50 Ⅳ_Vgrid-min(%) 10~95 50 Ⅴ_Vgrid-min(%) 10~95 50 Recover_Vgrid-min(%) 10~95 90 Ⅰ_T-Vlow trip(ms) 40~ Ⅱ_T- Vlow trip(ms) 40~ Ⅲ_T- Vlow trip(ms) 40~ Ⅳ_T- Vlow trip(ms) 40~ Ⅴ_T- Vlow trip(ms) 40~ Ⅰ_Fgrid-max(Hz) 50.2~55/60.2~ /60.5 Ⅱ_Fgrid-max(Hz) 50.2~55/60.2~ /60.5 Ⅲ_Fgrid-max(Hz) 50.2~55/60.2~ /60.5 Ⅳ_Fgrid-max(Hz) 50.2~55/60.2~ /60.5 Ⅴ_Fgrid-max(Hz) 50.2~55/60.2~ /60.5 Recover_Fgrid-max(Hz) 50.2~55/60.2~ /60.2 Ⅰ_T-Fhigh trip(ms) 40~ Ⅱ_T-Fhigh trip (ms) 40~ Ⅲ_T-Fhigh trip(ms) 40~ Ⅳ_T-Fhigh trip (ms) 40~ Ⅴ_T-Fhigh trip(ms) 40~ Ⅰ_Fgrid-min(Hz) 45~49.8/55~ /57.5 Ⅱ_Fgrid-min(Hz) 45~49.8/55~ /57.5 Ⅲ_Fgrid-min(Hz) 45~49.8/55~ /57.5 Ⅳ_Fgrid-min(Hz) 45~49.8/55~ /57.5 Ⅴ_Fgrid-min(Hz) 45~49.8/55~ /57.5 Recover_Fgrid-min(Hz) 45~49.8/55~ /57.5 Ⅰ_T-Flow trip(ms) 40~

78 9 LCD Menu Operation System Manual Parameter Range Default Ⅱ_T-Flow trip (ms) 40~ Ⅲ_T-Flow trip(ms) 40~ Ⅳ_T-Flow trip (ms) 40~ Ⅴ_T-Flow trip (ms) 40~ LVRT switch Enable/Disable Enable LVRT T1(ms) 2500~ LVRT T2(ms) 500~ LVRT voltage1(%) 50~90 90 LVRT voltage2(%) 5~50 20 LVRT dynamic Var Kf factor 0~4 1.5 HVRT switch Enable/Disable Enable HVRT T1(ms) 100~ HVRT T2(ms) 100~ HVRT voltage1(%) 110~ HVRT voltage2(%) 120~ Recover T-grid(s) 1~ Active Islanding Enable/Disable Disable I leakage-pro(a) 1~10 5 Door-protect enable Enable/Disable Disable Fault manual restart Enable/Disable Disable Negative Vgrid protect value(v) 20~ Grid_V-unbalanced protect value(%) 3~20 5 Grid_V-unbalanced protect time(s) 0.1~ Anti-PID mode Invalid/Suppression/Repair Invalid Ins monitor measure time(s) 30/150/300/ Ins monitor protect threshold(k) 15~ Ins monitor Vdc-start(V) 220~ Improper parameter configuration may affect the normal operation of the Turnkey Station! Only authorized personnel can configure these parameters. Should there be any question or doubt, please contact Sungrow. Please refer to the LCD screen for the specific setting ranges of these parameters. 70

79 10 Turnkey Station Functions 10.1 Operation Mode Mode Change After being energized, the Turnkey Station will switch among different modes as shown in the figure below. Stop Unrecoverable fault Stop and repair the Station Fault Initial standby Station is energized All the gridconnected requirements met Startup Fault occurred Run Fault cleared and setting time reached Idc 0A for 10 minutes Upv>UpvStart and setting time reached Standby Stop the Station via LCD panel Station restarts Key-stop Stop the Station via LCD panel Alarm removed Turn the Start/Stop switch to Stop or push down the Emergency stop button Alarm Run Station restarts Turn the Start/Stop switch to Stop or push down the Emergency stop button Emergencystop Fig Operation modes change Upv is the DC input voltage of the Turnkey Station. UpvStart is the DC side startup voltage of the Turnkey Station Operation Mode Description Stop This is the initial state of the Turnkey Station. The Turnkey Station DC and AC switches are in the OFF position; and the upstream and downstream connections are disconnected. The Turnkey Station is therefore electricity-free. Initial Standby When switches of the upstream and downstream devices are closed and the AC & DC switches of the Turnkey Station are in the ON position, the Turnkey Station turns to the Initial Standby mode. The Turnkey Station will continuously check if the PV array and the grid meet the grid-connection requirements. If the Turnkey Station DC input voltage is higher than the Turnkey Station startup voltage, the startup time is reached, and the requirements for the grid side parameter are satisfied, the Turnkey Station will turn from the Initial Standby mode into the Startup mode. 71

80 10 Turnkey Station Functions System Manual Startup This is the transient process between the Initial Standby mode and the Run mode. Once the Startup mode is activated, the Turnkey Station will start feeding power to the grid. Run In this mode, the Turnkey Station converts the DC energy into AC energy and feeds it to the grid by way of MPPT. The Turnkey Station tracks the PV arrays maximum power point (MPP) to maximize the output energy. Standby In Run mode, the Turnkey Station will enter the Standby mode if the DC side current is as low as 0A for a while. The Turnkey Station will continuously check if the PV array meets the grid-connection requirements. If the DC startup voltage of the Turnkey Station and the startup time are reached, it will turn into the Run mode. Fault If a fault occurs during operation, the Turnkey Station will enter the Fault mode. LCD panel will display the fault type with the Fault indicator on until the fault is removed and the Turnkey Station turns into the Run mode. If the fault is unrecoverable, the Turnkey Station must be stopped to perform maintenance work. It will automatically check if the fault is recoverable. When there is a DSP fault or module fault, restart of the Turnkey Station through the LCD is strictly prohibited. A power-off check is required before reenergizing the Turnkey Station. Otherwise, the machine may be damaged. Emergency-stop Stop the Turnkey Station by pressing the emergency stop button inside the monitoring window when a fault or an emergency occurs. The emergency stop button is used to disconnect the AC switch, the DC switch, and the auxiliary switch. Release the emergency stop button by using the specific key. Key-stop In the Run mode, the Turnkey Station will enter the Key-stop mode when stop instruction is sent via the LCD panel if the user needs to conduct maintenance or service work Alarm Run In Alarm Run mode, the Turnkey Station can keep running but send alarm signal. The user can check the present alarm information through the Working state on the LCD default screen or check the latest 200 history alarm information through Function/History information/his alarm. The Turnkey Station automatically turns to the Run mode when the alarm is removed. 72

81 System Manual 10 Turnkey Station Functions 10.2 Active Power Limitation Introduction to Active Power Limitation Situations, needing power limitation, are listed below: Potential threatens to the Turnkey Station safety operation Over-load of the grid branch connected to the Turnkey Station Islanding Factors affecting the stability of the static grid status and dynamic grid status Frequency rising affects the system stability Grid maintenance Grid management How to Realize Power Limitation Improper parameter configuration may affect the normal operation of the Turnkey Station! Only authorized personnel can configure these parameters. Should there be any question or doubt, please contact Sungrow. The user can adjust the Turnkey Station active power output through the LCD display: Step 1 Tap Function on the default menu; Step 2 Tap Set-parameter ; Step 3 Tap Run-parameter after entering the correct password; Step 4 Set the Limit Power (%) parameter by tapping the pop-up keypad; Step 5 Tap Enter to confirm the setting. Parameters related to power limitation (P-rise rate and P-decline rate) are also included in the running parameter setting sub-menu and can be set accordingly Reactive Power Adjustment The Turnkey Station can provide reactive power output. The user can open or close the reactive power adjustment switch and set the reactive power output through the LCD screen. Reactive power limitation is performed through the running information sub-menu as follows: Step 1 Tap Function on the default menu; Step 2 Tap Set-parameter ; Step 3 Tap Run-parameter after entering the correct password; 73

82 10 Turnkey Station Functions System Manual Step 4 Turn the page down to select the Q-adjust switch. Tap the pull-down list and there are six options: Close: reactive power cannot be adjusted Pf: adjust the reactive power by setting power factor Q-limit: adjust the reactive power by setting reactive power percentage QU mode: the reactive power changes with the grid voltage V auto-adjust: Voltage automatic adjusting: by setting the voltage adjusting benchmark and hysteresis, reactive power can be dynamically adjusted and the actual voltage tracking setting benchmark can be controlled. QP mode: the PF changes with the output power of the Turnkey Station Step 5 If "Pf" is selected, the "Pf" can be set on the running parameter interface; if "Q-limit" is selected, the "Q-limit" can be set on the running parameter interface; if "QU mode" is selected, QU-related parameter can be set on the running parameter interface, where the parameter name begins with "QU", for example, QU operation mode; and if "V auto-adjust" is selected, the "voltage automatic adjusting benchmark" and "voltage automatic adjusting hysteresis" can be set on the running paramter interface. P-Q Capability The Turnkey Station can support the grid by supplying the reactive power in different ways. The shaded area in the figure below shows the Turnkey Station s P-Q capability. 92% Pn 88% Pn 80% Pn P=115%Pn P=110%Pn P=100%Pn P (kw) φ Q (VAR) Ind. -69%-66%-60% 60% 66% 69% Cap. Fig The P-Q Capability of Turnkey Station The Pmax=3593KW, Pn=3125KW, Smax=3593KVA. The Max. Q is ±2155Kvar, when the power factor is ±0.8,at 25 ; The Q is ±1566Kvar, when the power factor is ±0.9,at

83 System Manual 10 Turnkey Station Functions Improper parameter configuration may affect the normal operation of the Turnkey Station! Only authorized personnel can configure these parameters. Should there be any question or doubt, please contact Sungrow LVRT Technical Requirements for Connecting Photovoltaic Power Station to Power System requires medium-and-large PV plant should be equipped with Low Voltage Ride Through (LVRT) ability. LVRT requires: PV plant can operate normally within certain voltage drop range and duration when the voltage of the grid-connected point drops due to the power system failure or disturbance; PV plant can provide the dynamic reactive power support during the period. Active power recovery If the power station still connects to the grid during power system failure, the active power will recover on the moment the fault is removed at the speed of at least 30% of nominal power/second. Dynamic reactive current support During LVRT, power station should feed reactive current to the power system as per requirements. For a station whose 500kV or 750kV voltage is stepped up from the 220kV or 330kV voltage and then connects to the power station group, it should feed reactive current to the grid when a short-circuit occurs and the voltage drops. Zero voltage ride through When the grid-connection point voltage drops to zero, the power station can operate normally for 1 second. UT/Upu U1 Power station operates normally Power station can disconnect from the grid U2 1(T2) 3(T1) Fig Lower voltage withstand requirements Time (s) Note: U T is the grid-connection point voltage; Upu is the grid-connection point nominal voltage. Sungrow s Turnkey Station meets the abovementioned requirements. 75

84 10 Turnkey Station Functions System Manual 10.5 High Voltage Ride Through (HVRT) Technical Requirements for Connecting Photovoltaic Power Station to Power System requires that the PV plant can operate as required within certain voltage range. Grid-connection pint voltage Requirements 1.1U pu<u T<1.2U pu Operate for at least 10s 1.2U pu U T 1.3U pu Operate for at least 0.5s Note: U T is the grid-connection point voltage; Upu is the grid-connection point nominal voltage. UT/Upu U2 Power station can disconnect from the grid Power station operates normally U1 Grid fault and voltage increases (T2) (T1) 14 Time (s) Fig High voltage withstand requirements Sungrow s Turnkey Station meets the abovementioned requirements Temperature Derating P/Pn Ambient Temperature [ ] Fig Turnkey Station temperature derating function 76

85 System Manual 10 Turnkey Station Functions 10.7 Altitude Derating Curve P/Pn Altitude [m] Altitude H H 2000m 2000m<H 3000m 3000m<H 4000m Turnkey Station operation state The Turnkey Station can run in the state of 1.15 times of overload for a long time The Turnkey Station can run in the state of 1 time of overload for a long time The Turnkey Station can run in derating state 10.8 MPPT Maximum Power Point Tracking (MPPT) is a technique that the Turnkey Station uses to get the maximum power from the PV arrays. PV arrays have a complex relationship between solar irradiation, temperature and total resistance that produces a non-linear output efficiency known as the I-V curve. I SC I-V Curve P MPP I MPP Current(A) P-V Curve Power(W) U MPP Uoc Voltage(V) Fig MPPT 77

86 10 Turnkey Station Functions System Manual 10.9 Intelligent Temperature-Control Technology The Turnkey Station will continuously detect the IGBT temperature and adjust the fan speed accordingly. When the module temperature is low, the Turnkey Station will decrease the fan speed to lower the device noise and decrease the device operation consumption. As the module temperature increases, the Turnkey Station will increase the fan speed for good ventilation. The intelligent temperature-control technology can synchronize the speed of fan and temperature of the IGBT module and thus optimize the module temperature and other conditions Insulation Monitoring Function Introduction Insulation resistance is an important parameter related to safety operation. If the insulation resistance is low, the direct contact protection and indirect contact protection may be failed; meanwhile, the fault current against the ground and the short circuit caused by low insulation resistance may lead to an electric fire, device damage, or even physical hazards. Sungrow s Turnkey Station is equipped with insulation resistance monitoring function to detect the system insulation resistance in real time. If low resistance is detected, it will send alarm at the first time to remind the user and prevent potential hazards Simple Troubleshooting Regardless of the Turnkey Station setting, when the insulation resistance is below the threshold (can be set on the LCD display), the Turnkey Station will send alarm signal and the Operation LED will turn to yellow. After receiving the low insulation resistance alarm signal, the user should stop the device and check the specific insulation resistance via the LCD screen Function/Run-information/Real time data. If the insulation resistance recovers to be normal, the fault loop is on the AC side. If the insulation resistance is still low, the fault loop is on the DC side. No matter the fault is on the DC side or on the AC side, a thorough checking and troubleshooting after the system is powered down is necessary Protection Function The Turnkey Station has complete protection functions to protect itself when input voltage or grid is abnormal. After the anomaly is removed, the Turnkey Station can operate normally DC over-voltage protection When the DC voltage of the PV array exceeds the max. DC voltage, the Turnkey Station will stop operating, send warning signal, and display the fault type on the LCD screen. The Turnkey Station can detect the abnormal voltage and respond quickly. 78

87 System Manual 10 Turnkey Station Functions AC over/under-voltage protection When the Turnkey Station AC output voltage exceeds the allowable range, the Turnkey Station will stop feeding the grid, send warning signal, and display the fault type on the LCD screen. The Turnkey Station can detect the abnormal voltage and respond quickly Frequency anomaly protection When the grid frequency exceeds the allowable range, the Turnkey Station will stop feeding the grid, send warning signal, and display the fault type on the LCD screen. The Turnkey Station can detect the abnormal frequency and respond quickly Islanding protection Islanding is a case that can occur if the utility grid is disconnected while the Turnkey Station is operating and the local load of the Turnkey Station is similar to the present output power. Islanding is a potential threaten to devices and operators. If the Turnkey Station continues supplying power after the grid is out of power supply, death or injury may occur to the maintainers during maintenance. When power grid fails, the Turnkey Station continues supplying power. Once the grid resumes, a surge current may occur and damage devices. The Turnkey Station is equipped with anti-islanding protection function. In anti-islanding protection state, high voltage is still present. Disconnect the main switch and discharge before testing or maintenance Reverse polarity protection When the PV array inputs polarities are connected reversely, the Turnkey Station will stop and protect itself against damage, and the Turnkey Station operate normally after the connection is corrected Overload protection When the PV array output power exceeds the Turnkey Station permissible maximum input power, the Turnkey Station will limit the power yield at maximum AC power point. If the temperature exceeds the permissible value, the Turnkey Station will automatically stop operating unless the the temperature recovers to be normal Ground protection The grounding cables are equipped with the leakage current sensor. When it is detected that the leakage current exceeds the setting value, the system will send an instruction to stop the Turnkey Station and display the fault type on the LCD screen Module over-temperature protection IGBT modules inside the Turnkey Station use a high-precision thermal sensor with to monitor the real-time module temperature. Once high module temperature is detected, DSP will send instruction to stop the Turnkey Station. 79

88 10 Turnkey Station Functions System Manual Internal over-temperature protection The Turnkey Station is equipped with high-precision thermal sensor to monitor the internal temperature of the Turnkey Station. Once the over-temperature is detected, the DSP will help to maintain the safe operation of the Turnkey Station by sending an instruction to stop the Turnkey Station Firefighting The Turnkey Station is equipped with the smoke detector and temperature & humidity sensor. Both the two detectors should be inspected and maintained regularly. When the smoke concentration and the temperature inside the turnkey station reach the set values, temperature anomaly or over temperature occurs. Correspondingly, the tripping of the DC and AC switches is triggered, so as to protect personal and property safety. The foregoing alarm information is displayed on the external LCD of the inverter. After eliminating the alarm, the user needs to remove the alarm signal manually. 80

89 11 Troubleshooting 11.1 Safety Instructions Lethal voltages are present inside the Turnkey Station when a fault occurs. Only qualified personnel can perform troubleshooting described in this chapter. Qualified personnel are those who have relevant training experience, especially safety-related experience. Do not perform any troubleshooting other than that specified in this manual. Respect all safety instructions during troubleshooting. The electrical components inside the Turnkey Station must be replaced by the same components from the same manufacturer and of the same model. The model can be found on the marking of the Turnkey Station or the component itself. If otherwise, please contact Sungrow. If the components need to be replaced with products from other manufacturers or of different model on site, a prior analysis and confirmation by Sungrow is required. Failure to follow this procedure may lead to physical injury or death and void all warranty from Sungrow. Disconnect all AC and DC switches before troubleshooting Fault Checking If any power output anomaly is detected, you may check the following items before contacting Sungrow. Open-circuit voltage of the PV arrays State of the emergency stop button Power limitation state Should there be any questions or doubts that are not covered by this manual, please contact us. If you provide our customer service assistant the following information, it will be of great help for us to diagnose and solve the problem in your system: 81

90 11 Troubleshooting System Manual Type and serial number of the Turnkey Station and internal devices Manufacturer, model, and configuration of the PV arrays and upstream & downstream combiner devices connected to the Turnkey Station Turnkey Station communication solution Fault and brief description of the fault phenomenon A picture of the fault if necessary 11.3 Fault and Troubleshooting on the LCD screen This section is dedicated to the faults shown on the LCD, possible reasons and troubleshooting. In case the fault cannot be removed following the instructions in this section, please contact Sungrow. Fault Possible reason Measure Remark Vdc-high DC voltage exceeds the max. DC voltage Check the configuration of the PV array and reduce the open-circuit voltage of the PV array Please contact the installers of the PV arrays Fault Possible reason Measure Remark Vac-high The grid voltage is above the max. grid voltage Check the grid voltage (or check if the grid-connected wire is too thin) The Turnkey Station automatically reconnects to the grid once the grid voltage recovers to be normal Fault Possible reason Measure Remark Vac-low The grid voltage is below the min. grid voltage Check the grid voltage Check if the AC cables are securely connected. The Turnkey Station automatically reconnects to the grid once the grid voltage recovers to be normal Fault Possible reason Measure Remark Cntr-flt Contactor connected to the gird failure Check the contactor after the device is voltage-free Stop the Turnkey Station if this fault occurs 5 times per day Fault Possible reason Measure Remark No grid Islanding detected The Turnkey Station enters into anti-islanding protection state automatically The Turnkey Station automatically reconnects to the grid once the grid becomes normal 82

91 System Manual 11 Troubleshooting Fault Possible reason Measure Remark F-fault The grid frequency is beyond the permitted range Check grid frequency Check if the AC cables are securely connected. The Turnkey Station automatically reconnects to the grid once the grid voltage recovers to be normal Fault Possible reason Measure Remark PDP-pro Internal fault Wait 5 minutes for device auto-reconnection or disconnect first and then connect the AC main switch Contact Sungrow if the fault insists Stop the Turnkey Station if this fault occurs 5 times per day Fault Gnd-flt Possible reason The Turnkey Station AC side leakage current to the ground exceeds the set value Measure - Remark The Turnkey Station automatically reconnects to the grid once the leakage current recovers Fault Possible reason Measure Remark Iac-high Internal short-circuit or internal components damages Check the AC side cable connection and the control circuit board. Contact Sungrow Fault Possible reason Measure Remark Meter-com-flt Measurement board communication abnormal. This inversion module stops. Stop the device to check and service the measurement board of the inversion module. Contact Sungrow Fault Possible reason Measure Remark GFDI-pro GFDI fault Stop the device to check and service the grounding part. Contact Sungrow Fault Possible reason Measure Remark Temp-flt The Turnkey Station internal temperature exceeds the permitted value Check functionality of fan after the device is voltage-free Stop the Turnkey Station if this fault occurs 10 times per day 83

92 11 Troubleshooting System Manual Alarm Possible reason Measure Remark RISO-flt The Turnkey Station DC side insulation resistance is lower than the set value. Check the PV panel insulation to the ground when the Turnkey Station is voltage-free Only alarm display. The Turnkey Station can operate normally. Fault Possible reason Measure Remark PM-high Module temperature exceeds the permitted value Check the module and ventilation after the device is voltage-free Stop the device if this fault occurs 5 times per day Fault I leakage pro Possible reason The ground protection is activated when the Turnkey Station AC leakage current to the ground is more than 5A (value can be set through the LCD). Measure - Remark The Turnkey Station can automatically reconnect to the grid and start operation when the leakage current to the ground recovers to be normal. Fault Possible reason Measure Remark Overload pro Capacity of the DC side panel is overload It is advisable to stop the device and disconnect half of the DC switches. Contact Sungrow Fault Possible reason Measure Remark Soft Start flt A fault occurs during the soft start process. Stop the device to check and service it. Contact Sungrow Fault Possible reason Measure Remark T&H-com flt Temperature and humidity sensor communication fault. Stop the device to check and service the temperature and humidity sensor and the cable connection. Contact Sungrow Fault AC switch breaking Possible This fault is reported when the AC circuit breaker is in trip-off state. reason Measure - Remark - Fault L over-temp Possible Reactor temperature exceeds the permitted value reason Measure Check the reactor after the device is voltage-free Remark - 84

93 System Manual 11 Troubleshooting Fault PV pol-rev Possible The positive and negative polarities of the DC side are connected reversely. reason Measure Check the DC connection to for reverse connection after the Turnkey Station voltage-free Remark - Fault Ctrol power supply-flt Possible CPS (Control power supply) inside the Turnkey Station cannot work normally reason Measure - Remark The Turnkey Station automatically reconnects to the grid once the CPS reverts to normal and the grid-connection requirements are fulfilled Fault Possible reason Measure Remark AC SPD flt AC SPD tripping, over-voltage protection Replace the SPD with the same model after the device is voltage-free Contact Sungrow Fault Possible reason Measure Remark DC SPD flt DC SPD tripping, over-voltage protection Replace the SPD with the same model after the device is voltage-free Contact Sungrow Fault Grid-V-unbalanced Possible AC side 3-phase voltage unbalance reason Measure Stop the device to check the AC side voltage Remark - Fault Possible reason Measure Remark Encoding repeat Different modules have the same address Check the dipswitch on the module control board, whether different modules have the same address. If yes, correct it. Contact Sungrow Fault Possible reason Measure Remark Vdc-samp-flt DC voltage sampling fault Stop the device to check and service. Contact Sungrow Fault Possible reason Measure Remark Fan1-flt Correspond to the fault of the Turnkey Station module fan 1 (left side fan from the front view) Check the functionality of fan after the device is voltage-free Contact Sungrow 85

94 11 Troubleshooting System Manual Fault Possible reason Measure Remark Fan2-flt Correspond to the fault of the Turnkey Station module fan 2 (right side fan from the front view) Check the functionality of fan after the device is voltage-free Contact Sungrow Alarm Possible reason Measure Remark AC breaker flt AC side circuit breaker is abnormal Check the AC circuit breaker when the Turnkey Station is voltage-free Before device stops, the Turnkey Station can operate in grid-connection normally Fault Possible reason Measure Remark Driver board fault Driver board fault Stop the device to check and service the driver board. Contact Sungrow Fault Possible reason Measure Remark Carrier synch flt Carrier synchronization fault The carrier synchronization cable is loose or broken. Contact Sungrow Fault Possible reason Measure Remark DC switch fault DC cabinet switch fault Stop the device to check and service the DC cabinet switch Contact Sungrow 11.4 LCD Display Alarm Information and Troubleshooting During alarm running state, the Turnkey Station can operate normally and send warning signal. The user can check the alarm information through the Work state on the default menu or through the Function->History-information->His-alarm interface to check the latest 200 history alarm information. The module will recover to normal operation once the alarm is removed. Alarm GFRT Run Possible reason Grid voltage below 0.9Un with LVRT function enabled or above 1.1Un with HVRT function enabled Measure Alarm will disappear automatically when grid voltage recover to be normal Remark - Alarm Possible reason Measure Remark CT Unbalanced Current transformer (CT) on the Turnkey Station control cabinet is abnormal Check and service the CT on the measuring board when the module is voltage-free Operation LED will keep green when this alarm occurs 86

95 System Manual 11 Troubleshooting Alarm DC Sensor-err Possible The Turnkey Station DC sensor abnormal reason Measure Check and service the DC sensor when the Turnkey Station is voltage-free Remark - Fault Possible reason Measure Remark DC switch anomaly DC switch is abnormal Stop the device to check and service the DC switch Contact Sungrow Alarm IDM-com-flt Possible The Turnkey Station internal communication abnormal reason Measure Check the IDM when the Turnkey Station is voltage-free Remark - Alarm Possible reason Measure Remark Branch rev-idc-high The detected reverse current of the branch on the DC side exceeds the permissible range Check the abnormal branch when the Turnkey Station is voltage-free Before the device stops, the non-abnormal branches can work normally and the Turnkey Station can operate in grid-connected mode normally Alarm Possible reason Measure Remark Branch fwd-idc-high The detected forward current of the branch on the DC side exceeds the permissible range Check the abnormal branch when the Turnkey Station is voltage-free Before the device stops, the non-abnormal branches can work normally and the Turnkey Station can operate in grid-connected mode normally Alarm Possible reason Measure Remark Branch breaker flt The circuit breaker of the branch on the DC side is abnormal and this branch cannot work normally Check the abnormal circuit breaker when the Turnkey Station is voltage-free Before the device stops, the non-abnormal branches can work normally and the Turnkey Station can operate in grid-connected mode normally 11.5 Other Faults Fault The Turnkey Station shuts down shortly after start-up Possible reason DC input voltage just reaches the Turnkey Station start-up voltage. The voltage will decrease and the Turnkey Station will stop when it is under load. Measure Design the serial and parallel connection in accordance with the open circuit voltage; increase the input DC voltage; and avoid adopting the critical voltage Remark - 87

96 11 Troubleshooting System Manual Fault LCD Display Cannot Start or Stop the Turnkey Station Possible reason Communication malfunction between the LCD display and the DSP; and LCD power supply malfunction Measure Check the connection between the LCD display and the DSP when the Turnkey Station is voltage-free Remark - Fault Possible reason Measure Remark Communication Failure with PC Possible reasons are various. Please refer to the Measure for troubleshooting Check if the address and the Baud rate of the LCD are the same as that of PC Check to ensure the circuits are properly connected and if the RS485 communication is adopted, the A and B ports are connected correctly Check if the communication converters are matched. Communicate again after replacing the converter The monitor disk is installed incorrectly. It is recommended to reinstall the disk If all the above-mentioned items are correct and this fault still exists, please replace the PC communication module on the LCD display The monitor disk might be incompatible with the antivirus software and thus cannot be installed correctly. You are recommended to disable the antivirus software and then install the monitor software. If the fault still occurs, please contact Sungrow 88

97 12 Routine Maintenance 12.1 Safety Instructions Due to the effect of ambient temperature, humidity, dust, and vibration, the Turnkey Station and the inner components will be aging and worn out. To ensure the system safety and maintain the efficiency of the Turnkey Station, it is necessary to carry out routine and periodic maintenance. All measures, which can help the Turnkey Station work in good conditions, are within the maintenance scope Safety Instructions Lethal voltage inside the Turnkey Station! After the Turnkey Station stops, wait at least 10 minutes before opening the cabinet door. Make sure the internal device is completely voltage-free before performing any work on the Turnkey Station. Only qualified personnel can perform the work described in this chapter. Do not leave any screws, washers, or other metallic parts inside the Turnkey Station to avoid damages to the Turnkey Station. Sand and moisture penetration may affect the performance of electric devices inside the Turnkey Station! Do not perform electrical connection in sandy season or when the ambient relative humidity is above 95%. Perform electrical connection on fine weather days. Disconnecting the AC & DC switches never means that the cable connection terminals inside the AC and DC cabinets are voltage-free. To avoid the risk of electric shock, before maintenance work, Disconnect the AC & DC switches; Disconnect the upstream and downstream switches of the Turnkey Station Five Safety Rules Respect the following five rules during maintenance or service on the Turnkey Station to ensure the safety of the maintainer. 89

98 12 Routine Maintenance System Manual Disconnect the Turnkey Station from all the external connections and internal power supplies. Ensure that the Turnkey Station will not be started inadvertently. Verify that the Turnkey Station interior discharges completely with a multimeter. Necessary ground and short circuit connection. Cover the adjacent electrical components with insulation cloth during operation Maintenance Introduction With IP54 protection degree, the Turnkey Station can be installed outdoors. Harsh environmental condition or long-time operation, however, may cause aging and damage to the Turnkey Station. Check and maintain the Turnkey Station periodically and replace the aged components, which can effectively prolong the service life and improve the performance of the devices inside the Turnkey Station. Unscheduled maintenance is also required, esp. when the system performance is poor Maintenance Interval Maintain the Turnkey Station and internal electric devices periodically to ensure the good performance of the Turnkey Station. The maintenance interval described in this chapter is indicative only. The actual interval depends on the on-site environment condition. If the Turnkey Station is located in harsh environment place, for example, desert areas, the maintenance interval shall be shortened. Esp. the cleaning of the Turnkey Station outside and anti-corrosion & anti-rust work should be more frequent. If the Turnkey Station is installed in the desert areas, it is recommended to check the Turnkey Station thoroughly and clean it carefully after sand storm. Check the module fans inside the Turnkey Station and the fans on top of the cabinet periodically for abnormal operation and abnormal noise due to dust penetration. Stop the Turnkey Station and clean the dust if necessary. Wait at least 10 minutes after the Turnkey Station discharge completely. Before cleaning, make sure, with the multimeter, the Turnkey Station internal is discharged completely to avoid electric shock. Almost all maintenance work needs the internal protective grid to be removed. Make sure to reassemble the grid and fasten all the screws after the maintenance work. Make sure all bolts are securely fixed. 90

99 System Manual 12 Routine Maintenance Once any anomaly is found during routine maintenance of the Turnkey Station and internal devices please make correction immediately. If there are any doubts, please contact Sungrow. Item Method Interval Make correction immediately once the External checking following items are found: Check if there are flammable materials on top of and around the Turnkey Station; and if there are other factors that may impair the system operation Check if the Turnkey Station and the foundation are firmly connected and if there is rust Every quarter Check the Turnkey Station and internal devices for deformation and damages Check the Turnkey Station and internal devices for abnormal noise Check if the temperature of the Turnkey Station interior and device enclosure is too high Once a month System states and cleaning Module cleaning Warning labels Cable connection Air inlet/outlet Check if the Turnkey Station internal humidity and dust deposition are too heavy. Clean the Turnkey Station. Check if the air inlet and outlet are blocked; Check if the circuit board and the component are clean; Check the temperature and dust of the heat-sink. Use a vacuum cleaner to clean the module if necessary; Replace the air filter if necessary Notice! Check the air inlet and outlet. The device may be damaged by overheating. Check if the warning labels are clearly visible. Replace them if necessary Check the cable connection after the Turnkey Station and internal devices are voltage free. Make correction once unconformity is found. Check if all cable entries are sealed properly; Check if there is water leakage inside the Turnkey Station; check if Turnkey Station windows and doors can close and open flexibly; check if the sealing strip is sealed properly Check if the power cable connections are loose. Retighten them with the torque specified in the manual if necessary Check if the power cables and control cables, especially the surface in contact with the metal are damaged; Check if the wrap belt of the connection terminals is strip-off Check if the air inlet filter and ventilation ducts of the Turnkey Station and internal devices are normal Clean or replace the filter From every six months to annually depending on the dust deposits. Once per year Once per year Every six months or maintain according to real situation 91

100 12 Routine Maintenance System Manual Fan Device maintenance Safety function Software maintenance LCD time display Check the running state of the fan inside the Turnkey Station Check if there is a crack in the fan blade Check if there is abnormal noise during the running of the fan; Routine check the corrosion of the metal components (once six months) Annually check the contactors (auxiliary switches and micro-switches) to ensure the optimal operation Check the running parameters (esp., voltage and insulation) Check the emergency stop button and the LCD stop function; Simulation shutdown Check the warning labels and other markings for damage or unclearness. Replace them if necessary Optimize software Check each parameter setting Check if the time displayed on the LCD display is correct; Replace the button cells on the back of the LCD panel if time is incorrect after calibration. Every six months or maintain according to real situation From every six months to annually From every six months to annually From every six months to annually From every six months to annually Follow related Firefighting device Check the functionality of the firefighting regulation where devices the project is located Other devices Replace the damaged lighting devices in time When necessary The maintenance operations could be more frequent according to the environmental conditions at the place where the Turnkey Station is suited, plant capacity, and on-site situations. The maintenance interval should be shortened if the sand or dust deposition around the operation site is serious Cleaning the Turnkey Station Introduction Cleaning the surrounding areas of the Turnkey Station and the Turnkey Station interior is important maintenance work. Due to the effect of ambient temperature, humidity, dust, and vibration, there may be dust deposition inside the Turnkey Station blocking the air entries and penetrating inside the Turnkey Station internal devices. There may be potential faults of the Turnkey Station internal devices and the service life of the internal devices as well as the power yields may be affected. During device normal operation, check and clean the device periodically to make sure the internal devices are in a relatively good condition Cleaning Interval The cleaning interval of the Turnkey Station depends on the operation conditions of the Turnkey Station, for example, the weather condition and etc.. It is recommended to check the Turnkey Station once every one or two months to make sure the Turnkey Station 92

101 System Manual 12 Routine Maintenance exterior and interior areas are clean. If the operation conditions are severe, in desert area for instance, the cleaning interval shall be once every half a month or even shorter. The cleaning of the internal devices and the air inlet and outlet shall be more frequent Cleaning the Internal Dust For cleaning the dust inside the Turnkey Station, please use a vacuum cleaner instead of a broom. The vacuum cleaner can get power supply from the backup socket inside the intelligent power distribution cabinet. For the marking of the backup socket, please refer to the circuit diagram inside the cabinet door of the intelligent power distribution cabinet Cleaning the Foundation The foundation is designed with maintenance entry. You should enter the foundation to check the cleanness periodically. Use a vacuum cleaner to clean the foundation if necessary Filter checking and cleaning It is recommended to check and clean the Turnkey Station filter at least every six months. The maintenance interval should be shortened to once every three months or shorter if the dust deposition is heavy. The air inlets located on the front and back sides of the Turnkey Station are entrances of cool air. Periodically clean and replace the filter cotton and filter screen to ensure air circulation and appropriate temperature inside the Turnkey Station. Cleaning and replacing operations are performed on the air inlet window outside the Turnkey Station: Step 1 Push the two spring lock catches toward the middle of the air inlet window to open the outside shutters of air inlet window. Step 2 Remove the air filter cotton inside the air inlet window, and shake the dust off. 93

102 12 Routine Maintenance System Manual Filter cotton Filter screen Step 3 Clean the filter screen with warm water and degreaser and then dry it in the air if necessary. Step 4 If the filter is broken, replace it. Put a proper new one when the old filter is removed. Step 5 When the filter cotton and screen are clean and dry, reassemble them in reverse order. Do not pull hard during cleaning and replacing the filter cotton and filter screen. Otherwise the cotton and the screen may be damaged. Contact Sungrow to order the filter. You can cut proper filters out of the larger filter Cleaning the Surface of the Turnkey Station If there is corrosion on the surface of the Turnkey Station, clean it with abrasive paper or brush. If the dust deposition is serious on the surface of the Turnkey Station, use a mop or big rag to clean the surface of the Turnkey Station. It is recommended to clean the Turnkey Station top first and then clean the Turnkey Station side. You can clean it directly or wash with water Checking the Lock and Hinge Check the functionality and state of the lock and hinge of the Turnkey Station after the cleaning work. Lubricate the lock and hinge if necessary Checking the Sealing Strip The sealing strip is used to prevent the water from penetrating insider the Turnkey Station. Check it carefully for damages. Replace the damaged sealing strip in time On-site painting make-up measures Check for the damages of the Turnkey Station appearance: Situation 1: smudginess on the surface caused by water and dust that can be cleaned Situation 2: smudginess on the surface & damage to the finishing coat that cannot be cleaned Situation 3: the undercoat is damaged and the primer is revealed Maintenance and operation steps for situation 1: Materials: 94

103 System Manual 12 Routine Maintenance Rag Water Alcohol or other non-corrosiveness detergents Step Figure Description 1 Clean the smudginess on the surface by rag (or other cleaning tools) with water 2 If the smudginess cannot be cleaned by water, use 97% alcohol until the surface is clean enough to accept. (Or try other local commonly used non-corrosiveness detergent) Maintenance and operation steps for situation 2: Materials: Abrasive paper Rag Water Alcohol Hairbrush Oil paint 95

104 12 Routine Maintenance System Manual Step Figure Description 1 Polish the rough oil paint surface or the scratched parts by abrasive paper until the surface is smooth 2 Clean the target parts by rag with water or use 97% alcohol 3 When the surface is clean and dry, paint the abraded parts of the oil paint by banister brush and make sure the painting is as uniform as possible Maintenance and operation steps for situation 3: Materials: Abrasive paper Rag Water Alcohol zinc primer Hairbrush Oil paint 96

105 System Manual 12 Routine Maintenance Step Figure Description 1 Polish the damaged parts of the oil paint to remove the surface rust or other roughness 2 Clean the target parts by rag with water or use 97% alcohol to clean the surface dust and dirty 3 When the surface is clean and dry, paint the base material revealed parts with zinc primer (or other local primers with the same function) for protection. The paints should cover the revealed primer completely 4 Paint the abraded parts by banister brush when the primer is dry, and make sure the painting is as uniform as possible 97