Prepared by Ashutosh

ABB PVS800
Operation & Maintenance

© ABB Group
June 14, 2017 | Slide 1
 ABB central inverters, PVS800
Electronics Boards

© ABB Group
June 14, 2017 | Slide 2
PVS800 – 3XR8i Connection Example

© ABB Group
June 14, 2017 | Slide 3
Main / Key Components inside PVS800

Printed circuit boards & Components typically in the PVS800 :-

§ Diagnostics and panel interface board, ADPI & CDP

§ Drive Control Unit, RDCU
§ Modbus (RMBA) & Ethernet (RETA) Interface Boards.
§ Main circuit interface board, AINT
§ PPCS Branching Unit , APBU-44C
§ Power supply board, APOW
§ Gate driver control board, AGDR
§ FAN Power supply (AFPS) & Fan Control board (AFIN)

© ABB Group
June 14, 2017 | Slide 4
Diagnostics and panel interface board, ADPI

Panel connectors
Red and green indication LEDs

© ABB Group
June 14, 2017 | Slide 5
CDP : Drive Control Panel

© ABB Group
June 14, 2017 | Slide 6
RDCU with Connection Options

© ABB Group
June 14, 2017 | Slide 7
Interface Boards for External Communications : RMBA & RETA

© ABB Group
June 14, 2017 | Slide 8
DDCS channel board, RDCO

§ Optic fiber link connection board required e.g. for DriveWindow

© ABB Group
June 14, 2017 | Slide 9
APBU :- PPCS Branching Unit

This unit act as interface between

Inverter control(RDCU) & Inverter
Power Modules controller (AINT)

© ABB Group
June 14, 2017 | Slide 10
AINT : Main Control Board

Contains all high voltage and internal

measurement, calculating and converting optical
and electrical signals components

© ABB Group
June 14, 2017 | Slide 11
APOW : Power Supply Board

Feeds power to AINT

© ABB Group
June 14, 2017 | Slide 12
AFPS : AFIN Power Supply Card

© ABB Group
June 14, 2017 | Slide 13
AFIN : R8i Cooling FAN Supply & Speed control card

© ABB Group
June 14, 2017 | Slide 14
PVS800 :Control Structure

PVS800 Control
Structure

Master Inverter
Control(GSXR,ID1) Control(ISXR ID2)

1. Auto Star & Stop Functions.

1. AC & DC Contactors control.
2. PV DC Voltage & Current
2. SLCL & DOOR Fan control.
Measurement.
3. Inverter Modules Control.
3. Negative Grounding control
4. Grid Support Functions
4. Active & Reactive Power
control.
References

1. Cabinet Temperature
1. Input Fuse & SPD Status. Measurements.
2. SCADA/ Data-logger Interface. 2. AC Parameters
3. Emergency Circuit Monitoring Measurements (Voltage ,
Current , Power)
© ABB Group
June 14, 2017 | Slide 15
PVS800 Control board Connections ( I/O Table)
RDCU (A43 , GSXR)

X21 : Analog I/O X22 : Digital Inputs X23 X25/26/27 : Digital Outputs

© ABB Group
June 14, 2017 | Slide 16
RDCU (A41, ISXR) I/O Table

X21 : Analog I/O X22 : Digital Inputs X23 X25/26/27 : Digital Outputs

© ABB Group
June 14, 2017 | Slide 17
RDIO ( 411 & 412 ) I/O Table

© ABB Group
June 14, 2017 | Slide 18
 Operation

ABB solar inverters

ABB PVS800 : Operation
© ABB Group
June 14, 2017 | Slide 19
Objectives

Upon the completion of this module,

you will be able to
§ Control the device with the control panel
§ Read and select the actual values on the display
§ Set up parameters with the panel
§ Read alarm and fault messages
Safety in installation and maintenance

© ABB Group
June 14, 2017 | Slide 21
CDP312R panel

§ Device used for controlling and programming

§ Can be attached directly to the module or door
of the cabinet
§ The keys are flat, labeled push-buttons
§ LCD display: 4x20 characters
Display

§ Row 1: Device status

§ ID Number of the selected device
§ Panel Status:
§ L = Local
§ ' ' = Remote
§ Value of the reference
§ Run status:
§ I = Run
§ 0 = Stop
§ ' ' = No start permission.

§ Rows 2-4: Actual Signal names and values

Operation Mode Keys

§ Operation mode keys

§ Actual (for displaying operational data or
Actual Signals)
§ Parameter (to display and edit parameter
names and values)
§ Function (to Upload/Download parameters)
§ Drive (for assigning device ID Numbers on a
network and change the panel connection
between devices)
Device Control Keys
§ Device Control keys
§ Start - used to start the device
§ Stop - used to stop the device
§ REF - used to set device reference value from keypad
§ Forward and Reverse keys - used to change the
direction of the reference (+/-)
§ LOC/REM - used to change device control location
between Local at the keypad and the Remote control
§ RESET - used to reset a fault of the device
Reading Actual Values

§ This mode contains two displays, the Actual

Status row Signal Display and the Fault History Display
Actual signals § The Actual Signal Display is shown first whenever
the Actual Signal Display Mode is entered
§ The actual display shows the following
information:
§ Status row
§ Three selectable actual signals
Setting Up Parameters

§ The Parameter Mode is used for changing

the PVS800 parameters
§ The display panel will show the following
information:
§ Status row
§ Group number and name
§ Parameter number and name
§ Parameter value

§ Changing parameters
§ Group can be changed with double arrows
§ Number can be changed with single arrows
§ Value can be changed using the arrows and
ENTER key
Reading Alarm & Fault Messages

§ When a fault or warning occurs the Fault Display appears

§ The panel display will show the following information:
§ Status row
§ Device Type
§ FAULT or WARNING message
§ Name and number of Warning or Fault.
§ Fault can be reset with RESET button or with a PC Tool
Fault History Display

§ Select Fault History Display by pressing the double-

arrow button in actual display mode
§ The display panel will show the following information:
§ Sequential number of the event, 1 being the most recent
event
§ Name of warning or fault
§ Event sign
+ indicates that the event is activated
- indicates that the event is deactivated

§ Total Power On time

§ By pressing the arrow keys you can scroll the Fault

History of the device
Function Mode

§ The Function Mode is used to select

special functions
§ Parameter Upload / Download
§ Setting the contrast of the Control Panel
display
§ Selecting a function
§ Page can be changed with double arrows
§ Row can be changed with single arrows
§ Function can be selected using the ENTER
key when cursor on the line
Drive Mode

§ Drive mode display contains basic

PVS800 XXXXX information of the module:
§ Device type
XXXXXX
§ Device software version
§ Device ID-number
§ To change device connection
§ Change device connection 1 -> 2
1. Press up arrow key
Device: Master control Inverter control
2. Press act key
§ Change device connection 2 -> 1
RDCU
RDCU

1. Press down arrow key

2. Press act key

ID number: 1 2 PVA & IDA = Master Control

ISU = Inverter Control
 Operation

ABB solar inverters

ABB PVS800 : Start & Stop Configuration
© ABB Group
June 14, 2017 | Slide 32
Start-up using the control panel

CDP 312R PVS800

§ When mains power is applied the control panel will show the following data:
§ Panel type and software version
§ Identification display of the module
§ Actual signal display
§ The module is now ready for the start-up

© ABB Group
June 14, 2017 | Slide 33
Setting up the sleep and wake-up levels

Master control Parameter Group 31

Wake up and Sleep parameters

Group 31
Open loop DC voltage
31.01 ENABLE MPPT
31.02 UDC SOURCE
31.03 UDC MAX SCALE Sleep mode Sleep mode
31.04 UDC START LIM
31.05 UDC START DLY DC voltage
31.06 UDC STOP LIM
31.07 UDC STOP DLY
31.08 UDC HIGH LIM
31.09 POWER SOURCE Power
31.10 POWER STOP LIM
31.11 POWER STOP DLY
31.12 GOTO SLEEP MODE
31.13 WAKE UP SOURCE
31.14 WAKE UP START LIM
Time
31.15 WAKE UP START DLY Start Stop
31.16 POWER LIMITING

© ABB Group
June 14, 2017 | Slide 34
Startup events (Process) for PVS800

§ PVS800 startup process Initialize automatically subject to startup conditions.

§ PVS800 Includes following two cycles :
§ ISU Startup Cycle
1. Charging Cycle : RDCU-Charging Contactors – R8i Modules – APBU – RDCU.
2. AC Contactors pickup cycle
3. DC Contactor Pickup cycle
§ MPPT Cycle
Actual Power flow from PV to Grid

© ABB Group
June 14, 2017 | Slide 35
PVS800 : Startup Cycle

AC Contactor
MPPT Cycle
•RDCU gives close
command to charging
cycle
contactor.
•R8i Module power up & •Close commands to DC
initialization. Contactors
•Close commands to AC
•Communication of status Contactors •Start Generating power
with RDCU via APBU

Charging DC Contactor
Cycle Cycle

ISU Startup Cycle MPPT Cycle

© ABB Group
June 14, 2017 | Slide 36
 Charging Initial Power Up of All ISU Units control
Circuit
RDCU – A41
PV Field
ISU Control

DC Contactor ON/OFF Control

K 2.1 K 2.2 K 2.3

ISU Control
APBU
ISU-1 ISU-2 ISU-3

AC Contactor ON/OFF Control

K 1.1 K 1.2 K 1.3

Grid

--------- Optical Communication line

 ABB solar inverters
PVS800 : Fault Tracing
© ABB Group
June 14, 2017 | Slide 38
Objectives

After completing this module, you will be able to

§ Explain the functions of PVS800 diagnostics
§ Find information on how to trace alarms and signals with the fault logger, data
logger and data words
§ Explain what kind of support material exists and where to find it
§ Get help for the fault tracing when needed
Fault tracing

§ Systematic fault tracing

§ Logical iteration, step by step
§ Make notes of fault tracing actions
§ Use application and other drawings
§ Is the fault in the device?
§ Application characteristics
§ External devices
§ Supply
§ PLC, relays, etc
Fault tracing principles

device Yes
“alive”?

No
Indications
Check network (CDP, LEDs,
voltages and
DriveWindow2, etc)
main circuit

other
network Fault device device Fault systems
location? location?

device supply

Check See device See device Check PLC,

Check DC
supplying hardware firmware cabling, etc
supply
network manuals manuals
Checking the other systems

n Upper level controls

– PLC
– Fieldbus
– Ethernet connection
– Check signals, status words
n Other sensors connected to the system
– Pressure, flow, etc.
– Temperature (PTC, Pt100,...)
– Sensors connected to the analog and digital inputs
PVS800 diagnostics

§ Software and hardware functions

§ Alarms and signals
Ø Fault indications
Ø Actual values
Ø Status words
§ Fault logger
§ Data loggers
§ Indicators
Ø Boards
Ø Displays
Ø Other indicators
Indicators

§ Other indicators
§ Relays
§ Fuses
§ Led
§ Circuit breakers
§ etc.
Warnings and faults

§ PVS products use a two-level protection system

§ Warning
§ Lower level
§ Generated by the device or control panel
§ Fault
§ Higher level
§ Generated by the device
§ In parallel-connected inverters fault/warning location is
indicated with numbers (ISU1 FAULT, ISU2 FAULT...)
(ISU1 WARNING, ISU2 WARNING)

ISU = Inverter control

Fault history

§ Faults and warnings are stored with the time stamp

§ Fault logger collects 64 latest faults
§ 16 of the latest faults are stored in power off
Fault logger

§ Reading the fault logger contents

§ CDP312 control panel
§ DriveWindow 2.x
§ Details of Alarm and fault codes
§ Firmware manuals
Viewing and resetting Fault History - CDP312

View and reset the fault history with control panel

1. Enter the Actual Signal Display Mode

2. Enter the Fault History Display

3. Select the next or previous fault/warning

4. Clear the Fault History

5. Return to Actual Signal Display Mode

How to Read Schemes
1 2 3 4 5 6 7 8
Part of scheme continue
A

B
Page. No./ Column, Row Number

F
© ABB Group
June 14, 2017 | Slide 49
Starting the inverter unit without solar generator power ( Back-Charge
Mode)
Ø The inverter unit of the PVS800 can be started in local control with the solar generator
Ø disconnected (that is, with the DC contactor open) as long as the inverter is connected to the grid.
Ø This special mode can be useful for testing during commissioning or troubleshooting. In this mode the
inverter will not produce active power.
Ø In the ISU local mode the inverter can be run without solar modules connected to the
Ø inverter, for example, to test the start-up procedure in an existing AC grid. DC contactors are not closed
in the ISU LOCAL mode.
Ø Demonstration of “ How to start PVS800 in back charge Mode” during hands on training

© ABB Group
June 14, 2017 | Slide 50
Example of Fault Tracing : Charging Fault

CHARGING FLT (3230), >CHARGING F (3284)

§ Switch off AC & DC Power supplies connected to PVS800 Inverter, keep AUX supply on & Check
Following:-
Ø Check when charging command has given, is Charging contactors 19.1-19.3 closing or Not.
Ø If Not, Check +24Volts at X22:6 Pin of A41(Only for ISXR7360 & 7380), if not check connection between
buffer units & RDCU-A41 as per scheme., also check 19.1-19.3 power connections as per scheme.
§ If Yes, then check Following:-
ü See the charging circuit fuses F19.1-19.3, F20.1-20.3 in ICU Section of the PVS800
ü Measure the resistance of charging resistance R1.1-R1.3 (Should be ≥ 5ohms) and check the contactor
connections & functionality of K19.1-19.3 See also the conductivity between the components in ICU
Section of Inverter.
ü See FO Connections between A41 & APBU-44C & ISU’s connected properly or Not.

© ABB Group
June 14, 2017 | Slide 51
How to Enable Reduced Run in 630kW Inverter

1. Remove the Optical Cables from ISU

Modules from the group which is not
working.

2. Go to ID-2 , In parameters menu,

change following parameters values as
shown in below table,
ISU-1 ISU-2

Parameter No. Default Value New Value

151.34 : USED MODULES MODULEs 1 & 2 MODULE 2

16.10 : INT CONFIG USER 2 1

151.37: ENA AIR TEMP MEAS ON OFF

Group-1 Group-2

© ABB Group
June 14, 2017 | Slide 52
Protection functions

§ Preprogrammed Fault and warning functions

§ Programmable Auto reset functions
§ See the Firmware manual for more details
§ 30 FAULT FUNCTIONS ( Master Control ,Reset Delay & Reset Trails)
 Prepared by : Ashutosh Bedarkar

ABB Solar Inverters

How to Test PV field for Ground leakage
How Test Ground

Behavior of a system without leakage

Due to the capacitive effect of the PV
generator, during the first moments that the
voltmeter is connected between one of the two
poles and ground, it will measure a voltage of
about Voc/2, which will tend to stabilize to
around 0V if there is no ground leakage, as
shown in the graph

© ABB Group
June 14, 2017 | Slide 55
How Test DC PV Field for Ground Leakage

measure the voltage between the positive pole and ground

and between the negative pole (of the PV generator) and
ground using a voltmeter whose input accepts a voltage
sufficient for the dimensions of the photovoltaic generator.

© ABB Group
June 14, 2017 | Slide 56
System With Leakage

If the voltage measured between one of the two poles and ground
does not tend to 0V and stabilizes on a value, there is a ground
leakage from the PV generator.

For Example , as shown below ,

If the system is made up of 10 modules in series and each one

supplies 50V,
When the measurement is made between positive pole and
ground, a voltage of 200V is measured
the leakage can be located between the 4th and 5th PV module.

© ABB Group
June 14, 2017 | Slide 57
Two Multi-Meter Test : Best Method To Test PV Field System Leakage

Best Method to test PV Field System leakage is to

Use of two Multi-meters at time , one Connected
between +Ve & Ground & Other MM between –Ve
& Ground, as shown in the picture

Vp = Voltage of MM1 between +Ve & Gnd.

Vn = Voltage of MM1 between -Ve & Gnd

MM2

1. If Vp = Vn, Then System is not leaking.

2. If Vp<Vn , then Positive is leaking with ground

MM1
3. Vp>Vn, Then Negative pole is leaking with ground

© ABB Group
June 14, 2017 | Slide 58
 Prepared by : Ashutosh Bedarkar

ABB solar inverters

ABB PVS800 : Maintenance
© ABB Group
June 14, 2017 | Slide 59
Recommended maintenance intervals after start-up

1) If the inverter is continuously used for reactive power

compensation during the night, halve the replacement
interval accordingly. If reactive power compensation is used
only partially, check the operating hours of fans
in the Inverter control program parameter 01.31 FAN ON-
TIME. Reset the counter when the fans are
replaced.

2) Estimated maintenance interval in ideal conditions:

ambient temperature between 0…40° C (104 °F), indoor
conditioned (IEC62109), and no cyclic heavy load.

3) If operation temperature is continuously below 40° C

(104 °F), replacement after 12 years. If above 40° C,
replacement after 9 years. Contact ABB for replacement.

© ABB Group
June 14, 2017 | Slide 60
Opening R8i Cooling Fan from the Inverter Module

1. Stop the inverter and do follow all steps in

section Precautions before electrical work on
slide 66 before you start the work.
2. Open the inverter cubicle door.
3. Disconnect the fan wiring plug (a).
4. Remove the locking screws (b).
5. Pull the fan out along its sliding rails (c).
6. Install new fan in reverse order.

© ABB Group
June 14, 2017 | Slide 61
How to Extract Module From Inverter
1. Stop the inverter and do the steps in section Precautions before
electrical work on slide 66 before you start the work.
2. Open the cubicle door.
3. Remove any shrouds that protect the busbars and cable entries.
4. Open the transparent cover on the front of the inverter module (the
rightmost module)
and disconnect the fiber optic cables. Move the cables aside.
5. Remove the L-shaped DC busbars on top of the module.
7. Remove the two module fastening screws (7a) at the top. At the
base of the module,
loosen the two fastening bolts (7b) but leave them in place; lift the
bracket (7c) and
fasten it into the up position carefully.
8. Insert the module pull-out ramp under the two bolts at the base of
the module and
tighten the bolts carefully.

© ABB Group
June 14, 2017 | Slide 62
9. Pull the module carefully out of the cubicle along the 10. Extend the support legs of the module. Keep the legs
ramp. Make sure the wires do not catch. While pulling on extended until the module is
the handle, keep a constant pressure with one foot on the about to be inserted back into the cubicle
base of the module to prevent the module from tipping
over. Use safety shoes with metal toe cap to avoid foot
injury.
.

© ABB Group
June 14, 2017 | Slide 63
Replacing SLCL Filter Cooling Fan
1. Stop the inverter and do the steps in section Precautions
before electrical work on slide no. 66 before you start the work.
2. Open the LCL filter cubicle door.
3. Disconnect the fan wiring plug.
4. Undo the screw of the fan fastening clip.
5. Pull the fan out.
6. Install a new fan in reverse order.

© ABB Group
June 14, 2017 | Slide 64
Replacing / Cleaning the Air filters

1. Remove the 3. Replace /

fasteners at the Clean the air
top of the grating filter mat.

2. Lift the grating and 4. Install the

© ABB Group
June 14, 2017 | Slide 65
pull it away from the grating in reverse
door. order
Regular Key Maintenance Activities

§ Door Filter Cleaning ( Every Three Months )

§ Cooling Fan Check (Every Month )
§ Power Connection Tightness ( Every Six Months).
§ Control cable connections check (Every Six Months).

© ABB Group
June 14, 2017 | Slide 66