operation manual hsi500 hsi640 hs1000 hsi1250 v31 eng

Translation of original operating manual Version 1.0

Operating Manual GGGGHSI500 / HSI640 / HSI1000 / HSI1250

Helios Systems

Eckernförder Landstrasse 78

24941 Flensburg

Germany

Tel.: +49-(0)461-318011-70

Fax: +49-(0)461-318011-71

Mail: [email protected]

All rights reserved.

Full or partial reproduction is only permitted with the consent of Helios Systems.

Creation date: 25. November 2010

Table of contens

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250 i

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Designated purpose .................................................................................................... 1

1.2 Intended use ............................................................................................................... 1

1.3 Improper use ............................................................................................................... 1

1.4 Standards and directives ............................................................................................ 2

1.5 About this operating manual ....................................................................................... 2

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1 Safety instructions ....................................................................................................... 3

2.2 Basic safety instructions ............................................................................................. 4

2.3 Obligations of the owner ............................................................................................. 8

2.4 Obligations of the qualified electrician ...................................................................... 10

2.5 Obligations of the crane operator .............................................................................. 10

2.6 Obligations of the industrial truck operator ............................................................... 11

2.7 Safety instructions on the central inverter ................................................................. 12

2.8 Identification of the HSI500 / HSI640 / HSI1000 / HSI1250 ...................................... 13

3 Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.1 Delivery ..................................................................................................................... 14

3.1.1 Included in the delivery ......................................................................................................... 14

3.2 Functional description ............................................................................................... 15

3.3 Principle of the systems ............................................................................................ 16

3.3.1 Principle of the HSI500 / HSI640 .......................................................................................... 16

3.3.2 Principle of the HSI1000 / HSI1250 ...................................................................................... 17

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

3.4.1 HSI500 / HSI640 exterior view .............................................................................................. 18

3.4.2 HSI1000 / HSI1250 external view ......................................................................................... 19

Table of contens

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250 ii

3.4.3 Display (optional) .................................................................................................................. 20

3.4.4 Emergency stop switch ......................................................................................................... 20

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

3.5.1 Central inverter interior view ................................................................................................. 21

3.5.2 HSI500 / HSI640 control cabinet interior view ...................................................................... 22

3.5.3 HSI1000 / HSI1250 control cabinet interior view .................................................................. 23

3.5.4 Optional heating elements .................................................................................................... 24

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

3.6.1 Technical data of the HSI500 ............................................................................................... 25

3.6.2 Technical data of the HSI640 ............................................................................................... 27

3.6.3 Technical data of the HSI1000 ............................................................................................. 29

3.6.4 Technical data of the HSI1250 ............................................................................................. 31

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

4.1 Packaging ................................................................................................................. 33

4.2 Transport ................................................................................................................... 33

4.2.1 General instructions .............................................................................................................. 33

4.2.2 Crane transport .................................................................................................................... 34

4.2.3 Industrial truck support ........................................................................................................ 35

4.2.4 Securing for transport ........................................................................................................... 36

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

4.3.1 Grid ....................................................................................................................................... 37

4.3.2 Connections .......................................................................................................................... 38

4.4 Foundation ................................................................................................................ 38

4.5 Distances .................................................................................................................. 39

4.6 Ventilation ................................................................................................................. 40

4.6.1 Ventilation of the central inverter .......................................................................................... 40

4.6.2 Ventilation of the control cabinet ........................................................................................... 41

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

Table of contens

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250 iii

5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

5.1 Installation of the central inverter .............................................................................. 43

5.1.1 Connect the solar generator (DC) ......................................................................................... 43

5.1.2 Connecting to the grid (AC) .................................................................................................. 44

5.2 Cable connections in the control cabinet .................................................................. 46

5.3 Installation of the control cabinet .............................................................................. 47

5.3.1 Internal connections between central inverter and control cabinet ....................................... 48

5.3.2 External connections of the control cabinet .......................................................................... 49

6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

7 Operating states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

7.1 Standby ..................................................................................................................... 54

7.2 Start up ..................................................................................................................... 54

7.3 MPP mode ................................................................................................................ 54

7.4 Shutdown .................................................................................................................. 54

7.5 Stop ........................................................................................................................... 55

8 De-commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

8.1 Emergency stop switch ............................................................................................. 56

8.2 Switching off the control voltage ............................................................................... 56

9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

9.1 Executing maintenance tasks ................................................................................... 57

9.2 Taking measurements .............................................................................................. 59

10 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

10.1 Disposal of the electrolytic capacitors ....................................................................... 61

Table of contens

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250 iv

11 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

12 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

12.1 Spare parts list for the HSI500 / HSI640 control cabinet .......................................... 65

12.2 Spare parts list for the HSI1000 / HSI1250 control cabinet ...................................... 67

12.3 Spare parts list for the inverter cabinet ..................................................................... 69

Introduction

Operating Manual HSI500 / HSI640 / HSI1000 / HSI1250 1

1 Introduction

1.1 Designated purpose

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

1.2 Intended use

The HSI500 / HSI640 / HSI1000 / HSI1250 may only be operated in photovoltaic systems and serves exclusively for the conversion of direct current into alternating current.It may only be operated in IT networks.

Intended use also includes reading the operating manual, as well as complying with all instructions contained in the operating manual, particularly the safety instructions. The operating manual must be kept for the entire service life of the product. Maintenance work of any type may only be performed by employees of Helios Systems. Observe all prescribed time intervals.

The HSI500 / HSI640 / HSI1000 / HSI1250 may only be set up within the ambient conditions specified in section “Technical data" on page 25.

1.3 Improper use

Any use other than the use specified under section “Intended use" on page 1 is considered improper use.The following uses of the HSI500 / HSI640 / HSI1000 / HSI1250 are included under improper use:

• in uninterruptible power supplies (UPS),

• in powered vehicles or

• as a component of a frequency converter.

In the case of improper use of the HSI500 / HSI640 / HSI1000 / HSI1250, safe operationis not guaranteed.Any modifications of the HSI500 / HSI640 / HSI1000 / HSI1250 are prohibited.

Introduction


1.4 Standards and directives

The HSI500 / HSI640 / HSI1000 / HSI1250 conforms to the standards and the declaration of conformity.

1.5 About this operating manual

This operating manual provides information about safety, function, transport, installation (including commissioning and decommissioning), disposal, faults and maintenance of the HSI500 / HSI640 / HSI1000 / HSI1250 from Helios Systems.

This operating manual is only intended for expert personnel authorised by the operator and trained in electrical engineering. The respective competences of the electrician must be clearly established by the operator.In addition, special qualifications are required for the following activities:

Activity Qualification/may only be performed by

Transport Authorised and trained specialists

Set-up Qualified electricians who have been trained and authorized

Commissioning Qualified electricians who have been trained and authorized

Instruction Employees of Helios Systems

Fault remedy Qualified electricians who have been trained and authorized

Maintenance/service Qualified electricians who have been trained and authorized

Cleaning Authorised and trained specialists

Repair Employees of Helios Systems

Decommissioning Qualified electricians who have been trained and authorized

Safety


2 Safety

2.1 Safety instructions

Safety instructions must be strictly complied with!

The safety instructions are classified according to the following risk levels:

DANGER!

Identifies a serious risk situation. Serious, irreversible injuries or fatal injuries will occur if this safety instruction is not complied with.

WARNING!

Identifies a serious risk situation. Severe, irreversible injury or death can occur if this safety instruction is not complied with.

CAUTION!

Identifies a risk situation. Minor or moderate injuries can occur if this safety instruction is not complied with.

NOTICE!

Identifies a risk of material damage. Material damage can occur if this safety instruction is not complied with.

Safety


2.2 Basic safety instructions

DANGER!

Life-threatening danger due to high voltage.

During operation the doors of the central inverter must remain closed!

DANGER!

Life-threatening danger due to residual voltage.

After switching off the central inverter, observe a minimum wait time of 30 minutes before opening, without fail!

DANGER!


For all tasks in the vicinity of the central inverter:

• Maintain the safety distance to the central inverter that must be complied with in accordance with BGV A3 (see Table 4/BGV A3 "Safety distances for non-electrical work, depending on the rated voltage")!

• Comply with the sequence of protective measures:

1. Disconnect,

2. Safeguard from being switched on again,

3. Ensure that equipment is de-energized,

4. Ground and short circuit,

5. Cover or shield adjacent live components.

• Have the work area marked before starting work (responsible party according to BGI 758).

Safety


DANGER!


Make sure that only authorized and trained electricians work on the central inverter. The respective competences of the qualified electrician must be clearly established. In addition, special qualifications are required for the following activities: (see section “About this operating manual" on page 2).

Prior to starting all tasks on the central inverter:

• Ensure that the central inverter is disconnected from the grid.

• Ensure that the intermediate circuit of the central inverter has discharged.

• Safeguard the central inverter from switching on again spontaneously.

• Prior to performing tasks on the central inverter use a suitable tool to ensure that residual voltage is not present.

• Use suitable tools with appropriate markings and PPE for working on live parts (VDE 0680/VDE 0682).

DANGER!

Life-threatening danger due to a lack of help.

• If there is an accident a second person must provide help.

• Always work with a second person near you!

NOTICE!

Warning against damage to the HSI500 / HSI640 / HSI1000 / HSI1250.

Improper repair work can cause damage to the central inverter.

All repair tasks should be performed by employees of Helios Systems.

DANGER!

Life-threatening danger due to failure to comply with the safety instructions.

• Comply with the information and safety instructions affixed to the device and in this operating manual.

• Make sure that the operating manual is kept near the HSI500 / HSI640 / HSI1000 / HSI1250.

Safety


WARNING!

Cut wounds due to hand tools.

• Only use suitable tools to cut and strip.

• Only use knives with a covered handle and cable measurement handles with a circular protrusion to prevent fingers from sliding in the direction of the blade.

• Wear protective gloves when using knives with a fixed blade.

• Do not keep a knife with open blade in work clothes or in the tool belt.

DANGER!

Danger of falling and injury when working on ladders.

• Check whether the tasks that must be performed can be safely performed from ladders. Otherwise, use work platforms or scaffolds.

• Select a suitable ladder and use it as intendede. g. do not use a step ladder as an extension ladder).

• Ensure that the set-up site is safe (capable of bearing a load, level, and that the ladder cannot slip).

• Wear safety footwear.

WARNING!

Warning - harmful to health.

The electrolytic capacitors contain ethylene glycol that is considered to be an irritant and harmful to health.

Wear protective goggles.Wear suitable protective clothing.

• In the case of contact, immediately seek a doctor.

• If there is eye contact rinse the eyes with water for at least 10 minutes.

• If swallowed drink plenty of water.

• Only induce vomiting if the affected person is fully conscious.

• Take off contaminated clothing immediately and remove it safely.

• If the case of skin contact wash off immediately with plenty of water.

Safety


DANGER!

Life-threatening danger due to flammable or explosive gasses.

• Ensure that the ambient air is free of flammable or explosive gasses.

DANGER!

Life-threatening danger due to corrosive substances.

• Ensure that the ambient air is free of corrosive substances.

DANGER!

Danger of injury due to inadequate protective clothing.

• Always wear safety shoes when working on the HSI500 / HSI640 / HSI1000 / HSI1250.

Safety


2.3 Obligations of the owner

DANGER!


Make sure that only authorized and trained electricians work on thecentral inverter. The respective competences of the qualified electrician must be clearly established. In addition, special qualifications are required for the following activities: (see section “About this operating manual" on page 2).

For tasks performed on the central inverter it must remain in a de-energised state to the extent possible for the entire duration of the tasks. This is achieved via the following five safety rules:

1. Disconnect – provide suitable devices for activating the switch elements.

2. Safeguard against restarting – provide suitable devices to safeguard against restarting.

3. Ensure de-energised state – provide suitable voltage detectors(up to 1000 V rated voltage, two-pole).

4. Ground and short circuit.

5. Cover or shield adjacent live components – provide suitable covering material appropriate for the activity to be performed.

The release for work should only be given after the person responsible for the work executes and checks the five safety rules.

Safety


DANGER!


Ensure that

• the operation of the HSI500 / HSI640 / HSI1000 / HSI1250 takes place in accordance with the valid legal provisions and the applicable safety instructions for the equipment in this operating manual,

• all safety instructions cited in this manual and affixed to the HSI500 / HSI640 / HSI1000 / HSI1250 are complied with, understood, and followed,

• all safety devices are always in faultless and functional operating status, (e. g. emergency stop switch on the control cabinet),

• the prescribed intervals or intervals specified in the operating manual for maintenance tasks are complied with,

• maintenance work may only be performed by authorizedand trained, qualified electricians,

• repair tasks are only executed by employees of Helios Systems.

Safety


2.4 Obligations of the qualified electrician

2.5 Obligations of the crane operator

Ensure that the guidelines specified in BGV D6: Cranes, are satisfied.The angle between the ropes or chains of the crane and the top side of the HSI500 / HSI640 / HSI1000 / HSI1250 must be at least 45° (see section “Crane transport" on page 34).

DANGER!


The HSI500 / HSI640 / HSI1000 / HSI1250 may only be installed, maintained, commissioned and de-commissioned by qualified electricians who have been trained and authorized.

• Ensure that a second instructed person, who can help in an emergency, is always present for all tasks performed on electrical equipment. If there is an accident the second person must switch off the power supply and provide help.

• After switching off the central inverter, observe a minimum wait time of 30 minutes prior to opening, without fail!

• Prior to performing tasks on the central inverter use a suitable tool to ensure that residual voltage is not present. On the display (optional), read out the DC voltage that is applied.

• Never open the central inverter during operation. Observe the operating manual, and especially the safety instructions, without fail.

• Observe the safety instructions affixed to the HSI500 / HSI640 / HSI1000 / HSI1250.

• Only operate the HSI500 / HSI640 / HSI1000 / HSI1250 in IT networks.

DANGER!

Danger of injury during crane operation.

Deficiencies emerging during crane operation can result in severe or fatal injuries.The crane should only be operated by authorized specialists who have been trained in the area of crane operation.

Safety


2.6 Obligations of the industrial truck operator

Ensure that the guidelines specified in BGV D27: Industrial trucks, are satisfied.

DANGER!

Danger of injury during transport.

Deficiencies emerging during transport can result in severe or fatal injuries.The industrial truck may only be operated by authorized, qualified personnel who are trained in the use of industrial trucks.

Safety


2.7 Safety instructions on the central inverter

DANGER!


You must wait at least 30 minutes until the intermediate circuit has discharged.

DANGER!


Ensure that only qualified electricians who have been trained and authorized work on the central inverter.

CAUTION!

Device damage due to loose power line.

ALUMINUM CONDUCTORSRecommendation! Observe the following when using aluminum conductors:

1. Remove the oxide layer of the conductor (wire) with a wire brush.

2. Grease the aluminum conductor (wire) with acid-free grease (e. g. Vaseline or terminal grease).

3. The conductor should be checked after approx. 4 weeks with a torque wrench (Nm), thereafter it should be checked yearly.

4. Only one conductor (wire) should be connected in one terminal.

Safety


2.8 Identification of the HSI500 / HSI640 / HSI1000 / HSI1250

The type plates of the inverter and the control cabinet are located at the bottom on the outside of the door, at the top on the inside of the door and on the respective mounting plates.

The type plate includes the following information:• Serial Number• Name• Type• Power• Voltage• Frequency• Short Circuit Level• Year of Manufacture

Examples of the respective type plates are shown in the following:

HSI500 power element HSI640 power element

HSI500 / HSI640 control cabinet HSI1000 / HSI1250 control cabinet

Technical description


3 Technical description

3.1 Delivery

Check the delivery for completeness. If the delivery is not complete, please contact Helios Systems.

Check the HSI500 / HSI640 / HSI1000 / HSI1250 for transport damage. If you determine that there is transport damage, immediately contact the freight forwarder.

3.1.1 Included in the delivery

The scope of delivery varies, depending on whether you are using the HSI500, HSI640, HSI1000 or HSI1250:

HSI500 / HSI640:

• 1x central inverter

• 1x control cabinet

• Control cabinet key for central inverter and control cabinet

• Operating manual

• Test log - final test

• Test protocol - insulation monitor

HSI1000 / HSI1250:

• 2x central inverter

• 1x control cabinet

• Control cabinet key for central inverter and control cabinet

• Operating manual

• Test log - final test

• Test protocol - insulation monitor



3.2 Functional description

The HSI500 / HSI640 / HSI1000 / HSI1250 from Helios Systems has been specially developed for use in photovoltaic systems and equipped with the state-of-the-art, efficiency-optimised technology.

It converts the DC voltage that is given off by the solar generators into grid-conformant alternating current and feeds it into the public power grid, three-phase. The HSI500 / HSI640 is comprised of a 500 kW / 640 kW central inverter and a control cabinet. The HSI1000 and HSI1250 are comprised of two 500 kW / 640 kW central inverters and a control cabinet. The central inverter is only intended for connection to the IT network.

Description Components

HSI500 1x 500 kW power element and 1x control cabinet






3.3 Principle of the systems

3.3.1 Principle of the HSI500 / HSI640

Fig.3-1 HSI500 / HSI640 principle circuit diagram

The HSI500 / HSI640 is a three-phase central inverter for grid-coupled photovoltaic systems.

The HSI500 / HSI640 is comprised of two cabinets, a central inverter and a control cabinet. From left to right: DC switch disconnector Q1, interference suppression filter (EMC), DC connection with IGBT bridge, interference suppression filter and the grid contactor K1.

HSI500



3.3.2 Principle of the HSI1000 / HSI1250

Fig.3-2 HSI1000 / HSI1250 principle circuit diagram

The HSI1000 / HSI1250 is a three-phase central inverter for grid-coupled photovoltaic systems.

The HSI1000 / HSI1250 is comprised of three cabinets, two central inverters and a controlcabinet. From left to right: DC switch disconnector Q1, interference suppression filter (EMC), IGBT bridge, interference suppression filter and the grid contactor K1.

HSI1000



3.4 Exterior views

3.4.1 HSI500 / HSI640 exterior view

Fig.3-3 HSI500 / HSI640 exterior view

1 Air guide boxes

2 Display (optional) (See "Display (optional)" on page 20)

3 Emergency stop switch (See "Emergency stop switch" on page 20)

4 Control cabinet

5 Central inverter

2

1

3

5 4



3.4.2 HSI1000 / HSI1250 external view

Fig.3-4 HSI1000 / HSI1250 external view

1 Air guide boxes of the respective central inverters

2 Display (optional) for the left central inverter (See "Display (optional)" on page 20)

3 Emergency stop switch (See "Emergency stop switch" on page 20)

4 Display (optional) for the right central inverter(See "Display (optional)" on page 20)

5 Central inverter

6 Control cabinet

21 13

65 5

4



3.4.3 Display (optional)

The display is used to show status data, to reset error messages, and to switch the central inverter on and off. The display and control functions of the display run parallel to the software interface.

3.4.4 Emergency stop switch

In an emergency the central inverter can be immediately disconnected from the grid (AC) and from the solar generator (DC) (See "Emergency stop switch" on page 56).

DANGER!


• Strictly maintain a minimum wait time of 30 minutes after switching off and prior to opening the central inverter!




3.5 Interior views

3.5.1 Central inverter interior view

Fig.3-5 Central inverter interior view

1 Intermediate circuit 5 DC switch disconnector Q1

2 IGBT bridge, L1, L2, L3 6 HF-Filter

3 Measuring transducer DC current 7 Contactor K1

4 Measuring transducer AC current

1

2

3

4

5

7

6



3.5.2 HSI500 / HSI640 control cabinet interior view

Fig.3-6 HSI500 / HSI640 control cabinet interior view

1 Communication board 5 Insulation monitor

2 Control card 6 3x 24 V power supply unit

3 Thermostats (only present if the heating option was selected)

7 Transformer for the internal power supply (optional)

4 Hygrostat (only present if the heating option was selected)

1

2

3

4

5

6

7



3.5.3 HSI1000 / HSI1250 control cabinet interior view

Fig.3-7 HSI1000 / HSI1250 control cabinet interior view

1 Communication board 5 Hygrostat (only present if the heating option was selected)

2 Control card 6 3x 24 V power supply unit

3 Thermostats (only present if the heating option was selected)

7 Transformer for the internal power supply (optional)

4 Insulation monitor

1

2

3

4

3

5

6

7



3.5.4 Optional heating elements

Fig.3-8 Heating elements (left HSI500 / HSI640;

right HSI1000 / HSI 1250, with and without the display option)

Optionally, two heating elements can be installed on the inside of the door. In addition, there are two thermostats and a hygrostat in the control cabinet.

The values are set at the factory and may not be changed:

• -BT1 -5 °C,

• -BT2 +5 °C,

• -BT3 > 90 % relative humidity.

The heating elements switch on automatically as soon as the temperature falls below 5 °C or the relative humidity exceeds 90 %. If the temperature falls below -5 °C the power supply of the control card is switched off. The heating elements remain switched on. If the temperature exceeds -5 °C, the power supply of the control card is automatically switched on again.

NOTICE!

Warning against damage to the HSI500 / HSI640 / HSI1000 / HSI1250.

The values of the thermostats and of the hygrostats should not be adjusted.

11



3.6 Technical data

3.6.1 Technical data of the HSI500

Electrical data

Rated output power 500 kW at +/-10 % of the rated grid voltage

Rated output power 560 kW at rated voltage

Grid voltage and frequency range 270 V +/-10 %, 3~, 50 Hz +/-2 Hz only IT network,

other frequencies on request

Maximum output current 1199 A

Power factor (cos ?) > 0,98 from 20 % rated output

Distortion factor (THD) < 3 % at rated power

Rated PV power 510 kW within +/-10 % rated grid voltage

Maximum PV power 575 kW at rated voltage

Maximum PV power 1230 A

Maximum PV off-load voltage 900 V=

MPP range 450 V= to 820 V= at rated PV power

Regulating procedure MPP tracking

Efficiency (97,0 | 98,0 | 98,0 | 97,9 | 97,8) % at (10 | 30 | 50 | 75 | 100) % power

EC efficiency 97,8 % excl. station service

Infeed from 700 W

Loss in standby/at night < 30 W

Maximum station service < 1000 W



General data

Ambient temperature 0 °C to 50 °C other on request

Humidity < 95 % Non-condensing

Set-up altitude up to 2000 m above sea level without power loss

Type of cooling Forced convection cooling 3600 m3/h

Minimum air quality Class 3S2 in accordance with EN60721-3-3

Protection class IP20

Dimensions (H x W x D) 2100 mm x 1800 mm x 850 mm Inverter + Control cabinet

Weight 1600 kg Inverter cabinet + Control cabinet

Cabinet colour RAL7035 other on request

EMC fulfils EN61000-6-2, EN61000-6-4

Low-voltage directive fulfils EN50178

Grid monitor in accordance with VDEW

guidelines

CE conformity Satisfied

Equipment/components

Buffer amplifier Load disconnect switch with motor drive

AC contactor

Emergency stop switch Present

Display Touch screen with numeric and graphic output

Ground fault monitor Insulation monitor

Overvoltage protector Monitored overvoltage protector - DC current side three-phase current side

Options

- Cabinet heater

- Display

Accessories

- DC distribution with up to 60 inputs (individually secured with switch disconnectors)

- String Monitoring System




Electrical data



Grid voltage and frequency range 300 V +/-10 %, 3~, 50 Hz +/-2 Hz only IT network,





Rated PV power 654 kW at rated voltage

Maximum PV power 695 kW at rated voltage

Maximum PV power 1308 A


MPP range 500 V= to 820 V= at rated PV power




Infeed from 700 W



General data




Type of cooling Forced convection cooling 3600 ml/h

Minimum air quality Class 3S2 in accordance with EN60721-3-3



Weight 1700 kg Inverter + Control cabinet


EMC fulfils EN61000-6-2, EN61000-6-4



guidelines






AC contactor





Options

- Cabinet heater

- Display

Accessories






Electrical data

Rated output power 1000 kW at +/-10 % of the rated grid voltage


Grid voltage range and

grid frequency270 V +/-10 %, 3~,

50 Hz/60 Hz +/- 2 Hz

only IT network





Rated PV power 2 x 511 kW within +/-10 % rated grid voltage

Maximum PV power 2 x 562 kW at rated voltage

Maximum PV power 2 x 1249 A


MPP range 2x (450 V= to 820 V=) at rated PV power




Infeed from 700 W per MPP tracker



General data





Min. air quality Class 3S2 in accordance with EN60721-3-3





EMC fulfils EN61000-6-2, EN61000-6-4



guidelines






AC contactor





Options

- Cabinet heater

- Display

Accessories






Electrical data



Grid voltage range and

grid frequency

300 V +/-10 %, 3 ~

50 Hz/60 Hz +/-2 Hz

only IT network





Rated PV power 2 x 654 kW at rated voltage

Maximum PV power 2 x 695 kW

Maximum PV power 2 x 1,308 A


MPP range 2 x (500 V= to 820 V=) at rated PV power




Infeed from 700 W per MPP tracker



General data





Min. air quality Class 3S2 in accordance with EN60721-3-3





EMC fulfils EN61000-6-2, EN61000-6-4



guidelines






AC contactor





Options

- Cabinet heater

- Display

Accessories



Transport and the necessary conditions at the installation site


4 Transport and the necessary conditions at the installation site

4.1 Packaging

Unless otherwise agreed, the packaging satisfies the HPE packaging guidelines that have been specified by the German Associations for Wooden Materials, Pallets, Export Packaging (Bundesverband Holzmittel, Paletten, Exportverpackung e. V).

4.2 Transport

4.2.1 General instructions

Check the delivery immediately after it arrives for completeness and possible transport damage. If the delivery is incomplete contact Helios Systems.

Only transport the inverter cabinet with an industrial truck. The control cabinet is supplied with transport eyes and can be transported using a crane or an industrial truck.

Use suitable transport equipment appropriate for the local conditions. Comply with the information in sections “Obligations of the crane operator" on page 10 and “Obligations of the industrial truck operator" on page 11 in this regard.

DANGER!

Life-threatening danger due to the HSI500 / HSI640 / HSI1000 / HSI1250 tipping over.

• Only transport the inverter cabinet of the HSI500 / HSI640 / HSI1000 / HSI1250 using an industrial truck with sufficient load-bearing capacity.

• Only transport the control cabinet of the HSI500 / HSI640 / HSI1000 / HSI1250 using a crane or industrial truck with sufficient load-bearing capacity.

• The HSI500 / HSI640 / HSI1000 / HSI1250 may only be transported by authorized, qualified personnel trained in the operation of industrial trucks and cranes.

NOTICE!

Improper transport can damage the device.

• Only transport the devices HSI500 / HSI640 / HSI1000 / HSI1250 in an upright position in order to prevent damage.



Only remove the transport safeguards when the HSI500 / HSI640 / HSI1000 / HSI1250 is standing vertically at the intended installation site.

4.2.2 Crane transport

Transport eyes in accordance with DIN 580 are provided for loading the control cabinet of the HSI500 / HSI640 / HSI1000 / HSI1250. The following permissible total loads apply for systematic load:

• At 45° cable angle 4800 N



DANGER!

Life-threatening danger due to falling loads.

Falling loads can cause fatal injuries.

• Only use the permissible lifting devices to lift loads.

• Ensure that no one is in the danger zone of the suspended load.

• Wear appropriate protective work clothing.

DANGER!

Life-threatening danger if the wrong lifting devices are used.

Use of the wrong lifting devices can cause severe or fatal injuries.

• When lifting the control cabinet of the HSI500 / HSI640 / HSI1000 / HSI1250, only use the permissible lifting devices (weight of the respective device: See "Technical data" on page 25).



4.2.3 Industrial truck support

Fig.4-1 Industrial truck transport of the HSI1000 / HSI1250

NOTICE!

Warning against use of the lifting device (e. g. forklift).

Components and connections on the underside of the base of the HSI500 / HSI640 / HSI1000 / HSI1250 can be damaged by the lifting device.

• When lifting the HSI500 / HSI640 / HSI1000 / HSI1250 equipment, ensure that components and connections on the base of the unit are not damaged.

• When lifting the HSI500 / HSI640 / HSI1000 / HSI1250 ensure that the stress or load is only applied in the area of the pedestal feet.



4.2.4 Securing for transport

NOTICE!

Warning against damage from improper transport safeguards.

Improper transport safeguarding can result in damage to the HSI500 / HSI640 / HSI1000 / HSI1250.

• For transport on a truck or trailer the HSI500 / HSI640 / HSI1000 / HSI1250 must be properly lashed. The truck or trailer must have lashing eyes.

• Trained, specialised personnel that meet the requirements specified in regulations VDI 2700 and VDI 2703 must load the central inverter. The correct dimensioning and implementation of load securing measures must be specified on a case-by-case basis.

• To lash the HSI500 / HSI640 / HSI1000 / HSI1250, fasten the ratchet strap on the lashing eyes of the equipment and the lashing eyes of the landing surface.

• Tighten the ratchet strap with the tensioning device.



4.3 Installation site prerequisites

4.3.1 Grid

The HSI500 / HSI640 / HSI1000 / HSI1250 may only be operated in an IT network. The connection of two or more inverters to an IT network is not permitted.

NOTICE!

Ensure that the rotary field is correct.

The rotary field must be clockwise. If this is not the case the central inverter will not establish a connection to the public grid.



4.3.2 Connections

The following connection cables must be present, prepared, and secured:

• Solar generator connection,

• Grid connection,

• Auxiliary voltage connection,

• Communication connection.

4.4 Foundation

The foundation must be able to support the weight of the HSI500 / HSI640 / HSI1000 / HSI1250 and the transport device.

The foundation must be level, stable, slip-resistant, and fire resistant.

DANGER!


Protect cables and lines against mechanical influences.

• All cables and lines must be protected by a highly flexible plastic protective hose.

• Offload the plastic protective hose on both ends with catching clamps to relieve the hose from pull and pressure.

• Fit a marked pull-in aid (not metal) on each plastic protective hose.

• Ensure that the cables and lines are introduced into the central inverter and control cabinet from below. In this regard at least protection class IP20 must be ensured.

DANGER!

Life-threatening danger due to defective lines and cable.

• Comply with the specified bend radii.

• Offload the plastic protective hose on both ends to relieve the hose from pull and pressure.

• Only route one cable through each cable gland.

• Ensure that the diameter of the cables and lines match the diameters of the cable glands and threaded unions.



4.5 Distances

The HSI500 / HSI640 / HSI1000 / HSI1250 must be easily accessible for operation and maintenance. In this regard the following distances must be maintained:

• Front: 500 mm minimum with open door.

• The HSI500 / HSI640 / HSI1000 / HSI1250 requires a minimum distance of 50 mm to the side and rear.

Fig.4-2 Distances with open door

(left HSI1000 / HSI1250; right HSI500 / HSI640)

min 50 mm

min 500 mm

min 50 mm

min

50

mm

min 50 mm

min 500 mm

min 50 mm

min

50

mm

HSI1000 / HSI1250 HSI500 / HSI650



4.6 Ventilation

4.6.1 Ventilation of the central inverter

The central inverter must be set up on a foundation that ensures that sufficient air can be suctioned in. The suctioned air is distributed in the interior of the central inverter by fans. The central inverter circulates the air with three small fans in the doors and two large radial fans in the cover. The air is suctioned in from below and blown out on the top side of the central inverter.

The required air quantity, the air quality and the protection class must fulfil the requirements in section “Technical data" on page 25.

DANGER!

Life-threatening danger due to flammable or explosive gasses.

• Ensure that the ambient air is free of flammable or explosive gasses.

DANGER!

Life-threatening danger due to corrosive substances.

• Ensure that the ambient air is free of corrosive substances.

NOTICE!

Warning - damage or overheating of the HSI500 / HSI640 / HSI1000 / HSI1250.

Insufficient cooling air for the HSI500 / HSI640 / HSI1000 / HSI1250 can lead to damage or overheating.

Ensure that sufficient cooling air is available at the installation site.



4.6.2 Ventilation of the control cabinet

The control cabinet must be set up on a foundation that ensures that sufficient air can be suctioned in. The suctioned air is distributed in the interior of the control cabinet by fans. The control cabinet circulates the air with fans in the cover. The air is suctioned in from below and blown out on the top side of the control cabinet.

The required air quantity, the air quality and the protection class must fulfil the requirements in section “Technical data" on page 25.

4.7 Ambient variables

The protection class must meet the specifications in section “Technical data" on page 25.

Installation


5 Installation

DANGER!


• The installation of the inverter and the control cabinet may only be performed by trained, qualified personnel authorized by the operator.

• Observe the safety instructions affixed to the HSI500 / HSI640 / HSI1000 / HSI1250 and in this operating manual.

• Check the cable feeds for damage.

NOTICE!

Material damage due to the incorrect torque.

If the cable lugs are tightened too tightly damage can occur.If the cable lugs are tightened too loosely the cables and lines can loosen.

NOTICE!

Material damage due to improper connection.

Ensure that

• the oxide layer of the aluminum conductor has been removed with a wire brush,

• the aluminum conductor (wire) has been greased with acid-free grease (e. g. Vaseline or terminal grease),

• the connection of the aluminum conductor is checked after approx. 4 weeks, with a torque wrench, thereafter it must be checked yearly,

• only one aluminum conductor is connected per terminal.

Installation


5.1 Installation of the central inverter

5.1.1 Connect the solar generator (DC)

1. Open the front door.

2. Remove the sliding floor plate.

3. Route the cable to the connection area from below.

4. Check the cable feeds for damage.

Fig.5-1 Copper rails for the connection of the solar generator

5. The cable lugs must be configured for fastening with M10 screws. Route the cable lugs to the correct copper rail. Ensure correct polarity.

6. Fasten the cable lugs (torque of 45 Nm).

7. If no other cables will be connected reinstall the sliding door.

DANGER!


The installation may only be carried out by qualified electricians who have been trained and authorized.

Installation


5.1.2 Connecting to the grid (AC)

1. Open the front door.

2. Remove the sliding floor plate.

3. Route the cable to the connection area from below.

4. Check the cable feeds of the grid connection for damage.

Fig.5-2 AC power switch Q2

5. The cable lugs must be configured for fastening with M12 screws. Route the cable lugs to the correct contactor inputs. The colour sequence is as follows, from left to right (tightening torque: 80 Nm).

- (1) L1 left/brown- (2) L2 centre/black- (3) L3 right/gray

NOTICE!

Ensure that the rotary field is correct.

The rotary field must be clockwise. Otherwise, the inverter will not establish a connection to the public grid.

1 2 3

Installation


6. Connect the PE conductor. The cable lug for the PE conductor must be configured for M8 screws (torque: 23 Nm).

Fig.5-3 PE conductor (green-yellow)

7. If no other cables will be connected reinstall the sliding door.

Installation


5.2 Cable connections in the control cabinet

The inverter cabinet is positioned to the left of the control cabinet. An additional converter cabinet is positioned to the right of the control cabinet for the HSI1000 / HSI1250.The left half of the control cabinet contains the following cable connections for the HSI500 / HSI640 / HSI1000 / HSI1250:

For the HSI1000 / HSI1250 the right half of the control cabinet contains the following additional cable connections:

HSI500 / HSI640 / HSI1000 / HSI1250

X1A • DC voltage for insulation monitor• AC voltage L1, L2 and L3 for AC voltage measurement• Supply voltage for roof fan

X3A • Q1 and K1 feedback• Overvoltage protection• Control signal for roof fan

X5A Control for intermediate circuit fans in the door and/or rear wall

X20A Q1 and K1 control

X13A 230 V supply voltage for the optional heating elements.

PE Screw the green-yellow PE cable on the mounting plate with 8 Nm.

Drive cable

DC measurement line

HSI1000 / HSI1250

X1B • DC voltage for insulation monitor• AC voltage L1, L2 and L3 for AC voltage measurement• Supply voltage for roof fan

X3B • Q1 and K1 feedback• Overvoltage protection• Control signal for roof fan

X5B Control for intermediate circuit fans in the door and/or rear wall

X20B Q1 and K1 control

X13B 230 V supply voltage for the optional heating elements.

PE Screw the green-yellow PE cable on the mounting plate with 8 Nm.

Drive cable

Measurement loc

Installation


5.3 Installation of the control cabinet

All connections between the inverter and the control cabinet were disconnected for transport. In the following an explanation on the basis of a control cabinet for the HSI1000 and 1250 is provided for which cables must be connected in order to ensure correct operation. The respective connections are only provided once in the control cabinet of the HSI500 or HSI640.

Fig. 5-4 Control cabinet connections

1 Ethernet connection

2 D-SUB plug connector

3 Plug connectors for periphery

4 Potential equalisation screws

5 Auxiliary transformer -T1

6 Terminal strip X9

Points 1 to 4 are provided twice. The left inverter is connected to the left and the right inverter is connected to the right.

1

2

3

6

4

5

Installation


5.3.1 Internal connections between central inverter and control cabinet

Fig.5-5 View of control cabinet with connected connections

1. Guide the cable through the provided opening from the inverter to the control cabinet.

2. Connect the D-SUB plug connections to the connections (2, see page 47) and screw them onto the control card.The D-SUB plug connections serve for the control of the power elements and, therefore, are of considerable importance for the correct operation of the inverter.The D-SUB plug connectors X104 to X105 serve for the control of the power stages. The plug X103 includes the Idc input current.

3. Then connect the five plug connectors for the periphery to the connections (3, see page 47) by plugging the respective plug connector into the terminal strip.

4. Fasten the green-yellow PE wire to the potential equalisation using the screw (4, see page 47).

Installation


5.3.2 External connections of the control cabinet

The supply, feedback and communication lines are connected to the control cabinet as external connections.

1. There are two different possibilities for connecting the external voltage supply. Both possibilities are achieve through the terminal strip X9 (6, see page 47).

• The inverter is supplied directly from the 270 / 300 V IT network. For this purpose, the connection takes place at terminals 1 and 2 of the terminal strip X9. The voltage is converted to 230 V TN using the auxiliary transformer -T1 (5, see page 47).

• The inverter is operated directly with a supply voltage of 230 V TN. Connect the supply to the terminals 6 to 8 of the terminal strip X9 (6, see page 47).

Fig.5-6 Terminal configuration of the connection X9.

DANGER!

Life-threatening danger from missing overload / lightning protection.

No lightning / overvoltage protection is installed for the communication lines.

If the lines should leave the building in which the HSI500 / HSI640 / HSI1000 / HSI1250 is located, appropriate lightning protection must be installed by an authorized electrician.

NOTICE!

Material damage from improper routeing of cable.

Use the available wiring conduit to route the cable within the control cabinet.

Installation


2. The data communication between the inverter and the monitoring system takes place through the Ethernet interface of the control cabinet (HSI500 / HSI640 each have one and the HSI1000 / HSI1250 each have two Ethernet connections).Connect the Ethernet cable to the Ethernet connection (1, see page 47). For further information about the monitoring system, the latest version is available for download at www.helios-systems.net.

3. Every inverter has zero potential signal and control contacts which can be used as necessary.

• "Inverter ready" changeover contact, connection X2A, terminals 1 to 3.

• Connection for external emergency stop switch, connection X2A, terminals 4 to 5.

• "Insulation monitor" changeover contact, connection X2A, terminals 6 to 7.

Fig.5-7 Zero potential signal and control contacts

external customer contact

"Unit A ready"

Emergency stop

costumer

Insulation

monitor

4 65 81X2A 2 3 7

21

22

-S2

from 230V or 24Vto 230V or 24V

to 230V or 24V/

//

Installation


4. In addition, external consumers can also be connected to the various outgoing supply voltage lines, such as for lighting or outlets for stations.

Fig.5-8 Outgoing supply voltage lines for external consumers

Power Supply

Light and Sockets

Power Supply

Light and Sockets

1-X14 2 3 5 6 7 8 9 10

1

2

-F8/2.1B6A

1

2

-F9/2.2B6A

1

2

-F10/2.2B6A

11 12

1

2

-F11/2.3B6A

4

PE/2a.6 PE / 2a.2

N / 2.6

L/2a.6 L / 2a.2

N/2.1

Commissioning


6 Commissioning

1. The central inverter must be connected on the DC main supply.

2. The central inverter must be connected on the AC main supply.

3. Measure the DC voltage. The polarity must correspond to the plus/minus markings, and the measured values must be within the tolerances (see section “Technical data" on page 25).

4. Switch on all DC power switches.

5. Measure the grid voltage AC from phase to phase.

The measured values must be within the tolerances (see section “Technical data" on page 25).

DANGER!


Observe the safety instructions affixed to the HSI500 / HSI640 / HSI1000 / HSI1250 and in this operating manual.The HSI500 / HSI640 / HSI1000 / HSI1250 may only be commissioned by qualified electricians who have been trained and authorized.

DANGER!


Ensure that

• the central inverter is de-energized,

• the slide switch on the DC switch disconnector Q1 is in position “Auto”,

• the emergency stop switch is pressed,

• all cables and lines are undamaged, correctly connected and in faultless condition,

• the threaded unions on all connection rails and terminal strips have the correct tightening torque.

DANGER!


Only take measurements with appropriate measurement devices.

Commissioning


6. Close the front door.

7. Unlock the emergency stop switch.

After a short wait time, the central inverter starts up.

WARNING!

Danger of pinching when closing the front door.

When closing the front door, ensure that bodily extremities (hands, fingers) do not get caught in the closing edges.

Operating states


7 Operating states

After commissioning, the central inverter runs through operating states described below.The parameters that cause the central inverter to change to a certain operating state are prescribed.

7.1 Standby

If the solar generator voltage is below Umpp min, the central inverter switches to "Standby" mode. The central inverter is connected to the grid via the grid contactor K1.

7.2 Start up

If the solar generator voltage increases to 50 V above Umpp min, infeed mode is started. If the solar generator current falls below the minimum value, infeed mode switches off for 30 seconds. If the solar generator voltage increases to 50 V above Umpp min, infeed mode is switched on again. If the solar generator current is continuously above the minimum value, the central inverter is in normal mode and infeed is continuous. Start-up can require various attempts; if necessary, a pause of a few minutes must be observed after several attempts.

7.3 MPP mode

Thanks to the Maximum Power Point Tracker (MPPT) the solar power of the solar generator is optimally used. The MPPT is comprised of the continuous MPPT and the cyclical MPPT.

The continuous MPPT varies the solar generator voltage in small increments, and determines the solar generator power after each increment. In this process the continuous MPPT always the tracks the path of optimal solar generator power.

The cyclic MPPT scans a defined voltage range in large increments. This takes place several time each day.If the cyclic MPPT has found the solar generator voltage with the greatest solar generator power, the continuous MPPT takes over this solar generator voltage for further tracking.

7.4 Shutdown

If the solar generator current drops below the minimum value, initially only the infeed operation is switched off. If the solar generator voltage drops below Umpp min, the central inverter is disconnected from the grid by opening the grid contactor K1.

Operating states


7.5 Stop

Fault monitoring is active in each operating state. If a fault occurs, all functions of the central inverter will be stopped automatically. An error message will be shown on the display. If the cause of the fault is eliminated, the central inverter returns to "Standby" mode after a wait time.

De-commissioning


8 De-commissioning

8.1 Emergency stop switch

Press the emergency stop switch to shut down the central inverter in an emergency.After unlocking the emergency stop switch the central inverter will resume operation after a brief wait time.

8.2 Switching off the control voltage

If there is an internal power supply the control voltage must be switched off on the automatic circuit breaker F7.

If there is an external power supply the control voltage must be switched off outside of thecentral inverter.

DANGER!


• Strictly maintain a minimum wait time of 30 minutes after switching off and prior to opening the central inverter!


NOTICE!

Only activate the emergency stop switch in an emergency.

In an emergency the emergency stop switch immediately disconnects the central inverter from the power supply (AC) and from the solar generator (DC). Only once the dangerous situation has passed and potential faults have been eliminated may the emergency stop switch be unlocked by pulling it out again.

Maintenance


9 Maintenance

9.1 Executing maintenance tasks

1. Switch off the HSI500 / HSI640 / HSI1000 / HSI1250 (see section “De-commissioning" on page 56).

DANGER!


The HSI500 / HSI640 / HSI1000 / HSI1250 may only be maintained by qualified electricians who have been trained and authorized.

• Using suitable tools, ensure that the HSI500 / HSI640 / HSI1000 / HSI1250 has been switched off and de-energised.

• Always work with a second person near you.

NOTICE!

Warning - damage to the central inverter.

Improper repair work can cause damage to the central inverter.

All repair tasks should be performed by employees of Helios Systems.

DANGER!

Life-threatening danger due to residual voltage when performing maintenance tasks on the outer area.

For all work near the HSI500 / HSI640 / HSI1000 / HSI1250

• Maintain the safe distance to the HSI500 / HSI640 / HSI1000 / HSI1250 that must be complied with in accordance with BGV A3 (see Table 4/BGV A3 "Safety distances for non-electrical work depending on the rated voltage")!

DANGER!

Life-threatening danger due to residual voltage when performingmaintenance tasks in the interior.

• After switching off the central inverter, observe a minimum waittime of 30 minutes before opening, without fail!

• Prior to opening the central inverter use a suitable tool to ensure that residual voltage is not present.

Maintenance


The maintenance tasks described must be executed within the specified intervals, starting with the installation date.

Maintenance tasks Every 12

months

Every 24

months

Check the housing and interior area for discolouration, corrosion, fouling,

significant dust and water accumulation, and damage.

X

Check all fans and their filters, if present. Check whether foreign objects on

the central inverter hinder air circulation.

X

Check the function of the DC load switch (Q1). X

Check the status of the copper rails. X

Check the status of all cables and lines. X

Check all fuses for damage. X

Check the AC and DC overvoltage protection for damage. X

Check the function of the internal 24 V power supply. X

Check the accuracy of the AC measured values (See "Taking

measurements" on page 59).

X

Check the function of the emergency stop switch. X

Check the status of the capacitors. X

Maintenance


9.2 Taking measurements

1. Check the output voltage of the internal 24 V power supply. The DC output voltage of the 24 V power supply unit should be 24 V +/- 0.5 V. Use a multimeter.

2. Check the accuracy of the AC measured values. The alternating current ofphases L1, L2 and L3 are shown on the display. Compare these display values with the values measured by the voltmeter. The accuracy should be +/-2.5 %.

3. Close the front door.

4. Switch on the HSI500 / HSI640 / HSI1000 / HSI1250 (See "Commissioning" on page 52).

DANGER!


• After switching off the central inverter, observe a minimum waittime of 30 minutes before opening.

• Prior to opening the central inverter use a suitable tool to ensure that residual voltage is not present.

• Only take measurements with measurement devices intended for this purpose.

WARNING!

Danger of pinching when closing the front door.

When closing the front door, ensure that bodily extremities (hands, fingers) do not get caught in the closing edges.

Disposal


10 Disposal

The HSI500 / HSI640 / HSI1000 / HSI1250 contains electrical components and metal.

Final and professional decommissioning and/or disposal of the HSI500 / HSI640 / HSI1000 / HSI1250 must be executed under the applicable statutory regulations of the country of use.Please observe the special regulations for electronics and electrical equipment, in particular.

The HSI500 / HSI640 / HSI1000 / HSI1250 has been manufactured in accordance with the applicable EC Directive 2002/95/EC on the Restriction of the use of certain Hazardous Substances in Electrical and Electronic Equipment (RoHS).

No solder points contain lead, thus there are no hazardous substances. Separate disposal is not necessary.

The waste management company is responsible for the correct coding and description of its waste.

DANGER!


The HSI500 / HSI640 / HSI1000 / HSI1250 may only be disassembled and disposed of by qualified electricians who have been trained and authorized.

Disposal


10.1 Disposal of the electrolytic capacitors

Electrolytic capacitors are in the intermediate circuit, in the 24 V power supply unit and in other electronic components.

Comply with the regulations for disposal of special waste, in particular. The regulations issued by government agencies apply, particularly the regulations associated with the European Waste Catalogue.

WARNING!

Warning - harmful to health.

The electrolytic capacitors contain ethylene glycol that is considered to be an irritant and harmful to health.

Wear protective goggles.

Wear suitable protective clothing.

• If there is contact seek medical attention immediately.

• If there is eye contact rinse eyes with water for at least 10 minutes.

• If swallowed drink plenty of water.

• Only induce vomiting if the affected person is fully conscious.

• Take off contaminated clothing immediately and remove it safely.

• If the case of skin contact wash off immediately with plenty of water.

CAUTION!

Environmental damage is possible because ethylene glycol poses a slight hazard to water.

The ethylene glycol from the electrolytic capacitors should not get into soil or ground water.

Faults


11 Faults

If a fault occurs during operation, the HSI500 / HSI640 / HSI1000 / HSI1250 goes into the “Stop” mode (see section “Operating states" on page 54). An error code and its description in English will appear on the display.

DANGER!


Faults on the HSI500 / HSI640 / HSI1000 / HSI1250 may only be corrected by qualified electricians who have been trained and authorized.

Error code Description Possible cause

Temperature

A high ambient temperature can increase the temperature in the interior of the HSI500 / HSI640 / HSI1000 /

HSI1250 and impair normal operation.

Keep the ambient variables of the HSI500 / HSI640 / HSI1000 / HSI1250 in the range of the data cited in section

“Technical data" on page 25.

11 Temperature inverter phase L1, HW driver

12 Temperature inverter phase L1, software Temperature IGBT L1 > 90 °C, ventilation

ok?



ok?



ok?

18 Temperature, ambient Ambient temperature > 50 °C

21 Temperature, control card Ambient temperature > 50 °C

Overvoltage

31 Overcurrent inverter phase L1, HW driver Excessive phase current

32 Overcurrent inverter phase L1, HW control

card

Excessive phase current

33 Overcurrent inverter phase L1, software Phase current L1 > 400 A

34 Overcurrent phase L1, software Grid current L1 > 180 A



card


Faults







card




43 Overcurrent I_DC, HW control card IDC too high

44 Overcurrent I_DC, software IDC > 280 A

45 Unsymmetric inverter currents

Overvoltage

70 Overvoltage grid phase L1, stage 5 Grid voltage > 110 % or setting error



81 Overvoltage DC link, HW control card DC voltage > 900 V or setting error

82 Overvoltage DC link, software DC voltage > 900 V or setting error

Undervoltage

120 Undervoltage grid phase L1, stage 5 Grid voltage < 90 %



Power switch

Check whether the power switches are switched on: AC power switch Q2, DC switch disconnector Q1.

151 Q1 tripped - DC switch disconnector Q1 in “tripped”

position.

- Is the emergency stop switch unlocked?

152 Q2 tripped AC switch disconnector Q2 in “tripped”

position

155 K1 tripped AC switch disconnector in “tripped” position

Faults



Hardware

Hardware faults indicate damage.

Contact the authorized service staff.

161 Inverter phase L1 Change the IGBT driver



164 Error_X103 Check the cable to the IDC sensor

166 Short-circuit DC link

167 Insulation error Problem with the insulation of the solar field

relative to PE (ground error)

168 Overvoltage protection

Grid

171 Grid rotation Check whether the rotary field is clockwise

(L1, L2, L3)

174 Grid frequency Check the grid frequency

Software

An internal error counter outputs a "Service Request" as soon as a certain number of errors has occurred. If too

many errors have occurred, the HSI500 / HSI640 / HSI1000 / HSI1250 switches to "Stop" mode

(Errorcounter overrun).

Contact the authorized service staff.

181 Wrong system parameters

183 Error counter overrun (x errors/hour)

184 User switched off inverter via display or

Ethernet

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ct

blo

ck M

CB

H-0

2-S

11

500

13

0

Insu

lation

teste

rF

AC

3X

/900

/C-A

81

540

00

9

Au

xili

ary

con

tact

Au

xili

ary

sw

itch

blo

ck C

EL

18

-10

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15

00

00

6

Re

lay

PL

C-R

SP

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0U

C/2

1-2

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U-K

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15

20

00

1

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we

r su

pp

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35

80

00

2

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rfa

ce

rela

yP

LC

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1-2

1-K

11A

15

20

01

0

Th

erm

osta

tT

yp

e F

ZK

+5

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60?

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11

550

00

2

Th

erm

osta

tT

yp

e F

ZK

-2

0...+

30?

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31

550

00

3

Fa

n-M

11

650

00

4

Cir

cu

it B

rea

ke

rS

201

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72

510

04

7

Ope

ratin

g M

anua

l H

SI5

00 / H

SI6

40 /

HS

I100

0 / H

SI1

250

66

App

en

dix

Ite

mT

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eL

oca

tio

nQ

ua

nti

tyH

elio

s ite

m n

um

be

r

Cir

cu

it B

rea

ke

rS

201

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5,

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11

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13

95

10

01

1

Inte

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ce

rela

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15

20

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0 V

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11

640

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Hold

er

CH

M2

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15

00

03

3

44

0m

A D

C f

use

100

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se

10

x3

82

500

03

2

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se

Hold

er

CH

M3

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1A

15

00

02

5

44

0m

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C f

use

100

0V

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0m

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se

10

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83

500

03

2

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sta

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FR

012

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21

550

00

4

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ratin

g M

anua

l H

SI5

00 / H

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40 /

HS

I100

0 / H

SI1

250

67

App

en

dix

12.2

S

pa

re p

art

s l

ist

for

the

HS

I100

0 / H

SI1

250

co

ntr

ol c

ab

ine

t

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mT

yp

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oca

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um

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r

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ol ca

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ith

out

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r pla

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12

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1

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pla

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32

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24

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40

00

6

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32

110

00

3

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top

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NC

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TO

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PM

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11

500

00

8

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nta

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lock

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blo

ck M

CB

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11

500

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0

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lation

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00

9

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18

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00

00

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lay

PL

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SP

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25

20

00

1

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we

r su

pp

lyT

RIO

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35

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00

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550

00

2

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31

550

00

3

Fa

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11

650

00

4

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cu

it B

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ke

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73

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7

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13

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15

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00

0 V

A-T

11

640

01

1

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ratin

g M

anua

l H

SI5

00 / H

SI6

40 /

HS

I100

0 / H

SI1

250

68

App

en

dix

Ite

mT

yp

eL

oca

tio

nQ

ua

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tyH

elio

s ite

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um

be

r

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se

Hold

er

CH

M2

D-F

12A

, -F

12

B2

500

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3

44

0m

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100

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10

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84

500

03

2

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se

Hold

er

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M3

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1A

, -F

1B

25

00

02

5

44

0m

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C f

use

100

0V

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0m

A fu

se

10

x3

86

500

03

2

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sta

tM

FR

012

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21

550

00

4

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ratin

g M

anua

l H

SI5

00 / H

SI6

40 /

HS

I100

0 / H

SI1

250

69

App

en

dix

12.3

S

pa

re p

art

s l

ist

for

the

in

ve

rter

cab

ine

t

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yp

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oca

tio

nQ

ua

nti

tyH

elio

s ite

m n

um

be

r

Ra

dia

l fa

nR

3G

310

-AN

43

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/-M

1B

26

50

00

9

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cu

it b

reaker

T7D

16

00

M-Q

11

510

06

7

Gea

r m

oto

rT

7 G

ea

r M

oto

r 23

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1

Un

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rea

ke

r2

30

VA

C-Q

11

Clo

sin

g r

ele

ase

SC

R 2

30

VA

C-Q

11

Au

xili

ary

con

tact

T7 a

uxili

ary

co

nta

ct

On

/Off

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1

Co

nta

cto

rC

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cto

r A

F 1

65

0-3

0-2

2 1

00

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AC

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15

20

03

2

Fu

se

ho

lde

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r D

C f

uses

Me

tal is

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tor

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15

00

02

5

44

0m

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C f

use

100

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se

10

x3

8-F

22

500

03

2

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r fo

r D

C f

uses

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2 2

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le-F

11

500

12

9

44

0m

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C f

use

100

0V

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0m

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se

10

x3

8-F

12

500

03

2

DC

- E

MC

in

pu

t filter

2-c

ond

ucto

r E

CM

filt

er

16

00A

760

V

440

V

-C1

16

70

00

5

Ca

pacito

r 0.4

7µ

F 1

20

0V

DC

PM

B 2

12

347

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SP

C7

0..C

96

27

220

00

3

Se

mix

IG

BT

Se

mix

553

GB

128

Ds

-V1

1…

-V3

92

76

10

00

1

SE

MIX

ad

ap

ter

3 p

ole

500

kW

V0.2

Pa

rt N

o. 0

16

A1

1…

A3

39

120

00

6

SE

MIX

accum

ula

tor

3 p

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50

0kW

Pa

rt N

o. 0

20

-A1

4…

-A3

43

120

00

7

Se

mix

drive

r V

05

4S

em

ix d

rive

r V

05

4-A

15…

-A3

53

120

00

2

Ope

ratin

g M

anua

l H

SI5

00 / H

SI6

40 /

HS

I100

0 / H

SI1

250

70

App

en

dix

Ite

mT

yp

eL

oca

tio

nQ

ua

nti

tyH

elio

s ite

m N

o.

Cu

rre

nt

co

nve

rte

rC

urr

en

t co

nvert

er

20

00

A E

S20

00

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…-T

12

45

30

00

5

3-p

ha

se

3-c

urr

en

t th

rott

le3

x0

,15

mH

107

0A

-L1

16

40

01

6

Po

we

r ca

pa

citor

MK

P 3

x5

5,7

µF

-C2

16

60

01

4

Dis

ch

arg

e m

od

ule

3x3

00

KO

hm

/ U

ma

x=

760

V-C

21

660

01

3

OV

ER

VO

LT

AG

E D

IVE

RT

ER

DG

100

0 F

M-F

4…

-F6

35

70

00

8

Dis

co

nn

ecto

rX

LP

00

-F3

15

00

05

6

Fu

se

in

se

rt 4

0A

6

90

VS

z.0

00

-F3

35

00

06

7

Po

we

r re

sis

tor

24

0W

0.2

Oh

m 1

0%

RN

O 2

9.1

65

-R1

…-R

66

660

00

9

Re

sis

tor

RB

50/6

33

kO

hm

1%

R1

0…

-R27

18

660

00

1

Bu

sb

ar

CD

E4

25

P1

93

50

01

9

Ca

pacito

r F

XR

3.0

00

µF

50

0V

64

x1

55

54

660

01

2

Fa

n-M

3…

-M8

66

50

00

8

Th

erm

osta

tT

yp

e F

ZK

0-6

0°C

-BT

11

550

00

2

Hygro

sta

tM

FR

012

-BT

21

550

00

4

Appendix


operation manual hsi500 hsi640 hs1000 hsi1250 v31 eng

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