OPERATING INSTRUCTIONS TKS-CS Compact Station for Connecting the Solar Inverter to Medium Voltage 8000031355 EN AEG Power Solutions GmbH, Warstein-Belecke Department: PS AE Revision: 01 Revision date: 15/10/2012 / Hagelstein Released: 15/10/2012 / Songur Document no.
Compact Station TKS-CS - Operating Instructions Revision Service Status Revision 00 01 Page 2 of 39 Corrections (pages 6, 15, 21) 8000043213 BAL Date Name 07/08/2012 Hagelstein 15/10/2012 Hagelstein
Compact Station TKS-CS - Operating Instructions Table of Contents 1 1.1 1.2 1.3 General Information .................................................... 6 Validity .......................................................................... 6 Appropriate Use ............................................................ 6 List of Abbreviations ...................................................... 6 2 2.1 2.2 Safety ...........................................................................
Compact Station TKS-CS - Operating Instructions 10.3 10.3.1 10.3.2 10.3.2.1 10.3.2.2 10.4 10.5 Repairs........................................................................ 31 Testing after Repairs ................................................... 31 Replacement Work ...................................................... 31 Replacing the Transformer .......................................... 31 Replacing the MV Switchgear ..................................... 33 Maintenance Schedule ..................
Compact Station TKS-CS - Operating Instructions AEG Power Solutions GmbH Emil-Siepmann-Strasse 32 59581 Warstein Germany Fax: +49 2902 763 100 +49 2902 763 645 E-mail: service.aegpss@aegps.com Internet: http://www.aegps.
Compact Station TKS-CS - Operating Instructions 1 General Information 1.1 Validity These instructions relate to the technical specifications of the equipment at the time of publication. These instructions are a component part of the system. Legal claims arising from this contractual relationship shall only be recognised by AEG Power Solutions GmbH subject to the terms agreed under the warranty obligation in the main contract. 1.
Compact Station TKS-CS - Operating Instructions 2 Safety The qualified skilled personnel are responsible for safety. The member of personnel who is responsible for the equipment must ensure that only suitably qualified persons are allowed access to the equipment. To ensure safety in the electrical operating areas, these areas should be lockable; i.e. suitable locking systems should be installed by the owner on all exterior doors of the compact station. 2.
Compact Station TKS-CS - Operating Instructions 3 Scope of Delivery Check that the following components have been delivered with the equipment: • 1x compact station TKS-CS inc.
Compact Station TKS-CS - Operating Instructions 4 Equipment Specifications 4.1 Structure The compact station TKS-CS consists of a metal housing with a detachable roof structure and a concrete base. The concrete base comprises a warp-resistant foundation with an oil and water-tight trough in the transformer compartment. 1 4 2 5 6 3 7 8 9 Figure 1 - Compact station TKS-CS 1 Transformer compartment 2 Roof structure 3 ISO small distribution box, PV.
Compact Station TKS-CS - Operating Instructions 4.2 Dimensions Figure 2 - Compact station side views Dimension [mm] Height of metal housing with roof 1686.5 Height of concrete base 780 MH depth (roof) 1750 (1804) MH width (roof) 2900 (2954) Table 1 - Dimensions 4.3 Low-Voltage Box 1 2 3 4 5 6 7 Figure 3 - Low-voltage box (example) 1 2 3 4 Page 10 of 39 Central earthing system Communications cabinet PV.
Compact Station TKS-CS - Operating Instructions The low-voltage box must remain closed during operation. 4.3.
Compact Station TKS-CS - Operating Instructions 4.3.2 ISO Small Distribution Box 1 2 5 6 3 5 4 7 8 Figure 5 - ISO small distribution box (example) 1 Cable duct (internal) 2 -F20 - FI switch 25 A 3 F21 - 27 miniature circuit breakers 4 -4Q0 - motor protection switch Fan 5 -3Q0 - motor protection switch Auxiliary transformer 6 -F0 - fuse max. 20 A Sub-distribution 7 -F1 - fuses max.
Compact Station TKS-CS - Operating Instructions 4.3.3 Communications Cabinet PV LoG-MH 1 5 2 6 7 3 8 3 9 4 Figure 6 - PV.LoG-MH (example) 1 2 3 4 Data logger Fuses UPS 24 V DC Short-circuit and overvoltage protection 5 6 7 8 9 Ethernet coupler Data acquisition boards CAN overvoltage protection Terminal strip Shield terminals The compact station TKS-CS features the PV.LoG-MH and a variety of interfaces for monitoring and control. Data exchange between the PV.
Compact Station TKS-CS - Operating Instructions No. H07V-K 2 [mm ] Name 1 70 Low-voltage box 2 95 Cable entry 3 70 4 16 Station housing Sub-distribution 5 16 Communications cabinet PV.LoG-MH 6 70 Medium-voltage system 7 70 Transformer Table 3 - Potential equalising strip The central earthing system is preinstalled on the potential equalising strip in the compact station. 4.
Compact Station TKS-CS - Operating Instructions 4.5 Transformer 1 2 7 8 3 4 5 4 6 2 Figure 9 - Transformer (example) 1 Temperature sensor/indication 2 Earth terminal 3 MV porcelain isolator 4 MV connection to MV system 5 6 7 8 LV connection to LV box Oil fill level valve Transport securing device Cooling fins All internal connections to and from the transformer are preinstalled in the compact station. The transformer is on vibration dampers and is secured for transport.
Compact Station TKS-CS - Operating Instructions 5 Functional Description PV.IcX PV.SuN max. 1 to 8 optional TKS-CS.1000 PV.LoG-MH PV.IcX Transformer TransformerMonitoring max. 1 to 8 PV.500-MH = ~ PV.500-MH = PV.IcX PV.SuN max. 1 to 8 optional Transfer station ~ Radio and ripple control / power utility interface TKS-CS.500 Energy meter Switchgear PV.ControL PV.LoG-MH TransformerMonitoring Transformer Internet connection CAN bus, max. 2 x 500 m FO, ring max.
Compact Station TKS-CS - Operating Instructions 6. Transport DANGER Suspended loads during transport Possibility of death or crushing. Select lifting gear according to the total weight to be transported. Do not step under suspended loads. Secure the danger zone. Wear personal protective equipment. Figure 11 - Crane transport The station may only be lifted using the crane rings on the longitudinal sides.
Compact Station TKS-CS - Operating Instructions 7 Assembly 7.1 Setting in Place The compact station TKS-CS does not need a foundation. The concrete base serves as its foundation. 1 2 3 4 5 2 3 5 Figure 12 - Setting the compact station in place 1 Ground 2 Concrete base 3 Metal housing 4 Transport eyelets 5 Transport rod Using the construction pit pin, create a construction pit on clear ground. The system may only be installed by crane ( Chapter 6 - Transport).
Compact Station TKS-CS - Operating Instructions 7.2 Installation WARNING Hinge side of the door when closing Fingers or hands may be crushed. Do not hold the hinge side of the door. Take care while closing the cabinet door. i 7.2.1 Observe the bending radius of the supply lines. With one bend: bending radius = 10 x diameter of supply line.
Compact Station TKS-CS - Operating Instructions 2. Establish the AC power connections and PE connections using the cable lug in accordance with the circuit diagram, and using the relevant tightening torque. 3. Remove any cable debris and tools from the equipment and replace the protective cover on the connection panel. 7.2.
Compact Station TKS-CS - Operating Instructions 7.2.4 Central Earthing System Connect the active earthing to the potential equalising strip according to the circuit diagram. 7.2.5 Medium-Voltage System 1 2 Figure 15 - Medium-voltage system (example) 1 Cable branch line L1/L2/L3 (left flap), external AC connections 2 Transformer branch line (right flap), internal AC connections from transformer to load interrupter switch The MV system is preinstalled in the compact station.
Compact Station TKS-CS - Operating Instructions 7.2.6 Medium-Voltage Transformer 1 2 3 4 2 5 6 3 4 Figure 16 - Transformer (example) 1 Earth connection Transformer cover 2 LV connection with porcelain isolator 3 MV porcelain isolator 4 MV elbow connector 5 Voltage tap changer 6 Retaining plate with cable clips The oil transformer is preinstalled and wired in the compact station TKS-CS. The LV connections are established in accordance with DIN EN 50386.
Compact Station TKS-CS - Operating Instructions 7.3 Tightening Torques for Screw Connections Mechanical connection Electrical connection Cheese head screw strength category 5.8 Hexagon screw strength category 8.8 Slotted cheese head screw DIN 84 [Nm] [Nm] [Nm] [Nm] M4 1.2 1.3 2.0 1.2 M5 2.0 2.65 4.0 2.0 M6 3.0 4.4 7.0 2.5 M8 6.0 10.5 17.0 3.5 M10 10.0 - 33.0 4.0 M12 15.5 - 56.0 - M16 30.0 - 140.0 - M20 52.0 - 260.0 - M24 80.0 - 445.
Compact Station TKS-CS - Operating Instructions 8 Start-up DANGER Working with voltages up to 1 kV Risk to life due to electric shock. Comply with BGV A3, DIN VDE 0105-100 (EN 50110, IEC 61243). Skilled personnel with a Working with Live Current certificate. Special AEG Power Solutions software and hardware tools must be used for initial start-up. Only skilled personnel trained by AEG PS are in a position to use these tools correctly and to perform initial start-up.
Compact Station TKS-CS - Operating Instructions 10 Servicing DANGER Contact with voltage Risk to life due to electric shock. Press emergency off. Move the victim away from live parts using dry insulating material. Get medical help and inform the control room. Disconnect the equipment safely. DANGER Working with voltages up to 1 kV Risk to life due to electric shock. Comply with BGV A3, DIN VDE 0105-100 (EN 50110, IEC 61243). Skilled personnel with a Working with Live Current certificate.
Compact Station TKS-CS - Operating Instructions ATTENTION Insufficient ventilation of equipment Equipment may overheat. Keep air vents clear. Ensure the equipment is sufficiently ventilated. WARNING Heat generation in resistors Risk of burning. Do not touch hot components. WARNING Hinge side of the door when closing Fingers or hands may be crushed. Do not hold the hinge side of the door. Take care while closing the cabinet door.
Compact Station TKS-CS - Operating Instructions The owner is responsible for correct servicing of the systems and the equipment. This also applies to system components that fall within the responsibility of the grid operator. In order to ensure uninterrupted availability of the equipment, preventive servicing work should be carried out based on the maintenance schedule. Regular maintenance reduces the risk of breakdowns and disruption due to technical faults.
Compact Station TKS-CS - Operating Instructions A correct test report, completed in full, is important for technicians as evidence of exoneration in case of later complaints or for investigations in case of damage. For this reason, test reports should be retained for a long time (around 10 years). 10.2 Maintenance and Inspection 10.2.1 Visual Inspection Visual inspections should be carried out in accordance with DIN EN 13018.
Compact Station TKS-CS - Operating Instructions The log for dry-cleaning low-voltage installations using a vacuum cleaner must be completed before and after cleaning work. Circuit and installation markings should be noted before cleaning, so that if a marking is damaged or falls off, this can be rectified. 10.2.3 Functional Test i Always perform a functional test after completing any servicing work and before starting operation.
Compact Station TKS-CS - Operating Instructions BGV A2 requires the owner to perform repeat tests at stipulated times in order to verify that the electrical equipment is in perfect working order. At stipulated times, the owner must check that the fault current, differential current and fault voltage protection devices are functioning properly. Carry out manual insulation testing. 10.2.5 Care 10.2.5.
Compact Station TKS-CS - Operating Instructions 10.3 Repairs Only AEG PS skilled personnel may carry out repairs and modifications on the compact station CS.xx. If you want other personnel to carry out this work, this will need to be authorised by means of written approval from AEG PS. Only original AEG PS spare parts (or spare parts purchased from AEG PS) may be used. 10.3.
Compact Station TKS-CS - Operating Instructions 1 2 3 Figure 19 - Station roof 1 Roof structure 2 Screw connection i 3 Station frame The roof structure weighs around 130 kg. Comply with Directive 90/269/EEC (handling of loads). 3. Open all doors and unscrew the 6 roof structure screw connections. Completely remove the roof structure from the compact station TKS.CS ( roof removal: Bosecker).
Compact Station TKS-CS - Operating Instructions 5. Place a new transformer in the compact station's trough and establish the connections. Finally, replace and align the roof structure, and establish the screw connections ( transformer operating instructions). 10.3.2.2 Replacing the MV Switchgear 1 2 3 4 Figure 21 - Partial top view TKS-CS (example) 1 Transformer compartment 2 Low-voltage box 3 Medium-voltage compartment 4 MV switchgear 1. Disconnect the equipment safely. 2.
Compact Station TKS-CS - Operating Instructions 10.4 Maintenance Schedule The maintenance schedule does not release the owner from his obligation to create his own maintenance and operating instructions for the location and to document them fully as quickly as possible. Maintenance instructions supplied by component manufacturers must be included in the detailed specifications relating to the scope of maintenance work.
Compact Station TKS-CS - Operating Instructions Annually Measuring and monitoring devices must comply with the VDE 0413 standard. Check and calibrate all measuring instruments.
Compact Station TKS-CS - Operating Instructions 11 Decommissioning and Dismantling The compact station TKS-CS can be decommissioned or dismantled for the purposes of changing its location or disposal. Before beginning any work on the equipment, it must be deenergised. For this purpose, the five safety rules of electrical engineering in accordance with DIN VDE 0105 (EN 50110) must be observed: 5 safety rules 1. Disconnect safely. 2. Secure the equipment against being switched back on. 3.
Compact Station TKS-CS - Operating Instructions DANGER Toppling of cargo during transport by industrial trucks Possibility of death or crushing. Lift cargo under its centre of gravity. Secure the cargo and danger zone. Wear personal protective equipment. If necessary, secure the transformer to prevent it slipping. Attach suitable load-carrying equipment to the compact station (using the transport eyelets on the concrete base). Lift the equipment carefully and remove cables. 11.
Compact Station TKS-CS - Operating Instructions Do not dispose of old batteries with refuse. They contain environmentally harmful materials (Hg, Cd or Pb). Ensure compliance with local legislation and regulations governing the storage, handling and disposal of batteries. Components such as plastics and insulating materials should be disposed of as industrial waste and should be recycled.
Compact Station TKS-CS - Operating Instructions List of Tables Table 1 - Dimensions ............................................................................... 10 Table 2 - Fuses ........................................................................................ 12 Table 3 - Potential equalising strip .......................................................... 14 Table 4 - LV box connections .................................................................. 19 Table 5 - Tightening torques .........