Manual Stations

Transcript

meteocontrol stations Operating manual Version 20160105 Copyright Copyright for this manual remains with the manufacturer. No part of this manual may be reproduced or edited, duplicated or distributed using electronic systems without written permission from meteocontrol GmbH. Compensation shall be payable in the event of any copyright infringements. All brand names mentioned in this manual are the property of their respective manufacturers and are hereby acknowledged. Contact data The manufacturer of the device described in this documentation is: meteocontrol GmbH Spicherer Str. 48 D-86157 Augsburg Tel.: +49 (0) 821 / 3 46 66-0 Web: www.meteocontrol.de Technical support: Tel.: +49 (0) 821 / 3 46 66-88 Fax: +49 (0) 821 / 3 46 66-11 E-mail: [email protected] Details regarding the manual The original operating manual is written in German. All other language versions are translations of the original operating manual and are hereby identified as such. © 2016 meteocontrol GmbH All rights reserved. All information in this operating manual has been compiled and checked with the greatest care and diligence. Nevertheless, the possibility of errors cannot be entirely excluded. meteocontrol GmbH therefore cannot accept any liability for errors or any circumstances resulting from errors. Subject to technical alterations. meteocontrol stations Contents 1. General notes ..............................................................................................................3 1.1 Safety instructions ............................................................................................... 3 1.2 Warning symbols ................................................................................................. 3 1.3 Additional information .......................................................................................... 3 1.4 Text display .......................................................................................................... 4 2. Advice on using the operating manual ..........................................................................5 2.1 Warranty and liability ............................................................................................ 6 2.2 Additional documentation ..................................................................................... 6 3. Product description ......................................................................................................7 3.1 Power Control Station Outdoor/Indoor ................................................................. 7 3.2 Power Control Station Compact ........................................................................... 8 3.3 Data Station Outdoor/Indoor................................................................................. 9 4. Transportation .............................................................................................................9 5. Safety instructions ..................................................................................................... 11 5.1 Intended use ...................................................................................................... 11 5.2 Personnel ........................................................................................................... 11 5.3 General precautionary measures ........................................................................ 12 5.4 Safety instructions for individual station components......................................... 12 5.4.1 Power supply units QUINT-PS/ 1AC/24DC/20 and QUINT-PS/ 1AC/24DC/10 ..... 13 5.4.2 QUINT-UPS/ 24DC/24DC/5 DC/DC converter ..................................................... 14 5.4.3 UPS-Bat/VRLA/24DC/x.xAH power storage ........................................................ 15 5.4.4 WEB’log ............................................................................................................. 17 5.4.5 Ethernet patch panel with RJ45 socket-socket connection ................................ 17 5.4.6 FR-104-C control cabinet cooling unit (only Outdoor Stations) ............................ 18 5.4.7 KTRRN-267.014 standard rail climate control unit (only Outdoor Stations) .......... 19 5.4.8 UMG604 E power quality analyser (only Power Control Stations)....................... 20 5.4.9 PCU+ (only Power Control Stations)................................................................... 21 6. Mounting and installation ........................................................................................... 22 6.1 Safety instructions for installation....................................................................... 22 6.2 Work flow for installation and commissioning .................................................... 23 6.3 Mounting the station .......................................................................................... 24 6.3.1 Power Control Station and Data Station Outdoor/Indoor .................................... 24 6.3.2 Power Control Station Compact ......................................................................... 25 6.3.3 Special Model Station......................................................................................... 25 6.3.4 Routing the network cable into the station ......................................................... 26 6.4 Cables and wiring ............................................................................................... 27 6.4.1 Cable types ........................................................................................................ 27 6.4.2 Maximum permissible cable lengths: ................................................................. 27 6.4.3 Shielding ............................................................................................................ 27 6.4.4 Terminals ........................................................................................................... 27 7. Commissioning.......................................................................................................... 28 7.1.1 Terminal assignment .......................................................................................... 29 8. Care and maintenance ............................................................................................... 32 8.1 Cleaning the control cabinet cooling unit (only Outdoor)..................................... 32 meteocontrol stations 1| 44 9. Technical data ........................................................................................................... 33 9.1 Conductor connection ........................................................................................ 33 9.1.1 Power Control Station Outdoor/Indoor ............................................................... 33 9.1.2 Power Control Station Compact ......................................................................... 34 9.1.3 Data Station Outdoor/Indoor .............................................................................. 34 9.1.4 Special Model Station ........................................................................................ 34 9.2 Widths of cable screw connections ................................................................... 34 10. Environmental protection and disposal ....................................................................... 35 11. Appendix .................................................................................................................. 36 11.1 Scale drawings................................................................................................... 36 11.1.1 Power Control Station Outdoor .......................................................................... 36 11.1.2 Power Control Station Indoor ............................................................................. 36 11.1.3 Power Control Station Compact ......................................................................... 37 11.1.4 Data Station Outdoor ......................................................................................... 37 11.1.5 Data Station Indoor ............................................................................................ 38 11.1.6 Special Model Station ........................................................................................ 38 11.2 CE certificates ................................................................................................... 39 11.3 RoHS Statement ................................................................................................ 40 11.4 List of figures ..................................................................................................... 41 2| 44 meteocontrol stations 1. General notes 1.1 Safety instructions Safety instructions warn of dangers when using the devices and explain how they can be avoided. The safety instructions are classified according to the severity of the risk and are subdivided into four groups: DANGER Imminent danger Failure to comply with the warning notice will lead to an imminent risk of death or serious physical injury! – WARNING Possible danger – Failure to comply with the warning notice may lead to a risk of death or serious physical injury! CAUTION Hazard with a risk of material damage – Failure to comply with the warning notice may lead to minor injuries! ATTENTION Hazard with a risk of material damage – Failure to comply with the warning notice will lead to material damage! 1.2 Warning symbols Particular dangers are highlighted using warning symbols. RISK OF ELECTRIC SHOCK Electric shock hazard! Danger to life and limb! – Failure to comply with the warning notice will lead to an imminent risk of serious injury or death. 1.3 Additional information This symbol can be found next to notes, additional information and tips. meteocontrol stations 3| 44 1.4 Text display Emphasised points are shown in bold and indicate important information. Lists are shown with bullet points (level 1) and dashes (level 2):   List 1 - Point A - Point B List 2 Instructions describe steps which are to be carried out in the given order. 1. Instruction 1 2. Instruction 2  Result of the operation Button names are shown in capitals and in "QUOTATION MARKS". In figures, item numbers are used to indicate components. The legend including item numbers and descriptions of the components is shown below the figure. Alternatively, direct references to components are made in the text. 4| 44 meteocontrol stations 2. Advice on using the operating manual This description is a key aid when it comes to ensuring proper operation of meteocontrol stations. It contains important information and safety notes to help you use the devices correctly, economically and in the intended manner. This operating manual helps to avoid dangers, to reduce repair costs and downtimes, and to increase the reliability and operating life of the stations and the built-in components. This manual is intended for persons who are responsible for planning the installation of, installing, starting up, operating, and maintaining the stations. Read this operating manual carefully and attentively before you start work on the stations. It is assumed that the reader has basic knowledge of electrical engineering, cabling, electrical components and the use of symbols in circuit diagrams. DANGER Danger through improper handling - - The staff responsible for the installation, operation and maintenance of the system must have read and understood this operating manual before the stations can be used safely! If necessary, the description and documents must be available at all times. meteocontrol GmbH accepts no liability for personal injury, damage to property, or system malfunctions and their consequences, insofar as these result from nonobservance of this operating manual. The manual is continually updated. The most up-to-date version of this description can be found on our Internet site. www.meteocontrol.de meteocontrol stations 5| 44 2.1 Warranty and liability Details of the scope and form of the warranty as well as the warranty period are given in the meteocontrol GmbH General Terms and Conditions. meteocontrol rejects any liability for damage arising from the non-observance of the operating manual. This applies, in particular, for damage from:  Unintended use  Faulty operation  Wrongly chosen materials and tools  Faulty or non-executed maintenance and repairs With Power Control, meteocontrol GmbH accepts no liability for events and occurrences outside of its control, such as: 2.2  the correctness of control commands given by an energy supply company or failure to implement control commands that have been passed on  hardware and/or software faults on the part of the system operator  switching processes at the end consumer.  Any liability for damage caused by such events and occurrences, such as lost profits, grid instability, damage to parts of the customer's system, for instance of an inverter, shall remain expressly excluded. Additional documentation Observance of the information contained in this operating manual does not release from also pay attention to technical documentation regarding the component parts of the stations! Please read any documentation supplied with the station relating to installed components. Please also adhere to documentation relating to the inverter and the sensors connected to the station. The enclosed circuit diagram and operating manual of WEB’log and PCU+ are instrumental for connection of external devices as well as setup of the station itself. 6| 44 meteocontrol stations 3. Product description 3.1 Power Control Station Outdoor/Indoor The measurement control cabinet for implementation of the grid feed-in management system in PV power plants, for indoor and outdoor use. These stations are used as an interface between network operators and the PV system. Actual product may vary Fig. 1: Power Control Station Overview of components in standard configuration  QUINT-PS/1AC/24DC/20 Phoenix power supply unit  QUINT-UPS/24DC/24DC/5 Phoenix UPS  UPS-Bat/VRLA/24DC/7.2AH Phoenix power storage  5-port Ethernet switch - NS205  WEB’log Pro Unlimited Ethernet (optional)  PCU+ (optional)  UMG 604 24V power quality analyser (optional)  Phoenix patch panel  alre KTRRN-267.014 climate controller (only Outdoor Stations)  DR.NEUMANN FR-104C control cabinet cooling unit (only Outdoor Stations)  ABB automatic circuit breakers  Phoenix relays  Phoenix measuring transducer disconnect terminal blocks meteocontrol stations 7| 44 3.2 Power Control Station Compact The compact measurement control cabinet for implementation of grid feed-in management system in PV power plants, for indoor and outdoor use. These stations are used as an interface between network operators and the PV system. Actual product may vary Fig. 2: Power Control Station Compact Overview of components in standard configuration 8| 44  QUINT-PS/1AC/24DC/10 Phoenix power supply unit  QUINT-UPS/24DC/24DC/5 Phoenix UPS  UPS-Bat/VRLA/24DC/3.4AH Phoenix power storage  5-port Ethernet switch - NS205  WEB’log Pro Unlimited Ethernet (optional)  PCU+ (optional)  UMG 604 24V power quality analyser (optional)  ABB automatic circuit breakers  Phoenix relays  Phoenix measuring transducer disconnect terminal blocks meteocontrol stations 3.3 Data Station Outdoor/Indoor The measurement control cabinet as centralised hub for data logging and processing for all system data of the PV power plant for outdoor and indoor use. These stations are used for centralized data acquisition and communication with safer'Sun Professional or VCOM. Actual product may vary Fig. 3: Data Station Overview of components in standard configuration 4.  QUINT-PS/1AC/24DC/20 Phoenix power supply unit  QUINT-UPS/24DC/24DC/5 Phoenix UPS  UPS-Bat/VRLA/24DC/7.2AH Phoenix power storage  5-port Ethernet switch - NS205  WEB’log Pro Unlimited Ethernet (optional)  Phoenix patch panel  alre KTRRN-267.014 climate controller (only Outdoor Stations)  DR.NEUMANN FR-104C control cabinet cooling unit (only Outdoor Stations)  ABB automatic circuit breakers  Phoenix relays Transportation Every product leaves our factory in perfect electrical and mechanical condition. On delivery, unpack the station and all accessories and check them for any damage. WARNING A damaged station must not be put into operation! Transport the station using a forklift truck or pallet lift truck - using a crane can lead to damage to the station. Transporting the station upright can lead to damage to the cable feedthroughs. It is also prohibited to transport the station on the front panel. During transport, ensure the station is sufficiently secured in place in order to prevent overturning or movement. Do not encumber the station. meteocontrol stations 9| 44 The following images show possible options for transport of the station. Fig. 4: Transportation lying on the side Fig. 5: Transportation lying on the rear panel Fig. 6: Transportation without a pallet Fig. 7: Do not transport via crane Fig. 8: Do not transport upright Fig. 9: Do not transport on the front plate ATTENTION Do not transport Outdoor Stations lying on the cooling unit – Never transport Outdoor Stations lying on the cooling unit! This can damage the cooling unit. 10| 44 meteocontrol stations 5. Safety instructions During installation, operation and maintenance of the station the safety regulations contained in this chapter have to be strictly adhered to. Non-compliance can lead to injuries or fatal accidents and/or damage to the station. Reading these safety regulations before working with the station is mandatory. 5.1 Intended use The connections for stations and modules in use may only subject to the approved signal types and strengths. Indoor Stations may only be installed within interior zones. Outdoor Stations are suitable for both installation in- and outdoors. For specific information about individual stations please note the respective station data sheet. 5.2 Personnel Installation, commissioning and maintenance may only be performed by a qualified electrician. Given their specialist training, knowledge, experience and familiarity with the relevant standards and regulations, a qualified electrician is in a position not only to carry out work on electrical systems but also to recognise and avoid possible dangers unaided. The qualified electrician must comply with the respective occupational health and safety laws in force. Please note in particular:  the national installation and assembly regulations (e.g. VDE in Germany),  the generally accepted codes of practice,  information on transport, installation, operation, service and maintenance and disposal given in this manual,  specific values, limit values and information relating to operating and ambient conditions on type plates and in data sheets. RISK OF ELECTRIC SHOCK Electric shock hazard! Danger to life and limb! – – meteocontrol stations Never work on the station or its input and output cables while the station is still connected to the grid. The station must be disconnected before starting work on the station itself or its components. This applies particularly to the uninterruptible power supply (UPS)! Potential-free wiring in the station also requires particular attention due to possible external power sources! Potential-free wiring can be identified by its bright orange cord. 11| 44 5.3 5.4 General precautionary measures  Read the safety regulations for the operational range and components installed in the station you are working on. Pay attention to the specific manuals of the station components!  Turn off all possible power sources.  All other possible live parts have to be protected against accidental contact.  Special precautionary measures are required when working close to bare conductors.  Check the system for tensionless state. Always take measurements to ensure a de-energised state. Safety instructions for individual station components Different components are installed in the stations depending on the type or model of station, such as power supply units, DC/DC converter, power storage, etc. The following pages provide an overview of safety instructions relating to optional components that may be installed in the station. The safety instructions listed here represent only some of the devices that may be installed in a station and makes no claim to be complete. A complete list of all the components installed in your station can be found in the accompanying circuit diagram of the station. It is imperative that you also pay attention to the documentation relating to the installed components. Observance of the following safety instructions does not release from the obligation of reading the safety regulations and documentation of all devices installed in the station! 12| 44 meteocontrol stations 5.4.1 Power supply units QUINT-PS/ 1AC/24DC/20 and QUINT-PS/ 1AC/24DC/10 The power supply unit is used to supply the station with power. On the output side, 24V DC is provided to supply the components installed in the station and the measuring devices connected to the station. DANGER Risk of explosion The electrical equipment may only be removed if de-energised and not located in a potentially explosive area! – RISK OF ELECTRIC SHOCK Electric shock hazard! Danger to life and limb! The power supply unit contains components with life-threatening voltages and a higher amount of stored energy! Never perform any work as long as voltage is applied! – WARNING Risk of injury – The casing may get very hot depending on ambient temperature and the load of the power supply unit! ATTENTION Hazard with a risk of material damage – An interaction with certain chemical substances could impair the sealing properties of the materials used in the power supply unit's sealed relay ("OUTPUT" connection).  Power supply units may only be installed and commissioned by qualified experts. All relevant country-specific regulations have to be complied with.  All supply lines must be sufficiently protected and dimensioned!  The protective conductor must be connected! meteocontrol stations 13| 44 5.4.2 QUINT-UPS/ 24DC/24DC/5 DC/DC converter The DC/DC converter is part of the station's uninterruptible power supply and is used to control the power storage. This converter provides 24V DC on the output side. DANGER Risk of explosion – The electrical equipment may only be removed if de-energised and not located in a potentially explosive area! RISK OF ELECTRIC SHOCK Electric shock hazard! Danger to life and limb! – The DC/DC converter contains components with life-threatening voltages and a higher amount of stored energy! Never perform any work as long as voltage is applied! WARNING Risk of injury – The casing may get very hot depending on the ambient temperature and the load of the DC/DC converter! 14| 44  The converter may only be installed and commissioned by qualified experts. All relevant country-specific regulations have to be complied with.  All supply lines must be sufficiently protected and dimensioned! meteocontrol stations 5.4.3 UPS-Bat/VRLA/24DC/x.xAH power storage In the event of a mains power failure, the battery modules continue to provide the connected components with power for a certain amount of time. The installed battery modules in the stations are delivered fully charged. The fuses of the battery modules are removed so that only natural self-discharging occurs. The selfdischarge is essentially dependent on the ambient temperature and the capacity of the accumulators. DANGER Risk of explosion – Do not expose the battery to open flames, embers or sparks. RISK OF ELECTRIC SHOCK Electric shock hazard! Danger to life and limb! – The device contains components with lethal voltages and a high amount of stored energy! Never perform any work as long as voltage is applied! – It is imperative to avoid short circuits at the pole terminals! WARNING Risk of injury – The casing may get very hot depending on the ambient temperature and the load of the power storage! ATTENTION Risk of damage to the battery modules To prevent an irreversible deep discharge of the battery modules, the following points must be observed: – The battery modules must not be exposed to extreme heat or extreme cold! – The battery modules must not be left for a long time in a discharged state! If longer power interruptions are planned, it should be ensured that the battery modules are fully charged and could not switch to UPS mode! The UPS mode can be prevented by removing the internal fuses. During the power interruption the state of charge of the batteries must be checked at regular intervals, if necessary the accumulators must be recharged. – meteocontrol stations 15| 44  The energy storage may only be installed and commissioned by qualified experts. All relevant country-specific regulations have to be complied with.  All supply lines must be sufficiently protected and dimensioned!  The protective conductor must be connected!  The battery modules may not be opened. The devices are protected electrically by an internal fuse. The rechargeable batteries can age differently, depending on the use of it. As a result, the backup time may be reduced in case of a power failure. To ensure full backup time a replacement of the batteries will be recommended at the appropriate time. 16| 44 meteocontrol stations 5.4.4 WEB’log The WEB’log records the data from inverters, energy meters and sensors and stores it centrally. The values from the WEB’log are transferred directly to the meteocontrol servers via a communication interface. Furthermore, in addition to discrete specifications, dynamic specifications on active and reactive power control are also processed and forwarded to the converter. 5.4.5  The memory card (Compact Flash) must not be removed while the WEB'log is in operation  The WEB'log may not be opened  The WEB’log may not be modified  Damaged devices must be taken out of operation immediately and checked by a qualified electrician  Local regulations must be observed when using the devices  The safety of the WEB'log and the user cannot be guaranteed if the safety precautions described are violated Ethernet patch panel with RJ45 socket-socket connection The Ethernet patch panel is the interface between the field cabling and the network inside the control cabinet. The connection between the patch panel and the end devices is ensured by a pre-assembled patch cable via the RJ45 sockets (CAT5e).  Only qualified experts may install, commission, and operate the device. Occupational health and safety regulations have to be complied with.  Only shielded twisted pair cables and adequately shielded RJ-45 plugs may be connected to the Ethernet interfaces. meteocontrol stations 17| 44 5.4.6 FR-104-C control cabinet cooling unit (only Outdoor Stations) The control cabinet cooling unit is used for climate control within the station to avoid critical temperatures. The control cabinet can be both heated and cooled by using the Peltier technology implemented in the cooling unit.  Assembly and installation of the control cabinet cooling unit may only be done by an electrician possessing the permit according to the Handicrafts Regulation Act (Appendix A, no. 25) and in compliance with all relevant regulations and laws.  During assembly of the cooling unit, it is imperative to comply with all requirements and regulations relating to safety and electromagnetic compatibility. For use in computerised systems, additional requirements and regulations for telecommunication terminals apply.  Before assembly, the responsible electrician has to ensure all devices and live parts in the immediate environment are disconnected from the power supply. During thunderstorm, the cooling unit may not be mounted or connected.  Fan guards and/or cover of the control cabinet cooling unit may never be removed during operation! Operation without fan guards and/or a cover is prohibited! WARNING Risk of injury – The exterior of the control cabinet cooling unit may get very hot, the inside very cold (and vice versa when heating). Touching the cooling unit during operation and up to approx. 30 minutes after deactivation should be avoided at all costs, unless suitable protective clothing (insulating gloves) is worn. When the heat exchange temperature reaches 90°C (±5°C), the control cabinet cooling unit switches off completely. Before the temperature-dependent safeguard is triggered, an alarm switch closes at a heat exchanger temperature of 80°C (±5°C) (this is detected by the WEB’log). 18| 44 meteocontrol stations In the event of an emergency, you must disconnect the control cabinet cooling unit immediately from the power supply and please notify your electrician. Repairs may only be performed by authorised experts. Examples of emergencies:  A non-functioning fan  A missing fan guard  Damage to the casing  Defective connecting terminals  Loose supply line cables  Damage to the supply line insulation  Ingress of fluids  Penetration by foreign objects WARNING Possible danger In the event of emergencies do not continue to operate the control cabinet cooling unit! Otherwise you are risking your safety! – 5.4.7 KTRRN-267.014 standard rail climate control unit (only Outdoor Stations) The KTRRN-267.014 climate control unit is instrumental in air-conditioning the station interior as higher level system to the control cabinet cooling unit.  This device may only be opened by an electrician and must be installed according to the relevant circuit diagram displayed in the housing cover / on the housing / in the operating manual. Any safety regulations contained therein must be complied with. ATTENTION Hazard with a risk of material damage – Operation in the proximity of devices not meeting EMC guidelines can lead to impact to device functionality. The controller operating manual has to be freely accessible to operating and maintenance personnel. meteocontrol stations 19| 44 5.4.8 UMG604 E power quality analyser (only Power Control Stations) The power quality analyser is provided for measurement and calculation of electrical values such as voltage, current, power, energy, harmonics, etc. Measurement voltages and measurement currents have to originate from the same mains supply.  Power supply units may only be installed and commissioned by qualified experts. All relevant country-specific regulations have to be complied with.  All supply lines must be sufficiently protected and dimensioned!  The UMG 604 is not suitable for measuring DC voltage!  The UMG 604 can only calculate measurement values with applied measurement voltage greater than 10Veff on at least one measurement input. RISK OF ELECTRIC SHOCK Electric shock hazard! Danger to life and limb! – Current measurement inputs are dangerous to touch! – Voltage measurement inputs are dangerous to touch! ATTENTION Hazard with a risk of material damage at the measuring inputs – The maximum measurable voltage is 300V AC conductor to earth (520V AC conductor to conductor). The measurement lines for stress measurement have to be suitable for these voltages! – Voltages of over 300V AC to earth must be connected via voltage converters – The secondary connections of current converters must be short-circuited to these before the power supply lines are disconnected from the UMG 604! – The measurement lines must be protected against short circuits using an overcurrent protective device (10A) and routed via circuit breakers Voltages and currents that lie outside the permissible measuring range can destroy the device! – 20| 44 meteocontrol stations 5.4.9 PCU+ (only Power Control Stations) The PCU+ add-on module enables the discrete and dynamic specifications on active and reactive power control to be processed and calculated. The PCU+ receives information from the energy supplier and forwards it to the WEB'log. The PCU+, in conjunction with the WEB'log, controls the grid feed-in of solar energy according to requirements.  The PCU+ may not be opened.  No modifications may be made to the PCU+  Damaged devices must be taken out of operation immediately and checked by a qualified electrician  Local regulations must be observed when using the devices  The safety of the PCU+ and the user cannot be guaranteed if the safety precautions described are violated meteocontrol stations 21| 44 6. Mounting and installation 6.1 Safety instructions for installation DANGER Electric shock hazard! Danger to life and limb! Fatal injuries or death from contact with cables and terminals. - Only connect or disconnect cables while they are de-energized. Take measures to prevent the power cable from being reactivated. CAUTION Hazard with a risk of material damage - Be careful of hot surfaces. Some parts within the control cabinet, such as the power supply cooling unit, remain hot for some time after the power supply has been switched off. - Ensure no drill or abrasive dust can penetrate the control cabinet during installation. Electrically conductive dust inside the device may lead to damage or malfunction. Mounting the cabinet using riveting should be avoided. As far as possible, all cables should be placed directly from below via the supplied cable glands into the station. Not used cable glands must be sealed with plugs. The glands should be tightened with a tool to achieve leakproofness. - - ATTENTION Damage due to improperly connected cables! Improperly connected cables can lead to damage or destruction of the measuring inputs and the device. - Connect cables only to the respectively allocated sockets. - Observe the polarity while connecting cables. ATTENTION Damage due to overvoltage! Overvoltage or voltage peaks may damage or destroy the device. - 22| 44 Protect the power supply against electrical surge. meteocontrol stations ATTENTION Damage due to overvoltage! Voltages of more than 10 V DC and currents of more than 50 mA on the analogue inputs can destroy the respective measuring inputs. - Ensure only voltages of up to 10 V DC are applied and only currents of up to 20 mA flow. Voltages of more than 60 V DC and currents of more than 50 mA on the digital inputs can destroy the respective measuring inputs. - Ensure only voltages of up to 60 V DC are applied and only currents of up to 50 mA flow. 6.2 Work flow for installation and commissioning Unpack and examine the station. Check whether all necessary modules and devices are provided and in perfect condition. Only devices in good condition may be put into operation. Check the station for damages in transit. For further information, please see the chapter regarding Transportation, page 9. Verify correct assembly of the station. For further information, please see the chapter Mounting the station, page 24. Lay the cables. For further information, please see the chapter Cables and wiring, page 27. Connect the power supply. Connect the bus cabling, sensor and network cables. You can find the terminal configuration in the circuit diagram is enclosed with the station. The WEB’log and PCU+ operating manuals are also of avail. Commission the station. For further information, please see chapter Commissioning page 28. meteocontrol stations 23| 44 6.3 Mounting the station The cabinet of the stations is generally suitable for installation in indoor and outdoor areas. The following rules must be observed:  6.3.1 The mounting surface should be horizontal and flat as possible to prevent leakage through warping of the cabinet. Power Control Station and Data Station Outdoor/Indoor Please use the 8-mm-diameter screws to fix the station to the wall. Fasten 4 screws to the wall using the distances stated in the diagram. The position of the mounting plates (above, to the side, below) is freely selectable. (A) 882mm (B) 782mm (C) 982mm (D) 1082mm Fig. 10: Mounting the station CAUTION Hazard with a risk of material damage Screws and dowels (if necessary) have to be right dimensioned so that the weight of the stations can be worn. - - - 24| 44 Outdoor stations shall not be exposed to direct weathering. Cabinets which are mounted on the roof or in open fields must be protected by separate rain roofs from sun and rain. Only mount Outdoor Stations in the shade. Direct sunlight may cause the station components to overheat. Mount Outdoor Stations at a minimum distance of 40 cm from the ground. Otherwise, the build-up of moisture may damage the station components. This does not apply to stations mounted with an earthing base. meteocontrol stations 6.3.2 Power Control Station Compact Please use the 8mm-diameter screws to fix the station to the wall. Fasten 4 screws to the wall using the distances stated in the diagram. The position of the mounting plates (above, to the side, below) is freely selectable. (A) 610mm (B) 527mm (C) 527mm (D) 610mm Fig. 11: Mounting the compact station CAUTION Hazard with a risk of material damage Screws and dowels (if necessary) have to be right dimensioned so that the weight of the stations can be worn. 6.3.3 Special Model Station The dimensions of Special Model Stations may deviate from the dimensions of the standard stations depending on the control cabinet used. Please consult the documentation of the relevant control cabinet for mounting instructions. meteocontrol stations 25| 44 6.3.4 Routing the network cable into the station Two KVT cable screw connections are used in the control cabinet to install a network cable in the station. To lay the network cable, the screw connections must first be removed from the switch cabinet. The screw nut and O-ring must be removed from the couplings. Afterwards the screw connection can be pressed apart using a screwdriver. Fig. 12: Open screw connection Once the blind plug has been removed from the cable seal, the seal can be placed around the network cable. During positioning of the seal, the required length for the network cable within the station has to be taken into consideration. The screw connection can now be reassembled and installed in the control cabinet. Fig. 13: Network cable seal ATTENTION Hazard with a risk of material damage – It is essential to keep the sealing plug within unused screw connections. 26| 44 meteocontrol stations 6.4 Cables and wiring 6.4.1 Cable types  Li2YCYv (TP) 2×2×0.5mm2 1) CAT 6  Sensors (irradiance sensor, temperature sensor) Sensor cable: LiYCY 2×2×0.5mm2  Meter (energy meter) Telephone cable: J-Y(ST)Y 2×0.6mm2 Ethernet network Network cable: CAT 5e / CAT 6  6.4.2 Bus cabling (inverters, current sensors) RS485, RS422 data cable, twisted and shielded: Network cable for bus: Maximum permissible cable lengths: 1)  Bus cabling (data cable RS485) 1200m 2) 3)  Sensor (voltage signal 0V – 10V) 100m  Sensor (current signal 4mA – 20mA) 600m4)  Meter 10m  Ethernet network 100m 3) We recommend using the cable type UNITRONIC® Li2YCYv (TP) manufactured by Lapp Kabel, or an equivalent cable type. This cable is suitable for laying in soil. 2) For longer cable lengths, repeaters must be used. 3) Several, separate cables of this length require a Hub. 4) Power supply of 24 V DC is required. Data cables must be separated of current cables according to EN 50174-2 using metallic cable carrier. 6.4.3 Shielding The cable shielding may only be grounded at one end of the connection. 6.4.4 Terminals For terminal cross-sections and insulation strip lengths, please consult the technical data on page 33. meteocontrol stations 27| 44 7. Commissioning The chapter gives details of the commissioning procedure for the station. RISK OF ELECTRIC SHOCK Electric shock hazard! Danger to life and limb! – During installation and commissioning please follow the safety instructions! See chapter Safety instructions on page 3. The station has to be installed, commissioned and maintained by a qualified electrician only.  Make sure the station is correctly mounted  Check if all cable connections are linked correctly. Also pay attention to the included circuit diagram as well as the WEB’log and PCU+ operating manual  Check whether the temperature for commissioning lies within limit values. For further information note chapter Technical data on page 33  If the station is brought from a cold environment into the operating environment, condensation water can be occurred. Before commissioning the station therefore must be 2 hours to wait until the harmonization with the ambient temperature is finished and the station is absolutely dry. Depending on ambient temperature, Outdoor Stations may be required to run the cooling unit continuously for some time preceding commissioning in order to regulate the internal temperature to the required values.  Switch on the power supply for all components  Wait until the WEB'logs have completed the start-up phase (Power LED glows and Status LED blinks)  The WEB’logs are then configured and operated according to the WEB’log operating manual The WEB’logs installed in the Power Control Station and Data Station are already pre-configured to the circuitry of each station. The assigned IP addresses of the data loggers can be shown on the display of the respective data logger. Alarm inputs, such as a mains power failure or disturbance to the heating/cooling system, are already parameterized. Similarly, status messages, such as battery charging mode active or battery mode active are parameterized. The WEB’logs installed in the Special Model Station are not preconfigured. The configuration must take place on-site during start-up. 28| 44 meteocontrol stations 7.1.1 Terminal assignment Data Station Outdoor Subsequently, the purpose of each terminal of the station is listed. Clamp 1X1 3X1 2X1 16X1 11X1 12X1 13X1 1X6 Function 100 V ... 240 V AC connection of the power supply of the station. Maximum power consumption about 12.3 A at 230 V AC, about 15.7 A at 110 V AC. 24 V DC UPS powered clamps for external devices. A maximum of 3 A is available. 24 V DC clamps for external devices (not powered by UPS). A maximum of 2 A is available. RS485 clamps of the WEB’logs Clamps for analog inputs, digital inputs and the digital output of WEB'log 1. Clamps for analog inputs, digital inputs and the digital output of WEB'log 2. Clamps for analog inputs, digital inputs and the digital output of WEB'log 3. Outlet. A maximum of 10 A is available. Data Station Indoor Subsequently, the purpose of each terminal of the station is listed. Clamp 1X1 3X1 2X1 16X1 11X1 12X1 13X1 1X6 meteocontrol stations Function 100 V ... 240 V AC connection of the power supply of the station. Maximum power consumption about 12.3 A at 230 V AC, about 15.7 A at 110 V AC. 24 V DC UPS powered clamps for external devices. A maximum of 3 A is available. 24 V DC clamps for external devices (not powered by UPS). A maximum of 2 A is available. RS485 clamps of the WEB’logs Clamps for analog inputs, digital inputs and the digital output of WEB'log 1. Clamps for analog inputs, digital inputs and the digital output of WEB'log 2. Clamps for analog inputs, digital inputs and the digital output of WEB'log 3. Outlet. A maximum of 10 A is available. 29| 44 Power Control Station Outdoor Subsequently, the purpose of each terminal of the station is listed. Clamp 1X1 3X1 10X2 10X4 11X2 11X4 2X1 15X1 12X1 13X1 9X1 1X6 Function 100 V ... 240 V AC connection of the power supply of the station. Maximum power consumption about 12.3 A at 230 V AC, about 15.7 A at 110 V AC. 24 V DC UPS powered clamps for external devices. A maximum of 2 A is available. Clamps via converter disconnect terminals for current measurement of the network quality analyzer. Clamps for voltage measurement of the network quality analyzer. Clamps for dic´gital I/O’s of the Power Control Unit + (PCU+). Clamps for analogue inputs and analogue outputs of the Power Control Unit + (PCU+). 24 V DC clamps for external devices (not powered by UPS). A maximum of 2 A is available. RS485 clamps of the WEB’logs Clamps for analog inputs, digital inputs and the digital output of WEB'log 1. Clamps for analog inputs, digital inputs and the digital output of WEB'log 2. 24 V DC base for connecting other components in the cabinet. A maximum of 1 A is available. Outlet. A maximum of 10 A is available. Power Control Station Indoor Subsequently, the purpose of each terminal of the station is listed. Clamp 1X1 3X1 10X2 10X4 11X2 11X4 2X1 15X1 12X1 13X1 9X1 1X6 30| 44 Function 100 V ... 240 V AC connection of the power supply of the station. Maximum power consumption about 12.3 A at 230 V AC, about 15.7 A at 110 V AC. 24 V DC UPS powered clamps for external devices. A maximum of 2 A is available. Clamps via converter disconnect terminals for current measurement of the network quality analyzer. Clamps for voltage measurement of the network quality analyzer. Clamps for dic´gital I/O’s of the Power Control Unit + (PCU+). Clamps for analogue inputs and analogue outputs of the Power Control Unit + (PCU+). 24 V DC clamps for external devices (not powered by UPS). A maximum of 2 A is available. RS485 clamps of the WEB’logs Clamps for analog inputs, digital inputs and the digital output of WEB'log 1. Clamps for analog inputs, digital inputs and the digital output of WEB'log 2. 24 V DC base for connecting other components in the cabinet. A maximum of 1 A is available. Outlet. A maximum of 10 A is available. meteocontrol stations Power Control Station Compact Subsequently, the purpose of each terminal of the station is listed. Clamp 1X1 3X1 7X2 7X4 8X2 8X4 2X1 9X1 10X1 6X1 Function 100 V ... 240 V AC connection of the power supply of the station. Maximum power consumption about 11.2 A at 230 V AC, about 13.1 A at 110 V AC. 24 V DC UPS powered clamps for external devices. A maximum of 2 A is available. Clamps via converter disconnect terminals for current measurement of the network quality analyzer. Clamps for voltage measurement of the network quality analyzer. Clamps for dic´gital I/O’s of the Power Control Unit + (PCU+). Clamps for analogue inputs and analogue outputs of the Power Control Unit + (PCU+). 24 V DC clamps for external devices (not powered by UPS). A maximum of 0.5 A is available. Clamps for analog inputs, digital inputs and the digital output of the WEB'log. RS485 clamps of the WEB’log 24 V DC base for connecting other components in the cabinet. A maximum of 1 A is available. Special Model Station The terminal assignment at the Special Model Station may differ from the terminal assignments of standard stations. Please refer to the wiring diagrams for each station. meteocontrol stations 31| 44 8. Care and maintenance The station requires only little maintenance when installed in an environment according to specification. meteocontrol recommends an annual check of the station to ensure optimal operation. Furthermore, a requalification in accordance with DIN VDE 0105 – "Operation of electrical installations" – has to be carried out. If necessary, the cabinet interior can be cleaned using a soft brush and a vacuum cleaner. For this procedure the safety instructions specified in chapter 5 have to be observed! 8.1 Cleaning the control cabinet cooling unit (only Outdoor) In environments with normal levels of soiling and low levels of dust, the exterior of the control cabinet cooling unit only needs to be cleaned every 6 months. During this process the cooling fins as well as the fan have to be dusted off. When used in rooms with high levels of soiling or dust, this interval must be shortened accordingly. If the control cabinet is not dustproof, the interior of the control cabinet cooling unit also has to be checked for soiling every so often. To clean the control cabinet cooling unit, please proceed as follows: 32| 44  Disconnect the control cabinet cooling unit from the power supply.  Secure the fan in place, for example by placing a pencil between the rotors.  Remove coarse soiling using a paint brush or a brush.  Then clean the fan and the cooling unit using compressed air or water (only on the exterior). Here the fan has to be protected from too high a rotational speed due to compressed air or water, for which the pencil or similar tool is used.  Reconnect the control cabinet cooling unit to the power supply. meteocontrol stations 9. Technical data Station type Dimensions (H x W x D) Temperature range Weight Supply voltage Current consumption Power Control Station Outdoor 1,035mm x 835mm x 300mm -20°C to 55°C 59.4kg 230V / 16A Max. 1.3A Power Control Station Indoor 1,035mm x 835mm x 300mm 0°C to 40°C 56.3kg 230V / 16A Max. 0.87A Power Control Station Compact 600 mm x 600mm x 200mm 0°C to 40°C 25.1kg 230V / 16A Max. 0.87A Data Station Outdoor 1,035mm x 835mm x 300mm -20°C to 55°C 58.5kg 230V / 16A Max. 1.23A Data Station Indoor 1,035mm x 835mm x 300mm 0°C to 40°C 55.4kg 230V / 16A Max. 0.87A (without external. devices) 9.1 Conductor connection 9.1.1 Power Control Station Outdoor/Indoor Connection Single wire Fine wire Fine wire with uninsulated wire ferrule Fine wire with insulated wire ferrule Strip length Supply 0.2mm2 to 6mm2 0.2mm2 to 4mm2 0.25mm2 to 4mm2 0.25mm2 to 4mm2 8mm to 10mm 24V 0.14mm2 to 4mm2 0.14mm2 to 2.5mm2 0.14mm2 to 2.5mm2 0.14mm2 to 2.5mm2 8mm to 10mm RS485 0.14mm2 to 4mm2 0.14mm2 to 2.5mm2 0.14mm2 to 2.5mm2 0.14mm2 to 2.5mm2 8mm to 10mm WEB’log DIOs and AIs 0.14mm2 to 1.5mm2 0.14mm2 to 1.5mm2 0.14mm2 to 1.5mm2 0.14mm2 to 1mm2 8mm PCU+ DIOs 0.14mm2 to 1.5mm2 0.14mm2 to 1.5mm2 0.14mm2 to 1.5mm2 0.14mm2 to 1mm2 8mm PCU+ AIOs 0.14mm2 to 4mm2 0.14mm2 to 2.5mm2 0.14mm2 to 2.5mm2 0.14mm2 to 2.5mm2 10mm PQA current measurement 0.2mm2 to 6mm2 0.2mm2 to 4mm2 0.25mm2 to 4mm2 0.25mm2 to 4mm2 12mm PQA voltage measurement 0.14mm2 to 4mm2 0.14mm2 to 2.5mm2 0.14mm2 to 2.5mm2 0.14mm2 to 2.5mm2 10mm All clamps are designed for push-in connections. meteocontrol stations 33| 44 9.1.2 Power Control Station Compact Connection Single wire Fine wire Fine wire with uninsulated wire ferrule Fine wire with insulated wire ferrule Strip length Supply 0.2mm2 to 6mm2 0.2mm2 to 4mm2 0.25mm2 to 4mm2 0.25mm2 to 4mm2 8mm to 10mm 24V 0.14mm2 to 4mm2 0.14mm2 to 2.5mm2 0.14mm2 to 2.5mm2 0.14mm2 to 2.5mm2 8mm to 10mm RS485 0.14mm2 to 4mm2 0.14mm2 to 2.5mm2 0.14mm2 to 2.5mm2 0.14mm2 to 2.5mm2 8mm to 10mm WEB’log DIOs and AIs 0.14mm2 to 1.5mm2 0.14mm2 to 1.5mm2 0.14mm2 to 1.5mm2 0.14mm2 to 1mm2 8mm PCU+ DIOs 0.14mm2 to 1.5mm2 0.14mm2 to 1.5mm2 0.14mm2 to 1.5mm2 0.14mm2 to 1mm2 8mm PCU+ AIOs 0.14mm2 to 4mm2 0.14mm2 to 2.5mm2 0.14mm2 to 2.5mm2 0.14mm2 to 2.5mm2 10mm PQA current measurement 0.2mm2 to 6mm2 0.2mm2 to 4mm2 0.25mm2 to 4mm2 0.25mm2 to 4mm2 12mm PQA voltage measurement 0.14mm2 to 4mm2 0.14mm2 to 2.5mm2 0.14mm2 to 2.5mm2 0.14mm2 to 2.5mm2 10mm All clamps are designed for push-in connections. 9.1.3 Data Station Outdoor/Indoor Connection Single wire Fine wire Fine wire with uninsulated wire ferrule Fine wire with insulated wire ferrule Strip length Supply 0.2mm2 to 6mm2 0.2mm2 to 4mm2 0.25mm2 to 4mm2 0.25mm2 to 4mm2 8mm to 10mm 24V 0.14mm2 to 4mm2 0.14mm2 to 2.5mm2 0.14mm2 to 2.5mm2 0.14mm2 to 2.5mm2 8mm to 10mm RS485 0.14mm2 to 4mm2 0.14mm2 to 2.5mm2 0.14mm2 to 2.5mm2 0.14mm2 to 2.5mm2 8mm to 10mm WEB’log DIOs and AIs 0.14mm2 to 1.5mm2 0.14mm2 to 1.5mm2 0.14mm2 to 1.5mm2 0.14mm2 to 1mm2 8mm All clamps are designed for push-in connections. 9.1.4 Special Model Station The connection data for conductors in the Special Model Station may vary. For the conductor connection, please consult the circuit diagram for the Special Model Station. 9.2 Widths of cable screw connections Connection M16 x 1.5 M20 x 1.5 M25 x 1.5 M32 x 1.5 KVT M32 x 1.5 with KT 4 Clamping range 34| 44 4mm to 9mm 6mm to 13mm 7mm to 17mm 13mm to 21mm 4mm to 5mm meteocontrol stations 10. Environmental protection and disposal Older stations no longer in serviceable condition have to be disposed of in accordance with national and local regulations for environmental protection and raw material recovery. Electronic components may not be disposed of along with household waste. meteocontrol stations 35| 44 11. Appendix 11.1 Scale drawings 11.1.1 Power Control Station Outdoor Fig. 14: Scale drawing of Power Control Station Outdoor 11.1.2 Power Control Station Indoor Fig. 15: Scale drawing of Power Control Station Indoor 36| 44 meteocontrol stations 11.1.3 Power Control Station Compact Fig. 16: Scale drawing of Power Control Station Compact 11.1.4 Data Station Outdoor Fig. 17: Scale drawing of Data Station Outdoor meteocontrol stations 37| 44 11.1.5 Data Station Indoor Fig. 18: Scale drawing of Data Station Indoor 11.1.6 Special Model Station For a scale drawing of the Special Model Station, please consult the circuit diagram for the station. 38| 44 meteocontrol stations 11.2 CE certificates meteocontrol GmbH EG- Konformitätserklärung EC Declaration of Conformity Hersteller: meteocontrol GmbH Manufacturer: Anschrift: Address: Produkte: Products: Spicherer Strasse 48 D – 86157 Augsburg Germany 421722 Data Station Outdoor 421723 Data Station Indoor 421724 Meteo Station II Outdoor 421725 Power Control Station Outdoor 421726 Power Control Station Indoor 421728 Power Control Station Compact 421741 Station Sonderausführung Wir erklären, dass die genannten Produkte folgenden Dokumenten und Normen entsprechen: We declare that the products described above are in compliance with following documents and norms: Directive 2006/95/EC Electrical Apparatus Low Voltage Directive Directive 2004/108/EC Electromagnetic Compatibility Sicherheit von Maschinen – El. Ausrüst. von Maschinen: DIN EN 60204-1 (2011-01) Safety of machinery - Electrical equipment of machines: IEC 60204-1 (2012-08) Für die Geräte “WEB’log”, “PCU+” und “IO-Modul”, welche in den oben aufgeführten Produkten verbaut sein können, verweisen wir hiermit auf die entsprechende EGKonformitätserklärung der einzelnen Produkte. For the devices “WEB’log”, “PCU+” and “IO-Modul”, which can be included in the products listed above, we refer to the corresponding EC Declaration of Conformity of the individual product. Augsburg, 15.03.2013 Jens Wening Ort, Datum Name und Unterschrift place, date name and signature Datei: mc_EC_Declaration_of_Conformity_Data_Meteo_Power-Control_Station.docx Seite 1/1 Datum: 14.11.2013 File: mc_EC_Declaration_of_Conformity_Data_Meteo_Power-Control_Station.docx Page 1/1 Date: 14.11.2013 meteocontrol stations 39| 44 11.3 RoHS Statement DECLARATION OF CONFORMITY 2011/65/EU (ROHS) meteocontrol GmbH declares that all manufactured products are RoHS compliant according to the Directive 2011/65/EU of the European Parliament and the Council from 8 June 2011 on restriction of the use of certain hazardous substances in electrical and electronic appliances. This concerns the following substances whose concentrations must not be exceeded: Lead 0.1% Mercury 0.1% Cadmium 0.01% Hexavalent chromium 0.1% Polybrominated biphenyls (PBB) 0.1% Polybrominated diphenyl ethers (PBDE) 0.1% Since we are guaranteed RoHS compliance by our suppliers, we, meteocontrol GmbH, can confirm with a clear conscience that all our products comply with the above mentioned Directive. Augsburg, 15th March 2013 Jens Wening Place, date Technical Director Energy&Weather Services Niederlassung Moers Carl-Zeiss-Straße 46 47445 Moers meteocontrol GmbH Spicherer Straße 48 86157 Augsburg Geschäftsführung Martin Schneider Robert Pfatischer Amtsgericht Augsburg HRB 16 415 DE 19 45 56 368 Hypovereinsbank Augsburg IBAN DE97 7202 0070 6770 1156 02 BIC HYVEEDEMM408 40| 44 meteocontrol stations 11.4 List of figures Fig. 1: Power Control Station ........................................................................................ 7 Fig. 2: Power Control Station Compact ......................................................................... 8 Fig. 3: Data Station ....................................................................................................... 9 Fig. 4: Transportation lying on the side ....................................................................... 10 Fig. 5: Transportation lying on the rear panel .............................................................. 10 Fig. 6: Transportation without a pallet ......................................................................... 10 Fig. 7: Do not transport via crane ................................................................................ 10 Fig. 8: Do not transport upright ................................................................................... 10 Fig. 9: Do not transport on the front plate ................................................................... 10 Fig. 10: Mounting the station ...................................................................................... 24 Fig. 11: Mounting the compact station ....................................................................... 25 Fig. 12: Open screw connection ................................................................................. 26 Fig. 13: Network cable seal ......................................................................................... 26 Fig. 14: Scale drawing of Power Control Station Outdoor ........................................... 36 Fig. 15: Scale drawing of Power Control Station Indoor .............................................. 36 Fig. 16: Scale drawing of Power Control Station Compact .......................................... 37 Fig. 17: Scale drawing of Data Station Outdoor .......................................................... 37 Fig. 18: Scale drawing of Data Station Indoor ............................................................. 38 meteocontrol stations 41| 44 42| 44 meteocontrol stations meteocontrol stations 43| 44 44| 44 meteocontrol stations Spicherer Str. 48  D-86157 Augsburg  Phone +49 (0) 821 / 3 46 66-88  Fax +49 (0) 821 / 3 46 66-11 [email protected]  www.meteocontrol.de Text and illustrations represent state-of-the-art technology at the time of printing  May be subject to technical updates  We assume no liability for printing errors. Item number 832039  Version 20160105