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CPS PSW2M-US User Manual

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CPS PSW2M-US / PSW2.4M-US PCS SKID
User Manual
CHITN POWER SYSTEMS AMERICA CO., LTD.
Rev 1.0
October 25, 2023

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  • Page 1 CPS PSW2M-US / PSW2.4M-US PCS SKID User Manual CHITN POWER SYSTEMS AMERICA CO., LTD. Rev 1.0 October 25, 2023...

  • Page 2: Table Of Contents

    Table of content Contents Preface ......................1 Chapter 1 Safety Instructions ............... 3 1.1 Definition of symbols in this manual: ............3 1.2 Interpretation of product markings: ............4 1.3 Precautions for product safety ..............5 Chapter 2 System Introduction ..............7 2.1 PCS Skid machine ..................
  • Page 3 Table of content 5.2 Power setting ................... 39 Chapter 6 Maintenance and Troubleshooting ........... 40 6.1 Maintenance .................... 40 6.1.1Regular maintenance ................40 6.2 Service and Replace ................40 6.2.1 Replace the PCS ................40 6.2.2 Replace cooling fans ..............44 6.3 Fault analysis and troubleshooting ............

  • Page 4: Preface

    Preface Preface Dear user, thank you very much for choosing the CPS PSW2M-US / PSW2.4M- US PCS skid (hereinafter referred to as "PCS skid" in this manual) products developed and produced by Shanghai Chint Power Systems Co., Ltd. CHINT PV grid-connected PCS skid is a highly reliable product, which is widely used in high-standard PV grid-connected systems.

  • Page 5: Version Upgrade

    Preface instructions in this manual may help you solve most of the use, installation and operation problems. Applicable Personnel This manual is applicable to authorized and qualified engineers or operators authorized by the owner, and these people can perform wiring, operation, maintenance, and daily management of the PCS skid.

  • Page 6: Chapter 1 Safety Instructions

    Safety Instructions Chapter 1 Safety Instructions Please read the safety instructions in this chapter carefully before installing and using the PCS skid. We will not be liable and provide quality assurance if personal injury or equipment damage is caused as a result of failing to follow the safety instructions in this manual! 1.1 Definition of symbols in this manual: Danger:...

  • Page 7: Interpretation Of Product Markings

    Safety Instructions 1.2 Interpretation of product markings: Electric Shock Hazard: This marking indicates that there is high voltage inside the machine body, and touching it may cause electric shock. Energy danger: Pay attention to the danger of electric shock, and please operate the machine 5 minutes after the discharge is completed.

  • Page 8: Precautions For Product Safety

    Safety Instructions 1.3 Precautions for product safety DANGER: It is necessary to manually shut down through the screen before the PCS skid is repaired. The DC switch on the PV side should be disconnected and the discharge procedure is executed, and then the ac switch on the grid side should be disconnected, confirm that the PCS skid has no power and the machine can be examined and repaired!
  • Page 9 Safety Instructions Please do not touch the cooling fin and metal surface of the PCS skid! NOTE: The PCS skid is specially designed to generated ac power and connect to the public grid. Do not directly connect the ac output terminal of the equipment to private ac electrical equipment.

  • Page 10: Chapter 2 System Introduction

    System Introduction Chapter 2 System Introduction 2.1 PCS Skid CPS PSW series PCS skid integrates PCS, step-up transformer, AC/DC power distribution, etc. It has the advantages of high efficiency, reliability and environmental protection. Functional characteristics of inverter boost integrated machine: ...

  • Page 11: Introduction Of Series And Model

    DC input terminal, and then converted into three-phase AC voltage (3*800VAC) through PCS, and then connected to the power grid after step-up. Fig. 2-1 Basic schematic diagram of CPS PSW2M-US / PSW2.4M-US...
  • Page 12 System Introduction...

  • Page 13: Appearance Description And Dimensions

    System Introduction 2.4 Appearance description and dimensions The appearance and main components of the PCS skid are shown in Fig. 2-2. Fig. 2-2 Appearance Diagram of PCS skid Name Function CHINT logo Identification of equipment manufacturers Indicator Indicate equipment operation and fault state EMS button Emergency shutdown button Table.
  • Page 14 System Introduction 1. PCS 4. Transformer 2. 1# DC combiner cabinet 5. Power supply control cabinet 3. 1# DC combiner cabinet The dimensions (unit: mm) of the PCS skid are shown in Fig. 2-3. Fig. 2-4 Schematic Diagram of Overall Dimensions IMPORTANT: The height of door lock and hinge are not included in the shown dimensions;...

  • Page 15: Optional Product Configuration

    System Introduction 2.5 Optional product configuration The following optional configurations are supported by the CPS PSW2M-US / PSW2.4M-US: Configuration Function Metering instrument Measurement of control load Table 2-2 Optional Configuration Table IMPORTANT: You need to confirm what optional functions are required for the PCS skid before ordering, ensure that the delivered PCS skid meets the use requirements.

  • Page 16: Chapter 3 Installation

    Keep away from flammables and explosives;  Keep away from electromagnetic interference sources. 3.2 Scope of supply CPS PSW2M-US / PSW2.4M-US is delivered in a complete machine package, and the delivered goods are shown in table 3-1. Description Qty. CPS PSW2M-US / PSW2.4M-US PCS skid...

  • Page 17: List Of Installation Tools

    Installation 3.3. List of installation tools Please refer to table 3-2 for the list of tools required for installing this product. Description Specification Purpose description Open-end wrench 14mm M8 hexagon head screw Open-end wrench 17mm M10 hexagon head screw Open-end wrench 19mm M12 hexagon head screw Straight...
  • Page 18 Installation Fig. 3-1 Location of incoming and outgoing line holes 1. DC wiring hole 2. High-voltage wiring hole 3. Communication wiring hole The installation foundation of the PCS skid must be designed and constructed in advance according to certain standards to meet the requirements of mechanical support, cable wiring, ventilation and heat dissipation.
  • Page 19 Installation (length × width) 6000mm×2500mm. The foundation height should be determined by the construction party according to the site geology;  Cable wiring should be considered in the construction of foundations. The cable trench can be constructed at the bottom of the inverter room according to the overall design planning of the power station, namely a preset cable trench in the foundation.
  • Page 20 Installation Appropriate distance must be reserved between the PCS skid and walls and other equipment to meet the requirements of minimum maintenance access, escape routes and ventilation, as shown in Fig. 3-3 and table 3- Fig. 3-3 Diagram of installation space distance Recommended Remarks minimum distance...

  • Page 21: On-Site Handling Of Pcs Skid Installation

    Installation 3.4.2 On-site handling of PCS skid installation Lifting Precautions. DANGER:  During the whole process of lifting the PCS integrated machine, the safety operation regulations of the crane must be strictly followed.  It is forbidden to stand within 10m of the operation area. In particular, it is forbidden to stand under the lifting arm and the lifted or moved machine to avoid casualties.
  • Page 22 Installation  The PCS integrated machine shall be lifted vertically, and no dragging on the ground is allowed during lifting. It shall not be dragged or pushed on any surface.  After the PCS integrated machine is lifted 300mm away from the supporting surface, suspend to lift and check the connection between the sling and the PCS integrated machine.
  • Page 23 Installation Fig. 3-4 Schematic Diagram of Crane Handling Fig. 3-5 Schematic Diagram of PCS All-in-one Machine Lifting...

  • Page 24: Electrical Connection

    Installation 3.5 Electrical connection WARNING:  The configuration of the PV array, grid level, frequency, and other technical parameters must meet the technical parameter requirements of a PCS skid.  The PCS skid can be connected to the power grid only after being approved by the local power supply company and installed by professional technicians.

  • Page 25: Dc Connection

    Installation All external wiring must pass through the threading hole under the machine, as shown in the following figure; Fig. 3-7 DC Wiring 3.5.2 DC Connection To get the best results from your PCS skid, follow these guidelines:  First, ensure that the maximum output voltage of the battery cluster is lower than 1500V ...
  • Page 26 Installation Fig. 3-8 Diameter of Copper Bar for DC Wiring (mm) Machine type CPS PSW2M-US CPS PSW2.4M-US Number of DC input channels 10-circuit 12-circuit Recommended cable diameter ≥2/0 AWG Bolt Torque 25Nm Table 3-4 Cable Parameters Connect the DC positive (1) and negative cables (2) to the positive and negative copper bars of the PCS skid accordingly.
  • Page 27 Installation NOTE: There are six groups of DC inputs on one side below the DC distribution isolating switch, with DC "+" wiring copper bar in front and DC "-" wiring copper bar behind. The following principles are recommended for DC input wiring: ...

  • Page 28: Ac Connection

    Installation 3.5.3 AC connection WARNING: Incorrect ac side wiring will cause failure of or even damage to the PCS skid! WARNING: The internal wiring identifications of the PCS skid shall be strictly followed, and the phase sequence of the power grid shall be correct during wiring! The cross-sectional area of each AC input phase of the booster is a maximum of 240mm...

  • Page 29: Earthing Connection

    Installation 3.5.4 Earthing connection 1. PCS all-in-one cabin body grounding For on-site cable connection, two ground points are designed for the all-in-one cabin body, as shown in the figure below, and two or one of two ground points are reliably connected according to the actual situation. At least one of the two points must be connected to meet the grounding requirements of the cabin body.
  • Page 30 Installation Fig. 3-12 Grounding diagram of the cabin body of PCS skid 2．Ground electrical devices Please refer to table 3-13 for the diameter of the grounding cable. Fix the wiring terminal of the grounding cable on the grounding copper bar (1) and tighten it with a torque wrench (torque: 25Nm), as shown in the following figure.

  • Page 31: Communication Connection

    Installation Phase Cross-sectional area of cable Bolt Torque 16mm²~35mm² 25Nm (or 4AWG~1AWG) Table 3-5 Parameters of Grounding Cable NOTE: The machine housing shall be reliably and nearby grounded. Avoid the possibility of electric shock to human body. WARNING: For large touch current, grounding is required before switching on the power supply.

  • Page 32: External Auxiliary Power Supply And Dry Contact Connection

    Installation Communication with background upper computer  Each PCS skid is reserved with 3 Ethernet signal interfaces and 2 optical fiber interfaces for communication with the background. The communication cable shall be a shielded network cable, and both ends of the crystal plug with a straight-through twisted pair shall comply with the 568B standard.
  • Page 33 Installation Fig. 3-15 Dry Contact Terminal  The input dry contact is used to receive BMS tripping signals, and the externally provided signals shall be passive switching signals;  The output dry contact is used for the tripping feedback signal of the grid-connected main switch, which is a passive switching signal.

  • Page 34: Chapter 4 Power-On And Power-Off Operations

    Power on and Power off Chapter 4 Power-on and Power-off Operations After the wiring is completed, turn on and turn off the system as follows. 4.1 Power-on operation process ○ ○ 1 in 1# DC combiner cabinet is started, QF8 2 is closed, the red power indicator of UPS is on, and the control circuit power supply is normal;...
  • Page 35 Power on and Power off Fig. 4-1 Schematic Diagram of Electrical Switch Fig. 4-2 American Transformer HV Indoor HV Load Switch (Closed)

  • Page 36: Power-Off Operation Process

    Power on and Power off 4.2 Power-off operation process Set the PCS output to “0” (refer to the Startup/Shutdown)to shutdown ○ the 1#~12# PCS 8 and open the PCS AC relays; ○ Disconnect QF1~QF6 7 in 1# AC combiner cabinet and QF7~QF12 in opposite 2# AC combiner cabinet;...
  • Page 37 Power on and Power off Adding note: What’s the purposes of yellow LED HL1? Please refer to the picture below: 1# AC combiner cabinet HL1（Yellow） ：Fault Alarm HL2（White） ：Energy storage HL3 (Red)：QFM Closed HL4 (Green)：QFM Opened Fig. 4-1 Schematic Diagram of Electrical Switch...
  • Page 38 Power on and Power off Fig. 4-2 American Transformer HV Indoor HV Load Switch (Closed)
  • Page 39 Power on and Power off Fig. 4-3 Control power cabinet diagram Control the power cabinet indicator： HL1(White)： Mains power HL2(Red)： UPS power HL3(Yellow)： Fault Alarm...

  • Page 40: Chapter 5 Operation

    Operation Chapter 5 Operation The local controller can be used to control the startup and shutdown of the PCS skid and set the power. 5.1 Startup/Shutdown Connect the laptop port to Ethernet1 of the local controller with a network cable, and open the "SVP Dashboard" client; After opening the client, click the website "http://localhost:8444"...
  • Page 41 Operation After entering the login interface, enter information according to the following figure and click "Open" after input; Fig. 5-3 Enter Login Information Click "703", find the Permit Enter Service (ES) column, enter data 0 or 1, and click "Write" below to complete the startup/shutdown operation; Enter “0”...

  • Page 42: Power Setting

    Operation 5.2 Power setting Open the startup/shutdown interface. Please refer to the steps in 6.1 "Startup and Shutdown"; Click "704" to find the column of Active Power Setpoint, enter data, and click "write" after entering to set active power. The input value is -1000~1000, and the representative power is set to - 100.0%~100.0%.

  • Page 43: Chapter 6 Maintenance And Troubleshooting

    Maintenance And Troubleshooting Chapter 6 Maintenance and Troubleshooting 6.1 Maintenance 6.1.1Regular maintenance Maintenance Item Method intervals 1. Check the temperature and dust of the 6 months to 1 PCS. Clean enclosure if necessary. year System 2. Check if the air inlet and outlet as well as (depending clean air vent filter are normal.
  • Page 44 Maintenance And Troubleshooting Fig. 6-1 DC switch Connect and hang the maintenance grounding cable at the cable connection between the DC incoming copper bar of the combiner box and the high-voltage chamber of the American transformer; Fig. 6-2 Grounding Cable Remove the DC cable and AC cable (1),, and PCS grounding cable (2) of PCS incoming and outgoing lines;...
  • Page 45 Maintenance And Troubleshooting Remove the four combination screws (1) of the PCS to remove it; Fig. 6-4 Remove the PCS Combination Screw Install a new PCS on the mounting bracket and tighten the four combination screws; Torque: 25 Nm; NOTE: The Weight of one PCS is about 120kg (≈265 pounds).
  • Page 46 Maintenance And Troubleshooting Fig. 6-5 Watch out for the Dropping Safety Line Connect the incoming and outgoing DC cables, AC cables, and PCS grounding cables in the reverse order of cable removal; Turn the DC Switch (1) on PCS to “On” position; Fig.

  • Page 47: Replace Cooling Fans

    Maintenance And Troubleshooting 6.2.2 Replace cooling fans If the internal temperature of the PCS is higher than normal operating temperature or abnormal noise is heard assuming the air vent is not blocked and is clean, it may be necessary to replace the external fans. Please refer to the following steps for replacing the cooling fans.
  • Page 48 Maintenance And Troubleshooting Put the PCS on flat ground and use a No.2 Phillips head screwdriver to unscrew the four screws on the front plate and take off the fan tray. Fig. 6-6 Remove screws Disconnect the cable connector from the cooling fan and cut the cable ties (1).
  • Page 49 Maintenance And Troubleshooting Use a No.2 Phillips head screwdriver to take off the four M4 screws (1) on the left or right clamp plate and remove the clamp plate (2). Fig. 6-8 remove the clamp plate out After removing the clamp plate, pull out the fan tray with the aid of the exposed handle (4) of the fan tray.
  • Page 50 Maintenance And Troubleshooting Cut off the cable ties between fan cable and fan tray, remove the damaged fans and replace them. Tighten the tapping screws with a torque value of 0.8-1N.m (7.1-8.91in-lbs). NOTICE: A rubber pad shall be placed between the fan and fan tray to reduce noise caused by vibration.

  • Page 51: Fault Analysis And Troubleshooting

    Maintenance And Troubleshooting 6.3 Fault analysis and troubleshooting Troubleshoot according to following table 6-2: Fault Fault Fault cause Fault handling name explanation 1.Temperature Sensor socket 1.Observe temperature display; Prompt connector 2.Switch off 3-phase working TempSensor detection poor contact; power supply and then reboot the abnormal 2.Temperature system;...
  • Page 52 Maintenance And Troubleshooting Fault Fault Fault cause Fault handling name explanation 1.Observe for 10 minutes and see whether the alarm will be 1.Grid frequency eliminated automatically; Grid voltage is abnormal; 2.Check whether grid frequency 2.Cable frequency is within the specified GridF.OutLim abnormal, connection...

  • Page 53: Chapter 7 Technical Data

    Technical Data Chapter 7 Technical Data Model Name CPS PSW2M-US / PSW2.4M-US DC Input Max. DC Input Voltage 1500V Min. DC Voltage 875V DC Voltage range for 950-1500V nominal power Number of CPSECB 200KTL/US-800 PCS Units Number of DC inputs...

  • Page 54: Chapter 8 Quality Assurance

    The replaced unqualified products shall be returned to us; We need a reasonable time to repair the device. If you have any questions about the CPS PSW2M-US / PSW2.4M-US PCS SKID, please contact us. We will be very happy to serve you.
  • Page 55 Shanghai Chint Power Systems Co., Ltd. Headquarters: Building 4, No. 3255, Sixian Road, Songjiang District, Shanghai, China Switchboard: +86-21-37791222 Fax: +86-21-37791222-866003 Website: www.chintpower.com Service hotline: +86-21-37791222-866300 E-mail: service.cps@chint.com The above information is subject to change without prior notice. Any unauthorized copying and plagiarism are prohibited.

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