Terra-Sas Operation and Maintenance Manual
Contents
1. 1 6 MECHANICAL DRAWINGS CH pl la NENENG TEENE RAR SUR Ie NONE NE UR OPU UIA GVA UPR UV er e W Nikki es RE SUUM Wy ARR Ee oU RAI PRUNES en E FE ENST E ene IS e H e ep e AETB y OG CR TerraSAS D C C ATAR ERR GN LEA Appen O JA O Figure 1 2 Front side and top views TerraSAS P Photovoltaic Simulator dnk S o ETS SOV 10 5A AMETEK2. g E Naja EEE E aa EEE sis B i EE DS E Ela SH zll idm Figure 1 3 Front panel I T RV j EY NG C3 J J N X J LJ C PAINS UL A NA KA VA ANEA SMS NIA ANA UV UV JUV UV VJ UV e D ANA A SAN OU DDD DDO DOU MU UD MU MU MU UU MM MH WU OU OS N i KEN eg HH I EEA EN A R EEN A A E a PEN JEN BA Pa C0 E I C8 CI C USB COHEN EHNEN ENEE EE CH CH EC 5 cerai ANA MANU KA NA LA XA NA NARA VA NA VA NS MA M Ew Iw WO Ok JL DIL 7 NY AC WI ET ET J AAN PPS IHE IE YS PS EN PPS ES A Y mm i VA n e sm cJ M ANAK INA UG VJ VU VU UV JUV UV JOU JUUL 2 fa N CN CN PN I8 8 ON Ar AA OG Nannnannnnnnnn AI T K M AN YS Figure 1 4 Rear
3. Browse Show extracted files when complete I select a destination Select the place where you want to extract the selected item s Then click the OK button gt g DVD Drive D c smi n A Insert a USB drive and navigate to it Click OK ca LACIE F and then click Extract on the previous dialog to store 4 wm ADATA UFD Gi gt A Commercial Software th e nstal set on th e US B d rive gt 4 FINAL TEST gt J PIC 32 C Language PIC32 REFERENCE gt J SAS TEST DVD ROM To view subfolders click the symbol next to a folder wera KE pr JC AS ADATA UFD G TerraSAS16 0 2 Web Install gt Organize v BB read Burn New folder Insert the USB drive into aco Toa any available USB port 8 Downloads Name Date modified Type iz S Recent Places EET e i on the computer running PV Updater Install 12 19 2011 8 10 AM File folder Gg Libraries 1 SCPI Test Install 12 16 2011 5 18 PM File folder TerraS AS ES 9 TerraSAS Install 12 16 2011 5 18 PM File folder s _ Example scripts v1 5 txt 1 26 2011 10 12 AM Text Document ge 8 M609155 01 Rev C pdf 6 9 20 942 AM PDF File READ ME txt 7 21 2011 2 23PM Text Document ball fal m ii Pictures z Videos B M609155 01 Rev C pdf Date modified 6 9 2011 9 42 AM Date created 6 9 2011 9 42 AM PDF File Size 3 91 MB Navigate to the TerraSAS x x x x Web Install folder Ope
4. exceed 1 000 V peak or the maximum string voltage of the optimizers whichever is lower e For transformerless inverters the AC leakage current must not exceed the threshold of the inverters RCMU protection residual current monitoring unit usually 30 mArms The actual current level depends on the amplitude frequency and harmonics content of the AC component present at the inverter input terminals which ultimately depends on the inverter design The AC leakage current can be estimated using the equation below C 6 28 f V N With the setup example shown above the AC leakage current would be approximately 12 mArms when there is no harmonics content f 60 Hz and V 100 Vrms since N 7 and the output to ground leakage capacitance of each ETS80 is 45 nF 24 3 3 4 Parallel connections The outputs of two or more ETS80 simulators can be paralleled to increase the available output current All sense lines must be connected and terminated as close as possible to the inverter under test to achieve the best possible measurement accuracy PV Simulator Inverter PV Simulator Figure 3 8 PV Simulators connected in parallel Once the electrical connections are made select System gt Channels grouping setup to configure the software for the desired wiring See the software user manual for full details The output wiring must be sized to minimize voltage drops at the maximum rated current of the inverter The voltage difference be
5. malfunction Table 4 Linear regulator temperature events 3 2 2 Over Power Protection OPP The linear regulator is rated for continuous operation when its power dissipation is below 230W which is the worst case condition when the load operates at the maximum power point The linear regulator is not designed to handle the full rated power of the unit and might shut down if the output is shorted Therefore this product cannot be used with shunt switching solar regulators and any load that does not operate near the maximum power point 20 The power dissipated on the linear regulator depends on IV curve parameters and output load It can be calculated as follows P Voc 3 Vinp Imp when the load operates at the maximum power point This is because the dc source feeding the linear regulator is always operated 3V above Voc see block diagram in section 1 4 The table below shows the amount of time the unit will operate under overload conditions Linear regulator power dissipation Protection trip time Watts seconds 231 61 0 0 40 When the protection trips the FLT indicator turns red and the power module is turned off When placing the cursor over the FLT indicator the type of fault OPP is shown 231 200 80 200 1040 To clear the fault turn off the unit and then turn it back on 3 2 3 Over Current Protection OCP Instantaneous current transients above 150 of the maximum rated current
6. s QUAD D A ALTERA DUAL A D DIFF AMP E PHY 16 bit CPLD 16 bit v amp 200 kS s 200 kS s FILTER USB 32 BIT RISC 128 KB RAM CAN CPU S SIARISIED ANALOG OPTICAL as is BM CONTROL LOOP CYCLE iz 0 19 ENG FIBERS E RATE 200KHz 0 1 DIGITAL ETS60 80 100 150 300 PV SIMULATOR Figure 1 1 PV Simulator block diagram At the heart of the PV simulator are two 80 MIPS RISC microcontrollers One processor interfaces with a 16 bit measurement and control system that monitors the output voltage and current at 5 us intervals At each interval the processor sends computed data to its 16 bit D A control system that adjusts the dc source and linear regulator to follow the programmed IV curve The other processor supports the Ethernet interface analog and digital I O While in static simulation mode the simulator executes a single IV curve In the PV Simulator memory an IV curve is represented by 1 024 data pairs or points Each pair of values represents a single voltage current point on the IV curve The PV simulator interpolates the 1 024 points in its curve memory with 16 bit accuracy delivering an actual curve resolution of 65 536 points When irradiance temperature profiles are executed dynamically updated IV curves are downloaded at fixed 1 second intervals The PV simulator linearly interpolates between consecutive curves 128 times per second 7 8 ms intervals delivering smooth voltage a
7. will trip the over current protection When the protection trips the FLT indicator turns red and the power module is turned off When placing the cursor over the FLT indicator the type of fault OCP is shown To clear the fault turn off the unit and then turn it back on 21 3 3 TEST SETUP AND APPLICATION DETAILS Carefully read the installation manual of the solar inverter micro inverter or battery charger before connecting it to the PV simulator In particular make sure the maximum V is never exceeded to avoid damaging the device under test It is strongly recommended to set the overvoltage protection at or below the maximum input voltage of the DUT to avoid accidentally damaging it OVP settings and indicators are covered in the TerraSAS software user manual p n M609155 01 which is included in PDF format in the software disk that comes with the unit The ETS80 has isolated DC outputs and supports negative and positive PV array grounding schemes Its low output leakage and high isolation also allows testing non isolated transformer less type inverters and micro inverters The maximum output to ground voltage is 1000V Exceeding this limit will damage the unit This type of damage is not covered by the warranty Always connect the sense lines as close as possible to the unit under test to maximize measurement accuracy 3 3 1 Microinverter test setup PV Simulator inverter Typical voltage and
8. 0 3 2 38 Over Current Protection OC 21 TABLE OF CONTENTS 3 3 Test Setup and Application deiails 22 3 3 1 X Microinverter test senn 22 3 3 2 Power optimizer test setup 23 3 3 3 Power optimizers feeding a solar inverter 24 3524 JParallel GOlnecllOPiS aars 25 9 95 5enes Col TiecllofiS saga aga ag aaa Ega Aa Gaga KAE BANG a eee NN 26 SECTION 4 COMPUTER MANAGEMENT enee ek KEE KEE KKK KKK KEE e 27 4 1 Performing TerraSAS software updates rrrnrrnnnnnrnrnnnrnnnnrrrvnnnrnvnnnrennnn 27 4 1 1 Step 1 Uninstall Terra 27 4 1 2 Step 2 Install a new TerraSAS software release 28 4 2 Performing firmware updaies 30 SECTION 5 CALIBRATION egeeeegeeeNeeENegEEESeE EES EEER SEENEN REENEN 33 5 4 REqUKEA equipmieriL oec Bete tate apu rb Area 33 0 2 EIERE eebe aan ag ana Darei unti inb lessees 33 5 9 TANDHA NONTON E 33 LIST OF FIGURES Figure 1 1 PV Simulator block diagram nnoannannnennnannnnnnnnnnnnesnrnnnnnnnernnrennee 6 Figure 1 2 Front side and top views 9 rigure T 9 FOM DANG nce und od ted aana aaa ised cre Used due ak Ba bak ada Da a aa bek tise 10 FOUE 14 HE VICW RETE T TTL 10 Figure 1 5 Rear I O oanel 10 Figure 3 1 Direct cable connection ENEE 17 Figure 3 2 Private network connection n nsensennsennennnnennrnrnnnrrenrnnrrrrrerennnne 18 Figure 3 3 Local area network Conpechon 18 Figure 3 4 Dual network CGonnechon 19 Figure 3 5 Mic
9. AMETEK PROGRAMMABLE POWER ELGAR ETS80X10 5C Photovoltaic Simulator Operation and Maintenance Manual Programmable Power Solutions M551066 04 Rev A www programmablepower com About AMETEK AMETEK Programmable Power Inc a Division of AMETEK Inc is a global leader in the design and manufacture of precision programmable power supplies for R amp D test and measurement process control power bus simulation and power conditioning applications across diverse industrial segments From bench top supplies to rack mounted industrial power subsystems AMETEK Programmable Power is the proud manufacturer of Elgar Sorensen California Instruments and Power Ten brand power supplies AMETEK Inc is a leading global manufacturer of electronic instruments and electromechanical devices with annualized sales of 2 5 billion The Company has over 11 000 colleagues working at more than 80 manufacturing facilities and more than 80 sales and service centers in the United States and around the world Trademarks AMETEK is a registered trademark of AMETEK Inc Other trademarks registered trademarks and product names are the property of their respective owners and are used herein for identification purposes only Notice of Copyright Terrestrial Solar Array Simulator Operation and Maintenance Manual 2010 AMETEK Programmable Power Inc All rights reserved Exclusion for Documentation UNLESS SPECIFICALLY AGREED TO IN WRITING AMETEK PR
10. ER The TerraSAS software can control one or more PV simulators over a single Ethernet link The CD that comes with the unit contains the installation files and the software user manual in Adobe PDF format Detailed installation instructions are included in the manual After installing the software follow the instructions below to establish communication with one or more PV simulators 3 1 1 Network configuration The easiest way to connect to a single PV simulator is outlined below IP address 10 0 0 1 Subnet M ask 255 255 0 0 PV Simulator IP address 10 0 0 2 Subnet M ask 255 255 0 0 Figure 3 1 Direct cable connection Internet Protocol Version 4 TCP IPv4 Properties oimply access the Ethernet adapter Properties page and set as indicated General You can get IP settings assigned automatically if your network supports this capability Otherwise you need to ask your network administrator the appropriate IP settings Obtain an IP address automatically With this topology a static IP address is pe a manually assigned to the computer IP address 10 0 0 2 Subnet mask 255 255 0 When the PV simulator is turned on it defaults to IP address 10 0 0 1 and communication is immediately established Default gateway Obtain DNS server address automatically Q Use the following DNS server addresses Preferred DNS server Alternate DNS server This method cannot be used to control two o
11. OGRAMMABLE POWER INC AMETEK a MAKES NO WARRANTY AS TO THE ACCURACY SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION b ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES DAMAGES COSTS OR EXPENSES WHETHER SPECIAL DIRECT INDIRECT CONSEQUENTIAL OR INCIDENTAL WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER S RISK AND c REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH ALTHOUGH STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION THE ACCURACY CANNOT BE GUARANTEED APPROVED AMETEK CONTENT IS CONTAINED WITH THE ENGLISH LANGUAGE VERSION WHICH IS POSTED AT WWW PROGRAMMABLEPOWER COM Date and Revision Apr 2013 Revision A Part Number M551066 04 Contact Information Telephone 800 733 5427 toll free in North America 858 450 0085 direct Fax 858 458 0267 Email Sales programmablepower com PPSsupport PPD ametek com Web www programmablepower com This page intentionally left blank Important Safety Instructions Before applying power to the system verify that your product is configured properly for your particular application personnel must use extreme caution when servicing this equipment Circuit boards test points and output voltages also may be floating above Hazardous voltages may be present when covers are removed Qualified WARNING be
12. a 1uF capacitor at the end of a 1 8m 6ft line at full load 20 MHz bandwidth lt 60 mAp p at maximum output current 650 KHz bandwidth 66 typical with Voc 80V Isc 10 5A Vmp 68 9V Imp 9 95A 100 VAC input 69 typical with Voc 80V Isc 10 5A Vmp 68 9V Imp 9 95A 200 VAC input 0 05 of set point after 30 minute warm up and over 8 hours at fixed line load and temperature typical 0 02 C of maximum output voltage rating for voltage set point typical 0 038 C of maximum output current rating for current set point typical 0 to 40 C 25 C to 65 C Relative humidity up to 95 non condensing 0 C 40 C Operating full power available up to 5 000 ft 1 500 m derate 10 of full power for every 1 000 feet higher non operating to 40 000 ft 12 000 m Front air inlet rear exhaust Temperature controlled variable speed fans Units may be stacked without spacing CSA 22 2 No 61010 1 60950 1 07 and UL61010 1 UL60950 1 2nd Ed 12 Marked with cCSAus CE for EMC amp low voltage directive 2 IEC 1010 1 EN 61326 1 2006 Rack Slides Elgar part number 105 375 08 qty 2 required Width 19 00 in 48 3 cm Depth 22 60 in 57 4 cm Height 1 75 in 44 4 cm Weight 21 Ibs 9 5 kg
13. active this signal starts executing a profile See software user manual for details about loading and executing irradiance temperature profiles 13 2 3 REAR PANEL SWITCHES AND INDICATORS LAN FEATURES see figure 1 5 ITEM TYPE FUNCTION INDICATOR PUSHBUTTON Select used during system configuration 2 4 FRONT PANEL STATUS INDICATOR The front panel STATUS indicator blue LED visually reports one of five possible operating conditions Blinking patterns are repeated every 2 seconds FRONT PANEL STATUS INDICATOR LIGHT STATUS DESCRIPTION PATTERN Steady OFF OFF The simulator is turned off front panel power switch off or no power Long pulse IDLE The simulator is turned on but not communicating with the system controller PC Output power is automatically turned off Steady ON ON The simulator is turned on and communicating with the system controller PC One short OVP Overvoltage protection tripped Reduce the output pulse voltage turn the output off then on to clear see TerraSAS software manual Two short Power module overheat or fault Turn the front pulses panel power switch off then on to clear Contact the factory if this condition becomes permanent and cannot be cleared 14 2 5 SYSTEM ASSEMBLY RECOMMENDATIONS When using a number of simulators to build a multi channel rack system the following information can be helpful Use rack slides Elgar p n 105 375 08 qty 2 required or steel b
14. ct or any part thereof e is damaged by misuse accident negligence or failure to maintain the same as specified or required by AMETEK e is damaged by modifications alterations or attachments thereto which are not authorized by AMETEK e is installed or operated contrary to the instructions of AMETEK e iS opened modified or disassembled in any way without AMETEK s consent or e is used in combination with items articles or materials not authorized by AMETEK The Buyer may not assert any claim that the Products are not in conformity with any warranty until the Buyer has made all payments to AMETEK provided for in the Purchase Order Agreement PRODUCT RETURN PROCEDURE 1 Request a Return Material Authorization RMA number from the repair facility must be done in the country in which it was purchased e Inthe USA contact the AMETEK Repair Department prior to the return of the product to AMETEK for repair Telephone 800 733 5427 ext 2295 or ext 2463 toll free North America 858 450 0085 ext 2295 or ext 2463 direct e Outside the United States contact the nearest Authorized Service Center ASC A full listing can be found either through your local distributor or our website www programmablepower com by clicking Support and going to the Service Centers tab 2 When requesting an RMA have the following information ready e Model number e Serial number e Description of the problem NOTE Unauthorized returns will
15. ctions are as follows AC line 100 240VAC 50 60 Hz Line 2 or Neutral Earth ground Table 1 AC line cord wire colors 2 2 2 DC Output See figure 1 4 to locate the DC output receptacle The supplied DC output cable allows to quickly connect the simulator to the device under test for bench top operation Remote sense lines are terminated at the alligator clips For rack mount installations use the supplied mating connector and crimp contacts Connections are listed below Positive output DC OUTPUT T ee 5 Negative output Positive output Negative remote sense 6 Negative output Table 2 DC output connections Terminal numbers are stamped on the body of the connectors Contacts p n 856 008 0Y Positronic p n MC114N can be crimped using tool AF 8 with positioner TH4 These are industry standard part numbers available from many electrical tooling distributors To maximize measurement accuracy always connect the sense lines as close as possible to the device under test input terminals 2 2 3 Ethernet Use the supplied CAT 5e shielded patch cord or equivalent Shielded patch cords are required to meet EMC regulations and recommended to avoid data corruption due to interference from the device s under test 12 2 2 4 USB USB Is not supported in the current firmware release and is intended for future use 2 2 5 AUX I O This is a Standard 15 pin female D SUB connecto
16. current osams sam waveforms observed across Age 21259 the input of the microinverter are shown in this oscilloscope capture which was taken while the unit under test was tracking the maximum power point ers 43 50 0 004 120 006 Hal diim By GR 100m Eu EPI PE 1 300 v DF FE eGo dm 21 55 01 22 3 3 2 Power optimizer test setup This setup allows testing a single power optimizer while fully controlling and monitoring its operating parameters including output voltage and current S Electronic PVSIM i Load DC DC CV mode Figure 3 6 Test setup for a single power optimizer Typical voltage and current waveforms observed across the input of the optimizer are shown in this oscilloscope capture which was taken while the unit under test was tracking the maximum power point i 2 ms 26 00 Adm 220 050 Hz LOY By GR 100m By RN PP dab V IB Dk SOP One 23 3 3 3 Power optimizers feeding a solar inverter Several ETS80 simulators can be connected as shown below to accurately evaluate their operation and performance while feeding a solar inverter Inverter Figure 3 7 Power optimizers feeding a solar inverter The maximum number of simulators and optimizers is limited by the following factors e The sum of all Vo settings must be equal to or less than the maximum input voltage of the inverter e The maximum voltage to ground of either inverter input terminal or cannot
17. es and Printers Default Programs Help and Support Click on Uninstall a program Hardware and Sound S View devices and printers Add a device 37 Programs a Uninstall a program Get programs 2 Right click on TerraSAS and click Uninstall Change Symantec Endpoint Protection Symantec Ct TerraSAS A Time Card Entry Program PS Visual Studio 2010 Tools for SQL Server Microsoft Cc ca Windows XP Mode Microsoft Cc E WinMerge 2124 Thingamahc 4 n TerraSAS Maint TerraSAS Choose the type of maintenance you need Help link file S Roberto 20Lucca e AMETEK PPD Product version 1 7 0 0 Click OK to remove TerraSAS This only removes the software System configuration curves profiles data log and any other user files are not affected 4 amp Remove the application from this computer Open Extract All Scan for Viruses Open with Share with WinMerge Restore previous versions Send to Cut Copy Create shortcut Delete Rename Properties 28 A new TerraSAS install set is usually e mailed as a download link through Ametek s file transfer service Amefex The file size is less than 10 Mbytes Download the file to your desktop then right click on it and select Extract All Select a Destination and Extract Files Files will be extracted to this folder CAUsersVrlucca Desktop TerraSAS 1 6 0 2 Web Install Click
18. fornia USA nor any of the subsidiary sales organizations can accept any responsibility for personnel material or inconsequential injury loss or damage that results from improper use of the equipment and accessories SAFETY SYMBOLS WARNING N CAUTION Risk of Electrical Shock Refer to Accompanying Documents Off Supply Direct Current DC Standby Supply ee Alternating Current AC On Supply 3 Three Phase Alternating Current Protective Conductor Terminal L Earth Ground Terminal 6 G amp 0 gt Fuse Jd Chassis Ground This page intentionally left blank Product Family Photovoltaic Simulator Warranty Period One Year WARRANTY TERMS AMETEK Programmable Power Inc AMETEK provides this written warranty covering the Product stated above and if the Buyer discovers and notifies AMETEK in writing of any defect in material or workmanship within the applicable warranty period stated above then AMETEK may at its option repair or replace the Product or issue a credit note for the defective Product or provide the Buyer with replacement parts for the Product The Buyer will at its expense return the defective Product or parts thereof to AMETEK in accordance with the return procedure specified below AMETEK will at its expense deliver the repaired or replaced Product or parts to the Buyer Any warranty of AMETEK will not apply if the Buyer is in default under the Purchase Order Agreement or where the Produ
19. he firmware update process START CLEAR WINDOW Verify that all PV simulators are detected Discovering PV simulators Found 10 PV simulators Click on the START button to begin a PY Simulator Firmware Update Utility v1 0 0 0 The process takes about one minute for Select a Instructions 1 pm connection Tum off the PV simulator s Set F5 ETS series or SW 8 all other PV each simulator during which activity imulators to the ON position f udpating a stand alone PV simulator plug i Deg the Deng cable and set the computer IP address to 10002 nehwok details are displayed When all PV RS 232 mask 255 255 0 0 If udpating a rack system no IP address changes are ired Ti the PV simulatoris On rack systems verify that all LAN A ge ee Pa bldene halo preceding tah cl DISCOVER D simulators are successfully updated a ct Verify that the number of units di di ct then click d Wim o green COMPLETED sign is shown DISCOVER CLEAR WINDOW COMPLETED UNIT 10 CPU 2 Bootload 1 0 S I PTE pen If any step fails on one or more units a UNIT 10 CPU 2 Erase flash sful d d UNIT 10 CPU 2 Program flash successful red FAILED SIGN IS displayed In this UNIT 10 CPU 2 Verification successful yg I er case scroll the activity window to locate UNIT 10 CPU 1 Bootload 1 0 UNIT 10 CP PU 1 Sofware verson PVSIM32 M003 v1 00 which un
20. it failed to update and then UNIT 10 CPU 1 Erase flash successful UNIT 10 CPU 1 P flash sful E serie contact the factory for assistance UNIT 10 CPU 1 Started execution e Turn off all PV simulators e Onall PV simulators slide the F5 switch back to the OFF position e urn on all PV simulators e Confirm the STATUS LED blinks as usual on all PV simulator front panels e Continue to section 4 1 2 to update the TerraSAS software and complete the process Note the firmware update process can be repeated as many times as desired in the unlikely case that something goes wrong However after one or two failed attempts it is strongly suggested to contact the factory for assistance IMPORTANT avoid shutting down power turning off the computer or the PV simulators while a firmware update is in progress While these events have been extensively tested and caused no harm during software verification it is advisable to refrain from intentionally causing them 31 32 This page intentionally left blank 5 1 5 2 SECTION 5 CALIBRATION REQUIRED EQUIPMENT The Elgar PV simulator supports fully automated calibration which requires the following equipment software and associated documentation Agilent model 34401A or Keithley 2000 Digital Multimeter TerraSAS Calibration Suitcase Elgar p n 5609175 01 TerraSAS Calibration software v2 0 0 1 or above Elgar p n 5609174 XX TerraSAS Calibratio
21. low chassis ground The equipment used contains ESD sensitive ports When installing equipment follow ESD Safety Procedures Electrostatic discharges might e cause damage to the equipment WARNIN Only qualified personnel who deal with attendant hazards in power supplies are allowed to perform installation and servicing Ensure that the AC power line ground is connected properly to the Power Rack input connector or chassis Similarly other power ground lines including those to application and maintenance equipment must be grounded properly for both personnel and equipment safety Always ensure that facility AC input power is de energized prior to connecting or disconnecting any cable In normal operation the operator does not have access to hazardous voltages within the chassis However depending on the user s application configuration HIGH VOLTAGES HAZARDOUS TO HUMAN SAFETY may be normally generated on the output terminals The customer user must ensure that the output power lines are labeled properly as to the safety hazards and that any inadvertent contact with hazardous voltages is eliminated Guard against risks of electrical shock during open cover checks by not touching any portion of the electrical circuits Even when power is off capacitors may retain an electrical charge Use safety glasses during open cover checks to avoid personal injury by any sudden component failure Neither AMETEK Programmable Power Inc San Diego Cali
22. n User Manual Elgar p n M609174 01 OPERATION The calibration suitcase has an internal calibrated precision shunt It connects to the simulator output the digital multimeter and the AUX I O connector on the rear panel All cables and accessories are included in the suitcase After installing and running the software the user is guided through a simple procedure which takes about five minutes to complete 5 3 CALIBRATION INTERVAL The recommended calibration interval for all Elgar PV Simulators is one year 33
23. n the READ ME file and if instructed to do so execute section 4 2 to update the PV simulator firmware ES m Open the folder named TerraSAS Organize v Open Burn New folder E Videos Name Date modified Install and double Click on the ll cnp Application Files ll Setu p exe file fb LocalDisk c T setup exe 7 21 2011 2 29 Se E TerraSas application 1 21 2011 2 29 ew ADATA UFD G L RLucca Nca san fsl ATI m 29 4 2 30 e ication Security Warni j Application Install Security wor MM Follow the instructions and then omenaa ri EE Z accept the security warning by clicking on the Install button Name ee The updated TerraSAS software pen ai gada jata agen IE E einer ang will launch as soon as the above Publisher dialog will complete Unknown Publisher Install Don t Install While applications from the Internet can be useful they can potentially harm your computer If you do not trust the source do not install this software More Information To complete the process copy the updated software user manual M609155 01 Rev X pdf and Example scripts vX X to your My Documents folder PERFORMING FIRMWARE UPDATES This procedure updates the computer code running on the two embedded processors within the PV simulator e Refer to the screenshots in section 4 1 2 to download and install the PV Updater software on the TerraSAS control com
24. nd current waveforms to the unit under test 1 5 ETS80X10 5C SPECIFICATIONS DC Output Output isolation Output leakage Tracking speed Accuracy Sampling resolution Curve Resolution Profiles resolution Curve equations PV Array Parameters Expansion Available I O Remote sense Input Nominal Voltage Open Circuit Voltage Voc 80 V Short Circuit Current Isc 10 5A Maximum output power 714W at fill factor 0 85 1000 Vpk positive or negative output to chassis ground continuous Output to chassis ground DC gt 100 MO Output to chassis ground AC 0 045 uF typical Compatible with micro inverters sweeping the MPP at up to 250 Hz and power optimizers Voltage programming and readback 0 2 of full scale voltage Current programming and readback 0 5 of full scale current Voltage and current are synchronously sampled by two independent 16 bit A D converters at 200 kS s 1 024 points Each point represents a single voltage current point on the IV curve The PV simulator interpolates the 1 024 points in its curve memory with 16 bit resolution delivering an actual curve resolution of 65 536 points There is no limit to the profile length One second profiles for a full day of simulation are typically 50k points The simulator interpolates between points 128 times per second delivering smooth voltage and current waveforms that closely resemble real solar arrays under cloudy conditions requires TerraSAS
25. not be accepted and will be returned at the shipper s expense NOTE A returned product found upon inspection by AMETEK to be in specification is subject to an evaluation fee and applicable freight charges vi This page intentionally left blank SECTION 1 PRODUCT OVERVIEW nnnnnnnnnnnnnnnnnnnnnnnnsnnnnnsnnnnnnnnnnnnnnnnnnnn 5 US MANON LOT EEE ENE EEE EE 5 hee USENET er 5 t3 ADPICADE Egar PATNIAMDES istis notio nies Ian a 5 1 4 PV Simulator Block Diagram secnm n a ga EN a NG 6 1 5 EIS80X10 5G Specifications vc ccc saa na nenne AN AN AA ENG 7 426 Mechanical ClAWING EE 9 SECTION 2 INSTALLATION siang ga weed ad a Ga paka a Waa aa aa aaa a ae aaa 11 2 1 UNPACKING ana NEPPE e vasse 11 22 PETN 12 ERE AGADU E 12 22 DENN 12 223 Ene ege aa IIa Ega NENENG M utedeta Ne 12 22 NI iden usui t dA iE 13 225 ON S Qm 13 2 3 Rear panel switches and indicators s sssesseseeenenennnrnrerreerrnrrnerreeene gt 14 2 4 Gaeren 14 2 5 System assembly recommendations n nnnnannnennnnnnnnennonnennnnnnnnennnenn 15 SECTION 3 OPERATION gg egertetege uiegg ba ngana geg aa aa aaa dead andet 17 3 1 CGonnechngfoaCGomputier 17 dud NEIWOIK CONHOOrAUOM riensi a 17 3 1 2 System configuration cccccceeccceeeeceeeeceeeceueeceueeseusecseeeseaees 19 92 Protecuons ara FaulbIhdiICalOlS vassere 20 3 2 1 Over Temperature Protection OTP 20 3 2 2 Over Power Protection OPP 2
26. puter If a previous version of the PV Updater is present refer to the screenshots in section 4 1 1 to remove it All PV simulators connected to the computer will be updated In case it is not desired to update some of the simulators that are present on the network turn them off before starting the process e Turn off all PV simulators Locate the 8 position switch on the rear side of the PV simulators see figure 1 5 e Onall PV simulators slide the F5 switch to the ON position e Turn on all PV simulators Note that the front panel STATUS LED does not blink as usual as PV simulators entered firmware update mode Wait 10 seconds to allow all simulators to acquire an IP address r a PV Simulator Firmware Update Utility v1 0 0 0 Selecta instructions Double click on the PV updater icon to start connection Tum off the PV simulator s Set F5 ETS series or SW 8 all other PV SE simulators to the ON position If udpating a stand alone PV simulator plug in ges the Ethemet cable and set the computer IP address to 10 0 0 2 network th e fi rmwa re u pd ate u tl Ity RS 232 mask 255 255 0 0 f udpating a rack system no IP address changes are required Tum on the PV simulator s On rack systems verify that all LAN USB LEDs are fast blinking before proceeding When ready click DISCOVER to connect Verify that the number of units discovered is correct then click Click on the DISCOVER button to con nect START to begin t
27. r The mating connector is provided with the unit Electrical signals are listed below AUX I O CONNECTIONS MATING CONNECTOR TYPE D SUB 15 PIN MALE DESCRIPTION VOLTAGE CURRENT COMMENTS CAN BUS H Not supported by current RS 485 D Not supported by current IRRADIANCE INPUT 0 to 2 5V 10 JA 0 to 1999 Wim 1 TEMPERATURE INPUT 0 to 2 5V 10 HA 100 C to 100 C 1 INTERLOCK Output turns off if interlock 24V 20 lt 3 mA signal is not present unless interlock override is active INTERLOCK DIP switch F3 2 FAULT OUTPUT Not supported by current 11 CAL RELAY Used by calibration fixture i 5 SIGNALS GROUND BODY GHASSISGROUND __ Connectto cable shield Table 3 Auxiliary LO connections NOTES 1 See software user manual for details about monitoring these signals or allowing them to control an IV curve in real time 2 The interlock input is isolated from ground and can tolerate up to 100V from each input to chassis ground This input is handled by the microcontrollers and is therefore not intended for safety critical applications Electromechanical relays or circuit breakers that remove the AC input to the simulator are required to meet safety regulations when failure to operate could harm human operators or otherwise represent a safety hazard 3 This input accepts standard TTL CMOS logic levels It also accepts an isolated relay contact due to the internal pull up resistor to 5V When
28. r more simulators Validate settings upon exit 17 18 When controlling more than one PV simulator an Ethernet switch is required PV Simulator Ethernet TerraSAS DHCP assigned Switch IP address and Subnet IP address 1 1 1 1 Subnet Mask 255 255 0 0 TerraSAS DHCP Server ACTIVE TerraSAS DHCP assigned IP address and Subnet Mask PV Simulator Figure 3 2 Private network connection When setting the computer s IP address to 1 1 1 1 the TerraSAS DHCP server is automatically enabled In this topology always make sure that the computer is turned on and a user is logged in before turning on the PV simulators Within a few seconds all PV simulators are assigned an IP address When this happens the LAN LED on the rear panel see figure 1 5 starts blinking faster This confirms that the Ethernet network is active and working properly If desired the Ethernet switch can be connected to the Local Area Network DHCP enabled LAN PV Simulator Ethernet DHCP assigned IP Switch address and Subnet Se DHCP assigned IP address and Subnet Mask PV Simulator DHCP assigned IP address and Subnet Mask Figure 3 3 Local area network connection In this topology the Ethernet adapter must be configured for DHCP Obtain an IP address automatically and Obtain DNS server address automatically see screenshot on previous page The advantage of this method is that PV simulators and computer
29. rackets to properly support the weight of the simulators Use the supplied M5x8mm screws to install the rack slides Longer screws will damage the unit Ensure adequate ventilation is provided to avoid excessive temperatures Elevated temperatures reduce the life of the unit and can cause over temperature protections to trip NA lt Solar inverters can produce EMI fields both radiated and conducted On the control computer it is advisable to avoid using touch pads as this technology is very sensitive to RF fields and will likely malfunction Optical trackballs or mice provide the best results Optical isolation on USB keyboards is recommended to avoid possible lock ups and erratic operation Suitable USB isolators can be purchased from Ametek isolator p n 881 004 06 and short A B cable p n 890 504 03 USB isolators need to support the USB 1 1 low speed protocol 1 5 Mbits s in order to work properly with most keyboards Keep data and control lines wiring as far as possible from AC and DC power and sense lines a Always use shielded Ethernet cables Use shielded cable for all signals connecting to the AUX I O connector Connect the shield to the connector body When connecting to transformer less inverters use wire terminal blocks and connectors rated for 1000V operation on all output and sense wiring 16 This page intentionally left blank SECTION 3 OPERATION 3 1 CONNECTING TO A COMPUT
30. roinverter test sein 22 Figure 3 6 Test setup for a single power optimizer 23 Figure 3 7 Power optimizers feeding a solar inverter 24 Figure 3 8 PV Simulators connected in parallel sss 25 Figure 3 9 PV Simulators connected in seres 26 LIST OF TABLES Table T AG Tine corda TTC e EE 12 Table 2 DC output connections saa ea ceeeceeeeeeeeeeeeseeeceeeeaeeeseeeseeeeaeeas 12 Table 3 Auxiliary I O connections Table 4 Linear regulator temperature events This page intentionally left blank SECTION 1 PRODUCT OVERVIEW 1 1 INTRODUCTION The Elgar PV Simulator is a programmable digital power source designed to simulate the electrical behavior of terrestrial photovoltaic arrays The simulator provides a turn key hardware and software solution to deliver all the functionality required to test the maximum peak power tracking MPPT characteristics of solar inverters and charge controllers The ability to simulate any fill factor and material technology allows the simulator to characterize the inverters MPPT algorithm performance quickly and efficiently It also allows to perform conversion efficiency thermal analysis and dynamic performance tests by supplying a highly stable and repeatable stimulus to the inverter under test 1 2 USER INTERFACE The simulator front panel only features an on off swi
31. s can be located anywhere on the LAN as long as they share the same subnet network segment behind a router The disadvantage is that PV simulators are accessible to any computer on the LAN which could lead to unauthorized access and safety hazards Never set the computer IP address to 1 1 1 1 in this topology as the TerraSAS DHCP server will interfere with the LAN s DHCP server and cause serious service disruptions When it is desirable to control the TerraSAS computer from a remote location a computer featuring two Ethernet adapters is recommended DHCP enabled LAN PV Simulator Adapter 1 DHCP assigned IP address and TerraSAS DHCP Subnet Mask assigned IP address and Subnet Mask Ethernet Switch Adapter 2 PV Simulator IP address 1 1 1 1 Subnet Mask TerraSAS DHCP 295 255 0 0 assigned IP address and Subnet Mask Figure 3 4 Dual network connection oee the software user manual for software configuration details and one time DHCP server startup procedures 3 1 2 System configuration Once the desired network has been wired and configured launch TerraSAS The software will inform that a system configuration table needs to be created and automatically opens the appropriate form The purpose of the configuration table is to establish which PV simulators are to be controlled and what channel number should be assigned to each one Once the system configuration table has been created and stored TerraSAS will only comm
32. software Equations used to calculate and translate the IV curves are found in Appendix A1 and A2 of the publication Performance test Protocol for Evaluating Inverters Used in Grid Connected Photovoltaic System October 2004 Sandia National Labs Irradiance level 0 to 1999 W m Temperature value 100 C to 100 C Voltage level 0 to 80 VDC Current level 0 to 10 5 A Voltage and power temperature coefficients 1 99 C Up to 48 units can be controlled by a single PC running TerraSAS Software Ethernet 10 100 Mb s TerraSAS software proprietary high speed link Analog Irradiance Temperature inputs allow to adjust the IV curve in real time based on two external analog signals Trigger input allows to start executing an irradiance temperature profile in sync with external equipment Useful for accurate energy measurements using external power analyzers SCPI interface through TerraSAS software Maximum line drop 1V per line Single phase ground 100 240 VAC nominal operating range 85 264 VAC Input Frequency Power Factor OVP Accuracy OVP Resolution Output noise Current noise Efficienc MPP Stabilit Temperature Coefficient Operating Temperature Storage Temperature Humidity Range Altitude Cooling Regulatory Pollution degree EMC Directive Accessories Physical 47 63 Hz gt 0 99 typical 0 2 of full scale voltage 0 002 of full scale voltage lt 0 35 Vpp measured across
33. tch and a status indicator The user interacts with the simulator through a remote Ethernet connection A single desktop or laptop computer running TerraSAS software can control up to 48 simulators Due to the high transmission speed and data integrity provided by the Ethernet architecture operating parameters are displayed in real time on the computer screen at refresh rates comparable to standard instrumentation The software allows modeling a PV panel from data normally found in the manufacturer data sheet These parameters are Voc open circuit voltage Isc short circuit current Vmp voltage at the maximum power point Imp current at the maximum power point Bv voltage temperature coefficient and Bp power temperature coefficient In addition to static tests the software allows to execute irradiance temperature profiles that can closely duplicate real life conditions or predefined test sequences 1 3 APPLICABLE ELGAR PART NUMBERS ETS80X10 5C PVF 80V 10 5A 100 240VAC ETS80X10 5C PVE 80V 10 5A 100 240VAC 1 4 PV SIMULATOR BLOCK DIAGRAM pe ee ee ee ee E AUXILIARY L SUPPLY FRONT PANEL N 24V 30W LOW LEAKAGE ON OFF SWITCH OUTPUT FILTER OUTPUT 100 240vac Loi OUT AN 47 63 Hz N DC SOURCE ST N G0 80 100 150 300 V OUT d 12A MAX 850 W GND VSET NEG A COMPUTER sns SNS A Em ETH2 ETHERNET 100 Mb
34. tween the simulator output and the inverter input must not exceed 2 V 25 3 3 5 Series connections Up to three ETS80 simulators can be connected in series to achieve output voltages of up to 240 V See electrical connections below PV Simulator Inverter PV Simulator PV Simulator Figure 3 9 PV Simulators connected in series Once the electrical connections are made select System gt Channels grouping setup to configure the software for the desired wiring See the software user manual for full details Series connections are not recommended and should only be used as a last resort when PV simulators with the appropriate output voltage cannot be procured Main areas of concern are e Measurement accuracy and response speed are negatively affected e Overvoltage protection levels under transient conditions can be inaccurate and can deviate from the programmed values Since one simulator in the string executes a slice of the programmed IV curve while the others are set to a fixed voltage to deliver the desired total Voc operation at fill factors below 0 7 can lead to noticeable IV curve distortions below V N where N is the number of series connected simulators 26 SECTION 4 COMPUTER MANAGEMENT 4 1 PERFORMING TERRASAS SOFTWARE UPDATES 4 1 1 Step 1 Uninstall TerraSAS Click on the Windows 7 logo and select Control Panel Calculator OrCAD Capture d FJ Paint Control Panel Devic
35. unicate with the specified simulators in the order that has been selected Up to four configuration tables can be stored and retrieved allowing additional flexibility Detailed system configuration instructions are described in the software user manual and are also shown on the configuration form that opens in the software Do not begin configuring a system until all simulators have acquired an IP address Network communication must be healthy before the PC can discover and connect to the simulators 3 2 PROTECTIONS AND FAULT INDICATORS The ETS80 features several protections that are designed to prevent damage to the unit when operating limits are exceeded When one or more fault conditions occur the FLT indicator turns red TerraSAS software and the unit s front panel status LED shows the two pulse sequence see section 2 4 3 2 1 Over Temperature Protection OTP The temperature of the linear regulator module is monitored by a precision sensor The reading is always displayed when placing the cursor on the FLT indicator If the temperature exceeds 70 C operation continues but the FLT indicator turns yellow warning that the over temperature protection will soon trip When the temperature reaches 75 C the FLT indicator turns red and the power module is turned off Operation resumes as soon as the temperature drops below 75 C the output is turned off Safety thermostat trips and protects the unit in case of temperature sensor
36. view 0000000 00000000 Figure 1 5 Rear I O panel 10 SECTION 2 INSTALLATION 2 1 UNPACKING AND INSPECTION After unpacking the unit inspect the contents for any obvious physical damage If damage has occurred contact the shipper of the hardware If replacement parts are required contact Ametek Customer Service at 1 800 733 5427 ext 2295 or 858 450 0085 ext 2295 The following items should be included ELGAR P N DESCRIPTION TY 5609520 01 CABLE ASSY DC OUTPUT ETS 1 890 890 72 CORD SET 15A 125V USA CANADA 1 890 006 05 CABLE 8P RIJ45 SHIELD CAT ae 5FT 1 856 017 06 CONN 6P HOUSING MALE PLUG 1 856 008 0Y CONN CONT 14 16AWG CRP PIN 6 856 247 15 CONN BACKSHELL 15P D SUB 2 PC 1 856 DA1 5P CONN 15P D SUB SOLDER CUP PIN 1 110 032 001 SCREW 10 32 X 500 BLACK 27038 4 110 M5F 08 SCREW M5 X 8MM PFH CS ZN PLATE 10 M551066 04 MANUAL PVSIM ETS80 TSAS 1 5609155 06 S W TERRASAS V1 7 3 0 TSAS 1 Extra items can be supplied on request Customized AC and DC cable assemblies can also be ordered Please contact the factory for details 11 2 2 ELECTRICAL CONNECTIONS 2 2 1 AC Input See figure 1 4 to locate the AC input receptacle The supplied AC cord allows to power the unit from domestic wall outlets rated for 120V 13A For rack mounted and international installations remove the Nema US style plug Strip the insulation jacket and connect the wires to a suitable terminal block or localized AC plug Conne
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