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User Manual - MLT Inverters

1. SP No Name Description Default Values 012 Src A Size Source A B total kVA capacity Must not be more than the total 8kVA kVA of the all the Inverter s internal inductor Contact MLT for details 013 Src B Size Source details can be found in Section O 8kVA Connecting External Sources 016 Src A Type Defines Source A B type there are three settings UTIL UTIL Utility Supply Grid Also use this setting for a manually started and stopped generator GEN Generator use this setting if the generator is to be 017 Src B Type controlled by the inverter UTIL NONE Use this setting to disable using the source 018 Source A Source A Optimum Load indicates the load level that the control 80 Optimum Load system will attempt to maintain on source A while operating in any automatic parallel mode This setting is expressed as a percentage of the SPO12 Src A Size setting 019 Source B Source B Optimum Load indicates the load level that the control 80 Optimum Load system will attempt to maintain on source B while operating in any automatic parallel mode This setting is expressed as a percentage of the SPO13 Src B Size setting POWERSTAR USER MANUAL PAGE 23 SP No Name Description Default Values 045 Source Import Inhibit Time Start From the Source Import Inhibit Time Start to Source Import Inhibit Time Stop the inverter will reduce the imported power to zero KW in the event that the source is a UTILITY If the
2. PAGE 78 POWERSTAR USER MANUAL Fault Message Displayed Description High Source A Volts High Source B Volts High Source A or Source B Volts Reason The voltage from the source that was on line was too high and out of range and the source has been disconnected If the source was a generator then the system will attempt to start and connect to it four times If the fault is still present the system selects another generator as the source Action a Reset source volt or replace source b Carry out Fault Reset C If fault continues contact Technical Support see page 12 Low Source A Volts Sag Low Source B Volts Sag Low Source A or Source B Sag Reason A sudden drop in the voltage supply from source A or B supply caused the system to disconnect from the source If the source is a generator 4 attempts reconnect are made The source is masked if the fault continues after the fourth attempt Action a Reset source volt or replace source b Carry out Fault Reset C If fault continues contact Technical Support see page 12 High Source A Volts Surge High Source B Volts Surge High Source A or Source B Surge Reason A sudden rise in the voltage supply from source A or B supply caused the system to disconnect from the source If the source is a generator 4 attempts reconnect are made The source is masked if the fault continues after the fourth attempt Action a Reset source volt or repl
3. 18 kVA or 18000W divided by 36V 500A PAGE 58 POWERSTAR USER MANUAL 185 Ah divided 500A x 100 37 Maximum Battery Charging Current 37 You battery settings should be as listed below Changes from default indicated in bold Setpoint Parameter Default New 068 Battery Capacity 0600 Ah 1850 Ah 069 Battery Peukert Factor 1 21 1 15 070 Batt Float Cell Volts 2 17VPC 2 25 VPC 071 Batt Bulk Cell Chg Volts 2 32VPC 072 Batt Equ Cell Volts 2 40VPC 073 Batt Equ Time Interval 744hrs 074 Batt Equ Chg Period 2hr 4hr 075 Batt Bulk Chg Period 2hr 076 Batt Min Bulk Chg 10 077 Equ Enabled NO YES 079 Batt Min Equ Chg 5 084 Upper Temp Compnsatn 5 5mV C 085 Lower Temp Compnsatn 5 5mV C 086 Zero Compnsatn Upper temp 30C 087 Zero Compnsatn Lower temp 2C 088 Min Compnsatn Upper Temp 50C 089 Min Compnsatn Lower Temp 1C 090 Max Batt Chg Amps 20 41 091 DC Recon Volts 2 250VPC 093 Batt Low Shut down Volts C1 1 700VPC 094 Batt Low Shut down Volts C5 1 800VPC 095 Batt Low Shut down Volts C100 1 950VPC 096 BattOvertemp Shut down 48 C 133 Blk Chg Start Time 00h00m 5 6 3 Exa mple 3 5 6 31 inverterand Battery Type You have a MLT PowerStar 4 KVA MLT 48V Inverter The battery comprises 2 strings of Delkor GP31 102 Ah at 20 hour discharge rate batteries As a Delkor GP31 battery has a 12 V nominal terminal voltage there are 4 batteries in each string to provide the required 48 V nominal voltage As there are 2 strings there are
4. Src A Cooling Down Source A is cooling down for the duration of the cool down period If the source is a utility the cool down period is less than 20 seconds Src B Cooling Down Source B is cooling down for the duration of the cool down period If the source is a utility the cool down period is less than 20 seconds Source A contactor has closed after the contactor coil has been Src A CB Closed energized Src BCB Closed Source B contactor has closed after the contactor coil has been energized SEKER Opened Source A contactor has opened after the contactor coil has been de P energized Also indicates that batteries are discharging Source B contactor has opened after the contactor coil has been de Src B CB Opened A P j energized Also indicates that batteries are discharging Src Stop High AC V Source Utility has been stopped because it is out of range AC Volts too high Source Utility has been stopped because it is out of range AC Volts Src Stop Low AC V too low Src Stop High Freq Source Utility has been stopped because it is out of range Frequency too high Src Stop Low Freq Source Utility has been stopped because it is out of range Frequency too low Src Stop High DC Source Utility has been stopped because it is out of range DC Voltage too high Island Detect Source has been stopped because it is out of range Islanding detected Gen Stop Low load
5. will disconnect Source B and report a Source B Low Voltage fault If Source B is set as utility it will reconnect when Source B is within normal operating range and the Utility Detect Time has expired 8196 053 Src B Low Freq Offset This setting defines the frequency offset from the System Nominal Frequency 50HZ that Source B can deviate before a Low Frequency Fault is reported If Source B is set as utility it will reconnect when Source B is within normal operating range and the Utility Detect Time has expired 3Hz 054 Src B High Freq Offset This setting defines the frequency offset from the System Nominal Frequency 50HZ that Source B can deviate before a High Frequency Fault is reported If Source B is set as utility it will reconnect when Source B is within normal operating range andthe Utility Detect Time has expired 3Hz POWERSTAR USER MANUAL PAGE 25 Table 3 MENU gt System Config Setup gt System Setup gt Utility Options SP No Name Description Default Values 057 Export Enabled Option to export power to the utility if excess renewable energy is available If export is disabled SP111 Inv Tracks Src Volts must be enabled No 058 Max Export Power The Maximum Export Power that can be delivered exported to a source For a Grid connected system this setting should be set to 100 to export as much renewable energy as
6. 8 B FUEL FLOWS ONLY DISPLAYED IF FUEL INMPUT SPEED SENSOR IS CONNECTED TOMPC FLOW SENSOR IN APPLICABLE GENERATOR IS CONNECTED TOMPC Figure 18 Screen 13 Miscellaneous Logs 3 14 Temperatures AMBIENT TEMPERATURE OUTSIDE MPC CABINET MPC INTERNAL HEATSINK BATTERY TEMPERATURE DISPLAYED ONLY IF MPC CABINET INTERNAL TEMPERATURES BATTERY TEMPERATURE SENSOR IS INSTALLED TEMPERATURE Figure 19 Screen 14 Temperatures 3 15 System Information MPC SOFTWARE VARIABLE TABLES DIGITAL SIGNAL PROCESSOR GSM FIRMWARE REVISION NUMBER VERSION NUMBER FIRMWARE VERSION VERSION NOMINAL VOLTAGE amp WiFi FIRMWARE KEYPAD FIRMWARE FREQUENCY VERSIOI VERSION MPC SERIAL NUMBER Figure 20 Screen 15 System Information PAGE 44 POWERSTAR USER MANUAL 4 Connecting Exemal Sources 41 General Generally external sources will be connected and setup at the time of the installation It may be however that a standby generator is required due to for example grid supply problems Another possibility is that your load has increased and the source generator you are using cannot cope and must be replaced by a higher capacity model 42 TypesofGenerator Both manual and electric start generators can be used If an electric start generator is installed the inverter can control its operation switching it on and off as required The better the quality of the generator that you install the less the likelihood there is of problems occurring after insta
7. 8 batteries in total The Delkor GP31 is a sealed lead acid battery with the following properties Capacity at 20 hour discharge rate C20 102 Ah Capacity at 5 hour discharge rate C5 85 Ah Peukert Factor 1 15 POWERSTAR USER MANUAL PAGE 59 5 6 32 Capacity and Peukert Factor Total capacity C5 of the system 2 strings 85 x 2 170 Ah 5 6 3 3 Battery Charging Hoat and Bulk Sage Voltages Check both the Battery Float Cell Charging Voltage and the Battery Bulk Cell Charging Voltage must be as specified in the battery data sheet In this case only the Battery Float Cell Voltage need be changed 5 6 34 Equalisation The Delkor GP31 is a Sealed Lead Acid Battery Do not Equalise Ensure Equalise Enable is left set to NO 5 6 35 Maximum Battery Charging Curent The battery shunt size in a 4 kVA inverter is 80A If the battery capacity at the 5 hour discharge rate is 170 Ah then the Maximum Battery Charging Current is 10 of 170 which is 17A 17A divided by 80A x 100 21 5 Maximum Battery Charge Amps Thus the default Maximum Battery Charging Current 5096 should be reduced You battery settings should be as listed below Changes from default indicated in bold Setpoint Parameter Default New O68 Battery Capacity 0600 Ah 170Ah 069 Battery Peukert Factor 124 1 15 070 BattFloat Cell Volts 2 14VPC 2 20 071 Batt Bulk Cell Chg Volts 2 35VPC 072 Batt Equ Cell Volts 2 40VPC 073 Batt Equ Time Interval 744hrs 07
8. A Bypass Switch must be fitted when the inverter is connected to the Grid grid tied It allows the grid supply to be fed directly through to the load and should be used whenever work has to be carried out on the Control Box Inverter Module or associated wiring A complicated Hot Swop Bypass Box circuit is shown in Figure 4 Alternatively a standard change over switch with sufficient current rating can be used Bypass Switch I Cc I T CE Supply Inverter I Inverter Load Input Output Breaker Breaker Bypass Switch CLOSED ON Bypass Inverter Input amp Output I E OFF Breaker OPEN Invarief pn ON Bypass Switch OPEN Normal Inverter Input amp Output mn OFF Breaker CLOSED T Battery Figure 4 Hot Swop Bypass Box Circ uit PAGE 18 POWERSTAR USER MANUAL 224 Hot Swop Bypass Switch 22 41 BypassOperation CAUTION ensure grid and inverter are in sync before closing bypass switch The inverter is synchronized to the grid if the inverter is in Auto Source Plus Inverter mode See section 4 1 1 Operational Modes To route grid supply directly to load 1 CLOSE turn ON Bypass Switch on Bypass Box i e route grid supply directly through to load 2 OPEN turn OFF Invert Input and Inverter Output Circuit Breakers on Bypass Box inverter is now isolated from grid NOTE Wait for at least 30 seconds before recovering from bypass and going to Normal Mode again 2242 Nomal Mod
9. Charge Period which is the maximum time that the equalizing charge is applied for default setting 2 hours SP077 Battery Equalisation Enabled which is set to YES for flooded batteries and NO for sealed batteries default setting NO Note that the default settings are typical settings and if necessary should be changed in accordance with the battery manufacturer s instructions A CAUTION An equalization charge MUST ONLY be performed on vented not sealed flooded lead acid batteries in a place with adequate airflow 542 Temperature Compensation Lead acid battery performance is temperature dependent in that the available capacity and maximum current both change from low temperature to raised temperatures To optimise performance over a wide temperature range inverter menu options allow the following to be set SP86 and SP87 Zero Compensation Upper Temp and Zero Compensation Lower Temp Between these two temperatures a compensation to the battery charging voltage curve is applied SP84 Upper Temp Compensation which is the temperature compensation voltage applied per degree centigrade for temperatures above the zero compensation upper temperature default setting 5 5 mV C PAGE 52 POWERSTAR USER MANUAL SP85 Lower Temp Compensation which is the temperature compensation voltage applied per degree centigrade for temperatures below the zero compensation lower temperature default setting 5 5 mV C SP88 Min Compensation Upper Tem
10. Fault a Carry out Fault Reset b If fault continues contact Technical Support see page 12 High DC Volts High DC Voltage Reason The battery voltage has exceeded its safe high limit The solar regulator will be tripped and if the fault persists the source will be masked If the condition still persists the inverter is masked eventually Action a Make sure that there are no external DC sources solar wind that are not controlled by the Multi Power Controller system and that could cause the battery to overcharge b If an external AC grid interactive system is connected make sure that the Inverter Charge Control setting is enabled and set up correctly Menu gt System Config Setup gt System Setup gt Inverter gt 126 Inv Chg Max C Carry out Fault Reset d If fault continues contact Technical Support see page 12 PAGE 76 POWERSTAR USER MANUAL Fault Message Description Displayed Low DC Volts Low DC Battery Voltage Reason The battery voltage is below the minimum required voltage and the inverter has shut down Discharging the batteries further will reduce their capacity and lifespan Action a Charge battery immediately to prevent permanent damage to the batteries b To charge the batteries Set the machine to auto and remove any loads Make sure a source is connected and running Tosee if the batteries are charging check screen 2 System Overview The top right corner should
11. Operation 63 8 l O Extender A eee t E EG ee EET ANE RES 64 SCH A EDO Ee 64 8 1 1 Generator Start oerte eee OEEESNEEEEeeEN 64 8 1 2 Smart Load Relay teu ii 64 A lA n en a t t e e eh a 66 8 3 7 3 Communications and Paralleling eee 67 9 System ConfiBU tatioris s 2 2 e d t toes a si a dre dae 68 9 1 Limiting Exports AA N TREE 68 TA Introd ction ii dt 68 9 1 2 Configuration a 68 92 Self ConsUMPUO st Ee N Ni ei i e E EO NET 68 EAM isi EE iia bici 68 9 2 2 Config ration a aaa 68 9 3 Paralleling Inverters si EE SN eet d ie e e e e ie 69 913 T Introduction ectetuer etie te deett ete eee renda 69 E en EE 69 0 33 Confipuratlon oii eene daa ie ie ie rete Ge i a Peter iet 69 10 TroubleshootlpB i RC nds 7 10 1 Events and Pauli oca 71 POWERSTAR USER MANUAL PAGE5 102 typical Problems A de 71 10 2 1 Why does the inverter not connect to a running generator 71 10 2 2 Why does the generator connect and then immediately drop out 71 10 2 3 Why does the Generator not stop when it should 72 10 2 4 Why didn t I get the usual capacity from my storage batteries 72 10 3 Fault Recover 73 10 3 1 Event Messages ss EE dee A ed yet ve iei eee pe S ERR Rea e 85 List of Tables Table 1 MENU gt System Config Setup gt System Setup gt System Options 22 Table 2 MENU gt System Config Setup gt
12. Period This setpoint sets the maximum time the system will remain in the battery bulk charge cycle This setpoint prevents prolonged charging of the batteries which may not reach Battery Minimum Bulk Charge SP76 due to a high internal resistance of the batteries which can be due to progressive ageing of the batteries The bulk charge cycle will end if this setpoint is reached or the Battery Minimum Bulk Charge SP76 limit has been reached 02h00m 076 Batt Min Bulk Chg Battery Minimum Bulk Charge The bulk charge will terminate if this setpoint is reached or the Battery Bulk Charge Period SP75 has expired This setpoint is expressed as a percentage of the battery shunt size SP67 10 077 Equ Enabled Equalisation Enabled If this setpoint is enabled the control system will periodically attempt to equalise the batteries to the equalisation cell voltage Set to NO for sealed batteries and YES for flooded load acid batteries NO 079 Batt Min Equ Chg Battery Minimum Equalisation Charge The equalisation charge cycle will end if this setpoint is reached or the Battery Equalisation Charge Period SP74 has expired This setpoint is expressed as a percentage of the battery shunt size SP66 596 082 Batt Taper To Float Rate This setting governs the time taken for the battery voltage to drop from the pre defined Bulk or Equalise battery voltage to the Battery Float Cell Voltage SP70 This sett
13. SrcB Iso SrcA Pwr Lo Source A Isolation Fail Source B Power Low or Source B Isolation Fail Source A Power Low Reason Source A or B isolation fail because Source B does not have enough power This fault will occur when selecting Manual Source B or A while in Manual Source A or B mode and Source B or A does not have the capacity to drive the current load Action a Reduce load or select other source b Carry out Fault Reset SrcA leo SrcB Masked SrcB Iso SrcA Masked Source A Isolation Fail Source B Masked or Source B Isolation Fail Source A Masked Reason Source A or B isolation fails because the alternate source was masked This fault will occur when selecting manual source B or A while in manual source A or B mode and source B or A is masked Action a Select other source b Carry out Fault Reset SrcA leo Inv Pwr Low SrcB lso Inv Pwr Low Source A Isolation Fail Inverter Power Low or Source B Isolation Fail Inverter Power Low Reason Source A or B could not be isolated because the inverter cannot supply the load onits own Action a Reduce load or select other source b Carry out Fault Reset POWERSTAR USER MANUAL PAGE 81 Fault Message Displayed Description Inverter CB Failed to Close Inverter Contactor Failed to Close Reason The inverter contactor did not close when required Could be wiring fault between the control box and the inverter module
14. Summary Screen SCREEN CURRENT BATTERY CHARGING NUMBER TIME STATE 0 1 2 3 OR 4 ROW 4 ROWS 2 amp 3 N SOLAR POWER BATTERY BANK TOTAL VOLTS amp AMPS BATTERY VOLTS PER CELL BATTERY BANK TEMPERATURE Figure 12 Screen 7 DC Summary POWERSTAR USER MANUAL PAGE 41 3 8 Battery StatusScreen SCREEN CURRENT TIME IN DAYS 01 HOURS MINUTES amp TEMPERATURE COMPENSATION NUMBER TIME SECONDS UNTIL THE NEXT EQUALISE CHARGE BEING APPLIED PER CELL BATTERY CHARGII BATTERY CHARGING MODE CURRENT INTO BATTERY BATTERY VOLTAGE PER STATE 0 1 2 30R 4 BULK EQUAL FLOAT OR NONE SHOWS OUT OF BATTERY CELL Figure 13 Screen 8 Battery Status For further information on equalising and temperature compensation see Equalisation on page 52 and Temperature Compensation on page 52 39 SolarSatusScreen SCREEN CURRENT IDENTIFIES WHAT THE SOLAR DUTY CYCLE NUMBER TIME SOLAR SYSTEM IS DOING SEE BELOW STATUS 09 03 09 Power 0000W MPPT REGULATOR FITTED SHOWS PANEL VOLTAGE CURRENT BEING DELIVERED POWER BEING DELIVERED BY OTHERWISE SHOWS BATTERY VOLTAGE BY THE SOLAR SYSTEM THE SOLAR SYSTEM DUTY CYCLE IS APPLICABLE ONLY TO BUILT IN MPPT REGULATORS AND SHOWS THE RATIO OF OUTPUT BATTERY TO INPUT SOLAR VOLTAGE E G AT 100 THE INPUT AND OUTPUT VOLTAGES WILL BE THE SAME BUT AT 50 THE OUTPUT WILL BE HALF OF THE INPUT VOLTAGE Figure 14 Screen 9 Solar Status 391 Current delivered by the Solar PV panels Duty cycle On
15. batteries b Source is a Generator and generator is on line and loading is less than minimum generator loading C Battery Voltage is greater than target voltage float voltage or bulk depending on charge stage d Battery Temperature is higher than battery over temperature setting e Heat sink 4 Solar reg is greater than inverter over temperature setting f Solar amps is greater than solar shunt size g Battery amps is greater than battery maximum charge current Action Take action depending on possible reasons listed above Wind Gen Trip Wind Generator Tripped Reason The battery voltage or temperature could not be reduced and the wind generator has been tripped or masked to reduce power to the batteries This fault can also occur if reverse power is supplied to the generator for too long Action a Check Generator settings b Check Battery settings e Contact Technical Support see page 12 Low Source A Volts Low Source B Volts Low Source A or Source B Volts Reason The voltage on the source that was on line was too low and out of range and the source has been disconnected If the source was a generator then the system will attempt to start and connect to it four times If the fault is still present the system selects another generator as the source Action a Reset source volt or replace source b Carry out Fault Reset C If fault continues contact Technical Support see page 12
16. by MLT Drives CAUTION Changing any of the settings without consulting MLT or the installation engineer may permanently damage the equipment and override safety features Overriding safety features may cause possible damage to the inverter external wiring and electrical equipment which may in turn cause fires damaging property POWERSTAR USER MANUAL Pe BP D POWERSTAR USER MANUAL CAUTION Do not cover the device or store it in a small space always keep it well ventilated well away from flammable gases or powders Components in the device can cause a small electric spark between contacts that could ignite flammable gas or powders Flammable gases are created by batteries in poorly ventilated spaces CAUTION For indoor use only and MUST be installed in a dry area free from conductive liquids or conductive debris If part of the inverter becomes submerged in water look for a safe way to isolate it at the distribution board and if possible at the fuses on the front Water can easily carry deadly electric current so if you are in any doubt call the fire brigade to disconnect the machine CAUTION Configuration and changes to system parameters should only be carried out by trained personnel unless otherwise specifically instructed by MLT support engineers CAUTION DO NOT connect solar panels directly to the solar input on a Powerstar that does not have a built in MPPT regulator PAGE 11 12 Contacting MLTDrives 121 Product Suppor
17. display either A I or BI to show that the source A or B is connected in parallel to the inverter 1 The battery current should be positive to charge batteries Note After al low DC volts fault the system will automatically clear the fault if a source is on line and the load is very low The inverter is then synchronized with this source and the batteries are re charged The low DC fault is also cleared if the battery voltage rises above the DC reconnect setting High DC Amps High DC Battery Amps Reason The charge current to the batteries is too high and could not be reduced with 10 seconds Action a Carry out Fault Reset b If fault persists the solar regulator could be unable to reduce the import current or the system settings are incorrect Contact Technical Support see page 12 Solar Trip Solar Source Tripped Reason The battery voltage or temperature could not be reduced and the solar source has been tripped or masked to reduce power to the batteries This fault can also occur if reverse power is supplied to the generator for too long Action a Check Generator settings b Check Battery settings c Contact Technical Support see page 12 POWERSTAR USER MANUAL PAGE 77 Fault Message Description Displayed Solar Charge Limit Solar Charge Limit Reason a Export is disabled Gird is present on line and Inverter would have to export excess power or dump itin order not to overcharge
18. generator use either TOGGLE ISOLATE SOURCE A or TOGGLE ISOLATE SOURCE B functions The output frequency of the generator is out of tolerance With budget priced generators the output frequency may increase with time If it exceeds Source High Frequency Offset assume set to 3 Hz then the generator will not connect This can be checked by accessing screen 2 System Overview and monitoring line 2 Src A B If the frequency displayed is 53 0 Hz it is out of tolerance The solution is to increase applicable Source High Frequency Offset maximum 10 Hz MENU gt System Config Setup gt System Setup gt Source gt 050 Src A High Freq Offset or 054 Src B High Freq Offset 922 Why doesthe generatorconnectand then immediately drop out This could be caused by the distortion of the output waveform of the generator being outside of the Fault Tolerance envelope that has been setup This fault generally occurs with budget priced generators The solution is to increase the Source Fault Tolerance MENU gt System Config Setup gt System Setup gt Source gt 056 Src Fault Tolerance until the generator stays connected POWERSTAR USER MANUAL PAGE 71 92 3 Why doesthe Generatornot stop when it should Access Menu gt Screens gt Source Status and check the display for a stop status message Reasons are CanStop The inverter has removed the generator signal and the generator should be stopping Generator Stop Average Period Src Ge
19. is manually or automatically issued Inv Unmasked The fault on the inverter module has been either manually or automatically cleared Inv CB Closed Inverter contactor has closed after the contactor coil has been energized Inv CB Opened Inverter contactor has opened after the contactor coil has been de energized Inv Ramp Down Signifies inverter power is ramping down to before disconnecting whilst in parallel mode Inv Fan Start Inverter heat sink fan has been started to cool the inverter Inv Fan Stop Inverter heat sink fan has been turned off as temperature is low enough Gen Start Src Fail Generator start as other source has failed Source A has been called to start either automatically or by selection of Start Src A Se Manual source A only from the keypad Source B has been called to start either automatically or by selection of Start Src B Manual source B only from the keypad Gen Saron Batt Generator is signaled to start as the battery voltage is less than the battery low threshold Gen Start High Load Source A or B is signaled to start as the inverter phase loading site is higher than the settable generator start on inverter load threshold Gen Start Inv Fail Source A or B is signaled to start as the inverter can no longer supply the load Gen Start Timed Start Source A or B is signaled to start as the generator periodic start period has expir
20. not cleared the inverter will shut down Sync L1 Fail The inverter will synchronise to phase 1 of the inverter Sync L2 Fail Reason On three phase systems the other phases are displaced by 120 degrees If Sync L3 Fail asignificant voltage is measured between the grid and the inverter voltage on any phase a sync error of the affected phase module will be displayed and the inverter is immediately stopped Action Contact Technical Support see page 12 POWERSTAR USER MANUAL PAGE 73 Fault Message Description Displayed Inv Overload Inverter Overload Reason The load on the inverter exceeds the inverter rating The inverter will have stopped to prevent overheating or damage to itself Action a Reduce Load and carry out Fault Reset b Contact Technical Support see page 12 Note In automatic mode the inverter will restart 4 times in an attempt to clear this fault If fault is not cleared the inverter will shut down Inv Current Limit L1 The current on this line phase on the inverter exceeded the maximum current of Inv Current LimitL2 200 peak Inv Current Limit L3 Reason This fault will occur if you short circuit the output terminals of the inverter or the load is too high Action a Reduce Load or remove short circuit then carry out Fault Reset b If the load is disconnected and the inverter still reports this fault then turn off the inverter or if a MOSFET fault is then reported contact technical support E
21. source was set up to be a GENERATOR and the Generator Start Time was disabled then the generator will not be started whilst the time is within the source inhibit time If a generator however was already running when the source inhibit time starts it will NOT be stopped but charging continues as normal until it is automatically stopped When the source is a utility the system will remain connected to the grid while the source is inhibited to allow power export if enabled but will not draw any power from the source When the battery voltage however reaches the 2 00VPC the system will start drawing some power to maintain the batteries at this low voltage and to prevent loss of power to the load To disable this function set both the Start and Stop time to 00 00 00h00m 046 Source Import Inhibit Time Stop See Source Import Inhibit Time Start 00h00m 047 Src A High Volts This setting defines the maximum percentage that Source A can go above the System Nominal Voltage 230V before the control will disconnect Source A and report a Source A High Voltage fault If Source A is set as utility it will automatically reconnect when Source A is within normal operating range and the Utility Detect Time has expired 119 048 Src A Low Volts This setting defines the minimum percentage that Source A can go below the System Nominal Voltage 230V before the control will disconnect Source A and report a Source A Low
22. stage maintains the cells and hence the batteries at a constant voltage until the bulk equalise period time has elapsed or the current into the batteries has become lower than a certain minimum value This charge period is around 2 hours 5 2 3 Stage 3 Ta perto Float Period The voltage per cell will be lowered to the float voltage per cell over a period of time no less than the number of seconds defined in the setting Battery Taper to Float Rate SP82 This is achieved by lowering the current into the battery cells 524 Stage 4 Float Taper Charge Period The current into the battery cells is reduced at a rate that allows the voltage on the cells to remain constant at the float voltage level If an auto start generator was used it will turn off when this stage is reached 53 Battery Bank Location The person who installed your inverter system will have installed the battery bank in a suitable and safe location If however you ever consider moving the battery bank position the following should be considered Batteries MUST be installed in a well ventilated environment away from sunlight Ensure that the battery leads are as short as possible for maximum efficiency A Battery Fuse MUST ALWAYS be installed and be as close as possible to the batteries ALWAYS observe the electrical wire colour coding convention i e connect red wire to POSITIVE and the black wire to NEGATIVE Batteries should be mounted on stands to ke
23. status will show when the MPPT regulator disconnects from as a result of low solar radiation Solar radiation is OK This status is shown when the solar radiation has at die reached its required level and the MPPT regulator can start up Firmware Up HMI System firmware on HMI has been updated Firmware Up GSM System firmware on GSM has been updated Firmware Up Wifi System firmware on WIFI has been updated Firmware Up DSP System firmware on DSP has been updated Firmware Up MIC System firmware on MIC has been updated Summation Cleared All summation logs have been cleared POWERSTAR USER MANUAL PAGE 89 Event Message Displayed Description Solar Charge Limit Aux Charge Limit Solar Aux controller limits the charge rate When this status is shown there is more solar power available that what the system is allowed to export to the grid or the AC load There are seven reasons why this limit is obtained 1 Export is disabled Grid is not present on line and the inverter would have to export excess power or dump it in order not to overcharge batteries 2 Source is a Generator and generator is on line and loading is less than minimum generator loading 3 Battery Voltage is greater than target voltage float voltage or bulk depending on charge stage 4 Battery Temperature is higher than battery over temperature setting 5 Heat sink 4 temperature is greater than invert
24. this setting set the Smart Load Bat VPC OFF the same as Smart Load Bat VPC ON 146 Smart Load Bat Battery per cell voltage that the battery must be below before the 1 97 VPC OFF smart load level will be decremented To disable this setting set the Smart Load Bat VPC OFF the same as Smart Load Bat VPC ON 147 Smart Load Disch Battery discharge current that the battery must be below 50 Amps ON before the smart load level will be incremented This is a percentage of the battery shunt size setting To disable this setting set it to zero 148 Smart Load Disch Battery discharge current that the battery must exceed before 70 Amps OFF the smart load level will be decremented This is a percentage of the battery shunt size setting To disable this setting set it to zero 149 Smart Load Solar Solar charge current that must be exceeded before the smart 096 Amps ON load level will be increased To disable this setting set it to zero This is a percentage of the solar shunt size 150 Smart Load Solar If the solar charge current drops below this setting the smart load 0 Amps OFF level will be decremented To disable this setting set it to zero This is a percentage of the solar shunt size 151 Smart Load Time Smart loads can be set up to only operate during certain times of 00h00 ON the day Set this setting up for the start time that smart loads will be incremented To disable this setting set this and Smart Load Time OFF to zero 152 Smart
25. to the inverter An optional extra available with the inverter is the MPPT Regulator which controls the solar panels MPPT is an acronym for Maximum Power Point Tracking This applies to solar regulators which are DC DC converters that allow the voltage of the solar panels to be different to the battery voltage MPPT Regulators will then control the voltage of the solar panels to find the point where the most power is obtained from them The point where maximum power is obtained differs between different types and makes of solar panels and a graph of panel volts versus amps can usually be found in the data sheet of your panel If you are considering adding a solar system to your installation contact MLT or the person who installed your system for further details on the MPPT Regulator and its installation It is important to understand that that if you decide NOT to install the MPPT or other built in Linear Regulator an external solar regulator MUST be used if you want to connect solar panels to your system Figure 2 on page 15 shows a system with the MPPT Regulator installed and identifies the solar panel connection points A CAUTION DO NOT connect solar panels directly to the solar input on a inverter that does not have a built in MPPT or solar linear regulator 63 Configuring the Solar Sytem Once you have installed your solar system it must be configured There is only one parameter that must be set which is SP97 Solar Control Access M
26. usual Action a Carry out Fault Reset b If fault continues contact Technical Support see page 12 PAGE 84 POWERSTAR USER MANUAL Fault Message Displayed Description CT fail Current Transformer Failure Reason A Current Transformer CT fault will occur ifthe system which is connected in parallel with the source is trying to export or import power from the source but reads zero KW for a long period from the current sensor The source will be disconnected and masked after the fault reset period Action a Carry out Fault Reset b If fault continues contact Technical Support see page 12 Shunt Cal Fail Shunt Calibration Failure Reason Every time the system boots up and if a solar MPPT regulator is installed the system will attempt to calibrate the solar current sensor If the sensor cannot be calibrated successfully this fault is displayed and the solar regulator will not be activated Action a Power down and restart system b If fault continues contact Technical Support see page 12 Smart Load Setting Fault Smart Load Setting Fault Reason The smart load has been set up incorrectly Some settings may be conflicting and are preventing correct smart load operation Action a Check all smart load related settings b Carry out Fault Reset C If fault continues contact Technical Support see page 12 9 3 1 Event Messages Ta ble 10 Event Messages Event Mes
27. 0 1 12 MIL21 540 750 1 12 MIL25 648 900 1 12 MTL25 756 1050 1 12 MTE21 990 1380 1 12 MTE25 1188 1660 1 13 MTE29 1386 1956 1 13 5 6 1 2 Peukert sLaw Peukert s law presented by the German scientist W Peukert in 1897 expresses the capacity of a lead acid battery in terms of the rate at which it is discharged As the rate increases the POWERSTAR USER MANUAL PAGE 55 battery s available capacity decreases If the battery is discharged in a shorter time with a higher current the delivered capacity is less 5 6 1 3 Capacity and Peukert Factor The default settings for both the Battery Capacity at the 5 hour discharge rate C5 and the Peukert Factor a fixed factor determined by the battery s effectivity of the internal chemical reaction must be changed to the values given in the above Table 5 6 1 4 Battery Charging Hoat and Bulk Sage Voltages FNB Solar M Cell are flooded load acid batteries which are not maintenance free and should be gassed periodically to prevent sulfation To achieve this both the Battery Float Cell Charging Voltage and the Battery Bulk Cell Charging Voltage must be as specified in the battery data sheet In this case only the Battery Bulk Cell Charging Voltage must be increased from the default settings 5 6 1 5 Equalisation Deep cycle flooded lead acid batteries need to be equalised periodically To configure this Equalise Enabled must be set to YES and the Battery Equalise Charge Period set to 4 ho
28. 076 Batt Min Chg Period 077 Equ Enabled 079 Batt Min Equ Chg 082 Batt Taper to FloatRate 084 Upper Temp Compnsatn 085 Lower Temp Compnsatn 086 Zero Compnsatn Upper Temp 087 Zero Compnsatn Lower Temp 088 Min Compnsatn Upper Temp 089 Min Compnsatn Lower Temp 090 Max Batt Chg Amps 091 DC Recon Volts 093 DC Low Shutdown Volts C1 094 DC Low Shutdown Volts C5 095 DC Low Shutdown Volts C100 096 Batt Overtemp Shutdown 133 Bulk Chg Start Time PAGE 21 MENU gt System Config Setup gt System Setup gt Keypad Setup No Name Description Derault Values 001 Button Sound Disables Enables an audible sound whenever a button on the ON keypad is pressed 002 Beep on The inverter makes an audible noise whenever it is busy ON Discharge discharging the battery This acts as a warning that no source is connected as present and inverter operation is from battery only This is typically disabled when using an external charge regulator 003 Backlight Backlight can be permanently ON AUTO or OFF AUTO 004 Backlight Time Backlight Time is only available when AUTO is selected and 60 will automatically dim the screen after this time has expired and turn on when a button is pressed 005 Confirm Power If enabled when the ON OFF switch is pressed will display a ON OFF warning message before power off 006 Alarm Sound Enables or disables the audible alarm sound for error messages ON Table 1 MENU gt Syst
29. 0Ah at C20 rating per 8kVA of inverter POWERSTAR USER MANUAL PAGE 49 52 4 Sage Battery Charge Curve e81eu oui SINOH y bes 7 c bes bes Q D Go A peuejsojne sem Joyesauab au VEIS UBD peg MOT O dS xe BUD MI DELAS po 0 siade Auayeq pue sdwy By peg XEN 06dS Aq peuiuuejep ayes abieyo Jaye ajejduioo abieyo SHO 1199 J20 4 neg OLdS ajajdwoy ap abieyo UMOPMUS 10 eJauac zabels SyoA Byo 1199 YING neg LIA JO euin jo ujbue sauluajap pouad By Ying neg G dS oAJn sulsseyy A1931eg occ ddA 1199 Jed s1oA Figure 24 4 Stage Battery Charging Curve POWERSTAR USER MANUAL PAGE 50 Figure 24 4 Stage Battery Charging Curve illustrates the built in 4 Stage battery charge that the PowerStar unit possesses The 4 stage charge cycle consists of a Constant Current Stage 1 an Absorption period Stage 2 at a higher voltage than float a Taper to Float Stage 3 and a Float period Stage 4 521 Sage 1 Constant Charge Period This is the first stage of charge using a constant current determined by SP90 Max Batt Chr Amps and SP130 Inv Che Max until the either the bulk voltage SP71 or equalise voltage is reached SP72 Bulk voltage for a normal charge or equalise if it the Time to next Equalise is zero or the manual equalise is selected via the keypad This charge period will typically last 8 10 hours 522 Stage 2 BulkorEqualise Charge Period This
30. 4 Batt Equ Chg Period 2hr 075 Batt Bulk Chg Period 2hr 076 Batt Min Bulk Chg 10 077 Equ Enabled NO 079 Batt Min Equ Chg 5 084 Upper Temp Compnsatn 5 5mV C 085 Lower Temp Compnsatn 5 5mV C 086 Zero Compnsatn Upper temp 30C 087 Zero Compnsatn Lower temp 2C 088 Min Compnsatn Upper Temp 50C 089 Min Compnsatn Lower Temp 1C 090 Max Batt Chg Amps 50 20 091 DCRecon Volts 2 250VPC PAGE 60 POWERSTAR USER MANUAL Setpoint Parameter Default New 092 DC High Shut down Volts 2 600VPC 093 DC Low Shut down Volts C1 1 700VPC 094 DC Low Shut down Volts C5 1 800VPC 095 DC Low Shut down Volts C10 1 850VPC 096 BattOvertemp Shut down 48 C 133 Blk Chg Start Time 00h00m The electrolyte level of sealed lead acid batteries does not need to be checked POWERSTAR USER MANUAL PAGE 61 6 About Solar Panels 61 Introduction Theterm solar panel refers to a panel comprising of a number of Photovoltaic PV cells which convert sunlight into electricity The PV cells in a panel are connected together to form a usable size and electricity output Solar panels are a source of renewable energy which is becoming increasingly accessible As with most renewable systems solar panels are unable to provide energy at all times as there may be insufficient sunlight available To fill the gaps electricity can be supplied from storage batteries or generators in stand alone systems or from the electricity grid in grid connected systems 62 Connecting a SolarSystem
31. 5 Enable Enable RS485 Connection Disables RS232 Top DE9 RS232 Plug RS232 Programming port Unisolated Bottom DE9 RS232 Plug RS232 MODBUS Communications Port Unisolated Complete MODBUS Specification available on request Vertical Grey Plug 3 External DC Hall Effect Sensor POWERSTAR USER MANUAL PAGE 67 8 System Configurations 81 Limiting Export 811 Introduction LS LI The Powerstar inverter has export limiting functionality that stops any power from being fed back into the source This is useful in situations where you cannot push any power back for example with a generator or a prepaid meter Unfortunately when exporting limiting is applied regulation must be turned off 8 1 2 Configuration The following settings and limitation apply 1 Set setpoint SP057 Export Enable to NO 2 Set setpoint SP111 Inv Tracks Src Volts to YES 82 Self Consumption 8 2 1 Introduction Self consumption is mainly used on systems where export limiting is set up When export limiting and the batteries are full the only power that the renewables can supply is the current load By cycling your batteries daily you can get more power from your renewables Unfortunately when you do cycle batteries you lose any UPS like functionality from the inverter since you cannot predict when a power failure will occur and your batteries might be low or empty This assumes that you have a grid set up as a source 822 Conf
32. 6 Inverter Line Summary 41 Figure 12 Screen 7 DC Summary 41 Figure 13 Screen 8 Battery Status 42 Figure 14 Screen 9 Solar Status eese enne ee Ee ee nnne trennen 42 Figure 15 Screen 10 Smart Loads sess 43 Figure 16 Screen 11 Summation Logs essent enne nennen Re ee 43 Figure 17 Screen 12 Run Hours and Site Logs eese 43 Figure 18 Screen 13 Miscellaneous Loge 44 Figure 19 Screen 14 Temperatures nennen enne Re ee nennen 44 Figure 20 Screen 15 System Information 44 Figure 21 Single Phase AC Input Output Connections for One Inverter Module 46 Figure 22 Single Phase AC Input Output Connections for Multiple Inverter Modules 46 Figure 23 3 Phase AC Input Output Connections ccccscssesssessesssessesssessesssessessseseessseseerses 47 Figure 24 4 Stage Battery Charging Cune essere 50 Figure 25 Danger of Short Circuits when using an Un insulated Spanner 54 Figure 26 PowerStar I O Relay Outputs EE 64 Figure 27 PowerStar I O Extender Inputs EE 66 Figure 28 PowerStar I O Extender Communications and Paralleling 67 POWERSTAR USER MANUAL PAGE 7 Glossary AC OC DC DSP EEPROM Equalisation Generator Grid HMI HPU Line 1 2 3 L1 L2 L3 PAGE 8 Alternating Current The utility generators and inverters can supply AC The AC voltage to homes in South Afri
33. Contact Technical Support see page 12 Note In automatic mode the inverter will restart 4 times in an attempt to clear this fault If fault is not cleared the inverter will shut down MOSFET Error L1A MOSFET failure MOSFET Error L2A Reason The MOSFET block inside the inverter module has failed MOSFET Error L3A Action MOSFET Error L1B a Carry out Fault Reset MOSFET Error L2B b Contact Technical Support see page 12 MOSFET Error L3B Inv Peak Current Inverter Peak Current High Reason The system has detected a high current or dc voltage disturbance and has temporarily shut down This fault is similar to a current limit fault except that it could not be traced to a specific line This fault could also be caused if the battery voltage rises above the hardware protection but is still below the high dc voltage setting Action a Carry out Fault Reset b Contact Technical Support see page 12 Note In automatic mode the inverter will restart 4 times in an attempt to clear this fault PAGE 74 POWERSTAR USER MANUAL Fault Message Displayed Description Src Sync Fault Source Synchronization Fault Reason a The system was not able to synchronize to the source within 30 seconds of the source coming into range The system will continue attempting to synchronize to the source b The source voltage might be subject to too many disturbances so that the inverter fails to synchronize itself successfully to
34. ENU gt SYSTEM SETUP CONFIG gt SYSTEM SETUP gt SOLAR gt 097 Solar Control The options available are OFF REG MPPT H MPPT S MPPT H S Their meaning is as follows OFF Use this option if a MPPT regulator is installed but not required Note that if a MPPT regulator is not installed then the inverter will not measure any solar input REG Use this option if an external or internal linear solar regulator is used The output of the solar regulator is connected to the solar input on the rear panel of the inverter PAGE 62 POWERSTAR USER MANUAL 64 which will measure the power is coming from the solar panels and display it on the Solar Status screen see page 42 NOTE The following settings apply only to systems with the optional MPPT Regulator installed MPPT H This option uses a method known as hill climbing to find the maximum power point of your solar panels MPPT S This option uses a method known as sweeping to find the maximum power point of solar panels It operates by carrying out a periodic sweep where the regulator checks across the entire range of the solar panels output to find the optimum point It then selects the optimum point and stays there until the next sweep The Sweep Interval default is 10 minutes but can be adjusted if required using SP 100 Solar MPPT Sweep Interval MPPT H S This option uses a combination of both hill climbing and sweeping It sweeps to find the initial maximum
35. Load Time Smart loads can be set up to only operate during certain times of 00h00 OFF the day Set this setting up for the stop time that smart loads will be decremented To disable this setting set this and Smart Load Time ON to zero POWERSTAR USER MANUAL PAGE 37 3 Displa y Information Normally when the inverter is switched on the Main Screen is displayed see Figure 6 which displays system status information There are a number of other screens available which are accessed via the FUNCTIONS menu Each screen is described below NOTE In the screen displays FROM and TO So a POSITIVE value from the source implies taking power FROM the source and a MINUS implies exporting power TO the source 3 1 Main Screen SCREEN NUMBER TIME LINE 2 MPC EVENT MPC OPERATIONAL SEE TABLE 9 MODE DATE LINE 4 BATTERY LINE 3 FAULTS STATUS DETECTED SEE TABLE 8 Figure 6 Screen 1 Main Screen 311 Operational Modes Auto Inv Only Automatic Inverter Only Mode The load is supplied directly from the batteries and available renewable DC sources only Auto mode is the mode that the inverter should be run in unless another specific mode is required Auto mode manages operations automatically starting and stopping generators charging batteries etc This mode is selected from the FUNCTIONS menu using the SYSTEM ON FULL AUTO option Auto Inv Src A or B In this mode the source such as grid or generator would be on lin
36. Run Generator B Screens System Config Setup 001 Main Screen 002 System Overview 003 Load Line Summary 004 Source Line Summary 005 Source Status 006 Inverter Line Summary 007 DC Summary 008 Battery Status 009 Solar Status 010 Summation Logs 011 Run Hours amp Site Logs 012 Miscellaneous Logs 013 Temperatures 014 System Information Date Time Setup Keypad Setup A ee ea 001 Button Sound 002 Beep on Discharge 003 Backlight 004 Backlight Time 005 Confirm Power OFF 006 Alarm Sound System Setup Password Access System 002 Sys Access Keycode 003 Sys Auto Restart Enabled 004 Remote Modem Access Ena 020 Max Cold Start Att Src A 021 Max Cold Start Att Src B 022 Generator Max Crank Time 023 Gen Control 027 Gen Start Inv Load 028 Gen Start Load Period 029 Gen Start Timer Gain 030 Low Battery Gen Start 031 Low Batt Start Period 032 Low Batt Timer Gain 033 Gen Reverse Pwr Limit 034 Gen Rev Pwr Fit 035 Gen Warm Up Time 036 Gen Cool Down Time 037 Gen Min UP Time 038 Src Timed Start 039 Gen Stop Min Site Load 040 Gen Stop Min 3Ph Load 042 Gen Stop Avg Period 043 Gen Optimum Load Control 044 Gen Stop Min Inv Chg 005 Logging Period 008 MODBUS Address Source Utility Generator 057 Export Enabled 058 Max Export Power 059 Util Detect Time 060 Gen
37. Source Generator has been stopped because the generator loading and battery charge rate are very low POWERSTAR USER MANUAL PAGE 87 Event Message Displayed Description System has completed a battery charge cycle and the generator stop Gen Stop Batt Chgd conditions have been met as to bring the generator off line Src A Stopped Source A has finished its cool down period and stopped Src B Stopped Source B has finished its cool down period and stopped Src A Masked Source A has been masked Src B Masked Source B has been masked sre K nmasked The fault on Source A has been either manually or automatically cleared Src B Unmasked The fault on Source B has been either manually or automatically cleared Src A Isolated Source A has been manually isolated from use Src B Isolated Source B has been manually isolated from use Src A Isolate Fail Unable to Isolate Source A as the site load may be too high for the inverter module Src B Isolate Fail Unable to Isolate Source B as the site load may be too high for the inverter module Src A Re Enable Source A has been manually made available again for use Src B Re Enable Source B has been manually made available again for use Source A has been switched to bypass Bypass is detected by means of Src A Bypass a normally closed contact connected to the bypass switch Source B has been switched to byp
38. Start Time 061 Island Detect Power 062 Active Island Detect Enabl 065 Util Bulk Chg Enable Volt CP73 High Cydesto Trip Grid CP74 Low Cycles to Trip Grid CP75 High Cydesto Trip Gen CP76 Low Cydes to Trip Gen 012 Src ASize 013 Src B Size 016 Src A Type 017 Src B Type 018 Src A Optimum Load 019 Src B Optimum Load 045 Src Import Inhibit Tim Start 046 Src Import Inhibit Tim Stop 047 Src A High Volts 048 Src A Low Volts 049 Src A Low Freq Offset 050 Src A Hish Freq Offset 051 Src B Hish Volts 052 Src B Low Volts 053 Src B Low Freq Offset 054 Src B Hish Freq Offset Battery Inverter 097 Solar Control 099 Solar MPPT Time Delay 103 Solar MPPT Min Chg Amps H Solar 131 Aux Max Charge 132 Aux Nominal Size 135 Aux Control 136 Std Max Wind 160 168 Aux Voltage Power POWERSTAR USER MANUAL 110 No Load Standby Power 111 Inv Tracks Src Volts 112 Inv Run On 113 Inv Start Priority 114 Inv Resource Priority 124 Inv Max Export Power 125 Ramp Down Enabled 126 Src Disconnect Level 127 Inv Charge Control 128 Inverter Standby Period 129 Inverter Delay to Standby 130 Inv Chg Max Figure 5 Menu Tree 068 Battery Capacity 069 Battery Peukert Factor 070 Batt Float Cell Volts 071 Batt Bulk Cell Chg Volts 072 Batt Equ Cell Volts 073 Batt Equ Time Interval 074 Batt Equ Chg Period 075 Batt Bulk Chg Period
39. System Setup gt Source Options ese sesse ee 23 Table 3 MENU gt System Config Setup gt System Setup gt Utility Options 26 Table 4 MENU gt System Config Setup gt System Setup gt Battery Options 27 Table 5 MENU gt System Config Setup gt System Setup gt Inverter Options 30 Table 6 MENU gt System Config Setup gt System Setup gt Generator Options 31 Table 7 MENU gt System Config Setup gt System Setup gt Solar Options 34 Table 8 MENU gt System Config Setup gt System Setup gt Relay Options 36 Table 9 Fa lt Messages es etr tere E ERE NER RENE NE RICE 73 Table 10 Event Messages tii et m ab d uei e er d he ced eden 85 List of Illustrations Figure 1 Typical Powerstar Inverter System 13 Figure 2 Single Phase 6 8 kVA inverter System Identifying Connectors Displays amp Controls 15 Figure 3 Keypad Eayolit samar AA ed etta 16 Figure 4 Hot Swop Bypass Box Orcuft eese enitn enne nennen nennen 18 Figure 5 Menu Tree EE EN Figure 6 Screen 1 Main Screen 38 Figure 7 Screen 2 Overview Screen 39 PAGE 6 POWERSTAR USER MANUAL Figure 8 Screen 3 Load Line Summary eese enne 39 Figure 9 Screen 4 Source Line Summary ee ee ee ee Re ener teens 40 Figure 10 Screen 5 Source Status 40 Figure 11 Screen
40. Time Delay Solar MPPT Time Delay is the step delay time in seconds This is the amount of time the system will delay before taking any increase or decrease in solar voltage during sweeping or hill climbing 100 103 Solar MPPT Min Chg Amps Solar MPPT Minimum Charging Amps When the current from the solar panel input was detected to be too low the MPPT will be suspended until the current from the solar panels rises above this threshold This setting is calculated as a percentage of the maximum MPPT rated current Table 8 MENU gt System Config Setup gt System Setup gt Aux Options SP No Name Description Default Values 131 AuxMaxChrg Aux Max Charge Amps Percentage of AuxNomsSize as a 100 maximum charging power PAGE 34 POWERSTAR USER MANUAL SP No Name Description Default Values 132 AuxNomsSize Windgen Nominal Size The size of the wind generator connected 5 to the Aux input in kW 135 AuxControl Auxiliary Control Select control method for Auxilary port 136 StdMaxWind Maximum Windspeed Displays the current windspeed using the below graph to calculate what the speed is 160 Aux Voltage 1 Aux Voltage vs Power Curve 60 Power 5 KW Wind Turbine Voltage output vs Power of a SW Wind Turbine 161 Aux Voltage 296 85 Power 162 Aux Voltage 4 91 Power 163 Aux Vol
41. USER MANUAL PAGE 47 13 Refit side panels to Inverter Module s 14 Check Generator s are set for required operation 15 Replace Battery Fuse and if applicable Solar Array Fuse 16 Power up inverter see page 17 17 If inverter is connected to grid set Normal Mode on Bypass Box see page 19 18 Configure Generator operations as required see 19 Table 2 on page 23 for a complete list of source configuration options Note that the following must be set SP Name Meaning Default Setting 012 Source A Size Set the size KVA of Source A 8 kVA per module 013 Source B Size Set the size KVA of Source B 016 Source A Type Set what Source A is Utility UTIL UTIL Generator GEN or no source fitted NONE 017 Source B Type Set what Source B is Utility UTIL Generator GEN or no source fitted NONE 023 Generator Control Must be set only if both sources are EQUAL generators EQUAL means both generators are of equal importance BACK A means Source A is the backup generator BACK B means Source B is the backup generator PAGE 48 POWERSTAR USER MANUAL 5 About Batteries 5 1 General A number of lead acid batteries are used together to form the battery bank for the inverter Basically there are two types of lead acid that can be used as follows n Standard Gel Sealed or Low Maintenance battery which is another name for a normal car battery This type of battery is designed
42. Voltage fault If Source A is set as utility it will reconnect when Source A is within normal operating range and the Utility Detect Time has expired 81 049 Src A Low Freq Offset This setting defines the frequency offset from the System Nominal Frequency 50H23 that Source A can deviate before a Low Frequency Fault is reported If Source A is set as utility it will reconnect when Source A is within normal operating range and the Utility Detect Time has expired 3 0Hz 050 Src AHigh Freq Offset This setting defines the frequency offset from the System Nominal Frequency 50HZ that Source A can deviate before a High Frequency Fault is reported If Source A is set as utility it will reconnect when Source A is within normal operating range andthe Utility Detect Time has expired 3 0Hz PAGE 24 POWERSTAR USER MANUAL SP No Name Description Default Values 051 Src B High Volts This setting defines the maximum percentage that Source B can go above the System Nominal Voltage 230V before the control will disconnect Source B and report a Source B High Voltage fault If Source B is set as utility it will reconnect when Source B is within normal operating range and the Utility Detect Time has expired 119 052 Src B Low Volts This setting defines the minimum percentage that Source B can go below the System Nominal Voltage 230V before the control
43. ace source b Carry out Fault Reset C If fault continues contact Technical Support see page 12 Low Source Freq Low Source Frequency Reason The frequency from the source that was on line was too low and out of range and the source has been disconnected If the source was a generator then the system will attempt to start and connect to it four times If the fault is still present the system selects another generator as the source Action a Reset source volt or replace source b Carry out Fault Reset C If fault continues contact Technical Support see page 12 POWERSTAR USER MANUAL PAGE 79 Fault Message Displayed Description High Source Freq High Source Frequency Reason The frequency from the source that was on line was too high and out of range and the source has been disconnected If the source was a generator then the system will attempt to start and connect to it four times If the fault is still present the system selects another generator as the source Action a Repair or replace source b Carry out Fault Reset C If fault continues contact Technical Support see page 12 Src A Failed To Start Src B Failed To Start Source A or Source B Failed to Start Reason After a start command has been issued to a generator and the warm up time has expired the generator voltage measured by the system was not in range The generator is thus stopped again and after the fault reset pe
44. age 12 POWERSTAR USER MANUAL PAGE 83 Fault Message Displayed Description Real Time Clock Fail Real Time Clock Failure Reason The real time clock on the controller card inside the control box has failed The system will no longer be able to keep time Action a Carry out Fault Reset b Iffault continues contact Technical Support see page 12 EEPROM Fail EEPROM Failure Reason The non volatile storage inside the control box has failed Any changes to Multi Power Controller s settings will not take effect The system operates with default settings only Action a Carry out Fault Reset b If fault continues contact Technical Support see page 12 Wifi Fail Wireless Communications Failure Reason The Wi Fi bridge inside the control box has failed No remote Wi Fi communications will be possible Action a Carry out Fault Reset b If fault continues contact Technical Support see page 12 Power Supply Fail Power Supply Failure Reason A power supply on the controller card in the Control Unit has failed Action a Carry out Fault Reset b If fault continues contact Technical Support see page 12 Comms Bus Fault Communications Failure Reason A communications fault has occurred on the control card in the Control Box The system continues running although user commands from the keypad or PC based user interface are unreliable and will execute slower than
45. ank Line refers to the AC live wire that feeds power from the source to the inverter module or to the load If an inverter has more than 1 module they are numbered as 1 2 and or 3 from the top SRC A L1 for example would be the 1 phase live wire from source A to the inverter module terminal labelled SRC A POWERSTAR USER MANUAL Masked MOSFET MPC MPPT Phase PV SCADA SP SRCor SOURCE Utility VPC WiFi Wind Turbine The peripheral has been permanently disabled and turned off by the system Only a fault reset will unmask and retry the possibly faulty peripheral such as inverter source or solar regulator Metal Oxide Semiconductor Field Effect Transistor Devices used in the inverter s power amplifier Multi power controller A bi directional inverter that offers grid voltage correction and takes power from the utility generator solar PV and batteries Maximum power point tracking used to improve the efficiency of PV panels by about 30 There are single phase or three phase machines and loads A three phase machine cannot be run off a single phase Proper description of phases is beyond the scope of this manual Photovoltaic cell Also known as solar panels PV cells generate DC electricity when sunlight strikes them Supervisory Control And Data Acquisition This is a computer used to monitor and control machines or hardware System Parameter Setpoint A non volatile inverter setting that con
46. ass Bypass is detected by means of Src B Bypass a normally closed contact connected to the bypass switch Gen Stop Grid OK Stop generator as the grid is back in spec and can be used Batt Chg Stage O No source on line and battery charging is not occurring from the source Batt Chg Stage 1 Signifies that battery charging has commenced from one of the sources Batt Chg Stage 2 Signifies that the Bulk or Equalize charge level has been achieved Batt Chg Stage 2B Signifies that the Extended Equalize mode has been implemented Batt Chg Stage 3 Signifies that the Bulk or Equalize or Extended Equalize charge has terminated Batt Chg Stage 4 Signifies that the system is in a Float charge stage Settings Retrieved Default settings have been uploaded Inverter Take Power Inverter takes all power and reduce source power to zero without disconnecting from source Low Batt Bulk Enabl Battery voltage has dropped below the bulk charge enable threshold If the bulk charge time was not set to OOhO0 the next charge will be a bulk charge done only at the bulk charge time Manual Equalise ON Equalise Mode has been manually selected by the operator Auto Equalise ON Equalise Mode has be automatically selected Manual Equalise OFF Equalise Mode has been manually de selected by the operator Solar Cntrl Enabled Solar Control Mode has been enabled battery and charging from the source on line will be reduced Excess So
47. ca is described as 230V AC 50Hz meaning 230V RMS that is alternating between a positive voltage and a negative voltage 50 times a second Control interface card A Current Transformer CT is used for measurement of electric currents When current in a circuit is too high to directly apply to measuring instruments a current transformer produces a reduced current accurately proportional to the current in the circuit which can be connected to measuring and recording instruments A current transformer also isolates the measuring instruments from what may be very high voltage in the primary circuit Direct Current Batteries solar panels PV and wind turbines provide DC The DC voltage for most battery banks is 48V meaning that the voltage between terminals of a battery are always positive Our inverters can take 48V DC from batteries and output 230V AC to supply homes and businesses Digital signal processor EEPROM also written E PROM and pronounced e e prom or simply e squared which stands for Electrically Erasable Programmable Read Only Memory is a type of non volatile memory used in computers and other electronic devices to store small amounts of data that must be saved when power is removed e g calibration tables or device configuration Individual batteries and individual cells within lead acid batteries react differently to being charged Over time battery performance will drop as differences become more pronounced At this sta
48. ctive energy so as to maintain the load voltage at its nominal value even if the grid voltage varies up to 1596 or as governed by the settings If a backup generator is available it can be started automatically and brought on line to supply the load and charge the batteries The starting can be set to be either a predetermined time or when the battery voltage reaches a predetermined level Whilst the AC source is present the load can be supplied with up to the combined rating of the AC source as well as that of the inverter rating The combined rating can decrease up to 5096 if the load drawn is not at unity In such cases the total power available is the maximum settable load on the AC source and the inverter power rating which is drawn from the batteries This will drain the batteries and is therefore not sustainable for long periods of time The maximum battery charging is governed by the sum of power available from the grid or generator and the renewables minus the power consumed by the load at that time The recommended minimum battery bank size is approximately 200Ah for a 6 8kVA inverter and 600Ah for an 18 24kVA inverter Any potential external AC source of power will be referred to as a Source in this manual The grid will typically be Source A and the generator will be Source B 14 SolarMPPTRegulator O ptional The MPPT Regulator allows control of solar panels by finding the point where the most power is obtained from the
49. divided 125A x 100 80 Maximum Inverter Charge Rate 80 5 6 1 7 Changesto Battery Settings Changes from default indicated in bold Setpoint Parameter Default New 068 Battery Capacity 0600 Ah 1188 Ah 069 Battery Peukert Factor 1 21 1 13 070 Batt Float Cell Volts 2 17VPC 2 25VPC 071 BattBulk Cell Chg Volts 2 32VPC 2 40VPC 072 Batt Equ Cell Volts 2 40VPC 2 50VPC 073 Batt Equ Time Interval 744hrs 074 Batt Equ Chg Period 2hr 4hr 075 Batt Bulk Chg Period 2hr 076 Batt Min Bulk Chg 10 077 Equ Enabled NO YES 079 Batt Min Equ Chg 5 084 Upper Temp Compnsatn 5 5mV C 085 Lower Temp Compnsatn 5 5mV C 086 Zero Compnsatn Upper temp 30C 087 Zero Compnsatn Lower temp 2C 088 Min Compnsatn Upper Temp 50C 089 Min Compnsatn Lower Temp 1C 090 Max Batt Chg Amps 50 100 POWERSTAR USER MANUAL PAGE 57 Setpoint Parameter Default New 091 DC Recon Volts 2 250VPC 093 Batt Low Shut down Volts C1 1 700VPC 094 Batt Low Shut down Volts C5 1 800VPC 095 Batt Low Shut down Volts C10 1 950VPC 096 BattOvertemp Shut down 48 C 133 Blk Chg Start Time 00h00m 5 6 2 Example 2 5 6 2 1 inverterand Battery Type You have a MLT PowerStar 18 KVA 36V Inverter The battery comprises 10 strings of Trojan T 105RE 6V 185 Ah at 5 hour discharge rate batteries As a Trojan T 105RE 6V battery has a 6V nominal terminal voltage there are 6 batteries in each string to provide the required 36 V nominal voltage As there are 10 strings there are 60 bat
50. dto Source A or B Contactor Failed to Open Open Reason Source B CB Failedto source A or B contactor did not open when required Dirty contacts could cause Open the contactor contacts to be welded closed Action a Carry out Fault Reset b If fault continues contact Technical Support see page 12 Source A CB Spurious Close Source B CB Spurious Close Source A or B Contactor Spurious Closing Reason Source A or B contactor closed when not required to Could be wiring fault between the control box and the inverter modules Action a Carry out Fault Reset b If fault continues contact Technical Support see page 12 Source A CB Spurious Open Source B CB Spurious Open Source A or B Contactor Spurious Opening Reason Source A or B contactor opened when not required to Could be wiring fault between the control box and the inverter modules Action a Carry out Fault Reset b If fault continues contact Technical Support see page 12 Flash Card Fail Flash Card Failure Reason Compact Flash Card inside the control box has failed Logging will be disabled Action a Carry out Fault Reset b If fault continues contact Technical Support see page 12 Modem Fail Modem Failure Reason The modem inside the control box has failed No remote GSM or landline communications are possible Action a Carry out Fault Reset b If fault continues contact Technical Support see p
51. e Operation To recover from Bypass Mode 1 Onocompletion CLOSE Invert Input and Inverter Output Circuit Breakers on Bypass Box 2 Using Keypad select Functions Recover from Bypass 3 Within 30 seconds OPEN Bypass Switch on Bypass Box 225 Fault Reset There are two methods of carrying out a Fault Reset as follows 1 Press and hold the Power ON OFF key for 3 seconds The screen will show Fault Reset in the Event line on the main screen 2 Using Keypad select Functions gt Fault Reset The screen will show Fault Reset in the Event line on the main screen POWERSTAR USER MANUAL PAGE 19 23 Menu CAUTION Configuration and changes to system parameters should A only be carried out by trained personnel unless otherwise specifically instructed by MLT support engineers The menu structure is divided into user and installer support engineer levels The user level menus allow the everyday operation of the system to be monitored and fault conditions reset when required The menus that allow system parameters to be changed can only be accessed by entering the appropriate password PAGE 20 POWERSTAR USER MANUAL 002 Bypass Recover Source A 003 Bypass Recover Source B 005 System On Full Auto 009 Toggle Isolate Source A 010 Toggle Isolate Source B MENU TREE 001 Battery Equalize I Fault Reset 004 System Off H Functions TT 006 Run Any Generator 007 Run Generator A 008
52. e and used The load is supplied from the Source and from the DC sources such as batteries and photovoltaic Auto Src A or B In this mode the inverter is turned off and only energy from the source such as the grid or generator is used Batteries will not be charged from the AC source or used to supply the load This mode will be used when the inverter is temporarily disabled because it has been previously bypassed or has encountered a problem PAGE 38 POWERSTAR USER MANUAL 3 2 Overview Screen SCREEN CURRENT ROW 1 BATTERY CHARGING SOURCES ON LINE NUMBER TIME SOURCE DATA STATE 0 1 2 3 OR 4 A BOR I INVERTER ROW 3 BATTERY DATA ROW 2 INVERTER DATA Figure 7 Screen 2 Overview Screen Row 2 Source A or B characteristics Source A is indicated in Figure 7 004 0 kW Real Power from the grid 004 0 kVA Apparent Power from the grid includes Reactive Power 230 V Source Voltage 50 0 Hz Frequency of the Source Row 3 Inverter characteristics 001 1 kW Real Power into the inverter 001 1 k VA Apparent Power from the grid includes Reactive Power 230 V Inverter and Load Voltage 50 0 Hz Inverter and Load Frequency Row 4 Battery Status 52 4V Instantaneous Battery Voltage 2 2 VPC Voltage Per Cell Nominal Battery Cell Voltage is 2 00 VPC 56 7 A Total current from or into the batteries Positive value indicates batteries charging 23 1 C Temperature of the batteries only displayed if optio
53. e system is running on the back up Generator and the primary Generator becomes operational the system will revert to the primary Generator at the next appropriate time to swap Generators NOTE For a grid connected system this setting is of no relevance EQUL 027 Gen Start Inv Load Generator Start Inverter Load This setting determines the stand alone inverter per phase load level which a generator will automatically start and then connect This setpoint is measured asa percentage with respect to the rated per phase capacity 8096 Phs 028 Gen Start Load Period Generator Start Load Period The integration delay before a generator is started and brought on line due to a high load level on the inverter This timer is modified by the over load error and SP29 120 sec 029 Gen Start Timer Gain Generator Start Timer Gain The Generator Start Load Period SP28 is modified by this value The delay before a generator connects automatically shortens by how far the load setpoint SP27 is exceeded 1 5 sec 030 Low Batt Gen Start Low Battery Generator Start Volts This setpoint determines the stand alone low battery voltage level per cell at which a generator will automatically start and connect NB This setpoint is not temperature compensated 1 95V 031 Low Batt Start Period Low Battery Start Period If the Low Battery Generator Start Volts SPO30 is reached this setpoint de
54. ed Gen Start Equalize Source A or B is signaled to start as the equalization period and the maximum delay to equalize have expired Batteries will be charged in equalize charge PAGE 86 POWERSTAR USER MANUAL Event Message Displayed Description Signifies that the external Force Generator Start on the input has been asserted or Force Start A B from the keypad has been instigated for Force en Gen Source A or B to start This can only be whilst the system is in AUTO mode Src A Warming Up Source A is inis in its warm up cycle Src B Warming Up Source B is in is in its warm up cycle Source started is found to be in spec If the source is a utility supply this Src is in Spec message signifies that the source was found to be in range and will be used Auto Src A Only System in Automatic Source Only mode Source A is the only source on line Auto Src B Only System in Automatic Source Only mode Source B is the only source on line Man Src A Only System iti Manual Source Only mode Source Ais the only source on line The inverter will not be brought on line automatically System in Manual Source Only mode Source B is the only source on ManisreBOnly line The inverter will not be brought on line automatically Parallel Inverter module is in parallel with either Source A or B Src Ramp Down Signifies Source A or B power is ramping down before disconnecting
55. ee Ge nnne nnne nt nnne ennt 41 4 8 Battery Status Screen re on ERR RR CREER SENSE EEN 42 A E 42 4 9 1 Current delivered by the Solar PV panels cessssssseeesesrsseesssesseeseeneees 42 4 10 Smart LOadS rte Rete attt ie tee AR UR E e Redde 43 4 11 Summation LOES A etna e eege 43 4 12 Run Hours arid Site Logs uge ee ee ee EE dure 43 4 13 Miscellaneous Logs u snr in re idaho 44 4 14 Kuul as 44 4 15 System lnforiiatiOn coe e E a 44 5 Connecting External Sources 45 51 EE N EE e 45 5 2 Types Of Generators avta v dee 45 5 3 UE KEE 45 5 4 installing a Generator ee ais 45 6 Abo t Batteries EAR 49 6 1 R E A e M 49 6 2 4 Stage Battery Charge Curve non aa eie 50 6 2 1 Stage 1 Constant Charge Period sese 51 6 2 2 Stage 2 Bulk or Equalise Charge Period 51 6 2 3 Stage 3 Taper to Float Period AE 51 6 2 4 Stage 4 Float Taper Charge Period 51 6 3 Battery Bank dere ele EE e n edi Re d e dia 51 6 4 MaintenanCe TNA 52 64 1 EagualisatiOn dns 52 6 4 2 Temperature Compensatlon non ee AR ee 52 PAGE 4 POWERSTAR USER MANUAL 6 6 Battery Charging Examples nono nnns 55 A O 55 6 62 Example Za o ie 58 6 03 EXAmPle iii aa a 59 7 About Solar SOSEER AE OE annin aoaeiaa na dna aiia iaii 62 73 introduction eee did 62 7 2 Connecting a Solar System to the Imverter sess 62 7 3 Configuring the Solar System 62 7 4 Monitoring the Solar System
56. elow this setpoint before the generator is stopped This setpoint is measured as a percentage with respect to the total inverter capacity SP104 5096 POWERSTAR USER MANUAL PAGE 33 the control will commit to battery charging before a generator can be stopped This setpoint must be smaller than the Inverter Charge Maximum setpoint SP125 SP No Name Description Default Values 042 Gen Stop Avg Generator Stop Average Period This setpoint is the integration 120 sec Period time for all the generator stopping decisions All conditions must be maintained for this time before the generator is stopped 044 Gen Stop Min Inv Generator Stop Minimum Inverter Charge This is the minimum 30 per Chg percentage of the rated per phase capacity of the inverter that Phase Table 7 MENU gt System Config Setup gt System Setup gt Solar Options SP No Name Description Default Values 097 Solar Control Solar Control sets the type of solar control that is done on the system 0 Solar Control Disabled 1 Solar Charge Regulator Only 2 Solar MPPT Hill climbing 3 Solar MPPT Sweeping 4 Solar MPPT Hill climbing amp Sweeping 5 Solar Preset Power Point When the solar regulator is set up for any automatic PPT function and the current offset calibration is set to zero the system will perform auto calibration of the shunt offset at every power up instance 099 Solar MPPT
57. em Config Setup gt System Setup gt System Options SP No Name Description Default Values 002 Sys Access System Access Keyword This setting allows the user to specifya 0001 Keycode four digit PIN number that needs to be entered to access the System Setup option For PIN numbers smaller than 1000 please precede the PIN with leading zeros Be sure that only authorised operators are in possession of the PIN number 003 Sys Auto Restart System Auto Restart Enabled This option enables the automatic NO Enabled start of the system upon power up or after a power outage If the start is successful the system resumes a supply mode Otherwise the system enters the System OFF mode and displays the last fault 004 Remote Modem Remote Modem Access Enabled If set to YES the system expects Yes Access Ena a locally connected modem and automatically performs the necessary modem management PAGE 22 POWERSTAR USER MANUAL Default SP No Name Description Values 005 Logging Period The optional internal data logger Will take a snapshot log of all 10 data fields such as voltages currents temperatures etc Minutes periodically in intervals set up by this setting Data logs are also captured on any event or mode change 008 MODBUS Address The Modbus address of the System 5 Ta ble 2 MENU gt System Config Setup gt System Setup gt Source Options
58. ep them clear of the ground If the batteries are ground mounted they should be thermally insulated from the ground temperature POWERSTAR USER MANUAL PAGE 51 54 Maintenance Battery maintenance required will be detailed in the documentation supplied with the battery and for flooded batteries generally includes checking of the electrolyte levels on a regular basis and topping up with distilled water when necessary Flooded batteries also require equalizing which is an overcharge performed on lead acid batteries after they have been fully charged see Equalisation on page 52 Maintenance free sealed or gel batteries MUST NOT be equalised Providing it is maintained and sized correctly a good quality battery bank should last at least 3 years of continuous cycling before needing replacement 541 Equalisation Individual batteries and individual cells within lead acid batteries react differently to being charged Over time battery performance will drop as differences become more pronounced Because of this it is necessary to perform an equalization charge at least once per month In the inverter menus there are four settings applicable to equalization SP072 Battery Equalisation Cell Volts which is used to set equalising charge voltage default setting 2 4 volts per cell SP073 Battery Equalisation Time Interval which is the time period between equalising charges and by default is set to 744 hours 31 days SP074 Battery Equalisation
59. er over temperature setting 6 Solar Aux amps is greater than solar aux shunt size 7 Battery amps is greater than battery maximum charge current WiFi Initialize WiFi Controller Initialized Modem Initialize Modem Controller Initialized HMI Initialize HMI Keypad Controller Initialized Smart Load Count Up Smart Load count increased This means that more non critical loads are now connected to the inverter Non critical loads may have up to 5 levels of priority when using RF radio controlled or 3 locally controlled loads Smart Load Count Down Smart Load count decreased This means that less non critical loads are now connected to the inverter Non critical loads may have up to 5 levels of priority when using RF radio controlled or 3 locally controlled loads PAGE 90 POWERSTAR USER MANUAL
60. es connected in parallel If two inverter modules are installed use the lower module as the input output module If three inverter modules are installed use the middle module as the input output module SOURCE B GENERATOR SOURCE A LIVE SOURCE A GRIDOR COMMON NEUTRAL GENERATOR CT Note The Neutral Source and Inverter interlinks between modules must be installed Figure 22 Single Phase AC Input Output Connections for Multiple Inverter Modules PAGE 46 POWERSTAR USER MANUAL 11 Three phase installation which will always have three Inverter Modules i e one for each phase see Figure 23 If both Source A and Source B inputs are used correct phases are connected to each Inverter Module Top module Red Phase Middle Module Yellow Phase and Bottom Module Blue Phase Earth and Neutral must be connected Phase 1 Li i SOURCE B i GENERATOR i SOURCEA GRIDOR GENERATOR Phase 2 SOURCE B GENERATOR SOURCE A GRIDOR GENERATOR INVERTER LIVE 1 LOAD Phase 3 SOURCE B GENERATOR SOURCE A GRIDOR GENERATOR aT XL Note The Neutral interlinks 1 between modules must be installed sl mal f IE f dt CF CR El E Tie Figure 23 3 Phase AC Input Output Connections 12 If Generator is to be controlled by inverter connect Electric Start on the Generator to Generator Start Output on rear panel or the optional IO Extender Interface of Control Box POWERSTAR
61. f after the set time the condition is still met it will carry out the next action in the sequence This process will be repeated a maximum of three times or the number as set up by the No of Smart Loads SP141 If any one of the conditions cannot be met and have exceeded the turn OFF setting then the lowest priority load is shed If the turn off condition is still exceeded each set time period the next load is removed until no more smart loads are active For example say a system is operating with three smart loads with a wait time of 1 minute with battery Voltage Per Cell thresholds of 2 1 turn ON and 1 97 turn OFF set If the battery VPCfalls to 1 97 for a period of 1 minute the inverter will shed the priority 3 load If after two hours the VPC again falls to 1 97 for the required period the inverter will shed the priority 2 load If the sequence repeats again the priority 1 load will be shed 7 1 22 Configuration Depending on the requirement not all of the smart loads may be required The number of smart loads being used is set using SP141 Number of Smart Loads The Smart Load Relay Wait Time SP142 is the time that a condition must be met before the next action in the sequence is carried out The thresholds that set when a load is shed and reconnected are listed below Inverter Export Power SP143 sets percentage of the inverter output at which the Smart Load is reconnected and SP144 sets the percentage at which t
62. g ryCharging B Can Stop S BASES CSI er EZ eru ROW 3 SOURCE CURRENT OPERATION ROW 4 SOURCE OUTPUT STATU Figure 10 Screen 5 Source Status NOTES If a Source is disabled the data for that Source will not be displayed To disable a Source set MENU gt SYSTEM CONFIG SETUP gt SYSTEM SETUP gt SOURCE gt SP16 Source A or SP17 Source B to NONE Row 2 Typical Source States are Running Stopped Cooling Down etc PAGE 40 POWERSTAR USER MANUAL Row 3 Gives the reason why the source is still required Manually controlled generators can be stopped if Can Stop is displayed Note that source current operations are listed under Why does the Generator not stop when it should on page 71 Row 4 If there is more than one fault with the source output the display will show each fault in turn at one second intervals For example if a Source is stopped the faults displayed will be Src Line V Low Source Line Volts Low and Src Hz Low Source Frequency Low 36 Inverter Line Summary SCREEN LOAD LINE 1 SINGLE OR RED PHASE LOAD DATA SOURCES ON LINE NUMBER VOLTAGE CURRENT REAL POWER REAL REACTIVE POWER A BOR I INVERTER LL CUM YELLOW amp BLUE PHASE LOAD LINES NOT DISPLAYED IN SINGLE PHASE SYSTEMS Figure 11 Screen 6 Inverter Line Summary The Source Line Summary screen shows the Load Voltage Current Real and Apparent Power Consumed Note that before a reading indicates to the inverter 37 DC
63. ge it is necessary to perform an equalization charge or refreshing charge usually once every 10 cycles at least once per month An equalization charge must only be performed on vented not sealed flooded lead acid batteries This is a machine that usually runs off diesel or petrol to provide AC power Generators are usually only run when needed A generator will be configured as a generator if the generator can be started remotely or a utility if the generator needs human intervention to start it Generators need to be run periodically to keep their moving parts functional Generators usually provide most power per litre when they are electrically loaded to 80 of their rating Obviously running a generator for longer than necessary will waste fuel and shorten its lifetime if the generator is run for too short a period the generator lifetime is reduced this is called the generator minimum run time The main AC input of the inverter A grid can be provided by the utility company or a machine like a generator The grid inputs of our inverters are called source A and source B Any two grids can be connected to the source A B inputs Human machine interface The technical name for both the screen and keypad combination with all the menus and screens for controlling the inverter machine Hybrid power unit A bi directional inverter that does not offer grid voltage correction and takes power from a large generator solar PV array and battery b
64. hat if a Fault Reset is required refer to page 19 for further information Table 9 Fault Messages Fault Message Description Displayed Low Inv Volts L1 The inverter voltage on the phase is low and out of range Low Inv Volts L2 Reason The fault could have been caused by the inverter voltage tolerance Low Inv Volts L3 settings being narrower than the source voltage tolerance and the inverter was set up to track the source voltage Action a Increase your source low voltage setting Menu gt System Config Setup gt System Setup gt Source gt 048 Src A Low Volts or 052 Src B Low Volts b Contact Technical Support see page 12 Note In automatic mode the inverter will restart 4 times in an attempt to clear this fault If fault is not cleared inverter will shut down High Inv Volts L1 The inverter voltage on this phase became high and out of range High Inv Volts L2 Reason The fault could have been caused by the inverter voltage tolerance High Inv Volts L3 settings being narrower than the source voltage tolerance and the inverter was set up to track the source voltage Action a Reduce your source high voltage tolerance The inverter may not operate continuously at more than 1296 of its nominal voltage rating Setup System Setup Source 047 Src A High Volts or 051 Src B High Volts b Contact Technical Support see page 12 Note In automatic mode the inverter will restart 4 times in an attempt to clear this fault If fault is
65. hat the charge state of the batteries was before they started discharging access the Event Browser MENU gt EVENT LOGS and browse back through the events until the event indicating that the batteries were discharging which would be either Src A CB Opened or Src B CB Opened depending on which source is being used Browse back from that event until the first battery charge event is displayed If it is anything other than Batt Chg Stage 4 is displayed the batteries were not fully charged To ensure a consistent performance from the batteries it is important that your batteries are charged correctly Each battery type flooded deep cycle sealed gel etc has different charging requirements Incorrect adjustment of battery settings is the most common cause of reduced backup time from your batteries Refer to Battery Charging Examples on page 55 for example configurations For Flooded Lead Acid Batteries it is important to check the battery electrolyte level periodically Never leave the battery cells with the electrolyte below the required level PAGE 72 POWERSTAR USER MANUAL One or more of the batteries in the battery bank is faulty Check the batteries in accordance with the manufacturer s documentation and replace as necessary see Temperature Compensation on page 52 93 FaultRecovery When a fault occurs 1 Note the Fault Message on the display and refer to Table 9 below 2 Identify the fault and carry out the required action Note t
66. he load is shed Battery Voltage SP145 sets the Voltage Per Cell VPC at which the Smart Load is reconnected and SP146 the VPC at which it is shed Battery Current SP147 sets the percentage of battery discharge current at which the load is reconnected and SP148 the percentage of battery discharge current at which it is shed Solar Current SP149 sets the solar charge current at which the load will be reconnected and SP150 the solar charge current at which the load will be shed Time Of Day Load Shedding SP151 sets the time of day when the load will be switched on and SP152 the time of day when the load will be shed To disable any of the above criteria set both turn ON and OFF to zero To disable the battery voltage threshold criteria set both ON and OFF to the same VPC level POWERSTAR USER MANUAL PAGE 65 72 Inputs Take spar pees GND sta END GND input END Reset B E e 4 Spar ola SND Pap END Fars GND Pozo GND SET Figure 27 PowerStarl O Extender Inputs There are a number of digital inputs with some specific functionality available on the PowerStar inverter Left Column Spare 2 Unused input 5V 5Vdc available for reference Solar Rad Solar Radiation Meter Input GND Ground Fuel Level Fuel Level Sensor Input Top Row GND Ground All input
67. iguration The following settings and limitation apply 1 Set the inverter to limit export as above 2 Set SP045 Source Import Inhibit Time Start point to when you want the batteries to start discharging Typically this would be set to 20h00 3 Set SPO46 Source Import Inhibit Time Stop point to when you want the batteries to stop discharging Typically this would be set to 16h00 Please note that the above is an example because of the multiple ways the inverter can be configured for example load size and battery size and that times must be adjusted to your individual configuration PAGE 68 POWERSTAR USER MANUAL 83 Paralleling Inverters 8 3 1 Introduction It is possible to parallel up to 4 PowerStar Inverters of the same size phase type One inverter is set to be the Master inverter A slave inverter cannot operate by itself and a Master inverter must always be functional and on line However Slave inverters may be shut down during operation to reduce P N standby consumption A Master inverter can thus be run as a stand alone inverter C C For parallel operation please ensure that all three inverters have the same software and hardware revision All inverter running in parallel must use the same battery bank 832 Setup A synchronization cable must be plugged into each inverter and RS485 Communications must be enabled The two end inverters must terminate the string by shorting the appropriate jumpers See
68. ing only applies during the final stage of the Bulk and Equalisation charge cycles 05m00s 084 Upper Temp Compnsatn Upper Temperature Compensation This setpoint specifies the temperature compensation applied to the batteries between Zero Compensation Upper Temperature SP86 and Minimum Compensation Upper Temperature SP88 5 5 mV C 085 Lower Temp Compnsatn Lower Temperature Compensation This setpoint specifies the temperature compensation applied to the batteries between Maximum Compensation Lower Temperature SP89 and Zero Compensation Lower Temperature SP87 5 5 mV C 086 Zero Compnsatn Upper temp Zero Compensation Upper Temperature For some batteries there is no temperature compensation of the battery voltage over a defined temperature range This setpoint defines the temperature limit at which temperature compensation will start for temperatures higher than this setpoint Upper Temperature Compensation SP84 defines the compensation applied for temperatures above this setpoint 30 C PAGE 28 POWERSTAR USER MANUAL SP No Name Description Default Values 087 Zero Compnsatn Zero Compensation Lower Temperature For some batteries 2 C Lower temp there is no temperature compensation of the battery voltage over a defined temperature range This setpoint defines the temperature limit at which temperature compensation will start f
69. ize before the solar import will start backing off 100 PAGE 30 POWERSTAR USER MANUAL SP No Name Description Default Values 125 Ramp Down Ramp Down Enabled When enabled it initiates a gradual shift of YES Enabled load from the source that is coming off line to the one that will be remaining on line This will be applicable when bringing off line Source A or B or bringing the inverter module off line 126 Src Disconnect Source Disconnect Level The level at which the source being 10 Level disconnected will actually disconnect from the AC bus Represented as a of the individual source capacity 127 Inverter Charge Inverter Charge Control is used when the inverter is running in 0 mV Control standalone mode The output frequency of the inverter is increased by this setting when the battery voltage rises above target voltage 128 Inverter Standby Inverter Standby Period 00m10s Period 130 Inv Chg Max Inverter Charge Maximum This setpoint represents a percentage 20 of the rated per phase kW capacity of the inverter that the Phase control will commit for battery charging This should be set in accordance with the C rating of the battery bank It should be noted that this setpoint is different to SP90 Maximum Battery Charge Current which controls the amount of current into the batteries from the renewable source and the inverter Table 6 MENU gt System Config Setup gt System Se
70. lar energy can be exported to the utility supply if on line PAGE 88 POWERSTAR USER MANUAL Event Message Displayed Description Solar Cntrl Disable Solar Control Mode has been disabled and the inverter will recommence charging the batteries from the source that is on line Aux Control Enabled Auxiliary Control Mode has been enabled battery and charging from the source on line will be reduced Excess Solar energy can be exported to the utility supply if on line Aux Cntrol Disabled Auxiliary Control Mode has been disabled and the inverter will recommence charging the batteries from the source that is on line MPPT Sweep Progress Solar MPPT sweep in progress Auto Calibrate MPPT Calibration of MPPT Solar regulator in progress This may take up to 5 minutes MPPT Control Active MPPT control is active Time Updated The system time has been updated Event Log Clear All event logs have been cleared Data Log Clear All data logs have been cleared Rmt GSM conn Remote GSM connection has been established to the system Rmt GSM disconn Remote GSM connection has been terminated Rmt WiFi conn Remote WiFi Connection has been established to the system Rmt WiFi disconn Remote WiFi connection has been terminated Settings Saved All settings have been successfully saved to non volatile memory Low Solar Rad Solar radiation too low This
71. llation 43 Preparation Before starting the installation ensure that you read the owner s handbook for the generator that you are installing and you are fully aware of requirements such as cable size and generator siting information Use shielded PVC wire 60A 10 mm per AC Input each module and Output Live and Neutral connections on this inverter system 44 Installing a Generator 1 Power down inverter see page 17 2 If inverter is connected to grid select Bypass Mode on Bypass Box see page 19 Switch OFF and isolate any connected generators Remove Battery Fuse If Solar Array is fitted remove Solar Array Fuse 9 Uu B Wait for approximately 20 to 30 seconds for the internal capacitors to discharge completely before resuming 7 Remove left side panels from each Inverter Module to access the AC Input and Output terminals 8 Connect Generator to Source A or Source B input connections on the Inverter Modules noting the following NOTE EARTHS MUST BE CONNECTED IN ALL INSTALLATIONS POWERSTAR USER MANUAL PAGE 45 9 Single phase with single inverter module Refer Figure 21 SOURCE B GENERATOR SOURCE A GRID OR GENERATOR SOURCE B LIVE I SOURCE A LIVE COMMON NEUTRAL INVERTER LIVE Figure 21 Single Phase AC Input Output Connectionsfor One Inverter Module 10 Single phase with multiple inverter modules see Figure 22 A single phase system can have a maximum of three Inverter Modul
72. m Configuration includes selecting the method used to find this point which differs between types and makes of solar panels 15 IO Extender Interface Card The IO Extender Interface Card allows you to enhance the operation of the system by connecting other devices such as Battery Temperature required for temperature compensation Solar Radiation Fuel Level and other Sensors and Emergency Stop Generator and Load Controls Smart Load Relay If the IO Extender option is installed it allows the configuration for shedding of loads set on a priority of 1 to 3 with 1 being the most important The shedding can be dependent on battery status load level and time of day 16 SCADA Control System Optional The SCADA System enables control of the system using a remote PC Use of this option is covered in a separate publication contact MLT Inverters for further information PAGE 14 POWERSTAR USER MANUAL Front View Side View Covers Removed Keypad and Display Source A Breaker Source B Breaker DC Pre charge Button DC Fuses Side Cover for AC and Battery Connections 1 0 Extender Inverter Serial and Specifications Source and Load Connection Terminals Battery Input Terminals Figure 2 Single Phase 6 8 kVA inverter System Identifying Connectors Displays amp Controls POWERSTAR USER MANUAL PAGE 15 2 Operating 2 1 Use ofthe Keypad PAGE 16 ON OFF MENU EXIT Figure 3 Keypad Layout Po
73. minimum start idle delay time before the generator is connected on line This setpoint does not apply to the grid supply inputs on inverter systems 10 sec 036 Gen Cool Down Time Generator Cool Down Time Once a generator is disconnected from a load it typically requires a cool down period This is especially important with turbo charged diesel generators View generator documentation for the recommended period 10 sec 037 Gen Min UP Time Generator Minimum Up Time Once a generator is started it should typically run for a minimum period on load before being stopped This ensures even mechanical wear and stress on parts This can also be used to avoid short start stop cycles This setting indicates the minimum generator run period before it may be turned off by the control system 15 minutes 038 Src Timed Start Source Timed Start This setting is the time after which the generator is automatically started and brought on line to run for the minimum run time SP37 Setting to 00 00 will negate the auto start 168 Hours 039 Gen Stop Min Site Load Generator Stop Minimum Site Load The generator loading per phase must be below this setpoint before the generator is stopped This setpoint is measured as a per phase percentage with respect to the inverter capacity SP104 7096 040 Gen Stop Min 3Ph Load Generator Stop Minimum 3 Phase Site Load The generator total loading must be b
74. mita 1 INVERTERS TN Ed 2014 MLT Inverters Based on DSP software versions 4 xx and up Edition 7 1 February 2015 PAGE2 POWERSTAR USER MANUAL Mult PowerControlerUserManual Contents EE CIT E 2 INtFOCUCTION ini 21 Warnings and Cali iii ia 2 2 Contacting MLT Drives eene 2 2 1 Product Support 22 2 Contact Details ere tee tt ertet 2 2 3 Telephone eg AE AE S cA eL o TA P M RUE 2 3 System Description eren eee iiber tior ed ke ek Re RAGE Kg ke nhe deno 2 4 Solar MPPT Regulator Optional eene 2 5 lO Extender Interface Card 2 6 SCADA Control System Optional 3 Operating see EE OR OR OE dinne ideene 3 1 UseoftheKeypad EE ES SE EER aia 3 2 User FUnCtons ot EER er eer eee er i a aa eed 3 2 1 Power Up Power Down 3 2 2 die Se EE EE OE EE 3 2 3 Bypass Willian EE RE SE Bk Ge ee GR Ed Pe e Pee ie eet 3 2 4 Hot Swop Bypass Switch 3 2 5 FUER 33 EE 3 3 1 Mem A SEENEN EEN 4 Display IO MATO iia N EE AE re eie de ENEE 4 1 1 Operational Modes essen nnne 4 2 Overview Screen ee ee ee ee ee ee Ge ee ee Ge Ge nn enn eene nente nennen 4 3 Load Line Summary ee ee Re Re a Re Re ee eE POWERSTAR USER MANUAL 4 4 Source Line Summan non nnnnn rn non nan ethernet nne nnne 40 45 SOUNCE Status WE 40 4 6 Inverter Line Summary essent enne enne nennen ethernet etes 41 4 7 DC Summary SCreen esse ee ee ee ee ee non nan ee ee
75. n Stp Avg Period This means that all the Stop conditions are met and the inverter will still run the generator until the Stop period has expired Battery Charging The battery is still busy going through the full charge cycle Site Load P P The Load on the inverter is too high Inv Charge P P Usually only appears on 3 phase systems where the load in very unbalanced the inverter might import on one or two phases and export on the others so that the generator sees a balanced load If the import power on any phase is too high then this will come up as a reason the generator cannot stop Force Start The generator was started after the user issued a Generator start command and will not stop automatically Source Load The Load on the generator is too high Minimum Up Time Min Up Time The generator has not yet run for its minimum run time If SP60 Gen Start Time was set up then the generator is used as a UPS backup and will run until the Utility comes back into range Set this setting to zero to allow automatic generator stopping when the batteries are charged for example 9 2 4 Why didn t I get the usual capacity from my sora ge batteries Were the batteries fully charged to start with The batteries are subjected to a four stage charging cycle Le constant current Batt Chg Stage 1 constant voltage Batt Chg Stage 2 taper Batt Chg Stage 3 and float voltage Batt Chg Stage 4 To check w
76. n the main screen of the inverter Most actions taken to control the inverter system cause an event message to be displayed on line 2 of the main display screen Events are also recorded in the Event Log thus providing a system operation history Faults are displayed on line 3 of the main display screen With most faults the system in automatic mode will attempt to recover by clearing and re trying the operation If the system clears the fault the fault message will clear after approximately 5 minutes automatically If after four attempts the fault could not be cleared the system will mask isolate the faulty peripheral and sound a 1 second interval beep beep All faults are recorded in the Event Log 92 Typical Problems 92 1 Why doesthe inverternot connectto a running generator Check that the generator is set up correctly and the inverter AC circuit breaker for the source is in the up position Did you start the generator manually A source set up as generator must be controlled by the inverter and will not connect if started manually Set up the source as a Utility SP16 17 set to UTIL to start and stop the generator manually Only use the Generator SP16 17 set to GEN setting if the generator must be automatically started and stopped by the inverter To force start a generator controlled by the inverter access the FUNCTION menu and use RUN ANY GENERATOR RUN GENERATOR A or RUN GENERATOR B as applicable To stop a
77. nal extra battery temp monitor is fitted 33 Load Line Summary SCREEN LOAD LINE 1 SINGLE OR RED PHASE LOAD DATA SOURCES ON LINE NUMBER VOLTAGE CURRENT REAL POWER REAL REACTIVE POWER A BOR I INVERTER EES YELLOW amp BLUE PHASE LOAD LINES NOT DISPLAYED IN SINGLE PHASE SYSTEMS Figure 8 Screen 3 Load Line Summary POWERSTAR USER MANUAL PAGE 39 The Load Line Summary screen shows the Load Voltage Current Real and Apparent Power Consumed L1 L2 or L3 abbreviates Line 1 2 or 3 and refers to the parameters associated with the AC line or module connected to the system A 12 KVA inverter system for example would have 2 x 6 KVA modules and would display the rows L1 and L2 that refer to the 1 and 2 4 inverter module stacked underneath the controller box For 3 phase systems phases are labelled L1 to L3 and each inverter module gets assigned a separate phase 34 Source Line Summary SCREEN LOAD LINE 1 SINGLE OR RED PHASE LOAD DATA SOURCES ON LINE NUMBER VOLTAGE CURRENT REAL POWER REAL REACTIVE POWER A BOR INVERTER TR YELLOW amp BLUE PHASE SOURCE LINES NOT DISPLAY ED IN SINGLE PHASE SYSTEMS Figure 9 Screen 4 Source Line Summary The Source Line Summary screen shows the Load Voltage Current Real and Apparent Power Consumed 35 Source StatusScreen SCREEN CURRENT ROW 2 SOURCES ON LINE NUMBER TME SOURCE STATE DATE A BOR I INVERTER SOURCE STATUS 09 03 09 A I Bi sitlolp pi eld n
78. or temperatures lower than this setpoint Lower Temperature Compensation SP85 defines the compensation applied for temperatures below this setpoint 088 Min Compnsatn Minimum Compensation Upper Temperature This setpoint 50 C Upper Temp defines the maximum temperature at which temperature compensation of the battery voltages does not change with temperature The compensation at this setpoint will be used for temperatures above this setpoint 089 Min Compnsatn Minimum Compensation Lower Temperature This setpoint 1 C Lower Temp defines the minimum temperature at which temperature compensation of the battery voltages does not change with temperature The compensation at this setpoint will be used for temperatures below this setpoint 090 Max Batt Chg Maximum Battery Charge Amperes This setpoint controls the 50 Amps maximum amount of the combined renewable and inverter charging current into the batteries and is expressed as a percentage of the battery shunt size This setpoint is used if large renewable sources are available and they can generate currents that exceed the safe maximum charge current limits of the battery bank 091 DC Recon Volts DC Reconnect Voltage This setpoint identifies at what terminal 2 25 VPC voltage the inverter can automatically re connect after it has shut down with a Low DC Volts It assumes that the renewable input has recharged the battery 093 DC Low Shut DC Low Shut down Voltage C1 If the DC voltage drops belo
79. p which is the maximum temperature at which the temperature compensation applied will change for an increase in temperature default setting 50 C This means that the compensation applied at 51 C will be the same as that applied at 50 C SP89 Min Compensation Lower Temp which is the minimum temperature at which the temperature compensation applied will change for a decrease in temperature default setting 1 C This means that the compensation applied at 0 C will be the same as that applied at 1 C The charging voltage needs to be raised as temperature falls to ensure that the battery continues to accept charge Similarly at higher temperature the charging voltage needs to be reduced to prevent excessive gassing due to overcharge Overcharge consumes electrolyte and can dramatically reduce the life of some types of battery in particular recombinant types so called sealed batteries 55 Replacing a Battery Always replace a battery with a battery of the same type and capacity Never replace a flooded battery with a maintenance free battery or vice versa If you not sure about the type and capacity of the batteries installed refer to the You can reach technical support by telephone directly Monday to Friday between 08h00 and 17h00 GMT 2 hours Queries outside of these hours or during South African public holidays should be directed to support mltinverters com and will be answered at the earliest opportunity When contacting technical su
80. possible to the utility For a Generator Sourced system this setpoint should be set to 0 to prevent reverse powering the generator Generally 100 is equivalent to the rated power capacity per phase of the source If setpoint 057 is set to NO then it sets the export power to 0 regardless of the Maximum Export Power setting 100 059 Util Detect Time Utility Detect Time Minimum time that the utility parameters must be within range before the utility is considered to be Good and can be connected to the load 10 sec 060 Gen Start Time Generator Start Time This is the time after the utility has failed and the respective source is BAD after which the backup generator is started When this setting is enabled the generator will not automatically stop To disable this setting set the time to 00 00 061 Island Detect Pwr Island Detect Power Performs a shift in power for detecting grid islanding conditions on inverter systems This setpoint is expressed as a percentage of the nominal per phase rating of the inverter 296 062 Activ Island Detect Enabl Active Island Detect Enable Enable island detection Islanding may occur if the inverter is set up not to track the source voltage SP111 Inv Tracks Source Voltage NO and should always be enabled in this instance Yes 065 Util Bulk Chg Enable Volt Utility Bulk Charge Enable Volts If the battery voltage drops below
81. power point and once there it uses hill climbing to ensure that it remains at the maximum power point for the full time until the next sweep Monitoring the Solar System Operation If required you can use the SOLAR STATUS screen to monitor the solar system operation Refer to Solar Status Screen on page 42 for the information displayed POWERSTAR USER MANUAL PAGE 63 7 VO ExtenderCard H H uz uz H MS Ng H m S Figure 26 PowerStarl O Relay Outputs 7 1 Relay Outputs The 3 auxiliary relays can be set up to perform various functions including generator starting and Smart Load load shedding functionality See the system tables for a full list of functions 7 11 GenentorStart The PowerStar can automatically start most electronic start generators When one of the relays are configured for Generator Start and the generator starting conditions are met the dry contact relay is closed when the generator must start and opened again when the stopping conditions are met Other more advanced functionality such as cranking warming and then starting also exists please contact MLT Drives for further information if your generator does not use a dry contact start option 712 Smart Load Relay 7 1 21 Introduction A The Smart Load Relay option has three priority om outputs which are available on the lO Extender E Y Interface The outputs are known as Priority 1 7 Priority 2 and Priori
82. pport please ensure that you have the information listed above available guide on page 12 To replace a battery 1 Power down inverter see page 17 2 If inverter is connected to grid select Bypass Mode on Bypass Box see page 19 Switch OFF and isolate any connected generators Remove Battery Fuse If Solar Array is fitted remove Solar Array Fuse gv Wr des uw Taking care not to short circuit the battery terminals disconnect and remove the faulty battery NOTE To prevent short circuits we recommend that you always use an insulated spanner when connecting or disconnecting individual batteries or battery banks see Figure 25 below POWERSTAR USER MANUAL PAGE 53 Figure 25 Dangerof Short Circuits when using an Un insulated Spanner 7 Place new battery in position and connect and tighten positive and negative connections red positive black negative 8 Repeat steps 6 and 7 for any other batteries that need replacing 9 Replace Battery Fuse and if applicable Solar Array Fuse 10 Power up inverter see page 17 If inverteris connected to grid set Normal Mode on Bypass Box see page 19 Configure Batteries as required see Battery Charging Examples on page 55 and 11 Table 4 on page 31 for a complete list of battery configuration options Note that the following Must be set SP Name Meaning Default Setting 070 Batt Float Cell Volts 071 Batt Bulk Cell Chg Volts PAGE 54 The float cha
83. rge voltage level for the system battery bank For flooded lead acid batteries typically use 2 30 VPC volts per nominal 2 00 volt cell 2 14 VPC For sealed batteries typically use 2 20 VPC The voltage level that the batteries must achieve during Battery Charge Stage 2 2 35 VPC For flooded lead acid batteries typically use 2 35 VPC volts per nominal 2 00 volt cell POWERSTAR USER MANUAL 072 Batt Equ Cell Volts 077 Equ Enabled For sealed batteries typically use 2 30 VPC This setting defines the equalisation voltage level of the battery bank MUST BE SET FOR FLOODED BATTERIES ONLY IF SEALED BATTERIES ARE USED SPO77 MUST BE SET TO NO If this setpoint is enabled the control system will periodically attempt to equalise the batteries to the equalisation cell voltage SET TO NO FOR SEALED BATTERIES YES FOR FLOODED BATTERIES 56 Battery Charging Examples All the examples given below refer to batteries that are supplied by MLT Drives 561 Example 1 5 6 1 1 inverterand Battery Type 2 40 VPC NO You have a MLT PowerStar 6 KVA 48V Inverter The battery cell used is a FNB Solar M Cell Type MTE25S There are 24 x 2 V cells connected in series to make the required 48V battery From the extract of the table below the capacity at the 5 hour discharge rate is 1188 Ah and 1660 Ah at 100 hour discharge rate Type Ah C5 Ah C100 Peukert k MIL15 378 530 1 13 MIL17 432 60
84. riod another start attempt is made on the same source The number of start attempts is defined by the Cold Start Attempts setting Action a Repair or replace source b Carry out Fault Reset C If fault continues contact Technical Support see page 12 Source A Overload Source B Overload Source A or Source B Overload Reason The load on this source exceeds the source size setting 012 Src A or 013 Src B size Action a Reduce the system load b Carry out Fault Reset c If fault continues contact Technical Support see page 12 Phase Sequence Fault Phase Sequence Fault Reason The phase rotation on three phase systems of an active source is wrong Action Disconnect the source causing the problem and swap two of the phases to clear the fault PAGE 80 POWERSTAR USER MANUAL Fault Message Displayed Description Reverse Power Fault Reverse Power Fault Reason This fault will occur if power was found to be feeding into a generator source The system will attempt to reduce this reverse power situation and if unsuccessful will disconnect the generator The system will attempt to recover from this fault 4 times before masking the source Action a Increase either the Generator Reverse Power Limit setting SPO33 or the Generator Reverse Power Fault Time 34 b Carry out Fault Reset G If fault continues contact Technical Support see page 12 SrcA leo SrcB Pwr Lo
85. ronments The Powerstar has a 150 overload capacity and is the perfect fit for low maintenance off grid remote installations and industrial or home power management A typical Powerstar system application is shown below in Figure 1 involving the integration of grid generator backup power solar energy and batteries If required the system can be managed remotely via a GSM interface phone line connection or local area network LAN The Powerstar is available in either single phase or three phase configurations A single phase system may comprise a Control Box and one two or three 6 KVA Inverter Modules connected in parallel The three phase system will always comprise a Control Box and three 6 8 KVA Inverter Modules one for each phase MPPT CONTROLLER O GRID POWERSTAR GENERATOR O E LOAD BATTERY AC DC INVERTER D B SOLAR Figure 1 Typical Powerstar Inverter System POWERSTAR USER MANUAL PAGE 13 The Powerstar system primarily ensures that quality power to the local site load is maintained at all times The source of power will be the solar energy first and then the AC power source from the grid or generator Discharging of the battery will occur if the grid is not present or is out of range and when the load draws more from the source than the rated inverter current When no renewable energy is available the site load will be powered by the grid supply if available The inverter can be configured to provide rea
86. s Action a Carry out Fault Reset b If fault continues contact Technical Support see page 12 Inverter CB Failed to Open Inverter Contactor Failed to Open Reason The inverter contactor did not open when required Dirty contacts could cause the contactor contacts to be welded closed Action a Carry out Fault Reset b If fault continues contact Technical Support see page 12 Inverter CB Spurious Close Inverter Contactor Spurious Closing Reason The inverter contactor closed when not required to Could be wiring fault between the control box and the inverter modules Action a Carry out Fault Reset b If fault continues contact Technical Support see page 12 Inverter CB Spurious Open Inverter Contactor Spurious Opening Reason The inverter contactor opened when not required to Could be wiring fault between the control box and the inverter modules Action a Carry out Fault Reset b If fault continues contact Technical Support see page 12 Source A CB Failed to Close Source B CB Failed to Close Source A or B Contactor Failed to Close Reason Source A or B contactor did not close when not required Could be wiring fault between the control box and the inverter modules Action a Carry out Fault Reset b If fault continues contact Technical Support see page 12 PAGE 82 POWERSTAR USER MANUAL Fault Message Description Displayed Source A CB Faile
87. s must be pulled to ground for operation Bypass When the Bypass input is ungrounded the inverter is in Inverter Bypass mode and will not output any power Typically used in conjunction with hot bypass circuitry See page 18 for details E Stop Causes an E STOP when this input is not grounded See section 3 2 2 Take Power Up to Software version 4 00 Reduce power intake from the Source configured as UTIL to zero while this input is grounded or Software 4 004 is used as a Solar Earth Fault input Spare Input Unused input Fault Reset Triggers the fault reset command as per HMI input GND Ground All inputs must be pulled to ground for operation Batt Temp Battery Temperature Sensor This uses a 10 mV K input PAGE 66 POWERSTAR USER MANUAL Amb Temp Ambient Temperature Sensor This uses a 10 mV K input Cab Temp Cabinet Temperature Sensor This uses a 10 mV K input Geys Temp Geyser Temperature Sensor This uses a 10 mV K input Spare 1 Unused input A typical 10 mV K input sensor is the LM335 73 7 3Communicationsand Paralleling UPS to PC Current Sense External HMI Figure 28 PowerStarl O Extender Communications and Paralleling From the Top Left to Right Top Left Grey Plug Inverter Paralleling Plug Top Right Grey Plug Inverter Paralleling Plug Term Enable Enable 1200 Termination Resistor for RS485 RS48
88. sage Displayed Description Waiting The system is idle and ready for any event to occur System Initialise Displayed after initial power up or a system reset Fault Reset User has instigated a fault reset as to acknowledge all faults and unmask all peripherals Emergency Stop Emergency Stop has been asserted No control functions can be performed POWERSTAR USER MANUAL PAGE 85 Event Message Displayed Description System Off System has been switched off manually System Fail System has been switched off due to a major system failure Generator not Available The generator is currently not available because is in not configured masked or the grid source is on line Inv Start Reconnect Volt Inverter has started as the battery voltage has risen above the DC reconnect threshold Inv Started Inverter has started but it is not on line yet System is in manual inverter only mode Inverter is the only source on Man Inv Only ing y d RSTO System is in auto inverter only mode Inverter is the only source on line y but other sources can be brought on line automatically sync OK Correct synchronization has been achieved between the Inverter and Y Source A or Source B before the relative source can come on line Inv Stopped Inverter has been stopped Inverter has been masked It cannot be used by the system any more Inv Masked d y d unless as fault reset
89. section 8 3 for location of jumpers and synchronization plugs All the Inverter Live outputs Neutral as well as any Source Inputs Outputs must be connected together respectively in order for parallel operation to work 8 333 Configuration This is considered an advanced procedure and a certain familiarity regarding PowerStar setup is implied The Master and slave needs to have the following changes applied to the setup Some of these changes require advanced system setup for which you will need to contact MLT Drives 83 31 MaserConfiguration 1 Setsetpoint SP155 to 1 This implies Master The inverter has to be restarted by physically disconnecting the DC after this change has been made 2 Setsetpoint SP121 Inverter Droop Control to 2 3 Set setpoint SP59 Util Detect Time to 1 30 minutes 4 Ensure that regulation inverter follows source is switched on 8 3 3 2 Slave Configuration 1 Setsetpoint SP155 to a value between 2 to 4 This implies a Slave Each Slave inverter within the array must have a unique address The inverter has to be restarted by physically disconnecting the DC after this change has been made POWERSTAR USER MANUAL PAGE 69 2 Set setpoint SP121 Inverter Droop Control to 2 3 Set setpoint SP59 Util Detect Time to 1 00 minutes 4 Ensure that regulation inverter follows source is switched on PAGE 70 POWERSTAR USER MANUAL 9 Toubleshooting 91 Eventsand Faults Both Events and Faults are shown o
90. systems that do not have a built in MPPT regulator the duty cycle will be 10096 most of the time If it is less then there is excess solar power available and not all of it is being utilized PAGE 42 POWERSTAR USER MANUAL 3 10 Smart Loads SCREEN CURRENT NUMBER TIME SMART LOADS 09 03 09 IF THE IO EXTENDER CARD OPTION IS INSTALLED THE SMART LOAD RELAY INSIDE THE INVERTER CAN BE CONFIGURED TO SHED LOADS AT SPECIFIC TIMES AND EVENTS THIS SCREEN SHOWS WHETHER THE SMART LOADS CONFIGURED ARE ON OR OFF IF NO SMART LOADS HAVE BEEN SETUP A CORRESPONDING MESSAGE IS DISPLAYED ON THE SCREEN Figure 15 Screen 10 Smart Loads See Smart Load Relay on page 64 for further information 3 11 Summation Logs MEGA WATTS HOUR EXPORTED BY THE MEGA WATTS HOUR IMPORTED BY THE INVERTER I SOURCE A A amp SOURCE B B INVERTER I SOURCE A A amp SOURCE B B Figure 16 Screen 11 Summation Logs 3 12 Run Hoursand Site Logs SITE TOTAL MEGA WATTS HOUR SOLAR TOTAL MEGA WATTS HOUR SOURCE A RUNNING HOURS SOURCE B RUNNING HOURS BATTERY EXPORT TOTAL MEGA WATTS HOUR BATTERY IMPORT TOTAL MEGA WATTS HOUR NOTE ALL TOTALS ARE CALCULATED FROM THE LAST SYSTEM RESET Figure 17 Screen 12 Run Hoursand Site Logs POWERSTAR USER MANUAL PAGE 43 3 13 Miscellaneous Logs GENERATOR FUEL LEVEL ONLY DISPLAYED IF FUEL SOLAR BADIATION FROM MEC LEVEL SENSOR IN GENERATOR IS CONNECTED TO MPC UNDEFINED WIND SPEED ONLY DISPLAYED IF WIND SOURCE A
91. t When contacting Product Support via telephone email or fax please provide the following information for the fastest possible service Type of Inverter Serial number Software and Firmware version numbers Error message shown on display a Battery type Battery bank capacity Battery bank voltage Options installed The above details apart from the Error Message should be available from your System Configuration sheet see page 12 Note that the software and firmware version numbers plus the serial number are available from the System Information screen which is accessed from the SCREENS menu see System Information on page 44 122 Contact Details Telephone 27 0 21 201 1335 Email info mltinverters com Address 103 Garfield Road Kenilworth 7708 Cape Town South Africa 123 Telephone You can reach technical support by telephone directly Monday to Friday between 08h00 and 17h00 GMT 2 hours Queries outside of these hours or during South African public holidays should be directed to support mltinverters com and will be answered at the earliest opportunity When contacting technical support please ensure that you have the information listed above available PAGE 12 POWERSTAR USER MANUAL 13 System Description MLT Multi Power Controller inverter Powerstar inverter systems are mechanically and electrically robust and tough with a wide operating temperature range suitable for operation in harsh envi
92. tage 6 100 Power 164 Aux Voltage 8 10 104 Power M If using a wind turbine with a maximum DC voltage output of 165 Aux Voltage 10 150V the turbine can be connected to the optional auxiliary input 107 Power module for power point tracking If the correct Power Curve as per manufacturer s specifications is 166 Aux Voltage 20 entered using these setpoints the maximum power point ofthe 115 Power turbine will be tracked 167 Aux Voltage 30 121 Power 168 Aux Voltage 40 152 Power 169 Aux Voltage 50 129 Power 170 Aux Voltage 60 131 Power 171 Aux Voltage 70 132 Power 172 Aux Voltage 80 134 Power 173 Aux Voltage 90 134 Power POWERSTAR USER MANUAL PAGE 35 SP No Name Description Default Values 174 Aux Voltage 137 100 Power NOTE Aux settings are only applicable if an internal regulator is installed and factory configured to accept Aux commands Table 8 MENU gt System Config Setup gt System Setup gt Relay Options SP No Name Description Default Values 138 Aux Relay 1Func This auxiliary relay can be set up for 1 out of 11 functions Start A 0 Smart Load A Run Signal for 1 Smart Load B Gen A 2 Smart Load C 4 Fault Alarm Output 5 Start A Coil 6 Start B Coil 7 External Inverter Fan Control 8 External Solar Relay 9 Generator A Starter Crank 10 Generator B Starter Crank 139 A
93. temperature is still too high the solar regulator is tripped and normal solar regulator operation can only occur after a fault reset has command has been issued Action a Disconnect solar input b Wait 15 minutes for heatsink to cool and carry out Fault Reset C If fault continues contact Technical Support see page 12 POWERSTAR USER MANUAL PAGE 75 Fault Message Description Displayed High Battery Temp High Battery Temperature Reason The battery temperature is too high The system should automatically reduce the battery voltage in an attempt to regulate the battery temperature This requires the battery temperature compensation and charge voltages to be set up correctly Ifthe temperature cannot be regulated the system will trip the solar regulator in an attempt to reduce the battery temperature If still unsuccessful the system will mask the inverter and continue running off a source Action a Disconnect batteries b Wait 15 minutes for heatsink to cool and carry out Fault Reset c If fault continues contact Technical Support see page 12 Bat Temp Sensor Fault Battery Heatsink Cabinet or Ambient Temperature Sensor Fault Heatsink Temp Sensor Reason Fault The sensor is giving an incorrect temperature reading Check that all wiring from Cabinet Temp Sensor the control boxtothe inverter modules is securely connected If this fault cannot Fault be reset contact technical support Ambient Temp Sensor Action
94. teries in total 5 6 2 2 Capacity and Peukert Factor The Battery Capacity is the capacity of each battery times the number of paralleled strings i e 185 Ah x 10 strings 1850 Ah The Peukert Factor also changes in accordance with the Battery Data Sheet 5 6 2 3 Battery Charging Hoat and Bulk Sage Voltages Trojan T 105RE 6V batteries are flooded lead acid batteries which are not maintenance free and should be gassed periodically to prevent sulfation To achieve this both the Battery Float Cell Charging Voltage and the Battery Bulk Cell Charging Voltage must be as specified in the battery data sheet In this case no changes are required to these two settings 5 6 2 4 Equalisation Deep cycle flooded lead acid batteries need to be equalised periodically To configure this Equalise Enabled must be set to YES and the Battery Equalise Charge Period set to 4 hours 5 6 2 5 Maximum Battery Charging Curent The Maximum Battery Charging Current is 10 of the nominal Ah capacity 185A Maximum DC Charge Rate for an 18 KVA 36V System 450A 185 Ah divided 450A x 100 41 Maximum Battery Charging Current 41 If you have alternative source charging the batteries too i e Solar PV then you do not necessarily need to increase the Maximum Inverter Charge Otherwise to enable a Maximum DC Charge Rate of 185A from the source you should increase the Maximum Inverter AC Charge rate Inv Chrg Max Setting 130 from 20 default setting to 37
95. termines the integration time for which the low battery condition must exist before a generator is automatically connected 120 sec 032 Low Batt Timer Gain Low Battery Timer Gain This is the timer modifier associated with Low Battery Start Period SP31 A generator will start and connect earlier than the preset time when batteries are severely low 5 sec mV PAGE 32 POWERSTAR USER MANUAL SP No Name Description Default Values 033 Gen Reverse Pwr Limit Generator Reverse Power Limit When a generator is online this setpoint governs the maximum amount of reverse power that the generator will tolerate before shutting down with a Reverse Power Fault This setpoint is expressed as a percentage of the nominal rating per phase of Generator A or Generator B This setpoint does not apply to the grid supply inputs on grid connected systems 10 034 Gen Reverse Pwr Flt Time Generator Reverse Power Fault Time This setpoint is the integration time before a generator will fault with the detection of reverse power If a separate generator control unit is installed this setpoint is not used This setpoint is used when the power into the generator exceeds the Generator Reverse Power Limit setpoint SP33 10 sec 035 Gen Warm Up Time Generator Warm Up Time When the generator starts a warm up time is required before a load maybe applied This setpoint determines the
96. the source Action a Switch to other Source or wait for source to stabalise b Contact Technical Support see page 12 Load too high Inverter Load Too High Reason A manual mode or isolate source command could not be executed because the load is too high This will only occur if the system was operating in parallel mode inverter source and a function was selected that would render the remaining power source too small The system will continue in parallel mode and the fault message will reset after 5 minutes High Temp HS1 High Temp HS2 High Temp HS3 High Temp HS4 High Temperature Heatsink 1 2 3 or 4 Reason The inverter heatsink temperature on this machine is too high and the inverter has shut down to protect itself again permanent damage Load supply will continue from the source only If no source was available the system will attempt to start and bring a generator on line Action a Wait 15 minutes for heatsink to cool and carry out Fault Reset b If fault continues contact Technical Support see page 12 Note In automatic mode the inverter will restart 4 times in an attempt to clear this fault If fault is not cleared inverter will shut down High Temp HS4 High Temperature Solar MPPT Regulator Reason The solar MPPT regulator heatsink temperature is too high The system will attempt to reduce this heatsink temperature by reducing the solar power from the MPPT regulator If the heatsink
97. this setting a bulk charge will be initiated at the time set by the Bulk Chrg Start Time SP133 This setting has no effect if the Bulk Chrg Start Time is set to zero 1 95 PAGE 26 POWERSTAR USER MANUAL Ta ble 4 MENU gt System Config Setup gt System Setup gt Battery Options SP No Name Description Default Values 068 Battery Capacity Rated Ampere Hour Capacity of the batteries at 5 hour discharge C5 time 0600Ah 069 Battery Peukert Value Rated Battery Peukert Value See battery manufacturer s specification This setting is used to calculate the battery state of charge SOC 1 21 070 Batt Float Cell Volts Battery Float Cell Volts The float charge voltage level per cell for the system battery bank Since the float cell voltage is a temperature compensated value this setpoint should be set to the value where there is no compensation which is typically at about 25 C 2 14 VPC 071 Batt Bulk Cell Chg Volts Battery Bulk Cell Charging Voltage Per Cell The voltage level that the batteries must achieve during the constant current charge phase After the bulk voltage is reached the battery current is tapered down for the Battery Bulk Charge Period SP75 After this time the control then maintains the float voltage SP70 Consult battery manufacturer for the bulk charge voltage Since the bulk cell voltage is a temperature compensated value this setpoint sho
98. to provide a large current for a very short period of time They are not designed to be regularly discharged by more than 25 of their capacity This battery is suitable for backup applications Deep cycle lead acid batteries are designed to be repeatedly discharged to at least 50 of their capacity which makes them suitable for homes using solar power or off grid power use Thus if in your application you are repeatedly charging and discharging your batteries you should be using deep cycle batteries If however you are using your system as a UPS low maintenance batteries may be sufficient Standard batteries can be flooded batteries which require regular maintenance or sealed which are maintenance free Deep cycle batteries are available only in the flooded variety If standard batteries are suitable maintenance free type should be selected as they do not require topping up of their electrolyte during their life Your inverter will have either a 36 or 48 volt battery bank while the number batteries will depend on the capacity required Batteries will be connected in series to give the required 36 or 48 volts Further strings of batteries may be connected in parallel with the first group to increase the capacity of the battery bank Depending on the size of the inverter a minimum Ampere hour bank size is recommended This is due to the internal voltage drop in a battery under high loads and load stability MLT Drives recommend at least 20
99. trols inverter settings A source abbreviated as SRC is the general definition for an AC supply such as the Grid or a Generator This is an AC power source that is usually will be present most of the time The utility is often provided by some power producing company and is not always reliable due to lack of capacity Volts Per Cell refers to the individual cell s nominal voltage within the battery Wi Fi short for wireless fidelity is a term for certain types of wireless local area network WLAN that use specifications in the 802 11 family The term Wi Fi was created by an organization called the Wi Fi Alliance which oversees tests that certify product interoperability A product that passes the alliance tests is given the label Wi Fi certified a registered trademark This is a modern form of wind mill Wind turbines generate electricity when their blades are rotated by the wind Wind turbines usually generate DC POWERSTAR USER MANUAL PAGE 9 1 Introduction 11 Wamingsand Cautions A safety instruction message includes a hazard alert symbol and a signal word WARNING or CAUTION Each signal word has the following meaning GPP PPP bbb PAGE 10 HIGH VOLTAGE This symbol indicates high voltage It calls your attention to items or operations that could be dangerous to you and other persons operation this equipment Read the message and follow the instructions carefully WARNING Indicates a potentially hazardous sit
100. ts If set to YES the inverter will track to the external source voltage when in parallel mode otherwise it will track to the internal reference voltage System Nominal Voltage 230V NO 112 Inv Run On Inverter Run ON If this setpoint is set to YES and Source A and Source B cannot successfully be brought on line whilst running in Full Auto the system will continue to supply power to the site from the inverter until a Low DC Link Voltage shut down occurs If itis set to NO the system will move to a Standby mode YES 113 Inv Start Priority Inverter Start Priority This setpoint defines if the inverter has start priority If this setpoint is set to YES then during the FULL AUTO mode the inverter will be the first resource to come online before any other source If it is set to NO either Source A or Source B will be the first resource to come online before the inverter YES 114 Inv Resource Priority Inverter Resource Priority If this setpoint is set to YES the inverter will remain online if there is a synchronisation fault while the paralleling source will be taken temporarily offline If it is set to NO the paralleling source will remain online and the inverter will be temporarily taken offline when a synchronisation fault Occurs YES 124 Inv Max Export Power Inverter Maximum Export Power This is the maximum exported power or current per phase as a of the inverter per phase s
101. tup gt Generator Options SP No Name Description Default Values 020 Max Cold Start At Maximum Cold Start Attempts Source A B which is the number 0 SrcA of attempts that will be made to bring Source A online before the control reports a fault Set to O zero if the Source is a grid 021 Max Cold Start At i e the control will continuously try to bring this source online 3 Src B 022 Generator Max Generator Maximum Crank Time This is the maximum time 00m04s Crank Time that a generator starter will be cranked Cranking will terminate 1 second after the generator voltage is within specification POWERSTAR USER MANUAL PAGE 31 SP No Name Description Default Values 023 Gen Control For an inverter system where both Source A and Source B are generators this setting defines the Generator control configuration of the Generators In the EQUL configuration the system will select which Generator to start based on the current Generators run hours in an attempt to equalize the run hours Inthe BACK A Backup A or BACK B Backup B configuration the system will primarily use one source however in the event of a failure the system will resort to the back up Generator If BACK A is selected Generator A will be the back up Generator and Generator B will be the primary Generator If BACK B is selected Generator B will be the back up Generator and Generator A will be the primary Generator If th
102. ty 3 Priority 1 has the highest priority and priority 3 the lowest Before installation some planning is required to determine which loads are your most important and which are the least important For example the geyser could be least important the stove the next most important while the fridge computer lights and TV are the most important The electrician doing the installation should implement your requirements ensuring that the Priority 3 output controlled the geyser circuit the Priority 2 output controlled the stove air conditioner and kettle circuits and the Priority 1 output controlled the fridge and TV circuits PAGE 64 POWERSTAR USER MANUAL WARNING The Smart Relay Option and the associated wiring should be installed by a qualified electrician Failure to observe this precaution could result in bodily injury There are a number of thresholds that can cause the shedding or reconnection of a load Each type of threshold can be disabled if not required The threshold types are described in Configuration below In operation the inverter monitors the turn ON thresholds If all of the set conditions are met the inverter waits a set time default 30 seconds and if after this period the condition is still met closes a relay that can activate the next smart load The inverter then returns to monitoring and the next time all turn ON conditions are met the inverter repeats the process and activates the next priority load I
103. uation which if not avoided can result in serious injury or death CAUTION Indicates a potentially hazardous situation which if not avoided can result in minor to moderate injury or serious damage to the product The situation described in the CAUTION may if not avoided lead to serious consequences WARNINGS DANGER OF ELECTRIC SHOCK There are no user serviceable parts inside either the Control Box or the Inverter Module DO NOT remove covers or open either unit unless on the instruction of MLT Service Engineers WARNING This equipment should be installed adjusted and serviced by qualified electrical maintenance personnel familiar with the construction and operation of the equipment and the hazards involved Failure to observe this precaution could result in bodily injury WARNING The Smart Relay Option and the associated wiring should be installed by a qualified electrician Failure to observe this precaution could result in bodily injury CAUTIONS CAUTION The Powerstar inverter has a considerable weight and could cause injury When moving the equipment ensure that there are sufficient people or the correct lifting equipment is available Always wear personal protective equipment protective clothing gloves and safety boots to avoid the danger of injuries CAUTION Proper grounds disconnecting devices e g bypass boxes and other safety devices and their location are the responsibility of the user and are not provided
104. uired press 4 to confirm or EXIT to cancel NOTE Confirmation is set to ON or OFF default OFF using MENU System Config Setup Keypad Setup gt Confirm Power Off 3 If required OPEN AC Breakers and then remove DC Fuses on inverter A CAUTION Always stop the inverter using the ON OFF switch on the keypad or alternatively OPEN AC Circuit Breakers before OPENING DC Fuses 2 2 12 PowerUp Power up inverter as follows 1 Press and hold pressed Pre Charge button for 3 seconds and then replace DC Fuses NOTES Pressing the Pre Charge button charges large capacitors inside the inverter thus preventing arcing when the DC fuses are replaced Use of the Pre POWERSTAR USER MANUAL PAGE 17 Charge button also prevents wear and tear on the fuses and fuse holders Always CLOSE DC Fuses before CLOSING AC Circuit Breakers 2 CLOSE AC Circuit Breakers on inverter 3 If the system was not set up to start automatically Sys Auto Restart Enabled NO press ON OFF button on keypad to switch ON inverter blank screen 4 Monitor Main Screen display for fault reports 2 2 2 Emergency Stop In an emergency and if Power Off Confirmation is required the inverter can be quickly stopped by OPENING the AC Circuit Breakers and then OPENING the DC Fuses This method should be avoided unless really necessary Alternatively an Emergency Stop Pushbutton can be wired into the IO Extender Interface on the Control Box 223 BypassSwitch
105. uld be set to the value where there is no compensation which is typically at about 25 C 2 32VPC 072 Batt Equ Cell Volts Battery Equalisation Charge Voltage Per Cell This setting defines the equalisation voltage level of the battery bank Consult battery manufacturer for equalisation voltage and equalisation frequency This setting is not used when sealed batteries are used Since the battery equalisation cell voltage is a temperature compensated value this setpoint should be set to the value where there is no compensation which is typically at about 25 C 2 40VPC 073 Batt Equ Time Interval Battery Equalisation Time Interval This setpoint determines the time between equalisation charge cycles in hours 0744Hrs 074 Batt Equ Chg Period Battery Equalisation Charge Period This setting sets the maximum time the system will remain in the battery equalisation charge region This setpoint prevents prolonged charging of the batteries which may not reach Battery Minimum Equalisation Charge SP79 due to a high internal resistance of the battery which can be due to progressive ageing of the batteries The equalisation charge cycle will end if this setpoint is reached or the Battery Minimum Equalisation Charge SP79 limit has been reached 02h00m POWERSTAR USER MANUAL PAGE 27 SP No Name Description Default Values 075 Batt Bulk Chg Period Battery Bulk Charge
106. urs NOTE For small size batteries Type MIL15 17 leave the Battery Equalise Charge Period to 2 hours For medium size batteries Type MIL21 to 25 set Battery Equalise Charge Period to 3 hrs 5 6 1 6 Maximum Battery Charging Curent The battery shunt size in a 6 kVA inverter is 100A If the battery capacity at the 5 hour discharge rate is 1188 Ah then the Maximum Battery Charging Current is 1096 of 1188 which is 118A If the Maximum Battery Charging Current is set 100 the inverter can charge the batteries at a current of up to 100A which is a little lower than the maximum DC charge rate of the MTE25 battery bank NOTE The Maximum DC Charge Rate is dependent on the kVA of the system and the DC voltage and is given in inverter Specification Sheet Typical values are PAGE 56 POWERSTAR USER MANUAL Maximum DC Charge Rate Inverter WA 6 D 18 8 16 24 48V Systems 125A 250A 375A 150A 300A 450A 36V Systems 150A 300A 450A To enable a Maximum DC Charge Rate of 100A you should increase the Maximum Battery Charging Current from 50 default setting to 100 If you have an alternative source charging the batteries too i e Solar PV then you do not necessarily need to increase the Maximum Inverter AC Charge rate Inv Chrg Max Setting 130 If only source power is used to charge you batteries then increase the maximum inverter AC charge rate to 80 6 KVA or 6000W divided by 48V 125 A 100A
107. ux Relay 2 Func This auxiliary relay can be set up for 1 out of 11 functions See Start B function options from Aux Relay 1 above Run Signal for Gen B 140 Aux Relay 3 Func This auxiliary relay can be set up for 1 out of 11 functions See Smart function options from Aux Relay 1 above Load A 141 No of Smart This is the total number of connected smart loads There may 0 Loads only be 3 locally connected smart loads OR up to 5 RF Radio Controlled Smart Loads Smart load A has the highest priority while smart load E will be the lowest and will be disconnected first when load shedding needs to occur To disable the smart load operation set this setting to zero 0 142 Smart Load Relay Before any new smart load will be connected or disconnected all 30 Wait conditions granting the change in load must be valid for this period 143 Smart Load Inv This is a percentage of the inverter per phase export capacity 5096 Load ON below which all phases must operate before a smart load level will be incremented PAGE 36 POWERSTAR USER MANUAL SP No Name Description Default Values 144 Smart Load Inv This is the percentage of the total inverter per phase size that any 70 Load OFF phase export power must exceed before the smart load level will be decremented 145 Smart Load Bat Battery per cell voltage that the battery must be above before the 2 1 VPCON smart load level will be incremented To disable
108. w 1 7VPC down Volts C1 discharge rate C1 for 10 seconds the system will shut down due to a Low Battery Volts fault 094 DC Low Shut DC Low Shut down Voltage C5 As for 093 but measured at 1 8VPC down Volts C5 discharge rate C5 095 DC Low Shut DC Low Shut down Voltage C100 As for 093 but measured at 1 85VPC down Volts C100 discharge rate C100 096 Batt Overtemp Battery Over Temperature Shut down The temperature of the 48 C Shut down battery bank where the Inverter will be shut down with a Battery Over Temp fault indicated POWERSTAR USER MANUAL PAGE 29 SP No Name Description Default Values 133 Bulk Chg Start Bulk Charge Start Time Defined as the time an automatic bulk 00h00m Time or equalize charge of the batteries could occur provided the bulk charge flag was set as per SP65 If this time is set to 00 00 systems will do a bulk charge whenever a source connects On systems with very erratic grid supply use this setting to prevent multiple bulk charge cycles per day Table 5 MENU gt System Config Setup gt System Setup gt Inverter Options SP No Name Description Default Values 110 No Load Standby Power No Load Standby Power represents the 96 of the total inverter power that must be detected as load in order to recover from Standby mode To disable load sensing on any systems set this setting to zero 00 0 111 Inv Tracks Src Volts Inverter Tracks Source Vol
109. wer ON OFF key E Press to start and run inverter in Auto Mode a Press to stop Powerstar inverter Fault Reset nu Press and hold for 3 seconds to reset inverter when a fault is displayed on line 3 of the display Menu key Press to access the inverter s menu Menu options are shown on the display see Menu on page 20 for further information Note that pressing MENU while in the menu exits the current menu and displays the top level menu Exit key Press to exit current menu option and go up one level Any data being entered is cancelled Return key E When browsing menu press to select the displayed option E When entering data or making selections press to save the current entry POWERSTAR USER MANUAL p Left Right Navigation key E When in the menu and entering data press to move gt the cursor one place to the left right E When browsing the menu press to page UP and DOWN through the current menu options 4 Up Down Navigation key E Press to browse through available screens 4 When browsing menu press to scroll through sub menu options L When in the menu and changing settings press to change the current setting e g from YES to NO E When entering data press to increase decrease the selected digit by one 22 UserFunctions 221 PowerUp PowerDown 22 11 Powerdown inverterasfollows 1 Press ON OFF button on keypad Display shows System Off 2 If display shows Confirmation Req

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