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RAPS 10kW - 15kW - Selectronic Australia

1. 4 00 L fa owe A A 00 4 power solutions austra lia v generator interactive sinewave inverter manual for installation amp operation Inverter types covered RAP 10 108 1 RAP 10 110 1 RAP 10 12 15 120 1 Copyright power solutions australia 1997 Part No PC0011 These instructions provide you with basic information for the installation operation and maintenance of your power solutions australia sine wave inverter power solutions australia shall have no obligation as to any equipment which has been improperly installed stored or handled or which has not been operated or maintained according to these instructions nor for any operating mistakes and consequences arising therefrom If you have any suggestions for improvements to either this manual or any power solutions australia product please contact us in writing at 20 Fletcher Road Mooroolbark VIC 3138 Contents Contents rain iii 3 INTO ei te E 1 PSA Product Warranty EEN rit 2 Operating ProceduresS curare 3 INIA ue BEE 3 Never open the DC circuit breaker while the inverter is operating eeeeeeeeseene 3 Turhthe INVETLSR EE 3 Checking system operation for the first me 3 Precautionsi ircii oiran irene 5 Electrical Installation icc nana a ei aaa aa 5 Generator Installation fera na ai Ee 5 Battery Installation iatale aa 5 Inverter Installation catarata al irta 5 Solar Array Instala Micol
2. The final charge is competed at the charge voltage and boost current It is held at the charge voltage until the charge time and minimum charge power conditions are satisfied This allows maximum charge rates to be applied at high efficiencies as many battery manufacturers allow higher charge currents while the battery voltage is low Float V 139 8 51260 lt ic This is the battery voltage maintained after the battery has reached charge condition and while it remains connected to a source of ac power such as the generator or mains In systems with mains supply permanently available a lower float voltage should be set Charge V 144 0 gt 132 0 lt i This is the battery voltage maintained in the charge condition provided the battery current is below the charge current limit and while the charge time described below has not been satisfied The battery is brought to this voltage and held for the charge time set below and until the charge power has fallen to less than the minimum charge power set above Copyright power solutions australia 1997 Doc No 251U16 Rev 1 27 5 97 28 Chg Time hr 0 3 gt 0 3 lt 12 0 This is the time that the inverter holds the battery at the charge voltage before shutting the generator down provided the charge power is below its setting and the generator load is below its shutdown level Boost V 147 0 gt 132 0 lt 147 0 This is the maximum battery voltage during a boost or equalise This voltage is set
3. 102 0 lt il ShutDwnV is the battery voltage averaged over 15 seconds which will shut the inverter down to avoid over discharge of the battery After such a shutdown the battery voltage must recover to above the nominal battery voltage by renewables charging the battery or there must be AC power present from the generator allowing the inverter to synchronise and start to charge the battery RenFloat V 136 2 gt 126 6 nil This voltage is used to monitor the effect of renewables charging the battery particularly if there is no renewable shunt present If this voltage is exceeded for the RenFloat hr the battery is considered charged the battery ampere hour is adjusted and boost charging is deferred for half a day RenFloat hr 2 0 gt 013 lt ER See RenFloat V description above Shunt A mV 1 00 gt 0 20 lt sn This is the calibration constant for the renewable current measuring shunt The default value is 1 00 A mV which corresponds to a 50mV 50A shunt or a 100mV 100A shunt A 50mV 100A shunt would require a value of 2A mV If large currents are being measured a 100mV or even 150mV shunt is preferred as this minimises errors in measurement In Chrg V 139 8 gt 126 0 lt ei This is the initial charge voltage which is applied when charging starts at full charge current Once the charge current has fallen below the boost current setting the final charge voltage is applied the current is reduced to the boost current setting
4. Edit Display List ha Ah 400 gt 20 lt 3000 Se si 6 0 lt 15 0 MinStrtDis 4 gt lt 80 censtrtDis 5 gt lt 80 NitestrtDis s 6 gt lt 80 star 117 0 gt 111 6 lt 125 4 Ee 32 gt lt 50 gt lt 9 NomAc Volt 240 gt 210 lt 260 RevPwr kW 0 30 gt 2 00 lt 0 20 Hi Lim Hz 55 02 65 00 gt 50 10 Lo Lim Hz 45 00 49 90 gt 43 00 60 90 shutDisch ole A tinche gem 4 Lia 111 0 gt 102 0 lt 111 RenFloat V 136 gt 126 6 lt 144 a hr 2 gt E er Shunt yee 1 00 gt 0 20 lt 5 00 In Chrg V 139 8 gt 126 0 lt 144 0 meee V 139 OO ON O gt 132 0 lt 147 i Ar 3 lt 12 8 gt 120 0 lt 144 0 Charge V 144 0 gt 132 0 lt 147 0 Chg gt ht 10 59 gt lt 12 0 Boost V 147 0 0 0 0 Doc No 300U15 Charge Amp gt 10 lt Boost Amp gt 5 lt BstFrq Day gt iper PrefGen hr gt By e LockGen hr gt Dy E UnlockG hr gt bi lt Time hr gt O lt lt Time min gt 0 lt Rev 3 1 10 97 26 Edit Display List BatSize Ah 400 gt 20 lt Sec This is the size of the battery in ampere hour The value set should be the capacity of the battery at the typical discharge rate expected in the system GenMax kW 6 0 gt 1 0 lt i This is the maximum power which will be held on the generator for any sustained time It must be set at less than 80 of the nominal KVA rating of th
5. General Electrical Specification Nominal DC Voltage 108 110 120Vdc One Hour Rating 14 kW at 40 C DC Working Voltage Range 100 to 155Vdc Surge Rating 10 sec at 20 kW Output Voltage 240 Vac AC Short circuit current gt 60 A lt 100A Output Voltage Tolerance Low load losses lt 110W 210 to 260 Vac 180 to 280 Vac 50Hz 46 to 54 Hz Efficiency 20 120 load gt 92 Peak Efficiency 96 Total Harmonic Distortion lt 4 to AS2279 RF Interference to AS1044 1990 sustained synchronised operation transient disturbances of lt 100ms Output Frequency Frequency Tolerance Continuous Power Rating 10 kW at 40 C Generator max size 20kVA Derating 6 kW at 60 C Protection Automatic Shutdown for DC over voltage DC under voltage Overload Over temperature AC over frequency AC under frequency AC over volts AC under volts Battery discharge Copyright power solutions australia 1997 Doc No 250U19 Rev 1 27 5 97 39 Failure Mode Diagnostics All units self test on start up and will not go on line unless test is passed Self test failure codes are displayed on LED display and help diagnosis down to module level In conjunction with logged data and event records fully remote system diagnosis via a modem minimises the cost of ownership LED Status Indication Normal Fault internal On load Unavailable Synchronised Unable to sync
6. Parameters Battery size Battery size is used to set the depth of discharge allowed so a value which is too large will cause higher depth of discharge and a value which is too small will result in more frequent generator starts Charge Boost Current If the battery is small it may also be necessary to reduce the charge and boost currents to meet the manufacturers recommendations Note in a three phase inverter the charge current and boost current settings are the per phase current hence a setting of charge current setting of 30A will generate an actual charge current of 90A in a three phase inverter However minimum charge power is the full three phase charge power Generator Size Generator maximum size limits the maximum power drawn from the generator to charge the battery and to supply load For example with a 7 kW GenMax setting on a system which has a load of 5 kW will limit the charge power to 2kW so the maximum load on the generator does not exceed 7kW Typically generator are rated in kVA and the corresponding GenMax value should be 0 8 time the kVA rating If a generator is old or in poor condition the engine may not even be capable of this level of power If when operating with the inverter the generator frequency falls below 47Hz it may be necessary to reduce the GenMax setting or to adjust the governor When the generator synchronises and before significant load is placed on the system the frequency should be no lower than 51Hz and
7. Rev 1 27 5 97 Alarm Relay 12 13 Normal Operation Inverter Self Test The inverter performs a self check as it starts up During the self test all the LED indicators on a module flash Only if no faults are detected will the inverter start Normal operation is indicated by steady illumination of the top green indicator light A flashing green indicator at the top indicates the self test has detected a fault and the inverter will be not be able to start If the top green indicator is flashing record the pattern of indicators which are illuminated and advise your supplier Starting and Stopping the Generator Manually Pressing the Enter button on the front panel when in normal display pages will start the generator charge the batteries and complete charging with a boost cycle If the generator is running and charging or boost charging is in progress pushing the ENTER button for 2 seconds and releasing will stop the generator and terminate the boost charge cycle The generator may also be started and stopped manually from the generator control box The inverter will automatically charge the batteries whenever AC power is available Once charged the battery voltage will be reduced to hold the battery in float Automatic Generator Control The generator is started and stopped to achieve the following objectives Limit the depth of battery discharge to give maximum battery life Perform boost charging periodically to maintain all batter
8. Serin DIE Input 1 Gen Avail Ree Sune out Dicomi23 CM Input 1 23 Common San Temo M7 Bat Temp ANSE Ser out DB Bat Temp APOM I 236 ZA interactive sinewave inverter LCD Close 223 22 221 220 Z19 Z18 z17 Z16 Z15 Zi4 RAP10 120 1 Display DC CB Up Down Start ZSI313 281313 2SI313 ZSI313 ZSI313 ZSB312 ZSB312 ZSB312 ZSB312 ZSB312 power solutions australia Enter Stop Z24 z25 226 z27 228 ER z12 Zi1 Zio E ZY4405 ZY4404 ES Zi DEE DO Voltage Battery Ounent ZSI313 251313 2SI313 ZSI313 2SI313 ZSB312 ZSB312 POETA aa ZY 4401 Deng ES D ee Battery Pos Battery Neg Renew Neg y o XDE XDE XDE a zo mM A B 2 ZI ZY4406 27 FERA PENNE gt z LED Display ma ZB440 1 ZB440 1 258650 ZSB650 ZSPAG ZSPAS ZSPAG ZSPAG Steady Rashing 274403 za B 7 P 5 Norma Fault ER ZE440 o On Load Unavail Synch Unable Label Comms ZSPAG ZSPAS ZSPAS ZSPAG o ZY4407 ZY4408 ZB440 2 Refer 1o draw a survey fors applicable change requests power solutions australia Rev e ni eration Application Protel Schematic 3 4 29 4 97 GG New design E File Narre 5_ 3 5 97 EG Change ac wiring Tile 10W iw So E C NVERT 1 RAPIO 1 RAPI0S 1 SCH 6 4697 GG _ NoveRAFiter er 10W verter Sebenetic Drawn GG Appd 7 16 7 97 GG _ Add shunt Ro Drg No 440501 Sheet 1 of 1 Date 16 Sep 1997 Rev 7 Electrical Connections psa Solar Regulator or similar Battery Pos 100V 10J Varistor or connect battery negative to earth Solar Fuse _ Generat
9. at the terminals Seeking Load Flashing with a brief on long off indicates that inverter is waiting for load on the output terminals before starting up Unavailable Flashing 50 on 50 off indicates that the inverter is not available to startup because it is in a fault or overload recovery situation In a 3 phase or parallel type system this means one of the following It is in a fault or overload recovery state it cannot communicate with a slave or one of the slaves is not in the proper state to allow startup For a slave it means it is unable to communicate with the master or it is ina fault or overload recovery state Synchronised Indicates that inverter is running synchronised and in parallel with a generator or external supply In this situation the inverter can charge the batteries or if a heavy load is present both the inverter and the AC generator work together to supply any load up to the sum of the inverter and generator capabilities Unable to Synchronise Indicates that it is unable to complete synchronisation because the external supply is out of tolerance The type of flash indicates whether the voltage or frequency is high or low If this occurs you need to get the generator supplier to adjust the governor speed setting or the output voltage It may help to put some load on the output of the diesel to stabilise the voltage and frequency Refer to questions and answers section for further information Charging Indic
10. data corresponding to the missed 15 minute logging time or times Remote shutdown of inverter If connected via modem hang up the phone using the command from your program Do not use the Quit command as this turns the inverter off in early software versions If the power is lost to the modem the inverter can only be started by someone on site turning the on off switch off and back on In software versions later than 20 August 94 the command is QUI and while this command still shuts down the inverter it will automatically be restarted by the watchdog timer Copyright power solutions australia 1997 Doc No 250U18 Rev 1 27 5 97 34 Processing Logged Data Converting data The retrieved data file can be converted to a text file suitable for reading into a spreadsheet using the program inconvd exe which operates under DOS or iconvw exe which operates under Windows The files CCCnn RTV and CCC TXT should be in the same directory as the conversion program Site file The file CCC TXT is called the site file licontains heading information for the columns of the spreadsheets the event file and some parameter definitions A description of this file is included in the file Readme txt distributed with the conversion program ICONVW program On starting the program asks for the site code CCC and then the retrieve code nn It then asks if the user wishes to override the date in the retrieved file This may be necessary if the time of day cloc
11. ee eae 16 Nooo a A A AA A ete 16 CU asii AA AAA AA Gide ila ii 16 O O 17 Seeking Load iii E ra 17 Unavailable EE 17 Syncros ed ninica aa aeni u ee ee Bee 17 Unable to Synchronise AA 17 AE EE 17 lee E le an lia vei hi tei ee aid On her ee thas 17 LOoW DOVolS 2 Salmi aiar aa 17 HIGH DG Volts iaia Aia ia 18 Me HEET 18 Over Temperature i 18 Generator Oki 18 e Ee BCE EE 18 Generator Stop pdas Ai a cai 18 Generator Faute 19 Questions and ANSWETS i 19 Generator runs at the wrong times 19 Restarting the generator after running out Of fuel nono 19 Generator doesn t stop 19 Starting or running big l0adS i 19 Bei EU 20 Standard Display Pages 20 Default Parameters AAA 22 Basic EE 23 ST EE 23 Charge Boost Current 23 Generato SiZ tiara lana ea 23 Charge Voltage MinChargePower ChargeShut kW Charge Time 23 Initial Charge Voltage Charge Voltage Charge Current and Boost Current 23 Edit Display Pages cocida ea a 24 Parameter Storage eni E eae ate dagen 24 Gelies 24 Restore a Parameter to the Default Value iii 24 Restore all Parameters to Defaults nano nancc conca arcano 24 Parameters and Software Versions nn nano carac cra rana 25 Recording Parameter Settings i 25 Mode Switch Settings iii 25 Standard Display Listin edie A Melodie erin face ae ia 26 Edi
12. hexadecimal value for that parameter Generate the decimal value from the known scaling factors and use a calculator such as the Windows scientific calculator to convert the value to hexadecimal Hexadecimal numbers use base 16 rather than base 10 so counting goees0123456789ABCDEF then 10 11 etc Display the contents of the existing parameter area using the command X 500 57F while capturing to a disk file to obtain a copy of the existing values for reference purposes Locate the address of the particular variable the lowest address contains the least significant digits and the next address the most significant digits Confirm the contents using the command XW nnn to display the word value in hexadecimal or XD nnn to display the value in decimal format In recent systems the command WD Write word Decimal is available to directly write a double byte value using a decimal input format A typical command would be WD 504 6000 Recent systems allow mixed entry of hexadecimal numbers and decimal numbers Hexadecimal numbers have no preceding sign hence the address 504 to which the value is to be loaded is a hexadecimal number and the value loaded 6000 has a preceding sign and is therefore a decimal value If decimal input is not available the value must be updated a byte at a time using the WX Write eXternal memory command The format for the same example above note 6000 decimal is 1770 hexadecimal is WX 504 504 70 to load the least significant byte a
13. initial final equalisation amp float fully parameterisable shares VARs with generator when rectifying fully floating ac output inverter A generator operate together to support high loads fully floating dc input automatic load search mode to further reduce losses field proven design temperature compensated data acquisition and logging LCD displays all relevant variables and parameters remote access via modem General Description A microprocessor based bi directional inverter designed for remote area power systems but with capability to be applied to a variety of other classes of system Smart software fully manages the system A fully automatic hybrid system can include only the inverter an electric start alternator and a battery bank Add renewables such as solar and wind the inverter integrates with solar and wind controllers to manage the battery and maximise renewable usage The inverter is fully bi directional Continuous control of power setting allows smooth control of inverter power from fully inverting supporting load to fully rectifying when charging batteries Battery charge conditions can be set to cover a wide variety of battery types with automatic periodic battery equalisation to maximise battery life while ensuring minimum generator operating time and high fuel efficiency Self testing data logging and event recording and remote access via a modem allows remote diagnosis and minimises the cost of ownership
14. key is pressed IW adr adr adr adr up to 10 addresses Display contents of internal memory in word format address range 0 to FF or 0 to 255 dec Many internal values such as power are held in two byte word format Up to 10 addresses can be requested they will be displayed in hexadecimal and their contents continuously updated until another key is pressed XB adr adr adr adr up to 10 addresses Display contents of external memory in byte format address range 0 to FFFF hex or 0 to 644535 dec Up to 10 addresses can be requested they will be displayed in hexadecimal and their contents continuously updated until another key is pressed XW adr adr adr adr up to 10 addresses Display contents of external memory in word format address range 0 to FFFF hex or 0 to 644535 dec Many internal values such as power are held in two byte word format Up to 10 addresses can be requested they will be displayed in hexadecimal and their contents continuously updated until another key is pressed XD adr adr adr adr up to 10 addresses New in systems after Nov 95 only Display contents of external memory in decimal word format address range 0 to FFFF hex or 0 to Copyright power solutions australia 1997 Doc No 250U17 Rev 1 27 5 97 30 644535 dec The value is displayed as a signed decimal integer in the range 32768 to 32767 Parameter values defining system operating conditions can be displayed in this format Many internal values such as power are h
15. no higher than 54Hz Charge Voltage MinChargePower ChargeShut kW Charge Time These parameters determine the level to which the battery is recharged before the generator is shut down If the battery is always fully recharged the generator will be kept running for long times at light loads and low fuel efficiency to put the final 15 of charge into the battery The charge efficiency of the battery is also low under these conditions Choosing a low charge voltage reduces corrosion in the battery but increases charge time a higher charge voltage charges at the highest possible rate reducing generator run time The charge time is the time which the battery voltage must be maintained at the charge voltage before the generator is allowed to shut down at the same time the minimum charge power must be satisfied to ensure that the battery has reached the desired state of charge The appropriateness of the settings can be determined by checking the battery Specific Gravity measurements of the battery electrolyte after charging is complete The battery should be around 70 charged If the SG values are too low consider increasing the charge time charge voltage or decreasing the minimum charge power Periodically the boost boost charge takes place this takes the battery up to a high state of charge and is terminated based purely on time at the boost charge voltage If renewable inputs are available they can also be used to complete boost charging without ru
16. on the display and the arrow symbol will disappear The arrow symbol will disappear if no push buttons are operated for 5 seconds and the up down push buttons revert to their normal function of stepping between display pages If no push buttons are pressed for one minute the message Params Unchanged will appear and the standard display will appear Restore a Parameter to the Default Value To restore a parameter on the display to the default value select the relevant edit page Press the Enter push button to enable editing then press the Enter push button for two seconds and release The default value will be restored on the display To make the default value permanent if the parameters have been modified press the Enter push button for a short time to store the value in the same way as if it had been changed and had to be made permanent Restore all Parameters to Defaults To restore all parameters to default values select any edit display Press both up and down push buttons simultaneously for two seconds and release The message Default params will be displayed and the default values will be used by the inverter Previous values in the EEPROM are erased No further action power solutions australia Doc No 300U15 Rev 3 1 10 97 24 is required Whenever the system is started the default values will be loaded from EPROM Values in the EEPROM will be ignored Parameters and Software Versions From time to time new software
17. or more Check and see if the Charge Boost light is flashing There may be a sustained load on the system check to see that appliances have not been left on If none of these reasons apply or you need to stop the generator for any reason you can do so by turning the REMOTE run switch ON and then OFF a few seconds later The generator will stop It may restart a minute or so later If this is the case the battery is discharged the battery volts are low or there is a load present you are not aware of You can always shut the generator down permanently by switching the AUTO MANUAL switch on the generator to MANUAL Starting or running big loads When try to start the 2 horsepower irrigation pump the lights go dull the motor groans along for ten seconds and then the power goes off What should do Use the REMOTE RUN switch to start the generator before you start the pump If you put it to ON for a few seconds the generator will start and provided you start the pump within two minutes the generator will remain running and then switch off automatically when it is no longer needed You can also just turn the remote run switch on for as long as you want When you turn it off the generator will also turn off but may restart a minute or so later if the batteries still need charging or there is a large load present You also can use the controls on the generator to run it in MANUAL mode independent of the inverter Copyright power solutions austra
18. represent various variables in different systems If there is dc load present and the system is set up to monitor it via a standard 50mV 50A shunt then it represents the dc load in Amps DC load is logged and used to calculate battery net charge current and state of discharge It may be used to monitor insolation or any other variable in which case the value is only logged and the calibration depends on the transducer scaling Htsnk C 28 Btry C 20 Htsnk C is the internal heatsink temperature If fans are fitted they are switched on when this reaches 50C and off when they fall to 45C If the temperature rises above 55C the charge current is reduced to reduce the risk of thermal shutdown during battery charging Btry C is the battery temperature as sensed by the battery temperature sensor If no sensor is fitted the indication will normally be shown as zero the battery temperature compensation is disabled and the nominal values for battery charge voltages are used BatSize Ah 400 aa kW Ga Battery size is the capacity in ampere hour set using the battery size edit page It is used to set the depth of discharge allowed so a value which is too large will cause higher depth of discharge and a value which is too small will result in more frequent generator starts If the battery is small it may also be necessary to reduce the charge and boost currents to meet the manufacturers recommendations Gen size is the Generator power not kVA rating set using the g
19. set if the system is being used without data logging With data logging the complete year month day hour and minute can be set using the TU command over the serial port Copyright power solutions australia 1997 Doc No 251U16 Rev 1 27 5 97 29 Monitor Interface amp Parameter Setting Using the Real Time Monitor Interface Monitor Program A monitor program runs constantly at low priority in the inverter It provided the ability to monitor internal variables in real time and to display and change selected parameters which control the operation of the inverter The present interface is direct into the inverter is limited in the facilities and convenience of operation A PC based interface is under development which will simplify access and extend the facilities available Memory Variables To use the existing facility requires knowledge of the location of variables inside memory the descriptions below list the commands available and some of the procedures For any system Power Solutions Australia can provide lists of the location of key variables and variable scaling At present there are two versions of the monitor in use Systems with ROMs prior to Nov 19 95 have only hexadecimal input and output of variables and the ability to input values only one byte at a time Systems after that date allow decimal input and display of data as well as the ability to input double byte decimal values most variables and parameters are represented by 16
20. the generator has been put into manual operation remember to turn it back to auto to allow the inverter to take control The inverter only has control if the generator OK indicator is steady If the inverter is behaving abnormally it can always be shut down and restarted by turning the On Off switch from On to Off and back to On Questions and Answers Generator runs at the wrong times My generator seems to be starting late at night and then never starts until the middle of the day what should do The time of day clock may be incorrectly set Contact your supplier who can reset it Check that the overnight load is not excessive and that the battery has not lost capacity and forcing the generator to start prematurely Restarting the generator after running out of fuel The generator ran out of fuel and put fuel back in but the second bottom light is still flashing and the generator is not starting You need to switch the generator back to MANUAL and then back to AUTO using the switch on the generator to tell the inverter that the problem is fixed and that it can take control again While you are in manual you can crank the generator manually and get it going again There can be air in the fuel line which may make it difficult for the inverter to start it with its three short crank tries Generator doesn t stop The generator seems to have been running for ages can stop it It may be doing its weekly boost charge this can take four hours
21. the standard pages but they can only be changed from edit pages The top line of an edit page shows the value and the second line the maximum and minimum values which may be set The inverter comes with a set of default parameters As the installer you may need to adjust parameters to e Set the correct battery size e Change charge boost or float voltage voltages from the standard values Some batteries need higher voltages for longer times to achieve good states of charge e Allow recognition of effective charging from renewables if the renewable regulator does not hold the battery volts above the renewable float voltage when charging from renewable sources is complete e Set the generator size to the correct value to prevent overloading and low frequency operation e Allow the system to be permanently connected to mains supply and to export significant surplus energy from renewable inputs such as solar or wind e Raise or lower the ac output voltage perhaps to match a generator which cannot be easily adjusted Note The battery type must be set for either Valve Regulated sealed or Flooded using the appropriate DIL switch on the Comms PCB The considerations involved in choosing the parameter settings are discussed in the list of editable parameters below Parameter Storage Parameters are held in RAM memory for use by the inverter The editing process described below changes the value in RAM and when editing is complete the entry fu
22. used to charge the battery system It must be connected in the negative lead of the renewable power lead which should be connected to the battery negative Refer to your supplier for shunt specifications Standard in RAP10 inverters The enclosed drawings identify the wiring required and the location of all terminals Refer to your supplier if wiring requirements are different Battery Wiring The high current wiring from the inverter should be connected as directly as possible to the battery bank The battery bank and its wiring should be arranged to minimise the total inductance of the DC wiring system by keeping the area enclosed by the path from inverter positive output through each battery and back to the inverter negative terminal to a minimum Connect other sources of DC power direct to the battery bank Do not wire the inverter so that power can be supplied from wind or solar direct to the inverter with the battery isolated Uncontrolled sources which are not limited in voltage by the battery can damage the inverter Battery currents up to 100A 300A for 3 phase inverters can flow during normal operation If battery fuses or circuit breakers are installed their rating should be above this and used to protect battery wiring not the inverter The inverter includes its own dc circuit breakers Never disconnect the battery while the inverter is connected Always shut down the inverter as described in the operating procedures open its DC ci
23. 4321 Temp Sensor CN5 Not Used 87654321 DO4 Used for renewable regulator functions Closed if regulator voltage should be raised to higher setpoint DI 1 Generator available input apply voltage when generator in auto mode DI 2 Not used DI 3 Remote run input apply voltage to start generator DI4 Notused DI5 Fuel level low apply voltage when fuel tank level low DI6 Fuel level shutdown apply voltage when fuel tank level below generator shutdown level Al1 Analogue Input Renewable shunt typically 50mV 50A Al2 Analogue input Auxiliary Specifications Relay Outputs 24Vdc max 32Vac max 1A max Digital Inputs lt 3V False gt 6V True 30Vdc max Analogue Inputs 250mV differential 5V common mode Temperature Sense 50uA C 5 to 50 C open circuit 20 C Simplified Schematic CNA CNS LEI DI A 275V 15 Alarm com ir T Z DI com 4 21 Alarm nc dae Ss ba aL ova al 120 o i DI2 DI RL Sp SL DI com 123 SL IL Temp sense Y 2 Ground 2 gt A OV CNS CN3 ATL SI 1 A gt DI 6 gt Alarm com 2 DI5 Alarm no DI com 56 DO com 123 Ground x DO 1 Analog 2 a DO 2 DI Analog 2 Y 51 Do3 Analog 1 RLS q La DO com 4 gt Analog 1 G NI 81 po4 Copyright power solutions australia 1997 Doc No 250U12
24. Act in your state or territory All installation and user conditions as set down in the instruction manual must be strictly adhered to failure to do so may void your warranty This product is not to be used for Life Support equipment Any faults caused by lightning water or moisture ingress faulty installation using the product in a manner which it is not intended vermin infestation improper voltage alteration which affects the reliability or performance of the unit but not attributable to faulty manufacture or faulty generator sets will not be covered under warranty In the event of the product being out of service the manufacturer shall bear no responsibility for any consequential losses or expenses The manufacturer will not be held responsible for any misleading or incorrect information conveyed by the salesperson or installer If service is required please contact your installer sales company first Copyright power solutions australia 1997 Doc No 250U4 Rev 1 27 65 97 Operating Procedures Initial Starting This procedure only needs to be followed when the inverter has been fully shut down and the DC circuit breaker has been opened The generator can be running or off Turn on all AC circuit breakers at the base of the unit e The Stop switch will be on and flashing If it does not check that the battery is connected to the inverter Battery fuses may have been disconnected e Press the Start switch to begin startup The volta
25. Gen kVAr is the generator reactive power value The sum of these two values is the load reactive power Large complementary values of inverter and reactive power in excess of 30 of inverter rating indicate that the inverter and generator voltage do no match well and either the generator or inverter output voltage should be adjusted A positive inverter reactive power value can be reduced by reducing the inverter output voltage or increasing the generator voltage Dis Ah 23 2 DC Volt 123 4 Dis Ah is the battery estimated discharge ampere hour The value is near zero when the battery is in a high state of charge and will increase to a positive value as the battery is discharged When the value reaches the relevant generator start discharge threshold the generator will be started provided the battery voltage is sufficiently low to indicate that it is being discharged During charging the value may go negative if more ampere hour are restored to the battery than were extracted When the generator shuts down after the battery reaches a high state of charge the value will be adjusted back to zero if it is significantly different from zero DC Volt is the battery voltage as described above Ren Amp 1 3 Aux mV 23 2 Ren Amp is the measured renewable input current as measured on the optional renewable input shunt This value is used in calculating the battery discharge ampere hour Aux mV is the dc voltage on the auxiliary analog input analog input 2 It can
26. SO Kia Lt Ti Kib T0501 one ele et t Load A BS R terminate direct to CB Batteryneg X2 A2 y D2 X4 LoadN A5 7 2VA ei u 7 SE oy NV a Mz Gesi Dive OT oa Bd e ae Renewable neg RS50A50 24V D z NV OT X5 GenN x3 men Qic 12 ONZA 12v plows G ove XDI6 ME s2 E e G be ti 12 Ti sese CVA sw Cep chanel ne Gesin ACS OnE Ge 3 quit Ser SPLG SE CBsw Cap Voltag Ea are Be BECH 163 Sparesw Rel coil Geh ST eat DER Stat Lamp Rel coil PONTE 4 E terminate direct to CB Seed SPLR o Fe col Tonno Ka Hu Te ed Ste CN2 10 Bla DS e M Ai A2 ga SCT ag a Spare Lamp 424v loaf AI DM1A400 cn k d Gen PE 66 SP SPLY 12 Spare OV fioa N Power crip oe KC55A240AC oo cr APSU ee EE o EE ml fia G RAI A8 3 cr VAIN l S 138 tp VNR Z 3 RLIAI Ni 7 tums ce RL BLUZ 1 2 ROT a E APLED 2 crap Re oi R1 3 CR BAS APMC2 E RAS A2 fa 6 8 Mi Me MF150 MF150 Micro Pos Mt A x ons comms 138 APRS 3 Se TN MTN Mea cnn 3 Dell Input6 Spare X X APLOD_2 DIS ue Input 5 Spare x10 e DI cors e Noa pase Gommon a wus MF150G ane 226 Analogue 2 Shunt xi LL ANG CAD Analogue 2 Shunt ANIT OB noo Su A SS L Se oe ai Kuken e x2 MF120 M120 M120 ens Am com Im com EK 9 Ke ni A LS RPR Comms Port agajn ANO iag Alarm NC lt lt lt ot ee ae 3 Oe ae DE CNBIE ra se Ez Ez Ez 3 sen Gul ie Dron Ge Output 4 Common TPR om S SS Osi Ot Ao seo H len Dicom Lo RTR B Sync in DEI input Remote run CNS ink com Dig OM Input 2 Spere CNS 5 et g
27. acking supplied with new software If system has been customised using the LCD verify that the message Params Loaded OK appears on power up If not use the LCD to enter the customised values again Important Check that the mode switch settings on the DIL switch on the Comms or LCD display do not have to be modified from the original configuration for the new software Software versions after 1 July 95 may use different mode switch settings See the section on mode switch settings U4 u3 U2 d H I Real Time RAM EPROM a Lal Reset CN4 EEPROM L Copyright power solutions australia 1997 Doc No 250U19 Rev 1 27 5 97 37 Specification y x power solutions austra lia abn 44 092 963 749 tel 03 9727 6600 fax 03 9727 6601 email psasales powersolution com au office 20 Fletcher Road Mooroolbark Vic 3138 RAP 10 series Remote Area Power Sinewave Inverter 10 kW 108 110 120 Vdc to 240 V 50 Hz Single Phase for Generator Battery Applications Features sine wave output low distortion lt 4 THD high efficiency gt 93 peak fully protected outputs operates into any power factor load low low load losses fully bi directional charges batteries at full inverter rating high reliability sources or sinks VARs for transient voltage changes frequency amp voltage tracking automatically synchronises to generator limits load on generator to rating four automatic charge modes
28. after a normal charge is completed Boost charges occur when the specified number of days has elapsed but also depend on how often renewables charge the battery The battery must be at this voltage for the boost time value set below Bst Time hr 3 0 gt 1 0 e 12 50 Refer Boost V description above Ee Amp i gt 10 lt 35 This is the maximum battery current supplied while the inverter is charging the battery The value should be set to hold the charge current within the battery manufacturers ratings Lower values can be used to prevent the inverter shutting down on over temperature during periods of sustained charging and at high temperatures In a three phase system this figure applies to the master phase and the total current charge current is three times this value Boost Amp 20 gt 5 lt 30 This is the maximum battery current supplied while the inverter is boosting or equalising the battery The value should be set to keep the boost current within the battery manufacturers recommendations particularly if the battery bank is small In a three phase system this figure applies to the master phase and the total current charge current is three times this value BstFrq Day 14 gt Ss 63 BstFrqDay allows the number of days between automatic boost cycles to be adjusted It should be adjusted along with charge voltage charge time and boost time to balance generator running time and battery performance Too frequent boosting will
29. alia dala 5 Electrical Safety sitiar ii 5 Installation nen alga sile iaia ein 6 Mans o E EE T T E E E meter nti rc EE ter rrr E 6 Control Wiring EE 6 Battery ll EE 6 gun EE 8 NENA TE 9 SCION E EE 10 Electrical Gonnections ciririiei iden 11 Comms PCB Connections s vxssrrrseerie eee ie iii iii 12 Typical FUNCION sirio nina tail elia era 12 CUTOUTS ce sazia dl anita 12 INPulsasazion A EEN 12 ee We le EE EE 12 lee EE E LEE 12 Normal Operat ON iii te riara iii iena el ian pallio EES 13 Inyerer Sel ST SSL are aida aa RR 13 Starting and Stopping the Generator Manually cnn 13 Automatic Generator Control 13 Generator Start and Stop i 14 Generator Stalin TEE E 14 G nerato Stop EE 14 Generator Won t Start crono nn nn rra nn nn nnnnnn nn nr naar rn nrnnnrnnrnnnnss 14 Generator Start Sequence nar c cnn cnn 14 SYNMCArONISAHON WEE 14 EE EEN tere EEN 15 Two Stage CharginQ iii 15 BoostGhargersa ia stra doni a rina lie i ina eo 15 Generator Charge Terminated by High Renewable Input 15 Operating Without the Generator conoci 15 Ee 15 Troubleshooting ccceeeeeceeeeeeeeeeeeeeee ee eeneeeseseeeeeseseeeeeseseneeeseseseeeeseseeeeeseseneeeseseeneeeeseenenes 16 DC Circuit Breaker Trip 16 lernen EE 16 e Eege ul EEN 16 LED Indications detail A eee 16 All Flashing asunsa ack ea RL ae 16 AMOO AMO AAA
30. ameters are 8 bit no parity 1 stop bit Dial the phone number of the modem at the inverter When the modem answers type H cr where cr represents the return key on the keyboard until the inverter returns with the help menu and a gt prompt is displayed Copyright power solutions australia 1997 Doc No 250U18 Rev 1 27 5 97 33 Retrieving Logged Data File name convention Use the menu or command keys to set the program to capture a text file The file name convention is CCCnn RTV where CCC represents a three character code for the site name and nn represents a two number retrieval number or code The extension RTV representing ReTrieVed data is used by the data conversion program to simplify file retrieval and processing Get All data Type GA cr Get All to initiate transfer off all data records available If the system has been operating for a sufficient time nine records will be transferred This will include the eight most recent complete days and the current day which will be incomplete with zero values in unused records Nine records take up some 63k bytes of disk space and take about 5 minutes to be received at 2400 Baud Get Day data Type GDddd cr Get Day to initiate transfer off a single day of data ddd is the day number in the year Jan 1 1 Dec 31 365 366 in a leap year The current day can always be obtained by typing the TD command described below When transfer is complete the gt prompt will reappear Use the com
31. an cause the generator to start and stop more frequently A low value can be used to keep the generator running provided the load is high and only revert to inverter o only operation when the load is low It should not be set to too low a value or the generator will run for extended time at low load and low fuel efficiency The generator power must be below this value and below the minimum charge power set below before the generator is shut down MinChrgPwr 4 gt 2 lt 9 If the battery charge current is above this value set as a percentage of the nominal energy storage capacity of the battery the generator will be kept running For example if a system had a 400Ah battery at 120V the nominal storage capacity is 48kWh 4 of this is 1 92kWh so the generator would be kept running until the charge power had fallen below 1 92 kW It is used to ensure that the battery has reached a good state of charge before the generator is shut down The charge time can also be used to ensure that the battery has reached a good state of charge NomAc Volt 240 gt 210 lt 260 This is the nominal ac output voltage Changing this value adjusts the output voltage The potentiometer RV4 should be used to adjust the actual output voltage to correspond to this value This ensures that the actual value corresponds to the indicated value and that the generator voltage is correctly displayed RevPwr kW 1 00 gt 10 00 si RevPwr kW is the reverse power which
32. ate new graphs with different or additional data using the standard Excel facilities Copyright power solutions australia 1997 Doc No 250U18 Rev 1 27 5 97 35 Troubleshooting Logged Data During normal operation the conversion program records that it has loaded the site parameters Then after each day s block of data has been processed it records the number of valid lines of binary data processed and the number of lines rejected as bad Each day s block of data includes 106 lines of data so the count should proceed in steps of 106 up to 954 if 9 days data is being processed It is normal for there to be one or more non binary lines at the beginning and end of the retrieved file but the bad line count should not increment while processing the main body of the file If it does or if the good line count does not increment in steps of 106 then the retrieved data is corrupt and should be re retrieved If either the retrieved data file or the site parameter file are not present then the name of the missing file will be announced and the output file will not be generated Possible causes are The conversion program site parameter file and retrieved data file are not in the same common directory The site parameter file has not been created or does not have the same site code at the retrieved data The number of the retrieval to be processed is not available or has been retrieved into another directory If the program terminates displaying an error messag
33. ates that battery is being charged if the load is temporarily higher than the generator can provide and the inverter is supplying power from the batteries as well as the generator this light will go out and come back on while the generator is running If the batteries have been fully charged but the system load is high the generator will remain running and the batteries will be float charged During float charge this indicator will be dark Boost Charge Indicates that the batteries are having their weekly boost equalise charge Boost charging ensures that individual cells in the battery bank do not gradually discharge The generator will be held running for two hours after normal charging is complete to do this charge so if the generator seems to be running for a long time check if this indicator is flashing A long push approx 2 seconds of the Enter push button will start or terminate a boost equalise cycle Low DC Volts If this indicator is on after the inverter has been delivering power without the generator for some hours it may be sufficient to remove all load from the inverter to allow the battery voltage to recover Once this has occurred and the generator problem perhaps no fuel has been fixed the inverter will restart and the generator will also be started If the system has been unattended and the generator has been inoperable for days it may help to turn the inverter off for some hours to allow recovery and then back on after fixi
34. atteries to store energy for periods when power demand is low and automatically starts a diesel generator set when demand is high or when the batteries require recharging This mode of operation ensures that diesel fuel is efficiently converted to electricity by only running the generator at medium to heavy loads and only for a small proportion of the day Power is drawn from the batteries and converted to a mains quality sine wave by a micro processor controlled inverter The generator is automatically started and stopped by the inverter While the generator is operating it supplies power to the load and the inverter recharges the batteries However if heavy loads occur both the inverter and the generator can supply the load giving a peak capacity equal to the sum of the inverter and generator ratings This allows smaller generators to be used compared with inverter charger systems Data logging operates continuously in the inverter to record power voltage and current variables Most variables are averaged over 15 minute periods but minimum and maximum values of selected variables during each 15 minute period are also recorded Data covering up to 8 days of testing is stored in non volatile memory in the inverter A single day of data or all stored data can be retrieved over a serial link The oldest day s data is automatically cleared and overwritten as each new day of logged data is added There is no need to clear logged data from the inverter An IBM com
35. bit integers stored in two bytes In the commands listed below variables such as address or data can be input as hexadecimal if not preceded by a sign eg 10B0 or as a decimal value if the number is preceded by a or sign eg 4272 A hexadecimal value of FFFF can be input as 1 More details of hexadecimal and decimal variables are given below in the section describing parameter modification Monitor Commands The commands available include SI XXXXXXXXXXXXXXXXXXXXXXXXXX An alpha numeric string of up to 48 ASCII Characters can be stored in non volatile memory to identify the site or the equipment when retrieving logged data The string is stored in non volatile memory in the real time clock chip It is not necessary to have battery backed RAM to store the data SV Displays the software version number and the identity string if present STG Start the generator provided it is under auto control SPG Stop the generator provided it is under auto control STB Initiate a boost cycle when the battery is next charged SPB Terminate a boost cycle either before it has been started or after it has started and set the days to the next boost to the days between boost as entered on the LCD IB adr adr adr adr up to 10 addresses Display contents of internal memory in byte format address range 0 to FF or 0 to 255 dec Up to 10 addresses can be requested they will be displayed in hexadecimal and their contents continuously updated until another
36. charging is completed The default initial charge value is 2 3V per cell which is suitable for most types of batteries The charge current applies during the initial charge phase which continues until the battery voltage reaches the initial charge voltage and the charge current including renewable input if measured falls below the value set for boost charging The maximum charge voltage is then raised to the charge voltage selected for that battery type and the maximum charge current is reduced to the boost charge value Boost Charge Once per week the battery will automatically be given an boost charge It will be held at a higher charge voltage for approximately three hours This allows any cells in the series battery bank which may be partly discharged to be restored to full charge During boost charging the generator will be held on irrespective of load and the charge indicator will flash Generator Charge Terminated by High Renewable Input If battery charging is in progress and the generator charge power becomes negative when averaged over 2 minutes due to renewable input the charge cycle is terminated If battery boost or equalisation is in progress and the generator charge power becomes negative when averaged over 2 minutes due to renewable input the boost cycle is terminated and rescheduled for the next day These conditions occur when the renewable input and any load exceed the charge power which can be accepted by the battery Th
37. d shuts down when the run signal is removed The inverter generator controller sequence involves e Energising the fuel solenoid output e Energising the Glow plugs by closing energising the PREHEAT input for 20 seconds before cranking e Cranking the engine for up to 3 seconds by energising the START input while monitoring for the presence of AC output volts During cranking the PREHEAT output is de energised If AC output voltage from the alternator is sensed during the crank cycle it is terminated immediately e Once the three seconds of cranking is complete the sequencer pauses for 15 seconds while monitoring for the presence of AC output from the alternator during this period the glow plugs are energised again If AC is detected the delay is terminated the glow plugs de energised and no further cranking will be attempted If no AC is detected another crank cycle will be initiated after 15 seconds e After the third attempt at cranking the generator still has not started no further attempts will be made and the fuel solenoid is de energised e When the inverter wishes to stop the generator it de energises the fuel solenoid output If the generator sequencer does not see the generator has started it will issue a stop command stopping the generator and lock out further start attempts Connections to the generator control system are shown in the block diagram in this manual Synchronisation When the generator starts or is started manua
38. e copy down the details and send a copy of the retrieved data file the site parameter file and the version number of the conversion program to Power Solutions Australia for analysis Check if the program operates correctly with a different retrieved data file or a different parameter file If the retrieved data appears to be the cause of the error re retrieve the data if possible and try re analysing the data Manipulating Logged Data The eight plus day records generated in the Detailed Log files are of a convenient length to graph to explore daily patterns Once imported into a spreadsheet and saved as a spreadsheet file the corresponding TXT file can be deleted One convenient method of graphing is to have pre defined graph formats available and to link these to each succeeding Logged Data File to display and print the new data The 24 Hour summary files are intended to provide a means of long term monitoring of key variables The last record in any retrieval will generally be incomplete but provided data is retrieved every eight days a complete version of this day will be available from the next retrieval It is therefore possible to copy the new data into a previous spreadsheet overwriting any duplicated or incomplete days with complete data from the new files If data is retrieved less frequently than every eight days then the summary data will have gaps but the totalisators will continue to record the total values until the system is reset by
39. e excess power is then exported by the inverter to the generator sometimes causing repeated disconnection and reconnection in the final stage of charging or boost charging because generator reverse power is detected Operating Without the Generator If the generator is not available the inverter can be turned off using the On Off switch when power is not required If available energy can recharge the battery Turning the inverter off reduces the load on the battery and allows the batteries to be recharged even if the input from the renewables is small If the battery becomes heavily discharged the Low DC indicator will come on and the inverter will shut down Turning the On Off switch off then back to on will reset the Low DC indicator and allow the inverter to be restarted for a short time at the expense of discharging the battery more deeply If the inverter shuts down on Low DC and the battery is partly recharged from renewable inputs the inverter will automatically restart It will also automatically restart if the generator is restarted Note All references to generator control switches refer to the switches normally provided on the generator manufacturers control box which is normally supplied as part of the electric start system for the generator Copyright power solutions australia 1997 Doc No 251U13 Rev 1 27 5 97 15 Troubleshooting Normally your inverter will operate automatically to stop and start the generator and maintain bat
40. e generator to ensure the generator is not overloaded In a system supplied from the grid it is the maximum power which will be drawn from the grid MinStrtDis 5 gt 4 lt 80 This is the minimum depth of discharge which will start the generator at the preferred charge hour GenStrtDis 20 gt dere 80 This is the depth of discharge which normally starts the generator except during the lockout time It is expressed as a percentage of the battery size For example a battery of 200Ah would be discharged by 66 ampere hour if the GenStrtDis was set to 33 NiteStrtDis 30 gt 4 lt 80 This is the depth of discharge expressed as a percentage of the battery capacity which will start the generator during the lockout time Normally it is set to a higher value than the standard depth of discharge to help keep the generator off during the lockout time However if it doesn t matter when the generator runs or if the system design is such that the generator has to run at night it should be set to the same value as the standard discharge GenStartV 117 0 gt 111 6 sii GenStart V is the battery voltage averaged over 15 seconds which will start the generator independent of the state of battery charge GenHoldOn 32 gt 20 lt A If the two minute average power level power produced by the generator is above this value which is set as a percentage of the generator maximum rating the generator will be kept running A high value c
41. e inverter tests its circuits If indicators remain on permanently or come on is some random pattern and stay on then the internal microprocessor is not starting correctly Contact your supplier to seek further advice If indicators don t come on at all after the circuit breaker is turned on after being off for several seconds then the battery may be completely discharged or the inverter has an internal power supply fault Check the battery voltage if it is less than 70 of normal it will have to be recharged If the battery voltage is normal contact your supplier to seek further advice Normal Indicates power on and inverter hardware and software functioning normally and that the indicators below have the functions listed marked on the panel Fault Indicates an internal inverter hardware or software fault In this situation other indicators are steady and display a code identifying the type of fault If a fault is not serious the inverter will start after 10 seconds of Copyright power solutions australia 1997 Doc No 250U15 Rev 1 27 5 97 16 displaying the fault code However if a serious fault is present the inverter will not start and you should contact your supplier after recording which indicators are on 02468ACE QOD OOOO O lt Flashing Second 06060600 off O Digit tf QOWBOCOSS Code OOOO OO 2 iat 9000 Dr 5000 Code QQQO 4 OOOO Value On Load Indicates that inverter is running and AC output is available
42. e is no response check the RS232 cable It may not have the wires connecting pins 2 amp 3 transposed The inverter also outputs a serial message on startup To further test your connection turn the on off switch off and back on The message should be displayed without any input being required from the terminal Connecting via a Modem The modem at the inverter end must be set up according to auto answer to default to 2400 Baud and to operate without returning result codes This is described in Modem Setup Procedure below The modem should be connected to the inverter using standard modem cable identical to that used to connect a modem to a computer No null modem adaptor gender changers or special cables are required The connection of the modem to the telephone line should include an approved surge diverter connected to the inverter and modem local ground Power Solutions Australia can provide as an option a modem serial cable and surge diverter already pre configured to auto answer and work with the inverter into a standard telephone line A matching modem for use at the central monitoring point can also be provided Power Solutions Australia can advise on the suitability of different modem types The PC should use a standard terminal program such as Telix if operating under DOS or the Terminal Accessory can be used under Windows The program should have the capacity to capture as text file ASCII data received from the inverter Communications par
43. eld in two byte word format Up to 10 addresses can be requested They will be displayed and their contents continuously updated until another key is pressed adr1 adr2 Dump the contents of internal memory from adr1 to adr2 to the serial port This is useful to get a picture of what is happening By capturing this to file a compete picture of the state of the inverter can be captured for later analysis A adr1 adr2 Dump the contents of external memory from adr1 to adr2 to the serial port This is useful to get a picture of what is happening By capturing this to file a compete picture of the state of the inverter can be captured for later analysis TD Display internal time of day in format YY DDD HH MM SS The value DDD is the day of the year with January 1 being day 1 All values displayed are in decimal format in all versions of the monitor TU yy mm dd hh mm Update internal time in the form year month day of month hour and minute All values are input in decimal format and do not require a preceding sign For example TD 95 11 20 19 25 sets the date to 20 November 1995 and the time to 7 25 PM and 00 second To synchronise to seconds wait until the change to the new minute before hitting the enter or return key on your keyboard QUI This command shuts down the inverter and takes it back to a standalone monitor program A prompt is displayed by this monitor Provided the watchdog timer has been inhibited by inserting the Watchdog Inhibit Lin
44. enerator size edit page Charge V 144 0 esse V in Chrge V is the normal battery charge voltage before application of any battery temperature compensation Boost V is the battery equalisation or boost voltage The battery will be held at this voltage for a period of at least four hours and until the charge current has fallen to below 10 of the battery capacity Float V 139 8 i battery Float V is the battery float voltage The battery will be held at this voltage after charging or after an equalise charge is completed if the generator continues running for example because of sustained load on the system The message below indicates that the set of battery charge voltages which have been power solutions austra lia Doc No 300U15 Rev 3 1 10 97 21 selected are those applicable to sealed or gel type batteries The other set of voltages which can be selected are those applying to flooded batteries which are generally higher but can also be adjusted using the relevant edit pages GenStartV 117 0 Set See GenStart V is the battery voltage averaged over 15 seconds which will start the generator independent of the state of battery charge ShutDwnV is the battery voltage averaged over 15 seconds which will shut the inverter down to avoid over discharge of the battery After such a shutdown the battery voltage must recover to above the nominal battery voltage by renewables charging the battery or there must be AC power present from the generator a
45. es of power such as solar or wind the batteries will be discharged and the inverter will shut down Check that the generator is operational Check that the generator circuit breaker is closed Start the generator manually You can restart the generator by putting it to MANUAL on the generator switch and returning it to AUTO to allow the inverter to take control again it will most likely start immediately if the batteries are discharged You can also manually start the generator using the controls at the generator The inverter should synchronise and start to charge the batteries If the Sync indicator is flashing and does not go to steady within two minutes the generator voltage or frequency is out of tolerance Check with your supplier Generator Stop Indicates that the generator stopped unexpectedly while under control by the inverter The most likely cause is that it ran out of fuel Check the fuel situation and that the generator circuit breaker is closed that the generator runs smoothly when started manually and that the sync indicator comes on steady within 60 seconds of starting the generator and remains on steady as the inverter loads up the generator Restore the system to automatic control by turning the generator switch back to AUTO A low fuel alarm and a separate low fuel shutdown can be fitted to the inverter The low fuel alarm records an event in the inverter data logging system and is wired to an external alarm light The low fuel shutd
46. first password gives access to the help menu and the ability to display and set the time of day Both passwords are required to access facilities to display and manipulate internal data and to change parameters Password entry is by typing p cccc to enter the low priority password and p CCCC to enter the high priority password The low priority password must be entered before the high priority password The strings cccc and CCCC are fixed for all systems and are supplied to customers with their systems Connecting via a PC A PC can be connected direct to the inverter using a serial null modem cable The inverter has a 25 way male DB25 connector implemented as a DTE similar to the male connectors used for serial connectors on PCs Any cable which allows serial communications between PCs should work Power solutions australia can provide a standard cable suitable for direct connection of the inverter to a PC The PC should use a standard terminal program such as Telix if operating under DOS or the Terminal accessory can be used under Windows The program should have the capacity to capture as a text file ASCII data received from the inverter Communications parameters are 2400 Baud 8 bit no parity 1 stop bit Use XON XOFF flow control not RTS CTS hardware control Start the program and in terminal mode type H cr where cr represents the return key on the keyboard until the inverter returns with the help menu and a gt prompt is displayed If ther
47. ge indicated on the dc voltmeter will begin to rise When it reaches about 80Vdc the indicator Close DC CB will be illuminated e Close the dc circuit breaker The Start switch will be illuminated the inverter will start its self test All indicator lights will flash e When self test is completed the top two indicator lights will be on and steady indicating the inverter is operating e Put the generator control to auto the Gen OK indicator should be on and steady e Note When the system is started and if there is no load at the load terminals the inverter may not connect to the load The SYNCH light will be flashing Connect a small load and normal operation will resume If the inverter is operating normally but the SYNCH light is flashing this indicates that the generator is not connected Check that the generator circuit breakers on the inverter and any external generator circuit breaker or overload circuits are closed and reset e Starting amp Stopping the Inverter e The inverter may be started and stopped by pressing the Start and Stop switches Shutting the System Down for Extended Periods Switch the generator control to off to stop if it is running and to stop it starting Turn off the AC circuit breakers Turn the inverter off by pressing the Stop switch The Stop switch will be illuminated Open the DC circuit breaker by pushing the switch down All indicators will go off If all power must be removed isolate all renewable input
48. hronise Generator out of limits Charging Boost Charging Low dc volts High dc volts Overload Over temperature Generator Failed to start Generator Stop Generator Fault Generator Connected Operation The inverter automatically starts and stops a generator in response to battery charge level or system load fully compatible with existing generator governors and voltage regulator systems Communications logging Facilities Electrically isolated RS232 interface for computer or modem connection Data Logging Logged data covering a period of eight days can be retrieved from the inverter via the communications link The following is logged every 15 minutes output power inverter VARS average AC voltage average DC current array voltage DC minimum voltage DC maximum voltage Heatsink maximum temperature Battery temperature Renewable input current Auxiliary input spare Average period Load Cumulative kWh Input Cumulative kWh generator renewables The following is logged every 24 hours cumulative ac kWh to load cumulative ac kWh from generator cumulative hours connected to the generator load ac kWh for day generator kWh for day hours connected to generator for day Event Register An event register logs for later retrieval changes in inverter operating status and fault conditions Data Integrity All data is stored in non volatile memory and can be retrieved directly v
49. ia RS232 port or modem Data format includes error detection Remote Parameterisation The units can be parameterised via the modem Approximately 60 internal and external system parameters can be adjusted via the modem Local Parameterisation Parameters can be adjusted via the LCD Display Input amp Output Isolation A DC circuit breaker at the input for isolation and protection An AC circuit breaker at the output for isolation and protection Controls Start Stop push buttons start and stop inverter Push buttons on LCD display allow selection of variables displayed and adjustment of parameters Alarm Output Voltage free contact closes on inverter fault abnormal condition Copyright power solutions australia 1997 Doc No 250U19 Rev 1 27 5 97 40 Liquid Crystal Alpha Numeric Display Display including the following dc voltage dc current Generator Voltage Inverter Voltage Generator Frequency Inverter Frequency Inverter kW Inverter VARS Average kWh for day Battery temperature Heat sink Temperature Analog Meters Analog meters included e Array Voltage e AC Current RFI Suppression Filters on ac output and dc input Mechanical Wall mounting enclosure dimensions Width 550mm Depth 510mm Height 1130mm Weight 260kg Termination Stud M8 DIN terminal through gland plate undrilled in bottom of enclosure Maximum wire size AC Output 16mm Control 1mm Environmental F
50. iently supplied direct from the generator When sustained loads are present which can be efficiently supplied by the generator the generator will be started It will only stop when the load has dropped and the batteries have been recharged Around 6 PM the generator will start to make sure the batteries are fully charged for overnight provided they are at least partly discharged After 11 PM the generator will shut down unless there is a heavy load on the system It will only start if the batteries are seriously discharged or if heavy or sustained high loads are present This ensures that under most conditions the generator will not be running or start in the early hours of the morning At 8AM the generator will probably start to replace the charge used overnight if it exceeds the normal 25 discharge level If solar or wind energy is sufficient to hold the battery charged in the presence of load the generator will not start however as soon as the battery state of charge falls the generator will start to restore charge to full conditions before shutting down In this situation it will only run for a short time infrequently Copyright power solutions australia 1997 Doc No 251U13 Rev 1 27 5 97 14 Generator Start and Stop The inverter will automatically start and stop the generator providing e The generator control switch is in the Auto position e The generator starting battery is charged e The generator has fuel oil and water Generat
51. increase generator running time but can be offset by having short charge times and high minimum charge power parameters to reduce the level of recharge during normal charge cycles PrefGen hr 20 gt Ba e 30 PrefGen hr is the hour at which the the generator will start if the minimum discharge level of the battery is exceeded It is normally set to 17 ie 50m when solar charging should be complete and helps ensure that generator A value of zero results in no preferred generator running time Values from 1 to 24 correspond to 1am to midnight Both values can be set in the edit pages LockGen hr 20 gt Sy lt 30 LockGen hr is the time at and after which the generator is inhibited from starting on standard discharge It will still start on low battery voltage and if the maximum discharge is exceeded A value of zero makes lockout immediately ineffective Values from 1 to 24 correspond to 1am to midnight UnlockG hr 20 gt Ban is 30 UnlockG hr is the time at which normal generator starting conditions are is restored A value of zero makes lockout immediately ineffective Values from 1 to 24 correspond to 1am to midnight Time hr 20 gt 0 lt 23 This allows the time of day hours to be set if the system is being used without data logging With data logging the complete year month day hour and minute can be set using the TU command over the serial port Time min 20 gt 0 lt 59 This allows the time of day minutes to be
52. is allowed to flow into the generator before disconnection takes place assuming that the generator has run out of fuel or the generator has been turned off manually and the inverter must disconnect to prevent it being driven as a motor Copyright power solutions australia 1997 Doc No 251U16 Rev 1 27 5 97 27 Hi Lim Hz 55 02 lt 65 00 zi This is the maximum frequency at which the inverter will synchronise to the generator or stay synchronised to the generator Values above 55Hz are not recommended as they may cause overloading and overheating of compressor loads such as refrigerators and air conditioners If the generator frequency is excessively high it should be adjusted if possible Lo Lim Hz 45 00 lt 49 90 Ber This is the minimum frequency at which the inverter will synchronise or stay synchronised to the generator Values below 45 Hz are not recommended as they may cause saturation and overheating in motors such as refrigerators ShutDisch 60 gt 0 lt LI This is the battery depth of discharge at which the inverter will shut down to prevent over discharge of the battery If renewables are providing charge current to the battery and there is no renewable shunt a value of zero should be used to disable shutdown on depth of discharge Shutdown will then only be based on battery voltage In systems without renewables and where a renewable shunt is fitted a typical value would be 60 of battery capacity ShutDwnV 111 0 gt
53. k for example from solar panels then the generator power value will be negative when power is being exported and positive when power is being drawn from the power network Inv Hz 50 02 Gen Hz 50 01 Inv Hz is the inverter operating frequency and Gen Hz the generator operating frequency The generator frequency will differ from the inverter frequency when it initially starts and before it synchronises When synchronised and operating with the generator the two frequencies will be very similar If the generator frequency is zero then the generator is not operating or the voltage is out of tolerance If the generator frequency is out of tolerance the inverter will not synchronise power solutions australia Doc No 300U15 Rev 3 1 10 97 20 Gen Volt 249 ES Hz SEH Gen Hz is the generator operating frequency and Gen Volt the generator output voltage When operating synchronised the generator voltage will be the same as the inverter voltage When the inverter is initially turned on or if the inverter output voltage has been adjusted to other than the nominal value using RV4 on the power pcb rather than using the LCD to adjust output voltage the voltage indicated may be in error several volts When the generator is off a small value may be indicated Inv kVAr 0 32 pe kVAr EE Inv KVAR is the inverter reactive power output a positive value indicates that the inverter is supplying VARs ie a lagging motor load results in a positive VAR value
54. k in the inverter has not been correctly set and incorrect dates are in the retrieved data The date should be entered in the format YY MM DD The date should be the known date of the first record in the retrieved data file This would normally be the date of retrieval minus 8 days if 9 data records were retrieved Normally it should not be necessary to select this option If the date is not being bypassed then the program will ask for the year number of the first data record At present the year value in the logged data record is zero and the year of the first data record in the retrieved data must be entered Entering a negative value will force the value from the year field in the logged data to be used and can be used with later releases of the inverter data logging software Created files Outputs of the conversion program include a Logged Data file CCCnn TXT containing 96 of 15 minute averages and peak values for each day The format is text values separated by tabs which is compatible with standard spreadsheet programs A second file CCCnnS TXT is a 24 hour summary containing totalisators of load energy source diesel energy and diesel running hours Also included are 24 hour load energy 24 hour diesel energy and 24 Hour diesel running hours All of these are derived from the 24 Hour totalisator record in the logged data Additional fields are calculated from the 15 minute data This file is also formatted ready for import into spreadsheet pr
55. k on the Power PCB the inverter will remain shutdown At the prompt the command G 0 will restart the inverter and the command G 10 will allow access to hardware test procedures to check the I O hardware including the output relays input status and the mode test switch Normally the Watchdog Inhibit link is removed and after half a second the inverter will automatically restart after a QUI command Modifying parameters via the Serial Port To modify parameters directly via a terminal attached to the serial port or via a modem requires knowledge of the location of the parameter in memory its scaling and the consequences of making the change to the value Scaling and location information changes with different types of inverter and software releases Power Solutions Australia can provide this information in the form of a partial memory map for particular systems if advised of the software version date the customer order number and date The significance of the variables is described Modification should only be undertaken by experienced staff and preferably over a communications link with an error correcting protocol operational It should never be undertaken if connected via a modem connection which is showing significant numbers of garbage characters Identify the parameter to be changed Use the partial memory map for the particular system to identify the location Compute the value which should be in that location It will be useful to know the
56. lia 1997 Doc No 250U15 Rev 1 27 5 97 19 LCD Display Below are listed the various LCD displays and their function There are two types of displays Standard displays are always available and display measured values or important parameters controlling the inverter operation Edit displays allow parameters to be adjusted and are only displayed when the edit enable switch is on This provides security against accidental changes to system operating parameters The values shown are typical of a 5kW 120V system Different display pages are accessed by moving forward using the Up push button or moving backward using the Down push button When standard displays are on the LCD the Enter push button can be used to start or stop the generator with a short push A long push approx 2 seconds starts or terminates a boost equalise cycle If the generator is running a short push will stop the generator If a boost has been initiated automatically or manually or is in progress it can be cancelled using a long push If edit displays are on the LCD the Enter push button initiates data entry mode and makes the modified data permanent Standard Display Pages Power Solut GIM EE E This display appears while the inverter is running its self test functions If it remains on the self test has failed the top green LED will be flashing and the remaining LEDs indicate a code which identifies the test which failed Power Solutions GIM Inverter This display a
57. lled by the inverter Confirm that inverter passes self test and starts up If a fault is indicated use diagnostic code to decide if further checking is worthwhile or the fault requires further diagnosis Confirm that generator can be started and runs smoothly with customer load directly applied without inverter operating i e no fuel blockages and that voltage and frequency are correct Confirm that generator can be started and stopped using the remote generator start stop push button If not check wiring and interface signals Check voltage of inverter both standalone and when operating in parallel with generator If outside normal tolerance check generator output voltage under various loads If inverter fails to synchronise and run in parallel check the frequency and voltage of the generator output that the generator voltage is present on the synchronising input and on the generator contactor Check the phase rotation of the inverter and generator in three phase systems If the generator synchronises then becomes unstable or disconnects there may be a problem with the governor the fuel supply or the actual power output capability of the generator LED Indications All Flashing This special test pattern is displayed while the inverter is testing its circuits after starting up All On or All Off All indicators are on briefly as the inverter is switched on Immediately after this they go into an upwards moving all flashing pattern while th
58. llowing the inverter to synchronise and start to charge the battery Std Dis Ah 79 SR Dis Ah cai Std Dis Ah is the discharge ampere hour which will normally cause the generator to start and recharge the battery Shut Dis Ah is the battery depth of discharge which will cause the inverter to shut down to prevent the battery being over discharged A depth of discharge of zero prevents shutdown on ampere hour and the inverter shuts down purely on battery voltage Min Dis Ah 26 A Dis Ah ci Min Dis Ah is the minimum discharge in ampere hour which allows the generator to start at the preferred charge hour refer below Nite Dis Ah is the depth of discharge allowed before the generator is started to charge the battery when the generator is locked out see below GenShut kW 1 96 o kW SS These are the power levels on the generator and for the battery charge power above which the generator will be kept operating Charge Shut kW is calculated from minimum charge power setting and battery size as described in the Edit display section below In Charg V 238 0 pee hr so In Charg V is the initial maximum charge voltage used while the current is limited to the charge current Once the charge current falls below the boost current setting the voltage is raised to the charge voltage and the current is reduced to the boost current PrefGen hr is the hour at which the the generator will start if the minimum discharge level of the battery is exceeded It is normall
59. lly or a mains supply is connected to the generator input terminals the inverter will synchronise that the AC voltage and close the generator contactor It will not synchronise if the AC voltage is out of tolerance in magnitude or frequency Once synchronised the generator will be used to charge the batteries and to meet the load on the system If the load on the system is greater than the generator capacity the inverter will abandon charging and Copyright power solutions australia 1997 Doc No 251U13 Rev 1 27 5 97 add its output to the generator drawing power from the batteries Once the load falls below the generator rating it will resume charging the batteries Battery Charging Battery charging is done in constant current constant voltage mode Once the float voltage is reached the battery will be held at that voltage As the current drawn by the battery falls the load on the generator decreases and when generator load falls below half the generator rating the generator will be shut down Hence if there is a significant load on the system the generator may continue to operate until that load is removed Two Stage Charging The first stage of charging is at a lower voltage and higher current than the final charge voltage This allows high rates of charge on smaller batteries A single initial charge voltage is now available on the LCD display The flooded and gel battery charge voltages are the final values which are used after initial
60. lt your supplier or an electrician Transient over current conditions which may occur due to the application of heavy loads may occasionally cause shut downs lasting less than second The inverter will restart almost immediately If the generator was already running before the inverter shut down the load was definitely too large Over Temperature Over temperature of the transformer or the power FETs will cause the inverter to shut down and the overload or over temperature indicators to be illuminated Once the system cools down the inverter will restart It has probably been running with sustained high loads for an extended time If the generator was not running check the generator indications below It may be that the generator failed to start to meet a load which normally the inverter and generator would share Check that the inverter is adequately ventilated and that hot air from the generator is not overheating the inverter Generator OK Indicates that the generator is available and connected for automatic startup If it is under manual control at the generator control switch this indicator is dark Failed to Start Indicates that following a request to start the generator the inverter detects that it is not running within 45 seconds or that it is out of voltage or frequency tolerance so the inverter was unable to synchronise This means that the batteries are being discharged and unless the situation is corrected or there are other sourc
61. mand or menu keys to terminate capture of the file It is recommended that the data be converted immediately to confirm that there has been no corruption If the data appears corrupted or shows corruption after processing repeat the retrieval using the GA command There is no need to reset the data memory the oldest day s data is automatically cleared when a new day starts Hence if retrieval is not done regularly every seven or eight days there will be gaps in the data but it will always be possible to retrieve full records for the last eight days Date Time display It is always worth checking the time of day when data is retrieved Type TD cr the inverter will respond with yy ddd hh mm ss where yy is the year ddd the day number of year hh the hour of day in 24 hour format and mm and ss the hours and minutes respectively Time Update To change the time enter TU yy mm dd hh mm cr All values are input in decimal format and do not require a preceding sign For example TD 97 06 20 19 25 sets the date to 20 June 1997 and the time to 7 25 PM and 00 second There is no second setting facility wait till zero seconds before hitting the return key The date is set as year month and day the inverter converts this to a day number for internal use and for recording in the logged data records The time should be set to standard not daylight saving time If the time is advanced past a 15 minute time xx00 xx15 xx30 or xx45 hours there will be a gap in the logged
62. nction stores two copies of the parameter values in an EEPROM Whenever the inverter starts operation it attempts to load the values from EEPROM if either copy is valid it will load the values from EEPROM and display the message Params Loaded OK If the default values are still in effect or if both copies of the parameters in EEPROM are invalid the message Default Params will be displayed and the default values will be loaded from ROM There are separate sets of values for 50Hz and 60Hz operation and for Sealed Gel Batteries and for Flooded batteries These alternate values are only effective and can only be changed if the mode switch is set for the corresponding mode of operation using the mode switch on the Comms PCB For example to edit the 60Hz frequency limits the inverter must be set for 60Hz operation Editing a Value Values may only be edited when an edit page is selected This is done by setting the mode switch 7 to on and then using the Up and Down push buttons to select the desired display An edit page has only one variable displayed and shows upper and lower limits for that variable on the bottom line To edit a value push the Enter push button for a short time an arrow symbol will appear on the display Use the Up and Down push buttons to step the value to the desired setting Press the Enter push button for a short time while the arrow symbol is displayed to make the value permanent The message Param updated will appear
63. nd WX 505 505 17 to load the most significant byte The two address for the WX command allow multiple bytes to be filled with the same value so the above Copyright power solutions australia 1997 Doc No 250U17 Rev 1 27 5 97 31 command fills location 504 to location 504 with the same value After each command a response confirming the addresses loaded and the values loaded will be displayed In many cases it is sufficient to modify just the most significant byte of the value Once the new value has been input confirm that the correct value is loaded in the correct location using the XW or XD command Once confirmed the new values should be loaded to EEPROM using the command EU Eeprom Update This will prevent the original values being overwritten when the system is restarted or when the parameter values are checked every hour Because checking takes place on the hour avoid making changes in the few minutes before the hour change Standard scalings The following scaling values have been applied to all inverters DC voltage 24V systems 1mV per bit 24 000V 24000 dec or 5DCO hex 48V systems 2mV per bit 48 000V 24000 dec or 5DCO hex 96 to 120V 5mV per bit 120 00V 24000 dec or 5DCO hex DC current All systems 0 05A per bit 10 0A 200 dec or C8 hex Battery Ah All systems 0 1 Ah per bit 100Ahr 1000 dec or 3E8 hex AC voltage All systems 0 25V per bit 240Vac 960 dec or 3C0 hex AC Power Varies depending on size of s
64. ng the generator problem Copyright power solutions australia 1997 Doc No 250U15 Rev 1 27 5 97 17 Check that the generator is operational that the Gen OK light is on and follow the procedure described under Generator Stops High DC Volts A DC overvoltage will shut the inverter down and is indicated by the high DC volts indicator on the front panel The inverter will restart when the voltage falls to within tolerance Gross over voltages in excess of 160 of nominal will cause the DC circuit breaker to trip to prevent damage to the inverter This could be caused by a faulty battery bank or other sources of power such as wind or solar power charging the batteries to excessive voltages Get your supplier to check the voltage set on the voltage regulators for any charging equipment attached to the batteries Overload Sustained overloads in excess of 10 seconds at more than 200 load or short circuits will cause the inverter to shut down It will restart after a delay of up to 60 seconds This is indicated by the overload indicator being on and the second yellow indicator flashing Turn off any heavy loads If heavy loads are to be placed on the system start the generator first using the remote start stop switch if available The generator can also be started manually If the overload persists after the heavy loads are removed open the load circuit breaker If the inverter then works correctly there may be a short in the house wiring consu
65. nning the generator provided the charge controller is coordinated with the inverter The appropriateness of the boost charge settings can also be assessed from the Specific Gravity measurements of the battery electrolyte after boost charge completes If the SG values are too low consider increasing the boost voltage or boost time Initial Charge Voltage Charge Voltage Charge Current and Boost Current The initial charge voltage is the first setting used when battery charging starts It is held at this value until the charge current falls below the boost current when the voltage is raised to the charge voltage and the charge current is limited to the boost current for the final charge This allows maximum charge rate on some batteries where the manufacturer allows higher charge current while battery voltage is low If there is no such limitation or the battery is very large compared to the inverter capacity the initial charge voltage may be set to the final charge voltage The Boost current should not be set to a low value or the final stage of charging may be extended Boost charging normally takes place at low currents anyway because the boost charge is not started until a normal charge has been competed and the charge current has fallen to a low value power solutions australia Doc No 300U15 Rev 3 1 10 97 23 Edit Display Pages These displays only appear when the mode switch 7 on the comms PCB is turned on Key parameters are displayed in
66. ograms To use these files with a spreadsheet it is necessary to import them as text files Check the file options of your spreadsheet program and set the mode to accept tab separated values Once in the spreadsheet data can be plotted and graphed The Event File CCCnn EVT is a text file containing a record of up to 32 events per day These events are of two types events type zero which record normal transitions from state to state and non zero events which record diagnostic and fault recovery information The file records the time of events with a brief description of the type of event together with the state of the inverter the generator controller and the scheduler Generating Spreadsheets and Graphs in EXCEL The text files CCCnn TXT and CCCnns TXT are suitable for directly importing into Excel to create spreadsheets and to generate graphs In File Open choose text and tab separated format On the disk supplied there is a sample Excel file which has a number of graphs included as workbook sheets Open the Sample file then Open the converted file Open File Type Text at the first dialogue box of the import wizard check that Original Data Type is Tab Delimited then click Finish Select All in your converted file Copy the data then move to the Sample file Select All and then Paste the data in and the graphs should all be updated with the new data You may need to alter the scale of some of the graphs to suit your data You may also cre
67. or o with remote run input ox Y 23 DE o A gt op E gt gt Vv gt Ee Battery Temp Sensor attached to battery Earth frame to earth stake and connect to inverter earth Individual load circuits Battery fuses optional If fitted rating to be four times maximum inverter current to protect against battery and wiring faults Wire renewables directly to battery Renewable fuse rating to suit to protect wiring from backfeed from battery Minimise battery inductance and lead length with good layout Keep positive and negative cables close to each other Renewables must have earth stake close by If renewables are remote from inverter add earth stake near inverter and connect to renewables earth cable Copyright power solutions australia 1997 Doc No 250U12 Rev 1 27 5 97 11 Comms PCB Connections Typical Function Depends on software configuration Outputs Alarm Contact closed or open when inverter off or in fault condition DO1 Fuel solenoid drive or run signal closed when generator required to run open to stop DO2 Crank closed when generator required to crank CN2 Available for other functions in basic run controller as DO3 Preheat relay drive closed for 15 seconds before rs generator is required to start Available for other functions in basic run controller Comms PCB 87654321 CN6 N 5 S Ze gt E So o ec CN4 Digital Inputs1 4 Serial Comms 87654321 8765
68. or Start The generator will be started for the following reasons e A sustained high load requires the load on the inverter to be reduced e A sustained medium load can be more efficiently supplied directly from the generator e The battery has been discharged to such a level that it requires recharging Generator Stop The generator will stop for the following reasons e The load on the system is low and the batteries have been recharged e The generator has run out of fuel e The control switch on the generator controller has been moved to the OFF position e The generator has shutdown on over temperature or low oil pressure Generator Won t Start The generator will not be started if e The battery voltage indicates that the renewable input is meeting the load and has kept the battery charged e The generator is not in automatic mode as indicated by the Gen OK indicator being illuminated e The generator has run out of fuel or failed to start e The LockGen hr parameter is set to prevent the generator from starting for some part of the 24 hour cycle This can largely eliminate running at times when noise may be a problem Generator Start Sequence The generator start sequence has been designed to work into a controller which accepts fuel crank and preheat input signals The inverter generator controller is compatible with an external controller which uses the fuel output as a run stop signal and internally performs multiple cranks an
69. own will stop the generator If the low fuel alarm is activated refill the fuel tank as soon as possible If the low fuel shutdown level is reached the generator will stop the Generator Stop indicator will be on steady and the Generator OK will flash Copyright power solutions australia 1997 Doc No 250U15 Rev 1 27 5 97 18 Refill the tank The Generator Stop indicator will be extinguished but the Generator OK will flash and the generator will not restart unless the generator controls are turned to manual or off and back to auto Manually starting the generator will also restore normal operation Generator Fault Indicates that the generator was stopped by the inverter because a generator fault switch operated This only applies to some models of generator and could be low oil pressure or over temperature Check your generator manual to determine recommended action When fixed restore the generator to automatic control by turning the generator to MANUAL position at the generator and back to AUTO All Generator Fault conditions will result in the inverter locking the generator out of operation Once locked out the inverter will periodically retry the generator and restore normal operation if it starts successfully To allow an immediate restart say after fuel supply is restored turn the generator control from auto to manual or off then back into auto The Gen OK indicator should then go steady and the generator will start if required If
70. patible PC program is provided which converts logged data from the inverter into spread sheet format and extracts event records which record the times at which tests start change mode and stop as well as other events associated with inverter operation An alpha numeric LCD display allows inverter variables to be displayed and allows suitably qualified technicians to adjust operating parameters to optimise system performance Copyright power solutions australia 1997 Doc No 250U4 Rev 1 27 65 97 PSA Product Warranty Your Power Solutions RAPS product is warranted by the manufacturer for a period of 24 months from date of purchase installation to the original end user purchaser only and a receipt will be requested at time of reported fault The manufacturer will bear the cost of parts and labour to repair any faults found within the terms and period of this warranty Faulty product or parts must be returned to Melbourne Australia for claim under warranty No allowance is made for installers labour or travelling time required to disconnect or reinstall faulty parts Cost of freight to return parts to the customer within Australia only will be paid by the manufacturer method of freight used will be determined by the manufacturer Unless otherwise specified to the purchaser the benefits conferred by this voluntary warranty are additional to all other conditions warranties guarantees rights and remedies expressed or implied by the Trade Practices
71. ppears after self test has completed and normal operation has started If a data editing display is selected and there are no key presses for 60 seconds the editing display is cancelled and this display returns dc Volt 123 16 dc Amp ni Battery dc voltage and inverter dc current A positive current value indicates the battery is being charged by the inverter a negative value indicates that the inverter is discharging the battery Inverter dc current does not include renewable charge current or dc load current Load kW 0 135 Ee Volt si Load kW is the total ac system load being supplied excluding power being supplied by the generator to charge the batteries Ac voltage is the nominal load voltage The voltage at the actual terminals may differ slightly from this value When operating with a generator values more than 7 different from nominal indicate that the generator voltage may need adjustment Load kW 0 15 li KWh Day Ke Load kW is the same as the previous display L kWh Day is the average energy supplied per day averaged over 7 days It compensates for the number of days the inverter has been operating so the value can be correct after only one day Gen kW 0 47 Inv kW 0 33 Generator power indicates the load on the generator including load being supplied directly and power being used to charge the batteries Generator power is normally positive If the inverter is connected to the mains and is being used to export power to the networ
72. r arcs which are difficult to extinguish Electrical Safety Do not open the inverter enclosure while the system is operating The system has multiple sources of power assume all terminals are live unless all power sources are isolated Copyright power solutions australia 1997 Doc No 250U7 Rev 1 27 65 97 Installation Mains Wiring External AC wiring is required to connect to the generator which should have its own circuit breaker and to the load The inverter alone can supply in excess of 70A into a short circuit and can therefore reliably trip circuit breakers up to 30A When operating with the generator fault levels will increase though the inverter will disconnect the generator within 100ms of the phase voltage falling below 200V RMS The combined output current of the inverter and the generator is in excess of 60A Conductor sizes and temperature ratings should be suitable for this current Control Wiring Control wiring is all low voltage and low current The current in any digital output circuit should be limited to a maximum of 1A If circuit loads are higher then an interposing relay should be fitted A battery temperature sensor is also supplied and should be connected It should be attached to the centre of one of the sides of one of the batteries Observe the polarity the voltage across the sensor should be about 4V if much lower reverse the sensor leads A renewable shunt is required if renewable dc inputs solar wind etc are
73. ration is as expected within 10 Apply the generator available signal by turning the generator controls to auto and confirm the Gen OK Led is illuminated Push the enter button on the LCD display to start the generator Confirm that it synchronises and starts to charge the batteries Check the generator output voltage If it is out of tolerance by more than 7 adjust it If the generator voltage cannot be changed adjust the inverter output voltage while the inverter is operating without the generator to within 7 of the generator voltage Copyright power solutions australia 1997 Doc No 440U14 Rev 1 27 65 97 e Allow the generator to run to allow charging to continue until float voltage is reached Confirm that the appropriate float voltage is held on the battery Push the enter button on the LCD display to shut down the generator Confirm that the generator shuts down without significant disturbance to the output voltage e Manually start the generator from its own control panel The inverter will synchronise and start to charge the battery again Turn the generator off from its own controls Verify that the inverter separates from the generator on reverse power without too large a disturbance If the generator is more than twice the inverter capacity it may be necessary to open the generator circuit breaker before shutting the generator down if the generator is to be regularly operated manually Normally the remote run push button should be
74. rcuit breaker and isolate wind or solar inputs before disconnecting the battery CAUTION When laying out the battery and working on the battery be aware that metal tools can short across battery terminals and generate high energy arcs which can cause serious burns and eject hot particles Where battery terminals at potential differences greater than 12V are close together place an insulating barrier between the terminals so tools cannot short between the terminals When batteries must be disconnected or connected ensure that the inverter is shut down and any other DC supplies to the batteries are isolated and there is negligible current being broken When renewable sources are connected to the inverter the battery negative terminal must be earthed to the frame to control induced lightning voltages Isolate the renewables and remove this link before working on the battery so that accidental connections between battery terminals and frame do not cause battery shorts When systems operate without renewable input the battery negative terminal is connected via a high value resistor to the inverter frame This ensures that the inverter electronics which are directly connected to the battery negative do not float at a high potential with respect to frame The renewable shunt must be connected in the negative terminal of the battery and must be permanently connected to the battery negative terminal If a dual pole isolator or circuit breaker is to be used on the
75. renewable input then it must be connected on the source side not the battery side of the shunt Copyright power solutions australia 1997 Doc No 250U7 Rev 1 27 65 97 Front View Internal View EB e PIS IE DC Input AC Input Output Copyright power solutions australia 1997 Doc No 440U9 Rev 1 27 5 97 10 Schematic PI PV200DC Aux de fuse Ri FS P4 Qta Fa RAZ5WIOR R2 RA25W10R R5 RAZSWIOR ave Fe fi L738 Fe RAZSWIOR RA2SWIOR de Circuit Breaker D uo Fe x CH CE4700U160 CPA7ON250 FFG Load PE temma j2 oi t mme Ci C7 C2 C3 CB C4 C5 C9 C6 i XDP16 sensi e Ad AS_XB1O REGIA T2 T32tums primary Inverter CB XIS cia oa Ls Te ops Oo LAS
76. s then finally open the battery circuit by removing the dc fuses or opening one or more links in the battery circuit Never open the DC circuit breaker while the inverter is operating e Running the generator without the inverter e The generator can be run to supply the load directly without the inverter provided the generator and load circuit breakers are on Turn the inverter off Checking system operation for the first time e With the generator controls off and the customer load isolated start the inverter If the system has been customised verify that the message Parameters Loaded Ok appears If not the parameters may have to be reloaded Verify that the parameters displayed particularly generator size battery type charge voltages and battery size correspond to the values expected for the site If the system is to be customised on site use the instructions in LCD Display to set the parameters to the desired values Record values set for the various parameters Check the AC output voltage using a multimeter If the voltage displayed on the LCD is in tolerance and the actual output voltage is out of tolerance adjust the output voltage using potentiometer RV4 at the top right of the power PCB If the system is to be set at a different operating voltage use the LCD to edit the voltage setpoint Connect appropriate loads to the output and confirm satisfactory operation Monitor the load magnitude on the LCD display and verify calib
77. shutting the inverter down and restarting it Later versions of inverter software may make these totals non volatile The event records in the EVT files record changes to inverter state and are useful to track the sequence of events during normal and abnormal operation The text explanation attached to each event lists the nature of the event Full details of the logged data is included in the file Readme txt distributed with the data conversion program Copyright power solutions australia 1997 Doc No 250U18 Rev 1 27 5 97 36 Upgrading amp Replacing Software Turn off power using ON OFF switch All LEDs should be extinguished Be aware that AC power can be present on contactor terminals if other power sources are not isolated Open front cover before touching any circuit ground yourself to remove static electricity by touching the chassis Remove U2 from its socket by levering up with a small screwdriver and replace with supplied software version Confirm that U7 has designation ending 12A1 3 or MEMG Replace with 12A1 3 if not Check that all pins have gone into the socket and that none are bent Check the orientation of all ICs replaced The index mark on the end of the IC should be as illustrated Turn inverter back on using ON OFF switch After confirming that new software is functioning correctly return old software to your supplier or Power Solutions Australia PO Box 571 Castlemaine Victoria 3450 Pack carefully in p
78. single phase parallel type inverter Green Grid inverter Master in 3 phase inverters Master in 3 phase inverters with external control Master in 3 phase inverters with external slave to CB status Master in single phase parallel type inverter Master in Green Grid 3 phase inverter Master in Green Grid single phase parallel type inverter Master in single phase parallel type inverter with external control Master in single phase parallel type inverter with external CB status Standard solar interactive inverter Master in solar interactive inverter E lu o OMNOOARWNHAD o on power solutions australia Doc No 300U15 Rev 3 1 10 97 25 Standard Display List Power Solut GIM Running Selftest Power Solutions GIM Inverter de Volt 123 16 dc Amp 1 2 Load kW 0 15 ac Volt 241 Load kW 0 15 L KWh Day 1 81 Gen kW 0 47 Inv kW 0 33 Inv Hz 50 02 Gen Hz 50 01 Gen Volt 249 Gen Hz 50 01 Inv kVAr 0 32 Gen kVAr 0 37 Dis Ah 23 2 DC Volt 123 4 Ren Amp 1 3 Aux mV 23 2 Htsnk C 28 Btry C 20 BatSize Ah 400 GenSize kW 6 00 Charge V 144 Boost V 147 Float V 139 Sealed battery GenStartV 117 ShutDwnV 110 Std Dis Ah 79 Shut Dis Ah 239 Min Dis Ah 26 Nite Dis Ah 111 GenShut kW 1 96 ChgShut kW 2 23 In Charg V 238 0 o o _ 0 OO PrefGen hr 17 LockGen hr 0 UnlockG hr 0 Day to Boost 7 Bstfrq Day 14 V2 0X 120V 5kW 30 July 1996 power solutions austra lia
79. t Display EE 26 Edit Display LlS tooodo iran 27 Monitor Interface amp Parameter Setting iii 30 Using the Real Time Monitor Interface 30 Monitor te e LEE 30 Memory Variables furore tini lesn eta el laura alieni 30 Mo itor ComM MaA EE 30 Modifying parameters via the Serial Port nara 31 Identify the parameter to be changed rn naar nnnnn cnn 31 SEIWERT EE 32 Data Loggihg enna iaia nei 33 INTFOGUEHON ciare liano doi ile 33 PassWord Neier 33 Gonhecting Via Padilla id ai rai 33 Connecting via a Modem i 33 Retrieving Logged Data ansaitaan eain aihe e a AE R AE AE AAGE FAE A 34 File name Conyernh Naninira e aari NA a e aa a A NESAS EKN EENAA 34 Get All eta rrene ne ae arata digli AA a E EA E A ara 34 CARDENAS EE 34 Date Ierger A E T T 34 mega eebe A 34 Remote shutdown of inverter i 34 Processing Logged Data i 35 Go nverning data TEE 35 A ET 35 CANA r a aa Aaaa aa a a aa aaa aa 35 EE les A ille ila aa aa 35 Generating Spreadsheets and Graphs in EXCEL 35 Troubleshooting Logged Data cnn r nano nn nr ran nn rra rca 36 Manipulating Logged Data i 36 Upgrading amp Replacing Software rrriiiiiiiiin 37 Specification Iran 38 Introduction The Power Solutions Australia Generator Interactive Inverter System provides mains quality power efficiently and automatically It uses b
80. tery charge However if the system appears to be not operating correctly you can use the indicating lights on the front panel to decide what problem is present and what action to take The inverter will shut down and where possible automatically restart if an abnormal condition is detected Typical abnormal conditions the inverter response and the actions which can be taken by users are listed below DC Circuit Breaker Trip If a very high current is detected which cannot be controlled electronically then the DC circuit breaker will be tripped and the inverter will stop operating Use the initial start up procedure If normal operation is not restored contact your supplier You can run the generator manually to supply power with the inverter shut down Inverter Shutdown If multiple shutdowns occur within a short time the inverter will allow up to 10 restarts After ten restarts have accumulated within one minute further restarts will be attempted once per minute If the inverter is regularly shutting down and normal operation cannot be restored by turning the on off switch off then back on then contact your supplier Field Diagnosis Full diagnostic procedures are given in the System Diagnostic Procedures in the power solutions australia Reference Manual Check inverter LEDs for fault indications Confirm that the Generator Available indication is present without the generator available input being energised the generator cannot be contro
81. ull power operation to 40 C Reduced power operation to 60 C self derating Relative Humidity 95 non condensing Manufacture Product design manufacture and software by Power Solutions Australia Pty Ltd Applicable Standard AS 3000 SAA Wiring Rules AS 2279 Limitation of Harmonics AS 1044 Limits of Electromagnetic Interference AS 3100 Requirements for Electrical Equipment AS 3901 ISO 9000 Quality Systems Front View Internal View Copyright power solutions australia 1997 Doc No 250U19 Rev 1 27 5 97
82. used to stop the generator and disconnect the inverter cleanly Copyright power solutions australia 1997 Doc No 440U14 Rev 1 27 65 97 Precautions Electrical Installation The installation and electrical connection of this system should only be undertaken by a qualified electrician Relevant national standards and practices for the installation should be followed Voltages generated by the equipment are lethal The system must be earthed Generator Installation The installation of the generator should follow relevant standards and practices for the installation of fuel storage for ventilation and dispersal of exhaust gas Exhaust gas in enclosed spaces can kill Battery Installation Batteries are very dangerous Use insulated tools when working on battery connections and avoid causing shorts Inverter Installation Install in a dry place clear of any water electrolyte corrosive aerosols acid spray etc Provide adequate ventilation space do not place near other hot equipment The inverter contains arcing contacts do not allow it to be installed where explosive gases mixtures could occur Solar Array Installation The solar array frame must be earthed and varistors installed between the array positive and negative terminals to the array frame both to protect the array and the inverter Solar array outputs produce high dc voltages Shorting or disconnecting array wiring which is energised or carrying current can produce dangerous powe
83. versions may become available which upgrade the performance of the system Most upgrades will improve the ability of the system to automatically adjust to unusual conditions If a system is operating well and the features added to the upgrade do not affect a particular installation there is no need to routinely upgrade the software If the upgrade will be beneficial to a particular site then the new software should be installed Changes to the parameter organisation in new versions may be different from earlier versions In this case the message Default params will appear when the new version is started and it will be necessary to re enter the parameter values if the default values in the new version are not suitable Recording Parameter Settings After you have adjusted parameters you should always record the values you have set in the rear of your manual This will enable the values to be checked if problems are experienced or restored if the system parameters have to be re entered for example after a software upgrade Mode Switch Settings Keb Mode switch settings on comms PCB Flooded Battery Sealed Battery Edit Enabled Edit Disabled Frequency 60Hz Frequency 50Hz T Spare Spare Code Value 8 7 Code Value 0 T Code Value 4 2 Code Value 0 Code Value 2 Code Value 0 Code Value 1 1 WWW Code Value 0 Code Function Standard single phase generator interactive inverter Slave in 3 phase inverters Slave in
84. y cells in a high state of charge to minimise risk of cell failure and loss of battery capacity Meet demands for heavy loads by starting as soon as a very heavy load is applied and sustained Deliver energy efficiently by supplying sustained large loads direct from the generator Ensure the generator ie loaded to the highest possible level while running to achieve best efficiency in converting diesel fuel to electricity Ensure that the generator does not do frequent starts and stops which degrade life expectancy and increase maintenance Only start late at night if absolutely necessary because of heavy loads or a deeply discharged battery If energy from solar or wind sources is available to only start if the battery is still being discharged and topping up from diesel is necessary With a normal household load the battery will be discharged at a modest but fluctuating rate The generator will start when 25 of the battery capacity has been used The generator will stop when the battery is close to fully recharged but will stay on if there is a load sufficiently high to supply directly and efficiently from the generator When very heavy loads up to twice the inverter rating have to be supplied the generator will start almost immediately to share the load and prevent over heating of the inverter After the large load is removed the generator will remain on to charge the batteries back to full capacity or if sufficient load remains to be effic
85. y set to 17 ie 50m when solar charging should be complete and helps ensure that generator A value of zero results in no preferred generator running time Values from 1 to 24 correspond to 1am to midnight Both values can be set in the edit pages LockGen hr 0 UnlockG hr al LockGen hr is the time at and after which the generator is inhibited from starting UnlockG hr is the time at which this inhibition is removed A value of zero for either makes lockout immediately ineffective Values from 1 to 24 correspond to 1am to midnight Both values can be set in the edit pages Day to Boost 7 Bstfrq Day il Day to Boost is the number of days until the next boost equalise charge takes place Bstfrq Day is the time in days between automatic boost cycles It can be set in the edit pages V2 0X 120V 5kW 30 July 1996 This is the software version identification Give this information to your supplier when reporting any problems Default Parameters Most default parameters are suitable for immediate operation of the inverter However basic parameters as listed below may need adjustment and all parameters should be reviewed to check that they are reasonable for the equipment installed In particular if sealed batteries are used the Sealed Battery parameters may have to be selected by setting the appropriate DIL switch as shown in the DIL switch settings sheet enclosed in the manual power solutions australia Doc No 300U15 Rev 3 1 10 97 22 Basic
86. ystem typical values are 1W per bit on 3 and 5kW inverters down to 0 25W per bit on small systems and up to 5 0W per bit on the largest systems If the value is not immediately available from documentation the scaling can be inferred from the known generator size on a system and checking the Generator Maximum Power variable in the parameters values read out of the site parameter area Alternately the site txt file used to process logged data includes the AC power calibration as the variable POWERCON Copyright power solutions australia 1997 Doc No 250U17 Rev 1 27 65 97 32 Data Logging Introduction The inverter optionally includes an RS232 serial port which can be used to retrieve logged data and to diagnose operation of the inverter either using a local terminal a directly connected PC or remotely via a modem The data collected will be permanently stored and will not be lost if the power to the inverter is turned off Password protection A fixed two level password system has been provided to prevent casual hackers from manipulating systems It does not provide high levels of security because passwords are fixed to avoid the need to provide access should the password be lost and to prevent manipulation by people changing passwords If high security is required modems with security features including ring back should be used No password is required to retrieve logged data so the passwords do not have to be widely distributed The

RAPS 10kW - 15kW - Selectronic Australia

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