EBA1030C INSTALLATION MANUAL
Contents
1. OK DAVILOA e DC OK r vaos Coase utj lena so EONI A On The inverter controller can be wired to suit many inverter brands with or without power ramping control The inverter control has a built in relay provided to isolate the inverter The EBA1030C has Bi directional CT s that connect to the electrical circuits Functionality When power is in a forward direction consumption the EBA will connect auxiliary power generators PV Solar to the grid As power exports this will then de energize the contactor thus isolating unwanted over generation from the supply All connections are energized to connect so on any sort of failure items are to disconnect isolate on de energize SPECIFICATIONS JN eV WV Power Limit Up to 50kW asinzi 3CTs 100mA 50ampst pa Power supply 24VDC 1 amp for EBA controller amp timer DCOK Inverters 3 Phase Inverters Contactor 3 x 40A relay per phase vr Box Material Power coated IP65 Rated Metal Box AV ADJ Dimensions 500 x 400 x 200mm Weight 15kg Environmental 20 C to 60 C 5 to 95 R H MW Accuracy gt 1 2 cea Power Consumption Max 5W 100 240VAC STATUS INDICATIONS sosote Power OK Fault RE Export Ramp signal EXPANSION INTERFACES Optional Wh pulse Interface to cascade timers for Ramp Communications Modbus RTU RS485 connection GETTING STARTED Installing the EBA involves the following steps FRA GC Grid Controller 1030C Installation Manual Feh 15 4 I2. are suspected perform the following diagnostics Using a mV meter set to AC measurements measure the mV reading on the input terminals of each CT between the 111 to 112 etc Non 5A GCs are configured to interpret a full scale of approximately 333mV AC That is a measurement of 333mV AC is proportional to the full scale rating of the GC as indicated in the part number and the front yellow sticker For example Full scale is 250A If mV AC measurement on current inputs is 100mV calculated measured current is approximately 100mV 333mV 250A 75A Keep in mind that this measurement is an approximation If this calculation yields the same approximate result as the GC FRA GC Grid Controller 1030C Installation Manual Feh 15 7 measurement the problem is before the GC Ensure that the CT wiring is not shorted and that the CT is not damaged In the case of split core CTs ensure that the two sides are properly mated together POWER FACTOR Verify that the power factor PF a PF b PF c readings are within 0 800 to 1 000 Readings that are very low or have a negative sign a marginally negative power factor ie 0 950 to 1 000 may be normal should be given closer examination Most installations have a nominal power factor within 0 800 to 1 000 positive This indicates a lagging power factor and is normal caused by motors fans etc An excessively low power factor may be an indicator of incorrect voltage to current phase matching t is
3. EBA1030C INSTALLATION MANUAL FRA GC Grid Controller 1020C Installation Manual Feh 15 1 INTRODUCTION The Grid Control Unit provides an affordable reliable and convenient method of installing grid connected PV systems to distribution networks that have restricted or zero export limitations LIVE PARTS The EBA 1030C grid controller comes complete with contactors and CTs Circuit breakers for inverters are provided in the IP66 metal enclosure to comply with network requirements Utility companies may require extra measures of protection than what inverters can provide FRA GC Grid Controller 1030C Installation Manual Feh 15 2 The EBA 1030C grid controller is a fully integrated unit with the ability to e Accurately monitor and measure forward and reverse direction of power flow in the mains of an installation e Accurately monitor and measure in real time Voltage Current Frequency Real Power Apparent Power and phase fail e Manage and limit export power to the grid by way of mechanical isolation e Optionally Log and record export consumption generation actual usage on site current VA kWatt voltage frequency e Optionally ramp SMA and Power One inverters up and down as the zero export limit nears HOW IT WORKS The unit is an all in one IP65 metal enclosure that incorporates sub main connection terminals CT connections inverter communications digital output connections din rail three phase contactor
4. and circuit breaker for the inverter AC output connections The controller is utility approved and typically throws a relay when solar generation exceeds load to ensure exports don t occur and create voltage rise The ramp option controls the inverter output up or down to maximize solar generation without exceeding the load The 1030C continuously measures and monitors the value and direction of power flow at the main feed The device can manage single and three phase systems through to multiple inverter systems up to a maximum of 30kW When the sites power demands are less than what is generated the 1030C prevents the over generation of power from being exported back to the grid by isolating the selected inverters via the contactor provided As the power demand increases the 1030C will measure and monitor the value and then reconnect the inverter to compensate the increase in demand Easily Configurable The configuration can be changed during commissioning and then protected by seals to ensure the integrity of the system Normally the GCU is set at factory and no need for installation setup The 1030C Zero Export Controller provides inverter output control by monitoring the site power at the point of connection to the inverters to maintain the maximum amount of solar power to be generated without exceeding the requirements set by the local network operator FRA GC Grid Controller 1030C Installation Manual Feh 15 3 ev v De
5. e The solid split core defines how the CT core is designed and how it can be installed Solid core CTs feature a closed loop which the primary conductor must be passed through Split core CTs can be temporarily opened to facilitate easier installation When using a split core CT the primary conductor need not be disconnected to install the CT and in most cases the conductor can continue to carry current while the CT is being installed Split core CTs have a large advantage in installations where shutdowns are not practical or economical CT Output Types 5A Output CTs FBA GC Grid Controller 1030C Installation Manual Feh 15 9 Traditionally CTs were designed to have a full scale output of 5A for a given full scale primary current Typical full scale input currents ranged from 50 to 2000 amps This would be represented as 50 5 or 2000 5 In a 2000 5 CT 5A flows in the secondary winding when 2000A is flowing through the primary winding By changing the number of secondary windings the CT manufacturer defines the input full scale 5A is a considerable amount of current and it was designed to be used with electromagnetic meters to provide the power to move the magnetic needles or power protective relays This style of CT has advantages in that the metering equipment is all configured for a 5A input The appropriate CT can therefore be chosen to determine the full scale measurement range of the metering equipment As far as the meter is c
6. g device In some installations however such as large bus bars the use of these CTs is unavoidable With the advent of digital metering the need for a large output current became unnecessary mA Output CTs The advantage of these CTs is the smaller size and cost as well as much safer conditions when the CTs are not shorted Many models have built in voltage suppression devices that will limit the output voltage to a low level typically around 20V when opened As with most FRA GC Grid Controller 1030C Installation Manual Feh 15 10 types of CTs the mA output types are available in solid and split core variants The solid core CTs can have extremely high precision due to the higher quality core and windings that are available Accuracy including linearity and phase shift can actually exceed the revenue grade 5A output CTs Split core varieties tend to have lower accuracy however their small size and extremely easy wiring makes them ideal for many installations A mA output split core CT can cost 1 3 that of a 5A output split core CT The main disadvantage of these CTs is that the metering equipment is tied to the CT type and the full scale is defined by the calibration within the metering equipment mV Output CTs Using the same hardware as the mA output CTs mV CTs contain an internal burden resistor that converts the mA signal into mV V IR The resistor can be chosen such that a pre determined output voltage is generated when a f
7. hases is negative Please note however in a three phase system assuming balanced phases if only one of the phases is reversed the NET will continue to be positive TROUBLESHOOTING via SOFTWARE Use of the GC Console software for troubleshooting and commissioning is highly recommended The software is capable of showing all real time and accumulated parameters as well as allowing viewing and changing of configuration parameters First an FRA GC Grid Controller 1030C Installation Manual Feh 15 6 RS485 connection must be available Typical solutions are RS232 to RS485 or USB toRS485 converters Many RS485 converters are labeled A B Typically A is wired to and B is wired to However if communications does not work try to switch the polarity For short runs it is not necessary to connect the GND connection Install the GC console software Make sure that the serial or USB converter is attached to the computer and start the software Click on the Port menu and ensure that the Drop down box is selected to the COM port associated with the Serial port or USB where the RS845 converter is connected By default the GC is configured for a Baud Rate of 9600bps Click OK Click on Options gt Device Address and ensure that the address is configured to the same setting as the DIP switch on the GC If the settings are correct the text should show COMM OK Click Close At this point real time data should appear on the screen If commu
8. he label H1 defines the direction as flowing into the CT ie the dot should face the source side The output wires are typically designated with the labels X1 and X2 X1 corresponds to H1 or the input The figure below shows various CT wiring notations X1 X2 SOURCE LOAD H1 X1 X2 H1 I CURRENT INPUT X1 X2 Care must always be taken with both the physical orientation of the CT as well as the wiring polarity Instructions must always be followed as per the metering manufacturer s manual and labelling FRA GC Grid Controller 1030C Installation Manual Feh 15 17
9. imperative that the voltages measured by the GC on the V1 V2 V3 terminals correspond to the same phases as the CTs on 111 112 121 122 and 131 132 The easiest way to verify this is to physically inspect the wiring to ensure that the V1 voltage and 111 112 CT are both connected to the same phase similarity for phases 2 and 3 A mismatch may be evidenced by a poor power factor reading Verify that the power Pa Pb Pc shows the correct sign For a typical installation with correctly wired and oriented CTs the power should show POSITIVE values This indicates that power is being imported consumed In a correctly installed system a negative reading indicates that power is being exported generated In most load only systems the cause for this is either reverse polarity of the CT into the Ix1 Ix2 terminals or incorrect orientation of the CT on the wire The solution is to reverse the CT on the wire or reverse the input polarity However before taking these steps it is prudent to understand the origin of the problem as haphazard re wiring may make the situation worse Always verify the correct wiring of the installation with the wiring diagram provided by the vendor The GC can be used with a variety of Current Transformers Because of this care must be taken to properly scale the data values pulse and analog outputs This document discusses the methods used to properly configure a system using various CT types The GC was designed from the pe
10. le of producing very high voltages and arcing when not shorted and as a result may cause serious injury or death Always ensure that 5A CTs are shorted via a shorting block or that power to the circuit which the CT is installed on is off before disconnecting from the meter GC meters with 5A inputs may be identified by the part number or by the yellow sticker on the face of the unit as below If unsure contact the vendor to determine GC type Power to the GC is provided by to the upper left black plug in two position connector Valid power supply ranges are 20 26VDC or 18 24VAC 100mA Power transformer is capable of sourcing at 100mA Preferred power is 24v DC and is attained by using a DIN rail mount switching power supply FBA GC Grid Controller 1030C Installation Manual Feh 15 5 The green Power LED should illuminate when the GC is receiving power however note that the LED will continue to be illuminated even during low voltage conditions That is the LED is not an indication of GC sanity or operation but rather that power is simply available Note that voltages can sag when other equipment is powered on especially when using a small VA control transformer Therefore it is best to verify the input voltage using a DMM on the terminals of the black plug in power connector to ensure that the proper voltage is present 2 DIAG LED The Red DIAG diagnostic LED has a variety of functions Depending on the state of the LED it ca
11. ltipliers since typically the factory is unaware of the CT ratio ahead of time Introduction to Current Transformers Current transformers are devices used to scale large primary currents to a smaller easy to measure secondary currents Like a traditional voltage transformer the ratio of the windings determines the relation between the input and output currents Current transformers of various shapes and sizes are used as an interfacing solution between high currents and instrumentation devices Current transformers CTs are an indispensable tool to aid in the measurement of AC current They provide a means of scaling a large primary input current into a smaller manageable output secondary current for measurement and instrumentation This indirect method of interfacing allows for easy installation and provides a high level of isolation between the primary circuit and secondary measurement circuits CTs are available in various sizes designs and input ranges and output signal types Basics A CT is useful for measurements made on AC waveforms there is no physical connection made to the measured line The CT uses magnetic fields generated by the AC current flowing through the primary wire to induce a secondary current The ratio of the number of secondary turns to the number of primary turns determines the amplitude of the current on the output The output of a CT acts as a current sourceCT cores can be of a solid closed or split open typ
12. n signify a number of conditions The table below summarizes the LED states and related conditions LED State Condition OFF Normal operation or insufficient power supply voltage see step 1 Fast Flashing Input Voltages below threshold typically lt 25VAC Solid ON Reverse NET Power kW condition Slow Flashing Reverse Sequence typically this is disabled from the factory Double Flash pause Double Flash Firmware update mode check DIP Address switch must not be 0 Potential firmware problem To test for GC functionality or sanity it is best to connect power and disconnect voltage inputs In this configuration the RED LED should flash rapidly This is an indication of proper operation Note this feature can be disabled in software however it is ON by default from the factory If the LED shows a Double Flash followed by a short pause and another Double Flash it may be indicative of Firmware problems Verify that the DIP switch is set to an address other than 0 By default from the factory the address is set to 1 If the address DIP switch is 0 set it to 1 and reset the power to the GC unplug the black power plug for 5 seconds and plug it back in During normal measurement operation ie voltage inputs above 25VAC the DIAG LED should be OFF If the LED stays ON constantly or turns on an off erratically it is an indication of reverse power detection This condition arises when the SUM of the real power watts in all three p
13. never be mixed and only CTs designed for the metering apparatus should be used with the device Use of the incorrect CT Output type may cause severe damage to the equipment and create a potential hazardous situation CT Installation During CT installation care should be taken in the placement of the CT primary wire Ideally the wire should be placed in the middle of the CT to obtain the best performance When using split core CTs the wire should be placed either in the middle or as far away from the opening mechanism as possible The air gap created by the opening mechanism induces error in the magnetic field and therefore the output accuracy A quick method to change the CT turns ratio is to FRA GC Grid Controller 1030C Installation Manual Feh 15 11 add multiple primary turns For example if the primary wire is passed through a 2000 turn CT 4 times the effective ratio becomes 4 2000 1 500 This method in effect decreases the effective full scale of the CT and has the added advantage of increasing accuracy by increasing the effective performance of the core CT Labeling The polarity of the CT must be taken into account to avoid phase reversal situations The voltage and current measurements must have the same polarity to keep the power factor and direction of power flow measurements accurate and consistent Most CTs are labeled with a means that shows which side of the CT should face either the source or the load Alternatively a dot or t
14. nications is still timing out status can be observed in the status bar across the bottom of the screen verify the address COM setting and RS485 wiring polarity If problems persist please refer to Modbus RTU Troubleshooting or contact the vendor Device appears as it is plugged in The GC Console displays all real time and accumulated parameters which the GC measures Using this tool it is easy to check for proper wiring and operation of the system When connected to an active system the measurements are shown on the screen and updated approximately once per second The software provides the capability to ensure that the wiring is correct and that the measurements are valid There are typically two common problems associated with CT wiring 1 Current Magnitude caused by improper CT selection CT ratio configuration and physical CT installation or damaged CT 2 Power Direction Low or negative Power Factor caused by reversed CT orientation on the wire reversed CT polarity wiring to GC or incorrect voltage current phase matchup These steps may only be performed on non 5A input meters Please see the disclaimer at the beginning of this application note Current Magnitude If possible take a measurement from the line where the GC CT is installed using a clamp on style amp meter In most typical three phase installations the loads should be fairly balanced and the currents should be approximately equal in all three phases If the currents
15. nstall neutral connection for the mains power supply from the Grid to the neutral bar Install the 3 phases mains supply to the bottom of the contactor The Solar power is connected to the top of the 3 phase circuit breaker Connect corresponding phases to VI V2 and V3 as close to grid CT s Connect the OUTPUT to the SOLAR INVERTER into the bottom of the contactor INPUT CTS Connections for the CT s to corresponding phases keeping cabling to the shortest length stops unwanted interference starting from the left PHI white black and so on CT s are directional look for the arrow and place accordingly All CT links should be open The Polarity of current transformers is extremely important Wrong connection of the current transformers can cause false operation of the device Connect as shown with split CTs external yellow LED should be off unless exporting GC Troubleshooting Basic troubleshooting and commissioning steps for implementation of GC meters in various wiring systems Danger Line voltages up to 600 VAC are present on the input terminals of the device and throughout the connected line circuits during normal operation These voltages may cause severe injury or death Installation and servicing must be performed only by qualified properly trained personnel GC Meters calibrated for use with 5A CTs have special precautions that must be taken NEVER disconnect a 5A CT without shorting it first These CTs are capab
16. oncerned it will see a range between 0 5A since the CT is chosen for the proper maximum primary current Many measurement and monitoring devices support 5A CT inputs as this has become a defacto standard in the metering industry especially for large building or sub metering installations However due to the relatively large 5A current requirement these CTs require a larger heavier core and a larger wire gauge This translates to a larger heavier final product and higher costs CTs can be extremely dangerous because of the large voltages that are induced when the CT secondaries are not shorted Since a CT acts as a current source following Ohm s law V IR If the resistance is increased a very high value when open circuited the induced voltage becomes very high Many of these CTs have enough power to cause large arcing across open secondary wires Special shorting blocks are required to ensure that the CTs remain shorted even if disconnected from the meter The induced voltages are large enough to cause serious injury or even death if the appropriate precautions are not taken to prevent open circuiting the output The added cost and burden of the shorting blocks and their installation must be considered when using these CTs 5A CTs are available in solid and split core varieties however typical 5A split core CTs are quite large and extremely expensive It is not unusual for a 5A split core CT to exceed the price of the meterin
17. rspective of ease of installation and use As a result it was required to streamline the method used for CT ratio configuration To adhere to industry standards the GC treats all CT types as though they have a 5A output This allows a consistent approach for system configuration regardless of the CT type being used For any given CT type and full scale the GC effectively registers a 5 0A reading Although not all CTs have a 5A output for the purpose of GC calculations their ratio should be treated as such The added advantage of this approach is that system software DDC PLC SCADA etc may tread every GC identically regardless of the actual CT type in use Regardless of the CT type used the correct CT ratio must be entered into the GC Modbus registers CT ratio Primary Secondary register 40131 40132 respectively for GC to compute the properly scaled values in the floating point register data bank 5A CTs with GC When using 5A output CTs the CT primary FBA GC Grid Controller 1030C Installation Manual Feh 15 R value must be written to register 40131 and the value 5 must be written in 40132 Example when using a 400 5 A CT Set 40131 400 Set 40132 5 The effective CT ratio is 400 5 80 This multiplier may need to be used for the analog outputs if they are computed without the CT ratio applied For model 1200 meters analog outputs in most cases the Calibration Sheet shows the analog output configuration WITHOUT CT ratio mu
18. ull scale current is flowing Typical full scale output voltages include 333mV and 1V For example a CT can be defined to output 333mV when 100A is flowing through the primary wire The added advantage of this type of CT is that the output voltage always remains safe regardless of the connection of the secondary wires Also because the full scale current is defined by the burden resistor inside the CT the metering hardware can be universal as with 5A CTs and changing the full scale input current is determined by the CT chosen However mV CTs face disadvantages Specifically the accuracy of the CT is greatly determined by the size of the burden resistor Typically manufacturers do not trim each CT and therefore the tolerance of the resistor plays a large role in determining accuracy Moreover the difference in calculated resistor value and actual resistor value resistors do not come in an infinite array of values so the manufacturer must choose the closest value available influences overall accuracy To complicate matters further typical resistor values are small and as such the resistance of the secondary wires plays a role in influencing the signal When using mV output CTs lead length should be kept to a minimum to avoid errors due to introduced resistance as well as noise issues due to pickup 5A and mA output CTs have the added advantage of higher noise immunity because of their characteristics as a current source CT types must
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