Emerson NetShine 101 CA1

NetShine 101 CA1

NetShine 101 CA1 Solar Controller

User Manual

V1.2

2011-03-17

BOM 31011799

Version: V1.2

Revision date: March 17, 2011

BOM: 31011799

518057

www.emersonnetworkpower.com.cn

4008876510

E-mail: [email protected]

Emerson Network Power provides customers with

technical support. Users may contact the nearest

Emerson local sales office or service center.

Copyright 2010 by Emerson Network Power

Co., Ltd.

All rights reserved. The contents in this document

are subject to change without notice.

Emerson Network Power Co., Ltd.

Address: No.1 Kefa Rd., Science & Industry Park,

Nanshan District 518057, Shenzhen China

Homepage: www.emersonnetworkpower.com.cn

E-mail: [email protected]

Safety Precautions

To reduce the chance of accident, please read the safety precautions carefully before operation. The Caution,

Notice, Warning, Danger in this book do not represent all the safety points to be observed, and are only

supplement to various safety points. Therefore, the installation and operation personnel must be strictly trained

and master the correct operations and all the safety points before actual operation.

When operating Emerson products, you must strictly observe the safety rules in the industry, the general safety

points and special safety instructions specified in this manual.

Electrical Safety

I. Hazardous voltage

Danger Danger

Some components of the solar controller carry hazardous voltage in operation. Direct contact or indirect contact through

moist objects with these components will result in fatal injury.

You must observe the safety rules in the industry when installing high DC voltage and AC power devices. The

installation personnel must be licensed to operate high DC voltage and AC power.

In operation, the installation personnel are not allowed to wear conductive objects such as watches, bracelets,

bangles, rings.

When water or moisture is found on the cabinet, please turn off the power immediately. In moist environment,

precautions must be taken to keep moisture out of the power system.

Prohibit warning label must be attached to the switches and buttons that are not permitted to operate during

installation.

Danger Danger

High voltage operation may cause fire and electric shock. The connection and wiring of AC cables must be in compliance

with the local rules and regulations. Only those who are licensed to operate high voltage and AC power can perform high

voltage operations.

II. Tools

Warning

In high voltage and AC operation, special tools must be used. No common or self-carried tools should be used.

III. Thunderstorm

Danger Danger

Never operate on high voltage, AC, iron tower or mast in the thunderstorm.

In thunderstorms, a strong electromagnetic field will be generated in the air. Therefore the equipment should be

well earthed in time to avoid damage by lightning strikes.

IV. ESD

Note

The static electricity generated by the human body will damage the static sensitive elements on PCBs, such as large-scale

ICs. Before touching any plug-in board, PCB or IC chip, ESD wrist strap must be worn to prevent body static from

damaging the sensitive components. The other end of the ESD wrist strap must be well earthed.

V. Short-circuit

Danger Danger

During operation, never short the positive and negative poles of the DC distribution unit of the system or the

non-grounding pole and the earth. The solar controller is constant-voltage DC power equipment, short circuit will result in

equipment burning and endanger human safety.

Check carefully the polarity of the cable and connection terminal when performing DC live operations.

As the operation space in the DC distribution unit is very tight, please carefully select the operation space.

Never wear a watch, bracelet, bangle, ring, or other conductive objects during operation.

Insulated tools must be used.

In live operation, keep the arm muscle tense, so that when tool connection is loosened, the free movement of

the human body and tool is reduced to a minimum.

Battery

Danger Danger

Before any operation on battery, read carefully the safety precautions for battery transportation and the correct battery

connection method.

Non-standard operation on the battery will cause danger. In operation, precautions should be taken to prevent

battery short circuit and overflow of electrolyte. The overflow of electrolyte will erode the metal objects and PCBs,

thus causing equipment damage and short circuit of PCBs.

Before any operation on battery, pay attention to the following points:

Remove the watch, bracelet, bangle, ring, and other metal objects on the wrist.

Use special insulated tools.

Use eye protection device, and take preventive measures.

Wear rubber gloves and apron to guard against electrolyte overflow.

In battery transportation, the electrode of the battery should always be kept facing upward. Never put the

battery upside down or slanted.

Others

I. Safety requirement

Warning Notice

Note

Always use the same fuse for replacement as the fuse of the solar controller.

II. Sharp object

Warning

When moving equipment by hand, you should wear protective gloves to avoid injury by sharp object.

III. Power cable

Note

Please verify the compliance of the cable and cable label with the actual installation prior to cable connection.

IV. Binding signal lines

Warning Notice

Note

The signal lines should be bound separately from heavy current and high voltage lines, with binding interval of at least

150mm.

Contents

Chapter 1 Introduction ......................................................................................................................................................... 1

1.1 Model Description ................................................................................................................................................. 1

1.2 Operation Theory .................................................................................................................................................. 1

1.3 Features ................................................................................................................................................................ 2

1.4 Functions .............................................................................................................................................................. 2

1.5 Technical Parameters ........................................................................................................................................... 5

Chapter 2 Installation And Commissioning.......................................................................................................................... 7

2.1 Safety Regulations ................................................................................................................................................ 7

2.2 Installation And Cable Connection ........................................................................................................................ 7

2.2.1 Installation Preparation .............................................................................................................................. 7

2.2.2 Mechanical Installation .............................................................................................................................. 8

2.2.3 Cable Connection ...................................................................................................................................... 8

2.2.4 Sealing Cable Entry Holes ....................................................................................................................... 10

2.3 Commissioning ................................................................................................................................................... 10

2.3.1 Check Before Power-on........................................................................................................................... 10

2.3.2 Power-on And Commissioning ................................................................................................................ 10

2.4 Final Steps .......................................................................................................................................................... 12

Chapter 3 Use Of Monitoring Board .................................................................................................................................. 13

3.1 Monitoring Board Introduction ............................................................................................................................. 13

3.2 Querying Status .................................................................................................................................................. 13

3.3 Querying Active Alarm ........................................................................................................................................ 14

3.4 Setting Parameters ............................................................................................................................................. 15

3.5 Maintenance ....................................................................................................................................................... 16

3.6 Querying History Alarm ....................................................................................................................................... 17

Appendix 1 Wiring Diagram ............................................................................................................................................... 18

Appendix 2 Glossary ......................................................................................................................................................... 19

Chapter 1 Introduction 1

NetShine 101 CA1 Solar Controller User Manual

Chapter 1 Introduction

The NetShine 101 CA1 solar controller (controller for short) is used for the outdoor wireless communication stations.

The controller can effectively control the solar energy to supply power to the battery and the load, making the battery

and the load work in safe voltage and current range.

This chapter introduces the model description, operation theory, features, functions and technical parameters of the

controller.

1.1 Model Description

The controller model description is shown in Figure 1-1.

1 0 A 1Version No.

Current or power level, 5: 50A;

A: 100A; F: 150A; K: 200A

Region or customer type, C: China

Product category, 1: standard controller

Brand name of Emerson solar controller

1 C

Function type, 0: solar; 1: solar & electric/solar &

DG; 2: wind & solar; 3: wind, solar & electric (DG)

Voltage type, 0: -48V system

NetShine

Figure 1-1 Model description

1.2 Operation Theory

In sunny days, the photovoltaic array (array for short) in the solar energy power system supplies power to the battery

and the load. During nights and cloudy days, the batteries sustain the load. The schematic diagram of the solar

energy power system is shown in Figure 1-2.

Input

SPD

Output power

board

Input power

board 1

Positive busbar

Negative busbar

MCB

I/O port

Prim

ary

loadOutput

SPD

Battery

Input power

board 2

Input

SPD

Output

SPD

Array 1 input

Array 2 input

Sla

ve lo

ad

Figure 1-2 Schematic diagram of the solar energy power system

2 Chapter 1 Introduction


By controlling the input power boards, the controller stabilizes the battery voltage within a specified range, and

determines the battery charge states according to the capacity and voltage of the battery. If the battery voltage is too

high, the output power board will disconnect the load to protect the load; if the battery voltage is too low, the output

power board will disconnect the load to protect the battery.

The controller has a monitoring board, which is used to monitor the operation condition of the controller, control each

input power board and output power board, and carry out battery management. The monitoring board provides the

RS232/RS485 port, alarm dry contact input port, alarm dry contact output port, and battery temperature sensor port.

1.3 Features

The LCD allows you to learn of the operation conditions of the controller and the battery status.

The controller uses ON/OFF mode and PWM mode to control array input, taking full advantage of solar energy

input.

Perfect battery management functions. Those functions include the battery low voltage disconnection,

temperature compensation and automatic voltage regulation.

Perfect protection function and fault alarm function.

The advanced EMC design satisfies EN55022 CLASS A and IEC61000-4 requirements.

The safety design of the controller complies with EN50178 standard.

1.4 Functions

Array management function

The controller uses ON/OFF mode (default) and PWM mode, you can manually choose one mode for battery charge.

In ON/OFF mode, the controller performs the switching control of the arrays through switching on/off of the input

power boards. In PWM mode, the controller performs the switching control of the arrays and takes full advantage of

the solar energy through high frequency switch according to operation status of the solar energy power system.

Protection function

Table 1-1 Protection function

Function Description Remark

Input overcurrent

protection

When one array has overcurrent input (adjustable, see 3.4 Setting

Parameters), the controller inside will control the current. If the

current is too large, the corresponding MCB will trip

When the fault is cleared, the

controller will resume automatically.

The tripping MCB should be switched

on manually

Output overcurrent

protection When one load output is shorted, the corresponding MCB will trip

The fault must be cleared before the

MCB of a shorted load output can be

closed

Battery overcurrent

protection In case of battery overcurrent, the corresponding MCB will trip

The MCB needs to be closed

manually

Overtemperature

protection

When the battery temperature is over 50C (adjustable, see 3.4

Setting Parameters), the controller will generate an overtemperature

alarm.

When the battery temperature is over 60C (adjustable, see 3.4

Setting Parameters), the controller will disconnect the array input and

perform overtemperature protection

In overtemperature protection state,

the battery will disconnect the array

input, lowering the utility rate of the

solar energy in sunny days. Therefore

the overtemperature function is

Disabled by default. When the

battery temperature is normal, the

controller will resume automatically

Surge protection

The controller has an internal SPD that can achieve surge protection.

When the SPD is found faulty, the controller will generate an SPD

fault alarm. Compliant with Class C surge protection standard

If the SPD is faulty, you need to

replace it manually



Measurement function

Table 1-2 Measurement function

Signal Measurement range Precision Environmental requirement

Open circuit voltage of array 20Vdc ~ 100Vdc 0.5Vdc

Ambient temperature: 25C

Operating current of array 0 ~ 50A 0.5A

Busbar/battery voltage 35Vdc ~ 65Vdc 0.2Vdc

Total charge/discharge current of the battery string -40A ~ +80A 1A

Load current 0 ~ 30A 0.5A

Battery temperature -30C ~ +65C 3C

Alarm function

The alarms are displayed on the LCD of the monitoring board, and are indicated by the corresponding indicators. The

alarms can be set through the monitoring board. Refer to 3.4 Setting Parameters for details.

Table 1-3 Alarm function

Name Alarm symptom Alarm triggering condition Alarm clearance condition

DC OverVolt

The yellow indicator on the

monitoring board turns on, and

the Active Alarm on the LCD

displays DC OverVolt

The busbar voltage is higher

than the battery overvoltage

alarm threshold

The busbar voltage is lower

than the battery overvoltage

alarm threshold

DC UnderVolt




displays DC UnderVolt

The busbar voltage is lower

than the battery undervoltage

alarm threshold


than the battery undervoltage

alarm threshold

LLVD

The red indicator on the



shows LLVD

The busbar voltage is

continuously lower than the

load low-voltage disconnection

threshold


than the load low-voltage

disconnection threshold

Array OverVolt




displays Array OverVolt

The open circuit voltage of the

array is higher than the array

input overvoltage threshold

The open circuit voltage of the

array is lower than the array

input overvoltage threshold

Array OverCurr




displays Array OverCurr

The operating current of the

array is higher than the array

input overcurrent threshold

The operating current of the

array is lower than the array

input overcurrent threshold

Array Lost




displays Array Lost

The controller detects array loss When the array is connected

normally, the alarm disappears

Array Reverse




displays Array Reverse

The input polarities of the array

are reversely connected

The input polarities of the array

are correctly connected

Input Circuit Open




displays Input Circuit Open

The input MCB of the array is

open or the input power board

is open

The input MCB of the array is

closed and the input power

board is closed

Input Power Board Short

Circuit




displays Input Power Board

Short Circuit

Input power board is shorted The short circuit fault is cleared

B-High Temp Alarm




displays B-High Temp Alarm

The battery temperature is

higher than the battery

overtemperature alarm

threshold


lower than battery

overtemperature alarm

threshold



Name Alarm symptom Alarm triggering condition Alarm clearance condition

B-OverTemp Prot




displays B-OverTemp Prot


higher than the B-OverTemp

Prot threshold, and the

BatTempProt EN is set to Y


lower than the B-OverTemp

Prot threshold, or the

BatTempProt EN is set to N

Over LoadCurr




displays Over LoadCurr

The load current is higher than

the load overcurrent threshold

The load current is lower than

the load overcurrent threshold

SPD Fails




displays SPD Fails

The SPD is faulty The SPD works normally

Controller Fails




displays Controller Fails

The monitoring board is faulty The monitoring board works

normally

Battery Circuit Open




displays Battery Circuit Open

The battery circuit open caused

by battery MCB open or other

causes

The battery circuit is closed

Load MCB Off




displays Load MCB Off

The load MCB trips The load MCB is closed

Auxiliary Charge Fails




displays Auxiliary Charge

Fails

The auxiliary charge is

abnormal, when the controller

sends signal for starting the

auxiliary charge

The battery voltage is up to

53V or the auxiliary charge is

off (automatic/manual)

CAN Com Fail




displays CAN Com Fail

The CAN fails to connection

with power system, when the

controller works in cooperation

mode

Normal connection

Bat Tem Sen Fail




displays Bat Tem Sen Fail

Battery temperature sensor is

disconnected or faulty

Battery temperature sensor is

connected normally

Input Alarm




displays Input Alarm

The input dry contact status is

changed

The status returns to normal

status

Alarm input function

Table 1-4 Alarm input function

Dry contact type Dry contact state

Normally-open (default), normally-closed Normally-open: open upon normal input, closed upon alarm input

Normally-closed: closed upon normal input, open upon alarm input

Alarm output function

Table 1-5 Alarm output function

SN. Output dry contact alarm Dry contact state

Output dry contact 1 Controller fault (settable, see 3.4 Setting Parameters) Normally-open is default. You

can set the dry contact state

through the jumpers (see Table

2-6) Output dry contact 2 Battery undervoltage (settable, 3.4 Setting Parameters)



Control function

The controller has two control modes: automatic control and manual control. In automatic control state, the controller

will perform automatic control functions according to preset parameters and logic. In manual control state, you can

control connections of the arrays and loads through keyboard on the monitoring board or host.

Communication function

The controller can communicate with the host through RS485/RS422 port. The RS485/RS422 port can be set through

jumpers in the board card, and the setting method is described in Table 2-6 in 2.3.2 Power-on And Commissioning.

The default communication mode is RS422. The host can set the controller parameters and maintenance, and it can

read the measurement values, active alarm values, historical alarm values and historical data.

Display function

The controller uses a 128 64 LCD, which displays the controller and battery states, measurement values and

alarms in real time.

Historical data record function

The controller can record the historical data (up to 31 days) which can be read through the host, including the

following information:

1. The highest battery temperature every day 2. The lowest battery temperature every day

3. The highest battery voltage every day 4. The lowest battery voltage every day

The controller can record 100 historical alarms, including the following alarm information:

1. Alarm content 2. Alarm start time and end time

3. Load current and battery voltage in the alarm time (available

through the host)

Battery management function

According to the input current and voltage, battery capacity, load status and busbar voltage, the controller performs

the battery management to ensure efficient charge and discharge of the battery, to prolong the battery lifetime and

make good use of the solar energy.

In battery FC mode, the busbar voltage is controlled within +1V of the preset FC point.

In battery BC mode, the busbar voltage is controlled within +1V of the preset BC point.

In FC state, the controller will control the battery to enter the BC mode when the FC voltage decreases to a point

lower than the preset FC to BC voltage.

In BC state, the controller will control the battery to enter the FC mode when the BC voltage is +1V higher than

the preset BC voltage.

If the controller uses the PWM mode, it will perform array input management according to the default PWM logic.

1.5 Technical Parameters

Table 1-6 Technical parameters

Type Item Description

Environment

Operating temperature -20C ~ +55C

Storage temperature -40C ~ +70C

Relative humidity 0 ~ 95%RH

Altitude 5500m (derating is necessary above 3,000m. Rated current decreases 20A

for every 1000m higher)

Others No conductive dust or erosive gases. No possibility of explosion

DC input

Array 2 routes 50A, 63A 2 (MCB)

Current (one route array) Rated current: 50A. Overcurrent alarm point: 55A

Voltage Rated voltage: 48Vdc. Max. open circuit voltage: 96Vdc



Type Item Description

DC output

Route Primary load: 2 routes, 16A 2 (MCB)

Slave load: 2 routes, 63A 2 (MCB)

Current Total load current is the sum of the primary load current and slave load current,

whose max. current is 30A

Voltage Rated voltage: 48Vdc.

Max. allowable output voltage: 60Vdc

Efficiency 99%

Battery

configuration

Battery route One route, 125A 1 (MCB). If the battery route is open, the controller will stop

working

Nominal capacity 50Ah ~ 5000Ah

EMC

Conducted emission Class A EN55022

Radiated emission

Immunity to EFT Level 3 EN61000-4-4

Immunity to ESD Level 3 EN61000-4-2

Immunity to surges Level 3 EN61000-4-5

Immunity to radiation Level 3 EN61000-4-3

Immunity to conduction Level 2 EN61000-4-6

SPD Lightning protection features The array input port and load port are configured with SPD, whose rated

capacity is 20kA and max. capacity is 40kA

Safety

Standard Compliant with EN50178 standard

Insulation resistance

At temperature of 15C ~ 35C and relative humidity not higher than 90%RH;

apply a test voltage of 500Vdc, and the insulation resistance between DC circuit

and earth is not less than 2M

Insulation strength

Remove the SPD from the system before the test.

Input/output circuit to earth: 1414Vdc.

Input/output circuit to communication output circuit: 2828Vdc.

Input/output circuit to dry contact output: 1414Vdc.

Communication output circuit to dry contact: 1414Vdc.

For all the four tests above, there should be no breakdown or flashover within 1

min, with leakage current not bigger than 10mA

Others

MTBF 100000h (Bellcore TR-332 reliability forecast), at 25C

Protection level IP55

ROHS Compliant with ROHS

Mechanical Dimension (mm) 290 (W) 150 (H) 420 (L)

Weight (kg) 11 (without packaging)

Chapter 2 Installation And Commissioning 7


Chapter 2 Installation And Commissioning

This chapter introduces the installation, cable connection, commissioning and final steps. Before installation, please

read the safety regulations carefully, and then follow the instructions in this chapter to carry out the installation and

connection.

2.1 Safety Regulations

Certain components in this controller have hazardous voltage and current. Always follow the instructions below:

1. Only qualified personnel with sufficient knowledge of the controller can carry out the installation. The safety

precautions and local safety rules shall be adhered to during the installation.

2. All external circuits that are below -48V and connected to the controller must comply with the requirements of

SELV defined in IEC60950.

3. Make sure that the power to the controller is cut off before any operations can be carried out within the controller.

4. After the installation and the commissioning, the controller shall be kept locked. The key should be kept in

possession by corresponding personnel.

5. The wiring of the power distribution cables should be arranged carefully and taken protective measures so that the

cables are kept away from the maintenance personnel.

6. All the tools before the installation must be insulated and ESD-proof processed.

2.2 Installation And Cable Connection

2.2.1 Installation Preparation

Unpacking inspection

The equipment should be unpacked and inspected after it arrives at the installation site. The inspection shall be

carried out by representatives of both the user and Emerson Network Power Co., Ltd.

To inspect the equipment, you should open the packing case, take out the packing list and check whether the

equipment is correct and complete. Make sure that the equipment is delivered intact.

Preparing cables

The cable should be selected in accordance with relevant industry standards. The CSA of cables depends on the

current flowing through the cable and the allowable voltage drop. The cable CSA selection is given in Table 2-1.

Table 2-1 Recommended cable CSA

Connection point Recommended CSA Recommended cable color Recommended max. distance

Battery to controller 25mm2 Blue for negative and black for positive 13m

Controller grounding cable 16mm2 Yellow-green 1m

Note: You should select the CSA and color of the cable according to the actual configuration

Select the battery cable CSA according to Table 2-2.

Table 2-2 Battery cable CSA selection

Battery MCB rated current Max. battery current Min. cable CSA Terminal type Max. cable length (allowable

volt drop: 0.5V)

125A 80A 25mm2

OT lug (+)

H shape terminal (-) 8m

Note:

1. The specifications are applicable at ambient temperature of 25C. If the temperature is too high, the CSA of the cable should be

increased.

2. The battery cable should reach at least +70C heat durability

8 Chapter 2 Installation And Commissioning


Select the load cable CSA according to Table 2-3.

Table 2-3 Load cable selection

Load route

rated current Max. output current

Min. cable

CSA

Max. cable length (volt drop: 0.5V,

with min. CSA) Max. cable CSA

Max. cable length (volt

drop: 0.5V, with max. CSA)

63A 50A 25mm2 13m 50mm

2 26m

16A 10A 10mm2 16m 16mm

2 26m

Note: The specifications are applicable at ambient temperature of 25C. If the temperature is too high, the CSA of the cable should

be increased

The MCB capacity should be strictly limited so that it can work properly upon overload. The recommended MCB

capacity is 1.5 ~ 2 times larger than the load rated capacity.

The CSA of the grounding cable should be not less than 16mm2.

The battery MCB and load MCB use H shape terminal for connection. Or you can use cables with insulation layers

broken up for connection.

There are six PG cable glands at the bottom of the controller. The specifications of the PG cable glands are PG21

(four pieces) and PG29 (two pieces).

2.2.2 Mechanical Installation

The controller supports wall installation mode.

Wall installation

When determining the installation position of the controller, make sure that there is an 800mm maintenance

clearance in the front. The installation method is shown below:

1. Use M4 8 bolts to install the four brackets onto the controller.

2. Drill holes and install M10 16 expansion bolts on the wall according to the dimensions shown in Figure 2-1.

290240

520

478

420

Figure 2-1 Wall installation dimensions (unit: mm)

3. Connect the brackets with the expansion bolts, and then use the nuts to fasten them.

2.2.3 Cable Connection

The controller uses bottom cabling method. The connection positions are shown in Figure 2-2.



Communication port

Connected to

temperature sensor

Connected to array

1 negative cable

Grounding

Connected to battery

Dry contact input

Dry contact output

Connected to load

Connected to all

Connected to array

2 negative cable

negative cable

negative cable

positive cables

Figure 2-2 Cable connection of the controller

Note

1. To ensure safety, users should check the polarities of the cables against those of the batteries and pull out the battery fuses

before connecting battery cables.

2. After the check, connect the positive battery cables to the positive busbar. Connect the negative battery cables to the negative

terminals of the battery fuses.

3. Check again to ensure that the polarities of the cables connected to the positive busbar and battery fuses are correct.

Warning

Reverse connection of the battery might cause the battery to burn or other major failures, and even endanger personal safety.

Only professionals are allowed to connect the batteries. During the operation, pay attention to polarities and prevent short circuit

to ensure personal safety.

Connect cables according to the information shown in Table 2-4.

Table 2-4 Description of cable connection

Cable Color Amount Connection

From To

Array input cable

Positive (+) Black 12 Positive pole of the array Positive busbar of the controller (12

routes)

Negative (-) Blue 12 Negative pole of the array Negative array terminal of the

controller (12 routes)

Battery cable

Positive (+) Black 1 Positive pole of the battery string Positive busbar of the controller (1

group)

Negative (-) Blue 1 Negative pole of the battery string Negative battery terminal of the

controller (1 group)

Output cable

Positive (+) Black 4 Positive busbar of the controller (4

routes) Positive pole of the load

Negative (-) Blue 4 Output terminal MCB of the

controller (4 routes) Negative pole of the load

Communication

cable 1

T+ / 1 Controller J18 Other monitor devices

T- / 1 Controller J18 Other monitor devices

R+ / 1 Controller J18 Other monitor devices

R- / 1 Controller J18 Other monitor devices



Cable Color Amount Connection

From To

Communication

cable 2

(cooperation

mode)

CAN+ / 1 Power system CAN+ Controller CAN+

CAN- / 1 Power system CAN- Controller CAN-

Auxiliary power

cable J21 Blue-black 1 Connected in controller J21 on main board

Grounding bar Metal 1 Positive busbar of the controller Grounding terminal of the controller

casing

Grounding cable Yellow-green 1 Grounding screw of the controller

housing Ground or support

Note:

1. The positive busbar of the controller is not connected to the grounding terminal of the controller casing at factory, you can choose

the grounding method according to the actual requirement.

2. You should lead the cables through the PG cable glands at the bottom, and then crimp the cable tap. The positive busbar uses

OT lugs for connection. For Negative poles, you can use H shape terminals for connection.

3. The load cable is provided by the equipment that uses power. For larger load, do not use two or more controllers to connect one

load simultaneously.

4. Colors of the cables can be adjusted on site according to the actual situation. Make sure that all the MCBs and loads are

disconnected before the cable connection

2.2.4 Sealing Cable Entry Holes

For outdoor controllers, you should seal all the cable entry holes after the installation. The procedures are as follows:

For the used holes, tighten them with PG cable glands.

For the holes with a small cable or with several cables, tighten them with PG cable glands and seal them with

waterproof mud (accessory).

For the unused holes, block them with rubber plugs and seal them with waterproof mud.

2.3 Commissioning

2.3.1 Check Before Power-on

Check the items given in Table 2-5. Ensure that the components are installed firmly and the cables are connected

reliably.

Table 2-5 Checking items before power-on

Type Item Content

Array Input Input cables

The polarities are correct. The connections are reliable. All the input and

output MCBs are switched off

Between positive and negative terminals No short circuit

Load output Output cables

The polarities are correct. The connections are reliable. All the input and

output MCBs are switched off


Battery Battery cables The polarities are correct. The connections are reliable


2.3.2 Power-on And Commissioning

The procedures for powering on and commissioning the controller are as follows:

1. Battery polarity check and power-on

Check that the polarities of the two batteries are correct, and then switch on the battery MCB. Meanwhile the auxiliary

power of the monitoring board in the controller starts to work. The controller starts self-test. After the self-test, the first

information screen will appear, as shown in Figure 2-3.



2009-07-01

55.2V 4.6A

No Alarm

Auto Discharge

Figure 2-3 First information screen

Check the indicator status of the controller. When the red and yellow indicators are off, it means that everything is

normal. If the red indicator and yellow indicators are on, you can remove the alarms according to Table 1-3.

When the checks are normal, switch on the array input MCB.

2. Load polarity and connection check

Check that the connection of the load output cables, the MCB connection of the load and the polarities of the load are

correct. After ensuring that everything is OK, go on to the next step.

3. Battery busbar voltage measurement

Use a multimeter to measure the battery busbar voltage. If the busbar voltage is within the normal output range (48V

~ 55V), switch on one load MCB. Check that the battery busbar voltage is within the normal range after the load

starts up and works normally. If the busbar voltage is close to 47V, do not switch on the next load MCB until the

batteries are properly charged. Repeat the operation until all the loads are powered on and work normally.

4. Parameter setting

Set the parameters according to the parameter card delivered with the controller.

Enter the corresponding operation interface and input the correct password to set the parameter, see 3.4 Setting

Parameters.

Note

1. If users do not reset certain parameters, the controller will use the default settings.

2. For significant parameters, it is recommended to use default settings if not specified.

1) Battery parameter

Set the battery capacity, busbar overvoltage alarm point, busbar undervoltage alarm point and busbar undervoltage

protection point in accordance with the actual battery configuration.

If the controller is configured with a battery temperature sensor, you need to set the battery overtemperature alarm

point and battery overtemperature protection point. If not, you do not need to set these parameters.

2) System control mode

The controller provides two array control modes: ON/OFF and PWM. You can select one control mode according to

your need. The ON/OFF mode is recommended.

3) Local address: 1 (default).

4) Date and time: In accordance with the actual time and date.

5) For setting jumpers of the board card, see Table 2-6. Use the default settings listed below.

Table 2-6 Jumper setting of the board card

SN. Screenprint Parameter Settings Default

1 GP1 Communication mode Pins 1, 2 short-circuited: RS422; pins 2, 3

short-circuited: RS485 RS422

2 J2 Output dry contact 1 Pins 1, 2 shorted: normally open; pins 2, 3 shorted:

normally closed Normally open

3 J3 Output dry contact 2 Pins 1, 2 shorted: normally open; pins 2, 3 shorted:

normally closed Normally open

6) Array parameter

For the array open-circuit voltage too high alarm point and input overcurrent alarm point, set these parameters

according to the actual maximum open circuit voltage and the short circuit current of the arrays, and the allowable

setting range listed in Table 1-3.

5. Alarm check



After the parameter settings, the system status should be No alarm. If the system status is Alarm, query the

corresponding alarm and do troubleshooting by referring to 3.3 Querying Active Alarm.

6. History alarm clearing

Clear all history alarms generated during the commissioning by referring to 3.6 Querying History Alarm.

7. Return to the system information screen

Press the ESC key to return to the system information screen.

2.4 Final Steps

After the installation and commissioning, fill the parameter settings in the parameter card.

Clear the installation field. Sort the accessories and store them properly.

Lock the controller cabinet. Keep the key.

Chapter 3 Use Of Monitoring Board 13


Chapter 3 Use Of Monitoring Board

This chapter introduces the use of the monitoring board, including the monitoring board introduction, querying

information, control and setting parameters.

3.1 Monitoring Board Introduction

The monitoring board of the controller is shown in Figure 3-1.

ESC

ENT

Run indicator

Alarm indicator

Critical alarm indicator

Functional keys

LCD

Figure 3-1 Monitoring board

Description of the indicators is in Table 3-1.

Table 3-1 Description of indicators

Indicator Color Normal state Fault state Fault cause

Run indicator Green On Off No operation power supply

Alarm indicator Yellow Off On At least one observation alarm

Critical alarm indicator Red Off On At least one major or critical alarm

The monitoring board uses a 128 64 LCD and a keypad with 6 functional keys. The interface language is

Chinese/English optional. Description of the functional keys is listed in Table 3-2.

Table 3-2 Description of functional keys

Keys Functions

ESC Return key: Press this key to go back to previous menu At the first information screen, press the ESC key and

you can see the software version information

ENT Confirmation key: Press this key to go to next menu or validate

the change made to a parameter setting

After a change, only pressing the ENT key can validate

the change

Press or to scroll through the menus. When the editable

options are character strings, pressing or can edit values

Four arrow keys can be used to change the parameter

value: Press or to move the cursor to the

parameter to be changed and press or to change

the parameter value

Press or to move the cursor

3.2 Querying Status

The system information can be queried from the information screen. For the first information screen, see Figure 3-2.

2009-07-01

55.2V 4.6A

No Alarm

Auto Discharge

Figure 3-2 First information screen

The first row displays the current date and time alternately. The second row displays the busbar voltage and the load

current of the controller. For example, 55.2V is the busbar voltage and 4.6A is the load current. The third row displays

the controller state, which is No alarm or Alarm. The fourth row displays the control mode and battery state. The

control mode includes Auto and Manual. The battery state includes BC, FC and discharge.

14 Chapter 3 Use Of Monitoring Board


Press continuously at the first information screen, you can query the information listed in Table 3-3.

Table 3-3 Querying information

SN. Status Content

1 Batt Volt The present battery voltage

2. Load Current The present load current

3. Operation Status Auto or Manual

4 PV State On, Off or PWM

5 PV OpenVolt The actual array voltage

6 PV Current The array real-time current

7 Battery Current The present battery current

8 Battery Temp The present battery temperature

9 Batt Remain Cap The present remaining battery capacity

10 Sys Run Time The total system run time

11 Batt Chrg Times The total battery charge times

12 Batt Disc Times The total battery discharge times

13 Daily Chrg Cap The total charge capacity of the day

14 Daily Disc Cap The total discharge capacity of the day

15 PV Input Cap The accumulated array input capacity

16 Load Output Cap The accumulated load output capacity

17 Max Batt Temp The maximum battery temperature of the day

18 Min Batt Temp The minimum battery temperature of the day

19 Max Batt Volt The maximum operating voltage of the day

20 Min Batt Volt The minimum operating voltage of the day

21 AUX Chrg State The present auxiliary charge state. Available when auxiliary charge is enabled

22 Current Chrg Time The current auxiliary charge time. Available when auxiliary charge is enabled

23 Total Chrg Time The accumulated auxiliary charge time. Available when auxiliary charge is enabled

24 AC Power State Available when cooperation mode is enabled

25 AC Power Load Cur Available when cooperation mode is enabled

26 AC Input Cur Available when cooperation mode is enabled

27 Rect Curr Available when cooperation mode is enabled

After querying all the information, press continuously to return to the first information screen, or press the ENT key

to enter the main menu screen, as shown in Figure 3-3.

Settings

Maintenance

Active Alarm

History Alarm

Figure 3-3 Main menu screen

3.3 Querying Active Alarm

1. Select the Active Alarm option from the main menu screen, as shown in Figure 3-4.

Active Alarm

Settings

Maintenance

History Alarm

Figure 3-4 Main menu screen: Active Alarm highlighted

2. Press the ENT key to enter the active alarm screen and view the active alarms, as shown in Figure 3-5.

Active Alarm 1

LLVD

09-07-01 20:3015:

Figure 3-5 Active alarm screen



3. Press at the active alarm screen, you can query all the active alarms. Press the ESC key to return to the main

menu screen.

3.4 Setting Parameters

1. Press at the main menu screen to select the Settings option, as shown in Figure 3-6.

Settings

Maintenance

History Alarm

Active Alarm

Figure 3-6 Main menu screen: Settings highlighted

2. Press the ENT key to enter the password confirmation screen, as shown in Figure 3-7.

Enter Password:

100000

Figure 3-7 Password confirmation screen

3. Enter the password: 100000.

To enter the password, press or to modify numbers, and press or to move the cursor. After entering the

password, press the ENT key to confirm the password and enter the settings screen, as shown in Figure 3-8.

1000Ah

Batt Capacity:

Batt OverVolt:

58.5V

Figure 3-8 Settings screen

Press continuously at the settings screen, you can query and set the parameters listed in Table 3-4.

Table 3-4 Setting parameters

SN. Parameter name Setting range Default

1 Batt Capacity 50Ah ~ 5000Ah 300Ah

2 Batt OverVolt BC voltage + 1.5Vdc (min. 58.0Vdc) ~ 60.0Vdc 58.5Vdc

3 Batt LowVolt LLVD + 0.5Vdc (min. 46.0Vdc) ~ 50.0Vdc 47.0Vdc

4 LLVD BLVD + 0.5Vdc (min. 45.5Vdc) ~ Batt LowVolt - 0.5Vdc

(max. 48.5Vdc) 46.5Vdc

5 BLVD 45.0Vdc ~ LLVD - 0.5Vdc (max. 48.0Vdc) 46.0Vdc

6 B-HighTemp Alm 35C ~ B-OverTemp Prot - 10C (max. 60C) 50C

7 B-Temp Prot EN Yes, No No

8 B-OverTemp Prot 45C ~ 70C 60C

9 Boost Chrg Volt 54.2Vdc (Float Chrg Volt + 2.2Vdc) ~ 57.5Vdc (HighVolt

Alarm - 1.5Vdc) 56.4Vdc

10 Float Chrg Volt 52.0Vdc (FC to BC Volt +1.5Vdc) ~ 56.3Vdc (Boost Chrg

Volt - 2.2Vdc) 53.5Vdc

11 Dry Contact NO, NC NO

12 DryCont Output 1

Array lost, battery undervoltage, battery circuit open,

LLVD, battery overtemperature, controller fault, auxiliary

charge

Controller fault

13 DryCont Output 2

Array lost, battery undervoltage, battery circuit open,

LLVD, battery overtemperature, controller fault, auxiliary

charge

Battery undervoltage

14 AUX Charge Mode Voltage mode, time mode Voltage mode

15 AUX Trigger Time 00:00 ~ 23:30 20:00

16 AUX Run Time 2h ~ 18h 10h

16 Chapter 3 Use Of Monitoring Board


SN. Parameter name Setting range Default

17 Temp Comp Set Yes, No Yes

18 Temp Comp Coeff 0 ~ 100 (mV/C.S) 72 (mV/C.S)

19 Address 1 ~ 254 1

20 Clear History Yes, No No

21 Reset parameter Yes, No No

22 Date & Time Yes, No No

23 Language Chinese, English English

24 Charge Mode PWM, ON/OFF ON/OFF

25 Cooperator None, AC None

3.5 Maintenance

1. Press at the main menu screen to select the Maintenance option, as shown in Figure 3-9.

Maintenance

History Alarm

Active Alarm

Settings

Figure 3-9 Main menu screen: Maintenance highlighted

2. Press the ENT key to enter the password confirmation screen, as shown in Figure 3-10.

Enter Password:

200000

Figure 3-10 Password confirmation screen

3. Enter the password: 200000.

To input the password, press or to modify numbers, and press or to move the cursor. After entering the

password, press the ENT key to confirm the password and enter the maintenance screen, as shown in Figure 3-11.

Modify Mode:

Auto

Figure 3-11 Maintenance screen

4. Press to change Auto into Manual, and press the ENT key to confirm the setting.

In the manual mode, you can perform the following array controls described in Table 3-5.

Table 3-5 Control parameters in manual mode

SN. Control parameter Setting range

1 Array 1* On, off

2 Array 2* On, off

3 Load 1 Reconnect, disconnect

4 Load 2 Reconnect, disconnect

5 AUX Charge On, off

Note*: The Array 1 and Array 2 will do the same operation, that is, when Array 1 is switched on, Array 2 will be on too



In the manual mode, the screen shown in Figure 3-12 will appear.

2

Array 1:On

Array 2:On

Figure 3-12 Array control screen

3.6 Querying History Alarm

1. Press at the main menu screen to select the History Alarm option, as shown in Figure 3-13.

History Alarm

Settings

Maintenance

Active Alarm

Figure 3-13 Main menu screen: History Alarm highlighted

2. Press the ENT key to enter the history alarm screen and view the history alarms, as shown in Figure 3-13.

History Alarm 1

Array 2 Fail

09-07-01

09-07-01

:20:3015

:20:3016

Figure 3-14 History alarm screen

3. Press continuously at the history alarm screen, you can query all the history alarms. Press the ESC key to return

to the main menu screen.

18 Appendix 1 Wiring Diagram


Appendix 1 Wiring Diagram

J1H1

2

1 1

2 2

11

2 2

11

2

2 11 2 3 4

12

34

56

78

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 4 3 2 1

Door

Chassis

U116

SPD4

BUS+

12

PE13

M11

M22

QFD6

QFD7

QFD8

QFD9

QFD10

QFD11

J301 J17

J9

J12

J5J6J8J7

5 6 7 8 9 10

1 2 3 4

J18 J11

1 2 3 4

J4

3 2 1

J15

1 2

1 2

J4

J3J5

H2

H1

M13

J3

12

34

56

78

J19

1 2

12

34

56

78

J6

W10

W2

W7

W4W5 W5

W 8 W9

W1 W2

W3

W8 W9 W6 W11

W7

W11

91

0

1-J

3-2

1-J

3-1

1-J

3-5

1-J

3-6

1-J

3-7

1-J

3-8

2-J

6-1

2-J

6-2

2-J

6-3

2-J

6-4

2-J

6-5

2-J

6-6

2-J

6-7

2-J

6-8

2-J

6-9

2-J

6-1

0

9-110-1

7-18-1

4-v-2

1 6 - J 6 -1

1 6 -J 6 -21 6 - J 6 -31 6 - J 6 -41 6 -J 6 -5

1 6 - J 6 -61 6 - J 6 -7

1 6 -J 6 -8

1 6 -J 6 - 1 01 6 -J 6 -9

18

-V-2

,2-J

10

4-V

-2,8

-21

6-J

12

-4

16

-J1

2-5

16

-J1

2-1

16

-J1

2-2

18

-V-1

7-2

4-V

-1,1

0-2

9-2

2-J

5

16

-J5

-3

H2

J3

16-J7-116-J7-2

16-J7-8

16-J7-516-J7-616-J7-7

18-12

6-1

11

-1

W6

W 4

13

18

-V+

12

2 1

1 2

1 2

W 11 W11

W 11

16

-J2

1

16-J9

J21

J10

J8

J7

J2

J9

W11

2-J8 2-J7

2-J9

1-H2

4-V

+

1 2 3 4

J18A

J13

W 8

16-J6-116-J6-2

16-J6-8

16-J6-516-J6-616-J6-7

2

1

W1

18

-V-2

12

34

56

78

J11

SPD18

W8

3-J

3-2

3-J

3-1

3-J

3-5

3-J

3-6

3-J

3-7

3-J

3-8

QFD17

16

-J5

-4

18

-V-1

,2-J

11

12

4-V

+

W3

W1 W2

17

-2,1

-H2

6-2

,3-H

2

V-1V-2

12 11V+

12

-13

, 2

-J2

16

-J1

2-7

4-1

2

W7W3

W5 W5

8-2

,2-J

-4

10

-2,2

-J3

V-1V-2

12 11V+

12

-12

, 2

-J2

18

-11

16

-J1

2-8

W7W3

4-v-1

3-H2

J301-2

11-2

2-J

8-1

2-J

5

17

-1

18-v

+

W3

16

-J5

-1

16-J

301-1

4-11

Figure 1 Wiring diagram

Appendix 2 Glossary 19


Appendix 2 Glossary

AC Alternating current

BC Boost charge

BLVD Battery low voltage disconnection

CSA Cross-sectional area

DC Direct current

DG Diesel generator

EMC Electromagnetic compatibility

FC Float charge

I/O Input/output

LCD Liquid crystal display

LLVD Load low voltage disconnection

LVD Low voltage disconnection

NC Normally closed

NO Normally open

PCB Printed circuit board

PV Photovoltaic

PWM Pulse-width modulation

SPD Surge protective devices

Documents

Emerson NetShine 101 CA1