Instruction Manual for SP PRO Interactive Inverter Charger Operation • Installation • SP LINK • Service
Selectronic Australia Pty Ltd © 2013 Suite 5, 20 Fletcher Rd Chirnside Park VIC 3116 Australia Ph +61 3 9727 6600 Fax +61 3 9727 6601 www.selectronic.com.
OPERATION Thank you for purchasing a Selectronic SP PRO series sine wave Interactive Inverter Charger. Selectronic has an accredited Quality Assurance system to AS/ISO9001-2008 covering both their manufacturing and design operations with over 25 years experience designing power conversion equipment for both domestic and industrial purposes. As a result Selectronic has had many opportunities to listen to both integrators and system owners to determine their real needs.
Contents Contents O P E R AT I O N Australian/New Zealand Warranty Using This Manual Included in this package Benefits of SP LINK Glossary of Terms Precautions and Safety Who should install this unit Multiple Hazardous Energy Sources Preparation Installation Maintenance Inverter or Generator may start automatically Battery 6 6 7 7 7 8 8 8 9 9 9 9 9 SP PRO System Integration 10 Controls and Indicators 14 SP PRO Operation 16 Off Grid Stand Alone Power Systems (SPS) Mobile Systems Solar Hybrid Su
Contents I N S TA L L AT I O N Installing for PRO Performance Preparation Residual Current Device (RCD) Type Recommendation Solar Hybrid (On-Grid) Preparation Off Grid Preparation Mobile Preparation Battery Wiring Preparation Installation of SPMC models Battery Cabling Requirements Fusing DC Wiring AC Wiring Earth Wiring SPMC1201 Expansion Card Warning Current Shunt Wiring Battery Temperature Sensor Generator Control Wiring Serial Port Connection Gland Plate Fitout Initial Start up Procedure Labelling In
OPERATION | Warranty and manual use Australian/New Zealand Warranty Your Selectronic SP PRO product is warranted by the manufacturer to the original purchaser only. The manufacturer will bear the cost of parts and labour to repair any faults found within the terms and period of this warranty. For full warranty terms and conditions please see the warranty card packed with your SP PRO inverter.
OPERATION | This Package and SP LINK Included in this package • • • • • • • • Mounting bracket Rear Outlet Mesh Cover (SPLC models only) Contents check list, checked and signed by Selectronic Know Your SP PRO display quick reference card Warranty card. Tool kit - (Hex Drive bits - T10 Torx, T20 Torx, T25 Torx, 5 mm Hex, 6 mm Hex, long extension) SP LINK software packed on USB Memory device USB Cable - Type B Benefits of SP LINK Provided with your SP PRO inverter is a free copy of the SP LINK software.
OPERATION | Precautions and Safety Precautions and S a fe t y Chapter One Who should install this unit While the SP PRO is designed for easy installation and can be installed by any suitably qualified person, to maximize the performance of your system and tailor the configuration of the SP PRO to your specific needs we recommend you use a Selectronic Authorised Integrator.
OPERATION | Precautions and Safety Preparation Whilst every effort has been made to pack the SP PRO in a way that will provide adequate protection, damage in transit can occur. Please carefully check the packaging and the SP PRO for signs of damage and for all components mentioned in the “Included in the Package” section of this manual. Please report any damage or missing parts to Selectronic or your Selectronic Authorised Distributor.
OPERATION | System Integration SP PRO System I n t e gr a t i o n Chapter Two Your SP PRO Sine wave Interactive Inverter Charger can be used in a number of different applications including off grid systems (SPS - where no mains grid is available), in mobile applications such as motor homes and boats or in Solar Hybrid (grid support / grid feed) systems. Off Grid Stand Alone Power Systems (SPS) The SP PRO is the heart of your power system.
OPERATION | System Integration With the generator running, the SP PRO will automatically charge the battery bank. The SP PRO charges the batteries in five stages (Initial, Bulk, Absorb, Float and Equalise) to ensure maximum energy is returned to the battery bank in the shortest possible time. The SP PRO will periodically perform an equalise charge after the completion of the normal charge cycle to keep the battery bank in good condition.
OPERATION | System Integration Mobile Systems The SP PRO can support either an on board generator (Primary AC Source) or shore power(Alternate AC Source). Both input power levels can be configured into the SP PRO and selected with an external switch. Solar Hybrid Support and Grid Feed Systems In Solar Hybrid, the renewable energy can be directed to power the AC load, recharge the battery bank and/or export to the grid.
OPERATION | System Integration Battery Sizing Sufficient battery capacity is imperative for optimum operation of your system. Working out the correct battery pack size that will suit your needs involves a number of factors including the daily discharge required for your system. A rough “rule of thumb” is to start with the expected daily energy required from your battery bank (in kilowatt hours or kWh) and multiple this by 1000.
OPERATION | Controls and Indicators Controls and I n d i c a to r s Chapter Three 1 2 3 4 13 5 12 6 11 7 10 9 8 User Interface The following page is a list of the SP PRO control and indicators which correspond to the labelled image above.
OPERATION | Controls and Indicators 1 AC Source * When illuminated,this shows the presence of AC supply voltage from either a motor generator or the mains grid, whichever is applicable. This is powered directly from the incoming AC supply. 2 Transfer * Illuminated when an external AC supply is connected through to the AC LOAD output.
OPERATION | SP PRO Operation SP PRO Operation Chapter Four The following section describes in detail the operation of the SP PRO. A good understanding of the operation of the SP PRO and its parameters will enable you to configure the SP PRO to meet the system design requirements. The SP PRO Battery management continuously monitors the system operation. This monitoring allows the SP PRO to ensure the batteries are correctly charged to maximise system reliability.
OPERATION | SP PRO Operation The SP PRO may be configured to use the grid or automatically start the generator when a battery charge cycle is required. It is important that the battery manufacturer’s recommendation be adhered to for ongoing monitoring and maintenance of batteries.
OPERATION | SP PRO Operation Battery Charging Operation The SP PRO charging system manages all charging sources in the power system giving priority as appropriate to the renewable energy sources. This ensures that the renewable sources are used in the most cost effective manner. The SP PRO continuously monitors all charging sources to recharge the battery in a five-stage cycle. Each stage or Charging Mode is controlled by voltage, current and time settings.
Battery Voltage Battery Current Charging Stage Initial Initial Time Initial Voltage Bulk Time Absorption Voltage Absorb Battery Charging Cycle Charging Bulk Bulk Current Initial Current Bulk Voltage Absorb Current Absorption Time Float Voltage (Equalise ) Float Equalise Current Equalisation Time Equalise Voltage Time OPERATION | SP PRO Operation Doc #OI0003 Part #004122 Rev 12 2013 | 19
OPERATION | SP PRO Operation Battery Temperature The SP PRO monitors the battery temperature via the sensor provided. The supplied battery temperature sensor must be mounted in thermal contact with the centre of the side of the battery. If the sensor is not in thermal contact with the battery bank the batteries will not be correctly charged. Check battery temperature is reading correctly in the Temperature Control section of Technical Data in SP LINK.
OPERATION | SP PRO Operation Automatic Generator Control The SP PRO may be configured to automatically control a generator in either an Off Grid power system or Solar Hybrid power system with generator backup (using the optional “Grid fail - Gen backup” module). The generator may be automatically started by the SP PRO as required to supply the load and charge the battery bank or be configured to allow manual control of the generator by the user.
OPERATION | SP PRO Operation Renewable Assist: If your system has been designed in such a fashion that the input from your renewable sources (solar, wind or other source) will always be lower than your usual daily power usage it is possible to start the day with a generator run period that will make up the shortfall. This ancillary charge is determined by Start SoC% and Stop SoC%.
OPERATION | SP PRO Operation Generator Scheduling Two schedule types are available each with four configurable start and stop times. Run Schedule For generator running intended to accommodate day to day peak load periods. While the SoC method of generator control is recommended to efficiently and reliably maintain the battery charge, generator schedules may be used as an alternative generator control method or as an adjunct to SoC control to cater for expected loads.
OPERATION | SP PRO Operation Remote Run Input The Remote Run switch operates as follows: • • A switch closure longer than 0.5 seconds and shorter than 2 seconds causes the SP PRO to start the generator. Another such closure stops it, else it is stopped automatically when the battery reaches full charge and any sustained large load ceases. The switch is typically a non latching push button.
OPERATION | SP PRO Operation Environmental Considerations Temperature Your SP PRO is designed for an ambient operating temperature between -20°C and 60°C, with a storage temperature range between –20°C and 70°C. AIR FLOW For best performance ensure nothing impedes ambient air from being drawn in the bottom of the unit and that hot exit air is vented away and doesn’t recirculate into the unit. Particular attention must be paid when installed inside a cabinet or enclosure.
OPERATION | Communications SP PRO Communications Chapter Five The SP PRO provides two isolated serial communications ports for monitoring and controlling the SP PRO and KACO devices. Each port has specific functions and are provisioned via different electrical interfaces dependant on the application. Only one type of electrical interface per serial port can be used at any one time. Either port can be used to connect to SP LINK via a local PC or another communications device.
OPERATION | Communications Port 2 Setup The SP PRO Port 2 is provisioned via two internal interfaces; an RS232 RJ45 Serial connector and and RS485 RJ45 Serial connector. Only one interface may be connected to and used at any one time. If one of the interfaces is being used and connection is required via either of the other two, the unwanted interface must be unplugged otherwise both interfaces will interfere with each other and communications will not be established.
INSTALLATION | Installing for PRO Performance INSTALLATION Installing fo r P R O Performance Chapter Six Many procedures covered in the INSTALLATION section of this manual have inherent risks. Whilst the SP PRO is designed to be safe, including safety features never before found in an inverter (such as Earth / Neutral bond monitoring), the fact remains that the voltages connected to or generated within the SP PRO are hazardous and potentially fatal. This very important point can never be stressed enough.
INSTALLATION | Installing for PRO Performance Residual Current Device (RCD) Type Recommendation The SP PRO produces a low distortion sine wave output via 50/60 Hz isolation transformer. This topology ensures that the output is sinusoidal and that their is no DC component associated with the SP PRO AC supply, whether that be feeding a domestic load or exporting solar to the grid. Standard Type AC RCDs are suitable for use with an SP PRO. Other types of RCDs may also be used with the SP PRO.
INSTALLATION | Installing for PRO Performance Off Grid Preparation The intended application and use of the SP PRO must be well understood to allow the SP PRO to be appropriately connected to the installation. The following diagram shows AC wiring only and indicates the generator connection and feed into the Switchboard.
INSTALLATION | Installing for PRO Performance Battery Wiring Preparation Battery wiring to the SP PRO is common, regardless of the application. The below schematic diagram shows the main battery isolator, battery sense isolator and included temperature sensor.
INSTALLATION | Installation of SPMC models Installation of SPMC models 1 - Unpack the SP PRO onto a flat surface. When removing the SP PRO from its packaging carefully inspect for any damage that may have occurred in transit. Damage must be reported to your supplier immediately. 3 - Mount the SP PRO on the mounting plate by first hooking the top of the inverter over the projections on the mounting plate and lowering it into position. Care should be taken to observe Pinch Point warning.
INSTALLATION | Installation of SPMC models 7- Wiring must only be carried out by suitably qualified installers and must adhere to all relevant standards. Detailed instruction for wiring the SP PRO are contained on the following pages. These MUST be followed before proceeding with installation. 8 - Important points • Failure to fill any holes in rear gland plate (A) or lower gland plate (B) will reduce IP rating and compromise thermal design.
INSTALLATION | Installation of SPMC models Battery Cabling Requirements Minimum Recommended Copper Battery Cable Sizes Total distance of one conductor from the SP PRO to the battery terminals Minimum Size Copper Battery Cables based on cable loss < 2% ( V90 or V-90HT insulation ) SPMC240 SPMC241 SPMC481 SPMC482 SPMC1201 <2m 50 mm2 70 mm2 50 mm2 50 mm2 35 mm2 2-5m 70 mm2 50 mm2 x 2 50 mm2 70 mm2 35 mm2 5 - 10 m N/A N/A 70 mm2 70 mm2 x 2 50 mm2 > 10 m N/A - NOT RECOMMENDED V90 or V
INSTALLATION | Installation of SPMC models DC Wiring The SP PRO does NOT contain an internal fuse or DC breaker. The DC wiring must be fitted with appropriate fusing or circuit breakers. The fuse or circuit breaker must be located in a user accessible position and be in close proximity to the battery system. The battery system must not be accessible by the user. There are four DC wiring connections that should be made. B+ and B-, Battery Sense / Pre Charge and optional MID point monitoring.
INSTALLATION | Installation of SPMC models SPMC1201 Expansion Card Warning SPMC1201 models - Hazardous Voltage - 120 V Battery Expansion card connects to both Hazardous and Safety Extra Low Voltage (SELV) wiring. The connector and wiring to J4 (marked in RED) MUST be treated as Hazardous and be physically segregated from other wiring connected to expansion card. Protective cover MUST be installed on the Expansion card.
INSTALLATION | Installation of SPMC models Generator Control Wiring Generator control wiring should be fed up through the appropriate gland and terminated to the SP PRO Expansion card. The minimum required is one pair of wires for a generator run signal which must be wired to one of the four relay outputs. “CAT5” type cabling or any multi conductor multi strand cable is suitable for all control wiring. The Expansion Card can be plugged in and out of the SP PRO for ease of wiring.
INSTALLATION | Installation of SPLC models Installation of SPLC models 38 1 - Undo ten bolts (7/16“) to remove lid. Cardboard tray contains mounting plate, rear air outlet mesh cover and all documentation. Inspect for damage in transit and report any to your supplier immediately. 2 - Cable entry is either from below or wall entry. Gland plates are inter changeable . Gland plates secure to the underside of unit base or to the inside of the mounting plate using four T10 Torx screws.
INSTALLATION | Installation of SPLC models 7- Undo five T10 Torx screws to remove terminal plate. Note: Gland plate shown in wall entry cable position. Expansion card not shown for clarity. 8 - Wiring can only be carried out by suitably qualified installers and must adhere to all relevant standards. Installations performed and signed off by a Selectronic Accredited Integrator will benefit from an additional warranty cover.
INSTALLATION | Installation of SPLC models Battery Cabling Requirements Minimum Recommended Copper Battery Cable Sizes Total distance of one conductor from the SP PRO to the battery terminals Minimum Size Copper Battery Cables based on cable loss < 2% (V90 or V-90HT insulation ) SPLC1202 <5m 50 mm2 5 - 10 m 70 mm2 > 10 m NOT RECOMMENDED V90 or V-90HT insulated cables are required to be spaced apart by at least the diameter of the cable.
INSTALLATION | Installation of SPLC models DC Wiring The SP PRO contains a 250 A DC circuit breaker and a low current Battery Sense / Pre charge DC switch. It may be necessary to fit additional fusing or circuit breakers to protect the battery system. Any additional fuse or circuit breaker must be located in a user accessible position and be in close proximity to the battery system. The battery system is hazardous and must not be accessible by the user.
INSTALLATION | Installation of SPLC models Expansion Card Warning Hazardous Voltage - 120 V Battery Expansion card connects to both Hazardous and Safety Extra Low Voltage (SELV) wiring. The connector and wiring to J4 (marked in RED) MUST be treated as Hazardous and be physically segregated from other wiring connected to expansion card. Protective cover MUST be installed on the Expansion card.
INSTALLATION | Installation of SPLC models Serial Port Connection The communication cable can be attached to either the USB or DB9 connections on the lower panel. Serial communication connections are galvanically isolated from the battery. Gland Plate Fitout To maintain the IP rating and safety approval of the SP PRO, all gland plate holes must be completely filled. Gland plates supplied with the SP PRO have “knock outs” for your convenience.
SP LINK | Using SP LINK SP LINK Using S P LINK Chapter Seven Overview “SP LINK is the pathway to the real power of your SP PRO” SP PRO is really many products in one. You can simply unpack the unit, mount it on a wall, connect the appropriate cables – and you’ve got power using the following default settings; • Off Grid • AC Source size is equal to the power output of the SP PRO model you are using • Sealed Batteries • No State of Charge readings, voltage only.
SP LINK | Using SP LINK SP PRO Firmware Version 7.0 onwards This SP LINK manual details configuration parameters and options found in SP PRO firmware version 7.0 onwards. Some parameters are no longer supported and are not detailed within this manual. Please refer to prior SP LINK manual for details of unsupported features. SP LINK is fully backward compatible with all prior versions of SP PRO firmware.
SP LINK | Using SP LINK When working with SP LINK you may require a refresher course on the function of some of the settings or hints about the function of a screen. Simply right click most headings and tabs and a pdf copy of the SP LINK manual will appear on the right hand side of your screen displaying the relevant section. You can also access both the SP PRO manual(this document) and SP LINK manual from the Help menu at any time.
SP LINK | Using SP LINK It is also helpful to place photos of the various system components under the “Components” tab to assist in the future system maintenance. Under the Connection settings tab you will need to select the Connection Type method to connect to the SP PRO. If you are simply going to plug your computer into the SP PRO then select Direct. Login Password A Login Password is required for connecting to the SP PRO. SP LINK can only connect through to the SP PRO with the correct password.
SP LINK | Using SP LINK Preparing a new configuration You can now start to prepare your Configuration. The SP PRO configuration is stored in a file within the site file and contains all of the SP PRO settings for transferring into the SP PRO. This can be done after you connect SP LINK to the SP PRO (see “Connecting to your SP PRO” ). Click on the Configuration settings tab. The SP PRO is a very advanced and intelligent product but don’t let the large number of settings concern you.
SP LINK | Using SP LINK The following tables have a minimal list of settings to consider for each particular application. SOlar Hybrid (on grid) grid backup settings setting AC Source Disconnect Alarm configuration tab System SoC Shutdown Periodic Recharge Inverter Battery comments Enable to alert users that system is running on battery supply The grid backup battery limit point Recharge self discharge losses in batteries held in Float for long period of time.
SP LINK | Using SP LINK Saving a new configuration Your configuration settings should now be saved to file before sending them to the SP PRO. To save the SP PRO configuration settings, click on File - Configuration Settings - Save. The configuration settings will be saved in the same location with the site information saved in the previous step. SP LINK will automatically use the default file name Config1 prefixed with the site name. The configuration settings are now stored on your computer.
SP LINK | Using SP LINK Configuring your SP PRO With SP LINK connected to the SP PRO, Click Configure SP PRO from the File - Configuration Settings menu or from the Configuration Setting page. SP LINK will - unless “Get SP PROs Configuration” has just been performed - warn that all settings will be overwritten. For security purposes, to ensure no-one can tamper with your SP PRO, you will now be asked to enter your passcode. The default passcode is 74, however you can alter this if you wish.
SERVICE | Service and Maintenance SERVICE Service and Maintenance Chapter Eight If fan filter cleaning is required: 1. Ensure fan is stationary 2. Remove the four retaining screws that hold the fan filter in place. 3. Clean the filter mesh with a soft brush or similar implement. 4. Replace filter and tighten the four retaining screws. All other maintenance on your SP PRO should be performed by a Selectronic Accredited Integrator. Above the fan filter is a safety grill.
SERVICE | Service and Maintenance Maintenance of your SP PRO Very little is required in order to maintain your SP PRO, however following the steps below will ensure smooth operation of the system. • • Cleaning. Large particles of dirt can be removed with a soft brush or similar implement. Dust can be removed with a damp cloth. Solvents, abrasives or corrosive chemicals must not be used for cleaning. When the fan filter requires cleaning the Attention indicator will illuminate.
SERVICE | Service and Maintenance Restoring to Factory Default settings The following procedure will restore factory defaults - Off Grid, Voltage Control mode - with the choice of either flooded or sealed battery voltage defaults. • • • • Set SP PRO in Idle mode with a long press of the ON button (AC Load Indicator OFF) Press and hold buttons B as shown, all indicators will go off.
SERVICE | Service and Maintenance Operating When the Generator is offline If the generator is not available (maybe due to maintenance or breakdown) then the following recommendations should be followed to conserve energy: • Turn on Econo Mode. The SP PRO will pulse the output voltage and only supply continuous voltage when the load exceeds a defined limit. If present, renewable energy will recharge the battery.
SERVICE | Troubleshooting Troubleshooting C h a p t e r Ni n e Service and Support In the event that you require support or have questions regarding the operation of your SP PRO, please contact your Accredited Integrator. Your Accredited Integrator has direct knowledge of the system components, the load profile and SP PRO configuration which affect the behaviour and operation of the SP PRO.
SERVICE | Troubleshooting General If the system is not operating correctly, perform a general check as follows: • Check if the front panel “Alarm” indicators show a problem, and take the recommended action as described in “Attention Required” section of the “Now” tab of “Data View”. • Switch the SP PRO to Idle via the push button for a few seconds then back on. If this does not restore normal operation, check the Performance Data Events for a cause.
SERVICE | Troubleshooting Inverter Start/Shutdown Problems SP PRO will not Start If the indicators remain dark when the SP PRO is switched on it is likely that DC power is not present. Check that the main battery fuse is closed. Retry the procedure, if it continues to fail contact your supplier for further instructions. If the SP PRO starts with the Shutdown indicator illuminated, check the reason in the Attention Required window in the Now tab in Data View area of SP LINK.
SERVICE | Troubleshooting Battery Problems Batteries are very dangerous. Please read the safety information provided by the battery supplier. Battery does not charge properly • Check that the battery charging requirements are correctly set up in the SP PRO. • Check that the solar regulator is correctly set up. • Check all cables and connections to the batteries. If the solar does not appear to be doing much, the solar regulator may be set too low. Check indicators and DC History in SP LINK.
SERVICE | Appendix A - Specifications Appendix A Specifications Appendix Standards Compliance AS62040.1.
SERVICE | Appendix A - Specifications SP PRO SERIES SPECIFICATIONS Nominal batter voltage Continuous, output power Continuous, charge current Continuous grid export power 20 second load rating 20 second output current 1 minute output power 60 minute output power DC input voltage range @ 25°C @ 40°C @ 40°C @ 40°C SPMC240 SPMC241 24 V 3,000 W 125 A 24 V 4,500 W 188 A 7,500 W 28 A 5,400 W 3,200 W 20 - 34 V 10,500 W 40 A 7,600 W 4,700 W 20 - 34 V SPMC481 TRANSFER SWITCH (Synchronous) AC transfer curre
NOTES 62 | Doc #OI0003 Part #004122 Rev 12 2013
Selectronic Australia Pty Ltd © 2013 Suite 5, 20 Fletcher Rd Chirnside Park VIC 3116 Australia Ph +61 3 9727 6600 Fax +61 3 9727 6601 www.selectronic.com.
