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OPERATION | SP PRO Operation

Doc #OI0003 Part #004122 Rev19 2014

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Battery Charging Cycle

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Summary of Contents for SP PRO

Page 1: ...Installation Operation Service Instruction Manual for SP PRO Interactive Inverter Charger ...

Page 2: ...Selectronic Australia Pty Ltd 2014 Suite 5 20 Fletcher Rd Chirnside Park VIC 3116 Australia Ph 61 3 9727 6600 Fax 61 3 9727 6601 www selectronic com au ...

Page 3: ...and the best charging parameters are essential Monitoring configuration software should be user friendly with intuitive at a glance menu clarity The SP PRO has been designed with these and many other criteria in mind In addition to power conversion the SP PRO controls the operation of the entire energy system ensuring all sources of renewable energy are fully utilised whilst reducing the use of ei...

Page 4: ...C Wiring SPLC Models 22 Expansion Card Warning 120VDC model 23 Current Shunt Wiring 23 Battery Temperature Sensor 23 Battery Wiring DC Preparation 24 AC Wiring 25 Earth Wiring 25 Residual Current Device RCD Type Recommendation 25 AC Wiring Preparation 26 Backup Generator Advanced Feature Control Wiring 27 Serial Port Connection 27 Gland Plate Fit out 27 Initial Start up Procedure 27 Labelling 27 I...

Page 5: ...ration 60 Battery Charging Cycle 61 Battery Temperature Compensation 62 Renewable Management 62 Generator Controls for Off Grid 63 Backup Generator Controls with option 63 Inverter External Alarm 63 SERVICE Service and Maintenance 64 Cleaning the Fan and Fan filter 64 Monitoring the Operation of the SP PRO 64 Resetting inverter with or without Restoring Factory Default settings 65 System Shutdown ...

Page 6: ...ilure to do so may void the warranty and not give the full benefits that this product can provide This manual is divided into four sections to allow fast access to relevant information The heading on each page indicates the section INTRODUCTION This section which provides a brief overview of the SP PRO including information about warranties and terms used in this manual INSTALLATION Contains infor...

Page 7: ...ion File Contains all the settings to be loaded into the SP PRO This is normally linked to a site file Solar Array A collection of Solar Panels PV Photo Voltaic solar power State of Charge SoC Referring to the battery charge condition 100 SoC means a full battery Sealed Battery A lead acid battery with no access to the electrolyte either valve regulated or gel No hydrogen gas discharge during norm...

Page 8: ... PRO is compatible with virtually any DC renewable charging source such as a DC solar controller Also any AC renewable source such as a grid tie inverter is compatible with the SP PRO in a Solar Hybrid system without limited export power For Off Grid Systems or Solar Hybrid systems requiring export limiting the Selectronic Managed AC Coupling must be used Its advanced features include the precise ...

Page 9: ...start and stop the generator as required to charge the batteries and supply loads heavier than the SP PRO can efficiently handle These features when correctly configured will increase the battery life and reduce generator running costs When the generator is running the SP PRO will use the generator to power the site load plus use any additional generator capacity to charge the batteries When the s...

Page 10: ...in all the SP PRO models is just a hazardous as grid electricity All AC connections and hazardous DC connections to the SP PRO must be carried out by a qualified Electrical contractor or similar failure to do so will contravene legal requirements All DC wiring must be carried out by a person experienced with DC electrical circuits and must understand high current low voltage circuits To ensure an ...

Page 11: ...res Inverter may start automatically The SP PRO automatically starts and or restarts and may restore power at any time If a fault or overload is detected the SP PRO will shutdown and may automatically attempt to restart at varying intervals of up to several hours Backup Generator may start automatically The SP PRO automatically starts and or restarts a backup generator when a Grid Fail Gen Backup ...

Page 12: ...n an inverter such as Earth Neutral bond monitoring the voltages connected to or generated within the SP PRO are hazardous and potentially fatal The following section provides general installation instructions for the SP PRO For information on specific configurations please refer to the Installation Specific Applications Section in this manual and the relevant installation guide supplied with any ...

Page 13: ...nd bottom Particular care must be taken when mounting near other heat producing equipment Humidity Tolerance The SP PRO is designed to operate in a humidity range of 0 99 non condensing Ingress of Particles The SP PRO has been designed to meet IP rating 43 Protected against solid objects larger than 1 0 mm protected against water falling as a spray at up to 60 degrees from the vertical i e may be ...

Page 14: ...om top bottom and sides In a covered location away from direct rain The SP PRO has an environmental rating of IP43 which makes it unsuitable for water spray that is greater than 60 deg from the vertical or greater than 0 7 litres per minute In a location shaded from direct sunlight Away from any explosive gas Rodent Proof In a clean environment away from dust iron filings workshop pollutants and o...

Page 15: ...art 004122 Rev19 2014 15 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 the supplier immediately Installation of SPMC models ...

Page 16: ...o give greater access to wiring terminals using T25 torx driver NB side screws need only be loosened Secure the bottom of the SP PRO to the mounting plate with two M5 Torx screws A on above diagram 7 STOP Detailed instruction for wiring SP PRO contained on the following pages These MUST be followed before proceeding with installation 2 Diagram previous page Choose a suitable weight bearing and tem...

Page 17: ...igned off by a Selectronic Accredited Integrator will benefit from additional warranty cover 9 When all the AC wiring is complete reinstall the terminal cover and expansion card 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 of the included battery temperature sensor is imperative for the corr...

Page 18: ... 004122 Rev19 2014 Installation of SPLC models 1 Undo ten bolts 7 16 to remove lid on packing crate Cardboard tray contains mounting plate rear air outlet mesh cover and all documentation Inspect for damage in transit and report any to the supplier immediately ...

Page 19: ...les HEAVY Take care when lifting 105 kg SHARP Use gloves handle edges sharp TOP HEAVY Secure unit when standing unit upright Stand unit upright using handles REAR AIR OUTLET MESH COVER Fit and secure with six thumb screws 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 ...

Page 20: ...ge switch under Expansion Card must be closed and pre charge complete before DC Breaker will close 7 Undo five T20 Torx screws to remove terminal plate Expansion card remains secured to SP PRO Note Expansion card not shown for clarity Note Gland plate shown in wall entry cable position 8 Wiring can only be carried out by suitably qualified installers and must adhere to all relevant standards Insta...

Page 21: ...e installation using three SPMC482 inverters the minimum battery cable size with a length of 2m 5m is 3 x 70 mm2 or equivalent Failure to follow cable size recommendations will reduce inverter performance to the published specifications due to excessive voltage drops Battery Sense Pre charge cable MUST be robust with solid insulation DO NOT USE CAT5 or equivalent cable Battery Fusing Circuit Break...

Page 22: ...hrough out The SPLC1200 and SPLC1202 models contain 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...

Page 23: ...h either lead to battery positive would short circuit the battery bank It is recommended that both these wires be fused The polarity of these shunt sense leads is not important if they are configured to either Load or any of the input selections such as Solar however polarity is important when using the shunt in Dual mode that is where the shunt is used for both input and output measurement to obt...

Page 24: ...e isolator and included temperature sensor For 48V and 120V battery banks it is a requirement that the Battery Sense Precharge connections are used and wired directly back to the battery bank terminals It is highly recommended that the Battery Sense Precharge is used for 24V battery banks but if not then the SP PRO Battery S and S terminals must be connected to B and B respectively ...

Page 25: ...no circumstances can the user access or touch wiring even after opening all circuit breakers Earth Wiring The inverter shall be earthed to the installations Earth system A minimum copper earthing conductor not less than the table below shall be used See the local regulations for further information on earthing conductor size Earth the inverter by connecting earth wiring from the switchboard to the...

Page 26: ...up The blow diagram shows AC wiring only and indicates the customer circuits some of which are battery back up protected some are grid supply only Attention must be paid to the Neutral conductor and connection through to the loads The neutral conductor connecting to the loads must be maintained such that operation of the inverter isolator would not alter the bonding between Neutral and Earth The N...

Page 27: ...nused gland holes and ensure all used holes have gland nuts supplied fitted Initial Start up Procedure Before turning on the SP PRO Check all connections paying particular attention to correct polarity Give each cable a firm tug to ensure they are securely fitted When satisfied everything is well attach the terminal cover plate and insert and secure the expansion card For SPMC1201 SPLC1200 and SPL...

Page 28: ...n System Configuration This section details the extra information needed to install and configure standard system configurations It is imperative that the installation details in the previous section have been followed before proceeding with the relevant installation instructions in this section ...

Page 29: ... can manage a maximum of five KACO grid tie inverters by commanding each grid tie inverter to output the right amount of power that is needed to simultaneously supply the load export any excess and maintain the battery bank at any particular point in time This is done via a communications link which also serves to retrieve all the operational data for display and logging by the SP PRO Communicatio...

Page 30: ...ged AC coupled system is installed with an existing grid connected PV system that has another brand of grid inverter generic grid inverter then the generic inverter is connected on the grid side of the system See diagram below If there is no existing grid inverter then ignore the grey wiring on the diagram below Line diagram for KACO Managed AC coupling Solar Hybrid Grid Connected System Line diag...

Page 31: ...240 Ah 100 Ah 6 2kW SPLC1200 30 kW 500 Ah 250 Ah 15kW SPLC1202 35 kW 600 Ah 250 Ah 15kW The table above shows the following 1 The maximum combined AC output of all the KACO inverters in the system for a particular SP PRO model 2 The minimum battery capacity at the C10 rate allowed when the maximum combination of AC output of all the KACO inverters is used 3 4 The minimum battery capacity at the C1...

Page 32: ...ar system requirements that need to be met See IN0034_xx SP PRO Generic AC Coupling installation notes for more detail Combined maximum AC output of all the connected generic inverters must not exceed the continuous SP PRO output power rating Battery bank must be sized to suit the SP PRO model and the combined maximum AC Output power of the generic inverters SP PRO generic AC coupling is only suit...

Page 33: ...ge of the Selectronic web found site at www selectronic com au Split Phase Preparation A split phase system is suitable for connection to a 480V split phase grid supply that is commonly found on Single Wire Earth Return SWER line feeds Installing a split phase system using two SP PRO inverters requires the following optional Kit Stock code 004775 Description Gx Multi Phase Pack series II Available...

Page 34: ...rformance and result in non optimal operation of the system For more detail on installing and integrating a DC charge controller refer to the relevant document in the table below All documents found on the USB stick supplied with this inverter or on the support page of the Selectronic web found site at www selectronic com au Document Number Document Name Applicable charge Controller TN0045 SP PRO ...

Page 35: ...Blank Page Doc OI0003 Part 004122 Rev19 2014 35 ...

Page 36: ...Relay Outputs x4 N C and N O dry contacts Maximum control voltage 60 VDC Maximum control current 500 mA DC Limited by internal current protection Digital outputs x3 Maximum control voltage 60 VDC Maximum control current 5 mADC Analogue Inputs The 24V and 48V SP PRO inverters have 2 analogue inputs that are logged and that can be used to control a digital or relay output based on set input voltages...

Page 37: ...ve will either stop the generator or prevent it from starting Initial stage input Causes the Battery charger in the SP PRO to drop to the Initial stage Bulk stage input Causes the Battery charger in the SP PRO to drop to the Bulk stage Absorb stage input Causes the Battery charger in the SP PRO to drop to the Absorb stage Float stage input Causes the Battery charger in the SP PRO to drop to the Fl...

Page 38: ...ontrol Output Provides a PWM signal to control an external solar regulator AC Coupled Inverter Output Controls a Solid State relay that turns off a generic AC coupled inverter when the grid has failed and the battery voltage reaches its charge target External AC Contactor Control Output Becomes active when the AC Source contactor opens Used to drive an External AC source contactor or as an AC sour...

Page 39: ...mer CT may be fitted With an external contactor transfer currents of up to 250A are possible 250A per phase in a three phase system The line diagrams below are for the external contactor in both a single phase configuration and three phase configuration For more detailed information please see TN0057_02 SP PRO External AC Source Contactor Option doc available on the USB stick packed with the SP PR...

Page 40: ...charge the battery bank The generator will continue to run until either the battery bank has recharged or grid power has been restored For more detailed information please see IN0020_01 004799 SP Grid Gen Backup Installation Notes supplied with the Grid Fail Generator Backup kit available on the USB stick packed with the SP PRO or from the selectronic web site www selectronic com au SP PRO Model G...

Page 41: ...igured to allow manual control of the generator by the user Generally automatic control of the generator is recommended for daily operation The line diagram below shows the connections AC connections for the generator The generator control link can be set up as a 2 wire or 3 wire configuration For more information on the control wiring please see document TN0025_xx SP PRO Generator Controller Wiri...

Page 42: ...phase or Split phase configuration RS485 Port 2 RJ45 Used to communicate with KACO inverters in a managed AC coupled system RS232 Port 2 RJ45 Provides RS232 communications with SP LINK Cannot be used when RS485 Port 2 is used RS232 Port 1 RJ45 Provides RS232 communications with SP LINK Cannot be used when USB port or DB9 port is used RS232 Port 1 DB9 Provides RS232 communications with SP LINK Cann...

Page 43: ...ernet Stock code 005081 Using the same Ethernet adaptor the SP PRO can be connected to the Internet This requires configuration of the router and advanced knowlege of networks Wireless RS485 Stock code 005075 Provides wireless communications between SP PRO and KACO inverters in a managed AC coupled system USB communications All SP PRO inverters come standard with a USB B interface to communicate w...

Page 44: ...N C Signal Ground 5 Signal Ground Signal Ground Signal Ground 6 Receive Input Data N C Receive Input Data 7 N C N C Data Carrier Detect 8 N C N C N C 9 12V 1A supply Wireless SP PRO to SP LINK By simply installing this option Stock code 005081 the SP PRO can be easily connected to a remote PC running SP LINK For more detailed information please see IN0023_xx SP PRO to SP LINK Wireless Link Install...

Page 45: ... Adaptor is connected to the LAN and access is established the SP PRO can then be given remote accessed to any PC that is connected to the Internet The configuring of the router to achieve remote access can be carried out by a person who is familiar with general router and gateway configuration plus operation of Domain Names Servers DNS For more detailed information please see TN0028_xx SP PRO Com...

Page 46: ... to configure the SP PRO for most applications or access the many advanced parameters to configure the SP PRO for a more complex system SP LINK software is available from the supplied USB stick or download the latest version from the Selectronic Web site at www selectronic com au We strongly suggest that SP LINK is installed on your PC before going to the installation site This section of the SP P...

Page 47: ... the Site Configuration Wizard enter in the system details and SP LINK will firstly validate the combination of system components then create a site file All that is left to do is add any custom functions to the Configuration Settings save the Site file to your computer then connect to the SP PRO and send it the configuration click Configure SP PRO button For more information select View SP LINK m...

Page 48: ...sist in diagnosing any system now and in the future To ensure that you receive the highest level of support please ensure that the following commissioning documents are completed and available before contacting Selectronic Support Diagnostics during Commissioning If the alarm buzzer sounds and one of the alarm LEDs is RED during the commissioning process please do the following to diagnose the sys...

Page 49: ...battery sense wiring including Connections to the battery bank Connection to the SP PRO s Insulation is not clamped in terminal Check polarity of precharge battery sense wiring including At the battery bank At the fuse or CB connections Checked that they are not crossed At the SP PRO s Battery Terminals With a multimeter check the voltage on the mid point terminal on the precharge battery sense Th...

Page 50: ...ised L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3 Put a load on the system that is about half the rating of the SP PRO s In the Data View Now tab L1 read and record the Battery Current Also read and record Battery Voltage Back in the Data View Technical Data tab read and record the Cable Loss L1 Cable Loss should be less than 1 of load power for 24V system 0 5 of load power for 48V and 120V systems Drop th...

Page 51: ...ck Result For KACO 1 Wake up the KACO 1 inverter by pressing the night switch on the base for 10 seconds The display should light up In the Service Settings tab click the Reset Counters button Wait 2 minutes then read and record Link 1 should be 3 Repeat for L2 and L3 in a three phase of split phase system L1 L2 L3 For KACO 2 Repeat above for KACO 2 then read and record Link 2 should be 3 L1 L2 L3...

Page 52: ... coupled For systems incorporating DC Coupled renewable energy the following items should be verified Please note that Common System Checks on page 49 should be completed first Refer to relevant document s referred to in DC couple Charge Controller Preparation on page 34 and ensure the system has first been installed and commissioned according to these document s Turn on the DC supply to the SP PR...

Page 53: ...rrent in DataVIew Now tab for L1 L2 and L3 Current should be zero or very close 0 2 A Record the results L1 L2 L3 Where a DC Solar shunt shunt 2 is installed turn off all DC Souces connected to the shunt 2 Read the Shunt 2 current in DataVIew Now tab for L1 L2 and L3 Current should be zero or very close 0 2 A Record the results L1 L2 L3 Long press the ON button on L1 so that only the blue AC Load ...

Page 54: ...w Now tab The External contactor has turned ON The AC Load Voltage reads the source voltage in the Data View Now tab On the front Panel of the SP PRO s check Both the blue AC Source and AC Load LEDs are lit The blue Transfer LED is NOT lit Turn OFF the AC source circuit breaker Turn ON the SP PRO s with a long press of the ON button Check the following AC Source Voltage is still zero in the Data V...

Page 55: ...th a SHORT press on the SP PRO front panel Generator button If generator does not start then check control wiring and SP PRO con figuration settings For manual start generator Start the generator manually In SP LINK Data View Now tab check the AC Source Voltage and AC Source Frequency before the SP PRO syncs to the generator Record results Volts Frequ Check that the SP PRO syncs to the generator w...

Page 56: ...rom the incoming AC supply 2 Transfer Illuminated when an external AC supply is connected through to the AC LOAD output If AC SOURCE is illuminated but not TRANSFER it would generally indicate that the AC supply is out of sync tolerance either the voltage or the frequency is beyond the set limits It is normal operation for this to flicker slightly This LED is ALWAYS off with an external AC source ...

Page 57: ...ttention Required in SP LINK Data View Now section to determine specific reason for the attention indicator 9 battery fuel Gauge These indicate the battery State of Charge SoC When the battery SoC is equal to the Shutdown SoC in Configuration Settings Inverter tab then only the bottom LED is green At 100 SoC all LEDs are green Top Indicator Flashing RED Instant Hi DC Voltage Shutdown Battery or ba...

Page 58: ...onitoring allows the SP PRO to ensure the batteries are correctly charged to maximise system reliability The monitoring includes any input from renewable sources AC or DC Coupled and any loads directly connected to the battery bank The SP PRO uses a five stage temperature compensated battery charging system This system gives a high degree of flexibility so it can charge the multitude of battery ty...

Page 59: ...city The accuracy of the battery SoC is limited by a number of factors including the charge and discharge efficiency of the battery bank To improve the accuracy of the battery SoC calculation the SP PRO employs an adaptive algorithm to constantly update a charge efficiency index which is used during recharge In an Off Grid system where a Generator is installed the state of charge is used to automa...

Page 60: ...absorb charge voltage is reached Once this voltage is reached the SP PRO will carefully monitor the rate of change of the charge current as set in the Absorb Float transition setting When the Absorb Float transition setting is met the charge cycle will switch to Float and terminate an auto start backup generator if connected If an Equalise charge is pending the Equalise charge cycle will now be pe...

Page 61: ...age Absorption Voltage Float Voltage Equalise Voltage Bulk Absorb Float Battery Current Initial Current Absorb Current Time Equalise Current Equalise Charging Bulk Current Initial Voltage Initial Initial Time Absorption Time Bulk Time Charging Stage Equalisation Time Battery Charging Cycle ...

Page 62: ... the battery charger to reduce the charge current limit point This will help also help protect the battery from overheating The temperature compensated charge voltage target and charge current target at any point in time can be viewed in SP LINK under the Data View Technical Data tab Target Charge Voltage and Target Charge Current Renewable Management SOLAR HYBRID GRID AVAILABLE In Solar Hybrid th...

Page 63: ...ional Grid fail Gen backup module During a grid outage the generator will be automatically started by the SP PRO as required to supply the load and charge the battery bank As part of the installation the SP PRO settings are configured to automatically run the generator during a grid outage to Limit the depth of battery discharge for maximum battery life Deliver energy efficiently by supplying sust...

Page 64: ...the Operation of the SP PRO Installing SP LINK software onto a PC also installs SP LINK Auto QuickView This program is a shortened version or SP LINK designed to automatically connect to and display information about the SP PRO Using this program allows the following items to be monitored on a regular basis Battery Voltage QuickView Tab this should never be below the nominal system voltage 24 V 48...

Page 65: ...ensuring all AC and DC connections are always tight there are only three areas that may require maintenance Fan Alert This can be checked in the Now tab of the Data View section A fan alert generally indicates that the fan is stationary when it should be running This will mean that either the fan needs replacement or that a foreign body is stuck in the fan Also see Cleaning the Fan and Fan filter ...

Page 66: ... its cause can be determined by using the indicators provided with the SP PRO and information available via SP LINK Front Panel Indicators The first and easy step is to look at the front panel of the SP PRO If all the LEDs are green then all is well and the system components that are measured or controlled by the SP PRO are functioning correctly 1 2 3 4 If any LEDs are Red then follow the informat...

Page 67: ...down Battery or battery wiring fault Bottom LED Yellow Low Battery Battery needs charging Bottom LED Red Low Battery Shutdown Inverter has shut down due to flat of faulty battery Bottom LED Flash RED Instant Low DC Voltage Shutdown Battery or battery wiring fault Solution 1 Give battery bank a full charge and equalise charge 2 Check all battery wiring including the battery bank interconnections co...

Page 68: ... to the SP LINK manual The manual lists all the SP PRO alerts the likely cause and possible remedies If further assistance is required then email the zip file in the Download to the System Integrator or to a Selectronic Accredited Integrator An Accredited Integrator has direct knowledge of the system components the load profile and SP PRO configuration which affect the behaviour and operation of t...

Page 69: ...k 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 If the battery is not operating correctly Physically inspect the battery and check for loose co...

Page 70: ...he integrator 3 The load during late night and early morning periods is higher than expected but not high enough to keep the generator running permanently There may be multiple starts and stops as the battery becomes discharged and is partly recharged Increase the generator minimum run time to increase the amount of battery recharge before stopping hence reducing the number of starts and stops 4 T...

Page 71: ...ark Not including the 3 blue LEDs along the top when the SP PRO is switched on it is likely that DC battery power is not present Check all the main battery wiring terminal and that the main battery fuse or circuit breaker is closed Retry the start up procedure and if the problem continues contact the installer for further instructions ...

Page 72: ...nce AS62040 1 1 2003 Uninterruptible power systems UPS General and safety requirements for UPS used in operator access areas AS NZS 61000 6 3 2007 Electromagnetic Compatibility EMC Part 6 3 Generic Standards Emission Standard For Residential Commercial And Light industrial Environments AS NZS 61000 6 4 2007 Electromagnetic Compatibility EMC Part 6 4 Generic Standards Emission Standard For Industry...

Page 73: ...oad 90 91 92 5 93 93 5 96 8 95 5 AC OUTPUT standalone Range 210 to 240 V 0 5 Regulation 1 droop 0 100 rated load 2 150 5 200 THD 3 0 200 rated load Frequency 50 or 60 Hz 0 005 standalone AC SOURCE input Nominal voltage 240 V AC current Recharge Bypass Normal modes 63 A 125 A 125 A Tolerance on nominal voltage Configurable 204 to 264 V Nominal input frequency 50 60 Hz Tolerance on nominal frequency...

Page 74: ...Blank Page 74 Doc OI0003 Part 004122 Rev19 2014 ...

Page 75: ...Blank Page Doc OI0003 Part 004122 Rev19 2014 75 ...

Page 76: ...Selectronic Australia Pty Ltd 2014 Suite 5 20 Fletcher Rd Chirnside Park VIC 3116 Australia Ph 61 3 9727 6600 Fax 61 3 9727 6601 www selectronic com au Doc OI0003 Part 004122 Rev19 2014 ...

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