Technical Manual SPB-LG. SPB-LG patented. Solar equipment for public lighting with GSM interface

Transcription

1 SPB-LG patented Solar equipment for public lighting with GSM interface 1

2 INDEX Features and introduction:...3 How to use the Serial Number:...3 Dimensions:...5 Cabling scheme:...6 System Power on:...8 Programming:...8 Table 1 electric features:...10 Maintenance:...10 Anomalous behaviours:...11 Accessories:...12 FEATURES: Control, programming, setting parameters through GSM net Microcontroller system MPPT recharge Mosfet devices 12V system 10A max current from panels Integrated blocking-diode Integrated light-sensor (with photovoltaic module) Time table programming Compensation in temperature of battery s recharge Low battery control Probe input for measure of remote battery s voltage Over-temperature protection Overload protection LED for state of charge and battery LED for intensity of recharge current Output 12V 7 A max Output of lamp luminosity control Easy cabling SMT technology Waterproof metal box 2

3 Features and introduction: SPB-LG is a charge regulator for batteries from PV module. It is suitable to be used in stand-alone systems for public lighting (ex. PV street-lamp). The system can be programmed and checked at a distance through GSM net; it is put inside a waterproof metallic box and it can be installed in outdoor applications without further protections. The circuit includes a switching system with microcontroller for recharge of either flooded lead acid or sealed 12V PB batteries and research of the MPPT point of maximum power of the PV modules MPPT (switching Western Enhanced for the maximum efficiency during recharge phase). A temperature sensor (which must be installed as near as possible to the battery) allows to adapt the recharge voltage to the variations of the environment temperature as reported in the graphic at the end of this manual. This guarantees a proper use of the battery even in case of large thermal excursions and make the charge regulator SPB-LG right even for outdoor applications. The recharge circuit needs to measure the battery voltage but, owing to the voltage drop on the cables that connect regulator and battery, such measure is as more distorted as longer are the cables. For this reason there is an auxiliary input for the revelation of remote battery voltage that we advise to connect id the cables length between SPB-GSM and battery is > of 1.5 metres. All these expedients guarantee an optimum recharge and, therefore, a maximum life duration of the battery. SPB_GSM manages a 12V output to which you can connect a lamp. We advise to use high efficiency lamps as, for instance, the sodium low pressure lamps (models SOX- E XX ): we remember that such lamps cannot be connected directly to the 12V output of SPB-LG but that they need an electronic ballast that is usually put inside the lamp-holder (see model SOX produced by Western CO. snc). The output that power supplies the lamp is ON at dusk (the light sensor is made by PV module, there is not the need of external light sensors) according to an hourly program which can be set through GSM net. The charge is automatically deactivated in condition of low battery; the voltage threshold for the recognizing of low battery can be set through GSM interface as well as the threshold of output from low battery condition. SPB-LG can turn on the lamp with reduced luminosity: this happens thanks to the Dimm output that signals to the external ballast circuit to reduce the lamp luminosity. This function allows to preserve the energy stored inside the batteries during the hours in which a lesser lighting is requested. In the electronic equipment there is a GSM modem where you have to put a SIM that must be activated from an mobile phone operator with a given phone number. From a remote PC which has a GSM modem, a SIM with its own phone number and a software (CCLS Western CO) it is possible to control the system by transmitting or receiving SMS towards the phone number given to the SIM which has been installed inside the PV street-lamp. Before the SIM purchase, we advise to verify that the mobile phone operator guarantees an adequate signal level where you decided to install the regulator SPB-GSM. Through GSM interface, SPB-LG can send SMS containing data concerning its own internal state to a PC remote location where it is installed a GSM modem and the CCLS Western CO software with which it is possible to interpret SMS and to know the state of the regulator. From the PC location you can send setting SMS to SPB-LG with which you can set the internal parameters of the regulator or the program of lamp hourly power on. For safety reasons SPB-LG answers to orders or transmits its own internal state only if these requests come from three phone numbers which have been memorized inside the SIM. This guarantees that ill-intentioned persons can cause problems or undesired workings of the regulator. So, before installing the SIM inside the regulator, it will be necessary pre-configure these phone numbers in the SIM memory and deactivate the protection code PIN o PUK. For such operations we advise to follow the procedure which is described in help on line relative to CCLS Western CO. software. How to use the Serial Number: SPB-LG is identified by a Serial Number (SN) which is put on the label in the external side of the metallic box. In the main offices of Western CO. snc Serial Numbers are registered in proper files. In case of communications concerning SPB-LG or in case of coming back to the seller/distributor or at Western CO. snc for any reason, always take note of the Serial Numbers of each SPB-LG and communicate them together with explanation of the case; write the serial number in the delivery notes and in warranty documents which have always go with the products. The production lot of the charge regulator is written on the Serial Number in the first 5 numbers from the left side: Example: SN XXXXX XXX production lot No. 317 of year

4 Fig. 2: general scheme 4

5 Dimensions: The external box of SPB GSM regulator has got some holes with cable gland; these holes are predisposed to receive different combinations of cables of different sections (fig. 4) Choose the combinations righter to your case and tighten the cable gland around the protective cover of the conductors. Plug all the unemployed cable glands by inserting short pieces of cable and tighten them so to avoid water penetration. 95 4xD Fig. 3: dimensions and holes of the charge regulator PG16 PANN PG16 BATT PG11 LAMPADA PG7 Sonda NTC BNC ANTENNA GSM Fig. 4: front view, cable gland disposition and advised use 5

6 Cabling scheme: + - lamp PV MODULE BATTERY Cable 2x6 Cable 2x dimm Ballast with dimmer Cable 3x1.5 Input sonda battery temperature Input sonda battery voltage 15 A Fuse Jumper JP3 JP4 Setting remote measure of battery reset button SIM MODEM GSM LED A: green panel current LED B: red Regulator state LED C: GSM state Fig. 5: cabling scheme Fig. 6- cable inserting inside the terminal block 6

7 Battery put at a distance < 1.5mt Battery put at a distance > 1.5mt Temp Temp Temp Temp +Vrem -Vrem BATTERY + - BATTERY Fig. 7- cabling scheme of remote batteries 7

8 Circuit assembling: - Assemble the mechanic part (cement basement, pole, support of panels, photovoltaic modules, lamp-bracket, lamp-holder, batteries). Please refer to the supplier s manuals of the mechanic structure. - Fix SPB-LG using the waterproof holes on the back of its box. It is better to mount the box so that the cable gland are towards the bottom. In the PV street-lamp code SSL26B-GSM-M WESTERN CO. the top-of-pole mounting structure has got predisposed holes inside the drawer on the back of the PV modules. - Fix the antenna and connect it to BNC connector of SPB-LG (fig. 4). The antenna base is magnetic, therefore it can be fixed without any screw. - Extract the 15A fuse (see fig. 5) from its housing. - Connect ALWAYS the cable with temperature sensor (NTC) to the correspondent terminal block (see fig. 5). - Bring the temperature sensor (NTC) to the battery and make it adhere to the battery by assuring an efficient thermic exchange. - If the battery is at a distance < than 1,5m and if the battery voltage probe is not connected place JP3 and JP4 jumpers in Local position (the battery voltage will be measured by +VBATT e VBATT circuit internal terminal blocks). - If the battery is at a distance > than 1,5m we advise to connect also the voltage probe as in fig. 7. When there is the voltage probe, JP3 e JP4 jumpers must be placed in Remote position. - Connect the lamp e and if you want to exploit the capacity of SPB-LG to regulate lamp luminosity you must connect also the DIMMER output. Remember: the DIMMER works only if it is connected to Western CO SOX ballast. Normally the ballast is inside the lamp-holder. - The equipment s box (and the antenna s cable) is electrically connected to the negative terminal block but IT CANNOT BE USED to close the circuit. So AVOID ABSOLUTELY the contact of battery cables and PV modules with the metallic box of the top-of pole mounting structure of the PV street-lamp (otherwise the circuit DAMAGES HEAVILY). We advise to isolate the ends of the cables. - With cable having section of 6mm 2 (never go under such a section) cable the poles of battery to the correspondent +BATT e BATT terminal blocks of the solar equipment. - Cable the PV modules to the +PANN -PANN terminal blocks of the equipment; if modules are more than, put in parallel the PV modules and bring 4 mm 2 cables from one of the panels to the +PANN -PANN terminal blocks. DO NOT place the blocking-diodes in series to the panel since they are included in SPB-LG. - Insert the SIM, previously configured, in the proper fissure of GSM modem (fig. 5). We remember that to configure the SIM you must use CCSL Western CO. software; please refer to the software help on line for description of the procedure to follow to prepare the SIM. System Power on: - Control again the cables polarities! - Insert the fuse (see fig. 5); the system turns on; the B LED (red) lightens for a few seconds and then it turns off. - If the red LED lightens at the bitter end there is some problem which has been described in the paragraph Diagnosis problems and their solutions. - The C LED (red) begins to lighten and this shows that the GSM modem is being configured. If after 1-2 minutes the LED does not turn off or change the way of lighting this means that there is a problem in the modem configuring. Please refer to the paragraph Diagnosis problems and their solutions. - According to the parameters programming and set up which is memorized internally (memorizing and variation through the GSM interface - optional) the system activates or does not activate the output and it recharges the battery. - The connection of PV modules is absolutely necessary for light-sensor working; to check a lamp s lighting during the day cover perfectly the PV modules to simulate darkness (the system is very sensitive and the cover must be well-made even on the back of the PV modules). More easily you can disconnect temporarily a wire coming from the panel to simulate the night (avoid short-circuits). If you want, as a test you can turn on the lamp during the day through remote software (exclusion of the light-sensor); - When the PV modules are irradiated the A LED (green) Ipan activates with an intensity proportional to the current delivered by the PV modules. Programming: - For a description of CCLS Western CO. software please refer to software online help. Here below there are the indications about the meanings of the parameters to set. - SETUP advised values: - They are the values that system uses in case of default condition. - For Vch values in graphic 1 there is the recharge voltage variation with temperature for all cases of setting; it is important to point out that in Vch setting the screen-visualized value a video is always at 58 C temperature. - For sealed batteries (AGM) the best voltage to set as Vch is 13.92V (reference value at 58 C) as below-reported; other kind of batteries want Vch different voltages (see graphic 1). o SYMB AGM SEALED BATTERIES UNITY Recharge voltage of the battery Vch V Voltage of low battery Vlb 12 V Difference between end-charge Vhb V voltage (Voff) and end-low battery voltage (Velb) Light-sensor sensibility Dark Low: a few darkness Any time-computation has got as reference the twilight which occurs when the natural light goes under the set threshold in the voice Dark of SETUP. 8

9 o o If you want to activate the lamp even during day ignoring the signal coming from the PV modules (for testing or maintenance) you have to set the voice Dark = Off; WARNING! Remember that at the end of the maintenance or testing to set again the voice Dark on one of the values Low, Mid, High. The time table programming is according to the power of the PV module, the capacity of the battery, the latitude, the period of the year, the tilt of the PV module. In Italy and in the temperate zones of the planet the critical period is Winter when usually the lamp power on is < than night duration. It is a good rule to respect the following formula: WHERE h ON lamp Ppan heq 0.6 Plamp h ON lamp = hours of lamp activation Ppan = power of PV module heq = equivalent hours of sun at maximum power according to season, latitude, orientation. 0.6 = coefficient that considers the losses and the energy fraction to store for periods with long darkness. Plamp = power of lamp o o o You can search heq values on tables which are supplied by public bodies (ex. in Italy: ENEA, Air Force, and so on) which deal with meteorology. The system deactivates the outputs automatically when the battery s voltage Vbatt< Vlb (discharged battery); when programming consider that a power on of the lamp too long in winter time cause the discharge of battery and, therefore, shortens the life of battery; if possible reduce the winter night activation following the over-reported formula. The lamp is re-activated when Vbatt > Voff Vhb (the battery has been recharged enough). 16,50 13,60 13,76 13,92 14,08 14,24 14,40 14,56 14,72 16,00 15,50 15,00 14,50 14,00 13, Graphic 1: recharge voltage according to temperature (reference Vch for SETUP is the value at 58 C) 9

10 Table 1 electric features: FEATURE SYM. CONDITION MIN. TYP. MAX. UNIT DC power supply (12V Pb battery) no load, no modules Working voltage Working current VDD IDD V ma Voltage of PV modules VPAN 0 17,2 21 V Current of PV modules IPAN A Power of PV modules PPAN Wp Recharge voltage Vch Battery temperature 25 C ±2 C 14,08 14,4 15,2 V Setting with GSM interface Threshold of discharged battery VLB Setting with GSM interface 11,2 12,16 12,4 V Difference between tra recharge voltage (endcharge) and minimum voltage of loads reactivation Vhb Setting with GSM interface -0,08-0,24-0,56 V Voltage of loads reactivation VELB Setting with GSM interface Vch-Vhb V Efficiency η Only regulator Global (regulator+ballast SOX) Compensation of voltage in temperature VTadj 2 TBATT>=-8 C<=58 C (see graphic 1) mv/ C Light-sensor threshold (for load: ON) Vlson Setting with GSM interface 1,92-4,48 V Light-sensor threshold (for load: OFF) Vlsoff Setting with GSM interface 4,32-6,88 V Temperature of working environment TA C Over-temperature threshold TOT Ta>Tot put the system in protection for overtemperature 65 C Section of cables from PV modules - 2, mm 2 Section of cables towards batteries mm 2 Duration of overload condition (overload) 2 minutes Output current causing over current Ioc for T 0.5 seconds 8.2 A Duration of over current condition (overcurrent) Toc 2 minutes Current on lamp output Ilamp A Voltage on lamp output Vlamp Vlb - Vch V GSM modem f Dual band 900/1800MHz 900/1800 MHz Power of GSM signal Pgsm At 900 MHz At 1800 MHz Internal temperature <50 C. 2 Regulation made at steps of 6 C. 3 For connections between 2 PV modules and circuit use 2.5mm 2 each; for connections between 1 PV module and circuit use 4mm 2 on distances <1.5m Maintenance: For a correct working of the system: - Pay attention to waterproof box putting the cover gasket in the proper way and fixing and sealing the cable gland; the not used cable gland have to be closed with short cable pieces; control periodically the status. Warranty does not cover regulators with water inside. Never make holes on the external box. - Program the system parameters (thresholds, timer, etc.) so to avoid deep discharges of battery. - Control periodically the conditions of batteries (tensions <,00V are critical for long periods). - Control periodically the cables. - Keep this manual in a safe place % % W W 10

11 Anomalous behaviours: Signals of B LED Condition of the charge regulator Noticed behaviour Interpretation Remedy On activation the B LED (red) Status lightens to the bitter end ONCE every 2 seconds. On activation the B LED (red) Status lightens to the bitter end TWICE every 2 seconds. On activation the B LED (red) Status lightens to the bitter end THREE TIMES every 2 seconds. At dusk the lamp does not turn on. At dusk the lamp does not turn on. At dusk the lamp does not turn on. At dusk the lamp does not turn on. The lamp lighting time in shorter than the programmed. The lamp lighting time in shorter than the programmed The lamp lighting time in shorter than the programmed The system does not reactivate after a long period of storage and/or inactivity. Low battery condition; the battery is Wait the battery recharging. discharged and all outputs are de-activated Overload condition; outputs are deactivated for 2 minutes after 2 minutes you can try to reactivate the load. If overload condition continues, every 2 minutes you have an attempt of reactivation until a maximum of 3 attempts. After that, the next attempt of power on will happen the next night. Over-temperature condition. If the battery is new, the PV module could be particular and give signal in input to the regulator even in darkness condition. The battery is discharged for a long period without sun. The lamp is exhausted or the cable is interrupted. After some working years the battery is naturally exhausted and not recharge anymore. The battery is discharged. The battery is not charged enough. After some working years the battery is naturally exhausted and it lost its capacity. The battery suffered auto-discharge and/or it has been stored in discharged condition for long time; as a consequence it exhausted. Control the output (cables, lamps, and so on) and remove the cause of overload. An end-life lamp can cause overload. Place the charge regulator in another place which is fresher. Modify the dark detection voltage of lightsensor. Wait the sun to recharge the batteries. Control cable and lamp and replace the broken component. Replace the battery. Wait the sun to recharge the batteries. Control if the cabling of PV modules has been interrupted somewhere. Replace the battery. Try to recharge the batteries with battery charger from grid; in negative case replace the battery. 11

12 Signals of C LED Condition of GSM Modem Noticed behaviour Interpretation Remedy On activation the C LED (red) Status GSM lightens to the bitter end ONCE every two You are executing the procedure of modem configuration. It is a normal situation that Wait 1 2 minutes until C LED turns off or changes its way of lighting. seconds. can happen both during the first power on and during the normal working. In such a period of time the regulator is not able to communicate with the remote PC. On activation the C LED (red) Status GSM lightens to the bitter end TWICE every two seconds. You did not insert the SIM in the proper fissure of GSM module. Insert SIM, push the RESET button (fig. 5) and wait that the C LED doesn t lighten anymore. On activation the C LED (red) Status GSM lightens to the bitter end THREE TIMES every two seconds. The signal level that has been measured by the modem is too low. Check that the antenna is properly connected to the BNC connector (fig. 4). Try to change position fo the antenna. You could be in a zone where mobile phone operator doesn t offer an adequate signal level. After that try to change operator. On activation the C LED (red) Status GSM You did not set up the phone numbers Execute the procedure to program the SIM. lightens to the bitter end FOUR TIMES every two seconds. which are qualified as the remote manager of the regulator in the SIM memory. On activation the C LED (red) Status GSM lightens to the bitter end FIVE TIMES every The SMS memory is full. Delete all the SMS in the internal memory of the SIM two seconds. On activation the C LED (red) Status GSM lightens to the bitter end SIX TIMES every two seconds. Communication mistake with GSM modem. It is an internal mistake that causes the turning off and the turning on of the GSM modem. Wait 2 3 minutes. Accessories: NTC Antenna TX Standard supplied Standard supplied NOT standard supplied. To be ordered as accessory code TX 1.5m bipolar signal cable with temperature sensor at the end. Antenna for ricetransmission GSM modem for communication, programming and monitoring Address: WESTERN CO. snc Via Pasubio San Benedetto del Tronto (AP) - Italy tel fax info@western.it web: Exhausted batteries are highly polluting DO NOT leave them in the environment. Bring them in an authorized collecting center. 12