AeroVironment Universal Solar Pump Controllers

Transcription

1 AeroVironment Universal Solar Pump Controllers (Installer s business information to be affixed here.) User Manual Models: USPC-2000 (AV Part Number Rev. D) USPC-5000 (AV Part Number Rev. D) R LISTED 70EL AV P/N , Rev B, AeroVironment Inc April 1998

2 WARNING HIGH VOLTAGES Voltages capable of causing severe injury or death by electrical shock are present in this unit. This unit should only be installed or serviced by an AeroVironment authorized supplier or dealer familiar with the USPC Systems and Installation Manual. Note any changes in the spaces provided below. To safely service the USPC, the following procedure must be used. 1. Securely cover the array with an opaque tarp. 2. The external solar panel DC disconnect switch must be in the OFF position. 3. Set the mode switch to 'DISABLE, then open the unit. 4. Remove the internal isolation disconnect and put it in a safe place. 5. Wait 15 seconds after removing power from the unit before servicing. SERVICE INFORMATION Contact the Supplier or Dealer of this unit for any service requirements or warranty claims. NOTICE TO INSTALLER NEC codes take precedence over suggestions in this manual. The registration card enclosed with this unit must be completed and sent to AeroVironment to validate the warranty. Refer to the USPC System and Installation Manual for instructions. We strongly recommend that the installation data be recorded into section 11 of this manual and that the manual remain in the unit. 1 18

3 11. INSTALLATION NOTES The following reference information must be noted during installation. Registration is the responsibility of the installer. Date Installed : USPC Serial No. (Bottom Label): USPC PC Board Serial No.: Model: USPC- USPC Software Version No. (Microprocessor) : Installer: Address: Phone: Location of Installation : Pump Manufacturer / Model No : Motor : HP, Vac, ph Well Depth : (m, ft) Pumping Rate Required : (lpd, gpd) Solar Module Manufacturer : Module Model Number : No. Modules in Series / Parallel : / Tilt Angle : Weather During Installation : Comments: TABLE OF CONTENTS Section Page 1. Product Description Product Specification External Configuration Internal Configuration Configuring the USPC Installation Requirements Electrical Installation Operation Maintenance Troubleshooting Installation Notes NOTICE This manual is intended to be used as a quick reference guide only and is not intended to replace the USPC Systems and Installation Manual. The information in this document is subject to change without notice. No part of this document may be reproduced in any form or by any means without the express written permission of AeroVironment Inc. AeroVironment Inc. All rights reserved. 17

4 2 1. PRODUCT DESCRIPTION The AeroVironment Universal Solar Pump Controller is a versatile, high performance, variable speed motor controller for solar powered pumping applications using pumps from 1/2 HP to 2 HP (using USPC-2000), 1/2 HP to 5 HP (using USPC-5000). Applications Livestock Water Supply Village Water Supply Small Scale Irrigation Desalination Versatility The USPC will power ANY standard three phase or three wire single phase pump motor. This allows less costly, locally available and serviceable pumps to be used. The USPC can be powered by ANY photovoltaic technology. Efficiency A power conversion efficiency of 97%, peak-power tracking and variable speed operation maximizes your system performance to get the most water from your installation using standard pumps. 3

5 Indicator Light Output Overload Output Underload Cause/Corrective Action More than expected power being drawn by pump motor in normal run mode. Check for fouling and/or replace pump motor as required. Also check wiring connections between the unit and the pump motor for shorts or water leak. Less than expected power being drawn by pump motor. Check and/or replace pump motor as required. Also check wiring connections between the unit and the pump motor. Check if well went dry. 10. TROUBLESHOOTING There are six indicator lights which indicate various system fault conditions. These lights are visible through holes in the front cover. A list of these indicator lights and recommended corrective actions are listed below. Indicator Light System Disabled Cause/Corrective Action Reset DIP switch or external disable switch engaged, or microprocessor defective. Set the memory reset DIP switch to normal operation, (SW-2, 1=off), and the external switch to the RUN position. Examples of what could cause the unit to appear to be working properly (no faults) but no water is pumped: bad connection to motor, miswired single phase motor, lost winding in motor, if the pump is installed in a dry well or with a blocked waterline. If the unit exhibits frequent overload or underload faults although there appears to be nothing wrong with the installation, try clearing the memory. This will permit the USPC to compensate for changes in power characteristics that may result from large seasonal variations in well water level or aging of the pump and motor. If a fault cannot be corrected, first call the supplier or dealer, then if necessary, contact Aerovironment at: Phone : (626) FAX: (626) Sales@aerovironment.com 16 System Fault Remote Shutdown Low Input Power Over current: Motor winding shorted or connection shorted to case, check motor and connection. Pump may have lightning protection installed, remove it (it is only needed for utility connected systems). Over temperature. Unit may be in direct sunlight or the heat sink may be blocked. Provide cover from sun or clean heat sink area. It is much more likely that a System Fault would indicate an excessive current than an over temperature fault. Remote shutdown switch open, wire disconnected, or broken Not enough input power to run the pump motor at the minimum speed. Caused by cloud cover or insufficient light at early morning or evening. Wait for clouds to pass and unit to restart. Also check wiring connections between the unit and solar array. Solar array may be damaged. 15

6 2. PRODUCT SPECIFICATIONS Input Power Voltage 210 Vdc (for 115 Vac, 60 Hz, 1Ø motors) 340 Vdc (for 230 Vac, 60 Hz, 3Ø motors) 385 Vdc (for 230 Vac, 60 Hz, 1Ø motors) 600 Vdc absolute maximum open circuit voltage, (includes max. Voc + 125% over that NEC requires) Current 8 Amps (Max. short circuit current USPC-2000) 18 Amps (Max. short circuit current USPC-5000) Ground Earth ground connected to chassis Common to negative of the solar array Output power Power Max. Sustained 2.2 kw (USPC-2000) 5.5 kw (USPC-5000) Efficiency 97% (3Ø), 95% (1Ø) Motor Rating / Vac HP 1Ø 3Ø , 208, , , 208, , , , , 230 to , 230 Current Max. 13 Amps peak, 9.5 Amps RMS (USPC-2000) 32 Amps peak, 24 Amps RMS (USPC-5000) Selectable Min. Freq. 10, 20, 30 or 40 Hz Selectable Nom. Freq. 50, 60 Hz Selectable Max. Freq. 0 or 5 Hz Over nominal Waveform Sine weighted PWM Shutoff switch Open circuit shuts off USPC The USPC will operate any standard three phase or three wire single phase pump motor. The USPC will not operate a 2-wire single phase motor which uses switching devices for the start winding. 4

7 3. EXTERNAL DESCRIPTION FRONT VIEW 9. MAINTENANCE The unit should be inspected every 6 months. Remove any external obstructions such as cobwebs, vegetation, etc. from the heat sink area. Well sealed electrical feed throughs on the unit will guard against intrusion into the electronics. No other maintenance is required. LED Fault Indicators Mode Switch RS-232 Port DC entry Float or Switch exit AC exit Provision for Lock BOTTOM VIEW 5 14

8 8. OPERATION Startup The unit is designed to operate automatically after; 1. All wiring connections are made, 2. The internal isolation disconnect is installed, 3. The external disconnect switch is enabled, and 4. The external mode switch is set to the RUN position. When the unit is first turned on, the memory must be cleared so that the USPC will calibrate to the new installation. If there is not enough array power to run the motor at the minimum frequency, the unit will shut down and attempt a restart at a later time indicating LOW INPUT POWER on the LEDs. Shutdown The USPC may be shut down in several ways; 1. Disconnect the PV Array at the external switch.* 2. Move the mode switch to the disable position. 3. Break the contact at the remote switch. Clearing Memory The internal memory is cleared by; 1. Turning on the unit, 2. Moving the mode switch to the DISABLE position, and then 3. Moving the mode switch to the CLEAR MEMORY position and holding it until the LEDs flash and then release the switch. Note: We recommend checking the pump before installing it in the well. Operate the pump for a few seconds to verify connections, rotation direction, and switch settings are correct. Motor should run smoothly. *Note: Only #1 removes power from the USPC INTERNAL DESCRIPTION DIP Switch, SW1 DIP Switch, SW2 Microprocessor Remote Shutoff Switch Connection AC Power Terminal Internal Isolation Disconnect DC Power Connections Ground Terminal FRONT VIEW

9 5. CONFIGURING THE USPC The USPC DIP switches must be set prior to installation and operation. These switches enable selection of motor type, motor voltage, motor frequency, and other operating parameters. Switch Block 1 (SW 1) SW 1 Motor phase Single-phase 1 = off, 2 = off Three-phase 1 = on, 2 = on Motor frequency select 50 Hz 3 = off (nominal) 60 Hz 3 = on Freq. increase max. Nominal 4 = off Nom. + 5Hz 4 = on Motor freq. min. 10 Hz 5 = off, 6 = off 20 Hz 5 = on, 6 = off 30 Hz 5 = off, 6 = on 40 Hz 5 = on, 6 = on Output voltage 115 Vac 7 = off, 8 = off 208 Vac 7 = off, 8 = on 230 Vac 7 = on, 8 = on AC Power Wiring to Pump Motor The local pump distributor or the pump installation manual should be consulted for specification of a suitable pump cable size. The three power leads for either single or three phase motors are to be attached to the output terminals marked A, B, and C located at the lower right portion of the power electronics circuit board. Fuses in the AC wiring to pump need to be used if PV array is mismatched to load, (oversized for motor used). Single Phase Motors The single phase wire connections will normally use the convention indicated in the table below. Do not connect a motor that has windings which are not clearly identified. Three Phase Motors The sequence of phases determines the direction of rotation of the pump. Water will flow even if the pump is rotating in the wrong direction but at a reduced rate. If uncertain, run pump both directions and check for max. flow. Normal three phase wire conventions are listed in the table below. Output Single-phase motors Three-phase motors A Main winding, (black) Winding A, (black) B Start winding, (red) Winding B, (yellow) C Neutral winding, (yellow) Winding C, (red) GND Ground wire, (green) Ground wire, (green) Optional Remote Switch A switch can be installed to turn on or off the unit remotely. The wire to the switch needs to be rated at 600V. 12 7

10 Internal Wiring Pre-installed internal wires are color coded and marked as follows. DO NOT miswire or equipment damage will occur. Red = positive ( + ) Black = negative ( - ) Green / Yellow = ground ( GND, or ) DC Power Wiring from Array WARNING - Voltages capable of causing severe injury or death by electrical shock are present. Refer to the USPC Systems and Installation Manual for proper wiring and selection. Use extreme caution and take the following precautions before wiring the USPC. 1. Securely cover the array with a completely opaque tarp. 2. The external solar panel DC disconnect switch must be in the OFF position. 3. Remove the internal isolation disconnect, put it in a safe place. Once DC power wires are disconnected from the solar array, the electrical wires may be routed to the appropriate connection terminals in the USPC. The ground wire is connected to the terminal at the bottom left corner of the unit. The positive and negative power wires are connected to the clearly marked terminals at the isolation disconnect. 11 Switch Block 2 (SW 2) SW 2 Memory reset Clear Normal oper. Switches 2 through = on 1 = off <== (std) 2, 3, 4 = off <== (std) Fault detection margin Wide margin 5 = on Normal margin 5 = off <== (std) Fault detection Disabled Enabled Modulation Limit Disabled Enabled System Disabled Enabled 6 = on 6 = off <== (std) 7 = on 7 = off <== (std) 8 = on 8 = off <== (std) The motor phase and nominal frequency may be determined by inspecting the motor nameplate. Provisions are made to add 5 Hz to the nominal frequency for increased pumping performance. Consult the pump supplier before selecting this option. Setting a motor minimum frequency to a value near that required to achieve flow will minimize the motor and pump wear. Refer to the USPC Systems and Installation Manual and the USPC System Sizing Software to determine an appropriate value. If uncertain, use 30 Hz. Consult the pump supplier before selecting 10 or 20 Hz. The output voltage must be set to the correct value or damage may result to the motor. Use 230Vac for 220 through 240Vac motors, 208Vac for 200 through 208Vac motors, and 115Vac for 110 through 120Vac motors. 8

11 6. INSTALLATION REQUIREMENTS The unit must be installed in a shaded location, away from any source of heat and moisture, and in an area free of vegetation. Provisions must also be made to protect the unit from damage by unauthorized persons, large animals, or other infestation. Whenever possible, the unit should be mounted at least 1 foot (30cm) above the ground. A minimum of 10 inches (25cm ) clearance above the USPC is required for internal access. There must not be any obstruction to air flow at the heat sink. Provisions for mounting are on the heat sink flanges, 6 places (¼ screws). A typical installation on an array structure is shown below. 7. ELECTRICAL INSTALLATION WARNING HIGH VOLTAGES Voltages capable of causing severe injury or death by electrical shock are present in this unit. This unit should only be installed or serviced by a trained individual. General The principal electrical elements of an installation include the solar array, a disconnect switch, the USPC, a pump, and a remote switch (optional). All electrical wire connections to the USPC are made through the holes at the bottom of the USPC. Make sure the AC and DC leads entering the bottom of the USPC are through different holes as shown below. Replace the bottom plastic plugs shipped with the unit with metal water tight listed plugs. 10.0" Min. Solar Array USPC-2000 ON OFF Remote Switch Heat Sink Earth Ground OF F ON " External Disconnect Switch Pump Follow local electrical codes and standards with respect to wiring and safety practices. Refer to the USPC Systems and Installation Manual for more specific and detailed instructions. Be certain to document the system configuration in Section 11 for future reference.