TSW True Sine Wave
Inverter / Charger
Technical Training
2011
Apollo Solar, Inc.
23 F. J. Clarke Circle
Bethel, CT 06801
(203) 790-6400
www.ApolloSolar.com
1
Mission Statement
In this technical training session, Apollo Solar will teach
and demonstrate the technical installation and operation of
the Apollo Solar Battery-Based Inverter/Chargers
1. The TSWs save time and money on installations because they
are easy to set up and operate. The Apollo ISM provides circuit
breaker housing. Complete pre-wired systems can be provided.
2. Apollo Solar provides all the electronics for battery-based
installations including the T80 and T80HV Charge Controller
and remote monitoring so system support is just a single call.
3. The unique Apollo Remote Monitoring provides system data to
any PC, thus eliminating many costly site visits.
4. The TSW is the only Inverter required for all your installations
because they provide 120VAC, 120/240VAC Split Phase or
230V 50Hz up to 32kW or 120/208VAC 3 phase up to 12kW.
2
Training Outline
1. Basic Approach to Off Grid System Design
2. Safety Issues – Lethal voltage and dangerous current
3. System overview
4. Applications
5. Inverter and Switchgear Mounting and Wiring
6. Battery Charging
7. Inverter Set-up using the Apollo Inverter Manager software
8. Monitoring Set-up and Operation
9. Technical Support
3
Off-Grid Power – 3.2kW to 56kW
These Apollo Solar Inverters
are providing 56kW for a hotel
in the Dominican Republic.
Our TSWs are the only
inverters that can be parallel
stacked for this much power.
They can also provide 3 phase
power for industrial sites.
The Inverter Switchgear
Modules house the circuit
breakers for each inverter.
4
4
Off Grid System Design - Approach
1.
Know the Loads ! MOST IMPORTANT STEP
a.
b.
2.
Continuous loads with number of hours per day
Peak loads like starting motors and pumps
Size the Inverter to meet both load requirements
Leave plenty of head room – users will add loads in the future
3.
Size the Battery to supply the daily loads
Keep the depth of discharge between 30 to 50%.
Battery storage capacity at least kWhr 2-3 times daily load requirement.
4.
Size the PV array to recharge the battery in 1 day
Don’t forget that the sun may not shine every day.
5.
Select the Charge Controller to recharge the battery
Watch the maximum Open Circuit Voltage limit.
6.
Add Communication Devices to monitor the system
You should know how well each system is working all the time.
5
CAUTION – BATTERY CURRENT IS DANGEROUS
1. TURN OFF all circuit breakers including the large Battery Circuit
Breaker before connecting battery or AC wiring.
2. Be careful of short circuits when connecting cables to batteries. A
short across the terminals can vaporize a wrench.
3. The sequence for powering up the Inverter / Charger is critical –
the battery voltage must be applied before the AC.
4. All connections must be tightened to the torque specified.
5. Wire sizes are critical. The high DC currents require heavy wire.
6. The AC voltage is lethal. Do not touch anything inside a TSW or ISM
unless the system is totally de-energized.
7. These systems have multiple sources of energy. Both the AC input
and the Battery connection must be disconnected before working
inside the enclosures.
6
Apollo Solar Inverter/Charger and Switchgear Module
The Apollo Solar True Sine Wave Inverter / Chargers are
available in 24 volt and 48 volt versions.
The TSW3224 is 3200 VA continuous at 24 volts and
the TSW4048 is 4000 VA continuous at 48 volts.
Both TSWs can be used in AC systems that are:
120/240 VAC Split Phase for US residential installations,
120 VAC single phase at 2X the current,
230 or 240 VAC for foreign installations.
The frequency is switch selectable 50 or 60 Hz.
Each TSW is capable of over current for short periods:
200% for 7 seconds, 150% for 30 seconds, 120% for 30
minutes.
The TSWs can be stacked in parallel up to 32kVA for
Single and Split Phase and can be wired for up to 12kVA
120/208 3 Phase.
The Inverter Switchgear Module is designed to provide all
the circuit breakers for each inverter and can be stacked.
It is shown here as a sub-system assembled and pre-wired
7
by Apollo Solar, ready for installation.
Apollo Solar Inverter Switchgear Module (ISM)
Low cost.
Stackable for parallel or 3 phase
inverter operation.
Set up for 120V, 230V or 240VAC
18 AC or DC DIN Rail breakers.
175A or 250A main DC breaker.
Small size:
11” wide, 15” tall, 7” deep.
280mm wide, 380 tall, 485 deep.
Pre-wired for fast installation.
8
Apollo Solar Components
Inverter Switchgear Module
(ISM)
Breakers, Bus Bars and
Connection Points as a
complete UL Certified
system
True Sine Wave Inverter /
Charger (TSW)
Provides DC to AC
conversion, battery
charger and transfer relay
all UL certified
SNMP Gateway
Converts the ASNET
bus data to Ethernet
9
Inverter / Charger - System Block Diagram
10
Apollo Solar TSW3224 and TSW4048 specifications
True Sine Wave Inverter SPECIFICAT IO NS
TSW3224
TSW4048
Max. Power Rating 25º C
Nominal DC Battery Input Voltage
Battery input current at rated power
3200 VA
24 VDC
148 Amps
4000 VA
48 VDC
95 Amps
Nominal AC Output Voltage
Selectable 120 / 240 VAC Split Phase, 120VAC single phase or 230VAC single phase
Surge Power Peak (1m s)
L-N: 80A AC, L-L: 41A AC
L-N: 80A AC, L-L: 41A AC
Surge Power RMS (100ms)
Overload Capacity from 25ºC start
L-N: 52A AC, L-L: 37A AC
L-N: 52A AC, L-L: 37A AC
6400 VA 200%
4800 VA 150%
3840 VA 120%
8000 VA 200%
6000 VA 150%
4600 VA 115%
7Seconds:
30 Seconds:
30 Minutes:
Max. AC RMS Amps Output @ 25º C
L-N: 26A AC, L-L: 13A AC
L-N: 30A AC, L-L: 15A AC
Full on, No load power consumption
Search mode power consumption
Inverter Efficiency (Peak)
~ 27 Watts
~ 4.5 Watts
>93%
~ 39 Watts
~ 4.5 Watts
>95%
Total Harmonic Distortion
Output Voltage Regulation
AC Output Frequency
AC Input Frequency Range
AC Input Voltage Range for Charge Mode
DC Output Range
Maxim um Input Short Circuit Current
Continuous Battery Charger Output at 25º C
Five Stage Battery Charger Output
Battery Charging Power Factor Corrected
Battery Charge temperature compensation
Transfer relay capability
Operating Temperature Range
Overtemperature Protection
Agency Certification
Warranty
Weight
Size
Enclosure
Cooling
Data Communication
Typical: 3.5%, Maximum: 5% (T rue sine wave)
+/- 3%
50 or 60Hz +/-1% (Switch Selectable)
46 to 55Hz at 50Hz Nominal, 55 to 65 Hz at 60Hz Nominal, Switch Selectable
L-N: 80 ―150 VAC for 120VAC mode, L-L: 160 ―270 VAC for 240VAC m ode
21.0 to 35.0 VDC
42.0 to 64.0 VDC
250A
250A
100 amps DC
70 amps DC
Bulk, Absorb, Float, Equalize & Standby
>0.92
With external temperature sensor
40 Amps per leg; 8 to 16ms transfer time
-20º C to +45º C
Sensors on MOSFETs, Transformer and Battery
UL 1741
UL 1741 & CSA C22.2 No. 107.1
5 Years
25.1kg, 55 lbs. (27.5kg, 60.6 lbs shipping weight)
572x229x184mm , 22.5"x9"x7.25" (686x330x305mm , 27"x13"x12" shipping box)
Powder coated steel
Variable Speed, Temperature controlled fans
ASNET (RS-485) and CANBUS
O PT IO NAL ACCESSO RIES
Charge Controllers
Ethernet / Internet Monitoring
Apollo Solar T 80 and T100 TurboCharger provide optimum charging from PV arrays.
Optional Communication Gateway provides full data monitoring from any computer.
Inverter Switchgear Module
Optional Switchgear Module includes all the DC and AC circuit breakers required.
11
Industrial Grade Backup Power
The system in the photo
provides 4kW of 3 phase
120/208 volts for 8 hours.
A large number of these are
installed in the Washington DC
subway system to provide
backup power for cellular
communications.
Apollo Solar TSWs were
selected based on Reliability,
Ease of installation, Remote
monitoring and cost.
12
Large-Scale Installations
Off-Grid Power – 3.2kW to 56kW
These Apollo Solar Inverters
are providing 56kW for a hotel
in the Dominican Republic.
Our TSWs are the only
inverters that can be parallel
stacked for this much power.
They can also provide 3 phase
power for industrial sites.
The Inverter Switchgear
Modules house the circuit
breakers for each inverter.
13
Apollo Solar T80 & TSW – Easy to install
anywhere in the World
Here is shown Apollo Solar Off-Grid System using the T80
Charge Controllers, TSW3224 Inverters and ISM
Switchgear Modules in a parallel system
14
Apollo Installations
These installations use our TSW Inverter /
Chargers to provide AC and to charge from a
generator in addition to our PV Charge Controllers.
15
Apollo Remote Telecom Sites
Telecom site using 3 Apollo Solar T80s
in the Mojave Desert region of
California.
16
Standard Products with Flexible Configurations
We offer a choice of NEMA 3R, 4 or 4X
enclosures with any combination of Inverters
and/or Charge Controllers. The options
17
designed for the needs of remote telecom.
Mounting Dimensions
and Air Flow
The TSW and ISM require a total of
37.4” in height. Since the battery wire
conduit is attached to the bottom of
the ISM, an additional 7” is
recommended under the ISM.
The ISM should be mounted first.
Air flow is required to cool the TSW
Inverter. At least 20 square inches of
air inlets are needed near the bottom
of the ISM, and 20 square inches for
air exhaust at the upper 1/3 of the
TSW as shown in the diagram.
If the air flow is restricted, the warranty
is void and damage can result.
18
TSW and ISM mounted on
back plate
The Inverter along with the Switchgear Module
is supplied mounted on the back plate wired and
tested.
It is ready to mount into an enclosure, when
required, and can even be on the outside wall of
a battery enclosure.
The “keyholes” at the top of the back plate make
it easy for one person to hang this assembly.
19
Simplified Wiring
TSW, ISM & Batteries
NOTE: AC NEUTRAL AND
DC NEGATIVE WIRES ARE
WHITE, BUT ARE SHOWN
AS LIGHT GRAY.
APOLLO SOLAR
TSW 3224 or TSW 4048
TRUE SINE WAVE
INVERTER/CHARGER
AC OUT AC IN
APOLLO SOLAR
TSW 3224
CAT-5
ETHERNET
CABLE
The AC wiring is done using No. 8
wire rated at 40 Amps.
INTERNET
APOLLO
COMMUNICATION
GATEWAY
(Optional)
TRUE SINE WAVE
INVERTER / CHARGER
ACG-1
APOLLO SOLAR
SWITCHGEAR
MODULE
ENCLOSURE
40A MAX AWG #8
The DC wiring to the Battery must be
heavy gauge No. 4/0 cables with the
proper terminations.
ASNET
500A SHUNT
250A DC
BREAKER
+BUS
GROUND BUS
AC NEUTRAL BUS
BYPASS
40A
40A
40A
40A
40A
40A
250
*GND
NOTE
AC OUT
240VAC
IN FROM
LINE OR
GENERATOR
L2
L1
CHASSIS
EARTH
GND
240VAC
OUT TO
LOAD
PANEL
* GND NOTE: IF THIS POWER CENTER IS THE SOURCE
OF THE BUILDING POWER, THE AC NEUTRAL MUST BE
CONNECTED TO EARTH GROUND AT THIS POINT ONLY.
IF THE SYSTEM HAS AN AC INPUT AT A CIRCUIT
BREAKER BOX, THE AC NEUTRAL MUST BE TIED TO
GROUND AT THAT SOURCE OF POWER ONLY.
4/0 GAUGE WIRE
NEUTRAL
OPTIONAL
DELTA 302R
LIGHTNING
ARRESTORS
BATTERY
WIRED FOR 120/240VAC SPLIT PHASE
.
- BUS
AC BREAKERS
NEUTRAL
The proper torque for each terminal
is specified on a label inside the ISM
near the terminals.
AC
AC IN
The battery connection should be
made last. Once this connection is
made, the enclosure is energized.
AC
L2
L1
CAUTION: The circuit breakers
must be turned OFF before any
connections are made.
AWG #6
DC IN
6V
BATT
6V
BATT
6V
BATT
6V
BATT
INVERTER
SWITCHGEAR MODULE
ISM 120/240
WIRING DIAGRAM
BATTERY BOX AND BATTERIES
(MADE BY OTHERS)
BATTERY MAY BE 24 OR 48V
DEPENDING ON THE INVERTER.
(24 VOLT VERSION SHOWN)
STRINGS MAY BE TIED IN
PARALLEL FOR MORE AMP-HRS.
20
Grounding Details
Bus Bars for AC
Neutral and Earth
Ground are located in
the Inverter
Switchgear Module
(ISM).
AC SYSTEM
HOT IN
AC
HOT IN
HOT OUT
HOT OUT
NEUTRAL
DC SYSTEM
TO
BATTERY
SYSTEM
BONDING
JUMPERS
GROUNDING
ELECTRODE
CONDUCTOR
APOLLO SOLAR TSW INVERTER
DC NEGATIVE
BUS-BAR
GROUND
BUS-BAR
DC
CHASSIS GROUND
EQUIPMENT
GROUND
CONDUCTOR
GROUNDING
ELECTRODE
AC TRANSFER
SWITCH AND
FILTER BOARD
For clarity, this
drawing shows a TSW
and ISM wired for
120V only.
NEUTRAL
NEUTRAL
BUS-BAR
CHASSIS GROUND
APOLLO SOLAR TSW
INVERTER
GROUNDING DETAILS
21
120/208 Volt 3 Phase explained
3 PHASE AC DEFINED: “Y” TRANSFORMER PRODUCES 208VRMS
BETWEEN ANY 2 LEGS AND 120V FROM ANY LEG TO NEUTRAL
3 PHASE 208VAC
UTILITY SOURCE
5.56
ms
L1
L1
L2
L3
120V
NEUTRAL
L3
120V
208V
L2
16.67ms
nc
•It is common for industrial AC power to be supplied as 208 volt 3 phase.
•Motors and other heavy equipment run more efficiently on 3 phase power.
•In addition to 208 volts between any 2 legs, any single leg and neutral provides 120 volts
for standard single phase loads.
•The Battery Backup Unit shown in the photo above produces 208 volts from 2 of the 3
phase legs and 120 volts from L1 to Neutral. Two 120V inverters are used with one
inverter on each of 2 legs.
22
3 Phase Wiring
Diagram
This is the actual wiring diagram of a
Battery Backup Unit for a telecom
system powered by 2 phases of a
208V 3 phase service showing both
the Master and Slave TSWs.
23
3 Phase Wiring Diagram
The TSWs use a stacking cable. The master sends timing signals to the slaves so
the zero crossing of phase 2 and phase 3 are each 120 degrees later.
24
AC Wiring Terminals
The photo at the left shows the AC wiring box with the cover removed.
Note the No. 8 AWG wires exit the wiring box and are routed between the
TSW and the back panel (or wall).
This illustration shows the 7 wires required for 240/120V operation:
1 – AC Line1 Output (Red)
2 – AC Line2 Output (Black)
3 – AC Neutral Out (White)
4 – Ground (Green)
5 – AC LINE1 In (Red)
6 – AC Line2 In (Black)
7 – AC Neutral in (White)
25
TSW Inverter bolted to the
Inverter Switchgear Module
Apollo Solar TSW4048
Inverter / Charger
TSW Positive Terminal bolted
to the positive bus bar
TSW Negative Terminal bolted
to the negative bus bar
Apollo Solar Inverter
Switchgear Module enclosure
with cover removed
Conduit in place for wires to the
battery box
26
Inverter Switchgear Module (ISM) with DC Wiring
Inverter Positive
Terminal
Current Shunt on
DC Negative 48v
Bus Bar
250 Amp DC
Circuit Breaker in
Positive 48v Bus
TSW Gnd
Lug
Inverter
bolted to
Negative
DC bus bar
AC Neutral
bus bar
Ground
bus bar
4/0 wires to batteries
DIN Rail for
AC Circuit
Breakers
27
AC Wiring from TSW, Line In and Line Out
In this 240/120 VAC system,
there are 7 AC wires from the
TSW into the ISM:
AC L1&2 In (Black&Red)
AC Neutral In (White)
AC L1&2 Out (Black&Red)
AC Neutral Out (White)
AC Ground (Green)
and 6 AC wires brought in from
outside to the AC Circuit
Breakers:
AC Line 1&2 (Black&Red)
AC Line Neutral (White)
AC Load 1&2 (Black&Red)
AC Load Neutral (White)
Green wire grounds from
outside go to the Gnd Bus Bar.
Inverter AC
Neutral
wires
Ground
Inverter AC
Hot Output
AC Line1
&2 inputs
Inverter AC
Line1&2
Inputs
AC Line1&2
Outputs to
Load
28
Battery Wiring
THIS IS AN EXAMPLE FOR
WIRING 48v BATTERIES IN
A SERIES-AND-PARALLEL
CONFIGURATION.
FOR THIS EXAMPLE, EACH
BATTERY CAN STORE UP
TO 300Ahr AT 6 VOLTS,
EACH GROUP CAN STORE
300 X 6 X 8 = 14,400 WATT
HOURS.
No. 4/0 WIRE TO CONNECT
BATTERIES TO THE
INVERTER / CHARGER
BUS BARS TO CONNECT
BATTERIES IN SERIES
29
Battery Charging in the TSW Inverter / Charger
3 Stage Charging
Algorithm
Bulk – Voltage
increases to Absorb
Set Point.
Absorb – Battery
takes less and less
current until full.
Float – Trickle charge
to overcome self
discharge.
LIFELINE RECOMMENDS:
ABSORB VOLTAGE SET
POINT = 56.8 TO 58.4V
FLOAT VOLTAGE SET
POINT = 52.4 TO 53.6V
30
Battery Charging with Temperature Compensation
1. A cold battery requires more voltage to achieve a full charge than a warm battery.
2. The TSW includes a temperature compensation constant using an external
battery temperature sensor.
3. The Battery Temperature Sensor should be located within the group of batteries
where it will be in contact with the highest temperature. A good place is in the
upper shelf of batteries, between batteries, in the middle of the group.
4. The nominal value for the Absorb and Float Set Points are set for 25 degrees C.
and the temperature compensation math modifies the Set Points up or down from
that point depending on the battery temperature.
5. The compensation rate is set for -5 mV per cell per degree C. That means that as
the temperature increases, the set points in the TSW are lowered by 0.005 volts
for each cell. A 48 volt battery has 24 cells, so the total is 0.120 volts lower for
each degree C of increased temperature. The compensation rate may be
selected from -2mV to -8mV/cell/deg C.
6. The TSW Inverter/Chargers have a safety feature. If the battery temperature
goes over a preset limit for any reason, the charging is immediately shut off.
31
Inverter Display
The Apollo Solar TSW is the only Inverter which
includes a display of the operating values.
(The Schneider XW has just a 3 digit LED for
voltage and frequency.)
We designed the TSW with an internal 2x16 LCD
which shows all the critical current values:
• AC Output Voltage
• Mode: Inverting or Charging
• AC Output Current
• Charging Current
• AC Output Power
• Error Codes
• AC Output Frequency
• ID Address
• DC Battery Voltage
• When stacked, the Master
• DC Battery Current
shows Total System values
32
Inverter Parameter Setup Tools
We looked at all the possible ways to set up Inverter parameters in the field:
• Currently our industry uses 4 line LCDs with 4 to 7 buttons and/or a knob.
We think this approach takes far too much time to learn and to use.
• We chose instead to use a full color graphic screen. We eliminated the
leaning curve by putting all the data on a few easy-to-read pages.
LCD
or
Full
Screen
33
Inverter Parameter Setup Tools
•
•
•
•
•
•
•
We call the setup tool the Apollo Inverter Manager (AIM).
The current software version is available on our Website at no cost.
It runs on any Windows based Labtop PC.
AND… We now offer a NetBook PC with the AIM preloaded and set to go.
We will go over the details on the AIM later in the training.
The AIM plugs into the TSW or stack of TSWs using the ASNET cable.
A stack of parallel or 3 phase TSWs can be setup with 1 connection.
34
Inverter Start Up Sequence
1. Start with all circuit breakers turned OFF. Re-read the safety page.
2. Inspect all wiring for proper connection, torque per spec, and possible nicked
insulation. Repair or replace if necessary.
3. Turn the AC input breakers OFF, and the AC output breakers ON. (This will
automatically turn the Bypass breaker OFF via the toggle.)
4. Energize the AC line input power to 120VAC, 60Hz. Make sure the battery is
connected properly.
5. Attached a known load to the AC output. (Like a 120VAC work light.)
6. Turn the DC Battery Breakers ON. Note the TSW LCD Screen. After the initial
screen showing model, serial number, and firmware revision, it will say: AutoStart
in 5 seconds, followed by the main status screen (voltage, current, power). Verify
that the DC input voltage is 44 to 50 volts. Verify that AC output: 120VAC, 60Hz.
7. Switch the AC Output breakers ON. The work light should illuminate.
8. Switch the AC Input Breakers ON. The work light may blink, but should remain
illuminated. The AC is now being supplied from the Utility Line input.
9. The TSW LCD screens should show Charging Mode.
35
Front Panel
LCD
TSW Inverter Operation
Startup and Inverter Mode
A P O L L O
S O L A R
T S W’
R E V X . X X
S / N X X X X X
A C
2 4 0 . 0 V
B A T : 4 8 . 0 V
0 0 . 0 A’
X X . X A
A U T O - S T A R T
A F T E R
5 . 0 S E C
’
Displayed for 2 sec when DC is applied.
Current firmware and Serial Number
Initial Status – AC Voltage, frequency and
battery voltage displayed.
Auto-Start Countdown…Then enters
inverter mode and displays status
I N V E R T I N G
2 4 0 . 0 V
X X X X V A’
6 0 . 0 H z
Main Status Screen #1: Total power,
Voltage and frequency displayed. Press
“Page” key for Status Screen #2.
I N V E R T I N G
L 1 : X X . X A
X X X X V A’
X X X X V A
Status Screen #2: Total Power and AC Line
1 current and power. Press “Page” for
Status Screen #3.
I N V E R T I N G
L 2 : X X . X A
X X X X V A’
X X X X V A
Status Screen #3: Total Power and AC Line
2 current and power. Press “Page” for
Status Screen #4.
I N V E R T I N G
B A T : 4 8 . 0 V
X X X X V A’
X X X . X A
Status Screen #4: Battery voltage and
current (DC). Press “Page” for Status
Screen #1.
36
TSW Inverter Operation
Charger Mode
C H A R G I N G
A C : 2 4 0 . 0 V
6 0 . 0 H z
X X . X A
C H A R G I N G
L 1 : X X . X A
6 0 . 0 H z
X X X X V A
C H A R G I N G
L 2 : X X . X A
6 0 . 0 H z
X X X X V A
C H A R G I N G
B A T : 4 8 . 0 V
X X X . X A
’
Main Status Screen #1: Input Voltage,
current and frequency displayed. Press
“Page” key for Status Screen #2.
’
Status Screen #2: Frequency and AC
Line 1 current and power. Press “Page”
for Status Screen #3.
’
Status Screen #3: Frequency and AC
Line 2 current and power. Press “Page”
for Status Screen #4.
’
Status Screen #4: Battery voltage and
charge current (DC). Press “Page” for
Status Screen #1.
37
Stacking Inverters
Parallel Mode Setup
S T A N D B Y
B A T : 4 8 . 0 V
1.
Turn on Inverter 1 and press
“Standby” key to enter standby
mode.
S E T T I N G
C O M M . I D =
2.
Press “Page” key for 5 seconds to
enter communication ID setting.
Press “Page” to change ID to 32 – 46.
S E T T I N G
M O D E =
P A R A L L E L
3.
Press “Page” key for 5 seconds to
enter mode setting. Press “Page” to
change to Parallel mode.
S T A N D B Y
B A T : 4 8 . 0 V
4.
Press “Page” key for 5 seconds to
return to standby mode.
5.
Set other Inverter(s) following steps 1
to 4. Please Note: Each inverter
must have a unique Comm. ID.
X X
38
Stacking TSW Inverters is a Simple Daisy Chain.
(No Hubs, No Network Cards)
’
8 TSW4048s in parallel for up to 32kVA and Battery
Charge Current up to 560Amps.
’
Uses CAT5 network cable for ASNET (RJ45) and 4 wire
(RJ11) CANBUS for Stacking. Terminators required at
both ends.
’
Automatic Master/Slave selection. (And a Slave will take
over immediately if the Master goes down.)
’
Easy Setup
39
PARALLEL STACKING ID SETTINGS
1. Use IDs in Group1
and Group2 for
parallel stacking.
2. Use IDs in Group 3
thru 7 for 3-phase
stacking. NOTE:
Observe Phasing –
Line 1 must be ID 48,
Line 2 must be ID 49,
Line 3 must be ID 50.
The ID can be set using
the Front Panel LCD.
ID
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
CANbus ID
0
1
2
3
4
5
6
7
0
1
2
3
4
5
6
7
0
1
2
3
4
5
6
7
0
1
2
3
4
5
6
7
Group
Function
phase
Group1
single phase parallel
Group2
Group3
Group4
Group5
Group6
Group7
3-phase parallel
0
120
240
0
120
240
0
120
240
0
120
240
0
120
240
40
Apollo Inverter Manager (AIM)
Easy visual setup and monitoring of the TSW Inverter / Charger with a Netbook / PC
View
Inverter
Status on
top half of
screen.
Set user
parameters
on bottom
half of
screen.
41
Apollo Inverter Manager (AIM)
Easy visual setup and monitoring of the TSW Inverter / Charger with a Netbook / PC
View Inverter
Status of up to 8
parallel (stacked)
units.
42
Apollo Inverter Manager (AIM)
Easy visual setup and monitoring of the TSW Inverter / Charger with a Netbook / PC
View Inverter
Status on top
half of screen.
Set user
parameters on
bottom half of
screen.
43
Setting the Parameters on the TSW using AIM
44
Setting the Parameters on the TSW using AIM
45
Setting the Parameters on the TSW using AIM
46
That completes the TSW Inverter / Charger
portion of this training
Before we go on to the Remote Monitoring part of the
training, we have an announcement:
Apollo Solar now offers Advanced Replacement
Program for the TSWs. If you have a problem
with our TSW in the field, call our Tech Support
department.
If the problem is an actual failure of the TSW, we will
ship a replacement unit to you within 24 hours.
Simply ship the failed unit back after you replace it.
47
Apollo Communications Gateway
Access any Apollo Solar
installation from any
computer via the Internet
Provides easy plug-and-play
connectivity to Apollo products
using Ethernet.
48
Apollo Solar Remote Data Monitoring
’ Apollo
Communication
Gateway
ACG-1
’ Apollo
Cellular
Modem
ACM-1
49
Apollo Remote Monitoring
How It Works
• The Apollo Communications Gateway initiates a TCP
connection every 3 minutes with the Apollo server.
(Because the Gateway initiates the connection, it works
through routers and firewalls.)
• The Apollo server runs an asynchronous multithreading
TCP server that does the following:
– It accepts the incoming connection,
– It discovers what charge controllers and inverters are attached,
– It gets data from the attached devices every 6 seconds.
• The data is then stored in a large SQL Server database
where it can be accessed by the Apollo web application.
50
System Diagram
User Browser
Optional Apollo
Cellular Modem
Apollo Solar Server
-TCP Server
- Database
- Website
Local PC Application
ASNet (Apollo communications protocol)
ASNet over TCP/IP
Conventional Internet
51
Apollo Remote Monitoring
What You Need
1.
Device connectivity – TSW inverters have communications built-in,
the T80 Charge Controllers use an ASNet card
2.
Device Addressing – to be properly discovered, T80 Charge
Controllers must have addresses beginning with 1 or 2 and
continuing sequentially up to 31, TSW Inverters need to start at
address 32 and continue sequentially.
3.
Apollo Communications Gateway – an Apollo Communications
Gateway and the cable supplied to it. The ACG must be connected
to one of the Apollo devices, and then the remaining devices are
connected daisy-chain style with user-supplied standard Ethernet
cables.
4.
Internet connectivity – The Gateway is connected (using the
supplied Ethernet cable) to an Ethernet, WiFi, or cellular network
that has Internet access.
52
Sample Monitoring
53
FAQ - Apollo Communications Gateway
1.
How many T80 charge controllers can be monitored from one Gateway?
–
2.
Up to 31
How many TSW inverters can be monitored from one Gateway?
–
3.
Up to 31
How many total devices can be monitored from one Gateway?
–
4.
Up to 255
How often is data sent from the Gateway to the server?
–
5.
The server asks for data from a device every six seconds, or 14,400 times a day. If there is one T80 in the
system, then there is data from the T80 every 6 seconds. If there is a T80 and a TSW inverter, then there is
data for the T80 every 12 seconds and for the inverter every 12 seconds
Does the Gateway have to powered from the included AC power supply?
–
6.
No, the Gateway can receive power from the T80 or TSW.
Does the Gateway have to be programmed or setup?
–
7.
No, the Gateway is strictly plug-and-play.
How can I tell if the Gateway is communicating with the T80 or TSW and sending data to the
Internet?
–
8.
Refer to the Gateway user guide for detailed information, however if the Transmitting Serial LED blinks every 6
seconds then the Gateway is communication with the server. If the Transmitting Serial and Receiving Serial
lights are blinking every 6 seconds then the Gateway is communicating with the server and with the attached
Apollo devices.
Can a user use software on a local PC to communicate and get data from the Apollo devices using
the Gateway?
–
Yes the Gateway will accept incoming requests. Apollo can provide sample code for communicating on a local
network.
54
FAQ - Apollo Cellular Modem
•
What cellular system does the ACM use?
–
•
What do I need to use the ACM?
–
•
Yes, you need to have a Gateway between the ACM and Apollo devices.
Do I need to configure the ACM?
–
•
The ACM will send and receive approximately 60 megabytes of data a month.
Do I need to use a Gateway if I’m going to use the ACM?
–
•
No, you need to enter into an agreement with your cellular provider for data services and pay
accordingly.
How much data does the ACM send?
–
•
You need to get a SIM card for the cellular system that you want to use, enabled for data. You also
need to get the APN (access point name) for the system.
Is the cost of sending and receiving data included in the cost of the modem?
–
•
The ACM uses GSM and supports the four different GSM frequencies used around the world, so it
is compatible with every GSM system in every country. The ACM uses GPRS or EDGE for sending
or receiving data.
Yes, because you need to install the SIM card and configure the ACM to work with your particular
cellular carrier’s system. The basic installation steps include: install the SIM card; change the
frequency of the modem if you are using it outside the USA; enter the APN (access point name)
and username and password if required.
What if I need or want to monitor using a carrier that uses CDMA?
–
On a special order basis Apollo can provide a CDMA modem or specify one for you.
55
FAQ - Apollo SNMP Gateway
•
Can the SNMP Gateway be customized in terms of SNMP traps and gets?
–
•
What SNMP protocols are supported?
–
•
Yes.
Can the SNMP Gateway be configured to log data and then have log files uploaded
remotely?
–
•
Yes, there is a watchdog timer that can be set to any interval.
Can the SNMP Gateway be configured and have new software installed from remote
locations?
–
•
SNMP versions 1, 2, and 3.
Does the SNMP Gateway have a watchdog timer?
–
•
Yes, Apollo can customize and provide matching MIB file
Yes.
Can the SNMP Gateway be programmed to monitor additional equipment or
sensors?
–
Yes, the SNMP Gateway can be configured to monitor additional devices that provide relay
or digital outputs, or which have a communications protocol. The SNMP Gateway currently
does not support analog inputs, although that is a possibility if the opportunity warrants it.
56
FAQ - Monitoring from the Apollo Website
• How do I setup monitoring for my system?
– Go to ApolloSolar.com and register.
– Send an email or call Apollo solar and ask to have your
monitoring setup. Email or have available your product serial
numbers. We will setup your monitoring page and email or call
you to let you know.
– Once we tell you that your monitoring page has been setup,
login to apollosolar.com and under the Monitoring tab you should
see a link to your page.
• Can I download data to Excel?
– Yes, just ask that a download page be setup for you.
• Can I get data reflecting my local time zone?
– We will provide this shortly.
57
SNMP Gateway – Data Monitoring
1. The Gateway captures data from the TSW Inverter / Charger and
converts it to Ethernet format and sends it to an Internet router.
2. The benefits of the Apollo Communications Gateway.
3. The Data available are as follows:
a) Battery Voltage
b) Battery Current (Charge or discharge)
c) AC Output Voltage
d) AC Output Frequency
e) AC Output Current
f) Aux (Door switches, Misc)
4. May be used directly to PC,
to internal intranet, or to the Internet via
Ethernet and/or Apollo GSM modem.
58
Technical Support for the Apollo Solar Products
•
All the Apollo Solar products carry a 5 year limited warranty which provides for
repair or replacement of our products if a failure should occur.
•
During the warranty period, technical support is available free of charge by calling
our office at (203) 790-6400.
•
When calling for Tech Support, it is will help us to serve you if you tell us this:
•
Your system battery voltage (e.g. 12, 24 or 48 volts).
•
The PV array specs: For example 3kW, 90volts max Voc, 72volts Vmp.
•
Serial Numbers and Firmware version of the Apollo Solar product(s) you are
calling about.
•
Any details you know about external loads like motors, pumps, etc.
•
For complex problems, it is wise to email or fax your wiring diagram to us.
•
The Apollo Solar Communication Gateway automatically gathers a host of
diagnostic data which Apollo Tech Support can see on the Apollo server and
which can be a great help to you and your customer.
59
Technical Leadership
Apollo has
pioneered lightning
protection for
remote power
systems.
Circuits we
developed have
improved the
reliability of the
transmission line
electronics by a
factor of 16 times.
Using Apollo protection circuits, these
solar driven products ran perfectly after
being hit by over 100 lightning strikes up
to 25kAmps each in this high voltage lab.
60
Technical Leadership
The results of our
research is a Surge
Protector that is
specifically designed for
PV inputs to our
Charge Controllers.
It will take many hits of
over 30kAmps and
when it reaches the end
of life, it reports locally
or remotely.
61
Q&A
62
T80/T80HV Charge Controller
Technical Training
2011
Apollo Solar, Inc.
23 F. J. Clarke Circle
Bethel, CT 06801
(203) 790-6400
www.ApolloSolar.com
63
T80 and T80HV
Installation, Setup, and Operation
Features:
’ Both units deliver 80 Amps into
batteries at up to 45oC ambient
’ Input Voltage (PV Open Circuit)
140V for the T80, 200V for the T80HV
’ 250 volt Circuit Breakers and Ground
Fault Protection available from Apollo
’ Use the 2 Sanyo PV modules or a
string of 7 ESA-210 Evergreens
’ Works with the Apollo ISM enclosures
64
Inverter
Inver Switchgear Module
’ DC and AC DIN rail breakers can be installed as a unit.
’ Custom bus bar connectors replace cumbersome wiring.
65
Switchgear
Module
NOTE: AC NEUTRAL AND
DC NEGATIVE WIRES ARE
WHITE, BUT ARE SHOWN
AS LIGHT GRAY.
AC OUT AC IN
APOLLO SOLAR
TSW 3224
APOLLO SOLAR
TSW 3224 or TSW 3648
TRUE SINE WAVE
INVERTER/CHARGER
CAT-5
ETHERNET
CABLE
Wiring Diagram
INTERNET
APOLLO
COMMUNICATION
GATEWAY
(OPTIONAL)
TRUE SINE WAVE
INVERTER / CHARGER
OPTIONAL
REMOTE DISPLAY
ACG-1
The Switchgear Module
accommodates all DC
and AC wiring providing
an easy means to
connect:
1. Battery Cables
2. PV input
3. External AC
APOLLO SOLAR
SWITCHGEAR
MODULE
ENCLOSURE
Solar Power Center
ASNET
APOLLO
SHUNT
BOARD
DC IN
AC
GFP
- BUS
AWG #3
250
+BUS
AC
AWG #3
125V DC
BREAKERS
TurboCharger
PV
IN
AC BREAKERS
BAT
OUT
BATTERY
OPTIONAL
DELTA 302R
LIGHTNING
ARRESTORS
CHASSIS
EARTH
GND
6V
BATT
PV
ARRAY
BATTERY
VOLTAGE
SENSE
WIRES
APOLLO SOLAR T80
PV CHARGE
CONTROLLER
GND
PV IN
240VAC
IN FROM
LINE OR
GENERATOR
240VAC
OUT TO
LOAD
PANEL
WIRED FOR 120/240VAC SPLIT PHASE
* GND NOTE: IF THIS POWER CENTER IS THE SOURCE
OF THE BUILDING POWER, THE AC NEUTRAL MUST BE
CONNECTED TO EARTH GROUND AT THIS POINT ONLY.
IF THE SYSTEM HAS AN AC INPUT AT A CIRCUIT
BREAKER BOX, THE AC NEUTRAL MUST BE TIED TO
GROUND AT THAT SOURCE OF POWER ONLY.
6V
BATT
6V
BATT
6V
BATT
PV
IN
APOLLO SOLAR
BATTERY
TEMPERATURE
SENSOR
PV INPUT
(UP TO 75A)
WIRES MAY BE AS
LARGE AS AWG #2
BATTERY BOX AND BATTERIES
(MADE BY OTHERS)
BATTERY MAY BE 24 OR 48V
DEPENDING ON THE INVERTER.
(24 VOLT VERSION SHOWN)
STRINGS MAY BE TIED IN
PARALLEL FOR MORE AMP-HRS.
INVERTER
SWITCHGEAR MODULE
ISM120/240-T80
WIRING DIAGRAM
66
Basic T80 System
T80 BASIC SYSTEM WIRING DIAGRAM
Input from PV Array
or Combiner Box
+
Wiring Diagram
Showing key
components:
_
BATT+
T80 TurboCharger
500Amp 50mV Shunt
Apollo Shunt Board
Batt Voltage Sense Wires
Batt Temperature Sensor
Cable back to T80
+BAT+ -BAT-
- PV -
DC RATED BREAKER
T80 TurboCharger
MODULAR CABLE WITH 3
TWISTED PAIRS.
FOR CURRENT SHUNT,
BATTERY VOLTAGE
SENSE AND BATTERY
TEMPERATURE.
USE SEPARATE CONDUIT
AND KEEP CLEAR OF
HIGH VOLTAGE WIRING.
+PV+
0
_
DC RATED
BREAKER
SYSTEM
EARTH
GROUND
0
_
+Bat
FUSE
-Bat
SHUNT
50mV
500AMP
Temp
TEMPERATURE
SENSOR
BATTERY
VOLTAGE
SENSE WIRES
APOLLO
SHUNT BOARD
67
Setting up the T80 “As easy as A-B-C”
A
B A T T E
N
C O
B
M
C
B
A
A
A
A
T
K
P
C
P
R
O
N
O L L O
S O L A R
Y
F O U N D
M I N A L
X X
V O L T S
F I R M :
N O
Y E S
’
Step A - T80 reads your
battery voltage. You just
confirm.
T E R Y
T Y P E = X X X X X X X
E =
G E N E R I C
A C I T Y =
X X X 0 A h r
K
+
N E X T
’
Step B - Set charging
parameters
B A T T E R Y
S E T U P
2
M A X
C H A R G E
A M P S =
B A C K
-
+
B A T T E R Y
S E T U P
2
M A X
C H A R G E
A M P S =
B A C K
S
T
D
B
E
I
A
A
-
+
(You provide the Battery
Type and Capacity, the T80
suggests the rest).
X X A
N E X T
X X A
N E X T
T
C L O C K
M O D E = X X H r
M E = H H : M M : S S A M
T E = M M / D D / Y Y
C K
+
N E X T
’
Step C - Set Time and Date,
and Go.
68
Operation of the T80
Main Status Screen
I
O
B
S
N
U T
A T
E T U
= X X X . X V
X
=
X X . X V
X
S O C = X X X %
P
S O C
D A
X
X
X
T
. X A m p s
. X A m p s
X X X X X X
A
’
Main Status Screen - Displays
Input and Output Voltage and
Current, and State of Charge
Data
I
O
B
S
N
U T
A T
E T U
= X X X . X V
X
=
X X . X V
X
S O C = X X X %
P
S O C
D A
X
X
X
T
. X A m p s
. X A m p s
X X X X X X
A
’
Status Field, indicates
operating mode: BULK,
ABSORB, FLOAT, and CHG
OFF.
69
Stacking Charge Controllers and Inverters
L N
OUTPUT
MASTER TSW
30A MAX No. 10 AWG WIRE
AC OUT AC IN
GND
GND
30A MAX No. 10 AWG WIRE
NEUTRAL
LINE IN
GND
NEUTRAL
LINE OUT
APOLLO SOLAR
TSW 4048
INVERTER/
CHARGER
AC OUT AC IN
L N
INPUT
AC CONNECTOR AT TOP OF TSW
TRUE SINE WAVE
INVERTER / CHARGER
TERMINATOR
FOR STACKING
CABLE
APOLLO SOLAR
INVERTER
SWITCHGEAR
MODULE
(ISM230)
APOLLO SOLAR
TSW 4048
INVERTER/
CHARGER
CAT-5 ETHERNET
CABLE TO THE
INTERNET
SLAVE TSW
TRUE SINE WAVE
INVERTER / CHARGER
APOLLO
SOLAR
GATEWAY
24V POWER
SUPPLY FOR
GATEWAY
GATEWAY AND
POWER SUPPLY MAY
BE MOUNTED IN THE
GUTTER RACEWAY
PARALLEL STACKING CABLE
DC IN
GROUND FAULT
PROTECTION
BREAKERS
ON PV INPUT
APOLLO
SHUNT
BOARD
APOLLO SOLAR T80
PV CHARGE
CONTROLLER
GROUND FAULT
PROTECTION
BREAKERS
ON PV INPUT
ASNET
ASNET
TSW
TSW
ASNET CAT5 CABLE
DC IN
APOLLO SOLAR T80
PV CHARGE
CONTROLLER
TRIGGER
INPUT
BAT
OUT
PV
IN
+BUS
50A
.5A
50A
50A
50A
5A
AWG #3
125V DC
BREAKERS
50A
50A
500A SHUNT
AWG #6
GROUND BUS
250A DC BREAKER
BYPASS
30A
AC OUT
AC IN
30A
AC
BREAKERS
PV
IN
TurboCharger
BAT
OUT
PV
IN
SLAVE
T80
GND
TurboCharger
250
AWG #3
PV
IN
AC NEUTRAL BUS
AWG #3
125V DC
BREAKERS
AWG #3
+BUS
30A
50A
.5A
50A
50A
50A
50A
50A
500A SHUNT
AWG #6
250A DC BREAKER
GROUND BUS
AC NEUTRAL BUS
BYPASS
30A
AC OUT
AC IN
30A
30A
60A
60A
GENSET IN
T80 AUX
RELAY
CONTACTS
AUX AUX
1
2
- BUS
GND
2 WIRE
START
AC
BREAKERS
250
MASTER
T80
RES
APOLLO SOLAR
GEN-START
MODULE
- BUS
RES
60 AMP
GENERATOR/LINE
SELECTOR PAC
AC LINE IN
TOGGLE
ISM230
AWG #6
4" GUTTER USED AS RACEWAY
FOR ALL WIRES ALONG BOTTOM
OF ISMs AND T80s.
4/0 GAUGE
4/0 GAUGE
GENERATOR
SUPPLIED BY
OTHERS
230/240VAC
IN FROM LINE
230/240VAC
OUT TO LOAD
LINE
NEUTRAL
GROUND
12V
BATT
60A MAX
No. 6 AWG
WIRE
60A MAX
No. 6 AWG
WIRE
AC WIRING NOTE: THIS DRAWING
SHOWS THE IEC COLOR CODE: BLUE
FOR NEUTRAL, BROWN FOR AC LINE.
FOR THE USA, THE NEUTRAL IS WHITE
AND THE AC LINE IS BLACK.
Copyright 2009, 2010 Apollo Solar, Inc.
BATTERY
VOLTAGE
SENSE
WIRES
12V
BATT
60A MAX
No. 6 AWG
WIRE
LINE
NEUTRAL
GROUND
GND
APOLLO SOLAR
BATTERY
TEMPERATURE
SENSOR
12V
BATT
12V
BATT
IN LINE
FUSE
2 WIRE
START
LINE
230/240VAC
NEUTRAL
IN FROM
GENERATOR GROUND
PV IN
48V BATTERY
BANK
BY OTHERS
DC IN FROM
PV ARRAY
140Voc max
70A max
BATTERY NOTE: THE BATTERIES MAY
BE SEALED GEL CELLS, AGM OR
FLOODED LEAD ACID. THE BATTERY
AMP-HOUR CAPACITY IS CHOSEN BY
THE SYSTEM DESIGNER BASED ON
THE LOADS AND DAYS OF AUTONOMY
REQUIRED WITHOUT SUNSHINE. THE
TSW CHARGING AMPS MUST BE SET
ACCORDING TO THE BATTERY SPECS.
CHASSIS
EARTH
GND
* GND NOTE: IF THIS POWER CENTER IS THE
SOURCE OF THE BUILDING POWER, THE AC
NEUTRAL MUST BE CONNECTED TO EARTH
GROUND AT THIS POINT ONLY.
IF THE SYSTEM HAS AN AC INPUT AT A CIRCUIT
BREAKER BOX, THE AC NEUTRAL MUST BE TIED
TO GROUND AT THAT SOURCE OF POWER ONLY.
TSW INVERTER NOTE: THE TSW4048 MAY BE SELECTED
FOR OPERATION AT EITHER 230V, 240V, 120V SINGLE
PHASE, or 120/240V SPLIT PHASE. THE FREQ MAY BE
SELECTED SEPARATELY FOR 50Hz OR 60Hz. THE
EXTERNAL WIRING IS THE SAME FOR ALL SINGLE PHASE
VOLTAGES. SPLIT PHASE OPERATION REQUIRES DUAL
CIRCUIT BREAKERS ON ALL AC LINES. ALL THE
BREAKERS ARE AVAILABLE FROM APOLLO SOLAR.
PV IN
GND
DC IN FROM
PV ARRAY
140Voc max
70A max
WIRING DIAGRAM FOR
2 TSW INVERTERS PARALLEL
STACKED FOR 230 or 240VAC
SINGLE PHASE OPERATION
WITH 2 T80HV CHARGE
CONTROLLERS AND
GENERATOR STARTING
23 F. J. Clarke Circle
Bethel, CT 06801
(203) 790-6400
www.ApolloSolar.com
8kVA SYSTEM – 2 TSWs & 2 T80s
WIRING DIAGRAM
20-JULY-2010
J. PFEIFER
REV 3
70