apollo solar tsw inverter training

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TSW True Sine WaveInverter / ChargerTechnical Training

February, 2011

Apollo Solar, Inc.23 F. J. Clarke Circle

Bethel, CT 06801(203) 790-6400

www.ApolloSolar.com

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Mission Statement

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 installationsbecause they provide 120VAC, 120/240VAC Split Phase up to 32kVA or 120/208VAC 3 phase up to 12kVA.

In this technical training session, Apollo Solar will teach and demonstrate the technical installation and operation of the Apollo Solar Battery-Based Inverter/Chargers

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Training Outline1. 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

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Off-Grid Power – 3.2kW to 56kWThese Apollo Solar Inverters These Apollo Solar Inverters are providing 56kW for a hotel are providing 56kW for a hotel in the Dominican Republic.in the Dominican Republic.

Our TSWs are the only Our TSWs are the only inverters that can be parallel inverters that can be parallel stacked for this much power. stacked for this much power. They can also provide 3 phase They can also provide 3 phase power for industrial sites.power for industrial sites.

The Inverter Switchgear The Inverter Switchgear Modules house the circuit Modules house the circuit breakers for each inverter. breakers for each inverter.

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Off Grid System Design - Approach1. Know the Loads ! MOST IMPORTANT STEP

a. Continuous loads with number of hours per dayb. Peak loads like starting motors and pumps

2. Size the Inverter to meet both load requirementsLeave plenty of head room – users will add loads in the future

3. Size the Battery to supply the daily loadsKeep the depth of discharge between 30 to 50%. Battery storage capacity at least 2-3 times daily load requirement.

4. Size the PV array to recharge the battery in 1 dayDon’t forget that the sun may not shine every day.

5. Select the Charge Controller to recharge the batteryWatch the maximum Open Circuit Voltage limit.

6. Add Communication Devices to monitor the systemYou should know how well each system is working all the time.

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CAUTION – BATTERY CURRENT IS DANGEROUS1. TURN OFF all circuit breakers including 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.

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Apollo Solar Inverter/Charger and Switchgear ModuleThe 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 only 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 by Apollo Solar, ready for installation.

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NEW - Apollo Solar Pre-Wired Panels

• Inverter Switchgear Module (ISM)• Breakers for DC and AC• Bus Bars and Connection Points for easy installation

• True Sine Wave (TSW) Inverter / Charger• Provides AC and battery charger• Internal transfer relay• 24 or 48 volt battery

PV IN

BAT OUT

GND

TurboCharger

TRUE SINE WAVEINVERTER / CHARGER

TSW4048 or 3224

AC OUT AC IN

APOLLO SOLAR ISM

(INVERTER SWITCHGEAR

MODULE)

Apo

llo

Sol

ar

Gat

eway

SER

IAL

PWR

ETH

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ET

T80HV

• Complete Off-Grid electrical supply system• All UL Certified Parts • Factory Pre-Wired and tested

• Communication Gateway• Remote Monitoring

• T80HV Charge Controller• 200 volts OCV from PV • 80 Amps into the battery

PWP4KW Pre Wired Panel with 4kW of AC

• 21” wide, 42” tall, 8” deep• Mounting holes on 16”centers

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Low cost.Low cost.Stackable for parallel or 3 phase Stackable for parallel or 3 phase

inverter operation.inverter operation.Set up for 120V, 230V or 240VAC Set up for 120V, 230V or 240VAC 18 AC or DC DIN Rail breakers. 18 AC or DC DIN Rail breakers. 175A or 250A main DC breaker.175A or 250A main DC breaker.Small size: Small size:

1111”” wide, 15wide, 15”” tall, 7tall, 7”” deep.deep.

280mm wide, 380 tall, 485 deep280mm wide, 380 tall, 485 deep. . PrePre--wired for fast installation.wired for fast installation.

Apollo Solar Inverter Switchgear Module (ISM)Apollo Solar Inverter Switchgear Module (ISM)

10101010

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 GatewayConverts the ASNET bus data to Ethernet

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Inverter / Charger - System Block Diagram

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Apollo Solar TSW3224 and TSW4048 specifications

True Sine Wave Inverter SPECIFICAT IO NS TSW3224 TSW4048 Max. Power Rating 25º C 3200 VA 4000 VA Nominal DC Battery Input Voltage 24 VDC 48 VDC Battery input current at rated power 148 Amps 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) L-N: 52A AC, L-L: 37A AC L-N: 52A AC, L-L: 37A AC Overload Capacity from 25ºC start

7Seconds: 6400 VA 200% 8000 VA 200% 30 Seconds: 4800 VA 150% 6000 VA 150% 30 Minutes: 3840 VA 120% 4600 VA 115%

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 ~ 27 Watts ~ 39 WattsSearch mode power consumption ~ 4.5 Watts ~ 4.5 Watts Inverter Efficiency (Peak) >93% >95% Total Harmonic Distortion Typical: 3.5%, Maximum: 5% (T rue sine wave) Output Voltage Regulation +/- 3% AC Output Frequency 50 or 60Hz +/-1% (Switch Selectable) AC Input Frequency Range 46 to 55Hz at 50Hz Nominal, 55 to 65 Hz at 60Hz Nominal, Switch Selectable AC Input Voltage Range for Charge Mode L-N: 80 ―150 VAC for 120VAC mode, L-L: 160 ―270 VAC for 240VAC m odeDC Output Range 21.0 to 35.0 VDC 42.0 to 64.0 VDC Maxim um Input Short Circuit Current 250A 250A Continuous Battery Charger Output at 25º C 100 amps DC 70 amps DC Five Stage Battery Charger Output Bulk, Absorb, Float, Equalize & Standby Battery Charging Power Factor Corrected >0.92 Battery Charge temperature compensation With external temperature sensor Transfer relay capability 40 Amps per leg; 8 to 16ms transfer time Operating Temperature Range -20º C to +45º C Overtemperature Protection Sensors on MOSFETs, Transformer and Battery Agency Certification UL 1741 UL 1741 & CSA C22.2 No. 107.1 Warranty 5 Years Weight 25.1kg, 55 lbs. (27.5kg, 60.6 lbs shipping weight) Size 572x229x184mm , 22.5"x9"x7.25" (686x330x305mm , 27"x13"x12" shipping box) Enclosure Powder coated steel Cooling Variable Speed, Temperature controlled fans Data Communication ASNET (RS-485) and CANBUS

O PT IO NAL ACCESSO RIES

Charge Controllers Apollo Solar T 80 and T100 TurboCharger provide optimum charging from PV arrays. Ethernet / Internet Monitoring 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.

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Industrial Grade Backup PowerThe 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 essential power for cellular communications.

Apollo Solar TSWs were selected based on Reliability, Ease of installation, Remote monitoring and cost.

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Large-Scale InstallationsOff-Grid Power – 3.2kW to 56kW

These Apollo Solar Inverters These Apollo Solar Inverters are providing 56kW for a hotel are providing 56kW for a hotel in the Dominican Republic.in the Dominican Republic.

Our TSWs are the only Our TSWs are the only inverters that can be parallel inverters that can be parallel stacked for this much power. stacked for this much power. They can also provide 3 phase They can also provide 3 phase power for industrial sites.power for industrial sites.

The Inverter Switchgear The Inverter Switchgear Modules house the circuit Modules house the circuit breakers for each inverter. breakers for each inverter.

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Here is shown Apollo Solar OffHere is shown Apollo Solar Off--Grid System using the T80 Grid System using the T80 Charge Controllers, TSW3224 Inverters and ISM Charge Controllers, TSW3224 Inverters and ISM Switchgear Modules in a parallel systemSwitchgear Modules in a parallel system

Apollo Solar T80 & TSW Apollo Solar T80 & TSW –– Easy to install Easy to install anywhere in the World anywhere in the World

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Standard Products with Flexible ConfigurationsStandard Products with Flexible Configurations

We offer a choice of NEMA 4 or 4X enclosures with any combination of Inverters and/or Charge Controllers. The options designed for the needs of remote telecom.

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Apollo InstallationsApollo Installations

These installations use our TSW Inverter / Chargers to provide AC and to charge from a generator in addition to our PV Charge Controllers.

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Mounting Dimensionsand 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.

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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.

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Simplified Wiring TSW, ISM & Batteries

The AC wiring is done using No. 8 wire rated at 40 Amps.

The DC wiring to the Battery must be heavy gauge No. 4/0 cables with the proper terminations.

CAUTION: The circuit breakers must be turned OFF before any connections are made.

The battery connection should be made last. Once this connection is made, the enclosure is energized.

The proper torque for each terminal is specified on a label inside the ISM near the terminals.

.

OPTIONAL DELTA 302R LIGHTNING

ARRESTORS

500A

SH

UN

T

+BU

S

- BUS

AC BREAKERS

CHASSIS EARTH

GND

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.

WIRED FOR 120/240VAC SPLIT PHASE

6VBATT

6V BATT

6VBATT

6VBATT

4/0

GAU

GE

WIR

E25

0A D

C

BR

EAK

ER

240VACIN FROM LINE OR

GENERATOR

NEU

TRA

L

L2

240VACOUT TO LOAD

PANEL

NEU

TRA

LL1

DC IN

APOLLO SOLAR TSW 3224


APOLLO SOLARTSW 3224 or TSW 4048

TRUE SINE WAVE INVERTER/CHARGER

AC

NEU

TRA

L B

US

GR

OU

ND

BU

S

AC

IN

AC

OU

T BATTERY

AC OUT AC IN

ASNET

CAT-5 ETHERNET

CABLE

INTERNET

APOLLO COMMUNICATION

GATEWAY(Optional)

ACG-1

40A

MA

X A

WG

#8APOLLO SOLAR

SWITCHGEAR MODULE

ENCLOSURE

250

L2 L1

BYP

ASS

40A

40A

40A

40A

40A

40A

*GN

D

NO

TE

INVERTER SWITCHGEAR MODULE

ISM 120/240WIRING DIAGRAM

* 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.

AC

AC

NOTE: AC NEUTRAL AND DC NEGATIVE WIRES ARE WHITE, BUT ARE SHOWN AS LIGHT GRAY.

AWG

#6

21212121

Grounding Details

DC SYSTEM

CHASSIS GROUND

AC SYSTEM

APOLLO SOLAR TSW INVERTER

NEUTRAL

GROUNDING ELECTRODE CONDUCTOR GROUNDING

ELECTRODE

NEUTRAL BUS-BAR

HOT IN

DC NEGATIVE BUS-BAR

TO BATTERY

GROUNDBUS-BAR

SYSTEM BONDING JUMPERS

EQUIPMENT GROUND CONDUCTOR

HOT OUT

HOT IN

HOT OUT

NEUTRAL

AC TRANSFER SW

ITCH AND FILTER BOARD

CHASSIS GROUND

DC

APOLLO SOLAR TSW INVERTER

GROUNDING DETAILS

AC

Bus Bars for AC Neutral and Earth Ground are located in the Inverter Switchgear Module (ISM).

For clarity, this drawing shows a TSW and ISM wired for 120V only.

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120/208 Volt 3 Phase explained

•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 drawing 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.

3 PHASE AC DEFINED: “Y” TRANSFORMER PRODUCES 208VRMS BETWEEN ANY 2 LEGS AND 120V FROM ANY LEG TO NEUTRAL

L1 L2 L3

5.56ms

16.67ms

L1

L2

L3NEUTRAL

120V

120V208V

nc

3 PHASE 208VAC UTILITY SOURCE

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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.

Note the extra circuit breaker in the far right which is a separate 20 Amp 120V circuit for the fans and a service outlet.

The Apollo Solar SNMP Gateway has input for door switches which are simply wired in series. The Gateway runs off 24v DC which is best supplied from ½ the battery bank. Note the 0.5Amp fuse in series with the Gateway power.

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3 Phase Wiring Diagram

Generic 3 Phase system wiring diagram.

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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) 5 – AC LINE1 In (Red)2 – AC Line2 Output (Black) 6 – AC Line2 In (Black)3 – AC Neutral Out (White) 7 – AC Neutral in (White)4 – Ground (Green)

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TSW Inverter bolted to the Inverter Switchgear Module

TSW Positive Terminal bolted to the positive bus bar

TSW Negative Terminal bolted to the negative bus bar

Apollo Solar TSW4048 Inverter / Charger

Apollo Solar Inverter Switchgear Module enclosure with cover removed

Conduit in place for wires to the battery box

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Inverter Switchgear Module (ISM) with DC Wiring

250 Amp DC Circuit Breaker in Positive 48v Bus

4/0 wires to batteries

AC Neutral bus bar

Ground bus bar

DIN Rail for AC Circuit Breakers

Current Shunt on DC Negative 48v Bus Bar

Inverter bolted to Negative DC bus bar

Inverter Positive Terminal

TSW GndLug

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AC Wiring from TSW, Line In and Line OutInverter AC Neutral wires

Ground

Inverter AC Hot Output

Inverter AC Line1&2 Inputs

AC Line1&2 Outputs to Load

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.

AC Line1 &2 inputs

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Battery WiringTHIS 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.

BUS BARS TO CONNECT BATTERIES IN SERIES

No. 4/0 WIRE TO CONNECT BATTERIES TO THE INVERTER / CHARGER

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Battery Charging in the TSW Inverter / Charger3 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

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Apollo Unique Charging Method for UPS Systems

The Apollo TSW has a special charge profile for UPS systems.

The standard Float stage is replaced with a Re-Bulk stage to optimize battery life.

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TTER

Y C

HA

RG

E VO

LTA

GE

CH

AR

GIN

G

CU

RR

ENT

STA

RT

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Battery Charging with Temperature Compensation1. 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.

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Inverter DisplayWe noted that only one of the other Inverters in

our market has an internal display.(The Schneider XW is the only [Off Grid] Inverter

with any display and that is just a 3 digit LED for inverter watts and charge current only.)

We designed the TSW with an internal 2x16 LCD which shows all the critical current values:

• AC Output Voltage• AC Output Current• AC Output Power• AC Output Frequency• DC Battery Voltage• DC Battery Current

• Mode: Inverting or Charging• Charging Current• Error Codes• ID Address• When stacked, the Master

shows Total System values

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Inverter Parameter Setup ToolsWe 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.

TheirLCD or

Apollo’s Full Color Graphic Screen

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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 Laptop 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.

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Inverter Start Up Sequence1. 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.

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TSW Inverter OperationStartup and Inverter Mode

I N V E R T I N G X X X X V A2 4 0 . 0 V 6 0 . 0 H z

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

Main Status Screen #1: Total power, Voltage and frequency displayed. Press “Page” key for Status Screen #2.

Status Screen #2: Total Power and AC Line 1 current and power. Press “Page” for Status Screen #3.

Status Screen #3: Total Power and AC Line 2 current and power. Press “Page” for Status Screen #4.

Status Screen #4: Battery voltage and current (DC). Press “Page” for Status Screen #1.

A C 2 4 0 . 0 V 0 0 . 0 AB A T : 4 8 . 0 V X X . X A

A U T O - S T A R T A F T E R 5 . 0 S E C

A P O L L O S O L A R T S WR E V X . X X S / N X X X X X

I N V E R T I N G X X X X V AL 1 : X X . X A X X X X V A

I N V E R T I N G X X X X V AL 2 : X X . X A X X X X V A

I N V E R T I N G X X X X V AB A T : 4 8 . 0 V X X X . X A

Front Panel LCD

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TSW Inverter OperationCharger Mode

C H A R G I N G 6 0 . 0 H zA C : 2 4 0 . 0 V 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.

C H A R G I N G 6 0 . 0 H zL 1 : X X . X A X X X X V A

C H A R G I N G 6 0 . 0 H zL 2 : X X . X A 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

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Stacking InvertersParallel 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.

2. Press “Page” key for 5 seconds to enter communication ID setting. Press “Page” to change ID to 32 – 46.

3. Press “Page” key for 5 seconds to enter mode setting. Press “Page” to change to Parallel mode.

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.

S E T T I N G C O M M . I D = X X

S E T T I N G M O D E = P A R A L L E L

S T A N D B Y B A T : 4 8 . 0 V

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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. (Up to twice that with separate AC buses.)

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

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PARALLEL MODE ID SETTINGS1. Use IDs in Group1

and Group2 for parallel stacking.

2. Use IDs in Group 3 thru 7 for 3-phase stacking.

The ID can be set using the Front Panel LCD.

ID CANbus ID Group Function phase32 033 134 235 336 437 538 639 740 041 142 243 344 445 546 647 748 0 049 1 12050 2 24051 3 052 4 12053 5 24054 6 055 7 12056 0 24057 1 058 2 12059 3 24060 4 061 5 12062 6 24063 7

Group7

single phase parallel

Group1

Group2

Group3

3-phase parallel

Group4

Group5

Group6

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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.

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View Inverter Status of up to 8 parallel (stacked) units.

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View Inverter Status on top half of screen.

Set user parameters on bottom half of screen.

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Setting the Parameters on the TSW using AIM

46464646


47474747


4848

TSW Significant Advantages1. Our AIM color graphic user interface is the quickest to learn and use.

2. Our TSW4048 can produce 120/240V Split Phase AND 120V at full 4kVA, and 230V all at either 50 or 60Hz.

Magnum can do only 3.5kVA at 120VAC, Outback has no 120/240.

3. The TSW4048s stack to 32kVA, and 3 phase to 12kVA.Magnum stacks to 17.6kVA, No 3 phaseOutback stacks to 35kVA, 3 phase to 10.8kVAXW stacks to 18kVA, 3 phase to 18kVA

4. Our Gateway provides Remote Monitoring on any PC or Smart Phone.Magnum and Outback do not provide remote monitoring

5. Apollo has the venerable T80 and T80HV integrated via the ISM. Magnum does not make a charge controller.

6. The TSW front panel LCD displays the important values at no extra cost.Magnum and Outback have no front panel display, XW is minimal.

7. The TSW4048 is the best value at $0.62 per watt MSRP.

8. Apollo is the only off-grid inverter manufacturer to offer:5 Year WarranteeAdvanced Replacement

Apollo TSWs can be mounted vertically (without a rain hat).Apollo TSWs can also mount horizontally to replace older

DRs, or SWs. With the DC on either right or left.The square front panel display can be rotated.Vertical or horizontal, there are no vent holes on the top or bottom to annoy UL.

Mounting Flexibility

Switchgear – Size matters when room is tight

Outback: Very large, Needs 2 inverters for 120/240 VAC split phase

Xantrex XW (Schneider) Smaller, (narrower, but taller)

30"

(7

6.2c

m)


Magnum w/ Midnite e-panel:Inverter hangs on the front, controller hangs on the side

30"

(7

6.2c

m)

12.9" Deep

Midnite E-Panel

23" (58.4cm)


Apollo Solar Pre-Wired PanelsSmall size & Modular for easy expansion up to 32kVA

30"

(7

6.2c

m)

12.9" Deep

Midnite E-Panel

23" (58.4cm)


54545454

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:

Starting today, Apollo Solar is offering a new Advanced Replacement Program for the TSWs. If you have a problem with our TSW in the field, call our Tech Support department for an RMA number.

If the problem is an actual failure of the TSW, we will ship a replacement unit to you within 24 hours.

After you replace the unit, send the old one back.

5555

Access any Apollo Solar installation from any computer via the Internet

Apollo Communications GatewayApollo Communications Gateway

Provides easy plug-and-play connectivity to Apollo products using Ethernet.

5656

Apollo Solar Remote Data MonitoringApollo Solar Remote Data MonitoringApollo Apollo Communication Communication Gateway Gateway ACGACG--1 1 Apollo Apollo

Cellular Cellular Modem Modem ACMACM--11

57

Apollo Remote MonitoringHow 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.

58

System Diagram

Apollo Solar Server-TCP Server- Database- Website

Optional Apollo Cellular Modem

User Browser

ASNet (Apollo communications protocol)

ASNet over TCP/IP

Conventional Internet

Local PC Application

59

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 ataddress 32 and continue sequentially.

3. Apollo Communications Gateway – an Apollo Communications Gateway and the cable supplied to it. The ACG must be connectedto one of the Apollo devices, and then the remaining devices areconnected 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.

60

Sample Monitoring

61

FAQ - Apollo Communications Gateway1. How many T80 charge controllers can be monitored from one Gateway?

– Up to 312. How many TSW inverters can be monitored from one Gateway?

– Up to 313. How many total devices can be monitored from one Gateway?

– Up to 2554. How often is data sent from the Gateway to the server?

– 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

5. Does the Gateway have to powered from the included AC power supply?– No, the Gateway can receive power from the T80 or TSW.

6. Does the Gateway have to be programmed or setup?– No, the Gateway is strictly plug-and-play.

7. How can I tell if the Gateway is communicating with the T80 or TSW and sending data to the Internet?

– 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.

8. 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.

62

FAQ - Apollo Cellular Modem• What cellular system does the ACM use?

– 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.

• What do I need to use the ACM?– 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?– 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?– 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?– Yes, you need to have a Gateway between the ACM and Apollo devices.

• Do I need to configure the ACM?– 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.

63

FAQ - Apollo SNMP Gateway• Can the SNMP Gateway be customized in terms of SNMP traps and gets?

– Yes, Apollo can customize and provide matching MIB file

• What SNMP protocols are supported?– SNMP versions 1, 2, and 3.

• Does the SNMP Gateway have a watchdog timer?– 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?

– Yes.

• Can the SNMP Gateway be configured to log data and then have log files uploaded remotely?

– 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.

64

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.

65656565

SNMP Gateway – Data Monitoring1. 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 Voltageb) Battery Current (Charge or discharge)c) AC Output Voltaged) AC Output Frequencye) 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.

66666666

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.

6767

Technical LeadershipApollo 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.

68

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.

Compare Features and BenefitsCompare Features and BenefitsApollo TSW4048 and the Magnum MS4448-PAE:

Parallel Stacking – Wire up to 8 TSW in parallel for 32kVA

Cost*: $2495 for the Apollo TSW4048*List Prices $2599 for the Magnum MS4448-PAE

Surge Capability: TSW is Full 8kVA for 10 seconds - Enough to start a 3 hp motor. MS4448-PAE spec is 5800watts for 5 seconds.

TSW Display Included – See what the inverter is doing without buying a separate display. The Magnum ME-RTR is $399 extra.

Wiring Box – Stackable ISM from Apollo, integrates with T80 and T80HV Charge Controllers. Magnum has no charge controller.

Internet Remote Monitoring : Available only from Apollo

Warranty: TSW 5 Years Standard – Magnum is 2 years standard

Compare Features and BenefitsCompare Features and BenefitsApollo TSW4048 and the Outback VFX3648:

Apollo TSW is Split Phase 120/240VACOutback inverters are 1 phase 120v or 240v only

Cost * $2495 for the Apollo TSW4048 120/240VAC*List Prices $2569 for the Outback VFX3648 (120VAC only)

Surge Capability: TSW --Full 8kVA for 10 sec. starts 3 hp motor.With 5kVA for 5 seconds, VFX3648 will not start the same motor.

Inverter Data Display: TSW LCD is included at no extra costThe Outback Mate is $295 extra.

Battery Charger: TSW is 70Amps, Power Factor Corrected to .98VFX is 45 Amps, Power Factor Correction NA

Internet Remote Monitoring: Available only from ApolloWarranty: TSW 5 Years Standard – VFX is 2 years standard

Compare Features and BenefitsCompare Features and Benefits

Apollo TSW4048 and the Xantrex XW :Cost*: $2495 for the Apollo TSW4048*List Prices $3600 for the Xantrex XW4548

Smaller Size: TSW is 21” tall x 9” wide x 7” deepXW is 30” tall x 16” wide x 9” deep

Lighter Weight: TSW is 50 lbs.XW is 116 lbs.

(The XW 165 lb shipping weight can not be shipped via UPS!)

Lower cost wiring box: Apollo ISM is $ 795.XW Distribution Box is $1500.


Compare Features and BenefitsCompare Features and BenefitsApollo TSW3224 and the Magnum MS4024PAE:

Parallel Stacking – Wire up to 8 TSW in parallel for 25.6kVA

Cost*: $2495 for the Apollo TSW3224*List Prices $2699 for the Magnum MS4024PAE

Surge Capability: TSW is Full 6400VA for 10 seconds - Enough to start a 3 hp motor. MS4024PAE spec is 5800watts for 5 seconds.

TSW Display Included – See what the inverter is doing without buying a separate display. The Magnum ME-RTR is $399 extra.

Wiring Box – Stackable ISM from Apollo, integrates with T80 and T80HV Charge Controllers. Magnum has no charge controller.


Warranty: TSW 5 Years Standard – Magnum is 2 years standard

Compare Features and BenefitsCompare Features and BenefitsApollo TSW3224 and the Outback VFX3524:

Apollo TSW is Split Phase 120/240VAC2 Outback inverters are required for 120/240 split phase.

Cost * $2495 for the Apollo TSW3224 120/240VAC*List Prices $2569 for the Outback VFX3524 (120VAC only)

Surge Capability: TSW --Full 6400VA for 10 sec. starts 3 hp motor.With 5000VA for 5 seconds, VFX3524 will not start the same motor.

Inverter Data Display: TSW LCD is included at no extra costThe Outback Mate is $295 extra.

Battery Charger: TSW is 100Amps, Power Factor Corrected to .98VFX is 85 Amps, Power Factor Correction NA

Internet Remote Monitoring: Available only from ApolloWarranty: TSW 5 Years Standard – VFX 2 years standard

Compare Features and BenefitsCompare Features and Benefits

Apollo TSW3224 and the Xantrex XW :Cost*: $2495 for the Apollo TSW3224*List Prices $3250 for the Xantrex XW4024 (30% more than the TSW)

Smaller Size: TSW is 21” tall x 9” wide x 7” deepXW is 30” tall x 16” wide x 9” deep

Lighter Weight: TSW is 50 lbs.XW is 116 lbs.

(The XW 165 lb shipping weight can not be shipped via UPS!)

Lower cost wiring box: Apollo ISM is $ 795.XW Distribution Box is $1500.


7575

Q & A

76767676

T80/T80HV Charge ControllerTechnical Training

February, 2011

Apollo Solar, Inc.23 F. J. Clarke Circle

Bethel, CT 06801(203) 790-6400

www.ApolloSolar.com

7777

T80 andT80 and T80HV T80HV Installation, Setup, and OperationInstallation, Setup, and Operation

Features:Features:

Both units deliver 80 Amps into Both units deliver 80 Amps into batteries at up to 45batteries at up to 45ooC ambientC ambient

Input Voltage (PV Open Circuit) Input Voltage (PV Open Circuit) 140V for the T80, 200V for the T80HV140V for the T80, 200V for the T80HV

250 volt Circuit Breakers and Ground 250 volt Circuit Breakers and Ground Fault Protection available from ApolloFault Protection available from Apollo

Use the 2 Sanyo PV modules or a Use the 2 Sanyo PV modules or a string of 7 ESAstring of 7 ESA--210 Evergreens210 Evergreens

Works with the Apollo ISM enclosuresWorks with the Apollo ISM enclosures

7878

Telecom site using 3 Apollo Solar T80s in the Mojave Desert region of

California.

ApolloApollo Remote Telecom SitesRemote Telecom Sites

7979

DC and AC DIN rail breakers can be installed as a unit.DC and AC DIN rail breakers can be installed as a unit.Custom bus bar connectors replace cumbersome wiring.Custom bus bar connectors replace cumbersome wiring.

InverInverter Switchgear Module with T80Switchgear Module with T80

8080

Switchgear Switchgear ModuleModule

Wiring DiagramWiring Diagram

The Switchgear Module The Switchgear Module accommodates all DC accommodates all DC and AC wiring providing and AC wiring providing an easy means to an easy means to connect:connect:1. Battery Cables1. Battery Cables2. PV input 2. PV input 3. External AC3. External AC OPTIONAL

DELTA 302R LIGHTNING

ARRESTORS

+BUS

- BUS

AC BREAKERS

CHASSIS EARTH

GND

APOLLO SOLAR BATTERY

TEMPERATURE SENSOR

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.

WIRED FOR 120/240VAC SPLIT PHASE

6VBATT

6V BATT

6VBATT

6VBATT

BATTERY VOLTAGE

SENSE WIRES

PV IN

240VACIN FROM LINE OR

GENERATOR

240VACOUT TO LOAD PANEL

DC IN

APOLLO SOLAR TSW 3224


APOLLO SOLARTSW 3224 or TSW 3648

TRUE SINE WAVE INVERTER/CHARGER

APOLLO SOLAR T80PV CHARGE

CONTROLLER

125V DC BREAKERS

APOLLO SHUNT BOARD

GND

BATTERY PV ARRAY

AC OUT AC IN

ASNET

CAT-5 ETHERNET

CABLE

INTERNET

OPTIONAL REMOTE DISPLAY

APOLLO COMMUNICATION

GATEWAY(OPTIONAL)

ACG-1

PV IN

BAT OUT

TurboCharger

Solar Power Center

PV INPUT(UP TO 75A)

WIRES MAY BE AS LARGE AS AWG #2

AWG #3

AWG #3

APOLLO SOLARSWITCHGEAR

MODULE ENCLOSURE

PV IN

250

GFP

INVERTER SWITCHGEAR MODULE

ISM120/240-T80WIRING DIAGRAM



AC

AC

NOTE: AC NEUTRAL AND DC NEGATIVE WIRES ARE WHITE, BUT ARE SHOWN AS LIGHT GRAY.

8181

Basic T80 System

Wiring Diagram Showing key components:

T80 TurboCharger500Amp 50mV ShuntApollo Shunt BoardBatt Voltage Sense WiresBatt Temperature SensorCable back to T80

T80 BASIC SYSTEM WIRING DIAGRAM Input from PV Array or Combiner Box

_

_

+ _

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.

0

DC RATED BREAKER

DC

RA

TED

BR

EAK

ER

0

BATT+

+BAT+ -BAT- +PV+- PV -

T80 TurboCharger

TEMPERATURE SENSOR

SHUNT 50mV

500AMP

APOLLO SHUNT BOARD

BATTERY VOLTAGE SENSE WIRES

+Bat

Temp

-Bat

FUSE

SYSTEM EARTH

GROUND

8282

Setting up the T80 “As easy as A-B-C” A P O L L O S O L A RB A T T E R Y F O U N D N O M I N A L X X V O L T S C O N F I R M : N O Y E S

Step A - T80 reads your battery voltage. You just confirm.

Step B - Set charging parameters

(You provide the Battery Type and Capacity, the T80 suggests the rest).

Step C - Set Time and Date, and Go.

B A T T E R Y T Y P E = X X X X X X XM A K E = G E N E R I CC A P A C I T Y = X X X 0 A h r B A C K - + N E X T

B A T T E R Y S E T U P 2M A X C H A R G E A M P S = X X A B A C K - + N E X T

B A T T E R Y S E T U P 2M A X C H A R G E A M P S = X X A B A C K - + N E X T

S E T C L O C K M O D E = X X H rT I M E = H H : M M : S S A MD A T E = M M / D D / Y YB A C K - + N E X T

8383

Operation of the T80Main Status Screen

Main Status Screen - Displays Input and Output Voltage and Current, and State of Charge Data

Status Field, indicates operating mode: BULK, ABSORB, FLOAT, and CHG OFF.

I N = X X X . X V X X . X A m p sO U T = X X . X V X X . X A m p sB A T S O C = X X X % X X X X X X XS E T U P S O C D A T A

I N = X X X . X V X X . X A m p sO U T = X X . X V X X . X A m p sB A T S O C = X X X % X X X X X X XS E T U P S O C D A T A

8484

Stacking Charge Controllers and Inverters

APOLLO SOLAR GEN-START

MODULE2 WIRESTART

TRIGGER INPUT

Copyright 2009, 2010 Apollo Solar, Inc.

- BUS

AC BREAKERS

CHASSIS EARTH

GND

250A

DC

BR

EAK

ER

APOLLO SOLARTSW 4048

INVERTER/CHARGER

GR

OU

ND

BU

S

CAT-5 ETHERNET CABLE TO THE

INTERNET

250

AWG

#6



AWG #6

DC IN


TSW

AC OUT AC IN

AS

NE

T

PV IN


CONTROLLER

125V DC BREAKERS

GND

PV IN

BAT OUT G

ND

TurboChargerAWG #3

AW

G #

3

PV IN

50A

50A

GROUND FAULT PROTECTION

BREAKERS ON PV INPUT

5A 50A

50A

.5A

RE

S

AC

OU

TAC

IN

50A

50A

APOLLO SOLAR

GATEWAY

WIRING DIAGRAM FOR 2 TSW INVERTERS PARALLEL STACKED FOR 230 or 240VACSINGLE PHASE OPERATION

WITH 2 T80HV CHARGE CONTROLLERS AND

GENERATOR STARTING

+BUS

- BUS

AC BREAKERS

250A

DC

BR

EAK

ER

APOLLO SOLARTSW 4048

INVERTER/CHARGER

AC

NEU

TRA

L B

US

GR

OU

ND

BU

S

30A

MA

X N

o. 1

0 A

WG

WIR

E

250

AWG

#6

230/240VAC OUT TO LOAD 48V BATTERY

BANK BY OTHERS

DC IN


TSW

AC OUT AC IN

AS

NE

T

PV IN


CONTROLLER

125V DC BREAKERS

APOLLO SHUNT BOARD

GND

PV IN

BAT OUT G

ND

TurboChargerAWG #3

AW

G #

3

PV IN

50A

50A

IN L

INE

FU

SE

12VBATT

12VBATT

12VBATT

12VBATT

4/0

GA

UG

E

BATTERY VOLTAGE SENSE WIRES

APOLLO SOLAR BATTERY TEMPERATURE SENSOR

DC IN FROM PV ARRAY140Voc max70A max

GROUND FAULT PROTECTION

BREAKERS ON PV INPUT

4/0 GAUGE

50A

50A

.5A

RE

S

AC

OU

T

AC

IN

50A

50A

8kVA SYSTEM – 2 TSWs & 2 T80s

23 F. J. Clarke CircleBethel, CT 06801(203) 790-6400www.ApolloSolar.com

WIRING DIAGRAM

20-JULY-2010 J. PFEIFER REV 3

4" GUTTER USED AS RACEWAY FOR ALL WIRES ALONG BOTTOM

OF ISMs AND T80s.

AC

NEU

TRA

L B

US

230/240VAC IN FROM LINE

PARALLEL STACKING CABLE

TERMINATOR FOR STACKING

CABLE

ASNET CAT5 CABLE

GATEWAY AND POWER SUPPLY MAY BE MOUNTED IN THE GUTTER RACEWAY

MASTER TSW

MASTER T80

SLAVE TSW

SLAVE T80

APOLLO SOLAR INVERTER

SWITCHGEAR MODULE (ISM230)

ISM230

BYP

ASS

30A

30A

30A

BYP

ASS

30A

30A

30A

30A

MA

X N

o. 1

0 A

WG

WIR

E

60A MAX No. 6 AWG

WIRE

60A MAX No. 6 AWG

WIRE

NLL N

GN

DG

ND

OUTPUT INPUT

LINE INNEUTRAL

GND

AC CONNECTOR AT TOP OF TSW

LINE OUTNEUTRAL

500A

SH

UN

T

24V POWER SUPPLY FOR

GATEWAY

DC IN FROM PV ARRAY140Voc max70A max

500A

SH

UN

T

+BUS

60 AMPGENERATOR/LINE

SELECTOR PAC

AC

LIN

E IN

GEN

SET

IN

TOG

GLE

60A

60A

LINENEUTRALGROUND

NEUTRALLINE

GROUND

230/240VAC IN FROM

GENERATORNEUTRAL

LINE

GROUND

T80 AUX RELAY

CONTACTS

2 WIRESTART

GENERATOR SUPPLIED BY

OTHERS

AUX 1

AUX 2

60A MAX No. 6 AWG

WIRE

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.

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.

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.

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