emerson netshine 101 ca1
DESCRIPTION
Emerson NetShine 101 CA1TRANSCRIPT
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NetShine 101 CA1
NetShine 101 CA1 Solar Controller
User Manual
V1.2
2011-03-17
BOM 31011799
Version: V1.2
Revision date: March 17, 2011
BOM: 31011799
518057
www.emersonnetworkpower.com.cn
4008876510
E-mail: [email protected]
Emerson Network Power provides customers with
technical support. Users may contact the nearest
Emerson local sales office or service center.
Copyright 2010 by Emerson Network Power
Co., Ltd.
All rights reserved. The contents in this document
are subject to change without notice.
Emerson Network Power Co., Ltd.
Address: No.1 Kefa Rd., Science & Industry Park,
Nanshan District 518057, Shenzhen China
Homepage: www.emersonnetworkpower.com.cn
E-mail: [email protected]
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Safety Precautions
To reduce the chance of accident, please read the safety precautions carefully before operation. The Caution,
Notice, Warning, Danger in this book do not represent all the safety points to be observed, and are only
supplement to various safety points. Therefore, the installation and operation personnel must be strictly trained
and master the correct operations and all the safety points before actual operation.
When operating Emerson products, you must strictly observe the safety rules in the industry, the general safety
points and special safety instructions specified in this manual.
Electrical Safety
I. Hazardous voltage
Danger Danger
Some components of the solar controller carry hazardous voltage in operation. Direct contact or indirect contact through
moist objects with these components will result in fatal injury.
You must observe the safety rules in the industry when installing high DC voltage and AC power devices. The
installation personnel must be licensed to operate high DC voltage and AC power.
In operation, the installation personnel are not allowed to wear conductive objects such as watches, bracelets,
bangles, rings.
When water or moisture is found on the cabinet, please turn off the power immediately. In moist environment,
precautions must be taken to keep moisture out of the power system.
Prohibit warning label must be attached to the switches and buttons that are not permitted to operate during
installation.
Danger Danger
High voltage operation may cause fire and electric shock. The connection and wiring of AC cables must be in compliance
with the local rules and regulations. Only those who are licensed to operate high voltage and AC power can perform high
voltage operations.
II. Tools
Warning
In high voltage and AC operation, special tools must be used. No common or self-carried tools should be used.
III. Thunderstorm
Danger Danger
Never operate on high voltage, AC, iron tower or mast in the thunderstorm.
In thunderstorms, a strong electromagnetic field will be generated in the air. Therefore the equipment should be
well earthed in time to avoid damage by lightning strikes.
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IV. ESD
Note
The static electricity generated by the human body will damage the static sensitive elements on PCBs, such as large-scale
ICs. Before touching any plug-in board, PCB or IC chip, ESD wrist strap must be worn to prevent body static from
damaging the sensitive components. The other end of the ESD wrist strap must be well earthed.
V. Short-circuit
Danger Danger
During operation, never short the positive and negative poles of the DC distribution unit of the system or the
non-grounding pole and the earth. The solar controller is constant-voltage DC power equipment, short circuit will result in
equipment burning and endanger human safety.
Check carefully the polarity of the cable and connection terminal when performing DC live operations.
As the operation space in the DC distribution unit is very tight, please carefully select the operation space.
Never wear a watch, bracelet, bangle, ring, or other conductive objects during operation.
Insulated tools must be used.
In live operation, keep the arm muscle tense, so that when tool connection is loosened, the free movement of
the human body and tool is reduced to a minimum.
Battery
Danger Danger
Before any operation on battery, read carefully the safety precautions for battery transportation and the correct battery
connection method.
Non-standard operation on the battery will cause danger. In operation, precautions should be taken to prevent
battery short circuit and overflow of electrolyte. The overflow of electrolyte will erode the metal objects and PCBs,
thus causing equipment damage and short circuit of PCBs.
Before any operation on battery, pay attention to the following points:
Remove the watch, bracelet, bangle, ring, and other metal objects on the wrist.
Use special insulated tools.
Use eye protection device, and take preventive measures.
Wear rubber gloves and apron to guard against electrolyte overflow.
In battery transportation, the electrode of the battery should always be kept facing upward. Never put the
battery upside down or slanted.
Others
I. Safety requirement
Warning Notice
Note
Always use the same fuse for replacement as the fuse of the solar controller.
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II. Sharp object
Warning
When moving equipment by hand, you should wear protective gloves to avoid injury by sharp object.
III. Power cable
Note
Please verify the compliance of the cable and cable label with the actual installation prior to cable connection.
IV. Binding signal lines
Warning Notice
Note
The signal lines should be bound separately from heavy current and high voltage lines, with binding interval of at least
150mm.
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Contents
Chapter 1 Introduction ......................................................................................................................................................... 1
1.1 Model Description ................................................................................................................................................. 1
1.2 Operation Theory .................................................................................................................................................. 1
1.3 Features ................................................................................................................................................................ 2
1.4 Functions .............................................................................................................................................................. 2
1.5 Technical Parameters ........................................................................................................................................... 5
Chapter 2 Installation And Commissioning.......................................................................................................................... 7
2.1 Safety Regulations ................................................................................................................................................ 7
2.2 Installation And Cable Connection ........................................................................................................................ 7
2.2.1 Installation Preparation .............................................................................................................................. 7
2.2.2 Mechanical Installation .............................................................................................................................. 8
2.2.3 Cable Connection ...................................................................................................................................... 8
2.2.4 Sealing Cable Entry Holes ....................................................................................................................... 10
2.3 Commissioning ................................................................................................................................................... 10
2.3.1 Check Before Power-on........................................................................................................................... 10
2.3.2 Power-on And Commissioning ................................................................................................................ 10
2.4 Final Steps .......................................................................................................................................................... 12
Chapter 3 Use Of Monitoring Board .................................................................................................................................. 13
3.1 Monitoring Board Introduction ............................................................................................................................. 13
3.2 Querying Status .................................................................................................................................................. 13
3.3 Querying Active Alarm ........................................................................................................................................ 14
3.4 Setting Parameters ............................................................................................................................................. 15
3.5 Maintenance ....................................................................................................................................................... 16
3.6 Querying History Alarm ....................................................................................................................................... 17
Appendix 1 Wiring Diagram ............................................................................................................................................... 18
Appendix 2 Glossary ......................................................................................................................................................... 19
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Chapter 1 Introduction 1
NetShine 101 CA1 Solar Controller User Manual
Chapter 1 Introduction
The NetShine 101 CA1 solar controller (controller for short) is used for the outdoor wireless communication stations.
The controller can effectively control the solar energy to supply power to the battery and the load, making the battery
and the load work in safe voltage and current range.
This chapter introduces the model description, operation theory, features, functions and technical parameters of the
controller.
1.1 Model Description
The controller model description is shown in Figure 1-1.
1 0 A 1Version No.
Current or power level, 5: 50A;
A: 100A; F: 150A; K: 200A
Region or customer type, C: China
Product category, 1: standard controller
Brand name of Emerson solar controller
1 C
Function type, 0: solar; 1: solar & electric/solar &
DG; 2: wind & solar; 3: wind, solar & electric (DG)
Voltage type, 0: -48V system
NetShine
Figure 1-1 Model description
1.2 Operation Theory
In sunny days, the photovoltaic array (array for short) in the solar energy power system supplies power to the battery
and the load. During nights and cloudy days, the batteries sustain the load. The schematic diagram of the solar
energy power system is shown in Figure 1-2.
Input
SPD
Output power
board
Input power
board 1
Positive busbar
Negative busbar
MCB
I/O port
Prim
ary
loadOutput
SPD
Battery
Input power
board 2
Input
SPD
Output
SPD
Array 1 input
Array 2 input
Sla
ve lo
ad
Figure 1-2 Schematic diagram of the solar energy power system
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2 Chapter 1 Introduction
NetShine 101 CA1 Solar Controller User Manual
By controlling the input power boards, the controller stabilizes the battery voltage within a specified range, and
determines the battery charge states according to the capacity and voltage of the battery. If the battery voltage is too
high, the output power board will disconnect the load to protect the load; if the battery voltage is too low, the output
power board will disconnect the load to protect the battery.
The controller has a monitoring board, which is used to monitor the operation condition of the controller, control each
input power board and output power board, and carry out battery management. The monitoring board provides the
RS232/RS485 port, alarm dry contact input port, alarm dry contact output port, and battery temperature sensor port.
1.3 Features
The LCD allows you to learn of the operation conditions of the controller and the battery status.
The controller uses ON/OFF mode and PWM mode to control array input, taking full advantage of solar energy
input.
Perfect battery management functions. Those functions include the battery low voltage disconnection,
temperature compensation and automatic voltage regulation.
Perfect protection function and fault alarm function.
The advanced EMC design satisfies EN55022 CLASS A and IEC61000-4 requirements.
The safety design of the controller complies with EN50178 standard.
1.4 Functions
Array management function
The controller uses ON/OFF mode (default) and PWM mode, you can manually choose one mode for battery charge.
In ON/OFF mode, the controller performs the switching control of the arrays through switching on/off of the input
power boards. In PWM mode, the controller performs the switching control of the arrays and takes full advantage of
the solar energy through high frequency switch according to operation status of the solar energy power system.
Protection function
Table 1-1 Protection function
Function Description Remark
Input overcurrent
protection
When one array has overcurrent input (adjustable, see 3.4 Setting
Parameters), the controller inside will control the current. If the
current is too large, the corresponding MCB will trip
When the fault is cleared, the
controller will resume automatically.
The tripping MCB should be switched
on manually
Output overcurrent
protection When one load output is shorted, the corresponding MCB will trip
The fault must be cleared before the
MCB of a shorted load output can be
closed
Battery overcurrent
protection In case of battery overcurrent, the corresponding MCB will trip
The MCB needs to be closed
manually
Overtemperature
protection
When the battery temperature is over 50C (adjustable, see 3.4
Setting Parameters), the controller will generate an overtemperature
alarm.
When the battery temperature is over 60C (adjustable, see 3.4
Setting Parameters), the controller will disconnect the array input and
perform overtemperature protection
In overtemperature protection state,
the battery will disconnect the array
input, lowering the utility rate of the
solar energy in sunny days. Therefore
the overtemperature function is
Disabled by default. When the
battery temperature is normal, the
controller will resume automatically
Surge protection
The controller has an internal SPD that can achieve surge protection.
When the SPD is found faulty, the controller will generate an SPD
fault alarm. Compliant with Class C surge protection standard
If the SPD is faulty, you need to
replace it manually
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NetShine 101 CA1 Solar Controller User Manual
Measurement function
Table 1-2 Measurement function
Signal Measurement range Precision Environmental requirement
Open circuit voltage of array 20Vdc ~ 100Vdc 0.5Vdc
Ambient temperature: 25C
Operating current of array 0 ~ 50A 0.5A
Busbar/battery voltage 35Vdc ~ 65Vdc 0.2Vdc
Total charge/discharge current of the battery string -40A ~ +80A 1A
Load current 0 ~ 30A 0.5A
Battery temperature -30C ~ +65C 3C
Alarm function
The alarms are displayed on the LCD of the monitoring board, and are indicated by the corresponding indicators. The
alarms can be set through the monitoring board. Refer to 3.4 Setting Parameters for details.
Table 1-3 Alarm function
Name Alarm symptom Alarm triggering condition Alarm clearance condition
DC OverVolt
The yellow indicator on the
monitoring board turns on, and
the Active Alarm on the LCD
displays DC OverVolt
The busbar voltage is higher
than the battery overvoltage
alarm threshold
The busbar voltage is lower
than the battery overvoltage
alarm threshold
DC UnderVolt
The yellow indicator on the
monitoring board turns on, and
the Active Alarm on the LCD
displays DC UnderVolt
The busbar voltage is lower
than the battery undervoltage
alarm threshold
The busbar voltage is higher
than the battery undervoltage
alarm threshold
LLVD
The red indicator on the
monitoring board turns on, and
the Active Alarm on the LCD
shows LLVD
The busbar voltage is
continuously lower than the
load low-voltage disconnection
threshold
The busbar voltage is higher
than the load low-voltage
disconnection threshold
Array OverVolt
The yellow indicator on the
monitoring board turns on, and
the Active Alarm on the LCD
displays Array OverVolt
The open circuit voltage of the
array is higher than the array
input overvoltage threshold
The open circuit voltage of the
array is lower than the array
input overvoltage threshold
Array OverCurr
The yellow indicator on the
monitoring board turns on, and
the Active Alarm on the LCD
displays Array OverCurr
The operating current of the
array is higher than the array
input overcurrent threshold
The operating current of the
array is lower than the array
input overcurrent threshold
Array Lost
The yellow indicator on the
monitoring board turns on, and
the Active Alarm on the LCD
displays Array Lost
The controller detects array loss When the array is connected
normally, the alarm disappears
Array Reverse
The red indicator on the
monitoring board turns on, and
the Active Alarm on the LCD
displays Array Reverse
The input polarities of the array
are reversely connected
The input polarities of the array
are correctly connected
Input Circuit Open
The yellow indicator on the
monitoring board turns on, and
the Active Alarm on the LCD
displays Input Circuit Open
The input MCB of the array is
open or the input power board
is open
The input MCB of the array is
closed and the input power
board is closed
Input Power Board Short
Circuit
The red indicator on the
monitoring board turns on, and
the Active Alarm on the LCD
displays Input Power Board
Short Circuit
Input power board is shorted The short circuit fault is cleared
B-High Temp Alarm
The yellow indicator on the
monitoring board turns on, and
the Active Alarm on the LCD
displays B-High Temp Alarm
The battery temperature is
higher than the battery
overtemperature alarm
threshold
The battery temperature is
lower than battery
overtemperature alarm
threshold
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4 Chapter 1 Introduction
NetShine 101 CA1 Solar Controller User Manual
Name Alarm symptom Alarm triggering condition Alarm clearance condition
B-OverTemp Prot
The yellow indicator on the
monitoring board turns on, and
the Active Alarm on the LCD
displays B-OverTemp Prot
The battery temperature is
higher than the B-OverTemp
Prot threshold, and the
BatTempProt EN is set to Y
The battery temperature is
lower than the B-OverTemp
Prot threshold, or the
BatTempProt EN is set to N
Over LoadCurr
The yellow indicator on the
monitoring board turns on, and
the Active Alarm on the LCD
displays Over LoadCurr
The load current is higher than
the load overcurrent threshold
The load current is lower than
the load overcurrent threshold
SPD Fails
The yellow indicator on the
monitoring board turns on, and
the Active Alarm on the LCD
displays SPD Fails
The SPD is faulty The SPD works normally
Controller Fails
The yellow indicator on the
monitoring board turns on, and
the Active Alarm on the LCD
displays Controller Fails
The monitoring board is faulty The monitoring board works
normally
Battery Circuit Open
The red indicator on the
monitoring board turns on, and
the Active Alarm on the LCD
displays Battery Circuit Open
The battery circuit open caused
by battery MCB open or other
causes
The battery circuit is closed
Load MCB Off
The red indicator on the
monitoring board turns on, and
the Active Alarm on the LCD
displays Load MCB Off
The load MCB trips The load MCB is closed
Auxiliary Charge Fails
The yellow indicator on the
monitoring board turns on, and
the Active Alarm on the LCD
displays Auxiliary Charge
Fails
The auxiliary charge is
abnormal, when the controller
sends signal for starting the
auxiliary charge
The battery voltage is up to
53V or the auxiliary charge is
off (automatic/manual)
CAN Com Fail
The yellow indicator on the
monitoring board turns on, and
the Active Alarm on the LCD
displays CAN Com Fail
The CAN fails to connection
with power system, when the
controller works in cooperation
mode
Normal connection
Bat Tem Sen Fail
The yellow indicator on the
monitoring board turns on, and
the Active Alarm on the LCD
displays Bat Tem Sen Fail
Battery temperature sensor is
disconnected or faulty
Battery temperature sensor is
connected normally
Input Alarm
The yellow indicator on the
monitoring board turns on, and
the Active Alarm on the LCD
displays Input Alarm
The input dry contact status is
changed
The status returns to normal
status
Alarm input function
Table 1-4 Alarm input function
Dry contact type Dry contact state
Normally-open (default), normally-closed Normally-open: open upon normal input, closed upon alarm input
Normally-closed: closed upon normal input, open upon alarm input
Alarm output function
Table 1-5 Alarm output function
SN. Output dry contact alarm Dry contact state
Output dry contact 1 Controller fault (settable, see 3.4 Setting Parameters) Normally-open is default. You
can set the dry contact state
through the jumpers (see Table
2-6) Output dry contact 2 Battery undervoltage (settable, 3.4 Setting Parameters)
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NetShine 101 CA1 Solar Controller User Manual
Control function
The controller has two control modes: automatic control and manual control. In automatic control state, the controller
will perform automatic control functions according to preset parameters and logic. In manual control state, you can
control connections of the arrays and loads through keyboard on the monitoring board or host.
Communication function
The controller can communicate with the host through RS485/RS422 port. The RS485/RS422 port can be set through
jumpers in the board card, and the setting method is described in Table 2-6 in 2.3.2 Power-on And Commissioning.
The default communication mode is RS422. The host can set the controller parameters and maintenance, and it can
read the measurement values, active alarm values, historical alarm values and historical data.
Display function
The controller uses a 128 64 LCD, which displays the controller and battery states, measurement values and
alarms in real time.
Historical data record function
The controller can record the historical data (up to 31 days) which can be read through the host, including the
following information:
1. The highest battery temperature every day 2. The lowest battery temperature every day
3. The highest battery voltage every day 4. The lowest battery voltage every day
The controller can record 100 historical alarms, including the following alarm information:
1. Alarm content 2. Alarm start time and end time
3. Load current and battery voltage in the alarm time (available
through the host)
Battery management function
According to the input current and voltage, battery capacity, load status and busbar voltage, the controller performs
the battery management to ensure efficient charge and discharge of the battery, to prolong the battery lifetime and
make good use of the solar energy.
In battery FC mode, the busbar voltage is controlled within +1V of the preset FC point.
In battery BC mode, the busbar voltage is controlled within +1V of the preset BC point.
In FC state, the controller will control the battery to enter the BC mode when the FC voltage decreases to a point
lower than the preset FC to BC voltage.
In BC state, the controller will control the battery to enter the FC mode when the BC voltage is +1V higher than
the preset BC voltage.
If the controller uses the PWM mode, it will perform array input management according to the default PWM logic.
1.5 Technical Parameters
Table 1-6 Technical parameters
Type Item Description
Environment
Operating temperature -20C ~ +55C
Storage temperature -40C ~ +70C
Relative humidity 0 ~ 95%RH
Altitude 5500m (derating is necessary above 3,000m. Rated current decreases 20A
for every 1000m higher)
Others No conductive dust or erosive gases. No possibility of explosion
DC input
Array 2 routes 50A, 63A 2 (MCB)
Current (one route array) Rated current: 50A. Overcurrent alarm point: 55A
Voltage Rated voltage: 48Vdc. Max. open circuit voltage: 96Vdc
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6 Chapter 1 Introduction
NetShine 101 CA1 Solar Controller User Manual
Type Item Description
DC output
Route Primary load: 2 routes, 16A 2 (MCB)
Slave load: 2 routes, 63A 2 (MCB)
Current Total load current is the sum of the primary load current and slave load current,
whose max. current is 30A
Voltage Rated voltage: 48Vdc.
Max. allowable output voltage: 60Vdc
Efficiency 99%
Battery
configuration
Battery route One route, 125A 1 (MCB). If the battery route is open, the controller will stop
working
Nominal capacity 50Ah ~ 5000Ah
EMC
Conducted emission Class A EN55022
Radiated emission
Immunity to EFT Level 3 EN61000-4-4
Immunity to ESD Level 3 EN61000-4-2
Immunity to surges Level 3 EN61000-4-5
Immunity to radiation Level 3 EN61000-4-3
Immunity to conduction Level 2 EN61000-4-6
SPD Lightning protection features The array input port and load port are configured with SPD, whose rated
capacity is 20kA and max. capacity is 40kA
Safety
Standard Compliant with EN50178 standard
Insulation resistance
At temperature of 15C ~ 35C and relative humidity not higher than 90%RH;
apply a test voltage of 500Vdc, and the insulation resistance between DC circuit
and earth is not less than 2M
Insulation strength
Remove the SPD from the system before the test.
Input/output circuit to earth: 1414Vdc.
Input/output circuit to communication output circuit: 2828Vdc.
Input/output circuit to dry contact output: 1414Vdc.
Communication output circuit to dry contact: 1414Vdc.
For all the four tests above, there should be no breakdown or flashover within 1
min, with leakage current not bigger than 10mA
Others
MTBF 100000h (Bellcore TR-332 reliability forecast), at 25C
Protection level IP55
ROHS Compliant with ROHS
Mechanical Dimension (mm) 290 (W) 150 (H) 420 (L)
Weight (kg) 11 (without packaging)
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Chapter 2 Installation And Commissioning 7
NetShine 101 CA1 Solar Controller User Manual
Chapter 2 Installation And Commissioning
This chapter introduces the installation, cable connection, commissioning and final steps. Before installation, please
read the safety regulations carefully, and then follow the instructions in this chapter to carry out the installation and
connection.
2.1 Safety Regulations
Certain components in this controller have hazardous voltage and current. Always follow the instructions below:
1. Only qualified personnel with sufficient knowledge of the controller can carry out the installation. The safety
precautions and local safety rules shall be adhered to during the installation.
2. All external circuits that are below -48V and connected to the controller must comply with the requirements of
SELV defined in IEC60950.
3. Make sure that the power to the controller is cut off before any operations can be carried out within the controller.
4. After the installation and the commissioning, the controller shall be kept locked. The key should be kept in
possession by corresponding personnel.
5. The wiring of the power distribution cables should be arranged carefully and taken protective measures so that the
cables are kept away from the maintenance personnel.
6. All the tools before the installation must be insulated and ESD-proof processed.
2.2 Installation And Cable Connection
2.2.1 Installation Preparation
Unpacking inspection
The equipment should be unpacked and inspected after it arrives at the installation site. The inspection shall be
carried out by representatives of both the user and Emerson Network Power Co., Ltd.
To inspect the equipment, you should open the packing case, take out the packing list and check whether the
equipment is correct and complete. Make sure that the equipment is delivered intact.
Preparing cables
The cable should be selected in accordance with relevant industry standards. The CSA of cables depends on the
current flowing through the cable and the allowable voltage drop. The cable CSA selection is given in Table 2-1.
Table 2-1 Recommended cable CSA
Connection point Recommended CSA Recommended cable color Recommended max. distance
Battery to controller 25mm2 Blue for negative and black for positive 13m
Controller grounding cable 16mm2 Yellow-green 1m
Note: You should select the CSA and color of the cable according to the actual configuration
Select the battery cable CSA according to Table 2-2.
Table 2-2 Battery cable CSA selection
Battery MCB rated current Max. battery current Min. cable CSA Terminal type Max. cable length (allowable
volt drop: 0.5V)
125A 80A 25mm2
OT lug (+)
H shape terminal (-) 8m
Note:
1. The specifications are applicable at ambient temperature of 25C. If the temperature is too high, the CSA of the cable should be
increased.
2. The battery cable should reach at least +70C heat durability
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8 Chapter 2 Installation And Commissioning
NetShine 101 CA1 Solar Controller User Manual
Select the load cable CSA according to Table 2-3.
Table 2-3 Load cable selection
Load route
rated current Max. output current
Min. cable
CSA
Max. cable length (volt drop: 0.5V,
with min. CSA) Max. cable CSA
Max. cable length (volt
drop: 0.5V, with max. CSA)
63A 50A 25mm2 13m 50mm
2 26m
16A 10A 10mm2 16m 16mm
2 26m
Note: The specifications are applicable at ambient temperature of 25C. If the temperature is too high, the CSA of the cable should
be increased
The MCB capacity should be strictly limited so that it can work properly upon overload. The recommended MCB
capacity is 1.5 ~ 2 times larger than the load rated capacity.
The CSA of the grounding cable should be not less than 16mm2.
The battery MCB and load MCB use H shape terminal for connection. Or you can use cables with insulation layers
broken up for connection.
There are six PG cable glands at the bottom of the controller. The specifications of the PG cable glands are PG21
(four pieces) and PG29 (two pieces).
2.2.2 Mechanical Installation
The controller supports wall installation mode.
Wall installation
When determining the installation position of the controller, make sure that there is an 800mm maintenance
clearance in the front. The installation method is shown below:
1. Use M4 8 bolts to install the four brackets onto the controller.
2. Drill holes and install M10 16 expansion bolts on the wall according to the dimensions shown in Figure 2-1.
290240
520
478
420
Figure 2-1 Wall installation dimensions (unit: mm)
3. Connect the brackets with the expansion bolts, and then use the nuts to fasten them.
2.2.3 Cable Connection
The controller uses bottom cabling method. The connection positions are shown in Figure 2-2.
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Chapter 2 Installation And Commissioning 9
NetShine 101 CA1 Solar Controller User Manual
Communication port
Connected to
temperature sensor
Connected to array
1 negative cable
Grounding
Connected to battery
Dry contact input
Dry contact output
Connected to load
Connected to all
Connected to array
2 negative cable
negative cable
negative cable
positive cables
Figure 2-2 Cable connection of the controller
Note
1. To ensure safety, users should check the polarities of the cables against those of the batteries and pull out the battery fuses
before connecting battery cables.
2. After the check, connect the positive battery cables to the positive busbar. Connect the negative battery cables to the negative
terminals of the battery fuses.
3. Check again to ensure that the polarities of the cables connected to the positive busbar and battery fuses are correct.
Warning
Reverse connection of the battery might cause the battery to burn or other major failures, and even endanger personal safety.
Only professionals are allowed to connect the batteries. During the operation, pay attention to polarities and prevent short circuit
to ensure personal safety.
Connect cables according to the information shown in Table 2-4.
Table 2-4 Description of cable connection
Cable Color Amount Connection
From To
Array input cable
Positive (+) Black 12 Positive pole of the array Positive busbar of the controller (12
routes)
Negative (-) Blue 12 Negative pole of the array Negative array terminal of the
controller (12 routes)
Battery cable
Positive (+) Black 1 Positive pole of the battery string Positive busbar of the controller (1
group)
Negative (-) Blue 1 Negative pole of the battery string Negative battery terminal of the
controller (1 group)
Output cable
Positive (+) Black 4 Positive busbar of the controller (4
routes) Positive pole of the load
Negative (-) Blue 4 Output terminal MCB of the
controller (4 routes) Negative pole of the load
Communication
cable 1
T+ / 1 Controller J18 Other monitor devices
T- / 1 Controller J18 Other monitor devices
R+ / 1 Controller J18 Other monitor devices
R- / 1 Controller J18 Other monitor devices
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10 Chapter 2 Installation And Commissioning
NetShine 101 CA1 Solar Controller User Manual
Cable Color Amount Connection
From To
Communication
cable 2
(cooperation
mode)
CAN+ / 1 Power system CAN+ Controller CAN+
CAN- / 1 Power system CAN- Controller CAN-
Auxiliary power
cable J21 Blue-black 1 Connected in controller J21 on main board
Grounding bar Metal 1 Positive busbar of the controller Grounding terminal of the controller
casing
Grounding cable Yellow-green 1 Grounding screw of the controller
housing Ground or support
Note:
1. The positive busbar of the controller is not connected to the grounding terminal of the controller casing at factory, you can choose
the grounding method according to the actual requirement.
2. You should lead the cables through the PG cable glands at the bottom, and then crimp the cable tap. The positive busbar uses
OT lugs for connection. For Negative poles, you can use H shape terminals for connection.
3. The load cable is provided by the equipment that uses power. For larger load, do not use two or more controllers to connect one
load simultaneously.
4. Colors of the cables can be adjusted on site according to the actual situation. Make sure that all the MCBs and loads are
disconnected before the cable connection
2.2.4 Sealing Cable Entry Holes
For outdoor controllers, you should seal all the cable entry holes after the installation. The procedures are as follows:
For the used holes, tighten them with PG cable glands.
For the holes with a small cable or with several cables, tighten them with PG cable glands and seal them with
waterproof mud (accessory).
For the unused holes, block them with rubber plugs and seal them with waterproof mud.
2.3 Commissioning
2.3.1 Check Before Power-on
Check the items given in Table 2-5. Ensure that the components are installed firmly and the cables are connected
reliably.
Table 2-5 Checking items before power-on
Type Item Content
Array Input Input cables
The polarities are correct. The connections are reliable. All the input and
output MCBs are switched off
Between positive and negative terminals No short circuit
Load output Output cables
The polarities are correct. The connections are reliable. All the input and
output MCBs are switched off
Between positive and negative terminals No short circuit
Battery Battery cables The polarities are correct. The connections are reliable
Between positive and negative terminals No short circuit
2.3.2 Power-on And Commissioning
The procedures for powering on and commissioning the controller are as follows:
1. Battery polarity check and power-on
Check that the polarities of the two batteries are correct, and then switch on the battery MCB. Meanwhile the auxiliary
power of the monitoring board in the controller starts to work. The controller starts self-test. After the self-test, the first
information screen will appear, as shown in Figure 2-3.
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Chapter 2 Installation And Commissioning 11
NetShine 101 CA1 Solar Controller User Manual
2009-07-01
55.2V 4.6A
No Alarm
Auto Discharge
Figure 2-3 First information screen
Check the indicator status of the controller. When the red and yellow indicators are off, it means that everything is
normal. If the red indicator and yellow indicators are on, you can remove the alarms according to Table 1-3.
When the checks are normal, switch on the array input MCB.
2. Load polarity and connection check
Check that the connection of the load output cables, the MCB connection of the load and the polarities of the load are
correct. After ensuring that everything is OK, go on to the next step.
3. Battery busbar voltage measurement
Use a multimeter to measure the battery busbar voltage. If the busbar voltage is within the normal output range (48V
~ 55V), switch on one load MCB. Check that the battery busbar voltage is within the normal range after the load
starts up and works normally. If the busbar voltage is close to 47V, do not switch on the next load MCB until the
batteries are properly charged. Repeat the operation until all the loads are powered on and work normally.
4. Parameter setting
Set the parameters according to the parameter card delivered with the controller.
Enter the corresponding operation interface and input the correct password to set the parameter, see 3.4 Setting
Parameters.
Note
1. If users do not reset certain parameters, the controller will use the default settings.
2. For significant parameters, it is recommended to use default settings if not specified.
1) Battery parameter
Set the battery capacity, busbar overvoltage alarm point, busbar undervoltage alarm point and busbar undervoltage
protection point in accordance with the actual battery configuration.
If the controller is configured with a battery temperature sensor, you need to set the battery overtemperature alarm
point and battery overtemperature protection point. If not, you do not need to set these parameters.
2) System control mode
The controller provides two array control modes: ON/OFF and PWM. You can select one control mode according to
your need. The ON/OFF mode is recommended.
3) Local address: 1 (default).
4) Date and time: In accordance with the actual time and date.
5) For setting jumpers of the board card, see Table 2-6. Use the default settings listed below.
Table 2-6 Jumper setting of the board card
SN. Screenprint Parameter Settings Default
1 GP1 Communication mode Pins 1, 2 short-circuited: RS422; pins 2, 3
short-circuited: RS485 RS422
2 J2 Output dry contact 1 Pins 1, 2 shorted: normally open; pins 2, 3 shorted:
normally closed Normally open
3 J3 Output dry contact 2 Pins 1, 2 shorted: normally open; pins 2, 3 shorted:
normally closed Normally open
6) Array parameter
For the array open-circuit voltage too high alarm point and input overcurrent alarm point, set these parameters
according to the actual maximum open circuit voltage and the short circuit current of the arrays, and the allowable
setting range listed in Table 1-3.
5. Alarm check
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12 Chapter 2 Installation And Commissioning
NetShine 101 CA1 Solar Controller User Manual
After the parameter settings, the system status should be No alarm. If the system status is Alarm, query the
corresponding alarm and do troubleshooting by referring to 3.3 Querying Active Alarm.
6. History alarm clearing
Clear all history alarms generated during the commissioning by referring to 3.6 Querying History Alarm.
7. Return to the system information screen
Press the ESC key to return to the system information screen.
2.4 Final Steps
After the installation and commissioning, fill the parameter settings in the parameter card.
Clear the installation field. Sort the accessories and store them properly.
Lock the controller cabinet. Keep the key.
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Chapter 3 Use Of Monitoring Board 13
NetShine 101 CA1 Solar Controller User Manual
Chapter 3 Use Of Monitoring Board
This chapter introduces the use of the monitoring board, including the monitoring board introduction, querying
information, control and setting parameters.
3.1 Monitoring Board Introduction
The monitoring board of the controller is shown in Figure 3-1.
ESC
ENT
Run indicator
Alarm indicator
Critical alarm indicator
Functional keys
LCD
Figure 3-1 Monitoring board
Description of the indicators is in Table 3-1.
Table 3-1 Description of indicators
Indicator Color Normal state Fault state Fault cause
Run indicator Green On Off No operation power supply
Alarm indicator Yellow Off On At least one observation alarm
Critical alarm indicator Red Off On At least one major or critical alarm
The monitoring board uses a 128 64 LCD and a keypad with 6 functional keys. The interface language is
Chinese/English optional. Description of the functional keys is listed in Table 3-2.
Table 3-2 Description of functional keys
Keys Functions
ESC Return key: Press this key to go back to previous menu At the first information screen, press the ESC key and
you can see the software version information
ENT Confirmation key: Press this key to go to next menu or validate
the change made to a parameter setting
After a change, only pressing the ENT key can validate
the change
Press or to scroll through the menus. When the editable
options are character strings, pressing or can edit values
Four arrow keys can be used to change the parameter
value: Press or to move the cursor to the
parameter to be changed and press or to change
the parameter value
Press or to move the cursor
3.2 Querying Status
The system information can be queried from the information screen. For the first information screen, see Figure 3-2.
2009-07-01
55.2V 4.6A
No Alarm
Auto Discharge
Figure 3-2 First information screen
The first row displays the current date and time alternately. The second row displays the busbar voltage and the load
current of the controller. For example, 55.2V is the busbar voltage and 4.6A is the load current. The third row displays
the controller state, which is No alarm or Alarm. The fourth row displays the control mode and battery state. The
control mode includes Auto and Manual. The battery state includes BC, FC and discharge.
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14 Chapter 3 Use Of Monitoring Board
NetShine 101 CA1 Solar Controller User Manual
Press continuously at the first information screen, you can query the information listed in Table 3-3.
Table 3-3 Querying information
SN. Status Content
1 Batt Volt The present battery voltage
2. Load Current The present load current
3. Operation Status Auto or Manual
4 PV State On, Off or PWM
5 PV OpenVolt The actual array voltage
6 PV Current The array real-time current
7 Battery Current The present battery current
8 Battery Temp The present battery temperature
9 Batt Remain Cap The present remaining battery capacity
10 Sys Run Time The total system run time
11 Batt Chrg Times The total battery charge times
12 Batt Disc Times The total battery discharge times
13 Daily Chrg Cap The total charge capacity of the day
14 Daily Disc Cap The total discharge capacity of the day
15 PV Input Cap The accumulated array input capacity
16 Load Output Cap The accumulated load output capacity
17 Max Batt Temp The maximum battery temperature of the day
18 Min Batt Temp The minimum battery temperature of the day
19 Max Batt Volt The maximum operating voltage of the day
20 Min Batt Volt The minimum operating voltage of the day
21 AUX Chrg State The present auxiliary charge state. Available when auxiliary charge is enabled
22 Current Chrg Time The current auxiliary charge time. Available when auxiliary charge is enabled
23 Total Chrg Time The accumulated auxiliary charge time. Available when auxiliary charge is enabled
24 AC Power State Available when cooperation mode is enabled
25 AC Power Load Cur Available when cooperation mode is enabled
26 AC Input Cur Available when cooperation mode is enabled
27 Rect Curr Available when cooperation mode is enabled
After querying all the information, press continuously to return to the first information screen, or press the ENT key
to enter the main menu screen, as shown in Figure 3-3.
Settings
Maintenance
Active Alarm
History Alarm
Figure 3-3 Main menu screen
3.3 Querying Active Alarm
1. Select the Active Alarm option from the main menu screen, as shown in Figure 3-4.
Active Alarm
Settings
Maintenance
History Alarm
Figure 3-4 Main menu screen: Active Alarm highlighted
2. Press the ENT key to enter the active alarm screen and view the active alarms, as shown in Figure 3-5.
Active Alarm 1
LLVD
09-07-01 20:3015:
Figure 3-5 Active alarm screen
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Chapter 3 Use Of Monitoring Board 15
NetShine 101 CA1 Solar Controller User Manual
3. Press at the active alarm screen, you can query all the active alarms. Press the ESC key to return to the main
menu screen.
3.4 Setting Parameters
1. Press at the main menu screen to select the Settings option, as shown in Figure 3-6.
Settings
Maintenance
History Alarm
Active Alarm
Figure 3-6 Main menu screen: Settings highlighted
2. Press the ENT key to enter the password confirmation screen, as shown in Figure 3-7.
Enter Password:
100000
Figure 3-7 Password confirmation screen
3. Enter the password: 100000.
To enter the password, press or to modify numbers, and press or to move the cursor. After entering the
password, press the ENT key to confirm the password and enter the settings screen, as shown in Figure 3-8.
1000Ah
Batt Capacity:
Batt OverVolt:
58.5V
Figure 3-8 Settings screen
Press continuously at the settings screen, you can query and set the parameters listed in Table 3-4.
Table 3-4 Setting parameters
SN. Parameter name Setting range Default
1 Batt Capacity 50Ah ~ 5000Ah 300Ah
2 Batt OverVolt BC voltage + 1.5Vdc (min. 58.0Vdc) ~ 60.0Vdc 58.5Vdc
3 Batt LowVolt LLVD + 0.5Vdc (min. 46.0Vdc) ~ 50.0Vdc 47.0Vdc
4 LLVD BLVD + 0.5Vdc (min. 45.5Vdc) ~ Batt LowVolt - 0.5Vdc
(max. 48.5Vdc) 46.5Vdc
5 BLVD 45.0Vdc ~ LLVD - 0.5Vdc (max. 48.0Vdc) 46.0Vdc
6 B-HighTemp Alm 35C ~ B-OverTemp Prot - 10C (max. 60C) 50C
7 B-Temp Prot EN Yes, No No
8 B-OverTemp Prot 45C ~ 70C 60C
9 Boost Chrg Volt 54.2Vdc (Float Chrg Volt + 2.2Vdc) ~ 57.5Vdc (HighVolt
Alarm - 1.5Vdc) 56.4Vdc
10 Float Chrg Volt 52.0Vdc (FC to BC Volt +1.5Vdc) ~ 56.3Vdc (Boost Chrg
Volt - 2.2Vdc) 53.5Vdc
11 Dry Contact NO, NC NO
12 DryCont Output 1
Array lost, battery undervoltage, battery circuit open,
LLVD, battery overtemperature, controller fault, auxiliary
charge
Controller fault
13 DryCont Output 2
Array lost, battery undervoltage, battery circuit open,
LLVD, battery overtemperature, controller fault, auxiliary
charge
Battery undervoltage
14 AUX Charge Mode Voltage mode, time mode Voltage mode
15 AUX Trigger Time 00:00 ~ 23:30 20:00
16 AUX Run Time 2h ~ 18h 10h
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16 Chapter 3 Use Of Monitoring Board
NetShine 101 CA1 Solar Controller User Manual
SN. Parameter name Setting range Default
17 Temp Comp Set Yes, No Yes
18 Temp Comp Coeff 0 ~ 100 (mV/C.S) 72 (mV/C.S)
19 Address 1 ~ 254 1
20 Clear History Yes, No No
21 Reset parameter Yes, No No
22 Date & Time Yes, No No
23 Language Chinese, English English
24 Charge Mode PWM, ON/OFF ON/OFF
25 Cooperator None, AC None
3.5 Maintenance
1. Press at the main menu screen to select the Maintenance option, as shown in Figure 3-9.
Maintenance
History Alarm
Active Alarm
Settings
Figure 3-9 Main menu screen: Maintenance highlighted
2. Press the ENT key to enter the password confirmation screen, as shown in Figure 3-10.
Enter Password:
200000
Figure 3-10 Password confirmation screen
3. Enter the password: 200000.
To input the password, press or to modify numbers, and press or to move the cursor. After entering the
password, press the ENT key to confirm the password and enter the maintenance screen, as shown in Figure 3-11.
Modify Mode:
Auto
Figure 3-11 Maintenance screen
4. Press to change Auto into Manual, and press the ENT key to confirm the setting.
In the manual mode, you can perform the following array controls described in Table 3-5.
Table 3-5 Control parameters in manual mode
SN. Control parameter Setting range
1 Array 1* On, off
2 Array 2* On, off
3 Load 1 Reconnect, disconnect
4 Load 2 Reconnect, disconnect
5 AUX Charge On, off
Note*: The Array 1 and Array 2 will do the same operation, that is, when Array 1 is switched on, Array 2 will be on too
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Chapter 3 Use Of Monitoring Board 17
NetShine 101 CA1 Solar Controller User Manual
In the manual mode, the screen shown in Figure 3-12 will appear.
2
Array 1:On
Array 2:On
Figure 3-12 Array control screen
3.6 Querying History Alarm
1. Press at the main menu screen to select the History Alarm option, as shown in Figure 3-13.
History Alarm
Settings
Maintenance
Active Alarm
Figure 3-13 Main menu screen: History Alarm highlighted
2. Press the ENT key to enter the history alarm screen and view the history alarms, as shown in Figure 3-13.
History Alarm 1
Array 2 Fail
09-07-01
09-07-01
:20:3015
:20:3016
Figure 3-14 History alarm screen
3. Press continuously at the history alarm screen, you can query all the history alarms. Press the ESC key to return
to the main menu screen.
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18 Appendix 1 Wiring Diagram
NetShine 101 CA1 Solar Controller User Manual
Appendix 1 Wiring Diagram
J1H1
2
1 1
2 2
11
2 2
11
2
2 11 2 3 4
12
34
56
78
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 4 3 2 1
Door
Chassis
U116
SPD4
BUS+
12
PE13
M11
M22
QFD6
QFD7
QFD8
QFD9
QFD10
QFD11
J301 J17
J9
J12
J5J6J8J7
5 6 7 8 9 10
1 2 3 4
J18 J11
1 2 3 4
J4
3 2 1
J15
1 2
1 2
J4
J3J5
H2
H1
M13
J3
12
34
56
78
J19
1 2
12
34
56
78
J6
W10
W2
W7
W4W5 W5
W 8 W9
W1 W2
W3
W8 W9 W6 W11
W7
W11
91
0
1-J
3-2
1-J
3-1
1-J
3-5
1-J
3-6
1-J
3-7
1-J
3-8
2-J
6-1
2-J
6-2
2-J
6-3
2-J
6-4
2-J
6-5
2-J
6-6
2-J
6-7
2-J
6-8
2-J
6-9
2-J
6-1
0
9-110-1
7-18-1
4-v-2
1 6 - J 6 -1
1 6 -J 6 -21 6 - J 6 -31 6 - J 6 -41 6 -J 6 -5
1 6 - J 6 -61 6 - J 6 -7
1 6 -J 6 -8
1 6 -J 6 - 1 01 6 -J 6 -9
18
-V-2
,2-J
10
4-V
-2,8
-21
6-J
12
-4
16
-J1
2-5
16
-J1
2-1
16
-J1
2-2
18
-V-1
7-2
4-V
-1,1
0-2
9-2
2-J
5
16
-J5
-3
H2
J3
16-J7-116-J7-2
16-J7-8
16-J7-516-J7-616-J7-7
18-12
6-1
11
-1
W6
W 4
13
18
-V+
12
2 1
1 2
1 2
W 11 W11
W 11
16
-J2
1
16-J9
J21
J10
J8
J7
J2
J9
W11
2-J8 2-J7
2-J9
1-H2
4-V
+
1 2 3 4
J18A
J13
W 8
16-J6-116-J6-2
16-J6-8
16-J6-516-J6-616-J6-7
2
1
W1
18
-V-2
12
34
56
78
J11
SPD18
W8
3-J
3-2
3-J
3-1
3-J
3-5
3-J
3-6
3-J
3-7
3-J
3-8
QFD17
16
-J5
-4
18
-V-1
,2-J
11
12
4-V
+
W3
W1 W2
17
-2,1
-H2
6-2
,3-H
2
V-1V-2
12 11V+
12
-13
, 2
-J2
16
-J1
2-7
4-1
2
W7W3
W5 W5
8-2
,2-J
-4
10
-2,2
-J3
V-1V-2
12 11V+
12
-12
, 2
-J2
18
-11
16
-J1
2-8
W7W3
4-v-1
3-H2
J301-2
11-2
2-J
8-1
2-J
5
17
-1
18-v
+
W3
16
-J5
-1
16-J
301-1
4-11
Figure 1 Wiring diagram
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Appendix 2 Glossary 19
NetShine 101 CA1 Solar Controller User Manual
Appendix 2 Glossary
AC Alternating current
BC Boost charge
BLVD Battery low voltage disconnection
CSA Cross-sectional area
DC Direct current
DG Diesel generator
EMC Electromagnetic compatibility
FC Float charge
I/O Input/output
LCD Liquid crystal display
LLVD Load low voltage disconnection
LVD Low voltage disconnection
NC Normally closed
NO Normally open
PCB Printed circuit board
PV Photovoltaic
PWM Pulse-width modulation
SPD Surge protective devices