elgris HYBRID BASIC User manual
Hybrid Controller
“Diesel – PV Off the shelve”
Manual
Version 2.5
Version: 7. Oktober 2018 12:40
www.elgrispower.com
Page 2 of 25
Table of Contents
1. INTRODUCTION___________________________________________________________________________ 4
1.1 Version overview_____________________________________________________________________ 5
2. INSTALLATION____________________________________________________________________________ 6
2.1 Safety instructions____________________________________________________________________ 6
2.1 Device overview______________________________________________________________________ 6
2.2 Pin description _______________________________________________________________________ 7
2.3 General connection overview GRID and FUEL SAVING_______________________________________ 8
2.4 RS 485 pin out _______________________________________________________________________ 9
2.5 Dipswitches _________________________________________________________________________ 9
3.0 SOFTWARE ____________________________________________________________________________ 11
3.1 Settings reading _____________________________________________________________________ 11
3.2 Settings changing____________________________________________________________________ 11
3.3 Parameter overview _________________________________________________________________ 12
3.4 Output selection type ________________________________________________________________ 12
3.5 Grid feed in protection modus _______________________________________________________ 13
3.6 Fuel Saving mode with generator _____________________________________________________ 14
4COMMISSIONING________________________________________________________________________ 14
4.1 First time power on __________________________________________________________________ 14
5GRAPHICAL USER INTERFACE ________________________________________________________ 15
5.1 Overview __________________________________________________________________________ 15
5.2 Inverter settings_____________________________________________________________________ 15
5.3 elgris cloud _________________________________________________________________________ 16
5.4 System settings _____________________________________________________________________ 17
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5.5 Multiple generators with elgris SMART METER ___________________________________________ 18
5.5.1 Grid and dual generator application example with optional storage _________________________ 19
6ADJUSTING THE PID SETTINGS_______________________________________________________ 20
6.1 Manual tuning ______________________________________________________________________ 20
6.2 Ziegler–Nichols method ______________________________________________________________ 21
7MODBUS GATEWAY FUNCTION_______________________________________________________ 21
8MODBUS SERVER _______________________________________________________________________ 22
8.1 Register mapping Common Model______________________________________________________ 22
8.2 Register mapping WYE connect Meter Model ____________________________________________ 23
8.3 Custom mapping ____________________________________________________________________ 25
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1. Introduction
Dear customer, thank you for purchasing this product. The HYBRID BASIC controller is the first series
produced control system which enable you to control a PV system connected with a Diesel generator
in an intelligent way. With the modern HYBRID BASIC series Diesel - PV controller you can control
your PV system in a way that Diesel load is minimised, and fuel saving is maximized. The modern
controllers offer the following functions:
•Multiple Generator set control
•Prime mover and generator protections
•Engine data measurement (optional trough external bus):
oOperating hours
oRunning hours
oStart attempts
oOil pressure
oCoolant temperature
oBattery voltage
oFuel level measurement
oEngine speed
oService hours
oEtc.
•Generator voltage, current and power measurement
•GRID control and GENERATOR control with one device
•Ethernet based web interface for remote control (optional)
•2x MODBUS RS-485 for engine control and easy expanding
Specializing in products for generators and hybrid power solutions, the HYBRID BASIC offers the
following features standard:
•Wide range power supply input from 85 - 265 VAC (50 - 60 Hz)
•Small footprint.
•Intuitive software.
•Wide temperature range of -25° –+85°.
•Industrial PUR protection coating for extra rugged environment.
•IP-68 on request.
If you have any questions or if something is unclear, you can contact us in several ways:
Per E-Mail : support@elgrispower.com
By Phone : +49 (0) 2423 9086501
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2. Installation
2.1 Safety instructions
Before installing the product in the end-installation, ensure that the device is not damages during
transport and everything looks in a normal way.
All the connecting cables must not be bent or squeezed. This can result in malfunctions, short circuits
and defects in the device and/or sensor connected.
Make sure that cables are not damaged when drilling or bolting in place.
The module may only be commissioned after it has been installed contact-free in a casing. This
product generates high frequency. Never operate it in the vicinity of medical devices (e.g.
pacemakers) and/or medical equipment (e.g. in hospitals). Look for a suitable installation site.
2.1 Device overview
Before wiring the device, be sure that the voltage is switched off.
+
-
OK
on
1 2
on
1 2 3 4 5 6
13 14 15 16
1
2
3
4
5
6
7
8
9
10
11
12
21
20
19
18
17
Ethernet
RS 485 A
RS 485 B
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2.2 Pin description
Signal connector
Pin
Description
Minimum
Maximum
1
Analogue input 1 positive
0 V / 0 mA
10 V / 20 mA*
2
Analogue input 2 positive
0 V / 0 mA
10 V / 20 mA*
3
Input common level
0 V
0 V
4
Digital input 1
Open
Closed
5
Digital input 2
Open
Closed
6
Input common level
0 V
0 V
Power input
7
K input current transformer L3
0 Aac
5 Aac
8
L input current transformer L3
0 Aac
5 Aac
9
K input current transformer L2
0 Aac
5 Aac
10
L input current transformer L2
0 Aac
5 Aac
11
K input current transformer L1
0 Aac
5 Aac
12
L input current transformer L1
0 Aac
5 Aac
13
Phase L1 voltage input
85 Vac
250 Vac
14
Phase L2 voltage input
85 Vac
250 Vac
15
Phase L3 voltage input
85 Vac
250 Vac
16
Neutral input of voltage
Control
input
17
Level 1 (0 % limitation)
2 A @ 250 VAC / 30 VDC
18
Level 2 (30 % limitation)
2 A @ 250 VAC / 30 VDC
19
Level 3 (60 % limitation)
2 A @ 250 VAC / 30 VDC
20
Level 4 (100 % limitation)
2 A @ 250 VAC / 30 VDC
21
Relay signal common
Check inverter specifications
Dipswitch
1
1
IP address selection
OFF = DHCP
ON = static
2
System frequency
OFF = 50 Hz
ON = 60 Hz
3
Single or Three phase
OFF = Three phase
ON = Single phase
4
Not used
Must be OFF
5
Analog selection channel 1
ON = 0 –20 mA
OFF = 0 –10 V
6
Analog selection channel 2
ON = 0 –20 mA
OFF = 0 –10 V
Dipswitch
2
1
120 Ohm termination RS-485 A
ON = 120 Ohm
OFF = Open
2
120 Ohm termination RS-485 B
ON = 120 Ohm
OFF = Open
* Depending on dipswitch 5 and 6
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2.4 RS 485 pin out
Pin
Description
1
Not connected
2
RS-232 TX (Only on A)
3
RS-232 RX (Only on A)
4
RS-485 B (D-)
5
RS-485 A (D+)
6
GND
7
Not connected
8
Not connected
2.5 Dipswitches
There are 2 dipswitches on the controller. The 2 switch is for the termination resistors of the RS 485
A and B and the 6 switches if for settings.
on
1 2
Dipswitch
Description
OFF
ON
1
No termination A
120 Ohm A
2
No termination B
120 Ohm B
on
123456
Dipswitch
Description
OFF
ON
1
DHCP
Static IP
2
50 Hz
60 Hz
3
Three phase
Single phase
4
Not used must be OFF
5
0 –10 Vdc
0 –20 mAdc
6
0 –10 Vdc
0 –20 mAdc
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2.6 LED status
The LED on board informs the user about the internal status.
LED colour
Meaning
Action
Off
No power or internal error
Contact support
Internal Error
Contact support
Date and time not set, no USB data
logging possible
Update date and time or check
internet connection for SNTP
Standby, no inverter online
Check inverter settings
Controller is throttling the PV
Normal operation
Power management active
Normal operation
Controller is not throttling PV
Normal operation
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3.0 Software
The software on the controller enables the user to change all relevant settings and adjust the system
to local needs for example during commissioning.
The HYBRID BASIC controller has an integrated menu which can be selected by pressing the OK
button. When the menu is active, the outputs are disabled and no control is possible. After leaving
the menu, the new settings will be stored in EEPROM and the controller automatically loads the new
parameters and start working.
When the system is working, you can read the actual power on the top display. The bottom display
shows error or other parameters, depending on the firmware version and type of HYBRID controller.
Availability of the settings and display screen depends on the firmware version.
3.1 Settings reading
To read out the actual parameters of the HYBRID BASIC controller press the OK button. The led will
start flashing green and by pressing UP and DOWN you can scroll through the parameters.
On the top screen you can read the parameter number and on the bottom screen you can read the
actual parameter value.
+
-
OK
LED solid green
3.2 Settings changing
You can change the settings by pressing the OK button when the parameter which needs to be
changed is selected and displayed on the screen.
+
-
OK
LED solid orange
The led will lid orange to indicate that the parameter can be changed.
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3.3 Parameter overview
The following parameters are available. Not all paramters can be changed. Parameters which can not
be changed are marked with a * and are read only. Most parameters which can not be changed are
for measurements only.
Parameter 4 and 9 are used for the power calculations. Parameter 4 holds the secundairy value of
the CT and parameter 9 the primairy.
Number
Description
Default
Minimum value
Maximum value
Symbol
P1
Generator power*
0
0
999
kW
P2
CT current*
0
0
1 –5
A
P3
CT current in % of maximum
0
0
100
%
P4
CT type (1A –5A)
1
1
5
A
P5
Minimum setpoint generator
50
0
100
%
P6
Ramp up speed
30
0
60
Seconds
P7
Ramp down speed
5
0
60
Seconds
P8
Power correction
1
0.00
2.00
P9
CT ratio (P4:P9)
100
1
1000
A
P10
Output type
1
1
5
See table
3.4 Output selection type
The 4 relays on the controller can be programmed with different functionality. There are 3 main
output modes, the BAR mode, the DOT mode and the BINAIR mode each having the possibility to set
a minimum value rather than having all the relays off.
When the time set with P7 is elapsed, the next output type is selected. When the value is below 0 %
either no output will be selected (without minimum) or the lowest possible value is selected (with
minimum).
Parameter 10
Mode
Limitation
Relay output
1
2
3
4
1
BAR without minimum
0 %
X
30 %
X
X
60 %
X
X
X
100 %
X
X
X
X
2
BAR with minimum after
delay of P7
0 %
X
0 %
X
X
30 %
X
X
X
60 %
X
X
X
X
100 %
X
X
X
X
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Parameter 10
Mode
Limitation
Relay output
1
2
3
4
3
DOT without minimum
0 %
X
30 %
X
60 %
X
100 %
X
4
DOT with minimum after
delay of P7
0 %
X
0 %
X
30 %
X
60 %
X
100 %
X
Parameter 10
Mode
Limitation
Relay output
1
2
3
4
5
Binair output
0
1
X
2
X
3
X
X
4
X
5
X
X
6
X
X
7
X
X
X
8
X
9
X
X
10
X
X
11
X
X
X
12
X
X
13
X
X
X
14
X
X
X
15
X
X
X
X
3.5 Grid feed in protection modus
The HYBRID BASIC controller can also be used to set a specific feed in limit, prevent the inverter from
feeding into a (public) grid (zero export) or have a minimum consumption from the grid.
The controller accepts two different setpoints which can be selected with digital input 1 (pin 4).
When the digital input 1 is open, the controller uses the grid setpoint.
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3.6 Fuel Saving mode with generator
In the “Fuel Saving” mode the controller automatically determines the optimum production point of
the solar system to archive maximum savings for the Diesel. Further the controller ensures that the
generator will not be running under the minimum load specified by the engine manufacturer.
The controller accepts two different setpoints which can be selected with digital input 1 (pin 4).
When the digital input 1 is open, the controller uses the grid setpoint.
4 Commissioning
Before starting with the commissioning of the HYBRID controller all safety precautions must be taken
which apply to the rules in your country and general safety rules. Never work on a system with a
running generator and short the output of the generator before working on the power system.
Only a few settings are needed to commissioning the HYBRID system. Most important is the settings
of the current transformer and the setpoints for grid mode and Fuel Saving mode.
4.1 First time power on
Follow the following steps when the system is first time being powered.
When using TCP for communication, all components needs to have static IP settings.
Switch off the PV inverter, disconnect the PV inverter from the system and start the
controller by applying power to L1 and N in case you use a single-phase system or L1, L2 and
L3 with N for three phase systems. When the HYBRID controller is working properly, the LED
is blinking green.
Connect to the embedded webserver by typing the default address 192.168.1.100 in a web
browser.
On the Menu select Settings to adjust the CT ratio. The CT ratio is defined as 1: value. For
example, when you have a CT 5:200 the value is 40.
When the CT ratio is changed the power readings on the overview page should match the
actual power. More detailed information can be obtained with 192.168.1.100/Meter
A positive value is consumption from the grid, a negative value means exporting to the grid.
When this is not correct, check the wiring of K and L of the CT.
Switch on the DC side of the PV system to commission the PV inverters. The steps to add an
inverter to the system is explained on page 15.
End
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5 Graphical User Interface
The HYBRID BASIC controller includes a webserver to adjust the system parameters and see the
status of the system.
By default, the webserver can be reached by typing the IP address 192.168.1.100 in a web browser.
Supported web browsers are Microsoft Edge, Google Chrome and Mozilla Firefox.
5.1 Overview
5.2 Inverter settings
After selecting the brand of the inverter which needs to be controlled, the type of communication
needs to be selected. Not all communication options are available for all inverters. Please refer to the
inverter support list on the website www.elgrispower.com
When selecting TCP as communication, the IP address and MODBUS TCP port (Default 502) must be
adjusted. When selecting RS 485 for communication, the MODBUS slave ID must be set, and the
serial port settings must match the inverter settings.
When all settings are correct they can be send to the inverter by pressing “Save settings”. Up to ten
inverters can be programmed by pressing “Add Inverter”.
Header with status
information and menu
Main area with system
information
Daily chart with load
and PV output
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5.3 elgris cloud
With the elgris cloud you can store data on the open source platform eCloud. This enables the user
to have a cloud solution where all data can be visualised and transferred on other mediums.
The eCloud software can run on the open source server, a self-hosted server or local server like
Raspberry PI.
To start logging, you must fill out the server address with its hostname, the user key for security and
optional a user name when you want to log more data under the same account.
With the interval time you can set the time between each update interval. By setting the time to
zero, the data logging to the remote sever stops.
The response of the communication is displayed as last messages. When everything is working fine,
the message ”Ok” will be displayed here.
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5.4 System settings
On the settings page the main settings and parameters can be changed. To enable the advanced
settings, the checkbox must be selected.
Status information
and settings for
information
Basic settings like IP
address and date /
time
Advanced settings for
RS 485 bus and
control parameters
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5.5 Multiple generators with elgris SMART METER
The elgris HYBRID controller has only one metering input which is shared for both grid mode and
generator “Fuel Saving”mode.
In case there are more than one generator in the system, or the physical location of the feeders do
not allow the use of the shared metering input, elgris SMART METERS can be used to obtain the
measurement data.
Only generators can be connected to the system as an elgris SMART METER slave. By design,
the grid is always the elgris HYBRID controller internal meter.
The maximum of single generators than can be add is 5.
Ensure that all SMART METERS are powered all the time, otherwise the communication is
delayed all the time.
To select the elgris SMART METER first select “elgris SM” in the dropdown and fill out the IP address.
MODBUS port is 502 by default.
Then press “Save Settings” to store the settings. After refreshing the page, the serial number and
load will be shown on the table.
The current used generator for control is shown as “active”. This is even active when the controller is
in grid mode but has no influence on the actual value taken for the controller as current value which
is still the measurement from the internal meter.
With the more button, detailed information can be obtained.
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5.5.1 Grid and dual generator application example with optional storage
G1 G2
GCB GCB
MCCB MCB
To load
elgris
SMART METER
MCB
~=
elgris BASIC
elgris
SMART METER
GRID Generator 1
200 kVA Generator 2
50 kVA
powerline
Ethernet
MCB
~=
STORAGE
3~ meter
switch
In this example the elgris BASIC is used as the master controller. The BASIC communicates with each
generator over Ethernet and collects the load of each generator. The BASIC controller automatically
determines the optimum setpoint for each generator and sends a setpoint to the PV inverters.
When the grid is connected to the load, the grid setpoint is used.
In case that the PV energy available is higher than the possible load for the whole system, an optional
storage can be charged and discharged later.
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6 Adjusting the PID settings
The elgris HYBRID controller has a real time PID controller to adjust the amount of PV power within
the system. By setting one value to zero, P, PI or PID controllers can be set. For standard applications,
the PI controller is a good starting point.
The PID controller takes the current power value (single or three phase) as current value and the
setpoint (grid or generator setpoint) as desired value.
The settings for P, I and D can be changed according to the application. Please note the following:
The P value is the proportional gain of the error between setpoint and current value. The
higher the P value, the more the controller will react to a change of load.
When the solar system over reacts on load changes, the P factor is too high. The other way
around, when the response is not high enough, the P factor is too small.
The I value is the integrated value of the past error over time. The longer and error exist, the
more the I part will affect the output.
When the reaction time on a load change is too slow, the I factor is too low. Opposite, when
the system is unstable (oscillating around a value) the I factor is too high.
The D value is for future trends. When there are big load changes in a very small time interval
this can be compensated by adding some D factor. The D factor only has influence on load
changes and not in a steady system.
The values entered on the settings page are divided by 1000.
6.1 Manual tuning
If the system must remain online, one tuning method is to first set I and D values to zero. Increase
the P until the output of the loop oscillates, then the P should be set to approximately half of that
value for a "quarter amplitude decay" type response. Then increase I until any offset is corrected in
enough time for the process. However, too much I will cause instability.
Finally, increase D, if required, until the loop is acceptably quick to reach its reference after a load
disturbance. However, too much D will cause excessive response and overshoot. A fast PID loop
tuning usually overshoots slightly to reach the setpoint more quickly; however, some systems cannot
accept overshoot, in which case an overdamped closed-loop system is required, which will require a
P setting significantly less than half that of the P setting that was causing oscillation.
Parameter
Rise time
Overshoot
Settling time
Steady-state error
Stability
P
Decrease
Increase
Small change
Decrease
Degrade
I
Decrease
Increase
Increase
Eliminate
Degrade
D
Minor change
Decrease
Decrease
No effect in theory
Improve if small
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