Firefly CYG/12/36 User manual
CYGNUS HPG 12-24
User manual v1
For use with the following models:
CYG/12/36 CYG/12/36/S CYG/12/48 CYG/12/48/S
CYG/18/36 CYG/18/36/S CYG/18/48 CYG/18/48/S
CYG/24/36 CYG/24/36/S CYG/24/48 CYG/24/48/S
Page 2 CYGHPG-User-Manual-v2
4
1.1 Foreword 4
1.2 Convenons 4
1.3 Warnings 5
1.4 Standards & Regulaons 6
1.5 Disposal & Recycling 6
1.6 Firey Contact Details 6
1.7 About Firey 7
8
2.1 Storage 8
2.2 Transporng, Liing & Posioning 8
2.2.1 Transportaon 8
2.2.2 Liing (Loading/Unloading) 8
2.2.3 Posioning 9
2.3 The Cygnus HPG Control Panel 10
2.4 Connecng Cygnus HPG 12
2.4.1 Earth aachment: Installing an Earth Rod 12
2.4.2 Input Opons 13
2.4.3 Connect The AC Input 15
2.4.4 Connect The AC Output 17
18
3.1 Turning The Power On 18
3.1.1 Descripon Of The Power Modes 18
3.1.2 Switching On The Cygnus HPG 19
3.1.3 Monitoring Baery Bank State of Charge 20
3.1.4 Emergency Stop Buon 21
3.1.5 Turning O The Cygnus HPG 21
3.1.6 Disconnecng Cygnus HPG 22
3.2 Charging From An AC Supply 22
3.3 System Sengs 23
Page 3CYGHPG-User-Manual-v2
Fig. 1 - Control Panel 10
Fig. 2 - Earth Point 12
Fig. 3 - Earth Rod 12
Fig. 4 - Input Current Sengs for use with 63 A Input 14
Fig. 5 - Inputs, Outputs and Circuit Breakers 16
Fig. 6 - 5 mm Double Barb Key 17
Fig. 7 - AC Output Bus Bar Connecons 17
Fig. 8 - The RCC 03 Baery Monitor Screen 20
Fig. 9 - Auxiliary Bus Bar 28
3.4 Care And Maintenance 26
3.4.1 General Cleaning 26
3.4.2 Caring For The Baery Bank 26
3.4.3 Tesng Cygnus HPG 26
3.5 Troubleshoong 27
28
4.1 Connecng To A Fuel Generator For Automac Stop/Start 28
4.1.1 Control Panel Auxiliary Connecons 28
4.1.2 Bus Bar Auxiliary Connecon 28
4.2 Earthing Cygnus HPG 29
4.2.1 When Used Inline With A Fuel Powered Generator 29
4.2.2 When Used As A Standalone Power Source 29
4.2.3 When Charging A Standalone Generator from An AC Source 29
4.3 Technical Data 30
Page 4 CYGHPG-User-Manual-v2
1.1 Foreword
Firey takes this opportunity to congratulate you on receiving your new Cygnus
HPG.
Designed and manufactured within the United Kingdom using only the nest
European sourced electrical components, your new Cygnus HPG oers
sustainable power generaon with the reliability that you demand.
The purpose of this manual is to introduce you to Cygnus HPG and provide you
with a guide to its safe installaon and operaon. This manual describes how
your Cygnus HPG works, will help you with fault nding and examines what key
components are doing and why.
1.2 Convenons
Throughout this user manual the following symbols are used:
This symbol warns of the presence of a dangerous voltage
which could cause harm to the operator or others.
This symbol indicates the potenal of damage to the unit or
connected devices.
This symbol indicates important or useful informaon.
Page 5CYGHPG-User-Manual-v2
The following terms are used in this manual to provide greater clarity:
• Firey will be referred to as “The manufacturer”.
• The Cygnus HPG Hybrid Power Generator will be referred to as “Cygnus
HPG” or “Unit”.
• Any items that consume power will be referred to as “Consumers”.
1.3 Warnings
This user manual is an important part of Cygnus HPG. It
must be kept available to all operators and kept close to the
unit so that it can be referred to at any me.
When the unit is operang it generates potenally lethal
voltages. Work must only be performed on the unit by the
manufacturer or a qualied service engineer approved by
the manufacturer.
All items connected to the unit including distribuon cables
and boxes should be regularly checked and adhere to the
same local regulaons and standards as a regular grid-ed
mains installaon.
Page 6 CYGHPG-User-Manual-v2
1.4 Standards & Regula ons
Cygnus HPG conforms to the following standards and regula ons:
• Manufactured in compliance with ISO 9001:2008
• LVD 2006/95/EEC: EN 50178:1197, EN 62040-1:2008
• EMC Direc ve 2004/108/EC: EN 61000-6-2:2005, EN 61000-6-3:2007,
EN 61000-3-2:2006, EN 61000-3-12:2005, EN 62040-2:2006
• IP44
• WEEE Direc ve
1.5 Disposal & Recycling
Cygnus HPG comprises of components that must be disposed of responsibly.
For the sake of the environment many of the components within the unit can be
recycled or reused. Fire y will ensure the safe decommissioning and recycling
of the unit at no charge if the unit is returned to the manufacturer. Otherwise,
please contact the manufacturer for more informa on on safe and proper
decommissioning of your Cygnus HPG.
1.6 Fire y Contact Details
Fire y Solar Generators Ltd
Unit 20 Cli e Industrial Estate
South Street
Lewes
East Sussex
BN8 6JL
United Kingdom
Tel: +44 (0) 1273 40 95 95
Fax: +44 (0) 1273 40 95 96
Web: www. re ycleanenergy.co.uk
Page 7CYGHPG-User-Manual-v2
1.7 About Firey
Firey is the market leading expert in the design and manufacture of o-grid,
portable Hybrid Power Soluons for temporary and permanent power
applicaons. Firey has built its highly regarded reputaon within the industry,
based on excellent customer service and product reliability. Founded in 2007 the
Company connues to develop innovave soluons to cater to the needs of its
ever growing customer sectors.
The Company oers green energy products and services that meet the needs of
environmentally concerned individuals and organisaons internaonally, that
are looking to reduce their carbon emissions caused by the use of fossil fuels
and diesel powered equipment. The unique range of renewable technology
soluons produce zero emissions, are truly silent running and eliminate the need
for fuel.
The systems are manufactured in the UK, under an ISO 9001:2008 approved
quality control system. Component suppliers are carefully selected to ensure
high levels of reliability and performance of the nal product. Installaon and
stringent tesng is carried out to ensure compliance with EU and local legislaon
where applicable.
Page 8 CYGHPG-User-Manual-v2
2.1 Storage
1. Cygnus HPG is designed to be used and stored outside. However, to
prevent unnecessary weathering it is recommended that the unit is
stored inside when possible.
2. It is recommended that the baery bank is charged regularly while in
storage. Refer to "3.2 Charging From An AC Supply" on page 22 for
further informaon.
3. The emergency stop should be engaged (pushed in) and output
protecon switches should be switched o when in storage and not
being charged to prevent unnecessary discharge of the baery bank.
2.2 Transporng, Liing & Posioning
This unit is considerably heavier than regular fuel powered
generators of similar physical dimensions. Be sure to double
check the capacity of liing equipment.
1. Cygnus HPG can be transported using its oponal trailer, light or heavy
goods vehicle with adequate available payload. Check the relevant
transportaon documentaon for suitability.
2. The gross weight of the unit can be found on the rang plate posioned
on the le hand side of the unit.
3. It is recommended that the unit is secured using suitable straps when
in transit to prevent it from moving.
1. Cygnus HPG must be loaded or unloaded using the correct equipment
operated by suitably trained personnel.
2. Using the fork pockets, Cygnus HPG can be loaded or unloaded with a
suitable fork-li truck.
3. Cygnus HPG can be safely lied using its integral liing ring.
Page 9CYGHPG-User-Manual-v2
Always check the rang plate to ascertain the gross weight
of the unit.
The unit must remain upright at all mes.
1. The unit must be posioned upright on a at, solid surface. Ensure that
the unit is not at risk from being submersed in water above the fork
pockets.
2. The unit should be posioned as close as possible to the chosen input
source (e.g. Gen. Set, solar array) and where necessary, close to its
earth point.
3. Ensure adequate space is allowed for venlaon on all sides and that
vents are not obstructed.
Refer to liing equipment’s operaon manual for liing
capacity and manufacturer’s operang instrucons.
Page 10 CYGHPG-User-Manual-v2
2.3 The Cygnus HPG Control Panel
Fig. 1 - Control Panel
Page 11CYGHPG-User-Manual-v2
Allows switching between the three power roung
modes and o
Press in to immediately halt all operaon
Provides signals for various
applicaons including the control of a Gen. Set.
§ Provides overload protecon for the
Solar Array inputs. Switch o to isolate the Solar Array circuit, on to
enable it.
§30 A MC3 connecons for solar arrays
Provides entry for hard wired AC output
connecon.
Provides status and control of the unit’s inverters and charge
controller§
over current MCB
230 V AC single phase 63 A CEE
Form plug
indicates presence of AC at input
connecon
indicates presence of AC on each line
of the input connecon
230 V AC three phase 63 A CEE Form
plug
over current MCB
230 V AC single phase 63 A CEE
Form socket
indicates presence of AC at output
connecon
RCD earth leakage and MCB over
current
RCD earth leakage and MCB over
current
indicates presence of AC on each
line of the output connecon
230 V AC three phase 63 A CEE
Form socket
§Solar inputs and charge controller only available on models with Solar Prep option
Page 12 CYGHPG-User-Manual-v2
2.4 Connecng Cygnus HPG
When using as a standalone power source, a protecve
earth must be connected to the unit in compliance with
applicable local standards and regulaons.
This can be done either by connecng to a suitable exisng
electrical earth, or by using an earth rod available from the
manufacturer as an accessory.
1. The Earth Point of Cygnus HPG is an M10 threaded stud with washers
and wing nut located on the skid to the right side of the unit.
2. Find a suitable place to drive the earth rod into the ground. The earth
rod should be driven down at least half way into the ground using a
mallet and placed as near to the unit as possible.
3. Check the earth cable is securely clamped to the rod. The clamp may
need re-ghtening aer driving the earth rod down.
4. Undo the wing nut from the unit’s earth bolt and remove one of the
washers. Then slide the ring terminal at the end of the earth cable onto
the earth bolt. Replace the washer and securely ghten the nut. Refer
to "Fig. 2 - Earth Point"
Fig. 2 - Earth Point
Fig. 3 - Earth Rod
Page 13CYGHPG-User-Manual-v2
The unit can accept inputs from an AC power source (single phase or three
phase. Further informaon on connecng these items is available in secon "3.2
Charging From An AC Supply" on page 22) and solar arrays using the oponal
Solar Prep kit.
The AC input current is adjustable, allowing the unit to be charged from AC
sources with lower current capacies. It is also necessary to adjust the input
current when switching between some modes.
1. Open the control centre door using the supplied key- see "Fig. 6 - 5 mm
Double Barb Key" on page 17
2. Ensure that the unit is switched on
3. Press the down buon to wake up the control centre
4. Press the down buon repeatedly unl the “Xtender sengs” screen is
displayed:
5. Press “SET”: “BASIC SETTINGS” is displayed:
Care must be taken to ensure
that the correct connecons
are made to avoid the risk of
electrocuon or possible
damage to the unit’s internal
components.
Ensure that the cumulave
power of connected
consumers does not exceed
the maximum power output of
your unit. Refer to the rang
plate to ascertain the unit’s
maximum power output.
All connected cables,
distribuon and consumers
must be t for purpose– refer
to the consumers’ rang plates
and manuals to ascertain the
required input.
Page 14 CYGHPG-User-Manual-v2
6. Press “SET”: the “Maximum current of AC source (Input Limit)” is
displayed:
7. Press “SET”: the AC Input Current value is selected:
8. Refer to "Fig. 4 - Input Current Sengs for use with 63 A Input" for
relevant values to enter.
9. Press “SET” to store the value.
10. The screen will revert to the main display aer 20 seconds of inacvity.
Mode Descripon Aac Value
Mode 1 Three Phase 50 A
Mode 2 Single Phase 21 A
Mode 3 Three Phase With L1 Backup 21 A
Fig. 4 - Input Current Sengs for use with 63 A Input
It is possible to adjust the unit
to accept inputs with lower
input currents (e.g. charging
from a 13 A socket). Contact the
manufacturer for further details.
Page 15CYGHPG-User-Manual-v2
Only one AC input can be connected at a me- damage will
be caused by aempng to simultaneously connect single
phase and three phase inputs.
1. Ensure that the AC supply being connected to the unit is switched o.
2. Ensure the input breakers are switched o.
3. Ensure that Cygnus HPG is in Mode 4: O.
4. Ensure that the CEE Form connectors are dry; wipe o any excess
moisture with an absorbent cloth.
5. Insert the 230 V AC supply’s CEE Form industrial socket into either the
single phase or three phase AC Input plug. See "Fig. 5 - Inputs, Outputs
and Circuit Breakers" on page 16
6. Switch on the AC input’s power supply.
7. The LED indicators next to the chosen AC input will illuminate to show
the presence of power.
8. Switch on the unit’s input breaker.
Page 16 CYGHPG-User-Manual-v2
163 A Single Phase Input 263 A Three Phase Input
3Single Phase Input MCB 4Three Phase Input MCB
5Single Phase Output RCD 6Three Phase Output RCD
7Single Phase Output MCB 8Three Phase Output MCB
963 A Single Phase Output 10 63 A Three Phase Output
Fig. 5 - Inputs, Outputs and Circuit Breakers
1 2
3
7
9
4
8
10
5 6
Page 17CYGHPG-User-Manual-v2
2.4.4.1 Connecng with CEE Form Industrial Plugs
1. Before any power connecons are made, ensure that Cygnus HPG is
in Mode 4: O. See "3.1.1 Descripon Of The Power Modes" on page
18
2. Ensure that the output breakers are switched down into the o
posion. See "Fig. 5 - Inputs, Outputs and Circuit Breakers" on page
16
3. Ensure that the CEE Form connectors to be used are dry; wipe o any
excess moisture with an absorbent cloth.
4. Plug the electrical consumers in to a 230 V AC Out CEE Form socket:
blue for single phase or red for three phase. See "Fig. 5 - Inputs,
Outputs and Circuit Breakers" on page 16
2.4.4.2 Connecng by Hard Wiring Into The Bus Bar
1. Before any power connecons are made, ensure that Cygnus HPG is
in Mode 4: O. See "3.1.1 Descripon Of The Power Modes" on page
18
2. Open the main door by unlocking the three locks located at its right
hand side using the provided 5 mm double barb key See "Fig. 6 - 5 mm
Double Barb Key" on page 17.
3. The Bus Bar is located at the boom le corner.
4. Pass the cables through the rubber ap in the door and connect to the
lower row of connecons using 10 mm ring terminals.
5. Remove the 17 mm nuts.
6. Aach ring terminals, referring to "Fig. 7 - AC Output Bus Bar
Connecons" on page 17
7. Replace and ghten the 17 mm nuts.
Fig. 6 - 5 mm Double Barb Key
Fig. 7 - AC Output Bus Bar
Connecons
L1 L2 L3 N E
Page 18 CYGHPG-User-Manual-v2
3.1 Turning The Power On
Once all connecons are complete, the AC Output of the unit is ready to be
switched on.
Cygnus HPG has three dierent modes of operaon. The modes control how the
inverters are congured and how the power is routed through the unit. The
mode is selected by depressing a single buon behind the top control panel door.
A three phase input is accepted. Three
phase power is backed up by the unit’s
baery bank and available at the
output. L1 of the three phase output
is also available at the single phase
output. The three phase breakers (see
4, 6 & 8 "Fig. 5 - Inputs, Outputs and
Circuit Breakers" on page 16)
protect the circuit.
A single phase input is accepted. The
unit provides a single phase output as
well as L1 of the three phase output.
The single phase breakers (see items
3, 5 & 7 "Fig. 5 - Inputs, Outputs and
Circuit Breakers" on page 16)
protect the circuit.
Page 19CYGHPG-User-Manual-v2
A three phase input is accepted.
Power on L1 and the single phase
output is backed up by the unit. L2 &
L3 power from the inputs is passed
through to the L2 & L3 outputs.
The three phase breakers (see 4, 6 & 8
"Fig. 5 - Inputs, Outputs and Circuit
Breakers" on page 16) protect the
circuit.
All primary internal circuitry is
disabled. Cooling systems remain
operaonal.
The relevant power mode must rst be decided upon. This will depend on the
power requirements of the installaon.
1. Ensure that the Emergency stop buon is released by rotang it
clockwise.
2. Switch on the relevant breakers. For “Mode 1: Three Phase” and
“Mode 3: Three Phase With L1 Backup”, the three phase breakers
must be switched up into the on posion. For “Mode 2: Single Phase”,
the single phase breakers must be switched up into the on posion.
3. Press the chosen mode buon. The selected mode buon’s LED
indicator will ash during inialisaon and remain solid once the
output is available.
4. The RCC-03 display should illuminate.
5. The LED indicators next to the chosen AC output connector will
illuminate, indicang that power is available at the selected output(s).
Page 20 CYGHPG-User-Manual-v2
The status of the unit’s internal ba ery bank is monitored using the RCC 03’s
controls. To access the controls
1. Open the control centre door using the supplied key- see "Fig. 6 - 5 mm
Double Barb Key" on page 17
2. The RCC 03 will ini ally be in standby mode. Pressing any bu on will
illuminate the display and prepare it for input
3. Press the down arrow once to access the main Ba ery Monitor screen
4. See "Fig. 8 - The RCC 03 Ba ery Monitor Screen" for a descrip on of
the available informa on.
1SoC quick overview
2Arrow s indicate direc on of current:
Up = charging
Down = discharging
3Voltage of internal ba ery bank
4
Power being consumed/ Power being used to charge the
ba ery bank
5SoC Percentage value
6During charge: Es mated me to 100% SoC
During discharge: Es mated run me at present power draw
Fig. 8 - The RCC 03 Ba ery Monitor Screen
13
4
5
2
6
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11
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