Firefly Cygnus CYG2400/460/24 User manual
CygnusUserManual-v3.02011 Page1
CygnusPortableSolarGenerator
UserManualv3.0
2011
Forusewiththefollowingmodels:
CYG2400/460/24,CYG2400/920/24,CYG2400/1380/24,CYG3500/920/24,CYG3500/1380/24,
CYG5000/920/24,CYG5000/1380/24
CygnusUserManual-v3.02011 Page2
TableofContents
1. Introducon .............................................................................................................................................. 4
1.1Foreword ............................................................................................................................................. 4
1.2Convenons......................................................................................................................................... 4
1.2.1Terminology .................................................................................................................................. 4
1.2.2Warnings ....................................................................................................................................... 4
1.3Standards&Regulaons ...................................................................................................................... 5
1.4Disposal&Recycling ............................................................................................................................ 5
1.5FireflySolarContactDetails ................................................................................................................. 5
1.6AboutFireflySolar ............................................................................................................................... 5
2. GengStarted ......................................................................................................................................... 6
2.1Storage ................................................................................................................................................ 6
2.2Transportaon,Loading/Unloading&Posioning................................................................................ 6
2.2.1Transportaon .............................................................................................................................. 6
2.2.2Loading/Unloading ........................................................................................................................ 6
2.2.3Posioning .................................................................................................................................... 6
2.3UnderstandingtheCygnusControlPanel ............................................................................................. 7
2.3.1DiagramoftheCygnusControlPanel ............................................................................................ 7
2.3.2ExplanaonoftheCygnusControlPanel ....................................................................................... 7
2.4ConnecngtheCygnusPortableSolarGenerator ................................................................................ 8
2.4.1EarthAachment:InstallingtheOponalEarthRod ..................................................................... 8
2.4.2ConnecttheInputs ........................................................................................................................ 8
2.4.3ConnecttheOutputPowerCables................................................................................................. 9
3. GeneralOperaon .................................................................................................................................. 10
3.1TurningthePowerOn ........................................................................................................................ 10
3.2MonitoringthePower ....................................................................................................................... 11
3.2.1DisplayingReal-meBaeryBankVoltage .................................................................................. 11
3.2.2DisplayingtheBaeryBankSOC.................................................................................................. 11
3.3EmergencyStopBuon ..................................................................................................................... 12
3.4TurningOffCygnus ............................................................................................................................ 12
3.5DisconnecngCygnus ........................................................................................................................ 12
3.6UnderstandingtheRCC-03 ................................................................................................................. 13
3.6.1ExplanaonoftheInformaonShownontheRCC-03 ................................................................. 13
3.7ChargingMethods ............................................................................................................................. 14
3.7.1ChargingwithFirefly’sPortableFoldingSolarArray(Fold-Array) ................................................. 14
3.7.1.1Connecng ............................................................................................................................ 14
3.7.1.2Disconnecng ....................................................................................................................... 14
3.7.2ChargingwithKinectricsEquipment ............................................................................................ 15
3.7.2.1Connecng ............................................................................................................................ 15
3.7.2.2Disconnecng ....................................................................................................................... 15
3.7.3ChargingwithACGridSupplyorSecondaryPowerSystem .......................................................... 15
4. ConnecngMulpleCygnusPortableSolarGenerators ......................................................................... 16
4.1Introducon ................................................................................................................................... 16
4.2ConnecnginParallel ..................................................................................................................... 16
4.3ConnecnginSeries ....................................................................................................................... 17
4.4TurningOfftheUnits ...................................................................................................................... 18
4.5DisconnecngDataInterlinkCables ............................................................................................... 18
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TableofContents(Connued)
5. CareandMaintenance ............................................................................................................................ 19
5.1GeneralCleaning ............................................................................................................................... 19
5.2WashingCygnuswithaHighPressureCleanerorHosepipe ............................................................... 19
5.3PaintworkRepair ............................................................................................................................... 19
5.4Tesng ............................................................................................................................................... 19
5.5CaringfortheBaeryBank ................................................................................................................ 19
6. Appendices ............................................................................................................................................. 20
6.1Appendix1-AddionalRCC-03Sengs ............................................................................................ 20
6.1.1BoosngtheVoltageOverDistance ............................................................................................ 20
6.1.2SengtheRCC-03Language ....................................................................................................... 20
6.2Appendix2-24VDCSPECPakInput/Output ..................................................................................... 21
6.2.1Connecng ................................................................................................................................. 21
6.2.2Disconnecng .............................................................................................................................. 21
6.3Appendix3-ExampleConfiguraons................................................................................................. 22
6.3.1OnorOffGridUPS....................................................................................................................... 22
6.3.2SingleCygnusPortableSolarGenerator ...................................................................................... 23
6.3.3ThreePhaseCygnusSystem ........................................................................................................ 24
6.3.4TwoUnitParallelCygnusSystem ................................................................................................. 25
6.3.5KinectricsPedGenConnectedtoSingleCygnus ........................................................................... 26
6.4Appendix4-TroubleshoongGuide .................................................................................................. 27
6.5Appendix5-TechnicalData ............................................................................................................... 28
6.6Appendix6-FurtherReading ............................................................................................................ 29
Figures
Fig.1-CygnusControlPanelComponentReference ................................................................................... 7
Fig.2-RCC03,UnitinStandby .................................................................................................................. 10
Fig.3-RCC03,UnitOn .............................................................................................................................. 10
Fig.4-TheRCC03 .................................................................................................................................... 13
Fig.5-24V80ADCSPECPakConnector ................................................................................................... 21
Fig.6-ExampleShowingaSingleUnitConnectedtoanACFeedandPoweringConsumers ..................... 22
Fig.7-ExampleShowingArraysDirectlyConnectedtotheUnit’sSolarInputs ......................................... 23
Fig.8-ExampleShowingtheuseofaJunconBoxtoAllowtheuseofMoreThanTwoArrays ................ 23
Fig.9-ExampleShowingtheuseofThreeUnitstoProvideaThreePhaseOutput ................................... 24
Fig.10-ExampleShowingtheuseofTwoUnitstoProvideaHigherOutput ............................................. 25
Fig.11-ExampleShowingtheuseofTwoKinectricsunitstoChargeCygnus ............................................ 26
Fig.12-ExampleShowingtheuseofEightKinectricsUnitstoChargeCygnus.......................................... 26
Fig.13-TechnicalData ............................................................................................................................. 28
CygnusUserManual-v3.02011 Page4
1.Introducon
1.1 Foreword
FireflySolarGeneratorsLimitedtakesthisopportunitytocongratulateyouonthepurchaseofyournewCygnusPorta
bleSolarGenerator.
DesignedandmanufacturedwithintheUnitedKingdomusingonlythefinestEuropeansourcedelectricalcomponents,
yournewCygnusPortableSolarGeneratorofferssustainablepowergeneraonwiththereliabilitythatyoudemand.
ThepurposeofthismanualistointroduceyoutotheCygnusPortableSolarGeneratorandprovideyouwithaguideto
theprocessesofsengupandoperangyournewproduct.ThismanualdescribeshowyourCygnusPortableSolar
Generatorworks,willhelpyouwithfaultfindingandexamineswhateachcomponentisdoingandwhy.
1.2 Convenons
Throughoutthisusermanualthefollowingsymbolsareused:
1.2.1 Terminology
Thefollowingtermsareusedinthismanualtoprovidegreaterclarity:
FireflySolarGeneratorsLtd.willbereferredtoas“Themanufacturer”.
TheCygnusPortableSolarGeneratorwillbereferredtoas‘Cygnus’or‘Unit’.
Anyitemsthatconsumepowerwillbereferredtoas‘Consumers’.
StateofChargeofthebaerybankwillbereferredtoas‘SOC’.
1.2.2 Warnings
WARNING
Thissymbolwarnsofthepresenceofadangerousvoltagewhichcouldcauseharmtotheoperator.
Thissymbolindicatesthepotenalofdamagetotheunitorconnecteddevices.
Thissymbolindicatesimportantorusefulinformaon.
ThisusermanualisanimportantpartoftheCygnusPortableSolarGenerator.Itmustbekept
availabletoalloperatorsandkeptclosetotheunitsothatitcanbereferredtoatanyme.
WARNING
Whentheunitisoperangitgeneratespotenallylethalvoltages.Workmustonlybeperformedon
theunitbythemanufactureroraqualifiedserviceengineerapprovedbythemanufacturer.
Undernocircumstancesshouldoperatorsopentheunit’senclosure.
Allitemsconnectedtotheunitincludingdistribuoncablesandboxesshouldberegularlychecked
andadheretothesamelocalregulaonsandstandardsasaregulargrid-edmainsinstallaon.
CygnusUserManual-v3.02011 Page5
1.3 Standards&Regulaons
TheCygnusPortableSolarGeneratorconformstothefollowingstandardsandregulaons:
ManufacturedincompliancewithISO9001:2008
LVD73/23/EEC
EN61000-6-1,EN61000-6-3,EN55014
IP23
WEEEDirecve
1.4 Disposal&Recycling
TheCygnusPortableSolarGeneratorcomprisesofcomponentsthatmustdisposedofresponsibly.Forthesakeofthe
environmentmanyofthecomponentswithintheunitcanberecycledorreused.FireflySolarGeneratorsLtd.willen
surethesafedecommissioningandrecyclingoftheunitatnochargeiftheunitisreturnedtothemanufacturer.Other
wise,pleasecontactthemanufacturerformoreinformaononsafeandproperdecommissioningofyourCygnusPorta
bleSolarGenerator.
1.5 FireflySolarContactDetails
1.6 AboutFireflySolar
FireflySolaristheEuropeanmarketleaderinthedesignandmanufacturerofoff-grid,portableandpermanentsolar-
poweredgenerators.Ourgreenenergyproductsandservicesmeettheneedsofenvironmentallyconcernedindividuals
andorganisaonswhoarelookingtoreducethecarbonemissionscausedbytheuseoffossilfuelsanddieselpowered
equipment.
FireflySolargeneratorsharnessenergysuppliedbythesunusingphotovoltaic(PV)cells,storingitforwhenit’sneeded.
Addionally,mul-chargeinputsallowskinecandwindenergytobestoredforconvenientuse.Wearespecialistsin
greenenergystoragesystems–ourexperseinbaeries,electronicsandsowarehasenabledourgeneratorstoover
comemanyoftheproblemsofintermiencywhichcanbeassociatedwithrenewableenergysources.
FireflySolargeneratorscanprovideanuninterruptedelectricalsupplyevenintheabsenceoflightorothercharging
input.Ouraward-winningproducts,whichincludetheOrion,Cygnus,Pictor&Pyxismodels,havebeenwidelyusedby
well-knownbrandssuchasCoca-ColaEnterprises,theBBC,Sky,Greenpeace,FriendsoftheEarthandSolarAid.
FireflySolarprovidetemporarystand-alonepowerfortheevents,broadcast,andconstruconindustries;permanent
stand-alonepowerforrurallocaonsandtelecommunicaons;andback-up(UPS)powerwithextendedrunmesfor
locaonswithintermientgridconnecvity.FireflySolarpowergenerangequipmentiszeroemission,truesilentrun
ningandeliminatestheneedforinflammablefuel.
FireflySolarGeneratorsLtd
TheGreenWarehouse
CourtFarmHouse
KingGeorgeVIAvenue
Hove
EastSussex
BN36XJ
UnitedKingdom
Tel:+44(0)1273617006
Fax:+44(0)1273316646
E-mail:info@fireflysolar.net
Web:www.fireflysolar.net
CygnusUserManual-v3.02011 Page6
2.GengStarted
2.1 Storage
1. Cygnusisdesignedtobeusedandstoredoutside.However,topreventunnecessaryweatheringitisrecom
mendedthattheunitisstoredinsidewhenpossible.
2. Itisrecommendedthatthebaerybankischargedregularlywhileinstorage.RefertoChapter4,Secon5for
furtherinformaon.
3. Cygnusshouldbeswitchedoffwheninstorageandnotbeingchargedtopreventunnecessarydischargeofthe
baerybank.
2.2 Transportaon,Loading/Unloading&Posioning
2.2.1 Transportaon
1. Cygnuscanbetransportedusingasuitabletrailer,lightorheavygoodsvehiclewithadequateavailable
payload.Checktherelevanttransportaondocumentaonforsuitability.
2. Thegrossweightoftheunitcanbefoundontherangplateposionedonthelehandsideof
theunit.Pleasenotethatdifferentmodelshavedifferentweights.
3. Itisrecommendedthattheunitissecuredusingsuitablestrapswhenintransittopreventitfrommoving.
2.2.2 Loading/Unloading
1. Cygnusmustbeloadedorunloadedusingthecorrectequipmentoperatedbysuitablytrainedpersonnel.
2. Usingtheliingring;Cygnuscanbeliedontoorofffromtransportaon.Theliingringissuitableforliing
allmodelsofCygnusregardlessoftheunit’sgrossweight.
3. Usingtheforkpockets;Cygnuscanbeloadedorunloadedwithasuitablefork-litruck.
2.2.3 Posioning
1. Theunitmustbeposioneduprightonaflat,solidsurface.Ensurethattheunitisnotatriskfrombeingsub
mersedinwaterabovetheforkpockets.
2. Theunitshouldbeposionedascloseaspossibletothechosenchargingsystem(e.g.solararray,Kinectrics
equipment,windturbine)andclosetoitsearthpoint.
Alwayschecktherangplatetoascertainthegrossweightofthespecificunitinqueson.
Refertothefork-litruckoperaonmanualforliingcapacityandmanufacturer’soperanginstruc
ons.
Theunitmustremainuprightatallmes.
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2.3 UnderstandingtheCygnusControlPanel
2.3.1DiagramoftheCygnusControlPanel
Fig.1-CygnusControlPanelComponentReference
A1 SolarArray1IsolatorSwitch–SwitchofftoisolatetheSolarArray1circuit,ontoenableit
A2 SolarArray2IsolatorSwitch–SwitchofftoisolatetheSolarArray2circuit,ontoenableit
A3 SolarArray1Inputs–24VMC3inputsforSolarArray1
A4 SolarArray2Inputs–24VMC3inputsforSolarArray2
B1 240VACOutRCD–EarthleakageproteconformainACoutput(ResidualCurrentDevice)
B2 240VACOutMCB–OverloadproteconformainACoutput(MiniatureCircuitBreaker)
C1 SmartgaugeBaeryMonitor–Providesareal-medisplayofbaerybankvoltageorSOC
C2 RCC-03–Displaysreal-meinformaononinputsandoutputs,alsoallowstheiradjustment
C3 Open/TerminateSwitch–UsedwhenmulpleCygnusPortableSolarGeneratorsarelinkedtogether
C4 PowerOn/OffSwitch–EnableordisableACoutput
C5 EarthConnecon–Forearthrod(ground)connecon
C6 EmergencyStopBuon–Disconnectsallcircuitsinanemergency
D1 Data1Connector–ForconnecngdatacableinfromanotherCygnuswhenmulpleunitsareused
D2 Data2Connector–ForconnecngdatacableouttoanotherCygnuswhenmulpleunitsareused
D3 Data3Connector–Forusewithoponalchargecontrollerremotecontrolanddisplay
E1 240VACInput–Forchargingtheunitfromthenaonalgridorsecondarypowersystem
E2 240VACOutput–Mainoutputforpoweringconsumers
F1 24VDCSPECPakInput/Output–ForchargingfromwindorKinectricsdevices.Alsogives2x24VDC40Aoutput
2.3.2ExplanaonoftheCygnusControlPanel
CygnusUserManual-v3.02011 Page8
2.4 ConnecngtheCygnusPortableSolarGenerator
2.4.1 Earthaachment:InstallingtheOponalEarthRod:
1. Findasuitableplacetodrivetheearthrodintotheground.Theearthrodshouldbedrivendownatleast
600mmintothegroundusingamalletandplacedasneartotheunitaspossible.
2. Checktheearthcableissecurelyclampedtotherod.Theclampmayneedreghteningaerdrivingtheearth
roddown.
3. Onthecontrolpanel,locatetheearthbolt(Fig.1,C5)undotheearthboltwingnutandremoveoneofthe
washers.Thenslidetheringterminalattheendoftheearthcableontotheearthbolt.Replacethewasherand
ghtenthewingnut.
2.4.2 ConnecttheInputs:
Thereareanumberofmeansavailabletochargetheunit.Instruconsonhowtoconnectcharginginputs(e.g.solarPV,
windturbines,Kinectricsequipment)areavailableasappendicestothismanualorincludedwiththoseproductsatthe
pointofpurchase.Allusermanualscanalsobedownloadedfromthemanufacturer’swebsiteatwww.fireflysolar.net
Itisalsopossibletooperatetheunitonlyusingtheinternalbaerybank,withoutexternalinputsconnected.
WhenCygnusisconnectedtoanexternalACsupply,theoutputvoltageistransferredfromitsinput.
InthiscasetheunitwillnotmodifytheACoutput:Consumerswillbesuppliedwithanoutput
idencaltothesource.
WARNING
Caremustbetakentoensurethatthecorrectconneconsaremadetoavoidtheriskofelectrocuon
orpossibledamagetotheunit’sinternalcomponents.
WARNING
Ensurethatthecumulavepowerofconnectedconsumersdoesnotexceedthemaximumpowerout
putofyourunit–refertotherangplatetoascertaintheunit’smaximumpoweroutput.
WARNING
Allconnectedconsumersmustbefitforpurpose–refertotheirrangplatesandmanualstoascertain
therequiredinput.
WARNING
Aprotecveearthmustbeconnectedtotheunitincompliancewithapplicablelocalstandardsand
regulaons.Thiscanbedoneeitherbyconnecngtoasuitableexisngelectricalearth,orbyusingan
oponalearthrodsuppliedbythemanufacturer.
CygnusUserManual-v3.02011 Page9
2.4.3 ConnecttheOutputPowerCables:
Cygnusissuppliedwitha16AindustrialCEEformsocketfortheconneconofACpowerouttoconsumersrequiring(Fig.
1,E2).
1. Beforeanypowerconneconsaremade,ensurethatboththeRCD(Fig.1,B1)andMCB(Fig.1,B2)areswitched
Off.
2. PlugintheelectricalconsumerstotheACOut(Fig.1,E2)socketonthecontrolpanelusinga16ACEEform
industrialplug.
CygnusUserManual-v3.02011 Page10
3.GeneralOperaon
3.1 TurningthePowerOn
Oncealltheaboveconneconsarecomplete,theunitisreadytobeswitchedon.
1. EnsurethattheEmergencyStopbuonisnotdepressedbyrotangclockwise(Fig.1,C6)
2. SwitchontheRCDandMCBswitches(Fig.1,B1&B2).
3. SwitchontheunitusingthePowerOn/OffSwitch(Fig.1,C4).
4. Astheunitisswitchedon,aloudbeepwillbeheardandtheRCC-03(Fig.1,C2)backlightwillilluminate.
5. Theunitisnowinstandbymode.
6. “Message012useofbaerytemperaturesensor”willbedisplayedforfiveseconds.
7. Aerwhich,thefollowingshouldbedisplayed:
8. PressESContheRCC-03.Themessage‘TurntheSystemOn?’willbedisplayed.
9. PressSETtoacceptandtheunitwillgooutofstandbymodeandturnon.Anumberofchangeswillappearon
theRCC-03.
10. ThefollowingwillbedisplayedontheRCC-03:
11. Theunitisnowonandreadytosupplypowertoconnectedconsumers.
Fig.2-RCC-03,UnitinStandby
Fig.3-RCC-03,UnitOn
CygnusUserManual-v3.02011 Page11
3.2 MonitoringthePower
Cygnus’controlpanelincludesabaerymonitoringsystemwhichdisplaysthestateofchargeandvoltageofitsbaerybank.
Monitoringthestateofcharge(SOC)ofthebaerybankallowstheusertoascertaintheremainingbaerycapacity.
3.2.1DisplayingReal-meBaeryBankVoltage
Thereal-mevoltageofthebaerybankisdisplayedbypressingtheVOLTbuonontheSmartgauge(Fig.1,C1).
3.2.2DisplayingBaeryBankSOC
TheSOCisdisplayedbypressingtheStatusbuonontheSmartgauge(Fig.1,C1)baerymonitor.Itisindicatedbya
numberprecededwiththeleer‘C’(e.g.C75).Thisindicatesthepercentageofbaerylifeleintheunit.E.g.C75
indicatesthatthereis75%baerycapacityremaining.
Ifthe30%lowerlimitisreachedtheSmartgauge’sinternalalarmwillbetriggeredanditsdisplaywillflashbetween
C29anderrorcode‘ALS’.TheredLEDindicatormarked‘ALARM’ontheSmartgaugewillalsoilluminate.
Torestarttheunit,thebaerybankmustbechargedbackuptoabove30%.
TheSmartgauge'sBATT2buonisnotusedandshouldbeignored.
OncetheSmartgaugereachesC30CygnuswillautomacallyswitchintoStandbyModeandstop
deliveringACpowerunlitissufficientlyrecharged.
TheSmartgaugewillonlyindicatethebaeryleveldowntoC30.Thisisbecausethebaeriesshould
notbedischargedbelow30%oftheircapacitytoensurethattheyareneverallowedtodischarge
completely,asthiswillshortentheirlifemeconsiderably.TheoperangrangeisfromC100toC30.
CygnusUserManual-v3.02011 Page12
3.3 EmergencyStopBuon
1. Ifthereisanemergencyanditisnecessarytostopthepowerfromtheunit,depresstheEmergencyStopBuon
(Fig.1,C6)ontheControlPanel.
2. Theunitwillthenshutdown.CygnuscannotbeswitchedonagainunltheEmergencyStopBuonis
releasedbytwisngtheredpartofthebuonclockwise.
3. FollowtheinstruconsinSecon4toswitchthepowerbackon.
3.4 TurningOffCygnus
1. ToturntheunitoffpressESContheRCC-03(Fig.1,C2).’TurntheSystemOff?’willbedisplayed.
2. PressSETtoaccept.Theunitwillthengointostandbymode.
3. TofullyshutdowntheunitpresstheOn/OffBuon(Fig.1,C4)onthecontrolpanel.
4. TurnofftheRCDandMCBswitches(Fig.1,B1&B2).
5. TheRCC-03(Fig.1,C2)screenwillthenturnoff.
6. Switchoffallsolarisolatorswitches(Fig.1,A1&A2)
3.5 DisconnecngCygnus
1. EnsurethatthestepsinSecon4“TurningOffCygnus”havebeenfollowed.
2. Disconnecttheinputcable(s).
3. Disconnecttheoutputcable(s)
4. Removetheearthcablebyunscrewingthewingnutandreplacethewasherandwingnutontotheearthbolt.
TheSmartgaugebaerymonitordisplaywillalwaysremainon.
CygnusUserManual-v3.02011 Page13
3.6 UnderstandingtheRCC-03
TheRCC-03givesareal-meindicaonofthepowerdrawofyourconsumers,theACchargefacility,DCvoltsandAmpsbeing
dischargedandthepresentstateofthesystemasawhole.
ThefollowingdiagramindicatestheinformaonavailablefromtheRCC-03:
3.6.1ExplanaonoftheinformaonshownontheRCC-03:
A1 ACInputVolts–indicatesthevoltagebeingreceivedbytheunitfromtheACsource.Thisvalueisautomacallytransferredto
theACoutput.Anyexcesscurrentnotbeingusedbytheconnectedconsumersisusedtochargethebaerybank.
A2 ACInputAmps-IndicatesthecurrentinAmpsbeingdrawnfromtheACsourcebyCygnus.
A3 ACInputConnecon-IndicaonofwhethertheACsourceisacceptableforCygnustouse.Whentheswitchsymbolisshown
closed,thecurrentisflowingtotheACOutputand/orchargingthebaerybank.
B1 AuxRelay1-Notusedinthestandardmodels.Therelayscanacvateexternalalarmsandautomacstartrelaysforsecond
arypowersystemsandcanbeaddedasanoponalextra.Pleasecontactthemanufacturerforfurtherinformaon.
B2 Notusedinthestandardmodels.Therelayscanacvateexternalalarmsandautomacstartrelaysforsecondarypower
systemsandcanbeaddedasanoponalextra.Pleasecontactthemanufacturerforfurtherinformaon.
C1 ACOutputVolts-IndicatesvoltagebeingsuppliedattheACoutput.
C2 ACOutputAmps-IndicatesthecurrentinAmpsbeingdrawnfromtheACoutputbytheconnectedconsumers.
D1 StandbyON/OFF-IndicateswhetherCygnusisinstandbymode.
E1 BaeryBankVolts-Indicatesthereal-mevoltageofthebaerybank.
E2 BaeryBankAmps-IndicatesthecurrentinAmpsbeingdrawnfromthebaerybank.
F1 PhaseIndicator-Indicatesthephaseoftheunit.Usedwhenmulpleunitsareconnectedinseries(3phase).
F2 CygnusNumber-Idenfiestheunit’snumber.Usedforseries(3phase)orparallellinkedsystems.
G1 BaeryBankConnecon-Indicatesthebaerybankusagei.e.chargingordischarging.
Fig.4-TheRCC-03
CygnusUserManual-v3.02011 Page14
3.7 ChargingMethods
CygnuscanbechargedusinganumberofmethodsincludingFirefly’sportablefoldingsolararrays(Fold-Array),Firefly’srange
ofKinectricsequipmentandanexternalACgridsupplyorsecondarypowersystem.Inaddiontothesechargingmethodsitis
alsopossibletochargeCygnususingwindturbinesoralternavesolararrays.Contactthemanufacturerforalistofapproved
productsandfurtherdetailsonconnecon.
3.7.1ChargingwithFirefly’sPortableFoldingSolarArray(Fold-Array)
3.7.1.1Connecng
1. Oncethearrayshavebeenposionedsuitably,anyjunconboxesconnectedandtheextensioncablessafelyrun
backtoCygnus,thearrayscanbeconnectedtotheunit.
2. BeforeconnecngthesolarextensioncablestoCygnus,ensurethattheSolarIsolatorSwitches(Fig.1,A1&A2)
areturnedoff.
3. ConnectyourfirstarraytotheSolarArray1connectors(Fig.1,A3)onthecontrolpanel.IfusingaFoldArraypar
alleljunconboxtoconnectmulplearrays,connectitsoutputtotheSolarArray1connectors.
4. TheLEDindicatortotherightoftheconnectorswillilluminatetoshowthattheconneconhasbeenmade.
5. Ifasecondarrayistobeused,connectthistotheSolarArray2connectors(Fig.1,A4)onthecontrolpanel.If
usingasecondFoldArrayparalleljunconboxtoconnectmulplearrays,connectitsoutputtotheSolarArray2
connectors.
6. TheLEDindicatortotherightoftheconnectorswillilluminatetoshowthattheconneconhasbeenmade.
7. Ensurethattheconnectorsarefullyengagedtoavoidtheriskofthempullingouteasilyandpossible
electrocuon.
8. OncetheSolarConnectorsareallsafelyconnected,switchonthesolarisolatorswitches(Fig.1,A1&A2)onthe
lehandsideofthecontrolpanel.
9. AgradualriseinvoltageshouldbedisplayedontheSmartgaugebaerymonitor.Itmaytakeupto2minutes
beforeanysignificantchangeasthepowerregulaoncircuitsopmisetheiruseofthepowerfromthesun’s
rays.(Thisisdependantonthepanelsreceivingsufficientlight).
3.7.1.2Disconnecng
1. TodisconnectthesolararrayfromCygnus,switchofftherelevantSolarIsolatorswitch(es)(Fig.1,A1/A2)onthe
controlpanel.
2. PulltheSolarextensioncablesoutfromthecontrolpanelconnectors(Fig.1,A3/A4).
Uptofive540WpFireflyPortableSolarFoldingArrayscanbeconnectedtooneunitusingsuitable
paralleljunconboxessuppliedbythemanufacturer.Theymustnotbeconnectedinseries.
Itispossibletoconnectalternatesolararraysuptoacombinedoutputof2.5kWpand145V.
Contactthemanufacturerbeforeconnecngarraysfromanalternatesupplier.
SeeAppendix3(6.3.2),foranexampleofconnecngmorethantwoarraystoaunit.
CygnusUserManual-v3.02011 Page15
3.7.2ChargingwithKinectricsEquipment
3.7.2.1Connecng
1. TheequipmentrequirestheuseofaSPECPakadapterforconnecngtotheDCinputsocketontheunit’scontrol
panel(Fig.1,F1).
2. WhenconnecngonetotwoKinectricsunitsaSPECPakto2x50AAndersonconnectorsadaptercanbeusedto
connecttheKinectricsequipmentdirectlytoaCygnuswithsuitableextensioncables.Theseareavailablefrom
themanufacturer.RefertoAppendix3(6.3.5)foranexamplesetup.
3. UptoeightKinectricsunitscanbeconnectedtoasingleunit.Ajunconboxisrequiredwhenconnecngbe
tweenthreeandfourKinectricsunits.
4. TwojunconboxesarerequiredwhenconnecngbetweenfiveandeightKinectricsunits.
5. OncetheKinectricsequipmenthasbeenposionedsuitably,theextensioncablesconnectedandsafelyrunback
toCygnus,theequipmentcanbeconnected.
6. ConnecttheSPECPakconnectortotheunit.RefertoAppendix2(6.2.1)forfurtherinformaononusingthe
SPECPakconnector.
3.7.2.2Disconnecng
1. RemovetheSPECPakconnectorfromtheunit.RefertoAppendix2(6.2.2)forfurtherinformaononusingthe
SPECPakconnector.
2. Disconnecttheremainingcablesandanyjunconboxes.
3.7.3ChargingwithACGridSupplyorSecondaryPowerSystem
Theunitcanbechargedviaa220-240VACsupplyfromeithertheACgridsupplyorasecondarypowersystem.Tocon
nectanACsupplytoCygnus:
1. Connectthe220-240VACsupplyleadtotheACInsocket(Fig.1,E1)onthecontrolpanel.
2. TheRCC-03(Fig.1,C2)willdisplayamessagetoconfirmthattheACsupplyhasbeenconnectedsuccessfully.
3. PressSETtoclearthemessage.
4. TheRCC-03inputvoltage(Fig.4,A1)willdisplaytheexternalvoltagebeingappliedtothechargefacilityofthe
unit.
5. Theunitchargesitsbaerybankautomacally,regulangthechargecycleandensuringthatthe
baeriesarenotovercharged.
6. OncetheunitisfullychargedtheSmartgauge(Fig.1,C1)willdisplay’C100’indicangthatitis100%full.
Itisrecommendedthattheunitchargesforafurther2hoursonceithasreached100%.Thisallows
thebaerybanktofullyabsorbthecharge.
WARNING
Cygnusrequiresaminimum13AsupplyforACcharging.Ensurethatyourpowersupplyandanyinter
connecngcablesandfuseshavethisminimumavailablecurrentrang.
CygnusUserManual-v3.02011 Page16
4. ConnecngMulpleCygnusPortableSolarGenerators
4.1Introducon
ItispossibletoconnectmulpleCygnusunitstogetherusingRJ45datainterlinkcablesandACjunconboxes.Therearetwo
possibleconfiguraons:
CygnusinParallel
Eithertwoorthreeunitscanbeconnectedinparallel.Ineachcasedoublingortriplingthepeakoutputandbaerybankca
pacitywhilstmaintainingasinglephase230VACoutput.
ConnecngthreeCygnusunitsinparallelwillmulplytherun-meapproximatelythreemescomparedwithusingasingle
Cygnuswiththesameload.Connecngmulpleunitswillmulplythecurrentavailableattheoutput.Forexample:connecng
2CYG500/1380/24unitswithapeakcapacityof5.0kVAprovidesatotalsystemoutputof10.0kVA.
CygnusinSeries(3Phase)
Unitscanbeconnectedinseriestoprovidea415Vthreephaseoutput.Thisrequiresthatthreeunitsareconnected
togetherusingajunconbox(availableseparatelyfromthemanufacturer).
4.2 ConnecnginParallel
Aparalleljunconbox(availableseparatelyfromthemanufacturer)isrequiredtoconnecttheACoutputsofeachunit.
1. Eithertwoorthreeunitsmaybeused.
2. TurnoffthepoweronallunitsusingthePowerOn/Offswitch(Fig.1,C4).
3. Ifusingtwounits,Cygnus1shouldbesetasopen(Fig.1,C3:rotateswitchan-clockwise)andCygnus2asTermi
nated(Fig.1,C3:rotateswitchclockwise).
4. Ifusingthreeunits,Cygnus1andCygnus2shouldbesetasOpen(Fig.1,C3:rotateswitchan-clockwise)and
Cygnus3asTerminated(Fig.1,C3:rotateswitchclockwise).
5. StarngwithCygnus1,unscrewtheprotecvecoverfromD2(Fig.1,D2)onthecontrolpanelandconnectthe
firstdatainterlinkcable.Ensurethatastheconnectorispluggedin,theconnector’sretainingringisscrewed
clockwiseintothereceptacleonthepanelconnector.Thisensuresthatwaterintegrityismaintained.
Parallelandseriesjunconboxesareonlytobeusedfortheirspecificroleandarenot
interchangeable.
Checkwiththemanufacturerthattheunitsarepreconfiguredforparallelorseriesusebefore
aempngconnecon.
ItisimportantthattheD1,D2&D3dataconnecons(Fig.4,D1-3)alwayshavethecapsorcablere
tainingringssecured.Failuretofollowthisprocedurewillcausewateringressdamageandinvalidate
thewarranty.
Unitswhichdonothavethesamemodelnumberprefixarenotsuitableforseriesorparallelconnec
on.Forexample:ItispossibletoconnecttwoorthreeCYG5000/----/--anditisnotpossibletocon
nectoneCYG5000/----/--tooneCYG3500/----/--.
Whenconnecnginseriesorparallel,thesowareversionofeveryunitmustbethesame.Otherwise
theunitsmaynotstart.
Onlyusedatacablessuppliedbythemanufacturer.
Anyinterruponofthedataconneconwillcauseallunitstopoweroff.
CygnusUserManual-v3.02011 Page17
6. IfathirdCygnusisbeingused,connectanotherdatacablebetweenD2(Fig.1,D1)ofCygnus2andD1(Fig.1,D2)
ofCygnus3byremovingthecorrespondingprotecvecoversandscrewingintheretainingrings.
7. Runa16ACEEformextensioncablefromtheACoutput(Fig.1,E2)ofeachCygnusintothecorrespondingnum
beredinletoftheparalleljunconbox.
8. Runa32Acablefromoutputconnectorofthejunconboxtoyourdesignatedpowerdistribuonunitordirectly
toyourconsumer(s).
9. SwitchontheRCDsandMCBs(Fig.1,B1&B2)onallunits.
10. TurnonCygnus1usingthePowerOn/OffSwitch(Fig.1,C4).Youwillhearalong‘beep’andthepanelbacklight
willilluminate.Cygnus1shouldbeleinStandbyModeatthispoint.
11. TurnonthePowerOn/OffSwitch(Fig.1,C4)onCygnus2andifused,Cygnus3sothatall3areinStandby
Mode.
12. OntheRCC-03(Fig.1,C2)ofCygnus1.PressUp,thenDowntoaccesstheParalleldisplay.
13. TurnonCygnus1usingitsRCC-03(Fig.1,C2).Allconnectedunitsshouldturnonsimultaneously.
14. Ensurealljunconboxredindicatorsareilluminated.Thisshowsthatallunitsareonandoperanginparallel
mode.CheckthatalltheRCDsandMCBs(Fig.1,B1&B2)aresllinthe‘On’posionandnoneofthemhave
trippedout.
4.3ConnecnginSeries
1. Threeunitsmustbeused.
2. Tocheckwhethertheunitsareconfiguredcorrectlyforthreephaseoperaon,checktheRCC-03Cygnusnumber
(Fig.4,F2).ThefirstunitshoulddisplayL1,thesecondL2andthethirdL3.Donotaempttoconnecttheunits
inseriesifthisisnotthecase.
3. Oncetheunitnumbershavebeendetermined,posionthethreeunitswithL1onthele,L2inthecentreand
L3ontheright.
4. TurnoffthepoweronallunitsusingthePowerOn/Offswitch(Fig.1,C4).
5. Cygnus1andCygnus2shouldbesetasOpen(Fig.1,C3:rotateswitchan-clockwise)andCygnus3asTerminat
ed(Fig.1,C3:rotateswitchclockwise).
6. StarngwithunitL1,connectthefirstdatainterlinkcabletoD2(Fig.1,D2)onthecontrolpanel.Ensurethatas
theconnectorsarepluggedin,theconnector’sretainingringisscrewedclockwiseintothereceptacleonthe
panelconnector.Thisensuresthatwaterintegrityismaintained.
7. ConnecttheotherendofthiscabletoD1(Fig.1,D1)onthecontrolpanelofunitL2.
8. PlugasecondDatacableintoD2(Fig.1,D2)onthecontrolpaneloftheunitL2.
9. ConnecttheotherendofthiscabletoD1(Fig.1,D1)onthecontrolpanelofunitL3.
10. Runa16AcablefromtheACoutput(Fig.1,E2)ofeachCygnusintothecorrespondingnumberedinputofthe
seriesjunconbox.
11. Runa32A3phase(3P+N+E)CEEformcablefromtheoutputconnectorofthejunconboxtoyourdesignated
powerdistribuonunitorconsumer(s).
12. Checkthatallthedatacableconneconsarepluggedincorrectly.
13. SwitchontheRCDsandMCBs(Fig.1,B1&B2)onallunits.
14. Doublecheckthatallconneconsaresecure,thenturnonunit1usingthePowerOn/OffSwitch(Fig.1,C4).A
long‘beep’willbeaudibleandtheRCC-03backlightwillilluminate.Unit1shouldbeleinstandbymodeatthis
point.
15. TurnonthePowerOn/OffSwitch(Fig.1,C4)onCygnus2andthenCygnus3sothatallthreeareinstandby
mode.
CygnusUserManual-v3.02011 Page18
16. UsingtheRCC-03controlscreen(Fig.1,C2)ofCygnus1.PressUp,thenDowntoaccesstheserialdisplay.
17. Turnonunit1usingitsRCC-03(Fig.1,C2).Todothis,presstheEscbuon:“Turnonthesystem?”isdisplayed.
PresstheSetbuontoselect.Allconnectedunitsshouldturnonsimultaneously.
18. Ensurethatallredindicatorsontheseriesjunconboxareilluminated.Thisshowsthatallunitsareonandthe3
phaseoutputisoperaonal.CheckthatalltheRCDsandMCBs(Fig.1,B1&B2)aresllinthe‘On’posionand
noneofthemhavetrippedout.
4.4TurningOffTheUnits
1. UsingtheRCC-03(Fig.1,C2)ofCygnus1.PressUp,thenDowntowakeupthecontrolpanel.
2. PresstheEscbuontochoosetopoweroffthescreen“Turnoffthesystem?”willbedisplayed,presstheSet
buontoconfirm.
4.5DisconnecngDataInterlinkCables:
1. Ensurethatallunitsareturnedoffbeforeanydatadisconneconsaremade.
2. Unscrewthedatainterlinkcable(s)retainingringsan-clockwiseandreplacetheweatherproofingcapsonto
theunitbyscrewingthembackonclockwise.
Ifproblemspersist,considerreplacingthedatacable(s)astheyaredelicateandsuccessfulseriesoper
aonoftheunitsreliesonthedataconnecontokeeptheunitsinphase.
CygnusUserManual-v3.02011 Page19
5.CareandMaintenance
5.1 Generalcleaning
Minorcleaningshouldbeperformedusingadampmicrofibercloth.Detergentsorchemicalsshouldnotbeused.
5.2 WashingCygnuswithaHighPressureCleanerorHosepipe
WhencleaningCygnuswithahighpressurecleanerorhosepipe,alwaysfollowtheoperanginstruconsfortheequip
ment.Ensurethatthestreamofwaterisalwaysdirecteddownwardsatanangleofnomorethan60°.Thisistoprevent
unwantedwateringresstotheunitviatheairflowventswhichcouldcauseelectricalfailure.Ifyoubelievethatwater
hasenteredtheunit,undernocircumstancesshouldtheunitbepoweredon.Contactthemanufacturerbeforeuse.
Thecontrolpanelshouldonlybecleanedwithadampmicrofibercloth.
Ensurethatthesystemisswitchedoffbeforecleaning.
5.3-PaintworkRepair
Minordamagetothepaintsuchasscratchesorstonechipsshouldbetouchedupwithoutdelaybeforethemetalstarts
tocorrode.SuitabletouchupbrushesorspraysforCygnuscanbeobtainedfromthemanufacturer.
5.4-Tesng
Itisrecommendthattheunitshouldbetestedannuallyforsafetybyaqualifiedelectrician.
Localregulaonsmayrequiremorefrequenttesng.Pleaserefertolocalregulaonsforfurtherdetails.
IfCygnusdoesnotpasstherelevanttests,donotuseoropentheunit.Itmustonlybeopenedbyaqualifiedservice
engineer.
Itisrecommendedthatafullserviceisperformedeverytwoyearsinordertoascertainthecondionofyoursystem.
Pleasecontactthemanufacturerforfurtherinformaon.
5.5 CaringfortheBaeryBank
Cygnususessealed,maintenancefreebaeries.Theonlyrounecarenecessaryistoensurethatwhennotinuse,the
unitischargedatleastonceamonthtokeepthebaerybanktoppedup.
WARNING
Openingtheunitmaycauseelectrocuon
Openingtheunitwillinvalidatethewarranty
WARNING
Undernocircumstancesshouldtheunitbeusedtopoweranycleaningequipmentbeingusedtoclean
theunit.
WARNING
Undernocircumstancesshouldthecontrolpanelbecleanedusingapressurewasherorhosepipe.
Detergentsmustnotbeused.
Leavingthebaeriesinastateofdischargeforextendedperiodswillseriouslyaffecttheirperfor
mance.
CygnusUserManual-v3.02011 Page20
6.1 Appendix1-AddionalRCC-03Sengs
TheRCC-03providescontroloveranumberofCygnus’sengs.Twousefulsengsincludingboosngthevoltageoverdis
tanceandthelanguageusedinthedisplay.
6.1.1BoosngtheVoltageOverDistance
IfthecablerunbetweentheunitandtheACconsumersismorethan50m,adropinvoltagecanoccur.Failuretoboost
thevoltagecanresultintheconsumersnotreceivingtherequiredvoltage.
Toboostthevoltage:
1. UsetheRCC-03arrowkeys(Fig.1,C2)tonavigatedownto‘BasicSengs’.
2. PressSETtoenterthissub-menu.
3. Usethearrowkeystonavigatedownto‘ACVoltage’.PressSETtoadjusttheseng.
4. Usethearrowkeystoinputtherequiredvoltage.Amaximumof245Visavailable.PressSETtoaccept.
5. PressESCtonavigatebacktothemainmenuandthearrowkeystoreturntothemainscreen.
6.1.2SengtheRCC-03Language
1. PressthedownRCC-03arrowkey(Fig.1,C2)tonavigateto‘RemoteControllerSengs’.
2. PresstheSETkeytoentertheRemoteControlSengs.
3. Thelanguagechoicesmenuisdisplayed.
4. PresstheSETkeytomodifythecurrentlanguage.
5. Usetheupwardsanddownwardsarrowkeystoselecttherequiredlanguage.
6. ConfirmtheseleconbymeansoftheSETkey(OK).
7. PressESCtoleavethesengsfortheremotecontrol.
Whenusingtheunitwithcablerunsoflessthan50maerboosngthevoltage,besuretoreturnthe
unittoitsdefaultvoltageseng.Repeattheabovestepsandreturnthevoltageto230Vinstep4.
This manual suits for next models
6
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