Firefly cygnus hpg User manual

CYGNUS HPG 12-24 KVA
User manual v1.6
For use with the following models:
CYG3/12/37/AGM CYG3/12/50/AGM
CYG3/18/37/AGM CYG3/18/50/AGM
CYG3/24/37/AGM CYG3/24/50/AGM
www.reycleanenergy.co.uk

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1 Introducon 4
1.1 Foreword 4
1.2 Convenons 4
1.3 Warnings 5
1.4 Standards & Regulaons 6
1.5 Disposal & Recycling 6
1.6 Firey Contact Details 6
1.7 About Firey 7
2 Geng Started 8
2.1 Storage 8
2.2 Transporng, Liing & Posioning 8
2.2.1 Transportaon 8
2.2.2 Liing (Loading/Unloading) 8
2.2.3 Posioning 9
2.3 The Cygnus HPG Control Panel 10
2.4 Connecng Cygnus HPG 12
2.4.1 Earth aachment: Installing an Earth Rod 12
2.4.2 Input Opons 13
2.4.3 Connect The AC Input 15
2.4.4 Connect The AC Output 17
3 General Operaon 18
3.1 Turning The Power On 18
3.1.1 Descripon Of The Power Modes 18
3.1.2 Switching On The Cygnus HPG 19
3.1.3 Monitoring Baery Bank State of Charge 20
3.1.4 Emergency Stop Buon 21
3.1.5 Turning O The Cygnus HPG 21
3.1.6 Disconnecng Cygnus HPG 22
3.2 Charging From An AC Supply 22
3.3 System Sengs 23
TABLE OF CONTENTS

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FIGURES
TABLE OF CONTENTS
Fig. 1 - Control Panel 10
Fig. 2 - Earth Point 12
Fig. 3 - Earth Rod 12
Fig. 4 - Input Current Sengs 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 Connecons 17
Fig. 8 - The RCC 03 Baery 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 Baery Bank 26
3.4.3 Tesng Cygnus HPG 26
3.5 Troubleshoong 27
4 Appendices 28
4.1 Connecng To A Fuel Generator For Automac Stop/Start 28
4.1.1 Control Panel Auxiliary Connecons 28
4.1.2 Bus Bar Auxiliary Connecon 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 Warnings 29
4.3.1 Safety Noce Regarding The Units’ Baeries 29
4.4 Technical Data 30
4.5 Warnings
4.5.1 Safety Noce Regarding The Units’ Baeries

Page 4 CYGHPG12-24-User-Manual-v1.6.indd
1 INTRODUCTION
1.1 Foreword
Firey 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 oers
sustainable power generaon 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 installaon and operaon. 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 Convenons
Throughout this user manual the following symbols are used:
W A R N I N G
This symbol warns of the presence of a dangerous voltage
which could cause harm to the operator or others.
This symbol indicates the potenal of damage to the unit or
connected devices.
This symbol indicates important or useful informaon.

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The following terms are used in this manual to provide greater clarity:
• Firey 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.
W A R N I N G
When the unit is operang it generates potenally lethal
voltages. Work must only be performed on the unit by the
manufacturer or a qualied service engineer approved by
the manufacturer.
All items connected to the unit including distribuon cables
and boxes should be regularly checked and adhere to the
same local regulaons and standards as a regular grid-ed
mains installaon.

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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 Limited
Unit 20 Clie Industrial Estate
South Street
Lewes
East Sussex
BN8 6JL
United Kingdom
Tel: [phone]
Fax: [phone]
E-mail: info@reycleanenergy.co.uk
Web: www.reycleanenergy.co.uk
IP56

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1.7 About Firey
Firey is the market leading expert in the design and manufacture of o-grid,
portable Hybrid Power Soluons for temporary and permanent power
applicaons. Firey has built its highly regarded reputaon within the industry,
based on excellent customer service and product reliability. Founded in 2007 the
Company connues to develop innovave soluons to cater to the needs of its
ever growing customer sectors.
The Company oers green energy products and services that meet the needs of
environmentally concerned individuals and organisaons internaonally, 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
soluons 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. Installaon and
stringent tesng is carried out to ensure compliance with EU and local legislaon
where applicable.

Page 8 CYGHPG12-24-User-Manual-v1.6.indd
2 GETTING STARTED
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 baery bank is charged regularly while in
storage. Refer to "3.2 Charging From An AC Supply" on page 21 for
further informaon.
3. The emergency stop should be engaged (pushed in) and output
protecon switches should be switched o when in storage and not
being charged to prevent unnecessary discharge of the baery bank.
2.2 Transporng, Liing & Posioning
This unit is considerably heavier than regular fuel powered
generators of similar physical dimensions. Be sure to double
check the capacity of liing equipment.
2.2.1 Transportaon
1. Cygnus HPG can be transported using its oponal trailer, light or heavy
goods vehicle with adequate available payload. Check the relevant
transportaon documentaon for suitability.
2. The gross weight of the unit can be found on the rang plate posioned
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.
2.2.2 Liing (Loading/Unloading)
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 or telehandler.
3. Cygnus HPG can be safely lied using its integral liing ring.

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Always check the rang plate to ascertain the gross weight
of the unit.
The unit must remain upright at all mes.
2.2.3 Posioning
1. The unit must be posioned 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 posioned 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 venlaon on all sides and that
vents are not obstructed.
Refer to liing equipment’s operaon manual for liing
capacity and manufacturer’s operang instrucons.

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2.3 The Cygnus HPG Control Panel
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
Fig. 1 - Control Panel

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1. Mode Selector- Allows switching between the three power roung
modes and o
2. Emergency Stop- Press in to immediately halt all operaon
3. Auxiliary connecons (Generator start)- Provides signals for various
applicaons including the control of a Gen. Set.
4. Solar Array Isolator Switches§- Provides overload protecon for the
Solar Array inputs. Switch o to isolate the Solar Array circuit, on to
enable it.
5. Solar Array Inputs§- 30 A MC3 connecons for solar arrays
6. Bus Bar Connecon- Provides entry for hard wired AC input and output
connecons.
7. RCC 03- Provides status and control of the unit’s inverters and charge
controller§
8. Single Phase AC Input Protecon- over current MCB
9. Single Phase AC Input Connector- 230 V AC single phase 63 A CEE
Form plug
10. Single Phase AC Input Indicator- indicates presence of AC at input
connecon
11. Three Phase AC Input Indicators- indicates presence of AC on each line
of the input connecon
12. Three Phase AC Input Connector- 230 V AC three phase 63 A CEE Form
plug
13. Three Phase AC Input Protecon- over current MCB
14. Single Phase AC Output Connector- 230 V AC single phase 63 A CEE
Form socket
15. Single Phase AC Output Indicator- indicates presence of AC at output
connecon
16. Single Phase AC Output Protecon- RCD earth leakage and MCB over
current
17. Three Phase AC Output Protecon- RCD earth leakage and MCB over
current
18. Three Phase AC Output Indicator- indicates presence of AC on each
line of the output connecon
19. Three Phase AC Output Connector - 230 V AC three phase 63 A CEE
Form socket
§Solar inputs and charge controller only available on models with Solar Prep option

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2.4 Connecng Cygnus HPG
W A R N I N G
When using as a standalone power source, a protecve
earth must be connected to the unit in compliance with
applicable local standards and regulaons.
This can be done either by connecng to a suitable exisng
electrical earth, or by using an earth rod available from the
manufacturer as an accessory.
2.4.1 Earth aachment: Installing an Earth Rod
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 aer 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

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2.4.2 Input Opons
The unit can accept inputs from an AC power source (single phase or three
phase. Further informaon on connecng these items is available in secon "3.2
Charging From An AC Supply" on page 21) and solar arrays using the oponal
Solar Prep kit.
The AC input current is adjustable, allowing the unit to be charged from AC
sources with lower current capacies.
2.4.3 Connect The AC Input
Only one AC input can be connected at a me- damage will
be caused by aempng to simultaneously connect single
phase and three phase inputs.
2.4.3.1 Select Input Method
1. Ensure that the unit is switched o- see "3.1.5 Turning O The Cygnus
HPG" on page 20.
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. 5 - 5 mm
Double Barb Key" on page 14.
3. Locate the Input Selector switch at the boom le corner- see "Fig. 6 -
AC & Aux. Bus Bar Connecons, Input Selector Switch" on page 14.
4. Turn switch an-clockwise to select Bus Bar input or clockwise for use
of the CEE Form connectors .
2.4.3.2 Connecng with CEE Form Industrial Plugs
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. 7 - Inputs, Outputs
and Circuit Breakers" on page 15
6. Switch on the AC input’s power supply.
Fig. 4 - 5 mm Double Barb Key

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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.
2.4.3.3 Connecng by Hard Wiring Into The AC Input Bus Bar
1. Before any power connecons are made, ensure that Cygnus HPG is
in Mode 4: O. See "3.1.1 Descripon Of The Power Modes" on page
17
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. 5 - 5 mm
Double Barb Key" on page 14.
3. The Bus Bar is located at the boom le corner.
4. Ensure that the wire used is suitable for the applicaon.
5. Pass the cables through the rubber ap in the door
6. Connect to the lower row of connecons using 6 mm ring terminals.
7. Remove the 10 mm nuts.
8. Aach ring terminals, referring to "Fig. 6 - AC & Aux. Bus Bar
Connecons, Input Selector Switch" on page 14 AC & Aux. Bus Bar Connecons,
Input Selector Switch

Page 15CYGHPG12-24-User-Manual-v1.6.indd
Replace and ghten the 17 mm nuts.
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

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2.4.4 Connect The AC Output
2.4.4.1 Connecng with CEE Form Industrial Plugs
1. Before any power connecons are made, ensure that Cygnus HPG is
in Mode 4: O. See "3.1.1 Descripon Of The Power Modes" on page
17
2. Ensure that the output breakers are switched down into the o
posion. See "Fig. 7 - Inputs, Outputs and Circuit Breakers" on page
15
3. Check that the Variable RCD is set correctly. See "4.4 Variable RCD" on
page 29
4. Ensure that the CEE Form connectors to be used are dry; wipe o any
excess moisture with an absorbent cloth.
5. 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. 7 - Inputs,
Outputs and Circuit Breakers" on page 15
2.4.4.2 Connecng by Hard Wiring Into The AC Output Bus
Bar
1. Before any power connecons are made, ensure that Cygnus HPG is
in Mode 4: O. See "3.1.1 Descripon Of The Power Modes" on page
17
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. 5 - 5 mm
Double Barb Key" on page 14.
3. The Bus Bar is located at the boom le corner.
4. Pass the cables through the rubber ap in the door
5. Connect to the lower row of connecons using 6 mm ring terminals.
6. Remove the 10 mm nuts.
7. Aach ring terminals, referring to "Fig. 6 - AC & Aux. Bus Bar
Connecons, Input Selector Switch" on page 14
8. Replace and ghten the 10 mm nuts.

Page 17CYGHPG12-24-User-Manual-v1.6.indd
3 GENERAL OPERATION
3.1 Turning The Power On
Once all connecons are complete, the AC Output of the unit is ready to be
switched on.
3.1.1 Descripon Of The Power Modes
Cygnus HPG has three dierent modes of operaon. The modes control how the
inverters are congured and how the power is routed through the unit. The
mode is selected by depressing a single buon behind the top control panel door.
Mode 1: Three Phase
A three phase input is accepted. Three
phase power is backed up by the unit’s
baery 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. 7 - Inputs, Outputs and
Circuit Breakers" on page 15)
protect the circuit.
Mode 2: Single Phase
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. 7 - Inputs, Outputs and
Circuit Breakers" on page 15)
protect the circuit.

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Mode 3: Three Phase With L1 Backup
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. 7 - Inputs, Outputs and Circuit
Breakers" on page 15) protect the
circuit.
O
All primary internal circuitry is
disabled. Cooling systems remain
operaonal.
3.1.2 Switching On The Cygnus HPG
The relevant power mode must rst be decided upon. This will depend on the
power requirements of the installaon.
1. Ensure that the Emergency stop buon is released by rotang 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 posion. For “Mode 2: Single Phase”,
the single phase breakers must be switched up into the on posion.
3. Press the chosen mode buon. The selected mode buon’s LED
indicator will ash during inialisaon 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, indicang that power is available at the selected output(s).

Page 19CYGHPG12-24-User-Manual-v1.6.indd
3.1.3 Monitoring Baery Bank State of Charge
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
2Arrows 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. 6 - The RCC 03 Baery Monitor Screen
13
4
5
2
6

Page 20 CYGHPG12-24-User-Manual-v1.6.indd
3.1.4 Emergency Stop Buon
1. If there is an emergency and it is necessary to stop the power from
the unit, depress the Emergency Stop Buon (Fig. 1, C6) on the Control
Panel.
2. The unit will then shut down. Cygnus HPG can not be
switched on again unl the Emergency Stop Buon is
released by twisng the red part of the buon clockwise.
3. Once the problem has been reced, follow the instrucons in "3.1
Turning The Power On" on page 17 to switch the power back on.
3.1.5 Turning O The Cygnus HPG
1. Open the control centre door using the supplied key- see "Fig. 4 - 5 mm
Double Barb Key" on page 13
2. Select the O buon- see "3.1.1 Descripon Of The Power Modes" on
page 17
3. The buon’s indicator will ash while the system is shung down and
stay illuminated when the system is in the o mode.
The unit’s internal cooling system may connue to operate
when the unit is in the O mode