Geotech Enfusion cell 3500 User manual

Cell 3500 Manual

Revision 5.0

Before You Get Started

IMPORTANT:

This manual contains important instructions that should be followed

during installation, operation and maintenance of the Cell 3500

controller. Carefully read and follow all safety instructions in this

manual.

Make sure that safety labels are always in good condition and

replace missing or damaged safety labels.

Before performing any service or maintenance inside the controller or

when connecting or disconnecting any wires, DISCONNECT the power

and WAIT 90 seconds to allow the capacitor bank inside the controller to

discharge to a level below 50V.

DO NOT turn on the power to the controller before terminating all wiring

connections and closing the cover door.

DO NOT

connect power wiring to the controller before mounting the box.

DO NOT service the device if your hands are wet or damp. Always make

sure hands are dry before working on the controller.

DO NOT modify equipment inside the controller.

DO NOT remove any parts of the controller unless instructed by this

manual.

The controller should be installed and inspected by technically qualied

personnel, and if the controller is not installed in compliance with

national and local electrical codes and ENFusion™ recommendations, the

controller can be damaged and fail to operate.

FOLLOW instructions in this manual and labels inside the controller for

proper and successful installation.

Cell 3500 Manual 5.0

TABLE OF CONTENTS

INSTALLATION .....................................................................................1

Task 1: Mount the Cell 3500 ................................................................2

Step One: Decide Best Location..............................................................2

Important Pre-Installation Warnings..................................................2

Cell 3500 Requirements for Safe Installation.....................................2

Cell 3500 Mounting Clearances..........................................................3

Cell 3500 Dimensions.........................................................................4

Step Two: Mount the Cell 3500 ................................................................4

Cell 3500 Unit Mounting Instructions .................................................4

Task 2: Wire the Cell 3500 ....................................................................7

Step One: Review Wiring Requirements and Warnings ...........................7

Installation Requirements ...................................................................7

Wiring Warnings...................................................................................7

Step Two: Review System Wiring Diagrams.............................................7

Review Overview Diagram of Cell 3500 Showing Five Cable Glands......7

Review Closeup of Internal Wiring Features.......................................8

Review Cell 3500 Circuit Board Diagram............................................ 9

Review Cell 3500 System Wiring Diagram ........................................ 11

Wiring For Single-Phase Motor Loads.. ............................................. 12

Step Three: Wire to DC (Solar) Sources.................................................. 12

Wire to DC Sources as Per Wiring Diagram ....................................... 12

Tighten The DIN Rail Terminals .......................................................... 13

Step Four: Set Cell 3500 DIP Switch Settings ........................................ 13

Set DIP Switches 1, 2, or 3 to Match Your Motor................................. 14

Set DIP Switches 4 and 5 to Match Minimum Operating Motor Frequency

.. 14

Set DIP Switches 6 and 7 for Overcurrent Protection ....................... 15

Set DIP Switch 8 (If DIP Switch 2 Is Set for Single-Phase Operation)

... 15

Set DIP Switch 9 for Flow Switch Dry Well Protection .......................16

Set DIP Switch 10 for Flow Switch Time Delay................................... 16

Set DIP Switch 11 for Automatic Dry Well Protection ........................ 17

Install Cover Door and Tighten It ....................................................... 17

Step Five: (Optional) Set Cell 3500 Sensor Setting................................ 17

Remote Turn On/Off With Digital Input or Standard Float Switch..... 17

Cell 3500 Can Incorporate Two External Analog Sensors................. 18

Task 3: Complete Installation Notes ....................................................19

After Installation, Complete Installation Notes.................................19

Tech Support Hotline: 877 230 7501 .................................................19

Keep This Manual With Your Cell 3500 Unit....................................... 19

CONFIGURATION .............................................................................. 20

Task 4: Congure the Cell 2000 .......................................................... 21

Step One: Size the Solar Panel Array to Motor Load Power Requirements ...21

Cell 3500 Manual 5.0

OPERATION........................................................................................22

Task 5: Initial Cell 3500 Startup ..........................................................23

Step One: Start Cell 3500 for the First Time ..........................................23

Step Two: Understand Meaning of Cell 3500’s LED Lights.......................... 23

Motor Is Properly Connected.............................................................23

Cell 3500 Overload Protection ..........................................................24

Solar Only Mode .................................................................................24

Step Three: Manually Shut Down Cell 3500 Operation..........................24

Understanding Automatic Shutdown of Cell 3500 ...........................24

Automatic Shutdown With Tank or Well Float Switch........................24

Automatic Shutoff Due to Temperature ............................................25

Power Deration Mode ........................................................................25

MAINTENANCE OF CELL 3500 ........................................................... 26

Task 6: Perform Recommended Maintenance ......................................27

Inspect Every Three Months...................................................................27

Maintain Optimal Operational Conditions ..............................................27

Keep Clear of External Obstructions .................................................27

Don’t Operate in Freezing Conditions ...............................................27

Check External Sensors Every 3 Months...........................................27

Keep the Unit Out of Direct Sunlight .................................................27

Troubleshoot LED Indicator Lights ....................................................27

Appendix A: Size the Solar System to Power the Cell 3500..................... 29

Understand How to Maximize Solar Energy .......................................... 29

Size the Solar System ....................................................................... 29

Minimum and Maximum Solar PV Array Requirements ................... 30

Appendix B: Product Description, Product Specications .................... 31

Product Description...............................................................................31

Product Specications..........................................................................32

Appendix C: Calculate Maximum Cable Lengths for Different Motor Load

Currents.............................................................................................33

Appendix D: Optional Cell 3500 Module..................................................34

About the Cell 3500 GFCI (Ground Fault Circuit Interrupter) Module.....34

Appendix E: Typical Diagram for Cell 3500 Operated Solar Water

Pumping ............................................................................................35

Terms and Conditions..........................................................................37

Cell 3500 Manual 5.0

INSTALLATION

Cell 3500 Manual 5.0

Task 1: Mount the Cell 3500

Step One: Decide Best Location

Important Pre-Installation Warnings

• Contact your ENFusion™ Supplier/Dealer for any service

or warranty claims at info@enfusionenergy.com.

• National Electric Code (NEC) takes precedence over suggestions

in this manual.

We strongly recommend that the installation data be recorded into

the “Installation Notes” (See Figure 22: Installation Notes) and that

you keep the manual stored near the unit.

Cell 3500 Requirements for Safe Installation

The Cell 3500 must be installed in a shaded location, away from

any source of heat and moisture, and in an area free of vegetation.

Measures must also be made to protect the unit from damage by

unauthorized persons, large animals, overgrowth, ooding or other

harm.

The Cell 3500 should not be exposed to direct sunlight. The ideal

location for the unit is to mount it underneath the solar panels, as

our illustrations show.

Do not ground the positive or negative leads of the PV modules!

Only ground the mounting frames of the PV modules.

Never run the Cell controller when the AC pump is not connected!

It might cause damage to the controller.

If an installed three-phase pump does not start pumping water, switch the

positions of any two of the three motor wires. It will change the direction

of rotation and it should start pumping water!

WARNING

Cell 3500 Manual 5.0

Cell 3500 Mounting Clearances

• The Cell 3500 should be mounted at least 24 inches (60cm)

above the ground when possible.

• A minimum of 10 inches (25cm) of clearance above the Cell

3500 is required for internal access.

• There must not be an obstruction of air ow to the heatsink.

A typical installation on an array structure is shown in Figure 1: Cell

3500 Mounting Clearances.

Figure 1: Cell 3500 Mounting Clearances

24”

10”

Solar PV Panel

ACLOAD

SOLAR

WARNING

Cell 3500 Manual 5.0

Cell 3500 Dimensions

Dimensions of the Cell 3500 and back panel are shown in Figure

2: Cell 3500 Dimensions with additional details on how to mount

the unit in Figure 3: Back View of Cell 3500 Mounting Bracket and

Figure 4: Cell 3500 Unit Mounting Instructions.

Figure 2: Cell 3500 Dimensions

Step Two: Mount the Cell 3500

Cell 3500 Unit Mounting Instructions

The Cell 3500 controller should be mounted on a wall or other

vertical surface using the back bracket (See Figure 3: Back View

of Cell 3500 Mounting Bracket).

On the back side of the unit there are two set screws (not included)

used to hang the unit on the back bracket. More detailed mounting

instructions are shown in Figure 4: Cell 3500 Unit Mounting

Instructions.

3”

13.5”8”

8.65”

12” 5.5”

20”

AC LOAD

SOLAR

WARNING

Cell 3500 Manual 5.0

Figure 3: Back View of Cell 3500 Mounting Bracket

Back Bracket

(Wall Mount)

Heatsink

Mounting

Holes

Cell 3500 Manual 5.0

Figure 4: Cell 3500 Unit Mounting Instructions

Shoulder Bolt

Fix the back bracket to the support

surface by inserting four screws

(not included) through the 4 holes

in the back bracket

Once the Cell is in place on the

back bracket, screw in the shoulder bolt

to secure the unit to the bracket

2Make sure all 4 set screws

are used to hang the Cell

onto the back bracket

AC LOAD

SOLAR

WARNING

Cell 3500 Manual 5.0

Task 2: Wire the Cell 3500

Step One: Review Wiring Requirements and Warnings

Installation Requirements:

All electrical installations must be carried out in accordance with

local standards and the National Electrical Code (NEC).

Conductor rated current, temperatures, operating conditions and

its power loss must be made in accordance with local standards

and the National Electrical Code (NEC).

Wiring Warnings

Step Two: Review System Wiring Diagrams

Review Overview Diagram of Cell 3500 Showing Five Cable Glands

The unit has ve cable glands:

• One large cable gland for a motor cable (middle)

• Two cable glands for solar PV arrays (right side)

• Two cable glands for data cables (left side) for a oat switch

sensor or other optional sensor

There is direct access to the power and signal terminals on the DIN

rail once the enclosure door is removed (See Figure 5: Overview

Diagram of Cell 3500 Showing Five Cable Glands).

Do not ground the positive or negative leads of the PV modules!

Only ground the mounting frames of the PV modules.

Never run the Cell controller when the AC pump is not connected!

It might cause damage to the controller.

If an installed three-phase pump does not start pumping water, switch the

positions of any two of the three motor wires. It will change the direction

of rotation and it should start pumping water!

WARNING

Cell 3500 Manual 5.0

Figure 5: Overview Diagram of Cell 3500 Showing ve Wire Glands

Review Closeup of Internal Wiring Features

Once the door of the enclosure is removed, there is access to the

input terminal blocks (DIN rail mounts) on the right. See Figure 6:

Closeup of Internal Wiring Features.

• Below the DIN rail is a grounding block for connecting the

equipment ground.

• The installer should only use the DIN rail terminals for

connecting all external wires to the Cell 3500 unit. On the

bottom left, just next to the external sensors gland, there is a

motor ON/OFF switch that controls the Cell 3500’s operation

of the motor.

Back Bracket

(Wall Mount)

Heatsink

DC Disconnect

Signal Wire

Glands

Back View Front View

Ground

Electrode Lug

Motor ON/OFF

Switch

Power Wire Glands

(Motor, Solar and AC Source)

Mounting

Holes

AC POWER

SOLAR

WARNING

AC LOAD

SOLAR

WARNING

Cell 3500 Manual 5.0

Figure 6: Closeup of Internal Wiring Features

Review Cell 3500 Circuit Board Diagram

The features of a Cell 3500’s printed circuit board are shown in

Figure 7: Cell 3500 Circuit Board Diagram.

The installer needs access to these features when conguring the

Cell 3500’s DIP switches to match the AC motor load specications

(described in greater detail in Step Four: Set Cell 3500 DIP Switch

Settings).

Solar PV

Input Terminal

Block 1

Solar PV

Input Terminal

Block 2

Motor Output

Terminal Blocks

Float Switch and

Sensor Input

Terminal Blocks

External

Sensor Input

Motor Load

ON/OFF Switch

Motor

Output

Ground

Bar

Motor and Both

Solar Input

Ground

Electrode Lug

Disconnect

Cell 3500 Manual 5.0

Figure 7: Cell 3500 Circuit Board Diagram

Closeup of DIP Switches

Minimum Motor

Frequency

3-Wire

Dry Well Protection

50Hz

Single-Phase

120V

230V

Three-Phase

60Hz

1 2 3 4 5 6 7 8 9 10 11 12

Ribbon Cable

Connector for Comm

Board (optional)

Terminal for Motor

ON/OFF Switch

24V for GFCI

Analog Sensor Inputs (P9)

Float Switches

Overload

Protection 2-Wire

Flow Switch

Do not modify DIP switch settings until power has been turned off and after

90 seconds have passed for internal voltages to discharge below voltage

of 50V! Power must be removed for DIP switch settings to take effect.

WARNING

Cell 3500 Manual 5.0

Review Cell 3500 System Wiring Diagram

Figure 8: Cell 3500 System Wiring Diagram is a top level wiring

diagram illustrating how the various components are wired into

the Cell 3500. Review Step One: Review Wiring Requirements and

Warnings.

Figure 8: Cell 3500 System Wiring Diagram

PV Solar Array 2

Float

Switch/Other

Sensors

PV Solar Array 1

AC Motor Pump

WARNING

Do not ground the positive or negative leads of the PV modules!

Only ground the mounting frames of the PV modules.

Never run the Cell controller when the AC pump is not connected!

It might cause damage to the controller.

If an installed three phase pump does not start pumping water, switch the

positions of any two of the three motor wires. It will change the direction

of rotation and it should start pumping water!

AC POWER

SOLAR

WARNING

AC LOAD

SOLAR

WARNING

Cell 3500 Manual 5.0

Wiring for Single-Phase Motor Loads

• Single-phase motor loads should be wired as shown in Figure 9:

Table of Wiring for Single-Phase Motor Loads.

• Single-phase 2-wire motors should be connected to phase A

and C, while 3-wire motors should be wired so that common

lead is wired to phase A, starting winding to phase B and main

winding to phase C. Use DIP Switch 8 for proper single-phase

motor selection.

Figure 9: Table of Wiring for Single-Phase Motor Loads

Step Three: Wire to DC (Solar) Sources

Wire to DC Sources as Per Wiring Diagram

Once the Cell 3500 is installed in a shaded location, as shown in

Figure 1: Cell 3500 Mounting Clearances, it should be wired to DC

(solar) sources. Voltage and current levels dened on Page 32:

Product Specications.

Maximum cable lengths for 115 and 230V for different load currents

are shown in Figure 28: Maximum Input Cable Lengths in Feet

(Based On 3% Voltage Drop).

Figure 10: Internal Wiring Diagram to DC (Solar) Sources

IMPORTANT:

Single-phase 2-wire

motor pumps:

Connect to A and C motor terminals of Cell

Single-phase 3-wire

motor pumps:

Ph_A: YELLOW wire - common motor lead

Ph_B: RED wire - start motor lead

Ph_C: BLACK wire - main motor lead

Float Switch/

Other Sensors

Motor

Solar PV 1

System

Ground

Solar PV 2

Cell 3500 Manual 5.0

Tighten the DIN Rail Terminals

Once the system is wired per Figure 10: Internal Wiring Diagram

to DC (Solar) Sources, the power conductors wired to the DIN rail

terminals inside the Cell 3500 should be tightened with torque

values of:

• Solar PV and motor load conductors: 11 lb-in.

• AC source conductors: 8 lb-in.

The cable glands (cord grips) on the bottom of the enclosure should

be used as:

• 1/2 inch cord grips should only be used with a cord that is

0.280-0.455 inch outer diameter.

• 3/4 inch cord grips should only be used with a cord that is

0.455-0.705 inch outer diameter.

Step Four: Set Cell 3500 DIP Switch Settings

Conguring DIP switch settings is crucial to the Cell 3500 to

recognize the motor (load) and any other parameters or constraints

in the application. NEVER skip DIP switch conguration. It will

always apply in one form or another to your application.

Note that the DIP switch board shows 12 slots. Only 11 slots are

currently in use as shown in Figure 12: Closeup of DIP Switches.

Figure 11: Location of DIP Switches on Circuit Board

Figure 12: Closeup of DIP Switches

DIP Switches

Minimum Motor

Frequency

3-Wire

Dry Well Protection

50Hz

Single-Phase

120V

230V

Three-Phase

60Hz

1 2 3 4 5 6 7 8 9 10 11 12

Overload

Protection 2-Wire

Flow Switch

Cell 3500 Manual 5.0

Set DIP Switches 1, 2, or 3 to Match Your Motor

The Cell 3500 controller can operate most AC motors up to the

power limits of the controller: single or three-phase; 50 or 60Hz;

120V or 230V. In order for the Cell 3500 to match the motor

specications, the rst three DIP switches on the left are used for

motor selection:

DIP Switch 1 – 120/230V:

• If switched ON (up – as in Figure 13:

Set Dip Switches 1, 2, 3 to Match Your

Motor) the unit is congured for 120V

pump operation.

• If switched OFF (down) the unit is

congured for 230V.

DIP Switch 2 – 1/3 phase:

• If switched ON (up – as in Figure

13: Set Dip Switches 1, 2, 3 to Match

Your Motor) the unit is congured for

single-phase motor operation.

• If switched OFF (down) the unit is congured

for three-phase motor operation.

DIP Switch 3 – 50/60Hz:

• If switched ON (up – as in Figure 13: Set Dip Switches 1, 2, 3 to

Match Your Motor) the unit is congured for 50Hz motors.

• If switched OFF (down) the unit is congured for 60Hz motors.

Set DIP Switches 4 and 5 to Match Minimum Operating

Motor Frequency

DIP Switches 4 and 5 - Minimum Operating Motor Frequency:

• It is possible to set up a minimum

operating motor frequency.

This is important when operating

in Solar Only mode and when

there is not enough solar power

available to pump water due to

high dynamic head.

• In order to prevent “dead heading,”

it is possible to set the minimum

frequency in the range of 30 to

50Hz, using a combination of

DIP switches 4 and 5 as shown in

Figure 14: DIP Switches 4 and 5 to

Match Minimum Operating Motor

Frequency.

• NOTE: The Cell 3500’s default minimum Hz setting is 30Hz.

1 2 3 4 5 6 7 8 9 10 11 12

1 2 3

50Hz120V

Single-Phase

Three-Phase

230V 60Hz

4 5

DIP

Switches

Minimum

Motor Frequency

30Hz

40Hz

45Hz

50Hz

1 2 3 4 5 6 7 8 9 10 11 12

4 5

Figure 13: Set Dip Switches

1, 2, 3 to Match Your Motor

Figure 14: DIP Switches 4 and

5 to Match Minimum Operating

Motor Frequency

Cell 3500 Manual 5.0

Set DIP Switches 6 and 7 for Overcurrent Protection

DIP Switches 6 and 7 - Overcurrent Protection:

• The Cell 3500 can set

overcurrent protection

based on the motor pump

and controller combination

being used.

• Figure 15: Set DIP Switches

6 and 7 for Overcurrent

Protection shows how to set

up overcurrent protection

using DIP switches 6 and 7.

• The default value of RMS

current (when both switches

are OFF) is 13A for single-phase

and 10.5A for three-phase.

• DIP switches 6 and 7, are to be used to match or exceed

the motor nameplate’s SFAMPS in order to protect from

overcurrent.

• For example, if a single-phase motor has SFAMPS: 9A,

then DIP switches 6 and 7 have to be set for 11.5A, as this

is the next highest protection current for this motor.

• Conguring Overcurrent Protection also congures

automatic Dry Well Protection.

• The Cell 3500 monitors motor amperage or dry well

protection, and no other dry well sensor input is needed

unless desired.

Set DIP Switch 8 (If DIP Switch 2 Is Set for Single-Phase

Operation)

DIP Switch 8 2-wire/3-wire: Single-Phase

• Used for setting up the proper mode

for single-phase operation.

• This is relevant only when DIP switch

2 is set for single-phase operation.

• The default setting is for single-

phase 2-wire motors, when DIP

switch 8 is in the OFF [down – as in

Figure 16: DIP Switch 8 (If DIP Switch

2 Is Set for Single-Phase Operation)]

position.

• For 3-wire single-phase motors, DIP switch 8 should be in

the ON (up) position.

Overcurrent

Single-Phase

Protection

Three-Phase

13A

11.5A

8.5A

6.5A

10.5A

7.5A

6 7

DIP

Switches

Figure 15: Set DIP Switches 6 and 7

for Overcurrent Protection

Figure 16: DIP Switch 8

(If DIP Switch 2 Is Set for

Single-Phase Operation)

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