National Semiconductor SolarMagic User manual

SolarMagicTM Weather Station
User Guide

DISCLAIMER
The information, specifications, configurations and other technical information regarding the products
referenced herein are subject to change without notice. All the statements, technical information and
recommendations contained herein are believed to be accurate and reliable but National Semiconductor
Corporation makes no representations or warranties with respect to accuracy or completeness of the
contents of this User Guide. Users must take full responsibility for the application of any products
referenced herein. No license whether express, implied, arising by estoppel or otherwise, to any intellec-
tual property rights is granted by this User Guide.
TO THE MAXIMUM EXTENT PERMITTED BY LAW, IN NO EVENT SHALL NATIONAL
SEMICONDUCTOR BE LIABLE TO BUYER, OR TO ANY PARTY CLAIMING THROUGH OR
UNDER BUYER, FOR ANY LOST PROFITS, LOSS OF DATA, INCREASED MANUFACTURING
COSTS, LOSS OF GOODWILL, OR FOR ANY INDIRECT, INCIDENTAL, SPECIAL, EXEMPLARY OR
CONSEQUENTIAL DAMAGES OF ANY KIND, ARISING OUT OF OR RELATED TO THE USE OF
THIS USER GUIDE, OR THE USE OF OR THE INABILITY TO USE ANY PRODUCT REFERENCED
HEREIN, EVEN IF NATIONAL SEMICONDUCTOR HAS BEEN ADVISED OF THE POSSIBILITY OF
SUCH DAMAGES. NATIONAL SEMICONDUCTOR’S TOTAL CUMULATIVE LIABILITY SHALL BE
LIMITED TO THE AMOUNTS PAID BY BUYER TO NATIONAL SEMICONDUCTOR FOR THE
PRODUCTS ORDERED PURSUANT TO THE APPLICABLE PURCHASE ORDER. TO THE EXTENT
SOME JURISDICTIONS DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL
OR CONSEQUENTIAL DAMAGES, THE ABOVE LIMITATIONS AND EXCLUSIONS MAY NOT
APPLY TO BUYER.
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form by any means, electronic or mechanical, for any purpose, without the express
written consent of National Semiconductor Corporation.
National Semiconductor, the National Semiconductor logo, SolarMagic and MYPVDATA are trademarks
or registered trademarks of National Semiconductor Corporation. All other brand or product names
may be trademarks or registered trademarks of their respective holders.
Copyright© 2010 National Semiconductor Corporation

WARRANTY
National Semiconductor Corporation (“Seller”) hereby warrants that the product for which this User Guide is
written (the “Equipment”) will comply in all material respects with Seller’s published specification for a period
of one (1) year from the date of shipment. For any material breach of the foregoing warranty, Seller’s sole and
exclusive obligation and buyer’s sole and exclusive remedy for breach of the foregoing warranty shall be, at
Seller’s option, to either repair, replace or issue credit for the nonconforming product, provided proof of pur-
chase and written notice of non-conformance are received by Seller within the period noted above and Seller
confirms the alleged non-conformity. This warranty shall not apply to Equipment that Seller determines has
been, by buyer or otherwise, subject to unauthorized modification, improper installation, misuse, or use for any
reason other than electrical power monitoring of solar power equipment.
THIS WARRANTY EXTENDS TO BUYER ONLY AND NOT TO BUYER’S CUSTOMERS OR USERS OF
BUYER’S PRODUCTS OR SERVICES AND IS IN LIEU OF, AND SELLER EXPRESSLY DISCLAIMS, ALL
OTHER WARRANTIES, WHETHER EXPRESSED, IMPLIED, STATUTORY, INCLUDING BUT NOT
LIMITED TO ANY WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE,
TITLE AND NON-INFRINGEMENT. THIS WARRANTY SHALL NOT BE ENLARGED BY, AND NO
OBLIGATION OR LIABILITY SHALL AIRISE OUT OF, SELLER’S RENDERING OF TECHNICAL ADVICE
OR SERVICES IN CONNECTION WITH THE DELIVERY OF THE EQUIPMENT. TO THE EXTENT SOME
JURISDICTIONS DO NOT ALLOW THE EXCLUSION OF CERTAIN WARRANTIES, SOME OF THE
ABOVE EXCLUSIONS MAY NOT APPLY TO BUYER.
For further details please go to Seller’s website at: www.solarmagic.com

Contents
i
Contents
Chapter 1...............................................................................................Welcome 1
1.1 Important Safety Instructions ..........................................................................................................................2
Chapter 2...........................................................About MYPVDATA® Services 4
2.1 System Manager Overview...............................................................................................................................5
Chapter 3............................................................................................... Planning 6
3.1 Enclosure..........................................................................................................................................................6
3.2 Sensors Overview .............................................................................................................................................7
3.3 Solar Irradiation Sensor....................................................................................................................................8
3.4 Wind Speed Sensor...........................................................................................................................................9
3.5 Wind Direction Sensor ......................................................................................................................................9
3.6Ambient Temperature Sensor ......................................................................................................................... 11
3.7 PV Cell Temperature Sensor............................................................................................................................12
3.8 Reference Cell/Temperature Sensor................................................................................................................12
3.9 Communication Module .................................................................................................................................13
Chapter 4...........................................................................................Installation 15
4.1 Standard Version ............................................................................................................................................15
Chapter 5....................................................................................Commissioning 21
5.1 Powering Up...................................................................................................................................................21
Chapter 6........................................................................................Maintenance 22
6.1 Calibration......................................................................................................................................................22
Chapter 7..................................................................................Troubleshooting 24
7.1 Technical Support ...........................................................................................................................................24

National Semiconductor •SolarMagic Weather Station User Guide
ii
AppendixA.........................................................................Reference Diagrams 27

Chapter 1 • Welcome
1
Chapter 1Welcome
ongratulations on your purchase of the SolarMagicTM weather
station. This instrument has been quality tested and approved
for providing accurate and reliable measurements. We are
confident that you will find the weather station to be a valuable asset
for your application. Should you require assistance, our technical staff
will be happy to help.
Reading this entire manual is recommended for full understanding of
the use of this product.
Should you have any comments on the product or this manual, we will
be pleased to receive them:
National Semiconductor
2900 Semiconductor Drive
Santa Clara, CA 95051
Phone [phone]
Fax [phone]
Email: [e-mail]
Web:
C
http://www.solarmagic.com

National Semiconductor •SolarMagic Weather Station User Guide
2
1.1 Important Safety Instructions
This manual contains important safety instructions that should be
followed during the installation and maintenance of this product. To
reduce the risk of electrical shock, and to ensure the safe installation
and operation of this product, the following safety symbols have been
placed throughout this manual to indicate dangerous conditions and
important safety instructions.
WARNING:
A dangerous voltage or condition exists in this area. Use extreme caution when
performing these tasks.
CAUTION:
This procedure is critical to the safe installation or operation of the unit. Follow
these instructions closely.
NOTE:
This statement is important for best performance. Follow these instructions
closely.
CAUTION: Follow All Electrical Codes
All electrical work must be done in accordance with local, national, and/or
international electrical codes.
CAUTION: Read All Instructions
Before installing or using this device, read all instructions and cautionary markings
located in (or on) the products and the manual.
WARNING: Use Insulated Tools
To reduce the chance of short-circuits when installing or working with the
products use insulated tools.
WARNING: Remove Jewelry
Remove all jewelry while installing this system. This will greatly reduce the chance
of accidental exposure to live circuits.
WARNING: Stay Away from Live Wires
Make sure the weather station mast and sensor frame cannot get in contact with
live wires. This could cause serious injury, death or fire.
Z
!
!
!
Z
Z
Z

Chapter 1 • Welcome
3
WARNING: Do Not Install in Rain
Do not install or handle the SolarMagicTM DC Monitoring Combiner Box if it is wet or
raining.
CAUTION: Call if there is Damage
Contact us if the SolarMagic DC Monitoring Combiner Box enclosure is damaged or if its
contents are compromised.
Z
!

National Semiconductor •SolarMagic Weather Station User Guide
4
Chapter 2About MYPVDATA®
Services
YPVDATA services is the web portal that provides access to
your SolarMagic system manager data. MYPVDATA services
are provided and hosted by National Semiconductor.
With focus on solar energy systems, National Semiconductor is the
leading provider of monitoring and management solutions for
photovoltaic (PV) systems. National Semiconductor recognizes the
importance of monitoring PV systems beyond just solar energy
production data. Detailed information is needed to utilize the system
to its full potential. By providing an enhanced web-based monitoring
and diagnostics solution, National Semiconductor addresses this
problem and safeguards your investment.
The system manager solution in conjunction with MYPVDATA
services brings the following benefits:
•Safeguard Your Investment and Maximize Your Return.
•Improved Efficiency.
•Lower Life Cycle Costs.
•Real-time and Historic Data Presented Using Web-based Devices.
•Alarm Functions Notify of a Decrease in Production and Device
Communication Failure.
•Remote Access to all Data Using Internet Technology.
M

Chapter 2 • About MYPVDATA® Services
5
2.1 System Manager Overview
The SolarMagic system manager is a lightweight Internet gateway and
data logger solution for remote data acquisition, which enables PV
system owners to benefit from advanced energy reports. The data
logger collects data from connected devices as energy meters, inverters
and weather stations, over the standard communications protocol
Modbus. System performance and energy information are logged into
a database on the Information Server, where it can be retrieved and
used for analysis via any standard web-browser enabled device by
logging in to the MYPVDATA site.
The system manager provides the following functions:
•AC Power Monitoring for Solar Production.
•Building Demand and Net Consumption Monitoring.
•Peak Demand Tracking.
•DC Monitoring to String Level.
•Real-time Power Values.
•Daily, Weekly and Monthly overviews.
•Local Data Storage Eliminates Need for Always-on Internet
Connection.
•Data Warehousing Facilitated on Internet Server.
•Web-based Presentation of Historical and Real-time Energy Data
in Graphs and Tables through MYPVDATA.com.
•Performance Alarming via Email and SMS.
Figure 2-1. Sys
tem
Overview

National Semiconductor •SolarMagic Weather Station User Guide
6
Chapter 3Planning
3.1 Enclosure
The SolarMagic weather station is housed in a painted galvanized steel
enclosure, suitable for outdoor mounting, type NEMA 4x. The
enclosure measures 10H x 8W x 4D.
3.1.2 Enclosure Specifications
•Type: 4-4x-12
•Material: 16 gauge painted galvanized steel
•Weight: 12lbs
•Size: 10”H x 8”W x 4”D
Figure 3-1. W
eather
Station Enclosure

Chapter 3 • Planning
7
3.2 Sensors Overview
Environmental sensors have many applications and therefore many
installation options. Where you locate the sensors for the weather
station is important in order to get accurate data. The sensors should
be located in a clear area on a level surface that represents the general
area of interest, and be away from obstructions such as buildings and
trees
All SolarMagic weather station weather sensors produce a 4–20mA
output signal. 4–20mA is an industrial standard signal for process
control monitoring. Most PLCs (Programmable Logic Controller) and
data acquisition systems accept this signal directly.
The communication module is already connected to the designated
input terminals on the input terminal block in the weather station. The
lead wires from the sensor will need to be connected to the input
terminals in the weather station enclosure. The weather station can be
installed up to 1000ft from the Data Logger and connects through a
twisted pair cable and RS-485 communication (National
Semiconductor recommends a size of stranded copper #18-22 twisted
pair with shielding and drain wire). The weather station also requires
24Vdc, which is typically sourced from the system manager
monitoring kit. The communication protocol is the widely spread
Modbus protocol.
The sensors are sampled continuously to provide real time data. Each
sensor draws between 4mA and 20mA depending on whether the
sensor is reading at the minimum or maximum of its range.
The weather station sensors include an assembly on a sturdy and
durable 1” OD stainless steel tube frame that can be mounted onto a
pre-existing base/mast or onto a tripod for upright installation. The
unit is designed for durability and endurance in harsh conditions. The
Solar Shield, a ventilated sun shield with high reflectiveness, low heat
retention, and low thermo conductivity, is provided as protection and a
mounting platform for the temperature sensor.
Choosing a proper installation location for weather sensors is
important to ensure accurate readings. For example, wind sensors
should not be installed too close to a building, as turbulence created by
the building can interfere with readings. To measure global irradiation
the solar irradiation sensor should be installed in direct sunlight on a
level surface (bubble level and leveling screws are included with
purchase) with similar sun exposure as the PV array.

National Semiconductor •SolarMagic Weather Station User Guide
8
NOTE: Sensor Cable Length
Most sensors are shipped with a 25ft sensor lead cable. Make sure that the sensor
cables will reach. The sensor lead wires can be extended to a maximum length of
400ft if stranded #22AWG or larger wires are used.
If both the wind direction and wind speed sensors are purchased, the
weather station comes with a T-mounting bar with a 1" OD stainless
steel coupling unit and an Allen wrench to install the set screws during
installation. Individual wind sensors or solar irradiation sensors
include 1" stainless steel elbow couplers and an Allen wrench for the
set screws. The Solar Shield (with a stainless steel elbow coupler) can
be used for protection and easy installation of the Temperature and
Humidity sensors.
NOTE:
We recommend use of guy wires to support the weather sensor mast/base.
3.3 Solar Irradiation Sensor
The solar irradiation sensor or pyranometer is an instrument for
measuring solar irradiation from the hemispherical field of view
centered on the sensor. It measures the energy flux density of both
direct beam and diffuse sky irradiation passing through a horizontal
plane of known unit area.
Solar irradiation varies significantly among regions. Season and time
of day are major considerations, but surrounding terrain elevation,
man-made obstructions, and surrounding trees can also cause large
variations in locations with a small area.
3.3.2 Solar Irradiation Sensor Specifications
•Output: 4–20mA
•Range: 0–1500 W/m2
•Accuracy: 1% of full scale
Figure 3-2.
Solar
Irradiation Sensor

Chapter 3 • Planning
9
•Operating Voltage: 10–36VDC
•Current Draw: Same as sensor output
•Warm Up Time: 3 seconds minimum
•Operating Temperature: –40°C to 55°C
•Size of Probe: 3" diameter × 1.5" high
•Weight: 0.25lb
3.4 Wind Speed Sensor
The wind speed sensor or anemometer produces a sine wave voltage
signal with a frequency that changes linearly with the wind speed. The
frequency is transformed into a 4–20mA sensor signal output.
3.4.2 Wind Speed Sensor Specifications
•Output: 4–20mA
•Range: 0-100MPH
•Accuracy: 0.2MPH over the range 11 to 55MPH
•Operating Voltage: 10–36VDC
•Current Draw: Same as sensor output
•Warm Up Time: 3 seconds minimum
•Operating Temp: –40° to +55°C
•Size of Probe: 7" diameter × 8.5" long
•Weight: 1lb
3.5 Wind Direction Sensor
A wind direction sensor produces a ratio metric voltage signal. That
voltage signal is transformed into a 4–20mA sensor output signal.
Figure 3-3. Wind
Speed
Sensor

National Semiconductor •SolarMagic Weather Station User Guide
10
3.5.2 Wind Direction Sensor Specifications
•Output: 4–20mA
•Range: 0 to 360° (352° electrical, 8° open)
•Accuracy: 1% of full scale
•Operating Voltage: 10–36VDC
•Current Draw: Same as sensor output
•Warm Up Time: 3 seconds minimum
•Operating Temp: –40° to +55°C
•Size: 8.5" diameter × 10 ½" long
•Weight: 1lb
3.5.3 Solar Shield
The solar shield is used to protect sensors, typically humidity and
temperature, from direct sunlight. Insert a sensor into one of the two
holes located on the underside of the shield. The shield provides a
friction lock so the sensors will not fall out. The sensors can be
removed by firmly twisting and pulling them out of the solar shield.
Figure 3-4.
Wind Direction
Sensor

Chapter 3 • Planning
11
The shield comes with a stainless steel elbow that can be mounted on a
1” OD diameter tube. For best results ensure that the shield is mounted
vertically.
•Size: 4” diameter × 8 ½” long,
•Weight: 1 lb.
3.6 Ambient Temperature Sensor
Figure 3-5 shows the temperature sensor installed in the solar shield.
3.6.1 Ambient Temperature Sensor Specifications
•Output: 4–20mA
•Range: –50°C to 50°C
•Accuracy: ±0.2° F or ±0.1° C
•Operating Voltage: 10–36VDC
•Current Draw: same as sensor output
•Warm Up Time: five seconds minimum
•Operating Temperature: –50°C to 100°C
•Size of Probe: 0.75" diameter × 4.5" long
•Weight: 0.5lb
Figure 3-5. Solar Shield

National Semiconductor •SolarMagic Weather Station User Guide
12
3.7 PV Cell Temperature Sensor
The PV Cell Temperature Sensor temperature sensor measures the
temperature of the aluminum heat sink located on the face.
3.7.2 PV Cell Temperature Sensor Specifications
•Sensor Type: 100 Ohm Platinum Class A RTD
•Output: 4–20mA
•Range: –50° C to 85°C
•Accuracy: ±0.5° F or ±0.25°C
•Operating Voltage: 10–36VDC
•Current Draw: Same as sensor output
•Warm Up Time: 3 seconds minimum
•Storage Temperature: –55°C to 90°C
•Sensing Surface: 0.75” × 1.5” Aluminum
•Housing: 2.0W” × 1.1H” × 3.8L” ABS
•Weight: 13oz with 25’ of cable
3.8 Reference Cell/Temperature Sensor
The Reference Cell/Temperature sensor is a combination sensor with
an irradiation sensor via a temperature compensated mono-crystalline
silicon cell and a temperature sensor.
Figure 3-6.
PV Cell
Temperature Sensor

Chapter 3 • Planning
13
3.8.2 Reference Cell/Temperature Sensor Specifications
•Solar Cell: Mono-crystalline Silicone (1.96in x 1.3in)
•Output: 4–20mA
•Range: –20° C to 70°C
•Irradiance Accuracy: +/- 5%
•Temperature Accuracy: +/- 2%
•Housing: 3.3W” × 1.5H” × 5.7L” Powder coated aluminum, IP65
•Weight: 8.8oz
3.9 Communication Module
The weather station includes a data acquisition module that provides
analog-to-digital conversion. The modules can be remotely controlled
using a set of commands, the Modbus RTU protocol. Communication
between the module and the SolarMagic Internet gateway / data logger
is via Modbus RTU over 2-wire RS-485 twisted pair. The weather
station module is set to 9600 baud in manufacturing for a more robust
communications network, and typically Modbus address 2.
3.9.1 Communication Module Specifications
The M-7017C is an 8-channel current input module.
•Channels: 8 current inputs
•Input Range: 4–20mA, ±20mA, or 0–20mA
Figure 3-7.
Reference
Cell/Temperature Sensor

National Semiconductor •SolarMagic Weather Station User Guide
14
•Resolution: 16-bit
•Sample rate: Maximum 10 samples/second
•Bandwidth: 15.7Hz
•Accuracy: 0.1%
•Isolation: 3000VDC
•Indication LED Light For Power and Communication
•Communication: RS-485, Modbus RTU Protocol
•Power supply: 10–30VDC, 1.3W