Off-Grid energy Standalone Power Essential System User manual
Securing your power and your future
Standalone Power
Essential System™User Manual
Standalone Power : Essential System™ : User Manual
Copyright © 2014 Off-Grid Energy Australia Pty Ltd
1"
This page is intentionally left blank
Standalone Power : Essential System™ : User Manual
Copyright © 2014 Off-Grid Energy Australia Pty Ltd
2"
TABLE OF CONTENTS
!"#$%&"'((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((')!
*#%++,-.'/'0".'(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((('1!
2&3%-4,54'67+$#,7&"-'(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((('8!
9,:"4.'!,-575;+'(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((('<!
=,5>:,$4>-"-+'?+"-'=,5>,#+'(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((('<!
@%&"'A5"-;.'=%574%-'((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((('B!
6CDE?9'9.+4"&'C%5:7;>-,47%5'((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((('F!
AG>73&"54'H,.%>4'((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((('I!
25J"-4"-KCL,-;"-'((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((('MN!
E,44"-.'E,5O'((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((('MM!
Checking Battery State-Of-Charge (SOC)................................................................................................................................12!
Charging the Batteries...................................................................................................................................................................13!
Charging using Automatic Controlled Generators (Auto-start) .....................................................................................15!
9%#,-'PL%4%J%#4,7$'Q--,.'((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((('M<!
9%#,-'=PPR'CL,-;"'C%54-%##"-'((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((('MB!
QC'9S74$LT%,-U'(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((('MF!
Circuit Breakers.................................................................................................................................................................................18!
Switchboard Meters .......................................................................................................................................................................18!
6C'9S74$LT%,-U'(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((('MI!
V>"#'P%S"-"U'*"5"-,4%-'+"4'((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((('WN!
Auto-Starting Generator ...............................................................................................................................................................22!
Manual-Starting Generator..........................................................................................................................................................22!
R-%>T#"+L%%475;'(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((('W)!
9.+4"&'C,-"',5U'=,754"5,5$"'(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((('W<!
!,--,54.'(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((('WB!
C%54,$4'?+'(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((('WF!
Standalone Power : Essential System™ : User Manual
Copyright © 2014 Off-Grid Energy Australia Pty Ltd
3"
Welcome
Welcome to the user manual for the Standalone Power System installed by Off-Grid Energy Australia.
Please take your time to read and familiarise yourself with the contents of this document as it contains
important information about the operation, servicing, troubleshooting and limitations of the off-grid
system.
Retain this document in a safe and accessible location for future reference.
Contact Off-Grid Energy Australia if you need any further advice.
This user manual has been produced and published by Off-Grid Energy Australia Pty Ltd
This document cannot be replicated, copied or saved on public access servers in any form without prior approval
from Off-Grid Energy Australia
ABN: 65 149 378 281
Standalone Power : Essential System™ : User Manual
Copyright © 2014 Off-Grid Energy Australia Pty Ltd
4"
Glossary & Key
Danger: indicates a hazardous situation that can result in serious injury or death if not avoided
Important Disclaimer: includes actions and non-compliance that could compromise equipment
and void warranties
Maintenance: ongoing care and upkeep required to ensure full functionality and longevity
Additional Information: additional information and knowledge about the system and its
components
Information: essential related information
Power
A = Amp: a measurement of the rate of electrical flow in a circuit (a component of power)
V = Volt: a measurement of electrical pressure across two parts of a circuit (a component of power)
W = Watt: a measurement of instantaneous power. A watt is the product of multiplying Volts and Amps
kW = Kilowatt: a measurement of true instantaneous power; 1000 Watts make a Kilowatt
kVA = Kilo Volt Amp: a measurement of apparent power before it is corrected for current and voltage
waveform misalignment (power factor or pf) to make it true power or Kilowatts.
Energy
Ah = Amp hour: the product of multiplying amps and hours; often used to measure the current delivery
capacity of battery banks at a specific discharge rate and time period such as 20 or 100 hours etc. (It is only a
component part of energy)
Wh = Watt hour: a measurement of energy; it means watts delivered, calculated over a one hour period.
kWh = Kilowatt hour: a measurement of energy that is often used for billing purposes for example; it
means Kilowatts delivered, calculated over a one hour period. A Kilowatt hour is the product of Volt x Amps
x Hours x 1000. One Kilowatt hour = 1000 watt hours. Kilowatt hours are sometimes used to measure
battery energy storage capacity; it is calculated by multiplying Amp hours by the battery bank nominal
voltage (e.g. 1000Ah battery storage capacity @ C100 rating x 48V battery configuration = 48kWh over 100hr
rate)
Voltage classes
LV = Low voltage class: includes mains power and is applicable to all equipment operating above 120
Volts DC or 50 Volts AC and not exceeding 1000 Volts AC or 1500 Volts DC. LV class equipment can only be
serviced by a licenced electrician.
ELV = Extra Low voltage: this voltage is typically used in battery banks. ELV class applies to electrical
equipment operating below 120 Volts DC or 50 Volts AC
DC = Direct Current: refers to a current that flows in only one direction.
AC = Alternating Current: refers to a system utilising a current that rapidly flows back and forth; for
mains power equipment the current typically runs back and forth at 50 times per second.
Hz = Hertz: is the name given to the measurement of frequency of alternating current reversals or cycles
per second. Regarding generator sets the frequency in Hertz usually relates directly to engine speed. For
example a two-pole generator running at 3000 revolutions per minute will deliver a 50 Hz frequency.
M.P.P.T. = an abbreviation for Maximum Power Point Tracking; it means an advanced method of extracting
the maximum possible power from a solar array (usually) within the solar inverter or solar charge controller
as opposed to older type basic regulators which do not have this feature
Standalone Power : Essential System™ : User Manual
Copyright © 2014 Off-Grid Energy Australia Pty Ltd
5"
Important Disclaimer
Your Off-Grid Energy System has been carefully designed to supply a specific daily quantity of electricity –
determined during consultation and assessment of your Load Demand Profile
(included at the back of this
manual for reference).
All components have been carefully selected and the system constructed,
programmed and tested accordingly.
Equipment Settings:
NO programming changes are permitted to equipment without prior approval from Off-Grid Energy
Australia. Failing to do so will immediately void your warranty and may cause equipment malfunction.
Equipment Modifications:
NO removal, replacement, modification or addition to your equipment is permitted without prior approval
from Off-Grid Energy Australia. Failing to do so will immediately void your warranty and may cause
equipment malfunction.
Additional Appliances:
NO significant additional electrical appliances are permitted without prior approval from Off-Grid Energy
Australia (excluding those items already listed on your Load Profile). Failure to do so will immediately void
your warranty and may cause equipment malfunction. Even a new small appliance that runs 24hrs a day can
have a significant impact on system performance.
Instantaneous Power Limitations:
Remember that there are limits to the amount of power your Inverter & batteries can deliver:
If you use more power
(W/kW)
than the system can provide at any moment – E.g. by switching on multiple
large appliances simultaneously - then your system may automatically shut down to protect the inverter and
batteries.
Tip:There is additional power available at times when your renewable energy is producing (E.g.
solar panels during sunlight hours) or when your fuel generator is running. This power gets
layered/added to the peak power capacity of the Inverter/Charger. Therefore these are ideal times
for using heavier appliances.
Daily Energy Limitations:
Remember that there is a limited amount of energy available for use: If you use more energy
(Wh/kWh)
than
is available over a period of time – E.g. by running appliances more often than suggested on your Load
Profile or after prolonged periods of bad weather – then this energy needs to come from somewhere.
Tip:Use your batteries less and prolong their life by using electricity directly from your renewable
energy sources instead (E.g. if the sun is shining then your solar panels can bypass your batteries
and supply power directly to your home!)
BE FULLY PREPARED:
Careful attention should be paid to the health and management of your off-grid system to ensure smooth
operation for years to come:
(please refer to system components and maintenance requirements outlined in
this manual and in separate component manuals provided)
If the system receives proper usage, attention and care, then system faults or power failure is unlikely.
Nevertheless it is important to remain fully prepared with contingencies for power failure should you get
caught out: (please refer to Trouble Shooting section of this manual for further advice)
For any questions or if you require any additional information or advice on your Off-Grid Energy installation,
please contact Off-Grid Energy Australia on 1300 334 839.
Standalone Power : Essential System™ : User Manual
Copyright © 2014 Off-Grid Energy Australia Pty Ltd
6"
Safety Warnings
WARNING
Your standalone power system produces 230-volt AC power. Risk of lethal or serious injury from electric
shock can occur if mains voltage equipment is mishandled, modified, opened without authorisation, or if AC
wiring is installed or extended by unqualified personnel.
Generator sets usually produce 240 Volt AC power; a risk of lethal or serious injury from electric shock can
occur if a generator is mishandled or modified. A risk of lethal or serious injury from burns can occur if
generator fuel is mishandled. A risk of lethal or serious injury from carbon monoxide poisoning can occur if
generator exhaust gasses are inhaled. Always follow the generator manufacturer’s safety instructions.
Do not climb on a roof without height safety training and using the appropriate safety equipment.
Do not interfere with solar array wiring; ELV class voltage up to 120 Volts DC may be present which can
deliver an electric shock, although a shock from this class of voltage would not normally be lethal it can
cause a person to fall from a height and sustain lethal or very serious injury.
An Extra Low Voltage class battery bank if mishandled or short circuited can cause extremely high current
discharges which can cause severe burns; eye injury or death from a resulting fire or explosion. Keep all
metal objects and fuel away from battery banks; do not interfere with battery banks without sufficient
training and authorisation.
Please carefully read and follow further safety advice in this document; in addition always read and follow
the equipment manufacturer’s safety instructions; please contact OEA for advice if you have any questions
about safety issues.
Manufacturers User Manuals
In addition to this user manual, we highly recommend you take the time to read all the equipment
manufacturer’s user manuals supplied with relevant equipment. Please keep all manuals together in a safe
place near the equipment where they can be readily consulted if needed.
Standalone Power : Essential System™ : User Manual
Copyright © 2014 Off-Grid Energy Australia Pty Ltd
7"
Home Energy Monitor
The home energy monitor device displays your energy and power consumption. It wirelessly transmits
information from your circuit board to the LCD display. This is a good way to check that your usage remains
comfortably within your systems limitations and design parameters.
oEasily monitor the energy and power that you are using
oCompare this usage over days, weeks or months (kWh)
oAlerts you when you use excessive Instantaneous Power (kW)
oInformation stored can be downloaded to personal computer
Press the top “Function” button to change the information displayed
from instant to average
Further instructions are available in the separate Efergy manual provided.
Instant
Average
History
This is the amount of power you are
consuming at this very moment (kW)
This is your average consumption (kWh)
(Compare days, weeks or months)
Consumption records for the last 7
days, 7 weeks or 24 months.
Standalone Power : Essential System™ : User Manual
Copyright © 2014 Off-Grid Energy Australia Pty Ltd
8"
DC-BUS System Configuration
Also known as a DC-Coupled configuration, the battery bank system uses Extra Low Voltage (ELV) DC (12V,
24V or 48V) as the primary input sharing connection for the solar array and energy inputs. The solar power
working at a higher voltage (up to 120 volts) is fed into a Maximum Power Point Tracking (MPPT) charge
controller (advanced regulator), which then by step down converter action directly charges the battery bank
at a lower voltage, advantageously as the voltage is stepped down the current is stepped up by a similar
ratio.
When 230V AC power is required, the Inverter/Charger draws power from the Battery bank (DC) and
inverts/converts the power into 230V AC for normal household use via the AC switchboard.
To cover times of poor solar input or increased demand, a generator set can be plugged into the system; this
then charges the battery bank via the Outback Inverter/Charger, while the generator set is supplying power
for battery charging the Inverter/Charger will automatically switch generator power directly to the house to
keep the house powered at this time.
Standalone Power : Essential System™ : User Manual
Copyright © 2014 Off-Grid Energy Australia Pty Ltd
9"
Equipment Layout
Your system is an Off-Grid Energy Australia
Adapt
unit. This unit is the nerve centre of your system,
incorporating your Inverter/charger and all applicable circuit protection. All energy generators and loads are
centrally connected and controlled from here. The battery bank is also connected to the
Adapt
board but
remains separated by a short distance or other divider for safety compliance reasons.
WARNING
oVarious components operate at high DC and AC voltages. Apply caution at all times.
oDo not touch or forcibly pull any electrical wiring connected to the system.
oDo not switch on your system if you observe any damaged or exposed cables.
oNo smoking or naked flames in enclosure area.
oKeep spark producing equipment and machinery away from the battery bank
AC
Switchboard
Outback
Inverter/Charger
Inverter/Charger &
Charge Controller
DC Battery Fuse
Disconnect
State of Charge
Meter Fuse
PV Array DC Isolator
(Located near MPPT
Charge Controller)
Battery State of
Charge Indicator
Solar MPPT Charge
Controller
Generator Inlet Plug
(15 Amp Socket Only)
Standalone Power : Essential System™ : User Manual
Copyright © 2014 Off-Grid Energy Australia Pty Ltd
10"
Inverter/Charger
The Outback Inverter/Charger is a robust battery inverter/charger that converts DC
battery bank voltage into mains 230V power.
When required, the Outback Inverter/Charger converts DC electricity from the battery bank into regular
230V 50Hz AC appliance friendly electricity for use. When the battery bank becomes low on charge it can be
recharged via the internal battery charger and a conventional 230V AC fuel powered generator set.
Inverter/Charger Operation
The Inverter/Charger has been pre-programmed before the installation to optimize its operation for your
specific requirements. The settings should not need adjusting.
(See disclaimer)
Status LED Lights
The top three lights on the inverter/charger indicate battery charge status at night only; where a separate
battery status indicator is installed the inverter battery status indicator lights will be blanked off to prevent
confusion. The bottom three-inverter status lights indicate:
The Green inverter light illuminates when the inverter is operating normally; if the light is flashing the
inverter is in Power Save / Search mode (Note: Power save/search mode is not normally activated).
A Flashing yellow AC In light indicates power is being received from the generator set and is being
monitored for 60 seconds while the generator is allowed to warm up.
If the yellow light continues to flash after this time this indicates the generator is not delivering voltage or
frequency within a safe range therefore the inverter/charger will disallow connection for safety reasons; the
generator will require repair or adjustment.
If the yellow AC In light does not flash at all no power is being received, recheck all plug connections are
correct and all circuit breakers are switched on.
The Yellow AC In light changes to solid yellow after 60 seconds once the fuel generator power is
transferred to the inverter/charger and switchboard, to indicate correct operation.
The Red error light indicates when an error fault condition has occurred with the inverter/charger. See the
Trouble shooting section.
oBattery Status information –
(See Battery SOC)
oLED’s and other status messages –
please refer to the separate Outback User Manual provided
oStart-up and Shutdown procedures –
instructions displayed on Inverter/Charger.
(Also see
Troubleshooting)
WARNING
oDo not touch or forcibly pull any electrical wiring connected to the inverter.
oDo not remove/open the inverter’s front cover.
oDo not switch on the inverter if you observe any damaged or exposed cables.
Use
Battery management and power delivery
Configuration
DC Bus systems
Inverter Input
Batteries – via DC switchboard
Inverter Output
230V AC to house loads – via AC switchboard
Charger Input
230V AC from fuel powered generators
Charger Output
Regulated DC Voltage for charging batteries – via DC switchboard
Standalone Power : Essential System™ : User Manual
Copyright © 2014 Off-Grid Energy Australia Pty Ltd
11"
Battery Bank
Batteries are a critical part of your Off-Grid Energy System as they store energy produced
by the renewable energy and fuel powered generators to be used at times when these
aren’t available.
The batteries have been carefully sized to meet your requirements according to your Load Demand
assessment. Although sealed-gel batteries do not need fluid top up like wet-cell batteries, they do need
careful looking after to guarantee safe operation and a long service life.
oHeavier demand leading to more frequent and deeper discharge/cycling than planned will shorten the
designed service life.
oNot fully recharging the battery bank on a regular basis will shorten the designed service life.
oAn average storage temperature of between 20°C -25°C will help preserve battery service life. Lower
temperatures temporarily decrease available capacity but higher temperatures decrease battery life
expectancy and should be avoided. Temperatures above 40° C should be avoided as far as possible by
implementing good cross ventilation and shading etc.
WARNING
oKeep batteries well ventilated with good cross-air flow
oKeep battery enclosure locked at all times
oKeep battery area clean from dirt and vermin at all times
oKeep battery area free of flammable fuels
oDO NOT touch any exposed cables or connections
oNo smoking near batteries
oNo naked flame near batteries
oNo spark causing items near batteries
oNo conductive items capable of falling on battery terminals near batteries
oDO NOT attempt to move batteries
oDO NOT remove safety labels
oThe following safety labels must remain displayed at all times in the battery enclosure
Use
Energy Storage
Battery Input
Regulated DC Voltage from the integrated charger – via DC switchboard
Battery Output
DC Voltage to Inverter/Charger – via DC switchboard
Battery Type
Lead Acid – Sealed Gel (Valve regulated no fluid top up required)
Standalone Power : Essential System™ : User Manual
Copyright © 2014 Off-Grid Energy Australia Pty Ltd
12"
Checking Battery State-Of-Charge (SOC)
Deep cycle batteries can be discharged and recharged (cycled) a set number of times during their service
life. Your system has been designed so that the batteries on average should only experience relatively small
daily cycles, thereby spreading these cycles out over a longer period of time.
Regularly use one of the following methods to determine the battery bank SOC.
1. MidNite State of Charge Display – This state of charge % display responds to
battery bank rest voltage, DO NOT READ THIS WHILE BATTERIES ARE ON CHARGE (False
high reading); FOR BEST RESULTS READ AT NIGHT ONLY with no major appliances
operating. The vertical last full re-charge status LED lights column on the far left hand side of the display can
be read at any time.
2. Charge controller MPPT – The Outback FM60 or FM80 charge controller home screen displays active
battery voltage (E.g. “Out 24.5 V”); use the chart over the page to read and compare the battery state of
charge approximation as per this voltage reading. Make sure you select the correct system voltage column
and present operating status (Night/Day/Generator) since the relationship between
voltage and state of charge is variable depending on its mode of use.
3. Mate2 display - The battery voltage can also be read remotely using a Mate 2
display / controller if this option has been installed. If necessary use the Outback
Mate 2 user manuals to assist navigating the user menus.
The mate2 controller can be used to navigate system information and parameters. It
can also be used to alter settings and programing if necessary.
Important Disclaimer: Changing of system programing without the prior approval of Off-Grid Energy
Australia may void your warranty. Contact Off-Grid Australia before attempting to adjust any programing or
parameters.
State of Charge
Scale LED Colour
Description
What to do
Green
Good – acceptable SOC level
Nothing, but keep an eye on SOC
Yellow
Ok – but don’t let it get to this level
frequently if you can manage it
Slightly reduce loads but not essential
Red
Bad – minimise use in this zone to
prevent loss of battery bank life
expectancy
Reduce loads and immediately start the generator.
Complete a full charging cycle
Standalone Power : Essential System™ : User Manual
Copyright © 2014 Off-Grid Energy Australia Pty Ltd
13"
Charging the Batteries
The charging of the batteries from the solar array is completed by the Solar MPPT Charge controller or with
the assistance of the fuel powered generator set via the inverter/charger as required. The MPPT Charge
controller has advanced charging methods to ensure power delivery from the solar panels is optimised in all
conditions and that the most appropriate charging modes; Bulk; Absorb; Float; Sleeping; or Equalising are
automatically selected.
Battery Voltage State of Charge Guide
Read battery voltage from the Charge controller display.
oThese voltage figures must be maintained for at least two full hours to complete an absorption cycle,
this will bring the batteries close to full charge.
oThis chart is only approximate. Temperature, current flow and battery capacity will influence the
readings.
At night
Sunny day
Voltage
Generator
running
Voltage
State of charge (SOC)
What to do
50.4V
>57.0V*
>57.0V*
Great – keep this up and your
batteries will last a long time!
Nothing
49.2V
56.0V
57.0V
Good – acceptable SOC level
Nothing, but keep an eye on SOC
48.0V
53.2V
54.0V
Ok – but don’t let it get to this level
frequently
Slightly reduce loads but not
essential
47.5V
50.4V
51.2V
Not good – below 50% is negatively
affecting the batteries, especially if
this happens regularly
Reduce loads to allow batteries to
recharge. Generator may also be
needed
45.6V
48.0V
48.0V
Bad – Unusable zone, the system
may shut down to protect itself
Reduce loads and immediately start
generator. Complete full charging
cycle
Standalone Power : Essential System™ : User Manual
Copyright © 2014 Off-Grid Energy Australia Pty Ltd
14"
Typical charging sequence of the FM60/80
A typical daily charging regime is outlined in the graph below – overseen and managed by the Outback
FM60 or FM80 Charge controller
.
Full Charge Procedure (Recommended every 10-days)
Follow these steps to achieve a battery maintenance full recharge every 10 days - if your available solar
power has not been sufficient enough to complete this task.
1. Firmly plug the generator into the inlet socket on the equipment board.
2. Start the Generator manually.
3. Allow the generator to run until the battery charger absorption set-point voltage is reached (about
29 volts for a 24-volt or 58 volts for a 48-volt battery system). Use the MPPT Charge Controller
display to monitor battery bank voltage - This reads as Out___V battery voltage.
4. Run the generator for at least another 2hrs to fully absorb the final charge. The battery voltage will
level off for the final 20% of the charging period however the charge is still being absorbed.
5. Stop the generator when complete.
Bulk Charge Procedure
If your generator is used regularly due to extended overcast weather conditions or increased demand then
you may occasionally skip a full recharge and instigate a Bulk Only partial recharge to save generator fuel.
Fully recharging the battery bank once every 10 days is still necessary for proper battery bank performance.
Proceed as follows for a bulk only recharge:
1. Firmly plug the generator into the inlet socket on the equipment board.
2. Start the Generator manually.
3. Allow the generator to run until the battery charger absorption set-point voltage is reached.
4. Stop the generator at this time; this procedure should achieve a SOC level of about 80% only.
Equalisation Charge Procedure (Recommended min 2x per year)
Battery equalisation is an important battery maintenance process that is usually required twice a year, or
more depending on system use (at the beginning and end of winter is ideal). It removes excess build-up of
sulphation on the plates of the battery cells, and balances the charge in the cells.
Once every six months complete a bulk recharge first; then run the gen-set for an additional 5hrs.
Alternately you may choose to equalise the battery bank four times annually as per above but use a 3-hour
duration instead after the bulk charge is completed.
Equalising should not be carried out in very hot weather; battery bank temperature should be monitored
during equalising, and should be terminated if the battery cell temperatures reach 35 degrees (and must be
terminated if 40 degrees Celsius is reached).
Mate 2 Notes - If your system has a Mate 2 display / controller option installed
you should manually select the equalising function here on the Mate 2 unit, to
Start and stop an EQ cycle proceed as follows:
Pressing the <EQ> key from the SETUP INV CHGR MENU brings up the EQUALIZE CONTROL screen.
This screen allows the MATE2M to issue system wide (global) charger commands.
When the <START> has been selected, two screens are displayed. The user then must answer <YES>
before an equalization charging cycle will begin.
You can stop the equalisation cycle at any time by selecting <STOP> from this control screen.
Standalone Power : Essential System™ : User Manual
Copyright © 2014 Off-Grid Energy Australia Pty Ltd
15"
Charging using Automatic Controlled Generators (Auto-start)
If your power system has an automatically controlled generator set with an auto-start function installed, the
generator will start and stop as required only for full recharge cycles. Bulk or equalisation charging does not
occur automatically and requires manual intervention.
When necessary switch the generator auto-start controller from Auto mode over to Manual run mode and
follow the Equalise Mode Charging instructions above. It is most important to remember to switch back to
Auto mode when complete. With an auto-start controlled generator the bulk only mode is not
recommended because of the higher possibility of user error.
Remember to regularly check generator fuel, oil and coolant levels, since these are more easily forgotten
when a generator is automatically controlled.
Standalone Power : Essential System™ : User Manual
Copyright © 2014 Off-Grid Energy Australia Pty Ltd
16"
Solar Photovoltaic Array
The solar array is the primary source of energy for this stand-alone power system.
Solar panels convert sunlight (not heat) into DC electricity. Many variables affect their
output production, including temperature, irradiance levels and sunlight hours. The
amount of energy generated from the solar panels varies seasonally as well as day-to-
day depending on weather variation.
Solar panels almost never produce their rated peak power output, as this is simply a measurement in test-
conditions. As an example, 3kW of solar might produce anywhere from 0W (night) – 2.8kW (on a cool, clear
day with sun adjacent to the solar panels). There are many factors at work when solar converts light to
electricity!
Also be aware the Charge controller will cut power production back at times to ensure the battery bank is
not being charged too quickly or is not being overcharged.
WARNING
oDo not touch or forcibly pull any electrical wiring connected to the solar array.
oDo not touch or come in contact with a solar module if it is found to be broken or has cracked glass –
risk of electrical shock
oBe very careful when cleaning panels at heights (OEA recommends using heights trained personnel)
Solar Array DC-Isolator
The solar DC-Isolator is usually located next to the solar array on the roof or on an adjacent
wall near the array.
This device can be used to stop the flow of DC-Voltage electricity from the solar array to
the solar MPPT/charger if necessary for electrical maintenance purposes.
CAUTION: More than one DC- Isolator may be installed, make sure all are switched off
as required.
Use
Convert sunlight into DC Voltage electricity
Solar Input
Converts solar irradiance/light into DC voltage electricity
Solar Output
DC voltage electricity to solar MPPT Inverter or Charge controller
Standalone Power : Essential System™ : User Manual
Copyright © 2014 Off-Grid Energy Australia Pty Ltd
17"
Solar MPPT Charge Controller
The MPPT (Maximum Power Point Tracker) continually works to maximise the amount of power
coming from the solar array for recharging the battery bank. It works fully automatically in several
different modes of operation, which are: Bulk, Absorb, Float, Sleep, and Equalising modes.
The MPPT charge controller, apart from maximising power production also protects the battery bank from
any possible overcharging from the solar array. The charge controller also displays:
oSolar array output current
oSolar array operating voltage
oGross output current going to battery bank and inverter/charger
oBattery bank voltage
The MPPT is not interconnected with the inverter/charger and cannot be used to adjust Inverter or auto-start
functions or parameters.
Programming of the MPPT can only be adjusted by the use of a password. Adjustments to programming of
the MPPT or inverter without prior approval from Off-Grid Energy Australia are prohibited. Unauthorised
adjustment may affect your warranty.
For a full operational description of your Solar MPPT Inverter, please refer to separate Operating Manual
supplied
WARNING
oDo not touch or forcibly pull any electrical wiring connected to the inverter.
oDo not remove/open the inverter’s front cover.
oDo not switch on the inverter if you observe any damaged or exposed cables.
oRISK OF SEVERE ELECTRIC SHOCK
Charge Controller Home Screen Display
Refer to manufacturers’ User Manual for more details
Use
Solar MPPT Charge Controller
Configuration
DC-Bus systems only
Input
Solar array – DC Voltage (up to 120V max)
Output
DC Voltage to Battery Bank
Standalone Power : Essential System™ : User Manual
Copyright © 2014 Off-Grid Energy Australia Pty Ltd
18"
AC Switchboard
The AC switchboard is the location for all 230V connections and safety devices.
Circuit Breakers
Main Switch (Normal Supply)
Off: Shuts off all house loads and area loads (typically shed power) that are powered by the system.
On: The house switchboard, house circuits and all connected outbuildings are energised.
Sub-Board Isolator
Used to supply power to the house switchboard, it can be used to isolate only the house switchboard while
leaving other local area power circuits energised for example.
Residual Current Devices/Circuit breakers
These devices marked “Power and “Light” are conveniently reserved for directly powering up added local
area power loads such as in the shed where the equipment is installed. They provide protection against over
current or earth leakage faults at this location. Note: Does not provide protection to loads connected via
the house Sub board circuit isolator, this is typically proved at the household switchboard.
Generator Circuit breaker/Isolating Switch
This provides over current protection or allows manual isolation of the 230V AC fuel powered generator set.
Contactor (marked cont.)
Note: Not applicable to EM model Inverter/chargers
This device automatically isolates any generator sockets or plugs from the AC switchboard once unplugged.
The device has a small flag status indicator in a clear window; a red flag indicates the circuit contacts are
connected, while a green flag indicates the device is isolating the circuit. No user intervention is required.
Switchboard Meters
House Energy Meter: a digital meter keeping record of the entire households’
energy consumption (kWh). Press the mode button twice to view instantaneous ac
power consumption in kilowatts.
Generator Meter: a digital meter keeping record of all generator energy delivered into the system (kWh)
Note: This meter will only show digits when the generator is running.
Use
Holds the AC circuit breakers
Configuration
AC-Bus and DC-Bus systems
Input
All applicable AC inputs – inverter/charger; fuelled generator
Output
230V AC – to house loads
Standalone Power : Essential System™ : User Manual
Copyright © 2014 Off-Grid Energy Australia Pty Ltd
19"
DC Switchboard
Battery Fuse Disconnect Switch
The DC switchboard/battery disconnection consists of the pull down handle and fuse inserts. The switch
and fuse assembly contains up to three High Rupture Current (HRC) type fuses. These are used as the main
battery fuse protection, the fuses are specifically sized to suit your unit, the fuse sizes will be marked on the
battery fuse disconnect unit.
NOTE: SHUTDOWN SYSTEM BEFORE DISCONNECTING THIS SWITCH
Incorrect operation may cause damage.
(See Shutdown procedure displayed on inverter/charger; also see Troubleshooting)
Only use as a part of the full shut down procedure for the purposes of:
oMaintenance
oRepairs
oAs part of the system restarting procedure
oWhen vacating property for extended periods so that electricity is not
required
oEMERGENCY disconnect in the event of a major malfunction or fire etc.
HRC fuses are located in the handle of the assembly
(as per picture)
Always follow the official shutdown procedure displayed adjacent to the
inverter/charger. If a shutdown procedure is not displayed then contact OEA to obtain
a replacement specific to your system. Use firm pressure to fully reclose the battery
disconnect handle.
PV Array DC Isolator Switch
Used to isolate or connect the Extra Low Voltage class direct current output (up to 120 VDC)
of the solar array to the MPPT Charge controller.
Use
Simultaneously connects/disconnects and protects main DC circuits
Configuration
DC-Bus systems
Connects
Inverter/Charger, Charge Controller, and Battery Bank
Output
DC sharing point for Inverter/Charger, Charge Controller and Battery Bank
Table of contents
