Solar Pump Controller User Manual
Contents
1. fault tonadi Gd ume Check communication communication devices and cables interruption Reserved pose Wiles or Check the wiring and connectors of control connectors board F018 Current Amplifying circuit detection fault sbnormal Hall sensor is damaged Ask for suppor Power circuit abnormal Inconsistence between Replace with the proper l controller and motor rating controller E019 Auto tuning fault Improper setting of motor rated parameters Set rated parameters according to motor nameplate 2 36 Solar Pump Inverter Novaplus Solar Pump Inverter Fault description Possible causes Remedy Bigger tolerance of parameters against Make motor uncoupled with standard parameters load and auto tune again Auto tuning fault after auto tuning Check motor wiring and Overtime of auto tuning parameters setting Well Level Dry well or slow water Waiting water recovery or re Fault E020 recovery install the pump Wait until water level comes Tank Level e Wa High level limit is below the low level limit and Fault E021 reached then the solar pump controller before auto start i will start the pump again Read Write fault of EEPROM fault control parameters EEPROM damaged Ask for support Push STOP RESET to reset 40 7 2 Common Faults and Remedies Controller may have following faults or malfunctions during operation please refer to the2. Figure 21 Solar Panels Wired in Combination Series Parallel 45 Novaplus Solar Pump Inverter Appendix Generator Selection Information Optional General Information Not all AC generators will perform sufficiently with the solar pump controller Always consult the generator manufacturer for application specific information In a solar pump controller AC input current flows directly through an input rectifier into a storage capacitor with no active power factor correction PFC circuitry Because of variation of generator performance when connected to an input circuit like this it is recommended that a suggested minimum kVA rating be obtained from the generator supplier for this type of application input rectifier to capacitor no PFC The AC input of a solar pump controller draws current only near the peaks of the sine wave generator voltage This pattern of current peaks may distort an input sine wave voltage limiting the generator s ability to maintain a voltage level required by the controller This behavior is typical for equipment without dedicated power factor correction circuits A generator s ability to provide low distortion voltage during such operation is limited by a generator parameter called sub transient output reactance The lower the sub transient output reactance the better the generator can maintain a low distortion sine wave output voltage Generators with greater to or at least e
3. e Make sure that the external DC disconnect switch is off e Make sure that AC power is disconnected if AC power supply is wired as backup power e Make sure that all wires are properly identified and marked a the cable from the PV to the external DC disconnect switch b the cable from the external DC disconnect to the solar pump controller 21 Novaplus Solar Pump Inverter AA CAUTION Do not connect a solar array directly to the DC input of the solar pump controller without protection such as DC disconnect switch In this controller the integral solid state short circuit protection of motor wiring does not provide circuit protection of wiring for input power Input wiring protection must be provided in accordance with all applicable national and local electrical codes In addition follow any manufacturer s recommendations for protection of a photovoltaic PV array and protection of a generator if used 4 3 Ground Wiring Ground terminal GND is labeled as this icon Please refer to the instruction to this icon or other equivalent icon or sign by local electrical codes or international standard Connect the ground wire to the ground terminal of solar pump controller Correct Grounding helps to prevent shock hazard if there is a fault in the motor See Figure 11 A WARNING Serious or fatal electrical shock may result from failure to connect the ground terminal to the motor
4. RPC10 4T5R5 144 4 237 RPC10 4T7R5 RPC10 4T011 RPC10 4T015 156 6 378 3 364 396 214 221 7 190 5 RPC10 4T18R5 RPC10 4T022 RPC10 4T030 235 447 463 285 289 6 210 3 7 RPC10 4T037 RPC10 4T045 260 380 390 284 8 RPC10 4T055 473 485 318 RPC10 4T075 343 674 650 701 5 10 Table 3 Solar Pump Controller Dimensions 15 Novaplus Solar Pump Inverter 3 Installation A WARNING High voltages both AC and DC capable of causing severe injury or death by electrical shock are present in this unit This unit should only be installed or serviced by technically qualified professionals Anytime working on or near the solar pump controller or system e Turn OFF the external DC rated disconnect from the solar array to the solar pump controller e Ensure AC power has been disconnected from the solar pump controller if used e Wait a minimum of 5 minutes after removing power from the solar pump controller before servicing READ THESE INSTRUCTIONS COMPLETELY BEFORE INSTALLATION Note During installation if a conflict arises between this manual and local or national electrical codes the applicable local or national electrical codes should prevail e The longevity and performance of the solar pumping package may be adversely affected by improper installation e The solar array structure modules and wiring harness must be properly assembled accordin
5. Supporting Alternating Current input with voltage rating of 220VAC single phase connecting to terminal R amp T Note 2 Supporting Alternating Current input with voltage rating of 3830VAC three phase connecting to terminal R S and T Table 1 Solar Pump Controller Model Description 07 Novaplus Solar Pump Inverter 2 5 Solar Pump Controller Specifications Controller Model RPC10 2SR75 RPC10 2S51R5 RPC10 2S2R2 Alternate AC Generator Input Data PV Source Max Input Voltage Voc V 450V Min Input Voltage at mpp V 180V Recommended voltage at mppt 280VDC 360VDC Max Amps Input A 4 3 8 6 12 5 Recommended Max Power at mppt kW 1 2 2 4 3 5 General Data Ambient Temperature Range Input voltage 220 230 240V AC 15 Single Phase Max Amps RMS A 8 2 14 0 23 0 Power and VA capability kVA 2 0 5 0 7 5 Output Data Output Power rated kW 0 75 1 5 2 2 Output Voltage rated 220 230 240V AC Three Phase Max Amps RMS A 4 5 7 0 10 Output Frequency 0 50Hz 60Hz Protection Surge protection Integrated Overvoltage protection Integrated Undervoltage protection Integrated Locked pump protection Integrated Open circuit protection Integrated Short circuit protection Integrated Overheated protection Integrated Dry run protection Integrated 20 C 60 C gt 45 C Derating as required Cooling Method Fan Cooling Ambient Humidity lt 95 RH Dimens
6. adds for each panel in series e Current Amps remains the same as a single panel in the series eo DC Breaker E Figure 19 Solar Panels Wired in Series Solar Panels Wired in Parallel When solar panels are wired in parallel the positive terminal of one solar panel is wired in to the positive terminal of the next solar panels Likewise the negative terminals are connected together to the negative terminals of the next solar panels When panels are connected in parallel e Voltage remains the same as a single panel in the parallel connection e Wattage accumulates adds for each panel added e Current Amps accumulates adds for each panel wired in parallel HEL PO roe DC Breaker E Figure 20 Solar Panels Wired in Parallel 44 Novaplus Solar Pump Inverter Solar Panels Wired in Combination Series parallel combination wiring requires that at least two sets or strings or panels wired in series are connected in parallel When panels are connection in combination e Voltage accumulates adds for each panel in a single series circuit but does not accumulate for additional strings wired in parallel e Wattage accumulates adds for each panel in a single series string AND each string in parallel circuit all panels in the array contribute additively to the total Wattage e Current Amps remains the same for single panels in a series but accumulates adds for additional strings connected in parallel
7. s soft start feature this will not harm the motor Over Temperature Foldback The solar pump controller is designed for full power operation from a solar array in ambient temperatures up to 60 C Under extreme thermal conditions the controller will reduce output power in an attempt to avoid shutdown Full pump output is restored when the controller temperature cools to a safe level Level Control Switch Up to four level control switches can be wired into the solar pump controller for water level control This is optional and is not very necessarily required to run the solar pump controller The solar pump controller can be used with one to four control switches or none at all This provides the user maximum adjustability when using the solar pump controller See INSTALLATION section for more information on installing and using control switches Switching to Backup AC Power The solar pump controller s input power terminal may be switched manually to a backup AC power source If there is sufficient voltage measured from the primary source solar array the controller draws from it to run the pump The solar pump controller can be manually switched to the alternate backup supply input if 02 Novaplus Solar Pump Inverter e The solar array input cannot provide at least 180 VDC 220VAC motor output or 350VDC 380VAC motor output to successfully start the motor AND e Generator backup power is available at the AC backup ter
8. 2 Common Faults and REMEICS cccccceecseeeeeeeeeeeeeeeceeeneeueeeeaeeeaeess 41 8 Periodic Mamtenance 42 9 Solar Array E 43 9 1 Example 255W Monocrystalline Solar Array Cumes 43 9 2 Solar Panel Wiring Configurations ccccccesccccseseecseseeeneseeeneeeeess 44 APPONdIX E 46 Novaplus Solar Pump Inverter Safety Information A NOTICE Important information for installers of this equipment This equipment is intended for installation by technically qualified personnel Failure to install it in compliance with national and local electrical codes and within manufacturer recommendations may result in electrical shock or fire hazard unsatisfactory performance and equipment failure The installation information is available from pump manufacturers and distributors and directly from the solar pump controller manufacturers A WARNING Serious or fatal electrical shock may result from failure to connect the motor control enclosures metal plumbing and all other metal near the motor or cable to a proper earth ground in accordance with local codes using wire no smaller than motor cable wires To reduce risk of electrical shock disconnect power before working on or around the water system Do not use motor in swimming areas A WARNING High voltages both AC and DC capable of causing severe injury or death by electrical shock are present in this unit More than one disconnect switch may
9. Input Data PV Source Max Input Voltage Voc V 750V Min Input Voltage at mpp V 350V Recommended voltage at mpp 500VDC 600VDC Max Amps Input A 35 2 48 0 57 6 Recommended Max Power at mpp kW 17 6 24 0 29 6 Alternate AC Generator Input voltage 380V AC 15 Three Phase Max Amps RMS A 26 0 35 0 38 0 Power and VA capability kVA 17 0 23 0 25 0 Output Data Output Power rated kW 11 0 18 5 Output Voltage rated 380V AC Three Phase Max Amps RMS A 25 0 32 0 37 0 Output Frequency 0 50Hz 60Hz Protection Surge protection Integrated Overvoltage protection Integrated Undervoltage protection Integrated Locked pump protection Integrated Open circuit protection Integrated Short circuit protection Integrated Overheated protection Integrated Dry run protection Integrated General Data Ambient Temperature Range 20 C 60 C gt 45 C Derating as required Cooling Method Fan Cooling Ambient Humidity lt 95 RH Dimensions H W D mm 364 214 190 5 Gross Weight kg 9 8 9 8 10 0 Standard Warranty month 18 Certificates IEC EN 61800 5 1 IEC EN 61800 2 2004 IEC EN 61800 3 2004 CE Table 2 4 Solar Pump Controller 11 18 5kW 380VAC 3 phase Specifications 2 Novaplus Solar Pump Inverter Controller Model RPC10 4T022 RPC10 4T030 RPC10 41T037 Input Data PV Source Max Input Voltage Voc V Min Input Voltage at mpp V 350V Recommended voltage at mpp 500VDC 600VDC Max Amps Input A 96 0 Reco
10. and bottom center mounting holes and secure mounting screws not included 19 Novaplus Solar Pump Inverter 4 Electrical Wiring 4 1 Terminals The following are typical figures of terminal blocks Note Terminals are different in shapes and combinations depending on different sizes of solar pump controller Control Terminals Main Terminals Figure 7 Terminals Arrangement of solar pump controller 11kW size with lower part of front cover been cut away Figure 9 Control terminals 11kW Die Novaplus Solar Pump Inverter A WARNING Capacitors inside the solar pump controller can still hold lethal voltage even after power has been disconnected Allow 5 minutes for dangerous internal voltage to discharge before removing solar pump controller cover to access the terminals 4 2 Power In DC Wiring For Solar Pumping Systems a two pole DC disconnect switch must be installed between the solar array and the solar pump controller Connect the cables which comes from the two pole DC disconnect Switch downstream terminals marked with and positive and negative poles of Solar panel output to solar pump controller s terminals block labeled as R T Do not over tighten the screws See Figure 11 A WARNING Before connect DC wiring following the steps below to prevent hazardous electric shock resulting in serious injury or device burning
11. be required to de energize the equipment before servicing This unit should only be installed or serviced by technically qualified professionals Anytime working on or near the solar pump controller or system e Turn OFF the external DC rated disconnect from the solar array to the solar pump controller e Ensure AC power has been disconnected from the solar pump controller if used e Wait a minimum of 5 minutes after removing power from the solar pump controller before servicing A WARNING Solar panels that have been exposed to full solar insolation for an extended period of time can achieve high temperatures and could be a potential source of burns to exposed skin if contacted Use caution when working around solar arrays Novaplus Solar Pump Inverter 1 How it Works 1 1 General Introduction The solar pumping system serves to provide water in remote applications where electrical grid power is either unreliable or unavailable The system pumps water using a high voltage DC power source such as an photovoltaic array of solar panels Which is abbreviated as solar array in this manual Since the sun is only available during certain hours of a day and only in good weather conditions the water is generally pumped into a storage pool or tank for further usage and water sources are those natural or special such as river lake well or waterway etc Two level switches one is High Level Switch the other is Lo
12. following remedies 7 2 1 No display after power on 1 Inspect whether the voltage of power supply is the same as the controller rated voltage or not with multi meter If the power supply has problem inspect and solve it 2 Inspect whether the three phase rectify bridge is in good condition or not If the rectification bridge is burst out ask for support 7 2 2 Power supply switch trips off when power on 1 Inspect whether the input power supply is grounded or short circuit Solve this problem 2 Inspect whether the rectify bridge has been burnt or not If it is damaged ask for support 7 2 3 Motor doesn t run after controller works 1 Inspect if there is balanced three phase output among U V W If yes then motor could be damaged or mechanically locked 2 If the output is unbalanced or lost the controller drive board or the output module may be damaged ask for support 7 2 4 Controller displays normally when power on but switch at the input side trips when running 1 Inspect whether the output side of controller is short circuit If yes ask for support 2 Inspect whether ground fault exists If yes solve it 3 If trip happens occasionally and the distance between motor and controller is too far it is recommended to install output AC reactor 4 Inspect whether the output module is burnt or not If yes ask for support A7 Solar Pump Inverter Novaplus Novaplus Solar Pump Inv
13. on the mounting pole for the solar array underneath the array for protection from the sun heat and weather elements e Keep the surrounding area clear of vegetation e Do not block airflow around the solar pump controller heat sink e Limit access of animals to the system e Protect wires from damage from wildlife and weathering by using conduit For additional protection bury the conduit in the ground s17 Novaplus Solar Pump Inverter 3 2 Control Box and Controller Location Selection The solar pump controller is intended for operation in ambient temperatures gt 50cm up to 60 C The following recommendations will help in the selection of il the proper location for the gt 500m solar pump controller Figure 5 Control Box and Controller Location AA CAUTION When using an alternate AC power source the ambient temperature is limited to 40 C for full power delivery e The solar pump controller must be installed into a control box which has a tight enclosure to avoid direct sunshine rain dust moisture animals plants etc The control box should has a bottom gland plate for installing wire cord or conduit To decide the size of control box Please refer to the following Figure 6 PLA LG a Ua Ae oust rt Ventilation o 4 aks Hot Air Ventilation 100mm and above et OF AT 4915 Ian pump Air Flow controller 100mm and above BALDAD IN TET Figure 6 Venti
14. switch can be set to NO or NC contact type from the USER DEFINABLE PARAMETER F5 27 When the LOW level switch acts as the water falls below LOW level threshold the solar pump controller starts the pump thus supply water to the tank or pool When the HIGH level switch acts as the water rises higher than HIGH level threshold the solar pump controller stops the pump to prevents water overflow Set the HIGH and LOW level switch threshold to appropriate value thus prevent the pump from switching on and off frequently See USER DEFINABLE PARAMETER F85 27 in operation section of manual for instructions Once it shuts off the solar pump controller then waits to run again until the switch reads CLOSED Mi Me wo jcom ma m5 me com 24v Figure 13 Well Tank Water Level Switch Wiring Connections 25 Novaplus Solar Pump Inverter 4 5 4 Well amp Tank Level Switches Position Figure 14 shows the demo of four level Switches installation position High Level High Level Low Level Low Level Pool Tank Well Pond Figure 14 Demo of Well amp Tank Level Switches Installation A CAUTION Tank level switch configurations are superseded by the Well level switch If the well switch detects low flow it will OPEN and override the run signals sent by the tank level switches to protect the well motor and controller 4 5 5 System Wiring Diagram oe om oe m A od Control switch Fl
15. the solar pump controller metal plumbing and all other metal near the motor or cable to a proper earth ground in accordance with local codes using wire no smaller than motor cable wires To minimize risk of electrical shock disconnect power before working on or around the solar pumping system Do not use motor in swimming areas SE Novaplus Solar Pump Inverter 4 4 Motor Wiring Connect the cable with four wires from the Motor to the controller terminal block to terminals U V W and GND See Figure 11 Do not over tighten the screws Motors with international leads are as shown in the table in Figure 10 Check motor lead color to ensure correct installation Note To reverse direction of motor rotation reverse any two wires US Black BLK International Gray GRY Red RED Yellow YEL Ground GND Black BLK Browm BRN Ground GND Figure 10 Motors with international leads Power in DC wiring Figure 11 Main Terminals Wiring aD 4 5 Control Circuit Wiring Optional The solar pump controller can be operated with control switches to control the controller ON OFF and water level switch sensing and control High Low pumping range Use a normally closed low voltage control switch with a contact rating suitable for instrumentation use i e Max 24 V 15mA 4 5 1 ON OFF Control Switch Operation Optinaltion e Solar pump controllers can be turned ON OFF by
16. 9 Novaplus Solar Pump Inverter Controller Model RPC10 4T7R5 Input Data PV Source Max Input Voltage Voc V 750V Min Input Voltage at mpp V 350V Recommended voltage at mpp 500VDC 600VDC Max Amps Input A 12 8 17 6 24 0 Recommended Max Power at mpp kW 6 4 8 8 12 0 Alternate AC Generator Input voltage 380V AC 15 Three Phase Max Amps RMS A 10 0 15 0 20 0 Power and VA capability kVA 6 6 9 0 13 0 Output Data Output Power rated kW 4 0 5 5 7 5 Output Voltage rated 380V AC Three Phase Max Amps RMS A 9 0 13 0 17 0 Output Frequency 0 50Hz 60Hz Protection Surge protection Integrated Overvoltage protection Integrated Undervoltage protection Integrated Locked pump protection Integrated Open circuit protection Integrated Short circuit protection Integrated Overheated protection Integrated Dry run protection Integrated General Data Ambient Temperature Range 20 C 60 C gt 45 C Derating as required Cooling Method Fan Cooling Ambient Humidity lt 95 RH Dimensions H W D mm 249 5 155 5 159 5 Gross Weight kg 3 4 3 5 3 6 Standard Warranty month 18 Certificates IEC EN 61800 5 1 IEC EN 61800 2 2004 IEC EN 61800 3 2004 CE Table 2 3 Solar Pump Controller 4 7 5kW 380VAC 3 phase output Specifications 10 Novaplus Solar Pump Inverter Controller Model RPC10 118R5
17. Internal diagnostics will tolerate a lower input voltage e Whenever possible the controller attempts to drive the pump load by maximizing power output from the solar array 05 Novaplus Solar Pump Inverter An easy to use interface is provided to enhance configurability and enable remote system monitoring e A LED display provides a detailed indication of system status e A small keypad offers flexibility for selection of user options 2 3 Protection Features Electronic monitoring gives the controller the capability to monitor the system and automatically shut down in the event of e Dry well conditions with low level switch e Bound pump with auto reversing torque e High Voltage Surge e Low Input Voltage e Open motor circuit e Short circuit e Over heat NOTE This controller provides motor overload protection by preventing motor current from exceeding rating current and by limiting the duty cycle in the event of low water level This controller does not provide over temperature sensing of the motor 06 Novaplus Solar Pump Inverter 2 4 Solar Pump Controller Model Description Segment Series ID Version 10 Standard type ID Basic version Motor Voltage Rating GH S Geen S 310VDC rating MPPT range 280VDC 360VDC Note 1 D Solar Panel Voltage range T 540VDC rating MPPT range 500VDC 600VDC Note 2 004 4kW Motor Power Rating 5R5 5 5kW R decimal point Note 1
18. Novaplus User Manual Solar Pumping Controller BIR Novaplus Solar Pump Inverter TABLE OF CONTENTS Te ee 01 1 1 General ee ET OW EE 01 1 2 Pump Check Valve Requirement cccccccssecceceeseeeeceeeeeseeeeeeseneees 02 kore le 03 2 Solar Pump Controller General Intormmaton 05 PM MISS a a S E AEE E A E E T E E E T 05 2 2 Descriptions and FOQUINCS sicce occscisedecaiwaiecdexeateihdvcattaceedeenhshsderssidacdedacedecs 05 2 3 Protection POAC yic5 soccer ccereneesesesnecnesecedeacnceeresaraerenedenasxetanandenrsestaccent 06 2 4 Solar Pump Controller Model Descrpton 07 2 5 Solar Pump Controller Specifications KEREN 08 2 6 Solar Pump Controller Dmmensions 14 SG MR eA Wicd EEN 16 3 1 Installation Preparation amp Requirement ccccccceseeeeceeeeeeseeeeeeees 17 3 2 Control Box and Controller Location Gelechon 18 3 9 Mounting te ere 19 4 Electrical le Le E ZU e rn e ere ene ere ete ene E ee eee eee ee 20 4 2 Power nDO WIIG E 21 Or Ground Winn E 22 AA Motor VV IMIG esera a E EE E EAEE EE RE 23 4 5 Control Circuit Wiring OptlOnall iccicscscsasnccnesivonssandsansansnncadensaauaiansedenaess 24 5 Start up and Operaton 27 5 1 Keypad Descrip e E 27 5 2 Keypad Operation EE uge 28 5 3 Commissioning Procedure ssssseseeeessrrrrrrerrrnrrrrssrrrrrrrsrrnrrrrssrrrrrrene 30 5 4 User Definable Parametere 31 6 Three Phase Motor Heourements 35 7 Diagnostics and Troublesbootmg 36 E WE COS EE 37 7
19. O O O O 50 00 o 00 50 elle e via o F1 F1 02 elle e F1 00 F1 via slije F1 01 50 00 Figure 17 Flow Chart of Parameter Setting 5 2 3 Fault Reset When controller malfunction occurs it will display the relative fault information Use the STOP RESET key or terminals determined by F5 group to reset the fault After fault reset controller is at stand by status If no fault reset when controller is at fault status it will keep operation protection status and cannot run 29 5 3 Commissioning Procedure e Check and make sure wiring are correct If needed take a megger to test the insulation of motor cable etc e Use a multimeter to test the PV output voltage at the DC switch e Power on the controller by switch on the DC switch e If necessary modify and set the parameters of motor to the controller With the pump ready Jog the motor shortly by ON OFF control switch with F0 01 set to 1 or RUN STOP on keypad with F0 01 set to 0 to see if the running direction of pump are correct If the direction is wrong change the motor wiring connections by shifting two leads according to Pump Motor Wiring Connections section or you can change Parameter FO 09 according to User defined Parameters section to let the controller drive the motor in another direction e Make sure the l
20. Replace with higher rating controller Too low input voltage SBER DEER wiring Improper setting of Properly setting of motor motor rated current rated current E011 Motor overload E012 Input phase loss Output phase E013 loss Improper motor s overload protection threshold Check load and boost the torque lower rating controller Phase loss of R S T broken wires in the output cable broken wires in the motor winding Loose output terminals Replace with higher rating controller Check input power supply or wiring Check the wiring and installation EE Solar Pump Inverter Fault description Possible causes Remedy Controller overheat Instantaneous overcurrent of controller Output short circuit Refer to over current remedy Re wiring of output Cooling fans of controller stopped or damaged Obstruction of ventilation channel Too high ambient temperature Replace cooling fan and clear the ventilation channel Decrease the ambient temperature if possible loose cables or terminals Inspect and tighten the wire and terminals Abnormal power circuit Abnormal control PCB board Ask for support External fault Faults tripped by external fault input terminals Inspect external equipment Communication Improper baud rate setting Receive wrong data Set proper baud rate Push STOP RESET to reset and ask for support
21. W 45 0 55 0 Output Voltage rated 75 0 380V AC Three Phase Max Amps RMS A Output Frequency Protection 90 0 105 0 0 50Hz 60Hz 150 0 Surge protection Overvoltage protection Undervoltage protection Integrated Integrated Integrated Locked pump protection Integrated Open circuit protection Short circuit protection Integrated Integrated Overheated protection Integrated Dry run protection Integrated General Data Ambient Temperature Range 20 C 60 C gt 45 C Derating as required Cooling Method Ambient Humidity Fan Cooling lt 95 RH Dimensions H W D mm Gross Weight kg Standard Warranty month 544 380 284 8 650 473 318 18 Certificates IEC EN 61800 5 1 IEC EN 61800 2 2004 IEC EN 61800 3 2004 CE Table 2 6 Solar Pump Controller 45 75kW 380VAC 3 phase Specifications BEER Novaplus Solar Pump Inverter 2 6 Solar Pump Controller Dimensions There are three types of solar pump controller dimensions as following Figure2 4 showing Table 3 lists all the frame sizes and mounting dimensions Figure 3 4 7 5kW Controller Dimensions 14 Novaplus Solar Pump Inverter Mounting M ti Controller Dimension Oe e a Diameter A B mm RPC10 2SR75 RPC10 2S1R5 92 142 7 RPC10 2S2R2 RPC10 4TR75 RPC10 4T1R5 92 142 7 RPC10 4T2R2 RPC10 4T004
22. Zb R A WARNING Do NOT touch any other piece inside the solar pump controller while power is applied To service any other areas of the controller disconnect ALL power sources and wait 5 minutes before continuing BA Novaplus Solar Pump Inverter 6 Three Phase Motor Requirements Normally considering about the selection of solar pump controller the motor s power rating should be equal to controller s power rating But if the length of cable for motor wiring is more than 50m to 100m depends on motor power rating the smaller the motor power rating is the short length are required the controller s power rating should be larger than the motor For example to an application of 100m deep well a 5 5kKW controller should be selected to control 4kW motor 35 Novaplus Solar Pump Inverter 7 Diagnostics and Troubleshooting The solar pump controller will attempt to drive the pump to deliver water even under adverse conditions To ensure years of reliable service it must also protect the system components from conditions that might result in equipment damage When adverse conditions arise the controller will continue to deliver as much water as possible at reduced output if necessary and will shut down only in extreme cases Full operation will resume automatically whenever abnormal conditions subside Error conditions may suspend certain features reduce output or shut down operation o
23. a control terminal input See Figure 12 for details Note F0 01 must be changed to 1 while the ON OFF Control Switch is needed M1 Ne ve com va M5 M6 foom 2v lt Cable gt ON OFF SS Figure 12 ON OFF Control Switch Circuit Wiring Connections 4 5 2 Well Level Switch Operation The solar pump controller is designed to utilize 2 level switches for well water level control One is HIGH level the other is LOW level See Figure 13 for wiring connection Both HIGH and LOW level switch can be set to NO or NC contact type from the USER DEFINABLE PARAMETER F5 27 When the LOW level switch acts as the water falls below LOW level threshold the solar pump controller stops the pump thus prevents the well water from exhausting in some case also protect the well When the HIGH level switch acts as the water rises higher than HIGH level threshold the solar pump controller starts the pump Set the HIGH and LOW level switch threshold to appropriate value thus prevent the pump from switching on and off frequently See USER DEFINABLE PARAMETER F85 27 in operation section of manual for instructions 24 Novaplus Solar Pump Inverter Novaplus Solar Pump Inverter 4 5 3 Tank Level Switch Operation The solar pump controller is designed to utilize 2 level switches for Tank or pool water level control One is HIGH level the other is LOW level See Figure 13 for wiring connection Both HIGH and LOW level
24. ature enhances long term motor reliability 1 2 Pump Check Valve Requirements In order to ensure maximum system reliability and water delivery check valves must be installed in the drop pipe The first check valve must be installed at the pump and additional check valves should be installed every 30m 100 ft of vertical pipe after the pump See the pump owner s manual for additional information 02 Novaplus Solar Pump Inverter 1 3 Features System Diagnostics The solar pump controller continuously monitors system performance and can detect a variety of abnormal conditions In many cases the controller will compensate as needed to maintain continuous system operation however if there is high risk of equipment damage the controller will protect the system and display the fault code If possible the controller will try to restart itself when the fault condition subsides See Diagnostics and Troubleshooting section for a list of Fault Codes and corrective actions Motor Soft Start Normally when there is a demand for water and power the solar pump controller will be operating Whenever the solar pump controller detects a need for water the controller always ramps up the motor speed while gradually increasing motor voltage resulting in a cooler motor and lower start up current compared to conventional water systems In cases where the demand for water is low the system may cycle on and off Due to the controller
25. ction selection 0 Running at low limit Options at low limit frequency frequency 1 Stop 2 Sleep at OHz Deceleration time 1 0 1 3600s l o 234 Novaplus Solar Pump Inverter 0 Not restore to default setting F0 20 Default setting 1 Restore to factory 0 e setting 2 Fault record clearing Parameter lock 0 Unlock parameter Geet setting 1 Lock parameter F2 Group Motor Parameters Different Motor rated power 0 4 700 0kW according to e controller model Motor rated frequency 10 00Hz F0 10 50 00Hz o Different Motor rated voltage O 480V according to o controller model Different Motor rated current 0 8 2000A according to e controller model F5 Group Digital Input Terminal Functions O Invalid 1 Forward 2 Reverse F5 00 1 39 Well High Level F5 01 2 F5 00 M1 M6 terminal L mit F5 02 39 40 Well Low Level O F5 05 function Limit F5 03 40 41 Tank High Level F5 04 41 Limit F5 05 42 42 Tank Low Level Limit BITO for M1 0 NO NO 1 NC O 1 NC BIT1 for M2 0 NO 1 NC M1 M6 Normally pit2 for M3 F5 27 Open Normally 0 NO 1 NC OC O Close Options BIT3 for M4 0 NO 1 NC BIT4 for M5 0 NO 1 NC BIT5 for M6 0 NO 1 NC F6 Group Output Terminal Parameters Relay 1 output 12 Input Over Voltage ES selection Fault 12 O E F7 Group Display Interface Parameters Novaplus Solar Pump Inverter F7 00 F7 10 Us
26. er password controller firmware version 0 9999 FA Group Protection and Malfunction Parameters FA 14 FA 15 FA 16 Fault Record of the one before last Last Fault Record Current Fault Record 0 No fault 1 Inverter module protection E001 2 Over current when accelerate E002 3 Over current when decelerate E003 4 Over current at constant speed E004 5 Over voltage when accelerate E005 6 Over voltage when decelerate E006 7 Over voltage at constant speed E007 8 Hardware overvoltage E008 9 Under voltage E009 10 controller overload E010 11 Motor overload E011 12 Phase lack of input E012 13 Phase lack of output E013 14 Heatsink overheating E014 15 External fault E015 16 Communication fault E016 17 Reserved 18 Current detection fault E018 19 Motor autotuning fault E019 20 Well Level Fault E020 21 Tank Level Fault E021 22 EEPROM fault E022 CR Novaplus Solar Pump Inverter Running frequency when fault occurs Output current when fault occurs DC bus voltage e when fault occurs FD Group Solar pumping special parameters 220VAC motor controller Max power point 360VDC voltage 380VAC motor controller 600VDC 220VAC motor controller Photovoltaic open 450V P circuit voltage 380VAC motor controller 750VAC 0 Disable Power on auto start 1 Enable 1 O Delay before auto start 9 90 9
27. erter 8 Periodic Maintenance e Solar pump controller Periodically checking of Status display error code display and fault record long term verification of cooling fan and cleaning of heat sink are needed e Solar panels Periodically cleaning of the surface of panels and checking wiring are required Please refer to manufacturer s instruction e Solar motor and pump Long term periodic maintenance and verification are required Please refer to manufacturer s instruction 42 Novaplus Solar Pump Inverter 9 Solar Array 9 1 Example 255W Monocrystalline Solar Array Curves Displaying Diminishing Solar Light Intensity Current Voltage amp Power Voltage Curve Current A N w a w a Ki g Voltage V Figure 18 example solar array Curves Each panel having the following values at standard test conditions STC of 1000 wim 25 deg C panel temp Isc 8 63A Voc 36 6 Vdc Imp 7 92 A Vmp 31 18 Vdc Curves calculated for five different light levels 200 to 1000 W m in 200 Wim steps at constant 25 deg C panel temperature 43 Novaplus Solar Pump Inverter 9 2 Solar Panel Wiring Configurations Solar Panels Wired in Series When solar panels are wired in series the positive terminal of one solar panel is wired in to the negative terminal of the next solar panel When panels are connected in series e Voltage accumulates adds for each panel in series e Wattage accumulates
28. evel switches contact type is compatible with the settings of Parameter F5 27 If not change the settings e With every parts mentioned above fixed you can try to run the system e Check if the tank and well level switches are functioning well e Let the system work an hour test the water supply capacity e Commissioning finished 30 Novaplus Solar Pump Inverter Novaplus Solar Pump Inverter 5 4 User Definable Parameters The following explains the menu structure and User Definable Parameters that is effective on solar pump controllers Tee o The parameters can be modified at stop or running status The parameters cannot be modified at running status e im e The parameters which are actual detecting record value and cannot be modified Ss Modifi Function SS Minimum Factory S Function Descriptions cation Code Unit Setting Type FO Group Basic Parameters Run 0 Keypad command source 1 Terminals 0 Digital Setting Modified by Up down key 1 Potentiometer of panel 2 AVI terminal 3 ACI terminal 4 Automatically adjusted by Light o intensity 5 Reserved 6 Multi function digital input terminals 7 PLC 8 PID 9 Communication interface Main Frequency Source X Selection 0 Forward 1 Reverse 2 Reverse running prohibited 0 Max output no 600 0Hz 60 00Hz e frequency Low limit of running 0 00Hz F0 12 20 00Hz O frequency Running dire
29. f the controller for varying amounts of time depending on the nature and severity of the error Problems that merely reduce features or performance generally restore full operation when the trouble condition subsides without stopping the pump or flashing an error code An severe error such as short circuit or over current requires stopping the motor immediately An overload error stops the controller with a delay by time load curves defined internally The error code is shown on the LED display If the controller has stopped to indicate a fault code on the display the associated time out delay will vary depending on the nature of the fault The number following the E symbol corresponds to the error code for the offending condition 36 7 1 Fault Codes Feld Fault description Possible causes Remedy code Too short acceleration Increase acceleration time time ag IGBT module Damaged IGBT module Ask for support fault Malfunction caused by Inspect external equipment interference and eliminate interference Improperly grounding Check grounding wire Too fast acceleration Increase acceleration time Over current Check the input power supply E002 during TOS TOW INPUT Vonage or wiring SEERSEEN Replace with higher rating lower rating controller controller Too fast deceleration Increase deceleration time Over current Too heavy and large E003 during inertia load pemplopen braking Unite SEN Replace with hi
30. g to the manufacturer s installation instructions before installing the solar pump controller e Wiring Requirements Use 75 C rated wire sized for a maximum voltage drop of 3 per local electric codes 16 Novaplus Solar Pump Inverter 3 1 Installation Preparation amp Requirements When installing the solar pump controller be aware that e High voltage is present in the controller when powered on use caution when live DC power is on e Do not allow any unauthorized persons near the solar array and connection sites while power is applied e It is strongly recommended that a DC rated disconnect box be used to disconnect the incoming DC power from the solar pump controller during installation and maintenance Use a Volt Meter to confirm the absence of voltage in the line before proceeding with installation or maintenance e The DC disconnect should be sized to be capable of adequately disconnecting the output open circuit voltage Voc and short circuit current Isc of the solar array e Keep all flammable materials away from the assembly site including dry brush and vegetation e For optimal performance avoid placing the solar array around any objects that can cast shadows or reduce sunlight to the array e Install the solar pump controller in a control box with control terminals and power wiring Install the control box out of direct sunlight to prevent overheating and reduced performance The optimum location is
31. gher rating lower rating controller controller Sudden change of load Check the load Over current at Too low input voltage Check the input power supply E004 constant running or wiring speed Over voltage lower rating controller Abnormal input voltage Restart the motor when Replace with higher rating controller Check input power E005 during Avoid prompt restart when acceleration Instantaneous trip off trip off occurs Too fast deceleration Increase deceleration time Over voltage Too heavy and large E006 during inertia load AOO Proper Staking Units deceleration Over voltage at E007 constant running speed Abnormal input voltage Abnormal input voltage Check input power supply or wiring Install proper input AC reactor Large inertia load Add proper braking units 237 a Novaplus Solar Pump Inverter Fault description Possible causes Remedy Hardware over voltage Under voltage of Abnormal input voltage Too fast deceleration Check input power supply or wiring Increase deceleration time Large inertia load Add proper braking units Check input power supply or E009 DC bus Too low input voltage wiring Too fast acceleration Increase acceleration time Restar me BEE WAEN Avoid prompt restart when instantaneous trip off trip off E010 Controller occurs overload i Too low input voltage Gelee NEE OWES SUPPIVOr wiring foe Heavyiead
32. ions H W D mm 151 7 101 126 8 Gross Weight kg 1 4 Standard Warranty month 18 Certificates IEC EN 61800 5 1 IEC EN 61800 2 2004 IEC EN 61800 3 2004 CE Table 2 1 Solar Pump Controller 0 75 2 2kW 220VAC 3 phase output Specifications 08 Novaplus Solar Pump Inverter Controller Model RPC10 4TR75 RPC10 4T1R5 RPC10 4T2R2 Input Data PV Source Max Input Voltage Voc V Min Input Voltage at mpp V 350V Recommended voltage at mpp 500VDC 600VDC Max Amps Input A 4 8 Recommended Max Power at mpp kW Alternate AC Generator Input voltage 380V AC 15 Three Phase Max Amps RMS A Power and VA capability kVA Output Data Output Power rated kW Output Voltage rated 380V AC Three Phase Protection Surge protection Integrated Overvoltage protection Integrated Undervoltage protection Integrated Locked pump protection Integrated Open circuit protection Integrated Short circuit protection Integrated Overheated protection Integrated Dry run protection Integrated General Data Ambient Temperature Range 20 C 60 C gt 45 C Derating as required Cooling Method Fan Cooling Ambient Humidity lt 95 RH Dimensions H W D mm 151 7 101 126 8 Gross Weight kg 1 4 1 4 1 5 Certificates IEC EN 61800 5 1 IEC EN 61800 2 2004 IEC EN 61800 3 2004 CE Table 2 2 Solar Pump Controller 0 75 2 2kW 380VAC 3 phase output Specifications 0
33. kW Please check the controller s model label according to solar pump controller Model Description section and make sure which case of connection you should follow A WARNING Connecting single phase generator to three phase solar pump controller with different voltage rating will result in controller malfunction or being destroyed Before connecting AC power or generator to main terminal R S T following steps must be carried out first otherwise touching the conductor or parts would lead to sever injury or even death while they are energized e Make sure the generator is powered off e Make sure the external DC disconnect switch is off 47 Novaplus Solar Pump Inverter Case 1 Single phase AC power connects to 220VAC rated output controller Case 2 Three phase AC power connects to 380VAC rated output controller Case 3 Three phase AC power connects to 220VAC rated output controller Figure 22 AC Wiring Connections R
34. lation Arrangement and Required Distances 18 Novaplus Solar Pump Inverter e The control box should be mounted on a sturdy supporting structure such as a wall or supporting post Please take into account the weight of the unit e The electronics inside the solar pump controller are air cooled As a result there should be at least 50 cm both above and below to allow for air flow and proper cooling If the control box is mounted under the PV make sure that it is at least 50 cm beneath the array e The solar pump controller should be mounted with the wiring end oriented downward The control box should not be placed in direct sunlight or other locations subject to extreme temperatures or humidity mounting location should not be subjected to freezing conditions Placing the control box in direct sunlight or high ambient temperatures will result in reduced performance due to temperature foldback protection of the solar pump controller For optimum performance maximize the shading of the control box 3 3 Mounting Procedure e Disconnect all electrical power supply e Install the control box with solar pump controller inside to a secure post using mounting screws not included The top mounting holes are slotted in order to hang the controller in place while the bottom fasteners are inserted to secure the unit from ever sliding up e If the mounting surface is narrower than the outer mounting slots use the top center
35. minals Note Depending on the model number solar pump controllers support power input either 220VAC single phase or 380VAC three phase Please contact the authorized agencies for details When the system is running on back up AC power please check for sufficient DC primary source power every 30 minutes If the primary DC power is available shut down the controller switch back to primary power and attempt to run on DC power supply A NOTICE A DC circuit switch and a generator power switch must be installed and these two switches must be mechanically interlocked each other to prevent switching on together resulting the solar PV and the generator being connected to the solar pump controller simultaneously Please check if the design is in accordance with all applicable national and local electrical codes 04 Novaplus Solar Pump Inverter 2 Solar Pump Controller General Information The solar pump controller is a variable speed motor drive designed to run any IEC three phase asynchronous motor The solar pumping system provides water to remote locations by converting high voltage direct current from a solar array into alternating current to run a standard three phase asynchronous motor When solar power is not available the controller can be switched manually to an alternate single phase or three phase AC input such as a generator or inverter from battery if available The controller provides fault detection mot
36. mmended Max Power at mpp kW Alternate AC Generator Input voltage 380V AC 15 Three Phase Max Amps RMS A Power and VA capability kVA Output Data Output Voltage rated 380V AC Three Ph Max Amps RMS A 45 0 60 0 75 0 Output Frequency 0 50Hz 60Hz Protection Surge protection Integrated Overvoltage protection Integrated Undervoltage protection Integrated Locked pump protection Integrated Open circuit protection Integrated Short circuit protection Integrated Overheated protection Integrated Dry run protection Integrated General Data Ambient Temperature Range 20 C 60 C gt 45 C Derating as required Cooling Method Fan Cooling Dimensions H W D mm 424 285 210 3 Gross Weight kg 17 2 17 2 17 6 Standard Warranty month 18 IEC EN 61800 5 1 IEC EN 61800 2 2004 IEC EN 61800 3 2004 CE Table 2 5 Solar Pump Controller 22 37kW 380VAC 3 phase Specifications Certificates 2 Novaplus Solar Pump Inverter Controller Model RPC10 4T045 RPC10 4T055 RPC10 4T075 Input Data PV Source Max Input Voltage Voc V Min Input Voltage at mpp V 350 Recommended voltage at mpp 500VDC 600VDC Max Amps Input A Recommended Max Power at mpp kW Alternate AC Generator Input voltage Max Amps RMS A 380V AC 15 Three Phase Power and VA capability kVA Output Data Output Power rated k
37. oat switch Power in DC wiring Motor wiring Figure 15 System Wiring Diagram 26 Novaplus Solar Pump Inverter 5 Start up and Operation 5 1 Keypad Description Function Indicator Light Digital Display Shift Key Potentiometer Knob Shortcut Key Program Exit Key Run Key Data Enter Key Stop Fault Reset Key ry Digital Modify Key KI Digital Modify Key Figure 16 Keypad Schematic Diagram 5 1 1 Button Function Description Symbol Button Name Function Description PRGM Program Exit Enter or exit of menu parameter setting ENT Data enter Progressively enter menu and confirm parameter A iS inerease Progressively increase setting value or function codes ka DOWN Progressively decrease setting value or function decrease codes Use it to select displayed parameters cyclically during running or stop status In parameter S shift setting mode press this button to select the bit to be modified RUN Run Start to run the controller in keypad control mode In running status restricted by function code STOP F7 04 it can be used to stop the controller RESET Stop reset In malfunction alarm status not restricted by function code F7 04 it can be used to reset the controller REV JOG Shortcut Determined by function code F7 03 ae 5 1 2 Functional LED indicator description Indicator Name Description Light on controller running status Light on cont
38. or soft start and speed control The solar pump controller is designed to provide these features with the plug and play ease of installation The solar pump controller is designed with the high standard of reliability The controller attempts to drive the pump and motor to deliver water even under adverse conditions reducing output as necessary to protect the system components from damage and only shutting down in extreme cases Full operation is restored automatically whenever abnormal conditions subside 2 1 Inspection Before you begin receive and inspect the solar pump controller unit Verify that the part number is correct and that no damage has occurred during transportation Note solar pump controller is one component of the solar pumping system which has other two optional components solar array and AC pump with motor 2 2 Descriptions and Features The solar pump controller is based on a standard platform controlling a standard three phase asynchronous motor driving a pump powered by a solar array or an optional AC generator backup The solar pump controller continuously monitors system performance and incorporates a number of features for pumping system protection In the event of a fault the solar pump controller will indicate the type of fault through the LED display mounted on the front cover of controller The solar pumping system is optimized for pumping under adverse input power conditions unique to solar arrays e
39. qual to the solar pump controller s kVA ratings are expected to be capable of providing adequate voltage to solar pump controller at rated power of the controllers Please refer to the solar pump controller s specifications for details The above information is a guideline for selecting a generator based on best known practice Not all AC generators will perform satisfactorily with the solar pump controller and can result in but not limited to nuisance tripping unsatisfactory performance or controller damage Always consult the generator manufacturer for best use practices 46 Novaplus Solar Pump Inverter Line reactors are typically available as three phase line reactors Follow the manufacturer s instructions for use in single phase application The reactors can be mounted at the generator using the proper enclosure rating determined to be adequate for the generator AC Power Wiring Connections The solar pump controller has AC Power wiring options such as a generator when Solar DC power is not available Connect the cables from the AC power or generator to solar pump controllerto terminals R S and T Figure 8 Do not over tighten the screws There are three cases of wiring connections showing in Figure 8 A NOTICE Depends on the given solar pump controller some has only single phase AC input mostly as power rating from 0 75kW to 2 2kW and some has three phase AC input mostly as power rating from 4kW to 55
40. roller stops or fault status Lights of FWD and RUN are on at the same time controller AN forward running status Lights of REV and RUN are on at the same time controller REV reversely running status 5 2 Keypad Operation Process 5 2 1 Parameter Setting Three levels of menu are as following e Function code group first class e Function code second class e Setting parameter of function code third class 5 2 2 Remarks Pressing PRGM or ENT can return to the second class menu from the third class menu The difference is Pressing ENT will save the setting parameters into control board and return to the second class menu with shifting to the next function code automatically While pressing PRGM will directly return to the second class menu without saving the parameters and keep staying at the current function code For example change the parameter 00 50Hz of function code F1 01 into 05 00Hz as the following Figure 14 flow chart shows Under the third class menu if the parameter has no flickering bit it means that the function code cannot be modified The possible reasons include 1 The parameter of this function code can t be modified such as actually detected parameter operation records and so on 2 This function code can t be modified during running status but can be modified during stop status en Novaplus Solar Pump Inverter Novaplus Solar Pump Inverter RUN STOP FWD REV
41. w Level Switch should be installed inside the pool or tank to regulate the water level If the water comes from a well another two level switches should be installed inside the well The Low Level Switch of the well serves as an indication that the well has run dry The system will shut down to protect the pump and motor until the well has recovered as the High Level Switch are reached by water Figure 1 shows a typical diagram of the solar pumping system The major parts and components in the system are listed after the diagram C Solar Controller F Tank level Switch A Solar Panel B DC Breaker E Well Level Switch Figure 1 solar pumping system 01 Novaplus Solar Pump Inverter To be part of a water supply the solar pumping system is designed which consists of A Solar Array B DC Breaker or Disconnect Switch C Solar Pump Controller D Pump and Motor E Water Source Level Switches optional F Tank Level Switches optional The solar pump controller runs at variable speed to match the changing power available from the solar array Variable speed operation means there is no in rush or surge of energy during the pump motor start up helping to eliminate wear on the motor and pumping system A leading cause of pump motor failure is the stress applied to the motor during a full voltage start up The solar variable speed operation ramps up the speed smoothly which eliminates starting stress This fe
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