STATCON ENERGIAA HBD Series Manuale utente

STATCON

Inspire Innovate Implement

ENERGIAA

PRODUCT MANUAL

HBD SERIES

1P (1-50 KVA) & 3P (5-250 KVA) HYBRID MPPT PCUs

Genuine ‘Hybrid’ - Not just ‘Off-Grid’

Contents

Copyright Declaration ............................................................................................................................................... 2

1. NOTES ON THE MANUAL ....................................................................................................................................... 3

1.1 SCOPE OF VALIDITY .......................................................................................................................................... 3

1.2 TARGET AUDIENCE ......................................................................................................................................... 4

1.3 SYMBOLS USED ................................................................................................................................................ 4

2. INTRODUCTION ....................................................................................................................................... 5

2.1 PRODUCT DESCRIPTION ........................................................................................................................................................... 5

2.2 KEY ELEMENTS OF MACHINE ................................................................................................................................................ 6

2.2.1 MPPT-BASED SOLAR CHARGE CONTROLLER ............................................................................................................... 6

2.2.2 BIDIRECTIONAL INVERTER .................................................................................................................................................. 6

2.2.3 AUTO BYPASS ARRANGEMENT ........................................................................................................................................... 6

2.2.4 DISPLAY KEYPAD UNIT .......................................................................................................................................................... 6

2.2.5 REMOTE MONITORING SYSTEM (OPTIONAL) ................................................................................................................. 6

2.3 PRODUCT NOMENCLATURE .................................................................................................................................................... 6

2.4 RATING PLATE AND ITS TERMS ............................................................................................................................................. 7

2.5 PHYSICAL APPEARANCE AND TERMINATION DETAILS OF INVERTERS .................................................................. 8

2.5.1 1kVA-3kVA SINGLE-PHASE INVERTER WITH SINGLE CHANNEL MPPT CHARGE CONTROLLER ................... 10

2.5.2 4kVA-6kVA SINGLE-PHASE INVERTER WITH SINGLE CHANNEL MPPT CHARGE CONTROLLER ................. 10

2.5.3 10kVA-12.5kVA SINGLE-PHASE INVERTER WITH SINGLE CHANNEL MPPT CHARGE CONTROLLER ........... 11

2.5.4 10kVA-15kVA SINGLE-PHASE/ THREE-PHASE INVERTER WITH SINGLE CHANNEL MPPT CHARGE

CONTROLLER ................................................................................................................................................................................. 11

2.5.5 20kVA-25kVA SINGLE-PHASE/ THREE-PHASE INVERTER WITH SINGLE CHANNEL MPPT CHARGE

CONTROLLER.................................................................................................................................................................................12

2.5.6 30kVA-40kVA SINGLE-PHASE/THREE-PHASE INVERTER WITH SINGLE MPPT CHARGE CONTROLLER.......12

2.5.7 50kVA-60kVA SINGLE-PHASE/THREE-PHASE INVERTER WITH SINGLE/THREE MPPT CHARGE

CONTROLLER ................................................................................................................................................................................ 13

2.5.8 70kVA-100kVA THREE-PHASE INVERTER WITH SINGLE MPPT CHARGE CONTROLLER .................................. 13

2.5.9 ABOVE THAN 100kVA THREE-PHASE INVERTER WITH THREE CHANNEL MPPT CHARGE CONTROLLER... 14

3. INSTALLATION ............................................................................................................................................... 15

3.1 UNPACKING AND CONTENTS INSIDE ............................................................................................................... 15

3.2 PLACEMENT AND LOCATION ........................................................................................................................... 16

3.3 WIRING PROCEDURES AND ROUTES ................................................................................................................ 17

3.4 EARTHING OR GROUNDING THE MACHINE...................................................................................................... 18

3.5 SURGE PROTECTION DEVICE (SPD) ........................................................................................................................ 18

4. COMMISSIONING........................................................................................................................................... 21

4.1 PRECHECKS BEFORE ENERGIZING .................................................................................................................... 21

4.2 ENERGIZING THE MACHINE FOR THE FIRST TIME ............................................................................................. 21

4.3 SETTINGS UPLOAD ......................................................................................................................................... 21

4.4 POWER UP AND LOAD TRANSFER .................................................................................................................... 22

5. DISPLAY KEYPAD UNIT ................................................................................................................................... 23

5.1 BUTTON DEFINITION ...................................................................................................................................... 23

5.2 DKU LED DESCRIPTION ................................................................................................................................... 23

5.3 DATE AND TIME SETTINGS .............................................................................................................................. 24

5.4 SCROLLING PAGES .......................................................................................................................................... 24

5.4.1 HOME PAGE ................................................................................................................................................ 24

5.4.2 BATTERY AND PV STATUS SCREEN ................................................................................................................... 25

5.4.3 TEMPERATURE STATUS SCREEN ........................................................................................................................................ 26

5.4.4 AC PARAMETERS (PHASE-NEUTRAL) ............................................................................................................. 26

5.4.5 LINE TO LINE PARAMETER STATUS ............................................................................................................... 26

5.4.6 CURRENT SCREEN ........................................................................................................................................ 27

5.4.7 POWER SCREEN ........................................................................................................................................... 27

5.4.8 GENERATION SCREEN .................................................................................................................................. 28

5.4.9 SOLAR GENERATION GRAPH ......................................................................................................................... 28

5.5 TURN ON AND TURN OFF THE INVERTER UNIT ................................................................................................ 29

5.6 FAULT RESET OF INVERTER .............................................................................................................................. 29

5.7 CHANGE OF SETTINGS .................................................................................................................................... 29

5.8 BATTERY BOOST CYCLE/ SETUP ....................................................................................................................... 30

6. BATTERY & BATTERY CHARGING ................................................................................................................... 32

6.1 BATTERY CHARGING TECHNIQUE IN HBD RANGE OF INVERTERS ..................................................................... 32

6.2 MPPT-BASED SOLAR CHARGE CONTROLLER .................................................................................................... 32

6.3 GRID BASED CHARGER ............................................................................................................................................................ 33

6.4 COMMON FEATURES ............................................................................................................................................ 33

6.5 BATTERY CURRENT LIMIT ............................................................................................................................................ 33

6.6 THREE STAGE CHARGING (FLOAT, BULK AND EQUALIZE) ................................................................................. 34

6.7 TEMPERATURE COMPENSATION FOR VRLA ..................................................................................................... 34

6.8 BOOST CYCLE ON START UP ............................................................................................................................ 34

6.9 BATTERY OVER VOLTAGE PROTECTION ........................................................................................................... 34

6.10 BATTERY UNDER VOLTAGE PROTECTION ...................................................................................................... 34

6.11 BATTERY CHARGING CURVE EXPLANATION .................................................................................................. 37

7. OPERATING MODES ........................................................................................................................................ 38

A. STANDALONE MODE .......................................................................................................................................... 38

B. HYBRID MODE .............................................................................................................................................. 38

C. HYBRID MODE WITH EXPORT ........................................................................................................................ 39

APPENDIX-1. DISPLAY FAULT ANALYSIS ................................................................................................................... 41

APPENDIX-2. HOW TO SELECT OPERATING MODE OF YOUR CHOICE ....................................................................... 44

APPENDIX-3. PV MODULE ARRAY SERIES-PARALLEL ARRANGEMENT ...................................................................... 44

APPENDIX-4. BATTERY CHARGING CURRENT AS PER BANK SIZE .............................................................................. 46

APPENDIX-5. SINGLE-PHASE SMART STORAGE SOLAR INVERTER DATASHEET ......................................................... 47

APPENDIX-6. THREE-PHASE SMART STORAGE SOLAR INVERTER DATASHEET .......................................................... 49

APPENDIX-7. TERMS AND CONDITIONS OF THE WARRANTY ................................................................................. 50

APPENDIX-8. SERVICING AND CUSTOMER CARE .................................................................................................... 51

The copyright of this manual exclusively belongs to STATCON ENERGIAA PVT. LTD. Any corporation or individual should

not plagiarise, partially or fully copy (including software, etc.) it. Reproduction or distribution of it in any form or in any

This document is subject to changes without prior notice. This is valid only for HBD-NG model machines and not for our

other custom-built models/ratings.

1. NOTES ON THE MANUAL

1.1 SCOPE OF VALIDITY

This manual is an integral part of the PCU, and it describes the assembly, installation, commissioning,

maintenance, and failure analysis/ troubleshooting of our hybrid inverters (HBD Series). List of

inverters/PCUs for which this operation manual is valid have been mentioned in the list below. This manual

is valid for HBD-NG inverters dispatched after 1st April 2021. This manual is not applicable for any other

custom-built rating, client may contact manufacturer if they have custom-built rating PCUs.

Sr. No.

Model

Sr. No.

Model

HBD-048-01K-1P

HBD-120-08K-1P

HBD-048-02K-1P

HBD-120-10K-1P

HBD-048-03K-1P

HBD-120-15K-1P

HBD-048-04K-1P

HBD-240-15K-1P

HBD-048-05K-1P

HBD-240-20K-1P

HBD-048-06K-1P

HBD-240-25K-1P

HBD-048-08K-1P

HBD-240-30K-1P

HBD-048-10K-1P

HBD-240-40K-1P

HBD-096-05K-1P

HBD-240-50K-1P

HBD-096-06K-1P

HBD-360-40K-1P

HBD-096-08K-1P

HBD-360-50K-1P

Sr. No.

Model

Sr. No.

Model

HBD-048-05K-3P

HBD-240-60K-3P

HBD-048-008K-3P

HBD-360-60K-3P

HBD-048-010K-3P

HBD-240-80K-3P

HBD-048-015K-3P

HBD-360-80K-3P

HBD-120-010K-3P

HBD-240-100K-3P

HBD-120-015K-3P

HBD-360-100K-3P

HBD-240-15K-3P

HBD-360-100K-3P

HBD-240-20K-3P

HBD-360-125K-3P

Table 1

SINGLE PHASE

THREE PHASE

NOTE!

“Note” provides tips that are valuable for the optimal operation of your product.

“Danger” indicates a hazardous

situation which,

if avoided/neglected, will result in

death or serious injury.

“Warning” indicates a hazardous

situation which could result in death

or serious injury if neglected.

Machine is working on high

voltage. Do not touch, it

may burn or shock the

nearest person.

CAUT ION! R ISK OF

ELECTRIC SHOCK!

DANGER!

WARNING! C a u t i o n ! ” i n d i c a t e s a

hazardous situation which,

if not followed, could result

in minor or moderate injury.

Table 2

Sr. No.

Model

Sr. No.

Model

HBD-240-25K-3P

HBD-480-125K-3P

HBD-240-30K-3P

HBD-360-150K-3P

HBD-360-30K-3P

HBD-480-150K-3P

HBD-240-40K-3P

HBD-360-200K-3P

HBD-360-40K-3P

HBD-480-200K-3P

HBD-240-50K-3P

HBD-480-250K-3P

HBD-360-50K-3P

HBD-576-250K-3P

NOTE : This manual may be applicable for other models as well on selective basis. In case your model

inverter is not mentioned in the above list, please contact manufacturer before using this manual.

Keep this manual close to the machine where it is easily accessible for the operator/ end-user.

VERSION: This manual is valid only for HBD-NG machines dispatched after 1 April 2021.

1.2 TARGET AUDIENCE

The tasks described in this manual can be performed by qualified electricians or SEPL authorised

electricians only. Also, they MUST follow the instructions in this manual for installation and troubleshooting,

failing which, the warranty may be considered null and void in some cases.

1.3 SYMBOLS USED

Following symbols will be used throughout the manual wherever applicable:

2. INTRODUCTION

2.1 PRODUCT DESCRIPTION

Smart Storage Solar Inverters (referred to as SSSI henceforth) are also known as HBD-NG range inverters.

These machines are mechanically and electrically robust with a wide operating temperature range and hence,

suitable for operation in harsh environments. These machines are a perfect fit for low maintenance, off-grid/

hybrid installations of industrial and residential nature both.

A typical block diagram is shown below in Figure 1 involving the integration of SOLAR, GRID, BATTERY and

GENSETS with the site loads. Inbuilt intelligence manages all the sources selectively to provide seamless power

to the loads so as incur minimum bills with optimum utilization. These HBD-NG range of inverters are available in

both 1-phase and 3-phase versions under the series name of MONO-POWER and TRI-POWER respectively.

MONO-POWER series has single-phase systems ranging from 1kVA to 50 kVA with same rating of MPPT charge

controller in different battery voltage ranges.

Similarly, TRI-POWER series has 3-Phase inverters ranging from 10 kVA to 250 kVA in different battery voltage

with same rating of MPPT charge controller. Kindly visit www.energiaa.in to know more about our products

range. Custom-built ratings of inverters are also available on request and can be designed as per user

requirement.

The SSSI can be broken down into 2 Parts – MPPT-based Solar Charge Controller and Bi-Directional Inverter.

Both parts are explained in detail in the subsequent sections of this manual. On the DC side, dedicated terminals

have been provided for PV and battery connections. Number of MPPT charge controllers depends on the rating of

the system. Similarly, on the AC side dedicated terminals have been provided for connecting grid (EB or Mains)

supply and the loads. All 4 terminations (2 on DC side and 2 on AC side) have isolators/ MCCBs for ease of

operation and maintenance. All the loads connected at the load terminals will have seamless power with less

than 5msec interruption time (in case of mode switching). Please be noted that either Grid supply or DG supply

can be connected to the unit on AC side. Any kind of Mains/ DG changeover has to be made before the unit

installation and is not in the scope of the PCU.

The sequence of power from Solar PV, Grid, DG and Battery depends on the mode of operation and has been

discussed in detail later in this document. We will now discuss the key organs that comprise this HBD-NG range of

Smart Storage Solar Inverters.

Figure 1

2.2 KEY ELEMENTS OF THE MACHINE

2.2.1 MPPT-BASED SOLAR CHARGE CONTROLLER

The unit has single/ multi MPPT-based Solar Charge Controllers to convert PV power into usable DC power as per

battery and load requirements. The MPPT charger is buck type convertor such that PV voltage (under all

circumstances) should be higher than the maximum battery voltage. Hence, the series-parallel arrangement of

PV array is very critical for maximum power generation. The number of charge controllers depends on the rating

of the system.

2.2.2 BI-DIRECTIONAL INVERTER

The heart of the system includes an Active-Front-End based Bi-directional inverter which can perform AC-DC as

well as DC-AC conversion and also synchronize with Grid or DG set. The convertor can import/ export power from

Grid/DG depending upon the mode of operation. Its 4-quadrant design ensures highest level of customization to

perform charge/discharge functions.

The Bi-directional convertor can act as an inverter under normal mode of operation such that it converts PV and

Battery power into 240V/ 415V AC 50Hz supply for the connected loads. The same convertor acts as a grid charger

to charge the batteries using grid supply whenever required.

In case of three-phase systems, each phase is capable of delivering one-third power of the total inverter capacity.

All the three phases have been designed for 100% power imbalance i.e., all the 3 phases need not be loaded equally

for operation. This has been guaranteed using 3 independent circuits for the 3 phases and a 12 IGBT design which

is perfect for imbalanced type of applications.

The inverter section has inbuilt galvanic isolation using power transformer of rated capacity which ensures

rugged design under extremely fluctuating and impure grid conditions. It also provides isolation between the DC

and AC sides.

2.2.3 AUTO BYPASS ARRANGEMENT

Auto Bypass Feature is an integrated part of this system such that no extra semi-conductor device is required to

perform this function. Being an Active-Front-End Convertor, there is synchronization between Grid and Inverter

Sine wave with a seamless transfer of power from inverter to grid with less than 5msec of changeover time.

However, Anti-Islanding functionality from Grid has been achieved through an Anti-islanding Switchgear device

as per IEC standards.

2.2.4 DISPLAY KEYPAD UNIT

The Display Keypad Unit (DKU) is the single point of interaction between the user and inverter. It consists of a blue

colored graphical LCD, 8 push buttons and 3 LEDs in the form of stickers. DKU is used for settings change,

parameter display, fault annunciation or any other indication in the machine.

2.2.5 REMOTE MONITORING SYSTEM (OPTIONAL)

HBD-NG range of inverters come with an option of Remote Monitoring System (RMS) depending upon the chosen

model. For any inverter rating, three types of models are available with the suffix C00, C01 or C02, depending upon

the type of communication. C00 model does not have any external communication, C01 comes with inbuilt

MODBUS over RS485 communication, and C02 has GPRS based remote monitoring.

2.3 PRODUCT NOMENCLATURE

HBD-NG range of Smart Storage Solar Inverters has been named using a common nomenclature to avoid any

confusion. Any part number (serial number) includes the capacity of inverter, no. of phases, battery voltage,

charge controller capacity, number of charge controllers, monitoring type as well as the overload capacity.

Please ensure that right from the ordering-stage to installation, reference is made to any unit using the correct

part number. This part number is mentioned on datasheet, quotation, invoice, and also the actual unit post-

dispatch. The warranty claim registration online also involves reference to this part number to avoid any

confusion. A sample part number has been explained below for clarity:

Figure 2

Figure 3

Note:Above nomenclature shall be valid only for Power Conditioning Unit/ Smart Storage Solar Inverter (SSSI)

(*) For HBD-NG series: As HBD-NG series is standard Power Conditioning Unit/ Smart Storage Solar Inverter, they are designed on

Unit Power Factor, so kVA=kW;

(**) For Non-Standard ratings (other HBD such as JHBD, JKHBD etc.), PCU are designed on other Unity Power Factor, so kVA=kW.

Inverter maximum output shall be mentioned on specs. Plate/Rating Sticker accordingly.

2.4 RATING PLATE/RATING STICKER AND ITS TERMS

For ease of usage, every HBD-NG inverter unit is provided with a rating sticker/ordering plate. This sticker can be

found on the front side or the rear side of the unit depending upon the model number. It contains all the relevant

technical details for ease of usage. The model no. and the serial no. are important for traceability of the unit

throughout its life.

2.5 PHYSICAL APPEARANCE AND TERMINATION DETAILS OF INVERTERS

MONOPOWER/ TRIPOWER series of HBD-NG inverters come in sheet metal enclosures of standard sizes and

color shades depending upon the size of the machine. Any machine may be either wall mounted type, tower type,

floor standing, or hinged door type floor standing, depending upon the capacity of the machine. All the units are for

indoor application only and should not be kept in the open. All these units are forced cooled until mentioned

otherwise for any of the models supplied.

All the units have a common user interface provided on the front side of the panel for ease of access. The display

unit has been explained in detail separately in this manual. All the wire connections to unit are made from the

bottom side, either on the front or the rear side, depending upon the size of the machine. The terminology and

sequence of terminals have been kept the same for as many models as possible for ease of understanding and

has been explained below in detail.

The below chart brings out all the variants available in terms of dimensions and capacity of the machine. These

machines come in 8 basic variants:

Sr. No.

Rating of

Machine

Dimensions

(W X D X H)

Enclosure

Type

Colour

Shade

Cable

Entry

Wheels

Available

Y/N

Figure

No.

1-3kVA

Single-phase

Inverters

300 X 428 X 334

Tower Type

Floor

Standing

RAL-9005

Rear

Bottom

Figure-4

4-6kVA

Single-phase

Inverters

310 X 625 X 500

Tower Type

Floor

Standing

RAL7035/

RAL3020

Rear

Bottom

Figure-5

10kVA-12.5kVA

Single-phase

Inverters

400X676.5X650

Sheet Metal,

Floor

Standing,

Front/ Rear

Door

RAL7035/

RAL3020

Front

Bottom

Figure-6

10kVA-15kVA

Three-

phase/20kVA-

25kVA Single-

phase

Inverters

530X897.4X750

Sheet Metal,

Floor

Standing,

Front/ Rear

Door

RAL7035/

RAL3020

Front

Bottom

Figure-7

20kVA-25kVA

Three-phase

Inverters

550X845X800

Sheet Metal,

Floor

Standing,

Front/ Rear

Door

RAL7035/

RAL3020

Front

Bottom

Figure-8

30kVA-40kVA

Three-phase

Inverters with

Single/Three

MPPT Charge

Controller

650 X 965 X 900

Sheet Metal,

Floor

Standing,

Front/ Rear

Door

RAL7035/

RAL3020

Front

Bottom

Figure-9

Sr. No.

Rating of

Machine

Dimensions

(W X D X H)

Enclosure

Type

Colour

Shade

Cable

Entry

Wheels

Available

Y/N

Views

50kVA-60kVA

Three-phase

Inverters with

Single/ Three

MPPT Charge

Controller

850X1050X1650

Sheet Metal,

Floor

Standing,

Front/ Rear

Door

RAL7035/

RAL3020

Front

Bottom

Figure-

70kVA-100kVA

Three-phase

Inverters with

Three MPPT

Charge

Controller

800 X 1050 X

1775

Sheet Metal,

Floor

Standing,

Front/ Rear

Door

RAL7035/

RAL3020

Front

Bottom

Figure-11

Above 100kVA

Three-phase

Inverters with

Three MPPT

Charge

Controller

2000X1400X1200

Sheet Metal,

Floor

Standing,

Front/ Rear

Door

RAL7035/

RAL3020

Front

Bottom

Figure-

Table 3

Please note that dimensions, weight, enclosure type, color shade and cable entry can be changed by the

manufacturer without prior notice. This is due to technical innovations.

Now we go through the front and rear view of each of these variants in detail. The termination details of each of

these variants are also provided in tabular form, after each variant drawing.

Indice

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