Nedap PowerRouter PR30S Application Manualline
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Nedap PowerRouter PR30S Application Manualline

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PowerRouter application guideline
Technical information about a self-use installation
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Summary of Contents for Nedap PowerRouter PR30S

  • Page 1 PowerRouter application guideline Technical information about a self-use installation...

  • Page 2: Table Of Contents

    Contents Introduction ........................3 Step 1. Assembly ......................4 Step 2. PowerRouter AC connection ................5 External relay for the backup power supply ..............8 External relay for load management ................9 Step 3: Connecting the sensor ..................11 Step 4: Connecting the solar strings ................14 Step 5: Connecting the batteries ...................

  • Page 3: Introduction

    The steps in this document are based on the standard procedure for connecting the system. Detailed information about the installation can be found in the installation manual that comes with the PowerRouter. That manual can be downloaded from www.PowerRouter.com. Nedap recommends you read this manual thoroughly before beginning the installation.

  • Page 4: Step 1. Assembly

    Step 1. Assembly Important considerations > The ingress protection rating of the PowerRouter is IP20 (protected against objects >12.5 mm; not protected against water) > The PowerRouter must be installed in a well-ventilated room in which the temperature is maintained between -10 and 40 °C.

  • Page 5: Step 2. Powerrouter Ac Connection

    Step 2. PowerRouter AC connection The PowerRouter is a 1-phase inverter that is connected to the utility grid via the ‘AC grid’ connection. Figure 3 is a simplified technical diagram of a self-use system based on the PowerRouter. Although not shown in this drawing, circuit breakers and a master switch must be installed.
  • Page 6 Optional backup power supply The PowerRouter provides users with a self-use system with backup power supply which intervenes in the event of a power outage. The PowerRouter has two AC connections: an AC GRID and an active AC LOCAL OUT. In the event of a grid failure, the PowerRouter will switch selected loads over to AC LOCAL OUT via an external 230V relay*, providing them with power.
  • Page 7 PR50SB-BS Cable cross section Nedap recommends you to connect the PowerRouter in the vicinity of the grid connection and use copper cables with a minimum cross section of 4 mm2. This eliminates unnecessary losses in the internal system and also prevents voltage disconnects caused by high grid impedance when supplying a high output current.

  • Page 8: External Relay For The Backup Power Supply

    External relay for the backup power supply Connecting an external relay Through use of an external relay, some of the single phase loads can be connected to the AC LOCAL OUT connection on the PowerRouter, which provides backup power during a power outage. This creates a backup system with a switch-over time of ≥...

  • Page 9: External Relay For Load Management

    External relay for load management Connecting the external relay To increase self-use it is possible to have the PowerRouter AC grid automatically connect larger loads when excess solar energy is available. Below is a circuit diagram which shows how the external relay (p/n PRA1RLY) is controlled by one set of potential-free contacts.
  • Page 10 Connecting alarm to potential-free contact Once the alarm settings have been configured, the alarm must be assigned to a set of potential-free contacts. The terminals for these contacts are labelled K201 (relay 1) and K202 (relay 2) and are located to the right of the AC LOCAL OUT connection.

  • Page 11: Step 3: Connecting The Sensor

    Step 3: Connecting the sensor The 1-phase sensor (p/n PRA1SENSE) or the 3-phase sensor (p/n PRA3SENSE) measures the flow of current to and from the public electricity grid. This enables the PowerRouter to measure the demand from the loads and detect the amount of power being supplied to the grid. When the battery is not fully charged, priority is first given to charging the battery.
  • Page 12 Figure 12: 1-phase sensor Figure 13: Connecting the 1-phase sensor The cable on the sensor is terminated with an RJ45 plug, which must be inserted into the PowerRouter’s CAN terminal. The sensor must be connected to the lower RJ45 socket, which is covered by a blind hole cover (see Figure 13).
  • Page 13 3-phase sensor With a 3-phase sensor, load demand can be measured for all three phases at the same time. When used with a generation/consumption meter that is capable of two-way communication, this makes it possible to compensate for consumption on one phase by feeding power into the grid on the other two phases. With this two-way communication, all power flows can be added together, so the meter indicates the total positive or negative balance.

  • Page 14: Step 4: Connecting The Solar Strings

    Step 4: Connecting the solar strings Because the PowerRouter’s photovoltaic connections are electrically isolated from the AC section, the PowerRouter can be used with all kinds of solar modules and a wide range of input voltages. Modules that can be connected to the PowerRouter: >...
  • Page 15 Photovoltaic modules often come with short cable connections (usually Ø 4 mm ) with MC4 connectors. If the total length of the free running cable between the modules and the PowerRouter is less than 50 m, Nedap recommends that you use a double-insulated solar cable with a diameter of 4 mm .
  • Page 16 DC disconnection switch Since the voltage across the photovoltaic connections can be very high, it is important that the PowerRouter can be disconnected from the photovoltaic modules for assembly or maintenance or in an emergency. A DC switch is located on the back side of the PowerRouter. On PowerRouters with two photovoltaic inputs, this switch disconnects both at the same time.

  • Page 17: Step 5: Connecting The Batteries

    Ah (24 V) and that a fully-charged battery can be discharged to 50% DOD. Nedap recommends that you connect a battery of at least 150 Ah at 24 V. The capacity value is specified in the battery datasheet as a C10 value (the 10 here stands for the time to discharge).
  • Page 18 The DOD can be confi gured using the Software Installation Tool. When using a 3-phase sensor, Nedap recommends limiting the level to which the battery can discharge. This is to avoid discharging the battery too quickly so that the C10 value no longer applies.
  • Page 19 Temperature effects Ambient temperatures have a large influence on battery capacity. At low temperatures, the capacity drops quickly. This is illustrated in figure 24 (capacity of a gel battery). The temperature of the room where the batteries are installed must therefore be kept above 10 °C. Maximising battery service life Batteries must not be left in the discharged state for too long, because doing so reduces their service life.
  • Page 20 When in winter mode, maintenance charging continues to be performed as usual. If the PowerRouter is configured to perform maintenance charging once every three weeks, the battery will be fully recharged at this interval. Even in winter mode, the battery is always available to provide backup power. When needed, the battery is reactivated and then used to provide the backup power.
  • Page 21 Place the battery as close as possible to the PowerRouter to keep the cable as short as possible (≤ 2.5 m). Voltage sense When using longer battery cables (> 2.5m), Nedap recommends connecting sensor wires for voltage compensation. This enables the PowerRouter to measure the voltage across the poles of the battery before any voltage losses through the cables and connections.
  • Page 22 The fuse, including holder, is supplied by Nedap. The matching fuse holder is manufactured by Pudenz and its part number is Figure 29: Fuse with holder 177.5701.00.

  • Page 23: Step 6: Connecting The Internet Connection

    Internet. The PowerRouter uses this connection to send log data to the Nedap server once per minute, which can then be read and monitored remotely. These log data are available to customers, installation engineers and dealers at myPowerRouter.com. The information provided by this webportal can be found in the myPowerRouter.com brochure.
  • Page 24 Monitoring – myPowerRouter.com Installation engineers and dealers can use the monitoring function in the myPowerRouter.com web portal to monitor the status of the PowerRouter remotely. When a customer phones with a question or to report a problem, the installation engineer or dealer can check the system and possibly even correct the problem without ever leaving the office.

  • Page 25: Step 7: Initialising The Powerrouter

    Step 7: Initialising the PowerRouter Perform the following steps to put a PowerRouter in service: Connect a charged battery to the PowerRouter Switch on the connection to the solar strings with the switch on the base of the PowerRouter Connect the PowerRouter to the grid power supply Switch on the PowerRouter with the switch to the right of the display The display now shows a message indicating that the PowerRouter can be confi gured in one of two ways.
  • Page 26 (around 1 night). If a C10 value is not specified, enter the closest C value. For the system to work well, the capacity must be between 150 Ah and 1000 Ah. On a 5kW system, Nedap recommends a battery capacity of 350 - 450 Ah.

  • Page 27: Three-Phase Self-Use System

    Three-phase self-use system The PowerRouter is a 1-phase inverter. It can be used to supply the energy to a single external conductor. Three PowerRouters and three battery banks allow you to set up a 15kW system which optimises self-use on three phases.

  • Page 28: Glossary

    Glossary 1-phase sensor Sensor that is clamped around the phase conductor which measures the direction and magnitude of the current into the grid. 3-phase sensor This sensor senses the current flow on all three phases of the grid connection at the same time. 3-stage charging Charging method in which a battery is charged in three stages, each with different characteristics.
  • Page 29 Backup time Indicates how long the connected load can be supplied with energy in the event of a grid failure. This depends on the continuous load. C10 value Capacity of the battery when discharged in 10 hours. CAN terminal Controller Area Network (CAN), a standard for the serial databus.
  • Page 30 Port 80 The port on an internet router which the PowerRouter uses to communicate with the Nedap web server. RJ45 connector Plastic connector with 8 contacts. State of Charge of the battery.
  • Page 31 TN-S/TN-C/TNC-S/TT Earthing systems. TN-S system: PE and N are separate conductors that are connected together only near the power source. TN-C system:a combined PEN conductor fulfills the functions of both a PE and an N conductor. TN-C-S system: part of the system uses a combined PEN conductor, which is at some point split up into separate PE and N lines.

This manual is also suitable for:

Powerrouter pr30sb-bsPowerrouter pr50sPowerrouter pr37sPowerrouter pr37sb-bsPowerrouter pr50sb-bs

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