Geotech enFUSION Cell 3500 Manual
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Geotech enFUSION Cell 3500 Manual

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Cell 3500 Manual
Revision 5.0

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Summary of Contents for Geotech enFUSION Cell 3500

  • Page 1 Cell 3500 Manual Revision 5.0...
  • Page 3 Before You Get Started IMPORTANT: This manual contains important instructions that should be followed during installation, operation and maintenance of the Cell 3500 controller. Carefully read and follow all safety instructions in this manual. Make sure that safety labels are always in good condition and replace missing or damaged safety labels.

  • Page 4: Table Of Contents

    Cell 3500 Manual 5.0 TABLE OF CONTENTS INSTALLATION ..................1 Task 1: Mount the Cell 3500 ..............2 Step One: Decide Best Location..............2 Important Pre-Installation Warnings..........2 Cell 3500 Requirements for Safe Installation........2 Cell 3500 Mounting Clearances............3 Cell 3500 Dimensions.................4 Step Two: Mount the Cell 3500 ..............4 Cell 3500 Unit Mounting Instructions ..........4 Task 2: Wire the Cell 3500 ..............7 Step One: Review Wiring Requirements and Warnings ......7...
  • Page 5 Cell 3500 Manual 5.0 OPERATION..................22 Task 5: Initial Cell 3500 Startup ............23 Step One: Start Cell 3500 for the First Time ..........23 Step Two: Understand Meaning of Cell 3500’s LED Lights......23 Motor Is Properly Connected .............23 Cell 3500 Overload Protection ............24 Solar Only Mode .................24 Step Three: Manually Shut Down Cell 3500 Operation ......24 Understanding Automatic Shutdown of Cell 3500 ......24...

  • Page 6: Installation

    Cell 3500 Manual 5.0 INSTALLATION Copyright© 2022, ENFusion™ Energy - All Rights Reserved. Unauthorized duplication or distribution is strictly prohibited.

  • Page 7: Task 1: Mount The Cell 3500

    Cell 3500 Manual 5.0 Task 1: Mount the Cell 3500 Step One: Decide Best Location Important Pre-Installation Warnings WARNING Do not ground the positive or negative leads of the PV modules! Only ground the mounting frames of the PV modules. Never run the Cell controller when the AC pump is not connected! It might cause damage to the controller.

  • Page 8: Cell 3500 Mounting Clearances

    Cell 3500 Manual 5.0 Cell 3500 Mounting Clearances • The Cell 3500 should be mounted at least 24 inches (60cm) above the ground when possible. • A minimum of 10 inches (25cm) of clearance above the Cell 3500 is required for internal access. •...

  • Page 9: Cell 3500 Dimensions

    Cell 3500 Manual 5.0 Cell 3500 Dimensions Dimensions of the Cell 3500 and back panel are shown in Figure 2: Cell 3500 Dimensions with additional details on how to mount the unit in Figure 3: Back View of Cell 3500 Mounting Bracket and Figure 4: Cell 3500 Unit Mounting Instructions.
  • Page 10 Cell 3500 Manual 5.0 Figure 3: Back View of Cell 3500 Mounting Bracket Back Bracket (Wall Mount) Mounting Holes Heatsink Copyright© 2022, ENFusion™ Energy - All Rights Reserved. Unauthorized duplication or distribution is strictly prohibited.
  • Page 11 Cell 3500 Manual 5.0 Figure 4: Cell 3500 Unit Mounting Instructions Fix the back bracket to the support surface by inserting four screws (not included) through the 4 holes in the back bracket Make sure all 4 set screws are used to hang the Cell Shoulder Bolt onto the back bracket Once the Cell is in place on the...

  • Page 12: Task 2: Wire The Cell 3500

    Cell 3500 Manual 5.0 Task 2: Wire the Cell 3500 Step One: Review Wiring Requirements and Warnings Installation Requirements: All electrical installations must be carried out in accordance with local standards and the National Electrical Code (NEC). Conductor rated current, temperatures, operating conditions and its power loss must be made in accordance with local standards and the National Electrical Code (NEC).

  • Page 13: Review Closeup Of Internal Wiring Features

    Cell 3500 Manual 5.0 Figure 5: Overview Diagram of Cell 3500 Showing five Wire Glands Back View Front View Back Bracket (Wall Mount) AC LO AD SO LA R W AR NI NG Mounting Holes Heatsink Motor ON/OFF Ground Signal Wire Electrode Lug Switch Glands...

  • Page 14: Review Cell 3500 Circuit Board Diagram

    Cell 3500 Manual 5.0 Figure 6: Closeup of Internal Wiring Features Solar PV Input Terminal Block 1 Solar PV Input Terminal Block 2 Float Switch and Sensor Input Terminal Blocks Motor Output Terminal Blocks Disconnect External Ground Sensor Input Electrode Lug Motor Load ON/OFF Switch Motor and Both...
  • Page 15 Cell 3500 Manual 5.0 Figure 7: Cell 3500 Circuit Board Diagram 24V for GFCI Ribbon Cable Analog Sensor Inputs (P9) Connector for Comm Board (optional) Float Switches Terminal for Motor ON/OFF Switch Closeup of DIP Switches 50Hz 3-Wire Minimum Motor Frequency Single-Phase Dry Well Protection...

  • Page 16: Review Cell 3500 System Wiring Diagram

    Cell 3500 Manual 5.0 Review Cell 3500 System Wiring Diagram Figure 8: Cell 3500 System Wiring Diagram is a top level wiring diagram illustrating how the various components are wired into the Cell 3500. Review Step One: Review Wiring Requirements and Warnings.

  • Page 17: Wiring For Single-Phase Motor Loads

    Cell 3500 Manual 5.0 Wiring for Single-Phase Motor Loads • Single-phase motor loads should be wired as shown in Figure 9: Table of Wiring for Single-Phase Motor Loads. • Single-phase 2-wire motors should be connected to phase A and C, while 3-wire motors should be wired so that common lead is wired to phase A, starting winding to phase B and main winding to phase C.

  • Page 18: Tighten The Din Rail Terminals

    Cell 3500 Manual 5.0 Tighten the DIN Rail Terminals Once the system is wired per Figure 10: Internal Wiring Diagram to DC (Solar) Sources, the power conductors wired to the DIN rail terminals inside the Cell 3500 should be tightened with torque values of: •...

  • Page 19: Set Dip Switches 1, 2, Or 3 To Match Your Motor

    Cell 3500 Manual 5.0 Set DIP Switches 1, 2, or 3 to Match Your Motor The Cell 3500 controller can operate most AC motors up to the power limits of the controller: single or three-phase; 50 or 60Hz; 120V or 230V. In order for the Cell 3500 to match the motor specifications, the first three DIP switches on the left are used for motor selection: DIP Switch 1 –...

  • Page 20: Set Dip Switches 6 And 7 For Overcurrent Protection

    Cell 3500 Manual 5.0 Set DIP Switches 6 and 7 for Overcurrent Protection DIP Switches 6 and 7 - Overcurrent Protection: • The Cell 3500 can set Figure 15: Set DIP Switches 6 and 7 overcurrent protection for Overcurrent Protection based on the motor pump Overcurrent Protection...

  • Page 21: Set Dip Switch 9 For Flow Switch Dry Well Protection

    Cell 3500 Manual 5.0 Set DIP Switch 9 for Flow Switch Dry Well Protection DIP Switch 9 Flow Switch Dry Well Protection: • When combined with an additional Figure 17: DIP Switch 9 flow switch, the Cell 3500 offers dry for Flow Switch Dry Well Protection well protection by setting DIP switch...

  • Page 22: Set Dip Switch 11 For Automatic Dry Well Protection

    Cell 3500 Manual 5.0 Set DIP Switch 11 for Automatic Dry Well Protection DIP Switch 11- Automatic Dry Well Protection: • See Figure 19: DIP Switch 11 for Figure 19: DIP Switch 11 for Automatic Dry Well Automatic Dry Well Protection. Protection The Cell 3500 monitors motor amperage for dry well protection.

  • Page 23: Cell 3500 Can Incorporate Two External Analog Sensors

    Cell 3500 Manual 5.0 A typical example of how tank and well switch signals can be used with a digital input port is shown in Figure 20: Example of “Water Tank Full” and “Well Empty”. • For a tank application, if the active wire is connected to Position 1 and the return wire (usually black) is connected to Position COM, then the Cell 3500 will stop the pump when the tank gets full because terminals 1 and COM will be “shorted”...

  • Page 24: Task 3: Complete Installation Notes

    Cell 3500 Manual 5.0 Task 3: Complete Installation Notes After Installation, Complete Installation Notes We strongly recommend that the you take an extra bit of time to fill out the installation notes (See Figure 22: Installation Notes) with valid data once installation is complete. When you call our technical support, we will ask you for this information.

  • Page 25: Configuration

    Cell 3500 Manual 5.0 CONFIGURATION Copyright© 2022, ENFusion™ Energy - All Rights Reserved. Unauthorized duplication or distribution is strictly prohibited.

  • Page 26: Task 4: Configure The Cell 2000

    Cell 3500 Manual 5.0 Task 4: Configure the Cell 3500 Step One: Size the Solar Panel Array to Motor Load Power Requirements • The Cell 3500 can power both single and three-phase motors. When sizing the solar panel array for the Cell 3500, it is necessary to know the motor load power requirements.

  • Page 27: Operation

    Cell 3500 Manual 5.0 OPERATION Copyright© 2022, ENFusion™ Energy - All Rights Reserved. Unauthorized duplication or distribution is strictly prohibited.

  • Page 28: Task 5: Initial Cell 3500 Startup

    Cell 3500 Manual 5.0 Task 5: Initial Cell 3500 Startup Step One: Start Cell 3500 for the First Time Once the Cell 3500 controller is wired to the solar source, a motor load and the DIP switches settings are configured to match the motor specification, then the Cell 3500 is ready for operation.

  • Page 29: Cell 3500 Overload Protection

    Cell 3500 Manual 5.0 The Cell 3500 immediately performs MPPT operation over the solar PV source. The MPPT operating range is 30 to 60Hz for 60Hz motors, and 25 to 50Hz for 50Hz rated motors. Cell 3500 Overload Protection The Cell 3500 has built-in overload protection. If a connected motor has a power level higher than the Cell 3500 limitations: •...

  • Page 30: Understanding Automatic Shutdown Of Cell 3500

    Cell 3500 Manual 5.0 Step Three: Manually Shut Down Cell 3500 Operation To stop the Cell 3500’s operation the ON/OFF toggle switch on the bottom of the unit should be used. Once in the OFF position the Cell 3500 will automatically stop the motor’s operation. Understanding Automatic Shutdown of Cell 3500 Automatic Shutdown With Tank or Well Float Switch However, if a tank or well float switch is used (See Figure 20:...

  • Page 31: Maintenance Of Cell 3500

    Cell 3500 Manual 5.0 MAINTENANCE Copyright© 2022, ENFusion™ Energy - All Rights Reserved. Unauthorized duplication or distribution is strictly prohibited.

  • Page 32: Task 6: Perform Recommended Maintenance

    Cell 3500 Manual 5.0 Task 6: Perform Recommended Maintenance Inspect Every Three Months The Cell 3500 unit is designed to operate autonomously. However, we suggest regular inspections every 3 months. Maintain Optimal Operational Conditions Keep Clear of External Obstructions. • If there are any external obstructions that prevent proper cooling of the heatsink area, please remove them to make sure nothing blocks the air flow from the bottom of the device.
  • Page 33 Cell 3500 Manual 5.0 Figure 26: Chart Explaining Meaning of LED Indicator Light Combinations OFF Mode Cell toggle switch is in the OFF position. Startup Mode Cell is in the process of starting the motor pump. Cell is running the motor pump. Running Mode Standby Mode There is not enough power from the solar PV panels for...

  • Page 34: Appendix A: Size The Solar System To Power The Cell 3500

    Cell 3500 Manual 5.0 Appendix A: Size the Solar System to Power the Cell 3500 Understand How to Maximize Solar Energy Size The Solar System Sizing the solar system to power the Cell 3500 and a given motor load (pump, compressor, fan, etc.) is based on the power requirement of the motor load, motor phase, daily duty cycle of the system and installation location.

  • Page 35: Minimum And Maximum Solar Pv Array Requirements

    Cell 3500 Manual 5.0 Figure 27: Sizing Solar PV Power With the Cell 3500 Controller Motor Power Solar Size 3 Solar Size 2 Solar Size 1 Time 1 Time 2 Time 3 Figure 27: Sizing Solar PV Power With the Cell 3500 Controller shows how three different solar capacities (solar power wattage) are affecting total daily pumping duration.

  • Page 36: Appendix B: Product Description, Product Specifications

    Cell 3500 Manual 5.0 Appendix B: Product Description, Product Specifications Cell 3500 Product Description The Cell solar controller is a universal, high performance, variable speed motor controller for solar applications using single-phase and three-phase AC loads in a power range from 1/3 HP to 1.5 HP. The Cell 3500 has input capability for connecting two separate solar panel arrays in parallel.

  • Page 37: Product Specifications

    Cell 3500 Manual 5.0 Cell 3500 Specifications Input Specification: • Dual Solar PV Array Input 400V* • Maximum Solar Open Circuit Voltage: 12A** • Maximum Solar PV Current in Series: • Earth-ground connected to chassis *DC PV input terminals shall only be connected to listed photovoltaic modules and panels that comply with UL 1703.

  • Page 38: Appendix C: Calculate Maximum Cable Lengths For Different Motor Load Currents

    Cell 3500 Manual 5.0 Appendix C: Calculate Maximum Cable Lengths for Different Motor Load Currents Figure 28: Maximum Input Cable Lengths in Feet (Based On 3% Voltage Drop) Motor Nominal AWG Copper Wire Sizes 90˚C Insulation [ft] LOAD [A] Voltage [V] 1200 IMPORTANT: Use copper conductors only! This unit was evaluated for temperature rating of 60/75°C on power...

  • Page 39: Appendix D: Optional Cell 3500 Module

    Cell 3500 Manual 5.0 Appendix D: Optional Cell 3500 Module About the Cell_GFCI (Ground Fault Circuit Interrupter) Module Cell GFCI includes an optional Ground Fault Circuit Interrupter (GFCI) module (See Figure 29: Internal View of Cell_GFCI) which is used for sensitive ground fault currents: 5, 10, and 30mA, and can be adjusted by using a simple jumper that is part of the GFCI module.

  • Page 40: Appendix E: Typical Diagram For Cell 3500 Operated Solar Water Pumping

    Cell 3500 Manual 5.0 Appendix E: Typical Diagram for Cell 3500 Operated Solar Water Pumping System To size the solar PV array to your specific motor please consult with your local dealer or ENFusion™ tech support. A typical diagram for a Cell 3500 operated solar water pumping system is shown in Figure 30: Typical Diagram for Cell 3500 Operated Solar Water Pumping System.
  • Page 41 Cell 3500 Manual 5.0 NOTES: Copyright© 2022, ENFusion™ Energy - All Rights Reserved. Unauthorized duplication or distribution is strictly prohibited.

  • Page 42: Terms And Conditions

    Cell 3500 Manual 5.0 Standard Terms and Conditions enfusionenergy.com THIS DOCUMENT CONTAINS PREMIER ENERGY HOLDINGS, INC., AND ALL OF ITS SUBSIDIARIES (COLLECTIVELY REFERRED TO AS “PEH”), NORTH AMERICAN STANDARD LIMITED WARRANTY, GENERAL SALES POLICIES AND CONTROLLING TERMS AND CONDITIONS. THIS NORTH AMERICAN STANDARD LIMITED WARRANTY, GENERAL SALES POLICIES AND CONTROLLING TERMS AND CONDITIONS SHALL NOT BE ALTERED OR AMENDED EXCEPT PURSUANT TO AN AUTHORIZED...
  • Page 43 Cell 3500 Manual 5.0 The due date of payment shall be measured from the invoice date. Terms are net thirty (30) days from date of invoice of each shipment, unless otherwise stated. Any portion of the purchase price which is not paid in accordance with applicable payment terms shall accrue interest at a rate equal to one and one-half percent (1 1/2 %) per month or the highest rate allowed by law, plus any attorney fees and other costs associated with collections.
  • Page 44 Cell 3500 Manual 5.0 assignable or transferable to any subsequent purchaser or user. THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, WRITTEN OR ORAL, STATUTORY, EXPRESS, OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. PURCHASER’S SOLE AND EXCLUSIVE REMEDY FOR PEH’S BREACH OF ITS OBLIGATIONS HEREUNDER, INCLUDING BREACH OF ANY EXPRESS OR IMPLIED WARRANTY OR OTHERWISE, UNLESS PROVIDED ON THE FACE HEREOF OR IN A WRITTEN INSTRUMENT MADE...
  • Page 45 Cell 3500 Manual 5.0 MISCELLANEOUS In compliance with Laws, Ordinances and Regulations PEH shall use reasonable efforts to cause the products to comply with federal safety, health and environmental regulations and insurance codes. However, PEH shall not be responsible for compliance of the products with local interpretations of such federal regulations or insurance codes, nor with any local laws, ordinances, codes and/or regulations which may at any time be in effect at any location where the products are to be...
  • Page 46 Cell 3500 Manual 5.0 Unless otherwise agreed in writing, no information disclosed in any manner or at any time by Purchaser to PEH shall be deemed secret or confidential, and Purchaser shall have no rights against PEH with respect thereto, except such rights as may exist under applicable patent laws.
  • Page 47 Cell 3500 Manual 5.0 NOTES: Copyright© 2022, ENFusion™ Energy - All Rights Reserved. Unauthorized duplication or distribution is strictly prohibited.
  • Page 48 US Patents: PATENT NO. 10,931,220 PATENT NO. 10,840,831 PATENT NO. 10,560,033 PATENT NO. 11,171,486 International Patents: PATENT NO. (EP) 3,362,867 PATENT NO. (AU) 2016338999 PATENT NO. (CN) 108431719...

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