Summary of Contents for Apollo Solar GEM
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Page 1: User Manual
Generated Energy Management System User Manual Installation Manual Revision 3, August 2015 Apollo Solar Electric Ltd... -
Page 2: Table Of Contents
Setting Water Temperatures Apollo GEM Set-up Mode User Set-up Screens Installer Set-up Screens Apollo GEM Variable Output Operating Modes Apollo GEM Threshold Output Operating Modes Apollo GEM Mixed Operating Modes Increasing Apollo GEM Output Power Variable mode increased power operation... - Page 3 Contents Apollo GEM Installation Guide Installing the Apollo GEM Controller Positioning Apollo GEM Control Unit Supply Apollo GEM Direct Wired System Schematic Apollo GEM Wireless System Schematic Electrical Connections Current sensor clamp connection Temperature Sensor Connection Connecting to the terminals...
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Page 4: Important Safety Information
Important Safety Information Warranty Apollo Solar Electric has made every effort to ensure the accuracy of the content of this manual. However, it is possible that it may contain technical inaccuracies or typographical or other errors. Apollo Solar Electric will assume no liability for any inaccuracy found in this publication, nor for damages, direct, indirect, incidental, consequential or otherwise, that may result from such an inaccuracy. -
Page 5: Introduction
If the water is normally heated using gas or oil the Apollo GEM system will work in conjunction with the normal water heating system. On days when there is insufficient energy available from your PV system to fully heat the water your gas or oil system will ‘top up’... -
Page 6: The Apollo Gem Control Unit
Apollo GEM User Manual The Apollo GEM Control Unit The Standard Apollo GEM control unit is usually located near the consumer unit and controls the operation of the whole system. With the optional wireless sensor transmitter kit the control unit can be located away from the consumer unit, typically near the hot water cylinder or other connected appliance. -
Page 7: The Apollo Gem Power Sensor
The Apollo GEM Power Sensor The Apollo GEM system senses the import and export power using a clamp-on current sensor unit located near the meter or consumer unit. The current sensor is connected to the Apollo GEM controller. the optional wireless sensor transmitter kit the current sensor is If the Apollo GEM is using connected to the sensor transmitter unit instead of the Apollo GEM controller unit. -
Page 8: Detailed Operation Description
Mixed Mode Operation The Apollo GEM has two outputs and it is possible to run one in variable power mode and the other in threshold mode. This can be used to heat a hot water cylinder, which when up to temperature, the system can then power an appliance in threshold mode if generated power is still available. -
Page 9: Other Apollo Gem Features
Other Apollo GEM Features Manual Boost Function In addition to the "optimising" modes where Apollo GEM is using the excess generated power, a manual boost function is provided to allow a connected heater or appliance to be manually turned on irrespective of whether there is excess generated power available or not. -
Page 10: The Apollo Gem Display
Apollo GEM User Manual The Apollo GEM Display Apollo GEM is provided with a 4 line illuminated LCD display to provide the user with information such as current hot water temperature, export and import power levels etc. Press any button in order to illuminate the display. The display will stay illuminated for 30 minutes after the last button is pressed before turning off. - Page 11 Apollo GEM User Manual System Function Display The system function messages are displayed on the 2 line of the home display. The messages that could be displayed are shown below. This is the normal display. Optimising is on and using output 1 in variable power mode and...
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Page 12: Error Message Display
Apollo GEM User Manual Error Message Display If no errors are detected by the system the bottom line of the display will show the current power being imported to or exported from the property. If the system detects an error this is displayed on the bottom line of the display instead of the import/export power. -
Page 13: Boost Mode
Apollo GEM User Manual Boost Mode If it is required to boost the hot water temperature at any time using the electric water element, this can be done by simply pressing the boost button. Boost can also be used to manually turn on an output when operating in threshold mode. -
Page 14: Setting The Timer
Apollo GEM User Manual Setting the Timer Apollo GEM timer can be programmed to give 3 on/off times per day for Monday to Friday and 3 different on/off times for Saturday & Sunday. When the timer is on, the water will be heated at full power regardless of whether any surplus PV power is available. -
Page 15: Legionella Control Function
Apollo GEM User Manual Legionella Control Function What is Legionella? Legionellosis is the collective name given to the pneumonia-like illness caused by legionella bacteria. Legionnaires’ disease is a potentially fatal form of pneumonia and everyone is susceptible to infection. However, some people are at higher risk, including: people over 45 years of age •... - Page 16 PV optimising will resume. If the Apollo GEM tank temperature sensor is not used, the temperature set by the electric hot water thermostat will be used, therefore this should be set to a minimum of The legionella cycle will always heat at full power until the required temperature is reached.
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Page 17: Setting Water Temperatures
Apollo GEM User Manual Setting Water Temperatures can use one of two methods to control the water temperature: Apollo GEM Using the electric water element thermostat (standard system), or Using the optional Apollo GEM tank temperature sensor. Each output can be programmed to use either method, or no temperature control. - Page 18 Apollo GEM will work well with an existing gas or oil heating system. The more energy Apollo GEM is able to deliver to the hot water system, the less energy will be needed by the normal hot water system. On summer days it is possible that no energy will be used at all by the normal heating system.
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Page 19: Apollo Gem Set-Up Mode
Apollo GEM User Manual Apollo GEM Set-up Mode Apollo GEM set-up mode is used to program various operating parameters such as the time/date, enable or disable the optimiser or timer, program the timer on/off times, enter the required optimiser and timer hot water temperatures etc. -
Page 20: User Set-Up Screens
GEM Installation Manual Apollo GEM User Manual User Set-up Screens All of the Apollo GEM set-up screens are shown below. Timer ENABLED Screen 1. Timer and optimiser enable/disable Optimiser ENABLED The timer and optimiser functions can be independently enabled or disabled. -
Page 21: Installer Set-Up Screens
Apollo GEM User Manual Installer Set-up Screens The installer menu Changing Installer Menu? to "YES" will display the 3 additional installer menu screens. See the installation guide section of this manual for more detailed information about the installer menu functions. -
Page 22: Apollo Gem Variable Output Operating Modes
Apollo GEM User Manual Apollo GEM Variable Output Operating Modes The diagrams below illustrate the various modes Apollo GEM can operate in using variable power output mode. Output 1 Output 1 VARIABLE Single Output GEM Controller GEM Controller Mode Output 2... -
Page 23: Apollo Gem Threshold Output Operating Modes
Apollo GEM User Manual Apollo GEM Threshold Output Operating Modes The diagrams below illustrate the various modes Apollo GEM can operate in using threshold power control mode. Output 1 Output 1 THRESHOLD GEM Controller GEM Controller Single Output Output 2... -
Page 24: Apollo Gem Mixed Operating Modes
Apollo GEM User Manual Apollo GEM Mixed Operating Modes The diagrams below are examples of mixed mode, variable and threshold mode, operation. Mixed 2 Output Output 1 Priority Mode VARIABLE GEM Controller Output 2 THRESHOLD Initially power is diverted to output 1 in variable mode. When output 1 has reached the set temperature... -
Page 25: Increasing Apollo Gem Output Power
For threshold mode operation power can be increased to 16KW. Variable mode increased power operation Note that if Apollo GEM is configured to operate in 6, 9 or 12KW mode then only output 1 will be available. Output 2 is used to control the external contactors. -
Page 26: Threshold Mode Increased Power Operation
Threshold mode increased power operation In threshold mode operation the standard Apollo GEM can support a total load of 3KW, i.e. 3KW on each output if operated in priority mode or a total of 3KW for both outputs if operated in 1 & 2 threshold mode. -
Page 27: Apollo Gem Installation Guide
If in doubt consult a qualified electrician. Electric Water (Immersion) Element The Apollo GEM system uses a standard electric water element up to 3KW and will electronically regulate the power flowing into the heating element to give a controlled power input from 50W to 3000W. -
Page 28: Installing The Apollo Gem Controller
Installing the Apollo GEM Controller Positioning The Apollo GEM control unit is generally installed in the vicinity of the main consumer unit. If used in wireless mode with the optional wireless power sensor the control unit can be positioned in the vicinity of the hot water cylinder. -
Page 29: Apollo Gem Control Unit Supply
(L1 or L2) and the water heater and positioned in the vicinity of the water heater. If the Apollo GEM controller is located in the vicinity of the water heater a double pole isolator must be incorporated in the supply to the Apollo GEM and co-located with the Apollo GEM controller. -
Page 30: Apollo Gem Direct Wired System Schematic
Apollo GEM Installation Manual Apollo GEM Direct Wired System Schematic The drawing below shows the wiring connections for the Apollo GEM system when directly wired. (earth connections not shown for clarity) Electric Hot Water Heater Element Double Pole Electric Hot Water... - Page 31 Apollo GEM Installation Manual Live to Electric hot water element Electric water MCB or Fuse Apollo GEM Direct wired electric hot water circuit before installation (Neutral and earth connections not shown for clarity) Live to Electric hot water element GEM Controller...
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Page 32: Apollo Gem Wireless System Schematic
Apollo GEM Installation Manual Apollo GEM Wireless System Schematic The drawing below shows the wiring connections in the complete Apollo GEM Wireless system. PV System Isolator Current Sensor Apollo Sensor Transmitter Immersion 6A Transmitter Radio Link Circuit** Supply Circuit* Water... -
Page 33: Electrical Connections
Current sensor clamp connection The current sensor is supplied with a 2-pin connector and is plugged into the two pin socket marked “CT CLAMP” on the main Apollo GEM circuit board. For wireless systems the CT clamp input is not used. -
Page 34: Connecting To The Terminals
Heating appliances draw high currents. It is important that the cables are properly connected to ensure safe operation of the equipment. Follow the steps below to ensure connections are properly made to the Apollo GEM controller. • Prepare the cable end as shown:... -
Page 35: Installing The Apollo Gem Current Sensor
Apollo GEM Installation Manual Installing the Apollo GEM Current Sensor The Apollo GEM current sensor is an opening clamp type sensor that is clamped around the meter tail cable between the main utility meter and the consumer unit. The current sensor together with the controller measure the power being imported to or exported from the building. - Page 36 Apollo GEM Installation Manual <<< or >>> PV System PV System Isolator Isolator Henley Block Consumer Unit Consumer Unit Current Sensor Positioning with Multiple Consumer Units. Position sensor on utility meter side of “Henley” block The current sensor clamp when installed on the live conductor is positioned with the label “This side facing main meter”...
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Page 37: Sensor Transmitter Installation (Wireless Systems)
Apollo GEM Installation Manual Sensor Transmitter Installation (Wireless Systems) The Apollo GEM transmitter is designed to attach to a standard DIN rail and so can be mounted inside a (plastic) consumer unit if there is room. The unit is 2 modules wide. -
Page 38: Setting Up The System
Apollo GEM Installation Manual Setting up the System Apollo GEM is a very flexible system with may configuration options to enable use in a wide variety of situations. If the system will be used for the standard application of diverting excess PV power to a hot water cylinder using a single water heating element the system can be used straight out of the box with no configuration. -
Page 39: Initial Checks (Non-Wireless Installation)
If the display shows “Exporting X.XKW” then the sensor clamp is positioned on the cable facing the wrong way. Unclamp the sensor and turn it around to face the other direction. 4. If the bottom line of the Apollo GEM display shows “Importing X.XKW” the PV system can be turned back on. -
Page 40: Initial Checks (Wireless Installation)
This is to ensure that only the correct power readings are received where two or more Apollo GEM systems are installed in overlapping coverage, e.g. next door properties. When displaying the [Pairing New Sensor] message Apollo GEM will search for a sensor signal which is transmitting the “find me”... -
Page 41: Control Unit - Sensor Transmitter Pairing
• Sensor transmitter or controller has been changed from the ones originally paired. A new sensor transmitter can be paired with the Apollo GEM controller by going to set-up screen 6 (installer menu) and changing the wireless parameter from “PAIRED” to “START PAIR”... -
Page 42: Apollo Gem Configuration Options
Apollo GEM Installation Manual Apollo GEM Configuration Options The system configuration options are found in the installer menus at the end of the set up menu screens. There are three installer menu pages. The first installer menu screen sets the basic mode (primary or secondary controller) and the output mode, i.e. -
Page 43: Apollo Gem Unit Modes
It is possible however to operate more than one Apollo GEM controller on the same supply and generation system. If two Apollo GEM controllers were used this would give a total output capability of 7.2KW into two 3KW loads which could be in different locations and would be applicable to micro generation systems sized between 4KW and 10KW. - Page 44 Apollo GEM Unit Modes Up to two Apollo GEM units can be used in the same system. For a two unit installation each controller is designated to be a primary or secondary unit using the unit mode parameter in the installer menu.
- Page 45 Apollo GEM Installation Manual Apollo GEM Output Modes Apollo GEM controller has two separate outputs. Each output is capable of driving a load up to 3KW. Each output can work in variable power mode (typically for heating loads) or in a threshold driven full power mode, typically used for non heating appliances.
- Page 46 Apollo GEM Installation Manual Installer Menu 2 & 3 (Output Configuration) Load Power Mode: 100W - 12000W Variable Threshold Tmr Only OP1 Variable 03000W Temp Control T/Stat Output Temperature Control: Number T/Stat Sensor None Output Options when output mode is Variable...
- Page 47 The output will use the mechanical thermostat built into the heater to control temperature. Note: for this option to be used the load must be directly connected to the Apollo GEM output and be >100W Sensor The output will use the optional temperature sensor to control temperature.
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Page 48: Summary Of Available Output Mode Combinations
1. This mode is only suitable for connection of "dumb" restive heating loads such as a standard immersion heater. Threshold mode load management using only output 1. GEM will wait until the ONLY O/P 1 exported excess PV power reaches the level programmed. Once the Threshold programmed level is reached output 1 is turned on fully. - Page 49 Apollo GEM Installation Manual Output Operation Mode setting Setting Variable Variable Variable Threshold Operation is the same as described for 1 THEN 2 but with the priority sequence 2 THEN 1 Threshold Variable reversed. Threshold Threshold In this mode both outputs are active in variable power mode. The available excess power is shared between output 1 and 2, i.e.
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Page 50: Installing The Apollo Gem Temperature Sensor
Apollo GEM controller. 5M and 10M temperature sensor extender cables are available from Apollo Solar Electric. If the cylinder has a temperature sensor pocket the Apollo GEM probe should be inserted into the pocket as far as it will go. -
Page 51: Apollo Gem 5 Year Warranty
Warranty. The customer agrees that all premises, plant, power, and other inputs that he/she is providing for the installation and use of the Apollo GEM Products are reasonable, are fit for purpose and will be properly used and provided. - Page 52 In the even the customer wishes to make a claim under his warranty such a claim must be made in writing by post or email to Apollo Solar Electric enclosing the following information: 1. Name and address of the end customer 2.
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Questions and answers
Our Apollo GEM is causing the house RCD to trip - any ideas why? We are experiencing some trouble with the local mains supply such as the occasional power surge - could this be the cause?I have turned the Gem off for now and the RCD is now holding. The Gem has worked perfectly since installed in 2014/15. Fairly certain that the power sensor is the problem - turn this off and no RCD trip. Thankyou for any advice.
The Apollo GEM may be causing the house RCD to trip due to incorrect sensor installation. If the current sensor is installed the wrong way around, it may cause incorrect power readings, leading to improper operation. The installation manual suggests checking the sensor installation by verifying LED indicators. If the orange LED flashes instead of the green LED, the sensor is reversed and needs to be re-clamped or have its wiring reversed. Additionally, connecting unsuitable appliances to the Apollo GEM’s variable power output may cause electrical issues, as only heating devices should be used in that mode.
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My generated energy manager has been working very well for many years.The screen has suddenly gone completely blank, it does not respond to pressing any of the buttons on the front. All electrics in the house are working normally. I am not sure whether the water is being heated as it should or not
My Apollo goes into boost at any time for between three and five minutes randomly