NRG Systems 11708, Instructions Manual

Page 1: ...All Weather PVH Kit NRG SRA System Kits 11708 11709 11710 Authors Technical Services ...

Page 2: ...S 5 In the Kits 5 Required Tools 5 Recommended Additional Documentation 5 Precautions 6 SECTION 1 ASSEMBLING THE ALL WEATHER SYSTEM TOWER 6 1 1 Construct and Erect the 2 2m Tower 6 SECTION 2 ASSEMBLING THE PV PANELS BRACKETS 7 2 1 Open and unpack all items 7 2 2 Construct the PV Frame 7 2 3 Attach Ventilator Control System Shelter Box to Tower 15 2 4 Mount 110S Temperature Sensor 16 ...

Page 3: ...re Sensor to the Control System 22 4 3 Wiring Status Signals from the Control System to the Data Logger 23 4 4 Wiring the Batteries to the Control System 24 4 5 Wiring the PV Panels to the Control System 25 SECTION 5 LOGGER CONFIGURATION FOR STATUS SIGNALS 26 5 1 Heater Status 26 5 2 Fan Status 26 5 3 Battery Bank Voltage Monitoring 27 5 4 Logger Configuration Summary Table 27 SECTION 6 CONFIGURIN...

Page 4: ...tion of snow and ice To accommodate the power requirements of the VU01 the PVH Kit uses a second 2 2m tower frame mounted PV panels a deep cycle battery bank and charge controller The system is controlled by a preprogrammed PLC which switches the fan and heater on and off The system status is monitored by our SymphoniePRO data logger NRG Systems has created three PVH Kit options depending on the c...

Page 5: ...ng Required Tools NRG SRA Tower tools see SRA System manual 3 16 hex key 5 32 hex key 7 16 combination wrench 3 4 combination wrench 5 16 nut driver or Cordless drill impact driver with 5 16 nut driver bit Small flathead screwdriver Diagonal cutters Tape measure 6ft stepladder Wire crimpers 5lb Sledgehammer or similar sized hammer Slope angle meter included with tower Compass or GPS Electrical tap...

Page 6: ...lip around the threaded hole When inserting a slide nut into an extruded aluminum rail the lip should always face the center of the rail not outward towards the bolt Failure to do so can prevent the nut from sliding easily inside the channels of the rail Do not overtighten bolts Overtightening bolts may result in damage to hardware Loctite 242 has been provided in all hardware kits NRG recommends ...

Page 7: ...damaged 2 2 Construct the PV Frame 2 2 1 Attach the longest frame pieces extruded aluminum 65 length to the PV panels Place PV panels on work surface face down Place multiple panels together with the long sides touching each other Be careful not to scratch glass surface Thread four 1 4 20x 375 hex bolts 11052 through the PV panel holes indicated Figure 2 1 and attach 1 4 flat washers and slide nut...

Page 8: ...um and panel Figure 2 4 Figure 2 3 Create space for aluminum rail Figure 2 4 Slide rail onto the slide nuts Determine which PV panel will be at the top then make sure it is flush with the ends of the rails If more than one panel is included with your kit leave a small about 1 8 gap between panels on the rails 2 2 3 Assemble the top tower mount Use the diagonal cutters to cut the zip tie packaging ...

Page 9: ...ssembled hinges on shorter aluminum rails Remove slide nuts from the 1 4 20x1 25 bolts on the V block then add Loctite to the threads and reattach Slide the V block assembly onto the 12 rail in the channel opposite of the hinge Figure 2 6 Center the block onto the rail and tighten bolts to secure Figure 2 6 Slide V block onto the 12 rail then center ...

Page 10: ... of the 25 aluminum crosspieces Figure 2 8 Orient the corner brackets so that the round hole is touching the crosspieces the oval holes will attach to the long PV mounted rails Do not tighten yet Figure 2 8 Corner brackets attached to crosspiece Note the orientation of the hinge Slide the crosspieces onto the 65 rails of the main assembly The top tower mount goes behind the top PV panel about 1 fr...

Page 11: ... assembly to the tower Loosen the nuts on the 3 5 U bolt to allow enough space to fit around the tower tube Using two people and the 6ft stepladder lift the assembly up and slide it over the top of the tower U bolt should be approximately 4 5 from the top of the tower for adequate spacing to mount the shelter box Tighten U bolt nuts with 3 4 wrench Figure 2 11 Do not overtighten Figure 2 11 PV fra...

Page 12: ...lide nuts and add Loctite then loosely reattach Figure 2 12 Out of box assembly of lower tower angle adjuster mount To mount around the tower first remove the components from one side of the threaded rods Figure 2 13 Slide around the tower approximately 44 below the U bolt and reassemble Figure 2 14 Ensure that the threaded rod is evenly distributed on each side of the mount 1 5 1 75 beyond the in...

Page 13: ...l of the outer components is not necessary Mount the 48 angle adjustment rails to the outer brackets of the assembly through the slide nuts Figure 2 15 Orient the rail such that the hinge attached to the end is at the top and the semicircular piece is facing the PV frame Figure 2 15 Complete assembly of lower tower angle adjuster mount Aluminum rail is mounted onto slide nut and outer bracket is n...

Page 14: ...e nuts from each semicircular piece Add Loctite to the threads of all three bolts in each hinge Figure 2 16 Semicircular end piece removed and attached to PV frame Reattach the slide nuts then slide semicircular end pieces onto the lower PV assembly crosspiece Figure 2 16 Line up with angle adjustment rail then tighten thru bolt to lock in place If lined up correctly the hinge should assemble easi...

Page 15: ...ystem Shelter Box to Tower Thread the provided band clamps through the outer slots of the brackets on the back of the shelter box Wrap the band clamps around the tower and secure with a 5 16 hex nut driver An electric drill or impactor with a 5 16 nut driver will speed up the tightening process Figures 2 18 2 19 Shelter box brackets and attachment to the tubular tower ...

Page 16: ...cessary to chain the included 12V deep cycle batteries using the supplied cables to create a battery bank These batteries contain a significant amount of energy Use caution or serious injury may result Place the batteries in the supplied battery boxes enclosures so they are protected from weather prior to making the connections Connect to on the batteries and connect to using the 4 Gauge AWG batte...

Page 17: ... 18 April 2018 SECTION 3 INSTALLATION OF THE VU01 TO THE SRA TOWER 3 1 Install the SR20 Pyranometer into the VU01 ventilator unit See section 5 2 and 5 3 of the Hukseflux VU01 manual for detailed instructions on how to install the SR20 into the VU01 ventilator unit Excerpts from the Hukseflux manual have been provided below ...

Page 18: ...NRG Instructions SRA System All Weather PVH Kit SRA_All Weather_PVH_Kit_Instructions Rev 5 0 support nrgsystems com Page 18 18 April 2018 ...

Page 19: ...or and pyranometer See figure 3 1 Note NRG SRA Tower top plates produced before September 2017 may not have the appropriate holes to mount the VU01 ventilator You can either measure and carefully drill the appropriate holes or contact NRG to purchase an updated top plate Figure 3 1 Mounted VU01 with SR20 and a second SR20 3 2 2 Connect the Hukseflux pyranometer to your SymphoniePRO data logger The...

Page 20: ...h a multi conductor cable which plugs into the ventilator At the other end the bare wires connect to the All Weather Control System according to Figure 4 1 and Table 4 1 below Figure 4 1 Note that the blue wire from the VU01 cable connects to the red wire of the supplied NRG 4C cable by a butt connector Crimp the connector properly to ensure that the bare wire ends adequately make contact with eac...

Page 21: ...IRE CONNECTIONS PIN VU01 Cable Wire VU01 Signal All Weather Control System Connection 1 Brown fan TECO PLC Q3 4 Yellow fan fan status signal Load 6 Blue fan status signal Crimp to NRG 4C Cable Red Wire 2 Red heater 1 TECO PLC Q1 8 Grey heater 1 Load 3 Pink heater 2 TECO PLC Q2 5 Green heater 2 Load 7 White not connected not connected 9 Black shield Load ...

Page 22: ...All Weather Control Algorithm relies on ambient temperature to operate the heaters The NRG 110S Temperature sensor connects to the TECO PLC A1 analog input Figure 4 2 Table 4 2 Figure 4 2 TABLE 4 2 110S TEMPERATURE SENSOR CONNECTIONS SENSOR Sensor Cable Wire All Weather Control System Connection EXCITATION Red Load SIGNAL Clear TECO PLC A1 GROUND Black Load SHIELD Bare Braided Load Red Black Clear...

Page 23: ... Wire All Weather Control System Connection Logger Connection PRO Logger Channels Signal Type HEATER ON OFF Clear TECO PLC Q1 Any Available Analog Channel P SCM Channel Sig with P SCM 9135 installed 16 26 0 Off 12 On Black Load Any Available Analog Channel P SCM Channel Sig with P SCM 9135 installed 16 26 FAN ON OFF Red Crimp to VU01 Cable Blue Wire Any Available Analog Channel P SCM Channel Sig w...

Page 24: ...nd of the 10 AWG 2C cable Connect the other end of the 10 AWG 2C cable to the locations specified in Figure 4 4 and Table 4 4 below Figure 4 4 Note keep the battery breaker switch in the off position until you are ready to power on the entire system after all connections have been made and double checked TABLE 4 4 BATTERY CONNECTIONS 12V BATTERY BANK Heavy Duty Battery Cable Wire All Weather Contr...

Page 25: ...rol System Connect the PV panel s to the system after everything else has been wired as shown in Sections 4 1 4 4 As shown in Figure 4 5 and Table 4 5 attach the wires from the PV panels to the solar terminal block Figure 4 5 TABLE 4 5 PV PANEL CONNECTIONS PV PANEL PV Cable s Wire s All Weather Control System Connection 1 Red PV Black PV 2 Red PV Black PV 3 Red PV Black PV ...

Page 26: ...re the logger channel as follows When the voltage is at 12V the heater is on and when the voltage is at 0 V the heater is off 5 2 Fan Status The fan status signal can be connected to any analog channel 13 26 Note channels 20 26 also require P SCM 9132 sold separately The fan status is considered healthy when the measured signal is between 2 5V and 0 4V Readings below 0 4V indicate an issue if the ...

Page 27: ... Note The PS 15M charge controller comes preconfigured for the NRG supplied batteries and the low voltage disconnect set to 11 5V If a different battery type is used the charging settings of the charge controller will need to be modified to minimize the risk of damaging the system The SymphoniePRO data logger and iPack at the SRA station are powered independently from the VU01 If the All Weather P...

Page 28: ...hen first powered on Note The NRG program must not be running in order to set the date and time If the PLC has the program running already you must stop the program first Press ESC arrow to STOP on the screen and press OK twice to confirm Then arrow down to select RTC SET menu and proceed Press the select button Use the left right arrows to navigate through YYYY MM DD HH MM and the up down arrows ...

Page 29: ... Optimized for sites where snow accumulates and ice builds up The 3 PVH Kit options contain a PLC preloaded with a control algorithm which works as follows Heater turns on 6 AM to 8 AM Heater turns on between 8 AM and 8 PM when ambient temperature is below 3 C Heater turns off between 8 AM and 8 PM when ambient temperature is above 5 C Ventilator turns on between 6 AM and 8 PM 14 hours day Heater ...

Page 30: ... Notes for Advanced Users Be careful when making adjustments to these settings as there is no master reset which can restore the PLC to the original NRG factory settings A programming key is required for factory reset Adjustments to the default settings can significantly change the power required to run the system As a reference the system runs on 12 Volts The heater consumes 10 Watts and the Vent...

Page 31: ... PLC home screen NRG Systems press the up arrow once to enter the heater switch time menu Press SEL Use the left right and up down arrows to make your selection Once you are on the setting you wish to modify press SEL Use the up down arrows to adjust the value for that setting Press OK to save your selection 6 6 3 Temperature Threshold for Switching on the Heater Press ESC You should see the PLC h...

Page 32: ...he left right and up down arrows to make your selection Once you are on the setting you wish to modify press SEL Use the up down arrows to adjust the value for that setting Press OK to save your selection 6 6 4 Temperature Threshold for Switching off the Heater Press ESC You should see the PLC home screen NRG Systems press the up arrow three times to enter the Temperature Threshold menu The thresh...

Page 33: ...the up down arrows to adjust the value for that setting Press OK to save your selection 6 6 5 Ventilator Continuous Operation or Off at Night Press ESC You should see the PLC home screen NRG Systems press the up arrow four times to enter the ventilator menu Press SEL You should see the default selection Turn Fan Off At Night If you wish to run the fan continuously o Press SEL o Use the left right ...