freedom WON 32-HV Lite Batteries Overview 80 Current Automation User Manual

freedom WON 32-HV Lite Batteries Overview 80 Current Automation

Hereford Road Longmeadow Business Estate Modderfontein Edenvale, 1609 South Africa
www.freedomwon.co.za

Technical and Installation Assistance – Contact:
Please contact your Freedom Won Distributor or Reseller Installer for technical and installation support. A directory of Distributors and Reseller Installers is available at www.freedomwon.co.za
For advanced support please contact [email protected]

Update Record

23/01/2024
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Introduction

Purpose of the User Manual
This manual is intended to provide assistance to trained technicians and installers for the installation and commissioning of a Freedom Won EMS (Energy Management System). This document is not intended to teach the inner workings of a Freedom Won EMS, the manuals function is to assist the installer in completing a successful installation and integration to other equipment.

The manual will not cover technical details required for integration of third- party equipment. Should this document not cover the required integration, or technical details please contact Freedom Won at [email protected]

System Requirements
The computer-based requirements for the system to be installed and function are as follows:
Compatible web browser: Microsoft Edge, Google Chrome, Firefox, Opera, Safari

Mobile devices will need an Android or MacOS.
In order to setup the software portion of the EMS system one will have to have access to the internet, setup a valid account on the EMS Portal and have the relevant permissions on that account to add and configure the hardware installed on site.

Contents of the EMS Package

The following items are included with your EMS purchase:
TABLE 1: PACKAGED CONTENTS

Installation

Prerequisites
In order to effectively install the EMS Panel and the get a reliable and consistent outcome from the installation, the correct tools and materials should be utilised.
These prerequisites will serve as a guide for the items required alongside the EMS offering to correctly install the system.

Basic EMS Installation
The following list will assist in having the right hardware to do a reliable installation.

1. EMS Panel
2. 6A Circuit Breaker
3. PG9 and PG11 Glands
4. 40x25mm Trunking
5. 1mm2 flat Twin and Earth
6. 8mm Fischer plugs and screws or appropriate Rawl bolts
7. Belden Shielded twisted pair 0.22mm2, or Belden Shielded twisted pair 0.5mm2
8. Cat5 With Shield or CAT6 LAN cable
9. RJ45 Connectors
10. RJ45 Cable Rubber
11. M12 4pin Connectors (120504-01-001)
12. Phone, Laptop or Tablet with the appropriate web browser
13. Stable Site internet connection

Controllers and Monitoring Requirements
The EMS panel can be connected to a wide variety of 3rd party supported hardware, or controllers. These controllers have to be wired with the appropriate supported communications. The EMS Systems supports Modbus RS-485 and Modbus TCP connections and communication protocols to the EMS Panel itself. The Panel has several physical connection inputs on the side of the panel to plug in the various controllers.
This hardware includes connection to:

• Power Meter
• Power analysers
• Solar Grid Tie Inverters
• DC Coupled Solar systems
• Generators

For a full list of the exact support hardware for the EMS system please visit Freedom Won.
For optimal function of your EMS system, install Electricity Meters or Power Analysers at each point of the connection through the power generation system. This will ensure that there is consistent reliable data getting fed to the EMS, which then processes the data and provide the best control to the system possible.

It is important that any power meters that are used need to be connected correctly to the EMS panel to insure accurate readings. Power Meters that have RS-485 or TCP/IP capabilities can be used to connect to the panel directly. If using RS-485, it is important that the A and B terminals are connected to the RS-485 pinout correctly. The A and B terminal polarity will not always be the same, so it is important that you look at the user manual to make sure you are wiring the power meter correctly.

FIGURE 1.1: ELECTRICITY METER CONNECTION EXAMPLE

As soon as multiple power providers are being summed into the same input it is advisable to put a power meter down at that summation point to give the most accurate readings possible.
The rule of thumb is that a measured value will always be more accurate than a calculated one. Use electricity meters or power analysers to provide this measurement rather that attempting to summate multiple power producers or consumers.

As an example, let’s look at the single line diagram below of a basic site with 2 generators and 2 grid tie solar systems. Take note of all the locations marked in red as these would be sites where one would install additional power meters to get the most accurate and reliable data rather than adding up the data from each separate system.
It is vital that the appropriate cables are run between the various monitors and the EMS panel, improper wire and communication wiring practice here will render the system unreliable and inconsistent.

EMS Panel Dimensions

Terminal Layouts
The terminal layouts are in 2 parts, there are terminals available inside the panel and ports available in the exterior of the panel on the right-hand side.

Internal Terminals
These are for wiring in Power, Digital Inputs, Digital Outputs, PT100 Temperature Probe inputs and CANbus input. Table 2 below highlights the various terminal numbers and their denominations in the EMS Panel.

TABLE 2: TERMINAL LAYOUT

Terminal Number| Power| Digital Inputs| Digital Outputs| Temperature Inputs| CANBUS
---|---|---|---|---|---
1| Earth| DI 1| DO 1| Temp 1A (Red)| CAN High +
2| Neutral| GND| GND| Temp 1B (White)| CAN Low –
3| Live| DI 2| DO 2| Temp 1B (White)| GND
4| | GND| GND| Temp 2A (Red)|
5| | DI 3| DO 3| Temp 2B (White)|
6| | GND| GND| Temp 2B (White)|
7| | DI 4| DO 4| Temp 3A (Red)|
8| | GND| GND| Temp 3B (White)|
9| | DI 5| | Temp 3B (White)|
10| | GND| | Temp 4A (Red)|
11| | DI 6| | Temp 4B (White)|
12| | GND| | Temp 4B (White)|
13| | DI 7| | |
14| | GND| | |

Power Input
The power to the system requires 230V AC. There are 3 connections for the power, namely Earth, Neutral and the positive.

Digital Inputs
The digital inputs can be found in the 2nd bank of terminals from the left- hand side in the panel. There are seven inputs in total. The odd pins (1,3,5,7 etc.) are wired directly to the PLC and the even terminals (2,4,6 etc.) are connected to ground. When the appropriate off and even are connect it will show “On”

Digital Outputs
Digital outputs are found in the 3rd bank of terminals in the EMS Panel. They function as powered outputs. The “Digital Outputs” on the odd terminals (1,3,5 etc.) provide +24V DC when the output is triggered. The even terminals (2,4,6 etc.) are ground terminals to complete the circuit.

Temperature Inputs
The temperature inputs can be found in the 4th bank of the EMS panels terminals. They are the start of the 3-tier terminals. And their wiring is available for 3wire PT100 temperature probes only. Follow the colour coding as described above to wire in the PT100 temperature probes.

CANBUS Terminal
The final 3-tier terminal standing alone is for the CANbus wiring. It has pins for CAN high, CAN low and the final pin Earth, which is used to earth the shielding to the chassis of the EMS panel.

External Ports
The second part is the external ports which cover the right-hand side of the EMS Panel. Thes are used to wire in the communication cables, antenna to the EMS Panel and for the Auxiliary power from the EMS for powering additional devices.

The external ports have a few different layouts. The main two that need to be addressed here are the COM ports which are the RS-485 ports and the EXT Power port.
The RS-485 port has its pins denoted as per the image below. This port is viewed directly at the panel itself. Meaning the left most pin in the port is the A+ port, the Right most pin on the port is the B+- port and the topmost pin on the port is the Ground port (GND)

Finally, the External or Auxiliary power port is the port used to power external 12V and 24V DC devices from the panels internal power supply. This includes providing backup power from the EMS panels internal backup battery.
This port’s pins are as follows, also looking directly at the port.

TABLE 4: AUXILIARY POWER PINOUT DENOTATIONS

Installation Steps
This section will take us through a step-by-step guide on the fitting and installation of the EMS Panel. This section will be broken down into sub tasks.

Site Inspection
A site inspection will need to conduct in order to determine the appropriate location to install the EMS Panel. inspect the site to see where it would be appropriate to install the EMS Panel. It is advisable to minimise the RS-485 and Modbus TCP Cable runs.
If there is no option but to run cables near high power lines, the follow these steps:

• Use shielded cables.
• Run the cables at minimum 100 mm away from the high-power lines when running in parallel.
• It is acceptable to run the communications cables perpendicular to the high-power lines.

Leave a minimum of 200mm space to the right of the panel as all the RS-485 Communications Ports (Comm Ports) are connected here while mounting the panel.

Mounting the EMS Panel
After the position of the panel has been determined, proceed to mount the EMS Panel.
There are four wall mounting brackets on the panel to attach it to a wall. These brackets will need to be screwed onto the back of the panel before mounting it to the wall. It would be preferable to use bolts or screws of at least 5mm diameter. As the panel does have a sizable mass.

Connecting Power to the EMS Panel

The EMS Panel takes 230V AC to power the system.
Before the procedure of connecting the power ensues all breakers in the panel should be in the down position and that any power has to be disconnected form the working area.
The EMS panel is powered by a permanent source such as a Distribution Board (DB). This DB board should be on AC output load of the inverter being monitored. This assists in keeping the EMS panel powered as consistently as possible.

Install the 6A circuit breaker in the DB board and run the 1mm2 cable from this breaker to the EMS panel terminal inputs.
There are 3 power input terminals in the bottom left of the EMS Panel, named PE, N and L, the layout for these is as follows:

Connecting Communication Cables
Special care needs to be taken when connecting the communications cables to ensure the correct pins are used and that the cable runs are in the appropriate place.
When planning the cable runs ensure that they are not near any high-power lines. If there is no other option, then adhere to the following guidelines:

• Use shielded cable.
• Run the cables at minimum 100 mm away from the high-power lines when running in parallel.
• It is acceptable to run the communications cables perpendicular to the high-power lines.

RS-485 connections
For the RS-485 Connections it is advised to use a Belden Shielded twisted pair or a similar cable. A suitable alternative is a CAT6 Ethernet cable.
For the pairing of the Modbus A+ and B- it is then imperative that one uses a specific twisted pair in the CAT6 ethernet cable, for example, Orange and Orange/white and to not cross or mix colours.

The connection for the RS-485 points can be found on the right-hand side of the EMS panel, they are denoted by Com Port 1-4. These ports require a M12 Male connector jack in order to plug the Modbus cable into the side of the unit. Four of these connector jacks were included in the EMS package.

When connecting to the various Modbus RS-485 enabled controllers it is important to note the sign and type of pins on the device. Ensure that one wires the EMS A+ and B- of each Comm Port to the appropriate A+ and B- of the controller being connected.
Note : Some controllers denote their Comm Ports as A- and B+ in this case follow the sign denotation of the + and – rather than the A and B notation.

In figure 8 below we have an example of connecting the RS-485 communications cables to an electricity meter.

Finally, ensure that the steps below for setting the appropriate serial communication settings are done on the controller being connected.

Modbus TCP Connections
For Modbus TCP Connections CAT6 Ethernet cable will be used. Standard Ethernet with the standard RJ45 LAN pinout will be used on either end of the cable.
Use the ports denoted by LAN 1-3 on the right-hand side of the EMS Panel to connect the various Modbus TCP controllers on the site to the panel.

Configuring 3rd party controllers

Each of the controllers being connected to the EMS panel need to have their communication protocols setup correctly in order for the EMS system to communicate with then successfully. It is imperative that the communication settings on the controllers, sensors and systems being connected to the EMS Panel are setup exactly as described below to have a successful connection.

The EMS Panel uses static IP’s and preconfigured Modbus TCP and RS-485 settings to streamline the installation and commissioning process.

Atess EMS Installation Wiki
SUNGROW EMS Install Wiki

Note : Ensure there is stable internet connectivity on site as some devices/ inverters etc require a mobile App to change these settings and those App’s will require internet to function.

RS-485 Based controllers
For the RS-485 controllers the wiring is covered above in 2.2.5, The communication settings one will need to go into the menu / settings on the physical controller, either on its keypad or its appropriate software or connection.

The following settings need to be set for the communications to work with the EMS system.

TABLE 6: MODBUS RS-485 NETWORK CONFIGURATIONS

Take note of what ID the controller was set to as this will be required when setting up the Cloud Portal

Baud Rate:| 9600pbs
Data bits:| 8
Parity:| None
Stop Bits:| 1
Modbus Type| Modbus RTU

Modbus TCP Based Controllers
For the Modbus TCP controllers the wiring is covered above in 2.2.5, as for the communication settings, they will need to be changed on the controller/ device individually. One will need to go into the menu / settings on the physical controller/ device, either on its keypad or its appropriate software and change the communication settings appropriately.

Special care needs to be taken when configuring the Modbus TCP network that the IP addresses are unique per device and that the IP addresses are set identically on the Cloud Portal during configuration as they are set on site.

TABLE 7: MODBUS TCP NETWORK CONFIGURATIONS

Modbus Slave ID| Unique per controller on the Modbus Network.

Take note of what ID the controller was set to as this will be required when setting up the Cloud Portal

---|---
IP Address| 192.168.35.XXX – (Unique to the device being connected)
Subnet Mark| 255.255.255.0
Default Gateway| 192.168.35.1

Connecting Internet to the EMS Panel

Internet needs to be provided to the EMS panel from a source on the site. This is so that the system can send its data to the cloud and that it can be accessed remotely.
To do this simply run an Ethernet cable to the WAN input RJ45 port provided on the right-hand side of the EMS panel.
The EMS Panel internet (WAN) input is set to DHCP so as long as there is an internet connection available it will assign itself an appropriate IP address and connect.

Note : The system will still run locally if the Internet connection fails for any reason. The data will be stored on the Glacier Edge directly and once a connection is reestablished it will upload its data and synchronise with the Cloud again. All logic and running of the site software will continue to run uninterrupted.

Connecting the GSM Antenna

• The EMS Panel comes with a built in Sim card and GSM connectivity for Freedom Won Remote support. This connection will not upload or grant access to clients. It is used solely to provide emergency access to the site and the EMS Panel remotely. This service can only be accessed by contacting the Freedom Won support team directly.
• In order for this emergency service to function the GSM Antenna will need to be installed correctly to enable the Glacier Gateway to connect to the available cellular networks. The antenna provided is on a 3-meter-long cable and will need to be mounted to the SMA Cable on the right-hand side of the panel.
• The antenna needs to be positioned in an open area and as high up as possible to get the best signal. The base of the antenna is magnetic, and it can be placed on top of the panel itself.
• The best practice is to ensure that the antenna is place outside when possible.
• Do not run the antenna cable or place the antenna itself near any high-power cables or transformers as this will disrupt the signal strength.

Connecting the backup batteries

Once all the connections have been run and the site is ready to power up then it’s time to connect the backup batteries.
In the EMS Panel itself there will be 2 sets of battery terminal connectors coming out the trunking on the right-hand side. They will be colour coded. Red Cable – Positive, Black Cable – Negative.
Place the batteries end to end in the panel and connect the red cables to each of the two positive terminals and the black cables to each of the negative terminals. So that the batteries are wired in parallel.
The EMS panel has a combined 15Ah of backup battery capacity which will run the EMS Panel and system without external power for 24hours.

Getting Started

Power ON
Now that the system has been successfully installed based on the procedure above and the site is ready to receive power we can power on the system.
To do this one need to follow this procedure:

1. Switch on the 6A breaker in the DB board,
2. Switch on the 6A breaker in the EMS Panel
3. If there is power on the site, the systems lights should come on
4. If there is no power on the site proceed to the next step to run the EMS Panel on its backup batteries.
5. Switch on the two 6A breakers for the batteries
6. If there was no mains power the system will now power on and run off its backup batteries.
7. If there were mains in 2.1 then the system will begin to charge the batteries

Lights on the EMS Panel
There are two lights on the front face of the EMS Panel, they are denoted “Power” and “Error”
The power light indicates that there is AC power coming into the EMS Panel.
The Error light indicates that there is an Error on the EMS system.

Commissioning of Devices

Commissioning of the site means adding the various devices to the Cloud Portal that are installed on site. In this step we will take the Modbus RS-485 settings and the TCP settings established in section 2.4.5 and setup the controllers/ devices on the Cloud with the same settings.

The Polar Cloud is where these devices will be commissioned online. Follow the link below to add setup an account and begin adding devices.
For assistance on these units please contact Freedom Won support for the 1st time setup procedure.
Click here for basic instructions on how to use the Cloud Platform.

Note : In order to finalise and test the setup of the EMS Panel an internet connection will be required.
Each EMS Panel comes with a unique serial number on the Polar Monitoring Glacier Edge. Use this serial number to begin the setup procedure under the Gateways tab on the Cloud.

Troubleshooting

Power switch not working.
In the event that the power light does not illuminate, it means that the EMS Panel is not getting power. This light will only illuminate if there is 230V AC power to the system.
Ensure that the DB supplying the EMS panel is on the output of the inverter and ensure that the inverter is powered on and giving out 230V AC supply from each phase to neutral.

Error light staying illuminated.
The Error light illuminating on the front of the panel is an indication of one of two things

Option 1: The first is that there is no internet connection present to the EMS panel.
In this case check the internet connection on the site to ensure it is up. Alternatively check the Ethernet cable that is providing the internet connection to the EMS Panel to make sure there is no damage to the cable and that it is secure into the RJ45 sockets.
If there is internet connection to the panel and the ethernet cable is working order, then there could be firewall issue on the network preventing the EMS Panel for gaining an internet connection. Contact your IT administrator to open the firewall for the EMS Panel.

Option 2: The second is if there are any communication failures between the EMS Panel and the controllers/ devices connected to it. This means that there is a device/ controller setup on the Cloud that is not sending its info back to the EMS Panel.
Firstly identify which controller/ device is having the issue by looking at the data on the Cloud and seeing which one is not sending its data through. Once identified,

1. Check all the communications cables going to this device/ controller
2. Double check the Comms settings to ensure that they are set correctly.
3. Ensure that the same Modbus Slave ID that is set on the Controller/ device is the same as the one set on the cloud.

Not getting communication to a controller on the site
Communication failures between the EMS Panel and the controllers, devices connected can have a number of causes. This will manifest itself as a controller/device setup on the Cloud is not sending any data upstream.
Firstly, identify which controller/ device is having the issue by looking at the data on the Cloud and seeing which one is not sending its data through. Once isolated,

1. Check all the communication cables going into the device/ controller. Search for any signs of damage, where they are plugged into the terminals, etc. Double check the Com Settings to ensure that they are set correctly.
2. Ensure that the same Modbus Slave ID that is set on the Controller/ device is the same as the one set on the cloud.

Upgrades
Upgrades to the system happen on a constant basis via the Cloud. There will be new software versions for updating on the physical Glacier Edge gateways in the EMS panels that can be downloaded.
The Cloud Portal will ever be evolving and automatically updating to bring you the best service possible, keep an eye on our Change Log here to view the latest changes and updates to the system as they get published.
Upgrades to the system, we can talk about additional upgrade panels.

Maintenance

The maintenance on the EMS panel is basic. Keep the panel clean and free from water ingress and the system will function for many years to come.
The Freedom Won batteries if cycled regularly will need to be changed every 5 years to ensure perfect redundancy on the power backup for the EMS Panel.
Do visual inspections of the EMS Panel and Cables at least once a year to ensure that there is no damage and that all connections are still secure.

Help and Support
For help and support please contact Freedom Won’s technical team.

1. www.freedomwon.co.za
2. Contact Us
3. At the bottom right of the page, follow Support Enquiries and Request Technical Support

Details

Alternatively, contact the Freedom Won Technical support team on [email protected] and +27 10 597 7794.

References

• LiTE energy storage products and solutions - Home - FREEDOM WON

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