MuscleGrid 7.2KW Series Hybrid Solar Inverter User Manual

MuscleGrid 7.2KW Series Hybrid Solar Inverter

USER MANUAL
HYBRID SOLAR INVERTER 7 .2KW /8.2KW /10.2KW

ABOUT THIS MANUAL

1. Purpose
   This manual describes the assembly, installation, operation and troubleshooting of this unit. Please read this manual carefully before installations and operations. Keep this manual for future reference.

2. Scope
   This manual provides safety and installation guidelines as well as information on tools and wiring.

SAFETY INSTRUCTIONS

WARNING: This chapter contains important safety and operating instructions. Read and keep this manual for future reference.

1. Before using the unit, read all instructions and cautionary markings on the unit, the batteries and all appropriate sections of this manual.
2. CAUTION –To reduce risk of injury, charge only deep-cycle lead acid type rechargeable batteries. Other types of batteries may burst, causing personal injury and damage.
3. Do not disassemble the unit. Take it to a qualified service center when service or repair is required. Incorrect re-assembly may result in a risk of electric shock or fire.
4. To reduce risk of electric shock, disconnect all wirings before attempting any maintenance or cleaning. Turning off the unit will not reduce this risk.
5. CAUTION – Only qualified personnel can install this device with battery.
6. NEVER charge a frozen battery.
7. For optimum operation of this inverter/charger, please follow required spec to select appropriate cable size. It’s very important to correctly operate this inverter/charger.
8. Be very cautious when working with metal tools on or around batteries. A potential risk exists to drop a tool to spark or short circuit batteries or other electrical parts and could cause an explosion.
9. Please strictly follow installation procedure when you want to disconnect AC or DC terminals. Please refer to INSTALLATION section of this manual for the details.
10. One piece of 150A fuse is provided as over-current protection for the battery supply.
11. GROUNDING INSTRUCTIONS -This inverter/charger should be connected to a permanent grounded wiring system. Be sure to comply with local requirements and regulation to install this inverter.
12. NEVER cause AC output and DC input short circuited. Do NOT connect to the mains when DC input short circuits.
13. Warning!! Only qualified service persons are able to service this device. If errors still persist after following troubleshooting table, please send this inverter/charger back to local dealer or service center for maintenance.

INTRODUCTION

This is a multi-function inverter/charger, combining functions of inverter, solar charger and battery charger to offer uninterruptible power support with portable size. Its comprehensive LCD display offers user-configurable and easy-accessible button operation such as battery charging current, AC/solar charger priority, and acceptable input voltage based on different applications.

Features

• Pure sine wave inverter
• Configurable input voltage range for home appliances and personal computers via LCD setting ? Configurable battery charging current based on applications via LCD setting
• Configurable AC/Solar Charger priority via LCD setting
• Compatible to mains voltage or generator power
• Auto restart while AC is recovering
• Overload/ Over temperature/ short circuit protection
• Smart battery charger design for optimized battery performance
• Cold start function

Basic SystemArchitecture
The following illustration shows basic application for this inverter/charger. It also includes following devices to have a complete running system:

• Generator or Utility.
• PV modules

Consult with your system integrator for other possible system architectures depending on your requirements. This inverter can power all kinds of appliances in home or office environment, including motor-type appliances such as tube light, fan, refrigerator and air conditioner.

Figure 1 Hybrid Power System

Product Overview

1. LCD display
2. Status indicator
3. Charging indicator
4. Fault indicator
5. Touch Function buttons
6. Power on/off switch
7. AC input
8. Main output
9. Second output
10. PV1 and PV2 input
11. RS-232/WIFI/Remove LCD communication port
12. Battery input
13. Anti dust kit

INSTALLATION

Unpacking and Inspection
Before installation, please inspect the unit. Be sure that nothing inside the package is damaged. You should have received the following items inside of package:

• The unit x 1
• User manual x 1
• DC Fuse x 1
• Ring terminal x 1
• Mc4 terminal head x2

Preparation
Before connecting all wirings, please take off bottom cover by removing two screws as shown below.

Mounting the Unit
Consider the following points before selecting where to install:

• Do not mount the inverter on flammable construction materials.
• Mount on a solid surface
• Install this inverter at eye level in order to allow the LCD display to be read at all times.
• For proper air circulation to dissipate heat, allow a clearance of approx. 20 cm to the side and approx. 50 cm above and below the unit.
• The ambient temperature should be between 0°C and 55°C to ensure optimal operation.
• The recommended installation position is to be adhered to the wall vertically.
• Be sure to keep other objects and surfaces as shown in the diagram to guarantee sufficient heat dissipation and to have enough space for removing wires

SUITABLE FOR MOUNTING ON CONCRETE OR OTHER NON-COMBUSTIBLE SURFACE ONLY.
Install the unit by screwing two screws. It’s recommended to use M4 or MS screws.

Battery Connection

CAUTION: For safety operation and regulation compliance, it’s requested to install a separate DC over-current protector or disconnect device between battery and inverter. It may not be requested to have a disconnect device in some applications, however, it’s still requested to have over-current protection installed. Please refer to typical amperage in below table as required fuse or breaker size.
WARNING! All wiring must be performed by a qualified personnel.
WARNING! It’s very important for system safety and efficient operation to use appropriate cable for battery connection. To reduce risk of injury, please use the proper recommended cable as below.
Recommended battery cable size:

Model| Wire Size| Cabl e {mm 2 )| Torque value C max)
---|---|---|---
7.2KW/8 .2KW/ 10.2KW| 1 X 2AWG| 25| 2 Nm

Please follow below steps to implement battery connection:

1. Remove insulation sleeve 18 mm for positive and negative conductors.
2. Suggest to put bootlace ferrules on the end of positive and negative wires with a proper crimping tool.
3. Connect all battery packs as below char
4. Insert the battery wires flatly into battery connectors of inverter and make sure the bolts are tightened with torque of 2 Nm in clockwise direction. Make sure polarity at both the battery and the inverter/charge is correctly connected and conductors are tightly screwed into the battery terminals.
   Recommended tool: #2 Pozi Screwdriver

WARNING: Shock Hazard
Installation must be performed with care due to high battery voltage in series.
CAUTION!! Before making the final DC connection or closing DC breaker/disconnector, be sure positive ( +) must be connected to positive ( +) and negative (-) must be connected to negative (-).

AC Input/Output Connection

CAUTION!! Before connecting to AC input power source, please install a separate AC breaker between inverter and AC input power source. This will ensure the inverter can be securely disconnected during maintenance and fully protected from over current of AC input. The recommended spec of AC breaker is 63A for 7 .2KW/8.2KW/10.2KW.
CAUTION!! There are two terminal blocks with “IN” and “OUT” markings. Please do NOT mis-connect input and output connectors.
WARNING! All wiring must be performed by a qualified personnel.
WARNING! It’s very important for system safety and efficient operation to use appropriate cable for AC input connection. To reduce risk of injury, please use the proper recommended cable size as below.
Suggested cable requirement for AC wires

Please follow below steps to implement AC input/output connection:

1. Before making AC input/output connection, be sure to open DC protector or disconnector first.

2. Remove insulation sleeve 10mm for six conductors. And shorten phase Land neutral conductor N 3 mm.

3. Insert AC input wires according to polarities indicated on terminal block and tighten the terminal screws. Be sure to connect PE protective conductor ) first.
   -Ground (yellow-green)
   L-LINE (brown or black)
   N-Neutral (blue) WARNING:
   Be sure that AC power source is disconnected before attempting to hardwire it to the unit.

4. Then, insert AC output wires according to polarities indicated on terminal block and tighten terminal screws.
   L- LINE (brown or black)
   N-Neutral (blue) 4. Then, insert AC output wires according to polarities indicated on terminal block and tighten terminal screws.
   L- LINE (brown or black)
   N-Neutral (blue)

5. Make sure the wires are securely connected.

CAUTION: Appliances such as air conditioner are required at least 2~3 minutes to restart because it’s required to have enough time to balance refrigerant gas inside of circuits. If a power shortage occurs and recovers in a short time, it will cause damage to your connected appliances. To prevent this kind of damage, please check manufacturer of air conditioner if it’s equipped with time-delay function before installation. Otherwise, this inverter/charger will trig overload fault and cut off output to protect your appliance but sometimes it still causes internal damage to the air conditioner.

PV Connection

CAUTION: Before connecting to PV modules, please install separately a DC circuit breaker between inverter and PV modules.
WARNING! It’s very important for system safety and efficient operation to use appropriate cable for PV module connection. To reduce risk of injury, please use the proper recommended cable size as below.

Model| Wire Size| Cable ( mm 2 )| Torque value (max)
---|---|---|---
7.2KW/8 .2KW/10 .2KW| 1 x 10AWG| 6| 1.2 Nm

PY Module Selection:
When selecting proper PV modules, please be sure to consider below parameters:

1. Open circuit Voltage (Voe) of PV modules not exceeds max. PV array open circuit voltage of inverter.
2. Open circuit Voltage (Voe) of PV modules should be higher than min. battery voltage.

Take 250Wp PV module as an example. After considering above two parameters, the recommended module configurations are listed as below table.

Solar Panel Spec. (reference)

– 250Wp

• Vmp: 30.lVdc
• Imp: 8.3A
• Voe: 37.Ndc
• Isc: 8.4A
• Cells: 60

| SOLAR INPUT|

Q’ty of panels

| Total input

power

---|---|---|---
(Min in serial: 6 pcs, max. in serial : 13 pcs)
6 pcs in serial| 6 pcs| 1500W
8 pcs in serial| 8 pcs| 2000W
12 pcs in serial| 12 pcs| 3000W
13 pcs in serial| 13 pcs| 3250W
12 pieces in serial and 3 sets in parallel| 36 pcs| 8200W
10 pieces in serial and 4 sets in parallel| 40 pcs| 10200W

PY Module Wire Connection
Step 1: Check the Input voltage of PV array modules. The acceptable Input voltage of the Inverter is 120VDC -SOOVDC. Please make sure that the maximum current load of each PV input connector is 10A.

CAUTION: Exceeding the maximum Input voltage can destroy the unit! l Check he system before wire connection.

Step 2: Disconnect the DC circuit breaker.
Step 3: Assemble provided PV connectors with PV modules by the following below steps. Components for PV connectors and Tools: cable preparatjon and connector assembly process;
Strip one cable 8 mm on both end sides and be careful NOT to nick conductors.

Then, use spanner to screw pressure dome tightly to female connector and male connector as shown below. Step 4: Check correct polarity of connection cable from ‘PY modules and PV Input connectors. Then, connect positive pole ( +) of connection cable to positive pole ( +) of PV Input connector. Connect negative pole (-) of connection cable to negative pole (-) of PV Input con ector.

FinalAssembly
After connecting all wirings, please put bottom cover back by screwing two screws as shown below.

Communication Connection

1. Wi-Fi cloud communication (option):
   Please use supplied communication cable to connect to inverter and Wi-Fi module. Download APP and installed from APP store, and Refer to “Wi-Fi Plug Quick Installation Guideline” to set up network and registering. The inverter status would be shown by mobile phone APP or webpage of computer.

2. GPRS cloud communication (option):
   Please use supplied communication cable to connect to inverter and GPRS module, and then applied external power to GPRS module. Download APP and installed from APP store, and Refer to “GPRS RTU Quick Installation Guideline” to set up network and registering. The inverter status would be shown by mobile phone APP or webpage of computer.
   RGB Light (option)

   • Battery Mode:red Light
   • Utility Mode:blue Light
   • PV Mode:purple Light

OPERATION

Power ON/OFF

Once the unit has been properly installed and the batteries are connected well, simply press On/Off switch (located on the button of the case) to turn on the unit.

Operation and Display Panel
The operation and display panel, shown in below chart, is on the front panel of the inverter. It includes three indicators, four function keys and a LCD display, indicating the operating status and input/output power information.

LED Indicator

Green

| Solid On| Output is powered by utility in Line mode.
Flashing| Output is powered by battery or PV in battery mode.
CHG |

Green

| Solid On| Battery is fully charged.
Flashing| Battery is charging.
FAULT |

Red

| Solid On| Fault occurs in the inverter.
Flashing| Warning condition occurs in the inverter.

Function Keys

LCD Display Icons

LCD Setting
After pressing and holding ENTER button for 3 seconds, the unit will enter setting mode. Press “UP” or “DOWN” button to select setting programs. And then, press “ENTER” button to confirm the selection or ESC button to exit.

Setting Programs

Display Setting
The LCD display information will be switched in turns by pressing “UP” or “DOWN” key. The selectable information is switched as below order: input voltage, input frequency, PV voltage, charging current, charging power, battery voltage, output voltage, output frequency, load percentage, load in Watt, load in VA, load in Watt, DC discharging current, main CPU Version.

Operating Mode Description

Battery Equalization Description
Equalization function is added into charge controller. It reverses the buildup of negative chemical effects like stratification, a condition where acid concentration is greater at the bottom of the battery than at the top. Equalization also helps to remove sulfate crystals that might have built up on the plates. If left unchecked, this condition, called sulfation, will reduce the overall capacity of the battery. Therefore, it’s recommended to equalize battery periodically.

How to Apply Equalization Function
You must enable battery equalization function in monitoring LCD setting program 30 first. Then, you may apply this function in device by either one of following methods:

1. Setting equalization interval in program 35.
2. Active equalization immediately in program 36.

When to Equalize
In float stage, when the setting equalization interval (battery equalization cycle) is arrived, or equalization is active immediately, the controller will start to enter Equalize stage.

Equalize charging time and timeout
In Equalize stage, the controller will supply power to charge battery as much as possible until battery voltage raises to battery equalization voltage. Then, constant-voltage regulation is applied to maintain battery voltage at the battery equalization voltage. The battery will remain in the Equalize stage until setting battery equalized time is arrived.

However, in Equalize stage, when battery equalized time is expired and battery voltage doesn’t rise to battery equalization voltage point, the charge controller will extend the battery equalized time until battery voltage achieves battery equalization voltage. If battery voltage is still lower than battery equalization voltage when battery equalized timeout setting is over, the charge controller will stop equalization and return to float stage.

Fault Reference Code

Warning Indicator

CLEARANCE AND MAINTENANCE FOR ANTI-DUST KIT

Overview
Every inverter is already installed with anti-dusk kit from factory. Inverter will automatically detect this kit and activate internal thermal sensor to adjust internal temperature. This kit also keeps dusk from your inverter and increases product reliability in harsh environment.

Clearance and Maintenance

1. Step 1 : Please loosen the screw in counterclockwise direction on the top of the inverter.
2. Step 2 : Then, dustproof case can be removed and take out air filter foam as shown in below chart.
3. Step 3 : Clean air filter foam and dustproof case. After clearance, re-assemble the dust-kit back to the inverter.
   NOTICE : The anti-dust kit should be cleaned from dust every one month.

SPECIFICATIONS

Table 1 Line Mode Specifications

Low Loss Voltage

| 170Vac±7V (UPS);

90Vac±7V (Appliances)

Low Loss Return Voltage

| 180Vac±7V (UPS);

100Vac±7V (Appliances)

High Loss Voltage| 280Vac±7V
High Loss Return Voltage| 270Vac±7V
Max AC Input Voltage| 300Vac
Nominal Input Frequency| S0Hz / 60Hz (Auto detection)
Low Loss Frequency| 40±1Hz
Low Loss Return Frequency| 42±1Hz
High Loss Frequency| 65±1Hz
High Loss Return Frequency| 63±1Hz
Output Short Circuit Protection| Circuit Breaker
Efficiency (Line Mode)| >95% ( Rated R load, battery full charged )

Transfer Time

| 10ms typical (UPS); 20ms typical (Appliances)
Output power derating:

When AC input voltage drops to 170V, the output power will be derated.

|

Table 2 Inverter Mode Specifications

Low DC Warning Voltage

@load< 50%

@load 50%

|

44.0Vdc

42.0Vdc

Low DC Warning Return Voltage

@load< 50%

@load 50%

| 45.0Vdc

44.0Vdc

Low DC Cut-off Voltage

@load< 50%

@load 50%

|

41.0Vdc

40.0Vdc

High DC Recovery Voltage| 62Vdc
High DC Cut-off Voltage| 63Vdc
No Load Power Consumption| 60W| 70W| 75W

Table 3 Two Load Output Power

Table 4 Charge Mode Specifications

Utility Charging Mode

INVERTER MODEL| 7.2KW| 8.2KW| 10.2KW
Charging Algorithm| 3-Step
AC Charging Current (Max)| 120Amp| 140Amp| 140Amp
Bulk Charging Voltage| Flooded Battery| 58.4
AGM / Gel Battery| 56.4
Floating Charging Voltage| 54Vdc
Charging Curve|
MPPT Solar Charging Mode
INVERTER MODEL| 7.2KW| 8.2KW| 10.2KW
Max. PV Array Power| 8200W| 8200W| 10200W
Nominal PV Voltage| 360Vdc
PV Array MPPT Voltage Range| 90Vdc~500Vdc
Max. PV Array Open Circuit Voltage| 500Vdc
Max Charging Current

(AC charger plus solar charger)

| 140Amp| 160Amp| 160Amp

Table 5 Grid-Tie Operation

98%

Table 6 General Specifications

TROUBLE SHOOTING

Problem| LCD/LED/Buzzer| Explanation / Possible cause| What to do
---|---|---|---
Unit shuts down automatically during startup process.| LCD/LEDs and buzzer will be active for 3 seconds and then complete off.| **** The battery voltage is too low ( <l.91V/Cell)|

1. **** Re-charge battery.
2. Replace battery.

No response after power on.| No indication.|

1. The battery voltage is far too low. ( <1.4V/Cell)
2. Internal fuse tripped.

|

1. Contact repair center for replacing the fuse.
2. Re-charge battery.
3. Replace battery.

Mains exist but the unit works in battery mode.

| Input voltage is displayed as O on the LCD and green LED is flashing.| **** Input protector is tripped| Check if AC breaker is tripped and AC wiring is connected well.

**** Green LED is flashing.

| **** Insufficient quality of AC power. (Shore or Generator)|

1. Check if AC wires are too thin and/or too long.
2. Check if generator (if applied) is working well or if input voltage range setting is correct. (UPSif Appliance)

Green LED is flashing.| Set “Solar First” as the priority of output source.| Change output source priority to Utility first.
When the unit is turned on, internal relay is switched on

and off repeatedly.

| LCD display and LEDs are flashing| Battery is disconnected.| **** Check if battery wires are connected well.

Buzzer beeps continuously and red LED is on.

| Fault code 07| Overload error. The inverter is overload 110% and time is up.| Reduce the connected load by switching off some equipment.
Fault code 05| **** Output short circuited.| Check if wiring is connected well and remove abnormal load.
Temperature of internal converter component is over 120°C.| Check whether the air flow of the unit is blocked or whether the ambient temperature is

too high.

Fault code 02| Internal temperature of inverter component is over 100°C.
Fault code 03| Battery is over-charged.| Return to repair center.
The battery voltage is too high.| Check if spec and quantity of batteries are meet requirements.
Fault code 01| Fan fault| Replace the fan.
**** Fault code 06/58| Output abnormal (Inverter voltage below than 190Vac or is higher than 260Vac)|

1. Reduce the connected load.
2. Return to repair center

Fault code 08/09/53/57| Internal components failed.| Return to repair center.
Fault code 51| Over current or surge.| ****

Restart the unit, if the error happens again, please return to repair center.

Fault code 52| Bus voltage is too low.
Fault code 55| Output voltage is unbalanced.

Appendix: Approximate Back-up Time Table

Model| Load (W)| Backup Time @ 48Vdc l00Ah (min)| Backup Time@ 48Vdc 200Ah (min)
---|---|---|---

7.2KW

8.2KW

10.2KW

| 500| 613| 1288
1000| 268| 613
1500| 158| 402
2000| 111| 271
2500| 90| 215
3200| 76| 182
3500| 65| 141
4000| 50| 112
4500| 44| 100
5000| 40| 90
6200| 36| 80
7200| 32| 70
8200| 28| 60
9200| 24| 50
10200| 20| 40

Note

1. Backup time depends on the quality of the battery, age of battery and type of battery. Specifications of batteries may vary depending on different manufacturers.
2. The final interpretation right of this pr oduct bel ongs to the company.

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