F08-064 Operating Manual ESS0460-H119 PV Module Solar Soaking Chamber 12/19/2008
Thank you for your purchase. We are confident you will be completely satisfied with your new system. If for any reason you need assistance, please contact us: EYE Lighting International / Iwasaki Electric 9150 Hendricks Road Mentor, OH 44060 888-665-2677 support@eyeappliedoptics.com In order to operate this system properly and prevent potential problems, please read the following operation instructions. Table of Contents 1. System Components 2. Installation 3. Control Panel 4. System Operation 5. Solar Lamps 6. Irradiation Intensity Control 7. Troubleshooting
1. System Components: 1 Solar Lighting Array Housing (60) 400W solar lamp array 2 Solar Lamp Power / Inverter Cabinet includes (5) inverter units (12 modules per unit; one module per lamp) and solar lamp starters (60 units; one starter per lamp) 3 Operation Control Panel control and failure alert 4 Main Power Breaker 3 phase main power switch for system 5 Solar Light Chamber Shields roll down curtains to shield excess light from work area 6 Solar Irradiation Chamber 7 Cooling Air Ducts dual axial blowers direct air over PV panels under test 8 PV Panel Support Trays interchangeable; (4) separate frames for standard thin-film modules (60cm x 120cm) and (4) free-format frames for all other size PV modules; trays provide for easy insertion of PV panels and allow cooling air to flow above and below panels
2. Installation A. When installing this chamber, please avoid placing it in any area where corrosive gas or explosive gas is present. It is also highly recommended that the area be as dust free as possible with controlled humidity. B. The chamber should be placed as close to the mains power source (power transformer) and mains breaker as possible. C. Due to the heat generated by the solar array, keep flammable materials away from the top of the chamber. D. Please refer to the following diagrams to ensure proper clearance around the chamber for proper operation and maintenance / inspection 600mm (24 in) 600mm (24 in) Rear Top 600mm Side 600mm 600mm Side 600mm (24 i ) Overhead View (24 i ) (24 i ) Frontal View (24 i ) This spacing is required for proper operation and routine inspection / maintenance Electrical / Power Characteristics System Power: 3 Ø; 208V AC; 60Hz; 35kVA (approximately 100 A) Cooling Blower Fans: 0.75 kw 2 units Solar Lamps: 208V; 400W 60 lamps Irradiation Power Control: 1500W solar lamp control circuit (approximately 3 A) Mains Power Connection: 3 Ø; 4 wire; RED, WHITE, BLACK power phase connections and GREEN ground connection; single phase solar lamp circuits are equally divided to balance the power over all three phases. To protect against unbalanced or open phase power failures, the system uses a voltage detecting (APR-S) phase reversal power breaker. Red White Black Chamber Power Connections Mains Power Normal electrical connection. If system does not function it may be due to phase connection mismatch with (APR-S) breaker. Please reconnect mains power as illustrated below. Alternative connections Red White Black Green Red White Black Electrical safety is provided through a dedicated earth connection. It is vital to ensure that the system is connected to earth ground. Chamber Power Connections Mains Power Alternative mains power phase connections. Red White Black Green
3. Control Panel 1 2 3 4 6 8 11 5 7 9 10 1 MAIN POWER INDICATOR LAMP Indicator lamp will illuminate when the Main Power Breaker is ON and power is supplied to the system 2 IRRADIATION AREA ZONE SWITCHES The solar array is arranged in 5 zones of 12 lamps each. Each zone is controlled independently and energized by its associated button. When a zone is energized, its switch is illuminated. NOTE: cooling fans must be turned on prior to switching solar zones on. The solar array zone switches will not function until the cooling fans are turned on. 3 CUMULATIVE OPERATION HOUR METERS A separate meter is assigned to each zone and records the cumulative operation hours for the lamps in that zone. Recording the lamp operating time is extremely beneficial for preventative maintenance. If less than all zones are often used for particular test applications, please try to periodically move the PV panels within the chamber to equalize the operating time across all zones. 4 TEST OPERATION HOUR CONTROLLER This counter timer provides the capability to program a desired test duration in hours and minutes. To initiate the test, press the TEST START button. At the conclusion of the test, the lamps will automatically turn off. The cooling fans will continue to run for ten (10) minutes after test shutdown, at which time the fans will automatically turn off.
5 TEST START SWITCH This button initiates the programmed test period. When initiated, this switch will be illuminated. At the conclusion of the programmed test time, the alarm buzzer will sound and the solar lamps will be turned off. The buzzer will turn off automatically after one (1) minute or you can turn the buzzer off manually by pressing the buzzer stop switch. 6 TROUBLE (SYSTEM FAILURE) INDICATOR LAMP If a system error occurs, the system will automatically shut down, the TROUBLE lamp will be illuminated and the alarm buzzer will sound. Under some error conditions the solar lamps will immediately shut off but the cooling fans will continue to operate for ten (10) minutes. Defined failure modes include: Power Failure phase / power abnormality; APR-S breaker may trip off; lamps and fans will shut down Fan (TH1, TH2) Failure cooling fan failure or thermal protection shutdown; fans and lamps will shut down System Overheat system chamber temperature exceeds default setting of 100 ºC; lamps will shut down, fans will continue to operate Irradiation Power Over-limit irradiation control circuit maximum voltage (10.4V) exceeded; lamps will shut down, fans will continue to operate Solar Lamp / Array Failure lamp or inverter failure; lamps will shut down, LAMP FAILURE light will be illuminated, fans will continue to operate 7 LAMP FAILURE INDICATOR LAMP When a solar lamp circuit failure is detected, this indicator lamp will be illuminated and the alarm buzzer will sound. Cause of failure could be the lamp, inverter, starter, or wiring defect. Solar lamps will shut down but fan will continue for 10 minutes. 8 COOLING FAN SWITCH This switch initiates the cooling fans and the switch will be illuminated. Pressing the switch again will turn the cooling fans off. At completion of a programmed test period, the switch indicator lamp will flash on and off and the fans will continue to operate for ten (10) minutes. The fans can be manually stopped at any time during this period by pressing this switch. NOTE: cooling fans must be turned on prior to switching solar zones on. The solar array zone switches will not function until the cooling fans are turned on. 9 BUZZER STOP SWITCH The system alarm buzzer will sound due to the completion of a programmed test period or because of a system error. This switch allows you to manually turn the buzzer off. 10 EMERGENCY STOP SWITCH Pressing this switch will immediately shut down the lamps and cooling fans. It will also initiate the system alarm buzzer. The switch will remain latched in the OFF position until manually released. After corrective measures have been performed, the emergency stop switch is released and reset by turning the switch clockwise. 11 IRRADIATION POWER (DIMMING) CONTROLLER This controller adjusts the solar array lamp power. The digital indicator displays the controller voltage (0 10V). It provides the capability to adjust the solar array output from 1000W/m 2 to 800W/m 2. Additionally, as the solar lamps age the lamp power can be increased, if required, to maintain an average 1000W/m 2. NOTE: controller voltage may not exceed 10.4V.
4. System Operation Full Chamber Manual Operation a) Ensure main power breaker is ON (Main Power Lamp will be illuminated). b) Turn cooling fans ON (solar array lamps will not function until fans are turned on). c) Turn on solar array by pressing LIGHTING AREA ZONE switches 1-5 sequentially. Allow ten (10) minutes for solar lamps to reach full power and spectrum stabilization. d) At completion of test, turn off solar array by pressing LIGHTING AREA ZONE switches 1-5 sequentially. e) Turn cooling fan OFF f) Turn OFF Main Power Breaker if desired. Programmed Test Operation a) Follow steps a) c) above. b) Program desired test duration time in hours and minutes on the TEST OPERATION HOUR controller. c) Initiate test by pressing TEST START switch d) At completion of test, solar array will automatically shut down, alarm buzzer will sound, cooling fans will continue to operate for ten (10) minutes and cooling fan switch lamp will flash. e) Cooling fans may be turned OFF by pressing the COOLING FAN switch. f) Turn OFF Main Power Breaker if desired. Partial Chamber Operation a) Follow steps a) and b) from Full Chamber Manual Operation section above. b) Turn on solar array segment by pressing the desired LIGHTING AREA ZONE switches 1-5 sequentially. Allow ten (10) minutes for solar lamps to reach full power and spectrum stabilization. To ensure minimum IEC class C uniformity over entire target irradiation area please observe the following guidelines: For QUARTER chamber (650mm x 650mm) target irradiation area, place PV panel(s) in chamber at far left (facing chamber) side and turn on LIGHTING AREA ZONE switches 1-3 sequentially. For HALF chamber (650mm x 1300mm) target irradiation area, place PV panel(s) in chamber starting at far left (facing chamber) side and turn on LIGHTING AREA ZONE switches 1-4 sequentially. Refer to Irradiation Intensity Distribution profiles in Section 2 of this manual for specific details c) If programmed test is desired, follow steps b) f) from Programmed Test Operation section above. d) If manual test is desired, follow steps d) f) from Full Chamber Manual Operation section above. 5. Solar Lamps A. Please allow ten (10) minutes after initial startup for solar lamps to reach full power and spectrum stabilization. B. If solar array has been in operation and is shut down (hot re-start), please allow about 20 minutes to re-start lamps and for solar lamps to reach full power and spectrum stabilization. C. For preventative maintenance, the solar lamp life is specified at 3,000 hours of operation. Although the lamps will typically last much longer, the lamp life is specified to ensure irradiation output and spectrum remain within required IEC class C specifications.
6. Irradiation Intensity Control The system irradiation intensity was set to an average 1000W/m 2 (+/-15%; class C uniformity) at the time of installation. This intensity distribution test is included in Section 3 of this manual. We recommend that the irradiation intensity is verified approximately every 500 hours of operation or once per month. To adjust the irradiation intensity, please follow the steps below. a) Refer to initial installation irradiation intensity distribution diagram included in Section 3 of this manual. b) Select at least two (2) distributed test locations from distribution grid (these positions are marked by tape on the bottom of the chamber roller shelf). c) Turn on full solar array and allow at least ten (10) minutes for the lamps to stabilize. d) Place a full spectrum pyranometer on the first of these selected positions and measure irradiation intensity, then repeat at the second selected position. e) Compare these measurements against the initial installation irradiation intensity measurements, if the difference is more than five (5) percent it is recommended that a full 18 point irradiation intensity grid measurement is performed. This will provide the minimum irradiation intensity point and allow the calculation of the average irradiation intensity and full target uniformity. f) If the minimum irradiation intensity is below 850W/m 2 the irradiation intensity power should be adjusted using the DIMMING CONTROL calibrated dial. This circuit outputs a 0-10V signal that controls the power output (0V = Max power; 10V = Min power). A typical value for a new installation (set to 1000W/m 2 ) will be approximately 4.2V. g) Place the pyranometer at the minimum measured irradiation intensity grid point and ensure the reading is stable. Adjust the controller voltage lower while reading the intensity level from the pyranometer (allow sufficient time after any adjustment for the intensity level to stabilize). h) Adjust the power such that the intensity level is increased to a value between 900-950W/m 2. i) Re-measure the full 18 point grid irradiation intensity and re-calculate the Max, Min, and Average values to ensure they are within specification. If, for a particular application, you desire to reduce the average irradiation intensity to a value lower than 1000W/m2 (such as 850W/m2), please follow steps g) i) above and adjust the power output proportionally to the desired average irradiation intensity level. NOTE: To ensure solar lamp irradiation and spectrum stability, the average irradiation intensity (power output) should not be reduced below 800W/m 2.
7. Troubleshooting Cooling Problem Blower Lamp Probable Cause Action Phase Error X X Temporarily power phase interruption or wiring error. Check power connections and mains power breakers. Re-set breakers and power on system. If error still exists, ensure balanced Emergency Stop Cooling Fan Overload X X Emergency Stop switch has been activated and is still latched in the STOP position. X X Thermal relay or abnormal current error from cooling fan motor. 208V 3 phase power is being supplied to system. If power input and connections are correct, please contact EYE Lighting technical support. Reset the Emergency Stop switch by rotating switch clockwise. Power on system and ensure there are no system errors (power, lamps, fans, etc.). Troubleshoot any specific failures that are identified. If no failure mode is identified by control circuits, please contact EYE Lighting technical support. Ensure there are no obstructions restricting rotation of fan blowers. Rotate shaft and check for deformation, abnormal noise, or binding. If no problems are identified, please contact EYE Lighting technical support. Overheat Continues for 10 X Occurs when the chamber temperature Check the chamber temperature reading at the control panel to ensure minutes after exceeds the maximum allowable an overheat condition does not exist. If the temperature reading is occurrence of temperature (set at the factory to 100 below 100 ºC, troubleshoot the thermocouple controller. If the failure ºC). This is continuously measured by a temperature reading is above 100 ºC, ensure the cooling fans are type K thermocouple located near the operating correctly. If fans are operating properly, please contact EYE top of the chamber. Lighting technical support. Lamp Failure Continues for 10 X Lamp failure to start, or failure during From a cold start, a solar lamp should start within approximately 40 Detection minutes after operation. Starter failure at startup. seconds. If a lamp does not start within this timeframe, the LAMP occurrence of FAILURE indicator lamp will be illuminated and the system will shut failure down. Replace the affected lamp and try to re-start system. If lamp still doesn't start, troubleshoot the lamp starter (Power/Control cabinet) and wiring from starter to lamp socket. If no problems are identified, please contact EYE Lighting technical support. Abnormal Continues for 10 X Solar lamp output power (DIMMING Irradiation intensity modulated voltage control (DIMMING CONTROL) Voltage minutes after CONTROL) set beyond maximum limit. must be set between 0V - 10V. Re-set irradiation intensity and re-start Limit occurrence of system. If failure persists, please contact EYE Lighting technical failure support. NOTE: X = System component will cease operation immediately on failure