Documentation GEM-C Wireless User & Installation Manual Revision October 2014 Apollo Solar Electric Limited
Contents GEM-C Wireless User Manual 3 Important Safety Information 3 Introduction 4 The GEM-C Control Unit 5 The GEM-C Power Sensor 6 Using The GEM-C 7 The GEM-C Display 7 Boost Mode 8 GEM-C Wireless Installation Manual 10 GEM-C System Components 11 GEM-C System Schematic 12 Installing the GEM-C Controller 13 Positioning 13 Electrical Connections 14 Connecting to the terminals 15 GEM-C Control Unit Supply 16 Installing the GEM-C Current Sensor 17 Current Sensor Installation 17 Sensor Transmitter Installation 19 Setting Up the System 20 Control Unit 21 Normal Operation 23 Setting Water Temperatures 23 Using GEM-C with Other Hot Water Heating Systems 24 Specifications 24 Page 2
Safety Information GEM-C Wireless User Manual Warranty Apollo Solar Electric Ltd. 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 Ltd. 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. Apollo Solar Electric Limited provides this manual as is, and does not issue a warranty of any kind, express or implied. The information provided in this manual is subject to change without notice. Apollo Solar Electric Ltd. reserves the right to alter product designs or specifications without notification. Apollo GEM-C is a registered trademark of Apollo Solar Electric Ltd. Important Safety Information All safety warnings give specific details of the potential danger/warning present and indicate how to reduce risk of injury, damage and electric shock resulting from improper use of the device. Carefully observe the following instructions: Installation and maintenance must be carried out by a competent person, in compliance with the manufacturer's instructions, the latest edition of the IEE wiring regulations and local safety regulations. If in any doubt, consult a qualified electrician. The device must be disconnected from the power supply before carrying out any installation work. A minimum of 50mm clearance must be provided each side of the device to allow adequate ventilation. Regulations require that the device is earthed. Do not remove the device cover while the power supply is connected. Do not operate the device with the cover removed. Do not attempt to repair or replace any part of the device. Do not touch the device with any wet part of the body. All Maintenance operations must be carried out by a qualified technician. This appliance is not suitable for outdoor use. The manufacturer accepts no responsibility for any damage or injury caused by improper use or failure to comply with these instructions. Page 3
GEM-C Wireless User Manual Introduction Micro generation systems are at their most efficient when all of the generated energy is used at the point of generation, i.e. within the household where the generator is sited. This results in the minimum possible use of imported energy. The Apollo GEM-C Generated Energy Management system will accurately monitor micro-generation energy production together with household energy demand and then ensure that any excess energy that would have been exported is stored for later use. The GEM-C system works by accurately monitoring the power being imported or exported to the property and diverts sufficient power into the hot water system in order to keep the exported power to as near zero as possible whilst at the same time ensuring that no additional power is ever imported to supply the hot water store. Priority is always given to the energy demands of the household appliances and only surplus energy that would have otherwise been exported is stored in the hot water system. The GEM-C system uses a standard immersion heater element to deliver the excess electrical power generated by the PV system to the hot water cylinder. If the water is normally heated using an electric immersion heater, the same GEM- C element will also perform a boost function at times when insufficient power is available from the PV system but more hot water is required. If the water is normally heated using gas or oil the GEM-C 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 the hot water to the required temperature. Therefore the more energy that is available from the PV system on a given day, the less gas, oil or imported electricity will be needed to provide hot water. Page 4
GEM-C Wireless User Manual The GEM-C Control Unit The GEM-C control unit is usually located near the hot water cylinder and controls the operation of the whole system. The picture below shows the GEM-C control unit and features. 1 2 1. LED Status Display 2. BOOST Button used to turn on 1 or 2 hour manual hot water boost Page 5
GEM-C Wireless User Manual The GEM-C Power Sensor The GEM-C 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 GEM Sensor Transmitter. Sensor aperture for meter tail cable GEM-C Current Sensor GEM Sensor Transmitter The sensor transmitter is usually located near or in the consumer unit and transmits the power import/export readings to the GEM control unit Page 6
GEM-C Wireless User Manual Using The GEM-C The GEM-C operation is totally automatic and no user intervention is required. For normal operation The GEM-C should be left permanently powered on. Whenever excess power is available from the PV system GEM-C will divert it into heating the hot water until the maximum temperature set by the immersion thermostat has been reached. If insufficient excess power was available from the PV system to fully heat the water the normal hot water system will come on at its pre-programmed time in order to top up the hot water to the required temperature. The GEM-C Display The GEM-C has 4 coloured LEDs to indicate the system operation and status. The function of the LED indicators is described below. LED FUNCTION DESCRIPTION IMPORT When flashing indicates that household power is being imported from the grid. The Speed of flashing is proportional to the amount of power being imported. EXPORT HEATER When flashing indicates that excess generated power is being exported to the grid. The Speed of flashing is proportional to the amount of power being exported Flashes when power is being diverted to the water heater. The speed of flashing is proportional to the amount of power going to the heater. During BOOST mode the LED will be on constantly. MAX TEMP Illuminated constantly when the set water temperature has been reached and the immersion thermostat has turned off. IMPORT EXPORT When BOTH LEDs are on constantly this indicates that power is neither being imported or exported and the system is in equilibrium. When BOTH LEDS flash slowly on and off TOGETHER this indicates that the unit is not synchronised to the transmitter and is trying to acquire the signal. When BOTH LEDS flash rapidly ALTERNATELY this indicates that the unit is in wireless pairing mode and is trying to pair with a transmitter. Page 7
GEM-C Wireless User Manual Boost Mode If it is required to boost the hot water temperature at any time using the immersion heater, this can be done by simply pressing the boost button. Press the BOOST button and the blue heater LED will flash once indicating that the unit will boost for 1 hour. The blue LED will then light continually to indicate the unit is in boost mode. If a 2 hour boost is required press the boost button again and the blue LED will flash twice indicating that the unit will now boost for 2 hours. The blue LED will then again light continually until the boost cycle has ended. If it is required to cancel boost, press the boost button again and boost will turn off. Normal PV Immersion Operation Press Boost Button Blue LED Flashes Once, then lights Continually Boosting for 1 hour Press Boost Button Blue LED Flashes Twice, then lights Continually Boosting for 2 hours Press Boost Button Blue LED goes OFF Boost Cancelled Page 8
GEM-C Wireless Installation Manual Page 9
GEM-C Wireless Installation Manual Installation of the GEM-C system can be carried out by any suitably qualified person. The installation does not need MCS approval and will not invalidate any part of the MCS approval of your PV installation. WARNING : ISOLATE MAINS SUPPLY BEFORE COMMENCING INSTALLATION INSTALLATION AND CONNECTION SHOULD ONLY BE CARRIED OUT BY A SUITABLY QUALIFIED PERSON AND IN ACCORDANCE WITH THE CURRENT EDITION OF THE IEE WIRING REGULATIONS. A means of disconnection from the supply having at least 3mm contact separation in both poles must be incorporated in the fixed wiring. If in doubt consult a qualified electrician. Immersion Heater The GEM-C system uses a standard 3KW immersion heater and will electronically regulate the power flowing into the heating element to give a controlled power input from 50W to 3000W. Prior to installing a GEM system the existing immersion heater may have never been used, or used rarely. It is recommended that the existing immersion heater is checked for correct operation before commencing the GEM installation. It is also strongly advised to inspect and check the existing immersion installation and ensure that: The cable is adequately sized The cable is in good condition The terminations in the immersion heater and isolator are in good condition and tight Page 10
GEM-C System Components GEM-C Control Unit The GEM-C control unit is usually located near the hot water tank and controls the operation of the whole system. GEM-C Current Sensor The current sensor clips around the meter tail (cable between the consumer unit and meter) and measures the current being imported or exported. The current sensor connects to the GEM-C controller. GEM Sensor Transmitter The sensor transmitter is usually located near or in the consumer unit and transmits the power import/export readings to the GEM control unit Page 11
GEM-C System Schematic The drawing below shows the wiring connections in the complete GEM-C system. (CPC [earth] connections not shown for clarity) PV System Isolator GEM Current Sensor GEM Sensor Transmitter 16A Immersion Circuit** 6A Transmitter Supply Circuit* Radio Link Immersion Heater Element GEM-C Controller Immersion Double Pole Isolator** * Transmitter can also be plugged into standard 13A socket ** A double pole & 13A fused isolator fed from a ring main circuit is also acceptable. A dedicated immersion circuit from the consumer unit is not mandatory. Page 12
Installing the GEM-C Controller Positioning The GEM-C control unit is generally installed in the vicinity of the main consumer unit. The control unit has a display and operator controls and so should be mounted in an easily accessible position. The GEM-C controller requires adequate ventilation and must be mounted such that a minimum of 50mm clearance is provided on both sides of the unit. GEM-C Controller Minimum 50mm Minimum 50mm Cover removal Remove the four screws on the front of the unit and the front cover will then slide off. Cable entry knockouts are provided for both rear and bottom cable entry. Use a Stanley knife or similar to cut out the cable access apertures relevant to your installation. Take care when removing the cut-outs as the edges can be very sharp. Run a file round the edge of the aperture to clean up any sharp edges. Mounting Mount the unit onto a wall or other secure surface using the mounting holes in the base of the unit. Page 13
Electrical Connections All electrical connections are made to the unit via a screw terminal block located under the front cover as shown: L N N L1 E E N L E Supply Earth Supply Cable Immersion Heater Cable TERMINAL L N L1 E CONNECTION Supply live from isolator switch (MCB) Supply neutral and Heater neutral Immersion Heater Live Supply earth and immersion element earth Page 14
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 GEM-C controller. Prepare the cable end as shown: Twist tightly together Do NOT solder Strip 8mm Insert the wire fully into the terminal Use the correct size screwdriver and ensure terminal screws are tight but not over tight. Check that there are no escaped wire strands at the terminal entry. Good Termination Wires not fully inserted or stripped too long Escaped wire strands Page 15
GEM-C Control Unit Supply The Incoming supply is connected to the GEM controller at the L,N & E terminals. The supply cable must be at least 1.5mm 2 CSA and rated at 16A. A method of disconnection from the supply (isolator) must be included in the supply cable. The isolator must be a double pole type rated for a least 16A. The GEM system can be supplied either by a dedicated circuit from the consumer unit which incorporates a 16A breaker or from a standard ring main. If the GEM/Immersion is supplied from a ring main the double pole isolator must also incorporate a 13A fuse. The GEM supply terminals must be connected directly to the immersion isolator. Any existing control or timer devices fitted in between the isolator and the old immersion element must be removed. If the original immersion heater cable is to be used for any part of the installation, i.e. the supply connection from the isolator to the GEM or the cable from the GEM to the immersion heater you must check that: The cable is adequately sized The cable is in good condition The terminations in the immersion heater or isolator are in good condition and tight ON GEM-C Controller 16A Double Pole Isolator ON GEM-C Controller Page 16
Installing the GEM-C Current Sensor Current Sensor Installation The GEM-C 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. The sensor can be clamped to the meter tail at any convenient location. In many cases the sensor can be inside the consumer unit itself. The sensor however must be located upstream of the PV system connection. If the PV system is connected to the main consumer unit then the current sensor may be clamped round the incoming supply to the consumer unit. If the PV system is connected via a Henley Block in parallel with the consumer unit then the sensor must be clamped round the incoming supply between the meter and the Henley Block. ENSURE THAT THE CLAMP IS FIRMLY CLICKED SHUT AROUND THE CABLE PV System Isolator Current sensor positioning with PV System connected to main consumer unit PV System Isolator Henley Block Current sensor positioning with PV System connected to Henley block Page 17
PV System Isolator <<< or >>> PV System Isolator Consumer Unit Henley Block 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 facing towards the utility meter. If it is more convenient, the sensor can be installed on the neutral supply cable instead of the live. In this case the label This side facing main meter should face away from the utility meter. Page 18
Sensor Transmitter Installation The GEM transmitter is designed to attach to a standard DIN rail and so can be mounted inside the consumer unit if there is room. The unit is 2 modules wide. Alternatively the transmitter can be wall mounted using the supplied bracket, or installed in a mini DIN rail enclosure. The GEM Sensor transmitter installed on a consumer unit DIN rail. The GEM Sensor wall mounted Power can be provided to the sensor transmitter by either plugging into a standard 13A power outlet or wiring directly to a 6A MCB in the consumer unit. Page 19
Setting Up the System Once all the connections have been made just a few simple checks are required to verify that the system is working correctly. 1. Turn off the PV system (this ensures that no power can be exported at this point) Sensor Transmitter Apply power to the sensor transmitter. On power up the orange LED should light, followed by the Green LED and then both LEDS should go out. After start-up either the green IMPORT LED should flash. The speed of flash will depend on how much power is being imported. If the green LED is flashing all is well and the solar PV isolator can be turned back on. If the orange LED is flashing the sensor is installed facing the wrong way round. If the sensor has been installed the wrong way round there a 3 ways to correct this; use whichever is most convenient: 1. Re-clamp the sensor facing the other way 2. Move the sensor from L to N or N to L 3. Reverse the two wires in the green plug at the top of the transmitter module. Check that the green LED is flashing (power being imported) Page 20
Control Unit Unit power up check 1. Turn on the GEM-C power 2. Observe that the 4 LEDs light briefly in sequence (Red, Orange, Blue, Green) Communication with sensor transmitter At this point, if this is the first time that the GEM controller has been powered up it will be searching for, and attempting to pair with a sensor transmitter unit within range. Paring mode is indicated by rapid alternate flashing of the RED and ORANGE LEDs Each sensor transmitter unit has a unique ID and the controller will only accept data from one particular transmitter. This is to ensure that only the correct power readings are received where two or more GEM systems are installed in overlapping coverage, e.g. next door properties. The GEM sensor transmitter will transmit the find me signal with details of its unique ID for the first 5 minutes after being switched on. If pairing is being attempted more than 5 minutes after the GEM transmitter was powered up then it will be necessary to turn the transmitter off and then back on. The transmitter will now send the pairing signal for a further 5 minutes. Once successfully paired and receiving data the raid flashing RED and ORANGE LEDs will stop and revert to normal display mode (see page 7) NOTE: If at any time it is required to pair a new transmitter or controller, e.g. if a transmitter or controller needs to be replaced, pairing mode can be re-entered by pressing and holding the BOOST button for 10 seconds. Page 21
Immersion Operation Check 1. If there is an isolator switch installed between the GEM-C and the immersion heater, check this is turned on. 2. Press the BOOST button. The BLUE HEATER LED should flash once briefly and then come on continually. Check the BLUE HEATER LED stays on and the GREEN MAX TEMP LED is off ** Check that the RED IMPORT LED flashing speed has increased. ** If after turning on the boost function the BLUE Boost LED goes out and the GREEN MAX TEMP LED comes on then the GEM has detected that the immersion thermostat has turned off and that the water is already hot. If the GREEN LED is on this indicates that the immersion heater is not drawing any power. If the water is not hot then this could be due to one of the following causes: a) The Immersion Isolator switch is turned off b) The immersion thermostat is set too low. Check and adjust. c) The immersion thermostat is faulty and permanently open circuit. d) The immersion heater element is faulty and open circuit e) Incorrect wiring between the GEM and immersion isolator. Page 22
Normal Operation Turn on the PV System The system is now ready for use. Once the inverter has restarted and assuming it is daytime any excess generated PV power will now be sent to the immersion heater. If excess power is available the BLUE HEATER LED should start flashing. The speed of flashing is proportional to the amount of power being diverted to the immersion heater. If power starts to be imported, indicated by the RED LED flashing, the power to the immersion will be reduced until power is no longer imported (assuming the PV power being generated is more than the household appliance load). If power starts to be exported, indicated by the ORANGE LED flashing, power to the immersion will be increased until power is no longer exported. When the system is in balance and the import/export power is being maintained at around zero both the RED IMPORT and ORANGE EXPORT LEDS will be on continuously. Setting Water Temperatures The water temperature is controlled by the immersion heater thermostat. Set the thermostat under the immersion heater terminal cover to the desired temperature using a small screwdriver. Note that to reduce the risk of scalding hot water temperature should not be set higher than 65 o C. If the hot water feed from the tank is fitted with a blending valve, a valve that mixes cold water with the hot water from the cylinder to limit the hot water output to a preset (safe) temperature, then higher tank temperatures than 65 o C could be used. The advantage of a higher tank temperature is that this will enable more energy to be stored in the tank. Page 23
Using GEM-C with Other Hot Water Heating Systems GEM-C will work well with an existing gas or oil heating system. The more energy GEM-C 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. In order to give priority to the GEM-C system but to ensure that sufficient hot water is always available it is recommended that the thermostat for the normal hot water system is set below that of the GEM-C system but high enough to give an acceptable hot water temperature. e.g. if the GEM-C optimiser temperature is set for (say) 65 o C, set the normal water heating system thermostat for (say) 50 o C or 55 o C. In this way if the water has been fully heated by GEM-C the normal water heating will be Held off and if there was insufficient surplus energy available to heat the water to the normal water temperature the normal hot water system will come on and top up to the required temperature. Specifications Specifications Microgeneration System Size Operating Voltage Control Unit Immersion or Heater Power Optimising Power Range Optimising Power Adjustment Period Variable Power Output Boost Function Temperature Setting Display Mounting Dimensions Power Sensor Unit Current Sensor Rating Mounting 0.5-5KWp 216-253 VAC, 1W 100W 300W 50W - 300W Every 2 seconds Output fully variable up to 3KW 1 or 2 Hours By immersion heater thermostat 4 x LED indicators Wall mount, bottom or rear cable entry 145h x 115w x 50d 100A Non-invasive clip-on, 16mm max cable diameter Page 24