CONTROL MICROSYSTEMS. SOLARPack 210. Hardware Manual

Transcription

1 SOLARPack 210 Hardware Manual CONTROL MICROSYSTEMS SCADA products... for the distance 48 Steacie Drive Telephone: Kanata, Ontario Facsimile: K2K 2A9 Technical Support: Canada 888-2CONTROL

2 SOLARPack Hardware Manual 2006 Control Microsystems Inc. All rights reserved. Printed in Canada. Trademarks TeleSAFE, TelePACE, SmartWIRE, SCADAPack, TeleSAFE Micro16 and TeleBUS are registered trademarks of Control Microsystems Inc. All other product names are copyright and registered trademarks or trade names of their respective owners. 1

3 Table of Contents 1 OVERVIEW IMPORTANT SAFETY INFORMATION GETTING STARTED Install Software and User Manuals Install Hardware Manual Install Optional Radio Configuration Software Install Optional SCADAPack Vision Configuration Software Mounting Pole Installation Antenna Installation Solar Panel Installation SOLARPack Installation SCADASense 4202 or 4203 Installation SOLARPack Configuration SCADASense 4202 or 4203 RealFLO Programming Vision Programming Radio Programming SOLARPACK OPERATION SOLARPACK INSTALLATION Single Enclosure System External Battery Enclosure System FIELD AND INTERNAL WIRING Communication Connections Vision Operator Interface (P1) Laptop Interface (P2) User Radio Interface (P3) Radio Setup Interface (P4) Field Wiring Connections Sensor Connections Wiring (P5)

4 6.2.2 Field Connections (P6) Power and Temperature Sensor Connections (P7) Internal Radio FreeWave 900 MHz Spread Spectrum Transceiver MDS TransNET 900 MHz Spread Spectrum Transceiver MaxStream XTend 900 MHz Spread Spectrum Transceiver Antenna Load Shedding LED Indicators DIP Switch Settings LED Power and Reset Switch MAINTENANCE CALIBRATION SPECIFICATIONS General Battery Charger LEDs Outputs Power supplies and power consumption Approvals and Certifications Index of Figures Figure 5-1: SOLARPack Single Enclosure...14 Figure 5-2: SOLARPack Single Enclosure Dimensions...15 Figure 5-3: SOLARPack Single Enclosure Pole Mounting...16 Figure 5-4: SOLARPack with External Battery Enclosure...17 Figure 5-5: SOLARPack with External Battery Enclosure Dimensions...18 Figure 5-6: Small Enclosure for 8GU1 or 8AU1 Batteries Dimensions...19 Figure 5-7: Large Enclosure for 8G22NF or 8A22NF Batteries Dimensions...20 Figure 6-1 SOLARPack Connection Overview...21 Figure 6-2: SOLARPack Control Board Layout...22 Figure 6-3 Communication Connections Block Diagram...23 Figure 6-4: Vision DE9-S Connector (P1) Pinout...25 Figure 6-5 Laptop RJ-45 Connector (P2) Pinout

5 Figure 6-6: User Radio RJ-45 Connector (P3) Pinout...28 Figure 6-7: Radio Setup RJ-45 Connector (P4) Pinout...29 Figure 6-8: Field Wiring Connections Overview...30 Figure 6-9: Sensor Connections Terminal Layout...30 Figure 6-10: 4202GFC-DR/DR2 Connection Diagram...32 Figure 6-11: 4202GFC-DS/DS2 Connection Diagram...34 Figure 6-12: Field Connections Terminal Layout...34 Figure 6-13: Solenoid Operation DIP Switch...36 Figure 6-14 Solenoid Pulsed Operation Timing...36 Figure 6-15 Solenoid continuous operation timing...37 Figure 6-16 Solenoid Wiring...38 Figure 6-17 Alarm Wiring...39 Figure 6-18 Solar Panel Wiring...40 Figure 6-19 Battery Wiring...41 Figure 6-20: Deka - East Penn 8GU1 or 8AU1 Battery Installation...42 Figure 6-21: Deka - East Penn 8G22NF or 8A22NF Battery Installation...42 Figure 6-22: External Battery Enclosure...43 Figure 6-23: Charge Voltage DIP Switch...44 Figure 6-24: Float Voltage DIP Switch...44 Figure 6-25: Battery Temperature Sensor...45 Figure 6-26 Auxiliary Load Wiring...46 Figure 6-27 Operation with Power supply...47 Figure 6-28: SOLARPack Battery and System LED Indicators...59 Figure 6-29: DIP Switch Settings...60 Index of Tables Table 6-1 Vision Connector...25 Table 6-2 RS-232 (Laptop) Connector...26 Table 6-3 External Radio Communications Wiring...28 Table 6-4 P4 Radio Setup Wiring...29 Table GFC-DR/DR2 to SOLARPack Wiring...31 Table GFC-DS/DS2 to SOLARPack Wiring...32 Table 6-7 Field Connections...34 Table 6-8 Solar Panel Selection...39 Table 6-9 Battery Selection...44 Table 6-10: SOLARPack LED Operation

6 1 Overview The SOLARPack is a solar power control and communication system, bringing integrated solar power, intelligent battery charging and reliable spread-spectrum communication to remote SCADASense 4202 or 4203 installations. Designed for use at remote sites where the environment is extreme and power hard to come by, the SOLARPack easily interfaces with a SCADASense 4202 or The SOLARPack is available in external or internal battery configurations and easily mounts on walls or standard 2 pipes. SOLARPack features: Temperature compensated battery charging. Charge and float voltage selectable for different battery types. Detection and isolation of defective batteries. Under voltage lockout prevents battery damage as battery approaches end of capacity. Load shedding allows the radio to be shutdown as battery approaches end of capacity. LED indication of battery charging state. Choice of optional FreeWave, MDS and MaxStream radio modules. Optional SCADAPack Vision 10 or 50 integrated into the enclosure door. Configured to convert the state-oriented DO from the SCADASense 4202 or 4203 into a pulse on/pulse off type output for latching solenoids. An external ventilated battery enclosure version is available for applications in hot environments. 5

7 2 Important Safety Information Power, input and output (i/o) wiring must be in accordance with Class I, Division 2 wiring methods Article (b) of the National Electrical Code, NFPA 70 for installations in the U.S., or as specified in Section 18-1J2 of the Canadian Electrical Code for installations within Canada and in accordance with the authority having jurisdiction. WARNING: Battery must be a 12V nominal Gelled electrolyte (gel) or Absorbed Glass Mat (AGM) valve regulated lead acid (VRLA) battery rated no less than 25Ahr (20 hour rating). Battery height, including terminals, must not exceed 9.3 inches. CAUTION: When installing a battery pay close attention to the polarity of the wiring and battery terminals. Failure to make these connections properly may result in damage to the SOLARPack and the battery. WARNING: Explosion Hazard. Substitution of components may impair suitability for Class 1, Division 2. Do not disconnect if circuits are live unless the area in known to be non hazardous. CAUTION: Use care when removing and installing the SOLARPack PCB cover. High currents and the potential for arcing is possible when internal points are accidentally shorted. The PCB cover should be removed only when the area in known to be non-hazardous. CAUTION: Solar panels must be installed and acceptable for use in Cl. 1, Div. 2 hazardous areas as per the CEC and NEC. 6

8 3 Getting Started This Getting Started Guide provides a brief overview of the installation of the SOLARPack and the optional accessories that may be included. The installation of the SOLARPack requires the user to install and refer to the SOLARPack User Manual. The installation instructions for the manual are found in the Install Hardware Manual section of this document. The installation of the SOLARPack includes: Confirm the SOLARPack shipment contents. Ensure any optional equipment that was ordered is included with the shipment. Ensure the hardware manual CD which includes the radio configuration software and optional Vision programming CDs are included. Install the software hardware manual contains the complete SOLARPack user manual that will be used as a reference in this document. Install mounting pole (2 ) if being used. Install antenna on pole highest point of mounting poll. Install solar panel bracket and panel and wiring. As per instructions. Install SOLARPack Install optional SCADASense 4202 or Install Batteries. Check operation. These steps are briefly described in the following sections. 3.1 Install Software and User Manuals The software and user manual installation will depend on the options ordered with the SOLARPack. The software and user manuals needed for the installation and operation of the SOLARPack systems will generally include the following. Hardware Manual The Configuration Software (Including Hardware Manual) CD is included with the SOLARPack shipment. The complete SOLARPack user and reference manual is included on this CD. Radio Programming Software The optional Radio Transceiver the programming software for all versions of available radios is included in the Configuration Software (Including Hardware Manual) CD. Vision Programming Software When the SOLARPack is equipped with the optional Vision display the SCADAPack Vision CD is included with the SOLARPack shipment. TelePACE or ISaGRAF Application Software This software is not included with the SOLARPack. This software is ordered separately and may be required depending on the application RealFLO Software This software is not included with the SOLARPack. This software is ordered separately and may be required depending on the application. 7

9 3.1.1 Install Hardware Manual The complete SOLARPack User and Reference manual is included on the Configuration Software (Including Hardware Manual) CD that was included in your SOLARPack shipment. The SOLARPack User and Reference manual must be installed as it is referenced in this Getting Started Guide. To install the SOLARPack User and Reference manual on your PC: Insert the Configuration Software (Including Hardware Manual) CD into your CD ROM drive. The CD will autorun and display a splash screen with a number of installation options. Click on the Install Hardware Documentation button and follow the Installation Wizard instructions to install the complete hardware manual. Note that the hardware user manuals are in Adobe PDF format. An installation for Adobe Reader is included on the CD if you do not have it installed on your PC. Once installed the SOLARPack User and Reference manual is opened by selecting: Windows Start >> All Programs >> Control Microsystems >> Hardware Manual. Once the Hardware Manual is opened select SOLARPack from the bookmarks at the left of the page Install Optional Radio Configuration Software Programming software for the optional radio transceivers is included on the Configuration Software (Including Hardware Manual) CD and should be installed at this time. If the SOLARPack includes an optional FreeWave radio transceiver you will need to install the FreeWave EZ Config software. Click on the Install FreeWave EZ Config button and follow the Installation Wizard instructions to install the FreeWave EX Config software. If the SOLARPack includes an optional Microwave Data Systems (MDS) radio transceiver you will need to install the TransNet Configuration software. Click on the Install TransNet Configuration button and follow the Installation Wizard instructions to install the FreeWave EX Config software. If the SOLARPack includes an optional MaxStream radio transceiver you will need to install the MaxStream X-CTU software. Click on the Install X-CTU button and follow the Installation Wizard instructions to install the MaxStream X-CTU software Install Optional SCADAPack Vision Configuration Software Programming software for the optional SCADAPack Vision included with the SOLARPack shipment. To install the SCADAPack Vision software on your PC: Insert the SCADAPack Vision CD into your CD drive. The CD will autorun and display a splash screen with a number of options. Click on the Install Vision Application button and follow the Installation Wizard instructions to install the complete hardware manual. Note that the SCADAPack Vision help file is in Adobe PDF format. An installation for Adobe Reader is included on the CD if you do not have it installed on your PC. 8

10 Once installed the SCADAPack Vision software is installed it is opened by selecting: Windows Start >> All Programs >> Vision >> Vision. SCADAPack Vision sample programs are available at Go to the Support >> On Line Technical Support >> Programming Sample section for a variety of example programs. 3.2 Mounting Pole Installation When a 2 inch mounting poll is used for SOLARPack installation the poll must be installed in a manner sufficient to support the weight and wind loading of the SOLARPack. When determining the mounting poll height consideration must be made for the antenna line of sight when the SOLARPack optional radio is used. 3.3 Antenna Installation The antenna should be mounted at the highest point on the pole. The optional antenna includes mounting hardware and instructions. Follow the manufacturer s instruction to mount the antenna. Ensure there is enough coax feed line to reach from the antenna connection to the SOLARPack PolyPhaser connection at the bottom of the SOLARPack. Connect the coax feed line to the antenna and seal the connection with weatherproof tape. 3.4 Solar Panel Installation The optional solar panel includes mounting hardware and instructions. Follow the manufacturer s instruction to mount the solar panel. The solar panel should be aimed due south. Ensure there is enough solar panel cable to reach from the solar panel to the SOLARPack. Tie-wrap or otherwise secure the antenna coax cable and solar panel cable to the pole. 3.5 SOLARPack Installation Note: The SOLARPack must be securely mounted in a manner sufficient to support the weight and wind loading. The installation must meet local electrical code requirements. The SOLARPack is available in two versions; the single enclosure version and the external battery enclosure version. For both versions mount the SOLARPack housing on the pole at a height which allows the optional Vision display to be easily read, approximately 66 inches Vision display to ground level. When mounting the SOLARPack to a mounting poll use the U bolt assembly provided to secure the SOLARPack to the mounting poll. Refer to the SOLARPack User Manual for mounting diagrams. When the SOLARPack is mounted to a flat surface secure the SOLARPack using nuts and bolts or lag screws as required. When the external battery box version of the SOLARPack is used the battery box is mounted not more that 6.5 feet (2 meters) from the SOLARPack. Use the included cable assembly to connect the external battery box battery to the SOLARPack. Refer to the SOLARPack User Manual for connection diagrams. Install the needed electrical fittings in bottom of SOLARPack housing to connect a SCADASense 4202 or 4203, solar panel and solenoids if used. 9

11 Attach the antenna cable to the SOLARPack PolyPhaser connector and seal the connection with weather-proof tape 3.6 SCADASense 4202 or 4203 Installation Refer to the 4202User Manual and the 4203 User Manual for complete installation instructions. The general procedure for installation of the SCADASense 4202 or 4203is as follows: Install the SCADASense 4202 or 4203and manifold on the meter run. Run the conduit or approved cable from the SCADASense 4202 or 4203to the SOLARPack housing. Connect the conduit or approved cable to the SCADASense 4202 or 4203 and make the necessary connections at the SCADASense 4202 or Install the RTD in and connect it to the SCADASense 4202 or Connect the conduit or approved cable to the SOLARPack housing and wire the connections from the SCADASense 4202 or 4203 on SOLARPack Sensor Connections terminal P5. Refer to the SOLARPack User Manual for connection diagrams. 3.7 SOLARPack Configuration Install the battery, being careful to avoid shorting the positive terminal to the cabinet. Refer to the SOLARPack User Manual for complete battery installation information. Ensure the battery is installed as shown in SOLARPack User Manual and the temperature sensor board is attached to the battery negative terminal. If the SOLARPack is an external battery box version the battery wiring must be connected to the SOLARPack Power Connection terminal P7. See the SOLARPack User Manual for connection details. With the battery connected, press the LED Power button and check that the SOLARPack System LED comes on and is green. Connect the solar panel to SOLARPack Power Connection terminal P7. See the SOLARPack User Manual for connection details. The Battery and Charger Status LED will now indicate current charge conditions. Set the SOLARPack DIP switches as required for the charge and float voltage for the battery type, radio load shedding and external solenoid operation. Press the SCADASense 4202 or 4203 LED Power button and ensure the Status LED comes on. 3.8 SCADASense 4202 or 4203 RealFLO Programming The RealFLO Application must be installed on the PC you are using. If it is not installed then insert the RealFLO CD into your CD-ROM drive and run install from the autorun menu. Open the RealFLO Gas Flow application by clicking the Windows Start button then selecting Programs then select the RealFLO group and click RealFLO. 10

12 The SCADASense 4202 or 4203 has been configured at the factory and a sample configuration is running in the SCADASense 4202 or The serial ports, COM2 and COM3 must be set for RS-485 communication when connected with a SOLARPack. Refer to the RealFLO User and Reference manual and the SCADASense 4202 User Manual or SCADASense 4203 User Manual for complete programming and configuration details. 3.9 Vision Programming The SCADAPack Vision software is used to configure the SCADAPack Vision operator interface to display data read from a PLC and to allow operator-entered data to be written to the PLC. A number of SCADAPack Vision 10 and Vision 50 sample applications are available on our web site at See the Support >> Online Technical Support >> Programming Samples section Radio Programming One of three optional radios may be installed in the SOLARPack at time of manufacture. Radios are installed in the factory and cannot be upgraded in the field. Refer to the SOLARPack part number or your order to determine which radio is installed. The optional radios available are: The FreeWave FGR09CSU 900 MHz Spread Spectrum Wireless Transceiver. The MDS TransNET 900 Frequency Hopping Spread Spectrum Transceiver. The MaxStream XTend OEM RF Module Transceiver. For detailed operation instructions for each of these radios refer to the user manuals installed with the Hardware Manuals CD. 11

13 4 SOLARPack Operation The SOLARPack uses a shunt regulator battery charger. Battery charging is achieved by shunting the solar panel using a high frequency PWM. Solar panel current is always flowing. The SOLARPack uses a proprietary charging algorithm to test for and determine the condition of the battery before proceeding with the charging stages. The charger will first bulk charge to replace the battery charge at the maximum rate of the solar panels. The second stage is the absorption stage at the charge voltage and a current limited by the battery. The final stage will maintain the battery with the float voltage until the charger recognizes that additional charging is required and will revert back the charge voltage. Every morning the condition of the batteries is determined and the charging sequence repeats beginning a battery test and continues on to the first charge stage. Defective battery conditions such as shorted or open cells are detected and the battery is safely isolated. Under these conditions, the SOLARPack will run given that the solar panel provides sufficient power to operate the device. It is not necessary to disconnect the solar panel to replace a battery. The device will recognize an open-circuit or missing battery and adjust its operation automatically. Provided that the solar panel generates sufficient power to operate the device, all loads will remain powered. 12

14 5 SOLARPack Installation The SOLARPack is mounted either on a 2 in. pipe using the U-bolt assemblies provided or on a flat surfaced wall. In both cases the mounting tabs on the top and bottom back of the enclosure are used. Refer to the following drawings; Figure 5-1: SOLARPack Single Enclosure, Figure 5-2: SOLARPack Single Enclosure Dimensions and Figure 5-3: SOLARPack Single Enclosure Pole Mounting in Section 5.1 for the enclosure and mounting dimensions. The SOLARPack must be securely mounted in a manner sufficient to support the weight and wind loading. The installation must meet local electrical code requirements. The SOLARPack is available in two enclosure formats, the single enclosure system and the external battery enclosure system. The single enclosure system contains a battery compartment internal to the enclosure. The external battery enclosure uses a vented external battery compartment. A number of knock outs are located at the bottom of the SOLARPack enclosures to facilitate wiring for the SCADASense 4202 or 4203, ground connection and external devices. 5.1 Single Enclosure System The SOLARPack is available complete with the battery housing integrated into a single compact enclosure. 13

15 Figure 5-1: SOLARPack Single Enclosure 14

16 Figure 5-2: SOLARPack Single Enclosure Dimensions 15

17 Figure 5-3: SOLARPack Single Enclosure Pole Mounting 16

18 5.2 External Battery Enclosure System The SOLARPack is available with the battery installed in a separate ventilated enclosure. The capacity and life expectancy of a sealed lead acid battery will be reduced at high ambient temperatures. In these applications it is recommended that the battery be installed in an external ventilated enclosure. The interconnection between the two enclosures must meet the requirements of the local electrical code. The wiring consists of the battery voltage and the temperature sensor. The maximum distance between the two enclosures is 2m (6.5 ft.). The external vented battery enclosure is available in two sizes depending on the battery size used. The small battery enclosure is used with Deka - East Penn 8GU1 or 8AU1 batteries and the large battery enclosure is used with Deka - East Penn 8G22NF or 8A22NF batteries. Figure 5-4: SOLARPack with External Battery Enclosure 17

19 Figure 5-5: SOLARPack with External Battery Enclosure Dimensions 18

20 Figure 5-6: Small Enclosure for 8GU1 or 8AU1 Batteries Dimensions 19

21 Figure 5-7: Large Enclosure for 8G22NF or 8A22NF Batteries Dimensions 20

22 6 Field and Internal Wiring The SOLARPack control board provides a number of easily accessed connection points for interfacing with field wiring. The connections, labeled P1 through P7, have the following functions: Connection Type Function P1 DE9-S Vision Operator Interface P2 RJ-45 Laptop Connection P3 RJ-45 User Radio Setup P4 RJ-45 Internal Radio Setup P5 Terminals SCADASense 4202 or 4203 Sensor Connections P6 Terminals SCADASense 4202 or 4203 Field Wiring Connections P7 Terminals Power and Temperature Sensor Connections Each of these connections is fully described in the sections following in this manual. An overview of the connections is shown in the following figure. SCADAPack Vision + Battery Internal Radio P1 Vision P2 Laptop RS-232 P3 User Radio P4 Radio Setup P5 Sensor Connections P6 Field Connections P7 Power and Temp Sensor Connections COM2, COM3, Power, IO IO Solenoids Aux. Load Figure 6-1 SOLARPack Connection Overview 21

23 The SOLARPack control board detail layout is shown in the following figure. This figure shows the location of the connections, LEDs, Dip-switches and LED power switch and is referred to throughout this manual. Figure 6-2: SOLARPack Control Board Layout 6.1 Communication Connections This section of the user manual describes the serial communication connections for the SOLARPack. An overview of the communication routing and connections in the SOLARPack is shown below. 22

24 RS-485 TTL TTL RS-232 FreeWave Radio MDS Radio MaxStream Radio RS-485 SCADAPack Vision RS-232 COM2 COM3 SCADAPack Vision is automatically disabled when P2- Laptop RS-232 in use. 4202/3 P2 - Laptop RS-232 Figure 6-3 Communication Connections Block Diagram The SOLARPack control board has four serial communication connections. Vision Operator Interface (connector P1). Laptop Connection (connector P2). User Radio Setup (connector P3). Internal Radio Setup (connector P4). These communication connections are each described in the following sections. The SCADASense 4202 or 4203 serial connections are described in the Sensor Connections Wiring (P5) section of this manual Vision Operator Interface (P1) The SOLARPack is optionally supplied with either a SCADAPack Vision 10 or SCADAPack Vision 50 operator interface. The operator interface is mounted on the front cover of the SOLARPack and is connected to the SOLARPack control board via SOLARPack Vision connector P1 (RJ-45 type). See Figure 6-1 SOLARPack Connection Overview for the location of connector P1. 23

25 The SCADAPack Vision communicates serially with the SCADASense 4202 or 4203 Flow Computer and provides, when programmed, operator interaction with the Flow Computer. Note: The SCADAPack Vision 10 or SCADAPack Vision 50 operator interface needs to be programmed for use in your application. The Vision programming software is provided on the SCADAPack Vision CD that was included in your shipment. A number of SCADAPack Vision 10 and Vision 50 sample applications are available on our web site at See the Support >> Online Technical Support >> Programming Samples section. The serial communication path between the SCADAPack Vision (PLC Port) and the SCADASense 4202 or 4203 (COM3) is controlled by the SOLARPack. The SCADAPack Vision PLC Port is connected to SOLARPack connector (P1) with a factory installed serial cable. See Table 6-2 Vision Cable for wiring detail for this cable. The SCADASense 4202 or 4203 is connected to the SOLARPack using the Sensor Connections connector P5. See section Sensor Connections Wiring (P5) for complete information on wiring the SCADASense 4202 or 4203 to connector P5. The SOLARPack internally routes the serial communication between the Vision connector (P1) and the SCADASense 4202 or 4203 COM3 connections (A, B and Common) on connector P5. Note: The 4202GFC COM3 serial port must be configured for RS-485 operation. The SOLARPack performs the RS-485 to RS-232 signal conversion needed between the Vision (P1) and the SCADASense 4202 or 4203 COM3 (P5). The SOLARPack supplies the 5VDC power, required by the SCADAPack Vision, through the serial cable connection between the SCADAPack Vision and the SOLARPack P1 connector. Power to the SCADAPack Vision is enabled or disabled using the ON button on the Vision face plate. Momentarily pressing the ON button turns the Vision display on. Pressing the ON button for 3 seconds turns the Vision display off. The SOLARPack will automatically remove power (turn the Vision display off) after 15 minutes. When an RS-232 device such as a laptop computer in connected to the Laptop P2 connector the Vision is disabled and the RS-232 device connected at P2 is connected to the SCADASense 4202 or 4203 COM3. The SOLARPack automatically detects when a device, such as a laptop computer, is connect to the Laptop P2 connector. Refer to Figure 6-3 Communication Connections Block Diagram. The SCADAPack Vision Operator Interface connects to the SOLARPack at the Vision connector P1. Connector P1 is DE9-S (female) connector. This connector has been wired specifically for the Vision for use with the cable supplied. Do not attempt to connect a PC or any other type of communication device to this connector. The pinout of this connector is shown in Table 6-1 Vision Connector. See Table 6-2 Vision Cable for wiring detail for the required cable. The Vision is connected to COM3 of the SCADASense 4202 or The SOLARPack includes the necessary RS-232 to RS-485 conversion. 24

26 Error! Objects cannot be created from editing field codes. Figure 6-4: Vision DE9-S Connector (P1) Pinout Table 6-1 Vision Connector Vision P1 Function and comments 1 Interrupt - From Vision to SOLARPack. 2 RxD - From Vision to SOLARPack. 3 TxD - From SOLARPack to Vision. 4 No connection. 5 Ground. 6 No connection. 7 No connection. 8 No connection. 9 5V Vision power - Controlled by the SOLARPack. See Vision Operator Interface. Table 6-2 Vision Cable Vision DE9-S Laptop Interface (P2) SOLARPack DE9-P (not required) (not required) 7 7 (not required) 8 8 (not required) 9 9 The Laptop Interface is used for serial communication between a laptop computer and the SCADASense 4202 or 4203 Flow Computer. See Figure 6-1 SOLARPack Connection Overview for the location of connector P2. Access to the Laptop P2 connector is available on an external connection on the SOLARPack enclosure. A cable from this external 8 pin modular (RJ-45) connector to the internal Laptop P2 (RJ- 45 type) connector is pre-wired in the SOLARPack. The pinout of both of these connectors is the same and is shown in Table 6-3 RS-232 (Laptop) Connector. CAUTION: Do not connect to the external port unless the area is known to be non hazardous. 25

27 The serial communication path between a PC and other RS-232 device connected to the Laptop (P2) connection and the SCADASense 4202 or 4203 (COM3) is controlled by the SOLARPack. The laptop is connected to SOLARPack Laptop connector P2 (or the external connector) with a standard null modem serial cable. The Control Microsystems cable Part Number is a suitable cable. The SCADASense 4202 or 4203 is connected to SOLARPack using the Sensor Connections connector P5. See section Sensor Connections Wiring (P5) for complete information on wiring the SCADASense 4202 or 4203 to connector P5. The SOLARPack internally routes the serial communication between the Laptop connector P2 and the SCADASense 4202 or 4203 COM3 connections (A, B and Common) on connector P5. Note: The SCADASense 4202 or 4203 COM3 serial port must be configured for RS-485 operation. See the 3 Getting Started section for information on how to set the serial parameters for the SCADASense 4202 or The SOLARPack performs the RS-485 to RS-232 signal conversion needed between the Laptop (P1) and the SCADASense 4202 or 4203 COM3 (P5). When an RS-232 device such as a laptop computer is connected to the Laptop P2 connector the Vision interface is disabled and the RS-232 device connected at P2 is connected to the SCADASense 4202 or 4203 COM3. The SOLARPack automatically detects when a device, such as a laptop computer, is connected to the Laptop P2 connector. Refer to Figure 6-3 Communication Connections Block Diagram. RJ-45 Modular Jack NC 2. NC 3. NC 4. GND 5. RxD 6. TxD 7. NC 8. NC Figure 6-5 Laptop RJ-45 Connector (P2) Pinout Table 6-3 RS-232 (Laptop) Connector RS-232 P2 Function and comments 1 No connection. 2 No connection. 3 No connection. 4 Ground. 26

28 RS-232 P2 Function and comments 5 RxD - Input to SOLARPack from external RS-232 device. 6 TxD - Output to external RS-232 device from SOLARPack. 7 No connection. 8 No connection. A standard Control Microsystems cable (Part number ) is available to connect RS-232 devices such as a PC that have a DE9-P serial connector. This cable is DE9-S on one end, 8 pin RJ- 45 plug on the other end and is 10 feet in length User Radio Interface (P3) The User Radio interface is available for use with external user supplied radios. The User Radio interface is an RJ-45 type connector labeled P3 on the SOLARPack. See Figure 6-1 SOLARPack Connection Overview for the location of connector P3. The serial communication path between a user supplied radio connected to the User Radio (P3) connection and the SCADASense 4202 or 4203 (COM2) is controlled by the SOLARPack. The user supplied radio is connected to the SOLARPack User Radio connector P3 with a cable that meets the requirements of Table 6-4 External Radio Communications Wiring below. The SCADASense 4202 or 4203 is connected to SOLARPack using the Sensor Connections connector P5. See section Sensor Connections Wiring (P5) for complete information on wiring the SCADASense 4202 or 4203 to connector P5. The SOLARPack internally routes the serial communication between the User Radio connector P3 and the 4202GFC COM2 connections. Refer to Table 6-4 External Radio Communications Wiring to follow the wiring from the P3 User Radio connector, through the Field Connections and on to the SCADASense 4202 or 4203 COM2. RJ-45 Modular Jack NC 2. NC 3. NC 4. GND 5. RxD 6. TxD 7. NC 8. NC Figure 6-6: User Radio RJ-45 Connector (P3) Pinout Table 6-4 External Radio Communications Wiring 27

29 P3 User Radio Pin 4 Common Pin 5 RS-485 B RS-232 RxD Pin 6 RS-485 B RS-232 TxD SOLARPack P5 Terminals Pin 5 Pin 3 Common Pin 4 Pin 2 RS-485 B RS-232 TxD Pin 3 Pin 1 RS-485 A RS-232 RxD SCADASense 4202 or 4203 COM2 Terminals Radio Setup Interface (P4) The Radio Setup interface is used to program the optional FreeWave or Microwave Data Systems (MDS) radio transceiver. The Radio Setup interface is an RJ-45 type connector labeled P4 on the SOLARPack. See Figure 6-1 SOLARPack Connection Overview for the location of connector P4. For further information on the SOLARPack radio transceivers see the Grounding section in this manual. Note: The FreeWave, MDS or MaxStream radio transceiver needs to be programmed for use in your application. The programming software is provided on the Configuration Software (Including Hardware Manual) CD that was included in your shipment. The serial communication path between the SOLARPack FreeWave, MDS or MaxStream radio transceiver connected to the Radio Setup (P4) connection and the SCADASense 4202 or 4203 (COM2) is controlled by the SOLARPack. The serial communication path between the SOLARPack FreeWave, and MDS radio transceiver connected to the Radio Setup (P4) connection and the SCADASense 4202 or 4203 (COM2) is controlled by the SOLARPack. User Radio Interface (P3) is used to program the MaxStream radio, using the RS-232 conversion to interface to RS485 connector see Figure 6-3 Communication Connections Block Diagram. The user supplied radio is connected to the SOLARPack User Radio connector P3 with a cable that meets the requirements of Table 6-4 External Radio Communications Wiring below. The SCADASense 4202 or 4203 is connected to SOLARPack using the Sensor Connections connector P5. See section Sensor Connections Wiring (P5) for complete information on wiring the SCADASense 4202 or 4203 to connector P5. The SOLARPack internally routes the serial communication between the User Radio connector P3 and the SCADASense 4202 or 4203 COM2 connections. Note: The SCADASense 4202 or 4203 COM2 serial port must be configured for RS-485 operation. See the 3 Getting Started section for information on how to set the serial parameters for the SCADASense 4202 or The SOLARPack performs the RS-485 to RS-232 signal conversion needed between the Radio Setup (P4) and the SCADASense 4202 or 4203 COM2 (P5). 28

30 + PWR PWR COM2 A COM2 B COM2 COM COM3 A COM3 B COM3 COM A0/AIN0 CTR1/AIN1 I/O COM CTR-IO0/IO0 IO1 SOLENOID PULSE IN IO1 IO2 IO3 IO4 IO5 COMMON SOLENOID CLOSE SOLENOID OPEN COMMON ALARM O/P + AUX. OUT AUX. OUT + SOLARPANEL SOLAR PANEL + BATTERY BATTERY TEMP. SENSOR CHASSIS GND RJ-45 Modular Jack NC 2. NC 3. NC 4. GND 5. RxD 6. TxD 7. NC 8. NC Figure 6-7: Radio Setup RJ-45 Connector (P4) Pinout Table 6-5 P4 Radio Setup Wiring P4 Radio Setup Function and comments 1 No connection. 2 No connection. 3 No connection. 4 Ground. 5 RxD - Input to FreeWave or MDS radio from external RS-232 device. 6 TxD - Output to external RS-232 device from FreeWave or MDS radio. 7 No connection. 8 No connection. 6.2 Field Wiring Connections This section of the user manual describes the field wiring connections for the SOLARPack. An overview of the field wiring connections in the SOLARPack is shown below. P5-4202GFC Connections P6 - Field I/O Connections P7 - Power Connections Model 4202GFC Sensor Power and RS-485. Optional 4202GFC IO connections. See manual for solenoid configuration. 4202GFC IO connections. Solenoid and alarm outputs. See manual. + See Manual + Solar Panel + Battery and Temperature Sensor Figure 6-8: Field Wiring Connections Overview 29

31 The SOLARPack control board has three field wiring connections. Sensor Connections (connector P5). Field Connections (connector P6). Power Connections (connector P7). These field wiring connections are each described in the following sections Sensor Connections Wiring (P5) The SOLARPack is connected with a SCADASense 4202 or 4203 Gas Flow Computer using Sensor Connections terminal P5. The SCADASense 4202 or 4203 communication ports, analog and digital I/O (input / output) and input power may all be connected to the SOLARPack using connector P5. The SOLARPack connector P5 supports connections with the SCADASense 4202DR, SCADASense 4202DS, SCADASense 4203DR or SCADASense 4203DS. Determine which version of SCADASense 4202 or 4203 you are using and refer to the following sections for connection details. Error! Objects cannot be created from editing field codes. Figure 6-9: Sensor Connections Terminal Layout SCADASense 4202DR or 4203DR Sensor Connections Depending on your application some or all of P5 connections, as shown in Table 6-6 SCADASense 4202DR or 4203DR to SOLARPack Wiring, will be required. For example connections P5,9 through P5,14 are provided as a convenience to the user and need not be wired if the 4202GFC- DR/DR2 I/O is not being used. Figure 6-10: SCADASense 4202DR or 4203DR Connection Diagram shows the terminal connections on the SCADASense 4202DR or 4203DR sensor. Note: The screw termination style connectors on the SOLARPack accommodate solid or stranded wires from 12 to 24 AWG. The SCADASense 4202DR or 4203DR screw termination connectors accommodate solid or stranded wires from 16 to 28 AWG. Refer to the SCADASense 4202 or 4203 User Manuals for complete information on the SCADASense 4202DR or 4203DR. Table 6-6 SCADASense 4202DR or 4203DR to SOLARPack Wiring 4202GFC- DR/DR2 Terminals SOLARPack P5 Terminal Function and comments P1,1 P5,1 PWR+ SOLARPack provides power to the SCADASense 4202 or The current is limited by a self-resetting circuit breaker to 1A continuous. See the Self-resetting Circuit Breakers section for further details. P1,2 P5,2 PWR P2,1 P5,3 COM2, A 30

32 4202GFC- DR/DR2 Terminals SOLARPack P5 Terminal Function and comments Set SCADASense 4202DR or 4203DR COM2 to RS-485 P2,2 P5,4 COM2, B P2,3 P5,5 COM2 common P3,1 P5,6 COM3, A Set SCADASense 4202DR or 4203DR COM3 to RS-485 P3,2 P5,7 COM3, B P3,3 P5,8 COM3 common P5,4 P5,9 SCADASense 4202DR or 4203DR Analog output Internally connects to SOLARPack P6,1 P5,3 P5,10 SCADASense 4202DR or 4203DR Counter 1 input Internally connects to SOLARPack P6,2 P5,2 P5,11 SCADASense 4202DR or 4203DR IO common Internally connects to SOLARPack P6,3 P5,1 P5,12 SCADASense 4202DR or 4203DR Counter 0 and Digital I/O Internally connects to SOLARPack P6,4 P5,13 No connection P5,14 Solenoid Configure. Connect to SOLARPack P5,12 when using solenoid outputs configured for Pulse or Continuous operation. See section Solenoid Outputs for information on the operation and wiring of solenoid outputs. Status LED Input Power Connections COM2 RS-232 or 485 Connections COM3 RS -232 or 485 Connections DC Power (+) DC Power (-) COM 2 TX / A COM 2 RX / B COM 2 com COM 2 (232 / 485) COM 3 (232 / 485) COM 3 TX / A COM 3 RX / B COM 3 com P1 P2 P3 F U S E P5 P4 AOUT CTR 1 COM CTR0/DIN/DOUT I R R IRET RTD Connections Analog Output, Digital Input/Output and Coun ter Input Connections Cold Boot Switch Figure 6-10: SCADASense 4202DR or 4203DR Connection Diagram 31

33 SCADASense 4202DS or 4203DS Sensor Connections Depending on your application some or all of P5 connections, as shown in Table 6-7 SCADASense 4202DS or 4203DS to SOLARPack Wiring, will be required. For example connections P5,9 through P5,14 are provided as a convenience to the user and need not be wired if the 4202GFC-DS I/O is not being used. Figure 6-11: SCADASense 4202DS or 4203DS Connection Diagram shows the terminal connections on the 4202GFC-DS/DS2 sensor. Note: The screw termination style connectors on the SOLARPack accommodate solid or stranded wires from 12 to 24 AWG. The SCADASense 4202DS or 4203DS screw termination connectors accommodate solid or stranded wires from 16 to 28 AWG. Refer to the SCADASense 4202 or 4203 User Manuals for complete information on the 4202GFC- DS/DS2. Table 6-7 SCADASense 4202DS or 4203DS to SOLARPack Wiring 4202GFC- DS/DS2 Terminal SOLARPack P5 Terminal Function and comments P1,1 P5,1 PWR+ SOLARPack provides power to the SCADASense 4202DS or 4203DS. The current is limited by a self-resetting circuit breaker to 1A continuous. See the Self-resetting Circuit Breakers section for further details. P1,2 P5,2 PWR P2,1 P5,3 COM2, A Set SCADASense 4202DS or 4203DS COM2 to RS-485 P2,2 P5,4 COM2, B P2,3 P5,5 COM2 common P3,1 P5,6 COM3, A Set SCADASense 4202DS or 4203DS COM3 to RS-485 P3,2 P5,7 COM3, B P3,3 P5,8 COM3 common P5,5 P5,9 SCADASense 4202DS or 4203DS Analog input 0 Internally connects to SOLARPack P6,1 P5,4 P5,10 SCADASense 4202DS or 4203DS Analog input 1 Internally connects to SOLARPack P6,2 P5,3 P5,11 SCADASense 4202DS or 4203DS IO common Internally connects to SOLARPack P6,3 P5,2 P5,12 SCADASense 4202DS or 4203DS Counter 0 and Digital I/O 0 Internally connects to SOLARPack P6,4 P5,1 P5,13 SCADASense 4202DS or 4203DS Counter 1 and Digital I/O 1 Internally connects to SOLARPack P6,5 P5,14 Solenoid Configure. Connect to SOLARPack P5,12 or P5,13 when using 32

34 4202GFC- DS/DS2 Terminal SOLARPack P5 Terminal Function and comments solenoid outputs configured for Pulse or Continuous operation. See section Solenoid Outputs for information on the operation and wiring of solenoid outputs. Error! Objects cannot be created from editing field codes. Figure 6-11: SCADASense 4202DS or 4203DS Connection Diagram Field Connections (P6) The Field Connections, P6, terminals provide convenient access to the SCADASense 4202 or 4203 I/O wired to connector P5 (Sensor Connections). In addition to the 4202GFC I/O the solenoid and alarm outputs are also accessed from connector P6. Wiring connections for connector P6 are listed in Table 6-8 Field Connections. The solenoid output operation and wiring details are described in the Solenoid Outputs section and the alarm output and wiring details are described in the Alarm Output section. Note: The screw termination style connectors on the SOLARPack accommodate solid or stranded wires from 12 to 24 AWG. The SCADASense 4202DS or 4203DS screw termination connectors accommodate solid or stranded wires from 16 to 28 AWG. Error! Objects cannot be created from editing field codes. Figure 6-12: Field Connections Terminal Layout The screw termination style connectors on the SOLARPack accommodate solid or stranded wires from 12 to 24 AWG. Table 6-8 Field Connections SOLARPack Connector P6 Function and comments GFC-DR/DR2 Analog output SCADASense 4202DS or 4203DS Analog input 0 Internally connected to P5,9 2 SCADASense 4202DR or 4203DR Counter 1 input SCADASense 4202DS or 4203DS Analog input 1 Internally connected to P5,10 3 SCADASense 4202DR or 4203DR IO common SCADASense 4202DS or 4203DS IO common Internally connected to P5,11 4 SCADASense 4202DR or 4203DR Counter 0 and Digital I/O SCADASense 4202DS or 4203DS Counter 0 and Digital I/O 0 Internally connected to P5,12 5 SCADASense 4202DS or 4203DS Counter 1 and Digital I/O 1 33

35 SOLARPack Connector P6 Function and comments Internally connected to P5,13 6 Common. Internally connected to the chassis and the negative side of all power supplies. 7 CLOSE solenoid output. This is a sourcing output. 8 OPEN solenoid output. This is a sourcing output. 9 Common. Internally connected to the chassis and the negative side of all power supplies. 10 Alarm output Solenoid Outputs The SOLARPack has two solenoid outputs that can be connected to field devices using the Field Connection connector P6. The solenoid outputs, OPEN (P6,8) and CLOSE (P6,7), are controlled by a single digital output, CTR0/DIO0, from the SCADASense 4202 or Note: CTR0/DIO0 must be used for Solenoid output control. The digital output must be connected to Sensor Connections terminal P5, 14. Refer to Sensor Connections Wiring (P5) section for information on connector P5. Note: An ISaGRAF, TelePACE or C application program must be created to control the digital output on the SCADASense 4202 or See the appropriate ISaGRAF, TelePACE or C Tools user manual for complete information on using an application program to control the digital output. The solenoid outputs are configured as Pulsed Operation or Continuous Operation. The operation of the solenoid outputs is determined by the configuration of DIP switch 2. Refer to Figure 6-2: SOLARPack Control Board Layout for the location of the DIP switch. Continuous Solenoid Operation 2 Pulsed Solenoid Operation 2 Slide the switch actuator to the gray position shown to set the SolarPack Solenoid monitor mode Pulsed Operation Figure 6-13: Solenoid Operation DIP Switch Pulsed operation is typically used for latching solenoid valves that are used in plunger control, sampler and ESD applications. In this mode the SOLARPack continually monitors the state of Sensor Connector P5,14 and generates a 75ms pulse outputs on P6,7 (CLOSE) and P6,8 (OPEN) when this input changes state. See Figure 6-14 Solenoid Pulsed Operation Timing. To enable pulsed operation: 34

36 Configure DIP switch 2 in the closed or right hand position, see Figure 6-13: Solenoid Operation DIP Switch. Connect the single SCADASense 4202 or 4203 Digital Output that is to be monitored to Sensor Connections terminal P5,14. The solenoid outputs are sourcing outputs. The output voltage is the system or battery voltage. The solenoid outputs use a self-resetting circuit breaker with "slow blow" characteristics. Refer to section Self-resetting Circuit Breakers. When Solenoid monitor (P5,14) goes low (on) the OPEN Solenoid output (P6,8) goes on for 75ms. When Solenoid monitor (P5,14) goes high (off) the CLOSE Solenoid output (P6,7) goes on for 75ms. P5,14 OFF ON 75 ms 75 ms P6,8 - OPEN solenoid output P6,7 - CLOSE solenoid output Figure 6-14 Solenoid Pulsed Operation Timing Continuous Operation In this mode the SOLARPack continually monitors the input on the Sensor Connector P5, 14 and generates two out of phase continuous outputs on P6,7 (OPEN) and P6,8 (CLOSE) that follow the state of the input. To enable continuous operation: Configure DIP switch 2 in the open or left hand position, see Figure 6-13: Solenoid Operation DIP Switch. Connect the single SCADASense 4202 or 4203 Digital Output that is to be monitored to Sensor Connections terminal P5,14. The solenoid outputs are sourcing outputs. The output voltage is the system or battery voltage. The solenoid outputs have self-resetting circuit breakers with "slow blow" characteristics. Refer to section Self-resetting Circuit Breakers. When Solenoid monitor (P5,14) goes low (on) the CLOSE Solenoid output (P6,8) goes on (high) and the OPEN Solenoid output (P6,7) goes off (low). 35

37 When Solenoid monitor (P5,14) goes high (off) the CLOSE Solenoid output (P6,8) goes off (low) and the OPEN Solenoid output (P6,7) goes on (high). P5,14 OFF ON OFF P6,7 - solenoid output ON P6,8 - solenoid output Figure 6-15 Solenoid continuous operation timing Solenoid Wiring The following figure shows the wiring connections for the SOLARPack solenoid outputs. P6 FIELD CONNECTIONS CLOSE OPEN Dual solenoid with shared negative common. Figure 6-16 Solenoid Wiring The Solenoid outputs current is limited by a self-resetting circuit breaker to 3A continuous. See the Self-resetting Circuit Breakers section for further details Alarm Output The SOLARPack has an alarm output that can be connected to a field device using the Field Connection connector P6, 10. There are three conditions that will turn on the alarm output. 36

38 Open Circuit Battery Faulty Temperature Sensor Over Current The battery circuit is not complete or the battery voltage is less than 6V. The device will not attempt to charge a battery with less than 6V. To clear this alarm, reconnect the battery, or replace a severely discharged battery with one whose voltage is greater than 6V. The Battery Status LED will also be red. If the temperature sensor is missing or defective the alarm output will turn on. Once the temperature sensor responds correctly, this alarm will clear. If the temperature sensor fails during operation, the device will remember the last valid temperature provided by the sensor. The SOLARPack has two self-resetting circuit breakers. If either of these circuit breakers trip, the alarm will be sustained for a minimum of 5 seconds Alarm Output Wiring The alarm output is a sinking output. Connect the ve side of the load to the alarm output and the +ve side of the load to a +ve voltage as shown in Figure 6-17 Alarm Wiring. P6 FIELD CONNECTIONS P7 POWER TEMP SENSOR CONNECTIONS * L O A D + Connect +ve side of load to either the Auxiliary output (P7,1) or the Battery (P7,5). (*) P7,1 is recommended because it is fused. Screw termination on chassis. Figure 6-17 Alarm Wiring The Alarm output current is limited by a self-resetting circuit breaker to 3A continuous. See the Self-resetting Circuit Breakers section for further details Power and Temperature Sensor Connections (P7) The Power Connections, P7, terminals provide connection points for the solar panel, battery, auxiliary power and chassis ground. The SOLARPack uses screw termination style connectors for termination of field wiring. They accommodate solid or stranded wires from 12 to 24 AWG Solar Panel Connection Solar Panels up to 100W designed for 12V battery systems can be used with the SOLARPack. The size of the solar panel depends on the amount of sunlight expected, the battery size and the number days of autonomy in the application. CAUTION: Do not use solar panels greater than 100W. Damage to the SOLARPack may result. 37

39 Do not connect a power supply to the Solar Panel power input on connector P7. This input is intended for solar panels only. If it is necessary to operate the SOLARPack from a power supply, refer to Operation with External Power Supplies section of this manual. CAUTION: Do not connect a power supply to the Solar Panel power input on connector P7. Connecting to a power supply to the Solar Panel input may result in damage to the power supply and SOLARPack. Refer to Table 6-9 Solar Panel Selection for a list of solar panels suitable for use with the SOLARPack. Similar panels from other manufacturers may also be used. CAUTION: The following solar panels were not part of the hazardous locations certification and have not been evaluated for use in Class 1, Div. 2 hazardous areas. Solar panels must be installed and acceptable for use in Cl. 1, Div. 2 hazardous areas as per the CEC and NEC. Table 6-9 Solar Panel Selection Manufacturer Model Number CMI Part Number Maximum Power BP Solar BP350U 50W (17.3V at 3.17A) 21.8V, 3.17A BP Solar SX-30U 30W (16.8V at 1.78A) 21.0V, 1.94A BP Solar SX-20U 20W (16.8V at 1.19A) 21.0V, 1.29A Carmanah CTI-11J W (17.4V at 0.63A) 22.0V, 0.65A Carmanah CTI-21J W (17.4V at 1.26A) 22.0V, 1.3A Carmanah CTI-32J W (17.4V at 1.85A) 22.0V, 1.95A Carmanah CTI-50J W (16.0V at 3.1A) 20.6V, 3.40A V (open circuit), I (short circuit) P7 POWER and TEMP SENSOR CONNECTIONS Solar Panel + Screw termination on chassis. Figure 6-18 Solar Panel Wiring 38

40 Battery Connection Three connections are made from the SOLARPack PCB connectors to the battery terminals as shown in Figure 6-19 Battery Wiring. Battery + (P7, 5): Connection to positive battery terminal. Battery (P7, 6): Connection to negative battery terminal. Temperature Sensor (P7, 7): Connection to battery temperature sensor. P7 POWER AND TEMP SENSOR CONNECTIONS Battery + Screw termination on chassis. Figure 6-19 Battery Wiring The SOLARPack is available with an integrated battery compartment or an external battery enclosure. Installation information for each type is found in the following sections. CAUTION: When installing a battery pay close attention to the polarity of the wiring and battery terminals. Failure to make these connections properly may result in damage to the SOLARPack and the battery SOLARPack Single Enclosure Battery Installation The SOLARPack single enclosure version is pre-wired for the battery and temperature sensor connections. The pre-wired cable assembly is connected to terminal P7. The Battery + (Red wire) and Battery (Black wire) are terminated with battery connection lugs. The Temperature Sensor (White wire) is terminated on the temperature sensor circuit board. Connection drawings are shown below for the large (Deka - East Penn 8G22NF or 8A22NF) and small (Deka - East Penn 8GU1 or 8AU1) batteries. Note that the battery temperature sensor must make good thermal contact with the negative battery terminal. Refer to section Battery Temperature Sensor Connection for further information. 39

41 Figure 6-20: Deka - East Penn 8GU1 or 8AU1 Battery Installation Figure 6-21: Deka - East Penn 8G22NF or 8A22NF Battery Installation SOLARPack External Enclosure Battery Installation When using an external battery enclosure version of the SOLARPack it is the responsibility of the user to wire the battery to the solar charger. The battery must be wired using a pair of 12AWG wires not exceeding 8 feet in length. This should allow a sufficient distance between the main SOLARPack enclosure and the battery enclosure of 6 feet and 1 foot inside each enclosure. 40

42 If the conduit has been cut to a length shorter than the supplied 6 feet then the battery wiring should be reduced accordingly. Do not leave excess battery wire inside the SOLARPack enclosure. A third temperature sensor wire is required. The gauge of this wire is not critical and in most installations will be 12AWG out of convenience. The battery temperature sensor must make good thermal contact with the battery terminal. Connect the battery temperature sensor to the negative terminal of the battery. Note that the temperature sensor has two terminations. Either of these two can be used to connect the single temperature sensor wire. Refer to section Battery Temperature Sensor Connection for further information. This wiring must meet the requirements of the NEC or CEC. Figure 6-22: External Battery Enclosure Battery Charging The SOLARPack uses a shunt regulator battery charger system. Battery charging is achieved by shunting the solar panel current using a high frequency pulse width modulator. Solar panel current is always flowing. The SOLARPack uses a proprietary charging algorithm to test for and determine the condition of the battery before proceeding with the charging stages. The charger will first bulk charge to replace the battery charge at the maximum rate of the solar panels. The second stage is the absorption stage at the charge voltage and a current limited by the battery. The final stage will maintain the battery with the float voltage until the charger recognizes that additional charging is required and will revert back the charge voltage. Every morning the condition of the batteries is determined and the charging sequence repeats beginning a battery test and continues on to the first charge stage. 41

43 Defective battery conditions such as shorted or open cells are detected and the battery is safely isolated. Under these conditions, the SOLARPack will run given that the solar panel provides sufficient power to operate the device. The charge and float voltage settings are selectable and depend on the type of battery, Gel Cell or Absorbed Glass Mat (AGM), being used. The Charge voltage is selected using DIP switch 3. See Figure 6-23: Charge Voltage DIP Switch below. Refer to Figure 6-2: SOLARPack Control Board Layout for the location of the DIP switch. For Gel Cell type batteries slide the switch to the left, 13.8V charge. For AGM type batteries slide the switch to the right, 14.4V charge. 13.8V Charge Gel 14.4V Charge AGM 3 3 Slide the switch actuator to the gray position shown to set the Charge voltages as shown. Figure 6-23: Charge Voltage DIP Switch The Float voltage is selected using DIP switch 4. See Figure 6-24: Float Voltage DIP Switch below. Refer to Figure 6-2: SOLARPack Control Board Layout for the location of the DIP switch. For Gel Cell type batteries slide the switch to the left, 13.5V float. For AGM type batteries slide the switch to the right, 14.4V float. 13.5V Float Gel V Float AGM 4 Slide the switch actuator to the gray position shown to set the Float voltages as shown. Figure 6-24: Float Voltage DIP Switch Approved Batteries The following batteries have been approved for use with the SOLARPack. CAUTION: Use only batteries that have been recommended or supplied by Control Microsystems. Battery must be a 12V nominal Gelled electrolyte (gel) or Absorbed Glass Mat (AGM) valve regulated lead acid (VRLA) battery rated no less than 25Ah (20 hour rating). Battery height, including terminals, must not exceed 9.3 inches. Table 6-10 Battery Selection 42

44 Manufacturer Type Deka - East Penn Sealed Gel Deka - East Penn Sealed Gel Deka - East Penn Absorbed Glass Mat Deka - East Penn Absorbed Glass Mat Model Number CMI Part Number 8GU G22NF AU A22NF hour discharge to 1.75V/cell Ah rating 100 hour discharge to 1.75V/cell Ah rating Charging requirements See 6.7 DIP Switch for settings V charge 13.5V float V charge 13.5V float V charge 13.8V float V charge 13.8V float Sonnenschein A512/30 G V charge 13.8V float Battery Temperature Sensor Connection The battery temperature sensor is wired with a single conductor from the SOLARPack PCB connector P7 at one end and to the temperature sensor assembly on the negative terminal of the battery at the other end. Note that the temperature sensor has two terminations. Either of these two can be used to connect the single temperature sensor wire. Figure 6-25: Battery Temperature Sensor Charging voltage is precisely regulated and adjusted according to battery temperature. The battery temperature sensor compensates the charge voltage by -32.5mV/ C over the temperature range of 15 C to +49 C. Disconnection or failure of this sensor can cause over-charging, hydrogen gassing, and permanent damage to the battery. Failure of the temperature sensor will result in the last valid measured temperature to be used. Failure of the temperature sensor at power up or reset will result in the last valid temperature that was measured to be used. Sustained operation with a missing or faulty temperature sensor should be avoided, especially at high ambient temperatures. The Alarm Output terminal, 10, on Field Connection connector P6 is turned on if the temperature sensor is missing or faulty. See the Alarm Output section for further details Battery Replacement It is not necessary to disconnect the solar panel to replace a battery. The SOLARPack will recognize an open-circuit or missing battery and adjust its operation automatically. Provided that the solar panel generates sufficient power to operate the device, all loads will remain powered. CAUTION: When installing a battery pay close attention to the polarity of the wiring and battery terminals. Failure to make these connections properly may result in damage to the SOLARPack and the battery. 43

45 Auxiliary Load Connection The system power supply (13.5V nominal) is available at the Auxiliary output. An external radio is a possible application for this output. The system power supply (13.5V nominal) is available at P7 pins 1 and 2 as shown in Figure 6-26 Auxiliary Load Wiring. The Auxiliary Load output current is limited by a self-resetting circuit breaker to 3A continuous. See the Self-resetting Circuit Breakers section for further details. P7 POWER TEMP SENSOR CONNECTIONS L O A D Screw termination on chassis. + Figure 6-26 Auxiliary Load Wiring Self-resetting Circuit Breakers The SOLARPack uses self-resetting circuit breakers instead of traditional replaceable fuses. The self-resetting circuit breakers are programmable with slow blow characteristics. They will conduct the continuous levels shown in the Specifications section and will conduct short term transients at higher current levels. A single self-resetting circuit breaker protects the two Solenoid outputs and the Auxiliary output. The output current is limited by the self-resetting circuit breaker to 3A continuous. A second self-resetting circuit breaker protects the SCADASense 4202 or 4203 power. The output current is limited by the self-resetting circuit breaker to 1A continuous. The sinking Alarm output does have a self-resetting circuit breaker. The Alarm output current is limited by a self-resetting circuit breaker to 3A continuous. It is recommended that the +ve side of the alarm output be connected to the Auxiliary output as shown in Figure 6-17 Alarm Wiring Operation with External Power Supplies Sometimes during development it is necessary to operate the SOLARPack without a battery or solar panels. This may be necessary in a lab or office environment for program development. It is important to observe the following precautions for the safety of the user and to prevent damage to the SOLARPack. CAUTION: Only connect a solar panel to the PANEL + and connections on P7. Never connect a power supply to these terminals. 44

46 Connect a DC power supply to the BATT + and connections on P7. The voltage must be 12 to 14Vdc. The current of this power supply must be sufficient for the loads in use. This can be done with or without a battery installed. If a battery is installed pay close attention to the voltage and current settings of the power supply to ensure that the battery is not being overcharged. A SELV (Safety or Separated Extra Low Voltage) power supply is required on the power (BATT) input. Power supplies with Vac inputs that comply with safety standard IEC/EN generally have SELV outputs. Check with the manufacturer or the agency certification listing to confirm that they have SELV outputs. CAUTION: Use extreme caution when connecting an external power supply to the SOLARPack. Pay close attention to the polarity of all connections and voltages. + AUX + PANEL + BATT TEMP GND P7 POWER CONNECTIONS X X Caution: Do not connect a power supply to the Solar Panel Input! Vdc Power Supply Figure 6-27 Operation with Power supply Charging the Battery with an External Charger It is permissible to charge the internal SOLARPack battery with an external charger. This procedure may be necessary when the battery requires a fast charge during system start up or after a battery has been replaced. External battery charging can be done with a solar panel connected to the SOLARPack. CAUTION: Use extreme caution when using an external battery charger to charge a battery that is installed in the SOLARPack. Pay close attention to the polarity of all connections Grounding The ground terminal on Power and Temperature Sensor Connections connector P7 is connected to the ground screw lug on the SOLARPack chassis. This ground terminal is internally connected to the GND pins on connectors P1, P2, P3 and P4. This ground terminal is also connected to the Common terminals on connectors P5 and P6 and the connections for the Auxiliary Output, Solar Panel and Battery connection on connector P7. The ground screw lug is available for connection to a suitable ground point. The grounding of the SOLARPack must meet the requirements of the NEC or CEC. 45

47 6.3 Internal Radio One of three optional radios may be installed in the SOLARPack at time of manufacture. Radios are installed in the factory and cannot be upgraded in the field. Refer to the SOLARPack part number or your order to determine which radio is installed. The optional radios available are: The FreeWave FGR09CSU MHz Spread Spectrum Wireless Transceiver. The MDS TransNET 900 Frequency Hopping Spread Spectrum Transceiver. The MaxStream XTend OEM RF Module Transceiver. The following sections describe the initial configuration of these radios. For detailed operation instructions for each of these radios refer to the user manuals installed with the Hardware Manuals CD FreeWave 900 MHz Spread Spectrum Transceiver The FreeWave FGR09CSU MHz Spread Spectrum Wireless Transceiver is one of the optional radios that may be supplied with the SOLARPack. The FreeWave transceiver is power from the system power supply (13.5V nominal) that is integrated into the SOLARPack. The FreeWave transceiver has two communication ports. The main communication port must be configured for RS-232 signal levels. This port is connected to the SCADASense 4202 or 4203 COM2. Refer to section Sensor Connections Wiring (P5). The SOLARPack performs the RS-485 to RS-232 signal conversion needed between the transceiver and the SCADASense 4202 or 4203 COM2 (P5). The diagnostics communication port is configured for RS-232 signal levels. This port is connected to the Radio Setup (P4) interface. Refer to section Radio Setup Interface (P4). CAUTION: Use care when removing and installing the SOLARPack PCB cover. High currents and the potential for arcing is possible when internal points are accidentally shorted. The PCB cover should be removed only when the area in known to be non-hazardous FreeWave Radio Module Configuration The typical installation for a FreeWave transceiver is in a point to multipoint configuration. In this configuration a single master transceiver communicates with a number of slave transceivers. The user is encouraged to thoroughly read the Multipoint Operation section of the FreeWave Spread Spectrum Wireless Data Transceiver User Manual for complete information on using Multipoint systems. It is recommended that the following steps be used to configure the Radio Modules in your network. Open the Radio Module Setup program. Set the Operation Mode for the master and slave Radio Modules. Set the Baud Rate for the main communication port (internally connected to the SCADASense 4202 or 4203 COM2 port). Set the Radio Transmission Characteristics. Set the Multipoint Parameters. 46

48 Radio Module Setup Program The FreeWave transceivers are shipped from the factory with default configuration settings. These setting will typically need to be adjusted for an individual network. The configuration of the FreeWave transceiver is done using a terminal emulation program, such as Windows HyperTerminal, and the Radio Setup (P4) serial port on the SOLARPack. The Radio Setup (P4) serial port on the FreeWave transceiver is set for baud, 8 data bits, no parity and 1 stop bit. The HyperTerminal communication properties must be set to match these settings Configure a HyperTerminal Session Open HyperTerminal and create a new connection. Once the new connection is created and named the Connect To dialog is opened. Select a serial port that is available on your PC. COM1 or COM2 etc. In the Properties dialog set the following parameters: Bits Per Second = 19, 200 Data Bits = 8 Parity = None Stop Bits = 1 Flow Control = XON/XOFF To enter the FreeWave Setup program, simply type a U (capital U) in the HyperTerminal window. The FreeWave configuration Main Menu will be displayed as shown below: The basic configuration changes required are discussed in the following paragraphs. The user is encouraged to read the detailed description for each parameter in the FreeWave Spread Spectrum Wireless Data Transceiver User Manual. 47

49 Set Operation Mode All FreeWave transceivers are shipped configured for Point to Multipoint Slave operation. In a typical network there will be one master FreeWave transceiver and multiple slave FreeWave transceivers. The Operation Mode for the master FreeWave transceiver must be set to Point to Multipoint Master operation. To configure a FreeWave transceiver for Point to Multipoint Master operation: From the FreeWave Setup program Main Menu enter 0 in the Enter Choice selection to open the Set Modem Mode menu. Enter 2 in the Enter Choice selection to select Point to Multipoint Master operation mode. Press the Esc key to return to the Main Menu. For further information on the Operation Modes refer to the Operation Modes Selections section of the FreeWave Spread Spectrum Wireless Data Transceiver User Manual Set Baud Rate The Set Baud Rate selection is used to set the baud rate, and communication parameters for the communications port on the FreeWave transceiver. This is the port that is connected to the SCADASense 4202 or 4203 COM2. Refer to section Sensor Connections Wiring (P5). The communications port settings on the FreeWave transceiver and the serial port settings for the SCADASense 4202 or 4203 COM2 serial port must be set to the same values. The communications port is set to 9600 baud, 8 data bits, no parity and 1 stop bit at the factory. Depending on your system configuration you may wish to change the communications port settings. To configure the FreeWave communications port parameters: From the FreeWave Setup program Main Menu enter 1 in the Enter Choice selection to open the Set Baud Rate menu. Enter the number for the required baud rate in the Enter Choice selection. 48

50 Press the Esc key to return to the Main Menu. For further information on other communications settings, such as data word length and parity refer to the Baud Rate Selections section of the FreeWave Spread Spectrum Wireless Data Transceiver User Manual Edit Radio Transmission Characteristics The Radio Transmission Characteristics are set to identical values for all FreeWave transceivers at the factory. If any changes are made to these settings they must be made identical for all FreeWave transceivers in the network. Note: Changes should only be made after consulting the Radio Transmission Parameters section of the FreeWave Spread Spectrum Wireless Data Transceiver User Manual. To configure the FreeWave transceivers Radio Transmission Characteristics: From the FreeWave Setup program Main Menu enter 3 in the Enter Choice selection to open the Radio Parameters menu. Enter the number for the parameter to modify in the Enter Choice selection. Press the Esc key to return to the Main Menu Edit Multipoint Parameters The Edit Multipoint Parameters are set to identical values for all FreeWave transceivers at the factory. With the exception of the Network ID these values will not usually require changes. The Network ID, for all FreeWave transceivers, needs to be changed from the factory default to ensure the FreeWave transceivers will communicate with the network master station. 49

51 If you are installing the network in an environment where other networks are operating in close proximity you may need to change some Multipoint and Radio Transmission Characteristics parameters. Refer to the Multipoint Operation section of the FreeWave Spread Spectrum Wireless Data Transceiver User Manual. To configure the FreeWave transceiver Network ID: From the FreeWave Setup program Main Menu enter 5 in the Enter Choice selection to open the Multipoint Parameters menu. Enter 6 in the Enter Choice selection to select Network ID. Enter the Network ID for you network. This number must not be 255 and must be between 0 and Note that all FreeWave transceivers in the network must have the same Network ID. Press the Esc key to return to the Main Menu MDS TransNET 900 MHz Spread Spectrum Transceiver The MDS TransNET 900 Frequency Hopping Spread Spectrum Transceiver is one of the optional radios that may be supplied with the SOLARPack. Refer to the Control Microsystems or MDS supplied documentation for complete details on the operation of the radio. The MDS radio is powered from the system power supply (13.5V nominal) that is integrated into the SOLARPack. The MDS radio has two communication ports. The main communication port must be configured for RS-232 signal levels. This port is connected to the SCADASense 4202 or 4203 COM2. Refer to section Sensor Connections Wiring (P5). RS-485 to RS-232 level signal conversion is included in the SOLARPack circuitry. The diagnostics communication port is configured for RS-232 signal levels. This port is connected to the Radio Setup (P4) interface. Refer to section Radio Setup Interface (P4). The MDS radio LEDs are visible when the SOLARPack PCB cover is removed MDS Transceiver Radio Module Configuration The typical installation for the MDS transceiver is in a point to multipoint configuration. In this configuration a single master MDS transceiver communicates with a number of MDS transceiver remote stations. The user is encouraged to thoroughly read the Typical Applications section of the MDS TransNET OEM Spread Spectrum Data Transceiver Manual for complete information on using Multipoint systems. It is recommended that the following steps be used to configure the Radio Modules in your network. Open the MDS TransNET Radio Configuration software. Set the Operation Mode for the master and remote MDS transceiver. Set the serial port parameters for the MDS transceiver main communication port. Set the MDS transceiver main communication port type. Set the MDS transceiver transmit power level. Set the Network Address for all MDS transceivers. 50

52 MDS Transceiver Setup Program The MDS transceivers are shipped from the factory with default configuration settings. These setting will typically need to be adjusted for an individual network. All MDS transceiver configuration is done using the MDS TransNET Radio Configuration program. The PC that is running the MDS TransNET Radio Configuration program must be connected to the Radio Setup (P4) interface. See section Refer to section Radio Setup Interface (P4) for information on the cable needed for this connection. The Radio Setup (P4) interface port on the SOLARPack is set for 8 data bits, no parity and 1 stop bit. The port automatically configures itself to function at 1200, 2400, 4800, 9600, 19200, 38400, and baud Setting up the Configuration Software The MDS TransNET Radio Configuration software is installed from the Configuration Software (Including Hardware Manual) CD that is included with all shipments from the factory. This CD will autorun when inserted into your CD drive. Click the Install MDS TransNET Configuration button to install the software. Start the MDS TransNET Radio Configuration program by selecting MDS TransNET Configuration from the Microwave Data Systems selection in the Windows Programs list. The MDS TransNET Configuration setup screen is shown below. 51

53 Connecting to MDS Transceiver A serial port on the PC running the MDS TransNET Radio Configuration program must be connected to the Radio Setup (P4) interface. Click the CommPort command on the menu bar and then select Setup. The setup dialog is opened as shown below. In the Port window select the desired PC serial communication port to use and then click the OK button. Click CommPort command on the menu bar and then select Port Open. The software will now connect to the radio and retrieve the current radio settings. The basic configuration changes required are discussed in the following paragraphs. The user is encouraged to read the detailed description for each parameter in the MDS TransNET OEM Spread Spectrum Data Transceiver Manual Set Operation Mode All MDS transceivers are shipped with the MDS transceiver configured for Remote (slave) operation. In a typical network there will be one master MDS transceiver and multiple slave MDS transceivers. The Radio Mode for the master MDS transceiver must be set to MODE M" (Master) operation. To configure a MDS transceiver for Master operation: Click on the tab labeled Radio Settings 1. Click anywhere in the Radio Mode window to open the Program Radio Mode dialog. Enter MODE M in the Radio Mode box to enable the Radio Module as a master Set Baud Rate The Data Baud Rate window is used to set the baud rate and communication parameters for the main communication port on the MDS transceiver. The settings for the main communication port of the MDS transceiver and the serial port of the SCADASense 4202 or 4203 must be the same. 52

54 The Radio Module main communication port is set to 9600 baud, 8 data bits, no parity and 1 stop bit at the factory. Depending on your system configuration you may wish to change the main communication port settings. To configure the main communication port parameters: Click on the tab labeled Radio Settings 1. Click anywhere in the Data Baud Rate window to open the Program Data Baud Rate dialog. Enter BAUD XXXX abc in the Data Baud Rate box, where XXXX is the desired baud rate, a is the number of data bits (7 or 8), b is the parity (N for None, O for Odd, E for Even) and c is the number of stop bits (1 or 2). Example: BAUD N Set Port Type The main communication port must be configured for RS-485 operation. To change the port type: Click on the tab labeled Radio Settings 1. Click anywhere in the Port window to open the Program Payload Port dialog. Enter either PORT RS485 in the Port box Set Power Level To change the radio output power level, follow these steps: Click on the tab labeled Radio Settings 1. Click anywhere in the Power Level window to open the Program Power Output Level dialog. 53

55 Enter PWR XXdBm in the Power Level box, where XX represents the level in dbm (max. +30dBm). For dbm to Watt conversion see the MDS TransNET OEM Spread Spectrum Data Transceiver Manual Set the Network Settings The Network Settings are set to identical values for all Radio Modules at the factory. All parameters must be identical for all radios in a network. With the exception of the Network Address these values will not usually require changes. The Network Address, for all Radio Modules, needs to be changed from the factory default (NONE) to ensure the Radio Modules will communicate with the network master station. To configure the Radio Module Network Address: Click on the Network Settings tab. The MDS TransNET Configuration setup screen changes as shown below. 54

56 Click anywhere in the Network Address window to open the Program Network Address dialog. Enter ADDR XXX in the Network Address box, where XXX is a number between 1 and 65,000. Note: For MODBUS operation the Data Buffering setting must be BUFF ON MaxStream XTend 900 MHz Spread Spectrum Transceiver The MaxStream XTend OEM RF Module is one of the optional radios that may be supplied with the SOLARPack. Refer to the Control Microsystems or MaxStream supplied documentation for complete details on the operation and configuration of the radio. The MaxStream radio is power from a 5V power supply that is integrated into the SOLARPack. 55

57 The MaxStream radio has a single TTL level communication port. This port has TTL level signaling. The port is connected to the SCADASense 4202 or 4203 COM2. RS-485 to TTL level signal conversion is included in the SOLARPack circuitry. See Figure 6-1 SOLARPack Connection Overview. The MaxStream radio can be returned to the factory default state by shorting the 2 pins labeled J1. This jumper is located on the SOLARPack PCB lower right hand corner and only accessible after removing the SOLARPack cover PCB. The pins can be shorted with a small screwdriver. See Figure 6-2: SOLARPack Control Board Layout for J1 location. CAUTION: Use care when removing and installing the SOLARPack PCB cover. High currents and the potential for arcing is possible when internal points are accidentally shorted. The PCB cover should be removed only when the area in known to be non-hazardous. The MaxStream radio is configured using the X-CTU configuration software. The installation for the X-CTU software is installed from the Configuration Software (Including Hardware Manual) CD that is included with all shipments from the factory. This CD will autorun when inserted into your CD drive. Click the Install X-CTU Configuration button to install the software. Start the X-CTU Radio Configuration program by selecting X-CTU from the MaxStream selection in the Windows Programs list. The MaxStream radio has a single communication port. Since this port is wired directly to the SCADASense 4202 or 4203 COM2 it is necessary to remove this wiring to gain direct access to the MaxStream radio. Remove the wiring on connector P5, pins 3 through 5 and connect as per tables Table 6-6 SCADASense 4202DR or 4203DR to SOLARPack Wiring or Table 6-7 SCADASense 4202DS or 4203DS to SOLARPack Wiring. Communication to the MaxStream radio must be RS Antenna There is a factory installed cable from the internal radio to the bulkhead lightning and surge protection device. The external antenna connector to the SOLARPack is an N-Type Female. 6.5 Load Shedding The ability to load shed is available in the SOLARPack. This allows the radio power to be disconnected as the battery reaches the end of its capacity. Enabling load shedding will extend the operating time of the SOLARPack by allowing the SCADASense 4202 or 4203 to continue operating on the remaining battery capacity. Load shedding is enabled with DIP Switch 1. If the switch is closed, load shedding is active. The radio will turn on at 11.8V and off at 11.4V. Otherwise, if switch is open, the radio will always be powered. Refer to 6.7 DIP Switch for additional information on setting the DIP switches. Radio always powered. 1 Radio load shedding enabled. 1 Slide the switch actuator to the gray position shown to enable the desired load shedding option. 56

58 6.6 LED Indicators There are 4 LEDs on the SOLARPack, RX, TX, LED1 and LED2. The LEDs are normally off to save power. Press the LED PWR switch once to enable the LEDs. Press the LED PWR switch once again to disable the LEDs. The LEDs are disabled automatically after 1 minute. The LEDs on the optional radio transceivers are not controlled by the LED PWR switch. The RX and TX LEDs are described in Table 6-11: SOLARPack LED Operation. See Figure 6-2: SOLARPack Control Board Layout for the location of these LEDs. The LED1 and LED2 LEDs provide battery and system information. These LEDs are described in Table 6-11: SOLARPack LED Operation. See Figure 6-2: SOLARPack Control Board Layout for the location of these LEDs.. Figure 6-28: SOLARPack Battery and System LED Indicators Table 6-11: SOLARPack LED Operation LED RX TX LED1 - Battery and charger status Function Indicates data received from the radio transmitted to the SCADASense 4202 or 4203 COM2 port. Indicates data received from the SCADASense 4202 or 4203 COM2 is being transmitted by the radio. Off Battery is being discharged or under very light charging. Red Battery fault. Red/Green First step of charging process - battery test. See Note 1. Green Flash Battery is being bulk charged to the Charge voltage. The LED may turn off or flicker under very light charging conditions. Green Battery is being float charged at the Float voltage. The LED may turn off or flicker under very light charging conditions. LED2 - System Off Unit is not functional. Red Alarm condition exists. Red Flash Low Voltage Lockout. System voltage < 10.5V. All loads are disabled. Red/Green Critical low voltage. 10.5V <= System Voltage <= 57