Hybrid Controller

Diesel PV Off the shelve

on

1 2 3 4

Manual
Version 0.3

elgris GmbH
Langerweher Str. 10
D-52459 Inden
Germany
www.elgrispower.com
info@elgrispower.com
 Table of Contents
1. INTRODUCTION ___________________________________________________________________________ 3

1.1 Version overview _____________________________________________________________________ 4

2. INSTALLATION ____________________________________________________________________________ 5

2.1 Safety instructions ____________________________________________________________________ 5

2.1 Device overview______________________________________________________________________ 5

2.2 Pin description _______________________________________________________________________ 6

2.3 Connection overview SMA without Ethernet ______________________________________________ 7

2.4 Connection overview SMA with Ethernet _________________________________________________ 8

2.4 Connection overview ABB with Ethernet and ABB PVI-MPU __________________________________ 9

2.5 Connection overview GRID mode SMA with FEED IN _______________________________________ 10

2.6 Connection overview GRID mode SMA without FEED IN ____________________________________ 11

3.0 SOFTWARE ____________________________________________________________________________ 12

3.1 Settings reading _____________________________________________________________________ 12

3.2 Settings changing ____________________________________________________________________ 12

3.3 Parameter overview _________________________________________________________________ 13

3.4 Output selection type ________________________________________________________________ 13

3.5 Grid feed in protection modus _______________________________________________________ 14
3.6 GRID mode with grid and generator ___________________________________________________ 15

4 COMMISSIONING ________________________________________________________________________ 15

4.1 First time power on __________________________________________________________________ 15

Version: 26. April 2016 15:50

www.elgrispower.com Page 2 of 15
1. Introduction

Dear customer, thank you for purchasing this product. The HYBRID controller is the first series
produced control system which enable you to control a PV system connected with a Diesel generator
in an intelligent way. With the modern HYBRID series Diesel - PV controller you can control your PV
system in a way that Diesel load is minimised and fuel saving is maximized. The modern controllers
offer the following functions:

Multiple Generator set control

Prime mover and generator protections
Engine data measurement (optional trough external bus):
o Operating hours
o Running hours
o Start attempts
o Oil pressure
o Coolant temperature
o Battery voltage
o Fuel level measurement
o Engine speed
o Service hours
o Etc.
Generator voltage, current and power measurement
GRID control and GENERATOR control with one device
Ethernet based web interface for remote control (optional)
2x MOD bus for engine control and easy expanding

Specializing in products for generators and hybrid power solutions, the DC-5 offers the following
features standard:

Wide range power supply input from 85 - 265 VAC (47 - 440 Hz) and 115 - 375 VDC
Small footprint.
Intuitive software.
Wide temperature range of -40 +85.
Industrial PUR protection coating for extra rugged environment.
IP-68 on request.

If you have any questions or if something is unclear, you can contact us in several ways:

Per E-Mail : support@elgrispower.com

By Phone : +49 (0) 2423 9086501

Version: 26. April 2016 15:50

www.elgrispower.com Page 3 of 15
1.1 Version overview
The HYBRID series controller consists of 6 models which are intended for different applications and
requirements. This manual covers all available versions of the HYBRID series controller. Please take
information about the difference from the table below:

Green line Blue line Red line

Functionality HY-G HY-GR HY-B HY-BR HY-R HY-RR
Generator power measuring
Generator protections
Rated power maximum kVA 50 50 150 150 250 250

Generator power input

PV power input

Number of inverters 1 1 5 5 15 15

Remote monitoring
MOD Bus 1
MOD Bus 2

Version: 26. April 2016 15:50

www.elgrispower.com Page 4 of 15
2. Installation
2.1 Safety instructions
Before installing the product in the end-installation, ensure that the device is not damages during
transport and everything looks in a normal way.
All the connecting cables must not be bent or squeezed. This can result in malfunctions, short circuits
and defects in the device and/or sensor connected.
Make sure that cables are not damaged when drilling or bolting in place.
The module may only be commissioned after it has been installed contact-free in a casing. This
product generates high frequency. Never operate it in the vicinity of medical devices (e.g.
pacemakers) and/or medical equipment (e.g. in hospitals). Look for a suitable installation site.

2.1 Device overview

Before wiring the device, be sure that the voltage is switched off.

on
-

1 2 3 4

OK

1
16
2
15
3
4 14

5 13
6 12

11

7 8 9 10

Version: 26. April 2016 15:50

www.elgrispower.com Page 5 of 15
2.2 Pin description

Pin Description Minimum Maximum

Signal connector

1 Analogue input 1 positive 0 V / 0 mA 10 V / 20 mA

Digital input for grid mode 0 V = Generator 10 V = Grid
2 Analogue input 1 ground 0V 0V
3 Analogue input 2 positive 0 V / 0 mA 10 V / 20 mA
4 Analogue input 2 ground 0V 0V
5 CT input positive 0A 1A/5A
6 CT input negative 0A 1A/5A
7 AC sensing input 207 V 250 V
Power input

8 AC sensing input 207 V 250 V

9 Supply input controller (Ethernet) 0 Vdc / GND 0 Vdc / GND
Supply input controller (No Ethernet) 85 VAC / 115 VDC 265 VAC / 375 VDC
10 Supply input controller (Ethernet) 6.5 36 VDC (12Vdc) 6.5 36 VDC (24 Vdc)
Supply input controller (No Ethernet) 85 VAC / 115 VDC 265 VAC / 375 VDC
11 Relay voltage in Check inverter specifications
Control input

12 Level 1 (0 % limitation) 2 A @ 250 VAC / 30 VDC

13 Level 2 (30 % limitation) 2 A @ 250 VAC / 30 VDC
14 Level 3 (60 % limitation) 2 A @ 250 VAC / 30 VDC
15 Level 4 (100 % limitation) 2 A @ 250 VAC / 30 VDC
16 Relay voltage out (for cascade) Check inverter specifications
1 120 Ohm termination ON = 120 Ohm OFF = Open
2 120 Ohm termination ON = 120 Ohm OFF = Open
3 Not used
Dipswitch

4 Not used
BCD Only for R versions to select remote 1 (0x01) 15 ( 0x0F)
monitoring address.
When address 0 is selected the
internal boot loader is activated.

Version: 26. April 2016 15:50

www.elgrispower.com Page 6 of 15
2.3 Connection overview SMA without Ethernet

1 * Take the fase with lowest current

2
G
3

INVERTER (SMA)

on

1 2 3 4

*Read manual before connecting

Please read the manual of the used inverter to check wiring scheme.

Note: Some inverters may need additional hardware to reduce the power by means of digital inputs.

Version: 26. April 2016 15:50

www.elgrispower.com Page 7 of 15
2.4 Connection overview SMA with Ethernet

1 * Take the fase with lowest current

2
G
3

INVERTER (SMA)

on

1 2 3 4

*Read manual before connecting

Ethernet

12V=

230V~

Please read the manual of the used inverter to check wiring scheme.

Note: Some inverters may need additional hardware to reduce the power by means of digital inputs.

Version: 26. April 2016 15:50

www.elgrispower.com Page 8 of 15
2.4 Connection overview ABB with Ethernet and ABB PVI-MPU

1 * Take the fase with lowest current

2
G
3

on

1 2 3 4

ABB PVI MPU

Rotary switch
postion 0 or 7

K1 (100 %)

K2 (60 %)

K3 (30 %)

K4 (0 %)

GND

*Read manual before connecting

Ethernet

12V=

230V~

Please read the manual of the used inverter to check wiring scheme.

Note: Some inverters may need additional hardware to reduce the power by means of digital inputs.

Version: 26. April 2016 15:50

www.elgrispower.com Page 9 of 15
2.5 Connection overview GRID mode SMA with FEED IN

L1
L2
GRID

L3
N

K1
ATS

1
* Take the fase with lowest current
2
G
3

INVERTER (SMA)

on
1 2 3 4

K1

*Read manual before connecting

Ethernet

12V=

230V~

Version: 26. April 2016 15:50

www.elgrispower.com Page 10 of 15
2.6 Connection overview GRID mode SMA without FEED IN
L1
L2
GRID

L3
* Take the fase with lowest current
N

L1
K1 L2
ATS
L3
N
L1

G L2
=
L3
N
=
PV inverter

INVERTER (SMA)

on
1 2 3 4

K1

*Read manual before connecting

Ethernet

12V=

230V~

Version: 26. April 2016 15:50

www.elgrispower.com Page 11 of 15
3.0 Software
The software on the controller enables the user to change all relevant settings and adjust the system
to local needs for example during commissioning.

The hybrid controller has an integrated menu which can be selected by pressing the OK button.
When the menu is active, the outputs are disabled and no control is possible. After leaving the menu,
the new settings will be stored in EEPROM and the controller automatically loads the new
parameters and start working.

When the system is working, you can read the actual power on the top display. The bottom display
shows error or other parameters, depending on the firmware version and type of HYBRID controller.

3.1 Settings reading

To read out the actual parameters of the HYBRID controller press the OK button. The led will start
flashing green and by pressing UP and DOWN you can scroll through the parameters.
On the top screen you can read the parameter number and on the bottom screen you can read the
actual parameter value.

OK

LED solid green

3.2 Settings changing

You can change the settings by pressing the OK button when the parameter which needs to be
changed is selected and displayed on the screen.

OK

LED solid orange

The led will lid orange to indicate that the parameter can be changed.

Version: 26. April 2016 15:50

www.elgrispower.com Page 12 of 15
3.3 Parameter overview
The following parameters are available. Not all paramters can be changed. Parameters which can not
be changed are marked with a * and are read only. Most parameters which can not be changed are
for measurements only.

Parameter 4 and 9 are used for the power calculations. Parameter 4 holds the secundairy value of
the CT and parameter 9 the primairy.

Number Description Default Minimum value Maximum value Symbol

P1 Generator power* 0 0 999 kW
P2 CT current* 0 0 15 A
P3 CT current in % of maximum 0 0 100 %
P4 CT type (1A 5A) 1 1 5 A
P5 Minimum setpoint generator 50 0 100 %
P6 Ramp up speed 30 0 60 Seconds
P7 Ramp down speed 5 0 60 Seconds
P8 Power correction 1 0.00 2.00
P9 CT ratio (P4:P9) 100 1 1000 A
P10 Output type 1 1 5 See table

3.4 Output selection type

The 4 relays on the controller can be programmed with different functionality. There are 3 main
output modes, the BAR mode, the DOT mode and the BINAIR mode each having the possibility to set
a minimum value rather than having all the relays off.

When the time set with P7 is elapsed, the next output type is selected. When the value is below 0 %
either no output will be selected (without minimum) or the lowest possible value is selected (with
minimum).

Parameter 10 Mode Limitation Relay output

1 2 3 4
1 BAR without minimum 0% X
30 % X X
60 % X X X
100 % X X X X

2 BAR with minimum after 0% X

delay of P7 0% X X
30 % X X X
60 % X X X X
100 % X X X X

Version: 26. April 2016 15:50

www.elgrispower.com Page 13 of 15
 Parameter 10 Mode Limitation Relay output
1 2 3 4
3 DOT without minimum 0% X
30 % X
60 % X
100 % X

4 DOT with minimum after 0% X

delay of P7 0% X
30 % X
60 % X
100 % X

Parameter 10 Mode Limitation Relay output

1 2 3 4
5 Binair output 0
1 X
2 X
3 X X
4 X
5 X X
6 X X
7 X X X
8 X
9 X X
10 X X
11 X X X
12 X X
13 X X X
14 X X X
15 X X X X

3.5 Grid feed in protection modus

The HYBRID controller can also be used to prevent the inverter from feeding into a (public) grid. To
use the controller for this application, set the minimum setpoint at a level where the maximum
limitation of the inverter is higher.

When you have a 10 kW inverter the lowest setpoint is 3 kW. Make sure that the 3 kW is the lowest
setpoint based on the CT current and CT type used.

Version: 26. April 2016 15:50

www.elgrispower.com Page 14 of 15
3.6 GRID mode with grid and generator
The GRID mode is selected by connecting the analogue input 1 with a high level (10 Vdc).
When the GRID mode is selected, the outputs are override by the controller and GRID mode is
selected. In GRID MODE always the highest output stage is selected, depending on the selection of
the output mode. When the input is low (0Vdc or not connected) the outputs are controlled by the
control system.

4 Commissioning
Before starting with the commissioning of the HYBRID controller all safety precautions must be taken
which apply to the rules in your country and general safety rules. Never work on a system with a
running generator and short the output of the generator before working on the power system.

Only a few settings are needed to commissioning the HYBRID system. Most important is the settings
of the current transformer and the minimum setpoint of the generator.

4.1 First time power on

Follow the following steps when the system is first time being powered.

Switch of the PV inverter, disconnect the PV inverter from the system and start the
generator. When the HYBRID unit is working, change parameter 4, 5, 9 and 10 accordingly to
the requirements of the installation.

Read out parameter 1 to check if the measurement is in range and the error is not more than
1% of the full scale. Since the HYBRID system measure only in 1 phase, there is always a small
error when the generator is not loaded equal over all phases.

Note: You can change the phase of the measurement CT to solve this, but the voltage match
input (pin 7 & 8) must be in the same phase.

To adjust the power measurement manually, you can use parameter 8. Use the following
equation to adjust the power level:

=

All settings are done at this stage and the performance of the system can be monitored.
When the load of the generator is above 50% of the nominal value the output relays must
switch on until the maximum of 0% PV limitation of the output is reached. Since no PV is
connected, this is only a test to check all wiring and settings. When the generator power is
below the 50% the power of the PV system must be reduced and the relays must switch to
the lowest possible setpoint (100 % limitation).
Switch on the PV system and check dynamic behaviour of the system. Depending on the
load, you may need to change the speed of power reducing and increasing by means of
parameter 6 & 7.

Version: 26. April 2016 15:50

www.elgrispower.com Page 15 of 15