Frequency inverter

FULL FU9000S Series

TABLE OF CONTENTS

才 How it 叭／arks........................................................................01
1.1 Features... ... ......... . ....... ... ......... . ....... ... ......... . ....... ... ........ .. ...... ... 03
2. FU9ooos Solar Controller General Information.....................05
2.1 Inspection....... .. ..... ... ..... ... ..... .. . ..... . .. ..... ........... ........................05
2.2 Descriptions and Features..……………………………………………. ..............05
2.3 Protection Features.……………………………………………………………………06
2.4 FU9000S Solar Controller Model Description ....................................... 07
2.5 FU9000S Solar Controller Specifications .............................................08
2.6 FU9000S Solar Controller Dimensions................................................. 17
3. Installation.…………………… …………………………………………… 21
3.1 Installation Preparation & Requirements ..............................................22
3.2 Control Box and Controller Location Selection ......................................23
3.3 Mounting Procedure..............................................................................24
4 巨 Iectrical Installation.......... ... ... ..... ... ... ....... .... ....... ..25
4.1 Terminals.. ... ........ ... ........ ... ........ ... ........ ............ ............ ............ ..25
4.2 Power In DC Wiring ..............................................................................26
4.3 Ground Wiring ... ..... ...... ........... ........... ..... ... ....... ..... ..... .................... 27
4.4 Motor Wiring.......... ........... ........... ........... ..................................... . 28
4.5 Control Circuit Wiring Connections (Optional)...................……...............2 9
5. Sta 凡up and Operation ..……….. ... .. . . . ... ... ... .. ... ... . ... ... .. . ...... 32
5.1 Keypad Description ................................................................................32
5.2 Keypad Operation Process.…................................................................33
5.3 Commissioning Procedure.....................................................................34
5.4 User Definable Parameters.…….............................................................35
6. Three-Phase Motor Specifications.......................................40
7. Diagnostics and Troub leshooting... ... ........ ..... ... ... .......41
7.1 Fault Codes............................................................................................ 42
7.2 Common Faults and Remedies.............................................................. 46
8. Periodic Maintenance........................ ... ......................... .. ...4 7
9. Solar Array ........ .. ......................... .. .................................48
9.1 Example: 255叭I Monocrystalline Solar Array Curves...........................48
9.2 Solar Panel Wiring Configurations.......................................................49
10. Cof'!lbiner Box. .51
Append ix .. ......... ... .. .. ...... ............. ...... .. ..... .......... .. ....... . .. . ...53
FULL FU9000S Series

Safety Information

A NOTICE
Important information for installers of this equipment!
This equipment is intended for installation by technically qualified personnel.
Failure to install it in compliance with national and local electrical codes.and
within SAJ recommendations, may result in electrical shock or fire hazard,
unsatisfactory performance, and equipment failure.
SAJ installation information is available from pump manufacturers and
distributors, and directly from SAJ.

牟 WARNING
Serious or fatal electrical shock may result from failure to connect the
motor.control enclosures, metal plumbing, and all other metal near the motor
or cable to a proper earth ground in accordance with local codes, using
wire no smaller than motor cable wires. To reduce risk of electrical shock,
disconnect power before working on or around the water system. Do not use
motor in swimming areas.

& WARNING
High voltages (both AC and DC) capable of causing severe injury or death
by electrical shock are present in this unit. More than one disconnect switch
may be required to de-energize the equipment before servicing. This unit
should only be installed or serviced by technically qualified professionals.
An ytime 识份 rking on or near the FU9000s Solar controller, or system:
• Turn OFF the external DC rated disconnect from the solar array to the
FU9000S Solar controller.
• Ensure AC power has been disconnected from the FU9000S Solar
controller (if used).
• Wait a minimum of 5 minutes after removing power from the FU9000S
Solar controller before servicing.

£ WARNING
Solar panels that have been exposed to full solar insolation for an extended
period of time can achieve high temperatures and could be a potential source
of burns to exposed skin if contacted.υse caution when working around
solar arrays.

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1. How it Works
FU9000S solar pumping system serves to provide water in remote applications
where electrical grid power is either unreliable or unavailable. The system
pumps water using a high” voltage DC power source such as an photovoltaic
array of solar panels（叭的ich is abbreviated as solar array in this manual). Since
the sun is only available during certain hours of a day and only in good weather
conditions, the water is generally pumped into a storage pool or tank for further
usage, and water sources are those natural or special such as river, lake, well
or waterw畔， etc. Two level switches, one is High Level Switch, the other is
Low Level Switch, should be installed inside the pool or tank to regulate the
water level. If the water comes from a well, another two level switches should
be installed inside the well. The Low Level Switch of the well serves as an
indication that the well has run dry. The system will shut down to protect the
pump and motor until the well has recovered as the High Level Switch are
reached by water. Figure 1 shows a typical diagram of FU9000S solar pumping
system. The major parts and components in the system are listed a fter the
diagram.

。
C.Sotar C ntroller

‘
CD:Dll

R牙an lovolSwlle”

A..B<ll.\r Parull
4

巳Well
LAvelSwU时，

Figure 1 FU9000S solar pumping system

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FULL FU9000S Series

To be pa付。f a water supply, the FU9000S solar pumping system is designed

which consists of:
A. Solar Array
B. DC Breaker or Disconnect SWitch
C. FU9000S series Solar Controller
D. Pump and Motor
E. Water Source Level Switches (optional)
F. Tank Level Switches (optional)

FU9000S solar controller runs at variable speed to match the changing power
available from the solar array. Variable speed operation means there is no in”
rush or surge of energy during the pump/motor start-up, helping to eliminate
wear on the motor and pumping system. A leading cause of pump motor failure
is the stress applied to the motor during a full voltage start心 P FU9000S solar
variable speed operation ramps up the speed smoothly, which eliminates
starting stress . T his feature enhances long” term motor reliability.

Pump Check Valve Requirements

Notice: In order to ensure maximum system reliability and water delivery, check

at the pump and additional check valves should be installed every 30m (10
我） of vertical pipe a我er the pump. See the pump owner ’ s manual for additional
。
valves must be in stalled in the drop pipe. T he first check valve must be installed

information.

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FULL FU9000S Series

唱 .1 Features
System Diagnostics
FU9000S solar controller continuously monitors system performance and can
detect a variety of abnormal conditions. In many cases, the controller will
compensate as needed to maintain continuous system operation; however, if
there is high risk of equipment damage, the controller will protect the system
and display the fault condition. If possible, the controller will try to restart itself
when the fault condition subsides. See Diagnostics and Troubleshooting section
for a list of Fault Codes and corrective actions.

Motor Soft-Start
Normally, when there is a demand for water and power is available, FU9000S
Solar Controller will be operating. Whenever FU9000S Solar Controller detects a
need for water, the controller always “ramps up” the motor speed while gradually
increasing motor voltage , resulting in a cooler motor and lower start-up current
compared to conventional water systems. In cases where the demand for water
is low, the system may cycle on and off. Due to the controller ’ s so作 start feature
this will not harm the motor.

Over Temperature Foldback

FU9000S Solar controller is designed for full power operation from a solar array
in ambient temperatures up to 60 。C. Under extreme thermal conditions, the
controller will reduce output power in an attempt to avoid shutdown. Full pump
output is restored when the controller temperature cools to a safe level.

Level Control Switch

υp to four level control switches can be wired into FU9000S solar controller for
water level control. This is optional and is not very necessarily required to run
FU9000S solar controller. FU9000S solar controller can be used with one to four
control switches ， 。r none at all. This provides the user maximum adjustability
when using FU9000S solar controller. See INSTALLATION section for more
information on installing and using control switches.

Sv词tching to Backup AC Power

FU9000S solar controll 衍 s input power terminal may be switched manually to
’

a backup AC power source. If there is sufficient voltage measured from the

primary source (solar array), the controller draws from it to run the pump. FU-
9000S solar controller can be manually switched to the alternate backup supply
input if:

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FULL FU9000S Series

。
• The solar array input cannot provide at least 180 VDC(220VAC mot r output)
or 350VDC (380VAC motor output) to successfully start the motor; AND
• Generator backup power is available at the AC backup terminals.

Note: Depending on the model number, FU9000S solar controllers support power
。
input either 220VAC single phase ， r 380VAC three phase, Please contact SAJ
or SAJ authorized agencies for details.
When the system is running on back-up AC power, please check for sufficient
DC primary source power every 30 minutes. If the primary DC power is
available, shut down the controller, switch back to primary power and attempt to
run on DC power supply.

A NO丁 ICE
A DC circuit switch and a generator power switch must be installed, and
these two switches must be mechanic 创 ly interlocked each other to prevent
switching on together resulting the solar PV and the generator being
connected to the solar FU9000S solar controller simultaneously! Please check if
the design is in accordance with all applicable national and local electrical
codes.

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FULL FU9000S Series

2. FU9000S Solar Controller General Information

FU9000S solar controller is a variable speed motor drive designed to run any
IEC three phase asynchronous motor. FU9000S solar pumping system provides
幡

water to remote locations by conve 役1ng high voltage, direct current from a solar
array into alternating current to run a standard three-phase asynchronous motor.
When solar power is not available, the controller can be switched manually to an
alternate single-phase or three”phase AC input such as a generator or inverter
from battery, if available. The controller provides fault detection, motor soft
sta役 ， and speed control. FU9000S solar controller is designed to provide these
features with the plug and play ease of installation.
FU9000S solar controller is designed with the high standard of reliability
expected of SAJ products. The controller attempts to drive the pump and motor
to deliver water even under adverse conditions, reducing output as necessary
to protect the system components from damage, and only shutting down in
extreme cases. Full operation is restored automatically whenever abnormal
conditions subside.

2.1 Inspection
Before you begin, receive and inspect FU9000S solar controller unit. Verify that
the part number is correct and that no damage has occurred during transit.
Note: FU9000S solar controller is one component of FU9ooos solar pumping system
which has other two optional components, solar array and AC pump with motor.

2.2 Descriptions and Features

F U9000S solar controller is based on a standard FU驯as platform controlling a
standard three-phase asynchronous motor driving a pump powered by a solar
array or an optional AC generator backup.
FU9000S solar controller continuou sly monitors system performance and
incorporates a number of features for pumping system protection. In the event
of a fault,FU9000S solar controller will indicate the type of fault through the LED
display mounted on the front cover of controller.

FU9000S solar pumping system is optimized for pumping under adverse

input power conditions unique to solar arrays.
• Internal diagnostics will tolerate a lower input voltage.
• Whenever possible, the controller attempts to drive the pump load by
maximizing power output from the solar array.

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FULL FU9000S Series

An easy to use interface is provided to enhance configurability and enable

remote system monitoring.
• A LED display provides a detailed indication of system status.
• A small keypad offers flexibility for selection of user options.

2.3 Protection Features

Electronic monitoring gives the controller the capability to monitor the system
and automatically shut down in the event of:
• Dry well conditions - with low level switch
• Bound pump 甲 。
with aut ”reversing torque.
• High Voltage Surge
• Low Input Voltage
•Open motor circuit
• Short circuit
•Over heat

NOTE: This controller provides motor overload protection by preventing motor

current from exceeding rating current and by limiting the duty cycle in the event
of low water level. This controller does not provide over temperature sensing of
the motor.

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External dimension and installation dimension of 3-ph 220VAC

A B H w D
(mm) (mm) (mm) (mm) (mm) Insta 川 ati
Inverter model
Power(kW) Insta 川 ation on Hole
Dimension External Dimension (mm)

FU9000S-OR7♂S
115 173 185 125 160
FU9000S斗 R5-2S
5
FU9000S之R2-2S
140 233 245 150 180
FU9000S-004-2S
FU9000S毛 R5-2S 203 306 320 217 200 6

。
A.3 lnstallati n Space

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Figure A-7 Installation of multiple inverters. Figure A-8 Safety space

Add the air deflecto 「 when apply the up-down installation.

。 。
A.4 Dimesi ns f External Keypad
70.0 28.0 70,0.2

问
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问 。 钊的 刷面

⑧⑩
⑧③
①①
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Figu 「e A-9 Dimension of sma 川 keypad. Figure A-10 Installation of small keypad

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FULL FU9000S Series

A.5 Disassembly and installati n 。

Figure A-11 Disassembly and installation of plastic cover

／仁

Figu 「e A-12 Disassembly and installation of metal plate cover.

Figure A-13 Disassembly and installation of open inverter cabinet.

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