CPS Flex Gateway User Manual

Flex Gateway Card
Installation and Operation Manual
For CPS 50kW/60kW 3-Phase String Inverters
CHINT POWER SYSTEMS AMERICA CO.
Revision 1.0 - June 2017
1
Chapter 1 Overview
1.1 Product Description
This optional site level inverter data logger and gateway was developed to
rd
enable customers and 3 parties to receive data directly via Ethernet based
XML exchange and enable CPS to improve its service offering with remote FW
capability. This manual is written specifically for installing the Flex Gateway
into the wire box of the CPS SCA50KTL-DO-US-480 and
SCA60KTL-DO/US-480 3-Phase String Inverters. The Flex Gateway acts as a
Modbus master data logger and gateway solution for monitoring and controlling
commercial and utility scale inverter applications. This flexible monitoring
solution enables three parallel outbound communication options:
(1) local pass-through Modbus data to 3rd party solutions;
(2) Ethernet-based communications to the CPS portal;
(3) a programmable Ethernet based connection to a location chosen by the
customer.
The Flex Gateway enables remote F/W upload by the CPS Service team,
enabling efficient field service solutions for our customers. The remote upload
function is facilitated by the CPS Monitoring Portal.
Key Features include:
1 Installed in a single inverter wire-box: no power or extra equipment required
2 Modbus communications input (up to 32 inverters per card) - Modbus RS485
3 Complete controls functionality via Modbus (per inverter or broadcast
command)
4 Flexible outbound communications
5 Programmable IP address for customer direct data (XML format)
6 Remote inverter F/W update capable
7 Pass-through data for local 3rd party solutions (Modbus RS485)
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1.2 Appearance and Main Item Description
①
Figure 1-1 Diagram of the Flex Gateway
1.3 Main items of the Flex Gateway:
1) Flex Gateway housing and circuit board.
2) 5-pin connector for inverter daisy chain connection via Modbus RS-485 (for
external installation only)
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3) 3-pin connector for 3
party data pass-through via Modbus RS-485 (for
external installation only)
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Chapter 2 Installation
This chapter describes the installation procedure for the Flex Gateway. Please
read each section carefully and install the product following the step-by-step
instructions.
The Flex Gateway and accessories are shipped in one package.
Before
installation, please check that the following items are included in the package:
Table 2-1 Main Items
No.
(1)
Item
Qty
Main enclosure of Flex
Gateway
1
(2)
5 pin Molex connector
1
(3)
3 pin Molex connector
1
(4)
Mounting screws
2
(5)
DIN Rail Mounting Clip
1
(6)
Installation manual
1
4
Note
Before You Begin
Planning the Ethernet connection
1.
The maximum cable length should be less than 100 meters;
2.
The recommended termination connector is RJ45.
3.
The recommended cable type is CAT5e 4x24AWG data
communication cable (eg. Belden 1583A)

Characteristic Impedance (Zo): 100 ohms

Mutual capacitance <= 15 pF/Foot

Capacitance to Shield <= 65 pF/Foot.

Propagation velocity >= 70%
Planning the Modbus RS-485 connection
1.
The maximum cable length should be less than 800 meters;
2.
The recommended termination connector is 5-pin Molex.
3.
The recommended cable type is 3x 22~18AWG communication cable
(eg. Belden 3106A)

Characteristic Impedance (Zo): 100 to 200 ohms

Mutual capacitance <= 12.5 pF/Foot

Capacitance to Shield <= 60 pF/Foot.

Propagation velocity >= 60%
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Network Connections
When the inverters are monitored via the Flex Gateway, a unique RS-485 address
for each inverter can be set up through the inverter LCD interface. Up to 32 inverters
can be connected together in the communication network. The daisy-chain topology
is recommended for the network connection, as shown in Figure 2-1. Other
communication topologies, such as the star networks are not recommended.
Figure 2-1 Network Connections
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1.
Communication Connection
This step will provide instructions on making the following connections:
a)
Connection from the Flex Gateway to the inverter(s) via Modbus
RS-485
b)
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Connection from the Flex Gateway to 3 party data pass-through via
Modbus RS-485 monitoring
c)
Ethernet connection from Flex Gateway to external internet portal.
d)
Flex Gateway Communication board description as figure 2-2
e)
Connectors and Flex Gateway
Figure 2-2 Flex Gateway
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Table 2-1 Communication Connection Interfaces
Item
Picture
Configuration description
1 -----12V+
① RS485 port
2 -----12V-
(5-pin connector)
3 -----RS485+
4 -----RS4855 -----COM
② RS485 port
1 -----RS485+
(3-pin connector)
2 -----RS485-
Pass through function
3 -----COM
③ Reset button
Restore the Flex Gateway to the
factory setting including the
default fixed IP address for data
uploads.
④ USB port S200
Firmware upgrade via USB
device
⑤ Ethernet Port
Ethernet connection via RJ45
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1) Built-in Installation Method:
(a) Only 50kW/60kW 3-Phase String Inverters support the built-in
installation method.
(b) Before install in the wiring box, the Flex Gateway metal housing must
be disassembled and the card removed from the metal housing.
Figure 2-3 Built-in Options
1.
Built-in Installation Mounting Method
The Flex Gateway is to be installed within the wire box of the 50kW/60kW
3-Phase String Inverter. To install the Flex Gateway inside the wire box
perform the following steps:
a)
Remove wire box cover.
b)
Locate the Interface Board.
c)
Using the mounting screws provided in the package, mount the Flex
Gateway onto the Interface Board by aligning the mounting holes
and 6-pin header.
d)
Tighten screws until tight.
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2.
Wiring Method
As shown is Fig 2-4, once the Flex Gateway Card is installed, the card and
additional inverters on the RS485 network are wired together via the 5-pin
connector. The 3rd Party pass-through RS485 is terminated at the 3-pin
connector. The Ethernet connection is terminated at the RJ45 port.
Figure 2-4 Built In Method Wiring Diagram
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2) External Installation Method (Internally Powered):
(a) Only 50kW/60kW 3-Phase String Inverters support the external
installation method using the internal inverter 12V power supply.
1.
External Installation Mounting Method
The Flex Gateway may be installed within an external NEMA 4 rated
communication enclosure using the DIN rail mount. To install the Flex
Gateway perform the following steps:
a)
Using the mounting screws provided in the package, mount the Flex
Gateway DIN rail mounting clip to the metal housing.
b)
Tighten screws until tight.
c)
Fasten the Flex Gateway to the DIN rail
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2.
Wiring Method
As shown is Fig 2-5, once the Flex Gateway Card is installed in the
external communication enclosure, the card and additional inverters on
the RS485 network are wired together via the 5-pin connector. The 3rd
Party pass-through RS485 is terminated at the 3-pin connector. The
Ethernet connection is terminated at the RJ45 port.
Figure 2-5 External Installation (internal power) Wiring Diagram
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3) External Installation Method (Externally Powered):
(a) Only 50kW/60kW 3-Phase String Inverters support the external
installation method using an external 12V power supply.
2.
External Installation Mounting Method
The Flex Gateway may be installed within an external NEMA 4 rated
communication enclosure using the DIN rail mount. To install the Flex
Gateway perform the following steps:
a)
Using the mounting screws provided in the package, mount the Flex
Gateway DIN rail mounting clip to the metal housing.
b)
Tighten screws until tight.
c)
Fasten the Flex Gateway to the DIN rail
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2.
Wiring Method
As shown is Fig 2-6, once the Flex Gateway Card is installed in the
external communication enclosure, the card and additional inverters on
the RS485 network are wired together via the 5-pin connector. The 3rd
Party pass-through RS485 is terminated at the 3-pin connector. The
Ethernet connection is terminated at the RJ45 port.
Figure 2-6 External Installation (external power) Wiring Diagram
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Chapter 3 Configuration
3.1 Flex Gateway Settings
3.1.1 Connect the laptop to the Flex Gateway by CAT5 Ethernet cable,Flex
Gateway;
3.1.2 Energize the inverter by turning on the DC disconnect switch.
Next,
press the Reset Button on the Flex Gateway for 8 seconds and release it after
the red indicator light on the Flex Gateway stops flashing;
3.1.3 Set the laptop to a fixed IP address per the following instructions:
IP address:
10.122.1.x
(x from 0-255, except 25)
Subnet mask: 255.255.255.0
Gateway:
10.122.1.254
3.1.4 Launch an internet browser and enter the IP address: 10.122.1.25.
Next, enter the username as “admin” and password as “admin”, in the fields
shown in Figure 3-1:
Figure 3-1
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3.1.5 After entering the username and password the display will automatically
show the Device tab.
Navigating the Flex Gateway Menu
The first tab, Device View, will display information for the inverters connected
to the Flex Gateway.
The second tab, Configure, will allow the user to set up connections to the
LAN network and remote upload server.
The third tab, Firmware, shows the firmware version of the Flex Gateway.
The fourth tab, Security, can be used to change the password for the Flex
Gateway.
Figure 3-2
Device Page
The display will auto-scroll through all the inverters that are discovered on the
Modbus network and auto-populate the fields for each device.
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Configure Page (Set-Up LAN Network)
3.1.6 The Flex Gateway must be set-up with a static IP address. To set the
static IP address the user needs to identify the default gateway of the host
network.
IP address:
aaa.bbb.ccc.xxx(xxx from 0-255, except the network Default
Gateway number)
Subnet mask: 255.255.255.0
Gateway:
aaa.bbb.ccc.ddd (enter the network Default Gateway)
DNS Server:
leave this field empty and allow the network to assign
Then click “Apply” field adjacent to the DNS Servers field.
Set-Up Remote Upload Server IP Address
1.
The Remote Main IP and RemoteMainPort settings should not be
changed. Leave default settings.
2.
Set the Remote Secondary IP (currently shown in Figure 3-3 as
Remote Back IP) address to the server IP address that the customer
provides.
This is the location that the data from the inverter(s) will
be uploaded to by the Flex Gateway.
3.
Set the Remote Secondary Port (currently shown in Figure 3-3 as
RemoteBackPort) to 10000.
4.
Set the Upload Window to the time interval for inverter data collection.
Data will be uploaded at the time interval set in this field.
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Figure 3-3
3.1.7 The Mac address and Device SN are the factory settings and should not
modified.
The IP address/subnet mask/gateway setting is to connect to the
local router.
Remote Domain IP/Remote Port is the CPS webserver address
and the US server domain IP is 47.88.3.190, the port number is 10000; the
below figure 3-4 shows all the data need to be modified;
Figure 3-4
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Chapter 4 Specifications
Model Name
CPS GW-3PKTL-US
Communications
Inverter interface
RS485
User interface
Standard: RS485, Ethernet, USB
Inverter connections
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per card
XML, HTTPS, DHCP, DNS Resolution,
Protocol
Modbus RTU
Monitoring
Web connections
IP addresses: CPS + Programmable location
Wired connection to the Data logger
Local monitoring
(integrated web GUI)
Remote monitoring
CPS platform or 3rd party platform
Data logging Specifications
Data sampling rate
Local data storage
Upgradeability
Programmable data sampling
(1 to 15 minute sample rate)
Log data for 30 days based on 15 minute intervals
Remotely via CPS platform or
3rd party platform / locally via USB
Modbus ID, Inverter S/N's, Model,
Data parameters
TYield/DYield(kWh), RunT(min),
Mode, Upv(V), Ipv(A), Pac(kW), PF,
Freq(Hz), Uabc(V), Iabc(A)
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Advanced Functions
Remote O&M operations
Inverter parameter settings / inverter
firmware upgrade
Capable of control commands via Modbus
Controls Capability
(ie; PF control, Active power curtailment,
Remote reset)
Power Supply
DC power supply
9-12Vdc, ~ 2W
Environmental Parameters
-30 to +85°C
Ambient temperature range
Environmental protection
Installed in NEMA 4X wire-box
Relative humidity
<85% Non-condensing
Mechanical Parameters (per unit)
Dimensions (H x W x D)
86mm × 69mm × 16mm
Weight
50g
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Chapter 5 CPS America Accessories Warranty
Chint Power Systems America Co. (“CPS”) and its parent company, Shanghai
Chint Power Systems Co., Ltd, warrant that all new inverter accessories sold
by CPS are free of any defects in material and workmanship for a standard
warranty period of two (2) years. The warranty period begins one (1) month
from the date CPS ships the product or the date of installation, whichever
comes first. Inverter accessories include; shade covers, disconnect covers,
data monitoring hardware, rack mounting equipment and energy balancer.
Scope of Warranty Services:

Covers new accessory products installed in North America.

CPS will repair, replace with a product of the similar type, or refund
the purchase price, at its sole discretion, at no cost to the customer if
the customer notifies CPS of any breach of warranty within the
warranty period.

CPS will, with commercially reasonable efforts, respond to customer
inquiries within 24 hours and provide a resolution plan within 48 hours
to rapidly resolve warranty issues.

If the unit is replaced in the field, the customer agrees to utilize the
CPS Return Material Authorization Policy (“RMA”) in place at the time
of replacement.

CPS warrants that any repaired or replaced product will be free from
defects in material or workmanship for the remainder of original unit
warranty period.
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Warranty Exclusions:

Damage from shipping or transportation.

Damage caused by improper installation, operation and maintenance
according to the installation manual or any local, state or federal
codes and requirements.

Replaceable service items.

Any costs incurred by the customer or installer for troubleshooting,
installation, removal or the value of lost energy production.

Damage caused by force majeure, including but not limited to flood,
fire, earthquakes and lightning.

Material or workmanship not provided by CPS or its approved service
providers.

Damage caused by rust or corrosion.

Use with non-CPS branded inverters.
If your product requires troubleshooting or warranty service, contact your
installer or dealer. If you are unable to contact your installer or dealer, or the
installer or dealer is unable to provide service, contact CPS directly at:
North American call center: 1-855-584-7168
AmericaSales@ChintPower.com
CPS LIABILITY FOR LOSSES CAUSED BY PRODUCT FAILURE OR
DAMAGE IS ONLY LIMITED TO THE VALUE OF THE PURCHASE PRICE
OF THE ORIGINAL PRODUCT AND EXCLUDES CONSEQUENTIAL
LOSSES. IN THE EVENT OF ANY DISCREPENCY BETWEEN OTHER
APPLICABLE QUALITY GUARANTEE OR AFTER-SALES PROVISIONS
AND THIS WARRANTY, THIS WARRANTY SHALL PREVAIL. IN THE EVENT
THAT PROVISIONS OF THIS WARRANTY ARE IN CONTRADICTION WITH
APPLICABLE STATE OR FEDERAL LAWS OR REGULATIONS, THE
LATTER SHALL HAVE TOP PRIORITY. THE RIGHT OF MODIFICATION
AND INTERPRETATION OF THIS WARRANTY IS RESERVED BY
SHANGHAI CHINT POWER SYSTEM CO., LTD.
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CHINT POWER SYSTEMS AMERICA CO., LTD.
Address: 700 International Parkway, Suite 102
Richardson, Texas 75081
Service Hotline: 855-584-7168
Email: AmericaSales@chintpower.com
Website: www.chintpowersystem.com
SHANGHAI CHINT POWER SYSTEMS CO., LTD.
Headquarters: Building 4, No. 3255, Sixian Road,
Songjiang District, Shanghai, China
Tele: +86 -21 -3779 1222 -6300
Fax: +86 -21 -3779 1222 -6001
Email: monitor@chint.com
Part No: 9.0020.0368A0
This manual is subject to change without prior notification. Copyright is reserved.
Duplication of any part of this issue is prohibited without written permission.
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