Generac Power Systems PWRcell Reference Manual
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Generac Power Systems PWRcell Reference Manual

Generac Power Systems PWRcell Reference Manual

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REFERENCE
MANUAL
Diagnostic Repair Manual
PWRcell™
• PWRcell Inverter
• PWRcell Battery
• PV Link™
• SnapRS™
• PWRcell ATS
C l e a n E n e r g y S y s t e m s
Diagnostic Repair Manual
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Summary of Contents for Generac Power Systems PWRcell

  • Page 1 ® REFERENCE MANUAL Diagnostic Repair Manual PWRcell™ • PWRcell Inverter • PWRcell Battery • PV Link™ • SnapRS™ • PWRcell ATS C l e a n E n e r g y S y s t e m s Diagnostic Repair Manual...

  • Page 2: Read This Manual Thoroughly

    DANGER (000003) Electrocution. Initiate a system-wide shutdown and turn the PWRcell DC Disconnect Switch OFF on all connected batteries before performing service. Failure to do so will NOTE: Notes provide additional information important to result in death, serious injury, or equipment and property a procedure or component.

  • Page 3: Table Of Contents

    Section 6 PV Link and SnapRS .......25 Remove Power Core ..........92 Device Profiles ............25 Install Replacement Power Core ......93 Diagnostics .............27 Section 11 PWRcell Inverter Lid Replacement ..97 Troubleshooting ............30 Overview ..............97 Device Confirmation ..........35 Required Tools ............97 Section 7 PWRcell Battery........37 Safety ..............
  • Page 4 Table of Contents Section 13 PWRcell Battery BMU Replacement ..109 Overview ...............109 Required Tools .............109 Before You Start ...........109 Disable PWRcell Battery ........109 Prepare BMU for Removal ........112 Remove BMU from PWRcell Battery Frame ..114 Install BMU to PWRcell Battery Frame ....114 Enable PWRcell Battery ........117...

  • Page 5: Section 1 The Pwrcell System

    • PWRcell Inverter • PV Link • PWRcell Battery • SnapRS 1-1, a REbus-compatible PWRcell inverter (E) is directly connected to each PV Link (B) and to a PWRcell Figure battery (C) on DC (REbus) lines (D). To the right of the inverter are AC lines: 240 VAC or 208 VAC for grid and home loads (G), and protected load (H) support.

  • Page 6: System Modes Overview

    Generac PWRcell offers several system modes for various installation configurations, markets, and applications. Connected REbus devices work together to manage the distribution of power based on the selected system mode. Some modes interact with PWRcell batteries to store power and/or balance production and consumption. Table 1-1 Table 1-2 for an overview of available system modes.
  • Page 7 If the battery is not fully charged, the inverter uses all available solar power to charge the battery. PWRcell Batteries will not export to grid in this system mode. Figure 1-6.

  • Page 8: Island Mode

    1-7. If solar and grid power are available, both can charge the battery. The system displays the In the event of a grid outage, the PWRcell Inverter enters amount of power being drawn from the grid and the Island Mode. While in Island Mode, the inverter discon-...

  • Page 9: Export Override

    (C) and pushing inward (D). NOTE: This feature requires CTs to be properly installed 5. Open all PWRcell DC Disconnects (E). Verify DC and calibrated prior to use. For more information on CT voltage reported on LCD screen has dropped to calibration, see the PWRcell Inverter Installation and below 10 VDC.
  • Page 10 Section 1 The PWRcell System • PWRcell inverter will stop sourcing power to REbus, and immediately disable all communicating power sources on REbus by sending a system- wide system mode change signal. NOTE: Successful signal transmission relies upon proper configuration of PLM channels across REbus devices (PV Links and Batteries).

  • Page 11: Section 2 Understanding Rebus

    Power Distribution Device Communications REbus nanogrid technology utilizes power curves on a common high voltage DC bus to regulate the flow and Generac PV Links, PWRcell Batteries, and the PWRcell distribution of power depending on the selected system Inverter utilize...

  • Page 12: Rebus Confirmation

    REbus. diagnostic procedures. • Yellow one or more devices are disabled, or no NOTE: If PWRcell system is installed in proximity to devices are detected. other PWRcell systems, cross talk may occur. Adjust all system channels accordingly. Refer to Commissioning 5.

  • Page 13: Section 3 Internet Connectivity

    Basic Requirements To connect a PWRcell Inverter to the Internet, the system requires a hard-line connection from the homeowner's router to the inverter. The Internet service should be basic high-speed broadband with minimum data transfer speeds of at least 5 Mbps upload/download.

  • Page 14: Diagnostics

    The Beacon will have its own device page like the Inverter, PV Links, and PWRcell Bat- tery regardless of whether there is an Internet sig- nal. It is connected to the inverter via USB.

  • Page 15: Internet Troubleshooting Flowchart

    Beacon 2. PWRcell Inverter through the Beacon, contact Generac • Two lights, green and amber are PWRcell Technical Support for RMA of illuminated on either side of pass-through/patch cable. Beacon ethernet port. Verify Inverter Displays...

  • Page 16: Internet Confirmation

    4. Homeowner or Business Requires Manual IP through and/or patch cable from the fac- Configuration tory may need replacing. Call Generac PWRcell System comes default set to connect via DHCP. PWRcell Technical Support 855-635- If connection requires manual IP configuration reference 5186.

  • Page 17: Section 4 Pwrcell Inverter

    Section 4 Device Profile The PWRcell Inverter, complete with its control panel LCD and its REbus Beacon, should be thought of as the central device in a PWRcell system. The PWRcell Inverter facilitates system-level functionality. It is important to follow all safety precautions when servicing this equipment.
  • Page 18 Grid Tied Turn EnaIslanding to 'off' and choose 'Grid Solar-only Tie' for the system mode. • If the inverter does not pass this test, call PWRcell Installation Technical Support. Battery Verify EnaIslanding is set to 'on' and 9. DC Disconnects...

  • Page 19: Troubleshooting

    NOTE: Problems and diagnostics procedures are described in detail below. Table 4-1. Inverter Troubleshooting Problem Observed Symptoms Diagnostics Multiple Inverter Devices from one PWRcell system show up on PLM Cross-talk Recovery Proce- – Refer to Systems Cross- another. Multiple inverter or Beacon pages on one dure...
  • Page 20 'error detected or REbus DC voltage does not reach a on PWRcell [model]'. Navigate to the inverter device minimum of 360 VDC, call Generac PWRcell page to view specific inverter state. Certain error states Technical Support.
  • Page 21 Re-energize the inverter. This allows for the 'NumTranSwtchs' is set to reflect the number internal processor to be reset. If comms do not of PWRcell ATS connected to the inverter return at this point, call Generac PWRcell system in the 'mod. settings' menu for the Technical Support.
  • Page 22 Use a DMM to check for proper AC voltage line-to-neutral and line-to-line. If too much load is applied to the PWRcell system during a grid outage, the system will go into an overload fault to NOTE: Split phase inverters must have true 240 Volt split protect itself.

  • Page 23: Device Confirmation

    Inverter. connections 120/240 120/208 nominal). 4. If unable to recover, Call Generac PWRcell Technical Support 855-635-5186. 5. Wattage is being produced at the home screen and the inverter device screen. Unknown Devices 'Offline' 6. PV Links are making power if the sun is shining; or 1.
  • Page 24 Section 4 PWRcell Inverter This page intentionally left blank. Diagnostic Repair Manual...

  • Page 25: Section 5 Pwrcell Cts

    Generac PowerCore CT (Cat 5) 010006 Figure 5-2. PWRcell Inverter Home Screen NOTE: CTs are NOT a factor in the ability of a PWRcell system to provide backup power during a grid outage. 011890 Protected Loads Panel Main Distribution Panel Figure 5-3.
  • Page 26 Section 5 PWRcell CTs – See Figure 5-4. If interconnection is achieved – Reference the inverter wiring compartment cover using a line side or supply side tap, place CTs for additional diagram and labeling. upstream (the meter side) of the tap.

  • Page 27: Troubleshooting

    The troubleshooting table below references the images and diagnostics contained in this section as well as relevant materials in the appendix. Use the diagnostic practices in the order they are listed to solve problems. If unable to resolve functionality call Generac PWRcell Technical Support 1-855-635-5186. Table 5-2. CTs Troubleshooting...

  • Page 28: Cts Troubleshooting Flowchart

    Section 5 PWRcell CTs CTs Troubleshooting Flowchart Verify Power Pole Attemp to Calibrate CTs: Determine if Icon Shows on see whether validation Success or Fail Inverter Home Screen messages appear on message inverter screen Failure = Success = CTs Calibrate CTs to...

  • Page 29: Section 6 Pv Link And Snaprs

    6-2. PWRcell equipment uses a substring topology to facilitate power production from the solar array through the inverter to the consumer loads. One “string” for PWRcell equipment consists of one home run (A) back to the inverter and up to three series substrings for a total of up to three PV Links.
  • Page 30 SnapRS per substring is 10 devices total. Follow permitted plan-set for building site and reference the PV Link Sizing Tool at https://www.generac.com/resources-and-tools/ce-installer-resources/system-sizing-tools. 011990 Figure 6-3. Single-String PV Substring with SnapRS Devices PWRcell Inverter PV Substring Input - REbus homerun PV Substring Input +...

  • Page 31: Diagnostics

    Section 6 PV Link and SnapRS Diagnostics 4. Disable/Enable • For non-terminal errors, disabling and re-enabling the PV Link from the inverter control panel may PV Link Universal clear the error state and allow the PV Link to return 1. PV Panel Configurations to operation.
  • Page 32 Section 6 PV Link and SnapRS • PV Link + SnapRS (NEC 2017 and newer) Make certain to turn Override PVRSS 'off' after troubleshooting. 1. PV Link Settings (see Appendix D PV Link) IMPORTANT NOTE: Leaving a PV Link operable with •...
  • Page 33 Section 6 PV Link and SnapRS • There are no functional tests that can be performed on SnapRS devices in the field. However, some simple checks with a digital multimeter (DMM) can confirm the general health of a SnapRS device. –...

  • Page 34: Troubleshooting

    Use the diagnostic practices in the order they are listed to solve problems. If unable to resolve functionality call Generac PWRcell Technical Support 1-855-635-5186. NOTE: Problems and diagnostics procedures are described in detail following the table.
  • Page 35 Section 6 PV Link and SnapRS Table 6-1. Troubleshooting Problem Observed Symptoms Diagnostics – Check PV Link Settings PVRSS Not Upon enabling PV Link, the message – Disable/ Enable Configured PVRSS not configured appears. – Disable/ Enable PVRSS Count Upon enabling PV Link, the message –...
  • Page 36 5. PV Wiring page. a. Low sun is either a settings issue or a PV b. If only one PWRcell inverter on site, access the wiring issue; it is not an issue with REbus 'mod. settings' menu for the inverter and wiring.
  • Page 37 Section 6 PV Link and SnapRS d. Navigate back to the PV Link in question: if it PV Link has not been enabled w/PVRSS. says 'disable' or 'enable,' it is back online. (1) Navigate to 'mod. settings' menu for PV (1) Change the PV Link PLM Channel back to Link.
  • Page 38 Section 6 PV Link and SnapRS Insulation Fault and locate SnapRS devices in the substring. 6. SnapRS Health Check An insulation fault occurs when there is an unintended a. Visually inspect SnapRS devices connected to electrical connection ground normally substring in question. ungrounded current carrying conductor in the PV array.

  • Page 39: Device Confirmation

    Section 6 PV Link and SnapRS 1. Disable/ Enable Device Confirmation a. Disable and re-enable the PV Link to clear the fault. 1. REbus LED is: b. This will force the PV Link to reevaluate the PV • Green indicating all devices are enabled and array for Insulation Faults and Ground Faults.
  • Page 40 Section 6 PV Link and SnapRS This page intentionally left blank. Diagnostic Repair Manual...

  • Page 41: Section 7 Pwrcell Battery

    Section 7 Device Profile The Generac PWRcell Battery is a DC-coupled lithium-ion battery system. The Battery Management Unit (BMU) provides the interface between the battery modules and REbus, moving power to and from the battery modules depending on the selected system mode, the available solar power, and the AC load demand at the inverter. In the event of a grid outage, the battery will maintain the DC bus and provide backup power to the inverter while continuing to be able to charge from available solar energy.

  • Page 42: Safety Information

    Table 7-1 Troubleshooting. Electrocution. Initiate a system-wide shutdown and turn the PWRcell DC Disconnect Switch OFF on all connected 1. REbus DC Wiring batteries before performing service. Failure to do so will • Verify REbus wiring (positive, negative, and result in death, serious injury, or equipment and property damage.
  • Page 43 Verify blue CAT5 cable in harness is connected the ON position. from output port of top-front module to input port of • Enable PWRcell battery from its device page on middle-back module the inverter screen. – [if >3 battery modules] Verify black CAT5 jumper •...
  • Page 44 Section 7 PWRcell Battery discharge of the battery to below 95% before verifying battery charging. • Verify discharging: – With battery enabled, from inverter main page, change system mode to Sell. – Verify that battery status changes to 'discharging' and the battery power reading is positive.

  • Page 45: Troubleshooting

    Appendix E Battery. Use the diagnostic practices in the order they are listed to solve problems. If unable to resolve functionality call Generac PWRcell Technical Support 1-855-635-5186. NOTE: Problems and diagnostics procedures are described in detail following the table. Table 7-1. Battery Troubleshooting...
  • Page 46 DMM set to measure DC voltage. a. Measure the right side of the fuse blocks with After enabling the battery, if an “Error on PWRcell” the red probe on the contact for the red wire message is displayed on the inverter screen and the...

  • Page 47: Device Confirmation

    1. Battery settings check: confirm the battery set 'charging', 'discharging', or 'standby.' points are valid. Navigate to the Mod. Settings 4. Battery settings are configured properly for the menu for the PWRcell [Battery]. installation and desired performance. a. Verify that the charge current limit settings are •...
  • Page 48 Section 7 PWRcell Battery This page intentionally left blank. Diagnostic Repair Manual...

  • Page 49: Section 8 Pwrcell Ats

    Section 8 PWRcell ATS PWRcell ATS Section 8 Contactor Switching Mechanisms Utility Closing Coil C1 The switching mechanism is physically responsible for Figure 8-3. The utility closing coil (C1) utilizes recti- carrying the rated electrical current and shifting the fied Utility source power to actuate the LOAD contacts to connection from one power source to another.

  • Page 50: Standard 100/200 Amp V-Type Transfer Switch

    For further information on the con- are rated 15 amps at 250 VAC. tactor assembly, refer to Contactor Basics. NOTE: *Auxiliary contacts are used by the PWRcell ATS controller for identifying contactor position. Auxillary A/C 1 Contact...

  • Page 51: Terminals 0, 194, And 23

    Section 8 PWRcell ATS ATS CAT5 Connection Inverter Only Configuration Wires N1 and N2 (Utility) are monitored by the Inverter The ATS controller CAT5 connection uses the RJ45 EIA/ through the ATS controller via the ATS CAT5 wire to the TIA 568B Wiring Standard.

  • Page 52: Operational Analysis - Inverter Only Configuration

    Section 8 PWRcell ATS Operational Analysis – Inverter Only Configuration Utility Source Voltage Available – Inverter Only Configuration Figure 8-7 shows the Switch is in the UTILITY position and utility source voltage is available. • Rated utility source voltage is available to the transfer switch terminal lugs N1 and N2 through sensing wires to the ATS controller through the CAT5 wire to the inverter.
  • Page 53 Section 8 PWRcell ATS Utility Source Voltage Failure – Inverter Only Configuration The inverter senses that utility voltage falls below a voltage dropout set point via N1 and N2. When the line interrupt drops below specifications, the inverter responds to the utility failure and will initiate transfer by grounding Wire 23. The inverter supplies voltage to the switch through E1 and E2.
  • Page 54 Transferring to Standby – Inverter Only Configuration The inverter takes Wire 23 to ground. This energizes the internal transfer relay (TR) within the ATS PWRcell controller. The TR contacts change state – opening on the UTILITY side (opens Wire N1A from Wire 126) – and closing on the STANDBY side (connecting Wire E2 and 205).
  • Page 55 Section 8 PWRcell ATS Transferred to Standby – Inverter Only Configuration When the XB1 limit switch opens voltage is removed from the coil, and the coil de-energizes. Spring tension in the switch mechanism now closes the switch to STANDBY. The next time it is actuated by the utility coil it will transfer to UTILITY.
  • Page 56 Section 8 PWRcell ATS Utility Restored – Inverter Only Configuration The switch is in the STANDBY position and the inverter is powering the load. When Utility voltage returns, the inverter sees the voltage from N1 and N2 through the CAT5 cable. If the voltage is higher than the voltage pickup setting the return to utility timer starts.
  • Page 57 Section 8 PWRcell ATS Utility Restored, Transferring Back to Utility – Inverter Only Configuration When all of the conditions are met, the inverter lifts the ground from Wire 23 and the transfer relay (TR) de-energizes. The TR contacts change states – opening E2A from 205, and closing N1A to 126.
  • Page 58 Section 8 PWRcell ATS Utility Restored, Transferred Back to Utility – Inverter Only Configuration The XA1 limit switch now opens. Spring tension in the switch mechanism closes the switch to the UTILITY position, and utility voltage powers the load through the main load lug connections.

  • Page 59: Operational Analysis - Generator Only Configuration

    Section 8 PWRcell ATS Operational Analysis – Generator Only Configuration Utility Source Voltage Available – Generator Only Configuration Figure 8-14 is a schematic representation of the transfer switch with utility source power available. The circuit condition is briefly described as follows: •...
  • Page 60 Section 8 PWRcell ATS Utility Source Voltage Failure – Generator Only Configuration If Utility source voltage drops below 65% of nominal voltage for five (5) seconds, the controller will initiate engine start. After the generator starts, a five (5) second engine warm-up timer is initiated. During this warm-up the generator is running at rated frequency and voltage.
  • Page 61 Section 8 PWRcell ATS Transferring to Standby – Generator Only Configuration 12 VDC is delivered to the transfer relay through Wire 194 and back to the controller through Wire 23. When the five second engine warm-up timer expires, the controller will take Wire 23 to ground which will energize the Transfer Relay.
  • Page 62 Section 8 PWRcell ATS Transferred to Standby – Generator Only Configuration When the standby coil (C2) energizes it pulls the contactor to an “over center” position towards the STANDBY position, the transfer switch electronically/mechanically snaps to that position. Upon closure of the main contacts to the STANDBY position limit switches XA1 and XB1 mechanically actuate to “arm”...
  • Page 63 Section 8 PWRcell ATS Utility Restored – Generator Only Configuration Utility voltage is restored and available to terminals N1 and N2. The Utility voltage is “sensed” by the controller and, if it is above 75% of nominal for 15 consecutive seconds, a transfer back to UTILITY will occur.
  • Page 64 Section 8 PWRcell ATS Utility Restored, Transferring Back to Utility – Generator Only Configuration After the 15 second return to utility delay expires, the controller will open the Wire 23 circuit from ground. The transfer relay de-energizes, the N.O. and N.C. contacts change state. Utility voltage is delivered to the utility closing coil (C1) through Wires N1A and N2A, the normally closed contacts containing Wires N1A and 126, and limit switch (XA1).

  • Page 65: Transferred Back To Utility, Generator Shutdown

    Section 8 PWRcell ATS Utility Restored, Transferred Back to Utility – Generator Only Configuration As the utility closing coil pulls the transfer switch to an “over center” position, the switch mechanically snaps to the UTILITY position. Upon closure of the contacts to UTILITY, the limit switches (XA1 and XB1) mechanically actuate to “arm”...

  • Page 66: Pwrcell Ats Controller

    PWRcell ATS controller will disable again. This will continue until the current is not exceeded when 2. Press and hold the TEST button on the PWRcell the priority is enabled, the system is returned to utility, or ATS Controller for approximately 1 second.

  • Page 67: Pwrcell Ats Controller Example

    Section 8 PWRcell ATS PWRcell ATS Controller Example Follow the sequence of operation when an overload condition occurs on example Priority Circuit 3. After a 30 minute timer expires, Priority 3 is activated. All priorities will remain active if the current load is still OK.
  • Page 68 Section 8 PWRcell ATS 013168 Figure 8-24. Priority 1 Enabled at 5 Minutes 013169 Figure 8-25. Priority 2 Enabled at 5 Minutes 15 Seconds Diagnostic Repair Manual...
  • Page 69 Section 8 PWRcell ATS 013170 Figure 8-26. Priority 3 Enabled at 5 Minutes 30 Seconds 013171 Figure 8-27. Priority 4 Enabled at 5 Minutes 45 Seconds Diagnostic Repair Manual...
  • Page 70 Section 8 PWRcell ATS 013172 Figure 8-28. All Priorities Enabled - Timer Reset 013173 Figure 8-29. Unidentified Overload - All Priorities Disabled - Begin 5 Minute Timer Diagnostic Repair Manual...
  • Page 71 Section 8 PWRcell ATS 013174 Figure 8-30. Priority 1 Enabled at 5 Minutes 013175 Figure 8-31. Priority 2 Enabled at 5 Minutes 15 Seconds Diagnostic Repair Manual...
  • Page 72 Section 8 PWRcell ATS 013176 Figure 8-32. Priority 3 Enabled at 5 Minutes 30 Seconds 013177 Figure 8-33. Overload - Priority 3 Disabled Diagnostic Repair Manual...
  • Page 73 Section 8 PWRcell ATS 013178 Figure 8-34. Priority 4 Enabled at 5 Minutes 45 Seconds 013179 Figure 8-35. Priority 3 Enabled at 30 Minutes Diagnostic Repair Manual...
  • Page 74 Section 8 PWRcell ATS 013180 Figure 8-36. Utility Returns - 5 Minute Timer Begins 013181 Figure 8-37. All Priorities Disabled for 5 Minutes Diagnostic Repair Manual...
  • Page 75 Section 8 PWRcell ATS 013182 Figure 8-38. Utility Power Present - All Priorities Enabled Diagnostic Repair Manual...

  • Page 76: V-Type Transfer Switch Troubleshooting

    Section 8 PWRcell ATS V-Type Transfer Switch Troubleshooting V-Type Transfer Switch with PWRcell ATS Controller with AC Generator ONLY (NO Inverter) – No Transfer to Standby • If minimum voltage is not available there is a prob- DANGER lem with the control board or harness.
  • Page 77 Section 8 PWRcell ATS V-Type Transfer Switch with PWRcell ATS Controller with AC Generator ONLY (NO Inverter) – No Transfer to Standby 1. Disconnect the main connector on the control board. DANGER 2. With the board not energized (Wire 23 NOT Electrocution.
  • Page 78 Section 8 PWRcell ATS V-Type Transfer Switch with PWRcell ATS Controller with AC Generator ONLY (NO Inverter) – Testing Operation of On-board (K5) Relay 2. Disconnect the main connector on the control board. DANGER 3. With the board energized (Wire 23 grounded) Electrocution.
  • Page 79 Section 8 PWRcell ATS V-Type Transfer Switch with PWRcell ATS Controller with AC Generator ONLY (NO Inverter) – No Transfer to Standby • If generator output voltage is NOT present at B and 205 troubleshoot the wiring harness relay contacts.
  • Page 80 Section 8 PWRcell ATS V-Type Transfer Switch with PWRcell ATS Controller with AC Generator ONLY (NO Inverter) – No Transfer to Standby • If generator output voltage not present replace wire E1A. DANGER • If generator output voltage is present proceed to Electrocution.
  • Page 81 Section 8 PWRcell ATS V-Type Transfer Switch with PWRcell ATS Controller with AC Generator ONLY (NO Inverter) – No Transfer to Utility NOTE: Inspect coil for mechanical or thermal damage, replace as necessary. DANGER • Electrocution. High voltage is present at If utility voltage is NOT present at A and N2A trou- transfer switch and terminals.
  • Page 82 Section 8 PWRcell ATS V-Type Transfer Switch with PWRcell ATS Controller with AC Generator ONLY (NO Inverter) – No Transfer to Utility 4. Measure for voltage at pin 2 Wire 126 (do not remove the wire). DANGER • If utility voltage is not measured the problem is with Electrocution.

  • Page 83: Section 9 Other Accessories

    SMM modules are self- monitoring and operate autonomously. SMM modules monitor the frequency (Hz) of the power being produced by a PWRcell Inverter system or standby generator. If the frequency falls below a certain threshold, module...

  • Page 84: Electrical Specifications

    Most installations will require the lockout switch to be DISABLED. When performing a whole house backup with a generator/PWRcell system not sized to manage all household loads, SMM's can be used to disable appliances or circuits during an outage. For non-essential loads that will not be used on generator or inverter power, set lockout switch to ENABLED.

  • Page 85: Setting Lockout (Later, Normally Closed Contactor)

    LOCKOUT DISABLED UTILITY Power is available on module output. NOTE: PWRcell systems do not support the operation of Mode Select Jumper in B position. Jumper Locations 9-2. Later SMM control boards are equipped The frequency jumper is factory set at the 60 Hz position.

  • Page 86: Tests

    9. Once load shed occurs, LED will flash at one stay ON. second intervals. 10. Allow time for each module to enable contactor Generator/PWRcell Inverter Test output per priority setting. 11. After predefined priority set time, each contactor 1. Enable Islanding and verify load shed settings.

  • Page 87: Troubleshooting

    Section 9 Other Accessories Generator/PWRcell Inverter Test with Lockout Switch Enabled (perform if Lockout Switch Enabled on any loads) 1. Enable Islanding and verify load shed settings. 2. Simulate a utility loss by turning MLCB (service disconnect) to OFF. 3. All modules will lose power and LEDs will disable.
  • Page 88 Section 9 Other Accessories Figure 9-3. SMM Functionality Flowchart Diagnostic Repair Manual...

  • Page 89: Revenue Grade Meter (Rgm) Kit

    Section 9 Other Accessories Revenue Grade Meter (RGM) Kit Device Profile The PWRcell RGM Kit allows for revenue grade metering of a PWRcell system. It includes a PWRview Meter, two CTs, a power cable, and a plastic mount for the meter. RGM PWR...
  • Page 90 Section 9 Other Accessories Troubleshooting Tree Troubleshooting START Problem: RGM data is missing/incorrect Issue Is the LED on the RGM Does it blink briefly Is RGM data resolved module blinking blue? every 30 seconds? available/correct? Check power winding from Check communication wiring Verify CT Installation inverter to RGM module.

  • Page 91: Lte Modem

    LTE Modem Device Profile The LTE Modem Kit allows for cellular connectivity between a PWRcell inverter and the Generac server for monitoring capabilities. The kit includes an LTE modem, an LTE antenna with cable, and one USB cable. The LTE modem requires additional cellular service not provided by Generac and is available only in select markets.
  • Page 92 Section 9 Other Accessories Troubleshooting Tree Troubleshooting START Problem: No blue LED for internet connectivity with LTE kit installed Is the green LED on the LTE module blinking? Is there any LED activity Verify SIM card is present on the LTE module? and properly installed Check power wiring Check communication...

  • Page 93: Section 10 Pwrcell Power Core Replacement

    Section 10 PWRcell Power Core Replacement PWRcell Power Core Replacement Section 10 Overview Figure 10-1. Replace the power core unit (A) within the PWRcell inverter. 013112 Figure 10-1. Required Tools Required Tools: Digital multimeter (DMM) Cloth/other protective hand wear Slotted head screwdriver — 6 mm Phillips head screwdriver —...

  • Page 94: De-Energize All Wiring To Inverter

    De-energize All Wiring To Inverter DANGER Electrocution. Initiate a system-wide shutdown and turn the PWRcell DC Disconnect Switch OFF on all connected batteries before performing service. Failure to do so will result in death, serious injury, or equipment and property damage.
  • Page 95 Section 10 PWRcell Power Core Replacement Unplug and tuck away accessory cables (E and NOTE: If green accessory screw terminals (F) are occupied with wiring, pull to remove the terminal blocks to avoid disconnecting individual wires. Tuck all wiring away.

  • Page 96: Remove Power Core

    If so, use of protective hand wear is DANGER recommended. Electrocution. Initiate a system-wide shutdown and turn the PWRcell DC Disconnect Switch OFF on all connected batteries before performing service. Failure to do so will result in death, serious injury, or equipment and property damage.

  • Page 97: Install Replacement Power Core

    Section 10 PWRcell Power Core Replacement Install Replacement Power Core Raise replacement Power Core into the enclosure over the top studs. 013121 Figure 10-12. NOTE: Align the clearance holes to slide over the nuts. 013122 Figure 10-13. Position bottom of Power Core as close to vertical as possible.
  • Page 98 Section 10 PWRcell Power Core Replacement Gripping the Power Core from the bottom, push up and to the right to align bottom studs with bottom holes (M). NOTE: The Power Core should now rest on all 4 studs. 013522 Figure 10-15.
  • Page 99 Section 10 PWRcell Power Core Replacement Connect accessory cables (S) and plug in green screw terminals (T) if previously removed. 013519 Figure 10-19. Connect AC wiring, grounds, the DC wiring connector, and LCD cable to Power Core. • Connect the DC wiring connector (U) and the LCD cable (V).
  • Page 100 Section 10 PWRcell Power Core Replacement This page intentionally left blank. Diagnostic Repair Manual...

  • Page 101: Section 11 Pwrcell Inverter Lid Replacement

    NOTE: 7 mm nut driver is also suitable for use. Safety DANGER Electrocution. Initiate a system-wide shutdown and turn the PWRcell DC Disconnect Switch OFF on all connected batteries before performing service. Failure to do so will result in death, serious injury, or equipment and property damage.
  • Page 102 Section 11 PWRcell Inverter Lid Replacement Use a 7 mm socket or nut driver to remove the 7 mm nut fastening braided wire grounding strap (for inverter screen) from the back plane of inverter housing. NOTE: Use caution to avoid dropping nut into DC breaker assembly.

  • Page 103: Removing Lid

    Section 11 PWRcell Inverter Lid Replacement Removing Lid Use a 2.5 mm Hex driver to loosen the two pivot bolts. Remove the two pivot bolts. NOTE: Be careful to not lose the plastic spacer between the inverter housing and lid.
  • Page 104 Section 11 PWRcell Inverter Lid Replacement Install lid pivot bolts with washers and spacers in correct placement. NOTE: See Figure 11-10. Spacer must be installed between lid and housing. Use needle nose pliers or the 2.5 mm hex driver to help position the spacer.
  • Page 105 Section 11 PWRcell Inverter Lid Replacement Replace 7 mm nut to fasten inverter screen braided wire ground strap to back plane of inverter housing. 013129 Figure 11-13. Diagnostic Repair Manual...
  • Page 106 Section 11 PWRcell Inverter Lid Replacement This page intentionally left blank. Diagnostic Repair Manual...

  • Page 107: Section 12 Dc Breaker Assembly Replacement

    Section 12 DC Breaker Assembly Replacement DC Breaker Assembly Replacement Section 12 Overview Replace the DC Breaker Assembly for a PWRcell Inverter. 013136 Figure 12-1. Required Tools Required Tools: 1. Digital Multimeter (DMM) 2. Phillips Head Screwdriver (No. 1 and No. 2) 3.

  • Page 108: Replace Dc Breaker Assembly

    Section 12 DC Breaker Assembly Replacement 1. De-energize all wiring to the inverter. 2. Disable any connected ESS (PWRcell Battery) 3. Open PWRcell DC disconnects 4. Open Interconnected System AC disconnect/AC Backfeed breaker 5. Wait for the inverter to power off.
  • Page 109 Section 12 DC Breaker Assembly Replacement 2. Disconnect DC wiring connector from Power Core. NOTE: This connector is a plug with red and blue wires coming from the DC breaker assembly to the Power Core. 013138 Figure 12-4. 3. See Figure 12-5.
  • Page 110 Section 12 DC Breaker Assembly Replacement 4. Remove the DC breaker assembly (see note below) and replace with the new DC breaker assembly. 013139 Figure 12-6. NOTE: See Figure 12-7. DC wiring assembly connector feeds through a hole built into inverter housing which may prevent the connector from being removed without handling.
  • Page 111 Section 12 DC Breaker Assembly Replacement 6. Connect DC wiring connector to Power Core. NOTE: This connector is a plug with red and blue wires coming from the DC breaker assembly to the Power Core. 013138 Figure 12-9. 7. Connect all REbus DC wiring connected to DC assembly terminal block.
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  • Page 113: Section 13 Pwrcell Battery Bmu Replacement

    MaxSoCRsrv: _________ (default = 100%) Disable PWRcell Battery DANGER Electrocution. Initiate a system-wide shutdown and turn the PWRcell DC Disconnect Switch OFF on all connected batteries before performing service. Failure to do so will result in death, serious injury, or equipment and property damage.
  • Page 114 Section 13 PWRcell Battery BMU Replacement 1. Locate the PWRcell Battery device page on PWRcell Inverter LCD display. Disable and Confirm to command battery off. 013143 Figure 13-3. 2. Locate the PWRcell DC Disconnect that the battery is landed on and turn to OFF position.
  • Page 115 013148 Figure 13-8. 9. Locate the battery string connector on the right side of PWRcell Battery frame. It is behind the REbus terminal blocks. NOTE: If the battery module connector was removed and zero volts measured in Step 8, there will be no voltage present on this connector.

  • Page 116: Prepare Bmu For Removal

    Section 13 PWRcell Battery BMU Replacement 10. Locate 12V positive lead on the BMU battery and disconnect. NOTE: This is the final step in successfully powering down the PWRcell battery. BATTERY DISCONNECT 013150 Figure 13-10. Prepare BMU for Removal 1. Remove REbus wires from the terminal block.
  • Page 117 Section 13 PWRcell Battery BMU Replacement 3. Remove two Phillips screws (A) holding the sheet metal cover on the top right side of the PWRcell Battery frame. NOTE: Let sheet metal cover hang by REbus wires. Secure sheet metal cover to avoid contact with other wires or painted surfaces.

  • Page 118: Remove Bmu From Pwrcell Battery Frame

    Section 13 PWRcell Battery BMU Replacement 7. Disconnect red 4 pin connector for master switch assembly from BMU. 8. Disconnect black 3 pin connector for led indicator. BATTERY DISCONNECT 9. Disconnect gray CAT5 cable for battery modules from underside of BMU.
  • Page 119 7. Connect 2-pin connector (C) and (if equipped) 3- pin connector (D). 013525 Figure 13-20. 8. Install two Phillips screws (B) holding the left side of the fan assembly to the PWRcell Battery frame. 013153 Figure 13-21. Diagnostic Repair Manual...
  • Page 120 Section 13 PWRcell Battery BMU Replacement 9. Fasten fan assembly and right side sheet metal cover with Phillips screws. 10. Land REbus wires on terminal block. 11. Connect battery string connector on top right side to BMU assembly. 12. Connect battery string connector into the DCB module where it was removed from.

  • Page 121: Enable Pwrcell Battery

    Section 13 PWRcell Battery BMU Replacement 16. Connect the battery string connector on the right side of PWRcell Battery frame. It is behind the REbus terminal blocks. 013149 Figure 13-25. 17. Connect DC connector on battery module. 013147 Figure 13-26.
  • Page 122 1. Locate the PWRcell DC Disconnect that the battery is landed on and turn to ON position. 013144 Figure 13-28. 2. Locate PWRcell Battery master switch on top left corner of frame. Turn to ON position. 013159 Figure 13-29. 3. Locate Generac PWRcell Battery page on inverter control panel.
  • Page 123 PWRcell Battery will close its contactors and display ‘battery connected.’ 013162 Figure 13-32. The PWRcell Battery will then go to ‘standby’ if it is ready to function. NOTE: Depending on available PV energy and system mode selected for PWRcell system, the PWRcell Battery may start charging or discharging after entering standby.
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  • Page 125: Section 14 Frequently Asked Questions

    Energy Storage System, there are some practical implications that might not make such a solution A: No, the PWRcell battery is designed to work only with viable (e.g. only the PV modules and racking would the Generac PWRcell Inverter. This ensures the best be reusable, the upgrade may nullify existing PPAs customer experience.
  • Page 126 2 battery cabinets for a total usable capacity of 36 kWh of energy. Maintenance Q: How many hours or days can the PWRcell Energy Storage System provide power without needing Q: What is the recommended maintenance for the to be recharged?

  • Page 127: Appendix A Definitions

    Power Line Modem Protected loads House or building loads that will be isolated from the grid and energized by the PWRcell system during an outage. Abbreviation for photovoltaic. Commonly used as shorthand to describe power from solar panels.
  • Page 128 Appendix A Definitions SnapRS Normally open frequency controlled switch used to achieve module-level shutdown for the PVRSS String One REbus home run and up to three paralleled substrings (three PV Links each with their own substrings connected in parallel to one home run). Substring A grouping of solar modules wired to the PV input of one PV Link Open circuit voltage...

  • Page 129: Appendix B Inverter

    Menu System Navigation Inverter LED Inverter LED (D) communicates the status of the utility The PWRcell system is controlled through the PWRcell grid and / or inverter through LED color and state. inverter control panel. The inverter control panel is used...
  • Page 130 1,500 – 3,000 Turns 1,500 Allows a different turns ratio to be set for specific CTs. Select 1 if using SMM devices to shed loads. Select 2 if using the PWRcell EnaLoadShed 0 / 1 / 2 ATS Controller to shed loads (with or without SMMs).

  • Page 131: Commissioning The System

    REbus-powered devices. In this way, tems steps 1-8. a PWRcell inverter behaves like a master device. If two Modify the PWRcell inverter PLM Channel to 0. or more master devices are communicating on the same NOTE: PLM Channel 0 is a catchall channel. Only use...
  • Page 132 PLM channel to the chosen channel (step 4) for that system. See device installation manual for specific instructions. Modify the PLM channel setpoint for the PWRcell inverter to match the PLM channel its REbus devices were set to in the previous step.

  • Page 133: Appendix C Cts

    Appendix C CTs Appendix C Table C-1. Automatic Detection Troubleshooting Table Event Name Event Code Description ct cal = 1 0x8061 Line 1 doesn’t have a valid CT calibration ct cal = 2 0x8062 Line 2 doesn’t have a valid CT calibration ct cal = 3 0x8063 Line 1 &...
  • Page 134 Appendix C CTs This page intentionally left blank. Diagnostic Repair Manual...

  • Page 135: Appendix Dpv Link

    Appendix D PV Link PV Link Appendix D Table D-1. PV Link Settings Setpoint Range Default Description Channel for REbus communications. All devices in a PLM Channel 1-12 system must use the same channel (except REbus Beacon). Minimum input voltage from the PV substring for the Vin Startup 60-135 Volts PV Link to make power.
  • Page 136 Appendix D PV Link This page intentionally left blank. Diagnostic Repair Manual...

  • Page 137: Appendix E Battery

    Appendix E Battery Battery Appendix E Table E-1. Battery Settings Setpoint Range Default Description Channel for REbus communications. All PLM Channel 1-12 devices in a system must use the same channel (except REbus Beacon). Minimum state of charge (SOC) absolute. MinSoCAbs 0-20% This is the percentage of charge the battery...

  • Page 138: Battery Status Led

    Appendix E Battery Battery Status LED Table E-2. Battery Status LED (On Battery Cabinet) LED Color / Interval Battery Status Orange, solid Disabled  Orange, strobe (2s) Waiting  Green / Orange, alternating Initializing  Green, solid Charging  Green, rapid blinking (0.5s) Discharging ...

  • Page 139: Battery Wiring Sequence Diagrams

    Appendix E Battery Battery Wiring Sequence Diagrams Gray CAT5 Blue CAT5 Orange CAT5 Black CAT5 Jumpers Empty Com Out Port 000000 Figure E-3. Battery Comms Wiring Diagram - 5 DCBs 000000 Figure E-1. Battery Comms Wiring Diagram - 3 DCBs 011875 Figure E-2.
  • Page 140 Appendix E Battery BLACK Contactors Snubber Battery String I/O Switch Black-start battery G R B REbus 380v DC REbus cable entrance Module Cat 5 COMs Cable Front Module Spacer Module 2 Module 1 Module 3 Back 009945 Figure E-5. Battery Power Wiring Diagram - 3 DCBs BLACK Contactors Snubber...

  • Page 141: Vset To Equalize Battery Module Voltages

    'Save' changes. Improper cell balance leads to lower power capacity of a From the PWRcell Battery device page, press the PWRcell system. When adding a new battery module to center button. an existing PWRcell system all of the module voltages Select 'Start Vset' from the PWRcell Battery main must be equalized.
  • Page 142 Appendix E Battery This page intentionally left blank. Diagnostic Repair Manual...

  • Page 143: Appendix F State And Event Codes

    Display texts for states will be steady and viewable on the inverter device page at the inverter control panel, unless listed below as transient. Refer to diagnostic procedures in the right most column as necessary. Refer to the inverter section of the PWRcell Diagnostic Repair Manual for detailed descriptions of diagnostic procedures. If unable to resolve functionality, please call PWRcell Technical Support at 1 (855) 635-5186.
  • Page 144 CTs but is configured to enforce Export Override, which requires CTs 0x7710 Bad Reset Steady Error The inverter experienced a bad - Contact PWRcell Technical Error reset error after losing power or Support updating firmware Diagnostic Repair Manual...
  • Page 145 0x9000 interrupt fault Error Attempt to power cycle the inverter. If persistent, contact PWRcell Technical Support. 0x9200 int. timer fault Error Internal processor issue. Contact PWRcell Technical Support. 0x9300 mux Stuck Error Internal processor issue. Contact PWRcell Technical Support. 0x932A...
  • Page 146 Appendix E State and Event Codes Table F-2. Inverter Events Code Display Severity Description 0x932D relay fault Fault (Low) The grid frequency went out of spec while the inverter was trying to drive the relays active, this can happen with grid outages.
  • Page 147 Fault (Med) The inverter was unable to determine whether the connection on line 2 was open or closed. 0xE100 EEPROM failure Error Internal processor issue. Contact PWRcell Technical Support. 0xE200 FLASH fault Error Internal processor issue. Power cycle inverter. If persistent, contact PWRcell Technical Support.

  • Page 148: Generac Pv Link™ State And Event Codes

    Refer to diagnostic procedures in the right most column as necessary. Refer to the PV Link and SnapRS™ section of the PWRcell Diagnostic Repair Manual for detailed descriptions of diagnostic procedures. If unable to resolve functionality, please call PWRcell Technical Support at 1 (855) 635-5186.
  • Page 149 (Low) time. - Check PV Link Settings 0x5120 PVRSS fail: low Transient Fault PV Link unable to read array - If persistent call PWRcell input (Low) substring voltage. Will lead to Technical Support “low sun” to state. 0x5130 PVRSS count...
  • Page 150 Appendix E State and Event Codes Table F-3. PV Link States Code Display Text Transient/ Severity Description Diagnostics Steady 0x7010 input over Steady Error PV Link input voltage was - Check PV Panel Config. voltage measured high out of range. - Check PV Wiring - Measure Substring Voltage 0x7300...

  • Page 151: Pv Link Events

    The hardware version in configuration does not match with the hardware version version of device firmware mismatch 0x900A interrupt fault Fault May indicate an internal processor issue. Contact PWRcell Technical Support. (Med) 0x9900 transistor Error Damage to the internal switching mechanism has occurred. Contact PWRcell failure Technical Support.
  • Page 152 PV Input overvoltage, voltage measurement is sampled fast. Unit will disconnect voltage (High) from PV input and timeout for 1 minute before trying again. 0xE100 EEPROM Error Internal processor issue. Contact PWRcell Technical Support. failure 0xE200 FLASH fault Error Internal processor issue. Contact PWRcell Technical Support. 0xF000...

  • Page 153: Pwrcell™ Battery State And Event Codes

    Valid for HW Versions 1217, 12171 FW Version 12940 Battery States Display texts for states will be steady and viewable on the PWRcell Battery device page at the inverter control panel, unless listed below as transient. Refer to diagnostic procedures in the right most column as necessary. Refer to the PWRcell Battery section of the PWRcell Diagnostic Repair Manual for detailed descriptions of diagnostic procedures.
  • Page 154 Fault False positives may be associated with turning the battery disconnect switch off (Med) while running, otherwise may indicate an internal processor issue. Contact PWRcell Technical Support. 0xA100 over temp Fault The B-Link measured a high temperature shutdown...
  • Page 155 Current input or output for the battery exceeded its limit current (Med) 0xC502 input high Fault Battery voltage has exceeded limit (Med) 0xE601 Bad reset error Fault B-Link internal processor issue. Contact PWRcell Technical Support if persistent. (Low) Diagnostic Repair Manual...
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  • Page 158 ©2022 Generac Power Systems, Inc. S45 W29290 Hwy. 59 All rights reserved. Waukesha, WI 53189 Specifications are subject to change without notice. 1-888-GENERAC (1-888-436-3722) No reproduction allowed in any form without prior written www.generac.com consent from Generac Power Systems, Inc.

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