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1111
Commissioning
the Apollo Solar Cabinets
Apollo Solar, Inc.23 F. J. Clarke Circle
Bethel, Connecticut 06801
USA
+1 203 790-6400
www.ApolloSolar.com
2
SAFETY FIRST
WARNINGS:
The Apollo Solar Cabinet is energized by multiple sources.
Turn OFF all sources of power before working in the cabinet.
Lethal Voltages inside Cabinets.
Use insulated tools.
Wear insulating gloves.
3
APOLLO SOLAR – REMOTE ENERGY SYSTEM – SYSTEM WIRING DIAGRAM
VOLTAGE SENSE +
VOLTAGE SENSE -
SYSTEM POWER +
SYSTEM POWER -
TEMPERATURE SENSEBATTERY +48V
BATTERY -48V
GSM ANTENNA
FOR MODEM
OUTSIDE OF
CABINET
6 ALARM OUTPUTS
PAIRS OF DRY
CONTACTS
EARTH
GROUND
PV THEFT ALARM
This wire is stitched through the frame
of every PV module. Breaking the wire
triggers the alarm.
End-of-Life switch on MOVs in the
Combiner Box are wired in series.
Any MOV can trigger an alarm.
PV INPUTSEXT ALARM
INPUTS
PV INPUTS TO THE T80HV CHARGE
CONTROLLERS ARE 75V TO 180V
AT 50 AMPS MAX EACH
GROUNDING NOTE:
The PV Array Frames and the Racking System
must be tied directly to Earth Ground.
The Combiner Box Ground should run with the
power wires back to the Charger Cabinet.
SYSTEM
EARTH
GROUND
48V DCESSENTIAL
LOADS 50A
NON-ESSENTIAL
LOADS 50A
AA
AB
AF
AG
PT
UV
AH
AI
AJ
AK
M N J K
GH
AD
AE
70
S1 S2S3 S4+ - + - + -
EC
FC
MOV EOL
PV THEFT ALARM
48 VOLT BATTERY BANK
WITH 2 STRINGS OF BATTERIES
BY OTHERS
APOLLO
IRRADIANCE
SENSOR AT
PV ARRAY
BATTERY BREAKER TRIPPED
LOAD BREAKER TRIPPED
LOW BATTERY VOLTAGEHIGH CABINET TEMPERATUREHIGH BATTERY VOLTAGEHIGH BATTERY TEMPERATURE
XS
+RED
-BLACK
GN
D
+ -P
AIR
OF
AW
G 4
/0
PA
IR O
F A
WG
4/0
+ - + -
APOLLO PVT
CABINET
+ -+ -+ - + -APOLLO TEMP
SENSOR ON
SIDE OF
BATTERY
250A
BATTERY
BREAKERS BK
48 VOLT 10kW
RECTIFIER
BY OTHERS48V DC
48V DC
+
-
+
-
+
-230VAC
NEUTRAL
GROUND
GROUND
230VAC 50Hz
DIESEL
GENERATOR
BY OTHERSBJ
CONTACT CLOSURE TO START GENERATORG
ND
PV ARRAY
APOLLO COMBINER
BOX WITH SURGE
PROTECTION DEVICE
PV ARRAY
APOLLO COMBINER
BOX WITH SURGE
PROTECTION DEVICE
PV ARRAY
APOLLO COMBINER
BOX WITH SURGE
PROTECTION DEVICE
PV ARRAY
APOLLO COMBINER
BOX WITH SURGE
PROTECTION DEVICE
23 F. J. Clarke Circle
Bethel, Connecticut 06801
USA +1 203 790 6400
www.ApolloSolar.com
27-MAR-2017 J. PFEIFER
ENERGY SYSTEM BLOCK DIAGRAM
REV 1
WITH HYBRID SOLAR / DIESEL OPTION
RECTIFIER
INPUT
GN
D
GN
D
GN
D
4
Commissioning - Overview
Commissioning is the final and MOST CRITICAL Quality Control step for the Installation Company.
Thorough Commissioning assures Safety and Performance of the Tower Energy System.
The Commissioning Report is often the key deliverable to trigger payment from the Mobile Carrier.
The Commissioning Report establishes the baseline for all maintenance and support in the future.
Apollo Solar reserves the right to request copies of all Commissioning Reports to help us protect the
reputation of the equipment which we manufacture.
1. Verify that applicable equipment and systems are installed according to the contract
documents, manufacturer’s recommendations and industry accepted minimum standards.
2. Verify that the energy system meets the requirements of the end-user / customer.
3. Verify that installing team performs adequate operational checkout.
4. Verify and document proper performance of equipment and systems.
5. Verify that the operations and maintenance (O&M) documentation left on-site is complete.
6. Verify that the owner’s operating personnel are adequately trained.
COMMISSIONING TASKS:
These major categories must be verified in addition to the detailed checklist.
THE PURPOSE OF COMMISSIONING:
5
Commissioning – Check List
1. Verify that the installation is complete, safe and done with good workmanship.
2. Verify that all components of the installation are robust and permanent.
3. Document as-built conditions including PV Module Outputs, Battery Voltages and Torques.
Suggested tables for these items and photos of test point locations are included in this presentation.
4. Verify system performance against established benchmarks.
5. Verify complete and proper system operation.
6. Complete all required acceptance documentation for the system owner.
The Commissioning should be done by someone other than those who wired the system.
The Commissioning party must have the authority to ask for errors to be corrected and retested.
Measurements of the PV Array should be done when there is irradiance of greater than 400 W/m2.
Allow enough time to do a complete job.
Do not try to squeeze the Commissioning in at the end of the day.
Now that the Purposes and Concepts are clear, we will go over the detailed checklist.
Each Installation Company will have an established Commissioning Procedure. Apollo Solar is not
trying to change that procedure, but simply highlighting details that are specific to the Apollo equipment.
GENERAL RULES:
6
Commissioning – Tools RequiredA typical set of tools required for Commissioning of the Apollo Solar remote energy system includes:
Insulated Torque Wrench (1.5 to 22 N-m) with bits to fit the following bolts or screw heads:
Phillips head screws
Slotted head screws
8mm Allen head screws
½” and 9/16” Socket for hex head bolts
DC Voltmeter – Handheld digital multi-meter which can read up to 250 volts DC
Ammeter – Handheld digital multi-meter with a clamp-on DC current probe for up to 500Amps
Irradiance Meter – Handheld meter with readout in Watts/m2 See suggested meters below.
Both of these Irradiance meters are available on line from Tequipment.net.
The Seaward Solar Survey 100
Price: $345
In addition to Irradiance, it can
be used to measure ambient
temperature and PV module
temperature.
The TPI Solar Irradiance Meter
Price: $125 to $150
Low cost meter for Irradiance.
Knipex Electrician's Insulated
Torque Wrench $480.
7
Commissioning
REMOTE ENERGY SYSTEM - COMMISSION REPORT
LOCATION:
DATE:
BATTERY TESTING - ALL CHARGING AND LOADS DISCONNECTED FOR AT LEAST 1 HOUR
INITIAL VOLTAGES OF CELLS
STRING NUMBER: 1 STRING NUMBER: 2 STRING NUMBER: 3 STRING NUMBER: 4
CELL
NUM
CELL
VOLTAGE
CELL
NUM
CELL
VOLTAGE
CELL
NUM
CELL
VOLTAGE
CELL
NUM
CELL
VOLTAGE
1 1 1 1
2 2 2 2
3 3 3 3
4 4 4 4
5 5 5 5
6 6 6 6
7 7 7 7
8 8 8 8
9 9 9 9
10 10 10 10
11 11 11 11
12 12 12 12
13 13 13 13
14 14 14 14
15 15 15 15
16 16 16 16
17 17 17 17
18 18 18 18
19 19 19 19
20 20 20 20
21 21 21 21
22 22 22 22
23 23 23 23
24 24 24 24
COMMISSION BY:INSTALLATION BY:
REMOTE ENERGY SYSTEM - COMMISSION REPORT
LOCATION:
DATE:
COMMISSION BY:
PV ARRAY TEST DATA
SUB-
ARRAY
STRING
NUMBER
STRING
VOLTAGE
IRRADIANCE
VALUE
ARRAY
TEMPERATURE
MODULE 1
VOLTAGE
MODULE 2
VOLTAGE
MODULE 3
VOLTAGE
1 1
1 2
1 3
1 4
1 5
1 6
2 1
2 2
2 3
2 4
2 5
2 6
3 1
3 2
3 3
3 4
3 5
3 6
4 1
4 2
4 3
4 4
4 5
4 6
INSTALLATION BY:
SUGGESTED COMMISSIONG FORMS FOR PV ARRAYS AND BATTERIES
Verify that the polarity is correct for every voltage measurement.
8
Commissioning – Torque Values
Verify that each high current terminal is tightened to the torque value specified in the chart.
APOLLO SOLAR - PVT GEN4 PANELS - PRODUCTION QUALITY ASSURANCE - CRITICAL TERMINAL TORQUE TEST
The torque of all high current terminals are measured and must meet the specified torque +/- 10%.
DEVICE LOCATION TERMINALS TOOL NUMBER OF TORQUE TORQUE INSTALL CHECK
TERMINALS N-m in-lbs BY BY
DC Surge Protector Bottom edge of panel + and - Slotted Screw 2 1.5 13.3
DC Surge Protector Bottom edge of panel GND Slotted Screw 1 2.3 20
T80HV Charge Controller Master & 1 to 3 Slaves Ground Lugs on Heat Sink Slotted Screw 1 on each T80HV 2.3 20
Circuit Breakers 100A and 50A, 250V Both Ends Slotted Screw 4 to 8 2.3 20
Circuit Breakers All single pole breakers Both Ends Phillips Screw 6 to 12 2.3 20
T80HV Charge Controller 1 to 4 units Gnd Wire to Chassis Ring Phillips Screw 1 on each T80HV 2.3 20
PV Input Terminals Right side of panel Top Ends Slotted Screw 2 per PV string 4.5 40
Earth Ground Bus Bar Bottom edge of panel Slotted Screw 4.5 40
48 volt Bus Bars Positive & Negative Small gauge screws Slotted Screw Many 4.5 40
T80HV Charge Controller 1 to 4 units PV IN & BATT OUT Lugs Slotted Screw 4 on each T80HV 5.6 50
Contactor - 160A, Latching Center of panel M8 x 1.25 Studs 1/2" Socket 2 to 6 9.5 84
250A Battery Circuit Breakers Lower center of panel 8mm Hex drive box lugs 8mm Allen Hex 2, 4 or 6 20.3 180
500Amp Shunt Tied to Neg 48V bus bar 3/8" brass hex head bolts 9/16" Socket 2 21.7 192
48 volt Bus Bars Positive & Negative 3/8" brass hex head bolts 9/16" Socket 1 to 3 21.7 192
Shunt Bus Bar Bolted to Shunt 3/8" brass hex head bolts 9/16" Socket up to 4 21.7 192
SIGNATURES DATE PANEL S/N DATES:
SIGN-OFF BY PRODUCTION TECHNICIAN
SIGN-OFF BY QUALITY ASSURANCE SUPERVISIOR
9
Commissioning Procedure – The PV Inputs
• CAUTION – During this procedure you will be working
around live conductors carrying lethal voltages.
Accuracy to +/- 1 volt is
sufficient. The PV Open
Circuit Voltages must be
between 75 volts and
180 volts.
PV ARRAY COMMISSIONING
1. Measure and record the Irradiance
before and after each step below.
2. In the Combiner Box, turn all the
Circuit Breakers ON. Measure and
record the Output Voltage of each
Combiner Box.
3. Turn all the Breakers OFF. Measure
the Open Circuit Voltage for each PV
string at the bottom of the circuit
breakers. Turn the breakers back ON.
4. In the Apollo cabinet, turn all the PV
Input Breakers OFF. With sun on the
PV array, carefully measure the DC
voltage at the PV Input Connectors.
Record each PV input separately.
PV-
AW
G 1
0
AW
G 6
AW
G 4
SU
RG
E
PR
OT
EC
T
ON
250V
16A
ON
250V
16A
ON
250V
16A
ON
250V
16A
ON
250V
16A
COMBINER BOX
Measure PV Open
Circuit Voltage for
each string with
Breakers OFF.
Measure Voltage
from each Combiner
with all Breakers ON.
+
+
-
-
10
Apollo Solar Gen 4 Power-Up Procedure
Warning to Prevent Damage
ALWAYS TURN THE BATTERY POWER TO THE T80HV CHARGE CONTROLLERS
ON BEFORE TURNING ON THE PV INPUTS.
ALWAYS TURN THE PV INPUT OFF BEFORE TURNING THE BATTERY POWER
OR THE T80HV OUTPUT CIRCUIT BREAKERS OFF.
The T80HV Charge Controllers in this product operate from the battery power. The
microprocessors inside the T80HV must have voltage applied so they can control the
FETs which switch power from the PV input. If the PV input power is allowed into
these FETs without the T80HV circuitry running from battery power, the FETs can
be damaged. This damage is NOT covered by the warranty.
Schematic Drawing of the
Apollo Hybrid Energy Cabinet
This Schematic represents a 2X
Cabinet. The 3rd and 4th T80HVs
are simply added to the space
between the other two.
This drawing shows the
reference designators for all the
parts and the numbers of each
wire.
EARTH GROUND BUS
Copyright 2015, 2016, 2017 Apollo Solar, Inc.
ALL INFORMATION ON THIS DRAWING
IS CONFIDENTIAL AND PROPRIETARY
TO APOLLO SOLAR, INC.
APOLLO SOLAR - GEN4 HYBRID SYSTEM – BLOCK DIAGRAM
EARTH
GROUND
PV ARRAY
FRAME SERIES
WIRE
APOLLO
BATTERY
TEMPERATURE
SENSOR
500A
SHUNT
AUX
CONTACTS
FOR MOV
END OF
LIFE
ESSENTIAL
LOADS
50A MAX
ALL CIRCUIT BREAKERS ARE
IEC / EN 60947-2 LISTED
NEG BUS
POS BUS
BU
S B
AR POSITIVE
GROUND POINT
A
71
CB
5
72
COM
N.C.
ANY PC
SERVER WITH
APOLLO
SOFTWARE AND
DATABASE
CB
2
BA
TT
ER
Y
HIG
H T
EM
P
EN
CL
OS
UR
E
HIG
H T
EM
P
DRY
CONTACT
ALARM
OUTPUTS
13
7
14
0
13
9
13
8
ASNET
CAT5
98
850 or
900MHz
EXT
ANTENNA
A2-
A1+
A2-A1+
12
24
14
2221
11
16
0A
LA
TC
HIN
G
CO
NT
AC
TO
R
RY6RY7
A
CB
18
LOAD
BKR
TRIP
ALARM
BATTERY
BREAKER
TRIP ALARM
BA
T T
RIP
AL
AR
M
1
2+
40
A2-
A1+
A2-A1+
12
24
14
2221
11
16
0A
LA
TC
HIN
G
CO
NT
AC
TO
R
RY4RY5 124
125
6869
70
144
145
146
155
154
149
SURGE PROTECTOR
DEVICES WITH AUX
CONTACTS ON MOVS IN
COMBINER BOXES
TO
AD
DIT
ION
AL
AL
AR
M O
UP
UT
S
PV ARRAY
EARTH
GROUND
MO
Vs
PV
AR
RA
Y
1
29
24V
24V
RETURN
A
C
CO
NN
EC
TIO
NS
TO
2N
D
CA
BIN
ET
IF
RE
QD
147
EARTH BUS
IRRADIANCE
SENSOR
X S
4/0
BU
S B
AR
95m
m2
APOLLO
SHUNT
BOARD
24V
RE
TU
RN
122
FE
68
69
5 A
MP
FU
SE
S
NON-ESSENTIAL
LOADS
50A MAX
13
51
36
CC
DO
OR
SW
ITC
H
TW
IST
ED
PA
IR
MO
Vs
PV
AR
RA
Y
5 VDC
REGULATOR
A
C
24V
5V
GSM +WiFi
GATEWAY
WiFi
ANT
A
C
24V
APOLLO SYSTEM CONROLLER
SD
US
B
US
B
RS
48
5
TW
IST
ED
PA
IR
BLUE
DATA-
FROM IRR
SENSOR
BLU/
WHT
DATA+
13
61
35
79A
79B
13
41
33
USB
ETHERNET
CAT5
24V A
D
A
C
RS
48
5
ALARM
INPUTS
EF CCJ K
M N
BATTERY
48 VOLTS
BATTERY
48 VOLTS
PARALLEL BATTERY STRINGS
AJ
AK U V
250A
BREAKER
ON EACH
BATTERY
STRING
47
2/0
CO
MN
.C.
AU
XC
OM
N.C
.T
RIP
CO
MN
.C.
TR
IPC
OM
N.C
.A
UX
67
CB
20
CB
21
6
163162
AA
AB
23 F. J. Clarke Circle
Bethel, Connecticut, 06801
USA +1 203 790-6400
www.ApolloSolar.com
6-MAR-2017 J. PFEIFER
REV 62
GEN4 POS GND HYBRID BLOCK DIAG
SOLENE – GUINEA CONAKRY
11
14
CIT
EL
48V
MO
V S
PD
150
AF
AG
15
7
15
6
44
ON
16A
ON
63A
ON
32A
UP
TO
5 L
OA
D
BR
EA
KE
RS
TO
TA
L
ON
16A
ON
63A
ON
32A
UP
TO
5 L
OA
D
BR
EA
KE
RS
TO
TA
L
DC
DISTRIBUTION
BREAKERS
ON
16AC
24V
RETURNC
8 CH
24BIT A/D
CONV
130 DATA-8
129 DATA+7
.1u
f
10
0o
hm
IN 0-
IN 0+12
1124V
141A
9PW+
24V
RETURN
142C
GND 10
IN 7+
IN 7- 6
5
IN 6+
IN 6- 4
3
IN 5+
IN 5-
1
2
IN 4+
IN 4- 19
20SPARE
AMBIENT
TEMP SENSOR
TO
LE
M C
UR
RE
NT
SE
NS
OR
S
PV ARRAY
APOLLO
COMBINERSPD
APOLLO SOLAR
T80HV MPPT
CHARGE
CONTROLLER
MASTER
CB
11
81
84 83
88
CB
10
82
87
85
ON
125VDC
100A
AP
OL
LO
50A
MP
SP
D
ON
63A
250V
PV ARRAY
APOLLO
COMBINERSPD
APOLLO SOLAR
T80HV MPPT
CHARGE
CONTROLLER
SLAVE 1
CB
13
91
94 93
88
CB
12
92
97
95
ON
125VDC
100A
AP
OL
LO
50
AM
P S
PD
ON
63A
250V
22
DIGITAL I/O
8 DRY CONTACT
INPUTS,
8 OPEN COLL
OUTPUTS
26
25
24
2117
16
15
27
DO 2
DO 3
DO 4
DI 0
DI 1
DO 0DO 1
DO 5
DI 4
DI 3
DI 2
DI 5
+VsDATA+ DATA-
GND
DO 6
DI 7
DO 7
DI 6
SPARES
D.GND
DO
COM
7
19131 132
23 126
C
24V
RETURN
22
18
INTERNET
INTERNET
LAPTOP
WiFi
LOCAL
GSM
TOWER
IN 3+18243
IN 3-17246
IN 2+16239
IN 2-242 15
IN 1+14235
IN 1-13238
41
LOAD1
LOAD2
DG INSPARE
DG V
SENSEZ
Y
63
A2-
A1+
A2-A1+
12
24
14
2221
11
16
0A
LA
TC
HIN
G
CO
NT
AC
TO
R
RYRY
ON
125VDC
100A
48VDC
INPUT FROM
RECTIFIER
100A MAX
2+
CIT
EL
48V
MO
V S
PD
TO A/D
CH6-
PIN4
19K
1K
A
2
1
43
ON
63A
250VOF
14
12
11
AU
X D
OF
14
12
11
AU
X C
ON
63A
250VOF
14
12
11
AU
X B
OF
14
12
11
AU
X A
35
621
C
22
4
3
HIGH BAT
VOLTAGE
LOW BAT
VOLTAGEALARM DRY CONTACTS
16
0
16
1
15
8
15
9
P T AH AI
AUX1 AUX2
TO AUX RELAYS
ON T80HV SLAVE 1
A2-A1+
12
24
14
2221
11
GEN START
A
24
7
24
8
249 250
BK
BJ
RY
10
255
256
257
260
259
258
230
231
123
261
261
26
2
263
23
2
234
ISO
LA
TE
D
24
V D
C
SU
PP
LY
233
233
A1+A1+
A2-A2-
2+
1
LEM 235
+5V
CA/D14
237
236LEM 243
244
245 +5V
CA/D18 LEM 239 A/D16
+5V
C240
241
89
7989
ASNET CAT5 79
.1u
f
256
CF
CE
CD
LM35
25
3
+5V
252
251
+4
8V
BU
S-4
8V
BU
S 20
A2-A1+
12
24
14
2221
11
48V FANS
A
37
64
Q R
RY
3
66 FUSE
38
FANS AND GEN START
ARE OPTIONS
230
264
Apollo Hybrid Energy System
Assembly Drawing
This drawing is the Panel in the Gen4 Cabinet
showing all available options. Your panel may be
simplified.
The key Voltage Measurement points are called
out.
12
A2
A1
LO
AD
2
12
A2
A1
LO
AD
1
12
A2
A1
RE
CT
IFIE
R
INP
UT
175
mm
ALARMS
ALARM OUTPUTS
DO
OR
CO
MM
ON
BA
T B
RE
AK
ER
16
21
63
AA
AB
LO
AD
BR
EA
KE
R1
57
15
6A
FA
G
LO
W B
AT
VO
LT
15
81
59
P T
CA
BIN
ET
TE
MP
13
91
40
U V
HIG
H B
AT
VO
LT
16
01
61
AH
AI
BA
T H
IGH
TE
MP
13
71
38
AJ
AK C
12
61
8D
DL
AH
-24
s
s
EQP
LINE
+ -IR
RA
DIA
NC
E
SE
NS
OR
X S13
613
5
DL
AH
-24
s
s
EQP
LINE
ALARM
INPUTS
CO
MM
ON
DL
AH
-24
s
s
EQP
LINE
F CP
V A
RR
AY
MO
Vs
CO
MM
ON
16
17
C C6 5
+ -
BA
TT
ER
YF
US
EF
US
E6
96
8NM
67
63
KJ
+ -
BA
TT
ER
Y
TEMP
SENSOR
25
22
51
CE
CF
25
3C
D
150
mm
150
mm
175
mm
12
0m
m
+ - + - + - + -
MA
ST
ER
T80
HV
SL
AV
E 3
T80
HV
SL
AV
E 2
T80
HV
SL
AV
E 1
T80
HV
UP TO AWG 0,
50mm20
.0m
m
DA
TU
M
BATTERY WIRES ARE 4/0 or 95mm2
EA
RT
H
GR
OU
ND
INPUTS FROM
PV COMBINER
BOXES
44
0m
m
71
AWG
#8
560mm
930mm
+ -
BAT 1
+ -
BAT 2+ -
BAT 3
24
VO
LT
2.1
AM
P
PO
WE
R S
UP
PL
Y
46
3
47
15
0
NON ESSENTIAL
LOADS
50A TOTAL
43
43
14
9
41
14
7
621
35
15
6
15
7
35
PV
IN
BAT
OUT GND
TurboCharger
T80HV
MASTER
79
82
83
71
88 PV
IN
BAT
OUT GND
TurboCharger
T80HV
SLAVE 1
PV
IN
BAT
OUT GND
TurboCharger
T80HV
SLAVE 2
10
8
10
5
10
4
PV
IN
BAT
OUT GND
TurboCharger
T80HV
SLAVE 3
11
8
+48V IN-48V IN
GND-24V OUT
+24V OUT
34
21
40
14
6
85
95
10
51
07
11
71
15 11
4
10
4
94
84
85
89
13
71
38
14
01
39
95
94
89
99
92
93
98
10
2
10
3
11
2
11
4
11
3
11
5
99
16
11
60
15
91
58
93103
113
83
81
82
91
92
10
2
10
1
11
1
11
2
TO 1, 2 OR 3 PARALLEL STRINGS
OF BATTERIES
450mm
14
9
GND
TO
BATTERY
10
9
10
9
GSM ANT WiFi ANT
44
38
A
NOTE: DLAH SURGE PROTECTORS
WILL TAKE AWG14 (2mm) WIRES.
21T AWG8
21T AWG8
21T AWG8
21T AWG8
20
KA
MO
V
20KA
MOV
20
KA
MO
V
20
KA
MO
V
20
KA
MO
V
20KA
MOV
20
KA
MO
V
20
KA
MO
V
20KA
MOV
20
KA
MO
V
20
KA
MO
V
20KA
MOV
1222
1121
1424
A1A2
LO
AD
125
29
122
125
124
26
1222
1121
1424
A1A2
23
155
154
145
144
24 7
2
DS
23
0S
-
48
DC
SP
D
RE
CT
IFIE
R +
48V
DC
IN
-
12 22
11 21
14 24
A1 A2
RY3
FA
N
RE
LA
Y20
37
38
64
BA
T T
EM
P S
EN
SO
R
B/W BLU
E7
9ZY
131
132
79A
79B
133
134
129
130
TWISTED
PAIR
69
68
174 172 171 170 169173
41
147
144
5V
RE
G+
24
GN
D+
5V
12
3
66
235236237
239240241
12 22
11 21
14 24
A1 A2
RY10
GE
N
ST
AR
T
247
248
249
25
0
C C A AC A
15
27
B
155
29
154
37
2
141
B C
12
2
B
142
C
164
165
168
238
236
240
244
24
224
6
237
241
245
170
16
9169
16
77
19
166
168
17
0
A247
252
254
25
3
23
0
23
0
1222
1121
1424
A1A2
256
255
257
258
259
260
TO
A/D
243244245
97
255
257
259
258
264
126
1
LO
AD
2
RE
CT
IFIE
R
INP
UT
+ -
87
ON
125VDC
100A
ON
125VDC
100A
23
02
31
23
1
23
32
33
DS
23
0S
-
48
DC
SP
D
ESSENTIAL
LOADS
50A TOTAL
23
2
23
4
425
mmON
125VDC
100A
DG IN
72
ON
6A
80V
24V
CB2
HESSENTIAL
LOADS
ON ON ONON ON
63A
250V
63A
250V
32A
250V32A
250V16A
250V
H
ON ON ONON ON
63A
250V
63A
250V
32A
250V32A
250V16A
250V
NON-ESSENTIAL
LOADS
LEM
14
6
146
LEM
40
40
LE
M
AE
10 DC DISTRIBUTION BREAKERS
48
V F
AN
S6
6
64
Q RF
US
E
ON
63A
250V
ON
63A
250V
ON
125VDC
100A ON
63A
250V
ON
63A
250V
ON
125VDC
100A
OF
14
12
11
ON
63A
250VOF
14
12
11
CB5 OUT
OF
14
12
11
ON
63A
250VOF
14
12
11
CB18 OUT
12
3
A/D CONV IS UNDER THE ADAM
DIGITAL I/O
DI C
OM
DI
1
DI
0
D.G
ND
DO
7
DO
6
DO
5
DO
4
DO
3
DO
2
DO
1
DO
0
DO
CO
M
DI C
OM
DI 2
DI 3
DI 4
DI 5
DI 6
DI 7
N/A
INIT
*
DA
TA
+ (
Y)
DA
TA
- (G
)
+V
s R
GN
D (
B)
23
207
22
21
25
26
19
18
17
16
27
15
132
13
12
4
RS485
248
260
25
6
ETH
Apollo System Controller
SD
US
B
US
B
ETH
USB
5V
RS
48
5134
133
TW
IST
ED
PA
IR
201
GSM MODEMSIM
24V166167
164165
145
124
125
NEG
BUS8
4
500A
DG
ST
AR
T/S
TO
PB
JB
K2
50
24
9
POS BUS7
0
26
32
61
26
2
35
0V
A IN
VE
RT
ER
2/0
2/0
2/0
702/0
2/0
2/0
PV Input Voltage from Combiner Boxes
Battery Voltage at Panel
The PV Input Breakers must be turned OFF
until battery voltage is applied to the T80HV
Charge Controllers.
13
Inside the Apollo Solar Cabinet
SOLAR CHARGE CONTROLLERS
The cabinet will support up to 4 T80HVs
at 4kW of PV each.
APOLLO SYSTEM CONTROLER –
The ASC provides smart control of all
power sources and distribution along with
the Remote Monitoring.
CIRCUIT BREAKERS – Hydraulic-
Magnetic Circuit Breakers are immune to
ambient temperature.
BATTERY BREAKERS – Multiple poles
are provided for parallel battery stacks.
EXTERNAL WIRES AND GLANDS –
Easy field wiring to well labeled terminals.
14
Apollo Solar Gen 4 Wiring Details
The DC Outputs to the
Essential Load and the
Non-Essential Load should
be measured at terminals
G/H and AD/AE.
The smaller terminals are used for
connecting the Irradiance Sensor,
the Alarm signals and the battery
voltage sense wires.
Terminals M and N from the battery
are fitted with 5 Amp automotive
type fuses.
The PV inputs have
screw type connectors
which will accept up to
AWG 2 wires from the
Combiner Boxes.
Torque the screws to
4.6 N-m (40 in-lbs).
The Earth Ground is a
single point with a
terminal strip to
connect to the
external Ground Rod.
Torque the screws to
4.6 N-m (40 in-lbs).
15
Apollo Solar Gen 4 Installation Details
The POSITIVE battery
cables are to the
POSITIVE BUS BAR.
The NEGATIVE battery cables
are to the LOWER TERMINAL
ON THE SHUNT.
The battery cables must be AWG 4/0 or 95mm2 for minimum
voltage drop. The terminals MUST be tightened with a
calibrated torque wrench 20.2 N-m (180 in-lbs.).
The Bus Bars are shown above with their covers removed.
The arrows point to their locations on the Gen 4 Panel.
16
Installation Details – Multi Cabinet Systems
The POSITIVE battery
cables terminate at the
POSITIVE BUS BAR.
The NEGATIVE battery cables
terminate at the lower terminals
on the Shunt Bus Bar.
The battery cables must be AWG 4/0 or 95mm2 for minimum voltage drop. The
terminals MUST be tightened with a calibrated torque wrench 20.2 N-m (180 in-lbs.).
The NEGATIVE BUS BAR
with terminals to connect to
additional cabinets
The 1000 Amp Shunt
Multiple Cabinet Systems are used when more then 4 T80HVs are required. The 1000 Amp
Shunt in the Master Cabinet provides high current terminals to connect to the Bus Bars in the
additional cabinets.
17
Gen 4 Wiring – 4X T80HV, 3 Battery Breakers
The 4 PV Combiner Boxes are connected
through the glands at the lower right to the
screw terminals marked for PV Inputs.
Torque the screws to 4.6 N-m (40 in-lbs).
Cables from the Batteries are connected
into the bottom of the Battery Circuit
Breakers.
Double check the Positive + and the
Negative – are correct.
Torque the Allen head screws to 20.2
N-m (180 in-lbs.).
FOR SAFETY, IT IS RECOMMENDED
THAT THE BATTERY SHOULD BE THE
VERY LAST CONNECTION MADE.
AFTER THE CABLES ARE CONNECTED TO THE BREAKER, THEN THE CABLES CAN BE CONNECTED TO THE BATTERIES THEMSELVES.
18
Inside the Mini Cabinet
One T80HV is shown with room for 2.
APOLLO SYSTEM CONTROLER – The ASC
provides smart control of all power sources and
distribution along with the Remote Monitoring.
BATTERY BREAKERS – A single pair of
250A breakers supports a single string of
batteries.
EXTERNAL WIRES AND GLANDS – Easy
field wiring to well labeled terminals.
GEN START RELAY – This is a HYBRID
system with a relay to start an external Diesel
Generator.
The Mini Cabinet provides the same features and
quality as the Standard Cabinet but with room for
only 2 Charge Controllers. It is designed for
systems with less than 10kW of PV array.
