OutBack Power SKYBOX Quick Start Manual

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Page 1

Quick Start Guide

Specifications

IMPORTANT:

Not intended for use with

life support equipment.

Contact Information

Mailing Corporate Headquarters

Address: 17825 – 59

Avenue NE Suite B Arlington, WA 98223 USA

Web Site: www.outbackpower.com

NOTE: Additional information on this product is available at www.outbackpower.com. For screen navigation, operation, and troubleshooting, see the SkyBox Overview Guide. For programming and applications, see the SkyBox Programming Guide.

Date and Revision

July 2018, Revision A

Listings:

o UL1778 5th Edition, 6/13/2016

o UL1741 2

Edition, 1/28/2010 with supplement SA

o CSA22.2, No. 107.1-01 Ed:3 (R2006)

Certifications:

o HECO Rule 14 SRD

o California Rule 21 SRD

o IEEE 1547-2003

o IEEE 1547.1-2005

System Grounding and Bonding:

In this product, the PV, AC, and battery circuits are isolated from the enclosure. This product has been evaluated, listed and identified by UL to meet the requirements of 690.41 and 250.4(A) of the NEC.

o The PV system ground reference and protection

is provided internal to the SkyBox, in accordance with NFPA 70 690.41(A)(6).

o The AC connections are not bonded to groun

e usual location for a neutral-ground bon

d is

at th

e main AC service panel. Make sure to

establish a neutral-ground bond wh

en installing

an off-grid application.

o The battery connection is not bonded to ground

Make sure to

establish a negative-ground bond for

each battery system.

Equipment grounding is required by Section 250 of the National Electric Code (ANSI/NFPA 70) and Canadian Electrical Code (C22.1).

Overcurrent Protection

o The battery disconnect device in the BOS does not

provide overcurrent protection. The installer must provide protection for the battery circuit according to the following parameters.

 Maximum 175 Adc

 Minimum 10 kA AIC

o AC overcurrent protection is provided in the BOS.

Dimensions:

o Height 47.2" (119.9 cm)

o Width 21.0" (53.3 cm)

o Depth 9.4" (23.9 cm)

Electrical Specifications

o Maximum continuous output: 5000 VA @ 45°C

o Nominal input and output voltage: 120/240 Vac

o Nominal frequency: 60 Hz

o Maximum continuous output current: 24 Aac

o Maximum grid input current: 48 Aac

o Maximum generator input current: 48 Aac

o Maximum PV source voltage: 600 Vdc

o Operating PV source voltage range: 200 to 600 Vdc

o Maximum PV input current: 20 Adc

o Maximum PV short-circuit current: 32 Adc

o A

UX output: 0.6 A @ 12 Vdc

o A

UX relay: 10 A @ 240 Vac, 5 A @ 30 Vdc

o Nominal battery voltage: 48 Vdc

o Maximum battery input current: 140 Adc

o Battery input voltage range: 42 to 60 Vdc

o Charging output voltage range: 42 to 60 Vdc

o Maximum battery charging current: 100 Adc

Supported Batteries

o Lead-acid

o Various lithium-ion models

Environmental Ratings:

o Environmental Category: Type 3R

o Maximum Altitude Rating: 10,000 feet

o Maximum Ambient Temperature: 60°C

Mounting Bracket

Ensure the mounting surface is strong enough to handle three times the unit weight. Add plywood or other material as necessary to strengthen the surface.

A Locate this horizontal slat at about eye level for easier display viewing.

B Do not locate the top of the bracket more than (about) 6' (183 cm)

off the floor. This ensures the SkyBox can be easily lifted onto the bracket.

Mark the placement of the bracket according to A and B, keeping in mind the dimensions in the second drawing. These dimensions show the SkyBox overlap (beyond the bracket) as well as the vertical measurements with respect to A. They also add the required minimum clearances of 6" (15.2 cm) to SkyBox top and sides.

IMPORTANT:

No lower clearance is shown. In outdoor installations a 36" minimum clearance above the ground or floor is required. The lower vertical measurement becomes 60.6” (153.9 cm) from A.

Weights:

o SkyBox: 87.7 lb (39.8 kg) o BOS: 23.6 lb (10.7 kg) o Mounting Bracket: 4.6 lb (2.1 kg)

True Hybrid Energy System

Tools Needed:

o 13 mm socket (torque) wrench o #2 Phillips (torque) driver o Flat blade (torque) driver

Place the bracket so that rails C and D are flush with the surface.

Conduit Knockouts (Underside of BOS)

SkyBox

BOS

(Balance of

System)

Left Right

1½" ¾” ¾” ¾” ¾” ¾” ¾”

6.0"

(15.2 cm)

Hole

spacing

16"

(40.5 cm)

Hole spacing

28.6"

(72.6 cm)

24.6"

(62.5 cm)

9.4"

(23.9 cm)

32"

(81.3 cm)

o 6 mm Allen wrench o Digital multimeter (DMM)

WARNING: Burn Hazard

The heat sink (at the top rear of the product) may reach temperatures greater than 70°C. Install this product so that casual contact does not occur.

WARNING: Fire/Explosion Hazard

Do not place combustible or flammable materials within 12 feet (3.7 m) of the equipment. This unit employs mechanical relays and is not ignitionprotected. Fumes or spills from flammable materials could be ignited by sparks.

WARNING: Personal Injury

Use safe lifting techniques and standard safety equipment when working with this equipment.

IMPORTANT:

 This document is for use by qualified personnel familiar with photovoltaic

(PV) systems and maximum power point tracking (MPPT) technology as well as basic inverter functionality. Users of this document should meet all local and governmental code requirements for licensing and training for the installation of electrical power systems with AC and DC voltage up to 600 volts. This product is only serviceable by qualified personnel.

 Clearance and access requirements may vary by location. A 36” (91.4 cm)

clear space in front of the system for access is recommended. Consult local electric code to confirm clearance and access requirements for the specific location. If this product is installed or used in a manner other than

specified, the protection it provides may be impaired.

 Fuses are not to exceed maximum output rating.

 When installed outdoors, use only UL514B-compliant wet location or

rain-tight conduit hubs for entry into the enclosure.

 See Specifications for instructions on system grounding and bonding.

CAUTION:

! To reduce the risk of fire, connect only to a circuit

provided with a 60 amperes maximum branch-circuit protection in accordance with the National Electric Code, ANSI/NFPA 70.

Page 2

Mounting

5 6 7

Attach the wall bracket. Center the mounting holes on wall studs. Six ¼ - 20 × 1½” lag screws and washers are provided. Any of the mounting holes can be used. Observe all mounting considerations (page 1), including the display location (A).

Place the rear brackets on the BOS studs (B). Attach the rear brackets to the BOS assembly using the four M6 nuts provided (C). Ensure that the pegs on each bracket (D) face inward (toward the opposite bracket).

Place the BOS assembly on the wall bracket by seating the pegs (D) in the slots (E).

The wall bracket has securing holes for the BOS (F). Secure the BOS by inserting an M6 × 40 mm screw on each side.

Install the SkyBox onto the wall bracket by lifting it into position. The SkyBox is equipped with rear brackets which are already attached (G).

NOTE: Two holes are available at the top of the SkyBox (H). A metal pipe, rod, or bar can be inserted across the top to assist with handling and lifting.

Insert the rear brackets into the designated slots (I

) on the wall bracket. Once the SkyBox is seated, the lifting bar can be removed.

The wall bracket has securing holes for the SkyBox (J). Secure the SkyBox in place by inserting an M6 × 40 mm screw on each side.

Mounting is complete. See the Commissioning section.

Wiring Access

Two areas house the system wiring. The BOS compartment opens with a latch. It connects to external wiring (battery, AC, PV, etc.) and conduit. These connections extend from the BOS into the SkyBox compartment, which opens with two Allen screws (K). If the SkyBox must be removed for service, the BOS and its wiring can remain. Some connections, such as communications, pass through the BOS to be made directly in the SkyBox.

BOS

Compartment

SkyBox

Compartment

Battery Cable Connections

Nut 3/8"

Spring

Lock

Washer

Battery

Positive

(+) Lug

Positive (+)

Plate

Spring

Lock

Washer

Negative (–)

Plate

Nut 3/8" DO NOT MOVE

Nut 3/8"

Battery

Negative

(–) Lug

Inverter

Negative

(–) Lug

2a 2b

NOTE: The spring lock washer used in these connections must be

installed with the rounded (convex) side facing outward. Installing in any other orientation will result in inadequate compression which may be hazardous. See the CAUTION to the far right.

CAUTION:

Equipment Damage

CAUTION:

Fire Hazard

Before energizing, confirm that all battery terminal hardware is installed as shown below. Stacking the terminal hardware in any other order can overheat the terminals.

Battery

Permitted Sizes Torque Requirements

AWG

2/0 to 4/0

#8 to #3

#18 to #4

#24 to #16

#14 to #10

#6 to #3

#1 to 1/0

70 to 120

6 to 25

1.5 to 25

0.25 to 1.5

2.5 to 4

6 to 10

16 to 25

In-lb

65 to 75 in-lb

18 to 22 in-lb

11 to 16 in-lb

N/A

7.3 to 8.5 Nm

2.0 to 2.5 Nm

1.2 to 1.8 Nm

N/A

2.3

2.8

4.0

4.5

5.7

Neutral,

Ground, and

PV Ground

Table 1: Wires and Conductors

When connecting to the battery terminals, make sure to observe the proper polarity. Connecting the cables incorrectly can damage or destroy the equipment and void the product warranty.

IMPORTANT

All PV, AC, and battery conductors must be copper-only and rated at 75°C.

Page 3

NEU

GROUND

AC Subpanel

Loads

NEU

GROUND

Utility

Grid

AC Distribution Panel

AC Generator

Generator

Start

L1 L2

L1 L2 N

Photovoltaic

(PV) Array

Neutral

HOT L1

Ground

AC LEGEND

HOT L2

Battery

Bank

RTS

BMS

Wiring

and : Connect ground wires for battery, AC, PV, and

additional PV equ

ipment.

: Connect to SkyBox negative (–) , then connect to

battery negative (–).

and : Connect PV array negative (–) and positive (+) wires.

Use terminals

and for a second array, if present.

: Connect all AC neutral wires.

: Connect SkyBox ground

wire to in BOS.

: Ensur

e the rapid shutdown jumper or device is installed into A

UX terminals. Remove the factory

jumper before installing an external device. Route the wires through channel . NOTE: The SkyBox will not function unless one of these is installed. It will show a Rapid Shutdown fault.

and : Connect to the matching sockets in the wiring compartment.

: Connect SkyBox PV negative (–) wire to . Do not remove the jumper cap.

NOTE: is on the opposite side of the switch from and .

: Connect SkyBox PV positive (+) wire to . Ensure that

all four screws at this location are tight.

: Connect AFCI cable assembly to SkyBox socket .

: Connect to battery positive (+).

: Connect to SkyBox positive (+) .

and : Connect to load subpanel L1 and L2 respectively.

and : Connect to utility grid L1 and L2 respectively.

and : Connect to generator L1 and L2 respectively.

: If current transducers (CT) are in use, install the wires into A

UX terminals.

Route the wires through channel . These are usually installed at the utility grid input to the main AC panel.

: Connect internet cable to S

KYBOX port . Route through channel .

NOTE: Do not connect this cable to the other ports on the display.

: For batteries with a separate battery management system (BMS):

The BMS (CAN bus) adapter cable converts the RJ45 cable end to RJ11. It connects to the B

AT MON port . Do not insert the RTS or any other

RJ11 cable into the BAT MON port.

: If a BMS is not present: Connect the remote temperature sensor

(RTS). Place the sensor on the battery sidewall, as close to the center of the bank as possible.

: Connect generator start wires into A

UX terminals . (See the

key to the right.) Route through channel .

: To stack an additional SkyBox, use a CAT5 cable to connect to the

ALL (RS-485) port on the next SkyBox. The last SkyBox in

sequence has nothing connected to , marking it as the end unit. (See the NETWORK tab in the SkyBox Programming Guide for additional steps.)

NOTES

 Make connections in the order indicated. If steps or connections are not applicable, they can be skipped.

 Tighten the applicable connections to the torque values specified in Table 1. (See opposite sheet.)

 Do not connect th e PV positive (+) or negative (–) conductors to ground.

 Perform all wiring in accordance with Article 690 of the National Electric Code.

Negative

Positive

Ground

DC LEGEND

3c 4c 5c

7c 7d

9 9a

5a 5b

3a 3b

4a 4b

7a 7b

3a3b4a4b5a

3c 4c 5c

7b 8b

Circuit #1

Circuit #2

NOTE: In off-grid installations,

ensure the neutral and ground are mechanically bonded. DO NOT establish more than one bond.

CT (L1)

Internet

Rapid

Shutdown

Initiator

Gen Start (AUX)

COMMUNICATIONS LEGEND

Rapid ShutdownRJ45

RTS

AFCI

CT (L1)

BMS

Next SkyBox

PV Cable

Connections for current transducers on L1 and L2 AC inputs. (Only L1 is shown in the image to the left.) 10 and 11 are for hot wires; 2 and 3 are ground. See the Programming Guide.

Rapid shutdown inputs (4 and 12). These terminals connect to normallyclosed dry contact terminals on the RSI (Rapid Shutdown Initiator). Use OutBack’s ICS Plus or an equivalent RSI system. See the RSI literature and the SkyBox Overview Guide (Troubleshooting section) for instructions if rapid shutdown occurs.

Rapid shutdown outputs (5 and 13). These are used to duplicate the RSD connection and function for an additional SkyBox. They should be wired to terminals 4 and 12 on the next SkyBox.

Auxiliary (AUX) dry contacts (7 and 15) or 12-volt contacts (8 and 16, up to 0.6 Adc) can serve as a switch for Advanced Generator Start. (See the SkyBox Programming Guide.)

Unused 1

XCT L2 GND 2

XCT L1 GND 3 RSD

INPUT 1 4

RSD

OUTPUT 1 5

Unused 6

UX RELAY 1 7

UX 12V GND 8

9 Unused 10 XCT L2

HIGH

11 XCT L1 HIGH 12 RSD INPUT 2 13 RSD

OUTPUT 2

14 Unused 15 A

UX RELAY 2

16 A

UX 12V

Page 4

1. If batteries are present: Verify input 48 Vdc using a DMM by measuring from to .

If batteries are not used in this system, skip to step 6.

Confirm the correct battery voltage and polarity. If the red LED indicator is lit, the polarity is reversed. Do NOT turn on the circuit breaker.

2. Once proper voltage and polarity are confirmed, turn on (close) the main

battery circuit breaker .

Wiring

Commissioning

Pre-startup Procedures:

1. Double-check all wiring connections. Using a digital multimeter (DMM), test for continuity between

and . Ensure a neutral-ground bond is installed in the system.

2. Inspect the enclosure. Ensure no debris or tools were left inside.

3. Ensure all AC loads at the backup (or protected) load panel are disconnected.

4. Ensure all AC input feeds to the BOS are disconnected at each source.

5. Using a Phillips screwdriver, remove the clear plastic (dead front) panel (not depicted). The four

required screws are marked with  in the image to the right.

6. Energize the system as below. Follow the procedures which are applicable to the system. If any

elements are not present (including batteries, PV, or a generator), ignore those procedures.

To energize the Skybox:

PV LED Legend

Caution

3. On the first power-up, a welcome message is shown. The right arrow 

proceeds to the Setup Wizard. This steps through language, region, and similar changes, then PV, battery, and AC settings. On the last screen, the Save key proceeds to the Home screen. (The Home screen appears after every subsequent power reset.)

4. From the Home screen, turn on the SkyBox with the O

N/OFF key .

NOTE: Do not close the LOAD circuit breaker .

5. Using a DMM, verify the inverted L1 output 120 Vac on the upper LOAD

terminals from t

o . Verify L2 by measuring from to .

6. Verify 240 Vac across the L

OAD terminals by measuring from to .

7. Turn on (close) the L

OAD circuit breaker . Do not connect loads at the

protected load panel.

8. Verify 120 Vac on L

OAD L1 by measuring with a DVM from to .

Verify L2 by measuring from to .

9. Verify 240 Vac across the L

OAD terminals by measuring from to .

10. Connect and test loads at the protected load panel.

11. If grid is present: Turn on the grid connection to the BOS at the source.

12. Verify 120 Vac on G

RID L1 by measuring with a DVM from to .

Verify L2 by measuring from to .

13. Verify 240 Vac across the G

RID terminals by measuring from to .

Setup Wizard (entry screen)

Setup Wizard (final screen)

Home Screen

3a 3b 4a 4b 5a 5b

8a 8b

5c 5d

1a 2a

CAUTION: Equipment Damage

Incorrect battery polarity will damage the equipment.

CAUTION: Reverse

polarity in negative

grounded system

Keep breaker in the OFF

position and check polarity

543

18. Turn on (close) the PV switch . Check indicators and again. Both indicators should light. Any other behavior means the

polarity at the top of the PV switch may be reversed.

19. On the Home screen, check the SOLAR tile (as shown to the right) and ensure it is operating normally. The SkyBox will connect to the PV source if the voltage is above 250 Vdc. (See the Overview Guide for more information.)

20. If a generator is present: Turn off (open) the G

RID circuit breaker .

21. Start the generator. Do not turn on (close) the G

EN circuit breaker . Repeat steps 12 and 13 using , , and .

22. Turn on (close) the GEN circuit breaker . Repeat step 14. The LOAD circuit breaker may remain on (closed).

23. Stop the generator.

24. Turn on (close) the G

RID circuit breaker . Wait for the programmed connection delay to elapse. Test any grid-interactive functions.

To de-energize or shut down the system:

There is no required shutdown order. It is common to de-energize circuits in the reverse order from which they were energized.

65b

5a 5b

64a 4b

65a

CAUTION: Equipment Damage

Incorrect PV polarity will damage the equipment.

14. Turn on (close) the GRID circuit breaker . The Wizard will appear for the first time if no batteries are installed. (Perform steps 3 through 10 if this is the case.) The SkyBox transfer relay should click and the GRID tile should read PASS THROUGH.

15. Using a DMM, test the pass-through (transferred) L1 output voltage at and . Test the L2 voltage at and .

16. If PV is present: Verify that the input is in the correct range of open-circuit voltage. Confirm polarity by measuring with a DVM from to (referred to as PV1 in the legend above). Confirm polarity from to (PV2, if present).

17. Check the green LED indicators and . If a single PV input is installed, one indicator should light. If two strings are installed, both should light. Any other behavior means the polarity may be reversed. Do NOT turn on the switch. Review all PV connections.

7a8a

63a

63b

3a 3b

5c 5d6 6



NOTES

If any onscreen faults or other problems occur during commissio ning, see the Troubleshooting section of the SkyBox Overview Guide.

5c 5d

PRODUCING

0 6

BEFORE CLOSING PV DISCONNECT ENSURE LED INDICATION IS CORRECT:

TERMINALS ON PV BOARD CORRECT

ONLY PV1 TERMINALS ONLY PV2 TERMINALS PV1 + PV2 TERMINALS

NOTE: PV VOLTAGE > 100 VDC

REQUIRED TO LIGHT LEDS

WARNING: Shock Hazard

Before performing maintenance, all sources (battery, PV, and AC) must be completely de-energized. All the unit to rest for at least five minutes.

OutBack Power SKYBOX Quick Start Manual

Specifications and Main Features

Frequently Asked Questions

User Manual