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PowerBack PB5000
User Manual
24 pgs2.88 Mb0

Sollatek PowerBack PB5000 User Manual

PowerBack PB5000
5KVA 220-230Vac 48Vdc
INVERTER / CHARGER
USER MANUAL
t h e p o w e r t o p rotec t
CONTENTS
PURPOSE 3 IMPORTANT SAFETY INSTRUCTIONS 3
General Precautions 3 Personal Precautions 4
DESCRIPTION OF OPERATION 4
Operational Data 5 Priority Loads 5
INSTALLATION 5
Unpacking and Inspection 5 Basic Configuration 5 Positioning of PowerBack and battery system 8 Batteries 8 Battery Cable Size 8 DC Disconnect and Over-Current Protection 9 Battery Cable Connection 9 AC Cable Size 10 AC Connections 11 AC Isolation and Overcurrent Protection 12 AC Loads 12 Protecting your PowerBack 12 Commissioning of PowerBack 12
OPERATION 13
Front Panel Controls and LCD Indicators 13 Power ON/OFF 13 Configuration Switch 14 LCD Indicator 15 Battery Charger 16 Internal Circuit Breaker 17 Workshop Serviceable Items 17
SPECIFICATIONS 18
Line Mode Specifications 18 Inverter Mode Specifications 19 Charge Mode Specifications 20 General Specifications 20 Fault code/ Audible alarm 21
TROUBLESHOOTING 22 SERVICING OF POWERBACK 23
Guarantee 23 Returns 23 Warranty 24
S O L LA T E K P O W ER B A CK M AN U A L 3
PURPOSE
This manual explains procedures for the unit’s installation, operation and troubleshooting Please take time to understand the contents of this manual prior to installation and operation.
IMPORTANT SAFETY INSTRUCTIONS
WARNING: This chapter contains important safety and operating instructions. Read and keep
this User Guide for future reference. Display this notice at location of bat teries.
General Precautions
1. Before using the unit, read all instructions and cautionary markings on: The unit (2) the batteries (3) all appropriate sections of this manual.
2. CAUTION -To reduce risk of injury, charge only deep-cycle lead acid type rechargeable batteries. Other types of batteries may burst, causing personal injury and damage.
3. Do not expose the unit to rain, snow or liquids of any type. The unit is designed for indoor use only. Protect the unit from splashing if used in vehicle applications.
4. Do not disassemble the unit. Take it to a qualified Sollatek service center when service or repair is required. Incorrect re-assembly may result in a risk of electric shock or fire.
5. To reduce risk of electric shock, disconnect all wiring before attempting any maintenance or cleaning. Turning off the unit will not reduce this risk.
WARNING: WORKING IN VICINITY OF A LEAD ACID BATTERY IS DANGEROUS.
BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL OPERATION. Provide ventilation
to outdoors from the battery compartment. The battery enclosure should be designed to prevent accumulation and concentration of hydrogen gas in “pockets” at the top of the compartment. Vent the battery compartment from the highest point. A sloped lid can also be used to direct the flow to the vent opening location.
7. NEVER charge a frozen battery.
8. No terminals or lugs are required for hook-up of the AC wiring.
AC wiring must be no less than 6mm csa (10 AWG) gauge copper wire and rated for 75ºC or higher. Battery cables must be rated for 75oC or higher and should be no less than 25mm csa (4AWG). Crimped and sealed copper ring terminal lugs with an 8mm (5/16) diameter hole should be used to connect the battery cables to the DC terminals of the unit. Soldered cable lugs are also acceptable.
9. Be extra cautious when working with metal tools on, or around batteries. The potential exists to drop a tool and short-circuit the batteries or other electrical parts resulting in sparks that could cause an explosion.
10. No AC or DC disconnects are provided as an integral part of this unit. Both AC and DC disconnects must be provided as part of the system installation. See INSTALL ATION section of this manual.
11. No over current protection for the battery supply is provided as an integral par t of this unit. Over current protection of the battery cables must be provided as part of the system installation. See INSTALLATION section of this manual.
12. GROUNDING INSTRUCTIONS -This battery charger should be connected to a grounded permanent wiring system. For most installations, the Ground Lug should be bonded to the grounding system at one (and only one point) in the system. All installations should comply with the relevant electrical installation international safety guidelines and local necessary codes and requirements.
Personal Precautions
1. Someone should be within range of your voice to come to your aid when you work near bat teries.
2. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.
3. Wear complete eye protection and clothing protection. Avoid touching eyes while working near batteries. Wash your hands when done.
4. If bat tery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eyes, immediately flood eyes with running cool water for at least 15 minutes and get medical attention immediately.
5. Baking soda neutralizes lead acid bat tery electrolyte. Keep a supply on hand in the area of the batteries.
6. NEVER smoke or allow a spark or flame in vicinity of a battery or generator.
7. Be extra cautious when working with metal tools on, and around batteries. Potential exists to short-circuit the batteries or other electrical parts which may result in a spark which could cause an explosion.
8. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a battery or any other live electrical equipment. A battery can produce a short-circuit current high enough to weld a ring, or the like, to metal causing severe burns.
9. If a remote or automatic generator start system is used, disable the automatic starting circuit and/ or disconnect the generator from its starting battery while servicing to prevent accidental starting during servicing.
DESCRIPTION OF OPERATION
Inverter type: Of fline standby switches to inverter mode (battery backup) when the utility supply goes beyond the selected input range.
Mains supply voltage is 230Vac.
Inverter output is nominal 230Vac.
Inverter input (battery) is 48Vdc.
Depending on which mode has been selected, the unit will switch to inverter mode when the mains voltage (utility supplier) goes outside the following input range:
1. Normal 170-280V.
2. Wide 90-280V.
3. Generator 90-280V
S O L LA T E K P O W ER B A CK M AN U A L 5
OPERATIONAL DATA
Max permissible current drawn from the utility mains is 32.2Aac (220-240Vac).
Consisting of:
21.7Aac for load equipment(5000VA at PF of 0.84)
10.5Aac for battery charging.
Total is 32.2Aac (5000VA at PF of 0.84) 4200W.
Maximum loading in Watts (to ensure calculated autonomy) is to be no greater than 85% as shown on the PowerBack LCD display (load % automatically increases as battery discharges).
PRIORITY LOADS
Depending on the users domestic load commitments , the installer may have to reconfigure the existing AC distribution panel to supply priority loads only.
INSTALLATION
Warning!
Installation must only be carried out by a competent person who has sufficient electrical training and is familiar with safe practices when working on or near electrical systems.
Unpacking and Inspection
Carefully unpack the Sollatek PowerBack inverter/charger from its shipping carton.
Verify all listed items list below are present. Please contact your Sollatek distributor if any items are missing.
• The unit
• 1 DC red cable
• 1 DC black cable
• 1 user’s manual
Basic Configuration
The following illustrations show basic applications for the PowerBack.
They include the following configurations:
• Utility Backup. see figure 1-1
• Renewable Energy Source and a Generator, see figure 1-2
Consult with your system designer for other possible configurations depending on site or code requirements.
Figure 1-1 Utility Backup
B A T T ER Y BA N K
L O A D S
A /C P C T EL E V I SI O N H O M E E L EC T RO N I CS
AC DIS T RIB U TIO N
PA NEL
U TI L I T Y S U P PL I E R
TO PR I M ARY
SY S TE M GR O UND
AC I/P
AC O/P
S O L LA T E K P O W ER B A CK M AN U A L 7
Figure 1-2 Renewable Energy Source
S O L AR H Y D R O W IN D
B A T T ER Y BA N K
L O A D S
A / C R EF R IG E R AT I ON O FF I C E / FA C TO R Y E L E CT R ON I C S
M A I NS
( OR GE N ER A TO R
S TA N DB Y )
D C
C O N T RO L L E R
A C D I S T RI B U T I O N P A N E L
The PowerBack PB5000 is able to supply the majority of mains operated domestic and office appliances, including small motors, lights, fans, refrigerators and air conditioners up to a maximum total demand of 5KVA.
Note: In extreme circumstances where the utility supply remains off and the battery back up has expired, appliances such as fridges and air conditioners require approximately 3 minutes restart delay (time is required to balance the refrigerant gas) before utility mains is reinstated . Please contact Sollatek distributors for advice on the Sollatek Voltshield premium range of products.
Positioning of PowerBack and battery system
The Powerback is designed to operate in a restricted access location, lockable and accessible only by competent persons. Installation must be in accordance with the requirements of IEC 60364-4-42.
The PowerBack must be installed in a dry shaded and dust free location with 300mm spacing all round the unit to allow adequate ventilation. The unit has forced cooling and the fans operate full time (Saver mode allow fans to turn off when no load applied)
Batteries must be installed in a dry shaded location. Take extra care to ensure there is adequate ventilation to prevent build up of explosive gases (depending on battery type used).
Batteries
The PowerBack requires a 48V dc battery bank with an absolute minimum capacity of 100Ah, 200Ah is the recommended minimum capacity to provide a realistic backup time (autonomy). Please refer to figure 2 for battery set up. Before proceeding, ensure you have appropriate sized batteries for this inverter. The unit can use deep cycle flooded lead-acid, or sealed GEL/AGM lead-acid batteries so ensure that your batteries are in one of these categories.
-+-+-
+
-+
12V 12V
12V
12V
-INVE R T E R
PB5000
+ -
Figure 2. 48V batteries string wiring (4 x12Vdc)
Battery Cable Size
Table below shows the minimum recommended battery cable size.
Model Number Minimum Amperage 1-3 metre one-way Torque value
PowerBack PB5000 125 A 25mm csa. 4AWG (min) 10-15 Nm
Minimum recommended battery cable size
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