the PowerRouter PowerRouter Solar Battery Installaton Manual
Read the nstallaton manual for detals A A A B mn. 300 mm mn. 800 mm Standby Drll template for the PowerRouter A B A Standby Standby Drll template for the PowerRouter Standby Standby Standby Max.40 C Mn.-10 C Standby Standby Standby Partno. 5555426,1 1 4 200 A AC GRID AC LOCAL OUT 2 5 Drll template for the PowerRouter the PowerRouter + mountng bracket 570 mm max. ø 5.5 mm 600 mm max. ø 10 mm 20 KG 370 mm Installaton steps 2 x 4 x 1 2 4 x 3 2 x 4 5 6 690 mm max. ø 5.5 mm + - 3 6 N L N L NO NC NO NC AC GRID AC LOCAL OUT
7 10 +BAT -BAT TMPS GND SH+ SH- AC GRID AC LOCAL OUT NO NC NO NC Red + - Black Temperature sensor Fuse 300 A 8 11 AC GRID AC LOCAL OUT 2 1 9 12 ETHERNET RJ45 1 1 2 3 4 5 6 nternet router PC, laptop, Mac to the router Cat5 network cable of a sutable length the PowerRouter to the router ADSL/ISDN/cable connecton power adapter to the router USB 2 3 4 6 CAN BUS CAN 5
13 Operatonal Chargng Grd Error YES NO ON OFF 14 Man menu Status menu Hstory menu Settngs menu Servce menu System Grd Language Reset Grd Solar Date&Tme Selftest Solar Battery Dsplay Errors Battery Install Wzard Internet connectons
PowerRouter Solar Battery 3000W, 3700W and 5000W EN Installaton manual Page 6 DE Installatonshandbuch Sete 20 FR Manuel d nstallaton Page 34 NL Installate handledng Bladzjde 48 IT Manuale d'nstallazone Pagna 62 ES Manual de nstalacón Págna 76 PT Manual de nstalação Págna 90 N.V. Nederlandsche Apparatenfabrek Nedap The Netherlands
EN Safety Informaton danger warnng Ths manual contans nstructons for the PowerRouter that should be followed durng nstallaton, operaton and mantenance of the unt. The PowerRouter s desgned and tested accordng to nternatonal safety requrements. To reduce the rsk of personal njury and to ensure safe nstallaton and operaton of the PowerRouter, carefully read and follow all nstructons, cautons and warnngs n ths nstallaton manual. The warnng symbol ndcates a hazard to ether the equpment or personnel. It draws attenton to a procedure whch, f not correctly executed, may result n damage to the PowerRouter or to the connected equpment. It could also result n personal njury. Danger Ths symbol ndcates a hazardous stuaton whch, f not avoded, wll result n death or serous njury. Warnng Ths symbol, when used alone or n conjuncton wth any of the followng cons, ndcates the need to consult the operatng nstructons provded wth the product. A potental rsk exsts f the operatng nstructons are not followed. CAUTION Cauton Ths symbol ndcates a hazardous stuaton whch, f not avoded, could result n mnor or moderate njury. 1 Informaton Ths symbol accompanes notes that call attenton to supplementary nformaton that you should know and use to ensure optmal operaton of the system. A bullet wth a number refers to an llustraton wth the same number. For llustratons refer to pages 2-4. Contents Safety Informaton 6 Contents 6 1 Introducton 7 2 Safety 7 3 Mountng 7 3.1 Choosng a mountng locaton 7 3.2 Dmensons and recommended clearances 8 3.3 Mountng procedure 8 4 Wrng 8 4.1 Wrng AC Connectons 8 4.2 Wrng Solar connectons 9 4.3 Wrng battery and sensor connectons 9 4.4 Bypass swtch (for the professonal models) 9 4.5 Internet connecton 10 4.6 Optonal can-bus 10 4.7 Free programmable general purpose contacts 10 5 Commssonng 10 6 Operaton 11 6.1 Navgatng 11 6.2 Servce menu 11 7 Malfunctons and errors 13 8 Cleanng and mantenance 13 9 Decommssonng 14 10 Dsposal 14 Appendx A Warranty 15 Appendx B Error codes 16 Appendx C Techncal Specfcatons 18 Appendx D PV-MS tool 19 Notes 19 danger To help avod problems durng the nstallaton, famlarze yourself wth the nstallaton process by readng the entre nstallaton manual before startng the nstallaton. Lethal voltages are present at varous ponts n a solar system. For safety reasons, t s recommended that only qualfed personnel nstall and operate ths equpment. Lethal currents are present wthn the battery. When the battery termnals are short crcuted, sparks may create burnmarks or a fre hazard. 6
1 Introducton EN Ths manual s sutable for the PowerRouter Solar Battery types: PR30SB (3000W), PR37SB (3700W) and PR50SB (5000W). The manual s ntended for certfed nstallers to mount, wre and commsson the PowerRouter unt. The PowerRouter s a DC to AC grd-ted utlty unt for use wth Photovoltacs (PV) and battery backup storage. The PowerRouter can be used for feed-n purposes. The optonal AC local output of the PowerRouter supples a no-break supply to the connected load n the event of a grd falure. For more nformaton vst: www.powerrouter.com. warnng 2 Safety Before nstallng or usng the PowerRouter, read all of the nstructons, cautons, and warnngs on the PowerRouter, the solar array and battery bank and n ths nstallaton manual. Before connectng the PowerRouter to the electrc grd, contact the local utlty company. Solar arrays produce electrcal energy when exposed to lght and can thus create an electrc shock hazard. Wrng of the solar arrays should only be performed by qualfed personnel. To prevent short crcutng of the battery, an solated box wrench should be used. The PowerRouter contans no user-servceable parts. For all repars and mantenance, contact your nstaller/dealer. Ant-slandng protecton The PowerRouter has a bult-n ant-slandng protecton functonalty n complance wth local regulatons. Durng a utlty falure, the PowerRouter unt wll dsconnect from the grd. Wth the optonal "Local Out" you may contnue supplyng your loads n ths event. Solar Seres fusng Seral fusng may be requred dependng on the type of PV module and confguraton used n the system. CE Complance The PowerRouter s complant accordng to CE Drectve. 3 Mountng Ths chapter provdes gudelnes to help select the best mountng locaton, provdes suggestons to ensure optmum performance, cautons and warnngs that you should follow n order to avod njury and equpment damage. Also ncluded are step-by-step nstructons for mountng the PowerRouter. 3.1 Choosng a mountng locaton 1 Take nto account the followng gudelnes, cautons, and warnngs when choosng a mountng locaton for the PowerRouter: The PowerRouter s desgned for ndoor nstallatons (IP21) Do not nstall the PowerRouter n drect sunlght Do not nstall the PowerRouter on flammable constructon materals Do not nstall the PowerRouter n areas where hghly flammable materals are stored Do not nstall the PowerRouter n potentally explosve areas Do not nstall the PowerRouter durng perods of precptaton or hgh humdty (>95%); mosture trapped wthn the locaton may cause corroson and damage to the electronc components Provde adequate ventlaton when usng batteres, and also read the warnng label on the bottom of the PowerRouter Install the PowerRouter n a locaton that mantans an ambent ar temperature that s less than 40 C; ths s to mantan a safe nternal component temperature, the PowerRouter reduces power f the ambent ar temperature exceeds 40 C The PowerRouter should be nstalled n a locaton that s not accessble for chldren The PowerRouter emts a slght vbratng nose when operatng. Ths nose s normal and has no effect on performance, but t can be dsturbng f the unt s mounted on a wall n a lvng area, on the outsde of a wall that s near a lvng area, or on certan types of materals, such as thn wood panellng or sheet metal The slope of the wall should be wthn ± 5 The PowerRouter weghs 20.5 kg; ensure that the mountng surface s strong enough to hold the weght of the PowerRouter The bottom of the PowerRouter s provded wth a label showng the ratngs; the PowerRouter must be mounted n such a manner that ths label remans vsble after nstallaton, as the label contans a seral number needed as a logn code for the nstall wzard and to regster at www.mypowerrouter.com for loggng and montorng If you are nstallng the PowerRouter n a cabnet, closet or other relatvely small enclosed area, suffcent ar crculaton must be provded n order to dsspate the heat generated by the unt. To prevent electrc shock or other njury, check for exstng electrcal or plumbng nstallatons n the walls before drllng mountng holes for the PowerRouter. 7
EN 2 2 3.2 Dmensons and recommended clearances Mount the PowerRouter wth 300 mm clearance at the top and bottom of the unt. If more PowerRouters are stacked, then use a clearance of 800 mm between each PowerRouter. Use the drll template provded wth the PowerRouter for drllng the bracket and mountng holes. Ensure that there s suffcent clearance for the arflow around the PowerRouter Local regulatons may requre larger workng clearances. Dmensons of the PowerRouter are 765 x 502 x 149 mm (W x H x D). 3.3 Mountng procedure The PowerRouter s shpped wth a wall-mountng bracket that s sutable for use on most walls. Mountng procedure: 1. Use the drll template provded wth the PowerRouter (follow the llustrated nstructons on the drll template) 2. Drll holes for the mountng bracket n the wall (f requred) 3. Drll holes for securng n the wall (f requred) 4. Mount the mountng bracket 5. Install the PowerRouter on the mountng bracket 6. Open front cover and secure wth screws (use screwdrver wth a blade-length of 160 mm) 4 Wrng Ths chapter provdes step-by-step nstructons and other nformaton requred for wrng the PowerRouter to the PV array, battery, the utlty grd and the optonal local out. To complete the nstallaton n a safe and effcent manner, follow the steps n the rght order. Before wrng the PowerRouter, make sure that all wres connected to the PowerRouter are not lve by turnng off all dsconnects and/or swtches. Wrng steps: 1. Use the quck nstallaton sheet provded wth the PowerRouter 2. Connect the wres of the AC voltage from the utlty grd and the load to the PowerRouter (refer to clause 4.1) 3. Connect the wres of the DC voltage from the PV array and battery to the PowerRouter (refer to clause 4.2 and 4.3) 3 4 4.1 Wrng AC Connectons Ths clause descrbes the AC connectons of the PowerRouter to the AC grd and the optonal AC local out. Use 4 mm² wres. Wrng ac connecton steps: (step 5,6 and 7 are optonal) 1. Strp the nsulaton off the wres and pass the wres through the gland openng 2. Connect the AC Grd ground wre to the AC Grd ground termnal 3. Connect the AC Grd Lne (L) wre to the AC Grd termnal labeled L 4. Connect the AC Grd Neutral (N) wre to the AC Grd termnal labeled N 5. Connect the AC Load ground wre to the AC Local Out ground termnal 6. Connect the AC Load Lne (L) wre to the AC Local Out termnal labeled L 7. Connect the AC Load Neutral (N) wre to the AC Local Out termnal labeled N 8. Tghten stran relefs Example of an electrcal resdental nstallaton. Verfy that all connectons are correctly wred and properly torqued (mn. 1.2 Nm, max. 1.5 Nm). Contacts need to be free of any mechancal stran. 8
4.2 Wrng Solar connectons Ths clause descrbes the connecton between the solar panels and the PowerRouter. EN 5 6 CAUTION Before connectng the PV strng connectors to the PV termnals check ths lst: Set DC swtch on the PowerRouter to OFF Use copper wre (4 mm 2 ) for all PV wrng connectons to the PowerRouter; apply only sold or stranded wre. Do not use fne stranded wre Verfy that the DC solar current and voltage of your nstallaton does not exceed the maxmum rates specfed on the type ratng label Check the polarty of the PV strngs Use specal tool for connectng MC4 connector on the PV wres; the PV MS tool s descrbed n Appendx D Connect 1 or 2 strngs to the PV nput termnals usng matng MC4 connectors. The 3kW unt only has 1 PV nput. Do not connect 1 PV-strng to both PV-termnals smultaneously (parallel connecton). Do not connect 1 PV-strng to both PV-termnals n seral. 4.3 Wrng battery and sensor connectons Ths clause descrbes the connecton between the PowerRouter and the battery and temperature sensor. Do not connect the battery before commsonng, refer to Chapter 5. 7 Battery connecton: 1. Apply battery cable wth a dameter of at least 95 mm 2, maxmum 2.5 m length per cable 2. Ft a fuse (300 A slow blow) n the postve battery cable as close as possble to the battery 3. Strp approx. 25 mm cable nsulaton 4. Insert cable nto the termnal (red to postve termnal, black to negatve termnal) 5. Tghten the cable connecton wth a hex drver (6 mm) (torque 15Nm - 20Nm) 6. Use cable lug (eyelet termnal) on the other end of the battery cable CAUTION Temperature sensor connecton: 1. Connect sensor wres to TMPS (red wre) and GND (black wre) termnals n the PowerRouter 2. Stck the self adhesve temperature sensor onto the battery near the (+) pole Verfy that the battery connectons are correctly wred and properly torqued. Connectng a battery can cause a spark. Mswrng can cause damage to the PowerRouter. Read the label on the battery. Battery chargng statons must be located n desgnated battery chargng areas. Ths s because of the dangers of hydrogen gas and battery acd. Do not smoke or brng open flames near hydrogen gas. Wear protectve gear when workng wth batteres. The temperature sensor s used for battery charge control and safety. 4.4 Bypass swtch (for the professonal models) Ths clause descrbes the usage of a bypass swtch. 8 The PowerRouter professonal models use the 'Local Out' to supply your loads. Ths unque feature enables t to supply backup power n the event of a grd falure, as a PowerRouter wth a 'Local Out' connecton can swtch to 'sland mode' when the grd fals. After a short delay t resumes operaton, enablng ts unque 'Local Out' connecton to supply a stable 230Vac power sgnal to the connected loads. Bypass swtches are crucal components wth whch the PowerRouter supports crtcal load stuatons. (The PowerRouter acts as a UPS system). The bypass swtch allows you to swtch off the PowerRouter for mantenance, wthout cuttng power to the load. When the swtch s actvated, the mans supply s drected away from the PowerRouter and s drectly connected to the load. The PowerRouter can then be servced and any mantenance work carred out wthout dsturbng the load. Once the PowerRouter s ready to be swtched on, the bypass swtch s deactvated and the supply s redrected to the PowerRouter; the load receves the PowerRouter supply agan. The Bypass swtch s an optonal component and should be obtaned and nstalled separately. (Bypass swtch contacts ratngs = 230V 40A). The AC grd nput and AC local output crcuts are solated from the enclosure and system groundng. AC groundng: connect the PowerRouter to the AC ground from the utlty va the ground termnal (PE). PV Groundng: check local regulatons. DC Groundng Electrode Conductor: a DC groundng electrode conductor may be requred by the local authortes. The AC local out connecton of the PowerRouter s an optonal connecton, dependng on how the PowerRouter wll be used. 9
EN 4.5 Internet connecton Ths clause descrbes the connecton of the PowerRouter to the nternet. 9 12 When the PowerRouter s connected to the nternet, the web portal mypowerrouter.com gves detaled system nformaton (e.g. performance, proft, solar yeld) on each PowerRouter unt. The PowerRouter can even be remotely updated wth new frmware contanng the latest features, so your system s always up to date. Connectng the PowerRouter to the nternet wth standard UTP / RJ45 network cable to your nternet router / gateway / swtch. More nformaton about possble connectons to the nternet s avalable on www.powerrouter.com. The PowerRouter only uses Internet port 80, ths s normally a standard settng of the network. It can be tested by connectng a PC to ths connecton and tryng to surf on the nternet. In case of applyng a proxy, contact your nstaller/dealer. 4.6 Optonal can-bus Ths clause descrbes the optonal CAN-bus of the PowerRouter. 9 Ths connector s for future use and s covered wth a plug to prevent msconnecton wth the nternet port. Check www.powerrouter.com to fnd out when ths opton becomes avalable. 4.7 Free programmable general purpose contacts Ths clause descrbes the PowerRouter general purpose contacts functonalty. 12 Two programmable contacts are avalable and the contacts are potental-free wth the ratngs: 230Vac - 1 A / 24Vdc - 1 A. The contacts swtch over when battery and/or grd levels are exceeded and they swtch back n safe condtons. The trplevels are adjustable wth the nstall wzard and nstallaton software tool; see also clause 6.2. The left contacts can be used for grd alarms, the rght contacts can be used for battery alarms. 5 Commssonng Ths chapter descrbes the commssonng of the PowerRouter. Before usng the PowerRouter, the unt must be ntalzed by settng system parameters. There are 2 methods to set the system parameters: A. Usng the bult-n nstall wzard B. Usng the software nstallaton tool wth a PC connected to the PowerRouter's USB port Commssonng method A (recommended): 1. Swtch utlty grd to the PowerRouter 2. Swtch the man swtch of the PowerRouter to on, the nstall wzard wll start, set system parameters of the PowerRouter by usng the nstall wzard 3. Swtch PV-panels (wth DC swtch), battery and load to the PowerRouter Commssonng method B (for advanced settngs): 1. Insert a USB cable nto the USB port of the PowerRouter and to a PC. 2. Swtch utlty grd to the PowerRouter 3. Swtch the man swtch of the PowerRouter to ON, use the software nstallaton tool and set the system parameters 4. Swtch PV-panels (wth DC swtch), battery and load to the PowerRouter After commssonng, the PowerRouter s ready to use. The USB port: The PowerRouter can be ntalzed by usng the PowerRouter software nstallaton tool. Download the PowerRouter software nstallaton tool and drver va the PowerRouter webste: www.powerrouter.com/software (you need your logn detals for ths webste). Check the Busness Partner webste regularly for updates to the PowerRouter software nstallaton tool. Connect the PowerRouter to a pc wth a standard USB B-type to A-type cable, and you can then use the software nstallaton tool. 10
6 Operaton Ths chapter descrbes the operaton of the PowerRouter. The PowerRouter has 4 buttons to operate. Navgatng and changng values can be done by usng these 4 buttons. The 4 rows dsplay shows the menus and other nformaton lke status, hstory and error messages. The user manual provded wth the PowerRouter explans how to operate the PowerRouter and s ntended for the end-user. Ths chapter explans the servce menu. EN 6.1 Navgatng 13 Navgaton buttons: Up / Down Scroll through the menus or lst or change value Yes Confrm choce or select tem No Return to prevous state 6.2 Servce menu Ths clause provdes nformaton about the servce menu. The servce menu gves access to servce-related functons lke Reset, Self test, Error hstory, nternet connecton and Install wzard. 14 Overvew of the menu structure. 6.2.1 Reset If the PowerRouter s not workng as expected then a reset can help. The PowerRouter wll then be restarted, and durng ths restart the load wll be dsconnected. Ths means that durng ths event no power wll be avalable for the end-user, dependng on the confguraton. The restart duraton s less than 1 mnute. Reset procedure: 1. Enter the servce menu 2. Select Reset 3. Press YES to contnue 4. Press YES to start the Reset procedure The PowerRouter should work as normal, otherwse contact your nstaller/dealer. 6.2.2 Self test The self test s a safety check requred by some countres. Durng ths test the PowerRouter wll smulate the grd voltage and frequency, the PowerRouter should respond safely on the smulated grd abnormaltes. The test wll pass f the PowerRouter responds wthn the country gven specfcatons; otherwse the PowerRouter shuts down. Self test procedure: 1. Enter the servce menu 2. Select Self test 3. Press YES to start the Self test procedure When the PowerRouter shuts down, start the PowerRouter and run the self test agan. If t stll fals contact your nstaller/dealer. 6.2.3 Error hstory The error hstory holds the last 10 error messages whch have occurred. When contactng your nstaller/dealer, the error codes n the error hstory can be helpful to determne the problem. Error hstory readout procedure: 1. Enter the servce menu 2. Select Error hstory 3. Press YES to enter the Error hstory 4. Press Up/Down to scroll through the error lst 11
EN 6.2.4 Install Wzard The nstall wzard gudes you through the setup of the system parameters. To prevent accdental system parameter changes, the PowerRouter asks you to logn (durng commssonng the logn s skpped). The last 4 dgts of the seral number on the ratng label s used for the logn code. Use the Up/Down buttons to set each dgt and press the YES button to confrm and go to the next dgt untl the last dgt s set. The followng parameters can be set: Language, Country, Date & Tme, Battery settngs (Sze, Current, Type, Charge, Vfloat, Vbulk, Low battery alarm), AC alarm relay. Install wzard procedure: 1. Enter the servce menu 2. Select Install wzard 3. Press YES to enter Install wzard 4. Press YES to contnue the wzard 5. Enter logn code 6. Press YES to contnue the wzard The table below shows the battery parameters whch can be set durng the Install wzard or the software nstallaton tool. Battery settngs (rght relay) Descrpton Default value Mnmum value Maxmum value Sze Capacty of the battery 400 Ah 100 Ah 40000 Ah Current Maxmum battery charge current 100 A 20 A 200 A Type GEL or WET GEL Charge* 3 Stage or Fx. float charge characterstc 3 stage Vfloat Charge voltage 26.4 V 26.0 V 28.0 V Vbulk Low battery alarm Charge voltage f 3-stage charge characterstc s set. Wll not be used f fxed float charge characterstc s set ON: Low battery alarm relay wll be actvated f battery voltage falls below set value OFF: Low battery alarm relay wll be de-actvated f battery voltage rses above set value * Select float charge for UPS use - select 3 stage for cyclc use. 28.8 V when 3-stage s set 28.0 V 30.0 V 22 V 19.0 V 23.0 V 24 V 24.0 V 26.0 V The table below shows the AC alarm relay parameters whch can be set durng the Install wzard or the software nstallaton tool. AC alarm relay (left relay) AC low alarm Mnmum dfference between ON and OFF settng s 15 V AC hgh alarm Mnmum dfference between ON and OFF settng s 15 V 6.2.5 Internet connecton Descrpton Default value Mnmum value ON: AC alarm relay wll be actvated f grd voltage below set value OFF: AC alarm relay wll be de-actvated f grd voltage above set value ON: AC alarm relay wll be actvated f grd voltage above set value OFF: AC alarm relay wll be de-actvated f grd voltage below set value Ths clause descrbes a check f your PowerRouter s connected to the nternet. The nternet connecton test procedure: 1. Enter the servce menu 2. Select Internet connecton Maxmum value 180 V 225 V 225 V 230 V 235 V 254 V 230 V 235 V The dsplay wll show nformaton about the nternet status lke: Internet connecton status (ok, error, countng), Last date and tme when the PowerRouter was nternet connected, IP number and status about frmware dstrbuton. 12
7 Malfunctons and errors Ths chapter provdes nformaton n case of a malfuncton or error of the PowerRouter. EN The PowerRouter wll ndcate the malfuncton on the unt both by the LED ndcators and on the dsplay. The malfuncton may be of any knd, ether nsde the unt or somewhere n the PV system. The unt wll not operate untl the fault has been corrected. The dfferent error codes and possble causes are addressed n ths secton. Refer to mypowerrouter.com for the latest error lst. LED ndcaton In case of malfuncton the LEDs wll ether be off or flashng as follows: Operaton LED color LED: ON LED: OFF LED: FLASHING Operatonal blue when unt s operatonal when unt s off or error n.a. Chargng blue when batteres are charged when unt s off or error when capacty of the batteres are lower then 30% Grd blue when grd s connected when no grd or off Grd avalable not connected Error red when error (*) n.a. when one module / functon down (**) * Requres servce nterventon ** Error may resolve tself; other module/functons actve. How to deal wth errors An error may prevent the system from operatng. Before the system can operate agan, the error has to be cleared. Errors are cleared automatcally by the system f the error condton dsappears. When the error message stays, press a button (YES or NO or UP/DOWN) on the PowerRouter to clear the error. Also the error message can be cleared usng the nstallaton software tool or va the nternet. Clear error message procedure: 1. Press NO for at least 3 seconds Troubleshootng If you encounter dffculty wth the operaton of your PowerRouter, please follow these steps n an effort to correct the problem: Check the LED dsplay Check and record the error message on the LCD dsplay or other communcaton system avalable and take approprate acton to correct the ssue by referrng to the error codes n Appendx B If the system problem perssts, contact your nstaller/dealer When contactng your nstaller, provde the followng nformaton: Seral number Model number Short descrpton of the problem Dsplay message Error codes lsted n the Servce/Error hstory menu Error codes are lsted n Appendx B and wll also be avalable on mypowerrouter.com. 8 Cleanng and mantenance CAUTION Ths chapter descrbes the cleanng and mantenance of the PowerRouter. Clean every 12 months (once per year) the housng wth a dry cloth and check that there s no arflow obstructon. Remove any dust buld-up from the locatons as ndcated. Check the PowerRouter and the cables for vsble external damage on a regular bass. When cleanng the arflow holes nsde the housng, cut off the power from the PowerRouter unt by decommssonng or by usng a bypass swtch. Internal cleanng s only to be carred out by certfed persons. Contact your nstaller/dealer f you fnd any defects. Do not perform any repar work yourself. 13
EN 9 Decommssonng Ths chapter descrbes the decommssonng procedure of the PowerRouter. The decommssonng procedure s needed to safely remove the PowerRouter. CAUTION Decommssonng procedure: 1. Swtch the PowerRouter unt OFF 2. Swtch OFF DC-swtches or dsconnects (Solar / Battery) 3. Swtch OFF AC-swtches or dsconnects (Grd / Load) 4. Wat 5 mnutes for de-energzng 5. Dsconnect communcaton and optonal connectons wrngs 6. Dsconnect battery wrng 7. Dsconnect PV wrng wth the specal tool as descrbed n Appendx D (Solar) 8. Dsconnect AC wrng (Grd / Load) The PowerRouter can now be removed for dsposal or repar. Decommssonng should only be carred out by certfed persons. Contact your nstaller/dealer. 10 Dsposal Ths chapter descrbes procedures for dsposal of the PowerRouter. When the PowerRouter needs to be dsposed of because t has reached the end of ts lfe, or for other reasons, have ths carred out accordng to local waste handlng regulatons. The PowerRouter must not be dsposed of wth household waste. Instead, t s the end-user's responsblty to have t dsposed of by handng t over to a desgnated collecton pont for the recyclng of waste electrcal and electronc equpment. 14
Appendx A Warranty PowerRouter factory warranty condtons Our qualty control program ensures that each PowerRouter product s manufactured to exact specfcatons and s thoroughly tested before leavng the factory. EN 5 year warranty The Nedap factory warranty perod s 5 years as from the purchase date of the PowerRouter system. The warranty condtons are based on the European EU drectve no. 99/44/EG. The legal rghts are appled for unmpeded. Extended warranty For all PowerRouter systems you can acqure an extenson of 5 years on the PowerRouter factory warranty, up to a total of 10 years warranty. The warranty s only avalable f purchased wthn 6 months of the PowerRouter delvery date. Warranty condtons If a PowerRouter becomes defectve durng the relevant PowerRouter warranty perod, one of the followng servces, as selected by the PowerRouter Helpdesk, wll be performed at no charge for materals, exclusve of labor costs: Repar at Nedap N.V., or Repar on-ste, or Exchange for a replacement unt (of equvalent value accordng to model and age) Excluson of lablty Warranty clams and lablty for drect or ndrect damage are excluded f arsng from: transport and storage damage ncorrect nstallaton and/or commssonng modfcatons, changes or attempted repars by untraned and unauthorzed personnel ncorrect use or napproprate operaton nsuffcent ventlaton of the unt falure to observe the applcable safety regulatons force majeure (e.g. lghtnng, overvoltage, storm, fre) cosmetc shortcomngs whch do not nfluence the functonng of the unt damage due to mosture and/or other envronmental condtons The nstaller/dealer who nstalled the PowerRouter must report the defectve PowerRouter system to the PowerRouter Helpdesk. Nedap reserves the rght to replace the unt wth an equal or better specfcaton accordng to Nedap's judgement. Dsclamer All rghts to the content of ths manual are owned by N.V. Nederlandsche Apparatenfabrek Nedap (herenafter Nedap). By usng ths manual you accept the terms of ths dsclamer. Nedap has made every effort to ensure that ths manual s accurate. Nedap dsclams lablty for any naccuraces or omssons that may have occurred and for any damages arsng from or related to the use of ths manual. No publshed data n ths manual may be reproduced or publshed n any form or by any means wthout pror wrtten consent by Nedap. Informaton n ths manual s subject to change wthout notce and does not represent any commtment on the part of Nedap. Nedap makes no commtment to update or keep current the nformaton n ths manual, and reserves the rght to make mprovements to ths manual and/ or to the products descrbed n ths manual, at any tme wthout notce. If you fnd nformaton n ths manual that s ncorrect, msleadng, or ncomplete, we would apprecate your comments and suggestons. 15
EN Appendx B Error codes Solar-related error codes Error code on dsplay Error cause User recommended acton S002-S Over temperature n Solar module Check ambent temperature of the PowerRouter. Check for obstructons n the ar flow channel. S004-S Solar panel voltage too hgh Check solar panel confguraton and wrng S007-S Solar panel current too hgh S005-S An nternal bus problem Contact your nstaller/dealer f ths fault occurs frequently S013-S S016-S Solar panel power output too hgh Internal communcaton error Battery-related error codes Error code on dsplay Error cause User recommended acton B002-S Battery voltage too low Allow battery to be charged by grd or by energy source (solar, wnd, external generator) or dsconnects loads B004-S B005-S Battery temperature too hgh (measured by the external temperature sensor) Battery temperature too low (measured by the external temperature sensor) Check ambent temperature of battery storage room. Provde suffcent coolng. Check ambent temperature of battery storage room. Provde suffcent heatng. B006-S Ambent temperature too hgh Check ambent temperature of the PowerRouter. Check for B007-S Internal temperature sensor detects an obstructons n the ar flow channel. B008-S overtemperature B009-S B014-S B015-S B016-S B017-S B018-S B019-S B010-H Battery termnals short crcut or overload Check battery wrng, remove the short crcut or overload B024-H B011-H An nternal bus problem Contact your nstaller/dealer f ths fault occurs frequently B012-H B013-S B020-S B021-H B026-H B028-H Battery module power does not match wth platform Hardware revson does not match expected hardware revson 16
Grd-related error codes Error code on dsplay Error cause User recommended acton D001-S Grd module temperature too hgh Check ambent temperature of the PowerRouter. Check for obstructons n the ar flow channel. D002-S An nternal bus problem Contact your nstaller/dealer f ths fault occurs frequently D003-S D007-S D007-H D010-S D015-S D025-H D027-H D028-H D029-S Grd relay falure Internal overload Internal communcaton error An nternal bus problem Internal supply voltages out of range Cold start faled D011-S Load voltage too low Check grd voltage D012-S Load voltage too hgh D013-H Load short crcut Check load D023-H Current overload Dsconnect excessve loads D031-H Power overload EN System-related error codes Error code on dsplay Error cause User recommended acton P027-H Internal voltage error Contact your nstaller/dealer f ths fault occurs frequently P028-H Internal frequency error P029-H Internal relay error P089-H Self-use sensor not found P092-H The PowerRouter s not confgured P098-H Hardware s not supported n software P081-H Install wzard error Reset the PowerRouter, re-run the Install Wzard 17
EN Appendx C Techncal Specfcatons Grd Contnuous output power at 40 C (P nom) AC output current AC output voltage (nomnal) AC output range Protecton Standby losses User nterface Connectvty Backup swtch over tme PR50SB-BU PR37SB-BU PR30SB-BU 5000 W (4600 W DE) 3700 W 3000 W 22A 16A 13A 230 Vac ± 2%, 50 Hz ± 0.2%, true sne wave <3% THD, sngle phase 180-264 Vac 45-55 Hz (lmted by local ant-slandng regulatons) electronc, fused 6W nteractve dsplay wth 4-button operaton ethernet RJ45, TCP/IP <1 second Solar Max. Input No. of strngs No. of MPP trackers DC Dsconnecton swtch Solar Voltage MPP Voltage Solar Connectons Max. Effcency Max. MPP Effcency PR50SB-BU PR37SB-BU PR30SB-BU 5.5 kwp and 15 A per strng 4 kwp and 15 A per strng 3.3 kwp 15 A 2 2 1 2, fully ndependent 2, fully ndependent 1 4-pole, 600V, 15A 4-pole, 600V, 15A 2-pole, 600V, 15A 150 600 Vdc per strng 100 480 Vdc per strng MC4 94.5% 99.9% Battery Output charge current Battery types Battery voltage output range (Vout) Battery capacty Chargng curve Short crcut protecton Multpurpose relay Battery temperature compensaton Battery voltage sense Current shunt PR50SB-BU PR37SB-BU PR30SB-BU 25-200 A contnuous, 25-155 A contnuous, 25-125 A contnuous, programmable programmable programmable Gel, AGM, NCd, L-on 18 32 Vdc mn. 100 Ah, at 25A charge current float or 3-stage adaptve wth mantenance electronc, at max. charge current, swtch off <1 sec 2 (NO/NC, 250 Vac, 1 A, 24 Vdc, 5 A) ncluded ncluded ncluded Envronmental Operatng Temperature Range (full power) Storage Temperature Humdty Regulatory Approvals and Standards Safety Emsson Immunty Ant Islandng Protecton Warranty PR50SB-BU PR37SB-BU PR30SB-BU -10 C to +50 C (deratng from 40 C) -40 C to +70 C maxmum 95%, non-condensng CE EN 60950-1, EN 62109-1, EN 60335-2-29 EN 55014-1, EN 61000-3-2, EN 61000-3-3, EN 61000-6-3 EN 55014-2, EN 61000-6-2 VDE 0126.1.1, G83/1(UK), RD1663/2000(ESP), DK5940 E.d. 2.2 (IT), AS4777(AUS) (check www.powerrouter.com for other country certfcatons) fve years (optonal: extenson to ten years) General Dmensons (WxHxD) Protecton Category Weght Topology Coolng PR50SB-BU PR37SB-BU PR30SB-BU 765 x 502 x 149 mm IP 21 20.5 kg galvanc solated transformer forced arflow 18
Appendx D PV-MS tool To prevent damage of the PV connectors when dsconnectng the PV from the PowerRouter, t's advsable to use the PV-MS tool to open the connector lockng mechansm. EN PV dsconnecton procedure: 1. Insert PV-MS tool wth the pns to the connector 2. Pull the PV connector out of the PowerRouter Ths tool s not delvered wth the PowerRouter, Installers/dealers can order the tool from Mult-Contact at www.mult-contact.com. Type: PV-MS, Order no.: 32.6024, Desgnaton: Open-end-spanner set. Notes 19
Scherhetshnwese DE Deses Handbuch enthält Anwesungen für de Installaton, den Betreb und de Wartung des PowerRouters. Der PowerRouter wurde gemäß den nternatonalen Scherhetsbestmmungen entwckelt und geprüft. Um das Verletzungsrsko herabzusetzen und ene schere Installaton sowe enen scheren Betreb des PowerRouters zu gewährlesten, lesen und befolgen Se alle Anwesungen, Scherhets- und Warnhnwese n desem Installatonshandbuch sorgfältg. Das Warnsymbol west auf ene Gefahr für Personen und Ausrüstung hn. Es macht auf en Verfahren aufmerksam, das be ncht ordnungsgemäßer Ausführung zu Schäden am PowerRouter oder der angeschlossenen Ausrüstung führen kann. Außerdem kann des unter Umständen zu Personenschäden führen. Gefahr Gefahr Deses Symbol west auf ene gefährlche Stuaton hn. Ene Nchtbeachtung deses Hnweses kann zu Tod oder zu schweren Verletzungen führen. Warnung Warnung Deses Symbol west entweder egenständg oder zusammen mt den folgenden Symbolen darauf hn, n den Gebrauchsanwesungen nachzuschlagen, de mt desem Produkt ausgelefert wurden. Werden de Gebrauchsanwesungen ncht befolgt, besteht en potenzelles Rsko. VORSICHT Vorscht Deses Symbol west auf ene gefährlche Stuaton hn. Ene Nchtbeachtung deses Hnweses kann zu lechten oder mttelschweren Verletzungen führen. 1 Informaton Deses Symbol st be Hnwesen mt zusätzlchen, wssenswerten Informatonen zu fnden, de für enen optmalen Betreb der Anlage anzuwenden snd. En nummerertes Aufzählungszechen west auf ene Abbldung mt derselben Nummer hn. De Abbldungen befnden sch auf den Seten 2 bs 4. Inhalt Scherhetshnwese 20 Inhalt 20 1 Enletung 21 2 Scherhet 21 3 Montage 21 3.1 Auswahl enes Montageortes 21 3.2 Abmessungen und empfohlene Montageabstände 22 3.3 Montageverfahren 22 4 Verdrahtung 22 4.1 Verdrahtung der AC-Anschlüsse 22 4.2 Verdrahtung der Solaranschlüsse 23 4.3 Verdrahtung von Battere und Temperatursensor 23 4.4 Bypass-Schalter (be Professonal-Modellen) 23 4.5 Anschluss an das Internet 24 4.6 Optonaler CAN-Bus 24 4.7 Fre programmerbare Mehrzweckkontakte 24 5 Inbetrebnahme 24 6 Bedenung 25 6.1 Navgaton 25 6.2 Menü Wartung (Servce) 25 7 Störungen und Fehler 27 8 Rengung und Wartung 27 9 Außerbetrebnahme 28 10 Entsorgung 28 Anhang A Garante 29 Anhang B Fehlercodes 30 Anhang C Technsche Daten 32 Anhang D PV-MS-Werkzeug 33 Notzen 33 Gefahr 20 Um Probleme während der Installaton zu vermeden, lesen Se vor Begnn der Installaton das Installatonshandbuch vollständg durch, um sch mt dem Installatonsverfahren vertraut machen. An bestmmten Stellen von Solaranlagen treten tödlche elektrsche Spannungen auf. Aus Scherhetsgründen wrd empfohlen, dass dese Art von Ausrüstung nur von dafür qualfzertem Personal nstallert und bedent wrd. In der Battere treten tödlche Stromstärken auf. Be enem Kurzschluss der Batterepole kann der Funkenschlag zu Brandverletzungen oder Brandgefahr führen.