OutBack Power SmartRE 3000 Manual de usuario

Installation Manual

About OutBack Power Systems

OutBack Power Systems is a leader in advanced energy conversion technology. Our products include

true sine wave inverter/chargers, maximum power point charge controllers, system communication

components, as well as breaker panels, breakers, accessories, and assembled systems.

Contact Information

Telephone: +1.360.435.6030 (North America)

+1.360.618.4363 (Technical Support)

+1.360.435.6019 (Fax)

+34.93.654.9568 (Barcelona, Spain)

Address: North America

19009 62nd Avenue NE

Arlington, WA USA

European Office:

C/ Castelló, 17

08830 - Sant Boi de Llobregat

BARCELONA, España

E-mail: [email protected]

Web Site: www.outbackpower.com

Disclaimer

UNLESS SPECIFICALLY AGREED TO IN WRITING, OUTBACK POWER SYSTEMS:

(a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL

OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION.

(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER DIRECT, INDIRECT,

CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE

USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER’S RISK.

Warranty Summary

OutBack Power Systems Inc. warrants that the products it manufactures will be free from defects in

materials and workmanship for a period of five (5) years subject to the conditions set forth in the

warranty detail found inside the back cover of this manual.

OutBack Power Systems cannot be responsible for system failure, damages, or injury resulting from

improper installation of their products.

Notice of Copyright

Trademarks

SmartRE is a registered trademark of OutBack Power Systems. OutBack Power is a registered

trademark of OutBack Power Systems.

Date and Revision

April 2009, Revision A

Part Number

900-0033-01-00 Rev A

900-0033-01-00 Rev A 1

Important Safety Instructions

READ AND SAVE THESE INSTRUCTIONS!

This manual contains important safety instructions for the SmartRE. Read all instructions and

cautionary markings on the SmartRE and on any accessories or additional equipment included in the

installation. Failure to adhere to these instructions could result in severe shock or possible

electrocution. Exercise extreme caution at all times to prevent accidents.

Symbols Used

Symbol Description

Ground

AC Current

DC Current

∅Single-Phase

Sine Wave

WARNING: Hazard to Human Life

This type of notation indicates that the hazard could be harmful to human life.

CAUTION: Hazard to Equipment

This type of notation indicates that the hazard may cause damage to

the equipment.

IMPORTANT:

This type of notation indicates that the information provided is important to

the installation, operation and/or maintenance of the equipment. Failure to

follow the recommendations in such a notation could result in voiding the

equipment warranty.

Audience

These instructions are for use by qualified personnel who 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 240 Vac and 150 Vdc.

Important Safety Instructions

2900-0033-01-00 Rev A

Definitions

Table 1 Terms and Acronyms used in this Installation Manual

Acronym Definition

AC Alternating Current

ANSI American National Standards Institute

DC Direct Current

FCC Federal Communications Commission (North America)

GND Ground

IEEE Institute of Electrical and Electronics Engineers

N AC Neutral

NEC National Electric Code (North America)

NFPA National Fire Protection Association

OSHA Occupational Safety and Health Association

PV Photovoltaic

RE Renewable Energy

UL Underwriters Laboratory

General Safety

WARNING: Limitations on Use

This equipment is NOT intended for use with life support equipment or other

medical equipment or devices.

CAUTION: Equipment Damage

Only use components or accessories recommended or sold by OutBack Power

Systems or its authorized agents.

IMPORTANT:

Do not attempt to install this equipment if it appears to be damaged in any

way. See the Troubleshooting Section for instructions on how to return the

equipment if you know, or suspect, it is damaged.

Important Safety Instructions

900-0033-01-00 Rev A 3

Personal Safety

WARNING: Personal Injury

¾This equipment weighs over 100 lbs (45 kg). Use safe lifting techniques

when lifting this equipment as prescribed by the Occupational Safety and

Health Association (OSHA) or other local codes.

¾Use standard safety equipment such as safety glasses, ear protection, steel-

toed safety boots, safety hard hats, etc. as prescribed by the Occupational

Safety and Health Association (or other local codes) when working on this

equipment.

¾Use standard safety practices when working with electrical equipment

(e.g., remove all jewelry, use insulated tools, wear cotton clothing, etc.)

¾Never work alone when installing or servicing this equipment. Have

someone nearby that can come to your aid if necessary.

SmartRE System Safety

WARNING: Lethal Voltage

¾Review the system configuration to identify all possible sources of energy.

Ensure ALL sources of power are disconnected before performing any

installation or maintenance on this equipment. Confirm that the terminals

are de-energized using a validated voltmeter (rated for a minimum

1000 Vac and 1000 Vdc) to verify the de-energized condition.

¾Do not perform any servicing other than that specified in the installation

instructions unless qualified to do so or as instructed to do so by OutBack

Power Systems Technical Support personnel.

WARNING: Burn Hazard

Internal parts can become hot during operation. Do not remove the cover

during operation or touch any internal parts. Be sure to allow them sufficient

time to cool down before attempting to perform any maintenance.

WARNING: Fire Hazard

¾In residential installations: check for multi-wire branch circuit wiring at the

location for the installation. A possible fire hazard can exist if 120 Vac only

sources (such as inverters and generators) are wired incorrectly into

120/240 Vac panels containing multi-wire branch circuits. Consult the local

electric code for assistance.

¾Do not place combustible or flammable materials within 12 feet (3.7 m) of

the equipment.

¾Use only the recommended cable sizes (or greater) for AC and DC

conductors in compliance with local codes. Ensure all conductors and

connections are in good condition. Do not operate the unit with damaged

or substandard cabling.

Important Safety Instructions

4900-0033-01-00 Rev A

CAUTION: Equipment Damage

¾When connecting cables from the inverter to the battery terminals, ensure

the proper polarity is observed. Connecting the cables incorrectly can

damage or destroy the equipment.

¾Thoroughly inspect the equipment prior to energizing. Verify that no tools

or equipment have been inadvertently left behind.

¾Ensure clearance requirements are strictly enforced and that all vents are

clear of obstructions that can prevent proper air flow around or through

the unit.

¾Sensitive electronics inside the equipment can be destroyed by static

electricity. Be sure to discharge any static electricity built up before

touching the equipment and wear appropriate protective gear.

PV Safety

WARNING: Shock Hazard

Photovoltaic (PV) arrays can be energized with minimal ambient light available.

Therefore to ensure a safe disconnect from the system, be sure to install a PV

disconnect, breaker, or accessible fuse box (depending on local code

requirements).

CAUTION: Equipment Damage

PV Arrays must be wired with correct polarity (positive-to-positive, negative-to-

negative). Connecting the cables incorrectly can damage or destroy the

equipment.

Battery Safety

WARNING: Electrocution Hazard

¾Use the battery types recommended by OutBack Power Systems. Follow

the battery manufacturer’s recommendations for installation and

maintenance.

¾Ensure clearance requirements are strictly enforced around batteries.

¾Ensure the area around the batteries is well ventilated and clean of debris.

¾Always use insulated tools. Avoid dropping tools onto batteries or other

electrical parts.

¾Keep plenty of fresh water and soap nearby in case battery acid contacts

skin, clothing, or eyes.

¾If you need to remove a battery, always remove the ground terminal from

the battery first. Make sure all accessories are turned off so you don’t cause

a spark.

¾If a remote or automatic generator control system is used, disable the

automatic starting circuit and/or disconnect the generator from its starting

battery while performing maintenance to prevent accidental starting.

Important Safety Instructions

900-0033-01-00 Rev A 5

WARNING: Fire or Burn Hazard

¾Ensure the cables are properly sized. Failure to size the cables properly can

result in a Fire Hazard.

¾Wear complete eye protection and clothing protection when working with

batteries. Avoid touching your eyes while working near batteries.

¾If battery acid contacts skin or clothing, wash immediately with soap and

water. If acid enters the eye, immediately flood it with running cold water

for at least 20 minutes and get medical attention immediately.

¾Never smoke or allow a spark or flame near the batteries.

¾Keep plenty of fresh water and soap nearby in case battery acid contacts

skin, clothing, or eyes.

WARNING: Explosion Hazard

Never charge a frozen battery.

CAUTION: Equipment Damage

When connecting cables from the DC input breaker to the battery terminals,

ensure the proper polarity is observed (positive-to-positive, negative-to-

negative). Connecting the cables incorrectly can damage or destroy the

equipment.

IMPORTANT:

Baking Soda neutralizes lead-acid battery electrolyte.

Vinegar neutralizes NiCad and NiFe battery electrolyte.

Have a supply of either substance readily available if using these types

of batteries.

Regulatory References

¾National Electric Code (NEC) Article 690, (current edition)

¾Canadian Electrical Code, Part I (CSA 107.1)

¾UL 1741-2005 Static Inverter and Charge Controllers for Use in Photovoltaic Power Systems

¾American National Standards Institute/National Fire Protection Agency (ANSI/NFPA) 70

Recycling Information

IMPORTANT: Recycle Electronics and Batteries

Batteries are considered hazardous waste and must be recycled according to

local jurisdiction. Inverters and other electronics contain metals and plastics

that can (and should) be recycled. The following are some websites and phone

numbers that provide information and “how” and “where” to recycle batteries

and other electronic equipment.

OutBack Power Systems strongly encourages you to learn about recycling and

to dispose of recyclable items accordingly. The Earth, and OutBack Power

Systems, thanks you for that effort.

Important Safety Instructions

6900-0033-01-00 Rev A

Earth 911

Web site: www.Earth911.com

Address: 14646 N. Kierland Blvd., Suite 100

Scottsdale, AZ 85254

Phone: +1.480.337.3025 (direct)

OurEarth.org

There is a place on the website for contacting OurEarth.org using email. No direct email address

is provided.

Web site: http://www.ourearth.org/recycling.htm

Environmental Protection Agency, USA

Web site: www.epa.gov/recyclecity/

Phone: +1.415.947.8000

(Monday –Friday 8:00 AM to 12:00 PM and 1:00 PM to 4:00 PM PST)

Email: [email protected]

Keep America Beautiful, USA

Web site: www.kab.org/

Address: 1010 Washington Boulevard

Stamford, CT 06901

Phone: +1.203.659.3000 (Main number)

Fax: +1.203.659.3001

Email: [email protected]

Natural Resources Canada

Address: 580 Booth, Ottawa, ON K1A 0E8

Phone: +1.613.995.0947

TTY: +1.613.996.4397

(Phone and TTY: Monday to Friday, 8:30 a.m. to 4:30 p.m. ET)

Web site: http://www.nrcan-rncan.gc.ca/mms-smm/busi-indu/rec-rec-eng.htm

Office of Waste Management, Canada

Address: Office of Waste Management

Conservation and Protection

Environment Canada

Ottawa, Ontaro K1A 0H3

Phone: +1. 819.997.2800

Web site: http://www.portaec.net/library/recycling/recycling_in_canada.html

900-0033-01-00 Rev A 7

Table of Contents

Important Safety Instructions ........................................................................1

Symbols Used ........................................................................................................................................................................1

Audience .................................................................................................................................................................................1

Definitions...............................................................................................................................................................................2

General Safety .......................................................................................................................................................................2

Personal Safety......................................................................................................................................................................3

SmartRE System Safety.......................................................................................................................................................3

PV Safety..................................................................................................................................................................................4

Battery Safety.........................................................................................................................................................................4

Regulatory References........................................................................................................................................................5

Recycling Information ........................................................................................................................................................5

Earth 911 .............................................................................................................................................................................................6

OurEarth.org ......................................................................................................................................................................................6

Environmental Protection Agency, USA...................................................................................................................................6

Keep America Beautiful, USA .......................................................................................................................................................6

Natural Resources Canada ............................................................................................................................................................6

Office of Waste Management, Canada .....................................................................................................................................6

Introduction...............................................................................................11

Components ....................................................................................................................................................................... 12

Accessories.......................................................................................................................................................................................12

Applications ........................................................................................................................................................................ 13

PV Array Planning ..........................................................................................................................................................................13

Battery Bank Planning ..................................................................................................................................................................14

Generators........................................................................................................................................................................................14

Preparation.......................................................................................................................................................................... 15

Tools Required ................................................................................................................................................................................15

Materials Required.........................................................................................................................................................................15

Accessories.......................................................................................................................................................................................15

Location.............................................................................................................................................................................................15

Environmental.................................................................................................................................................................................16

Clearance and Access Requirements ......................................................................................................................... 16

Dimensions.......................................................................................................................................................................... 17

Conduit and Knockout Preparation............................................................................................................................ 18

Horizontal Arrangements............................................................................................................................................... 19

Vertical Arrangements..................................................................................................................................................... 19

Mounting.............................................................................................................................................................................. 21

Installing the Wall Brackets for a Horizontal Position ........................................................................................................22

Installing the Bottom Bracket for an Elevated Position.....................................................................................................23

Installing Wall Brackets for Vertical Position.........................................................................................................................24

Removing the Interior Cover......................................................................................................................................... 27

Accessing the Wiring Compartment .......................................................................................................................... 28

Table of Contents

8900-0033-01-00 Rev A

Wiring .................................................................................................................................................................................... 29

Grounding and Neutral Connections......................................................................................................................................29

DC Connections..............................................................................................................................................................................30

AC Connections ..............................................................................................................................................................................31

MATE2 Installation.........................................................................................................................................................................32

Functional Test/Commissioning.................................................................................................................................. 35

Pre-startup Procedures ................................................................................................................................................................35

Energize/Startup ............................................................................................................................................................................35

Setting Time, Date & Display......................................................................................................................................................36

Setting System Parameters – The Advanced Menu ...........................................................................................................38

Setting Battery Amp-Hours and Return Amps.....................................................................................................................39

De-energize/Shutdown ...............................................................................................................................................................40

Reassembling the Enclosures ....................................................................................................................................... 41

Electronics Enclosure Interior Cover........................................................................................................................................41

Adding the Front Cover Brackets to Electronics Enclosure..............................................................................................41

Battery Enclosure Interior Cover ...............................................................................................................................................42

Adding the Front Cover Brackets to Battery Enclosure.....................................................................................................42

For Outdoor Installations (3R-Rating) ........................................................................................................................ 43

Installing the Top Cap...................................................................................................................................................................43

Installing the Locking Bracket....................................................................................................................................................43

Installing the Front Cover............................................................................................................................................................44

Specifications .............................................................................................45

Electrical Specifications................................................................................................................................................... 45

Mechanical Specifications.............................................................................................................................................. 46

Environmental Specifications ....................................................................................................................................... 46

Renewable Energy Input & Storage............................................................................................................................ 47

PV Sizing............................................................................................................................................................................................47

Battery Bank Sizing........................................................................................................................................................................47

Amp-Hour Requirements ............................................................................................................................................................47

Wiring Configurations .................................................................................53

120 Vac Vertical Installation with an External Sub-panel.................................................................................... 55

120 Vac Vertical Installation using Internal Sub-panel ........................................................................................ 56

120 Vac Horizontal Installation with an External Sub-panel.............................................................................. 57

120 Vac Horizontal Installation using the Internal Sub-panel........................................................................... 58

120/240 Vac Horizontal Installation............................................................................................................................ 59

Wiring Schematic for 2500 W and 3000 W, 120 Vac Configurations .............................................................. 60

Wiring Schematic for 2500 W and 3000 W, 120/240 Vac Configurations ..................................................... 61

Warranty....................................................................................................63

How to Arrange for Warranty Service ........................................................................................................................ 64

Return Material Authorization (RMA)......................................................................................................................................64

Returning Product to OutBack ..................................................................................................................................................64

Index .........................................................................................................65