Installation Manual

CPS 5000-King 5.2k

Table of Contents

1. INTRODUCTION
   

1. GENERAL INFORMATION
   
2. DOCUMENT SCOPE
   
3. TERMINOLOGY
   

2. SAFETY FIRST
   

1. CRITICAL SAFETY REQUIREMENTS
   
2. WARRANTY REQUIREMENTS
   

3. STRUCTURAL INFORMATION
   

1. LIST OF COMPONENTS
   
2. PRODUCT LAYOUT
   

4. INSTALLATION
   

1. PRE-INSTALLATION
   

3. Product Applications
   
4. Requirements & Limitations
   
5. Wiring Diagram
   

2. STANDARD INSTALLATION (UPS APPLICATION)
   

3. ADDING SOLAR (PV APPLICATION)
   

5. BATTERY OPERATION
   

6. OPERATING INSTRUCTIONS
   

1. INVERTER
   
2. BATTERY DISPLAY PANEL
   

7. EMERGENCY & FIRST AID
   

8. SUPPORTING DOCUMENTS
   

1. Introduction
   

1. GENERAL INFORMATION
   

Congratulations on purchasing a high-quality BlueNova® product.

2. DOCUMENT SCOPE
   

This is a technical support document applicable to the following product(s):

• BlueNova® CPS 5000-King 5.2k
  

The information in this document includes the following

• Product Assembly & Installation Procedures
  
• Operating Instructions
  
• Maintenance & Troubleshooting Guidelines
  
• Emergency Procedures
  

3. TERMINOLOGY
   

The table below contains an alphabetical list of industry-specific abbreviations as well as product-specific terms used throughout this document:

Term	Definition
AC  (abbr.)	Alternating Current (as supplied by utilities & most generators).
Battery  (term)	A product subcomponent, in this case specifically 1 x BN52V-100-5.2k DU (Daily Use) Lithium Iron Phosphate battery. See: G. Supporting Documents for more technical information.
Battery Pack  (term)	Two or more BN52V-100-5.2k DU batteries connected to each other in parallel, up to a maximum of 9.
BMS  (abbr.)	Battery Management System: Battery-integrated electronic circuitry & components. Supports cell health, product safety & peripheral compatibility functionalities.
DB  (abbr.)	Electrical Distribution Board. Site DB refers to the main electrical distribution board (if available) of the building or site at which the product will be installed. DB-A or DB-B refers to either one of the two electrical distribution boards integrated as subcomponents within the CPS5000 system (see: C. Structural Information - 1. Product Layout)
DC  (abbr.)	Direct Current. Batteries & solar panels supply DC.
DoD  (abbr.)	Depth of Discharge. Refers to a percentage of the total available energy capacity of a battery or battery pack.
MPPT  (abbr.)	Maximum Power Point Tracker: An integral component in modern solar systems, mainly supportive towards the stabilisation of solar-supplied energy to the rest of the system.
Product  (term)	Refers to a complete (read: fully assembled) CPS 5000-5.2k system.
Subcomponent  (term)	Refers to one or more of the main functional components that the CPS system consists of (as illustrated in section C. Structural Information - 1. Product Layout) below. Does not refer to screws, wiring & other small system components.
SoC  (abbr.)	State of Charge: A percentage value indication of the amount of energy stored within a battery.
SoH  (abbr.)	State of Health: A percentage value indication of the amount of energy capacity that a battery has retained at any point during its service life. Conversely indicates the percentage with which a battery has faded (read: lost capacity) from being used over time.
UPS  (abbr.)	Uninterruptable Power Supply

2. Safety First
   

1. CRITICAL SAFETY REQUIREMENTS
   

IMPORTANT: Failure to adhere to any one or more of the requirements listed below may result in serious personal injury or death. For your own safety, it is therefore of utmost importance that any & all requirements listed below are strictly adhered to:

• Product installation & maintenance should be performed by a qualified electrical installer or authorised BlueNova® representative only.
  
• Do not crush, burn or incinerate the product or any of its subcomponents.
  
• Ensure that product-integrated battery/batteries are fully recharged at least once every 3 months in accordance with maintenance procedures listed in this document while/whenever the product is non-operational and/or in storage.
  
• Do not install the product in direct sunlight. Do not expose the product or any of its subcomponents to ambient and/or direct temperatures exceeding 55°C.
  
• Avoid short-circuiting battery terminals. Do not connect batteries to any peripheral subcomponents in reverse polarity.
  
• Always disconnect the product from external power sources before commencing with maintenance procedures. In some cases, disconnecting the battery or battery pack might also be required. Read maintenance instructions carefully.
  
• This product has been designed for general home use. It should not be used to supply power to life-sustaining medical appliances, automotive systems or other devices from which interrupted operation may lead to damage, personal injury or death.
  
• Always wear the necessary protective gear during installation and/or maintenance.
  

2. WARRANTY REQUIREMENTS
   

This product consists of various subcomponents, some of which include individual warranties supplied by the manufacturer and/or distributor in each case. Please see 

G. Supporting Documents for full documentation of BlueNova product & workmanship warranties, as well as third-party supplier warranties. 

IMPORTANT: The application for which this product is installed might require integration with existing on-site electrical systems and/or components. Depending on the extent of such installations, a Certificate of Compliance might have to be obtained following completion of such installations, as per South African legislature. CoC documents issued in this regard should be kept safe & will be supportive in the event of future warranty claims.

For installations outside the borders of South Africa, any local legislative requirements and/or laws comparable to the above should also be adhered to, following installation,

especially if some similar form of certification can be obtained.

3. Structural Information
   

1. PRODUCT LAYOUT
   

A CPS 5000-King 5.2k system consists of 2 x main wall-mountable sections.

The top section consists of a backboard which houses the inverter, distribution boards & output socket sets, while the bottom section consists of a bracket supporting a LiFePO4 battery:

The distribution boards in the top section contain the following components:

The diagram below illustrates the layout of the unit’s BN52V-100-5.2k DU battery:

2. LIST OF COMPONENTS
   

Each CPS5000-King 5.2k product is packaged for shipment in 2 x boxes. Please check the contents of each box upon delivery to ensure that you have received all the components & quantities listed below:

Box 1: Top unit	Qty	Specifications / Notes
Backboard, including: -  Inverter (pre-installed) -  DB’s & breakers (pre-installed) -  Socket sets (pre-installed)	1	Powder-coated steel
		1	Axpert 5kVA King
		2	See D. Installation for more info
		2	Compliant to latest industry standards
Rawl bolts	4	For mounting the backboard section

Box 2: Bottom unit	Qty	Specifications / Notes
Battery	1	BN52V-100-5.2k DU (Daily Use)  Lithium Iron Phosphate battery
Battery mounting bracket	1	Single bracket (supports 1 x of the above   batteries), powder-coated steel.

4. Installation
   

1. PRE-INSTALLATION
   

1.1 Product Applications

The CPS5000 has been designed to be suitable towards various applications, mainly due to the fact the the product-integrated inverter is compatible by design with several peripheral hardware components. A few applications for which the product can be configured are described below:

Product Application	Description
UPS Application	UPS solutions are required in systems where power supplied to the load should remain uninterrupted & stable regardless of grid supply stability. Typically, UPS solutions are installed in systems where inconsistent & unreliable grid-supplied power is the only available power source. Following installation, the product’s integrated battery/batteries provide a secondary power source from which the supply of energy to connected essential load devices is triggered instantly whenever grid-supplied power is interrupted.
Daily Cycling Application	Daily cycling applications can be found in multi-component systems that include one or more batteries. Such systems are designed to ensure maximum usage of the installed batteries on a regular basis. Apart from grid power, daily cycling systems typically include the integration of additional power sources or components required for energy generation, such as a solar panel array, backup generator or wind turbine. Much of the energy generated by renewable means during the day is typically supplied to increase battery SoC for use at night.
Off-grid Application	Off-grid systems do not make use of utility/grid power supply. Batteries are always included in such systems. These batteries are recharged from alternative sources such as solar panel arrays, wind turbines and/or generators.

2. Requirements & Limitations
   

Please note that the CPS 5000-King 5.2k has been pre-configured for UPS applications. The product is therefore not “solar-ready” but can be reconfigured for such purposes. Please see D3. Adding Solar below. Also, please refer to the individual data sheets of all relevant subcomponents listed in section G. Supporting Documents before commencing with product assembly & installation. Familiarising yourself with system subcomponents minimises the risk of failure during product installation. For non-standard applications of the product, one or more of the product’s integrated components might have to be reconfigured to ensure maximum application compatibility. In such cases, it is especially important to reference the technical specifications of all relevant subcomponents – especially the limitations of each. ensure that none of these are exceeded during subcomponent reconfiguration.

3. Wiring Diagram
   

The simplified wiring diagram below illustrates how the CPS 5000-5.2k’s components have been connected to each other. Note that a solar panel array & connection has been illustrated even though these components are not supplied with the product.

2. PRE-INSTALLATION: PRODUCT ASSEMBLY
   

The following section lists instructions for assembling the CPS5000-King 5.2k prior to installation. For the purposes of this document, assembly instructions include mounting the 2 sections of the product onto a wall. Therefore, before commencing with product assembly, careful consideration should be taken towards where the product should be installed. 

STEP 1	Connect utility/grid supply to the inverter. Remove the cover of DB-B. Thread a 3-core (earth, live & neutral) wire through one of the compression glands at the bottom of the top section, then through one of the openings available on the distribution board. Connect the wire to the top of the breaker labelled AC IN. The opposite open end of this wire can then be connected to the AC supply from the site DB directly or fitted with a plug so that the system can be charged from one of the site’s wall outlets.
STEP 2	Mount the top section backboard onto a sturdy wall.  Use a levelling tool during this step to ensure neat, level installation. Don’t remove the inverter or any other pre-installed subcomponents from the backboard during mounting. Use all the rawl bolts supplied. The top section should be mounted as high as possible without compromising access to the inverter’s user interface and/or legibility of any information that might be displayed thereon. Typically, the top section would be mounted at an overall height that would leave the inverter’s UI on eye-level with a standing person of average height.
STEP 3	Mount the battery bracket below the newly-mounted top section.  The battery bracket should be installed directly below the newly-mounted top section & vertically-centred with it. The distance between the top section & bracket should be short enough to allow the battery to be connected to the inverter with the cables included for this purpose. Before mounting the bracket, check to ensure that the bracket’s chosen location will allow for successful connection. Space constraints & other site restrictions might require side-by-side installation (or other non-standard orientations) of the two sections, for which the supplied cables might be too short. In such cases, please ensure that replacement cables comply to industry-standard requirements & are based on the relevant max. continuous performance specifics of the battery/battery pack and the inverter (see G. Supporting Documents for data sheets).
STEP 4	Install the battery onto the bracket, then connect to the top section. To connect the battery to the top section, connect the red wire to the battery’s positive terminal & connect the black wire to the battery’s negative terminal. The black negative wire is already connected to the inverter directly, while the red positive wire is connected to the inverter via the DB-A breaker labelled Battery (+)
STEP 5	Connect the load. The load can now be connected to one or both of the socket sets available on the top section. Please take note of the following limitations: The maximum power that the inverter can supply at any given time at 25°C is 4000W. Should this output limitation be exceeded for more than a few seconds, the inverter will auto-disconnect. At temperatures higher than 25°C, maximum inverter output will derate to less than 4000W. See the inverter manual included with shipment for more information. The AC breakers installed on DB-B for the 2 socket sets are rated at 16A for each socket set. Should the total current demanded from either socket set exceed this limitation, the associated breaker will trip.

3. ADDING SOLAR (PV APPLICATION)
   

A solar array can be connected to the CPS 5000-5.2k’s inverter via the integrated distribution panel. Such installations should only be undertaken by qualified industry personnel. Please also ensure that the solar array’s open-circuit voltage does not exceed the maximum specified value (as per inverter data sheet appended to this document).

The suggested PV addition is 1000W with a maximum of 102VDC on the PV input side and also a maximum charging current of 60A (adjustable via inverter UI). Depending on the specific panels that are being installed (panel Open Circuit Voltage), 2-3 panels might be placed in series to achieve the necessary input voltage required by the integrated MPPT.

Note: Care should be taken regarding the maximum open circuit voltage from the solar panel string by leaving a “buffer voltage” of ±10V for safety purposes. With the addition of PV onto the CPS 5000-5.2k unit, the following menu items should be adjusted via the inverter’s UI:

Menu #	Description
01	Output Source Priority
02	Maximum Charge Current (total)
11	Maximum Charge Current (utility/grid)
16	Charger Source Priority

4. ADDING MORE BATTERIES
   

Additional batteries can be connected to the original battery to increase overall capacity.

Batteries should be connected as illustrated below:

5. Battery Operation
   

SYSTEM START / SHUT DOWN / RESET:

FUNCTION	OPERATION
Start	Press the RESET button for 3s when the battery is in sleep mode to switch it on. Led on the panel flashes from the Left to Right.
Shut down	Press the RESET button for 3s when the battery is in idle/discharge mode to switch it OFF. Led on the panel flashes from Right to Left.
Resetting	Press the RESET button for 6s when the battery is in idle/discharge mode to reset the BMS.

    

    COMMUNICATION PORTS:

COMPONENT	FUNCTION / DESCRIPTION
RS232 (RJ11)	Not active
CAN Ports (RJ45 x 2)	Serial communication via CAN Bus. PIN configuration as follows: 7 : CAN-H 8 : CAN-L
RS485 Ports (RJ45 x 2)	Pin configuration as follows: 1/8 : A 2/7 : B 3/6 : GND 4/5 : NC

DIP SWITCH PANEL CONFIGURATION:

Address

DIP Switch Number

Master / Slave (CAN)

Definition (RS485)

Parallel Configuration

#1

#2

#3

#4

1

ON

OFF

OFF

OFF

Master

Pack1

2

OFF

ON

OFF

OFF

Slave 1

Pack2

3

ON

ON

OFF

OFF

Slave 2

Pack3

4

OFF

OFF

ON

OFF

Slave 3

Pack4

5

ON

OFF

ON

OFF

Slave 4

Pack5

6

OFF

ON

ON

OFF

Slave 5

Pack6

7

ON

ON

ON

OFF

Slave 6

Pack7

8

OFF

OFF

OFF

ON

Slave 7

Pack8

9

ON

OFF

OFF

ON

Slave 8

Pack9

It is essential to set the DIP address number in order when connected with a CAN bus inverter, otherwise the BMS will report an error.

STATE-OF-CHARGE:

COMPONENT	FUNCTION / DESCRIPTION
State-of-charge indicator	0% – 25% SoC	25% – 50% SoC	50% – 75% SoC	75% – 100% SoC

LED indicators:

Status

Running condition

SOC

RUN

ALM

Description

Switch Off

Sleep mode

off

off

off

off

off

off

All off

Stand by

Normal

| off

off

off

| off

| Flash 1

off

Idle

Alarm

off

| off

| off

off

Flash 3

| Flash 3

ALM and RUN Flash 3

Charging

Normal

According to real-time capacity

on

off

Highest LED Flash 2

OV Alarm

According to real-time capacity

on

off

Highest LED Flash 2

OC Alarm

According to real-time capacity

on

Flash 3

Highest LED Flash 2

OV Protect

on

on

on

on

on

off

OC Protect (charge limit off)

off

off

off

off

off

on

Stop charging

Charge limit

According to real-time capacity

on

off

Highest LED Flash 2

Discharging

Normal

According to real-time capacity

Flash 3

off

According to real-time capacity indicate

Alarm

According to real-time capacity

Flash 3

Flash 3

ALM and RUN Flash 3

OC/short circuit/revere connection

off

off

off

off

off

on

Stop discharging

UV

off

off

off

off

off

off

Stop discharging

Temp

Normal

According to status

Charge alarm

According to real-time capacity

on

Flash 3

Highest LED Flash 2

Discharge alarm

According to real-time capacity

Flash 3

Flash 3

Protect

off

off

off

Off

off

on

6. Operating Instructions
   

1. INVERTER
   

Please refer to the inverter manual enclosed within the product packaging.

The values with which the inverter has been preconfigured for UPS applications are listed in this document under G. Supporting Documents

2. RECOVERY FROM OVER-DISCHARGE
   

If the batteries are over-discharge and left uncharged for a period of time, they will enter protection mode. To recover the batteries from this mode, follow the procedure below:

• Turn off battery circuit breaker(s) on the unit’s integrated DB.
  
• Turn on mains supply breaker. You have to have a working mains supply.
  
• Wait for 2 hours, then turn on the battery breaker(s). The inverter must start and charge the battery with a positive current at this point. Reference the integrated battery display.
  
• If the batteries are not charged, repeat steps 1 to 3 above.
  
• Should the system not start up at this point, please contact BlueNova technical support.
  

7. Emergency & First Aid
   

1. IN CASE OF FIRE
   

1. Evacuate danger zone. Open ventilation in the room if possible.
   
2. Extinguish fire with a CO2 fire extinguisher.
   
3. After the fire has been extinguished, immerse any remaining smoking cells completely in water.
   

Wear protective gear during this procedure.

2. SKIN CONTACT
   

1. Wash the affected area immediately with soap and water.
   
2. If irritation persists, seek medical attention.
   

3. EYE CONTACT
   

1. Rinse eyes immediately with clean water continuously for at least 15 minutes.
   
2. Seek medical attention immediately afterwards.
   

4. INGESTION
   

1. Refrain from taking any emetic or vomit-inducing medicine.
   
2. Seek medical attention immediately.
   

8. Supporting documents