Installation Manual

CPS 5000-Vic 10.4k

Table of Contents

1. INTRODUCTION
   

1. GENERAL INFORMATION
   
2. DOCUMENT SCOPE
   
3. TERMINOLOGY
   

2. SAFETY FIRST
   

1. GENERAL SAFETY PRECAUTIONS
   
2. OPERATIONAL GUIDELINES & GOOD PRACTICE
   

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. OPERATING INSTRUCTIONS
   

1. INVERTER
   
2. BATTERY DISPLAY PANEL
   

6. EMERGENCY & FIRST AID
   

7. 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-Vic 10.4k
  

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 a list of industry terms used throughout this document & the definition of each:

Term	Definition
AC	Alternating current
DC	Direct current
Product	Refers to CPS 5000-Vic 10.4k (complete) including all subcomponents.
Subcomponent	Components that the product consists of (incl. main components such as the batteries & inverter as well as smaller components such as switches, sockets screws & wiring)
Battery	One of either two BN52V-100-5.2k integrated batteries.
Battery Pack	Both BN52V-100-5.2k batteries, connected in serie
SoC	Battery / battery pack state of charge
DoD	Battery / battery pack depth of discharge
SoH	Battery /battery pack state of health
BMS	Battery management system
MPPT	Maximum power point tracker
UPS	Uninterruptable power supply

2. Safety First
   

1. GENERAL SAFETY PRECAUTIONS
   

Product installation should be performed by a qualified electrical technician or authorised BlueNova® representative only, in strict accordance with the relevant instructions contained within this document. The following precautions should be taken:

• Do not crush, burn or incinerate the product or any of its subcomponents.
  
• Ensure that the batteries of stored units are fully recharged at least once every 3 months in accordance with recharge procedures herein.
  
• Do not install the product in direct sunlight. Do not expose the product or any of its subcomponents to temperatures exceeding 55°C.
  
• Avoid short-circuiting battery terminals and/or connecting batteries to other components in reverse polarity.
  
• Disconnect the product from external power sources before commencing with maintenance procedures. Some procedures might require disconnecting the battery pack as well.
  
• This product has been designed for general home use. It should not be used to supply power to life-sustaining medical appliances, automotive systems etc.
  

2. OPERATIONAL GUIDELINES & GOOD PRACTICE
   

For health & safety reasons, the following guidelines should be adhered to:

• Always wear the necessary protective gear during installation and/or maintenance.
  

3. Structural Information
   

1. LIST OF COMPONENTS
   

The CPS 5000-King 5.2k wall-mountable unit is shipped with the following pre-assembled subcomponents included:

Component	Qty	Supplier
Batteries: BN52V-100-5.2k	2	BlueNova®
Inverter: MultiPlus II	1	Victron
Distribution Board	1	(Miscellaneous)
Isolator Switch	1	(Miscellaneous)
Battery Display Panel	1	BlueNova®
Output Socket Sets	2	(Miscellaneous)
Nameplate	1	BlueNova®

Please also check the product packaging for the following installation components:

Component	Qty	Supplier
10mm Rawl bolt	2	(Miscellaneous)
Inverter manual	1	Victron
Battery Display Manual	1	BlueNova®
Certificate of compliance	1	(Miscellaneous)

Apart from the above, additional supporting documentation is appended within this document (See G. Supporting Documents). This manual as well as all other supporting documentation is also available online at www.bluenova.co.za

2. PRODUCT LAYOUT
   

4. Installation
   

1. PRE-INSTALLATION
   

1.1 Product Applications

Please note that the CPS 5000-Vic 10.4k (the inverter, in particular) has been pre-configured to be used for UPS applications. The product is therefore not “solar-ready” but can be reconfigured for such purposes as described in D3. Adding Solar below.

2. Requirements & Limitations
   

Please refer to the data sheets & other technical documents included within this manual to ensure that the product and/or any of its subcomponents are installed correctly. Furthermore, in order to prolong product lifespan & ensure optimal operation the following requirements must be met:

• The electrical input & output applied to the product should not allow for the product or any of its subcomponents to exceed stated performance limitations.
  
• For non-standard applications of the product, one or more of the product’s integrated components might have to be reconfigured to ensure compatibility with peripherals.
  

3. Wiring Diagram
   

The simplified wiring diagram below illustrates how the CPS 5000-Vic 10.4k k’s components have been connected to each other. Note that the solar panel array connection has been illustrated even though solar panels are not supplied by BlueNova.

2. STANDARD INSTALLATION (UPS APPLICATION)
   

The following procedure describes how to correctly install your CPS 5000-Vic 10.4k:

STEP 1	Remove the pre-assembled main unit from the packaging. Also remove the 2 x 10mm rawl bolts included.
STEP 2	Drill 2 x horizontally level holes spaced 68.5cm apart into a sturdy concrete or brick wall. Use a 10mm concrete drill bit & ensure that each hole is drilled to at least 50 mm deep. Tip: It is recommended that the holes be drilled so that the inverter’s display panel will end up being more or less “head height” after the unit is installed. Refer to the product layout illustration & actual unit.

STEP 3	Unscrew the bolts from the anchor of each rawl bolt, then insert the anchors into each of the holes. The anchors should fit snugly & flush with the wall surface.
STEP 4	Screw each bolt back into its anchor. Ensure to leave just enough space between the wall and lip of each bolt to allow for the pre-assembled main unit to be hooked over the bolts when hung. A gap of about 3mm should be sufficient.
STEP 5	Check to ensure that all subcomponents on the main unit are secure, then tilt the whole unit upright. With one person on each side of the unit, lift it and hook it over the installed rawl bolts in the wall. Note: Each bolt head should fit into the respective keyhole cut-out at the top of the unit chassis. Do not hang the unit onto the rawl bolts from any other location(s) on the chassis other than the keyhole cut-outs provided.

IMPORTANT: Should you install your CPS 5000-Vic 10.4k unit as a UPS application & charge it from one of your wall sockets directly, obtaining a certificate of compliance subsequent to installation is not necessary. Obtaining such a certificate would only be necessary if the unit is connected to charge directly from the distribution panel on the premises.

3. ADDING SOLAR (PV APPLICATION)
   

A solar array can be connected to the CPS 5000-Vic 10.4k’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 102V DC on the PV(solar) input side and also a maximum charging  current of 60A .(adjustable via inverter settings…)

Depending on the specific panel chosen( panel Open Circuit Voltage)2 - 3 panels might be placed in series to achieve the necessary input voltage on the MPPT(Solar) input.

However,  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-Vic 10.4k unit,  the folllowing menu items should be adjusted :

Menu #  :

01 - Output Source Priority

02 - Maximum Charging Current - utility & solar charging

11 - Maximum utility charging current

16 - Charger Source Priority

5. 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. BATTERY DISPLAY PANEL
   

The integrated battery display panel displays the following variables:

3. 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.
  

6. 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.
   

7. Supporting documents