Installation Manual

CPS 5000-Vic 5.2k

Table of Contents

A. INTRODUCTION
1. GENERAL INFORMATION
2. DOCUMENT SCOPE
3. TERMINOLOGY

B. SAFETY FIRST
1. CRITICAL SAFETY REQUIREMENTS
2. WARRANTY REQUIREMENTS

C. STRUCTURAL INFORMATION
1. LIST OF COMPONENTS
2. PRODUCT LAYOUT

D. INSTALLATION
1. PRE-INSTALLATION
1.1 Product Applications
1.2 Requirements & Limitations
1.3 Wiring Diagram

2. STANDARD INSTALLATION (UPS APPLICATION)

3. ADDING SOLAR (PV APPLICATION)

E. BATTERY OPERATION

F. OPERATING INSTRUCTIONS
1. INVERTER
2. BATTERY DISPLAY PANEL

G. EMERGENCY & FIRST AID

A. 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 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
Alternating Current (as supplied by utilities & most generators).
(abbr.)
A product subcomponent, in this case specifically 1 x BN52V-100-
Battery
5.2k DU (Daily Use) Lithium Iron Phosphate battery.
(term)
See: G. Supporting Documents for more technical information.
Battery Pack Two or more BN52V-100-5.2k DU batteries connected to each other
(term) in parallel, up to a maximum of 9.
Battery Management System: Battery-integrated electronic circuitry
BMS
& components. Supports cell health, product safety & peripheral
(abbr.)
compatibility functionalities.
Electrical Distribution Board.

Site DB refers to the main electrical distribution board (if available)

DB of the building or site at which the product will be installed.
(abbr.)
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
Direct Current. Batteries & solar panels supply DC.
(abbr.)
DoD Depth of Discharge. Refers to a percentage of the total available
(abbr.) energy capacity of a battery or battery pack.
 Maximum Power Point Tracker: An integral component in modern
MPPT
solar systems, mainly supportive towards the stabilisation of solar-
(abbr.)
supplied energy to the rest of the system.
Product
Refers to a complete (read: fully assembled) CPS 5000-5.2k system.
(term)
Refers to one or more of the main functional components that the
Subcomponent CPS system consists of (as illustrated in section C. Structural
(term) Information - 1. Product Layout) below. Does not refer to screws,
wiring & other small system components.
SoC State of Charge: A percentage value indication of the amount of
(abbr.) energy stored within a battery.
State of Health: A percentage value indication of the amount of
SoH energy capacity that a battery has retained at any point during its
(abbr.) service life. Conversely indicates the percentage with which a
battery has faded (read: lost capacity) from being used over time.
UPS
Uninterruptable Power Supply
(abbr.)

B. 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.

C. Structural Information

1. PRODUCT LAYOUT
A CPS 5000-Vic 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-Vic 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)
Rawl bolts
1 Powder-coated steel
1 Victron Multiplus II 5kVA
2 See D. Installation for more info
2 Compliant to latest industry standards
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.

D. Installation

1. PRE-INSTALLATION

1.1 Product Applications

The CPS5000 has been designed to be suitable towards various applications, mainly due
to the fact that 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.

1.2 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. 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.

1.3 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-Vic 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)

In order to connect a solar panel array to the CPS5000 system, a suitable Victron MPPT
module will have to be installed. Such installations should only be performed by qualified
electrical technicians with experience in Victron installations.

Please contact your nearest Victron-accredited installer for such installations.

Alternatively, please contact BlueNova if you would like to be referred to one or more
such installers.
4. ADDING MORE BATTERIES

Additional batteries can be connected to the original battery to increase overall capacity.
Batteries should be connected as illustrated below:
E. Battery Operation

SYSTEM START / SHUT DOWN / RESET:

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

COMMUNICATION PORTS:

COMPONENT FUNCTION / DESCRIPTION

RS232 (RJ11) Not active
Serial communication via CAN
Bus. PIN configuration as follows:
CAN Ports (RJ45 x 2) - 7 : CAN-H
- 8 : CAN-L

Pin configuration as follows:

- 1/8 : A
- 2/7 : B
RS485 Ports (RJ45 x 2)
- 3/6 : GND
- 4/5 : NC

DIP SWITCH PANEL CONFIGURATION:

DIP Switch Number Master Definition ON

Address Parallel Configuration / Slave (RS485)
(CAN) 1 2 3 4 5 6 OFF

#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:

Running SOC RUN ALM

Status Description
condition
Switch Off Sleep mode off off off off off off All off
Normal off off off off Flash 1 off Idle
Stand by ALM and RUN Flash
Alarm off off off off Flash 3 Flash 3
3
According to real-time
Normal on off Highest LED Flash 2
capacity
According to real-time
OV Alarm on off Highest LED Flash 2
capacity
According to real-time
OC Alarm on Flash 3 Highest LED Flash 2
capacity
Charging
OV Protect on on on on on off
OC Protect
(charge limit off off off off off on Stop charging
off)
According to real-time
Charge limit on off Highest LED Flash 2
capacity
According to real-
According to real-time
Normal Flash 3 off time capacity
capacity
indicate
According to real-time ALM and RUN Flash
Alarm Flash 3 Flash 3
Discharging capacity 3
OC/short
circuit/revere off off off off off on Stop discharging
connection
UV off off off off off off Stop discharging
Normal According to status
According to real-time
Charge alarm on Flash 3 Highest LED Flash 2
capacity
Temp
Discharge According to real-time
Flash 3 Flash 3
alarm capacity
Protect off off off Off off on
F. Operating Instructions

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

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.

G. Emergency & First Aid

1. IN CASE OF FIRE

a. Evacuate danger zone. Open ventilation in the room if possible.

b. Extinguish fire with a CO2 fire extinguisher.
c. After the fire has been extinguished, immerse any remaining smoking cells completely in
water.
Wear protective gear during this procedure.

2. SKIN CONTACT

a. Wash the affected area immediately with soap and water.

b. If irritation persists, seek medical attention.

3. EYE CONTACT

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

4. INGESTION

a. Refrain from taking any emetic or vomit-inducing medicine.

b. Seek medical attention immediately.