Allied AS-2560 User manual

;
Installation, Operation and Maintenance Manual
AS-2560
Installation, Operation and Maintenance Manual
Allied Solar Pty Ltd
9 Morriett St
Attadale, WA, 6156
Australia
Ph: 0407 443598
Email [email protected]om
Web: www.alliedsolar.com.au
Allied Solar

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P-MAN-01-1a_Rev B Installation, Operation and Maintenance Manual – AS-2560
Contents
1 Legal Provisions ............................................................................................................................................ 3
2 Warnings ...................................................................................................................................................... 4
2.1 Installation Work .................................................................................................................................. 4
2.2 Battery Pack ......................................................................................................................................... 4
2.3 Arc Flash ............................................................................................................................................... 4
2.4 Solar Panel Wiring ................................................................................................................................ 4
2.5 Power Continuity ................................................................................................................................. 5
2.6 Water ................................................................................................................................................... 5
2.7 Connected Load ................................................................................................................................... 5
2.8 Fire ....................................................................................................................................................... 5
2.9 Direct Sun ............................................................................................................................................. 5
2.10 Inverter Frequency ............................................................................................................................... 5
3 General Information .................................................................................................................................... 6
3.1 Overview .............................................................................................................................................. 6
3.2 External Features of the Off Grid Solar Unit ........................................................................................ 6
3.3 Internal Features of the Off Grid Solar Unit ......................................................................................... 7
4 Installation ................................................................................................................................................... 9
4.1 Solar Panel Installation ........................................................................................................................ 9
4.2 Solar Cables ........................................................................................................................................ 11
4.3 Allied Solar Cabinet Installation ......................................................................................................... 12
4.4 Commissioning ................................................................................................................................... 13
4.5 Generator Installation ........................................................................................................................ 13
4.6 Specifications ..................................................................................................................................... 14
4.7 Installation Checklist .......................................................................................................................... 16
5 Operation ................................................................................................................................................... 17
5.1 Switching the System On ................................................................................................................... 17
5.2 Shutting down the system ................................................................................................................. 17
5.3 Transfer to Generator mode (if installed) .......................................................................................... 17
5.4 Isolate power supply .......................................................................................................................... 17
6 Maintenance .............................................................................................................................................. 18
7 Battery Level Gauge ................................................................................................................................... 19

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P-MAN-01-1a_Rev B Installation, Operation and Maintenance Manual – AS-2560
1 Legal Provisions
The information contained in these documents is the property of Allied Solar Pty Ltd. No part of this
document may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, be
it electronic, mechanical, photographic, magnetic or otherwise, without the prior written permission of
Allied Solar Pty Ltd. Reproduction used solely for the purpose of product evaluation, Installation, Operation
or Maintenance is allowed and does not require prior approval.
Allied Solar Pty Ltd makes no representations or warranties, express or implied, with respect to this
documentation or any of the equipment it may describe, including (with no limitation) any implied
warranties of utility, merchantability, or fitness for any particular purpose. All such representations or
warranties are expressly disclaimed. Allied Solar Pty Ltd shall not be liable for any indirect, incidental, or
consequential damages under any circumstances.
Specifications are subject to change without notice. Every attempt has been made to make this document
complete, accurate and up-to-date. Readers are cautioned, however, that product improvements and field
usage experience may cause changes to these specifications without advance notice.
Allied Solar Pty Ltd shall not be responsible for any damages, including indirect, incidental or consequential
damages, caused by reliance on the material presented in this document.

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P-MAN-01-1a_Rev B Installation, Operation and Maintenance Manual – AS-2560
2 Warnings
2.1 Dangerous voltages
There are dangerous voltages inside the AS-2560 cabinet while operating. Do not open the AS-2560 cabinet
unless the system is shut down. Follow the instructions to shut down the system.
2.2 Installation Work
The installation of the AS-2560 requires skill in mounting the PV panel framing and running the electrical
wires. If you are not confident that you have the necessary skills then Allied Solar recommends the unit is
installed by a qualified solar installer or someone with experience in electrical work and who has read and
understood this manual and associated documents.
2.3 Battery Pack
Do not dismantle the battery pack. The battery pack is not a serviceable item and the unit must be returned
to the factory if there are problems with the battery pack. Do not remove the battery pack covers, bus bars,
BMS or any other fittings on the battery pack. Do not tamper with the battery cells in any way. If the cells
are damaged then shut down the AS-2560 if safe to do so, refer to the battery MSDS and call Allied Solar.
2.4 Arc Flash
Arc flash is a large energy discharge in the form of an electric arc and can cause serious injury and burns from
flash energy and molten/vaporised metal emitting from the equipment at over 5000oC. Batteries are
capable of delivering over 5,000A which could result in a large energy discharge.
Arc flashes can result from loose cables, components, tools or jewellery creating a short during maintenance
or from a failure.
Under no circumstance should maintenance work be performed on the battery pack and the battery pack
should always remain covered.
While performing any other work inside the cabinet:
 Do not remove the protective cover over the batteries.
 Wear appropriate PPE including safety glasses, insulating gloves and long sleeve non-flammable
shirt.
 Remove any jewellery such as bracelets, rings, necklaces, watches, metallic pens and clothing with
metal zips. Ensure you are not wearing any other conductive items.
 Disconnect the battery pack using the isolators provided.
 Ensure all tools are insulated as far as practical using electrical tape on the handles.
2.5 Solar Panel Wiring
Pay special attention to the wiring of the solar panels. The panels must be wired in the configuration shown.
If you are un-sure please contact Allied Solar.
WARNING: Lithium Battery Hazard
CAUTION: Do not dispose of batteries in a fire. The batteries may explode.
CAUTION: Do not open or mutilate batteries. Released electrolyte is harmful to the
skin and eyes. It is toxic.

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P-MAN-01-1a_Rev B Installation, Operation and Maintenance Manual – AS-2560
Do not disconnect solar cable connectors under load. Always turn the PV Array Main Switch off on the side
of the cabinet before unplugging any solar cables or connectors.
PV Open circuit voltage (Voc) must be less than 120V for DIY installation or 150V if a PV installer is doing the
work.
2.6 Power Continuity
The power supplied by the Allied Solar AS-2560 System will be disrupted from time to time as a result of:
 Switching to or from back-up Generator (5 to 10 seconds) or when the batteries empty with no back-
up generator (off until the batteries re-charge to 10%);
 Over-loading of the Inverter (off for 3 seconds or until the inverter is reset)
 Hi or low temperatures.
Do not use the Allied Solar AS-2560 System if a smooth un-interruptible power supply is required.
2.7 Water
Do not direct any water jets onto the unit. Water jets such as sprinklers, reticulation or hoses must not be
directed at the unit. The unit is rated for normal weather conditions only. If water should enter the unit due
to water jets then disconnect any external supplies (such as generator), Switch the batteries off using the
external battery switch. Call Allied Solar for assistance.
2.8 Connected Load
Do not over-load the inverter. The inverter is rated at 3000W continuous and 6000W peak power. At
3750W the inverter will alarm and shut down within 20 seconds. Switching on electric motors will draw up
to seven times the running power during start-up and can easily cause overload shutdown.
2.9 Fire
In the event of fire the unit can emit toxic fumes from the battery cells and other equipment – Do not breath
in any fumes. Use a dry powder fire extinguisher. Hose down surrounding areas. Do not use water on the
batteries or anywhere inside the unit. Breathing apparatus should be worn in this situation. Refer to the
MSDS for more information.
2.10 Direct Sun
Your Allied Solar AS-2560 system will perform best and last longer if it is located away from direct sunlight.
Higher temperatures reduce the life of the capacitors within the equipment and equipment such as the
inverter and charge controller may be de-rated at higher temperatures.
2.11 Inverter Frequency
The average inverter frequency is not referenced to a precision clock. This means that devices with clocks
that use the grid frequency as a clock source (i.e. some microwaves, fridges, alarm clocks, power point timer
switches etc) will become inaccurate and the time displayed could drift by several minutes per day.

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3 General Information
3.1 Overview
Thank you for choosing an Allied Solar AS-2560 system. The unit is factory assembled as a ready to go
energy storage system and is designed for simple DIY installation for providing solar energy for your home,
caravan, shed, cabin or remote equipment.
The Allied Solar AS-2560 is a pre-assembled integrated battery energy storage system and complies with the
following guides, codes and standards:
 AS/NZS 4509.1 Stand-alone power systems - Safety and installation
 AS/NZS 4509.2 Stand-alone power systems - System design
 AS/NZS 5033 Installation of photovoltaic (PV) arrays
Installation is simple with the unit rated for either indoor or out-door use and its smart looking, slim line
design means it can be installed against the home in a convenient location. The unit is designed to be
essentially plug and play and can be installed by a competent person without the need for an electrical
licence.
The AS-2560 is designed for 4 or 6 solar panels of 200 to 400 watts although fewer or more panels may be
connected if desired. With 6 x 285W panels connected the AS-2560 will provide around 9kWhr of energy per
day during sunny summer days and around 4.2 kWh on overcast winter days (less on very overcast days).
The batteries are able to store up to 2.56 kWh of energy for night time use although it is recommended to
size the system for 60% depth of discharge (or 1.5kWhr of electrical consumption overnight). This is enough
to run a small fridge, 5 x LED lights for 4 hours, 100cm TV for 2 hours and a lap top computer for 4 hours.
If the AS-2560 includes the backup generator interface then the unit will start a 2-wire start generator and
switch the load over if the batteries are depleted or the inverter is switched off. The AS-2560 will revert back
to solar/ batteries when the battery level goes above above10% or the inverter is switched back on. The
generator will be switched off automatically. There is a time delay of a few seconds when switching from
one source to another.
3.2 External Features of the Off Grid Solar Unit
Figure 3-1 Allied Solar AS-2560 unit side view

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P-MAN-01-1a_Rev B Installation, Operation and Maintenance Manual – AS-2560
1. Air Outlet Vents: The unit has cooling air flowing in the mesh screen underneath and out of the
vents at the top. Care should be taken to ensure these vents are not obstructed or blocked in any
way.
2. Battery level: indicator shows critical battery information such as battery level, charging rate and
battery voltage. Note that the batteries have a very flat voltage curve and so the voltage is not a
reliable indicator of the remaining capacity unless the batteries are almost full or almost empty. The
capacity shown is calculated from the charging / discharging current which is the most accurate
method but even this can become inaccurate sometimes. The calculated capacity is reset to 100%
each time the batteries become full.
3. PV Array Main Switch: The PV Array Main Switch disconnects the solar panels from the components
inside the AS-2560. Always disconnect the solar panels before disconnecting the batteries.
4. Inverter on/off switch: Turns the inverter off. If a back-up generator is connected then turning the
inverter off will trigger the unit to switch over to generator mode.
5. Battery System DC Isolator: This will disconnect the positive side of the battery from the inverter.
The PV panels must be disconnected using the PV Array Main Switch before switching this off.
Failing to do this may damage the AS-2560.
6. Solar Inputs: The solar panel strings are to be wired according to the PV wiring diagram and the 10m
PV extension cables plug into these input connectors. There are male and female plugs for the
positive and negative leads.
7. Generator Input: If the generator interface option is included then this is where the generator
power cable plugs into the Allied Solar AS-2560 System.
8. Front Door: provides access to the internal components of the off grid cabinet. Follow the
guidelines when accessing the inside of the compartment.
9. Generator start cable: plugs into the generator and provides a start signal to the generator (volt free
relay contacts close to start the generator). A 15m cable is provided with the generator interface
option.
10. Power Outlet: is a 15A GPO power outlet that is protected by 25A breaker and residual current
device (RCD). The outlet is connected to the inverter during normal operations and is switched to
the generator power when the AS-2560 switches to generator mode (if installed). There is a delay of
a few seconds when switching from one power source to the other where there is no power
available at the outlet.
11. Earth cable: The coil of earth cable is to follow the PV extension cables and connect to the framing
of the solar array. It is important that the earth wiring is completed correctly to ensure the earth
leakage protection device (RCD) works correctly and helps protect people from electrocution. Refer
to the installation section.
12. Hold down bolt holes: for securing the off grid cabinet to the ground and prevent from being
knocked over. The unit can also be secured to a wall using the bolt holes in the back of the unit near
the top corners.
13. Air inlet: is located under the off grid cabinet between the legs. Ensure there is good air flow under
the unit and the vents do not become blocked.
14. Earth stake: must be hammered into the ground near the load (cabin, caravan, house..). Ensure the
earth cable is not damaged and remains connected to the off grid cabinet.
3.3 Internal Features of the Off Grid Solar Unit

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P-MAN-01-1a_Rev B Installation, Operation and Maintenance Manual – AS-2560
Figure 3-2 Allied Solar AS-2560 unit inside view
1. Inverter: 3kW (6kW peak) pure sine wave inverter.
2. Battery Level Monitor: This part of the battery level gauge measures the current going in or out of
the batteries.
3. Battery Disconnect: This knob, when unscrewed, will disconnect the negative terminal of the battery
from the rest of the AS-2560 (except for the BMS) and should be turned off in the event of a fault in
the unit or if maintenance work is to be done. Ensure the incoming solar power is disconnected first
and the inverter is switched off. Refer to the shut-down procedures.
4. 160A Fuse: Prevents serious overloads or short circuits from damaging cables and minimises arc
flash energies. If this fuse blows then switch of the PV array main switch immediately.
5. Battery Cell Protection: This is not to be removed. If there is a fault with the battery pack the unit
must be returned to Allied Solar for repair.
6. Battery Cells: are Lithium Iron Phosphate cells (LiFe PO4). These cells contain hazardous substances
and must not be punctured or dismantled. Refer to the MSDS if a spillage occurs.
7. Air inlet: is located under the off grid cabinet between the legs. Ensure there is good air flow under
the unit and the vents do not become blocked.
8. Charge Controller: This display will show PV voltage and current, battery voltage and charging
current from the controller, battery type (must be set to ‘user’), charging mode. Note that the
charging current is the current being delivered by the charge controller. Some of this current may be
going to the inverter and so the reading may be different to the current shown on the external
display. The difference between the two readings is the current going to the inverter. Note also that
the battery level shown on this display is based on battery voltage and is not accurate. Do not
change any settings on the charge controller.
9. RCD and relays: The Earth leakage circuit breaker (RDC) will trip if there is an earth leak or over
current. Tripping of the RCD may indicate a fault in the house and an electrician should be called to
investigate. If a generator interface option is included in your system then there will be additional
relays installed.
10. Battery Management System: The Battery Management System (BMS) monitors each battery cell
and prevents over-charge, over-discharge and over current. It also balances the cells (top balance).

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P-MAN-01-1a_Rev B Installation, Operation and Maintenance Manual – AS-2560
Figure 3-3 AS-2560 Schematic
4 Installation
Before installation check all equipment for any transportation damage and take photos of any visible
transportation damage to packaging or equipment.
1. Check the packaging and cabinet for any transportation damage.
2. Check wiring to ensure there are no loose connections. (refer to PPE requirements for entering
the cabinet and ensure the cabinet is shut down)
3. Check vents are intact.
4. Check panels are not broken or scratched.
5. Check Solar Panel rails are not bent or dented.
6. Check the packing list to ensure all components are accounted for.
Installation consists of:
 Install the solar panel framing on the roof or other support structure.
 Install the solar panels onto the framing.
 Connect the solar panels according to the wiring diagram and labelling.
 Install the AS-2560 unit
 Install the generator and plug into the AS-2560 (if the generator interface is included)
 Plug the load into the AS-2560 power outlet and switch on.
4.1 Solar Panel Installation
 Solar panels mounted on roofs should have between 50mm and 100mm gap between the panels
and the roof. The panels should be more than 200mm from any edge.
 Ideally the panels will face north.
 Keep way from any shading. If there is shade on any part of any panel it will significantly reduce the
performance of that string of panels. Place panels where they won’t be shaded by vent pipes, trees
or aerials.
 If you have purchased panels with your kit they will be labelled according to Figure 4-1or Figure 4-2.

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P-MAN-01-1a_Rev B Installation, Operation and Maintenance Manual – AS-2560
 If you are using your own panels then label the panels and wires according to the appropriate figure
for 4 or 6 panels. Label the panels clearly before mounting them – It will make the wiring on the roof
much easier.
 Install the framing and panels according to the Titan Solar – Solar Roof Mounting System.
o Assemble the PV rails using the spice plates provided and finalise the position of the panels
on the roof. For the 6 panel kit each rail consists of 3 x 2.1m lengths and two splice plates.
o Mark the alignment of the battens under the tin using a string line or chalk line following the
line of existing roof screws.
o Install the Aluminium Tin Roof L feet using the new roof screws and in new positions along
the roof batten (don’t remove any existing roof bolts). Place the L feet / hooks 500mm from
each end and approx. 1100mm apart (maximum 1200 apart). Use a string line to ensure the
L feet are in a straight line and the screws penetrate the purlin securely.
o Install the grounding clips under the panels at each mid clamp along one of the rails.
Figure 4-1 Panel Labelling Guide – 4 panels
Figure 4-2 Panel Labelling Guide - 6 Panels

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P-MAN-01-1a_Rev B Installation, Operation and Maintenance Manual – AS-2560
4.2 Solar Cables
Figure 4-3 PV Panel Wiring – 4 Panels
Figure 4-4 PV Panel Wiring - 6 Panels
Connect the PV panels together in two strings of 2 panels, as shown inFigure 4-3 or Figure 4-4. The panels
and cables are labelled.
If you have a multi meter check the voltage of each string to ensure each string has a similar voltage and the
same polarity. Check the voltages at C and E for string 1 and at D and F for string 2 before plugging into the Y
joiners. Also check that the resistance from each connector (C, H, G and F) to the framing is high (more than
120kΩ).
The cables are to be installed in conduit where they are accessible (within reach of the ground) and where
they are exposed to sunlight (not shaded by the panels or in the ceiling) except for the last 200mm where
they plug into the cabinet.
If using the boot to enter the ceiling space (refer to Figure 4-5) then place the boot under one of the panels
to help protect the entry from the weather and sun (do this before installing the panel).
Run the PV cables and earth wire from the Allied Solar AS-2560 to the solar panels on the roof placing the
cables in conduit in exposed locations.

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P-MAN-01-1a_Rev B Installation, Operation and Maintenance Manual – AS-2560
Connect the earth cable to the PV rail (the one with the grounding clips) using the grounding lug provided.
The other end is already connected to the earth stake.
Secure the cables and conduit using clamps and cable ties provided.
Ensure the cables are not touching any sharp edges, are not under tension and have mechanical protection.
Figure 4-5 Roof Cable Entry Boot
4.3 Allied Solar Cabinet Installation
The cabinet is rated for outdoor use, however, to obtain optimum performance and service life, it is
recommended to install the cabinet in a cool dry place away from direct sunlight, humidity and dust. Lower
operating temperatures increase the life expectancy of the AS-2560. If dust builds up in the AS-2560 unit
then electrical circuits and cooling may be affected and life expectancy will reduce.
1. Install the cabinet on a solid level surface and secure the cabinet to a wall or the ground to prevent
the possibility of it being knocked over. There are holes in the feet and brackets for the top of the
cabinet for securing the unit in place if required.
2. The AS-2560 produces heat when operating – Ensure there is sufficient ventilation around the unit
(more than 500m3/hour or a room larger than 4m x 6m x 2m, or an air-conditioned room).
3. Ensure the unit is not exposed to excessive dust.
4. Ensure the unit is protected from damage / impact from moving vehicles and the like.
5. Ensure the inlet vent under the unit and the outlet vents are not blocked and that leaves and debris
are prevented from accumulating and blocking any vents.
6. Ensure there will be no water jets from sprinklers or hoses that may impinge on the AS-2560.
7. Hammer the earth stake into the ground near the load (cabin, caravan, house etc) and ensure there
is a good electrical connection from the stake back to the cabinet. Ensure the stake is positioned
such that it is not a trip hazard. Ensure the load (cabin, caravan, house etc) is also earthed or the
frame is connected to the earth stake using 4mm earth cable.
8. Ensure the RCD, the PV Array Main Switch and the inverter switch are all off (toggle switches in the
down position).
9. Connect the solar panel extension cables to the solar inputs on the side of the AS-2560.

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P-MAN-01-1a_Rev B Installation, Operation and Maintenance Manual – AS-2560
4.4 Commissioning
1. Complete the installation checklist in Figure 4-6
2. Ensure the system is shut down – especially the Battery Isolator and the inverter on/off switch are
off.
3. Switch the PV Array Main Switch on.
4. Check the screen of the charge controller inside the cabinet to ensure the PV voltage is between 40
and 120 volts (or up to 150V if a licenced electrician is completing the work). You may need to press
the select button to scroll through the various screens. If the voltage is incorrect or if the screen has
gone blank then switch off the PV CB’s immediately and check the wiring.
5. Check the charge controller is operating correctly by scrolling through the screens and checking:
a. PV voltage is between 32 and 120 volts while operating.
b. PV Current is greater than 0.
c.
6. Check that the batteries are charging.
7. Ensure there is nothing inside the cabinet that may impede air flow and close the AS-2560 door.
8. Switch the battery isolator on the side of the cabinet to the on position.
9. Check that there is power to the battery level screen. The screen will NOT show the correct battery
level at this stage.
10. Switch on the inverter using the inverter on/off switch on the side of the AS-2560.
11. Check that the 15A power point on the side of the AS-2560 is turned off.
12. Turn on the RCD on the side of the AS-2560 (switch in the up position)
13. Ensure the RCD does not trip.
14. Connect your load to the 15A power socket on the side of the AS-2560.
15. Switch the power point on to provide power to your load.
16. Check that the power switches on and that the RCD does not trip. If the RCD trips there could be a
fault in the load wiring and you should call an electrician to check the load wiring (cabin, caravan or
house).
4.5 Generator Installation
Install the generator in accordance with the installation manual for the generator.
Run the “generator start cable” and a 15A extension lead from the Allied Solar Cabinet to the generator.
Switch the generator to Auto ready for starting automatically.
To check the change-over function, Turn the AS-2560 to the “Generator” setting and check that the
generator starts and the AS-2560 switches the load over to the generator after a few seconds.
PV is connected
Load is on
Current flowing
System Voltage is 24V

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P-MAN-01-1a_Rev B Installation, Operation and Maintenance Manual – AS-2560
4.6 Specifications
Following is a list of specifications and settings for the Allied Solar AS-2560. These settings should
already be programmed into the unit.
General
Output p
ower (
m
aximum
c
ontinuous)
3000
W
Voltage
220
–
240
V AC
Frequency
50
Hz
Current
(
m
aximum
c
ontinuous)
1
3
A
Phases
1
Ambient temperature range
-
5 to 45
C
Altitude
0
–
3000
m
Batteries
Calb CA100
Capacity
100
Ah
Nominal Voltage
25.6
V
Capacity (100%)
2
.56
k
W
h
Capacity (100%)
9.22
MJ
Capacity (working range 95%)
2
.43
k
W
h
Capacity (working range 95%)
8.75
MJ
Fully charged Voltage
27.8
V
Fully discharged Voltage
21.0
V
Working temperature range
0 to 45
Deg C
Solar Panels
Recommend
-
Risen
370W
Number of inputs
1
Number of strings per input
Max
2
Number of panels per string
Min 2
–
Max 3
*
Voc per string
Min 4
7
–
Max 1
5
0
V
Charge Controller
e
-
Smart3
Maximum charging current
60
A
Battery
t
ype
“User”
Maximum Voc (string)
150
V
Load
type
On
System Voltage
24
V
Inverter
Voltage
220
–
240
V AC
Power (Peak)
6000
W
Power
(Continuous)
3000
W
Battery Meter
Settings
CAP
100
Ah
Full
27.55
V
Zero
21.1
V
Drift
Do not change
mA
Back
-
up power supply (Generator)
Voltage
220
–
240
V AC

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P-MAN-01-1a_Rev B Installation, Operation and Maintenance Manual – AS-2560
Plug / Lead Rating
15
A
AS
-
2560
Dimensions
Weight
70
k
g
Height
92
cm
Width
71
cm
Depth
26
cm

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4.7 Installation Checklist
Following are the installation checks that are to be completed prior to switching the system on.
Fill out the check list to confirm that the installation is complete, compliant and safe to switch on and
operate. Photograph the completed checklist and forward a copy to Allied Solar to obtain your full warranty.
Invoice Number:
Name:
Serial Number
PV Rails:
All of the L feet are
screwed into roof battens
and are
evenly spaced (max 1200 apart)
Y / N / NA
PV rails and any splice plates are bolted tight.
Y / N / NA
Earth plates are used on each panel.
Y / N / NA
End clamps are straight and not angled up or down
Y / N / NA
Mid clamps are snug between
panels with no more than
1mm gap between edge of panel and mid clamp.
Y / N / NA
Mid clamps are bolted tight and all panels are secure.
Y / N / NA
Earth cable is clamped to the PV rail with the earth plates
on.
Y / N
PV Cables:
PV cable and
earth cable are not exposed to direct sunlight
and are not accessible or are enclosed in conduit (except for
the last 200mm at the connection to the cabinet).
Y / N
If the roof entry boot is used then it is installed under a
panel and in accordance with the manufacturer’s
instructions and sealed.
Y / N
PV cable and earth cable are kept away from sharp edges.
Y / N
PV cables and earth cables are secured in place.(cable ties /
conduit), protected from damage and not under tension.
Y / N
AS
-
2560 Ca
binet:
Cabinet will not be subject to water jets or strong sprays
(sprinkler systems)
Y / N
Cabinet is
on a level concrete or wooden surface or similar
and secured to prevent it from being knocked over.
Y / N
Cabinet is not blocking any corridors
or door way.
Y / N
Cabinet is not under stairs.
Y / N
The cabinet is not in an enclosed space that would restrict
cooling. The cabinet vents are not blocked.
Y / N
The earth stake is imbedded into the ground and connected
to the PV array and the cabinet
Y / N
All plug connections are secure and in good condition.
Y / N
Figure 4-6 Installation Checklist

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5 Operation
5.1 Switching the System On
Once the installation checklist is complete and the system is confirmed to be safe then switch the system on
following this procedure.
1. Check the charge controller is on.
2. Close the AS-2560 door.
3. Turn the battery isolator to the ON position (on the side of the cabinet)
4. Switch the PV Array Main Switch on (on the side of the cabinet)
5. Switch the inverter on (on the side of the cabinet)
6. Check the RCD switch is on (in the up position)
7. Connect the load.
8. Switch the 15A power point on.
Note that the battery level will not be accurate until the batteries become fully charged – at which point the
battery level gauge will reset its self to 100%.
5.2 Shutting down the system
Follow this procedure to switch off and isolate the system.
1. If applicable, switch the Generator to the off position and un plug the generator.
2. Switch the PV Array Main Switch to the OFF position
3. Switch the load off at the GPO switch
4. Switch the inverter off on the side of the cabinet.
5. Turn the battery isolator off (Side of the cabinet)
5.3 Transfer to Generator mode (if installed)
Transferring to generator mode can be useful to conserve battery power during over cast days so that the
system can operate on batteries over night when it is less desirable to have the generator running.
If your system has the generator interface option then simply switch to the generator mode on the side of
the cabinet. The system should start the generator and switch over automatically. To switch back to
batteries/ solar simply turn the switch back to “Auto”.
If your system does not have the generator option then start the generator, transfer the power leads to the
generator and then switch off the AS-2650 inverter using the inverter on/off switch.
5.4 Isolate power supply
To isolate the supply of power from the AS-2560 switch the power off at the power outlet and disconnect
the lead.
If the AS-2560 has been hard wired to the home then isolate using the RCD switch and switching off the
inverter.
5.5 BMS Operation
The AS-2560 includes a Battery Management System (BMS) to ensure the battery cells remain operating in
the desired ranges for temperature and cell voltage and also balances the cell charges ensuring the

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P-MAN-01-1a_Rev B Installation, Operation and Maintenance Manual – AS-2560
maximum capacity is available for use. Ensure the AS-2560 inverter is shut down and isolated is accessing
inside the cabinet.
Figure 5-1BMS Features
1. Menu button: turns the display on and switches between display screens.
2. Reset Button: resets the BMS.
3. LED-1 is blue and flashes during normal operation (short flash every 2 seconds) and on during cell
balancing. During cell balancing, one or more of the Balance LED’s will also turn on.
4. Charger Control: This cable is to remain plugged into the charger at all times. This turns the charger
off if the battery cells reach their maximum voltage (3650 mV)
5. LED-2 is a Red LED and flashes if there is a fault. Scroll through the display screens using the menu
button to see the error messages.
6. The current sense cable is used for monitoring the charging or discharging current of the cells.
7. Battery Temperature sensor – The sensor should be placed under the cover of the battery cells
The BMS screen displays 4 separate pages.
1. Page 1 displays the cell voltages in mV (B1 to B8) and the temperature measurements:
a. T0 = internal temperature of the BMS chip.
b. T1 = Battery Cell Temperature.
c. T2 = MOSFET temperature 1
d. T3 = MOSFET temperature 2
e. T4 = Current measurement raw data.
2. Pages 2 to 4 display various error messages if any
If there is a fault then:
1. Scroll through the screens using the menu button and note down any error messages.
2. If there is a broken wire or missing sensor then first see if there are any obvious loose connections.
3. Correct any loose connections to the BMS. If the loose cable is repaired the fault condition will
cancel within 20 seconds.
4. Reset the BMS if the error persists and all wiring looks secure.
5. Phone Allied Solar if the error is not rectified.

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P-MAN-01-1a_Rev B Installation, Operation and Maintenance Manual – AS-2560
6 Maintenance
Monthly Inspection:
1. Check inside the cabinet for dust. If dust is building up above the batteries then check the cause and
clean the filters / fix seals as required. If dust is getting into the AS-2560 then Allied Solar can
provide an additional filter for the air inlet.
2. Check the operation of the RCD
3. Check the charger control cable is in place and secure from the BMS to the charger.
4. Check to ensure vents (underneath and the sides at the top) are not blocked by any leaves or debris.
5. Check the cabinet for any signs of moisture ingress or rust and fix any points of water ingress.
6. Check the PV panels for debris, leaves or bird droppings
7. Check the generator fuel and oil.
8. Start and run the generator for 20 minutes if it has not been used.
7 Battery Level Gauge
Settings:
1. Press the ↵ key for 3 seconds to enter the settings menu
2. Press ∆ or ∇ key to select items
3. Press the ↵ key to change the selected setting
4. Press ∆ or ∇ key to change the selected digit
5. Press the ↵ key to move to other digits.
6. Press the ↵ key for 3 seconds when done to save setting.
7. Press ∆ and ∇ together to exit the settings menu.
Notes:
1. Close the display cover when not in use as UV exposure will cause the display to deteriorate.
2. The battery level will reset to 0% or 100% when the battery becomes fully charged or fully
discharged. When first switched on the battery level will be incorrect.
CAP : 100.00 Ah
FULL V : 027.6 V
ZERO U :021.0 V
DRIFT : 000 MA