Nedap PowerRouter PR50SB-PR/S24 User manual

Installation Manual
PowerRouter Solar Battery – Back-up / Stand-alone
Date: 181213

PowerRouter • Back-up / Stand-alone • Installation Manual
Illustrations Page 1
Installation Manual
Original instructions
Page 9
EN

PowerRouter • Back-up / Stand-alone • Installation Manual Illustrations
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1
2
(IP20)
mounting bracket
690 mm max. ø 5.5 mm
600 mm max. ø 10 mm
570 mm max. ø 5.5 mm
370 mm
Standby
12 3
4 x
4 x
2 x
2 x
45 6
Standby
+
Standby
Standby
Standby Standby
Standby
Standby
Standby
min. 300 mm
min. 800 mm
Max.40°C
Min.-10°C
!
i
20 KG20 KG
A
A
A
A
A
B
B
Drill template the PowerRouter
Drill template the PowerRouter Drill template the PowerRouter
Installation steps
Partno. 5555426,1
Read the installation manual for details
the PowerRouter

Illustrations PowerRouter • Back-up / Stand-alone • Installation Manual
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3
45
017763
300A
+BAT
-BAT
TMPS
GND
SH+
SH-
NLNL
IMD
25A RelayAC Local out
NL
Load
AC Local out RCD
NL

PowerRouter • Back-up / Stand-alone • Installation Manual Illustrations
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6
7
017763
017763
NL
017763
NL
017763
NL
CAN
NL
NLNL
11 N
fuse 315 mA
1 L1
4 L2
7 L3
9 L3
6 L2
3 L1

Illustrations PowerRouter • Back-up / Stand-alone • Installation Manual
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8
9
10
11 12
2
1
34
R1 R2
L
N
56
R7 R8
A1 A2
NL NL
AC
local out
AC grid
external relay
NO NC
AC GRID AC LOCAL OUT
NO NO NC NC
L
N
L
N
K201/K202
017763
NL
1
2
34
5
6
1
5
47
8
6
2
3
2

PowerRouter • Back-up / Stand-alone • Installation Manual Illustrations
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13 14
15
017763
L3L2
100%
L1N
R7 R8
A1 A2
R1 R2
Ripple
control
receiver
AC grid
external relay
NL
AC GRID AC LOCAL OUT
NO NO NC NC
-
+
-
+
6
3
2
14
5

Illustrations PowerRouter • Back-up / Stand-alone • Installation Manual
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16
17 18
RJ45 Pin#
Orange/White Tracer 1
Orange 2
Green/White Tracer 3
Blue 4
Blue/White Tracer 5
Green 6
Brown/White Tracer 7
Brown 8
GND
GND
GND
GND
C
D
1
2
5
6
4
3
AB
N
L
NL
CBEU-02
CSAP-01
NO NC
AC GRID AC LOCAL OUT
NO NO NC NC
> 300mm
K201/K202
AC
local out
AA
5 mm
4
1
2
3

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21 22

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PowerRouter • Back-up / Stand-alone • Installation Manual Contents
9
EN
Contents
Contents ............................................................................................................................................. 9
1 Introduction ..................................................................................................................................... 12
1.1 Applicability ............................................................................................................................. 12
1.2 Symbols used in the documentation ..................................................................................... 12
1.3 Warranty ................................................................................................................................... 12
2 Safety ................................................................................................................................................ 15
2.1 General safety .......................................................................................................................... 15
2.2 PowerRouter ............................................................................................................................ 15
2.3 Local grid .................................................................................................................................. 15
2.4 Public grid ................................................................................................................................ 16
2.5 Solar panels ............................................................................................................................. 16
2.6 Batteries ................................................................................................................................... 16
3 General description ......................................................................................................................... 17
3.1 The PowerRouter - intended use ............................................................................................ 17
3.1.1 Internet connection .......................................................................................................17
3.1.2 PowerRouter software installation tool ......................................................................... 17
3.2 1-phase sensor (accessory PRA1SENSE) ............................................................................. 17
3.3 3-phase sensor (accessory PRA3SENSE) ............................................................................. 18
3.4 External relay (accessory PRA1RLY) .................................................................................... 18
3.5 Wireless Energy Management Kit (accessory PRA1WEMK) ............................................... 18
3.6 Batteries ................................................................................................................................... 18
3.7 Battery temperature sensor (standard) ................................................................................. 18
4 Installation ....................................................................................................................................... 19
4.1 Check the contents of the PowerRouter box ........................................................................ 19
4.2 Determine the mounting location ........................................................................................... 19
4.3 Mount the PowerRouter .......................................................................................................... 20
4.4 Connect the AC grid ................................................................................................................ 20
4.5 Connect the AC local out ........................................................................................................ 21
4.6 Connect the solar panels ........................................................................................................ 21
4.7 Connect the 24V lead-acid batteries ...................................................................................... 22
4.8 Connect a self-use sensor ...................................................................................................... 23
4.8.1 Connect the 1-phase sensor (accessory) ..................................................................... 23
4.8.2 Connect the 3-phase sensor (accessory) ..................................................................... 23
4.9 Connect the external relay (accessory) ................................................................................. 24
4.9.1 Connect the external relay for energy management .................................................... 24

Contents PowerRouter • Back-up / Stand-alone • Installation Manual
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EN 4.9.2 Connect the external relay to isolate the PowerRouter from the public grid ................. 24
4.10Install the PRA1WEMK ............................................................................................................ 24
4.11Connect the additional cable (Italy) .......................................................................................26
4.12Switch on the system .............................................................................................................. 26
4.13Initialise the PowerRouter ....................................................................................................... 26
4.13.1 Installation wizard (on the display) ...............................................................................26
4.13.2 Software installation tool (for advanced settings) ......................................................... 27
4.13.3 Run the self test (Italy) ..................................................................................................28
4.14Connect the PowerRouter to the internet .............................................................................. 29
4.14.1 Connect to an internet router ........................................................................................29
4.14.2 Connect via a switch to an internet router .................................................................... 29
4.14.3 Connect to a wireless access point .............................................................................. 30
4.14.4 Register the PowerRouter on www.myPowerRouter.com ............................................30
4.14.5 Register additional PowerRouters on one login ...........................................................30
5 Software installation tool ................................................................................................................ 32
5.1 Introduction .............................................................................................................................. 32
5.2 Display settings ....................................................................................................................... 32
5.2.1 Backlight ....................................................................................................................... 32
5.2.2 Display ..........................................................................................................................32
5.2.3 Language ......................................................................................................................32
5.3 PowerRouter settings .............................................................................................................. 33
5.3.1 Scenario ....................................................................................................................... 33
5.3.2 Alarm 1 / Alarm 2 ..........................................................................................................33
5.3.3 Standby ........................................................................................................................ 34
5.3.4 Standby timer ...............................................................................................................34
5.4 Grid ........................................................................................................................................... 34
5.4.1 Country .........................................................................................................................34
5.4.2 EEG 2012 .....................................................................................................................34
5.4.3 VDE 4105 .....................................................................................................................34
5.4.4 Dynamic feed-in limiter ................................................................................................. 34
5.5 Battery pack ............................................................................................................................. 35
5.5.1 Battery charging ...........................................................................................................35
5.5.2 Maintenance charge ..................................................................................................... 35
5.5.3 Self-use battery settings ............................................................................................... 35
5.5.4 Wintermode ..................................................................................................................35
6 Operation ......................................................................................................................................... 36
6.1 Display menu ........................................................................................................................... 36
7 Troubleshoot ................................................................................................................................... 37
7.1 Troubleshooting ...................................................................................................................... 37
7.2 Check the LED status .............................................................................................................. 37
7.3 Check the error messages ...................................................................................................... 38
7.4 Error explanation ..................................................................................................................... 38
7.4.1 Hard error .....................................................................................................................38
7.4.2 Soft error ....................................................................................................................... 38
7.4.3 Error code ..................................................................................................................... 38

PowerRouter • Back-up / Stand-alone • Installation Manual Contents
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EN
7.5 Errors ........................................................................................................................................ 39
7.6 Procedures ............................................................................................................................... 43
7.6.1 Restart the PowerRouter .............................................................................................. 43
7.6.2 Check the PowerRouter airflow .................................................................................... 43
7.6.3 Check the internet connection ...................................................................................... 43
7.6.4 Look up the firmware versions and id number ............................................................. 43
7.6.5 Reset the PowerRouter ................................................................................................ 43
8 De-installation .................................................................................................................................. 44
8.1 De-install ................................................................................................................................... 44
8.2 Disposal .................................................................................................................................... 45
9 Technical specifications ................................................................................................................. 46

1 Introduction PowerRouter • Back-up / Stand-alone • Installation Manual
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EN 1 Introduction
1.1 Applicability
This installation manual is intended for qualified installation personnel. It describes how you can safely
install, connect and start the following PowerRouter types:
• PR50SB-PR/S24
• PR37SB-PR/S24
• PR30SB-PR/S24
1.2 Symbols used in the documentation
DANGER
This symbol indicates a hazardous situation which, if not avoided, could result in death or serious
injury.
WARNING
This symbol indicates a situation which, if the instructions are not followed, could result in injury and
damage to the equipment.
CAUTION
This symbol indicates a situation which, if the instructions are not followed, could result in damage to the
equipment.
i
This symbol indicates additional information to ensure optimal operation of the system.
1.3 Warranty
PowerRouter factory warranty conditions
Our quality control program ensures that each PowerRouter product is manufactured to exact
specifications and is thoroughly tested before leaving the factory.
5 year warranty
The Nedap factory warranty period is 5 years from the purchase date of the PowerRouter system. The
warranty conditions are based on EU Directive 99/44/EC, without prejudice to any legal rights.

PowerRouter • Back-up / Stand-alone • Installation Manual 1 Introduction
13
EN
Extended warranty
For all PowerRouter systems you can acquire a 5-year extension to the PowerRouter factory warranty, for
a total of 10 years of warranty coverage. The extended warranty can only be purchased within 6 months of
the PowerRouter delivery date.
Warranty conditions
If a PowerRouter becomes defective during its warranty period, one of the following services will be
performed at no charge for materials, but exclusive of labour costs, at the discretion of the PowerRouter
Helpdesk:
• Repair at Nedap N.V.
• Repair on site
• Exchange for a replacement unit (of equivalent value according to model and age)
Exclusion of liability
Warranty claims and liability for direct or indirect damage are excluded if arising from:
• Transport and storage damage
• Incorrect installation and/or commissioning
• Modifications, changes or attempted repairs by untrained and unauthorised personnel
• Incorrect use or inappropriate operation
• Insufficient ventilation of the device
• Failure to observe the applicable safety regulations
• Force majeure (e.g. lightning, overvoltage, storm, fire)
• Cosmetic shortcomings which do not influence the functioning of the unit
• Damage due to moisture and/or other environmental conditions
i
The installer/dealer who installed the PowerRouter must report the defective PowerRouter system to the
PowerRouter Helpdesk. Nedap reserves the right to replace the unit with one having equal or better
specifications, at Nedap's judgement.
Information for Australian purchasers - Consumer statutory rights
In Australia, this warranty is given by, and all Australian warranty claims should be directed to:
Nedap Energy Systems Australia
4B/4602 Mitchell Highway
Lucknow NSW 2795
Telephone: [phone]
Email: [email protected]
The benefits to the consumer given by this factory warranty are in addition to other rights and remedies of
the consumer that are stipulated by law, and which are not affected by this factory warranty.
Our products come with guarantees that cannot be excluded under the Australian Consumer Law. You are
entitled to a replacement or refund for a major failure and for compensation for any other reasonable
foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail
to be of acceptable quality and the failure does not amount to a major failure.

1 Introduction PowerRouter • Back-up / Stand-alone • Installation Manual
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EN Disclaimer
All rights to the content of this manual are owned by N.V. Nederlandsche Apparatenfabriek 'Nedap'
(hereinafter Nedap). By using this manual you accept the terms of this disclaimer.
Nedap has made every effort to ensure that this manual is accurate. Nedap accepts no liability for any
inaccuracies or omissions in this manual nor for any damages arising from or related to its use.
No data published in this manual may be reproduced or published in any form or by any means without the
prior written consent of Nedap. Information in this manual is subject to change without notice and does not
represent any commitment on the part of Nedap. Nedap does not assume any obligation to update the
information in this manual after publication and reserves the right to make improvements to this manual
and/or to the products described in this manual at any time without notice. If you find information in this
manual that is incorrect, misleading or incomplete, we would appreciate your comments and suggestions.

PowerRouter • Back-up / Stand-alone • Installation Manual 2 Safety
15
EN
2Safety
2.1 General safety
Before installing or using the PowerRouter, read all of the instructions and alerts on the hardware and in
the user and installation manual.
WARNING
The local output is floating if the system is not connected to the public grid
2.2 PowerRouter
There are two labels on the PowerRouter (figure 1):
• A warning label with battery warnings.
• A type label that provides technical specifications.
i
The image shows an example of the labels. The labels may be different depending on the PowerRouter
type.
2.3 Local grid
DANGER
The local grid delivers electrical power (230 V, 50 Hz).
WARNING
As an extra safety measure it is required that a 2-pole emergency switch is installed at the AC LOCAL
OUT connection (if used). This emergency switch must be connected in accordance with the UPS-safety
standard.

2 Safety PowerRouter • Back-up / Stand-alone • Installation Manual
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EN 2.4 Public grid
DANGER
The AC grid delivers electrical power (230 V, 50 Hz).
WARNING
Before you connect the PowerRouter to the Public AC grid, contact the local utility company. They have to
confirm that it is allowed to connect the system.
2.5 Solar panels
DANGER
Solar panels produce electrical power when exposed to light and can cause an electric shock,
energy, or fire hazard.
WARNING
Series fuse protection may be required, depending on the type and configuration of the solar panels used
in the system.
2.6 Batteries
DANGER
Batteries deliver electric power and can cause an energy or fire hazard when they are shorted, or
wrongly installed.
WARNING
• Series fuse protection is required for the 24V lead-acid batteries.
• Batteries must be located in a designated battery area. A battery area must comply with the local
regulations.This is because of the dangers of hydrogen gas and battery acid.
• Explosive gasses. Prevent flames and sparks. Provide adequate ventilation during charging.
CAUTION
As a feature the 24V lead-acid batteries are equipped with a battery temperature sensor, the PowerRouter
uses the sensor input to control charging of the batteries. If batteries become too hot, the PowerRouter will
stop charging the batteries.

PowerRouter • Back-up / Stand-alone • Installation Manual 3 General description
17
EN
3 General description
3.1 The PowerRouter - intended use
The PowerRouter is a DC to AC solar inverter, designed for indoor use. It is designed for use in areas
without a grid connection or with an unreliable and unstable grid. The PowerRouter works with solar panels
and battery storage to provide energy on the local out. Therefore the load, or part of the load, is always
connected to the AC local out and the batteries are charged when energy is available. If the PowerRouter
is connenected to the grid, the grid power will be used to charge the batteries or to provide energy to the
local out. For more information visit www.PowerRouter.com.
The PowerRouter is compliant with the following standards:
• 2004/108/EC (EMI)
• 2006/95/EC (low voltage directive)
CAUTION
The PowerRouter has no servicable parts inside.
3.1.1 Internet connection
When the PowerRouter is connected to the internet the myPowerRouter.com web portal provides detailed
system information (for example performance, profit) of your PowerRouter. The PowerRouter can even be
remotely updated with new firmware containing the latest features, so the system is always kept up to
date.
3.1.2 PowerRouter software installation tool
The software installation tool helps you to initialize the PowerRouter, make advanced setting, and update
the PowerRouter firmware if applicable.
Before you can use the software installation tool, you must install the software on your computer. You can
download the software installation tool from the website: www.PowerRouter.com. The software installation
tool includes the latest available firmware version, so no additional downloads are required.
i
You can download the PowerRouter software installation tool, driver, and guideline via the PowerRouter
website. You need your login details for this website. You can request login details via
www.PowerRouter.com. Check the website regularly for updates to the PowerRouter software installation
tool.
3.2 1-phase sensor (accessory PRA1SENSE)
With the signal from the 1-phase sensor, the PowerRouter determines the energy export and consumption
with the public grid on one phase. The 1-phase sensor is a measuring point for energy management and
can be used for clipping the grid. The 1-phase sensor can be ordered via your local Business Partner.

3 General description PowerRouter • Back-up / Stand-alone • Installation Manual
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EN 3.3 3-phase sensor (accessory PRA3SENSE)
With the signal from the 3-phase sensor, the PowerRouter determines the energy export and consumption
with the public grid for a 3-phase system, and compensates on 1-phase if a compensating electric meter is
used. The 3-phase sensor is a measuring point for energy management and can be used for clipping the
grid.The 3-phase sensor can be ordered via your local Business Partner.
3.4 External relay (accessory PRA1RLY)
You can use the external relay to:
• Energy management (figure 10).
If the amount of solar energy fed to the public grid exceeds the programmed value, the PowerRouter
can switch on additional loads via the external relay. How long the load stays switched on can be
programmed in the PowerRouter, via advanced settings in the software installation tool.
• Isolate the PowerRouter from the public grid by a ripple control receiver (figure 13).
The ripple control receiver is not included. The disconnection is according to the German directive
EEG2012. Only the disconnect contacts of the relay are used.
The external relay can be ordered via your local Business Partner.
3.5 Wireless Energy Management Kit (accessory PRA1WEMK)
The Wireless Energy Management Kit can be used with PowerRouter products that support energy
management. If the amount of solar energy fed to the public grid exceeds the programmed value, the
PowerRouter can switch on additional loads via the Wireless Energy Management Kit. The Wireless
Energy Management Kit is available in several country dependend versions and can be ordered via your
local Business Partner. The Wireless Energy Management Kit contains a:
• Binary input module (Eaton CBEU-02/xx).
• Wireless plug-in actuator (Eaton CSAP-01/xx).
3.6 Batteries
The PowerRouter models function with any 24V lead-acid batteries. Proper settings can be made via
advanced settings in the software installation tool.
CAUTION
Never exchange 24V batteries with 48V batteries or vice versa.
i
Always check the specifications of the supplier, before making the settings.
3.7 Battery temperature sensor (standard)
The battery temperature sensor is installed on the 24V lead-acid batteries. The PowerRouter uses the
sensor input to optimise charging of the batteries. When the batteries overheat, the PowerRouter stops
charging the batteries. Proper settings can be made via advanced settings in the software installation tool.