OutBack Power SKYBOX User manual

Quick Start Guide
Specifications
900-0195-01-00 REV A
©2018 OutBack Power Technologies. All Rights Reserved.
IMPORTANT:
Not intended for use with
life support equipment.
Contact Information
Mailing Corporate Headquarters
Address: 17825 – 59th Avenue NE
Suite B
Arlington, WA 98223 USA
Web Site: www.outbackpower.com
NOTE: Additional information on
this product is available at
www.outbackpower.com.
For screen navigation, operation,
and troubleshooting, see the
SkyBox Overview Guide. For
programming and applications, see
the SkyBox Programming Guide.
Date and Revision
July 2018, Revision A
Listings:
oUL1778 5th Edition, 6/13/2016
oUL1741 2nd Edition, 1/28/2010 with supplement SA
oCSA22.2, No. 107.1-01 Ed:3 (R2006)
Certifications:
oHECO Rule 14 SRD
oCalifornia Rule 21 SRD
oIEEE 1547-2003
oIEEE 1547.1-2005
System Grounding and Bonding:
In this product, the PV, AC, and battery circuits are
isolated from the enclosure. This product has been
evaluated, listed and identified by UL to meet the
requirements of 690.41 and 250.4(A) of the NEC.
oThe PV system ground reference and protection
is provided internal to the SkyBox, in accordance
with NFPA 70 690.41(A)(6).
oThe AC connections are not bonded to ground.
The usual location for a neutral-ground bond is
at the main AC service panel. Make sure to
establish a neutral-ground bond when installing
in an off-grid application.
oThe battery connection is not bonded to ground.
Make sure to establish a negative-ground bond for
each battery system.
Equipment grounding is required by Section 250 of the
National Electric Code (ANSI/NFPA 70) and Canadian
Electrical Code (C22.1).
Overcurrent Protection
oThe battery disconnect device in the BOS does not
provide overcurrent protection. The installer must
provide protection for the battery circuit according to
the following parameters.
 Maximum 175 Adc
 Minimum 10 kA AIC
oAC overcurrent protection is provided in the BOS.
Dimensions:
oHeight 47.2" (119.9 cm)
oWidth 21.0" (53.3 cm)
oDepth 9.4" (23.9 cm)
Electrical Specifications
oMaximum continuous output: 5000 VA @ 45°C
oNominal input and output voltage: 120/240 Vac
oNominal frequency: 60 Hz
oMaximum continuous output current: 24 Aac
oMaximum grid input current: 48 Aac
oMaximum generator input current: 48 Aac
oMaximum PV source voltage: 600 Vdc
oOperating PV source voltage range: 200 to 600 Vdc
oMaximum PV input current: 20 Adc
oMaximum PV short-circuit current: 32 Adc
oAUX output: 0.6 A @ 12 Vdc
oAUX relay: 10 A @ 240 Vac, 5 A @ 30 Vdc
oNominal battery voltage: 48 Vdc
oMaximum battery input current: 140 Adc
oBattery input voltage range: 42 to 60 Vdc
oCharging output voltage range: 42 to 60 Vdc
oMaximum battery charging current: 100 Adc
Supported Batteries
o Lead-acid
oVarious lithium-ion models
Environmental Ratings:
oEnvironmental Category: Type 3R
oMaximum Altitude Rating: 10,000 feet
oMaximum Ambient Temperature: 60°C
Mounting Bracket
Ensure the mounting surface is strong enough to handle
three times the unit weight. Add plywood or other material
as necessary to strengthen the surface.
ALocate this horizontal slat at about eye level for easier display viewing.
BDo not locate the top of the bracket more than (about) 6' (183 cm)
off the floor. This ensures the SkyBox can be easily lifted onto the bracket.
Mark the placement of the bracket according to A and B, keeping in mind the
dimensions in the second drawing. These dimensions show the SkyBox overlap
(beyond the bracket) as well as the vertical measurements with respect to A. They
also add the required minimum clearances of 6" (15.2 cm) to SkyBox top and sides.
IMPORTANT:
No lower clearance is shown. In outdoor installations a 36" minimum clearance above the
ground or floor is required. The lower vertical measurement becomes 60.6” (153.9 cm) from A.
Weights:
oSkyBox: 87.7 lb (39.8 kg)
oBOS: 23.6 lb (10.7 kg)
oMounting Bracket: 4.6 lb (2.1 kg)
True Hybrid Energy System
Tools Needed:
o13 mm socket (torque) wrench
o#2 Phillips (torque) driver
oFlat blade (torque) driver
Place the bracket so that
rails C and D are flush
with the surface.
Conduit Knockouts
(Underside of BOS)
SkyBox
BOS
(Balance of
System)
Left Right
1½" ¾” ¾” ¾” ¾” ¾” ¾”
6.0"
(15.2 cm)
Hole
spacing
B
A
16"
(40.5 cm)
Hole spacing
28.6"
(72.6 cm)
A
24.6"
(62.5 cm)
9.4"
(23.9 cm)
32"
(81.3 cm)
C
D
o6 mm Allen wrench
oDigital multimeter (DMM)
WARNING: Burn Hazard
The heat sink (at the top rear of the product) may
reach temperatures greater than 70°C. Install this
product so that casual contact does not occur.
WARNING: Fire/Explosion Hazard
Do not place combustible or flammable materials
within 12 feet (3.7 m) of the equipment. This unit
employs mechanical relays and is not ignition-
protected. Fumes or spills from flammable materials
could be ignited by sparks.
WARNING: Personal Injury
Use safe lifting techniques and standard safety
equipment when working with this equipment.
IMPORTANT:
 This document is for use by qualified personnel familiar with photovoltaic
(PV) systems and maximum power point tracking (MPPT) technology as
well as basic inverter functionality. Users of this document should meet
all local and governmental code requirements for licensing and training
for the installation of electrical power systems with AC and DC voltage
up to 600 volts. This product is only serviceable by qualified personnel.
 Clearance and access requirements may vary by location. A 36” (91.4 cm)
clear space in front of the system for access is recommended. Consult
local electric code to confirm clearance and access requirements for the
specific location. If this product is installed or used in a manner other than
specified, the protection it provides may be impaired.
 Fuses are not to exceed maximum output rating.
 When installed outdoors, use only UL514B-compliant wet location or
rain-tight conduit hubs for entry into the enclosure.
 See Specifications for instructions on system grounding and bonding.
CAUTION:
!To reduce the risk of fire, connect only to a circuit
provided with a 60 amperes maximum branch-circuit
protection in accordance with the National Electric Code,
ANSI/NFPA 70.
!

D
D
Mounting
900-0195-01-00 REV A
©2018 OutBack Power Technologies. All Rights Reserved.
43
Mounting
21
5 6 7
J
J
Attach the wall bracket.
Center the mounting holes
on wall studs. Six ¼ - 20 ×
1½” lag screws and washers
are provided. Any of the
mounting holes can be
used. Observe all mounting
considerations (page 1),
including the display
location (A).
Place the rear brackets on the BOS studs (B). Attach
the rear brackets to the BOS assembly using the four
M6 nuts provided (C). Ensure that the pegs on each
bracket (D) face inward (toward the opposite bracket).
Place the BOS assembly
on the wall bracket by
seating the pegs (D) in
the slots (E).
The wall bracket has securing holes for the
BOS (F). Secure the BOS by inserting an
M6 × 40 mm screw on each side.
Install the SkyBox onto the wall bracket by lifting
it into position. The SkyBox is equipped with
rear brackets which are already attached (G).
NOTE: Two holes are available at the top of
the SkyBox (H). A metal pipe, rod, or bar can
be inserted across the top to assist with
handling and lifting.
Insert the rear
brackets into the
designated slots
(I) on the wall
bracket. Once the
SkyBox is seated,
the lifting bar can
be removed.
The wall bracket has
securing holes for the
SkyBox (J). Secure the
SkyBox in place by
inserting an M6 × 40 mm
screw on each side.
Mounting is complete.
See the
Commissioning
section.
Wiring Access
A
I
J
F
F
E
B
C
D
D
G
H
H
Two areas house the system wiring. The BOS compartment opens with a latch. It connects
to external wiring (battery, AC, PV, etc.) and conduit. These connections extend from the
BOS into the SkyBox compartment, which opens with two Allen screws (K). If the SkyBox
must be removed for service, the BOS and its wiring can remain. Some connections, such
as communications, pass through the BOS to be made directly in the SkyBox.
I
BOS
Compartment
SkyBox
Compartment
K
K
Battery Cable Connections
Nut 3/8" Spring
Lock
Washer
Battery
Positive
(+) Lug
DC
Positive (+)
Plate
Spring
Lock
Washer
DC
Negative (–)
Plate
Nut 3/8"
DO NOT MOVE
Nut 3/8"
Battery
Negative
(–) Lug
Inverter
Negative
(–) Lug
2a 2b
or 1a
NOTE: The spring lock washer used in these connections must be
installed with the rounded (convex) side facing outward. Installing in
any other orientation will result in inadequate compression which
may be hazardous. See the CAUTION to the far right.
CAUTION:
Equipment Damage
!
CAUTION:
Fire Hazard
Before energizing, confirm that
all battery terminal hardware is
installed as shown below.
Stacking the terminal hardware
in any other order can overheat
the terminals.
!
Battery
AC
PV
AUX
Permitted Sizes Torque Requirements
AWG
2/0 to 4/0
#8 to #3
#18 to #4
#24 to #16
#14 to #10
#8
#6 to #3
#2
#1 to 1/0
mm2
70 to 120
6 to 25
1.5 to 25
0.25 to 1.5
2.5 to 4
6 to 10
16 to 25
35
50
In-lb
65 to 75 in-lb
18 to 22 in-lb
11 to 16 in-lb
N/A
20
25
35
40
50
Nm
7.3 to 8.5 Nm
2.0 to 2.5 Nm
1.2 to 1.8 Nm
N/A
2.3
2.8
4.0
4.5
5.7
Neutral,
Ground, and
PV Ground
Table 1: Wires and Conductors
When connecting to the
battery terminals, make sure to
observe the proper polarity.
Connecting the cables
incorrectly can damage or
destroy the equipment and
void the product warranty.
IMPORTANT
All PV, AC, and battery conductors must be copper-only and rated at 75°C.

L1 L2
NEU
GROUND
AC Subpanel
Loads
L1
L2 NEU
GROUND
Utility
Grid
AC Distribution Panel
N
AC Generator
Generator
Start
L1 L2
L1 L2 N
Photovoltaic
(PV) Array
Neutral
HOT L1
Ground
AC LEGEND
N
L1
HOT L2 L2
Battery
Bank
RTS
BMS
900-0195-01-00 REV A
©2018 OutBack Power Technologies. All Rights Reserved.
Wiring
and : Connect ground wires for battery, AC, PV, and
additional PV equipment.
: Connect to SkyBox negative (–) , then connect to
battery negative (–).
and : Connect PV array negative (–) and positive (+) wires.
Use terminals and for a second array, if present.
: Connect all AC neutral wires.
: Connect SkyBox ground wire to in BOS.
: Ensure the rapid shutdown jumper or device is installed into AUX terminals. Remove the factory
jumper before installing an external device. Route the wires through channel .
NOTE: The SkyBox will not function unless one of these is installed. It will show a Rapid Shutdown fault.
and : Connect to the matching sockets in the wiring compartment.
: Connect SkyBox PV negative (–) wire to . Do not remove the jumper cap.
NOTE: is on the opposite side of the switch from and .
: Connect SkyBox PV positive (+) wire to . Ensure that
all four screws at this location are tight.
: Connect AFCI cable assembly to SkyBox socket .
: Connect to battery positive (+).
: Connect to SkyBox positive (+) .
and : Connect to load subpanel L1 and L2 respectively.
and : Connect to utility grid L1 and L2 respectively.
and : Connect to generator L1 and L2 respectively.
: If current transducers (CT) are in use, install the wires into AUX terminals.
Route the wires through channel . These are usually installed at the
utility grid input to the main AC panel.
: Connect internet cable to SKYBOX port . Route through channel .
NOTE: Do not connect this cable to the other ports on the display.
: For batteries with a separate battery management system (BMS):
The BMS (CAN bus) adapter cable converts the RJ45 cable end to RJ11.
It connects to the BAT MON port . Do not insert the RTS or any other
RJ11 cable into the BAT MON port.
: If a BMS is not present: Connect the remote temperature sensor
(RTS). Place the sensor on the battery sidewall, as close to the
center of the bank as possible.
: Connect generator start wires into AUX terminals . (See the
key to the right.) Route through channel .
: To stack an additional SkyBox, use a CAT5 cable to connect to the
WALL (RS-485) port on the next SkyBox. The last SkyBox in
sequence has nothing connected to , marking it as the end unit.
(See the NETWORK tab in the SkyBox Programming Guide for
additional steps.)
1a
NOTES
 Make connections in the order indicated. If steps or connections are not applicable, they can be skipped.
 Tighten the applicable connections to the torque values specified in Table 1. (See opposite sheet.)
 Do not connect the PV positive (+) or negative (–) conductors to ground.
 Perform all wiring in accordance with Article 690 of the National Electric Code.
Negative
Positive
Ground
DC LEGEND
7a
7b
6
3c 4c 5c
7c 7d
99a
2a
2b 2c
5a 5b
3a 3b
4a 4b
14
16
18
13
13
7d
12 19
15
12
17
16
1b
7a 7b
13
18
2a
1a
3a
3b
4a
4b
5a
5b
6
7a
11
17
9
2c
1b
2b
3c 4c 5c
14
15
9a
8a
7b 8b
Circuit #1
Circuit #2
NOTE: In off-grid installations,
ensure the neutral and ground are
mechanically bonded. DO NOT
establish more than one bond.
z
CT (L1)
Internet
Rapid
Shutdown
Initiator
Gen Start (AUX)
COMMUNICATIONS LEGEND
Rapid ShutdownRJ45
RTS
AFCI CT (L1)
BMS
Next SkyBox
PV Cable
12
13
17
Connections for current transducers on L1 and L2
AC inputs. (Only L1 is shown in the image to the left.)
10 and 11 are for hot wires; 2 and 3 are ground.
See the Programming Guide.
Rapid shutdown inputs (4 and 12).
These terminals connect to normally-
closed dry contact terminals on the
RSI (Rapid Shutdown Initiator). Use
OutBack’s ICS Plus or an equivalent
RSI system. See the RSI literature
and the SkyBox Overview Guide
(Troubleshooting section) for
instructions if rapid shutdown occurs.
Rapid shutdown outputs
(5 and 13). These are used to
duplicate the RSD connection
and function for an additional
SkyBox. They should be wired
to terminals 4 and 12 on the
next SkyBox.
Auxiliary (AUX) dry contacts (7 and 15) or 12-volt
contacts (8 and 16, up to 0.6 Adc) can serve as a
switch for Advanced Generator Start. (See the
SkyBox Programming Guide.)
Unused 1
XCT L2 GND 2
XCT L1 GND 3
RSD INPUT 1 4
RSD OUTPUT 1 5
Unused 6
AUX RELAY 1 7
AUX 12V GND 8
9 Unused
10 XCT L2 HIGH
11 XCT L1 HIGH
12 RSD INPUT 2
13 RSD OUTPUT 2
14 Unused
15 AUX RELAY 2
16 AUX 12V

1. If batteries are present: Verify input 48 Vdc using a DMM by measuring from
to .
If batteries are not used in this system, skip to step 6.
Confirm the correct battery voltage and polarity. If the red LED indicator
is lit, the polarity is reversed. Do NOT turn on the circuit breaker.
2. Once proper voltage and polarity are confirmed, turn on (close) the main
battery circuit breaker .
Wiring
Commissioning
Pre-startup Procedures:
1. Double-check all wiring connections. Using a digital multimeter (DMM), test for continuity between
and . Ensure a neutral-ground bond is installed in the system.
2. Inspect the enclosure. Ensure no debris or tools were left inside.
3. Ensure all AC loads at the backup (or protected) load panel are disconnected.
4. Ensure all AC input feeds to the BOS are disconnected at each source.
5. Using a Phillips screwdriver, remove the clear plastic (dead front) panel (not depicted). The four
required screws are marked with  in the image to the right.
6. Energize the system as below. Follow the procedures which are applicable to the system. If any
elements are not present (including batteries, PV, or a generator), ignore those procedures.
To energize the Skybox:
PV LED Legend
Caution
3. On the first power-up, a welcome message is shown. The right arrow 
proceeds to the Setup Wizard. This steps through language, region, and
similar changes, then PV, battery, and AC settings. On the last screen,
the Save key proceeds to the Home screen. (The Home screen appears
after every subsequent power reset.)
4. From the Home screen, turn on the SkyBox with the ON/OFF key .
NOTE: Do not close the LOAD circuit breaker .
5. Using a DMM, verify the inverted L1 output 120 Vac on the upper LOAD
terminals from to . Verify L2 by measuring from to .
6. Verify 240 Vac across the LOAD terminals by measuring from to .
7. Turn on (close) the LOAD circuit breaker . Do not connect loads at the
protected load panel.
8. Verify 120 Vac on LOAD L1 by measuring with a DVM from to .
Verify L2 by measuring from to .
9. Verify 240 Vac across the LOAD terminals by measuring from to .
10. Connect and test loads at the protected load panel.
11. If grid is present: Turn on the grid connection to the BOS at the source.
12. Verify 120 Vac on GRID L1 by measuring with a DVM from to .
Verify L2 by measuring from to .
13. Verify 240 Vac across the GRID terminals by measuring from to .
Setup Wizard (entry screen)
Setup Wizard (final screen)
Home Screen
1a
2a
2
1c
7a
3a 3b 4a 4b 5a 5b
6
11
8a 8b
900-0195-01-00 REV A
©2018 OutBack Power Technologies. All Rights Reserved.
5c 5d
1c
1a 2a
CAUTION: Equipment Damage
Incorrect battery polarity will damage the equipment.
!
2
1c
CAUTION: Reverse
polarity in negative
grounded system
Keep breaker in the OFF
position and check polarity
!
543
5c 5d
5
18. Turn on (close) the PV switch . Check indicators and again. Both indicators should light. Any other behavior means the
polarity at the top of the PV switch may be reversed.
19. On the Home screen, check the SOLAR tile (as shown to the right) and ensure it is operating normally. The SkyBox will connect to the
PV source if the voltage is above 250 Vdc. (See the Overview Guide for more information.)
20. If a generator is present: Turn off (open) the GRID circuit breaker .
21. Start the generator. Do not turn on (close) the GEN circuit breaker . Repeat steps 12 and 13 using , , and .
22. Turn on (close) the GEN circuit breaker . Repeat step 14. The LOAD circuit breaker may remain on (closed).
23. Stop the generator.
24. Turn on (close) the GRID circuit breaker . Wait for the programmed connection delay to elapse. Test any grid-interactive functions.
To de-energize or shut down the system:
There is no required shutdown order. It is common to de-energize circuits in the reverse order from which they were energized.
65b
5a 5b
64a 4b
11
65a
CAUTION: Equipment Damage
Incorrect PV polarity will damage the equipment.
!
14. Turn on (close) the GRID circuit breaker . The Wizard will appear for the first time if no batteries are installed. (Perform steps 3 through 10 if this is the case.)
The SkyBox transfer relay should click and the GRID tile should read PASS THROUGH.
15. Using a DMM, test the pass-through (transferred) L1 output voltage at and . Test the L2 voltage at and .
16. If PV is present: Verify that the input is in the correct range of open-circuit voltage. Confirm polarity by measuring with a DVM from to (referred to as PV1
in the legend above). Confirm polarity from to (PV2, if present).
17. Check the green LED indicators and . If a single PV input is installed, one indicator should light. If two strings are installed, both should light. Any other
behavior means the polarity may be reversed. Do NOT turn on the switch. Review all PV connections.
7a8a
5
3
4
4
63a
63b
3a 3b
3
5c 5d6 6




6
NOTES
If any onscreen faults or other problems occur during commissioning,
see the Troubleshooting section of the SkyBox Overview Guide.
66
5c 5d PRODUCING
KW
0 6
7b
BEFORE CLOSING PV DISCONNECT
ENSURE LED INDICATION IS CORRECT:
TERMINALS ON PV BOARD CORRECT
ONLY PV1 TERMINALS
ONLY PV2 TERMINALS
PV1 + PV2 TERMINALS
NOTE: PV VOLTAGE > 100 VDC
REQUIRED TO LIGHT LEDS
3
WARNING: Shock Hazard
Before performing maintenance, all sources (battery, PV, and AC) must be completely de-energized. All the unit to rest for at least five minutes.