PORTABLE ELECTRIC VOLTstack 5k User manual

OWNER’S MANUAL
North America

VERSION DATE APPROVED DETAILS
1.0 September 2019 JC Initial Release
Version 1.0 September 2019 2

HELPFUL TIPS
Your VOLTstack DOES NOT produce any hazardous emissions or chemicals of any kind.
Congratulations on choosing a safer product for yourself, others and the environment.
INTRODUCTION
Congratulations on your selection of a VOLTstack®. In using this product you are ensuring a cleaner, healthier local
environment, while reducing GHG emissions that contribute to global climate change. You are proving that a gas generator is
no longer the only option. We are certain you will be pleased and pleasantly surprised with your purchase of one of the finest
electric generators on the market.
We want to ensure you get the best results from your new VOLTstack®, and operate it without issue. This manual contains the
information on how to use your VOLTstack®eectively and safely, please read it carefully.
As you read this manual, you will find information preceded by a section like this
That information is intended to help you use your VOLTstack®to its utmost potential, and avoid damage to your unit, other
property or your environment.
We are confident you will find the experience of using a VOLTstack®simple and enjoyable. It is the future of power; simple,
silent, emissions-free and ecient.
Best wishes,
Portable Electric Ltd.
INFORMATION
Version 1.0 September 2019 3

WARNING
It is the operator’s responsibility to read and understand all safety instructions in this Owner’s Manual before operating the
VOLTstack. Failure to do so may result in serious injury or death.
This Owner’s Manual should be regarded as a permanent component of the VOLTstack and be available for reference at all times.
The information and specifications provided in this Owner’s Manual were approved by Portable Electric Ltd at the time of
publication. Portable Electric Ltd reserves the right to change or discontinue products at any time without notice. No content in
this publication is to be reproduced without the written permission of Portable Electric Ltd.
WARNING
Do not use electrical equipment in wet or damp conditions, such as rain or snow. Doing so may result
in an electrical shock that may result in serious injury or electrocution.
DANGER
This VOLTstack produces lethal voltage and may cause an electric shock or electrocution if misused.
Read and understand all safety instructions before operating.
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SAFETY OVERVIEW
The safety of the operator and those around them is of absolute importance. It is the operator’s responsibility to ensure the
VOLTstack is used safely and responsibly.
While it is not practical to outline all possible hazardous situations, we have provided many operating procedures and
precautions to allow the operator to use the VOLTstack safely with good judgment.
Safety Instruction Convention
Important safety instructions will be outlined throughout this Owner’s Manual following the DANGER and WARNING
convention below.
Operational Tips and Instruction Convention
Beyond safety, there are good practices and operating procedures that should be followed to ensure optimal performance and
reliability of the unit.
Important operating procedures and helpful tips will be outlined throughout this Owner’s Manual following the IMPORTANT and
HELPFUL TIPS convention below.
DANGER
If not avoided, this hazardous situation will result in serious injury or death.
IMPORTANT
Important information that should be considered to avoid damage to the equipment or other property.
WARNING
If not avoided, this hazardous situation may result in serious injury or death.
HELPFUL TIPS
Helpful tips and best practices to ensure optimal performance.
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TABLE OF CONTENTS
INTRODUCTION 3
SAFETY OVERVIEW 5
Safety Instruction Convention 5
Operational Tips and Instruction
Convention
5
TABLE OF CONTENTS 6
TERMINOLOGY 7
VOLTstack Power Modes 7
VOLTstack Power States 7
Amp Hour (Ah) 7
Battery Management System (BMS) 7
Battery Pack 7
Face Plate 7
KiloWatt Hour (kWh) 7
Net Power 8
Rear Plate 8
Run Time 8
State of Charge 8
SUNstack Solar Kit 8
Surge 8
VOLTstack Power Block 8
VOLTSTACK SAFETY 9
Safety Label Locations 9
Important Safety Information 9
Operator Responsibility 9
Environmental Considerations 10
Paralleling Outputs 10
Electrical Arcing 11
Grounding 11
Floating Neutral 11
Connecting to Grid 12
COMPONENT IDENTIFICATION
AND LOCATION
13
Exterior 13
Face Plate 14
Rear Plate 14
Interior 15
Serial Number 15
GETTING STARTED 16
Pre-Operation Check 16
Recharging 16
Turning Power On 16
Turning Power O 16
OPERATION 17
Applications 17
Battery Storage Capacity 18
Battery Monitor State of Charge 18
Battery Monitor Operation 19
Type 1 Battery Monitor 19
Discharging 19
Charging 19
State or Charge Low 19
Fault Warning 19
Connection Error 19
Standby Operation 19
Power ON Operation 20
Low State of Charge Cut-o 20
Load vs Run Time 20
AC Charging Operation 20
Solar Charging Operation 21
Important Safety Information 21
Getting Started 22
Charging Complete 22
Power On While Charging 23
USB 5V Charging 24
Self Consumption 24
Controller Settings 24
DC Operating Fuse Replacement 24
Hot and Cold Temperature Operation 24
High Temperature AC Output 25
High Temperature AC Charging 25
High Temperature Shut-Down 25
Cold Temperature AC Output 25
Cold Temperature AC Charging 25
MAINTENANCE 26
Maintenance Schedule 26
Opening the Lid 28
Caster Maintenance 28
Air Intake Filter Maintenance 29
Environmental Fan Maintenance 30
Interior and Power Block Maintenance 31
Connection Points Maintenance 31
Battery System Maintenance 31
Replacement Parts 32
STORAGE 33
Storage Environment 33
Storage Procedure 33
Storage Precautions 33
VOLTstack Health in Storage 34
TRANSPORTATION 35
Transportation Preparation 35
Ground Transportation 35
Transportation by Air 35
TROUBLESHOOTING 36
TECHNICAL INFO 37
5k Wiring Diagram 37
AC Terminal Strip Wiring 38
Device Power Ratings 39
Spec Sheet 40
Dimension Sheet 41
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TERMINOLOGY
VOLTstack Power Modes
O:
Zero power state with no AC output power
Use: Shipping and long term storage
Indicators: No lights ON Face Plate and Rear Plate
Standby:
DC Systems on with no AC output power
Use: low power consumption mode, can be used for charging or between operations
Indicators: Battery Monitor ON, Master Battery ON, ON/OFF button OFF
Power On:
All systems on with AC output
Use: For full power output & usage
Indicator: ON/OFF button ON, Green Output Lights ON
VOLTstack Power States
Discharging (negative Net Power):
Power State in which the net power is less than zero, and the VOLTstack State of Charge is decreasing
Charging (positive Net Power):
Power State in which the net power is greater than zero, and the VOLTstack State of Charge is increasing
Idle (zero Net Power):
Power State in which the net power is zero and the State of Charge is decreasing according to the
self consumption of the VOLTstack Power Mode.
Amp Hour (Ah)
Amp hour is a unit of measurement for electrical capacity commonly used for battery storage devices. One
amp hour is equivalent to one amp being used continuously over a 1 hour period.
Battery Management System (BMS)
Battery Management System is an integrated controller that monitors and protects a Battery Pack from
harmful conditions such as short circuits, over charging, over discharging and temperature eects.
Battery Pack
A Battery Pack consists of a fixed number of battery cells combined in series and/or parallel to form a higher
voltage and capacity battery. The cells are assembled into a protective enclosure with an integrated Battery
Management System.
Face Plate
The Face Plate is located at the front of the VOLTstack. It serves as the user interface and contains all
charging and output controls. See the Component Identification and Location section for details.
KiloWatt Hour (kWh)
Kilowatt hour is a unit of measurement for electrical energy, it is analogous to “litres of gasoline”. One
kilowatt hour is the amount of energy equivalent to 1000 watts being used continuously over a 1 hour period.
Version 1.0 September 2019 7

Net Power
Net Power is the summation of the total charging power less the total device load power. Net Power can be
positive or negative.
Total Charging Power (W) — Total Device Load (W) = Net Power
Rear Plate
The Rear Plate is located at the rear of the VOLTstack. It contains the Master Battery On/O buttons, USB
Data Ports, Solar Charging Ports and Rear Vents. See the Components Identification and Location sections
for details.
Run Time
Run time is defined as the total amount of time your VOLTstack will output power until the unit needs to be
re-charged.
State of Charge
State of Charge is a numerical value (0%-100%) representing the energy remaining in a battery system. It
refers to the usable energy remaining as opposed to the maximum storage capacity of the battery.
SUNstack™ Solar Kit
SUNstack Solar Kits are a plug and play system developed by Portable Electric which include a SUNstack
Solar Panel, and SUNstack Carry Bag and a SUNstack Cable.
Surge
A temporary increase in the current or voltage of an electrical circuit. Surges often occur when power is
initially supplied to a device to switch on components such as motors or compressors.
VOLTstack Power Block
The Power Block is located inside of the VOLTstack and is the source of AC Power. See the Components
Identification and Location sections for details.
TERMINOLOGY CONT.
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VOLTSTACK SAFETY
Safety Label Locations
The safety labels that are applied to the VOLTstack by the manufacturer must remain on the unit throughout its lifetime. Should
a label come o or get damaged, contact the manufacturer to receive a replacement. Application instructions will be supplied.
Important Safety Information
VOLTstacks are designed to give safe and dependable service when operated according to the instructions. It is important for
all operators to read and understand this Owner’s Manual before use. Operating the unit safely by observing safe operating
procedures will help prevent accidental injury.
Operator Responsibility
Be sure that anyone who operates a VOLTstack receives proper instruction and understands:
•How to stop the unit quickly in the event of any emergency
•How to use all of the VOLTstack controls, output receptacles, and connections
Do not let children operate the unit without supervision.
DANGEROUS GOODS
CLASS 9 LABEL
CAUTION: TO REDUCE THE
RISK OF ELECTRIC SHOCK,
GROUND THIS UNIT AND
THE SUPPLY SOURCE AND
USE ONLY IN THE UPRIGHT
POSITION.
ATTENTION: POUR RÉDUIRE LE
RISQUE DE CHOC ÉLECTRIQUE
EFFECLUEZ LA MISE A LA
TERRE DE CET APPAREIL A LA
SOURCE D ALIMEF’LLATION EL
ULIJISEZLE UNIQUEMENT EN
POSITION VERLICALE.
CAUTION: THIS UNIT HAS
MORE THAN ONE POWER
SUPPLY – 2 – DISCONNECT
ALL SUPPLIES BEFORE
SERVICING TO AVOID
ELECTRIC SHOCK
ATTENTION: CET APPAREIL A
PLUS D’UNE ALIMENTATION
– 2 – DÉBRANCHEZ TOUTES
LES FOURNITURES AVANT
D’ENTRETIEN POUR ÉVITER
LES CHOCS ÉLECTRIQUES
MADE IN CANADA
Version 1.0 September 2019 9

WARNING
The unit should be properly monitored by the operator at all times. Do not leave
the unit unattended during use.
WARNING
Ensure the unit is free from moisture before and during use.
Environmental Considerations
VOLTstack units are Type 1 Enclosures and are designed for use in dry environments. Usage when snow, rain or other moisture
is present could result in an electric shock or electrocution and should therefore be avoided. Ensure that both the VOLTstack
and your hands are dry during operation.
Storage of the VOLTstack in an unsheltered environment could result in moisture or ice build-up on the Face Plate or on other
electrical components. To avoid potential malfunctions, short circuits and electrocution, check components before each use to
make sure they are free from moisture.
Paralleling Outputs
Outputs from separate VOLTstack units cannot be connected together in parallel. Contact your distributor for
more information.
IMPORTANT
Do not parallel the outputs of multiple VOLTstacks. Contact your distributor for more
information and options regarding parallel operation.
Version 1.0 September 2019 10

WARNING
Make sure the unit is properly grounded according to local regulations.
WARNING
Do not operate your VOLTstack near combustible fumes. Electrical arcing within the unit or
arcing on inlet/outlet connections can ignite combustible fumes.
Electrical Arcing
The VOLTstack can cause electrical arcing; do not operate near combustible fumes.
Grounding
VOLTstack units have a ground system that connects frame components to the ground terminals of the AC Input and Output
Receptacles. The Grounding Lug should be connected to a reliable external ground source when in use using a ¼-20 nut.
Floating Neutral
The VOLTstack system is a floating neutral configuration and the AC neutral is not connected to the ground terminal. When
using a receptacle tester, this will NOT show the same ground circuit condition as a home receptacle.
IMPORTANT
The VOLTstack uses a floating neutral configuration. Understand the
implications of this configuration before operating.
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Connecting to Grid
The VOLTstack AC output should not be connected to a grid system.
DANGER
Do not connect the VOLTstack AC output to any other AC sources such as grid power or generators.
Doing so will permanently damage the unit and may cause an electric shock.
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Exterior
COMPONENT IDENTIFICATION AND LOCATION
Use the following diagrams to reference component names and locations discussed throughout this Owner’s Manual.
Lid Locks
Lift Bars
Fixed Casters
Swivel Locking
Caster
Grounding
Lug
Swivel Caster
Lift Bars
Nameplate
Air Intakes
Lid
Version 1.0 September 2019 13

Face Plate
Rear Plate
On/O Button
Charging Ports
Charging Lights
Charging Breakers
Battery Monitor
Output Breakers
Output Lights
Output Receptacles
USB 5V
Rear Vents
USB Data Ports
(No Charging)
Solar Charing
Ports
Master Battery
On/O
Version 1.0 September 2019 14

Interior
Serial Number
Refer to your VOLTstack by the serial number indicated on the nameplate.
Portable Electric Ltd
Model Name: VOLTSTACK 5K
Max A/C Output: 120V / 60 Hz / 40A
Max A/C Input: 120V / 60 Hz/ 30A
Enclosure: Type 1 Enclosure
Serial# 005kXXXX-XXXXXX-XXXXXXXX-X
Wattage: 4800W
Capacity: 5600Wh
Environmental
Fans VOLTstack Power
Block
AC Terminal
Strip
Controller
Version 1.0 September 2019 15

GETTING STARTED
Pre-Operation Check
Before starting your VOLTstack, perform a pre-operation check to avoid any potential issues during use.
•Ensure Air Intakes and Rear Vents are clear from debris
•Ensure unit is in upright position during usage
•Ensure proper grounding of the Grounding Lug
•Ensure device power rating is within the maximum power output of the VOLTstack displayed on the nameplate
Recharging
When the State of Charge of your VOLTstack reaches 0%, it will need to be recharged. Before using your VOLTstack, it is
recommended to plan out your recharging method. Recharging can be done from either an AC power source or from a
SUNstack solar product. For fastest recharge rates, AC charging is recommended.
Turning Power On
1. Complete Pre-Operation check
2. Turn unit from O to Standby
a.From the Rear Plate, lift the covers on both of the Master Battery On/O buttons.
b.Press both of the buttons beneath and the blue button lights will illuminate.
3. Turn unit from Standby to Power On
a.From the Face Plate, press the On/O Button. The blue light will illuminate.
b.You will hear two beeps and after 6 seconds the two green Output Lights will illuminate. You now have power!
Turning Power O
1. Turn unit from Power On to Standby
a.Turn o and unplug devices being powered.
b.From the Face Plate, press the On/O Button. This will cut power to the Output Receptacles and the green
Output Lights will turn o.
2. Turn unit from Standby to O
a.From the Rear Plate, lift the covers on both of the Master Battery On/O buttons.
b.Press both of the buttons beneath and the blue button lights will turn o.
Version 1.0 September 2019 16

Applications
VOLTstack units can be used to power any device that uses 100-120V AC power and does not exceed a sustained current
draw of 20A. The power rating of the device will determine how fast the State of Charge decreases.
Before operation, check the power rating of your device to ensure it is within the maximum power output of the VOLTstack.
The following devices are examples of low and medium load applications. See Technical Info section for more information
on common device loads.
TYPICAL APPLIANCE POWER CONSUMPTION
LOAD LEVEL DEVICE TYPICAL CONSTANT POWER RATING
(W)
TYPICAL SURGE POWER RATING
(W)
Low
LED Light Bulb 4-10 N/A
Computer w/ Monitor 300 N/A
Medium
Drill 1/2” 600 900
Small Refrigerator 350 500
High
Circular Saw 1500 3000
Space Heater 750-1500 N/A
HELPFUL TIPS
Choose lower energy devices when possible to extend the remaining capacity of the
VOLTstack. For example, use LED lighting in place of incandescent lighting.
OPERATION
Version 1.0 September 2019 17

Battery Storage Capacity
The State of Charge operating range of the VOLTstack (0-100%) is based on the capacity listed below, and incorporates a
reserve from the maximum capacity of the battery. The VOLTstack can be used from 0 to 100% State of Charge on a regular
basis.
The DC operating voltage range and nominal storage capacity of your VOLTstack is listed in the table below.
Battery Monitor State of Charge
The State of Charge of the VOLTstack will reduce over time according to the Power Mode and Power State. This is shown on
the Battery Monitor. The expected Run Time of the VOLTstack can be estimated with the formula below using the total storage
capacity, the State of Charge remaining, and the power rating of the device being powered.
BATTERY SPECIFICATIONS
Battery Cell Chemistry LiFePO4
Voltage
Minimum 24.0
Nominal 25.6
Maximum 27.2
Watt Hours (Wh) Total 5600
Amp Hours (Ah) Total 220
VOLTstack Capacity (Wh) x State of Charge
Device Power Rating (W) = Run Time (h)
For example, when using a 1000W heater with a VOLTstack 5k at 70% State of Charge:
Run Time assumes the device is using constant power. Equipment can be plugged in without drawing any power. In this case,
see the Idle Power Consumption section. Some other factors such as ambient temperature and device load duty cycle can
aect the Run Time, however this method described above will provide a good estimate.
5600 Wh x 0.7
1000 W = 3.92 hours Run Time
*Electrical Specifications at 25°C
Version 1.0 September 2019 18

Battery Monitor Operation
The Battery Monitor located on the Face Plate is used to display the State of Charge remaining, as well as the VOLTstack
Power State. The Power State is based on the Net Power of the VOLTstack.
Type 1 Battery Monitor
The Type 1 Battery Monitor has ten blue LEDs. Full illumination of the ten LED’s indicates 100% State of Charge.
Discharging Charging State of Charge
Discharging
The Battery Monitor will show the State
of Charge when discharging.
Charging
The right most blue LED will blink.
State of Charge Low
The last remaining LED will blink indicating
the State of Charge is approaching zero.
Blink Low
Fault Warning
All of the LEDs will blink. This can indicate an
overload fault warning, or over temperature
fault warning.
Connection Error
A single blue LED will move continually from
left to right and back again. This indicates a
connection error in the Battery Monitor.
Fault Connection
Standby Operation
In Standby mode, all DC power systems are available as well as the unit’s State of Charge. USB charging output, solar
charging, as well as AC charging can be accomplished in Standby Mode. Use this mode between operations where lower
power consumption is desirable.
0% SOC 100% SOC
Blink
Version 1.0 September 2019 19

Power ON Operation
In Power ON mode, all systems are functional including AC power output at the Output Receptacles. The Output Receptacles
are NOT ground fault protected. Solar charging and AC charging can also be done in Power ON mode. Use this mode when
full power output is desired.
AC Charging Operation
The VOLTstack 5k has the ability to charge from either Charging Port, or from both Charging Ports simultaneously. Charging
times and charging source requirements are listed in the Table below.
To initiate AC Charging, from Standby or Power On mode, plug AC power into a Charging Port. Ensure the corresponding
Charging Breaker is in the On position. The Charging Light should illuminate orange indicating AC power supplied to
VOLTstack is functioning. The Battery Monitor will indicate charging.
It is recommended to AC Charge in Power ON mode to ensure the Environmental Fans are operating.
Low State of Charge Cut-o
When the Battery Monitor shows one remaining bar flashing, the State of Charge of your VOLTstack is less than
15%. When the State of Charge reaches zero, the unit will automatically turn o the AC output, indicated by the
green Output Lights turning o. At this point, it is time to charge the unit.
Load vs Run Time
You may notice your VOLTstack will last longer if you reduce the load it is powering. This is normal behaviour; a
smaller load is able to utilize more of the battery pack energy than a maximum power load.
WARNING
The output receptacles are NOT GROUND FAULT PROTECTED.
Do not use in wet or damp conditions.
HELPFUL TIPS
AC charge in Power ON mode for best performance.
Check your AC charging source to ensure you have enough power available. The VOLTstack 5k has two Charging Ports that
will each draw maximum power regardless of your source power limitations.
CHARGING SOURCE REQUIREMENTS
CHARGING PORT 1 OR 2 CHARGING PORT 1 & 2
Charging Voltage 100-125 VAC 100-125 VAC
Charging Frequency 50-60 Hz 50-60 Hz
Charging Current 13.4A @ 100 VAC 10.6A @ 125 VAC 26.8A @ 100 VAC 21.2A @ 125 VAC
Charging Time* 5 hrs 2.5 hrs
*Charging Time is based on 0%-90% charge @ 25°C
Version 1.0 September 2019 20