Power-Blox PBX-200 PB User manual

Swarm-enabled Solar Battery System
Installation and operating instructions
PBX-200 Pb
PBX-200 Li
PBX-200 Li/LE
EN
06-2020

Installation and Operating Instructions PBX-200 Pb ; Li ; Li/LE Page 2
Table of contents
1INTRODUCTION AND GENERAL................................................................................................................... 4
1.1 FOREWORD .......................................................................................................................................................4
1.2 CONTACT DETAILS...............................................................................................................................................5
1.3 EXPLANATION OF SYMBOLS...................................................................................................................................5
1.4 GENERAL SAFETY INSTRUCTIONS ...........................................................................................................................5
2SCOPE OF DELIVERY, TRANSPORT AND STORAGE........................................................................................ 7
2.1 AVAILABLE VERSIONS...........................................................................................................................................7
2.2 SCOPE OF DELIVERY.............................................................................................................................................7
2.3 STORAGE AND TRANSPORT ...................................................................................................................................7
3OVERVIEW OF THE PBX-200 ....................................................................................................................... 8
4PROPERTIES AND TECHNICAL DATA...........................................................................................................11
4.1 PBX-200 PICTORIAL SCHEMATIC .........................................................................................................................14
5SAFETY AND ACCIDENT PREVENTION.........................................................................................................15
5.1 PERSONNEL .....................................................................................................................................................15
5.2 PROTECTION AGAINST ELECTRIC SHOCK.................................................................................................................15
5.3 INFORMATION ABOUT THE BATTERIES...................................................................................................................16
5.3.1 Approved battery types............................................................................................................................16
5.3.2 Protective equipment...............................................................................................................................17
5.3.3 Potential hazards of AGM lead-acid batteries (PBX-200 Pb)...................................................................17
5.3.4 First aid measures for AGM lead acid batteries (PBX-200 Pb).................................................................18
5.3.5 Measures in case of accidental release of lead acid................................................................................18
5.3.6 Potential hazards of LiFePO4 batteries (PBX-200 Li) ...............................................................................18
5.3.7 First aid measures for LiFePO4 batteries Electrolyte (PBX-200 Li)...........................................................18
5.3.8 Measures in case of accidental release of LiFePO4 batteries Electrolyte ................................................19
5.4 IN CASE OF FIRE ................................................................................................................................................19
5.4.1 General notes...........................................................................................................................................19
5.4.2 Fire fighting measures for AGM lead-acid batteries (PBX-200 Pb)..........................................................19
5.4.3 Fire fighting measures for LiFePO4 batteries (PBX-200 Li) ......................................................................19
6INSTALLATION AND COMMISSIONING.......................................................................................................20
6.1 GENERAL.........................................................................................................................................................20
6.2 SITE CONDITIONS ..............................................................................................................................................21
6.3 CONNECTING THE SOLAR MODULE TO THE PBX-200 ..............................................................................................22
6.3.1 Plug mounting of the solar connection....................................................................................................23
6.4 COUPLING OF PBX-200.....................................................................................................................................24
6.5 MINIMUM DISTANCES .......................................................................................................................................26
6.6 INTERCONNECTING SEVERAL TOWERS TO FORM A "POWER WALL"............................................................................27
6.7 USE OF THE CONNECTION TERMINALS...................................................................................................................27
6.7.1 Connecting the terminal cables ...............................................................................................................29
6.8 INTERCONNECTION TYPES...................................................................................................................................30
6.8.1 Solar-powered PBX-200 ...........................................................................................................................31
6.8.2 Solar and network operated PBX-200......................................................................................................31
6.8.3 Backup system .........................................................................................................................................32
6.8.4 Combined solar / grid system with connection to the terminal blocks....................................................32
6.9 INSTALL PBX-200.............................................................................................................................................33
6.9.1 Installation of a single PBX-200 ...............................................................................................................33
6.9.2 Installation of additional PBX-200s to a tower or Power Wall (maximum 9 units).................................33
6.9.3 Installation of power systems larger than nine PBX-200.........................................................................34
7OPERATION ..............................................................................................................................................35
7.1 IMPORTANT NOTES BEFORE COMMISSIONING ........................................................................................................35
7.2 LED DISPLAY ....................................................................................................................................................35

Installation and Operating Instructions PBX-200 Pb ; Li ; Li/LE Page 3
7.2.1 Battery charge level indicator..................................................................................................................35
7.2.2 Display of the battery status....................................................................................................................36
7.2.3 Display during synchronization................................................................................................................36
7.2.4 Display on overheating ............................................................................................................................36
7.2.5 Display in case of fault .............................................................................................................................36
7.3 IMPORTANT ASPECTS OF HANDLING BATTERIES ......................................................................................................37
7.3.1 Lead-acid batteries (Type AGM) ..............................................................................................................37
7.3.2 Li batteries (type LiFePO4) .......................................................................................................................37
8MAINTENANCE .........................................................................................................................................38
8.1 CLEANING THE HOUSING ....................................................................................................................................38
8.2 BATTERY .........................................................................................................................................................38
9REPAIR AND TROUBLESHOOTING ..............................................................................................................39
9.1 TROUBLESHOOTING...........................................................................................................................................39
9.1.1 General.....................................................................................................................................................39
9.1.2 The LED display shows nothing................................................................................................................39
9.1.3 No output voltage at the 230 V socket ....................................................................................................39
9.1.4 The PBX-200 has a voltage at the sockets, but not full 230 V .................................................................40
9.1.5 The PBX-200 does not charge, the battery indicator shows a falling charge level although the sun is
shining 40
9.1.6 The PBX-200 only supplies power in direct sunlight ................................................................................40
9.1.7 The PBX-200 regularly goes into fault mode (whole display flashes red)................................................40
9.1.8 The PBX-200 is overheated (whole display flashes orange) ....................................................................41
10 RETURN / DISPOSAL..................................................................................................................................42
10.1 REMOVING THE BATTERY....................................................................................................................................42
10.2 DISPOSAL ........................................................................................................................................................45
11 DISCLAIMER..............................................................................................................................................46
12 LEGAL INFORMATION ...............................................................................................................................47
13 EU DECLARATION OF CONFORMITY...........................................................................................................48

Installation and Operating Instructions PBX-200 Pb ; Li ; Li/LE Page 4
1Introduction and General
1.1 Foreword
Thank you for choosing Power-Blox. We are sure that you will enjoy our innovative energy cube. We have
spent several years developing the product to make it as easy as possible to use and to give you access to
sustainable electricity even in places where there is no power outlet.
With Power-Blox you can use solar energy in a simple, flexible and scalable way. No matter whether you
use a Power-Blox as a single device, combined as a tower or even as a Power Wall of up to nine or more
devices. Set no limits to your imagination and your energy projects. The swarming algorithm we have
developed, on which the Power-Blox is based, makes off-grid and mini-grid energy projects easier than
ever before.
Actually no manual is needed for the "normal" use of the Power-Blox. Set it up, plug in the solar module,
switch it on, done. Nevertheless, the Power-Blox is an energy product that produces dangerous
alternating current with a voltage of 230 V. In addition, unfavourable handling can considerably reduce its
service life. To enable you to operate the Power-Blox safely for several years, we would ask you to study
these instructions carefully. You can also visit our YouTube channel and watch short films about the
essential steps.
Whatever you plan to do with your Power-Blox: We wish you many sunny days and a high-energy time.
Best wishes,
Your
CTO & Co-Founder
Frick, August 23, 2019

Installation and Operating Instructions PBX-200 Pb ; Li ; Li/LE Page 5
1.2 Contact details
Power-Blox AG
Dammstrasse 3
CH-5070 Frick
Switzerland
www.power-blox.com
e-mail: [e-mail]
Tel: [phone]
1.3 Explanation of symbols
Symbol
Description
Caution, Danger
Caution, risk of electric shock
Important note
Read instructions before using the product
WEEE marking
Do not dispose of the product with household waste, but after
valid disposal regulations for electronic waste.
1.4 General Safety Instructions
This manual is an integral part PBX 200 product and is provided digitally on the Power-Blox AG
website.
Only install and use the PBX-200 after you have read and understood this document.
Always carry out the measures described in this document in the order given.
Keep this document for the lifetime of the PBX-200. Pass the document on to subsequent owners and
users.
Improper operation can reduce the yield of the solar system or damage system components.
The PBX-200 must not be operated with a damaged housing.
Put the PBX-200 out of operation immediately and disconnect it from the solar module and the mains
/ generator if one of the following components is damaged:
-Device (visible damage, smoke development, penetrated liquid, etc.)
-Connected lines
-Solar module
Do not switch on the PBX-200 again before:
-the device has been repaired by the dealer or manufacturer.

Installation and Operating Instructions PBX-200 Pb ; Li ; Li/LE Page 6
-damaged lines or solar modules have been repaired by a qualified technician.
Treat battery acid on skin or clothing immediately with soapy water and rinse with plenty of water. In
case of injury, consult a doctor immediately.
Battery acid in the eyes rinse immediately with plenty of water and consult a doctor.
Do not open the electronics housing: Danger to life! Warranty claim expires!
Never alter, remove or obscure signs and markings applied by the factory.
When using external devices that are not described in this document, the manufacturer's instructions
must be observed! Incorrectly connected devices can damage the PBX-200.
The PBX-200 is not intended for:
-Kids.
-People with physical, sensory or mental impairments.
-Persons who do not have sufficient experience and knowledge Unless they have been
instructed in the use of the device by a person responsible for their safety.
-People with a pacemaker.
Never operate the PBX-200 with safety-relevant devices.

Installation and Operating Instructions PBX-200 Pb ; Li ; Li/LE Page 7
2Scope of delivery, transport and storage
2.1 Available versions
The product is available in several configurations:
1. With network and network-independent charging capability (PBX-200 Li, PBX-200 Pb)
OR
2. Only with mains-independent charging capability (PBX-200 Li/LE)
For details of the differences, see chapter 4.
2.2 Scope of delivery
PBX-200 Pb, PBX-200 Li, or PBX-200 Li/LE
Power cord
Brief instructions
Optional accessories:
Solar cable with MC-4 connectors and Neutrik powerCON plug
Neutrik Plug powerCON
Solar module
Print version Installation and Operating Instructions (also available online)
2.3 Storage and transport
If the PBX-200 is stored or not used for a long time, make sure that the PBX-200 is switched off via the
main switch.
The PBX-200 must be stored fully charged in clean, dry, cool and frost-free rooms. Too high storage
temperatures lead to increased self-discharge and premature aging. To prevent a deep discharge of the
batteries and to achieve the longest possible battery life, the PBX-200 must be recharged regularly:
- PBX-200 Pb: fully recharge every 3-4 months
- PBX-200 Li: recharge to only about 50% every 6-7 months
Alternatively, a solar module can also be connected to the PBX-200. When the solar module surface is
exposed to sunlight, the battery of the PBX-200 charges even if the PBX-200 is switched off via the main
switch.
To prevent damage to the product, a suitable transport device and the original transport packaging must
be used when shipping or transporting the PBX-200. During transport, the PBX-200 must be properly
secured to prevent damage and potentially dangerous malfunctions to the PBX-200 and the battery.
When transporting the PBX-200 by car, truck, ship, and plane, the respective applicable standards and
regulations must be observed.

Installation and Operating Instructions PBX-200 Pb ; Li ; Li/LE Page 8
3Overview of the PBX-200
The two integrated AC sockets (1) on the top of the lid supply 230 V AC (alternating current). It is possible
to connect commercially available devices directly via these sockets. The power of the PBX-200 should not
be exceeded (for a single PBX-200: 200 W, short-term 400 W). Only one consumer device per socket is
permitted.
Figure 1: PBX-200 front panel
Below the LED display (2) and next to the main switch (3), the PBX-200 provides two 5 V USB ports with up
to 2.1 A (5). The additional 12 V car socket (4) to the left of the main switch supplies up to 3 A. In total,
consumer devices with a total output of 36 W can be connected to (4) and (5).

Installation and Operating Instructions PBX-200 Pb ; Li ; Li/LE Page 9
Figure 2: Front connections and main switch
The extensive range of electrical connections is located on the back of the PBX-200. A solar module can be
connected directly to the PBX-200 using an adapter cable (solar cable) at the solar input socket (8). If the
solar module does not supply enough energy, for example on short winter days, the PBX-200 can also be
connected and charged directly to a 230 V socket via the cold appliance socket (7). Two resettable
miniature circuit breakers (13) protect the PBX-200 against overload. At the transfer sockets (6), further
PBX-200s can be connected to a network via the transfer cable (9). A resettable miniature circuit breaker
(12) protects the transfer lines / the swarm against overload. The transfer cable can be stowed in the
cable ducts (10, 11). To prevent the PBX-200 from changing hands unintentionally, it can be chained via
the anti-theft protection (15). There are additional clamp connections (16-19) under the cover (14).
Figure 3: PBX-200 rear panel
The clamp connections are an alternative way of connecting the PBX-200 to a solar module (16) or an
external 230 V power source (18). Several solar modules can be connected to the PBX-200 in parallel. The

Installation and Operating Instructions PBX-200 Pb ; Li ; Li/LE Page 10
total possible current must not exceed 8 A, otherwise the solar modules must be protected by a DC fuse.
Access to the clamping area is only permitted for qualified electricians. The installation flap (14) covers
and protects the terminal connections. For safety reasons, the installation flap must be closed and
screwed on both sides during operation.
Figure 4: Terminal connections behind installation flap
Legend of components and connections
1Alternating current socket, 230 V
2LED display
3Main switch
4Cigarette lighter socket 12 V DC, 3 A
52 x USB connections 5V, 2.1 A
6Sockets for transfer cable
7Socket for mains / generator (input)
8Solar socket for optional solar cable (input)
9Transfer cable for connecting several PBX-200
10 Vertical cable duct
11 Horizontal cable ducts
12 Resettable circuit breaker (10 A) for transfer socket
13 Resettable circuit breaker (10 A) for mains / generator input
14 Installation flap for terminal connections
15 Anti-theft bolts
16 Terminal block Transfer connection
17 Micro-USB connection (for service work)
18 Terminal block for mains / generator input
19 Terminal block Solar connection
20 Strain relief web
21 Carrying handle