SportsArt Fitness Green System Technical manual

Green System
Customer Planning Guide
REV.1 5/21/2013

2
WARNING!
A LICENSED ELECTRICIAN
IS REQUIRED TO INSTALL
THIS PRODUCT
IT IS HIGHLY RECOMMENDED THAT
THE INVERTER BE AVAILABLE
FOR THE ELECTRICIAN PRIOR TO
SYSTEM INSTALLATION

3
SPORTSART GREEN SYSTEM CUSTOMER PLANNING GUIDE
Table of Contents
1. Pre-Order Checklist ...................................................................................................................... 4
2. Pre-Installation Checklist .............................................................................................................. 6
3. Installation Procedures Overview ................................................................................................. 7
4. Post Installation Checklist ............................................................................................................ 19
5. Inverter Power Up Checklist ......................................................................................................... 22
6. Cardio Units Setup and Operation ............................................................................................... 23
7. Post-Installation Certications ...................................................................................................... 24
CongratulationsforincludingSportsArt’space-settingGreenSysteminyourfacility!
This cutting-edge technology puts your facility in the forefront of sustainable and
renewable energy production. In order to ensure a smooth transition incorporating
this technology, please follow the steps outlined above.
19510 144th Ave NE, Suite A-1
Woodinville, WA 98072
425-481-9479 *800-709-1400
Fax [phone]

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1. PRE-ORDER CHECKLIST
All Green Systems need to be linked together via cables. A cable from one of the end Boost Converters in each
Pod needs to be connected to a dedicated Inverter. The Inverter needs to be wired to your electrical panel by a
licensed electrician. This system only works with 220 volt AC grid power. Below is an illustration of Cardio Units, Boost
Converters, Inverter, and grid power connections in a simple Pod conguration.
Example Standard Layout:
Standard Cable Lengths:
-Inverter to rst Boost Converter (one 5m or
16’5” cable comes attached to Inverter)
-Individual Boost Converter cables (one 1.2m
or 47” cable comes with each Boost Converter)
Optional (Special Order)
-8m or 26’ 3” Inverter to Boost Converter cable (part #
100391021)
-5m or 16’ 5” Boost Converter cable (part # 145091090)
-Longer Boost Converter cables can be custom fabricated;
allow 2 weeks from time of order
-Y-Connectors are available for non-sequential Pod
congurations
*Note: Maximum total Boost Converter cable length for each Pod from the Inverter is 34m or 111’ 7” including a .3m
or 12” allowance for the internal length of each Booster Box in the Pod. See item 4 on page 5.
Pre-Order Checklist
G572R
G572U

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1. PRE-ORDER CHECKLIST (CONTINUED)
Legend:
I= Inverter
B= Boost Converter
C= Cardio Unit
Y= Y-Connector
Parallel: Tree:
C
Y
I
BC
BC
BC
B
C
B
B
C
C
Y
I
BC
BC
B
B
C
C
B
Y
C
B
B
C
1. Select the number and type of Cardio Units desired.
2. Determine the number of Pods desired: 1 Inverter is required per Pod. Up to 10 Cardio Units can
be connected in a single Pod.
Series:
I
B C
B C
B C
3. Construct a site plan by laying out desired equipment locations and assigned footprints on a scale
drawing. Include all Inverters, Cardio Units, and Boost Converter, plus Y-Connectors if needed. There
is a space planner application on our website that can be used to do this at: http://www.sportsartamerica.
com/SAF/space_planner.asp or you can ask your SportsArt Rep to provide site planning assistance.
4. Determine the Boost Converter cable lengths required. See page 4 for available lengths. Add up
all Boost Converter cable lengths plus 12” for each Boost Converter in the Pod and compare the
total with the maximum allowed length of 34m (111’ 7”).
5. Determine the number of raceways needed to cover exposed Boost Converter cables. Each
raceway is 1m or 39” long.*
*Note: Included in the standard order are four raceways for the Inverter and one for each Cardio Unit.
It is recommended that all of the exposed cables should be covered with the raceways to minimize trip
hazards.
Additional raceways and one custom length cable will be provided at no extra charge if specied at the
time of original order. All Y-Connectors, cables and raceways ordered after the original order will be
charged.
Cardio Units can be arranged in many topologies within a pod. These are some of the congurations possible:
Pre-Order Checklist Pre-Order Checklist

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2. PRE-INSTALLATION CHECKLIST
1. Have a licensed and bonded electrician:
a. Examine facility electrical service panel(s) and establish location and type of dedicated 250V
15A circuit breaker to be assigned to each Inverter; order circuit breakers as needed.
b. Determine length, conductor sizes, and routing of 3-wire cables needed between each Inverter
and its dedicated circuit breaker; order required cables. Each cable is to be a home run between
the Inverter and its respective breaker. There are to be no shared lines
c. Review Pgs 13-15, Electrical Connections.
2. Prepare for installing Inverter Mounting Bracket(s) (Pgs 8-12) by coordinating best location with
electrician and reviewing with installers.
*It is recommended that the Inverter be mounted and wired to its respective circuit breaker
prior to installing the rest of the Green System. Upon request, the Inverter can be shipped in
advance.
3. Review Site Plan and Installation Procedures Overview (Section 3) with installers. Include
assembling recommended tools:
-Drill and 5/16” diameter bit for hanging Inverter Mounting Bracket(s)
-Hand tools for assembling the Cardio Units
-Phillips screwdriver for connecting Boost Converter cables between Boost Converters
-Miter Box for cutting plastic cable raceways to length
Pre-Installation Checklist

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3. INSTALLATION PROCEDURES OVERVIEW
Procedure 1: Install the Mounting Bracket (pgs 8-12)
Procedure 2: Hardwire Inverter to a Dedicated Circuit Breaker (pgs 13-15)
Procedure 3: Unbox and Assemble Cardio Units ( See Individual Cardio Unit’s manual or you can nd them at
http://www.sportsartamerica.com/saf/support/technicalsupport/owners_manuals.asp)
Procedure 4: Install the Boost Converters (pg 16)
Procedure 5: Link Boost Converters (pg 17)
Procedure 6: Connect Inverter to an End Boost Converter (pg 18)
Procedure 7: Conduct Post-Installation Checklist (Section 4, pgs 19-21)
Procedure 8: Perform Inverter Power Up Checklist (Section 5, pg 22)
Procedure 9: Set up Cardio Unit Consoles (Section 6, pg 23)
Procedure 10: Check Cardio Units for Proper Operation (See individual manuals)
Procedure 11: Submit Post-Installation Certication (Section 7, pg 24)
Pre-Installation Checklist
Installation Procedures Overview

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3. INSTALLATION PROCEDURES OVERVIEW (CONTINUED)
Assembly Parts
No. Name Qty. No. Name Qty.
A1 Inverter 1 A3 Mounting bracket 1
A2 Bypass Box 1 A4 Inverter DC power cord
(Inverter-to-Boost Converter) 1
Components in the Hardware Kit
No. Name Qty. Specication Notes
21 Mushroom top Phillips screw 4 3/16”*L1”
22 Plastic anchor for screws 4 5/16”*1-1/4”
23 Phillips screw 2 M6*P1.0*L16
41 Phillips screw 2 M6*P1.0*L16
Procedure 1: Install the Mounting Bracket
Installation Procedures Overview

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3. INSTALLATION PROCEDURES OVERVIEW (CONTINUED)
Please follow instructions (a) through (d) to install the mount bracket.
(a) Using a 5/16” drill bit, drill holes in the wall where the Inverter will be installed. Note that position specications
shown here are for reference only. (* Note: When mounted on the bracket, the Inverter display will be at a
height ~1 1/2” lower than the top mounting bracket screws. Mount at a height that will make the display easy
to read.)
(b) Insert one screw anchor (22) into each of the four holes. Secure screws (21) in the upper holes but leave at
least 8 mm of each screw exposed.
(c) Hang the mounting bracket (A3) onto the upper screws (21) as follows. First, hold the mounting bracket so
one screw is inserted through the enlarged part of the screw slot. Then slide the mounting bracket (A3) so the
other screw comes into place in its slot.
Installation Procedures Overview Installation Procedures Overview

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3. INSTALLATION PROCEDURES OVERVIEW (CONTINUED)
(d) Slide the mount bracket to the left or right until it is level. Then fully secure upper screws (21) into place.
Insert and secure lower screws (21) into place. Finally, remove screws (41) from the mount bracket (A3).
Installation Procedures Overview

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3. INSTALLATION PROCEDURES OVERVIEW (CONTINUED)
Connect the Inverter bypass to the Inverter mounting bracket as follows. First, place the left wing of the Inverter
bypass onto the mounting bracket. Then place the right wing of the Inverter bypass onto the mounting bracket.
Use screws (23) to secure the Inverter bypass (A2) onto the mounting bracket (A3).
Installation Procedures Overview Installation Procedures Overview

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Hang the Inverter (A1) onto the mount bracket (A3), and use screws (41) to secure it into place.
3. INSTALLATION PROCEDURES OVERVIEW (CONTINUED)
Installation Procedures Overview

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3. INSTALLATION PROCEDURES OVERVIEW (CONTINUED)
CAUTION
These servicing instructions are for use by qualied personnel only. To reduce the risk of electric
shock, do not perform any servicing other than that specied in the operating instructions unless you
are qualied to do so.
Both AC and DC voltage sources are terminated inside this equipment. Each circuit must be individually discon-
nected before servicing. Do not remove cover until 5 minutes after disconnecting all sources of supply.
This unit contains active anti-islanding protection.
Operation temperature range: +5~+35 C
Storage temperature range: +5~+35 C
Enclosure Type 1: “indoor use only”
Inverter Electronic Specications
DC
Maximum input voltage 480V DC
Operating voltage range 290~470V DC
Maximum input current 6A
Maximum utility backfeed current 2A
AC
Nominal operating voltage 200~240V AC
Nominal operating frequency 50Hz/60Hz(by jumper setting)
Grid power voltage range 183~264V AC
Operating frequency range
47.5~50.2Hz(for 50Hz)
59.3~60.5Hz(for 60Hz)
Maximum continuous output power 2000W
Maximum continuous output current 10A
Maximum output over current protection 15A
Output power factor 0.99
Procedure 2: Hardwire Inverter to a Dedicated Circuit Breaker
Installation Procedures Overview Installation Procedures Overview

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WARNING!
The work of connecting the Inverter to the power grid must be carried out by a licensed/bonded electrician.
Moreover, this work must be done in compliance with electrical regulations.
Inverter power supply must be connected to grid power via the facility electrical panel, and a circuit breaker
must be used. Before connecting cables, make sure that the breaker is OFF.
Electrical power supply specications: single phase 183 - 264VAC. If voltage exceeds this range, the Inverter
will automatically shut off as a protective measure. For most consistent operation, we recommend a voltage
range of 200 to 240VAC.
1. Power cable must be AWG 14 , 80C (176F ) or larger and have three stranded copper conducting wires.
2. Power cables wires and the strain relief must be placed as shown in Figure 1 below. First, strip the insulation
from the wire cores and secure them into place in the protective cover as shown in Figure 2, then adhere the
labels appropriately. Connect the power source L or L1 wire, and secure the L/L1 label to it. Connect the N or L2
wire, and secure the N/L2 label to it. Connect the ground wire, and secure the G label to it as shown in Figure
3. Before inserting the copper wire into the terminal, roll the wire to consolidate the strands and prevent them
from splitting. Connect to the Inverter AC terminals by matching like markings with the labels on the Inverter.
After inserting wires into the terminal, use screws to secure the wires into place. Note: In areas with 100 to 130V
power supply, this product is suitable for L1, L2 power supply markings. In areas with 200 to 240V power supply,
this product is suitable for L, N power supply markings.
3. Pull the wires individually (one-at-a-time) to make sure that each one is connected securely. Then secure the
protective cover on the Inverter.
4. Connect the other end of the power cord to grid power. First, select a 15A 250VAC rated circuit breaker.
Make sure that the circuit breaker is off before beginning installation.
5. Connect the ground wire to the ground terminal in the electrical panel. Connect L/L1 and N/L2 wires to corre-
sponding circuit breaker terminals to complete Inverter-to-grid power connections. Leave the Inverter power
switch off until the entire Pod is installed and all Boost Converters are connected.
Figure 1. Figure 2. Figure 3.
3. INSTALLATION PROCEDURES OVERVIEW (CONTINUED)
Installation Procedures Overview

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DC Side Power Cord Instructions
1. To simplify installation, the power cord on the DC side has been pre-attached to the Inverter at the factory.
The DC power cord uses a special Powerpole® Connector by Anderson Power Products. Do not replace it with
any other type of connector.
2. The DC cords comply with UL (AWM 2586) specications:AWG16, 105°C ( 221°F), 600V, three wire, with
colors red, black, and green with yellow. The red wire connects to positive(+), the black connects to negative(-),
and the green with yellow connects to ground (G).
3. INSTALLATION PROCEDURES OVERVIEW (CONTINUED)
AC Connections
Installation Procedures Overview
Installation Procedures Overview

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3. INSTALLATION PROCEDURES OVERVIEW (CONTINUED)
Procedure 4: Install the Boost Converter Boxes
Please follow below steps to install a Boost Converter.
1. Remove screws (28) from the front frame (A2).
2. Insert wires from the Boost Converter (A12) into connectors in area A and B on the Cardio Unit in order
(1) (2). Note: In area A, place the open line (with no wire) on top. In area B, directly insert the plug into the
connector on the Cardio Unit.
3. Align the holes in the Boost Converter (A12) with the screw holes in the product frame (A2). Use the screws
(28) removed in step (a) to secure the Boost Converter to the Cardio Unit frame. (Note: Tighten the screws until
the metal plates contact each other securely.)
Installation Procedures Overview

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3. INSTALLATION PROCEDURES OVERVIEW (CONTINUED)
Procedure 5: Link Boost Converter
Before making connections, make sure that Inverter power is off. Remove connector covers on the sides of the
Boost Converter (A12). Insert the between-unit power cord (A13) into the connector on the Boost Converter.
Then use screws to secure the connection. Only connect up to ten products per Inverter. For any end Boost
Converters, leave the connector cover in place on the side with no cable connection.
Installation Procedures Overview Installation Procedures Overview

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3. INSTALLATION PROCEDURES OVERVIEW (CONTINUED)
Procedure 6: Connect the Inverter to Boost Converter
Set power switches on the Boost Converter and the cardio unit to the off position. Remove the protective cover
on the side of the selected end Boost Converter.
Connect the DC power cord (A4) from the Inverter to the selected end Boost Converters in the end. Then use
the screws to secure connector.
Installation Procedures Overview

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4. POST-INSTALLATION CHECKLIST
***USE A SEPARATE INSTALLATION CHECKLIST FOR EACH POD***
***ADDITIONAL COPIES OF THIS CHECKLIST CAN BE FOUND AT:
http://www.sportsartamerica.com/saf/support/technicalsupport/technical_support3.asp ***
Inverter Serial Number :
After setting up a Green System Pod (one Inverter and less than or equal to ten Green System Cardio
Units) inspect the following:
ITEM 1: Before checking anything else, rst make sure that the electrical panel circuit breaker,
and Inverter power switch are turned off. If not, turn off power in those areas to prevent electrical
shock during the inspection.
ITEM 2: Inspect the Inverter/Boost Converter connection. Make sure that the connectors are
inserted fully, that screws are in place, and that screws are tight. Double check that the power
cord is connected properly.
ITEM 3: Make sure connectors between Green System tness products are in place and
secured with screws. Collect and hide power cords into their raceway channels. All raceway
channels should be trimmed to t, completely covering the cords.
Installation Procedures Overview
Post Installation Checklist