Solar Nexus Power Center Installation Manual

SolarNexus Power Center
System Installation Manual
SYSTEM SNS-SUN200-2DC4006-NR
INCLUDES
SolarNexus Off-Grid Power Center
(SNPC-SS300E-PS30-TM2025)
SureSine 300 Inverter - 230V, 50Hz
ProStar 30 PV Charge Controller
Trimetric 2025 Battery Amp-Hour
Meter
DC and AC Circuit Breakers
2 x 195W SUN PV Modules
Complete Wiring
2 x 6V Deep Cycle Sealed Batteries
DC and AC Lightning Arrestors
© Copyright 2011, SolarNexus International
Box 894 / 1016 Discovery Way
Eastsound, WA 98245 USA
Tel. 360-376-6842
www.solarnexusinternational.com

WARNING: No spare parts included. Don’t lose anything!
System Parts List
Major Components
1.
2.
3.
4.
5.
2 - SUN Photovoltaic Module 195W - 2
1 - SolarNexus Power Center (SNPC-SS300E-PS30-
TM2025)
2 - Sealed AGM Batteries - 6V 400 Amp-Hours
Balance of Systems Box - 1
1 - Solar Panel Combiner Box Bracket (Aluminum)
6.
7.
8.
9.
#2 USE-2 PV Solar Array Wire
#4 USE-2 PV Solar Array Wire
#6 Bare Copper Ground Wire for Solar Systems
#10 XHHW Stranded Green 500R Wire
Balance of Systems Box
1. 1 - Solar Nexus PV Combiner box (SNPVC)
2. 1 - DC Lightning Arrestor (LA302)
3. 1 - AC Lightning Arrestor (LA302R)
4. 1 - Battery Jumper Cable Assembly
5. 1 - Solar Array Wire Assembly (MC extension 6
cable) - 1/2m
6. 1 - Solar Array Wire Assembly (MC extension
cable) - 2m
7. 10 - UV-Resistant Cable Ties - 14.5” - 120#
9
8. Product Literature
9. 1 - BOS Hardware Bag (see contents below)
7
8
1
5
4
3
2
Hardware Bag
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
2 - Strain Relief - 1/2”, 2 holes
2 - Nuts - 1/2” locknuts - for strain reliefs
2 - Ground Lay-In Lugs (14-4 Cu/Tn) - 2
8 - #10-12 - 1.5” - Sheet Metal Screw
8 - A6 1/4” - 6mm - “Alligator” Wall Anchors
1 - Lugs - #2 x 1/4” - Tinned Copper
1 - Lugs - #2 AWG - Solder Slug
1 - Lugs - #4 x 1/4” - Tinned Copper
1 - Lugs - #4 AWG - Solder Slug - Gray
1 - 1” 2-Screw Cable Clamp
6 - Screws #10-32 x 3/4” for Lay-in Lugs and
SNPVC Mounting
6 - Nuts - #10
6 - Washers - #10
6 - Lock Washers - #10
3 - Plastic Snap-In Bushing
2 - 1/2” 2-Screw Cable Clamp
10
1,2
4
8,9
6,7
5
16
12
13,14
15
3
11

System Plan
Order of Assembly
1. Establish earth grounding connection
2. Mount SolarNexus Power Center (“SolarNexus”)
to the wall
3. Move batteries into place
4. Connect earth ground wires to SolarNexus
5. Mount PV modules on the roof
6. Mount PV combiner box on roof
7. Complete PV Array wiring
8. Connect PV Array wiring to SolarNexus
9. Mount lightning arrestor on SolarNexus
10. Connect DC and AC output (load) circuits
11. Connect battery cables
grounding rod

Assembly
1. ESTABLISH EARTH GROUNDING CONNECTION
• The earth ground electrode should be located as
close as practical to the Nexus and the PV array
• Use the earthing procedures appropriate to your local
location
• As a minimum, drive one steel or copper ground rod
deeply into the soil
• Attach earth ground wire securely to rods with
proper wiring hardware
• DO NOT connect earth grounding system to lightning
rods or lightning attractant systems
• Lightning rods, if installed should be above and
away from array with separate direct connection to
earth
2. MOUNT SOLARNEXUS SECURELY TO THE WALL
• Leave all breakers OFF until installation is complete
• Hold Nexus against the wall to mark locations for drilling
holes
• Drill holes for 1.5” screws provided
• Use plastic wall anchors if wall material is plaster
• Secure SolarNexus to wall with at least 4 screws
• Remove SolarNexus cover, front panel and side panels in
preparation for wiring
3. MOVE BATTERIES INTO PLACE
CAUTION!
SHOCK HAZARD IS PRESENT ACROSS BATTERY
TERMINALS -- USE CAUTION WITH CONDUCTIVE
TOOLS AND MATERIALS
• Batteries must be within 8 feet (2.5 meters) of the
SolarNexus mounting location
• Batteries must be located in cool, shaded location
• Keep batteries on the ground to help maintain constant
temperature
• Cover battery tops with wooden or plastic lids to
protect terminals

4. CONNECT EARTH GROUND WIRE TO NEXUS
• To access grounding bus bar, the Trimetric meter (TM 2025)
must be temporarily removed
• Remove 4 screws holding TM2025 meter in place, allowing meter
to hang down
• Use long-handled screw driver to attach grounding wires to bus
bar mounted on back of unit. The grounding bus bar has green
screws
Grounding
bus bar
(has green screws)
5. MOUNT PV ARRAY ON ROOF
• Attach the rack securely to the roof framing members
using stainless steel screws or other appropriate
fasteners
• PREVENT LEAKS! Use good sealant or caulk to make
attachment waterproof
• The PV array rack should be strong enough to support
the weight of one person per PV module that
will be mounted on the rack
• Attach PV modules securely to the rails
• Aluminum rails with stainless steel hardware best
• Steel should be painted to prevent rust
• Consider using theft prevention hardware, such as
padlocks
6. MOUNT THE PV ARRAY COMBINER BOX (SNPVC)
• Mount SNPVC box vertically or at roof slope to ensure
rain cannot enter the box
• Use 4 stainless steel machine screws, washers, lock
washers and nuts to attach SNPVC to aluminum
mounting bracket
• Knock out the proper number of 1/2” knockouts for
PV input circuits and DC lightning arrestor (if used)
• Knock out the center 1” knockout on the bottom of
the SNPVC
• Attach the 1” steel 2-screw cable clamp for the PV array
to Nexus wiring

7. PV ARRAY WIRING
• Connect the PV array wire extension cables to the
modules
• Run wires cleanly together to the SNPVC combiner
• Secure wires to rack with UV-resistant cable ties
• Cut excess wire, leaving at least 30cm to go inside box
• Mount 2-hole strain relief in the knockouts on the
SNPVC
• Push the PV array wires through the strain relief fittings
• Mark the PV POSITIVE wires inside SNPVC with red
tape
• Connect the PV + and - wires to their appropriate bus
bars in the SNPVC box
• The SNPVC box is the recommended location for the
DC lightning arrestor
• Attach ground lugs to modules (and/or rails) to connect
PV array earth ground wire
8. BRING PV ARRAY WIRE TO THE SOLARNEXUS
• Stretch the heavy gauge wires along the shortest
route between the array and the SolarNexus
• Line up wires perpendicular or parallel to building
framing members, walls and doors
• Secure wires with staples, cable ties and other wire
management hardware and attach wires to the building
at least every 1 meter (3 feet)
• Pass the wiring into the SolarNexus through the
wiring channel in the top or bottom or through any
of the knockouts, protected with plastic bushings
or metallic strain relief fittings. If passing wires in
through the top of the channel, a hole must be cut in
the SolarNexus outside cover
9. CONNECT PV ARRAY WIRE INSIDE THE SOLARNEXUS
• Attach the incoming PV array wire to
the top stud of the PV breaker in the
SolarNexus.
• Make sure to use a soldered or
crimped lug on the positive wire and
choose the correct size lug for the wire
(will be #2 or #4)
• Note: Lugs should be crimped to the
wire with a proper crimping tool OR
soldered with solder slug provided
(directions on top of next page)
• Use the DC Negative (-) bus bar for
the negative wire

SOLDER SLUG DIRECTIONS
(use this method if no crimping tool is available)
10. MOUNT LIGHTNING ARRESTOR ON SOLARNEXUS BOX
• Hammer out a 1/2” knockout hole from bottom of
SolarNexus unit, then push lightning arrestor neck
through hole and secure with locknut
• Connect AC lightning arrestor wires , Black = HOT,
White = Neutral
• ( position 4+ and 4- on SolarNexus diagram)
• DC lightning arrestor can be mounted at SNPVC or
SolarNexus. AC lightning arrestor should only be
mounted on SolarNexus unit
• Connect all earth grounding wires to common ground
bus bar
• Ensure system has a strong, reliable earth grounding
system
• Strip wire insulation correct length for the lug
• Hold the lug with pliers or a vice
• Place solder slug inside lug
• Use propane or butane torch to melt lead solder
• Insert wire into the lug quickly and smoothly
• Allow the lug to cool before use
11. CONNECT DC & AC OUTPUT (LOAD) CIRCUITS
• Insulated bus bars in SolarNexus provide convenient circuit distribution points
• Connect equipment grounds to common earthing bus bar
• See diagram on next page for AC and DC connection points
• Utilize high-quality wire, wiring components, conduit and trunking
• Complete all wiring installations in a tidy, professional manner
• Route wires perpendicular and parallel to frame of building
• Secure wires every 1 meter (3ft) , mimize slack between attachments
12. CONNECT NEXUS BATTERY CABLES TO BATTERIES
• Clean battery terminals before connection - use wire brush
• Ensure solid direct contact between wire lugs and battery lead
• Bolt lugs securely to studs with hardware and locking washers
• Connect series jumper cable as final step to provide battery
power to Nexus
• Cover batteries with wooden or plastic lid to protect terminals
from damage or tampering and to protect from shock hazards

TEST SYSTEM & POWER UP!
NOTE: Leave all circuit breakers turned OFF (handles down position), until instructed
1.
2.
3.
4.
5.
6.
7.
8.
9.
Visually inspect all of the wiring to be sure it is complete, well-secured and properly terminated
- tug firmly on all wire terminals to ensure that all bus bars and circuit breakers are
well tightened
Check for battery voltage between test points 1+ and 1- on picture below.
Check for open circuit PV voltage (Voc) at test points 2+ and 2-
Turn ON the battery circuit breaker. Look to see the green LED on the charge controller
Turn ON the PV circuit breaker. Look to see the charging indicator LED light up on the
charge controller
Verify the PV array is charging the batteries by looking at the Trimetric meter to see that the
‘charging’ light is lit and shows postive amperage on the AMPS display channel
Turn ON both inverter circuit breakers (AC light symbol). The breaker on the far left is DC
INPUT to inverter, the red handled breaker on the right is AC OUTPUT from inverter. Look
for a green light on the inverter to indicate proper operation. Check AC output voltage at
test points 4+ and 4-
Turn ON the DC load circuit breaker (DC light symbol). Check DC output voltage with meter
at test points 3+ and 3- , or connect a DC load
When all systems work, re-install covers.
Load busbar color code: RED=DC+ BLACK=DC- BROWN=AC+ BLUE=AC-

SOLARNEXUS WIRING

System Technical Specifications
PV ARRAY SPECIFICATIONS
MODULE SUN 195
# of Modules in Series 1
# of Parallel Strings 2
Module Array Totals
Maximum Power (Pmax) 195 Watts 390 Watts
Maximum Power Voltage (Vmp) 17.6 Volts 17.6 Volts
Maximum Power Current (Imp) 11.08 Amps 22.16 Amps
Open Circuit Voltage (Voc) 21.7 Volts 21.7 Volts
Short Circuit Current (Isc) 12.1 Amps 24.2 Amps
TriMetric Meter
Custom Settings Upon Delivery
P1 14.1
P7 L3
P2 10 P10 94
P3 400
P4 A
P11 Sh.L
P12 On
P5 10 P13 10.0
P6 Off P14 0.0
See TM2025 instruction manual for details
PV Charge/Load Controller
Model ProStar 30
Rated Solar Current 30 Amps
Rated Load Current 30 Amps
Digital Meter
Yes
Remote Temperature Probe Optional
Inverter
Model SureSine 300
Continuous Power Rating 300 Watts
Peak Power Rating
600 Watts
DC Input Voltage 10.0V - 15.5V
Waveform
Pure Sine Wave
AC Output Voltage (RMS) 220V or 115V +/- 10%
AC Output Frequency 50 or 60 Hz +/- 0.1%
Peak Efficiency 92%
Self-Consumption
Inverter “On” - no load 450mA
Inverter “Off”
25mA
“Stand-By” (sleep mode) 55mA
Low Voltage Disconnect 11.5V
Low Voltage Reconnect 12.6V
Battery Voltage Setpoints
Gel Sealed Flooded
Regulation Voltage 14 14.15 14.4
Float 13.7 13.7 13.7
Equalization n/a 14.35 14.9/15.1
Load Disconnect 11.4 11.4 11.4
Load Reconnect 12.6 12.6 12.6
Photovoltaic Energy Budget for this System
Name:
Type:
e.g. school
Location:
Installation Date:
Loads # Watts Hours Total WH
Example: LED Lights 5 3 8 120
Laptop Computer
etc.
Estimated Daily Energy Requirement:
Storage and Conversion Efficiency: %
Shading Loss: %
Peak Sun Hours:
Suggested Minimum PV Power: