EnerSys OutBack Power SkyBox User manual

SkyBox

True Hybrid Energy System

Handbook

About OutBack Power

OutBack Power Technologies is a leader in advanced energy conversion technology. OutBack Power products include true sine wave

inverter/chargers, maximum power point tracking charge controllers, and system communication components, as well as circuit

breakers, batteries, accessories, and assembled systems.

Applicability

These instructions apply to OutBack Power model SBX5048-120/240 only.

Contact Information

Address: 1628 West Williams Drive

Phoenix, AZ 85027 USA

Telephone:

Fax:

+1 360.435.6030

+1.360.435.6019

Website: www.outbackpower.com

Warranty

The warranty for this product can be downloaded from https://www.outbackpower.com/resources/warranty/procedures

or you may request a copy by sending a self addressed envelope to the above address.

Notice of Copyright

Trademarks

Trademarks and logos are the property of Outback Power Technologies, Inc. and its affiliates unless otherwise noted. Subject to

revisions without notice. E. & O.E.

Date and Revision

March 2021, Revision A

Part Number

900-00272-01-001 Rev A

900-00272-01-001 Rev A 3

Table of Contents

Preface................................................................................................... 4

The Screen ..................................................................................................................................... 4

The Set-Up Wizard ......................................................................................................................... 4

Making it Run........................................................................................... 5

Materials ......................................................................................................................................... 5

Choosing the Right AC Profile ....................................................................................................... 5

Programming .................................................................................................................................. 5

The Basics .............................................................................................. 6

The Power Grid and You ................................................................................................................ 6

Keeping Your Battery Alive and Well............................................................................................ 10

Charge Cycle ........................................................................................................................................................10

Battery Temperature Compensation .........................................................................................................11

Charging Source........................................................................................................................................11

Charge Cycle Initiation ..............................................................................................................................12

Battery Charging Precautions ...................................................................................................................12

Harnessing the Sun ...................................................................................................................... 13

Solar Gotchas............................................................................................................................................13

Maximum Power Point Tracking................................................................................................................13

Computer Stuff.............................................................................................................................. 14

Setting Up Your OPTICS RE Account.......................................................................................................14

The Nitty Gritty ....................................................................................... 17

More Power Please ...................................................................................................................... 17

What About This Inverter I Already Have? (AC Coupling)........................................................... 17

It’s Cloudy, My Batteries Are Dead, and the Power is Out – What Now? (Using a Generator).... 18

Using My Own Custom Batteries.................................................................................................. 18

Aux Terminals and Rapid Shutdown ............................................................................................ 20

Rapid Shutdown Options...........................................................................................................................20

Modbus Controls........................................................................................................................... 20

External CTs ................................................................................................................................. 21

Energy Arbitrage (aka: I just want my utility bill to shrink already!).............................................. 23

The Catch-All Section ................................................................................................................... 26

PV Self-Tests.............................................................................................................................................26

Troubleshooting...................................................................................... 28

Index.................................................................................................... 30

900-00272-01-001 Rev A

Preface

The SkyBox True Hybrid Energy System is a machine that connects the solar panels on your roof to the

toaster in your kitchen so you can use solar or battery energy to power that toaster. This guide will walk you

through the basic decisions you need to make to successfully set up a SkyBox. We will also dive into the

details for each component of the SkyBox for ambitious installers and tinkerers out there.

This Handbook does not have linear instructions. You can pick which chapter is most relevant to your situation

and go straight there without wading through pages of unnecessary information. However, this Handbook

IS NOT a replacement for the SkyBox Quick Start Guide (link 1)1provided in the box with the product.

We won’t be reviewing any wiring steps, just operation and behaviors.

If you’re a SkyBox newbie, the best place to start is at the beginning with Making it Run on page 5. Go

through this section, try it out on your SkyBox, then come back and read about all the details and special

features that make SkyBox unique. The details and special features of this inverter are covered in The Nitty

Gritty on page 17.

The following sections will sometimes make references to SkyBox settings. These are shown in bold italic

text. Detailed explanations can be found in the SkyBox Programming Guide.

The Screen

The SkyBox display is a resistive, touch-sensitive interface.

Unlike your cell phone, this screen supports single touch and

relies on pressure from your finger or a stylus — it does not

make use of the human body's natural conductivity. It

monitors all aspects of SkyBox performance. Items such as

buttons, tiles

, or icons respond or open when tapped

with a finger or stylus.

For a description of all controls, see the SkyBox Overview

Guide (link 2). For an in-depth description of all functions,

see the SkyBox Programming Guide (link 3).

The Set-Up Wizard

The set-up wizard walks you through each section of settings in order to get your SkyBox up and running.

The first time your SkyBox is turned on, the Wizard will appear. The Wizard does not cover rapid shutdown

or the use of the auxiliary terminals.

One setting in the Wizard is the selection of AC Profile. The AC Profile tells the SkyBox how to interact with

the utility grid. You must select an AC Profile during setup, regardless of whether grid power will be used.

To decide which AC Profile to use, see page 5.

After the initial setup, you can access the wizard by logging in as Installer and navigating to the Configure

menu on the System tab.

Each numbered link is an active hyperlink, but it also refers to the corresponding QR code at the top of the page.

Figure 1 SkyBox Screen

1 2 3

Making it Run

Materials

You will need the following:

Properly installed SkyBox inverter

oSkyBox BOS

oSkyBox Overview Guide

oSkyBox Quick Start Guide

Optional:

A small stylus to tap on the SkyBox touchscreen

oSkyBox Programming Guide

Choosing the Right

AC Profile

Use the flow chart to the right to determine which grid

use profile is the most appropriate for your system.

Each profile is discussed in more detail in The Power

Grid and You on page 6.

Programming

To make the initial program settings, use the Setup

Wizard that appears during power-up. These settings

include the AC Profile, battery charging, screen

brightness, passwords, and so on.

To make additional settings after closing the Wizard,

see the SkyBox Programming Guide.

900-00272-01-001 Rev A

Figure 3 AC Profile Flowchart

Net Metering

with Backup

Net Metering

with Backup

Figure 3 AC Profiles

900-00272-01-001 Rev A

The Basics

The Power Grid and You

SkyBox is designed with four AC profiles. Each profile interacts with the utility grid in a different manner.

In all of the AC profiles, no battery power will be supplied to the site when the battery reaches Minimum SOC

(state-of-charge). This means if there is a power outage and you drain your battery to this low setting, your

refrigerator, freezer, wifi, etc. will be off until the utility power returns or the battery is charged.

Sell for All You’re Worth (Net Metering With Backup)

When the Net metering with backup profile is selected, the SkyBox harvests as much solar power as it can.

After sending power to your protected loads, all extra power will be sent to the utility.

Protected loads are those household items needing electricity to run that you’d rather not lose during a power

outage. This usually includes things like your freezer, refrigerator, internet router, etc. If the load demand (the

amount of electricity needed to run all those things) exceeds the available solar power, the SkyBox will buy

power from the utility to cover the difference.

IMPORTANT:

This is the ONLY profile which functions correctly WITHOUT a battery installed.

When running in a standalone fashion

(without a battery), the SkyBox operates

like any other grid-dependent inverter.

Solar power is produced, harvested,

and sent to the utility while the utility is

active (no power outage). During an

outage, the SkyBox shuts down and no

solar power is harvested.

When paired with batteries, the SkyBox

keeps the batteries full. This ensures

that when power goes out, your lights

stay on for the maximum time. Ideally,

your installer (or you, the installer) sizes

the system so this maximum time is an

entire night of protected loads. This

assumes the sun is available the next

morning and solar power takes over,

allowing the battery to take a break.

This profile is best used when the utility

is normally stable and only short

interruptions are expected.

Figure 4 Net Metering with Backup Power Flow

900-00272-01-001 Rev A

Cycle That Battery (Self-Consumption)

Self-consumption is the best profile for those who have high energy rates and low return when selling power,

but are still able to send power back to the utility. When this profile is selected, the SkyBox will harvest as

much solar power as it can. After sending power to your protected loads, all extra power will be sent to the

utility grid.

When the protected loads (freezer, refrigerator, etc.) need more power than the available solar power, the

SkyBox uses the battery to make up the difference. The SkyBox drains the battery as long as solar power is

less than the load demand until the battery reaches the Minimum SOC setting. At this point, the SkyBox stops

draining the battery and makes up any power needed by buying from the utility.

Because you’ve told the SkyBox to ‘zero’ its utility use, the only allowed charging source for the battery is

solar power. There are a few exceptions to this rule, but in this section we are only covering the main ideas.

The exceptions are found in Charging Source on page 11.

Here’s the ideal scenario for this profile. The battery reaches Minimum SOC sometime during the night and

the loads are powered from the grid for a minimal amount of time. Once the sun rises and the array starts

producing power, the SkyBox begins charging the battery. The battery only charges if the power needed by

the loads is less than the available solar power.

The SkyBox will continue charging the battery until it reaches the Maximum SOC setting. The battery is not

drained again until it reaches the Maximum SOC setting.

Figure 5 Self-consumption Power Flow

900-00272-01-001 Rev A

Don’t Sell (Non-Export)

The Non-export profile is best for systems in utility districts that do not allow power to be sold back to the

utility. As the name implies, the SkyBox will not export any power when programmed in this profile. Unlike

Net metering with backup and Self-consumption, a SkyBox in Non-export only harvests enough solar

power to meet the power needed by the loads. This means some power could be lost when loads are low and

the sun is shining. Typically, this occurs during midday.

When the protected loads (freezer, refrigerator, etc.) need more power than the available solar power, the

SkyBox uses the battery to make up the difference. The SkyBox drains the battery as long as solar power is

less than the load demand until the battery reaches the Minimum SOC setting. At this point, the SkyBox stops

draining the battery and makes up any power needed by buying from the utility.

Because you’ve told the SkyBox to ‘zero’ its utility use, the only allowed charging source for the battery is

solar power. There are a few exceptions to this rule, but in this section we are only covering the main ideas.

The exceptions are found in Charging Source.

Here’s the ideal scenario for this profile. The battery reaches Minimum SOC sometime during the night and

the loads are powered from the grid for a minimal amount of time. Once the sun rises and the array starts

producing power, the SkyBox begins charging the battery. The battery only charges if the power needed by

the loads is less than the available solar power.

The SkyBox will continue charging the battery until it reaches the Maximum SOC setting. The battery is not

drained again until it reaches the Maximum SOC setting.

Figure 6 Non-export Power Flow

900-00272-01-001 Rev A

I Want To Be Off-Grid, But Not Really

(Maximum Independence)

This profile should not be chosen without a lot of forethought. It is intentionally not included in the flow chart on

page 5. The solar array must be sized appropriately to support both the average loads and battery charging

simultaneously. The battery bank must be sized to support the loads overnight at the very least.

In this profile, the SkyBox physically disconnects from the grid and runs off solar power and battery alone until

the battery reaches the Minimum SOC setting. At this point, the SkyBox re-connects to the grid and

any loads are carried by the grid. Until the batteries reach 85% of the Maximum SOC setting, solar power

will not contribute to the loads. The SkyBox disconnects from the grid once the battery reaches the

Maximum SOC setting.

Figure 7 Maximum Independence Power Flow

900-00272-01-001 Rev A

Keeping Your Battery Alive and Well

IMPORTANT:

The minimum allowed battery voltage is 42 Vdc. The SkyBox will not connect to a

battery below 42 Vdc. A battery discharged below this level must be charged from an

external source.

Battery Types

Many batteries have been tested and are compatible with the SkyBox. Each choice in the drop-down menu

loads the SkyBox with the correct charging voltages for each battery. All that is needed is to tell the SkyBox

the number of paralleled items (strings) in the energy storage system.

Given the increasing popularity and variety of lithium-ion batteries now available, it is important to clarify the

interoperability and safety considerations for pairing these batteries with OutBack Power inverters and charge

controllers. Lithium-ion batteries present different safety risks and performance impacts than the lead-acid

batteries many of our products were originally designed around. For this reason, OutBack Power has adopted

a white-list approach to battery interoperability. The Compatible Batteries list (link 4) includes batteries that

have been reviewed and tested by OutBack Power personnel and whose manufacturers have provided specific

guidance on equipment settings and limitations. Use of batteries not on this list — including unlisted battery

models from the same manufacturers — is at the risk of the installer and host site and may result in your

warranty being void. This remains the case regardless of any technical advice or assistance that may be

provided by OutBack Power, its personnel, or representatives.

Please refer to the application notes (link 5) and any manufacturer recommendations for recommended

settings. Note that inclusion on this list does not constitute an endorsement of these battery products and that

not all combinations carry the safety listings required by some permitting authorities.

PLEASE NOTE THAT OUTBACK POWER DOES NOT CLAIM RESPONSIBILITY FOR ANY DAMAGE DONE

BY OR TO BATTERIES THAT ARE DEPLOYED USING THE INFORMATION FOUND IN THIS NOTICE.

What if you’ve chosen to add energy storage later? In this case, your system should be operating in Net

metering with backup and your battery choice should be None. This tells the SkyBox that no interaction is

necessary with the battery and that no loads can be powered when there is a utility outage.

If you’ve chosen to use a battery that is not included in the pre-configured list, you’ll need to read Using My

Own Custom Batteries on page 18.

Charge Cycle

The SkyBox uses a three-stage charging method.

The SkyBox Programming Guide provides a basic

explanation of this process.

What you’ll see on the SkyBox screen for

Charge status

Charger Off – No charge cycle triggered

oBulk – Battery has reached re-bulk voltage or Minimum

SOC or is currently charging up to absorb voltage

oAbsorb – Battery has finished the bulk stage and is

charging at the absorb voltage

oFloat – Battery has reached re-float voltage or is

currently charging at the float voltage

Figure 8 Battery Details Screen

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