PowerFlex Nexus Remote Zigbee Installation Guide

Product Specifications

All specifications and descriptions contained in this document are verified to be accurate at the time of printing. However, because continuous improvement is a goal at PowerFlex, the right to make product modifications at any time is reserved. To communicate any inaccuracies or omissions, send an e-mail to: site-support@powerflex.com.

Safety Concerns

This guide contains important instructions for the PowerFlex Nexus™ Remote enclosure that must be followed during installation and maintenance. Special symbols are used throughout the guide:

• ⚠️ Warning: Indicates a hazardous situation that could result in injury or death.
• ⚡ Risk of electric shock: Indicates components or a procedure that risks electric shock or injury.
• ⚠️ Caution: Indicates a hazardous situation that could result in minor injury or equipment damage.
• ℹ️ Note: A best practice alert, tip, or technique that results in successful results.

The unauthorized use of any trademark displayed in this document or on the product is strictly prohibited. PowerFlex X, PowerFlex Nexus, Nexus Core, Nexus Sense, and Nexus Remote are trademarks of PowerFlex Systems, LLC. Zigbee is a registered trademark of ZigBee Alliance Corporation. Lufft is a registered trademark of G. Lufft Mess und Regeltechnik GmbH, LLC. All other trademarks are the property of their respective owners.

Getting Technical Assistance

To get assistance for Nexus Remote installation or commissioning, please contact PowerFlex support at site-support@powerflex.com or 833-4-FPWFLX, during the hours of 9 am to 5 pm (PST).

Getting Started

Welcome to the PowerFlex Nexus™ family of products

PowerFlex Nexus™ is a proprietary hardware and software system that enables real-time insights and intelligent control of onsite distributed energy resources (DERs). This flexible platform is designed to seamlessly integrate and adapt to energy demand, and provides the ability to integrate with solar photovoltaic systems (PV), battery energy storage systems (BESS), and electric vehicle (EV) charging equipment. Key features include:

• State-of-the-art optimization and control of energy assets.
• Data acquisition and telemetry, enabling remote asset management through PowerFlex X™.
• Power and energy metering for numerous single-phase and/or three-phase loads.
• Cybersecure Internet of Things (IoT) connectivity to the cloud.

Diagram Description: An illustration shows the PowerFlex Nexus ecosystem. PowerFlex X is the central platform. It connects to Nexus Core, which acts as the central brain with industrial computer, storage, network, and cellular communications, located in the electrical room or BESS storage pad. Nexus Sense provides power and energy metering and network communications, often near the utility interconnection or a remote metering subpanel. Nexus Remote acts as a network extension for WiFi, Zigbee, and remote DERs, enabling communication to devices like rooftop solar or EV chargers in remote locations such as parking garages. WiFi AXP for remote EV chargers is also depicted.

By leveraging the PowerFlex X family of technology products, Nexus Core™ acts as the central brain of the Nexus platform. PowerFlex grid-edge and cloud-based energy management system ensures reliable and high-quality dynamic optimization for your site's EV chargers and BESS operation. Nexus Core communicates directly with DERs or intermediary controllers through wired and/or wireless network communications, offering flexibility for applications in distant or hard-to-reach locations. Nexus Remote™ Zigbee® is a network-connectivity extension, primarily for EV charging or solar monitoring locations where Zigbee, Wi-Fi, or Ethernet needs to be extended to remote (or difficult-to-reach) locations such as remote subpanels, parking garage levels, or rooftop inverters. The design is optimized for ease of installation and minimal intrusion to the site where Power over Ethernet (PoE) suffices for most installations from the Nexus Core enclosure. Nexus Remote transmits data back to Nexus Core via a PoE switch.

ℹ️ Note: Every PowerFlex installation requires a Nexus Core. Additional Nexus Sense™ and Nexus Remote units can be added to a project as needed.

An Overview of PowerFlex Nexus Remote

The Nexus Remote Zigbee enclosure includes the following components:

Diagram Description: An illustration shows the Nexus Remote Zigbee enclosure. Key internal components are labeled: Communication Adapters, Nema 3R Enclosure, Network PoE Switch, Zigbee Radio, and Input Power (120VAC or PoE). The features listed are Wi-Fi Access Point and Network Switch.

How to Use This Guide

To complete the installation of a Nexus Remote enclosure, follow these steps (some activities may be performed in parallel or in a slightly different order):

1. Planning: Download the FastField Forms (FFF) app to collect site information, inspect the Nexus Remote's box contents, and gather tools. An account through PowerFlex is required to access the form on the app.
2. Installation: Mount the Nexus Remote's enclosure and connect wiring as required at your site.
3. Inspection: Record site information in the app and start the commissioning process.
4. Validation: Energize Nexus Remote and confirm that everything is up and running.

More help in this guide:

• Troubleshooting and FAQ
• Checklist of things to do during installation
• Technical specifications

More help in other documents:

• Nexus Core Installation Guide: Includes instructions on how to set up Nexus Core and information about the FastField Forms (FFF) app.

Setting Up Nexus Remote Zigbee

Step 1: Planning

To plan for a Nexus Remote installation, you will:

• Get an introduction to using the FFF app.
• Verify power and connectivity at the site of the installation.
• Learn how Nexus Remote collects data.
• Know what is in the Nexus Remote box.
• Identify the tools necessary to bring onsite for the installation.

For most installations, getting a Nexus Remote installed and energized should only take a few hours and can be performed by one technician. However, the timeframe can vary due to external factors (e.g., energization may require an electrical inspection). In most installations, plan to install Nexus Core before or in conjunction with Nexus Remote installation.

Using the FastField Forms app to record site installation information

PowerFlex Forms is a custom implementation of the FastField Forms (FFF) mobile app. The FFF app provides a convenient way for an installer to collect site information and photographs of the installation. This benefits both PowerFlex support and installers with a historical record for each installation. The FFF app is also used to update site installation notes in the future.

The importance of the FFF app ...

Filling out the FastField Forms app is a requirement for a successful installation. The app makes it easy to capture equipment serial numbers, descriptions, locations, and photographs needed by PowerFlex support. This is critical for all Nexus enclosures installed on a PowerFlex site. The FFF mobile app can be downloaded onto a Google or Apple phone (or tablet). More information on how to get started with the app can be found under the heading "Step 1: Planning" in the Nexus Core Installation Guide.

Availability of Services at the Site

There are several critical site services that need to be confirmed by the installer:

1. Power: Review project design diagrams and confirm necessary power connections are available. The Nexus Remote requires Power over Ethernet (PoE). When PoE is not feasible, a 120VAC powered enclosure is required with a dedicated power supply.
2. Enclosure for the site: Each enclosure is preconfigured with a unique identifier number. Your PowerFlex representative should confirm that your unique enclosure matches its intended location.
3. Site safety: Conduct a job hazard assessment (JHA) to ensure a safe working environment.

How Nexus Remote Collects Information

The Nexus Remote incorporates keyboard-monitor-mouse (KVM) receiver communication adapters, a Zigbee remote, and a PoE network switch to enable operation and communication with Zigbee-enabled EV chargers. The Nexus Remote can power auxiliary devices such as Wi-Fi access points (WAP) over PoE. This acts as a power and communication relay system between EV chargers and Nexus Core. Data collected over Zigbee radio is made available on the PowerFlex X platform via Ethernet or fiber connection to Nexus Core.

What's in the Box

The Nexus Remote comes preassembled for your specific installation:

Diagram Description: A photograph shows the Nexus Remote enclosure. Text on the enclosure reads "PowerFlex Nexus Remote". The enclosure dimensions are 18.9" H x 16.8" W x 11.3" D (480.06 x 426.72 x 287.02 mm) and it weighs about 23 lbs (10 kg). The power supply requirement is over PoE (802.3af).

ℹ️ Note: Additional Nexus Remote technical details can be found in "Technical Specifications" at the end of this guide.

What You'll Need

You'll need these tools and materials to install the Nexus Remote enclosure:

• Personal protective equipment (PPE) for low voltage electrical work (class 00 recommended).
• #2 Phillips and flathead screwdrivers.
• RJ45 crimping tool.
• RJ45 connectors.
• Crimping tool used for electrical wiring.
• Multimeter that measures AC/DC voltage and continuity.
• A smartphone to complete the site inspection form and use as a compass for OTT Lufft® WS501.
• Label maker.
• Hole saw.
• ½ inch (or 5/16 inch) rigid or flex conduit for power and data cables.
• ½ inch (or 5/16 inch) rain tight connector.
• ¼ inch fasteners and anchors rated for at least 35 lbs.
• Cat6 Ethernet wiring (if not installed in a conduit, it must be armored/outdoor rated cable).
• Compass aligning OTT Lufft® WS501 to the North (can use app on smartphone).
• Open-end ring spanner (SW13).

Depending on how the Nexus Remote will be installed, you may need one or more of the following:

• Hammer drill with appropriately sized bits.
• Impact driver.

Before proceeding to the next step ...

1. Make sure that the Nexus Remote accessories package (cardboard liner) includes the lock and that the package has been removed from the enclosure.
2. You have downloaded the FFF app and have successfully logged in. (Check the Nexus Core Installation Guide for more information.)
3. Gather all the tools you'll need for the site installation.
4. Don't forget to use our checklist to check off tasks during installation.
5. For information about installing other Nexus products, refer to Nexus Core Installation Guide and Nexus Sense Installation Guide.

Step 2: Installation

To perform a Nexus System installation, you will:

• Mount the enclosure at the site.
• Connect power and communications.
• Energize power to all Nexus Remote subsystems.

Mount the Enclosure

The Nexus Remote enclosure should be mounted at eye level to an upright surface for easy access and servicing. Ideally, install the Nexus Remote at a location that isn't subject to harsh weather conditions or exposure to direct sun. In locations where ambient temperatures are above 107°F, consider mounting the Nexus Remote in the shade to avoid overheating.

There are three common methods to mount Nexus Remote:

• Wall: Using the outer openings on the enclosure's mounting bracket, use 1.5-inch (or 2-inch) concrete anchors to firmly install to the wall. To mount on wallboard, ensure mounting brackets are securely attached to the studs.
• Unistrut: Fasten the corners of the enclosure's mounting bracket onto the Unistrut.
• Pedestal: Attach a Unistrut onto the pedestal pole and fasten the corners of the enclosure's mounting bracket to the Unistrut.

⚠️ For safety reasons, it is required that both mounting brackets are used for proper installation.

Connecting Power and Communications

For most installations, connecting power and installing wireless communications is straightforward and shouldn't take long. Power and antennas are installed at the bottom of the enclosure.

⚠️ No side or top penetrations are allowed on the enclosure; all penetrations must be on the bottom.

Connecting Ethernet to the Nexus Core

Connect an Ethernet cable from the Nexus Core, pushed through the cable gland, to the PoE IN port on the PoE network switch (NS-1). Connect another Ethernet cable (e.g., pink one shown) from the KVM-Zigbee link to the PoE network switch (NS-1).

Diagram Description: A photograph shows the bottom of the Nexus Remote enclosure with cable glands. Another image shows the PoE network switch (labeled "Gigabit Ethernet PoE Extender") with multiple ports. A third image shows the internal connection within the enclosure, with Ethernet cables plugged into the PoE switch and a KVM-Zigbee link device.

Energize Power to Nexus Remote

Once installation and inspections have been completed, energize the Nexus Remote unit with the PoE source. As there is no power indicator on the outside of the enclosure, open the cover to inspect the inside. Verify that the following enclosure's components are powered up:

• PoE network switch
• PoE splitter
• KVM receiver
• Zigbee remote

To verify that power is supplied to all subsystems, make sure the following subsystems are energized:

1. PoE network switch: both amber and green LEDs should be on. The number of KVM-Zigbee links that can be connected depends on PoE port availability from the Nexus Core's network switch. If, for example, at least three PoE ports from the Nexus Core's network switch are available, no more than two KVM-Zigbee links can be connected to the Nexus Remote's network switch.
2. PoE splitter: both amber and green LEDs should be on (L). If the PoE splitter needs to be replaced, only acquire a quality PS5712TG-compatible unit (R).

Diagram Description: Photographs show the PoE network switch and the PoE splitter with their respective LED indicators. The PoE splitter image also shows a replacement unit (R) with model number PS5712TG.

3. KVM receiver: both amber and green LED should be on. Ensure that the KVM receiver's Channel ID DIP switch is the same as Nexus Core's KVM transmitter settings.
4. Zigbee remote: red LED should be on.

Diagram Description: Photographs show the KVM receiver with its LEDs and DIP switch, and the Zigbee remote with its red LED indicator.

Before proceeding to the next step ...

1. Confirm that the Nexus Remote enclosure is securely mounted.
2. Verify that all cables inside the enclosure are fully connected and properly labeled.
3. Attach power and ground bond to the enclosure.
4. Verify that the system has been energized.
5. Make sure that all external connections are properly sealed to avoid water infiltration.

Step 3: Inspection

To perform a Nexus Remote inspection, you will need to use the FFF app. This section is a quick recap.

Using the FFF app

The FastField Forms (FFF) mobile app has been customized for PowerFlex installers to gather important installation information and photographs before performing the final validation step. Log in to your account, tap Forms, and select the Site Inspection Form. To start, tap the Start Form button.

Diagram Description: Screenshots of the FastField Forms mobile app are shown. The first shows the login screen. The second shows the main menu with options like "Form Libraries", "Forms", "Inbox", "In Progress", "Sync", "Submitted", and "Kiosk Mode". The third screenshot shows the "Site Inspection Form" with a "Start Form" button.

The first page of the site inspection form contains general information. If the form contains more information than can fit on a single screen, flick the screen up to see more.

Diagram Description: Two screenshots of the "Site Inspection Form" are shown, illustrating how to navigate through form fields like "Installer Company Name", "Site Name", "Street Address", "City", "Zip", and "Utility Meter". An arrow indicates scrolling down to see more fields.

Learning how to use the app ... More comprehensive instructions on how to use the FFF app are described in "Step 3: Inspection" of the Nexus Core Installation Guide.

Submit the Site Inspection Form in FFF

Once Nexus Remote information has been collected in the site inspection form, tap the Submit button at the bottom of the app's screen. If there are errors or missing elements, the app will display a warning message.

Before proceeding to the next step ...

Verify the following:

1. The Nexus enclosure has been securely mounted.
2. Power and connectivity have been set up and energized.
3. The app has captured all the required site information.
4. The site inspection form has been submitted to PowerFlex.

Step 4: Validation

To perform a Nexus Remote validation, you will:

• Confirm end-to-end operation.
• Securely lock up the Nexus Remote enclosure.

Verify End-to-End Operation

The Nexus is not operational or functional until the Nexus Core and Nexus Remote are fully commissioned by PowerFlex support. Once the Nexus Remote has been installed, wired, energized, and confirmed to be set up correctly, the installation will be ready for PowerFlex support personnel to run remote diagnostics. Please contact PowerFlex support (or your PowerFlex representative):

e-mail: site-support@powerflex.com, phone: 833-4-FPWFLX

Locking the Enclosure

After installation, lock the enclosure with the provided combination lock. The lock combination is preset for each site. After securing the latches on the side of the enclosure to the cover, insert the lock in the padlock eye in either latch hook.

Diagram Description: A photograph shows the Nexus Remote enclosure latched shut. A padlock is inserted into the latch hook. A warning label is visible on the enclosure. Text notes that depending on the installation location, a different warning label might be affixed on the enclosure (between the latches).

⚠️ To avoid any security issues or unauthorized access with the Nexus Remote, never leave the enclosure unlocked.

Installation Checklist

Troubleshooting/FAQ

ℹ️ Note: Always contact PowerFlex support if you have any questions.

Maintenance and Warranty

All maintenance and troubleshooting should only be performed by qualified personnel. Nexus hardware products are designed to require minimal maintenance. All maintenance should be performed with power to the cabinet turned off. Shutting down power to Nexus hardware affects site operations, and site administrators should be contacted before this maintenance is performed. The following should be performed annually to ensure optimal safety, longevity, and performance:

• Visually inspect the enclosure.
• Remove the metal screen from the enclosure. Use a mild dish soap and, if needed, a soft-bristle brush, soft scrub pad, or cloth to help dislodge stubborn dirt. When clean, rinse the screen, and when dry, re-install the screen.
• Clean cabinet if necessary, using 70% isopropyl alcohol.

The PowerFlex Nexus Limited Warranty applies to Nexus Enclosures. The limited warranty period starts on the date of initial installation and initial power-up of the Nexus component and lasts for three (3) years (the "Warranty Period"). A claim under this Limited Warranty must be submitted by or on behalf of the end user who acquired and put the Nexus into use for the first time or by a subsequent owner of the Nexus who provides proof of ownership. This Limited Warranty covers defects in materials and workmanship of the PowerFlex Nexus Components. For this Limited Warranty to apply, your PowerFlex Nexus must meet the following criteria: (i) it was purchased from PowerFlex or a PowerFlex certified installer in the United States of America; (ii) it has one of the part numbers referenced above; and (iii) it is installed in the United States of America. For concerns or questions about PowerFlex-certified installers, please contact PowerFlex. Please see the complete Nexus Product Limited Warranty for more information.

Appendix A: Technical Specifications

Enclosure

Zigbee 3.0

Network switch

Communications

Index

battery energy storage systems (BESS): 2

Cat6 Ethernet cable: 17

checklist: 16

combination lock: 7, 15

commissioning: 4, 15

distributed energy resources (DERs): 2

electric vehicle (EV): 2

enclosure:

• locking: 15
• what's inside: 6

energizing the Nexus Remote: 9

Ethernet connectivity: 10

FastField Forms (FFF). See FFF

FFF: 5

• site inspection form: 13
• submitting form: 14
• using: 13

inspection step: 4, 13

installation step: 4, 9

Internet of Things (IoT): 2

job hazard assessment (JHA): 6

keyboard-monitor-mouse (KVM): 6

KVM-Zigbee connectivity: 10

maintenance: 18

mounting: 9

Nexus Core: 8, 15

Nexus overview: 2

Nexus Remote: 8

Pedestal mounting: 9

photovoltaic systems (PV): 2

planning step: 4, 5

power: 6, 11

• KVM receiver: 12
• PoE network switch: 11
• PoE splitter: 11
• Zigbee remote: 12

Power over Ethernet (PoE): 3, 6

PowerFlex X: 2

PS5712TG (PoE splitter): 11

serial RS232/RS485: 3

services at site: 6

technical support: ii

temperatures: 9

troubleshooting and FAQ: 17

validation step: 4, 15

warranty: 18

weather conditions: 9

Wi-Fi access point (WAP): 6

Zigbee: 2