PowerFlex Nexus Core Installation Guide

Product Specifications & Safety

All specifications and descriptions in this document are verified as accurate at the time of printing. PowerFlex reserves the right to make product modifications at any time due to continuous improvement. For inaccuracies or omissions, contact site-support@powerflex.com.

This guide contains important instructions for the PowerFlex Nexus™ Core enclosure. Special symbols are used throughout:

• ⚠️ Warning: Indicates a hazardous situation that could result in injury or death.
• ⚡ Risk of electric shock: Indicates components or procedures that risk 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 for successful results.

Unauthorized use of trademarks is prohibited. PowerFlex X and PowerFlex Nexus are trademarks of PowerFlex Systems, LLC. Adaptive Load Management is a registered trademark of PowerFlex Systems, LLC. Zigbee is a registered trademark of ZigBee Alliance Corporation. Modbus is a registered trademark of Schneider Electric USA, Inc. AT&T, Verizon, and T-Mobile are registered trademarks of their respective owners.

Getting technical assistance: For installation or commissioning assistance, contact PowerFlex support at site-support@powerflex.com or 833-4-PWRFLX (9 am - 5 pm PST).

Getting Started

Welcome to the PowerFlex Nexus family of products

PowerFlex Nexus™ is a proprietary hardware and software system enabling real-time insights and intelligent control of onsite distributed energy resources (DERs). It integrates with solar photovoltaic systems (PV), battery energy storage systems (BESS), and electric vehicle (EV) charging equipment. Key features include state-of-the-art optimization, data acquisition for remote asset management via PowerFlex X™, power and energy metering, and cybersecure Internet of Things (IoT) connectivity.

Nexus Core serves as the central brain of the Nexus platform, ensuring reliable and high-quality dynamic optimization for EV chargers and BESS operations. It communicates with DERs via wired or wireless network communications.

Diagram Description: The system diagram illustrates the PowerFlex ecosystem, showing the Nexus Core as the central hub connecting to Nexus Sense (for metering), Nexus Remote (for network extensions), and EV chargers/solar/BESS (DERs). It highlights connections via Wi-Fi, cellular, and wired networks, originating from a facility's electrical room and utility interconnection.

An overview of PowerFlex Nexus Core

Nexus Core acts as the central brain for energy optimization and Adaptive Load Management® (ALM) functions. It houses a powerful central computer for optimization and logging, along with network communication capabilities including an Ethernet switch. Nexus Core supports Zigbee® 3.0 and Wi-Fi/OCPP communications.

Diagram Description: An internal view of the Nexus Core enclosure shows key components: Wi-Fi access point, industrial computer, network switch, NEMA 3R enclosure, cellular modem, 48V power adapter, 120VAC power input, and an optional Zigbee radio.

How to use this guide

The installation process involves four main steps:

1. Planning: Download the FastField Forms (FFF) app, collect site information, inspect box contents, and gather tools.
2. Installation: Mount the Nexus Core enclosure and connect wiring.
3. Inspection: Record site information via the app and start the commissioning process.
4. Validation: Energize Nexus Core and DERs, and confirm operation.

These steps may be performed in parallel. Refer to the Troubleshooting and FAQ, Checklist, and Technical Specifications sections for further assistance.

Ensure quality work by verifying each step before proceeding.

Setting up Nexus Core

Step 1: Planning

To plan for Nexus Core installation, you will need to:

• Investigate cellular signal and Internet connectivity.
• Download and log into the FFF app.
• Ensure power and connectivity are available at the site.
• Identify what is in the Nexus Core box.
• Identify necessary tools for the installation.

Installation typically takes a few hours by one technician, but can vary based on external factors like electrical inspections.

Test the cellular signal and Internet connectivity

Nexus Core requires sufficient data connectivity bandwidth. It uses a cellular modem compatible with major carriers, or can utilize a local Internet Service Provider (ISP) or local area network (LAN).

To evaluate the cellular signal:

Cellular signals are electromagnetic waves. Signal quality can be affected by distance, obstacles, and interference. Cellular IoT connectivity is crucial for DERs.

To evaluate signal health at the proposed location:

• Use a cellular signal meter for site surveys.
• Ensure test equipment is in good condition.
• Choose a location within sight of a cell tower if possible.
• Confirm cellular carrier provides adequate signal health.

For more information, contact site-support@powerflex.com.

Connecting to an ISP via a customer LAN

Nexus can optionally connect to the internet via a LAN. Connect an Ethernet cable to the WAN port of the Nexus cellular router. Ensure firewalls allow traffic for Nexus Core.

Set up your PowerFlex Forms account

PowerFlex Forms is a customized FastField Forms (FFF) mobile app for collecting site information and photographs, creating a historical record. The app can be downloaded from Google Play or the App Store.

Steps to set up an account:

1. Download the FFF app.
2. Request a PowerFlex FFF account by emailing site-support@powerflex.com with your first and last name.
3. Follow instructions in the confirmation email to verify your account and create a password.

Note: Write down your password securely. Facial recognition is also an option.

Log into the FastField Forms app

Run the FFF app, enter your credentials (email and password), and tap 'Sign In'. The main screen will display. Tap 'Logout' to exit the app.

Importance of the FFF app: It simplifies capturing equipment serial numbers, descriptions, locations, and photographs required by PowerFlex support. Use it during inspection (Step 3) or earlier for better record-keeping.

Availability of services at the site

Confirm the following critical site services:

1. Cellular signal strength: Ensure adequate signal for Nexus Core. A wired ISP connection is an alternative.
2. Power: Verify necessary power connections are available per project design diagrams.
3. Enclosure for the site: Confirm the unique enclosure identifier matches its intended location.
4. Site safety: Conduct a Job Hazard Assessment (JHA) for a safe working environment.

What's in the box

The Nexus Core enclosure measures 18.9" H x 16.8" W x 11.3" D and weighs approximately 31.5 lbs (14 kg). It requires single-phase 120VAC power (500W peak) and typically uses a 20A or 15A breaker.

Optional power sources (208VAC, 240VAC, 277VAC) may require a separate control transformer, as specified in the project's single-line diagram.

Open the enclosure latches to access the preassembled components and the taped accessories package. The Wi-Fi access point is also included.

Accessories package contents:

What you'll need

Tools required:

• Personal protective equipment (PPE) for low voltage electrical work (Class 00 recommended).
• #2 Phillips flathead and #2 square screwdrivers.
• RJ45 crimping tool and connectors.
• #14 fork or ring terminal connectors.
• Crimping tool for electrical wiring.
• Portable label maker.
• Multimeter (AC voltage and continuity).
• Smartphone (for FFF app).

Optional tools:

• Commercial-grade RF meter.
• Hammer drill with appropriately sized bits.
• Impact driver.
• Hole saw.
• 1/2 inch (or 5/16 inch) rigid or flex conduit.
• 1/4 inch fasteners and anchors (rated for at least 35 lbs).
• Cat6 Ethernet wiring (armored/outdoor rated if not in conduit).

Before proceeding: Ensure all accessories are present, the FFF app is downloaded and logged into, tools are gathered, and consult the checklist.

Step 2: Installation

Mount the Nexus Core

Install the Nexus Core in a location protected from harsh weather and direct sun. Use shade for temperatures above 104°F (40°C) and mount indoors for temperatures below 32°F (0°C).

Mount the enclosure upright at eye level for easy access. It must be at least 4 feet above the ground with 1 foot of clearance above and below. Maintain a distance of 4-5 feet from transformers. The enclosure has integrated top and bottom brackets.

Mounting methods:

• Wall: Use 1.5-inch (or 2-inch) concrete anchors through the bracket openings. Ensure anchors support at least 35 lbs. For wallboard, secure brackets to studs.
• Unistrut: Fasten the bracket corners to the Unistrut. Ensure upper and lower brackets are utilized.
• Pedestal: Attach a Unistrut to the pedestal pole and fasten the bracket corners to the Unistrut. Ensure upper and lower brackets are utilized.

Diagram Description: Illustrations show mounting the enclosure on a wall using anchors, on a Unistrut frame, and on a pedestal via Unistrut.

Connect power and communications

Power and antennas are typically installed at the bottom of the enclosure. No side or top penetrations are allowed; all must be on the bottom.

1. Ground bond (optional): Securely connect a ground bond to the enclosure per the National Electrical Code (NEC).
2. Power: Connect a 120VAC power cable through a 1/2-inch liquid flex connector. Unscrew the connector, pull the power cable through, remove the plastic strip, and connect #14 AWG fork or ring terminals to the power conductors on the terminal strips. Connect cables as N-G-L (Neutral-Ground-Line).

Warning: #14 fork or ring terminal connectors are required. Ensure conductors and protective devices are correctly sized for the 500W maximum capacity.

Diagram Description: Shows two configurations of bottom penetrations (with and without Zigbee) and the internal terminal strip for power connection.

• Wi-Fi Ethernet cable: Connect to the PoE port of the network switch and the external Wi-Fi access point.
• 4G LTE and Zigbee antennas: Install and hand-tighten the 4G LTE antennas (red label) and the optional Zigbee antenna (blue label) to the corresponding connectors at the bottom of the enclosure.

Diagram Description: Illustrates the connection of Ethernet cable to the network switch and the attachment of color-coded antennas.

An overview of power and communications subsystems

Inside the Nexus Core enclosure are several subsystems:

Diagram Description: An internal view of the Nexus Core enclosure with components labeled A through E. A: Industrial Computer, B: Network Switch, C: 4G LTE Cellular Modem, D: 48V Power Supply, E: Zigbee Coordinator.

A circuitry protection system is located behind the back metal plate.

Some configurations use wired Internet from an ISP or connect to Nexus Sense/Remote:

• Drill a conduit opening in the bottom for an Ethernet cable to the switch.
• Connect Cat6 cable from network switch port 7 to the computer's Ethernet LAN port.
• Connect Cat6 cable from network switch port 8 to the modem's LAN port.
• Insert the Cat6 cable from the ISP into the network switch.

Warning: Post a directory identifying controlled devices and circuits on the managed electrical panel and label it as remotely controlled by an energy management system.

Energize power to Nexus Core

Once all connections are complete, energize the Nexus Core with a 120VAC source. There is no external power indication; open the cover to inspect inside. Verify that all internal components have active light indicators.

Note: Nexus Core is not fully operational until validated and commissioned. DERs should be energized separately.

Warning: Energizing any system on site must be done by qualified electrical personnel only.

Verify subsystem energization:

• A: Industrial computer and power supply: Green LED light on power supply, flashing red LED when HDD active. Green LED power indicator for Ethernet ports. Green LED power indicator on computer's power adapter.
• B: Network switch: Blue power light indicator above Ethernet ports. PoE ports have amber/green LEDs; standard ports use green LEDs.
• C: 4G LTE cellular modem: Green power light indicators with blue signal-strength bars.
• D: 48V power supply: Green LED when power is applied.
• E: Zigbee Coordinator (optional): Red-light indicator. Check USB and antenna cable connections.

If indicators are not functioning correctly, investigate incoming connections and ensure proper termination, power, and condition.

Step 3: Inspection

To perform a Nexus Core inspection, you will need to know how to use the FFF app, gather information with it, and submit the site inspection form.

Using the FFF app

The FFF mobile app is customized for PowerFlex installers to gather installation information and photographs. PowerFlex support requires this information before final validation.

App workflow: Log in, tap 'Forms', select 'Site Inspection Form', and tap 'Start Form'.

Diagram Description: Screenshots show the FFF app login screen, the main forms screen with categories like 'Form Libraries' and 'Inbox', and the 'Site Inspection Form' selection with a 'Start Form' button.

Note: App screenshots are from iOS but operate similarly on Android devices.

Gather installation information with FFF

Fill in general information, ensuring all fields marked with an asterisk (*) are completed. Enter your name, date/time, location/GPS, installer company name, site name, street address, city, and zip.

The app can detect the installation location. Use the Installer Company Name recognized by PowerFlex. Ensure the site address matches permit drawings.

Use 'Next' to advance through subforms and 'Prev' to go back. Tap 'Submit' when complete.

Site photos are crucial for support:

• Tap the 'Utility Meter, 1ft away' thumbnail to take a photo of the meter.
• Tap 'More' to retake photos or 'Done' to return to the form.
• Take a second photo of the utility meter (5 feet away) and tap 'Done'.
• For general site photos, tap the 'camera+' symbol to take multiple photos (PowerFlex recommends three to five).
• Tap 'Done' when finished with photos.
• To re-examine photos, tap the thumbnail; the number indicates the count.

Photo management: Tap a thumbnail to retake or zoom. Use 'Notes' to add comments. Swipe left and tap 'Delete' to remove unwanted photos (e.g., accidental foot photo).

Finally, take a photo of the Nexus nameplate label or the white label starting with 'PF-' on the cellular modem. If unclear, enter it as a note.

Respond to additional questions and take photos on the main site inspection form. After the 'BESS installed?' question, tap 'Next' to fill out electrical equipment and other subforms.

Special notes for FFF app usage:

• Navigating subforms: Use the 'Index' menu for sections like Nexus Sense, external meter, Nexus Remote, electrical equipment, BESS, etc.
• Panel form: Capture which breaker is used for each equipment (EV chargers, Nexus Core) with photos and notes. Mark breakers clearly on the inside cover label sheet.
• Identification of equipment: Capture serial numbers using XBee or QR scans. If a QR code isn't recognized, take a photo.
• Multi-station information: For additional EV stations, assume information is the same as the previous one unless changes are needed.

Information entered in the app is retained locally, even without internet connectivity. You can continue inspections later via 'In Progress'.

Submit the site inspection form

Once all information is collected, tap the 'Submit' button. A warning will appear if there are errors or missing information; use the 'Index' button to navigate to specific subforms.

After submission, PowerFlex support will process your form for three days. You will receive an email confirming if the installation can proceed to final validation or if issues need mitigation.

Before proceeding to the next step: Confirm the Nexus enclosure is mounted, power/connectivity are set up, the app has captured required information, and the site inspection form has been submitted.

Step 4: Validation

Verify end-to-end operation

The PowerFlex network is not operational until the Nexus Core is fully commissioned and approved by PowerFlex site support.

Once installed, wired, and energized correctly, the installation is ready for remote diagnostics by PowerFlex engineers. Contact PowerFlex site support or your representative via email (site-support@powerflex.com) or phone (833-4-PWRFLX).

Locking the enclosure

After installation, lock the enclosure with the provided combination lock. Close the front door, secure the latches, and insert the lock into the padlock eye. The lock combination is preset for each site.

Warning: To avoid security issues or unauthorized access, never leave the enclosure unlocked.

Installation checklist

Step 1: Planning

• Download Fast Field Forms (FFF) app and request account.
• Confirm PowerFlex forms account and create password.
• Verify site services: Cellular service (or Ethernet), suitable power (120VAC, 20A).
• Verify enclosure specific to the site.
• Conduct a job hazard assessment (JHA).
• Unbox Nexus enclosures and verify contents.
• Gather all required tools.

Step 2: Installation

• Install Nexus enclosures securely (wall, Unistrut, or pedestal).
• Attach power, communications, and ground bond.
• Energize power to Nexus Core.
• Ensure external connections are properly sealed against moisture.

Step 3: Inspection

• Gather and submit site information using the FFF app.
• Contact PowerFlex site support (site-support@powerflex.com, 833-4-PWRFLX) to confirm readiness for commissioning.

Step 4: Validation

• Inspect power and comm indicators inside the Nexus Core enclosure.
• Work with PowerFlex site support to confirm Nexus is functioning correctly.
• Securely lock the Nexus Core enclosure.

Troubleshooting/FAQ

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

Maintenance and Warranty

All maintenance and troubleshooting must be performed by qualified personnel. Nexus hardware requires minimal maintenance. Perform maintenance with power to the cabinet turned off, after contacting site administrators.

Annual maintenance includes:

• Visually inspect the enclosure.
• Remove and clean the metal screen with mild soap and a soft brush/cloth. Rinse and dry before re-installing.
• Clean the cabinet with 70% isopropyl alcohol if necessary.

The PowerFlex Nexus Limited Warranty applies to Nexus Enclosures for three (3) years from the date of initial installation and power-up. Claims must be submitted by the end user or subsequent owner with proof of ownership. The warranty covers defects in materials and workmanship. To apply, the Nexus must have been purchased from PowerFlex or a certified installer in the USA and installed in the USA.

For questions about certified installers, contact PowerFlex. Refer to the complete Nexus Product Limited Warranty for more information.

Appendix A: Technical Specifications

Enclosure

Modem

Network switch

Communications

Safety compliance

¹ To establish connectivity, an external WAP is typically mounted near EV chargers away from the Nexus Core enclosure.