GS Load Center Installation Manual
About OutBack Power Technologies OutBack Power Technologies is a leader in advanced energy conversion technology. OutBack 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.
Table of Contents Introduction .........................................................................................................5 Welcome to OutBack Power Technologies ................................................................................................................. 5 GSLC – Components ........................................................................................................................................................... 7 GSLC175-120/240 – Components ...............
Table of Contents Specifications .....................................................................................................51 Electrical Specifications ................................................................................................................................................... 51 Mechanical Specifications ..............................................................................................................................................
Table of Contents Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 Figure 37 Figure 38 Figure 39 Figure 40 Figure 41 Figure 42 Figure 43 Figure 44 Figure 45 Figure 46 Figure 47 FN-DC and Wiring Block ............................................................................................................. 33 Installing the FLEXnet DC .......................................................................................................... 33 PV Connections in the GSLC ....
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Introduction Welcome to OutBack Power Technologies Thank you for purchasing a GS Load Center (GSLC) from OutBack Power Technologies. The GSLC is part of an OutBack Grid/Hybrid™ system. It is a balance-of-systems enclosure intended to work with Radian Series (GS) inverter/chargers, FLEXmax Charge Controllers, and an OutBack HUB Communications Manager. The removable front cover allows for opening from either side of the enclosure.
Introduction GSLC175-PV-120/240 – GS Load Center for PV and AC applications (split-phase). Factory-prepared with dual 175 Adc inverter circuit breakers, dual AC inputs, 120/240 Vac maintenance bypass assembly, PV GFDI, and two PV array inputs, FLEXnet DC battery monitor and three shunts. Intended as a “plug-and-play” solution for systems with a single inverter, two FLEXmax charge controllers, and battery monitoring. ∼ GSLC175-PV-230 – GS Load Center for PV and AC applications (single-phase).
Introduction GSLC – Components Legend Inverter Negative (–) DC Bus Bars Negative (–) Terminal Bus Bar (TBB-WHITE) Ground TBB (TBB-GROUND) NOTE: The installed Neutral TBB has white insulators (TBB-WHITE). A set of blue insulators (TBB -BLUE) is included in the kit for locations where blue is standard. The DC Positive (+) Bus Plate (FW-BBUS) and the other inverter positive (+) DC bus bars are also included in the kit.
Introduction GSLC175-120/240 – Components Legend 1 Inverter Negative (–) DC Bus Bar 8 Inverter Positive (+) DC Bus Bar 2 Negative (–) Terminal Bus Bar (TBB-WHITE) 9 Shunt (FW-SHUNT500) 3 Ground TBB (TBB-GROUND) 10 AC Input Circuit Breakers (PNL-50D-AC-120/240V) 4 Neutral TBB (TBB-WHITE) 11 Maintenance Bypass Interlock 5 PV Positive (+) TBB (TBB-RED) 12 AC TBB (Inverter Output) L1, L2 (STBB-RED or BLACK) 6 DC Positive (+) Cable Plate (FW-BBUS) 13 AC TBB (Grid) L1, L2 (STBB-RED or BLAC
Introduction GSLC175-230 – Components Legend 1 Inverter Negative (–) DC Bus Bar 8 Inverter Positive (+) DC Bus Bar 2 Negative (–) Terminal Bus Bar (TBB-WHITE) 9 Shunt (FW-SHUNT500) 3 Ground TBB (TBB-GROUND) 10 AC Input Circuit Breakers (PNL-50-AC-230V) 4 Neutral TBB (TBB-BLUE) 11 Maintenance Bypass Interlock 5 PV Positive (+) TBB (TBB-RED) 12 AC TBB (Inverter Output) (TBB-BROWN) 6 DC Positive (+) Cable Plate (FW-BBUS) 13 AC TBB (Grid) (TBB-BROWN) 7 Main Inverter Disconnect(s) (PNL-175-
Introduction GSLC175-PV-120/240 – Components Legend 1 Inverter Negative (–) DC Bus Bar 10 AC Input Circuit Breakers (PNL-50D-AC-120/240V) 2 Negative (–) Terminal Bus Bar (TBB-WHITE) 11 Maintenance Bypass Interlock 3 Ground TBB (TBB-GROUND) 12 AC TBB (Inverter Output) L1, L2 (STBB-RED or BLACK) 4 Neutral TBB (TBB-WHITE) 13 AC TBB (Grid) L1, L2 (STBB-RED or BLACK) 5 PV Positive (+) TBB (TBB-RED) 14 AC TBB (Generator) L1, L2 (STBB-RED or BLACK) 6 DC Positive (+) Cable Plate (FW-BBUS) 15
Introduction GSLC175-PV-230 – Components Legend 1 Inverter Negative (–) DC Bus Bar 10 AC Input Circuit Breakers (PNL-50-AC-230V) 2 Negative (–) Terminal Bus Bar (TBB-WHITE) 11 Maintenance Bypass Interlock 3 Ground TBB (TBB-GROUND) 12 AC TBB (Inverter Output) (TBB-BROWN) 4 Neutral TBB (TBB-BLUE) 13 AC TBB (Grid) (TBB-BROWN) 5 PV Positive (+) TBB (TBB-RED) 14 AC TBB (Generator) (TBB-BROWN) 6 DC Positive (+) Cable Plate (FW-BBUS) 15 PV Input Disconnects (PNL-80-DC) Shunt Bus (GS-SBUS)
Introduction GSLC175PV1-120/240 – Components Legend 1 Inverter Negative (–) DC Bus Bar 10 Maintenance Bypass Interlock 2 Negative (–) Terminal Bus Bar (TBB-WHITE) 11 AC TBB (Inverter Output) L1, L2 (STBB-RED or BLACK) 3 Ground TBB (TBB-GROUND) 12 AC TBB (Grid) L1, L2 (STBB-RED or BLACK) 4 Neutral TBB (TBB-WHITE) 13 AC TBB (Generator) L1, L2 (STBB-RED or BLACK) 5 PV Positive (+) TBB (TBB-RED) 14 PV Input Disconnect (PNL-80-DC) 6 Main Inverter Disconnect (PNL-175-DC) 15 Shunt Bus (GS-SBUS)
Introduction GSLC175PV1-230 – Components Legend 1 Inverter Negative (–) DC Bus Bar 10 Maintenance Bypass Interlock 2 Negative (–) Terminal Bus Bar (TBB-WHITE) 11 AC TBB (Inverter Output) (TBB-BROWN) 3 Ground TBB (TBB-GROUND) 12 AC TBB (Grid) (TBB-BROWN) 4 Neutral TBB (TBB-WHITE) 13 AC TBB (Generator) (TBB-BROWN) 5 PV Positive (+) TBB (TBB-RED) 14 PV Input Disconnect (PNL-80-DC) 6 Main Inverter Disconnect (PNL-175-DC) 15 Shunt Bus (GS-SBUS) 7 Inverter Positive (+) DC Bus Bar 16 Ba
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Planning Tools Required Open-ended wrenches (9/16" and13 mm) Wire cutters/strippers Torque wrenches Assorted insulated screwdrivers Digital Voltmeter (DVM) or regular voltmeter Materials Required Conductors for wiring Conduits Location/Environmental Requirements Indoor mount only Side View Front View 8½" (21.6 cm) deep 16" (40.6 cm) wide 17" (43.
Planning Legend Cable Knockouts (U.S.
Installation Hardware Options The seven versions of the GSLC come with different components already installed. GSLC, the “basic” or “empty” version, requires almost all components to be installed if they are needed. Instructions for this product begin on page 19. GSLC175-120/240 and GSLC175-230 are the “inverter only” versions for Radian models GS8048, GS8048A, and GS7048E. They have hardware for Radian inverter AC and DC connections. Battery monitoring or PV capability must be installed as needed.
Installation Remove Top Cover To Remove the Top Cover: 1. Remove the four screws; one in each corner. 2. Lift the top off the enclosure. Enclosure with Top Removed Figure 14 Removing the Top Cover from the GSLC Remove Front Door To Remove the Front Door: 1. Open the door to about 90 degrees. 2. Lift the hinges out of the slots at the inside edge. Lift up to remove.
Assembly Remove Interior Cover In order to make any wiring connections or to install components, the interior cover must be removed to expose the interior of the enclosure. (This cover is sometimes called the “dead front.”) To Remove the Interior Cover: 1. Remove the three screws along the top of the enclosure (with one star washer). 2. Remove the three screws along the bottom of the enclosure (with one star washer). 3. Lift the front cover off the enclosure.
Installation Assembling DC Positive (+) Cable Plate (Bus Bar) NOTE: These instructions are not used with model GSLCPV1-120/240 and models GSLC175PV1-230. If using either of these models, proceed to page 21 or the next appropriate instruction. The bottom of each DC disconnect (circuit breaker) is bolted to a metal plate (bus bar) which receives the inverter’s positive (+) battery cables. To assemble the DC Positive Plate: 1.
Assembly Installing Inverter Positive Bus Bars The GSLC parts kit contains two bus bars, A and B, which attach to the tops of the DC disconnects. These bus bars make the connections with the Radian inverter’s positive DC terminals. Although they have similar shapes, the bus bars are not interchangeable. NOTE: B is not included with model GSLC175PV1-120/240 or model GSLC175PV1-230. When these models are in use, begin the instructions with step 2. A B B To assemble the Inverter Positive (+) Bus Bars: 1.
Installation Installing Inverter Main DC Disconnects To mount the inverter main DC disconnects: 1. If the negative top bar is installed, loosen or remove it. 2. Slide the disconnect assembly through the opening in the top of the GSLC and place it behind the premounted bracket. Center the disconnect assembly so that the raised area around the switch protrudes through the bracket. It may be necessary to hold the assembly in place by hand. 3.
Assembly Installing DC Shunts A single 500 Adc/50 mV shunt is included with the GSLC. Up to two more shunts can be installed as needed. These shunts are used in conjunction with the FLEXnet DC battery monitor. See page 31 for more instructions on wiring. To mount DC Shunts: 1. Four mounting holes are located to the lower left of the first shunt. Center each shunt across one pair of mounting holes. These should line up with the mounting holes built into each shunt. 2.
Installation Installing PV and AC Circuit Breakers and GFDI To mount circuit breakers: 1. It may be necessary to remove the knockout from the location where the circuit breaker is to be placed to make room for the circuit breaker to be installed. Be sure to remove any debris that may occur from removing the knockout. 2. Place each circuit breaker behind the premounted rail. Center the device so that the raised area around the switch protrudes through the bracket.
Assembly Mounting on the Inverter IMPORTANT: The Radian inverter and GSLC are intended for indoor use only. Ensure that the mounting surface is strong enough to support the full weight of the Radian inverter/charger and the GSLC. Use a minimum 3/4" (19 mm) sheet of plywood to strengthen the wall surface if required. To mount the GSLC to the Radian inverter: Bottom Screws 1. Install the Radian inverter on the mounting bracket.
Installation ...continued from the previous page. Bottom Screws Keyhole Slots Keyhole Slots 7. Realign the GSLC along the bottom of the inverter and slide the mounting screws into the keyhole slots. 8. Secure the enclosure to the mounting surface using all four mounting feet holes. 9. Using the bolts provided on the Radian inverter’s battery terminals, connect the terminals to the GSLC’s inverter bus bars. Tighten to the value shown in Table 1 on page 19.
Assembly Mounting FLEXmax Charge Controller The GSLC enclosure accommodates up to two FLEXmax charge controllers and a HUB Communications Manager. NOTE: The following instructions are for the FLEXmax 60 or FLEXmax 80 only. The FLEXmax Extreme charge controller connects directly to the wall and does not need additional brackets. To mount the FLEXmax Charge controller to the side of the GSLC enclosure: 1.
Installation Mounting the HUB Communications Manager The GSLC provides mounting holes to support a HUB Communications Manager. To mount the HUB Communications Manager to the side of the GSLC enclosure: 1. Locate the mounting holes on the side of the GSLC enclosure as shown in Figure 11 on page 16. 2. Remove the knockouts and add bushings. 3. Align the HUB (vertically) over the mounting holes with the HUB product’s ports facing forward. 4.
Wiring Wiring Table 2 Terminal Bus Bar (TBB) Wire Size and Torque Requirements Conductor Size AWG #14 – #10 #8 #6– #3 #2 #1 – 1/0 mm² 2.5 – 4 6 – 10 16 – 25 35 50 Torque Requirements In-lb 20 25 35 40 50 Nm 2.3 2.8 4.0 4.5 5.7 Grounding WARNING: Shock Hazard The unit must be connected to a permanent wiring system that is grounded according to the IEC 60364 TN standard. Make sure that no more than one bond is present in the AC system at any time.
Installation Bonding All GSLC models are equipped with a mechanical bond between AC neutral and ground. All models that do not include the GFDI are also equipped with a mechanical bond between DC negative and ground. These can be useful in stand-alone systems where no other bond is provided. If other bonds are present, or if the GFDI is installed later, the GSLC bonds need to be removed.
Wiring DC Wiring WARNING: Shock Hazard Ensure all circuit breakers or disconnect devices are turned off or disconnected before connecting any wires. CAUTION: Fire Hazard Never install extra washers or hardware between the mounting surface and the battery cable lug. When installing multiple ring terminals or lugs, stack them on the mounting surface so that the largest conductor is in direct contact. Smaller ring terminals should be placed next in decreasing size order.
Installation Battery Negative (–) Cable The battery negative (–) cables connect to the pre-installed shunt. This shunt is located to the upper left of the main inverter disconnect. It is designed for several ring lugs to be bolted to it, with openings of 3/8" (10 mm) diameter. See item C in Figure 28 for an illustration of hardware installation order on the shunt. The shunt plate (GS-SBUS) may or may not be present. NOTE: Do not install hardware in a different order from the illustrations in Figure 28.
Wiring Installing the FLEXnet DC The OutBack FLEXnet DC (FN-DC), or a similar battery monitor, may be added to the GSLC for observing DC current flow and providing battery state-of-charge information. HUB port Wiring block ` Figure 29 FN-DC and Wiring Block To install the FN-DC : 1. Assemble the FN-DC wiring as shown in the manual for the FN-DC. Mounting screws Attach sense wires to FN-DC wiring block and plug it into the FN-DC. Plug the CAT5 cable into the port labeled HUB. 2.
Installation DC Devices In addition to inverter or PV connections, other devices may be connected to the GSLC, such as DC loads or sources. The wiring on these devices will vary with the application. In most cases the device will have a separate circuit breaker which is mounted on the rail as shown on page 24. It will be wired into the battery system using the existing bus bars or shunts. The number and location of these connections will vary with the options or accessories installed.
Wiring Negative TBB Shunt DC Positive (+) cable plate (bus bar) GFDI PV Disconnect PV Positive (+) TBB ` Figure 31 PV Positive (+) PV Negative (–) PV Connections in the GSLC Battery Positive (+) PV+ PV– BAT– BAT+ Battery Negative (–) ` Figure 32 900-0123-01-00 Rev C PV Connections in the FLEXmax Charge Controller 35
Installation NOTES: 36 900-0123-01-00 Rev C
Wiring AC Wiring WARNING: Shock Hazard Ensure all circuit breakers or disconnect devices are turned off or disconnected before wiring. Make certain the inverter and other active devices are turned off or disabled before wiring. Split-Phase Wiring The GSLC can have multiple terminal bus bars for multiple AC connections. Because the Radian inverter possesses two sets of AC input connections and one set of output connections, up to three TBB sets are available.
Installation Bypass Assembly Bypass switching can be used when the inverter is shut down for maintenance. This topic is discussed more beginning on page 42. The GSLC can be equipped with the GS-IOB-120/240VAC bypass assembly. The instructions on this page are for making external connections to the bypass assembly after installation. (The installation wiring for the GS-IOB-120/240VAC is described on page 41.
Wiring Single-Phase Wiring The GSLC allows multiple terminal bus bars (TBB) for multiple AC connections. Because the Radian inverter possesses two sets of AC input connections and one set of output connections, three terminal bus bars are available for hot connections, as well as one neutral bus bar. The hot bus bars use brown insulators in 230 Vac models. The neutral bus bar uses blue insulators in 230 vac models. The TBB on the left is generally used for the inverter’s AC output connections.
Installation Bypass Assembly Bypass switching can be used when the inverter is shut down for maintenance. This topic is discussed more beginning on page 42. The GSLC can be equipped with the GS-IOB-230VAC bypass assembly. The instructions on this page are for making external connections to the bypass assembly after installation. (The installation wiring for the GS-IOB-230VAC is described on page 42.
Wiring Wiring the AC Bypass Assembly All models other than the “empty” GSLC are equipped with a maintenance bypass assembly. As needed, the GSLC can be equipped with a bypass assembly using the GS-IOB-120/240VAC or GS-IOB230VAC accessory kit as appropriate. The accessory kit should be installed according to its own instructions. Once installed, it can be wired by following the steps shown in Figure 37 or Figure 38 . The operation of the bypass assembly is discussed on page 42.
Installation To wire the GS-IOB-230VAC after installation: 1. 2. On the disconnect for the AC source that will be used during bypass, install a wire from the left side as shown by 1. Connect it to the input bypass switch as shown by 2. 4 Output Inverter Bypass 2 AC Source 1 3 Install a wire on the right side of the input bypass switch as shown by 3. Connect it to the right side of the output switch as shown by 4.
Wiring In Figure 39, when Switch 1 is on (normal operation), the inverter’s output sends power to the loads. Switch 2 is off, preventing the inverter from sending power back to the AC source (backfeeding). When Switch 2 is on (bypass operation), the AC source sends power directly to the loads. Switch 1 is off, removing the inverter’s output from the loads. This also prevents the AC source from backfeeding the inverter. With the inverter removed from the circuit, maintenance can be performed as necessary.
Installation External Bypass Device Input Wiring Output Wiring Inactive Radian Inverters AC Source 1 1 1 1 Figure 41 44 AC Loads GSLC Bypass Devices (must be removed if installed previously) Bypass Switching for Multiple Inverters (split-phase) 900-0123-01-00 Rev C
Wiring Wiring Diagrams This GSLC model has a neutral-ground bond and a negative-ground bond which are added during construction. They are not depicted here. The bonds can be removed if necessary. See page 30.
Installation This GSLC model has a neutral-ground bond which is added during construction. It is not depicted here. The bond can be removed if necessary. See page 28.
Wiring This GSLC model has a neutral-ground bond which is added during construction. It is not depicted here. The bond can be removed if necessary. See page 28.
Installation This GSLC model has a neutral-ground bond and a negative-ground bond which are added during construction. They are not depicted here. The bonds can be removed if necessary. See page 28.
Wiring This GSLC model has a neutral-ground bond which is added during construction. It is not depicted here. The bond can be removed if necessary. See page 28.
Installation This GSLC model has a neutral-ground bond which is added during construction. It is not depicted here. The bond can be removed if necessary. See page 28.
Electrical Specifications Table 3 Specifications Electrical Specifications Specification Measurement Maximum Input Voltage Maximum Input Current Operating Frequency Range 600 Volts 500 Amps 50/60 Hz to DC Mechanical Specifications Table 4 Mechanical Specifications Specification Measurement Dimensions (H x W x D) Shipping Dimensions (L x W x H) Weight Shipping Weight Enclosure Type 17" x 16" x 8.5" (43.2 cm x 40.6 cm x 21.6 cm) 23.25" x 20.5" x 13.25" (59.1 cm x 52.1 cm x 33.7 cm) 26 lb (11.
Specifications Definitions The following is a list of initials, terms, and definitions used in conjunction with this product. Table 5 Term AC 52 Terms and Definitions Definition Alternating Current; refers to voltage produced by the inverter, utility grid, or generator AUX One of several auxiliary outputs on the GS inverter/charger. CSA Canadian Standards Association; establishes Canadian national standards and the Canadian Electrical Code, including C22.1 and C22.
Index A AC Bypass Assembly ..................................... 38, 40, 41, 42 AC Circuit Breakers ............................................................. 24 AC Terminal Bus Bars ........................................................ 37 AC Wiring ........................................................................ 37, 45 120/240 Vac ............................................................. 37, 45 Additional Components .................................................. 17 AUX ...............
Index N Stacking Inverters ............................................................... 42 Negative-Ground Bonding ............................................. 30 Neutral-Ground Bonding ................................................ 30 T O Optional Hardware ............................................................ 17 P Positive Bus Hardware ............................................... 20, 21 PV Circuit Breakers ............................................................. 24 PV Wiring ....
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