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 Audience ................................................................................................................................... 6 Symbols Used ........................................................................................................................... 6 General Safety .......................................................................................................................... 6 Introduction ..........................................................
Table of Contents Specifications .................................................................................... 59 Electrical and Mechanical Specifications ................................................................................ 59 Regulatory Specifications ....................................................................................................... 59 Definitions .........................................................................................................................
Table of Contents 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 Figure 48 Figure 49 Figure 50 Figure 51 PV Connections in the GSLC................................................................... 39 PV Connections in the FLEXmax Charge Controller ............................... 39 AC Terminal Bus Bars (split-phase) .........................................................
Table of Contents Audience This book provides instructions for the functional settings and operation of this product. These instructions are for use by qualified personnel who meet all local and governmental code requirements for licensing and training for the installation of electrical power systems with AC and DC voltage up to 600 volts. This product is only serviceable by qualified personnel. Do not use this product without reading the appropriate Radian inverter/charger literature.
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 o GSLC175-230 – GS Load Center for AC applications (single-phase). Factory-prepared with dual 175 Adc inverter circuit breakers, dual AC inputs, and 230 Vac maintenance bypass assembly. Recommended for systems which have a single Radian inverter and an AC source, but can be customized in other ways. o GSLC175-PV-120/240 – GS Load Center for PV and AC applications (split-phase).
Introduction o GSLCPV1-300VDC-230 — GS Load Center for PV and AC applications (single-phase). Factoryprepared with one 175 Adc inverter circuit breaker, dual AC inputs, 230 Vac maintenance bypass assembly, one PV array input, FLEXnet DC battery monitor, and two shunts. Intended as a “plugand-play” solution for systems with a single inverter, one FLEXmax 100 charge controller, and battery monitoring. Intended for Radian model GS3548E and 300 Vdc charge controllers.
Introduction GSLC – Components Legend 1 Inverter Negative (–) DC Bus Bars 2 Negative (–) Terminal Bus Bar (TBB-WHITE) 3 Ground TBB (TBB-GROUND) 4 Neutral TBB (TBB-WHITE) 5 PV Positive (+) TBB (TBB-RED) 6 Shunt (FW-SHUNT500) 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.
Introduction GSLC175-120/240 – Components Legend 11 Inverter Negative (–) DC Bus Bar 8 Inverter Positive (+) DC Bus Bar 22 Negative (–) Terminal Bus Bar (TBB-WHITE) 9 Shunt (FW-SHUNT500) 33 Ground TBB (TBB-GROUND) 10 10 AC Input Circuit Breakers (PNL-50D-AC-120/240V) 4 4 Neutral TBB (TBB-WHITE) 11 11 Maintenance Bypass Interlock 55 PV Positive (+) TBB (TBB-RED) 12 12 AC TBB (Inverter Output) L1, L2 (STBB-RED or BLACK) 66 DC Positive (+) Cable Plate (FW-BBUS) 13 13 AC TBB (Grid) L1, L
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 and GSLC-PV-300VDC – 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 P
Introduction GSLC175-PV-230 and GSLC-PV-300VDC-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
Introduction GSLC175PV1-120/240 and GSLC-PV1-300VDC – 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 or PNL-80-300VDC) 6 Main Inverter Disconn
Introduction GSLC175PV1-230 and GSLCPV1-300VDC-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 or PNL-80-300VDC) 6 Main Inverter Disconnect (PNL-175-DC) 15 Shunt Bus (GS-SBUS) 7
Planning Tools Required o Open-ended wrenches (7/16”, 9/16" and 13 mm) o Wire cutters/strippers o Torque wrenches o Assorted insulated screwdrivers o Digital Voltmeter (DVM) or regular voltmeter Materials Required o Conductors for wiring o Conduits Location/Environmental Requirements o Indoor mount only Side View Front View 8½" (21.6 cm) 16" (40.6 cm) 17" (43.
Planning Legend Cable Knockouts (U.S.
Installation Hardware Options Different versions of the GSLC come with different components already installed. o GSLC, the “basic” or “empty” version, requires almost all components to be installed if they are needed. Instructions for this product begin on page 22. o 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 The following components are sold separately for the GSLC175-120/240 and GSLC175-230: o o o o PV Ground Fault Detector-Interrupter (GFDI) FLEXnet DC Battery Monitor (FN-DC); see page 37 Additional DC shunts and GS-SBUS PV Disconnect 80-amp circuit breaker (PNL-80-DC) Figure 13 GSLC175-120/240 and GSLC175-230 – Additional Components Remove Top Cover To Remove the Top Cover: 1. Remove the four screws; one in each corner. 2. Lift the top off the enclosure.
Assembly 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. Open to 90 degrees (shown partly open) Figure 15 Removing the Front Door from the GSLC Remove Interior Cover In order to make any wiring connections or to install components, the interior cover must be removed to expose the enclosure interior. (This cover is sometimes called the “dead front.”) To Remove the Interior Cover: 1.
Installation Installing the Internal Hardware Table 1 Requirements for Circuit Breakers and Bus Bars Item Terminal/Bolt Size Torque Requirements Inverter Positive (+) Bus Bars M8 60 in-lb (6.8 Nm) Shunt Bolts 3/8" 60 in-lb (6.8 Nm) DC Positive (+) Cable Plate Top Holes (x3) 60 in-lb (6.8 Nm) Bottom Holes (x7) 50 in-lb (5.7 Nm) M8 20 in-lb (2.3 Nm) 1/4" 35 in-lb (4.0 Nm) 5/16" 50 in-lb (5.7 Nm) 3/8" 225 in-lb (25.5 Nm) Circuit Breaker Studs Top Holes 0.5" (12.7 mm) 0.
Assembly Assembling DC Positive (+) Cable Plate (Bus Bar) NOTE: These instructions are not used with models GSLC175PV1-120/240, GSLC175PV1230, GSLC-PV1-300VDC, or GSLCPV1-300VDC-230. If using any of these models, proceed to page 24 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.
Installation Installing Inverter Positive Bus Bars The GSLC parts kit contains two bus bars, A and B, which attach to the top of each DC disconnect. 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: Item B is not included with models GSLC175PV1-120/240, GSLC175PV1-230, GSLC-PV1-300VDC, or GSLCPV1-300VDC-230. When these models are in use, begin the instructions with step 2.
Assembly 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.
Installation 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 35 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.
Assembly Installing 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. It may be necessary to hold the device in place by hand.
Installation Mounting on the Inverter IMPORTANT: The Radian inverter and GSLC are intended for indoor use only. Ensure 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: 1. Install the inverter on the mounting bracket. Remove knockouts from the bottom of the inverter if necessary and install bushings. 2.
Assembly ...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 22.
Installation 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 100 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.
Assembly 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 18. 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. Insert the mounting screws from the outside into the GSLC enclosure.
Installation NOTES: 32 900-0123-01-01 Rev A
Wiring Wiring IMPORTANT: 300 Vdc models require wiring rated for 90°C or greater. Table 2 Terminal Bus Bar (TBB) Wire Size and Torque Requirements Conductor Size AWG mm² #14 – #10 2.5 – 4 #8 6 – 10 #6– #3 16 – 25 #2 35 #1 – 1/0 50 Torque Requirements In-lb Nm 20 2.3 25 2.8 35 4.0 40 4.5 50 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.
Installation Bonding All GSLC models, including those in prewired applications, are equipped with a mechanical bond between AC neutral and ground. Some models are 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 a GFDI is installed later, the GSLC bond needs 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. o Attach sense wires to the FN-DC wiring block and plug it into the FN-DC. o Plug the CAT5 cable into the port labeled HUB.
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 that is mounted on the rail as shown on page 27. 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) Charge Controller PV Disconnect PV Positive (+) TBB ` Figure 31 PV Positive (+) PV Negative (–) PV Connections in the GSLC Battery Positive (+) PV+ PV– BAT– BAT+ Battery Negative (–) Ground ` Figure 32 900-0123-01-01 Rev A PV Connections in the FLEXmax Charge Controller 39
Installation NOTES: 40 900-0123-01-01 Rev A
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 47. The GSLC can be equipped with the GS-IOB120/240VAC bypass assembly. The instructions on this page are for making external connections to the bypass assembly after installation. (The installation wiring for the GS-IOB120/240VAC is described on page 45.
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 47. 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 47.
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-IOB-230VAC 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 47.
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. Output 4 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 Bypass Switches Inverter systems are often equipped with maintenance bypass switches or interlocks. If the inverter system ever needs to be shut down or removed, its AC sources and loads must be disconnected. A bypass device allows the AC source to “bypass” the inverter and deliver power directly to the loads. This can minimize disruption to the system and it avoids the need for extensive rewiring.
Installation IMPORTANT: If multiple Radian inverters are stacked in a single system, these devices cannot be used. The bypass function must be simultaneous for all inverters. The GSLC bypass kits operate independently, not simultaneously. In a new system with multiple Radian inverters, the basic GSLC should be used in conjunction with an external assembly of this kind, as shown in Figure 41. The GS-IOB kits should not be installed, or if previously installed, should be removed and all wires disconnected.
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 34.
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 34.
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 34.
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 34.
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 34.
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 34.
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 34.
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 34.
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 34.
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 34.
Specifications Electrical and Mechanical Specifications Table 3 Specifications Specification Measurement Maximum Voltages 240 Vac and 300 Vdc Maximum Continuous Currents 40 Aac and 100 Adc Operating Frequency Range 50/60 Hz or DC Temperature Range –20 to 50°C Dimensions (H x W x D) 17 x 16 x 8.5" (43.2 × 40.6 × 21.6 cm) Shipping Dimensions (L x W x H) 23.25 x 20.5 x 13.25" (59.1 × 52.1 × 33.7 cm) Weight 26 lb (11.8 kg) minimum — varies with options Shipping Weight 34 lb (15.
Specifications Definitions The following is a list of initials, terms, and definitions used in conjunction with this product. Table 4 Term AC CSA DC DVM FN-DC GFDI 60 Terms and Definitions Definition Alternating Current; refers to voltage produced by the inverter, utility grid, or generator Canadian Standards Association; establishes Canadian national standards and the Canadian Electrical Code, including C22.1 and C22.
Index A AC Bypass Assembly .....................42, 44, 45, 47 AC Circuit Breakers.......................................... 27 AC Terminal Bus Bars................................41, 43 AC Wiring 120/240 Vac .................. 41, 49, 50, 51, 52, 53 230 Vac ......................... 43, 54, 55, 56, 57, 58 Additional Components .................................... 19 Audience ............................................................ 6 AUX ..................................................................
Index N Stacking Inverters ............................................ 46 Symbols Used .................................................... 6 Negative-Ground Bonding................................ 34 Neutral-Ground Bonding .................................. 34 Note Symbol ....................................................... 6 T O Optional Hardware ........................................... 19 Terms and Definitions ...................................... 60 Tools Required..........................
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