Outback Power Systems GS Load Center Installation Instructions
GS Load Center
Installation Manual
Address:
Corporate Headquarters
Arlington, WA 98223 USA
European Office
Schwabach, Germany
Telephone:
+1.360.435.6030
+1.360.435.6019 (Fax)
+49.9122.79889.0
Email:
Support@outbackpower.com
Website:
http://www.outbackpower.com
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.
Grid/Hybrid™
As a leader in off-grid energy systems designed around energy storage, OutBack Power is an innovator in Grid/Hybrid system
technology, providing the best of both worlds: grid-tied system savings during normal or daylight operation, and off-grid
independence during peak energy times or in the event of a power outage or an emergency. Grid/Hybrid systems have the
intelligence, agility and interoperability to operate in multiple energy modes quickly, efficiently, and seamlessly, in order to
deliver clean, continuous and reliable power to residential and commercial users while maintaining grid stability.
Contact Information
17825 – 59th Avenue N.E.
Suite B
+1.360.618.4363 (Technical Support)
Hansastrasse 8
D-91126
+49.9122.79889.21 (Fax)
Disclaimer
UNLESS SPECIFICALLY AGREED TO IN WRITING, OUTBACK POWER TECHNOLOGIES:
(a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER
INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION.
(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER DIRECT, INDIRECT, CONSEQUENTIAL OR
INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE
ENTIRELY AT THE USER’S RISK.
OutBack Power Technologies cannot be responsible for system failure, damages, or injury resulting from improper
installation of their products.
Information included in this manual is subject to change without notice.
Notice of Copyright
GS Load Center Installation Manual © 2012 by OutBack Power Technologies. All Rights Reserved.
Trademarks
OutBack Power, the OutBack Power logo, FLEXpower ONE, and Grid/Hybrid are trademarks owned and used by OutBack
Power Technologies, Inc. The ALPHA logo and the phrase “member of the Alpha Group” are trademarks owned and used by
Alpha Technologies Inc. These trademarks may be registered in the United States and other countries.
Date and Revision
February 2014, Revision C
Part Number
900-0123-01-00 Rev C
Table of Contents
Introduction ......................................................................................................... 5
Welcome to OutBack Power Technologies ................................................................................................................. 5
GSLC – Components ........................................................................................................................................................... 7
GSLC175-120/240 – Components .................................................................................................................................. 8
GSLC175-230 – Components ........................................................................................................................................... 9
GSLC175-PV-120/240 – Components ........................................................................................................................ 10
GSLC175-PV-230 – Components ................................................................................................................................. 11
GSLC175PV1-120/240 – Components ....................................................................................................................... 12
GSLC175PV1-230 – Components ................................................................................................................................ 13
Planning ............................................................................................................ 15
Tools Required .................................................................................................................................................................... 15
Materials Required ............................................................................................................................................................ 15
Location/Environmental Requirements .................................................................................................................... 15
Installation ......................................................................................................... 17
Hardware Options ............................................................................................................................................................. 17
Remove Top Cover ............................................................................................................................................................ 18
Remove Front Door .......................................................................................................................................................... 18
Remove Interior Cover ..................................................................................................................................................... 19
Installing the Internal Hardware .................................................................................................................................. 19
Assembling DC Positive (+) Cable Plate (Bus Bar) .................................................................................................................. 20
Installing Inverter Positive Bus Bars ............................................................................................................................................. 21
Installing Inverter Main DC Disconnects ................................................................................................................................... 22
Installing DC Shunts .......................................................................................................................................................................... 23
Installing PV and AC Circuit Breakers and GFDI ...................................................................................................................... 24
Mounting on the Inverter .......................................................................................................................................................................... 25
Mounting FLEXmax Charge Controller ...................................................................................................................................... 27
Mounting the HUB Communications Manager ...................................................................................................................... 28
Wiring .................................................................................................................................................................................... 29
Grounding ............................................................................................................................................................................................. 29
Bonding ........................................................................................................................................................................................................... 30
DC Wiring ............................................................................................................................................................................................... 31
Inverter Wiring .............................................................................................................................................................................................. 31
Battery Wiring ............................................................................................................................................................................................... 31
Installing the FLEXnet DC .......................................................................................................................................................................... 33
DC Devices ..................................................................................................................................................................................................... 34
PV and Charge Controller Wiring ............................................................................................................................................................ 34
AC Wiring ............................................................................................................................................................................................... 37
Split-Phase Wiring ........................................................................................................................................................................................ 37
Single-Phase Wiring .................................................................................................................................................................................... 39
Wiring the AC Bypass Assembly .............................................................................................................................................................. 41
Multiple-Inverter Installations (Stacking Inverters) ........................................................................................................................... 42
Bypass Switches ............................................................................................................................................................................................ 42
Wiring Diagrams ................................................................................................................................................................................. 45
900-0123-01-00 Rev C 1
Table of Contents
Specifications ..................................................................................................... 51
Electrical Specifications ................................................................................................................................................... 51
Mechanical Specifications .............................................................................................................................................. 51
Regulatory Specifications ............................................................................................................................................... 51
Definitions ............................................................................................................................................................................ 52
Index ................................................................................................................. 53
List of Tables
Table 1 Size and Torque Requirements for Circuit Breakers and Bus Bars .................................... 19
Table 2 Terminal Bus Bar (TBB) Wire Size and Torque Requirements ............................................. 29
Table 3 Electrical Specifications ................................................................................................................... 51
Table 4 Mechanical Specifications .............................................................................................................. 51
Table 5 Terms and Definitions ..................................................................................................................... 52
List of Figures
Figure 1 GS Load Center (GSLC) ................................................................................................................. 5
Figure 2 GS Load Center with Devices ..................................................................................................... 6
Figure 3 GSLC Components ......................................................................................................................... 7
Figure 4 GSLC175-120/240 Components ................................................................................................ 8
Figure 5 GSLC175-230 Components ......................................................................................................... 9
Figure 6 GSLC175-PV-120/240 Components ....................................................................................... 10
Figure 7 GSLC175-PV-230 Components ................................................................................................ 11
Figure 8 GSLC175PV1-120/240 Components ...................................................................................... 12
Figure 9 GSLC175PV1-230 Components ............................................................................................... 13
Figure 10 Dimensions ..................................................................................................................................... 15
Figure 11 Knockouts and Mounting Holesfor Devices ....................................................................... 16
Figure 12 GSLC – Additional Components .............................................................................................. 17
Figure 13 GSLC175-120/240 and GSLC175-230 – Additional Components ................................ 17
Figure 14 Removing the Top Cover from the GSLC ............................................................................. 18
Figure 15 Removing the Front Door from the GSLC ............................................................................ 18
Figure 16 Removing the Interior Cover from the GSLC ...................................................................... 19
Figure 17 DC Positive Cable Plate (FW-BBUS) ........................................................................................ 19
Figure 18 Assembling the DC Positive (+) Cable Plate ........................................................................ 20
Figure 19 Inverter Bus Bars ........................................................................................................................... 21
Figure 20 Inverter Main DC Disconnects .................................................................................................. 22
Figure 21 DC Shunts ....................................................................................................................................... 23
Figure 22 Circuit Breakers ............................................................................................................................. 24
Figure 23 Mounting the GSLC ..................................................................................................................... 25
Figure 24 Mounting the Charge Controller to the GSLC Enclosure ................................................ 27
Figure 25 Mounting the HUB Product to the GSLC Enclosure .......................................................... 28
Figure 26 Grounding....................................................................................................................................... 29
Figure 27 Removing Bonding Connections ............................................................................................ 30
Figure 28 Battery Connections .................................................................................................................... 32
2 900-0123-01-00 Rev C
Table of Contents
Figure 29 FN-DC and Wiring Block ............................................................................................................. 33
Figure 30 Installing the FLEXnet DC .......................................................................................................... 33
Figure 31 PV Connections in the GSLC ..................................................................................................... 35
Figure 32 PV Connections in the FLEXmax Charge Controller ......................................................... 35
Figure 33 AC Terminal Bus Bars (split-phase) ......................................................................................... 37
Figure 34 Inverter AC Connections (split-phase) .................................................................................. 38
Figure 35 AC Terminal Bus Bars (single-phase) ...................................................................................... 39
Figure 36 Inverter AC Connections (single-phase) ............................................................................... 40
Figure 37 Maintenance Bypass Wiring (split-phase) ............................................................................ 41
Figure 38 Maintenance Bypass Wiring (single-phase)......................................................................... 42
Figure 39 Bypass Switches ............................................................................................................................ 43
Figure 40 OutBack Bypass (split-phase) ................................................................................................... 43
Figure 41 Bypass Switching for Multiple Inverters (split-phase) ...................................................... 44
Figure 42 Wiring Diagram – GSLC175-120/240 ..................................................................................... 45
Figure 43 Wiring Diagram – GSLC175-PV-120/240 with FNDC ........................................................ 46
Figure 44 Wiring Diagram – GSLC175PV1-120/240 with FNDC ....................................................... 47
Figure 45 Wiring Diagram – GSLC175-230 .............................................................................................. 48
Figure 46 Wiring Diagram – GSLC175-PV-230 with FNDC ................................................................. 49
Figure 47 Wiring Diagram – GSLC175PV1-230 with FNDC ................................................................ 50
900-0123-01-00 Rev C 3
Table of Contents
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4 900-0123-01-00 Rev C
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.
Figure 1 GS Load Center (GSLC)
The product is designed in the following configurations:
900-0123-01-00 Rev C 5
– GS Load Center for Radian Series. Recommended for custom-built systems. Recommended for use
GSLC
with multiple Radian inverters (one GSLC per inverter). Can be used with other inverter models. The term
“GSLC” is also used to refer generically to the product line.
Intended for any Radian model.
∼
GSLC175-120/240
inverter circuit breakers, dual AC inputs, and 120/240 Vac maintenance bypass assembly. Recommended for
systems which have a single Radian inverter and an AC source, but can be customized in other ways.
Intended for Radian models GS8048 and GS8048A.
∼
GSLC175-230
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.
Intended for Radian model GS7048E.
∼
– GS Load Center for AC applications (split-phase). Factory-prepared with dual 175 Adc
– GS Load Center for AC applications (single-phase). Factory-prepared with dual 175 Adc
Introduction
The enclosure provides mounting holes for the HUB Communications Manager on the left.
Manual for more information.
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.
Intended for Radian models GS8048 and GS8048A.
∼
GSLC175-PV-230
inverter circuit breakers, dual AC inputs, 230 Vac maintenance bypass assembly, PV GFDI, 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.
Intended for Radian model GS7048E.
∼
GSLC175PV1-120/240
inverter circuit breaker, dual AC inputs, 120/240 Vac maintenance bypass assembly, PV GFDI, one PV array input,
FLEXnet DC battery monitor, and two shunts. Intended as a “plug-and-play” solution for systems with a single inverter,
one FLEXmax charge controller, and battery monitoring.
Intended for Radian model GS4048A.
∼
GSLC175PV1-230
inverter circuit breakers, dual AC inputs, 230 Vac maintenance bypass assembly, PV GFDI, one PV array input, FLEXnet DC
battery monitor, and two shunts. Intended as a “plug-and-play” solution for systems with a single inverter, one FLEXmax
charge controller, and battery monitoring.
Intended for Radian model GS3548E.
– GS Load Center for PV and AC applications (single-phase). Factory-prepared with dual 175 Adc
— GS Load Center for PV and AC applications (split-phase). Factory-prepared with one 175 Adc
— GS Load Center for PV and AC applications (single-phase). Factory-prepared with one 175 Adc
On the right, the enclosure has mounting holes for brackets to mount up to two FLEXmax charge controllers.
NOTE: OutBack FLEXmax Extreme charge controllers do not mount directly to the GSLC and do not require
additional mounting brackets. They are mounted beside the inverter or the GSLC. See the Radian Series Installation
Figure 2 GS Load Center with Devices
6 900-0123-01-00 Rev C
Introduction
GSLC – Components
Inverter Negative (–) DC Bus Bars
NOTE: The installed Neutral TBB has white insulators
Legend
Negative (–) Terminal Bus Bar (TBB-WHITE)
Ground TBB (TBB-GROUND)
Neutral TBB (TBB-WHITE)
PV Positive (+) TBB (TBB-RED)
Shunt (FW-SHUNT500)
(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.
900-0123-01-00 Rev C 7
Figure 3 GSLC Components
Introduction
GSLC175-120/240 – Components
Inverter Negative (–) DC Bus Bar
Inverter Positive (+) DC Bus Bar
Legend
12
11
1
2
3 4 5 6 7
8
9
101413
NOTE: The factory wiring has been omitted from this illustration for clarity.
Negative (–) Terminal Bus Bar (TBB-WHITE)
Ground TBB (TBB-GROUND)
Neutral TBB (TBB-WHITE)
PV Positive (+) TBB (TBB-RED)
DC Positive (+) Cable Plate (FW-BBUS)
Main Inverter Disconnect(s) (PNL-175-DC)
Shunt (FW-SHUNT500)
AC Input Circuit Breakers (PNL-50D-AC-120/240V)
Maintenance Bypass Interlock
AC TBB (Inverter Output) L1, L2 (STBB-RED or BLACK)
AC TBB (Grid) L1, L2 (STBB-RED or BLACK)
AC TBB (Generator) L1, L2 (STBB-RED or BLACK)
8 900-0123-01-00 Rev C
Figure 4 GSLC175-120/240 Components
Introduction
GSLC175-230 – Components
Inverter Negative (–) DC Bus Bar
Main Inverter Disconnect(s) (PNL-175-DC)
Inverter Positive (+) DC Bus Bar
Legend
12
11
1
2 3 4
5 6 7 8 9
10
14
13
NOTE:
Negative (–) Terminal Bus Bar (TBB-WHITE)
Ground TBB (TBB-GROUND)
Neutral TBB (TBB-BLUE)
PV Positive (+) TBB (TBB-RED)
DC Positive (+) Cable Plate (FW-BBUS)
Shunt (FW-SHUNT500)
AC Input Circuit Breakers (PNL-50-AC-230V)
Maintenance Bypass Interlock
AC TBB (Inverter Output) (TBB-BROWN)
AC TBB (Grid) (TBB-BROWN)
AC TBB (Generator) (TBB-BROWN)
900-0123-01-00 Rev C 9
The factory wiring has been omitted from this illustration for clarity.
Figure 5 GSLC175-230 Components
Introduction
GSLC175-PV-120/240 – Components
Inverter Negative (–) DC Bus Bar
Legend
NOTE:
1 2 3
4
5 6 7
8
9
AC Input Circuit Breakers (PNL-50D-AC-120/240V)
12111014131615
18
17
Negative (–) Terminal Bus Bar (TBB-WHITE)
Ground TBB (TBB-GROUND)
Neutral TBB (TBB-WHITE)
PV Positive (+) TBB (TBB-RED)
DC Positive (+) Cable Plate (FW-BBUS)
Main Inverter Disconnect(s) (PNL-175-DC)
Inverter Positive (+) DC Bus Bar
Shunt (FW-SHUNT500)
Maintenance Bypass Interlock
AC TBB (Inverter Output) L1, L2 (STBB-RED or BLACK)
AC TBB (Grid) L1, L2 (STBB-RED or BLACK)
AC TBB (Generator) L1, L2 (STBB-RED or BLACK)
PV Input Disconnects (PNL-80-DC)
Shunt Bus (GS-SBUS)
Battery Monitor (FN-DC)
PV Ground Fault Detector/Interrupter
(PNL-GFDI-80D)
Figure 6 GSLC175-PV-120/240 Components
10 900-0123-01-00 Rev C
The factory wiring has been omitted from this illustration for clarity.
Introduction
GSLC175-PV-230 – Components
Inverter Negative (–) DC Bus Bar
Legend
NOTE:
1 2 3 4 5
6 7 8
9
AC Input Circuit Breakers (PNL-50-AC-230V)
(PNL-GFDI-80D)
121110
141316
15
18
17
Negative (–) Terminal Bus Bar (TBB-WHITE)
Ground TBB (TBB-GROUND)
Neutral TBB (TBB-BLUE)
PV Positive (+) TBB (TBB-RED)
DC Positive (+) Cable Plate (FW-BBUS)
Main Inverter Disconnect(s) (PNL-175-DC)
Inverter Positive (+) DC Bus Bar
Shunt (FW-SHUNT500)
Maintenance Bypass Interlock
AC TBB (Inverter Output) (TBB-BROWN)
AC TBB (Grid) (TBB-BROWN)
AC TBB (Generator) (TBB-BROWN)
PV Input Disconnects (PNL-80-DC)
Shunt Bus (GS-SBUS)
Battery Monitor (FN-DC)
PV Ground Fault Detector/Interrupter
900-0123-01-00 Rev C 11
The factory wiring has been omitted from this illustration for clarity.
Figure 7 GSLC175-PV-230 Components
Introduction
GSLC175PV1-120/240 – Components
Inverter Negative (–) DC Bus Bar
Legend
NOTE:
1 2 3
4
5 6 7
8
9
Maintenance Bypass Interlock
12111014131615
17
Negative (–) Terminal Bus Bar (TBB-WHITE)
Ground TBB (TBB-GROUND)
Neutral TBB (TBB-WHITE)
PV Positive (+) TBB (TBB-RED)
Main Inverter Disconnect (PNL-175-DC)
Inverter Positive (+) DC Bus Bar
Shunt (FW-SHUNT500)
AC Input Circuit Breakers (PNL-50D-AC-120/240V)
AC TBB (Inverter Output) L1, L2 (STBB-RED or BLACK)
AC TBB (Grid) L1, L2 (STBB-RED or BLACK)
AC TBB (Generator) L1, L2 (STBB-RED or BLACK)
PV Input Disconnect (PNL-80-DC)
Shunt Bus (GS-SBUS)
Battery Monitor (FN-DC)
PV Ground Fault Detector/Interrupter
(PNL-GFDI-80)
12 900-0123-01-00 Rev C
The factory wiring has been omitted from this illustration for clarity.
Figure 8 GSLC175PV1-120/240 Components
Introduction
GSLC175PV1-230 – Components
Inverter Negative (–) DC Bus Bar
Legend
NOTE:
1 2 3
4
5 6 7
8
9
Maintenance Bypass Interlock
12111014131615
17
Negative (–) Terminal Bus Bar (TBB-WHITE)
Ground TBB (TBB-GROUND)
Neutral TBB (TBB-WHITE)
PV Positive (+) TBB (TBB-RED)
Main Inverter Disconnect (PNL-175-DC)
Inverter Positive (+) DC Bus Bar
Shunt (FW-SHUNT500)
AC Input Circuit Breakers (PNL-50-AC-230V)
AC TBB (Inverter Output) (TBB-BROWN)
AC TBB (Grid) (TBB-BROWN)
AC TBB (Generator) (TBB-BROWN)
PV Input Disconnect (PNL-80-DC)
Shunt Bus (GS-SBUS)
Battery Monitor (FN-DC)
PV Ground Fault Detector/Interrupter
(PNL-GFDI-80D)
900-0123-01-00 Rev C 13
The factory wiring has been omitted from this illustration for clarity.
Figure 9 GSLC175PV1-230 Components
Introduction
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14 900-0123-01-00 Rev C
Planning
8½" (21.6 cm) deep
Side View
17"
high
16" (40.6 cm) wide
Front View
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
(43.2 cm)
Figure 10 Dimensions
900-0123-01-00 Rev C 15
Planning
Legend
Mounting holes for FW-CCB
and FW-CCB2 brackets
2” or 63 mm
1¼” or 40 mm
½” or 20 mm
1½” or 50 mm
1” or 32 mm
1
2 3 4
5
Top View
1
1
4 4 7
8
Cable Knockouts
Mounting holes for HUB product
Side View
4
4 7 4
Side View
4
4
8 8 4 4 1 5 7
4
4
1 4 4 5 1
8 8 1
Bottom View
4 4 1 1 2 3 3
4
3 5 5
(U.S. Trade Size or Metric Trade Size)
16 900-0123-01-00 Rev C
Figure 11 Knockouts and Mounting Holesfor Devices
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