OutBack Power FLEXWare FLEXmax 100 Manual de usuario
FLEXware FLEXmax 100
Rapid Shutdown Solution
Owner’s 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.
Contact Information
Address: Corporate Headquarters
17825 – 59th Avenue N.E.
Suite B
Arlington, WA 98223 USA
Website: http://www.outbackpower.com
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
FLEXware FLEXmax 100 Rapid Shutdown Solution Owner’s Manual © 2018 by OutBack Power Technologies.
All Rights Reserved.
Trademarks
OutBack Power, FLEXware, FLEXmax, and the OutBack Power logo 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
October 2018, Revision A
Part Number
900-0239-01-00 Rev A
900-0239-01-00 Rev A 3
Table of Contents
Symbols Used ........................................................................................................................... 4
General Safety .......................................................................................................................... 4
Introduction ..................................................................................................5
Audience ................................................................................................................................... 5
Welcome to OutBack Power Technologies ............................................................................... 5
Product Overview ...................................................................................................................... 5
Features ............................................................................................................................................... 5
Components ......................................................................................................................................... 5
Components .............................................................................................................................. 7
Combiner .............................................................................................................................................. 7
RSI ........................................................................................................................................................ 8
Functions.....................................................................................................9
Arc Fault Circuit Interruption ..................................................................................................... 9
Detection .............................................................................................................................................. 9
Reset .................................................................................................................................................... 9
Arc Fault Self-Test .............................................................................................................................. 10
Rapid Shutdown ...................................................................................................................... 10
Rapid Shutdown Self-Test .................................................................................................................. 10
Verification .......................................................................................................................................... 10
PV Combiner Disconnect ................................................................................................................... 10
Installation .................................................................................................11
Mounting Information .............................................................................................................. 11
Surge Protector .................................................................................................................................. 11
Connection Information ........................................................................................................... 12
Troubleshooting ..........................................................................................15
LED Indicators ........................................................................................................................ 15
Basic Troubleshooting ............................................................................................................ 15
Specifications .............................................................................................17
Device Specifications .............................................................................................................. 17
Regulatory Specifications ....................................................................................................... 18
Listings ............................................................................................................................................... 18
Compliance ......................................................................................................................................... 18
Definitions ............................................................................................................................... 19
Important Safety Instructions
4
900-0239-01-00 Rev A
READ AND SAVE THESE INSTRUCTIONS!
This manual contains important safety instructions for the Rapid Shutdown Solution product.
Symbols Used
WARNING: Hazard to Human Life
This type of notation indicates that the hazard could be harmful to human life.
CAUTION: Hazard to Equipment
This type of notation indicates that the hazard may cause damage to
the equipment.
IMPORTANT:
This type of notation indicates that the information provided is important to the
installation, operation and/or maintenance of the equipment. Failure to follow the
recommendations in such a notation could result in voiding the
equipment warranty.
NOTE:
This type of notation indicates that the information provided is important to
understanding the operation and limits of the equipment. Failure to follow the
recommendations in such a notation could result in improper or failed operation.
MORE INFORMATION
When this symbol appears next to text, it means that more information is available in other manuals
relating to the subject. The most common reference is to the FLEXware FLEXmax 100 Rapid
Shutdown Solution Quick Start Guide.
General Safety
WARNING: Limitations on Use
This equipment is NOT intended for use with life support equipment or other
medical equipment or devices.
WARNING: Reduced Protection
If this product is used in a manner not specified by product literature, the product’s
internal safety protection may be impaired.
CAUTION: Equipment Damage
Only use components or accessories recommended or sold by OutBack Power
Technologies or its authorized agents.
900-0239-01-00 Rev A 5
Introduction
Audience
This manual provides instructions for installation, setup, and operation of the 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.
Welcome to OutBack Power Technologies
Thank you for purchasing the FLEXware FLEXmax 100 Rapid Shutdown Solution (RSD-AFCI).
This product is intended to work in conjunction with the FLEXmax 100 charge controller.
It allows a system to meet the 2014 National Electric Code requirements for PV systems.
o NEC 690.12 — Rapid shutdown (allows first responders to safely de-energize controlled conductors)
o NEC 690.15 — DC combiner disconnect (opens all ungrounded circuit conductors from all energy sources)
Product Overview
Features
o End-to-end solution listed to UL1741 with PV rapid shutdown equipment (PVRSE)
o Arc fault circuit interrupter (AFCI) listed to UL1699B with local and remote indication
o Type 3R enclosures rated for indoor or outdoor installation
o Flexible design — install the combiner box vertically, horizontally, or at any intermediate angle;
mount to racking or under the PV array
o Interoperability with compatible third-party PVRSE with a dry contact input
o Combiner box has removable component panel for ease of wire management and for serviceability
o Combiner box has easy-to-install DIN-mount fuses for bi-directional overcurrent protection
o Lockable disconnects on combiner and rapid shutdown boxes
o Communications use building wire commonly available in the field (THHN/THWN-2)
o Ground lug and grounding terminal bus bar for system and equipment grounding
o Internal factory prewiring to save time during installation
Components
The primary component in the RSD-AFCI system is the DC combiner box. This combines up to
six PV source circuits and provides an overcurrent protective device (OCPD) for each circuit.
The combiner provides a local disconnecting means. It also provides a contactor for PV rapid
shutdown functionality to de-energize PV circuits within 10 feet of the PV array.
The other main component is the Rapid Shutdown Initiator (RSI) which works with the combiner
to induce the rapid shutdown function. To power the RSI, an isolated Class 2 DC power supply
(24 Vdc ± 3%, up to 1.5 Adc) must be used.
Introduction
6
900-0239-01-00 Rev A
Figure 1 Example of Residence with RSD-AFCI
Fuses
Contactors
PV Arra
y
≤10 Feet
Utility
Meter
Combiner
RSI
Radian
Battery Bank
oCombiner Box
Contains OCPD, AFCI, main contactors, PV combiner disconnect
Includes local disconnect to de-energize PV circuits within 10 feet of the array (required
distance may vary with local code requirements)
oRapid Shutdown Initiator (RSI)
Contains control circuit for PVRSE
Includes PVRSE disconnect switch
Includes LED indicators for PV connection or disconnection
HOUSE EXTERIOR
HOUSE INTERIOR
ROOF
FM100
AFCI
Introduction
900-0239-01-00 Rev A 7
Components
Combiner
Figure 2 Components of Combiner Box
1
Gasketed Door/
Type 3R
Enclosure
Protects from the
environment 12 Ground Cable
T
erminal
Provides “lay-in” lug for
optional pass-through
ground wire
2
Component
Panel
(Removable)
For ease of wire management
and for serviceability 13 Fuse
Holders
PV source overcurrent
protection; fuses provided
by user
3 Bidirectional PV
Contacto
r
Opens PV circuits for local
disconnect or rapid shutdown 14
Combiner
Control
Board
Controls all functions within
the combiner; commands
the contactor
4 Ground Terminal
Bus Ba
r
Provides a means for system
and equipment grounding 15 Arc Fault
Self-Test Button
Allows AFCI to be tested without
opening the combiner box
5 Negative
T
erminal Bus Ba
r
Combines negative PV
source circuits 16 PV Input
Connections
Connections for positive PV
source circuits
6 PV Positive
Output Terminal
Connection on contactor for
PV positive output circuit 17 Communications
Terminals
Communicates with RSI and
additional combiner boxes
7 Internal
Prewiring
Factory-installed for ease of
installation 18 AFCI
ANNUNCIATOR
Illuminates during an arc fault
event or test
8
PV
Combiner
Disconnect
Activates the contactor for
disconnection; can be
padlocked in the OFF position
19 2” EKO
(PV Output)
Accommodates conduit and a
UL 514-compliant fitting for
PV output circuits
9
A
rc Fault
Detection Device
Detects series DC
arc fault events 20 Cable Glands
(PV Input)
Provide waterproof strain relief
for PV source circuits
10 Secu
r
e
Latch
Fastens door;
can be padlocked 21 ½” EKO
(optional)
For installation of a third-party
surge protection device
(provided by user)
11 Securing
Scre
w
Secures door in place if
padlock is not used 22
½” and ¾”
(2 ea) EKO
(Communications)
Accommodate conduit and a
UL 514-compliant fitting for
communication wires
NOTE: All external wires are provided by installer
1
2 3
4 5
6 7 8
11
8
10
13 14
16 17 18
12
9
10
15 15
22
20
19 21
18
Introduction
8
900-0239-01-00 Rev A
RSI
Figure 3 Components of RSI
1 Rapid Shutdown switch Initiates the PV Rapid Shutdown function; disconnects main
contactor in combiner.
2 SOLAR ON indicator Green LED indicator; illuminates when DC voltage is present and
Rapid Shutdown switch is in the ON position.
3 SOLAR OFF indicator
Red LED indicator. SOLAR OFF must be illuminated to confirm PV
shutdown. This indicator tells responders that the Rapid Shutdown
switch is in the OFF position to create a “safe” condition.
4 AFCI indicator Red LED indicator; illuminates when receiving an “arc fault” signal
from the combiner.
5 ½” (3) EKO These accommodate conduit and a UL 514-compliant fitting for
communication wires
NOTE:
SOLAR ON does not necessarily indicate that the PV system is active.
See the Troubleshooting section on page 15.
1
5
2 3
5
4
4
5
900-0239-01-00 Rev A
9
Functions
Arc Fault Circuit Interruption
In a PV system, an electrical arc occurs when current bridges a gap between conductive
surfaces. Gaps can occur due to conductor damage, or can be caused by inadequate
system connections.
An “arc fault” is a safety concern for several reasons:
o
Risk of electric shock if the mounting system or other components become electrified.
o Fire hazard due to heat buildup from the current flow.
A series arc occurs across open connections in a single conductor. A parallel arc occurs if the
current bridges multiple conductors that were meant to remain separate. The arc fault circuit
interrupter (AFCI) in the combiner is intended to protect against series arcs.
Detection
The combiner has a dedicated arc fault detection device. The device operates by detecting the
distinct electrical noise created by an arc. The detector has two current transducers, each of
which monitors up to three PV circuits. If an arc is detected, the detector sends a signal to the
main control board in the combiner box.
o
The control board sends a signal to open the combiner’s main contactor. The A
FCI
A
NNUNCIATOR
turns on.
o The control board also sends a signal to the RSI and turns on the A
FCI
indicator.
NOTES:
This is a simple alarm indicating that an arc fault has occurred somewhere in the system.
If multiple combiners are in use, the RSI cannot specify which combiner triggered it.
Only the combiner with the detected arc will open its contactor. Any other combiners in
the system will continue to operate.
If an arc fault occurs, see the Troubleshooting section on page 15.
Upon an arc fault event, the system is required by NEC 690.11 to be reset manually.
The manual reset also resets the RSI AFCI indicator and the combiner AFCI ANNUNCIATOR.
Reset
To reset the detector following an arc fault:
1. Turn the PV Combiner Disconnect switch (or the Rapid Shutdown switch) to the O
FF
position.
The A
FCI
A
NNUNCIATOR
and A
FCI
indicator should turn off. All combiner box contactors will open.
2. Turn the same switch to the O
N
position. The A
FCI
A
NNUNCIATOR
and A
FCI
indicator should
remain off. All combiner box contactors will close.
NOTE:
The Rapid Shutdown switch can be used to reset all combiners at once from a central location.
Introduction
10 900-0239-01-00 Rev A
An arc fault can also be reset by disconnecting all DC power from the system, including
the batteries.
The arc fault detector has been evaluated to have a low instance of nuisance tripping.
However, installing external DC components may increase the risk of nuisance tripping.
Arc Fault Self-Test
The arc fault function can be manually tested. The arc fault self-test mimics the conditions of an
arc fault. The combiner and RSI give the same indications as described in Detection on page 9.
To perform the arc fault self-test:
1. Ensure the system is functioning and all indicators are normal.
2. Push the arc fault self-test button as shown in Figure 2 on page 7.
3. Listen for an audible click as the contactor opens.
4. Check the AFCI ANNUNCIATOR on the combiner. It should be illuminated.
5. Optional (if installed): Check the AFCI indicator on the RSI. It should be illuminated.
Reset the system by the same method as described on page 9.
Rapid Shutdown
The rapid shutdown requirement is intended for firefighters or first responders. In an
emergency, a responder may need to set the PV system in a “safe” (de-energized) state
according to NEC 690.12.
For this reason, the RSI is required to be mounted close to the main utility meter. The RSI
must be easily visible.
The RSI includes a Rapid Shutdown switch that initiates a disconnection of all elements of
the PV system. Opening this switch sends a signal to all combiners to open the main contactor
on each.
Opening this switch also sends a signal to the FLEXmax 100, ordering it to open its contacts.
According to NEC 690.12, the rapid shutdown must reduce the DC circuit to less than 30 Vdc
and 240 VA within ten seconds of initiation.
Rapid Shutdown Self-Test
The rapid shutdown should be tested every six months. This test should be performed as
described in the Verification section.
Verification
Turning the Rapid Shutdown switch to the right (clockwise) puts it in the OFF position. The
SOLAR OFF LED indicator will illuminate upon successful shutdown. If this does not occur, see
the Troubleshooting section on page 15.
PV Combiner Disconnect
Each combiner has a PV Combiner Disconnect switch which is used to turn off a particular
array. This is used if the array or circuit needs to be serviced. The switch can be padlocked in
the OFF position as a “lockout/tagout” procedure to prevent a shock hazard.
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