Alpha Group OutBack Power FLEXware Integrated Combiner Solution... User manual

FLEXware Integrated
Combiner Solution Plus
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.
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
Address: Corporate Headquarters
17825 – 59th Avenue N.E.
Suite B
Arlington, WA 98223 USA
European Office
Hansastrasse 8
D-91126
Schwabach, Germany
Telephone: [phone]
+1.360.618.4363 (Technical Support)
+1.360.435.6019 (Fax)
+49.9122.79889.0
+49.9122.79889.21 (Fax)
Email: [email protected]
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
Integrated Combiner Solution Plus Owner’s Manual © 2016 by OutBack Power Technologies. All Rights Reserved.
Trademarks
OutBack Power, FLEXware, 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
June 2016, Revision A
Part Number
900-0184-01-00 Rev A

900-0184-01-00 Rev A 3
Table of Contents
Important Safety Instructions..................................................................................4
Symbols Used ........................................................................................................................................................................4
General Safety .......................................................................................................................................................................4
Introduction ..........................................................................................................5
Audience .................................................................................................................................................................................5
Welcome to OutBack Power Technologies.................................................................................................................5
Product Overview.................................................................................................................................................................5
Features...............................................................................................................................................................................................5
Components......................................................................................................................................................................................6
Packages .............................................................................................................................................................................................6
Components ..........................................................................................................................................................................8
Combiner............................................................................................................................................................................................8
RSI.......................................................................................................................................................................................................... 9
Functions ............................................................................................................11
Arc Fault Circuit Interruption ........................................................................................................................................ 11
Detection ..........................................................................................................................................................................................11
Reset...................................................................................................................................................................................................11
Arc Fault Self-Test ..........................................................................................................................................................................12
Rapid Shutdown ................................................................................................................................................................ 12
Rapid Shutdown Self-Test...........................................................................................................................................................12
Verification .......................................................................................................................................................................................12
PV Combiner Disconnect................................................................................................................................................ 12
Installation ..........................................................................................................13
Mounting Information..................................................................................................................................................... 13
Connection Information ................................................................................................................................................. 14
Other Applications ...............................................................................................17
Alternative System Requirements............................................................................................................................... 17
Positive Ground ................................................................................................................................................................. 18
Troubleshooting ..................................................................................................19
LED Indicators..................................................................................................................................................................... 19
Basic Troubleshooting..................................................................................................................................................... 19
Specifications ......................................................................................................21
Device Specifications....................................................................................................................................................... 21
Regulatory Specifications............................................................................................................................................... 22
Listings...............................................................................................................................................................................................22
Compliance......................................................................................................................................................................................22
Component Compliance .............................................................................................................................................................23
Definitions............................................................................................................................................................................ 23

Table of Contents
4 900-0184-01-00 Rev A
Important Safety Instructions
READ AND SAVE THESE INSTRUCTIONS!
This manual contains important safety instructions for the Integrated Combiner Solution Plus
(ICS Plus) 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 ICS Plus 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 ICS Plus 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.

900-0184-01-00 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 OutBack Integrated Combiner Solution Plus (ICS Plus). It provides
comprehensive PV rapid shutdown and arc fault protection. This product allows a system to meet the
2014 National Electric Code requirements for PV systems.
NEC 690.11 — Arc fault protection (protects against arc faults due to loose connections, damaged wires, or
other DC component failures)
NEC 690.12 — Rapid shutdown (allows first responders to safely de-energize controlled conductors)
NEC 690.15 — DC combiner disconnect (opens all ungrounded circuit conductors from all energy sources)
Product Overview
Features
First end-to-end solution listed to UL1741 with PV rapid shutdown systems (PVRSS)
Arc fault circuit interrupter (AFCI) listed to UL1699B with local and remote indication
Type 3R enclosures rated for indoor or outdoor installation
Flexible design — install the combiner box vertically, horizontally, or at any intermediate angle;
mount to racking or under the PV array
Interoperability with compatible third-party PV rapid shutdown system equipment (PVRSE) with a
dry contact input
Three complete packages simplify the design and ordering process
Combiner box has removable component panel for ease of wire management and for serviceability
Combiner box has easy-to-install DIN-mount fuses for bi-directional overcurrent protection
Lockable disconnects on combiner and rapid shutdown boxes
Communications use building wire commonly available in the field (THHN/THWN-2)
Ground lug and grounding terminal bus bar for system and equipment grounding
Internal factory prewiring to save time during installation

Introduction
6 900-0184-01-00 Rev A
Components
The primary component in the ICS Plus 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 AFCI device
is located here.
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.
Other components include:
Rapid Shutdown Initiator (RSI) which works with the combiner box to induce the rapid shutdown function
Relay-Trip Breaker (RTB) which physically opens the circuits near the charge controller(s)
Breaker control and power supply (BRK-CTRL-DC) which powers the RSI, RTB, and combiner
Packages
The ICS Plus has three prepackaged solutions for battery-based systems.
Table 1 Packaged Systems
Package ICSPLUS-1 ICSPLUS-2 ICSPLUS-3
FWPV6-FH600-SDA combiner 1 2 4
Compatibility 6 PV strings
1 charge controller
12 PV strings
2 charge controllers
24 PV strings
4 charge controllers
RSI Standard
BKR-CTRL-DC Standard
Relay-Trip Breaker PNL-75-DC-RT PNL-75D-DC-RT PNL-75Q-DC-RT

Introduction
900-0184-01-00 Rev A 7
Figure 1 Example of Residence with ICS Plus
Fuses
AFCI
Contactor
PV Array
≤ 10 Feet
Utility
Meter
Combiner
RSI
Battery-Based Inverter
Charge
Controller
Battery
Bank
RTB
BKR-CTRL-DC
Combiner Box
Contains OCPD, AFCI, main contactor, PV Combiner Disconnect
Includes local disconnect to de-energize PV circuits within 10 feet of the array
Rapid Shutdown Initiator (RSI)
Contains control circuit for PVRSS (contactors and relay-trip breakers)
Includes PVRSS disconnect switch
Includes LED indicators for PV connection, disconnection, or arc fault
Relay-Trip Breaker (RTB)
Removes charge controller(s) from PV circuit
Can be integrated into OutBack GSLC or FLEXware enclosures
Circuit Breaker Control Box (BKR-CTRL-DC)
Provides power to combiner, RSI, and RTB
HOUSE EXTERIOR
HOUSE INTERIOR
ROOF

Introduction
8 900-0184-01-00 Rev A
Components
NOTE:
This manual depicts the use of a negative-grounded system. For positive grounding,
see page 18.
Combiner
Figure 2 Components of Combiner Box
1
2
3
4
5
6
7
8
9
10
11
8
10
1
Gasketed Door/
Type 3R Enclosure
Protects from the environment 12
Ground Cable
Terminal
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
Contactor
Opens PV circuits for AFCI and
for local or remote disconnect 14
Combiner Control
Board
Controls all functions within the
combiner; commands the contactor
4
Ground Terminal
Bus Bar
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
Terminal Bus Bar
Combines negative PV
source circuits 16
PV Input
Connections
Connections for positive PV
source circuits
6
PV
Positive
Output
Terminal
Connection 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
Arc Fault
Detection Device
Detects series DC
arc fault events 20
Cable Glands
(PV Input)
Provide waterproof strain relief for
PV source circuits
10
Secur
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 Screw
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
22
13
14
15
15
16
17
18
18
20
12
19
21
NOTE: All external wires
are provided by installer

Introduction
900-0184-01-00 Rev A 9
RSI
Figure 3 Components of RSI
1 Rapid Shutdown switch Initiates the PVRSS function; disconnects RTB and 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 19 .
1
2 3 4
5 5 5

Introduction
10 900-0184-01-00 Rev A
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