OutBack POWER RSD-AFCI FLEXmax 100 Rapid Shutdown Kit Owner’s Manual

POWER RSD-AFCI FLEXmax 100 Rapid Shutdown Kit
Owner’s Manual

About OutBack Power
OutBack Power Technologies is a leader in advanced energy storage and conversion technology.
OutBack Power products include true sine wave inverter/chargers, batteries, maximum power point tracking charge controllers, and system communication components, as well as circuit breakers, accessories, and assembled systems.

Contact Information

Warranty
The warranty for this product can be downloaded from www.outbackpower.com/downloads/warranty_and_safety.
A printed copy is available by sending a self-addressed envelope to the above address.
Notice of Copyright
FLEXware FLEXmax 100 Rapid Shutdown Solution Owner’s Manual ©2018 by OutBack Power Technologies, Inc.
All Rights Reserved.
Trademarks
Trademarks and logos are the property of EnerSys and its affiliates unless otherwise noted. Subject to revisions without prior notice. E. & O.E. UL® is the registered trademark of UL LLC.
Date and Revision
August 2021, Revision C
Part Number
900-0239-01-00 Rev C

Important Safety Instructions
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.
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| 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 operations.

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.
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| 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 or its authorized agents.

Introduction

Audience
This manual provides instructions for the 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
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.

• 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

• End-to-end solution listed to UL1741 with PV rapid shutdown equipment (PVRSE)
• 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 PVRSE with a dry contact input
• Combiner box has a 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 a 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

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 (48 Vdc source, 24 Vdc output ± 3%, up to 1.5 Adc) must be used. ![OutBack POWER RSD AFCI FLEXmax 100 Rapid Shutdown Kit

• figure 1](https://manuals.plus/wp-content/uploads/2022/04/OutBack-POWER-RSD- AFCI-FLEXmax-100-Rapid-Shutdown-Kit-figure-1-550x508.jpg)

Combiner 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)

Rapid Shutdown Initiator (RSI)

• Contains control circuit for PVRSE
• Includes PVRSE disconnect switch
• Includes LED indicators for PV connection or disconnection

Figure 1 Example of Residence with RSD-AFCI

Components

Combiner

RSI

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:

• Risk of electric shock if the mounting system or other components become electrified.
• 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.

• The control board sends a signal to open the combiner’s main contactor. The AFCI ANNUNCIATOR turns on.
• The control board also sends a signal to the RSI and turns on the AFCI 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 OFF position.
   The AFCI ANNUNCIATOR and AFCI indicator should turn off. All combiner box contactors will open.

2. Turn the same switch to the ON position. The AFCI ANNUNCIATOR and AFCI indicator should remain off. All combiner box contractors will close.

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.

Installation

This section assumes the use of the combiner and the RSI.

• The combiner box is a required part of all RSD-AFCI systems. All examples in OutBack Power literature show one or more combiners in use, including the Quick Start  Guide.
• The RSI is required for all RSD-AFCI systems utilizing the PV Rapid Shutdown function.

Mounting Information
The RSD-AFCI combiner box accommodates multiple mounting types.

• It can be mounted horizontally, vertically, or at any intermediate angle.
• It has slotted mounting feet which allow a variety of positions.
• It is capable of being mounted directly under the PV array if necessary.
• It must be mounted at least 36” (91.4 cm) above the ground.
• The combiner box has a latch that should be padlocked to limit internal access.
• The main disconnect can also be padlocked in the OFF position for safety.
  NOTE:
  If the box is not padlocked, the securing screw must be used to secure the door. See Figure 2 on page 7.

The RSI has mounting brackets at the top and bottom.

• It should be installed near the service meter.
• It must be mounted vertically and must be at least 36” (91.4 cm) above the ground.
• The Rapid Shutdown switch can be padlocked in the OFF position for safety.

NOTE:
If the structure where the RSI is installed is also equipped with utility service, the structure must have a permanent sign or plaque reading “PHOTOVOLTAIC [or PV]  SYSTEM EQUIPPED WITH RAPID SHUTDOWN”. This plaque must be reflective, with all letters capitalized and having a minimum height of ⅜” (9.5 mm) in white on a red background.

Surge Protector
An optional surge protection device can be installed in the combiner. A knockout has been provided to accommodate this type of device. Figure 4 shows the underside of the combiner and the location of the knockout.

NOTE:
Any installed devices must be liquid-tight to sustain the combiner’s environmental rating.

A. PV Conduit (2”)
B. PV Cable Glands
C. Surge Protector (½”)
D. Communications Conduits (½” and ¾”)

Figure 4 Surge Protector and other Knockout Locations

Connection Information
Combiner
The combiner box can take input circuits from up to six PV subarrays. It provides a single output that is connected to the DC load center. When its contactors are closed, it sends power to the load center PV connections, charge controller, and batteries (1). See Figure 5 on page 13.

• The combiner’s control board receives power from the RSI (3). It sends rapid shutdown status information (5) and arc fault status information (4) to the RSI. Both sets of wires must be connected for correct rapid shutdown operation.
• The communication wires may be run in the same conduit as the PV wire only if the communication wiring is rated for the highest system voltage.
• Up to six combiners can be used in a single system with a single RSI. The control wires must be placed in series (“daisy-chained”) between combiners.
• Regardless of the number of combiners in use, the last combiner must have a jumper placed across its sensing terminals to close the circuit. If only one combiner is present,  the jumper must be placed there as shown in the installation instructions.

RSI
The RSI communicates with the combiner box (and with any additional combiners also connected to it). See Figure 5 on page 13.

• It receives power (2) from the isolated Class 2 power supply.
• It sends power (3) to the combiner(s) control board.
• It receives arc fault and rapid shutdown status information from the combiner(s) (4) and (5).
• It sends rapid shutdown information to the charge controller (6) and receives status information from the charge controller in response (7). Both sets of wires must be connected for correct rapid shutdown operation.

CAUTION: Equipment Damage
The 24-volt conductor is not grounded and is not to be connected to the chassis or any other grounding system.

Optional Connections
RSI
The RSI has several sets of auxiliary terminals. Terminal J6 has a factory- installed jumper.
J3, J4, and J5 do not. The terminals can be wired to the FLEXmax 100, or possibly other devices, to send or receive status messages.

| IMPORTANT:
• J4 must be connected. With no connections, the SOLAR OFF (“safe”) indicator will not light even if the Rapid  Shutdown switch is OFF.
• J6 must have the jumper installed (or another source of continuity). With no connections, the system will enter a continuous Rapid Shutdown.
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| NOTE:
When the RSI is mounted adjacent to the FLEXmax 100, any Rapid Shutdown
signal will be easily visible on the FLEXmax. The J4 function may not be needed.
A jumper may be installed across the J4 terminals to send the “safe” signal.

Figure 6 Interface Connections

Troubleshooting

LED Indicators
Table 1

be lit at the same time as AFCI.
Despite the label, SOLAR ON does not indicate that the PV system is active. It will illuminate even if PV is completely disconnected or if an arc fault is present. The name indicates to responders that this control does not shut down other parts of the electrical system. It only affects PV-related devices.
RSI| SOLAR OFF (red)| The system is in “safe” mode. Rapid Shutdown switches OFF.| This indicator should never be lit at the same time as any other.
RSI| AFCI (red)| Arc fault condition or deliberate arc fault self-test.| Accompanied by at least one AFC ANNUNCIATOR (on one or more combiners). May be lit at the same time
as SOLAR ON.
Combiner| AFCI ANNUNCIATOR
(red)| Arc fault condition or deliberate arc fault self-test.| Accompanied by AFCI on RSI. Will not be accompanied by AFC! ANNUNCIATORS in other combiners unless other arc faults are present. May be lit at the same time as SOLAR ON.

Basic Troubleshooting
The following table describes known situations that can cause unexpected behavior in the RSD-AFCI. The table also describes all known situations which will cause the LED  indicators to light.

| NOTE:
When a true arc fault event occurs, the RSD-AFCI disconnects the PV by design.
RSD-AFCI troubleshooting is not required. However, it may be necessary to troubleshoot and locate the cause of the problem. Diagnosis of an arc fault is not covered under the scope of this document. See Table 2.
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| WARNING: Shock Hazard
An arc fault causes the AFCI to disconnect that section of the PV system to prevent fire or shock injuries. These hazards may still exist on the array itself if physical troubleshooting is required. Make certain to cover the PV modules and take any other necessary steps to reduce risk.

See the next page for a table of basic troubleshooting steps.
Table 2

the shutdown of the system constitutes correct operation. The RSD-AFCI does not need troubleshooting. Investigate any potential causes throughout the PV system.
The arc fault self-test button was pressed.| Turn the combiner disconnect switch or Rapid Disconnect switch off, then on.
AFCI indicator lit. Combiner AFCI ANNUNCIATOR
not lit.| Arc fault in another combiner (multiple combiner system only).
NOTE: The SOLAR ON indicator remains lit.| Check all combiners. An arc fault will activate the AFCI ANNUNCIATOR in that combiner only.
Missing connection or loose jumper in RSI.| Check J6 in RSI (see page 14).
SOLAR OFF indicator and another indicator are both lit.| RSI miswired.| Check all wiring between RSI and combiner.
SOLAR ON
indicator lit, but the charge controller does not register PV input.| The combiner disconnect switch turned off.| Turn on the combiner disconnect switch.
SOLAR ON
indicator lit, but charge controller registers reduced PV input.| Array wiring error or poor connection.| Check all PV wiring to the combiner. Use DVM to confirm the voltage of each subarray at combiner input terminals.
Fuses blew in the combiner box.| Check all fuses.
No indicators lit.| The battery or DC source is disconnected. Loss of combiner box control voltage caused the PV contractor to disconnect. The system is not in the formal “safe” condition, although the PV array is still forced to be off.| Check all power supply fuses. Check power supply terminals.
SOLAR OFF indicator does not light when the Rapid Shutdown switch is turned off.| The battery or DC source is disconnected. The system is not in the formal “safe” condition, although the PV array is still forced to be off.| Check all power supply fuses. Check power supply terminals.
Missing connection in RSI.| Check J4 in RSI (see page 14).

Specifications

Device Specifications
Table 3 Electrical and General Specifications

status
Compatibility| Can accommodate 6 PV input strings per combiner| Can control up to 6 combiner boxes
Terminals:
Input| #14 to #8 AWG (2.5 to 10 mm2) (cable glands)| #24 to #16 AWG (0.25 to 1.5 mm2)
Output| #14 to 2/0 AWG
LED indicators| AFCI ANNUNCIATOR| •SOLAR ON
•SOLAR OFF
•AFCI
Overcurrent Protection| (6) 600 Vdc DIN rail fuse holders| N/A
Voltage Rating| 600 Vdc| 24 Vdc ± 3%
Total Current (maximum)| 64 Adc| N/A
DC input| 24 Vdc ± 3%| 24 Vdc ± 3%
Normal Operation
Power Draw| 0.10 Adc| 0.06 Adc

Table 4 Mechanical and Environmental Specifications

position
Mounting| Vertical to horizontal (adjustable feet)| Vertical only (brackets)
Knockouts| 2″, 1/2″, and %”|
Dimensions
(H x W x D)| 15.5 x 19.5 x 4.5″ (39.4 x 49.5 x 11.4 cm)| 14.1 x7.3 x 3.75″ (30.5 x 17.8 x 12.7cm)
Weight| – 12 lb (5.4 kg)| – 4 lb (1.8 kg)

Regulatory Specifications
Listings
This product carries a listing report by UL. It is listed to the following standards:

• UL 1741 — Inverters, Converters, Controllers, and Interconnection System Equipment for Use With Distributed Energy Resources (2 nd Edition, 1/28/2010, with  revisions through 3/23/2016) with PV Rapid Shutdown
• UL1699 — Standard for Arc-Fault Circuit Interrupters (2nd Edition, revised 11/08/2013)
• UL1699B — Photovoltaic (PV) DC Arc-Fault Circuit Protection (Issue: 1/14/2013)
• CSA C22.2 — General Use Power Supplies, No. 107.1-01 Issue: 2001/09/01 Ed:3 (R2011) with PV Rapid Shutdown

Compliance
This product has been tested to comply with the following standards:

• FCC Part 15, Class B

FCC Information to the User
This equipment has been tested and found to comply with the limits for a Class B digital device when powered by a DC source, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and the receiver.
• Consult the dealer or an experienced radio/TV technician for help.

Definitions
The following is a list of initials, terms, and definitions that may be used in conjunction with this product.
Table 5 Terms and Definitions

circuit protection
Controlled conductor| A section of wire between the combiner and either the RTB or the PVRSE device
CSA| Canadian Standards Association; establishes Canadian national standards and the Canadian Electrical Code, including C22.1 and C22.2
Dry contact| A relay contact with no source voltage; switches the continuity to be used by an external device
DVM| Digital Voltmeter
EKO| Electrical Knockout
Grounded Conductor| The DC conductor (negative or positive) is mechanically bonded to the ground in one place
NEW| National Electric Code
PVRSE| Photovoltaic Rapid Shutdown (System) Equipment
RSI| Rapid Shutdown Initiator
GSLC| GS Load Center; the DC and AC load center for Radian series inverters
UL| Underwriters Laboratories; refers to a set of safety standards governing electrical products

Masters of the Off-Grid.™ First Choice for the New Grid.
7360 – South Kyrene Road
Tempe, AZ 85283 USA

Documents / Resources

| OutBack POWER RSD-AFCI FLEXmax 100 Rapid Shutdown Kit [pdf] Owner's Manual
RSD-AFCI, FLEXmax 100 Rapid Shutdown Kit, RSD-AFCI FLEXmax 100 Rapid Shutdown Kit
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References

• Residential & Commercial Solar Solutions with Energy Storage - OutBack Power Inc
• outbackpower.com/downloads/warranty_and_safety

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