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EG4 GRIDBOSS User Manual

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E G 4
G R I D B O S S
®
U S E R M A N U A L
©2025 EG4
®
ELECTRONICS, LLC. ALL RIGHTS RESERVED.
VERSION 1.1.7 | INFORMATION SUBJECT TO CHANGE WITHOUT NOTICE.
MODEL #: MI-200-2P-HYB-AW-01 / MI-200-2P-HYB-AW-02

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Summary of Contents for EG4 GRIDBOSS

  • Page 1 E G 4 G R I D B O S S ® U S E R M A N U A L ©2025 EG4 ® ELECTRONICS, LLC. ALL RIGHTS RESERVED. VERSION 1.1.7 | INFORMATION SUBJECT TO CHANGE WITHOUT NOTICE. MODEL #: MI-200-2P-HYB-AW-01 / MI-200-2P-HYB-AW-02...

  • Page 2: Table Of Contents

    EXISTING ACCOUNTS ........................51 EG4 MONITOR CENTER .......................... 53 MAINTENANCE TAB........................54 FIRMWARE UPDATES ..........................59 SYSTEM - EG4 MOBILE APP ......................59 SYSTEM - EG4 MONITOR CENTER ................... 60 INVERTER LCD – USB DRIVE ....................... 61 TROUBLESHOOTING ..........................63 10.1...

  • Page 3: Technical Specifications

    *Install a properly sized breaker based on the connected inverter: 50A - 12kPV; 70A - 18kPV; 90A – FlexBOSS18 & 21. **Third-party inverters are not supported and cannot be connected to the hybrid ports. ***For information regarding warranty registration on EG4 ®...
  • Page 4 STANDARDS AND CERTIFICATIONS UL1741, UL67, UL869A* FCC PART 15, CLASS B *When used with a 200A Eaton CSR2200N (CSR25K) main breaker.

  • Page 5: Abbreviations

    2. ABBREVIATIONS • AWG – American Wire Gauge • In-lbs. – Inch Pounds • A – Amps • kW – Kilowatt • Ah – Amp hour(s) • kWh – Kilowatt-hour • AC – Alternating Current • LCD – Liquid Crystal Display AFCI –...

  • Page 6: Safety

    “off” or “open” position before installing or working on the inverter. Use a voltmeter to confirm there is no voltage present to avoid electric shock. 2. Do not open the internal GridBOSS cover while it is operating to avoid electric shock and damage from live voltage and current within the system.
  • Page 7 5. The installer should consider the safety of future users when choosing the correct position and location for the GridBOSS as specified in this manual. 6. Keep children from touching or misusing the inverter and relevant systems.
  • Page 8 Les réglementations internationales de sécurité ont été strictement observées dans la conception et les tests du GridBOSS. Avant de commencer tout travail, lisez attentivement toutes les instructions de sécurité et respectez-les toujours lorsque vous travaillez sur ou avec l'onduleur. L'installation doit suivre toutes les normes et réglementations nationales ou locales applicables.
  • Page 9 être clairement visibles et ne doivent pas être retirées ou couvertes. 5. L'installateur doit prendre en compte la sécurité des futurs utilisateurs lors du choix de la position et de l'emplacement corrects pour le GridBOSS, comme spécifié dans ce manuel.

  • Page 10: Product Overview

    IMPORTANT The breakers displayed in the image above are the maximum supported sizes for each port. The maximum allowed total output amperage is set at 200 amps. If the current draw exceeds 200A, GridBOSS will begin to limit load output.
  • Page 11 ITEM DESCRIPTION Wi-Fi dongle RSD/ESS switch Chassis handles Door latches Door lock mechanism for padlock Port LEDs Smart port breakers Hybrid port breakers Manual bypass interlock Backup port breaker Manual bypass breaker Generator breaker Grid breaker (optional)

  • Page 12: Dimensions

    5.1 DIMENSIONS U.S. NOMINAL TRADE SIZE ACTUAL SIZE 3/4 in. 1.14 in. (28.9 mm) 1 1/2 in. 1.98 in. (50.4 mm) 2 in. 2.48 in. (63 mm)

  • Page 13: Packing List

    5.2 PACKING LIST The items listed below will arrive with each product shipment: GridBOSS (x1) Mounting Bracket Neutral-Ground L-Bracket (x2) (x1) Bonding Jumper (x1) Waterproof Cover Two Pole • M63 (x8) Breaker Cover (x2) Extra Fuse (x2) Breaker (x8)* G-M50 (x3) •...

  • Page 14: Installation

    6.1 MOUNTING AREA & SPACING REQUIREMENTS Follow the requirements listed below for system installation: 1. The mounting wall must be strong enough to support the weight of all equipment (GridBOSS, inverters, wall-mounted batteries, etc.). 2. Maintain the minimum clearances on all sides (see next page).
  • Page 15 0 in. (0 mm) 5 3/16 in. (135 mm) 2 3/8 in. The GridBOSS is designed to be (60 mm) wall mounted using the included wall mount bracket. 17 5/16 in. (440 mm) It should be installed vertically on a 18 1/8 in.

  • Page 16: Recommended Tools

    Torque Wrench Masonry Bit 6.3 MOUNT THE UNIT 1. Select a suitable location to install the GridBOSS as described in section 6.1. 2. Use the wall mounting bracket as a template to mark where the screws will be installed. When installing the wall bracket to studs, verify that the marks for the screws are centered over a stud.
  • Page 17 (packaged with the expansion bolts) to affix the bracket to the wall. For stud wall installation, use the proper screws and affix the bracket to the wall. 5. Using the team-lift technique, place the GridBOSS onto the wall bracket and secure it to the wall.
  • Page 18 6. Temporarily mount the L-bracket to the side of the GridBOSS (located at the bottom, one on each side). Place a mark on the wall based on the hole location inside the L-bracket. Repeat this step for both sides. 7. Remove the L-bracket and drill a hole at the marking.

  • Page 19: Install Breakers

    6.4 INSTALL BREAKERS This section provides the steps to install the 2-pole breakers included with the GridBOSS and the optional main breaker. To begin the installation, open the front door by releasing the clasps on the right side of the unit.
  • Page 20 Breaker Installation: When installing a 2-pole breaker, hold it at an angle and place the bottom slot on the metal bracket inside the GridBOSS chassis. Then, pivot the breaker towards the chassis until the top snaps onto the busbar blade.
  • Page 21 Optional Main Breaker Installation: 1. Remove the internal orange cover by first removing the two nuts using a 7mm socket and the four screws using a Phillips screwdriver. Then, lift the cover out of the unit.
  • Page 22 2. With the inside cover removed, locate the lugs for both line 1 and line 2 (outlined with a dashed line). Unscrew the fastener holding each lug in place, then remove each lug. Remove the small Phillips head screw (circled) and set it aside.
  • Page 23 b. Anti-twist plates with raised edges pointing upward, in both variations. Raised Edges Raised Edges 4. Before installing the breaker, adjust the insulation sheet's position by pushing it to the right side.
  • Page 24 5. Install the 200A Eaton CSR2200N (CSR25K) breaker by sliding it into place, aligning the bolt holes in the breaker lugs to the holes on the busbar. 6. Using a 10 mm socket, install the two M6 screws in the busbar, then install the M4 screw that holds the opposite end of the breaker in place.

  • Page 25: Install Cables

    6.5 INSTALL CABLES Use the information in this section for guidance on connecting the AC wiring. Using a multimeter, verify that each wire does not carry voltage/current before making any connections to the GridBOSS. WARNING Use ONLY COPPER WIRE for ALL GridBOSS connections! Failure to use copper wire could result in equipment damage, as the unit has not been approved to accept other types of wiring.
  • Page 26 The unit ships with a neutral-ground bonding jumper (bracket) that connects the ground bar to the neutral bar. This should only be attached if the GridBOSS is the first service disconnect, as there can only be one neutral bond connection in the electrical system. Use the M6-1x38 mm screw included with the unit packaging to attach the jumper to the neutral bar side.
  • Page 27 If a first service disconnect is already installed after the power meter, the GridBOSS will be attached in series with the existing first service disconnect. In this case, the bonding jumper should not be used. If there are questions concerning the neutral ground bond, contact a licensed electrician for assistance.
  • Page 28 GENERATOR PORT The GridBOSS can utilize supplemental 240VAC generator power for backup and battery charging in the case of a grid failure. When the grid power goes down, the generator port can supply power to the backup port, the hybrid ports, and the configured smart ports. To support automatic generator startup, the GridBOSS has a 2-wire start/stop terminal for controlling 2-wire start-capable generators.

  • Page 29: Generator Operation

    1 is closed. When start/stop relay 1 is closed, the GridBOSS must wait until the generator can supply stable output power. This wait time is configured using the generator warm-up time setting in the EG4 ®...
  • Page 30 CAUTION The non-backup port is not controlled by a breaker or relay and will always receive current if the GridBOSS is supplied with grid input. WARNING The non-backup port does not have built-in overcurrent protection at the port output.
  • Page 31 BACKUP LOADS PORT The backup loads port provides power to any panel that needs to be backed up by the EG4 ESS. This could be the home's main breaker panel, a critical loads subpanel, or any combination of main panels and subpanels.
  • Page 32 The GridBOSS hybrid ports connect to supported EG4 ® hybrid inverters. When cabling the AC connection to the hybrid inverter, only connect the inverter’s grid port to the GridBOSS hybrid port. See the chart below for supported EG4 hybrid inverters. WARNING: •...
  • Page 33 When operating a hybrid inverter with the GridBOSS, smart port functionality is moved from the hybrid inverter to the GridBOSS. All devices that connect through a smart port must be cabled directly to a GridBOSS smart port. Select GridBOSS in EG4 ®...
  • Page 34 RAPID SHUTDOWN & ESS DISCONNECT The GridBOSS supports a rapid shutdown system that complies with 2017 and 2020 NEC 690.12 and an ESS Disconnect that complies with NEC 706.15 requirements. When used, the rapid shutdown switch on the right side of the GridBOSS will initiate total system shutdown, including the inverters, backed-up loads, smart ports, supported batteries, and PV (if properly equipped).
  • Page 35 REPLACE THE CABLE BOX COVER. Before replacing the cable box cover, remove any knockouts where a breaker was installed. The knockouts are designed to be rocked back and forth until the small connection point between the knockout and the cover is broken, allowing the knockout to be removed. Install the grid and generator cover plate if breakers are not installed in those areas.

  • Page 36: Configure The Hybrid Inverters

    If using multiple inverters, verify they are set up in a functioning parallel configuration. • • DO NOT connect the inverter’s load port to the GridBOSS. The inverter’s load port must remain in the off position. • DO NOT cable anything to the inverter’s generator port (if equipped). The inverter’s generator breaker should remain in the off position.

  • Page 37: Configure Gridboss

    • All GridBOSS breakers are in the off position. • If a main breaker is not installed in the GridBOSS, verify that the source providing power to • the GridBOSS is in the off position. If the non-backup port is connected to an electrical panel, verify that the breaker in that panel •...
  • Page 38 12kPV and 18kPV can be set up using their front LCD panel. When setting up the FlexBOSS inverters, use the EG4 ® Monitor Center website or the optional EG4 FlexBOSS Screen Kit (sold separately). LCD Panel: Navigate to the Advanced page and select the “Grid Boss” setting, and then •...

  • Page 39: Verify Configuration

    All grid sell-back functionality is configured within the inverter settings. The FlexBOSS will require using the EG4 Monitor Center, mobile app, or external FlexBOSS Screen Kit. 7. Enable grid input to the GridBOSS by turning on the grid breaker (if equipped) or the breaker providing grid access.
  • Page 40 Role: Verify the GridBOSS has only ONE master inverter. The master inverter should be set to • “1 Phase primary,” and all other inverters should be set to “Slave.” Remember to press the “Auto Detect Phase” reset button if any changes are made to the parallel settings.

  • Page 41: System Operation & Configuration Examples

    7. SYSTEM OPERATION & CONFIGURATION EXAMPLES To power up and be ready for operation, the GridBOSS must be set up with at least one powered input. The input can be from the grid, a hybrid inverter, or a generator. The GridBOSS is a power distribution unit that controls power flow using internal relays and software.
  • Page 42 Inverter Settings: Application: Power Backup: Enable Grid Sell Back: Enable Fast Zero Export: Disable Off-Grid Mode: Disable Charge: AC Charge: Enable or Disable based on need Discharge: Forced Discharge Enable: Disable PVSellToGrid (Comp. w/ NEM3.0): Enable GridBOSS Settings: No changes required...
  • Page 43 AC charging is enabled. When AC charging is in use, the main grid relay will close. The non-backup loads can only be powered by the grid. Inverter Settings: Application: Power Backup: Enable Grid Sell Back: Disable Fast Zero Export: Enable Off-Grid Mode: Enable GridBOSS Settings: No setting changes required...

  • Page 44: Generator

    7.2 GENERATOR In this example, a generator has been added to the GridBOSS to power the backup loads and to supplement charging the batteries, if needed. The generator breaker and relay are closed, allowing current to flow to the backup loads. Generator output could assist in charging the batteries as long as the proper settings are configured and the loads are small enough, leaving the extra power from the generator to charge the batteries.

  • Page 45: Manual Bypass Mode

    7.3 MANUAL BYPASS MODE In this scenario, all the relays in the GridBOSS are bypassed, allowing grid current to flow directly to the backup loads port, powering the critical loads panel. The bypass mode was set up to support critical loads in the unforeseen circumstance that GridBOSS needs to be bypassed. The non-backup loads port also receives power from the grid when in bypass mode.

  • Page 46: Smart Loads

    Another option is using load shedding, which adds an additional setting for the PV input level. NOTE: Smart port functionality is not supported at the hybrid inverter when attached to a GridBOSS. All devices powered by a smart port must be connected directly to a GridBOSS smart port. See the next page for example configurations.
  • Page 47 Example Configurations: 1. Always On: The following examples show how to configure a smart load to be always enabled. This can be done in two ways: either by using the “Grid Always On” setting or by using the “Time” setting. Using “Grid Always On” enables the smart port when there is grid input. If the grid goes down, the relay will open, and the smart port will no longer receive power.

  • Page 48: Ac Coupling

    AC-coupled device is UL1741, UL1741SA, or UL1741SB certified. Uncertified devices may cause hardware damage to the equipment. NOTE: Smart port functionality is not supported at the inverter generator port when attached to a GridBOSS. All AC-coupled devices must be connected directly to a GridBOSS smart port.
  • Page 49 Once the batteries are fully charged, AC-coupled power will continue to assist with powering loads. This configuration will only work when grid input is present. GridBOSS Settings: Inverter Settings: Battery Control (Common Settings):...

  • Page 50: Remote System Management

    Once the dongle is physically installed on the chassis, its serial number and PIN need to be added to an EG4 user account to set up remote connectivity. New EG4 users must create a new account. Existing users can also add GridBOSS to an existing account, as shown in section 8.2.

  • Page 51: Create New Account

    8.1 CREATE NEW ACCOUNT Using EG4 Monitor Center ® 1. Using a web browser, connect to “monitor.eg4electronics.com” and select “Register”. 2. Complete the registration form as shown below. Contact the distributor for the customer code. The dongle serial number (SN) and dongle PIN can be found on the sticker attached...
  • Page 52 3. Once the registration is complete, return to the EG4 ® Monitor Center web page and log in using the username and password created during the registration process. Using the Mobile App 1. Download the “EG4 Monitor” app for iOS or Android. After installation is complete, open the ®...

  • Page 53: Existing Accounts

    8.2 EXISTING ACCOUNTS When an EG4 account already exists, newly added EG4 hardware that uses a dongle can be added ® to it. This can be completed using the EG4 ® Monitor Center or the mobile app. Using EG4 ®...
  • Page 54 Using the Mobile App 1. Open the “EG4 ® Monitor” app and log in using an existing name and password. 2. Select the back arrow in the upper left corner of the screen. 3. Select “Add Dongle”. 4. Scan or enter the dongle information located on the dongle sticker, then select “Add...

  • Page 55: Eg4 Monitor Center

    Monitor Center main page when viewing GridBOSS. All AC input and ® output information shows what is directly connected to the GridBOSS ports. All DC input and output information is pulled from the hybrid inverter. A. Smart Ports: Smart port information by port (numbered left to right) B.

  • Page 56: Maintenance Tab

    9.1 MAINTENANCE TAB This section describes the settings for each area within GridBOSS. As a best practice, always start by selecting the “Read” button at the top of the maintenance page. This will refresh the settings page, displaying the values currently set for each option.
  • Page 57 SMART LOADS This section describes the various smart load settings. There are three areas within the smart port settings page. The first area is used for load shedding and uses SOC/voltage to enable and disable the load port (outlined in blue). The goal is to turn off a smart load when the battery SOC hits a low threshold.
  • Page 58 This section describes the various AC coupling settings. When configuring AC coupling, the enablement and start/stop settings are configured within the GridBOSS settings area of the EG4 ® Monitor Center. There are inverter settings that also interact with the functionality of the GridBOSS AC-coupled port.
  • Page 59 AC-coupled relay will be closed (powered on) when the hybrid inverter’s “Export to Grid” setting is enabled and the time period logic is met. The GridBOSS will also open (power off) the AC-coupled port relay when the hybrid inverter’s “Export to Grid” is disabled to avoid pushing power to the grid.
  • Page 60 Generator Warm Up Time(s): [30 – 600] Sets generator warm-up time in seconds. The generator relay will close only after the warmup time is complete. GridBOSS will restart the warmup period if the generator’s voltage is detected as abnormal during the warm-up process.

  • Page 61: Firmware Updates

    3. With the app still running, return to the mobile device’s Wi-Fi settings. Connect the home Wi-Fi network for internet access. 4. Switch back to the EG4 app on the mobile device. Select the correct device type from the drop- down menu. Then select the “DOWNLOAD FIRMWARE” button. To view the firmware change log, select the “Changelog”...

  • Page 62: System - Eg4 Monitor Center

    10.2 SYSTEM - EG4 MONITOR CENTER 1. Log in to the EG4 Monitor website. Select the “Maintenance” tab. ® 2. Select “Remote Update” on the left side of the screen. 3. Locate the unit needing the update by serial number. Select the blue question mark box next to the current firmware version.

  • Page 63: Inverter Lcd - Usb Drive

    Download the LCD firmware file using the QR code listed below. The firmware update will be listed under Inverters  18kPV Firmware updates. EG4 Electronics - Inverters LCD Update Steps: 1. Plug the USB flash drive into a Windows PC.
  • Page 64 7. Safely remove the USB flash drive from the computer. 8. Power off the inverter. 9. Insert the USB flash drive into the USB port on the inverter’s communications board, as shown in the image. 10. After the USB flash drive has been connected, power on the inverter.

  • Page 65: Troubleshooting

    The inverter is running an older Update the inverter FW to a version Firmware firmware that is not compatible E004 supported by the GridBOSS. Mismatch with the GridBOSS. Verify that the total system load is The current is more than 80% of...

  • Page 66: Warning Codes

    INFO DESCRIPTION RECOMMENDATION CODE Check the parallel CAN cable Parallel comm Parallel CAN communication W000 between the GridBOSS and the fault fault master inverter. Turn off the RSD switch to restart W001 RSD Active RSD is active in the system the system.

  • Page 67: Internal Fuse Replacement

    11.4 INTERNAL FUSE REPLACEMENT GridBOSS contains two internal fuses that protect the unit from overcurrent situations. One fuse protects line 1, and the other protects line 2. If a fuse needs to be replaced, follow the steps listed below. Before starting the replacement procedure, locate the two extra fuses shipped with the GridBOSS.
  • Page 68 2. Remove the internal orange cover by first removing the two nuts using a 7mm socket and the four screws using a Phillips screwdriver. Then, lift the cover out of the unit.
  • Page 69 3. Locate the two internal fuses outlined in blue in the image below. 4. Remove the M6 screws (2 per fuse) as indicated by the blue arrows. Then, remove each fuse.
  • Page 70 5. Set the new fuse in place. Verify that the direction of the fuse matches the image below. The smaller notch open to the side should be towards the grid input, and the longer notch open on the end should be towards the inside of the chassis. Longer end notch Smaller side notch 6.

  • Page 71: Changelog

    Modified wording in Section 5.5 p.23 Generator Port. Value changed from 3% to 12%. Changed the shipping hybrid port breaker to 90A • Removed requirement for shared battery when using more than one inverter with GridBOSS. • • Added fault and warning codes to section 11.
  • Page 72 Corrected link for the QR code on the front page. • Added ground and neutral torque settings. • Updated minimum FW for inverters when connected to GridBOSS • • Updated GridBOSS enable settings and image in section 6.6 Added torque wrench to the recommended tools list •...
  • Page 73 NOTES...
  • Page 74 CONTACT US support@eg4electronics.com (903) 609-1988 www.eg4electronics.com...