Outback Power Systems GFX1312E User's Manual
Contents
1. 1 DUO 1 USET 1 DEVS E 2 2 3 a 3 4 FR CIM Ay CES GIN SNNT Ec 5 ce MAALLE Sg E 5 Introd uction 00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000 9 Welcome to OutBack Power Technologies csssssssssssssssssssssesssssssessssssssssssesesesescscsesesssssseseacscsesessssseeseseseseaeacaeseeses 9 MOTER Tm 9 eerie Um dam 10 Planning 1 1 9 11 sante viram qm m adt ated meae 12 E 12 12 Installation e 00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000 1 5 Location amp Environmental REQUIFEMENMS ccccssssssssssssssssssssssssssssssssssssssssssssssesesesesesesesesesescecsesesess2. 18 Parallel Three Inverters 29 Temperatu 15 Three Phase Three Inverters e ER 31 Terms and Definitions eeeeereeer erre nnn 2 dest cod n AM Ml S 32 X Three Phase Stacking esses 30 Tools Required 16 LAND OM NON t 17 Torgue Reguirements 36 900 0111 01 00 Rev A 900 0111 01 00 37 North America 19009 62nd Avenue NE Arlington WA 98223 USA 1 360 435 6030 900 0111 01 00 Rev Cut Back POWER member of The Group European Office Barcelona Spain 34 93 654 9568
3. 27 Figure 20 Example of Parallel Stacking Arrangement Three 28 Figure 21 Parallel Wiring Four 29 Figure 22 Example of Three Phase Stacking Arrangement Three Inverters 30 Figure 23 Three Phase Wiring Three 31 8 900 0111 01 00 Rev A introduction Welcome to OutBack Power Technologies Thank you for purchasing the OutBack International Series GFX Inverter Charger This product offers a complete power conversion system between batteries and AC power It can provide backup power or complete off grid service Battery to AC inverting which delivers 230 Vac at 50 Hz gt AC to battery charging Rapid transfer between AC source and inverter output with minimal delay time Inverter load support for a small AC source 12 24 and 48 volt units Wattages from 1 3 kVA to 1 4 kVA Stackable in parallel and three phase configurations v v ON ON Y Uses energy from PV wind and other renewable sources if appropriate controllers are used Grid interactive capable V CE Compliant for off grid use Figure 1 International Series GFX Inverter Charger Models The International Series GFX inverters are designed for harsher environments
4. Battery Cable Lug Figure 9 Reguired Order of Battery Cable Hardware CAUTION Fire Hazard Never install extra washers or hardware between the mounting surface and the battery cable lug The decreased surface area can build up heat 20 900 0111 01 00 Rev A installation AC Wiring Table5 AC Conductor Size and Torque Requirements Conductor Size Recommendation Torque Requirements Minimum 6 10 AWG or 0 008 in 4 0 Nm 35 in lbs The two Neutral terminals are electrically common Use only one terminal if The AC Hot Out terminal connects to the load panel It can carry up to 30 amps using the inverter s transfer relay Use the inverter connecting to an external wattage to determine actual neutral bus An external maximum load Size the breakers OUT bus is often placed in the accordingly main electrical panel which is the Loads panel CHASSIS GROUND PE shown in Figure 11 Use The AC Hot In terminal brings the other terminal if power from the AC source It z NEUTRAL connecting to a device powers both battery charger and with its own neutral wire loads Use the source amperage to such as generator determine actual maximum draw gt Size the breakers accordingly CHASSIS GROUND PE Figure 10 AC Terminals All system wiring must comply with national and local codes and regulations Multiple AC Sources It is usually require
5. Figure 18 Single Inverter Wiring 26 900 0111 01 00 Rev A installation Multiple Inverter Installations Stacking Installing multiple inverters in a single AC system allows larger loads than a single inverter can handle This requires stacking Stacking inverters does not refer to physically placing one on top of another It refers to how they are wired within the system and then programmed to coordinate activity Stacking allows all units to work together as a single system Examples of stacking configurations include parallel and three phase configurations Stacking Connections Stacking requires an OutBack HUB product as well as a system display such as the OutBack MATE A system using four or fewer units may use the HUB4 Systems using up to ten units require the HUB10 All interconnections are made using CAT5 non crossover cable HUB4 MATE Additional Ports Port1 MATE Port Figure 19 and Each inverter must be assigned a status master or slave The master is the primary and most heavily used unit The master inverter s MATE HUB port must connect to port 1 on the HUB Slave inverters provide assistance when the loads are more than the master can handle alone Slaves plug into ports 2 and above on the HUB In general it does not matter which slave connects to which port However it is always important to keep track of units and ports for programming purposes
6. gt T LI AC HUB Neutral Neutral Neutral IN Lt L1 IN L1 Inverter Slave 3 Inverter Slave 2 Inverter Slave 1 Inverter L1 Master AC Neutral HOT OUT Ground M L1 AC Neutral AC HOT OUT Ground OUT L1 AC Neutral AC HOT OUT Ground OUT L1 AC Neutral HOT Our Ground our L1 LJ 1 11 1 ll 3 ov a ma m sa m m s m gt mm gt jM PK E 5 ee 445 5 Primary System Ground H I mm zm e Mechanical Interlock Bypass Ground TBB may E be within AC Conduit Box i 1 PILLE om mm s me o am a 9 mus mm s 4 EEE EE EE EE EEO 6 4 NOTES 1 All cables are to be 6 10 AWG THHN or larger m m s mm 4 Om gt N 2 Neutral common conductor may be connected from only one inverter Neutral terminal to a common bus bar in the AC Conduit Box 3 Colors depicted here may be different from wiring standards ps yum m EE Figure 21 Parallel Wiring Four Inverters 900 0111 01 00 Rev A 29 install
7. 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 B gt gt Polle 900 0111 01 00 Rev 1 Important Safety Instructions Definitions The following is a list of initials terms and definitions used in conjunction with this product Table 1 Terms and Definitions Definition Inverter s 12 volt auxiliary output Conformit Europ enne French for European Conformity a marking on OutBack products indicating that they meet European Union requirements DVM Direct Current refers to voltage produced by the batteries or renewable source GFDI Ground Fault Detector Interruptor a safety device for PV systems Grid interactive Utility grid power is available for use and the inverter is a model capable of returning grid intertie grid tie selling electricity back to the utility grid Chassis Ground Protective Earth and PE N ED NE Remote Temperature Sensor accessory that measures battery temperature for charging System display Remote interface device such as the MATE used for monitoring programming and communicating with the inverter also called remote system display Utility
8. Programming involves using the system display to assign a status and stacking value to the inverter on each port Each inverter is assigned to power an individual phase of the system These assignments can be changed at any time as long as the master is plugged into port 1 i IMPORTANT gt The master inverter must always be connected to port 1 on the HUB Connecting it elsewhere or connecting a slave to port 1 will result in backfeed or output voltage errors which will shut the system down immediately gt Installing multiple inverters without stacking them or stacking them improperly will result in similar errors and shutdown Although stacking allows greater capacity the loads wiring and breakers must still be sized appropriately Overloading may cause breakers to trip or the inverters to shut down 900 0111 01 00 Rev A 27 installation Parallel Stacking Dual Stack and Larger In parallel stacking two or more inverters are stacked to create a single common 230 Vac bus gt All inverters share a common input AC source and run loads on a common output gt Upto ten inverters may be installed in a parallel arrangement The example on this page shows three inverters The wiring diagram on the next page shows four LOAD PANEL 3 9 kVA 230 Vac 1 3 kVA 230 Vac 1 3 230 Vac 1 3 230 Vac Figure 20 Example of Parallel Stacking Arrangement Three Inverters When installing a p
9. F to 122 F Note that the inverter s maximum wattage will derate in temperatures above 25 Theinverter will function but will not necessarily meet its specifications if operated in a temperature range of 40 C to 60 40 F to 140 F This is also the allowable temperature range for storage The specifications are listed in the nternational Series GFX Operator s Manual Dimensions Length 41 cm 16 25 Width Height 21 cm 8 25 33 cm 13 Figure 4 Dimensions 900 0111 01 00 Rev A 15 installation Tools Required gt Wire cutters strippers gt Torque wrenches gt Assorted insulated screwdrivers gt DVM or Voltmeter Mounting gt Itis easier for two people to install the GFX inverter due to its weight gt The unit must be secured with appropriate fasteners a sturdy mounting surface capable of supporting its weight OutBack cannot be responsible for damage if inadequate fasteners are used gt The unit has four mounting holes one in each corner Use fasteners in all four corners for a secure installation gt Due tothe variance in other mounting methods OutBack only endorses the use of FLEXware or previous versions of its mounting plate using M6 x 20 mm machine screws one per corner Follow the instructions with each mounting system gt If mounting the inverter on other surfaces such as plywood wall studs or masonry use appropriate fasteners to support its weigh
10. sources in phase order The master should be phase A the first slave should be phase B and the second slave should be phase C All inverter wiring and input breakers must be sized for 30 Aac or less All inverters must be of the same model The AC input generator or utility grid must be 230 400 Vac at 50 Hz a three phase wye configuration V NW V V When wiring the AC source to the inverters local codes may require the inverter breakers to be located at the bottom of the main panel This prevents overloading of the AC bus IMPORTANT Although the HUB manual states that it is necessary to move the HUB s jumper to the three phase position that statement is not applicable for this model The jumper must be left in its original position 30 900 0111 01 00 Rev A installation A Source HUB 1 4321 MATE Cats Cable Cat5 Cable AC Neutral IN Phase A AC Neutral OUT Cat5 Cable 1 7 4 4 4 Utility Grid or Generator AC Conduit Box Phase B Phase Phase i Tee fae et Mm o 5 E l 1 Input Input Input 1 Breaker Breaker Breaker E kt i F ii s ld AC AC HUB AC 1 HOT IN Neutra mare MATE HOTIN I s IN IN la Invert Invert Ri nvert
11. and where to recycle batteries and other electronic equipment OutBack Power Technologies strongly encourages you to learn about recycling and to dispose of recyclable items accordingly The Earth and OutBack Power Technologies thanks you for that effort Earth 911 com Web site www Earth911 com Address 14646 N Kierland Blvd Suite 100 Scottsdale AZ 85254 Phone 1 480 337 3025 direct OurEarth org There is a place on the website for contacting OurEarth org using email No direct email address is provided Web site http www ourearth org Address P O Box 62133 Durham NC 27715 Phone 1 410 878 6485 PETCORE org The following website provides information about PET Recycling in Europe Web site www PETCore org Address Avenue E Van Nieuwenhuyse 4 3 B 1160 Brussels Belgium Fax 32 0 2 675 39 35 E mail petcore btconnect com 900 0111 01 00 Rev A 5 Important Safety Instructions EuroRecycle net The following website provides general information about recycling in Europe It also provides a list of companies and organizations that provide recycling information or assistance Website http euro recycle net E mail http euro recycle net cgi bin feedback1 cgi w lt 27 This is an online form providing a means to contact the owners of the website 6 900 0111 01 00 Rev Table of Contents Important Safety Instructions
12. COVER Covers the DC terminal area and provides space to mount other components such as a DC current shunt AC CONDUIT PLATE Connects to AC conduit for installations which do not utilize OutBack s optional FLEXware conduit boxes BATTERY TERMINAL COVER Protects terminals from accidental contact Made of stiff plastic with a snap on design Always keep covers installed during normal operation gt When required remove covers carefully using a flat blade screwdriver inserted into the slots on the sides of each cover gt The DCC does not replace the battery terminal covers they must be installed in addition to the DCC Figure 2 GFX Components 10 900 0111 01 00 Rev A Planning Applications The International Series GFX inverters are intended for on grid off grid and grid interactive applications These models are designed to use a battery bank to store energy They can work in conjunction with photovoltaic PV panels to harvest solar energy as well as wind turbines and other renewable sources These sources charge the battery which in turn is used by the inverter In on grid applications grid power is used to run the loads When excess PV or another renewable energy source is available from the batteries the inverter supports those loads with the PV When the PV exceeds the load reguirements the inverter sells that excess power back through its input to the utility grid When the utility grid is not av
13. control one function at a time The terminals can supply up to 0 7 amps at 12 Vdc 8 4 watts This is sufficient to drive a small fan or a relay which can control a larger device The terminals accept up to 2 5 mm 14 AWG wire The AUX circuit contains electronic overcurrent protection which resets after being overloaded No additional fuses are required for the AUX terminals AC HOT IN mm T In this example the AUX directly drives a 12 volt vent The AUX LED fan The and wires on illuminates when the the fan are connected to the AUX output AUX and AUX terminals becomes active Fan Figure 14 Connections for Vent Fan Example In this example the AUX drives a relay that diverts wind power The relay s coil is connected to the AUX and AUX terminals When the AUX closes the relay based on battery voltage the Turbine relay diverts the excess wind power to a water heating element Note Relays and elements shown are examples only and may vary depending on the installation Element gt Figure 15 Connections for Diversion Example 900 0111 01 00 Rev A 23 installation Automatic Generator Start AGS The AUX terminals can be used to perform two wire generator start A two wire start generator is the simplest type where most of the circuits are automated It usually has a single switch with two positions that is turned ON to start OFF to stop Either
14. 17 18 Einem d E 17 22 L LED Indicators neret 2 17 BN NN 15 17 22 27 att etae 9 MOUNUNG 16 Multiple AC Sources eese 21 O On Off Switch Installing sess 22 P Parallel Stacking 28 Ports RJ45 and RITI 17 22 R Recycling Information 5 REG WAL ONY 5 AC 21 Remote System 1 lt 2 12 siamo tno Ode NORIS 19 Remote Temperature Sensor 5 2 10 17 22 Ground Terminals 18 Renewable 12 U CINCY rr 2 11 21 26 28 30 1 s ew ND 4 General adstante M IH AN O RO RA DNA 2 V nisi X 3 23 8 3 27 28 30 Wiring Symbols Used EO A VOLNO 1 APER ED ALEN 21 System Display 2 12 17 21 22 23 24 27 28 30 32 AUX Connections xoci o re Erde 23 DC Connectlolls ooi ERRARE UE 19 Ground
15. ATE Ports port The INVERTER ON OFF jumper bridges two pins This jumper JP1 parallels the two INVERTER ON OFF terminals on the Control Wiring Terminal Block If either set of connections is closed the inverter is ON Because the jumper is factory installed the inverter usually remains ON unless given a command by the system display AC HOT IN INVERTER Removing the jumper will turn the inverter OFF To remove the jumper su uselong nose pliers or a similar tool AUX ON OFF e se e e a INVERTER ON O AUX X Tat Once the plastic INVERTER ON OFF RY TEMP Jumper On jumper has been removed the INVERTER MA TE HUB ON OFF terminals on the Control Wiring Terminal Block can be used to wire a manual on off switch m EATTEDV I P FULL STATUS INVERTER Figure 13 Jumper and Connections 22 900 0111 01 00 Rev installation AUX Wiring The AUX and AUX terminals are a switched 12 Vdc supply The AUX can respond to many criteria and control many functions These include cooling fans vent fans load diversion fault alarms and automatic generator control The AUX output can also be controlled externally through the system display For generator control see the next page For all other functions see the system display manual and the International Series GFX Operator s Manual The AUX can only
16. Cut Back POWER member of The alpha Group International Series GFX Inverter Charger GFX1312E GFX1424E GFX1448E Installation Manual Cut Back member of The Group About OutBack Power Technologies OutBack Power Technologies is a leader in advanced energy conversion technology Our products include true sine wave inverter chargers maximum power point tracking charge controllers system communication components as well as breaker panels breakers accessories and assembled systems Contact Information Telephone 1 360 435 6030 North America 34 93 654 9568 Barcelona Spain 1 360 618 4363 Technical Support 1 360 435 6019 Fax Address North America 19009 62nd Avenue NE Arlington WA 98223 USA E mail Supporteoutbackpower com Web Site 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 Warranty Summary OutBack Power Technologies Inc warrants that the products it manufactures will be free from defects in materials and workmanship for a
17. RTER LED tells if the inverting function is on The yellow AC IN LED tells if an AC source is present The red ERROR LED indicates either a Warning or an Error A Warning is an alert for a problem that is not severe enough for shutdown An Error usually accompanies inverter shutdown See the Operator s Manual for more information VV V Terminals Ports and Features WARNING Shock Hazard The inverter s AC output is defaulted to ON from the factory It will deliver 230 Vac as soon as DC power is 17 installation Grounding WARNING Shock Hazard The unit must be connected to a grounded permanent wiring system If a bond is made between neutral and ground make sure only one bond is present in the AC system at any time Some codes reguire the bond to be made at the main panel only WARNING Shock Hazard For all installations the negative battery conductor should be bonded to the grounding system at only one point If the OutBack GFDI is present it can provide the bond IMPORTANT OutBack products are not designed for use in a positive grounded system If it is necessary to build a positive ground system with OutBack products contact OutBack Technical Support at 360 618 4363 before proceeding Additionally consult the online forum at www outbackpower com forum where this subject has been discussed extensively Table 3 Ground Conductor Size and Torque Requirements Terminal Location Minimum Conductor
18. Size Torgue Reguirements Center AC Terminals 6 mm 10 AWG or 0 008 in 2 8 Nm 25 in lbs DC Box Lug 16 mm 6 AWG or 0 021 in 5 1 Nm 45 in lbs The inverter s DC ground is a box lug located next to the negative DC battery terminal Local codes or regulations may require the DC ground to be run separately from the AC ground Also if present it will be necessary to remove the DC Cover before making the ground connection See the next page Figure 6 DC Ground Lug The two Chassis Ground PE terminals are electrically common Only one terminal can be used if connecting to an external ground bus The other terminal may be used if connecting to a device with its own ground wire such as a generator 4 FO not S B B P 7 Ground Terminals 18 900 0111 01 00 Rev A installation DC Wiring O CAUTION Eguipment Damage Never reverse the polarity of the battery cables Always use correct polarity CAUTION Fire Hazard Always install a breaker fuse or protective device to protect the DC system Table4 DC Conductor Size and Torque Requirements wen Nominal DC Amps Conductor Size Breaker Size Derated 125 Minimum GFX1312E 130 70 mm 2 0 AWG or 0 105 in 175 Adc GFX1424E 70 70 mm 1 0 AWG or 0 083 in 125 Adc 35 100 Terminal Location When installing DC cables Note minimum sizes in Table 4 but refer to local
19. ailable the inverter takes over to run the loads with PV and energy stored in the battery bank If the inverter is used as the primary source the grid power will be used when the batteries have been drained In this situation the AC power PV harvest or other renewable energy can be used to recharge the battery bank In off grid applications the inverter can use the harvested energy from the battery bank as the primary power source An AC generator can also be connected to support the system when required Utility Grid le AC IN OR MI AC Generator AC OUT FLEXmax 60 or 80 Photovoltaic Controller qui A PV Harvest AC IN d i Load OUT DC OUT Enclosure AC Battery Charging or Vonted Battery Excess AC Power not being used by the AC Loads Uses bidirectional AC input for sell back Requires a GFX Inverter Charger programmed for a grid interactive application AC power used for input only GFX inverter should have its grid interactive feature disabled when using a generator Figure 3 Applications Example 900 0111 01 00 Rev A 11 Renewable Energy The inverter cannot connect directly to PV wind or other renewable sources The batteries are the inverter s primary source of power However if these sources are used to charge the batteries the inverter can use their energy by drawing it from the batteries The renewable sourc
20. and can survive casual exposure to the elements However enclosed protection is still recommended These inverters have an internal fan but do not use outside air for cooling gt GFX1312E 1 3 kVA output 12 Vdc gt GFX1424E 1 4 kVA output 24 Vdc gt GFX1448E 1 4 kVA output 48 Inverter model numbers use the following naming convention gt Grid interactive models all models in this series begin with the letter For example model GFX1424E is grid interactive model VFX3524 is not The model number includes FX as the inverter series The first two digits show the wattage of that model For example GFX1312E is 1300 watts The second pair of digits shows the inverter s nominal DC voltage For example GFX1424E is 24 volts ON ON The letter E at the end of the model number indicates an inverter that can deliver 230 Vac at 50 Hz 900 0111 01 00 Rev A 9 Introduction Each model inverter has a single phase output marked with this symbol 2 Each inverter puts out sine wave waveform marked with this symbol X 7 Components and Accessories Table2 Components and Accessories Installed Components Included in Box Battery Terminal Cover red GFX Series Installation Manual this book Battery Terminal Cover black GFX Series Operator s Manual AC Conduit Plate WARNING ELECTRICAL SHOCK sticker DC Cover DCC Remote Temperature Sensor RTS Hf Silicone Grease Packet DCC DC
21. arallel system the following rules must be observed Parallel stacking requires a system display and a HUB gt The inverter that is mounted physically lowest is always the master and is programmed as Master See the system display manual for programming Mounting below the other inverters allows the master to avoid heat buildup and remain relatively cool as it sees the greatest duty cycle The master must be connected to port 1 of the HUB Other inverters must not be selected as master All slave inverters regardless of quantity should be selected as OB Slave L1 during programming All inverter wiring and input breakers must be sized for 30 Aac or less All inverters must be of the same model The AC input generator or utility grid must be 230 Vac at 50 Hz single phase V V V WV When wiring the AC source to the inverters local codes may require the inverter breakers to be located at the bottom of the main panel This prevents overloading of the AC bus 28 900 0111 01 00 Rev A installation AC Source LEGEND mi me Hot Utility Grid or Generator Neutral TRU 4321 Cat5 Cable AC Conduit Box X oe o m 6 Om 9 N Input Breaker Input Input Breaker Breaker HUB
22. ation Three Phase Stacking In three phase stacking inverters are stacked to create three separate 230 Vac output legs in a wye configuration gt The output of each inverter is 120 out of phase from the others Any two outputs produce 400 Vac between them The outputs can be used to power three phase loads when all inverters work together gt Only three inverters one per phase may be installed in a three phase arrangement LOAD PANEL 1 3 kVA 230 Vac 1 3 230 NC a 45 22 K kVA 230 400 3 9 1 3 230 Vac 1 3 230 Vac Figure 22 Example of Three Phase Stacking Arrangement Three Inverters When installing a three phase system the following rules must be observed gt Three phase stacking requires a system display and a gt The inverter that is mounted physically lowest is always the master and is programmed as Master See the system display manual for programming Mounting below the other inverters allows the master to avoid heat buildup and remain relatively cool as it sees the greatest duty cycle gt The master must be connected to port 1 of the HUB Other inverters must not be selected as master One slave inverter must be programmed as 3p Classic B The other must be programmed as 3p Classic C See the system display manual for programming V The inverters should be wired to loads and to
23. codes for absolute cable size recommendations Battery positive and negative cables should be no longer than 3 meters 10 feet each to minimize voltage loss and other effects gt Always install breakers or fuses on the positive cable gt The cables listed above are for each inverter in a system In a system with multiple inverters each inverter requires its own cables and breakers of the size indicated gt The inverter s battery terminal is a threaded stud which accepts a ring terminal lug Use crimped and sealed copper ring lugs with 0 79 cm 5 16 in holes or use compression lugs gt Tie tape or twist cables together to reduce self inductance Run positive and negative cables through the same knockouts and conduit Makecertain the DC breaker is turned to the off position or the fuse is removed before proceeding If present remove the battery terminal covers These are made of stiff plastic with a snap on design Remove carefully using a flat screwdriver inserted into the slots on the sides of each cover Figure 8 Battery Terminal Covers 900 0111 01 00 Rev A 19 installation M8 x 1 25 Stud Install battery cable lug nuts and washers in the 13 mm Nut order illustrated The battery cable lug should be the first item installed on the stud It should make solid contact with the mounting surface Do not install hardware in a different order than shown Flat Washer lt Lock Washer J laa al al
24. d in most cases for safety reasons CAUTION Hazard to Equipment Batteries can emit hydrogen sulfide gas which is corrosive over long periods of time Installing the inverter in the battery compartment may cause corrosion which is not covered by the product warranty Sealed batteries may be an exception Generator The GFX inverters can work with any generator that delivers clean 230 Vac at 50 Hz Inverters stacked for three phase output can work with three phase generators gt If automatic generator starting is desired the generator must be an electric start model with an automatic choke The inverter can only perform two wire starting See page 24 For other starting configurations additional equipment is required gt In all cases the inverter must be programmed appropriately using a remote system display See the International Series GFX Operator s Manual and the system display manual Generator Sizing 12 900 0111 01 00 Rev A A generator should be sized to provide enough power for all the loads and the battery charging gt Available generator power may be limited by ratings for circuit breakers and or generator connectors gt The generator must be able to provide current to all inverters on a given phase or leg Minimum generator wattage is usually recommended to be twice the wattage of the inverter system Many portable generators may not be able to maintain AC voltage or frequency for long periods of time if t
25. d to have a selector switch that changes between multiple AC sources The switch should be the type which disconnects from one source before contacting another This prevents the risk of connecting to two out of phase sources at the same time or connecting them to each other Utility Grid Generator HOT NEU GND Inverter Single Pole Double Throw Switch Figure 11 Multiple AC Sources IMPORTANT When installing a generator it is recommended to turn off the GFX inverter s Sell feature See the system display manual for instructions 900 0111 01 00 Rev A 21 installation Accessory Wiring The AC Wiring Compartment Board has ports for both the Remote Temperature Sensor RTS and 4 AGHOTIN the system display The system display port is labeled MATE HUB If a HUB is in use it occupies the inverter s MATE HUB port RTS cable RJ1 1 4 conductor telephone 4 MATE HUB port See the Operator s Manual for more information on MATE cable RJ45 the RTS 8 conductor CAT5 non crossover Figure 12 Accessory Connections When a HUB occupies the inverter s MATE HUB port the system display connects directly to the HUB Inverters plug into ports 1 and above Charge controllers and other devices plug into additional ports after the last inverter is connected See Stacking on page 27 for information on connecting inverters See the HUB manual for other devices Additional M
26. e is always treated as a battery charger even if all of its power is used immediately The renewable source must have a charge controller or some way to prevent overcharging OutBack Power s FLEXmax charge controllers can be used for this purpose as can other products Battery Bank IMPORTANT Battery charger settings need to be correct for a given battery type Always follow battery manufacturer recommendations Making incorrect settings or leaving them at factory default settings may cause the batteries to be undercharged or overcharged When planning a battery bank consider the following gt The GFX inverters work best with lead chemistry batteries intended for deep discharge These include batteries for marine golf cart and forklift applications They also include gel cell batteries and absorbed glass mat AGM batteries OutBack Power recommends the use of batteries designed specifically for RE applications Automotive batteries are strongly discouraged and will have a short life if used in inverter applications Nickel based batteries and lithium ion batteries are discouraged due to limitations in the inverter s battery charger gt These inverters are designed to work with 12 24 or 48 volt battery banks depending on inverter model Before constructing a battery bank check the inverter model and confirm nominal battery voltage gt Avented enclosure for the battery bank may be required by electric code and is recommende
27. e or destroy the equipment and void the product warranty gt Thoroughly inspect the equipment prior to energizing Verify that no tools or equipment have been inadvertently left behind gt Ensure clearance requirements are strictly enforced Keep all vents clear of obstructions that can prevent proper air flow around or through the unit gt Sensitive electronics inside the equipment can be destroyed by static electricity Be sure to discharge any static electricity before touching the equipment and wear appropriate protective gear Battery Safety WARNING Explosion Electrocution or Fire Hazard gt V V V Use the battery types recommended by OutBack Power Technologies Follow the battery manufacturer s recommendations for installation and maintenance Ensure the cables are properly sized Failure to size the cables properly can result in a fire hazard Ensure clearance reguirements are strictly enforced around the batteries Ensure the area around the batteries is well ventilated and clean of debris Never smoke or allow a spark or flame near the batteries Always use insulated tools Avoid dropping tools onto batteries or other electrical parts Keep plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eyes Wear complete eye and clothing protection when working with batteries Avoid touching bare skin or eyes while working near batteries If battery acid co
28. er Inverter Slava Slave p Phase Phase C I a AC HOT Ar AC HOT e AG HOT Neutral Neutral Ground OUT Ground OUTE OUT Ground OUTE l z n I b mam Ground TEB may be within Conduit d Box Primary System Ground LEGEND m Neutral a a m a Ground Terminal Bus Bar TBB Figure 23 900 0111 01 00 Rev A Output Breakers x3 1 PA ose os FE 8 GE 4 i li er TI E 1 2 m Rt ly phen 1 All cables are to be mm 10 AWG THHN or larger 2 Neutral common conductor may be connected from only one inverter Neutral terminal to a common bus bar in the Conduit Box 3 Colors depicted here may be different from wiring standards Three Phase Wiring Three Inverters 3 installation Functional Test Once the mounting wiring and other installation steps are completed proceed to the International Series GFX Operator s Manual The Operator s Manual has steps for powering up and performing a functional test on the inverter system as well as powering down and adding new devices to an existing system Refer to the system display manual for programming instructions and menus 32 900 0111 01 00 Rev A installation NOTES 33 900 0111 01 00 Rev A installati
29. grid The electrical service and infrastructure supported by the electrical or utility company also called mains utility service or grid General Safety WARNING Limitations on Use This eguipment is NOT intended for use with life support eguipment or other medical eguipment or devices 2 900 0111 01 00 Rev Important Safety Instructions CAUTION Equipment Damage Only use components or accessories recommended or sold by OutBack Power Technologies or its authorized agents IMPORTANT Do not attempt to install this equipment if it appears to be damaged in any way See the Troubleshooting Section for instructions on how to return the equipment if it is damaged or suspected to be damaged Personal Safety WARNING Personal Injury gt This equipment weighs in excess of 22 kg 49 Ibs Use safe lifting techniques when lifting this equipment as prescribed by local codes gt Use standard safety equipment such as safety glasses ear protection steel toed safety boots safety hard hats etc as prescribed by local codes when working on this equipment gt Use standard safety practices when working with electrical equipment e g remove all jewelry use insulated tools wear cotton clothing etc gt Never work alone when installing or servicing this equipment Have someone nearby that can assist if necessary Inverter Safety gt 900 0111 01 00 Rev A WARNING Let
30. hal Voltage gt Review the system configuration to identify all possible sources of energy Ensure ALL sources of power are disconnected before performing any installation or maintenance on this equipment Confirm that the terminals are de energized using a validated voltmeter rated for a minimum 1000 Vac and 1000 to verify the de energized condition gt Do not perform any servicing other than that specified in the installation instructions unless gualified to do so or have been instructed to do so by OutBack Power Technologies Technical Support personnel WARNING Burn Hazard Internal parts can become hot during operation Do not remove the cover during operation or touch any internal parts Be sure to allow sufficient time for internal parts to cool down before attempting to perform any maintenance WARNING Fire Hazard gt Do not place combustible or flammable materials within 3 7 m 12 feet of the eguipment gt This product contains relays with moving parts and is not ignition protected Ensure AC and DC cable sizes conform to local codes See pages 19 through 21 for minimum size requirements Ensure all conductors are in good condition Do not operate the unit with damaged or substandard cabling Important Safety Instructions CAUTION Equipment Damage gt When connecting cables from the inverter to the battery terminals ensure the proper polarity is observed Connecting the cables incorrectly can damag
31. hey are loaded more than 8096 of rated capacity after de ratings for peak versus continuous power for load power factor considerations for altitude and for ambient temperature 900 0111 01 00 Rev A 13 NOTES 900 0111 01 00 Rev A installation Location and Environmental Reguirements The International Series GFX inverters can be located outdoors but OutBack still recommends that they be protected from the environment gt If protected from the environment the inverter can mount in any position or orientation If exposed to the environment it cannot be placed upside down to ensure that water will not accumulate under the DC cover It can be mounted in any other position or orientation gt For installations where the inverter may be exposed to water spray the inverter must be mounted either with the base down shelf mounting or with the AC wiring compartment facing down wall mounting mounted with the base down water cannot be allowed to accumulate around the inverter s base There is a drainage system on the base of the inverter to dispel condensation If submerged water can enter this drain and cause failure gt The inverter will perform more efficiently in locations offering plenty of air circulation The recommended minimum clearance is 5 to 10 cm 2 to 4 inches on all sides of the inverter gt The inverter will function to all of its specifications if operated in a range of 0 to 50 32
32. ntacts skin or clothing wash immediately with soap and water If acid enters the eye immediately flood it with running cold water for at least 20 minutes and get medical attention as soon as possible Never charge a frozen battery Insulate batteries as appropriate against freezing temperatures A discharged battery will freeze more easily than a charged one If a battery must be removed always remove the grounded terminal from the battery first Make sure all devices are de energized or disconnected to avoid causing a spark If a remote or automatic generator control system is used disable the starting circuit and or disconnect the generator from its starting battery while performing maintenance to prevent accidental starting IMPORTANT Baking Soda neutralizes lead acid battery electrolyte Vinegar neutralizes NiCad and NiFe battery electrolyte Have a supply of either substance readily available if using these types of batteries 900 0111 01 00 Rev A Important Safety Instructions Regulatory Listings The International Series GFX Inverter Charger is CE compliant for off grid use Recycling Information IMPORTANT Recycle Electronics and Batteries Batteries are considered hazardous waste and must be recycled according to local jurisdiction Inverters and other electronics contain metals and plastics that can and should be recycled The following are some websites and phone numbers that provide information regarding how
33. on NOTES 900 0111 01 00 Rev A lt AC Conduit Plate 10 AC 17 ME MI RE NINA 21 1E E e EEA a ME 2 AD PE zena ea ee 11 PAN a TE 1 Automatic Generator 5 2 24 POD A SEEN MOR OO A PINI 2 AUX ETNA S 17 Battery BARK 12 Battery Terminal 10 19 C Communication 22 27 COMPONEMNG scscccccsscscecsecscecsesecsceesecscecsesecscerserseecerserses 10 Conductor Size AC CONA OS 21 DC 19 Ground Conductors eerte 18 Control Wiring Terminal Block 17 D DCC 10 15 ea us 17 20 19 DENI IS AS 2 DIMENSIONS 15 Diversion 23 Drawings General System 11 Parallel Stacked System 29 5 26 Three Phase 31 2 16 900 0111 01 00 11 12 21 24 25 26 28 30 a NM 13 FED ES 2 18 UVE iona 2 11 ires
34. period of two 2 years subject to the conditions set forth in the warranty detail found in the nternational Series GFX Operator s Manual OutBack Power Technologies cannot be responsible for system failure damages or injury resulting from improper installation of their products Notice of Copyright International Series GFX Installation Manual September 2010 by OutBack Power Technologies All Rights Reserved Trademarks OutBack Power is a registered trademark of OutBack Power Technologies Date and Revision September 2010 Revision A Part Number 900 0111 01 00 Rev A for firmware revision 002 094 xxx Important Safety Instructions READ AND SAVE THESE INSTRUCTIONS This manual contains important safety instructions for the International Series GFX inverters Read all instructions and cautionary markings on the inverter and on any accessories or additional equipment included in the installation Failure to adhere to these instructions could result in severe shock or possible electrocution Exercise extreme caution at all times to prevent accidents Audience 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 Symbols Used Single Phase WARNING Hazard to Human Life This type of notation indicates that the hazard could be harmful to human life
35. re 1 International Series GFX Inverter Charger eee eese ee eeeee entere tatontn tnos 9 Fig re2 GFX Parts and Accessories tierra 10 Figure Applications Example vana 11 Figure MN PIS ne E EU T 15 Figure5 Terminals Ports and 17 Rigure6 DEGUNA t a Det RE 18 Figure 7 AC Ground osos oni i op OO Nn in dae o roni ib aus 18 Figure 8 Battery Terminal 4 0 19 Figure9 Required Order of Battery Cable Hardware eere ee tertntnntns 20 Figure 10 don ena tina o dani 21 Figure Ti Multiple CSOUFEES n da e d ven ern pe etn 21 Figure 12 Accessory S t edle he dnm enini tn a 22 Figure 13 ON OFF Jumper and Connections cccsssssessssssesscessesscsssssscesssssssceesssecsssesecscasseseeasscsecscaees 22 Figure 14 AUX Connections for Vent Fan Example 23 Figure 15 AUX Connections for Diversion Example 23 Figure 16 Two Wire Generator Start Example 24 Figure 17 Three Wire Generator Start Example 25 Figure 15 Sindlesinverer WIEITIQ as datis Ni t d cte p et nt 26 Figure 9 OutBack HUBA and
36. sesssesesesees 15 EEA 15 A ele 16 MOUNN 16 URSUS OSEE A 17 Groundin 18 19 RR UU 21 UDE 5 S a a o a le k ba ae 21 Jao E V RE 22 PM Va UM IME 23 Generator 24 Single Inverter InstallatiOns nanana 26 Multiple Inverter Installations Stacking csssssssssssssssssscscscsssssssesssssssssssssescscsssesessssssssssesesesesescsseseseseseseaeseseeses 27 Parallel Stacking Dual Stack and Larger 28 de E m m an 30 ONA SSI SS T 32 dH 35 900 0111 01 00 Rev A 7 List of Tables Table 1 2 Table 2 Components and ACCESSONES stitit eoi tomba EE Ee 10 Table 3 Ground Conductor Size and Torque Requirements eene 18 Table4 DC Conductor Size and Torque Requirements 19 Table 5 AC Conductor Size and Torque 5 21 Figu
37. t OutBack cannot be responsible for damage to the product if it is attached with inadequate fasteners gt Mount secure each component before attaching any wiring gt When the inverter is used with other metal chassis make sure that all chassis are grounded appropriately See the grounding instructions on page 18 Grounding other chassis may involve metal to metal contact or separate ground wires IMPORTANT using an OutBack FLEXware Mounting Plate avoid large air gaps behind the plate These can result in louder mechanical noise during heavy inverting or charging 16 900 0111 01 00 Rev A installation Terminals and Ports DC TERMINALS Connect to battery cables and DC system See page 19 for instructions CONTROL WIRING TERMINAL BLOCK Receives control wires for a variety of functions including automatic generator starting See pages 23 and 24 for instructions and the International Series GFX Operator s Manual for more information The Terminal Block can be unplugged from the AC board for convenience While installed keep screws tight and the block itself secured tightly to the AC board to prevent malfunction INVERTER ON OFF Receives wires for a manual on off switch to control the inverter The JP1 jump alongside disables these terminals when installed factory default In this state the inverter is always ON and can only be controlled by the system display See page 22 for instr
38. the system display or the FLEXnet DC can be programmed to perform automatic generator start using the AUX terminals See the system display or FLEXnet manuals for programming instructions The 12 Vdc signal provided by the AUX can be switched on and off to provide a start signal It is not usually recommended to connect the AUX directly to the generator but to energize a 12 Vdc automotive or similar relay with it Depicted is the OutBack FLEXware Relay Assembly which is sold for this purpose The relay contacts can conduct power to start the generator from the battery or whatever source is used The drawing below is one example of a possible arrangement Specific arrangements relays and other elements depend on the requirements of the installation and of the generator Note that it is more common for the battery to be incorporated in the generator Battery s BATTERY TEMP Relay Two Wire Start Generator Figure 16 Two Wire Generator Start Example 24 900 0111 01 00 Rev A installation three wire start generator has two or more starting circuits It usually has a separate switch or position for cranking the generator The AUX terminals cannot control this type of generator without using a three wire to two wire conversion kit Atkinson Electronics http atkinsonelectronics com makes these kits among other companies The Atkinson GSCM Mini is designed to work with OutBack inverters and others The drawing belo
39. uctions AUX OUTPUT AUX AUX Delivers 12 Vdc up to 0 7 amps 8 4 watts The output can be switched on and off for many functions The default function is to drive a cooling fan See page 23 for hookup instructions See the system display manual for programming instructions AUX LED INDICATOR Amber LED turns on when 12 Vdc output is present Figure 5 connected 900 0111 01 00 RevA DC and GROUND TERMINALS Connect to grounding system for both batteries and AC See page 18 for instructions ut Back Power Systems AC TERMINAL BLOCK Receives AC input and output wires See page 21 for instructions AC HOT OUT AC NEUTRAL OUT N CHASSIS GROUND PE CHASSIS GROUND PE Non operational terminals Do not connect anything to them AC NEUTRAL IN AC HOT IN ip opes zd MATE and RTS PORTS Receive the RJ45 and RJ11 plugs from the system display and Remote Temp Sensor See page 22 for instructions 7 ec A gt BAT ZRY TEMP The jacks are mounted sideways When viewed from the left side they appear as shown below STATUS INVERTER LED INDICATORS Display the unit status and battery voltage The Operator s Manual contains extensive descriptions of the LED functions gt The three BATTERY LEDs green yellow and red are based on DC voltage and provide a very general idea of battery state The green INVE
40. w is one example of a possible arrangement Specific arrangements relays and other elements depend on the requirements of the installation and of the generator Note that it is more common for the battery to be incorporated in the generator BATTERY TEME MATE HUB Atkinson GSCM Mini na L Zt 4 Three Wire Start Generator Figure 17 Three Wire Generator Start Example 900 0111 01 00 Rev 25 installation Single Inverter Installations When installing an inverter AC system the following rules must be observed gt All wiring and input breakers must be sized for 30 Mac or less gt All output breakers must be sized appropriately for loads and inverter wattage AC Source Utility Grid or AC Generator AC Conduit Box 5 Cable Input i Breaker HUB AC Neutral MATE HOT IN IN Inverter Charger AC AC Neutral HOT OUT OUT Mechanical Interlock i Output Bypass D tu Breaker 4 Breaker LO Ground may be within AC Conduit Box Primary system Ground AC Loads NOTES 1 All cables are to be 6 mm 10 AWG THHN or larger 2 Meutral common conductor may be connected from only one inverter Neutral terminal to a common bus bar in the AC Conduit Box 3 Colors depicted here may be different from wiring standards LEGEND HOT e ona Ground Terminal Bus Bar
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