Outback Power Systems GFX1424 User's Manual
Contents
1. Q 34 Index 900 0113 01 00 Table of Contents Table 1 Table 2 Table 3 Table 4 Table 5 Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 List of Tables Terms abd Del CLOWNS 2 Components and ACCeSSOTIGS 10 Ground Conductor Size and Torque Requirements eerte 18 DC Conductor Size and Torque 19 AC Conductor Size and Torque Requirements eene teonones 21 GFX Series Inverter Charge nsss aA 9 NT 10 Applications EXamiple Glenn ato aei adeste notte Led 11 NETT I TINTE 15 Terminals Ports and Features tatnen totos enean tete 17 DE Cie Ue RR UU a 18 AC Ground i atn Sn 18 Battery Terminal COVE ananena Noe ata 19 Required Order of Battery Cable Hardware 20 AC NU AA 21 Multiple AC SOUT ES 21 Accessoby CONNECTIONS 22 ON OFF Jumper and Connections sanies easier a ene2. 11 Renewable T YO 12 Battery Baile scenes 12 12 Insta lation e 000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000 1 5 Location and Environmental REQUIFEMENMS cccscscsssssssssssssssssssssssssssssssssssseseseseseseceseseseseseseseseseseeseseseseseseseees 15 DAOR 15 ERE M 16 16 TEMNA POS 17 18 19 21 C OUr EE sarr E E nena 21 AE SO VN ee eee ee eet ee eee 22 AUX 23 Automatic Generator start AGS ONES 24 Single inverter IIMS CAM ATIOINS anno 26 Multiple Inverter Installations Stacking 27 Classic Series Stacking D al StacK ous revisit oa re v EIER 28 Parallel Stacking Dual Stack and 30 MIAO Phare de MT 32 suc NE CT T O
3. 32 99 TS CA oov eps 1 System Display 2 12 17 21 22 23 24 27 30 32 34 Tem DETE 15 Terms and 2 e EE 34 Three Phase Stacking eee 32 36 T6615 REGU E Ona od n 16 Torque Requirements AC asd itat ttu ne 21 DC TEMNA Sana aaa eati doses 19 Ground 18 U AE N 2 11 21 26 30 32 V Vent Palicanus te tre peste aoc D 23 Wiring AC COMMECHONS 21 AUK EOMMECHONS OE eS 23 DC 19 Ground Connections 18 Parallel Three 31 Three Phase Three Inverters 33 900 0113 01 00 Rev A 900 0113 01 00 37 North America 19009 62nd Avenue NE Arlington WA 98223 USA 1 360 435 6030 900 0113 01 00 Cut Back POWER member of The cim Group Europe Barcelona Spain 34 93 654 9568
4. o mo 1 1 i r m Mechanical i Output h Interlock j C Bypass i Breakers oe Breakers Ground TBB be within x4 1 4 Primary System 1 im i l Ground ee pd 1 bum d ae Kam ani d uni ani m umi aly ae mee 4 Tag E l gt ME E o r4 a ME NOTES i eS d A Men Ld Neutral i Fog 1 conductor may be p 4 3 a ty connected from only one inverter Meutral terminal to a common bus bar in the Conduit Box Figure 23 Parallel Wiring Four Inverters 900 0113 01 00 Rev A 31 installation Three Phase Stacking In three phase stacking inverters are stacked to create three separate 120 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 208 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 120 Vac 3 9 kVA 208 Vac 1 3 120 1 3 1 3 120 120 Figure 24 Example of Three Phase Stacking Arrangement Three Inverters When installin
5. All inverters must be of the same model The AC input generator or utility grid must be 120 Vac at 60 Hz single phase VV ON ON ON Y 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 30 900 0113 01 00 Rev A installation LEGEND AC Source Utility Grid or AC Generator Hat Neutral Terminal Bus Bar TEB MNE ME umo i EAD AA i A ME a o Y 1 input Inpul Breaker Breaker Lipi MATE Inverter Slave 3 Inverter Inverter Inverter L1 Master Slave 1 Slave 2 AC Neutral HOT Noutral AC HOT Neutral AC HOT AC Heutral AC HOT our our Ground guru our Smund OUT Freund rE 1 LE 101 101 211 11 X11 11 C11 11 11 11 11 21 11 11 1 S EEE EA EA AA EE LE EE TE EE 11331 31061 FT Fu Il lb WEE EE ES EE EE lll Il II EE EE LCE LE FE 8 9 E Sig r gP
6. Once the mounting wiring and other installation steps are completed proceed to the GFX Series 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 900 0113 01 00 Rev A 34 AC Conduit 10 AC WOW AUS aa anni ia 17 n eR die 21 LC 2 Applications uiid 11 JA 1 Automatic Generator 5 2 24 Di 2 AUX Terminals RR M 17 B Battery Balle oot 12 Battery Terminal 10 19 C Classic Series Stacking esses 28 Communication 1 22 27 cec 10 Conductor Size nc CODGMHEEOES 21 DC Conductors sisse auti aaa TH HIDE PU 19 Ground Conductors eene 18 Control Wiring Terminal Block 17 D DC Cover IC 10 15 DC Terminals 17 20 19 2 DIMENSIONS M 15 Diversion Control eese eeeeeee terere ntntus 23 Drawings General System La
7. Control Wiring Terminal Block can be used to wire a manual on off switch 3 lt E HUB L STATUS INVERTER 5 peo AD Z ra eee ieee Figure 13 ON OFF Jumper and Connections 22 900 0113 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 GFX Series Operator s Manual The AUX can only 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 relay which can control a larger device The terminals accept up to 14 AWG 2 5 mm wire The AUX circuit contains electronic overcurrent protection which resets after being overloaded No additional fuses are reguired for the AUX terminals 4 In this example the AUX e MP S directly drives a 12 volt vent The AUX LED fan The and wires on gt illuminates when the the fan are connected to the AUX output AUX and AUX terminals becomes active INVERTER ON OFF INVERTER BP AF TEMP AE RUB Fan Figure14 AUX Conn
8. 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 Europe The following website provides information about PET Recycling in Europe Website 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 6 900 0113 01 00 Rev A Table of Contents Important Safety Instructions M M Des 1 ineo 1 Bi 2 General ANS o theses 2 3 DMV STS a MIU adde RINT nU 3 ELELE 4 enke 5 Introd uction 9 Welcome to OutBack Power Techn ologies sssscsssssssesssssssssssssscsescssscssssssssssesesesesesssesesessssssesesesesesssesseseseseseseacers 9 lt S 9 Components ACCeSSOFIOS auci 10 Pla n ning 000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000 1 1 1922
9. 2 00 PM and 1 00 PM to 4 00 PM PST Email r9 recyclecityaepa gov Keep America Beautiful USA Website www kab org Address 1010 Washington Boulevard Stamford CT 06901 Phone 1 203 659 3000 Main number Fax 1 203 659 3001 Email info kab org OurEarth org USA 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 Box 62133 Durham NC 27715 Phone 1 410 878 6485 900 0113 01 00 RevA Important Safety Instructions National Institute of Recyclers Mexico Web site http www inare org mx Email a57841279 prodigy net mx margarita inare org mx Phone 1 55 57 85 9160 Fax 1 55 57 84 1279 Natural Resources Canada Address 580 Booth Ottawa ON K1A OE8 Phone 1 613 995 0947 1 613 996 4397 Phone and TTY Monday to Friday 8 30 a m to 4 30 p m ET Website X http www nrcan rncan gc ca mms smm busi indu rec rec eng htm Office of Waste Management Canada Address Office of Waste Management Conservation and Protection Environment Canada Ottawa Ontaro KTA 0H3 Phone 1 819 997 2800 Website X http www portaec net library recycling recycling in canada html EuroRecycle net Europe 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 X http
10. AC Hot In terminal brings the other terminal if power from the AC source It AC NEUTRAL IN connecting to a device powers both battery charger and with its own neutral wire loads Use the source amperage to such as a generator determine actual maximum draw Size the breakers accordingly Figure 10 AC Terminals Multiple AC Sources It is usually required 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 Generator e HOT NEU GND Utility Grid HOT NEU GND The arrow between the output neutral and ground wires indicates that these two wires have been bonded together usually at the main electrical panel Only one bond should be made between neutral and ground at any time If a generator is present in a building based installation its neutral and ground Q D should be isolated Double Throw Switch Figure 11 Multiple AC Sources All system wiring must comply with national and local codes and regulations 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 0113 01 00 Rev A 21 installation Accessory Wiring The AC Wiring Compartment Board has ports
11. AUTION Fire Hazard Always install a breaker fuse or protective device to protect the DC system Table4 Conductor Size and Torque Requirements Nominal DC Amps Conductor Size Breaker Size Derated 125 Minimum GFX1312 130 2 0 AWG or 0 105 in 70 mm 175 Adc GFX1424 70 1 0 AWG or 0 083 in 70 mm 125 Adc Terminal Location When installing DC cables Note minimum sizes in Table 4 but refer to local codes for absolute cable size recommendations Battery positive and negative cables should be no longer than 10 feet 3 meters each to minimize voltage loss and other effects 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 inverter s battery terminal is a threaded stud which accepts ring terminal lug Use crimped and sealed copper ring lugs with 5 16 in 0 79 cm 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 side
12. Outdsack member of The ahim Group GFX Series Inverter Charger GFX1312 GFX1424 GFX1548 Installation Manual Cut Back POWER member of The arin 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 Support outbackpower 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 period of two 2 years sub
13. T IN MATE and RTS PORTS Receive the RJ45 and RJ11 plugs from the system display and Remote Temp Sensor See page 22 for instructions The jacks are mounted sideways When viewed from the left side they appear as shown below STATUS INVERTER O ERROR LED INDICATORS Display the unit status and battery voltage The Operator s Manual contains extensive descriptions of the LED functions The three BATTERY LEDs green yellow and red are based on DC voltage and provide a very general idea of battery state The green INVERTER 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 Terminals Ports and Features WARNING Shock Hazard The inverter s AC output is defaulted to ON from the factory It will deliver 120 Vac as soon as DC power is 17 installation Grounding AN 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 require the bond to be made at the main panel only AN WARNING Shock Hazard For all installations the negative battery conductor should be bonded to the groun
14. able of supporting its weight OutBack cannot be responsible for damage if inadeguate 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 Dueto the variance in other mounting methods OutBack only endorses the use of FLEXware or previous versions of its mounting plate Use M6 x 20 mm machine screws one per corner to attach the inverter to the mounting plate 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 weight OutBack cannot be responsible for damage to the product if it is attached with inadequate fasteners gt Mount and 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 If 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 0113 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 func
15. artment facing down wall mounting If 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 The inverter will perform more efficiently in locations offering plenty of air circulation The recommended minimum clearance is 2 to 4 inches 5 to 10 cm on all sides of the inverter The inverter will function to all of its specifications if operated in a range of 32 to 122 F 0 C to 50 Note that the inverter s maximum wattage will derate in temperatures above 77 25 The inverter will function but will not necessarily meet its specifications if operated in a temperature range of 40 F to 140 F 40 to 60 C This is also the allowable temperature range for storage The specifications are listed in the GFX Series Operator s Manual Dimensions Length 16 25 41 cm Width Height 8 25 21 cm 13 33 cm B ZM ll Wit Figure 4 Dimensions 900 0113 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 to a sturdy mounting surface cap
16. attery 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 vented enclosure for the battery bank may be required by electric code and is recommended in most cases for saf
17. ding 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 Table3 Ground Conductor Size and Torque Requirements Terminal Location Minimum Conductor Size Torque Requirements Center AC Terminals 8 AWG or 0 016 in 10 mm 25 in Ibs 2 8 Nm DC Box Lug 6 AWG or 0 025 16 mm 45 in lbs 5 1 Nm 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 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 D OSS Figure 7 AC Ground Terminals 18 900 0113 01 00 Rev A installation DC Wiring O CAUTION Eguipment Damage Never reverse the polarity of the battery cables Always use correct polarity O C
18. ected from only one inverter Neutral terminal to a common bus Ground bar in the AC Conduit Box Terminal Bus Bar TBB Figure 21 Classic Series Wiring Two Inverters 900 0113 01 00 Rev A 29 installation Parallel Stacking Dual Stack and Larger In parallel stacking two or more inverters are stacked to create a single common 120 Vac bus gt Allinverters 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 120 Vac 1 3 kVA 120 Vac 1 3 kVA 120 Vac 1 3 kVA 120 Vac Figure 22 Example of Parallel Stacking Arrangement Three Inverters When installing a parallel system the following rules must be observed gt 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 60 Aac or less
19. ections for Vent Fan Example In this example the AUX drives a relay that AGBOT IN K 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 relay diverts the excess wind power to a water heating element Turbine INVERTER ON OFF INVERTER BATTERY TEMP Note Relays and elements shown are examples only Element and may vary depending on the installation Figure 15 Connections for Diversion Example 900 0113 01 00 Rev 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 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 so
20. equire the HUB10 All interconnections are made using CAT5 non crossover cable Sei TES ILE HUB4 MATE Additional Ports Port1 MATE Port Figure 19 OutBack and MATE 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 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 a specified phase of the system These assignments can be changed at any time as long as the master is plugged into port 1 i IMPORTANT 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 brea
21. er 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 x M AC Generator AC OUT ae AC IN Battery Loads gt Battery Bank PV NS Vonted Battery AC OUT DC OUT Enclosure 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 FLEXmax 60 or 80 Photovoltaic MPPT Controller E 1 AC power used for input only GFX inverter should have its grid interactive feature disabled when using a generator Figure 3 Applications Example 900 0113 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 source is always treated as a b
22. ers the DC terminal area and provides space to mount other components such as a DC current shunt AC CONDUIT PLATE D Connects to AC conduit for installations which do not utilize OutBack s optional FLEXware conduit boxes pum 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 0113 01 00 Rev A Planning Applications The GFX Series 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 requirements the inverter sells that excess power back through its input to the utility grid When the utility grid is not available the invert
23. ety 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 120 Vac at 60 Hz Inverters stacked for split phase output 120 240 Vac can work with both legs of a split phase generator 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 nallcases the inverter must be programmed appropriately using a remote system display See the GFX Series Operator s Manual and the system display manual 12 900 0113 01 00 Rev A Generator Sizing A generator should be sized to provide enough power for all the loads and the battery charger 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 ab
24. fere eee 22 AUX Connections for Vent Fan 23 AUX Connections for Diversion Example eese tette 23 Two Wire Generator Start 24 Three Wire Generator Start EXAMPLE uu 25 SMIE e r WINN O EE loti d be dcn a MGR SAT d 26 OutBack and MATE onini e ebat a t ERU UR 27 Example of Classic Series Stacking Arrangement esent 28 Classic Series Wiring Two Inverters 29 Example of Parallel Stacking Arrangement Three Inverters 30 Parallel Wiring Four Inverters 31 Example of Three Phase Stacking Arrangement Three Inverters 32 Three Phase Wiring Three 33 900 0113 01 00 Rev A Introduction Welcome to OutBack Power Technologies Thank you for purchasing the OutBack GFX Series 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 120 Vac at 60 Hz AC to battery charging gt 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
25. for both the Remote Temperature Sensor RTS and AC HOT IN 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 INVERTER ON OFF RTS cable RJ1 1 4 conductor telephone RTS port 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 MATE Ports port The INVERTER ON OFF jumper bridges two pins This jumper JP1 AC HOT IN 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 Removing the jumper will turn the inverter OFF To remove the jumper m use long nose pliers or a similar tool m z Be 2 7 Once the plastic INVERTER ON OFF 1 TEMP Jumper jumper has been removed the INVERTER ON OFF terminals on the
26. from 1 3 kVA to 1 5 kVA Stackable in series parallel and three phase configurations VV ON Y V Uses energy from PV wind and other renewable sources if appropriate controllers are used gt Grid interactive capable Figure 1 GFX Series Inverter Charger Models The GFX Series inverters are designed for harsher environments 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 GFX1312 1 3 kVA output 12 gt GFX1424 1 4 kVA output 24 Vdc gt GFX1548 1 5 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 GFX1424 is grid interactive model VFX3524 is not gt The model number includes FX as the inverter series Thefirst two digits show the wattage of that model For example GFX1312 is 1300 watts gt The second pair of digits shows the inverter s nominal DC voltage For example GFX1424 is 24 volts 900 0113 01 00 Rev A 9 Introduction Each model inverter has a single phase output marked with this symbol Each inverter puts out a sine wave waveform marked with this symbol X 7 Components and Accessories Table2 Components and Accessories Included in Box GFX Series Installation Manual this book DCC DC COVER Cov
27. g a three phase system the following rules must be observed Three phase 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 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 The inverters should be wired to loads and to AC 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 60 Aac or less All inverters must be of the same model The AC input generator or utility grid must be 120 208 Vac at 60 Hz a three phase wye configuration 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 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 or
28. iginal position 32 900 0113 01 00 Rev A installation AC Source Utility Grid or AC Generator HUB za AC Conduit Box 4321 MATE Phase A PhasaB Cats Cable L L yv mE Cats Cable i i rd AH ew A _ Dos AC AC Hug Neutral MATE HOTIN Neutral MATE IH IN IN i rt i nverter Inverter aka Phase Phase B Phase C AC AC AC 1 l AC HOT Neutral AC HOT Neutral HOT s OUT Ground OUTE Ground OUT Ground oUTC i rd i od 1d 1 1 m semi ma NEON gt OE MN OE c ae i 7 Ground may be within Mechanical 4 AC Conduit T Interlock _ D Bypass Primary System eaters ans Ground p c x3 i poi eo mam mu a ly iar MET i i aoe L 1 JH me aM OR z 1 ES S mo s ss E a S E 1 LEGEND NOTES Neutral common conductor may be connected from only one inverter Neutral terminal to a common bus bar in the AC Conduit Box Terminal Bus Bar TBB Figure 25 Three Phase Wiring Three Inverters 900 0113 01 00 Rev A 33 installation Functional Test
29. ity Be sure to discharge any static electricity before touching the equipment and wear appropriate protective gear Battery Safety A WARNING Explosion Electrocution or Fire Hazard gt V V WV 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 requirements 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 contacts 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
30. ject to the conditions set forth in the warranty detail found in the GFX Series 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 GFX Series Installation Manual October 2010 by OutBack Power Technologies All Rights Reserved Trademarks OutBack Power is a registered trademark of OutBack Power Technologies Date and Revision October 2010 Revision A Part Number 900 0113 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 GFX Series 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 Ground PE Single Phase WARNING Hazard to Human Life This type of notation indicates that the hazard could be harmful to human life CAUTION Hazard to Equipment This type of notati
31. kers to trip or the inverters to shut down 900 0113 01 00 Rev A 27 installation Classic Series Stacking Dual Stack In classic series stacking two inverters create two separate 120 Vac output phases legs One leg is the master The other is the slave which creates a 120 Vac output that is intentionally 180 out of phase with the master Each of these legs can be used to power a separate set of 120 Vac loads Collectively they form a split phase configuration This configuration produces 240 Vac which can be used to power 240 Vac loads when both inverters work together gt The two legs operate independently of each other Each can run in independent Search mode if desired gt The 120 Vacloads on each leg cannot exceed a given inverter s wattage The second inverter cannot assist gt Only two inverters one per phase may be installed in a classic series arrangement LOAD PANEL 1 3 kVA 120 Vac 2 6 kVA 240 Vac 1 3 kVA 120 Vac 1 3 120 Figure 20 Example of Classic Series Stacking Arrangement When installing a series inverter system the following rules must be observed gt Series stacking requires a MATE and 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
32. le to maintain AC voltage or frequency for long periods of time if they 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 gt A generator that is to be installed in a building should not have a bond between the neutral and ground connections gt In addition if a split phase 120 240 Vac generator is powering a single phase 120 Vac inverter system with no other compensation it is required to be at least twice the wattage of the inverters A split phase generator that is heavily loaded on one output leg may suffer severely from balancing issues The OutBack FW X240 or PSX 240 balancing transformers may compensate for this condition 900 0113 01 00 Rev A 13 NOTES 900 0113 01 00 Rev A Installation Location and Environmental Requirements The GFX Series inverters can be located outdoors but OutBack still recommends that they be protected from the environment 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 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 comp
33. on 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 900 0113 01 00 Rev A 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 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 grid The electrical service and infrastructure supported by the electrical or utility company H also called mains utility service or grid General Safety WARNING Limitations on Use This equipment is NOT intended for use with life support equipment or other medical equipment or devices CAUTION Equipment Damage Only use components or accessories recommended or sold by OutBack Power Technologies or i
34. r less gt All output breakers must be sized appropriately for loads and inverter wattage AC Source Utility Grid or AC Generator AC Conduit Box CATS Cable Input Breaker Inverter Charger Ground Mechanical Interlock 2 Output Bypass Breaker o Breaker Ground TBB may be within AC Conduit d Box Primary System Ground AC Loads LEGEND HOT NOTES Neutral Neutral common conductor may be connected from Ground only one inverter Neutral terminal to a common bus bar in the AC Conduit Box Terminal Bus Bar TBB Figure 18 Single Inverter Wiring 26 900 0113 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 series parallel and three phase configurations Stacking Connections Stacking requires an OutBack HUB product as well as a system display such as the OutBack MATE The MATE must have firmware revision 4 1 6 or above A system using four or fewer units may use the Systems using up to ten units r
35. ructions unless qualified 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 gt Do not place combustible or flammable materials within 12 feet 3 7 m of the equipment This product contains relays with moving parts and is not ignition protected Ensure AC DC and ground cable sizes conform to local codes See pages 18 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 damage 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 electric
36. s of each cover Figure 8 Battery Terminal Covers 900 0113 01 00 Rev A 19 installation M8 x 1 25 Stud Install battery cable lug nuts and washers in the 13 mm Nut _ a order illustrated The battery cable lug should be the H ME s k first item installed the stud It should make solid CUM 4 contact with the mounting surface Do not install hardware in a different order than shown 20 Mounting Surface Insulator Battery Cable Lug Figure 9 Required 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 900 0113 01 00 Rev A installation AC Wiring Table5 Conductor Size and Torque Requirements Conductor Size Recommendation Torque Requirements Minimum 6 AWG or 0 025 in 16 mm 35 in lbs 4 0 Nm 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 60 amps using the inverter s transfer relay Use the inverter ACHOTOUD connecting to an external wattage to determine actual neutral bus An external maximum load Size the breakers AG NEUTRAL QUT bus is often placed in the accordingly main electrical panel CRASSIS GNOUMDIFE which is the Loads panel CHASSIS GROUND PE shown in Figure 11 Use The
37. 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 0113 01 00 Rev A Important Safety Instructions 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 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 USA Web site www Earth911 com Address 14646 N Kierland Blvd Suite 100 Scottsdale AZ 85254 Phone 1 480 337 3025 direct Environmental Protection Agency USA Website www epa gov recyclecity Phone 1 415 947 8000 Monday Friday 8 00 AM to 1
38. the greatest duty cycle The master must be connected to port 1 of the HUB Other inverters must not be selected as master The slave inverter must be selected as a Classic Slave during programming All inverter wiring and input breakers must be sized for 60 Aac or less All output breakers must be sized appropriately for loads and inverter wattage Both inverters must be of the same model The AC input generator or utility grid must be 120 240 Vac split phase VV ON ON ON ON 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 0113 01 00 Rev A installation AC Source Utility Grid or AC Generator AC Conduit Box CD 1 4321 MATE o Cat5 Cable Cat5 Cable Wm Cat5 Cable ri ij HOT IN i MATE L1 Inverter Inverter es i L1 Master 1 Neutral AC HOT Neutral AC HOT OUT Ground L1 our Ground OUT L2 Po X wm z Mechanical Interlock _ C Ground TBB 00 within Breakers AC Conduit x2 Box _ d Primary System E oap Ground Neutral Hot L1 Hot L2 TBB TBB TBB AC Loads i SP y v LEGEND mmm ME ME Mm HOT L1 HOT L2 NOTES Neutral Neutral common conductor may be conn
39. tions including automatic generator starting See pages 23 and 24 for instructions and the GFX Series 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 jumper alongside JP1 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 instructions 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 0113 01 00 Rev A N CHASSIS GROUND PE DC and AC GROUND TERMINALS Connect to grounding system for both batteries and AC See page 18 for instructions ut Snack Power Systems AC TERMINAL BLOCK Receives AC input and output wires See page 21 for instructions AC HOT OUT AC NEUTRAL OUT CHASSIS GROUND PE Non operational terminals Do not connect anything to them AC NEUTRAL IN Sopes ma AC HO
40. ts authorized agents 2 900 0113 01 00 Rev A Important Safety Instructions 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 This equipment weighs in excess of 49 Ibs 22 kg 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 AN WARNING Lethal 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 A 900 0113 01 00 Rev A inst
41. urce 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 9 mm VNVERTER ON OFF BATTERY TEMP MATE HUB Relay Two Wire Start Generator Figure 16 Two Wire Generator Start Example 24 900 0113 01 00 Rev A installation A 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 below is one example of a possible arrangement Specific arrangements relays and other elements depend on the reguirements of the installation and of the generator AC HOT IN 2 INVERTER BATTERY TEME Atkinson GSCM Mini Three Wire Start Generator Figure 17 Three Wire Generator Start Example 900 0113 01 00 Rev A 25 installation Single Inverter Installations When installing an inverter AC system the following rules must be observed All wiring and input breakers must be sized for 60 Aac o
42. yout sss 11 Parallel Stacked 5 31 Single Inverter 26 Three Phase 5 5 33 piu 2 16 Environmental Requirements 15 900 0113 01 00 Rev A 11 12 21 24 26 30 32 13 2 18 2 11 17 18 17 22 1 LED 2 17 6 a EOR RNI 15 NE 17 22 27 9 16 Multiple AC 504 21 O On Off Switch Installing sss 22 P Parallel Stacking ees 30 Ports RJA5 ana RIT 17 22 35 Recycling Information esses 5 Remote System 1 lt 2 12 Remote Temperature Sensor RTS 2 10 17 22 Renewable Energy 12 Safety 1 2 6 er CR 4 General Matai NOE 2 acetate etm teni 3 Personal auteni on p is tous 3 x diro Ne MERE UM HE Mm RUN 27 Classic eec va oce 28 30 IN Se PR hase
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