Alpha Group OutBack Power GS3548E Installation Manual Download Page 3

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Table of Contents

................................................................................................. 3

Audience ................................................................................................................................................................................. 3

Welcome to OutBack Power Technologies ................................................................................................................. 3

Components and Accessories ......................................................................................................................................... 4

Planning

...................................................................................................... 5

Applications ........................................................................................................................................................................... 5

Input Modes ............................................................................................................................................................................................ 6

Renewable Energy ............................................................................................................................................................... 6

Battery Bank ........................................................................................................................................................................... 7

Generator ................................................................................................................................................................................ 9

Maintenance Bypass Switching ................................................................................................................................... 10

Installation

................................................................................................. 11

Location and Environmental Requirements ............................................................................................................ 11

Dimensions .......................................................................................................................................................................... 11

Tools Required .................................................................................................................................................................... 13

Mounting .............................................................................................................................................................................. 13

Component Mounting...................................................................................................................................................................... 15

Removing Front Cover .................................................................................................................................................... 16

Terminals and Ports .......................................................................................................................................................... 17

Wiring .................................................................................................................................................................................... 19

Grounding ............................................................................................................................................................................................. 19

DC Wiring ............................................................................................................................................................................................... 20

AC Wiring ............................................................................................................................................................................................... 22

Accessory Wiring ................................................................................................................................................................................. 24

AUX Wiring ............................................................................................................................................................................................ 25

Generator Control .............................................................................................................................................................................. 26

AC Configurations ............................................................................................................................................................. 29

Single-Inverter ..................................................................................................................................................................................... 29

Multiple-Inverter AC Installations (Stacking) ........................................................................................................................... 31

Functional Test ................................................................................................................................................................... 40

Preventative Maintenance ............................................................................................................................................. 40

Symbols, Terms, and Definitions

.................................................................. 41

Symbols Used ..................................................................................................................................................................... 41

Definitions ............................................................................................................................................................................ 41

Index

......................................................................................................... 43

Summary of Contents for OutBack Power GS3548E

Page 1: ...Radian Series Inverter Charger GS7048E GS3548E Installation Manual ...

Page 2: ...63 Technical Support 1 360 435 6019 Fax 49 9122 79889 0 49 9122 79889 21 Fax Email Support outbackpower com Website http www outbackpower com Disclaimer UNLESS SPECIFICALLY AGREED TO IN WRITING OUTBACK POWER TECHNOLOGIES a MAKES NO WARRANTY AS TO THE ACCURACY SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION b ASSUMES NO RESPONSIBILITY ...

Page 3: ...11 Location and Environmental Requirements 11 Dimensions 11 Tools Required 13 Mounting 13 Component Mounting 15 Removing Front Cover 16 Terminals and Ports 17 Wiring 19 Grounding 19 DC Wiring 20 AC Wiring 22 Accessory Wiring 24 AUX Wiring 25 Generator Control 26 AC Configurations 29 Single Inverter 29 Multiple Inverter AC Installations Stacking 31 Functional Test 40 Preventative Maintenance 40 Sym...

Page 4: ...round Bus 18 Figure 14 Chassis Ground TBB 19 Figure 15 GS7048E and GS3548E Battery Terminals 20 Figure 16 DC Cable Hardware Radian inverter 21 Figure 17 AC Terminals 22 Figure 18 AC Sources 23 Figure 19 Accessory Connections 24 Figure 20 ON OFF Jumper and Connections 24 Figure 21 AUX Connections for Vent Fan Example 25 Figure 22 AUX Connections for Diversion Example 26 Figure 23 Two Wire Generator...

Page 5: ...These are intended as examples only Designed to be integrated with other components as part of an OutBack Grid Hybrid system Battery to AC inverting which delivers single phase power 220 to 240 Vac at 50 or 60 Hz Model GS7048E can continuously produce 7 kVA 30 Aac Model GS3548E can continuously produce 3 5 kVA 15 Aac Mounts easily with supplied mounting plate All terminals exit at the bottom of th...

Page 6: ...nsor Radian Series Operator s Manual Hardware Kit Mounting Bracket Optional Components for Attachment to Radian Inverter MATE3 System Display and Controller FLEXmax Series Charge Controller FW MB3 MATE3 bracket FW CCB or FW CCB2 charge controller brackets GSLC GS Load Center series HUB Series Communications Manager Figure 2 Radian Inverter and Components NOTE The system display is required if any ...

Page 7: ...r renewable sources These sources charge the battery which in turn is used by the inverter The Radian inverter has two sets of AC input terminals Two AC sources such as a gas or diesel generator and the utility grid can be connected to the inverter Other combinations of AC sources are possible NOTE The inverter can only accept one source at a time The input marked Grid has priority although this c...

Page 8: ...rter will supply energy to the loads from the battery bank until the AC source returns Mini Grid This mode is intended for systems that have the utility grid as an input and a sizable amount of renewable energy The system will run off the renewable energy until the battery voltage falls to a specified low level When this occurs the Radian inverter will connect to the utility grid to power the load...

Page 9: ...r Bank Size Battery bank capacity is measured in amp hours Determine the required bank specifications as accurately as possible beginning with the items below This avoids underperformance or wasted capacity These ten items are obtainable in different places summarized in Table 2 on the next page Some of the information is specific to the site or application Some can be obtained from the battery ma...

Page 10: ...ystem voltage item G 3 Determine the daily load consumption in ampere hours amp hours or Ahr Multiply the step 2 result by the daily usage hours item B 4 Adjust the total for required days of autonomy the days the system must operate without recharging and the maximum DoD Multiply the step 3 result by C and divide by J The result is the total amp hour capacity required for the battery bank 5 Deter...

Page 11: ...tential fluctuations in generator AC voltage Generator Sizing A generator should be sized to provide enough power for all the loads and the battery charger Available generator power may be limited by ratings for circuit breakers and or generator connectors The maximum allowed AC circuit breaker size is 50 Aac per Radian inverter charger The generator must be able to provide current to all inverter...

Page 12: ...he GSLC bypass kits should not be used The bypass function must be simultaneous for all inverters The GSLC bypass kits operate independently not simultaneously Both manual and automatic double throw bypass switches are commonly available in a range of sizes and options These are highly recommended for systems with more than a single inverter WARNING Shock Hazard or Equipment Damage Using independe...

Page 13: ...than two Radian inverters are installed side by side with the GSLC the inverters should be separated by at least 2 3 cm 0 9 inches to accommodate the GSLC hinged doors The Radian inverter will function best if operated in a temperature range of 20 C to 25 C 4 F to 77 F At temperatures up to 50 C 122 F all inverter components meet their specifications but the inverter s power is derated It can func...

Page 14: ...5 34 8 cm 13 7 71 1 cm 28 73 7 cm 29 0 31 8 cm 12 5 114 3 cm 45 0 22 2 cm 8 75 35 6 cm 14 0 This illustration can be used as a basic template for planning layouts marking mounting holes etc when installing a system The requirements for mounting the Radian inverter are described beginning on the next page ...

Page 15: ...ling the Mounting Plate IMPORTANT Use correct fasteners to secure the mounting plate and the Radian inverter charger to the mounting surface OutBack cannot be responsible for damage to the product if it is attached with inadequate fasteners The Radian inverter is mounted using these steps 1 The mounting plate is to be screwed or bolted directly to a solid mounting surface such as wall studs See Fi...

Page 16: ...erter this way will prevent it from dislodging from the mounting plate in the event of an earthquake or similar event NOTE The left corner is used for securing the inverter to a stud If the Radian inverter is mounted on plywood or a similar wide area mounting surface as shown any of the slots in the mounting flange may be used 2 Place the Radian inverter against the wall and slide it directly over...

Page 17: ...secure the GSLC to the inverter when they are tightened The long screwdriver recommended on page 13 may be needed to reach these screws The GSLC should be secured to the wall using screws or wall anchors The GSLC also makes a mechanical connection to the Radian using bus bars that bolt to the inverter s DC terminals Other connections are wired as necessary Several system components can mount direc...

Page 18: ...screws are located around the perimeter Remove these screws with a 2 Phillips screwdriver Once they are removed the cover can be lifted off NOTE The screws which secure the plastic plates to the cover do not need to be removed Figure 11 Removing the Front Cover NOTE The Radian inverter may ship with only a few screws installed to make it easier to perform the initial installation The remaining scr...

Page 19: ...control the inverter See page 24 for instructions NOTE The ON OFF INV jumper J3 overrides these terminals when installed See above RELAY AUX Relay contacts with no voltage 10 amps at 250 Vac or 30 Vdc The relay can be switched on and off for many functions See page 25 for details ON OFF INV JUMPER J3 Overrides the SWITCH INV terminals when installed When installed the inverter is ON The ON or OFF ...

Page 20: ... the RJ45 and RJ11 plugs from the MATE3 system display and Remote Temp Sensor See page 24 for instructions AC TERMINAL BLOCK Receives AC input wires for two input sources Also receives AC output wires All neutral wires are electrically common See page 22 for instructions CONTROL WIRING TERMINAL BLOCK Receives control wires for a variety of functions including generator control See facing page for ...

Page 21: ...bond in the GSLC may need to be removed 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 The GSLC is also equipped with its own bond which may need to be removed IMPORTANT Most OutBack products are not designed for use in a positive grounded system If it is nec...

Page 22: ...r minimum cable sizes Other codes may supersede OutBack s requirements Consult local codes for final size requirements Figure 15 GS7048E and GS3548E Battery Terminals The Radian inverter has four battery cable terminals two positive and two negative Each terminal is a threaded hole which accepts a hex bolt provided Notes on assembly and cabling are shown on the next page IMPORTANT The Radian GS704...

Page 23: ...conduit NOTE Do not install hardware in a different order from the illustrations shown in Figure 16 In all cases the battery cable lug must be the first item installed It must make solid contact with the surface Figure 16 DC Cable Hardware Radian inverter If the battery cables are connected directly to the Radian inverter the hardware should be arranged as shown in image A The inverter s battery t...

Page 24: ...onnect to the hot or line wires All system wiring must comply with national and local codes and regulations Three neutral N terminals are available These terminals are electrically common Any of them can be used to connect to neutral wires from various parts of the system The most common connections are to the neutral bus on the main panel or utility grid service the neutral bus on the output load...

Page 25: ...t to one AC source at a time It cannot use both utility grid and generator power at the same time If presented with two sources of power the default setting is to accept the source connected to the GRID terminals The source priority can be changed using the system display NOTE The terminals are labeled due to common conventions not inverter requirements The GEN terminals can accept grid power if n...

Page 26: ...s MATE port Inverters connect to communications manager ports 1 and above Charge controllers and other devices connect to additional ports after the last inverter is connected See Stacking on page 27 for information on connecting inverters The ON OFF INV jumper bridges two pins This jumper J3 parallels the two Switch INV terminals on the terminal block If either set of connections is closed the in...

Page 27: ...led to protect the circuit Since the internal circuitry of the RELAY AUX terminals does not incorporate overcurrent protection it is the responsibility of the installer to ensure the circuit is protected Internal failure that results from lack of protection is not covered by the Radian warranty Each set of terminals has its own set of programmed criteria NOTE The menus for each set of terminals ha...

Page 28: ...ually has a single switch with two positions that is turned ON to start OFF to stop Two Wire Start RELAY AUX Terminals The RELAY AUX terminals can be wired in place of the generator s start switch as shown in Figure 23 This method is only advised if the generator s starting circuit is triggered by continuity This circuit must use fewer than 10 amps CAUTION Equipment Damage This circuit has no over...

Page 29: ...he coil of a 12 Vdc automotive or similar relay The OutBack FLEXware Relay Assembly depicted in Figure 24 is sold for this purpose The relay contacts can serve in place of the generator s start switch The battery shown in Figure 24 is shown for clarity Usually it is part of the generator s internal starting circuit and is not an external component The drawing below is one example of a possible arr...

Page 30: ...lectronics com is one company that makes these kits The Atkinson GSCM Mini is intended to work with OutBack inverters NOTE The conversion kit requires a 12 volt signal which the RELAY AUX terminals cannot provide The 12V AUX terminals may be used to operate the conversion kit as shown in Figure 25 If the AUX terminals are being used for another purpose it may be necessary for the RELAY AUX termina...

Page 31: ...more All output circuit breakers must be sized appropriately for loads and inverter wattage The Radian inverter has wiring connections for two AC sources but it can only accept one source at a time Figure 26 Single Inverter AC System 1 The Radian inverter has separate neutral connections for grid input generator input and output These are electrically common If an external neutral bus exists as sh...

Page 32: ...generator input and output These are electrically common If an external neutral bus exists as shown in the GSLC not all of the Radian neutral connections need to be made In this example only the Grid neutral terminal on the inverter is connected 3 The GSLC AC circuit breakers are designed as a maintenance bypass switching assembly The assembly can be used so that the inverter can be taken offline ...

Page 33: ...nd C phases perform this monitoring and allow greater control over the system There are two types of slave modes A classic slave is used for stacking when the slave operates semi independently of the master Although the master sets the phase relationship the slave creates an output independent of the master Classic stacked inverters can go into Search mode independently of the master if necessary ...

Page 34: ...e configuration To optimize the Power Save function GS3548E inverters should have higher rank numbers than any GS7048E inverter This is true regardless of the quantity of either model In addition the GS3548E should not be the master inverter in a mixed system The master inverter must always be connected to port 1 on the communications manager Connecting it elsewhere or connecting a slave to port 1...

Page 35: ... AC and network connections This figure is a physical diagram for wiring the GSLC network components and external AC devices with each inverter Figure 29 Example of Parallel Stacking Arrangement Three Inverters When installing a parallel system the following rules must be observed Parallel stacking requires the system display and a communications manager One inverter and one inverter only is alway...

Page 36: ...entire system These assemblies usually include an interlock mechanism that isolates AC lines from each other This figure shows the general design of a bypass system 3 When multiple inverters are stacked the GS Load Center GSLC for each inverter can be wired together to serve as a common input conduit box and AC load center However the GSLC bypass switching assemblies are only sized for single inve...

Page 37: ...eutral connections for grid input generator input and output These are electrically common If an external neutral bus exists as shown in the GSLC not all of the Radian neutral connections need to be made In this example only the Grid neutral terminal on each inverter is connected 3 The bypass assembly in each GSLC cannot be used with multiple inverters and is not depicted here External bypass asse...

Page 38: ...ltage in a wye configuration as shown below Figure 32 Example of Three Phase Stacking Three Inverters Figure 33 Example of Three Phase Stacking Nine Inverters 21 kVA 230 400 Vac 7 kVA 230 Vac 7 kVA 230 Vac 7 kVA 230 Vac 7 kVA 230 Vac 7 kVA 230 Vac 7 kVA 230 Vac 21 kVA 230 Vac 7 kVA 230 Vac x3 21 kVA 230 7 kVA 230 Vac x3 7 kVA 230 Vac x3 21 kVA 230 63 kVA 230 400 Vac ...

Page 39: ...ted to port 1 of the communications manager Other inverters must not be selected as master Two subphase master inverters are required regardless of whether any slave inverters are installed One subphase master controls the phase B output The other controls phase C The inverters should be wired to the loads and to the AC sources in phase order If a HUB4 or HUB10 is used the B and C subphase master ...

Page 40: ...usually include an interlock mechanism that isolates AC lines from each other This figure shows the general design of a bypass system 3 When multiple inverters are stacked the GS Load Center GSLC for each inverter can be wired together to serve as a common input conduit box and AC load center However the GSLC bypass switching assemblies are only sized for single inverters and cannot work in conjun...

Page 41: ...rter can only accept one source at a time 3 The Radian inverter has separate neutral connections for grid input generator input and output These are electrically common If an external neutral bus exists as shown in the GSLC not all of the Radian neutral connections need to be made In this example only the Grid neutral terminal on each inverter is connected 4 The bypass assembly in each GSLC cannot...

Page 42: ...for programming instructions and menus When commissioning a grid interactive system for use in Australia To meet the standard AS4777 3 the acceptance settings shall not exceed the following The factory default settings meet these requirements Table 5 AS4777 3 Acceptance Settings Minimum Voltage Maximum Voltage Minimum Frequency Maximum Frequency 200 Vac 270 Vac 45 Hz 55 Hz Preventative Maintenance...

Page 43: ...most common reference is to the Radian Series Inverter Charger Operator s Manual Another common reference is the system display manual Definitions The following is a list of initials terms and definitions used with this product Table 6 Terms and Definitions Term Definition 12V AUX Auxiliary connection that supplies 12 Vdc to control external devices AC Alternating Current refers to voltage produce...

Page 44: ...enter the wiring box for the Radian GS inverter HUB A line of OutBack communications manager products IEC International Electrotechnical Commission an international standards organization MATE3 An OutBack system display used for monitoring programming and communicating with the inverter NEU AC Neutral also known as Common Off grid Utility grid power is not available for use PV Photovoltaic RELAY A...

Page 45: ...g 20 Definitions See Terms and Definitions Dimensions Inverter 11 System 12 Diversion Control 26 Drawings Multiple AC Sources 23 Parallel Stacked System 33 Three Phase Stacked System 36 Transfer Relay 23 DVM 13 41 E Environmental Requirements 11 EPO 24 42 F Features 3 FLEXmax 4 15 FLEXmax Extreme 15 Front Cover 16 G Generator 23 33 36 Applications 5 Automatic Control 25 Requirements 9 23 Three Wir...

Page 46: ... Temperature Sensor RTS 4 18 24 Renewable Energy 6 Ribbon Cables 17 S Stacking 31 Parallel 33 Three Phase 36 Switch 17 24 Symbols Used 41 System Display 4 24 33 36 42 T Temperatures 11 Terms and Definitions 41 Three Phase Stacking 36 Tools Required 13 Torque Requirements DC Terminals 21 Ground Terminals 19 Transfer Relay 23 U Utility Grid 23 33 36 42 Applications 5 Wiring 22 W Wiring AC Connection...

Page 47: ...900 0144 01 01 Rev A 45 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 48: ... A Masters of the Off Grid First Choice for the New Grid Corporate Headquarters 17825 59th Avenue N E Suite B Arlington WA 98223 USA 1 360 435 6030 European Office Hansastrasse 8 D 91126 Schwabach Germany 49 9122 79889 0 ...

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