Outback Power Systems GS4048A User Manual

Setup and Programming
Quick Start Guide
RADIAN Series
!
CAUTION: Equipment Damage
These procedures should be done by a qualified installer who is trained on programming inverter power systems. Failure to set accurate parameters for the system could potentially cause equipment damage. Damage caused by inaccurate programming is not covered by the limited warranty for the system.
IMPORTANT
Check the firmware revision of all OutBack devices before use. The Radian inverter and MATE3 system display may not communicate or operate correctly unless their firmware is above a specified revision number.
For models GS8048A and GS4048A, the firmware must be revision 001.005.xxx or higher. The MATE3 must be revision 002.017.xxx or higher.
The MATE3 Configuration Wizard allows quick setup of parameters that apply to all systems. The Configuration Wizard is reached from the MATE3 Main Menu as shown to the right.
The firmware revision of all devices can be confirmed by navigating from the MATE3 Main Menu as shown below. Upgrades to the firmware revision can be downloaded from the OutBack website www.outbackpower.com.
Firmware Revision
Settings >>
Settings
Configuration Wizard >> Device Data Logs >> Event Logs >> Firmware Update >>
System
System >> Inverter >> Charge Controller >> Battery Monitor >> MATE3 >>
System Information >> Save / Store Information >> Firmware Version >> Date and Time >> LCD Display >>
MATE3 002.017.018 1: GS8048A 001.005.002 2: GS8048A 001.005.002
Configuration Wizard
Settings >> Configuration Wizard >>
Configuration Wizard
Device Data Logs >> Event Logs >> Firmware Update >>
New Configuration
New Configuration >> Existing Configuration >> Restore Configuration >>
New Configuration Initialized
Back Continue
Off Grid
System Type Off Grid System Voltage 48 VDC Array Wattage 1000 Battery Type FLA Capacity 500 Ah
Back Continue
Absorb Voltage 57.6 VDC Time 1.0 Float Voltage 54.4 VDC Time 1.0 Equalize Voltage 60.0 VDC Time 3.0 Re-Float Voltage 44.0 VDC
Back Continue
AC Output Voltage 240 VAC AC Phase Single AC Input Breaker Size 50 A Maximum Output Load 33 A
Back Continue
Generator Installed Y Generator Type AC Size 5.0 kW Generator Start Manual AUX Output Device Port 1
Back Continue
Note: See the MATE3 manual for details on generator control.
If FN-DC is installed...
WARNING: Fire/Explosion Hazard
Do not place combustible or flammable materials within 12 feet (3.7 m) of the equipment. This unit employs mechanical relays and is not ignition­protected. Fumes or spills from flammable materials could be ignited by sparks.
WARNING: Personal Injury
Use safe lifting techniques and standard safety equipment when working wi th this equipment.
IMPORTANT:
Clearance and access requirements may vary by location. Maintaining a 36”
Major Components
Radian System Products
Inverter/Charger
GS Load Center
System Display and Controller
GS8048A GS4048A
GSLC175-PV-120/240 GSLC175PV1-120/240 (both depicted)
MATE3 depicted (with FW-MB3 mounting bracket)
(91.4 cm) clear space in front of the system for access is recommended.
Consult local electric code to confirm clearance and access requirements
Grid Tied Backup
System Type Grid Tied System Voltage 48 VDC Array Wattage 1000 Battery Type FLA Capacity 500 Ah
Back Continue
Absorb Voltage 57.6 VDC Time 1.0 Float Voltage 54.4 VDC Time 1.0 Equalize Voltage 60.0 VDC Time 3.0 Re-Float Voltage 44.0 VDC
Back Continue
AC Output Voltage 240 VAC AC Phase Single AC Input Breaker Size 50 A Maximum Output Load 33 A
Back Continue
Generator Installed N Generator Type AC Size 5.0 kW Generator Start Manual AUX Output Device Port 1
Back Continue
Period 1 Enable N Weekday Use 0:00 Drop 0:00 Weekend Use 0:00 Drop 0:00
Back Continue
System Type Backup System Voltage 48 VDC Array Wattage 1000 Battery Type FLA Capacity 500 Ah
Back Continue
Absorb Voltage 57.6 VDC Time 1.0 Float Voltage 54.4 VDC Time 1.0 Equalize Voltage 60.0 VDC Time 3.0 Re-Float Voltage 44.0 VDC
Back Continue
AC Output Voltage 240 VAC AC Phase Single AC Input Breaker Size 50 A Maximum Output Load 33 A
Back Continue
Generator Installed N Generator Type AC Size 5.0 kW Generator Start Manual AUX Output Device Port 1
Back Continue
Period 1 Enable N Weekday Use 0:00 Drop 0:00 Weekend Use 0:00 Drop 0:00
Back Continue
for the specific location.
Radian Inverter/Charger
MATE3
System
Display and
Controller
Optional OutBack Components
Communications
Manager
Charge Controller
PV Combiner Box PV12 depicted
Remote Temperature Sensor (RTS)
FLEXnet DC Monitor (FN-DC)
Battery Bank
HUB10.3 depicted
FLEXmax 80 depicted (with FW-CCB2 mounting bracket)
EnergyCell depicted
Customer-Supplied Components
AC Source
Utility Grid or AC Generator
Period 2 Enable N Weekday Use 0:00 Drop 0:00
Back Continue
Period 3 Enable N Weekday Use 0:00 Drop 0:00
Back Continue
C
Mode Disabled Grid Connect 48.0 VDC Delay 60 Min Grid Disconnect 52.0 VDC Delay 60 Min Grid Connect SOC 60% Disconnect SOC 95%
Back Continue
If FN-DC is installed...
C
Period 2 Enable N Weekday Use 0:00 Drop 0:00
Back Continue
Period 3 Enable N Weekday Use 0:00 Drop 0:00
Back Continue
Mode Disabled Grid Connect 48.0 VDC Delay 60 Min Grid Disconnect 52.0 VDC Delay 60 Min Grid Connect SOC 60% Disconnect SOC 95%
Back Continue
If FN-DC is installed...
Main Electrical Panel (or overcurrent device for the AC source)
FM80 Charge
Controllers
(x2)
Electrical Distribution Subpanel (Load Panel)
Photovoltaic (PV) Array
HUB 10.3
Communications
C
Manager
IMPORTANT:
Not intended for use with
life support equipment.
This advances the display to the
S
Setup Complete screen.
This advances the display to the
C
Setup Complete screen if the
FLEXnet DC is not installed. If the FLEXnet DC is installed, the display advances to the Shunt screens.
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Shunt A Connection Inverter
Back Continue
Shunt B Connection Charge Controller
Back Continue
Shunt C Connection Charge Controller
Back Continue
Shunt A Connection Inverter
Back Continue
Shunt B Connection Charge Control ler
Back Continue
Shunt C Connection Charge Control ler
Back Continue
Shunt A Connection Inverter
Back Continue
Shunt B Connection Charge Controller
Back Continue
Shunt C Connection Charge Controller
Back Continue
S S S
GS Load Center
(GSLC)
Contact Technical Support:
Telephone: +1.360.618.4363 Email: Support@outbackpower.com Website: www.outbackpower.com
Masters of the Off-Grid.™ First Choice for the New Grid.
Installation
RADIAN Series
Ensure the mounting surface is strong enough to handle 3 times the total weight of all the components. Add plywood or other
1
reinforcing material as necessary to strengthen the surface. Attach the wall bracket. Center the mounting holes on the wall studs. Use all 6 mounting screws to secure the bracket.
2
Lift the inverter so that the inverter bracket is above the wall bracket.
3
Lower the inverter so that the inverter bracket slips into the wall bracket.
4
If GSLC is not used: Secure the inverter to the surface using a minimum of 1 wall screw (or appropriate hardware).
5
If GSLC is used: Unscrew the inverter bottom screws approximately ¼” (0.6 cm) to 3/16" (0.5 cm).
6
Align the GSLC along the bottom of the inverter. Slide the bottom screws into the keyhole slots.
7
Mark the spots for the GSLC mounting feet. (If necessary, remove the GSLC to install wall anchors.) Install screws to secure the feet.
8 9
Follow the appropriate instructions for installing other components. Different mounting locations are available.
16" (40.6 cm)
ON/OFF
INV
+ -
Battery
RELAY
Switch
Remote
12V
Temp
AUX
INV
AUX
45.0"
(114.3
cm)
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N
N
N
L1 L2
L1 L2
L1 L2
E
E
E
GRID
GEN
OUT
U
U
U
The Radian has one mounting location for the HUB product. The GSLC also has one location.
Wall Stud
16" (40.6 cm)
Wall Stud
1
Plywood (Optional)
4.1"
(10.4 cm)
2
Wall Bracket
5.0"
(12.7 cm)
MATE3
Wall Board
6.0"
(15.2 cm)
0.5" (1.3 cm)0.5" (1.3 cm)
8.75"
(22 cm)
Wall Stud
AC Wire Sizes and Torque Values
Wire Size Torque
AWG In-lb
#14 to #10 20
13.7"
(34.8 cm)
Inverter Bracket
Wall Board
Plywood
(Optional)
3
Wall
Bracket
5
Keyhole Slots
6
Bottom Screws
#8 25
#6 to #4 35
#3 35 #2 40 #1 50
1/0 50
8.0"
(20.3 cm)
2
mm
2.5 to 6 10
16 to 25
35 35 50 70
Nm
2.3
2.8
4.0
4.0
4.5
5.6
5.6
9
ON/OFF
INV
+ -
Battery
RELAY
Switch
Remote
12V
Temp
AUX
INV
AUX
9
10
1
N
N
N
L1 L2
L1 L2
L1 L2
E
E
E
GRID
GEN
OUT
U
U
U
HUB
10.3
9
3
7
OutBack recommends that conductors be
#6 AWG THHN copper, or larger, rated to 75°C
(minimum) unless local code requires otherwise.
Minimum DC Cable based on
the DC Circuit Breaker
Circuit
Breaker
Cable Size
125 1/0 (70 mm2) 175 2/0 (70 mm2) 250 4/0 (120 mm2)
Torque
In-lb Nm
35 4.060 #6 AWG (16 mm2) 35 4.080 #4 AWG (25 mm2)
50 5.6 225 25.4 225 25.4
5
6
(71.1 cm)
When
stacking
multiple
inverters:
For GSLC door clearance, space systems 0.9" (3.2 cm) apart.
28.0"
29.1"
7
(74.0 cm)
4
14.0"
(35.6 cm)
GSLC175-PV-120/240
Left Side:
The Radian allows two locations for the MATE3 mounting bracket (FW-MB3).
Right Side:
The FLEXmax charge controller is mounted with the FW-CCB bracket. The FW-CCB2 allows two controllers side by side (using the forward holes to allow for conduit.)
8
(31.8 cm)
Circuit Breaker
Stud
M8 20 2.3
¼ - 20 35 4.0
5/16 - 18 50 5.6
3/8 - 16 225 25.4
12.0"
Torque Requirements
Torque
In-lb Nm
DC Plates
Upper holes (+)
Lower holes (+)
Shunt Bolts (–) and GS-SBUS
Torque
In-lb Nm
60
60 50
60
6.8
5.6
6.8
The Radian has two sets of
9
bracket positions. The GSLC has one set.
NOTE: The FLEXmax Extreme charge controller attaches directly to the wall, not the Radian system.
It does not use OutBack brackets.
DC Positive (+) Plate
19
Positive Battery Cable Connections
4
Flat
Washer
Lock
Washer
Bolt 3/8"
Flat
Washer
Nut
Battery Positive (+) Lug
DC Disconnect
Stud
FM80
Positive (+)
Terminal
FN-DC
Positive (+)
Sense
Terminal
GSLC175-PV-120/240 GSLC175PV1-120/240
Battery
Positive
(+) Lug
Flat
Washer
Lock
Washer
Nut
CAUTION:
!
Equipment Damage
When connecting cables from the Radian inverter to the battery terminals, make sure to observe the proper polarity. Connecting the cables incorrectly can damage or destroy the equipment and void the product warranty.
DC
Negative (-)
Plate
(GS-SBUS)
22
GS8048A
2 2
20
22
20
20
18
1112131415
4
19
17
16
FN-DC LED Indicators
Color
Green
Yellow 80% Yellow Yellow
Red
Negative Battery Cable
Connections
Bolt 3/8"
Battery
Lock
Washer
Negative
(–) Lug
Shunt
20
Flat
Washer
21
21
> 90% (blinks if charge parameters
70% 60% 60% off, < 60% solid, < 50% blinks
1
AC Terminals - Inverter
2
DC Terminals - Inverter AC Circuit Breakers
3
DC Circuit Breakers
4
GFDI
5 6
PV Circuit Breakers Mechanical Interlock (Bypass)
7
Charge Controller Terminals
8
Communication Ports
9
Auxiliary Terminals
10
AC OUT Bus Bar L1
11
AC OUT Bus Bar L2
12 13
GRID IN Bus Bar L1
14
GRID IN Bus Bar L2
15
GEN IN Bus Bar L1
16
GEN IN Bus Bar L2
17
AC Neutral
18
Ground DC Positive (+) Plate (not used
19
on GSLC175PV1-120/240)
20
PV Negative (–) Terminals
21
PV Positive (+) Bus Bars DC Negative (–) Plate (GS-SBUS)
22
9
8
9
10
FM80 #1 FM80 #2
FN-DC
Battery State of Charge
are met)
FN-DC wiring is displayed on the Wiring page.
Wiring to AC terminals is
1
displayed on the Wiring page.
N
L1 L2
E
OUT
U
8
10
GRID
N E U
N E U
L1 L2
GEN
L1 L2
Energize/Startup Procedures
De-energize/Shutdown
RADIAN Series
Procedures
CAUTION: Fire Hazard
!
Before energizing, confirm that all hardware is installed as shown on the Installation page. Stacking battery terminal hardware in any other order can overheat the terminals.
Pre-startup Procedures:
1. Double-check all wiring connections.
2. Inspect the enclosure to ensure no
4
debris or tools have been left inside.
3. Disconnect all AC loads at the backup (or critical) load panel.
4. Disconnect the AC input feed to the GSLC at the source.
To energize or start the OutBack devices:
1. Using a digital voltmeter (DVM), verify 48 Vdc on the DC input terminals by placing the DVM leads
1a 1b
on and .
Confirm that the battery voltage is correct for the inverter and charge controller models.
Confirm the polarity.
CAUTION: Equipment Damage
!
Incorrect polarity will damage the equipment.
2. Turn on (close) the GFDI circuit breaker.
3. Verify that the PV input for each charge controller is in the correct range of open-circuit voltage and confirm the polarity by:
a) placing the DVM leads on and , and b) placing the DVM leads on and .
4. Turn on (close) the PV input circuit breakers.
5. Turn on (close) the DC circuit breakers from the battery bank to the inverter.
6. If the inverter is in the Off state, turn it On.
7. Verify 120 Vac on the AC Output L1 TBB by placing the DVM leads on and .
8. Verify 120 Vac on the AC Output L2 TBB and .
9. Verify 240 Vac between the AC Output TBBs by placing the DVM leads on and .
10. Turn on (close) the AC output circuit breakers.
11. Start the generator if appropriate. Verify 120/240 Vac on the terminals of the AC input sources.
12. Turn on the AC input feed to the GSLC at the source.
11. Verify 120 Vac on the GRID IN L1 TBB by placing the DVM leads on and .
12. Verify 120 Vac on the GRID IN L2 TBB and .
13. Verify 240 Vac between the GRID IN TBBs by placing the DVM leads on and .
14. Verify 120 Vac on the GEN IN L1 TBB by placing the DVM leads on and .
15. Verify 120 Vac on the GEN IN L2 TBB and .
16. Verify 240 Vac between the GEN IN TBBs by placing the DVM leads on and .
17. Turn on (close) the AC input circuit breakers.
18. Turn on the AC disconnects at the backup (or critical) load panel and test the loads.
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1
1b2a 1b2b
4
3b 3c
4b 3c
5b
2
5
3c
6
5
6
6
1
2
4a 3c
5a
3a
3b
3
3a 3c
3a 3b
4a 4b
3c
5a 5b
1b
4a4b5a
5b
1a
3c
Functional
Functional
Test Points
Battery Voltage Test Points
1a 1b
PV Voltage Test Points
2c2a 2b 2d 1b
AC OUT Voltage Test Points
(Terminal bus bar = TBB)
3a 3b 3c
GRID IN Voltage Test Points
(Terminal bus bar = TBB)
4a 3c4b
GEN IN Voltage Test Points
(Terminal bus bar = TBB)
5a 3c5b
1c 1d
1 1
3
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 them sufficient time to cool down before attempting to perform any
4
3
Test points 2c and 2d refer to the
right terminal of each circuit breaker.
2a
2b
In 23.2 V 0.0 A Out 27.6 V 0.0 A
0.000 kW 0.0 kWH
AUX: OFF Sleeping
In 23.2 V 0.0 A Out 27.6 V 0.0 A
0.000 kW 0.0 kWH
AUX: OFF Sleeping
maintenance.
WARNING: Lethal Voltage
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 Vdc) to verify the de-energized condition.
WARNING: Lethal Voltage
The numbered steps will remove power from the inverter and charge controllers. However, sources of energy may still be present inside the GSLC and other locations. To ensure absolute safety, disconnect ALL power
connections at the source.
1b
2
In 23.2 V 0.0 A Out 27.6 V 0.0 A
0.000 kW 0.0 kWH
3a
2c
3c
3b
2d
AUX: OFF Sleeping
To de-energize or shut down the OutBack devices:
1. Turn off (open) the AC circuit breakers.
2. Turn off (open) the DC circuit breakers for the battery. Wait 5 minutes for the devices to internally discharge themselves.
3. Turn off (open) the PV circuit breakers.
4. Turn off (open) the GFDI circuit breaker.
5. Verify 0 Vdc on the first DC bus of the inverter by placing the voltmeter leads on and .
6. Verify 0 Vdc on the second DC bus by placing the voltmeter leads on and .
7. Verify 0 Vdc on one PV circuit by placing the voltmeter leads on and .
8. Verify 0 Vdc on the other PV circuit by placing the voltmeter leads on and .
9. Verify 0 Vac on the AC output circuit breakers by placing the voltmeter leads on and . Repeat this step for and .
1d
1b
1b
1b
3a
1c
3c
Test Points
Battery Voltage Test Points
1a 1b 1c 1d
PV Voltage Test Points
2a 2b 2c 2d 1b
AC OUT Voltage Test Points
(Terminal bus bar = TBB)
3a 3b 3c
In 23.2 V 0.0 A Out 27.6 V 0.0 A
0.000 kW 0.0 kWH
AUX: OFF Sleeping
1
2
3
4
3b
3c
1b
2c
2d
Wiring RADIAN Series
Utility Grid
AC LEGEND
Neutral
HOT L1
HOT L2
Ground
On/Off Switch or EPO
EPO
N
L1
L2
Remove
On/Off Jumper
AC Generator
AC Distribution Panel
L2
NEU
Remote
L1
L2
N
L1
L2
Ground
Electrode
Conductor
(Ground Rod)
RELAY
AUX
Generator
Start
L1
AC
Source
GROUND
+ -
Switch
12V AUX
INV
N
Neutral-Ground
Bond
Battery
Temp
RTS
Cable
CAT5 Cable
FLEXnet DC
+ -
RELAY
Switch
12V
AUX
INV
AUX
N
L1 L2
L N
E
OUT
OUT
U
N
L N
E U
L1 L2
GEN
GEN
Battery
Remote
Temp
N
L1 L2
L N
E
GRID
GRID
U
Twisted-pair wiring
(+) Positive
Relay Connections
3
(not shown)
4
1
(–) Negative
2
(–) Bus Bar
5 6
(–) FM-80 #2
7
(–) Bus Bar
8
(–) FM-80 #1
9
(–) Bus Bar
10
(–) Inverter
Battery
Sense
Shunt C
Shunt B
Shunt A
GS8048A wiring and
external system
with GSLC175-PV-120/240
and grid bypass
5
6
2
10
10
7
5
8
6
L1
L1
9 9
L1
1
GS4048A wiring
With GSLC175PV1-120/240 and grid bypass
To ports as shown below
N
N
N
L1 L2
L1 L2
L1 L2
L N
L N
L N
E
E
E
GRID
GEN
OUT OUT
GEN
GRID
U
U
U
L1
L2
To AC, DC, and PV as below
FM80 #1
2
L1
L2
7
8
10
9
L1
1
L2
N
FM80 #2
GS8048A multiple inverters (stacking)
To ports as shown below
AC Output Bus
(Loads)
When stacking in parallel configuration (GS8048A or GS4048A):
AC input and output conductors can share common connections from external AC input and output buses. These are shown above. Do not use the OutBack bypass assembly in the GSLC. Connect all DC, PV, AC neutral (common), and ground wires as shown in the main GS8048A diagram. Connect all CAT5 cables using the appropriate ports in the communications manager.
PV Array #2
I
OIOIOIOIO
O
PV Array #1
I
with GSLC175-PV-120/240; PV and FLEXnet DC not shown
N
L1
AC Input Bus
(Generator)
L2
L1
L2
AC Input Bus
(Utility Grid)
PV Array #1 PV Array #2
I
I
OIOIOIOIO
O
N
To
batteries
Battery Bank
L1
L2
AC Subpanel
L1
Loads
GROUND
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L2
NEU
L2
L2
L2
N
PV
LEGEND
Negative
Positive
Ground
BATTERY
LEGEND
Negative
Positive
Ground
Vented Battery Enclosure
RTS
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