Outback Power Systems GS8048 User Manual

MATE3 Programming

IMPORTANT:

Programming should be done by a qualified installer who is trained on programming inverter power systems. Failure to program 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.

Components

GS8048 Inverter/Charger

RADIAN Series

Major Components

Radian System Products

Note: For automatic generator

start features see the MATE3 manual for details.

MATE3

System

Display and

Controller

Communication

Manager

(HUB10)

FLEXmax 80

Charge Controllers

(x2) (Optional)

Inverter/Charger

GS Load Center

System Display

and Controller

Communications

Manager

FLEXnet DC Monitor (FNDC) Surge Protector Remote Temperature Sensor (RTS)

GS8048

GSLC175-PV-120/240 MATE3 (FW-MB3

mounting bracket)

HUB10 HUB 4

Optional OutBack Components

Charge Controller

*Including appropriate Mounting Bracket.

PV Combiner Box

FLEXmax 80* FLEXmax 60*

PV8 PV12

Color

Green

Yellow

GS Load Center

FNDC LED Indicators

Battery State-of-Charge

> 90% (blinks if charge parameters are met)

≥ 80%

≥ 70%

≥ 60%

Red

≥ 60% off, < 60% solid, < 50% blinks

(GSLC)

IMPORTANT:

Not intended for use with

life support equipment.

Customer-Supplied Components

AC Source

Main Electrical Panel

(or overcurrent device for the AC source)

Electrical Distribution Subpanel

(Load Panel)

Battery Bank

Photovoltaic (PV) Array (with PV Combiner Box [PV8 or PV12])

Contact Technical Support:

Telephone: +1.360.618.4363 Email: Support@outbackpower.com Website: www.outbackpower.com

Utility Grid, or AC Generator

Mounting

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 ignition-protected. Fumes or spills from flammable materials could be ignited by sparks.

WARNING: Personal Injury

Use safe lifting techniques and standard safety equipment when working with this equipment.

IMPORTANT:

Clearance and access requirements may vary by location. Maintaining a 36” (91.4 cm) clear space in front of the system

for access is recommended. Consult local electric code to confirm clearance and access requ irements for the specific

location.

Radian Dimensions (includes MATE3 and 2 FLEXmax 80 Charge Controllers):

Wall Stud

Charge Controller Mounting Bracket

29.1" (85 cm) tall X 35.4" (50 cm) wide

Radian Mounting:

1. Ensure the mounting surface is strong enough to handle 3 times the total weight of

all the components. Add a piece of plywood if necessary to strengthen the surface.

2. Attach the wall bracket to the surface centering the mounting holes on the sides with the wall studs. Use all 6 mounting screws to secure the bracket.

3. Lift the inverter so that the inverter bracket is above the wall bracket.

4. Lower the Inverter into place so that the inverter bracket slips into the wall bracket.

5. Secure the inverter to the surface using a minimum of 1 wall screw (or other appropriate hardware).

Wall Stud

Wall Board

Inverter Bracket

Side View

Plywood

(Optional)

Bracket

6. Follow the instructions for installing the GS Load Center.

7. Follow the instructions for installing the HUB Communication Manager.

8. Follow the instructions for installing the brackets for the charge controllers.

9. Follow the instructions for installing the bracket for the MATE3.

Wall

MATE3

Mounting

HUB

Manager

Bracket

MATE3

Communication

Radian Series

Inverter/Charger

GS Load Center

16" (40.6 cm)

Plywood (Optional)

Wall Bracket

Wall Board

Charge Controller Mounting Bracket

Wall Stud

FLEXmax 80

Charge Controllers

Wire Sizes/Torque Requirements

GS8048

MATE3

Plate

ON/OFF INV

+ -

RELAY

Switch

Remote

12V

AUX

INV

AUX

L1 L2

GEN

OUT

Jumper

Battery

Temp

L1 L2

GRID

Flat Washer

Shunt

1112131415

Control Wiring Terminal Block:

The Inverter ON/OFF terminals are used for connecting an external ON/OFF switch. To use this feature, the jumper must be removed. (See Radian manual for details.)

The AUX terminals can be used to start a generator or to control external devices.

AUX terminals are also available on the charge controller and the FLEXnet DC. (See the charge controller or FNDC installation manuals for details.)

HUB10

GSLC

Negative Battery Cable Connections

Negative (-)

Bolt 3/8"

Lock Washer

AC Terminals - Inverter

DC Terminals - Inverter AC Circuit Breakers

DC Circuit Breakers

GFDI

5 6

PV Circuit Breakers Mechanical Interlock (Bypass)

PV Input/Output Terminals

Communication Ports

Auxiliary Terminals

AC OUT Bus Bar L1

AC OUT Bus Bar L2

12 13

GRID IN Bus Bar L1

GRID IN Bus Bar L2

GEN IN Bus Bar L1

GEN IN Bus Bar L2

AC Neutral

Ground

DC Positive (+) Plate

DC Negative (–) Bus Bar

PV Positive (+) Bus Bars DC Negative(–)Plate (GS-SBUS)

Charge

Controller #2

Charge

Controller #1

Positive Battery Cable Connections

Battery Negative (–) Lug

FNDC

DC Positive (+)

RADIAN Series

AC Wire Sizes and Torque Values

Wire Size Torque

AWG In-lb

#14 - 10 20

#8 25

#6 - 4 35

#3 35

#2 40

#1 50

1/0 50

It is recommended 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

Cable Size

Breaker

125 1/0 (70 mm2)

175 2/0 (70 mm2)

250 4/0 (120 mm2)

Torque Requirements

Circuit Breaker Stud

M8 20 2.3

¼ - 20 35 4.0

5/16 - 18 50 5.6

3/8 - 16 225 25.4

DC Plates

3/8 - 16 225 25.4Upper holes (+) 60 6.8

3/8 - 16 225 25.4Lower holes (+) 225 25.4

Lower holes (+) 50 5.6

3/8 - 16 225 25.4Shunt Bolts (–) and GS-SBUS 60 6.8

CAUTION: Equipment Damage

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.

Flat Washer

Plate

Lock Washer

2.5 – 6

16 – 25

Torque

In-lb Nm

35 4.060 #6 AWG (16 mm2)

35 4.080 #4 AWG (25 mm2)

50 5.6

225 25.4

Torque

In-lb Nm

Bolt 3/8"

Flat Washer

Nut

2.3

2.8

4.0

4.5

5.6

Battery Positive (+) Lug

Energize/Startup Procedures

De-energize/Shutdown

RADIAN Series

Procedures

Pre-startup Procedures:

1. Double-check all wiring connections.

2. Inspect the enclosure to ensure no tools or debris has 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 on and .

1a 1b

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.

4a4b5a

3. Verify that the PV output 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 .

2b2a 2c2a

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.

3a 3c

3b 3c

3a 3b

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 .

4b 3c

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.

4a 3c

4a 4b

5a 5b

18. Turn on the AC disconnects at the backup (or critical) load panel and test the loads.

Functional

Test Points

Battery Voltage Test Points

1a 1b

PV Voltage Test Points

2a 2b 2c

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

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

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

Test points 2d and 2e refer to the

right terminal of each circuit breaker.

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.

Functional

Test Points

Battery Voltage Test Points

1a 1b 1c 1d

PV Voltage Test Points

2b2a 2c 2d 2e

AC OUT Voltage Test Points

(Terminal bus bar = TBB)

3a 3b 3c

1c 1d

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

1 1

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 .

General Wiring

RADIAN Series

AC LEGEND

Neutral

HOT L1

HOT L2

Ground

Electrode

Conductor

(Ground Rod)

Distribution Panel

Source

GROUND

NEU

Neutral-Ground Bond

Radian Inverter/Charger

+ -

RELAY

Switch

Battery

12V

Remote

AUX

INV

Temp

AUX

PV Array #1

IMPORTANT: Example only. Actual wiring

may vary depending on local electric code.

PV Array #2

Factory wiring is not shown.

PV Array #1

AC Generator

Loads

(240 Vac)

Subpanel

GROUND

OIOIOIOIO

LEGEND

L1 L2

GRID

GEN

OUT

NEU

Charge

Controller #1

Charge

Controller #2

Battery Bank

Negative

Loads

(120 Vac)

Vented Battery Enclosure

RTS

Positive

Ground

BATTERY

LEGEND

Negative

Positive

Ground

Outback Power Systems GS8048 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual