Radian Series Inverter/Charger GS8048A GS4048A Installation Manual
About OutBack Power Technologies OutBack Power Technologies is a leader in advanced energy conversion technology. OutBack products include true sine wave inverter/chargers, maximum power point tracking charge controllers, and system communication components, as well as circuit breakers, batteries, accessories, and assembled systems.
Table of Contents Introduction ................................................................................................. 3 Audience ................................................................................................................................................................................. 3 Welcome to OutBack Power Technologies ................................................................................................................. 3 Components and Accessories ...........
Table of Contents List of Tables Table 1 Table 2 Table 3 Table 4 Table 5 Components and Accessories......................................................................................................... 4 Battery Bank Elements....................................................................................................................... 8 Ground Conductor Size and Torque Requirements .............................................................. 19 DC Conductor Size and Torque Requirements ......
Introduction Audience This book provides instructions for the physical installation and wiring of this product. 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. This product is only serviceable by qualified personnel. Welcome to OutBack Power Technologies Thank you for purchasing the OutBack Radian Series Inverter/Charger.
Introduction Components and Accessories IMPORTANT: This product is not compatible with the OutBack MATE or MATE2 System Display and Controller. Use of these products is not supported with the Radian Series. IMPORTANT: This product is not stackable with the GS8048 inverter. See page 32.
Planning Applications The Radian Series Inverter/Charger is intended for both off-grid and grid-interactive (Grid/Hybrid) applications. It is designed to use a battery bank to store energy. It can work in conjunction with photovoltaic (PV) modules 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. The Radian inverter has two sets of AC input terminals.
Planning Input Modes The Radian inverter has seven modes of operation. These modes determine how the Radian interacts with an AC source. Each mode has functions and priorities that are intended for a designated application. Each of the Radian’s two AC inputs can be set to a different operating mode, so that different applications can be supported. Generator: This mode is intended for a wide range of AC sources, including generators with a rough or imperfect AC waveform.
Planning Battery Bank When planning a battery bank, consider the following: Cables: Recommendations for battery cable size and length are shown on page 20. The maximum length will determine the placement of the battery bank. Other local codes or regulations may apply and may take priority over OutBack recommendations. Battery Type: The Radian inverter/charger uses a three-stage charge cycle. ~ The cycle was designed for lead-chemistry batteries intended for deep discharge.
Planning G. System DC voltage: The Radian inverter requires nominal 48 Vdc to operate. H. Battery voltage: Most individual battery voltages are less than the system DC voltage. The batteries need to be placed in series to deliver the correct voltage. Table 2 Battery Bank Elements Item A. Load Size B. Daily Hours C. Days of Autonomy D. Application E. Conductor Efficiency F. Inverter Efficiency G. System Vdc H. Battery Vdc I. Capacity J.
Planning EXAMPLE #2 A. Backup loads: 1.75 kW (1750 W) B. Hours of use: 8 C. Days of autonomy: 2 D. Off-grid system (GS4048A inverter) 1) A ÷ [E x F] 1750 ÷ (0.97 x 0.93) = 1939.9 W 2) 1÷G 1939.9 ÷ 48 = 40.4 Adc 3) 2xB 40.4 x 8 = 323.3 Ahr E. Conductor efficiency: 97% (0.97) 4) [3 x C] ÷ J [323.3 x 2] ÷ 0.5 = 1293.3 Ahr F. Inverter efficiency: 93% (0.93) 5) 4÷I 1293.3 ÷ 167.5 = 7.7 (rounded to 8) 6) [G ÷ H] x 5 [48 ÷ 12] x 8 strings = 32 batteries G. System voltage: 48 Vdc H.
Planning Maintenance Bypass Switching Inverter systems are often equipped with AC maintenance bypass switches or interlocks. If the inverter system ever needs to be shut down or removed, the AC sources and loads must be disconnected. A bypass device allows the AC source to deliver power directly to the loads, bypassing the inverter. This can minimize disruption to the system and avoids the need for extensive rewiring.
Installation Location and Environmental Requirements Radian Series Inverter/Chargers must be located in a weather-proof enclosure or enclosed area. It is not designed for exposure to water or excessive wind-blown dust and debris. It carries an Ingress Protection (IP) rating of 20 and a Relative Humidity (RH) rating of 93%. The Radian inverter must be wall-mounted in an upright position. The inverter is not approved for mounting in any other position or orientation.
Installation 0.45” (1.1 cm) 0.45” (1.1 cm) 8.75” (22.2 cm) Width 16.0” (40.6 cm) 13.7” (34.8 cm) 28” (71.1 cm ) 29.0” (73.7 cm) 45.0” (114.3 cm) 12.5” (31.8 cm) 14.0” (35.6 cm) Figure 7 12 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.
Installation Tools Required The following tools may be required for this installation: Wrench and socket sets; should include torque and ratchet wrenches; also reversible (stubby) wrenches for narrow access Insulated screwdriver set; should include a #2 Phillips screwdriver 15 to16” long Wire cutters/strippers Long-nose pliers DVM or Voltmeter Mounting Two or more people may be needed to install the Radian inverter/charger due to its weight.
Installation …continued from the previous page… 2. Radian Inverter Place the Radian inverter against the wall and slide it directly over the upper lip of the mounting plate. The inverter’s mounting flange should come to rest within the lip so that it hangs securely. To assist in alignment, dimples have been placed on the side of the unit to mark the lower edge of the flange. In the picture to the left, the two X symbols show the location of the dimples. xx Mounting Plate 3.
Installation Component Mounting The top of the GS Load Center (GSLC) connects to the bottom of the Radian inverter using four keyhole slots. The keyhole slots fit over four screws on the bottom of the inverter that 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.
Installation Removing Front Cover The front cover must be removed in order to access the Radian inverter’s AC terminals and other connections. These include the Remote and Batt Temp ports, as well as several sets of auxiliary terminals. Twenty-two machine 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.
Installation Terminals and Ports DC TERMINALS Connects to the battery cables and DC system. There are two DC positive and two DC negative terminals. Each DC positive terminal requires separate cables and separate overcurrent protection. See page 20 for instructions. RIBBON CABLES Connects the Radian’s power modules and control board. See Warning below. ON/OFF INV JUMPER (J3): Overrides the SWITCH INV terminals when installed. When installed, the inverter is ON.
Installation CONTROL WIRING TERMINAL BLOCK: Receives control wires for a variety of functions, including generator control. See facing page for terminal descriptions. REMOTE and BATTERY TEMP PORTS: Receive the RJ45 and RJ11 plugs from the MATE3 system display and Remote Temp Sensor. See page 25 for instructions. AC TERMINAL BLOCK Receives AC input wires for two input sources (L1, L2, and neutral for each). Also receives AC output wires (L1, L2, and neutral). All neutral wires are electrically common.
Installation Wiring It will be necessary to remove knockouts from the chassis to run wires. Bushings are included with the hardware kit to protect the wires. Make sure to install these bushings in the holes. Use copper wire only. Wire must be rated at 75°C or higher. Grounding WARNING: Shock Hazard This unit meets the IEC requirements of Protection Class I. The unit must be connected to a permanent wiring system that is grounded according to the IEC 60364 TN standard.
Installation DC Wiring WARNING: Shock Hazard Use caution when working in the vicinity of the inverter’s battery terminals. CAUTION: Equipment Damage Never reverse the polarity of the battery cables. Always ensure correct polarity. CAUTION: Fire Hazard The installer is responsible for providing overcurrent protection. Install a circuit breaker or overcurrent device on each DC positive (+) conductor to protect the DC system.
Installation Table 4 Inverter DC Conductor Size and Torque Requirements Nominal DC Amps Conductor Size (Minimum, per breaker) Breaker Size (Minimum, per breaker) (Derated 125%) 104 104 2/0 AWG 0.105 in²) or 70 mm² 2/0 AWG 0.105 in²) or 70 mm² 175 Adc/AIC 10kA 175 Adc/AIC 10kA GS8048A GS4048A Terminal Location Torque Requirements Inverter DC Terminals Battery Terminals 60 in-lb (6.
Installation AC Wiring WARNING: Shock Hazard The neutral and ground conductors should be mechanically bonded. Ensure there is no more than one AC neutral-ground bond at any time. Local or national codes may require the bond to be made at the main panel only. The GS Load Center (GSLC) is equipped with its own bond, which may need to be removed. WARNING: Fire Hazard Do not install the GS4048A using a load center that has multiwire branch circuits connected.
Installation The terminals labeled L1 and L2 GRID are used to connect to the two utility grid “hot” wires. The L1 and L2 wires are usually black and red respectively, and read 120 Vac each when measured with respect to neutral. In a standard service, L1 and L2 are 180 degrees out of phase and should read 240 Vac when measured from one to the other. The L1 and L2 GEN terminals are used to connect to the “hot” wires on a 120/240 Vac generator. Three neutral (N) terminals are available.
Installation AC Sources The inverter’s transfer relay is normally set to provide inverter power to the output. The conditions for AC acceptance are defined by the inverter’s programmed settings and AC input mode. The relay will switch to transfer the AC source power to the output when the AC acceptance conditions are met. The Radian inverter has connections for two AC sources, GEN (generator) and GRID, for ease of installation. Each source is transferred with a separate relay.
Installation Accessory Wiring System Display port RTS port The upper board has ports for both the Remote Temperature Sensor (RTS) and the system display. The system display port is labeled Remote. The RTS port is labeled Battery Temp. If a HUB Communications Manager is in use, it occupies the inverter’s Remote port. The system display plugs into the HUB product.
Installation AUX Wiring The Radian inverter has two sets of terminals which can respond to different criteria and control many functions. These include cooling fans, vent fans, load diversion, fault alarms, and the Advanced Generator Start (AGS) function. The 12V AUX terminals are a switched 12 Vdc power supply. They can control any of the Auxiliary Output functions available in the system display (MATE3). The 12V AUX terminals can supply up to 0.7 amps at 12 Vdc (8.4 watts).
Installation In this example, the 12V AUX terminals drive a relay that diverts wind power. The relay’s coil is connected to the 12V AUX terminals. When the AUX function closes the relay (based on battery voltage), the relay diverts the excess wind power to a water heating element. Turbine Relay NOTE: Relays and elements shown are examples only and may vary depending on the installation.
Installation In other cases, or in the case of a three-wire-start generator, the inverter should use the 12V AUX terminals instead, in conjunction with a three-to-two wire converter. (See pages 28 and 29.) Two-Wire-Start Generator Starting Switch Figure 23 Two-Wire Generator Start (RELAY AUX) Two-Wire-Start (12V AUX Terminals) The 12 Vdc signal provided by the 12V AUX terminals can be switched on and off to provide a start signal.
Installation Three-Wire-Start A “three-wire-start” generator has two or more starting circuits. It usually has a separate switch or position for cranking the generator. A three-wire generator has fewer automated functions than a two-wire. It usually requires multiple controls for starting, running, or stopping. The inverter terminals cannot control this type of generator without using a three-wire to two-wire conversion kit. Atkinson Electronics (http://atkinsonelectronics.
Installation NOTES: 30 900-0160-01-00 Rev A
Installation AC Configurations Single-Inverter Figure 26 (below) shows the general wiring of the Radian inverter and the AC system connected to it. This figure is not a physical representation of the inverter and does not depict the GSLC. Figure 27 (see next page) shows the locations of AC and network connections. This figure is a physical diagram for wiring the GSLC, network components, and external AC devices with the inverter.
Installation NOTES: 1. Ground wiring is not shown for reasons of simplicity. Regardless, this system must be connected to a grounded, permanent wiring system. See page 19. 2. 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 the inverter is connected. 3.
Installation Multiple-Inverter AC Installations (Stacking) Installing multiple inverters in a single AC system supports larger loads than a single inverter can handle. This requires stacking. Stacking refers to how the inverters are wired within the system and then programmed to coordinate activity. Stacking allows all units to work together as a single system. The GS4048A and GS8048A models can stack up to ten units in parallel.
Installation IMPORTANT: 34 Neither the GS8048A nor the GS4048A can stack with the previous model GS8048. The GS8048 can share a HUB product with the others if it is wired independently. The GS8048A can be stacked with the GS4048A using HUB products. To optimize the Power Save function, GS4048A inverters should have higher rank numbers than any GS8048A inverter. This is true regardless of the quantity of either model. In addition, the GS4048A should not be the master inverter in a mixed system.
Installation Parallel Stacking (Dual-Stack and Larger) In parallel stacking, two or more inverters are stacked to create a single, common AC bus as shown in Figure 29. The slave outputs are controlled directly by the master and cannot operate independently. All inverters share a common input (AC source) and run loads on a common output. Slave inverters can go into Power Save mode when not in use. The master will activate individual slaves based on load demand.
Installation NOTES: 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 shown in the AC Load Panel above), not all of the Radian neutral connections need to be made. 2. Maintenance bypass switching assemblies are commonly used so that the inverter can be taken offline, if necessary, without shutting down the entire system.
Installation NOTES: 1. Ground wiring is not shown for reasons of simplicity. Regardless, this system must be connected to a grounded, permanent wiring system. See page 19. 2. 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. 3.
Installation Functional Test Once the mounting, wiring, and other installation steps are completed, proceed to the Radian Series Inverter/Charger Operator’s Manual. The Operator’s Manual has steps for system commissioning. These include powering up and performing a functional test on the inverter system, as well as powering down and adding new devices to an existing system.
Symbols, Terms, and Definitions Symbols Used 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 notation indicates that the hazard may cause damage to the equipment. IMPORTANT: This type of notation indicates that the information provided is important to the installation, operation and/or maintenance of the equipment.
Terms and Definitions Table 5 Terms and Definitions Term Definition EPO Emergency Power Off; a switching product used for emergency shutdown GFDI Ground Fault Detector Interruptor; a safety device for PV systems GND Ground; a permanent conductive connection to earth for safety reasons; also known as Chassis Ground, Protective Earth, PE, Grounding Electrode Conductor, and GEC Grid/Hybrid™ System technology which optimizes both grid-interactive and off-grid options Grid-interactive, grid-intertie, g
Index A F AC Inputs .............................................................5, 18, 22, 24 AC Wiring ........................................................................ 18, 22 Advanced Generator Start (AGS) .................................. 26 Applications ............................................................................. 5 AUX ............................................................................ 17, 26, 39 Features .............................................................
Index MATE3 ...................................................................4, 15, 18, 40 AUX .................................................................................... 26 Stacking ............................................................................ 33 Mounting Components ................................................................... 15 Dimensions .............................................................. 11, 12 Orientation ......................................................
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