GFX Series Inverter/Charger GFX1312 GFX1424 GFX1548 Installation Manual
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: Address: E-mail: Web Site: +1.360.435.6030 (North America) +1.360.618.4363 (Technical Support) +1.360.435.6019 (Fax) +34.93.654.
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.
Important Safety Instructions Definitions The following is a list of initials, terms, and definitions used in conjunction with this product.
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 lbs (22 kg). Use safe lifting techniques when lifting this equipment as prescribed by local codes.
Important Safety Instructions 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. Thoroughly inspect the equipment prior to energizing. Verify that no tools or equipment have been inadvertently left behind. Ensure clearance requirements are strictly enforced.
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.
Important Safety Instructions National Institute of Recyclers, Mexico Web site: Email: Phone: Fax: http://www.inare.org.mx/ a57841279@prodigy.net.mx, margarita@inare.org.mx +1.55.57.85.9160 +1.55.57.84.1279 Natural Resources Canada Address: Phone: TTY: Web site: 580 Booth, Ottawa, ON K1A 0E8 +1.613.995.0947 +1.613.996.4397 (Phone and TTY: Monday to Friday, 8:30 a.m. to 4:30 p.m. ET) http://www.nrcan-rncan.gc.ca/mms-smm/busi-indu/rec-rec-eng.
Table of Contents Important Safety Instructions ........................................................................1 Audience .................................................................................................................................................................................1 Symbols Used ........................................................................................................................................................................1 Definitions........
Table of Contents List of Tables Table 1 Table 2 Table 3 Table 4 Table 5 Terms and Definitions......................................................................................................................2 Components and Accessories ....................................................................................................10 Ground Conductor Size and Torque Requirements ..........................................................18 DC Conductor Size and Torque Requirements..................
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.
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: Components and Accessories Table 2 Components and Accessories Installed Components Battery Terminal Cover, red Battery Terminal Cover, black AC Conduit Plate DC Cover (DCC) Included in Box GFX Series Installation Manual (this book) GFX Series Operator’s Manual “WARNING ELECTRICAL SHOCK” sticker Remote Temperature Sensor (RTS) Silicone Grease Packet
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.
Planning 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 battery charger, even if all of its power is used immediately. The renewable source must have a charge controller or some way to prevent overcharging.
Planning 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 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.
Planning NOTES: 14 900-0113-01-00 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.
Installation Tools Required Wire cutters/strippers Torque wrenches Assorted insulated screwdrivers DVM or Voltmeter Mounting It is easier for two people to install the GFX inverter due to its weight. The unit must be secured with appropriate fasteners to a sturdy mounting surface capable of supporting its weight. OutBack cannot be responsible for damage if inadequate fasteners are used. The unit has four mounting holes, one in each corner.
Installation Terminals and Ports DC TERMINALS: Connect to battery cables and DC system. See page 19 for instructions. DC and AC GROUND TERMINALS: Connect to grounding system for both batteries and AC. See page 18 for instructions. CONTROL WIRING TERMINAL BLOCK: Receives control wires for a variety of functions, including automatic generator starting. See pages 23 and 24 for instructions and the GFX Series Operator’s Manual for more information. AC TERMINAL BLOCK: Receives AC input and output wires.
Installation Grounding 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. 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.
Installation DC Wiring CAUTION: Equipment Damage Never reverse the polarity of the battery cables. Always use correct polarity. CAUTION: Fire Hazard Always install a breaker, fuse, or protective device to protect the DC system. Table 4 DC Conductor Size and Torque Requirements Inverter Nominal DC Amps Conductor Size (Derated 125%) (Minimum) 130 70 37.5 2/0 AWG or 0.105 in2 (70 mm2) 1/0 AWG or 0.083 in2 (70 mm2) #1 AWG or 0.
Installation M8 x 1.25 Stud 13 mm Nut Install battery cable lug, nuts and washers in the order illustrated. The battery cable lug should be the Flat Washer first item installed on the stud. It should make solid contact with the mounting surface. Do not install Mounting Surface hardware in a different order than shown.
Installation AC Wiring Table 5 AC Conductor Size and Torque Requirements Conductor Size Recommendation Torque Requirements Minimum #6 AWG or 0.025 in2 (16 mm2) 35 in-lbs (4.0 Nm) 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 wattage to determine actual maximum load. Size the breakers accordingly. The two Neutral terminals are electrically common. Use only one terminal if connecting to an external neutral bus.
Installation Accessory Wiring The AC Wiring Compartment Board has ports for both the Remote Temperature Sensor (RTS) and 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. RTS port RTS cable (RJ11, 4-conductor, telephone) MATE/HUB port See the Operator’s Manual for more information on the RTS.
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.
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.
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.
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 or less. All output breakers must be sized appropriately for loads and inverter wattage.
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.
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.
Installation Figure 21 900-0113-01-00 Rev A Classic Series Wiring (Two Inverters) 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. All inverters share a common input (AC source) and run loads on a common output. Up to 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. 1.3 kVA 120 Vac Figure 22 1.3 kVA 120 Vac 3.9 kVA 120 Vac 1.
Installation Figure 23 900-0113-01-00 Rev A Parallel Wiring (Four Inverters) 31
Installation Three-Phase Stacking In three-phase stacking, inverters are stacked to create three separate 120 Vac output legs in a wye configuration. 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. Only three inverters, one per phase, may be installed in a three-phase arrangement. 1.3 kVA 120 Vac 1.3 kVA 120 Vac 1.3 kVA 120 Vac 1.3 kVA 120 Vac 1.
Installation Figure 25 900-0113-01-00 Rev A Three-Phase Wiring (Three Inverters) 33
Installation Functional Test 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.
Index A F AC Conduit Plate................................................................10 AC Terminals .......................................................................17 AC Wiring .............................................................................21 AGS...........................................................................................2 Applications ........................................................................11 Audience ...............................................
Index R Recycling Information........................................................5 Remote System Display.............................................. 2, 12 Remote Temperature Sensor (RTS) .......... 2, 10, 17, 22 Renewable Energy ............................................................12 S Safety.......................................................................................1 Battery ...............................................................................4 General ..................
Index 900-0113-01-00 Rev A 37
North America 19009 62nd Avenue NE Arlington, WA 98223 USA +1.360.435.6030 900-0113-01-00 Rev A Europe: Barcelona, Spain +34.93.654.
