OutBack Power Systems “Americas” and “Mobile” FX and VFX Inverter/Charger Installation and Programming Manual Document Revision 7.2 FX 2012T - 2.0 kW / 12 VDC / 120 VAC / 60 Hz (Sealed + Turbo / Americas) FX 2524T - 2.0 kW / 24 VDC / 120 VAC / 60 Hz (Sealed + Turbo / Americas) FX 3048T - 2.5 kW / 48 VDC / 120 VAC / 60 Hz (Sealed + Turbo / Americas) VFX 2812 - 2.8 kW / 12 VDC / 120 VAC / 60 Hz (Ventilated / Americas) VFX 3524 - 3.5 kW / 24 VDC / 120 VAC / 60 Hz (Ventilated / Americas) VFX 3648 - 3.
Installation & Programming Manual FX & VFX Series Inverter/Charger System 900-0027-1 Page 2 Rev 7.2 08/26/05 Copyright 2003 OutBack Power Systems, Inc.
TABLE OF CONTENTS IMPORTANT SAFETY INSTRUCTIONS ........................................................................................... 5 Installation Guidelines ....................................................................................................................... 5 General Precautions ........................................................................................................................... 6 Additional Notices ...........................................................
POWER SAVE LEVEL SLAVE ADJUST ONLY................................................................................................ 28 System Examples .............................................................................................................................. 28 DUAL-STACKED SYSTEM USING “CLASSIC” STACKING ........................................................................ 28 STACKED SYSTEM USING OUTBACK’S “PARALLEL” STACKING........................................................
IMPORTANT SAFETY INSTRUCTIONS Installation Guidelines This manual contains important instructions for the OutBack FX series inverter/charger system with the software which allows classic (two FX’s in series), parallel and series/parallel stacking of two to ten FX’s for higher power and/or higher voltage systems. 1 All of the AC wiring to the AC terminals is to be torqued to 30 inch-pounds (equivalent to 2.5 foot-pounds or 3.4 Nm).
IMPORTANT SAFETY INSTRUCTIONS General Precautions 1. 2. 3. 4. 5. 6. 7. Before using the FX, read all instructions and cautionary markings on (1) the FX, (2) the batteries and (3) all appropriate sections of this installation and operation manual. CAUTION - To reduce risk of injury, charge only deep-cycle lead acid, lead antimony, lead calcium, gel cell or absorbed glass mat type rechargeable batteries. Other types of batteries may burst, causing personal injury and damage.
RATINGS ATTENTION: All “FX” inverter/chargers are ETL listed to UL 1741. All “Mobile” FX inverter/chargers are ETL listed to UL 458. ETL is a Nationally Recognized Testing Laboratory (NRTL). NOMINAL SYSTEM AC VOLTAGE: This is the AC output voltage produced by an FX system. Each FX produces 120 VAC but multiple FXs can be configured in parallel, series or 3-phase to produce different voltages between their AC output connections.
RATINGS MAXIMUM CURRENT FOR BATTERY CHARGER: The FX uses AC current from the AC input source to charge the battery. Due to heat constraints, the FX limits this amount of current. The maximum and default values for this setting are shown below. Please refer to the programming section to adjust this setting. The battery charger has an efficiency of about 90%. There are other factors like cable losses that may reduce this efficiency. The maximum DC current that can be produced is also shown below.
MOUNTING All FX’s can be mounted in any position. Better performance will be achieved if it is mounted in a location which allows for air to circulate around the exterior of the casting. Locating the FX in a cool location will ensure the highest efficiency and power capacity. The following drawings provide the mounting and overall dimensions of the FX with the DCC, ACA and DCA attached. All VFXs come with the DCC and all FX “T”s come with the Turbo. The ACA and the DCA must be ordered separately.
COMPLETE OUTBACK INTEGRATED SYSTEMS Shown below are complete systems of OutBack FX’s for indoor installations. The system with four FX’s is shown mounted to the OutBack PS4MP (Power System 4 Mounting Plate where the “4” in refers to the maximum number of FX’s that will fit). The PS4MP comes with six 1x20mm thread forming screws for attaching FX’s and breaker boxes.
AC WIRING CONNECTIONS The FX system and the other OutBack balance of system components are designed to make it easy to meet both local and National Electrical Codes (NEC) installation requirements. If you are not familiar with the NEC, you should have the equipment installed by a qualified renewable energy equipment electrician. Contact your dealer for information on qualified electricians. All wiring methods are to be made in accordance with the National Electrical Code, ANSI/NFPA 70.
INDICATORS & CONTROL WIRING The AC wiring compartment also encloses the following items; a 6-port terminal block, an RJ-11 jack, an RJ-45 jack, a set of three “Battery” LEDs and a set of three “Status” LEDs. The 6-port terminal block contains ports for Inverter & On/Off, AUX + & AUX –, and XCT + & XCT -. The RJ-11 “Battery Temp” jack accepts only OutBack’s “RTS” battery temperature sensor.
BATTERY - FX CABLING DC BATTERY TERMINALS The DC terminals are made from solid brass with a stainless steel threaded stud. The threads are M8 x 1.25. The black terminal is negative and the red terminal is positive. DO NOT PUT ANY WASHERS BETWEEN THE TERMINAL MOUNTING SURFACE AND THE ACTUAL BATTERY CABLE LUG. Place the lug, washers and nut in the following order: Lug, Flat Washer, Lock Washer, Nut. TORQUE TO 60 INCH-POUNDS (5 FOOT POUNDS) MAXIMUM (6.77 NM).
FX ACCESSORIES ACA (AC CONDUIT ADAPTER) This plastic box slips into grooves on the AC end of the FX. This adapter extends the AC wiring compartment to match the PS4AC or PS2AC. It also provides more room for wiring than is available when using the supplied AC conduit plate. There is a 2-inch TSC cut-out on the plastic box to allow it to be used with the PS4AC or PS2AC disconnect enclosure or 2-inch conduit.
TURBO KIT INFORMATION The Turbo Kit is an addition that is either included or can be added to any sealed FX. Typically, the Turbo Kit adds 300-500 watts of power to a sealed FX. This extra power is included in the model number for sealed FXs that come with Turbos. If the sealed FX did not come with a Turbo and one is added, then the FX will be able to produce the extra 300-500 watts of power in addition to the power that the model number indicates.
HUB COMMUNICATION MANAGER The HUB communication manager allows the MATE to control and monitor a maximum of ten OutBack products. Currently the HUB comes in two types. The HUB-4 can connect up to four Outback products (FX’s and/or MX-60’s). The HUB-10 (shown below) can connect up to ten Outback products (FX’s and/or MX-60’s). The FX’s can be operated in a stacked or independent configuration. If the FX’s are to be stacked, the HUB must be part of the system.
FX SYSTEM CONFIGURATIONS The FX System Configuration section shows diagrams of some typical system configurations using the FX. These diagrams are for non-Mobile FX installations only. Below these diagrams are notes for how to change each diagrams to accommodate a Mobile installation. There are diagrams for a single FX, two FX’s in series or series/parallel (see NOTE below), two FX’s in parallel, four FX’s in series/parallel (see NOTE below), four FX’s in parallel, and a 3-phase system.
FX SYSTEM CONFIGURATION – SERIES OR SERIES/PARALLEL DUAL FX SYSTEM Series or Series/Parallel Dual FX System The following diagram illustrates a typical series FX installation using two FX’s. This diagram is for a non-Mobile FX installation only. Below this diagram are notes for how to change this diagram to accommodate a Mobile installation. The AC wiring from the AC source and to the AC loads must handle 50 amps AC or more. All other AC wiring must handle a capacity of 50 amps AC or more.
FX SYSTEM CONFIGURATION – PARALLELED DUAL FX SYSTEM Paralleled Dual FX System The following diagram illustrates a typical paralleled FX installation using two FX’s. This diagram is for a non-Mobile FX installation only. Below this diagram are notes for how to change this diagram to accommodate a Mobile installation. The AC wiring from the AC source and to the AC loads must handle 100 amps AC or more. All other AC wiring must handle a capacity of 50 amps AC or more.
FX SYSTEM CONFIGURATION – SERIES/PARALLEL QUAD FX SYSTEM Series/Parallel Quad FX System The following diagram illustrates a typical series/parallel FX installation using four FX’s. This diagram is for a non-Mobile FX installation only. Below this diagram are notes for how to change this diagram to accommodate a Mobile installation. The AC wiring from the AC source and to the AC loads must handle 120 amps AC or more.
FX SYSTEM CONFIGURATION – PARALLEDED QUAD FX SYSTEM Paralleled Quad FX System The following diagram illustrates a typical paralleled FX installation using four FX’s. This diagram is for a non-Mobile FX installation only. Below this diagram are notes for how to change this diagram to accommodate a Mobile installation. The AC wiring from the AC source and to the AC loads must handle 200 amps AC or more. The AC wiring connected to the QUO 100A dual bypass breakers must handle 100 amps AC or more.
FX SYSTEM CONFIGURATION – 3 PHASE FX SYSTEM 3-Phase FX System The following diagram illustrates a typical 3-phase FX installation using three FX’s. This diagram is for a non-Mobile FX installation only. Below this diagram are notes for how to change this diagram to accommodate a Mobile installation. This system will produce 120VAC per phase and 208VAC from phase to phase. At this time there can only be one FX per phase on a 3-phase system.
START-UP & OPERATION Once the FX system installation is completed, it is time to power the system. Leave the breakers on the AC side in the OFF position until the FX’s are powered and programmed. Power the FX’s (and any MX-60 charge controllers) by switching the DC disconnect breakers to the ON position. The LED’s (Light Emitting Diodes) in the AC compartment of each FX will begin to light. For each FX, one “BATTERY” LED will be lit.
BATTERY CHARGING INFORMATION A battery bank may last for over 10 years if properly cared for, but it can also be ruined in less than a month if not properly charged. Batteries represent a large percentage of the cost of a system. Keeping your battery bank healthy is very important.
BATTERY CHARGING INFORMATION The following bullets describe the steps in the battery charging sequence. • The first stage of the charging sequence is the “Bulk” stage. The FX uses as much AC current as possible from the AC input source to raise the battery voltage to the “Absorb” voltage setting. See the “Maximum Current for Battery Charging” heading in the RATINGS section for the FX’s default and maximum values of the AC current used for charging.
STACKING INFORMATION Classic, OutBack, and 3-Phase Stacking Methods OutBack Power Systems offers four different ways to stack multiple FX’s (up to 10 for single or split phase systems, only 3 for threephase systems).
STACKING INSTRUCTIONS Stacking Procedure This section will help inform you on how to set up stacking correctly and what the screens in the stacking menu mean. (Remember, for 3-phase stacking a jumper must be set to the 3-ph position in the HUB. See HUB manual for further information.) Make sure that the FX’s connect to the lowest numbered ports of the HUB. First, turn off all AC breakers (the Bypass breaker can be left on).
STACKING INSTRUCTIONS Stacking Procedure (Continued) The next two screens in the “Stack” menu on the MATE are the “POWER SAVE LEVEL MASTER ADJUST ONLY” and “POWER SAVE LEVEL SLAVE ADJUST ONLY” screen. You can access these screens by pressing DOWN once or twice if you are currently on the STACK PHASE screen. Since nobody (seriously, even here at OutBack) understands these screens the first 3-4 times they are explained, we offer our best effort right here.
STACKING INSTRUCTIONS System Examples (Continued) Using the MATE, go to the stacking menu (explained earlier in the “Stacking Instructions” section). You are now at the 1st stacking menu called “Stack Phase”. In the upper right hand corner of the mate screen will always be the HUB port number of the FX you’re working with at the time. Let’s start out with the FX that’s on port 1. If something other than P01 appears in the upper right hand corner then press the PORT button until P01 appears.
STACKING INSTRUCTIONS System Examples (Continued) By making this FX the 1st rank slave, we are turning both Legs “On” directly, thus producing 240VAC without using the X-240. If you have a system that is different from this example then press the PORT button until you get to a slave FX that is in series (“OB Slave L2”) with the master. On this screen the setting from the factory should be set to 1 which indicates the 1st rank slave.
AUTOMATIC GENERATOR START INSTRUCTIONS The Aux output of the FX can be programmed to start a 2-wire gas or diesel generator automatically when the batteries need charging. There are two separate ways to accomplish this function; AGS (Advanced Generator Start) and GenAlert. AGS is a function of the MATE while GenAlert is a function of the FX. AGS has more features and therefore it can start the generator under many different types of conditions.
MOBILE FX INFORMATION General GROUND SWITCHING How it works: With no AC input signal present, the FX inverter’s Neutral Output is tied to Chassis Ground and hence to the Boat or RV Ground. This is similar to any Home installation where one conductor (Neutral for the US) must be grounded. When an AC input is applied and the inverter allows it to transfer, the Neutral Output to Ground bond within the inverter is broken.
MOBLIE FX INFORMATION Dual Input Transfer Switch Setup In many cases, systems will have the option of using either an onboard generator or the utility grid (shore power) as their AC input. When this is the case, both the AC “Hot” and AC “Neutral” lines must be connected to the appropriate source. Currently, OutBack Power Systems does not produce a product that will accomplish this function. Therefore, the consumer must purchase a device that accomplishes this task.
MATE - SYSTEM CONTROLLER AND DISPLAY The OutBack MATE system controller and display allows you to program, control, and monitor the operation of one or more FX’s as well as any other OutBack products (such as the MX60 MPPT charge controller). When connecting a MATE to more than one product is required, a HUB-4 or HUB-10 communication manager must be included in the system. The MATE can be located up to 1000 feet (300 meters) from the FX system using standard 8 conductor CAT-5 type communication cabling.
MATE - SYSTEM CONTROLLER AND DISPLAY OUTBACK MATE System Controller and Display Inverter LED Indicator (green) AC Input LED Indicator (yellow) Dedicated Inverter Control “HOT” Key Dedicated AC Input Control “HOT” Key “Soft” Keys Each one of the soft keys corresponds to a word on the bottom line of the LCD display The menu system displayed on the MATE will vary depending on the software version that the MATE was programmed with at the time of manufacturing or during its last software upgrade.
MATE – SYSTEM CONTROLLER AND DISPLAY This section of the manual will cover how to use the buttons on the MATE to navigate the menus. NOTE: The menu system displayed on the MATE will vary depending on the software version that the MATE was programmed with at the time of manufacturing or during its last software upgrade. MENU STRUCTURE MAIN MENU The OutBack MATE uses a branching menu structure to display various OutBack products operation modes and status.
MATE – SYSTEM CONTROLLER AND DISPLAY ‘SOFT’ KEYS The four buttons under the LCD are referred to as the ‘soft’ keys. Their operation is dependent on what their label says. The label is the word on the bottom line of the LCD directly above the button. Soft keys used to navigate the menus are commonly labeled , , , , or .
MATE – SYSTEM CONTROLLER AND DISPLAY Inverter Control INV The OutBack MATE includes an INV “hot” key to allow direct control of the inverter from anywhere in the menu system. The INV key is located on the right side of the MATE LCD display. Pressing the INV key takes you to the INVERTER CONTROL menu shown below.
MATE – SYSTEM CONTROLLER AND DISPLAY AC Input Control AC IN The OutBack MATE includes a AC IN “hot” key to allow direct control of the AC input from anywhere in the menu system. The AC IN key is located on the left side of the MATE’s LCD display. Above the AC IN key is a yellow LED indicator which flashes when an AC source is available but not connected, and is on continuously when the AC source is connected. If no AC source is available the yellow LED indicator will remain off.
MATE - MENU MAP Installation & Programming Manual FX & VFX Series Inverter/Charger System 900-0027-1 Page 40 Rev 7.2 08/26/05 Copyright 2003 OutBack Power Systems, Inc.
MATE – MENU MAP Copyright 2003 OutBack Power Systems, Inc. 19009 62nd Ave NE, Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 FX & VFX Series Inverter/Charger System Installation & Programming Manual 900-0027-1 Rev 7.
MATE SCREENS Summary Screen The OutBack MATE includes a SUMMARY screen to allow easy understanding of the FX operation. The display uses both words and symbols to show what currently is happening in the system, along with a limited amount of numbers. This makes it easier for the system user to understand where the power is flowing within the system. The first line of the summary screen displays “DCÅÆAC” and is measured in kilowatts (kW).
MATE SCREENS Status Screens The STATUS screens allow the system user to check the operation of the FX system. Both AC and DC voltage and AC current meters are provided to enable monitoring, adjustment and troubleshooting of the system operation. MODES MENU The MODES section lets the user view and change the various modes for a specific FX by pressing the PORT button to access a specific FX. The modes include inverter, ac in, charger, auxiliary, and equalize.
MATE SCREENS METER MENU The METER section lets the user view the AC voltage and AC current meters as well as the software revision of the FX’s microprocessor. The user can view the input and output AC voltages, as well as the input, inverter, charger and sell currents. This can be used to verify that the FX is sensing voltages and currents and also helps discern what the FX is doing (like charging or inverting). The software revision is helpful when troubleshooting.
MATE SCREENS BATTERY MENU The BATTERY menu section allows the user to check the status of the battery voltage and the battery charging process. Both the actual battery voltage and the temperature compensated battery voltage are provided. The battery charging process set points are displayed along with the associated timer for the charging process. No adjustments are allowed from this section. To change the battery charger’s operation, go the ADVANCED programming section.
MATE SCREENS ERROR MENU The ERROR section allows the user to check the cause of an error condition. When an error has occurred, the red error LED indicator in the FX’s wiring compartment will be illuminated (not to be confused with a blinking “ERROR” LED that indicates a WARNING). If an error occurs, the FX will cease operation and the MATE will display an error screen.
MATE SCREENS WARNING MENU The WARNINGS section of the STATUS menu allows the user to check the cause of a warning condition for the FX. When a warning condition has occurred, the red “ERROR” LED indicator in the FX’s wiring compartment will flash. The cause of the warning will not be displayed on the MATE like an ERROR will. Instead, you must access this WARNINGS menu and scroll down the list to find out which warning is present.
MATE SCREENS DISCONNECT MENU The FX includes a section that displays the reason for last DISCONNECT from the AC source. This is helpful if the FX rejects the AC source and the user wants an explanation and help on rectifying the problem. The FX will disconnect from an AC source if the AC source falls out of the FX’s frequency or voltage ranges.
MATE SCREENS SELL MENU The SELL section of the STATUS menu has only one screen. This screen gives a number that refers to a reason the FX would stop selling. OutBack Power Systems technicians use this number to quickly understand what the FX thinks is happening. The system user should not be concerned about this number unless they are experiencing many unknown grid disconnects and they need troubleshooting help. This screen is only operational with “Grid-Tie” FX’s.
MATE SCREENS Setup Screens The OutBack FX includes a SETUP menu to allow limited adjustment of some of the settings which may need to be accessed by the system user. SEARCH MENU The SEARCH mode is an automatic system which reduces the power consumption of the FX during periods of no power demand. It is primarily used for off-grid applications where the power is being generated by solar panels or other renewable energy sources and the system user is concerned about conserving every possible watt of power.
MATE SCREENS INPUT MENU The other settings currently accessible to the system user in the SETUP menu involve the AC INPUT. The system user can specify what type of AC INPUT is being used, whether it is a generator (GEN) or the utility grid (GRID). Following this are two screens, one for GEN and one for GRID, that allow the user to adjust the maximum AC current that the FX will allow to enter before the FX backs off the charger.
MATE SCREENS Advanced Screens The ADVANCED menu section allows adjustment of all the settings involved with the operation of the FX. Changes made to these settings are stored internally in non-volatile memory inside of the FX – the settings are not lost when the MATE is removed or battery power is disconnected. Some settings appear both in the SETUP and in the ADV menus. Changes made to these settings in one area will cause the same changes to occur in the other area.
MATE SCREENS INVERTER MENU The INVERTER category of the advanced menu section allows adjustment of the inverter’s operation to match the AC load and battery requirements. Specifically, this section allows adjustment of the search function, the low battery cut-out function, the FX’s AC output voltage, and allows the user to reset the FX to its factory defaults.
MATE SCREENS CHARGER MENU The CHARGER section allows for adjustment of the battery charger’s operation to match the requirements of the batteries used. OutBack’s default battery charging set points may not be correct for the type of batteries being used. Please contact the battery manufacturer for correct ABSORB, FLOAT and EQUALIZE voltages. See the BATTERY CHARGING INSTRUCTIONS section for guidelines on how to set some of these values and for more information on the battery charging process.
MATE SCREENS GRID MENU The GRID category of the advanced menu section allows for adjustment of the AC input voltage window and time delays to match the characteristics of the AC source if that AC source is the utility grid. This setting can be found in the SETUP/FX/INPUT menu. Only “Grid-Tie” FX’s have a default of GRID as the AC source. All other FX types have an AC input default of GEN.
MATE SCREENS GENERATOR MENU The GEN (generator) category of the advanced menu section allows for adjustment of the AC input voltage window and time delays to match the characteristics of the AC source if that AC source is a generator. This setting can be found in the SETUP/FX/INPUT menu. All OutBack Power System FX’s other than the “Grid-Tie” FX’s have a default of GEN (generator) as the AC source.
MATE SCREENS AUXILIARY MENU The AUX (auxiliary) section can be used to control external AC or DC loads, signal a generator start system, send a fault alarm signal, or to run a fan. The AUX output provides a 12 vdc, 0.7 adc max signal on the AUX terminals located in the AC wiring compartment.
MATE SCREENS AUXILIARY MENU (CONTINUED) This page contains to settings for some of the functions that can be chosen in the AUX OUTPUT FUNCTION screen described on the previous page. The functions that do not have setting perform automatically as described on the previous page. There are voltage and time period settings for ‘GenAlert’, ‘LoadShed’, ‘VentFan’, and ‘Diversion’.
MATE SCREENS STACKING MENU The STACK (stacking) section is used to program the stacking of the FX’s. An explanation of stacking can be found in the STACKING INFORMATION and STACKING INSTRUCTIONS sections of this manual. The FX’s can be connected in series, parallel or 3-phase for higher voltage and/or higher power. There are four types of stacking available; ‘Classic Stacking’, ‘OutBack Parallel Stacking’, ‘OutBack Series Stacking’ and ‘3-Phase Stacking’.
MATE SCREENS SELL MENU The SELL menu is used to set the functions that control the process of selling power back to the utility grid. This menu only pertains to Grid-Tied FX’s. These functions include setting the voltage at which the FX sells back to the utility grid, setting the window in which the Grid-Tie function operates, and to enable or disable the Grid-Tie function. The default values enable the FX to sell back to the utility grid after the FX has completed a charge cycle.
MATE SCREENS CALIBRATION MENU The CAL (calibration) section is used in the factory or field to make fine adjustments in the operation of the FX. It is particularly useful when multiple FX’s are connected together in the different stacking configurations to maximize the performance of the FX’s. In most cases, the user will not need to adjust these settings from the factory default values.
WIRE SIZES The following chart contains information on wire sizes, the DC resistance of the wires and the corresponding diameters and areas of these wires. This information can be used to calculate the voltage drop of the wires or to find an equivalent wire size. SIZE (AWG) DC Resistance in Ohms CROSS-SECTIONAL AREA APPROXIMATE DIAMETER (1000 feet) MILLIMETERS INCHES MILLIMETERS 14 3.14 .0032 2.08 .078 1.98 12 1.98 .0051 3.31 .101 2.57 10 1.24 .0082 5.26 .126 3.20 8 0.78 .
WARRANTY OutBack Power Systems Two Year Limited Warranty OutBack Power Systems Inc. warrants that the products it manufactures will be free from defects in materials and workmanship for a period of two (2) years subject to the conditions set forth below. The limited warranty is extended to the original user and is transferable. The limited warranty term begins on the date of invoice to the original user of the product.
Installation & Programming Manual FX & VFX Series Inverter/Charger System 900-0027-1 Page 64 Rev 7.2 08/26/05 Copyright 2003 OutBack Power Systems, Inc.
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