OutBack Power Systems “Export” FX and VFX Inverter/Charger Installation and Programming Manual Document Revision 7.1 FX 2012ET - 2.0 kW / 12 VDC / 230 VAC / 50 Hz (Sealed + Turbo / Export) FX 2024ET - 2.0 kW / 24 VDC / 230 VAC / 50 Hz (Sealed + Turbo / Export) FX 2348ET - 2.3 kW / 48 VDC / 230 VAC / 50 Hz (Sealed + Turbo / Export) VFX 2612E - 2.6 kW / 12 VDC / 230 VAC / 50 Hz (Ventilated / Export) VFX 3024E - 3.0 kW / 24 VDC / 230 VAC / 50 Hz (Ventilated / Export) VFX 3048E - 3.
Installation & Programming Manual FX & VFX “E” Series Inverter/Charger System 900-0027-2 Page 2 Rev 7.1 06/08/06 Copyright 2003 OutBack Power Systems, Inc.
TABLE OF CONTENTS DECLARATION OF CONFORMITY .................................................................................................. 5 IMPORTANT SAFETY INSTRUCTIONS........................................................................................... 6 Installation Guidelines ....................................................................................................................... 6 General Precautions...............................................................................
STACKING INSTRUCTIONS..............................................................................................................24 OutBack & 3-phase Stacking Methods ...........................................................................................24 Stacking Procedure...........................................................................................................................24 STACK PHASE..............................................................................................
DECLARATION OF CONFORMITY EU Declaration of Conformity According to ISO / IEC Guide 22 and EN 45014 Product Type: Power Inverter/Charger Product Model Numbers: FX2012E, VFX2612E, FX2024E, VFX3024E, FX2348E, VFX3048E, These products comply with the following EU directives: Electromagnetic Compatibility 89/336/EEC, “Council Directive of 3 May 1989 On the approximation of the laws of member States relating to Electromagnetic compatibility” Low Voltage Directive 73/23/EEC, “Council Directive of 19 February
IMPORTANT SAFETY INSTRUCTIONS Installation Guidelines This manual contains important instructions for the OutBack FX “Export” (or “E”) series inverter/charger system with the software which allows parallel and 3-phase stacking of multiple units for higher power and/or higher voltage systems. 1 All of the AC field wiring terminals are to be torqued to 30 inch-pounds (equivalent to 2.5 foot-pounds or 3.4 Nm). Wiring to these terminals must meet requirements of the local electric code.
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 NOMINAL SYSTEM AC VOLTAGE: This is the AC output voltage produced by an FX system. Each FX produces 230 VAC (volts of AC) but multiple FXs can be configured in parallel or 3-phase and these configurations may produce different voltages on the AC output legs.
RATINGS AC INPUT FREQUENCY RANGE: This is the AC input source’s frequency range that the FX will accept and stay connected. If the AC input source is out of this range, the FX will not connect or stay connected. All “Export” FXs 45 - 55 Hz MAXIMUM AC OUTPUT CURRENT: This is the amount of “Surge” current that the FX will supply. This amount of surge can only be supplied for a split second. After this split second the FX lowers this surge limit.
MOUNTING All OutBack 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 improve the operation and ensure the highest efficiency and power capacity. The following drawing provides the mounting and overall dimensions of the FX with the FXA kit (DCC + ACA + DCA) attached.
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 PSMP (Power System Mounting Plate). The PSMP comes with six 1x20mm thread forming screws for attaching FX’s and breaker boxes. The use of an external toothed star washer (provided) is required on one screw on each piece of equipment in order to bite through the powder coating and ensure grounding of all metal components.
AC WIRING CONNECTIONS The FX system and the other OutBack balance of system components are designed to make it easy to meet any local and national electrical installation requirements. When used outside of the USA, follow the local installation codes for your country. If you are not familiar with the local installation codes, you should have the equipment installed by a qualified renewable energy equipment dealer or electrician. All wiring methods are to be made in accordance with the local electric code.
INDICATORS / CONTROL WIRING The AC wiring compartment also encloses the green terminal block used for the low voltage control wiring. This six position terminal block can be unplugged to make wiring easier and to simplify the removal and reinstallation of an inverter. Two sets of multi-colored LED indicators are provided to display the operation of the system. One set of three LED’s is provided to indicate the voltage level of the battery connected to the DC terminals of the FX.
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 flat washer, lock washer and nut on top of the battery terminal lug. TORQUE TO 60 INCH-POUNDS (5 FOOT-POUNDS OR 6.8 NM) MAXIMUM.
FX ACCESSORIES FX-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 PSAC or PS2AC. It also provides more room for wiring than is available when using the supplied flat knockout plate. There is a 2-inch TSC cut-out on the plastic box to allow it to be used with the PSAC or PS2AC disconnect enclosure. FX-DCA (DC CONDUIT ADAPTER) The FX-DCA allows the connection of 2-inch TSC conduit to the FX.
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 FX’s, MX-60 MPPT charge controllers or a combination of the two. The HUB-10 (shown below) can connect up to ten Outback FX’s, MX-60 MPPT charge controllers or a combination of the two. The FX’s can be operated in a stacked or independent configuration.
TURBO KIT INFORMATION The Turbo Kit is an addition that can be added to any sealed FX. It is highly recommended in hot climates or for installations that can use a few hundred watts of extra power. Typically, the Turbo Kit adds 300-500 watts of power to the FX. In hot climates or when the FX is the primary charging device, the chances of the FX overheating are heightened. When the FX gets to its temperature limits, it will back off the charging process to avoid overheating (and a shutdown of the FX).
FX SYSTEM CONFIGURATION - SINGLE FX SYSTEM The FX System Configuration section shows diagrams of some typical system configurations using the “Export” FX. There are diagrams for a single FX, two FX’s in parallel, four FX’s in parallel, and a 3-phase system. The diagrams show the proper breakers and wiring for the AC side of the installations as well as connections to the HUB or MATE. Also included is information on the maximum continuous power of the systems and proper DC breaker sizes.
FX SYSTEM CONFIGURATION - PARALLELED DUAL FX SYSTEM Paralleled Dual FX System The following diagram illustrates a typical paralleled FX installation using two FX’s. For this type of installation, use of OutBack Power Systems PS2 system is recommended. The bypass kit for the PS2 system with two FX’s is an AC-IOB-30D using four CBI breakers with a bypass mechanism. Please specify CBI breakers when ordering this bypass kit. The dual FX system will require two additional CBI 30 amp breakers for the AC input.
FX SYSTEM CONFIGURATION - PARALLELED QUAD FX SYSTEM Paralleled Quad FX System The following diagram illustrates a typical paralleled FX installation using four FX’s. For this type of installation, use of OutBack Power Systems PS system is recommended. This FX system will require one AC-IOB-60Q bypass kit. The AC-IOB-60Q bypass kit includes two QOU 60 amp breakers for the bypass and four 30 amp CBI breakers for the AC outputs.
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 system will produce 230VAC per phase and 400VAC from phase to phase. At this time there can only be one FX per phase on a 3-phase system. For this type of installation, use of OutBack Power Systems PS-3PH system is recommended.
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 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. This “BATTERY” LED should be either the green “FULL” LED or yellow “OK” LED.
BATTERY CHARGING INSTRUCTIONS Keeping your battery bank healthy is very important. Although a battery bank may last for over 10 years if properly cared for, it can also be ruined in less than a month if neglected. Since the batteries are the lifeblood of the system and represent a large percentage of the cost to the consumer, keeping them healthy is necessary.
STACKING INSTRUCTIONS OutBack & 3-phase Stacking Methods OutBack Power Systems offers two different ways to stack multiple FX’s (up to 10 for single phase systems, but only 3 for three-phase systems). The first thing to consider is if you want all of the FX’s in parallel (FX’s on same AC Output Leg producing 230VAC only) or in 3-phase (maximum of three FX’s, one on each AC Output Leg, producing 230VAC on each Leg and 400VAC between each set of Legs). A HUB-4 or HUB-10 must be included to stack FX’s.
STACKING INSTRUCTIONS Stacking Procedure (Continued) OB SLAVE L1: Split Phase: (NOT TO BE USED ON “EXPORT” SYSTEMS) Alternately, if you have a system with two to ten FX’s and an X-240 autotransformer and you wish to produce 120VAC on both AC Output Legs and also 240VAC between the two AC Output Legs (where applicable) then set the stack phase of the FX’s you want as parallel slaves (Leg 1) to “OB Slave L1”. Make sure the slave FX’s are in the lowest numbered ports of the HUB.
STACKING INSTRUCTIONS System Examples STACKED SYSTEM USING OUTBACK’S “PARALLEL” STACKING This type of system may have between 2 and 10 FX’s that will have their AC Outputs connected to the same Leg. We will be using a Quad-Stacked (4 FX) system as an example. If you have less than four FX’s then any reference to FX’s on ports greater than the amount of FX’s in your system will not apply to your system.
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.
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 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 (305 meters) from the FX system using standard 8 conductor CAT5 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 Variable “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. MAIN MENU MENU STRUCTURE STATUS 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 “E” Series Inverter/Charger System 900-0027-2 Page 34 Rev 7.1 06/08/06 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 “E” Series Inverter/Charger System Installation & Programming Manual 900-0027-2 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 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 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 LED that indicates a WARNING). If an error occurs, the FX will cease operation and the MATE will display an error screen.
MATE SCREENS WARNINGS 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 immediately 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 gives a warning.
MATE SCREENS Advanced Screens The ADVANCED (ADV) 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 disconnect. 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 on page 24 for guidelines on how to set some of these values. The FX’s battery charger includes five stages.
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. 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 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 output on the AUX terminals located in the AC wiring compartment. ADV/FX/PAGE1-------choose category: ADV PG2 ↓ ADV/FX/PAGE2-------choose category: PG1 INV GRID CHGR PG3 ↓ ADV/FX/PAGE3-------choose category: Selecting shows a third screen of categories.
MATE SCREENS AUXILIARY MENU (CONTINUED) This page contains to settings for the various functions that can be chosen in the AUX OUTPUT FUNCTION screen described on the previous page. There are voltage and time period settings for ‘GenAlert’, ‘LoadShed’, ‘VentFan’, and ‘Diversion’. The following displays allow the adjustment of the particular AUX OUTPUT FUNCTION that was selected on the previous screen in the AUX menu section. ADV/FX/AUX-------P00 genalert 11.
MATE SCREENS STACKING MENU The STACK (stacking) section is used to program the stacking of the FX’s as well as which ‘Slave’ FX’s will stay ON at all times (won’t go into ‘Power Save’ mode) and in what order the slave FX’s will come ON (if they are in ‘Power Save’ mode). An explanation of stacking can be found on pages 24-26 of this manual.
MATE SCREENS SELL MENU The SELL section is used to set the functions that control the process of selling power back to the utility grid. This menu is only operational for Grid-Tie FX’s and is not operational with “Export” FX’s at this time. 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.
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 APPROXIMATE DIAMETER CROSS-SECTIONAL AREA (1000 feet) SQUARE INCHES SQUARE 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 .
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 “E” Series Inverter/Charger System 900-0027-2 Page 58 Rev 7.1 06/08/06 Copyright 2003 OutBack Power Systems, Inc.
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