Rugged Water Resistant Inverter / Charger OBX-IC2024S-120/60 Owner’s Manual Installation and Operation
OutBack Power Systems OutBack Power Systems is a leader in advanced energy conversion technology. Our products include true sine wave inverter/chargers, maximum power point charge controllers, system communication components, as well as breaker panels, breakers, accessories, and assembled systems. Contact Information Telephone: (+1) 360.435.6030 (North America) Fax: (+1) 360.435.6019 (+34) 93.654.
TABLE OF CONTENTS Welcome to the OutBack Extreme Rugged Water Resistant Inverter/Charger.............................................2 Parts Included.........................................................................................................................................................................................3 Unit Dimensions.................................................................................................................................................................
Welcome to the OutBack Extreme Rugged Water Resistant Inverter/Charger The OutBack Extreme Rugged Water Resistant Inverter/Charger (hereafter called the Inverter) provides 120 Vac, 60 Hz, true-sine wave power, from a 24 Vdc battery source. It is designed for rugged operational environments in an unprotected, uncontrolled climate. This equipment is intended for use on tracked and wheeled vehicles, and above deck and other areas where it will be exposed to unfavorable conditions.
Parts Included Standard with the OutBack Extreme Rugged Water Resistant Inverter/Charger, Model OBX-IC2024S-120/60: • One Owner’s Manual • One DC Cover (DCC) • One red (positive) and one black (negative) battery terminal cap Additional parts, included when purchasing the complete system OBX-IC2024S-120/60-K2: • • • • • • One OutBack MATE2 System Controller and Display One NATO Battery Cable Connector, unwired Two 2/0 battery cables (one positive and one negative), 15’ One Maxicon cable assembly for waterti
R EA D F IR ST ! IMPORTANT SAFETY INSTRUCTIONS READ FIRST! SAVE THESE INSTRUCTIONS Read all instructions and cautionary markings on the Inverter, the batteries and all appropriate sections of this installation and user manual as well as other component manuals before using the system. Be cautious around electricity, electrical components, and batteries. Shocks, burns, injury, and even death can occur if anyone comes in contact with electricity.
IMPORTANT BATTERY INSTRUCTIONS WARNING: WORKING NEAR LEAD ACID BATTERIES CAN BE DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL OPERATION. Design the battery enclosure to prevent accumulation and concentration of hydrogen gas in “pockets” at the top of the enclosure. Vent the battery compartment from the highest point to the outside. A sloped lid can also be used to direct the flow of hydrogen to the vent opening.
12.0” (30.48 cm) Insert fasteners at all four corners of the Inverter for a secure installation. 8.25” (20.95 cm) 16.25” (41.27 cm) MOUNTING • The Inverter weighs 57.5 lbs (26.08 kg) and must be secured with appropriate fasteners to a sturdy mounting surface capable of supporting its weight. Depending on application, it may be easier for two people to install the unit due to the Inverter’s weight.
SYSTEM PROTECTION Electrical systems are designed to protect you, the wires, the components, and the devices served by the system. • Each Inverter must be part of a permanently grounded electrical system (see below). Grounding protects people and equipment from electrical shock. Grounding must be performed according to required codes and regulations. • Circuit breakers protect wiring by limiting the amount of current entering a system.
WIRE CONNECTIONS DC Wiring The Inverter uses DC brass battery terminals with 8M x 1.00 stainless steel threaded studs. You can access the terminals by removing the four screws that attach the DC cover plate, and pulling it off.
BATTERY WIRING In DC systems, batteries are connected to each other in one of three ways: • Series (voltage increases, amperage stays the same as a single battery) • Parallel (voltage stays the same as a single battery, amperage increases) SERIES/PARALLEL (EXAMPLE) PARALLEL (EXAMPLE) SERIES (EXAMPLE) • Series/Parallel (both voltage and amperage increase) - 12 V/200 amp-hours 12 V/200 amp-hours 12 V/200 amp-hours 12 V + 12 V + 12 V + 12 V = 48 V 12 V/200 amp-hours 12 V/200 amp-hours 12 V/200 amp-
6 V Battery Wiring Examples for a 24-volt system - 6 V/200 amp-hours 6 V/200 amp-hours - 6 V/200 amp-hours 6 V/200 amp-hours DC DISCONNECT (FUSE OR CIRCUIT BREAKER) 24-volt Inverter SERIES: 200 amp-hours - - - - 6 V/200 amp-hours 6 V/200 amp-hours 6 V/200 amp-hours 6 V/200 amp-hours SERIES STRING 1 CONNECTS TO SERIES STRING 1 INVERTER’S POSITIVE TERMINAL - - - 6 V/200 amp-hours 6 V/200 amp-hours 6 V/200 amp-hours 6 V/200 amp-hours SERIES STRING 2 SERIES STRING 2 CONNECTS DC DISC
12 V Battery Wiring Examples for a 24-volt system - 12 V/200 amp-hours 12 V/200 amp-hours DC DISCONNECT (FUSE OR CIRCUIT BREAKER) 24-volt Inverter SERIES: 200 amp-hours - 12 V/200 amp-hours 12 V/200 amp-hours SERIES STRING 1 CONNECTS TO SERIES STRING 1 INVERTER’S POSITIVE TERMINAL - 12 V/200 amp-hours 12 V/200 amp-hours SERIES STRING 2 DC DISCONNECT (FUSE OR CIRCUIT BREAKER) SERIES/PARALLEL: 400 amp-hours 24-volt Inverter 11
AC Wiring Connector Plate • AC OUT SOCKET— Maxicon circular molded watertight connector supplies power to the loads using the provided AC cable and plug. • AC IN SOCKET — Maxicon circular molded watertight connector supplies incoming AC from the grid or a generator to the Inverter. This AC is used to run loads and recharge batteries. • MATE (REMOTE) SOCKET — Minicon circular molded watertight connector provides an interface with the optional MATE2 System Controller and Display.
Follow these steps to wire the Inverter to your system: 1. Open all DC breakers or remove any fuses before connecting wiring. 2. Open all AC breakers or remove any fuses before connecting wiring. 3. With all power off, connect the AC IN Maxicon plug wires to the AC source. The AC input wires should have a (maximum) 30-amp AC breaker to provide overcurrent protection. The AC IN Maxicon plug has a total of six conductors. Two are black, two are white, one is green, and one is green with a yellow stripe.
locking collar AC OUT PLUG AC IN PLUG MATE PLUG To connect cables to the Connector Plate sockets: Position each cable plug over the appropriate jack. The cables are easy to tell apart, as the AC In plug has six pins, the AC Out plug only has five, and the MATE plug is smaller than the others. Match each cable to its matching jack and fit the plugs into the jacks. If necessary, twist the plugs back and forth until they fit, and then push them in until they seat in place.
THE MATE2 SYSTEM CONTROLLER AND DISPLAY The MATE serves several functions: • Allows you to monitor the Inverter through a series of convenient display screens. These display the status messages, and allow you to take both DC (voltage) and AC (voltage and current) meter readings. • Enables you to troubleshoot problems with the Inverter and the rest of your system, by looking up warning and fault messages.
HOT KEYS “Hot” keys have fixed functions. Pressing a hot key always takes you to the same menu or series of menus. INV Hot Key The INV hot key takes you to the Inverter Control screen, allowing direct control of the inverting function from anywhere in the menu system. (The inverting function is defined as the process of converting DC to AC, as compared to the charging or other functions.
AC IN Hot Key The AC IN hot key allows direct control of the AC input from anywhere in the menu system.
PRESS THREE TIMES: CHARGER CONTROL currently: OFF AUTO • The CHARGER CONTROL screen appears. This allows the operation of the Inverter’s battery charger to be preset for an available AC source. AUTO ON OK disables all charger functions in the Inverter. enables automatic battery charging, silent, and “re-float” when an AC input source is connected.
SOFT KEYS “Soft” keys are the four buttons on the bottom of the MATE. Soft key functions vary with each menu. Menus with options have those options displayed along the bottom of the screen. When they are displayed, pressing a soft key picks the option directly above that key. Also, to return to the Main screen from anywhere in the system, simultaneously press the two soft keys on the left. The Main screen has soft keys for the Summary, Status, Setup and Advanced menus. The Summary screens are shown below.
SETUP SCREENS The Setup screens allow you to change several settings, to make your system run more smoothly. You can program the amperage size of the AC source, to keep the Inverter from overdrawing a generator. You can program the Summary screen to pop up automatically like a computer screensaver. In advanced systems, you can order the MATE to search for any new devices, in case it has lost communication with the Inverter.
SUMMARY SETUP SCREENS MAIN-------------------------------12:00:30P To program the operation of the SUMMARY screen, press the soft key from the MAIN screen. SUM STATUS SETUP ADV SETUP-----------------------------choose category: FX MATE SETUP/MATE/PAGE1-------------mate code rev 4.1.6 choose category CLOCK CNT GLOW PG2 SETUP/MATE/PAGE2-------------choose category: PG1 SUMRY COM TYPE From the SETUP/MATE/PAGE1 screen, press the soft key.
SETUP/MATE/SUM/TYPE--------summary None screen type BACK INC DEC SETUP/MATE/SUM/TYPE--------summary FX Only screen type BACK INC DEC Press either the and soft keys to change the SUMMARY screen to one of the following items: None — disables the SUMMARY screen from automatically opening; the SUMMARY screen can still be accessed via the soft key on the MAIN screen. FX Only—the SUMMARY screen for the Inverter is enabled and will open after a delay time (see below).
SETUP/MATE/SUMMARY/TYPE-sum screen 19 minutes delay time BACK INC DEC SETUP/MATE/SUMMARY/TYPE-sum screen 19 minutes delay time BACK INC TYPE After the SUMMARY screen delay time is chosen, press the soft key to return you to the summary control screen. DEC SETUP/MATE/SUMMARY---------summary control BACK Sum screen delay time in SUMMARY mode shows how long it takes for a SUMMARY screen to be automatically displayed.
SETUP-----------------------------choose category: FX Press the MATE soft key to enter the series of menus for MATE setup and display. MATE SETUP/MATE/PAGE1-------------mate code rev 4.1.6 choose category CLOCK CNT GLOW PG2 From the SETUP/MATE/PAGE1 screen, press the soft key. SETUP/MATE/PAGE2-------------choose category: From the SETUP/MATE/PAGE2 screen, press the soft key.
STATUS SCREENS Status screens give the user a breakdown of individual activities of the Inverter, including AC and DC voltage and AC current meters. It is these individual readings that combine to produce the Summary screens noted on page 19 and allow monitoring of the system operation.
Reading a Status Screen STATUS/FX/PAGE1--------------choose category STATUS/FX/PAGE2--------------choose category STATUS/FX/PAGE3--------------choose category MODES PG1 PG2 METER BATT PG2 ERROR WARN PG3 DISCON SELL MAIN • MODES: not recommended for use with the OBX-IC2024S-120/60 Inverter -- do not select this option • METER: displays inverter and charger activity, including output and input AC voltage, and AC inverter, charger, and input current • BATT: displays the battery temperature, volt
Status Meter Screens Pressing the soft key brings up the first METER screen. STATUS/FX/PAGE1-------choose category: MODES METER BATT Pressing the soft key brings up successive METER screens. PG2 Charge inv 0.0kw chg 0.0kw P00 zer 0.0kw buy 0.0 kw STATUS/FX/METER---------P00 output 117 vac voltage STATUS/FX/METER---------P00 input 118 vac voltage DOWN STATUS PORT DOWN DOWN UP TOP PORT UP TOP PORT STATUS/FX/METER------------P00 inverter 0.
Status Batt(ery) Screens STATUS/FX/PAGE 1---------------choose category: MODES Pressing the soft key brings up the first BATT screen. Pressing the soft key brings up successive BATT screens. METER BATT PG2 STATUS/FX/MODE-------------P00 battery 27.8 vdc actual STATUS/FX/MODE-------------P00 battery 27.8 vdc temp compensated STATUS/FX/METER-------------P00 absorb 28.8 vdc setpoint DOWN DOWN DOWN STATUS PORT UP TOP PORT UP TOP PORT STATUS/FX/BATT---------------P00 absorb 00.
Status Error Screens STATUS/FX/PAGE1------------------choose category: MODES METER BATT PG2 STATUS/FX/PAGE2------------------choose category: PG1 ERROR WARN PG3 Pressing the soft key brings up more STATUS categories. Pressing the soft key brings up the first ERROR screen. Pressing the soft key brings up successive METER screens.
Status Warn(ing) Screens STATUS/FX/PAGE2----------------choose category: PG1 ERROR WARN PG3 STATUS/FX/WARN-------------P00 acin freq No too high DOWN STATUS PORT STATUS/FX/WARN-------------P00 acin voltage No too low DOWN UP TOP PORT STATUS/FX/WARN-------------P00 internal comm No error detected DOWN UP TOP PORT STATUS/FX/WARN-----------P00 fettemp 184 DOWN UP PORT Pressing the soft key brings up the first WARN screen. Pressing the soft key brings up successive WARN screens.
WARN(ING) Screens All warning screens read status as “No” under normal conditions. If the appropriate condition is met, that screen will change to “Yes.
INSTALLATION DRAWING • A 30A input breaker (maximum) must be used with the AC source • A 30A breaker (maximum) must be used to protect the output circuit • A single Inverter can continuously power up to 2.0 kW of loads depending on the ambient temperature.
INSTALLATION CHECK LIST ITEM YES NO Manual read and reviewed? System mounted with the recommended number and sized fasteners? System installed according to required codes and regulations? System inspected? System grounded? Inverter output connected to load circuit with 30 AC amp maximum overcurrent protection? Inverter AC sources protected with 30 AC amp maximum overcurrent protection? Per the instructions regarding neutral and ground installation on page 7, If the installation is non-bo
OBX-IC2024S-120/60 Inverter/Charger Specifications Nominal DC Input Voltage Range 24 Vdc Nominal AC Voltage / Frequency 120 Vac / 60 Hz Continuous Power Rating at 25°C Ambient 2000 VA Continuous AC RMS Output at 25°C 16.
AC Input Operating Voltage Range Note: This is the recommended AC input voltage range to be supplied to the Inverter. Voltages outside of this range will not be accepted by the Inverter. OBX-IC2024S-120/60 Inverter 80 – 150 Vac (Vac = volts AC) AC Input Frequency Range Note: If the AC input source is out of the range noted below, the Inverter will not connect or stay connected.
INVERTER DEFAULT VALUES (subject to change with upgrades) 36 24 VDC System DEFAULT MINIMUM MAXIMUM Float Voltage Absorb Voltage EQ Voltage ReFloat LBCO Absorb Time EQ Time Float Time Charger Draw AC1/Grid Transfer Delay AC2/Gen Transfer Delay 27.4 Vdc 29.4 Vdc 28.8 V 25 Vdc 21 Vdc 2.0 hours 1.0 hours 1.0 hours 5 Aac 6 AC cycles 60 AC cycles 24 Vdc 26 Vdc 28 Vdc 22 Vdc 18 Vdc 0.0 hours 0.0 hours 0.0 hours 0 Aac 0 AC cycles 0 AC cycles 30 Vdc 32 Vdc 34 Vdc 26 Vdc 24 Vdc 24.0 hours 24.0 hours 24.
Maintenance • Following exposure to salt water, rinse all exposed surfaces to prevent corrosion. Recoat the DC lugs and other exposed conductors with dielectric grease. • Periodically check that the battery cable lugs are tight and secure according to the recommended torque settings on page 8. • Brush off excessive dust from the Inverter as needed. • Check that fasteners securing the Inverter to its mounting surface are tight. • Check that the screws securing the DC Cover to the Inverter are tight.
1-Year Limited Warranty OutBack Extreme Inverter/Chargers OutBack Power Systems, Inc. (“OutBack”) provides a one year (1) limited warranty (“Warranty”) against defects in materials and workmanship for its OutBack Extreme Inverter/Charger (“Product”) if installed in a permanently mounted installation. The Warranty term begins ninety (90) days from the date of initial invoice.
After receiving the RMA number, pack the Product(s) authorized for return, along with a copy of the original purchase invoice and warranty certificate, in the original Product shipping container(s) or packaging providing equivalent protection and mark the outside clearly with the RMA number. The sender must prepay all shipping charges, and insure the shipment, or accept the risk of loss or damage during shipment.
OUTBACK EXTREME INVERTER/CHARGER LIMITED WARRANTY REGISTRATION Complete this form and return it to: OutBack Power Systems Inc. 19009 62nd Ave.
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Corporate Headquarters 19009 62nd Avenue NE Arlington, WA 98223 USA Phone: (+1) 360.435.6030 European Sales Office Barcelona, España Phone: +34.93.654.9568 www.outbackpower.
