FXR Series Inverter/Charger FXR2012A FXR2524A FXR3048A VFXR2812A VFXR3524A VFXR3648A 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. Applicability These instructions apply to OutBack inverter/charger models FXR2012A, FXR2524A, FXR3048A, VFXR2812A, VFXR3524A, and VFXR3648A only.
Table of Contents Introduction ................................................................................................. 5 Audience ................................................................................................................................................................................. 5 Welcome to OutBack Power Technologies ................................................................................................................. 5 Models ...............................
Table of Contents List of Tables Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Models .....................................................................................................................................6 Components and Accessories .................................................................................................. 6 Battery Bank Elements ..........................................................................................................
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 FXR Series Inverter/Charger.
Introduction Models Vented FXR (VFXR) models are intended for indoor or protected installation only. Vented inverters have an internal fan and use outside air for cooling. On average, the power of the vented models is rated higher than sealed models due to their greater cooling capabilities. Sealed FXR models are designed for harsher environments and can survive casual exposure to the elements. However, enclosed protection is still recommended. (See page 15.
Introduction DCC (DC Cover) This covers the DC terminal area on vented inverters. The DCC provides space to mount other components such as a DC current shunt. AC Plate This plate is used for installations which do not utilize OutBack’s optional FLEXware conduit boxes. The knockouts are used to install strain relief for flexible cable. NOTE: This plate is not to be connected to conduit. Battery Terminal Cover These protect the terminals from accidental contact.
Introduction NOTES: 8 900-0166-01-00 Rev A
Planning Applications OutBack inverter/chargers are designed to use a battery bank to store energy. They work together with power from the utility grid or from renewable energy sources, such as photovoltaic (PV) modules, wind turbines, and other renewable sources. These sources charge the battery, which in turn is used by the inverter. FXR series inverters have been designed to work with all types of renewable systems. These include off-grid, backup, and grid-interactive applications.
Planning Input Modes The FXR inverter has many modes of operation. See the FXR Series Inverter/Charger Operator’s Manual for additional information on these modes, including reasons and considerations for using each mode. The modes determine how the inverter interacts with an AC source. Each mode has functions and priorities that are intended for a designated application. Each of the inverter’s input selections can be set to a different operating mode to support different applications.
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. Local codes or regulations may apply and may take priority over OutBack recommendations. Battery Type: The FXR 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: Each inverter model requires a specific DC voltage to operate. H. Battery voltage: Most individual battery voltages are less than the system DC voltage. The batteries may need to be placed in series to deliver the correct voltage. I. Table 3 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: 720 W B. Hours of use: 3 C. Days of autonomy: 2 D. Off-grid system (VFXR3524A inverter) 1) A ÷ [E x F] 720 ÷ (0.97 x 0.9) = 801.8 W 2) 1 ÷ G 824.7 ÷ 24 = 34.4 Adc 3) 2 x B 34.4 x 3 = 103.1 Ahr E. Conductor efficiency: 97% (0.97) 4) [3 x C] ÷ J [103.1 x 2] ÷ 0.5 = 412.4 Ahr F. Inverter efficiency: 92% (0.9) 5) 4 ÷ I 412.4 ÷ 167.5 = 2.5 (rounded to 3) 6) [G ÷ H] x 5 [24 ÷ 12] x 3 strings = 6 batteries G. System voltage: 24 Vdc H.
Planning NOTES: 14 900-0166-01-00 Rev A
Installation Location and Environmental Requirements Sealed (FXR) models are resistant to water and other elements but are not designed for permanent outdoor installations. If outdoor installation is required, the FXR inverter must be installed under cover and protected from direct exposure to the environment. Vented (VFXR) models are not resistant to water and other elements. They must be installed indoors. The inverter can often be mounted in any position or orientation.
Installation Mounting One person can install the FXR inverter, but installation may be easier with two people. The unit has four mounting holes, one in each corner. Use fasteners in all corners for a secure installation. IMPORTANT: Use correct fasteners to secure the inverter to the mounting surface, regardless of the type of surface. OutBack cannot be responsible for damage to the product if it is attached with inadequate fasteners.
Installation Terminals and Ports DC and AC GROUND TERMINALS DC TERMINALS These terminals connect to the battery cables and the DC system. See page 20 for instructions. These terminals connect to a grounding system for both batteries and AC. See page 18 for instructions. CONTROL WIRING TERMINAL BLOCK These terminals receive control wires for a variety of functions including generator control. See pages 26 and 27 for instructions and the Operator’s Manual for more information.
Installation Wiring It will be necessary to remove knockouts from the AC Plate to run wires. The AC Plate has one knockout of ½” size and two knockouts of ¾” size. Install appropriate bushings to protect the wires. 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 The inverter’s DC ground is a box lug located next to the negative DC battery terminal. This lug accepts up to 1/0 AWG (70 mm2 or 0.109 in2) wire. Local codes or regulations may require the DC ground to be run separately from the AC ground. Also, if present, it will be necessary to remove the DC Cover or Turbo Fan before making the ground connection. (See page 22.) Box Lug Figure 6 DC Ground Lug CHASSIS GROUND/PE The two CHASSIS GROUND/PE terminals are electrically common.
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 To install DC cables and hardware: 1. Install all DC cables. Do not install hardware in a different order from Figure 8. The battery cable lug should be the first item installed on the stud. It should make solid contact with the mounting surface. Do not close the main DC disconnect until wiring is complete and the system is prepared for commissioning. M8 x 1.
Installation DC Cover or Turbo Fan Attachment COVER ATTACHMENT FXR inverters are equipped with either the DC Cover or the Turbo Fan. To attach either cover, put the cover in place and insert a screw at each corner using a Phillips screwdriver. As part of attaching the Turbo Fan, follow the wiring instructions in Figure 11. Figure 10 DC Cover Attachment TURBO FAN WIRING Install the wires in the AC Wiring Compartment to make the Turbo Fan operational.
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. IMPORTANT: The AC input and output may need to be protected with branch-rated circuit breakers of maximum 60 Aac size to meet applicable code requirements.
Installation AC Sources The inverter has a single set of AC terminals which are intended to connect to a single AC source. It cannot be directly wired to more than one AC source at the same time. If multiple sources are used, it is usually required to have a selector switch that changes from one to the next. The switch should be the “break before make” type which disconnects from one source before contacting another.
Installation ON and OFF Wiring The INVERTER ON/OFF jumper bridges two pins. The ON/OFF jumper parallels the two INVERTER ON/OFF terminals on the Control Wiring Terminal Block. If either connection is closed, the inverter is ON. The jumper is installed in the factory, but the inverter is given an external OFF command at the same time. Its initial state will be OFF. (An inverter in the OFF state will not invert. However, it may still transfer power to loads and charge batteries from an AC source.
Installation AUX Wiring The AUX+ and AUX– terminals are a switched 12 Vdc supply. The AUX 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 terminals can supply up to 0.7 amps at 12 Vdc (8.4 watts). This is sufficient to drive a small fan or a relay controlling a larger device. The terminals accept wire up to #14 AWG (2.5 mm2).
Installation Generator Control The AUX terminals can provide a signal to control an automatic-start generator. The control function can be Advanced Generator Start (AGS), which is situated in the system display. AGS can start the generator using settings from the system display, or it can use battery readings from the FLEXnet DC battery monitor. Alternately, the control function can be Gen Alert, which is a simpler function based directly in the FXR inverter.
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 AUX terminals cannot control this type of generator without using a three-wire to two-wire conversion kit. Atkinson Electronics (http://atkinsonelectronics.
Installation AC Configurations Single-Inverter When installing an inverter AC system, the following rules must be observed. All overcurrent devices must be sized for 60 Aac or less. All wiring must be sized for 60 Aac or more. All output circuit breakers must be sized appropriately for loads and inverter power. The AC input (generator or utility grid) must be a single-phase source of the proper voltage and frequency. AC Source (Utility Grid or AC Generator) LEGEND Hot Neutral Ground NOTES: 1.
Installation Multiple-Inverter AC Installations (Stacking) Installing multiple inverters in a single AC system allows larger loads than a single inverter can handle. This requires stacking. Stacking inverters 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. Examples of stacking configurations include “series”, “parallel”, “series/parallel”, and “three-phase”.
Installation IMPORTANT: The master inverter must always be connected to port 1 on the communications manager. Connecting it elsewhere, or connecting a slave to port 1, will result in backfeed or output voltage errors which will shut the system down immediately. Installing multiple inverters without stacking them (or stacking them incorrectly) will result in similar errors and shutdown.
Installation The second inverter must be programmed as L2 Phase Master. It must be connected to port 7. All overcurrent devices must be sized for 60 Aac or less. All wiring must be sized for 60 Aac or more. All output circuit breakers must be sized appropriately for loads and inverter power. The AC input (generator or utility grid) must be a split-phase source of the proper voltage and frequency.
Installation Parallel Stacking (Dual-Stack and Larger) In parallel stacking, two or more inverters create a single, common 120 Vac5 bus. 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 Silent mode when not in use. The master will activate individual slaves based on load demand. This reduces idle power consumption and improves system efficiency.
Installation AC Source (Utility Grid or AC Generator) MATE3 LEGEND Hot L1 Neutral HUB 10.
Installation Series/Parallel Stacking (Quad-Stack or Larger) In series/parallel stacking, inverters create separate 120 Vac6 output legs and 240 Vac collectively, as in series stacking. However, in this configuration, each output has parallel inverters. One output contains the master; the other uses a subphase master. Each output has at least one slave. The 120 Vac loads on each leg can exceed the size of a single inverter. They can be powered by all the inverters on that leg.
Installation AC Source (Utility Grid or AC Generator) MATE3 LEGEND Hot L1 Hot L2 Neutral HUB 10.
Installation Three-Phase Stacking In three-phase stacking, inverters create three separate 120 Vac7 output legs in a wye configuration. The three legs operate independently of each other. The inverters on one leg cannot assist another. Several inverters can be installed in parallel on one leg to power all 120 Vac loads on that leg. The output of each inverter is 120° out of phase from the others. Any two outputs produce 208 Vac between them.
Installation When installing a three-phase system, observe the following rules. Three-phase stacking requires both the system display and the communications manager. See the HUB10.3 literature for any required jumper configurations. The inverter that is mounted physically lowest is always master and is programmed as Master. Mounting below the other inverters allows the master to avoid heat buildup and remain relatively cool as it sees the greatest duty cycle.
Installation AC Source (Utility Grid or AC Generator) MATE3 HUB 10.
Installation Functional Test Once the mounting, wiring, and other installation steps are completed, proceed to the FXR 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. Refer to the system display manual for programming instructions and menus. Emissions Compliance with FCC Part 15.
Installation Definitions The following is a list of initials, terms, and definitions used with this product. Table 6 Terms and Definitions Term Definition AC Alternating Current; refers to voltage produced by the inverter, utility grid, or generator AC Plate Inverter accessory to accommodate flexible cable when conduit is not used AGS Advanced Generator Start AUX Inverter’s 12-volt auxiliary output Communications manager Multi-port device such as the OutBack HUB10.
Installation Table 6 Term Terms and Definitions Definition RTS Remote Temperature Sensor; accessory that measures battery temperature for charging Slave An inverter which adds additional power to the master or subphase master in a stacked system; a slave does not provide an output of its own Split-phase A type of utility electrical system with two “hot” lines that typically carry 120 Vac with respect to neutral and 240 Vac with respect to each other; common in North America Subphase Master An inver
Index A E AC Plate................................................................................... 6 AC Terminals ........................................................... 9, 17, 23 Advanced Generator Start (AGS) ..................................27 Applications .......................................................................... 9 Automatic Generator Start .............................................27 AUX Terminals ....................................................................
Index M Master (Stacking)................................... 30, 31, 33, 35, 37 MATE/HUB Port .................................................................. 25 MATE3 ................................................................. 5, 25, 30, 42 Models .................................................................................... 6 Modes ................................................................................... 10 Mounting .................................................................
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