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 Symbols Used ................................................................................................................................. 5 General Safety ...................................................................
Table of Contents List of Tables Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Models ............................................................................................................................. 7 Components and Accessories ........................................................................................ 7 Battery Bank Elements .................................................................................................. 12 Ground Conductor Size and Torque Requirements ......
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.
Introduction Welcome to OutBack Power Technologies Thank you for purchasing the OutBack FXR Series Inverter/Charger. This product offers a complete power conversion system between batteries and AC power. It can provide backup power, sell power back to the utility grid, or provide complete stand-alone off-grid service. 12-, 24-, and 48-volt models Output power from 2.0 kVA to 3.
Introduction Models Vented FXR (VFXR) models have an internal fan and use outside air for cooling. On average, VFXR models have higher power ratings than FXR models due to their greater cooling capabilities. Sealed FXR models have an internal fan, but do not use outside air for cooling. To compensate, sealed models are also equipped with the OutBack Turbo Fan assembly, using external air to remove heat from the chassis. (Vented FXR models are not equipped with the Turbo Fan and cannot use it.
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.
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 is used by the inverter. The FXR inverter’s settings can be changed to accommodate many applications. 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 Renewable Energy The FXR inverter cannot connect directly to PV, wind turbines, or other unregulated DC sources. The batteries are the inverter’s primary source of power. A renewable energy source is always treated as a battery charger, even if all of its power is used immediately by the inverter. The renewable source must have a charge controller, or some other regulation method, to prevent overcharging.
Planning Bank Size: Battery bank capacity is measured in amp-hours. Determine the required bank specifications as accurately as possible, beginning with the items below. This avoids underperformance or wasted capacity. These ten items are obtainable in different places, summarized in Table 3. Some of the information is specific to the site or application. Some can be obtained from the battery manufacturer. Information on OutBack products is available from OutBack Power Technologies or its dealers. A.
Planning To Calculate Minimum Battery Bank Size (refer to previous page for letter designations): 1. The load size, item A, is measured in watts. Compensate this figure for efficiency loss. Multiply the conductor efficiency by the inverter efficiency (E x F). (These items are represented as percentages, but may be displayed as decimals for calculation.) Divide item A by the result. 2. Convert the compensated load into amperes (Adc). Divide the step 1 result by the system voltage (G). 3.
Planning Generator FXR inverters can accept power from a single-phase generator that delivers clean AC power in the range of voltage and frequency specified for that model. ~ Inverters stacked for split-phase output (120/240 Vac) can work with both output lines of a split-phase generator. ~ Inverters stacked for three-phase output can work with three-phase (120V/208Y) generators. The inverter/charger can provide a start signal to control an automatic start generator.
Installation Location and Environmental Requirements FXR and VFXR series inverter/chargers must be located indoors or in a weather-proof enclosure. They are not designed for exposure to water, salt air, or excessive wind-blown dust and debris. The inverter can often be mounted in any position or orientation. When inverters are installed with an OutBack FLEXpower system, the system must be installed in the upright orientation due to the requirements of the circuit breakers.
Installation Dimensions Height with DCC 12” (30.5 cm) Length 16.25” (41 cm) Width 8.
Commissioning Terminals and Ports DC TERMINALS These terminals connect to the battery cables and the DC system. See page 20 for instructions. DC and AC GROUND TERMINALS 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 28 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.
Commissioning 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.
Commissioning To install DC cables and hardware: 1. Install all DC cables. 2. 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. 3. 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. Make certain the red and black battery terminals are installed before attaching the cover. As part of attaching the Turbo Fan, follow the wiring instructions in Figure 11.
Commissioning 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 installer is responsible for providing overcurrent protection. 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.
Commissioning ON and OFF Wiring The INVERTER ON/OFF jumper bridges two pins. This jumper parallels the two INVERTER ON/OFF terminals on the Control Wiring Terminal Block. If either connection is closed, this sets the inverter to On as long as the internal programming has not been set to Off with the system display. (The inverter is given an external OFF command in the factory. Its initial state will be Off.) An inverter in the Off state will not invert.
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. RTS cable (RJ11, 4-conductor, telephone) RTS port MATE/HUB port See the Operator’s Manual for more information on the RTS. System Display cable (RJ45, 8-conductor, CAT5 non-crossover) If a HUB Communications Manager is used, it occupies the inverter’s MATE/HUB port. The system display plugs into the HUB product.
Commissioning In this example, the AUX directly drives a 12-volt vent fan. The + and – wires on the fan are connected to the AUX+ and AUX– terminals. AUX LED INDICATOR The AUX indicator illuminates when the AUX output becomes active. Fan Figure 17 AUX Connections for Vent Fan (Example) In this example, the AUX output drives a relay that diverts wind power. The relay’s coil is connected to the AUX+ and AUX– terminals.
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. Note that AGS cannot be used if the system display is removed.
Commissioning 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 generator with three-wire start has fewer automated functions than a two-wire-start generator. 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 output wiring and circuit breakers must be sized appropriately for loads and inverter power. The AC input (generator or utility grid) must be single-phase and the proper voltage and frequency. LEGEND NOTES: AC Source (Utility Grid or AC Generator) Hot Neutral Ground TBB = Terminal Bus Bar 2.
Commissioning 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 Each inverter is assigned to a particular phase when assigned a port on the HUB10.3 communications manager. Port assignments will vary with the system. The master must be plugged into port 1. In parallel stacking, any slave inverter can use any other port, beginning with port 2. In series or three-phase stacking, the port assignments are very specific. See the HUB10.3 literature for more information. Regardless, it is important to keep track of units and ports for programming purposes.
Commissioning Stacking Configurations Series Stacking (Dual-Stack) In series stacking, two inverters create two separate 120 Vac4 output phases. One phase is the master. The second inverter is a subphase master. It creates a 120 Vac output that is intentionally 180° out of phase with the master. Each of these outputs can be used to power a separate set of 120 Vac loads. Collectively they form a “split-phase” configuration.
Installation AC Source (Utility Grid or AC Generator) AC Conduit Box MATE3s HUB 10.3 Hot L1 TBB Neutral TBB GND Hot L2 TBB 10 9 8 7 6 5 4 3 2 1 MATE CAT5 Cables Input Circuit Breaker AC HUB/ AC Neutral MATE Hot IN (L1) IN AC HUB/ AC Neutral MATE Hot IN IN (L2) Inverter Inverter L1 Master L2 Subphase Master AC Neutral OUT GND AC Hot OUT AC Neutral OUT Hot L2 Neutral Ground TBB = Terminal Bus Bar GND Neutral TBB Hot L1 TBB AC Loads Hot L2 TBB NOTES: 1.
Commissioning 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 MATE3s LEGEND (Utility Grid or AC Generator) Hot L1 Neutral HUB 10.
Commissioning Series/Parallel Stacking (Quad-Stack or Larger) In series/parallel stacking, inverters create separate 120 Vac6 output phases and 240 Vac collectively, as in series stacking. However, in this configuration, each output uses inverters in parallel. One output contains the master; the other uses a subphase master. Each output has at least one slave. The 120 Vac loads on each output can exceed the size of a single inverter. They can be powered by all the inverters on that output.
Installation AC Source MATE3s LEGEND (Utility Grid or AC Generator) Hot L1 Hot L2 HUB 10.
Commissioning Three-Phase Stacking In three-phase stacking, inverters create three separate 120 Vac7 output phases in wye configuration. The three phases (A, B, and C) operate independently of each other. The inverters on one phase cannot assist another. Several inverters can be installed in parallel on each phase to power all 120 Vac loads on each of those phases. 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.
Commissioning MATE3s AC Source (Utility Grid or AC Generator) HUB 10 9 8 7 6 5 4 3 2 1 AC Conduit Box MATE Neutral TBB GND Phase A TBB Phase B TBB Phase C TBB CAT5 Cables Input Circuit Breaker Input Circuit Breaker Input Circuit Breaker AC HUB/ AC Neutral MATE Hot IN IN (B) AC HUB/ AC Neutral MATE Hot IN IN (C) Inverter Inverter Inverter Phase A Master Phase B Subphase Master Phase C Subphase Master AC Neutral OUT AC AC Neutral Hot OUT OUT (C) GND AC HUB/ AC Neutral MATE Hot IN IN (A)
Installation Power Save IMPORTANT: In any system that features slave inverters, Power Save must be programmed before commissioning. Leaving the inverters at the factory default settings (or setting them incorrectly) will cause erratic system performance. See the FXR Series Inverter/Charger Operator’s Manual for a table of menu items and settings. See the system display literature for navigation instructions.
Commissioning assignments are very specific. They are also different from each other, as illustrated in the HUB10.3 literature. Master Power Save Level appears on an inverter which is set as master (the default setting). The range of rank numbers is 0 to 10. The default value is 0. The master is normally left at this value. The Master Power Save Level function is used for the master inverter on Port 1. It is also used for any subphase masters in a series or three-phase system.
Installation Master Port 1 Master Power Save = 0 Slave 1 Port 2 Slave Power Save = 1 Slave 3 Port 4 Slave Power Save = 3 <12 Aac On Off Off 12 Aac On On Off Off 24 Aac On On On Off 36 Aac On On On On 16 Aac On On On Off Figure 33 Slave 2 Port 3 Slave Power Save = 2 Off Power Save Priority (Parallel) The fourth line shows that loads of 36 Aac or more (approximately 4 to 4.5 kW) are present on the system. This load causes all four inverters to be activated.
Commissioning Functional Test WARNING: Shock Hazard and Equipment Damage The inverter’s AC and DC covers must be removed to perform these tests. The components are close together and carry hazardous voltages. Use appropriate care to avoid the risk of electric shock or equipment damage. It is highly recommended that all applicable steps be performed in the following order. However, if steps are inapplicable, they can be omitted.
Commissioning Figure 35 AC Terminals 3. Turn on the inverter using the system display (or external switch, if one has been installed). The inverter’s default condition is Off. Do not turn on any AC circuit breakers at this time. 4. Using a DVM, verify 120 Vac (or appropriate voltage) between the AC HOT OUT and AC NEUTRAL OUT terminals. (See Figure 35.) The inverter is working correctly if the AC output reads within 10% of 120 Vac or the programmed output voltage. 5.
Commissioning After output testing is completed, perform the following steps: 6. Close the AC output circuit breakers. If AC bypass switches are present, place them in the normal (non-bypass) position. Do not connect an AC input source or close any AC input circuits. 7. Use a high-resolution voltmeter to verify correct voltage at the AC load panel. 8. Connect a small AC load and test for proper functionality. 9. Close the AC input circuit breakers and connect an AC source.
Commissioning Firmware Updates IMPORTANT: All inverters will shut down during firmware updates. If loads need to be run while updating the firmware, bypass the inverter with a maintenance bypass switch. Communication cables must remain connected and DC power must remain on. Interrupted communication will cause the update to fail and the inverter(s) may not work afterward. Inverters automatically update one at a time beginning with the highest port. Each requires about 5 minutes.
Commissioning To install Grid Support .GIP Files: 1. Perform a firmware update as noted above. NOTES: The MATE3s should be revision 1.001.000 or greater for Grid Support functionality. For grid-interactive parameters, the Installer Password is required and may need to be changed from the default setting of 1732. See the MATE3s Programming Guide for more information. 2. From the MATE3s Main Menu (A in Figure 36), choose Firmware Update (B) and then FXR Inverter (C).
Commissioning Preventative Maintenance The FXR inverter requires almost no regular maintenance. However, OutBack recommends the following items on a periodic basis: Check all electrical connections periodically for tightness using the torque values from pages 18 through 20. For vented (VFXR) models, clean the air filter inside the DC cover every three months. (See page 22 to remove the cover.) Rinse the filter with warm tap water and allow it to fully air-dry before reinstalling.
Commissioning Table 6 Terms and Definitions Term Definition NEU AC Neutral; also known as Common Neutral-to-ground bond A mechanical connection between the AC neutral (Common) bus and the ground (PE) bus; this bond makes the AC neutral safe to handle Off-grid Utility grid power is not available for use On-grid Utility grid power is available for use (does not imply grid-interactive capability) PV Photovoltaic RE Renewable Energy RTS Remote Temperature Sensor; accessory that measures battery
Commissioning NOTES: 52 900-0166-01-01 Rev A
Index A AC Plate ................................................................ 7 AC Terminals ............................................ 9, 17, 23 AC Test Points .................................................... 46 Adding New Devices ........................................... 47 Advanced Generator Start (AGS) ................. 26, 28 Applications ........................................................... 9 AUX Terminals .................................................... 17 AXS Port..............
Commissioning I IEC ................................................................ 18, 50 Important Symbol.................................................. 5 Ingress Protection (IP) ........................................ 15 Input Modes ........................................................ 10 J Jumper .......................................................... 17, 25 L LED Indicators .................................................... 17 Listings ...................................................
Index Single Inverter ................................................ 30 Stacking Parallel ....................................................... 36 Series ......................................................... 33 Series/Parallel ...................................... 37, 38 Three-phase............................................... 41 W Warning Symbol .................................................... 5 Website ............................................................... 48 Wiring ..............
Masters of the Off-Grid.™ First Choice for the New Grid. Corporate Headquarters 17825 – 59th Avenue N.E.
