Outback FXR2012E, FXR2348E, FXR2024E, VFXR3048E, VFXR2612E Installation Manual

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Page 1

FXR Series Inverter/Charger

FXR2012E FXR2024E FXR2348E

VFXR2612E VFXR3024E VFXR3048E

Installation Manual

Page 2

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 FXR2012E, FXR2024E, FXR2348E, VFXR2612E, VFXR3024E, and VFXR3048E only.

Contact Information

Address: Corporate Headquarters

17825 – 59 Suite B Arlington, WA 98223 USA

Telephone:

Email: Support@outbackpower.com

Website: http://www.outbackpower.com

.360

+1 +1.360.618.4363 (Technical Support) +1.360.435.6019 (Fax)

Avenue N.E.

.435.6030

European Office Hansastrasse 8 D-91126 Schwabach, Germany

+49.9122.79889.0 +49.9122.79889.21 (Fax)

Disclaimer

UNLESS SPECIFICALLY AGREED TO IN WRITING, OUTBACK POWER TECHNOLOGIES:

(a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION.

(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER’S RISK.

OutBack Power Technologies cannot be responsible for system failure, damages, or injury resulting from improper installation of their products.

Information included in this manual is subject to change without notice.

Notice of Copyright

Trademarks

OutBack Power, the OutBack Power logo, FLEXpower ONE, Grid/Hybrid, and OPTICS RE are trademarks owned and used by OutBack Power Technologies, Inc. The ALPHA logo and the phrase “member of the Alpha Group” are trademarks owned and used by Alpha Technologies Inc. These trademarks may be registered in the United States and other countries.

Date and Revision

February 2015, Revision A

Part Number

900-0168-01-00 Rev A

Page 3

Table of Contents

Introduction ................................................................................................. 5

Audience ................................................................................................................................................................................. 5

Welcome to OutBack Power Technologies ................................................................................................................. 5

Models ...................................................................................................................................................................................... 6

Inverter Model Names .................................................................................................................................................................... 6

Components and Accessories ..................................................................................................................................................... 6

Planning ...................................................................................................... 9

Applications ........................................................................................................................................................................... 9

Input Modes ..................................................................................................................................................................................... 10

Renewable Energy ......................................................................................................................................................................... 10

Battery Bank ..................................................................................................................................................................................... 11

Generator .......................................................................................................................................................................................... 13

Installation ................................................................................................. 15

Location and Environmental Requirements ............................................................................................................ 15

Tools Required .................................................................................................................................................................... 15

Mounting .............................................................................................................................................................................. 16

Dimensions .......................................................................................................................................................................... 16

Terminals and Ports .......................................................................................................................................................... 17

Grounding ........................................................................................................................................................................................ 18

DC Wiring ............................................................................................................................................................................. 20

AC Wiring.............................................................................................................................................................................. 23

AC Sources ........................................................................................................................................................................................ 24

ON and OFF Wiring ........................................................................................................................................................... 25

Accessory Wiring ............................................................................................................................................................................ 25

AUX Wiring .......................................................................................................................................................................... 26

Generator Control .......................................................................................................................................................................... 27

AC Configurations ............................................................................................................................................................. 29

Single-Inverter ................................................................................................................................................................................. 29

Multiple-Inverter AC Installations (Stacking) ........................................................................................................................ 30

Stacking Configurations .............................................................................................................................................................. 31

Functional Test ................................................................................................................................................................... 36

Emissions .............................................................................................................................................................................. 36

Symbols Used ..................................................................................................................................................................... 36

Definitions ............................................................................................................................................................................ 37

Index ......................................................................................................... 39

900-0168-01-00 Rev A 3

Page 4

Table of Contents

List of Tables

Table 1 Models ................................................................................................................................................................. 6

Table 2 Components and Accessories .................................................................................................................... 6

Table 3 Battery Bank Elements .................................................................................................................................12

Table 4 Ground Conductor Size and Torque Requirements .........................................................................18

Table 5 DC Conductor Size and Torque Requirements ...................................................................................20

Table 6 Terms and Definitions .................................................................................................................................37

List of Figures

Figure 1 FXR Series Inverter/Charger ........................................................................................................................ 5

Figure 2 Components ..................................................................................................................................................... 7

Figure 3 Applications (Example) ................................................................................................................................. 9

Figure 4 Dimensions ......................................................................................................................................................16

Figure 5 Terminals, Ports, and Features ..................................................................................................................17

Figure 6 DC Ground Lug ..............................................................................................................................................19

Figure 7 Chassis Ground/PE ........................................................................................................................................19

Figure 8 Required Order of Battery Cable Hardware .........................................................................................21

Figure 9 Battery Terminal Covers ..............................................................................................................................21

Figure 10 DC Cover Attachment ..................................................................................................................................22

Figure 11 Turbo Fan Wiring ...........................................................................................................................................22

Figure 12 AC Terminals ...................................................................................................................................................23

Figure 13 AC Sources .......................................................................................................................................................24

Figure 14 AC Sources and Transfer Relay .................................................................................................................24

Figure 15 ON/OFF Jumper and Connections ..........................................................................................................25

Figure 16 Accessory Connections ...............................................................................................................................25

Figure 17 AUX Connections for Vent Fan (Example) ............................................................................................26

Figure 18 AUX Connections for Diversion (Example) ...........................................................................................26

Figure 19 Two-Wire Generator Start (Example) .....................................................................................................27

Figure 20 Three-Wire Generator Start (Example) ..................................................................................................28

Figure 21 Single-Inverter Wiring Figure 22 OutBack HUB10.3 and MATE3

Figure 23 Example of Parallel Stacking Arrangement (Three Inverters) .......................................................31

Figure 24 Parallel Wiring (Four Inverters) .................................................................................................................32

Figure 25 Example of Three-Phase Stacking Arrangement (Three Inverters) .............................................33

Figure 26 Example of Three-Phase Stacking Arrangement (Nine Inverters) ...............................................33

Figure 27 Three-Phase Wiring (Three Inverters) ....................................................................................................35

..................................................................................................................................29

..................................................................................................................30

4 900-0168-01-00 Rev A

Page 5

Introduction

Audience

This book provides instructions for the physical installation and wiring of this product.

e instructions are for use by qualified personnel who meet all local and governmental code

Thes 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. 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.



-, 24-, and 48-volt models



Output power from 2.0 kVA to 3.0 kVA



Designed to be integrated as part of an OutBack Grid/Hybrid™ system using FLEXware™ components



Battery-to-AC inverting which delivers single-phase adjustable output for such standards as 230 Vac, 220 Vac, or 240 Vac (at 50 or 60 Hz)



AC-to-battery charging (OutBack systems are battery-based)

 Uses battery energy stored from renewable resources

~ Can utilize stored energy from PV arrays, wind turbines, etc.

~ OutBack FLEXmax charge controllers will optimize PV output



Inverter load support for a small AC source



Sell-back to utility (grid-interactive function)

~ Available in 24- and 48-volt models



Rapid transfer between AC source and inverter output with minimal delay time



Uses the MATE3™ System Display and Controller or the AXS Port™ SunSpec Modbus Interface (sold separately) for user interface as part of a Grid/Hybrid system



Supports the OPTICS RE™ online tool1 for a cloud-based remote monitoring and control application

∼ Requires the MATE3 or the AXS Port ∼ Visit www.outbackpower.com to download



Uses the HUB10.3™ Communications Manager for stacking as part of a Grid/Hybrid system

~ Stackable in parallel and three-phase configurations

Figure 1 FXR Series Inverter/Charger

: This product has a settable AC output range. In this manual, many references to the output

NOTE

refer to the entire range. However, some references are made to 230 Vac or 50 Hz output. These are intended as examples only.

Outback Power Technologies Intuitive Control System for Renewable Energy

900-0168-01-00 Rev A 5

Page 6

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.) Sealed inverters 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 models are not equipped with the Turbo Fan and cannot use it.)

Table 1 Models

Model Type Power Battery Application

FXR2012E Sealed 2.0 kVA 12 Vdc Off-grid, backup

VFXR2612E Vented 2.6 kVA 12 Vdc Off-grid, backup FXR2024E Sealed 2.0 kVA 24 Vdc Off-grid, backup, grid-interactive VFXR3024E Vented 3.0 kVA 24 Vdc Off-grid, backup, grid-interactive FXR2348E Sealed 2.3 kVA 48 Vdc Off-grid, backup, grid-interactive VFXR3048E Vented 3.0 kVA 48 Vdc Off-grid, backup, grid-interactive

Inverter Model Names

FXR series model numbers use the following naming conventions.



The model number includes “FXR” as the inverter series. “R” indicates that the FXR was designed for renewable applications. Off-grid and grid-interactive functions are integrated in the same inverter.



Vented models are preceded with “V”, as in “VFXR3048E”. If a model number does not begin with “V”, it is a sealed model and is equipped with a Turbo Fan. This is not indicated otherwise.



The first two digits show the wattage of that model. For example, “FXR2012E” is 2000 watts.



The second pair of digits shows the inverter’s nominal DC voltage. For example, “FXR2024E” is 24 volts.



The model number is followed by “E”. This designates the inverter’s output as nominally 230 Vac (used in Europe, Africa, and other regions).

Components and Accessories

Table 2 Components and Accessories

Components to be Installed Accessories Included

Battery Terminal Cover, red FXR Inverter/Charger Installation Manual (this book)

Battery Terminal Cover, black FXR Inverter/Charger Operator’s Manual

AC Plate “WARNING ELECTRICAL SHOCK” sticker

DC Cover (DCC) or Turbo Fan Silicone Grease Packet

Remote Temperature Sensor (RTS)

6 900-0168-01-00 Rev A

Page 7

Introduction

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.

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.

Battery Terminal Cover

These protect the terminals from accidental contact. They are made of stiff plastic with a snap-on design.

Always keep covers installed during normal operation.

Turbo Fan Cover

Included in place of the DCC on sealed inverters. Convectively cools

chassis with the external OutBack Turbo Fan to allow maximum power.

NOTE: Do not install the Turbo Fan on a vented inverter.

NOTE: The DC Cover or Turbo Fan does not replace the battery terminal

covers. These covers must be installed in addition to the DCC or fan.

900-0168-01-00 Rev A 7

Figure 2 Components

Page 8

Introduction

NOTES:

8 900-0168-01-00 Rev A

Page 9

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 interactive applications. The inverter’s settings can be changed to accommodate many applications. Changes are made with the system display.

The FXR inverter has one set of terminals for a single AC source. However, it can use two different AC sources when an external transfer switch is installed. The inverter can be independently programmed for each source. It is common to use utility grid power and a gas or diesel generator. Other combinations of AC sources are possible.

Utility Grid

AC Generator

AC IN

AC OUT

Charge

Controller

PV Array

DC IN

AC IN

Loads

AC OUT

Battery Charging

AC or PV

DC OUT

Load Support

PV Harvest

Battery Ban

Figure 3 Applications (Example)

In Figure 3, the inverter uses a bidirectional AC input to sell power back to the utility grid. The power being delivered to the grid (labeled “AC Out”) is excess AC power not being used by the AC loads. Selling requires an inverter/charger with

900-0168-01-00 Rev A 9

Grid Tied

mode available and active.

Page 10

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.

 Generator: This mode is intended for a wide range of AC sources, including generators with a rough or

imperfect AC waveform. The inverter can use generator power even when the generator is undersized or substandard.

 Support: This mode is intended for systems using the utility grid or a generator. AC source size, wiring, or

other limitations may require temporary assistance to run very large loads. The inverter adds renewable or battery power to the AC source to ensure that the loads receive the power they require. This mode can reduce peak load demand from the utility.

 Grid Tied: This mode is intended for grid-interactive systems. When renewable energy sources charge the

batteries above a selected “target” voltage, the inverter will send the excess energy to any loads. If the loads do not use all the excess energy, then the inverter will send (sell) that energy to the utility grid.

This mode is only available in 24-volt and 48-volt models.

NOTE:



 Backup: This mode is intended for systems that have the utility grid or a generator available, but do not

: This mode is intended for systems primarily intended to maintain power to the loads with minimal

UPS

interruption when switching between AC input and batteries. The response speed has been increased so that if an AC disconnect occurs the response time will be minimized.

have specialty requirements such as selling or support. The AC source will flow through the inverter to power the loads unless power is lost. If power is lost, then the inverter will supply energy to the loads from the battery bank until the AC source returns.

 Mini Grid: This mode is intended for systems that have the utility grid as an input and a sizable amount of

renewable energy. The system will run off the renewable energy until the battery voltage falls to a specified low level. When this occurs, the inverter will connect to the utility grid to power the loads. The inverter will disconnect from the utility grid when the batteries are sufficiently recharged.



Grid Zero

renewable energy. The loads will remain connected to the utility grid, but will restrict the grid use except when no other power is available. The default power sources are the batteries and renewable energy, which attempt to “zero” the use of the AC source. The batteries are discharged and recharged (from renewable sources) while remaining grid-connected. This mode does not allow the inverter to charge batteries or sell.

: This mode is intended for systems that have the utility grid as an input and a sizable amount of

Programming

Selection of the input modes and all other inverter programming are performed using a system display such as the MATE3. The system display can customize a wide range of parameters.

Renewable Energy

The inverter cannot connect directly to PV, wind turbines, or other renewable sources. The batteries are the inverter’s primary source of power. However, if the renewable sources are used to charge the batteries, the inverter can use their energy by drawing it from the batteries.

The renewable source is always treated as a battery charger, even if all of its power is used immediately. The renewable source must have a charge controller, or some other regulation method, to prevent overcharging. OutBack Power’s FLEXmax family of charge controllers can be used for this purpose, as can other products.

10 900-0168-01-00 Rev A

Page 11

Planning

Battery Bank

When planning a battery bank, consider the following:



Cables:

will determine the placement of the battery bank. Other 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. These include

~ Using OutBack’s Advanced Battery Charging (ABC), most charging stages can be reconfigured or



Nominal Voltage:

different depending on inverter model. Before constructing a battery bank, check the inverter model and confirm nominal battery voltage.



Charger Settings and Maintenance:

usually recommended for safety reasons. It may be necessary to use a fan to ventilate the battery enclosure. Batteries must be regularly maintained according to the instructions of the battery manufacturer.

Recommendations for battery cable size and length are shown on page 20. The maximum length

batteries for marine, golf-cart, and forklift applications. They also include gel-cell batteries and absorbed glass-mat (AGM) batteries. OutBack Power recommends the use of batteries designed specifically for renewable energy applications. Automotive batteries are strongly discouraged and will have a short life if used in inverter applications.

omitted from the cycle if necessary. The charger can be customized to charge a wide range of battery technologies including nickel, lithium-ion, and sodium-sulfur batteries. This programming is performed using the system display.

These inverters are designed to work with specific battery bank voltages, which are

A vented battery enclosure may be required by electric code and is

IMPORTANT:

Battery charger settings need to be correct for a given battery type. Always follow battery manufacturer recommendations. Making incorrect settings, or leaving them at factory default settings, may cause the batteries to be undercharged or overcharged.

CAUTION: Hazard to Equipment

Batteries can emit vapors which are corrosive over long periods of time. Installing the inverter in the battery compartment may cause corrosion which is not covered by the product warranty. (Sealed batteries may be an exception.)



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 on the next page. 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. Size of load: B. Daily hours of use: C. Days of autonomy:

hese are the most basic and essential factors used to determine bank size.

D. Application: This often helps define or prioritize the previous three items. Off-grid systems often

require enough capacity to last for an extended period before recharging. Grid-connected systems frequently need only enough capacity for short-term backup during outages.

E. Conductor efficiency: Wire size and other factors

Any losses are essentially amp-hour

will waste power due to resistance and voltage drop. Typical acceptable efficiency is 96 to 99%.

F. Inverter efficiency: FXR specifications list “Typical

Efficiency” to help estimate operating loss.

capacity that the system cannot use. The battery bank size can be increased to account for losses.

900-0168-01-00 Rev A

Page 12

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. Capacity: Battery capacity, which is measured

in amp-hours, is not usually a fixed number. It is specified based on the rate of discharge. For example, the OutBack EnergyCell 200RE is rated at 154.7 Ahr when discharged at the

Table 3 Battery Bank Elements

Item Source of information

A. Load Size Site-specific B. Daily Hours Site-specific C. Days of Autonomy Site-specific D. Application Site-specific E. Conductor Efficiency Site-specific F. Inverter Efficiency Inverter manufacturer G. System Vdc Inverter manufacturer H. Battery Vdc Battery manufacturer I. Capacity Battery manufacturer J. Maximum DoD Battery manufacturer

5-hour rate (to terminal voltage 1.85 Vpc). This is a high rate of discharge that would hypothetically drain the battery in 5 hours. The same battery is rated at 215.8 Ahr when used at the 100-hour rate. Use the appropriate discharge rate (correlated to the expected loads) to measure the capacity of a battery. Use battery specifications for terminal voltage 1.85 Vpc whenever possible.

NOTE: Capacity ratings are for batteries at 25°C. Capacity is reduced at cooler temperatures.

J. Maximum depth of discharge (DoD): Most batteries cannot be discharged below a certain level

without damage. The bank requires enough total capacity to keep this from happening.

To Calculate Minimum Battery Bank Size (refer to Table 3 for letter designations):

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

(item G).

3. Determine the daily load consumption in ampere-hours (amp-hours, or Ahr). Multiply the step 2

result by the daily usage hours (item B).

4. Adjust the total for required days of autonomy (the days the system must operate without

recharging) and the maximum DoD. Multiply the step 3 result by C and divide by J.

The result is the total amp-hour capacity required for the battery bank.

5. Determine the number of parallel battery strings required. Divide the Ahr figure from step 4 by the

individual battery capacity (I). Round the result to the next highest whole number.

6. Determine the total number of batteries required. Divide the system voltage by the battery voltage

(G ÷ H). Multiply the result by the step 5 result.

The result is the total required quantity of the chosen battery model.

EXAMPLE #1

A. Backup loads: 1.0 kW (1000 W) B. Hours of use: 8 C. Days of autonomy: 1 D. Grid-interactive system (FXR2348E inverter) E. Conductor efficiency: 98% (0.98) F. Inverter efficiency: 93% (0.93) G. System voltage: 48 Vdc H. Batteries: OutBack EnergyCell 220GH (12 Vdc) I. Capacity at 8-hour rate: 199.8 Ahr J. Maximum DoD: 80% (0.8)

12 900-0168-01-00 Rev A

1) A ÷ [E x F] 1000 ÷ (0.98 x 0.93) = 1097.2 W

2) 1 ÷ G 1097.2 ÷ 48 = 22.9 Adc

3) 2 x B 22.9 x 8 = 182.9 Ahr

4) [3 x C] ÷ J [182.9 x 1] ÷ 0.8 = 228.6 Ahr

5) 4 ÷ I 228.6 ÷ 199.8 = 1.14 (rounded to 2)

6) [G ÷ H] x 5 [48 ÷ 12] x 2 strings = 8 batteries

Page 13

EXAMPLE #2

Planning

A. Backup loads: 720 W) B. Hours of use: 3 C. Days of autonomy: 2 D. Off-grid system (VFXR3024E inverter) E. Conductor efficiency: 97% (0.97) F. Inverter efficiency: 92% (0.9) G. System voltage: 24 Vdc H. Batteries: OutBack EnergyCell 200RE (12 Vdc) I. Capacity at 8-hour rate: 167.5 Ahr J. Maximum DoD: 50% (0.5)

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 three-phase output can work with three-phase generators.



The inverter/charger can provide a start signal to control an automatic start generator. If automatic generator starting is required, the generator must be an electric-start model with automatic choke. It should have two-wire start capability. For other configurations, additional equipment may be required.



In any configuration, the inverter may need to be specifically programmed using the system display. Perform all programming according to the specifications of the generator and the required operation of the inverter. Parameters to be program med may include generator size, automatic starting requirements, and potential fluctuations in generator AC voltage.

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

4) [3 x C] ÷ J [103.1 x 2] ÷ 0.5 = 412.4 Ahr

5) 4 ÷ I 412.4 ÷ 167.5 = 2.5 (rounded to 3)

6) [G ÷ H] x 5 [24 ÷ 12] x 3 strings = 6 batteries

A generator that is to be installed in a building usually should



ground connections. The generator should only be bonded if there is a specific need. Local or national codes may require the neutral and ground to be bonded at the main electrical panel. See page 19 for more information on neutral-ground bonding.

have a bond between the neutral and

not

Generator Sizing

A generator should be sized to provide enough power for all the loads and the battery charger. The generator size should assume maximum loads and maximum charging at the same time.



Available generator power may be limited by ratings for circuit breakers and/or generator connectors.



The generator must be able to provide current to all inverters on a given phase or leg. Minimum generator

is recommended to be twice the power of the inverter system. For example, a 2 kVA inverter should

size have a 4 kVA generator. Many generators may not be able to maintain AC voltage or frequency for long periods of time if they are loaded more than 80% of rated capacity.

2 This is the generator size after derating for environment, use, and other factors.

900-0168-01-00 Rev A 13

Page 14

Planning

NOTES:

14 900-0168-01-00 Rev A

Page 15

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. If there is any exposure to moisture or condensation, the inverter must not be mounted upside-down. This ensures that water will not accumulate under the DC cover. However, it can still be mounted in other positions or orientations.



For installations where the inverter may be exposed to water spray, a sealed model must be used and mounted either with the base down (shelf mounting) or with the AC wiring compartment facing down (wall mounting). If mounted with the base down, water cannot be allowed to accumulate around the inverter’s base. There is a drainage system on the base of the inverter to dispel condensation. If submerged, water can enter this drain and cause failure.



Vented inverters must be installed in a weather-proof enclosure or enclosed area. These models are not designed for exposure to water or excessive wind-blown dust and debris.



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.



Any inverter will perform more efficiently in locations offering plenty of air circulation. The recommended minimum clearance is 5 cm (2 inches) on all sides of the inverter.



Any inverter will function to all of its specifications if operated in a range of –20°C to 50°C (–4°F to 122°F).



The inverter will function, but will not necessarily meet its specifications, if operated in a temperature range of –40°C to 60°C (–40°F to 140°F). This is also the allowable temperature range for storage.



The FXR series of inverters carry an Ingress Protection (IP) rating of 20 and a Relative Humidity (RH) rating of 93% (non-condensing).



Inverter specifications are listed in the FXR Series Inverter/Charger Operator’s Manual.

Tools Required



Wire cutters/strippers



Torque wrenches



Assorted insulated screwdrivers



DVM or standard voltmeter

900-0168-01-00 Rev A 15

Page 16

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.



Due to the variance in other mounting methods, OutBack only endorses the use of FLEXware mounting products or previous versions of OutBack mounting plates. Use M6 x 20 mm machine screws, one per corner, to attach the inverter to the mounting plate. Follow the instructions with each mounting system.



Mount and secure each component before attaching any wiring.



When the inverter is used with other metal chassis, make sure that all chassis are grounded appropriately. (See the grounding instructions on page 17.) Grounding other chassis may involve metal-to-metal contact, or separate ground wires.

If using an OutBack FLEXware Mounting Plate, avoid large air gaps behind the plate. These can result in louder mechanical noise during heavy inverting or charging. Mount the plate on a flat, solid mounting surface.

Dimensions

Length 41 cm (16.25”)

Height

without

Turbo

30.5 cm (12”)

Width 21 cm (8.25”)

Height

with Turbo

33 cm (13”)

Figure 4 Dimensions

900-0168-01-00 Rev A

Page 17

Installation

Terminals and Ports

DC TERMINALS

These terminals connect to the

battery cables and the DC system.

See page 20 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.

The Terminal Block can be unplugged from the

AC board for convenience. While installed, keep

screws tight and the block itself secured tightly

to the AC board to

These terminals receive wires for a manual

The jumper alongside these terminals overrides them and turns the inverter on. (See page 25 for instructions.) With the jumper installed, a switch

display can turn it off or on. The system display

These terminals deliver 12 Vdc up to 0.7 amps

(8.4 watts). The output can be switched on and

off for many functions. The default function is

programmed using the system display.

on/off switch to control the inverter.

cannot turn the inverter off, but the system

cannot turn it on if the jumper is not installed.

AUX OUTPUT (AUX+/AUX-)

to drive a cooling fan or the Turbo Fan.

The functions for the AUX output can be

revent malfunction.

INVERTER ON/OFF

ON/OFF JUMPER

See page 26 for details.

DC and AC GROUND TERMINALS

These terminals connect to a grounding system for both batteries and AC. See page 17 for instructions.

AC TERMINAL BLOCK

These terminals receive AC input and output wires. See page 23 for instructions.

XCT+/XCT-

Non-operational terminals. Do not connect anything to them.

MATE/HUB and RTS PORTS

These ports receive the RJ45 and RJ11 plugs from the system display and Remote Temp Sensor. See page 25 for instructions.

The ports are mounted sideways. When viewed from the left side, they appear as shown below.

AUX LED INDICATOR

Orange LED indicator turns on when 12 Vdc output is present.

Figure 5 Terminals, Ports, and Features

: The INVERTER ON/OFF Jumper is installed to the ON position during manufacture, but the FXR

NOTE

inverter is given an external OFF command at the same time. Its initial state is OFF.

900-0168-01-00 Rev A

LED INDICATORS

These indicators display the inverter status and battery voltage.  The three BATTERY LED indicators (green, yellow, and red) are based on

DC voltage, and provide a very general idea of battery state.

 The green INVERTER LED indicator shows if the inverting function is on.  The yellow AC IN LED indicator shows if an AC source is present.  The red ERROR LED indicator shows either a Warning or an Error. A

Warning is an alert for a problem that is not severe enough for shutdown. An Error usually accompanies inverter shutdown.

Page 18

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.



The input and output circuits are isolated from ground. The installer is responsible for system grounding according to all applicable codes.



For safety, the neutral and ground conductors should be mechanically bonded. OutBack does not bond these conductors within the inverter. Some codes require the bond to be made at the main panel only. Make sure that no more than one bond is present in the AC system at any time.

WARNING: Shock Hazard

For all installations, the negative battery conductor should be bonded to the grounding system at only one point. If the OutBack GFDI is present, it can provide the bond.

IMPORTANT:

Not all OutBack products can be used in a positive-ground system. If it is necessary to build a positive-ground system with OutBack products, contact OutBack Technical Support at +1.360.618.4363 before proceeding. Additionally, consult the online forum at www.outbackpower.com/forum/, where this subject has been discussed extensively.

Table 4 Ground Conductor Size and Torque Requirements

Terminal Location Minimum Conductor Size Torque Requirements

Central AC Terminals

DC Box Lug

6 mm or #10 AWG (0.009 in) 2.8 Nm (25 in-lb)

16 mm or #6 AWG (0.025 in) 5.1 Nm (45 in-lb)

Table 4 contains OutBack’s recommendations for minimum safe cable sizes. Other codes may supersede OutBack’s recommendations. Consult applicable codes for final size requirements.

900-0168-01-00 Rev A

Page 19

Installation

The inverter’s DC ground is a box lug located next to the negative DC battery terminal. This lug accepts up to 70 mm (1/0 AWG or 0.109 in) 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. If connecting to an external ground bus, only one terminal needs to be used. The other terminal may be used if connecting to a device with its own ground wire, such as a generator.

900-0168-01-00 Rev A 19

Figure 7 Chassis Ground/PE

Page 20

Installation

DC Wiring

Table 5 DC Conductor Size and Torque Requirements

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.



Never install extra washers or hardware between the mounting surface and the battery cable lug. The decreased surface area can build up heat. See the hardware diagrams on page 21.

IMPORTANT:



The DC terminals must be encased in an enclosure to meet the requirements of some local or national codes.



Table 5 contains OutBack’s recommendations for minimum safe cable sizes. Other codes may supersede OutBack’s recommendations. Consult applicable codes for final size requirements.

Inverter

(Wattage/Voltage)

FXR2012E 200 120 mm (4/0 AWG) or 0.186 in 250 Adc

VFXR2612E 260 120 mm (4/0 AWG) or 0.186 in 250 Adc

FXR2024E 100 70 mm (2/0 AWG) or 0.109 in 175 Adc

VFXR3024E 150 120 mm (4/0 AWG) or 0.186 in 250 Adc

FXR2348E 57.5 70 mm (1/0 AWG) or 0.109 in 125 Adc

VFXR3048E 75 70 mm (1/0 AWG) or 0.109 in 125 Adc

Nominal DC Amps

(Derated 125%)

Conductor Size3

(Minimum)

Breaker Size

(Minimum)

Terminal Location Torque Requirements

Inverter DC Terminals 6.9 Nm (60 in-lb) Battery Terminals See battery manufacturer’s recommendations

When installing DC cables:



Battery positive and negative cables should be no longer than 3 meters (10 feet) each, to minimize voltage loss and other possible effects.



Turn off DC circuit breakers or remove fuses before proceeding.



Tie, tape, or twist cables together to reduce self-inductance. Run positive and negative cables through the same knockouts and conduit.



The inverter’s battery terminal is a threaded stud which accepts a ring terminal lug. Use crimped and sealed copper ring lugs with 0.79 cm (5/16 inch) holes, or use compression lugs.



Install all overcurrent devices on the positive cable.

Cable sizes are for each inverter in a system. In a system with multiple inverters, each inverter requires its own cables and overcurrent

devices of the size indicated.

900-0168-01-00 Rev A

Page 21

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 1.25 Stud

13 mm Nut

Flat Washer

Mounting Surface

Lock Washer

Battery Cable Lug

Insulator

Figure 8 Required Order of Battery Cable Hardware

CAUTION: Fire Hazard

Never install extra washers or hardware between the mounting surface and the battery cable lug. The decreased surface area can build up heat.

2. Install the battery terminal covers. These are made of stiff plastic with a snap-on design.

If it is necessary to remove the covers, remove

carefully using a flat screwdriver.

Insert the screwdriver into the slot on the

side of each cover and unsnap the cover.

900-0168-01-00 Rev A 21

REMOVAL SLOT

Figure 9 Battery Terminal Covers

Page 22

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. The AUX+ and

AUX– terminals receive the red (+) and black (–)

wires. Tighten with a Phillips screwdriver.

To safely run the wires into the AC compartment,

pass the wires through the notch in the

compartment cover.

Notch

Edge of Cover

Compartment

Figure 11 Turbo Fan Wiring

If it is necessary to remove the Turbo Fan:

1. Remove the compartment cover.

If necessary, the green terminal block can be unplugged b

pulling it gently away from the AC board.

Make certain the AUX programming is correct for proper fan operation.

2. Unscrew the AUX+ and AUX– terminal screws.

3. Remove the wires.

4. Remove the screws at the four corners of the Turbo Fan.

5. Remove the Turbo Fan.

22 900-0168-01-00 Rev A

Page 23

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:

This page contains OutBack’s recommendations for minimum safe cable sizes. Other codes may supersede OutBack’s recommendations. Consult applicable codes for final size requirement

All system wiring must comply with national and local codes and regulations.

The FXR inverter’s AC terminal block has six positions for AC wires. The minimum recommended wire size is 6 mm (#10 AWG) or 0.008 in. Larger wire gauges may be required for specific con The largest size that can be used with the termi

AC HOT OUT

The AC HOT OUT

terminal connects to the

output load panel.

The terminal can carry

up to 30 amps using the

er’s transfer relay.

invert

Use the inverter

power to size the actual

maximum output load.

Size the circuit breakers

accordingly.

nals is 16 mm

(#6 AWG) or 0.021 in wire.

NEUTRAL

The two NEUTRAL terminals are electrically common.

If connecting to an external neutral bus, only one terminal needs to be used. An external neutral bus is often located in the main electrical panel.

Use the other terminal if connecting to a device that has its own neutral wire, such as a generator.

ditions.

AC HOT IN

The AC HOT IN terminal brings current from the AC source. It powers both battery charger and loads. Use the source size to determine actual current draw. Size all circuit breakers accordingly.

900-0168-01-00 Rev A

Figure 12 AC Terminals

Page 24

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. This prevents the risk of connecting to two out-of-phase sources at the same time or connecting them to each other.

Utility Grid Generator

Inverter

GND NEU HOT

Single-Pole

Double-Throw

Switch

NEU HOT (internal connections)

Internal

Transfer Relay

OUTPUT NEU

Loads

GND

Figure 13 AC Sources

The inverter’s transfer relay is normally set to provide inverter power to the output. This is shown in Figure 13, where the internal transfer relay is switched to the inverter function.

Utility Grid Generator

Inverter

GND NEU HOT

Single-Pole

Double-Throw

Switch

NEU HOT (internal connections)

Internal

Transfer Relay

OUTPUT NEU

Loads

GND

Figure 14 AC Sources and Transfer Relay

When an AC source is connected and accepted, the internal transfer relay switches to transfer the AC source power to the loads. Figure 14 shows the utility grid switch closed. The internal transfer relay has switched accordingly so that the loads receive utility power. (See the Operator’s Manual for the inverter’s acceptance criteria.)

24 900-0168-01-00 Rev A

Page 25

Installation

Jumper Off

RTS cable

4-conductor,

MATE cable

CAT5 non

crossover

MATE/HUB port

RTS port

See the

MATE

Additional ports

ON and OFF Wiring

The INVERTER ON/OFF jumper bridges two pins. The ON/OFF jumper p

arallels 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.)

To turn the inverter initially ON, remove the

jumper briefly and then replace it. This requires long-nose pliers or a similar tool.

After this, removing the

jumper will immediately turn the inverter OFF.

umper On

Once the jumper has been removed, the I

NVERTER ON/OFF terminals on the Control Wiring Terminal Block can be used to wire a manual on/off switch. These terminals can also be used to control an Emergency Power Off (EPO) device instead of a standard switch.

Figure 15 ON/OFF Jumper and Connections

Accessory Wiring

The AC Wiring Compartment Board has ports for both t

he Remote Temperature Sensor (RTS) and the system

display. The system display port is labeled MATE/HUB.

If a HUB Communications Manager is in use, it occupies the inverter’s MATE/HUB port.

RJ11,

J45, 8-conductor,

When a HUB product occupies the inverter’s MATE/HUB port, t

he system display connects directly to the HUB product.

Inverters plug into ports 1 and above. Charge controllers and other devices plug into unassigned ports not used by inverters.

See Stacking on page 30 for information on connecting inverters. See the HUB product literature for other devices.

port

Figure 16 Accessory Connections

Operator’s M

anual for more

information on the RTS.

900-0168-01-00 Rev A 25

Page 26

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 2.5 mm (#14 AWG). The

AUX

circuit contains electronic overcurrent protection, which resets after being overloaded. No additional fuses are required for the

AUX

terminals.

The default setting for the AUX output is to control the Turbo Fan included with sealed models. (See Figure 17.) The AUX output can only control one function at a time. It cannot be used for anything else if the Turbo Fan is connected.

The control logic for the AUX output is not always located in the same device. Inverter AUX functions are located within the inverter itself and are described accordingly. Although inverter-based functions require the system display for programming, they will function even if the display is removed. However, AGS programming is located within the system display and will not work if the display is removed. Other devices may also be able to control the terminals. For generator control, see page 27.

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. When the AUX output closes the relay (based on battery voltage), the relay diverts the excess wind power to a water heating element.

Turbine

Rela

NOTE: Relays and elements shown are examples only and may

depending on the installation.

var

Element

Figure 18 AUX Connections for Diversion (Example)

26 900-0168-01-00 Rev A

Page 27

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. The choice of control function depends on system needs and the capabilities of each device.

The generator must be an electric-start model with automatic choke. It is recommended to have “two-wire” start capability. A two-wire-start generator is the simplest type, where the cranking and starting routine is automated. It usually has a single switch with two positions that is turned ON to start, OFF to stop.

Two-Wire-Start

The 12 Vdc signal provided by the is possible to send a 12-Vdc signal directly to the generator. However, this should never be done if it connects the

output directly to the generator’s own battery. It is more common to use the

AUX

terminals to energize the coil of a 12 Vdc automotive or similar relay.

The OutBack FLEXware Relay Assembly depicted in Figure 19 is sold for this purpose. The relay contacts can serve in place of the generator’s start switch. The battery shown below is depicted for clarity. In most cases, it is part of the generator’s internal starting circuit and is not an external component.

output can be switched on and off to provide a start signal. It

AUX

The drawing below is one example of a possible arrangement. Specific arrangements, relays, and other elements depend on the requirements of the installation and of the generator.

Relay

Coil

Relay

Contact

Starting

Terminal

Generator

Battery

Figure 19 Two-Wire Generator Start (Example)

900-0168-01-00 Rev A

Two-Wire-Start

Generator

Page 28

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.com)

is one company that makes these kits. The

Atkinson GSCM-Mini is intended to work with OutBack inverters.

The drawing below is one example of a possible arrangement. Specific arrangements, relays, and other elements depend on the requirements of the installation and of the generator.

Atkinson

GSCM-Mini

Figure 20 Three-Wire Generator Start (Example)

28 900-0168-01-00 Rev A

Three-Wire-Start

Generator

Page 29

Installation

CAT5 Cable

(Utility Grid or AC Generator)

AC Conduit Box

GND HOT

Neutral

HUB/

Neutral

GROUND

NEU

HOT

AC Loads

Ground TBB

(may be within AC

Primary

LEGEND

Ground

Hot Neutral

TBB = Terminal Bus Bar

NOTES:

Bypass

Circuit

Breaker

Mechanical

Interlock

AC Configurations

Single-Inverter

When installing an inverter AC system, the following rules must be observed.



All overcurrent devices for must be sized for 30 Aac or less.



All wiring must be sized for 30 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.

MATE3

NEU

AC Source

1. Neutral (common) conductor may be co

nnected from only one inverter neutral terminal to a common bus bar in the AC conduit box.

2. Colors depicted here may be different from wiring standards.

Conduit Box)

MATE

Inverter/Charger

GND

Input C

ircuit

Breaker

Hot

Output Circuit Breaker

System Ground

900-0168-01-00 Rev A 29

Figure 21 Single-Inverter Wiring

Page 30

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 “parallel” and “three-phase” configurations.

Stacking Connections

Stacking requires an OutBack HUB10.3 communications manager and a system display. All interconnections between the products are made using CAT5 non-crossover cable.

MATE3 Port

HUB10.3

Additional Ports

Port 1

MATE3

Figure 22 OutBack HUB10.3 and MATE3

Each inverter must be assigned a stacking mode, “master” or “slave”, depending on the configuration.



The master provides the primary output phase. Other inverters in the system base their phase on that of the master. If the master shuts off, all other inverters also shut off. The master must sense and connect to an AC source before other inverters can connect.

In a parallel-stacked system, the master tends to be the most heavily used unit. “Subphase master” inverters are used in three-phase systems. A subphase master inverter operates

semi-independently of the master inverter. Although the master inverter sets the phase relationship, the subphase master creates an output independent of the master.

The master on the A phase output cannot measure loads and voltages on any other output. Subphase masters are required to perform monitoring and regulation on the B and C phase outputs.



A slave inverter does not create an independent output. It simply assists the master or subphase master by adding power to the output as needed.

~ The Power Save function can place slave inverters in “Silent” mode when not in use. They are activated

by the master or subphase master when required.

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 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.

Programming uses the system display to assign a status and stacking value to the inverter on each port. As long as the master is plugged into port 1, these assignments can be changed as needed.

900-0168-01-00 Rev A

Page 31

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.



Although stacking allows greater capacity, the loads, wiring, and overcurrent devices must still be sized appropriately. Overloading may cause circuit breakers to open or the inverters to shut down.

Stacking Configurations

Installation

Parallel Stacking (Dual-Stack and Larger)

In parallel stacking, two or more inverters create a single, common 230 Vac4 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.



Up to ten inverters may be installed in a parallel arrangement. The example on this page shows three inverters. The wiring diagram on the next page shows four. All inverters must be the same model.

PANEL

Master Slave Slave

6.0 kVA

2.0 kVA 230 Vac

230 Vac

Figure 23 Example of Parallel Stacking Arrangement (Three Inverters)

When installing a parallel inverter system, observe the following rules.

LOAD



Parallel 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 the master and is programmed as Mounting below the other inverters allows the master to avoid heat buildup and remain relatively cool as it sees the greatest duty cycle.



The master must be connected to port 1 of the communications manager. Other inverters must not be selected as master.



All slave inverters, regardless of number, should be selected as connected to any port numbered 2 and above.



All overcurrent devices must be sized for 30 Aac or less. All wiring must be sized for 30 Aac or more.



All output circuit breakers must be sized appropriately for loads and inverter wattage.

Output voltages may vary with regional voltage standards.

900-0168-01-00 Rev A

Master.

during programming. Slaves can be

Slave

Page 32

Installation

(L1)



The AC input (generator or utility grid) must be a single-phase source of the proper voltage and frequency.



When wiring the AC source to the inverters, local codes may require the inverter circuits to be located at the opposite end of the panel from the main circuit breaker. This prevents overloading of the AC bus.

HUB 10.3

10 9 8 7 6 5 4 3 2 1 MATE

CAT5 Cables

MATE3

Neutral

Inverter

L1 Master

Neutral

OUT

AC Source

(Utility Grid or AC Generator)

AC Conduit

Input Circuit

Breaker

Neutral

TBB

Neutral

HUB/

MATE

Hot IN

(L1)

GND Hot L1 TBB

HUB/

MATE

Hot IN

(L1)

Inverter Inverter

L1 Slave

Neutral

OUT

Hot OUT

(L1) GND

GND

Hot OUT

(L1)

Input Circuit

Breaker

Neutral

OUT

HUB/

MATE

L1 Slave

GND

TBB = Terminal Bus Bar

Input Circuit

Breaker

Hot IN

Hot OUT

(L1)

Neutral

LEGEND

Hot L1 Neutral

Ground

HUB/

MATE

Inverter

L1 Slave

OUT

GND

Hot IN

Hot OUT

(L1)

Input Circuit

Breaker

Ground TBB

(may be within

AC Conduit Box)

GND Hot L1 TBB

Neutral TBB

Figure 24 Parallel Wiring (Four Inverters)

32 900-0168-01-00 Rev A

AC Loads

Mechanical Interlock

Output Circuit Breakers

Bypass

Circuit

Breakers

NOTES:

1. Neutral (common) conductor may be connected from only one inverter neutral terminal to a common bus bar in the AC conduit box.

2. Colors shown here may be different from wiring standards.

Page 33

Three-Phase Stacking

In three-phase stacking, inverters create three separate 230 Vac5 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 230 Vac loads on that leg.



The output of each inverter is 120° out of phase from the others. Any two outputs produce 400 Vac between them. The outputs can be used to power three-phase loads when all inverters work together.



Up to nine inverters, three per phase, may be installed in a three-phase arrangement. (The wiring drawing on the next page shows only one inverter per phase.) All inverters must be the same model.

LOAD PANEL

Master

Installation

2.0 kVA 230 Vac

Figure 25 Example of Three-Phase Stacking Arrangement (Three Inverters)

LOAD PANEL

Master

2.0 kVA 230 Vac

B Phase Master

2.0 kVA 230 Vac

Slave

2.0 kVA 230 Vac

6.0 kVA 230 Vac

6.0 kVA 400 Vac

18.0 kVA 400 Vac

C Phase

2.0 kVA 230 Vac

Figure 26 Example of Three-Phase Stacking Arrangement (Nine Inverters)

Output voltages may vary with regional voltage standards.

900-0168-01-00 Rev A 33

Slave

2.0 kVA 230 Vac

Slave

2.0 kVA 230 Vac

6.0 kVA 230 Vac

Page 34

Installation

When installing a three-phase inverter 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.



The master must be connected to port 1 of the communications manager. Other inverters must not be selected as master.



Any other inverter on the Phase A output (parallel with the master) should be selected as programming. These can be connected to ports 2 or 3. Phase A inverters cannot use other ports.



The subphase master for the Phase B output must be programmed as

B Phase Master

. It must be

connected to port 4.



Any other inverter on the Phase B output (parallel with the B subphase master) should be selected as during programming. These can be connected to ports 5 or 6. Phase B inverters cannot use other ports.



The subphase master for the Phase C output must be programmed as

C Phase Master

. It must be

connected to port 7.



Any other inverter on the Phase C output (parallel with the C subphase master) should be selected as during programming. These can be connected to ports 8 or 9. Phase C inverters cannot use other ports.



All overcurrent devices must be sized for 30 Aac or less. All wiring must be sized for 30 Aac or more.



All output circuit breakers must be sized appropriately for loads and inverter wattage.



The AC input (generator or utility grid) must be a three-phase wye configuration source of the proper voltage and frequency.



Slave

during

Slave

34 900-0168-01-00 Rev A

Page 35

Installation

HUB 10.3

10 9 8 7 6 5 4 3 2 1 MATE

CAT5 Cables

MATE3

HUB/

MATE

Neutral

Inverter

Phase A Master

Neutral

GND

OUT

GND

Hot IN

Hot OUT

(A)

AC Source

(Utility Grid or AC Generator)

AC Conduit Box

Neutral TBB

Neutral

HUB/

MATE

Phase A

TBB

Hot IN

Inverter

Phase B

Subphase Master

Neutral

OUT

GND

Hot OUT

Input Circuit Breaker

(B)

Phase B

TBB

Input Circuit Breaker

Neutral

Phase C

TBB

HUB/ MATE

Input Circuit Breaker

Hot IN

(C)

Inverter

Phase C

Hot OUT

(C)

Subphase Master

Neutral

GND

OUT

Ground TBB

(may be within

AC Conduit Box)

Primary System Ground

LEGEND

Phase A Phase B Phase C

Neutral

Ground

TBB = Terminal Bus Bar

Figure 27 Three-Phase Wiring (Three Inverters)

GND

Neutral

TBB

Phase A

TBB

Phase B

TBB

Phase C

TBB

Mechanical

Bypass

Circuit

Breakers

Output Circuit Breakers

Interloc

NOTES:

1. Neutral (common) conductor may be connected from only one inverter neutral terminal to a common bus bar in the AC conduit box.

2. Colors shown here may be

different from wiring standards.

900-0168-01-00 Rev A 35

Page 36

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 the EMC directive for emissions is achieved with installation of EMC kit FXR-FILTER or equivalent. Installation instructions for FXR-FILTER are available.

Symbols Used

WARNING: Hazard to Human Life

This type of notation indicates that the hazard could be harmful to human life.

CAUTION: Hazard to Equipment

This type of notation indicates that the hazard may cause damage to the equipment.

IMPORTANT:

This type of notation indicates that the information provided is important to the installation, operation and/or maintenance of the equipment. Failure to follow the recommendations in such a notation could result in voiding the equipment warranty.

MORE INFORMATION

When this symbol appears next to text, it means that more information is available in other manuals relating to the subject. The most common reference is to the Operator’s Manual for the appropriate inverter model. Another common reference is the system display manual.

36 900-0168-01-00 Rev A

Page 37

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

DC Direct Current; refers to voltage produced by the batteries or renewable source

DCC DC Cover; shields the DC terminal area on vented FX-class inverters

DVM Digital Voltmeter

ETL Electrical Testing Laboratories; short for the company ETL Semko; refers to a certification issued by

Multi-port device such as the OutBack HUB10.3; used for connecting multiple OutBack devices on a single remote display; essential for stacking inverters

ETL to OutBack products indicating that they meet certain UL standards

GFDI Ground Fault Detector Interruptor; a safety device for PV systems

GND Ground; a permanent conductive connection to earth for safety reasons; also known as Chassis

Ground, Protective Earth, and PE

Grid-interactive, grid-intertie, grid-tie

HUB10.3 An OutBack communications manager product; used for system stacking and coordination

LED Light-Emitting Diode; refers to indicators used by the inverter and the system display

Master An inverter which provides the primary output phase of a stacked system; other stacked inverters

MATE3

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

Off-grid

On-grid Utility grid power is available for use (does not imply grid-interactive capability)

PV Photovoltaic

Utility grid power is available for use and the inverter is a model capable of returning (selling) electricity back to the utility grid

base their output and on/off state on the master

An OutBack system display product, used for monitoring, programming and communicating with the inverter

bond makes the AC neutral safe to handle

Utility grid power

available for use

is no

RE Renewable Energy

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

900-0168-01-00 Rev A 37

Page 38

Installation

Table 6 Terms and Definitions

Term Definition

Subphase Master An inverter which provides the output for additional phases of a stacked system; the output of a

subphase master is based on the output of the master

System display Remote interface device (such as the MATE3), used for monitoring, programming and

communicating with the inverter; also called “remote system display”

Three-phase, 3-phase A type of utility electrical system with three “hot” lines, each 120° out of phase;

each carries the nominal line voltage with respect to neutral; each carries voltage with respect to each other equaling the line voltage multiplied by 1.732

Turbo Fan External cooling fan used in place of the DCC on sealed FXR inverters

UL Underwriters Laboratories; refers to a set of safety standards governing electrical products

Utility grid The electrical service and infrastructure supported by the electrical or utility company; also called

“mains”, “utility service”, or “grid”

NOTES:

38 900-0168-01-00 Rev A

Page 39

Index

Emergency Power Off (EPO) .......................................... 25



AC Plate ................................................................................... 6

AC Terminals ........................................................... 9, 17, 23

Advanced Generator Start (AGS) .................................. 27

Applications .......................................................................... 9

Automatic Generator Start ............................................. 27

AUX Terminals .................................................................... 17

AXS Port .................................................................................. 5



Battery Bank ........................................................................ 11

Sizing ................................................................................ 12

Battery Terminal Covers .................................................... 6



Communication Cables ..................................... 17, 25, 30

Communications Manager

Connections..................................................... 17, 25, 30

Stacking.................................................................... 31, 33

Components ......................................................................... 6

Conductor Size

AC Conductors .............................................................. 23

DC Conductors ............................................................. 20

Ground Conductors .................................................... 18

Control Wiring Terminal Block ...................................... 17



DC Cover (DCC) ...................................................... 6, 15, 22

DC Terminals ......................................................... 17, 20, 21

Definitions ............................................................................ 37

Dimensions .......................................................................... 16

Diversion Control ............................................................... 26

Drawings

General System Layout ................................................ 9

Parallel-Stacked System ............................................. 32

Single-Inverter System ............................................... 29

Three-Phase System .................................................... 35

DVM ........................................................................................ 15



EMC ........................................................................................ 36

900-0168-01-00 Rev A 39

Emissions .............................................................................. 36

Environmental Requirements ....................................... 15



Features .................................................................................. 5

Filter ....................................................................................... 36

Functional Test ................................................................... 36



Gen Alert ............................................................................... 27

Generator ............................................................... 29, 31, 33

Applications .............................................................. 9, 24

Control ...................................................................... 27, 28

Sizing ................................................................................ 13

Type .................................................................................. 13

GFDI................................................................................. 18, 37

Grid-Interactive ............................................................. 9, 37

Grounding ..................................................................... 17, 18



HUB10.3 ......................................................................... 25, 30



Ingress Protection (IP) ...................................................... 15

Input Modes ........................................................................ 10



Jumper ........................................................................... 17, 25



LED Indicators ..................................................................... 17

Location ................................................................................ 15



Master (Stacking) ................................................. 30, 31, 33

MATE/HUB Port .................................................................. 25

MATE3 ................................................................ 5, 25, 30, 38

Models ..................................................................................... 6

Modes .................................................................................... 10

Page 40

Mounting ............................................................................. 16

Multiple AC Sources ......................................................... 24



Neutral-Ground Bonding.................................. 13, 18, 23



On and Off .................................................................... 17, 25

OPTICS RE .............................................................................. 5



Parallel Stacking ................................................................ 31

Ports, RJ45 and RJ11 .................................................. 17, 25

Positive Grounding ........................................................... 18

PV ....................................................................................... 9, 10



Relative Humidity (RH) .................................................... 15

Remote Temperature Sensor (RTS) .................. 6, 17, 25

Renewable Energy ............................................................ 10

Index



Temperatures ..................................................................... 15

Terms and Definitions ..................................................... 37

Test ......................................................................................... 36

Three-Phase Stacking ...................................................... 33

Tools Required ................................................................... 15

Torque Requirements

AC Terminals ................................................................. 23

DC Terminals ................................................................. 20

Ground Terminals ........................................................ 18

Turbo Fan ......................................................................... 6, 22



Utility Grid .............................................................. 29, 31, 33

Applications .............................................................. 9, 24



Vent Fan ............................................................................... 26

Vented Models ............................................................... 6, 15



Sealed Models ................................................................ 6, 15

Sizing ..................................................................................... 29

Slave (Stacking) .................................................... 30, 31, 33

Stacking ................................................................................ 30

Parallel ............................................................................. 31

Three-Phase ................................................................... 33

Stacking Mode Programming ........................................ 31

Subphase Master (Stacking) ................................... 30, 33

Symbols Used ..................................................................... 36

System Display ............................................................ 36, 38

Connections ........................................................... 17, 25

Programming........................................... 13, 26, 27, 30

Stacking ................................................................... 31, 33

40 900-0168-01-00 Rev A

Wiring .................................................................................... 18

AC Connections ........................................................... 23

AUX Connections ........................................................ 26

DC Connections ........................................................... 20

Ground Connections .................................................. 18

Single Inverter .............................................................. 29

Stacking

Parallel ....................................................................... 32

Three-phase ............................................................. 35



XCT ......................................................................................... 17

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900-0168-01-00 Rev A 41

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900-0168-01-00 Rev A

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900-0168-01-00 Rev A 43

Page 44

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Corporate Headquarters 17825 – 59 Suite B Arlington, WA 98223 USA +1.360.435.6030

900-0168-01-00 Rev A

Avenue N.E.

European Office Hansastrasse 8 D-91126 Schwabach, Germany +49.9122.79889.0

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