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.
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.
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.
Welcome to OutBack Power Technologies ................................................................................................................. 5
Inverter Model Names .................................................................................................................................................................... 6
Components and Accessories ..................................................................................................................................................... 6
Renewable Energy ......................................................................................................................................................................... 10
Battery Bank ..................................................................................................................................................................................... 11
Terminals and Ports .......................................................................................................................................................... 17
DC Wiring ............................................................................................................................................................................. 20
AC Wiring.............................................................................................................................................................................. 23
AC Sources ........................................................................................................................................................................................ 24
ON and OFF Wiring ........................................................................................................................................................... 25
AUX Wiring .......................................................................................................................................................................... 26
Generator Control .......................................................................................................................................................................... 27
AC Configurations ............................................................................................................................................................. 29
Functional Test ................................................................................................................................................................... 36
Symbols Used ..................................................................................................................................................................... 36
Table 2Components and Accessories .................................................................................................................... 6
Table 3Battery Bank Elements .................................................................................................................................12
Table 4Ground Conductor Size and Torque Requirements .........................................................................18
Table 5DC Conductor Size and Torque Requirements ...................................................................................20
Table 6Terms and Definitions .................................................................................................................................37
List of Figures
Figure 1FXR Series Inverter/Charger ........................................................................................................................ 5
Figure 5Terminals, Ports, and Features ..................................................................................................................17
Figure 11Turbo Fan Wiring ...........................................................................................................................................22
Figure 14AC Sources and Transfer Relay .................................................................................................................24
Figure 15ON/OFF Jumper and Connections ..........................................................................................................25
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.
12
-, 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.
1
Outback Power Technologies Intuitive Control System for Renewable Energy
900-0168-01-00 Rev A5
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 1Models
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
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 A7
Figure 2 Components
Introduction
NOTES:
8 900-0168-01-00 Rev A
Planning
k
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
OR
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 A9
Grid Tied
mode available and active.
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
T
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
11
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
1.
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
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
2
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 A13
Planning
NOTES:
14 900-0168-01-00 Rev A
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