OutBack Power FXR2012A, VFXR2812A, FXR3048A, VFXR3648A, FXR2524A Installation Manual

...

FXR Series Inverter/Charger

FXR2012A FXR2524A FXR3048A

VFXR2812A VFXR3524A VFXR3648A

Installation Manual

About OutBack Power Technologies

OutBack Power Technologies is a leader in advanced energy conversion technology. OutBack products include true sine wave inverter/chargers, maximum power point tracking charge controllers, and system communication components, as well as circuit breakers, batteries, accessories, and assembled systems.

Applicability

These instructions apply to OutBack inverter/charger models FXR2012A, FXR2524A, FXR3048A, VFXR2812A, VFXR3524A, and VFXR3648A only.

Contact Information

Address: Corporate Headquarters

17825 – 59 Suite B Arlington, WA 98223 USA

Website: http://www.outbackpower.com

Avenue N.E.

European Office Hansastrasse 8 D-91126 Schwabach, Germany

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, and Grid/Hybrid 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

September 2017, Revision A

Part Number

900-0166-01-01 Rev A

Table of Contents

Introduction ...................................................................................................... 5

Audience ......................................................................................................................................... 5

Symbols Used ................................................................................................................................. 5

General Safety ................................................................................................................................ 5

Welcome to OutBack Power Technologies ..................................................................................... 6

Models ............................................................................................................................................ 7

Inverter Model Names ................................................................................................................................ 7

Components and Accessories .................................................................................................................... 7

Planning ........................................................................................................... 9

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

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

Renewable Energy ........................................................................................................................ 11

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

Generator ...................................................................................................................................... 14

Generator Sizing ....................................................................................................................................... 14

Three-Phase Source ..................................................................................................................... 14

Installation ...................................................................................................... 15

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

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

Mounting ....................................................................................................................................... 15

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

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

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

Grounding ................................................................................................................................................. 18

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

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

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

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

Accessory Wiring ...................................................................................................................................... 26

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

Generator Control ..................................................................................................................................... 28

AC Configurations ......................................................................................................................... 30

Single-Inverter .......................................................................................................................................... 30

Multiple-Inverter AC Installations (Stacking) ............................................................................................ 31

Stacking Configurations ........................................................................................................................... 33

Commissioning............................................................................................... 45

Functional Test ............................................................................................................................. 45

Pre-startup Procedures ............................................................................................................................ 45

Startup ...................................................................................................................................................... 45

Powering Down ........................................................................................................................................ 47

Adding New Devices ................................................................................................................................ 47

Operation ...................................................................................................................................... 47

Firmware Updates .................................................................................................................................... 48

.GIP File Installation for Grid Support ....................................................................................................... 48

Preventative Maintenance ............................................................................................................ 50

Definitions ..................................................................................................................................... 50

Index .............................................................................................................. 53

900-0166-01-01 Rev A 3

Table of Contents

List of Tables

Table 1 Models ............................................................................................................................. 7

Table 2 Components and Accessories ........................................................................................ 7

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 ................................................................................................... 50

List of Figures

Figure 1 FXR Series Inverter/Charger ........................................................................................... 6

Figure 2 Components .................................................................................................................... 8

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 ................................................................................................. 26

Figure 17 AUX Connections for Vent Fan (Example) .................................................................... 27

Figure 18 AUX Connections for Diversion (Example) ................................................................... 27

Figure 19 Two-Wire Generator Start (Example) ............................................................................ 28

Figure 20 Three-Wire Generator Start (Example) ......................................................................... 29

Figure 21 Single-Inverter Wiring .................................................................................................... 30

Figure 22 OutBack Communications Manager and System Display ............................................. 31

Figure 23 Example of Series Stacking Arrangement ..................................................................... 33

Figure 24 Series Wiring (Two Inverters) ........................................................................................ 34

Figure 25 Example of Parallel Stacking Arrangement (Three Inverters) ....................................... 35

Figure 26 Parallel Wiring (Four Inverters) ..................................................................................... 36

Figure 27 Example of Series/Parallel Stacking Arrangement (Four Inverters) .............................. 37

Figure 28 Series/Parallel Wiring .................................................................................................... 38

Figure 29 Example of Three-Phase Stacking Arrangement (Three Inverters) .............................. 39

Figure 30 Example of Three-Phase Stacking Arrangement (Nine Inverters) ................................ 39

Figure 31 Three-Phase Wiring (Three Inverters) ........................................................................... 41

Figure 32 Power Save Levels and Loads ...................................................................................... 42

Figure 33 Power Save Priority (Parallel) ....................................................................................... 44

Figure 34 Power Save Priority (Split-Phase) ................................................................................. 44

Figure 35 AC Terminals ................................................................................................................ 46

Figure 36 Grid Support Screens .................................................................................................... 49

4 900-0166-01-01 Rev A

Introduction

Audience

This book provides instructions for the physical installation and wiring of this product. These instructions are for use by qualified personnel who meet all local and governmental code requirements for licensing and training for the installation of electrical power systems with AC and DC voltage up to 600 volts. This product is only serviceable by qualified personnel.

Symbols Used

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 FXR Series Inverter/Charger Operator’s Manual. Another common reference is the system display manual.

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.

NOTE:

This type of notation indicates useful information. This symbol is not always used.

General Safety

900-0166-01-01 Rev A

WARNING: Limitations on Use

This equipment is NOT intended for use with life support equipment or other medical equipment or devices.

WARNING: Reduced Protection

If this product is used in a manner not specified by FXR product literature, the product’s internal safety protection may be impaired.

CAUTION: Equipment Damage

Only use components or accessories recommended or sold by OutBack Power Technologies or its authorized agents.

Introduction

Welcome to OutBack Power Technologies

Thank you for purchasing the OutBack FXR Series Inverter/Charger. This product offers a complete power conversion system between batteries and AC power. It can provide backup power, sell power back to the utility grid, or provide complete stand-alone off-grid service.

12-, 24-, and 48-volt models



Output power from 2.0 kVA to 3.6 kVA



Designed to be integrated as part of an OutBack Grid/Hybrid™



system using FLEXware™ components

Battery-to-AC inverting with single-phase adjustable



output for such standards as 120 Vac, 100 Vac, or 127 Vac (at 60 or 50 Hz)

AC-to-battery charging (FXR 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™ class of System Display and Controller products, or the AXS Port™ SunSpec



Modbus Interface (sold separately) for user interface as part of a Grid/Hybrid system

~ MATE3s system display is required for grid support functionality; requires revision 1.001.000

or greater

Supports the OPTICS RE™ online tool



for a cloud-based remote monitoring and control application

~ Requires MATE3-class device or 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 series, parallel, series/parallel, and three-phase configurations

Listed by ETL to UL 1741 (2



Edition with supplement SA) and CSA 22.2

Figure 1 FXR Series Inverter/Charger

NOTE

This product has a settable AC output range. In this manual, many references to the output refer to the entire range. However, some references are made to 120 Vac or 60 Hz. These are intended as examples only.

Outback Power Technologies Intuitive Control System for Renewable Energy

900-0166-01-01 Rev A

Introduction

Models

Vented FXR (VFXR) models have an internal fan and use outside air for cooling. On average, VFXR models have higher power ratings than FXR models due to their greater cooling capabilities.

Sealed FXR models have an internal fan, but do not use outside air for cooling. To compensate, sealed models are also equipped with the OutBack Turbo Fan assembly, using external air to remove heat from the chassis. (Vented FXR models are not equipped with the Turbo Fan and cannot use it.)

IMPORTANT:

All models, sealed or vented, must be installed indoors.

Table 1 Models

Model Type Power Battery Application

FXR2012A Sealed 2.0 kVA 12 Vdc Off-grid, backup

VFXR2812A Vented 2.8 kVA 12 Vdc Off-grid, backup

FXR2524A Sealed 2.5 kVA 24 Vdc Off-grid, backup, grid-interactive

VFXR3524A Vented 3.5 kVA 24 Vdc Off-grid, backup, grid-interactive

FXR3048A Sealed 3.0 kVA 48 Vdc Off-grid, backup, grid-interactive

VFXR3648A Vented 3.6 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 “VFXR3648A”. 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 power of that model. For example, “FXR2012A” is 2000 watts.



The second pair of digits shows the inverter’s nominal DC voltage. For example, “FXR2524A” is 24 volts.



The model number is followed by “A”. This designates the inverter’s output as nominally 120 Vac (used



in North America, Latin America, Asia, and other regions).

Components and Accessories

Table 2 Components and Accessories

Components Included Accessories Included

Battery Terminal Cover, red FXR Series Inverter/Charger Quick Start Guide

Battery Terminal Cover, black “WARNING ELECTRICAL SHOCK” sticker

AC Plate Silicone Grease Packet

DC Cover (DCC) or Turbo Fan

Remote Temperature Sensor (RTS)

900-0166-01-01 Rev A

Introduction

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.

AC Plate

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 Turbo Fan.

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.

Figure 2 Components

900-0166-01-01 Rev A

Planning

Applications

OutBack inverter/chargers are designed to use a battery bank to store energy. They work together with power from the utility grid or from renewable energy sources, such as photovoltaic (PV) modules, wind turbines, and other renewable sources. These sources charge the battery, which is used by the inverter.

The FXR inverter’s settings can be changed to accommodate many applications. These include off-grid, backup, and grid-interactive applications.

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.

This product includes grid support functionality according to UL1741 SA. See the

Manual

for more information. Contact the utility company for any specific installation requirements.

Utility Grid

AC IN*

AC Generator

AC OUT

AC IN*

Battery

Charging

AC or PV

Operator’s

PV Array

Charge

Controlle

DC IN

PV Harvest

Loads

AC OUT

*Two sources utilizing an AC selector switch on one input

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

900-0166-01-01 Rev A

DC OUT

Load

Support

Figure 3 Applications (Example)

Grid Tied

mode available and active.

Planning

Input Modes

The FXR inverter has many modes of operation. See the

Manual

for additional information on these modes, including reasons and considerations for using

FXR Series Inverter/Charger Operator’s

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



performance and waveform irregularities than other modes. The inverter can use generator power even when the generator is substandard.

Support



of current available from the source is limited due to size, wiring, or other reasons. If large loads need to be run, the FXR inverter augments (supports) the AC source. The inverter uses battery power and additional sources to ensure that the loads receive the power they demand.

Grid Tied



charged and protected loads are serve, the inverter will export power to the utility grid. Grid support functionality is available in this mode.

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

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.

: This mode enables the battery charging function to tolerate a wider range of generator

: This mode is intended for systems using utility grid or a generator. In some cases the amount

: This mode is intended for grid-interactive systems that are net metered. Once the battery is

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

Backup



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



of renewable energy. It behaves like an off-grid system using the utility grid as a backup generator. The system will use 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.

GridZero



of 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. Grid support functionality is available in this mode.

See the

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

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

FXR Series Inverter/Charger Operator’s Manual

for additional information on these modes,

including the reasons and considerations for using each mode.

Programming

Selection of the input modes and all other inverter programming is performed using a system display such as the MATE3s. This product can customize a wide range of parameters.

10 900-0166-01-01 Rev A

Renewable Energy

The FXR inverter cannot connect directly to PV, wind turbines, or other unregulated DC sources. The batteries are the inverter’s primary source of power.

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

Planning

Battery Bank

When planning a battery bank, consider the following:

 Cables

length will determine the placement of the battery bank. Local codes or regulations may apply and may take priority over OutBack recommendations.

 Battery Type

The default inverter/charger settings assume a deep-cycle stationary lead-acid battery, such as OutBack’s EnergyCell RE or NC series batteries. The charging configuration is highly customizable so that lithium-ion and other advanced chemistry charging cycles can be accommodated. Consult the documentation for the specific batteries used in the system to ensure that the settings are appropriate.

 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

and is 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

: The FXR inverter/charger uses a three-stage charge cycle.

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

: A vented battery enclosure may be required by electric code

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 flammable and 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.)

900-0166-01-01 Rev A

Planning

 Bank Size:

Battery bank capacity is measured in amp-hours. Determine the required bank

specifications as accurately as possible, beginning with the items below. This avoids underperformance or wasted capacity.

These ten items are obtainable in different places, summarized in Table 3. Some of the information is specific to the site or application. Some can be obtained from the battery manufacturer. Information on OutBack products is available from OutBack Power Technologies or its dealers.

A. Size of load:

B. Daily hours of use:

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

C. Days of autonomy:

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

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

F. Inverter efficiency: FXR specifications list “Typical

Any losses are essentially amp-hour capacity that the system cannot use. The battery bank size can be increased to account for losses.

Efficiency” to help estimate operating loss.

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 ampere-hours (amp-hours or Ah), is not usually a fixed number. It is specified based on the rate of discharge. For example, the OutBack EnergyCell 200RE is rated at 128.4 Ah when discharged at the 4-hour rate (to terminal voltage 1.85 Vpc). This is a high rate of discharge that would hypothetically drain the battery in 4 hours. The same battery is rated at 170 Ah when used at the 20-hour rate.

In general, use the 8-hour capacity or less. The larger the load, the more severe the discharge. In these cases conservative values with faster discharge times from the table (for

Battery Bank Elements

Item Source of information

. Load Size

. Daily Hours

. Days of Autonomy

. Application

. Conductor Efficiency

. Inverter Efficiency

. System Vdc

. Battery Vdc

Capacity Ah

Example:

Model

200RE 82.0 120.0 119.1 128.4 148.8 170.0

220GH 127.3 151.4 162.9 169.6 190.8 206.0

. Maximum DoD

Table 3

Site-specific

Inverter manufacturer

Battery manufacturer

Discharge in Hours

1 2 3 4 8 20

Battery manufacturer

example, the 2- or 3-hour capacity) are better.

To choose accurately, the best method is to divide each Ah figure by the discharge in hours. (An example from Table 3 for the OutBack 200RE would be 119.1 ÷ 3 hours = 39.7 Adc.) If the number is equal or greater than the load size (in DC amperes), that column can be used as the capacity.

NOTES:

~ The battery’s selected rated capacity may have little to do with the actual hours of use; this figure

simply reflects the rate of discharge.

~ Use battery specifications for terminal voltage 1.85 Vpc whenever possible.

~ 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. DoD is usually described as a percentage, although it is shown as a decimal in calculations.

12 900-0166-01-01 Rev A

Planning

To Calculate Minimum Battery Bank Size (refer to previous page for letter designations):

1. The load size, item A, is measured in watts. Compensate this figure for efficiency loss. Multiply the

conductor efficiency by the inverter efficiency (E x F). (These items are represented as percentages, but may be displayed as decimals for calculation.) Divide item A by the result.

2. Convert the compensated load into amperes (Adc). Divide the step 1 result by the system voltage (G).

3. Determine the best battery capacity (I) by dividing each rated capacity by the time in hours (as shown in

Table 3). This is the estimated discharge rate at that battery capacity. The number is usable if the step 2 result (the actual load rate) does not exceed it. Choose the closest (or smaller) rated amp-hour capacity.

4. Determine the daily load consumption in ampere-hours (Ah). Multiply the step 2 result by the daily usage hours (item B).

5. Adjust the total for required days of autonomy (the days the system must operate without recharging) and the maximum DoD. Multiply the step 4 result by C and divide by J.

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

6. Determine the number of parallel battery strings required. Divide the Ah figure from step 5 by the individual battery capacity (I) determined in step 3. Round the result to the next highest whole number.

7. Determine the total number of batteries required. Divide the system voltage by the battery voltage (G ÷ H). Multiply the result by the step 6 result.

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

EXAMPLE #1

. Backup loads: 1.0 kW (1000 W)

. Hours of use: 8

. Days of autonomy: 1

. Grid-interactive system

(FXR3048A inverter)

. Conductor efficiency: 98% (0.98)

. Inverter efficiency: 93% (0.93)

. System voltage: 48 Vdc

. Batteries: OutBack EnergyCell

220GH (12 Vdc)

. Capacity determined at 8-hour rate: 184.8 Ahr

. Maximum DoD: 80% (0.8)

EXAMPLE #2

. Backup loads: 720 W

. Hours of use: 2.5

. Days of autonomy: 2

. Off-grid system (VFXR3524A inverter)

. Conductor efficiency: 97% (0.97)

. Inverter efficiency: 92% (0.9)

. System voltage: 24 Vdc

. Batteries: OutBack EnergyCell

200RE (12 Vdc)

. Capacity determined at 3-hour rate: 119.1 Ahr

. Maximum DoD: 50% (0.5)

900-0166-01-01 Rev A 13

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

2. 1 ÷ G 1097.2 ÷ 48 = 22.9 Adc

3. I = Ah ÷ hours 184.8 ÷ 8 = 23.1 Adc (larger than 22.9; Compare to 2 this means 184.8 Ah is acceptable)

4. 2 × B 22.9 × 8 = 182.9 Ah

5. [4 × C] ÷ J [182.9 × 1] ÷ 0.8 = 228.6 Ah

6. 5 ÷ I 228.6 ÷ 184.8 = 1.24 (rounded to 2)

7. [G ÷ H] × 6 [48 ÷ 12] × 2 strings = 8 batteries

1. A ÷ [E × F] 720 ÷ (0.97 × 0.9) = 824.7 W

2. 1 ÷ G 824.7 ÷ 24 = 34.4 Adc

3. I = Ah ÷ hours 119.1 ÷ 3 = 39.7 Adc (larger than 34.4; Compare to 2 this means 119.1 Ah is acceptable)

4. 2 × B 34.4 × 2.5 = 85.9 Ahr

5. [4 × C] ÷ J [85.9 × 2] ÷ 0.5 = 343.6 Ahr

6. 5 ÷ I 343.6 ÷ 119.1 = 2.9 (rounded to 3)

7. [G ÷ H] × 6 [24 ÷ 12] × 3 strings = 6 batteries

Planning

Generator

FXR inverters can accept power from a single-phase generator that delivers clean AC power in the range



of voltage and frequency specified for that model.

~ Inverters stacked for split-phase output (120/240 Vac) can work with both output lines of a

split-phase generator.

~ Inverters stacked for three-phase output can work with three-phase (120V/208Y) generators.

The inverter/charger can provide a start signal to control an automatic start generator. 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 programmed may include generator size, automatic starting requirements, and potential fluctuations in generator AC voltage.

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. Installations in North America are expected to bond the neutral and ground at the main electrical panel. See page 18 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 expected use.

A conservative estimate assumes that both the loads and charging will be maximized at the same time.



However, this can result in an oversized generator with inefficient operation.

A smaller generator may be used for average loads with the inverter’s



from the batteries during peak loads. The loads can be manually disconnected while charging.

In general, the generator should be sufficiently powerful to handle all necessary load surges.



Support

mode providing support

Other considerations:

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



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. This statement may not apply to inverter-based generators, which typically have more stable voltage and frequency regulation.

If a split-phase 120/240 Vac generator is powering a single-phase 120 Vac inverter system with no other



compensation, it may suffer from balancing issues. The OutBack FW-X240 or PSX-240 balancing transformers may compensate for this condition.

Three-Phase Source

As noted above, FXR inverters stacked for three-phase power can accept three-phase (120V/208Y) sources. In addition, two inverters can accept two phases of a 120V/208Y three-phase source to power a split-phase load panel if necessary. There are several concerns when operating this way.

The inverters must be stacked in three-phase configuration. One must be designated



other as

The inverters will continue to deliver 120V/208Y output. They can power 120 Vac loads, but cannot



power 120/240 Vac loads.

14 900-0166-01-01 Rev A

B Phase Master

. See page 39 for more information.

Master

and the

Installation

Location and Environmental Requirements

FXR and VFXR series inverter/chargers must be located indoors or in a weather-proof enclosure. They are not designed for exposure to water, salt air, or excessive wind-blown dust and debris.

The inverter can often be mounted in any position or orientation. When inverters are installed with an



OutBack FLEXpower system, the system must be installed in the upright orientation due to the requirements of the circuit breakers.

These inverters will perform more efficiently in locations offering plenty of air circulation. The minimum



recommended clearance is 2 inches (5 cm) on all sides of the inverter.

These inverters will operate normally in a range of –4°F to 122°F (–20°C to 50°C). Maximum output will



begin to decline at ambient temperatures above 25°F (77°C).

The allowable temperature range for storage is –40°F to 140°F (–40°C to 60°C).



These 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

The following tools may be required for this installation:

Wrench and socket sets; should include



~ torque and ratchet wrenches

Wire cutters/strippers



Insulated screwdriver set (flat and Phillips)



Long-nose pliers



High-resolution voltmeter



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.



Due to the variance in other mounting methods, OutBack only endorses the use of FLEXware mounting



products. 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 the plate on a flat, solid mounting surface. Ensure the surface is strong enough to handle three



times the total weight of all the components. If using a FLEXware Mounting Plate, avoid large air gaps behind the plate. These can result in louder mechanical noise during heavy inverting or charging.

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 18.) Grounding other chassis may involve metal-to-metal contact, or separate ground wires.

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.

900-0166-01-01 Rev A

Installation

(

Dimensions

Length 16.25” (41 cm)

Width

8.25”

12” (30.5 cm)

21 cm)

with Turbo

13”

Height

with DCC

Height

33 cm)

Figure 4 Dimensions

900-0166-01-01 Rev A

Commissioning

Terminals and Ports

DC TERMINALS

These terminals connect to the battery cables and

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 28 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 prevent malfunction.

These terminals receive wires for a manual

on/off switch to control the inverter.

The jumper alongside these terminals

overrides them and turns the inverter on.

(See page 26 for instructions.) With the

jumper installed, a switch cannot turn the

inverter off, but the system display can turn it

off or on. The system display cannot turn it on

AUX OUTPUT (AUX+/AUX-)

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 to drive a cooling fan or

the Turbo Fan. See page 26 for details.

The functions for the AUX output can be

programmed using the system display.

the DC system.

INVERTER ON/OFF

ON/OFF JUMPER

if the jumper is not installed.

Figure 5 Terminals, Ports, and Features

NOTE

The inverter is given an external

NVERTER ON/OFF

jumper is installed to the

OFF

LED INDICATORS

These indicators display the inverter status and battery voltage.

 The three B

 The green I

 The yellow A

 The red E

See the Operator’s Manual for more information.

command at the same time. Its initial state is Off.

DC and AC GROUND TERMINALS

These terminals connect to a grounding system for both batteries and AC. See page 18 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 26 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.

on DC voltage. They provide a very general idea of battery state.

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

ATTERY LED indicators (green, yellow, and red) are based

NVERTER LED indicator shows if the inverting function is on.

C IN LED indicator shows if an AC source is present.

RROR LED indicator shows either a Warning or an Error.

position during manufacture, but the FXR

900-0166-01-01 Rev A

+ 39 hidden pages

OutBack Power FXR2012A, VFXR2812A, FXR3048A, VFXR3648A, FXR2524A Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual