Outback Power Systems PSX-240 Installation Instructions

PSX-240-Relay

Enclosed Autotransformer

With Auto-Disconnect

Installation Manual

Outback Power PSX-240-Relay User’s Guide

Outback Power PSX-240-Relay User’s Guide

Introduction

Congratulations on your purchase of the PSX-240-Relay
Autotransformer with Auto-Disconnect from OutBack Power
Systems. This booklet contains important safety and user
instructions for the PSX-240-Relay that shall be followed
during its installation and maintenance. Please read the entire
booklet and all cautionary warnings on the PSX-240-Relay
carefully before installing the device.

PLEASE SAVE THESE INSTRUCTIONS!

IMPORTANT SAFETY GUIDELINES

Working with or around electrical components requires care and special
attention during installations. Shock, burns, equipment damage, fire and

even death can result from mishandling or incorrectly installing
electrical equipment. Please be aware of the following precautions:

• Installation must be performed by a licensed installer familiar

with local and national wiring codes. All installations must
comply with these codes as well as codes for structural
installation.

• All of the AC wiring to the circuit breaker terminals and the

neutral bus bar must be torqued according to the torque specs in
the MECHANICAL INSTALLATION section of this manual.

• Wiring to circuit breaker terminals must meet requirements of

the National Electric Code (NEC).

REGISTRATION

Your purchase of an OutBack Power Systems product is an important
investment. Registering your products will help us maintain the standard of
excellence you expect from us in terms of performance, quality and reliability.

Please take a moment to register and provide us with some important
information.

Name: __________________________________________

Address: ________________________________________

City, State, Zip Code, Country:
________________________________________________

Telephone Number: _______________________________

E-Mail: _________________________________________

Sold by: ________________________________________

Installer: ________________________________________

Purchase Date: ___________________________________

Model Number: ___________________________________

Serial Number: ___________________________________

Circle all that apply:

Off-Grid Installation Residential Installation

North America Location Utility Connected Installation

Commercial Installation Other ____________________

Mail to: Attn: Warranty Registration

Outback Power Systems
19009 62
Arlington, WA 98223

nd

Ave. NE

NOTE: The circuit breaker terminals will accept up to 10 AWG
wire. Use copper conductors only with insulation rated for at
least 75˚ C. See the WIRING CONNECTIONS AND TORQUE
SPECS section of this manual for more information.

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Outback Power PSX-240-Relay User’s Guide

Outback Power PSX-240-Relay User’s Guide

• For equipment grounding hook up, see the WIRING

CONNECTIONS AND TORQUE SPECS section in this
manual. This product is intended to be installed as part of a
permanently grounded electrical system per the NEC.

• The equipment ground on the PSX-240-Relay is marked with

this symbol:

GENERAL PRECAUTIONS

•

The PSX-240-Relay is approved for indoor mounting only in the
positions described in the MECHANICAL INSTALLATION
section of this manual.

•

Do not disassemble the PSX-240-Relay beyond the instructions
included in this manual. Refer servicing to a qualified service
center when service or repair is required. Incorrect re-assembly
may result in a risk of electric shock or fire.

To reduce risk of electric shock, disconnect all wiring before

•

attempting any maintenance or cleaning.

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Outback Power PSX-240-Relay User’s Guide

Basic Description of the PSX-240-Relay

The PSX-240-Relay has an autotransformer containing, in its raw form,
two sets of windings in a 1:1 ratio. By connecting wire #2 and wire #3
together, the X-240 can transform 120 VAC to 240 VAC and vice-versa.
The X-240 is pre-wired within the enclosure for user convenience.

1

Figure 1

( denotes start of winding)

Two 25 Amp AC circuit breakers and a neutral bus bar provide the
input/output connection points for the X-240. The PSX-240-Relay
contains a DPDT relay and three feet of wiring to control this relay. This
relay will disconnect the X-240 from the system when an AC input
source connects to the system.

Figure 2 on the next page shows the diagram for the internal wiring of
the PSX-240-Relay.

3

WARRANTY

OutBack Power Systems

Two Year Limited Warranty

OutBack Power Systems Inc. warrants that the products it manufactures will be free from defects in
materials and workmanship for a period of two (2) years subject to the conditions set forth below.

The limited warranty is extended to the original user and is transferable. The limited warranty term
begins on the date of invoice to the original user of the product. The limited warranty does not apply to
any product or part thereof damaged by a) alteration or disassembly, b) accident or abuse, c) corrosion,
d) lightning, e) reverse polarity, f) repair or service provided by an unauthorized repair facility, g)
operation or installation contrary to instructions pertaining to the product.

OutBack Power Systems’ liability for any defective product or any part thereof shall be limited to the
repair or replacement of the product, at OutBack Power Systems’ discretion. OutBack Power Systems
does not warrant or guarantee the workmanship performed by any person or firm installing its products.

THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO
HAVE OTHER RIGHTS THAT VARY FROM STATE TO STATE (OR JURISDICTION TO
JURISDICTION). OUTBACK POWER SYSTEMS’ RESPONSIBILITY FOR MALFUNCTIONS
AND DEFECTS IN HARDWARE IS LIMITED TO REPAIR AND REPLACEMENT AS SET FORTH
IN THIS LIMITED WARRANTY STATEMENT. ALL EXPRESS AND IMPLIED WARRANTIES
FOR THE PRODUCT, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF
AND CONDITIONS OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE,
ARE LIMITED IN DURATION TO THE LIMITED WARRANTY PERIOD SET FORTH ABOVE
AND NO WARRANTIES, WHETHER EXPRESS OR IMPLIED, WILL APPLY AFTER SUCH
PERIOD. SOME STATES (OR JURISDICTIONS) DO NOT ALLOW LIMITATIONS ON HOW
LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO
YOU.

OUTBACK POWER SYSTEMS DOES NOT ACCEPT LIABILITY BEYOND THE REMEDIES SET
FORTH IN THIS LIMITED WARRANTY STATEMENT OR LIABILITY FOR INCIDENTAL OR
CONSEQUENTIAL DAMAGES, INCLUDING WITHOUT LIMITATION ANY LIABILITY FOR
PRODUCTS NOT BEING AVAILABLE FOR USE. SOME STATES (OR JURISDICTIONS) DO
NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL
DAMAGES, SO THE ABOVE EXCLUSION OR LIMITATION MAY NOT APPLY TO YOU.

During the two year period beginning on the invoice date, OutBack Power Systems will repair or replace
products covered under this limited warranty that are returned to OutBack Power Systems’ facility or to
an OutBack Power Systems authorized repair facility, or that are repaired on site by an OutBack Power
Systems authorized repair technician. To request limited warranty service, you must contact OutBack
Power Systems at 360-435-6030 within the limited warranty period. If limited warranty service is
required, OutBack Power Systems will issue a Return Material Authorization (RMA) Number. Mark the
outside of the package with the RMA number and include a copy of the purchase invoice in the package.
You must ship the products back to OutBack Power Systems in their original or equivalent packaging,
prepay shipping charges, and insure the shipment or accept the risk of loss or damage during shipment.
OutBack Power Systems will ship the repaired or replacement products to you freight prepaid if you use
an address in the continental United States, where applicable. Shipments to other locations will be made
freight collect.

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Outback Power PSX-240-Relay User’s Guide

C

Switc

Outback Power PSX-240-Relay User’s Guide

PSX-240-Relay Diagram

Neutral

AC Hot L1

AC Hot L2 Aux +/-

Neutral Bus

25A
Breakers

Fan

Relay

Relay

ontacts

X-240

Thermal

h

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Figure 2

Outback Power PSX-240-Relay User’s Guide

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A

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Outback Power PSX-240-Relay User’s Guide

Configuration

The PSX-240-Relay must be connected to the AC output circuit of the
FX system and is intended for installations that include the following:

• An installation with two or more OutBack FX Series

Inverter/Chargers wired to produce split phase 120/240 VAC.

• The FX system is programmed using “OutBack” Stacking (not

“Classic” Stacking).

• AC input source to the FX system is either two in-phase 120

VAC circuits, 120/240 VAC split phase, or two phases of a
120/208 VAC wye-connected 3-phase source.

If your system does not conform to the configuration conditions
described above, please contact your dealer.

Note:

• The proper connections must be made in the field. This

information is located in the MECHANICAL INSTRUCTIONS
section of this manual.

• The FX system must be programmed in order for the PSX-240-

Relay to disconnect properly. This information is located in the
PROGRAMMING INSTRUCTIONS section of this manual.

Step Down/Balancing Configuration

The step down/balancing configuration for the PSX-240-Relay allows
large 120 VAC loads on one leg to be powered by FXs on opposite legs
(step down). It also allows each FX to produce the same amount of
power even though the L1 and L2 legs may have different power needs
(balancing).

When an AC input is not present, 240 VAC between legs L1 and L2 is
applied to the 25A breakers of the PSX-240-Relay. 120VAC is then
available from either L1 or L2 to system neutral.

¨ ¨ ¨

MAIN---------------------------

3:43:44P

SUM STATUS SETUP ADV

DV/SETTINGS/WARNING
changes made could
adversely effect system
performance

DV/PASSWORD

enter the password

132

ENTER INC DEC EXIT

| | | z z z z z | z | |

¨ ¨ ¨

DV/PASSWORD

enter the password

141

ENTER INC DEC EXIT

DV--------------------------­ choose product

FX MX MATE MAIN

DV/FX/PAGE 1

choose category:

ADV INV CHGR PG2

z | | | z | | | | | | z

¨ ¨ ¨

DV/FX/PAGE 2

choose category:

PG1 GRID GEN PG3

DV/FX/PAGE 3
choose category:

PG2 AUX STACK PG4

DV/FX/AUX----------------P00
aux output OFF
control

DOWN INC DEC PORT

| | | z | z | | | | | z

¨ ¨ ¨

DV/FX/AUX----------------P00
aux output AUTO
control

DOWN INC DEC PORT

DV/FX/AUX----------------P00
aux output AC Drop
function

DOWN INC DEC PORT

DV/FX/AUX----------------

aux output
setup completed

TOP ADV MAIN

z z z | z z z | | z | |

¨ ¨ ¨

ADV/FX/AUX--------------P00

DV/FX/AUX----------------P00

aux output AUTO

aux output AUTO

control

control

DOWN INC DEC PORT

DOWN INC DEC PORT

DV/FX/AUX----------------P00
aux output ON
control

DOWN INC DEC PORT

| z | | | | z | | | | |

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Outback Power PSX-240-Relay User’s Guide

• If you don’t hear a click, press <DEC> until the screen reads

“OFF” and then <INC> until the screen reads “ON” and listen
again for the click. If a click is heard, press <DEC> until the
screen shows “AUTO” mode.

• If still no click is heard, repeat all programming instructions.

Contact your dealer if the programming is unsuccessful.

With a successfully installed and programmed PSX-240-Relay, you can
now enjoy the worry-free performance of your OutBack Power System.

Disconnect Configuration

When an AC input is present, the PSX-240-Relay will disconnect from
the system when that AC input connects to the FX system. This ensures
the PSX-240-Relay breakers do not trip if the AC input is not a 120/240
VAC power source.

A 12 VDC signal from the Auxiliary output of the one of the FXs in the
system causes a relay to open at the precise time the AC input connects,
effectively disconnecting the X-240 from the system.

Mechanical Installation

Please review the IMPORTANT SAFETY GUIDELINES and
GENERAL PRECAUTIONS sections at the front of this manual

before installing the PSX-240-Relay!

The PSX-240-Relay may be installed on a vertical or horizontal surface
utilizing the four mounting holes on the base of the unit. The holes are
sized to #10 screws. Be sure to use the appropriate style and grade of
fastener for your particular application. The PSX-240-Relay can only be
mounted in three positions.

Vertical Surface: The PSX-240-Relay breakers must be positioned
either to the right or to the left of the PSX-240-Relay enclosure.

Horizontal Surface: The PSX-240-Relay breakers must be facing
upward.

Wiring Connections and Torque Specs

The PSX-240-Relay is not supplied with the AC input wiring. This wire
must be obtained elsewhere. The wires should be stranded, rated for the
appropriate weather conditions, rated at least 75° Celsius, and be sized
large enough for a 25A breaker to protect them per the NEC. There are
multiple knock-outs on the PSX-240-Relay enclosure for routing these
wires.

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Outback Power PSX-240-Relay User’s Guide

Outback Power PSX-240-Relay User’s Guide

It is necessary to connect an AC neutral wire to the “AC Neutral” bus bar
within the PSX-240-Relay. The torque for the screws in the neutral bus
bar varies depending on the hole in which the wiring is installed. The
larger of the two hole sizes in the neutral bar are the MAIN HOLES; the
smaller holes are the TAP HOLES. The wire size range and torque specs
are shown in the table below. Lower torque may be required when
utilizing stranded wire.

Main Holes Tap Holes

1/0-14 AWG: 50 in-lbs 6-14 AWG: 40 in-lbs

It is also necessary to connect an AC Hot L1 wire originating at the
system’s “AC Hot Out L1” bus to the left most breaker (assuming the
breakers are positioned on the right side of the enclosure) and an AC Hot
L2 wire originating at the system’s “AC Hot Out L2” bus to the right
most breaker within the PSX-240 Relay.

25A Breakers

10-14 AWG: 20 in-lbs

A ground lug is positioned near the breakers within the PSX-240-Relay.
The ground wire making connection to this ground lug should be the
same gauge as the neutral wire entering the PSX-240-Relay.

Programming Instructions

The following FX programming is necessary to use the auto-disconnect
feature of the PSX-240-Relay. Before programming, turn off the AC
input breakers. Also make sure that the control wires from the PSX-240­Relay are connected correctly to the Auxiliary + (AUX+) and Auxiliary –
(AUX-) terminals of the FX that you intend to control the PSX-240­Relay.
Here are the programming steps (MATE screens shown on following
page):

• From the MATE’s “Main” screen, press the <ADV> soft key,

key in the password, and then press the <FX> soft key.

• Press the <PG2> and <PG3> soft keys on the next two screens

respectively.

• Press the <AUX> soft key on the ADV/FX/PAGE3 screen.

• If the FX intended to control the PSX-240-Relay is connected to

a HUB, press the <PORT> soft key repeatedly until its port
designation appears in the upper right corner of the screen.

• On the “Aux Output Control” screen adjust the value to “Auto”

by using the <INC> and <DEC> soft keys.

• Press the <DOWN> soft key to get to the ADV/FX/AUX “Aux

Output Function” screen.

Ground Lug

2-14 AWG: 40 in-lbs

The PSX-240-Relay comes with three feet of 16 AWG SOOW, two­conductor control wiring. This control wiring connects to the Auxiliary
+ (AUX+) and Auxiliary – (AUX-) terminals of one of the FXs in the
system. To locate these terminals, refer to the FX manual. The polarity
of the auxiliary output connections does not matter, they will work either
way.

There is some required MATE programming for proper operation of the
PSX-240-Relay. This information can be found in the next section of
this manual.

• Adjust the value on this screen to “AC Drop” by using the

<INC> and <DEC> soft keys.

• Press < DOWN> repeatedly until you reach the “End of

Auxiliary Menu” screen.

• Press the <TOP> soft key to return to the “Aux Output Control”

screen.

• Someone needs to be very close to the PSX-240-Relay to listen

for a click ensuring the FX is correctly programmed and the
PSX-240-Relay works properly. Press the <ON> soft key and
listen for the relay in the PSX-240-Relay to click. Once you
hear the click, press the <DEC> soft key to return the value to
“AUTO”.

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