Outback Power Systems VFX User Manual
INTERNATIONAL
FX/VFX SERIES
INVERTER/CHARGER
FX2012ET FX 2024ET FX2348ET
VFX2612E VFX3024E VFX3048E
Installation Manual
Mounting and Installation
Warranty Introduction
Dear OutBack Customer,
Thank you for your purchase of OutBack products. We make every e ort to assure our power
conversion products will give you long and reliable service for your renewable energy system.
As with any manufactured device, repairs might be needed due to damage, inappropriate use, or
unintentional defect. Please note the following guidelines regarding warranty service of OutBack
products:
• Any and all warranty repairs must conform to the terms of the warranty.
• All OutBack equipment must be installed according to their accompanying instructions and manuals
with speci ed over-current protection in order to maintain their warranties.
• The customer must return the component(s) to OutBack, securely packaged, properly addressed,
and shipping paid. We recommend insuring your package when shipping. Packages that are not
securely packaged can sustain additional damage not covered by the warranty or can void warranty
repairs.
• There is no allowance or reimbursement for an installer’s or user’s labor or travel time required to
disconnect, service, or reinstall the damaged component(s).
• OutBack will ship the repaired or replacement component(s) prepaid to addresses in the continental
United States, where applicable. Shipments outside the U.S. will be sent freight collect.
• In the event of a product malfunction, OutBack cannot bear any responsibility for consequential
losses, expenses, or damage to other components.
• Please read the full warranty at the end of this manual for more information.
About OutBack Power Systems
OutBack Power Systems is a leader in advanced energy conversion technology. Our products include
true sine wave inverter/chargers, maximum power point charge controllers, system communication
components, as well as breaker panels, breakers, accessories, and assembled systems.
Notice of Copyright
International FX and VFX Series Inverter/Charger Installation Manual REV B © 2008 All rights reserved.
Disclaimer
UNLESS SPECIFICALLY AGREED TO IN WRITING, OUTBACK POWER SYSTEMS:
(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.
Contact Information
OutBack Power Systems
19009 62nd Ave. NE • Arlington, WA 98223
Phone (360) 435-6030 • Fax (360) 435-6019
www.outbackpower.com
TABLE OF CONTENTS
EU Declaration of Conformity ......................................................................................................................................................2
Welcome to the OutBack Power Systems FX Series Inverter/Charger System .............................................3
FX Series Inverter/Charger Models ...........................................................................................................................................3
Safety ...........................................................................................................................................................................................................4
System Protection.................................................................................................................................................... ...........................6
DC Wiring Origination....................................................................................................................................... ...............................6
AC Wiring Origination........................................................................................................................................ ...............................7
AC Wiring Compartment Board................................................................................................................... ..............................7
Low Voltage Terminals ......................................................................................................................................................................8
AC and DC Grounding Requirements............................................................................................. .......................................9
FX Parts and Accessories................................................................................................................... ...........................................10
Mounting........................................................................................................................................................... ....................................11
Wire Connections........................................................................................................................... ..................................................12
12V Battery Wiring Samples .......................................................................................................................................................13
AC Wiring Notes ...............................................................................................................................................................................20
Low Voltage Wiring..........................................................................................................................................................................21
Inverter and On/O ................................................................................................................................................. .... ..........21
Auxiliary Output (AUX+ / AUX-)......................................................................................................................... ............22
XCT+ / XCT-................................................................................................................................................................. ...............22
RTS, MATE/HUB Wiring................................................................................................................................................... .... ...........23
Sample Installations.......................................................................................................................................................... ... ...........24
Single FX System.................................................................................................................................................... .................24
Paralleled Dual FX System .................................................................................................................................................25
Paralleled Quad FX System ...............................................................................................................................................26
3-Phase System............................................................................................................................................. ...........................26
Generator Interfaces............................................................................................................................................ ..... ......................29
Installation Check List..................................................................................................................................... ..... ..........................30
Appendix............................................................................................................................................................ ............................31-33
Voltage, Current, and Frequency Ranges....................................................................................................................34-36
Maximum Overcurrent Protection Ampacity..................................................................................................................37
Wire Sizes............................................................................................................................................................ ............................37-38
Maintenance .......................................................................................................................................................................................38
FX Default Values ..............................................................................................................................................................................39
Warranty............................................................................................................................................................... ..................................40
Product Registration..................................................................................................................................... ..................................42
1
EU DECLARATION OF CONFORMITY
According to ISO / IEC Guide 22 and EN45014
Product Type: Inverter/Charger
Product Model Numbers:
• FX2012ET • FX2024ET • FX2348ET • VFX2612E • VFX3024E • VFX3048E
The OutBack Power Systems FX Series Inverter/Chargers export (“E”) models comply with the following
EU directives when installed in o -grid applications only:
• EU Declaration of Conformity regarding Electromagnetic Compatibility 89/336/EEC (“Council
Directive of 3 May 1989”)
• Low Voltage Directive 73/23/EEC (“Council Directive of 19 February 1973”).
The compliance of the above-mentioned products with the directive and the following essential
requirements is hereby con rmed:
Emissions Immunity Safety
EN 61000-6-3 (2001) EN 61000-6-1 (2001) EN 61000-3-2 (2000) EN 61000-3-3 (1995)
These inverter/chargers are not to be connected to the mains under any circumstances.
The AC-IN connection on each E model inverter/charger is only approved for connection to an AC
generator.
All associated technical les are located in the Engineering Department at OutBack Power Systems, Inc.,
Arlington, Washington, USA.
As the manufacturer, we declare under our sole responsibility that the above-mentioned products
comply with the above-named directives.
19009 62nd Ave. NE
Arlington, WA. 98223 USA
(360) 435-6030
2
Welcome to the OutBack Power Systems FX Series Inverter/Charger System
The FX Series Inverter/Charger o ers a complete power conversion system—DC to AC, battery
charging, and an AC transfer relay—and can be used as a stand-alone or back-up application. It is
designed for indoor or enclosed locations.
OutBack Power Systems does everything possible to assure the components you purchase will
function properly and safely when installed as instructed according to local and national electrical
codes. Please read all of the following instructions and the instructions that come with any OutBack
components that make up your power system. Further instructions on individual FX set-ups as well as
system assemblies are included with the FLEXware manuals.
• The Export FX is CE tested (see “EU Declaration of Conformity” on the previous page).
The International FX and VFX Series Inverter/Charger Installation Manual covers the following information:
• Safety
• FX parts, standard and optional
• Initial inspection of the component
• Preparing the mounting surface
• Fastening the FX to the mounting surface
• General electrical information
E Series FX Series Inverter/Charger Models
Sealed Units (designed for harsher environments, but still require enclosed protection)
•
FX2012ET (12 VDC/2000 VA) 230VAC/50 Hz
•
FX2024ET (24 VDC/2000 VA) 230VAC/50 Hz
•
FX2348ET (48 VDC/2300 VA) 230VAC/50 Hz
Vented Units (designed for more protected environments)
•
VFX2612E (12 VDC/2600 VA) 230VAC/50 Hz
•
VFX3024E (24 VDC/3000VA) 230VAC/50 Hz
VFX3048E (48 VDC/3000VA) 230VAC/50 Hz
•
Each model FX has a single phase output marked with this symbol:
Each inverter puts out a sine wave waveform marked with this symbol:
Parts Included
• One E Series FX Series Inverter/Charger
• One “WARNING ELECTRICAL SHOCK” sticker to place on the exterior of the FX
• One packet of silicone grease to protect CAT 5 cable connections
• One installation manual
• One programming manual
• One Turbo Kit (sealed units)
• One DC Wiring Cover or DCC (vented units)
• DC terminal covers (one red and one black)
• AC Wire Compartment Plate
3
READ FIRST!
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
Read all instructions and cautionary markings on the FX, the batteries and all appropriate sections of
this installation and user manual as well as other component manuals before using the system.
Be cautious around electricity, electrical components, and batteries. Shocks, burns, injury, and even
death can occur if an installer comes in contact with electricity.
Install all components and wiring according to national and local electrical and building codes. This
includes:
• Submitting a plan to the local building department
• Passing inspection
• Requiring a licensed electrician to do the work when mandated
OutBack Power Systems cannot be responsible for system failure, damages, or injury resulting from
improper installation of their products.
Use only the recommended DC and AC wire sizes or greater. Be sure all wires are in good condition.
Install the FX in a dry location, preferably indoors.
• Install the FX in a shaded area out of direct
sunlight for best operation.
• For installations where the FX may be exposed to water spray, a sealed FX 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 FX’s base. There
is a drainage system on the base of the FX to dispel condensation. If submerged, water can enter this
drain and cause failure.
• The Vented FX (VFX) must be installed in a weather-proof enclosure or enclosed area.
It is not designed for exposure to water or excessive wind-blown dust and debris.
INITIAL INSPECTION
Your FX is stoutly packaged for secure shipping. Please inspect the packaging and component for
damage prior to installation. Retain this packaging in the unlikely event your FX is ever returned to
OutBack for servicing (see page 39).
4
WARNING: WORKING NEAR LEAD ACID BATTERIES CAN BE DANGEROUS. BATTERIES
GENERATE EXPLOSIVE GASES DURING NORMAL OPERATION.
Design the battery enclosure to prevent accumulation and concentration of hydrogen gas in “pockets”
at the top of the enclosure. Vent the battery compartment from the highest point to the outside. A
sloped lid can also be used to direct the ow of hydrogen to the vent opening.
CAUTION
To reduce risk of injury, charge only deep-cycle lead acid, lead antimony, lead calcium, gel cell or
absorbed glass mat type rechargeable batteries. Other types of batteries may burst, causing personal
injury and damage. Never charge a frozen battery.
PERSONAL PRECAUTIONS
• Someone should be within range of your voice to come to your aid if needed.
• Keep plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.
• Wear complete eye protection. Avoid touching eyes while working near batteries. Wash your hands
with soap and warm water when done.
• If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters an
eye, ood the eye with cool running water at once for at least 15 minutes and get medical attention
immediately following.
• Baking soda neutralizes lead acid battery electrolyte. Keep a supply on hand in the area of the
batteries.
• NEVER smoke or allow a spark or ame in vicinity of a battery or generator.
• Be extra cautious to reduce the risk of dropping a metal tool onto batteries. It could short-circuit the
batteries or other electrical parts which can result in re or explosion.
• Remove personal metal items such as rings, bracelets, necklaces, and watches when working with
a battery or other electrical current. A battery can produce a short circuit current high enough to
weld a ring or the like to metal, causing severe burns.
5
SYSTEM PROTECTION
Electrical systems are designed to protect you, the wires, the components, and the devices served by
the system.
Each FX must be part of a permanently grounded
electrical system (see page 9). Grounding protects
people and equipment from electrical shock.
Grounding must be done according to local and
national electrical codes.
OutBack circuit breakers—rated at 100% duty
cycle— protect wiring by limiting the amount
of current entering a system. All wired electrical
systems require circuit breakers or fuses for
protection.
OutBack o ers both breakers and fuses for overcurrent protection. If they are provided by other
vendors, they must be properly rated.
DC WIRING ORIGINATION
DC brass battery terminals with 8M x 1.00 stainless steel threaded studs
Red terminal=battery positive
Black terminal = battery negative
Battery terminal covers
6
AC WIRING ORIGINATION
Lexan cover protects AC Wiring
Compartment Board
AC WIRING COMPARTMENT BOARD
AC Wiring Board
AC HOT OUT
AC NEUTRAL OUT
CHASSIS GROUND/PE
CHASSIS GROUND/PE
AC NEUTRAL IN
AC HOT IN
AUX+
ON/OFF
INVERTER ON/OFF
INVERTER
BATTERY TEMP
MATE/HUB
FULLOKLOW
BATTERY
AUX-
XCT+
XCT-
STATUS
INVERTER
AC IN
ERROR
AC Terminal Block secures AC
connections to the FX using set screws
AC HOT (PHASE) OUT supplies power to the
loads.
AC NEUTRAL OUT acts as neutral leg for loads
supplied by the FX and is common with the AC
NEUTRAL IN.
CHASSIS GROUND connections are common
and act as grounds for both the incoming and
outgoing AC circuits.
AC NEUTRAL IN acts as the neutral leg for AC
power supplied by a generator to the FX and is
common with the AC NEUTRAL OUT.
AC HOT (PHASE) IN connects incoming AC from
the a generator to the FX through an internal AC
transfer relay. This AC is used to run loads and
recharge batteries.
NOTE: 16.0 mm
2
(6 AWG) is the largest wire
size the AC Wiring Compartment Board can
accommodate.
7
LOW VOLTAGE TERMINALS
CHASSIS GROUND/PE
CHASSIS GROUND/PE
Control Terminal
Wiring Block
Jumper
INVERTER ON/OFF
INVERTER ON/OFF:
Allows for manual
switch to control the
FX (default operation
is “ON”); controlled by
the MATE when the
jumper is present.
BATTERY TEMP
AC HOT OUT
AC NEUTRAL OUT
AC NEUTRAL IN
AC HOT IN
AUX+
ON/OFF
INVERTER
MATE/HUB
FULLOKLOW
BATTERY
AUX-
XCT+
XCT-
STATUS
INVERTER
AC IN
ERROR
NOTE: Keep Control
Wiring Terminal Block
screws tight and the
block itself secured tightly
to AC Board. Otherwise,
the FX can malfunction.
The Terminal Block can be
unplugged for easier wire
installation and removal/
reinstallation of the FX.
AUX OUTPUT
(AUX+/AUX-):
at 0.7 amps (8.4 watts)
maximum is available at
these terminals; the AUX’s
default is to drive cooling
fans or the Turbo Fan.
12VDC
XCT+/XCT- are nonoperational terminals (do
not connect).
8
AC AND DC GROUNDING REQUIREMENTS
• Connect only to a grounded, permanent wiring system. Ensure there is only one neutral-ground
connection in the system at any time. Some codes require this connection be made at the main
panel only.
• Some generators have their own neutral ground connection. If a generator is used, its neutral-
ground connection will need to be disengaged for proper system operation.
• For all installations, the negative battery conductor should be bonded to the grounding system at
one (and only one) point in the system.
• OutBack products are not designed for use in a positive grounded system. Please contact OutBack
Technical Support for further information.
The equipment ground on each is marked with this symbol:
Box lug for grounding the FX chassis
9
FX PARTS AND ACCESSORIES
AC CONDUIT PLATE*
• AC conduit connects to the AC
Conduit Plate for installations which
do not utilize an optional ACA.
BATTERY TERMINAL COVERS
• The caps are made of sti plastic with a snap-on
design; remove them carefully using a at-blade
screwdriver inserted into the slots on the sides of
each cover.
• DC conduit may be required for exposed
installations.
• The DCA cover option (see below) allows conduit
connection.
• Always keep the battery terminal covers installed.
DCC (DC COMPARTMENT COVER)
• Covers the DC terminal area and provides
space to mount other components such as a
DC current shunt
• Can be used with or without the DCA)
• This is an optional accessory.
FX-ACA (AC CONDUIT ADAPTER)
• Extends the AC wiring compartment
• Connects to OutBack’s FLEXware enclosures
• Protects and secures exible cable with strain
relief
• Houses the OutBack Surge Protector (FW-SP)
• Knockouts are intended for cables/strain relief
• This is an optional accessory.
TURBO FAN COVER
Included in place of a DCC on sealed FXs
•
DCA (DC CONDUIT ADAPTER)
• Allows the connection of two-inch TSC (Trade
Size Conduit) to the FX
• Connects to OutBack’s FLEXware enclosures
10
13.02” (33.07 CM)
SIDE VIEW
22” (55.99 CM)
8.25” (20.95 CM)
TOP VIEW
Weight is approximately 56 lbs (25.40 kg)
MOUNTING
• The E Series FX Series Inverter/Charger is approved for indoor or enclosed protected mounting only.
• An FX weighs approximately
a sturdy mounting surface capable of supporting its weight. It is easier for two people to install the
FX due to its weight.
• OutBack FXs can be mounted in any position, but they perform better in locations o ering plenty of
air circulation.
56 lbs (25.40 kg)
and must be secured with appropriate fasteners to
• NOTE: If using an OutBack FLEXware Mounting Plate, avoid large air gaps behind the plate which
can result in louder mechanical noise during inverting/charging under heavy loads.
• Due to the variance in other mounting methods, OutBack only endorses the use of FLEXware or
previous versions of its mounting plate for installing the FX and associated system components
using M6 X 20 mm machine screws (stainless steel for FLEXware and self-tapping for older
mounting plates), one per corner. Follow the instruction manual that comes with each mounting
system.
• If mounting the FX on other surfaces such as plywood, wall studs, or masonry, use appropriate
fasteners to support approximately its weight. OutBack cannot be responsible for damage to the FX
if it is attached with inadequate fasteners.
• Install and secure each FX before attaching any wiring.
11
WIRE CONNECTIONS
NOTE: A system’s individual voltage requirements (230 or 3-phase) as well as how each FX is to
function all determine how the FXs are wired. Each FX must be wired to the logical leg or phase of the
system. Each FX must be programmed or “stacked” according to this phase. Please see the International
FX and VFX Series Inverter/Charger Programming Manual before connecting any wires to or from the FX.
AC
Follow these steps to wire the FX to your system:
1. Shut all AC breakers o or remove any fuses before connecting any wiring.
2. Shut o all DC breakers, including the PV breakers.
3. With all power o , run lengths of 6 AWG (16.0 mm
Board AC out terminals and su cient over current protection via an AC circuit breaker whose
ampacity matches or exceeds the maximum AC input current of the FX model used in the system
(see FX product speci cations). The breaker should be installed inside of a metal chassis such as
OutBack’s FLEXware series or an existing panel.
4. With the over current protection connected, run lengths of 6 AWG (13.3 mm
AC Wiring Compartment Board AC IN terminals and the AC input breaker. The breaker should be
installed inside of a metal chassis such as OutBack’s FLEXware series or an existing panel. The AC
input hot conductor must be supplied through an AC branch-rated circuit breaker whose ampacity
matches or exceeds the maximum AC input current of the FX model used in the system (see FX
product speci cations)
2)
wire between the AC Wiring Compartment
2
) wire between the
DC
• Use crimped and sealed copper ring terminal lugs with 5/16” (8 mm) hole or compression-type lug to
connect battery cables to DC terminals. Soldered cable lugs are also acceptable.
• Use recommended cable sizes (see page 36) to reduce losses and ensure high performance of FX (smaller
cables can reduce performance and possibly damage the unit).
• Keep cables together (e.g., using a tie-wrap) as much as possible.
• Ensure cables pass through the same knockout and conduit ttings to allow inductive currents to cancel.
TORQUE REQUIREMENTS
CONNECTION TORQUE IN POUND MEASURES
AC and PV breakers to 22 inch-lbs = 2.5 Nm
DC shunt to 15 foot-lbs = 20.4 Nm
DC battery connections to 10 foot-lbs = 13.6 Nm
FX’s DC Terminals to 10 foot-lbs = 13.6 Nm
FX’s AC Terminals to 30 inch-lbs = 3.38 Nm
12
Table 1 Torque Values for Installation
Battery Wiring Examples
In renewable energy systems, batteries are connected to each other in one of three ways:
• Series (voltage increases, amperage stays the same as a single battery)
• Parallel (voltage stays the same as a single battery, amperage increases)
• Series/Parallel (both voltage and amperage increase)
SERIES
PARALLEL
+ -
12V/200 Amp Hours
12V + 12V + 12V + 12V = 48 V Amp Hours remain at 200
+ -
12V/200 Amp Hours
Voltage remains at 12V 200AH + 200AH + 200AH + 200 AH=800 AH
+ -
12V/200 Amp Hours
+ -
+ -
12V/200 Amp Hours
+ -
12V/200 Amp Hours
+ -
12V/200 Amp Hours
+ -
+ -
12V/200 Amp Hours
+ -
12V/200 Amp Hours
+ -
12V/200 Amp Hours
+ -
+ -
12V/200 Amp Hours
+ -
12V/200 Amp Hours
+ -
SERIES/PARALLEL
Lock Washer
Flat Washer
12V/200 Amp Hours
Two strings of batteries in series are connected in parallel. The voltage increases to 48V and the
amp hours increase to 400
Stud
Nut
12V/200 Amp Hours
Battery Cable Lug
12V/200 Amp Hours
12V/200 Amp Hours
• Never install extra washers between the
terminal mounting surface and the battery
cable lug—the connection must be direct and
secure.
• Always install breakers or fuses within the
positive battery cable.
Insulator
• Torque 2/0, (67.4 mm
2
) 4/0 (107 mm2), or larger
code-approved cables rated 75°C or higher to
60-inch pounds/6.77Nm.
13
Loading...