OutBack Power FXR2012A Installation Manual
Fxr series inverter/charger
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Also See for FXR2012A:
- Operator's manual (80 pages) ,
- Instructions manual (11 pages) ,
- Quick start manual (6 pages)
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Summary of Contents for OutBack Power FXR2012A
- Page 1 FXR Series Inverter/Charger FXR2012A FXR2524A FXR3048A VFXR2812A VFXR3524A VFXR3648A Installation Manual...
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Page 2: Contact Information
All Rights Reserved. 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. -
Page 3: Table Of Contents
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 ............................. - Page 4 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 ....................
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Page 5: Introduction
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. 900-0166-01-01 Rev A... -
Page 6: Welcome To Outback Power Technologies
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... -
Page 7: Models
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. -
Page 8: Figure 2 Components
Introduction 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 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. -
Page 9: Planning
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. -
Page 10: Input Modes
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. -
Page 11: Renewable Energy
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. -
Page 12: Table 3 Battery Bank Elements
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: These are the most basic B. - Page 13 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.
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Page 14: Generator
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. -
Page 15: Installation
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. -
Page 16: Dimensions
Installation Dimensions Height with DCC 12” (30.5 cm) Length 16.25” (41 cm) Width 8.25” (21 cm) Height with Turbo 13” (33 cm) Figure 4 Dimensions 900-0166-01-01 Rev A... -
Page 17: Terminals And Ports
Commissioning Terminals and Ports DC TERMINALS DC and AC These terminals connect GROUND TERMINALS to the battery cables and These terminals connect to the DC system. a grounding system for See page 20 for instructions. both batteries and AC. See page 18 for instructions. -
Page 18: Wiring
Installation Wiring It will be necessary to remove knockouts from the AC Plate to run wires. The AC Plate has one knockout of ½” size and two knockouts of ¾” size. Install appropriate bushings to protect the wires. Use copper wire only. Wire must be rated at 75°C or higher. Grounding WARNING: Shock Hazard ... -
Page 19: Figure 6 Dc Ground Lug
Commissioning The inverter’s DC ground is a box lug located next to the negative DC battery terminal. This lug accepts up to 1/0 AWG (70 mm² or 0.109 in²) wire. Local codes or regulations may require the DC ground to be run separately from the AC ground. Also, if present, it will be necessary to remove the DC Cover or Turbo Fan before making the ground connection. -
Page 20: Dc Wiring
Inverter Nominal DC Amps Conductor Size Breaker Size (Minimum, per breaker) (Derated 125%) (Minimum) (Minimum) FXR2012A 4/0 AWG (120 mm²) or 0.186 in² 250 Adc VFXR2812A 4/0 AWG (120 mm²) or 0.186 in² 250 Adc FXR2524A 2/0 AWG (70 mm²) or 0.109 in²... -
Page 21: Figure 8 Required Order Of Battery Cable Hardware
Commissioning To install DC cables and hardware: 1. Install all DC cables. 2. Do not install hardware in a different order from Figure 8. The battery cable lug should be the first item installed on the stud. It should make solid contact with the mounting surface. 3. -
Page 22: Figure 10 Dc Cover Attachment
Installation DC Cover or Turbo Fan Attachment COVER ATTACHMENT FXR inverters are equipped with either the DC Cover or the Turbo Fan. To attach either cover, put the cover in place and insert a screw at each corner using a Phillips screwdriver. -
Page 23: Ac Wiring
Commissioning AC Wiring WARNING: Shock Hazard The neutral and ground conductors should be mechanically bonded. Ensure there is no more than one AC neutral-ground bond at any time. Local or national codes may require the bond to be made at the main panel only. IMPORTANT: ... -
Page 24: Ac Sources
Installation AC Sources The inverter has a single set of AC terminals which are intended to connect to a single AC source. It cannot be directly wired to more than one AC source at the same time. If multiple sources are used, it is usually required to have a selector switch that changes from one to the next. -
Page 25: On And Off Wiring
Commissioning ON and OFF Wiring The I jumper bridges two pins. NVERTER This jumper parallels the two I NVERTER terminals on the Control Wiring Terminal Block. If either connection is closed, this sets the inverter to On as long as the internal programming has not been set to Off with the system display. -
Page 26: Accessory Wiring
Installation Accessory Wiring The AC Wiring Compartment Board has ports for both the Remote Temperature Sensor (RTS) and the system display. The system display port is labeled M RTS cable RTS port (RJ11, 4-conductor, telephone) port See the Operator’s Manual for more information on System Display cable the RTS. -
Page 27: Figure 17 Aux Connections For Vent Fan (Example)
Commissioning In this example, the A directly drives a 12-volt vent fan. The + and – wires on the fan are connected to the A + and A – terminals. LED INDICATOR The A indicator illuminates when the A output becomes active. Figure 17 AUX Connections for Vent Fan (Example) In this example, the A... -
Page 28: Generator Control
Installation Generator Control The A terminals can provide a signal to control an automatic-start generator. The control function can be Advanced Generator Start (AGS), which is situated in the system display. AGS can start the generator using settings from the system display, or it can use battery readings from the FLEXnet DC battery monitor. -
Page 29: Figure 20 Three-Wire Generator Start (Example)
Commissioning Three-Wire Start A “three-wire-start” generator has two or more starting circuits. It usually has a separate switch or position for cranking the generator. A generator with three-wire start has fewer automated functions than a two-wire-start generator. It usually requires multiple controls for starting, running, or stopping. -
Page 30: Ac Configurations
Installation AC Configurations Single-Inverter When installing an inverter AC system, the following rules must be observed. All overcurrent devices must be sized for 60 Aac or less. All output wiring and circuit breakers must be sized appropriately for loads and inverter power. ... -
Page 31: Multiple-Inverter Ac Installations (Stacking)
Commissioning Multiple-Inverter AC Installations (Stacking) Installing multiple inverters in a single AC system allows larger loads than a single inverter can handle. This requires “stacking”. Stacking inverters refers to how they are wired within the system and then programmed to coordinate activity. Stacking allows all units to work together as a single system. - Page 32 Installation Each inverter is assigned to a particular phase when assigned a port on the HUB10.3 communications manager. Port assignments will vary with the system. The master must be plugged into port 1. In parallel stacking, any slave inverter can use any other port, beginning with port 2.
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Page 33: Stacking Configurations
Commissioning Stacking Configurations Series Stacking (Dual-Stack) In series stacking, two inverters create two separate 120 Vac output phases. One phase is the master. The second inverter is a subphase master. It creates a 120 Vac output that is intentionally 180° out of phase with the master. Each of these outputs can be used to power a separate set of 120 Vac loads. -
Page 34: Figure 24 Series Wiring (Two Inverters)
Installation AC Source (Utility Grid or AC Generator) AC Conduit Box MATE3s Neutral Hot L1 Hot L2 HUB 10.3 10 9 8 7 6 5 4 3 2 1 MATE CAT5 Cables Input Input Circuit Circuit Breaker Breaker HUB/ HUB/ Neutral MATE Hot IN... -
Page 35: Figure 25 Example Of Parallel Stacking Arrangement (Three Inverters)
Commissioning Parallel Stacking (Dual-Stack and Larger) In parallel stacking, two or more inverters create a single, common 120 Vac bus. The slave outputs are controlled directly by the master and cannot operate independently. All inverters share a common input (AC source) and run loads on a common output. ... -
Page 36: Figure 26 Parallel Wiring (Four Inverters)
Installation AC Source LEGEND MATE3s (Utility Grid or Hot L1 AC Generator) Neutral HUB 10.3 Ground 10 9 8 7 6 5 4 3 2 1 MATE TBB = Terminal Bus Bar AC Conduit CAT5 Cables Neutral Hot L1 TBB Input Input Input... -
Page 37: Figure 27 Example Of Series/Parallel Stacking Arrangement (Four Inverters)
Commissioning Series/Parallel Stacking (Quad-Stack or Larger) In series/parallel stacking, inverters create separate 120 Vac output phases and 240 Vac collectively, as in series stacking. However, in this configuration, each output uses inverters in parallel. One output contains the master; the other uses a subphase master. Each output has at least one slave. -
Page 38: Figure 28 Series/Parallel Wiring
Installation AC Source MATE3s LEGEND (Utility Grid or Hot L1 AC Generator) Hot L2 HUB 10.3 Neutral Ground 10 9 8 7 6 5 4 3 2 1 MATE TBB = Terminal Bus Bar AC Conduit Box CAT5 Cables Neutral Hot L1 Hot L2 Input... -
Page 39: Figure 29 Example Of Three-Phase Stacking Arrangement (Three Inverters)
Commissioning Three-Phase Stacking In three-phase stacking, inverters create three separate 120 Vac output phases in wye configuration. The three phases (A, B, and C) operate independently of each other. The inverters on one phase cannot assist another. Several inverters can be installed in parallel on each phase to power all 120 Vac loads on each of those phases. - Page 40 Installation When installing a three-phase system, observe the following rules. Three-phase stacking requires both the system display and the communications manager. See the HUB10.3 literature for any required jumper configurations. The inverter that is mounted physically lowest is always master and is programmed as Master. Mounting below the other inverters allows the master to avoid heat buildup and remain relatively cool as it sees the greatest duty cycle.
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Page 41: Figure 31 Three-Phase Wiring (Three Inverters)
Commissioning MATE3s AC Source (Utility Grid or AC Generator) AC Conduit Box 10 9 8 7 6 5 4 3 2 1 MATE Neutral Phase B Phase C Phase A CAT5 Cables Input Input Input Circuit Circuit Circuit Breaker Breaker Breaker HUB/ HUB/... -
Page 42: Figure 32 Power Save Levels And Loads
Installation Power Save IMPORTANT: In any system that features slave inverters, Power Save must be programmed before commissioning. Leaving the inverters at the factory default settings (or setting them incorrectly) will cause erratic system performance. See the FXR Series Inverter/Charger Operator’s Manual for a table of menu items and settings. - Page 43 For more information on charging with stacked inverters, see the FXR Series Inverter/Charger Operator’s Manual. Figure 33 shows a system of four FXR2012A inverters (the master and three slaves). These inverters in a parallel system with a common load bus.
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Page 44: Figure 33 Power Save Priority (Parallel)
12 Aac, a second slave would go silent. Figure 34 shows a system of six FXR2012A inverters. In this example the inverters have been stacked in a split-phase system. The master inverter is on the L1 output while a subphase master is on L2. -
Page 45: Commissioning
Commissioning Functional Test WARNING: Shock Hazard and Equipment Damage The inverter’s AC and DC covers must be removed to perform these tests. The components are close together and carry hazardous voltages. Use appropriate care to avoid the risk of electric shock or equipment damage. -
Page 46: Figure 35 Ac Terminals
Commissioning Figure 35 AC Terminals 3. Turn on the inverter using the system display (or external switch, if one has been installed). The inverter’s default condition is Off. Do not turn on any AC circuit breakers at this time. 4. Using a DVM, verify 120 Vac (or appropriate voltage) between the AC H and AC terminals. -
Page 47: Powering Down
Commissioning After output testing is completed, perform the following steps: 6. Close the AC output circuit breakers. If AC bypass switches are present, place them in the normal (non-bypass) position. Do not connect an AC input source or close any AC input circuits. -
Page 48: Firmware Updates
Commissioning Firmware Updates IMPORTANT: All inverters will shut down during firmware updates. If loads need to be run while updating the firmware, bypass the inverter with a maintenance bypass switch. Communication cables must remain connected and DC power must remain on. Interrupted communication will cause the update to fail and the inverter(s) may not work afterward. -
Page 49: Figure 36 Grid Support Screens
Commissioning To install Grid Support .GIP Files: 1. Perform a firmware update as noted above. NOTES: The MATE3s should be revision 1.001.000 or greater for Grid Support functionality. For grid-interactive parameters, the Installer Password is required and may need to be changed from the default setting of 1732 . -
Page 50: Preventative Maintenance
Commissioning Preventative Maintenance The FXR inverter requires almost no regular maintenance. However, OutBack recommends the following items on a periodic basis: Check all electrical connections periodically for tightness using the torque values from pages 18 through 20. For vented (VFXR) models, clean the air filter inside the DC cover every three months. (See page 22 to remove the cover.) Rinse the filter with warm tap water and allow it to fully air-dry before reinstalling. - Page 51 Commissioning Table 6 Terms and Definitions Term Definition AC Neutral; also known as Common Neutral-to-ground A mechanical connection between the AC neutral (Common) bus and the ground (PE) bus; bond this bond makes the AC neutral safe to handle Off-grid Utility grid power is not available for use On-grid Utility grid power is available for use (does not imply grid-interactive capability)
- Page 52 Commissioning NOTES: 900-0166-01-01 Rev A...
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Page 53: Index
Index Multiple AC Sources ........24 Parallel-Stacked System ......35, 36 Series/Parallel System ......37, 38 Series-Stacked System ......33, 34 AC Plate ..............7 Single-Inverter System ........30 AC Terminals ..........9, 17, 23 Three-Phase System ........41 AC Test Points ............ 46 Transfer Relay .......... - Page 54 Commissioning Remote Temperature Sensor (RTS) ..7, 17, 26 Renewable Energy ..........11 Revision ............48, 49 IEC ..............18, 50 Important Symbol ..........5 Ingress Protection (IP) ........15 Input Modes ............10 Sealed Models ..........7, 15 Series Stacking ..........33, 34 Series/Parallel Stacking ........
- Page 55 Index Single Inverter ..........30 Stacking Parallel ............36 Warning Symbol ............ 5 Series ............33 Website ............... 48 Series/Parallel ........37, 38 Wiring ..............18 Three-phase ..........41 AC Connections ..........23 AUX Connections ........... 26 DC Connections ..........20 Ground Connections ........
- Page 56 Masters of the Off-Grid.™ First Choice for the New Grid. Corporate Headquarters European Office 17825 – 59 Avenue N.E. Hansastrasse 8 Suite B D-91126 Arlington, WA 98223 USA Schwabach, Germany 900-0166-01-01 Rev A...
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