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Outback FX-Class Service Instructions Manual

Inverter/charger
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Purpose and Scope
These instructions detail how to remove and replace the following parts of any FX-class or
FXR-class inverter/charger.
 Control Printed-Circuit Board Assembly (PCBA)
 AC Printed-Circuit Board Assembly (PCBA)
 FET Printed-Circuit Board Assembly (PCBA)
 Ribbon Cables
These instructions extend to all FX, FXR, VFX, VFXR, GTFX, GVFX, and GFX models, including all
mobile and international models.

Tools Required

 #2 Phillips screwdriver
 3/8" flat blade screwdriver
 4mm hex wrench (included)
 Strap wrench
 Long-nose pliers
 10mm socket with 12" extension & torque wrench
 10mm wrench (standard and torque)
 Power supply (9-volt batteries may be used)
 Voltmeter or DVM
Disassembly
This procedure describes the removal of all circuit boards in an FX-class or FXR-class inverter. The
exact steps and order may vary with the repairs needed.
The order of removal depicted here is:
1.
Control PCBA
2.
AC PCBA
3.
FET PCBA
If not all boards need to be replaced, the installer may proceed through the steps that are required
and ignore the subsequent disassembly. (Note that replacing the AC PCBA requires removal of the
Control PCBA regardless of any other steps.)
The installer should then proceed to the reassembly and testing steps, which begin on page 7.
900-0107-01-00 Rev A
FX-Class and FXR-Class
Inverter/Charger
Service Instructions
1

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Summary of Contents for Outback FX-Class

  • Page 1: Tools Required

     Power supply (9-volt batteries may be used)  Voltmeter or DVM Disassembly This procedure describes the removal of all circuit boards in an FX-class or FXR-class inverter. The exact steps and order may vary with the repairs needed. The order of removal depicted here is:...
  • Page 2 FX-Class and FXR-Class To disassemble the inverter: Disconnect power; turn off all DC and AC sources to the inverter. Remove the DC Cover or Turbo Fan. Remove the battery terminal covers. Using a #2 Phillips screwdriver, remove the two screws attaching the AC Cover as shown in Figure 1. Remove the rubber washers, rubber grommet, and AC Cover as shown in Figure 1.
  • Page 3 Part Replacement Instructions Using a #2 Phillips screwdriver, remove the 6 screws located in the AC wiring compartment. See Figure 3. Screws Figure 3 AC Compartment Screws Using the 4mm hex wrench, remove all 8 hex bolts that connect the top cover to the bottom chassis of the inverter.
  • Page 4 FX-Class and FXR-Class Disconnect the fan wire. The connector locations are different for FX-class and FXR-class inverters. The locations are shown in Figure 5. PCB Connector (FX-class) PCB Connector (FXR-class) Figure 5 Fan Connector 10. Remove the top cover and set it aside.
  • Page 5 Part Replacement Instructions Levers NOTE: Two other levers are located below the chassis lip. Figure 7 FET to Control Ribbon Cable Levers NOTE: Two other levers are located below the chassis lip. Figure 8 AC to Control Ribbon Cable 13. Gently lift the AC PCBA until there is resistance from the AC output wires connected to the AC Assembly.
  • Page 6 FX-Class and FXR-Class 14. Before removing the AC PCBA, using a pair of long-nose pliers, disconnect the white and black AC output wires connected at the bottom of the board. (See Figure 10 for the location of the wire connectors.) Remove the AC PCBA.
  • Page 7 Part Replacement Instructions Thermistor Connection Figure 12 Thermistor Connection 17. Remove the FET PCBA. Assembly The order of assembly depicted here is: FET PCBA AC PCBA Control PCBA If the FET and or AC boards do not need to be replaced or have not been removed, the installer may ignore these steps and proceed through the steps that are required.
  • Page 8 FX-Class and FXR-Class Before bolting down the FET PCBA, it may be necessary to loosen the bolt that mounts the transformer bus bar to the transformer. Loosening this bolt will make it easier to align the FET PCBA correctly. See Figure 13.

  • Page 9: Ribbon Cables

    Once each PCBA is seated and secured in the chassis, re-attach the ribbon cables to the boards. NOTE: FX-class inverters use two identical cables with 34 pins. Ensure that the cables are bent as shown in Figure 15 so that they can be routed correctly inside the inverter.
  • Page 10 FX-Class and FXR-Class Install the ribbon cable that is bent in half to the AC PCBA and the Control PCBA. (See Figure 17 and also Figure 8 if necessary.) This cable has 34 pins. Make sure the red stripe is oriented toward the bottom.
  • Page 11 Once the inverter power-up sequence is confirmed, disconnect the DC power supply. The test is successful if the inverter completed each routine. If this did not occur, it may be necessary to contact OutBack technical support for troubleshooting. Completion To finish reassembly: Connect the fan cable.

  • Page 12: Contact Information

    This completes the procedure for replacing circuit boards in the FX-class or FXR-class inverters. Recycling Parts Use the box from the new circuit boards to return the old boards to OutBack Power Technologies for recycling, or use a local recycling service. Do not throw the old circuit boards into the garbage.

This manual is also suitable for:

Fxr-class