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Related Manuals for OutBack Power FLEXpower ONE VFX3524
Summary of Contents for OutBack Power FLEXpower ONE VFX3524
- Page 1 power ONE Installation Manual...
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Page 2: Contact Information
USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER’S RISK. Warranty Summary OutBack Power Systems Inc. warrants that the products it manufactures will be free from defects in materials and workmanship for a period of five (5) years subject to the conditions set forth in the warranty detail found inside the back cover of this manual. -
Page 3: Important Safety Instructions
Important Safety Instructions READ AND SAVE THESE INSTRUCTIONS! This manual contains important safety instructions for the FLEXpower ONE. Read all instructions and cautionary markings on the FLEXpower ONE and on any accessories or additional equipment included in the installation. Failure to adhere to these instructions could result in severe shock or possible electrocution. -
Page 4: Definitions
This equipment is NOT intended for use with life support equipment or other medical equipment or devices. CAUTION: Equipment Damage Only use components or accessories recommended or sold by OutBack Power Systems or its authorized agents. IMPORTANT: Do not attempt to install this equipment if it appears to be damaged in any way. -
Page 5: Personal Safety
Important Safety Instructions Personal Safety WARNING: Personal Injury This equipment weighs approximately 98 lbs (44.5 kg). Use safe lifting techniques when lifting this equipment as prescribed by the Occupational Safety and Health Association (OSHA) or other local codes. Use standard safety equipment such as safety glasses, ear protection, steel- toed safety boots, safety hard hats, etc. -
Page 6: Pv Safety
Connecting the cables incorrectly can damage or destroy the equipment. Battery Safety WARNING: Electrocution Hazard Use the battery types recommended by OutBack Power Systems. Follow the battery manufacturer’s recommendations for installation and maintenance. Ensure clearance requirements are strictly enforced around batteries. -
Page 7: Regulatory References
“how” and “where” to recycle batteries and other electronic equipment. OutBack Power Systems strongly encourages you to learn about recycling and to dispose of recyclable items accordingly. The Earth, and OutBack Power Systems, thanks you for that effort. -
Page 8: Earth 911
Important Safety Instructions Earth 911 Web site: www.Earth911.com Address: 14646 N. Kierland Blvd., Suite 100 Scottsdale, AZ 85254 Phone: +1.480.337.3025 (direct) Environmental Protection Agency, USA Web site: www.epa.gov/recyclecity/ Phone: +1.415.947.8000 (Monday –Friday 8:00 AM to 12:00 PM and 1:00 PM to 4:00 PM PST) Email: r9.recyclecity@epa.gov Keep America Beautiful, USA... -
Page 9: Table Of Contents
Table of Contents Important Safety Instructions ..............1 Symbols Used ..................................1 Audience ....................................1 Definitions....................................2 General Safety ..................................2 Personal Safety..................................3 FLEXpower ONE System Safety............................3 PV Safety....................................4 Battery Safety..................................4 Regulatory References................................5 Recycling Information ................................5 Earth 911 ......................................6 Environmental Protection Agency, USA...........................6 Keep America Beautiful, USA ...............................6 Office of Waste Management, Canada .............................6 National Institute of Recyclers, Mexico.............................6 EuroRecycle.net ....................................6... - Page 10 Table of Contents AC Connections ....................................31 Functional Test/Commissioning..........................33 Pre-startup Procedures ................................33 Energize/Startup ....................................33 Reassembling the Enclosures ............................35 Operation....................39 Setting Basic Parameters ..............................39 MATE2 Settings....................................39 Charger Settings.....................................39 Setting Time, Date & Display on the MATE2 .........................40 Selecting the AC Source and AC Input Limit on the Inverter ..................42 Accessing the Advanced Menu ..............................43 Setting Battery Amp-Hours and Return Amps using the FLEXnet DC Monitor ............44 Setting Charging Parameters..............................45...
- Page 11 Table of Contents List of Tables Table 1 Acronyms....................................2 Table 2 Basic Components of a FLEXpower ONE System....................12 Table 3 Ground Conductor Size and Torque Requirements.....................26 Table 4 DC Conductor Size and Torque Requirements......................27 Table 5 AC Conductor Size and Torque Requirements ......................31 Table 6 Feature Matrix...................................49 Table 7...
- Page 12 Table of Contents List of Figures Figure 1 FLEXpower ONE System Overview ..........................11 Figure 2 Basic Components of a FLEXpower ONE System....................12 Figure 3 On-Grid Applications (Example) ..........................13 Figure 4 Off-Grid Applications (Example)..........................14 Figure 5 Grid-Interactive Applications (Example)........................14 Figure 6 Clearance and Access Requirements ........................18 Figure 7 Dimensions ..................................19...
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Page 13: Introduction
Introduction Thank you for choosing a FLEXpower ONE System from OutBack Power Systems. FLEXpower ONE is an integrated power system solution designed to be quick to install and easy to use. The FLEXpower ONE System is intended for off-grid and on-grid applications up to 3.6 kW. It is intended for use with photovoltaic (PV) modules for harvesting energy and a battery bank for energy storage. -
Page 14: Components
Introduction Components A complete FLEXpower ONE is composed of the following components. See page 49 for details on specific configurations. Table 2 Basic Components of a FLEXpower ONE System Components Documentation FX Series Inverter/Charger FLEXpower ONE Installation Manual (VFX or GVFX) (this book) Mounting Plate (with mounting bracket) -
Page 15: Applications
Planning Applications The FLEXpower ONE is intended for on-grid, off-grid, and grid-interactive applications. It is designed to use photovoltaic (PV) panels to harvest solar energy and a battery bank to store the harvested energy. On-Grid Applications In on-grid applications, the FLEXpower ONE can use the grid power as the primary power source or as the backup source of power. -
Page 16: Off-Grid Applications
Planning Off-Grid Applications In off-grid applications, the FLEXpower ONE can use the harvested energy from the battery bank as the primary power source. An AC generator can also be connected to support the system when required. Figure 4 Off-Grid Applications (Example) Grid-Interactive Applications In grid-interactive applications, grid power is used to run the loads. -
Page 17: Pv Array Planning
FLEXpower ONE System uses Maximum Power Point Tracking (MPPT) technology to maximize the PV harvest. A PV Combiner box (not included) may be required for multiple PV strings. PV Combiner Boxes are available from OutBack Power Systems for 8 to 12 PV strings. -
Page 18: Generator Requirements
The OutBack MATE can be used to program an inverter’s AUX output to start and stop a generator. This 12 V output can often control a two-wire-start generator directly. Three-wire-start generators require an interface such as an Atkinson module. For additional information, see… ~ OutBack Power Systems AGS Brochure: http://www.outbackpower.com/pdf/brochures/Automatic_Generator_Start.pdf ~ OutBack Power Systems MATE Manual: http://www.outbackpower.com/pdf/manuals/mate.pdf... -
Page 19: Preparation
Planning Preparation Tools Required The following tools may be required for installing this equipment. Wire cutters/strippers Drill and drill-bits Torque wrenches Ratchet drives Assorted insulated screw-drivers Digital Voltmeter Materials Required The following materials may be required for installing this equipment. ... -
Page 20: Clearance And Access Requirements
Planning Clearance and Access Requirements WARNING: Fire/Explosion Hazard Do not place combustible or flammable materials within 12 feet (3.7 m) of the equipment. This unit employs mechanical relays and is not ignition- protected. Fumes or spills from flammable materials could be ignited by sparks. IMPORTANT: Clearance and access requirements may vary by location. -
Page 21: Dimensions
Planning Dimensions 19¾” (481 cm) 16” (41 cm) Mounting Bracket ≈13” (33 cm) 33½” (851 cm) Side View Figure Dimensions 900-0095-01-00 Rev A... -
Page 22: Conduit And Knockout Preparation
Planning Conduit and Knockout Preparation Knockouts (two 1”, one 2”) are provided on the ends of the AC and DC enclosures for routing cable into the enclosures. Conduit and bushings are recommended to prevent damage to conductors from sharp edges along knockout holes. 1. -
Page 23: Mounting
Installation The FLEXpower ONE system is designed for flexibility and easy installation. The system comes attached to a mounting plate with the selected components pre-installed and wired. The Mounting Plate attaches to a mounting bracket that attaches to a wall. WARNING: Personal Injury ... -
Page 24: Figure 9 Installing The Mounting Bracket
Installation Mounting the bracket to wall studs 16” apart. Mounting the bracket to wall studs 24” apart. Mounting the bracket to plywood. Figure 9 Installing the Mounting Bracket 900-0095-01-00 Rev A... -
Page 25: Figure 10 Attaching The Mounting Plate To The Mounting Bracket
Installation Lift the Mounting Plate Slip the top of the above the wall bracket. Mounting Plate over the angled lip of the wall bracket. Secure the Mounting Plate to the wall at the 3 locations shown below. Secure the Mounting Plate to the wall at the 3 locations shown here. -
Page 26: Removing The Covers
Installation Removing the Covers Note: The AC Enclosure has two covers: the access cover and the front cover. Both covers need to be opened to make conductor connections. Once connections are Remove the screws on the made, the access cover can be used for visual inspection, Remove the screws in so that the wiring will not be disturbed when inspected AC Access Cover (x2). -
Page 27: Accessing The Wiring Compartments
Installation Accessing the Wiring Compartments Inverter Terminal Enlargement Internal components may vary from model to model. Factory wiring is not shown. FLEXnet DC Monitor (If installed) Terminal Bus Bar for Neutral Connections AC Input, Output, & Bypass Breakers (x3) (120-NA: 60 A) (230 EU : 30 A) Mechanical Interlock Breaker for AC Outlet (X1) -
Page 28: Wiring
Installation Wiring IMPORTANT: All connections must comply with local electric code. Local code may require sizes other than those recommended in this manual. For all wiring, use copper conductors rated at 75°C minimum. If the installation involves grid-tie activities such as selling power back to the grid, per NEC 690, ensure the total value of the breakers installed in either the main AC distribution panel or the AC sub-panel does not exceed the total rating on the terminal distribution bus in the distribution panel. -
Page 29: Dc Connections
Installation Figure Ground Connections DC Connections Table 4 DC Conductor Size and Torque Requirements DC Terminal Minimum Allowed Maximum Torque Breaker Conductor Size Conductor Size Requirements Size Battery Positive (+) 2/0 AWG (67.5mm N/A (ring terminal) 50 in-lb (5.7 Nm) 175 Adc Battery Negative (–) 2/0 AWG (67.5 mm... -
Page 30: Figure 14 Battery Connections With The Flexnet Dc Monitor
Installation To make the battery connections in a system with the FLEXnet DC Monitor: 1. Remove all hardware from the side of Shunt A that is not connected to the Inverter. 2. Place the Inverter Negative (–) cable lug and Charge Controller Negative (–) cable lug onto Shunt A. -
Page 31: Figure 15 Battery Connections Without The Flexnet Dc
Installation To make the battery connections in a system without the FLEXnet DC Monitor: 1. Remove all hardware from the inverter’s battery negative (–) terminal post. 2. Place the Inverter Negative (–) cable lug and Charge Controller Negative (–) lug onto the terminal post. -
Page 32: Figure 16 Pv Connections With A Flexnet Dc Monitor
Installation To make the PV connections: 1. Ensure the PV array is properly grounded. 2. Route the PV (–) through the bottom of the DC enclosure and into the wiring compartment of the FM80 charge controller. Connect the PV (–) conductor to the PV (–) terminal in the FM80 charge controller. -
Page 33: Ac Connections
Installation AC Connections WARNING: Fire Hazard Multi-wire branch circuits in residential installations can create a potential fire hazard with inverter installations. Be sure to check for multi-wire branch circuits before making any AC connections and make any changes required to remove the hazard. -
Page 34: Figure 18 Ac Out Connections
Installation WARNING: Shock Hazard Ensure there is only one Neutral-to-Ground Bond in the system. The FLEXpower ONE comes with a Neutral-to-Ground Bond installed. If a Neutral- to-Ground bond exists elsewhere in the system (e.g., in the main panel, or a generator), the Neutral-to-Ground Bond in the FLEXpower ONE AC Enclosure will need to be removed. -
Page 35: Functional Test/Commissioning
Installation Functional Test/Commissioning Pre-startup Procedures 1. Double-check all wiring connections. 2. Inspect the enclosure to ensure no tools or debris has been left inside. Energize/Startup Using a digital volt-meter (DVM), verify 24 or 48 Vdc on the Battery terminals (i.e., place DVM leads on in Figure 20). -
Page 36: Figure 20 Functional Test Procedures For Initial Startup
Installation 4– 6– 1– Note: The shunt may or may not be installed on your model. Use the same test point in all cases. 8– Figure 20 Functional Test Points for Energizing Systems 900-0095-01-00 Rev A... -
Page 37: Reassembling The Enclosures
Installation Reassembling the Enclosures To Replace the Raceway: Slip the lip on the Raceway into the slot on the mounting panel. Align the holes on the bottom of the Raceway with the holes provided on the mounting panel. Secure the Raceway in place with the screws provided. -
Page 38: Figure 23 Replacing The Ac Enclosure
Installation The Front Cover of the AC Enclosure will not be completely removed due to the surge protector cabling. Work with care not to damage the surge protector or dislodge the cabling as you replace the Front Cover. To Replace the Front of AC Enclosure: Align the holes (x4) in the enclosure front cover with the holes in the chassis. -
Page 39: Figure 25 Replacing The Dc Enclosure
Installation To Replace the DC Enclosure Front Cover: Align the holes in the DC Enclosure Front cover with the holes in the chassis. Ensure that the “lip” fits into the notch in the chassis. Replace the screws removed in the beginning. DC Enclosure Front Cover Notch... - Page 40 Installation 900-0095-01-00 Rev A...
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Page 41: Operation
Operation Setting Basic Parameters IMPORTANT: This section assumes that the operator is familiar with the basic operation and navigation of the installed components. Detailed information about component settings is provided in each of the components respective manuals. Although some of the programming will be pre-set at the factory (i.e., grid-tie features for grid- interactive units, charging for 24 or 48 Vdc battery banks), the following parameters may need to be adjusted on-site depending on the configuration of the system. -
Page 42: Setting Time, Date & Display On The Mate2
Operation Setting Time, Date & Display on the MATE2 IMPORTANT: The following information assumes the installer is familiar with the basic operation of a MATE2 System Controller and Display. If the installer is not familiar with basic operation, please refer to the MATE Installation and User Manual for general information. -
Page 43: Figure 28 Mate2 Setup Screen (Page 2 And 3)
Operation MATE2 Setup Screen Continued from page 40. PAGE 3 MATE2 Setup Screen PAGE 2 Figure 28 MATE2 Setup Screen (Page 2 and 3) 900-0095-01-00 Rev A... -
Page 44: Selecting The Ac Source And Ac Input Limit On The Inverter
Operation Selecting the AC Source and AC Input Limit on the Inverter AC1 GRID Menu: Adjusts the maximum current the inverter will draw from the grid for either supporting loads or battery charging (between 5.0 Aac and 60.0 Aac). AC2 GEN Menu: Adjusts the maximum current the inverter will draw from the generator for either supporting loads or battery charging (between 2.0 Aac and... -
Page 45: Accessing The Advanced Menu
Operation Accessing the Advanced Menu In most cases, the charging parameters set at the factory will work for most systems. However, if changes are required, these parameters are set using the Advanced Menu system. This includes the charging input current limit and the voltage and time limit for each stage of charging. IMPORTANT: ... -
Page 46: Setting Battery Amp-Hours And Return Amps Using The Flexnet Dc Monitor
Operation Setting Battery Amp-Hours and Return Amps using the FLEXnet DC Monitor If a FLEXnet DC Monitor is installed in the configuration, the following parameters will need to be set. Battery Amp-Hours refers to the total amp-hour capacity of the battery bank (not just amp-hour rating of the individual batteries within the battery bank). -
Page 47: Setting Charging Parameters
Operation Setting Charging Parameters If changes need to be made to charging parameters, follow the menu map below. IMPORTANT: Access the Advanced Menu as instructed on page 43. To Set Charging Limits: Press the <CHGR> Soft Key. Press the <INC> or <DEC> Soft Key to change the parameter. -
Page 48: De-Energize/Shutdown
Operation De-energize/Shutdown WARNING: Lethal Voltage Review the system configuration to identify all possible sources of energy. Ensure ALL sources of power are disconnected before performing any installation or maintenance on this equipment. Confirm that the terminals are de-energized using a validated voltmeter (rated for a minimum 1000 Vac and 1000 Vdc) to verify the de-energized condition. -
Page 49: Figure 34 Functional Test Procedures To Confirm The Unit Is De-Energized
Operation 6– Note: The shunt may or may not be installed on your model. Use the same test point in all cases. 4– 5– Figure 34 Functional Test Points for De-Energizing Systems 900-0095-01-00 Rev A... - Page 50 Operation 900-0095-01-00 Rev A...
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Page 51: Specifications
Specifications Feature Matrix The following Matrix shows the FLEXpower ONE models that are described in this manual. Table 6 Feature Matrix FLEXnet DC Monitor AC Enclosure DC Enclosure INVERTER Surge MODEL FM80 MATE GFDI FN-DC FN-DC MODEL Protector SHUNT A SHUNT B 175A 250A... -
Page 52: Electrical Specifications, 120 Vac/60 Hz Models
Specifications Electrical Specifications, 120 Vac/60 Hz Models Product Name FP1-1 FP1-2 FP1-3 FP1-4 Inverter Model VFX3524 VFX3648 GVFX3524 GVFX3648 Grid-Interactive Anti-Islanding Protection UL1741-2005/ IEEE1547 UL1741-2005/ IEEE1547 Total Sell Current < 5% < 5% Harmonic Distortion Invert Voltage 2% Typical 2% Typical Output Waveform True Sine Wave Nominal... -
Page 53: Electrical Specifications, 230 Vac/50 Hz Models
Specifications Electrical Specifications, 230 Vac/50 Hz Models Product Name FP1-5 FP1-6 Inverter Model VFX3024E VFX3048E Output Waveform True Sine Wave Nominal 24 Vdc 48 Vdc Battery Voltage Operating Range 20-30 Vdc 40-60 Vdc Recommended Minimum Battery Capacity 200 Amp-hours 100 Amp-hours For Models with FM80 Charge Controller: Maximum PV Array Wattage 2000 Wdc... -
Page 54: Surge Protector
Specifications Surge Protector The FLEXware Surge Protector is designed to protect the FLEXpower ONE’s sensitive components from excessively high voltages (e.g., electrical storms). Thermally-fused metal oxide varistors (MOVs) limit (“clamp”) these voltages and transfer the resulting current to a lower-voltage port. -
Page 55: Renewable Energy Input & Storage
Specifications Renewable Energy Input & Storage PV Sizing Single charge control systems can support photovoltaic arrays with the following specifications. Dual charge controller systems can handle 2 arrays with the following specifications. Maximum Array Size 4,000 W on 48 Vdc system, 2,000 W on 24dc system ... -
Page 56: Discharge Rate
Specifications Discharge Rate Deep cycle batteries express the amp-hour rating as "at the x-hour rate". This is an average rate of current flow that would take x number of hours to discharge the batteries. Common amp-hour figures are at the 6-hour rate, the 20-hour rate, and the 100-hour rate. A battery is classified as having fewer amp hours if it is discharged at a faster rate, such as the 6-hour rate. - Page 57 Specifications Refrigerators and ice-makers typically run only about 1/3 of the time, therefore, the running wattage is 1/3 of the total wattage of the appliance. Divide the total wattage of the appliance by 3 when determining the battery requirements. Calculating Amp-Hours To determine the amp-hours that will be consumed, list the anticipated loads and the length of time they will operate.
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Page 58: Table 7 Worksheet For Determining Average Daily Load In Amp-Hours
Specifications Worksheet for Calculating Amp-hour Requirements Use the following worksheet to calculate the amp-hour requirements. Table 7 Worksheet for Determining Average Daily Load in Amp-hours Weekly Days per watt- Load Watts Hours per Day week used hours Total weekly watt-hours of AC load Divided by days per week 7 Average total watt-hours per day Divided by DC nominal voltage (48) -
Page 59: Table 8 Worksheet For Determining Battery Bank Size
Specifications Worksheet for Calculating Battery Bank Size Use the following worksheet to calculate the battery bank size. Table 8 Worksheet for Determining Battery Bank Size Average amp-hours per day (from Table 7) Divided by inverter efficiency Divided by battery efficiency (usually 0.75) Adjusted amp-hours per day Divided by Depth-of-Discharge (usually 60%) Multiplied by days of autonomy... - Page 60 Specifications This page intentionally left blank. 900-0095-01-00 Rev A...
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Page 61: Wiring Configurations
Wiring Configurations The following wiring configurations are provided as examples only. Actual wiring requirements may vary depending on local electric code. All installations must comply with local electric code. FLEXpower ONE with FLEXnet DC Monitor and GFDI FLEXpower ONE with FLEXnet DC Monitor Only (No GFDI) ... - Page 62 Wiring Configurations This page intentionally left blank. 900-0095-01-00 Rev A...
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Page 67: Warranty
Warranty 5-Year Limited Warranty for FLEXpower ONE Products OutBack Power Systems, Inc. (“OutBack”) provides a five-year (5) limited warranty (“Warranty”) against defects in materials and workmanship for its FLEXpower ONE products (“Product”) if installed in fixed location applications within the United States and Canada. -
Page 68: How To Arrange For Warranty Service
During the warranty 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. -
Page 69: Index
Index AC Conductor Size and Torque Requirements ..... 33 Energize....................35 AC Connections ................34 Environmental..................17 Access Requirements ..............18 Accessing the Advanced Menus..........46 Accessories................... 17 Advanced Menu ................45 Functional Test ..................35 Applications..................13 Audience ....................1 Generator Requirements.............16 Grid-Interactive Applications............14 Batteries Ground Conductor Size and Torque Requirements...28 Amp-Hour Capacity.............. - Page 70 Warranty Information Planning....................13 Setup Screens MATE2 ....................43 Preparation................... 17 Shutdown .....................49 Pre-startup Procedures..............35 PV Connections................. 32 Shutdown Procedures ..............49 Specifications PV Planning..................15 PV Sizing ....................55 Environmental..............52, 53 Feature Matrix................51 Mechanical ................52, 53 Startup.....................35 Surge Protector .................54 Reassembling the Enclosures...........
- Page 71 Thank you for supporting OutBack Power Systems by installing this product. Your patronage is greatly appreciated. This product was proudly assembled in the United States of America and demonstrates the quality and pride of this great team of employees. We sincerely hope your experience has been pleasant, positive, and professional and hope that you’ll consider OutBack Power Systems for future purchases.
- Page 72 North America European Office: 19009 62nd Avenue NE Arlington, WA USA Barcelona, España 1.360.435.6030 34.93.654.9568...