Related Manuals for Forza Fusion Series
Summary of Contents for Forza Fusion Series
- Page 1 User Manual Off-grid hybrid solar inverter and charger FIO-F11K12P / FIO-F12K24P / FIO-F13K48P 1KW/2KW/3KW...
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Page 2: Table Of Contents
Table of content IMPORTANT SAFETY INSTRUCTIONS 1. Introduction 2. Product overview 3. Preliminary steps 4. HARDWARE CONNECTIONS 4.1 AC connections 4.2 PV 4.3 Other communications 5. Operation 5.1 Power on/off 5.2 Display panel 6. Advanced operation 6.1 Main LCD configuration screen 6.2 Display information 6.3. -
Page 3: Introduction
MPPT charger, the FUSION optimizes energy harvesting while reducing system maintenance and operational costs. As the inverter has been conceived to easily integrate with the Forza battery and the embedded application, it provides seamless status monitoring along with remote management, all in real-time. It also features parallel operation with up to 9 identical units when used in conjunction with the optional parallel kit. - Page 4 Basic system architecture The following diagram illustrates a basic application for this inverter/charger. A complete running system should include the following power sources: - Generator or utility - PV modules Consult with your system integrator for other possible system architectures depending on your requirements. This inverter can power a wide assortment of appliances in home or office environments, including motor-type appliances such as fans, refrigerators, air conditioners and even tube lights.
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Page 5: Product Overview
2. Product overview 1. LCD display panel 2. Status LED indicator 3. Charging LED indicator 4. Fault LED indicator 5. Configuration buttons 6. Power on/off switch 7. Grid connection (input) 8. AC output (load connection) 9. PV connector 10. Battery input 11. - Page 6 Preparation 1. On the underside of the unit, unfasten the screws holding the cover in place. 2. Remove the bottom cover to expose the wired connections and ports. Leave the screws in a safe place for replacing the cover once the hardware connections are completed. Mounting the unit Important •...
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Page 7: Hardware Connections
For proper ventilation and heat dissipation, allow clearances of approximately 8in (20cm) to either side and 20in (50cm) above and below the unit. When more than one unit is installed, make sure to position them at the same level. • To secure the unit(s) in place, insert the supplied M5x12mm hex screws at points A, B and C. M4 screws can be used as well. - Page 8 3. Insert the positive (+) and negative (–) ring terminals on the studs of the inverter observing the correct polarity at both ends. Ring terminal: 4. Tighten all connections according to the torque values listed in the table. It also contains the amperage values, plus the recommended size of cables and terminals.
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Page 9: Ac Connections
4.1 AC connections Before any connections are made, open all disconnect devices on both AC and DC sources. CAUTION!! Before connecting to AC input power, install a separate circuit breaker between the inverter and AC source. It is needed for AC input overcurrent protection and also as a manual disconnect device during maintenance. - Page 10 3. After inserting the AC output wires observing the polarity marked on the terminal block, proceed to tighten the screws. The protective earth (PE) conductor ( ) must be connected first. Ground (yellow-green) LINE (brown or black) Neutral (blue) 4. Verify that that all wire connections are properly secured. Recommended AC conductor size Model Gauge...
- Page 11 Table– Module voltages Solar charging mode INVERTER MODEL Max. PV array open-circuit voltage 145VDC PV array MPPT voltage range 15~115VDC 30~115VDC 60~115VDC Min. battery voltage for PV charge 8.5VDC 17VDC 34VDC Connection of the modules NOTES: • PV wires should be sized according to the table below. •...
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Page 12: Other Communications
Final assembly 1. Place the bottom cover near the inverter housing. 2. Install the supplied communication cables in the corresponding ports. 3. Set the bottom cover in place. Then, secure it using the same screws that were removed in the previous steps. 4.3 Other communications The inverter supports several forms of communication. -
Page 13: Operation
Dry contact terminals: Unit status Condition Normally closed (NC) Common (C) Normally open (NO) State NC and C NO and C Power off The inverter is off, and no power is supplied to the output Close Open The output is being powered from an AC source Close Open The output... -
Page 14: Display Panel
5.2. Display panel Located on the front of the unit, this panel features a LCD screen, LED indicators and configuration buttons. LCD display LED indicators Configuration buttons LED indicators The display panel features three LED indicators. Description Status Solid Loads are powered by an AC source in Line mode Green Intermittent Loads are powered by battery or in PV mode... - Page 15 LCD display icons The display contains a variety of icons showing the status and operation mode of the inverter. Icon Function description Input source information Indicates that an AC input is connected Indicates that PV input is connected Indicates AC input voltage and frequency, PV voltage, charging current and battery voltage Settings, warning and fault indications Displays the setting screen mode...
- Page 16 Battery data Battery level indicator at 0-24%, 25-49%, 50-74%, and 75-100% of its capacity In battery mode, the number of bars shows the remaining charge In line mode, the number of bars indicates how much charge it will need to reach its full capacity In AC mode, the battery state of charge is displayed Status...
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Page 17: Advanced Operation
Mode of operation Indicates that the unit is connected to an AC source Indicates that the unit is connected to a PV panel Indicates that the inverter is operating in bypass mode Indicates that the inverter is operating in ECO mode Indicates that the AC source is charging the battery Indicates that the DC-AC conversion is enabled Mute control... - Page 18 The total input generated 60A (default) This setting ranges from 10A to 140A by solar and AC sources with increments of 10A per click 60A combined is the default value (Max. charging current = utility charging current + solar charging current) AGM (default) Flood Battery type...
- Page 19 Available options in the 1KW model 11.0V 11.3V 11.5V (default) 11.3V 12.0V 12.3V 12.5V 12.8V 13.0V 13.3V Defines the AC transfer voltage when the priority source in item 01 is set to SBU or SUB 13.5V 13.8V 14.0V 14.3V For the 2KW model, the setting ranges from 22.0V to 28.50V in increments of 0.5V per click.
- Page 20 Available options in the 1KW model Fully-charged battery 12.0V 12.3V 12.5V 12.8V 13.0V 13.3V 13.5V (default) 13.8V 14.0V 14.3V 14.5V Defines the battery transfer voltage when the priority source has been set to 14.8V 15.0V SBU or SOL in item 01 15.3V 15.5V 15.8V...
- Page 21 SbL: Solar for battery first Solar energy will be used to charge UCB: Utility power available to the battery as first priority. charge battery (default) AC power can be used to charge the battery when solar energy is not available SbL: Solar for battery first Solar energy will be the only charger UdC: Utility power not allowed...
- Page 22 Bypass forbidden If selected, the inverter won’t be able to operate in either bypass or ECO mode Bypass disabled If selected, the inverter will be able to operate in bypass or ECO mode only when it has been switched on and AC Bypass function power is available Bypass enabled (default)
- Page 23 1KW default setting: 13.5V 2KW default setting: 27.0V Float charging voltage 3KW default setting: 54.0V This is selectable when item 05 is set to USER-DEFINED - Selection range (1KW model): 12.0V to 16.0V - Selection range (2KW model): 24.0V to 32.0V - Selection range (3KW model): 48.0V to 64.0V Increments of 0.1V per click Single:...
- Page 24 1KW default setting: 10.5V 2KW default setting: 21.0V 3KW default setting: 42.0V Low DC-cutoff voltage It is the low battery voltage setting which shuts down the inverter. This is selectable when item 05 is set to USER-DEFINED - Selection range (1KW model): 10.0V to 13.5V - Selection range (2KW model): 20.0V to 27.0V - Selection range (3KW model): 40.0V to 54.0V Increments of 0.1V per click...
- Page 25 1KW default setting: 14.6V 1.4KW/2KW default setting: 29.2V Equalization voltage 2.6KW/3KW default setting: 58.4V - Selection range (1KW model): 12.0V to 16.0V - Selection range (2KW model): 24.0V to 32.0V - Selection range (3KW model): 48.0V to 64.0V Increments of 0.1V per click 60min (default) The time allowed for the equalization to take place.
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Page 26: Display Information
Display information The LCD display has three sections with system information and readings. These readings can be switched to display the different parameters. The order illustrated in the table is the sequence of the screens when the UP and DOWN selection keys are pressed: input voltage, input frequency, PV voltage, MPPT charging current, MPPT charging power, battery voltage, output voltage, output frequency, load percentage, load in VA, load in Watt, DC discharging current, main CPU Version and second CPU Version. - Page 27 Battery voltage (with decimal) Battery voltage=25.5V / Output voltage=120V The upper left field displays the BATT and V markers The upper right field continues to display AC output voltage Output frequency (with decimal) Output frequency=60Hz This is displayed on the upper right field, which also displays a Hz marker.
- Page 28 Load in watts When the load size is less than 1kW, the right field will display the W marker, as shown below The upper right field displays a W marker The upper left field continues to display battery voltage When the load size exceeds 1kW (≥1KW), the right field and marker will change to kW, as shown below DC discharge current Battery voltage=25.5V / Discharge current=1A...
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Page 29: Battery Charging
6.3 Battery charging Mode Description LCD display Standby mode In this state, even though the unit Charging from utility and PV power The charger can operate does not supply output to the loads, even if the inverter is not it can still provide power to charge turned on the battery from PV or AC sources. - Page 30 ECO mode The unit will provide output power Charging from utility and PV power from the utility. PV and utility power will be used for the batteries. Failure on the main line will open up the bypass circuit and the inverter will supply power to the loads Charging from PV power Charging from an AC source...
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Page 31: Battery Equalization
BATTERY EQUALIZATION Equalization mode is used for Flood and User-defined batteries. Equalization is an advanced charging process of the inverter, designed to improve the performance and to extend the life of a multi-battery string. By carrying out a controlled overcharge, it brings the batteries to a much higher voltage than usual and maintains them there for a time. -
Page 32: Parallel Operation
ABSORPTION FLOAT EQUALIZE 7. Parallel operation 1. Introduction For parallel operation, you need to purchase the optional kit from Forza. The package includes: • Parallel board • Parallel communication cable (1) • Share current cable This inverter can be used in parallel with two different operation modes. -
Page 33: Parallel Board Installation
7.1 Parallel board installation 1. Remove the two screws from the bottom cover to take it off. 2. Unfasten the two screws attaching the communication board to the inverter, as shown below. 3. Remove the screws and detach the cable connectors (2-pin and 14-pin) from the communication board. Slide out the board as shown in the image below. - Page 34 5. Take the parallel board from this kit and re-connect the 2-pin and 14-pin connectors (in their original position) to the parallel board. 6. Fasten the parallel board using the two screws removed earlier. Parallel board Communication board 7. Screw the communication board back into the inverter. 8.
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Page 35: Wiring Considerations
7.2. Wiring considerations NOTE: the connection to battery is required for parallel operation. The recommended size of cables and terminals for the batteries connected to each inverter is included in the table below. Battery cable size for each inverter Ring terminal: Ring terminal Terminal Model... -
Page 36: Parallel Connections On A Single-Phase System
Breaker specification of AC input in single phase Model 2 units 3 units 4 units 5 units 6 units 7 units 8 units 9 units 112A 128A 144A 128A 160A 192A 224A 256A 288A 144A 192A 240A 288A 336A 384A 432A Note 1: Also, you can use a 16A breaker for the 1KW model, 32A for the 2KW model and a 48A for the 3KW model with only 1 unit, and install one breaker at the AC input of each inverter. - Page 37 Three inverters in parallel: Power connection Communication connection Four inverters in parallel: Power connection Communication connection...
- Page 38 Five inverters in parallel: Power connection Communication connection Six inverters in parallel: Power connection Communication connection...
- Page 39 Seven to nine inverters in parallel: Power connection Communication connection - Seven inverters in parallel - Eight inverters in parallel - Nine inverters in parallel...
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Page 40: Parallel Connections On A Three-Phase System
7.4. Parallel connections on a three-phase system Three inverters in each phase: Power connection Communication connection Three inverters in one phase, three inverters in the second phase and two inverters for the third phase: Communication connection... - Page 41 Three inverters in one phase, two inverters in second phase and two inverters for the third phase: Power connection Communication connection Two inverters in each phase: Power connection Communication connection...
- Page 42 Four inverters in one phase and one inverter for the other two phases: Power connection Communication connection Three inverters in one phase, two inverters in the second phase and one inverter for the third phase: Power connection Communication connection...
- Page 43 Three inverters in one phase and only one inverter for the remaining two phases: Power connection Communication connection Two inverters in two phases and only one inverter for the remaining phase: Power connection Communication connection...
- Page 44 Two inverters in one phase and only one inverter for the remaining phases: Power connection Communication connection One inverter in each phase: Power connection Communication connection WARNING: Do NOT use the share current cable to connect units which are different phases. Doing so can cause damage to the inverter and its internal components.
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Page 45: Advanced Lcd Configuration Screen
8. Advanced LCD configuration screen Item Description Selectable parameters Single: When the unit is operated alone, select SIG in item 28 Parallel: When the units are operated in parallel and on a single-phase system, select PAL in item 28 Refer to the Parallel section for detailed information L1 phase: When the units are operated on a three-... -
Page 46: Commissioning And Maintenance
9. Commissioning and maintenance Parallel inverters on a single-phase configuration Step 1: Ensure that the following requirements are met before commissioning: • Check that all inverters in the system are wired correctly. • Make sure that circuit breakers on the AC input side are open and that all inverter’s neutral wires are connected together. - Page 47 Parallel inverters on a three-phase configuration Step 1: Ensure that the following requirements are met before commissioning: • Check that all inverters in the system are wired correctly. • Make sure that circuit breakers on the AC input side are open and that all inverter’s neutral wires are connected together.
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Page 48: Fault Codes And Warning Indicators
10. Fault codes and warning indicators The inverter has indications for error or warning conditions. An error is defined as a critical fault that shuts the unit down. A warning is a non-critical fault that allows the unit to continue operating. Some warnings may become errors if unattended. -
Page 49: Troubleshooting
Battery voltage detected inconsistent AC input voltage and frequency detected are inconsistent AC output current unbalanced AC output mode setting inconsistent Warning indicators Warning code Event Audible alarm Flashing icon Fan is locked when inverter Beeps three times every second is on Overtemperature None... - Page 50 CAN data loss 1. Check if communication cables are correctly connected and restart the inverters. Host data loss 2. If the problem remains, please contact your installer Synchronization data loss 1. Make sure all inverters share the same battery bank. 2.
- Page 51 Problem LCD/LED/Buzzer Explanation / Possible cause What to do LCD/LEDs and buzzer Unit shuts down turn on for about The battery voltage is too low 1. Re-charge battery. automatically during 3 seconds before (<1.91V/Cell) 2. Replace battery. the startup process completely shutting off 1.
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Page 52: Approximate Runtime Chart
Fault code 50 PFC overcurrent or surge Fault code 51 Overcurrent or surge Restart the unit, if the error happens again, please return to repair center Fault code 52 Bus voltage is too low Fault code 55 Output voltage is unbalanced If the battery connection Battery is not properly connected Fault code 56... -
Page 53: Technical Specifications
13. Technical specifications Table 1 Line mode specifications INVERTER MODEL Input voltage waveform Sinusoidal Nominal input voltage 120VAC Low-loss voltage 95VAC±3V Low-loss return voltage 100VAC±3V High-loss voltage 140VAC±3V High-loss return voltage 135VAC±3V Max AC input voltage 150VAC Nominal input frequency 60Hz / 50Hz (autosensing) Low-loss frequency 56 (46)±1Hz... - Page 54 Table 3 Charge mode specifications Utility charging mode INVERTER MODEL Charging current Default: 30A, max: 60A at Nominal input voltage Flooded battery 14.6VDC 29.2VDC 58.4VDC Bulk charging voltage AGM / Gel 14.1VDC 28.2VDC 56.4VDC battery Floating charging voltage 13.5VDC 27VDC 54VDC Overcharge protection 16.5VDC...
- Page 55 Table 4 ECO/Bypass mode specifications INVERTER MODEL Input voltage waveform Sinusoidal Low-loss voltage 85VAC±3V Low-loss return voltage 90VAC±3V High loss voltage 140VAC±3V High-loss return voltage 130VAC±3V Nominal input frequency 60Hz / 50Hz (autosensing) Low-loss frequency 56 (46)±1Hz Low-loss return frequency 57 (46.5)±1Hz High-loss frequency 64 (54)±1Hz...
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