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EG4 FLEXBOSS21 User Manual

Hybrid inverter
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E G 4
F L E X B O S S 2 1
®
H Y B R I D I N V E R T E R
U S E R M A N U A L
©2024 EG4 ELECTRONICS, LLC. ALL RIGHTS RESERVED.
VERSION 1.1.2 | INFORMATION SUBJECT TO CHANGE WITHOUT NOTICE.
MODEL#: IV-16000-HYB-AW-FX-00

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  • Page 1 H Y B R I D I N V E R T E R U S E R M A N U A L ©2024 EG4 ELECTRONICS, LLC. ALL RIGHTS RESERVED. VERSION 1.1.2 | INFORMATION SUBJECT TO CHANGE WITHOUT NOTICE.

  • Page 3: Table Of Contents

    ONLINE MONITORING SYSTEM USER INTERFACE ................35 10.3 ® MONITOR APP SETUP ........................35 10.4 ENABLE APP NOTIFICATIONS ......................... 37 10.5 LOCAL MONITORING SETUP WITH THE EG4 MONITOR APP ............39 ® 10.6 THIRD-PARTY RS485 COMMUNICATION ..................... 39 MONITOR CENTER SETTINGS .......................... 40 11.1 COMMON SETTING ...........................

  • Page 4: Technical Specifications

    1. TECHNICAL SPECIFICATIONS AC INPUT DATA NOMINAL AC VOLTAGE 120/240VAC; 120/208VAC (L1/L2/N required) 60 Hz (Default) | 50 Hz FREQUENCY MAX. AC CURRENT 50A @ 240V | 57.7A @ 208V MAX. AC INPUT POWER 12kW MAX. AC BYPASS AC GRID OUTPUT DATA MAX.

  • Page 5: Battery Data

    Hawaii Rule 14H [HECO SRD IEEE 1547.1-2020 Ed. 2] Rapid Shutdown (RSD) NEC 2020:690.12 FCC Part 15, Class B (PENDING) For information regarding warranty registration on EG4® Electronics products, please navigate to https://eg4electronics.com/warranty/ and select the corresponding product to begin the registration process.

  • Page 6: Abbreviations

    2. ABBREVIATIONS In-lbs. – Inch Pounds • • AWG – American Wire Gauge kW – Kilowatt • A – Amps • kWh – Kilowatt-hour • Ah – Amp hour(s) • LCD – Liquid Crystal Display • AC – Alternating Current •...

  • Page 7: Inverter Safety

    3. INVERTER SAFETY SAFETY INSTRUCTIONS International safety regulations have been strictly observed in the design and testing of the inverter. Before beginning any work, carefully read all safety instructions, and always observe them when working on or with the inverter. The installation must follow all applicable national or local standards and regulations.
  • Page 8 WARNING: TO REDUCE THE RISK OF INJURY, READ ALL INSTRUCTIONS! All work on this product (system design, installation, operation, setting, configuration, and maintenance) must be carried out by qualified personnel. To reduce the risk of electric shock, do not perform any servicing other than those specified in the operating instructions unless qualified to do so.

  • Page 9: Packing List

    4. PACKING LIST When the product is unpacked, the contents should match the list below. Wi-Fi Dongle Wall Mount 1” CT (×2) L Bracket (×2) Template RJ45 Terminals Mounting Bracket Phillips Head Phillips Head Screw M5×10 (×4) Hybrid Inverter (×4) Screw M3×10 (×4) Battery Parallel...

  • Page 10: Product Dimensions

    5. PRODUCT DIMENSIONS LABEL COMPONENT DESCRIPTION Use for installation. Handles See section 7.2. Used to quickly monitor system status. LED Panel See section 14.3 Used to connect and disconnect power from solar panels. PV Disconnect Switch See section 7.4 Use to open cable box. Clasps See section 7.3 Used to communicate with Monitor Center app or website.
  • Page 11 22.28 in. (566 mm)
  • Page 12 Bottom View of Cable Box Bottom View of Cable Box Knockouts...
  • Page 13 Back View of Cable Box Knockouts U.S. NOM. TRADE SIZE ACTUAL KNOCKOUT SIZE 1/2 in. 0.88 in. (22.2 mm) 3/4 in. 1.12 in. (28.5 mm) 1 in. 1.38 in. (35 mm) 1 1/4 in. 1.73 in. (44 mm) 1 1/2 in. 1.99 in.

  • Page 14: Product Overview

    16kW with solar PV gain when connected to the grid. It can bypass 90A of utility power from its grid port to load port. The FlexBOSS21 is an enhanced power-level cousin to EG4’s flagship 18kPV inverter. Though it can perform as a standalone inverter, it has been designed to work optimally with EG4’s GridBOSS power gateway.

  • Page 15: System Diagrams

    6.2 SYSTEM DIAGRAMS This unit and its associated system are suitable for the following applications:...

  • Page 16: System Installation

    7. SYSTEM INSTALLATION 7.1 TOOLS NEEDED FOR INSTALLATION Safety Goggles Dielectric Shoes Gloves Mask Multimeter Utility Knife Wire Cutters Wire Stripper Marking Pen Tape Measure Electric Drill and Hex Wrenches Screwdriver Hammer Socket Set Drill Bits Heavy Duty Hand Truck with Wood Screws All Terrain Tires Torque Wrench...

  • Page 17: Installing The Inverter

    3. Never position the inverter in direct sunlight, rain, or snow. Refer to the figure below and choose a well-shaded site or in an indoor location to protect the inverter from the elements. The inverter should be installed upright on a vertical surface. Installing the Inverter The inverter is designed to be wall-mounted on a vertical, solid, non-combustible surface such as brick or concrete.

  • Page 18: Mounting Steps

    Mounting Steps 1. Select a location for the inverter’s final placement. 2. Use the wall mounting template to mark where the mounting bracket screws will be installed. Use a level to ensure the bracket will be installed parallel with the ground.
  • Page 19 5. Using the team lift technique, place the inverter onto the wall bracket, securing it to the wall. 6. Temporarily mount the L bracket to the side of the inverter (located at the bottom, one on each side). Mark holes on the wall based on the hole location on the L bracket (repeat this step for both sides).

  • Page 20: Connection Overview

    7.3 CONNECTION OVERVIEW To expose the cable box area, open the bottom cover by opening the clasps on the side of the inverter and remove the three screws on the internal wire box cover as indicated in the image below. Once the cover is open, follow the sections below for connecting the wiring for PV, battery, AC, parallelled inverters, and rapid shutdown.
  • Page 21 Cable Box Overview COMPONENT DESCRIPTION LABEL Used to connect communications cables, set DIP switches, Communication Board add CTs, and connect external RSD Battery (DC) Connections Used to connect battery cables Integrated Bonded Battery Breaker Overcurrent protection for connected batteries AC Connections Used for wiring AC power from the grid and to the loads PV Input Used for wiring DC power from solar units to the inverter...
  • Page 22 Communication Board Overview DESCRIPTION LABEL Reserved Reserved Parallel DIP Switches: Set DIP switches when using inverters in parallel Battery Communication Port (CAN & RS485) Fan Power Supply 485 balance resistance Reserved CT Interface Reserved Reserved Paralleling Communication Port DRY (NO, NC): Reserved RSD Terminals NTC: Connection for temperature sensor for lead-acid battery Meter 485B &...

  • Page 23: Pv Connections

    7.4 PV CONNECTIONS Cable Requirements*: MINIMUM INSULATOR VOLTAGE MAX. AMPERAGE PER MPPT CABLE SIZE MPPT 1: 26A 10 AWG – 6 AWG (max.) 600V MPPT 2: 26A (6 mm – 16 mm MPPT 3: 15A *Consult installer to ensure that appropriate cable sizing is used due to various factors such as distance, operating voltage, and amperage.

  • Page 24: String Sizing

    String Sizing MPPT 1 MPPT 2 MPPT 1 EG4 String Sizer Tool Each string should ideally contain the same model, brand, and quantity of panels for ease of • design, racking, and wiring. However, varying string sizes can be used for unique MPPTs. If two strings are used for MPPT 1, they MUST be the same model, brand, and number per string.
  • Page 25 All panels on a series/parallel string should face the same orientation and be exposed to • roughly the same shading across the string. Consideration should be placed on string location and wiring order on the racking to minimize shading effects. One shaded module can disproportionately reduce output for the entire string.

  • Page 26: Battery Connections

    7.5 BATTERY CONNECTIONS The FlexBOSS21 comes equipped with two battery inputs with 2 positive and 2 negative points of connection. The two positive battery terminals are protected by a 300A breaker. This is to accommodate using parallel conductors as supplied with the WallMount battery series. It is designed to utilize 4 battery cables up to 20 feet by using two sets of cables rather than resorting to larger cable sizes.
  • Page 27 “Maintenance,” “Remote Set,” and choose battery type under “Common Settings.” For closed-loop communication between the inverter and lithium batteries, choose “Lithium” • as the battery type. For inter-battery communication and battery setup with EG4 batteries, ® refer to the respective battery manual. •...

  • Page 28: Ac Wiring Information

    7.6 AC WIRING INFORMATION When sizing AC wires, adhere to the following information*: MAX. AMPERAGE TERMINAL CABLE SIZE TORQUE VALUES RATING CONNECTION Grid 6 – 1 AWG (16 mm – 50 mm 93 in-lbs. (10.5Nm) 100A Load 8 – 6 AWG (10 mm –...
  • Page 29 Steps for AC Connection The FlexBOSS21 comes equipped with L1 and L2 terminals for AC input (labeled GRID) and output (labeled LOAD). It is designed to utilize up to 50A of input and up to 66.7A of output. These terminals ARE NOT connected to a breaker;...

  • Page 30: Pin Description

    CT/Meter Connection To measure the power imported from and exported to the grid, a pair of CTs or one three-phase meter must be installed at the service entry point in or near the main service panel. Two (2) CTs are provided with each inverter with a 300A rating.

  • Page 31: Parallel System Connection

    CT Clamp Ratio: The inverter supports three ratios of CT clamps: 1000:1, 2000:1, and 3000:1. The included CTs are 3000:1. If using a 3rd party CT, ensure the CT ratio is of the supported types. Be sure to select the correct CT ratio setting on the inverter.
  • Page 32 REMINDER: Put the CAN communication pin to ON status for the first and last inverter and OFF for inverters in between. Both switches in the “ON” position translate to address 1. Both switches in the “OFF” position translates to address 0. Parallel line (n to 1) The max.
  • Page 33 2. Make sure the power cables and parallel communication cables have been wired correctly and verify the DIP switch configurations are correct. 3. Power on the inverters. 4. Login to the Monitor Center Website or the EG4 Electronics app. See section 10 for more ®...

  • Page 34: Grid, Load, And Ac Information

    Commissioning Steps via the EG4 ® App: 1. On the EG4 Electronics App, select the “Setting” icon. ® 2. At the top, select the device to set as the “Master” in the drop-down menu. 3. Toggle the “Standby/Normal” setting off.

  • Page 35: Rapid Shutdown/Ess Disconnect

    In case of emergency, press the rapid shutdown button to cut off the power supply, cutting the inverter’s AC output along with dropping the PV conductor’s voltage to <30V in 30 seconds. NOTE: When using supported EG4 ® batteries in closed-loop communications with the inverter, the RSD also initiates ESS disconnect as required by NEC code.

  • Page 36: Inverter Start-Up And Shutdown Procedure

    3. Turn off the PV disconnect and then the battery breaker. Wait for the LED lights to go off. 9. WORKING WITH A GRIDBOSS While the FlexBOSS21 is a hybrid inverter that is capable of functioning on its own, pairing it with the GridBOSS allows for more flexibility and functionality.

  • Page 37: Monitor System Setup

    10. MONITOR SYSTEM SETUP There are multiple ways for the inverter to be programmed and monitored. The most common and convenient are the EG4 Monitor Center Website (monitor.eg4electronics.com) and the EG4 Monitor ® ® App. The following sections discuss the various ways to communicate with the inverter.

  • Page 38: Online Monitoring System User Interface

    10.3 EG4 MONITOR APP SETUP ® Register a monitoring account and set the Wi-Fi password for the Wi-Fi dongle by following the steps below before using EG4's monitoring system. 1. Register an account: Visit monitor.eg4electronics.com or download the EG4 Monitor ®...
  • Page 39 2. When registering the account, provide the following information: Select the box to scan the QR code on the dongle shell to automatically input the information. a. Customer code: Contact the distributor or installer to obtain this code. b. Dongle SN: The serial number is attached to the dongle shell.

  • Page 40: Enable App Notifications

    10.4 ENABLE APP NOTIFICATIONS The EG4 Mobile App allows the end user to easily check real-time system information regarding the ® inverters, batteries, and other informative values. Enable Notifications in Monitor Center: 1. Go to monitor.eg4electronics.com and login. 2. At the top of the screen, select “Configuration,” then “Users.”...
  • Page 41 Enable Notifications on a Mobile Device: NOTE: Make sure the app is up to date before beginning! 1. Login to the EG4 Monitor App. Select the user icon at the top right corner of the screen. ® 2. Select “Notifications,” “Allow Notifications,” and make selections for which notifications to receive.

  • Page 42: Local Monitoring Setup With The Eg4 Monitor App

    10.5 LOCAL MONITORING SETUP WITH THE EG4 MONITOR APP ® If there is no Wi-Fi available at the location, use the local function to monitor or set up the system: 1. Download the EG4 Monitor app. ® 2. Connect the mobile device to the dongle’s Wi-Fi hotspot after the INV LED on the Wi-Fi module is solid on.

  • Page 43: Monitor Center Settings

    The following settings are found on the Monitor Center Website at monitor.eg4electronics.com under the Maintenance tab. For more information, scan the following QR code: EG4 Monitor Center Overview 11.1 COMMON SETTING Time: Set the time/date on the inverter. The input format is 2019-02-14 14:44:00 (YYYY-MM- •...

  • Page 44: Application Setting

    11.2 APPLICATION SETTING No Batteries: Allows access to off-grid mode when there is no battery and solar is the only • input available. Power Backup: If Power Backup function is Enabled, the LOAD terminal will maintain output • when AC is interrupted. Set “Power Backup” via web/app (When enabling this mode, LOAD output will be uninterrupted).

  • Page 45: System Grid Connect Setting

    System Charge SOC/Volt Limit: Set charge limits based on SOC or Voltage. • Parallel Settings Set System Type: The EG4 FlexBoss21 supports paralleling of multiple inverters; in this • ® scenario, set one of the inverters to master and the others to slave. If all inverters are installed in one phase, set one of the inverters to “1 Phase Master”.

  • Page 46: Charge Setting

    11.4 CHARGE SETTING Batt Charge Control (Volt/SOC): Batt Charge Control will charge the battery bank according • to Voltage/SOC depending on selection. Charge Last: Charges battery as a last priority. • Charge Current Limit (Adc): Set the maximum battery charge current. •...

  • Page 47: Discharge Setting

    “VOLT.” NOTE: When using EG4 batteries with the FlexBOSS21 inverter, it is recommended to set ® the cut-off SOC to 20% to maintain the 80% Depth of Discharge (DOD). Discharge Current Limit(Adc): Sets the discharge limit for lead-acid batteries.

  • Page 48: Working Modes And Related Settings

    Peak Shaving Grid Peak-Shaving: Peak-Shaving is used to avoid peak demand charges from the grid. • Peak shaving can be accomplished by halting grid charging at specific times. For example, during periods of peak demand (i.e., high grid rates), or when the batteries are fully charged based on SOC/Voltage.
  • Page 49 Input the inverter’s information on the next screen and select update. Afterwards, select “Management,” then “Edit.” Set charging times and percentages based on electricity use patterns and weather conditions. The platform sends user settings to the inverter, and the inverter provides feedback, confirming the receipt of setting and executing charging operations according to user-defined parameters.

  • Page 50: Working Modes

    Working Modes Working modes are pre-set priority systems that allow users to configure the system to meet their demands through extensive customizations. These modes can be found under the Maintenance tab by clicking “Working Mode.” Scroll past “Application Setting” to the “Working Mode Setting” section. Working Mode Definitions: Backup Mode: Used to save battery power as a last resort.
  • Page 51 Peak Shaving Grid Peak-Shaving: Enable grid peak-shaving. • Grid Peak-Shaving Power(kW)/Grid Peak-Shaving Power2(kW): Set the maximum • amount of power that will be drawn from the grid. Start Peak-Shaving Volt 1(V)/Start Peak-Shaving Volt 2(V): Set the starting point of peak- •...
  • Page 52 PV Charge Priority The order of priority for solar power usage will be Battery >Load >Grid. During the “PV Charge Priority” period, loads are first supplied power from the grid. If there is excess solar power after charging batteries, the excess solar will power the loads along with grid power. Solar power will be used to charge the battery bank first.
  • Page 53 Forced Discharge/ Export PV Only Forced Discharge Enable: Enable this setting to forcefully discharge the station’s battery • bank. Export PV Only: Enable this setting to sell back generated PV power to the grid. • • Forced Discharge Power(kW): Set the maximum power limit of battery discharge. Stop Discharge SOC(%)/Volt: Stop the forced discharge upon reaching the set SOC/ •...
  • Page 54 Self Consumption The station will default to Self Consumption mode. The order of priority for powering loads is Solar > Battery > Grid. The order priority for solar power is Load > Battery > Grid which creates an ideal scenario when needing to prioritize solar power generation over other types of power. Self Consumption mode will increase the self-consumption rate of solar power and reduce energy bills significantly.

  • Page 55: Firmware Updates

    13.1 FIRMWARE UPDATES VIA EG4 ELECTRONICS APP ® Before updating firmware through the EG4 Monitor app, ensure the mobile device being used has ® enough battery life to last through the update. While the update is ongoing, do not close the application.

  • Page 56: Firmware Update Via Monitor Center (Website)

    13.2 FIRMWARE UPDATE VIA MONITOR CENTER (WEBSITE) 1. Distributors and installers can update firmware by using the EG4 Electronics website ® monitoring system. Contact EG4 to make sure the files are correct. ® 2. Log in to the EG4 Electronics Monitor System. Select “Maintenance,” and then select ®...

  • Page 57: Led Description

    14.2 LED DESCRIPTION If a warning or fault occurs, users can troubleshoot according to the LED status description and the warning/fault information found in the “Event History” tab on the app or Monitor Center website. DISPLAY DESCRIPTION ACTION Solid on Working normally No action needed Green LED...
  • Page 58 Ensure the PV string voltage is within the inverter specification. If string voltage is Vbus over range DC Bus voltage too high within range and this fault persists, contact the supplier. Check if the wires on load terminal and grid Load terminal and grid terminal are wired EPS connect fault terminal are wired correctly.
  • Page 59 Rated power of parallel inverters are Confirm that the rated power of all Para rating Diff inconsistent inverters is the same. Confirm the wiring for the parallel system is correct. Once verified, connect each inverter to the grid. The Para Phase set system will automatically detect the Incorrect setting of phase in parallel error...

  • Page 60: Standards And Certifications

    15. STANDARDS AND CERTIFICATIONS The EG4 FlexBOSS21 is cETL listed and complies with national and international standards for safety ® and reliability when connected to the grid. Safety UL1741, SA, SB •...

  • Page 61: Warranty Information

    16. WARRANTY INFORMATION For information regarding warranty registration on EG4 Electronics products, please navigate to ® https://eg4electronics.com/warranty/ and select the corresponding product to begin the registration process.

  • Page 62: Changelog

    17. CHANGELOG 11-12-24 Published v1.1.2 • • Updated wire sizing and torque tables in Section 7.5 Updated Idle Consumption in Section 1 • 12-4-24 Updated Warranty Information • 13-31-24 Modified FCC Part 15, Class B to show (pending) in spec sheet •...
  • Page 63 NOTES...
  • Page 64 CONTACT US support@eg4electronics.com (903) 609-1988 www.eg4electronics.com...

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