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Lux Power Technology 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
©2025 EG4
®
ELECTRONICS, LLC. ALL RIGHTS RESERVED.
VERSION 1.2.2 | INFORMATION SUBJECT TO CHANGE WITHOUT NOTICE.
MODEL#: IV-16000-HYB-AW-FX-XX (XX is a number between 00-99)

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Summary of Contents for Lux Power Technology EG4 FLEXBOSS21

  • Page 1 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 ©2025 EG4 ®...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS TECHNICAL SPECIFICATIONS ..............................1 ABBREVIATIONS ..................................3 INVERTER SAFETY ..................................4 SAFETY INSTRUCTIONS ............................... 4 IMPORTANT SAFETY NOTIFICATIONS ........................4 SÉCURITÉ DE L'ONDULEUR ..............................6 INSTRUCTIONS DE SÉCURITÉ ............................. 6 NOTIFICATIONS DE SÉCURITÉ IMPORTANTES ...................... 6 PRODUCT OVERVIEW ................................8 PACKING LIST ..................................

  • Page 3: Technical Specifications

    1. TECHNICAL SPECIFICATIONS INVERTER TYPE & MODEL # IV-16000-HYB-AW-FX-XX (XX is a number between 00-99) HYBRID AC INPUT/OUTPUT NOMINAL GRID VOLTAGE (INPUT & OUTPUT) 120/240 VAC; 120/208 VAC (L1/L2/N required) FREQUENCY 60 Hz (Default) | 50 Hz 12kW MAX. CONTINUOUS OUTPUT POWER MAX.
  • Page 4 OPERATING HUMIDITY 0-100% relative humidity MAX ALTITUDE OF OPERATION <6561 ft (<2000 m) ENCLOSURE RATING NEMA 4X -13° – 140°F (-25° – 60°C) STORAGE TEMPERATURE RATING COOLING (OR COOLING CONCEPT) Fans GENERAL SPECIFICATIONS DIMENSIONS (H x W x D) 30.43 × 22.28 × 11.22 in. (773 × 566 × 285 mm) TOTAL WEIGHT 121 lbs.

  • Page 5: 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 6: 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 7 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 8: Sécurité De L'onduleur

    4. SÉCURITÉ DE L'ONDULEUR 4.1 INSTRUCTIONS DE SÉCURITÉ Les réglementations internationales de sécurité ont été strictement observées lors de la conception et des tests de l'onduleur. Avant de commencer tout travail, lisez attentivement toutes les instructions de sécurité et respectez-les toujours lorsque vous travaillez sur ou avec l'onduleur. L'installation doit suivre toutes les normes et réglementations nationales ou locales applicables.
  • Page 9 AVERTISSEMENT : POUR RÉDUIRE LE RISQUE DE BLESSURE, LISEZ TOUTES LES INSTRUCTIONS ! Tous les travaux sur ce produit (conception du système, installation, exploitation, réglage, configuration et maintenance) doivent être effectués par du personnel qualifié. Pour réduire le risque de choc électrique, ne réalisez aucun entretien autre que ceux spécifiés dans les instructions de fonctionnement, sauf si vous êtes qualifié...

  • Page 10: Product Overview

    5. PRODUCT OVERVIEW The EG4 FlexBOSS21 is a 16kW, 120/240 VAC split-phase, all-in-one, hybrid, sine wave inverter ® designed for the residential and small commercial markets. The FlexBOSS21 can utilize 21kW of DC (STC) solar PV on three MPPTs (26/26/15A) and can generate 12kW of power during non-peak sunlight conditions and 16kW with solar PV gain when connected to the grid.

  • Page 11: Features Overview

    5.2 FEATURES OVERVIEW • FlexBOSS21 is a split-phase hybrid inverter that has the ability to operate off and on the grid. Designed for rural and suburban homeowners, and small commercial companies seeking • energy savings and independence. • Charge batteries and power loads simultaneously as users harness multiple power sources, including photovoltaic (PV), battery storage, as well as the grid.

  • Page 12: Product Feature Identification

    5.3 PRODUCT FEATURE IDENTIFICATION LABEL COMPONENT DESCRIPTION Handles Use for installation. LED Panel Used to quickly monitor system status. PV Disconnect Switch Used to connect and disconnect power from solar panels. Clasps Use to open cable box. Wi-Fi Dongle Used to communicate with Monitor Center app or website. RSD Button Rapid Shut Down.
  • Page 13 Cable Box Overview LABEL COMPONENT DESCRIPTION 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 14 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 15: Product Dimensions

    5.4 PRODUCT DIMENSIONS 22.28 in. (566 mm)
  • Page 16 Bottom View of Cable Box Knockouts 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.

  • Page 17: System Diagrams

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

  • Page 18: Storing The Inverter

    6. STORING THE INVERTER If placing the inverter into storage before installation, keep the following factors in mind while selecting a storage location: CAUTION: • The inverter and its components must be stored in its original packaging. • The storage temperature should be within -13 – 140°F (-25 – 60°C) with humidity between 0 –...

  • Page 19: 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 20: Location Selection And Installation

    7.2 LOCATION SELECTION AND INSTALLATION Requirements for Installation DANGER: Ensure there is at least 5.91 inches (150 mm) of space on the left and right side of the inverter and at least 11.81 inches (300 mm) above the unit for heat to dissipate or else there is a risk of fire.

  • Page 21: Installing The Inverter

    Installing the Inverter The inverter is designed to be wall-mounted on a vertical, solid, non-combustible surface such as brick or concrete. Two or more people may be needed to install the inverter due to its weight. The slots on the mounting bracket can accommodate various stud spacings from 12 in. (305 mm) to 16 in.
  • Page 22 4. For concrete or brick installation, insert the expansion bolts into the drilled holes. Install the bracket to the wall, ensuring the arrow is pointing up. Use the corresponding nuts and washers (packaged together with the expansion bolts) to affix the bracket to the wall. For stud wall installation, use the proper screws and affix the bracket to the wall.

  • Page 23: Connection Overview

    8. Attach the L brackets (one on each side) to the inverter and to the wall using the correct hardware. Once the bracket is secure, the wall installation is complete. 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.

  • Page 24: Battery Connections

    7.4 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 25 Battery Communication Cable Connections: • Use the included orange battery communication cable to connect the battery to the inverter. Put the inverter in standby mode to protect batteries until values are set. • The battery communication port on the inverter is an RJ45 socket with the pinout for the RJ45 plug shown below.

  • Page 26: Pv Connections

    For Lead-Acid Batteries: Closed loop communication is not available with lead-acid batteries; however, a third-party external temperature sensor will enable the inverter to control the charge/discharge of the battery. Follow the battery’s manual to determine setting parameters and for more information. 7.5 PV CONNECTIONS Cable Requirements*: MINIMUM INSULATOR VOLTAGE...
  • Page 27 String Usage & Sizing String 1 MPPT 1 String 2 String 1 MPPT 2 String 2 MPPT 3 String 1 The maximum utilized solar input of the inverter is 21kW (DC). • • MPPT 1 and MPPT 2 can each utilize up to 26A of solar input, with a maximum input of 31A. Exceeding 31A can damage the equipment.

  • Page 28: Ac Wiring Information

    NOTE: For all modules, the calculations need to be performed or verified by using a string calculator or consulting a professional. DANGER: DAMAGE WILL OCCUR if the string voltage on a cold, sunny morning exceeds the inverter’s maximum input voltage of 600V! IMPORTANT: The array can have a higher Imp than the 26A/15A specified, but the MPPTs will not make full use of the extra current.
  • Page 29 NOTE: • Always be sure to connect the AC Output ground wire to the Ground terminal first before installing the AC Outputs for L1 and L2. • If using fine stranded wire, use ferrules to secure the connection. • When installing multiple inverters in parallel, it is recommended to use equal length AC cables from each inverter to the main panel and from each inverter to the loads panel.
  • Page 30 CAUTION • Do not misconnect the grid input and loads output connections, which could cause damage to the inverter and attached devices. • Be sure to connect AC wires with correct polarity. If L and N wires are connected reversely, it may cause utility to short-circuit when the inverters are working in parallel operation.

  • 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. Black= L1 Red= L2 Orange= Neutral...
  • Page 32 REMINDER: If the inverter-to-inverter paralleling cable needs to be extended, ensure the cable is a straight-through CAT5 or higher CAT-rated cable. See image below for reference. 1. Set the CAN communication PIN to ON position for the first and the last inverter. Set the PIN to the OFF position for any inverters between the first and last.
  • Page 33 3. Ensure each inverter circuit breaker is in the open (OFF) position. No voltage should be coming in or out of the inverter at this point. 4. Using a multimeter, check the following: a. Check the battery bank voltage is within operating range at the inverter DC breaker, or the external DC disconnect.
  • Page 34 Parallel Configuration: 1. Before commissioning the system, verify that all inverters are updated to the latest firmware. Visit www.eg4electronics.com for the latest firmware version. 2. Make sure the power cables and parallel communication cables have been wired correctly and verify the DIP switch configurations are correct. 3.

  • Page 35: 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. 4.

  • Page 36: Rapid Shutdown/Ess Disconnect

    7.9 RAPID SHUTDOWN/ESS DISCONNECT The inverter includes a rapid shutdown system with built-in RSD transmitter and RSD/ESS disconnect initiator. 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.

  • Page 37: Inverter Start-Up And Shutdown Procedure

    8. INVERTER START-UP AND SHUTDOWN PROCEDURE Starting up the inverter 1. If using an external DC breaker between the battery bank and the inverter, turn it on. If not, turn on the BAT breaker located in the cable box of the inverter and then power on the battery system one battery at a time.

  • Page 38: Monitor System Setup

    For more information on GridBOSS and specific use cases, scan the following QR code: A qr code with black squares Description automatically generated GridBOSS User Manual 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...

  • Page 39: Wi-Fi/4G Dongle Connection

    10.1 WI-FI/4G DONGLE CONNECTION A Wi-Fi/4G dongle is used to monitor the inverter and remotely view the monitoring data on a computer or mobile device. Attach this module by plugging it in to the side of the inverter and securing it with the four (4) Phillips head screws. 10.2 CONNECTIVITY REQUIREMENTS Due to certain limitations of the Wi-Fi Dongle, please ensure that the home Wi-Fi network signal and security settings meet the following requirements:...

  • Page 40: Online Monitoring System User Interface

    10.3 ONLINE MONITORING SYSTEM USER INTERFACE NOTE: The monitoring system may change due to updates. Therefore, UI descriptions may vary from the current pages on the site. If you have any questions, or to create distributor or installer accounts, contact support@eg4electronics.com for assistance.
  • Page 41 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 42: Enable App Notifications

    10.5 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.” 3.
  • Page 43 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 44: Local Monitoring Setup With The Eg4 Monitor App

    10.6 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 45: Monitor Center Settings

    11. MONITOR CENTER SETTINGS IMPORTANT: These settings may need to be adjusted after installation. Consult with the installer/distributor before making any changes to avoid conflicting settings or damage to the system! The following settings are found on the Monitor Center Website at monitor.eg4electronics.com under the Maintenance tab.

  • Page 46: 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 47: System Grid Connect Setting

    Restart Inverter: Turns the inverter off and back on. • • Micro-Grid: Only set this when generator is connected to the inverter’s grid terminal. With this setting enabled, the inverter will use AC power to charge the battery and will not export power.

  • Page 48: 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 49: Discharge Setting

    11.5 DISCHARGE SETTING Batt Discharge Control: If the inverter communicates with the lithium battery and is capable • of closed-loop communication, select charge control according to “SOC.” When using lead- acid batteries or lithium batteries without communication, select charge control according to “VOLT.”...

  • Page 50: 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 51 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 52: 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 53 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 54 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 55 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 •...
  • Page 56 Self Consumption The system 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 57: Firmware Updates

    13. 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 58: 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 59: 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 60 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 61 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 62: Standards And Certifications

    Check whether the battery voltage is Bat volt low Battery voltage too low under 40V; battery voltage should be within inverter specification. Check the battery breaker or fuse. Bat open Battery is disconnected from inverter Reconnect as needed. Check if load power on inverter LOAD Off-grid overload Overload on Load terminal terminal is within inverter specification.

  • Page 63: 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 64: Changelog

    17. CHANGELOG V1.2.2 Minor formatting changes for easier readability • • Modified Note quick-part in section 7.4 for updated communication protocol information Modified verbiage in section 7.9 for External RSD • Modified various sections for better readability based on latest EG4 Hybrid Inverter template •...
  • Page 65 v1.0 First revision of document completed •...
  • Page 66 NOTES...
  • Page 67 CONTACT US support@eg4electronics.com (903) 609-1988 www.eg4electronics.com...