Outback Power Systems FX 2024 T User's Manual
Contents
1. 34 MEM E 39 Welcome to the OutBack Power Systems FX Series Inverter Charger System The FX Series Inverter Charger offers a complete power conversion system DC to AC battery charging and an AC transfer switch and can be used as a stand alone or back up application It is designed for indoor or enclosed locations OutBack Power Systems does everything possible to assure the components you purchase will function properly and safely when installed as instructed according to local and national electrical codes NEC Please read all of the following instructions and the instructions that come with any other OutBack components that make up your power system Further instructions on individual FX set ups as well as systems assemblies are included with the FLEXware manuals The non Mobile FX is ETL listed to UL1741 Inverters Converters Controllers and Interconnection System Equipment for Use with Distributed Energy Resources All Mobile FX Series Inverter Chargers are ETL listed to UL 458 The FX and VFX Series Inverter Charger Installation Manual covers the following information Safety FX parts standard and optional Initial inspection of the component Preparing the mounting surface Fastening the FX to the mounting surface General electrical information FX Series Inverter Charger Models Sealed Units designed for harsher environments but still require overhead and sidewall protec2. 2 s m M 2 FX Series Inverter Charger ModelS uu ccssssssssssssssssssssssssssssesssssssssssssssssssssesessossssssvessossssssssvessessssssssssessesssssssssesssessssossseesseesssesees 2 N AE TE 2 3 tata 5 be HO 3 AP e Eo m T 6 AC Wiring Compartment BOO rm 6 AC and DC Grounding REQUIFEMENTS 0 ccssssssssssssssssesssssssssssssssesssscsssesessossessssessesssssssssesssssscessssse crm 7 2 8 9 10 1 AC Wiring Notes for the Non Mobile FX 13 AC Wiring Notes for the Mobile PX incre mms 14 NS Mi oss 15 Inverter O VO cinc crm secs ss 15 RUINY AUX F AUK PO CR OEI 16 PP 17 MALE petaca e I E AO o OE O SP DRE mpm 18 A O 18 Single or Series Parallel Dual FX Configuration ettet 19 Paraleled Daal 22 Series Parallel Quad FX System encarece 23 o 24 Generator INtTEri aCe NER M ias 26 27 jascicuenifia edE 28 O o 29 29 31 Maximum Overcurrent Protection AMPACITY cecssssssssssssescssssssssssssssssssssssssssssesssssuscesssssusesssssssusssessssusesessssssucessssseeces 32 EA 32 o A A o ce Do cic
3. 5 Power Systems FX AND VFX SERIES INVERTER CHARGER Installation Manual Includes Mounting Installation and Product Registration Warranty Introduction Dear OutBack Customer Thank you for your purchase of OutBack products We make every effort to assure Our power conver sion products will give you long and reliable service for your renewable energy system As with any manufactured device repairs might be needed due to damage inappropriate use or unin tentional defect Please note the following guidelines regarding warranty service of OutBack products Any and all warranty repairs must conform to the terms of the warranty All OutBack equipment must be installed according to their accompanying instructions and manuals with specified over current protection in order to maintain their warranties The customer must return the component s to OutBack securely packaged properly addressed and shipping paid We recommend insuring your package when shipping Packages that are not securely packaged can sustain additional damage not covered by the warranty or can void warranty repairs here is no allowance or reimbursement for installer s or user s labor or travel time required to disconnect service or reinstall the damaged component s OutBack will ship the repaired or replacement component s prepaid to addresses in the continental United States where applicable Shipments outside the U S wil
4. 991 2 NHHL DMW9 aq o ee sepqeo S8 0N OUTPUT L1 BLACK TBB AC INPUT L1 BLACK GROUND TBB AC INPUT FROM UTILITY GRID OR GENERATOR TO LOADS y m a eA Q D D on Qu gt dme Series Parallel Using Four FXs 21 PARALLELED DUAL FX SYSTEM All AC wiring from the AC source and to the AC loads must collectively handle 100 amps AC or more All other AC wiring capacity must equal 60 amps AC Mobile FX units must handle 30 amps AC A paralleled dual FX system can continuously power four 7 2kW of loads depending on which model is used NOTE Program the lowest installed FX as Master 1 2ph MASTER and the second FX as an OutBack L1 Slave OB SLAVE L1 TO AG LOADS AC OUTPUT L1 BLACK TBB NEUTRAL INPUT AND OUTPUT CONNECTIONS NEUTRAL WHITE TBB minimally SAWG THHN 1 All cables to bs 2 Terminal Bus 0 0 0 o Li SLAVE GROUND TBB AC INPUT L1 BLACK AG INPUT FROM UTILITY GRID OR GENERATOR Parallel Dual System with Two FXs 22 23 SERIES PARALLEL QUAD FX SYSTEM All AC wiring from the AC source and to the AC loads must collectively handle 120 amps AC or more e All other AC wiring must handle a capacity of 60 amps AC Mobile FX AC wiring must handle 30 amps This system can continuously power eight 14 4kW of loads depen
5. A Mobile FX requires 30A input breakers NOTE Stacking FXs in series parallel means there are FXs directly connected to two separate 120 output legs These legs produce 240 VAC between them the series portion This allows all of the FXs to power either of the 120VAC output legs the parallel portion Series parallel stacking requires an FW X240 Auto Transformer and must use OutBack stacking programming When the FXs are connected in series for 120 240 the FW X240 Auto Transformer can be connected to the AC output both FXs are then available on either 120 VAC output circuit This allows higher efficiency and better performance as heavy 120 VAC loads are powered by both FXs The FW X240 Auto Transformer also allows the Master to power loads on either 120 VAC output circuit with the Slave FX off reducing idle power consumption and improving system efficiency The Slave FX must be programmed through the MATE as a Classic Slave series stacking no FW X240 Auto Transformer or as OB Slave L2 series parallel stacking FW X240 included The FX connected to Port 01 of the HUB is always the Master 1 2ph MASTER JEH sng 991 z eq 591982 v SEJON SNOLLISNAICO ELLMEN IO A ONY LA gal AC INPUT L1 BLACK TBB AC INPUT FROM UTILITY GRID OR GENERATOR AC INPUT L2 RED TEB Series Parallel Using Two FXs Jag sng
6. Back loads AC NEUTRAL OUT AC NEUTRAL IN D DM Both neutral terminals are common with each other within the FX Only one neutral needs to connect at the AC NEUTRAL OUT CHASSIS GROUND PE terminal if a separate common neutral bus bar is installed e CHASSIS GROUND PE CHASSIS GROUND AC NEUTRAL IN Both CHASSIS GROUND terminals are common within the FX The AC input and AC output ground wires can connect to these terminals or one can AC HOT IN be connected if a common ground bus 5 bar 15 installed 5 AC HOT IN amp The AC hot input conductor black must be supplied through 60 amp maximum BATTERY TEMP AC branch rated circuit breaker MATE HUB 6 AWG wire is required for the FX s AC transfer switch we 49 Y p 4 ru M Y 4 y y A b y b e p E LES IN ELTE Ey 85 1 lt u gt 4 4 i P N 4 y AC WIRING NOTES THE MOBILE FX AC HOT OUT e Supplies the AC hot output conductors through a 30 amp maximum AC branch rated circuit breaker using 6 AWG wire and connect to the AC Ciut Back Power Systems AC NEUTRAL OUT AC NEUTRAL IN D Connects the AC neural input conductor to p the AC NEUTRAL IN terminal Connects the AC neutral output conductor BU to the AC NEUTRAL OUT terminal dm D
7. SYSTEMS RESPONSIBILITY FOR MALFUNCTIONS AND DEFECTS IN HARDWARE IS LIMITED TO REPAIR AND REPLACEMENT AS SET FORTH IN THIS LIMITED WARRANTY STATEMENT ALL EXPRESS AND IMPLIED WARRANTIES FOR THE PRODUCT INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF AND CONDITIONS OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE LIMITED WARRANTY PERIOD SET FORTH ABOVE AND NO WARRANTIES WHETHER EXPRESS OR IMPLIED WILL APPLY AFTER SUCH PERIOD SOME STATES OR JURISDICTIONS DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU OUTBACK POWER SYSTEMS DOES NOT ACCEPT LIABILITY BEYOND THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY STATEMENT OR LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING WITHOUT LIMITATION ANY LIABILITY FOR PRODUCTS NOT BEING AVAILABLE FOR USE SOME STATES OR JURISDICTIONS DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE EXCLUSION OR LIMITATION MAY NOT APPLY TO YOU During the two year 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 To request limited warranty service you must contact OutBack Power Systems at 360 435 6
8. air circulation Due to the variance in other mounting methods OutBack only endorses the use of FLEXware or previous versions of its mounting plate for installing the FX and associated system components using M6 X 20mm machine screws stainless steel for FLEXware and self tapping for older mounting plates one per corner Follow the instruction manual that comes with each mounting system e If mounting the FX on other surfaces such as plywood wall studs or masonry use appropriate fasteners to support approximately its weight OutBack cannot be responsible for damage to the FX if itis attached with inadequate fasteners e Install and secure each FX before attaching any wiring LOW VOLTAGE TERMINALS Ciut Back Power Systems AC HOT OUT AC NEUTRAL OUT CHASSIS GROUND PE CHASSIS GROUND PE Control Terminal AC NEUTRAL IN Wiring Block HOT IN Jumper t 2 INVERTER ON OFF BATTERY TEMP allows for manual MATE HUB switch to control the FX default operation is ON controlled by the MATE when the installed jumper connecting these terminals is present NOTE Keep Control Wiring Terminal Block screws tight and the block itself secured tightly to AC Board Otherwise the FX can malfunction The Terminal Block can be unplugged for easier wire installation and removal reinstallation of the FX AUX OUTPUT AUX AUX 12VDC at 0 7 amps 8 4 watts maximum is available at these terminals the AUX s
9. 030 within the limited warranty period If limited warranty service is required OutBack Power Systems will issue a Return Material Authorization RMA Number Mark the outside of the package with the RMA number and include a copy of the purchase invoice in the package You must ship the products back to OutBack Power Systems in their original or equivalent packaging prepay shipping charges and insure the shipment or accept the risk of loss or damage during shipment OutBack Power Systems will ship the repaired or replacement products to you freight prepaid if you use an address in the continental United States where applicable Shioments to other locations will be made freight collect 34 35 PRODUCT REGISTRATION Your purchase of an OutBack Power Systems product is an important investment Registering your products will help us maintain the standard of excellence you expect from us in terms of performance quality and reliability Please take a moment to register and provide us with some important information NAME E MAIL ADDRESS SOLD BY CIWY STATE ZIPCODE __ PURCHASE DATE COUNTRY MODEL NUMBER TELEPHONE NUMBER SERIAL NUMBER Circle all that apply Off Grid Installation Residential Installation North America Location Utility Connected Installation Commercial Installation Other Extended Warranty Application U S and Canada only OutBack Power Systems offers an optional three year extension to the standard tw
10. OUT CHASSIS GROUND PE CHASSIS GROUND PE AC NEUTRAL IN AC HOT IN VAT DES NOTE CHASSIS GROUND the AC terminal block reads as NEU GROUND BOND ON FX MOBILE SERIES AC HOT OUT supplies power to the loads AC NEUTRAL OUT acts as neutral leg for loads Supplied by the FX CHASSIS GROUND connections are common and act as grounds for both the incoming and outgoing AC circuits AC NEUTRAL IN acts as the neutral leg for AC power supplied by either the grid or a generator to the FX AC HOT IN connects incoming AC from the grid or a generator to the FX This AC is used to run loads and recharge batteries INVERTER ON OFF INVERTER AND DC GROUNDING REQUIREMENTS Connect only to a grounded permanent wiring system Ensure there is only one neutral ground connection in the system at any time Some codes require this connection be made at the main panel only e If the system has a generator its neutral ground connection will probably need to be disengaged For all installations the negative battery conductor should be bonded to the grounding system at one and only one point in the system The FX should never be positive grounded The equipment ground on each is marked with this symbol e5 Box lug for grounding the FX chassis FX PARTS AND ACCESSORIES FX DCC DC COMPARTMENT COVER TURBO FAN COVER Covers the DC terminal area and provides space to mount other components such as a DC cu
11. OUTPUT 1 BLACK TBB AG OUTPUT PH3 BLUE TBB NOULYOINNAAODO 9 13 328 LZEF 906153860 LG OY UN RES SIESYHO NI TELLS NI LOH LG zv YILSYA AC INPUT FH1 BLACK TBH UG Me LnaW ov Od nee MI THES 7 M LOH LG FF SAV1S Hd AG INPUT PH2 RED TRE BLUE TAB AC INPUT PH3 AG INPUT FROM UTILITY GRID OR GENERATOR Three Phase System 25 GENERATOR AUTO START The following schematic shows how to hook up a relay that interfaces with the two wire start generator Three wire start generators require an adapter like the Atkinson GSCM available at www atkinsonelectronics com GENERATOR HOOK UP GENERATOR INVERTER ORO Select one between 2 and 30 amp contacts Two such relays are 1 Radio Shack SPST 30 amp Auto Relay 275 226 2 Grainger 10 amp SPDT relay 5ZH14 MFR Omron G2R 1 S DC1 2 The socket for this relay is Grainger 6C898 MFR Omron P2RF 05 E MOBILE FX INFORMATION When a Mobile system has the option of using either an onboard generator or the utility grid or shore power see next diagram as their AC input e Both the AC Hot and AC Neutral lines must be connected to the appropriate source e A connection can be made using a double pole double throw sw
12. YSTEM PROTECTION An FX Series Inverter Charger is part of an electrical system that protects da Each FX must be part of a permanently grounded The wires electrical system see page 7 Grounding protects The components people and equipment from electrical shock The devices served by the system Grounding must be done according to local and national electrical codes OutBack circuit breakers protect wiring by limiting the amount of current entering a system wired electrical systems require circuit breakers or fuses for protection OutBack offers both breakers and fuses for over current protection If they are provided by other vendors they must be properly rated DC WIRING ORIGINATION DC brass battery terminals with 8M x 1 25 stainless steel threaded studs Red positive Black negative Battery terminal covers Never install extra washers between the terminal mounting surface and the battery cable lug the connection must be direct and secure Always install breakers or fuses within the positive battery cable Torque 2 0 4 0 or larger NEC approved cables rated 75 or higher to 60 inch pounds Nut p di Lock Washer Flat Washer Battery Cable Lug gt 4 Stud AC WIRING ORIGINATION Lexan cover protects AC Wiring Compartment Board AC Wiring Board 9 Ciut Back Bower System AC Terminal Block secures AC connections to the FX using set screws AC HOT OUT AC NEUTRAL
13. als to manually n INVERTER BATTERY TEMP control the FX MATE HUB XCT XCT are not operational INVERTER and ON OFF Replacing the pre installed jumper connecting the ON OFF terminals with switch allows manual control of the FX e Without an ON OFF switch the inverter s will always be ON e Cycling the switch again returns the inverter to the ON mode INVERTER ON OFF id Control Wiring Terminal Block side view Jumper Prior to installing an ON OFF switch if the FX s AC output is off check that the jumper is present and well connected before installing a switch You want to confirm the system is in good working order Suggested switches include Push On Push Off Switches 275 671 275 1555 275 1565 275 617 and 275 011 from Radio Shack Should you decide to install an OutBack MATE at a later date bear in mind the installed switch overrides the control provided by the MATE if the switch is set to OFF If the switch is set to ON the MATE will function normally and control the inverter s system is ordered with a MATE the MATE handles all FX ON OFF functions AUXILIARY OUTPUT AUX AUX The Auxiliary output system uses the AUX and AUX terminals It is programmed through the MATE to do a variety of tasks The default use for these terminals drives the OutBack FX Turbo Kit or DC12 FAN fan for external cooling NOTE These terminals should not be conne
14. ays be used in conjuncture with a disconnect mechanism FXs used in home installations should use properly sized DC circuit breakers A DC breaker includes both overcurrent protection and disconnect capability OutBack Power Systems recommends Class T fuses for marine installations where a DC disconnect is not required FX2532 M T Class T 300 Mobile Only FX2548T Not Recommended VEX3648 Not Recommended WIRE SIZES The following chart contains information on wire sizes the DC resistance of the wires and the corresponding diameters and areas of these wires This information can be used to calculate the voltage drop of the wires or to find an equivalent wire size DC CROSS SECTIONAL AREA APPROXIMATE DIAMETER AWG Resistance in Ohms 1000 feet MILLIMETERS e oa 14 12 10 2 1 1 0 2 0 3 0 0 32 33 MAINTENANCE If damaged or malfunctioning the FX should be repaired by a qualified user installer or service center following OutBack Power Systems instructions and guidelines Please contact your energy dealer for assistance Incorrect repairs and or reassembly risks malfunction electric shock or fire For routine user approved maintenance e Disconnect all circuit breakers and related electrical connections before doing any cleaning or adjustments Solar modules may produce hazardous voltages when exposed to light cover them with opaque material before servicing any connecte
15. cted to any type of DC load greater than one amp The FX includes internal electronic over current protection for the AUX 12 VDC output circuit which auto resets if it is short circuited No additional fuses are required e For automatic or advanced generator start functions the Auxiliary Output can drive a 12V automo tive relay for the two wire starting circuitry of a generator OutBack recommends a good quality gold plated relay NOTE OutBack Power Systems does not support three wire start generators however a three wire to two wire conversion kit is available from an electronic control manufacturer such as Atkinson Electron ICS XCT XCT These terminals are not operational at this time 16 17 RTS MATE HUB WIRING Ciut Back Power Systems AC HOT OUT AC NEUTRAL OUT CHASSIS GROUND PE CHASSIS GROUND PE AC NEUTRAL IN AC HOT IN DVODSS INVERTER ON OFF INVERTER BATTERY TEMP MATE HUB Battery Lights Green Solid GREEN Flashing GREEN Off Yellow O Solid YELLOW Flashing YELLOW Off Solid RED Flashing RED LED Color Green 12 5 or higher Yellow 11 5 to 12 5 Red 11 5 or lower RJ 11 modular jack connects RTS the optional external battery temperature sensor RJ 45 jack connects MATE or HUB to FX using CAT5 cable When a HUB is used plug the RTS into the Master FX which should be plugged into Port 01 The RTS cable is folded and routed u
16. d equipment or service at night e f a remote or automatic generator start system is used disable the automatic starting circuit and or disconnect the generator from its starting battery while servicing it to prevent starting while servicing WARRANTY OutBack Power Systems Two Year Limited Warranty OutBack Power Systems Inc warrants that the products it manufactures will be free from defects in materials and workmanship for a period of two 2 years subject to the conditions set forth below The limited warranty is extended to the original user and is transferable The limited warranty term begins on the date of invoice to the original user of the product The limited warranty does not apply to any product or part thereof damaged by a alteration or disassembly b accident or abuse corrosion d lightning e reverse polarity f repair or service provided by an unauthorized repair facility g operation or installation contrary to instructions pertaining to the product OutBack Power Systems liability for any defective product or any part thereof shall be limited to the repair or replacement of the product at OutBack Power Systems discretion OutBack Power Systems does not warrant or guarantee the workmanship performed by any person or firm installing its products THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS THAT VARY FROM STATE TO STATE OR JURISDICTION TO JURISDICTION OUTBACK POWER
17. default is to drive cooling fans or the Turbo Fan XCT ECT are non operational terminals do not connect 10 WIRE CONNECTIONS NOTE A systems individual voltage requirements 120 single phase 120 240 split phase 3 phase as well as how each FX is to function all determine how the FXs are wired Each FX must be wired to the logical leg or phase of the system Each FX must be programmed or stacked according to this phase Please see the FX and VFX Series Inverter Charger Programming Manual before connecting any wires to or from the FX AC Follow these steps to wire the FX to your system 1 Shut all AC breakers off or remove any fuses before connecting any wiring 2 Shut off all DC breakers including the PV breakers 3 With all power off run lengths of 6 AWG wire between the AC Wiring Compartment Board AC out terminals and a 30 or 60 amp over current protection circuit breaker depending on the FX model The breaker should be installed inside of a metal chassis such as OutBack s FLEXware series PS 2 PS 4 or an existing panel 4 With the over current protection connected run lengths of 6 AWG wire between the AC Wiring Compartment Board AC IN terminals and the AC input breaker The breaker should be installed inside of a metal chassis such as OutBack s PS 2 PS 4 FLEXware series or an existing panel The AC input hot conductor must be supplied through a 60 amp maximum AC branch rated circuit breaker NOTE Connec
18. ding on which model is used e Connecting more power than the continuous rating of the FX may cause breakers to trip or the FX to shut off its AC output e A HUB MATE and FW X240 must be connected to successfully stack these FXs in series parallel NOTES Program the lowest installed FX as the Master 1 2 MASTER the first Slave as an Outback L1 Slave 3 PHASE FX SYSTEM e This system produces 120VAC per phase and 208VAC from phase to phase There can only be one FX per phase on a 3 phase system The non Mobile AC wiring from the AC source and to the AC loads must handle 60 amps All other non Mobile AC wiring must handle a capacity of 60 amps AC Mobile must handle 30 amps e This system can power continuously up to 10 8kW of loads depending on which model is used Connecting more power than the continuous rating of the FX may cause breakers to trip or the FX to shut off its AC output The jumper in the HUB must be moved for 3 phase configuration please see the HUB Installation and User Guide NOTE Program the bottom FX as Master 3ph MASTER and the two lower FXs as 3 phase Slaves 3ph SLAVE Keep the phases in order phase one is connected to the FX programmed L1 phase two is connected to L2 and phase three to L3 or phases A and to inverters and 24 TO AC LOADS AC QUTPUT PH2 RED TBB Jeg sng AL 2 NHHL DMVY9 eq 0 S9QE9 y AC
19. en to the vent opening CAUTION To reduce risk of injury charge only deep cycle lead acid lead antimony lead calcium gel cell or absorbed glass mat type rechargeable batteries Other types of batteries may burst causing personal injury and damage Never charge a frozen battery PERSONAL PRECAUTIONS e Someone should be within range of your voice to come to your aid if needed e Keep plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eyes Wear complete eye protection Avoid touching eyes while working near batteries Wash your hands with soap and warm water when done f battery acid contacts skin or clothing wash immediately with soap and water If acid enters an eye flood the eye with cool running water at once for at least 15 minutes and get medical attention immediately following Baking soda neutralizes lead acid battery electrolyte Keep a supply on hand in the area of the batteries NEVER smoke or allow a spark or flame in vicinity of a battery or generator e Be extra cautious to reduce the risk of dropping a metal tool onto batteries It could short circuit the batteries or other electrical parts can result in fire or explosion Remove personal metal items such as rings bracelets necklaces and watches when working with a battery or other electrical current A battery can produce a short circuit current high enough to weld a ring or the like to metal causing severe burns S
20. imum branch circuit over current protection gt All cables torqued to OutBack specifications gt AC and PV breakers to 22 inch lbs gt All DC connections to 10 foot Ibs gt FX AC terminals to 30 inch lbs gt FX battery breaker to 45 inch lbs All terminal block screws torqued to 2 5 foot Ibs lt 28 29 APPENDIX RATINGS NOMINAL AC OUTPUT VOLTAGE OF AN FX SYSTEM Single Phase 120 VAC at 60 Hz Series Stacked 120 VAC at 60 Hz per AC output leg 240 VAC at 60Hz between the AC output legs Parallel Stacked 120 VAC at 60 Hz on one AC output leg Three Phase Stacked 120 VAC at 60 Hz per AC output leg limit three 208 VAC at 60 Hz between AC output legs RECOMMENDED FX DC VOLTAGE RANGE NOTE The last two digits in the model number designate the nominal DC voltage Example FX2024MT 24V DC Voltage 12V Systems 11 16 VDC VDC volts DC 24V Systems 22 32 VDC 32V Systems 29 43 VDC 48V Systems 44 64 VDC MAXIMUM DC INPUT CURRENT NOTE This is the maximum DC current the FX will draw from the battery when starting very large AC loads It is not used for sizing the DC disconnect or selecting DC cable gauge It is used to select the minimum reasonable battery capacity 12V FXs 600 ADC per FX ADC amps DC 24V FXs 300 ADC per FX 32V FXs 225 ADC per FX 48V FXs 150 ADC per FX RATED DC INPUT CURRENT NOTE This is the maximum continuous DC current that the FX will draw fro
21. itch currently unavailable from OutBack but available from electrical component suppliers which has one connection each for AC hot and AC neutral This switch must be rated to handle the system s maximum AC voltage and AC current SHORE GEN ra nr Mobile FX Double Pole Double Throw Switch h bac INPUT g Ground Switching Contact The Mobile FX s AC input consists of a Hot H Neutral N and Neu Ground Bond G The Mobile FX has an internal Ground Switching Contact that will close when it connects to an AC input 27 INSTALLATION CHECK LIST ITEM All manuals read and reviewed gt OutBack Charge Controller gt MATE gt HUB System mounted with the recommended number and sized fasteners System installed according to National Electrical Code NEC and local codes System inspected FT gt System permanently grounded Did the installer use OutBack recommended wire type and gauge adjusted for temperature ratings and length Non Mobile FX connected to AC circuit with 60 amp maximum branch circuit gt All AC wiring rated for 75 or higher gt Battery cables rated 75 or higher gt 6 AWG wire used for non Mobile FX AC Input Hot gt 10 AWG or larger wire used for HOT OUT gt 10 AWG wire or larger used for Mobile FX AC Input Hot over current protection Mobile FX connected to AC circuit with 30 amp max
22. l be sent freight collect In the event of a product malfunction OutBack cannot bear any responsibility for consequential losses expenses or damage to other components Please read the full warranty at the end of this manual for more information About OutBack Power Systems OutBack Power Systems is a leader in advanced energy conversion technology Our products include true sine wave inverter chargers maximum power point charge controllers system communication components as well as breaker panels breakers accessories and assembled systems Notice of Copyright FX and VFX Series Inverter Charger Installation Manual O 2007 All rights reserved Disclaimer UNLESS SPECIFICALLY AGREED TO IN WRITING OUTBACK POWER SYSTEMS a MAKES NO WARRANTY AS TO THE ACCURACY SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN 115 MANUALS OR OTHER DOCUMENTATION b ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE WHETHER DIRECT INDIRECT CONSEQUENTIAL OR INCIDENTAL WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER S RISK Contact Information OutBack Power Systems 19009 62nd Ave NE Arlington WA 98223 Phone 360 435 6030 Fax 360 435 6019 www outbackpower com Date and Revision September 2007 REV TABLE OF CONTENTS Welcome to the OutBack Power Systems FX Series Inverter Charger 5
23. m the batteries when inverting FX2012 M T 190 ADC ADC Amps DC FX2524 M T 95 ADC FX2532 M T 90 ADC FX3048T 60 ADC vias AC INPUT OPERATING VOLTAGE RANGE NOTE This is the recommended AC input voltage range to be supplied to the FX Voltages outside of this range may damage AC loads connected to the FXs AC output terminals All FX Series Inverter Chargers 90 150 volts AC MAXIMUM AC INPUT CURRENT An AC input source connected to the FX supplies power for two separate internal AC circuits the AC transfer switch and the battery charging system The AC transfer switch transfers the input power to the AC loads The FX s battery charger will back off if the total AC loads including the charger exceed the AC input current limit default setting is 28 AAC This Input Limit can be adjusted using the MATE to avoid overloading a generator or trip a circuit breaker If your generator cannot produce 28 AAC or you are connecting to an AC input source that has a breaker that is rated for less than 30 AAC please refer to the FX and VFX Series Inverter Charger Programming Manual to change this setting All Mobile FXs 30 AAC per FX AAC Amps AC All 120 VAC FXs 60 AAC per FX AAC Amps AC MAXIMUM CURRENT FOR BATTERY CHARGER Due to heat restraints the FX limits incoming AC current to recharge the battery Please refer to the FX and VFX Series Inverter Charger Program
24. ming Manual to adjust this setting The battery charger has an efficiency of 90 Other factors such as cable losses might reduce this efficiency 30 31 MAXIMUM AND DEFAULT AC INPUT AND DC bulk stage OUTPUT VALUES VFX2812 M AC Max 16 AAC Default 14 AAC DC Max 125 ADC VFX3524 M AC Max 20 AAC Default 18 AAC DC Max 85 ADC VFX3232 M AC Max 20 AAC Default 18 AAC DC Max 60 ADC VFX3648 AC Max 20 AAC Default 18 AAC DC 45 ADC INPUT FREQUENCY RANGE NOTE If the AC input source is out of the range noted below the FX will not connect or stay connected All FX Models 56 64 Hz MAXIMUM AC OUTPUT CURRENT This is the amount of surge current that the FX will quickly supply for a split second Depending on the size of the surge the FX can be overloaded for a minimum time of 5 seconds to a maximum time of 30 minutes All 12 VDC FXs 56 AAC per FX for 1 millisecond All Other FXs 70 AAC per FX for 1 millisecond MAXIMUM CONTINUOUS OUTPUT POWER An FX Series Inverter Charger s model number indicates its maximum continuous output power by changing the last two digits to zeros For instance an FX2012MT has a maximum continuous output power of 2000 volt amps MAXIMUM OVERCURRENT PROTECTION AMPACITY This rating specifies the proper overcurrent protection ampacity breakers panel mount circuit breakers e Class T DC fuses are terminal mounted and should alw
25. nder the AC Wiring Compartment s Lexan cover fitting into a small indentation in the aluminum casting between the battery terminals ONLY USE THE OUTBACK RTS OTHER BRANDS YIELD INCORRECT READINGS If the system has multiple FXs and or OutBack Charge Controllers a HUB is required LED Indicates Inverter ON Search Mode or Slave Power Inverter OFF AC Source is Connected AC Input Live Waiting to Connect to the FX No AC Input Present Error An Error Message will be automatically displayed on the MATE Warning A non critical fault happened to the FX the MATE can access this info 25 0 or higher 23 0 to 25 0 23 0 or lower 50 0 or higher 46 0 to 50 0 6 0 or lower SAMPLE INSTALLATIONS SINGLE FX SYSTEM All non Mobile FX AC wiring must handle 60 amps AC or more A60A input breaker must be used for a non Mobile FX and a 30A input breaker for a Mobile FX Asingle FX can continuously power two to three 6KW of loads depending on which model is used Q lt lt 15 60 NEUTRAL NEUTRAL 100 TO 250 AMP DC BREAKER INVERTER CHARGER BATTERY NEUTRAL 15 TO 60 AMP AC BREAKER cS NEUTRAL y DM OO e NX lt 9 18 SERIES SERIES PARALLEL DUAL FX CONFIGURATION This system can continuously power four 7 2kW of loads depending on which model is used All non Mobile FX AC wiring must handle 60A AC or more
26. njury resulting from improper installation of their products Use only the recommended DC and AC wire sizes or greater Be sure all wires are in good condition Install the FX in a dry location preferably indoors LIL M FP Zw Install the FX in a shaded area out of direct sun P d 7 light for best operation For installations where the FX may be exposed to water spray a sealed FX must be used and mounted either with the base down shelf mounting or with the AC wiring compartment facing down wall mounting e If mounted with the base down water cannot be allowed to accumulate around the FX s base There is a drainage system on the base of the FX to dispel condensation e If submerged water can enter this drain and cause failure The Vented FX VFX must be installed in a weather proof enclosure or enclosed area It is not designed for exposure to water or excessive wind blown dust and debris INITIAL INSPECTION Your FX is stoutly packaged for secure shipping Please inspect the packaging and component for damage prior to intallation WARNING WORKING NEAR LEAD ACID BATTERIES CAN BE DANGEROUS BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL OPERATION Design the battery enclosure to prevent accumulation and concentration of hydrogen gas in pockets at the top of the enclosure Vent the battery compartment from the highest point to the outside A sloped lid can also be used to direct the flow of hydrog
27. o not assume these terminals are QR S zu common in the Mobile FX A oo GROUND AC NEUTRAL IN O Connects both the AC input and AC output ground conductors to the CHASSIS GROUND AC HOT IN e and NEU GROUND BOND terminals e f there is only one Mobile FX in the system leave the copper bus provided installed between the CHASSIS GROUND and NEU GROUND BOND terminals If there is more than one Mobile FX in the system remove the copper bus from every Slave FX AUX AUX XCT XCT lt 2 gt INVERTER e ON OFF EN e e BATTERY TEMP MATE HUB AC HOT IN BATTERY INVERTER The AC hot input conductor black must be STATUS Supplied through a 30 amp maximum AC branch rated circuit breaker and connected to the AC HOT IN e 6 AWG wire is required for the FX s AC transfer switch 14 LOW VOLTAGE WIRING This six position terminal block can be unplugged to make wiring easier and to Cut Back simplify the removal and reinstallation of an FX powo It must be securely and completely plugged Spee in for proper FX functioning Otherwise operational SITOIS Carr oc CUT AC NEUTRAL OUT CHASSIS GROUND PE CHASSIS GROUND PE Control Wiring Terminal Block AC NEUTRAL IN AC HOT IN 12 VDC at 0 7 amps 8 4 is available at the AUX AUX terminals yA c LL gt 2 A switch be wired to the INVERTER and ON OFF termin
28. o year limited warranty Purchase of extended warranty coverage is available on products listed below provided conditions shown are met Extended warranty coverage must be purchased within 90 days of the original sale of the product covered PRODUCT COST REQUIRED SURGE PROTECTION EXTENDED WARRANTY Any FX Series Inverter Charger AC Input AC Output DC Input 300 00 OutBack Charge Controller DC Input DC Output 100 00 MATE NA 50 00 HUB 4 NA 35 00 HUB 10 NA 50 00 Product Covered Serial Number Quantity Extended Warranty Cost Total Send check or money order payable to OutBack Power Systems Washington residents please include 8 5 sales tax Include a completed copy of this application and send to OutBack Power Systems Extended Warranty Program 19009 62nd Ave Arlington WA 98223 USA 5 Power Systems 19009 62nd Avenue NE European Sales Office Arlington WA 98223 USA Barcelona ESPANA 1 360 435 6030 34 600 843 845 www outbackpower com 900 0083 01 00 REVA
29. rrent shunt can be used with or without the FX DCA FX DCA DC CONDUIT ADAPTER FX ACA AC CONDUIT ADAPTER Allows the connection of two inch TSC Traffic Extends the AC wiring compartment Signal Conduit to the FX e Connects to OutBack s FLEXware enclosures Connects to OutBack s FLEXware enclosures Protects and secures conduit and cables e Allows for AC breakers and mounting AC CONDUIT PLATE BATTERY TERMINAL COVERS AC conduit connects to the AC Conduit Plate for The caps are made of stiff plastic with a snap on de installations which do not utilize an ACA sign remove them carefully using a flat blade screw driver inserted into the slots on the sides of each cover DC conduit may be required for exposed installations FX DCA and FX ACA cover options allow conduit con nection Always keep the battery terminal covers installed at 40 N p o a C 5 5 Eg Er QY amp 21 Weight is approximately 62 pounds MOUNTING The FX Series Inverter Charger is approved for indoor or enclosed protected mounting only An FX weighs approximately 62 lbs and must be secured with appropriate fasteners to a sturdy mounting surface capable of supporting its weight It is easier for two people to install the FX due to its weight OutBack FXs can be mounted in any position but they perform better in locations offering plenty of
30. t Mobile FX equipment to an AC circuit with 30 amp maximum branch circuit over current protection as per NEC ANSI NFPA 70 While 60 amp over current protection reduces the risk of fire for further reduction do not connect a single FX to both hot legs of a 120 240 VAC AC load center having multi wire common neutral branch circuits connected Use either two FX Series Inverter Chargers wired in a series configuration or an FW X240 Auto Transformer instead DC Use crimped and sealed copper ring terminal lugs with 5 16 hole or compression type lug to connect battery cables to DC terminals Soldered cable lugs are also acceptable e Use recommended cable sizes see page 32 to reduce losses and ensure high performance of FX smaller cables can reduce performance and possibly damage the unit Keep cables together e g using a tie wrap as much as possible e Ensure cables pass through the same knockout and conduit fittings to allow inductive currents to cancel TORQUE REQUIREMENTS CONNECTION TORQUE IN POUND MEASURES AC and PV breakers to 22 inch lbs 2 48 Nm DC shunt to 15 foot lbs 20 4 Nm FX s DC Terminals to 10 foot lbs 13 6 Nm DC battery connections to 10 foot lbs 13 6 Nm FX s AC Terminals to 30 inch lbs 3 38 Nm Table 1 Torque Values for Installation 12 13 AC WIRING NOTES FOR THE NON MOBILE FX AC HOT OUT AC hot output conductor black wire gauge must be sized to the breakers and Qut
31. tion e FX 2012 T 12 VDC 2000 VA e FX 2024 T 24 VDC 2000 VA FX 3048 T 48 VDC 3000 VA Vented Units designed for more protected environments 2812 12 VDC 2800 VA e VFX 3524 24 VDC 3500VA e VFX 3648 48 VDC 3600VA Each model FX has a single phase output marked with this symbol Each inverter puts out a sine wave waveform marked with this symbol N Parts Included One FX Series Inverter Charger e One WARNING ELECTRICAL SHOCK sticker to place on the exterior of the FX One packet of silicone grease to protect CAT 5 cable connections e One installation manual One programming manual e One Turbo Kit sealed units One DC Wiring Cover or DCC vented units READ FIRST IMPORTANT SAFETY INSTRUCTIONS Read all instructions and cautionary markings on the FX the batteries and all appropriate sections of this installation and user manual as well as other component manuals before using the system Be cautious around electricity electrical components and batteries Shocks burns injury and even death can occur if an installer comes in contact with electricity Install all components and wiring according to national and local electrical and building codes This includes Submitting a plan to the local building department Passing inspection Requiring a licensed electrician to do the work when mandated OutBack Power Systems cannot be responsible for system failure damages or i
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