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FX Inverter manual

1. X 240 8 amp 14 4KW 20 240VAC MATE 4i 4283 4 SERIES 200A BYPASS pem G N Li i ds AC LOADS ses A MASTER iere 120 240VAC was 100 AMPS MAX T3 HUB PER LINE _ e oma e eje leiere e a ejejeje L 9 SLAVE DER sis 100 AMP DUAL BYPASS ah livvass on ON o on on on AC OUT SA OUTPUT BREAKERS tt NEUTRAL Gunes STANDARD ON MODEL Il WER soa EE D sta sta 50A Cep kiractos icoo i ACIN 4 ei Q v OUTPUT x 240 INPUT INPUT K i f FOUR ADDITIONAL 50A ele e ejojeo e o e ejoje 5 Q CBI BREAKERS FOR THE AC ads 2 TT SLAVE WC INPUTS TWO ADDITIONAL 25A CBI NEUTRAL BREAKERS FOR THE X 240 AC IN 100 AMPS MAX e e o G2 aGe PER LINE L2 A SLAVE QU AC SOURCE P Pb NEUTRAL Gies 120 240VAC AC IN E d ul i e e e NEUTRAL ALL BREAKERS SHOWN AC BOX 8 10KW 120 240VAC 11 2 14 4KW 120 240VAC BYPASS MECHANISM AC LOADS xao JH ei Le PC BOX SERIES SEALED SERIES VENTED AND TERMINAL 200A MAX mE BLOCKS ARE HOUSED IN 120 240VAC 20 ZE 12V 250A BRKRS 12V 250A BRKRS THE OUTBACK PSAC100Q S 24V 175A BRKRS 24V 250A BRKRS nmm Cour Back 4 50A 48V 100A BRKRS 48V 175A BRKRS s fewer Bits OUTPUT FX BREAKERS 15 M SKW 4 FX2024 M 4 FX2012 M
2. ADV choose product FX MATE L ADV FX PAGE1 choose category ADV INV CHGR PG2 l ADV FX PAGE2 choose category PGI GRID GEN PG3 L ADV FX GEN POO ac input 00 5 min connect delay DOWN INC DEC PORT JL ADV FX GEN POO ac2 gen 108 vac lower limit DOWN INC DEC PORT JL ADV FX GEN POO ac2 gen 140 vac upper limit DOWN INC DEC PORT JL ADV FX GEN POO ac2 gen 30 0 aac input limit DOWN INC DEC PORT JL ADV FX GEN POO ac2 gen 60 cycles transfer delay DOWN INC DEC PORT L ADV FX GEN POO ac2 gen OFF support DOWN OFF ON PORT JL ADV FX GEN GEN programming completed TOP ADV MAIN Installation amp Programming Manual Page 56 Once the password has been correctly entered the ADV CHOOSE PRODUCT is displayed Selecting FX allows adjustment of the FX s advanced programming Selecting PG2 advances the user to the second page of the advanced menu Selecting GEN allows adjustment of the AC input set points and operation The AC INPUT CONNECT DELAY set point adjusts the time period of when the FX sees an acceptable AC source to when it connects the AC loads to that source This is useful to allow a generator to warm up This setting has a range between 0 2 minutes to 15 minutes in 0 1 minute increments The AC2 GEN LOWER LIMIT set point allows adjustment of the min
3. ep T SLAVE i SLAVE SLAVE A total of up to ten OutBack products plus one MATE displays can be used with a HUB 10 shown above The HUB 4 will only accept four OutBack products plus one MATE NOTE There is a limit of ten FX s when operated as a stacked system Installation amp Programming Manual FX amp VFX Series Inverter Charger System Copyright 2003 OutBack Power Systems Inc 900 0027 1 19009 62 Ave NE Arlington WA 98223 USA Page 16 Rev 7 2 08 26 05 Tel 360 435 6030 Fax 360 435 6019 FX SYSTEM CONFIGURATIONS The FX System Configuration section shows diagrams of some typical system configurations using the FX These diagrams are for non Mobile FX installations only Below these diagrams are notes for how to change each diagrams to accommodate a Mobile installation There are diagrams for a single FX two FX s in series or series parallel see NOTE below two FX s in parallel four FX s in series parallel see NOTE below four FX s in parallel and a 3 phase system The diagrams show the proper breakers and wiring for the AC side of the installations as well as connections to the HUB MATE and X 240 if applicable Also included is information on the maximum continuous power of the sys
4. ac output o backfeed DOWN UP TOP PORT i STATUS FX ERROR P00 nd of error menu UP TOP STATUS Installation amp Programming Manual Page 46 The MAIN screen is where the menu system starts The four words in the bottom line of the display correspond to the four buttons located below the display The word in BOLD on the bottom line indicates the selection used to advance the display to the next screen Pressing the left two buttons simultaneously from anywhere in the menu will return you to this screen Allows selection of the product type FX FX inverter charger system MX MX60 PV MPPT charge controller MODES Status and allows adjustment of Inverter AC input Charger Aux and EQ METER Provides the AC voltages and currents of the FX BATT Provides the battery voltage and charger set points and timers PG2 Displays additional sections ERRORS WARNINGS and PG3 PG1 Returns to page 1 of the STATUS section ERROR Displays the different causes for errors and qualifies each cause with a Yes or No WARN Displays the different causes for warnings and qualifies each with a Yes or No PG3 Displays additional sections reason for last DISCONNECT and SELL LOW AC OUTPUT VOLTAGE indicates that the inverter was not able to maintain adequate AC output voltage 105 VAC or above to power the loads connected This is typically caused by the load demanding more power than the inverter is abl
5. aarmer 22021200 360 435 6030 120VAC BREAKERS P UM T S M d 4 0 7 2KW 5DA B YPASS PAR NOTES Program the top FX as Master 1 2PH MASTER and the lower FX as an OutBack L1 Slave OB SLAVE L1 See the STACKING INFORMATION section of the manual for more info NON MOBILE FX NOTES The AC OUTPUT NEUTRAL IS NOT BONDED TO THE CHASSIS OR THE GROUND TERMINAL of the FX system This connection is to be made by the installer either in the AC service entrance or within the AC load distribution panel of the electrical system The AC input AC output and DC terminals are isolated from the metal chassis of the FX Proper grounding of these circuits and the chassis of the FX is the responsibility of the installer MOBILE FX NOTES The AC input source to the FX grid and or generator must have an internal neutral ground connection On the above diagram the AC source s neutral conductor must go directly to the FXs AC NEUTRAL IN terminal or to a separate neutral busbar that is isolated from the FX s AC output neutral The AC output of the FX must go to a separate AC output busbar that is isolated from the AC input neutral A bypass mechanism must bypass the AC source s hot and neutral wires Proper grounding of the DC circuit and the chassis of the FX is the responsibility of the installer Copyright 2003 OutBack Power Systems Inc FX amp VFX Series Inverter Charger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 9822
6. GRID MENU The GRID category of the advanced menu section allows for adjustment of the AC input voltage window and time delays to match the characteristics of the AC source if that AC source is the utility grid This setting can be found in the SETUP FX INPUT menu Only Grid Tie FX s have a default of GRID as the AC source All other FX types have an AC input default of GEN If the users AC source is the utility grid return to the SETUP FX INPUT section page 49 and change the AC Transfer Control screen to GRID Once the password has been correctly entered the ADV CHOOSE PRODUCT is displayed Selecting FX allows adjustment of the FX s advanced programming ADV choose product FX MATE ADV FX PAGE1 choose category Selecting PG2 advances the user to the second page of the advanced menu ADV INV CHGR PG2 ADV FX PAGE2 Selecting lt GRID gt allows adjustment of the AC input set points and operation choose category PG1 GRID GEN PG3 4 ADV FX GRID POO The AC INPUT CONNECT DELAY set point adjusts the time period of when the FX sees an ac input 00 5 min acceptable AC source to when it connects the AC loads to that source This is useful to allow the utility grid to become stable after a utility power outage This setting has a range between 0 2 connect delay i minutes to 15 minutes in 0 1 minute increments DOWN INC DE
7. L ADV FX INVERTER inverter programming completed TOP ADV MAIN Copyright 2003 O OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 Once the password has been correctly entered the ADV CHOOSE PRODUCT menu is displayed Selecting lt FX gt allows adjustment of the FX s advanced programming Selecting lt INV gt allows adjustment of the FX s inverter set points and operation The SEARCH SENSITIVITY setting determines how much AC load is required to make the FX switch from the search mode to the normal inverter on mode Increasing the number INC decreases the sensitivity more power must be turned on to bring the FX out of search while decreasing the number DEC increases the sensitivity less power must be turned on to bring the FX out of search Adjusting this setting to zero will effectively disable the search mode operation The SEARCH PULSE LENGTH setting determines the number of pulses produced by the inverter in quick succession actually AC cycles which are used to detect level of AC load connected Some AC loads do not draw much power from a single AC pulse setting this value to 8 or more pulses may allow the AC load to be detected more reliably This setting has a range between 4 cycles and 20 cycles in 1 cycle increments The SEARCH PULSE SPACING is the number of AC cycles that the inverter
8. MATE MENU MAP eed ge d WO TI3S NIWA WO TI CO LOd X3 AQ0Vv Used 9e d ye d eed MOVIS II N39 Qno FC MOVIS Xv c9d 9d NAS Oe 19d Od X4 A0Y COd XJ AQv NIYA ALVA XW Xd nN3lN Q3ONVAGQV SUSSDS huo9 y po2uEeApV Xd SALVIA ced qued 49H9 ANI cod MWNOHO ANI Av LOd X3 AQV Installation amp Programming Manual FX amp VFX Series Inverter Charger System Copyright 2003 O OutBack Power Systems Inc 900 0027 1 Rev 7 2 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 Page 41 08 26 05 MATE SCREENS Summary Screen The OutBack MATE includes a SUMMARY screen to allow easy understanding of the FX operation The display uses both words and symbols to show what currently is happening in the system along with a limited amount of numbers This makes it easier for the System user to understand where the power is flowing within the system The first line of the summary screen displays DC AC and is measured in kilowatts KW This is to indicate the approximate AC power that is being both produced and consumed by all the FX s connected to the MATE multiple FX s can be connected to one MATE through the HUB Basically it shows how much work the FX s are doing and relates to energy being transferred between the FX s and the batteries The second line of the summary screen displays AC Load and has a light bulb symbol that appears for every 500 watts of po
9. POWER SAVE LEVEL MASTER ADJUST ONLY to 2 and watch the 2 slave s port 2 Inverter LED turn on Adjust the POWER SAVE LEVEL MASTER ADJUST ONLY to 3 and watch the 3 slave s port 4 Inverter LED turn on If you have more than three slaves then keep increasing the value in the POWER SAVE LEVEL MASTER ADJUST ONLY screen and verify that each slave s Inverter LED comes on as expected You have now verified that all FX s are stacked correctly so adjust the POWER SAVE LEVEL MASTER ADJUST ONLY back down to 0 and have fun with your system 3 PHASE STACKED SYSTEM 3 FX S ONLY This type of system will include only three FX s and must be set up as described here Turn off all AC Output and AC Input breakers before powering up FX s In 3 phase stacking am assuming that the top FX is plugged into port 1 of the HUB the 2 d EX down is plugged into port 2 and the 3 FX down is plugged into port 3 This is not a rule just for simplicity The HUB has a jumper on it that needs to be changed for 3 phase stacking refer to the HUB manual Using the MATE go to the stacking menu explained earlier in the Stacking Instructions section You are now at the 1 stacking menu called Stack Phase In the upper right hand corner of the mate screen will always be the HUB port number of the FX you re working with at the time Let s start out with the FX that s on port 1 If something other than P01 appears in the upper right hand corner
10. OFF OFF OFF S0A 50A SOA JS0A OFF OFF SOAESOA OFF OFF 2sa 254 X 240 KE BYPASS ole OUTPUT eje INPUT oola Oa 2 o AC SOURCE x 120 240VACF e 02 Oo 20o NEUTRAL AC IN e e e eOc ezOe e NEUTRAL 4 5KW 120 240VAC 5 6 7 2KW 120 240VAC au Breakers sHown PS2AC PS2DC SERIES SEALED SERIES VENTED SAX succ AT AC LOADS 4z roe FX Le 12V 250A BRKRS 12V 250A BRKRS IN THE OUTBACK PS2ACSOD 120 240VAC 00 308 BYPASS rh a 24V 175A BRKRS 24V 250A BRKRS MIB 45y 100A BRKRS 48V 175A BRKRS g 2 POLE Cutach 50A OUTPUT 7 Power Systems BREAKERS 4 0KW 2 FX2024 M 2 FX2012 M n AC SOURCE mjo ke FX s SE 19009 62nd AVE NE 2 50A pesi pe t dd pcr ARLINGTON WA 98223 120 240VAC 00 M X INPUT L2 BATTERY mu Mm PC 360 435 6030 bp BREAKERS d UCM z gt NEE 4 0 7 2KW SDA BYPASS SER NOTES The X 240 autotransformer located at the top middle of the diagram should never be used in a system that is programmed for Classic stacking If an X 240 is connected between two 120 VAC output legs program the top FX as Master 1 2PH MASTER and the lower FX as an OutBack L2 slave OB SLAVE L2 If the X 240 is not included
11. All VFXs come with the DCC and all FX T s come with the Turbo The ACA and the DCA must be ordered separately The first dimension is inches and the second value in parenthesis is the metric value in millimeters DCC or Turbo ACA K U T O A L je DCA Depth out from Wall Height up from Shelf 11 87 inches 301 mm 12 87 INCHES 327mm with Turbo installed For installations where the FX may be exposed to water spray a sealed FX must be used A sealed FX that may be exposed to water spray should be mounted either with the base down shelf mounting or with the AC wiring compartment facing down wall mounting This will minimize the entry of water into the AC wiring compartment 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 If submerged water can enter this drain and cause failure The ACA can be used to connect the FX to the PS2AC PS4AC or 2 conduit The side of the ACA can be used to add an AC outlet and one or two of OutBack s AC rated OBDC circuit breakers up to 70 amps max When these items are added to the FX it should only be used in an area that is protected from rain The DCA can be used to connect the FX to the PS2DC PS4DC or 2 conduit AC Wiring Compartment with Outlet or Circuit T i UU T f ia i Breaker Knock Outs VII uit frm LL o e F
12. Black flush mount version of the MATE shown below This option includes an RS 232 port MATE2M Black flush mount version with a simplified menu designed specifically for the Mobile market Includes RS 232 access OutBack MATE System Controllers MATE MATE 2 amp MATE 2M Installation amp Programming Manual FX amp VFX Series Inverter Charger System Copyright 2003 OutBack Power Systems Inc 900 0027 1 19009 62 Ave NE Arlington WA 98223 USA Page 34 Rev 7 2 08 26 05 Tel 360 435 6030 Fax 360 435 6019 MATE SYSTEM CONTROLLER AND DISPLAY OUTBACK MATE System Controller and Display Inverter AC Input LED Indicator LED Indicator green yellow Dedicated Dedicated AC Input Inverter Control Control HOT Key HOT Key Soft Keys Each one of the soft keys corresponds to a word on the bottom line of the LCD display The menu system displayed on the MATE will vary depending on the software version that the MATE was programmed with at the time of manufacturing or during its last software upgrade For your particular menu system consult your MATE manual The following pages show the portion of the menu structure that relates to the FX Most of the menu will be consistent no matter what type of FX you have purchased The MATE displays that follow are from the most current MATE being sold by OutBack Power Systems The DC voltage values the letters vdc usually follow these values shown in the
13. Quad Stacked 4 FX system as an example If you have less than four FX s then any reference to FX s on ports greater than the amount of FX s in your system will not apply to your system If you have more than four FX s then follow the natural pattern of programming that will become apparent in this example In a quad stack am assuming that the top FX is plugged into port 1 of the HUB the 2 EX down is plugged into port 2 the 3 FX down is plugged into port 3 and the 4 FX down is plugged into port 4 again location of the FXs is not a rule just for simplicity Installation amp Programming Manual FX amp VFX Series Inverter Charger System Copyright 2003 OutBack Power Systems Inc 900 0027 1 19009 62 Ave NE Arlington WA 98223 USA Page 28 Rev 7 2 08 26 05 Tel 360 435 6030 Fax 360 435 6019 STACKING INSTRUCTIONS System Examples Continued Using the MATE go to the stacking menu explained earlier in the Stacking Instructions section You are now at the i stacking menu called Stack Phase In the upper right hand corner of the mate screen will always be the HUB port number of the FX you re working with at the time Let s start out with the FX that s on port 1 If something other than P01 appears in the upper right hand corner then press the PORT button until PO1 appears Set the Stack Phase of the port 1 FX to 1 2 PH Master Press the PORT button and verify that the label in the upper right hand corner d
14. half of the FX s on each Leg Connected between the AC Output Legs will be an X 240 autotransformer that gets installed in the PSAC or PS2AC The X 240 can perform two operations that a classically stacked system cannot perform and can handle more that two FX s First it can produce 240VAC from one Leg if that 240VAC load is small enough This saves power in the long run by keeping the FX s on the other Leg in sleep mode Secondly the X 240 allows each FX to power loads on the Leg of which it is not directly connected This allow the Master FX on Leg 1 to power loads on Leg 2 without waking and Slave FX s unnecessarily The biggest advantage is that this system is very tolerant of imbalanced loads on the two 120 vac Legs on the AC output By the magic of the X 240 autotransformer together with the control method used in the FX the AC loads are balanced on the two Legs automatically This maximizes the efficiency of the FX system and allows larger loads to be operated without overloading one of the FX s The AC Input source generator or grid must be 240VAC for both Legs to be powered and for no faults to occur 3 PHASE This stacking method pertains to a system that has three FX s connected to three 120VAC Output Legs that will produce 208VAC between any two Legs of the 3 phase system In this stacking method only three FX s can be used Each of the three FX s will be connected to its own 120VAC Output Leg To set the system up properly an
15. maintenance watering and more gassing always vent the batteries out of the building but will save you money on gas and generator repairs Please ask the battery manufacturer for the maximum Absorb voltage of the batteries BATTERY EQUALIZATION In order to make sure the batteries stay healthy they should not be discharged over 5096 and should be regularly charged back to near full capacity For flooded lead acid batteries full capacity is only achieved by equalizing the batteries Sealed batteries should never be equalized unless specifically recommended by the battery manufacturer An Equalize charge should be performed every one to six months depending on how deep and how often your batteries get discharged The FX will not automatically perform an Equalize charge The user must use the MATE to manually start an Equalize charge Check with the battery manufacturer for proper equalizing instructions RTS THE REMOTE TEMPERATURE SENSOR The Temperature Compensated Battery Voltage is on the MATE screen Main Status FX Batt Down When an RTS is plugged into the system the Absorb Float and Equalize voltage set points are temperature compensated The Refloat voltage generator start set points and all low battery voltage initializations are not temperature compensated BATTERY CHARGING SEQUENCE The following diagram shows the algorithm that the FX uses to charge the batteries When an AC voltage source is conn
16. master and is considered to be the L2 phase Classic stacking can only stack two FX s and there is no load sharing which is possible with OutBack stacking OB SLAVE L1 Single Phase If you have a system with two to ten FX s and you wish to produce 120VAC on the same AC Output Leg set the stack phase of the FX s you want as the slaves to OB Slave L1 and make sure that they are in the lowest numbered ports of the HUB OB Slave L1 is used for FX s that run in parallel with the master These FX s are considered the L1 phase Split Phase Alternately if you have a system with two to ten FX s and an X 240 autotransformer and you wish to produce 120VAC on both AC Output Legs and also 240VAC between the two AC Output Legs then set the stack phase of the FX s you want as parallel slaves Leg 1 to OB Slave L1 Make sure the slave FX s are in the lowest numbered ports of the HUB OB Slave L1 is used for FX s that run in parallel with the master OutBack s X 240 autotransfromer must be included in the system to use the split phase stacking option This FX is considered the L1 phase OB SLAVE L2 If you have a system with two to ten FX s and an X 240 autotransformer and you wish to produce 120VAC on both AC Output Legs and also 240VAC between the two AC Output Legs then set the stack phase of the FX s you want as series slaves Leg 2 to OB Slave L2 Make sure the slave FX s are in the lowest numbered ports of the HUB OB Slave L2 is used for F
17. the ac1 grid limit setting In this example there are multiple operating modes for the aux output function Pressing INC or DEC will cycle through the available modes Copyright 2003 OutBack Power Systems Inc FX amp VFX Series Inverter Charger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA 900 0027 1 Tel 360 435 6030 Fax 360 435 6019 Rev 7 2 08 26 05 Page 37 MATE SYSTEM CONTROLLER AND DISPLAY Inverter Control The OutBack MATE includes an INV hot key to allow direct control of the inverter from anywhere in the menu system The INV key is located on the right side of the MATE LCD display Pressing the INV key takes you to the INVERTER CONTROL menu shown below A green LED indicator is located above the INV key which flashes when the inverter is either in the search or power save modes and is on continuously when full AC output voltage is available from the inverter When the inverter is turned off the green LED will not be illuminated CINES INVERTER CONTROL currently OFF SRCH ON ON OK Installation amp Programming Manual Page 38 Pressing the INV key once brings up the INVERTER CONTROL screen To turn the inverter ON press the key located below the word ON Selecting SRCH will cause the inverter to begin operating in the search mode as long as the AC load connected is smaller than allowed by the programming of the search function
18. 1 of the HUB The default for every FX is 1 2ph Master Pressing PORT will select the next port that a FX is plugged into When the port for the FX has been chosen press INC until the proper master or slave type appears 1 2ph Master Classic Slave OB Slave L1 OB Slave L2 3ph Master or 3ph Slave The POWER SAVE LEVEL MASTER ADJUST ONLY is used to set the number of slaves that will remain On when the system is operating at light load levels The value corresponds to the rank of the SLAVE For example setting this value to 2 allows all SLAVE s with POWER SAVE LEVEL SLAVE ADJUST ONLY see next screen values of 2 or less to stay on at all times This setting is for OutBack Stacking methods only system with OB Slave L1 or OB Slave L2 slaves The POWER SAVE LEVEL SLAVE ADJUST ONLY is used to set a slave inverter s priority for operation when the total FX system is operating at medium to heavy loads By setting each of the slaves to a different number you can control the sequence that the slave inverters are turned on by the master inverter This setting is necessary for OutBack Stacking methods Selecting TOP returns the user to the top of the ADV FX STACK menu section Selecting ADV returns you to the advanced screen to allow selection of another product connected to the MATE Selecting MAIN returns the display to the MAIN screen FX amp VFX Series Inverter Charger System 900 0027 1 Rev 7 2 In
19. 435 6019 Rev 7 2 08 26 05 Page 15 HUB COMMUNICATION MANAGER The HUB communication manager allows the MATE to control and monitor a maximum of ten OutBack products Currently the HUB comes in two types The HUB 4 can connect up to four Outback products FX s and or MX 60 s The HUB 10 shown below can connect up to ten Outback products FX s and or MX 60 s The FX s can be operated in a stacked or independent configuration If the FX s are to be stacked the HUB must be part of the system In a stacked configuration the Master FX must be plugged into port 1 of the HUB The Slave inverters must use the following ports example for 8 inverters and 2 MX 60 s the Master must be plugged into Port 1 and the seven Slaves must be plugged into Ports 2 8 The MX 60 s can use Ports 9 amp 10 Future OutBack products will also be compatible with the HUB When using the HUB the MATE must be plugged into the 1st MATE port of the HUB The HUB manages both the inter FX communications and the MATE FX communication When a HUB is used in conjuncture with the RTS the RTS Remote Temperature Sensor must be plugged into the Master FX which must be plugged into port 1 of the HUB If this is the case only one RTS is required for all devices plugged into the HUB When two or more FX s are stacked in a series or parallel configuration the system automatically turns off any excess slave FX s to save power and maximize conversion efficiency This power save system
20. ACAs AC Compartment Adapter When two or more FX s are installed in close proximity such as in this installation it may be useful to install one or more DC 12 Fan Kits inside the PS4DC or PS2DC only one will fit that will pressurize this enclosure forcing air up through the DC Manifold and down over the external fins of the FXs This will improve the battery charging performance by reducing the possibility of the FX s limiting charging due to reaching their maximum allowed temperatures The AUX output of the FX can be used to power the DC 12 Fan These components are designed to complete the installation to NEC code while offering flexibility for future expansion 0 00 0 0 door TT 00000000 8 Installation amp Programming Manual FX amp VFX Series Inverter Charger System Copyright 2003 OutBack Power Systems Inc 900 0027 1 19009 62 Ave NE Arlington WA 98223 USA Page 10 Rev 7 2 08 26 05 Tel 360 435 6030 Fax 360 435 6019 AC WIRING CONNECTIONS The FX system and the other OutBack balance of system components are designed to make it easy to meet bot
21. AGS functions The generators starting circuitry must be connected to the currently MAN OFF AUX ports of the control terminal block see pages 11 amp 12 to use this screen to manually turn the generator ON or OFF or to let the FX automatically perform the AGS functions When the OFF AUTO ON OK AGS functions have not been programmed the screen will show MAN OFF indicating that the generator is controlled manually and is OFF Pressing the ON button will change the screen into MAN ON and the generator will turn ON To put this screen in AUTO mode you must access the AGS SETUP menu See your MATE manual for details CHARGER CONTROL Pressing the AC IN key a third time brings up the CHARGER CONTROL screen This allows ee x AUTO operation of the battery charger to be preset for when an AC source is available In AUTO ae mode the charger will start charging when an AC source connects to the FX or when the FX OFF AUTO OK decides the batteries need charging In OFF mode the charger stays off but the AC source is still passed through to the loads Pressing the AC IN key a fourth time brings up the CHARGER MODE CONTROL screen This CHARGERS MODE GONTROL screen allows the MATE to issue system wide global charger commands Both OutBack MX SC EE Mode and FX products will respond to global charger commands if they are connected through the BULK EQ OK HUE Pressing BULK brings up the BUL
22. CABLE OutBack also offers stud mounted fuses SMF for non NEC code installations in 100 175 and 250 amp sizes These are the same fuses included with the Mobile FX The minimum recommended cable size varies with the DC voltage VFX2812 VFX2812M FX2012T FX2012MT VFX3524 and VFX3524M installations must use 4 0 AWG 120mm2 cable minimum VFX3648 FX2524T FX2524MT and FX3048T installations can use 2 0 AWG 70mm2 cable as long as the distances are short less than 10 feet 3 meters per cable If longer distances are required increase the cable size to the next size as a minimum Keep the cables together as much as possible for their entire length Tying or taping the cables together is also advisable EQUIPMENT GROUND TERMINALS A set screw type box lug is provided near the DC terminals to allow the connection of an equipment grounding conductor for the metal chassis of the inverter It is located behind the battery negative terminal on the top of the inverter casting A green ground symbol marks the location When mounting an FX to a PS2MP or PSAMP a star washer located under one of the four screws that connect the FXs chassis to the mounting plate provides grounding of the FX to the mounting plate Connection to the ground terminal is not required if the star washer is used to connect the FX to the mounting plate and the mounting plate is grounded BATTERY TERMINAL COVERS The battery terminal covers simply snap on They are a little bri
23. Copyright 2003 OutBack Power Systems Inc 900 0027 1 19009 62 Ave NE Arlington WA 98223 USA Page 32 Rev 7 2 08 26 05 Tel 360 435 6030 Fax 360 435 6019 MOBLIE FX INFORMATION Dual Input Transfer Switch Setup In many cases systems will have the option of using either an onboard generator or the utility grid shore power as their AC input When this is the case both the AC Hot and AC Neutral lines must be connected to the appropriate source Currently OutBack Power Systems does not produce a product that will accomplish this function Therefore the consumer must purchase a device that accomplishes this task The simplest form of this device is a double pole double throw switch The words double pole indicates that there are two connections one for AC Hot and one for AC Neutral The words double throw indicate that there are two sets of poles that can be contacted This switch must be rated to handle the maximum AC voltage and AC current that it will see When using a Mobile FX with an onboard generator and a connection that can be made to shore power refer to the diagram below 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 open when it connects to an AC input This allows the FX to make the neutral ground bond when an AC input is not connected yet when an AC input connects the neutral ground bond
24. FX is the primary charging device the chances of the FX overheating are heightened When the FX gets to its temperature limits it will back off the charging process to avoid overheating and a shutdown of the FX The Turbo Kit solves this problem by directing air over the casting and its fins thus causing better convection cooling of the FX The signal powering the Turbo Kit fan comes from the auxiliary output of the FX The default setting of the auxiliary output is set to CoolFan which starts the Turbo Kit automatically when the FX starts heating up The instructions for adding a Turbo Kit are included with the Turbo Kit or the FX If you are also automatically starting a generator using the auxiliary output you can program the auxiliary output to GenAlert or use the Advanced Generator Start AGS system and parallel the generator start wires with the Turbo Kit wires When the generator is running the Turbo Kit is also running This solution works because the FX gets hottest when it is charging If the paralleling of the generator and the Turbo Kit doesn t work properly adding a 470 uF micro Farad electrolytic capacitor found at your local electronics shop across the auxiliary output will solve this problem Out Back PowerSystems Copyright 2003 OutBack Power Systems Inc FX amp VFX Series Inverter Charger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA 900 0027 1 Tel 360 435 6030 Fax 360
25. Light Emitting Diodes in the AC compartment of each FX will begin to light For each FX one BATTERY LED will be lit This BATTERY LED should be either the green FULL LED or yellow OK LED If the red LOW LED is lit check the battery voltage and the battery to FX cabling for reasons why the FX thinks the batteries are low The other set of STATUS LED S will begin to light The red ERROR LED may blink a few times but this is just a symptom of powering the FX About 5 seconds to 10 seconds after power is applied the green INVERTER LED should be lit and the AC IN and ERROR LED s should not be lit At this point the FX is producing an AC output voltage or inverting hence the reason the Inverter LED is lit If the user were to connect AC loads to the FX the FX would use battery power to produce AC power to power the loads Before doing this the programming of the FX should be performed using the MATE If applicable this programming should include the following e Choose the AC input type of grid or generator Generator is the default See the SETUP MENU page in the ADVANCED section for more info e Stacking of multiple FX s See the STACKING INFORMATION and the STACKING INSTRUCTION sections for proper setup info Also see the STACKING MENU in the ADVANCED section for programming info e Adjust the charging set points using the battery manufacturers specification See the BATTERY CHARGING INFORMATION s
26. PAGE3 choose category PG2 DISCON SELL MAIN L STATUS FX DISCON P00 acin freq No too high DOWN STATUS PORT Y STATUS FX DISCON P00 acin freq No too low DOWN UP TOP PORT Y STATUS FX DISCON P00 acin voltage No gt max DOWN UP TOP PORT Y STATUS FX DISCON P00 acin voltage No lt min DOWN UP TOP PORT Y STATUS FX DISCON end of DISCON menu UP TOP STATUS Installation amp Programming Manual Page 48 The MAIN screen is where the menu system starts The four words in the bottom line of the display correspond to the four buttons located below the display The word in BOLD on the bottom line indicates the selection used to advance the display to the next screen Pressing the left two buttons simultaneously from anywhere in the menu will return you to this screen Allows selection of the product type FX FX inverter charger system MX MX60 PV MPPT charge controller MODES Status and allows adjustment of Inverter AC input Charger Aux and EQ METER Provides the AC voltages and currents of the FX BATT Provides the battery voltage and charger set points and timers lt PG2 gt Displays additional sections ERRORS WARNINGS and PG3 PG1 Returns to page 1 of the STATUS section ERROR Displays the different causes for errors and qualifies each cause with a Yes or No WARN Displays the different causes for warnings and qualifies each with a Yes or N
27. Selecting OFF turns off the inverters AC output signal Select OK to return to the point in the menu system from where you entered the INVERTER CONTROL screen FX amp VFX Series Inverter Charger System Copyright 2003 OutBack Power Systems Inc 900 0027 1 19009 62 Ave NE Arlington WA 98223 USA Rev7 2 08 26 05 Tel 360 435 6030 Fax 360 435 6019 MATE SYSTEM CONTROLLER AND DISPLAY AC Input Control The OutBack MATE includes a AC IN hot key to allow direct control of the AC input from anywhere in the menu system The AC IN key is located on the left side of the MATE s LCD display Above the AC IN key is a yellow LED indicator which flashes when an AC Source is available but not connected and is on continuously when the AC source is connected If no AC source is available the yellow LED indicator will remain off The screens shown on this page apply to the MATE the MATE B and the MATE 2 only AC INPUT CONTROL Pressing the AC IN key once brings up the AC INPUT CONTROL screen USE enables the currently USE inverter to connect to the AC source when it is available DROP disconnects the AC source but will allow it to be reconnected if the battery gets too low or the inverter is overloaded DROP USE OK Pressing the AC IN key a second time brings up the GEN START CONTROL screen This allows operation of the generator either manually or automatically using the Advanced GEN START CONTROL Generator Start
28. The programming will be saved within the FX s non volatile memory even if the FX is completely shut down AC LOADS 120VAC 4 ea 5 MASTER C39 LLLI 50 AMPS MAX KW e000 Y 50A SINGLE BYPASS WITH ONE 50A OUTPUT BREAKER STANDARD ON MODEL PS2AC 50 BYPASS KIT AC IOB 50 ONE 50A CBI BREAKER FOR THE AC INPUT 50 AMPS MAX AC SOURCE 120VAC el Joto eFe eGo e NEUTRAL 2 0 2 5KW 120VAC 2 8 5 6KW 120VAC ALL BREAKERS SHOWN PS2AC PS2DC SEALED VENTED AND TERMINAL AC LOADS DC POLE GET SUN BED 12V 250A BRKRS IN THE OUTBACK PS2AC5O 120VAC POAMAX 50A BYPASS 24V 175A BRKRS 24V 250A BRKRS FX m ae 48V 100A BRKRS 48V 175A BRKRS 4C re soa OUTPUT gt L1 Ouah BREAKER 2 0KW 1 FX2024 M 1 FX2012 M 3608 ae AC SOURCE Kilo 50A Z eee LU ARLINGTON WA 98223 120VAC POAMAX INPUT gt BATTERY 3 5KW 1 VFX3524 M 360 435 6030 BREAKER 3 6KW 1 VFX3648 2 0 3 6KW 50A BYPASS NON MOBILE FX NOTES The AC OUTPUT NEUTRAL IS NOT BONDED TO THE CHASSIS OR THE GROUND TERMINAL of the FX system This connection is to be made by the installer either in the AC service entrance or within the AC load distribution panel of the electric
29. UP TOP PORT the AC loads subtract the CHARGER CURRENT value from the INPUT CURRENT value L STATUS FX METER P00 The SELL CURRENT meter indicates the amount of AC current that the FX is pushing back into the sell 0 0 aac utility grid This screen is only operational on Grid Tie FX models Multiply this number by the current INPUT VOLTAGE to get the power being sold back to the utility grid DOWN UP TOP PORT L STATUS FX METER P00 This menu displays the FX FIRMWARE REVISION number for the software loaded into the FX s FX firmware 75 microcomputer This may be required when troubleshooting or expanding your system This is not revision the same as the software version in the MATE DOWN UP TOP PORT L STATUS AEN AMETER Selecting TOP returns the user to the top of the STATUS FX METER menu section Selecting end of meter menu STATUS returns to the STATUS screen UP TOP STATUS Installation amp Programming Manual FX amp VFX Series Inverter Charger System Copyright 2003 O OutBack Power Systems Inc 900 0027 1 19009 62 Ave NE Arlington WA 98223 USA Page 44 Rev 7 2 08 26 05 Tel 360 435 6030 Fax 360 435 6019 MATE SCREENS BATTERY MENU The BATTERY menu section allows the user to check the status of the battery voltage and the battery charging process Both the actual battery voltage and the temperature compensated battery voltage are provided The battery charging process set points are displayed along with the associated ti
30. VAC output leg Power higher than 3000 watts can be transferred through the X 240 for starting loads that require large surges but should not be used on a continuous basis Installation amp Programming Manual FX amp VFX Series Inverter Charger System Copyright 2003 O OutBack Power Systems Inc 900 0027 1 19009 62 Ave NE Arlington WA 98223 USA Page 26 Rev 7 2 08 26 05 Tel 360 435 6030 Fax 360 435 6019 STACKING INSTRUCTIONS Stacking Procedure This section will help inform you on how to set up stacking correctly and what the screens in the stacking menu mean Remember for 3 phase stacking a jumper must be set to the 3 ph position in the HUB See HUB manual for further information Make sure that the FX s connect to the lowest numbered ports of the HUB First turn off all AC breakers the Bypass breaker can be left on Next turn on all FX s using their DC breakers and verify that the MATE recognizes all FX s You can verify this by watching the MATE go through its boot up sequence The MATE s boot up sequence will show the following screens 1 G day Mate 2 OutBack Power Systems 3 Version 4 HUB Found 5 Hub ports and the OutBack devices connected to them Screen 5 will allow you to verify that the MATE sees all of the FX s If it doesn t see all of the FX s or if you aren t sure you can do one of two things Either disconnect and reconnect the MATE to the HUB or do a re poll with the MATE A re poll on the MATE
31. adjustment to the HUB is necessary Within the HUB is a jumper that needs to be changed in order for the system to operate correctly See the HUB manual for instructions on this procedure The AC Input source generator or grid must be a 120VAC 208VAC 3 phase source connected to the AC Input terminals of the three FX s X 240 AUTOTRANSFORMER CAPACITY The X 240 autotransformer option is rated at 4000 VA continuously and consumes about 12 watts The PSAC and PS2AC enclosures include mounting for this option and the PSAC not the PS2AC also includes a space to allow the addition of two 12 vdc powered 4 inch muffin fans to increase the continuous power rating of the X 240 This fan can be powered directly from the AUX output of an FX when the AUX output function has been programmed for COOLFAN default mode This enables the 12 vdc fan to turn on automatically when the FX s are powering heavy loads With the additional air flow on the X240 it can handle a maximum of 6000 VA continuously The X 240 option includes a 25 amp 2 pole circuit breaker which is rated for 10096 continuous duty applications It may be necessary to use two X 240 s in systems that include more than four FX s depending on how much power needs to be transferred from one AC Output Leg to the other AC Output Leg In the balancing transformer application with series stacked inverters the X 240 is able to transfer up to 3000 VA from one of the 120 VAC output legs to the other 120
32. are DC terminal mounted fuses and should always be used in conjuncture with a disconnect mechanism FX s used in home installations should use properly sized DC circuit breakers An OBDC circuit breaker includes both overcurrent protection and disconnection capability SMFs are used primarily for marine installations where only DC overcurrent protection is required SMFs are included with all Mobile FXs MODEL AMPACITY DC BREAKER DC FUSE FX2012 M T 250 amps OBDC 250 SMF 250 Mobile Only FX2524 M T 175 amps OBDC 175 SMF 175 Mobile Only FX2532 M T 175 amps OBDC 175 SMF 175 Mobile Only FX3048T 100 amps OBDC 100 Not Recommended VFX2812 M 250 amps OBDC 250 SMF 250 Mobile Only VFX3524 M 250 amps OBDC 250 SMF 250 Mobile Only VFX3232 M 175 amps OBDC 175 SMF 175 Mobile Only VFX3648 175 amps OBDC 175 Not Recommended Installation amp Programming Manual FX amp VFX Series Inverter Charger System Copyright 2003 OutBack Power Systems Inc 900 0027 1 19009 62 Ave NE Arlington WA 98223 USA Page 8 Rev 7 2 08 26 05 Tel 360 435 6030 Fax 360 435 6019 MOUNTING All FX s can be mounted in any position Better performance will be achieved if it is mounted in a location which allows for air to circulate around the exterior of the casting Locating the FX in a cool location will ensure the highest efficiency and power capacity The following drawings provide the mounting and overall dimensions of the FX with the DCC ACA and DCA attached
33. as the soft keys Their operation is dependent on what their label says The label is the word on the bottom line of the LCD directly above the button Soft keys used to navigate the menus are commonly labeled UP lt DOWN gt lt NEXT gt lt BACK gt or lt TOP gt Soft keys that change settings are labeled either with the change they will make such as OFF AUTO and ON or if there are more then a couple values that the setting can be changed to INC and DEC are used to mean increase and decrease respectively SETUP FX INPUT P00 ac transfer GEN In this example pressing DOWN will take you to the next set point screen in control the SETUP FX INPUT menu DOWN GRID GEN PORT SETUP FX INPUT P00 Input setup completed TOP SETUP MAIN SETUP FX INPUT P00 ac transfer GEN control DOWN GRID GEN PORT SETUP FX INPUT P00 acl grid 60 0 aac limit DOWN INC DEC PORT ADV FX AUX aux output CoolFan function DOWN INC DEC PORT In this example pressing lt TOP gt will take you to the first screen in the SETUP FX INPUT menu SETUP will return you to the SETUP FX screen and MAIN will take you back to the Main screen In this example pressing lt GRID gt will change the FX AC transfer control to GRID mode Conversely pressing GEN will change the FX AC transfer control to GEN mode In this example pressing INC or DEC will change the numerical value of
34. battery charger set points and operation choose category ADV INV CHGR PG2 Y ADV FX CHARGER P00 The CHARGER LIMIT is the maximum amount of AC current that will be used by the FX to charge the charger 18 0 aac batteries In most systems this setting will not need to be changed This setting has a range as low as limit 0 0 aac and as high as 12 0 aac to 20 0 aac depending on the model in 1 0 aac increments DOWN INC DEC PORT a 00 The ABSORB SET POINT is the voltage that the batteries will be charged to during the first stage of D the charging process The BULK stage of charging raises the battery voltage to the ABSORB voltage absorb 14 4 vdc S j SUR setpoint and allows the batteries to regain their charge The Absorb Time Limit must be long enough for the DOWN INC DEC PORT batteries to regain 85 95 of their charge This setting has a range between 13 0 vdc and 16 0 vdc t in 0 1 vdc increments ADV FX CHARGER p00 The ABSORB TIME LIMIT can be adjusted to provide enough time at the Absorb Setpoint to achieve absorb 01 0 hrs a fully recharged battery For large battery banks a longer time may be required small battery banks time limit may require a lower setting This setting has a range between 0 hours and 24 hours in 0 1 hour DOWN INC DEC PORT increments ee 0o The FLOAT SET POINT is the voltage that the batteries will be trickle charged to manually started float 13 6 vac ge
35. can be done by following the path MAIN SETUP MATE PG2 COMM REPOLL see the MATE manual for proper operation of the MATE Once you are sure that the MATE recognizes all the FX s connected to the HUB you must access the STACK menu This can be found on the MATE by following the path MAIN ADV any button this screen serves as a warning only PASSWORD press the INC and DEC buttons until the number is 141 and then press ENTER FX PG2 PG3 STACK You are now in the menu used for stacking FX s Before continuing we will inform you on what each screen pertains to the possible selections of that screen and how to choose the next FX for proper programming STACK PHASE The Stack Phase screen establishes which FX is the master and which FX s follows the master s commands Each FX has a default of 1 2ph Master one or two phase Master The FX on port 1 of the HUB is always a Master and usually the only Master otherwise the MATE will give a communication error For a single phase or split two phase system the FX in port 1 of the HUB should remain a 1 2ph Master For a 3 phase system the FX on port 1 of the HUB must be changed to a 3ph Master this procedure will be explained soon To select the next FX connected to the HUB press the PORT button on the MATE In the upper right hand corner of the MATE s screen is the port indicator It will display a P followed by a number indicating the port it is controlling for
36. display will change back to NO as shown below and the red LED will stop flashing A warning will not shut the FX down like an error will STATUS FX PAGE2 PG1 Returns to page 1 of the STATUS section choose category ERROR Displays the different causes for errors and qualifies each cause with a Yes or No E lt WARN gt Displays the different causes for warnings and qualifies each with a Yes or No RGT ERROR WARN PGS PG3 Displays additional sections reason for last DISCONNECT and SELL STATUS FX WARN P00 AC IN FREQUENCY TOO HIGH indicates that the AC input connected to the FX is above the upper acin freq No limit of its frequency window and will not connect to the AC source if the frequency stays this high If too high the frequency of the AC source is above 66 Hz the FX will display this warning DOWN STATUS PORT STRT US FX WARN P00 AC IN FREQUENCY TOO LOW indicates that the AC input connected to the FX is below the lower acin freq No limit of its frequency window and will not connect to the AC source if the frequency stays this low If too low the frequency of the AC source is below 54 Hz the FX will display this warning DOWN UP TOP PORT Y STATUS FX WARN P00 AC IN VOLTAGE TOO HIGH indicates that the AC source s voltage is over the upper limit default acin voltage No is 140 VAC of the FX s voltage window The FX will not connect to the AC source until the voltage too high drops be
37. following MATE displays will be the default values for a 12V version of the FX For the 24V version multiply these values by 2 For the 48V version multiply these values by 4 This multiplication process must be performed for the incremental values as well When changing a voltage setting you will use the increment INC or decrement DEC buttons For example for a 12V FX the increment value is 0 1V A 24V FX has an incremental value of 0 2V and a 48V FX has an incremental value of 0 4V All values displayed in the Setup and Advanced menus are the default values unless otherwise stated For M versions of the MATE example MATE 2 M only the Status and Advanced menus are the same as non M versions of the MATE If you are using an M version of the MATE please consult the MATE manual for proper navigation and screen information Copyright 2003 OutBack Power Systems Inc FX amp VFX Series Inverter Charger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA 900 0027 1 Tel 360 435 6030 Fax 360 435 6019 Rev 7 2 08 26 05 Page 35 MATE SYSTEM CONTROLLER AND DISPLAY This section of the manual will cover how to use the buttons on the MATE to navigate the menus NOTE The menu system displayed on the MATE will vary depending on the software version that the MATE was programmed with at the time of manufacturing or during its last software upgrade MENU STRUCTURE
38. is fully automatic and works with or without the MATE connected to the system Some programming is required when more than two FXs are stacked together See the STACKING INFORMATION section of this manual for more information Currently on 3 phase systems there is a limit of one FX per phase totaling three FX s To convert the HUB into 3 phase mode you must move the jumper on the HUB to the 3 PH position See the HUB instruction manual for details One MATE system controller and display can be connected to the HUB Although there are two Mate ports on the HUB only the 1st Mate port is currently operational The MATE can be located up to 1000 feet 305 meters from the HUB system location Cabling from the HUB to the MATE is completed using standard CAT 5 type ethernet cable with RJ45 modular 8 conductor jacks This wiring is considered to be low voltage limited energy circuitry Refer to the MATE manual for more information on the MATE All cabling from the FX and MX60 communication ports to the HUB is made with CAT 5 type ethernet cabling The maximum distance from the HUB 4 to the FX or MX 60 should be less than 10 feet OutBack includes two 3 foot 1 meter and two 6 foot 2 meter long CAT 5 cables standard with the HUB 4 OutBack includes two 3 foot 1 meter long and four 6 foot 2 meter long CAT 5 cables standard with the HUB 10 Check with your OutBack dealer for additional cables OurBaek ewer Sagamg
39. legs 120 240 VAC split phase or 120 208 VAC three phase there are often slightly different voltages present on each leg This is more likely with generators since their power is small compared to the utility grid When the AC voltage on one leg is reduced to the FX s AC input Lower Limit the FX s connected to that particular leg will reduce their charging current so as not to disconnect from the AC input Source This is a similar situation as the Low AC Input Voltage bullet above but with multiple AC input legs The other FXs on the other AC input legs will not reduce their charging rates unless they too have reached a Lower Limit voltage condition Temperature Limit is Reached Each FX has three temperature sensors that measure the temperature of the FX s capacitors FETs and transformer These temperature sensors will indicate when a temperature has been reached that will adversely affect the FX s operation At these temperatures the FX will back off the charger to reduce the temperature to a sustainable level If you notice that the FX is not charging as hard as you think it should and the FX is very hot to the touch and it gets hot you can be assured that the FX is limiting the charge due to heat Battery Voltage Target is Reached In a system that has only one FX that FX will back off the charger when it reaches a Target voltage Target voltage is either Absorb Float or Equalize In a system with multiple FX s the S
40. page 4 of the advanced menu Selecting MAIN will return the user to the MAIN screen FX amp VFX Series Inverter Charger System 900 0027 1 Rev 7 2 Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA 08 26 05 Tel 360 435 6030 Fax 360 435 6019 MATE SCREENS INVERTER MENU The INVERTER category of the advanced menu section allows adjustment of the inverter s operation to match the AC load and battery requirements Specifically this section allows adjustment of the search function the low battery cut out function the FX s AC output voltage and allows the user to reset the FX to its factory defaults ADV choose product FX MX ATE MAIN d ADV FX PAGE1l choose category ADV INV CHGR PG2 l ADV FX INVERTER P00 search 6 sensitivity DOWN INC DEC L ADV FX INVERTER P00 search 8 cycles pulse length DOWN INC DEC J ADV FX INVERTER P00 search 60 cycles pulse spacing DOWN INC DEC l ADV FX INVERTER P00 low battery 10 5 vdc cut out set point DOWN INC DEC l ADV FX INVERTER P00 low battery 12 5 vdc cut in set point DOWN INC DEC J ADV FX INVERTER P00 adjust 120 vac output voltage DOWN INC DEC u ADV FX INVERTER reset FX to factory defaults DOWN MORE
41. rt E EL E 1 Trianon ool I II I ILI HUHHUH H ILE d Side view of FX with FXA kit attached The Turbo Kit adds 1 25mm additional height to achieve a total height of 12 87 327mm Copyright 2003 OutBack Power Systems Inc FX amp VFX Series Inverter Charger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA 900 0027 1 Tel 360 435 6030 Fax 360 435 6019 Rev 7 2 08 26 05 Page 9 COMPLETE OUTBACK INTEGRATED SYSTEMS Shown below are complete systems of OutBack FX s for indoor installations The system with four FX s is shown mounted to the OutBack PSAMP Power System 4 Mounting Plate where the 4 in refers to the maximum number of FX s that will fit The PSAMP comes with six 1x20mm thread forming screws for attaching FX s and breaker boxes The use of an external toothed star washer provided is required on one screw on each piece of equipment in order to bite through the powder coating and ensure grounding of all metal components The system with two FX s is shown mounted to the smaller PS2MP power system mounting plate The mounting plate will typically need to be bolted to the studs in a wall using at least four 1 4 or 5 16 lag bolts 2 long In addition to the mounting plate these installations are also shown with an OutBack PS4DC or PS2DC DC breaker box PS4AC or PS2AC AC breaker box DCAs DC Conduit Adapter DCCs DC Compartment Cover and
42. soft keys and are used for navigating around the menus and changing values Each soft key has various functions dependent on the label directly above it on the lower line of the LCD The 1 line on the MATE usually displays the path or location of where you are in the menu system The 2 and 3 lines of the MATE usually give you a description of what meter is being displayed or what parameter is currently set in the MATE The words to the left of the 2 and 3 lines should be read together while ignoring the Menu Item Value to the right For instance the parameter on the above MATE screen should be read ac transfer control whose value is GEN The 4 line on the MATE is almost exclusively used for labels to the four soft keys below Each button below the 4 line of the MATE s display corresponds to the word directly above it This manual will denote soft key button presses as BUTTON where BUTTON corresponds with the label displayed on the screen directly above the soft key NOTE Pressing the left two buttons simultaneously from anywhere in the menu will return you to the MAIN menu screen Installation amp Programming Manual FX amp VFX Series Inverter Charger System Copyright 2003 OutBack Power Systems Inc 900 0027 1 19009 62 Ave NE Arlington WA 98223 USA Page 36 Rev 7 2 08 26 05 Tel 360 435 6030 Fax 360 435 6019 MATE SYSTEM CONTROLLER AND DISPLAY SOFT KEYS The four buttons under the LCD are referred to
43. specify what type of AC INPUT is being used whether it is a generator GEN or the utility grid GRID Following this are two screens one for GEN and one for GRID that allow the user to adjust the maximum AC current that the FX will allow to enter before the FX backs off the charger If the charger has backed off all the way and the loads require more current than the AC1 Grid or AC2 Gen limits are set to the FX will produce a warning MAIN The MAIN screen is where the menu system starts The four words in the bottom line of the 6 54 42P display correspond to the four buttons located below the display The word in BOLD on the bottom line indicates the selection used to advance the display to the next screen Pressing the SUM STATUS SETUP ADV left two buttons simultaneously from anywhere in the menu will return you to this screen JL SETUP Allows selection of the product type choose product FX FX inverter charger system MATE MATE system display and user interface FX MATE JL SETUP FX The categories are then displayed for the settings which can be adjusted in the setup menu choose category SRCH Allows adjustment of the settings for the Search mode lt INPUT gt Allows selection of the AC INPUT and current limit adjustment SRCH INPUT MAIN MAIN Returns the display to the MAIN screen l SETUP FX INPUT P00 The AC TRANSFER CONTROL screen lets the use
44. then press the PORT button until PO1 appears Set the Stack Phase of the port 1 FX to 3ph Master The Master FX is considered phase A Press the PORT button and verify that the label in the upper right hand corner displays P02 We are still in the Stack Phase menu but we are now talking to the FX on port 2 Push the INC button five times to set the Stack Phase to 3ph Slave Now you ve set this FX P02 as phase B producing 208VAC between itself and the master P01 Press the PORT button again and verify that the label in the upper right hand corner displays PO3 We are still in the Stack Phase menu but we are now talking to the FX on port 3 Push the INC button five times to set the Stack Phase to 3ph Slave Now you ve set this FX P03 as phase C producing 208VAC between itself and the master P01 and also 208VAC between itself and the FX on phase B The next two screens in the STACK menu do not apply to a 3 phase system so you need not worry about them Remember that the AC input to a 3 phase system must be a 3 phase source generator or grid Have fun with your system Installation amp Programming Manual FX amp VFX Series Inverter Charger System Copyright 2003 O OutBack Power Systems Inc 900 0027 1 19009 62 Ave NE Arlington WA 98223 USA Page 30 Rev 7 2 08 26 05 Tel 360 435 6030 Fax 360 435 6019 AUTOMATIC GENERATOR START INSTRUCTIONS The Aux output of the FX can be programmed to start a 2 wire gas or diesel gen
45. tn sese totas e seta sese ease soto ease e tae sese eaae setae sesta a 25 STACKING INFORMIAT ION iiis ss oceos apae Fasten s eu irn sapra po geed nonas ky eet oko S duoc pea kei Eege NEEN 26 Classic OutBack and 3 Phase Stacking Methods eee eee eee serene eee ee ee eren setas etn nae 26 X 240 AUTOTRANSFORMER CAPACITY eee esee eren eee een tees tn nose totns ese to ense seta sese tease s toes eee ta sese etas esta 26 SLEACKING INSIRUC ECKE deeg egen 27 Stacking PFOCEUUFG ina ne nn nn Ope Etui vU REO NM RUE Eu eE M aded ueus 27 STACK PHASE EE 27 POWER SAVE LEVEL MASTER ADJUST ONLY 4 eee ee eee eee eee eee tane tn aset tasa seen toss etta sese seen ae setae sese tna 28 Copyright 2003 O OutBack Power Systems Inc FX amp VFX Series Inverter Charger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA 900 0027 1 Tel 360 435 6030 Fax 360 435 6019 Rev 7 2 08 26 05 Page 3 POWER SAVE LEVEL SLAVE ADJUST ONLY ssssessnssossnssosonssosenssosenssosenssosenssossvssossnssosssssnsenssesevssesevssesesennse 28 System NAM PLES c M RIA DUAL STACKED SYSTEM USING CLASSIC STACKING sen 28 STACKED SYSTEM USING OUTBACK S PARALLEL STACKIND seen 28 STACKED SYSTEM USING OUTBACK S SERIES PARALLEL STACKING em 29 3 PHASE STACKED SYSTEM 3 FX s ONLY 30 AUTOMATIC GENERATOR START INSTRUCTIONS eee eene entente ense
46. vdc and 14 0 vdc in 0 1 vdc increments The GENALERT ON DELAY is the amount of time that the battery voltage must remain below the GENALERT ON SET POINT voltage for the AUX output to become energized This setting is provided to allow for short periods of heavy load usage This screen is applicable if the AUX OUTPUT FUNCTION has been set to GENALERT This setting has a range between 0 minutes and 240 minutes in 1 minute increments The GENALERT OFF SET POINT is the battery voltage at which the FX will start counting down the GenAlert Off Delay see next screen After the GenAlert Off Delay time has been reached the AUX output is de energized and turns the generator off This screen is applicable if the AUX OUTPUT FUNCTION has been set to GENALERT This setting has a range between 12 0 vdc and 18 0 vdc in 0 1 vdc increments The GENALERT OFF DELAY is the amount of time that the battery voltage must remain above the GENALERT OFF SET POINT voltage for the AUX output to become de energized This setting is provided to allow for smaller battery banks that may attain higher voltages more quickly This screen is applicable if the AUX OUTPUT FUNCTION has been set to GENALERT This setting has a range between 0 minutes and 240 minutes in 1 minute increments The LOADSHED OFF SETPOINT is the battery voltage at which the AUX output is energized to reduce the load on the FX system Once the battery voltage has dropped below this setting for 3 seconds
47. voltage on the AC input of the FX system from an AC input 120 vac source such as utility grid or back up generator When the FX is connected to an AC source the voltage input AC voltage will equal the output AC voltage If the FX is not connected to the AC source the DOWN UP TOP PORT two voltages can differ significantly L STATUS FX METER P00 The INVERTER CURRENT meter indicates the amount of current being supplied to the AC loads Wee 0 0 aac connected to the FX s AC output terminals when the inverter is ON and no AC source is connected current Each aac amp AC equals approximately 120 watts of load When the FX system is connected to DOWN UP TOP PORT an AC source this meter will read 0 L STATUS FX METER P00 The CHARGER CURRENT meter indicates the amount of AC current being used by the battery charger 0 0 aac charger of the FX Each aac amp AC equals approximately 120 watts of charge This meter will current read zero when the FX is not connected to an AC source DOWN UP TOP PORT The INPUT CURRENT meter indicates the total amount of current flowing into the AC input of the STATUS FX METER P00 FX Some of this power may be used by the battery charger with the remainder flowing through the og EE AC transfer switch to the AC loads Passing Thru To estimate the amount of current being used by DOWN
48. will be released by the FX and made by the AC input If the system is 120 240 VAC with 120 240 VAC inputs a Triple Pole Double Throw Switch is required Mobile FX H N e INPUT c P Ground Switching Contact Double Pole Double Throw Switch Copyright 2003 OutBack Power Systems Inc FX amp VFX Series Inverter Charger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA 900 0027 1 Tel 360 435 6030 Fax 360 435 6019 Rev 7 2 08 26 05 Page 33 MATE SYSTEM CONTROLLER AND DISPLAY The OutBack MATE system controller and display allows you to program control and monitor the operation of one or more FX s as well as any other OutBack products such as the MX60 MPPT charge controller When connecting a MATE to more than one product is required a HUB 4 or HUB 10 communication manager must be included in the system The MATE can be located up to 1000 feet 300 meters from the FX system using standard 8 conductor CAT 5 type communication cabling This wiring is considered to be a low voltage limited energy circuit The MATE can be used to program the FX and then removed in most cases There are however some settings that are located within the MATE itself Settings that require the use of the MATE s time and date programmable through the MATE are stored within the MATE and therefore the MATE must be connected to the FX or HUB for these setting to work All of the setti
49. will include only two FX s and must be set up as described here Turn off all AC Output and AC Input breakers before powering up FX s In a dual stack am assuming that the top FX is plugged into port 1 of the HUB and the 2 7 FX down is plugged into port 2 the location of the FXs is not a rule just for simplicity Using the MATE go to the stacking menu explained earlier in the Stacking Instructions section You are now at the 1 stacking menu called Stack Phase In the upper right hand corner of the mate screen will always be the HUB port number of the FX you re working with at the time Let s start out with the FX that s on port 1 If something other than P01 appears in the upper right hand corner then press the PORT button until PO1 appears Set the Stack Phase of the port 1 FX to 1 2 PH Master Press the PORT button and verify that the label in the upper right hand corner displays P02 We are still in the Stack Phase menu but we are now talking to the FX on port 2 Push the INC button once to set the Stack Phase to Classic Slave Now you ve set 1 FX P02 to be in series with the master P01 The next two screens in the STACK menu do not apply to a Classically stacked system so you need not worry about them Have fun with your system STACKED SYSTEM USING OUTBACK S PARALLEL STACKING This type of system may have between 2 and 10 FX s that will have their AC Outputs connected to the same Leg We will be using a
50. work of generator HOOK UP starting Select one between 2 and 30 GENERATOR amp contacts 1 Radio Shack SPST 30 amp Auto Relay 275 226 2 Grainger 10 amp SPDT relay 5ZH14 MFR Omron G2R 1 S DC12 The socket for this relay is Grainger 6C898 MFR Omron P2RF 05 E Copyright 2003 OutBack Power Systems Inc FX amp VFX Series Inverter Charger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA 900 0027 1 Tel 360 435 6030 Fax 360 435 6019 Rev 7 2 08 26 05 Page 31 MOBILE FX INFORMATION General GROUND SWITCHING How it works With no AC input signal present the FX inverter s Neutral Output is tied to Chassis Ground and hence to the Boat or RV Ground This is similar to any Home installation where one conductor Neutral for the US must be grounded When an AC input is applied and the inverter allows it to transfer the Neutral Output to Ground bond within the inverter is broken The Neutral Output line is then connected to the Input s Neutral and also the Ground of the Input source At this point the FX inverter is using the Ground supplied by shore power or the generator as its Neutral to Ground bond and this Ground becomes the inverters Ground STACKING MOBILE FX INVERTER CHARGERS The Master will be configured normally where the AC Input s Ground is connected to the bussed GND NEU connection of the FX inverter The slave inverters must have the buss removed and the Groun
51. 08 26 05 Tel 360 435 6030 Fax 360 435 6019 Installation amp Programming Manual FX amp VFX Series Inverter Charger System Copyright 2003 OutBack Power Systems Inc 900 0027 1 19009 62 Ave NE Arlington WA 98223 USA Page 2 Rev 7 2 08 26 05 Tel 360435 6030 Fax 360 435 6019 TABLE OF CONTENTS IMPORTANT SAFETY INSTRUCTIONS sisscsussveisensccsssavesnsssvecstpsssennecssascestssvaeiuaspsceepscsossceussssconsessande 5 Installation Guidelines ss ceedasssvesdasouiseCasssSsccasevadecespassadancuisacssoisans seseseedssbeseedsssaiadistvers siseaveedssssyeds 5 General PF CAUTIONS RET m 6 Additional NOUCES eebe eege 6 Personal Precautions While Working with Batteries sssssssssseeeeeserse 6 RATINGS EE 7 MOUNTIN nent nintendo ohne 9 COMPLETE OUTBACK INTEGRATED SYSTEMS eese eee ee eene ee ee eto eese etna esee etna esee tensa aeo 10 AC WIRING CONNECT IQNS 5 54 5 saauob e rpasee eoa su pa bn OPE e Ra arenas aa be ERENNERT SEENEN 11 INDICATORS amp CONTROL WIRING ee eee ee eeee eese en ense sete ta so esee eo se eee aa aee teta asse seen see teen ae 12 DC BATTERY MEE LIU DES Bo 13 EQUIPMENT GROUND TERMINALS eee ee ee eene eee enne toos etta nose totas ese to sese etta Pese eo ense etta Pese ee ea sese toss esten a 13 BATTERY TERMINAL COVERS 2 etos rta nets sons ere eed oras uUo p ra een ca ree ePe Fea bo oe Ce o Uo CER s
52. 10 74 2 0 0 10 1045 67 43 508 12 90 3 0 0 08 1318 85 01 576 14 63 4 0 0 06 1662 107 20 645 16 38 Copyright 2003 OutBack Power Systems Inc FX amp VFX Series Inverter Charger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA 900 0027 1 Tel 360 435 6030 Fax 360 435 6019 Rev 7 2 08 26 05 Page 62 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 c 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 HAV
53. 19009 62nd AVE NE uem L2 10KW 4 FX2548 ARLINGTON WA 98223 AC SOURCE 4 50A zr P BATTERY 11 2KW 4 VFX2812 M 360 435 6030 120 240VAC 200 MAX qc Lette Lei L2 at DN bed 8 14 4KW 100A BYPASS SER NOTES Program the top FX as the Master 1 2PH MASTER the first Slave as an Outback L1 slave OB Slave L1 and the second and third Slaves as OutBack L2 slaves OB SLAVE L2 See the STACKING INFORMATION section of the manual for more info In systems that include three or more FX s and must be series stacked an X 240 autotransformer must be used When the FX s are connected in series for 120 240 VAC the X 240 can be connected to the two AC output legs to allow all of the FX s capacity to be available on either of the 120 VAC output circuits This allows higher efficiency and better performance as heavy 120 VAC loads are powered by more of the FX s The X 240 also allows the master to power loads on either of the 120 VAC output circuits with the slave off This reduces the idle power consumption and improves the system efficiency NON MOBILE FX NOTES The AC OUTPUT NEUTRAL IS NOT BONDED TO THE CHASSIS OR THE GROUND TERMINAL of the FX system This connection is to be made by the installer either in the AC service entrance or within the AC load distribution panel of the electrical system The AC input AC output and DC terminals are isolated from the metal chassis of the FX Proper groun
54. 3 USA 900 0027 1 Tel 360 435 6030 Fax 360 435 6019 Rev 7 2 08 26 05 Page 19 FX SYSTEM CONFIGURATION SERIES PARALLEL QUAD FX SYSTEM Series Parallel Quad FX System The following diagram illustrates a typical series parallel FX installation using four FX s This diagram is for a non Mobile FX installation only Below this diagram are notes for how to change this diagram to accommodate a Mobile installation The AC wiring from the AC source and to the AC loads must handle 120 amps AC or more The AC wiring connected to the QUO 100A dual bypass breakers must handle 100 amps AC or more All other AC wiring must handle a capacity of 50 amps AC or more For a Mobile FX system 30A input breakers should be used due to the maximum AC input pass through rating of the Mobile FX s This type of FX system can continuously power 8 14 4KW 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 A HUB MATE and X 240 must be connected to successfully stack these FX s in series parallel The MATE must be connected to adjust any parameters or to display any meters Once the FX s have been programmed using the MATE the MATE can be disconnected The programming will be saved within the FX s non volatile memory even if the FX is completely shut down
55. 4 42P SUM STATUS SETUP ADV u ADV SETTINGS WARNING changes made could adversely effect system performance li li l D ADV PASSWORD enter the password 1 32 ENTER INC DEC EXIT L ADV choose product FX MX ATE MAIN l ADV FX PAGE1 choose category ADV INV CHGR PG2 ADV FX PAGE2 choose category PGI GRID GEN PG3 ADV FX PAGE3 choose category PG2 AUX STACK PG4 ADV FX PAGE3 choose category PG3 SELL CAL MAIN Installation amp Programming Manual Page 52 PASSWORD CODE 141 The MAIN screen is where the menu system starts The four words in the bottom line of the display correspond to the four buttons located below the display The word in BOLD on the bottom line indicates the selection used to advance the display to the next screen Pressing the left two buttons simultaneously from anywhere in the menu will return you to this screen Selecting ADV brings up a warning message Please read the message Pressing any of the four keys below the display advances the display to the password screen Entering the correct password number is done by pressing the INC key to increase the number or the DEC key to decrease the number Once the number shown matches the password code 141 press the key below the word ZENTER To leave the advanced menu area withou
56. 435 6030 Fax 360 435 6019 BATTERY FX CABLING DC BATTERY TERMINALS The DC terminals are made from solid brass with a stainless steel threaded stud The threads are M8 x 1 25 The black terminal is negative and the red terminal is positive DO NOT PUT ANY WASHERS BETWEEN THE TERMINAL MOUNTING SURFACE AND THE ACTUAL BATTERY CABLE LUG Place the lug washers and nut in the following order Lug Flat Washer Lock Washer Nut TORQUE TO 60 INCH POUNDS 5 FOOT POUNDS MAXIMUM 6 77 NM Mobile FXs come with a fuse for protection of the battery cables connected to the FX If used the fuse must be mounted to the positive terminal red The hole of the battery cable lugs must be at least 10mm to properly fit the fuse If using a 3 8 hole file this down to produce a 10mm hole Place the lug fuse and fuse nut on the terminal in the following order Fuse Lug Fuse Nut TORQUE THE FUSE NUT TO 60 INCH POUNDS 5 FOOT POUNDS MAXIMUM 6 77 NM Too much torque on the fuse nut will cause the fuse nut to shatter This will put your installation on hold It is recommended that a separate means of disconnecting the positive battery cable be included in systems that use fuses UL listed DC rated circuit breakers are available from OutBack Power Systems with amperages of 100 175 and 250 amps DC All of the OutBack DC breakers come with threaded studs out the back for connection to ring type terminal lugs ALWAYS INSTALL BREAKERS OR FUSES WITHIN THE POSITIVE BATTERY
57. 5 6019 Rev 7 2 08 26 05 Page 27 STACKING INSTRUCTIONS Stacking Procedure Continued The next two screens in the Stack menu on the MATE are the POWER SAVE LEVEL MASTER ADJUST ONLY and POWER SAVE LEVEL SLAVE ADJUST ONLY screen You can access these screens by pressing DOWN once or twice if you are currently on the STACK PHASE screen Since nobody seriously even here at OutBack understands these screens the first 3 4 times they are explained we offer our best effort right here These screens only make complete sense after you ve read and understand both of them These two screens only pertain to systems that have OB Slave L1 and OB Slave L2 type slaves POWER SAVE LEVEL MASTER ADJUST ONLY Only adjust the value on this screen if you wish to have one or more of the Slave FX s AC outputs On at all times This may be necessary if you wish to have instantaneous power on Leg 2 or are having trouble starting large loads The first thing to note is that this screen pertains to the Master FX only and therefore you must be on port 1 P01 in the upper right hand corner of the MATE Press PORT on the MATE until you see P01 on the MATE The number to the right of the screen is the Slave Rank Designator The default value for the Slave Rank Designator is zero 0 on every FX By pressing INC on the MATE you can increment by whole numbers this value If this value is set to a number greater than zero then the Master FX will keep the Slav
58. 6 vde occasion An equalization charge can be started through the AC IN Hot key An AC source must be setpoint connected in order to start an equalization charge The batteries must be supervised throughout the DOWN INC DEC PORT equalization process Consult the battery supplier as to specific instruction on the battery equalizing t process This setting has a range between 14 0 vdc and 17 0 vdc in 0 1 vdc increments ADV FX CHARGER p00 The EQUALIZE TIME PERIOD can be adjusted to limit the amount of time that the battery is equalize 01 0 hrs equalized The timer starts to advance once the battery voltage exceeds the absorb voltage set point time period Once the timer completes the equalize time period the charger goes into the silent stage of the DOWN INC DEC PORT charging process This setting has a range between 0 hours and 24 hours in 0 1 hour increments i ADV FX CHARGER Selecting TOP returns the user to the top of the ADV FX CHARGER menu section Selecting ADV charger programming returns you to the advanced screen to allow selection of another product connected to the MATE completed Selecting MAIN returns the display to the MAIN screen TOP ADV MAIN Installation amp Programming Manual FX amp VFX Series Inverter Charger System Copyright 2003 O OutBack Power Systems Inc 900 0027 1 19009 62 Ave NE Arlington WA 98223 USA Page 54 Rev 7 2 08 26 05 Tel 360 435 6030 Fax 360 435 6019 MATE SCREENS
59. 7 1 Tel 360 435 6030 Fax 360 435 6019 Rev 7 2 08 26 05 Page 65
60. AIN S 6 54 42P SUM STATUS SETUP ADV l STATUS choose product FX MX J STATUS FX PAGE1 choose category MODES METER BATT PG2 STATUS FX PAGE2 choose category PGI ERROR WARN PG3 STATUS FX PAGE3 choose category PG2 DISCON SELL MAIN l STATUS FX SELL P00 stop sell 14 reason STATUS PORT Copyright 2003 O OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 The MAIN screen is where the menu system starts The four words in the bottom line of the display correspond to the four buttons located below the display The word in BOLD on the bottom line indicates the selection used to advance the display to the next screen Pressing the left two buttons simultaneously from anywhere in the menu will return you to this screen Allows selection of the product type lt FX gt FX inverter charger system MX MX60 PV MPPT charge controller MODES Status and allows adjustment of Inverter AC input Charger Aux and EQ METER Provides the AC voltages and currents of the FX BATT Provides the battery voltage and charger set points and timers lt PG2 gt Displays additional sections ERRORS WARNINGS and PG3 PG1 Returns to page 1 of the STATUS section ERROR Displays the different causes for errors and qualifies each cause with a Yes or No WARN Displays the different c
61. C PORT 4 ADV FX GRID POO The AC1 GRID LOWER LIMIT set point allows adjustment of the minimum voltage that the AC acl grid 108 vac source is allowed to be in order for the FX to connect to that source The FX will back off the lower limit charger if the AC source is at this lower limit If the AC source falls below this limit the FX will DOWN INC DEC PORT disconnect from the AC source until it is above this value This setting has a range between 70 i vac and 110 vac in 1 vac increments The AC1 GRID UPPER LIMIT set point allows adjustment of the maximum voltage that the AC source is allowed to be in order for the FX to connect to that source If the AC source exceeds this value the FX will disconnect from the AC source until it is below this value This setting has a range between 130 vac and 150 vac in 1 vac increments ADV FX GRID POO acl grid 140 vac upper limit DOWN INC DEC PORT l ADV FX GRID POO The AC1 GRID INPUT LIMIT sets the maximum amount of current the FX allows to be drawn acl grid SR Se from the AC source When the AC input current limit is reached the power draw of the battery charger is backed off to prevent overloading the AC source If the AC loads exceed this limit the FX will give a warning and start blinking the red ERROR LED This setting has a range between 5 0 aac and 60 0 aac in 1 0 aac increments input limit DOWN INC DEC PORT JL ADV FX GRID POO T
62. D section to change this setting All Mobile FXs 30 AAC per FX AAC amps AC All Other FXs 60 AAC per FX AAC amps AC Copyright 2003 OutBack Power Systems Inc FX amp VFX Series Inverter Charger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA 900 0027 1 Tel 360 435 6030 Fax 360 435 6019 Rev 7 2 08 26 05 Page 7 RATINGS MAXIMUM CURRENT FOR BATTERY CHARGER The FX uses AC current from the AC input source to charge the battery Due to heat constraints the FX limits this amount of current The maximum and default values for this setting are shown below Please refer to the programming section to adjust this setting The battery charger has an efficiency of about 90 There are other factors like cable losses that may reduce this efficiency The maximum DC current that can be produced is also shown below These maximum DC currents can only be attained in the Bulk charging stage FX2012 M T AC Max 12 AAC Default 10 AAC DC Max 100 ADC FX2524 M T AC Max 14 AAC Default 12 AAC DC Max 55 ADC FX2532 M T AC Max 14 AAC Default 12 AAC DC Max 40 ADC FX3048T AC Max 14 AAC Default 12 AAC DC Max 35 ADC 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 Max 45 ADC AC INPUT FREQUENCY
63. E OTHER RIGHTS THAT VARY FROM STATE TO STATE OR JURISDICTION TO JURISDICTION OUTBACK POWER 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 technic
64. ENU ciicccsccseccsscceccsscsescsececanseossscsecseessassendsccesscssansecesendsossoseestcedecses sensevss svsesseesoasecdsentd sods socasosseccoscassees 59 SELL L LR 60 Ie YBIDIEVILOBUTDALU H 61 Extended Warranty Application iieeo erento roro toto eee o so pre ven deeg beoe kpeu o eeu Ua versu seue pee suse esenucts OF Installation amp Programming Manual FX amp VFX Series Inverter Charger System Copyright 2003 OutBack Power Systems Inc 900 0027 1 19009 62 Ave NE Arlington WA 98223 USA Page 4 Rev 7 2 08 26 05 Tel 360 435 6030 Fax 360 435 6019 IMPORTANT SAFETY INSTRUCTIONS Installation Guidelines This manual contains important instructions for the OutBack FX series inverter charger system with the software which allows classic two FX s in series parallel and series parallel stacking of two to ten FX s for higher power and or higher voltage systems 1 All of the AC wiring to the AC terminals is to be torqued to 30 inch pounds equivalent to 2 5 foot pounds or 3 4 Nm Wiring to these terminals must meet requirements of the National Electric Code NEC The terminals will accept up to 6AWG Use copper conductors only with insulation rated for 75 C See the AC WIRING CONNECTIONS section of this manual for more information 2 Torque the DC connections to 60 inch pounds equivalent to 5 foot pounds or 6 8 Nm Cables to these terminals must use a crimp on type ring terminal or compr
65. HE PREVIOUS PROGRAMMING TO BE LOST Selecting MORE displays a screen that allows the user to select which port on the HUB that the FX to be reset is on Once the user has chosen the PORT of if there is not a HUB the user should press NEXT to proceed To complete the reset to factory defaults the user must press 1 and then 2 Selecting TOP returns the user to the top of the ADV FX INVERTER menu section Selecting ADV returns you to the advanced screen to allow selection of another product connected to the MATE Selecting MAIN returns the display to the MAIN screen FX amp VFX Series Inverter Charger System 900 0027 1 Rev 7 2 08 26 05 Installation amp Programming Manual Page 53 MATE SCREENS CHARGER MENU The CHARGER section allows for adjustment of the battery charger s operation to match the requirements of the batteries used OutBack s default battery charging set points may not be correct for the type of batteries being used Please contact the battery manufacturer for correct ABSORB FLOAT and EQUALIZE voltages See the BATTERY CHARGING INSTRUCTIONS section for guidelines on how to set some of these values and for more information on the battery charging process ADV Once the password has been correctly entered the ADV CHOOSE PRODUCT is displayed choose product Selecting FX allows adjustment of the FX s advanced programming FX MATE i ADV FX PAGEl1 Selecting CHGR allows adjustment of the
66. K CONTROL screen it will allow the user to start and or BULK CONTROL stop a bulk charge cycle manually by pressing lt START gt or STOP respectively Pressing lt EQ gt brings up the EQUALIZE CONTROL screen START STOP OK When lt START gt has been selected two informational screens are displayed The user then must answer lt YES gt before an equalize charging cycle is allowed to begin Once the equalizing process has started you can stop it at anytime by selecting lt STOP gt from this same control screen Copyright 2003 OutBack Power Systems Inc FX amp VFX Series Inverter Charger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA 900 0027 1 Tel 360 435 6030 Fax 360 435 6019 Rev 7 2 08 26 05 Page 39 MATE MENU MAP MATE s FX Screens MAIN MENU SUM STATUS SETUP ADV ADVANCED MENU FX MX MATE MAIN Advanced Menu SUMMARY continued on next page SCREEN p 40 STATUS FX PG1 STATUS FX PG2 STATUS FX PG3 MODES METER BATT PG2 PG1 ERROR WARN PG3 PG2 DISCON SELL MAIN MODES p 41 ERROR WARN DISCON SELL p 44 p 45 p 46 p 47 METER p 42 SETUP FX SEARCH INPUT MAIN BATT p 43 SEARCH INPUT p 48 p 49 FX amp VFX Series Inverter Charger System Copyright 2003 OutBack Power Systems Inc Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA 900 0027 1 Rev 7 2 Tel 360 435 6030 Fax 360 435 6019 08 26 05 Page 40
67. MAIN MENU STATUS The OutBack MATE uses a branching menu structure to display various OutBack products operation modes and status The menus are divided by SETUP product type and are categorized by type of setting or by information being displayed METERS I OUTPUT VOLTAGE An example of the menu structure is shown to the right All the screens that e NE show AC meters are grouped together in one menu tree allowing the user to dr find the required meter with a minimum of button presses CURRENT The top line of the MATE display will show the path to the current menu in this example it is STATUS FX METERS STATUS FX METERS output 120 vac voltage DOWN UP TOP PORT MATE BUTTONS Port Designation Menu Path 1 Line SETUP FX INPUT P00 Menu Item 2 Line l ac transfer GEN amp control DOWN GRID GE RT 3 Line Menu Item Value Menu Choices 4 Line The MATE uses a six button user interface to navigate the menus and to change set points of various OutBack products Two buttons are dedicated to the FX and are labeled AC IN and INV These buttons are special in that they can be pressed at any time anywhere in the MATE menu structure and they take you to the same screens For this reason they are referred to as Hot keys Many common functions that need to be accessed often are found under the AC IN and INV button The four lower buttons under the LCD are called
68. Mobile FX inverter chargers are ETL listed to UL 458 ETL is a Nationally Recognized Testing Laboratory NRTL NOMINAL SYSTEM AC VOLTAGE This is the AC output voltage produced by an FX system Each FX produces 120 VAC but multiple FXs can be configured in parallel series or 3 phase to produce different voltages between their AC output connections Single Phase 120 VAC at 60 Hz VAC volts AC Hz hertz Series Stacked 120 VAC at 60 Hz per AC output leg 240VAC 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 208 VAC at 60 Hz between AC output legs Y connected RECOMMENDED DC VOLTAGE RANGE This is the DC battery voltage range to be used for operating the FX The last two digits in the model number designate the nominal DC voltage Example FX2024MT 24V DC Voltage The recommended battery voltage range is as follows 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 This is the maximum DC current that 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 CURRE
69. N b s LINE AC HOT IN L2 A UI LI 3 PHASE AC HOT IN L3 AC SOURC 190 208 Gre e e o aGe 2 a e NEUTRAL AC BDX pc BOX 6 7 5KW e 120 208AC 8 4 10 8KW 120 208VAC St MWh a puer Je wats POLE FX 3 PHASE SEALED 3 PHASE VENTED ipe io Ma AC LOADS kel 1504 BYPAS E oe 12V 250A BRKRS 12V 2504 BRKRS AND TERMINAL 190 208 VAC 24V 175A BRKRS 24V i 1754 BRKRS SUE eege N Sue m F mmm 48V 100A BRKRS 48V 175A BRKRS DUTPUT nt SS 4 Sa D e BREAKERS II L2 Cour Back 3 PUASE FX skW 3 KEE FX2012 M Power Systems z 1504 MAXIT cC 5 m r 548 19009 62nd AVE NE AC SOURC SEH bb 3 re BATTERY Bj4AKw 3 VEX2812 M gt ARLINGTON WA 98223 Em INPUT p c 4 120 208 VAC BEARES 105KW 3 VEX3524 M 260 435 6030 108KW 3 VFX3648 6 10 8KW 1504 BYPASS PAR NOTES Program the top FX as Master 3PH MASTER and the two lower FX s as 3 phase Slaves 3PH SLAVE See the STACKING INFORMATION section of the manual for more info The 3 phase system is a 120 208 VAC Y connected power system The AC source must also be a 120 208 VAC Y connected 3 phase source NON MOBILE FX NOTES The AC OUTPUT NEUTRAL IS NOT BONDED TO THE CHASSIS OR THE GROUND TERMINAL of the FX system This connect
70. NT This is the maximum continuous DC current that the FX will draw from the batteries when inverting FX2012 M T 190 ADC ADC amps DC FX2524 M T 120 ADC FX2532 M T 90 ADC FX3048T 70 ADC VFX2812 M 265 ADC VFX3524 M 170 ADC VFX3232 M 115 ADC VFX3648 85 ADC AC INPUT OPERATING VOLTAGE RANGE 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 This is only a recommendation neither the FX s defaults nor the set point limits All FXs 90 150 VAC VAC volts AC Defaults 108 140 VAC 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 charger The AC transfer switch transfers the AC input power through the FX to the AC loads connected to the AC output of the FX The FX s battery charger will back off when the combined amperage of the AC loads and the battery charger exceeds the AC Input Limit default of 28 AAC for Mobile FXs 48 AAC for non Moblie FXs This AC Input Limit can be adjusted so as not to overload a generator or trip a breaker that is connected to the AC input of the FX If your generator cannot continuously produce the AC Input Limit or you are connecting to an AC input source that has a breaker that is rated for less than the AC Input Limit please refer to the ADVANCE
71. OWN INC DEC PORT i ADV FX AUX POO aux output Vent Fan function DOWN INC DEC PORT ADV FX AUX POO aux output Fault function DOWN INC DEC PORT ADV FX AUX POO aux output GenAlert function DOWN INC DEC PORT ADV FX AUX POO aux output LoadShed function DOWN INC DEC PORT ADV FX AUX POO aux output Remote function DOWN INC DEC PORT l Copyright 2003 O OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 Once the password has been correctly entered the ADV CHOOSE CATEGORY screen is displayed Selecting PG2 shows a second screen of categories Selecting lt PG3 gt shows a third screen of categories Selecting lt AUX gt allows adjustment of the auxiliary output set points and operation The AUX OUTPUT CONTROL screen allows selection of the mode of the AUX output Selecting INC or DEC changes the mode between OFF AUTO and ON Selecting OFF disables the AUX output from operating Selecting ON forces the AUX output to be ON regardless of the function selected Selecting AUTO in the AUX OUTPUT CONTROL screen allows the AUX output to automatically perform the function that is selected in the AUX OUTPUT FUNCTION screens below Pressing DOWN allows the selection of the AUX OUTPUT FUNCTION There are nine functions in this section The default setting is Cool Fan which is set to run a Turbo Kit without any further programming The function at th
72. OutBack Power Systems Americas and Mobile FX and VFX Inverter Charger Installation and Programming Manual Document Revision 7 2 FX 2012T 2 0 kW 12 VDC 120 VAC 60 Hz Sealed Turbo Americas FX 2524T 2 0 kW 24 VDC 120 VAC 60 Hz Sealed Turbo Americas FX 3048T 2 5 kW 48 VDC 120 VAC 60 Hz Sealed Turbo Americas VFX 2812 2 8 kW 12 VDC 120 VAC 60 Hz Ventilated Americas VEX 3524 3 5 kW 24 VDC 120 VAC 60 Hz Ventilated Americas VEX 3648 3 6 kW 48 VDC 120 VAC 60 Hz Ventilated Americas FX 2012MT 2 0 kW 12 VDC 120 VAC 60 Hz Sealed Turbo Mobile FX 2524MT 2 0 kW 24 VDC 120 VAC 60 Hz Sealed Turbo Mobile FX 2532MT 2 5 kW 32 VDC 120 VAC 60 Hz Sealed Turbo Mobile VFX 2812M 2 8 kW 12 VDC 120 VAC 60 Hz Ventilated Mobile VFX 3524M 3 5 kW 24 VDC 120 VAC 60 Hz Ventilated Mobile VFX 3232M 3 2 kW 32 VDC 120 VAC 60 Hz Ventilated Mobile T stands for Turbo M stands for Mobile The Sealed version of the FX The Vented version of the FX The Turbo Kit that comes with the FX T series is shown on page 15 Please check our website at www outbackpower com for the latest product information Installation amp Programming Manual FX amp VFX Series Inverter Charger System Copyright 2003 OutBack Power Systems Inc 900 0027 1 19009 62 Ave NE Arlington WA 98223 USA Page 1 Rev 7 2
73. Power Systems Inc FX amp VFX Series Inverter Charger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA 900 0027 1 Tel 360 435 6030 Fax 360 435 6019 Rev 7 2 08 26 05 Page 5 1 MATE SCREENS Advanced Screens The ADVANCED menu section allows adjustment of all the settings involved with the operation of the FX Changes made to these settings are stored internally in non volatile memory inside of the FX the settings are not lost when the MATE is removed or battery power is disconnected Some settings appear both in the SETUP and in the ADV menus Changes made to these settings in one area will cause the same changes to occur in the other area The settings are provided in both menus to make it more convenient for the FX programmer by giving access to all of the settings in the advanced menu Access to the settings in the advanced menu is restricted through the use of a password This password is required to view and adjust the settings Once the password has been entered all ADVANCED categories can be adjusted without having to re enter the password If the advanced menu is exited and re entered the password must be re entered however Use of the Hot keys AC IN and INV is allowed from the advanced menu and selecting OK from these screens will return you to the same point in the advanced menu The password for the FX is currently fixed to the same value for all of the FX s MAIN ES 6 5
74. Pressing the UP button returns you to the previous page of the MODES menu Pressing the CHANGE MODE button opens a screen that gives the options of turning the Aux OFF turning the Aux ON or putting the Aux into AUTO mode In AUTO mode it will follow the Aux Output Function and its parameters that can be set in the Advanced ADV menu Pressing PORT will access the next FX if a HUB is present The EQ ENABLED screen lets you see if the FX is in an equalize charging cycle and can also start or stop a cycle Pressing the UP button returns you to the previous page of the MODES menu Pressing the CHANGE MODE button opens a screen that gives the options of START or STOP to initiate or cancel an equalize charge Pressing PORT will access the next FX if a HUB is present FX amp VFX Series Inverter Charger System 900 0027 1 Rev 7 2 Installation amp Programming Manual 08 26 05 Page 43 MATE SCREENS MEIER MENU The METER section lets the user view the AC voltage and AC current meters as well as the software revision of the FX s microprocessor The user can view the input and output AC voltages as well as the input inverter charger and sell currents This can be used to verify that the FX is sensing voltages and currents and also helps discern what the FX is doing like charging or inverting The software revision is helpful when troubleshooting Some functions of certain software revisions are incompatible with older MATEs The va
75. RANGE This is the AC input source s frequency range of which the FX will accept and stay connected If the AC input source is out of this range the FX will not connect or stay connected All FXs 56 64Hz MAXIMUM AC OUTPUT CURRENT This is the amount of AC Surge current that the FX will supply This amount of surge can only be supplies for a split second After this split second the FX lowers this surge limit 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 When passing an AC source through the FX via the AC transfer switch the maximum AC output fault current will be determined by the AC source All 12 VDC FXs 40 AAC per FX for 1 millisecond All Other FXs 50 AAC per FX for 1 millisecond MAXIMUM CONTINUOUS OUTPUT POWER Each FX has a maximum continuous output power it can deliver This maximum continuous output power is hidden in the model number of the FX For instance an FX2012MT has a maximum continuous output power of 2000VA volt amps The last two numbers 12 in this case can be changed to 0 s because they refer to the battery voltage FX2012 M T 2000 VA VA volt amps FX2524 M T 2500 VA FX2532 M T 2500 VA FX3048T 3000 VA VFX2812 M 2800 VA VFX3524 M 3500 VA VFX3232 M 3200 VA VFX3648 3600 VA MAXIMUM OVERCURRENT PROTECTION AMPACITY This rating specifies the proper overcurrent protection ampacity OBDC are panel mount circuit breakers SMF
76. S KIT AC IOB 100 FOUR ADDITIONAL SOA eje ojejoje Gelee le SLAVE CBI BREAKERS ARE AC OUT NECESSARY FOR THE AC INPUTS NEUTRAL 200 AMPS AC IN MAX N Lat H 2 s SLAVE Ge saii iy NEUTRAL AC IN NEUTRAL 5 AC BOX Leed pc Box 8 10KW 120VAC 11 2 14 4KW 120VAC ALL BREAKERS SHOWN eel eee in Px ep PARALLEL SEALED PARALLEL VENTED BYPASS MECHANISM cone ET 100A BYPASS 12V 250A BRKRS 12V 250A BRKRS AND TERMINA ED gt 4 50A gen Las E BR 24V 175A BRKRS 24V 250A BRKRS THE OUTBACK PSAC100Q l m 48V 100A BRKRS 48V 175A BRKRS Com Bach REAK D a pr re 8KW 4 FX2024 M 4 FX2012 M Power Systems AC SOURCE Geo MAXI 4 50A cf 10KW 4 FX2548 19009 62nd AVE NE 120VAC p INPUT a BATTERY 11 2KW 4 VFX2812 M ARLINGTON WA 98223 Breakers Irch FX lp 14KW 4 VFX3524 M 360 435 6030 rem n 14 4KW 4 VFX3648 8 14 4K W 100A B YPASS PAR NOTES Program the top FX as Master 1 2PH MASTER and the three lower FX s as OutBack L1 Slaves OB SLAVE L1 See the STACKING INFORMATION section of the manual for more info NON MOBILE FX NOTES The AC OUTPUT NEUTRAL IS NOT BONDED TO THE CHASSIS OR THE GROUND TERMINAL of the FX system This connection is to be made by the installer either in the AC service entrance or within the AC load distribution panel of the electrical system The AC input AC output and DC terminals are isolated from the metal chassis of the FX Proper gro
77. STER ADJUST ONLY screen then all of the Slave FX s will remain Off until the Master FX needs help and calls for the Slave FX s with Slave Rank equal to 1 to come On This will turn on all of the Slaves If your system includes more than one Slave FX then will want to choose a different Slave Rank for each Slave FX This allows them to come On one at a time which saves power in the long run To change the Slave Rank of a given Slave FX press the PORT button on the MATE until the Slave FX s port appears in the upper right hand corner of the MATE Next press INC to increase the value until it is what you desire Repeat this process for each Slave in the system When a Slave FX has a POWER SAVE LEVEL SLAVE ADJUST ONLY value greater than the Master FX s POWER SAVE LEVEL MASTER ADJUST ONLY it will remain Asleep and save about 18 watts When large loads are present the Master FX will call out for Slave Rank 1 to come On unless it is already On due to the POWER SAVE LEVEL MASTER ADJUST ONLY setting being 1 or greater If the Master FX needs even more power then it will call out for Slave Rank 2 to come On and so on Using these three screens will allow you to stack your system in many different configurations As an addition to the explanations above we have offered some examples of common systems outlined below System Examples DUAL STACKED SYSTEM USING CLASSIC STACKING This type of system
78. TOP ADV MAIN Installation amp Programming Manual Page 60 Once the password has been correctly entered the ADV CHOOSE CATEGORY screen is displayed Selecting PG2 shows a second screen of categories Selecting lt PG3 gt shows a third screen of categories Selecting lt PG4 gt shows a fourth screen of categories Selecting SELL allows adjustment of the Grid tie and selling set points and operation The SELL RE VOLTS RE Renewable Energy screen allows the user to set the voltage at which they would like to sell battery power back to the utility grid If the battery voltage is above the voltage shown on this screen and the FX isn t charging then the FX will sell power back to the utility grid This setting has a range between 10 0 vdc and 15 0 vdc in 0 1vdc increments The GRID TIE WINDOW screen controls the voltage and frequency windows that the grid tie function operates in If the FX repeatedly disconnects from the utility grid this value may need to be changed This function should not repeat should not be changed without consulting OutBack Power Systems first The GRID TIE AUTHORITY screen allows the user to turn on or off the selling function of the FX When the screen displays GridTie default the FX will sell power under the correct conditions Pressing DEC will change GridTie to No Sell and the selling function will be disabled Pressing INC will change the display back from No Sell to G
79. X s that run in series with the master OutBack s X 240 autotransfromer must be included in the system to use this stacking option This FX is considered L2 phase 3PH MASTER ff you have a system with three and only three FX s and you wish to produce 120VAC on three AC Output Legs as well as 208VAC between each AC Output Leg set the stack phase of the FX you want as the master to 3PH Master and make sure it is in port 1 of the HUB The 3 phase stacking is similar to Classic stacking in the sense that each FX acts independently and cannot help out other phases The HUB also has a jumper on it that needs to be changed for 3 phase stacking refer to the HUB manual This FX is considered phase A 3PH SLAVE If you have a system with three and only three FX s and you wish to produce 120VAC on three AC Output Legs as well as 208VAC between each AC Output Leg set the stack phase of the 2 FX s you want as the slaves to 3PH Slave and make sure they are in ports 2 and 3 of the HUB There are no selections to differentiate between phases B and C When you set the jumper in the HUB for 3 phase the HUB tells each slave which phase they are 3PH slave on HUB port 2 is considered phase B 3PH slave on HUB port 3 is considered phase C Copyright 2003 OutBack Power Systems Inc FX amp VFX Series Inverter Charger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA 900 0027 1 Tel 360 435 6030 Fax 360 43
80. al system The AC input AC output and DC terminals are isolated from the metal chassis of the FX Proper grounding of these circuits and the chassis of the FX is the responsibility of the installer MOBILE FX NOTES The AC input source to the FX grid and or generator must have an internal neutral ground connection On the above diagram the AC source s neutral conductor must go directly to the FXs AC NEUTRAL IN terminal or to a separate neutral busbar that is isolated from the FX s AC output neutral The AC output of the FX must go to a separate AC output busbar that is isolated from the AC input neutral A bypass mechanism must bypass the AC source s hot and neutral wires Proper grounding of the DC circuit and the chassis of the FX is the responsibility of the installer Copyright 2003 OutBack Power Systems Inc FX amp VFX Series Inverter Charger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA 900 0027 1 Tel 360 435 6030 Fax 360 435 6019 Rev 7 2 08 26 05 Page 17 FX SYSTEM CONFIGURATION SERIES OR SERIES PARALLEL DUAL FX SYSTEM Series or Series Parallel Dual FX System The following diagram illustrates a typical series FX installation using two FX s This diagram is for a non Mobile FX installation only Below this diagram are notes for how to change this diagram to accommodate a Mobile installation The AC wiring from the AC source and to the AC loads must handle 50 amps AC or more All other AC w
81. atus and allows adjustment of Inverter AC input Charger Aux and EQ METER Provides the AC voltages and currents of the FX BATT Provides the battery voltage and charger set points and timers PG2 Displays additional sections ERRORS WARNINGS and PG3 The INV CONTROL screen lets you see the status of the inverter function of the FX Pressing the STAT button returns you to the first page of the status menu Pressing the CHANGE MODE button opens a screen that gives the options of turning the inverter OFF turning the inverter ON or putting the inverter into SEARCH Pressing PORT will access the next FX if a HUB is present The AC IN CONTROL screen lets you see if the FX will accept an AC source at its input terminals Pressing the UP button returns you to the previous page of the MODES menu Pressing the CHANGE MODE button opens a screen that gives the options of rejecting an AC source by pressing DROP or accepting an AC source by pressing USE Pressing PORT will access the next FX if a HUB is present The CHR CONTROL screen lets you see what mode the charger is in Pressing the UP button returns you to the previous page of the MODES menu Pressing the CHANGE MODE button opens a screen that gives the options of turning the charger OFF or putting the charger into AUTO where it will follow the 5 stage charging algorithm Pressing PORT will access the next FX if a HUB is present The AUX CONTROL screen lets you see the status of the auxiliary output
82. auses for warnings and qualifies each with a Yes or No PG3 Displays additional sections reason for last DISCONNECT and SELL PG2 Displays additional sections ERRORS WARNINGS and PG3 DISCON Displays the reason that the FX last disconnected from the AC source SELL Displays the code related to the reason for the last disconnection while selling MAIN Returns the user to the MAIN menu The STOP SELL REASON displays a numerical value that indicates a reason that the FX stopped selling to the utility grid It could indicate that the utility grid s voltage or frequency is out of the acceptable ranges or that the utility grid failed altogether This screen is used for troubleshooting by OutBack Power Systems technicians Selecting STATUS returns the user to the beginning of the STATUS menu Selecting PORT selects the next FX on the HUB FX amp VFX Series Inverter Charger System 900 0027 1 Rev 7 2 Installation amp Programming Manual 08 26 05 Page 49 MATE SCREENS Setup Screens The OutBack FX includes a SETUP menu to allow limited adjustment of some of the settings which may need to be accessed by the system user SEARCH MENU The SEARCH mode is an automatic system which reduces the power consumption of the FX during periods of no power demand It is primarily used for off grid applications where the power is being generated by solar panels or other renewable energy sources and the system user is concerned about conserving
83. cles and 240cycles in 1 cycle increments The AC2 GEN SUPPORT setting is not operational at this time Selecting TOP returns the user to the top of the ADV FX GEN menu section Selecting ADV returns you to the advanced screen to allow selection of another product connected to the MATE Selecting MAIN returns the display to the MAIN screen FX amp VFX Series Inverter Charger System 900 0027 1 Rev 7 2 Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA 08 26 05 Tel 360 435 6030 Fax 360 435 6019 MATE SCREENS AUXILIARY MENU The AUX auxiliary section can be used to control external AC or DC loads signal a generator start system send a fault alarm signal The AUX output provides a 12 vdc 0 7 adc max signal on the AUX terminals located in the AC wiring compartment or to run a fan ADV FX PAGE1 choose category ADV INV CHGR PG2 i ADV FX PAGE2 choose category PGI GRID GEN PG3 i ADV FX PAGE3 choose category PG2 AUX STACK PG4 ADV FX AUX POO aux output AUTO control DOWN INC DEC PORT l ADV FX AUX POO aux output AC Drop function DOWN INC DEC PORT ADV FX AUX POO aux output DivertAC function DOWN INC DEC PORT ADV FX AUX POO aux output DivertDC function DOWN INC DEC PORT ADV FX AUX POO aux output Cool Fan function D
84. creen i DC OAC D Dk To access the summary screen select SUM from the MAIN screen A typical summary screen AC Load is shown here for a FX when the inverter is off and no AC source is connected NO ACIN aa oue Battery 12 8V The battery voltage is provided in the lower right corner of the display EXAMPLES DCEDAC gt gt gt 1 4kW INVERTING The FX is inverting and producing AC output voltage which is powering 1 4kW of AC Load mmm AC loads No AC source is connected to the inverter No ACIN Battery 12 1V DC 2AC 0 0kW PASS THROUGH An AC source has been connected and the AC loads are drawing power AC Load mt from the AC source that is passing through the FX The top line shows 0 0 KW indicating that Buying the charger is in SILENT mode and is not charging the batteries Approximately 1 0 kW loads Battery 12 6V are being powered from the AC source assuming the system consists of one FX DC 2OAC gt gt gt 1 7kW BUYING CHARGING amp PASS THROUGH The FX is buying four 2 0KW more power AC Toad fb quw than it is delivering to the loads one xt 0 5kW This is an indication that the FX is using the Buying excess power to charge the batteries The charger is charging at a rate of 1 7 kW of AC power Battery 13 4V going into the battery The AC loads are low and are being powered from the AC source DCEDAC 2 5kW AC DROP The inverter is on and powering 2 5 KW
85. d Diversion The following displays allow the adjustment of the particular AUX OUTPUT FUNCTION that was selected on the previous screen in the AUX menu section if applicable ADV FX AUX POO genalert 11 0 vdc on setpoint DOWN INC DEC PORT l ADV FX AUX POO genalert 4 min on delay DOWN INC DEC PORT 4 ADV FX AUX POO genalert 14 0 vdc off setpoint DOWN INC DEC PORT l ADV FX AUX genalert off delay DOWN I J ADV FX AUX POO loadshed 11 0 vdc off setpoint DOWN INC DEC PORT 4 ADV FX AUX POO ventfan 13 0 vdc on setpoint DOWN INC DEC PORT 4 ADV FX AUX POO ventfan off 5 min period DOWN INC DEC PORT J ADV FX AUX POO diversion 14 6 vdc on setpoint DOWN INC DEC PORT 4 ADV FX AUX POO diversion 30 sec off delay DOWN INC DEC PORT l ADV FX AUX aux output setup completed TOP ADV MAIN Installation amp Programming Manual Page 58 The GENALERT ON SET POINT is the battery voltage at which the FX will start counting down the GenAlert On Delay see next screen After the GenAlert On Delay time has been reached the AUX output is energized and turns the generator on through a 12 vdc relay This screen is applicable if the AUX OUTPUT FUNCTION has been set to GENALERT This setting has a range between 10 0
86. d the FX will use the necessary AC current to sustain this voltage for the Absorb Time default of 1 hour The AC current will decrease as the Absorb charge continues After the Absorb Time Period the FX goes into Silent mode The charger is turned off and the FX continues to monitor the battery voltage If a generator has been automatically started on a low voltage condition using AGS see MATE manual the FX will automatically turn off the generator after the Absorb Time Period If a generator has been manually started or the utility grid is connected the FX will let the battery voltage drop to the Refloat voltage and then it will start a Float charge The Float stage will raise the battery voltage to the Float Setpoint for the Float Time Limit The Float stage is meant for maintaining batteries that have DC loads connected to them If there aren t any DC loads on the batteries the battery voltage will usually remain above the Refloat voltage set point After the Float Time Limit default of 1 hour the FX goes back into Silent mode and waits until the battery voltage drops to the Refloat voltage again It then repeats the Float charge for the Float Time Period The FX will continue this cycle of Silent Refloat and Float until the AC source is disconnected BATTERY CHARGING CONSTRAINTS There are some settings and situations that affect the battery chargin
87. d of the AC Input must be connected directly to the Chassis Ground of the inverter The reason for this configuration is that if each inverter has a bussed Neutral to Ground bond and any inverter transfers sooner than the rest the remaining inverters will have a different Neutral to Ground bond One to the mobile Ground rather than shore Ground In this case there will be multiple Neutral to Ground bonds and the GFP breaker may blow if a noticeable voltage is present By removing the Neutral to Ground buss this problem is eliminated MAXIMUM AC INPUT CURRENT Mobile FX inverter chargers limit the AC input current to 30 amps Outback Power has decided to do this because they use only on of the three poles of the input relay within the FX In a non mobile FX all three poles are used and can therefore carry three times the current theoretically since they are paralleled this limit decreases The mobile FX uses two poles of this relay for ground switching so only one pole is available Due to this fact we recommend a 30 amp breaker for the AC input to the FX Relay Diagram with AC Input Not Connected AC Terminal Block Input Relay Output Relay HOT AC IN CHASSIS GROUND Buss NEU GND BOND Ground Relay Diagram with Ground Switched Connected to Utility Shore Power Neutral and Ground AC Terminal Block Input Relay Output Relay HOT AC IN Installation amp Programming Manual FX amp VFX Series Inverter Charger System
88. des the battery voltage and charger set points and timers PG2 Displays additional sections ERRORS WARNINGS and PG3 Selecting BATT displays the BATTERY ACTUALvoltage measured by the FX If the RTS battery temperature sensor is connected then the actual battery voltage will probably not equal the temperature compensated battery voltage When charging the FX uses the temperature compensated battery voltage reading next screen down to obtain the charging voltages This menu displays the BATTERY TEMP COMPENSATED voltage which is used by the battery charger for regulation The Remote Temperature Sensor RTS must be connected to the Master FX for temperature compensation If the RTS is connected then this value will be higher than the ACTUAL BATTERY VOLTAGE when the battery is hot and will be lower than the actual battery voltage when the battery is cold Refer to this value to verify the state of the charging process This is the battery charger set point for the absorb stage of the battery charging process The voltage will be held at the ABSORB SET POINT voltage level for the ABSORB TIME LIMIT period that is set in the ADVANCED menu section This value can only be changed in the ADVANCED menu The ABSORB TIME REMAINING is the period of time remaining for the absorb cycle When the FX is performing an absorb charge this time value will start counting down once the absorb voltage has been reached When this value reaches 0 0 hrs the FX will go in
89. ding of these circuits and the chassis of the FX is the responsibility of the installer MOBILE FX NOTES The AC input source to the FX grid and or generator must have an internal neutral ground connection On the above diagram the AC source s neutral conductor must go directly to the FXs AC NEUTRAL IN terminal or to a separate neutral busbar that is isolated from the FX s AC output neutral The AC output of the FX must go to a separate AC output busbar that is isolated from the AC input neutral A bypass mechanism must bypass the AC source s hot and neutral wires Proper grounding of the DC circuit and the chassis of the FX is the responsibility of the installer Installation amp Programming Manual FX amp VFX Series Inverter Charger System Copyright 2003 OutBack Power Systems Inc 900 0027 1 19009 62 Ave NE Arlington WA 98223 USA Page 20 Rev 7 2 08 26 05 Tel 360 435 6030 Fax 360 435 6019 FX SYSTEM CONFIGURATION PARALLEDED QUAD FX SYSTEM Paralleled Quad FX System The following diagram illustrates a typical paralleled FX installation using four FX s This diagram is for a non Mobile FX installation only Below this diagram are notes for how to change this diagram to accommodate a Mobile installation The AC wiring from the AC source and to the AC loads must handle 200 amps AC or more The AC wiring connected to the QUO 100A dual bypass breakers must handle 100 amps AC or more All other AC wiring must handle a capacity of 50 amp
90. e connect a error detected DOWN UP OB DET working cable and perform a Re Poll of the system using the MATE See the MATE manual for instructions If this does not solve the problem call your dealer for assistance 4 STATUS FX WARN P00 INTERNAL FAN FAILURE DETECTED warns that the fan mounted above the transformer inside internal fan No the FX has stopped working or is not functioning properly This will eventually cause an INVERTER failure detected OVERTEMP error if the cause of the fan failure is not fixed Restart the FX and listen for the fan to 2 UP TOP PORT verify a fan failure The fan should run for about 15 seconds on start up STATUS FX WARN PO0 AIRTEMP shows a numerical value that the FX understands as a temperature The value comes airtemp 206 from a sensor inside the FX that measures the temperature of the air or transformer depending DOWN UP D RT upon the FX s serial number This warning is given for troubleshooting purposes 4 STATUS FX WARN P00 FETTEMP shows a numerical value that the FX understands as a temperature The value comes fettemp 200 from a sensor inside the FX that measures the temperature of the FETs Field Effect Transistors This warning is given for troubleshooting purposes DOWN UP PORT Y STATUS FX WARN P00 CAPTEMP shows a numerical value that the FX understands as a temperature The value comes captemp 203 from a sensor inside the FX that measures the
91. e pulse length AC loads do not draw much power from a single AC pulse setting this value to 8 or more pulses DOWN INC DEC PORT may allow the AC load to be detected more reliably This setting has a range between 4 cycles l and 20 cycles in 1 cycle increments SETUP FX SEARCH PO00 The SEARCH PULSE SPACING is the amount of time in number of AC cycles that the inverter search 60 cycles waits before producing additional AC pulses to sense a load The larger this search pulse spacing pulse spacing number is the lower the power consumption of the FX but the more noticeable the delay between DOWN INC DEC PORT when the AC load is turned on and when it actually comes on This setting has a range between 4 cycles and 120 cycles 2 seconds in 1 cycle increments SETUP FX SEARCH Selecting TOP returns the user to the top of the SETUP FX SEARCH menu section Selecting search setup SETUP returns you to the setup screen to allow selection of another product connected to the completed MATE Selecting MAIN returns the display to the MAIN screen TOP SETUP MAIN Installation amp Programming Manual FX amp VFX Series Inverter Charger System Copyright 2003 O OutBack Power Systems Inc 900 0027 1 19009 62 Ave NE Arlington WA 98223 USA Page 50 Rev 7 2 08 26 05 Tel 360 435 6030 Fax 360 435 6019 MATE SCREENS INPUT MENU The other settings currently accessible to the system user in the SETUP menu involve the AC INPUT The system user can
92. e FX s AC outputs On if they have a POWER SAVE LEVEL SLAVE ADJUST ONLY value equal to or less than this number for instance if this value is set to 2 then all the Slaves with POWER SAVE LEVEL SLAVE ADJUST ONLY values of 1 or 2 will have their AC outputs kept On Any Slave with a POWER SAVE LEVEL SLAVE ADJUST ONLY value greater than the Masters POWER SAVE LEVEL MASTER ADJUST ONLY value will be asleep AC output is Off until the Master calls upon it to help with large loads POWER SAVE LEVEL SLAVE ADJUST ONLY This screen allows you to assign the Slave Rank of the Slave FX s in the system The first thing to note is that this screen pertains to the Slave FX s only and therefore you must be on port 2 or greater on the MATE shown in the upper right hand corner of the MATE as P02 or P03 etc Press PORT on the MATE until you see the port that you wish to program displayed on the MATE The number to the right of the screen is the Slave Rank All Slave FX s have POWER SAVE LEVEL SLAVE ADJUST ONLY or Slave Rank default values of 1 If this value is not changed from 1 then one of two things will happen First if the Master FX has been programmed with a value of 1 or greater in the POWER SAVE LEVEL MASTER ADJUST ONLY screen then all of the Slave FX s with Slave Rank 1 will remain On at all times Second if the Master FX has been programmed with a value of zero in the POWER SAVE LEVEL MA
93. e Se CF Ra ape c o vb ev tosis 13 FX ACCESSORIES E 14 TURBO KIT INFORWEA TION siscsccssecs stnscneds cdiucceateasscdssanntssdassecidassbecseatabebcsddsspesuancisecseausacsdldsssseceassbils 15 HUB COMMUNICATION MANAGER ccsssccssssssocssssssssccsssscccsssccsscsssssssssccssssseccsseccssccssseseccssnecees 16 EX SYSTEM CONFIGURATIONS cations 17 MIDI IP err rirgi eec 17 Series or Series Parallel Dual EX System 4 ertet eene coe tone o eepe een eo eoe ra o etn On go plea PURSE a UT eV He Up U E 18 Parall l d Dual FX System rr RES 19 Series Parallel Quad FX System m s ete d s 20 Farallel d Quad EX E 21 EE dirigi ri dim CC 22 START UP amp OPERA TION ege eege deeg EUR 23 BATTERY CHARGING INFORMAT ION eee ee eese ee eo enne se seen ao sete eeo se sete ea aes teta posee tesa aee tease 24 BATTERY CHARGING SETPOINTS ec cetu ne teure neu n SES Go ee tm Es Se eoo eaa nao ee sou E eS Do rasan no ce o eo si se seen resa unus 24 BATTERY EQUALIZATION ecce eene eerte nnne 24 RTS THE REMOTE TEMPERATURE SENSOR cete ee ee eee ee etn eese to nose etta sese toto sese tones eee ta sesto sesta au 24 BATTERY CHARGING SEQUENCE ee eere eese eo oo seen taa e e topo se eo Po Peto Pon e too Pee eo Oo Pee Po aee to Pose seen aee esas ee ep a 24 BATTERY CHARGING CONSTRAINTS ee ecce eene eee en neenon eet
94. e to deliver STACKING ERROR DETECTED indicates that a problem has occurred with the communication cabling between stacked FX s or if the FX s are stacked incorrectly Check the stacking programming If this condition persists contact your dealer for servicing instructions INVERTER OVERTEMP indicates that the FX reached its maximum allowed operating temp This can be caused by powering large AC loads or charging for too long It can also be caused by restricting the amount of air which is able to flow around the casting or operation in high temp environments The FX will automatically reset and resume operation once it cools down LOW BATTERY VOLTAGE indicates that the battery voltage dropped below the LOW BATTERY CUT OUT VOLTAGE set point default of 10 5 volts for a 12 volt FX for 5 minutes The inverter will restart once the battery voltage exceeds the LOW BATTERY CUT IN VOLTAGE set point default of 12 5 volts for a 12 volt FX for 10 minutes PHASE LOSS ERROR is not operational at this time If a Yes accompanies this Error please disregard and look for other error causes HIGH BATTERY VOLTAGE indicates that the battery voltage rose above the high battery voltage level default of 20 volts for a 12 volt FX for 10 seconds The inverter will restart once the battery voltage drops below the high battery voltage default of 20 volts for a 12 volt FX for 1 second AC OUTPUT SHORTED indicates that the inverter immediately reached its max
95. e top of the menu is AC Drop The user must press INC three times in order to get to the top of the list of functions From the top one can press DEC to cycle through the whole list of auxiliary functions See the next page to adjust the set points for the functions that have set points Selecting AC DROP enables the AUX output when an AC source is connected to the FX When the AC source ceases due to a power outage or a generator quitting the Aux output will be deactivated This allows the user to attach an indicator to the AUX output to show the user when an AC source is connected Selecting DIVERT AC or DIVERT DC enables the AUX output to function as a diversion controller This can be used to send excess power from a renewable energy source to a load This can allow control of sources such as wind turbines or hydro generators Two choices of DIVERT are provided DivertDC and DivertAC DivertDC is used to divert power to DC loads and DivertAC is used to divert power to AC loads The only difference is that the DivertAC setting will turn off the AUX output if the inverter is overloaded These settings have two set point screens see following page Selecting COOLFAN default enables the AUX output to function as a thermostatically operated ventilation system controller When the FX approaches an over temperature condition the AUX output will be energized This can be used to power a small 12 vdc brushless
96. ected to the FX s AC input terminals the FX will connect in about 30 seconds default setting and pass the AC voltage from the AC source through the FX s AC transfer switch to the loads connected to the FX s AC output terminals When an AC voltage source connects to the FX a battery charging sequence begins ABSORB VOLTAGE ABSORB TIME INITIATED FLOAT FLOAT INITIATED TIME SILENT 2 z LL LLELEL LE e DT w FLOAT i i i i VOLTAGE t Ee RE SRE E E R i i gt RE FLOAT i s i i i VOLTAGE TIME MATE Setting Only for Auto Gen Start Installation amp Programming Manual FX amp VFX Series Inverter Charger System Copyright 2003 O OutBack Power Systems Inc 900 0027 1 19009 62 Ave NE Arlington WA 98223 USA Page 24 Rev 7 2 08 26 05 Tel 360 435 6030 Fax 360 435 6019 BATTERY CHARGING INFORMATION The following bullets describe the steps in the battery charging sequence The first stage of the charging sequence is the Bulk stage The FX uses as much AC current as possible from the AC input source to raise the battery voltage to the Absorb voltage setting See the Maximum Current for Battery Charging heading in the RATINGS section for the FX s default and maximum values of the AC current used for charging The time period of the Bulk stage will vary with the battery bank s age capacity voltage and AC source Once the Absorb voltage has been reache
97. ection to directions and familiarity of the FX s charging process Also see the CHARGER MENU in the ADVANCED section for programming info e Set the time and the date on the MATE see MATE manual e Program the Auxiliary output for the function you wish it to perform If you wish to automatically start a generator see the AUTOMATIC GENERATOR START section of this manual you may also need the MATE manual In any case also see the AUXILIARY MENU in the ADVANCED section of this manual for programming info e Perform any other programming that you wish in the ADVANCED section of this manual The FX system is now ready to perform per your specification Switch the AC output breakers on with the bypass mechanism switched to Normal If there are X 240 breakers switch them on at this time Next switch on the AC input breakers Provided that the AC source to the FX s is available the yellow AC IN LED in the AC compartment will begin to blink If the voltage of the utility grid or generator is within 108 vac to 140 vac and the frequency is within 54 Hz to 66 Hz the FX will connect to the utility grid or generator This process takes about 30 seconds and the AC IN LED will stop blinking and stay lit when connection occurs When the AC IN LED is lit the AC transfer switch within the FX is activated and the utility grid or generator power is applied to the loads Atthis time the FX will perform a charge on the batteries The charging process is di
98. ed TOP ADV MAIN Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 Once the password has been correctly entered the ADV CHOOSE CATEGORY screen is displayed Selecting lt PG2 gt shows a second screen of categories Selecting lt PG3 gt shows a third screen of categories Selecting lt PG4 gt shows a fourth screen of categories Selecting lt CAL gt allows calibration of the AC input AC output and battery voltage set points The VAC INPUT ADJUSTMENT allows calibration of the AC input voltage If the AC source is measured and is different than the value read from the MATE the user can adjust it to match the measured value This value can be raised by pressing the INC button Conversely this value can be lowered by pressing the DEC button The value can be raised or lowered up to 2 vac The VAC OUTPUT ADJUSTMENT allows calibration of the AC output voltage If the AC output is measured and is different than the value read from the MATE the user can adjust the reading to match the measured value This value can be raised up to 2 vac by pressing the INC button and lowered up to 2 vac by pressing the DEC button NOTE This only affects the MATE s voltage display See page 51 ADJ OUTPUT VOLTAGE for actual adjustment of inverter VAC output The BATTERY VDC ADJUSTMENT allows calibration of the battery voltage If the battery voltage is measured and is d
99. ed to one of two Legs am assuming that half of the FX s will be connected to each AC Output Leg Actually it is acceptable to divide the FX s between the two Legs in the way you see fit but at least one FX must be on each Leg We will be using a Quad Stacked 4 FX system with two FX s on each Leg in this example When we set an FX as OB Slave L1 this indicates that it is in parallel on the same Leg with the master FX When we set an FX as OB Slave L2 this indicates that it is in series on the opposite Leg with the master FX If you have a different amount of FX s than the four FX s in our example or if you are overloading one Leg of your system then you might be putting the slave FX s on different Legs than what is shown in the example We will try to alleviate any confusion when we get to the part of the process where this is important The sentences in italics are intended for instructions on systems that are different than the example In a quad stack am assuming that the top FX is plugged into port 1 of the HUB the 2 EX down is plugged into port 2 the 3 FX down is plugged into port 3 and the 4 EX down is plugged into port 4 again the location of the FXs is not a rule just for simplicity Using the MATE go to the stacking menu explained earlier in the Stacking Instructions section You are now at the 1 stacking menu called Stack Phase In the upper right hand corner of the mate screen will always be the HUB port number
100. enclosure When installing an FX with a PS4DC or PS2DC disconnect enclosure both the DCA and DCC or Turbo are required DCC DC COMPARTMENT COVER The DCC covers the DC terminal area and allows a space which can be used to mount other components such as a DC current shunt The DCC can be used with or without the DCA When installing an FX with a PS4DC or PS2DC disconnect enclosure both the DCA and DCC or Turbo are required The DCC is provided with all VFX inverter chargers Installation amp Programming Manual FX amp VFX Series Inverter Charger System 900 0027 1 Page 14 Rev 7 2 08 26 05 Cut Back Power Systems Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 TURBO KIT INFORMATION The Turbo Kit is an addition that is either included or can be added to any sealed FX Typically the Turbo Kit adds 300 500 watts of power to a sealed FX This extra power is included in the model number for sealed FXs that come with Turbos If the sealed FX did not come with a Turbo and one is added then the FX will be able to produce the extra 300 500 watts of power in addition to the power that the model number indicates Do not use the Turbo with a vented VFX It will actually reduce the output power of the VFX The Turbo is highly recommended in hot climates or for installations that can use a few hundred watts of extra power In hot climates or when the
101. er of the AC wiring compartment to allow connection to the battery There is a small indentation in the aluminum casting between the battery terminals to allow for the wire to pass without affecting the sealing of the covers When running additional wires under the smoked lexan cover it may be required to snip some lexan away to allow for wire routing The lexan will not crack when cutting or filing IMPORTANT Do not connect a different brand of battery temp sensor It may cause battery failure MATE HUB The 8 conductor Ethernet RJ 45 modular jack allows direct connection of a MATE system controller and display to the FX using standard CAT 5 type cabling If multiple FX s or a FX and a MX charge controller are both in the system an OutBack HUB communication manager is connected to this RJ 45 jack for stacking of the FX s and for efficient system performance The HUB acts similarly to a computer hub to combine the communication signals of the devices together into a networked system OutBack offers two different HUB products at this time The HUB 4 accepts up to four OutBack products and one MATE The HUB 10 connects up to ten OutBack products and one MATE NOTE Although the HUB has 2 ports for MATEs only the 1 port is operational Installation amp Programming Manual FX amp VFX Series Inverter Charger System Copyright 2003 OutBack Power Systems Inc 900 0027 1 19009 62 Ave NE Arlington WA 98223 USA Page 12 Rev 7 2 08 26 05 Tel 360
102. erator automatically when the batteries need charging There are two separate ways to accomplish this function AGS Advanced Generator Start and GenAlert AGS is a function of the MATE while GenAlert is a function of the FX AGS has more features and therefore it can start the generator under many different types of conditions The AGS features include Quiet Time Voltage Start Load Start Must Run and Exercise Since AGS is a function of the MATE see the MATE manual for instructions NOTE The MATE must have a Code revision of 3 30 or greater found on the third start up screen of the MATE GenAlert is another way to automatically start the generator It is programmed through the MATE but it doesn t have all of the features that AGS has It works on a voltage start system where the generator will start when the battery voltage reaches a certain voltage for a specific period of time and stop when the battery voltage reaches a higher voltage for a different period of time These voltages and time periods are programmed through the MATE If you wish to use the GenAlert option follow the instructions below NOTE If both AGS and GenAlert are programmed AGS will be used Starting from the main menu press the ADV button to get into the advanced menu the password is 141 press INC until the number reads 141 and then press lt ENTER gt From the Advanced menu press the lt PG2 gt button then the lt PG3 gt button then the AUX button
103. ession type lug Cable must meet the requirements of the National Electrical Code Use of large gauge cables 2 0 or 4 0 AWG or larger is advisable to reduce losses and ensure high performance of the FX Cables of too small a gauge can result in poor performance and even damage the FX Keep the cables together as much as possible and ensure that both cables pass through the same knockout and conduit fittings and to allow the inductive currents to cancel 3 For equipment grounding hook up see the system configuration sections in this manual Non mobile M FXs are intended to be installed as part of a permanently grounded electrical system per the NEC Mobile FXs include integral Ground switching mechanisms Please refer to the MOBILE FX INFORMATION section of this manual for proper grounding instructions 4 AC overcurrent protection for all connections must be provided by others as part of the installation 5 DC battery circuit overcurrent protection must be provided by others as part of the installation OutBack offers 100 175 and 250 amp DC breakers part number OBDC XXX which can be used with the FX For Mobile installations OutBack includes a stud mounted fuse which can be connected directly to the positive DC terminal of the FX it is available in 100 175 and 250 amp sizes part number SMF XXX The stud mounted fuses require a 10mm hole in the battery terminal lug US lugs are typically 3 8 diameter Light filing may be required to
104. every possible watt of power Properly setup and operated SEARCH mode can save considerable amounts of power compared to keeping an inverter in the ON mode 24 hours a day The FX includes a load detection method that is called search mode in which the inverter produces a pulsed AC output to detect the magnitude of the AC load which is connected to the inverter AC output Once a large enough load has been turned on the inverter resumes normal operation providing continuous AC power If the AC load is reduced to a level below the SEARCH SENSITIVITY setting then the inverter turns off and the pulsed AC output search mode is resumed The power saved by using the SEARCH pulsing method comes both from the reduced consumption of the inverter itself and from the elimination of the power consumed by phantom AC loads appliances which consume power even though they are not operating The SEARCH SENSITIVITY setting can be adjusted to ignore small AC loads such as a VCR display etc Use of the search mode requires some tuning of the settings for the particular loads connected and may not work well with some loads such as fluorescent lights with magnetic ballasts MAIN The MAIN screen is where the menu system starts The four words in the bottom line of the 6 54 42P display correspond to the four buttons located below the display The word in BOLD
105. example P01 indicates port 1 the Master FX s port Repeatedly pressing PORT on the MATE will cycle through the ports on the HUB that have FX s connected to them Stop when you have reached a port that has an FX on it that needs to be a Slave By pressing the INC increase and DEC decrease buttons on the MATE you can select the proper type of Slave that is appropriate for your system Below are the different selections in the STACK PHASE menu with a description of what they do 1 2 PH MASTER 1 2 PH MASTER is used for stand alone one FX systems OR as the MASTER of a single phase or split phase system Set the stack phase of the FX you want as the master to 1 2 PH Master if it isn t already and make sure it is in port 1 of the HUB It is acceptable to have every FX connected to the HUB be a 1 2ph Master If this is the case each FX must be connected to a separate AC Output Leg both Hot and Neutral The master FX is always considered to be the L1 phase CLASSIC SLAVE If you have a system with two FX s that you wish to produce 240VAC with but without an X 240 autotransformer set the stack phase of the FX you want as the slave to Classic Slave and make sure it is in port 2 of the hub Classic stacking is meant for 120 240 vac systems where each FX handles their own 120 volt phase The combination of the two FX s creates 240 volts to run 240 loads If this FX is set to Classic Slave then its output is 180 degrees out of phase from the
106. f each type of system The next four pages explain the Stacking menu and how to program the various types of stacked systems PARALLEL OUTBACK This stacking method pertains to a system that has two to ten FX s all connected to the same 120VAC Output Leg The system can be programmed such that only one FX the Master stays On and the rest of the FX s the Slaves are asleep The Slaves come on only when the power requirement is high enough that the Master FX calls on the Slave FX s to help with the load Itis also possible to program the system to keep any number of FX s On while the remaining FX s are asleep The AC Input Source usually a generator or utility grid must be 120VAC or stepped down to 120VAC form a 240VAC source using the X 240 autotransformer SERIES CLASSIC This stacking method pertain to a system that has only two FX s and two 120VAC Output Legs that will produce 240VAC between them In this system the Master FX and the Slave FX operate independently from each other In other words each FX will power its own 120VAC Output Leg but if any 240VAC loads need to be powered both FX s will be used The AC Input source generator or grid must be 240VAC for both Legs to be powered SERIES OUTBACK This stacking method pertains to a system that has two to ten FX s connected to two 120VAC Output Legs that will produce 240VAC between them In this stacking method the FX s will be connected to either of the two AC Output Legs usually
107. fferent depending on whether the generator has been started automatically or manually The start of either charging process will Bulk raise the battery voltage until they reach the Absorb voltage The FX will maintain this Absorb voltage for the Absorb Time Limit default of 1 hour If the generator had been automatically started the generator will now be shut off However if the generator had been manually started the charging process continues After the Absorb stage the FX goes into Silent mode letting the battery voltage drop until it levels out If the battery voltage drops to the Re Float voltage the FX will perform a Float charge It raises the battery voltage to the Float voltage and it then sustains this voltage for the Float Time Period default of 1 hour Once this hour is up the FX will go back into Silent mode and again wait for the battery voltage to drop to Re Float This process of Silent Re Float Float Silent Re Float etc will continue until the generator is manually shut off Copyright 2003 OutBack Power Systems Inc FX amp VFX Series Inverter Charger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA 900 0027 1 Tel 360 435 6030 Fax 360 435 6019 Rev 7 2 08 26 05 Page 23 BATTERY CHARGING INFORMATION A battery bank may last for over 10 years if properly cared for but it can also be ruined in less than a month if not prope
108. g process These settings and situations are described by the following bullets Rated Continuous Current of the AC Input Source This applies to generators only since the utility grid can produce power levels much higher This setting is for the maximum AC generator current at 120 VAC that the FX will accept before is turns down its charger This setting is called AC 2 Gen Limit and can be accessed through the MATE by following the path Main Setup FX Input Down Down The rated continuous AC current of the generator should be set in this screen When the combined AC current used by the FX s charger and the loads connected to the FX s AC output exceed this AC 2 Gen Limit the FX will reduce the AC current used for the charger to ensure that the generator is not overloaded Low AC Input Voltage When the FX is connected to an AC input source it passes through the AC input sources voltage and current The FX has minimum and maximum voltage settings for the AC input source to ensure that the AC input source does not damage downstream loads with low or high voltage If the FX is charging and passing through power the AC input source voltage can be dragged down to the FX s low voltage limit When this happens the FX will back off the charger to sustain an acceptable voltage If the FX goes below the low voltage limit it will disconnect from the AC input source and cease charging If you are experiencing low AC input voltage from a generator i
109. h local and National Electrical Codes NEC installation requirements If you are not familiar with the NEC you should have the equipment installed by a qualified renewable energy equipment electrician Contact your dealer for information on qualified electricians All wiring methods are to be made in accordance with the National Electrical Code ANSI NFPA 70 The FX includes an AC wiring compartment with both a removable cover and AC conduit plate Depending on the type of installation the AC conduit plate may or may not be used MATE HUB Jack AC Terminal Block OUTBACK POWER SYSTEMS ERROR 626006 wa STATUS LED s MATE BATTERY TEMP Jack ke ke a a z z ke 8 8 2 2 5 q GC 4 0 amp S x E uo SS w l BATTERY LED s C 3 2 e 2 qd 2 9 zc E z 8 2 i o ZS amp o o i Control Wiring Reads Terminal Block NEU GROUND BOND on Mobile FXs The AC terminal block is designed to accept up to 6 AWG 13 3mm wires A typical installation will use THHN type wire 6 AWG 13 3mm wire is required in order to handle the 60 amp capacity of the non Mobile FX s AC transfer switch 10 AWG 5 3 mm wire or larger is required in order to handle the 30 amp capacity of the Mobile FX s AC transfer switch All AC wiring connected to the AC terminal block must be rated for at least 75 C Torque all of the set screws on the AC terminal block to 30 inch pounds equivalent to 2 5 foot pou
110. he AC1 GRID TRANSFER DELAY is the amount of time that the AC input will remain connected acl grid 6 cycles to the AC source when the AC input voltage drops below the AC1 GRID lower limit setting Once transfer delay the AC voltage has risen above the AC1 GRID lower limit setting for the AC INPUT CONNECT DOWN INC DEC PORT DELAY time period the AC source will be reconnected This setting has a range between 0 l cycles and 240 cycles in 1 cycle increments TOP ADV MAIN Copyright 2003 O OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 ADV FX GRID Selecting TOP returns the user to the top of the ADV FX GRID menu section Selecting ADV GRID programming returns you to the advanced screen to allow selection of another product connected to the MATE completed Selecting MAIN returns the display to the MAIN screen FX amp VFX Series Inverter Charger System 900 0027 1 Rev 7 2 08 26 05 Installation amp Programming Manual Page 55 MATE SCREENS GENERATOR MENU The GEN generator category of the advanced menu section allows for adjustment of the AC input voltage window and time delays to match the characteristics of the AC source if that AC source is a generator This setting can be found in the SETUP FX INPUT menu All OutBack Power System FX s other than the Grid Tie FX s have a default of GEN generator as the AC source
111. ian To request limited warranty service you must contact OutBack Power Systems at 360 435 6030 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 Shipments to other locations will be made freight collect Copyright 2003 OutBack Power Systems Inc FX amp VFX Series Inverter Charger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA 900 0027 1 Tel 360 435 6030 Fax 360 435 6019 Rev 7 2 08 26 05 Page 63 Installation amp Programming Manual FX amp VFX Series Inverter Charger System Copyright 2003 OutBack Power Systems Inc 900 0027 1 19009 62 Ave NE Arlington WA 98223 USA Page 64 Rev 7 2 08 26 05 Tel 360 435 6030 Fax 360 435 6019 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
112. ifferent than the value read from the MATE the user can adjust it to match the measured value This value can be raised by pressing the INC button Conversely this value can be lowered by pressing the DEC button The value can be raised or lowered up to 0 2 vdc for 12V battery system 0 4V for 24V battery systems and 0 8V for 48Vbattery systems Selecting TOP returns the user to the top of the ADV FX CALIBRATION menu section Selecting ADV returns you to the advanced screen to allow selection of another product connected to the MATE Selecting MAIN returns the display to the MAIN screen END OF ADVANCED MENU SYSTEM FX amp VFX Series Inverter Charger System 900 0027 1 Rev 7 2 08 26 05 Installation amp Programming Manual Page 61 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 SIZE DC CROSS SECTIONAL AREA APPROXIMATE Resistance DIAMETER AWG in Ohms 1000 feet INCHES MILLIMETERS INCHES MILLIMETERS 14 3 14 0032 2 08 078 1 98 12 1 98 0051 3 31 101 2 57 10 1 24 0082 5 26 126 3 20 8 0 78 0130 8 37 162 4 11 6 0 50 0206 13 30 215 5 46 4 0 31 0328 21 15 269 6 83 2 0 19 0521 33 62 337 8 56 1 0 15 0657 42 41 376 9 55 1 0 0 12 0829 53 50 423
113. imum current and shut down This is usually caused by a short circuit condition hence the AC OUTPUT SHORTED label but can also be caused by attempting to operate a load which far exceeds the inverter output capability AC OUTPUT BACKFEED indicates that another AC source of power was connected to the AC output of the FX Usually this is an installation issue It often occurs when there is an X 240 transformer in the system that hasn t been installed properly Also check that there are no connections between the AC input and AC output circuitry Selecting TOP returns the user to the top of the STATUS FX ERROR menu section Selecting STATUS returns to the first page of the STATUS screen FX amp VFX Series Inverter Charger System Copyright 2003 OutBack Power Systems Inc 900 0027 1 19009 62 Ave NE Arlington WA 98223 USA Rev 7 2 08 26 05 Tel 360 435 6030 Fax 360 435 6019 MATE SCREENS WARNING MENU The WARNINGS section of the STATUS menu allows the user to check the cause of a warning condition for the FX When a warning condition has occurred the red ERROR LED indicator in the FX s wiring compartment will flash The cause of the warning will not be displayed on the MATE like an ERROR will Instead you must access this WARNINGS menu and scroll down the list to find out which warning is present This is indicated by the presence of a YES next to the appropriate cause listed Once the cause for the warning is no longer present the
114. imum voltage that the AC source is allowed to be in order for the FX to connect to that source The FX will back off the charger if the AC source is at this lower limit If the AC source falls below this limit the FX will disconnect from the AC source until it is above this value This setting has a range between 70 vac and 110 vac in 1 vac increments The AC2 GEN UPPER LIMIT set point allows adjustment of the maximum voltage that the AC source is allowed to be in order for the FX to connect to that source If the AC source exceeds this value the FX will disconnect from the AC source until it is below this value This setting has a range between 130 vac and 150 vac in 1 vac increments The AC2 GEN INPUT LIMIT sets the maximum amount of current the FX allows to be drawn from the AC source When the AC input current limit is reached the power draw of the battery charger is backed off to prevent overloading the AC source If the AC loads exceed this limit the FX will give a warning and start blinking the red ERROR LED This setting has a range between 5 0 aac and 60 0 aac in 1 0 aac increments The AC2 GEN TRANSFER DELAY is the amount of time that the AC input will remain connected to the AC source when the AC input voltage drops below the AC2 GEN lower limit setting Once the AC voltage has risen above the AC2 GEN lower limit setting for the AC INPUT CONNECT DELAY time period the AC source will be reconnected This setting has a range between 0 cy
115. in the system program the top FX as Master 1 2PH MASTER and the lower FX as an OutBack L2 slave OB SLAVE L2 See the STACKING INFORMATION section of the manual for more info When the FX s are connected in series for 120 240 VAC the X 240 autotransformer can be connected to the AC output to allow both of the FX s capacity to be available on either of the 120 VAC output circuits This allows higher efficiency and better performance as heavy 120 VAC loads are powered by both of the FX s The X 240 autotransformer also allows the master to power loads on either of the 120 VAC output circuits with the slave off This reduces the idle power consumption and improves the system efficiency NON MOBILE FX NOTES The AC OUTPUT NEUTRAL IS NOT BONDED TO THE CHASSIS OR THE GROUND TERMINAL of the FX system This connection is to be made by the installer either in the AC service entrance or within the AC load distribution panel of the electrical system The AC input AC output and DC terminals are isolated from the metal chassis of the FX Proper grounding of these circuits and the chassis of the FX is the responsibility of the installer MOBILE FX NOTES The AC input source to the FX grid and or generator must have an internal neutral ground connection On the above diagram the AC source s neutral conductor must go directly to the FXs AC NEUTRAL IN terminal or to a separate neutral busbar that is isolated from the FX s AC output neutral The AC output of the FX m
116. ing or press the INC button three times for series stacking In this example we ve set 1 FX P02 to be in parallel with the master P01 and 2 FX s P03 amp P04 to be in series with the master Press the DOWN button 2 times to get into the POWER SAVE LEVEL SLAVE ADJUST ONLY menu This menu allows you to set the order in which the slave FX s come On Press the PORT button until PO3 is displayed in the upper right corner of the screen We re starting out with port 3 because the FX on port 3 is the first slave that is in series OB Slave L2 with the master Copyright 2003 OutBack Power Systems Inc FX amp VFX Series Inverter Charger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA 900 0027 1 Tel 360 435 6030 Fax 360 435 6019 Rev 7 2 08 26 05 Page 29 STACKING INSTRUCTIONS System Examples Continued By making this FX the 1 rank slave we are turning both Legs On directly thus producing 240VAC without using the X 240 If you have a system that is different from this example then press the PORT button until you get to a slave FX that is in series OB Slave L2 with the master On this screen the setting from the factory should be set to 1 which indicates the 1 rank slave If it s anything other than 1 then press the DEC button until it becomes 1 Press the PORT button until you reach P02 to talk to the port 2 FX If you have a system that is different from this example then p
117. insure proper fit of the nut shoulder into the lug hole 6 The equipment ground on the inverter is marked with this symbol 7 This inverter has a single phase output It is marked with this symbol 92 nu 9 CAUTION To reduce the risk of fire connect only to a circuit provided with 60 amp maximum branch circuit overcurrent protection in accordance with the National Electrical Code ANSI NFPA 70 8 This inverter puts out a sine wave waveform It is marked with this symbol 10 WARNING To reduce the risk of fire 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 two FX s wired in a series configuration or the addition of an X 240 autotransformer if you are connecting to a 120 240 VAC multi wire system 11 IMPORTANT Always install the battery terminal covers even in systems that include the DCC DC Compartment Cover Copyright 2003 O OutBack Power Systems Inc FX amp VFX Series Inverter Charger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA 900 0027 1 Tel 360 435 6030 Fax 360 435 6019 Rev 7 2 08 26 05 Page 5 IMPORTANT SAFETY INSTRUCTIONS General Precautions 1 10 11 Before using the FX read all instructions and cautionary markings on 1 the FX 2 the batteries and 3 all appropriate sections of this installation and operation manual CAUTION To reduce risk of injury charge only dee
118. ion is to be made by the installer either in the AC service entrance or within the AC load distribution panel of the electrical system The AC input AC output and DC terminals are isolated from the metal chassis of the FX Proper grounding of these circuits and the chassis of the FX is the responsibility of the installer MOBILE FX NOTES The AC input source to the FX grid and or generator must have an internal neutral ground connection On the above diagram the AC source s neutral conductor must go directly to the FXs AC NEUTRAL IN terminal or to a separate neutral busbar that is isolated from the FX s AC output neutral The AC output of the FX must go to a separate AC output busbar that is isolated from the AC input neutral A bypass mechanism must bypass the AC source s hot and neutral wires Proper grounding of the DC circuit and the chassis of the FX is the responsibility of the installer Installation amp Programming Manual FX amp VFX Series Inverter Charger System Copyright 2003 OutBack Power Systems Inc 900 0027 1 19009 62 Ave NE Arlington WA 98223 USA Page 22 Rev 7 2 08 26 05 Tel 360 435 6030 Fax 360 435 6019 START UP amp OPERATION Once the FX system installation is completed it is time to power the system Leave the breakers on the AC side in the OFF position until the FX s are powered and programmed Power the FX s and any MX 60 charge controllers by switching the DC disconnect breakers to the ON position The LED s
119. iring must handle a capacity of 50 amps AC or more For a Mobile FX system 30A input breakers should be used due to the maximum AC input pass through rating of the Mobile FX s This type of FX system can continuously power 4 7 2KW 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 A HUB and a MATE must be connected to stack these FX s in series The MATE must be connected to adjust any parameters or to display any meters The slave FX must be programmed through the MATE as a Classic Slave series stacking no X 240 or as OB Slave L2 series parallel stacking X 240 included Once the FX has been programmed using the MATE the MATE can be disconnected The programming will be saved within the FX s non volatile memory even if the FX is completely shut down X 240 4 0 7 2KW 120 240VAC NOT USED TOR SERIES 100A BYPASS CLASSIC STACKING AC LOADS 1 2 amp 3 4 E d MASTER 120 240VAC H L2 N D ogr Oo 20o eQo o Og aGa s 50 AMPS PER LINE A MAX re 50A DUAL BYPASS WITH TWO SOA OUTPUT BREAKER STANDARD ON MODEL PS2AC 50D BYPASS KIT AC IOB 50 TWO 50A CBI BREAKERS FOR THE AC INPUT ONE ADDITIONAL 25A CBI BREAKER FOR THE X 240 50 AMPS PER LINE MAX AC OUT NEUTRAL AC IN 2 ajo e e i E OFF
120. isplays P02 We are still in the Stack Phase menu but we are now talking to the FX on port 2 Push the INC button two times to set the Stack Phase to OB Slave L1 Press the PORT button again to talk to the FX on port 3 Push the INC button two times to set the Stack Phase to OB Slave L1 Press the PORT button again to talk to the FX on port 4 Push the INC button two times to set the Stack Phase to OB Slave L1 Now you ve set 3 FX s P02 P04 to be in parallel with the master P01 If you have more FX s in the system then program them as OB Slave L1 Press the DOWN button 2 times to get into the POWER SAVE LEVEL SLAVE ADJUST ONLY menu Press the PORT button until PO2 is displayed in the upper right corner of the screen This menu pertains to the slaves only which is why we re starting out with port 2 The setting from the factory should be already set to 1 which is the 1 rank slave If it s anything other than 1 appears press the INC or DEC buttons to make it 1 Press the PORT button to talk to the port 3 FX Press the INC button to change the power save level slave adjust only to 2 which is the 2 rank slave Press the PORT button to talk to the port 4 FX Press the INC button until the setting is 3 for 3 rank slave Now you ve set the rank for all the slaves If you have more FX s in the system then press the PORT button to access the next FX and press INC until the number on the screen is 1 number less than the p
121. lave FX s will back off before the Master FX leaving the Master FX to finish the charge Copyright 2003 OutBack Power Systems Inc FX amp VFX Series Inverter Charger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA 900 0027 1 Tel 360 435 6030 Fax 360 435 6019 Rev 7 2 08 26 05 Page 25 STACKING INFORMATION Classic OutBack and 3 Phase Stacking Methods OutBack Power Systems offers four different ways to stack multiple FX s up to 10 for single or split phase systems only 3 for three phase systems The first thing to consider is if you want all of the FX s in parallel FX s on same AC Output Leg producing 120VAC only in series FX s divided between two AC Output Legs producing 120VAC on each Leg and 240VAC between the two Legs or in 3 phase maximum of three FX s one on each AC Output Leg producing 120VAC on each Leg and 208VAC between each set of Legs A HUB 4 or HUB 10 must be included to stack FX s If you choose to stack the FX s in series the second thing to consider is how many FX s you will use If you are series stacking three to ten FX s you must use OutBack stacking and include an X 240 autotransformer If you are series stacking only two FX s you can choose between Classic stacking and OutBack stacking Keep in mind that if you choose to series stack FX s using OutBack stacking you must include an X 240 autotransformer in the system Below is an explanation o
122. low the upper limit DOWN UP TOP PORT SINUS FX WARN P00 AC IN VOLTAGE TOO LOW indicates that the AC source s voltage is below the lower limit default acin voltage No is 108 VAC of the FX s voltage window The FX will not connect to the AC source until the voltage too low rises above the lower limit DOWN UP TOP PORT x AC INPUT CURRENT EXCEEDS MAX indicates that the AC loads are drawing more current than STATUS FX WARN P00 ac input No current exceeds max the AC INPUT LIMIT of the FX is programmed for Exceeding this current limit for an extended period of time could cause the FX to fail a generator to disconnect or a breaker to trip Reduce the DOWN UP TOP PORT loads on the FX s AC output to prevent damage and for Mobile versions of the FX make sure a SR 30A breaker maximum is used on the AC input line STATUS FX WARN P00 TEMPERATURE SENSOR FAULT indicates that one of the temperature sensors internally located bn No in the FX is not working correctly The FX needs to be checked by a qualified repair technician sensor au x d DOWN UP T B DORT The AIRTEMP FETTEMP and CAPTEMP screens shown below can help with troubleshooting Y INTERNAL COMMUNICATION ERROR DETECTED indicates that a communication problem has STATUS FX WARN PO00 occurred between the MATE and the FX This warning may occur if the communication lines internal comm No between the FX and the MATE have been severed or disconnected If this is the cas
123. lues displayed are not defaults STATUS FX PAGE1 MODES Shows status and allows adjustment of Inverter AC input Charger Aux and EQ choose category METER Provides the AC voltages and currents of the FX BATT Provides the battery voltage and charger set points and timers MODES METER BATT PG2 PG2 Displays additional sections ERRORS WARNINGS and PG3 JL This screen shows the mode and where power is flowing within the FX The modes include Invert Charge Pass Through Support and Sell When the FX is in the Invert Support or Sell mode the inv 0 0kw meter will change When the FX is in the Charge mode the chg 0 0kw meter will change Only for Grid Tie FX s the zer 0 0kw will change to sel 0 0kw and change when the FX is in the Sell Invert POO inv O 0kw zer 0 0kw chg 0 0kw buy 0 0kw DOWN STATUS PORT d M T mode The buy 0 0kw meter will change when the FX is either in Pass Through or Charge mode STATUS FX METER P00 The OUTPUT VOLTAGE meter indicates the AC voltage on the AC output of the FX which is output 120 vac available to power the AC loads When the inverter is in the SEARCH mode the AC output voltage voltage may not be the nominal output of 120 VAC This is a normal condition Increasing the AC load or DOWN UP TOP PORT selecting ON from the INVERTER CONTROL menu screen will return the AC output voltage to l normal STATUS FX METER P00 The INPUT VOLTAGE meter indicates the AC
124. lugs with a 5 16 hole should be used to connect the battery cables to the DC terminals of this FX If using the stud mounted fuse the positive lug must have a hole of atleast 10mm Soldered cable lugs are also acceptable Torque all AC wiring connections to 30 inch pounds equivalent to 2 5 foot pounds or 3 4 Nm Torque the DC connections to 60 inch pounds equivalent to 5 foot pounds or 6 8 Nm Be careful with tools to reduce the risk of dropping metal objects onto batteries It may short circuit the batteries or other electrical parts resulting in fire or explosion Additional Notices TOO NE For instructions on mounting see the MOUNTING section of this manual For battery installation and maintenance read the battery manufacturer s instructions prior to installation and operation All installations must comply with local and national electrical codes and standards GROUNDING INSTRUCTIONS The FX should be connected to a grounded permanent wiring system For all installations the negative battery conductor should be bonded to the grounding system at one and only one point in the system All installations should comply with national and local codes and ordinances Do not positive ground the FX Personal Precautions While Working with Batteries 1 Someone should be within range of your voice to come to your aid 2 Have plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eyes 3 Wear comple
125. mer for the charging process No adjustments are allowed from this section To change the battery charger s operation go the ADVANCED programming section The values displayed are not defaults STATUS FX PAGE1 choose category MODES METER BATT PG2 Y STATUS FX BATT P00 battery 12 2 vdc actual DOWN STATUS PORT STATUS FX BATT P00 battery 12 2 vdc temp compensated DOWN UP TOP PORT L STATUS FX BATT P00 absorb 14 4 vdc set point DOWN UP TOP PORT L STATUS FX BATT P00 absorb 01 0 hrs time remaining DOWN UP TOP PORT Y STATUS FX BATT P00 float 13 6 vdc set point DOWN UP TOP PORT Y STATUS FX BATT P00 float 00 0 hrs time remaining DOWN UP TOP PORT Y STATUS FX BATT P00 refloat 12 2 vdc set point DOWN UP TOP PORT L STATUS FX BATT P00 equalize 14 6 vdc set point DOWN UP TOP PORT U STATUS FX BATT P00 equalize 00 0 hrs time remaining DOWN UP TOP PORT H STATUS FX BATT P00 battery temp 255 not in degrees C F DOWN UP TOP PORT l STATUS FX BATT end of battery menu UP TOP STATUS Tel 360 435 6030 Fax 360 435 6019 Copyright 2003 OutBack Power Systems Inc 9009 62 Ave NE Arlington WA 98223 USA MODES Shows status and allows adjustment of Inverter AC input Charger Aux and EQ METER Provides the AC voltages and currents of the FX lt BATT gt Provi
126. muffin type fan the Turbo Kit or can be used to control a larger cooling fan via a 12 vdc coil relay Selecting VENTFAN enables the AUX output to function as an automatic battery ventilation system controller The AUX output can provide 0 7 amps of power for connection to a 12 vdc brushless muffin type fan The fan will be automatically turned on when the voltage exceeds the VENTFAN ON voltage set point The fan can be set to operate intermittently by adjusting the VENTFAN OFF TIME PERIOD This setting has two set point screens see following page Selecting FAULT enables the AUX output to function as an alarm output When the FX enters any of the error conditions the AUX output is energized This can be used to send an alarm signal via radio pager or telephone dialer It also can be used to log error conditions by using it to trigger an event recording device Selecting GENALERT enables the AUX output to function as a simple voltage controlled generator start signal GenAlert can be used to alert the system user to start the generator due to the battery voltage being low GenAlert can also be used to connect a 2 wire type generator through a 12 volt DC relay Time delays for ON and OFF are adjustable Using Advanced Generator Start AGS a different generator start system will override this and any AUX function that is programmed on the port that AGS is set up on GenAlert has four set point screens see following page Selec
127. n This is helpful if the user wishes to quickly enable or disable a particular function of a specific FX if necessary If the system is OutBack stacked only the Master s modes with the exception of the Aux can be changed MAIN 6 54 42P SUM STATUS SETUP ADV J STATUS choose product FX MX l STATUS FX PAGE1 choose category MODES METER BATT PG2 l STATUS FX MODE P00 inv control ON CHANGE DOWN STAT MODE PORT l STATUS FX MODE P00 ac in control USE CHANGE DOWN UP ODE PORT l STATUS FX MODE P00 chr control AUTO CHANGE DOWN UP ODE PORT l STATUS FX MODE P00 aux control AUTO CHANGE DOWN UP ODE PORT L STATUS FX MODE P00 eq enabled No CHANGE UP ODE PORT Copyright 2003 O OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 The MAIN screen is where the menu system starts The four words in the bottom line of the display correspond to the four buttons located below the display The word in BOLD on the bottom line indicates the selection used to advance the display to the next screen Pressing the left two buttons simultaneously from anywhere in the menu will return you to this screen Selecting STATUS allows selection of the product type FX FX inverter charger system MX MX60 PV MPPT charge controller lt MODES gt Shows st
128. n and the MATE will display an error screen Pressing VIEW ERROR from this screen brings the user to the 1 screen of a list of error causes that will be available by pressing the DOWN button The presence of the word YES to the right of the appropriate cause indicates that this error has occurred It is possible for multiple errors to occur simultaneously Check every error condition to make sure An error can be cleared by pressing the INV button on the MATE and then turning the FX lt OFF gt and then ON The inverter automatically resets from over temperature and low or high battery voltage conditions 6 54 42P SUM STATUS SETUP ADV STATUS choose product FX MX v STATUS FX PAGE1 choose category MODES METER BATT PG2 STATUS FX PAGE2 choose category PG1 ERROR WARN PG3 Y STATUS FX ERROR P00 low ac output o voltage DOWN STATUS PORT v STATUS FX ERROR P00 stacking o error detected DOWN UP TOP PORT v STATUS FX ERROR P00 inverter o overtemp DOWN UP TOP PORT v STATUS FX ERROR P00 low battery o voltage DOWN UP TOP PORT v STATUS FX ERROR P00 phase loss O error DOWN UP TOP PORT VW STATUS FX ERROR P00 high battery O voltage DOWN UP TOP PORT de STATUS FX ERROR P00 ac output o shorted DOWN UP TOP PORT v STATUS FX ERROR P00
129. nds or 3 4 Nm For a non Mobile FX the AC hot input and hot output conductors should be supplied through 60 amp maximum AC branch rated circuit breakers The AC hot input conductor should be connected to the AC HOT IN terminal and the AC HOT OUT terminal respectively The AC neutral input and AC neutral output conductors may be connected to the AC NEUTRAL IN and AC NEUTRAL OUT terminals or a common Neutral bus The AC NEUTRAL OUT terminal is common with the AC NEUTRAL IN terminal within the non Mobile FX and only one AC neutral connection is required to be connected to the FX if a separate AC neutral bus is installed The ground wires of the AC input and the AC output may be onnected to the two CHASSIS GROUND terminals or a common Ground bus The two CHASSIS GROUND terminals are common within the non Mobile FX so only one of them needs to be connected if a common Ground bus is installed in the system For a Mobile FX the AC hot input and hot output conductors should be supplied through 30 amp maximum AC branch rated circuit breakers The AC hot input conductor should be connected to the AC HOT IN terminal and the AC HOT OUT terminal respectively The AC neutral input conductor must be connected to the Mobile FX s AC NEUTRAL IN terminal The AC neutral output conductor must be connected to the Mobile FX s AC NEUTRAL OUT terminal These two neutral terminals are not always connected within the Mobile FX and are necessary for the proper functioning and pro
130. nerator only This charge will finish the charging process by putting the last few percentage points setpoint of charge into the batteries This set point can be adjusted to match the specific requirements of the DOWN INC DEC port batteries being charged This setting has a range between 12 0 vdc and 15 0 vdc in 0 1 vdc increments Y ADV FX CHARGER P00 The FLOAT TIME PERIOD can be adjusted to set the amount of time that the battery bank is held at float 01 0 hrs the Float Setpoint For large battery banks a longer time may be required smaller battery banks may time period require a lower setting Once the battery has been held at the Float Setpoint for the Float Time DOWN INC DEC port Period the battery charger goes silent and provides no charge to the battery This setting has a range i between 0 hours and 24 hours in 0 1 hour increments ADV FX CHARGER P00 The REFLOAT SET POINT voltage is used to trigger the battery charger back into another FLOAT refloat 12 2 vdc cycle when the battery voltage falls to this set point This can provide maintenance charging of setpoint batteries and is also useful when intermittent DC loads are operated from a battery system and an AC DOWN INC DEC PORT source is available This setting has a range between 12 0 vdc and 13 0 vdc in 0 1 vdc increments Ge 00 The EQUALIZE SET POINT voltage can be set for a high voltage to de stratify the batteries on Sal e 14
131. ngs pertaining only to the FX are stored in non volatile memory inside of the FX itself The battery can then be disconnected from the FX and the settings will not be lost The MATE also allows for monitoring and control of the FX system s operation Some of the more advanced system operating modes such as the HIGH BATTERY TRANSFER HBX function the ADVANCED GENERATOR START AGS function and the GRID USE function requires that a MATE be connected to the FX system all of the time To use these functions properly the MATE s time and date should be set The MATE s settings are also stored in non volatile memory and a battery within the MATE keeps the time and date current when disconnected from an FX or the HUB The operating software used in the MATE is upgradeable to allow for the addition of new features to existing systems It can be easily removed and exchanged by the system user The MATE includes an RS 232 PC serial communication port to allow monitoring and remote modem access of the system via phone or internet This PC software is currently being developed by third party companies and will soon be offered as an option through your OutBack Power Systems dealer Tracking software is available at www RightHandEng com OutBack Outback Power Systems currently offers the following different versions of the MATE MATE Basic MATE with an oval encasing shown below The casing is grayish white in color This option includes an RS 232 port MATE2
132. o PG3 Displays additional sections reason for last DISCONNECT and SELL PG2 Displays additional sections ERRORS WARNINGS and PG3 lt DISCON gt Displays the reason that the FX last disconnected from the AC source SELL Displays the code related to the reason for the last disconnection while selling MAIN Returns the user to the MAIN menu The ACIN FREQ TOO HIGH screen displays a Yes if the FX disconnected from the AC source due to the frequency of the AC source exceeding 69 Hz The MATE does not display the frequency of the AC source but this can be verified using an oscilloscope If this message occurs and the AC Source is a generator it may be possible to adjust the frequency of the generator The ACIN FREQ TOO LOW screen displays a Yes if the FX disconnected from the AC source due to the frequency of the AC source being below 51 Hz The MATE does not display the frequency of the AC source but this can be verified using an oscilloscope If this message occurs and the AC Source is a generator it may be possible to adjust the frequency of the generator The ACIN VOLTAGE MAX screen indicates that the AC source s voltage exceeded the maximum AC voltage the FX allows 140 vac default This value can be adjusted in the ADVANCED menu in the GRID or GEN sections depending on your input type The FX disconnects to protect the loads from high voltage If you expect significant voltage drop due to long cable runs it may be safe
133. of AC load from the batteries The AC AC Load ge source is available but DROP was selected in the AC INPUT CONTROL This will also be AC Drop displayed when an AC source is available but not in use such as during the initial time delay Battery 12 3V period once an AC source has been connected DOOSSG SEES AKN SELLING The FX is selling power back to the utility grid at about 1 5kW Itis also supplying Ee about 0 5kW of AC loads The FX is taking about 2 2kW of power from the batteries This EE pe excess battery power is coming from a different source solar wind hydro etc This screen Battery 13 4V will only appear on Grid Tie FX s Installation amp Programming Manual FX amp VFX Series Inverter Charger System Copyright 2003 OutBack Power Systems Inc 900 0027 1 19009 62 Ave NE Arlington WA 98223 USA Page 42 Rev 7 2 08 26 05 Tel 360 435 6030 Fax 360 435 6019 MATE SCREENS Status Screens The STATUS screens allow the system user to check the operation of the FX system Both AC and DC voltage and AC current meters are provided to enable monitoring adjustment and troubleshooting of the system operation MODES MENU The MODES section lets the user view and change the various modes for a specific FX by pressing the PORT button to access a specific FX The modes include inverter ac in charger auxiliary and equalize The operation of these modes can be changed by selecting the CHANGE MODE option on the scree
134. of performance quality and reliability Please take a moment to register and provide us with some important information Name Address City State Zip Code Country Telephone Number E mail Sold by Installer Purchase Date Model Number Serial Number Circle all that apply Off Grid Installation Residential Installation North America Location Utility Connected Installation Commercial Installation Other Extended Warranty Application OutBack Power Systems offers an optional three year extension to the standard two 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 REQUIRED SURGE PROTECTION EXTENDED WARRANTY COST Any FX Series Inverter Charger AC Input AC Output DC Input 300 00 MX60 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 Include a completed copy of this application and send to OutBack Power Systems Extended Warranty Program 19009 62nd Ave NE Arlington WA 98223 USA Copyright 2003 OutBack Power Systems Inc FX amp VFX Series Inverter Charger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA 900 002
135. of the FX you re working with at the time Let s start out with the FX that s on port 1 If something other than P01 appears in the upper right hand corner then press the PORT button until PO1 appears Set the Stack Phase of the port 1 FX to 1 2 PH Master Press the PORT button and verify that the label in the upper right hand corner displays P02 We are still in the Stack Phase menu but we are now talking to the FX on port 2 Push the INC button two times to set the Stack Phase to OB Slave L1 If you have a system with only two FX s or you wish to put the FX connected to port 2 in series with the master push the INC button one additional time three times total to set the Stack Phase to OB Slave L2 Press the PORT button again to talk to the FX on port 3 Push the INC button three times to set the Stack Phase to OB Slave L2 If you wish to put the EX connected to port 3 in parallel with the master push the INC button only two times to set the Stack Phase to OB Slave L1 Press the PORT button again to talk to the FX on port 4 Push the INC button three times to set the Stack Phase to OB Slave L2 Again if you wish to put the EX connected to port 3 in parallel with the master push the INC button only two times to set the Stack Phase to OB Slave L1 Any additional EX s in the system can be programmed by pressing the PORT button to get to the next FX and then press INC two times OB Slave L1 for parallel stack
136. ogramming Manual 19009 62 Ave NE Arlington WA 98223 USA 900 0027 1 Tel 360 435 6030 Fax 360 435 6019 Rev 7 2 08 26 05 Page 11 INDICATORS amp CONTROL WIRING The AC wiring compartment also encloses the following items a 6 port terminal block an RJ 11 jack an RJ 45 jack a set of three Battery LEDs and a set of three Status LEDs The 6 port terminal block contains ports for Inverter amp On Off AUX amp AUX and XCT amp XCT The RJ 11 Battery Temp jack accepts only OutBack s RTS battery temperature sensor Non OutBack sensors may fit but if their thermister value is not identical to the RTS s your battery bank could be destroyed The RJ 45 MATE HUB jack accepts the CAT 5 cable that is included with the MATE and the HUB The Battery LEDs give a quick indication of the battery voltage The Status LEDs give a quick indication of whether the FX is inverting has AC input power or if an Error has occurred The Battery LEDs operate at the following voltage levels Nominal Battery Voltage LED Color 12 VDC 24 VDC 48 VDC Green 12 5 or higher 25 0 or higher 50 0 or higher Yellow 11 5 to 12 5 23 0 to 25 0 46 0 to 50 0 Red 11 5 or lower 23 0 or lower 46 0 or lower The Status LEDs operate under the following conditions LED Color LED Action LED Indicates Green Solid GREEN Inverter ON Flashing GREEN Search Mode or Slave Power Save Mode Off Inverter OFF Yellow Solid YELLOW AC Source is connected Fla
137. on the bottom line indicates the selection used to advance the display to the next screen Pressing the left two SUM STATUS SETUP ADV buttons simultaneously from anywhere in the menu will return you to this screen JL SETUP Allows selection of the product type choose product FX FX inverter charger system MATE MATE system display and user interface FX MATE JL SETUP FX The categories are then displayed for the settings which can be adjusted in the setup menu Choose category lt SRCH gt Allows adjustment of the settings for the Search mode INPUT Allows selection of the AC INPUT and current limit adjustment TT INEUE MAIN MAIN Returns the display to the MAIN screen SETUP FX SEARCH PO0 The SEARCH SENSITIVITY setting determines how much AC load watts is required to make the PUE l 6 FX switch from the search mode to the normal inverter on mode Increasing the number INC sensitivity decreases the sensitivity more watts must be turned on to bring the FX out of search while DOWN INC DEC PORT decreasing the number DEC increases the sensitivity less watts must be turned on to bring the T FX out of search Adjusting this setting to zero will effectively disable the search mode operation SETUP FX SEARCH P00 The SEARCH PULSE LENGTH setting determines the number of pulses produced by the inverter search 8 cycles in quick succession actually AC cycles which are used to the AC load that is connected Som
138. op the generator The default setting is 14 28 or 56 volts depending on your FX which you can adjust Press the INC or DEC buttons to change this setting Press the DOWN button to get into the genalert off delay menu This menu adjusts the time you will allow the battery to be at the genalert off setpoint before stopping the generator The default setting is 9 minutes at the genalert off setpoint and the generator will stop Press the INC or DEC buttons to change this setting Even though you have set the off function for the generator there are two other ways that the auxiliary output can stop the generator If the charger settings of the FX reach float or silent mode that overrides the genalert off setpoint because the FX figures that the batteries are charged The generator will turn off based on whatever comes first genalert off float or silent If you want to stop the generator based on float or silent either extend the genalert off delay beyond what is capable of the charger to achieve or raise the genalert off setpoint higher than the absorb setpoint default of 14 4 28 8 or 57 6 volts depending on your FX The following schematic shows how to hook up a relay that interfaces with the 2 wire start generator 3 wire start generators require an adapter like the Atkinson GSCM available at www atkinsonelectronics com TWO WIRE START Here are a couple of relays to use GENERATOR Most 12V relays will
139. ort number i e if you are on P05 the number on the screen should be 4 Let s back track a little by going to the POWER SAVE LEVEL MASTER ADJUST ONLY menu Do this by pressing the DOWN button TOP button then DOWN button Verify that the screen you are on now is the POWER SAVE LEVEL MASTER ADJUST ONLY screen and change the port to P01 Turn on all of your FX s AC Output breakers The master FX s Inverter LED should be solid and all the slaves Inverter LED s should be blinking Adjust the POWER SAVE LEVEL MASTER ADJUST ONLY from 0 to 1 and watch the 1 slave s Inverter LED go solid When the Inverter LED is on solid this means that the inverter is on When the Inverter LED on the slave is blinking this means the FX is asleep Adjust the POWER SAVE LEVEL MASTER ADJUST ONLY to 2 and watch the 2 slave s Inverter LED turn on Adjust the POWER SAVE LEVEL MASTER ADJUST ONLY to 3 and watch the 3 slave s Inverter LED turn on If you have more than three slaves then keep increasing the value in the POWER SAVE LEVEL MASTER ADJUST ONLY screen and verify that each slave s Inverter LED comes on as expected You have now verified that all FX s are stacked correctly so adjust the POWER SAVE LEVEL MASTER ADJUST ONLY back down to 0 and have fun with your system STACKED SYSTEM USING OUTBACKS SERIES PARALLEL STACKING This type of system may have between 2 and 10 FX s that will have their AC Outputs connect
140. p 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 The FX is approved for indoor mounting only and can be mounted in any position Do not disassemble the FX Refer servicing to a qualified service center when service or repair is required Incorrect re assembly may result in a risk of electric shock or fire To reduce risk of electric shock disconnect all wiring before attempting any maintenance or cleaning Turning off the FX may not reduce this risk Solar modules may produce hazardous voltages when exposed to light cover them with opaque material before servicing any connected equipment WARNING WORKING IN THE VICINITY OF A LEAD ACID BATTERY IS DANGEROUS BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL OPERATION Provide ventilation to outdoors from the battery compartment The battery enclosure should be designed to prevent accumulation and concentration of hydrogen gas in pockets at the top of the enclosure Vent the battery compartment from the highest point A sloped lid can also be used to direct the flow of hydrogen to the vent opening at the highest possible location NEVER charge a frozen battery No terminals or lugs are required for hook up of the AC wiring AC wiring must be copper wire and rated for 75 C or higher Battery cables must be rated for 75 C or higher Crimped and sealed copper ring terminal
141. qualization process must be manually triggered while an AC source is connected to the FX s AC input Equalize can be triggered by pressing the AC IN button four times pressing the EQ button then selecting START EQ is not temp compensated The EQUALIZE TIME REMAINING is the amount of time remaining for the equalize stage of the battery charging process Once the EQUALIZE TIME period has been met the charger turns off When the FX is in the Equalize charging stage the equalize time remaining value appears and starts to count down The BATTERY TEMP is a reference value used by the battery charger when an RTS is connected to the FX A displayed value of 255 means the sensor is not connected or has been damaged At normal room temperatures a value around 130 x 15 will be shown As the battery temperature increases the value displayed will get lower and vice versa Selecting TOP returns the user to the top of the STATUS FX BATT menu section Selecting STATUS returns to the STATUS screen FX amp VFX Series Inverter Charger System 900 0027 1 Rev 7 2 Installation amp Programming Manual 08 26 05 Page 45 MATE SCREENS ERROR MENU The ERROR section allows the user to check the cause of an error condition When an error has occurred the red error LED indicator in the FX s wiring compartment will be illuminated not to be confused with a blinking ERROR LED that indicates a WARNING If an error occurs the FX will cease operatio
142. r select the type of AC input which is ac transfer Gen connected to the FX This is used to choose the source of the AC input entering the FX The control two choices are GRID for the utility grid or GEN for a generator The settings for the AC source DOWN GRID GEN PORT are found in the advanced menu under the headings GRID and GEN see next page SETUP FX INPUT P00 The AC1 GRID LIMIT is the maximum amount of current that the FX will allow to be drawn by acl grid 60 0 aac AC loads and battery charger together from the utility grid When this limit is reached the limit charger will be backed off to keep from overloading the utility grid This setting has a range DOWN INC DEC PORT between 5 0 aac and 60 0 aac in 1 0 aac increments l SETUP FX INPUT POO0 The AC2 GEN LIMIT is the maximum amount of current that the FX will allow to be drawn by ac2 30 0 AC loads and battery charger together from the generator When this limit is reached the gen aac F i i limit charger will be backed off to keep from overloading the generator This setting has a range DOWN INC DEC PORT between 5 0 aac and 60 0 aac in 1 0 aac increments l SETUP FX INPUT Selecting TOP returns the user to the top of the SETUP FX INPUT menu section Selecting input setup SETUP returns you to the setup screen to allow selection of another product connected to the completed MATE Selecting MAIN returns the display to the MAIN screen TOP SETUP MAIN Copyright 2003 OutBack
143. r voltage and or higher power There are four types of stacking available Classic Stacking OutBack Parallel Stacking OutBack Series Stacking and 3 Phase Stacking The programming of the master and slave units must be completed with the inverters OFF in order to prevent possible problems ADV FX PAGEl1 choose category ADV INV CHGR PG2 l ADV FX PAGE2 choose category PGI GRID GEN PG3 l ADV FX PAGE3 choose category PG2 AUX STACK PGA J ADV FX STACK POO Stack 1 2ph Master phase DOWN INC DEC PORT L ADV FX STACK POO power save level 0 master adjust only DOWN INC DEC POR JL ADV FX STACK POO power save level slave adjust only DOWN INC DEC POR L ADV FX STACK stacking setup completed TOP ADV MAIN Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fa x 360 435 6019 Once the password has been correctly entered the ADV CHOOSE CATEGORY screen is displayed Selecting lt PG2 gt shows a second screen of categories Selecting lt PG3 gt shows a third screen of categories Selecting STACK allows adjustment of the stacking set points and operation The STACK PHASE screen sets the hierarchy of the FX s If the system is to be stacked a HUB must be included and the FX that is to be the MASTER must be plugged into port
144. ress the PORT button until you get to a slave FX that is in parallel OB Slave L1 with the master Press the INC button to change the POWER SAVE LEVEL SLAVE ADJUST ONLY to 2 which is the 2 rank slave Press the PORT button twice to talk to the port 4 FX If you have a system that is different from this example then press the PORT button until you get to the next slave FX that is in series OB Slave L2 with the master Press the INC button until the setting is 3 for 3 rank slave Any additional FX s in the system can be programmed by pressing the PORT button to get to the next FX and then press INC until the setting is 4 for the 4 rank slave Continue this process making sure each FX has its own Slave Rank until you have set all EX s Let s back track a little by going to the POWER SAVE LEVEL MASTER ADJUST ONLY menu Do this by pressing the DOWN button TOP button then DOWN button Verify that the screen you are on now is the POWER SAVE LEVEL MASTER ADJUST ONLY screen and change the port to P01 Turn on all of your FX s AC Output breakers The master FX s Inverter LED should be solid and all the slaves Inverter LED s should be blinking Adjust the POWER SAVE LEVEL MASTER ADJUST ONLY from 0 to 1 and watch the 1 slave s port 3 Inverter LED go solid When the Inverter LED is on solid this means that the inverter is on When the Inverter LED on the slave is blinking this means the FX is asleep Adjust the
145. ridTie Selecting TOP returns the user to the top of the ADV FX SELL menu section Selecting ADV returns you to the advanced screen to allow selection of another product connected to the MATE Selecting MAIN returns the display to the MAIN screen FX amp VFX Series Inverter Charger System Copyright 2003 OutBack Power Systems Inc 900 0027 1 19009 62 Ave NE Arlington WA 98223 USA Rev 7 2 08 26 05 Tel 360 435 6030 Fax 360 435 6019 MATE SCREENS CALIBRATION MENU The CAL calibration section is used in the factory or field to make fine adjustments in the operation of the FX It is particularly useful when multiple FX s are connected together in the different stacking configurations to maximize the performance of the FX s In most cases the user will not need to adjust these settings from the factory default values ADV FX PAGE1 choose category ADV INV CHGR PG2 l ADV FX PAGE2 choose category PGI GRID GEN PG3 ADV FX PAGE3 choose category PG2 AUX STACK PG4 ADV FX PAGE4 choose category PG3 SELL CAL MAIN L ADV FX CALIBRATE P00 vac input 120 vac adjustment DOWN INC DEC PORT ADV FX CALIBRATE P00 vac output 120 vac adjustment DOWN INC DEC PORT l ADV FX CALIBRATE P00 battery vdc 12 8 vdc adjustment DOWN INC DEC PORT l ADV FX CALIBRATION calibration setup complet
146. rly charged Batteries represent a large percentage of the cost of a system Keeping your battery bank healthy is very important BATTERY CHARGING SETPOINTS It is necessary for the system operator to gather the following information from the battery manufacturer e The Absorb Voltage e The Float Voltage e The Equalize Voltage If you don t obtain and enter this information into the MATE you could be overcharging or undercharging the batteries The FX s default charging settings are set to low values to protect from overcharging of the batteries so to be safe make the call These Absorb Float and Equalize voltage set points as well as the Absorb Time Period should be programmed into the FX through the MATE in the ADV FX CHARGER menu section To access this section refer to the Menu Map and Charger Menu located in the MATE SCREENS section of this manual A Note on the Absorb Setting Some battery manufacturers recommend a low Absorb voltage and a long Absorb Time Period claiming that this will extend the life of the batteries This may be true but remember that the longer the Absorb Time Period the longer your generator will run The cost for gas and the wear on the generator may outweigh the projected loss of life on your batteries Since most of the charge gets put back into the batteries before they reach the Absorb voltage a higher Absorb voltage may be better This means more battery
147. s AC or more For a Mobile FX system 30A input breakers should be used due to the maximum AC input pass through rating of the Mobile FX s This type of FX system can continuously power 8 14 4KW 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 A HUB and a MATE must be connected to stack these FX s in parallel The MATE must be connected to adjust any parameters or to display any meters Once the FX has been programmed using the MATE the MATE can be disconnected The programming will be saved within the FX s non volatile memory even if the FX is completely shut down 8 14 4KW 120VAC SS E z PARALLEL 200A BYPASS pem AC LOADS IF MASTER deal 120VAC AC OUT amp SA NEUTRAL Get ue HUB 200 AMPS AC IN Le MAX p e s e Ce D ALL OTHER WIRE ele olelele elelele 15 aSLAVE Leg Reb 6AWG 100 AMP DUAL E D PUE n aie BYPASS WITH FOUR cor boot mrlorlorclor OFF OFF OFF OFF NEUTRAL 50 AMP OUTPUT isoA soa soA s0A IsoA soa soA soA a EE Ge 4 OUTPUT INPUT INPUT AC IN A BYPAS
148. s seensseeesees OL EI T EI ERE EE ELM p ELSE INL 32 STACKING MOBILE FX INVERTER CHARGERG ccscsssssssssessssssesesesssscssnesccseesesanesssecsssesesscssesaseessseees 32 MAXIMUM AC INPUT CURRENT e eeeeeeeee reete nette notatus tatnen sins tn sese sustain sense assa sese snae ta sens en sensa sese sn ana 32 Dual Input Transfer Switch Setup E OO MATE SYSTEM CONTROLLER AND DISPLAY e eeeeee ee eene en nene ense ense enses senses seenseess OF Inverter dv OUT ACN Put Oe EE oO S mmary Scree cT a LR E o RS P 42 STATUS SCr NS Este T DE e l L0DURIUNL 43 METER MIEN U 5 sers Fe qo eU SENSE UR ones SEES RES se VUA FERE PEEL sne Uo re UP SU ons Rae We esse Te a Eus one vna PE ee UE a an etes ee RU RE ct ee 44 RN ETA ei EE 45 ERROR MENU 25i ne SR 46 ET OILeA DL 47 DISCONNECT MENT 3 5 eco stes eaa ee ne epo eet so osse Pea S eon E Sn R e USE SUR ea RENS epo sean e Oe sas se do eS ste SENSE Toe von secs nain sisas ect re 48 MIU DUREE 49 INVERTER 53 CHARGER MENU m 54 Le RUE OE Bn sosecssesuaseasssos scussotseosscodesscescesles p Sesee Soasenss ste nec it as est 55 GENERATOR ALNU 56 AUXILIARY MENU sscssssssssscsssscssscscnssosssnsssnssassvessnsssassenssenssenssesssesassnessasesassnssoesssnssanssassosssasssnssenssensssnsscsasess 57 STACKING M
149. shing YELLOW AC Input Live Waiting to connect to the FX Off No AC Input Present Red Solid RED Error An Error Message will be automatically displayed on the MATE Flashing RED Warning A non critical fault happened to the FX The MATE can access this info INVERTER ON OFF The left two terminals of the 6 port terminal block marked INVERTER and ON OFF can be used to control the inverter s output Connecting the two terminals through a switch will allow control of the inverter output if a MATE is not available A small jumper wire is pre installed into these two ports of the terminal block and must be removed in order to add the external switch If the FX s AC output is off check that the jumper wire is present and well connected An installed switch overrides the control provided by the OutBack MATE If the switch is set to OFF the MATE will not be able to turn ON the inverter The switch cannot put the FX into Search mode AUXILIARY OUTPUT AUX AUX The Auxiliary output system uses the AUX and AUX terminals and is able to be programmed through the MATE to do a variety of tasks The default use for these terminals is to drive one 12 volt fan for external cooling The power available at these terminals is 12 VDC at 1 0 amps 12 watts maximum These terminals should not be connected to any type of DC load which has a high inrush current requirement The FX includes internal electronic overcurrent protection for this 12 VDC output circuit
150. stallation amp Programming Manual 08 26 05 Page 59 MATE SCREENS SELL MENU The SELL menu is used to set the functions that control the process of selling power back to the utility grid This menu only pertains to Grid Tied FX s These functions include setting the voltage at which the FX sells back to the utility grid setting the window in which the Grid Tie function operates and to enable or disable the Grid Tie function The default values enable the FX to sell back to the utility grid after the FX has completed a charge cycle To disable this charge cycle press the AC IN hot button four times press lt BULK gt press STOP and then press OK The FX waits 5 minutes after it has accepted the utility grid as an AC source and must be above the sell RE volts found in this menu to start selling ADV FX PAGE1 choose category ADV INV CHGR PG2 ADV FX PAGE2 choose category PGI GRID GEN PG3 ADV FX PAGE3 choose category PG2 AUX STACK PG4 ADV FX PAGE4 choose category PG3 SELL CAL MAIN L ADV FX SELL POO sell re 12 8vdc volts DOWN INC DEC PORT ADV FX SELL POO grid tie IEEE window DOWN IEEE USER PORT i ADV FX SELL POO grid tie GridTie authority DOWN INC DEC PORT i ADV FX SELL selling setup completed
151. t handle a capacity of 50 amps AC or more For a Mobile FX system 30A input breakers should be used due to the maximum AC input pass through rating of the Mobile FX s This type of FX system can continuously power 6 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 A HUB and a MATE must be connected to stack these FX s in 3 phase The MATE must be connected to adjust any parameters or to display any meters A jumper in the HUB must be moved to let the system operate in 3 phase Check the HUB manual for instructions Once the FX has been programmed using the MATE the MATE can be disconnected The programming will be saved within the FX s non volatile memory even if the FX is completely shut down AC HOT OUT L1 MATE AC HOT OUT Le set A 3 PHASE zi AC LOADS AC HOT OUT L3 AC OUT s Sse 120 208 VACEI T 50 AMPS AC I g PER LINE A A o T oa o MAK elele elele o e e 2g E Keen NORMAL Sa ne z CBI 50 AMP TRIPLE GE BYPASS WITH THREE SIE ore Lors EET Ld baa Ead NEIRA Gates CBI 50 AMP OUTPUT mveass i AC IN BREAKERS Vv OUTPUT INPU ele e eflele ejeje Se m THREE CBI 50 AMP f AC DU SLAVE INPUT BREAKERS eT 50 AMPS AC HOT IN Li mr AC I
152. t is possible to adjust some generators to raise their voltage External Dump Load is Limiting Battery Voltage Many systems include sources of power that vary depending on the weather such as wind turbines and micro hydro systems In high wind or water conditions these power sources can produce voltages above what the battery bank should handle These systems often use Dump Loads to get rid of this extra power at a particular battery Dump voltage Sometimes the battery Dump voltage is below the FX s Target voltage Target voltage refers to a voltage set point that the FX is trying to reach like Absorb Float or Equalize If the Dump voltage is below the Target voltage the FX will never reach the Target because the Dump Load limits the battery voltage The FX will continue to try to charge the batteries to the Target voltage while the Dump Load will continue to Dump the FX s charging power Since the FX wants to complete a charge it will be stuck charging This can cause a generator to run until it runs out of gas or if connected to the utility grid it can cause a lot of unnecessary power consumption To remedy this situation reduce the FX s Target voltage to a value slightly below the Dump Load voltage or raise the Dump Load voltage above the FX s Target voltage remember not to overcharge the batteries AC Input Voltage is Different on Different Legs In systems that have multiple AC input
153. t making any changes press EXIT Following the password screen is a screen that allows selection of the OutBack product type Selecting lt FX gt allows adjustment of the FX s advanced programming Selecting MX will allow access to the advanced sections of any MX 60 s connected to the system through a HUB Selecting MATE will allow access to the MATE s advanced screens Selecting MAIN returns the user to the MAIN menu There are eight categories of settings in the FX INV Allows adjustment of the INVERTER settings and operation CHGR Allows adjustment of the CHARGER settings and operation GRID Allows adjustment of the AC input settings and operation if the FX s input is set to GRID in the SETUP FX INPUT ac transfer control screen see previous page GEN Allows adjustment of the AC input settings and operation if the FX s input is set to GEN in the SETUP FX INPUT ac transfer control screen see previous page AUX Allows adjustment of the AUXILIARY output settings and operation STACK Allows adjustment of the master slave settings for multi FX systems SELL Allows adjustment of the Grid Tie settings and operation CAL Allows adjustment of the voltage calibration measurements to improve operation Selecting ADV will send the user back one screen to the choose product screen in the advanced menu PG2 will advance the user to page 2 of the advanced menu PG3 will advance the user to page 3 of the advanced menu PG4 will advance the user to
154. te eye protection Avoid touching eyes while working near batteries Wash your hands with soap and warm water when done 4 If battery acid contacts skin or clothing wash immediately with soap and water If acid enters eye immediately flood eye with running cool water for at least 15 minutes and get medical attention immediately 5 Baking soda neutralizes lead acid battery electrolyte Keep a supply on hand in the area of the batteries 6 NEVER smoke or allow a spark or flame in vicinity of a battery or generator 7 Beextra cautious to reduce the risk of dropping a metal tool onto batteries It could short circuit the batteries or other electrical parts that may result in fire or explosion 8 Remove personal metal items such as rings bracelets necklaces and watches when working with a battery A battery can produce a short circuit current high enough to weld a ring or the like to metal causing severe burns 9 Ifa 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 Installation amp Programming Manual FX amp VFX Series Inverter Charger System Copyright 2003 OutBack Power Systems Inc 900 0027 1 19009 62 Ave NE Arlington WA 98223 USA Page 6 Rev 7 2 08 26 05 Tel 360 435 6030 Fax 360 435 6019 RATINGS ATTENTION All FX inverter chargers are ETL listed to UL 1741 All
155. tection of the Mobile FX s ground switching system Connect the ground conductors of the AC input and AC output to the CHASSIS GROUND terminal of the Mobile FX If 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 Many installations will use the AC IOB input output bypass breaker assembly mounted in the PS2AC or PS4AC This bypass assembly allows the user to completely bypass the FX system for servicing or replacement In Normal mode the FXs AC hot outputs are connected through the AC IOB s output breakers to the load bank In Bypass mode the AC source generator or grid is connected through the AC IOB s bypass breakers to the load bank In addition to the AC IOB input output bypass assembly each FX has a separate AC input breaker When in Bypass mode these AC input breakers should be turned off to ensure no AC power is connected to the FXs After the FX has been powered down through the DC breaker it can then be removed for servicing or replacement without loss of AC power to the AC loads of the system NOTE Non Mobile FXs need only bypass the AC input hot conductors Mobile FXs need to bypass both the AC input hot and AC input neutral conductors Copyright 2003 OutBack Power Systems Inc FX amp VFX Series Inverter Charger System Installation amp Pr
156. temperature of the ripple capacitors This warning is given for troubleshooting purposes DOWN UP PORT Y STATUS FX WARN Selecting TOP returns the user to the top of the STATUS FX WARN menu section Selecting end of warnings menu STATUS returns to the STATUS screen to allow selection of another product UP TOP STATUS Copyright 2003 OutBack Power Systems Inc FX amp VFX Series Inverter Charger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA 900 0027 1 Tel 360 435 6030 Fax 360 435 6019 Rev 7 2 08 26 05 Page 47 MATE SCREENS DISCONNECT MENU The FX includes a section that displays the reason for last DISCONNECT from the AC source This is helpful if the FX rejects the AC source and the user wants an explanation and help on rectifying the problem The FX will disconnect from an AC source if the AC source falls out of the FX s frequency or voltage ranges If the AC source disconnects from the FX and none of the reasons for disconnect are followed by a Yes it is possible that the AC source shut itself down this is sometimes the case with smaller generators or generators with an internal temperature shutdown switch 6 54 42P SUM STATUS SETUP ADV Uu STATUS choose product FX MX J STATUS FX PAGE1 choose category MODES METER BATT PG2 STATUS FX PAGE2 choose category PGI ERROR WARN PG3 STATUS FX
157. tems and proper DC breaker sizes This information is dependent on whether the FX s are sealed or vented and on the system s battery voltage NOTE Stacking FX s in series parallel means that there are FX s directly connected to two separate 120VAC output legs These two 120VAC output legs produce 240VAC between them the series portion By connecting the X 240 autotransformer between the two 120VAC output legs these legs are magnetically coupled indirectly connected This allows all of the FX s to power either of the 120VAC output legs the parallel portion Series parallel stacking requires the use of the X 240 autotransformer and must use OutBack stacking programming Single FX System The following diagram illustrates a typical single FX installation This diagram is for a non Mobile FX installation only Below this diagram are notes for how to change this diagram to accommodate a Mobile installation All AC wiring must handle a capacity of 50 amps AC or more For Mobile FX s a 30A input breaker should be used due to the maximum AC input pass through rating of the Mobile FX s A single FX system can continuously power 2 3 6KW 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 A MATE must be connected to adjust any parameters or to display any meters Once the FX has been programmed using the MATE the MATE can be disconnected
158. the FX has been programmed using the MATE the MATE can be disconnected The programming will be saved within the FX s non volatile memory even if the FX is completely shut down 4 0 2KW 120VAC PARALLEL 100A BYPASS AC LOADS MATE 120VAC L1 cesa J MASTER 100 AMPS AC OUT Kee MAX ON NEUTRAL XO 2 E e HUB 50A DUAL BYPASS rame ei e olo AC IN Ss as WITH TWO 50A OUTPUT mo G Omen BREAKER STANDARD ON TTT MODEL PS2AC 50D olor OFF OFF BYPASS KIT AC IOB 50 soajsoa soafsoa soafsoa TWO 50A CBI BREAKERS E FOR THE AC INPUT BYPASS OUT PUT INPUT ele ele ele 100 AMP MAX eoo Dgo L 1 AC SOURCE soute d SLAVE 120VAC s NEUTRAL CE5 AC IN el 2000 Oooo O NEUTRAL 4 5 W 20VAC 5 6 7 2KW 120VAC ALL BREAKERS SHOWN PS2AC PS2DC PARALLEL SEALED PARALLEL VENTED TERMINALS AC LOADS 2 Pore FX 12V 250A BRKRS 12V 250A BRKRS EE 100 ax 50A BYPASS gt LE i 120VAC BR AKERS L1 CC 24V 175A BRKRS 24V 250A BRKRS SS 48V 100A BRKRS 48V 175A BRKRS Cu Back 50A OUTPUT Power Systems AC SOURCE FX SSC 2 EN EIRMOD 19009 62nd AVE NE iow eur ba L1 D
159. the battery voltage reaches this set point the auxiliary output will be activated This screen is applicable if the AUX OUTPUT FUNCTION has been set to either DIVERT AC or DIVERT DC This setting has a range between 12 0 vdc and 16 0 vdc in 0 1 vdc increments The DIVERSION OFF DELAY is the amount of time that the AUX output will continue to be energized after the battery voltage falls below the DIVERSION ON SETPOINT voltage In cases where the battery voltage is hovering around the DIVERSION ON SETPOINT voltage the AUX output won t flicker This screen is applicable if the AUX OUTPUT FUNCTION has been set to either DIVERT AC or DIVERT DC This setting has a range between 0 seconds and 240 seconds in 1 second increments Selecting TOP returns the user to the top of the ADV FX AUX menu section Selecting ADV returns you to the advanced screen to allow selection of another product connected to the MATE Selecting MAIN returns the display to the MAIN screen FX amp VFX Series Inverter Charger System 900 0027 1 Rev 7 2 08 26 05 Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA Tel 360 435 6030 Fax 360 435 6019 MATE SCREENS STACKING MENU The STACK stacking section is used to program the stacking of the FX s An explanation of stacking can be found in the STACKING INFORMATION and STACKING INSTRUCTIONS sections of this manual The FX s can be connected in series parallel or 3 phase for highe
160. the AUX output will provide 12 vdc to power a DC coil relay to disconnect an AC load Once the LOADSHED function has been triggered it will remain on for a minimum of 3 minutes This screen is applicable if the AUX OUTPUT FUNCTION has been set to LOADSHED This setting has a range between 10 0 vdc and 14 0 vdc in 0 1 vdc increments The VENTFAN ON SETPOINT is the battery voltage at which the AUX output is energized to vent a battery enclosure to prevent hydrogen gas from accumulating When the battery voltage rises to this setting s value the AUX output is activated to power a 12 vdc fan This screen is applicable if the AUX OUTPUT FUNCTION has been set to VENTFAN This setting has a range between 10 0 vdc and 16 0 vdc in 0 1 vdc increments The VENTFAN OFF PERIOD set point can be used to allow for intermittent operation of the battery enclosure ventilation system Setting the time period to 5 minutes will operate the fan at a 5096 duty cycle as the on time period is fixed at 5 minutes Setting the VENTFAN OFF PERIOD to zero will keep the fan on continuously when the battery voltage exceeds the VENTFAN ON voltage set point This screen is applicable if the AUX OUTPUT FUNCTION has been set to VENTFAN This setting has a range between 0 minutes and 30 minutes in 1 minute increments The DIVERSION ON SETPOINT enables the AUX output to function as a diversion controller This can be used to send excess power from a renewable energy source to a load When
161. ting LOADSHED enables the AUX output to function as a load management system When the battery voltage drops below the LOAD DISCONNECT set point for more than 3 seconds the AUX output is energized Connecting a normally closed NC relay to the circuitry of non vital loads will disengage them with this function LOADSHED will also occur when the FX approaches an over temperature condition or when the AC output voltage drops below 105 vac for more than 3 seconds There is a 3 minute fixed delay before the AUX output is de energized This setting has one set point screen see following page Selecting REMOTE enables the AUX output to be controlled by the MATE or a PC computer connected to the MATE PC communication port This function is currently not operational It will be operational in the future Press DOWN after selecting the AUX OUTPUT FUNCTION of your choice it should be showing on the screen The AUX menu section is continued on the following page FX amp VFX Series Inverter Charger System 900 0027 1 Rev 7 2 Installation amp Programming Manual 08 26 05 Page 57 MATE SCREENS AUXILIARY MENU CONTINUED This page contains to settings for some of the functions that can be chosen in the AUX OUTPUT FUNCTION screen described on the previous page The functions that do not have setting perform automatically as described on the previous page There are voltage and time period settings for GenAlert LoadShed VentFan an
162. to raise the limit This screen is not operational at this time The ACIN VOLTAGE MIN screen indicates that the AC source s voltage is below the minimum AC voltage the FX allows 108 vac default This value can be adjusted in the ADVANCED menu in the GRID or GEN sections depending on your input type The FX disconnects to protect the loads from low voltage If your AC source operates near this voltage limit it could affect the charging function the FX backs off the charger if the AC voltage reaches the lower limit and adjusting the limit lower may be in order This screen is not operational at this time Selecting TOP returns the user to the top of the STATUS FX DISCON menu section Selecting STATUS returns to the STATUS screen to allow selection of another product FX amp VFX Series Inverter Charger System 900 0027 1 Rev 7 2 Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA 08 26 05 Tel 360 435 6030 Fax 360 435 6019 MATE SCREENS SELL MENU The SELL section of the STATUS menu has only one screen This screen gives a number that refers to a reason the FX would stop selling OutBack Power Systems technicians use this number to quickly understand what the FX thinks is happening The system user should not be concerned about this number unless they are experiencing many unknown grid disconnects and they need troubleshooting help This screen is only operational with Grid Tie FX s M
163. to SILENT charger turns off mode until the battery voltage drops to the REFLOAT voltage This is the battery charger set point for the float stage of the battery charging process After finishing the absorb charging stage the charger turns off and waits for the battery voltage to drop to the refloat voltage set point before the charger begins to float the battery The voltage will be held at the FLOAT SET POINT voltage level for the float time period that is shown in the next screen down The FLOAT TIME REMAINING is the amount of time remaining for the float stage of the battery charging process The battery charger does not continuously float the batteries It instead only floats for the FLOAT TIME LIMIT period set in the ADVANCED menu section Once the time period has been met the charger turns off called SILENT on the SUMMARY screen Only when the FX is in the Float charging stage will the float time remaining value appear and start to count down The REFLOAT SET POINT is the battery voltage at which the battery charger will restart the float charging process and hold it there for the FLOAT TIME PERIOD This setting is compared with the BATTERY ACTUAL voltage not the BATTERY TEMP COMPENSATED voltage This is the battery charger set point for the equalize stage of the battery charging process The voltage will be held at the EQUALIZE SET POINT voltage level for the equalize time period that is programmed in the ADVANCED menu section The e
164. to get into the auxiliary menu The first screen that comes up is the aux output control which tells the FX to keep the aux output off on or automatically do what the auxiliary output function is In this case we want to keep the default setting on AUTO Press the DOWN button to get into the aux output function menu This is the menu where we tell the auxiliary output what function we want itto be In this case we want it to start a generator The default setting is CoolFan so press the DEC button 3 times so the display reads GenAlert Now that the function is set to start a 2 wire start generator the start and stop parameters need to be set Press the DOWN button to get into the genalert on setpoint menu This menu adjusts the battery voltage set point to where you want the generator to start at The default setting is 11 22 or 44 volts depending on your FX which you can adjust Press the INC or DEC buttons to change this setting Press the DOWN button to get into the genalert on delay menu This menu adjusts the time you will allow the battery to be at the genalert on setpoint voltage before starting the generator The default setting is 4 minutes at the genalert on setpoint and the generator will start Press the INC or DEC buttons to change this setting Press the DOWN button to get into the genalert off setpoint menu This menu adjusts the battery voltage set point to where you want to st
165. ttle so use some care Use a flat bladed screw driver blade in the slots provided on the sides of the cover to pry the cap off If the installation is exposed DC conduit may be required Connection of 2 inch conduit is possible when the DCA option is added to the FX Always install the Battery Terminal Covers even in systems that have an DCC or a Turbo included Battery Terminal Covers ________ 4 Copyright 2003 OutBack Power Systems Inc FX amp VFX Series Inverter Charger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA 900 0027 1 Tel 360 435 6030 Fax 360 435 6019 Rev 7 2 08 26 05 Page 13 FX ACCESSORIES ACA AC CONDUIT ADAPTER This plastic box slips into grooves on the AC end of the FX This adapter extends the AC wiring compartment to match the PS4AC or PS2AC It also provides more room for wiring than is available when using the supplied AC conduit plate There is a 2 inch TSC cut out on the plastic box to allow it to be used with the PS4AC or PS2AC disconnect enclosure or 2 inch conduit The ACA may also be used for mounting two breakers OBDC breakers rated for AC and or an AC outlet through the knockouts provided DCA DC CONDUIT ADAPTER The DCA allows the connection of 2 inch TSC conduit to the FX It fits on the opposite end of the FX from the AC wiring compartment The location of the 2 inch conduit opening matches the 2 inch knockouts provided in the PS4DC or PS2DC
166. unding of these circuits and the chassis of the FX is the responsibility of the installer MOBILE FX NOTES The AC input source to the FX grid and or generator must have an internal neutral ground connection On the above diagram the AC source s neutral conductor must go directly to the FXs AC NEUTRAL IN terminal or to a separate neutral busbar that is isolated from the FX s AC output neutral The AC output of the FX must go to a separate AC output busbar that is isolated from the AC input neutral A bypass mechanism must bypass the AC source s hot and neutral wires Proper grounding of the DC circuit and the chassis of the FX is the responsibility of the installer Copyright 2003 OutBack Power Systems Inc FX amp VFX Series Inverter Charger System Installation amp Programming Manual 19009 62 Ave NE Arlington WA 98223 USA 900 0027 1 Tel 360 435 6030 Fax 360 435 6019 Rev 7 2 08 26 05 Page 21 FX SYSTEM CONFIGURATION 3 PHASE FX SYSTEM 3 Phase FX System The following diagram illustrates a typical 3 phase FX installation using three FX s This diagram is for a non Mobile FX installation only Below this diagram are notes for how to change this diagram to accommodate a Mobile installation This system will produce 120VAC per phase and 208VAC from phase to phase At this time there can only be one FX per phase on a 3 phase system The AC wiring from the AC source and to the AC loads must handle 50 amps AC or more All other AC wiring mus
167. ust go to a separate AC output busbar that is isolated from the AC input neutral A bypass mechanism must bypass the AC source s hot and neutral wires Proper grounding of the DC circuit and the chassis of the FX is the responsibility of the installer Installation amp Programming Manual FX amp VFX Series Inverter Charger System 900 0027 1 Rev 7 2 Copyright 2003 OutBack Power Systems Inc 19009 62 Ave NE Arlington WA 98223 USA 08 26 05 Tel 360 435 6030 Fax 360 435 6019 Page 18 FX SYSTEM CONFIGURATION PARALLELED DUAL FX SYSTEM Paralleled Dual FX System The following diagram illustrates a typical paralleled FX installation using two FX s This diagram is for a non Mobile FX installation only Below this diagram are notes for how to change this diagram to accommodate a Mobile installation The AC wiring from the AC source and to the AC loads must handle 100 amps AC or more All other AC wiring must handle a capacity of 50 amps AC or more For a Mobile FX system 30A input breakers should be used due to the maximum AC input pass through rating of the Mobile FX s This type of FX system can continuously power 4 7 2KW 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 A HUB and a MATE must be connected to stack these FX s in parallel The MATE must be connected to adjust any parameters or to display any meters Once
168. waits before producing additional AC pulses The larger this search pulse spacing number is the lower the power consumption but the more noticeable the delay becomes when an AC load is first turned on This setting has a range between 4 cycles and 120 cycles 2 seconds in 1 cycle increments The LOW BATTERY CUT OUT setting determines when the inverter will turn off to prevent over discharge of the battery system If an AC source is available and the AC INPUT was set to DROP the FX will change this setting to USE and connect to the AC source to save the batteries A fixed delay of 5 minutes is included to reduce nuisance inverter shutdowns This setting has a range between 9 0 vdc and 12 0 vdc in 0 1 vdc increments The LOW BATTERY CUT IN setting determines when the inverter will turn back on after it had shut off due to a low battery situation A fixed delay of 10 minutes is provided to reduce the possibility of the system cycling on and off This setting has a range between 10 0 vdc and 14 0 vdc in 0 1 vdc increments The ADJUST OUTPUT VOLTAGE setting allows the user to change the output voltage to a lower or higher voltage This may be necessary if some loads are far away from the FX or if some loads are sensitive to higher voltages This setting has a range between 110 vac and 125 vac in 1 vac increments The RESET FX TO FACTORY DEFAULTS resets all of the settings in the FX back to the factory default set points THIS WILL CAUSE ALL OF T
169. wer per FX that is being delivered to the AC loads so 1 one light bulb equals 1KW when two inverters are used with a single MATE The third line displays four different things depending of the status of the AC input It displays No ACIN when the FX doesn t sense an AC source present It displays AC Drop when an AC source is present but not connected It displays Buying when an AC source is connected and the FX is using the source to charge or pass through to the loads Finally it displays Selling when the FX is pushing power back into the AC source Grid Tie FX s only In the third line the symbol used to denote 500 watts or power per inverter is a dollar sign The fourth line of the summary screen provides information about the battery limited to battery voltage at this time To access the summary screen press the button under the label SUM from the MAIN screen Included below are some examples of different summary screens with an explanation of the information represented MAIN The MAIN screen is where the menu system starts The four words in the bottom line of the 6 54 42P display correspond to the four buttons located below the display The word in BOLD on the bottom line indicates the selection used to advance the display to the next screen Pressing SUM STATUS SETUP ADV the left two buttons simultaneously from anywhere in the menu will return you to this s
170. which auto resets if it is short circuited No additional fuses are required Use the OutBack FX Turbo Kit or DC12 FAN for cooling For automatic or advanced generator start functions the Auxiliary Output can drive a 12V automotive relay for the 2 wire starting circuitry of a generator OutBack Power Systems does not support 3 wire start generators however a 3 wire to 2 wire conversion kit is available from other sources XCT XCT These terminals are not operational at this time BATTERY TEMP REMOTE TEMPERATURE SENSOR RTS The OutBack FX has a 4 conductor phone RJ 11 modular jack located in the AC compartment for the connection of an optional external battery temperature sensor the RTS sold separately that allows for automatic adjustment of the battery charging process based on the temperature of the battery Battery manufacturers provide recommended charge voltages based on temperatures of 25 C TT F With the RTS attached the FX adjusts the battery voltage 0 03 volts per degree Celsius for every 12 volts of battery present When a HUB is used the RTS must be plugged into the Master FX which must be plugged into port 1 of the HUB If this is the case only one RTS is required for all devices plugged into the HUB The RTS should be stuck to the side of a battery below the electrolyte level so it can measure the temperature of the batteries The wire from the RTS can be folded and routed underneath the transparent gray plastic lexan cov

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