FLEXPOWER TWO VFXR Series Manual

Components
Setup and Programming
Contact Technical Support:
Telephone: [phone]
Email: [e-mail]
Website: www.outbackpower.com
> 90% (blinks if charge parameters are met)
Color
Red
Yellow
Yellow
Yellow
Green
≥80%
≥70%
≥60%
≥60% off, < 60% solid, < 50% blinks
Battery State-of-Charge
FN-DC LED Indicators
Phase
Active Error
DC
AC IN
AC OUT
RedYellow
Yellow
Yellow
Red
Red
Surge Protector LEDs
LED Indicators on the Inverter
Inverter Status LED Indicators
Green
Yellow
Red
Inverter on (solid) or standing by (flash)
AC source in use (solid) or standing by (flash)
Inverter error or warning (see manual)
Green
Yellow
Red
12.5 Vdc or higher
11.5 to 12.4 Vdc
11.4 Vdc or lower
Color
Battery Status LED Indicators
25.0 Vdc or higher
23.0 to 24.8 Vdc
22.8 Vdc or lower
50.0 Vdc or higher
46.0 to 49.6 Vdc
45.6 Vdc or lower
12 V Inverter 24 V Inverter 48 V Inverter
AC Enclosure DC Enclosure
Charge Controller
(FLEXmax 80 x2)
FLEXnet DC
Battery Monitor
Surge Protector
(Inside)
Inverter/Charger x2
System Display
and
Controller
(MATE3)
HUB
Communications
Manager
Battery Status and Inverter Status
LED Indicators
AC Source Utility Grid or AC Generator
Main Electrical Panel (or overcurrent device for the AC source)
Battery Bank
Photovoltaic (PV) Array (with PV Combiner Box)
Customer-Supplied Components
Electrical Distribution Subpanel (Load Panel)
Inverter/Chargers (x2)
AC Conduit Box
(with Bypass Assembly)
DC Enclosure Box
(with Inverter Circuit Breaker)
System Display and Controller
Communications Manager
Remote Temperature Sensor (RTS)
FLEXpower System Products
Major Components
Charge Controller
Balancing Transformer
FLEXnet DC Monitor (FN-DC)
Surge Protector
IMPORTANT:
Not intended for use with
life support equipment.
900-0158-01-00REV B.vsd
©2013 OutBack Power Technologies. All Rights Reserved.
Supports the OPTICS RE™ online tool for a cloud-based remote monitoring and control application.
Please refer to the OPTICS RE setup instructions, or visit www.outbackpower.com to download.
The firmware revision of all
devices can be confirmed by
navigating from the MATE3
Main Menu as shown below.
Upgrades to the firmware
revision can be downloaded
from the OutBack website
www.outbackpower.com.
Firmware Revision
Configuration Wizard
The MATE3 Configuration Wizard allows quick setup of parameters that apply to all systems. The Configuration Wizard is reached from
the MATE3 Main Menu as shown below.
Note: See the MATE3
manual for details on
generator control.
Off Grid
Grid Tied Backup
The Continue key advances the display
to the Setup Complete screen if the
FLEXnet DC is not installed. If the
FLEXnet DC is installed, the display
advances to the Shunt screens.
Configuration Wizard
New Configuration >>
Existing Configuration >>
Restore Configuration >>
Wizard System Type
System Type Grid Tied
System Voltage 48 VDC
Array Wattage 1000
Battery Type FLA Capacity 500 Ah
Back Continue
Wizard Battery Charging
Absorb Voltage 57.6 VDC Time 1.0
Float Voltage 54.4 VDC Time 1.0
Equalize Voltage 60.0 VDC Time 3.0
Re-Float Voltage 44.0 VDC
Back Continue
Configuration Wizard
New Configuration Initialized
Back Continue
Wizard Grid Use Schedule
Period 1 Enable N
Weekday Use 0:00 Drop 0:00
Weekend Use 0:00 Drop 0:00
Back Continue
Wizard Grid Use Schedule
Period 2 Enable N
Weekday Use 0:00 Drop 0:00
Back Continue
Wizard Grid Use Schedule
Period 3 Enable N
Weekday Use 0:00 Drop 0:00
Back Continue
Wizard Battery Monitor
Shunt B
Connection Charge Controller
Back Continue
Wizard Grid Use Schedule
Period 3 Enable N
Weekday Use 0:00 Drop 0:00
Back Continue
Wizard High Battery Transfer
Mode Disabled
Grid Connect 48.0 VDC Delay 60 Min
Grid Disconnect 52.0 VDC Delay 60 Min
Grid Connect SOC 60% Disconnect SOC 95%
Back Continue
Wizard Grid Use Schedule
Period 1 Enable N
Weekday Use 0:00 Drop 0:00
Weekend Use 0:00 Drop 0:00
Back Continue
Wizard Generator Configuration
Generator Installed N
Generator Type AC Size 5.0 kW
Generator Start Manual
AUX Output Device Port 1
Back Continue
Wizard AC Configuration
AC Output Voltage 230 VAC
AC Phase Single
AC Input Breaker Size 50 A
Maximum Output Load 30 A
Back Continue
Wizard Grid Use Schedule
Period 2 Enable N
Weekday Use 0:00 Drop 0:00
Back Continue
Wizard Generator Configuration
Generator Installed N
Generator Type AC Size 5.0 kW
Generator Start Manual
AUX Output Device Port 1
Back Continue
Wizard Battery Charging
Absorb Voltage 57.6 VDC Time 1.0
Float Voltage 54.4 VDC Time 1.0
Equalize Voltage 60.0 VDC Time 3.0
Re-Float Voltage 44.0 VDC
Back Continue
Wizard AC Configuration
AC Output Voltage 230 VAC
AC Phase Single
AC Input Breaker Size 50 A
Maximum Output Load 30 A
Back Continue
Wizard System Type
System Type Backup
System Voltage 48 VDC
Array Wattage 1000
Battery Type FLA Capacity 500 Ah
Back Continue
Wizard Battery Monitor
Shunt A
Connection Inverter
Back Continue
Wizard AC Configuration
AC Output Voltage 230 VAC
AC Phase Single
AC Input Breaker Size 50 A
Maximum Output Load 30 A
Back Continue
Wizard Battery Charging
Absorb Voltage 57.6 VDC Time 1.0
Float Voltage 54.4 VDC Time 1.0
Equalize Voltage 60.0 VDC Time 3.0
Re-Float Voltage 44.0 VDC
Back Continue
Wizard System Type
System Type Off Grid
System Voltage 48 VDC
Array Wattage 1000
Battery Type FLA Capacity 500 Ah
Back Continue
Main Menu
Settings >>
Configuration Wizard >>
Device Data Logs >>
Event Logs >>
Firmware Update >>
Configuration Wizard
New Configuration
Settings Menu
System >>
Inverter >>
Charge Controller >>
Battery Monitor >>
MATE3 >>
System
System Configuration
System Information >>
Save / Store Information >>
Firmware Version >>
Date and Time >>
LCD Display >>
Firmware Versions
MATE3 003.002.005
1: VFXR3048E 001.006.002
2: VFXR3048E 001.006.002
Main Menu
Settings >>
Configuration Wizard >>
Device Data Logs >>
Event Logs >>
Firmware Update >>
Settings
!CAUTION: Equipment Damage
These procedures should be done by a qualified installer who is trained on programming inverter power systems. Failure to set
accurate parameters for the system could potentially cause equipment damage. Damage caused by inaccurate programming is
not covered by the limited warranty for the system.
IMPORTANT
Check the firmware revision of all OutBack devices before use. The MATE3 system display must be revision 003.002.xxx or
higher. If the revision is lower, the MATE3 and inverter may not communicate or operate correctly.
Wizard High Battery Transfer
Mode Disabled
Grid Connect 48.0 VDC Delay 60 Min
Grid Disconnect 52.0 VDC Delay 60 Min
Grid Connect SOC 60% Disconnect SOC 95%
Back Continue
Wizard Generator Configuration
Generator Installed Y
Generator Type AC Size 5.0 kW
Generator Start Manual
AUX Output Device Port 1
Back Continue
Wizard Battery Monitor
Shunt C
Connection Charge Controller
Back Continue

Wire Sizes/Torque
Requirements
AC Circuit Breakers
DC Circuit Breakers
DC Enclosure
Control Wiring Terminal Block:
The Inverter ON/OFF terminals are used for connecting an
external ON/OFF switch. To use this feature, the jumper
must be removed. (See installation manual for details.)
The AUX terminals provide a 12 Vdc signal. The AUX
terminals can be used to start a generator or to control
external devices.
AUX terminals are also available on the charge
controller and the FLEXnet DC. (See the charge
controller or FNDC installation manuals for details.)
Mounting
WARNING: Fire/Explosion Hazard
Do not place combustible or flammable materials within 3.7 m (12 feet) of the equipment. This unit employs mechanical
relays and is not ignition-protected. Fumes or spills from flammable materials could be ignited by sparks.
WARNING: Personal Injury
Use safe lifting techniques and standard safety equipment when working with this equipment.
IMPORTANT:
Clearance and access requirements may vary by location. Maintaining a 91.4 cm (36”) clear space in front of the system
for access is recommended. Consult local electric code to confirm clearance and access requirements for the specific
location.
FP2 Dimensions:
51.4 cm (20.25") H X 92.6 cm (36.5") W X 34.3 cm (13.5") D
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©2013 OutBack Power Technologies. All Rights Reserved.
AC Enclosure
Communication Manager HUB10
DC Enclosure
FLEXmax 80 Charge Controller
1
2
3
4
AC Enclosure
12
Master Inverter
Slave Inverter
3
4
6
7
8
9
10
56
Mechanical Interlock (Bypass)
7
8 8
MATE3 System Display and Controller
9
10
Charge Controller Terminals
Inverter DC Circuit Breakers
GFDI
PV Input Circuit Breakers
FLEXnet DC (FN-DC)
11
12
13
14
15
11
12
13 14 15 15
5
AUX Control Terminals
16
16
16 16 16
Inverter Chassis Ground
DC Positive (+) Plate
17
18
19
Charge Controller Chassis Ground
20
DC Negative (–) Plate
17
18
19
19
20 20
Surge Protector
CC Communication Ports
21
22
23
FN-DC Communication Port
24
Inverter Communication Ports
21 21
22
22
23
23
24
FP2 Mounting:
1. Ensure the mounting
surface is strong enough
to handle 3 times the total
weight of all the
components.
2. Using additional people to
assist with lifting, place the
panel on the wall. Ensure
the panel is level.
3. Secure the panel into the
surface using a minimum
of 10 lag bolts (or other
appropriate hardware).
4. Remove the covers from
the AC Enclosure and the
DC Enclosure.
5. Follow the instructions for
installing the bracket for
the MATE3.
6. Follow the instructions for
installing the brackets for
the charge controllers.
1
2
3
4
5
6
1
2
4
4
4
4
56
16
AC Wire Sizes and Torque Values
It is recommended that conductors be
16–25mm2(#6 AWG) THHN copper, or
larger, rated to 75°C (minimum) unless
local code requires otherwise.
Wire Size Torque
Nm
2.3
2.8
4.0
4.0
4.5
5.6
5.6
In-lb
20
25
35
35
40
50
50
mm2
2.5 – 6
10
16 – 25
35
35
50
70
AWG
#14 - 10
#8
#6 - 4
#3
#2
#1
1/0
Minimum DC Cable based on the
DC Circuit Breaker
Torque
DC
Circuit
Breaker Cable Size
125 70 mm2(1/0)
175 70 mm2 (2/0)
250 120 mm2(4/0)
80 25 mm2(#4 AWG)
60 16 mm2(#6 AWG)
Nm
5.6
25.4
25.4
4.0
4.0
In-lb
50
225
225
35
35
Torque requirements for
the conductor lugs
Circuit
Breaker Stud
Torque
M8
¼ - 20
5/16 - 18
3/8 - 16
Nm
2.3
4.0
5.6
25.4
In-lb
20
35
50
225
4
4
3
CAUTION: Equipment Damage
When connecting cables from the inverter to the
battery terminals, ensure the proper polarity is
observed. Connecting the cables incorrectly can
damage or destroy the equipment and void the
product warranty.
Shunt
Bolt 3/8"
Lock Washer
Flat Washer
Battery
Negative
(–) Lug
Negative (–) Battery
Cable Connections Bolt 3/8"
DC
Positive
(+) Plate
Battery
Positive
(+) Lug
Flat Washer
Positive (+) Battery
Cable Connections
Nut
Lock
Washer
DC
Negative
(–) Plate
Flat Washer
18 17

MATE RTS
CB
3
CB
2
CB
1
CB
6
CB
5
CB
4
CB
8
CB
7
CB
10
CB
9
CB
12
CB
11
CB
14
CB
13
CB
16
CB
15
GND
AC IN
DC
POSITIV
E
I/ON I/ON
I/ON I/ONI/ONI/ON
NORMAL
UP
DOWN
BYPASSED
O/
OFF O/ OFF
GND
DC
NEGATIVE
SHUNT A
SHUNT C
SHUNT B
AC IN
DC
AC OUT
AC IN
DC
AC
OUT
MATE RTS
AC HOT OUT
AC NEUTRAL OUT
CHASSIS GROUND/
PE
CHASSIS GROUND/
PE
AC NEUTRAL IN
AC HOT IN
MATE RTS
AC HOT OUT
AC NEUTRAL OUT
CHASSIS GROUND/
PE
CHASSIS GROUND/
PE
AC NEUTRAL IN
AC HOT IN
MASTER
BYPASS
SLAVE L2
BYPASS
MASTER OUTPUT
SLAVE
L2
OUTPUT
MASTER
INPUT
SLAVE
L2
INPUT
250
ON
250
ON
OFF
O
SLAVE L2
INVERTER
MASTER
INVERTER
PV
ARRA
Y
PV
ARRA
YFNDC
OFF
O
OFF
O
GROUND
FAULT
Charge
Controlle
r
Charge
Controller
OFF
O
O
F
F
O
FAULT
PV
INACTIVE
NORMAL
PV ACTIVE
PV ARRAY
GROUND
FAULT
DETECTOR
INTERRUPTE
R
Energize/Startup
Procedures
Pre-startup Procedures:
After opening the AC and DC enclosures:
1. Double-check all wiring connections.
2. Inspect the enclosure to ensure no tools
or debris has been left inside.
3. Disconnect AC loads at the load panel.
4. Disconnect AC inputs at the source.
5. Place the mechanical interlock in the
normal (non-bypass) position.
Functional Test
Points
Battery Voltage Test Points
AC IN Voltage Test Points
(Terminal bus bar = TBB)
AC OUT Voltage Test Points
(Terminal bus bar = TBB)
De-energize/Shutdown
Procedures
WARNING: Lethal Voltage
Review the system configuration to identify
all possible sources of energy. Ensure ALL
sources of power are disconnected before
performing any installation or maintenance
on this equipment. Confirm that the
terminals are de-energized using a
validated voltmeter (rated for a minimum
1000 Vac and 1000 Vdc) to verify the
de-energized condition.
WARNING: Lethal Voltage
The numbered steps will remove power from
the inverter and charge controllers.
However, sources of energy may still be
present in the AC and DC wiring boxes. To
ensure absolute safety, disconnect ALL
power connections at the source.
WARNING: Burn Hazard
Internal parts can become hot during
operation. Do not remove the cover during
operation or touch any internal parts.
Be sure to allow the parts sufficient time to
cool down before attempting to perform
any maintenance.
To de-energize or shut down the OutBack devices:
1. Turnoff(open)theACcircuitbreakers.
2. Turnoff(open)theDCcircuitbreakersforthebattery.
Wait5minutesforthedevicestointernallydischargethemselves.
3. Turnoff(open)thePVcircuitbreakers.
4. Turnoff(open)theGFDIcircuitbreaker.
5. Verify0VdcontheDCinputterminalofthemasterinverterbyplacingthe
voltmeterleadsonand.
6. Verify0VdcontheDCinputterminaloftheslaveinverterbyplacingthe
voltmeterleadsonand.
7. Verify0VdconthePVterminalsofonechargecontrollerbyplacingthe
voltmeterleadsonand.
8. Verify0VdconthePVterminalsoftheotherchargecontrollerbyplacingthe
voltmeterleadsonand.
9. Verify0VacontheACoutputcircuitbreakersbyplacingthevoltmeterleads
onand.
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©2013 OutBack Power Technologies. All Rights Reserved.
1b 1c
1
1b
1a
1
2
3
4
2
42a 2c
5
3
4
2
4
5
3
43
3
5
PV Voltage Test Points
1
3
CAUTION: Equipment Damage
Incorrect battery polarity will damage the equipment.
1
1d
1b 1d
2e2b
2d 2f
Test points 2a and
2c refer to the
bottom terminal of
the circuit
breakers.
1b1a 1c 1d
2a 2b 2c 2d 2f2e
1c
2e
2b
2f
2d
2
53
To energize or start up the OutBack devices:
1. Using a digital voltmeter (DVM), verify 12, 24, or 48 Vdc on the DC input terminals by placing
the DVM leads on and . Confirm that the voltage is correct for the inverter and charge
controller models. Confirm the polarity.
2. Verify that the PV output for each charge controller is in the correct range of open-circuit
voltage and confirm the polarity by:
a) placing the DVM leads on and , and
b) placing the DVM leads on and .
3. Verify 230 Vac on the terminals of the AC source and connect the source.
4. Verify 230 Vac on the AC Input TBB by placing the DVM leads on and .
7. Turn on (close) the GFDI circuit breaker.
8. Turn on (close) the PV input circuit breakers.
9. Turn on (close) the DC circuit breakers from the battery bank to the inverter.
10. Check the system display or LED indicators. Ensure the inverter is in the ON state.
The factory default state for FXR inverters is OFF.
11. Turn on (close) the FN-DC circuit breaker.
12. Turn on (close) the AC output circuit breakers.
13. Verify 230 Vac on the AC Output TBB by placing the DVM leads on and .
NOTE: Assumes correct stacking programming with the Configuration Wizard.
16. Replace the covers on the AC and DC enclosures.
17. Turn on (close) the AC input circuit breakers.
18. Turn on the AC disconnects at the load panel and test the loads.
4
1b1a
3 5
3
1
2
3 4
5
2a 2b
2c 2d

Neutral
Ground
AC IN
MATE RTS
CB3 CB2 CB1
CB6 CB5
CB4
CB8 CB7 CB1
0
CB9 CB1
2
CB1
1
CB1
4
CB1
3
CB1
6
CB1
5
GND
I/ON I/ON
I/ON I/ONI/ONI/ON
NORMAL
UP
DOWN
BYPASSE
D
O/OFFO/OFF
GND
DC
NEGATIVE
SHUNT A
SHUNT C
SHUNT B
AC IN
DC
AC OUT
AC IN
DC
AC OUT
MATE RTS
AC HOT OUT
AC NEUTRAL OUT
CHASSIS GROUND/PE
CHASSIS GROUND/PE
AC NEUTRAL IN
AC HOT IN
MATE RTS
AC HOT OUT
AC NEUTRAL OUT
CHASSIS GROUND/PE
CHASSIS GROUND/PE
AC NEUTRAL IN
AC HOT IN
MASTER
BYPASS
SLAVE L2
BYPASS
MASTER OUTPUT
SLAVE L2
OUTPUT
MASTER
INPUT
SLAVE L2
INPUT
250
ON
250
ON
OFF
O
SLAVE L2
INVERTER
MASTER
INVERTER
FNDC
OFF
O
OFF
O
Charge
Controller
OFF
O
O
F
F
O
FAULT
PV
INACTIVE
NORMAL
PV ACTIVE
PV ARRAY
GROUND
FAULT
DETECTOR
INTERRUPTER
GROUND
FAULT PV
ARRAY
General Wiring
O
I
O
I
O
I
O
I
O
I
O
I
O
I
O
I
O
I
O
I
O
I
O
I
AC
Source
Ground Electrode
System (Ground Rod)
900-0158-01-00REV B.vsd
©2013 OutBack Power Technologies. All Rights Reserved.
PV Array #1
Battery Bank
Vented Battery Enclosure
AC
Distribution Panel
PV Array #2
PV Combiner Box
Charge
Controller #1 Charge
Controller #2
DC
POSITIVE
Negative
Positive
Ground
DC
LEGEND
IMPORTANT: Example only.
Actual wiring may vary depending on local
electric code. Factory wiring is not shown.
Master
Inverter
Slave
Inverter
Charge
Controller
MATE3
Ground
Electrode
Conductor
RTS
CAT5
Cable
PV
ARRAY
AC IN NEUTRAL
GROUND
AC Subpanel
Loads
(230 Vac)
L1
N
N
Neutral
HOT L1
Ground
AC LEGEND
L1
N
L1
AC IN AC OUT
AC
OUT AC OUT