Outback Power Systems FX AND VFX SERIES User manual

FX AND VFX SERIES
INVERTER/CHARGER
Installation Manual
Includes Mounting, Installation, and Product Registration

Warranty Introduction
Dear OutBack Customer,
Thank you for your purchase of OutBack products. We make every eort to assure our power conver-
sion products will give you long and reliable service for your renewable energy system.
As with any manufactured device, repairs might be needed due to damage, inappropriate use, or unin-
tentional defect. Please note the following guidelines regarding warranty service of OutBack products:
• Any and all warranty repairs must conform to the terms of the warranty.
• All OutBack equipment must be installed according to their accompanying instructions and manuals
with specied over-current protection in order to maintain their warranties.
• The customer must return the component(s) to OutBack, securely packaged, properly addressed,
and shipping paid. We recommend insuring your package when shipping. Packages that are not
securely packaged can sustain additional damage not covered by the warranty or can void warranty
repairs.
• There is no allowance or reimbursement for an installer’s or user’s labor or travel time required to
disconnect, service, or reinstall the damaged component(s).
• OutBack will ship the repaired or replacement component(s) prepaid to addresses in the continental
United States, where applicable. Shipments outside the U.S. will be sent freight collect.
• In the event of a product malfunction, OutBack cannot bear any responsibility for consequential
losses, expenses, or damage to other components.
• Please read the full warranty at the end of this manual for more information.
About OutBack Power Systems
OutBack Power Systems is a leader in advanced energy conversion technology. Our products include
true sine wave inverter/chargers, maximum power point charge controllers, system communication
components, as well as breaker panels, breakers, accessories, and assembled systems.
Notice of Copyright
FX and VFX Series Inverter/Charger Installation Manual © 2007 All rights reserved.
Disclaimer
UNLESS SPECIFICALLY AGREED TO IN WRITING, OUTBACK POWER SYSTEMS:
(a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR
OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION.
(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER DIRECT, INDIRECT,
CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE
USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER’S RISK.
Contact Information
OutBack Power Systems
19009 62nd Ave. NE
Arlington, WA 98223 Phone [phone] • Fax [phone] www.outbackpower.com
Date and Revision • September 2007 REV A

TABLE OF CONTENTS
Welcome to the OutBack Power Systems FX Series Inverter/Charger System.............................................2
Safety.................................................................................................................................................................................................2
FX Series Inverter/Charger Models...........................................................................................................................................2
Parts Included........................................................................................................................................................................................2
Safety Instructions...............................................................................................................................................................................3
System Protection...............................................................................................................................................................................5
DC Wiring Origination....................................................................................................................................... ...............................5
AC Wiring Origination.......................................................................................................................................................................6
AC Wiring Compartment Board................................................................................................................... ..............................6
AC and DC Grounding Requirements............................................................................................. .......................................7
FX Parts and Accessories.................................................................................................................................................................8
Mounting..................................................................................................................................................................................................9
Low Voltage Terminals...................................................................................................................................................................10
Wire Connections.............................................................................................................................................................................11
AC Wiring Notes for the Non-Mobile FX.............................................................................................................................13
AC Wiring Notes for the Mobile FX........................................................................................................................................14
Low Voltage Wiring..........................................................................................................................................................................15
Inverter and On/O...............................................................................................................................................................15
Auxiliary Output (AUX+ / AUX-).....................................................................................................................................16
XCT+ / XCT-................................................................................................................................................................. ...............17
RTS, MATE/HUB Wiring..................................................................................................................................................................17
System Installation...........................................................................................................................................................................18
Single FX System.....................................................................................................................................................................18
Single or Series Parallel Dual FX Conguration....................................................................................................19
Paralleled Dual FX System .................................................................................................................................................22
Series/Parallel Quad FX System......................................................................................................................................23
3-Phase System............................................................................................................................................. ...........................24
Generator Interfaces.......................................................................................................................................................................26
Mobile FX Information..................................................................................................................................................................27
Installation Check List....................................................................................................................................................................28
Appendix...............................................................................................................................................................................................29
Voltage, Current, and Frequency Ranges.....................................................................................................................29-31
Maximum Overcurrent Protection Ampacity...................................................................................................................32
Wire Sizes...............................................................................................................................................................................................32
Maintenance........................................................................................................................................................................................33
Warranty.................................................................................................................................................................................................34
Product Registration.......................................................................................................................................................................35
1

Welcome to the OutBack Power Systems FX Series Inverter/Charger System
The FX Series Inverter/Charger oers a complete power conversion system—DC to AC, battery
charging, and an AC transfer switch—and can be used as a stand-alone or back-up application. It is
designed for indoor or enclosed locations.
OutBack Power Systems does everything possible to assure the components you purchase will
function properly and safely when installed as instructed according to local and national electrical
codes (NEC). Please read all of the following instructions and the instructions that come with any
other OutBack components that make up your power system. Further instructions on individual FX set-
ups as well as systems assemblies are included with the FLEXware manuals.
• The non-Mobile FX is ETL listed to UL1741 (Inverters, Converters, Controllers, and Interconnection
System Equipment for Use with Distributed Energy Resources)
• All Mobile FX Series Inverter/Chargers are ETL listed to UL 458.
The FX and VFX Series Inverter/Charger Installation Manual covers the following information:
• Safety
• FX parts, standard and optional
• Initial inspection of the component
• Preparing the mounting surface
• Fastening the FX to the mounting surface
• General electrical information
FX Series Inverter/Charger Models
Sealed Units (designed for harsher environments, but still require overhead and sidewall protection)
FX 2012 T (12 VDC/2000 VA)
FX 2024 T (24 VDC/2000 VA)
FX 3048 T (48 VDC/3000 VA)
Vented Units (designed for more protected environments)
VFX 2812 (12 VDC/2800 VA)
VFX 3524 (24 VDC/3500VA)
VFX 3648 (48 VDC/3600VA)
Each model FX has a single phase output marked with this symbol:
Each inverter puts out a sine wave waveform marked with this symbol:
Parts Included
One FX Series Inverter/Charger
One “WARNING ELECTRICAL SHOCK” sticker to place on the exterior of the FX
One packet of silicone grease to protect CAT 5 cable connections
One installation manual
One programming manual
One Turbo Kit (sealed units)
One DC Wiring Cover or DCC (vented units)
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2

REA D FIR ST!
IMPORTANT SAFETY INSTRUCTIONS
Read all instructions and cautionary markings on the FX, the batteries and all appropriate sections of
this installation and user manual as well as other component manuals before using the system.
Be cautious around electricity, electrical components, and batteries. Shocks, burns, injury, and even
death can occur if an installer comes in contact with electricity.
Install all components and wiring according to national and local electrical and building codes. This
includes:
• Submitting a plan to the local building department
• Passing inspection
• Requiring a licensed electrician to do the work when mandated
OutBack Power Systems cannot be responsible for system failure, damages, or injury resulting from
improper installation of their products.
Use only the recommended DC and AC wire sizes or greater. Be sure all wires are in good condition.
Install the FX in a dry location, preferably indoors.
• Install the FX in a shaded area out of direct sun
light for best operation.
• For installations where the FX may be exposed to water spray, a sealed FX must be used and
mounted either with the base down (shelf mounting) or with the AC wiring compartment facing
down (wall mounting).
• 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 Vented FX (VFX) must be installed in a weather-proof enclosure or enclosed area.
It is not designed for exposure to water or excessive wind-blown dust and debris.
3
INITIAL INSPECTION
Your FX is stoutly packaged for secure shipping. Please inspect the packaging and component for
damage prior to intallation.
READ FIRST!

Design the battery enclosure to prevent accumulation and concentration of hydrogen gas in“pockets”
at the top of the enclosure. Vent the battery compartment from the highest point to the outside. A
sloped lid can also be used to direct the ow of hydrogen to the vent opening.
CAUTION
To reduce risk of injury, charge only deep-cycle lead acid, lead antimony, lead calcium, gel cell or
absorbed glass mat type rechargeable batteries. Other types of batteries may burst, causing personal
injury and damage. Never charge a frozen battery.
PERSONAL PRECAUTIONS
• Someone should be within range of your voice to come to your aid if needed.
• Keep plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.
• Wear complete eye protection. Avoid touching eyes while working near batteries. Wash your hands
with soap and warm water when done.
• If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters an
eye, ood the eye with cool running water at once for at least 15 minutes and get medical attention
immediately following.
• Baking soda neutralizes lead acid battery electrolyte. Keep a supply on hand in the area of the
batteries.
• NEVER smoke or allow a spark or ame in vicinity of a battery or generator.
• Be extra cautious to reduce the risk of dropping a metal tool onto batteries. It could short-circuit the
batteries or other electrical parts can result in re or explosion.
• Remove personal metal items such as rings, bracelets, necklaces, and watches when working with
a battery or other electrical current. A battery can produce a short circuit current high enough to
weld a ring or the like to metal, causing severe burns.
4
WARNING: WORKING NEAR LEAD ACID BATTERIES CAN BE DANGEROUS. BATTERIES
GENERATE EXPLOSIVE GASES DURING NORMAL OPERATION.

5
• Never install extra washers between the
terminal mounting surface and the battery
cable lug—the connection must be direct and
secure.
• Always install breakers or fuses within the
positive battery cable.
• Torque 2/0, 4/0, or larger NEC approved cables
rated 75° or higher to 60-inch pounds.
SYSTEM PROTECTION
An FX Series Inverter/Charger is part of an electrical system that protects:
• You
• The wires
• The components
• The devices served by the system
OutBack circuit breakers protect wiring by limiting
the amount of current entering a system. All
wired electrical systems require circuit breakers or
fuses for protection.
OutBack oers both breakers and fuses for over-
current protection. If they are provided by other
vendors, they must be properly rated.
Each FX must be part of a permanently grounded
electrical system (see page 7). Grounding protects
people and equipment from electrical shock.
Grounding must be done according to local and
national electrical codes.
DC WIRING ORIGINATION
DC brass battery terminals with 8M x 1.25 stainless steel threaded studs
Black=negativeRed=positive Battery terminal covers
Battery Cable Lug
Lock Washer
Flat Washer
Nut
Stud

6
AC WIRING ORIGINATION
Lexan cover protects AC Wiring
Compartment Board
AC WIRING COMPARTMENT BOARD
• AC HOT OUT supplies power to the loads.
• AC NEUTRAL OUT acts as neutral leg for loads
supplied by the FX.
• CHASSIS GROUND connections are common
and act as grounds for both the incoming and
outgoing AC circuits.
• AC NEUTRAL IN acts as the neutral leg for AC
power supplied by either the grid or a generator
to the FX.
• AC HOT IN connects incoming AC from the grid
or a generator to the FX. This AC is used to run
loads and recharge batteries.
NOTE: “CHASSIS GROUND” in the AC terminal
block reads as “NEU/GROUND BOND” ON FX
MOBILE SERIES.
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AC Terminal Block--secures AC connections
to the FX using set screws
AC Wiring Board

7
AC AND DC GROUNDING REQUIREMENTS
• Connect only to a grounded, permanent wiring system. Ensure there is only one neutral-ground
connection in the system at any time. Some codes require this connection be made at the main
panel only.
• If the system has a generator, its neutral-ground connection will probably need to be disengaged.
• For all installations, the negative battery conductor should be bonded to the grounding system at
one (and only one) point in the system.
• The FX should never be positive grounded.
The equipment ground on each is marked with this symbol:
Box lug for grounding the FX chassis