OutBack POWER VFXR Series Hybrid Inverter Charger User Guide

: June 13, 2024
: OutBack POWER

Table of Contents

VFXR Series Hybrid Inverter Charger
Installation
Wiring Data
Energize/Startup Procedures
De-energize/Shutdown Procedures
Setup and Programming
Specifications
Warranty
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

Quick Start Guide
FXR™ and VFXR™ (A) Series Inverter/Charger

VFXR Series Hybrid Inverter Charger

This Quick Start Guide is printed in unbound format. The pages can be read in any order, or shown alongside one another.
WARNING: Fire/Explosion Hazard
Do not place combustible or flammable materials within 12 feet (3.7 m) 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 36” (91.4 cm) 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.
IMPORTANT:

These instructions are for use by qualified personnel who meet all local and governmental code requirements for licensing and training for the installation of electrical power systems with AC and DC voltage up to 600 volts. This product is only serviceable by qualified personnel. All system wiring must comply with national and local codes and regulations.
This product is designed and tested for stationary applications only. It is not listed or warranted for mobile use.

NOTE:

This document is for installation of a single inverter. For stacking of multiple inverters, product specifications, functions, applications, and programming instructions, see the FXR and VFXR product literature.
**** This document assumes the use of the MATE3s system display. For menu navigation, see the system display product literature.
This document contains hyperlinks and QR codes leading to the product literature at www.outbackpower.com.

Major System Components
FLEXpower™ System Products
Inverter/Charger
AC Enclosure (with Bypass Assembly)
DC Enclosure (with Inverter Disconnect)
System Display and Controller (MATE3s™)
PV Charge Controller
Communications Manager
Battery Monitor
Remote Temperature Sensor (RTS)
Surge Protector
Other Components
AC Source
Utility Grid, or AC Generator
Main Electrical Panel and
Distribution Subpanel (Load Panel)
Photovoltaic (PV) Array and Combiner
Battery Bank
FXR (A Series) Sealed Inverter with Turbo Fan IMPORTANT:
Not intended for use with life support equipment.

Installation

Requirements

The FXR and VFXR inverter/chargers are intended for indoor installation only.

IMPORTANT:
While sealed FXR models are more tolerant of incidental dust and moisture than VFX models, none of these products are intended for installation outdoors. Failure to adequately protect the inverter from weather will void the warranty.

Ensure the mounting surface is strong enough to handle 3 times the total weight of all the components.
The inverter has four 0.313″ (8 mm) mounting holes (A), one in each corner. Use fasteners in all corners.

IMPORTANT:
Use correct fasteners to secure the inverter to the mounting surface. OutBack cannot be responsible for damage to the product if it is attached with inadequate fasteners.

Due to the variance in other mounting methods, OutBack Power only endorses the use of FLEXware mounting products. Use M6 × 20 mm machine screws, one per corner, to attach the inverter to the mounting plate. Follow the instructions with each mounting system.
Mount and secure each component before attaching any wiring.
When the inverter is used with other metal chassis, make sure that all chassis are grounded. Use either metal-tometal contact or separate ground wires as appropriate.
For more information, see the FXR Installation Manual. ****
See QR code above.

Materials in Box

Inverter
Quick Start Guide (this document)
Battery terminal covers, red/black
AC plate
DC Cover (DCC) or Turbo Fan
Remote Temp. Sensor (RTS)
Silicone grease packet
“WARNING ELECTRICAL SHOCK” sticker

Tools Required

Wrench and socket sets; should include
- Torque and ratchet wrenches
Wire cutters/strippers
Insulated screwdriver set (flat and Phillips); should include
- Miniature flat screwdriver for AUX connections
Long-nose pliers
High-resolution voltmeter

DC Cover or Turbo Fan Attachment If necessary, the green terminal block can be unplugged by pulling it gently away from the AC board.

If it becomes necessary to remove the Turbo Fan:

Remove the screws at the four corners of the Turbo Fan.
Remove the compartment cover.
Unscrew the AUX+ and AUX– terminal screws.
Remove the wires.
Remove the Turbo Fan.

Wiring Data

CAUTION:
Equipment Damage
When connecting battery cables to the inverter, observe the proper polarity. Incorrect connection can damage or destroy the equipment and void the product warranty.

Battery Negative Stud
Battery Positive Stud
Ground Lug
AC Hot Out Terminal AC Neutral
Terminals
6Ground Terminals
AC Hot In Terminal
Inverter On/Off Jumper
Inverter On/Off Terminals
Auxiliary Terminals
Temperature Sensor Port
Communication Port
Battery LED Indicators
Status LED Indicators

**CAUTION:** Fire Hazard
Do not stack battery terminal hardware in any other order than shown here.
Stacking terminal hardware in any other order can overheat the terminals.
Other devices may be installed on the same inverter studs above the hardware shown here.

IMPORTANT

This product requires batteries for operation. The required nominal voltage is either 12, 24, or 48 Vdc, depending on model.
The default inverter/charger settings assume a deep-cycle stationary lead-acid battery, such as OutBack Power’s EnergyCell RE or NC series batteries. Ensure the settings are appropriate for the specific batteries used in the system.
Protection for the battery circuit external to this product must be provided by the installer.
Protection for the AC circuit external to this product must be provided by the installer.
For more information, see the FXR Installation Manual.

Inverter (Wattage/Voltage)| Nominal DC Amps (Derated 125%)| Conductor Size (Minimum)| Breaker Size (Minimum)
---|---|---|---
FXR2012A| 200| 4/0 AWG (120 mm²) or 0.186 in²| 250 Adc
VFXR2812A| 280| 4/0 AWG (120 mm²) or 0.186 in²| 250 Adc
FXR2524A| 125| 2/0 AWG (70 mm²) or 0.109 in²| 175 Adc
VFXR3524A| 175| 4/0 AWG (120 mm²) or 0.186 in²| 250 Adc
FXR3048A| 75| 1/0 AWG (70 mm²) or 0.109 in²| 125 Adc
VFXR3648A| 90| 1/0 AWG (70 mm²) or 0.109 in²| 125 Adc
Terminal Location| Torque Requirements
Inverter DC Terminals| 60 in-lb (6.9 Nm)
Battery Terminals| See battery manufacturer’s recommendations

AC Wiring Notes

Recommended conductor size is #6 AWG (16 mm² ) or 0.021 in².
Inverter output varies with model. Size the loads accordingly.
The transfer relay is rated 60 Aac; AC input and output may need to be protected with branch-rated circuit breakers of maximum 60 Aac size to meet applicable code requirements.
The neutral terminals are common. Typically only one is used.
Only one AC source can be wired at a time. Use an external selector switch if more than one source is available.

Generator Notes

A generator should be sized to provide enough power for maximum loads and charging at the same time.
Minimum generator size is recommended to be twice the power of the inverter(s) due to overload and/or balancing issues.

Grounding Notes

This product meets the IEC requirements of Protection Class I.
This product must be connected to a permanent wiring system that is grounded according to the IEC 60364 TN standard.
The input and output circuits are isolated from ground. The installer is responsible for system grounding according to all applicable codes.
The central AC ground terminals are common. Typically only one is used.

WARNING: Shock Hazard

For safety, the neutral and ground conductors should be mechanically bonded. OutBack Power does not bond these conductors within the inverter. Some codes require the bond to be made at the main panel only. Make sure that no more than one bond is present in the AC system at any time.
For all installations, the negative battery conductor should be bonded to the grounding system at only one point. If the OutBack Power GFDI is present, it can provide the bond.

Terminal Location	Minimum Conductor Size	Torque Requirements
Central AC Terminals	#10 AWG (0.009 in²) or 6 mm²	25 in-lb (2.8 Nm)
DC Box Lug	#6 AWG* (0.025 in²) or 16 mm²	45 in-lb (5.1 Nm)

*Accepts up to 1/0 AWG (70 mm² or 0.109 in²) wire. The DC Cover or Turbo Fan must be removed before making the ground connection.
DC Wiring Notes

Battery cables should be no longer than 10 feet (3 m) each to minimize voltage loss and other possible effects.
Turn off DC circuit breakers before proceeding.
Tie, tape, or twist cables together to reduce self-inductance. Run positive and negative cables through the same knockouts and conduit.
Each inverter battery terminal is a threaded stud which accepts a ring terminal lug. Use crimped and sealed copper ring lugs with 5 /16 inch (0.79 cm) holes, or use compression lugs.
Install overcurrent devices according to applicable codes.
The DC terminals must be installed in an enclosure to meet the requirements of some local or national codes.

Energize/Startup Procedures

**CAUTION:** Fire Hazard
Before energizing, confirm that all hardware is installed as shown on the Installation page.
Stacking battery terminal hardware in any other order can overheat the terminals.
Pre-startup Procedures After opening the AC and DC enclosures:

Double-check all wiring connections. Ensure all torque values are met. See Wiring Data on the other side of this sheet.
Inspect any enclosures to ensure no tools or debris were left inside.
Disconnect all AC loads at the backup (or critical) load panel.
Disconnect the AC input to the inverter system at the source.
If a mechanical interlock is used, place it in the normal (non-bypass) position.
Using a digital voltmeter, verify 12, 24, or 48 Vdc at the battery source. Confirm the polarity.

These instructions assume the use of AC and DC wiring boxes of OutBack Power models.
**CAUTION: Equipment Damage
Incorrect battery polarity will damage the equipment.
To energize or start up the OutBack Power devices:**

Close the DC circuit breaker from the battery bank to the inverter. 1
Using a digital voltmeter, verify 12, 24, or 48 Vdc on the DC input terminals by placing the DVM leads on and . Confirm that the voltage and polarity are correct for the inverter and charge controller models.
If PV is installed, verify the correct voltage and polarity at the charge controller terminals.
Close the ground-fault circuit breaker, if present. 2
Close the PV input circuit breakers, if present. 3
Close the circuit breaker for the Flexner DC, if present. 4
Using the system display, perform any necessary programming, particularly for the size of the AC input source(s). See Sheet 3 for the Profile Wizard.
The factory default state for all FXR inverters is OFF. Using the system display, turn the inverter to the ON state.
Using the DVM, verify the inverter AC output on the AC output circuit terminals 4a and 4b
Without closing the inverter system’s AC input circuit breakers: Using the DVM, test the voltage of any input AC source(s).
Connect the AC source. Close the inverter system’s AC input circuit breakers 5. Using the DVM, verify 120 Vac on the AC input circuit terminals 3a and 3b .
NOTE: After a brief delay, the inverter’s transfer relay will activate unless the inverter’s settings have been changed. Using the system display, verify the input source and the inverter’s charging function. After verification, disconnect the AC source.
Replace the covers on the AC and DC enclosures.
Close the AC output circuit breakers. 6 Turn on the AC disconnects at the load panel and test the inverter’s output while operating loads.

NOTES:

If a system display is not present, the inverter must be turned off or on using an external switch or the ON/OFF jumper. See the Installation Manual for more instructions.
If any of these tests do not function as described, or for other troubleshooting, see the Operator’s Manual. 2

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 controller. However, sources of energy may still be present inside the wiring boxes and other locations. 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 them sufficient time to cool down before attempting to perform any maintenance.
To de-energize or shut down the OutBack Power devices:

Open the AC circuit breakers. 1
Open the DC circuit breaker for the battery. 2
Open the PV circuit breaker, if present. 3
Open the ground-fault circuit breaker, if present. 4
Open the Flexner DC circuit breaker, if present. 5
Verify 0 Vdc on the DC input terminals of the inverter by placing the voltmeter leads on 1 and 2.
Verify 0 Vdc on the PV charge controller terminals, if present.
Verify less than 5 Vac on the AC output circuit terminals 4a and 4b .
Verify less than 5 Vac on the AC input circuit terminals 3a and 3b.

Functional Test Points

Battery Positive (+) Terminal
Battery Negative (–) Terminal
3a AC HOT IN Terminal
3b AC NEUTRAL IN Terminal
4a AC HOT OUT Terminal
4b AC NEUTRAL OUT Terminal

*Terminals 3b and 4b are electrically common.

Setup and Programming

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

Ensure all settings are correct for the system. The Profile Wizard can be used for rapid setup. For Grid Support functions it may be necessary to load a .GIP file. This document assumes the use of the MATE3s System Display.
Verify the firmware revision of all OutBack Power devices before use. The FXR inverter and system display may not communicate or operate correctly unless their firmware is above a specified revision number. Radian inverters with firmware revision 001.006.061 or higher must use the MATE3s system display.
For firmware and .GIP file installation, see the Installation Manual. For settings and functions, see the Operator’s Manual.

Profile Wizard
In the MATE3s system display, the Profile Wizard allows quick setup of parameters that apply to all systems. The Profile Wizard is reached from the Main Menu as shown in B .
The Profile Wizard is useful for rapid setup of multiple parameters including date, time, battery charging, AC source size and limits, and System Type. It can also configure functions such as High Battery Transfer and Grid Use times. Note that these two functions are not available if the System Type is set to Off Grid.
NOTE: The Wizard does not configure the entire system. It does not select AC input modes for the FXR inverter, parameters for automatic generators, or “fully charged” parameters if the FLEXnet DC battery monitor is in use. If settings are made in the wrong order, the Wizard can overwrite some customized settings. See MATE3s Programming Guide for more information. 3 The firmware revision of all devices can be confirmed by navigating from the Main Menu as shown in A . Upgrades to the firmware
revision can be downloaded from the OutBack Power website. 4

A If the System Type is Grid Tied or Backup, the display advances to the Grid Use Schedule screens. If the System Type is Off Grid, see . B
B If the Flexner DC is installed, the display advances to the Shunt screens. If the FLEXnet DC is not installed, see B .
C This advances the display to the Setup Complete screen.

FLEXnet DC Battery Monitor
The FLEXnet DC (FN-DC) is a battery monitor which measures DC current flow on one or more shunts.
It provides battery state-of-charge (SoC) information.
Exact measurements and programming are performed with the system display. (See the system display and FLEXnet DC literature.) The LED indicators shown below provide approximate measurements of the battery state of charge.
The FLEXnet DC (FN-DC) is a battery monitor which measures DC current flow on one or more shunts.
It provides battery state-of-charge (SoC) information.
Exact measurements and programming are performed with the system display. (See the system display and FLEXnet DC literature.) The LED indicators shown below provide approximate measurements of the battery state of charge.

FN-DC LED Indicators

After commissioning and programming the FXR system, perform a full battery charge.
Reset the FN-DC by unplugging the communications cable and then plugging it back in. (The system must be energized at the time.) The FN-DC will reset to 100% SoC, matching the batteries if they have been charged.
NOTE: The user must program the FN-DC with correct values for battery capacity and charging requirements. The factory default values may not be correct. If not programmed accurately, the FN-DC readings and LED indicators will not be accurate.
The same is true if the shunt(s) are not wired correctly. See the FLEXnet DC Overview Guide for more information.
LED Indicators
The inverter has two sets of LED indicators. (See Sheet 2 for locations.)
The BATTERY indicators show the approximate battery state.
NOTE: Due to different system states, battery voltage does not always indicate an accurate state of charge. The FN-DC is more accurate.

A green indicator (FULL) means the batteries have an adequate charge. It does not always mean they are full.
A yellow indicator (OK) means the batteries are somewhat discharged.
A red indicator (LOW) means the batteries are greatly discharged and may require attention. A low battery error may be accompanied by a red STATUS indicator.

The STATUS indicators show the inverter’s operating condition as shown below.

Battery Status LED Indicators

Color| 12 V Inverter| 24 V Inverter| 48 V Inverter
Green| 12.5 Vdc or higher| 25.0 Vdc or higher| 50.0 Vdc or higher
Yellow| 11.5 to 12.4 Vdc| 23.0 to 24.8 Vdc| 46.0 to 49.6 Vdc
Red| 11.4 Vdc or lower| 22.8 Vdc or lower| 45.6 Vdc or lower
Inverter Status LED Indicators

Green| Inverter on (solid) or standing by (flash)
Yellow| AC source in use (solid) or standing by (flash)
Red| Inverter error or warning (see manual)

See the inverter Operator’s Manual for full descriptions of these LED indicators.

Specifications

Environmental Specifications

Specification	Value

Rated Temperature Range (meets component specifications; however, please note that the inverter output wattage is dated above 25°C)| —4°F to 122°F (-20°C to 50°C)
Operational Temperature Range (functions, but not rated for operation; does not necessarily meet all component specifications)| 40°F to 140°F to 60°C) (-40°C)
Storage Temperature Range| —40°F to 140°F (-40°C to 60°C)
IP (Ingress Protection) Rating of Enclosure| IP20
Environmental Category| Indoor, Unconditioned
Wet Locations Classification| Wet locations: No
Relative Humidity Rating| 93%
Pollution Degree Classification| PD 2
Maximum Altitude Rating| 6561′ (2000 m)
Overvoltage Category (AC Input)| 3
Overvoltage Category (DC Input)| 1

All FXR inverters can deliver their full rated wattage at temperatures up to 25°C (77°F). The FXR maximum wattage is rated less in higher temperatures. Above 25°C, each inverter model is derated by a factor of 1% of that model’s rated wattage for every increase of 1°C. This derating applies to all power conversion functions (inverting, charging, selling, offsetting, etc.)
IMPORTANT:
This inverter is intended for indoor use only. Failure to adequately protect the inverter will void the warranty.
Contact Information
Mailing Address:3767 Alpha Way
Bellingham, WA 98226 USA
Web Site: www.outbackpower.com
Date and Revision
September 2022, Revision B

Warranty

The warranty for this product can be downloaded from
https://www.outbackpower.com/resources/warranty/procedures
A copy is available by sending a self-addressed envelope to the address noted to the left.

| World Headquarters
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6300 Zug Switzerland| EnerSys Asia
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Gateway East Building #11-08
Singapore 189721 / +65 6508-1780
---|---|---|---

For more information visit www.enersys.com
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900-0213-01-00 REV B
Do not copy or distribute without permission.