OutBack Power FLEXpower ONE GVFX3524 Installation Manual Download

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power ONE

T M

Installation Manual

Summary of Contents for FLEXpower ONE GVFX3524

Page 1: ...power ONE T M Installation Manual...

Page 2: ...ENTATION 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 INFORM...

Page 3: ...zard to Human Life This type of notation indicates that the hazard could be harmful to human life CAUTION Hazard to Equipment This type of notation indicates that the hazard may cause damage to the eq...

Page 4: ...nstitute of Electrical and Electronics Engineers N AC Neutral NEC National Electric Code North America NFPA National Fire Protection Association OSHA Occupational Safety and Health Association PV Phot...

Page 5: ...energized using a validated voltmeter rated for a minimum 1000 Vac and 1000 Vdc to verify the de energized condition Do not perform any servicing other than that specified in the installation instruc...

Page 6: ...box depending on local code requirements CAUTION Equipment Damage PV Arrays must be wired with correct polarity positive to positive negative to negative Connecting the cables incorrectly can damage...

Page 7: ...ive Connecting the cables incorrectly can damage or destroy the equipment IMPORTANT Baking Soda neutralizes lead acid battery electrolyte Vinegar neutralizes NiCad and NiFe battery electrolyte Have a...

Page 8: ...ment Canada Address Office of Waste Management Conservation and Protection Environment Canada Ottawa Ontaro K1A 0H3 Phone 1 819 997 2800 Web site http www portaec net library recycling recycling_in_ca...

Page 9: ...ada 6 National Institute of Recyclers Mexico 6 EuroRecycle net 6 Introduction 11 Components 12 Applications 13 On Grid Applications 13 Off Grid Applications 14 Grid Interactive Applications 14 PV Arra...

Page 10: ...ecifications 49 Feature Matrix 49 Electrical Specifications 120 Vac 60 Hz Models 50 Mechanical Specifications 120 Vac 60 Hz Models 50 Electrical Specifications 230 Vac 50 Hz Models 51 Mechanical Speci...

Page 11: ...stem 12 Table 3 Ground Conductor Size and Torque Requirements 26 Table 4 DC Conductor Size and Torque Requirements 27 Table 5 AC Conductor Size and Torque Requirements 31 Table 6 Feature Matrix 49 Tab...

Page 12: ...32 Figure 19 Energize Procedures 33 Figure 20 Functional Test Procedures for Initial Startup 34 Figure 21 Replacing the Raceway and FLEXmax 80 Front Cover 35 Figure 22 Replacing the Inverter s AC Term...

Page 13: ...t excess energy energy that exceeds usage will be returned to the Grid Sell Mode The FLEXpower ONE System is designed with the following features 3 5 kW and 3 6 kW units 120 Vac 60 Hz configurations a...

Page 14: ...cuments DC Enclosure 125 175 or 250A MATE Installation and User s Manual FLEXnet DC Battery Monitor FLEXnet DC Monitor FLEXmax 80 Charge Controller FX or Grid Interactive Programming Manual Raceway FL...

Page 15: ...In on grid applications the FLEXpower ONE can use the grid power as the primary power source or as the backup source of power If the FLEXpower ONE is used as backup to the grid the FLEXpower ONE will...

Page 16: ...In grid interactive applications grid power is used to run the loads When excess PV is available from the batteries the FLEXpower ONE supports those loads with the PV When the PV exceeds the load requ...

Page 17: ...24 Vdc system 150 VOC including local temperature correction factor per NEC 690 7 64 A ISC maximum PV array current per NEC 690 8 For a PV Planning Tool see the following website http outbackpower com...

Page 18: ...tings for circuit breakers and or generator output connectors Full generator output power may not be available from a single generator connector Generator sizing may be affected by start up surge curr...

Page 19: ...are available for purchase PV8 PV12 Combiner Box See the OutBack catalog for a complete list of other parts and components that are available Location FLEXpower ONE is rated for indoor installations I...

Page 20: ...IMPORTANT Clearance and access requirements may vary by location Maintaining a 36 0 91 cm clear space in front of the system for access is recommended Consult local electric code to confirm clearance...

Page 21: ...Planning Dimensions 33 851 cm 19 481 cm Mounting Bracket 16 41 cm 13 33 cm Side View Figure 7 Dimensions 900 0095 01 00 Rev A 19...

Page 22: ...nockout holes 1 Remove the 2 knockout on the DC end to accommodate the larger battery cables and Remote Temperature Sensor cable 2 Remove the 1 knockout s on the AC end to accommodate the AC cabling 3...

Page 23: ...in it with the outside holes measuring 16 center to center This allows the mounting bracket to be secured to wall studs 16 apart If the wall studs are 24 apart the center mounting holes should be used...

Page 24: ...Installation Mounting the bracket to wall studs 16 apart Mounting the bracket to wall studs 24 apart Mounting the bracket to plywood Figure 9 Installing the Mounting Bracket 22 900 0095 01 00 Rev A...

Page 25: ...Plate to the wall at the 3 locations shown below Slip the top of the Mounting Plate over the angled lip of the wall bracket Secure the Mounting Plate to the wall at the 3 locations shown here Figure...

Page 26: ...Cover x4 1 Remove the screws on the FLEXMax 80 Charge Controller x3 1 Remove the screws on the Raceway x2 1 The Raceway and front cover on the FLEXmax 80 Charge Controller only need to be removed if...

Page 27: ...nect 125 175 or 250 Adc GFDI Breaker 1 Adc PV Disconnect 80 Adc Battery Positive Battery Negative Breaker for FNDC 1 A if installed Shunt A1 1 Required by FLEXnet DC Monitor Shunt A monitors inverter...

Page 28: ...reakers must be sized accordingly to protect smaller wires Grounding IMPORTANT System grounding is the responsibility of the installer Grounding requirements may vary by location depending on the loca...

Page 29: ...mm2 N A ring terminal 50 in lb 5 7 Nm N A PV Positive 4 AWG 21 2 mm2 2 AWG 33 6 mm2 35 in lb 4 Nm 80 Adc PV Negative 4 AWG 21 2 mm2 2 AWG 33 6 mm2 35 in lb 4 Nm N A Ground Bus Bar 12 AWG 3 3 mm2 1 0...

Page 30: ...the Battery Temperature Sensor RTS cable to the BATT TEMP port on the Inverter and the other side to one of the batteries in the middle of the Battery Bank Internal components shown may vary from mode...

Page 31: ...nel Torque to 50 in lb 5 7 Nm 5 Attach one end of the Battery Temperature Sensor RTS cable to the BATT TEMP port on the Inverter and the other side to one of the batteries in the middle of the Battery...

Page 32: ...80 charge controller Connect the PV conductor to the PV terminal in the FM80 charge controller Torque to 35 in lb 4 Nm 3 Connect the PV to the top terminal of the PV Disconnect in the DC Enclosure Tor...

Page 33: ...al Minimum Allowed Conductor Size Maximum Conductor Size Torque Requirements Breaker Size AC IN 14 AWG 2 1 mm2 1 0 AWG 53 5 mm2 35 in lb 4 Nm 60 Aac AC OUT 14 AWG 2 1 mm2 1 0 AWG 53 5 mm2 35 in lb 4 N...

Page 34: ...ONE AC Enclosure will need to be removed See Figure 18 Check local code for specific requirements AC Enclosure Factory installed Neutral To Ground Bond Internal components shown may vary from model to...

Page 35: ...re 19 4 Using a digital voltmeter verify 120 Vac on the AC Breakers i e place voltmeter leads on 4 and 4 in Figure 20 5 Close the AC Input Breakers 5 See Figure 19 6 Using a digital voltmeter verify 1...

Page 36: ...nstallation 34 900 0095 01 00 Rev A Figure 20 Functional Test Points for Energizing Systems 4 4 6 6 1 Note The shunt may or may not be installed on your model Use the same test point in all cases 1 8...

Page 37: ...ews provided To Replace the FLEXmax 80 Front Cover 1 Align the holes on the FM80 Front Cover 2 Secure the FM80 Front Cover in place with the screws provided Figure 21 Replacing the Raceway and FLEXmax...

Page 38: ...abling Work with care not to damage the surge protector or dislodge the cabling as you replace the Front Cover Figure 23 Replacing the AC Enclosure Front Cover Cabling not shown To Replace the Top of...

Page 39: ...e screws removed in the beginning To Replace the DC Enclosure Front Cover Cabling not shown Figure 25 Replacing the DC Enclosure Front Cover DC Cover 3 Replace the screws removed in the beginning 2 Al...

Page 40: ...Installation 38 900 0095 01 00 Rev A...

Page 41: ...ions for setting the AC Input Current follow the menu map on page 42 For instructions on setting other inverter features see the MATE Installation and User Manual Charger Settings Charging settings in...

Page 42: ...iar with the basic operation of a MATE2 System Controller and Display If the installer is not familiar with basic operation please refer to the MATE Installation and User Manual for general informatio...

Page 43: ...Operation MATE2 Setup Screen PAGE 2 MATE2 Setup Screen PAGE 3 Continued from page 40 Figure 28 MATE2 Setup Screen Page 2 and 3 900 0095 01 00 Rev A 41...

Page 44: ...u Adjusts the maximum current the inverter will draw from the generator for either supporting loads or battery charging between 2 0 Aac and 60 0 Aac AC1 GRID Menu Adjusts the maximum current the inver...

Page 45: ...limit and the voltage and time limit for each stage of charging IMPORTANT Making changes to the Advanced Settings could adversely affect current system performance Only make changes to the factory de...

Page 46: ...fore the battery is judged to be full Use the battery manufacturer s specifications or 2 of the battery bank capacity IMPORTANT Access the Advanced Menu as instructed on page 43 To change Battery Amp...

Page 47: ...PORTANT 4 Continue pressing DOWN to cycle through all the settings To Set Charging Limits 1 Press the CHGR Soft Key 2 Press the INC or DEC Soft Key to change the parameter 3 Press DOWN to advance to t...

Page 48: ...sure to allow them sufficient time to cool down before attempting to perform any maintenance 46 900 0095 01 00 Rev A Figure 33 Shutdown Procedures 1 Open the PV Breakers 1 2 Open the AC Breakers 2 3...

Page 49: ...Operation 6 6 Note The shunt may or may not be installed on your model Use the same test point in all cases 900 0095 01 00 Rev A 47 4 4 5 5 Figure 34 Functional Test Points for De Energizing Systems...

Page 50: ...Operation 48 900 0095 01 00 Rev A...

Page 51: ...atrix FLEXnet DC Monitor AC Enclosure DC Enclosure MODEL INVERTER MODEL FM80 FN DC SHUNT A FN DC SHUNT B HUB Surge Protector MATE GFDI 120 Vac 230 Vac 175A 250A FP1 1 VFX3524 X X X X X X X X X FP1 2 V...

Page 52: ...on factor PV Maximum Short Circuit Current 64 A ISC Protection AC and DC Surge Protection MOV Current Diversion with LED Warnings PV Ground Fault Protection 80 Adc Breaker Detection 0 5 A For Models w...

Page 53: ...Adc Breaker Detection 0 5 A For Models with FLEXnet DC Battery Monitor State of Charge Display 5 LED Bar Graph or 1 100 scale using MATE2 Battery Capacity Range 100 to 10 000 Amp hours Current Resolut...

Page 54: ...m The LED means a significant surge has damaged the FLEXware Surge Protector and protection in that circuit is compromised Although decreased protection remains it is recommended that the FLEXware Sur...

Page 55: ...n a limited basis such as a prolonged utility outage Totally discharging a battery can reduce its effective life or permanently damage it Consult the battery manufacturer for specific depth of dischar...

Page 56: ...oad by the length of time it will operate Watts to Amps To calculate amps when the power consumption is expressed in watts use the following equation A W V where W watts and V volts DC For example A 1...

Page 57: ...f days during the week that the load will be used Use the worksheet on page 56 to list the respective values and calculate the amp hour requirement In summary to calculate the amp hour requirements 1...

Page 58: ...lculate the amp hour requirements Table 7 Worksheet for Determining Average Daily Load in Amp hours Load Watts Hours per Day Days per week used Weekly watt hours Total weekly watt hours of AC load Div...

Page 59: ...ulate the battery bank size Table 8 Worksheet for Determining Battery Bank Size Average amp hours per day from Table 7 Divided by inverter efficiency Divided by battery efficiency usually 0 75 Adjuste...

Page 60: ...Specifications 58 900 0095 01 00 Rev A This page intentionally left blank...

Page 61: ...tual wiring requirements may vary depending on local electric code All installations must comply with local electric code FLEXpower ONE with FLEXnet DC Monitor and GFDI FLEXpower ONE with FLEXnet DC M...

Page 62: ...Wiring Configurations 60 900 0095 01 00 Rev A This page intentionally left blank...

Page 63: ...Wiring Configurations 900 0095 01 00 Rev A 61 FLEXpower ONE with FLEXnet DC Monitor and GFDI Figure 35 FLEXpower ONE with FLEXnet DC Monitor and GFDI...

Page 64: ...Wiring Configurations 62 900 0095 01 00 Rev A FLEXpower ONE with FLEXnet DC Monitor Only no GFDI Figure 36 FLEXpower ONE with FLEXnet DC Monitor Only No GFDI...

Page 65: ...Wiring Configurations 900 0095 01 00 Rev A 63 FLEXpower ONE with GFDI Only no FLEXnet DC Monitor Figure 37 FLEXpower ONE with GFDI Only no FLEXnet DC Monitor...

Page 66: ...Wiring Configurations 64 900 0095 01 00 Rev A FLEXpower ONE no FLEXnet DC Monitor or GFDI Figure 38 FLEXpower ONE no FLEXnet DC Monitor or GFDI...

Page 67: ...power system Any product whose serial number has been altered defaced or removed or Any other event not foreseeable by OutBack OutBack s liability for any defective Product or any Product part shall b...

Page 68: ...Product to OutBack After receiving the RMA number pack the Product s authorized for return along with a copy of the original purchase invoice and warranty certificate in the original Product shipping...

Page 69: ...Bank Size 59 Worksheet for Calculationg Amp Hour Reqmts 58 Battery Bank Types of Batteries 15 Battery Bank Planning 15 C Clearance 18 Commissioning 35 Components 12 D DC Conductor Size and Torque Requ...

Page 70: ...r Cover 26 S Safety 1 Battery 4 General 2 Personal 3 Photovoltaic 4 Sytstem 3 Setting Battery Amp Hours 46 Setting the Date 42 Setting Time 42 Setup Screens MATE2 43 Shutdown 49 Shutdown Procedures 49...

Page 71: ...oudly assembled in the United States of America and demonstrates the quality and pride of this great team of employees We sincerely hope your experience has been pleasant positive and professional and...

Page 72: ...North America 19009 62nd Avenue NE Arlington WA USA 1 360 435 6030 European Office Barcelona Espa a 34 93 654 9568...

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