Outback Power Systems DC manual

U ser ’ s Guide Includes M ounting and Installation net DC TM[...]

1 Dear OutBack Customer , Thank you for y our purchase of OutBack pr oducts. W e make ever y e or t to assure our power conversion pr oducts will give you long and reliable service for your r enewable energy system. As with any manufactured device , repairs might be needed due to damage , inappropriate use, or unintentional defect. Please not e [...]

2 Disclaimer UNLESS SPECIFICALL Y A GREED T O IN WRITING, OUTBACK POWER SYSTEMS: (a) MAKES NO W ARRANT Y AS TO THE ACCURACY , SUFFICIENCY OR SUIT ABILIT Y OF ANY TECHNICAL OR O THER INFORMA TION PR OVIDED IN ITS MANU ALS OR OTHER DOCUMENT A TION. (b) ASSUMES NO RESPONSIBILIT Y OR LIABILIT Y FOR LOSS OR D AM AGE, WHETHER DIREC T , INDIREC T , CONSEQ[...]

3 T ABLE OF C ONTENTS W arranty Summar y..................................................................................................................................................................... 1 Introduction .................................................................................................................. ..............[...]

4 Introduction The OutBack P ow er Systems FLEXnet DC The FLEXNet DC collects, monitors and recor ds time -based battery amp, watt and volt data for displa y on the OutBack MA TE series of products, allowing for more accurate set point adjustments and pr ecise batter y rechar ging. F ive LEDs on the FLEXnet DC act as a state - of-charge indicator b[...]

5 Think of the input shunts as breaks or junctions in the DC (-) conductor . The current is conducted as though it were a continuous conductor , but the shunts allow the user to monitor the current, providing inf ormation for more accurate batt er y recharg ing. BA T + BA T - CHARGE CONTROLLER FX INVERTER/CHARGER SHUNT C SHUNT B SHUNT A CHARGE CONT[...]

6 LEDs* 10-postion wiring block 1: BA T - 2: BA T+ 3. Relay 4. Relay 5: C DEVICE SIDE 6: C BA T (-) SIDE 7: B DEVICE SIDE 8: B BA T (-) SIDE 9: A DEVICE SIDE 10: A BA T (-) SIDE • BA T+/- must connect directly to battery terminals of the bank being monitored . • Pr oper polarity must be obser ved on all connections. 1 2 3 4 5 6 7 8 9 10 • Bli[...]

7 The FLEXNet DC package includes: A. FLEXnet DC B. T en-pin wiring plug for shunt, rela y and batter y connections C. Six feet of CA T5 cable for HUB connection D . T en-foot color-coded twisted pair ( TP) cable connects to the batter y E. Thr ee six-f oot, color-coded, twisted pair cables for shunt connections F . T wo #6-32 X 3/8” panhead mach[...]

8 • Inser t the FLEXNet DC inside the DC breaker box and through the back side of the breaker bracket; secure with two #6-32 X 3/8 panhead machine screws (included) torqued at 5 t o 8 inch-pounds • Connect all wires to the ten-pin wiring connector . Do not leave an y loose wires! • C onnect each twisted pair to a shunt. Example: • Battery s[...]

9 • Black/Whit e twisted pair connects directly to the batter y bank being monitored: Whit e to BA T (-) Black to BA T (+) An appropriate fuse—with a rating of 5 amps or less and greater than 100 volts DC—may be placed in the black conduc tor W iring Block Connections Color-coded twisted pair 18 A WG connects the wiring block and shunt(s) or [...]

10 (Installing the FLEXnet DC continued) • Insert the 10-pin connec tor to the wiring block on the back of the FLEXnet DC. • Install the CA T5 cable into the RJ45 jack in the back of the FLEXNet DC. Connect the other end of the cable to the HUB using P ort #2 or higher . • Replace the breaker bracket and secure with its four corner fasteners [...]

11 FLEXNet DC Measurements The FLEXNet DC can measure and recor d: • V olts for one batt er y bank* • Amps** • KiloWatts • kWhrs removed fr om the batteries • kWhrs returned to the batteries • Amp hours removed fr om the batteries • Amp hours returned to the batteries • Batter y bank state- of- charge • Lifetime kiloamp hours remo[...]

12 Logged Data* The previous 128 days of data ar e accessible with the MA TE. The data is logged each night at midnight. Be sure the M A TE’ s clock is set to the correct local time (ref er to your M A TE manual). * Data Logg ing User A djustable Set P oints • Batter y charge factor (65-100%) [see page 29] • Batter y bank capacity 0-10000 amp[...]

13 P rog ramming and Using the MA TE for FLEXNet DC Operations At initial power up , use the MA TE (see pages 17-28) to program: • Batter y Bank 20 Hour Capacity (provided by the manufacturer) in amp hours (from 100- 10,000 amp-hours in ten amp increments) • Batter y charge parameters Return amps: See the manufacturer recommendations or set to [...]

14 FLEXNet DC Modes - Channel A is enabled by default - Each input channel is either enabled or disabled. - A disabled channel will show zero values only . - All enabled channels will run in parallel. - An enabled channel monitors and totals all current  owing into or out of the batter y bank through its shunt. Any DC loads or sour ces wired dir[...]

15 The FLEXnet DC ’ s LEDs indicate the SOC by their individual ON/OFF states. Excluding the RED or last LED , when viewing the remaining f our LEDs—GREEN, YELL O W , YELL O W , AND YELL O W— the f ollowing are true: • All LEDs on = 90-100% SOC GREEN LED blinking— charge parameters met Solid GREEN LED—SOC is above 90% • All but top LE[...]

16 Relay L ogic: • Expressed as NO/NC (Normally Open/Normally Closed), basically o /on • May be controlled via the inv er t logic selection from the M A TE. • T oggling the relay log ic setting changes the logic mode for Hi or L o set points Example: The relay ’ s contac ts are closed when the Hi set point is satis ed and open again w[...]

17 F rom the MAIN M A TE menu, pr ess the <SUM> soft ke y to view a summar y of the system ’ s operation. MA TE Screens DC T oday min/SOC 76% In 347AH 9.040kWH Out 331AH 8.510kWH Bat 16AH 0.530kWH • Minimum SOC today (since midnight) • In: Amp hours and kiloWatt hours fr om sources today • Out: Amp hours and kiloW att hours output by [...]

18 DC BA T 12.5V 99% Bat -0.6A 0.000kW Net -4AH 00.7kWH Days Since Full 4.8 The fourth SUM screen shows: • Batter y voltage • The current state- of- charge • Batter y readings show the instantaneous amp , amp hour , kilowatt, and k ilowatt hour  gures. When compar ing the amp hours reading to “FULL, ” the  gure is charge factor comp[...]

19 The second METER screen shows the accumulated amp hours and kilowatt hours for each shunt. Pr ess the <DOWN> soft key to view the next METER screen. This screen shows the number of remov ed amp hours and watt hours as measured by SHUNT A. P ress the <DO WN> soft ke y to view the SHUNT A charged screen. The fourth meter screen display[...]

20 Pr essing the <DOWN> soft key brings up the SHUNT C charged scr een. Pr essing the <DOWN> soft key leads to the end of the meter menu Pr ess the <ST A TUS> soft k ey to return to the ST A TUS screen. Pr ess the <SHUNT> soft key to view the amps and kilowatts removed and charged in each shunt Pr essing the <DOWN> sof[...]

21 Displaying the kilowatts removed provides the user with more precise ener gy usage information. This  gure can be returned to 0 b y pressing the <RESET> soft ke y . P ress the <DOWN> soft key to view the max charged scr een. SHUNT A shows a maximum of 39.8 amps charged. Pr essing the <RESET> soft key returns this value to 0.[...]

22 ST A TUS/DC/BA T T provides the number of days since the batter y last met its charge parameters . P ress the <RESET> soft ke y to restart the timer . Press the <DOWN> soft key to view the next batter y status screen. batttery min(imum) displays the minimum batter y voltage since it was last reset by the user . Pr essing the <RESE[...]

23 lifetime kAH removed shows the t otal k ilowatt amp hours removed fr om the batter y . This is essentially an “ odometer ” for batter y usage. P ress the <DO WN> soft ke y to continue. ST A TUS/DC/BA T T lifetime kAH removed 5 DOWN UP RESET TOP Pr ess the  rst two soft ke ys to return to the MAIN menu . ST A TUS/DC/BA T T ----------[...]

24 Shunt 1 is, by default, enabled or active when the FX is powered up . P ressing the <DIS> soft key disables the  rst shunt. Pr essing the <DOWN> soft key leads to the shunt 2 mode and shunt 3 mode screens. These shunts are disabled at power-up and ar e enabled by pressing the <EN> soft key . When the setup for all shunts has[...]

25 The return amps screen allows the user t o set the end of charge amps using the <INC> and <DEC> soft keys. Pr ess the <DOWN> soft key to view the batter y charge screen. ADV/DC/CHARGE-------------- return amps DOWN INC DEC TOP ADV/DC/CHARGE--------------- battery charge DOWN INC DEC TOP Pr ess the <CHARGE> soft key. ADV/D[...]

26 ADV/DC/PAGE 1---------------- choose category ADV BA T SHUNT PG2 Pr ess the <PG2> soft key. Use the low volts scr een and the <INC> and <DEC> soft keys to control the A UX by a low voltage value. P ress the <DOWN> soft key to view the SOC high % screen. ADV/DC/AUX LOW VOL T ------ low volts vdc DOWN INC DEC TOP Pr ess the[...]

27 T o activate the invert logic func tion, press the <Y ES> soft k ey ; press the <NO> soft key to deactivate it. Press the <DO WN> soft ke y to view the last A UX screen. ADV/DC/AUX/INVER T --------- invert logic DOWN YES NO TOP Change the SOC low % values using the <INC> and <DEC> soft ke ys. P ress the <DO WN>[...]

28 Pr essing the <RESET> soft key resets the FLEXnet DC to its factor y default settings. Pr essing the <CLR> soft key clears the data log memor y . ADV/DC/AUX/PAGE 3---------- choose category: PG2 RESET CLR MAIN Pr ess the <PG3> soft key. ADV/DC/PAGE 2----------------- choose category: PG1 CHARGE AUX PG3[...]

29 T echnical Not es Battery Charge F actor (BCF) Some energy is lost both when rechar ging and discharg ing a batter y . The FLEXnet DC compensates for these losses by discounting the amp-hours charg ing the batter y , meaning it doesn ’t count every hour used for rechar ging as actually recharg ing. Some of them are lost due to heat and gassing[...]

30 Revision.2007-08-29 2- Y ear Limited W arranty FLEXnet Pr oducts OutBack P ower Systems , Inc. (“OutBack ”) provides a two year (2) limited warranty (“ Warranty ”) against defects in materials and workmanship for its FLEXnet products (“Pr oducts”) if installed in  xed location applications. F or this Warranty to be valid, the P ro[...]

31 T o request warranty ser vice, you must contact OutBack T echnical Ser vices at (360) 435-6030 or suppor t@outbackpower .com within the e ective warrant y period. If warrant y ser vice is required , OutBack will issue a Return Material Authorization (RMA) number . A request for an RMA number r equires all of the following inf ormation: 1. P r[...]

32 T w o Y ear Limited FLEXnet DC W arr anty Registr ation Limited W arranty Registration Complete this form to request a Limited W arranty and return it to: Outback P ower Systems Inc. 19009 62nd Ave . NE Arlington, W A 98223 Note: A Limited Warranty Cer ti cate will only be issued if this Registration Car d is received by OutBack within 90 day[...]

900-0093-01-00 REV B European Sales O c e C/ Castelló , 17 08830 - Sant Boi de Llobregat BARCEL ONA, España Phone: (+34) 93.654.9568 Corporate O c e 19009 62nd Av enue NE Arlington, W A USA Phone: (+1) 360.435.6030 ww w .outback power .com[...]