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Rugged Water Resistant
Inverter / Charger
OBX-IC2024S-120/60
Owner’s Manual
Installation and Operation
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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. Contact Information Telephone: (+1) 360.435.6030 (North America) Fax: (+1) 360.435.6019 (+34) 93.654.9568 (Barcelona, Spain) Address: North America 19009 62nd Avenue NE Arlin
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TABLE OF CONTENTS Welcome to the OutBack Extreme Rugged Water Resistant Inverter/Charger ............................................2 Parts Included................................................................................................................................................................ ........................3 Unit Dimensions...................................................................................................................................................
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Welcome to the OutBack Extreme Rugged Water Resistant Inverter/Charger The OutBack Extreme Rugged Water Resistant Inverter/Charger (hereafter called the Inverter) provides 120 Vac, 60 Hz, true-sine wave power, from a 24 Vdc battery source. It is designed for rugged operational environments in an unprotected, uncontrolled climate. This equipment is intended for use on tracked and wheeled vehicles, and above deck and other areas where it will be exposed to unfavorable conditions. OutBack Po
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Parts Included Standard with the OutBack Extreme Rugged Water Resistant Inverter/Charger, Model OBX-IC2024S-120/60: • One O wner ’ s M anual • One DC C o v er (DC C ) • One r ed (positiv e) and one black (nega tiv e) ba tt er y t er minal cap Additional parts, included when purchasing the complete system OBX-IC2024S-120/60-K2: • One O utBack M A TE2 S y st em C on tr oller and Displa y • One NA T O Ba tt er y C able C onnec t or , un wir ed • T w o 2/0 ba tt er y cables (one positiv e and
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R EA D F IR ST ! IMPORTANT SAFETY INSTRUCTIONS READ FIRST! SAVE THESE INSTRUCTIONS Read all instructions and cautionary markings on the Inverter, 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 anyone comes in contact with electricity. Install all components and wiring according
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IMPORTANT BATTERY INSTRUCTIONS WARNING: WORKING NEAR LEAD ACID BATTERIES CAN BE DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL OPERATION. 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 flow of hydrogen to the vent opening. CAUTION To reduce risk of injury, charge only deep-cycle lead aci
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16.25” (41.27 cm) Insert fasteners at all four corners of the Inverter for a secure installation. MOUNTING • T he I n v er t er w eighs 57.5 lbs (26.08 kg) and must be secur ed with appr opr ia t e fast eners t o a stur dy mounting surface capable of supporting its weight. Depending on application, it may be easier for two people to install the unit due to the Inverter’s weight. • If internally mounted (protected from the environment), the Inverter can be mounted in any position or ori
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SYSTEM PROTECTION Electrical systems are designed to protect you, the wires, the components, and the devices served by the system. • Each Inverter must be part of a permanently grounded electrical system (see below). Grounding protects people and equipment from electrical shock. Grounding must be performed according to required codes and regulations. • Circuit breakers protect wiring by limiting the amount of current entering a system. All wired electrical systems require
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WIRE CONNECTIONS DC Wiring The Inverter uses DC brass battery terminals with 8M x 1.00 stainless steel threaded studs. You can access the terminals by removing the four screws that attach the DC cover plate, and pulling it off. Black terminal = battery negative Red terminal=battery positive Battery terminal covers Stud Nut Lock Washer Battery Cable Lug Flat Washer Insulator • Never install extra washers or any other hardware between the terminal mounting surface and the battery cable lug—the
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BATTERY WIRING In DC systems, batteries are connected to each other in one of three ways: • Series (voltage increases, amperage stays the same as a single battery) • Parallel (voltage stays the same as a single battery, amperage increases) • Series/Parallel (both voltage and amperage increase) - - - - 12 V/200 amp-hours 12 V/200 amp-hours 12 V/200 amp-hours 12 V/200 amp-hours 12 V + 12 V + 12 V + 12 V = 48 V Amp-hours remain at 200 - - - - 12 V/200 amp-h
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6 V Battery Wiring Examples for a 24-volt system - - - - 6 V/200 amp-hours 6 V/200 amp-hours 6 V/200 amp-hours 6 V/200 amp-hours DC DISCONNECT (FUSE OR CIRCUIT BREAKER) - 24-volt Inverter SERIES: 200 amp-hours - - - - 6 V/200 amp-hours 6 V/200 amp-hours 6 V/200 amp-hours 6 V/200 amp-hours SERIES STRING 1 SERIES STRING 1 CONNECTS TO INVERTER’S POSITIVE TERMINAL - - - - 6 V/200 amp-hours 6 V/200 amp-hours 6 V/200 amp-hours 6 V/200 amp-hours SERIES STRING 2 DC DISCONNECT (FUSE OR CIRCUIT SERIES
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12 V Battery Wiring Examples for a 24-volt system - - 12 V/200 12 V/200 amp-hours amp-hours DC DISCONNECT (FUSE OR CIRCUIT BREAKER) - 24-volt Inverter SERIES: 200 amp-hours - - 12 V/200 amp-hours 12 V/200 amp-hours SERIES STRING 1 CONNECTS TO SERIES STRING 1 INVERTER’S POSITIVE TERMINAL - - 12 V/200 amp-hours 12 V/200 amp-hours SERIES STRING 2 DC DISCONNECT (FUSE OR CIRCUIT BREAKER) - SERIES/PARALLEL: 400 amp-hours 24-volt Inverter 11
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AC Wiring Connector Plate • AC OUT SOCKET— Maxicon circular molded watertight connector supplies power to the loads using the provided AC cable and plug. • AC IN SOCKET — Maxicon circular molded watertight connector supplies incoming AC from the grid or a generator to the Inverter. This AC is used to run loads and recharge batteries. • MATE (REMOTE) SOCKET — Minicon circular molded watertight connector provides an interface with the optional MATE2 System Controller and Display. Wh
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Follow these steps to wire the Inverter to your system: 1. Open all DC breakers or remove any fuses before connecting wiring. 2. Open all AC breakers or remove any fuses before connecting wiring. 3. With all power off, connect the AC IN Maxicon plug wires to the AC source. The AC input wires should have a (maximum) 30-amp AC breaker to provide overcurrent protection. The AC IN Maxicon plug has a total of six conductors. Two are black, two are white, one is green, and one is green with a y
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locking collar AC OUT PLUG AC IN PLUG MATE PLUG To connect cables to the Connector Plate sockets: Position each cable plug over the appropriate jack. The cables are easy to tell apart, as the AC In plug has six pins, the AC Out plug only has five, and the MATE plug is smaller than the others. Match each cable to its matching jack and fit the plugs into the jacks. If necessary, twist the plugs back and forth until they fit, and then push them in until they seat in place. (The plugs are key
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THE MATE2 SYSTEM CONTROLLER AND DISPLAY The MATE serves several functions: • Allows you to monitor the Inverter through a series of convenient display screens. These display the status messages, and allow you to take both DC (voltage) and AC (voltage and current) meter readings. • Enables you to troubleshoot problems with the Inverter and the rest of your system, by looking up warning and fault messages. • The MATE allows a user to view, monitor, and establish all the pertinent settings
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INVERTER CONTROL Currently: ON OFF SRCH ON OK HOT KEYS “Hot” keys have fixed functions. Pressing a hot key always takes you to the same menu or series of menus. INV Hot Key The INV hot key takes you to the Inverter Control screen, allowing direct control of the inverting function from anywhere in the menu system. (The inverting function is defined as the process of converting DC to AC, as compared to the charging or other functions.) MAIN----------------------
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AC INPUT CONTROL currently: USE DROP USE OK GEN START CONTROL currently: MAN-OFF OFF AUTO ON OK AC IN Hot Key The AC IN hot key allows direct control of the AC input from anywhere in the menu system. MAIN-------------------------- AC IN 1:35:04p Hot SUM STATUS SETUP ADV Key The yellow LED indicator above the AC IN “hot” key has three modes: • Flashing - an AC source is available, but not connected •
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CHARGER CONTROL currently: AUTO OFF AUTO ON OK CHARGER MODE CONTROL global charger mode BULK EQ OK EQUALIZE CONTROL eq enabled START STOP OK BULK CONTROL START STOP OK BULK CONTROL BULK CONTROL bulk charge stopped bulk charge started OK MAIN OK MAIN PRESS THREE TIMES: • The CHARGER CONTROL screen appears. This allows the operation of
