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EG4 FLEXBOSS21 User Manual

Hybrid inverter
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E G 4
F L E X B O S S 2 1
®
H Y B R I D I N V E R T E R
U S E R M A N U A L
©2024 EG4® ELECTRONICS, LLC. ALL RIGHTS RESERVED.
VERSION 1.0| INFORMATION SUBJECT TO CHANGE WITHOUT NOTICE.
MODEL#: IV-16000-HYB-AW-FX-00

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Summary of Contents for EG4 FLEXBOSS21

  • Page 1 H Y B R I D I N V E R T E R U S E R M A N U A L ©2024 EG4® ELECTRONICS, LLC. ALL RIGHTS RESERVED. VERSION 1.0| INFORMATION SUBJECT TO CHANGE WITHOUT NOTICE. MODEL#: IV-16000-HYB-AW-FX-00...

  • Page 3: Table Of Contents

    10.3 EG4® MONITOR APP SETUP ........................25 10.4 ENABLE APP NOTIFICATIONS ........................26 10.5 LOCAL MONITORING SETUP WITH THE EG4® MONITOR APP ............28 10.6 THIRD-PARTY RS485 COMMUNICATION ....................29 MONITOR CENTER SETTINGS ..........................30 11.1 COMMON SETTING ............................30 11.2...

  • Page 5: Technical Specifications

    1. TECHNICAL SPECIFICATIONS AC INPUT DATA 120/240VAC; 120/208VAC (L1/L2/N required) NOMINAL AC VOLTAGE FREQUENCY 60 Hz Default | 50 Hz Capable MAX. AC CURRENT 50A @ 240V | 57.7A @ 208V 12kW MAX. AC INPUT POWER MAX. AC BYPASS AC GRID OUTPUT DATA 66.7A MAX.
  • Page 6 CSA 22.2.107.1:2016 Ed. 4 CSA 22.2.330:2017 Ed. 1 IEEE 1547.1:2020; IEEE 1547:2018 Hawaii Rule 14H [HECO SRD IEEE1547.1-2020 Ed. 2] Rapid Shut Down (RSD) NEC 2020:690.12 (PENDING) FCC Part 15, Class B (PENDING) *See EG4 Warranty Registration for terms and conditions. ®...

  • Page 7: Abbreviations

    2. ABBREVIATIONS • In-lbs. – Inch Pounds • AWG – American Wire Gauge • kW – Kilowatt • A – Amps • kWh – Kilowatt-hour • Ah – Amp hour(s) • LCD – Liquid Crystal Display • AC – Alternating Current LFP –...

  • Page 8: Inverter Safety

    3. INVERTER SAFETY SAFETY INSTRUCTIONS International safety regulations have been strictly observed in the design and testing of the inverter. Before beginning any work, carefully read all safety instructions, and always observe them when working on or with the inverter. The installation must follow all applicable national or local standards and regulations.
  • Page 9 WARNING: TO REDUCE THE RISK OF INJURY, READ ALL INSTRUCTIONS! All work on this product (system design, installation, operation, setting, configuration, and maintenance) must be carried out by qualified personnel. To reduce the risk of electric shock, do not perform any servicing other than those specified in the operating instructions unless qualified to do so.

  • Page 10: Packing List

    4. PACKING LIST When the product is unpacked, the contents should match the list below. Wi-Fi Dongle Keys 1” CT (×2) L Bracket (×2) RJ45 Terminals Wall Mount Mounting Bracket Phillips Head (×4) Template Screw M3×10 (×4) Hybrid Inverter Battery Communication Phillips Head Self-Tapping Expansion Bolts...

  • Page 11: Product Dimensions

    5. PRODUCT DIMENSIONS 22.28 in. (566 mm)
  • Page 12 Back View of the Cable Box Knockouts Bottom View of Cable Box Knockouts U.S. NOM. TRADE SIZE ACTUAL KO SIZE ACTUAL KO SIZE 1/2 in. 0.88 in. 22.2 mm 3/4 in. 1.11 in. 28.2 mm 1 in. 1.38 in. 34.9 mm 1-1/4 in.

  • Page 13: Product Overview

    6.2 OPERATION OVERVIEW The information below provides a high-level overview of the general operation of the inverter. FlexBOSS21 is a split-phase hybrid inverter that has the ability to operate off and on the grid. • Designed for rural and suburban homeowners, and small commercial companies seeking •...

  • Page 14: System Diagrams

    6.3 SYSTEM DIAGRAMS This unit and its associated system are suitable for the following applications: On-grid solar system without battery Off-grid and back up applications Single and three phase paralleling system Energy storage system with peak shaving function Solar and battery storage system...

  • Page 15: System Installation

    7. SYSTEM INSTALLATION 7.1 TOOLS NEEDED FOR INSTALLATION Hand truck with all-terrain tires 14 mm or 9/16 socket for anchors • • Tape measure 13 mm or 1/2 socket for lag screws • • Drill and drill bits (5/15) Level •...

  • Page 17: Location Selection And Installation

    7.2 LOCATION SELECTION AND INSTALLATION Requirements for installation location DANGER: Ensure there is at least 15.8 inches of space around the inverter for heat to dissipate or else there is a risk of fire. Ensure the inverter is mounted away from all combustible materials.

  • Page 18: Installing The Inverter

    3. Never position the inverter in direct sunlight, rain, or snow. Refer to the figure below and choose a well-shaded site or a shed to protect the inverter from the elements. The inverter should be installed upright on a vertical surface. Installing the Inverter The inverter is designed to be wall-mounted on a vertical, solid non-combustible surface such as brick or concrete.

  • Page 19: Mounting Steps

    Mounting Steps: 1. Select a location for the inverter’s final placement. 2. Use the wall mounting template to mark where the mounting bracket screws will be installed. Use a level to ensure the bracket will be installed straight. When installing the bracket to studs, verify the marks for the screws (not included) are centered over a stud.
  • Page 20 6. Temporarily mount the L bracket to the side of the inverter (located at the bottom, one on each side). Mark holes on the wall based on the hole location on the right-angled bracket (repeat this step for both sides). 7.

  • Page 21: Connection Overview

    7.3 CONNECTION OVERVIEW To expose the cable box area, open the bottom cover by opening the two clasps on the side of the inverter. Once the cover is open, follow the sections below for connecting the wiring for PV, battery, AC, parallelled inverters, and Rapid Shut Down.
  • Page 22 Communications Board Overview: A. Reserved H. Meter 485B & 485A: For meter B. Parallel DIP Switches: Set DIP switches communication when using inverters in parallel NTC: Connection for temperature sensor C. Battery Communication Port (CAN & of lead-acid battery RS485) J.

  • Page 23: Pv Connection

    7.4 PV CONNECTION Cable Requirements*: Cable Size Minimum Insulator Voltage 10 AWG – 6 AWG (Max.) (6 mm – 16 mm 600V *Consult installer to ensure that appropriate cable sizing is used due to various factors such as distance and operating voltage and amperage. IMPORTANT •...

  • Page 24: String Sizing

    String Sizing MPPT1 MPPT2 MPPT3 • Each string should ideally contain the same model, brand, and quantity of panels for ease of design, racking, and wiring. However, varying string sizes can be used for unique MPPTs. If two strings are used for MPPT1, they MUST be the same model, brand, and number per string.
  • Page 25 NOTE: For all modules, the calculations need to be performed or verified by using a string calculator or consulting a professional. DANGER: DAMAGE WILL OCCUR if the string voltage on a cold, sunny morning exceeds the inverter’s maximum input voltage of 600V! The array can have a higher Imp than the 26A/15A specified, but the MPPTs will not make full use of the extra current.

  • Page 26: Connecting Batteries To The Inverter

    7.5 CONNECTING BATTERIES TO THE INVERTER The FlexBOSS21 comes equipped with two battery positive terminals and two battery negative terminals. Each of the two positive battery terminals are protected by a 300 amp breaker. This is to accommodate using parallel conductors as supplied with the WallMount battery series. It is designed to utilize 4/0 battery cables up to 20 feet by using two sets of cables rather than resorting to larger cable sized.

  • Page 27: Cable Installation

    LifePower4 batteries in the system, a firmware update may be required for closed-loop communications. Contact the distributor for this file or navigate to https://www.eg4electronics.com/ for the most recent updates and documentation. For communication with EG4 batteries, select “Lithium” under “Battery Type” and then select “0:EG4” under “Lithium Batteries”...

  • Page 28: Pin Description

    “Maintenance”, “Remote Set”, and choose battery type under “Common Settings.” For Lithium Battery: Be sure that the lithium battery being used is compatible with the inverter. EG4 ® strongly • recommends using closed-loop communications between the battery bank and inverter.

  • Page 29: Ac Wiring Information

    7.6 AC WIRING INFORMATION When sizing AC wires, adhere to the following information: Terminal Max. Amperage Cable Size Torque Values Connection Rating 6 – 4/0 AWG 95 – 165 in-lbs. Grid (26.7 mm – 107mm (10.7Nm – 18.6Nm) depending on wire 6 –...
  • Page 30 Steps for AC Connection: The FlexBOSS21 comes equipped with a L1 and L2 terminal for AC input (labeled GRID) and output (labeled LOAD). It is designed to utilize up to 50A of input and up to 66.7A of output. These terminals ARE NOT connected to a breaker;...
  • Page 31 Refer to the connection diagram to the right for the correct position of the CTs. Clamp the 2 CTs onto the L1 and L2 wires at the service entry point in the main service panel as close to the meter base as possible.

  • Page 32: Parallel System Connection

    7.7 PARALLEL SYSTEM CONNECTION REMINDER: • All setting changes for parallel inverters must be done while in Standby Mode. • If the system is connected to a lithium battery, the host battery must communicate with the inverter that is set as master in the parallel system. •...

  • Page 33: Parallel Configuration

    DIP switch configurations are correct. Power on the inverters. • • Login to the Monitor Center Website or the EG4 ® Electronics app. See section 10 for more information on how to access these and detailed information on how to use the app and website.
  • Page 34 Commissioning Steps via the Monitor Center Website: 1. On the Monitor Center Website, select which unit to set as the Master in the drop-down menu at the top of the page. 2. Select “Maintenance” and scroll to “Application Setting”. 3. Select “1 Phase” or “3 Phase Master” under “Set System Type” (a three-phase system must have three or more inverters).

  • Page 35: Grid, Load, And Ac Information

    Commissioning Steps via the EG4 ® App: 1. On the EG4 ® Electronics App, select the settings icon. 2. At the top, select the device to set as the Master in the drop-down menu. 3. Toggle the “Standby/Normal” setting off.

  • Page 36: Ess Disconnect/Rapid Shutdown (Rsd)

    AC Output along with dropping the PV Conductors voltage to <30V in 30 seconds. NOTE: When using supported EG4 ® batteries in closed-loop communications with the inverter, the RSD also initiates ESS Disconnect as required by NEC code.

  • Page 37: Inverter Start-Up And Shutdown Procedure

    8. INVERTER START-UP AND SHUTDOWN PROCEDURE Starting up the inverter: 1. If equipped, turn on (close) the DC breaker between the battery bank and inverter first. Turn on the BAT breaker located in the cable box of the inverter and then power on the battery system.

  • Page 38: Working With A Gridboss

    9. WORKING WITH A GRIDBOSS...

  • Page 39: Monitor System Setup

    While the FlexBOSS21 is a hybrid inverter that is capable of functioning on its own, EG4 ® GridBOSS allows for more flexibility and functionality. Function Description AC Coupling Allows the user to pair the FlexBOSS21 and GridBOSS with an existing solar system.

  • Page 40: Wi-Fi/4G Dongle Connection

    Attach this module by plugging it in to the side of the inverter and securing it with the four (4) Phillips head screws. View data on a mobile device: A QR code with a link to the EG4 ® website with app installation steps can be found on the side of the inverter.

  • Page 41: Eg4® Monitor App Setup

    10.3 EG4® MONITOR APP SETUP Register a monitoring account and set the Wi-Fi password for the Wi-Fi dongle before using EG4's monitoring system. 1. Register an account: Visit monitor.eg4electronics.com or download the “EG4 Monitor” app to ® register for an end-user account. Contact support@eg4electronics.com...

  • Page 42: Enable App Notifications

    Return to the login page and input account and password to begin monitoring the system. 10.4 ENABLE APP NOTIFICATIONS The EG4 ® Mobile App allows the end-user to easily check real-time system information regarding the inverters, batteries, and other informative values.
  • Page 43 4. Choose which settings to enable, and at what values to be notified. Select “Edit”. Enable Notifications on a Mobile Device: NOTE: Make sure the app is up to date before beginning! 1. Login to the EG4 ® Monitor App. Select the user icon at the top right corner of the screen.

  • Page 44: Local Monitoring Setup With The Eg4® Monitor App

    Toggle selection on to “Allow Notifications” on device and choose how to receive notifications. 10.5 LOCAL MONITORING SETUP WITH THE EG4® MONITOR APP If there is no Wi-Fi available at the location, use the local function to monitor or set up the system: 1.

  • Page 45: Third-Party Rs485 Communication

    10.6 THIRD-PARTY RS485 COMMUNICATION INV485 is shared with the Wi-Fi module. If the Wi-Fi module is not in use, this interface can be used to communicate with the inverter. Relay 485B and 485A are used for third-party communication systems using the RS485 Modbus protocol.

  • Page 46: Monitor Center Settings

    The following settings are found on the Monitor Center Website at monitor.eg4electronics.com under the Maintenance tab. For more information, scan the following QR code: EG4 Monitor Center Overview 11.1 COMMON SETTING Time: Set the time/date of the inverter. The input format is 2019-02-14 14:44:00 (YYYY-MM-DD •...

  • Page 47: Application Settings

    Firmware version: • • LCD Version: 11.2 APPLICATION SETTINGS No Batteries: Allows access to Off-Grid mode when there is no battery and solar is the only • input available. Power Backup: If Power Backup function is Enabled, the LOAD terminal will maintain output •...

  • Page 48: Grid Connect Setting

    System Charge SOC/Volt Limit: Set charge limits based on SOC or Voltage. • Parallel Settings Set System Type: The EG4 FlexBoss 21 supports paralleling of multiple inverters; connect • the LOAD terminals together for paralleling. In this scenario, set one of the inverters to Master and the others to Slave.

  • Page 49: Charge Settings

    11.4 CHARGE SETTINGS Batt Charge Control (Volt/SOC): Batt Charge Control will charge the battery bank according • to Voltage/SOC% depending on selection. Charge Last: Charges battery as a last priority • Charge Current Limit (Amps DC): Users can set the maximum battery charge current. •...

  • Page 50: Discharge Settings

    • Off-Grid Discharge Cut-Off SOC(%)/Volt(V): Select how low to drain battery bank before going on-grid and allow battery bank to charge. With EG4 batteries, do not allow this value to go below 20%. Forced Discharge Forced Discharge Enable/Disable: If the customer wants to discharge the battery, enable •...

  • Page 51: Working Modes And Related Settings

    Peak Shaving Grid Peak-Shaving: Peak-Shaving is used to avoid peak demand charges from the grid. • Peak shaving can be accomplished by halting Grid Charging at specific times. For example, during periods of peak demand (i.e., high grid rates), or when the batteries are fully charged based on SOC/Voltage.
  • Page 52 To enable this feature, select “Maintenance” at the top of the Monitor Center Webpage. Select “Weather Optimization” to the left of the screen. Select the desired inverter and click the location button. Input the inverter’s information on the next screen and select update. •...

  • Page 53: Working Mode Setting

    Working Modes: Working modes are pre-set priority systems that allow users to configure the system to meet their demands through extensive customizations. These modes can be found under the Maintenance tab by clicking “Working Mode.” Scroll past “Application Setting” to the “Working Mode Setting” section. Working Mode Definitions: Peak Shaving: Used to avoid peak demand charges from the grid by using a combination of •...
  • Page 54 Peak Shaving • Grid Peak-Shaving Enable or disable grid peak-shaving. Grid Peak-Shaving Power(kW)/Grid Peak-Shaving Power2(kW) • Set the maximum amount of power that will be drawn from the grid. Start Peak-Shaving Volt 1(V)/Start Peak-Shaving Volt 2(V) • Set the starting point of peak-shaving when using voltage setpoints for batteries. Start Peak-Shaving SOC 1(%)/Start Peak-Shaving SOC 2(%) •...
  • Page 55 AC Charge Mode: AC Charge Enable • Enable or disable the system’s ability to charge batteries from the grid. • AC Charge Power(kw) Set the maximum power drawn from the grid to charge batteries. AC Charge Based On (SOC/Volt/Time) • Configure how the system will charge batteries from the grid by setting custom voltage points, SOC% of batteries, or by time.
  • Page 56 PV Charge Priority: The order of priority for solar power usage will be Battery -->Load -->Grid. During the “PV Charge Priority” period, loads are first supplied power from the grid. If there is excess solar power after charging batteries, the excess solar will power the loads along with grid power. Solar power will be used to charge the battery bank first.
  • Page 57 Forced Discharge/Export PV Only: Forced Discharge Enable • Enable this setting to forcefully discharge the station’s battery bank. Export PV Only • Enable this setting to sell back generated PV power to the grid. Forced Discharge Power(kW) • Set the maximum power limit of battery discharge. Stop Discharge SOC(%) •...
  • Page 58 Self-Consumption: The station will default to Self-Consumption mode. The order of priority for powering loads is Solar > Battery > Grid. The order priority for solar power is Load > Battery > Grid which creates an ideal scenario when needing to prioritize solar power generation over other types of power. Self-usage mode will increase the self-consumption rate of solar power and reduce energy bills significantly.

  • Page 59: Firmware Updates

    While the update is ongoing, do not close the application. Ensure the Wi-Fi dongle is securely connected and correctly configured (see Section 10.1 for details) before performing the following steps: 1. Open the EG4 Electronics app on a mobile device and select the “DOWNLOAD FIRMWARE” button.

  • Page 60: Firmware Update Via Monitor Center (Website)

    ® system. Contact EG4 to make sure the files are correct. 2. Log in to the EG4 Electronics Monitor System. Select “Maintenance,” and then select “Remote Update.” 3. Choose the inverter to update and then select “Standard Update”. The Monitor Center will begin updating both firmware files in the inverter.

  • Page 61: Regular Maintenance

    2. Prior to setting the password, add the dongle to the system. After registering and entering the Wi-Fi SN and PIN, the dongle is automatically added to the system. While logged in, go to the “Configuration” tab. Select “Dongles”, and “Add dongle, on monitor.eg4electronics.com to add this dongle to the current configuration if there...

  • Page 62: Led Description

    14.3 LED DESCRIPTION If a warning or fault occurs, users can troubleshoot according to the LED status description and the warning/fault information found in the “Event History” tab on the App or Monitor Center website. Display Description Action Solid lit Working normally No action needed Green LED...

  • Page 63: Fault And Alarm Lists

    14.4 FAULT AND ALARM LISTS Fault Meaning Troubleshooting M3 microprocessor fails to receive data M3 Rx failure Restart the inverter. If the error persists, from DSP contact the supplier. Model fault Incorrect model value Check if the L1, L2, and N wires are connected correctly at the inverter Inverter detected short-circuit on load load output terminal.
  • Page 64 If a Master has been configured in the system, the fault will automatically be removed after the Master works. If a Master has not been configured Para master loss No Master in the parallel system and there are only Slaves in the system, set the Master first.

  • Page 65: Standards And Certifications

    Master and set the other as Slave. 15. STANDARDS AND CERTIFICATIONS The EG4 ® FlexBOSS21 is ETL & cETL listed and complies with national and international standards for safety and reliability when connected to the grid. Safety • UL1741, SA, SB •...

  • Page 66: Grid Connection

    Grid Connection • IEEE 1547.1:2020; IEEE 1547:2018 • Hawaii Rule 14H [HECO SRD IEEE 1547.1-2020 Ed. 2] California Rule 21 Phase I, II, III • • FCC Part 15 Class B (PENDING) Outdoor Rating • NEMA 4X/IP65...

  • Page 67: Eg4® 10-Year Limited Warranty

    EG4 shall not be liable for any direct or indirect loss of life, including but not limited to bodily injury, illness, or death arising from the misuse or mishandling of the product, whether caused by negligence or otherwise.
  • Page 68 NOTES...
  • Page 69 NOTES...
  • Page 70 CONTACT US support@eg4electronics.com (903) 609-1988 www.eg4electronics.com...

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