Outback FX-Class Betriebsanleitung
900-0107-01-00 Rev A 1
FX-Class and FXR-Class
Inverter/Charger
Service Instructions
Purpose and Scope
These instructions detail how to remove and replace the following parts of any FX-class or
FXR-class inverter/charger.
Control Printed-Circuit Board Assembly (PCBA)
AC Printed-Circuit Board Assembly (PCBA)
FET Printed-Circuit Board Assembly (PCBA)
Ribbon Cables
These instructions extend to all FX, FXR, VFX, VFXR, GTFX, GVFX, and GFX models, including all
mobile and international models.
Tools Required
#2 Phillips screwdriver
3/8” flat blade screwdriver
4mm hex wrench (included)
Strap wrench
Long-nose pliers
10mm socket with 12” extension & torque wrench
10mm wrench (standard and torque)
Power supply (9-volt batteries may be used)
Voltmeter or DVM
Disassembly
This procedure describes the removal of all circuit boards in an FX-class or FXR-class inverter. The
exact steps and order may vary with the repairs needed.
The order of removal depicted here is:
1. Control PCBA
2. AC PCBA
3. FET PCBA
If not all boards need to be replaced, the installer may proceed through the steps that are required
and ignore the subsequent disassembly. (Note that replacing the AC PCBA requires removal of the
Control PCBA regardless of any other steps.)
The installer should then proceed to the reassembly and testing steps, which begin on page 7.
FX-Class and FXR-Class
2 900-0107-01-00 Rev A
To disassemble the inverter:
1. Disconnect power; turn off all DC and AC sources to the inverter.
2. Remove the DC Cover or Turbo Fan. Remove the battery terminal covers. Using a #2 Phillips
screwdriver, remove the two screws attaching the AC Cover as shown in Figure 1. Remove the rubber
washers, rubber grommet, and AC Cover as shown in Figure 1.
Figure 1 AC Cover & Access Plate
3. Remove the AC Plate. See Figure 1.
4. Disconnect all AC and DC wiring to the inverter. Using a meter, verify that no AC or DC voltage is present.
5. Using the strap wrench, remove the red and black ring nuts located on the battery terminals. See Figure 2.
NOTE: If the ring nuts are too tight, a hammer and flat screwdriver may be used to tap the ring nuts
counterclockwise. A small pipe wrench may be used. Cover the jaws of the wrench with tape to
minimize damage to the plastic nuts.
Figure 2 Ring Nuts
Grommet Screw
Washer
AC Plate
Screw
Ring Nuts
Part Replacement Instructions
900-0107-01-00 Rev A 3
6. Using a #2 Phillips screwdriver, remove the 6 screws located in the AC wiring compartment. See Figure 3.
Figure 3 AC Compartment Screws
7. Using the 4mm hex wrench, remove all 8 hex bolts that connect the top cover to the bottom chassis of
the inverter. The locations of these bolts are shown in Figure 4.
IMPORTANT:
After removing the hex bolts, read the next step carefully before removing the cover.
CAUTION: Equipment Damage
Inverter components will be damaged if the cover is removed too quickly. The cover
and fan are wired to the internal FET board with a PCB connector. See Figure 5.
Figure 4 Top Cover Hex Bolts
8. Carefully lift the inverter cover, just far enough to locate the fan wire.
Screws
FX-Class and FXR-Class
4 900-0107-01-00 Rev A
9. Disconnect the fan wire. The connector locations are different for FX-class and FXR-class inverters. The
locations are shown in Figure 5.
Figure 5 Fan Connector
10. Remove the top cover and set it aside.
11. Remove the O-rings that are seated on the battery terminals. Remove the gasket located on top of the
AC PCBA. See Figure 6.
NOTE: A larger O-ring travels the perimeter of the chassis and may come off during disassembly. If so,
reinstall the O-ring during reassembly.
Figure 6 Gasket and O-Rings
12. Remove the two ribbon cables that join all three circuit boards. One cable connects the FET PCBA to the
Control PCBA. The other connects the AC PCBA to the Control PCBA.
To remove the ribbon cables, release the levers on each connector that holds the cable in place. The
locations of the cable connectors are shown in Figure 7 and Figure 8.
PCB Connector
(FX-class)
PCB Connector (FXR-class)
Battery Terminal O-Rings
AC Compartment Gasket
Inverter O-Ring
Part Replacement Instructions
900-0107-01-00 Rev A 5
Figure 7 FET to Control Ribbon Cable
Figure 8 AC to Control Ribbon Cable
13. Gently lift the AC PCBA until there is resistance from the AC output wires connected to the AC
Assembly. Pull out the Control PCBA. See Figure 9.
NOTE: No more disassembly is needed if the Control PCBA is the only board to be replaced.
Figure 9 Removing the Control PCBA
Levers
NOTE: Two other levers are located
below the chassis lip.
Levers
NOTE: Two other levers are located
below the chassis lip.
Lift AC PCBA
Remove Control PCBA
FX-Class and FXR-Class
6
900-0107-01-00 Rev A
14. Before removing the AC PCBA, using a pair of long-nose pliers, disconnect the white and black AC
output wires connected at the bottom of the board. (See Figure 10 for the location of the wire
connectors.) Remove the AC PCBA.
NOTE: No more disassembly is needed if the AC and/or Control PCBA are the only boards to be replaced.
Figure 10 AC Output Wires
15. Remove the two bolts that connect the FET PCBA to the transformer. Use the 10mm socket with 12”
extension on bolt #1 and two 10mm wrenches on Bolt #2. See Figure 11.
Figure 11 Bolt Removal
16. Remove the thermistor wire from the FET PCBA. Figure 12 shows the location of the connector.
CAUTION: Equipment Damage
The thermistor wire must be disconnected before removing the FET PCBA from the
inverter. Failure to do so will destroy the thermistor wire when it is pulled out. It will
also damage the connections.
Transformer Neutral (White)
Transformer Hot (Black)
Gap (see page 8)
Bolt #1
FET Bus Bar to
Transformer Bus Bar
Bolt #2
FET Idle Arm to Transformer
Idle Arm
Part Replacement Instructions
900-0107-01-00 Rev A 7
Figure 12 Thermistor Connection
17. Remove the FET PCBA.
Assembly
The order of assembly depicted here is:
1. FET PCBA
2. AC PCBA
3. Control PCBA
If the FET and or AC boards do not need to be replaced or have not been removed, the installer
may ignore these steps and proceed through the steps that are required. The installer should then
proceed to the testing steps, which begin on page 11.
To assemble the inverter:
1. Check the replacement FET PCBA to see if a thermistor clip was installed. (See Figure 12.) If one is
present, remove it and discard.
2. Guide the FET PCBA into the proper slot of the chassis; lower it only halfway down. Plug the green
thermistor wire from the transformer into the FET PCBA. (See Figure 12 for the location of this
connector.) Push the FET PCBA all the way down into the chassis.
IMPORTANT:
Ensure that the AC wires from the transformer (see step 5) are routed through the gap
on the bottom of the FET PCBA. Routing them elsewhere may pinch the wires and
could cause the inverter to fail.
Thermistor
Connection
FX-Class and FXR-Class
8
900-0107-01-00 Rev A
3. Before bolting down the FET PCBA, it may be necessary to loosen the bolt that mounts the transformer
bus bar to the transformer. Loosening this bolt will make it easier to align the FET PCBA correctly.
See Figure 13.
Figure 13 Loosen Bolt
4. Once the FET PCBA is aligned, tighten all bolts to a torque value of 72 in-lb.
5. Guide the AC PCBA half way down into the chassis. Attach the AC output wires to their connectors. The
black wire connects to terminal XFMR HOT. The white wire connects to XFMR NEU. See Figure 14 (and
also Figure 10 if necessary) for the location of the wire connectors.
Figure 14 AC PCBA and Control PCBA
AC PCBA
Control PCBA
Lip
XFMR NEU (White wire)
XFMR HOT (Black wire)
Lip
Copper Prongs
Part Replacement Instructions
900-0107-01-00 Rev A 9
6. With the AC PCBA lifted as high as possible, guide the Control PCBA into its slot in the chassis. Lower
the AC PCBA over the top of the Control PCBA. As shown in Figure 14, there is a “lip” on the AC PCBA
that fits over the top of the Control PCBA.
IMPORTANT:
Ensure the AC wires from the transformer (see step 5) are routed through the gap
on the bottom of the AC PCBA. (See Figure 10.) Routing them elsewhere will
pinch the wires and could cause the inverter to fail.
Ensure that the copper prongs on the AC PCBA do not pinch the output wires
when the board is lowered into place.
7. Once each PCBA is seated and secured in the chassis, re-attach the ribbon cables to the boards.
NOTE: FX-class inverters use two identical cables with 34 pins. Ensure that the cables are bent as
shown in Figure 15 so that they can be routed correctly inside the inverter.
NOTE: FXR-class inverters do not have identical cables. Do not confuse them. The cable between the
AC PCBA and Control PCBA has 34 pins. The cable between the FET PCBA and Control PCBA has 40 pins.
Ensure the cables are bent as shown in Figure 15 so that they can be routed correctly inside the inverter.
Figure 15 Ribbon Cables
8. Install the ribbon cable that is bent on one end to the FET PCBA and the Control PCBA. (See Figure 16 and
also Figure 7 if necessary.) In the FX inverter, this cable has 34 pins. In the FXR inverter, it has 40 pins.
Make sure the red stripe is oriented toward the top of the chassis. Push down on each end until the levers
click and the plug is secure.
Figure 16 FET to Control Ribbon Cable
AC to Control
Ribbon Cable
(34 pins)
FET to Control
Ribbon Cable
(34 pins for FX,
40 pins for FXR)
Red Stripe to Top
Red Stripe to Bottom
Red Stripe to Top
FX-Class and FXR-Class
10 900-0107-01-00 Rev A
9. Install the ribbon cable that is bent in half to the AC PCBA and the Control PCBA. (See Figure 17 and
also Figure 8 if necessary.) This cable has 34 pins. Make sure the red stripe is oriented toward the
bottom. Push down on each end until the levers click and the plug is secure.
Figure 17 AC to Control Ribbon Cable
10. Install the gasket between the AC PCBA and the top cover. This gasket is used to keep water out. Make
sure to line up the holes on the gasket with the holes in the AC PBCA. See Figure 18.
Figure 18 Gasket and O-Rings
11. Install the two small O-rings on the FET PCBA battery terminals. See Figure 18.
12. If the large chassis O-ring is out of position, re-seat it into the groove on the chassis. See Figure 18.
Red Stripe to Bottom
Battery
Terminal O-Rings
AC
Compartment
Gasket
Inverter O-Ring
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