Help! Fxr3048A stopped working

MauiSun · February 2017

I set up an fp2 about a month ago, everything was running flawlessly, then yesterday the power suddenly went out.
Checked the fp2 and the master inverter was getting power (orange active status light on), but not doing anything (both battery and status lights off). The sub master had all its lights on and seems to be working but has an error (battery light green, status light red).

I checked the mate3 and found the following errors:
-stacking error
-phase loss warning
-Inverter firmware revisions are different

I also get the following error message:
" a inverter firmware mismatch has been detected. Inverters 7 are disabled. Visit outbackpower.com for current Inverter firmwares"
I've tried updating the firmware for both the fxr and the mate3 but still getting the firmware error.

I've tried restarting the system, but every time I turn on the inverter breakers the master inverter won't make a sound and only the orange status light will turn on, where the submaster inverter will turn on, test the fan, and all the lights turn on.

When I look at the hub, the green light for the master inverter (slot 1) doesn't blink. The one for the submaster (slot 7) does blink. If I switch the inverters from slot 1 and 7, then I get a blinking light on 1 but not 7.
So it appears to me that there is a communication failure between the Inverter that is currently the master, and the hub. The hub doesn't appear to be detecting the master Inverter.
But, wouldnt the master Inverter still kick on (test fan, battery and statues lights turning on) even if it's not able to communicate with the hub?

Vic · February 2017

Hi MauiSun,

Have you tried contacting OB Tech Support via email, or phone?

OR, Tech Support does offer a lot of support on the OB Forum:
http://www.outbackpower.com/forum/

These are the only things that I can offer. Good Luck, Vic

MauiSun · February 2017

Yes, tried calling outback support and they wouldn't offer any help unless they were talking to a licensed electrical technician. Searched the forums and couldn't find anything similar to this issue.

Vic · February 2017

Hi Mauai..,

Very sorry that OB will NOT support the end-user ... this appears to be a very large change from previous Policy.

Try joining the OB Forum as a Member, and post your questions there. The Forum seems to have support from OB Tech, it might take a day for a reply from Tech.

Also, there are a number of knowledgeable members there who might be able to help.

Good Luck, Vic

MauiSun · February 2017

UPDATE!! Problem found! I'll post what I discovered in case others encounter a similar issue.

OK, ran some more tests and...
So I changed the inverter settings on the mate3 to single master inverter in the "inverter stacking" menu. Plugged in the sub master inverter (working inverter) directly into the mate3, and the mate would turn on when I turned on the inverter by hitting the slave inverter switch. OK, now I know the firmware update error bullshit was just that... inverter works fine with the firmware it has.

Then I tried plugging in the master inverter (non working inverter) directly into the mate3, but when I hit the master inverter breaker the mate did not turn on. For some reason the inverter is not only doesn't have any AC out voltage, but the communication wire doesn't either..... this explains the stacking error.

The inverter itself still did the same thing as before; the orange "active" light for "DC" turns on, but the "AC out" was off, the inverter fan did not kick on, and the green yellow red battery and inverter status LEDs were off. This turned out to be important in the troubleshoot, so if your symptoms are similar, keep on reading.

So I called outback again, told them the problem was somewhere between the DC input and the communication board for the AC output. The tech asked me a few questions about which lights would turn on. When I told him neither the green yellow red battery and inverter status LEDS or the fan were turning on, but that the orange DC light on the left side of the display was on (but not the orange AC out) he told me that that narrows it down to the DC motherboard.

The board you see, with the AC out connections, temperature sensor, GYR led battery and inverter status, etc is the AC motherboard. BEHIND that there is a DC motherboard. If that board is fried, the orange active light will turn on, but the GYR LEDS won't! The entire AC motherboard will not get power if the DC board is fried.
It turns out this is a recent and know problem regarding this DC motherboard! They have since made an updated version with more powerful resistors, and said they would send a replacement right away.

So if you have a similar issue, call outback and be very precise about the symptoms, bring up the DC motherboard and have them send you a replacement! Don't let them tell you they can only speak to an electrician!

Unfortunately, I wasn't able to convince them to send two updated DC boards for the other FXR.... let's hope that one doesn't crap out in the future too...

Estragon · February 2017

Interesting.

I had a similar issue about 18 months ago but the inverter was completely dead. Switching the former slave to master also got me running again.

I emailed Outback support with the symptoms and tests I had done, and they sent forms to RMA and replace boards fairly quickly. They didn't ask if I was an electrician, and I didn't tell them (I'm not). Replaced boards and no problems since.

MauiSun · August 2017

Here's a video i made of the fix.

https://www.youtube.com/watch?v=JH1UrzzelTM

mike95490 · August 2017

For those of us in the sticks and lousy internet, can you briefly describe what is in the mystery video ?

BB. · August 2017

The video is a time lapse of removing and replacing a control board from an installed Outback inverter. Here is a snapshot of the board being replaced:

Image: https://us.v-cdn.net/6024911/uploads/editor/e0/orhtn53aus96.png

Boy--that was a lot of work.

-Bill

Estragon · August 2017

It's worth watching the Outback video if you can get out of the sticks. Swapping the boards isn't that hard, but there are a few tips (like checking gasket, routing ribbon cables, etc) that might be gotchas otherwise. Not sure if that's the MauiSun video (I'm also in the sticks).

Help! Fxr3048A stopped working

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