OutBack Power FLEXmax 100, FLEXWare SD-AFCI Quick Start Manual

Specifications

Quick Start Guide

Specifications

Device

Voltage

Total Current

DC Input

Compatibility

Overcurrent

Protection

Power Draw

Enclosure Rating

Ambient Temp.

LED indicators

Knockouts

Combiner

600 Vdc

64 Adc

24 Vdc ± 3%

Up to 6 PV input
strings per combiner

(6) 600 Vdc DIN rail

fuse holders

0.10 Adc

UL Type 3R

–25 to 60°C

Arc Fault

2", ½”, ¾”

RSI

24 Vdc ± 3%

N/A

24 Vdc ± 3%

Controls up to 6 combiner boxes

N/A

0.06 Adc

UL Type 3R

–25 to 60°C

SOLAR ON

SOLAR OFF

A

FCI

½”

Listings

o UL1741

 including PVRSE

o UL1699B

o CSA C22.2

 including PVRSE

Compliance

o FCC Part 15, Class B

NOTES:

 The DC input and output circuits

are isolated from the enclosure.

 The photovoltaic system grounding shall be

installed according to the requirements of Sections

690.41 through 690.47 of the National Electric
Code (ANSI/NFPA 70). The installer is responsible
for all system grounding.

 Use only UL514B-compliant wet location or

rain-tight conduit hubs for entry into the enclosure.

FLEXmax 100

Rapid Shutdown Solution (RSD-AFCI)

IMPORTANT

This document is for use by qualified personnel familiar with photovoltaic (PV) systems.
Users of this document should meet all local and governmental code requirements for
licensing and training for the installation of electrical power systems with AC and DC voltage

up to 600 volts. This product is only serviceable by qualified personnel

The RSD-AFCI works in conjunction with the FLEXmax 100 charge controller. It allows a system to meet the
2014 National Electric Code requirements for PV systems.

Features:

o End-to-end solution listed to UL1741 with PV rapid shutdown equipment (PVRSE)

o Type 3R enclosures rated for indoor or outdoor installation

o Flexible design — install the combiner box vertically or horizontally and mount to racking or under an array

o Interoperability with compatible third-party PV rapid shutdown devices (PVRSE with dry contact)

.

Dimensions

14.75"

(37.5 cm)

All ½”

5.0” (

14.1"

(35.8 cm)

7.3” (

6.6” (17.8 cm)

12.7 cm)

18.5 cm)

3.75” (9.5 cm)

12.0"

(30.5 cm)

15.5"

(39.4 cm)

PV DISCONNECT

13.75"

(34.9 cm)

AFCI SELF TEST

AFCI ANNUNCIATOR

5.75" (14.6 cm)
with feet

fully extended

11.3"

(28.7 cm)

4.5"

(11.4 cm)

2"

19.5" (49.5 cm)

½”

½”

and

¾”

Components Included:

o Combiner Box

 FWPV6-FH600-SDA

o Rapid Shutdown Initiator Box

 RSI

IMPORTANT

An isolated Class 2 DC power supply with the following
specifications must be used to power the RSI:

24 Vdc ± 3% maximum over input voltage, ambient

temperature, output load, and initial accuracy

Up to 1.5 Adc

Accessories Available:

o Box of (10) 15A Fuses

 FUSE-15-600VDC

o Box of (10) 20A Fuses

 FUSE-20-600VDC

o 30A, 1000 Vdc Fuse Holder

 FH-30-1000VDC-DIN

Combiner

Adjustable mounting feet

Lockable PV disconnect

Lockable latch

Securing Screw

Arc fault test button

AFCI annunciator

RSI

Lockable

rapid shutdown

switch

LED

indicators

900-0238-01-00 REV B
©2018 OutBack Power. All Rights Reserved.

Installation (SAVE THESE INSTRUCTIONS)

A

This document contains important instructions that shall be followed during installation
and maintenance of the power system.

Wiring

Wiring:

Mounting:

IMPORTANT

The surface and fastening hardware must be able to support the weight of all products.

1) Remove any necessary knockouts.

2)

3)

nt the RSI box using the holes located in the mounting brackets. (See A

Mou

 Secure th

he RSI box should be installed near the service meter. It must be moun

 T

vertically a

nt the combiner box using the four mounting feet. During shipping

Mou

e RSI appropriately for the mounting ty

nd must be at least 36" (91.4 cm) above the ground.

pe.

are attached facing inward. They should usually be repositioned facing outward f
mounting as shown in B. The feet are slotted for exact spacing requirements in
differing locations

 Secure th

 Th

e combiner box can be mounted horizontally, vertically, or at a
intermed
groun

d. See C.

.

e combiner appropriately for the mounting

type.

ny

iate angle. It must be mounted at least 36" (91.4 cm) above th

 To meet PVRSE requirements, mount the combiner within 10' (3m) of t

array. (Required distance may vary with local code requirements.)

PV

.)

ted

, these feet

or

e

he

B

B

C

A

B

B

NOTE:

These instructions assume the use of FLEXmax 100 charge controller, one combiner, the RSI, and
a battery source. (The FLEXmax 100 must be installed according to the appropriate instructions.)

1) Ensure all electrical so

2) Wire all system compo
and load cen

 Conn

ter internal wiring are

ect the red and black terminals (3 and 4) on the RSI port labeled J2 (24 Vdc

urces to the system are disconnected. These include utility grid, PV, and batteries.

nents as noted below. See the next sheet for wiring illustrations.

not depicted.

supply) to the red and black terminals (1 and 2) on the combiner port labeled J1.

 Connect the white terminal (2) on the RSI J2 port to the white terminal (3)

the combin

er J1 port.

 Connect the green terminal (1) on the RSI J2 port to the green terminal (4)

the combin

er J1 port.

 Connect the PV array positive (+), negative (–) and ground to the combin

fuse hold

ers and terminal bus bars (TBB).

NOTE: PV input wiring must be outdoor rated. It must be suitable for b

t locations and UV exposure.

we

 Connect the combiner positive (+), negative (–) and ground to the load center

bus bars. Connect the RSI ground to the load center ground bar.

3) Tigh

ten all connections to the torque values on the table to the left.

er

oth

Note that battery connections

on

Combiner

on

1 2 3 4 1 2 3 4

RSI

1 2 3 4 1 2 3 4

J1 J2

J1 J2

Torque Requirements by Wire Size (copper conductors only)

Negative (–)

Cable Size*

2/0 AWG (70 mm2)

1/0 to #1 AWG (50 mm2)

#2 to #3 AWG (35 mm2) 50 in-lb (5.7 Nm) — 50 in-lb (5.7 Nm)— 50 in-lb (5.7 Nm)

#4 AWG (25 mm2)

#6 AWG (16 mm2)

#8 AWG (10 mm2)

Combiner TBB

(large holes)

50 in-lb (5.7 Nm)

50 in-lb (5.7 Nm)

45 in-lb (5.1 Nm)

45 in-lb (5.1 Nm)

40 in-lb (4.5 Nm)

35 in-lb (4.0 Nm)#10 AWG (6 mm2)

35 in-lb (4.0 Nm)#14 to #12 AWG (2.5 to 4 mm2) 20 in-lb (2.3 Nm) 35 in-lb (4.0 Nm)20 in-lb (2.3 Nm) 35 in-lb (4.0 Nm)

NOTES

 The large cable gland in the combiner box requires a torque value of 29.2 ft-lb (39.5 Nm) to retain the Type 3R rating. The small

cable gland requires a torque value of 19.2 ft-lb (26.0 Nm). Tighten each sealing nut until it is almost even with the rest of the gland.
(See the next sheet.)

 Minimum rating for all wires is 90°C. The exception is for PV source circuits above 50°C, which require wire rated for 105°C to

avoid der

ating.

Negative (–)

Combiner TBB

(small holes)

—

—

—

—

25 in-lb (2.8 Nm)

20 in-lb (2.3 Nm)

Ground TBB

—

—

35 in-lb (4.0 Nm)

35 in-lb (4.0 Nm)

25 in-lb (2.8 Nm)

20 in-lb (2.3 Nm)

Ground Lug

(combiner)

—

50 in-lb (5.7 Nm)

45 in-lb (5.1 Nm)

45 in-lb (5.1 Nm)

40 in-lb (4.5 Nm)

35 in-lb (4.0 Nm)

Contactor

Terminal

50 in-lb (5.7 Nm)

50 in-lb (5.7 Nm)

45 in-lb (5.1 Nm)

45 in-lb (5.1 Nm)

40 in-lb (4.5 Nm)

35 in-lb (4.0 Nm)

4) Conn

ect PV and other sources. Apply power to the system as appropriate.

CAUTION: EQUIPMENT DAMAGE

!

The 24-volt negative conductor is not grounded and is not to be connected to chassis
or any other grounding system.

Other Wire Sizes

Connection Minimum* Maximum*

Combiner Fuse Holder

Communication Connectors #22 AWG (0.5 mm2) #16 AWG (1.5 mm2)

PV Input Glands

*AWG size conversions are listed to the closest equivalent mm2 commercial size.

#14 AWG (2.5 mm2)

—

#8 AWG (25 mm2)

Up to 7.7 mm diameter

900-0238-01-00 REV B
©2018 OutBack Power. All Rights Reserved.

Installation

Communications Wire Length

Wire Size

#16 AWG

#18 AWG 125'

#20 AWG

#22 AWG

GS Load Center

Length

200'

80'

50'

Wiring Drawing

Photovoltaic (PV) Array

FWPV6-FH600-SDA

FLEXmax 100

Charge Controller

1
0

5

6

9

Example of Class 2

power supply

Ground

Electrode

Conductor

RSI

J3

J4

J5

J6

J2 J1

DC LEGEND

PV Negative

PV Positive

Ground

Not used

J2 (Combiner)J1 (Power Supply)

24V RSI Supply
Positive (+)

24V RSI Supply
Negative (–)

24V Combiner
Supply Positive (+)

24V Combiner
Supply Negative (–)

PV Arc Fault

PV RSI Safe

J3 to RAPID SHUTDOWN
Terminals

900-0238-01-00 REV B
©2018 OutBack Power. All Rights Reserved.

J4 to Relay

Relay to AUX

Multiple Combiners

Additional Applications

Multiple Combiners

Up to six combiners can be used with a single Rapid Shutdown Initiator. The RSI can be used as an emergency
shutoff for all of the six systems. Six combiners can be powered by a single RSI and power supply.

Connect the control wires of additional combiners in series with the first combiner (designated below).
The J1 terminals for are connected to the RSI as shown on the previous page. The J2 terminals are
connected to the J1 terminals on . The J2 terminals on are connected to the J1 terminals on

1

2

2

if present, and so on.

NOTE: J1 and J2 are interchangeable in the combiner and can be reversed if necessary. (See the connections between

4

and below.) This statement is only true for combiner boxes.

1

2 3

1

3

Surge Protector

An optional surge protection device can be installed in the combiner. A knockout has been provided to
accommodate this type of device. This image shows the underside of the combiner and the location of
the knockout.

3

PV Conduit PV Cable

Glands

NOTE: Any installed devices must be liquid-tight to sustain the combiner’s environmental rating.

Surge

Protector

Communications

Conduits

To RSI

J2 J1

6

J1 J2 J2J1

J2 J2J1

5

J2 J1 J2J1

4

Contact Information

OutBack Power
17825 – 59th Avenue NE
Suite B
Arlington, WA 98223

Date and Revision

May 2019, Revision B

900-0238-01-00 REV B
©2018 OutBack Power. All Rights Reserved.

Website: www.outbackpower.com