Outback Power Systems FLEXpower ONE User Manual
System Overview –
Recommended Wire Sizes and Torque Requirements……..…… 1
Application Overviews –
On-Grid Applications………………………………………..………. 2
Grid-Interactive Applications………………………………..……… 3
Off-Grid Applications……………………………………..…………. 4
Wiring Overviews –
On-Grid Applications (with FLEXnet DC)……………...…..……… 5
On-Grid Applications …………………..……………………..…….. 6
Contents
Off-Grid Applications (with FLEXnet DC)……………….....……… 7
Off-Grid Applications ………………………..………………..…….. 8
WARNING: SHOCK HAZARD
This information is for use by qualified personnel who
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 240 Vac
and 150 Vdc.
Consult the FLEXpower ONE Installation Manual for
detailed information on safety and installation
procedures.
900-0094-01-00 Rev A.vsd\TOC\2012-03-02
©2011 OutBack Power Technologies. All Rights Reserved.
Major Components
OutBack Power Technologies
Products:
Inverter/Charger
(FX, VFX, GVFX or GTFX models)
FW250-AC-120V-NA
FW250-DC-125, FW250-DC-175, or
FW250-DC-250
System Display and Controller
(MATE2 or MATE3)
Charge Controller
(FLEXmax 80 or FLEXmax 60)
Remote Temperature Sensor (RTS)
Communications Manager (HUB4 or HUB10)
FLEXnet DC Monitor
Surge Protector
Customer Supplied Components:
AC Source:
~ Utility Grid (if available) or
~ AC Generator with circuit breaker or
overcurrent device
Main AC Distribution Panel
AC Distribution Sub-Panel (Load Panel)
Battery Bank (24 or 48 Vdc)
Photovoltaic (PV) Array and PV Combiner Box
Reference Documentation:
FLEXpower ONE Installation Manual
FX Inverter/Charger Installation Manuals
FX Operator’s Manuals
MATE Series or MATE3 Owner’s Manual
HUB Owner’s Manual
FLEXmax Series Charge Controllers
Owner’s Manual
FLEXnet DC Monitor Owner’s Manual
IMPORTANT:
All configurations must comply with local and national electric
codes. Consult your local electric authority to ensure
compliance. Actual wiring requirements may vary.
Factory wiring is not shown.
FLEXnet DC
FW250-AC-120V-
NA
Surge Protector
(Inside)
RTS
MATE
MATE RTS
FW250-DC-125
(175 or 250)
HUB Communication Manager
(HUB4 or HUB10)
System Display and
Controller (MATE2)
MAIN----------------
AC IN
3:02:14P
SUM STATUS SETUP ADV
INV
Inverter/
Charger
Charge Controller
(FLEXmax 80)
In 23.2 V 0.0 A
Out 27.6 V 0.0 A
0.000 kW 0.0 kWH
AUX: OFF Sleeping
GFCI Outlet
(240V models only)
Side View
AC Breakers
(120V models only)
DC Breakers
Mechanical
GFCI Outlet
Battery Bank
Battery Status
Monitor
GFDI
Charge
Controller
PV Array
Interlock
(Bypass)
AC Wire Sizes and Torque Values
Wire Size Torque
AWG In-lb
#14 - 10 20
#8 25
#6 - 4 35
#3 35
#2 40
#1 50
1/0 50
It is recommended that conductors
be #6 AWG THHN copper, or larger,
unless local code requires otherwise.
AC Terminal
Compartment
DC Terminals
Torque Data for Breaker Lugs
Breaker Stud
Minimum DC Conductor
based on DC Breaker
DC
Breaker
125 1/0 (70 mm2)
175 2/0 (70 mm2)
250 4/0 (120 mm2)
2
mm
2.5 – 6
10
16 – 25
35
35
50
70
rated to 75 °C (minimum)
Torque
In-lb Nm
M8 20 2.3
¼ - 20 35 4.0
5/16 - 18 50 5.6
3/8 - 16 225 25.4
Conductor
Size
Torque
In-lb Nm
50 5.6
225 25.4
225 25.4
IMPORTANT:
Not intended for use with
life support equipment.
Nm
2.3
2.8
4.0
4.0
4.5
5.6
5.6
System Overview
900-0094-01-00 Rev A.vsd\Wiring Info\2012-03-02
©2011 OutBack Power Technologies. All Rights Reserved.
Page 1
Utility
Grid
or...
AC
Generator
HONDA
AC IN
FLEXnet DC
FW250-AC-120V-
NA
Surge Protector
(Inside)
MATE RTS
HUB Communication Manager
(HUB4 or HUB10)
System Display and
Controller (MATE2)
MAIN----------------
Inverter/
Charger
AC IN
Charge Controller
3:02:14P
SUM STATUS SETUP ADV
(FLEXmax 80)
INV
Major Components
OutBack Power System Products:
Inverter/Charger (FX or VFX models)
FW250-AC-120V-NA
FW250-DC-125, FW250-DC-175, or FW250-DC-250
System Display and Controller (MATE2 or MATE3)
Charge Controller (FLEXmax 80 or FLEXmax 60)
Remote Temperature Sensor (RTS)
Communications Manager (HUB4 or HUB10)
FLEXnet DC Monitor
Surge Protector
Customer Supplied Components:
AC Source:
~ Utility Grid AC or
~ AC Generator with circuit breaker or
overcurrent device
Main AC Distribution Panel
AC Distribution Sub-Panel (Load Panel)
Battery Bank (24 or 48 Vdc)
Photovoltaic (PV) Array
On-Grid Overview
Renewable Energy (RE)
Loads
IMPORTANT: Example only. Actual configuration will vary
depending on the specific installation requirements.
AC OUT
FW250-DC-125
(175 or 250)
In 23.2 V 0.0 A
Out 27.6 V 0.0 A
0.000 kW 0.0 kWH
AUX: OFF Sleeping
DC IN
PV Harvest
Battery
Charging
Inverter
Out
FLEXware
PV8 or PV12
I
OIOIOIOIOIOIOIO
Combiner
Box
AC
or
DC
DC OUT
Photovoltaic Array
(PV)
Battery Bank
Vented
24 or 48 Vdc
Battery
Enclosure
900-0094-01-00 Rev A.vsd\On Grid Overview\2012-03-02
©2011 OutBack Power Technologies. All Rights Reserved.
Page 2
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