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.

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

4.5

5.6

System Overview

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

Page 2

Utility Grid

AC IN

FLEXnet DC

FW250-AC-120V-

NA

HUB Communication Manager

(HUB4 or HUB10)

Major Components

OutBack Power System Products:

Inverter/Charger (GVFX or GTFX models only) 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

OPTIONAL: An AC Generator with a circuit breaker or overcurrent device can be used in this application for backup purposes. However, a specific kind of generator is required. See the inverter literature for additional details.

AC OUT

1

(Selling)

1

Excess RE not being used by the AC Loads. The loads get priority over selling back to the grid.

Surge Protector

(Inside)

RTS

MATE

MATE RTS

Inverter/

Charger

System Display and

Controller (MATE2)

MAIN----------------

AC IN

Charge Controller

3:02:14P

SUM STATUS SETUP ADV

(FLEXmax 80)

INV

DC IN

PV Harvest

Customer Supplied Components:

AC Source: ~ Utility Grid AC Main AC Distribution Panel AC Distribution Sub-Panel (Load Panel) Battery Bank (24 or 48 Vdc) Photovoltaic (PV) Array

Renewable Energy (RE)

FLEXware

PV8 or PV12

I

OIOIOIOIOIOIOIO

Combiner

Box

Photovoltaic Array

(PV)

Loads

AC OUT2

2

from utility grid by default. IF RE is available, it gets 1 priority here. The remainder is sold. (See note 1 above).

IMPORTANT: Example only. Actual configuration will vary depending on the specific installation requirements.

Grid-Tie Overview

In 23.2 V 0.0 A Out 27.6 V 0.0 A

0.000 kW 0.0 kWH

AUX: OFF Sleeping

Battery Bank

AC

Battery

Charging

st

FW250-DC-125

(175 or 250)

DC

Inverter Out

or

Vented Battery

Enclosure24 or 48 Vdc

DC OUT

Page 3

Major Components

AC

Generat

or

HONDA

Circuit Breaker

or Overcurrent

Device

AC IN

FLEXnet DC

FW250-AC-120V-

NA

Surge Protector

(Inside)

RTS

MATE

MATE RTS

HUB Communication Manager

(HUB4 or HUB10)

System Display and

Controller (MATE2)

MAIN----------------

AC IN

Inverter/

Charger

Charge Controller

3:02:14P

SUM STATUS SETUP ADV

(FLEXmax 80)

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: ~ AC Generator with a circuit breaker or

overcurrent device AC Distribution Sub-Panel (Load Panel) Battery Bank (24 or 48 Vdc)

INV

Photovoltaic (PV) Array

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

Battery Bank

Vented

24 or 48 Vdc

Battery

Enclosure

(PV)

Off-Grid Overview

Page 4

AC LEGEND

Neutral

N

AC Distribution

Panel

(Main Panel)

(120/240 Vac)

L1

L2

Input

Output

Bypass

Outlet

(with FLEXnet DC)

IMPORTANT: Example only. Actual wiring may vary.

L1

Factory wiring not shown. All configurations must comply

with local and national electric codes. Consult your local

electric authority to ensure compliance.

Photovoltaic Array

N

(PV)

L1

On-Grid Wiring

HOT L1

L1

Ground

Primary System

Ground

(Ground Electrode

Conductor)

GROUND ROD

AC Sub-Panel

60 A Circuit

(Maximum)

(120 Vac)

Breaker

GROUND

NEUTRAL

L1

N

FLEXware PV8

L1

MATE RTS

AC IN

MAIN----------------

3:02:14P

SUM STATUS SETUP ADV

INV

Combiner Box

I

OIOIOIOIOIOIO

O

I

DC LEGEND

Negative

Positive

HOT

Loads

L1

(120 Vac)

NEUTRAL

N

GROUND

Ground

In 23.2 V 0.0 A

N

Out 27.6 V 0.0 A

0.000 kW 0.0 kWH

AUX: OFF Sleeping

Battery Bank

Battery

Status

GFDI

CC

PV Circuit

Breaker

1

Connects to the terminal on the circuit breaker that is opposite the inverter DC cable.

1

(RTS)

24 or 48 Vdc

Vented Battery

Enclosure

Page 5

AC LEGEND

Neutral

HOT L1

N

L1

AC Distribution

Panel

(Main Panel)

(120/240 Vac)

L1

L2

NEUTRAL

Input

Output

Bypass

Outlet

IMPORTANT: Example only. Actual wiring may vary.

L1

Factory wiring not shown. All configurations must

comply with local and national electric codes. Consult

your local electric authority to ensure compliance.

N

L1

Photovoltaic Array

(PV)

On-Grid Wiring

Ground

Primary System

Ground

(Ground Electrode

Conductor)

GROUND ROD

AC Sub-Panel

(120 Vac)

HOT

60 A Circuit

Breaker

(Maximum)

GROUND

N

FLEXware

L1

MATE RTS

L1

AC IN

MAIN----------------

3:02:14P

SUM STATUS SETUP ADV

INV

PV8

I

OIOIOIOIOIOIO

O

I

DC LEGEND

Negative

Positive

Ground

Loads

L1

(120 Vac)

NEUTRAL

N

GROUND

In 23.2 V 0.0 A

N

Out 27.6 V 0.0 A

0.000 kW 0.0 kWH

AUX: OFF Sleeping

Battery Bank

(RTS)

1

GFDI

CC

Vented

PV Circuit

Breaker

1

Connects to the terminal on the circuit breaker that is opposite the inverter DC cable.

24 or 48 Vdc

Battery

Enclosure

Page 6

(with FLEXnet DC)

AC LEGEND

AC

Generator

Neutral

HOT L1

Ground

Some generators may have

1

an integrated circuit breaker or disconnect device. If not, one must be provided.

Primary System Ground

(Ground Electrode Conductor)

N

L1

Generator

1

Terminals

(120 Vac)

HOT

(L1)

Neutral

NL1

Input

Output

Bypass

Outlet

MATE RTS

N

L1

IMPORTANT: Example only. Actual wiring may vary.

Factory wiring not shown. All configurations must

comply with local and national electric codes. Consult your

local electric authority to ensure compliance.

N

Photovoltaic Array

L1

FLEXware

MAIN----------------

AC IN

3:02:14P

SUM STATUS SETUP ADV

INV

PV8

I

OIOIOIOIOIOIO

O

I

(PV)

Off-Grid Wiring

GROUND ROD

AC Distribution Panel

(120 Vac)

Loads

(120 Vac)

HOT

L1

N

GROUND

NEUTRAL

DC LEGEND

Negative

Positive

L1

Ground

In 23.2 V 0.0 A Out 27.6 V 0.0 A

N

0.000 kW 0.0 kWH

AUX: OFF Sleeping

Battery Bank

(RTS)

2

Battery

Status

GFDI

CC

Vented

PV Circuit

Breaker

24 or 48 Vdc

Battery

Enclosure

2

Connects to the terminal on the circuit breaker that is opposite the inverter DC cable.

Page 7

AC LEGEND

Neutral

N

AC

Generator

(120 Vac)

N

L1

IMPORTANT: Example only. Actual wiring may vary.

Factory wiring not shown. All configurations must

comply with local and national electric codes. Consult your

local electric authority to ensure compliance.

HOT L1

L1

Ground

Generator

1

Terminals

Some generators may have

1

an integrated circuit breaker or disconnect device. If not, one must be provided.

Primary System Ground

(Ground Electrode Conductor)

GROUND ROD

HOT

(L1)

L1

Neutral

Input

Output

Bypass

Outlet

N

L1

N

Photovoltaic Array

(PV)

FLEXware

PV8

I

OIOIOIOIOIOIO

O

I

MATE RTS

MAIN----------------

AC IN

3:02:14P

SUM STATUS SETUP ADV

INV

Off-Grid Wiring

DC LEGEND

AC Distribution Panel

Loads

(120 Vac)

HOT

N

L1

NEUTRAL

GROUND

Negative

L1

Positive

Ground

In 23.2 V 0.0 A Out 27.6 V 0.0 A

N

0.000 kW 0.0 kWH

AUX: OFF Sleeping

Battery Bank

(RTS)

2

GFDI

CC

Vented

PV Circuit

Breaker

24 or 48 Vdc

Battery

Enclosure

2

Connects to the terminal on the circuit breaker that is opposite the inverter DC cable.

Page 8

About OutBack Power Technologies

OutBack Power Technologies is a leader in advanced energy conversion technology. Our products include true sine wave inverter/chargers, maximum power point tracking charge controllers, and system communication components, as well as circuit breakers, batteries, accessories, and assembled systems.

Contact Information

Telephone: +1.360.435.6030 (Main)

+1.360.618.4363 (Technical Support) +1.360.435.6019 (Fax)

Mailing Address: OutBack Power Technologies Sales & Marketing

5917 - 195th Street N.E. 6115 – 192nd Street NE Arlington, WA 98223 USA Arlington, WA 98223 USA

E-mail: Support@outbackpower.com

Web Site: www.outbackpower.com

Disclaimer

UNLESS SPECIFICALLY AGREED TO IN WRITING, OUTBACK POWER TECHNOLOGIES: (a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF

ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION.

(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER’S RISK.

Warranty Summary

OutBack Power Technologies warrants that the products it manufactures will be free from defects in materials and workmanship for a period of five (5) years subject to the conditions set forth in the warranty detail, found in the product manual.

OutBack Power Technologies cannot be responsible for system failure, damages, or injury resulting from improper installation of their products.

Notice of Copyright

Trademarks

OutBack Power is a registered trademark of OutBack Power Technologies.

Date and Revision

January 2012, Revision A

Part Number

900-0094-01-00 Rev A

North America: 5917 - 195th Street N.E. Arlington, WA USA +1.360.435.6030

900-0131-01-00 Rev A

Outback Power Systems FLEXpower ONE User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual