Outback Power Systems FLEXpower ONE Quick Start Guide

MATE3 Programming

IMPORTANT:

Programming should be done by a qualified installer who is trained on programming inverter power systems. Failure to program accurate parameters for the system could potentially cause equipment damage. Damage caused by inaccurate programming is not covered by the limited warranty for the system.

Components

FLEXnet DC

Battery Monitor

HUB Communication Manager

(HUB4 or HUB10)

Major Components

FLEXpower System Products

FW250-AC-120V-NA

Surge Protector

(Inside)

Battery Status LEDs Inverter Status LEDs

CHASSIS GROUND/PE

AC NEUTRAL OUT

AC NEUTRAL IN

AC HOT IN

RTS

MATE

RTS

MATE

RTS

Inverter/Charger

FX Series VFX Series GTFX Series GVFX Series GFX Series

System Display and Controller

(MATE3)

AC Conduit Box DC Conduit Box

FW250-AC-120V-NA FW250-DC-125

FW250-DC-175 FW250-DC-250

AC HOT OUT

AC IN

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

3:02:14P

SUM STATUS SETUP ADV

INV

System Display and

Controller

Charge Controller

MATE2 MATE3

FLEXmax 60 FLEXmax 80

Charge Controller

(FLEXmax 80)

Communications

Manager

HUB4 HUB10

Remote Temp Sensor RTS FLEXnet DC Monitor FNDC

Inverter/

Charger

Surge Protector FW-SP-ACA

Customer-Supplied Components

AC Source

Utility Grid, or AC Generator

FW250-DC-125

(175 or 250)

LED Indicators on the Inverter

Battery Status LED Indicators

Color

Green

Yellow

Green

Yellow

12 V Inverter 24 V Inverter 48 V Inverter

12.5 Vdc or higher

11.5 to 12.4 Vdc

Red

11.4 Vdc or lower

25.0 Vdc or higher

23.0 to 24.8 Vdc

22.8 Vdc or lower

Inverter Status LED Indicators

Inverter on (solid) or standing by (flash)

AC source in use (solid) or standing by (flash)

Red

Inverter error or warning (see manual)

50.0 Vdc or higher

46.0 to 49.6 Vdc

45.6 Vdc or lower

In 23.2 V 0.0 A Out 27.6 V 0.0 A

0.000 kW 0.0 kWH

AUX: OFF Sleeping

Surge Protector LEDs

Active Error

Yellow

RedYellow

Red

Phase

AC IN

AC OUT

IMPORTANT:

Not intended for use with

life support equipment.

Main Electrical Panel

(or overcurrent device for AC source)

Electrical Distribution Subpanel

(Load Panel) Battery Bank

Photovoltaic (PV) Array (with PV Combiner Box [PV8 or PV12])

FNDC LED Indicators

Color

Green

Yellow

Red

Battery State-of-Charge

> 90% (blinks if charge parameters are met)

≥ 80%

≥ 70%

≥ 60%

≥ 60% off, < 60% solid, < 50% blinks

Contact Technical Support:

Telephone: +1.360.618.4363 Email: Support@outbackpower.com Website: www.outbackpower.com

Mounting

Wire Sizes/Torque Requirements

WARNING: Fire/Explosion Hazard

Do not place combustible or flammable materials within 12 feet (3.7 m) of the equipment. This unit employs mechanical relays and is not ignitionprotected. Fumes or spills from flammable materials could be ignited by sparks.

WARNING: Personal Injury

Use safe lifting techniques and standard safety equipment when working with this equipment.

IMPORTANT:

Clearance and access requirements may vary by location. Maintaining a 36” (91.4 cm) clear space in front of the system for access is recommended.

Consult local electric code to confirm clearance and access requirements for the specific location.

FP1 Dimensions:

33.5" (85 cm) tall X 19.75" (50 cm) wide

To install the mounting bracket:

1. Place the mounting bracket at the

desired height for the panel.

2. Secure the mounting bracket to the

surface. Use all six mounting slots provided on the bracket.

To mount the FP1 panel on the bracket:

3. Lift the mounting plate above the wall bracket.

4. Slip the top of the mounting plate over the angled lip of the wall bracket.

5. Secure the lower back flange of the

mounting plate to the wall (with appropriate hardware).

6. Insert all three 1-inch nylon hole plugs into the rear slot access holes.

Wall Stud

Wall Board

FP1

Mounting

Panel

Mounting the bracket to

the wall studs 16" apart.

Mounting the bracket to

the wall studs 24" apart.

Mounting the bracket

to plywood

Plywood

(if used)

Mounting

Bracket

Secure the mounting plate to the wall at the

three locations. See .

FP1

Mounting

Plate

Mounting

Bracket

AC Conduit Box

AC Circuit Breakers

Mechanical

Interlock (Bypass)

DC Circuit Breakers

GFDI

PV Array

DC Conduit Box

Battery Cable Connections with the FNDC

Charge Controller

Battery (–) Lug

GFCI Outlet

Battery Bank

Battery Status Monitor

Charge Controller

Flat Washer

Shunt

Side View

Terminals

Control

Wiring

Terminals

Battery

Terminals

Torque requirements for

Breaker Stud

Terminals

Bolt M8 x 1.25

Lock Washer

*must install upside-down on units with both Shunt A and Turbo Kit.

AC Wire Sizes and Torque Values

the conductor lugs

Circuit

M8 20 2.3

¼ - 20 35 4.0

5/16 - 18 50 5.6

3/8 - 16 225 25.4

Inverter Battery (–) Lug

Torque

In-lb Nm

CAUTION: Equipment Damage

When connecting cables from the inverter to the battery terminals, ensure the proper polarity is observed. Connecting the cables incorrectly can damage or destroy the equipment and void the product warranty.

Battery Cable Connections without the FNDC

Surge Protector

Charge Controller

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, rated to 75°C

(minimum) unless local code requires otherwise.

2.5 – 6

16 – 25

Control Wiring Terminal Block:

The Inverter ON/OFF terminals are used for connecting an external ON/ OFF switch. To use this feature, the jumper must be removed. (See installation manual for details.)

The AUX terminals provide a 12 Vdc signal. The AUX terminals can be used to start a generator or to control external devices.

AUX terminals are also available in the charge controller and FLEXnet DC. See the charge controller or FNDC manuals for details.

2.3

2.8

4.0

4.5

5.6

Minimum DC Cable based on the

DC Circuit Breaker

Circuit

Breaker

125 1/0 (70 mm2)

175 2/0 (70 mm2)

250 4/0 (120 mm2)

Cable Lug

Flat Washer

Battery (–) Lug

Mounting Surface

Cable Size

Nut

In-lb Nm

225 25.4

Nut

Lock Washer

Bolt M8 x 1.25

Isolator

Inverter Battery (–)

Terminal Post

Torque

50 5.6

GFDI Cable Lug

Inverter Battery (–) Lug

Energize/Startup

De-energize/Shutdown

Procedures

Side View

AC Conduit Box

AC Circuit Breakers

Mechanical

Interlock (Bypass)

DC Circuit Breakers

GFDI

PV Array

Battery Bank

Procedures

Pre-startup Procedures:

1. Double-check all wiring connections.

2. Inspect the enclosure to ensure no tools or debris has been left inside.

3. Disconnect all AC loads at the backup (or critical) load panel.

4. Disconnect the AC input feed to the FLEXpower ONE at the source.

To energize or start up the OutBack devices:

1. Using a digital voltmeter (DVM), verify 12, 24, or 48 Vdc on the DC input

terminals by placing the DVM leads on and . Confirm that the

voltage is correct for the inverter and charge controller models. Confirm the polarity.

CAUTION: Equipment Damage

Incorrect battery polarity will damage the equipment.

2. Turn on (close) the GFDI circuit breaker.

3. Verify the voltage on the PV terminal is in the correct range of open-circuit

voltage by placing the DVM leads on and . Confirm the polarity.

4. Turn on (close) the PV input circuit breakers.

5. Turn on (close) the DC circuit breaker from the battery bank to the inverter.

2a 2b

6. Verify 120 Vac on the AC output circuit breakers by placing the DVM leads on and .

3+ 3–

7. Turn on (close) the AC output circuit breakers.

8. Connect the AC source. Verify 120 Vac on the AC input circuit breakers by placing the DVM leads on and .

9. Turn on (close) the AC input circuit breakers.

4+ 4–

10. Turn on the AC disconnects at the load panel and test the loads.

4–

3–

Functional

Test Points

Battery Voltage

Test Points

Battery Negative (–)

Terminal on the Inverter

Circuit Breaker Terminal connected to the Battery

Positive (+) Cable

Circuit Breaker Terminal

connected to the Inverter

DC Positive (+) Cable

PV Voltage Test Points

PV Negative (–) Terminal

on the Charge Controller

Circuit Breaker terminal

for the PV

PV Positive (+) Terminal

on the Charge Controller

AC OUT Voltage

Test Points

3+ 3–

4+ 3+

Side View

AC Conduit Box

Mechanical

Interlock (Bypass)

GFDI

PV Array

AC Circuit Breakers

DC Circuit Breakers

Battery Bank

WARNING: Lethal Voltage

Review the system configuration to identify all possible sources of energy. Ensure ALL sources of power are disconnected before performing any installation or maintenance on this equipment. Confirm that the terminals are de-energized using a validated voltmeter

(rated for a minimum 1000 Vac and 1000 Vdc) to verify the de-energized condition.

WARNING: Lethal Voltage

The numbered steps will remove power from the inverter and charge controller. However, sources of energy may still be present inside the GSLC and other locations. To ensure absolute safety, disconnect ALL power connections at the source.

WARNING: Burn Hazard

Internal parts can become hot during operation. Do not remove the cover during operation or touch any internal parts. Be sure to allow them sufficient time to cool

down before attempting to perform any maintenance.

To de-energize or shut down the OutBack devices:

1. Turn off (open) the AC circuit breakers.

2. Turn off (open) the DC circuit breaker for the battery.

3. Turn off (open) the PV circuit breaker.

4. Turn off (open) the GFDI circuit breaker.

5. *Verify 0 Vdc on the DC input terminals of the inverter by placing the voltmeter leads on and .

6. *Verify 0 Vdc on the PV terminal by placing the voltmeter

leads on and .

7. *Verify 0 Vac on the AC output circuit breakers by placing the voltmeter leads on and .

*See the Functional Test Points key that is included with the Startup Procedures.

3+ 3–

DC Conduit Box

AC IN Voltage

Test Points

4+ 4–

DC Conduit Box

General Wiring

AC Source

(single)

AC LEGEND

Neutral

HOT L1

Ground

AC Distribution

Panel

(or disconnect device)

60 A Circuit

Breaker

(Maximum)

GROUND

NEUTRAL

Input

Output

Bypass

Outlet

MATE RTS

Actual wiring may vary. Factory wiring not shown.

IMPORTANT: Example only.

All configurations must comply with local and national electric codes.

Consult your local electric authority to ensure compliance.

IMPORTANT:

Indoor installation only.

CHASSIS GROUND/PE

AC NEUTRAL OUT

AC NEUTRAL IN

AC HOT IN

AC HOT OUT

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

AC IN

3:02:14P

SUM STATUS SETUP ADV

INV

If the FLEXnet DC battery monitor is not installed, the DC shunt will not be installed.

If the DC shunt is not installed, connect the DC negative (–) cable directly to the DC negative (–) terminal on the inverter.

DC Negative (—)

Terminal on the

Inverter

FLEXware PV8

Photovoltaic Array (PV)

OIOIOIOIOIOIO

Ground Electrode

Conductor

Loads

(120 Vac)

AC Subpanel

HOT

NEUTRAL

GROUND

DC Negative (—) Cable

DC LEGEND

Negative

In 23.2 V 0.0 A Out 27.6 V 0.0 A

0.000 kW 0.0 kWH

AUX: OFF Sleeping

Positive

Ground

Battery Status

GFDI

Charge Controller

(RTS)

Battery Bank

PV Circuit Breaker

Connects to the terminal on the circuit breaker

that is opposite the inverter DC cable.

Vented Battery Enclosure

Outback Power Systems FLEXpower ONE Quick Start Guide

Specifications and Main Features

Frequently Asked Questions

User Manual