Outback Power Systems FLEXware 500 User Manual

500

User’s Guide

Includes Mounting, Installation, and
Product Registration

OutBack Power Systems FLEXware is a system of modular aluminum mounting hardware and installation
components designed for convenient system installation and integration.

About OutBack Power Systems

OutBack Power Systems is a leader in advanced energy conversion technology. Our products include
true sine wave inverter/chargers, a maximum power point charge controller, system communication
components, as well as breaker panels, breakers, accessories, and assembled systems.

Notice of Copyright

FLEXware 500 Manual Copyright © 2006 All rights reserved.

Disclaimer

UNLESS SPECIFICALLY AGREED TO IN WRITING, OUTBACK POWER SYSTEMS:
(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.

Date and Revision

November 1, 2006 1.0

Contact Information

OutBack Power Systems
19009 62nd Ave. NE
Arlington, WA 98223
Phone [phone]
Fax [phone]
www.outbackpower.com

Requirements and Warnings

The OutBack FLEXware 500 enclosures (FW500-AC and FW500-DC) are listed by ETL as indoor

enclosures to UL standard UL 508A Industrial Control Panels.

This enclosure is intended for battery circuits congured for 12 to 48 volts nominal.

Grounding Instructions – Each enclosure should be connected to a grounded, permanent wiring

system. For most installations, the negative battery conductor should be bonded to the grounding

system at one (and only one) point in the DC system. All installations must comply with all national

and local codes and ordinances. System grounding as required by the National Electric Code, ANSI

/NFPA 70-1996, is the responsibility of the system installer.

The equipment ground on FLEXware 500 is marked with this symbol:

FLEXware is designed for indoor mounting only with appropriate fasteners and a secure mounting

surface that can handle the full weight of an assembled system.

Welcome to OutBack Power Systems’ FLEXware

FLEXware is a convenient all-aluminum power system oering simpler, code-compliant installation

of OutBack power electronics components. Three versions of FLEXware are available:

• FLEXware 250 for single FX Series Inverter/Charger installations along with the desired AC and

DC disconnects

• FLEXware 500, which supports up to two FXs and two MX Charge Controllers, accommodating

both split-phase and/or higher power output as needed

• FLEXware 1000 accommodates up to four FXs and four MX Charge Controllers

Please Note: Both the FLEXware 500 and the FLEXware 1000 power systems provide locations for

FW-X240 Auto-Transformers, multiple DC shunts and other essential components required in

higher kW systems.

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HUB

Getting to Know FLEXware 500

MX60s

AC Breakers ACA FX (with DCC) DCA

IOB Kit FW500-AC FW Mounting Plate DC Breakers MX60 DC FW500-DC
Disconnect
Breaker

Figure 1: Complete FLEXware 500 System installed (vertical installation is acceptable when

mounting space is limited)

Note: Although FLEXware 500 supports two MX Charge Controllers, both locations—top and

side—are shown in Figure 1.

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Knockouts and Dimensions

11.40

18.27

12.06

Front View

Side View

Figure 2

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A complete FLEXware 500 System consists of the following in addition to the FW500-AC

and FW500-DC:

• FLEXware Mounting Plate (FW-MP)

• two FX Series Inverter/Chargers

• AC Conduit Adapter (ACA) and a DC Conduit Adapter (DCA), which connect each FX to the

FW500-AC and FW500-DC

• MX Charge Controller(s) (normally part of this system) and mounting brackets

• AC and DC breakers including a specic AC Input/Output/Bypass Breaker (IOB) Kit

per installation

• bus bars and DC current shunts as required per specic installation

• DC and AC ground fault protection

Some systems will work optimally with an FW-X240 Auto-Transformer installed.

Note: Be sure you have all the parts required for your intended system installation. As every

installation is dierent, consult with your dealer or installer for further information.

FLEXware 500 Parts List

FLEXware 500 consists of the FW500-AC and FW500-DC. Each is an aluminum chassis for mounting

AC and DC breakers, respectively, along with the components listed below:

FW500-DC components:

FW500-AC components:

• aluminum enclosure

• DIN rail bracket

• Breaker and Bypass Mounting Bracket

• TBB-GROUND

• ex nylon conduit and ttings

(conduit runs between the FW500-AC

and FW500-DC as needed)

• aluminum enclosure

• 500 amp shunt with TBB attached

• TBB-GROUND

• FW breaker bus

• DC Breaker Mounting Bracket

• FW500-DC Hardware Kit

• DC positive bus bar

• jumper wire from DC negative to ground

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Installation Tips

• Never use less than the minimum recommended number and type of fasteners when installing

the FLEXware Mounting Plates.

• Each FX weighs in excess of 50 lbs and is often more easily installed by two people rather

than one.

• Be sure the DC enclosure is secured to the FLEXware Mounting Plate before attaching the

MX Charge Controller to it.

• Installation of each enclosure and breakers is normally easier by removing the breaker brackets

rst. Do not remove any breaker knockouts from these brackets without referring to the chosen

AC IOB kits and DC breaker selections rst.

• It is also easier if all conduit knockouts are removed before mounting the enclosures.

Mounting and Installation

FLEXware 500 is designed for mounting on the FLEXware Mounting Plate (FW-MP). Although the

components can be secured to other surfaces, the FW-MP is an engineered platform designed

for the FLEXware 500 installation. This manual illustrates such an installation. OutBack does not

endorse other installation methods and therefore cannot recommend fasteners or other means of

attachment due to the variety of installations possible in the eld.

Please see the FLEXware Mounting Plate Instructions for further information.

In addition to installing the AC and DC chassis, a typical installation includes two FX Series

Inverter/Chargers, an MX60 Charge Controller, a HUB Communications Manager, and AC and DC

conduit adapters. The installation of these components is also displayed in these instructions.

Slot indicates this is the top edge of the FW-MP

T

Figure 3: FLEXware Mounting Plate

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