Outback Power Systems FW-SP-R, FW-SP-ACA, FW-SP-250 User Manual
Surge Protector
FW-SP-ACA
FW-SP-250
FW-SP-R
User’s Guide
Includes Mounting and Installation
About OutBack Power Systems
OutBack Power Systems is a leader in advanced energy conversion technology. Our products
include true sine wave inverter/chargers, maximum power point charge controllers, system com-
munication components, as well as breaker panels, breakers, accessories, and assembled systems.
Notice of Copyright
FLEXware Surge Protector
FLEXware Surge Protector-ACA (FW-SP-ACA)
FLEXware Surge Protector-250 (FW-SP-250)
FLEXware Surge Protector-R (FW-SP-R)
© 2007 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, INDI-
RECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFOR-
MATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER’S RISK.
Contact Information
OutBack Power Systems
19009 62nd Ave. NE, Arlington, WA 98223
Phone (360)435-6030
Fax (360)435-6019
www.outbackpower.com
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Warranty Introduction
Dear OutBack Customer,
Thank you for your purchase of OutBack products. We make every e ort to assure our power con-
version products will give you long and reliable service for your renewable energy system.
As with any manufactured device, repairs might be needed due to damage, inappropriate use, or
unintentional defect. Please note the following guidelines regarding warranty service of OutBack
products:
• Any and all warranty repairs must conform to the terms of the warranty.
• All OutBack equipment must be installed according to their accompanying instructions and
manuals with speci ed over-current protection in order to maintain their warranties.
• The customer must return the component(s) to OutBack, securely packaged, properly ad-
dressed, and shipping paid. We recommend insuring your package when shipping. Packages
that are not securely packaged can sustain additional damage not covered by the warranty or
can void warranty repairs.
• There is no allowance or reimbursement for an installer’s or user’s labor or travel time required to
disconnect, service, or reinstall the damaged component(s).
• OutBack will ship the repaired or replacement component(s) prepaid to addresses in the conti-
nental United States, where applicable. Shipments outside the U.S. will be sent freight collect.
• In the event of a product malfunction, OutBack cannot bear any responsibility for consequential
losses, expenses, or damage to other components.
• The FW Surge Protector comes with a standard two-year warranty or is covered by any extended
warranty of the FX is it connected to, whichever is longer. The product registration must be
returned to obtain this extended warranty.
Please read the full warranty at the end of this manual for more information.
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OUTBACK FLEXware Surge Protector
INSTALLATION GUIDELINES AND SAFETY INSTRUCTIONS
This product is intended to be installed as part of a permanently grounded electrical system .
• The FLEXware Surge Protector is designed for indoor installation or installation inside a
weatherproof enclosure.
• For full system protection, one FLEXware Surge Protector per FX Series Inverter/Charger should
be installed.
Models
There are three FLEXware Surge Protector products:
• FW-SP-ACA, which is a combination FW-ACA enclosure and surge protector for the FLEXware
500 and FLEXware 1000 systems
• FW-SP-250, a combination surge protector board and FW250 AC cover which ts onto the
FLEXware 250 Enclosure
• FW-SP-R, a replacement surge protector board for the FW-ACA, FW-SP-ACA,
and the FW-SP-250
NOTE:
It is a UL 1741 (2005) requirement for a grid-tie system to have approved surge protection.
Installing an FLEXware Surge Protector is also recommended if your AC source is irregular or
unreliable with power surges (a lower quality generator or inconsistent utility power, for instance).
IMPORTANT SAFETY INSTRUCTIONS
Read all instructions, cautionary markings, and all appropriate sections of this installation and user
manual as well as other component manuals before using the system.
Be cautious around electricity, electrical components, and batteries. Shocks, burns, injury, and even
death can occur if an installer comes in contact with electricity. The FLEXware Surge Protector is
designed for dry, indoor installation and should not be exposed to water.
Install all components and wiring according to national (NEC in the United States) and local
electrical and building codes. This includes submitting a plan to the local building department and
passing an inspection.
NOTE: The FW-ACA, which houses the surge protector, is designed as a wireway between FX
Series Inverter/Chargers and OutBack enclosures (508A Industrial Control Panels) including the
FLEXware 500 and FLEXware 1000. The FW-ACA’s knockouts are not intended for conduit, but can
accommodate exible cables with appropriate strain relief.
OutBack Power Systems cannot be responsible for system failure, damages, or injury resulting from
improper installation of their products.
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INTRODUCTION
The OutBack FLEXware Surge Protector connects to the following FX Series Inverter/Charger ports:
• DC+
• DC-
• AC HOT IN
• AC NEUTRAL IN
• AC HOT OUT
• AC NEUTRAL OUT
• GROUND
The FLEXware Surge Protector is designed to protect the FX’s sensitive components from
excessively high voltages (e.g., electrical storms). Thermally fused metal oxide varistors (MOVs) limit
or “clamp” these voltages and transfer the resulting current from a higher voltage port to a lower
voltage port. The FLEXware Surge Protector features ACTIVE and ERROR LEDs for the DC, AC IN,
and AC OUT circuits.
• The yellow ACTIVE LEDs light when power is applied to that circuit.
• A red ERROR light indicates a signi cant surge has damaged the FLEXware Surge Protector and
although decreased protection remains, it is recommended the FLEXware Surge Protector be
replaced at this time before further damage to it and ultimately the FX can occur.
NOTE: A circuit must be ACTIVE in order for an ERROR indication to occur.
Figure 1: Metal Oxide Varistor (MOV), thermally fused
The FLEXware Surge Protector shunts excess current from:
• DC+ GROUND
• AC HOT IN GROUND
• AC NEUTRAL IN GROUND
• AC HOT OUT AC NEUTRAL OUT
• AC HOT OUT GROUND
• AC NEUTRAL OUT GROUND
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Electrical Connections and LED Indicators
Each AC and DC wire is marked near the
Figure 2: Wiring designations
A
C
T
I
V
E
E
R
R
O
R
LEDs
DC
AC IN
AC OUT
Figure 3: Surge Protector LEDs
LEDs
• ACTIVE lights are yellow (power is present).
• ERROR lights are red (protection in that circuit is compromised, replacing the surge protector is
recommended).
• For the ERROR light to show, its circuit must be powered; its ACTIVE light will also glow.
terminal end of each wire.
The FLEXware Surge Protector Speci cations
Nominal Voltage Protection Maximum Energy Frequency Protection Protected
Voltage Level Surge Current Rating Type Circuit
120-240 VAC 390VAC 30kA per 2500 Joules 50/60 Hz Thermally 2AC
12-48 VDC 150 VDC circuit Fused MOV 1DC
Mounting
• FW-SP-250 Mounts inside an FW250
• FW-SP-ACA Mounts on an FX
• FW-SP-R (REPLACEMENT) Mounts inside either the FW250 or the FW-ACA
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FW-SP-ACA
The FW-SP-ACA consists of an FW-ACA with an included surge protector and is installed onto an
FX Series Inverter/Charger.
Underside screw secures
FW-SP-ACA to FX
Phillips screw secures
FW-SP-ACA bracket and
surge protector board to
the FW-SP-ACA
LEDs
Underside screw secures
FW-SP-ACA to FX
Figure 4: FLEXware Surge Protector-ACA
Tools Required to Install: Purpose:
• Slotted screwdriver • Wiring to the AC wiring block
• Phillips screwdriver • Remove and install covers
• 13 mm socket (torque ratchet) • Securing wires to FX DC terminals
• Utility knife • Removing plastic knockouts
• 4 mm Allen wrench • Removing and installing FX M5 hex bolts
Procedure
Turn o the system’s DC, AC IN, and AC OUT breakers (if available, use BYPASS mode to power any
loads).
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