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Outback Power Systems FLEXware 500 manual

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Table of contents for the manual

  • Page 1

    500 U ser ’ s Guide Includes Mounting, Installation, and Pr oduct Registration[...]

  • Page 2

    OutBack P ower Systems FLEXwar e is a system of modular aluminum mounting hardware and installation components designed for con venient system installation and integration. About OutBack P ower Sy stems OutBack P ower Systems is a leader in advanced energy con version technology . Our products include true sine wave inv er ter/chargers , a maximum [...]

  • Page 3

    Requirements and W ar nings The OutBack FLEXwar e 500 enclosures (FW500-AC and FW500-DC) are listed by ETL as indoor enclosures to UL standar d UL 508A Industr ial Control P anels. This enclosure is intended f or battery circuits congured for 12 to 48 v olts nominal. Grounding Instructions – Each enclosure should be connected to a grounded , p[...]

  • Page 4

    W elcome to OutBack P ower S ystems ’ FLEX ware FLEXware is a con venient all-aluminum power system o ering simpler , code - compliant installation of OutBack power electronics components . Three versions of FLEX ware are a vailable: • FLEXware 250 f or single FX Series I nverter/Charger installations along with the desired A C and DC discon[...]

  • Page 5

    HUB MX60s Figur e 1: Complete FLEXwar e 500 System installed (vertical installation is acceptable when mounting space is limited) Note: Although FLEXwar e 500 suppor ts two MX Charge Controllers , both locations—top and side —are shown in F igure 1. Getting to Know FLEXw are 500 IOB Kit FW500-AC FW Mounting Plate DC Breakers MX60 DC FW500-DC Di[...]

  • Page 6

    F ront View Side View Figur e 2 Knockouts and Dimensions 11.40 18.27 12.06 3[...]

  • Page 7

    A complete FLEXwar e 500 System consists of the following in addition t o the FW500-AC and FW500-DC: • FLEXware Mounting Plat e (FW-MP) • two FX Series I nverter/Chargers • AC Conduit A dapter (ACA) and a DC Conduit A dapter (DCA), which connect each FX to the FW500-AC and FW500-DC • MX Charge Contr oller(s) (normally par t of this system) [...]

  • Page 8

    Installation Tips • Never use less than the minimum recommended number and type of fasteners when installing the FLEXware Mounting Plat es. • Each FX weighs in excess of 50 lbs and is often mor e easily installed by two people rather than one. • Be sure the DC enclosure is secur ed to the FLEXware Mounting Plat e before attaching the MX Charg[...]

  • Page 9

    Figur e 4: F irst FX installed With the Mounting Plate and the hanging screws (f or the FX Inverter/Chargers) inser ted, install the FXs. • Star t with the top FX. • Hang the FX on the hanging screws , but continue to hold onto it. • Loosely install f our M6 X 20 mm screws, included with the FW -MP , one in each corner ; tighten them when all[...]

  • Page 10

    After the FXs are installed , mount the AC chassis and the DC chassis in either order . Note: It is easier to remove the appropriate side knock outs from both the AC and DC chassis befor e installing either of them. If needed, the back knock outs must be removed befor e installation. Figur e 6: Removing chassis side knock outs When installing the A[...]

  • Page 11

    Installation of the AC Chassis and DC Chassis T o install the chassis: • Hold each chassis up to its respective mounting holes on the FW-MP . • Place one M6 X 10mm machine screw (pr ovided with the FW-MP) in each corner , tightening only enough to keep the chassis in place. AC side DC side Figur e 7: Chassis Mounting Holes AC Chassis Mounting H[...]

  • Page 12

    Clear plastic AC cover AC Conduit Plat e Figur e 9: FX Series I nverter/Charger DC Wiring Cover (DC C) Figur e 8: AC and DC chassis mounted With each chassis loosely mounted , the AC Conduit Adapt er (ACA) and DC Conduit Adapt er (DCA) are installed on each FX. • Remove the clear plastic AC cov er and AC Conduit Plat e from each FX. Corrugated Co[...]

  • Page 13

    • Line up either the ACA or DCA on its respective side of the FX, starting at the top. • T o attach a DCA, line up its t wo screw holes with the upper and low er right DCC screw holes. • When lined up, loosely install the upper scr ew to hold the DCA in place. • Slide the DC chassis over snug against the DCA (the scr ew slots in each chassi[...]

  • Page 14

    Plastic bushing, DC side Figur e 11: DCA bushing Note: The DCA will be held rmly in place when the DCC (FX cover) is secured at the end of the installation. T o install an ACA: • F ollow the separate ACA instructions f or mounting to the FX. • Line each ACA up with its conduit hole in the AC chassis . • When aligned, mo ve the AC chassis s[...]

  • Page 15

    F igure 12: ACAs installed With both the AC Chassis and DC Chassis installed , the breaker brackets, AC din rail(s), and optional AC and DC breakers can be installed. P lease see the individual Input/Output/B ypass Breaker (IOB) kit for instructions. Each ACA ts against the AC chassis 13[...]

  • Page 16

    MX60 Installation A FLEXware 500 Syst em will normally have up to two MX Charge Contr ollers installed on the FW500-DC. The chassis accommodates both side and top installation. Newer MXs have r ear knock outs allowing them to be mounted dir ectly to the side of the enclosure without the need for additional mounting brackets. Mounting brackets are a[...]

  • Page 17

    The MX Charge Contr oller attaches to the chassis using three #10 X 3/8” sheet metal screws included in the hardware kit. Two ar e inser ted from inside the MX and the third through the hanger on the top of the MX. MX Knockouts Figur e 13: MX Charge Contr oller 1” knock outs Charge Controller knock outs 15[...]

  • Page 18

    Installing an OutBack HUB An OutBack HUB allows the FX Series Inver ter/Chargers , MX60 Charge Controllers , and MA TE to communicate with each other . I t attaches to the outside of the FW500-AC (har dware included with the HUB). Figur e 14: OutBack HUB HUB connection 16[...]

  • Page 19

    Figur e 15: Wiring Diagram 17[...]

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  • Page 22

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  • Page 23

    Pr oduct Registration Please take a moment to regist er and provide us with some important information. Send to: OutBack P ower Systems , 19009 62nd Avenue NE, Arlington, W A 98223 USA. Name: ����������������������������������������������������?[...]

  • Page 24

    European Sales Office Barcelona, España (+34) 600-843-845 19009 62nd A venue NE Arlington, W A USA (+1) 360-435-6030 www .outback power .com 900-0061-1[...]