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Surge Protector
FW-SP-ACA
FW-SP-250
FW-SP-R
User’s Guide
Includes Mounting and Installation
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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 res
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Warranty Introduction Dear OutBack Customer, Thank you for your purchase of OutBack products. We make every eff 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 w
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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 combinatio
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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. Th
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Electrical Connections and LED Indicators Each AC and DC wire is marked near the terminal end of each wire. Figure 2: Wiring designations A C E T R I R V O E 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. The FLEXware Surge Protec
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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 so
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(3) Remove the AC Wiring (2) Remove the DC battery (1) Remove the DCC or Compartment plastic caps (under the DCC or Turbo) Turbo (secured by four cover (secured with two Phillips corner screws) Phillips screws) (4) Remove these two M5 hex bolts from the FX (5) Remove the AC Con- duit Plate, which slides up and out from the FX Figure 5: Removing various covers from the FX 7
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(6) Remove the cover from the FW-SP-ACA (secured with two Phillips screws) (7) Remove the appropriate knockouts for the individual power application. Note that knockouts should be scored fi rst with a utility knife and then removed. The dual, concentric knockout on the back off ers openings for the FW500, FW1000, PS2 and PS4 AC enclosures. (8) Remove any AC wires from the FX AC Wiring Block by loosening the slotted screws. These wires will be installed through the FW-SP-ACA. (9) The FW-S
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(10) Route the FW-SP-ACA FW-SP-ACA slides down FX slots wires through to the AC Wiring Compartment and to the battery lugs (11) Insert a bushing into the AC enclosure (it is not critical that this bushing line up precisely with the FW-SP-ACA); if fl exible cable is used instead of an enclosure, appropriate strain relief is required. Screws (included) secure the FW-SP-ACA to an FX Figure 7: Top view of FW-SP-ACA installed on an FX (12) Secure the surge protector’s wiring in the appropriat
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FW-SP-250 The FW-SP-250 is a two-piece combined FLEXware 250 top cover and FLEXware Surge Protector. It replaces an existing FLEXware 250 cover, attaching at the AC end of the FLEXware 250. 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
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(5) Install the top section of the cover contain- ing the surge protector fi rst. (6) The lower secton of the FW-SP-250 slides inside the FW250 and is then screwed into the previously installed top section. Removing the lower section allows viewing the inside of the FW250 to check the placement of wires and components. (7) Both sections of the FW-SP-250 are installed and secured with six Phillips screws. (8) Route the FW-SP-250 wires through to the AC Wiring Compartment and to the batt
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FW-SP-R (REPLACEMENT) for the FW-SP-ACA or the FW-ACA An FW-SP-R can replace a damaged surge protector in an FW-SP-ACA or FW-SP-250 or be installed in an FW-ACA when surge protection is desired. The FW-ACA includes a bracket for securing the FW-SP-R. 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 terminals • Utility knife • Removing plastic knoc
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1/3/07 The locating pin on the FW-ACA bracket fi ts in this slot FW-SP-R LEDs (4) Pass the FW-SP-R wires through the FW- ACA Bracket opening, lining up the locating pin with the slot on the surge protector. Figures 12: FW-SP-R and FW-ACA Bracket 13
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(5) With the FW-SP-R attached to the FW-ACA Bracket, hold the ends of the FW-SP-R wires and slide it and the bracket back inside the FW-ACA to its original location. NOTE: The FW-SP-R slides into a double slot at the bottom of the FW-ACA. The LEDs should be level with the top of the FW-ACA housing. (6) Secure the FW-ACA Bracket with Phillips screw (7) If installing the FW-SP-R in an FW-ACA, place the FW-ACA plastic cover on the housing and attach the LED label to the cover, lining it up w
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FW-SP-R (REPLACEMENT) for the FW-SP-250 In the event an FW-SP-250’s board is damaged, it can be replaced without going to the expense of replacing the cover as well. 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 Procedure: Be sure all AC and DC power to the FX is shut off before installing the FW-SP-250. (2) Remove the AC Wiring (
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Wiring and Connecting the FLEXware Surge Protector With the FW-SP-250 or FW-SP-ACA secured, connect all AC and DC wiring as well as any HUB, MATE, AUX, and BATTERY TEMP cables. • Install all AC and DC power cables fi rst followed by the surge protector wires in their appropriate locations; each wire is labeled on the shrink-wrapped ends near the DC ring terminals and the AC spade lugs • If the AC cables are already installed, loosen the AC wiring block screws in order to insert the surge pro
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• Install the various covers in this order with the DCC or Turbo last: (1) DC battery terminals (2) FW-ACA (if used) (3) AC Wiring Compartment The surge protector’s DC + and DC- cables and the BATT TEMP sensor cable pass under this rubber bushing Figure 16: After wiring, install all covers. Figure 17: DCC or Turbo is installed last. The system can now be powered up • DC power lights up the surge protector’s DC ACTIVE LED • AC OUTPUT from the FX will light up the AC OUT ACTIVE
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FLEXware™ Surge Protector Limited Warranty OutBack Power Systems, Inc. (“OutBack”) provides a limited warranty (“Warranty”) against defects in materials and workmanship for its FLEXware Surge Protector Products (“Product”) if installed for use with OutBack FX Series Inverter/Chargers in fi xed location applications. The eff ective time period of this Warranty is determined by the length of the warranty for the FX series Inverter/Charger installed for use with the Product. For this Warranty t
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1. Proof-of-purchase in the form of a copy of the original Product purchase invoice or receipt confi rming the Product model number and serial number; 2. OutBack issued warranty certifi cate for the FX Series Inverter/Charger used with the Product; 3. Description of the problem; and 4. Shipping address for the replacement equipment. After receiving the RMA number, pack the Product(s) authorized for return, along with a copy of the original purchase invoice and warranty certifi cate, in the or
