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500
User’s Guide
Includes Mounting, Installation, and
Product Registration
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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 Copyrigh
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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 configured 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
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Welcome to OutBack Power Systems’ FLEXware FLEXware is a convenient all-aluminum power system offering 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 100
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Getting to Know FLEXware 500 MX60s AC Breakers ACA FX (with DCC) DCA HUB 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. 2
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Knockouts and Dimensions 11.40 Front View 12.06 Side View 18.27 Figure 2 3
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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 specific AC Input/Output/Bypass Breaker (IOB) Kit per installation • bus bars and DC current shunts as
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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 first. Do not remove any brea
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With the Mounting Plate and the hanging screws (for the FX Inverter/Chargers) inserted, install the FXs. • Start with the top FX. • Hang the FX on the hanging screws, but continue to hold onto it. • Loosely install four M6 X 20 mm screws, included with the FW-MP, one in each corner; tighten them when all four are installed and the FX is aligned. • Install the remaining FX in the same manner. AC side DC side Figure 4: First FX installed Figure 5: Both FXs
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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 knockouts from both the AC and DC chassis before installing either of them. If needed, the back knockouts must be removed before installation. Figure 6: Removing chassis side knockouts When installing the AC chassis and the DC chassis: • Either chassis can be installed first, the order is not important. • Only loosely install the four screws securing each
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Installation of the AC Chassis and DC Chassis To install the chassis: • Hold each chassis up to its respective mounting holes on the FW-MP. • Place one M6 X 10mm machine screw (provided with the FW-MP) in each corner, tightening only enough to keep the chassis in place. AC side DC side AC Chassis DC Chassis Mounting Holes Mounting Holes Figure 7: Chassis Mounting Holes 8
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Corrugated Conduit installs between the chassis Figure 8: AC and DC chassis mounted With each chassis loosely mounted, the AC Conduit Adapter (ACA) and DC Conduit Adapter (DCA) are installed on each FX. • Remove the clear plastic AC cover and AC Conduit Plate from each FX. DC Wiring Cover (DCC) Clear plastic AC cover AC Conduit Plate Figure 9: FX Series Inverter/Charger 9
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• Line up either the ACA or DCA on its respective side of the FX, starting at the top. • To attach a DCA, line up its two screw holes with the upper and lower right DCC screw holes. • When lined up, loosely install the upper screw to hold the DCA in place. • Slide the DC chassis over snug against the DCA (the screw slots in each chassis are oval-shaped to allow for movement) so the DCA lines up with the conduit adapter hole on the chassis. • Install the plastic bushing from inside the chassis
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Plastic bushing, DC side Figure 11: DCA bushing Note: The DCA will be held firmly in place when the DCC (FX cover) is secured at the end of the installation. To install an ACA: • Follow the separate ACA instructions for mounting to the FX. • Line each ACA up with its conduit hole in the AC chassis. • When aligned, move the AC chassis snug against the ACAs after the ACA installations. • Press a 1” plastic bushing from inside the AC chassis out to the ACA through each previously removed knoc
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Each ACA fits against the AC chassis Figure 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. Please see the individual Input/Output/Bypass Breaker (IOB) kit for instructions. 13
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MX60 Installation A FLEXware 500 System will normally have up to two MX Charge Controllers installed on the FW500-DC. The chassis accommodates both side and top installation. Newer MXs have rear knockouts allowing them to be mounted directly to the side of the enclosure without the need for additional mounting brackets. Mounting brackets are available for top installation of all MX models and for side installation less recent models. Bracket screw locations are Screw locations for directly a
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MX Knockouts Charge Controller knockouts Figure 13: MX Charge Controller 1” knockouts The MX Charge Controller attaches to the chassis using three #10 X 3/8” sheet metal screws included in the hardware kit. Two are inserted from inside the MX and the third through the hanger on the top of the MX. 15
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Installing an OutBack HUB An OutBack HUB allows the FX Series Inverter/Chargers, MX60 Charge Controllers, and MATE to communicate with each other. It attaches to the outside of the FW500-AC (hardware included with the HUB). HUB connection Figure 14: OutBack HUB 16
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Figure 15: Wiring Diagram 17
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