Outback Power Systems 500 - Manual

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 ...

Page 3 - Requirements and Warnings

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 enclosur...

Page 4 - Welcome to OutBack Power Systems’ FLEXware

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 ...

Page 5 - Getting to Know FLEXware 500

HUB MX60s 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. Getting to Know FLEXware 500 IOB Kit FW500-AC FW Mounting...

Page 6 - Knockouts and Dimensions

Front View Side View Figure 2 Knockouts and Dimensions 11.40 18.27 12.06 3

Page 7 - FLEXware 500 Parts List

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) (...

Page 8 - OutBack does not; Slot indicates this is the top edge of the FW-MP; FLEXware Mounting Plate

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 Mount...

Page 9 - AC side DC side; Both FXs installed

Figure 4: First FX installed 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 eac...

Page 11 - Installation of the AC Chassis and DC Chassis; To install the chassis:; AC side; Chassis Mounting Holes; AC Chassis

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 Figure 7: Cha...

Page 12 - FX Series Inverter/Charger; Corrugated Conduit installs between the chassis

Clear plastic AC cover AC Conduit Plate Figure 9: FX Series Inverter/Charger DC Wiring Cover (DCC) 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 Con...

Page 13 - DCA in place

• 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 D...

Page 14 - DCA bushing

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.• ...

Page 15 - ACAs installed; 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. Each ACA fits against the AC chassis 13

Page 16 - MX60 Installation; MX Charge Controller mounting options

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 addition...

Page 18 - Installing an OutBack HUB; OutBack HUB; HUB connection

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). Figure 14: OutBack HUB HUB connection 16

Page 19 - Wiring Diagram

Page 23 - Product Registration

Product Registration Please take a moment to register and provide us with some important information. Send to: OutBack Power Systems, 19009 62nd Avenue NE, Arlington, WA 98223 USA. Name: �� Address: ��...

Page 24 - European Sales Office

European Sales Office Barcelona, España (+34) 600-843-845 19009 62nd Avenue NE Arlington, WA USA(+1) 360-435-6030 www.outbackpower.com 900-0061-1