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 communication 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.
Warranty Introduction Dear OutBack Customer, Thank you for your purchase of OutBack products. We make every effort to assure our power conversion 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.
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.
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.
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 T I V E E R R O R DC AC IN AC OUT LEDs 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.
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.
(3) Remove the AC Wiring Compartment plastic cover (secured with two Phillips screws) (2) Remove the DC battery caps (under the DCC or Turbo) (1) Remove the DCC or Turbo (secured by four Phillips corner screws) (4) Remove these two M5 hex bolts from the FX (5) Remove the AC Conduit Plate, which slides up and out from the FX Figure 5: Removing various covers from the FX 7
(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 first with a utility knife and then removed. The dual, concentric knockout on the back offers 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.
(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 flexible cable is used instead of an enclosure, appropriate strain relief is required.
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.
(5) Install the top section of the cover containing the surge protector first. (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 battery lugs.
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.
The locating pin on the FW-ACA bracket fits in this slot 1/ 3/ 07 FW-SP-R LEDs (4) Pass the FW-SP-R wires through the FWACA Bracket opening, lining up the locating pin with the slot on the surge protector.
(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.
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 • Phillips screwdriver • 13 mm socket (torque ratchet) • Wiring to the AC wiring block • Remove and install covers • 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.
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 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 DCcables 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.
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 fixed location applications. The effective 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.
1. Proof-of-purchase in the form of a copy of the original Product purchase invoice or receipt confirming the Product model number and serial number; 2. OutBack issued warranty certificate for the FX Series Inverter/Charger used with the Product; 3. Description of the problem; and 4. Shipping address for the replacement equipment.
Surge Protector Limited Warranty Registration Complete this form to request a Limited Warranty, and return it to: Outback Power Systems Inc. 19009 62nd Ave. NE Arlington, WA 98223 Note: A Limited Warranty Certificate will only be issued if this Registration Card is received by OutBack within 90 days of the date of the first retail sale of the eligible Product.
19009 62nd Avenue NE Arlington, WA USA (+1) 360-435-6030 European Sales Office Barcelona, España (+34) 600-843-845 www.outbackpower.
