Surge Protector
FW-SP-ACA
FW-SP-250
FW-SP-R
User’s Guide
Includes Mounting and Installation
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Warranty Introduction
Dear OutBack Customer,
Thank you for your purchase of OutBack products. We make every effort 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 warranty.
• All OutBack equipment must be installed according to their accompanying instructions and
manuals with specified over-current protection in order to maintain their warranties.
• The customer must return the component(s) to OutBack, securely packaged, properly ad-
dressed, and shipping paid. We recommend insuring your package when shipping. Packages
that are not securely packaged can sustain additional damage not covered by the warranty or
can void warranty repairs.
• There is no allowance or reimbursement for an installer’s or user’s labor or travel time required to
disconnect, service, or reinstall the damaged component(s).
• OutBack will ship the repaired or replacement component(s) prepaid to addresses in the conti-
nental United States, where applicable. Shipments outside the U.S. will be sent freight collect.
• In the event of a product malfunction, OutBack cannot bear any responsibility for consequential
losses, expenses, or damage to other components.
• The FW Surge Protector comes with a standard two-year warranty or is covered by any extended
warranty of the FX is it connected to, whichever is longer. The product registration must be
returned to obtain this extended warranty.
Please read the full warranty at the end of this manual for more information.
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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 combination FW-ACA enclosure and surge protector for the FLEXware
500 and FLEXware 1000 systems
• FW-SP-250, a combination surge protector board and FW250 AC cover which fits onto the
FLEXware 250 Enclosure
• FW-SP-R, a replacement surge protector board for the FW-ACA, FW-SP-ACA,
and the FW-SP-250
NOTE: It is a UL 1741 (2005) requirement for a grid-tie system to have approved surge protection.
Installing an FLEXware Surge Protector is also recommended if your AC source is irregular or
unreliable with power surges (a lower quality generator or inconsistent utility power, for instance).
IMPORTANT SAFETY INSTRUCTIONS
Read all instructions, cautionary markings, and all appropriate sections of this installation and user
manual as well as other component manuals before using the system.
Be cautious around electricity, electrical components, and batteries. Shocks, burns, injury, and even
death can occur if an installer comes in contact with electricity. The FLEXware Surge Protector is
designed for dry, indoor installation and should not be exposed to water.
Install all components and wiring according to national (NEC in the United States) and local
electrical and building codes. This includes submitting a plan to the local building department and
passing an inspection.
NOTE: The FW-ACA, which houses the surge protector, is designed as a wireway between FX
Series Inverter/Chargers and OutBack enclosures (508A Industrial Control Panels) including the
FLEXware 500 and FLEXware 1000. The FW-ACA’s knockouts are not intended for conduit, but can
accommodate flexible cables with appropriate strain relief.
OutBack Power Systems cannot be responsible for system failure, damages, or injury resulting from
improper installation of their products.
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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. The FLEXware Surge Protector features ACTIVE and ERROR LEDs for the DC, AC IN,
and AC OUT circuits.
• The yellow ACTIVE LEDs light when power is applied to that circuit.
• A red ERROR light indicates a significant surge has damaged the FLEXware Surge Protector and
although decreased protection remains, it is recommended the FLEXware Surge Protector be
replaced at this time before further damage to it and ultimately the FX can occur.
NOTE: A circuit must be ACTIVE in order for an ERROR indication to occur.
The FLEXware Surge Protector shunts excess current from:
• DC+
GROUND
• AC HOT IN
GROUND
• AC NEUTRAL IN
• AC HOT OUT
• AC HOT OUT
• AC NEUTRAL OUT
GROUND
AC NEUTRAL OUT
GROUND
GROUND
Figure 1: Metal Oxide Varistor (MOV), thermally fused
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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
T
I
E
R
R
O
R
V
E
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 Protector Specifications
Nominal
Voltage
Voltage Protection
Level
Maximum
Surge Current
Energy
Rating
Frequency
Protection
Type
Protected
Circuit
120-240 VAC 390VAC
30kA per
circuit
2500 Joules 50/60 Hz
Thermally
Fused MOV
2AC
1DC
12-48 VDC
150 VDC
Mounting
• FW-SP-250
• FW-SP-ACA
Mounts inside an FW250
Mounts on an FX
• FW-SP-R (REPLACEMENT)
Mounts inside either the FW250 or the FW-ACA
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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:
• Slotted screwdriver
• Phillips screwdriver
• 13 mm socket (torque ratchet)
• Utility knife
Purpose:
•
Wiring to the AC wiring block
• Remove and install covers
• Securing wires to FX DC terminals
• Removing plastic knockouts
• Removing and installing FX M5 hex bolts
• 4 mm Allen wrench
Procedure
Turn off the system’s DC, AC IN, and AC OUT breakers (if available, use BYPASS mode to power any
loads).
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(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 Con-
duit Plate, which slides
up and out from the FX
Figure 5: Removing various covers from the FX
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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 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.
(9) The FW-SP-ACA slides onto the FX in
the same location as the now removed AC
Conduit Plate and secures to the FX with its
own factory-supplied screws in the same
location as the removed M5 hex bolts.
Figure 6: Preparing and installing the FW-SP-ACA onto an FX
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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 flexible
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 appropriate locations and replace the various plastic
covers as per the wiring instructions on page 16.
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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:
• Slotted screwdriver
• Phillips screwdriver
• 13 mm socket (torque ratchet)
• Utility knife
Purpose:
•
•
•
•
•
Wiring to the AC wiring block
Remove and install covers
Securing wires to FX DC terminals
Removing plastic knockouts
• 4 mm Allen wrench
Removing and installing FX M5 hex bolts
Procedure
The FLEXware 250 AC should already be installed (see FW250 AC instructions) and all AC and DC
power shut off.
(3) Remove the standard FLEXware 250
AC cover (secured by four Phillips screws).
(1) Remove the DCC or Turbo
cover (secured by four Phillips
screws) and the two battery caps.
(2) Remove the AC Wiring
Compartment cover (secured by
two Phillips screws).
Figure 8: FLEXware 250 AC
(4) Replace the standard FLEXware 250 AC cover
with the FW-SP-250, securing it with six Phillips
screws (four from the removed FW250 AC cover
and two additional that come with the FW-SP-
250).
Figure 9: FW-SP-250
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(5) Install the top section of the cover contain-
ing 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.
(9) Secure the surge protector’s wiring in the appropriate locations and replace the various plastic
covers as per the wiring instructions on page 16.
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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:
• Slotted screwdriver
• Phillips screwdriver
• 13 mm socket (torque ratchet)
• Utility knife
Purpose:
• Wiring to the AC wiring block
• Remove and install covers
• Securing wires to FX terminals
• Removing plastic knockouts
• Removing and installing FX M5 hex bolts
• 4 mm Allen wrench
NOTE: Always shut off the AC and DC power to the FX before replacing a damaged board or
installing a surge protector.
(1)To install an FW-SP-R inside an FW-SP-ACA, remove the FW-SP-ACA by reversing the installation
steps on pages 7-9.
Procedure
Installing an FW-SP-R inside an FW-ACA or an FW-SP-ACA
(2) Remove the FW-ACA plastic
cover (secured with two
Phillips screws)
(3) Remove the FW-
ACA Bracket (secured
with one Phillips
screw); if a damaged
FLEXware Surge
Protector is being
replaced, remove it
by disengaging the
locating pin
FW-ACA housing
Locating pin
Figure 11: FW-ACA
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The locating pin on the FW-ACA
bracket fits 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 with the LEDs
below.
A
E
R
R
O
R
C
T
I
V
E
Figure 13: FW-SP-R installed inside the FW-ACA
DC
AC IN
AC OUT
LED label
(8) Install the FW-ACA onto the AC side of the FX Series Inverter/Charger (see pages 7-8) and
attach the wiring (see page 16).
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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:
• Slotted screwdriver
Purpose:
• Wiring to the AC wiring block
• Remove and install covers
• Securing wires to FX DC terminals
• Phillips screwdriver
• 13 mm socket (torque ratchet)
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
Compartment cover (secured by
two Phillips screws).
(1) Remove the DCC or Turbo
cover (secured by four Phillips
screws) and the DC battery caps.
(3) Remove the FW-SP-250 (secured
by six Phillips screws).
(5) The new FW-SP-R installs
on these four standoffs on
the inside of the FW-SP-250
cover; torque to 8-12 inch-
pounds.
(4) Remove
the damaged
FLEXware Surge
Protector by
unfastening
these four
(6) When the new surge protector board has been secured
to the FW-SP-250 cover, reinstall the FW-SP-250 as shown on
pages 10-11.
Philips screws.
15
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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 first 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
protector cables
Each surge protector wire inserts directly on top of any installed power wire with its label facing up.
The surge protector spade lugs will sit on top of the AC wires connected to the wiring block. The surge
protector ring terminals will sit on top of the FX’s DC lugs
•
Secure the AC wiring block screws to 22 inch-pounds and the DC cables to five foot-pounds after installing
each power cable and surge protector wire
MATE/HUB
Battery Temp
Figure 15: Securely connect the surge protector wires to the FX and
connect any power, HUB, MATE, AUX, and/or BATTERY TEMP sensor
wiring.
FLEXware Surge Protector Wiring Designations:
• DC+
• DC-
• AC HOT OUT
• AC HOT IN
• AC NEUTRAL OUT
• AC NEUTRAL IN
• GROUND
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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 LED
AC INPUT from a utility grid or generator will light the AC IN ACTIVE LED
Initially, if any ERROR LED lights, check all wiring and inspect the surge protector circuit board
for damage. If no damage or wiring problems are found but the ERROR light stays lit, please
contact OutBack Technical Services
•
Check the surge protector periodically and particularly after any suspected surge event. If an
ERROR occurs, replace the board with an FW-SP-R or contact OutBack Technical Services
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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 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.
For this Warranty to be valid, the Product purchaser must complete and submit the applicable
Product registration card within ninety (90) days of the eligible Product’s first retail sale and
OutBack must acknowledge receipt of the registration card through the issuance of an
OutBack Warranty Certificate. This Warranty applies to the original OutBack Product purchaser
and is transferable only if the Product remains installed in the original use location with the
original OutBack FX Series Inverter/Charger. This Warranty does not apply to any Product or
Product part that has been modified or damaged by the following:
•
•
•
•
•
•
•
•
•
•
•
•
•
Installation or Removal;
Alteration or Disassembly;
Normal Wear and Tear;
Accident or Abuse;
Corrosion;
Lightning;
Repair or service provided by an unauthorized repair facility;
Operation contrary to manufacturer product instructions;
Fire, Floods or Acts of God;
Shipping or Transportation;
Incidental or consequential damage caused by other components of the power system;
Any product whose serial number has been altered, defaced or removed; or
Any other event not foreseeable by OutBack.
OutBack’s liability for any defective Product, or any Product part, shall be limited to the repair
or replacement of the Product at OutBack’s discretion. OutBack does not warrant or guarantee
workmanship performed by any person or firm installing the Products. This Warranty does not
cover the costs of installation, removal, shipping (except as described below), or reinstallation
of the Products.
To request warranty service, you must contact OutBack Technical Services at (360) 435-6030
required, OutBack will issue a Return Material Authorization (RMA) number. A request for an
RMA number requires all of the following information:
Revision 2007-06-20
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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.
After receiving the RMA number, pack the Product(s) authorized for return, along with a copy
of the original purchase invoice and warranty certificate, in the original Product shipping
container(s) or packaging providing equivalent protection; mark the outside of the container
clearly with the RMA number. The sender must prepay all shipping charges, and insure the
shipment, or accept the risk of loss or damage during shipment. OutBack is not responsible
for shipping damage caused by improperly packaged Products, the repairs this damage might
require, or the costs of these repairs. If, upon receipt of the Product, OutBack determines the
Product is defective and that the defect is covered under the terms of this Warranty, OutBack
will then and only then ship a repaired or replacement Product to the purchaser freight
prepaid, non-expedited, using a carrier of OutBack’s choice within the continental United
States where applicable.
Shipments to other locations will be made freight collect. The warranty period of any repaired
or replacement Product is twelve (12) months from the date of shipment from OutBack, or the
remainder of the initial FX Series Inverter/Charger warranty term, whichever is greater.
THIS LIMITED WARRANTY IS THE EXCLUSIVE WARRANTY APPLICABLE TO OUTBACK PRODUCTS,
AND OUTBACK EXPRESSLY DISCLAIMS ANY OTHER EXPRESS OR IMPLIED WARRANTIES
OF ITS PRODUCTS, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. OUTBACK ALSO EXPRESSLY
LIMITS ITS LIABILITY IN THE EVENT OF A PRODUCT DEFECT TO REPAIR OR REPLACEMENT IN
ACCORDANCE WITH THE TERMS OF THIS LIMITED WARRANTY AND EXCLUDES ALL LIABILITY
FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING WITHOUT LIMITATION ANY
LIABILITY FOR PRODUCTS NOT BEING AVAILABLE FOR USE OR LOST REVENUES OR PROFITS,
EVEN IF IT IS MADE AWARE OF SUCH POTENTIAL DAMAGES. SOME STATES (OR JURISDICTIONS)
MAY NOT ALLOW THE EXCLUSION OR LIMITATION OF WARRANTIES OR DAMAGES, SO THE
ABOVE EXCLUSIONS OR LIMITATIONS MAY NOT APPLY TO YOU.
Revision 2007-06-20
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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. Please submit a copy (not the
original) of the Product purchase invoice, which confirms the date and location of purchase, the price
paid, and the Product Model and Serial Number.
Surge Protector Limited Warranty Registration
System Owner
Name: __________________________________________________________________________________
Address: ________________________________________________________________________________
City, State, Zip Code: _________________________________________Country: _______________________
Telephone Number: ____________________________________E-mail: ______________________________
Product Model Number:____________________________Product Serial Number:______________________
Sold by:_________________________________________Purchase Date: ____________________________
The following questions refer to the FX Series Inverter/Charger on which the FLEXware Surge Protector is installed:
FX Series Inverter/Charger Model Number:______________________________________________________
FX Series Inverter/Charger Serial Number:_______________________________________________________
Please circle the three most important factors affecting your purchase decision:
Price
Product Reputation
Product Features
Reputation of OutBack Power
Value
System Install/Commission Date: ________________________System Array Size: ______________________
System Array Nominal Voltage: __________________________Type of PV Modules: _____________________
System Battery Bank Size (Amp Hours):____________________Type of Batteries:________________________
Please List Other sources of Back-up Power:_____________________________________________________
Installer: ___________________________________________Contractor Number:______________________
Installer Address: __________________________________________________________________________
Installer City, State, Zip: _____________________________________________________________________
Installer E-mail:____________________________________________________________________________
Revision 2007-06-20
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19009 62nd Avenue NE
Arlington, WA USA
(+1) 360-435-6030
European Sales Office
Barcelona, España
(+34) 600-843-845
900-0089-01-00 REV A
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