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Integration Guide
Integration Guide
2007 1
Printed on Recycled Paper Copyright 2007®
Welcome
OutBack Power Systems is proud to begin another year
of designing and manufacturing solutions with you, the
customer, in mind. OutBack maintains the philosophy
that listening to our customers and innovating to meet
their needs is paramount to our success.
This past year OutBacks engineering, marketing and
operations teams have been focusing on taking the
suggestions provided by our customers to develop a
new line of products called FLEXware. FLEXware is an
evolution in balance of system components which are
simple to order, easy to assemble and fast to install. In
conjunction with this product development, we have
made efforts to further enhance our industry-leading
level of customer service by building our team of
qualified technical and order service personnel.
OutBack is excited about what the future will bring. We
will continue to listen to and learn from our customers,
and continue to innovate. The power electronics and
communications technologies we have developed over
the past several years will allow OutBack to continue
to provide the cutting edge solutions our customers are
looking for as we move ahead.
We are confident that OutBack will continue to lead the
way in bringing the solutions and services that people
have come to depend on.
Thank you for your support as we continue Powering
the Planet.
History
2001
OutBack was started by a passionate group of engineers
who wanted to bring power conversion electronics technology into
the 21st century.
This small startup quickly grew by offering innovative and well
designed solutions to renewable energy problems. OutBack listened
to their customers and made many of the changes that were
suggested, creating a truly customer focused company in the power
conversion electronics industry.
2002
OutBack introduces its first sealed sinewave inverter/
charger, the FX2024 - with resounding success.
This single model changed the way people looked at system
design by offering unprecedented flexibility in system design and
expansion while the sealed construction allowed for uses which
previously would have been considered too extreme for other
inverter/chargers.
OutBack releases the MX60 solar MPPT Charge Controller redefining
performance and value.
This revolutionary product changed the way solar systems were
being installed and quickly gained a reputation for getting the most
power possible from a PV array - often making it more expensive to
not use one.
2003
OutBack launches the first of the vented versions of the FX
Series inverter/chargers.
These VFX models were introduced in direct response to our
customers requests providing higher power at a similar price as the
sealed counterpart.
OutBack launches the PS2, value priced system integration
accessories.
This line of accessories addressed the needs of our customers for
competitively priced system integration accessories for smaller
systems.
2004
OutBack releases the worlds most efficient
grid-interactive inverter/charger.
These models raise the bar for performance and value for battery-
connected grid-interactive inverter/charger systems. OutBack
introduces the PS1 fully integrated grid-interactive power system.
This unique system sets a new standard for system integration,
performance and ease of installation in grid-interactive applications.
2005
OutBack reaches milestones in product deliveries and
product recognition.
MX60 and FX Inverter production lines each ship 10,000th unit.
OutBack Power equipped teams sweep the top three places in the
2005 Solar Decathlon, a competition between International
universities to develop and build the most energy efficient home.
2006
OutBack launches FLEXware, a new line of balance of system
components. 2
Introducing the FLEXware System
FLEXware is the latest example of OutBacks continuous
efforts to bring you the most value packed and
technologically advanced products available.
Our integrating partners, dealers, installers, and
system owners spokeand we listened. The resulting
FLEXware is the most integrated, modular, and
spacious installation system OutBack has ever
designed. Its components are more versatile, the wiring
space is larger, and the all-aluminum, powder-coated
construction not only resists corrosion longer, but is
lighter and easier to handle than our previous steel
construction. OutBacks new FLEXware makes for a
great looking installation that will look great for years
and years to come.
Designed to work as a modular building block
architecture, FLEXware offers more versatility than
ever before. From single inverter back-up systems to a
multiple inverter village power system FLEXware is
the solution.
The FLEXware 250 offers the lowest cost solution for
single inverter/charger installations when space and
budget are primary concerns.
The FLEXware 500 supports up to two inverter/
chargers and two charge controllers in an attractive,
versatile and code-compliant package when more
power is needed.
The FLEXware 1000 accommodates up to four
inverter/chargers and four charge controllers. It can
also be used for large systems with multiple power
panels for systems up to 36 kW.
Both the FLEXware 500 and FLEXware 1000 systems
provide ample locations for additional breakers, DC
current shunts, an autotransformer and other items
required in higher kW systems.
The new FLEXware MP mounting plate shows
the versatility of the FLEXware system with its
compatibility with both the FLEXware 500 and
FLEXware 1000 systems.
All of the FLEXware options have also been simplified,
making the design, ordering and installation of power
system easier than ever. 250
For applications with modest power requirements such as cabins, remote
communication sites and back-up power systems. The FLEXware 250
accommodates all of the essential protective devices in the smallest possible
space at the lowest installed cost. Utilizing an extremely compact design
and unique mounting features, one or two FLEXware 250 enclosures
can be mounted on each end of a single FX Series Inverter/Charger. The
FLEXware 250 enclosure is contructed of power-coated aluminum and has
been ETL listed. It provides breaker spaces for battery, PV array or PV GFP
breakers and mounting locations for AC GFCI outlet, AC breakers and
even an Input-Output-Bypass Assembly. In keeping with the philosophy of
FLEXware, the FLEXwares 250 flexibility is evident in the generous number
of knock-outs allowing the installation of conduit, cable glands and other
installation accessories.
3
Breaker Configuration Diagram
AC Side
DC Side
Knockout Location Diagram
Holds one large 1.5
(39 mm) wide 175
or 250 Amp breaker.
Includes large DC
breaker guard.
Holds up to four small 0.75
(19 mm) wide AC rated panel
mount breakers (not included).
The small sizes are rated for
1-60 Amps of AC current.
Support for optional AC Input-
Output-Bypass Assembly.
Holds up to four small 0.75
(19 mm) wide DC rated panel
mount breakers (not included).
The small sizes are rated for
1-80 Amps of DC current.
Holds one ground
fault duplex
receptacle.
AC Side
(1) 2 knockout (2.468 diameter)
(1) 1 knockout (1.359 diameter)
(1) ¾ knockout (1.093 diameter)
DC side
(1) 2 knockout (2.468 diameter)
(2) ½ knockout (0.875 diameter)
Back
(1) 2 knockout (2.468 diameter)
(2) 1 knockout (1.359 diameter)
Bottom
(1) 2 knockout (2.468 diameter) 4
FLEXware 250

Model: FW250
Description: DC and/or AC breaker enclosure for one FX Series Inverter/Charger
Includes: Ground bus bar, DC breaker handle guard, breaker mounting hardware and enclosure mounting hardware
Unit Dimensions (H x W x D)
Shipping Dimensions (H x W x L)
Shipping Weight
Enclosure Type
7.5 x 6.5 x 8.6 (19.1 x 16.5 x 21.8 cm)
9.75 x 8.4 x 11.6 (24.8 x 21.3 x 29.5 cm)
5 lbs. (2.3 kg)
Type-1 indoor (IP30)



Holds up to eight 1 to 80 Amp, one 175 or 250 Amp panel mount breaker and a GFCI AC outlet (not included).

Does not use the DCA or ACA for connection to an FX Inverter/Charger.

DC current shunt not included
FLEXware 250 AC Input-Output-Bypass Assemblies
Field installable kit for bypassing the AC input to the AC output for inverter maintainence or installation. Also
provides over-current protection.
Model: FW-IOB-S-120VAC

Includes: Three 60A 120VAC single pole PANEL mount breakers, sliding bypass interlock plate, wire and hardward kit
System Rating
Bypass Breaker
Input Breaker
Output Breaker
Single Phase 120VAC
One Pole @ 60 Amps 7.2 kW
One Pole @ 60 Amps 7.2 kW
One Pole @ 60 Amps 7.2 kW
60 Amp 7.2 kW
Model: FW-IOB-S-230VAC
Includes: Three 30A 120VAC single pole PANEL mount breakers, sliding bypass interlock plate, wire and hardware kit

System Rating
Bypass Breaker
Input Breaker
Output Breaker
Single Phase 230VAC
One Pole @ 30 Amps 6.9 kW
One Pole @ 30 Amps 6.9 kW
One Pole @ 30 Amps 6.9 kW
30 Amp 6.9 kW Knockout Location Diagram
Breaker Configuration Diagram
AC Side
DC Side
For applications with medium power requirements such as homes,
light commercial or larger back-up power systems. The FLEXware
500 system architecture is capable of supporting up to two OutBack FX
Series Inverter/Chargers, up to two MX60 Charge Controllers a