Wire sizes/torque requirements, Mounting, Warning: personal injury – Outback Power Systems FLEXpower TWO Quick Start Guide User Manual
Page 2: Warning: fire/explosion hazard, Important, Fp2 mounting, Ac wire sizes and torque values
Wire Sizes/Torque
Requirements
AC Circuit Breakers
DC Circuit Breakers
DC Enclosure
Control Wiring Terminal Block:
The Inverter ON/OFF terminals are used for connecting an
external ON/OFF switch. To use this feature, the jumper
must be removed. (See installation manual for details.)
The AUX terminals provide a 12 Vdc signal. The AUX
terminals can be used to start a generator or to control
external devices.
AUX terminals are also available on the charge
controller and the FLEXnet DC. (See the charge
controller or FNDC installation manuals for details.)
Mounting
WARNING: Fire/Explosion Hazard
Do not place combustible or flammable materials within 12 feet (3.7 m) of the equipment. This unit employs mechanical
relays and is not ignition-protected. Fumes or spills from flammable materials could be ignited by sparks.
WARNING: Personal Injury
Use safe lifting techniques and standard safety equipment when working with this equipment.
IMPORTANT:
Clearance and access requirements may vary by location. Maintaining a 36” (91.4 cm) clear space in front of the system
for access is recommended. Consult local electric code to confirm clearance and access requirements for the specific
location.
FP2 Dimensions:
20.25" (51.4 cm) H X 36.5" (92.6 cm) W X 13.5" (34.3 cm) D
900-0152-01-00 Rev A.vsd\Page-2\2013-01-17
©2012 OutBack Power Technologies. All Rights Reserved.
CAUTION: Equipment Damage
When connecting cables from the inverter to the battery
terminals, ensure the proper polarity is observed.
Connecting the cables incorrectly can damage or
destroy the equipment and void the product warranty.
Torque requirements for
the conductor lugs
Circuit
Breaker Stud
Torque
In-lb
Nm
M8
20
2.3
¼ - 20
35
4.0
5/16 - 18
50
5.6
3/8 - 16
225
25.4
AC Wire Sizes and Torque Values
It is recommended that conductors be #6 AWG
THHN copper, or larger, rated to 75°C
(minimum) unless local code requires otherwise.
AWG
In-lb
#14 - 10
20
#8
25
#6 - 4
35
#3
35
#2
40
#1
50
1/0
50
mm
2
2.5 – 6
10
16 – 25
35
35
50
70
Nm
2.3
2.8
4.0
4.0
4.5
5.6
5.6
Wire Size
Torque
Shunt
Bolt 3/8"
Lock Washer
Flat Washer
Battery
Negative (–)
Lug
Negative (–) Battery Cable
Connections
Bolt 3/8"
DC Positive (+)
Plate
Battery
Positive (+)
Lug
Flat Washer
Positive (+) Battery Cable
Connections
Nut
Lock Washer
AC Enclosure
Communication Manager HUB10
DC Enclosure
FLEXmax 80 Charge Controller
1
2
3
4
AC Enclosure
1
2
Master Inverter
Slave Inverter
3
4
6
7
8
9
10
5
6
Mechanical Interlock (Bypass)
7
8
8
MATE3 System Display and Controller
9
10
Charge Controller Terminals
Inverter DC Circuit Breakers
GFDI
PV Input Circuit Breakers
FLEXnet DC (FNDC)
11
12
13
14
15
11
12
13
14
15
15
5
AUX Control Terminals
16
16
16
16
16
Inverter Chassis Ground
DC Positive (+) Plate
17
18
19
Charge Controller Chassis Ground
20
DC Negative (–) Plate
17
18
19
19
20
20
Surge Protector
CC Communication Ports
21
22
23
FNDC Communication Port
24
Inverter Communication Ports
21
21
22
22
23
23
24
FP2 Mounting:
1. Ensure the mounting
surface is strong enough
to handle 3 times the total
weight of all the
components.
2. Using additional people to
assist with lifting, place the
panel on the wall. Ensure
the panel is level.
3. Secure the panel into the
surface using a minimum
of 10 lag bolts (or other
appropriate hardware).
4. Remove the covers from
the AC Enclosure and the
DC Enclosure.
5. Follow the instructions for
installing the bracket for
the MATE3.
6. Follow the instructions for
installing the brackets for
the charge controllers.
1
2
3
4
5
6
1
2
3
4
4
4
4
5
6
Minimum DC Cable based on the
DC Circuit Breaker
Torque
In-lb
Nm
50
5.6
225
25.4
225
25.4
DC
Circuit
Breaker
Cable Size
125
1/0 (70 mm
2
)
175
2/0 (70 mm
2
)
250
4/0 (120 mm
2
)
35
4.0
80
#4 AWG (25 mm
2
)
35
4.0
60
#6 AWG (16 mm
2
)
16
16
DC
Negative (–)
Plate
Flat Washer
18
17