Outback Power Systems Power Supply FW X240 User Manual

FW-X240  
AUTO TRANSFORMER  
Installation Manual  
 
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  
FW-X240 Auto Transformer Installation Manual © 2007 All rights reserved.  
Disclaimer  
UNLESS SPECIFICALLY AGREED TO IN WRITING, OUTBACK POWER SYSTEMS:  
(a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR  
OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION.  
(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER DIRECT, INDIRECT,  
CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION.  
THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER’S RISK.  
Date and Revision - July, 2008  
Contact Information:  
OutBack Power Systems  
19009 62nd Ave. NE  
Arlington, WA 98223  
Phone: 360.435.6030  
Fax: 360.435.6019  
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Welcome to the OutBack Power Systems FW-X240 Auto Transformer  
The FW-X240 Auto Transformer can be used for step-up, step-down, generator and split phase output  
balancing or with series-stacked FX or VFX Series Inverter/Chargers for inverter balancing.  
OutBack Power Systems does everything possible to assure the components you purchase will func-  
tion properly and safely when installed as instructed according to local and national electrical codes  
(NEC). Please read all of the following instructions and the instructions that come with any other  
OutBack components that make up your power system.  
The FW-X240 Auto Transformer Specifications:  
• 120 volt/25 amp primary and secondary side  
• 120 or 240 VAC 60 Hz systems only  
• Allows powering 240 volt items ( e.g., a deep well pump) with a single 120 volt AC source  
• Step-down feature allows battery charging with both legs of a 240 volt generator through a single  
120 volt FX Series Inverter/Charger  
Two identical windings:  
• Winding one is between leads #1 and #2  
• Winding two is between leads #3 and #4  
• The start for each winding are on lead #1 and on lead #3  
IMPORTANT SAFETY INSTRUCTIONS  
SAVE THESE INSTRUCTIONS  
Please read all instructions and cautionary markings on the FW-X240 and other system components  
and their instructional manuals.  
To reduce risk of electric shock:  
• Disconnect all DC and AC power sources before attempting any maintenance or repair.  
• The input side of the AC and DC breakers may be live even though the breakers are off.  
• Be sure to test all terminals with a voltmeter before touching or using any tools.  
• Always use caution when using metal tools to prevent contact with live parts or terminals.  
• All installations must be in compliance with all local and national electrical codes and standards.  
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Grounding Instructions  
The FW-X240’s metal mounting bracket must be connected to a permanently grounded  
system. System grounding as required by the National Electric Code, ANSI /NFPA 70-1996, is the  
responsibility of the system installer.  
• The FW-X240 hardware kit includes grounding washers to penetrate a powder-coated finish,  
assuring a proper ground connection to any FLEXware enclosure or mounting plate.  
• An installation might call for an optional grounding wire between the FW-X240 and the FLEXware  
enclosure or mounting plate to which it’s attached depending on local code requirements or the  
nature of the installation itself.  
Connections  
• No additional terminals or lugs are required for hook-up of the AC wiring.  
• AC wiring must be no less than 10 AWG gauge copper wire, rated for 75 degrees C or higher and  
must be sized appropriately to the circuit breaker.  
Hardware Kit  
The FW-X240 comes with four M6 X 20 mm screws, four flat washers, and four grounding washers for  
mounting to a FLEXware Mounting Plate from inside a FLEXware AC enclosure.  
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Figure 1: FW-X240 Auto Transformer, top view  
Mounting Slots  
The FW-X240 is installed inside a FLEXware enclosure which is designed for attachment to a FLEXware  
Mounting Plate.  
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MOUNTING SLOTS  
(HARDWARE  
INCLUDED)  
Figure 2: FW500 AC Chassis  
Note: The FW-X240 should be installed inside the FW500 after the FW500 is secured to the FLEXware  
Mounting Plate.  
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Notes:  
• The FW-X240 should be installed inside the FW1000  
after the FW1000 is secured to the FLEXware  
Mounting Plate.  
• The FW-X240 can be fastened to other surfaces  
providing the surface and fasteners used can safely  
sustain a weight in excess of 25 lbs.  
Figure 3 FW1000 AC Chassis  
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Figure 4: Step-Down Wiring  
Diagram  
• L1: Black  
• L2: Red  
• Neutral: White  
• TBB: Terminal Bus Bar  
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Figure 5: Generator Step-  
Up Wiring Diagram  
• L1: Black  
• L2: Red  
• Neutral: White  
• TBB: Terminal Bus Bar  
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Figure 6: OutBack  
Stacking Wiring Diagram  
• L1: Black  
• L2: Red  
• Neutral: White  
• TBB: Terminal Bus Bar  
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LOAD L1 120VAC  
500WATTS  
LOAD L2 120VAC  
4500WATTS  
TO LOADS  
TO LOADS  
4500W  
500W  
X240  
25 AMP  
25 AMP  
RED  
BLACK  
2000W  
2000W  
2500W  
2500W  
WHITE  
WHITE  
AC NEUTRAL BUS  
120V  
120V  
Figure 7: FW-X240 Installation Balancing Two FX Series Inverter/Chargers (OutBack Stacking)*  
* Figure 9 shows current flowing from the L1 FX through the FW-X240 to run in parallel with the L2 FX  
output. The L1 inverter is producing almost half of the power required to power the load on L2 and  
at the same time is supplying power to its own L1 load.  
• When both FXs are awake and producing power, a 240 Volt load will be powered by both inverters  
equally.  
• If there is less than 1000 watts on L1, then the L2 FX will go to sleep. The FW-X240 is still active and  
producing 240VAC.  
• A small 240VAC load would be powered from the L1 inverter and the FW-X240.  
• A large load turning on will wake up the L2 FX. The L2 inverter will go back to sleep as soon as the  
large load on L2 goes away.  
Note: Systems with more than four FXs might require two FW-X240s in parallel and require 35 amp  
breakers as well.  
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T M  
Product Registration  
Please take a moment to register and provide  
us with some important information and return it to:  
Outback Power Systems Inc.  
19009 62nd Ave. NE  
Arlington, WA 98223  
NOTE: Please complete one form for all installed FLEXware product.  
FLEXware Product Registration  
System Owner  
Name: _______________________________________ Address: ________________________________________  
City, State, Zip Code: ____________________________ Country: ________________________________________  
Telephone Number:_____________________________ E-mail: _________________________________________  
Installer  
Company: ____________________________________ Contractor Number:_______________________________  
Installer Address: _______________________________ Installer City, State, Zip: ____________________________  
Installer E-mail:_________________________________  
System  
System Install/Commission Date: __________________  
Sold by: ______________________________________ Purchase Date: ___________________________________  
Please circle type of application:  
Off-Grid  
Grid-Interactive  
AC Coupled  
Backup  
Mobile  
Please circle installed components:  
FLEXware Enclosures and Mounting Components  
IOB Kits  
FW-IOB-S-120VAC  
FW-IOB-S-230VAC  
FW-IOB-D-120/240VAC  
FW-IOB-D-120VC  
FW-IOB-T-120/208VAC  
FW-IOB-T-230/400VAC  
FW-IOB-Q-120/240VAC  
FW-IOB-Q-230VAC  
FLEXware 250  
FLEXware MP  
FLEXware PV 8  
FLEXware PV 12  
FLEXware 500 AC  
FLEXware 500 DC  
FLEXware 1000 AC  
FLEXware 1000 DC  
FW-IOB-D-230VAC  
The system is equipped with (circle one):  
FW-X240 PSX-240 PSX-240-Relay  
Please circle the three most important factors affecting your purchase decision:  
• Price • Product Reputation • Product Features • Reputation of OutBack Power Systems  
• Value  
I am interested in receiving information concerning OutBack Power Systems products and  
events (circle one):  
Yes  
No  
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Corporate Office  
European Sales Office  
C/ Castelló, 17  
08830 - Sant Boi de Llobregat  
BARCELONA, España  
+34.93.654.9568  
19009 62nd Avenue NE  
Arlington, WA USA  
(+1) 360-435-6030  
900-0076-01-00 REV C  
 

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