FLEXmax Series Charge Controllers - OutBack Power Inc

FLEXmax SeriesCharge Controllers(FLEXmax 80, FLEXmax 60)Owner’s Manual

About OutBack PowerOutBack Power is a leader in advanced energy conversion technology. OutBack productsinclude true sine wave inverter/chargers, maximum power point tracking charge controllers, andsystem communication components, as well as circuit breakers, batteries, accessories, andassembled systems.Contact InformationAddress:17825 – 59th Avenue N.E.Suite BArlington, WA 98223 LESS SPECIFICALLY AGREED TO IN WRITING, OUTBACK POWER:(a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OFANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHERDOCUMENTATION.(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHERDIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OFTHE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BEENTIRELY AT THE USER’S RISK.Notice of CopyrightFLEXmax Series Charge Controllers Owner’s Manual 2008 by OutBack Power.All Rights Reserved.TrademarksOutBack Power and the OutBack Power logo are trademarks owned and used by OutBackPower, an EnerSys company. These trademarks may be registered in the United States andother countries.Date and RevisionJanuary 2020, Revision DPart Number900-0009-01-00 Rev D

Table of ContentsIntroduction . 7Features . 7Firmware . 7Soft Keys . 8Installation . 9Standards and Requirements . 9Rapid Shutdown . 9Grounding . 9DC / Battery-Related Installation Requirements . 9Dimensions . 10Mounting the Charge Controller . 11Wiring . 12Wire and Disconnect Sizing . 12FLEXmax 80 . 12FLEXmax 60 . 12Wiring Compartment. 13Operation . 17Power Up Screens . 17Version and/or Voltage Setting Screens . 18Status Screen . 19End-of-Day Summary Screen . 20Navigating End-of-Day Screens & Data Logging . 21Modes of Operation . 22Absorbing . 22Auto Start (Auto ReStart) . 23BatTmpErr . 23BatTooHot . 23Charged . 23EQ . 23EQ Done . 23EX-Absorb . 24Floating . 24GT Mode. 24High Voc . 24Low Light or Snoozing . 24MPPT Bulk. 24MPPT Float. 25MPPT EQ . 25New Voc. 25OvrCurrent . 25Over Temp. 25Re-Cal . 25Sleeping. 25Sys Error . 26Tracking . 26Unloaded . 26Wakeup . 26Zzzzz. . 26900-0009-01-00 Rev D3

Table of ContentsInitial Operation. 27Changing the Settings on the FLEXmax . 27Accessing the Main Menu . 27Main Menu Map . 28Charger Screen . 29Aux Screens . 30AUX MODE Screen Navigation . 32Vent Fan (AUX Mode) . 33PV Trigger (AUX Mode) . 34Error Output (AUX Mode) . 35Night Light (AUX Mode) . 36Float (AUX Mode) . 37Diversion (AUX Mode) . 38Low Battery Disconnect (AUX Mode) . 43Remote (AUX Mode) . 44Backlight . 44EQ – Battery Equalize . 45Misc Screen . 47Advanced Menu . 49Snooze Mode (Advanced Menu) . 49Wakeup Mode (Advanced Menu) . 50MPPT Mode (Advanced Menu) . 50Absorb Time Limits (Advanced Menu) . 52Absorb End Amps (Advanced Menu) . 52Rebulk Voltage (Advanced Menu) . 53Vbatt Calibration (Advanced Menu) . 53RTS Compensation (Advanced Menu) . 53Auto ReStart (Advanced Menu) . 55Aux Polarity (Advanced Menu) . 56Reset to Defaults? . 56Logging . 57Stats . 58Viewing the Firmware Revision . 59Extended Play Mode . 59Rebooting the FLEXmax . 60MATE3-class System Display and Controller . 61Display and LED Status Indicators . 61Charge Controller Soft Key . 62DataLog Screen . 63Graph Screens . 64Menu Structure in the MATE3 and MATE3s . 65Charge Controller Settings . 66Charger . 66MPPT . 66Temperature Compensation. 67Battery Equalize . 67Grid-Tie Mode. 67Auxiliary Output (Charge Controller) . 68Aux Modes for the Charge Controller . 68Restart Mode . 69Calibrate . 70Reset Charge Controller to Factory Defaults . 70Device Data Logs . 71Saving Data Logs for the FLEXmax Controller . 71Data Log File Format . 724900-0009-01-00 Rev D

Table of ContentsMATE-Class System Display and Controller . 73Summary Screens . 73Status Screens . 74MODE Screens. 74METER Screens . 75SETPT Screens . 76LOG Screens . 77STAT Screens . 78Advanced Menus . 79Accessing the Advanced Menus . 79CHGR Menu . 80CC ADVANCED Menu . 81EQ Menu . 82AUX Menu . 83MATE and MATE2 FLEXmax Menu Maps . 84STATUS Menu Map . 84Advanced Menu Map . 86Menu Maps for the FLEXmax . 89Troubleshooting . 93Specifications . 95Electrical and Mechanical Specifications. 95Firmware Revision . 95Regulatory Specifications . 95Default Settings and Ranges . 96Applications . 97Maximum Power Point Tracking . 97Three-Stage Battery Charging . 98BULK . 98ABSORBING . 99FLOAT . 99Battery Temperature Compensation . 99Array Design . 100Sizing Guidelines . 100Open Circuit Voltage (Voc) . 100Weather Conditions. 100Maximum-Power Voltage (Vmp) . 101Standard vs. Australian Default Settings . 101Hydroelectric and Fuel Cell Applications Performance Optimization . 102Auto Track Mode . 102U-Pick Mode . 102Grid-Interactive Settings . 104FLEXmax Efficiency vs. Input Power. 104Definitions . 105Index . 107900-0009-01-00 Rev D5

Table of ContentsList of TablesTable 1Table 2Table 3Table 4Table 5Table 6Table 76Battery Voltage and Charge Timer . 23Aux Mode Functions . 30Regulatory Specifications for All Models . 95FLEXmax Settings . 96Maximum PV Input Wattage per Charge Controller . 100Default Settings Standard vs. Australian . 101Terms and Definitions. 105900-0009-01-00 Rev D

IntroductionIMPORTANT:This manual provides safety guidelines and installation information for theFLEXmax Series Charge Controllers. It does not provide information aboutspecific brands of PV modules and supplies limited information on batteries.Contact the supplier or manufacturer of the PV modules or batteries foradditional information.Thank you for purchasing a FLEXmax Series Charge Controller (CC). These charge controllersoffer an efficient, safe, multi-stage recharging process that prolongs battery life and assurespeak performance from a PV array.Each charge controller is designed to seamlessly integrate with other OutBack components andcan be remotely monitored and configured (up to 1000 feet or 300 meters away) using theoptional OutBack Power system displays.FeaturesThe FLEXmax Charge Controllers use continuous Maximum Power Point Tracking (MPPT),which seeks out the maximum power available from a PV array and uses it to recharge thebatteries. Without this feature, the PV array does not operate at the ideal voltage and can onlyoperate at the level of the battery voltage itself. (See page 97 for a description of MPPT.) Eachcharge controller continuously tracks the array’s maximum operating power.The FLEXmax Series has two models available:oFLEXmax 80: 80 amps maximum continuous output current (up to 40 C without thermal derating)oFLEXmax 60: 60 amps maximum continuous output current (up to 40 C without thermal derating)Both models have the following features:oSupports 12, 24, 36, 48, and 60 Vdc battery voltagesoBacklit LCD display screen with 80 characters (4 lines, 20 characters per line)oLast 128 days of operational data are logged for reviewoVoltage step-down capability allowing a higher PV array voltage configurationoManual and auto-equalize cycleFirmwareThis manual covers FLEXmax firmware revision 003.003.000 or higher.900-0009-01-00 Rev D7

IntroductionLCD ScreenSoft KeysFLEXmax 80Figure 1FLEXmax 60Charge Controller FeaturesSoft KeysFour “soft” keys are located directly below the LCD. The functions of the soft keys will varydepending on the location of the user within the menu structure. Some soft keys will be used fornavigation. Some soft keys will be used for programming.Soft key functions are identified by text in the LCD screen directly above the key (e.g., EXIT).In this manual, soft keys will be identified by brackets (for example, EXIT ). Not every softkey may be used in some screens.Main Menu Charger AuxLightEQMisc AdvancedLoggingStatsEXIT GOSoft Key ButtonsLCDSoft Key Commands( EXIT , GO etc.)SK1 SK2 SK3 SK4Figure 28Soft Keys900-0009-01-00 Rev D

InstallationStandards and RequirementsAll installations must comply with national and local electrical codes; professional installationis recommended.IMPORTANT:The charge controller is designed for indoor installation or installation inside a weatherproofenclosure. It must not be exposed to rain and should be installed out of direct sunlight.Rapid ShutdownThe FLEXmax 60 and FLEXmax 80 charge controllers are not to be installed on controlledconductors of a PV Rapid Shutdown System (PVRSS). Controlled conductors are defined bythe 2017 National Electrical Code and may be different from local requirements.GroundingThis product is intended to be installed as part of a permanently grounded electrical system asshown in the wiring diagrams shown in Figure 6, Figure 7, and Figure 8.oThe FLEXmax equipment ground is marked with this symbol:The following important restrictions apply unless superseded by local or national codes:oooThe negative battery conductor should be bonded to the grounding system at only one point in thesystem. If a GFDI is present, the battery negative and ground are not bonded together directly butare connected together by the GFDI device when it is on. All negative conductor connections mustbe kept separate from the grounding conductor connections.The FLEXmax controller is not intended to be wired into a positive-ground configuration. However,certain telecom applications may require this configuration. If a positive-ground system is necessary,consult www.outbackpower.com/forum/, where this subject has been discussed extensively.If damaged or malfunctioning, the FLEXmax should only be disassembled and repaired by a qualifiedservice center. Please contact the local renewable energy dealer/installer for assistance. Incorrectreassembly risks malfunction, electric shock or fire.DC / Battery-Related Installation RequirementsShut off all DC circuit breakers before connecting any wiring.Torque all the FLEXmax wire lugs and ground terminals to 4 Nm (35 in-lb).Copper wiring must be rated at 75 C or higher.Use up to 35 mm2 (2 AWG) to reduce losses and ensure highest performance of the FLEXmax.Smaller cables can reduce performance and possibly damage the unit.o Run positive and negative cables side by side. Keep cables together as much as possible to allow the inductive currents to cancel. Ensure paired cables pass through the same knockout and conduit fittings.o DC battery overcurrent protection must be used as part of the installation. OutBack offers both circuitbreakers and fuses for overcurrent protection.900-0009-01-00 Rev D9oooo

InstallationDimensions16.25” (41.3 cm)FLEXmax 80Controller5.75”(14.6 cm)FLEXmax 60ControllerFigure 3104.0”(10.2 cm)13.5” (34.3 cm)FLEXmax 80 and FLEXmax 60 Dimensions900-0009-01-00 Rev D

InstallationMounting the Charge ControllerIMPORTANT:Install the FLEXmax in an upright position out of direct sunlight.The FLEXmax is designed to attachdirectly to OutBack’s FLEXware 500 DCand FLEXware 1000 DC enclosures(FLEXware 500 shown) or attach to itsown charge controller brackets (FW-CCB,FW-CCB2, and FW-CCB2T).Mounting directly to a FLEXwareDC enclosure:1. Remove the fan cover and bottomcover from the FLEXmax.2. Insert a #10 ⅜” sheet metal screwin the top hole on the side of the DCenclosure. This will act as a hangingscrew for the keyhole slot at the topcenter of the FLEXmax.Insert screwsthrough lowerholes insidethe chargecontrollerHoles for#10 x 3/8”sheet metal3. Hang the FLEXmax on the topscrew and line up its bottom twoscrew holes with the holes onthe enclosure.4. Insert a #10 ⅜” sheet metal screwthrough each hole and tighten againstthe enclosure (screws are includedwith each DC enclosure).5. Keep the cover off until wiringis completed.The conduit nipple assembly creates asealed connection from the FLEXmax tothe enclosure.DCEnclosureCharge Controller(front view)Use 1-5/8” wood screws to secure theFLEXmax at the top slotted holes andother interior lower holes as need

This manual covers FLEXmax firmware revision 003.003.000 or higher. Introduction 8 900-0009-01-00 Rev D Figure 1 Charge Controller Features . " keys are located directly below the LCD. The functions of the soft keys will vary depending on the location of the user within the menu structure. Some soft keys will be used for navigation. Some .