max TM 80 Maximum Power Point Tracking Charge Controller User’s Guide Installation, Programming and User’s Manual
Warranty Summary Dear OutBack Customer, Thank you for your purchase of OutBack products. We make every effort to assure our power conversion 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.
The OutBack Power Systems FLEXmax 80 Maximum Power Point Tracking Charge Controller is ETL listed in North America to UL1741 (Inverters, Converters, Controllers, and Interconnection System Equipment for Use with Distributed Energy Resources). It is also in compliance with European Union standards EN 61000-6-1 and EN 61000-6-3 (see page 89). About OutBack Power Systems OutBack Power Systems is a leader in advanced energy conversion technology.
TABLE OF CONTENTS SCOPE ....................................................................................................................................................................................................... 5 INTRODUCTION................................................................................................................................................................................... 5 INSTALLATION GUIDELINES AND SAFETY INSTRUCTIONS.............................................
Vbatt Calibration...........................................................................................................................................................................50 RTS Compensation......................................................................................................................................................................50 Auto Restart............................................................................................................................
SCOPE The manual provides safety guidelines and installation information for the FLEXmax 80 Maximum Power Point Tracking Charge Controller. It does not provide information about specific brands of solar panels and supplies limited information on batteries. Contact the supplier or manufacturer of the solar panels or batteries for further information.
OUTBACK FLEXmax 80 CHARGE CONTROLLER INSTALLATION GUIDELINES AND SAFETY INSTRUCTIONS This product is intended to be installed as part of a permanently grounded electrical system as shown in the system configuration sections (see pages 12-14) of this manual. The following important restrictions apply unless superseded by local or national codes: • The negative battery conductor should be bonded to the grounding system at only one point in the system.
WARNING - WORKING IN THE VICINITY OF A LEAD ACID BATTERY IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL OPERATION. Design the battery enclosure to prevent accumulation and concentration of hydrogen gas in “pockets” at the top of the enclosure. Vent the battery compartment from the highest point to the outside. A sloped lid can also be used to direct the flow of hydrogen to the vent opening.
THE OUTBACK POWER SYSTEMS FLEXmax 80 Maximum Power Point Tracking Charge Controller
1. Installing the FLEXmax 80 FLEXware DC Enclosures TheFLEXmax 80 is designed to attach directly to OutBack’s FLEXware 500 DC and FLEXware 1000 DC enclosures (FLEXware 500 shown) or attach to its own charge control brackets (FW-CCB, FWCCB2, and FW-CCB2T). NOTE: Install the FLEXmax 80 in an upright position out of direct sunlight.
2. Determining Wire Sizes Open Circuit Voltage/Wire and Disconnect Size Maximum Open Circuit Voltage (VOC) • VOC is the unloaded voltage generated by the solar array. • Greater than 145VDC g FLEXmax 80 suspends operation to protect components • 150DC g max open circuit voltage with the coldest environment NOTE: Although the FLEXmax 80 shuts down at a voltage greater than 145VDC, it can withstand up to 150VDC from the array; anything higher than 150VDC will damage the FLEXmax 80).
3. FLEXmax 80 Wiring Connections Figure 1 FLEXmax 80 wiring compartment Use up to 2 AWG (33.6 mm2) wire and torque to 35-inch pounds at terminals. PV+ PV- BAT- BAT+ Wire Lugs MATE/HUB RJ45 jack Chassis/Equipment Ground Lug Battery Remote Temp Sensor (RTS) RJ11 jack Programmable AUX Output Jack (supplies up to 200mA @ 12 VDC Screw holes for attaching FLEXmax 80 The PV (-) and BAT (-) terminals are connected internally.
Figure 2 Single Charge Controller wiring diagram with 24 volt PV array 12
Figure 3 Charge Controller Wiring Diagram with an FX, HUB 4, and an RTS 13
Figure 4 Charge Controller with PV array ground fault protection wiring digram.
How to Read the FLEXmax 80 Screen Diagrams Soft keys: (#1) (#2) (#3) (#4) Solid black indicates key is to be pressed: Down arrow will lead to the next screen: Up arrow points to one or more keys that will change a value: The keys correspond to any text immediately above them.
4. Powering Up The FLEXmax 80 power-up sequence first activates the unit and the SELECT VERSION screen (to determine a choice of English, Espanola, or Australian settings). A SYSTEM VOLTAGE screen soon follows. However, when it auto-detects the system’s battery voltage, in some instances the FLEXmax 80 might not reflect the correct system voltage (e.g., if a 36VDC system falls to a voltage range that could be misread as a 24VDC system).
Select Version Elija la Version USA NEXT ENTER ENTRA SEL The FLEXmax 80 screens are offered in English (standard screens) and Spanish. For Australian users, some of the charging values are of different voltages and the FLEXmax 80 accommodates these. By pressing the soft key, the user can choose USA, Australia, or Espanola versions of the screens. After pressing the soft key, a password must be entered before selecting the screen version.
Are you sure? USA NO YES The FLEXmax 80 auto detects the system’s battery voltage. To confirm this voltage, press the soft key. If incorrect, press the “g” soft key to select a battery voltage. The FLEXmax 80’s default values are based on a 12VDC system. Selecting a higher voltage system will change all the default values (e.g., the values will double with a 24VDC system, triple with a 36 VDC system, etc.). “^^” indicates the chosen voltage.
5. Status Screen The STATUS Screen displays system information. See page 63 for detailed information of the different Operational Modes. The optional OutBack MATE displays CC (Charge Controller) STATUS screens for convenient distant viewing from the installation location of the FLEXmax 80. Please see pages 65-67 to view the Charge Controller screens displayed on the MATE.
6. End of Day Summary Screen The End of Day summary screen appears after one hour of continuous sleeping. This screen can be opened anytime by pressing the second soft key while in the STATUS screen, providing a summary up to that point. Peak output current Day (up to 128 days) Peak Input Voltage Maximum batt voltage obtained Accumulated amp hours Today 0000AH 00.0 kWH 011Vp 00.0Ap 0.00kWp MAX 14.7 V ABS 01:00 MIN 14.
8. Accessing the MAIN Menu The MAIN Menu allows the user to adjust and calibrate the FLEXmax 80 for maximum performance. From the STATUS screen, press the first soft key on the left to open the MAIN Menu screen. g Charger Aux Light EQ Misc Advanced Logging Stats EXIT f g GO Press the soft key after aligning the arrow in front of the selected menu choice. Pressing the soft key in the MAIN Menu returns to the STATUS screen.
7. Charger Set-Up This screen allows changes to the FLEXmax 80’s recharging voltage set points—Current Limit, Absorb and Float (for an explanation of battery charging, see pages 81-82): • The presently selected numerical value will have an arrow “ g ” to the left of it. • Pressing < > selects the value to be changed. • You may need to re-enter the password to change these settings. • The default charger output current limit setting is 80 amps and is adjustable from 5-80 amps.
8. AUX Mode and Its Functions The AUX is a secondary control circuit—essentially, a small power supply that provides a 12VDC (up to 200 milliamps) output current. It is either active (12VDC on) or inactive (0VDC). Most AUX modes or functions are designed for specialized applications and are infrequently used. • To access the AUX MODE from the MAIN Menu, press the < > soft key until the arrow is in front of the Aux selection (see next page).
AUX MODE Menu Path g Charger AUX MODE Vent Fan Output: Off Off EXIT NEXT SET MODE Charger gAux Light EQ Misc Advance Logging Stats g GO EXIT f Aux Light EQ Misc Advance Logging Stats EXIT f g GO g PASSWORD ***150*** g AUX MODE Vent Fan Output: Off Off EXIT NEXT SET MODE ENTER - + g To access the AUX Output Menu: • Press the first soft key once from the STATUS Menu to open the MAIN Menu.
AUX modes in order of appearance on the FLEXmax 80 display: • Vent Fan • PV Trigger • Error Output • Night Light • Float • Diversion Relay • Diversion Solid State • Low Battery Disconnect • Remote Note: All AUX functions can be manually activated in On, Off, or Auto mode. In Auto mode, the function will automatically activate when a user-determined value is met and deactivate or shut down when other conditions described here, such as a certain amount of time passing, occur.
9. Programming the AUX MODES VENT FAN AUX MODE Vent Fan Output: Off Off EXIT NEXT SET MODE AUX MODE Vent Fan EXIT VOLT VENT FAN VOLTS > 14.4 BACK - + 26 On Off Auto Press the soft key to manually activate or deactivate (On or Off) the Vent Fan; if set to Auto, the Vent Fan will turn on when a user-determined voltage is met. Press the soft key to view the Vent Fan screen. To view other screens, continue to press the soft key.
AUX MODE Vent Fan Press the soft key return to the main Vent Fan screen. EXIT VOLT AUX MODE Vent Fan Output: Off Off Press the sot key to view the PV Trigger screen EXIT NEXT SET MODE g PV TRIGGER AUX MODE PV Trigger Output: Off Off EXIT NEXT SET MODE 27 When the PV input exceeds the user-determined VOLT set point, the AUX MODE PV Trigger activates in Off Auto Mode.
g AUX MODE PV Trigger Output: On On Press the soft key to open the PV Trigger’s TIME and VOLT(age) set menus. AUX MODE PV Trigger g EXIT NEXT SET MODE To adjust the voltage, press the soft key. EXIT TIME VOLT PV VOLTS >140 Adjust the voltage within a range of 20V-150V by pressing the < - > or < + > soft key.
Press the < - > or < + > soft key to adjust the Hold Time, then press the soft key to return to the PV Trigger screen. In this example, the AUX MODE will remain active for 1.1 seconds after the PV voltage is below the PV Trigger voltage before deactivating the PV Trigger and reconnecting to the array. Hold Time Sec 01.
ERROR OUTPUT AUX MODE ERROR OUTPUT Output: On On EXIT NEXT SET MODE On Off Auto AUX MODE ERROR OUTPUT 01 hrs EXIT VOLT ERROR LOW BATT VOLTS <11.5 BACK - + AUX MODE ERROR OUTPUT 01 hrs EXIT VOLT AUX MODE ERROR OUTPUT Output: On On EXIT NEXT SET MODE 30 The ERROR OUTPUT default state is On, meaning 12 VDC is present at the AUX terminal.
NIGHT LIGHT g AUX MODE Night Light Output: Off Off Off g EXIT NEXT SET MODE AUX MODE Night Light Output: Off Auto On Auto The Night Light illuminates a user provided low-wattage light when the PV voltage falls below a user-determined voltage. Off is the default value. Press the soft key to change the Night Light MODE (Off, On, or Auto). This example shows Auto MODE selected. Press the soft key to open the Hysteresis and PV Voltage screens.
Use the < - > and < + > soft keys to adjust the time required for the PV input voltage to be above the threshold voltage before the Night Light is disabled. Press the soft key twice to return to the Night Light screen. Night Light Off Hysteresis Time Minutes 000 AUX MODE Night Light g BACK - + EXIT HYST TIME VOLT Night Light On Time Hours 23 Use the < - > and < + > soft keys to adjust the number of hours the Night Light remains on.
g AUX MODE Night Light Press the soft key to return to the Night Light AUX mode. AUX MODE Night Light Output: Off Auto g EXIT HYST TIME VOLT Press the soft key ro view the AUX Float screen.
g AUX MODE Diversion: Relay EXIT TIME VOLT Hold 01.0 Time seconds Delay 00 Press the
g AUX MODE Diversion: Relay Press the soft key. AUX MODE Diversion: Relay Output: Off On g EXIT TIME VOLT If a Solid State Relay is used, press the soft key to access the Diversion Solid St screen.
Figure 5 Diversion Load and AUX Wiring Set-Up Illustrated 36
LOW BATTERY DISCONNECT AUX MODE Low Batt Disconnect Output: On On On EXIT NEXT SET MODE Off Auto AUX MODE Low Batt Disconnect When the battery voltage falls below the disconnect volts, the AUX connected loads only are disconnected; the AUX connected loads only are connected when the battery voltage rises above the reconnect volts. To adjust these set points, press the
AUX MODE Low Batt Disconnect EXIT TIME VOLT DISCONNECT VOLTS < 13.6 In the Low Batt Disconnect screen, press the soft key to adjust the battery voltage disconnects set point. Press either the < - > or the < + > soft key to adjust the disconnect voltage. Press the soft key to open the RE-CONNECT VOLTS screen. BACK - + ReCon RE-CONNECT VOLTS > 14.4 BACK - + DisV 38 Press either the < - > or the < + > soft key to adjust the RE-CONNECT VOLTS value.
AUX MODE Low Batt Disconnect Press the soft key. EXIT TIME VOLT AUX MODE Low Batt Disconnect Output: Off On Press the soft key to view the Remote screen. EXIT NEXT SET MODE REMOTE AUX MODE Remote Output: Off On EXIT NEXT SET MODE On Off In Remote AUX MODE, the OutBack MATE can control the FLEXmax 80’s AUX MODE. Press the soft key twice to return to the MAIN Menu screen.
10. Backlight On BACKLIGHT CONTROL Auto Time 2 Minutes Auto EXIT - + MODE Off Auto Auto (default) leaves backlight and soft keys on for up to nine minutes whenever any soft key is pressed (pressing any soft key when the LCD is not lighted does not change any settings). Minutes are adjustable using the < -> and < + > soft keys. On or Off states are also available.
BATTERY EQUALIZE Volts 15.0 EXIT NEXT -EQV +EQV BATTERY EQUALIZE Time 01 Hours EXIT NEXT -HRS +HRS Press either the < –EQV> or <+EQV > soft key to change the EQ voltage, following your battery manufacturer’s recommendations. Note that the factory default EQ voltage is set low, the same as the factory default Absorb voltage. Press the soft key to view the BATTERY EQUALIZE Time screen.
AUTO MODE COUNT 00 EQ INTERVAL 000 EXIT -DAY +DAY Use the <-DAY> and <+DAY> soft keys to preset the interval day to initiate an automatic equalization cycle. The EQ INTERVAL displays the number of days in the interval between cycles and COUNT displays how many days of the interval have passed. To view the MAIN EQ screens, press the soft key. NOTE: • Auto Mode initiates when a preset interval day (1-250 days) is reached.
12. MISC—Miscellaneous The MISCELLANEOUS screens display extra settings and technical information, some of which is useful for OutBack Power Systems Technical Services. The Grid Tie (GT) value is sent from G-series inverter through the MATE and HUB for Grid Tie control communications. GT means THE FLEXmax 80 is in grid tie mode and communicating with the GT Series Inverter. Each MPPT operation is a state. This number is useful for OutBack troubleshooting. This is the duty cycle of the converter.
GT State PWM% ChgT 255 07 50.0 005 Press the soft key to view the FORCE FLOAT, or BULK screen. EXIT NEXT RSTRT FORCE EXIT NEXT FLOAT BULK Pressing the or soft key forces the FLEXmax 80 to that specific recharging cycle and returns to the STATUS screen. Forcing a FLOAT or BULK recharge will end an EQ cycle. Press the soft key to view the third MISCELLANEOUS screen.
13. Advanced The ADVANCED MENU allows fine-tuning of the FLEXmax 80 operations including Snooze periods and Maximum Power Point limits.
ADVANCED MENU Wakeup Mode 1.5V 05m EXIT NEXT +VOC +Min U-Pick %Voc and Auto Track are the two modes appearing on this screen. ADVANCED MENU MPPT Mode Auto Track EXIT NEXT nonGT MODE Wakeup Mode selects how often the FLEXmax 80 does a “Wakeup” during “Snoozing” periods.
ADVANCED MENU Park Mpp 77 % Voc ADVANCED MENU Park Mpp Watts 0251 77 % Voc EXIT NEXT -% +% EXIT NEXT -% +% As the user changes the %Voc value using the <-%> and <+%> soft keys, the displayed Watts value also changes. Watts appears when U-Pick is selected. Press the soft key to view the Park Mpp screen.
14. Charging-Related Screens ADVANCED MENU Absorb Time Limits 01.0 hours EXIT NEXT - + In the Absorb Time Limits screen, the user can set the duration the FLEXmax 80 stays in the Absorb recharge cycle. • Absorb Time is adjustable from 0 to 24 hours (consult your battery manufacturer’s recommendations). • A Bulk cycle starts each morning (see chart next page). The charge timer (ChgT) is preset to zero.
Figure 6 NOTE: In BULK, the FLEXmax 80 will charge as long as necessary to complete the cycle, regardless of the timer’s set points ADVANCED MENU Absorb End Amps 00 A EXIT NEXT - + An Absorb charge cycle normally ends when a battery voltage is maintained at the Absorb set point for the userdetermined time period. Use the < -> or < + > soft keys to adjust the Absorb End Amps to an optimal value (the default value is 00).
ADVANCED MENU Vbatt Calibration 14.1 V 0.0 V EXIT NEXT - + RTS Compensation* ADVANCED MENU RTS Compensation A 14.1 V F 13.8V EXIT NEXT WIDE A quality calibrated voltmeter will provide even more accurate FLEXmax 80 battery readings if an undesirable voltage drop occurs. When measuring battery voltage, ensure a good connection is made to the four wire lugs.
ADVANCED MENU RTS Compensation A 14.4 V F 13.8V Press the soft key to view the Auto Restart screen. EXIT NEXT LIMIT SET AUTO RESTART ADVANCED MENU Auto ReStart MODE 2 EXIT NEXT MODE ADVANCED MENU Auto ReStart MODE 0 EXIT NEXT MODE ADVANCED MENU Auto ReStart MODE 1 EXIT NEXT MODE 51 Pressing the fourth soft key selects among the three FLEXmax 80 Auto ReStart modes: 0 (default), 1, and 2.
ADVANCED MENU Auto ReStart MODE 2 From the Auto Restart MODE 2 screen, press the soft key to view the Aux Polarity screen. EXIT NEXT MODE g ADVANCED MENU Aux Polarity Active High EXIT NEXT MODE g ADVANCED MENU Aux Polarity Active Low EXIT NEXT MODE When the AUX function is ON, 12 volts is present at the AUX terminal; when it’s OFF, 0 volts are present at the terminal.
Are you sure? Reset to Defaults YES NO ADVANCED MENU Reset to Defaults? Pressing the soft key brings up a Reset to Defaults screen momentarily before returning to the Reset to Defaults? screen Press the key twice to return to the MAIN Menu screen.
15. Logging Today 0000Ah 00.0 KWH 011Vp 00.0Ap 0.00kWp MAX 14.7V ABS 01:00 MIN 14.6V FLT 00:00 CLEAR LOG BACK TOTL DAILY Are you sure? NO YES Today 0000Ah 00.0 KWH 011Vp 00.0Ap 0.00kWp MAX 14.7V ABS 01:00 MIN 14.6V FLT 00:00 A user can clear either the daily or accumulated statistics of the FLEXmax 80 by pressing the second button from the left in this screen. This will bring up the CLEAR LOG screen.
16. Stats Charger Aux Light Eq Misc Advanced Logging gStats EXIT f g From the MAIN Menu, press the soft key to move the arrow next to the Stats function and then press the soft key GO The STATS screen displays additional voltage and time information. Daily high VOC value Maximum battery voltage seen by the FLEXmax 80 Max Watt seen by the FLEXmax 80 The highest Voc seen by the FLEXmax 80 Max Bat Voc MaxVoc 14.9 036.6 133.
Secondary STATS screen Total 0000 kWH Total 000.0 kAH BACK DCkWH Total 0000 kWHAC Total 000.0 kAH BACK ACkWH 56 The Secondary Stats screen shows the total accumulated DC and AC kilowatt hours and kiloamp hours of the FLEXmax 80.
17. Micro-Hydro and Fuel Cell Applications The FLEXmax 80 is designed to work with solar arrays. Although it will work with micro-hydro turbines and fuel cell, OutBack Power Systems can only offer limited technical support for these applications because there is too much variance in micro-hydro and fuel cell generator specifications.
18. Advanced Menu (Micro-Hydro and Fuel Cell Applications) Mpp Range Limit % (Auto Track Mode only) The FLEXmax 80 searches for the MPP voltage by tracking the input voltage up to one half (default) of the Voc, which is based on values appropriate for a solar array. Micro-hydro and fuel cell systems can require a broader range, normally on the lower end.
19. Abbreviated Menu Map Much of the FLEXmax 80 activity takes place around the MAIN screen. From this screen, the user can access other screens to both observe system activiy and make adjustments to certain critical functions.
20. Application Notes OutBack Power System GTFX/GVFX Grid-tie settings In a GFX/GVFX Series Inverter/Charger, FLEXmax 80, HUB, and MATE installation set the FLEXmax 80 to GT mode in the ADVANCED MENU. GT mode allows the GFX/GVFX to manage the FLEXmax 80 float setting ensuring the FLEXmax 80 is always keeping the battery above the sell voltage of the GFX/GVFX.
21. FLEXmax 80 EFFICIENCY vs.
22. Understanding the Various Operational Modes The FLEXmax 80 modes of operation will change occasionally during the day based on the PV array output and the battery system state of charge. The FLEXmax 80 operating modes are displayed at the bottom right hand corner of the STATUS screen. Absorbing The FLEXmax 80 is in the Absorb (constant voltage) charge stage, regulating the battery voltage at the Absorb voltage set point (modified by battery temperature compensation if installed).
GT Mode In a system with an OutBack FX Grid-Tie Series Inverter(s), HUB and MATE, the FLEXmax 80 will display GT Mode if and only if the inverter is in Sell mode and the FLEXmax 80 is in Bulk (MPPT BULK) or Float (MPPT FLOAT) cycle. This is also a good indicator for establishing proper Grid-Tie mode communication between the FX G-Series Inverter(s) and FLEXmax 80. GT must be selected in the MPPT Mode Advanced menu in order to be viewed.
Sleeping The PV voltage is two volts less than the battery voltage. This may also appear during the day when the FLEXmax 80 is transitioning between certain states, or due to other conditions. SysError (Very rare) System Error indicates an internal non-volatile memory error. The unit will stop operating when this message is displayed. Call the factory if you see this message (360-435-6030).
23. MATE-Displayed FLEXmax 80 Screens Status Mode Screens The FLEXmax 80 STATUS MODE Screens displayed on the optional OutBack MATE (Rev 4.0.4 or greater) include MODE, METER, and SET (SETPOINT). In STATUS Mode, these functions can be viewed by the MATE, but not changed. Please see the MATE Installation and User Manual for more information.
MATE-Displayed FLEXmax 80 Status Meter Screens mode: Silent P02 in 10.2 vdc 0 adc out: 13.4 vdc 0 adc DOWN STATUS PORT STATUS/CC/METER--------P02 charger 0 w watts DOWN UP TOP PORT g STATUS/CC/METER-------P02 charger +000 adc amps dc DOWN UP TOP PORT STATUS/CC/METER-----P02 charger 0.
MATE-Displayed FLEXmax 80 STATUS SETPT (SET POINT) Screen STATUS/CC/SETPT---------P00 Absorb 28.8 VDC STATUS/CC/SETPT---------P00 Float 27.2 VDC DOWN STATUS PORT DOWN UP TOP PORT g STATUS/CC/METER-----end of setpoint menu UP TOP STATUS Press the first two soft keys simultaneously to return to the MAIN Menu.
24. FLEXmax 80 Advanced Menu ADV/CC/ADVANCED--------P01 wakeup mode VOC change 1.5 V DOWN INC DEC PORT ADV/CC/ADVANCED--------P01 snooze now < 0.
FLEXmax 80 EQ Screens ADV/CC/EQ-----------------P01 eq voltage 14.
25. ABBREVIATED CHARGER SET-UP OutBack Current Limit Absorbing Float EXIT - 12V Power Systems FLEXmax 80 80.0 A 14.4 V 13.
ADVANCED MENU Park Mpp 77% VOC EXIT NEXT +VOC +Min ADVANCED MENU Reset to Defaults? EXIT NEXT REVISION 001.008.009 RESET PUSH TWICE ADVANCED MENU Mpp Range Limit %Voc Min Max EXIT NEXT 1/2 90% Charger Aux Light EQ Misc Advanced Logging Stats EXIT GO PUSH THE ARROW KEY AND THEN PUSH GO ADVANCED MENU Absorb Time 01.0 hours EXIT NEXT + Today 0000AH 00.0kWH 012Vp 00.0Ap 0.00KWp MAX 14.9V ABS 00:00 MIN 14.8V FLT 00:00 PUSH ONCE ADVANCED MENU Absorb End Amps 00 A EXIT NEXT + In 11.6 V 0.0 A Out 14.
26. Troubleshooting Guide FLEXmax 80 does not boot/power-up (blank LCD) Be sure to check out the OutBack customer and user forum at www.outbackpower.com/forum/ for more FLEXmax 80 information. • Check the battery connection and polarity. • Reverse polarity or an improper connection will cause power-up issues. • Check the battery breaker. • Ensure that the battery breaker is sized appropriately. • A battery voltage below 10.5VDC may not power up the FLEXmax 80 (measure the battery-side of wire lugs).
• Are the batteries charged? Is the FLEXmax 80 in the Absorbing or Float stage? If either case is true, the FLEXmax 80 will produce enough power to regulate the voltage at the ABSORB or FLOAT set point voltage, therefore, requiring less power in these modes. • What is the short circuit current of the PV array? Use a multi-meter to determine if a short circuit current is as expected. There might be a loose PV array connection.
FLEXmax 80 Internal Fan • The internal fan will only run when the internal temperature has reached approximately 112°F. The fan will continue running until the internal temperature is less than 104°F. FLEXmax 80 is beeping • When the FLEXmax 80 is in Extended Play mode, the array is very hot, and the MPP is close to the battery voltage, or the nominal PV voltage is higher than the nominal battery voltage, beeping can occur.
27. Typical Array Sizing Guide Below is a list of recommended array sizing for the FLEXmax 80 for various nominal voltage batteries: Nominal Battery Voltage 12V 24V 36V 48V 60V Recommended Array Size (in watts, Standard Test Conditions) 1250W 2500W 3750W 5000W 6250W The FLEXmax 80 PV MPPT Charge Controller is capable of an input open circuit voltage (VOC) of up to 150 VDC. Cooler climates can cause the VOC to rise above the panel VOC rating.
28. STANDARD vs. AUSTRALIAN DEFAULT SETTINGS The Australian version FLEXmax 80 has a few default settings that differ from the Standard version default settings. However, there are no differences in performance and efficiency between the two versions.
29. Wire Distance Chart To meet NEC compliance (North America), the largest PV array that can be connected to the FLEXmax 80 must have a rated short-circuit current of 64 amps or less The following charts show the maximum distance of various gauge two-conductor copper wire from the PV array to the FLEXmax 80 with a 1.5% maximum voltage drop. Temperature and conduit fill corrections may be required.
48V PV ARRAY (64v Vmp) AMPS WIRE GAUGE 10 20 30 40 50 60 70 #8 62 31 21 15 12 10 9 #6 98 49 33 24 20 16 14 #4 156 78 52 39 31 26 22 #3 196 98 65 49 39 33 28 #2 247 124 82 62 49 41 35 METRIC #1/0 393 197 131 98 79 66 56 #2/0 496 248 165 124 99 83 71 #4/0 789 395 263 197 158 132 113 #8…8.37mm2 #6…13.30mm2 #4…21.15mm2 #3…26.7mm2 #2…33.6mm2 #1/0…53.5mm2 #2/0…67.
30. WIRE AND DISCONNECT SIZING The FLEXmax 80 is a buck type converter with the following properties: • 80 amp DC output current limit (default setting) • Listed to operate continuously at 80 amps (40°C/104° F) With an 80 amp FLEXmax 80 output current limit and PV array output higher than 80 amps offers little, if any, current boosting or Maximum Power Point Tracking advantage; in effect, any excess power beyond 80 amps is lost.
31. WIRING COMPARTMENT The wiring terminals and compartment of the FLEXmax 80 Charge Controller are fully compliant with all NEC and UL requirements. The following summary is specific for North American applications where NEC and UL standards govern installations.
32. FLEXmax 80 MULTI-STAGE BATTERY CHARGING The FLEXmax 80 charge controller is a sophisticated, multi-stage battery charger that uses several regulation stages to allow fast recharging of the battery system while ensuring a long battery life. This process can be used with both sealed and non-sealed batteries.
BULK cycle provides the maximum power to the battery –the voltage increases while recharging. A Bulk cycle is automatically initiated when the battery voltage is below the Absorb and Float* recharge voltage set points. The Bulk cycle will continue until the Absorb voltage set point is achieved. MPPT Bulk is displayed on the screen. ABSORBING cycle limits the amount of power going to the battery—the voltage is held constant.
33. BATTERY TEMPERATURE COMPENSATED VOLATGE SET POINT The temperature of a battery has an impact on the recharging process—in higher ambient temperatures, the regulation set points (Absorb and Float) need to be reduced to prevent overcharging of the batteries. In lower ambient temperature conditions, the voltage regulation set points need to be increased to ensure complete recharging of the batteries. The default charger settings of the FLEXmax 80 are based on typical lead acid battery systems.
34. SUGGESTED BATTERY CHARGER SET POINTS The battery manufacturer should provide you with specific instructions on the following maintenance and voltage set point limits for the specific batteries. The following information can be used when the manufacturer’s information is not available. SEALED LEAD ACID – AGM / GEL 12V 24V 48V ABSORB voltage set point 14.4V 28.8V 57.6V FLOAT voltage set point 13.4V 26.8V 53.6V NON-SEALED LEAD ACID 12V 24V 48V ABSORB voltage set point 14.8V 29.6V 59.
35. CALLING THE FACTORY FOR ASSISTANCE When calling OutBack Power for product assistance, please have the following information ready: • FLEXmax 80 Serial number and software version (the software version can be viewed by pressing the #1 soft key on the STATUS screen and then pressing a second time and holding the soft key down). • The nominal PV array and battery voltage.
FIVE YEAR LIMITED WARRANTY INFORMATION FLEXmax Products OutBack Power Systems, Inc. (“OutBack”) provides a five year (5) limited warranty (“Warranty”) against defects in materials and workmanship for its FLEXmax products (“Products”) if installed in fixed location applications. 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.
To request warranty service, you must contact OutBack Technical Services at (360) 435-6030 or support@outbackpower.com within the effective warranty period. If warranty service is required, OutBack will issue a Return Material Authorization (RMA) number. A request for an RMA number requires all of the following information: 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.
max TM 80 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.
EU DECLARATION OF CONFORMITY According to ISO / IEC Guide 22 and EN 45014 Product Type: Photovoltaic Charge Controller Product Model Number: FLEXmax 80 This product complies with the following EU directives: Electromagnetic Compatibility 89/336/EEC, “Council Directive of 3 May 1989 On the approximation of the laws of member States relating to Electromagnetic compatibility” Low Voltage Directive 73/23/EEC, “Council Directive of 19 February 1973 on the harmonization of the laws of Member States relating to el
OWNER’S SYSTEM INFORMATION Date of Purchase: _ __________________________________________________________________ Vendor: ___________________________________________________________________________ Date of Installation: __________________________________________________________________ Installer: _ _________________________________________________________________________ Installer Contact Information: __________________________________________________________ FLEXmax 80 Serial Number: _ ____________________
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