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TM
max 80
Maximum Power Point Tracking Charge Controller
User’s Guide
Installation, Programming and User’s Manual
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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 warra
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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. Our products include true sine wave inverter/char
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TABLE OF CONTENTS SCOPE .......................................................................................................................................................................................................5 INTRODUCTION ..................................................................................................................................................................................5 INSTALLATION GUIDELINES AND SAFETY INSTRUCTIONS .................................
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Vbatt Calibration ..........................................................................................................................................................................50 RTS Compensation .....................................................................................................................................................................50 Auto Restart ............................................................................................................
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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. INTRODUCTION FLEXmax 80 Maximum Power Point Tracking Charge Controller The OutBack FLEXmax 80 Maximum Power Point Tracking Charge Controller offe
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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. If a GFP is present, the battery negative
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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. CAUTION - To reduce risk of injury, charge only deep-cycle lead acid, lead antimo
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THE OUTBACK POWER SYSTEMS FLEXmax 80 Maximum Power Point Tracking Charge Controller 8 PB
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. 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, FW- CCB2, and FW-CCB2T). NOTE: Install the FLEXmax 80 in an upright posi- tion out of direct sunlight. To mount directly to a FLEXware DC enclosure: • Remove the fan cover and bottom cover from the FLEXmax 80. • Insert a #10 X 3/8” sheet metal screw in the to
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. 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). • As every
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. FLEXmax 80 Wiring Connections Figure 1 FLEXmax 80 wiring compartment Use up to 2 AWG 2 (33.6 mm ) wire and torque to PV+ PV- BAT- BAT+ 35-inch pounds at Wire Lugs terminals. 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. Only one negative wire may be needed to connect to the (-)
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Figure 2 Single Charge Controller wiring diagram with 24 volt PV array PB
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Figure 3 Charge Controller Wiring Diagram with an FX, HUB 4, and an RTS PB
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Figure 4 Charge Controller with PV array ground fault protection wiring digram. PB
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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. PB
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. Powering Up The FLEXmax 80 power-up sequence first activates the unit and the SELECT VERSION screen (to de- termine 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). The SYSTEM VOLTAGE screens allow the user to adjust th
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SelectV ersion The FLEXmax 80 screens are offered in English (standard Elijala Version screens) and Spanish. For Australian users, some of the USA charging values are of different voltages and the FLEXmax NEXTENTER ENTRA SEL 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. Password Screen Press the
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Are you sure? Press the soft key to confirm your choice or to return to the SELECT VERSION screen. USA NOYES The FLEXmax 80 auto detects the system’s battery voltage. To confirm this voltage, press the soft System Voltage Screen key. If incorrect, press the “g” soft key to select a battery voltage. The FLEXmax 80’s default values are based on SYTEM VOLTAGE a 12VDC system. Selecting a higher voltage system will 12 24 36 48 60 change all the
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. S tatus 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. The PV voltage will slowly rise to the battery voltage level even when the PV breaker is off – this is normal as the
