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Outback Power Systems FLEXnet DC User Manual

Includes mounting and installation
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User's Guide
Includes Mounting and Installation

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Summary of Contents for Outback Power Systems FLEXnet DC

  • Page 1 net DC User’s Guide Includes Mounting and Installation...

  • Page 2: Warranty Summary

    • Please read the full warranty at the end of this manual for more information. 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 tracking charge controllers, system communication components, as well as breaker panels, breakers, accessories, and assembled systems.
  • Page 3 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.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Warranty Summary... 1 Introduction ... 4 System Overview ... 5 Reading the FLEXnet DC ... 6 FLEXnet DC Package ... 7 Installing the FLEXnet DC ...7-10 FLEXnet DC Measurements ...11 Logged Data ...12 User Adjustable Set Points ...12 Programming and Using the MATE for FLEXnet Operations...13...

  • Page 5: Introduction

    The FLEXnet DC also off ers an auxiliary (AUX) relay that acts like a switch to turn on or off a user-installed light, alarm, or similar low voltage DC device. It can also be set up as a two-wire auto generator starter.

  • Page 6: System Overview

    SYSTEM OVERVIEW CHARGE CONTROLLER BATTERY - BAT + BAT - SHUNT C CHARGE CONTROLLER FX BATTERY - SHUNT B B DEVICE net DC FX INVERTER/CHARGER OTHER DC BATTERY - SOURCE OR LOAD SHUNT A Think of the input shunts as breaks or junctions in the DC (-) conductor. The current is conducted as though it were a continuous conductor, but the shunts allow the user to monitor the current, providing information for more accurate battery recharging.

  • Page 7: Reading The Flexnet Dc

    Reading the FLEXnet DC LEDs* (GREEN) (YELLOW) (YELLOW) (YELLOW) (RED) >90% • Blinking green LED: Charge parameters met • Solid green LED: SOC** is above 90% • Solid red LED: SOC is greater than 49% but less than 60% • Off red LED: SOC is above 59% •...

  • Page 8: Flexnet Dc Package

    G. Colored labels identifying shunts Installing the FLEXnet DC The FLEXnet DC mounts in a 3/4” DC breaker slot in an OutBack DC breaker bracket installed inside a FLEXware enclosure or previous model OutBack enclosure. To mount the FLEXnet DC inside an...
  • Page 9 (negative) side of the shunt NOTE: Color of wiring jacket can vary NOTE: The FLEXNet DC shunts must be connected in the negative (low) side of whatever they monitor. Otherwise, the unit can be damaged. Source/Load Negative Battery Negative...
  • Page 10 The wires connected to the wiring block should match the color-coded label where the wiring block inserts into the FLEXnet DC. • Green and White/Green • Orange and White/Orange •...
  • Page 11 FLEXnet DC. • Install the CAT5 cable into the RJ45 jack in the back of the FLEXNet DC. Connect the other end of the cable to the HUB using Port #2 or higher. FLEXnet DC removed from the breaker bracket for clarity.

  • Page 12: Flexnet Dc Measurements

    FLEXNet DC Measurements The FLEXNet DC can measure and record: • Volts for one battery bank* • Amps** • KiloWatts • kWhrs removed from the batteries • kWhrs returned to the batteries • Amp hours removed from the batteries • Amp hours returned to the batteries •...

  • Page 13: Logged Data

    Logged Data* The previous 128 days of data are accessible with the MATE. The data is logged each night at midnight. Be sure the MATE’s clock is set to the correct local time (refer to your MATE manual). * Data Logging User Adjustable Set Points •...

  • Page 14: Programming And Using The Mate For Flexnet Operations

    The default setting is 94%, meaning 94% of the charging current is being used for recharging and 6% is lost. OutBack suggests maintaining the default setting until the FLEXNet DC has monitored the system through a few charge/discharge cycles. •...

  • Page 15: Flexnet Dc Modes

    High side connection may result in erratic operation and/or failure of the FLEXNet DC. Charge Cycle At power up, the FLEXNet DC assumes the battery is full regardless of the battery state-of-charge. The batteries should receive a full charge at this time to meet the user-determined charge parameters (entered at start up).
  • Page 16 NOTE: The bottom LED is always off unless the SOC is less than 60% 5. When the SOC is less than 90%, enough of a discharge has taken place that the FLEXnet DC’s data can be used to determine, among other things, an accurate Battery Charge Factor. A battery amp- hour charge factor* and the battery kWhr effi ciency factor** for the last cycle are calculated using the stored values from the previous charge cycle (if the SOC is higher than 90%, the values aren’t...

  • Page 17: Programming The Auxiliary Relay

    Programming the Auxiliary Relay The FLEXNet DC’s unpowered relay is rated 5 amps/30VDC. NOTE: This relay is not fused and requires appropriate sized wiring and over-current protection. Damage due to unprotected relay devices is not covered by the warranty. The relay may be confi gured in one of two modes: 1.

  • Page 18: Mate Screens

    MATE Screens MAIN------------------------------- 11:30:55A STATUS SETUP ADV Battery Charging State of charge 99% DC NOW 12.5V 0.0A 0.000kW 0.5A 0.000kW -0.5A 0.000kW DC Today min/SOC 347AH 9.040kWH 331AH 8.510kWH 16AH 0.530kWH Press to view previous days’ history Press to move forward one day From the MAIN MATE menu, press the <SUM>...
  • Page 19 From the MAIN menu, press the <SUM> soft key to view a summary of the system’s operation. This information is a sum of all FlexNet DC data. Press the second soft key to view the next SUM screen The fourth SUM screen shows: •...
  • Page 20 0.1A 0.000 kW 0.0A 0.000 kW 0.0A 0.000 kW DOWN STATUS -1AH 0.100kWH 0.000kWH 0.O00kWH DOWN METER/DC/SHUNT A removed 12AH 0.030kWH DOWN METER/DC/SHUNT A charged 12AH 0.160kWH DOWN METER/DC/SHUNT B removed 0kWH DOWN METER/DC/SHUNT B charged 0kWH DOWN The fi rst METER screen shows the amount of instantaneous current running through each shunt.
  • Page 21 METER/DC/SHUNT C removed DOWN METER/DC/SHUNT C charged DOWN STATUS/FN/METER DC fi rmware revision 000.00/040 DOWN STATUS/FN/METER end of meter menu TOP STATUS STATUS/FN STATS METER SHUNT BATT TOP STATUS/DC/SHUNT A max removed amps DOWN RESET TOP Pressing the <DOWN> soft key brings up the SHUNT 0kWH C charged screen.
  • Page 22 SHUNT A. When fi nished with SHUNT C, the end of shunt status menu screen appears Press the <STATUS> soft key. Press the <BATT> soft key to view the FlexNet DC battery readings STATUS/DC/BATT displays the number of days the 100% battery has been at 100% SOC.
  • Page 23 STATUS/DC/BATT days since charge parameters DOWN STATUS/DC/BATT battery min today 12.4 vdc DOWN RESET STATUS/DC/BATT battery max today 12.7 vdc DOWN RESET STATUS/DC/BATT temp comp’d batt setpoint 14.2 vdc DOWN STATUS/DC/BATT system battery temperature DOWN STATUS/DC/BATT cycle charge factor DOWN STATUS/DC/BATT cycle KwHr charge effi...
  • Page 24 STATUS/DC/BATT lifetime kAH removed 5 DOWN RESET STATUS/DC/BATT---------------- end of battery status menu UP TOP STATUS MAIN------------------------------- 11:30:55A STATUS SETUP ADV ADV/SETTINGS/WARNING Changes made could adversely effect system performance ADV/PASSWORD enter the password ENTER EXIT ADV/PASSWORD enter the password ENTER EXIT ADV-------------------------------- choose device:...
  • Page 25 ADV/DC/PAGE 1---------------- choose category SHUNT PG2 ADV/DC/BAT------------------- battery capacity amp hours ADV/DC/PAGE 1---------------- choose category SHUNT PG2 ADV/DC/SHUNT 1 --------------- shunt 1 mode DOWN Pressing the <DOWN> soft key changes the shunt being enabled or disabled. ADV/DC/SHUNT----------------- shunt setup complete MAIN ADV-------------------------------- choose device:...
  • Page 26 ADV/DC/PAGE 2---------------- choose category PG1 CHARGE AUX PG3 ADV/DC/CHARGE-------------- return amps DOWN INC ADV/DC/CHARGE--------------- battery charge DOWN INC ADV/DC/CHARGE--------------- parameters met time minutes DOWN INC ADV/DC/CHARGE-------------- charge factor DOWN INC ADV/DC/CHARGE-------------- charge parameters complete ADV MAIN ADV-------------------------------- choose device: MATE Press the <CHARGE>...
  • Page 27 ADV/DC/PAGE 1---------------- choose category SHUNT PG2 ADV/DC/PAGE 2----------------- choose category: PG1 CHARGE AUX ADV/DC/AUX CONTROL-------- currently: Auto On DOWN AUTO ON ADV/DC/AUX HIGH VOLT------ high volts DOWN INC ADV/DC/AUX LOW VOLT------ low volts DOWN INC ADV/DC/AUX SOC HIGH-------- SOC high DOWN INC Press the <PG2>...
  • Page 28 ADV/DC/AUX SOC LOW-------- SOC low DOWN INC ADV/DC/AUX/HI DELAY HIGH- high setpoint delay minutes DOWN INC ADV/DC/AUX/LO DELAY HIGH- low setpoint delay minutes DOWN INC ADV/DC/AUX/INVERT--------- invert logic DOWN ADV/DC/AUX---------------- aux parameters complete TOP ADV MAIN ADV-------------------------------- choose device: MATE ADV/DC/PAGE 1---------------- choose category SHUNT PG2...
  • Page 29 PG1 CHARGE AUX ADV/DC/AUX/PAGE 3---------- choose category: RESET CLR MAIN Press the <PG3> soft key. Pressing the <RESET> soft key resets the FLEXnet DC to its factory default settings. Pressing the <CLR> soft key clears the data log memory.

  • Page 30: Technical Notes

    Some of them are lost due to heat and gassing. The FLEXnet DC’s default BCF is 94, which means for every 100 amp hours of charge to the battery, only 94 are shown in the amp hour display for a BCF of 94%.

  • Page 31: Warranty

    2-Year Limited Warranty FLEXnet Products OutBack Power Systems, Inc. (“OutBack”) provides a two year (2) limited warranty (“Warranty”) against defects in materials and workmanship for its FLEXnet products (“Products”) if installed in fi xed 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 fi rst retail sale.

  • Page 32: Warranty

    To request warranty service, you must contact OutBack Technical Services at (360) 435-6030 or support@outbackpower.com within the eff ective 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.

  • Page 33: Limited Warranty Registration

    *Extended Warranty - OutBack Power Systems off ers an optional three year extension to the standard two year Limited Warranty in North America for the FLEXnet DC product. To request a 3-year Limited Warranty extension for a total eff ective warranty coverage period of fi ve years(5);...
  • Page 34 Corporate Offi ce European Sales Offi ce C/ Castelló, 17 19009 62nd Avenue NE 08830 - Sant Boi de Llobregat Arlington, WA USA BARCELONA, España Phone: (+1) 360.435.6030 Phone: (+34) 93.654.9568 www.outbackpower.com 900-0093-01-00 REV B...

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