OutBack Power FLEXmax 60 Owner's Manual
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OutBack Power FLEXmax 60 Owner's Manual

Flexmax series charge controllers
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FLEXmax Series
Charge Controllers
(FLEXmax 80, FLEXmax 60)
Owner's Manual

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Summary of Contents for OutBack Power FLEXmax 60

  • Page 1 FLEXmax Series Charge Controllers (FLEXmax 80, FLEXmax 60) Owner’s Manual...
  • Page 2 Rights Reserved. Trademarks OutBack Power and the OutBack Power logo are trademarks owned and used by OutBack Power Technologies, Inc. The ALPHA logo and the phrase “member of the Alpha Group” are trademarks owned and used by Alpha Technologies Inc. These trademarks may be registered in the United States and other countries.

  • Page 3: Table Of Contents

    Mounting the Charge Controller ..............................9   Wiring ........................................10   Wire and Disconnect Sizing ................................ 10   FLEXmax 80 ....................................10   FLEXmax 60 ....................................10   Wiring Compartment ..................................11 Operation ..................................15     Power Up Screens ....................................15  ...
  • Page 4 Table of Contents   Changing the Settings on the FLEXmax ............................24   Accessing the Main Menu ................................24   Main Menu Map ....................................25   Charger Screen ..................................26   Aux Screens ....................................27   AUX MODE Screen Navigation ............................. 29  ...
  • Page 5 Table of Contents   Summary Screens ....................................71   Status Screens ....................................... 72   MODE Screens ....................................72   METER Screens ....................................73   SETPT Screens ....................................74   LOG Screens ..................................... 75   STAT Screens ....................................76   Advanced Menus ....................................77  ...
  • Page 6 Table of Contents List of Tables     Table 1 Battery Voltage and Charge Timer ..........................21     Table 2 Aux Mode Functions ............................... 27     Table 3 Regulatory Specifications for All Models ......................... 93     Table 4 FLEXmax Settings ................................

  • Page 7: Introduction

    The FLEXmax Series has two models available:  FLEXmax 80: 80 amps maximum continuous output current (up to 40°C without thermal derating)  FLEXmax 60: 60 amps maximum continuous output current (up to 40°C without thermal derating) Both models have the following features: ...

  • Page 8: Soft Keys

    Introduction LCD Screen Soft Keys FLEXmax 80 FLEXmax 60 Figure 1 Charge Controller Features Soft Keys Four “soft” 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.

  • Page 9: Installation

    Installation Standards and Requirements All installations must comply with national and local electrical codes; professional installation is recommended. IMPORTANT: The charge controller is designed for indoor installation or installation inside a weatherproof enclosure. It must not be exposed to rain and should be installed out of direct sunlight.

  • Page 10: Dimensions

    Installation Dimensions 16.25” (41.3 cm) FLEXmax 80 Charge Controller 5.75” 4.0” (14.6 cm) (10.2 cm) FLEXmax 60 Charge Controller 13.5” (34.3 cm) Figure 3 FLEXmax 80 and FLEXmax 60 Dimensions 900-0009-01-00 Rev...

  • Page 11: Mounting The Charge Controller

    Installation Mounting the Charge Controller IMPORTANT: Install the FLEXmax in an upright position out of direct sunlight. The FLEXmax 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 controller brackets (FW-CCB, FW-CCB2, and FW-CCB2T).

  • Page 12: Wiring

     Install OutBack PNL-60-AC/DC or PNL-80-DC circuit breakers for disconnect and overcurrent protection.  Use a minimum of #6 AWG (16 mm ) wire for the output between the FLEXmax 60 and the battery bus bar conductors.  The largest PV array must have a rated short-circuit current of 48 amps or less under STC (Standard Test Conditions).

  • Page 13: Wiring Compartment

    Installation Wiring Compartment WARNING: Shock Hazard Make sure all DC circuit breakers are OFF (open) BEFORE making any wiring connections. Use a DVM to check for voltage on all wires. The PV (-) and BAT (-) terminals are connected internally. Only one negative wire may be needed to connect to the (-) wire lugs if the PV - and BAT- conductors are bonded at the negative bus bar.
  • Page 14 Installation Figure 6 Wiring Diagram - Single Charge Controller with PV Array 900-0009-01-00 Rev...
  • Page 15 Installation Figure 7 Wiring Diagram – Charge Controller with PV Array and Inverter 900-0009-01-00 Rev...
  • Page 16 Installation Figure 8 Wiring Diagram – Charge Controller with PV Array Ground Fault Protection 900-0009-01-00 Rev...

  • Page 17: Operation

    Operation Operation of this unit consists of monitoring screens and programming screens. The majority of programming screens are accessed using the main menu. See page 24. Power Up Screens IMPORTANT:  The default settings of the FLEXmax are for a 12 Vdc battery bank. Change the setting after powering up if a different battery voltage is used.

  • Page 18: Version And/Or Voltage Setting Screens

    Operation Version and/or Voltage Setting Screens Once the password has been entered, the display will return to the Select Version screen. Select Version Screen To change the version: Select Version Press <NEXT> or <SEL> to cycle through the version Elija la Version choices of: English NEXT ENTER ENTRA SEL...

  • Page 19: Status Screen

    Operation Status Screen The status screen displays system information. See page 18 for detailed information of the different modes of operation. The optional OutBack system display shows CC (Charge Controller) status screens for convenient distant viewing from the installation location. See page 59 for the FLEXmax screens displayed on the MATE3.

  • Page 20: End-Of-Day Summary Screen

    Operation End-of-Day Summary Screen The end-of-day summary screen appears after one hour of continuous Sleeping (see page 23). This screen can be opened any time by pressing the second soft key while in the status screen, providing a summary up to that point. End-of-Day Screen Today 000Ah...

  • Page 21: Navigating The End-Of-Day Screens And Data Logging

    Operation Navigating the End-of-Day Screens and Data Logging Status Screen End-of-Day Screen 11.6V 0.0 A Today 000Ah 00.0kWH 13.8V 0.0 A 011Vp 00.0Ap 0.00kWp 0.000 kW 0.0 kWH MAX 14.7 V ABS 01:00 AUX: OFF Sleeping MIN 14.6 V FLT 00:00 Press SK1 to return to the Pressing the second soft key status screen.

  • Page 22: Modes Of Operation

    Operation Modes of Operation The FLEXmax has 25 different modes that will display on the status screen. These messages will vary with function. The FLEXmax modes consist of various charging stages, equalization, various reasons for stopping charging, and certain specialized operating modes. The amount of time required before starting operation is dependent on the module type, ambient temperature, and the amount of sunlight directly on the PV array.

  • Page 23: Auto Start (Auto Restart)

    Operation Table 1 Battery Voltage and Charge Timer Battery Voltage ChgT (Charge Timer) Activity/Display  12.4 V, 24.8 V, 37.2 V, 49.6 V, or 62.0 V, No change. and less than the Absorbing voltage <12.4 V, 24.8 V, 37.2 V, 49.6 V, or 62.0 V For every minute elapsed, 1 minute is subtracted from the timer <12.0 V, 24.0 V, 36.0 V, 48.0 V, or 60.0 V...

  • Page 24: Ex-Absorb

    Operation EX-Absorb There is an external DC source other than PV keeping the battery above the Absorbing voltage set point. The FLEXmax will stop charging because it is not needed. Floating The FLEXmax is in the Float stage of a three-stage cycle, regulating the battery voltage at the Float voltage set point.

  • Page 25: Mppt Eq

    Operation MPPT EQ The equalization cycle has started and the charge controller is trying to regulate the batteries at the BATTERY EQUALIZE VOLTS set point. Once this voltage has been reached, the displayed mode will change to EQ. Before equalizing, battery loads should be turned off and the battery should be charged so the charge controller can quickly reach the EQ voltage set point.

  • Page 26: Unloaded

    Operation Unloaded The battery terminals have become disconnected. This may mean that the battery circuit breaker breaker has tripped. It can also appear if the nominal battery voltage is set too low. Wakeup As the PV open circuit voltage (Voc) rises above the battery system voltage by two volts, the FLEXmax prepares to deliver power to the batteries, although it does not perform MPPT in this mode.

  • Page 27: Main Menu Map

    Operation Main Menu Map Main Menu From the main menu, a user can choose among the Charger Light following FLEXmax functions by aligning the arrow Misc Advanced Logging Stats next to the desired selection.   EXIT <EXIT> returns to the Status screen. <>...

  • Page 28: Charger Screen

    Operation Charger Screen Charging settings should follow the battery manufacturer's recommendations. This screen allows changes to the recharging voltage set points if the default settings do not match the manufacturer's recommendations. (For an explanation of battery charging, see pages 96 and 97). ...

  • Page 29: Aux Screens

    Operation Aux Screens The AUX (Auxiliary) is a secondary control circuit — essentially, a small power supply that provides a 12 Vdc output current (up to 200 milliamps/2.4 watts) to an isolated load. It is either ON (Active High) with 12 Vdc available at the output or OFF (Active Low) with 0 Vdc at the output. It can also be set to AUTO, so that it activates when certain criteria are met.
  • Page 30 Operation Table 2 Aux Mode Functions Mode Name Function/Purpose Set Points Aux Polarity  Threshold Error Output Not Available Function: Voltage When the voltage decreases below the threshold voltage for 10 minutes or more, the AUX output will change state. Purpose: This mode is useful for monitoring remote sites.

  • Page 31: Aux Mode Screen Navigation

    Operation Table 2 Aux Mode Functions Mode Name Function/Purpose Set Points Aux Polarity  Threshold Function: Low Battery Not Available Voltage for Disconnect When the battery voltage falls below the disconnect threshold disconnect voltage, the AUX output activates. When the battery voltage rises above ...

  • Page 32: Vent Fan (Aux Mode)

    Operation Vent Fan (AUX Mode) This mode is intended to operate a vent fan for a battery enclosure which helps ventilate hydrogen gas from the enclosure. If the voltage remains above the threshold voltage set point, the vent fan will remain active.

  • Page 33: Pv Trigger (Aux Mode)

    Operation PV Trigger (AUX Mode) This mode is intended to operate an alarm, or relay that disconnects the PV array, when PV input exceeds the threshold voltage set by the user. The mode turns off the alarm or PV disconnect after the PV voltage decreases below the threshold for a time period that is set by the user.

  • Page 34: Error Output (Aux Mode)

    Operation Error Output (AUX Mode) This mode is useful for monitoring remote sites. It is intended to signal when the charge controller has not charged the batteries for 26 hours or more or if the battery voltage has fallen below the threshold voltage for more than 10 minutes.

  • Page 35: Night Light (Aux Mode)

    Operation Night Light (AUX Mode) This mode is intended to operate a user-provided, low wattage light for as long as the charge controller remains in Sleep mode or for the ON time set by the user. OFF is the default value. Main Menu To set the mode for Night Light: Charger...

  • Page 36: Float (Aux Mode)

    Operation Float (AUX Mode) This mode is intended to operate a load when the FLEXmax is in the Float stage of charging the batteries. Main Menu Charger Light To set the mode for Float: Misc Advanced Logging Stats From the main menu, press <> or <> to move the ...

  • Page 37: Diversion (Aux Mode)

    Operation Diversion (AUX Mode) When external DC sources (wind, hydroelectric) are directly connected to a battery bank, any excess power should be sent to a diversion load, such as a heating element, using a mechanical relay or solid-state relay. In Diversion mode, the user programs set points — from -5.0 volts to 5.0 volts relative to the Absorbing, Float, and EQ voltages —...
  • Page 38 Operation ...continued from previous page.  To change the set points for Diversion:Relay: AUX MODE Diversion:Relay Output: Off Press <SET> to advance to the set point screens; EXIT NEXT MODE <VOLT> and <TIME>. Press <TIME> to advance to the Time screen. This allows the user to adjust the minimum time the AUX output is active after the battery voltage falls below the hysteresis voltage.
  • Page 39 Operation Diversion:Solid St (AUX Mode) Main Menu IMPORTANT Charger Light  If using wind or hydroelectric turbines, Misc Advanced Logging Stats keep the charge controller’s diversion   EXIT voltage slightly above its Absorb and Float voltage settings for efficient functioning. ...
  • Page 40 Operation Continued from previous page… To change the set points for Diversion:Solid St: AUX MODE Diversion:Solid St Press <SET> to advance to the set point screens; Output: Off <VOLT> and <TIME>. EXIT NEXT MODE Press <TIME> to advance to the Time screen. This allows the user to adjust the minimum time the AUX output is active after the battery voltage falls below the hysteresis voltage.
  • Page 41 Operation Figure 27 Wiring Diagram for Diversion Load and AUX Wiring 900-0009-01-00 Rev...

  • Page 42: Low Battery Disconnect (Aux Mode)

    Operation Low Battery Disconnect (AUX Mode) This mode disconnects “auxiliary” loads from the batteries in the event of low voltage. These are separate from the usual loads. Auxiliary loads are controlled by the AUX output, usually by a larger relay. When the battery voltage falls below the DISCONNECT VOLTS setting, the AUX loads are disconnected.

  • Page 43: Remote (Aux Mode)

    Operation Remote (AUX Mode) Remote allows an OutBack system display to control the charge controller's auxiliary output. Some displays may require a certain level of software in order to use this feature. Consult the owner's manual for the system display being used for details. Main Menu To set the mode for Remote: Light...

  • Page 44: Eq - Battery Equalize

    Operation EQ – Battery Equalize Equalization is a controlled overcharge that is part of regular battery maintenance. Equalization brings the batteries to a much higher voltage than usual and “simmers” them for a period of time. This has the result of removing inert compounds from the battery plates and reducing stratification in the electrolyte.
  • Page 45 Operation Automatic Equalization Mode To enable an automatic equalization mode, an interval must be set for the number of days to pass between equalization cycles. This interval can be between 1 to 250 days. The default equalization interval setting is 000 which disables this feature.

  • Page 46: Misc Screen

    Operation Misc Screen There are three Misc screens that provide technical information about the operating state of the system. These are read-only screens and allow for no changes to any of the settings. They do provide the means to wake up the charge controller if it is in Snooze mode. They also provide a means to force the charger into a Bulk or Float stage.
  • Page 47 Operation Misc Screen #1 To bring the charge controller out of Snoozing mode: STATE PWM% ChgT 50.0 Press <RSTRT>. EXIT NEXT RSTRT Press <EXIT> to return to the main menu. Misc Screen #1 To force the charger into a Bulk or Float charge cycle: STATE PWM% ChgT 50.0...

  • Page 48: Advanced Menu

    Operation Advanced Menu The Advanced menu allows fine-tuning of the FLEXmax operations including Snooze periods and Maximum Power Point limits (see page 95). The following modes are available in the Advanced menu. They will appear in the following order.  Snooze Mode ...

  • Page 49: Wakeup Mode (Advanced Menu)

    Operation Wakeup Mode (Advanced Menu) Wakeup Mode sets the open-circuit voltage (Voc) conditions that cause the charge controller to wake up during Sleep and Snooze modes. Since environmental conditions impact the open-circuit voltage of an array, the Voc can be based on the last measured Voc value. Before changing these values, monitor the system for a week or so using the factory defaults and then gradually adjust the set points.
  • Page 50 Operation  GT allows the FLEXmax to work more effectively with a grid-interactive OutBack inverter. This setting automatically raises the charge controller’s Float voltage to equal its Absorption voltage. Since the inverter sells power to maintain its own Float, Absorption, or Sell settings (all of which should be lower than those of the controller), this mode makes it easier for the inverter to sell power.

  • Page 51: Absorb Time Limits (Advanced Menu)

    Operation Absorb Time Limits (Advanced Menu) The amount of time the charge controller stays in the Absorbing stage of charging can be adjusted in the Absorb Time Limits screen. An Absorbing charge stage normally ends when the battery voltage is maintained at the Absorbing set point for the time period set in the Absorb Time Limits screen.

  • Page 52: Rebulk Voltage (Advanced Menu)

    Operation Rebulk Voltage (Advanced Menu) In the Float stage, if the battery voltage falls below the ReBulk Voltage set point for at least 90 seconds, the FLEXmax will automatically initiate a new charge cycle. To adjust the set points in the Rebulk Voltage screen: Rebulk Voltage Navigate to the Rebulk Voltage screen through the ADVANCED MENU...
  • Page 53 Operation For example:  During cold weather, a battery often requires a higher charging voltage. Some inverters might not accommodate these higher voltages and can shut down during charging, cutting off power to their loads.  During hot weather, limiting the RTS Compensation values assures the voltage stays high enough to charge the batteries instead of dropping too low in reaction to a higher ambient temperature.

  • Page 54: Auto Restart (Advanced Menu)

    Operation Auto ReStart (Advanced Menu) This setting allows the user to choose between continuous maximum power point (MPP) tracking, or occasional restarts of the sweeping process. A restart means the controller abandons the existing maximum power point value it was using and “re-sweeps”, or begins gathering new power point data. (See page 95 for more information on MPP tracking.) Auto ReStart has three options available: ...

  • Page 55: Aux Polarity (Advanced Menu)

    Operation Aux Polarity (Advanced Menu) When the AUX function is ON, 12 volts DC is present at the AUX terminals (Active High). When the AUX function is OFF, 0 volts DC are present at the terminals (Active Low). Aux Polarity allows the user to reverse the availability of this voltage for the Night Light, PV Trigger, or Diversion Relay functions.

  • Page 56: Logging

    Operation Logging The Logging screen in the main menu enables the user to clear the daily and cumulative logs if necessary. Logs can be downloaded to an SD card if a MATE3 is installed. See page 69 for details. The FLEXmax daily log begins when the controller enters Wakeup. See page 24. IMPORTANT: If two or more charge controllers are used in the same system and are started up or cleared on different days, their numeric dates will not be the same.

  • Page 57: Stats

    Operation Stats The STATS screen in the main menu displays additional voltage and time information. In a stand-alone FLEXmax controller — one that is not connected to a system display — Sunrise shows how long ago the FLEXmax woke up for the first time each day and when the daily and total logged values were updated and cleared. If the FLEXmax is connected to a system display, the logging occurs at midnight.

  • Page 58: Viewing The Firmware Revision

    Operation Secondary STATS Screen The Secondary Stats screen shows the total accumulated DC and AC kilowatt-hours and kiloamp-hours of the charge controller. Total 00000 Total 0000.0 kAH Pressing the <DCkWH> soft key switches the screen between BACK DCkWH DC kilowatt-hours and AC kilowatt-hours. ...

  • Page 59: Rebooting The Flexmax

    Operation Rebooting the FLEXmax If the screen becomes garbled or the FLEXmax controller otherwise will not respond to commands, it may be necessary to reboot its internal processor. IMPORTANT: Rebooting the FLEXmax controller will return all the values and set points to the factory defaults.
  • Page 60 Operation NOTES: 900-0009-01-00 Rev...

  • Page 61: Mate3 System Display And Controller

    MATE3 System Display and Controller The MATE3 provides the means for programming the FLEXmax charge controller and other devices when preprogrammed default settings do not work for the destined installation. Display and LED Status Indicators LCD Screen Battery Status LEDs (x3) Inverter LED Events LED Charger LED...

  • Page 62: Charge Controller Soft Key

    MATE3 Screens Charge Controller Soft Key PV Icon Charge Controller Soft Key Press this soft key to view FLEXmax charge controller status information. If no charge controller is present, the PV icon will be blank and this Charge Controller’s soft key will be inoperative. Mode Charge Controller Modes: ...

  • Page 63: Datalog Screen

    MATE3 Screens DataLog Screen The <DataLog> soft key shows accumulated daily amp-hour and watt-hour statistics, as well as maximum current, wattage, and maximum and minimum voltage figures. These maintain a continuous daily log, up to 128 days, which can be recalled. One day can be displayed at a time. See page 55 for more information.

  • Page 64: Graph Screens

    MATE3 Screens Graph Screens The <Graph> soft key brings up the following screens which plot various type of data over time. The first screen shows changes in PV wattage over time. This axis shows date and time in 6-hour increments. This axis shows PV wattage.

  • Page 65: Menu Structure In The Mate3

    MATE3 Screens Menu Structure in the MATE3 Figure 60 shows the MATE3 menu structure for adjusting the FLEXmax charge controller settings. Figure 60 Menu Structure The Main Menu shown above is accessed with the LOCK button and a password. Use the MATE3’s control wheel to move up and down between menus (or options within a menu).

  • Page 66: Charge Controller Settings

    MATE3 Screens Charge Controller Settings Charge Controller menu options include the following: Charger ------------------------------------------------------------- > See page 64. MPPT ---------------------------------------------------------------- > See page 64. Temperature Compensation ------------------------------- > See page 65. Battery Equalize ------------------------------------------------ > See page 65. Grid-Tie Mode --------------------------------------------------- >...

  • Page 67: Temperature Compensation

    MATE3 Screens Temperature Compensation When equipped with the Remote Temperature Sensor (RTS), the charge controller compensates for temperature changes by raising or lowering its charging voltages. However, in some cases the sensitivity of other DC devices may require this temperature compensation to be limited. This menu allows the user to manually adjust the upper and lower limits of temperature compensation.

  • Page 68: Auxiliary Output (Charge Controller)

    MATE3 Screens Auxiliary Output (Charge Controller) This menu controls the output and functionality of the Auxiliary (AUX) output. The charge controller’s AUX terminals provide a 12 Vdc output that can deliver up to 0.2 Adc to control external loads. Typical loads include signaling a generator to start, sending a fault alarm signal, or running a fan to cool the inverter.

  • Page 69: Restart Mode

    MATE3 Screens Night Light Set Points :  Active: High  Threshold  Hysteresis Time  ON Time Figure 70 Night Light Float Set Points : None Figure 71 Float Diversion: Relay and Solid St Set Points (NOTE: All items function identically for both Diversion: Active: High Relay and Diversion: Solid St, except for ...

  • Page 70: Calibrate

    MATE3 Screens Calibrate The Calibrate menu allows adjustment of the charge controller’s battery voltmeter. If a particular controller’s readings do not match those of another device, or a hand-held meter, the calibration feature may improve consistency. Set Points:  Battery Voltage – Calibrates the Vdc measurement made at the controller’s battery terminals Calibration Offset...

  • Page 71: Device Data Logs

    MATE3 Screens Device Data Logs Users of the MATE3 can create Device Data Logs for the FLEXmax charge controller. The Data Logs can then be uploaded and saved to an SD card. Saving Data Logs for the FLEXmax Charge Controller To create a data log for the FLEXmax Charge Controller: Access the Main Menu...

  • Page 72: Data Log File Format

    MATE3 Screens Data Log File Format Information generated by this function will be saved on the SD card in a generic .csv file format, which can be read by most spreadsheet programs. Data Logging example: NOTE: This header line is NOT included in the download. Absorb Float Date...

  • Page 73: Mate/Mate2 Screens

    MATE/MATE2 Screens Summary Screens If a FLEXnet DC is installed in the system, the following summary screens will be available. FLEXnet DC Summary Screen #1 FLEXnet DC Summary Screen #2 FLEXnet DC Summary Screen #3 FLEXnet DC Summary Screen #4 FX Inverter/Charger Summary Screen (If the FNDC is not installed, this...

  • Page 74: Status Screens

    MATE/MATE2 Screens Status Screens To view the status screens of a FLEXmax 60 or FLEXmax 80 using a MATE, follow the illustration below. Changes to FLEXmax settings can only be changed from the charge controller user interface; changes can not be done when viewing these screens on a MATE.

  • Page 75: Meter Screens

    MATE/MATE2 Screens METER Screens MAIN------------------ Navigation for STATUS/CC/METER 1:35:04p  <STATUS> returns to the CC/PAGE1 screen. SUM STATUS SETUP ADV  <DOWN> moves to the next menu item in the diagram.  <UP> moves to the previous menu item in the diagram. ...

  • Page 76: Setpt Screens

    MATE/MATE2 Screens SETPT Screens Navigation for STATUS/CC/SETPT MAIN------------------  <STATUS> returns to the CC/PAGE1 screen. 1:35:04p  <DOWN> moves to the next menu item in the SUM STATUS SETUP ADV diagram.  <UP> moves to the previous menu item in the diagram.

  • Page 77: Log Screens

    MATE/MATE2 Screens LOG Screens MAIN------------------ Navigation for STATUS/CC/LOGS 1:35:04p  <STATUS> returns to the CC/PG2 screen. SUM STATUS SETUP ADV  <DOWN> moves to the next menu item in the diagram.  <UP> moves to the previous menu item in the diagram. STATUS---------------- choose device ...

  • Page 78: Stat Screens

    MATE/MATE2 Screens STAT Screens Navigation for STATUS/CC/STAT MAIN------------------ 1:35:04p  <STATUS> returns to the CC/PAGE2 screen. SUM STATUS SETUP ADV  <DOWN> moves to the next menu item in the diagram.  <UP> moves to the previous menu item in the diagram.

  • Page 79: Advanced Menus

    MATE/MATE2 Screens Advanced Menus The Advanced menus available in the MATE or MATE2 system display allow the following options:  Change the settings of the FLEXmax battery charger and temperature compensation  Change the parameters of the FLEXmax MPPT process ...

  • Page 80: Chgr Menu

    MATE/MATE2 Screens CHGR Menu Navigation for ADV/CC/CHGR  <DOWN> moves to the next menu item in the diagram.  <INC> increases the value of the selection.  <DEC> decreases the value of the selection.  <PORT> directs the MATE to read the next device (port) on the HUB.

  • Page 81: Cc Advanced Menu

    MATE/MATE2 Screens CC ADVANCED Menu CC/Advanced The ADVANCED screens adjust the same settings that are available on the Advanced screen in the FLEXmax (see page 46). These settings relate to charging, MPPT, temperature compensation, and calibration. Navigation for ADV/CC/ADVANCED  <DOWN>...

  • Page 82: Eq Menu

    MATE/MATE2 Screens EQ Menu Navigation for ADV/CC/EQ  <DOWN> moves to the next menu item in the diagram.  <INC> increases the value of the selection.  <DEC> decreases the value of the selection.  <PORT> directs the MATE to read the next device (port) on the HUB.

  • Page 83: Aux Menu

    MATE/MATE2 Screens AUX Menu Navigation for ADV/CC/AUX  <DOWN> moves to the next menu item in the diagram.  <INC> increases the value of the selection.  <DEC> decreases the value of the selection.  <PORT> directs the MATE to read the next device (port) on the HUB.

  • Page 84: Mate And Mate2 Menu Maps For The Flexmax

    MATE/MATE2 Screens MATE and MATE2 Menu Maps for the FLEXmax STATUS Menu Map Navigation for STATUS/CC/PAGE1  <DOWN> moves to the next menu item in the diagram.  <UP> returns to the previous menu item in the diagram.  <PORT> directs the MATE to read the next device (port) on the HUB.
  • Page 85 MATE/MATE2 Screens Navigation for STATUS/CC/PAGE2  <DOWN> moves to the next menu item in the diagram.  <UP> returns to the previous menu item in the diagram.  <PORT> directs the MATE to read the next device (port) on the HUB. ...

  • Page 86: Advanced Menu Map

    MATE/MATE2 Screens Advanced Menu Map Navigation for ADV/CC/PAGE1  <DOWN> moves to the next menu item in the diagram.  <UP> returns to the previous menu item in the diagram.  <PORT> directs the MATE to read the next device (port) on the HUB.
  • Page 87 MATE/MATE2 Screens Navigation for ADV/CC/PAGE2  <DOWN> moves to the next menu item in the diagram.  <UP> returns to the previous menu item in the diagram.  <PORT> directs the MATE to read the next device (port) on the HUB. ...
  • Page 88 MATE/MATE2 Screens This page intentionally left blank. 900-0009-01-00 Rev...

  • Page 89: Menu Maps For The Flexmax

    Menu Maps for the FLEXmax Figure 95 FLEXmax Startup Screens 900-0009-01-00 Rev...
  • Page 90 FLEXmax Menu Maps Figure 96 FLEXmax Menu Map (Page 1) 900-0009-01-00 Rev...
  • Page 91 FLEXmax Menu Maps Figure 97 FLEXmax Menu Map (Page 2) 900-0009-01-00 Rev...
  • Page 92 FLEXmax Menu Maps Figure 98 FLEXmax Menu Map (Page 3) 900-0009-01-00 Rev...

  • Page 93: Troubleshooting

    Troubleshooting IMPORTANT: Be sure to check out the OutBack customer and user forum at www.outbackpower.com/forum/ for more FLEXmax information. Symptom Remedy  Check the battery connection and polarity. Reverse polarity or an improper FLEXmax does not connection will cause power-up issues. boot/power-up ...
  • Page 94 Troubleshooting Symptom Remedy  Check battery voltage. If the battery voltage is at or above the Absorbing FLEXmax is always voltage set point (compensated for battery temperature), the FLEXmax will SLEEPING not wake up.  Check PV voltage. The PV voltage has to be at least two volts greater than the battery voltage for the initial wakeup.

  • Page 95: Specifications

    RTS, HUB 4, HUB 10, MATE, MATE2, MATE3 Menu Languages English and Spanish Firmware Revision This manual applies to FLEXmax 80 or FLEXmax 60 charge controllers with a firmware revision of 002.001.xxx or higher. Regulatory Specifications Table 3 Regulatory Specifications for All Models UL 1741 1st Edition;...

  • Page 96: Default Settings And Ranges

    Current Limit (FLEXmax 80) Low Battery Disconnect Range: 5 to 80 Adc <On, Auto, Off> Default 01 second Default 60 Adc Current Limit (FLEXmax 60) Delay Time Sec Range: 5 to 60 Adc Range: 000 to 250 sec. (cont’d) Charger Default 13.6 Vdc...

  • Page 97: Applications

    Applications Maximum Power Point Tracking Maximum Power Point Tracking (MPPT) is the technology used by FLEXmax controllers to optimize the harvest of power from PV arrays. PV modules do not have a defined operating voltage. Their voltage is defined strictly by the load connected to them.

  • Page 98: Three-Stage Battery Charging

    Applications Three-Stage Battery Charging The FLEXmax 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. The FLEXmax is a “buck” converter which turns higher PV voltages into the lower charging voltages used by batteries (with correspondingly higher currents).

  • Page 99: Absorbing

    Applications ABSORBING This is the second stage of charging. It is a constant-voltage stage. Current varies as needed to maintain the Absorbing voltage setting. However, it will typically decrease to a very low number over time. This “tops off the tank”, leaving the batteries at essentially 100% of capacity. The duration of the Absorbing stage is the user-defined Absorb Time Limit.

  • Page 100: Array Design

    Table 5 Maximum PV Input Wattage per Charge Controller Nominal Maximum Array Size (in watts, Standard Test Conditions) Battery Voltage FLEXmax 80 FLEXmax 60 12 V 1000 W 800 W 24 V 2000 W 1600 W 36 V 3000 W...

  • Page 101: Maximum-Power Voltage (Vmp)

    Applications Maximum-Power Voltage (Vmp) Maximum-power voltage (Vmp) is the operating voltage for the PV array at which the array generates the most wattage. When designing the PV array, it is recommended for the Vmp to be approximately 12 to 24 volts higher than the nominal battery voltage for optimum performance. This will ensure that the Vmp is always above the battery voltage, which is required for charging.

  • Page 102: Hydroelectric And Fuel Cell Applications Performance Optimization

    The FLEXmax Charge Controller is designed to work with PV arrays. Although it will work with hydroelectric turbines and fuel cells, OutBack Power Technologies can only offer limited technical support for these applications due to variance in turbine and fuel cell specifications.
  • Page 103 Applications Main Menu To adjust the Lower Mpp Range Limit: Charger Light Misc Advanced Logging Stats From the main menu, press <> to move the arrow next to   EXIT the Advanced function. ADV SETUP Screen Charger Aux Light Press <GO>.

  • Page 104: Grid-Interactive Settings

    Applications Grid-Interactive Settings When using an OutBack inverter, FLEXmax, HUB, and system display, set the FLEXmax to GT in the Advanced menu. GT mode allows the inverter to manage the FLEXmax Float setting. It ensures the FLEXmax always keeps the battery above the sell voltage of the inverter. (See page 48.) When using a FLEXmax charge controller with an inverter without the use of a HUB, GT mode will not work because the FLEXmax cannot communicate with the inverter.

  • Page 105: Definitions

    Applications Definitions The following is a list of initials, terms, and definitions used with this product. Table 7 Terms and Definitions Term Definition Alternating Current; refers to voltage produced by the inverter, utility grid, or generator Advanced Generator Start Inverter’s 12-volt auxiliary output Conformité...
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  • Page 107: Index

    Index Charger Setup ..............26, 64, 78 Contact Information................ 2     Absorb End Amps ................49 Absorb Time Limits ............... 49 Absorbing .................. 20, 97 Data Logging ............19, 54, 61, 69, 75 Advanced Menu ................46 Default Settings ............... 94, 99 Absorb End Amps ..............
  • Page 108 Applications High Voc ..................22   Low Light ..................22 MPPT Bulk ................... 22 Language ................... 15, 16 MPPT EQ ..................23 Logging ................ 19, 54, 69, 75 MPPT Float ................. 22 New Voc ..................23   Over Temp .................. 23 OvrCurrent .................
  • Page 109 Applications Three-Stage Battery Charging ..........96   Timers Float (reading) ................61 Vbatt Calibration ..............50, 68 Troubleshooting ................91 Vmp ....................95, 99 Voc ....................95, 98     U-Pick ....................47 Wakeup Mode ................. 47 Weather Conditions ..............98 Wiring ............
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  • Page 111 Applications THIS PAGE INTENTIONALLY LEFT BLANK. 900-0009-01-00 Rev...
  • Page 112 Corporate Headquarters European Office 17825 – 59 Avenue N.E. Hansastrasse 8 Suite B D-91126 Arlington, WA 98223 USA Schwabach, Germany +1.360.435.6030 +49.9122.79889.0 900-0009-01-00 Rev C...

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Flexmax 80

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