OutBack Power FLEXmax 100 Owner's Manual
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OutBack Power FLEXmax 100 Owner's Manual

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FLEXmax 100
Charge Controller
Owner's Manual

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Summary of Contents for OutBack Power FLEXmax 100

  • Page 1 FLEXmax 100 Charge Controller Owner’s Manual...
  • Page 2 Grid/Hybrid™ As a leader in off-grid energy systems, which are designed around energy storage, OutBack Power is an innovator in Grid/Hybrid system technology which provides the best of both worlds: grid-tied system savings during normal or daylight operation, and off-grid independence during peak energy times or in the event of a power outage or an emergency.

  • Page 3: Table Of Contents

    Table of Contents Important Safety Instructions ..................6 Symbols Used ............................6 General Safety ............................6 Introduction ........................7 Audience ..............................7 Features ..............................7 Firmware ..............................7 Components and Accessories ........................8 Battery Types ............................8 Installation ........................9 Standards and Requirements ........................
  • Page 4 Reset Charge Controller to Factory Defaults ..................50 Firmware Revision ......................... 51 Device Data Logs ........................... 51 Saving Data Logs for the FLEXmax 100 .................... 51 Data Log File Format ......................... 52 Updating the Firmware ........................... 53 Using MATE3s ............................ 53 Without MATE3s ..........................
  • Page 5 Table of Contents Applications ......................... 65 Array Design ............................65 Sizing Guidelines ..........................65 Maximum-Power Voltage (V ) ......................65 Open Circuit Voltage (V ) ........................65 Temperature Conditions ........................66 Maximum Power Point Tracking ......................66 Three-Stage Battery Charging ........................ 67 Bulk ..............................

  • Page 6: Important Safety Instructions

    When this symbol appears next to text, it means that more information is available in other manuals relating to the subject. The most common reference is to the FLEXmax 100 Quick Start Guide. Another common reference is the system display manual.

  • Page 7: Introduction

    Introduction Thank you for purchasing a FLEXmax 100 Series Charge Controller. These charge controllers offer an efficient, safe, multi-stage recharging process that prolongs battery life and assures peak performance from a PV array of up to 300 open-circuit volts (V Audience This manual provides instructions for installation, setup, and operation of the product.

  • Page 8: Components And Accessories

    Features & Wiring Cover Battery Types The default settings of the FLEXmax 100 charge controller are for lead-chemistry batteries intended for deep discharge. These include all energy storage offered by OutBack Power as well as batteries for marine, golf-cart, and forklift applications. They also include gel-cell batteries and absorbed glass-mat (AGM) batteries.

  • Page 9: Installation

    Installations must comply with all national and local electrical codes. Professional installation is recommended. See page 7 for qualifications of installers. A FLEXmax 100 charge controller operating in unventilated or in other conditions above an ambient temperature of 25°C (77°F) will have a derated power output. See page 61 for more information.

  • Page 10: Installation

    Mounting the Charge Controller The FLEXmax 100 must be mounted upright on a wall or similar flat upright mounting surface. It must be mounted at least 36” (91.4 cm) above the ground or floor. No other mounting positions are allowed.

  • Page 11: Keyhole Slot Mount

    To mount using keyhole slots (A): Keyhole slots 1. Use two slotted #14 wood screws. The mounting surface must be strong enough to support the weight of the FLEXmax 100. NOTE : OutBack is not responsible for damage resulting from inadequate mounting hardware or preparation.

  • Page 12: Bracket Mount

    The second mounting method uses brackets on the top and bottom of the controller. This method is useful when mounting the controller next to an OutBack inverter system, as the conduit openings will align. It is also useful for mounting without making advance measurements. The FLEXmax 100 controller comes with two identical brackets.

  • Page 13: Wiring

    NEC or other codes. The FLEXmax 100 uses a jumper wire to create a functional ground for one conductor. Connecting this wire completes a mechanical connection (bond) between one battery conductor and the ground. The default position creates a negative-to-ground bond, the most common configuration (item A in Figure 6).

  • Page 14: Positive-Ground Systems

    Battery – Figure 6 Bonding Jumper Positive-Ground Systems The FLEXmax 100 has several critical requirements when used in a positive-ground system.  The internal GFDI function cannot be used. However, make certain to leave the GFDI fuse in place. ...

  • Page 15: Ground Fault Detection And Interruption (Gfdi)

    Ground Fault Detection and Interruption (GFDI) If a ground-fault event occurs, the controller’s GFDI fuse will open. The FLEXmax 100 GFDI circuit detects continuity across the fuse. Lack of continuity will cause the charge controller to shut down. If the fuse is not initially installed, the controller will be unable to operate.

  • Page 16: Wiring Size And Requirements

    Please refer to the NEC and other electrical codes for PV array cable sizing, cable length, and cable ampacity.  Use #4 AWG (25 mm ) wire (minimum) for the output between the FLEXmax 100 and the battery bus bar conductors. Smaller cables can reduce performance and possibly damage the unit. ...

  • Page 17: Physical Requirements And Conduit

    Use a DVM to check for voltage on all wires. CAUTION: Equipment Damage Each FLEXmax 100 requires its own PV array. DO NOT PARALLEL PV+ and PV- TERMINALS OF MULTIPLE CONTROLLERS ON THE SAME ARRAY! The negative (–) PV and negative (–) BAT terminals are connected internally. Only one wire is needed to connect to the negative (–) wire lugs if the negative (–) PV and BAT conductors are connected at the...

  • Page 18: Accessory Terminals And Ports

    Figure 9 Wiring Compartment Reset Button This button is used for several functions, including updating the FLEXmax 100 firmware. See page 53. HUB Port This is an RJ-45 port for a CAT5-style cable to connect OutBack system displays or the HUB communications manager.

  • Page 19: Sd Card

    When enabled, the microSD card inserted in the slot will record operational status data about the system. The FLEXmax 100 will record data to the microSD card up to the limit of the card. (It has been tested with microSD cards up to 16 GB.) If the card’s capacity is exceeded, the data will begin to be overwritten starting with the oldest first.
  • Page 20 Installation terminals 5 and 6 are the A output – and + terminals. These terminals are colored gray (–) and orange (+) for easy reference. The terminals can supply up to 250 mA at 12 Vdc (3 W). This circuit contains electronic overcurrent protection, which resets after being overloaded.

  • Page 21: Battery Sense Terminals

    (See Figure 26 on page 35.) This voltage is used for generator starting and other functions. If no other devices are present, it will show the reading of the FLEXmax 100. Unless:  If OutBack inverters are present, the inverter voltage replaces the FLEXmax 100 as the ...

  • Page 22: Wiring Diagrams

    Installation Wiring Diagrams Photovoltaic (PV) Charge Controller Ground PV– BAT– BAT+ Ground Bus Bar Disconnect Battery Bank Panel Shunt NOTES: System-specific wiring is not shown. This image shows a single (common) negative conductor instead of separate BAT– and PV– conductors. Figure 14 Wiring Diagram –...
  • Page 23 Installation Photovoltaic (PV) Array MATE3s Charge Controller HUB/DEVICE Ground PV– BAT– BAT+ CAT 5E Ground Disconnect Ground Bus Bar Panel Inverter HUB/ MATE Shunt Inverter DC Disconnect Battery Bank NOTE: System-specific wiring is not shown. Figure 16 Wiring Diagram — System with Inverter 900-0209-01-00 Rev A...

  • Page 24: Wiring The Rapid Shutdown Terminals

    1 and 3 with a small jumper wire. IMPORTANT: The FLEXmax 100 will not function unless either the disabling jumper, the OutBack RSI, or a similar normally-closed device is installed. Initial power-up will result in a Rapid Shutdown signal.
  • Page 25 Installation Charge Controller A Charge Controller B PV Array A PV Array B Control Wiring Control Wiring Ground Ground Terminal Block Terminal Block PV+ PV– BAT– BAT+ PV+ PV– BAT– BAT+ NOTE: Bonding jumper is shown in negative-ground position in the first Ground Bus Bar controller only.

  • Page 26: Power Up

    2. Connect PV power to the controller by closing the disconnect. See Initial Operation on page 27. The FLEXmax 100 uses power from the battery bank to operate. The battery voltage must be at least 15 volts or higher to power up the charge controller.

  • Page 27: Initial Operation

    (red) will illuminate. AULT 4. Release the E switch and disconnect the batteries. QUALIZE The system display can be used to reset the FLEXmax 100 to its factory default settings. See page 50 for more information. 900-0209-01-00 Rev A...
  • Page 28 Installation NOTES: 900-0209-01-00 Rev A...

  • Page 29: Status And Information

    Status and Information LED Indicators The FLEXmax 100 charge controller has no graphical display. It is equipped with four LED indicators. Table 2 LED Indicators Indicators HARGING TATUS UXILIARY AULT All off (with PV power available) = Rapid Shutdown IMPORTANT: The LED indicators do not necessarily tell the amount the controller is actively charging.
  • Page 30 Status and Information (Blue): HARGE Illuminates when more than 10 watts of PV power is available. It is solid or flashing depending on the charging stage. The system display represents these stages as operating modes in the S menu. See page 36 for a TATUS list of modes.

  • Page 31: Modes Of Operation

    Status and Information Modes of Operation The FLEXmax 100 goes through many states during its operation. Figure 20 shows an example of the various stages of battery charging and several states when the controller is not charging. (The graph in Figure 20 shows a typical day of charging with a nominal 48-volt system.

  • Page 32: Absorb

    If the battery voltage drops below the Absorb Voltage set point before the Absorb time is reached (see page 42), the FLEXmax 100 reverts back to the Bulk charge stage. The system display shows Bulk as shown on page 31.

  • Page 33: Floating

    Float Voltage. If the battery voltage drops below the Float Voltage, the FLEXmax 100 will employ the MPPT function to draw more power from the PV array. (This may occur if the batteries are powering loads.) If this occurs, the operation may change to constant-current, variable-voltage.

  • Page 34: Silent

    Status and Information Silent The system display shows the operating mode as Silent if the charge controller has stopped charging. This message represents a variety of conditions, many of which are common. For example, Silent is shown at night or any period of insufficient light. Table 4 lists the LED indicators and the PV open-circuit voltage which show specific Silent conditions.

  • Page 35: Mate3S System Display

    The MATE3s System Display and Controller is a display which allows the user to read the operating mode, measurements, and any status messages from the FLEXmax 100 charge controller. It can also change the charge controller’s settings when the default settings are not enough.

  • Page 36: Charge Controller Soft Key

    Charge Controller Soft Key Screens NOTE: If the FLEXmax 100 shuts down due to a fault condition, the system display will display the status as Silent. The Error screen (see page 38) will show the cause if it is one of the defined errors on that screen.

  • Page 37: Stats Screen

    Status and Information Stats Screen From the Charge Controller screen, the <Next> soft key proceeds to the Charge Controller Stats screen. This screen shows data accumulated since the system went online or since the last reset. Screen Items: The Maximum statistics are not incremental. They are updated only if a higher value is measured.

  • Page 38: Error Screen

    Upper limits: 24-volt system = 275 vdc, 36-volt system = 283 Vdc, 48-volt system = 290 Vdc This error can clear automatically.  Over Temperature: The FLEXmax 100 is too hot to operate and has shut down. This error can clear automatically. See the temperature readings in Figure 31.

  • Page 39: Datalog Screen

    Status and Information DataLog Screen From the Charge Controller Error screen, the <DataLog> soft key proceeds to the Charge Controller Datalog screen. This screen 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.

  • Page 40: Graph Screens

    Status and Information Graph Screens The <Graph> soft key brings up the following screens which plot various types 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 41: Programming The Flexmax 100

    Programming the FLEXmax 100 Menu Structure in the MATE3s Figure 36 shows the menu structure for adjusting the controller settings in a MATE3s system display. The Main Menu shown below is accessed with the LOCK button and a password. Use the system display control wheel to move up and down between menus (or options within a menu).

  • Page 42: Charge Controller Settings

    MATE3s Screens Charge Controller Settings Charge Controller menu options include the following: Charger -------------------------------------------------------- > See below. MPPT ----------------------------------------------------------- > See page 43 Temperature Compensation ---------------------------- > See page 43. Battery Equalize -------------------------------------------- > See page 44. Grid-Tie Mode ---------------------------------------------- > See page 44.

  • Page 43: Mppt

    MATE3s Screens MPPT The charge controller uses a maximum power point tracking (MPPT) algorithm which manipulates the output of the PV array to harvest maximum wattage. Although this function is automatic, this menu allows the user to adjust many of its parameters for special applications. See page 66. Set Points: ...

  • Page 44: Battery Equalize

    HUB, Grid-Tie mode will not function. Grid-Tie mode allows the FLEXmax 100 to work more effectively with any grid-interactive inverter installed on the HUB. This mode automatically raises the controller’s Float voltage to equal its Absorption voltage.

  • Page 45: Auxiliary Output

    MATE3s Screens Auxiliary Output The A (Auxiliary) is a secondary control circuit — essentially, a small power supply that provides a 12 Vdc output current (up to 250 milliamps or 3 watts) to an isolated load. It can be ON with 12 Vdc available at the output, or OFF with 0 Vdc at the output.
  • Page 46 MATE3s Screens Table 6 AUX Mode Functions Mode Name Function/Purpose Set Points Polarity  Enable Active High: PV Trigger Activates when the Voltage voltage exceeds the  Hold Time set point. Active Low: Activates when the Function: voltage drops below When the Enable Voltage set point is exceeded, the the set point;...
  • Page 47 Rapid Shutdown. Float None Not Available Function: When the FLEXmax 100 is in the Float stage, the output activates. Purpose: This mode is intended to operate a device such as a “battery full” indicator when the FLEXmax 100 is in the Float stage of battery charging.
  • Page 48 FLEXmax 100. If the system display connects only to a This mode is intended to allow functions such as FLEXmax 100, AGS will only work with AGS to control the A output. See the system DC generator programming. The other display literature for information on AGS.
  • Page 49 MATE3s Screens Photovoltaic (PV) Array Diversion Relay Coil Common Charge Controller Ground PV+ PV– BAT– BAT+ NOTE: DC Disconnect Disconnect See page 48 Panel for important requirements when using DC Disconnect the mode Inverter Negative Diversion: Solid St. Shunt DC Disconnect Diversion Load Inverter Terminal Bus Bar...

  • Page 50: Calibrate

    FLEXnet DC Battery Monitor or an inverter. It also does not affect voltages displayed using the FLEXmax 100 Battery Sense terminals (see page 21). If any of these readings are shown on the system display, adjusting the Calibrate screen will have no effect.

  • Page 51: Firmware Revision

    Reading the Firmware Revision Device Data Logs Users of a MATE3-class system display can create Device Data Logs for the FLEXmax 100 charge controller. The Data Logs can then be uploaded and saved to an SD card. Saving Data Logs for the FLEXmax 100 To create a data log for the FLEXmax 100: 1.

  • Page 52: Data Log File Format

    MATE3s Screens Saving Data Logs (continued) To save a new data log over the name highlighted on the list: 1. Use the control wheel to scroll through the list. 2. When the name to be replaced is highlighted, press <Save>. 3.

  • Page 53: Updating The Firmware

    1. Turn off the battery and PV disconnect devices. Ensure the FLEXmax 100 has no power from any source. 2. If present, remove the microSD card from the FLEXmax 100. (See Figure 50.) The card can be ejected by pressing on the exposed end. It should depress slightly and then protrude with a click.
  • Page 54 5. Before removing the card from the computer it is recommended to eject it using the computer’s onscreen Eject command (usually titled Safely Remove Hardware, Eject Media, etc.). 6. Insert the card back into the FLEXmax 100. Ensure it clicks into position similarly to the way it was previously removed.

  • Page 55: Troubleshooting

     Check the battery circuit breaker or device. Ensure all items are sized appropriately. system display  Check the battery voltage at the FLEXmax 100 terminals. A battery voltage below operation) 15 Vdc may not power up the charge controller. A poor connection may not allow sufficient voltage to reach the charge controller.
  • Page 56  High temperature fault. Check controller temperature (see page 38). conditions The FLEXmax 100 will stop functioning at an Output FETs reading of 90°C. The system display Over Temperature error will indicate Y. (See page 38.)  High V fault.

  • Page 57: Troubleshooting Error Messages

    Controller has shut down This occurs if more than 80 amps flow from the battery to the FLEXmax 100, or if more than 120 amps flow from the controller to the battery.  To restart the FLEXmax 100, remove all power from the controller and then reconnect the batteries.

  • Page 58: Troubleshooting Firmware Updates

    Troubleshooting Troubleshooting Firmware Updates Certain problems may occur when updating the controller’s firmware revision. See page 53. Table 9 Firmware Update Issues Symptom Possible Cause Possible Remedy MicroSD card not installed or Insert microSD card. Make certain it MATE3s displays No SD Card completely seated is completely seated.

  • Page 59: Specifications

    Specifications Table 10 Electrical and Mechanical Specifications Specification Value Maximum Continuous Output Current 100 Adc Maximum Input Current (short-circuit) 64 Adc Nominal Battery System Voltage 24, 36, or 48 Vdc (automatically adjusted) PV Open-Circuit Voltage 300 Vdc (highest open-circuit voltage before equipment damage) 15 Vdc (lowest battery voltage for functionality) Operating Voltage Range High...

  • Page 60: Fcc Information To The User

    Consult the dealer or an experienced radio/TV technician for help. Firmware Revision This manual applies to FLEXmax 100 charge controllers with a firmware revision of 001.001.000 or higher. To check the current revision using the system display, see page 51.

  • Page 61: Temperature Range And Derating

    Specifications Temperature Range and Derating In standard installations, the FLEXmax 100 can operate at its full 100-amp capacity at ambient temperatures up to 25°C (77°F). Above this temperature, its output is derated as described below. The values depicted in Figure 52 are examples for a system with a PV input of 220 Vdc. Lower input voltage will improve the controller’s thermal performance.

  • Page 62: Default Settings And Ranges

    Specifications Default Settings and Ranges The settings in this table are as shown in the system display. Table 12 FLEXmax Settings Setting Mode Menu Item Value 24-volt 36-volt 48-volt Default 28.8 Vdc 43.2 Vdc 57.6 Vdc Absorb Voltage Range Float setting to 68.0 Vdc Default 01.0 hours (Absorb) Time...
  • Page 63 Specifications Table 12 FLEXmax Settings Setting Mode Menu Item Value 24-volt 36-volt 48-volt Default <Off> Error Output <On, Auto, Off> Range Default 23.0 Vdc 34.5 Vdc 46.0 Vdc Low Battery Voltage Range 20.0 to 68.0 Vdc Default <Off> Night Light <On, Auto, Off>...
  • Page 64 Specifications NOTES: 900-0209-01-00 Rev A...

  • Page 65: Applications

    Array Design Sizing Guidelines Below is a list of maximum array wattages for the FLEXmax 100 for various nominal voltage batteries. This should be used for sizing an array. Note that every PV module is different. The specifications for every model should be consulted before designing or assembling a PV array.

  • Page 66: Maximum-Power Voltage

    V The FLEXmax 100 controller places a variable load on the PV array and tracks the result to determine the maximum power point. This process, MPPT, is maintained so that the controller can deliver the maximum PV power regardless of any change in conditions.

  • Page 67: Three-Stage Battery Charging

    It will charge as long as necessary, regardless of any timer set points. If little PV energy is available, it may take a long time for Bulk to complete. If the FLEXmax 100 is in a different charging stage and little PV energy is available, it may return to Bulk.

  • Page 68: Float

    This is the third stage of charging. It is a constant-voltage stage. The batteries are maintained at the Float set point. This stage is not timed. The FLEXmax 100 will continue to maintain Float as long as PV energy is available. Current varies as needed to maintain the voltage, but typically drops to a low number.

  • Page 69: Flexnet Dc Battery Monitor (Fn-Dc)

    +3.6 Vdc FLEXnet DC Battery Monitor (FN-DC) The OutBack FLEXnet DC will work normally if it is networked with the FLEXmax 100 and OutBack inverters. This requires a HUB Communications Manager. If the FN-DC is networked exclusively with FLEXmax 100 charge controllers and a HUB product, jumper J4 must be in the left-hand position as shown in item A below.

  • Page 70: Positive-Ground Applications

    No devices are connected to the CAT5 port on the system display  The CAT5 port on the system display can be used if the network is limited to one or more FLEXmax 100 controllers. No other OutBack devices can be present.

  • Page 71: Grid-Interactive Settings

    (See page 44.) When using a FLEXmax 100 charge controller with an inverter without the use of a HUB, GT mode will not work because the charge controller cannot communicate with the inverter. In this situation, when selling electricity back to the grid, keep the inverter’s “sell”...
  • Page 72 Applications Table 15 Terms and Definitions Term Definition Network A set of OutBack devices which communicate on a bus established by the HUB Communications Manager Positive-Ground A wiring system that bonds the positive conductor to ground for safety Pulse-Width Modulation Photovoltaic Rapid Shutdown A function allowing emergency responders to quickly place the PV system in a de-energized...

  • Page 73: Index

    Index Absorbing ............32, 67 Efficiency ..............61 Accessory Terminal Block ........18 Equalize ............. 33, 68 Advanced Generator Start (AGS) ....... 48, 71 Switch .............. 8, 44 AGS ......See Advanced Generator Start Error ..........36, 38, 55, 56, 57 AIC Rating ..............
  • Page 74 Index Ports Fan ..............18 HUB ..............18 LED Indicators..........29, 30, 31 MATE3s .............. 18 Charging ..........31, 32, 33, 34 RTS ..............18 Error ..............56 Positive Ground ..........13, 22, 70 Fault ..........34, 38, 55, 57 Power Up ..............
  • Page 75 Index Warning Symbol ............6 Weather Conditions ..........66 Wiring ............... 13 Updating Firmware ..........53, 58 Conduit ..............17 Diagrams ............22, 49 PV ............... 17 Rapid Shutdown ..........24 Vmp ..............65, 66 with Multiple Controllers........25 Voc ............... 27, 65, 66 Size ...............
  • Page 76 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 +49.9122.79889.0 900-0209-01-00 Rev A...

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