Related Manuals for OutBack Power FLEXmax Series
Summary of Contents for OutBack Power FLEXmax Series
- Page 1 Board Replacement Inst ruct ions for FLEXmax Charge Cont rollers Including Cont rol Board, But t on Board, Power Board, and FLEXmax 60 Fan...
- Page 2 About Out Back Power Syst ems 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.
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Page 3: Important Safety Instructions
Import ant Safet y Inst ruct ions READ AND SAVE THESE INSTRUCTIONS! This manual contains important safety instructions for replacing parts on the FLEXmax Series Charge Controllers. Read all instructions and cautionary markings on the FLEXmax Series Charge Controllers and on any accessories or additional equipment included in the installation. Failure to adhere to these instructions could result in severe shock or possible electrocution. -
Page 4: Definitions
Import ant Safet y Inst ruct ions Definit ions Table 1 Terms and Acronyms Acronym Definit ion Button Board Flat board containing the push-buttons and LCD. Control Board Narrow circuit board containing the unit’s programming. Field Effect Transistor. The FETs used for power switching in the FLEXmax are classified as MOSFETs (Metal-Oxide-Semiconductor Field-Effect Transistors). -
Page 5: Equipment Safety
CAUTION: Equipment Damage Do not perform any servicing other than that specified in these instructions unless qualified to do so and have been instructed to do so by OutBack Power Systems Technical Support personnel. Only use components or accessories recommended or sold by OutBack Power Systems or its authorized agents. - Page 6 Import ant Safet y Inst ruct ions This page intentionally left blank. 900-0054-01-00 Rev...
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Page 7: Table Of Contents
Table of Contents Important Safety Instructions ................1 Symbols Used ..................................1 Audience ....................................1 Definitions....................................2 Personal Safety..................................2 General Safety ..................................2 Equipment Safety.................................3 PV Safety........................Error! Bookmark not defined. Introduction....................7 Overview....................................7 Tools Required..................................8 Preliminary....................................8 Summary List of Instructions................................8 FLEXmax Charge Controller Disassembly............9 Removing the FLEXmax 80 Fan Cable..........................9 Removing Chassis Screws..............................10 Removing the Heat Sink ..............................11 Removing the FET Bar..............................12... - Page 8 Table of Cont ent s Figure 4 Removing Cable Jack............................9 Figure 5 Back Screw Removal ............................10 Figure 6 Side Screw Removal (part 1)........................10 Figure 7 Side Screw Removal (part 2)........................10 Figure 8 Heat Sink Removal............................11 Figure 9 FET Bar Screw Removal ..........................
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Page 9: Introduction
This step-by-step guide illustrates the replacement of the Control Board, Power Board and Button Board for all FLEXmax Series Charge Controllers. It also illustrates the replacement of the Fan for FLEXmax 60 charge controllers only. It does not cover replacing the fan in a FLEXmax 80 charge controller. -
Page 10: Tools Required
Int roduct ion Tools Required Phillips Screwdriver Flat Screwdriver Long-Nose Pliers Diagonal Wire Cutters (not shown) Preliminary WARNING: Shock Hazard If the unit has been in use, power can still be present even after the unit has been disconnected. Remove all electrical connections from the FLEXmax controller. -
Page 11: Flexmax Charge Controller Disassembly
FLEXmax Charge Controller Disassembly If you have a FLEXmax 60, proceed with removing the chassis screws as described on page 10. Removing t he FLEXmax 80 Fan Cable 1. Remove the machine screw that secures the fan cover. 2. Press both sides of the fan cover to release the Press Press tabs. -
Page 12: Removing Chassis Screws
Disassembly Removing Chassis Screws 1. Set the unit on its side to remove the two back screws. Keep the screws and star washers together. Figure 5 Back Screw Removal 2. With the unit still on its side, remove two side screws. Figure 6 Side Screw Removal (part 1) 3. -
Page 13: Removing The Heat Sink
Disassembly Removing t he Heat Sink 1. To remove the heat sink, grip it along each flank and raise its lower end. 2. Slide the control board past the grounding lug. Make certain the power board is raised high enough to avoid the grounding lug Grounding lug 3. -
Page 14: Removing The Fet Bar
Disassembly Removing t he FET Bar 1. Set the unit on its side as shown in Figure 9 and remove the 12 screws securing the FET mounting bar to the heat sink. Figure 9 FET Bar Screw Removal 2. Remove the FET mounting bar. Figure 10 FET Bar Removal Continued on next page. -
Page 15: Figure 11 Freeing The Fet From The Insulator
Disassembly 3. Lift the tab of the FETs off from the Sil-Pad (gray insulator pad) using your finger and thumb. CAUTION! Do not attempt to remove the FETs from the power board. The FET pins are soldered to the board. Figure 11 Freeing t he FET from t he Insulat or If the FETs are difficult to break free, rock the tabs... -
Page 16: Separating The Heat Sink From The Power Board
Disassembly Separat ing t he Heat Sink from t he Power Board Place the charge controller upside down and remove the seven screws circled in white in Figure 13, on the left. Do not remove the four cradle screws and washers identified with the X symbol in Figure 13 on the right. -
Page 17: Figure 15 Heat Sink Removal
Disassembly 3. With all the screws removed, the heat sink can be separated from the power board. Set the unit upright and carefully pry and lift the heat sink off the power board. Figure 15 Heat Sink Removal CAUTION! Do not force the removal. -
Page 18: Figure 17 Cable Removal
Disassembly 4. Set the heat sink on its side and the power board down flat. 5. Remove the ribbon cable connector from the LCD connector. The connector may have a dollop of silicone sealant on it which must be peeled off. When reassembling the controller, it is recommended to apply more silicone sealant if available.) If you have a FLEXmax 60 controller and... -
Page 19: Fan And Button Board
Fan and Button Board Replacing t he FLEXmax 60 Fan Disassemble the controller as described on page 9 through page 16. Removing t he Fan To remove t he fan: 1. Disconnect the connector from the LCD. The connector may have a dollop of silicone sealant to Silicone Sealant ensure a firm connection. -
Page 20: Fan Test Procedures
Fan and But t on Board Fan Test Procedures Test the fan using the following procedures:. 1. Remove the Remote Temperature Sensor (RTS) jack from the port, if present. 2. Insert a flat screwdriver inside the RTS port. Gently press the screwdriver tip against all the pins at once. -
Page 21: Replacing The Button Board
Fan and But t on Board Replacing t he But t on Board To locate the button board: 1. Disassemble the controller as described on page 11 through page 18. 2. Remove the Remote Temperature Sensor (RTS) from the port, if present. 3. -
Page 22: Figure 24 Exposing The Button Board Mounting Peg
Fan and But t on Board The button board is mounted to the heat sink on four metal pegs at the corners of the board. It is retained in place by push-nuts which slide over each peg, and which are covered in turn by silicone sealant. -
Page 23: Figure 26 Deforming The Push-Nut
Fan and But t on Board 2. Slowly close the wire cutters, exerting enough pressure to crush or deform the push-nut. The push-nut cannot be reused after doing this. Figure 26 Deforming t he Push-nut 3. Once the push-nut is deformed, push the wire cutters beneath it and pry it off the peg. -
Page 24: Figure 29 Inserting The New Button Board
Fan and But t on Board 5. Insert the replacement board and align it with the four pegs. Figure 29 Insert ing t he New But t on Board 6. Lay a replacement push-nut over each peg. The push-nuts are not flat. Make certain to place them so that the edges are lower and the convex center is higher. -
Page 25: Control Board And Power Board
Control Board and Power Board Removing t he Cont rol Board 1. Raise the one set of inductor wires that passes over the control board, to allow room for the control board to move. Do not raise the other set of wires. Raise t hese induct or wires Cont rol Board Do NOT raise t hese... -
Page 26: Replacing The Control Board Or Power Board
Cont rol Board and Power Board Replacing t he Cont rol Board or Power Board 1. Inspect the connector pins on the control board for any bends. Straighten any bent pins with a flat screwdriver or your finger. Figure 34 Bent Pin on Cont rol Board 2. -
Page 27: Figure 37 Fets And Sil-Pad Insulator On Heat Sink
Cont rol Board and Power Board 6. Using the replacement that came with the new board, replace the gray Sil-Pad insulator on the heat sink. Screw Hole on t he Heat Sink Sil-Pad Figure 37 FETs and Sil-Pad Insulat or on Heat Sink IMPORTANT: Make certain the new Sil-Pad is lined up with the screw holes on the heat sink. - Page 28 Cont rol Board and Power Board Not es: 900-0054-01-00 Rev...
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Page 29: Reassembly
Reassembly Reseat ing t he Cont rol or Power Board 1. Push on both ends of the control board to confirm it is still properly seated on the power board. Figure 38 Reseat ing Cont rol Board 2. Bend and move the inductor wires over the control board. -
Page 30: Reconnecting The Heat Sink To The Power Board
Reassembly Reconnect ing t he Heat Sink t o t he Power Board 1. With the control board secured to the power board, connect the ribbon cable. CAUTION! The ribbon cable is not keyed. Do not install it backward. In the correct orientation, the red stripe must face the heat sink side wall. -
Page 31: Figure 43 Aligning Fets And Installing The Fet Bar
Reassembly 6. Set the unit on its side with the FETs in between the screw holes on the heat sink. If they do not line up, move the tabs on the FETs to align them between the screw holes. The alignment of the FETs between the screw holes protects them from damage when reinstalling the FET mounting bar and screws. -
Page 32: Reconnecting The Heat Sink To The Chassis
Reassembly Reconnect ing t he Heat Sink t o t he Chassis 1. Slide the reassembled unit into the chassis working around the Grounding lug. Grounding lug Figure 45 Reinst alling t he Heat Sink ont o t he Chassis 2. -
Page 33: Reinstalling Flexmax 80 Fan Plug
Reassembly For the FLEXmax 80 Controller, follow the steps on for reinstalling the fan plug before proceeding. Reinst alling FLEXmax 80 Fan Plug 1. Snap the fan cable jack into the bracket. Figure 47 Reinst alling Cable Jack 2. Snap the fan cable into the jack. Figure 48 Reinst alling Cable Plug 3. -
Page 34: System Functional Test
Reassembly Syst em Funct ional Test Perform a Functional Test as follows before putting the system back into full service. 1. Reinstall FLEXmax Charge Controller back into the system. 2. Initially apply only battery power to the FLEXmax controller. 3. The display should “boot up” and the soft keys should function properly. Test the soft keys by cycling through the menus. - Page 35 Reassembly Not es: 900-0054-01-00 Rev...
- Page 36 North America European Office: 19009 62nd Avenue NE Arlington, WA USA Barcelona, España +1.360.435.6030 +34.93.654.9568 900-0054-01-00 Rev...