OutBack Power FLEXmax 100 Owner's Manual

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FLEXmax 100 Charge Controller

FM100-300VDC-01

FM100-300VDC-AFCI

Owner's Manual

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Page 1 FLEXmax 100 Charge Controller FM100-300VDC-01 FM100-300VDC-AFCI Owner’s Manual...
Page 2 About OutBack Power OutBack Power™ is a leader in advanced energy storage and conversion technology. OutBack Power products include true sine wave inverter/chargers, batteries, maximum power point tracking charge controllers, and system communication components, as well as circuit breakers, accessories, and assembled systems.
Page 3 Table of Contents General Safety ................. 9 Audience ............................9 Symbols Used ..........................9 Introduction ................... 11 Welcome to OutBack Power ......................11 Audience ............................11 Features ............................11 Components and Accessories ...................... 12 Battery Types ............................13 Installation ..................15 Standards and Requirements .......................
Page 4 Reset Charge Controller to Factory Defaults .................... 56 Firmware Revision ........................57 Device Data Logs ......................... 57 Saving Data Logs for the FLEXmax 100 ....................57 Data Log File Format ........................58 Updating the Firmware ......................... 59 ...
Page 5 Table of Contents Applications ................... 73 Array Design ..........................73 Sizing Guidelines ............................73 Maximum-Power Voltage (V ) ........................ 73 Open Circuit Voltage (V ) ........................73 Temperature Conditions ........................... 74 Maximum Power Point Tracking ....................74 Three-Stage Battery Charging ......................
Page 6 Figure 18 Two Charge Controllers with Rapid Shutdown .............. 31 Figure 19 Third-Party Module-Level Rapid Shutdown..............32 Figure 20 LED Indicators ....................... 36 Figure 21 FLEXmax 100 Battery Charging and Modes ..............37 Figure 22 LED Indicators (Bulk) ....................37 Figure 23 LED Indicators (Absorb) ....................38 ...
Page 7 Figure 46 Restoring the Charge Controller to Factory Default Settings ........56 Figure 47 Reading the Firmware Revision ..................57 Figure 48 Uploading and Saving a Data Log for the FLEXmax 100 ..........57 Figure 49 Uploading and Saving a Data Log (continued) .............. 58 ...
Page 8 Table of Contents This page intentionally left blank. 900-0253-01-00 Rev C...
Page 9 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 11 Introduction Welcome to OutBack Power 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 12 Introduction Components and Accessories Table 1 Components Included FLEXmax 100 Charge Controller MicroSD Card (already installed) Mounting Bracket (× 2) Warning Label (to be applied to battery) Silicone Grease Package Product Literature Rainproof enclosure Status indicators with universal symbols Equalize...
Page 13 Introduction 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 15 Installations must comply with all national and local electrical codes. Professional installation is recommended. See page 11 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 69 for more information.
Page 16 Installation Mounting the Charge Controller The FLEXmax 100 must be mounted upright on a wall or similar flat upright mounting surface. No other mounting positions are allowed. Installation in shade is recommended. Two mounting methods are available. The first method uses keyhole slots on the back of the controller for hanging directly on a wall and flush with the surface.
Page 17 The second mounting method uses brackets on the top and bottom of the controller. This method mounts the controller 0.83” (2.1 cm) from the wall. It is useful when mounting the controller next to an OutBack Power inverter system, as the conduit openings will align. It is also useful for mounting without making advance measurements.
Page 18 This damage is not covered under warranty. Failure to follow these instructions may also result in noncompliance with 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 5).
Page 19 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 20 If alternate PV system grounding configurations or GFDI methods are required, remove the ground bonding jumper wire from all FLEXmax 100 controllers (see Figure 5 on page 19). Do not remove the GFDI fuses from any controllers. Once the bonding wire has been removed, the external ground fault device can be installed according to its own instructions.
Page 21 The largest PV array must have a rated short-circuit current of 64 amps or less under STC after accounting for all thermal derating factors. The output current limit of the FLEXmax 100 is 100 amps. DC battery overcurrent protection must be used as part of the installation. OutBack Power offers both circuit breakers and fuses for overcurrent protection.
Page 22 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! Do not connect battery power to the PV terminals.
Page 23 This button does NOT reset the FLEXmax 100 to factory default settings. See page 34. HUB Port This is an RJ-45 port for a CAT5-style cable to connect OutBack Power system displays or the HUB communications manager. Device and LAN Ports These ports are not currently active.
Page 24 PV system in a de-energized state. These terminals can receive Rapid Shutdown commands to quickly shut down the FLEXmax 100. Multiple controllers can be connected in parallel on a single Rapid Shutdown circuit. See page 30 for more discussion of the Rapid Shutdown function, including hookup diagrams.
Page 25 Installation AUX Terminals The A (Auxiliary) output is a small power supply that provides a 12 Vdc output current to an isolated load. The A output can respond to many criteria and control many functions. These include cooling fans, vent fans, load diversion, fault alarms, and automatic generator control.
Page 26 (See Figure 27 on page 41.) 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 Power inverters are present, the inverter voltage replaces the FLEXmax 100 as ...
Page 27 Arc Fault Circuit Interruption (Option) The FLEXmax 100 has a circuit card that provides arc fault detection. This device orders the controller to shut down if arcing occurs in the PV circuit. The card operates automatically as long as the controller receives battery power.
Page 28 Installation Wiring Diagrams Photovoltaic (PV) Array Charge Controller Ground PV– BAT– BAT+ Ground Bus Bar Disconnect Battery Bank Panel Shunt NOTES: System-specific wiring is not shown. Figure 14 Wiring Diagram – Single Charge Controller with PV Array Photovoltaic (PV) Array Charge Controller Ground PV–...
Page 29 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 900-0253-01-00 Rev C...
Page 30 A single wire is run from one of the yellow terminals ( 1 or 2 ). A second single wire is run from one of the purple terminals ( 3 or 4 ). Terminals 1 and 3 are the most commonly used. On the OutBack Power RSI these wires are connected to the A contacts.
Page 31 Installation Charge Controller A Charge Controller B PV Array A PV Array B Ground Control Wiring Ground Control Wiring 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 32 Installation Integration of FM100 and Third-Party Module-Level Rapid Shutdown Products Many rapid-shutdown devices are designed to disconnect a PV array at the level of individual modules. This type of module-level rapid shutdown is used to meet the requirements of NEC 2017 690.12 (B) (2). The FM100 can be integrated with these products.
Page 33 2. Connect PV power to the controller by closing the disconnect. See Initial Operation on page 34. 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 34 PV array. Normally, the FLEXmax 100 starts in the morning within a few minutes of the PV array being exposed to sufficient direct sunlight.
Page 35 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 Controller Status Voltage Indicators Pattern Off = less than 10 W PV being harvested Battery rest...
Page 36 Status and Information (Blue): HARGING Illuminates when more than 10 watts of PV power is being actively harvested. It is solid or flashing depending on the charging stage. The system display represents these stages as operating modes in the S menu.
Page 37 MATE3s Screens Modes of Operation The FLEXmax 100 goes through many states during its operation. Figure 21 shows an example of the various stages of battery charging and several states when the controller is not charging. The graph in Figure 21 shows a typical day of charging with a nominal 48-volt system. Charging is described in detail on page 75.
Page 38 If the battery voltage drops below the Absorb Voltage set point before the Absorb time is reached (see page 48), the FLEXmax 100 reverts back to the Bulk charge stage. The system display shows Bulk as shown on page 42.
Page 39 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 40 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 41 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 42 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 . The Error screen (see page 38) will show the cause if it is one of the Silent defined errors on that screen.
Page 43 MATE3s Screens 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 44 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 32.
Page 45 MATE3s Screens 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 46 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 47 Programming the FLEXmax 100 Menu Structure in the MATE3s Figure 37 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 48 MATE3s Screens Charge Controller Settings Charge Controller menu options include the following: Charger ------------------------------------------------------- > See below. MPPT ---------------------------------------------------------- > See page 49. Temperature Compensation --------------------------- > See page 49. Battery Equalize -------------------------------------------- > See page 50. Grid-Tie Mode ---------------------------------------------- > See page 50.
Page 49 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 74. Set Points: MPPT Mode –...
Page 50 This system-wide compensation only works if there is a single RTS on the system and it is connected to the FLEXmax 100. In all cases, the batteries should be monitored to ensure they are being charged according to the battery manufacturer’s recommendations.
Page 51 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 52 MATE3s Screens Table 6 AUX Mode Functions Mode Name Function/Purpose Set Points Polarity Enable Active High : PV Trigger Voltage Activates when the voltage exceeds Hold Time the set point. Active Low : Activates when the Function: voltage drops When the Enable Voltage set point is exceeded, the below the set point;...
Page 53 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 54 HUB, inverter, and FLEXmax 100. If the system display Purpose: connects only to a FLEXmax 100, AGS will This mode is intended to allow functions such as only work with DC generator programming. AGS to control the A output.
Page 55 MATE3s Screens Photovoltaic (PV) Array Diversion Relay Coil Common Charge Controller Ground PV+ PV– BAT– BAT+ NOTE: Disconnect DC Disconnect See page 54 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 56 MATE3s Screens Calibrate The Calibrate menu allows adjustment of the controller’s battery voltmeter. If a controller’s readings do not match those of another device or a hand-held meter, calibration may improve consistency. Set Points: Battery Voltage – Calibrates the Vdc measurement made at the controller’s battery terminals Calibration Offset...
Page 57 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 58 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 59 1. Turn off 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 51.) The card can be ejected by pressing on the exposed end. It should depress slightly and then protrude with a click. Afterward it can be easily removed.
Page 60 Eject command (usually titled Safely Remove Hardware, Eject Media, etc.). 7. Insert the microSD card back into the FLEXmax 100. Ensure the card clicks into position similarly to the way it was previously removed. The FM100 will select the appropriate .bin file based on its hardware configuration.
Page 61 48-volt system = 290 Vdc. See page 74 for more information. IMPORTANT: The FLEXmax 100 will not function unless jumper J5, the OutBack Power RSI, or a similar normally-closed device is installed on the rapid shutdown terminals. Initial power-up will result in a rapid shutdown signal. See page 30.
Page 62 Unit not operating; high, the controller cannot safely operate. The system display VOC Too High unit had worked error will indicate Y (see page 44). The FLEXmax 100 will automatically restart normally before; operation once the V decreases to a safe level.
Page 63 Troubleshooting Table 7 Troubleshooting Symptom Remedy Battery Calibration The system display will not report this setting if remote battery sensing is connected. setting does not To test this function, temporarily disconnect remote battery sensing. See pages 26 respond. and 56. Check equalization settings using the system display (see pages 50 and 76).
Page 64 Over Current Fault Controller has shut down. To restart the FLEXmax 100, remove all power from the controller and then reconnect the batteries. If the problem recurs, contacts may be loose or shorted. The PV array may also be oversized.
Page 65 Troubleshooting Troubleshooting Firmware Updates Certain problems may occur when updating the controller’s firmware revision. See page 59. Table 9 Firmware Update Issues Symptom Possible Cause Possible Remedy Insert microSD card. Make certain it MATE3s displays No SD Card MicroSD card not installed or is completely seated.
Page 67 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 68 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 002.001.000 or higher. To check the current revision using the system display, see page 57.
Page 69 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 53 are examples for a system with a PV input of 220 Vdc. Lower input voltage will improve the controller’s thermal performance.
Page 70 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 71 Specifications Table 12 FLEXmax Settings Setting Mode Menu Item Value 24-volt 36-volt 48-volt Voltage Range 20 to 250 Vdc Default 0 Vdc Hold Time Range 0 to 25 seconds Default <Off> Error Output <On, Auto, Off> Range Default 23.0 Vdc 34.5 Vdc 46.0 Vdc Low Battery...
Page 73 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 74 , is the highest that can be drawn while still maintaining the highest 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 75 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 76 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.
Page 77 +3.6 Vdc FLEXnet DC Battery Monitor (FN-DC) The FLEXnet DC will work normally if it is networked with the FLEXmax 100 and OutBack Power 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 78 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 Power devices can be present.
Page 79 (See page 50.) When using a FLEXmax 100 charge controller with an inverter without the use of a HUB product, the 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 80 Term Definition Negative-Ground A wiring system that bonds the negative conductor to ground for safety A set of OutBack Power devices which communicate on a bus established by the HUB Network Communications Manager Positive-Ground A wiring system that bonds the positive conductor to ground for safety...
Page 81 Index Diagrams, Wiring Diversion Control ..........55 General ............28 Positive Ground ..........28 Absorbing ............38, 75 Rapid Shutdown ..........30 Accessory Terminal Block ......23, 24 with Multiple Controllers ....... 31, 32 Advanced Generator Start (AGS) ....54, 79 With Inverter ...........
Page 82 Index Maximum Power Point Tracking ..... 49, 74, 79 Maximum-Power Voltage ......73, 74 Modes..............37 Important Symbol ..........9 Absorb ............. 38 Indicators ............35, 36 Bulk ..............37 Absorption ............38 EQ ..............39 Battery (MATE3s) ........... 41 Float ..............
Page 83 Index Terminals Accessory Terminal Block ......23, 24 AUX ..............25 SD Card ............... 24 Battery Sense ..........26 Data Log ........... 57, 58 Rapid Shutdown ........24, 30 Firmware Update ........59, 65 Wiring ............. 22 Port ............23, 59 Third-Party Products and Rapid Shutdown ..
Page 84 Worldwide Corporate Offices Headquarter Germany France and Benelux Africa Eastern Europe Hansastrasse 8 africa@alpha-outback-energy.com ee@alpha-outback-energy.com fbnl@alpha-outback-energy.com D-91126 Schwabach Tel: +49 9122 79889 0 Spain Middle East Mail: info@alpha-outback-energy.com me@alpha-outback-energy.com spain@alpha-outback-energy.com Alpha and Outback Energy GmbH reserves the right to make changes to the products and information contained in this document without notice. Copyright © 2020 Alpha and Outback Energy GmbH. All Rights reserved.

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