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Outback Power Systems FLEXnet DC User Manual

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

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Summary of Contents for Outback Power Systems FLEXnet DC

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

  • Page 3: Warranty Summary

    • Please read the full warranty at the end of this manual for more information. About OutBack Power Systems OutBack Power Systems is a leader in advanced energy conversion technology. Our products include true sine wave inverter/chargers, maximum power point tracking charge controllers, system communication components, as well as breaker panels, breakers, accessories, and assembled systems.

  • Page 4: Contact Information

    Disclaimer UNLESS SPECIFICALLY AGREED TO IN WRITING, OUTBACK POWER SYSTEMS: (a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION. (b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION.

  • Page 5: Table Of Contents

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

  • Page 6: Introduction

    FW-SHUNT500, each rated 500A/50mV) also available from OutBack. Only a single FLEXNet DC is needed for any system using OutBack components. The FLEXnet DC is not intended to be used with the MATE2M. It is designed to work with the MATE or the MATE2.

  • Page 7: System Overview

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

  • Page 8: Reading The Flexnet Dc

    Reading the FLEXnet DC RJ45 jack connects to Port 2 or higher in HUB LEDs* 10-postion wiring block (GREEN) 1: BAT- (YELLOW) 2: BAT+ (YELLOW) 3. Relay (YELLOW) 4. Relay (RED) 5: C DEVICE SIDE 6: C BAT (-) SIDE >90%...

  • Page 9: Flexnet Dc Package

    G. Colored labels identifying shunts Installing the FLEXnet DC The FLEXnet DC mounts in a 3/4” DC breaker slot in an OutBack DC breaker bracket installed inside a FLEXware enclosure or previous model OutBack enclosure. To mount the FLEXnet DC inside an...
  • Page 10 (negative) side of the shunt NOTE: Color of wiring jacket can vary NOTE: The FLEXNet DC shunts must be connected in the negative (low) side of whatever they monitor. Otherwise, the unit can be damaged.
  • Page 11 The wires connected to the wiring block should match the color-coded label where the wiring block inserts into the FLEXnet DC. • Green and White/Green 6’ twisted pair wires with #8 forked spade •...
  • Page 12 FLEXnet DC. • Install the CAT5 cable into the RJ45 jack in the back of the FLEXNet DC. Connect the other end of the cable to the HUB using Port #2 or higher. FLEXnet DC removed from the breaker bracket for clarity.

  • Page 13: Flexnet Dc Measurements

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

  • Page 14: Logged Data

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

  • Page 15: Programming And Using The Mate For Flexnet Operations

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

  • Page 16: Flexnet Dc Modes

    High side connection may result in erratic operation and/or failure of the FLEXNet DC. Charge Cycle At power up, the FLEXNet DC assumes the battery is full regardless of the battery state-of-charge. The batteries should receive a full charge at this time to meet the user-determined charge parameters (entered at start up).
  • Page 17 NOTE: The bottom LED is always off unless the SOC is less than 60% 5. When the SOC is less than 90%, enough of a discharge has taken place that the FLEXnet DC’s data can be used to determine, among other things, an accurate Battery Charge Factor. A battery amp- hour charge factor* and the battery kWhr efficiency factor** for the last cycle are calculated using the stored values from the previous charge cycle (if the SOC is higher than 90%, the values aren’t...

  • Page 18: Programming The Auxiliary Relay

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

  • Page 19: Mate Screens

    MATE Screens MAIN------------------------------- From the MAIN MATE menu, press the <SUM> soft key 11:30:55A to view a summary of the system’s operation. STATUS SETUP ADV This first summary screen appears for a few seconds to display the battery State of Charge. The screen Battery Charging automatically disappears and a system summary State of charge 99%...
  • Page 20 12.6V view a summary of the system’s operation. This information is Inverting 0.000kW AC Loads 0.000kW a sum of all FlexNet DC data. Press the second soft key to view Buying 0.000kW the next SUM screen DC BAT 12.5V The fourth SUM screen shows: -0.6A...
  • Page 21 The first METER screen shows the amount of instantaneous 0.1A 0.000 kW 0.0A 0.000 kW current running through each shunt. A positive value 0.0A 0.000 kW indicates current flow into the battery; a negative value DOWN STATUS means a load is being supplied. Press the <DOWN> soft key to view the amp hour and watt hour screen.
  • Page 22 METER/DC/SHUNT C Pressing the <DOWN> soft key brings up the SHUNT remove 0kWH C charged screen. DOWN METER/DC/SHUNT C Pressing the <DOWN> soft key brings up the FN charged 0kWH firmware screen. DOWN STATUS/FN/METER Pressing the <DOWN> soft key leads to the end of DC firmware revision 000.00/040 the meter menu...
  • Page 23 STATUS/DC/SHUNT Press the <STATUS> soft key. end of shunt status menu TOP STATUS STATUS/DC Press the <BATT> soft key to view the FlexNet DC STATS battery readings METER SHUNT BATT TOP STATUS/DC/BATT displays the number of days the STATUS/DC/BATT total...
  • Page 24 STATUS/DC/BATT provides the number of days since the STATUS/DC/BATT days since charge batter last met its charge parameters. Press the <RESET> soft parameters key to restart the timer. Press the <DOWN> soft key to view DOWN the next battery status screen. batttery minimum displays the minimum battery voltage STATUS/DC/BATT since it was last reset by the user.
  • Page 25 STATUS/DC/BATT llifetime kAH removed shows the total kilowatt amp hours lifetime kAH removed 5 removed from the battery. This is essentially an “odometer” for DOWN RESET battery usage. Press the <DOWN> soft key to continue. STATUS/DC/BATT---------------- end of battery Press the first two soft keys to return to the MAIN menu. status menu UP TOP STATUS...
  • Page 26 ADV/DC/PAGE 1---------------- choose category Press the <BAT> soft key. SHUNT PG2 ADV/DC/BAT------------------- Use the battery capacity screen to set the battery bank battery capacity capacity using either the <INC> or <DEC> soft key. When amp hours finished, press the <TOP> soft key. ADV/DC/PAGE 1---------------- Press the <SHUNT>...
  • Page 27 ADV/DC/PAGE 2---------------- choose category Press the <CHARGE> soft key. PG1 CHARGE AUX PG3 The return amps screen allows the user to set the end of ADV/DC/CHARGE-------------- return amps charge amps using the <INC> and <DEC> soft keys. Press the DOWN INC <DOWN>...
  • Page 28 ADV/DC/PAGE 1---------------- choose category Press the <PG2> soft key. SHUNT PG2 ADV/DC/PAGE 2----------------- choose category: Press the <AUX> soft key. PG1 CHARGE AUX Pressing the <OFF> or <ON> soft keys will manually shut the ADV/DC/AUX CONTROL-------- currently: Auto On AUX off (the relay is open) or turn it on (the relay is closed), respectively.
  • Page 29 ADV/DC/AUX SOC LOW-------- Change the SOC low % values using the <INC> and <DEC> SOC low soft keys. Press the <DOWN> soft key to continue. DOWN INC ADV/DC/AUX/HI DELAY HIGH- Change the high setpoint delay minutes using the <INC> and high setpoint delay minutes <DEC>...
  • Page 30 ADV/DC/PAGE 2----------------- choose category: Press the <PG3> soft key. PG1 CHARGE AUX ADV/DC/AUX/PAGE 3---------- Pressing the <RESET> soft key resets the FLEXnet DC choose category: to its factory default settings. RESET CLR MAIN Pressing the <CLR> soft key clears the data log...

  • Page 31: Technical Notes

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

  • Page 32: Warranty

    -Year Limited Warranty FLEXnet Products OutBack Power Systems, Inc. (“OutBack”) provides a two year (2) limited warranty (“Warranty”) against defects in materials and workmanship for its FLEXnet products (“Products”) if installed in fixed location applications. For this Warranty to be valid, the Product purchaser must complete and submit the applicable Product registration card within ninety (90) days of the eligible Product’s first retail sale.

  • Page 33: Warranty

    To request warranty service, you must contact OutBack Technical Services at (360) 435-6030 or support@outbackpower.com within the effective warranty period. If warranty service is required, OutBack will issue a Return Material Authorization (RMA) number. A request for an RMA number requires all of the following information: 1.

  • Page 34: Warrranty Registration

    *Extended Warranty - OutBack Power Systems offers an optional three year extension to the standard two year Limited Warranty in North America for the FLEXnet DC product. To request a 3-year Limited Warranty extension for a total effective warranty coverage period of five years(5); include a check or money order in the amount of $50USD payable to OutBack Power Systems, Inc.
  • Page 36 European Sales Office 19009 nd Avenue NE www.outbackpower.com Arlington, WA 983 USA Barcelona, ESPAÑA (+1) 30.35.030 (+3) 00.83.85 900-0093-01-00 REV A...

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