Outback Power Systems 80 manual

Maximum P ow er P oint T racking Charge C ontr oller U ser ’ s Guide Installation, Pr ogramming and User’ s Manual ma x T M 8 0[...]

1 PB W arranty Summar y Dear OutBack Customer , Thank you f or your purchase of OutBack pr oducts. W e make ever y eor t to assure our pow er conversion pr oducts will give you long and reliable service for your r enewable energy system. As with any manufactured device , repairs might be needed due to damage, inappr opriate use, or unintentional[...]

2 PB The OutBack P ower Systems FLEXmax 80 Maximum Po wer P oint T rack ing Charge Controller is ETL listed in Nor th America to UL1741 (Inver ters, Con verters, Controllers , and Interconnection System Equipment for Use with Distributed Ener gy Resources). It is also in compliance with European Union standards EN 61000-6-1 and EN 61000-6-3 (see pa[...]

3 PB T ABLE OF C ONTENTS SCOPE ....................................................................................................................................................................................................... 5 INTRODUC TION .......................................................................................................[...]

4 PB Vbatt Calibration ...................................................................................................................................... .................................... 50 RTS Compensation .......................................................................................................................................[...]

5 PB SC OPE The manual provides saf ety guidelines and installation information for the FLEXmax 80 Maximum Po wer P oint T rack ing Charge Controller . I t does not provide inf ormation about specic brands of solar panels and supplies limited information on batteries . Contact the supplier or manufacturer of the solar panels or batteries for fur[...]

6 PB OUTBACK FLEXmax 80 CHARGE C ONTROLLER INST ALLA TION GUIDELINES AND SAFET Y INSTRUC TIONS This product is intended to be installed as part of a permanently grounded electrical system as shown in the system conguration sections (see pages 12-14) of this manual. The following impor tant restrictions apply unless superseded by local or nationa[...]

7 PB W ARNING - WORKING IN THE VICINIT Y OF A LEAD ACID BA T TER Y IS DANGEROUS. BA T TERIES GENERA TE EXPL OSIVE GASES DURING NORMAL OPERA TION. Design the batter y enclosure to pr event accumulation and concentration of hydr ogen gas in “pockets” at the top of the enclosure. Vent the battery compar tment from the highest point to the outside.[...]

8 PB THE OUTBACK POWER SY STEMS FLEXmax 80 Maximum P ow er P oint T racking Charge C ontr oller[...]

9 PB TheFLEXmax 80 is designed to attach dir ectly to OutBack ’ s FLEXware 500 DC and FLEXware 1000 DC enclosures (FLEXwar e 500 shown) or attach to its own charge contr ol brackets (FW-CCB, FW- CCB2, and FW -CCB2T ). NOT E: I nstall the FLEXmax 80 in an upright posi- tion out of direct sunlight. T o mount directly to a FLEXwar e DC enclosure: ?[...]

10 PB 2. Determining W ire Siz es Open Circuit Voltage/W ire and Disc onnect Size Maximum Open Circuit V oltage ( VOC) • VOC is the unloaded voltage generated by the solar array . • Greater than 145VDC g FLEXmax 80 suspends operation to pr otect components • 150DC g max open circuit voltage with the coldest en vironment NOT E: Although the FL[...]

11 PB The PV (-) and BA T (-) terminals are connected internally . Only one negative wir e may be needed to connect to the (-) wire lugs if the PV - and BA T - conduc tors are bonded at the negative bus bar . See F igures 2 and 3 f or sample wiring diagrams. See Wire and Disconnect Sizing on page 80 for suitable conductor/wire sizing . NOT E S: •[...]

12 PB Figur e 2 Single Charge Contr oller wiring diagram with 24 volt PV array[...]

13 PB Figur e 3 Charge Contr oller Wiring Diagram with an FX, HUB 4, and an RTS[...]

14 PB Figur e 4 Charge Contr oller with PV array ground fault prot ection wir ing digram.[...]

15 PB Soft k eys: Solid black indicates key is to be pressed: Down arrow will lead to the next screen: Up arrow points to one or mor e keys that will change a value: The keys correspond to any text immediately above them. (#1) (#2) (#3) (#4) How to Read the FLEXmax 80 Screen Diag rams[...]

16 PB 4. P ow ering Up The FLEXmax 80 power -up sequence rst activates the unit and the SELECT VERSION screen (to de- termine a choice of English, Espanola, or Australian settings). A SYSTEM VOL T A GE screen soon follo ws. However , when it auto- detects the system ’ s batter y voltage, in some instances the FLEXmax 80 might not reect the [...]

17 PB The FLEXmax 80 screens ar e oer ed in English (standard screens) and Spanish. F or Australian users, some of the charging values ar e of dier ent voltages and the FLEXmax 80 accommodates these. By pressing the <NEXT> soft key, the user can choose USA, A ustralia, or Espanola versions of the screens . After pressing the <NEXT>[...]

18 PB System V oltage Screen Pr ess the <YES> soft key to proceed if the selected batter y voltage is correct. If incorrect, press <NO> to re- enter the correct voltage. The <YES> soft key will open the ST A TUS screen. SYTEM VOL T AGE 12 24 36 48 60 ^^ g ENTER Are you sure? 12 24 36 48 60 ^^ NO Y es NOT E: R epeating the P owerin[...]

19 PB NOT E: • Pr essing the rst soft key opens the MAIN Menu screen. • Pr essing second soft key opens the End of the Day summar y menu/logging. 5. Status Screen The ST A TUS Screen displays system inf ormation. See page 63 for detailed information of the di erent Operational Modes. The optional OutBack MA TE displays C C (Charge Contr o[...]

20 PB NOT E: • Pr essing the rst soft key opens the ST A TUS screen. • Pr essing the second soft key br ings up the CLEAR L OG screen. • Pr essing the third soft key shows the previous day ’ s summar y ; continually pressing this soft key will bring up additional past summaries up to 128 days. • Pr essing the fourth soft k ey will brin[...]

21 PB 8. Ac cessing the MAIN Menu The MAIN Menu allows the user to adjust and calibrate the FLEXmax 80 f or maximum per formance. F rom the ST A TUS screen, pr ess the rst soft k ey on the left to open the MAIN Menu screen. Pr ess the <GO> soft key af ter aligning the arrow in front of the selected menu choice. Pr essing the <EXIT> s[...]

22 PB 7. Charger Set-Up This screen allows changes t o the FLEXmax 80’ s recharging v oltage set points—Current Limit, Absorb and Float (f or an explanation of batter y charging , see pages 81-82): • The presently selected numerical value will have an arro w “ g ” to the left of it. • Pr essing < > selec ts the value to be changed[...]

23 PB 8. A UX Mode and Its F unctions The A UX is a secondar y control circuit—essentially , a small power supply that pr ovides a 12VDC (up to 200 milliamps) output current. It is either ac tive (12VDC on) or inactive (0VDC). M ost AUX modes or functions are designed f or specialized applications and are infr equently used. • T o access the AU[...]

24 PB A UX MODE Menu P ath T o access the AUX Output Menu: • Pr ess the rst soft key once from the ST A TUS Menu to open the MAIN Menu. • Pr ess either of the arrow soft keys until the “ g ” is to the lef t of Aux . • Pr ess the <GO> soft key. If more than ten minutes ha ve passed since any activity , the P ASSWORD screen becomes[...]

25 PB A UX modes in order of appearanc e on the FLEXmax 80 display: • V ent F an • PV T rigger • Error Output • Night Light • Float • Diversion Relay • Diversion Solid State • L ow Battery D isconnect • Remote When an AUX MODE is in A UT O , 12VDC is available at the A UX terminals and a condition, such as a voltage set point, is [...]

26 PB VENT F AN Pr ess the <MODE> soft key to manually ac tivate or deactivate ( On or O  ) the Vent F an ; if set to Auto , the V ent F an will turn on when a user-determined voltage is met. P ress the <SET> soft key to view the V ent F an screen. T o view other screens, con- tinue to press the <NEXT> soft key. The V ent F an [...]

27 PB Pr ess the <EXIT> soft key return to the main Vent F an scr een. Pr ess the <NEXT> sot key to view the PV T rigger screen When the PV input exceeds the user-determined VOL T set point, the A UX MODE PV T rigger ac tivates in Auto Mode. P ress the <MODE> soft key to establish another PV T rigger mode ( O n, O  , or Auto ).[...]

28 PB Pr ess the <SET> soft ke y to open the PV T rigger ’ s TIME and VOL T (age) set menus. T o adjust the voltage, pr ess the <VOL T> soft k ey. Adjust the voltage within a range of 20V -150V by pressing the < - > or < + > soft key. When nished, press the <BA CK> soft key to return to the PV T rigger screen T o [...]

29 PB Hold Time Sec 01.1 BACK - + AUX MODE PV T rigger Output: On On EXIT NEXT SET MODE Pr ess the < - > or < + > soft key to adjust the Hold Time, then pr ess the <BA CK> soft ke y to return to the PV T rigger screen. In this example, the AUX MODE will remain active for 1.1 seconds after the PV voltage is below the PV T rigger vo[...]

30 PB The ERROR OUTPUT default state is On , meaning 12 VDC is present at the A UX terminal. If the FLEXmax 80 has not charged the batteries f or 26 hours or more continuously , the inaudible ERR OR OUTPUT goes into an O state. The ERROR OUTPUT is intended for r emote locations to sig nal (e.g., a telecommunication signal to a comput er) when th[...]

31 PB This example shows Auto MODE selected. P ress the <SET> soft k ey to open the Hysteresis and PV V oltage screens. Pr ess the <HY ST> sof t key to open the On H ysteresis T ime screen. Use the < - > and < + > soft ke ys to adjust the time required f or the PV input voltage to be below the threshold voltage bef ore the N[...]

32 PB Pr ess the <TIME> soft key to adjust the length of time the Night Light remains on. If the time is set to 0, the Night Light remains on until the o condition is met. Use the < - > and < + > soft ke ys to adjust the number of hours the Night Light remains on. P ress the <BA CK> soft key to return to the previous Nigh[...]

33 PB Pr ess the <NEXT> soft ke y ro view the A UX Float screen. The A UX MODE is active when the FLEXmax 80 is in Float and pr oducing power . Press the <NEXT> soft key to advance to the Diversion screen. When external DC sources (wind, hy dro) are dir ectly connected to a batter y bank, any excess power should be sent to a diversion l[...]

34 PB Pr ess the <TIME> soft key to advance to the T ime screen which allows the user to adjust the minimum time the A UX MODE is active after the batter y voltage falls below the Hysteresis voltage . Hold T ime shows how long the AUX MODE sta ys active after the batter y voltage has fallen below the HYST (Hysteresis) set point. The user can [...]

35 PB Example of Diversion Each recharg ing state— Absorb, Float , or EQ —has a r echarging v oltage set point. The Diversion A UX MODE can be active ( On ) when the batter y voltage is raised above one of these set points for a certain amount of time or inactive ( O  ) when it falls below . The user can determine these voltages and times. I[...]

36 PB Figur e 5 Diversion Load and A UX Wiring Set-Up Illustrated[...]

37 PB L OW BA T TERY DISCONNECT When the batter y voltage falls below the disconnect volts, the A UX c onnected loads only are disconnected; the A UX connected loads only are connected when the batter y voltage rises above the reconnect volts . T o adjust these set points, press the <TIME> and <VOL T> soft k eys. Pr ess the <TIME>[...]

38 PB In the Lo w Batt Disconnect screen, press the <V OL T> sof t key to adjust the batter y voltage disconnects set point. Pr ess either the < - > or the < + > soft key to adjust the disconnect voltage. P ress the <ReC on> soft ke y to open the RE-CONNECT VOL T S screen. Pr ess either the < - > or the < + > sof[...]

39 PB REMO TE AUX MODE Low Batt Disconnect EXIT TIME VOL T Pr ess the <EXIT> soft key. Pr ess the <NEXT> soft ke y to view the Remote screen. Pr ess the < g > soft key to move the ” g ” to the Light option. When the g is in front of Light , pr ess the <GO> soft ke y . Charger g Aux Light Eq Misc Adv anced Logging Stats E[...]

40 PB Auto (default) leaves backlight and soft ke ys on for up to nine minutes whenever an y soft k ey is pressed (pressing any soft key when the L CD is not lighted does not change any settings). Minutes are adjustable using the < - > and < + > soft keys. On or O  states are also available. Pr ess the <EXIT> soft key t wice to[...]

41 PB Pr ess either the < –EQV> or <+EQV > soft key to change the EQ voltage, f ollowing your battery manufacturer ’ s recommendations. Not e that the factor y default EQ voltage is set low , the same as the fac tor y default Absorb voltage. P ress the <NEXT> soft key to view the BA T TERY EQUALIZE T ime screen. Pr ess either [...]

42 PB Use the <-DA Y> and <+DA Y> soft keys to preset the inter val day to initiate an aut omatic equalization c ycle. The EQ INTERV AL displays the number of days in the inter val between c ycles and C OUNT displays how man y days of the interval have passed. T o vie w the MAIN EQ screens, pr ess the <EXIT> soft key. Pr ess the ?[...]

43 PB 12. MISC—Miscellaneous The MISCELLANEOUS screens display extra settings and technical inf ormation, some of which is useful for OutBack P ow er Systems T echnical S er vices. The Grid Tie (GT ) value is sent from G-series inverter through the MA TE and HUB for Grid Tie contr ol communications. GT means THE FLEXmax 80 is in grid tie mode and[...]

44 PB GT State PWM% ChgT 255 07 50.0 005 EXIT NEXT RSTR T Pr ess the <NEXT> soft ke y to view the FORCE FL OA T , or BULK screen. Pr essing the <FL O A T> or <BULK> sof t key forces the FLEXmax 80 to that specic rechar ging cycle and returns to the ST A TUS screen. F or cing a FL OA T or BULK r echarge will end an EQ cycle. Pr [...]

45 PB 13. Advanc ed The ADV ANCED MENU allows ne -tuning of the FLEXmax 80 operations including Snooze periods and Maximum Po wer P oint limits. In order of appearance, the f ollowing modes occur in the ADV ANCED M enu selections: • Snooze Mode • W akeup • MPP T Mode • P ark Mpp • M pp Range Limit % Voc • Absorb T ime • Rebulk Volt[...]

46 PB W akeup Mode selects how often the FLEXmax 80 does a “ Wakeup ” during “Snoozing” periods. Since environmental conditions impact the open circuit voltage ( V oc) of an array , a user selectable V oc rise in value will allow the controller to “ wakeup ” sooner or later based on the last measured Voc value. A selectable delay time i[...]

47 PB U-Pick % ( Voc) MPPT mode operates the PV voltage at a user-selected percentage of the V OC which is displayed in the P ark Mpp % Voc screen. P r ess the <NEXT> soft k ey to view the Mpp Range Limit % screen. The Mpp Range Limit % Voc adjusts the upper Mpp limit of the VOC. The default FLEXmax 80 MPP v oltage limit is set at 90% of the [...]

48 PB ADV ANCED MENU Absorb Time Limits 01.0 hours EXIT NEXT - + In the Absorb T ime Limits screen, the user can set the duration the FLEXmax 80 stays in the Absorb rechar ge cycle. • Absorb T ime is adjustable from 0 to 24 hours (consult your battery manufac turer ’ s recommendations). • A Bulk cycle star ts each morning (see char t next pag[...]

49 PB ADV ANCED MENU Absorb End Amps 00 A EXIT NEXT - + ADV ANCED MENU Rebulk V oltage 12.6 V EXIT NEXT - + An Absorb charge cycle normally ends when a batter y voltage is maintained at the Absorb set point for the user - determined time period. Use the < -> or < + > soft ke ys to adjust the Absorb End Amps to an optimal value (the defa[...]

50 PB ADV ANCED MENU RTS Compensation A 14.1 V F 13.8V EXIT NEXT WIDE During cold weather , a batter y of ten requires a higher recharg ing voltage. L ower quality inv er ters might not accommodate these higher voltages and can shut down during recharging , cutting o power t o their loads. The FLEXmax 80 allows the user to low er the compensated[...]

51 PB Pr ess the <NEXT> soft ke y to view the Auto Restar t screen. Pr essing the fourth soft k ey selects among the three FLEXmax 80 Auto ReStar t modes: 0 (default), 1, and 2. Auto ReStar t allows the FLEXmax 80 to per form internal recalibrations. • Mode 0 — Auto ReStar t mode is disabled; the FLEXmax 80 recharges continuously fr om an[...]

52 PB ADV ANCED MENU Auto R eStart MODE 2 EXIT NEXT MODE F rom the Auto Restart MODE 2 screen, press the <NEXT> soft ke y to view the Aux P olarity screen. When the A UX function is ON, 12 volts is present at the A UX terminal; when it ’ s OFF , 0 volts are present at the terminal. Aux P olarity allows the user to reverse the availability o[...]

53 PB ADV ANCED MENU Reset to Def aults? EXIT NEXT RESET Pr essing the <YES> soft key brings up a Reset to D efaults screen momentarily befor e returning to the Reset to Defaults? screen Pr ess the <EXIT> key twice to return to the MAIN Menu screen. F rom the MAIN Menu, pr ess the < g > soft k ey to move the arrow next to the L og[...]

54 PB CLEAR LOG BACK T O TL DAIL Y Are you sure? NO YES T oday 0000Ah 00.0 KWH 011Vp 00.0Ap 0.00kWp MAX 14. 7V ABS 01:00 MIN 14.6V FL T 00:00 T oday 0000Ah 00.0 KWH 011Vp 00.0Ap 0.00kWp MAX 14. 7V ABS 01:00 MIN 14.6V FL T 00:00 A user can clear either the daily or accumulated statistics of the FLEXmax 80 by pressing the second button fr om the left[...]

55 PB Charger Aux Light Eq Misc Adv anced Logging g Stats EXIT f g GO F rom the M AIN Menu, press the < g > soft key to move the arrow next to the Stats function and then press the <GO> soft ke y The ST A T S screen displays additional v oltage and time information. Press the <NEXT> soft key to view the second ST A TS screen The h[...]

56 PB T otal 0000 kWH T otal 000.0 kAH BACK DCkWH The Secondary Stats screen shows the total accumulated DC and AC kilowatt hours and k iloamp hours of the FLEXmax 80. Pr essing the <DCkWH> soft key switches the screen between DC k ilowatt hours and AC kilowatt hours • DCkWH shows the DC kilowatthours and should be used in a non-grid-tied s[...]

57 PB 17. Micro-H ydro and F uel Cell Applications The FLEXmax 80 is designed to w ork with solar arrays. Although it will work with micro-hydro turbines and fuel cell, OutBack P ower S ystems can only oer limited t echnical suppor t for these applications because there is too much variance in micro-hy dro and fuel cell generator specications[...]

58 PB 18. Advanc ed Menu (M icro-Hydro and F uel Cell Applications) Mpp R ange Limit % (Auto T rack Mode only) The FLEXmax 80 searches f or the MPP voltage by tracking the input voltage up to one half (default) of the V oc, which is based on values appr opriate for a solar array . Micro-hydr o and fuel cell systems can require a br oader range, nor[...]

59 PB g Charger Aux Light EQ Misc Adv anced Logging Stats EXIT f g GO Adjusts the Current Limit, Absorb, and Float r echarging voltage set points A UX control includes: • V ent F an • PV T rigger • Error Output • Night Light • Float • Diversion: Relay • Diversion: Solid State • Low Batt er y Disconnect • Remote The Light featur e [...]

60 PB 20. Application Notes OutBack P ower Sy stem GTFX/GVFX Grid-tie settings In a GFX/GVFX Ser ies Inver ter/Charger , FLEXmax 80, HUB, and MA TE installation set the FLEXmax 80 to GT mode in the ADV ANCED MENU. GT mode allows the GFX/GVFX t o manage the FLEXmax 80 oat setting ensuring the FLEXmax 80 is always keeping the batter y above the se[...]

61 PB 21. FLEXmax 80 EFFICIENCY vs. INPUT POWER GRAPH Figur e 7 12V Batter y System Ecienc y Curve Figur e 8 24V Batter y System Ecienc y Curve Figur e 9 48V Batter y System Ecienc y Curve[...]

62 PB 22. Understanding the Various Opera tional Modes The FLEXmax 80 modes of operation will change occasionally during the day based on the PV array output and the batter y system state of charge . The FLEXmax 80 operating modes ar e displayed at the bottom right hand corner of the ST A TUS screen. Absorbing The FLEXmax 80 is in the Absorb (const[...]

63 PB GT Mode In a system with an OutBack FX Grid- Tie Series I nverter(s), HUB and MA TE, the FLEXmax 80 will display GT Mode if and only if the inv er ter is in Sell mode and the FLEXmax 80 is in Bulk (MPPT BULK ) or F loat (MPPT FL OA T ) cycle. This is also a good indicat or for establishing proper Grid- Tie mode communication between the FX G-[...]

64 PB Sleeping The PV voltage is two volts less than the battery voltage. This may also appear during the day when the FLEXmax 80 is transitioning between cer tain states, or due to other conditions . SysError ( Very rare) System Error indicates an internal non-volatile memory error . The unit will stop operating when this message is displayed . Ca[...]

65 PB 23. MA TE-Displayed FLEXmax 80 Screens Status Mode Screens The FLEXmax 80 ST A TUS MODE Screens displayed on the optional OutBack MA TE (Rev 4.0.4 or greater) include MODE, METER, and SE T (SE TPOINT ). In ST A TUS M ode, these functions can be viewed by the MA TE, but not changed. Please see the MA TE Installation and User M anual for mor e [...]

66 PB MA TE-Displayed FLEXmax 80 Status Meter Scr eens FLEXmax METER S creens • mode/pv/in/bat/out: displays the charger mode , the PV array voltage, the incoming PV amps, the batter y voltage, and the outgoing amps t o the batter y • charger w atts: charger output measured in watts • charger kwhrs: k ilowatt hours produced toda y by the FLEX[...]

67 PB MA TE-Displayed FLEXmax 80 ST A TUS SE TPT (SE T POINT ) S creen Pr ess the rst two soft keys simultaneously to return to the M AIN Menu. C C SE TP(OINT ) Screens • Absorb: displays the voltage that initiates and maintains the Absorb cycle • Float: displa ys the voltage that begins the F loat cycle and is maintained during this c ycle [...]

68 PB ADV/CC/ADVANCED--------P01 snooze now < 0.6 amp DOWN INC DEC POR T ADV/CC/ADVANCED--------P01 wakeup mode VOC change 1.5 V DOWN INC DEC POR T ADV/CC/ADVANCED--------P01 wakeup mode time 5 minutes DOWN INC DEC POR T ADV/CC/ADVANCED--------P01 MPPT mode auto track DOWN INC DEC POR T ADV/CC/ADVANCED--------P01 grid tie mode non GT DOWN INC DE[...]

69 PB FLEXmax 80 EQ Screens ADV/CC/AUX/MODE--------P01 Night Light DOWN INC SET POR T ADV/CC/AUX/--------------P01 aux output OFF control DOWN ON OFF POR T ADV/CC/AUX/----------------- end of menu TOP ADV MAIN ADV/CC/EQ-----------------P01 eq voltage 14.4 vdc DOWN INC DEC POR T ADV/CC/EQ-----------------P01 eq time 1 hrs DOWN INC DEC POR T ADV/CC/E[...]

70 PB 25. ABBREVIA TED CHARGER SET -UP Select V ersion EliJa la V ersion USA NEXT ENTER ENTRA SEL P ASSWORD CONTRASENA ***150*** ENTRA - + ENTER Select V ersion EliJa la V ersion USA NEXT ENTER ENTRA SEL ARE YOU SURE USA NO YES SYSTEM VOL T AGE 12 24 36 48 60 ENTER OutBack 12V Po wer Systems FLEXmax 80 In 11.6 V 0.0 A Out 14.1 V 0.0 A 0.000kW 0.0 k[...]

71 PB ADV ANCED MENU Absorb Time 01.0 hours EXIT NEXT - + ADV ANCED MENU Rebulk Voltage 12.4V EXIT NEXT - + ADV ANCED MENU Vbatt Calibration 14.9V 0.0V EXIT NEXT -V +V ADV ANCED MENU RTS Compensation A 14.4V F 13.6V EXIT NEXT WIDE ADV ANCED MENU Auto Restart MODE 2 EXIT NEXT MODE ADV ANCED MENU Absorb End Amps 00 A EXIT NEXT - + T oday 0000AH 00.0k[...]

72 PB 26. T r oubleshooting Guide FLEXmax 80 does not boot/power -up (blank L CD) • Check the batter y connection and polarit y . • Reverse polarit y or an improper connection will cause power-up issues . • Check the batter y breaker . • Ensure that the battery breaker is sized appropriately . • A batter y voltage below 10.5VDC may not po[...]

73 PB • Are the batteries charged? Is the FLEXmax 80 in the Absorbing or F loat stage? If either case is true, the FLEXmax 80 will produce enough po wer to regulat e the voltage at the ABSORB or FL OA T set point voltage , theref ore, r equiring less power in these modes. • What is the shor t circuit current of the PV array? Use a multi-meter t[...]

74 PB FLEXmax 80 Internal F an • The internal fan will only run when the internal temperature has r eached approximat ely 112°F . The fan will continue running until the internal temperature is less than 104°F . FLEXmax 80 is beeping • When the FLEXmax 80 is in Extended Play mode, the array is very hot, and the MPP is close to the batter y vo[...]

75 PB 27. T ypical Arra y Sizing Guide Below is a list of recommended array sizing f or the FLEXmax 80 for various nominal voltage batteries: Nominal Battery V oltage Recommended Array Size (in watts, Standar d T est Conditions) 12V 1250W 24V 2500W 36V 3750W 48V 5000W 60V 6250W The FLEXmax 80 PV MPPT Charge Controller is capable of an input open ci[...]

76 PB 28. ST ANDARD v s. A USTRALIAN DEF AUL T SET TINGS The Australian version FLEXmax 80 has a f ew default settings that dier fr om the Standard version default settings. How ever , ther e are no dier ences in per formance and eciency bet ween the two versions. The Standard and Australian v ersion can be identied as follows: Standard[...]

77 PB 29. Wire Distance Chart T o meet NEC compliance (Nor th America), the largest PV array that can be connected to the FLEXmax 80 must have a rated short-circuit current of 64 amps or less The f ollowing charts show the maximum distance of various gauge two -conduc tor copper wire from the PV array to the FLEXmax 80 with a 1.5% maximum voltage d[...]

78 PB 48V PV ARRA Y (64v V mp) #8 #6 #4 #3 #2 #1/0 #2/0 #4/0 10 62 98 156 196 247 393 496 789 20 31 49 78 98 124 197 248 395 30 21 33 52 65 82 131 165 263 40 15 24 39 49 62 98 124 197 50 12 20 31 39 49 79 99 158 60 10 16 26 33 41 66 83 132 70 9 14 22 28 35 56 71 113 60V PV ARRA Y (80v V mp) #8 #6 #4 #3 #2 #1/0 #2/0 #4/0 10 77 122 195 245 309 492 62[...]

79 PB 30. WIRE AND DISCONNEC T SIZING The FLEXmax 80 is a buck type converter with the following properties: • 80 amp DC output current limit (default setting) • Listed to operate continuously at 80 amps (40°C/104° F) With an 80 amp FLEXmax 80 output current limit and PV array output higher than 80 amps oers little , if any , current boost[...]

80 PB 31. WIRING COMP ARTMENT The wiring terminals and compar tment of the FLEXmax 80 Charge Controller ar e fully compliant with all NEC and UL requirements . The following summary is specic for Nor th American applications wher e NEC and UL standards govern installations . Recommended Conductor and Breaker Siz es for the FLEXmax 80 Output Rati[...]

81 PB 32. FLEXmax 80 MUL TI-ST AGE BA T TERY CHARGING The FLEXmax 80 charge contr oller is a sophisticated, multi-stage battery charger that uses several regulation stages to allow fast r echarging of the batt er y system while ensuring a long batter y life. This process can be used with both sealed and non-sealed batteries . The FLEXmax 80 has a p[...]

82 PB BULK cycle provides the maximum pow er to the battery –the voltage increases while rechar ging . A Bulk cycle is automatically initiated when the battery voltage is below the Absorb and Float * r echarge voltage set points. The Bulk cycle will continue until the Absorb voltage set point is achieved. MPPT Bulk is displayed on the scr een. AB[...]

83 PB 33. BA T TERY TEMPERA TURE COMPENSA TED VOLA TGE SET POINT The temperature of a batt er y has an impact on the recharging process—in higher ambient t empera- tures, the r egulation set points ( Absorb and Float ) need t o be reduced to pr event over charging of the batteries. In lower ambient temperatur e conditions, the voltage r egulation[...]

84 PB 34. SUGGESTED BA T TER Y CHARGER SE T POINTS The battery manufac turer should provide y ou with specic instructions on the following maintenance and voltage set point limits for the specic batt eries. The following information can be used when the manufacturer ’ s inf ormation is not available. SEALED LEAD ACID – A GM / GEL 12V 24V [...]

85 PB 35. CALLING THE F AC T ORY FOR ASSIST ANCE When calling OutBack P ower f or product assistance, please have the f ollowing inf ormation ready : • FLEXmax 80 Serial number and soft ware version (the software version can be viewed by pr essing the #1 soft ke y on the ST A TUS screen and then pressing a second time and holding the soft key dow[...]

86 PB FIVE YEAR LIMITED W ARRANT Y INFORMA TION FLEXmax Pr oducts OutBack P ower Systems , Inc. (“OutBack ”) provides a ve year (5) limit ed warranty (“ W arranty ”) against defects in materials and workmanship for its FLEXmax products (“Pr oducts”) if installed in xed location applications. F or this W arranty to be valid, the P [...]

87 PB T o request warranty ser vice, you must contact OutBack T echnical Ser vices at (360) 435-6030 or suppor t@outback power .com within the eective warranty per iod. If warranty ser vice is r equired, OutBack will issue a Return Material Authorization (RMA) number . A r equest for an RM A number requires all of the f ollowing inf ormation: 1.[...]

88 PB Limited W arranty Registration Complete this form to request a Limited W arrant y , and return it to: Outback P ower Systems Inc. 19009 62nd Ave . NE Arlington, W A 98223 NOT E: A Limited W ar ranty Cer ticate will only be issued if this Registration Card is r eceived by OutBack within 90 days of the date of the rst r etail sale of the [...]

89 PB EU DECLARA TION OF CONFORMITY According t o ISO / IEC Guide 22 and EN 45014 Pr oduct T ype: Photo voltaic Charge Contr oller Pr oduct Model Number : FLEXmax 80 This product complies with the follo wing EU directives: Electromagnetic Compatibility 89/336/EEC, “Council Dir ective of 3 May 1989 On the approximation of the la ws of member State[...]

90 PB OWNER’S SYSTEM INFORM A TION Date of P urchase: __________________________________________________________________ V endor: __________________________________________________________________________ Date of Installation: _________________________________________________________________ Installer : ___________________________________________[...]

900-0082-01-00 REV A European Sales Oce C/ Castelló , 17 08830 - Sant Boi de Llobregat BARCEL ONA, España Phone: +34.93.654.9568 Corporat e Office 19009 62nd A venue NE Arlington, W A USA Phone: (+1) 360-435-6030 www .outbackpower .com[...]