Outback Power Systems 80 user manual Scope, Introduction, Firmware

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SCOPE

The manual provides safety guidelines and installation information for the FLEXmax 80 Maximum Power Point Tracking Charge Controller. It does not provide information about specific brands of solar panels and supplies limited information on batteries. Contact the supplier or manufacturer of the solar panels or batteries for further information.

INTRODUCTION

FLEXmax 80 Maximum Power Point Tracking Charge Controller

The OutBack FLEXmax 80 Maximum Power Point Tracking Charge Controller offers an efficient, safe, multi- stage recharging process that prolongs battery life and assures peak performance from a solar array. This component allows customized battery recharging. The FLEXmax 80 features include:

80 amps maximum continuous output current up to 40° C without thermal derating

Engineered to work with 12, 24, 36, 48, and 60VDC battery voltages

Backlit LCD display screen with 80 characters (4 lines, 20 characters per line)

Last 128 days of operational data are logged for review

Voltage step-down capability allowing a higher PV array voltage configuration

Manual and auto-equalize cycle

The following are the maximum recommended wattage for the most common solar arrays under Standard Test Conditions (1000 watts per square meter to solar panel at 25° C or 77° F):

12VDC battery systems—up to 1250 watts of solar panels

24VDC battery systems—up to 2500 watts of solar panels

36VDC battery systems—up to 3750 watts of solar panels

48VDC battery systems—up to 5000 watts of solar panels

60VDC battery systems—up to 6250 watts of solar panels

The FLEXmax 80 also features Continuous Maximum Power Point Tracking (MPPT), which seeks out the maximum power available from a solar array and uses it to recharge the batteries. Without this feature, the solar array does not operate at the ideal operating voltage and can only recharge at the level of the battery voltage itself. The FLEXmax 80 continuously tracks the array’s maximum operating power.

This manual covers the wiring, installation, and use of the FLEXmax 80, including explanations of all the menus displayed on the LCD screen. The FLEXmax 80 is designed to seamlessly integrate with other OutBack components and can be remotely monitored and configured (up to 1000 feet) by the optional OutBack Power Systems MATE display (version 4.0.4 or greater).

FIRMWARE

This manual covers FLEXmax 80 firmware version 001.008.009



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Contents User’s Guide Warranty Summary Dear OutBack CustomerDate and Revision About OutBack Power SystemsDisclaimer Contact InformationTable of Contents Product Registration and Optional Extended Warranty Introduction FLEXmax 80 Maximum Power Point Tracking Charge ControllerScope FirmwareStandards and Requirements Personal Precautions During Installation Outback Power Systems FLEXmax Installing the FLEXmax 80 FLEXware DC Enclosures Mounting to PlywoodDC Enclosure FLEXmax Bushing Locknut Conduit Nipple Determining Wire Sizes Wire and Disconnect SizingOpen Circuit Voltage/Wire and Disconnect Size FLEXmax 80 Wiring Connections FLEXmax 80 wiring compartmentPage Page Page How to Read the FLEXmax 80 Screen Diagrams Soft keysPowering Up Power Up ScreenOutBack12V Power Systems FLEXmax USA Next Enter Entra SEL Password ContrasenaSelect Version Elija la Version 150USA Noyes Sytem VoltageEnter Status Screen AUX OFFRecharging Using the PV Array End of Day Summary ScreenAccessing the Main Menu Charger Aux Light EQ Misc Advanced Logging StatsExit F G GO 80.0A Charger Set-UpCurrent Limit Absorbing 14.4V Float 13.8VExit Next SET Mode AUX Mode and Its FunctionsAUX Mode Night Light Output OffAUX Mode Menu Path Pressing the Next soft key scrolls through the AUX functionsAUX modes in order of appearance on the FLEXmax 80 display Vent Fan Programming the AUX ModesOff Exitvolt Vent FAN VoltsPV Trigger Output Off Exit VoltExit Next SET Fan screenExit Time Volt PV Volts Output OnPV Trigger Exit Time VoltPress the Next soft key to view the Error Output screen Hold Time Sec 01.1 Back +PV Trigger Output On Error Output 01 hrs Exitvolt Error LOW Batt VoltsExitvolt AUX Mode Error Output Exit Next SET Mode AUX Mode Exit Hyst Time VoltBack + OFF Night Light Threshold Voltage 010 Back + Night Light Off Hysteresis Time Minutes Back +Night Light On Time Hours Back + Press the Volt soft keyDiversion Relay Output Off Output Off AutoFloat Output Off Press the Next soft key ro view the AUX Float screenDiversion Relay Hold Delay 01.0 Time SecondsBack DLY+ AUX Mode Absorb--Float--EQ Relative VoltsExample of Diversion Exit Time Volt AUX ModeDiversion Solid St Output On Press the Exit soft keyDiversion Load and AUX Wiring Set-Up Illustrated Delay Time Sec Timer Back + Press the Time and Volt soft keys to adjust the set pointsLow Batt Disconnect Exit Time Volt Disconnect Volts BackRE-CONNECT Volts Logging Stats Remote Output OffCharger GAux Light Misc Exit soft key twice to return to the Main Menu Off screenBacklight EQ-Battery EqualizeExit + Mode Charger Aux GLight EQ Misc Optimize Logging StatsExit Next -HRS +HRS Battery Equalize Battery EqualizeExit Next -EQV +EQV Battery Equalize Back Auto Start StopExit DAY +DAY Count000 Exit Next -EQV +EQVExit Next MISC-MiscellaneousGT State PWM% ChgT 255 07 50.0 Press Next to Continue to the Force Bulk/Float ScreenExit Next Float Bulk PWM%Force PCBCharger Aux Light Misc GAdvanced Logging Stats Snooze Mode .6 ampAdvanced Exit Advanced MenuThis screen allows the user to choose one of these modes Wakeup Mode 1.5V 05m Exit Next +VOC +MinMppt Mode Auto Track Exit Next nonGT Mode Press the Next soft key to view the Park Mpp screenMpp Range Limit %Voc Min Max Exit Next 1/2 90% Park Mpp 77 % VocExit Next -% +% Advanced Menu Park Mpp Watts 77 % VocCharging-Related Screens Advanced Menu Absorb Time Limits HoursExit Next + 00 a 12.6Exit Next Wide Advanced Menu Vbatt Calibration 14.1RTS Compensation 14.1 Exit Next Limit SET RTS CompensationRTS Compensation 14.4 V F Mode Exit Next Mode Advanced MenuMode Exit Next Mode Exit Next Limit SETExit Next Mode Advanced Menu Reset to Defaults?Aux Polarity Charger Are you sure? Reset to DefaultsYesno Advanced Menu GLogging StatsToday 0000Ah 00.0 KWH 011Vp 00.0Ap 00kWp MAX LoggingClear LOG Back Totl Daily MIN FLTStats Secondary Stats screen Warranty its use in these applications Micro-Hydro and Fuel Cell ApplicationsAdvanced Menu Micro-Hydro and Fuel Cell Applications Mppt Mode Auto TrackTo adjust the Lower Mpp Range Limit Park Mpp WattsAbbreviated Menu Map Grid-tie applications non-OutBack inverter/chargers OutBack Power System GTFX/GVFX Grid-tie settingsApplication Notes Positive grounded systems12V Battery System Efficiency Curve 24V Battery System Efficiency CurveUnderstanding the Various Operational Modes Page Page MATE-Displayed FLEXmax 80 Screens Status Mode Screens Aux relay state indicates if the AUX is on or OFFMATE-Displayed FLEXmax 80 Status Meter Screens FLEXmax Meter ScreensPress Setp to view Setpoint screens MATE-Displayed FLEXmax 80 Status Setpt SET Point Screen MATE-Displayed FLEXmax 80 Advanced ScreensCC Setpoint Screens FLEXmax 80 Advanced Menu FLEXmax 80 Displayed Screens FLEXmax 80 EQ ScreensFLEXmax 80 AUX Screens FLEXmax 80 Stats ScreensAbbreviated Exit Next + Advanced Menu FLEXmax 80 not producing expected power Troubleshooting GuideFLEXmax 80 does not boot/power-up blank LCD FLEXmax 80 is always SleepingFLEXmax 80 Battery Temperature Compensated Voltage FLEXmax 80 is not equalizingTo enable/open the FLEXmax Select Version screens FLEXmax 80 Internal FanFLEXmax 80 is beeping Typical Array Sizing Guide Standard vs. Australian Default Settings 24V PV Array 32v Vmp Wire Distance Chart12V PV Array 16v Vmp 36V PV Array 48v Vmp48V PV Array 64v Vmp 60V PV Array 80v Vmp72V PV Array 96v Vmp PV Side of the Controller Wire and Disconnect SizingBattery Side of the Controller NEC ComplianceRecommended Conductor and Breaker Sizes for the FLEXmax Wiring CompartmentMaximum recommended battery conductor is #2** AWG Output Rating less than 64 ampsFLEXmax 80 MULTI-STAGE Battery Charging Page Non-Battery Temperature Compensated System Battery Temperature Compensated SystemBattery temperature compensation with other slopes Suggested Battery Charger SET Points Battery Voltage and State of ChargeSpecifications Calling the Factory for AssistanceFive Year Limited Warranty Information FLEXmax ProductsRevision.2007-10-02 Limited Warranty Registration Outback Power Systems Inc 19009 62nd Ave. NEEU Declaration of Conformity OWNER’S System Information Phone +1 BARCELONA, España Phone +34.93.654.9568