Outback Power Systems 80 user manual Standards and Requirements

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OUTBACK FLEXmax 80 CHARGE CONTROLLER INSTALLATION GUIDELINES AND SAFETY INSTRUCTIONS

This product is intended to be installed as part of a permanently grounded electrical system as shown in the system configuration sections (see pages 12-14) of this manual. The following important restrictions apply unless superseded by local or national codes:

•The negative battery conductor should be bonded to the grounding system at only one point in the system. If a GFP is present, the battery negative and ground are not bonded together directly but are connected together by the GFP device when it is on. All negative conductor connections must be kept separate from the grounding conductor connections.

•With the exception of certain telcom applications, the FLEXmax 80 should never be positive grounded (see page 60, Applications Notes).

• The FLEXmax 80 equipment ground is marked with this symbol:

•If damaged or malfunctioning, the FLEXmax 80 should only be disassembled and repaired by a qualified service center. Please contact your renewable energy dealer/installer for assistance. Incorrect reassembly risks malfunction, electric shock or fire.

•The FLEXmax 80 is designed for indoor installation or installation inside a weatherproof enclosure. It must not be exposed to rain and should be installed out of direct sunlight.

For routine, user-approved maintenance:

•Turn off all circuit breakers, including those to the solar modules, and related electrical connections before cleaning the air vents.

Standards and Requirements

All installations must comply with national and local electrical codes; professional installation is recommended. NEC requires ground protection for all residential PV installations

DC and Battery-Related Installation Requirements:

• All DC cables must meet NEC standards.

• Shut off all DC breakers before connecting any wiring.

•Torque all the FLEXmax 80’s wire lugs and ground terminals to 35 inch-pounds (4 Nm).

•All wiring must be rated at 75° C or higher.

•Use up to 2 AWG (33.6 mm2 ) to reduce losses and ensure high performance of FLEXmax 80 (smaller cables can reduce performance and possibly damage the unit).

•Keep cables together (e.g., using a tie-wrap) as much as possible.

•Ensure both cables pass through the same knockout and conduit fittings to allow the inductive currents to cancel.

•DC battery over-current protection must be used as part of the installation. OutBack offers both



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Contents User’s Guide Dear OutBack Customer Warranty SummaryContact Information About OutBack Power SystemsDisclaimer Date and RevisionTable of Contents Product Registration and Optional Extended Warranty Firmware FLEXmax 80 Maximum Power Point Tracking Charge ControllerScope IntroductionStandards and Requirements Personal Precautions During Installation Outback Power Systems FLEXmax Mounting to Plywood Installing the FLEXmax 80 FLEXware DC EnclosuresDC Enclosure FLEXmax Bushing Locknut Conduit Nipple Wire and Disconnect Sizing Determining Wire SizesOpen Circuit Voltage/Wire and Disconnect Size FLEXmax 80 wiring compartment FLEXmax 80 Wiring ConnectionsPage Page Page Soft keys How to Read the FLEXmax 80 Screen DiagramsPower Up Screen Powering UpOutBack12V Power Systems FLEXmax 150 Password ContrasenaSelect Version Elija la Version USA Next Enter Entra SELSytem Voltage USA NoyesEnter AUX OFF Status ScreenEnd of Day Summary Screen Recharging Using the PV ArrayCharger Aux Light EQ Misc Advanced Logging Stats Accessing the Main MenuExit F G GO Absorbing 14.4V Float 13.8V Charger Set-UpCurrent Limit 80.0ANight Light Output Off AUX Mode and Its FunctionsAUX Mode Exit Next SET ModePressing the Next soft key scrolls through the AUX functions AUX Mode Menu PathAUX modes in order of appearance on the FLEXmax 80 display Exitvolt Vent FAN Volts Programming the AUX ModesOff Vent FanFan screen Exit VoltExit Next SET PV Trigger Output OffExit Time Volt Output OnPV Trigger Exit Time Volt PV VoltsHold Time Sec 01.1 Back + Press the Next soft key to view the Error Output screenPV Trigger Output On Exitvolt Error LOW Batt Volts Error Output 01 hrsExitvolt AUX Mode Error Output Exit Hyst Time Volt Exit Next SET Mode AUX ModeBack + OFF Press the Volt soft key Night Light Off Hysteresis Time Minutes Back +Night Light On Time Hours Back + Night Light Threshold Voltage 010 Back +Press the Next soft key ro view the AUX Float screen Output Off AutoFloat Output Off Diversion Relay Output OffAbsorb--Float--EQ Relative Volts Hold Delay 01.0 Time SecondsBack DLY+ AUX Mode Diversion RelayPress the Exit soft key Exit Time Volt AUX ModeDiversion Solid St Output On Example of DiversionDiversion Load and AUX Wiring Set-Up Illustrated Press the Time and Volt soft keys to adjust the set points Delay Time Sec Timer Back +Low Batt Disconnect Back Exit Time Volt Disconnect VoltsRE-CONNECT Volts Exit soft key twice to return to the Main Menu Off screen Remote Output OffCharger GAux Light Misc Logging StatsCharger Aux GLight EQ Misc Optimize Logging Stats EQ-Battery EqualizeExit + Mode BacklightBack Auto Start Stop Battery EqualizeExit Next -EQV +EQV Battery Equalize Exit Next -HRS +HRS Battery EqualizeExit Next -EQV +EQV Count000 Exit DAY +DAYPress Next to Continue to the Force Bulk/Float Screen MISC-MiscellaneousGT State PWM% ChgT 255 07 50.0 Exit NextPCB PWM%Force Exit Next Float BulkExit Advanced Menu Snooze Mode .6 ampAdvanced Charger Aux Light Misc GAdvanced Logging StatsPress the Next soft key to view the Park Mpp screen Wakeup Mode 1.5V 05m Exit Next +VOC +MinMppt Mode Auto Track Exit Next nonGT Mode This screen allows the user to choose one of these modesPark Mpp Watts 77 % Voc Park Mpp 77 % VocExit Next -% +% Advanced Menu Mpp Range Limit %Voc Min Max Exit Next 1/2 90%Advanced Menu Absorb Time Limits Hours Charging-Related ScreensExit Next + 12.6 00 aExit Next Limit SET RTS Compensation Vbatt Calibration 14.1RTS Compensation 14.1 Exit Next Wide Advanced MenuExit Next Limit SET Mode Exit Next Mode Advanced MenuMode Exit Next Mode RTS Compensation 14.4 V FReset to Defaults? Exit Next Mode Advanced MenuAux Polarity GLogging Stats Are you sure? Reset to DefaultsYesno Advanced Menu ChargerMIN FLT LoggingClear LOG Back Totl Daily Today 0000Ah 00.0 KWH 011Vp 00.0Ap 00kWp MAXStats Secondary Stats screen Micro-Hydro and Fuel Cell Applications Warranty its use in these applicationsPark Mpp Watts Mppt Mode Auto TrackTo adjust the Lower Mpp Range Limit Advanced Menu Micro-Hydro and Fuel Cell ApplicationsAbbreviated Menu Map Positive grounded systems OutBack Power System GTFX/GVFX Grid-tie settingsApplication Notes Grid-tie applications non-OutBack inverter/chargers24V Battery System Efficiency Curve 12V Battery System Efficiency CurveUnderstanding the Various Operational Modes Page Page Aux relay state indicates if the AUX is on or OFF MATE-Displayed FLEXmax 80 Screens Status Mode ScreensFLEXmax Meter Screens MATE-Displayed FLEXmax 80 Status Meter ScreensPress Setp to view Setpoint screens MATE-Displayed FLEXmax 80 Advanced Screens MATE-Displayed FLEXmax 80 Status Setpt SET Point ScreenCC Setpoint Screens FLEXmax 80 Advanced Menu FLEXmax 80 Stats Screens FLEXmax 80 EQ ScreensFLEXmax 80 AUX Screens FLEXmax 80 Displayed ScreensAbbreviated Exit Next + Advanced Menu FLEXmax 80 is always Sleeping Troubleshooting GuideFLEXmax 80 does not boot/power-up blank LCD FLEXmax 80 not producing expected powerFLEXmax 80 is not equalizing FLEXmax 80 Battery Temperature Compensated VoltageFLEXmax 80 Internal Fan To enable/open the FLEXmax Select Version screensFLEXmax 80 is beeping Typical Array Sizing Guide Standard vs. Australian Default Settings 36V PV Array 48v Vmp Wire Distance Chart12V PV Array 16v Vmp 24V PV Array 32v Vmp60V PV Array 80v Vmp 48V PV Array 64v Vmp72V PV Array 96v Vmp NEC Compliance Wire and Disconnect SizingBattery Side of the Controller PV Side of the ControllerOutput Rating less than 64 amps Wiring CompartmentMaximum recommended battery conductor is #2** AWG Recommended Conductor and Breaker Sizes for the FLEXmaxFLEXmax 80 MULTI-STAGE Battery Charging Page Battery Temperature Compensated System Non-Battery Temperature Compensated SystemBattery temperature compensation with other slopes Battery Voltage and State of Charge Suggested Battery Charger SET PointsCalling the Factory for Assistance SpecificationsFLEXmax Products Five Year Limited Warranty InformationRevision.2007-10-02 Outback Power Systems Inc 19009 62nd Ave. NE Limited Warranty RegistrationEU Declaration of Conformity OWNER’S System Information Phone +1 BARCELONA, España Phone +34.93.654.9568
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