Outback Power Systems 80 user manual Personal Precautions During Installation

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WARNING - WORKING IN THE VICINITY OF A LEAD ACID BATTERY IS DANGEROUS.

BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL OPERATION. Design the

battery enclosure to prevent accumulation and concentration of hydrogen gas in “pockets” at the top of the enclosure. Vent the battery compartment from the highest point to the outside. A sloped lid can also be used to direct the flow of hydrogen to the vent opening.

CAUTION - To reduce risk of injury, charge only deep-cycle lead acid, lead antimony, lead calcium, gel cell or absorbed glass mat type rechargeable batteries. Other types of batteries may burst, causing personal injury and damage. Never charge a frozen battery.

PERSONAL PRECAUTIONS DURING INSTALLATION

•Someone should be within range of your voice to come to your aid if needed.

•Keep plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.

•Wear complete eye protection. Avoid touching eyes while working near batteries. Wash your hands with soap and warm water when done.

•If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters an eye, flood the eye with running cool water at once for at least 15 minutes and get medical attention immediately following.

•Baking soda neutralizes lead acid battery electrolyte. Keep a supply on hand in the area of the batteries.

•NEVER smoke or allow a spark or flame in vicinity of a battery or generator.

•Be extra cautious to reduce the risk of dropping a metal tool onto batteries. It could short-circuit the batteries or other electrical parts that can result in fire or explosion.

•Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a battery or other electrical current. A battery can produce a short circuit current high enough to weld a ring or the like to metal, causing severe burns.

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Contents User’s Guide Warranty Summary Dear OutBack CustomerAbout OutBack Power Systems DisclaimerDate and Revision Contact InformationTable of Contents Product Registration and Optional Extended Warranty FLEXmax 80 Maximum Power Point Tracking Charge Controller ScopeIntroduction FirmwareStandards and Requirements Personal Precautions During Installation Outback Power Systems FLEXmax DC Enclosure FLEXmax Bushing Locknut Conduit Nipple Installing the FLEXmax 80 FLEXware DC EnclosuresMounting to Plywood Open Circuit Voltage/Wire and Disconnect Size Determining Wire SizesWire and Disconnect Sizing FLEXmax 80 Wiring Connections FLEXmax 80 wiring compartmentPage Page Page How to Read the FLEXmax 80 Screen Diagrams Soft keysOutBack12V Power Systems FLEXmax Powering UpPower Up Screen Password Contrasena Select Version Elija la VersionUSA Next Enter Entra SEL 150Enter USA NoyesSytem Voltage Status Screen AUX OFFRecharging Using the PV Array End of Day Summary ScreenExit F G GO Accessing the Main MenuCharger Aux Light EQ Misc Advanced Logging Stats Charger Set-Up Current Limit80.0A Absorbing 14.4V Float 13.8VAUX Mode and Its Functions AUX ModeExit Next SET 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 Programming the AUX Modes OffVent Fan Exitvolt Vent FAN VoltsExit Volt Exit Next SETPV Trigger Output Off Fan screenOutput On PV TriggerExit Time Volt PV Volts Exit Time VoltPV Trigger Output On Press the Next soft key to view the Error Output screenHold Time Sec 01.1 Back + Exitvolt AUX Mode Error Output Error Output 01 hrsExitvolt Error LOW Batt Volts Back + OFF Exit Next SET Mode AUX ModeExit Hyst Time Volt Night Light Off Hysteresis Time Minutes Back + Night Light On Time Hours Back +Night Light Threshold Voltage 010 Back + Press the Volt soft keyOutput Off Auto Float Output OffDiversion Relay Output Off Press the Next soft key ro view the AUX Float screenHold Delay 01.0 Time Seconds Back DLY+ AUX ModeDiversion Relay Absorb--Float--EQ Relative VoltsExit Time Volt AUX Mode Diversion Solid St Output OnExample of Diversion Press the Exit soft keyDiversion Load and AUX Wiring Set-Up Illustrated Low Batt Disconnect Delay Time Sec Timer Back +Press the Time and Volt soft keys to adjust the set points RE-CONNECT Volts Exit Time Volt Disconnect VoltsBack Remote Output Off Charger GAux Light MiscLogging Stats Exit soft key twice to return to the Main Menu Off screenEQ-Battery Equalize Exit + ModeBacklight Charger Aux GLight EQ Misc Optimize Logging StatsBattery Equalize Exit Next -EQV +EQV Battery EqualizeExit Next -HRS +HRS Battery Equalize Back Auto Start StopCount 000Exit DAY +DAY Exit Next -EQV +EQVMISC-Miscellaneous GT State PWM% ChgT 255 07 50.0Exit Next Press Next to Continue to the Force Bulk/Float ScreenPWM% ForceExit Next Float Bulk PCBSnooze Mode .6 amp AdvancedCharger Aux Light Misc GAdvanced Logging Stats Exit Advanced MenuWakeup Mode 1.5V 05m Exit Next +VOC +Min Mppt Mode Auto Track Exit Next nonGT ModeThis screen allows the user to choose one of these modes Press the Next soft key to view the Park Mpp screenPark Mpp 77 % Voc Exit Next -% +% Advanced MenuMpp Range Limit %Voc Min Max Exit Next 1/2 90% Park Mpp Watts 77 % VocExit Next + Charging-Related ScreensAdvanced Menu Absorb Time Limits Hours 00 a 12.6Vbatt Calibration 14.1 RTS Compensation 14.1Exit Next Wide Advanced Menu Exit Next Limit SET RTS CompensationMode Exit Next Mode Advanced Menu Mode Exit Next ModeRTS Compensation 14.4 V F Exit Next Limit SETAux Polarity Exit Next Mode Advanced MenuReset to Defaults? Are you sure? Reset to Defaults Yesno Advanced MenuCharger GLogging StatsLogging Clear LOG Back Totl DailyToday 0000Ah 00.0 KWH 011Vp 00.0Ap 00kWp MAX MIN FLTStats Secondary Stats screen Warranty its use in these applications Micro-Hydro and Fuel Cell ApplicationsMppt Mode Auto Track To adjust the Lower Mpp Range LimitAdvanced Menu Micro-Hydro and Fuel Cell Applications Park Mpp WattsAbbreviated Menu Map OutBack Power System GTFX/GVFX Grid-tie settings Application NotesGrid-tie applications non-OutBack inverter/chargers 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 OFFPress Setp to view Setpoint screens MATE-Displayed FLEXmax 80 Status Meter ScreensFLEXmax Meter Screens CC Setpoint Screens MATE-Displayed FLEXmax 80 Status Setpt SET Point ScreenMATE-Displayed FLEXmax 80 Advanced Screens FLEXmax 80 Advanced Menu FLEXmax 80 EQ Screens FLEXmax 80 AUX ScreensFLEXmax 80 Displayed Screens FLEXmax 80 Stats ScreensAbbreviated Exit Next + Advanced Menu Troubleshooting Guide FLEXmax 80 does not boot/power-up blank LCDFLEXmax 80 not producing expected power FLEXmax 80 is always SleepingFLEXmax 80 Battery Temperature Compensated Voltage FLEXmax 80 is not equalizingFLEXmax 80 is beeping To enable/open the FLEXmax Select Version screensFLEXmax 80 Internal Fan Typical Array Sizing Guide Standard vs. Australian Default Settings Wire Distance Chart 12V PV Array 16v Vmp24V PV Array 32v Vmp 36V PV Array 48v Vmp72V PV Array 96v Vmp 48V PV Array 64v Vmp60V PV Array 80v Vmp Wire and Disconnect Sizing Battery Side of the ControllerPV Side of the Controller NEC ComplianceWiring Compartment Maximum recommended battery conductor is #2** AWGRecommended Conductor and Breaker Sizes for the FLEXmax Output Rating less than 64 ampsFLEXmax 80 MULTI-STAGE Battery Charging Page Battery temperature compensation with other slopes Non-Battery Temperature Compensated SystemBattery Temperature Compensated System 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