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80 user manual Maximum Power Point Tracking Charge Controller, User’s Guide
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80
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Troubleshooting
Specs
Install
How to Read the FLEXmax 80 Screen Diagrams
Warranty
Determining Wire Sizes
Description of the problem and
ADVANCED MENU Reset to Defaults?
Charger-CHARGER SETUP
Press the NEXT soft key to view the ERROR OUTPUT screen
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Maximum Power Point Tracking Charge Controller
User’s Guide
Installation, Programming and User’s Manual
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Contents
Installation, Programming and User’s Manual
Maximum Power Point Tracking Charge Controller
User’s Guide
maxT M
Warranty Summary
Notice of Copyright
About OutBack Power Systems
Disclaimer
Date and Revision
INSTALLATION GUIDELINES AND SAFETY INSTRUCTIONS
TABLE OF CONTENTS
OPEN CIRCUIT VOLTAGE/WIRE AND DISCONNECT SIZING
HOW TO READ THE FLEXmax 80 SCREEN DIAGRAMS
MICRO-HYDRO, WIND TURBINE, AND FUEL CELL APPLICATIONS
INTRODUCTION
SCOPE
FIRMWARE
Standards and Requirements
PERSONAL PRECAUTIONS DURING INSTALLATION
WARNING - WORKING IN THE VICINITY OF A LEAD ACID BATTERY IS DANGEROUS
Maximum Power Point Tracking Charge Controller
THE OUTBACK POWER SYSTEMS FLEXmax
Mounting to Plywood
1. Installing the FLEXmax 80 FLEXware DC Enclosures
Wire and Disconnect Sizing
2. Determining Wire Sizes
Open Circuit Voltage/Wire and Disconnect Size
3. FLEXmax 80 Wiring Connections
Page
Page
Page
Soft keys
How to Read the FLEXmax 80 Screen Diagrams
Solid black indicates key is to be pressed
Down arrow will lead to the next screen
Power Up Screen
4. Powering Up
OutBack12V Power Systems FLEXmax
PASSWORD CONTRASENA 150 ENTRA - + ENTER
Password Screen
Select Version Elija la Version USA NEXT ENTER ENTRA SEL
Select Version Elija la Version USA NEXT ENTER ENTRA SEL
System Voltage Screen
Are you sure? USA NOYES
SYTEM VOLTAGE 12 24 36 48
G ENTER
Pressing the first soft key opens the MAIN Menu screen
5. Status Screen
6. End of Day Summary Screen
7. Recharging Using the PV Array
Charger-CHARGER SETUP
8. Accessing the MAIN Menu
EQ-BATTERY EQUALIZE
G Charger Aux Light EQ Misc Advanced Logging Stats EXIT F G GO
Current Limit
7. Charger Set-Up
80.0A
Absorbing
AUX MODE
8. AUX Mode and Its Functions
Night Light
Output Off
To access the AUX Output Menu
AUX MODE Menu Path
Pressing the NEXT soft key scrolls through the AUX functions
Diversion Solid State Low Battery Disconnect Remote
AUX modes in order of appearance on the FLEXmax 80 display
AUX MODE Vent Fan EXITVOLT VENT FAN VOLTS 14.4 BACK - +
SET MODE
AUX MODE
9. Programming the AUX MODES
PV TRIGGER
and VOLTage set menus
Press the EXIT soft key to return to the initial PV Trigger screen
Press the NEXT soft key to view the ERROR OUTPUT screen
AUX MODE ERROR OUTPUT 01 hrs EXITVOLT ERROR LOW BATT VOLTS BACK - +
ERROR OUTPUT
AUX MODE ERROR OUTPUT 01 hrs EXITVOLT AUX MODE ERROR OUTPUT
ERROR OUTPUT
NIGHT LIGHT
EXIT HYST TIME VOLT Night Light On Time Hours BACK - +
Night Light Off Hysteresis Time Minutes BACK - +
EXIT HYST TIME VOLT Night Light Threshold Voltage 010 BACK - +
AUX MODE
RELAY
FLOAT
Press the EXIT soft key to return to the Night Light AUX mode
Press the NEXT soft key ro view the AUX Float screen
Page
Press the EXIT soft key
Example of Diversion
Figure 5 Diversion Load and AUX Wiring Set-Up Illustrated
AUX MODE Low Batt Disconnect
LOW BATTERY DISCONNECT
Delay Time Sec 01 Timer BACK - +
Low Batt Disconnect
+ ReCon
DISCONNECT VOLTS 13.6
RE-CONNECT VOLTS 14.4 BACK - + DisV
AUX MODE Low Batt Disconnect
Press the NEXT soft key to view the Remote screen
REMOTE
+ MODE
11. EQ-Battery Equalize
10. Backlight
Charger Aux GLight EQ Misc Optimize Logging Stats EXIT F G GO
01 Hours EXIT NEXT -HRS +HRS BATTERY EQUALIZE 1 Hours 15.0 Volts
BATTERY EQUALIZE Volts EXIT NEXT -EQV +EQV BATTERY EQUALIZE Time
Manual Mode default mode
Check water level BACK AUTO START STOP
EQ INTERVAL
AUTO MODE
GT State PWM% ChgT 255 07 50.0
12. MISC-Miscellaneous
EXIT NEXT
BULK screen
13. Advanced
ADVANCED MENU MPPT Mode Auto Track EXIT NEXT nonGT MODE
ADVANCED MENU Wakeup Mode 1.5V 05m EXIT NEXT +VOC +Min
This screen allows the user to choose one of these modes
Press the NEXT soft key to view the Park Mpp screen
Mpp Range Limit %Voc Min Max EXIT NEXT 1/2 90%
ADVANCED MENU Park Mpp 77 % Voc EXIT NEXT -% +% ADVANCED MENU
ADVANCED MENU Park Mpp
Watts
ADVANCED MENU Absorb Time Limits 01.0 hours EXIT NEXT - +
14. Charging-Related Screens
12.6 EXIT NEXT - +
00 A EXIT NEXT - +
ADVANCED MENU Absorb End Amps
ADVANCED MENU Rebulk Voltage
RTS Compensation
Auto ReStart MODE EXIT NEXT MODE ADVANCED MENU Auto ReStart MODE
ADVANCED MENU Auto ReStart MODE EXIT NEXT MODE ADVANCED MENU
EXIT NEXT MODE
ADVANCED MENU RTS Compensation A 14.4 V F EXIT NEXT LIMIT SET
Aux Polarity
ADVANCED MENU Reset to Defaults?
ADVANCED MENU Aux Polarity
ADVANCED MENU Auto ReStart MODE EXIT NEXT MODE ADVANCED MENU
Press the EXIT key twice to return to the MAIN Menu screen
CLEAR LOG BACK TOTL DAILY Are you sure? NOYES
15. Logging
Today 0000Ah
00.0 KWH
16. Stats
Total 0000 kWH Total 000.0 kAH BACK DCkWH
Secondary STATS screen
Total 0000 kWHAC Total 000.0 kAH BACK ACkWH
MICRO-HYDRO AND FUEL CELL SYSTEMS PERFORMANCE OPTIMIZATION
17. Micro-Hydro and Fuel Cell Applications
18. Advanced Menu Micro-Hydro and Fuel Cell Applications
Snooze Mode Wakeup Mode MPPT Mode Park Mpp Mpp Range Limit % VOC
19. Abbreviated Menu Map
RTS Compensation Auto Restart Aux Polarity Reset to Defaults?
G Charger Aux Light EQ Misc Advanced Logging Stats EXIT F G GO
20. Application Notes
OutBack Power System GTFX/GVFX Grid-tie settings
Grid-tie applications non-OutBack inverter/chargers
Positive grounded systems
Figure 7 12V Battery System Efficiency Curve
21. FLEXmax 80 EFFICIENCY vs. INPUT POWER GRAPH
Figure 8 24V Battery System Efficiency Curve
Figure 9 48V Battery System Efficiency Curve
22. Understanding the Various Operational Modes
GT Mode In a system with an OutBack FX Grid-Tie Series Inverters, HUB and MATE, the FLEXmax
Page
Charge Controller MODE Screens
23. MATE-Displayed FLEXmax 80 Screens Status Mode Screens
aux relay state indicates if the AUX is ON or OFF
FLEXmax METER Screens
MATE-Displayed FLEXmax 80 Status Meter Screens
MATE-Displayed FLEXmax 80 Advanced Screens
MATE-Displayed FLEXmax 80 STATUS SETPT SET POINT Screen
CC SETPOINT Screens
24. FLEXmax 80 Advanced Menu
FLEXmax 80 AUX Screens
FLEXmax 80 EQ Screens
FLEXmax 80 Displayed Screens
FLEXmax 80 STATS Screens
AUX MODES
25. ABBREVIATED
Absorb Time 01.0 hours
FLEXmax 80 does not boot/power-up blank LCD
26. Troubleshooting Guide
FLEXmax 80 not producing expected power
FLEXmax 80 is always SLEEPING
FLEXmax 80 is not equalizing
FLEXmax 80 Battery Temperature Compensated Voltage
FLEXmax 80 Internal Fan
To enable/open the FLEXmax SELECT VERSION screens
FLEXmax 80 is beeping
Nominal Battery Voltage
27. Typical Array Sizing Guide
Standard Version
28. STANDARD vs. AUSTRALIAN DEFAULT SETTINGS
Standard
Australian
12V PV ARRAY 16v Vmp
29. Wire Distance Chart
24V PV ARRAY 32v Vmp
36V PV ARRAY 48v Vmp
60V PV ARRAY 80v Vmp
48V PV ARRAY 64v Vmp
72V PV ARRAY 96v Vmp
Battery Side of the Controller
30. WIRE AND DISCONNECT SIZING
PV Side of the Controller
NEC Compliance
Recommended Conductor and Breaker Sizes for the FLEXmax
31. WIRING COMPARTMENT
Output Rating less than 64 amps
32. FLEXmax 80 MULTI-STAGE BATTERY CHARGING
BULK cycle provides the maximum power to the battery -the voltage increases while recharging
Non-Battery Temperature Compensated System
33. BATTERY TEMPERATURE COMPENSATED VOLATGE SET POINT
Battery Temperature Compensated System
Battery temperature compensation with other slopes
Battery Voltage and State of Charge
34. SUGGESTED BATTERY CHARGER SET POINTS
STATE OF CHARGE
35. CALLING THE FACTORY FOR ASSISTANCE
36. SPECIFICATIONS
FLEXmax Products
FIVE YEAR LIMITED WARRANTY INFORMATION
2. Description of the problem and
Five Year Limited FLEXmax Warranty Registration
Limited Warranty Registration
Installer
Complete this form to request a Limited Warranty, and return it to
EU DECLARATION OF CONFORMITY
Date of Purchase Vendor Date of Installation Installer
OWNER’S SYSTEM INFORMATION
Installer Contact Information FLEXmax 80 Serial Number
Battery Voltage PV Voltage PV Module Type and Manufacturer
European Sales Office
Corporate Office
19009 62nd Avenue NE
C/ Castelló