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Outback Power Systems user manual FLEXmax 80 Wiring Connections

Models: 80

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3. FLEXmax 80 Wiring Connections

3. FLEXmax 80 Wiring Connections

Figure 1 FLEXmax 80 wiring compartment

Use up to 2 AWG (33.6 mm2) wire and torque to

35-inch pounds at terminals.

MATE/HUB

RJ45 jack

Battery Remote Temp Sensor (RTS) RJ11 jack

Programmable AUX Output Jack (supplies up to 200mA @ 12 VDC

PV+ PV- BAT- BAT+

Wire Lugs

Chassis/Equipment

Ground Lug

Screw holes for attaching FLEXmax 80

The PV (-) and BAT (-) terminals are connected internally. Only one negative wire may be needed to connect to the (-) wire lugs if the PV - and BAT- conductors are bonded at the negative bus bar. See Figures 2 and 3 for sample wiring diagrams. See Wire and Disconnect Sizing on page 80 for suitable conductor/wire sizing.

NOTES:

•Each FLEXmax 80 requires its own PV array. DO NOT PARALLEL FLEXmax 80 PV+ and PV- TERMINALS ON THE SAME ARRAY!

•An optional battery Remote Temperature Sensor (RTS) is recommended for accurate battery recharging (only one RTS is needed for multiple OutBack Series Inverter/Chargers and FLEXmax 80 units when an OutBack HUB and a MATE are parts of the system). When one RTS is used, it must be connected to the component plugged into the Port 1 of the HUB.

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Outback Power Systems user manual FLEXmax 80 Wiring Connections

Contents

Maximum Power Point Tracking Charge Controller Installation, Programming and User’s ManualUser’s Guide maxT MWarranty Summary About OutBack Power Systems Notice of CopyrightDisclaimer Date and RevisionTABLE OF CONTENTS INSTALLATION GUIDELINES AND SAFETY INSTRUCTIONSOPEN CIRCUIT VOLTAGE/WIRE AND DISCONNECT SIZING HOW TO READ THE FLEXmax 80 SCREEN DIAGRAMSMICRO-HYDRO, WIND TURBINE, AND FUEL CELL APPLICATIONS SCOPE INTRODUCTIONFIRMWARE Standards and Requirements WARNING - WORKING IN THE VICINITY OF A LEAD ACID BATTERY IS DANGEROUS PERSONAL PRECAUTIONS DURING INSTALLATIONTHE OUTBACK POWER SYSTEMS FLEXmax Maximum Power Point Tracking Charge Controller1. Installing the FLEXmax 80 FLEXware DC Enclosures Mounting to Plywood2. Determining Wire Sizes Wire and Disconnect SizingOpen Circuit Voltage/Wire and Disconnect Size 3. FLEXmax 80 Wiring Connections Page Page Page How to Read the FLEXmax 80 Screen Diagrams Soft keysSolid black indicates key is to be pressed Down arrow will lead to the next screen4. Powering Up Power Up ScreenOutBack12V Power Systems FLEXmax Password Screen PASSWORD CONTRASENA 150 ENTRA - + ENTERSelect Version Elija la Version USA NEXT ENTER ENTRA SEL Select Version Elija la Version USA NEXT ENTER ENTRA SELAre you sure? USA NOYES System Voltage ScreenSYTEM VOLTAGE 12 24 36 48 G ENTER5. Status Screen Pressing the first soft key opens the MAIN Menu screen7. Recharging Using the PV Array 6. End of Day Summary Screen8. Accessing the MAIN Menu Charger-CHARGER SETUPEQ-BATTERY EQUALIZE G Charger Aux Light EQ Misc Advanced Logging Stats EXIT F G GO7. Charger Set-Up Current Limit80.0A Absorbing8. AUX Mode and Its Functions AUX MODENight Light Output OffAUX MODE Menu Path To access the AUX Output MenuPressing the NEXT soft key scrolls through the AUX functions AUX modes in order of appearance on the FLEXmax 80 display Diversion Solid State Low Battery Disconnect RemoteSET MODE AUX MODE Vent Fan EXITVOLT VENT FAN VOLTS 14.4 BACK - +AUX MODE 9. Programming the AUX MODESPV TRIGGER and VOLTage set menus Press the NEXT soft key to view the ERROR OUTPUT screen Press the EXIT soft key to return to the initial PV Trigger screenERROR OUTPUT AUX MODE ERROR OUTPUT 01 hrs EXITVOLT ERROR LOW BATT VOLTS BACK - +AUX MODE ERROR OUTPUT 01 hrs EXITVOLT AUX MODE ERROR OUTPUT ERROR OUTPUTNIGHT LIGHT Night Light Off Hysteresis Time Minutes BACK - + EXIT HYST TIME VOLT Night Light On Time Hours BACK - +EXIT HYST TIME VOLT Night Light Threshold Voltage 010 BACK - + AUX MODEFLOAT RELAYPress the EXIT soft key to return to the Night Light AUX mode Press the NEXT soft key ro view the AUX Float screenPage Example of Diversion Press the EXIT soft keyFigure 5 Diversion Load and AUX Wiring Set-Up Illustrated LOW BATTERY DISCONNECT AUX MODE Low Batt DisconnectDelay Time Sec 01 Timer BACK - + Low Batt DisconnectDISCONNECT VOLTS 13.6 + ReConRE-CONNECT VOLTS 14.4 BACK - + DisV AUX MODE Low Batt DisconnectREMOTE Press the NEXT soft key to view the Remote screen11. EQ-Battery Equalize + MODE10. Backlight Charger Aux GLight EQ Misc Optimize Logging Stats EXIT F G GOBATTERY EQUALIZE Volts EXIT NEXT -EQV +EQV BATTERY EQUALIZE Time 01 Hours EXIT NEXT -HRS +HRS BATTERY EQUALIZE 1 Hours 15.0 VoltsManual Mode default mode Check water level BACK AUTO START STOPAUTO MODE EQ INTERVAL12. MISC-Miscellaneous GT State PWM% ChgT 255 07 50.0EXIT NEXT BULK screen 13. Advanced ADVANCED MENU Wakeup Mode 1.5V 05m EXIT NEXT +VOC +Min ADVANCED MENU 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 screenADVANCED MENU Park Mpp 77 % Voc EXIT NEXT -% +% ADVANCED MENU Mpp Range Limit %Voc Min Max EXIT NEXT 1/2 90%ADVANCED MENU Park Mpp Watts14. Charging-Related Screens ADVANCED MENU Absorb Time Limits 01.0 hours EXIT NEXT - +00 A EXIT NEXT - + 12.6 EXIT NEXT - +ADVANCED MENU Absorb End Amps ADVANCED MENU Rebulk VoltageRTS Compensation ADVANCED MENU Auto ReStart MODE EXIT NEXT MODE ADVANCED MENU Auto ReStart MODE EXIT NEXT MODE ADVANCED MENU Auto ReStart MODEEXIT NEXT MODE ADVANCED MENU RTS Compensation A 14.4 V F EXIT NEXT LIMIT SETADVANCED MENU Reset to Defaults? Aux PolarityADVANCED MENU Aux Polarity ADVANCED MENU Auto ReStart MODE EXIT NEXT MODE ADVANCED MENUPress the EXIT key twice to return to the MAIN Menu screen 15. Logging CLEAR LOG BACK TOTL DAILY Are you sure? NOYESToday 0000Ah 00.0 KWH16. Stats Secondary STATS screen Total 0000 kWH Total 000.0 kAH BACK DCkWHTotal 0000 kWHAC Total 000.0 kAH BACK ACkWH 17. Micro-Hydro and Fuel Cell Applications MICRO-HYDRO AND FUEL CELL SYSTEMS PERFORMANCE OPTIMIZATION18. Advanced Menu Micro-Hydro and Fuel Cell Applications 19. Abbreviated Menu Map Snooze Mode Wakeup Mode MPPT Mode Park Mpp Mpp Range Limit % VOCRTS Compensation Auto Restart Aux Polarity Reset to Defaults? G Charger Aux Light EQ Misc Advanced Logging Stats EXIT F G GOOutBack Power System GTFX/GVFX Grid-tie settings 20. Application NotesGrid-tie applications non-OutBack inverter/chargers Positive grounded systems21. FLEXmax 80 EFFICIENCY vs. INPUT POWER GRAPH Figure 7 12V Battery System Efficiency CurveFigure 8 24V Battery System Efficiency Curve Figure 9 48V Battery System Efficiency Curve22. Understanding the Various Operational Modes GT Mode In a system with an OutBack FX Grid-Tie Series Inverters, HUB and MATE, the FLEXmax Page 23. MATE-Displayed FLEXmax 80 Screens Status Mode Screens Charge Controller MODE Screensaux relay state indicates if the AUX is ON or OFF MATE-Displayed FLEXmax 80 Status Meter Screens FLEXmax METER ScreensMATE-Displayed FLEXmax 80 STATUS SETPT SET POINT Screen MATE-Displayed FLEXmax 80 Advanced ScreensCC SETPOINT Screens 24. FLEXmax 80 Advanced Menu FLEXmax 80 EQ Screens FLEXmax 80 AUX ScreensFLEXmax 80 Displayed Screens FLEXmax 80 STATS Screens25. ABBREVIATED AUX MODESAbsorb Time 01.0 hours 26. 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 equalizingTo enable/open the FLEXmax SELECT VERSION screens FLEXmax 80 Internal FanFLEXmax 80 is beeping 27. Typical Array Sizing Guide Nominal Battery Voltage28. STANDARD vs. AUSTRALIAN DEFAULT SETTINGS Standard VersionStandard Australian29. Wire Distance Chart 12V PV ARRAY 16v Vmp24V PV ARRAY 32v Vmp 36V PV ARRAY 48v Vmp48V PV ARRAY 64v Vmp 60V PV ARRAY 80v Vmp72V PV ARRAY 96v Vmp 30. WIRE AND DISCONNECT SIZING Battery Side of the ControllerPV Side of the Controller NEC Compliance31. WIRING COMPARTMENT Recommended Conductor and Breaker Sizes for the FLEXmaxOutput 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 33. BATTERY TEMPERATURE COMPENSATED VOLATGE SET POINT Non-Battery Temperature Compensated SystemBattery Temperature Compensated System Battery temperature compensation with other slopes34. SUGGESTED BATTERY CHARGER SET POINTS Battery Voltage and State of ChargeSTATE OF CHARGE 36. SPECIFICATIONS 35. CALLING THE FACTORY FOR ASSISTANCEFIVE YEAR LIMITED WARRANTY INFORMATION FLEXmax Products2. Description of the problem and Limited Warranty Registration Five Year Limited FLEXmax Warranty RegistrationInstaller Complete this form to request a Limited Warranty, and return it toEU DECLARATION OF CONFORMITY OWNER’S SYSTEM INFORMATION Date of Purchase Vendor Date of Installation InstallerInstaller Contact Information FLEXmax 80 Serial Number Battery Voltage PV Voltage PV Module Type and ManufacturerCorporate Office European Sales Office19009 62nd Avenue NE C/ Castelló