Outback Power Systems FLEXMAX 80 User Manual

4.2 (6)
Maximum Power Point Tracking Charge Controller
max
TM
80
User’s Guide
Installation, Programming and User’s Manual
Warranty Summary
Dear OutBack Customer, Thank you for your purchase of OutBack products. We make every eort to assure our power conversion products will give you long and reliable service for your renewable energy system.
As with any manufactured device, repairs might be needed due to damage, inappropriate use, or unintentional defect. Please note the following guidelines regarding warranty service of OutBack products:
• Any and all warranty repairs must conform to the terms of the warranty.
• All OutBack equipment must be installed according to their accompanying instructions and manuals with specied over-current protection in order to maintain their warranties.
• The customer must return the component(s) to OutBack, securely packaged, properly addressed, and shipping paid. We recommend insuring your package when shipping. Packages that are not securely packaged can sustain additional damage not covered by the warranty or can void warranty repairs.
• There is no allowance or reimbursement for an installer’s or user’s labor or travel time required to disconnect, service, or reinstall the damaged component(s).
• OutBack will ship the repaired or replacement component(s) prepaid to addresses in the continental United States, where applicable. Shipments outside the U.S. will be sent freight collect.
• In the event of a product malfunction, OutBack cannot bear any responsibility for consequential losses, expenses, or damage to other components.
• Please read the full warranty at the end of this manual for more information.
1
The OutBack Power Systems FLEXmax 80 North America to UL1741 (Inverters, Converters, Controllers, and Interconnection System Equipment for Use with Distributed Energy Resources). It is also in compliance with European Union standards EN 61000-6-1 and EN 61000-6-3 (see page 89).
Maximum Power Point Tracking Charge Controller
is ETL listed in
About OutBack Power Systems
OutBack Power Systems is a leader in advanced energy conversion technology. Our products include true sine wave inverter/chargers, a maximum power point charge controller, system communication components, as well as breaker panels, breakers, accessories, and assembled systems.
Notice of Copyright
FLEXmax 80 User’s Manual Copyright © 2008 All rights reserved.
Maximum Power Point Tracking Charge Controlle
r User’s Guide: Installation, Programming and
Disclaimer
UNLESS SPECIFICALLY AGREED TO IN WRITING, OUTBACK POWER SYSTEMS: (a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION. (b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER’S RISK.
Date and Revision
January 2008 REV A
Contact Information
OutBack Power Systems 19009 62nd Ave. NE Arlington, WA 98223 Phone (360) 435-6030 Fax (360) 435-6019 www.outbackpower.com
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TABLE OF CONTENTS
SCOPE ....................................................................................................................................................................................................... 5
INTRODUCTION ..................................................................................................................................................................................5
INSTALLATION GUIDELINES AND SAFETY INSTRUCTIONS .......................................................................................6
Standards and Requirements ...........................................................................................................................................
Battery Safety ..............................................................................................................................................................................
INSTALLING THE FLEXmax 80 ON FLEXware ENCLOSURES .....................................................................................9
OPEN CIRCUIT VOLTAGE/WIRE AND DISCONNECT SIZING ................................................................................... 10
HOW TO READ THE FLEXmax 80 SCREEN DIAGRAMS ............................................................................................. 15
POWERING UP .................................................................................................................................................................................. 16
STATUS SCREEN ................................................................................................................................................................................ 19
END OF DAY SUMMARY SCREEN .......................................................................................................................................... 19
RECHARGING USING THE PV ARRAY ................................................................................................................................... 19
ACCESSING THE MAIN MENU .................................................................................................................................................. 21
CHARGER SETUP ............................................................................................................................................................................. 22
AUX MODE AND ITS FUNCTIONS .........................................................................................................................................23
AUX Mode Path ......................................................................................................................................................................
AUX Modes Described .......................................................................................................................................................
Programming the AUX Modes .....................................................................................................................................
Vent Fan ............................................................................................................................................................................
PV Trigger .........................................................................................................................................................................
Error Output ...................................................................................................................................................................
Night Light ......................................................................................................................................................................
Float .....................................................................................................................................................................................
Diversion: Relay ............................................................................................................................................................
Diversion: Solid State ................................................................................................................................................
Low Battery Disconnect ..........................................................................................................................................
Remote ..............................................................................................................................................................................
BACKLIGHT.......................................................................................................................................................................................... 40
EQ (Equalize) ...................................................................................................................................................................................... 40
MISC-MISCELLANEOUS ............................................................................................................................................................... 43
ADVANCED ......................................................................................................................................................................................... 45 Snooze Mode
Wakeup Mode .........................................................................................................................................................................
MPPT Mode ..............................................................................................................................................................................
Park Mpp ....................................................................................................................................................................................
CHARGING RELATED SCREENS ............................................................................................................................................... 48
Absorb Time .............................................................................................................................................................................
Rebulk Voltage ........................................................................................................................................................................
........................................................................................................................................................................... 45
24 25 26 26 27 30 31 33 33 35 37 39
46 46 47
48 49
6 7
3
Vbatt Calibration ..........................................................................................................................................................................50
RTS Compensation .....................................................................................................................................................................
Auto Restart ....................................................................................................................................................................................
Aux Polarity .....................................................................................................................................................................................
Reset to Defaults? .......................................................................................................................................................................
50 51 52
52
(DATA) LOGGING ....................................................................................................................................................................................54
Clearing Total and Daily Stats ...............................................................................................................................................
54
STATS .............................................................................................................................................................................................................55
Secondary Stats Screen ............................................................................................................................................................
56
MICRO-HYDRO, WIND TURBINE, AND FUEL CELL APPLICATIONS............................................................................57
ADVANCED MENU (Micro-Hydro) ...............................................................................................................................................58
FLEXmax 80 ABBREVIATED MENU MAP ...................................................................................................................................59
APPLICATION NOTES ...........................................................................................................................................................................60
FLEXmax 80 EFFICIENCY vs. INPUT POWER GRAPH .........................................................................................................61
UNDERSTANDING THE VARIOUS OPERATIONAL MODES ..............................................................................................62
MATE-DISPLAYED CHARGE CONTROLLER STATUS MODE Screens .........................................................................65
MATE-DISPLAYED CHARGE CONTROLLER STATUS METER Screens .......................................................................66
MATE-DISPLAYED CHARGE CONTROLLER STATUS SETP(OINT) Screens ..............................................................67
MATE-DISPLAYED FLEXmax 80 ADVANCED SCREENS ....................................................................................................67
ADVANCED MENU ................................................................................................................................................................................68
EQ SCREENS ..............................................................................................................................................................................................69
AUX SCREENS ...........................................................................................................................................................................................69
ABBREVIATED MENU ............................................................................................................................................................................70
TROUBLESHOOTING GUIDE ............................................................................................................................................................72
TYPICAL ARRAY SIZING GUIDE ......................................................................................................................................................75
STANDARD vs. AUSTRALIAN DEFAULT SETTINGS ...............................................................................................................76
WIRE DISTANCE CHART ......................................................................................................................................................................77
WIRE AND DISCONNECT SIZING ..................................................................................................................................................79
MULTI-STAGE BATTERY CHARGING .............................................................................................................................................81
BATTERY TEMPERATURE COMPENSATED VOLTAGE SET POINT .................................................................................83
SUGGESTED BATTERY CHARGER SET POINTS ......................................................................................................................84
CALLING THE FACTORY FOR ASSISTANCE ..............................................................................................................................85
WARRANTY INFORMATION ..............................................................................................................................................................86
PRODUCT REGISTRATION AND OPTIONAL EXTENDED WARRANTY ......................................................................88
EU DECLARATION OF CONFORMITY..........................................................................................................................................89
OWNER’S SYSTEM INFORMATION ............................................................................................................................................. 90
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SCOPE
The manual provides safety guidelines and installation information for the FLEXmax 80 Point Tracking Charge and supplies limited information on batteries. Contact the supplier or manufacturer of the solar panels or batteries for further information.
Controller. It does not provide information about specic brands of solar panels
Maximum Power
INTRODUCTION
FLEXmax 80
The OutBack FLEXmax 80
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 conguration
• 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
Maximum Power Point Tracking Charge
Maximum Power Point Tracking Charge
Controller
Controller oers an ecient, safe, multi-
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 congured (up to 1000 feet) by the optional OutBack Power Systems MATE display (version 4.0.4 or greater).
FIRMWARE
This manual covers FLEXmax 80 rmware version 001.008.009
5
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 conguration 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
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
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
qualied service center. Please contact your renewable energy dealer/installer for assistance. Incorrect reassembly risks malfunction, electric shock or re.
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.
never be positive
one point in the
For routine, user-approved maintenance:
• Turn o 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 o 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.
2
• Use up to 2 AWG (33.6 mm
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
currents to cancel.
• DC battery over-current protection must be used as part of the installation. OutBack oers both
) to reduce losses and ensure high performance of FLEXmax 80 (smaller
same knockout and conduit ttings to allow the inductive
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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 ow 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,
ood 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 ame 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 re 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.
7
THE OUTBACK POWER SYSTEMS FLEXmax 80
Maximum Power Point Tracking Charge Controller
8
1. Installing the FLEXmax 80 FLEXware DC Enclosures
TheFLEXmax 80 is designed to attach directly to OutBack’s FLEXware 500 DC and FLEXware 1000 DC enclosures (FLEXware 500 shown) or attach to its own charge control brackets (FW-CCB, FW­CCB2, and FW-CCB2T).
NOTE: Install the FLEXmax 80 in an upright posi­tion out of direct sunlight.
To mount directly to a FLEXware DC enclosure:
• Remove the fan cover and bottom cover from the FLEXmax 80.
• Insert a #10 X 3/8” sheet metal screw in the top hole on the side of the DC enclosure. This will act as a hanging screw for the keyhole slot at
Screw holes for #10 X 3/8” sheet metal screws
Insert screws through lower holes inside FLEXmax 80
To mount the FLEXmax 80 to charge control brackets, see the individual instruction sheet for those brackets.
the top center of the FLEXmax 80.
• Hang the FLEXmax 80 on the top screw and line up its bottom two screw holes with the holes on the enclosure.
• Insert a #10 X 3/8” sheet metal screw through each hole and tighten against the enclosure (screws are included with each DC enclosure).
• Keep the cover o until wiring is completed.
The Conduit Nipple Assembly creates a sealed pass-through from the FLEXmax 80 to the enclosure
DC Enclosure FLEXmax 80
Mounting to Plywood
Bushing Locknut Locknut Conduit
Use 1 5/8” wood screws to secure the FLEXmax 80 at the top slotted holes and other interior lower holes as needed, making sure the unit is straight and level.
Nipple
9
2. Determining Wire Sizes
Open Circuit Voltage/Wire and Disconnect Size
Maximum Open Circuit Voltage (VOC)
• VOC is the
• Greater than 145VDC
• 150DC
NOTE: Although the FLEXmax 80 shuts down at a voltage greater than 145VDC, it can withstand up to 150VDC from the array; anything higher than 150VDC will damage the FLEXmax 80).
• As every brand of panel is dierent, be sure to know the manufacturer’s specications.
• Weather conditions vary and will aect panel voltage.
• Hot weather: lower open circuit voltage/lower maximum power point voltage
• Cold weather: higher open circuit voltage/higher maximum power point voltage
• Allow for ambient temperature correction using the following table: 25° to 10° C (77° to 50° F) multiply VOC by 1.06 9° to 0° C (49° to 32° F) multiply VOC by 1.10
-1° to -10° C (31° to 14° F) multiply VOC by 1.13
-11° to -20° C (13° to -4° F) multiply VOC by 1.17
-21° to -40° C (-5° to -40° F) multiply VOC by 1.25
unloaded voltage generated by the solar array.
g FLEXmax 80 suspends operation to protect components
g max open circuit voltage with the coldest environment
• Check the PV array voltage before connecting it to the FLEXmax 80 (see page 76)
Wire and Disconnect Sizing
• The output current limit of the FLEXmax 80 is 80 amps.
2)
• Use a minimum of 4 AWG (21.15 mm bus bar conductors.
• Install OutBack OBB-80-150VDC-PNL breakers for disconnect and overcurrent protection.
• The largest PV array that can connect to an FLEXmax 80 must have a rated short-circuit current of 64 amps or less under STC (Standard Test Conditions).
• Input conductors and circuit breakers must be rated at 1.56 times the short-circuit current of the PV array. OutBack 100% duty continuous breakers only need to be rated at 1.25 times the short-circuit current.
• Please see the wire Distance Chart and complete Wire and Disconnect Sizing on pages 77-79 for other suitable conductor/wire sizing.
wire for the output between the FLEXmax 80 and the battery
10
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
PV+ PV- BAT- BAT+
Wire Lugs
Chassis/Equipment Ground Lug
Programmable AUX Output Jack (supplies up to 200mA @ 12 VDC
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.
11
12
Figure 2 Single Charge Controller wiring diagram with 24 volt PV array
13
Figure 3 Charge Controller Wiring Diagram with an FX, HUB 4, and an RTS
14
Figure 4 Charge Controller with PV array ground fault protection wiring digram.
How to Read the FLEXmax 80 Screen Diagrams
Soft keys:
(#1) (#2) (#3) (#4)
Solid black indicates key is to be pressed:
Down arrow will lead to the next screen:
Up arrow points to one or more keys that will change a value:
The keys correspond to any text immediately above them.
15
4. Powering Up
The FLEXmax 80 power-up sequence rst activates the unit and the SELECT VERSION screen (to de­termine a choice of English, Espanola, or Australian settings). A SYSTEM VOLTAGE screen soon follows. However, when it auto-detects the system’s battery voltage, in some instances the FLEXmax 80 might not reect the correct system voltage (e.g., if a 36VDC system falls to a voltage range that could be misread as a 24VDC system). The SYSTEM VOLTAGE screens allow the user to adjust the FLEXmax 80 to the correct voltage.
Be sure the PV input and battery breakers are o before starting the power-up sequence.
NOTE:
OFF SCREEN (this screen is initially blank at power up)
With the PV array and battery breakers o, turn on the battery breaker.
: The battery voltage must be at least 10.5V or higher to power up the FLEXmax 80. If the screen
NOTE
reads Low Battery Voltage, please see the Troubleshooting Guide on page 72.
Power Up Screen
OutBack 12V
Power
The FLEXmax 80 will show the system battery voltage in the upper right corner of the screen. The Select Version screen appears next.
Systems FLEXmax 80
NOTE:
• The FLEXmax 80’s default setting is for a 12 VDC battery.
• Change the setting after powering up the FLEXmax 80 if a dierent battery voltage is used.
• The PV array voltage—which must not exceed 150 VDC open circuit—is automatically detected.
16
Select Version
Elija la Version
USA
NEXT ENTER ENTRA SEL
Password Screen
The FLEXmax 80 screens are oered in English (standard screens) and Spanish. For Australian users, some of the charging values are of dierent voltages and the FLEXmax 80 accommodates these. By pressing the <NEXT> soft key, the user can choose USA, Australia, or Espanola versions of the screens. After pressing the <NEXT> soft key, a password must be entered before selecting the screen version.
PASSWORD
CONTRASENA
***150***
ENTRA - + ENTER
Select Version
Elija la Version
USA
NEXT ENTER ENTRA SEL
Press the “ – “ soft key until the password 141 shows on the screen. Press the <ENTER> soft key to return to the Select Version screen.
141 is the password for all OutBack products
NOTE:
displayed on a screen.
Press the <NEXT> to choose the desired screen version. Press the <ENTER> soft key to view the version conrmation screen.
17
Are you sure?
USA
NO YES
System Voltage Screen
SYTEM VOLTAGE 12 24 36 48 60 ^^
g ENTER
Press the <YES> soft key to conrm your choice or <NO> to return to the SELECT VERSION screen.
The FLEXmax 80 auto detects the system’s battery voltage. To conrm this voltage, press the <ENTER> soft
key. If incorrect, press the “g” soft key to select a battery voltage. The FLEXmax 80’s default values are based on a 12VDC system. Selecting a higher voltage system will change all the default values (e.g., the values will double with a 24VDC system, triple with a 36 VDC system, etc.). “^^” indicates the chosen voltage. The FLEXmax 80 will automatically accept the selected battery voltage if left unattended for 5 minutes in this screen. After choosing the voltage, press the <ENTER> soft key to proceed.
Verication Screen
Are you sure? 12 24 36 48 60 ^^
NO Yes
Press the <YES> soft key to proceed if the selected battery voltage is correct. If incorrect, press <NO> to re­enter the correct voltage. The <YES> soft key will open the STATUS screen.
NOTE: Repeating the Powering Up sequence resets the FLEXmax 80 Charge Controller to its factory default settings (see page 76).
18
5. Status Screen
The STATUS Screen displays system information. See page 63 for detailed information of the dierent Operational Modes. The optional OutBack MATE displays CC (Charge Controller) STATUS screens for convenient distant viewing from the installation location of the FLEXmax 80. Please see pages 65-67 to view the Charge Controller screens displayed on the MATE.
The PV voltage will slowly rise to the battery voltage level even when the PV breaker is o – this is normal as the PV capacitors charge up.
PV Input Voltage
Battery Voltage
Instantaneous Watts
AUX status (ON or OFF)
In 11.6 V 0.0 A Out 13.8 V 0.0 A
0.000 kW 0.0 kWH AUX: OFF Sleeping
PV Input Current
Output current
Daily accumulated kiloWatt Hours
Operational Mode
NOTE:
• Pressing the rst soft key opens the MAIN Menu screen.
• Pressing second soft key opens the End of the Day summary menu/logging.
19
6. End of Day Summary Screen
The End of Day summary screen appears after one hour of continuous sleeping. This screen can be opened anytime by pressing the second soft key while in the STATUS screen, providing a summary up to that point.
Accumulated amp hoursPeak output current
Day (up to 128 days)
Peak Input Voltage
Today 0000AH 00.0 kWH 011Vp 00.0Ap 0.00kWp MAX 14.7 V ABS 01:00
Maximum batt
voltage obtained
Minimum batt
voltage obtained
NOTE:
• Pressing the rst soft key opens the STATUS screen.
• Pressing the second soft key brings up the CLEAR LOG screen.
• Pressing the third soft key shows the previous day’s summary; continually pressing this soft key will bring up additional past summaries up to 128 days.
• Pressing the fourth soft key will bring up summary for the 128th day back.
MIN 14.6 V FLT 00:00
Accumulated KWh total power production
Peak kiloWatt hours
Accumulated absorb time
Accumulated oat time
7. Recharging Using the PV Array
In 113.6 V 0.0 A Out 12.5 V 0.0 A
0.000 kW 0.0 kWH AUX: OFF Sleeping
Turn the PV input breaker on. The FLEXmax 80 automatically detects the PV input voltage. (Note: If PV voltage registers “000V” when the breaker is on, please check the polarity of the PV wires.)
20
In 87.6 V 5.0 A Out 12.5 V 32.9 A
0.410 kW 0.0 kWH
AUX OFF MPPT Bulk
The FLEXmax 80 enters a “Wakeup” stage, transitions to “Tracking” and prepares to charge the batteries by tracking the maximum power point of the solar array.
During the FLEXmax 80’s initial tracking, the input source (e.g., solar) is gradually loaded from the open circuit voltage (VOC) to one-half of the VOC. Within this range, the FLEXmax 80 seeks the maximum power point. When the FLEXmax 80 goes into Re-Cal, Auto Restart, Wakeup, or RSTRT (restart) modes, among other conditions, it performs an initial tracking.
8. Accessing the MAIN Menu
The MAIN Menu allows the user to adjust and calibrate the FLEXmax 80 for maximum performance. From the STATUS screen, press the rst soft key on the left to open the MAIN Menu screen.
g Charger Aux Light
Press the <GO> soft key after aligning the arrow in front of the selected menu choice.
EQ Misc Advanced Logging Stats EXIT f g GO
Press or to move the " “ to the left of the desired screen. The arrow allows access to any screen to its right.
From the MAIN Menu, a user can choose among the following FLEXmax 80 functions by aligning the arrow:
Charger—CHARGER SETUP
- Adjusts the Current Limit, Absorb, and Float recharging voltage set points
Aux—AUX OUTPUT CONTROL
- Secondary control circuit for a vent fan, error alarm, and other system-related additions
Light—BACKLIGHT CONTROL
- Adjusts the backlighting of LCD screen and soft key buttons
EQ—BATTERY EQUALIZE
- Activates battery equalization recharging (manually or automatically)
Misc—MISCELLANEOUS
- Additional settings and service information
Advanced —ADVANCE MENU
- Optimizing/ne-tuning the FLEXmax 80 (these are advanced Menus that should be left alone
until the user has a good working knowledge of the FLEXmax 80 and its operations)
Logging—DATA LOGGING
- Displays recorded power production information
STATS—Statistics
- Displays recorded peak system information and cumulative kilowatt hours and amp hours
Pressing the <EXIT> soft key in the MAIN Menu returns to the STATUS screen.
21
7. Charger Set-Up
This screen allows changes to the FLEXmax 80’s recharging voltage set points—Current Limit, Absorb and Float (for an explanation of battery charging, see pages 81-82):
• The presently selected numerical value will have an arrow “
• Pressing <
may need to re-enter the password to change these settings.
• You
• The default charger output current limit setting is 80 amps and is adjustable from 5-80 amps. An
appropriate breaker must be used between the battery and the FLEXmax 80.
• Change Absorbing and Float set points using this screen if the battery manufacturer’s recommenda
tions are dierent than the default values. Otherwise, see page 84 for suggested recharging voltage set points.
> selects the value to be changed.
g ” to the left of it.
-
g Charger Aux Light
EQ Misc Advanced Logging Stats EXIT f g GO
Current Limit g 80.0A
Absorbing 14.4V Float 13.8V
EXIT
i - +
From the MAIN screen, press or to move the " “ to the left of the Charger function and then press the <GO> soft key. This will open the Charger Set-Up screen.
NOTE:
If a battery remote temperature sensor (RTS)
is used, set the ABSORB and FLOAT setting voltage based on a 25°C / 77°F setting. These are typically the manufacturer’s set points (always consult the battery
manufacturer’s recommendations). RTS compen­sated voltage values can be viewed in the Advanced menu screen under the RTS Compensation heading.
If an RTS is not in use, please see the Non-Battery Temperature Compensated System values (page 83) and adjust the ABSORB/FLOAT values accordingly.
22
8. AUX Mode and Its Functions
The AUX is a secondary control circuit—essentially, a small power supply that provides a 12VDC (up to 200 milliamps) output current. It is either active (12VDC on) or inactive (0VDC). Most AUX modes or functions are designed for specialized applications and are infrequently used.
• To access the AUX MODE from the MAIN Menu, press the <
the Aux selection (see next page).
Charger gAux Light EQ Misc Advance Logging Stats EXIT f g GO
• A 200 milliamps or less, 12VDC/2.4W device can be wired directly to the AUX terminal; higher output
DC loads require a 12VDC coil relay—also rated up to 200 milliamps or less for the DC coil—which itself is connected to the AUX output. An internal, re-settable Positive Temperature Co-ecient (PTC) fuse protects the AUX internal components from overcurrent or a short circuit.
• For certain AUX control applications the use of a solid state relay is preferred. This is particularly
benecial with applications such as the Diversion mode where fast switching (often called PWM control) allows a more constant battery voltage to be maintained. Both DC and AC load switching solid state relays are widely available from many sources. Eurotherm and Power-IO are two suggested solid state relay manufacturers.
• Only one AUX MODE can operate at a time (
even if other modes have been preset).
• See Figure 5, page 36, for an AUX set-up wiring diagram example.
In this Menu, On and O
indicators show the present
state of the Aux terminals.
Pressing the <MODE> soft
key changes the outputs
value (On, O, or Auto)
Output: Off Off
EXIT NEXT SET MODE
AUX MODE Night Light
> soft key until the arrow is in front of
This arrow indicates AUX Polarity applies to this function allowing the user to reverse the conditions that activate this function.
The second line indicates the present mode for the Aux Output. When this line blinks, it indicates a pending AUX Mode.
23
On indicates the Aux Output
is in an active state; O
indicates an inactive state.
Pressing the <NEXT> soft key changes to the next mode.
TERMS
• AUX MODE: what is displayed on the Menu
• Aux Output: 12VDC is either available or unavailable at the Aux Terminal
• Aux Terminal: the jack to which a relay is wired
When the preferred mode is displayed, press the <SET> soft key to select it.
AUX MODE Menu Path
g Charger Aux Light
EQ Misc Advance Logging Stats EXIT f g GO
Charger gAux Light EQ Misc Advance Logging Stats EXIT
f g GO
Output: Off Off EXIT NEXT SET MODE
AUX MODE
Vent Fan
g g
PASSWORD
***150***
ENTER - +
Output: Off Off EXIT NEXT SET MODE
AUX MODE
Vent Fan
g
To access the AUX Output Menu:
• Press the rst soft key once from the STATUS Menu to open the MAIN Menu.
• Press either of the arrow soft keys until the “
• Press the
<GO> soft key. If more than ten minutes have passed since any activity, the PASSWORD
g” is to the left of Aux.
screen becomes active, requiring the user to input the 141 PASSWORD and press < ENTER>.
• Pressing the <NEXT> soft key scrolls through the AUX functions.
The most commonly used AUX modes are Vent Fan, Low Battery Disconnect and Diversion.
AUX MODE
Vent Fan Output: Off Off EXIT NEXT SET MODE
AUX MODE
Night Light Output: Off Off EXIT NEXT SET MODE
AUX MODE
Diversion: Solid St Output: Off Off EXIT NEXT SET MODE
AUX MODE
Output: Off Off EXIT NEXT SET MODE
PV Trigger
g g
g
Output: Off Off EXIT NEXT SET MODE
AUX MODE
Float
g
AUX MODE
Low Batt Disconnect Output: Off Off EXIT NEXT SET MODE
g
g
AUX MODE
ERROR OUTPUT Output: Off Off EXIT NEXT SET MODE
AUX MODE
Diversion: Relay Output: Off Off EXIT NEXT SET MODE
g
AUX MODE
Remote Output: Off Off EXIT NEXT SET MODE
g
g
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AUX modes in order of appearance on the FLEXmax 80 display:
• Vent Fan • PV Trigger • Error Output • Night Light • Float • Diversion Relay
• Diversion Solid State • Low Battery Disconnect • Remote
NOTE: All AUX functions can be manually activated in On, O, or Auto mode. In Auto mode, the function will automatically activate when a user-determined value is met and deactivate or shut down when other conditions described here, such as a certain amount of time passing, occur.
When an AUX MODE is in AUTO, 12VDC is available at the AUX terminals and a condition, such as a voltage
set point, is met. Other modes can be programmed in lieu of the specic ones listed here, but the Vent Fan
mode is most easily changed (e.g., to activate an alarm instead of a fan). Here are the default AUX modes:
Vent Fan— when the Vent Fan voltage set point is exceeded, the vent fan will run for at least 15 seconds
(the fan helps remove hydrogen from battery enclosure), even if the set point is exceeded for only a few
seconds due to a surge. If the set point is exceeded for longer than 15 seconds, the fan will stay on until
the voltage drops below the set point. It then takes 15 seconds before the fan shuts o. This is an optional
external fan and not to be confused with the FLEXmax 80’s internal, thermally activated fan which cools
the unit.
PV Trigger*—activates an alarm or relay (that disconnects the array); when the PV input exceeds the
user-determined voltage set point (to avoid damage, do not go over 150VDC), the PV Trigger disconnects
after a minimal adjustable amount of Hold Time.
Error Output—useful for monitoring remote sites, switches to the O state if the FLEXmax 80 has not
charged the batteries for 26 hours or more (not an audible alarm, only displayed as a printed message
on FLEXmax 80 AUX Menu) or the battery voltage has fallen below a user-determined set point for 10
continuous minutes. In the No Error state, the AUX output is on.
Night Light*—after the PV voltage is below a threshold voltage for a user-determined time period, a
user-provided light illuminates as long as the FLEXmax 80 remains sleeping or as determined by the
user-established time limit.
Float—powers a load if the FLEXmax 80 is producing power in the Float stage
Diversion Relay*—diverts excess power away from batteries when a wind or hydro generator is
connected directly to the batteries.
Diversion Solid St—same as Diversion Relay, but applies when a solid state relay is used rather than a
mechanical relay
Low Batt Disconnect—activates/deactivates the AUX load(s) when a user-determined voltage and time
levels are reached.
Remote—allows OutBack MATE control of the AUX MODE (see MATE manual for details).
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* These functions support AUX polarity.
9. Programming the AUX MODES
VENT FAN
AUX MODE
Vent Fan
Output: Off Off
EXIT NEXT SET MODE
AUX MODE
Vent Fan
EXIT VOLT
VENT FAN VOLTS
> 14.4
On
O
Auto
Press the <MODE> soft key to manually activate or deactivate (On or O) the Vent Fan; if set to Auto, the Vent Fan will turn on when a user-determined voltage is met. Press the <SET> soft key to view the Vent Fan screen. To view other screens, con- tinue to press the <NEXT> soft key.
The Vent Fan helps remove hydrogen from the bat- tery box. The ventilation fan referred to here is not the same as the FLEXmax 80 cooling fan. Press the <VOLT> soft key to determine the battery voltage that will activate the AUX MODE and start the fan.
Adjust the voltage level using the < - > and < + > soft keys. Press the <BACK> soft key to return to the Vent Fan screen.
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BACK - +
AUX MODE
Vent Fan
EXIT VOLT
Press the <EXIT> soft key return to the main Vent Fan screen.
Output: Off Off
EXIT NEXT SET MODE
PV TRIGGER
Output: Off Off
EXIT NEXT SET MODE
AUX MODE
Vent Fan
AUX MODE
PV Trigger
g
Press the <NEXT> sot key to view the PV Trigger screen
When the PV input exceeds the user-determined
On
VOLT set point, the AUX MODE PV Trigger activates in
O
Auto Mode. Press the <MODE> soft key to establish another PV Trigger mode (On, O, or Auto).
Auto
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