OutBack Power FLEXmax, FLEXmax60, FLEXmax80 Series Manual
Board Replacement Inst ructions for
FLEXmax Charge Controllers
Including Control Board, Button Board,
Power Board, and FLEXmax 60 Fan
About OutBack Power Systems
Out Back Power Systems is a leader in advanced energy conversion technology. Our products include
true sine wave inverter/chargers, maximum power point tracking ch arg e con t ro ll ers, syst em
communi cat i on co m p onen t s, as wel l as b r eaker panel s, b r eakers, accessor ies, an d assem bl ed syst em s.
Contact Information
Tel ep hon e: +1.360.435.6030 (Nort h America)
+1.360.618.4363 (Technical Support)
+1.360.435.6019 (Fax)
Address: North America
19009 62nd Avenue NE
Arlington, WA USA
E-mail: Support@outbackpower.com
Web Site: www.outbackpower.com
+34.93.654.9568 (Barcelona, Spain)
Disclaimer
U N L ESS SPEC I F I CA L L Y A GREED TO I N W RI T I N G, O U TB A CK PO W ER SYST EM S:
( a ) M A K ES N O W A RRA N T Y A S T O TH E A CC U RA CY , SU FF I CI EN CY O R SU I T A BILITY 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.
Notice of Copyright
Board Replacement Instruct ions for FLEXmax Charge Cont rollers © December 2009 by Out Back Power
Syst em s. Al l Rig ht s Reserv ed .
Trademarks
Out Back Power is a register ed t rademark of Out Back Power Systems.
Dat e and Rev i si on
December 2009, Revision A
Part Number
900-0054-01-00 Rev A
Important Safety Instructions
READ AND SAVE THESE INSTRUCTI ONS!
This manual contains important safety instructions for replacing parts on the FLEXmax Series Charge
Cont rollers. Read all instruct i ons and caut ionary markings on t he FLEXmax Series Charge Cont roll ers
and on any accessories or addit i onal equipment included in t he installat ion. Failure t o adhere t o t hese
instruct ions could resul t in severe shock or possible electrocut ion. Exercise extreme caution at all
times to prevent accidents.
Sy m b o l s Used
Sy m bo l De scr i p t i o n
Ground
AC Current
DC Current
Single-Phase
Si n e W a v e
WA RNING: Hazar d t o Hu m an Li f e
This type of n ot at ion i ndicates that t he hazard coul d be harmful to human l ife.
CAUTION: Hazar d t o Eq ui pm en t
This type of n ot at ion i ndicates that t he hazard may cause damage t o t he equi pment.
IM PORTANT:
This type of notation indicates that the information provided is i mp ort an t t o
the installation, op eration and/or maint enance of the equip ment . Fail ure t o
follow the recommendations in such a notation could result in voiding the
equipm ent warrant y.
Audience
These instruct ions are f or use by qualified person nel w ho meet all local and governmental code
requirements for licensing and training for the installation of elect rical power systems wit h AC and DC
volt age up to 600 volts.
900-0054-01-00 Rev A 1
Important Safety Instructions
Definit ions
Tab le 1 Ter ms and Acr onyms
Acronym Definition
But ton Board Flat board containing the push-buttons and LCD.
Control Board Narrow circuit board containing the unit’s programming.
FET
LCD
Power Board Large circuit board containing the unit’s power-switching circuitry.
PV
ield Effect Tran sistor. The FETs used f or p o w er swit ch i n g in t he FLEXmax are
F
classified as MOSFETs (Met al-Oxide-Semiconductor Field-Effect Transistors).
iquid-Crystal Displ ay; refers to t he FLEXmax d at a readout .
L
hotovoltaic; refers to the photovoltaic panels or modules used with the FLEXmax.
P
Per sonal Saf et y
WARNING: Personal Injury
Use standard safety equi pment such as safet y glasses, ear protection, steel-toed
safet y boots, safet y hard hat s, et c. as prescri bed by t he Occup ational Safety and
Healt h Associat i on (or other l ocal cod es) when w orkin g on t his equip ment.
Use standard safety pract ices when working with elect rical equi pment (e.g., rem ove
all jewelry, use insulated tools, wear cotton clothing, etc.)
Never wor k alo ne when i nstalli ng or servicin g t his equ ipment . Have someone
nearby that can come to your aid if necessary.
PV Saf et y
WARNING: Shock Hazar d
Phot ovolt aic (PV) arrays can be energized wit h minim al ambient light available.
Theref ore t o ensure a safe disconnect from t he system, be sure t o inst all a PV disconnect ,
breaker, or accessible f use box (dep endi ng on l ocal code requirement s).
CAUTION: Equ i p men t Dam ag e
PV Arrays must be wired with correct polarity (positive-to-positive, negative-tonegative). Connecting the cables incorrectly can damage or dest roy t he equi p ment .
2 900-0054-01-00 Rev A
Eq u i p m en t Sa f et y
CAUTION: Equ ip men t Dam ag e f r om St at i c Di sch ar ge
A static-safeguarded workspace should be used to preserve the FLEXmax controller’s
static-sensitive components during the removal and installation procedure. This
includes grounding yourself and your workspace t o remove any possi bl e st at i c c har ge .
Practices that will help avoid static include standing on a concret e flo or, preferably on a
rubber flo or m at , doin g t he repai rs on a met al w orkbench, an d avoiding static-causing
synthetic clothing.
WA RNING: Let h al Vol t ag e
Review the system configuration to identify all sources of energy. (PV arrays can be
energized with minimal ambient light available.) Ensure ALL sources of power are
disconnected before performing any installation or maintenance on this equipment.
Confirm that t he terminals are de-energi zed using a vali d at ed volt met er (rat ed for a
minimum 1000 Vac and 1000 Vdc) to verify the de-energized condi tion.
WARNING: Burn Hazard
Int ernal p art s can becom e h ot dur ing o p eration . Do not remove the cover during
op erat i on o r t ouch any int ernal part s. Be sure to all ow t hem sufficient time to cool down
before at tem p t ing t o performance any main t enance.
Important Safety Instructions
WA RNING: Fi re Hazar d
Do n ot place combust ible or f lammab l e mat erials wit hin 12 feet (3.7 m) of
the equip ment.
Use only t he recom mended cabl e sizes (or g reat er) for AC and DC conductors in
compliance with local codes. Ensure all conductors are in good condition. Do not
operate the unit with damaged or substandard cabling.
CAUTION: Equ i p men t Dam ag e
Do n ot perform any servicin g ot her t han t hat speci fied in t hese instructions unless
qu alified t o do so and have b een instruct ed t o do so b y OutBack Power Syst em s
Technical Support personnel.
On ly u se co mp on ent s o r accesso ri es r ecom men de d o r sol d by Ou t Back Power
Systems or its authorized agents.
Thoroughly inspect the equipment prior to energizing. Verify t hat no tools or
equipment have been inadvertently left behind.
Ensur e cl earance requi rements are st rict l y enf orced and t hat all vents are clear of
obstructions that can prevent proper airflow around or through the unit.
900-0054-01-00 Rev A 3
Important Safety Instructions
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4 900-0054-01-00 Rev A
Table of Contents
Important Safety Instructions ........................................................................1
Symbols Used ........................................................................................................................................................................1
Audience .................................................................................................................................................................................1
Defi n i tions...............................................................................................................................................................................2
Personal Safet y......................................................................................................................................................................2
General Safet y .......................................................................................................................................................................2
Eq uipmen t Saf ety .................................................................................................................................................................3
PV Safety ......................................................................................................................Error! Bookmark not defined.
Introduction.................................................................................................7
Overview ..................................................................................................................................................................................7
Tools Required.......................................................................................................................................................................8
Prelimi n ary ..............................................................................................................................................................................8
Summary List of Instruct i ons.............................................................................................................................................................8
FLEXmax Charge Controller Disassembly........................................................9
Removi ng t he FLEXmax 80 Fan Cable ..........................................................................................................................9
Removi ng Chassis Screw s.............................................................................................................................................. 10
Removi n g t he Heat Sink ................................................................................................................................................. 11
Removi ng t he FET Bar...................................................................................................................................................... 12
Separat i ng t he Heat Sink from t h e Power Board ...................................................................................................14
Fan and Button Board .................................................................................17
Replacing t he FLEXmax 60 Fan .................................................................................................................................... 17
Removing t he Fan...............................................................................................................................................................................17
Replacing the Fan ...............................................................................................................................................................................17
Fan Test Proced ures ......................................................................................................................................................... 18
Replacing t he But t on Board .......................................................................................................................................... 19
Control Board and Power Board...................................................................23
Removi ng t he Con t rol Board ........................................................................................................................................ 23
Replacing t he Cont rol Board or Pow er Board .........................................................................................................24
Reassembly................................................................................................27
Reseating t he Cont rol or Power Boar d ...................................................................................................................... 27
Reconnect ing t he Heat Sink t o t he Pow er Board .................................................................................................. 28
Reconnect ing t he Heat Sink t o t he Chassis .............................................................................................................30
Reinstalli n g FLEXmax 80 Fan Plug .............................................................................................................................. 31
Syst em Funct ional Test ................................................................................................................................................... 32
Li st of Figu r es
Fi g ur e 1 Component s ........................................................................................................................................................7
Fi g ur e 2 Charg e Cont roller “ At Rest” ............................................................................................................................8
Fi g ur e 3 Removi n g Fan Cover .........................................................................................................................................9
900-0054-01-00 Rev A 5
Tab le of Cont en t s
Fi g ur e 4 Removi ng Cable Jack........................................................................................................................................9
Fi g ur e 5 Back Screw Removal ...................................................................................................................................... 10
Fi g ur e 6 Si de Screw Removal (part 1)........................................................................................................................ 10
Fi g ur e 7 Si de Screw Removal (part 2)........................................................................................................................ 10
Fi g ur e 8 Heat Sink Removal........................................................................................................................................... 11
Fi g ur e 9 FET Bar Screw Removal ................................................................................................................................. 12
Fi g ur e 10 FET Bar Removal .............................................................................................................................................. 12
Fi g ur e 11 Freei n g t he FET from t he Insul at or .......................................................................................................... 13
Fi g ur e 12 Freei n g t he FET wit h Pli ers .......................................................................................................................... 13
Fi g ur e 13 Bot tom/ Crad l e Screw Remo val .................................................................................................................. 14
Fi g ur e 14 Removi ng Remaini n g Screw s..................................................................................................................... 14
Fi g ur e 15 Heat Sink Removal .......................................................................................................................................... 15
Fi g ur e 16 Heat Sink Connect ed t o Power Board ..................................................................................................... 15
Fi g ur e 17 Cable Removal ................................................................................................................................................. 16
Fi g ur e 18 Power Board - Top View ............................................................................................................................... 16
Fi g ur e 19 Fan Removal ..................................................................................................................................................... 17
Fi g ur e 20 Fan Replacem ent ............................................................................................................................................ 17
Fi g ur e 21 Fan Test Proced ure......................................................................................................................................... 18
Fi g ur e 22 Locati n g t he But t on Board .......................................................................................................................... 19
Figure 23 Disconnect ing t he Fan .................................................................................................................................. 19
Fi g ur e 24 Exposing the Button Board Mounting Peg............................................................................................ 20
Fi g ur e 25 Grippi ng t he Push-nut .................................................................................................................................. 20
Fi g ur e 26 Deforming t he Push-nut .............................................................................................................................. 21
Fi g ur e 27 Removi ng Push-nut ....................................................................................................................................... 21
Fi g ur e 28 Removi n g t he But t on Board ....................................................................................................................... 21
Fi g ur e 29 Insert i ng t he New But ton Board ................................................................................................................ 22
Fi g ur e 30 Insert i ng New Pu sh-nu t ................................................................................................................................ 22
Fi g ur e 31 Reconnect ing t he Fan ................................................................................................................................... 22
Fi g ur e 32 Lift ing t he Induct or Wires ............................................................................................................................ 23
Fi g ur e 33 Sl iding t he Cont rol Board Out .................................................................................................................... 23
Fi g ur e 34 Bent Pi n on Cont rol Board ........................................................................................................................... 24
Fi g ur e 35 Insert i ng Cont rol Board ................................................................................................................................ 24
Fi g ur e 36 Pins and Con nectors...................................................................................................................................... 24
Fi g ur e 37 FETs and Sil-Pad Insul ator on Heat Sink.................................................................................................. 25
Fi g ur e 38 Reseating Cont rol Board .............................................................................................................................. 27
Fi g ur e 39 Placing Induct or Wires.................................................................................................................................. 27
Fi g ur e 40 Reinstalli n g Ri b bon Cabl e ............................................................................................................................ 28
Fi g ur e 41 Gent ly Pull i ng On Rib bon Cabl e................................................................................................................ 28
Fi g ur e 42 Inst al l ing an d Tight ening Screw s.............................................................................................................. 28
Fi g ur e 43 Aligni ng FETs and Installing t he FET Bar................................................................................................. 29
Fi g ur e 44 Inst al l ing FET Bar Screws .............................................................................................................................. 29
Fi g ur e 45 Reinstalli ng t he Heat Sink onto t he Chassis .......................................................................................... 30
Fi g ur e 46 Replacing t he Chassis Scr ews..................................................................................................................... 30
Fi g ur e 47 Reinstalli n g Cable Jack.................................................................................................................................. 31
Fi g ur e 48 Reinstalli n g Cable Plu g ................................................................................................................................. 31
Fi g ur e 49 Fan Cover ........................................................................................................................................................... 31
6 900-0054-01-00 Rev A
Introduction
Overview
This step-by-step guide illustrates the replacement of the Control Board, Power Board and Button Board
for all FLEXmax Series Charge Controllers. It also illustrates t h e r ep lacement of t he Fan for FLEXmax 60
charg e cont rollers only. It does not cover replacing the f an in a FLEXmax 80 charge controller.
A static-safeguarded workspace should be used to preserve the FLEXmax controller’s static-sensitive
compon ent s during t he removal and i n st al l at ion procedure. See the sect ion t it led Equipment Safet y on
page 3 for more speci f ic i nstruct ions.
Please review this guide and familiarize yourself with the complete repair procedure. OutBack technical
support is also available at
CAUTION: Equ ip men t Dam ag e
This procedure involves sensitive electronics which must be handled gently
and carefully during removal and installation. Applying excess force can
damage the components and cause the FLEXmax controller to malfunction.
(360) 618-4363
or
support@outbackpower.com
.
But t on Boar d
(front )
Power Boar d
Cont rol Board
Power Boar d
(back)
Figure 1 Components
900-0054-01-00 Rev A 7
Tools Requi r ed
Phillips Screwdriver
Fl at Scr ew d r i ve r
Long-Nose Pli er s
Diagonal Wire Cutters (not shown)
Preliminary
Introduction
WARNING: Shock Hazar d
If the unit has been in use, power can
still be present even after the unit has
been disconnect ed.
Remove all electrical connections
fro m t he FLEXmax cont roller.
Allow the cont rol ler to “ rest” for
approximately ten minutes to fully
di scharge t he PV inp ut capacit ors.
Figure 2 Charge Controller “ At Rest”
: As many as 33 screws may be removed duri n g t his proced ure. Be sure to put them aside in t he
NOTE
order they are removed.
Summary List of Instructions
The following is a list of the instructions that are included in this document.
For instructions for
For instructions for
For instructions for
For instructions for
For instructions for
For instructions for
For instructions for
For instructions for
Removing the FLEXmax 80 Fan Cable
Di sassem b li ng t he Chassi s
Removing the Heat Sink
Rem ov in g t h e FET Bar
Sep ar at i ng t h e Heat Si nk f ro m t he Po wer Bo ar d
Replacing the Fan and Button Board
Replacing the Control Board and Power Board
Reassembling the Char ge Cont roller
, start on page 10.
, see page 11.
, see page 12
8 900-0054-01-00 Rev A
, see page 9.
, see page 14.
, see page 17.
, see page 23.
, see page 27.
FLEXmax Charge Controller Disassembly
p
If you have a FLEXmax 60, proceed w i th removing t he chassis screws as described on page 10.
Removing the FLEXmax 80 Fan Cable
1. Remove t he machine screw t hat secures the
fan cover.
Pre ss
Pr es s
6. Not e the jack for t he fan
cable, whi ch is snapped
into t he f an bracket.
2. Press bot h sides of t he f an cover t o release t h e
tabs. Pull up on the cover.
3. Remove t he fan cover once t he t abs have
cleared t heir slot s. Keep t he fan cover and
machine screw in a safe place.
4. Note the fan cable plugged into the jack.
5.
Rem ove t he fan cable
by squeezing the tabs
on eit her side of t he
plug. You can do this
wit h your f i n gers, or
wit h a pair of longnose
liers.
Figure 3 Removing Fan Cover
7. Remove the cabl e jack by
pinching the retaining
tabs on eit her side of the
jack, using long-nose
pliers. The jack can b e
taken out through the
rear of t he bracket .
Figure 4 Removing Cable Jack
900-0054-01-00 Rev A 9
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