Outback Power Systems FLEXmax Extreme Quick Start Guide
FLEXmax Extreme
Included in Package
FM Extreme-150VDC
2 x Mounting Bracket
Silicone Grease Package
2 x Ferrite Clamp (install
on HUB/DEVICE and
RTS ports)
Provided by Customer
PV Array
Batteries
MATE3
Fan Kit
Disconnect Devices
Ground Fault Protection
Wiring & Cabling
Dimensions
Height: 18.8" (47.1 cm); with fan 22.06" (56.0 cm)
Width: 8.8" (22.4 cm)
Depth to Wall: 6.0" (15.2 cm)
Mounting
The FLEXmax Extreme must be mounted upright at least 36" (91.4 cm)
above the ground or floor. Installation in shade is recommended.
Conduit hubs must be connected to the conduit before connecting to
the FLEXmax Extreme.
Clearance requirements are a minimum of 6“ (15.2 cm) above and
below the controller.
The unit can be mounted using either brackets (see A) or keyhole slots
(see B) on a secure mounting surface.
Temperature
A
Range of ambient operating
temperature: -20°C to 45°C
(-4°F to 113°F)
Unit output derated above 45°C
(113°F)
WARNING: Burn Hazard
2
The heat sink can become hot when the charge controller is operating.
Use caution when touching it during operation.
1
¼” hex head
lag screws
Indicator Controller State
Name Color Pattern Bulk Abs Float EQ Other
LED I ndi cators ( see wi ri ng s ecti on)
4
Off Off < 10 W PV available Battery rest
Blue Solid X X
Blue Flash long X
Blue Flash short X Float
Amber Solid X X ≥ 1.91 Vpc
Green Solid X
Red Solid X X Battery discharge <1.91 Vpc
Red Flash X X Critical batt discharge <1.75 Vpc
Amber/ Green Flash X ≤ EQ
Amber/ Red Flash X Critical batt discharge <1.75 Vpc
Yellow Solid AUX activ e
Red Solid External Fault
3
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©2013 OutBack Power Technologies. All Rights Reserved.
Charge
Status
AUX
Fault
B
Keyhole Slots
(#14 slotted wood screws)
N/A
Any
N/A
Securing Holes
(¼” hex head lag screws)
Voltage
IMPORTANT: Example only.
Actual wiring may vary. All
configurations must comply with
local and national electric codes.
Consult your local electric authority
to ensure compliance.
IMPORTANT:
Wire sizes must
comply with local and
national codes. To
comply with the NEC,
input conductors and
circuit breakers must
be rated at 1.56 times
the short-circuit current
of the PV array.
Tighten all wire lugs and
ground terminals to 4 Nm
(35 in-lb) torque.
Use copper wiring only
(rated 90°C or higher).
Refer to the NEC and other
electrical codes for PV array
cable sizing, length, and
ampacity.
Use #4 AWG (25 mm2)
(minimum) for the controller
output terminals to the
batteries; output can accept
up to #2 AWG (35 mm
2
).
Negative-ground installation is
depicted here; positive
grounding is also permitted.
DC LEGEND
Negative
Positive
Ground
Battery Bank
Battery Nominal Voltages:
12-volt, 24-volt, 36-volt,48-volt, 60-volt
LED Indicators
Charging (Blue)
Status (Green/Red or Amber)
Auxiliary
Fault
Photovoltaic Array (PV)
PV Combiner
ON
PV
Disconnect
(external)
OFF
Negative
Bus
NOTE: Overcurrent protection
for the battery circuit is to be
provided by installer.
Charge Controller
LED Indicators
(see above)
BAT–
PV+
BAT+
PV–
ON
Battery
Disconnect
OFF
(external)
NORMAL
Ground
Bus
Ground Fault Protection
(not provided, required by Article 690 of NEC)
PV ACTIVE
O
F
OFF
PV ARRAY
O
F
GROUND FAULT
DETECTOR
O
INTERRUPTER
FAULT
PV
INACTIVE
FLEXmax Extreme
Ports and Connectors
MATE3
System Display
and Controller
SunSpec Modbus
Interface
NOTE: See the FLEXmax Extreme
Owner’s Manual for details on the settings
available in the main menu.
AXS Card MATE3 RTS
Install ferrite
clamps on
these cables
for EMI
suppression
Accessory Terminal Block
2 3 4
1
External Fault Terminals
(see page 1 for GFDI function)
GFDI or other shutdown functions can be used for multiple
controllers. Terminals 2 and 4 are wired to the next controller
as shown.
2 3 4
1
5 6
7 8
65
Auxiliary (AUX)
Terminals
Used for diversion control
and other functions
Remote Temperature Sensor (RTS)
Battery performance changes when the temperature varies above or below room temperature
(77°F or 25°C). Temperature compensation is a process that adjusts charging to correct for these
changes. If not compensated, a battery may remain undercharged in cold temperatures and may
become overcharged when hot. Below room temperature, the charging set points are raised above
their normal values. Above room temperature the set points are lowered.
The RTS is attached to a single battery near the center of the bank. When charging, the RTS will
increase or decrease the charge voltage by a certain voltage per degree Celsius per battery cell.
The compensation value (the “slope”) is adjustable from 2 mV to 6 mV. Most batteries use a value
of 5 mV.
This setting affects the Absorbing and Float set points. Equalization is not compensated in the
FLEXmax Extreme.
Total compensation is determined by measuring the
number of degrees C above or below 25. This number
is multiplied by the number of 2-volt battery cells and
the slope value.
Examples of Compensation
Cells
(Volts)
6 (12V) 5 mV 8°C -17 6 x 0.005 x 17 +0.5 Vdc
12 (24V) 3 mV 36°C +11 12 x 0.003 x 11 -0.4 Vdc
18 (36V) 5 mV 26°C +1 18 x 0.005 x 1 -0.1 V dc
24 (48V) 6 mV 0°C -25 24 x 0.006 x 25 +3.6 Vdc
30 (60V) 2 mV 37°C +12 30 x 0.002 x 12 -0.7 Vdc
Slope
Value Temp
25°C
± Calculation
Vdc
Adjust
Fan Mounting
Fan Wiring
OFF
O
GFDI
NORMAL
PV ACTIVE
O
F
PV ARRAY
F
GROUND FAULT
DETECTOR
O
INTERRUPTER
FAULT
PV
INACTIVE
Controller 1 Controller 2
Battery Sense Terminals
These terminals monitor battery voltage more accurately than the main cable connections.
A twisted-pair cable is recommended. The connections are made directly on the battery
terminals. NOTE: Overcurrent protection devices are not shown.
DC Terminals
87
PV+ PV- BAT- BAT+
Recommended
protection for sense
conductors is:
Fast-acting device
80 Vdc or greater
1 A or smaller
Cold resistance
10 ohms or less
Contact Technical Support:
Telephone: +1.360.618.4363
Email: Support@outbackpower.com
Website: www.outbackpower.com
IMPORTANT:
Not intended for use with
life support equipment.
900-0151-01-00 Rev A.vsd\Accessories\2013-05-31
©2013 OutBack Power Technologies. All Rights Reserved.
OutBack Power and the OutBack Power logo are trademarks owned and used by OutBack Power Technologies, Inc. The ALPHA logo and the
phrase “member of the Alpha Group” are trademarks owned and used by Alpha Technologies. These trademarks may be registered in the United
States and other countries.
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