Outback Power Systems FLEXmax Extreme Owners Manual
FLEXmax Extreme Charge Controller
Owner’s Manual
T
About OutBack Power Technologies
OutBack Power Technologies is a leader in advanced energy conversion technology. OutBack products include
true sine wave inverter/chargers, maximum power point tracking charge controllers, and system communication
components, as well as circuit breakers, batteries, accessories, and assembled systems.
Grid/Hybrid™
As a leader in off-grid energy systems, which are designed around energy storage, OutBack Power is an
innovator in Grid/Hybrid system technology which provides the best of both worlds: grid-tied system savings
during normal or daylight operation, and off-grid independence during peak energy times or in the event of a
power outage or an emergency. Grid/Hybrid systems have the intelligence, agility, and interoperability to
operate in multiple energy modes quickly, efficiently, and seamlessly, in order to deliver clean, continuous and
reliable power to residential and commercial users while maintaining grid stability.
Contact Information
Address: Corporate Headquarters
17825 – 59
Suite B
Arlington, WA 98223 USA
elephone:
Email: Support@outbackpower.com
Website: http://www.outbackpower.com
+1.360.435.6030
+1.360.618.4363 (Technical Support)
+1.360.435.6019 (Fax)
th
Avenue N.E.
European Office
Hansastrasse 8
D-91126
Schwabach, Germany
+49.9122.79889.0
+49.9122.79889.21 (Fax)
Disclaimer
UNLESS SPECIFICALLY AGREED TO IN WRITING, OUTBACK POWER TECHNOLOGIES:
(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.
OutBack Power Technologies cannot be responsible for system failure, damages, or injury resulting from
improper installation of their products.
Notice of Copyright
FLEXmax Extreme Charge Controller Owner’s Manual © 2013 by OutBack Power Technologies. All Rights Reserved.
Trademarks
OutBack Power, the OutBack Power logo, FLEXpower ONE, and Grid/Hybrid 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 Inc. These trademarks may be registered in the United
States and other countries.
Date and Revision
June 2013, Revision A
Part Number
900-0150-01-00 Rev A
Table of Contents
Introduction ................................................................................................................................................................. 5
Audience................................................................................................................................................................................................... 5
Features .................................................................................................................................................................................................... 5
Firmware ................................................................................................................................................................................................... 5
Components and Accessories ........................................................................................................................................................... 6
Battery Types ..................................................................................................................................................................................... 6
Installation .................................................................................................................................................................... 7
Standards and Requirements ............................................................................................................................................................ 7
Dimensions ........................................................................................................................................................................................ 7
Mounting the Charge Controller ...................................................................................................................................................... 8
Installing the Fan ................................................................................................................................................................................. 10
Installing the AXS Card ...................................................................................................................................................................... 11
Wiring ...................................................................................................................................................................................................... 12
Grounding ........................................................................................................................................................................................ 12
Wiring Size and Requirements .................................................................................................................................................. 12
Physical Requirements and Conduit ....................................................................................................................................... 13
PV and Battery Terminals ............................................................................................................................................................ 13
Accessory Terminals and Ports .................................................................................................................................................. 16
HUB/Display Port ...................................................................................................................................................................... 16
Remote Temperature Sensor ............................................................................................................................................... 16
AXS Card ...................................................................................................................................................................................... 16
Fan Port ........................................................................................................................................................................................ 16
Accessory Terminal Block ...................................................................................................................................................... 16
AUX Terminals ..................................................................................................................................................................... 17
Battery Sense Terminals ................................................................................................................................................... 18
External Fault Terminals ................................................................................................................................................... 18
Power Up ................................................................................................................................................................................................ 21
Setting the Nominal Voltage ...................................................................................................................................................... 21
Resetting to Factory Defaults ..................................................................................................................................................... 22
Initial Operation ................................................................................................................................................................................... 22
Status and Information .......................................................................................................................................... 23
LED Indicators ....................................................................................................................................................................................... 23
Modes of Operation ................................................................................................................................................................ 25
Bulk .......................................................................................................................................................................................... 25
Absorb .................................................................................................................................................................................... 26
Floating .................................................................................................................................................................................. 27
EQ ............................................................................................................................................................................................. 27
Silent ....................................................................................................................................................................................... 28
MATE3 System Display and Controller ......................................................................................................................................... 29
Battery Status Indicators .............................................................................................................................................................. 29
Charger Indicator ........................................................................................................................................................................... 29
Charge Controller Soft Key ......................................................................................................................................................... 30
Status Screen ............................................................................................................................................................................. 30
Stats Screen ...................................................................................................................................................................................... 31
Error Screen ...................................................................................................................................................................................... 32
Temps Screen .................................................................................................................................................................................. 32
DataLog Screen .............................................................................................................................................................................. 33
900-0150-01-00 Rev A 1
Table of Contents
Graph Screens ................................................................................................................................................................................. 34
Programming the FLEXmax Extreme ............................................................................................................... 35
Menu Structure in the MATE3 ......................................................................................................................................................... 35
Charge Controller Settings ............................................................................................................................................................... 36
Charger .............................................................................................................................................................................................. 36
MPPT ................................................................................................................................................................................................... 37
Temperature Compensation ...................................................................................................................................................... 38
Battery Equalize .............................................................................................................................................................................. 38
Grid-Tie Mode.................................................................................................................................................................................. 39
Auxiliary Output ............................................................................................................................................................................. 39
Auxiliary Mode Screens .......................................................................................................................................................... 40
Restart Mode ................................................................................................................................................................................... 45
Calibrate ............................................................................................................................................................................................ 45
Reset Charge Controller to Factory Defaults ........................................................................................................................ 45
Firmware Revision .................................................................................................................................................................... 46
Updating the Firmware .................................................................................................................................................... 46
Device Data Logs ................................................................................................................................................................................. 47
Saving Data Logs for the FLEXmax Extreme ......................................................................................................................... 47
Data Log File Format ......................................................................................................................................................... 48
MATE/MATE2 Screens ............................................................................................................................................ 49
Summary Screens ................................................................................................................................................................................ 49
Status Screens ....................................................................................................................................................................................... 50
MODE Screens ................................................................................................................................................................................. 50
METER Screens ................................................................................................................................................................................ 51
SETPT Screens ................................................................................................................................................................................. 52
LOG Screens ..................................................................................................................................................................................... 53
STAT Screens ................................................................................................................................................................................... 54
Advanced Menus ................................................................................................................................................................................. 55
Accessing the Advanced Menus ............................................................................................................................................... 55
CHGR Menu ...................................................................................................................................................................................... 56
CC ADVANCED Menu .................................................................................................................................................................... 57
EQ Menu ............................................................................................................................................................................................ 58
AUX Menu ......................................................................................................................................................................................... 59
Troubleshooting ...................................................................................................................................................... 61
Specifications ............................................................................................................................................................ 63
Electrical and Mechanical Specifications ..................................................................................................................................... 63
Environmental Specifications .......................................................................................................................................................... 63
Regulatory Specifications ................................................................................................................................................................. 64
FCC Information to the User ....................................................................................................................................................... 64
Firmware Revision ............................................................................................................................................................................... 64
Temperature Range and Derating ................................................................................................................................................. 65
Default Settings and Ranges ............................................................................................................................................................ 66
Applications ............................................................................................................................................................... 69
Array Design .......................................................................................................................................................................................... 69
Sizing Guidelines ............................................................................................................................................................................ 69
Maximum-Power Voltage (Vmp) ................................................................................................................................................. 69
Open Circuit Voltage (Voc) ........................................................................................................................................................... 69
Weather Conditions ...................................................................................................................................................................... 70
Maximum Power Point Tracking .................................................................................................................................................... 70
Three-Stage Battery Charging ......................................................................................................................................................... 71
Bulk ..................................................................................................................................................................................................... 71
Absorption ....................................................................................................................................................................................... 71
Float .................................................................................................................................................................................................... 72
2 900-0150-01-00 Rev A
Table of Contents
Equalize ............................................................................................................................................................................................. 72
Battery Temperature Compensation ....................................................................................................................................... 72
FLEXnet DC Battery Monitor (FN-DC) ........................................................................................................................................... 73
Positive-Ground Systems .................................................................................................................................................................. 74
Networked Devices ....................................................................................................................................................................... 74
Non-Networked Devices.............................................................................................................................................................. 74
Grid-Interactive Settings ................................................................................................................................................................... 75
Hydroelectric and Fuel Cell Applications Performance Optimization ............................................................................... 75
Auto Track Mode ............................................................................................................................................................................ 75
U-Pick Mode ..................................................................................................................................................................................... 75
Definitions .............................................................................................................................................................................................. 77
Index ............................................................................................................................................................................. 79
List of Tables
Table 1 Components Included ..................................................................................................................................................... 6
Table 2 LED Indicators ................................................................................................................................................................... 24
Table 3 Absorption Timer ............................................................................................................................................................. 26
Table 4 Reasons for Silent Mode ................................................................................................................................................ 28
Table 5 Battery Status LED Indicators ....................................................................................................................................... 29
Table 6 AUX Mode Functions ...................................................................................................................................................... 40
Table 7 Troubleshooting .............................................................................................................................................................. 61
Table 8 Electrical and Mechanical Specifications for All Models ..................................................................................... 63
Table 9 Environmental Specifications for All Models .......................................................................................................... 63
Table 10 FLEXmax Settings (MATE3) ........................................................................................................................................... 66
Table 11 Maximum Input Wattage Per Charge Controller .................................................................................................. 69
Table 12 Examples of Compensation ......................................................................................................................................... 73
Table 13 Terms and Definitions .................................................................................................................................................... 77
900-0150-01-00 Rev A 3
Table of Contents
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4 900-0150-01-00 Rev A
Introduction
Thank you for purchasing a FLEXmax Extreme Series Charge Controller. These
efficient, safe, multi-stage recharging process that prolongs battery life and assures peak performance from a
PV array.
charge
controllers offer an
Audience
This manual is intended for use by anyone required to install and operate this equipment. Be sure to review this
manual carefully to identify any potential safety risks before proceeding. Installers and operators must be
familiar with all the features and functions of this equipment before proceeding. Failure to install or use this
equipment as instructed in the manual can result in damage to the equipment that may not be covered under
the limited warranty. This product is only serviceable by qualified personnel.
IMPORTANT:
This manual provides safety guidelines and installation information for the FLEXmax
Extreme charge controller. It does not provide information about specific brands of PV
modules and supplies limited information on batteries.
Contact the supplier of the PV modules or batteries for additional information.
Features
The FLEXmax Extreme charge controller uses continuous Maximum Power Point Tracking (MPPT). This function
continuously seeks out the maximum power available from a PV array and harvests it. This power is used to
recharge the batteries. Without MPPT, the system can only harvest power at the level of the battery voltage.
See page 70 for a description of MPPT.
The FLEXmax Extreme has the following features:
Designed for FLEXgrid™ operation as part of an OutBack Grid/Hybrid™ system
Supports 12, 24, 36, 48, and 60 Vdc battery voltages
Performs voltage step-down capability allowing the use of a higher-voltage PV array configuration
Controls an equalization cycle manually or automatically
Capable of delivering full current without derating in temperatures up to 45°C (113°F)
Capable of full current without derating up to 55°C (131°F) when using optional fan kit
Rain-proof enclosure
Logs up to 128 days of operational data
Field-upgradeable firmware
Can be remotely monitored and configured (up to 300 feet or 100 meters away) using the optional MATE3
system display
Can be remotely monitored and upgraded using the optional AXS Card product
Firmware
This manual covers FLEXmax Extreme firmware revision 001.xxx.000.
900-0150-01-00 Rev A 5
Introduction
Components and Accessories
Table 1 Components Included
1 x FM Extreme-150VDC
2 x Mounting Bracket 1 x Silicone Grease Package
2 x Ferrite Clamp, EMI Suppression (install on HUB/DEVICE port and RTS port; see page 16)
WARNING: Shock Hazard
This unit is not provided with a GFDI device. This charge controller must be used with
an external GFDI device as required by Article 690 of the National Electrical Code for the
installation location.
Rainproof
enclosure
Status indicators
with universal symbols
Equalize switch
Easily accessible
wiring
compartment
To remove the wiring compartment cover:
1. Using a Phillips screwdriver, remove the two
screws from the bottom of the compartment
cover. (See above.)
2. Grasp the lower edge as shown. Swing the
Cover screws
cover out while pulling downward.
Figure 1 Features & Wiring Cover
Battery Types
The FLEXmax Extreme charge controller works best with lead-chemistry batteries intended for deep discharge.
These include batteries for marine, golf-cart, and forklift applications. They also include gel-cell batteries and
absorbed glass-mat (AGM) batteries. OutBack Power recommends the use of batteries designed specifically for
renewable energy applications. Lithium-based batteries and other advanced battery technologies may require
special considerations. Please contact OutBack Technical Support at +1.360.618.4363 before implementing
advanced battery technologies.
6 900-0150-01-00 Rev A
Installation
Standards and Requirements
All installations must comply with national and local electrical codes. Professional installation is recommended.
A FLEXmax Extreme charge controller operating in unventilated or in other conditions where the ambient
temperature exceeds 45°C (113°F) will have a derated power output. See page 65 for more information.
If damaged or malfunctioning, the FLEXmax Extreme should only be serviced by qualified personnel.
Please contact the local renewable energy dealer/installer for assistance.
Dimensions
Wiring box
height 4.4”
(11.2 cm)
Width 8.8” (22.4 cm)
Depth 6.0” (15.2 cm)
Height 18.6”
(47.1 cm)
Wiring box opening width 6.9” (17.6 cm)
Side Plugs:
3.27” (8.3 cm)
For height with optional fan installed, see page 10
Bottom Plugs:
3.3” (8.4 cm)
Figure 2 FLEXmax Extreme Dimensions
900-0150-01-00 Rev A 7
Installation
Mounting the Charge Controller
The FLEXmax Extreme must be mounted upright on a wall or similar flat upright mounting surface. It must be
mounted at least 36” (91.4 cm) above the ground or floor. No other mounting positions are allowed. Installation
in shade is recommended.
Clearance requirements are a minimum of 6“ (15.2 cm) above and below the controller.
Two mounting methods are available. The first method uses keyhole slots on the back of the controller for
hanging directly on a wall. This method is useful for a standalone installation.
Keyhole slots
To mount using keyhole slots:
1. Use two slotted #14 wood screws. The mounting surface must be
strong enough to support the weight of the FLEXmax Extreme.
NOTE: OutBack is not responsible for damage resulting from
inadequate mounting hardware or preparation.
2. Mark the locations where the screws will be inserted on the surface.
Space them according to the keyhole slot locations (see below).
NOTE: The brackets included with the controller have holes with
the same spacing which can be used as a marking template.
3. Using the appropriate tools, set the screws into the surface
(see below). The heads should protrude by 1/8” (0.3 cm).
4. Hang the FLEXmax Extreme by placing its back against the
mounting surface and aligning the keyhole slots with the screws.
Settle the controller so that the screws are seated in the narrow end
of each slot.
5. Secure the base of the controller to the surface by inserting two ¼”
hex head lag screws into the holes shown to the left.
Slot spacing 7.9” (20.1 cm)
Securing holes
Distance
16.9” (42.9 cm)
Hole spacing 5.5” (13.9 cm)
Mounting is complete. Proceed to charge controller wiring or other installation steps.
Figure 3 Mounting the Charge Controller (keyhole)
8 900-0150-01-00 Rev A
Installation
The second mounting method uses brackets on the top and bottom of the controller. This method is useful
when mounting the controller next to an OutBack inverter system, as the conduit openings will align. It is also
useful for mounting without making advance measurements. The FLEXmax Extreme controller comes with two
identical brackets.
To mount using brackets:
1. Using two ¼” hex head lag screws, mount the lower
bracket with the tabs facing upward. The mounting
surface must be strong enough to support the added
weight of the FLEXmax Extreme.
NOTE: OutBack is not responsible for damage
resulting from inadequate mounting preparation.
2. Lower the FLEXmax Extreme onto the bracket as
shown to the left. The bracket tabs can be inserted in
one of two positions: forward or rear.
To mount the controller flush against the wall,
insert the tabs in the forward slots as shown below.
To mount the controller 0.83” (2.1 cm) from the
wall to align with an OutBack mounting plate,
insert the tabs in the rear slots as shown below.
Forward
slot
Rear
slot
NOTE: The charge controller can rest on the lower
bracket for the rest of the procedure, although it will
need at least one hand to steady it.
3. Insert the upper bracket into the same set of slots as
were used with the lower bracket (forward or rear) as
shown to the left.
4. Using two ¼” hex head lag screws, attach the upper
bracket to the mounting surface as shown to the left.
Mounting is complete. Proceed to charge controller
wiring or other installation steps.
Figure 4 Mounting the Charge Controller (brackets)
900-0150-01-00 Rev A 9
Rear
slot
Forward
slot
Installation
T
Installing the Fan
An optional fan is available for the FLEXmax Extreme to provide additional cooling. The fan is mounted on the
bottom of the charge controller. The total unit height with the fan attached is shown below. See page 65 for
information on the fan’s effects on unit performance.
To install the optional cooling fan:
1. Place the fan against the base of the FLEXmax Extreme.
he fan is equipped with two locking tabs. Two of the heat sink
fins have holes which receive the tabs. Align the tabs with
these fins (see below).
2. Press the fan straight along the fins until the tabs snap into
the holes.
Height
with fan
22.06” (56 cm)
Heat sink fins
Tab
3. Insert the fan connector into the fan
port in the controller’s wiring box. It
may be necessary to remove the rear
plug and insert a bushing. (See
illustration to the left; also see page 16.)
Installation is complete. The fan will
operate automatically based on the
FLEXmax Extreme internal temperature.
See page 32 to read the temperature using
the MATE3 System Display. This page also
lists the temperatures at which the fan
turns on and off.
Figure 5 Installing the Fan
10 900-0150-01-00 Rev A
Installation
p
Installing the AXS Card
An optional AXS Card enables Ethernet access to the FLEXmax Extreme using the Modbus protocol. (The AXS
Card is identical in function to the OutBack AXS Port product. See the AXS Port SunSpec Modbus Interface Owner’s
Manual for more information. NOTE: The AXS Port product is not interchangeable with the AXS Card and
cannot be used in this compartment.
To install the AXS Card:
1. Remove the factory-installed blank
compartment cover from the FLEXmax
Extreme. The cover is held in place with
two Phillips screws.
Screws
3. Install the alternate compartment cover
which was included with the AXS Card.
Use the Phillips screws which were
removed from the blank cover.
Insert
Screws
2. Insert the AXS Card onto the rails
on each side of the compartment.
Slide it in until the card presses
firmly onto the connector at the
rear of the com
artment.
Installation is complete. See the AXS Port SunSpec Modbus Interface Owner’s Manual for information on use.
Figure 6 Installing the AXS Card
900-0150-01-00 Rev A 11
Installation
Wiring
This section provides instructions on installing PV array wiring into the charge controller. See page 69 for more
notes on PV array sizing. All wiring must comply with local and national codes.
Grounding
This product is intended to be installed as part of a permanently grounded electrical system. This is shown in the
wiring diagrams in this book. Grounding methods must comply with local and national codes.
The FLEXmax Extreme equipment ground is marked with this symbol:
IMPORTANT:
Article 690 of the NEC requires ground-fault protection such as the OutBack GFDI.
It is recommended to bond one of the DC conductors to the ground on the battery
side of the system.
The DC conductor is connected to the ground as a result of installing the OutBack
GFDI. They should not be bonded separately. If a separate bond is already present
in the system, it should be removed. If present, it will defeat the GFDI protection.
(See page 19.)
Bonding the negative and ground is most common. However, the FLEXmax
Extreme can be used normally in either negative-ground or positive-ground
systems. Page 14 shows examples of both types of system wiring. See below for
restrictions on positive grounding. Also see page 74.
CAUTION: Equipment Damage
The FLEXmax Extreme can be used in a positive-ground system when networked with
one OutBack inverter. This requires a HUB Communications Manager. (See page 15.)
It cannot be networked in a positive-ground system with multiple inverters. For use of
the FLEXnet DC Battery Monitor or other devices in these applications, see page 74.
Failure to follow these instructions can damage the controller and other devices. This
damage is not covered under warranty.
The following important restrictions apply unless superseded by local or national codes:
The grounding conductors must be routed separately from all battery conductors.
The battery conductor (positive or negative) must be bonded to the grounding system at only one point.
Wiring Size and Requirements
IMPORTANT:
Wire sizes must comply with local and national codes. Input conductors and circuit
breakers must be rated at 1.56 times the short-circuit current of the PV array (per NEC).
OutBack 100% duty continuous circuit breakers only need to be rated at 1.25 times the
short-circuit current.
Please refer to the NEC and other electrical codes for PV array cable sizing, cable length, and cable ampacity.
Use #4 AWG (25 mm
bar conductors. Smaller cables can reduce performance and possibly damage the unit.
The output can accept up to #2 AWG (35 mm2) wire. Larger conductors will reduce losses and ensure
highest performance of the FLEXmax Extreme.
Install properly sized overcurrent protection devices. The required AIC rating of the device is 4000 Adc.
12 900-0150-01-00 Rev A
2
) wire (minimum) for the output between the FLEXmax Extreme and the battery bus
Installation
The largest PV array must have a rated short-circuit current of 64 amps or less under STC (Standard
Test Conditions). The output current limit of the FLEXmax Extreme is 80 amps.
DC battery overcurrent protection must be used as part of the installation. OutBack offers both circuit
breakers and fuses for overcurrent protection.
Physical Requirements and Conduit
IMPORTANT:
Conduit hubs must connect to the conduit before connecting to the FLEXmax Extreme.
WARNING: Burn Hazard
The heat sink can become hot when the charge controller is operating. Use caution
when touching it during operation.
All wire lugs and ground terminals are to be tightened to a torque value of 4 Nm (35 in-lb).
Use copper wiring only. Wiring must be rated at 90°C or higher.
If installing in a wet location, any conduit hubs must comply with the requirements of UL 514B.
Run positive and negative cables side by side.
~ Tie or twist cables together as much as possible to allow the inductive currents to cancel.
~ Ensure paired cables pass through the same knockout and conduit fittings.
PV and Battery Terminals
WARNING: Shock Hazard
When a PV array is exposed to light, it immediately generates a voltage. Make sure all
DC circuit breakers are OFF (open) BEFORE making any wiring connections. Open both
the battery disconnect devices and the array disconnect devices to ensure isolation of
the controller. Use a DVM to check for voltage on all wires.
CAUTION: Equipment Damage
Each FLEXmax Extreme requires its own PV array. DO NOT PARALLEL PV+ and PVTERMINALS OF MULTIPLE CONTROLLERS ON THE SAME ARRAY!
The negative (-) PV and negative (-) BAT terminals are connected internally. Only one wire is needed to connect
to the negative (-) wire lugs if the negative (-) PV and BAT conductors are bonded at the negative bus bar.
See Figure 8, Figure 10, Figure 16
DC
Terminals
DC TERMINALS
PV + PV - BAT - BAT +
, and Figure 17 for sample wiring diagrams.
Ground
Bus
Figure 7 Wiring Compartment
900-0150-01-00 Rev A 13
Installation
NOTE: Ground Fault and system-specific
wiring not shown
Figure 8 Wiring Diagram – Single Charge Controller with PV Array
NOTE: Ground Fault and system-specific
wiring not shown
Figure 9 Wiring Diagram – Single Charge Controller (Positive-Ground)
14 900-0150-01-00 Rev A
Installation
NOTE: Ground Fault and system-specific wiring not shown
Figure 10 Wiring Diagram – Charge Controller with PV Array and Inverter
CAUTION: Equipment Damage
The FLEXmax Extreme can be used in a positive-ground system with one OutBack
inverter as shown above. It cannot be used in a positive-ground system with multiple
OutBack inverters. For other devices or configurations, see page 74.
900-0150-01-00 Rev A 15
Installation
Accessory Terminals and Ports
HUB/System Display Port
Remote
Temperature
Sensor (RTS) Port
AXS Card
(optional)
Fan Connector
Accessory Terminal Block
Figure 11 Wiring Compartment
HUB/Display Port
This is an RJ-45 port for a CAT5 cable to connect OutBack system displays or communications managers. A
ferrite clamp (see page 6) should be installed on this cable inside the compartment.
Remote Temperature Sensor
An optional battery Remote Temperature Sensor (RTS) is recommended for accurate battery charging. A ferrite
clamp (see page 6) should be installed on this cable inside the compartment.
When the system includes an OutBack HUB Communications Manager and a system display, only one RTS is
needed for multiple inverters and charge controllers. Specialized temperature compensation is available.
See page 38 for more information.
AXS Card
This is the location for the AXS Card, which is available as an option for the FLEXmax Extreme. See page 11.
Fan Port
This is the connection for the FLEXmax Extreme cooling fan. See page 10.
Accessory Terminal Block
This block of terminals has connections for the AUX output, for the Battery Sense function, and for the External
Fault function. The terminals accept wire from 16 AWG to 24 AWG.
External
Fault
AUX
Figure 12 Accessory Terminal Block
16 900-0150-01-00 Rev A
Battery
Sense
Installation
AUX Terminals
The AUX (Auxiliary) output is a small power supply that provides a 12 Vdc output current to an isolated load. The
AUX output can respond to many criteria and control many functions. These include cooling fans, vent fans,
load diversion, fault alarms, and automatic generator control. The AUX can only control one function at a time.
Terminals
and are the + and – terminals for the AUX output. These terminals are colored gray (–) and
brown (+) for easy reference. The terminals can supply up to 250 mA at 12 Vdc (3 W). The AUX circuit contains
electronic overcurrent protection, which resets after being overloaded. No additional fuses are required for the
AUX terminals.
The AUX LED illuminates when the output becomes active. (See page 23 for an illustration of LED indicators.)
In this example, the AUX output directly drives a
12-volt vent fan. The – and + wires on the fan are
connected to terminals
AUX+ terminals.
and , the AUX– and
Figure 13 AUX Vent Fan
In this example, the AUX output drives a relay that
diverts wind power. The relay’s coil is connected to
terminals
terminals. When the AUX output closes the relay
(based on battery voltage), the relay diverts excess
power to a water heating element.
NOTE: Relays and elements shown are examples only and may
vary depending on the installation.
Figure 14 AUX Diversion Control
and , the AUX+ and AUX–
Relay
Element
Turbine
900-0150-01-00 Rev A 17
Installation
Battery Sense Terminals
The remote Battery Sense terminals are used for accurate voltage monitoring. These terminals connect directly
to the batteries. Using the controller’s main battery cables for voltage sensing is less accurate. This is due to
voltage rise caused by charging currents on the battery conductors.
Terminals
black (-) and red (+) for easy reference. A twisted-pair cable is recommended. (See wire sizing on page 16.)
This function operates automatically when it detects a voltage within 2 volts of the battery voltage reading at
the charge controller’s main terminals. If the reading varies by more than 2 volts, the Battery Sense function is
disabled. The assumption is that the terminals are not connected. (If the terminals are connected, there may be
a wiring problem.)
The MATE3 allows the user to calibrate the battery meter at the charge controller’s main terminals. (See page 45
and the MATE3 manual for more information.) This calibration does not affect the Battery Sense function. If
Battery Sense is in use, calibration changes can be made, but will have no effect until Battery Sense is disabled.
and are the – and + terminals for the Battery Sense function. These terminals are colored
IMPORTANT:
The MATE3 display shows the system voltage as measured at the battery terminals of
various devices. (See Figure 26 on page 29.) This voltage is used for generator starting
and other functions.
If no other devices are present, it will show the reading of the FLEXmax Extreme.
If OutBack inverters are present, the inverter voltage replaces the FLEXmax
Extreme as the system voltage reading.
If the FLEXmax Extreme Battery Sense terminals are in use, this reading replaces
the inverter or the regular charge controller readings as the system voltage.
The FLEXnet DC Battery Monitor is the highest priority and will replace the
Battery Sense reading as the system voltage.
The Battery Sense reading is still shown on the Charge Controller screen. (See Figure 27
on page 30.) This reading is still used to adjust the FLEXmax Extreme charging.
NOTE: Overcurrent protection is
not shown. Recommended
protection for sense conductors is:
Fast-acting device
80 Vdc or greater
1 A or smaller
Cold resistance 10 ohms or less
Figure 15 Battery Voltage Sensing
External Fault Terminals
The External Fault terminals are used to make connections to the OutBack Ground Fault Detector/Interruptor
(GFDI) product. A single wire is run from one of the yellow terminals (
from one of the purple terminals (
or ). Terminals and are the most commonly used. These wires
are connected to a normally-open set of contacts on the OutBack GFDI. Figure 16 and Figure 17 show terminals
to without the rest of the control terminal block.
18 900-0150-01-00 Rev A
or ). A second single wire is run
Installation
The terminals detect electrical continuity. These contacts remain closed as long as the GFDI bonding switch
remains closed. If a ground-fault event occurs, both the GFDI switch and the GFDI contacts will open. The
External Fault circuit will detect the loss of continuity and will shut down the charge controller.
If multiple charge controllers are in use, they can be paralleled so that all controllers use a common GFDI.
Terminals
and are a parallel set of connections to terminals and .
In the first controller, terminals
and
that it will react accordingly. If a third controller is present, its terminals
connecting to terminals
can be added as needed.
If the terminals are not in use, this function should be disabled. This is performed by directly shorting terminals
on the second controller. This allows the second controller to sense the same conditions as the first so
and with a small jumper wire.
and should have a parallel set of wires which connect to terminals
and should have wires
and on the second controller, and so on. (See Figure 17.) Additional controllers
IMPORTANT:
The FLEXmax Extreme will not function unless either the OutBack GFDI or the
disabling jumper is installed. Initial power-up will result in an External Fault
signal. (See page 61.)
Figure 16 Charge Controller with PV Array Ground Fault Protection
In Figure 16, a wire has been run from terminal to one of the dedicated GFDI terminals. A wire has also been
run from terminal
will read as electrically continuous to the External Fault circuit.
In the event of a ground fault or any other condition which trips the GFDI, these terminals will register loss of
900-0150-01-00 Rev A 19
to the other side of the GFDI. As long as the GFDI remains closed, that pole of the GFDI
Installation
continuity. The External Fault circuit will detect this loss immediately and shut down the the controller. The red
Fault LED indicator will illuminate. See pages 24, 32, and 61.
Other possible uses for the External Fault terminals include devices such as arc fault protection, or an Emergency
Power Off (EPO) switch for a fast manual shutdown. Any device with normally open contacts can work with this
function. If more than one device is used, all contacts must be wired in series so that any one device will shut
down the controller.
Figure 17 Two Charge Controllers with PV Array Ground Fault Protection
In Figure 17, a wire has been run from terminal on Charge Controller A to one of the dedicated GFDI
terminals. A wire has also been run from terminal
In addition, Terminal
Similarly, Terminal
places the External Fault circuits on both controllers in parallel.
As long as the GFDI remains closed, that pole of the GFDI will read as electrically continuous to the External Fault
circuit on both controllers. In the event of a ground fault or any other condition which trips the GFDI, these
terminals will register loss of continuity. The External Fault circuit on both controllers will detect this loss
immediately. Both controllers will shut down and display the red Fault LED indicator. See pages 24, 32, and 61.
To reset the controller after an external fault:
1. Remove all sources of power (PV and battery) from the controller.
2. Correct the cause of the fault condition.
3. Follow the power-up procedure on page 21.
20 900-0150-01-00 Rev A
on Charge Controller A has been connected to terminal on Charge Controller B.
on Charge Controller A has been connected to Terminal on Charge Controller B. This
to the other side of the GFDI.
Installation
Power Up
IMPORTANT:
The charge controller automatically senses the nominal battery voltage upon
connection. Once set, it retains the nominal voltage setting. Following any type of
shutdown or disconnect, it will return to operation automatically.
The PV array voltage is automatically detected upon connection. The PV array
voltage must never exceed 150 V
It is recommended to restore the FLEXmax Extreme to factory default settings
(see page 45) and reset the nominal voltage (see below) any time the system is
substantially revised or the controller is relocated.
The FLEXmax Extreme uses power from the battery bank to operate. The battery voltage must be at least
10.5 volts or higher to power up the charge controller. When battery power is detected, the charge controller
will flash each of its LED indicators twice in a self-test.
The Status indicator (see page 23) will then flash to show the nominal system voltage that was detected. Each
flash indicates an increment of 12 volts; therefore, one flash = 12 Vdc, two flashes = 24 Vdc, and so on.
.
oc
Charging Indicator — Blue LED
Status Indicator — Green/Red (or Amber) LED
AUX Indicator — Yellow LED
Fault Indicator — Red LED
Figure 18 LED Indicators
Setting the Nominal Voltage
Upon initial power-up, the FLEXmax Extreme will sense the battery voltage and use this reading to determine
the nominal system voltage — a battery bank of 12, 24, 36, 48, or 60 volts DC.
The ranges of detection for each nominal battery voltage are:
12-volt system — 10.5 Vdc to 15.7 Vdc
24-volt system — above 15.7 Vdc to 31.4 Vdc
36-volt system — above 31.4 Vdc to 43.2 Vdc
48-volt system — above 43.2 Vdc to 62.8 Vdc
60-volt system — above 62.8 Vdc to 78 Vdc
The batteries must be within the appropriate voltage range for the controller to take the correct reading. A
severely discharged 24-volt battery bank, for example, could read as a 12-volt bank and cause the controller to
900-0150-01-00 Rev A 21
Installation
charge inappropriately (or not at all).
Normally the nominal system voltage is retained. If the FLEXmax Extreme is disconnected from the batteries or
otherwise loses power, upon a new power-up it will continue using the nominal voltage and settings
determined previously.
If it is necessary to change the nominal voltage:
1. Reset the FLEXmax Extreme to factory default settings as described below.
2. Remove all sources of power (PV and battery) from the FLEXmax Extreme and then reconnect battery
power. The controller will sense the battery voltage and use this reading to determine the new nominal
system voltage. This will not occur until the power is turned off and then on again.
Resetting to Factory Defaults
The MATE3 system display can be used to reset the FLEXmax Extreme to its factory default settings. See page 45
for more information.
To reset to defaults without using the MATE3:
1. Remove all sources of power (PV and battery) from the FLEXmax Extreme.
2. Press and hold the Equalize switch (see page 6) while reconnecting battery power.
3. Continue holding the Equalize switch. After approximately 10 seconds, the Status indicator will blink
green rapidly. Continue holding the switch until the Status indicator begins blinking amber more slowly.
4. Release the Equalize switch and disconnect the batteries.
Initial Operation
When the PV input circuit breaker is turned on, the FLEXmax Extreme automatically detects the PV input voltage.
It then enters the “Wakeup” state (see page 28) and prepares to charge the batteries by tracking the maximum
power point of the solar array. During the initial tracking, the input PV source is gradually loaded from the
open-circuit voltage (V
power point. The amount of time required before starting operation is dependent on the module type, ambient
temperature, and the amount of sunlight directly on the PV array. Normally, the FLEXmax Extreme starts in the
morning within a few minutes of the PV array being exposed to direct sunlight.
Once the controller begins maximum power point tracking, it will enter a three-stage battery charging cycle.
This cycle can be observed with the controller’s LED indicators. (See page 23.) If the OutBack MATE3 or another
system display is available, it is possible to observe the specific charging stage, mode messages, and readings of
the charge controller.
) to ½ of the Voc. Within this range, the FLEXmax Extreme seeks the maximum
oc
22 900-0150-01-00 Rev A
LED Indicators
Status and Information
Charging Indicator — Blue LED
Status Indicator — Green/Red (or Amber) LED
AUX Indicator — Yellow LED
Fault Indicator — Red LED
Figure 19 LED Indicators
The FLEXmax Extreme charge controller has no graphical display. It is equipped with four LED indicators that
show the charge controller’s condition.
The top LED, the Charge indicator, is blue. It illuminates when more than 10 watts of PV power is available.
It is solid when bulk or equalization charging. It flashes when absorption or float charging. The MATE3
system display represents these stages as operating modes in the Status menu. See page 30 for a list of
modes. See page 71 for a description of charging stages.
The Charge indicator will not turn solid if less than 10 watts of PV power is available. It will flash in
constant-voltage charging regardless of how much PV power is available. Note that in some cases it may
illuminate when power is available but the controller is not charging. (See Table 4 on page 28.)
This indicator will flash while performing firmware updates to the FLEXmax Extreme (see page 46).
The second LED down is the Status indicator. It is a tri-color LED which can be red, green, or amber. This
LED is used to indicate either battery voltage or charger status. See Table 2 on page 24.
The following patterns usually indicate particular charging stages.
~ The indicator turns amber (a combination of the red and green colors) if the batteries are equal or
greater than 1.91 volts per cell (Vpc). This often accompanies Bulk or Absorption stage.
~ It turns green upon entering the Float stage. It will remain green regardless of the battery voltage until
it falls below 2.08 Vpc. This will trigger a new charge cycle.
~ It will alternate amber/green during equalization. It can also flash amber/red. (See pages 27 and 72.)
900-0150-01-00 Rev A 23
Operation
NOTE: The Status indicator turns red if the battery voltage falls below 1.91 Vpc. The red color shows an urgent
condition, indicating that the batteries are discharged. A red flash means the batteries have fallen below 1.75
Vpc, a critically low voltage. These patterns will appear regardless of the charging stage. If it appears, the Status
indicator cannot show the stage, although it may still be shown by the blue Charge indicator.
IMPORTANT:
The LED indicators do not necessarily tell the amount the controller is actively charging.
The Charge indicator may still indicate Absorption and the Status indicator may indicate
rising battery voltage, even if another charging source is doing most of the work.
Table 2 LED Indicators
Indicator Controller State
Name Color Pattern Bulk Absorb Float EQ Other
Off Off N/A < 10 W PV available Battery rest
Charge
Status
AUX Yellow Solid (see page 17) Any AUX active
Fault Red Solid N/A External Fault
Blue Solid X X
Blue Flash long (see page 26) X
Blue Flash short (see page 27) 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 battery discharge <1.75 Vpc
Amber/Green Flash (see page 26) X ≤ EQ
Amber/Red Flash (see page 27) X Critical battery discharge <1.75 Vpc
The third LED, the AUX indicator, is yellow. This indicator illuminates when the AUX output becomes active.
Voltage
The fourth (bottom) LED, the Fault indicator, is red. It will turn solid if the charge controller shuts down due
to an External Fault condition. See pages 19 and 20 for more information on the External Fault circuit. If the
MATE3 System Display is present, it will deliver a
Fault Input Active
error message (see page 32).
See Table 7 beginning on page 61 for information on resetting this error.
24 900-0150-01-00 Rev A
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