Alpha Group OutBack Power FLEXmax 80 User manual

(FLEXmax 80/FLEXmax 60)
Overview

Contents
Overview …………………………………………………………..……… 1
Startup, Charger Configuration, and Status Menus………... 2
Auxiliary Modes…………………………………………………...……. 3
Configuration Modes and Data Logging……..…………...……. 4
900-0135-01-00 Rev A.vsd\TOC\2012-03-21
©2012 OutBack Power Technologies. All Rights Reserved.
WARNING: SHOCK HAZARD
This information is for use by qualified personnel who meet
all local and governmental code requirements for licensing
and training for the installation of electrical power systems
with DC voltage up to 150 Vdc.
Consult the FLEXmax Series Owner’s Manual for detailed
information on safety and installation procedures.

900-0135-01-00 Rev A.vsd\Overview\2012-03-21
©2012 OutBack Power Technologies. All Rights Reserved. Page 1
Overview
In 23.2 V 0.0 A
Out 27.6 V 0.0 A
0.000 kW 0.0 kWH
AUX: OFF Sleeping
In 23.2 V 0.0 A
Out 27.6 V 0.0 A
0.000 kW 0.0 kWH
AUX: OFF Sleeping
ÎCharger Aux Light
EQ Misc Advanced
Logging Stats
E
XIT ÍÎGO
LCD Screen
Main Menu
Soft Key
Buttons
Soft Key
Commands
<EXIT>,
<GO> etc.
Navigation:
1
2Advances to the
end-of-day screens
Advances to the
main menu screens
IN 23.2 V 0.0 A
OUT 27.6 V 0.0 A
0.000 kW 0.0 kWH
AUX: OFF Sleeping
Status Screen
OutBack 24V
Power
Systems
Charge Controller
Startup Screen
NOTE: See page 2-4 of this guide for menu maps for setting the
versions, changing the language of the screens, and accessing
the main menu.
See the FLEXmax Series Owner’s Manual for details on the
settings available in the main menu.
PV Input Voltage
Battery Voltage
AUX Status
Instantaneous Kilowatts
PV Input Current
Output Current
Mode of Operation
Daily Accumulated
Kilowatt-hours
Select this option to proceed
Available menus
Adjusts the set points value
Switches between devices on the
ports of the Communications HUB
Soft Key Color Code:
Navigation colors
Selects a function (e.g., ON, OFF, AUTO)
NOTE: Soft key functions will vary depending on the selected
menu and are defined by the word above the key in the LCD.
If accompanied by a dashed
line, pressing that soft key will
return the user to the location
identified by the dashed line.
This will vary depending on the
devices in the system.
Indicates a 1-screen movement within a
Menu. These are color coded according to
their function or purpose.
Models:
FLEXmax 80: 80 amps maximum continuous
output current (up to 40°C without thermal derating)
FLEXmax 60: 60 amps maximum continuous
output current (up to 40°C without thermal derating)
Features:
Supports 12, 24, 36, 48, and 60 Vdc
battery voltages
Backlit display screen (LCD) with 80 characters
(4 lines, 20 characters per line)
Last 128 days of operational data logging
Voltage step-down capability allowing a higher PV
array voltage configuration
Manual and automatic equalization cycles
Screen Versions:
English
Spanish
Australian (English with different default settings)
FLEXmax 80 Charge
Controller
FLEXmax 60 Charge
Controller
Recommended Input PV Wattage
per Charge Controller*
Battery Bank
Voltage
Maximum PV
Input Wattage
for the
FLEXmax 80
Maximum PV
Input Wattage
for the
FLEXmax 60
12 Vdc 1000 W 750 W
24 Vdc 2000 W 1500 W
36 Vdc 3000 W 2250 W
48 Vdc 4000 W 3000 W
60 Vdc 5000 W 3750 W
LCD Screen
Soft Keys
PV
+PV –BAT –BAT +
MATE
Port
(RJ45)
RTS
Port
(RJ11)
Terminals
Torque =
4 Nm (35 in-lb)
1 2
The interior design is identical in each model.
*Standard Test Conditions

900-0135-01-00 Rev A.vsd\Startup\2012-03-21
©2012 OutBack Power Technologies. All Rights Reserved. Page 2
NOTE: The
values shown in
this illustration will
vary depending
on the nominal
DC voltage.
Are you sure?
English
NO YES
SYSTEM VOLTAGE
12 24 36 48 60
^^
ENTER
Select Version
Elija La Version
English
NEXT ENTER ENTRA SEL
Are you sure?
12 24 36 48 60
^^
NO YES
Today 0000Ah 00.0 KWH
011Vp 00.0Ap 0.00kWp
MAX 29.4V ABS 01:00
MIN 29.2V FLT 00:00
End-of-Day (EOD)
Summary Screen
(current day)
-1day 0000Ah 00.0 KWH
011Vp 00.0Ap 0.00kWp
MAX 29.4V ABS 01:00
MIN 29.2V FLT 00:00
EOD
(Previous day)
-128d 0000Ah 00.0 KWH
011Vp 00.0Ap 0.00kWp
MAX 29.4V ABS 01:00
MIN 29.2V FLT 00:00
EOD
(Day 1 of 128
days past)
Continuing to press this soft
key will cycle forward by
1 day up to 128 days.
Press and hold this soft key
to automatically scroll
forward through the
available days.
IN 23.2 V 0.0 A
OUT 27.6 V 0.0 A
0.000 kW 0.0 kWH
AUX: OFF Sleeping
Status Screen
End-of-Day (EOD)
Summary Screens
Continuing to press this soft
key will cycle backwards by
1 day up to 128 days.
Press and hold this soft key
to automatically scroll
backwards through the
available days.
3 4
Charger—CHARGER SETUP
Adjusts the Current Limit, Absorbing, and Float recharging voltage set points
Aux—AUX OUTPUT CONTROL
Secondary control circuit for a vent fan, AGS, 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 (manually or automatically)
Misc—MISCELLANEOUS
Additional settings and service information
Advanced —ADVANCED MENU
Optimizes/fine-tunes the charge controller
Logging—DATA LOGGING
Displays recorded power production information
STATS—STATISTICS
Displays recorded peak system information and cumulative kilowatt-hours and
amp-hours
Main Menu Screen
To access the Main Menu:
Charger Aux Light
EQ Misc Advanced
Logging Stats
EXIT GO
IN 23.2 V 0.0 A
OUT 27.6 V 0.0 A
0.000 kW 0.0 kWH
AUX: OFF Sleeping
2
1. Press the < –> soft key until “141” is
displayed on the LCD.
2. Press the <ENTER> or <ENTRA> soft
key to accept the password and move
forward to the Select Version Screen.
PASSWORD
CONTRASENA
***141***
Entra - + ENTER
PASSWORD
CONTRASENA
***150***
Entra - + ENTER
B
¨Estas Seguro?
Espanol
NO SI
B
C
C C
Select Version
Elija La Version
English
NEXT ENTER ENTRA SEL
OutBack 24V
Power
Systems
Charge Controller
Voltaje del Sistema
12 24 36 48 60
^^
ENTRA
¨Estas Seguro?
12 24 36 48 60
^^
NO YES
To change the Language, Screen Version
or System Voltage:
Select Version
Elija La Version
Espanol
NEXT ENTER ENTRA SEL
1 2
A
-2day 0000Ah 00.0 KWH
011Vp 00.0Ap 0.00kWp
MAX 29.4V ABS 01:00
MIN 29.2V FLT 00:00
43
Status Screen
To select a menu from the Main
Menu, press the < > or the < > soft
key to move the cursor ( ). When the
is next to the desired menu, press <GO>.
The Spanish Status Screen is
not shown in this illustration. It
is available in the Spanish
translation of this document.
IMPORTANT:
To access the screens to change the
language or system voltage, press and
hold the 1st and 3rd soft key at the same
time, THEN CLOSE THE DC BREAKERS.
NOTE: Changing these setting will revert
all other settings back to the factory
defaults. Any customized settings will be
lost. See the FLEXmax Series Charge
Controller Owner’s Manual for details.
A
CLEAR LOG
BACK TOTL DAILY
Today 0000Ah 00.0 KWH
011Vp 00.0Ap 0.00kWp
MAX 29.4V ABS 01:00
MIN 29.2V FLT 00:00
Are you sure?
NO YES
43
IN 23.2 V 0.0 A
OUT 27.6 V 0.0 A
0.000 kW 0.0 kWH
AUX: OFF Sleeping
Status Screen Current Limit 80.0A
Absorbing 28.8V
Float 27.6V
EXIT -+
Main Menu Screen
Charger Aux Light
EQ Misc Advanced
Logging Stats
EXIT GO
Charger Screen
Continued on
the next page.
Press < > to move the next to the desired setting.
Press < –> or <+> to adjust the setting.
Press <EXIT> to return to the main menu.
Startup, Charger
Configuration, & Monitoring
1

900-0135-01-00 Rev A.vsd\Aux Modes\2012-03-21
©2012 OutBack Power Technologies. All Rights Reserved. Page 3
Status Screen
Charger Aux Light
EQ Misc Advanced
Logging Stats
EXIT GO
IN 23.2 V 0.0 A
OUT 27.6 V 0.0 A
0.000 kW 0.0 kWH
AUX: OFF Sleeping
AUX MODE
Diversion: Solid St
EXIT TIME VOLT
Absorb–Float–EQ
Relative Volts
0.0 00.2
BACK - + HYST
Hold Delay
01.0 Time 00
Seconds
BACK - + DLY+
Main Menu Screen
Error Output Night Light Float Diversion: Relay Diversion: Solid St Low Batt Disconnect Remote
AUX MODE
Float
Output: Off OFF
EXIT NEXT SET MODE
AUX MODE
Diversion: Solid St
Output: Off OFF
EXIT NEXT SET MODE
AUX MODE
Remote
Output: Off ON
EXIT NEXT SET MODE
Continued on
the next page.
Continued from the
previous page.
AUX MODE
Low Batt Disconnect
Output: Off OFF
EXIT NEXT SET MODE
AUX MODE
Diversion: Relay
EXIT TIME VOLT
Hold Delay
01.0 Time 00
Seconds
BACK - + DLY+
Absorb–Float–EQ
Relative Volts
0.0 00.2
BACK - + HYST
AUX MODE
Diversion: Relay
Output: Off OFF
EXIT NEXT SET MODE
Returns to the
Vent Fan Screen.
1
Vent
Fan PV Trigger
AUX MODE
Vent Fan
Output: Off OFF
EXIT NEXT SET MODE
AUX MODE
PV Trigger
Output: Off OFF
EXIT NEXT SET MODE
AUX MODE
ERROR OUTPUT
Output: Off OFF
EXIT NEXT SET MODE
AUX MODE
Night Light
Output: Off OFF
EXIT NEXT SET MODE
AUX MODE
Low Batt Disconnect
EXIT TIME VOLT
Delay Time Sec
01 Timer
001
BACK - +
DISCONNECT VOLTS
<27.2
BACK - +
Night Light
On Hysteresis Time
Minutes 000
BACK - + OFF
AUX MODE
Night Light
EXIT HYST TIME VOLT
AUX MODE
> 28.8
BACK - +
AUX MODE
Vent Fan
EXIT VOLT
AUX MODE
PV Trigger
EXIT TIME VOLT
DISCONNECT VOLTS
<13.6
BACK - +
Delay Time Sec
01 Timer
001
BACK - +
AUX MODE
ERROR OUTPUT
01 hrs
EXIT VOLT
ERROR LOW BATT VOLTS
<23.0
001
BACK - +
Night Light
Off Hysteresis Time
Minutes 000
BACK - +
Night Light On Time
23 hours
BACK - +
Night Light
Threshold Voltage
BACK - +
Auxiliary Modes

900-0135-01-00 Rev A.vsd\Config mods\2012-03-21
©2012 OutBack Power Technologies. All Rights Reserved. Page 4
NOTE: The values shown in this illustration will vary depending
on the model of the charge controller and/or the inverter.
Charger Aux Light
EQ Misc Advanced
Logging Stats
EXIT GO
Charger Aux Light
EQ Misc Advanced
Logging Stats
EXIT GO
Max Bat Voc MaxVoc
149 036.6 133.0
MaxWatt 0000 Sunrise
EXIT NEXT 01:30:33
Total 0000 kWH
Total 000.0 kAH
Back DCkWH
Total 0000 kWHAC
Total 000.0 kAH
Back ACkWH
Charger Aux Light
EQ Misc Advanced
Logging Stats
EXIT GO
GT State PWM% ChgT
255 07 50.0 005
EXIT NEXT RSTRT
PCB Target Btmp CFB
512 28.8v 255 0712
EXIT BACK
Charger Aux Light
EQ Misc Advanced
Logging Stats
EXIT GO
ADVANCED MENU
Snooze Mode
< 0.6 amp
EXIT NEXT AMP Amp
Values
0.2
0.4
0.6
0.8
1.0
ADVANCED MENU
Wakeup Mode
1.5V 05m
EXIT NEXT AMP
ADVANCED MENU
Park Mpp
77% Voc
EXIT NEXT -% +%
ADVANCED MENU
MPPT Mode
Auto Track
EXIT NEXT nonGT MODE
ADVANCED MENU
Park Mpp
Watts 0251 77% Voc
EXIT NEXT -% +%
ADVANCED MENU
Mpp Range Limit %Voc
Min Max
EXIT NEXT 1/2 90%
ADVANCED MENU
MPPT Mode
Auto Track
EXIT NEXT nonGT MODE
ADVANCED MENU
Absorb Time Limits
01.1 hours
EXIT NEXT - +
ADVANCED MENU
Absorb End Amps
00 A
EXIT NEXT - +
ADVANCED MENU
Rebulk Voltage
25.2V
EXIT NEXT - +
1
1
Charger Aux Light
EQ Misc Advanced
Logging Stats
EXIT GO
BACKLIGHT CONTROL
Auto Time 2 Minutes
Auto
EXIT - + MODE
FORCE
EXIT NEXT FLOAT BULK
2
2Setpoints:
nonGT
GT
Today 0000Ah 00.0 KWH
011Vp 00.0Ap 0.00kWp
MAX 29.4V ABS 01:00
MIN 29.2V FLT 00:00
End-of-Day (EOD)
Summary Screen
(current day)
CLEAR LOG
BACK TOTL DAILY
Today 0000Ah 00.0 KWH
011Vp 00.0Ap 0.00kWp
MAX 29.4V ABS 01:00
MIN 29.2V FLT 00:00
Are you sure?
NO YES
-1day 0000Ah 00.0 KWH
011Vp 00.0Ap 0.00kWp
MAX 29.4V ABS 01:00
MIN 29.2V FLT 00:00
EOD
(Previous day)
-128d 0000Ah 00.0 KWH
011Vp 00.0Ap 0.00kWp
MAX 29.4V ABS 01:00
MIN 29.2V FLT 00:00
EOD
(128 days past)
Range: 2-9 minutes
Continued from the
previous page….
Main Menu Screens (continued)
Charger Aux Light
EQ Misc Advanced
Logging Stats
EXIT GO
BATTERY EQUALIZE
Volts
30.0
EXIT NEXT -EQV +EQV
BATTERY EQUALIZE
Time
01 Hours
EXIT NEXT -EQV +EQV
BATTERY EQUALIZE
1 Hours 30.0 Volts
Check water level
BACK AUTO START STOP
COUNT EQ INTERVAL
00 000
EXIT -DAY +DAY
ADVANCED MENU
RTS Compensation
A 28.2V F 27.6V
EXIT NEXT WIDE
ADVANCED MENU
Auto Restart
Mode 0
EXIT NEXT MODE
3
ADVANCED MENU
Aux Polarity
Active Low
EXIT NEXT MODE
ADVANCED MENU
Reset to Defaults
EXIT NEXT RESET
Are you sure?
Reset to Defaults
YES NO
ADVANCED MENU
RTS Compensation
A 28.2V F 27.3V
EXIT NEXT LMIT SET
RTS Compensation
Upper LIMIT 28.2V
Lower LIMIT 16.2V
BACK -+
Setpoints:
Mode 0
Mode 1
Mode 2
3
ADVANCED MENU
Vbatt Calibration
28.2V 0.0V
EXIT NEXT - +
Backlight Equalization Miscellaneous Advanced Logging
Statistics
Advanced (continued)
2 3
2 3
Logging: End-of-Day (EOD) Screens
ADVANCED MENU
MPPT Mode
U-Pick %Voc
EXIT NEXT nonGT MODE
1
1
Advanced:
When entering the Advanced Menu for the first time, pressing the <GO> soft
key advances to the Snooze Mode screen.
From inside the Advanced Menu, pressing the <EXIT> key returns to the Main
screen. If the <GO> soft key is pressed at this point, it will return to the screen
where the <EXIT> key was pressed.
Continuing to press this soft key will cycle backwards by 1 day up to 128 days.
Press and hold this soft key to automatically scroll backwards through the
available days.
2
3Continuing to press this soft key will cycle forward by 1 day up to 128 days.
Press and hold this soft key to automatically scroll forward through the
available days.
4
From the End-of-Day Summary Screen for the current day, pressing
this soft key returns the display to 128 days past.
4
ADVANCED MENU
Aux Polarity
Active High
EXIT NEXT MODE
Configuration Modes
and Data Logging

About OutBack Power Technologies
OutBack Power Technologies is a leader in advanced energy conversion technology. Our
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.
Contact Information
Telephone: [phone] (Main)
+1.360.618.4363 (Technical Support)
+1.360.435.6019 (Fax)
Mailing Address: OutBack Power Technologies Sales & Marketing
5917 - 195th Street N.E. 6115 – 192nd Street NE
Arlington, WA 98223 USA Arlington, WA 98223 USA
E-mail: [e-mail]
Web Site: www.outbackpower.com
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.
Warranty Summary
OutBack Power Technologies warrants that the products it manufactures will be free from
defects in materials and workmanship for a period of five (5) years subject to the conditions
set forth in the warranty detail, found in the product manual.
OutBack Power Technologies cannot be responsible for system failure, damages, or injury
resulting from improper installation of their products.
Notice of Copyright
FLEXmax Overview © January 2012 by OutBack Power Technologies.
All Rights Reserved.
Trademarks
OutBack Power is a registered trademark of OutBack Power Technologies.
Date and Revision
January 2012, Revision A
Part Number
900-0135-01-00 Rev A

North America:
5917 - 195th Street N.E.
Arlington, WA USA
+1.360.435.6030
900-0135-01-00 Rev A