Outback Power Systems FLEXmax 60 User manual

Maximum Power Point Tracking Charge Controller
User’s Manual
Installation and Programming
max
T M
80
max
T M
60

1
Warranty Summary
Dear OutBack Customer,
Thank you for your purchase of OutBack products. We make every eort to assure our power
conversion products will give you long and reliable service for your renewable energy system.
As with any manufactured device, repairs might be needed due to damage, inappropriate use,
or unintentional defect. Please note the following guidelines regarding warranty service of
OutBack products:
• Any and all warranty repairs must conform to the terms of the warranty.
• All OutBack equipment must be installed according to their accompanying instructions and
manuals with specied over-current protection in order to maintain their warranties.
• The customer must return the component(s) to OutBack, securely packaged, properly addressed,
and shipping paid. We recommend insuring your package when shipping. Packages that are not
securely packaged can sustain additional damage not covered by the warranty or can void
warranty repairs.
• There is no allowance or reimbursement for an installer’s or user’s labor or travel time required to
disconnect, service, or reinstall the damaged component(s).
• OutBack will ship the repaired or replacement component(s) prepaid to addresses in the continental
United States, where applicable. Shipments outside the U.S. will be sent freight collect.
• In the event of a product malfunction, OutBack cannot bear any responsibility for consequential
losses, expenses, or damage to other components.
• Please read the full warranty at the end of this manual for more information.

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The OutBack Power Systems FLEXmax 80 and FLEXmax 60 Maximum Power Point Tracking Charge
Controller
s are ETL listed in North America to UL1741 (Inverters, Converters, Controllers, and
Interconnection System Equipment for Use with Distributed Energy Resources). It is also in compliance
with European Union standards EN 61000-6-1 and EN 61000-6-3 (see page 91).
About OutBack Power Systems
OutBack Power Systems is a leader in advanced energy conversion technology. Our products include
true sine wave inverter/chargers, a maximum power point charge controller, system communication
components, as well as breaker panels, breakers, accessories, and assembled systems.
Notice of Copyright
FLEXmax 60 and FLEXmax 80 Maximum Power Point Tracking Charge Controlle rs User’s Guide: Installation,
Programming and User’s Manual
Copyright © 2008 All rights reserved.
Disclaimer
UNLESS SPECIFICALLY AGREED TO IN WRITING, OUTBACK POWER SYSTEMS:
(a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR
OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION.
(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER DIRECT,
INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH
INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER’S RISK.
Date and Revision
April 2008 REV A
Contact Information
OutBack Power Systems
19009 62nd Ave. NE
Arlington, WA 98223
Phone [phone]
Fax [phone]
www.outbackpower.com

3
TABLE OF CONTENTS
SCOPE .......................................................................................................................................................................................................5
INTRODUCTION..................................................................................................................................................................................5
INSTALLATION GUIDELINES AND SAFETY INSTRUCTIONS.......................................................................................6
Standards and Requirements...........................................................................................................................................6
Battery Safety..............................................................................................................................................................................7
INSTALLING THE Charge Controller ON FLEXware ENCLOSURES..................................................................... 10
OPEN CIRCUIT VOLTAGE/WIRE AND DISCONNECT SIZING................................................................................... 10
CHARGE CONTROLLER CONNECTIONS............................................................................................................................ 12
HOW TO READ THE Charge Controller SCREEN DIAGRAMS................................................................................. 16
POWERING UP .................................................................................................................................................................................. 17
STATUS SCREEN................................................................................................................................................................................ 20
END OF DAY SUMMARY SCREEN .......................................................................................................................................... 21
RECHARGING USING THE PV ARRAY ................................................................................................................................... 21
ACCESSING THE MAIN MENU.................................................................................................................................................. 22
CHARGER SETUP ............................................................................................................................................................................. 23
AUX MODE AND ITS FUNCTIONS......................................................................................................................................... 24
AUX Mode Path...................................................................................................................................................................... 25
AUX Modes Described....................................................................................................................................................... 26
Programming the AUX Modes ..................................................................................................................................... 27
Vent Fan ............................................................................................................................................................................ 27
PV Trigger ......................................................................................................................................................................... 28
Error Output ................................................................................................................................................................... 31
Night Light ...................................................................................................................................................................... 32
Float..................................................................................................................................................................................... 34
Diversion: Relay ............................................................................................................................................................ 34
Diversion: Solid State ................................................................................................................................................ 36
Low Battery Disconnect.......................................................................................................................................... 38
Remote.............................................................................................................................................................................. 40
BACKLIGHT.......................................................................................................................................................................................... 41
EQ (Equalize)...................................................................................................................................................................................... 41
MISC-MISCELLANEOUS............................................................................................................................................................... 44
ADVANCED......................................................................................................................................................................................... 46
Snooze Mode........................................................................................................................................................................... 46
Wakeup Mode......................................................................................................................................................................... 47
MPPT Mode .............................................................................................................................................................................. 47
Park Mpp .................................................................................................................................................................................... 48
CHARGING RELATED SCREENS............................................................................................................................................... 49
Absorb Time............................................................................................................................................................................. 49
Rebulk Voltage........................................................................................................................................................................ 50

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Vbatt Calibration..........................................................................................................................................................................51
RTS Compensation.....................................................................................................................................................................51
Auto Restart....................................................................................................................................................................................52
Aux Polarity.....................................................................................................................................................................................53
Reset to Defaults? .......................................................................................................................................................................53
(DATA) LOGGING....................................................................................................................................................................................55
Clearing Total and Daily Stats ...............................................................................................................................................55
STATS .............................................................................................................................................................................................................56
Secondary Stats Screen............................................................................................................................................................57
MICRO-HYDRO, WIND TURBINE, AND FUEL CELL APPLICATIONS............................................................................58
ADVANCED MENU (Micro-Hydro) ...............................................................................................................................................59
Charge Controller ABBREVIATED MENU MAP......................................................................................................................60
APPLICATION NOTES ...........................................................................................................................................................................61
Charge Controller EFFICIENCY vs. INPUT POWER GRAPH ............................................................................................62
UNDERSTANDING THE VARIOUS OPERATIONAL MODES..............................................................................................63
MATE-DISPLAYED CHARGE CONTROLLER STATUS MODE Screens.........................................................................66
MATE-DISPLAYED CHARGE CONTROLLER STATUS METER Screens.......................................................................67
MATE-DISPLAYED CHARGE CONTROLLER STATUS SETP(OINT) Screens..............................................................68
MATE-DISPLAYED Charge Controller ADVANCED SCREENS........................................................................................68
ADVANCED MENU ................................................................................................................................................................................69
EQ SCREENS..............................................................................................................................................................................................70
AUX SCREENS...........................................................................................................................................................................................70
ABBREVIATED MENU............................................................................................................................................................................71
TROUBLESHOOTING GUIDE ............................................................................................................................................................73
TYPICAL ARRAY SIZING GUIDE ......................................................................................................................................................76
STANDARD vs. AUSTRALIAN DEFAULT SETTINGS...............................................................................................................77
WIRE DISTANCE CHART FLEXMAX 80........................................................................................................................................78
WIRE AND DISCONNECT SIZING FLEXMAX 80 ....................................................................................................................80
WIRE AND DISCONNECT SIZING FLEXMAX 60 ....................................................................................................................81
WIRING COMPARTMENT....................................................................................................................................................................82
MULTI-STAGE BATTERY CHARGING.............................................................................................................................................83
BATTERY TEMPERATURE COMPENSATED VOLTAGE SET POINT.................................................................................85
SUGGESTED BATTERY CHARGER SET POINTS ......................................................................................................................86
CALLING THE FACTORY FOR ASSISTANCE..............................................................................................................................87
WARRANTY INFORMATION..............................................................................................................................................................88
PRODUCT REGISTRATION AND OPTIONAL EXTENDED WARRANTY......................................................................90
EU DECLARATION OF CONFORMITY..........................................................................................................................................91
OWNER’S SYSTEM INFORMATION ............................................................................................................................................. 92

5
SCOPE
This manual provides safety guidelines and installation information for the FLEXmax 60 and FLEXmax
80 Charge Controller
Maximum Power Point Tracking Charge Controllers. It does not provide information
about specic brands of solar panels and supplies limited information on batteries. Contact the
supplier or manufacturer of the solar panels or batteries for further information.
INTRODUCTION
The FLEXmax 60 and FLEXmax 80 Maximum Power Point Tracking Charge Controllers *
The OutBack
Maximum Power Point Tracking Charge Controllers oer an ecient, safe, multi-stage
recharging process that prolongs battery life and assures peak performance from a solar array. Each
Charge Controller allows customized battery recharging. The Charge Controller features include:
• 80 amps maximum continuous output current up to 40° C without thermal derating for the
FLEXmax 80 and 60 amps for the FLEXmax 60
• Engineered to work with 12, 24, 36, 48, and 60VDC battery voltages
• Backlit LCD display screen with 80 characters (4 lines, 20 characters per line)
• Last 128 days of operational data are logged for review
• Voltage step-down capability allowing a higher PV array voltage conguration
• Manual and auto-equalize cycle
The following are the maximum recommended wattage for the most common solar arrays under
Standard Test Conditions (1000 watts per square meter to solar panel at 25° C or 77° F):
• 12VDC battery systems—up to 1250 watts (FLEXmax 80) or 800 watts (FLEXmax 60) of solar panels
• 24VDC battery systems—up to 2500 watts (FLEXmax 80) or 1600 watts (FLEXmax 60) of solar panels
• 36VDC battery systems—up to 3750 watts (FLEXmax 80) or 1200 watts (FLEXmax 60) of solar panels
• 48VDC battery systems—up to 5000 watts (FLEXmax 80) or 3200 watts (FLEXmax 60) of solar panels
• 60VDC battery systems—up to 6250 watts (FLEXmax 60) or 4000 watts (FLEXmax 60) of solar panels
Each Charge Controller also features Continuous Maximum Power Point Tracking (MPPT), which seeks
out the maximum power available from a solar array and uses it to recharge the batteries. Without this
feature, the solar array does not operate at the ideal operating voltage and can only recharge at the
level of the battery voltage itself. Each Charge Controller continuously tracks the array’s maximum
operating power.
This manual covers the wiring, installation, and use of the Charge Controllers, including explanations of
all the menus displayed on the LCD screen. Each Charge Controller is designed to seamlessly integrate
with other OutBack components and can be remotely monitored and congured (up to 1000 feet) by
the optional OutBack Power Systems MATE display (version 4.0.4 or greater).
FIRMWARE
This manual covers Charge Controller rmware version 001.009.001
*For simplicity’s sake, both the FLEXmax 60 and FLEXmax 80 will be referred to in this manual as“Charge
Controller or by the abbreviation “CC.”

6
OUTBACK CHARGE CONTROLLER INSTALLATION GUIDELINES AND SAFETY
INSTRUCTIONS
This product is intended to be installed as part of a permanently grounded electrical system
as shown in the system conguration sections (see pages 12-15) of this manual. The following
important restrictions apply unless superseded by local or national codes:
• The negative battery conductor should be bonded to the grounding system at only one point in the
system. If a GFP is present, the battery negative and ground are not bonded together directly but are
connected together by the GFP device when it is on. All negative conductor connections must be
kept separate from the grounding conductor connections.
• With the exception of certain telcom applications, the Charge Controller should never be positive
grounded (see page 61, Applications Notes).
• The Charge Controller equipment ground is marked with this symbol:
• If damaged or malfunctioning, the Charge Controller should only be disassembled and repaired by a
qualied service center. Please contact your renewable energy dealer/installer for assistance.
Incorrect reassembly risks malfunction, electric shock or re.
• The Charge Controller is designed for indoor installation or installation inside a weatherproof enclosure. It
must not be exposed to rain and should be installed out of direct sunlight.
For routine, user-approved maintenance:
• Turn o all circuit breakers, including those to the solar modules, and related electrical connections
before cleaning the air vents.
Standards and Requirements
All installations must comply with national and local electrical codes; professional installation
is recommended. NEC requires ground protection for all residential PV installations
DC and Battery-Related Installation Requirements:
• All DC cables must meet local and national codes.
• Shut o all DC breakers before connecting any wiring.
• Torque all the Charge Controller’s wire lugs and ground terminals to 35 inch-pounds (4 Nm).
• Copper wiring must be rated at 75° C or higher.
• Use up to 2 AWG (33.6 mm2) to reduce losses and ensure high performance of Charge Controller
(smaller cables can reduce performance and possibly damage the unit).
• Keep cables together (e.g., using a tie-wrap) as much as possible.
• Ensure both cables pass through the same knockout and conduit ttings to allow the inductive
currents to cancel.
• DC battery over-current protection must be used as part of the installation. OutBack oers both
breakers and fuses for overcurrent protection.

7
WARNING - WORKING IN THE VICINITY OF A LEAD ACID BATTERY IS DANGEROUS.
BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL OPERATION. Design the
battery enclosure to prevent accumulation and concentration of hydrogen gas in “pockets”at the top
of the enclosure. Vent the battery compartment from the highest point to the outside. A sloped lid can
also be used to direct the ow of hydrogen to the vent opening.
CAUTION - To reduce risk of injury, charge only deep-cycle lead acid, lead antimony, lead calcium,
gel cell or absorbed glass mat type rechargeable batteries. Other types of batteries may burst, causing
personal injury and damage. Never charge a frozen battery.
PERSONAL PRECAUTIONS DURING INSTALLATION
• Someone should be within range of your voice to come to your aid if needed.
• Keep plenty of fresh water and soap nearby in case battery acid contacts skin, clothing,
or eyes.
• Wear complete eye protection. Avoid touching eyes while working near batteries. Wash your hands
with soap and warm water when done.
• If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters an eye,
ood the eye with running cool water at once for at least 15 minutes and get medical attention
immediately following.
• Baking soda neutralizes lead acid battery electrolyte. Keep a supply on hand in the area of
the batteries.
• NEVER smoke or allow a spark or ame in vicinity of a battery or generator.
• Be extra cautious to reduce the risk of dropping a metal tool onto batteries. It could short-circuit the
batteries or other electrical parts that can result in re or explosion.
• Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a
battery or other electrical current. A battery can produce a short circuit current high enough to weld
a ring or the like to metal, causing severe burns.

8
max
T M
80 max
T M
60

9
The Charge Controller is designed to attach
directly to OutBack’s FLEXware 500 DC and
FLEXware 1000 DC enclosures (FLEXware 500
shown) or attach to its own charge control
brackets (FW-CCB, FW-CCB2, and FW-CCB2T).
NOTE: Install the Charge Controller in an upright
position out of direct sunlight.
To mount directly to a FLEXware DC enclosure:
• Remove the fan cover and bottom cover from
the Charge Controller.
• Insert a #10 X 3/8” sheet metal screw in the top
hole on the side of the DC enclosure. This will
act as a hanging screw for the keyhole slot at
the top center of the Charge Controller.
• Hang the Charge Controller on the top screw
and line up its bottom two screw holes with
the holes on the enclosure.
• Insert a #10 X 3/8” sheet metal screw through
each hole and tighten against the enclosure
(screws are included with each DC enclosure).
• Keep the cover o until wiring is completed.
The Conduit Nipple Assembly creates a sealed
pass-through from the Charge Controller to the
enclosure
1. Installing the Charge Controller
Mounting to Plywood
Use 1 5/8” wood screws to secure the Charge
Controller at the top slotted holes and other
interior lower holes as needed, making sure the
unit is straight and level.
DC Enclosure
Charge Controller
Bushing
Locknut
Locknut
Conduit Nipple
Screw holes
for #10 X 3/8”
sheet metal
screws
Insert screws
through
lower holes
inside Charge
Controller
To mount the
Charge Controller
to charge control
brackets, see
the individual
instruction sheet
for those brackets.