OutBack Power FLEXmax Extreme User manual

B
A
Installation and Functions
900-0151-01-00 Rev C.vsdx
©2013 OutBack Power Technologies. All Rights Reserved.

Dimensions
Height: 18.8" (47.1 cm); with fan 22.06" (56.0 cm)
Width: 8.8" (22.4 cm)
Depth to Wall: 6.0" (15.2 cm)
Mounting
The FLEXmax Extreme must be mounted upright at least 36" (91.4 cm)
above the ground or floor. Installation in shade is recommended.
Conduit hubs must be connected to the conduit before connecting to
the FLEXmax Extreme.
Clearance requirements are a minimum of 6“ (15.2 cm) above and
below the controller.
The unit can be mounted using either brackets (see A) or keyhole slots
(see B) on a secure mounting surface.
Included in Package
 FM Extreme-150VDC
 2 x Mounting Bracket
 Silicone Grease Package
 2 x Ferrite Clamp (install
on HUB/DEVICE and
RTS ports)
Provided by Customer
 PV Array
 Batteries
 MATE3
 Fan Kit
 Disconnect Devices
 Ground Fault Protection
 Wiring & Cabling
FLEXmax Extreme
Tighten all wire lugs and ground terminals
to 4 Nm (35 in-lb) torque.
Use copper wiring only (rated 90°C or
higher).
Refer to the NEC and other electrical codes
for PV array cable sizing, length, and
ampacity.
Use #4 AWG (25 mm2) (minimum) for the
controller output terminals to the batteries;
output can accept
up to #2 AWG (35 mm2).
Negative-ground installation is depicted
here; positive grounding is also permitted.
IMPORTANT: Example only.
Actual wiring may vary. All configurations must comply
with local and national electric codes. Consult the local
electric authority to ensure compliance.
Negative
Positive
Ground
DC LEGEND
¼” hex head
lag screws
Keyhole Slots
(#14 slotted wood
screws)
Securing Holes
(¼” hex head lag
screws) LED Indicators
Charging (Blue)
Status (Green/Red or Amber)
Auxiliary
Fault

1
4

2
3
Quick Start Guide
Charge Controller
PV
Combiner
Photovoltaic Array (PV)
Ground
Bus
Battery
Bank
ON
OFF
BAT
+
BAT
–
PV
–
PV
+
Battery
Disconnect
(external)
Ground Fault Protection
(not provided, required by Article 690 of NEC)
Negative
Bus
ON
OFF
PV
Disconnect
(external)
OFF
O
O
F
F
O
FAULT
PV
INACTIVE
NORMAL
PV ACTIVE
PV ARRAY
GROUND FAULT
DETECTOR
INTERRUPTER
LED Indicators
(see above)
NOTE: Overcurrent protection
for the battery circuit is to be
provided by installer.
Battery Nominal Voltages:
12-volt, 24-volt, 36-volt,48-volt, 60-volt
(-4°F to 113°F)
Environmental Specifications
NOTES:
 Unit output derated above 45°C (113°F)
 Absolute maximum temperature range is
–40°C to 60°C (–40°F to 140°F)

Accessories and Devices
900-0151-01-00 Rev C.vsdx
©2013 OutBack Power Technologies. All Rights Reserved.
FLEXmax Extreme
MATE3
System Display
and Controller
NOTE: See the FLEXmax Extreme
Owner’s Manual for details on the settings
available in the main menu.
Accessory Terminal Block
Ports and Connectors
Fan Wiring

12 3 4
5 6 7 8
IMPORTANT:
Not intended for use with
life support equipment.
OutBackPowerandtheOutBackPowerlogoaretrademarksownedandusedbyOutBackPowerTechnologies,Inc.TheALPHAlogoandthephrase“member
oftheAlphaGroup”aretrademarksownedandusedbyAlphaTechnologies.ThesetrademarksmayberegisteredintheUnitedStatesandothercountries.
Contact Technical Support:
Telephone: [phone]
Email: [email protected]
Website: www.outbackpower.com
Fan Mounting
Remote Temperature Sensor (RTS)
Battery performance changes when the temperature varies above or below room temperature
(77°F or 25°C). Temperature compensation is a process that adjusts charging to correct for these
changes. If not compensated, a battery may remain undercharged in cold temperatures and may
become overcharged when hot. Below room temperature, the charging set points are raised above
their normal values. Above room temperature the set points are lowered.
The RTS is attached to a single battery near the center of the bank. When charging, the RTS will
increase or decrease the charge voltage by a certain voltage per degree Celsius per battery cell.
The compensation value (the “slope”) is adjustable from 2 mV to 6 mV. Most batteries use a value
of 5 mV.
This setting affects the Absorbing and Float set points. Equalization is not compensated in the
FLEXmax Extreme.
Total compensation is determined by measuring the
number of degrees C above or below 25. This number
is multiplied by the number of 2-volt battery cells and
the slope value.
SunSpec Modbus
Interface
External Fault Terminals
(see page 1 for GFDI function)
GFDI or other shutdown functions can be used for multiple
controllers. Terminals 2 and 4 are wired to the next controller
as shown.
OFF
O
O
F
F
O
FAULT
PV
INACTIVE
NORMAL
PV ACTIVE
PV ARRAY
GROUND FAULT
DETECTOR
INTERRUPTER
Controller 1 Controller 2
12 3 4
GFDI

Battery Sense Terminals
These terminals monitor battery voltage more accurately than the main cable connections.
A twisted-pair cable is recommended. The connections are made directly on the battery
terminals. NOTE: Overcurrent protection devices are not shown.
8

7
DC Terminals
PV+ PV- BAT- BAT+
Auxiliary (AUX)
Terminals
Used for diversion control
and other functions
6

5
Cells
(Volts)
Slope
Value Temp
25°C
± Calculation
Vdc
Adjust
6 (12V) 5 mV 8°C -17 6 x 0.005 x 17 +0.5 Vdc
12 (24V) 3 mV 36°C +11 12 x 0.003 x 11 -0.4 Vdc
18 (36V) 5 mV 26°C +1 18 x 0.005 x 1 -0.1 Vdc
24 (48V) 6 mV 0°C -25 24 x 0.006 x 25 +3.6 Vdc
30 (60V) 2 mV 37°C +12 30 x 0.002 x 12 -0.7 Vdc
Examples of Compensation
Install ferrite
clamps on
these cables
for EMI
suppression
AXS Card MATE3 RTS
Recommended
protection for sense
conductors is:
 Fast-acting device
 80 Vdc or greater
 1 A or smaller
 Cold resistance
10 ohms or less