OutBack Power FLEXmax Series User manual

Board Replacement Instructions for
FLEXmax Charge Controllers
Including Control Board, Button Board,
Power Board, and FLEXmax 60 Fan

About OutBack Power Systems
OutBack Power Systems is a leader in advanced energy conversion technology. Our products include
true sine wave inverter/chargers, maximum power point tracking charge cont rollers, syst em
communicat ion component s, as well as breaker panels, breakers, accessories, and assembled syst ems.
Contact Information
Tel ephone: +1.360.435.6030 (North America)
+1.360.618.4363 (Technical Support)
+1.360.435.6019 (Fax)
+34.93.654.9568 (Barcelona, Spain)
Address: North America
19009 62nd Avenue NE
Arlington, WA USA
E-mail: [e-mail]
Web Site: www.outbackpower.com
Disclaimer
U N L ESS SPECI FI CA L L Y A GREED TO I N W RI T I N G, O U TBA CK PO WER SYSTEM S:
( a ) M A KES N O W A RRA N TY A S TO TH E A CCU RA CY, SU FFI CI EN CY O R SU I T A BILITY 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.
Notice of Copyright
Board Replacement Inst ruct ions for FLEXmax Charge Cont rollers © December 2009 by OutBack Power
Syst ems. Al l Ri ght s Reserved .
Trademarks
Out Back Power is a registered t rademark of Out Back Power Syst ems.
Dat e an d Rev i si o n
December 2009, Revision A
Part Number
900-0054-01-00 Rev A

900-0054-01-00 Rev A 1
Important Safety Instructions
READ AND SAVE THESE INSTRUCTIONS!
This manual contains important safety instructions for replacing parts on the FLEXmax Series Charge
Cont rollers. Read all inst ruct ions and caut ionary markings on the FLEXmax Series Charge Cont rollers
and on any accessories or addit ional equipment included in the inst allat ion. Failure t o adhere t o t hese
instructions could result in severe shock or possible electrocut ion. Exercise extreme caution at all
times to prevent accidents.
Sy m b o l s Used
Sy m b o l Descr i p t i o n
Ground
AC Current
DC Current
Single-Phase
Si n e W a v e
WARNI NG: Hazar d t o Hu man Li f e
This type of not at ion indicat es t hat the hazard could be harmful t o human life.
CAUTI ON: Hazar d t o Equ i p m en t
This type of not at ion indicat es t hat t he hazard may cause damage t o t he equipment .
IMPORTANT:
This type of notation indicates that the information provided is i mp ort ant t o
the inst allation, operation and/ or maint enance of the equipment . Failure t o
follow the recommendations in such a notation could result in voiding the
equipment warranty.
Audience
These instruct ions are for use by qualified personnel who meet all local and governmental code
requirements for licensing and training for the installation of electrical power systems wit h AC and DC
voltage up t o 600 volts.

Important Safety Instructions
2 900-0054-01-00 Rev A
Definit ions
Table 1 Ter ms and Acronyms
Acronym Definition
Button Board Flat board containing the push-buttons and LCD.
Control Board Narrow circuit board containing the unit’s programming.
FET Field Effect Transist or. The FETs used for power swit ching in t he FLEXmax are
classified as MOSFETs (Met al-Oxide-Semiconduct or Field-Effect Transistors).
LCD Liquid-C
rystal Display; refers t o t he FLEXmax dat a readout .
Power Board Large circuit board containing the unit’s power-switching circuitry.
PV Photovoltaic; refers to the photovoltaic panels or modules used with the FLEXmax.
Per sonal Saf et y
WARNING: Personal Injury
Use standard safet y equipment such as safet y glasses, ear prot ection, steel-toed
safet y boot s, safet y hard hats, et c. as prescribed by t he Occupational Safety and
Healt h Association (or ot her local codes) when working on t his equipment.
Use standard safet y practices when working wit h elect rical equipment (e.g., remove
all jewelry, use insulated tools, wear cotton clothing, etc.)
Never work alone when installing or servicing t his equipment. Have someone
nearby that can come to your aid if necessary.
PV Saf et y
WARNING: Shock Hazar d
Phot ovoltaic (PV) arrays can be energized wit h minimal ambient light available.
Therefore to ensure a safe disconnect from the syst em, be sure t o install a PV disconnect,
breaker, or accessible fuse box (depending on local code requirement s).
CAUTI ON: Eq u i p men t Dam ag e
PV Arrays must be wired with correct polarity (positive-to-positive, negative-to-
negative). Connecting the cables incorrectly can damage or dest roy t he equipment .

Important Safety Instructions
900-0054-01-00 Rev A 3
Eq u i p m en t Saf et y
CAUTION: Eq u i p m en t Damag e f r o m St at i c Di sch ar g e
A static-safeguarded workspace should be used to preserve the FLEXmax controller’s
static-sensitive components during the removal and installation procedure. This
includes grounding yourself and your workspace to remove any possi b le st at ic charg e.
Practices that will help avoid static include standing on a concrete floor, preferably on a
rubber floor mat , doing t he repairs on a met al workbench, and avoiding static-causing
synthetic clothing.
WARNI NG: Let h al Vo l t ag e
Review the system configuration to identify all sources of energy. (PV arrays can be
energized with minimal ambient light available.) Ensure ALL sources of power are
disconnected before performing any installation or maintenance on this equipment.
Confirm that the terminals are de-energized using a validat ed voltmet er (rated for a
minimum 1000 Vac and 1000 Vdc) to verify the de-energized condition.
WARNING: Burn Hazard
Int ernal parts can become hot during operation. Do not remove the cover during
operation or touch any int ernal part s. Be sure t o allow t hem sufficient time to cool down
before at t empt ing t o performance any maintenance.
WARNING: Fi r e Hazar d
Do not place combustible or flammable materials wit hin 12 feet (3.7 m) of
the equipment .
Use only t he recommended cable sizes (or great er) for AC and DC conductors in
compliance with local codes. Ensure all conductors are in good condition. Do not
operate the unit with damaged or substandard cabling.
CAUTI ON: Eq u i p men t Dam ag e
Do not perform any servicing ot her t han t hat specified in t hese instructions unless
qualified t o do so and have been instructed t o do so by Out Back Power Syst ems
Technical Support personnel.
On l y u se co m pon ent s or accessori es reco m men d ed o r sol d b y Ou t Back Power
Systems or its authorized agents.
Thoroughly inspect the equipment prior to energizing. Verify that no tools or
equipment have been inadvertently left behind.
Ensure clearance requirements are strict ly enforced and t hat all vents are clear of
obstructions that can prevent proper airflow around or through the unit.

Important Safety Instructions
4 900-0054-01-00 Rev A
This page intentionally left blank.

900-0054-01-00 Rev A 5
Table of Contents
Important Safety Instructions ........................................................................1
Symbols Used ........................................................................................................................................................................1
Audience .................................................................................................................................................................................1
Definit ions...............................................................................................................................................................................2
Personal Safet y......................................................................................................................................................................2
General Safet y .......................................................................................................................................................................2
Equipment Safet y.................................................................................................................................................................3
PV Safet y ......................................................................................................................Error! Bookmark not defined.
Introduction.................................................................................................7
Overview..................................................................................................................................................................................7
Tools Required.......................................................................................................................................................................8
Preliminary..............................................................................................................................................................................8
Summary List of Inst ruct ions.............................................................................................................................................................8
FLEXmax Charge Controller Disassembly........................................................9
Removing t he FLEXmax 80 Fan Cable ..........................................................................................................................9
Removing Chassis Screws .............................................................................................................................................. 10
Removing t he Heat Sink ................................................................................................................................................. 11
Removing t he FET Bar...................................................................................................................................................... 12
Separat ing t he Heat Sink from t he Power Board ................................................................................................... 14
Fan and Button Board .................................................................................17
Replacing t he FLEXmax 60 Fan .................................................................................................................................... 17
Removing t he Fan ...............................................................................................................................................................................17
Replacing t he Fan ...............................................................................................................................................................................17
Fan Test Procedures......................................................................................................................................................... 18
Replacing t he But t on Board .......................................................................................................................................... 19
Control Board and Power Board...................................................................23
Removing t he Cont rol Board ........................................................................................................................................ 23
Replacing t he Cont rol Board or Power Board ......................................................................................................... 24
Reassembly................................................................................................27
Reseat ing t he Cont rol or Power Board ...................................................................................................................... 27
Reconnect ing t he Heat Sink t o t he Power Board .................................................................................................. 28
Reconnect ing t he Heat Sink t o t he Chassis ............................................................................................................. 30
Reinstalling FLEXmax 80 Fan Plug .............................................................................................................................. 31
Syst em Funct ional Test ................................................................................................................................................... 32
Li st of Figures
Fi gure 1 Comp onent s ........................................................................................................................................................7
Fi gure 2 Charge Cont roller “At Rest” ............................................................................................................................8
Fi gure 3 Removing Fan Cover.........................................................................................................................................9

Tabl e of Cont ent s
6 900-0054-01-00 Rev A
Fi gure 4 Removing Cable Jack........................................................................................................................................9
Fi gure 5 Back Screw Removal ...................................................................................................................................... 10
Fi gure 6 Side Screw Removal (part 1)........................................................................................................................ 10
Fi gure 7 Side Screw Removal (part 2)........................................................................................................................ 10
Fi gure 8 Heat Sink Removal........................................................................................................................................... 11
Fi gure 9 FET Bar Screw Removal ................................................................................................................................. 12
Fi gure 10 FET Bar Removal .............................................................................................................................................. 12
Fi gure 11 Freeing t he FET from t he Insulator .......................................................................................................... 13
Fi gure 12 Freeing t he FET wit h Pliers .......................................................................................................................... 13
Fi gure 13 Bot tom/ Cradle Screw Removal .................................................................................................................. 14
Fi gure 14 Removing Remaining Screws..................................................................................................................... 14
Fi gure 15 Heat Sink Removal .......................................................................................................................................... 15
Fi gure 16 Heat Sink Connect ed t o Power Board ..................................................................................................... 15
Fi gure 17 Cable Removal ................................................................................................................................................. 16
Fi gure 18 Power Board - Top View ............................................................................................................................... 16
Fi gure 19 Fan Removal ..................................................................................................................................................... 17
Fi gure 20 Fan Replacement ............................................................................................................................................ 17
Fi gure 21 Fan Test Procedure......................................................................................................................................... 18
Fi gure 22 Locat ing t he But t on Board .......................................................................................................................... 19
Figure 23 Disconnect ing t he Fan .................................................................................................................................. 19
Fi gure 24 Exposing the Button Board Mounting Peg............................................................................................ 20
Fi gure 25 Gripping t he Push-nut .................................................................................................................................. 20
Fi gure 26 Deforming t he Push-nut .............................................................................................................................. 21
Fi gure 27 Removing Push-nut ....................................................................................................................................... 21
Fi gure 28 Removing t he But t on Board ....................................................................................................................... 21
Fi gure 29 Insert ing t he New But ton Board ................................................................................................................ 22
Fi gure 30 Insert ing New Push-nut ................................................................................................................................ 22
Fi gure 31 Reconnect ing t he Fan ................................................................................................................................... 22
Fi gure 32 Lift ing t he Induct or Wires ............................................................................................................................ 23
Fi gure 33 Sliding t he Cont rol Board Out .................................................................................................................... 23
Fi gure 34 Bent Pin on Cont rol Board ........................................................................................................................... 24
Fi gure 35 Insert ing Cont rol Board ................................................................................................................................ 24
Fi gure 36 Pins and Connectors...................................................................................................................................... 24
Fi gure 37 FETs and Sil-Pad Insulat or on Heat Sink.................................................................................................. 25
Fi gure 38 Reseat ing Cont rol Board .............................................................................................................................. 27
Fi gure 39 Placing Induct or Wires .................................................................................................................................. 27
Fi gure 40 Reinst alling Ribbon Cable............................................................................................................................ 28
Fi gure 41 Gent ly Pulling On Ribbon Cable ................................................................................................................ 28
Fi gure 42 Inst alling and Tight ening Screws.............................................................................................................. 28
Fi gure 43 Aligning FETs and Inst alling t he FET Bar................................................................................................. 29
Fi gure 44 Inst alling FET Bar Screws.............................................................................................................................. 29
Fi gure 45 Reinstalling t he Heat Sink ont o t he Chassis.......................................................................................... 30
Fi gure 46 Replacing t he Chassis Screws..................................................................................................................... 30
Fi gure 47 Reinst alling Cable Jack .................................................................................................................................. 31
Fi gure 48 Reinst alling Cable Plug ................................................................................................................................. 31
Fi gure 49 Fan Cover ........................................................................................................................................................... 31

900-0054-01-00 Rev A 7
Introduction
Overview
This step-by-step guide illustrates the replacement of the Control Board, Power Board and Button Board
for all FLEXmax Series Charge Controllers. It also illustrates t he replacement of t he Fan for FLEXmax 60
charge cont rollers only. It does not cover replacing t he fan in a FLEXmax 80 charge controller.
A static-safeguarded workspace should be used to preserve the FLEXmax controller’s static-sensitive
component s during t he removal and inst allat ion procedure. See t he sect ion t itled Equipment Safet y on
page 3 for more specific inst ruct ions.
Please review this guide and familiarize yourself with the complete repair procedure. OutBack technical
support is also available at [phone] or [e-mail].
CAUTION: Eq u i p m en t Dam ag e
This procedure involves sensitive electronics which must be handled gently
and carefully during removal and installation. Applying excess force can
damage the components and cause the FLEXmax controller to malfunction.
Figure 1 Components
Pow er Boar d
Control Board
But t on Boar d
(front )
Pow er Boar d
(back)

Introduction
8 900-0054-01-00 Rev A
Tools Requi r ed
Phillips Screwdriver
Fl at Scr ew d ri ver
Long-Nose Pliers
Diagonal Wire Cutters (not shown)
Preliminary
Figure 2 Charge Controller “At Rest”
NOTE: As many as 33 screws may be removed during t his procedure. Be sure to put them aside in the
order they are removed.
Summary List of Instructions
The following is a list of the instructions that are included in this document.
For instructions for Removing the FLEXmax 80 Fan Cable, see page 9.
For instructions for Di sassembl i ng t he Chassi s, st art on page 10.
For instructions for Removing the Heat Sink, see page 11.
For instructions for Rem o v i ng t he FET Bar , see page 12
For instructions for Sep ar at i n g t h e Heat Si n k f r o m t h e Po w er Bo ar d , see page 14.
For instructions for Replacing the Fan and Button Board, see page 17.
For instructions for Replacing the Control Board and Power Board, see page 23.
For instructions for Reassembling the Charge Cont roller, see page 27.
WARNING: Shock Hazar d
If the unit has been in use, power can
still be present even after the unit has
been disconnect ed.
Remove all electrical connections
from t he FLEXmax cont roller.
Allow the cont roller to “rest ” for
approximately ten minutes to fully
discharge the PV input capacit ors.

900-0054-01-00 Rev A 9
FLEXmax Charge Controller Disassembly
If you have a FLEXmax 60, proceed wit h removing t he chassis screws as described on page 10.
Removing the FLEXmax 80 Fan Cable
Figure 3 Removing Fan Cover
Figure 4 Removing Cable Jack
1. Remove the machine screw that secures the
fan cover.
2. Press bot h sides of t he fan cover t o release t he
tabs. Pull up on the cover.
3. Remove the fan cover once the tabs have
cleared t heir slot s. Keep t he fan cover and
machine screw in a safe place.
4. Note the fan cable plugged into the jack.
6. Not e t he jack for t he fan
cable, which is snapped
int o t he fan bracket.
5.
Remove t he fan cable
by squeezing the tabs
on eit her side of the
plug. You can do this
with your fingers, or
with a pair of long-
nose
p
liers.
Pr ess
7. Remove the cable jack by
pinching the retaining
tabs on either side of the
jack, using long-nose
pliers. The jack can be
taken out through the
rear of t he bracket .
Press

Disassembly
10 900-0054-01-00 Rev A
Removing Chassis Screws
1. Set t he unit on it s side t o remove t he t wo back screws. Keep t he screws and st ar washers together.
Fi gur e 5 Back Scr ew Removal
2. With the unit still on its side, remove two side screws.
Figure 6 Side Screw Removal (part 1)
3. Set the unit on its other side and remove the two remaining screws.
Figure 7 Side Screw Removal (part 2)
The heat sink can now be removed from the chassis.

Disassembly
900-0054-01-00 Rev A 11
Removing the Heat Sink
Fi gur e 8 Heat Si nk Removal
1. To remove the heat sink, grip it along
each flank and raise its lower end.
2. Slide t he control board past t he
grounding lug. Make certain the power
board is raised high enough to avoid
the grounding lug
3. Slide t he heat sink away from
the chassis.
Grounding lug

Disassembly
12 900-0054-01-00 Rev A
Remo v i n g t h e FET Bar
1. Set the unit on its side as shown in Figure 9 and remove the 12 screws securing the FET mounting bar
t o t he heat sink.
Fi g u r e 9 FET Bar Scr ew Remov al
Fi gur e 10 FET Bar Removal
Continued on next page.
2. Remove the FET mount ing bar.

Disassembly
900-0054-01-00 Rev A 13
Fi gur e 11 Fr eei n g t he FET f r om t he In sul at or
Fi gur e 12 Fr eei ng t h e FET wi t h Pl i er s
3. Lift t he t ab of t he FETs off
from the Sil-Pad (gray
insulator pad) using your
finger and t humb.
CAUTION! Do not att empt
to remove the FETs from
the power board. The FET
pins are soldered t o t he
board.
If t he FETs are difficult to
break free, rock the tabs
gently with long-nose pliers
until they lift off the Sil-Pad.

Disassembly
14 900-0054-01-00 Rev A
Sep ar at i n g t h e Heat Si n k f r o m t he Po w er Boar d
Place the charge cont roller upside down and remove t he seven screws circled in whit e in Figure 13, on
t he left . Do not remove t he four cradle screws and washers ident ified with t he X symbo l in Fi g ur e 13 on
the right.
Figure 13 Bottom/Cradle Screw Removal
Figure 14 Removing Remaining Screws
Continued on next page.
Do NOT Remove the screws
ident ified here with an “X”.
2. Remove the last three (3)
remaining screws, circled
in whit e in Figure 14.

Disassembly
900-0054-01-00 Rev A 15
Figure 15 Heat Sink Removal
Fi g u r e 16 Heat Si n k Co n n ect ed t o Po w er Boar d
Continued on next page.
3. With all the screws
removed, the heat sink can
be separated from the
power board. Set t he unit
upright and carefully pry
and lift t he heat sink off t he
p
ower board.
CAUTI ON! Do not force t he
removal. The heat sink is
connected to the power board
by a ribbon cable from t he
control board.

Disassembly
16 900-0054-01-00 Rev A
Fi gur e 17 Cab l e Removal
Figure 18 Power Board - Top View
For instructions on Rep l aci ng t h e Fan i n a FLEXm ax 60 Ch ar g e Co n t r o l l er , see page 17.
For instructions on Replacing the Button Board, see page 19
For instructions on Replacing the Control Board and Power Board, see page 24.
For instructions on Reassembling the Controller, see page 27.
4. Set t he heat sink on it s side and t he
power board down flat.
5. Remove the ribbon cable connect or
from t he LCD connect or.
The connector may have a dollop of
silicone sealant on it which must be
peeled off. When reassembling the
controller, it is recommended to apply
more silicone sealant if available.)
If you have a FLEXmax 60 controller and
are only replacing the fan, it is not
necessary t o remove t he cable.

900-0054-01-00 Rev A 17
Fan an d Bu t t on Boar d
Replacing the FLEXmax 60 Fan
Disassemble the controller as described on page 9 through page 16.
Remo v i n g t h e Fan
Fi gur e 19 Fan Removal
Rep l aci n g t h e Fan
Fi gur e 20 Fan Rep l acemen t
If no ot her repairs are necessary, see t he reassembly inst ruct ions on page 27. After reassembly, return to
page 18 for testing procedures.
To remove the f an:
1.
Disconnect the connector from the LCD. The
connector may have a dollop of silicone sealant to
ensure a firm connection. This should be peeled or
pulled off.
2.
Remove the four screws holding t he fan in place.
Fan Scr ews (x 4) Fan Connector
NOTE: The ribbon cable is shown disconnect ed
in this illustration for convenience only.
Silicone Sealant
Silicone Sealant
Black Wi r e
Red Wi r e
Scr ew Po st
Scr ew Po st To r ep l ace t he f an :
1. Insert the new fan aligning the mounting holes to
the heat sink.
2. Align t he connect or so t hat t he red wire of t he
connect or lines up wit h the positive (+) pin and the
black wire wit h t he negative (-) pin as shown in
Figure 20. Position the wires between the
screw p ost s.
3. Plug in the connector.
4. Tight en t he screws so t he fan is snug against the
heat sink.
5. Reapply silicone sealant to secure the connector
(if possible).

Fan and Button Board
18 900-0054-01-00 Rev A
Fan Test Pr ocedur es
Test t he fan using t he following procedures:.
Figure 21 Fan Test Procedure
You may now apply PV input to the FLEXmax Charge Controller to resume charging.
3. Check t he LCD. The operat ional mode on
the FLEXmax screen should change from
“Sleeping” t o “BatTmpErr”. The fan will
begin running.
1. Remove the Remote Temperature
Sensor (RTS) jack from t he port , if
present.
2. Insert a flat screwdriver inside the RTS
port. Gently press the screwdriver tip
against all the pins at once. This will
create a false signal t hat will t urn t he
fan on.
4. Once the fan operation has been verified,
remove t he screwdriver from t he RTS port
and reconnect t he RTS, if available.
IN 005 V OUT 25.0 V
00.0 A 00.0 A
Watts 0000 AuxOff
kWHrs 00.0 BatTm
p
Err
LCD Display
RTS Po r t