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Alpha Group OutBack Power FLEXmax Extreme Series, Owner'S Manual

The Alpha Group OutBack Power FLEXmax Extreme Series is an advanced solar charge controller designed for maximum efficiency and durability. To learn how to get the most out of your device, make sure to download the free Owner's Manual from our website manualshive.com. It contains detailed instructions and insights for optimal performance.

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900-0150-01-00 Rev A 

1 

 

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

 

Summary of Contents for OutBack Power FLEXmax Extreme Series

Page 1: ...FLEXmax Extreme Charge Controller Owner s Manual ...

Page 2: ...y Telephone 1 360 435 6030 1 360 618 4363 Technical Support 1 360 435 6019 Fax 49 9122 79889 0 49 9122 79889 21 Fax Email Support outbackpower com Website http 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 DOC...

Page 3: ...erminals 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...

Page 4: ... 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...

Page 5: ...nitions 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 ...

Page 6: ...Table of Contents 4 900 0150 01 00 Rev A THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 7: ...les 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 M...

Page 8: ... 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...

Page 9: ...3 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 Figure 2 FLEXmax Extreme Dimensions Width 8 8 22 4 cm Depth 6 0 15 2 cm Height 18 6 47 1 cm Wiring box height 4 4 11 2 cm Wiring box opening width 6 ...

Page 10: ... 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 t...

Page 11: ...nting 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 NOTE ...

Page 12: ...o 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 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 comple...

Page 13: ...re 6 Installing the AXS Card 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 Installation is complete See the AXS Port SunSpec Modbus Interface Owner s Manual for information on use Screws 2 Insert the AXS Card onto the rails on each side of the compartment Slide it in until the card presses...

Page 14: ...nd 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...

Page 15: ...un 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 co...

Page 16: ... Figure 8 Wiring Diagram Single Charge Controller with PV Array Figure 9 Wiring Diagram Single Charge Controller Positive Ground NOTE Ground Fault and system specific wiring not shown NOTE Ground Fault and system specific wiring not shown ...

Page 17: ... 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 NOTE Ground Fault and system specific wiring not shown ...

Page 18: ... 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 Bloc...

Page 19: ...nt 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 Figure 13 AUX Vent Fan Figure 14 AUX Diversion Control In this example the AUX output directly drives a 12 volt vent fan The and wires on the fan are connected to terminals and the AUX and A...

Page 20: ...ntroller screen See Figure 27 on page 30 This reading is still used to adjust the FLEXmax Extreme charging 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 th...

Page 21: ...d controller is present its terminals and should have wires connecting to terminals and on the second controller and so on See Figure 17 Additional controllers can be added as needed If the terminals are not in use this function should be disabled This is performed by directly shorting terminals and with a small jumper wire IMPORTANT The FLEXmax Extreme will not function unless either the OutBack ...

Page 22: ...en run from terminal to the other side of the GFDI In addition Terminal on Charge Controller A has been connected to terminal on Charge Controller B Similarly Terminal on Charge Controller A has been connected to Terminal on Charge Controller B This 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 ...

Page 23: ...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 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 vo...

Page 24: ...ch 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 ...

Page 25: ...lluminate 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...

Page 26: ...ge Name Color Pattern Bulk Absorb Float EQ Other Charge Off Off N A 10 W PV available Battery rest Blue Solid X X Blue Flash long see page 26 X Blue Flash short see page 27 X Float Status 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 ...

Page 27: ...x Extreme Battery Charging and Modes Bulk This is a Maximum Power Point Tracking mode which harvests the maximum wattage available from the PV array The controller is trying to regulate the battery voltage towards the Absorb Voltage set point Normally the charge controller enters this mode at the beginning of the day or when a new charge cycle begins The controller may also enter this stage if the...

Page 28: ... charge stage The MATE3 displays Bulk as shown on page 25 The internal timer may not always begin at zero if the last charge was interrupted or ended early If the batteries drop below the voltages noted on Table 3 the timer will begin counting down toward zero This adds to the duration of the next Absorption stage If the timer reaches zero it will last for the full duration of the Absorb time sett...

Page 29: ...ent variable voltage The mode will still show Float Figure 23 LED Indicators Float EQ The MATE3 displays this message if the charger is in a cycle of equalization See page 72 for an explanation of equalization Before equalizing battery loads should be turned off and the battery should be charged so the charge controller can quickly reach the Equalization Voltage set point See page 38 Otherwise the...

Page 30: ...nergy or Sleep mode If the Voc is less than battery voltage the controller is sleeping This is normal at night The threshold for Sleep mode is settable See page 37 Above battery Low light or Snooze mode Voc is greater than battery voltage but not enough array current is available for charging This is normal in the morning evening or in heavy clouds low light The threshold for Snooze mode is settab...

Page 31: ...nit 24 Vdc Unit 0 2 Vdc 36 Vdc Unit 0 3 Vdc 48 Vdc Unit 0 4 Vdc Battery Status GREEN 12 5 Vdc or higher 25 0 Vdc or higher 37 5 Vdc or higher 50 0 Vdc or higher ACCEPTABLE YELLOW 11 5 to 12 4 Vdc 23 0 to 24 8 Vdc 34 5 to 37 2 Vdc 46 0 to 49 6 Vdc MARGINAL RED 11 4 Vdc or lower 22 8 Vdc or lower 34 2 Vdc or lower 45 6 Vdc or lower LOW NOTES Gaps in the table higher voltage units are due to the reso...

Page 32: ... information over time The graphs include inverter and charger wattage power imported from an AC source battery voltage and others These screens are all shown beginning on page 34 Port cycles through each device connected to the network If more than one charge controller is installed in the system pressing the Port soft key will cycle through each controller Back returns to the previous screen Scr...

Page 33: ...higher numbers or greater accumulations Soft Keys Next proceeds to the Error Datalog and Temps screens see pages 32 and 33 Reset proceeds to the Reset screens for the items under Maximum and Total See Figure 29 Back returns to the previous screen Port cycles through each device connected to the network Screen Items The items under Maximum are not incremental They are updated only if a higher value...

Page 34: ... Enclosure Over Temp error 130 78 Output derates 86 73 Fan turns on 76 72 Fan turns off 61 67 Soft Keys DataLog proceeds to the Datalog screen see page 33 Temps proceeds to the Temps screen see Figure 31 Back returns to the previous screen Port cycles through each device connected to the network Screen Items VOC Too High The PV array Voc has exceeded 145 Vdc and has shut down This error can clear ...

Page 35: ...Soft Keys Day advances the display forward by a single day If the display reads Today it does nothing Day advances the display backward by a single day and will display the selected date Back returns to the previous screen Port cycles through each device connected to the network Current Date Screen Items The upper left corner shows the date of the selected Datalog screen The current Datalog screen...

Page 36: ...tery voltage over time Figure 34 Battery Graph The Next soft key brings up a screen showing changes in PV voltage over time Figure 35 PV Graph Continuing to press the Next soft key will proceed through the same graphs again from the beginning This axis shows PV voltage This axis shows date and time in 6 hour increments This axis shows battery voltage This axis shows date and time in 6 hour increme...

Page 37: ...gs The Main Menu shown below is accessed with the LOCK button and a password Use the MATE3 s control wheel to move up and down between menus or options within a menu Use the center button on the control wheel to make a selection See the MATE3 manual for more information Some menus may not be accessible if the user access levels are restricted Figure 36 Menu Structure ...

Page 38: ...cycle which utilizes multiple settings This menu controls the voltages and timers for the battery charger See page 71 for an explanation of the three stage cycle and a description of individual stages See page 25 to see what indicators and messages appear at each stage Figure 37 Charger Absorb Time is adjustable from 0 to 24 hours consult the battery manufacturer s recommendations When the Absorb ...

Page 39: ...st the upper range limit of the charge controller s maximum power point MPP tracking The default Max MPP voltage limit is set at 90 of the Voc and should not normally be adjusted for a PV array If necessary the adjustable limits are 80 85 90 and 99 of the Voc Min optimizes the tracking window for MPPT The default setting of Half establishes the lower limit of this window as one half the Voc The Mi...

Page 40: ... advisability Always follow manufacturer recommendations for equalization Equalization is a controlled overcharge that is part of regular battery maintenance See page 72 for an explanation of equalization The Battery Equalize screen allows the user to control the settings for the equalization process Figure 40 Battery Equalize Equalization can be triggered manually See pages 27 and 72 Equalization...

Page 41: ...ondary control circuit essentially a small power supply that provides a 12 Vdc output current up to 250 milliamps or 3 watts to an isolated load It can be ON with 12 Vdc available at the output or OFF with 0 Vdc at the output It can also be set to AUTO In this setting the AUX output turns on or off according to specific criteria such as high or low voltage In some cases such as the PV Trigger Nigh...

Page 42: ...the AUX output will remain active for another 15 seconds It will then deactivate Purpose This mode is intended to operate a vent fan to ventilate hydrogen gas from a battery enclosure Enable Voltage Not Available PV Trigger Function When the Enable Voltage set point is exceeded the AUX output will activate Once the voltage decreases below the set point the output will remain active for the duratio...

Page 43: ...Low Battery Voltage Active Low only Deactivates the output when the voltage drops below the set point for a set amount of time Night Light Function When the battery voltage drops below the Threshold voltage set point for the Hysteresis Time the AUX output changes states and remains in that state for the ON Time setting Purpose This mode is intended to illuminate a user provided low wattage light f...

Page 44: ...ctive Low Activates when battery voltage drops below the set point deactivates when the voltage exceeds the set point Diversion Solid St Function When the battery voltage increases the AUX output goes into pulse width modulation at a rate of 200 Hz The response is relative to the charger s present stage of operation The voltage must exceed the charger setting Absorb Float or EQ by the value of the...

Page 45: ...ntrolled by the AUX output Any loads not controlled this way may continue discharging the batteries Disconnect Re Connect Disconnect Delay Not Available Remote Function An OutBack system display such as the MATE3 can send external commands to control the AUX output See the system display manual for details Purpose This mode is intended to allow functions such as AGS to control the AUX output accor...

Page 46: ...MATE3 Screens 44 900 0150 01 00 Rev A Figure 43 Wiring Diagram for Diversion Load and AUX Wiring ...

Page 47: ...ments in places other than the charge controller s terminals may differ regardless of calibration For example it is possible to get a different reading at the charge controller s DC terminals than on the batteries Connection problems corrosion and the effects of induction and resistance may all result in voltage differences If this occurs it is an issue with the system not the charge controller Ca...

Page 48: ...layed along with that of the MATE3 and other devices To access the Reset to Factory Defaults menu 1 Access the main menu as shown on page 35 2 Select the Settings menu This option may be highlighted by default 3 Select Charge Controller in the device Settings menu 4 Select the Reset to Factory Defaults menu 5 Use the soft keys to select No or Yes If No is selected the screen returns to the Charge ...

Page 49: ...ighlighted on the list 6 After saving the data log is complete press Continue to return to the Upload and Save Data Log screen To save a new data log over the name highlighted on the list 1 Use the control wheel to scroll through the list 2 When the name to be replaced is highlighted press Save 3 Wait for the message confirming that the profile has been saved to the SD card 4 Press Continue to ret...

Page 50: ... Figure 49 Data Log Example for the Charge Controller Date AH Kwh Max Amps Max Watts Absorb Time Float Time Min Battery V Max Battery V MAX Voc 6 13 11 0 0 1 2 29 0 00 0 00 24 1 29 1 122 6 12 11 38 0 9 5 5 143 0 00 0 00 24 1 29 122 6 11 11 32 0 8 5 6 144 0 00 0 00 24 1 28 7 120 6 10 11 9 0 2 3 5 89 0 00 0 00 24 1 28 9 120 6 09 11 31 0 7 6 8 173 0 00 0 00 24 1 28 8 119 NOTE This header line is NOT ...

Page 51: ...t the bottom of the screen order Figure 50 Summary Screens Charge Controller Summary Screen FLEXnet DC Summary Screen 1 FLEXnet DC Summary Screen 2 FLEXnet DC Summary Screen 3 FLEXnet DC Summary Screen 4 Inverter Charger Summary Screen If a FLEXnet DC is installed in the system the following summary screens will be available If the FN DC is not installed this will be the first Summary Screen The C...

Page 52: ...e are the same as those displayed in the Status Menu of the MATE3 See page 30 for descriptions charger mode Bulk Absorption Float Silent Equalization aux relay mode vent fan pv trigger error output night light float diversion relay diversion solid st low batt ery disconnect remote aux relay state This screen indicates if the AUX output is ON OFF STATUS choose device FX CC DC MAIN MAIN 1 35 04p SUM...

Page 53: ...STATUS CC METER P00 charger 0 w watts DOWN UP TOP PORT STATUS choose device FX CC DC MAIN MAIN 1 35 04p SUM STATUS SETUP ADV STATUS CC PAGE1 MODE METER SETPT PG2 STATUS CC METER P00 charger 0 0 kwh kwhrs DOWN UP TOP PORT Navigation for STATUS CC METER STATUS returns to the CC PAGE1 screen DOWN moves to the next menu item in the diagram UP moves to the previous menu item in the diagram TOP returns ...

Page 54: ... shown PORT directs the MATE to read the next device port on the HUB Charge Controller SETPT set point Screens The SETPT screens display the current settings for the FLEXmax Extreme battery charger as described on page 71 Absorb Float STATUS CC SETPT P00 end of set point menu UP TOP STATUS STATUS choose device FX CC DC MAIN MAIN 1 35 04p SUM STATUS SETUP ADV STATUS CC PAGE1 MODE METER SETPT PG2 ST...

Page 55: ...ATUS STATUS choose device FX CC DC MAIN MAIN 1 35 04p SUM STATUS SETUP ADV STATUS CC PAGE1 MODE METER SETPT PG2 STATUS CC PAGE2 PG1 LOGS STAT MAIN STATUS CC LOG1 P00 TODAY 0 AH 00 0 kWH 21Vp 00 0Ap 0 00kWp DOWN DAY DAY PORT STATUS CC LOG2 P00 TODAY battery max 14 5V min 14 4V DOWN DAY DAY PORT STATUS CC LOG3 P00 TODAY absorb float 00 00 00 00 DOWN DAY DAY PORT Charge Controller Logs The LOG screen...

Page 56: ...STATUS CC STAT P00 maximum battery 15 1 Vdc DOWN UP STATUS CC STAT P00 voc 21 0 vdc STATUS CC STAT P00 max voc 21 0 vdc STATUS CC STAT P00 maximum wattage 400 W DOWN UP TOP STATUS CC STAT P00 total kWH DC 307 STATUS CC STAT P00 total kAH 25 6 DOWN UP TOP Charge Controller Stats The STAT screens contain historical data including peak voltages peak wattage and total accumulations These statistics in...

Page 57: ...gs or functions of other OutBack devices which are connected to the system display see appropriate manuals The following pages detail the MATE or MATE2 Control Modes Please note that whenever a password is called for the system password is 141 Accessing the Advanced Menus Figure 56 Accessing the Advanced Menus Press any soft key to advance to the next screen ADV SETTINGS WARNING changes made could...

Page 58: ...decreases the value of the selection PORT directs the MATE to read the next device port on the HUB ADV returns to the CC PAGE1 screen TOP returns to the CC CHGR screen MAIN exits the Advanced menus and returns to the main menu see page 55 CC Charger The CHGR screens adjust most of the same settings that are available on the Charger screen in the MATE3 see page 36 output current limit absorb voltag...

Page 59: ...OP returns to the CC ADVANCED screen ADV returns to the CC PAGE1 screen MAIN exits the Advanced menus and returns to the main menu see page 55 CC Advanced The ADVANCED screens include a series of settings which are located in a variety of places in the MATE3 These include the MATE3 Charger screen see page 36 the MPPT screen see page 37 the Temperature Compensation screen see page 38 the Grid Tie M...

Page 60: ...C decreases the value of the selection PORT directs the MATE to read the next device port on the HUB TOP returns to the CC EQ screen ADV returns to the choose device screen MAIN exits the Advanced menus and returns to the main menu see page 55 CC Equalization The EQ screens adjust the same settings that are available on the Battery Equalize screen in the MATE3 see page 38 eq voltage eq time eq aut...

Page 61: ... CC PAGE2 screen ADV returns to the choose device screen MAIN exits the Advanced menus and returns to the main menu see page 55 CC AUX The AUX screens adjust the same settings that are available on the Auxiliary Output screen in the MATE3 see page 39 AUX mode vent fan pv trigger error output night light float diversion relay diversion solid st low batt ery disconnect remote The remote mode also ca...

Page 62: ...MATE MATE2 Screens 60 900 0150 01 00 Rev A THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 63: ...ode it may not track at the maximum power point This mode is not normally selected when using PV Check battery conditions and charging stage If the batteries are charged if the controller is in the Absorbing or Float stage the controller will produce only enough power to regulate the voltage at those set points Less power is required Determine the specified short circuit current of the PV array Th...

Page 64: ...ly restart operation once the Voc falls to a safe level 145 Vdc or lower CAUTION Hazard to Equipment Voltages in excess of 150 Vdc are likely to damage the FLEXmax Extreme The PV array should be designed to avoid ever reaching these voltages High temperature fault Check controller temperature see page 32 The FLEXmax Extreme will stop functioning at an Enclosure reading of 78 C and an Output FETs r...

Page 65: ...Charge Cycle Three stage Minimum Battery Bank Size 100 Ah Charging Output Range 13 to 80 Vdc Temperature Compensation Adjustable from 2 mV cell C to 6 mV cell C Remote Interface RJ45 modular connector CAT 5 8 wire cable Conduit Openings Front rear sides plugs inserted Dimensions H x W x D 18 56 x 8 8 x 6 0 47 1 cm x 20 9 cm x 15 2 cm Shipping Dimensions D x W X L 9 69 x 11 75 x 22 0 24 6 cm x 29 8...

Page 66: ...owered by a DC source pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio communications However there is no guarantee tha...

Page 67: ...output is derated to a maximum of 53 Adc The controller is not rated for operation above this temperature If the optional fan is installed see page 10 the FLEXmax Extreme does not begin to derate until it reaches 55 C 131 F At 60 C 140 F the output is only derated to 71 Adc The controller is still not rated above this temperature even with the fan installed See page 32 for the internal temperature...

Page 68: ... Amps Default 0 6 Adc Range 0 2 to 1 0 Adc MPP Range Minimum Default Half Half or Full MPP Range Maximum Default 90 80 85 90 99 Temperature Compensation Mode Default Wide Wide or Limited Slope Default 5 mV Range 2 to 6 mV Lower Battery Voltage Default 14 1 Vdc Range 10 Vdc to Upper Battery Voltage setting Upper Battery Voltage Default 14 1 Vdc Range Lower Voltage setting to 80 Vdc Battery Equalize...

Page 69: ...nnect Delay Default 01 second Range 0 to 250 seconds Remote Default Off On Auto Off Vent Fan Default Off On Auto Off Enable Voltage Default 14 4 Vdc Range 10 0 to 80 0 Vdc PV Trigger Default Off On Auto Off Active Default Active High Range Active High or Active Low Enable Voltage Default 140 Vdc Range 20 to150 Vdc Hold Time Default 01 1 second Range 0 to 25 seconds Error Output Default Off On Auto...

Page 70: ...Specifications 68 900 0150 01 00 Rev A THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 71: ...volts higher than the nominal battery voltage for optimum performance This will ensure that the Vmp is always above the battery voltage which is required for charging Higher voltages are not recommended as they may reduce the FLEXmax Extreme conversion efficiency IMPORTANT Check the PV array voltage before connecting it to the FLEXmax Extreme Open Circuit Voltage Voc Open circuit voltage Voc is th...

Page 72: ...lthough it delivers the maximum short circuit current Isc In neither case does it produce usable wattage When partially loaded a PV module delivers partial current and voltage These numbers can be multiplied to see the available wattage However the delivery of wattage is not linear The current and voltage delivered at a given load will change with the load along a curve such as that shown in the d...

Page 73: ...ned by another means If so they may not need to be recharged Bulk This is the first stage in the three stage charge cycle It is a constant current stage which drives the battery voltage up The DC current is the maximum current the charger can deliver This stage typically leaves the batteries at 75 to 90 of their capacity depending on conditions In Bulk the controller will charge the batteries to t...

Page 74: ...ons on equalization voltage duration schedule and or advisability Always follow manufacturer recommendations for equalization Equalization is normally performed only on flooded lead acid batteries The schedule for equalization varies with battery use and type but it is usually performed every few months If performed correctly this process can extend battery life by a considerable amount Equalizati...

Page 75: ...er and a system display only one RTS is needed for multiple inverters and charge controllers See page 38 for more information on these items Table 12 Examples of Compensation Cells volts Slope Value Temp 25 Calculation Total Compensation 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 ...

Page 76: ...DC is not present on the network No devices are connected to the Ethernet port on the MATE3 This configuration is depicted on page 14 using one inverter and one FLEXmax Extreme The FN DC can be networked with one or more FLEXmax Extreme charge controllers if the following conditions are true No OutBack inverters are on the network No previous model OutBack charge controllers are on the network No ...

Page 77: ...splay the maximum power point tracking MPPT function can be set to Auto or U Pick VOC mode See page 37 The MPPT function is based on the open circuit voltage Voc of the DC source This is the unloaded voltage displayed by the source when it is disconnected MPPT values are expressed as a percentage of Voc Auto mode allows the FLEXmax Extreme to sweep the range of percentages The Auto mode begins at ...

Page 78: ...range limits 1 In the MATE3 navigate to the MPPT menu See page 35 See page 37 for more information about the items on this page 2 Select the MPPT Mode menu item Set it to U Pick 3 Select the U Pick VOC menu item Set it to a percentage value that is appropriate to the charging source 4 Select the MPP Range Minimum menu item Set it to Full ...

Page 79: ...ower on short notice FET Field Effect Transistor a reference to a temperature reading by the FLEXmax Extreme FN DC FLEXnet DC the OutBack Battery Monitor GFDI Ground Fault Detector Interruptor shuts down the system if a ground fault event occurs Grid interactive grid tie Utility grid power is available for use and the system is capable of returning selling electricity back to the utility grid Grou...

Page 80: ...lope A selectable rate of battery temperature compensation Sweep Part of the MPPT process the controller is attempting to locate the Vmp System display Remote interface device such as the MATE MATE2 or MATE3 used for monitoring programming and communicating with the inverter also called remote system display Vmp Maximum power voltage the voltage sought by MPPT where maximum power is harvested Voc ...

Page 81: ...ta Logging MATE 53 Default Settings 66 Defaults 45 Definitions 77 Diagrams 14 20 Dimensions 7 Diversion Control 17 E Efficiency 65 Equalizing 27 38 72 Error 30 32 61 62 F Factory Defaults 22 Fan 10 16 FCC 64 Features 5 6 Firmware Revision 5 46 64 FLEXnet DC 18 29 49 Limits on use 12 73 74 Float 27 72 Fuel Cell Applications 75 76 G GFDI 6 12 18 20 Graph Screens 34 Grid Tie 39 75 77 Ground Fault See...

Page 82: ... Voltage 69 70 Modes 25 30 Absorb 26 AutoRestart 45 AutoStart 45 Bulk 25 EQ 27 Float 27 GT Mode 39 Silent 28 Mounting 8 MPPT See Maximum Power Point Tracking N Nominal Battery Voltage 21 O Open Circuit Voltage 69 70 P Password 55 Photovoltaic 78 Ports Fan 16 HUB 16 MATE3 16 RTS 16 Positive Ground 12 14 15 74 Power Up 21 PV Design 69 R Remote Temperature Sensor 61 62 72 78 Port 16 Settings 38 Slope...

Page 83: ...l Block 16 AUX 17 Battery Sense 18 External Fault 18 Three Stage Battery Charging 25 71 Three Stage Charging 36 Troubleshooting 61 U Updating Firmware 46 V Vmp 69 70 Voc 22 69 70 W Weather Conditions 70 Wiring 12 14 20 44 Conduit 13 PV 13 Size 12 16 ...

Page 84: ...Indect 900 0150 01 00 Rev A Corporate Headquarters 17825 59th Avenue N E Suite B Arlington WA 98223 USA 1 360 435 6030 European Office Hansastrasse 8 D 91126 Schwabach Germany 49 9122 79889 0 ...

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