OutBack Power FLEXmax Series Manual Download Page 35 | Manualshive

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Reassembly

900-0054-01-00 Rev

A

33

Notes:

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Summary of Contents for FLEXmax Series

Page 1: ...Board Replacement Instructionsfor FLEXmax Charge Controllers Including Control Board Button Board Power Board and FLEXmax 60 Fan...

Page 2: ...r com Web Site www outbackpower com Disclaimer UNLESSSPECIFICALLYAGREED TOIN WRITING OUTBACKPOWERSYSTEMS a MAKESNOWARRANTYASTOTHEACCURACY SUFFICIENCYORSUITABILITYOFANYTECHNICAL OROTHERINFORMATION PROV...

Page 3: ...nd ACCurrent DCCurrent Single Phase Sine Wave WARNING Hazard to Human Life Thistype of notation indicatesthat the hazard could be harmful to human life CAUTION Hazard to Equipment Thistype of notation...

Page 4: ...safety glasses ear protection steel toed safety boots safety hard hats etc asprescribed by the Occupational Safety and Health Association or other local codes when working on thisequipment Use standar...

Page 5: ...zed condition WARNING Burn Hazard Internal partscan become hot during operation Do not remove the cover during operation or touch any internal parts Be sureto allow them sufficient time to cool down b...

Page 6: ...Important Safety Instructions 4 900 0054 01 00 Rev A Thispage intentionally left blank...

Page 7: ...ETBar 12 Separating the Heat Sink from the Power Board 14 Fan and Button Board 17 Replacing the FLEXmax 60 Fan 17 Removing the Fan 17 Replacing the Fan 17 Fan Test Procedures 18 Replacing the Button B...

Page 8: ...0 Figure 25 Gripping the Push nut 20 Figure 26 Deforming the Push nut 21 Figure 27 Removing Push nut 21 Figure 28 Removing the Button Board 21 Figure 29 Inserting the New Button Board 22 Figure 30 Ins...

Page 9: ...tive componentsduring the removal and installation procedure See the section titled Equipment Safety on page 3 for more specific instructions Please review thisguide and familiarize yourself with the...

Page 10: ...he Chassis start on page 10 For instructionsfor Removing the Heat Sink see page 11 For instructionsfor Removing the FET Bar see page 12 For instructionsfor Separating the Heat Sink from the Power Boar...

Page 11: ...on the cover 3 Remove the fan cover once the tabshave cleared their slots Keep the fan cover and machine screw in asafe place 4 Note the fan cable plugged into the jack 6 Note the jack for the fan cab...

Page 12: ...s Keep the screwsand star washerstogether Figure 5 Back Screw Removal 2 With the unit still on itsside remove two side screws Figure 6 Side Screw Removal part 1 3 Set the unit on itsother side and rem...

Page 13: ...Sink Removal 1 To remove the heat sink grip it along each flank and raise itslower end 2 Slide the control board past the grounding lug Make certain the power board israised high enough to avoid the...

Page 14: ...ving the FET Bar 1 Set the unit on itsside asshown in Figure 9 and remove the 12 screwssecuring the FETmounting bar to the heat sink Figure 9 FET Bar Screw Removal Figure 10 FET Bar Removal Continuedo...

Page 15: ...liers 3 Lift the tab of the FETsoff from the Sil Pad gray insulator pad using your finger and thumb CAUTION Do not attempt to remove the FETsfrom the power board The FET pinsare soldered to the board...

Page 16: ...d in whitein Figure 13 on the left Do not remove the four cradle screwsand washersidentified with the X symbol in Figure 13 on the right Figure 13 Bottom Cradle Screw Removal Figure 14 Removing Remain...

Page 17: ...d Continuedon next page 3 With all the screws removed the heat sink can be separated from the power board Set the unit upright and carefully pry and lift the heat sink off the power board CAUTION Do n...

Page 18: ...Power Board see page 24 For instructionson Reassembling the Controller see page 27 4 Set the heat sink on itsside and the power board down flat 5 Remove the ribbon cable connector from the LCD connect...

Page 19: ...sshould be peeled or pulled off 2 Remove the four screwsholding the fan in place Fan Screws x4 Fan Connector NOTE The ribbon cable isshown disconnected in thisillustration for convenience only Silicon...

Page 20: ...Sleeping to BatTmpErr The fan will begin running 1 Remove the Remote Temperature Sensor RTS jack from the port if present 2 Insert aflat screwdriver inside the RTS port Gently pressthe screwdriver tip...

Page 21: ...troller asdescribed on page 11 through page 18 2 Remove the Remote Temperature Sensor RTS from the port if present 3 The Button Board islocated on the inside of the heat sink Fan Connector Fan Connect...

Page 22: ...ch are covered in turn by silicone sealant To expose the pegs 1 Remove the silicone sealant from all four pegs Once the push nutsare exposed they will need to be removed without damagingthemetal pegs...

Page 23: ...n Board Continuedon next page 4 Finally work the button board free of the four pegsand remove it from the housing 2 Slowly close the wire cutters exerting enough pressure to crush or deform the push n...

Page 24: ...convex center ishigher 7 Using the wire cuttersor long nose pliers pressalong both sidesof the push nut so that it isdriven onto the peg Continue pressing until the push nut isfirmly against the butt...

Page 25: ...ard to move Do not raise the other set of wires Raise these inductor wires Do NOT raise these inductor wires Control Board 2 Pinch the endsof the control board and pull upward 3 If the board resists g...

Page 26: ...t pinswith aflat screwdriver or your finger 2 Slide the control board into the power board Do not hit any componentson the power board 3 Inspect the pinsagain before connecting the control board to th...

Page 27: ...t sink CAUTION Equipment Failure Alwaysreplace the Sil Pad even if theold Sil Pad appearsusable It could easily have been damaged when removing the heat sink from the power board Even apin sized hole...

Page 28: ...Control Board and Power Board 26 900 0054 01 00 Rev A Notes...

Page 29: ...or Wires 1 Push on both endsof the control board to confirm it isstill properly seated on the power board 2 Bend and move the inductor wiresover the control board These are the same inductor wires whi...

Page 30: ...bbon cable It keepsthe cable from interfering with the alignment of the heat sink and the power board 4 Set the unit upside down and align the power board screw holesagainst the heat sink screw holes...

Page 31: ...rews 6 Set the unit on itsside with the FETsin between the screw holeson the heat sink If they do not line up move the tabson the FETsto align them between the screw holes The alignment of the FETs be...

Page 32: ...the Heat Sink onto the Chassis Figure 46 Replacing the Chassis Screws 1 Slide the reassembled unit into the chassisworking around the Grounding lug Grounding lug 2 Replace and tighten down all the sc...

Page 33: ...for reinstalling the fan plug before proceeding Reinstalling FLEXmax 80 Fan Plug Figure 47 Reinstalling Cable Jack Figure 48 Reinstalling Cable Plug Figure 49 Fan Cover 1 Snap the fan cable jack into...

Page 34: ...sby cycling through the menus 4 Once proper operation isverified apply PVinput to the FLEXmax Charge Controller to resume charging 5 Using adigital multimeter test the applicable test pointsto confirm...

Page 35: ...Reassembly 900 0054 01 00 Rev A 33 Notes...

Page 36: ...900 0054 01 00 Rev A North America 19009 62nd Avenue NE Arlington WA USA 1 360 435 6030 European Office Barcelona Espa a 34 93 654 9568...

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