900-0054-01-00 Rev
A
5
Table of Contents
Important Safety Instructions ........................................................................1
Symbols Used ........................................................................................................................................................................1
Audience .................................................................................................................................................................................1
Definitions...............................................................................................................................................................................2
Personal Safety......................................................................................................................................................................2
General Safety .......................................................................................................................................................................2
Equipment Safety.................................................................................................................................................................3
PV Safety......................................................................................................................Error! Bookmark not defined.
Introduction.................................................................................................7
Overview..................................................................................................................................................................................7
Tools Required.......................................................................................................................................................................8
Preliminary..............................................................................................................................................................................8
Summary List of Instructions.............................................................................................................................................................8
FLEXmax Charge Controller Disassembly........................................................9
Removing the FLEXmax 80 Fan Cable..........................................................................................................................9
Removing Chassis Screws..............................................................................................................................................10
Removing the Heat Sink .................................................................................................................................................11
Removing the FET Bar......................................................................................................................................................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 Board ..........................................................................................................................................19
Control Board and Power Board...................................................................23
Removing the Control Board ........................................................................................................................................23
Replacing the Control Board or Power Board.........................................................................................................24
Reassembly................................................................................................27
Reseating the Control or Power Board ......................................................................................................................27
Reconnecting the Heat Sink to the Power Board ..................................................................................................28
Reconnecting the Heat Sink to the Chassis.............................................................................................................30
Reinstalling FLEXmax 80 Fan Plug ..............................................................................................................................31
System Functional Test ...................................................................................................................................................32
List of Figures
Figure 1
Components........................................................................................................................................................7
Figure 2
Charge Controller “At Rest” ............................................................................................................................8
Figure 3
Removing Fan Cover.........................................................................................................................................9
