OutBack Power Technologies FLEXmax 80, 60 Charge Controller Owner’s Manual

FLEXmax Series
Charge Controllers
(FLEXmax 80, FLEXmax 60)
Owner’s Manual
About OutBack Power Technologies
OutBack Power Technologies is a leader in advanced energy conversion technology. Our products
include true sine wave inverter/chargers, maximum power point tracking charge controllers, and
system communication components, as well as circuit breakers, batteries, accessories, and
assembled systems.
Contact Information
Telephone:
+1.360.435.6030 (North America)
+1.360.618.4363 (Technical Support)
+1.360.435.6019 (Fax)
Mailing Address:
(North America)
OutBack Power Technologies
5917 – 195th Street N.E., #7
Arlington, WA 98223 USA
E-mail:
[email protected]
Web Site:
www.outbackpower.com
Address:
Sales, Marketing, & Warranty
6115 – 192nd Street NE
Arlington, WA 98223 USA
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 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.
Warranty Summary
OutBack Power Technologies warrants that the products it manufactures will be free from defects in
materials and workmanship for a period of five (5) years subject to the conditions set forth in the
warranty detail, found inside the back cover of this manual.
OutBack Power Technologies cannot be responsible for system failure, damages, or injury resulting
from improper installation of their products.
Notice of Copyright
FLEXmax Series Charge Controllers Owner’s Manual © February 2012 by OutBack Power Technologies.
All Rights Reserved.
Trademarks
OutBack Power is a registered trademark of OutBack Power Technologies.
Date and Revision
February 2012, Revision B
Part Number
900-0009-01-00 Rev B
Important Safety Instructions
READ AND SAVE THESE INSTRUCTIONS!
This manual contains important safety instructions for the FLEXmax 60 and FLEXmax 80 Charge
Controllers. Read all instructions and cautionary markings on the charge controller and on any
accessories or additional equipment in the installation. Failure to follow these instructions could
result in severe shock or possible electrocution. Use extreme caution at all times to prevent accidents.
Audience
This manual is intended for use by anyone required to install and operate this equipment. Be sure to
review this manual carefully to identify any potential safety risks before proceeding. Installers and
operators must be familiar with all the features and functions of this equipment before proceeding.
Failure to install or use this equipment as instructed in this manual can result in damage to the
equipment that may not be covered under the limited warranty.
Symbols Used
Symbol
Description
Ground
WARNING: Hazard to Human Life
This type of notation indicates that the hazard could be harmful to human life.
CAUTION: Hazard to Equipment
This type of notation indicates that the hazard may cause damage to the equipment.
IMPORTANT:
This type of notation indicates that the information provided is important to
the installation, operation, and/or maintenance of the equipment. Failure to
follow the recommendations in such a notation could result in voiding the
equipment warranty.
Definitions
The following is a list of initials, terms, and definitions used with this product.
Table 1
Terms and Definitions
Term
Definition
AC
Alternating Current; refers to voltage produced by the inverter, utility grid, or generator
AGS
Advanced Generator Start
AUX
Inverter’s 12-volt auxiliary output
900-0009-01-00 Rev B
1
Important Safety Instructions
Table 1
Terms and Definitions
Term
Definition
CE
Conformité Européenne; French for “European Conformity”; a marking on OutBack
products indicating that they meet European Union requirements
DC
Direct Current; refers to voltage produced by the batteries or renewable source
DVM
Digital Voltmeter
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.
LED
Light-Emitting Diode; refers to indicators used by the inverter and the system display
MPP, MPPT
Maximum Power Point, Maximum Power Point Tracking
PWM
Pulse-Width Modulation
PV
Photovoltaic
RTS
Remote Temperature Sensor; accessory that measures battery temperature for charging
SK
Soft Key; a key with programming that varies with screen
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; voltage sought by MPPT where maximum power is harvested
Voc
Open-circuit voltage; the unloaded voltage displayed by a PV module or array
General Safety
WARNING: Limitations on Use
This equipment is NOT intended for use with life support equipment or other medical
equipment or devices.
CAUTION: Equipment Damage
Only use components or accessories recommended or sold by OutBack Power
Technologies or its authorized agents.
IMPORTANT:
Do not attempt to install this equipment if it appears to be damaged in any way. See
the Warranty section for instructions on returning the equipment.
Personal Safety
WARNING: Personal Injury



2
Use standard safety equipment such as safety glasses, ear protection, steel-toed
safety boots, safety hard hats, etc. as prescribed by the Occupational Safety and
Health Association (or other local codes) when working on this equipment.
Use standard safety practices when working with electrical equipment (Remove all
jewelry, use insulated tools, wear cotton clothing, etc.)
Never work alone when installing or servicing this equipment. Have someone
nearby in case emergency assistance is required.
900-0009-01-00 Rev B
Important Safety Instructions
Product Safety
WARNING: Lethal Voltage


Review the system configuration to identify all sources of energy. Disconnect ALL
sources of power before performing any installation or maintenance on this
equipment. Confirm that the terminals are de-energized using a validated
voltmeter (rated for a minimum 1000 Vdc) to verify the de-energized condition.
Do not perform any servicing other than that specified in the installation
instructions unless qualified to do so and have been instructed to do so by OutBack
Power Technologies Technical Support personnel.
WARNING: Burn Hazard
Internal parts can become hot during operation. Do not remove the cover during
operation or touch any internal parts. Be sure to allow them sufficient time to cool
down before attempting to performance any maintenance.
WARNING: Fire Hazard


Do not place combustible or flammable materials within 3.7 m (12 feet) of
the equipment.
Use only the recommended cable sizes for DC conductors in compliance with local
codes. Ensure all conductors are in good condition. Do not operate the unit with
damaged or substandard cabling.
CAUTION: Equipment Damage



Thoroughly inspect the equipment prior to energizing. Verify that no tools or
equipment have been inadvertently left behind.
Ensure clearance requirements are strictly enforced. Keep all vents clear of
obstructions that can prevent air flow around, or through, the unit.
Sensitive electronics inside the equipment can be destroyed by static electricity.
Be sure to discharge any static electricity built up before touching the equipment
and wear appropriate protective gear.
PV Safety
WARNING: Shock Hazard
Photovoltaic (PV) arrays can be energized with minimal ambient light available.
Therefore to ensure a safe disconnect from the system, be sure to install a PV
disconnect, breaker, or accessible fuse box (depending on local code requirements).
CAUTION: Equipment Damage
PV Arrays must be wired with correct polarity (positive-to-positive, negative-tonegative). Connecting the cables incorrectly can damage or destroy the equipment.
900-0009-01-00 Rev B
3
Additional Resources
Battery Safety
WARNING: Explosion, Electrocution, or Fire Hazard











Use the battery types recommended by OutBack Power Technologies. Follow the
battery manufacturer’s recommendations for installation and maintenance.
Ensure the cables are properly sized. Failure to size the cables properly can results
in a fire hazard.
Ensure clearance requirements are strictly enforced around batteries.
Ensure the area around the batteries is well ventilated and clean of debris.
Never smoke or allow a spark or flame near the batteries.
Always use insulated tools. Avoid dropping tools onto batteries or other
electrical parts.
Keep plenty of fresh water and soap nearby in case battery acid contacts skin,
clothing, or eyes.
Wear complete eye protection and clothing protection when working with
batteries. Avoid touching bare skin or eyes while working near batteries.
If battery acid contacts skin or clothing, wash immediately with soap and water.
If acid enters the eye, immediately flood it with running cold water for at least 20
minutes and get medical attention immediately.
Never charge a frozen battery.
If a battery needs to be removed, always remove the ground terminal from the
battery first. Make sure all accessories are turned off to avoid creating sparks.
IMPORTANT:
Baking Soda neutralizes lead-acid battery electrolyte.
Vinegar neutralizes NiCad and NiFe battery electrolyte.
Have a supply of either substance readily available if using these types of batteries.
Regulatory Specifications
See page 99 for all specifications and regulatory information.
Required Resources
This product is required to be installed according to pertinent safety codes and standards. If installed
in the United States, wiring practices must meet the requirements of the National Electrical Code
(NEC). If installed in Canada, wiring practices must meet the requirements of the Canadian
Electrical Code.


National Electrical Code (NEC)/NFPA 70, Current Edition
Canadian Electrical Code, C22.1, Current Edition
Additional Resources
The following are references which may be used when installing this equipment. Depending on the
nature of the installation, it may be highly recommended to consult any or all of these resources.




4
National Electrical Code (NEC) or NFPA 70 Handbook, Current Edition
UL 1741, Current Edition, Static Inverter and Charge Controllers for Use in Photovoltaic Power Systems
International Building Code (IBC), Current Edition
Photovoltaic Power Systems and the 2005 National Electrical Code: Suggested Practices
900-0009-01-00 Rev B
Additional Resources
Recycling Information
IMPORTANT: Recycle Electronics and Batteries
Batteries are considered hazardous waste and must be recycled according to local
jurisdiction. Inverters and other electronics contain metals and plastics that should also
be recycled. The following websites and phone numbers provide additional
information for recycling electronic products and batteries.
Earth 911, USA
Web site:
Address:
Phone:
http://www.Earth911.com
14646 N. Kierland Blvd., Suite 100
Scottsdale, AZ 85254
+1.480.337.3025 (direct)
Environmental Protection Agency, USA
Web site:
Address:
http://www.epa.gov/wastes/conserve/materials/ecycling/donate.htm
EPA USA
Office of Resource Conservation and Recovery (5305P)
1200 Pennsylvania Avenue NW
Washington, DC 20460
Keep America Beautiful, USA
Web site:
Email:
Address:
Phone:
Fax:
www.kab.org/
[email protected]
1010 Washington Boulevard
Stamford, CT 06901
+1.203.659.3000 (Main number)
+1.203.659.3001
OurEarth.org, USA
There is a place on the Web site for contacting OurEarth.org using email. No direct email address
is provided.
Web site:
Address:
Phone:
http://www.ourearth.org
P.O. Box 62133
Durham, NC 27715
+1.410.878.6485
Natural Resources Canada
Address:
Phone:
TTY:
Web site:
900-0009-01-00 Rev B
580 Booth, Ottawa, ON K1A 0E8
+1.613.995.0947
+1.613.996.4397
(Phone 7and TTY: Monday to Friday, 8:30 a.m. to 4:30 p.m. ET)
http://www.nrcan-rncan.gc.ca/mms-smm/busi-indu/rec-rec-eng.htm
5
Additional Resources
Office of Waste Management, Canada
Address:
Phone:
Web site:
Office of Waste Management
Conservation and Protection
Environment Canada
Ottawa, Ontario K1A 0H3
+1. 819.997.2800
http://www.portaec.net/library/recycling/recycling_in_canada.html
National Institute of Recyclers, Mexico
Web site:
Email:
Phone:
Fax:
http://www.inare.org.mx/
[email protected], [email protected]
55.57.85.9160
55.57.84.1279
EuroRecycle.net
The following Web site provides general information about recycling in Europe. It also provides a list
of companies and organizations that provide recycling information or assistance.
Web site:
E-mail:
6
http://euro.recycle.net/assn/index.html
http://euro.recycle.net/cgi-bin/feedback1.cgi?w=27
(This is an online form providing a means to contact the owners of the web site.)
900-0009-01-00 Rev B
Table of Contents
Important Safety Instructions ............................................................................................................................... 1
Audience................................................................................................................................................................................................... 1
Symbols Used ......................................................................................................................................................................................... 1
Definitions................................................................................................................................................................................................ 1
General Safety......................................................................................................................................................................................... 2
Personal Safety ....................................................................................................................................................................................... 2
Product Safety ........................................................................................................................................................................................ 3
PV Safety................................................................................................................................................................................................... 3
Battery Safety.......................................................................................................................................................................................... 4
Regulatory Specifications ................................................................................................................................................................... 4
Required Resources .............................................................................................................................................................................. 4
Additional Resources............................................................................................................................................................................ 4
Recycling Information.......................................................................................................................................................................... 5
Introduction...............................................................................................................................................................11
Features ..................................................................................................................................................................................................11
Firmware.................................................................................................................................................................................................11
Soft Keys .................................................................................................................................................................................................12
Installation..................................................................................................................................................................13
Standards and Requirements ..........................................................................................................................................................13
Grounding ........................................................................................................................................................................................13
DC and Battery-Related Installation Requirements............................................................................................................13
Dimensions............................................................................................................................................................................................14
Mounting the Charge Controller....................................................................................................................................................15
Wiring ......................................................................................................................................................................................................16
Wire and Disconnect Sizing........................................................................................................................................................16
FLEXmax 80 ................................................................................................................................................................................16
FLEXmax 60 ................................................................................................................................................................................16
Wiring Compartment....................................................................................................................................................................17
Operation....................................................................................................................................................................21
Power Up Screens................................................................................................................................................................................21
Version and/or Voltage Setting Screens.................................................................................................................................22
Status Screen ...................................................................................................................................................................................23
End-of-Day Summary Screen .....................................................................................................................................................24
Navigating the End-of-Day Screens and Data Logging ....................................................................................................25
Modes of Operation............................................................................................................................................................................26
Absorbing.........................................................................................................................................................................................26
Auto Start (Auto ReStart).............................................................................................................................................................27
BatTmpErr.........................................................................................................................................................................................27
BatTooHot ........................................................................................................................................................................................27
Charged.............................................................................................................................................................................................27
EQ ........................................................................................................................................................................................................27
EQ Done ............................................................................................................................................................................................27
EX-Absorb.........................................................................................................................................................................................28
Floating .............................................................................................................................................................................................28
GT Mode............................................................................................................................................................................................28
High Voc............................................................................................................................................................................................28
Low Light or Snoozing .................................................................................................................................................................28
MPPT Bulk.........................................................................................................................................................................................28
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7
Table of Contents
MPPT Float........................................................................................................................................................................................28
MPPT EQ............................................................................................................................................................................................29
New Voc ............................................................................................................................................................................................29
OvrCurrent........................................................................................................................................................................................29
Over Temp........................................................................................................................................................................................29
Re-Cal .................................................................................................................................................................................................29
Sleeping ............................................................................................................................................................................................29
Sys Error.............................................................................................................................................................................................29
Tracking.............................................................................................................................................................................................29
Unloaded ..........................................................................................................................................................................................30
Wakeup..............................................................................................................................................................................................30
Zzzzz... ................................................................................................................................................................................................30
Initial Operation ...................................................................................................................................................................................30
Changing the Settings on the FLEXmax ......................................................................................................................................30
Accessing the Main Menu ...........................................................................................................................................................30
Main Menu Map..............................................................................................................................................................................31
Charger Screen..........................................................................................................................................................................32
Aux Screens................................................................................................................................................................................33
AUX MODE Screen Navigation.............................................................................................................................................35
Vent Fan (AUX Mode)........................................................................................................................................................36
PV Trigger (AUX Mode).....................................................................................................................................................37
Error Output (AUX Mode) ................................................................................................................................................38
Night Light (AUX Mode) ...................................................................................................................................................39
Float (AUX Mode) ...............................................................................................................................................................40
Diversion (AUX Mode).......................................................................................................................................................41
Low Battery Disconnect (AUX Mode)...........................................................................................................................46
Remote (AUX Mode)..........................................................................................................................................................47
Backlight......................................................................................................................................................................................47
EQ – Battery Equalize ..............................................................................................................................................................48
Misc Screen.................................................................................................................................................................................50
Advanced Menu........................................................................................................................................................................52
Snooze Mode (Advanced Menu)...................................................................................................................................52
Wakeup Mode (Advanced Menu) ................................................................................................................................53
MPPT Mode (Advanced Menu) ......................................................................................................................................53
Absorb Time Limits (Advanced Menu)........................................................................................................................55
Absorb End Amps (Advanced Menu)...........................................................................................................................55
Rebulk Voltage (Advanced Menu) ................................................................................................................................56
Vbatt Calibration (Advanced Menu).............................................................................................................................56
RTS Compensation (Advanced Menu).........................................................................................................................56
Auto ReStart (Advanced Menu) .....................................................................................................................................58
Aux Polarity (Advanced Menu) ......................................................................................................................................59
Reset to Defaults? ...............................................................................................................................................................59
Logging .......................................................................................................................................................................................60
Stats ..............................................................................................................................................................................................61
Viewing the Firmware Revision.................................................................................................................................................62
Extended Play Mode .....................................................................................................................................................................62
Rebooting the FLEXmax ..............................................................................................................................................................63
MATE3 System Display and Controller............................................................................................................65
Display and LED Status Indicators..................................................................................................................................................65
Charge Controller Soft Key....................................................................................................................................................66
DataLog Screen ...................................................................................................................................................................67
Graph Screens......................................................................................................................................................................68
Menu Structure in the MATE3 .........................................................................................................................................................69
Charge Controller Settings...............................................................................................................................................................70
Charger..............................................................................................................................................................................................70
MPPT...................................................................................................................................................................................................70
8
900-0009-01-00 Rev B
Table of Contents
Temperature Compensation......................................................................................................................................................71
Battery Equalize..............................................................................................................................................................................71
Grid-Tie Mode..................................................................................................................................................................................71
Auxiliary Output (Charge Controller) ......................................................................................................................................72
Aux Modes for the Charge Controller ...............................................................................................................................72
Restart Mode..............................................................................................................................................................................73
Calibrate ......................................................................................................................................................................................74
Reset Charge Controller to Factory Defaults...................................................................................................................74
Device Data Logs .................................................................................................................................................................................75
Saving Data Logs for the FLEXmax Charge Controller ......................................................................................................75
Data Log File Format .........................................................................................................................................................76
MATE/MATE2 Screens............................................................................................................................................77
Summary Screens ................................................................................................................................................................................77
Status Screens.......................................................................................................................................................................................78
MODE Screens.................................................................................................................................................................................78
METER Screens ................................................................................................................................................................................79
SETPT Screens .................................................................................................................................................................................80
LOG Screens.....................................................................................................................................................................................81
STAT Screens ...................................................................................................................................................................................82
Advanced Menus.................................................................................................................................................................................83
Accessing the Advanced Menus ...............................................................................................................................................83
CHGR Menu......................................................................................................................................................................................84
CC ADVANCED Menu....................................................................................................................................................................85
EQ Menu............................................................................................................................................................................................86
AUX Menu.........................................................................................................................................................................................87
MATE and MATE2 Menu Maps for the FLEXmax.......................................................................................................................88
STATUS Menu Map ........................................................................................................................................................................88
Advanced Menu Map ...................................................................................................................................................................90
Menu Maps for the FLEXmax ..............................................................................................................................93
Troubleshooting ......................................................................................................................................................97
Specifications ............................................................................................................................................................99
Electrical and Mechanical Specifications.....................................................................................................................................99
Firmware Revision ...............................................................................................................................................................................99
Regulatory Specifications .................................................................................................................................................................99
Default Settings and Ranges......................................................................................................................................................... 100
Applications............................................................................................................................................................ 101
Maximum Power Point Tracking ................................................................................................................................................. 101
Three-Stage Battery Charging...................................................................................................................................................... 102
BULK ................................................................................................................................................................................................ 102
ABSORBING ................................................................................................................................................................................... 103
FLOAT.............................................................................................................................................................................................. 103
Battery Temperature Compensation.................................................................................................................................... 103
Array Design....................................................................................................................................................................................... 104
Sizing Guidelines......................................................................................................................................................................... 104
Open Circuit Voltage (Voc) ................................................................................................................................................... 104
Weather Conditions.............................................................................................................................................................. 104
Maximum-Power Voltage (Vmp) ........................................................................................................................................... 105
Standard vs. Australian Default Settings .................................................................................................................................. 105
Hydroelectric and Fuel Cell Applications Performance Optimization............................................................................ 106
Auto Track Mode......................................................................................................................................................................... 106
U-Pick Mode.................................................................................................................................................................................. 106
Grid-Interactive Settings ................................................................................................................................................................ 108
Charge Controller Efficiency vs. Input Power.......................................................................................................................... 108
900-0009-01-00 Rev B
9
Table of Contents
Product Registration............................................................................................................................................ 109
Extended Warranty .......................................................................................................................................................................... 110
Warranty................................................................................................................................................................... 111
How to Arrange for Warranty Service........................................................................................................................................ 112
Contacting OutBack ................................................................................................................................................................... 112
Troubleshooting.......................................................................................................................................................................... 112
Return Material Authorization (RMA)................................................................................................................................... 112
Returning Product to OutBack ............................................................................................................................................... 113
Out of Warranty ..................................................................................................................................................................... 113
Index.......................................................................................................................................................................... 115
List of Tables
Table 1
Table 2
Table 3
Table 4
Table 5
Table 6
Table 7
10
Terms and Definitions ...................................................................................................................................................... 1
Battery Voltage and Charge Timer.............................................................................................................................27
Aux Mode Functions.......................................................................................................................................................33
Regulatory Specifications for All Models .................................................................................................................99
FLEXmax Settings ......................................................................................................................................................... 100
Maximum PV Input Wattage per Charge Controller......................................................................................... 104
Default Settings Standard vs. Australian .............................................................................................................. 105
900-0009-01-00 Rev B
Introduction
IMPORTANT:
This manual provides safety guidelines and installation information for the
FLEXmax Series Charge Controllers. It does not provide information about
specific brands of PV modules and supplies limited information on batteries.
Contact the supplier or manufacturer of the PV modules or batteries for
additional information.
Thank you for purchasing a FLEXmax Series Charge Controller (CC). These charge controllers offer an
efficient, safe, multi-stage recharging process that prolongs battery life and assures peak performance
from a PV array.
Each charge controller is designed to seamlessly integrate with other OutBack components and can
be remotely monitored and configured (up to 1000 feet or 300 meters away) using the optional
OutBack Power Technologies system displays.
Features
The FLEXmax Charge Controllers use continuous Maximum Power Point Tracking (MPPT), which seeks
out the maximum power available from a PV array and uses it to recharge the batteries. Without this
feature, the PV array does not operate at the ideal voltage and can only operate at the level of the
battery voltage itself. (See page 101 for a description of MPPT.) Each charge controller continuously
tracks the array’s maximum operating power.
The FLEXmax Series has two models available:

FLEXmax 80: 80 amps maximum continuous output current (up to 40°C without thermal derating)

FLEXmax 60: 60 amps maximum continuous output current (up to 40°C without thermal derating)
Both models have the following features:

Supports 12, 24, 36, 48, and 60 Vdc battery voltages

Backlit LCD display screen with 80 characters (4 lines, 20 characters per line)

Last 128 days of operational data are logged for review

Voltage step-down capability allowing a higher PV array voltage configuration

Manual and auto-equalize cycle
Firmware
This manual covers FLEXmax firmware revision 002.001.xxx.
900-0009-01-00 Rev B
11
Introduction
LCD Screen
Soft Keys
FLEXmax 80
Figure 1
FLEXmax 60
Charge Controller Features
Soft Keys
Four “soft” keys are located directly below the LCD. The functions of the soft keys will vary depending
on the location of the user within the menu structure. Some soft keys will be used for navigation.
Some soft keys will be used for programming.
Soft key functions are identified by text in the LCD screen directly above the key (e.g., EXIT). In this
manual, soft keys will be identified by brackets (for example, <EXIT>). Not every soft key may be used
in some screens.
Main Menu
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT

GO
Soft Key Buttons
LCD
Soft Key Commands
<EXIT>, <GO> etc.
SK1 SK2 SK3 SK4
Figure 2
12
Soft Keys
900-0009-01-00 Rev B
Installation
Standards and Requirements
All installations must comply with national and local electrical codes; professional installation is
recommended.
IMPORTANT:
The charge controller is designed for indoor installation or installation inside a
weatherproof enclosure. It must not be exposed to rain and should be installed out of
direct sunlight.
Grounding
This product is intended to be installed as part of a permanently grounded electrical system as shown
in the wiring diagrams shown in Figure 6, Figure 7, and Figure 8.

The FLEXmax equipment ground is marked with this symbol:
The following important restrictions apply unless superseded by local or national codes:

The negative battery conductor should be bonded to the grounding system at only one point in the system.
If a GFDI is present, the battery negative and ground are not bonded together directly but are connected
together by the GFDI device when it is on. All negative conductor connections must be kept separate from
the grounding conductor connections.

The FLEXmax controller is not intended to be wired into a positive-ground configuration. However, certain
telecom applications may require this configuration. If it is necessary to build a positive-ground system with
OutBack products, contact OutBack Technical Support at +1.360.618.4363 before proceeding.
Additionally, consult the online forum at www.outbackpower.com/forum/, where this subject has been
discussed extensively.
If damaged or malfunctioning, the FLEXmax should only be disassembled and repaired by a qualified service
center. Please contact the local renewable energy dealer/installer for assistance. Incorrect reassembly risks
malfunction, electric shock or fire.

DC and Battery-Related Installation Requirements


Shut off all DC circuit breakers before connecting any wiring.
Torque all the FLEXmax wire lugs and ground terminals to 4 Nm (35 in-lb).


Copper wiring must be rated at 75°C or higher.
Use up to 35 mm2 (2 AWG) to reduce losses and ensure highest performance of the FLEXmax (smaller cables
can reduce performance and possibly damage the unit).

Run positive and negative cables side by side.
~ Keep cables together (e.g., using a tie-wrap) as much as possible to allow the inductive currents
to cancel.

~ Ensure paired cables pass through the same knockout and conduit fittings.
DC battery overcurrent protection must be used as part of the installation. OutBack offers both circuit
breakers and fuses for overcurrent protection.
900-0009-01-00 Rev B
13
Installation
Dimensions
16.25” (41.3 cm)
FLEXmax 80
Charge Controller
5.75”
(14.6 cm)
FLEXmax 60
Charge Controller
Figure 3
14
4.0”
(10.2 cm)
13.5” (34.3 cm)
FLEXmax 80 and FLEXmax 60 Dimensions
900-0009-01-00 Rev B
Installation
Mounting the Charge Controller
IMPORTANT:
Install the FLEXmax in an upright position out of direct sunlight.
The FLEXmax is designed to attach
directly to OutBack’s FLEXware 500 DC
and FLEXware 1000 DC enclosures
(FLEXware 500 shown) or attach to its
own charge controller brackets (FW-CCB,
FW-CCB2, and FW-CCB2T).
Mounting directly to a FLEXware DC
enclosure:
1. Remove the fan cover and bottom
cover from the FLEXmax.
2. Insert a #10 X 3/8” sheet metal screw
in the top hole on the side of the DC
enclosure. This will act as a hanging
screw for the keyhole slot at the top
center of the FLEXmax.
Holes for
#10 x 3/8” sheet
metal screws
Insert screws
through lower
holes inside
the charge
controller.
3. Hang the FLEXmax on the top screw
and line up its bottom two screw
holes with the holes on the enclosure.
4. Insert a #10 x 3/8” sheet metal screw
through each hole and tighten
against the enclosure (screws are
included with each DC enclosure).
5. Keep the cover off until wiring is
completed.
The conduit nipple assembly creates a
sealed connection from the FLEXmax to
the enclosure.
DC Enclosure
Charge Controller
(front view)
Mounting to Plywood
Use 1-5/8” wood screws to secure the
FLEXmax at the top slotted holes and
other interior lower holes as needed,
making sure the unit is straight and level.
Bushing
Lock Nut
Lock Nut
Figure 4
900-0009-01-00 Rev B
Conduit
Nipple
Mounting the Charge Controller
15
Installation
Wiring
This section provides instructions on installing PV array wiring into the FLEXmax controller. See
page 104 for more notes on PV array sizing and operation.
Wire and Disconnect Sizing
IMPORTANT:



Wire sizes must comply with local and national codes. See page 4.
Input conductors and circuit breakers must be rated at 1.56 times the short-circuit
current of the PV array (per NEC). OutBack 100% duty continuous circuit breakers
only need to be rated at 1.25 times the short-circuit current.
Copper wiring must be rated at 75°C or higher.
Use up to 2 AWG (33.6 mm2) to reduce losses and ensure high performance of the
FLEXmax (smaller cables can reduce performance and possibly damage the unit).
FLEXmax 80

The output current limit of the FLEXmax 80 is 80 amps.

Install OutBack PNL-80-DC circuit breakers for disconnect and overcurrent protection

Use a minimum of #4 AWG (25 mm2) wire for the output between the FLEXmax 80 and the battery bus bar
conductors.

The largest PV array must have a rated short-circuit current of 64 amps or less under STC (Standard
Test Conditions).

Torque all the FLEXmax wire lugs and ground terminals to 4 Nm (35 in-lb).
FLEXmax 60

The output current limit of the FLEXmax 60 is 60 amps.

Install OutBack PNL-60-AC/DC or PNL-80-DC circuit breakers for disconnect and overcurrent protection.

Use a minimum of #6 AWG (16 mm2) wire for the output between the FLEXmax 60 and the battery bus bar
conductors.

The largest PV array must have a rated short-circuit current of 48 amps or less under STC (Standard
Test Conditions).

Torque all the FLEXmax wire lugs and ground terminals to 4 Nm (35 in-lb).
Please refer to the NEC and other electrical codes for recommendations on PV array cable sizing and
recommended length and ampacity.
16
900-0009-01-00 Rev B
Installation
Wiring Compartment
WARNING: Shock Hazard
Make sure all DC circuit breakers are OFF (open) BEFORE making any wiring
connections. Use a DVM to check for voltage on all wires.
The PV (-) and BAT (-) terminals are connected internally. Only one negative wire may be needed to
connect to the (-) wire lugs if the PV - and BAT- conductors are bonded at the negative bus bar.
See Figure 6, Figure 7, and Figure 8 for sample wiring diagrams.
Auxiliary output
terminals
Wire terminals
Battery Remote
Temp Sensor (RTS)
RJ11 port
PV+
PV–
BAT–
BAT+
MATE/HUB
RJ45 port

Use up to 35 mm2
(2 AWG) wire

Torque to 4 Nm
(35 in-lb)
Chassis/Equipment
Ground Lug
Screw holes for mounting the
charge controller
Figure 5
Wiring Compartment
CAUTION: Equipment Damage
Each FLEXmax requires its own PV array. DO NOT PARALLEL FLEXmax PV+ and PVTERMINALS ON THE SAME ARRAY!
An optional battery Remote Temperature Sensor (RTS) is recommended for accurate battery charging.

Only one RTS is needed for multiple OutBack inverter/chargers and charge controller units when the system
includes an OutBack HUB and a system display.

When one RTS is used, it must be connected to the component plugged into the Port 1 of the HUB.
900-0009-01-00 Rev B
17
Installation
Figure 6
18
Wiring Diagram - Single Charge Controller with PV Array
900-0009-01-00 Rev B
Installation
Figure 7
900-0009-01-00 Rev B
Wiring Diagram – Charge Controller with PV Array and Inverter
19
Installation
Figure 8
20
Wiring Diagram – Charge Controller with
PV Array Ground Fault Protection
900-0009-01-00 Rev B
Operation
Operation of this unit consists of monitoring screens and programming screens. The majority of
programming screens are accessed using the main menu. See page 30.
Power Up Screens
IMPORTANT:




The default settings of the FLEXmax are for a 12 Vdc battery bank. Change the
setting after powering up if a different battery voltage is used.
Once set, the FLEXmax retains the nominal voltage setting. Following any type of
shutdown or disconnect, it will return to operation automatically.
The PV array voltage is automatically detected. The PV array voltage must never
exceed 150 Voc.
It is recommended to restore the FLEXmax to factory default settings (see page 59)
and reset the nominal voltage any time the system is substantially revised or the
controller is relocated.
The FLEXmax uses power from the battery bank to operate. The battery voltage must be at least
10.5 volts or higher to power up the FLEXmax. When battery power is detected, the FLEXmax will go
through a series of power-up screens.
Power Up Screen
OutBack
System Voltage
12V
Power
Systems
Charge Controller - AU
On Australian
versions only
To power up the charge controller:
1. Ensure the PV array and battery circuit breakers are OFF.
2. Turn ON the battery circuit breaker only.
 The FLEXmax will show the system battery voltage in the
upper right corner of the screen. If the screen reads
Low Battery Voltage, please see the Troubleshooting
section on page 97.
 If the Australian version was previously selected, AU will
be displayed in the lower right corner of the screen.
To change version settings:
OutBack
12V
While turning on the circuit breaker, press and hold the first
and third soft keys. This brings up the Select Version screen.
Changing the version settings requires entering a password.
Systems
Charge Controller - AU
Power
NOTE: This process will reset the FLEXmax to its default
settings. It may be necessary to re-enter previous settings.
To change the system password:
1.
Press <NEXT> or <SEL> when the Select Version screen
appears on power up.
This will open the PASSWORD screen.
2.
Press <–> or <+> to reduce the number from 150 to 141.
3.
Press <ENTRA> or <ENTER> to enter the new password.
Figure 9
PASSWORD
CONTRASENA
***150***
ENTRA
+
ENTER
PASSWORD
Screen
Continued on next page...
Powering up the FLEXmax
Select Version offers two types of options. The English (default) or Spanish selections offer
standardized charge settings in two languages. Selecting Australian leaves the menus in English, but
changes the charging parameters. (For details, see Table 7 on page 105.)
900-0009-01-00 Rev B
21
Operation
Version and/or Voltage Setting Screens
Once the password has been entered, the display will return to the Select Version screen.
Select Version Screen
To change the version:
Select Version
Elija la Version
English
NEXT ENTER ENTRA SEL
1.
or
Select Version Screen
Select Version
Elija la Version
English
NEXT ENTER ENTRA SEL
Press <NEXT> or <SEL> to cycle through the version
choices of:

English,

Australian, or

Espanola.
2.
When the desired version is displayed, press <ENTER> or
<ENTRA> to proceed to the confirmation screen.
3.
Press <YES> to confirm the selection.
or
Confirmation Screen
Are you sure?
English
NO
YES
SYSTEM VOLTAGE Screen
SYSTEM VOLTAGE
24 36 48 60
12
^^

The SYSTEM VOLTAGE screen appears next.
ENTER
The FLEXmax automatically detects the system’s battery voltage
and indicates it by placing two ^^ symbols below the value.
Verification Screen
12
^^
NO
Are you sure?
24 36 48 60

If the value indicated is correct, press <ENTER>.

If the value indicate is not correct for the present system,
press <> to move the ^^ to below the correct voltage.

Press <YES> to confirm the selection.
YES
Status Screen
In
Out
11.6V
13.8V
0.000 kW
AUX: OFF
0.0 A
0.0 A
0.0 kWH
Sleeping
Figure 10
22
The Status screen is the last screen to be displayed after startup.
The soft keys below the Status screen navigate to the main
menu and the End-of-Day summary screen. See page 23 for
details on the Status screen.
Changing the Version Setting
900-0009-01-00 Rev B
Operation
Status Screen
The status screen displays system information. See page 24 for detailed information of the different
modes of operation.
The optional OutBack system display shows CC (Charge Controller) status screens for convenient
distant viewing from the installation location. See page 65 for the FLEXmax screens displayed on the
MATE3. Please see pages 77 to 89 to view the FLEXmax screens displayed on the MATE (or MATE2).
Status Screen
In
Out
11.6V
13.8V
0.000 kW
AUX: OFF
0.0 A
0.0 A
0.0 kWH
Sleeping
PV Input Voltage
In
Out
11.6V
13.8V
0.000 kW
AUX: OFF
0.0 A
0.0 A
0.0 kWH
Sleeping
PV Input Current
In
Out
11.6V
13.8V
0.000 kW
AUX: OFF
0.0 A
0.0 A
0.0 kWH
Sleeping
Battery Voltage
In
Out
11.6V
13.8V
0.000 kW
AUX: OFF
0.0 A
0.0 A
0.0 kWH
Sleeping
In
Out
11.6V
13.8V
0.000 kW
AUX: OFF
0.0 A
0.0 A
0.0 kWH
Sleeping
In
Out
11.6V
13.8V
0.000 kW
AUX: OFF
0.0 A
0.0 A
0.0 kWH
Sleeping
Daily Accumulated
Kilowatt-hours
In
Out
0.0 A
0.0 A
0.0 kWH
Sleeping
AUX Status
(ON or OFF)
The PV voltage will slowly rise to the battery
voltage level even when the PV breaker is off –
this is normal as the PV capacitors charge up.
Navigation
Status Screen
11.6V
13.8V
0.000 kW
AUX: OFF
Output Current
Instantaneous
Kilowatts
In
Out
11.6V
13.8V
0.000 kW
AUX: OFF
0.0 A
0.0 A
0.0 kWH
Sleeping
Pressing the first soft key (SK1)
opens the main menu screen.
Status Screen
In
Out
11.6V
13.8V
0.000 kW
AUX: OFF
0.0 A
0.0 A
0.0 kWH
Sleeping
Pressing SK2 opens the end-of-day
summary menu and logging.
In
Out
11.6V
13.8V
0.000 kW
AUX: OFF
0.0 A
0.0 A
0.0 kWH
Sleeping
Mode of Operation
See page 26
Figure 11
900-0009-01-00 Rev B
Status Screen
23
Operation
End-of-Day Summary Screen
The end-of-day summary screen appears after one hour of continuous Sleeping (see page 29). This
screen can be opened any time by pressing the second soft key while in the status screen, providing a
summary up to that point.
End-of-Day Screen
NOTE:
When finished viewing the
end-of-day screen(s), be sure to
return the display to the status
screen. Otherwise, it will not reset
the counters when the sun rises the
next morning. The values will
continue to accumulate.
Figure 12
24
Today 000Ah
00.0kWH
011Vp 00.0Ap 0.00kWp
MAX 14.7 V
ABS 01:00
MIN 14.6 V
FLT 00:00
Day (up to 128 days)
Today 000Ah
00.0kWH
011Vp 00.0Ap 0.00kWp
MAX 14.7 V
ABS 01:00
MIN 14.6 V
FLT 00:00
Accumulated
Amp-hours
Today 000Ah
00.0kWH
011Vp 00.0Ap 0.00kWp
MAX 14.7 V
ABS 01:00
MIN 14.6 V
FLT 00:00
Accumulated kWh
Total Power
Today 000Ah
00.0kWH
011Vp 00.0Ap 0.00kWp
MAX 14.7 V
ABS 01:00
MIN 14.6 V
FLT 00:00
Peak Input Voltage
Today 000Ah
00.0kWH
011Vp 00.0Ap 0.00kWp
MAX 14.7 V
ABS 01:00
MIN 14.6 V
FLT 00:00
Peak Output Current
Today 000Ah
00.0kWH
011Vp 00.0Ap 0.00kWp
MAX 14.7 V
ABS 01:00
MIN 14.6 V
FLT 00:00
Peak Output Power
in Kilowatts
Today 000Ah
00.0kWH
011Vp 00.0Ap 0.00kWp
MAX 14.7 V
ABS 01:00
MIN 14.6 V
FLT 00:00
Maximum Battery
Voltage Obtained
Today 000Ah
00.0kWH
011Vp 00.0Ap 0.00kWp
MAX 14.7 V
ABS 01:00
MIN 14.6 V
FLT 00:00
Accumulated
Absorb Time
Today 000Ah
00.0kWH
011Vp 00.0Ap 0.00kWp
MAX 14.7 V
ABS 01:00
MIN 14.6 V
FLT 00:00
Minimum Battery
Voltage Obtained
Today 000Ah
00.0kWH
011Vp 00.0Ap 0.00kWp
MAX 14.7 V
ABS 01:00
MIN 14.6 V
FLT 00:00
Accumulated
Float Time
End-of-Day Summary Screen
900-0009-01-00 Rev B
Operation
Navigating the End-of-Day Screens and Data Logging
Status Screen
In
Out
11.6V
13.8V
0.000 kW
AUX: OFF
End-of-Day Screen
0.0 A
0.0 A
0.0 kWH
Sleeping
Today 000Ah
00.0kWH
011Vp 00.0Ap 0.00kWp
MAX 14.7 V
ABS 01:00
MIN 14.6 V
FLT 00:00
Press SK1 to return to the
status screen.
Pressing the second soft key
(SK2) opens the end-of-day
summary menu/logging.
CLEAR LOG Screen
The daily statistics or the accumulated
statistics are stored on the charge controller's
static memory. A new log “day” begins when
the controller enters Wakeup. (See page 30.)
Logs accumulate for up to 128 days. See
pages 81 and page 82 for details.
End-of-Day Screen
Today 000Ah
00.0kWH
011Vp 00.0Ap 0.00kWp
MAX 14.7 V
ABS 01:00
MIN 14.6 V
FLT 00:00
CLEAR LOG
Press SK2 to open the
CLEAR LOG screen.
BACK
TOTL
DAILY
OR
End-of-Day Screen
Today 000Ah
00.0kWH
011Vp 00.0Ap 0.00kWp
MAX 14.7 V
ABS 01:00
MIN 14.6 V
FLT 00:00
Are you sure?
NO
YES
OR
Press SK3 to open the previous
day’s summary screen.
Continuing to press this soft key
will cycle back through the last
128 daily summary screens.
End-of-Day Screen
Today 000Ah
00.0kWH
011Vp 00.0Ap 0.00kWp
MAX 14.7 V
ABS 01:00
MIN 14.6 V
FLT 00:00
Pressing SK4 will bring up
the summary for the 128th
day back.
Figure 13
900-0009-01-00 Rev B
End-of-Day Screen
Today 000Ah
00.0kWH
011Vp 00.0Ap 0.00kWp
MAX 14.7 V
ABS 01:00
MIN 14.6 V
FLT 00:00
Press SK1 to return to the
status screen.
This data log can be downloaded to an SD
card. The MATE3 system display is required
for this download. See page 75 for details on
this feature.
Navigating the End-of-Day Summary Screen
25
Operation
Modes of Operation
The FLEXmax has 25 different modes that will display on the status screen. These messages will vary
with function. The FLEXmax modes consist of various charging stages, equalization, various reasons
for stopping charging, and certain specialized operating modes.
The amount of time required before starting operation is dependent on the module type, ambient
temperature, and the amount of sunlight directly on the PV array. Normally, the FLEXmax starts in the
morning within a few minutes of the PV array being exposed to direct sunlight.
The FLEXmax modes of operation will change occasionally during the day based on the PV array
output and the battery system state of charge. The FLEXmax operating modes are displayed at the
bottom right hand corner of the status screen. See Figure 11.
Figure 14 shows an example of the various stages of operation during battery charging and the
messages shown during each stage. Battery charging is described in detail on page 102.
Figure 14
FLEXmax Battery Charging and Modes
Absorbing
The FLEXmax is in the Absorbing stage of a three-stage cycle, regulating the battery voltage at the
Absorbing voltage set point. While the batteries are held at this voltage, the ChgT counter in the Misc
menu counts up from zero toward the user-defined Absorb Time Limit. (See pages 50 and 55.) The
charger will exit this stage and enter the Float stage if the ChgT timer reaches the time limit, or if the
Absorb End Amps setting is reached. (See page 55.)
If the battery voltage drops below the Absorbing voltage (see page 32), the FLEXmax reverts back to
the Bulk charge stage and displays MPPT Bulk as shown on page 28. The ChgT counter will begin
counting back toward zero. Lower voltages will cause the timer to subtract minutes at a faster rate, as
shown on Table 2 on page 27.
26
900-0009-01-00 Rev B
Operation
Table 2
Battery Voltage and Charge Timer
Battery Voltage
ChgT (Charge Timer) Activity/Display
 12.4 V, 24.8 V, 37.2 V, 49.6 V, or 62.0 V,
and less than the Absorbing voltage
No change.
<12.4 V, 24.8 V, 37.2 V, 49.6 V, or 62.0 V
For every minute elapsed, 1 minute is
subtracted from the timer
<12.0 V, 24.0 V, 36.0 V, 48.0 V, or 60.0 V
For every minute elapsed, 2 minutes is
subtracted from the timer
< 11.6 V, 23.2 V, 34.8 V, 46.6 V, or 58.0 V
For every minute elapsed, 4 minutes is
subtracted from the timer.
Auto Start (Auto ReStart)
This setting allows the user to choose between continuous MPP tracking or occasional restarts of the
sweeping process. A restart means the controller abandons the existing maximum power point and
“re-sweeps”, or begins gathering new power point data. See page 58 for more information.



Mode 1: Once every 1.5 hours in the Bulk charging stage
Mode 2: Once every 1.5 hours in the Bulk, Absorbing and Float recharging stages
Mode 0: Auto ReStart is disabled completely. It will continously track the maximum power point without
starting over.
NOTE: If enabled, AutoStart also occurs during the MPPT EQ cycle. See page 29.
BatTmpErr
The battery temperature sensor is shorted or damaged. The charging voltage will not be temperature
compensated and the cooling fan will continuously operate. See the section on RTS compensation on
page 56.
BatTooHot
The battery temperature sensor has detected a battery temperature of over 50°C. The FLEXmax will
stop charging the battery and wait for the battery to cool below 50°C.
Charged
There is an external DC source other than PV keeping the battery above the Float voltage set point
(see page 32). The FLEXmax will stop charging because it is not needed. The display may also appear
when the cycle is transitioning from Absorbing (upper target voltage) to Floating (lower voltage).
EQ
The charger is in a cycle of equalization. (See page 48.) This is the time elapsed in hours and minutes
since the BATTERY EQUALIZE VOLTS set point was met.
If this set point is not maintained, the controller will revert back to MPPT EQ. (See page 29.) The EQ
timer will pause until the batteries are regulated at the BATTERY EQUALIZE VOLTS set point again.
The paused time can be viewed in the End-of-day Summary screen (see page 24).
EQ Done
Once the set EQ time (between 1 and 7 hours) has successfully completed, the FLEXmax will transition
to Float stage. EQ Done will be displayed either until a button is pressed or the next morning’s
wakeup. The FLEXmax will transition to Float stage at the end of the completed equalization cycle.
900-0009-01-00 Rev B
27
Operation
EX-Absorb
There is an external DC source other than PV keeping the battery above the Absorbing voltage set
point. The FLEXmax will stop charging because it is not needed.
Floating
The FLEXmax is in the Float stage of a three-stage cycle, regulating the battery voltage at the Float
voltage set point. This stage is temperature compensated. (See page 103.) If the battery voltage
drops below the Float voltage, the FLEXmax will employ the MPPT function to draw more power from
the PV array. (This may occur if the batteries are powering loads.) If this happens, the operating mode
will change to MPPT Float. (See below.)
GT Mode
The FLEXmax is in Grid-Tie mode. In a system with an OutBack grid-interactive inverter, a HUB, and a
system display, the FLEXmax will display GT Mode, if and only if, the inverter is in Sell mode and the
FLEXmax is in the MPPT BULK or MPPT FLOAT modes. This message also indicates that Grid-Tie mode
communication has been established between the inverter and charge controller. GT must be
selected in the MPPT Mode advanced menu in order to be viewed. (See page 53.)
High Voc
This indicates the PV array’s open-circuit voltage is too high for the controller to safely operate
(> 145 Vdc). This should only occur with systems using 72 Vdc nominal PV arrays in very cold
temperatures (below -15°C / 5°F). The FLEXmax will automatically restart operation once the PV
array’s open-circuit voltage falls to a safe level (145 Vdc or lower).
CAUTION: Equipment Damage
Voltages in excess of 150 Vdc are likely to damage the FLEXmax controller. The PV array
should be designed to avoid ever reaching these voltages.
Low Light or Snoozing
A Low Light or Snoozing mode indicates that the PV voltage is high enough to activate the FLEXmax,
but there is not enough current available to charge. During the initial tracking (see Wakeup and
Tracking), if it is determined to be too late (or too early) in the day, the FLEXmax will display Low Light
for a few seconds and then display Snoozing for five minutes (default). This reduces energy usage and
unnecessary powering of the FLEXmax. This message is also displayed in extremely cloudy weather.
MPPT 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 Absorbing 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 there is not enough PV energy to
maintain a different stage, such as Absorbing. See page 26 for more information.
MPPT Float
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 Float voltage set
point. Normally, the charge controller enters this mode if it was in the Floating mode (see above) and
there was not enough energy to maintain the battery voltage.
28
900-0009-01-00 Rev B
Operation
MPPT EQ
The equalization cycle has started and the charge controller is trying to regulate the batteries at the
BATTERY EQUALIZE VOLTS set point. Once this voltage has been reached, the displayed mode will
change to EQ.
Before equalizing, battery loads should be turned off and the battery should be charged so the charge
controller can quickly reach the EQ voltage set point. Otherwise, the charge controller may have
difficulty reaching or maintaining the equalization process.
Equalization is not battery temperature compensated.
New Voc
The FLEXmax is measuring a new open-circuit panel voltage (Voc). This mode tells the user that
external conditions have changed. After displaying this message, the charge controller will enter
Tracking mode to perform power point tracking again.
OvrCurrent
This condition occurs if more than 6 amps flows from the battery to the FLEXmax, or if more than
100 amps is drawn from the FLEXmax by the battery. To reinitiate power production, press <RSTRT>
in the Misc menu (see page 51). If this continues to occur, the unit may be malfunctioning.
Over Temp
The FLEXmax is too hot. If this message appears, carefully check to see if the heat sink is extremely
hot. To help control its operating temperature, avoid installing the FLEXmax in direct sunlight.
Re-Cal
There are certain conditions that can confuse the current measuring method in the FLEXmax. If this
happens, the FLEXmax will temporarily stop and re-calibrate. This may happen because of high
temperatures or current flowing from the battery. After displaying this message, the charge controller
will enter Tracking mode to perform power point tracking again.
Sleeping
The PV voltage is two volts less than the battery voltage. This normally appears at night, when no PV
energy is available. This may also appear during the day when the FLEXmax is transitioning between
certain states, or due to other conditions. After three hours of Sleeping, the FLEXmax will transition to
Zzzzz... mode.
Sys Error
This indicates an internal non-volatile memory error. The unit will stop operating when this message
is displayed. Call OutBack Technical Support if this message appears (+1.360.618.4363).
Tracking
In Tracking mode, the FLEXmax is doing an initial tracking of the panel voltage from Voc towards
battery voltage after wakeup. This is also displayed when the controller transitions from a target set
point (Absorbing, Floating, or EQ) to the MPPT state (MPPT Bulk, MPPT Float, or MPPT EQ).
900-0009-01-00 Rev B
29
Operation
Unloaded
The battery terminals have become disconnected. This may mean that the battery circuit breaker
breaker has tripped. It can also appear if the nominal battery voltage is set too low.
Wakeup
As the PV open circuit voltage (Voc) rises above the battery system voltage by two volts, the FLEXmax
prepares to deliver power to the batteries, although it does not perform MPPT in this mode. During
this period (initial tracking), the FLEXmax is calculating the PWM duty cycles, turning on power supply
voltages in the proper sequences, and making internal calibrations. It also measures a new Voc at this
time. In Wakeup, the daily statistics of a single FLEXmax (amp-hours, kilowatt-hours, etc.), will
accumulate into the total statistics. The daily statistics and the end-of-day summary will clear, and the
controller will begin logging a new “day”. A FLEXmax combined with a HUB and a MATE will log this
information at midnight. On the MATE3, the data logging will occur at the interval scheduled in the
MATE3 data logging parameters.
Zzzzz...
The FLEXmax will display Zzzzz... after 3 hours of continuous Sleeping. This transition indicates that
the controller recognizes it is night. It will perform Wakeup when voltage is available (see above).
Initial Operation
Status Screen
In
Out
113.6V
12.5V
0.000 kW
AUX: OFF
0.0 A
0.0 A
0.0 kWH
Sleeping
Status Screen
In
Out
000.0V
12.5V
0.000 kW
AUX: OFF
0.0 A
0.0 A
0.0 kWH
Sleeping
Turn the PV input circuit breaker ON. The FLEXmax automatically detects the
PV input voltage.
The FLEXmax enters Wakeup, transitions to Tracking, and prepares to
charge the batteries by tracking the maximum power point of the solar array.
During the initial tracking, the input PV source is gradually loaded from the
open-circuit voltage (Voc) to ½ of the Voc. Within this range, the FLEXmax
seeks the maximum power point.
When the FLEXmax goes into Re-Cal, Auto Restart, or Wakeup, modes,
among other conditions, it performs an initial tracking.
If PV voltage registers 000V when the PV circuit breaker is
ON, check the polarity of the PV connections.
Figure 15
Initial Operation
Changing the Settings on the FLEXmax
Accessing the Main Menu
The main menu allows the user to adjust and calibrate the FLEXmax for maximum performance.
Main Menu
Status Screen
From the status screen, press SK1 to
open the main menu screen.
To return to the status screen from the
main menu, press <EXIT>
(also SK1).
Figure 16
30
In
Out
113.6V
12.5V
0.000 kW
AUX: OFF
0.0 A
0.0 A
0.0 kWH
Sleeping
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
Accessing the Main Menu
900-0009-01-00 Rev B
Operation
Main Menu Map
Main Menu
From the main menu, a user can choose among the
following FLEXmax functions by aligning the arrow
next to the desired selection.
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
<EXIT> returns to the Status screen.
<> moves the cursor to the left.
<> moves the cursor to the right.
<GO> goes to the setup screen for the
chosen option.
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO

Charger—CHARGER SETUP
Adjusts the Current Limit, Absorbing,
and Float recharging voltage set points.
See page 32 for details.
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO

Aux—AUX OUTPUT CONTROL
Provides a secondary control circuit for a vent fan,
error alarm, and other system-related additions.
See page 33 for details.
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO

Light—BACKLIGHT CONTROL
Adjusts the backlighting of LCD screen and soft
key buttons.
See page 47 for details.
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO

EQ—BATTERY EQUALIZE
Activates battery equalization recharging
(manually or automatically).
See page 48 for details.
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO

Additional settings and service information.
See page 50 for details.

Advanced —ADVANCED MENU
Optimizes/fine-tunes the charge controller.
See page 52 for details.

Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
Logging—DATA LOGGING
Displays recorded power production information.
See page 60 for details.

Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
STATS—STATISTICS
Displays recorded peak system information and
cumulative kilowatt-hours and amp-hours.
See page 61 for details.
Figure 17
900-0009-01-00 Rev B
Misc—MISCELLANEOUS
Main Menu
31
Operation
Charger Screen
Charging settings should follow the battery manufacturer's recommendations. This screen allows
changes to the recharging voltage set points if the default settings do not match the manufacturer's
recommendations. (For an explanation of battery charging, see pages 102 and 103).



Current Limit
Absorbing
Float
The default charger output current limit setting is:


80 amps for the FM80, and
60 amps for the FM60.
This setting is adjustable from 5-80 amps.
IMPORTANT:

Check the battery manufacturer’s recommendations for the optimal charging
settings for the type of batteries being used.

An appropriate circuit breaker, or overcurrent device, must be used between the
battery and the FLEXmax.

If a battery remote temperature sensor (RTS) is used, set the Absorbing and Float
setting voltage based on a 25°C/77°F setting. RTS compensated voltage values can
be viewed in the Advanced menu screen under the RTS Compensation heading.
Main Menu
To access the Charger screen and adjust the settings:
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
1.
From the main menu, press the <> or <> soft key to
move the  to the left of the Charger function.
2.
Press <GO> to open the Charger screen.
The  indicates which set point is selected.
3.
Press <> to move the  to the set point that needs to
be changed.
4.
Press <+> to increase the value or (–) to decrease
the value.
Charger Screen
Current Limit 
80A
Absorbing
14.4V
Float
13.8V

+
EXIT
To Exit:
Figure 18
32

Press <EXIT> once to return to the main menu.

Press <EXIT> twice to return to the status screen.
Charger Setup Menu
900-0009-01-00 Rev B
Operation
Aux Screens
The AUX (Auxiliary) is a secondary control circuit — essentially, a small power supply that provides a
12 Vdc output current (up to 200 milliamps/2.4 watts) to an isolated load. It is either ON (Active High)
with 12 Vdc available at the output or OFF (Active Low) with 0 Vdc at the output. It can also be set to
AUTO, so that it activates when certain criteria are met.
The AUX output can respond to specific criteria and control cooling fans, vent fans, load diversion,
fault alarms, and automatic generator control. In some cases, such as the PV Trigger, Night Light, or
Diversion:Relay applications, the polarity of the output can be reversed so that a lack of power
activates the output. This function is controlled through the Aux Polarity screen in the ADVANCED
MENU. (See page 59.)
NOTE: Diversion:Relay and Diversion:Solid St can be used for AC coupling applications.
The AUX output can also be controlled externally through the system display. See the Owner's Manual
for the system display (if used) for details.

Only one AUX MODE can operate at a time (even if other modes have been preset).

See Figure 27, page 45, for an auxiliary setup wiring diagram example.
Table 3
Mode Name
Vent Fan
Aux Mode Functions
Function/Purpose
Function:
When the threshold voltage set point is
exceeded, the AUX output will change state for
at least 15 seconds. If the set point continues to
be exceeded, the output will remain in that state
until the voltage falls below the set point.
Set Points
Aux Polarity
 Threshold
Voltage
Not Available
 Threshold
Voltage
Active High: Activates the
output when the voltage
exceeds the set point.
Once the voltage decreases below the threshold
voltage, the AUX output will remain in that state
for another 15 seconds. It will then deactivate.
Purpose:
This mode is intended to operate a vent fan for a
battery enclosure to ventilate hydrogen gas
from the enclosure.
PV Trigger
Function:
When the threshold voltage set point is
exceeded, the AUX output will activate.
When the threshold voltage decreases below
the voltage set point, the output will remain
active for the duration of the hold time set by
the user.
 Hold Time
Active Low: Deactivates the
output when the voltage
exceeds the set point.
Purpose:
This mode is intended to operate an alarm, or
relay that disconnects the PV array, when
PV input exceeds the threshold voltage set by
the user. The mode deactivates the alarm or
PV disconnect after the time set point has
been reached.
NOTE: Do not exceed 150 Vdc or the FLEXmax
could be damaged.
900-0009-01-00 Rev B
33
Operation
Table 3
Mode Name
Error Output
Aux Mode Functions
Function/Purpose
Function:
When the voltage decreases below the
threshold voltage for 10 minutes or more, the
AUX output will change state.
Set Points
Aux Polarity
 Threshold
Voltage
Not Available
 Threshold
voltage
Active High: Activates for a
set amount of time when the
voltage drops below the
threshold for a set amount
of time.
Purpose:
This mode is useful for monitoring remote sites.
It is intended to signal when the charge
controller has not charged the batteries for 26
hours or more or if the battery voltage has fallen
below the threshold voltage for more than 10
minutes.
When set as Active Low, it can activate an alarm
by sending a signal through a modem to a
computer to alert the operator of the problem.
Night Light
Function:
When the voltage drops below the threshold
voltage set point for the amount of time set in
the Hysteresis time, the AUX output changes
states and remains in that state for the amount
of time set for the ON time.
 ON Time
 Hysteresis
Time
Purpose:
This mode is intended to illuminate a
user-provided, low wattage light for as long as
the charge controller remains in Sleep mode or
for the ON time set by the user.
Float
Function:
When the FLEXmax is in the Float stage, the
output activates to power a load.
Active Low: Deactivates for a
set amount of time when the
voltage drops below the
threshold for a set amount of
time.
None
Not Available
 Threshold
Voltage
Active High: Controls an
auxiliary load to divert power
away from the batteries when
a wind or hydroelectric turbine
is connected directly to the
batteries.
Purpose:
This mode is intended to power a load when the
FLEXmax is in the Float stage of charging the
batteries.
Diversion:
Relay
Function:
When the battery voltage exceeds the threshold
voltage, the AUX output changes state. Often
used with wind or hydroelectric sources.
 Time
Purpose:
This mode is intended to divert power from the
batteries to prevent overcharging by activating
a diversion load at the appropriate time.
Diversion: Solid
St
Function:
When the battery voltage exceeds the threshold
voltage, the AUX output goes into pulse-width
modulation at a rate of 200 Hz. Often used with
wind or hydroelectric sources.
Active Low: Deactivates an
auxiliary load to stop diverting
from batteries.
 Threshold
Voltage
Not Available
 Time
Purpose:
This mode is intended to divert power from the
batteries to prevent overcharging by operating
a diversion load at the appropriate PWM level.
Recommended for use with a solid-state relay
for fast and precise load control.
34
900-0009-01-00 Rev B
Operation
Table 3
Mode Name
Low Battery
Disconnect
Aux Mode Functions
Function/Purpose
Set Points
Function:
When the battery voltage falls below the
threshold disconnect voltage, the AUX output
activates. When the battery voltage rises above
the threshold reconnect voltage, the AUX
deactivates.
Purpose:
 Threshold
Voltage for
disconnect
Aux Polarity
Not Available
 Threshold
voltage for
reconnect
 Time delay
This mode is intended to operate a relay to turn
off loads and save battery capacity.
Remote
Allows an OutBack system display to control the
AUX output (see the system display manual
for details).
None
Not Available
AUX MODE Screen Navigation
Main Menu
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
To access the AUX MODE screen and adjust the settings:
1.
From the main menu, press <> or <> to move the  to
the left of Aux.
2.
Press <GO> to open the Aux screen.
3.
Press <NEXT> to cycle through the available auxiliary modes.
4.
Press <MODE> to cycle through the mode set points ON, OFF,
or AUTO. In AUTO mode, the function will automatically
activate when a user-determined value is met and deactivate
(or shut down) when other conditions are met, such as a
certain amount of time passing.
5.
Press <SET> to select the set point(s) (if available).
6.
Press <EXIT> once to return to the main menu.
7.
Press <EXIT> twice to return to the status screen.
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
AUX MODE Screen
AUX MODE
Night Light
Output: Off
EXIT NEXT SET

Off
MODE
NOTE: If more than 10 minutes have passed since
any activity, the PASSWORD screen becomes active,
requiring the user to reenter the password (141).
Figure 19
900-0009-01-00 Rev B
AUX MODE
Name
AUX MODE

Night Light
Output: Off
Off
EXIT NEXT SET MODE
Aux Polarity
See page 59.
AUX MODE
Set Point
Aux Screen Navigation
35
Operation
Vent Fan (AUX Mode)
This mode is intended to operate a vent fan for a battery enclosure which helps ventilate hydrogen
gas from the enclosure. If the voltage remains above the threshold voltage set point, the vent fan will
remain active.
When the voltage falls back below the set point, the vent fan will continue for another 15 seconds,
then turn off.
Main Menu
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
AUX MODE
Vent Fan
Output: Off
EXIT NEXT SET
To set the mode for Vent Fan:
1.
From the main menu, press <> or <> to move the 
to the left of Aux.
2.
Press <GO> to open the AUX MODE screen.
3.
The Vent Fan screen should be the first default screen to
display. If any other mode screen is displayed, press
<NEXT> to cycle through the available modes until
Vent Fan is displayed again.
4.
Press <MODE> to switch between ON, OFF, or AUTO.

ON activates the AUX output.

OFF deactivates the AUX output.

AUTO controls the output according to the criteria of
the selected AUX mode.
Off
MODE
<NEXT> advances to the
next AUX MODE screen.
AUX MODE
Vent Fan
Output: Off
EXIT NEXT
SET
To change the set points for Vent Fan:
Off
MODE
1.
Press <SET> to advance to the set point screen.
2.
Press <VOLT> to advance to the VENT FAN VOLTS screen.
3.
Press <-> or <+> to increase or decrease the value.
4.
Press <BACK> to return to the Vent Fan set point screen.
5.
Press <EXIT> to return to the AUX Mode screen.
AUX MODE
Vent Fan
EXIT
VOLT
VENT FAN VOLTS
> 14.4
BACK
-
+
Figure 20
36
To Exit:

Press <EXIT> once to return to the main menu.

Press <EXIT> twice to return to the status screen.
Setting the Vent Fan Aux Mode
900-0009-01-00 Rev B
Operation
PV Trigger (AUX Mode)
This mode is intended to operate an alarm, or relay that disconnects the PV array, when PV input
exceeds the threshold voltage set by the user. The mode turns off the alarm or PV disconnect after the
PV voltage decreases below the threshold for a time period that is set by the user.
CAUTION: Hazard to Equipment
Do not exceed 150 Vdc or the FLEXmax could be damaged.
To set the mode for PV Trigger:
Main Menu
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
1.
From the main menu, press <> or <> to move the  to
the left of Aux.
2.
Press <GO> to open the AUX MODE screen.
3.
Press <NEXT> until PV Trigger is displayed in the AUX MODE
screen.
4.
Press <MODE> to cycle through ON, OFF, or AUTO.
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
AUX MODE
PV Trigger
Output: Off
EXIT NEXT SET


ON activates the AUX output.

OFF deactivates the AUX output.

AUTO controls the output according to the criteria of the
selected AUX mode.
Indicates Aux Polarity
is Active High
Off
MODE
<NEXT> proceeds to the
next AUX MODE screen.
AUX MODE
PV Trigger
Output: Off
EXIT NEXT
SET

To change the set points for PV Trigger:
Off
MODE
1.
Press <SET> to advance to the set points screens;
<VOLT> and <TIME>.
2.
Press <-> or <+> to increase or decrease the values.
3.
Press <BACK> to return to the set point screen.
4.
Press <EXIT> to return to the AUX Mode screen.
AUX MODE
PV Trigger
EXIT
TIME
VOLT
Hold Time Sec
01.1
BACK
-
+
Figure 21
900-0009-01-00 Rev B
PV VOLTS
> 140
BACK
-
To Exit:

Press <EXIT> once to return to
the main menu.

Press <EXIT> twice to return to
the status screen.
+
Setting the PV Trigger Aux Mode
37
Operation
Error Output (AUX Mode)
This mode is useful for monitoring remote sites. It is intended to signal when the charge controller
has not charged the batteries for 26 hours or more or if the battery voltage has fallen below the
threshold voltage for more than 10 minutes. The 26-hour timer can be viewed.
When set as Active Low, it can operate an alarm by sending a signal through a modem to a computer
to alert the operator of the condition.
Main Menu
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
To set the mode for Error Output:
1.
From the main menu, press <> or <> to move the  to the
left of the Aux function.
2.
Press <GO> to open the AUX MODE screen.
3.
Press <NEXT> until ERROR OUTPUT is displayed in the AUX MODE
screen.
4.
Press <MODE> to cycle through ON, OFF, or AUTO.

ON activates the AUX output.

OFF deactivates the AUX output.

AUTO controls the output according to the criteria of the
selected AUX mode.
AUX MODE
ERROR OUTPUT
Output: On
On
EXIT NEXT SET
MODE
<NEXT> proceeds to the
next AUX MODE screen.
AUX MODE
ERROR OUTPUT
Output: Off
On
EXIT NEXT
SET MODE
NOTE: To advance to the timer screen, press <SET>. This timer counts
up to the 26-hour limit before the AUX output is activated.
The voltage set point for this mode can also be changed.
To change the set point for ERROR OUTPUT:
AUX MODE
ERROR OUTPUT
01 hrs
EXIT
VOLT
1.
Advance to the timer screen as noted above.
2.
Press <VOLT> to advance to the ERROR LOW BATT VOLTS screen.
3.
Press <-> or <+> to increase or decrease the value.
4.
Press <BACK> to return to the ERROR OUTPUT set point screen.
5.
Press <EXIT> to return to the AUX Mode screen.
ERROR LOW BATT VOLTS
< 11.5
To Exit:
BACK
-
+
Figure 22
38

Press <EXIT> once to return to the main menu.

Press <EXIT> twice to return to the status screen.
Setting the Error Output Aux Mode
900-0009-01-00 Rev B
Operation
Night Light (AUX Mode)
This mode is intended to operate a user-provided, low wattage light for as long as the charge
controller remains in Sleep mode or for the ON time set by the user. OFF is the default value.
Main Menu
To set the mode for Night Light:
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
1.
From the main menu, press <> or <> to move the  to the
left of the Aux function.
2.
Press <GO> to open the AUX MODE screen.
The  indicates that the mode supports polarity. See page 59.
3.
Press <NEXT> until Night Light is displayed in the AUX MODE
screen.
4.
Press <MODE> to cycle through ON, OFF, or AUTO.

ON activates the AUX output.

OFF deactivates the AUX output.

AUTO controls the output according to the criteria of the
selected AUX mode.
Indicates Aux Polarity
is Active High
AUX MODE

Night Light
Output: Off
Off
EXIT NEXT SET
MODE
<NEXT> proceeds to the
next AUX MODE screen.
AUX MODE
Night Light
Output: Off
EXIT NEXT
SET
To change the set points for Night Light:

Off
MODE
1.
Press <SET> to advance to the set point screens.
<HYST>, <VOLT>, and <TIME>.
2.
Press <-> or <+> to increase or decrease the values.
4.
Press <BACK> to return to the ERROR OUTPUT set point screen.
5.
Press <EXIT> to return to the AUX Mode screen.
AUX MODE
Night Light
EXIT
To Exit:
HYST TIME VOLT
Night Light
ON Hysteresis Time
Minutes 000
BACK
+
OFF
Night Light
OFF Hysteresis Time
Minutes 000
BACK
+
Press <EXIT> once to return to the main menu.

Press <EXIT> twice to return to the status screen.
Night Light On Time
Hours 23
BACK
-
+
Adjusts the amount of
time the night light
remains on.
Figure 23
900-0009-01-00 Rev B

Night Light
Threshold Voltage
010
BACK
+
Adjusts the threshold of
the voltage that triggers
the function.
Setting the Night Light Mode
39
Operation
Float (AUX Mode)
This mode is intended to operate a load when the FLEXmax is in the Float stage of charging the
batteries.
Main Menu
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
To set the mode for Float:
1.
From the main menu, press <> or <> to move the
 to the left of Aux.
2.
Press <GO> to open the AUX MODE screen.
3.
Press <NEXT> until Float is displayed in the AUX MODE
screen.
4.
Press <MODE> to cycle through the mode set points ON,
OFF, or AUTO.
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
AUX MODE
Float
Output: Off
EXIT NEXT SET

ON activates the AUX output.

OFF deactivates the AUX output.

AUTO controls the output according to the criteria
of the selected AUX mode.

To Exit:
Off
MODE

Press <EXIT> once to return to the main menu.

Press <EXIT> twice to return to the status screen.
<NEXT> proceeds to the
next AUX MODE screen.
Figure 24
40
Setting the Float Mode
900-0009-01-00 Rev B
Operation
Diversion (AUX Mode)
When external DC sources (wind, hydroelectric) are directly connected to a battery bank, any excess
power should be sent to a diversion load, such as a heating element, using a mechanical relay or
solid-state relay.
In Diversion mode, the user programs set points — from -5.0 volts to 5.0 volts relative to the
Absorbing, Float, and EQ voltages — to activate the AUX output. The Diversion AUX mode can be
active (ON) when the battery voltage is raised above one of these set points for a certain amount of
time or inactive (OFF) when it falls below.

To control a mechanical relay for basic on/off switching of a standard diversion load, follow the instructions
in Figure 25 (both pages).

To control a solid-state relay for PWM switching and precise control of a load, follow the instructions in
Figure 26 (both pages). This application should not be used with a mechanical relay. It requires the use of a
resistive load and should not be used with other sorts of loads.
For a wiring diagram illustrating how to connect this function, see Figure 27.
Diversion:Relay Mode
Main Menu
IMPORTANT:
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
If using wind or hydroelectric turbines, keep the
charge controller’s diversion voltage slightly
above the Absorbing and Float voltage settings
for efficient functioning.
To set the mode for Diversion:Relay:
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
AUX MODE
Diversion:Relay
Output: Off
EXIT NEXT SET

Off
MODE
1.
From the main menu, press <> or <> to move the  to the
left of Aux.
2.
Press <GO> to open the AUX MODE screen.
3.
Press <NEXT> until Diversion:Relay is displayed in the AUX
MODE screen.
4.
Press <MODE> to cycle through the mode set points
ON, OFF, or AUTO.

ON activates the AUX output.

OFF deactivates the AUX output.

AUTO controls the output according to the criteria of the
selected AUX mode.
Continued on next page....
<NEXT> proceeds to the
next AUX MODE screen.
Figure 25
900-0009-01-00 Rev B
Setting the Diversion:Relay AUX Mode (Part 1)
41
Operation
...continued from previous page.
AUX MODE
Diversion:Relay
Output: Off
EXIT NEXT
SET

To change the set points for Diversion:Relay:
Off
MODE
1.
Press <SET> to advance to the set point screens;
<VOLT> and <TIME>.
2.
Press <TIME> to advance to the Time screen. This allows the user
to adjust the minimum time the AUX output is active after the
battery voltage falls below the hysteresis voltage.
3.
Press <-> or <+> to increase or decrease the Hold time values.
4.
Press <DLY+> to increase the Delay Time.
5.
Press <BACK> to return to the Diversion:Relay TIME and VOLT
screen.
6.
Press <VOLT> to move into the Relative Volts screen.
7.
Press <-> or <+> to increase or decrease the values.
8.
Press <HYST> to select the hysteresis value.
9.
Press <BACK> to return to the main Diversion;Relay TIME and
VOLT screen.
10. From the Diversion:Relay screen, press <EXIT> to return to the
AUX MODE screen.
To Exit:
AUX MODE
Diversion:Relay
EXIT
Hold
01.0
BACK
Time
Seconds
+
Delay
00
DLY+
Hold time shows how long the AUX output
stays active after the battery voltage has
fallen below the HYST (hysteresis) set point.
The user can adjust the Hold time from 0.1
to 25 seconds.
The Delay time shows how long the
battery voltage must be above the Relative
Volts before the AUX mode is activated. It
can be adjusted from 0 to 24 seconds, but is
rarely required.
TIME
VOLT

Press <EXIT> once to return
to the main menu.

Press <EXIT> twice to return
to the status screen.
Absorb--Float--EQ
Relative Volts
0.0
00.2
BACK
+
HYST
Use this screen to establish the set points for starting
and ending the AUX mode relative to the Absorb,
Float, and EQ voltages.
The <HYST> (hysteresis) set point establishes when
the AUX mode becomes inactive after the battery
voltage falls below the Relative Volts voltage minus
the hysteresis value.
Pressing the <BACK> soft key returns to the
AUX MODE Diversion: Relay TIME and
VOLT screen.
Figure 25
42
Setting the Diversion:Relay Mode (Part 2)
900-0009-01-00 Rev B
Operation
Diversion:Solid St (AUX Mode)
Main Menu
IMPORTANT:
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO



Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
AUX MODE

Diversion:Solid St
Output: Off
Off
EXIT NEXT SET
MODE
<NEXT> proceeds to the
next AUX MODE screen.
If using wind or hydroelectric turbines,
keep the charge controller’s diversion
voltage slightly above its Absorb and Float
voltage settings for efficient functioning.
Do not use Diversion:Solid St with a
mechanical relay. The PWM action could
cause irregular relay activity.
Diversion:Solid St requires the use of a
purely resistive load. The PWM action may
work poorly with mechanical loads.
To set the mode for Diversion:Solid St:
1.
From the main menu, press <> or <> to move the  to the
left of Aux.
2.
Press <GO> to open the AUX MODE screen.
3.
Press <NEXT> until the Diversion:Solid St mode is displayed in
the AUX MODE screen.
4.
Press <MODE> to cycle through ON, OFF, or AUTO.

ON activates the AUX output.

OFF deactivates the AUX output.

AUTO controls the output according to the criteria of the
selected AUX mode.
Continued on next page...
Figure 26
900-0009-01-00 Rev B
Setting the Diversion:Solid St AUX Mode (Part 1)
43
Operation
Continued from previous page…
To change the set points for Diversion:Solid St:
AUX MODE
Diversion:Solid St
Output: Off
Off
EXIT NEXT
SET MODE
1.
Press <SET> to advance to the set point screens;
<VOLT> and <TIME>.
2.
Press <TIME> to advance to the Time screen. This allows the
user to adjust the minimum time the AUX output is active after
the battery voltage falls below the hysteresis voltage.
3.
Press <-> or <+> to increase or decrease the Hold time values.
4.
Press <DLY+> to increase the Delay time.
5.
Press <BACK> to return to the Diversion:Solid St TIME and
VOLT screen.
6.
Press <VOLT> to move into the Relative Volts screen.
7.
Press <-> or <+> to increase or decrease the values.
8.
Press <HYST> to select the hysteresis value.
9.
Press <BACK> to return to the Diversion:Solid St Time and Volt
screen.
10. From the Diversion:Solid St screen, press <EXIT> to return to
the AUX MODE screen.
To Exit:

Press <EXIT> once to return
to the main menu.

Press <EXIT> twice to return
to the status screen.
AUX MODE
Diversion:Solid St
EXIT
Hold
01.0
BACK
Time
Seconds
+
Delay
00
DLY+
Hold time shows how long the AUX mode
stays active after the battery voltage has
fallen below the HYST (Hysteresis) set point.
The user can adjust the Hold time from 0.1 to
25 seconds.
The Delay Time shows how long the battery
voltage must be above the Relative Volts
before the AUX mode is activated. It can be
adjusted from 0 to 24 seconds, but is
rarely required.
Figure 26
44
TIME
VOLT
Absorb--Float--EQ
Relative Volts
0.0
00.2
BACK
+
HYST
Use this screen to establish the set points for
starting and ending the AUX mode relative to the
Absorb, Float, and EQ voltages.
The <HYST> (hysteresis) set point establishes
when the AUX mode becomes inactive after the
battery voltage falls below the Relative Volts
voltage minus the HYST value.
Setting the Diversion:Solid St Mode (Part 2)
900-0009-01-00 Rev B
Operation
Figure 27
900-0009-01-00 Rev B
Wiring Diagram for Diversion Load and AUX Wiring
45
Operation
Low Battery Disconnect (AUX Mode)
This mode disconnects “auxiliary” loads from the batteries in the event of low voltage. These are
separate from the usual loads. Auxiliary loads are controlled by the AUX output, usually by a larger
relay. When the battery voltage falls below the DISCONNECT VOLTS setting, the AUX loads are
disconnected. When the voltage rises above the RE-CONNECT VOLTS, they will be reconnected.
Any loads not controlled this way, such as an inverter, may continue discharging the battery.
Main Menu
To set the mode for Low Battery Disconnect in Aux mode:
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
1.
From the main menu, press <> or <> to move the  to the
left of the Aux.
2.
Press <GO> to open the AUX MODE screen.
3.
Press <NEXT> until the Low Batt Disconnect Mode is displayed in
the AUX MODE screen.
4.
Press <MODE> to cycle through the mode set points;
ON, OFF, or AUTO.

ON activates the AUX output.

OFF deactivates the AUX output.

AUTO controls the output according to the criteria of the
selected AUX mode.
AUX MODE
Low Batt Disconnect
Output: Off
Off
EXIT NEXT SET
MODE
<NEXT> proceeds to the
next AUX MODE screen.
AUX MODE
Low Batt Disconnect
Output: Off
Off
EXIT NEXT
SET MODE
AUX MODE
Low Batt Disconnect
EXIT
TIME
VOLT
To change the set points for Low Battery Disconnect:
1.
Press <SET> to advance to the set point screens; <VOLT> and <TIME>.
2.
Press <TIME> to advance to the Delay Time Sec screen.
3.
Press <-> or <+> to increase or decrease the values.
4.
Press <BACK> to return to the main Low Batt Disconnect screen.
5.
Press <VOLT> to advance to the DISCONNECT VOLTS screen.
6.
Press <-> or <+> to increase or decrease the values.
7.
Press <RECON> to advance to the RE-CONNECT VOLTS screen.
8.
Press <-> or <+> to increase or decrease the values.
9.
Press <DisV> to return to the DISCONNECT VOLTS screen.
10. Press <BACK> to return to the Low Batt Disconnect screen.
Delay Time Sec
01
Timer
001
BACK
+
This is the time period the FLEXmax waits before either
activating or deactivating the AUX mode when either
the disconnect or reconnect voltages are reached.
DISCONNECT VOLTS
< 13.6
BACK
-
+
ReCon
RE-CONNECT VOLTS
> 14.4
BACK
-
+
To Exit:

Press <EXIT> once
to return to the
main menu.

Press <EXIT> twice
to return to the
status screen.
DisV
When the low voltage occurs, the timer shows the
seconds remaining before disconnecting.
Figure 28
46
Low Battery Disconnect Mode
900-0009-01-00 Rev B
Operation
Remote (AUX Mode)
Remote allows an OutBack system display to control the charge controller's auxiliary output. Some
displays may require a certain level of software in order to use this feature. Consult the owner's
manual for the system display being used for details.
Main Menu
To set the mode for Remote:
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
1.
2.
3.
4.
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
AUX MODE
Remote
Output: Off
EXIT NEXT SET
From the main menu, press <> or <> to move the  to the left
of the Aux.
Press <GO> to open the AUX MODE screen.
Press <NEXT> until the Remote mode is displayed in the AUX MODE
screen.
Press <MODE> to cycle through ON, OFF, or AUTO.
 ON activates the AUX output.
 OFF deactivates the AUX output.
 AUTO controls the output according to the criteria of the
selected AUX mode. This setting may be required depending on
the type of system display being used.
To Exit:
 Press <EXIT> once to return to the main menu.
 Press <EXIT> twice to return to the status screen.
Off
MODE
The FLEXmax AUX output can be used for the AGS (Advanced Generator
Start) function of a system display. Remote must be activated for this to
work. The system display must be set to the HUB port used by the FLEXmax.
See the system display manual for more information on AGS. If using a
MATE, see page 87 of this book. If using a MATE3, see page 73.
Figure 29
Setting the Remote Mode
Backlight
The Backlight selection allows the LCD and soft keys to remain illuminated for up to nine minutes
whenever any soft key is pressed. The default setting for this mode is AUTO. Pressing any soft key
when the LCD is not illuminated does not change any settings.
Main Menu
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
To set the mode for Backlight:
1.
From the main menu, press <> or <> to move the  to
the left of Light.
2.
Press <GO> to open the Backlight Control screen.
3.
Press < MODE> to cycle through ON, OFF, or AUTO.
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
BACKLIGHT CONTROL
Auto Time 2 Minutes
AUTO
EXIT
+
MODE
Figure 30
900-0009-01-00 Rev B

ON activates the backlight.

OFF deactivates the backlight.

AUTO activates the backlight on a timer.
4.
Press <-> or <+> to increase or decrease the number of
minutes (up to 9) for the Auto Time mode.
5.
Press <EXIT> twice to return to the status screen.
To Exit:

Press <EXIT> once to return to the main menu.

Press <EXIT> twice to return to the status screen.
Operating the Backlight
47
Operation
EQ – Battery Equalize
Equalization is a controlled overcharge that is part of regular battery maintenance. Equalization
brings the batteries to a much higher voltage than usual and “simmers” them for a period of time.
This has the result of removing inert compounds from the battery plates and reducing stratification in
the electrolyte. Equalization follows the same pattern as standard three-stage charging. However,
instead of the Absorption voltage set points, it is controlled by the Battery Equalize Volts settings.
The time is controlled by the Battery Equalize Time setting.
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.
CAUTION: Battery Damage


Do not equalize any sealed battery types (VRLA, AGM, Gel, or other) unless
approved by the manufacturer. Some batteries may suffer severe damage from
equalization.
Contact the battery manufacturer for recommendations on equalization voltage,
duration, schedule, and/or advisability. Always follow manufacturer
recommendations for equalization.
MAIN Menu
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
BATTERY EQUALIZE
Volts
15.0
EXIT NEXT -EQV +EQV
BATTERY EQUALIZE
Time
01 Hours
EXIT NEXT -HRS +HRS
BATTERY EQUALIZE
1 Hours
15.0 Volts
Check water level
BACK AUTO START STOP
To change the EQ mode settings:
1.
From the main menu, press <> or <> to move the  to
the left of EQ .
2.
Press <GO> to open the BATTERY EQUALIZE Volts screen.
3.
Press <-EQV> to decrease the value.
4.
Press <+EQV> to increase the value.
5.
Press <NEXT> to advance to the Battery Equalize Time screen.
6.
Press <-HRS> to decrease the value.
7.
Press <+HRS> to increase the value.
8.
Press <NEXT> to advance to the
Battery Equalize Start screen.
9.
Choose one of the following equalization modes:
Press <START> to start a manual equalization charge.

Press <STOP> to stop an equalization charge.

Press <AUTO> to view the auto equalization screen.
See Figure 32 for details.
10. Press <BACK> to return to the EQ screen.
To Exit:

Press <EXIT> once to return to the main menu.

Press <EXIT> twice to return to the status screen.
Figure 31
48

Using Equalization
900-0009-01-00 Rev B
Operation
Automatic Equalization Mode
To enable an automatic equalization mode, an interval must be set for the number of days to pass between
equalization cycles. This interval can be between 1 to 250 days. The default equalization interval setting is 000
which disables this feature.
The Equalization Interval screen allows the user to set the interval between equalization cycles. It also displays
how many days of the interval has passed. The COUNT value will be cleared to 000 when an equalization cycle is
started, manually stopped, or if the charge controller has been powered off.
Equalization Interval
Screen
Days of the interval
that have elapsed
COUNT
000
EQ INTERVAL
000
EXIT
-DAY +DAY
EQ INTERVAL
(1 to 250)
BATTERY EQUALIZE
START Screen
BATTERY EQUALIZE
1 Hours
15.0 Volts
Check water level
BACK AUTO START STOP
To enable an automatic EQ cycle:
1.
Press <AUTO> to display the equalization interval screen.
2.
Use <-DAY> or <+DAY> to set the number of days between each
equalization cycle.
3.
Press <BACK> to return to the status screen.
Equalization Interval
Screen
COUNT
000
EQ INTERVAL
000
EXIT
-DAY +DAY
To Exit:

Press <EXIT> once to return to the EQ screen.
Status Screen
In
Out
11.6V
13.8V
0.000 kW
AUX: OFF
0.0 A
0.0 A
0.0 kWH
EQ-MPPT
In
Out
11.6V
13.8V
0.000 kW
AUX: OFF
0.0 A
0.0 A
0.0 kWH
EQ 0:00
In
Out
0.0 A
0.0 A
0.0 kWH
EQ DONE
11.6V
13.8V
0.000 kW
AUX: OFF
On the Status Screen:

EQ-MPPT will display to indicate the FLEXmax is trying to reach
the target equalize set point.

EQ 0:00 in Hours:Minutes will display after the equalize set point
is reached.

After recharging, an EQ DONE message displays and a Float
cycle begins. EQ DONE is displayed until (1) any soft key is
pressed, or (2) a new day occurs for systems using an OutBack
system display.
The incomplete equalization cycle continues into the next day unless
the FLEXmax is powered off or manually stopped. The remaining EQ
time can be viewed in the End-of-day Summary screen (see page 24).
Figure 32
900-0009-01-00 Rev B
Setting the EQ AUTO Interval
49
Operation
Misc Screen
There are three Misc screens that provide technical information about the operating state of the
system. These are read-only screens and allow for no changes to any of the settings. They do provide
the means to wake up the charge controller if it is in Snooze mode. They also provide a means to force
the charger into a Bulk or Float stage.
Main Menu
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
To access the Misc screens:
1.
From the main menu, press <> or <> to move the  to
the left of the Misc function.
2.
Press <GO> to open the Misc screen.
Charger Aux
Light
EQ Misc Advanced
Logging
Stats
EXIT


GO
Misc Screen #1
GT STATE
255
07
EXIT
GT STATE
255
07
EXIT
PWM%
50.0
NEXT
GT STATE
255
07
EXIT
NEXT
GT STATE
255
07
EXIT
NEXT
GT STATE
255
07
EXIT
RSTRT
Press <EXIT> to return to the
main menu.
Each MPPT operation has a state which is indicated by a
number. These numbers are for engineering purposes and are
not significant in normal use.
This indicates the percentage of "on" time for the FETs as they
are performing pulse width modulation.
ChgT
005
RSTRT
PWM%
50.0
NEXT
ChgT
005
RSTRT
PWM%
50.0
NEXT
ChgT
005
A number below GT means the FLEXmax is in grid-tie mode
and communicating with an OutBack grid-interactive inverter.
These numbers are for engineering purposes and are not
significant in normal use. If the inverter is not grid-interactive,
then this number will read 000. (See pages 54 and 108.)
ChgT
005
RSTRT
PWM%
50.0
PWM%
50.0
The charge timer (ChgT) counts up to the Absorb time
limit when the charger is in the Absorb stage. See
pages 26 and 55.
ChgT
005
RSTRT
Misc Screen #1
GT STATE
255
07
EXIT
Figure 33
50
NEXT
PWM%
50.0
ChgT
005
Press <NEXT> to continue to the
Force Bulk/Float screen.
RSTRT
Miscellaneous Screen #1
900-0009-01-00 Rev B
Operation
Misc Screen #1
GT STATE
255
07
EXIT
PWM%
50.0
NEXT
To bring the charge controller out of Snoozing mode:
ChgT
005
RSTRT
1.
Press <RSTRT>.
2.
Press <EXIT> to return to the main menu.
Misc Screen #1
GT STATE
255
07
EXIT
PWM%
50.0
NEXT
To force the charger into a Bulk or Float charge cycle:
ChgT
005
1.
Press <NEXT>.
2.
Select either a Float or Bulk charge cycle. Forcing a Float or
Bulk recharge will end an EQ cycle. See page 26 for details on
these modes.
RSTRT
Force Bulk/Float Screen
FORCE
NEXT FLOAT BULK
EXIT
3.

Press <FLOAT> to force a Float charge.

Press <BULK> to force a Bulk charge.
Press <EXIT> to return to the main menu, or
press <NEXT> to view the next miscellaneous screen.
Misc Screen #2
PCB
512
Target
14.4v
EXIT
BACK
PCB
512
Target
14.4v
EXIT
BACK
PCB
512
Target
14.4v
EXIT
BACK
PCB
512
Target
14.4v
EXIT
BACK
PCB
512
Target
14.4v
EXIT
BACK

Press <BACK> to return to the
Force Bulk/Float screen.

Press <EXIT> twice to return to
the main menu.
BTMP CFB
255 0712
PCB represents the temperature of the internal components. It
is used to control the cooling fan. These values are in digital
counts, not degrees. The lower the number, the higher the
temperature. (25°C is approximately a value of 525.)
BTMP CFB
255 0712
The target voltage the controller is trying to reach. This will
depend on the active stage of the charger and the set target
value for that stage.
BTMP CFB
255 0712
BTMP CFB
255 0712
Figure 34
900-0009-01-00 Rev B
BTMP CFB
255 0712
BTMP is a battery temperature sensor reference value, used to
compensate the charging voltage. The range is 0 to 255. These
values are in digital counts, not degrees.
An X next to this value indicates an external RTS is being used in a
system with a HUB and system display.
CFB represents Current FeedBack. This is the output value of the
internal current sensor and is used to calculate output amps and
watts to track the maximum power point of the array.
Miscellaneous Screen #2
51
Operation
Advanced Menu
The Advanced menu allows fine-tuning of the FLEXmax operations including Snooze periods and
Maximum Power Point limits (see page 101). The following modes are available in
the Advanced menu. They will appear in the following order.












Snooze Mode
Wakeup
MPPT Mode
Park Mpp
Mpp Range Limit % Voc
Absorb Time
Rebulk Voltage
Vbatt Calibration
RTS Compensation
Auto Restart
Aux Polarity
Reset to Defaults?
Main Menu
To Access the Advanced Menus:
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
Figure 35
1.
From the main menu, press <> or <> to move the 
to the left of Advanced.
2.
Press <GO> to open the first Advanced menu screen.
3.
Press <NEXT> to cycle through the available modes. The
Snooze Mode screen should be the first screen to display.
4.
Press <EXIT> to return to the status screen.
Accessing the Advanced Menu
Snooze Mode (Advanced Menu)
Snoozing occurs if the charging current does not reach the user-selected cutoff current set point as
shown in this screen.
Snooze Mode
ADVANCED MENU
Snooze Mode
< 0.6 amp
EXIT NEXT
AMP
To adjust the set point in the Snooze Mode screen:
1.
Navigate to the Snooze Mode screen through the
ADVANCED MENU as instructed in Figure 35.
2.
Press <AMP> to adjust the amp setting.
Amp values increments include: 0.2, 0.4, 0.6, 0.8 and 1.0.
3.
Press <NEXT> to advance to the Wakeup Mode screen.
To Exit:

Press <EXIT> once to return to the main menu.

Press <EXIT> twice to return to the status screen.
Figure 36
52
Snooze Mode
900-0009-01-00 Rev B
Operation
Wakeup Mode (Advanced Menu)
Wakeup Mode sets the open-circuit voltage (Voc) conditions that cause the charge controller to wake
up during Sleep and Snooze modes. Since environmental conditions impact the open-circuit voltage
of an array, the Voc can be based on the last measured Voc value.
Before changing these values, monitor the system for a week or so using the factory defaults and then
gradually adjust the set points. If the set points are set too high, the charge controller might not wake
up soon enough or often enough, which means a loss of power production.
Wakeup Mode
Amp Settings
To adjust the set points in Wakeup Mode:
ADVANCED MENU
Wakeup Mode
< 0.6 amp
EXIT NEXT
AMP
1.
Navigate to the Wakeup Mode screen through the
ADVANCED MENU as instructed in Figure 35.
2.
Press <AMP> to adjust the amp setting. Amp values
increment include: 0.2, 0.4, 0.6, 0.8 and 1.0.
3.
Press <NEXT> for the voltage settings screen.
4.
Press <+VOC> or <-Min> to adjust the voltage and
delay settings.
Wakeup Mode
Voltage Settings
ADVANCED MENU
Wakeup Mode
1.5V 05m
EXIT NEXT
+VOC -Min
5.

<+VOC> ranges from 1.5 V up to 9.5 V

<+MIN> ranges from 5 up to 15 minutes
Press <NEXT> for the MPPT Mode screen.
To Exit:

Press <EXIT> once to return to the main menu.

Press <EXIT> twice to return to the status screen.
Figure 37
Wakeup Mode
MPPT Mode (Advanced Menu)
This screen allows the user to choose from the following modes:

Auto Track MPPT mode (default) automatically tracks the PV upon wakeup and then tracks the MPP of the
array. If Auto Restart is set to 1 or 2, the charge controller awakes every 1.5 hours and does an initial
tracking. (See page 58.)

U-Pick % (Voc) MPPT mode allows the user to manually adjust the MPP tracking limit as a percentage of the
array's open-circuit voltage (Voc). This percentage is displayed in the Park Mpp % Voc screen along with the
current output wattage. (See page 54.) The wattage value changes as the user adjusts the Voc percentage,
letting the user lock in the most advantageous percentage value. U-Pick % acquires a new Voc value every
1.5 hours if Auto Restart is set to 1 or 2.
To select the MPPT Mode:
MPPT Mode
ADVANCED MENU
MPPT Mode
Auto Track
EXIT NEXT nonGT MODE
1.
Navigate to the MPPT Mode screen through the ADVANCED MENU
as instructed in Figure 35.
2.
Press <MODE> to choose an MPPT mode. If the system has an
OutBack grid-interactive inverter with a HUB and system display,
press <nonGT> to change it to <GT>. This will place the charge
controllers in GT mode to allow the inverter to sell excess power.
3.
Press <NEXT> to view the Park Mpp screen.
To Exit:

Press <EXIT> once to return to the main menu.

Press <EXIT> twice to return to the status screen.
Figure 38
900-0009-01-00 Rev B
MPPT Mode – Auto Track
53
Operation

GT allows the FLEXmax to work more effectively with a grid-interactive OutBack inverter. This setting
automatically raises the charge controller’s Float voltage to equal its Absorption voltage. Since the inverter
sells power to maintain its own Float, Absorption, or Sell settings (all of which should be lower than those of
the controller), this mode makes it easier for the inverter to sell power. (See pages 50 and 108 for more
information on this mode.)

NOTE: The charge controller’s Float voltage returns to normal any time the inverter enters PassThru or
Silent modes. (See the inverter Operator's Manual for inverter modes.)

The Park Mpp screen will be slightly different between Auto Track mode and U-pick mode. In the U-pick
mode, the Watts will appear in addition to the %Voc value.
MPPT Mode
Auto Track
MPPT Mode
U-pick%
ADVANCED MENU
MPPT Mode
Auto Track
EXIT NEXT nonGT MODE
ADVANCED MENU
MPPT Mode
U-pick%
EXIT NEXT nonGT MODE
Auto Track Park Mpp
U-pick% Park Mpp
ADVANCED MENU
Park Mpp
77 % Voc
EXIT NEXT
-%
+%
ADVANCED MENU
Park Mpp
Watts 0251
77 % Voc
EXIT NEXT
-%
+%
Mpp Range Limit % Voc
Mpp Range Limit % Voc
ADVANCED MENU
Mpp Range Limit %VOC
Min
Max
EXIT NEXT
1/2
90%
ADVANCED MENU
Mpp Range Limit %VOC
Min
Max
EXIT NEXT
1/2
90%
To adjust the Park Mpp voltage
percentage settings:
1.
Press <NEXT> to view the Mpp
Range Limit % VOC screen.
2.
Choose one of the following
options:

Press <-%> to decrease
the value.

Press <+%> to increase
the value.
3.
Press <NEXT> to advance to the
Mpp Range Limit %Voc screen.
4.
Press <Min> or <Max> to adjust the
MPP range limit.
To Exit:
The Mpp Range Limit % Voc adjusts the upper range limit of the
FLEXmax controller’s maximum power point (MPP) tracking.
The default Max MPP voltage limit is set at 90% of the Voc and is
normally not adjusted for a PV array. If necessary, the adjustable
limits are 80%, 85%, 90%, and 99% of the Voc.

Press <EXIT> once to return to the
main menu.

Press <EXIT> twice to return to the
status screen.

Press <NEXT> to advance to the
Absorb Time Limits screen.
Min optimizes the tracking window for MPPT. The default Min
setting of 1/2 establishes the lower limit of this window as one-half
the Voc.
The Min range limit setting may be set to FULL if something other
than a PV array is connected to the input of the FLEXmax, such as a
hydroelectric turbine (see page 106). However , the input voltage
must never exceed 150 Vdc at any time.
Figure 39
54
MPPT Mode – U-Pick %
900-0009-01-00 Rev B
Operation
Absorb Time Limits (Advanced Menu)
The amount of time the charge controller stays in the Absorbing stage of charging can be adjusted in
the Absorb Time Limits screen. An Absorbing charge stage normally ends when the battery voltage is
maintained at the Absorbing set point for the time period set in the Absorb Time Limits screen.

Absorb Time is adjustable from 0 to 24 hours (consult the battery manufacturer’s recommendations).

When the Absorb Time Limit is reached, the charge controller goes into Float stage and may briefly display
Charged, then Float. When the battery voltage drops below the Float voltage set point, the charge
controller recharges to maintain this set point, employing the MPPT function in MPPT Float mode.
To adjust the set points in the Absorb Time Limits screen:
Absorb Time Limits
ADVANCED MENU
Absorb Time Limits
01.0 hours
EXIT NEXT
+
1.
Navigate to the Absorb Time Limits screen through the
ADVANCED MENU as instructed in Figure 35.
2.
Use < -> or < + > to adjust the Absorb time from 0.0 to 24.0 hours
following the recommendation of the battery manufacturer.
3.
Press <NEXT> to advance to the Absorb End Amps screen.
To Exit:

Press <EXIT> once to return to the main menu.

Press <EXIT> twice to return to the status screen.
Figure 40
Absorb Time Limits Screen
Absorb End Amps (Advanced Menu)
While the battery voltage is at or above the Absorbing voltage target (see page 26) and the
Absorb End Amps value is reached for a time delay of 15 seconds, the charge controller will switch to
the Float stage. This happens regardless of the charger time minutes as shown in the Misc menu
under ChgT (see page 50). The charger timer will be reset to zero.
Absorb End Amps
ADVANCED MENU
Absorb End Amps
EXIT
NEXT
-
00 A
+
To adjust the set points in the Absorb End Amps screen:
1.
Navigate to the Absorb End Amps screen through the
ADVANCED MENU as instructed in Figure 35.
2.
Use < -> or < + > to adjust the amperage limit following the
recommendation of the battery manufacturer. The default value is 00.
3.
Press <NEXT> to advance to the Rebulk Voltage screen.
To Exit:

Press <EXIT> once to return to the main menu.

Press <EXIT> twice to return to the status screen.
Figure 41
900-0009-01-00 Rev B
Absorb End Amps Screen
55
Operation
Rebulk Voltage (Advanced Menu)
In the Float stage, if the battery voltage falls below the ReBulk Voltage set point for at least
90 seconds, the FLEXmax will automatically initiate a new charge cycle.
To adjust the set points in the Rebulk Voltage screen:
Rebulk Voltage
1.
ADVANCED MENU
Rebulk Voltage
12.0V
EXIT NEXT
+
Navigate to the Rebulk Voltage screen through the
ADVANCED MENU as instructed in Figure 35.
2.
Use < -> or < + > to adjust the voltage limit following the
recommendation of the battery manufacturer. The default
values are 12.0 V, 24.0 V, 36.0 V, 48.0V and 60.0 V.
3.
Press <NEXT> to advance to the Vbatt Calibration screen.
To Exit:

Press <EXIT> once to return to the main menu.

Press <EXIT> twice to return to the status screen.
Figure 42
Rebulk Voltage
Vbatt Calibration (Advanced Menu)
A quality, calibrated voltmeter will provide even more accurate FLEXmax battery readings if an
undesirable voltage drop occurs. When measuring battery voltage, ensure a good connection is made
to the four wire lugs. Check the battery temperature compensation voltages if the voltages are much
different than expected from the charger setup Absorbing and Float voltage settings.
Vbatt Calibration
Adjusted
Voltage
ADVANCED MENU
Vbatt Calibration
14.1 V
0.0 V
EXIT NEXT
+
Adjustment
Value
NOTE: The adjusted voltage value
should appear on the status screen.
To adjust the set points in the Vbatt Calibration
screen:
1.
Navigate to the Vbatt Calibration screen through
the ADVANCED MENU as instructed in Figure 35.
2.
Use < -> or < + > to increase or decrease the
value. The voltage will change in increments
of 0.1 Vdc.
3.
Press <NEXT> to advance to the
RTS Compensation screen.
To Exit:
Figure 43

Press <EXIT> once to return to the main menu.

Press <EXIT> twice to return to the status screen.
Vbatt Calibration
RTS Compensation (Advanced Menu)
The RTS Compensation screen allows the user to control the Absorbing and Float voltage limits
during charging when using a Remote Temperature Sensor (RTS). The RTS adjusts charging voltage
depending on battery temperature. (See page 103 for the amount of compensation per degree.)
However, some conditions can make compensation less than optimal, such as extreme weather (hot
or cold), or charging restrictions from the battery manufacturer. Therefore, the RTS Compensation
screen allows the user to control the limits used by the compensation feature.
56
900-0009-01-00 Rev B
Operation
For example:

During cold weather, a battery often requires a higher charging voltage. Some inverters might not
accommodate these higher voltages and can shut down during charging, cutting off power to their loads.

During hot weather, limiting the RTS Compensation values assures the voltage stays high enough to charge
the batteries instead of dropping too low in reaction to a higher ambient temperature.

Battery manufacturer specifications indicate not to exceed a certain voltage or battery damage could occur.
In all cases, the batteries should be monitored to ensure they are being charged according to the
battery manufacturer’s recommendations.
RTS Compensation has two options available.

WIDE allows the RTS full control over charging. This option uses the default values for the RTS.

LIMIT sets the minimum and maximum voltages for the RTS.
Pressing the soft key below each option switches between the two options. When the LIMIT option is
visible, a <SET> soft key is available to advance to a screen that allows the user to adjust the settings.
RTS Compensation Screen
ADVANCED MENU
RTS Compensation
A 14.1 V
F 13.8 V
EXIT NEXT WIDE
Press <WIDE> to
switch to LIMIT.
ADVANCED MENU
RTS Compensation
A 14.1 V
F 13.8 V
EXIT NEXT LIMIT SET
To use the default RTS compensation values:
1.
Navigate to the RTS Compensation screen through the
ADVANCED MENU as instructed in Figure 35.
2.
If WIDE is visible above the soft key, the absorb and float values
shown in this screen will be used by the system.
To Exit:

Press <NEXT> to advance to the Auto ReStart menu.

Press <EXIT> once to return to the main menu.

Press <EXIT> twice to return to the status screen.
Press <LIMIT> to
switch back to WIDE.
To limit the RTS compensation values:
ADVANCED MENU
RTS Compensation
A 14.1 V
F 13.8 V
EXIT NEXT LIMIT SET
1.
Navigate to the RTS Compensation screen through the
ADVANCED MENU as instructed in Figure 35.
2.
If WIDE is visible above the soft key, press the <WIDE> soft key to
change the display to show LIMIT.
3.
Press <SET> to advance to the RTS COMPENSATION limits screen.
RTS COMPENSATION
Upper LIMIT
14.1 V
Upper LIMIT
14.1 V
BACK

+

Press < > until the  is next to the limit to be changed.
The  will switch between the upper and lower limit values
each time it is pressed.

Press <-> to decrease the value.

Press <+> to increase the value.
To Exit:

Press <BACK> to return to the main RTS Compensation screen.

Press <EXIT> once to return to the main menu.

Press <EXIT> twice to return to the status screen.
Figure 44
900-0009-01-00 Rev B
RTS Compensation
57
Operation
Auto ReStart (Advanced Menu)
This setting allows the user to choose between continuous maximum power point (MPP) tracking, or
occasional restarts of the sweeping process. A restart means the controller abandons the existing
maximum power point value it was using and “re-sweeps”, or begins gathering new power point data.
(See page 101 for more information on MPP tracking.)
Auto ReStart has three options available:

Mode 0 – Initial sweep only and then continuous MPP tracking. Auto ReStart is disabled. The FLEXmax will
continously track the maximum power point without starting over.

Mode 1 – Automatic re-sweep every 90 minutes if controller is in an MPPT mode (MPPT Float, MPPT
Bulk, etc). This will not reset any counters, charging stages, or statistics.

Mode 2 – Automatic re-sweep every 90 minutes if controller is in any charging mode. This will not reset any
counters, charging stages, or statistics.
Auto ReStart Screen
To select an Auto ReStart mode:
ADVANCED MENU
Auto ReStart
MODE 0
EXIT NEXT
MODE
1.
Navigate to the Auto ReStart screen through the
ADVANCED MENU as instructed in Figure 35.
ADVANCED MENU
Auto ReStart
MODE 1
EXIT NEXT
MODE
2.
Press <MODE> to switch between the three Auto
ReStart modes: MODE 0 (default), MODE1, and
MODE2.
ADVANCED MENU
Auto ReStart
MODE 2
EXIT NEXT
MODE
ADVANCED MENU
Auto ReStart
Mode 0
EXIT NEXT
MODE
To Exit:

Press <NEXT> to advance to the Aux Polarity screen.

Press <EXIT> once to return to the main menu.

Press <EXIT> twice to return to the status screen.
Figure 45
58
Auto ReStart
900-0009-01-00 Rev B
Operation
Aux Polarity (Advanced Menu)
When the AUX function is ON, 12 volts DC is present at the AUX terminals (Active High). When the
AUX function is OFF, 0 volts DC are present at the terminals (Active Low).
Aux Polarity allows the user to reverse the availability of this voltage for the Night Light, PV Trigger,
or Diversion Relay functions. When one of the these functions has been chosen as the AUX function,
an arrow in the right hand corner of the screen will reflect the Aux Polarity state.

In Active High, the user establishes certain conditions for these functions.

In the Active Low, zero voltage will be available for a function that in Active High would normally
have voltage.
Aux Polarity Screen
To select the mode for Aux Polarity :
ADVANCED MENU
Aux Polarity
 Active High
EXIT NEXT
MODE
1.
Navigate to the Aux Polarity screen through the
ADVANCED MENU as instructed in Figure 35.
2.
Press <MODE> to switch between:
 Active High or  Active Low
To Exit:
ADVANCED MENU
Aux Polarity
 Active Low
EXIT NEXT
MODE

Press <NEXT> to advance the Reset to Defaults? screen.

Press <EXIT> once to return to the main menu.

Press <EXIT> twice to return to the status screen.
AUX MODE
(Active Low)
AUX MODE
PV Trigger
Output: Off
EXIT NEXT SET
Figure 46
AUX MODE
(Active High)

OFF
MODE
AUX MODE
PV Trigger
Output: Off
EXIT NEXT SET

OFF
MODE
Aux Polarity Screen
Reset to Defaults?
Reset to Defaults? Screen
ADVANCED MENU
Reset to Defaults?
EXIT
NEXT
RESET
To exit the Reset to Defaults menu without resetting the charge
controller:

Press <EXIT> to return to the main menu.

Press <EXIT> again to return to the status screen.
This will exit the menu without making any changes to the current settings.
To reset the FLEXmax to factory default settings:
Are you Sure?
Reset to Defaults
YES
NO
ADVANCED MENU
Reset to Defaults?
EXIT
NEXT
RESET
1.
Press <RESET>.
2.
Press <YES> to confirm the reset. Upon the next power-up, the
FLEXmax will prompt the user to confirm the voltage (see page 22.)
3.
Press <EXIT> twice to return to the main menu.
4.
Press <NEXT>to return to the beginning of the ADVANCED MENU
(see page 52).
This procedure is recommended any time the controller is relocated or the
system is substantially revised. The settings can also be reset to the defaults
by performing a reboot (see page 63).
Figure 47
900-0009-01-00 Rev B
Reset to Defaults? Screen
59
Operation
Logging
The Logging screen in the main menu enables the user to clear the daily and cumulative logs if
necessary. Logs can be downloaded to an SD card if a MATE3 is installed. See page 75 for details.
The FLEXmax daily log begins when the controller enters Wakeup. See page 30.
IMPORTANT:
If two or more charge controllers are used in the same system and are started up or
cleared on different days, their numeric dates will not be the same. This can lead to
some misunderstandings when looking back and comparing data between the two or
more units. A user looking back at day 12 on both units would find very different
results.
Main Menu
 Charger Aux Light
EQ
Misc Advanced
Logging Stats
EXIT


GO
Charger Aux
Light
EQ
Misc Advanced
 Logging Stats
EXIT


GO
To clear the logs:
1.
From the main menu, press <> to move the arrow next to
Logging.
2.
Press <GO> to advance to the End-of-the-Day
summary screen.
3.
Press the second soft key (SK2) to bring up the CLEAR Log
screen. The CLEAR LOG screen offers the option of clearing
up to 128 days of accumulated statistics or the total in the
secondary STATS screen (page 62).
4.
Press and hold either <TOTL> (total) or <DAILY> to clear
those specific statistics. The Are you sure? screen appears.
5.
Pressing <YES> returns to the CLEAR LOG screen; pressing
<NO> returns to the Logging screen.
6.
Press <BACK> to return to the End-of-Day summary screen.
End-of-Day Summary
Screen
Today 000Ah
00.0kWH
011Vp 00.0Ap 0.00kWp
MAX 14.7 V
ABS 01:00
MIN 14.6 V
FLT 00:00
CLEAR LOG
BACK
TOTL
DAILY
Pressing SK3 and SK4 changes the displayed day’s
statistics, by moving either forward or backward within
the 128 days of available statistics that are viewable.
Are you Sure?
NO
Today 000Ah
00.0kWH
011Vp 00.0Ap 0.00kWp
MAX 14.7 V
ABS 01:00
MIN 14.6 V
FLT 00:00
YES
Figure 48
60
Logging Mode
900-0009-01-00 Rev B
Operation
Stats
The STATS screen in the main menu displays additional voltage and time information. In a stand-alone FLEXmax
controller — one that is not connected to a system display — Sunrise shows how long ago the FLEXmax woke
up for the first time each day and when the daily and total logged values were updated and cleared. If the
FLEXmax is connected to a system display, the logging occurs at midnight.
Main Menu
 Charger Aux Light
EQ
Misc Advanced
Logging Stats
EXIT


GO
To view the STATS screen:
1.
From the main menu, press <> to move the arrow
next to STATS.
2.
Press <GO> to advance to the statistics screens.
Charger Aux
Light
EQ
Misc Advanced
Logging  Stats
EXIT


GO
Max Bat Voc
MaxVoc
14.9
036.6 133.0
MaxWatt 0000 Sunrise
EXIT NEXT
01:30:33
Maximum historical battery voltage
occurring on the FLEXmax
Max Bat Voc
MaxVoc
14.9
036.6 133.0
MaxWatt 0000 Sunrise
EXIT NEXT
01:30:33
Daily high Voc value
Max Bat Voc
MaxVoc
14.9
036.6 133.0
MaxWatt 0000 Sunrise
EXIT NEXT
01:30:33
The highest historical
Voc occurring on the
FLEXmax.
Max Bat Voc
MaxVoc
14.9
036.6 133.0
MaxWatt 0000 Sunrise
EXIT NEXT
01:30:33
Maximum wattage
seen by the FLEXmax
Max Bat Voc
MaxVoc
14.9
036.6 133.0
MaxWatt 0000 Sunrise
EXIT NEXT
01:30:33
The time the logs were
cleared and reset
Max Bat Voc
MaxVoc
14.9
036.6 133.0
MaxWatt 0000 Sunrise
EXIT NEXT
01:30:33
Press <NEXT> to view the second STATS screen.
Figure 49
900-0009-01-00 Rev B
STATS Mode
61
Operation
The Secondary Stats screen shows the total accumulated DC and AC
kilowatt-hours and kiloamp-hours of the charge controller.
Secondary STATS Screen
Total
Total
BACK
Total
Total
BACK
00000
0000.0
kWH
kAH
Pressing the <DCkWH> soft key switches the screen between
DC kilowatt-hours and AC kilowatt-hours.
DCkWH
00000
0000.0
kWHAC
kAH

DCkWH shows the DC kilowatt-hours and should be used in a system
that is not grid-interactive.

ACkWH is used with a grid-interactive system. This measure is based
on a 90% inverter efficiency (1 kWh DC= 0.9 kWh AC).
Pressing the <BACK> key three times returns to the main menu.
ACkW
Figure 50
Secondary STATS Screen
Viewing the Firmware Revision
The current firmware revision of the FLEXmax controller can be viewed on its own screen.
Main Menu
Status Screen
In
Out
113.6V
12.5V
0.000 kW
AUX: OFF
Return to the main menu screen.
From the status screen, press the first
soft key (SK1) to open the main
menu screen.
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
0.0 A
0.0 A
0.0 kWH
Sleeping
From the main menu screen, press
and hold <EXIT> (SK1). As long as
SK1 is held, it will show a Revision
screen with the current firmware
revision of the FLEXmax.
Revision
002.001.000
Figure 51
Firmware Revision Screen
Extended Play Mode
If the MPP voltage is low enough to approach the battery voltage (usually when the PV array is very
hot), it is near the effective limit of the MPPT function. Side effects may cause the FLEXmax
components to make a squealing noise. Extended Play mode alleviates this problem by extending the
parameters of the MPPT sweep. (See page 98 for additional notes.)
To activate or deactivate the Extended Play feature:
Revision Screen
Follow the instructions in Figure 51
for reaching the Revision screen.
While continuing to hold SK1, press
and hold SK3. After a few seconds,
the screen will toggle the status of
Extended Play and display it. X on
means the mode is on. If necessary,
continue to press and hold SK3 until
it reads X on.
Revision
X on
002.001.000
To deactivate this function, repeat the process until the screen reads X off.
Figure 52
62
Extended Play Screen
Extended Play Mode
900-0009-01-00 Rev B
Operation
Rebooting the FLEXmax
If the screen becomes garbled or the FLEXmax controller otherwise will not respond to commands, it
may be necessary to reboot its internal processor.
IMPORTANT:
Rebooting the FLEXmax controller will return all the values and set points to the factory
defaults. These values are listed on page 100. It is advisable to record all custom values
before rebooting.
To reboot the FLEXmax:
1. Turn off the battery and PV array circuit
breakers. The FLEXmax should have no
sources of power connected. Observe the
screen until it goes blank.
DC Circuit Breakers
2. Press and hold the first and third soft keys
(SK1 and SK3).
3. While holding down these soft keys, switch
on the battery circuit breaker.
This process follows the power-up sequence
shown on page 21. Continue to follow the
Select Version screen instructions from the
beginning of the manual.
SK1 and SK3
Figure 53
900-0009-01-00 Rev B
Rebooting the FLEXmax
63
Operation
NOTES:
64
900-0009-01-00 Rev B
MATE3 System Display and
Controller
The MATE3 provides the means for programming the FLEXmax charge controller and other devices
when preprogrammed default settings do not work for the destined installation.
Display and LED Status Indicators
Battery Status LEDs (x3)
LCD Screen
Inverter LED
Events LED
Charger LED
AC Input LED
Generator LED
Favorite LED
Figure 54
900-0009-01-00 Rev B
Display and LED Status Indicators
65
MATE3 Screens
Charge Controller Soft Key
PV Icon
Charge Controller Soft Key
Press this soft key to view FLEXmax
charge controller status information.
If no charge controller is present,
the PV icon will be blank and this
soft key will be inoperative.
Charge Controller’s
Mode
Charge Controller Modes:





Bulk
Absorb
Float
EQ
Silent
The FLEXmax has over 25 modes. The MATE3
can only display five status messages and
may substitute one of the five for a FLEXmax
mode not on this list. Check the FLEXmax
status screen to determine its exact mode.
See page 26 for a description of modes.
See page 102 for a description of battery
charging.
The upper left corner of the screen shows the FLEXmax charge
controller’s current mode of operation. Bulk is shown in this
illustration.
Soft Keys:
In displays the present PV array operating voltage and the
current being harvested from the array.
<Datalog> brings up a group of charge
controller statistics that are maintained as a
continuous daily log. These screens are all
shown beginning on page 67.
<Graph> brings up a series of screens that
plot various charge controller 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 68.
VOC displays the open-circuit voltage available from the PV.
Out displays the present battery voltage and the current
being delivered from the charge controller(s) to charge the
battery bank. To the right, this line displays the number of
kilowatt-hours and amp-hours accumulated that day.
Operating displays the total hours the charger has operated
that day in any stage.
Float displays the run time of the Float timer when in the
Float stage.
<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.
Absorb displays the run time of the timer when in the
Absorbing stage.
<Back> returns to the previous screen.
The lower right corner shows the current status of the charge
controller’s Auxiliary (AUX) output. (See page 72.)
Figure 55
66
Screen Items:
Maximum displays the maximum amperage and wattage
harvested from the PV array that day, and the time both were
recorded.
Charge Controller Soft Key Screens
900-0009-01-00 Rev B
MATE3 Screens
DataLog Screen
The <DataLog> soft key shows accumulated daily amp-hour and watt-hour statistics, as well as
maximum current, wattage, and maximum and minimum voltage figures. These maintain a
continuous daily log, up to 128 days, which can be recalled. One day can be displayed at a time.
See page 61 for more information.
Current Date
Screen Items:
The upper left corner shows the date of the
selected Datalog screen. (The current Datalog
screen reads "Today.") To the right, this line also
displays the kilowatt-hours and amp-hours
accumulated that day.
Max Output displays the maximum current
and wattage recorded that day.
Soft Keys:
Absorb The amount of time the Absorbing
<+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.
Figure 56
900-0009-01-00 Rev B
timer ran that day.
Float The amount of time the Float timer ran
that day.
High VOC displays the highest open-circuit
voltage (VOC) recorded that day.
Min Batt displays the lowest battery voltage
recorded that day.
Max Batt displays the highest battery voltage
recorded that day.
DataLog Screen
67
MATE3 Screens
Graph Screens
The <Graph> soft key brings up the following screens which plot various type of data over time.
The first screen shows changes in PV wattage over time.
This axis shows date and time
in 6-hour increments.
This axis shows
PV wattage.
Figure 57
Output Graph
The <Next> soft key brings up a screen showing changes in battery voltage over time.
This axis shows date and time
in 6-hour increments.
This axis shows
battery voltage.
Figure 58
Battery Graph
The <Next> soft key brings up a screen showing changes in PV voltage over time.
This axis shows date and time
in 6-hour increments.
This axis shows
PV voltage.
Figure 59
PV Graph
Continuing to press the <Next> soft key will proceed through the same graphs again from
the beginning.
68
900-0009-01-00 Rev B
MATE3 Screens
Menu Structure in the MATE3
Figure 60 shows the MATE3 menu structure for adjusting the FLEXmax charge controller settings.
Figure 60
Menu Structure
The Main Menu shown above 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.
900-0009-01-00 Rev B
69
MATE3 Screens
Charge Controller Settings
Charge Controller menu options include the following:
Charger ------------------------------------------------------------- >
MPPT ---------------------------------------------------------------- >
Temperature Compensation ------------------------------- >
Battery Equalize ------------------------------------------------ >
Grid-Tie Mode --------------------------------------------------- >
Auxiliary Output ------------------------------------------------ >
Restart Mode ----------------------------------------------------- >
Calibrate ----------------------------------------------------------- >
Reset Charge Controller to Factory Defaults -------- >
See page 70.
See page 70.
See page 71.
See page 71.
See page 71.
See page 72.
See page 73.
See page 74.
See page 74.
Charger
IMPORTANT:
Battery charger settings need to be correct for a given battery type. Always follow battery
manufacturer recommendations. Making incorrect settings, or leaving them at factory default
settings, may cause the batteries to be undercharged or overcharged.
The charge controller uses a “three-stage” battery charging cycle which utilizes multiple settings. This
menu controls the voltages and timers for the battery charger. See page 102 for an explanation of the
three-stage cycle and a description of the individual stages.
Set Points:
 Absorb Voltage
 (Absorb) Time
 Float Voltage
 Rebulk Voltage
 Current Limit
 Absorb End Amps
Figure 61
Charger
MPPT
The charge controller uses a maximum power point tracking (MPPT) algorithm which manipulates the
output of the PV array to harvest maximum wattage. Although this function is automatic, this menu
allows the user to adjust many of its parameters for special applications. See page 53, 54, and 106.
Set Points:



MPPT Mode
U-Pick VOC
Wakeup VOC Change VDC and Wakeup VOC
Change Time – The FLEXmax screen refers to these
items under the title “Wakeup Mode”


Snooze Mode Amps
MPP Range Minimum and MPP Range Maximum –
The FLEXmax screen refers to these items under the
title “Mpp Range Limit %”
Figure 62
70
MPPT
900-0009-01-00 Rev B
MATE3 Screens
Temperature Compensation
When equipped with the Remote Temperature Sensor (RTS), the charge controller compensates for
temperature changes by raising or lowering its charging voltages. However, in some cases the
sensitivity of other DC devices may require this temperature compensation to be limited. This menu
allows the user to manually adjust the upper and lower limits of temperature compensation. See page
103 for an explanation of compensation. See page 56 for the FLEXmax RTS Compensation menu.
Set Points:
 Mode
 Limited: Lower Battery Voltage
 Limited: Upper Battery Voltage
The FLEXmax menu features these items as options under “RTS
Compensation.”
Figure 63
Temperature Compensation
Battery Equalize
CAUTION: Battery Damage


Do not equalize any sealed battery types (VRLA, AGM, Gel, or other) unless approved by the
manufacturer. Some batteries may suffer severe damage from equalization.
Contact the battery manufacturer for recommendations on equalization voltage, duration,
schedule, and/or advisability. Always follow manufacturer recommendations for equalization.
This menu controls the settings for the equalization process, which is used for battery maintenance.
See page 48 for an explanation of equalization and how it relates to the regular charging process.
Set Points:



Figure 64
Equalization Voltage
(Equalization) Hours
Automatic Battery Equalization
Battery Equalize
Grid-Tie Mode
IMPORTANT:
This mode requires a grid-interactive inverter model (also known as grid-tie enabled).
Not all inverters are grid-interactive. If the system is connected to an inverter that is not
grid-interactive, Grid-Tie mode will not function if selected.
This menu allows the charge controller to work more effectively with any grid-interactive inverters
present on the HUB. See pages 50, 54, and 108 for more information.
Set Points:

Two options are available in this menu; N and Y:
~
~
Figure 65
900-0009-01-00 Rev B
N (No) disables Grid-Tie Mode;
Y (Yes) enables Grid-Tie Mode
Grid-Tie Mode
71
MATE3 Screens
Auxiliary Output (Charge Controller)
This menu controls the output and functionality of the Auxiliary (AUX) output. The charge controller’s
AUX terminals provide a 12 Vdc output that can deliver up to 0.2 Adc to control external loads. Typical
loads include signaling a generator to start, sending a fault alarm signal, or running a fan to cool the
inverter. See page 17 for an image of the AUX terminals. See page 33 for a description of AUX modes.
Set Points:

Status – The Auxiliary Output status is controlled by the
<Off>, <Auto>, and <On> soft keys.

Aux Mode –Selects one of nine options: Vent Fan, PV
Trigger, Error Output, Night Light, Float, Diversion:Relay,
Diversion:Solid St, Low Battery Disconnect, and Remote.
Figure 66
Auxiliary Output
Aux Modes for the Charge Controller
Aux Modes include nine options with automatic criteria. The options appear in the following order
when the wheel is drawn clockwise. The Vent Fan option appears first if the charge controller is set at
factory default values; otherwise, it will tend to display the last option selected. (The options are
described in greater detail beginning on page 35.)
NOTE: The Remote option allows the MATE3 to use the AUX output for AGS (see page 47). AGS is
intended for systems with a HUB, inverter, and FLEXmax. If the MATE3 connects only to a FLEXmax,
AGS will only work with DC genset programming. The other AGS functions will not work properly.
Vent Fan
Set Points:

Enable Voltage
Figure 67
Vent Fan
PV Trigger
Set Points:

Enable Voltage

Hold Time

Active: High or Low.
Figure 68
PV Trigger
Error Output
Set Points:

Figure 69
72
Low Battery Voltage
Error Output
900-0009-01-00 Rev B
MATE3 Screens
Night Light
Set Points :




Active: High or Low.
Threshold
Hysteresis Time
ON Time
Figure 70
Night Light
Float
Set Points : None
Figure 71
Float
Diversion: Relay and Solid St
Set Points (NOTE: All items function identically for both Diversion:
Relay and Diversion: Solid St, except for Active: High or Low):





Figure 72
Active: High or Low. (Not present in Diversion: Solid St)
Relative Voltage
Hysteresis
Hold
Delay
Diversion:Relay and Diversion: Solid St
Low Batt Disconnect
Set Points:
 Disconnect
 Re-Connect
 Disconnect Delay
Figure 73
Low Batt Disconnect
Remote
Set Points: None
This mode can also be used for the MATE3’s AGS function. See
pages 47 and 72 for important information on this function.
Figure 74
Remote
Restart Mode
This item selects between continuous MPPT, or occasional MPPT restarts. (See pages 27 and 58.)
Set Points:

0 – Continuous MPPT, 1 – Automatic re-sweep every 90 minutes
in MPPT charging, 2 – Automatic re-sweep every 90 minutes in
any mode.
Figure 75
900-0009-01-00 Rev B
Restart Mode
73
MATE3 Screens
Calibrate
The Calibrate menu allows adjustment of the charge controller’s battery voltmeter. If a particular
controller’s readings do not match those of another device, or a hand-held meter, the calibration
feature may improve consistency.
Set Points:

Battery Voltage – Calibrates the Vdc measurement
made at the controller’s battery terminals
Calibration Offset
Figure 76
Calibrate
NOTE: Calibration does not change the actual voltage of the charge controller, only the reading of
that voltage.
Also, measurements 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, note that this is an issue with the system, not the
charge controller. Calibration cannot correct for it.
Reset Charge Controller to Factory Defaults
This menu allows the user to erase all settings from the selected charge controller and start over with
the values programmed at the factory. These values are listed on page 100.
To access the Reset to Factory Defaults menu:
1.
Access the main menu as shown in Figure 16.
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 Controller menu. No changes will be made
to any settings.
 If <Yes> is selected, the inverter’s settings will
immediately change to the original factory values.
The screen will display the message Charge
Controller Restored to Factory Defaults. A
<Continue> soft key will appear. Pressing this key
will return the screen to the Charge Controller
menu.
6.
After resetting the charge controller to factory default
parameters:
 press the <Continue> soft key or the Up navigation
key to return to the Charge Controller menu, or
 press the Top navigation key to return to the
Settings menu.
Figure 77
74
Press <Continue> to return to the
Charge Controller Menu.
Restoring the Charge Controller to Factory Default Settings
900-0009-01-00 Rev B
MATE3 Screens
Device Data Logs
Users of the MATE3 can create Device Data Logs for the FLEXmax charge controller. The Data Logs can
then be uploaded and saved to an SD card.
Saving Data Logs for the FLEXmax Charge Controller
To create a data log for the FLEXmax Charge Controller:
1.
Access the Main Menu as shown in Figure 16.
2.
Select the Device Data Logs menu.
3.
Select FLEXmax Charge Controller menu.
4.
Select Upload and Save Data Log on the FM Charge
Controller Data Log menu.
5.
Select one of the two options.
 Press <New> to give the new data log a unique name. Or
 Press <Save> to save the data log over the name that is
highlighted 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 return to the Upload and Save Data
Log menu.
Returns to the Upload and
Save Data Log screen.
To create a new name for the data log (up to 8 characters
maximum):
1.
Use the control wheel to scroll through the available
characters.
2.
Use <> and <> to move to the next character location.
3.
Press <Delete> to erase the character that is highlighted.
4.
Press <Save> to save the new data log on the SD card.
4.
Press <Continue> to return to the Upload and Save Data
Log menu.
Returns to the Upload and
Save Data Log screen.
Figure 78
900-0009-01-00 Rev B
Uploading and Saving a Data Log for the FM Charge Controller
75
MATE3 Screens
Data Log File Format
Information generated by this function will be saved on the SD card in a generic .csv file format, which
can be read by most spreadsheet programs.
Data Logging example:
NOTE: This header line is NOT included in the download.
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
Figure 79
76
Data Log Example for the Charge Controller
900-0009-01-00 Rev B
MATE/MATE2 Screens
Summary Screens
If a FLEXnet DC is
installed in the system,
the following summary
screens will be available.
FLEXnet DC
Summary Screen #1
FLEXnet DC
Summary Screen #2
FLEXnet DC
Summary Screen #3
FLEXnet DC
Summary Screen #4
FX Inverter/Charger
Summary Screen
(If the FNDC is not installed, this
will be the 1st Summary Screen.)
FLEXmax Charge Controller
Summary Screen
Figure 80
900-0009-01-00 Rev B
Summary Screens
77
MATE/MATE2 Screens
Status Screens
To view the status screens of a FLEXmax 60 or FLEXmax 80 using a MATE, follow the illustration below.
Changes to FLEXmax settings can only be changed from the charge controller user interface; changes
can not be done when viewing these screens on a MATE.
MODE Screens
MAIN-----------------1:35:04p
Navigation for STATUS/CC/MODE
SUM

<STATUS> returns to the STATUS/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 to the first CC/MODE screen for the port
shown.

<PORT> directs the MATE to read the next device (port)
on the HUB.
STATUS
SETUP ADV
STATUS---------------choose device
FX
CC
DC
MAIN
STATUS/CC/PAGE1
Charge Controller Modes
MODE METER
The MODE screens describe the current operating mode for
the FLEXmax charger (see page 26) and AUX output
(see page 33).
SETPT PG2
STATUS/CC/MODE-----P00
charger mode:
Silent
DOWN
STATUS PORT
STATUS/CC/MODE-----P00
aux relay mode:
Low Batt
DOWN
UP
TOP
PORT
STATUS/CC/MODE-----P00
aux relay state:
ON
DOWN
UP
TOP
PORT
STATUS/CC/MODE-----P00
End of mode menu
UP
TOP STATUS
The FLEXmax has over 25 modes. The MATE can only display five
status messages and may substitute one of the five for a FLEXmax
mode not on this list. Check the FLEXmax status screen to
determine its exact mode.
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


Figure 81
78
ON
OFF
MODE Screens
900-0009-01-00 Rev B
MATE/MATE2 Screens
METER Screens
MAIN-----------------1:35:04p
Navigation for STATUS/CC/METER
SUM

<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 to the first CC/METER screen for the
port shown.

<PORT> directs the MATE to read the next device (port)
on the HUB.
STATUS
SETUP ADV
STATUS---------------choose device
FX
CC
DC
MAIN
Charge Controller METER Screens
STATUS/CC/PAGE1
MODE METER
SETPT PG2
The METER screens display readings for power, current, and
voltage handled by the FLEXmax. (See page 78 for more
information on the mode messages displayed here.)
mode/pv-in/bat-out:

mode: Silent
P00
in 11.2 vdc
0 adc
out 14.4 vdc
0 adc
DOWN
STATUS PORT
STATUS/CC/METER----P00
charger
0 w
watts
DOWN
UP
TOP
PORT
mode (charger )
~ Bulk
~ Absorption
~ Float
~ Silent
~ Equalization

in vdc (PV array voltage)

adc (incoming PV current)

out vdc (battery voltage)

adc (outgoing current
delivered to the battery)
charger watts: Charger output to the battery (watts).
charger kwhrs: Kilowatt-hours sent to the batteries today.
charger amps dc: Charger current to the battery (Adc).
battery voltage: Battery voltage (Vdc).
panel voltage: PV array voltage (Vdc).
STATUS/CC/METER----P00
charger
0.0 kwh
kwhrs
DOWN
UP
TOP
PORT
CC Firmware revision: The level of the last revision or
programming upgrade to the FLEXmax.
STATUS/CC/METER----P00
charger
+000 Adc
amps DC
DOWN
UP
TOP
PORT
STATUS/CC/METER----P00
battery
13.7 Vdc
voltage
DOWN
UP
TOP
PORT
STATUS/CC/METER----P00
CC Firmware revision
002.001.000
DOWN
UP
TOP
PORT
STATUS/CC/METER----P00
charger
0 ah
amp hour
DOWN
UP
TOP
PORT
STATUS/CC/METER----P00
panel
33 Vdc
voltage
DOWN
UP
TOP
PORT
STATUS/CC/METER----P00
End of meter menu
Figure 82
900-0009-01-00 Rev B
UP
TOP STATUS
METER Screens
79
MATE/MATE2 Screens
SETPT Screens
Navigation for STATUS/CC/SETPT
MAIN-----------------1:35:04p

<STATUS> returns to the CC/PAGE1 screen.
SUM

<DOWN> moves to the next menu item in the
diagram.

<UP> moves to the previous menu item in the
diagram.

<TOP> returns to the first CC/SETPT screen for the
port shown.

<PORT> directs the MATE to read the next device
(port) on the HUB.
STATUS
SETUP ADV
STATUS---------------choose device
FX
CC
DC
MAIN
STATUS/CC/PAGE1
MODE METER
SETPT PG2
Charge Controller SETPT (set point) Screens
STATUS/CC/SETPT----P00
absorb
14.4 Vdc
The SETPT screens display the current settings for
the FLEXmax battery charger, as described on
page 32.
DOWN STATUS

Absorb

Float
PORT
STATUS/CC/SETPT----P00
float
13.6 Vdc
DOWN
UP
TOP
PORT
STATUS/CC/SETPT----P00
end of set point
menu
UP
TOP STATUS
Figure 83
80
SETPT Screens
900-0009-01-00 Rev B
MATE/MATE2 Screens
LOG Screens
MAIN-----------------1:35:04p
Navigation for STATUS/CC/LOGS
SUM

<STATUS> returns to the CC/PG2 screen.

<DOWN> moves to the next menu item
in the diagram.

<UP> moves to the previous menu item
in the diagram.

<TOP> returns to the 1st CC/LOG1 screen
for the port shown.

<PORT> directs the MATE to read the
next device (port) on the HUB.

<DAY–> displays log information from
one day earlier. Logs can be displayed
from as far as 128 days in the past.

<DAY+> displays log information from
one day later. If the present day is
displayed, then pressing this key will
return the log to 128 days in the past.
STATUS
SETUP ADV
STATUS---------------choose device
FX
CC
DC
MAIN
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 screens contain information
collected from the FLEXmax on individual
days. These logs include daily accumulated
amp-hours and kilowatt-hours, and peak
readings for power, current, and voltage. It
also includes the timers for the FLEXmax
battery charger. This data is the same as
that shown on the FLEXmax End-of-Day
Summary screen (see page 24.)
Log 1 Today:

AH (accumulated battery amp-hours)

Kwh (accumulated battery
kilowatt-hours)

Vp (peak PV voltage)

Ap (peak PV current)

kWp (peak PV kilowatt-hours)
Log 2 Today:
STATUS/CC/METER----P00
end of cc logs display
TOP
STATUS
max V (maximum battery voltage)

min V (minimum battery voltage)
Log 3 Today:
Figure 84
900-0009-01-00 Rev B


absorb timer

float timer
LOG Screens
81
MATE/MATE2 Screens
STAT Screens
MAIN-----------------1:35:04p
SUM
STATUS
SETUP ADV
STATUS---------------choose device
FX
CC
DC

<STATUS> returns to the CC/PAGE2 screen.

<DOWN> moves to the next menu item in
the diagram.

<UP> moves to the previous menu item in
the diagram.

<TOP> returns to the CC/STAT/PAGE2
screen for the port shown, with the
exception of the “end of the cc stats” menu.
From the “end” menu, the <TOP> soft key
returns to the 1st CC/STAT screen.

<PORT> directs the MATE to read the next
device (port) on the HUB.
MAIN
STATUS/CC/PAGE1
MODE METER
Navigation for STATUS/CC/STAT
SETPT PG2
Charge Controller Stats
STATUS/CC/PAGE2------PG1
LOGS
STAT
MAIN
STATUS/CC/STAT-----P00
maximum battery
15.1 Vdc
DOWN
UP
PORT
STATUS/CC/STAT-----P00
voc
21.0 vdc
DOWN
UP
TOP
PORT
STATUS/CC/STAT-----P00
max voc
21.0 vdc
DOWN
UP
TOP
PORT
STATUS/CC/STAT-----P00
maximum wattage
400 W
DOWN
UP
TOP PORT
Figure 85
82
The STAT screens contain historical data for the
FLEXmax, including peak voltages, peak wattage,
and total accumulations. (See page 61.)
maximum battery Vdc:
voc:
max voc:
maximum wattage:
total kWH DC:
total kAH:
STATUS/CC/STAT-----P00
total
kWH DC
307
DOWN
UP
TOP PORT
STATUS/CC/STAT-----P00
total
kAH
25.6
DOWN
UP
TOP PORT
STATUS/CC/STAT----P00
end of cc stats menu
UP
TOP STATUS
STATUS STAT Screens
900-0009-01-00 Rev B
MATE/MATE2 Screens
Advanced Menus
The Advanced menus available in the MATE or MATE2 system display allow the following options:

Change the settings of the FLEXmax battery charger and temperature compensation

Change the parameters of the FLEXmax MPPT process

Change the settings of the FLEXmax equalization process

Calibrate the FLEXmax meters

Change the settings of the Auxiliary output to run small AC or DC loads

Start a generator using Advanced Generator Start (AGS) Mode (see page 47)

Adjust the settings 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 whenever a password is
called for, the system password is:
141
Accessing the Advanced Menus
MAIN-----------------1:35:04p
SUM
STATUS
SETUP ADV
ADV/SETTINGS/WARNING
changes made could
adversely affect
system performance
ADV/PASSWORD---------Enter the password
132
ENTER INC DEC
EXIT
ADV/PASSWORD---------Enter the password
141
ENTER INC DEC
EXIT
Figure 86
900-0009-01-00 Rev B

Press any soft key to advance to
the next screen.

Press the <INC> soft key until 132
becomes 141.

Press <ENTER> when the number 141 is
displayed. This will proceed into the ADV choose
device menu in the Advanced menu map.

Press <EXIT> to return to the main menu without
changing the password.
Accessing the Advanced Menus
83
MATE/MATE2 Screens
CHGR Menu
Navigation for ADV/CC/CHGR

<DOWN> moves to the next
menu item in the diagram.

<INC> increases the value of the
selection.

<DEC> 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 83).
CC/Charger
The CHGR screens adjust the same
settings that are available on the
Charger screen in the FLEXmax
(see page 32).
Figure 87
84

output current limit

absorb voltage

float voltage
ADV Menu for Charging Features
900-0009-01-00 Rev B
MATE/MATE2 Screens
CC ADVANCED Menu
CC/Advanced
The ADVANCED screens adjust the same settings that are available on the Advanced screen in the
FLEXmax (see page 52). These settings relate to charging, MPPT, temperature compensation, and
calibration.
Navigation for ADV/CC/ADVANCED







Figure 88
900-0009-01-00 Rev B
<DOWN> moves to the next menu item in the diagram.
<INC> increases the value of the selection.
<DEC> decreases the value of the selection.
<PORT> directs the MATE to the next device (port) on the HUB.
<TOP> 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 83).
ADV Menu for the Advanced Charging Features
85
MATE/MATE2 Screens
EQ Menu
Navigation for ADV/CC/EQ

<DOWN> moves to the next menu item in
the diagram.

<INC> increases the value of the selection.

<DEC> 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 83).
CC/Equalization
The EQ screens adjust the same settings that are
available on the EQ screen in the FLEXmax
(see page 48).
Figure 89
86

eq voltage

eq time

eq auto eq interval
ADV Menu for EQ Charging Features
900-0009-01-00 Rev B
MATE/MATE2 Screens
AUX Menu
Navigation for ADV/CC/AUX

<DOWN> moves to the next menu item in
the diagram.

<INC> increases the value of the selection.

<DEC> decreases the value of the selection.

<PORT> directs the MATE to read the next
device (port) on the HUB.

<TOP> returns to the CC/PAGE2 screen.

<ADV> returns to the choose device screen.

<MAIN> exits the Advanced menus and
returns to the main menu (see page 83).
CC/AUX
The AUX screens adjust the same settings that
are available on the Aux screen in the FLEXmax
(see page 33).
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 can be used for the
MATE’s AGS function. See page 47.
NOTE: The AGS function is only intended for use
in systems with a HUB, inverter, and FLEXmax. If
the MATE connects only to a FLEXmax, the only
AGS function that will work is the DC genset
programming. The other AGS functions will not
work properly.
NOTE: The MATE must have firmware revision
4.1.6 or higher for AGS to work.
aux control
Figure 90
900-0009-01-00 Rev B

ON

OFF
ADV Menu for the AUX Features
87
MATE/MATE2 Screens
MATE and MATE2 Menu Maps for the FLEXmax
STATUS Menu Map
Navigation for
STATUS/CC/PAGE1

<DOWN> moves to the next
menu item in the diagram.

<UP> returns to the
previous menu item in the
diagram.

<PORT> directs the MATE to
read the next device (port)
on the HUB.

<TOP> returns to the
STATUS/CC/PAGE1 screen.

<STATUS> returns to the
screen at the top of the
respective column.
Figure 91
88
MATE STATUS Menu Map (Page 1)
900-0009-01-00 Rev B
MATE/MATE2 Screens
Navigation for
STATUS/CC/PAGE2

<DOWN> moves to the next
menu item in the diagram.

<UP> returns to the
previous menu item in the
diagram.

<PORT> directs the MATE to
read the next device (port)
on the HUB.

<TOP> returns to the
STATUS/CC/PAGE2 screen.

<STATUS> returns to the
screen at the top of the
respective column.
Figure 92
900-0009-01-00 Rev B
MATE STATUS Menu Map (Page 2)
89
MATE/MATE2 Screens
Advanced Menu Map
Navigation for
ADV/CC/PAGE1

<DOWN> moves to the
next menu item in the
diagram.

<UP> returns to the
previous menu item in
the diagram.

<PORT> directs the
MATE to read the next
device (port) on
the HUB.

<TOP> returns to the
CC/PAGE1 screen.

<ADV> returnsto the
choose device screen.
Figure 93
90
MATE ADVanced Menu Map (Page 1)
900-0009-01-00 Rev B
MATE/MATE2 Screens
Navigation for
ADV/CC/PAGE2

<DOWN> moves to the
next menu item in the
diagram.

<UP> returns to the
previous menu item in
the diagram.

<PORT> directs the
MATE to read the next
device (port) on
the HUB.

<TOP> returns to the
CC/PAGE2 screen.

<ADV> returns to the
choose device screen.
Figure 94
900-0009-01-00 Rev B
MATE ADVanced Menu Map (Page 2)
91
MATE/MATE2 Screens
This page intentionally left blank.
92
900-0009-01-00 Rev B
Menu Maps for the FLEXmax
Figure 95
900-0009-01-00 Rev B
FLEXmax Startup Screens
93
FLEXmax Menu Maps
Figure 96
94
FLEXmax Menu Map (Page 1)
900-0009-01-00 Rev B
FLEXmax Menu Maps
Figure 97
900-0009-01-00 Rev B
FLEXmax Menu Map (Page 2)
95
FLEXmax Menu Maps
Figure 98
96
FLEXmax Menu Map (Page 3)
900-0009-01-00 Rev B
Troubleshooting
IMPORTANT:
Be sure to check out the OutBack customer and user forum at
www.outbackpower.com/forum/ for more FLEXmax information.
Symptom
FLEXmax does not
boot/power-up
(blank LCD)
Remedy
 Check the battery connection and polarity. Reverse polarity or an improper
connection will cause power-up issues.
 Check the battery disconnect or circuit breaker. Ensure all circuit breakers
are sized appropriately.
 Check the battery voltage at the FLEXmax terminals. A battery voltage
below 10.5 Vdc may not power up the FLEXmax. A poor connection may
not allow sufficient voltage to reach the FLEXmax.
FLEXmax not producing
expected power
 Check PV conditions. Clouds, partial shading, or dirty panels can cause
poor performance.
 Check settings. The lower current limit set point in the Charger menu will
yield a loss of power or poor performance symptoms. If the FLEXmax is in
U-Pick mode, it may not track at the maximum power point.
 Check battery conditions and charging stage. If the batteries are charged
(if the FLEXmax is in the Absorbing or Float stage), the FLEXmax will
produce only enough power to regulate the voltage at the Absorbing or
Float set point voltage. Less power is required during these stages.
 Determine the specified short-circuit current of the PV array. The MPP
current is related to this number. Use a multimeter to determine if the
short-circuit current is in the expected range. Array or wiring problems
may restrict the available power.
 Check the PV array temperature. At high temperatures, the maximum
power point voltage may be near or or lower than the battery voltage.
FLEXmax not equalizing
 Make certain the equalization cycle has been started.
~ In the EQ menu, press START to begin the process. When the
equalization cycle has been initiated, MPPT EQ will be displayed.
 The equalization cycle has been initiated, but the battery is not equalizing.
900-0009-01-00 Rev B
~
The cycle will begin when the target EQ set point voltage has been
reached. A small array or cloudy weather will delay the EQ cycle.
Running too many battery loads will also delay the cycle.
~
Check the PV array temperature. At high temperatures, the maximum
power point voltage may be near or lower than the battery voltage.
This can delay the cycle.
97
Troubleshooting
Symptom
FLEXmax is always
SLEEPING
Remedy
 Check battery voltage. If the battery voltage is at or above the Absorbing
voltage set point (compensated for battery temperature), the FLEXmax will
not wake up.
 Check PV voltage. The PV voltage has to be at least two volts greater than
the battery voltage for the initial wakeup.
 If voltage is not present, check the PV array breaker (or fuse). Confirm the
PV array breaker (or fuse) is sized appropriately.
PV voltage reads 000
 If the PV array voltage on the display rises with the PV breaker OFF, but
reads 000 with the PV circuit breaker on, the PV array polarity may be
reversed or shorted.
 If the PV voltage still reads 000 with the PV circuit breaker off after a minute,
call OutBack Technical Support for assistance.
Status screen shows
BatTmpErr
 Confirm the type of temperature sensor. Only the OutBack RTS (remote
temperature sensor) can be used with the FLEXmax.
 If the RTS is correct, it may be faulty or damaged. Disconnect the RTS from
the jack to resume normal operation. Replace the RTS as soon as possible.
FLEXmax internal fan
not running
The internal fan will only run when the internal temperature has reached
approximately 112°F. The fan will continue running until the internal
temperature is less than 104°F.
FLEXmax makes a
squealing sound
If the MPP voltage is low enough to approach the battery voltage (usually when
the array is very hot), it is near the effective limit of the MPPT function. This may
cause the FLEXmax components to make a squealing noise. The problem can
be alleviated by placing the FLEXmax in Extended Play, which extends the
parameters of the MPPT sweep. See page 62 for instructions on using
Extended Play.
This mode may not be desirable under more standard conditions when the PV
voltage is higher. The efficiency of the FLEXmax controller may be reduced.
LCD display scrambled
Reboot the FLEXmax controller as described on page 63. This will clear any
operating problems or glitches. It will also restore all programming items to
their factory default settings.
98
900-0009-01-00 Rev B
Specifications
Electrical and Mechanical Specifications
Specification
FLEXmax 60
FLEXmax 80
Output Current Rating @ 40°C ambient
60 amps continuous
80 amps continuous
Nominal Battery System Voltage
12, 24, 36, 48 or 60 Vdc (adjustable)
PV open circuit voltage
150 Vdc maximum (ETL Rating for UL1741 Standard);
145 Vdc temperature corrected Voc (operational maximum)
Standby power consumption
Less than 1 watt typical
Charge cycle
Three-stage
Voltage regulation set points
13-80 Vdc
Temperature compensation
5 mV per °C per 2 V cell (with optional RTS)
PV input capability
Down convert from any acceptable array voltage to any battery voltage.
Examples: 72 Vdc array to 24 Vdc battery; 60 Vdc array to 48 Vdc battery
Digital Display
4-line, 20-character per line backlit LCD display
Remote Interface
RJ45 modular connector Cat 5 cable 8 wire
Operating Temperature Range*
-40° to 60°C (automaticaly derated above 40°C)
Conduit knockouts
One 1” on the back; one 1” on the left side; two 1” on the bottom
Warranty
Five years parts and labor
Dimensions
13.5” H x 5.75” W x 4” D
16.25” H x 5.75” W x 4”D
Shipping Dimensions
18” H x 11” W x 8” D
21” H x 10.5” W x 9.75”D
Weight
11.6 lb (14 lb boxed)
12.20 lb (15.75 lb boxed)
Options
RTS, HUB 4, HUB 10, MATE, MATE2, MATE3
Menu Languages
English and Spanish
Firmware Revision
This manual applies to FLEXmax 80 or FLEXmax 60 charge controllers with a firmware revision of
002.001.xxx or higher.
Regulatory Specifications
Table 4
Regulatory Specifications for All Models
UL 1741 1st Edition; 2005 Version, CSA 107.1-01
CE Conformance European EN 55022 Class B
900-0009-01-00 Rev B
99
Specifications
Default Settings and Ranges
Table 5
Mode
Menu Item
Setting
Current Limit (FLEXmax 80)
Default 80 Adc
Range: 5 to 80 Adc
Current Limit (FLEXmax 60)
Default 60 Adc
Range: 5 to 60 Adc
Charger
Absorbing
Float
Vent Fan
Volts
PV Trigger
Hold Time Sec
PV VOLTS
ERROR OUTPUT
ERROR LOW BAT
VOLTS
Night Light
ON Hysteresis Time
(Minutes)
On Time (Hours)
Threshold Voltage
Aux
Float
Diversion:Relay
Hold Time (Seconds)
Delay Time (Seconds)
Absorb-Float-EQ
Relative Volts
HYST
Diversion:Solid St
Hold Time (Seconds)
Delay Time (Seconds)
Absorb-Float-EQ
Relative Volts
HYST
100
FLEXmax Settings
Default 14.4 Vdc
Range: Float setting to
80 Vdc
Default 13.8 Vdc
Range: 12.0 Vdc to
Absorbing setting
Default <Off>
<On, Auto, Off>
Default 14.4 Vdc
Range: 10. 0 to 80.0 Vdc
Default <Off>
<On, Auto, Off>
Default 01.1 second
Range: 0 to 25 seconds
Default 140 Vdc
Range: 20 to150 Vdc
Default <Off>
<On, Auto, Off>
Default 11.5 Vdc
Range: 10 to 80 Vdc
Mode
Menu Item
Setting
Low Battery Disconnect
Aux
(cont’d)
Delay Time Sec
DISCONNECT VOLTS
RECONNECT VOLTS
Default <Off>
<On, Auto, Off>
Remote
Default <AUTO>
<ON, AUTO, OFF>
Default 2 minutes
Range: 1 to 9 minutes
Default 14.4 Vdc
Range: Absorbing
setting to 80 Vdc
Default 01 hours
Range: 1 to 7 hours
Default 000 days
Range: 000 to 250 days
Default 0.6 Adc
Range: 0.2 to 1.0 Adc
Default 1.5 Vdc
Range: 1.5 to 9.5 Vdc
Default 05 minutes
Range: 05 to 15 min.
MODE
Light
Auto Time
BATTERY EQUALIZE Volts
EQ
BATTERY EQUALIZE Time
EQ INTERVAL
Snooze Mode
Wakeup Mode Volts
Default <Off>
<On, Auto, Off>
Default 001 minute
Range: 001 to 255 min.
Default 04 hours
Range: 00 to 23 hours
Default 010 Vdc
Range: 005 to 150 Vdc
Wakeup Mode Time
Default <Auto Track >
<Auto Track or
U-Pick>
Default 77% Voc
Range: 40 to 90% Voc
MPPT Mode
Park Mpp
Default <Off>
<On, Auto, Off>
MPP Range Limit (Max)
Default <Off>
<On, Auto, Off>
Default 0.1 second
Range: 0.0 to 25 sec.
Default 0.0 seconds
Range: 0.0 to 24 sec.
Default 0.0 Vdc
Range: 0.0 to 5.0 Vdc
Default 00.2 Vdc
Range: 0.0 to12.0 Vdc
MPP Range Limit (Min)
Default <Off>
<On, Auto, Off>
Default 0.1 second
Range: 0.0 to 25 sec.
Default 00 seconds
Range: 00 to 24 sec.
Default 0.0 Vdc
Range: 0.0 to 5.0 Vdc
Default 00.2 Vdc
Range: 0.0 to12.0 Vdc
Absorb Time Limits
Advanced
Absorb End Amps
Rebulk Voltage
Vbatt Calibration
RTS Compensation
Upper Limit
RTS Compensation
Lower Limit
Default <Off>
<On, Auto, Off>
Default 01 second
Range: 000 to 250 sec.
Default 13.6 Vdc
Range: 10 to 80 sec.
Default14.4 Vdc
Range: 10 to 80 sec.
Default <90%>
<80, 85, 90, 99%>
Default <1/2>
<1/2 or FULL>
Default 01.0 hours
Range: 00.0 to 24 hours
Default 00 Adc
Range: 00 to 55 Adc
Default 12.0 Vdc
Range: 12.0 Vdc to
Float setting
Default 0.0 Vdc
Range: -0.5 to 0.5 Vdc
Default 14.1 Vdc
Range: Lower Limit
setting to 80 Vdc
Default 14.1 Vdc
Range: 10 Vdc to Upper
Limit setting
Auto ReStart
Default <0>
Selections <0, 1 , 2>
Aux Polarity
Default <Active High>
<Active High or Low>
900-0009-01-00 Rev B
Applications
Maximum Power Point Tracking
Maximum Power Point Tracking (MPPT) is the technology used by FLEXmax controllers to optimize the
harvest of power from PV arrays.
PV modules do not have a defined operating voltage. Their voltage is defined strictly by the load
connected to them. With no load (disconnected), a module displays “open-circuit” voltage (Voc), and
delivers no current. At full load (shorted), a module has no voltage, although 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 drawing to the left in Figure 99. This is known as the V-I curve. The wattage is different at every
point along the curve. (The V-I curve also varies with module type and manufacturer.) Only one point
on the V-I curve represents the delivery of the module’s maximum (rated) wattage. This is known as
the maximum power point , or MPP. The current at this point, Imp, is the highest that can be drawn
while still maintaining the highest voltage, Vmp.
The FLEXmax controller places a variable load on the PV array and tracks the result to determine the
maximum power point. This process, MPPT, is maintained so that the FLEXmax can deliver the
maximum PV power regardless of any change in conditions. The drawing to the right in Figure 99
shows the MPP and compares the V-I curve against the available wattage.
Isc
Isc
MPP
CURRENT
CURRENT
Imp
VOLTAGE
Voc
V-I curve
Vmp
Voc
Available wattage
Figure 99
900-0009-01-00 Rev B
VOLTAGE
Maximum Power Point Tracking
101
Applications
Three-Stage Battery Charging
The FLEXmax charge controller is a sophisticated, multi-stage battery charger that uses several
regulation stages to allow fast recharging of the battery system while ensuring a long battery life. This
process can be used with both sealed and non-sealed batteries. The FLEXmax is a “buck” converter
which turns higher PV voltages into the lower charging voltages used by batteries (with
correspondingly higher currents). The chart in Figure 100 shows the voltage levels achieved by the PV
array throughout a typical day, and the battery voltages (by stage) during the same times.
Input Votlage (24 Vdc system example)
The FLEXmax has preset recharging voltage set points (Absorbing and Float voltages); however,
OutBack always recommends using the battery manufacturer’s recommended charging voltages.
Time
Figure 100
FLEXmax 80 Three-stage Battery Charging
A new charge cycle is started any time the battery voltage decreases below the Rebulk set point .
(See page 56.) This usually occurs each night unless the batteries were maintained by another means.
(If so, they may not need to be recharged). See pages 26 through 30 for the messages displayed
onscreen during the various stages.
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 the Bulk stage, the FLEXmax will charge the batteries to the Absorbing voltage setting (see
page 32). This stage is not timed. It will charge as long as necessary to complete the stage, regardless
of any timer set points. If little PV energy is available, it may take a long time for this stage to
complete. If the FLEXmax is in a different charging stage and little PV energy is available, it may return
to Bulk. (See page 26.) This stage is temperature-compensated. (See page 103.)
102
900-0009-01-00 Rev B
Applications
ABSORBING
This is the second stage of charging. It is a constant-voltage stage. Current varies as needed to
maintain the Absorbing voltage setting. However, it will typically decrease to a very low number over
time. This “tops off the tank”, leaving the batteries at essentially 100% of capacity.
The duration of the Absorbing stage is the user-defined Absorb Time Limit. The ChgT timer is preset
to zero following the previous charge cycle. Once in Absorbing, ChgT will count until it reaches this
limit. (See pages 26, 50, and 54.) The charger will then exit Absorbing and enter the Float stage. The
charger will also also exit Absorbing if the Absorb End Amps setting is reached, regardless of the timer.
This resets the timer to zero. (See page 50.) This stage is temperature compensated. (See page 103.)
FLOAT
When the charger enters this stage, it reduces the charging voltage to prevent overcharging of the
batteries. The batteries are maintained at the Float set point. Floating is displayed on the screen.
This stage is not timed. The FLEXmax will continue to maintain Float as long as PV energy is available.
If the PV cannot supply enough power to maintain the Float set point, the FLEXmax will not
immediately initiate a new charge cycle. It will attempt to draw more PV energy and recharge the
battery until the Float voltage set point is reached. When this occurs, MPPT Float is displayed
(see page 28). This stage is temperature compensated. (See page 103.)
A new charge cycle can be initiated if the voltage falls below the ReBulk set point (see page 56).
Battery Temperature Compensation
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.
When a battery is cooler than room temperature, its internal resistance goes up and the voltage
changes more quickly. This makes it easier for the charger to reach its voltage set points. However,
while accomplishing this process, it will not deliver all the current that the battery requires. As a result,
the battery will tend to be undercharged.
Conversely, when a battery is warmer than room temperature, its internal resistance goes down and
the voltage changes more slowly. This makes it harder for the charger to reach its voltage set points.
It will continue to deliver energy as time passes until the charging set points are reached. However,
this tends to be far more than the battery requires, meaning it will tend to be overcharged.
The FLEXmax controller, when equipped with the Remote Temperature Sensor (RTS) will compensate
for temperature. 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 5 mV per degree Celsius per battery cell. This
setting affects the Absorbing and Float set points. Equalization is not compensated in the FLEXmax.
 In a 12 Vdc system (6 cells, 2 volts each), this means 0.03 volts per degree Celsius above or below 25°C.
Maximum compensation is ± 0.6 Vdc.
 In a 24 Vdc system (12 cells, 2 volts each), this means 0.06 volts per degree Celsius above or below 25°C.
Maximum compensation is ± 1.2 Vdc.
 In a 48 Vdc system (24 cells, 2 volts each), this means 0.12 volts per degree Celsius above or below 25°C.
Maximum compensation is ± 2.4 Vdc.
Examples:
 A 12 Vdc system with 10°C batteries will compensate its charging to 0.45 Vdc higher than the set points.
 A 24 Vdc system with 35°C batteries will compensate its charging to 0.6 Vdc lower than the set points.
 A 48 Vdc system with 15°C batteries will compensate its charging to 1.2 Vdc higher than the set points.
900-0009-01-00 Rev B
103
Applications
Array Design
Sizing Guidelines
Below is a list of maximum array wattages for the FLEXmax for various nominal voltage batteries. This
should be used for sizing an array. Note that every PV module is different. The specifications for every
model should be consulted before designing or assembling a PV array.
Table 6
Maximum PV Input Wattage per Charge Controller1
Nominal
Battery
Voltage
Maximum Array Size
(in watts, Standard Test Conditions)
FLEXmax 80
FLEXmax 60
12 V
1250 W
800 W
24 V
2500 W
1600 W
36 V
3750 W
2400 W
48 V
5000 W
3200 W
60 V
6250 W
4000 W
Open Circuit Voltage (Voc)
Open-circuit voltage (Voc) is the unloaded voltage generated by the PV array. The FLEXmax controller
can withstand Voc of up to150 Vdc. However, if the Voc exceeds 145 Vdc, the FLEXmax will suspend
operation to protect the system components.
CAUTION: Equipment Damage
Although the FLEXmax shuts down when voltage is greater than 145 Vdc, this will not
prevent the array from generating voltage. Anything higher than 150 Vdc will damage
the FLEXmax, whether it has shut down or not. The array should be designed so that
voltage never exceeds 145 Vdc in order to prevent equipment damage.
Weather Conditions
Cooler climates can cause the Voc to rise above the array’s rated Voc. In climates that observe
temperatures less than approximately -15°C (5°F), a Voc greater than 125 Vdc is not recommended.

Hot weather: lower Voc and lower Vmp

Cold weather: higher Voc and higher Vmp
If the specific voltage temperature correction factor is not known for a particular module, allow for ambient
temperature correction using the following information:
1
25° to 10°C (77° to 50°F)
multiply Voc by 1.06
9° to 0°C (49° to 32°F)
multiply Voc by 1.10
-1° to -10°C (31° to 14°F)
multiply Voc by 1.13
-11° to -20°C (13° to -4°F)
multiply Voc by 1.17
-21° to -40°C (-5° to -40°F)
multiply Voc by 1.25
Based on the most common solar arrays under Standard Test Conditions (1000 watts per square meter to solar
panel at 25°C [77°F] ).
104
900-0009-01-00 Rev B
Applications
Maximum-Power Voltage (Vmp)
Maximum-power voltage (Vmp) is the operating voltage for the PV array at which the array generates
the most wattage. When designing the PV array, it is recommended for the Vmp to be approximately
12 to 24 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 conversion efficiency.
IMPORTANT:
Check the PV array voltage before connecting it to the FLEXmax.
Standard vs. Australian Default Settings
Several version settings are available for the FLEXmax upon initial setup. These can be selected upon
initial power-up. (See page 21.) The English and Spanish versions have the same standard default
settings; however, the Australian version has certain default settings that are different. However, there
are no differences in performance and efficiency between the two versions. The standard and
Australian version can be identified as follows:
Standard Power Up Screen
OutBack
Australian Power Up Screen
12V
OutBack
12V
Power
Power
Systems
Charge Controller
Systems
Charge Controller - AU
Figure 101
Table 7
Standard vs. Australian Power-up Screens
Default Settings Standard vs. Australian
Settings
Standard
Australian
Charger
Absorbing
Float
Absorbing
Float
12 V
14.4 V
13.6 V
14.4 V
13.8 V
24 V
28.8 V
27.2 V
28.8 V
27.6 V
36 V
43.2 V
40.8 V
43.2 V
41.4 V
48 V
57.6 V
54.4 V
57.6 V
55.2 V
60 V
72.0 V
68.0 V
72.0 V
69.0 V
Equalize
Equalize Volts
Equalize Volts
12 V
14.4 V
14.7 V
24 V
28.8 V
29.4 V
36 V
43.2 V
44.1 V
48 V
57.6 V
58.8 V
60 V
72.0 V
73.5 V
Equalize Time
01 Hours
03 Hours
900-0009-01-00 Rev B
105
Applications
Hydroelectric and Fuel Cell Applications
Performance Optimization
The FLEXmax Charge Controller is designed to work with PV arrays. Although it will work with
hydroelectric turbines and fuel cells, OutBack Power Technologies can only offer limited technical
support for these applications due to variance in turbine and fuel cell specifications.
IMPORTANT:
The FLEXmax Charge Controller is not usable for direct regulation of wind turbine input
and OutBack cannot warranty its use in these applications. In wind turbine applications,
the FLEXmax is recommended as a diversion controller. (See page 41.)
The FLEXmax maximum power point tracking (MPPT) function can be set to Auto Track or U-Pick%
mode as described on page 54. 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 Track mode allows the FLEXmax to sweep the range of
percentages. The Auto Track mode begins at the maximum value and loads the array, working its way
through lower voltages, until it locates the input voltage that yields maximum wattage.
Auto Track Mode
The default minimum value of Auto Track is 1/2 (50% of Voc). The default maximum is 90% of Voc.
This is the standard maximum-power range for PV. A hydroelectric or fuel-cell system’s operating
voltage may operate in a different range and often have a maximum-power voltage close to the
battery voltage. The FLEXmax allows a user to set a sweep range more appropriate for the source.
The minimum setting can be changed to FULL, which is 40% of the Voc. The maximum value can be
set from 80% to 99% of Voc if necessary.
This adjustment only affects the initial tracking at the beginning of the day and any subsequent
trackings caused by Auto-Restart or any forced restart of the FLEXmax.
U-Pick Mode
If an optimal voltage is known for a given DC source, then this voltage can be set as a designated Voc
percentage in U-Pick% mode. This percentage is assigned in the Park Mpp set point, which allows a
range of 40% to 99% of Voc. If U-Pick % Voc is chosen, the FLEXmax will load the source to operate
continuously at the designated voltage. It will not sweep for the maximum power point and will
ignore all Auto Track values.
106
900-0009-01-00 Rev B
Applications
Main Menu
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
To adjust the Lower Mpp Range Limit:
1.
From the main menu, press <> to move the arrow next to
the Advanced function.
Charger Aux
Light
EQ
Misc Advanced
Logging
Stats
EXIT


GO
2.
Press <GO>.
ADVANCED MENU
Snooze Mode
< 0.6 amp
EXIT NEXT
AMP
3.
In the ADVANCED MENU screen, press <NEXT> again to
display the Mpp Range Limit % Voc screen.
4.
Press <1/2> until FULL appears.
5.
When finished, press <NEXT> until the MPPT Mode
screen appears.
ADV SETUP Screen
Mpp Range Limit % Voc
ADVANCED MENU
Mpp Range Limit %VOC
Min
Max
EXIT NEXT
1/2
90%
MPPT Mode (Auto Track)
ADVANCED MENU
MPPT Mode
Auto Track
EXIT NEXT nonGT MODE
To pick between Auto Track or U-Pick % MPPT Mode and determine the
charge controller’s operating Voc percentage, press <MODE> to interchange
between the two modes.
Re-entering the password might be required. After choosing a mode, press
<NEXT> in the ADVANCED MENU to view the Park Mpp screen (only
applicable for U-Pick mode).
U-pick% (Voc) MPPT
ADVANCED MENU
Park Mpp
Watts 0251
77 % Voc
EXIT NEXT
-%
+%
Figure 102
900-0009-01-00 Rev B
Press < -%> or <+%> to select one of the percentage values; U-Pick always
uses the Park Mpp value.
Adjusting Range Limits for Hydroelectric or Fuel-cell Applications
107
Applications
Grid-Interactive Settings
When using an OutBack inverter, FLEXmax, HUB, and system display, set the FLEXmax to GT in the
Advanced menu. GT mode allows the inverter to manage the FLEXmax Float setting. It ensures the
FLEXmax always keeps the battery above the sell voltage of the inverter. (See page 54.)
When using a FLEXmax charge controller with an inverter without the use of a HUB, GT mode will not
work because the FLEXmax cannot communicate with the inverter. In this situation, when selling
electricity back to the grid, keep the inverter’s “sell” voltage setting below the FLEXmax Float setting.
In a 24-volt battery system, the difference should be at least 0.5 Vdc. In a 48-volt system, the
difference should be at least 1.0 Vdc.
Charge Controller Efficiency vs. Input Power
Figure 103
108
Efficiency Curves
900-0009-01-00 Rev B
Product Registration
The purchase of an OutBack Power Technologies product is an important investment. Registering the
products will help us maintain the standard of excellence expected in terms of performance, quality
and reliability.
Please take a moment to register and provide us with some important information.
Registration can be done as follows:
 Go to the following website.
10Hhttp://www.outbackpower.com/resources/warranty/
or
 Fill out the information on this form (pages113 and 114) and return a paper copy using a postal service to
the following address:
OutBack Power Technologies
Attn: Warranty Registration
5917 – 195th Street N.E., #7
Arlington, WA 98223 USA
Be sure to keep a copy for your records.
SYSTEM OWNER
Name
Address
City, State, Postal Code or
Zip Code
Country
Telephone Number
E-mail
SYSTEM PURCHASE
Product Model Number
Product Serial Number
Sold by
Purchase Date
900-0009-01-00 Rev B
109
Product Registration
INSTALLATION INFORMATION
System Install/Commission Date
System Array Size
System Array Nominal Voltage
Type of PV Modules
System Battery Bank Size (Amp-Hours)
Brand and Model of Batteries
Does this system include an auxiliary AC generator?
If yes, please specify brand and model of generator
INSTALLER INFORMATION
Contractor Number
Installer Name
Installer Address
Installer City, State, Postal or Zip Code, Country
Installer Telephone/E-mail
Please check ALL factors affecting purchase decision:






Product Reputation
Back-up Capability
Reputation of OutBack Power Technologies
Value
Looks
Other
Extended Warranty
OutBack Power Technologies offers an optional five (5) year extension to the standard five (5) year
Limited Warranty for the FLEXmax Charge Controller. To request a 5-year limited warranty extension
for a total effective warranty coverage period of ten (10) years, please include a payment in the
amount of $250 USD per charge controller, payable to OutBack Power Technologies, Inc. along with
the Warranty Registration. Please submit within 90 days of the first retail sale of the inverter(s). Please
indicate the quantity of each product.
110
900-0009-01-00 Rev B
Warranty
5-Year Limited Warranty for FLEXmax Products
OutBack Power Technologies, Inc. (“OutBack”) provides a five-year (5) limited warranty (“Warranty”)
against defects in materials and workmanship for its FLEXmax Series Charge Controller (“Product”).
The term of this Warranty begins on the Product(s) initial purchase date, or the date of receipt of the
Product(s) by the end user, whichever is later. This must be indicated on the invoice, bill of sale, and/or
warranty registration submitted to OutBack. This Warranty applies to the original OutBack Product
purchaser, and is transferable only if the Product remains installed in the original use location. The
warranty does not apply to any Product or Product part that has been modified or damaged by
the following:













Installation or Removal;
Alteration or Disassembly;
Normal Wear and Tear;
Accident or Abuse;
Corrosion;
Lightning;
Repair or service provided by an unauthorized repair facility;
Operation or installation contrary to manufacturer product instructions;
Fire, Floods or Acts of God;
Shipping or Transportation;
Incidental or consequential damage caused by other components of the power system;
Any product whose serial number has been altered, defaced or removed;
Any other event not foreseeable by OutBack.
OutBack’s liability for any defective Product, or any Product part, shall be limited to the repair or
replacement of the Product, at OutBack’s discretion. OutBack does not warrant or guarantee
workmanship performed by any person or firm installing its Products. This Warranty does not cover
the costs of installation, removal, shipping (except as described below), or reinstallation of Products or
parts of Products.
THIS LIMITED WARRANTY IS THE EXCLUSIVE WARRANTY APPLICABLE TO OUTBACK PRODUCTS.
OUTBACK EXPRESSLY DISCLAIMS ANY OTHER EXPRESS OR IMPLIED WARRANTIES OF ITS PRODUCTS,
INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE. OUTBACK ALSO EXPRESSLY LIMITS ITS LIABILITY IN THE EVENT OF A PRODUCT
DEFECT TO REPAIR OR REPLACEMENT IN ACCORDANCE WITH THE TERMS OF THIS LIMITED WARRANTY
AND EXCLUDES ALL LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING
WITHOUT LIMITATION ANY LIABILITY FOR PRODUCTS NOT BEING AVAILABLE FOR USE OR LOST
REVENUES OR PROFITS, EVEN IF IT IS MADE AWARE OF SUCH POTENTIAL DAMAGES. IF YOU ARE A
CONSUMER THAT PURCHASED THIS PRODUCT IN A MEMBER STATE OF THE EUROPEAN UNION, YOU
MAY HAVE ADDITIONAL STATUTORY RIGHTS UNDER DIRECTIVE 1999/44/EC. THESE RIGHTS MAY VARY
FROM EU MEMBER STATE TO EU MEMBER STATE. SOME STATES (OR JURISDICTIONS) MAY NOT ALLOW
THE EXCLUSION OR LIMITATION OF WARRANTIES OR DAMAGES, SO THE ABOVE EXCLUSIONS OR
LIMITATIONS MAY NOT APPLY TO YOU.
900-0009-01-00 Rev B
111
Warranty
How to Arrange for Warranty Service
During the warranty period beginning on the invoice date, OutBack Power Technologies will repair or
replace products covered under this limited warranty that are returned to OutBack Power
Technologies’ facility or to an OutBack Power Technologies authorized repair facility, or that are
repaired on site by an OutBack Power Technologies authorized repair person.
IMPORTANT:
For full Warranty description, see previous page.
Contacting OutBack
To request warranty service:

call OutBack Technical Support at +1.360.435.6030, or direct at +1.360.618.4363, or

send an email to Technical Support at [email protected].
10H2
To ensure warranty coverage, this contact must be within the effective warranty period. If service is
required, the OutBack Technical Support representative will issue a Return Material Authorization
(RMA) number.
Troubleshooting
In the event of a Product failure, the customer will need to work with an OutBack Technical Support
representative to perform the necessary troubleshooting. This is a required step before a return can
be performed. Troubleshooting requires a qualified technician to be present at the site of the Product,
with a quality voltmeter that measures both DC and AC. The OutBack representative will request
voltmeter readings, Product error messages, and other information. Many, many problems can be
resolved on-site. If the customer is not willing or able to provide these readings (or is not willing or
able to visit the site), and the Product is found to have no problems upon return, OutBack may choose
to charge additional labor and handling fees up to $180.00 U.S.
Return Material Authorization (RMA)
A request for an RMA number requires all of the following information:
1. Product model and serial number;
2. Proof-of-purchase in the form of a copy of the original Product purchase invoice or receipt
confirming the Product model number and serial number;
3. Description of the problem; and
4. Shipping address for the repaired or replacement equipment.
Upon receiving this information, the OutBack representative can issue an RMA number.
112
900-0009-01-00 Rev B
Warranty
Returning Product to OutBack
After receiving the RMA number, the customer must pack the Product(s) authorized for return, along
with a copy of the original purchase invoice and product registration, in the original Product shipping
container(s) or packaging providing equivalent or reasonable protection. The RMA number must be
written on the outside of the packaging where it is clearly visible.
If Product is within the warranty period, OutBack will cover prepaid shipping with prior arrangement.
The Product(s) must be shipped back to OutBack Power Technologies in their original or equivalent
packaging, to the following address:
OutBack Power Technologies
RMA # ____________________
6115 192nd Street NE
Arlington, WA 98223 USA
The customer must insure the shipment, or accept the risk of loss or damage during shipment. If a
shipping box is needed for return of a Product, OutBack will, upon request, send a shipping box.
IMPORTANT:
OutBack is not responsible for shipping damage caused by improperly packaged
Products, the repairs this damage might require, or the costs of these repairs.
If, upon receipt of the Product, OutBack determines the Product or Product part is defective and that
the defect is covered under the terms of this Warranty, OutBack will then, and only then, ship a
repaired or replacement Product or Product part to the purchaser freight prepaid, non-expedited,
using a carrier of OutBack’s choice, where applicable.
If Product fails in ninety (90) or fewer days from original purchase date, OutBack will replace with
a new Product. If Product fails after ninety (90) days and up to expiration of warranty, OutBack will, at
its discretion, either repair and return a Product, or ship a replacement Product. OutBack will
determine whether a Product is to be repaired or replaced in accordance with Product age and model.
OutBack will authorize advance shipment of a replacement based on Product age and model.
In cases where an OutBack dealer or distributor replaces a Product more than ninety (90) days old with
a new Product, OutBack will NOT compensate that dealer or distributor with new stock unless the
exchange was authorized in advance by OutBack.
Out of Warranty
If Product is out of warranty, OutBack will repair and return Product for a fee. Alternately, if applicable,
upon request, OutBack will advance-ship replacement parts for a fee.
If a shipping box is needed for return of out-of-warranty Product, OutBack will, upon request, send a
shipping box. The customer is responsible for paying shipping to OutBack.
The warranty period of any repaired or replacement Product or Product part is ninety (90) days from
the date of shipment from OutBack, or the remainder of the initial warranty term, whichever is greater.
This Warranty is void for any Product that has been modified by the customer without authorization
by OutBack. A Product with a voided warranty will be treated the same as one with an expired
warranty.
900-0009-01-00 Rev B
113
Warranty
This page intentionally left blank.
114
900-0009-01-00 Rev B
Index
Index
A
D
Absorb End Amps.......................................................................... 55
Absorb Time Limits ....................................................................... 55
Absorbing................................................................................26, 103
Advanced Menu............................................................................. 52
Absorb End Amps ................................................................... 55
Absorb Time Limits................................................................. 55
Auto ReStart.............................................................................. 58
AUX Polarity .............................................................................. 59
Logging ...................................................................................... 60
MPPT Mode ............................................................................... 53
Rebulk Voltage......................................................................... 56
Reset to Defaults ..................................................................... 59
RTS Compensation ................................................................. 56
Snooze ........................................................................................ 52
Stats.............................................................................................. 61
Vbatt Calibration ..................................................................... 56
Wakeup Mode .......................................................................... 53
AGS .............................................See Automatic Generator Start
Applications...................................................................................101
Array Design..................................................................................104
Audience..............................................................................................1
Australian Settings......................................................................105
Auto ReStart ...................................................................... 27, 58, 73
Auto Track ........................................................................................ 53
Automatic Generator Start (AGS) ........................................1, 47
AUX........................................................................................................1
AUX Modes ............................................................................... 33, 72
Diversion .................................................................................... 41
Error Output.............................................................................. 38
Float ............................................................................................. 40
Low Battery Disconnect........................................................ 46
Night Light................................................................................. 39
PV Trigger................................................................................... 37
Remote........................................................................................ 47
Vent Fan...................................................................................... 36
AUX Polarity..................................................................................... 59
AUX Terminals ................................................................................ 17
Data Logging.......................................................25, 60, 67, 75, 81
Default Settings ..................................................................100, 105
Defaults..............................................................................................74
Defaults................................................................................21, 59, 63
Definitions .......................................................................................... 1
Diagrams ......................................................................18, 19, 20, 45
Dimensions.......................................................................................14
Diversion
Relay .............................................................................................41
Solid St.........................................................................................43
E
Efficiency ........................................................................................ 108
End-of-Day Summary Screen.....................................................24
Equalizing ....................................................................27, 29, 48, 71
Extended Play...........................................................................62, 98
F
Features ......................................................................................11, 12
Firmware Revision ...........................................................11, 62, 99
FLEXware...........................................................................................15
Float .......................................................................................... 28, 103
Fuel Cell Applications................................................................ 106
G
Graph Screens .................................................................................68
Grid-Tie ..................................................................2, 28, 54, 71, 108
Grounding .................................................................................13, 17
GT Mode .................................................................... 28, 54, 71, 108
H
Hydroelectric Applications ...................................................... 106
B
Backlight ........................................................................................... 47
Battery Charging..............................................32, 70, 80, 84, 102
Battery Voltage............................................................................... 21
Bulk ............................................................................................28, 102
I
Initial Operation..............................................................................30
Installation........................................................................................13
Introduction.....................................................................................11
C
L
Calibration................................................................................. 56, 74
Charger Setup................................................................... 32, 70, 84
Contact Information........................................................................2
Language ..........................................................................................21
Logging ........................................................................25, 60, 75, 81
900-0009-01-00 Rev B
115
Index
M
Main Menu ................................................................................ 21, 30
MATE or MATE2
Advanced Menus .................................................................... 83
AUX .............................................................................87
CC ADV.......................................................................85
CHRG ..........................................................................84
EQ ................................................................................86
Menu Map ................................................................90
CC ADV Menu Map .......................................................... 90, 91
CC STATUS Menu Map ................................................... 88, 89
Password .................................................................................... 83
Status Screens .......................................................................... 78
CC LOG.......................................................................81
CC SETPT ...................................................................80
CC STAT .....................................................................82
Menu Map ................................................................88
Meter ..........................................................................79
Mode ..........................................................................78
Summary Screens ................................................................... 77
MATE3
Auxiliary Output ...................................................................... 72
Calibrate ..................................................................................... 74
Charger Settings...................................................................... 70
Device Data Logs..................................................................... 75
Equalization............................................................................... 71
Grid-Tie Mode........................................................................... 71
Menu Structure........................................................................ 69
MPPT............................................................................................ 70
Password .................................................................................... 69
Restart Mode............................................................................. 73
Screens........................................................................................ 65
Temperature Compensation .............................................. 71
Maximum Power Point Tracking.....................................53, 101
Maximum PV Wattage ...............................................................104
Maximum-Power Voltage............................................... 101, 105
Menu Maps ...................................................................................... 31
FLEXmax................................................................ 93, 94, 95, 96
MATE or MATE2 .................................................. 88, 89, 90, 91
MATE3 ......................................................................................... 69
Misc Screen ...................................................................................... 50
Modes ................................................................................................ 26
Absorbing .................................................................................. 26
AutoRestart ................................................................. 27, 58, 73
AutoStart............................................................................. 27, 73
BatTmpErr ........................................................................... 27, 98
BatTooHot.................................................................................. 27
Charged ...................................................................................... 27
EQ ................................................................................................. 27
EQ Done...................................................................................... 27
EX Absorb................................................................................... 28
Floating....................................................................................... 28
GT Mode .............................................................................. 28, 71
High Voc ..................................................................................... 28
Low Light ................................................................................... 28
MPPT Bulk .................................................................................. 28
MPPT EQ ..................................................................................... 29
MPPT Float................................................................................. 28
New Voc...................................................................................... 29
116
Over Temp..................................................................................29
OvrCurrent .................................................................................29
Re-Cal ...........................................................................................29
Sleeping ...............................................................................29, 98
Snoozing.....................................................................................28
Sys Error ......................................................................................29
Tracking.......................................................................................29
Unloaded ....................................................................................30
Wakeup .......................................................................................30
Zzzzz.............................................................................................30
Modes.................................................................................................66
Mounting ..........................................................................................15
MPPT.....................................................................................2, 53, 101
O
Open-Circuit Voltage........................................................101, 104
Operation..........................................................................................21
P
Password .............................................................................21, 69, 83
Photovoltaic....................................................................................... 2
Ports....................................................................................................17
Powering Up ....................................................................................21
PV Design....................................................................................... 104
R
Rebooting the FLEXmax..............................................................63
Rebulk Voltage................................................................................56
Recycling Information .................................................................... 5
Registration................................................................................... 109
Remote Temperature Sensor.................................. 2, 17, 56, 71
Reset to Defaults .......................................................21, 59, 63, 74
Returning Product to OutBack............................................... 113
RTS..........................................See Remote Temperature Sensor
S
Safety.................................................................................................... 1
Battery ........................................................................................... 4
General .......................................................................................... 2
Inverter .......................................................................................... 3
Personal......................................................................................... 2
PV ................................................................................................... 3
Settings..............................................................................................30
SK ..................................................................................See Soft Keys
Snooze Mode...................................................................................52
Soft Keys....................................................................................... 2, 12
Specifications ..................................................................................99
Standard vs. Australian Default Settings............................ 105
STATS Menu ..............................................................................61, 82
Status Screen ............................................................................23, 26
Symbols Used.................................................................................... 1
System Display.................................................................................. 2
MATE or MATE2........................................................................77
MATE3..........................................................................................65
900-0009-01-00 Rev B
Index
T
Vmp.........................................................................................101, 105
Voc...........................................................................................101, 104
Temperature................................................... 29, 56, 71, 103, 104
Terminals .......................................................................................... 17
Three-Stage Battery Charging ................................................102
Troubleshooting ...................................................................97, 112
W
U
U-Pick ................................................................................................. 53
V
Wakeup Mode .................................................................................53
Warranty.....................................................................................2, 111
How to Arrange for Service............................................... 112
RMA ........................................................................................... 112
Terms and Conditions......................................................... 111
Weather Conditions ................................................................... 104
Wiring .......................................................13, 16, 17, 18, 19, 20, 45
Vbatt Calibration..................................................................... 56, 74
900-0009-01-00 Rev B
117
North America
5917 – 195th Street N.E., #7
Arlington, WA 98223 USA
+1.360.435.6030
900-0009-01-00 Rev B
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