OutBack Power FLEXmax Extreme Quick Start Manual

900-0151-01-00 Rev C.vsdx ©2013 OutBack Power Technologies. All Rights Reserved. Dimensions Height: 18.8" (47.1 cm); with fan 22.06" (56.0 cm) Width: 8.8" (22.4 cm) Depth to Wall: 6.0" (15.2 cm) Mounting The FLEXmax Extreme must be mounted upright at least 36" (91.4 cm) above the ground or floor. Installation in shade is recommended. Conduit hubs must be connected to the conduit before connecting to the FLEXmax Extreme. Clearance requirements are a minimum of 6“ (15.2 cm) above and below the controller. The unit can be mounted using either brackets (see A) or keyhole slots (see B) on a secure mounting surface. Included in Package  FM Extreme-150VDC  2 x Mounting Bracket  Silicone Grease Package  2 x Ferrite Clamp (install on HUB/DEVICE and RTS ports) Provided by Customer  PV Array  Batteries  MATE3  Fan Kit  Disconnect Devices  Ground Fault Protection  Wiring & Cabling FLEXmax Extreme Tighten all wire lugs and ground terminals to 4 Nm (35 in-lb) torque. Use copper wiring only (rated 90°C or higher). Refer to the NEC and other electrical codes for PV array cable sizing, length, and ampacity. Use #4 AWG (25 mm2) (minimum) for the controller output terminals to the batteries; output can accept up to #2 AWG (35 mm2). Negative-ground installation is depicted here; positive grounding is also permitted. IMPORTANT: Example only. Actual wiring may vary. All configurations must comply with local and national electric codes. Consult the local electric authority to ensure compliance. Negative Positive Ground DC LEGEND ¼” hex head lag screws Keyhole Slots (#14 slotted wood screws) Securing Holes (¼” hex head lag screws) LED Indicators Charging (Blue) Status (Green/Red or Amber) Auxiliary Fault 1 4  2 3 Quick Start Guide Charge Controller PV Combiner Photovoltaic Array (PV) Ground Bus Battery Bank ON OFF BAT + BAT – PV – PV + Battery Disconnect (external) Ground Fault Protection (not provided, required by Article 690 of NEC) Negative Bus ON OFF PV Disconnect (external) OFF O O F F O FAULT PV INACTIVE NORMAL PV ACTIVE PV ARRAY GROUND FAULT DETECTOR INTERRUPTER LED Indicators (see above) NOTE: Overcurrent protection for the battery circuit is to be provided by installer. Battery Nominal Voltages: 12-volt, 24-volt, 36-volt,48-volt, 60-volt (-4°F to 113°F) Environmental Specifications NOTES:  Unit output derated above 45°C (113°F)  Absolute maximum temperature range is –40°C to 60°C (–40°F to 140°F)

900-0151-01-00 Rev C.vsdx ©2013 OutBack Power Technologies. All Rights Reserved. FLEXmax Extreme MATE3 System Display and Controller NOTE: See the FLEXmax Extreme Owner’s Manual for details on the settings available in the main menu. Accessory Terminal Block Ports and Connectors Fan Wiring 1 2 3 4  5 6 7 8 IMPORTANT: Not intended for use with life support equipment. OutBack Power and the OutBack Power logo are trademarks owned and used by OutBack Power Technologies, Inc.  The ALPHA logo and the phrase “member of the Alpha Group” are trademarks owned and used by Alpha Technologies.  These trademarks may be registered in the United States and other countries. Contact Technical Support: Telephone: +1.360.618.4363 Email: [email protected] Website: www.outbackpower.com Fan Mounting Remote Temperature Sensor (RTS) 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. If not compensated, a battery may remain undercharged in cold temperatures and may become overcharged when hot. Below room temperature, the charging set points are raised above their normal values. Above room temperature the set points are lowered. 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 a certain voltage per degree Celsius per battery cell. The compensation value (the “slope”) is adjustable from 2 mV to 6 mV. Most batteries use a value of 5 mV. This setting affects the Absorbing and Float set points. Equalization is not compensated in the FLEXmax Extreme. Total compensation is determined by measuring the number of degrees C above or below 25. This number is multiplied by the number of 2-volt battery cells and the slope value. SunSpec Modbus Interface External Fault Terminals (see page 1 for GFDI function) GFDI or other shutdown functions can be used for multiple controllers. Terminals 2 and 4 are wired to the next controller as shown. OFF O O F F O FAULT PV INACTIVE NORMAL PV ACTIVE PV ARRAY GROUND FAULT DETECTOR INTERRUPTER Controller 1 Controller 2  1 2 3 4 GFDI Battery Sense Terminals These terminals monitor battery voltage more accurately than the main cable connections. A twisted-pair cable is recommended. The connections are made directly on the battery terminals. NOTE: Overcurrent protection devices are not shown. 8  7 DC Terminals PV+ PV- BAT- BAT+ Auxiliary (AUX) Terminals Used for diversion control and other functions 6  5 Cells (Volts) Slope Value Temp 25°C ± Calculation Vdc Adjust 6 (12V) 5 mV 8°C -17 6 x 0.005 x 17 +0.5 Vdc 12 (24V) 3 mV 36°C +11 12 x 0.003 x 11 -0.4 Vdc 18 (36V) 5 mV 26°C +1 18 x 0.005 x 1 -0.1 Vdc 24 (48V) 6 mV 0°C -25 24 x 0.006 x 25 +3.6 Vdc 30 (60V) 2 mV 37°C +12 30 x 0.002 x 12 -0.7 Vdc Examples of Compensation Install ferrite clamps on these cables for EMI suppression AXS Card MATE3 RTS Recommended protection for sense conductors is:  Fast-acting device  80 Vdc or greater  1 A or smaller  Cold resistance 10 ohms or less