Charge Controllers Data

An Introduction to Charge Controllers
Page Topics How do MPPT controllers work?

What is a charge controller?
Low Voltage Disconnect (LVD)
Blocking Reverse Current The deep-cycle batteries used in renewable
energy systems are designed to be discharged by
Preventing Overcharge about 80 percent. If they are discharged 100
percent, they are immediately damaged. Imagine
Control Set Points vs. Temperature a pot of water boiling on your kitchen stove. The
moment it runs dry, the pot overheats. If you
Control Set Points vs. Battery Type wait until the steaming stops, it is already too
late!
Low Voltage Disconnect (LVD)
Similarly, if you wait until your lights look dim,
Overload Protection some battery damage will have already occurred.
Every time this happens, both the capacity and
Displays and Metering the life of the battery will be reduced by a small
amount. If the battery sits in this overdischarged
Have It All with a Power Center state for days or weeks at a time, it can be ruined
quickly.
Charge Controllers for Wind and Hydro
The only way to prevent overdischarge when all
Is It Working? else fails, is to disconnect loads (appliances,
lights, etc.), and then to reconnect them only
Conclusion when the voltage has recovered due to some
substantial charging. When overdischarge is
A charge controller is an essential part of nearly approaching, a 12 volt battery drops below 11
all power systems that charge batteries, whether volts (a 24 V battery drops below 22 V).
the power source is PV, wind, hydro, fuel, or
utility grid. Its purpose is to keep your batteries A low voltage disconnect circuit will disconnect
properly fed and safe for the long term. loads at that set point. It will reconnect the loads
only when the battery voltage has substantially
The basic functions of a controller are quite recovered due to the accumulation of some
simple. Charge controllers block reverse current charge. A typical LVD reset point is 13 volts (26
and prevent battery overcharge. Some controllers V on a 24 V system).
also prevent battery overdischarge, protect from
electrical overload, and/or display battery status All modern dc power inverters have LVD built
and the flow of power. Let's examine each in, even cheap pocket-sized ones. The inverter
function individually. will turn off to protect itself and your loads as
well as your battery. Normally, an inverter is
Blocking Reverse Current connected directly to the batteries, not through
Photovoltaic panels work by pumping current the charge controller, because its current draw
through your battery in one direction. At night, can be very high, and because it does not require
the panels may pass a bit of current in the external LVD.
reverse direction, causing a slight discharge from
the battery. (Our term "battery" represents either If you have any DC loads, you should have an
a single battery or bank of batteries.) The LVD. Some charge controllers have one built in.
potential loss is minor, but it is easy to prevent. You can also obtain a separate LVD device.
Some types of wind and hydro generators also Some LVD systems have a "mercy switch" to let
draw reverse current when they stop (most do you draw a minimal amount of energy, at least
not except under fault conditions). long enough to find the candles and matches!
DC refrigerators have LVD built in.
In most controllers, charge current passes
through a semiconductor (a transistor) which If you purchase a charge controller with built-in
acts like a valve to control the current. It is called LVD, make sure that it has enough capacity to
a "semiconductor" because it passes current only handle your DC loads. For example, let's say you
in one direction. It prevents reverse current need a charge controller to handle less than 10
without any extra effort or cost. amps of charge current, but you have a DC water
pressurizing pump that draws 20 amps (for short
In some controllers, an electromagnetic coil periods) plus a 6 amp DC lighting load. A charge
opens and closes a mechanical switch. This is controller with a 30 amp LVD would be
called a relay. (You can hear it click on and off.) appropriate. Don't buy a 10 amp charge
The relay switches off at night, to block reverse controller that has only a 10 or 15 amp load
current. capacity!
If you are using a PV array only to trickle-charge Overload Protection

a battery (a very small array relative to the size A circuit is overloaded when the current flowing
of the battery), then you may not need a charge in it is higher than it can safely handle. This can
controller. This is a rare application. An example cause overheating and can even be a fire hazard.
is a tiny maintenance module that prevents Overload can be caused by a fault (short circuit)
battery discharge in a parked vehicle but will not in the wiring, or by a faulty appliance (like a
support significant loads. You can install a frozen water pump). Some charge controllers
simple diode in that case, to block reverse have overload protection built in, usually with a
current. A diode used for this purpose is called a push-button reset.
"blocking diode."
Built-in overload protection can be useful, but
Preventing Overcharge most systems require additional protection in the
When a battery reaches full charge, it can no form of fuses or circuit breakers. If you have a
longer store incoming energy. If energy circuit with a wire size for which the safe
continues to be applied at the full rate, the carrying capacity (ampacity) is less than the
battery voltage gets too high. Water separates overload limit of the controller, then you must
into hydrogen and oxygen and bubbles out protect that circuit with a fuse or breaker of a
rapidly. (It looks like it's boiling so we suitably lower amp rating. In any case, follow
sometimes call it that, although it's not actually the manufacturer's requirements and the National
hot.) There is excessive loss of water, and a Electrical Code for any external fuse or circuit
chance that the gasses can ignite and cause a breaker requirements.
small explosion. The battery will also degrade
rapidly and may possibly overheat. Excessive Displays and Metering
voltage can also stress your loads (lights, Charge controllers include a variety of possible
appliances, etc.) or cause your inverter to shut displays, ranging from a single red light to
off. digital displays of voltage and current. These
indicators are important and useful. Imagine
Preventing overcharge is simply a matter of driving across the country with no instrument
reducing the flow of energy to the battery when panel in your car! A display system can indicate
the battery reaches a specific voltage. When the the flow of power into and out of the system, the
voltage drops due to lower sun intensity or an approximate state of charge of your battery, and
increase in electrical usage, the controller again when various limits are reached.
allows the maximum possible charge. This is
called "voltage regulating." It is the most If you want complete and accurate monitoring
essential function of all charge controllers. The however, spend about US$200 for a separate
controller "looks at" the voltage, and regulates digital device that includes an amp-hour meter. It
the battery charging in response. acts like an electronic accountant to keep track
of the energy available in your battery. If you
Some controllers regulate the flow of energy to have a separate system monitor, then it is not
the battery by switching the current fully on or important to have digital displays in the charge
fully off. This is called "on/off control." Others controller itself. Even the cheapest system
reduce the current gradually. This is called should include a voltmeter as a bare minimum
"pulse width modulation" (PWM). Both methods indicator of system function and status.
work well when set properly for your type of
battery. Have It All with a Power Center
If you are installing a system to power a modern
A PWM controller holds the voltage more home, then you will need safety shutoffs and
constant. If it has two-stage regulation, it will interconnections to handle high current. The
first hold the voltage to a safe maximum for the electrical hardware can be bulky, expensive and
battery to reach full charge. Then, it will drop the laborious to install. To make things economical
voltage lower, to sustain a "finish" or "trickle" and compact, obtain a ready-built "power
charge. Two-stage regulating is important for a center." It can include a charge controller with
system that may experience many days or weeks LVD and digital monitoring as options. This
of excess energy (or little use of energy). It makes it easy for an electrician to tie in the
maintains a full charge but minimizes water loss major system components, and to meet the safety
and stress. requirements of the National Electrical Code or
your local authorities.
The voltages at which the controller changes the
charge rate are called set points. When Charge Controllers for Wind and Hydro
determining the ideal set points, there is some A charge controller for a wind-electric or hydro-
compromise between charging quickly before electric charging system must protect batteries
the sun goes down, and mildly overcharging the from overcharge, just like a PV controller.
battery. The determination of set points depends However, a load must be kept on the generator at
on the anticipated patterns of usage, the type of all times to prevent overspeed of the turbine.
battery, and to some extent, the experience and Instead of disconnecting the generator from the
philosophy of the system designer or operator. battery (like most PV controllers) it diverts
Some controllers have adjustable set points, excess energy to a special load that absorbs most
while others do not. of the power from the generator. That load is
usually a heating element, which "burns off"
Control Set Points vs. Temperature excess energy as heat. If you can put the heat to
The ideal set points for charge control vary with good use, fine!
a battery's temperature. Some controllers have a
feature called "temperature compensation." Is It Working?
When the controller senses a low battery How do you know if a controller is
temperature, it will raise the set points. malfunctioning? Watch your voltmeter as the
Otherwise when the battery is cold, it will reduce batteries reach full charge. Is the voltage
the charge too soon. If your batteries are exposed reaching (but not exceeding) the appropriate set
to temperature swings greater than about 30° F points for your type of battery? Use your ears
(17° C), compensation is essential. and eyes-are the batteries bubbling severely? Is
there a lot of moisture accumulation on the
Some controllers have a temperature sensor built battery tops? These are signs of possible
in. Such a controller must be mounted in a place overcharge. Are you getting the capacity that
where the temperature is close to that of the you expect from your battery bank? If not, there
batteries. Better controllers have a remote may be a problem with your controller, and it
temperature probe, on a small cable. The probe may be damaging your batteries.
should be attached directly to a battery in order
to report its temperature to the controller. Conclusion
The control of battery charging is so important
An alternative to automatic temperature that most manufacturers of high quality batteries
compensation is to manually adjust the set points (with warranties of five years or longer) specify
(if possible) according to the seasons. It may be the requirements for voltage regulation, low
sufficient to do this only twice a year, in spring voltage disconnect and temperature
and fall. compensation. When these limits are not
respected, it is common for batteries to fail after
Control Set Points vs. Battery Type less than one quarter of their normal life
The ideal set points for charge controlling expectancy, regardless of their quality or their
depend on the design of the battery. The vast cost.
majority of RE systems use deep-cycle lead-acid
batteries of either the flooded type or the sealed A good charge controller is not expensive in
type. Flooded batteries are filled with liquid. relation to the total cost of a power system. Nor
These are the standard, economical deep cycle is it very mysterious. I hope this article has given
batteries. you the background that you need to make a
good choice of controls for your power system.
Sealed batteries use saturated pads between the
plates. They are also called "valve-regulated" or
"absorbed glass mat," or simply "maintenance- At Wholesale Solar, we will be happy to help
free." They need to be regulated to a slightly find the products that are right for you. For
lower voltage than flooded batteries or they will pricing and product information give us a call.
dry out and be ruined. Some controllers have a We'll also answer any questions you might have
means to select the type of battery. Never use a about your system. 1 (800) 472-1142
controller that is not intended for your type of
battery.
Typical set points for 12 V lead-acid batteries at
77° F (25° C)
(These are typical, presented here only for
example.)
High limit (flooded battery): 14.4 V
High limit (sealed battery): 14.0 V
Resume full charge: 13.0 V
Low voltage disconnect: 10.8 V
Reconnect: 12.5 V
Temperature compensation for 12V battery:
-.03 V per ° C deviation from standard 25° C
Apollo Solar Midnite Solar Outback Power

Blue Sky Energy Morningstar Xantrex
max TM
60
max TM
80
Maximum Power Point Tracking Charge Controller
User’s Manual
Installation and Programming
Warranty Summary
Dear OutBack Customer,

Thank you for your purchase of OutBack products. We make every effort to assure our power
conversion products will give you long and reliable service for your renewable energy system.
As with any manufactured device, repairs might be needed due to damage, inappropriate use,
or unintentional defect. Please note the following guidelines regarding warranty service of
OutBack products:
• Any and all warranty repairs must conform to the terms of the warranty.
• All OutBack equipment must be installed according to their accompanying instructions and
manuals with specified over-current protection in order to maintain their warranties.
• The customer must return the component(s) to OutBack, securely packaged, properly addressed,
and shipping paid. We recommend insuring your package when shipping. Packages that are not
securely packaged can sustain additional damage not covered by the warranty or can void
warranty repairs.
• There is no allowance or reimbursement for an installer’s or user’s labor or travel time required to
disconnect, service, or reinstall the damaged component(s).
• OutBack will ship the repaired or replacement component(s) prepaid to addresses in the continental
United States, where applicable. Shipments outside the U.S. will be sent freight collect.
• In the event of a product malfunction, OutBack cannot bear any responsibility for consequential
losses, expenses, or damage to other components.
• Please read the full warranty at the end of this manual for more information.
1
The OutBack Power Systems FLEXmax 80 and FLEXmax 60 Maximum Power Point Tracking Charge
Controllers are ETL listed in North America to UL1741 (Inverters, Converters, Controllers, and
Interconnection System Equipment for Use with Distributed Energy Resources). It is also in compliance
with European Union standards EN 61000-6-1 and EN 61000-6-3 (see page 91).
About OutBack Power Systems

OutBack Power Systems is a leader in advanced energy conversion technology. Our products include
true sine wave inverter/chargers, a maximum power point charge controller, system communication
components, as well as breaker panels, breakers, accessories, and assembled systems.
Notice of Copyright
FLEXmax 60 and FLEXmax 80 Maximum Power Point Tracking Charge Controllers User’s Guide: Installation,
Programming and User’s Manual
Copyright © 2008 All rights reserved.
Disclaimer
UNLESS SPECIFICALLY AGREED TO IN WRITING, OUTBACK POWER SYSTEMS:
(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.
Date and Revision

April 2008 REV A
Contact Information
OutBack Power Systems
19009 62nd Ave. NE
Arlington, WA 98223
Phone (360) 435-6030
Fax (360) 435-6019
www.outbackpower.com
2
TABLE OF CONTENTS
SCOPE ....................................................................................................................................................................................................... 5
INTRODUCTION .................................................................................................................................................................................. 5
INSTALLATION GUIDELINES AND SAFETY INSTRUCTIONS ....................................................................................... 6
Standards and Requirements ........................................................................................................................................... 6
Battery Safety .............................................................................................................................................................................. 7
INSTALLING THE Charge Controller ON FLEXware ENCLOSURES ..................................................................... 10
OPEN CIRCUIT VOLTAGE/WIRE AND DISCONNECT SIZING ................................................................................... 10
CHARGE CONTROLLER CONNECTIONS ............................................................................................................................ 12
HOW TO READ THE Charge Controller SCREEN DIAGRAMS................................................................................. 16
POWERING UP .................................................................................................................................................................................. 17
STATUS SCREEN................................................................................................................................................................................ 20
END OF DAY SUMMARY SCREEN .......................................................................................................................................... 21
RECHARGING USING THE PV ARRAY ................................................................................................................................... 21
ACCESSING THE MAIN MENU .................................................................................................................................................. 22
CHARGER SETUP ............................................................................................................................................................................. 23
AUX MODE AND ITS FUNCTIONS ......................................................................................................................................... 24
AUX Mode Path ...................................................................................................................................................................... 25
AUX Modes Described ....................................................................................................................................................... 26
Programming the AUX Modes ..................................................................................................................................... 27
Vent Fan ............................................................................................................................................................................ 27
PV Trigger ......................................................................................................................................................................... 28
Error Output ................................................................................................................................................................... 31
Night Light ...................................................................................................................................................................... 32
Float ..................................................................................................................................................................................... 34
Diversion: Relay ............................................................................................................................................................ 34
Diversion: Solid State ................................................................................................................................................ 36
Low Battery Disconnect .......................................................................................................................................... 38
Remote .............................................................................................................................................................................. 40
BACKLIGHT.......................................................................................................................................................................................... 41
EQ (Equalize) ...................................................................................................................................................................................... 41
MISC-MISCELLANEOUS ............................................................................................................................................................... 44
ADVANCED ......................................................................................................................................................................................... 46
Snooze Mode........................................................................................................................................................................... 46
Wakeup Mode ......................................................................................................................................................................... 47
MPPT Mode .............................................................................................................................................................................. 47
Park Mpp .................................................................................................................................................................................... 48
CHARGING RELATED SCREENS ............................................................................................................................................... 49
Absorb Time ............................................................................................................................................................................. 49
Rebulk Voltage ........................................................................................................................................................................ 50
3
Vbatt Calibration ..........................................................................................................................................................................51
RTS Compensation.....................................................................................................................................................................51
Auto Restart ....................................................................................................................................................................................52
Aux Polarity .....................................................................................................................................................................................53
Reset to Defaults? .......................................................................................................................................................................53
(DATA) LOGGING ....................................................................................................................................................................................55
Clearing Total and Daily Stats ...............................................................................................................................................55
STATS .............................................................................................................................................................................................................56
Secondary Stats Screen ............................................................................................................................................................57
MICRO-HYDRO, WIND TURBINE, AND FUEL CELL APPLICATIONS............................................................................58
ADVANCED MENU (Micro-Hydro) ...............................................................................................................................................59
Charge Controller ABBREVIATED MENU MAP ......................................................................................................................60
APPLICATION NOTES ...........................................................................................................................................................................61
Charge Controller EFFICIENCY vs. INPUT POWER GRAPH ............................................................................................62
UNDERSTANDING THE VARIOUS OPERATIONAL MODES ..............................................................................................63
MATE-DISPLAYED CHARGE CONTROLLER STATUS MODE Screens .........................................................................66
MATE-DISPLAYED CHARGE CONTROLLER STATUS METER Screens .......................................................................67
MATE-DISPLAYED CHARGE CONTROLLER STATUS SETP(OINT) Screens ..............................................................68
MATE-DISPLAYED Charge Controller ADVANCED SCREENS........................................................................................68
ADVANCED MENU ................................................................................................................................................................................69
EQ SCREENS ..............................................................................................................................................................................................70
AUX SCREENS ...........................................................................................................................................................................................70
ABBREVIATED MENU ............................................................................................................................................................................71
TROUBLESHOOTING GUIDE ............................................................................................................................................................73
TYPICAL ARRAY SIZING GUIDE ......................................................................................................................................................76
STANDARD vs. AUSTRALIAN DEFAULT SETTINGS...............................................................................................................77
WIRE DISTANCE CHART FLEXMAX 80 ........................................................................................................................................78
WIRE AND DISCONNECT SIZING FLEXMAX 80 ....................................................................................................................80
WIRE AND DISCONNECT SIZING FLEXMAX 60 ....................................................................................................................81
WIRING COMPARTMENT....................................................................................................................................................................82
MULTI-STAGE BATTERY CHARGING.............................................................................................................................................83
BATTERY TEMPERATURE COMPENSATED VOLTAGE SET POINT .................................................................................85
SUGGESTED BATTERY CHARGER SET POINTS ......................................................................................................................86
CALLING THE FACTORY FOR ASSISTANCE ..............................................................................................................................87
WARRANTY INFORMATION ..............................................................................................................................................................88
PRODUCT REGISTRATION AND OPTIONAL EXTENDED WARRANTY ......................................................................90
EU DECLARATION OF CONFORMITY..........................................................................................................................................91
OWNER’S SYSTEM INFORMATION ............................................................................................................................................. 92
4
SCOPE
This manual provides safety guidelines and installation information for the FLEXmax 60 and FLEXmax
80 Charge Controller Maximum Power Point Tracking Charge Controllers. It does not provide information
about specific brands of solar panels and supplies limited information on batteries. Contact the
supplier or manufacturer of the solar panels or batteries for further information.
INTRODUCTION
The FLEXmax 60 and FLEXmax 80 Maximum Power Point Tracking Charge Controllers *
The OutBack Maximum Power Point Tracking Charge Controllers offer an efficient, safe, multi-stage
recharging process that prolongs battery life and assures peak performance from a solar array. Each
Charge Controller allows customized battery recharging. The Charge Controller features include:
• 80 amps maximum continuous output current up to 40° C without thermal derating for the
FLEXmax 80 and 60 amps for the FLEXmax 60
• Engineered to work with 12, 24, 36, 48, and 60VDC 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
The following are the maximum recommended wattage for the most common solar arrays under
Standard Test Conditions (1000 watts per square meter to solar panel at 25° C or 77° F):
• 12VDC battery systems—up to 1250 watts (FLEXmax 80) or 800 watts (FLEXmax 60) of solar panels
Each Charge Controller also features Continuous Maximum Power Point Tracking (MPPT), which seeks
out the maximum power available from a solar array and uses it to recharge the batteries. Without this
feature, the solar array does not operate at the ideal operating voltage and can only recharge at the
level of the battery voltage itself. Each Charge Controller continuously tracks the array’s maximum
operating power.
This manual covers the wiring, installation, and use of the Charge Controllers, including explanations of
all the menus displayed on the LCD screen. Each Charge Controller is designed to seamlessly integrate
with other OutBack components and can be remotely monitored and configured (up to 1000 feet) by
the optional OutBack Power Systems MATE display (version 4.0.4 or greater).
FIRMWARE
This manual covers Charge Controller firmware version 001.009.001
*For simplicity’s sake, both the FLEXmax 60 and FLEXmax 80 will be referred to in this manual as “Charge
Controller or by the abbreviation “CC.”
5
OUTBACK CHARGE CONTROLLER INSTALLATION GUIDELINES AND SAFETY
INSTRUCTIONS
This product is intended to be installed as part of a permanently grounded electrical system

as shown in the system configuration sections (see pages 12-15) of this manual. 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 GFP is present, the battery negative and ground are not bonded together directly but are
connected together by the GFP device when it is on. All negative conductor connections must be
kept separate from the grounding conductor connections.
• With the exception of certain telcom applications, the Charge Controller should never be positive
grounded (see page 61, Applications Notes).
• The Charge Controller equipment ground is marked with this symbol:
• If damaged or malfunctioning, the Charge Controller should only be disassembled and repaired by a
qualified service center. Please contact your renewable energy dealer/installer for assistance.
Incorrect reassembly risks malfunction, electric shock or fire.
• 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.
For routine, user-approved maintenance:

• Turn off all circuit breakers, including those to the solar modules, and related electrical connections
before cleaning the air vents.
Standards and Requirements

All installations must comply with national and local electrical codes; professional installation
is recommended. NEC requires ground protection for all residential PV installations
DC and Battery-Related Installation Requirements:

• All DC cables must meet local and national codes.
• Shut off all DC breakers before connecting any wiring.
• Torque all the Charge Controller’s wire lugs and ground terminals to 35 inch-pounds (4 Nm).
• 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 Charge Controller
(smaller cables can reduce performance and possibly damage the unit).
• Keep cables together (e.g., using a tie-wrap) as much as possible.
• Ensure both cables pass through the same knockout and conduit fittings to allow the inductive
currents to cancel.
• DC battery over-current protection must be used as part of the installation. OutBack offers both
breakers and fuses for overcurrent protection.
6
WARNING - WORKING IN THE VICINITY OF A LEAD ACID BATTERY IS DANGEROUS.
BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL OPERATION. Design the

battery enclosure to prevent accumulation and concentration of hydrogen gas in “pockets” at the top
of the enclosure. Vent the battery compartment from the highest point to the outside. A sloped lid can
also be used to direct the flow of hydrogen to the vent opening.
CAUTION - To reduce risk of injury, charge only deep-cycle lead acid, lead antimony, lead calcium,
gel cell or absorbed glass mat type rechargeable batteries. Other types of batteries may burst, causing
personal injury and damage. Never charge a frozen battery.
PERSONAL PRECAUTIONS DURING INSTALLATION

• Someone should be within range of your voice to come to your aid if needed.
• Keep plenty of fresh water and soap nearby in case battery acid contacts skin, clothing,
or eyes.
• Wear complete eye protection. Avoid touching eyes while working near batteries. Wash your hands
with soap and warm water when done.
• If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters an eye,
flood the eye with running cool water at once for at least 15 minutes and get medical attention
immediately following.
• Baking soda neutralizes lead acid battery electrolyte. Keep a supply on hand in the area of
the batteries.
• NEVER smoke or allow a spark or flame in vicinity of a battery or generator.
• Be extra cautious to reduce the risk of dropping a metal tool onto batteries. It could short-circuit the
batteries or other electrical parts that can result in fire or explosion.
• Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a
battery or other electrical current. A battery can produce a short circuit current high enough to weld
a ring or the like to metal, causing severe burns.
7
max TM
80 max TM
60
8
1. Installing the Charge Controller
The Charge Controller 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 control
brackets (FW-CCB, FW-CCB2, and FW-CCB2T).
NOTE: Install the Charge Controller in an upright

position out of direct sunlight.
To mount directly to a FLEXware DC enclosure:
• Remove the fan cover and bottom cover from

the Charge Controller.
• 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
Insert screws the top center of the Charge Controller.
through
• Hang the Charge Controller on the top screw
Screw holes lower holes
for #10 X 3/8” inside Charge and line up its bottom two screw holes with
sheet metal Controller the holes on the enclosure.
screws • Insert a #10 X 3/8” sheet metal screw through
each hole and tighten against the enclosure
To mount the (screws are included with each DC enclosure).
Charge Controller
• Keep the cover off until wiring is completed.
to charge control
brackets, see
the individual
instruction sheet
for those brackets.
The Conduit Nipple Assembly creates a sealed

pass-through from the Charge Controller to the
enclosure
DC Enclosure
Charge Controller Mounting to Plywood
Bushing Use 1 5/8” wood screws to secure the Charge

Controller at the top slotted holes and other
Locknut interior lower holes as needed, making sure the
Locknut unit is straight and level.
Conduit Nipple
9
2. Determining Wire Sizes
Open Circuit Voltage/Wire and Disconnect Size
Maximum Open Circuit Voltage (VOC)

• VOC is the unloaded voltage generated by the solar array.
• Greater than 145VDC Charge Controller suspends operation to protect components
• 150DC max open circuit voltage with the coldest environment
NOTE: Although the Charge Controller shuts down at a voltage greater than 145VDC, it can withstand
up to 150VDC from the array; anything higher than 150VDC will damage the Charge Controller).
• As every brand of panel is different, be sure to know the manufacturer’s specifications.

• Weather conditions vary and will affect panel voltage.
• Hot weather: lower open circuit voltage/lower maximum power point voltage
• Cold weather: higher open circuit voltage/higher maximum power point voltage
• Allow for ambient temperature correction using the following table:
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
• Check the PV array voltage before connecting it to the Charge Controller (see page 76)
Wire and Disconnect Sizing
FLEXmax 80
• The output current limit of the FLEXmax 80 is 80 amps

• Use a minimum of 4 AWG (21.15 mm2) wire for the output between the FLEXmax 80 and the battery
bus bar conductors
• Install OutBack OBB-80-150VDC-PNL breakers for disconnect and overcurrent protection
• The largest PV array that can connect to a Charge Controller must have a rated short-circuit current
of 64 amps or less under STC (Standard Test Conditions).
FLEXmax 60
• The output current limit of the FLEXmax 60 is 60 amps

• Use a minimum of 6 AWG (13.3 mm2) wire for the output between the FLEXmax 60 and the battery
bus bar conductors
• Install OutBack OBB-60-150VDC-PNL or OBB-80-150VDC-PNL breakers for disconnect and overcur-
rent protection
• The largest PV array that can connect to a Charge Controller must have a rated short-circuit current
of 48 amps or less under STC (Standard Test Conditions).
10
NOTE: Input conductors and circuit breakers must be rated at 1.56 times the short-circuit current of
the PV array. OutBack 100% duty continuous breakers only need to be rated at 1.25 times the short-
circuit current.
• Please see the wire Distance Chart and complete Wire and Disconnect Sizing on pages 78-81 for
other suitable conductor/wire sizing.
11
3. Charge Controller Wiring Connections
Figure 1 Charge Controller wiring compartment
Use up to 2 AWG
(33.6 mm2) wire
and torque to
35-inch pounds at PV+ PV- BAT- BAT+
terminals. Wire Lugs
MATE/HUB
RJ45 jack Chassis/Equipment
Ground Lug
Battery Remote Temp
Sensor (RTS) RJ11 jack
Programmable
AUX Output Jack
(supplies up to
200mA @ 12 VDC
Screw holes for attaching Charge Controller
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
Figures 2 and 3 for sample wiring diagrams. See Wire and Disconnect Sizing on page 80 for suitable
conductor/wire sizing.
NOTES:
• Each Charge Controller requires its own PV array. DO NOT PARALLEL Charge Controller PV+ and PV-
TERMINALS ON THE SAME ARRAY!
• An optional battery Remote Temperature Sensor (RTS) is recommended for accurate battery
recharging (only one RTS is needed for multiple OutBack Series Inverter/Chargers and Charge
Controller units when an OutBack HUB and a MATE are parts of the system). When one RTS is used,
it must be connected to the component plugged into the Port 1 of the HUB.
12
Figure 2 Single Charge Controller wiring diagram with 24 volt PV array
13
Figure 3 Charge Controller Wiring Diagram with an FX, HUB 4, and an RTS
14
Figure 4 Charge Controller with PV array ground fault protection wiring digram.
15
How to Read the Charge Controller Screen Diagrams
Soft keys:
(#1) (#2) (#3) (#4)
Solid black indicates key is to be pressed:
Down arrow will lead to the next screen:
Up arrow points to one or more keys that will change a value:
The keys correspond to any text immediately above them.
16
4. Powering Up
The Charge Controller power-up sequence first activates the unit and the SELECT VERSION screen (to
determine a choice of English, Espanola, or Australian settings). A SYSTEM VOLTAGE screen soon follows.
However, when it auto-detects the system’s battery voltage, in some instances the Charge Controller
might not reflect the correct system voltage (e.g., if a 36VDC system falls to a voltage range that could
be misread as a 24VDC system). The SYSTEM VOLTAGE screens allow the user to adjust the Charge
Controller to the correct voltage.
NOTE: Be sure the PV input and battery breakers are off before starting the power-up sequence.
OFF SCREEN (this screen is initially blank at power up)
With the PV array and battery breakers off, turn on the

battery breaker.
NOTE: The battery voltage must be at least 10.5V or higher to power up the Charge Controller. If the
screen reads Low Battery Voltage, please see the Troubleshooting Guide on page 73.
Power Up Screen
The Charge Controller will show the system battery

OutBack 12V voltage in the upper right corner of the screen. The
Power Select Version screen appears next.
Systems
Charge Controller
NOTE:
• The Charge Controller’s default setting is for a 12 VDC
battery.
• Change the setting after powering up the Charge
Controller if a different battery voltage is used.
• The PV array voltage—which must not exceed 150
VDC open circuit—is automatically detected.
17
Select Version
The Charge Controller screens are offered in English
Elija la Version (standard screens) and Spanish. For Australian users, some
English of the charging values are of different voltages and the
NEXT ENTER ENTRA SEL Charge Controller accommodates these. By pressing the
<NEXT> soft key, the user can choose English, Australia,
or Espanola versions of the screens. After pressing the
<NEXT> soft key, a password must be entered before
selecting the screen version.
Password Screen
Press the “ – “ soft key until the password 141 shows on

PASSWORD
the screen. Press the <ENTER> soft key to return to the
CONTRASENA Select Version screen.
***150***
ENTRA - + ENTER NOTE: 141 is the password for all OutBack products.
Press the <NEXT> to choose the desired screen

Select Version version. Press the <ENTER> soft key to view the version
Elija la Version confirmation screen.
English
NEXT ENTER ENTRA SEL
18
Are you sure?
Press the <YES> soft key to confirm your choice or
<NO> to return to the SELECT VERSION screen.
English
NO YES
The Charge Controller auto detects the system’s battery

System Voltage Screen voltage. To confirm this voltage, press the <ENTER> soft
key. If incorrect, press the “ ” soft key to select a battery
voltage. The Charge Controller’s default values are based
on a 12VDC system. Selecting a higher voltage system
will change all the default values (e.g., the values will
double with a 24VDC system, triple with a 36 VDC system,
etc.). “^^” indicates the chosen voltage. The Charge
Controller will automatically accept the selected battery
voltage if left unattended for 5 minutes in this screen.
After choosing the voltage, press the <ENTER> soft key
to proceed.
Verification Screen
Are you sure?

Press the <YES> soft key to proceed if the selected
12 24 36 48 60
battery voltage is correct. If incorrect, press <NO> to re-
^^
enter the correct voltage. The <YES> soft key will open
NO Yes the STATUS screen.
NOTE: Repeating the Powering Up sequence resets the

Charge Controller Charge Controller to its factory default
settings (see page 77).
19
5. Status Screen
The STATUS Screen displays system information. See page 63 for detailed information of the different
Operational Modes. The optional OutBack MATE displays CC (Charge Controller) STATUS screens for
convenient distant viewing from the installation location of the Charge Controller. Please see pages
66-68 to view the Charge Controller screens displayed on the MATE.
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.
PV Input Voltage PV Input Current

Battery Voltage In 11.6 V 0.0 A Output current
Out 13.8 V 0.0 A
Instantaneous Watts Daily accumulated kiloWatt Hours
0.000 kW 0.0 kWH
AUX status (ON or OFF) AUX: OFF Sleeping Operational Mode
NOTE:
• Pressing the first soft key opens the MAIN Menu screen.
• Pressing second soft key opens the End of the Day summary menu/logging.
20
6. End of Day Summary Screen
The End of Day summary screen appears after one hour of continuous sleeping. This screen can be
opened anytime by pressing the second soft key while in the STATUS screen, providing a summary up
to that point.
Peak output current Accumulated amp hours
Day (up to 128 days) Accumulated KWh total

Today 0000AH 00.0 kWH
power production
Peak Input Voltage 011Vp 00.0Ap 0.00kWp
MAX 14.7 V ABS 01:00 Peak kiloWatt hours
Maximum batt MIN 14.6 V FLT 00:00
voltage obtained Accumulated absorb time
Minimum batt Accumulated float time

voltage obtained
NOTE:
• Pressing the first soft key opens the STATUS screen.
• Pressing the second soft key brings up the CLEAR LOG screen.
• Pressing the third soft key shows the previous day’s summary; continually pressing this soft key will
bring up additional past summaries up to 128 days.
• Pressing the fourth soft key will bring up summary for the 128th day back.
7. Recharging Using the PV Array
Turn the PV input breaker on. The Charge Controller

In 113.6 V 0.0 A
automatically detects the PV input voltage.
Out 12.5 V 0.0 A
(NOTE: If PV voltage registers “000V” when the breaker is
0.000 kW 0.0 kWH
on, please check the polarity of the PV wires.)
AUX: OFF Sleeping
The Charge Controller enters a “Wakeup” stage, transitions

to “Tracking” and prepares to charge the batteries by
tracking the maximum power point of the solar array.
In 87.6 V 5.0 A
Out 12.5 V 32.9 A
0.410 kW 0.0 kWH During the Charge Controller’s initial tracking, the input
source (e.g., solar) is gradually loaded from the open
AUX OFF MPPT Bulk
circuit voltage (VOC) to one-half of the VOC. Within this
range, the Charge Controller seeks the maximum power
point. When the Charge Controller goes into Re-Cal,
Auto Restart, Wakeup, or RSTRT (restart) modes, among
other conditions, it performs an initial tracking.
21
8. Accessing the MAIN Menu
The MAIN Menu allows the user to adjust and calibrate the Charge Controller for maximum perfor-
mance. From the STATUS screen, press the first soft key on the left to open the MAIN Menu screen.
Press the <GO> soft key after aligning the arrow in

Charger Aux Light
front of the selected menu choice.
EQ Misc Advanced
Logging Stats Pressing the <EXIT> soft key in the MAIN Menu
EXIT GO returns to the STATUS screen.
Press or to move the " “ to

the left of the desired screen. The arrow
allows access to any screen to its right.
From the MAIN Menu, a user can choose among the following Charge Controller functions by align-
ing the arrow:
• Charger—CHARGER SETUP
- Adjusts the Current Limit, Absorb, and Float recharging voltage set points
• Aux—AUX OUTPUT CONTROL
- Secondary control circuit for a vent fan, error alarm, and other system-related additions
• Light—BACKLIGHT CONTROL
- Adjusts the backlighting of LCD screen and soft key buttons
• EQ—BATTERY EQUALIZE
- Activates battery equalization recharging (manually or automatically)
• Misc—MISCELLANEOUS
- Additional settings and service information
• Advanced —ADVANCE MENU
- Optimizing/fine-tuning the Charge Controller (these are advanced Menus that should be left
alone until the user has a good working knowledge of the Charge Controller and its operations)
• Logging—DATA LOGGING
- Displays recorded power production information
• STATS—Statistics
- Displays recorded peak system information and cumulative kilowatt hours and amp hours
22
7. Charger Set-Up
This screen allows changes to the Charge Controller’s recharging voltage set points—Current Limit,
Absorb and Float (for an explanation of battery charging, see pages 83-84):
• The presently selected numerical value will have an arrow “ ” to the left of it.
• Pressing < > selects the value to be changed.
• You may need to re-enter the password to change these settings.
• 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. An appropriate breaker must be used between the bat-
tery and the Charge Controller.
• Change Absorbing and Float set points using this screen if the battery manufacturer’s recommenda-
tions are different than the default values. Otherwise, see page 8 for suggested recharging voltage
set points.
From the MAIN screen, press or < > to move

Charger Aux Light
the " “ to the left of the Charger function and then
EQ Misc Advanced press the <GO> soft key. This will open the Charger
Logging Stats Set-Up screen.
EXIT GO
NOTE: If a battery remote temperature sensor (RTS)

is used, set the ABSORB and FLOAT setting voltage
based on a 25°C / 77°F setting. These are typically
Current Limit 80.0A the manufacturer’s set points (always consult
Absorbing 14.4V the battery manufacturer’s recommendations).
Float 13.8V RTS compensated voltage values can be viewed
EXIT - + in the Advanced menu screen under the RTS
Compensation heading. If an RTS is not in use, please
see the Non-Battery Temperature Compensated
System values (page 85) and adjust the ABSORB/
FLOAT values accordingly.
23
8. AUX Mode and Its Functions
The AUX is a secondary control circuit—essentially, a small power supply that provides a 12VDC (up
to 200 milliamps) output current. It is either active (12VDC on) or inactive (0VDC). Most AUX modes or
functions are designed for specialized applications and are infrequently used.
• To access the AUX MODE from the MAIN Menu, press the < > soft key until the arrow is in front of
the Aux selection (see next page). Charger ux Light
EQ Misc Advance
Logging Stats
EXIT GO
• A 200 milliamps or less, 12VDC/2.4W device can be wired directly to the AUX terminal; higher output
DC loads require a 12VDC coil relay—also rated up to 200 milliamps or less for the DC coil—which
itself is connected to the AUX output. An internal, re-settable Positive Temperature Co-efficient (PTC)
fuse protects the AUX internal components from overcurrent or a short circuit.
• For certain AUX control applications the use of a solid state relay is preferred. This is particularly
beneficial with applications such as the Diversion mode where fast switching (often called PWM
control) allows a more constant battery voltage to be maintained. Both DC and AC load
switching solid state relays are widely available from many sources. Eurotherm and Power-IO
are two suggested solid state relay manufacturers.
• Only one AUX MODE can operate at a time (even if other modes have been preset).
• See Figure 5, page 36, for an AUX set-up wiring diagram example.
This arrow indicates AUX
Polarity applies to this function
allowing the user to reverse the
conditions that activate this
In this Menu, On and Off AUX MODE function.
indicators show the present
state of the Aux terminals.
Night Light The second line indicates the
Pressing the <MODE> soft Output: Off Off present mode for the Aux Output.
When this line blinks, it indicates a
key changes the outputs
value (On, Off, or Auto) EXIT NEXT SET MODE pending AUX Mode.
When the preferred mode is

On indicates the Aux Output
displayed, press the <SET> soft
is in an active state; Off
key to select it.
indicates an inactive state.
Pressing the <NEXT> soft key

changes to the next mode.
TERMS
• AUX MODE: what is displayed on the Menu
• Aux Output: 12VDC is either available or unavailable at the Aux Terminal
• Aux Terminal: the jack to which a relay is wired
24
AUX MODE Menu Path
Charger Aux Light Charger Aux Light AUX MODE
EQ Misc Advance EQ Misc Advance Vent Fan
Logging Stats Logging Stats Output: Off Off
EXIT GO EXIT GO EXIT NEXT SET MODE
PASSWORD AUX MODE

***150*** Vent Fan
Output: Off Off
ENTER - + EXIT NEXT SET MODE
To access the AUX Output Menu:

• Press the first soft key once from the STATUS Menu to open the MAIN Menu.
• Press either of the arrow soft keys until the “ ” is to the left of Aux.
• Press the <GO> soft key. If more than ten minutes have passed since any activity, the PASSWORD
screen becomes active, requiring the user to input the 141 PASSWORD and press < ENTER>.
• Pressing the <NEXT> soft key scrolls through the AUX functions.
• The most commonly used AUX modes are Vent Fan, Low Battery Disconnect and Diversion.
AUX MODE AUX MODE AUX MODE

Vent Fan PV Trigger ERROR OUTPUT
Output: Off Off Output: Off Off Output: Off Off
EXIT NEXT SET MODE EXIT NEXT SET MODE EXIT NEXT SET MODE

Night Light Float Diversion: Relay

Diversion: Solid St Low Batt Disconnect Remote
25
AUX modes in order of appearance on the Charge Controller display:
• Vent Fan • PV Trigger • Error Output • Night Light • Float • Diversion Relay
• Diversion Solid State • Low Battery Disconnect • Remote
NOTE: All AUX functions can be manually activated in On, Off, or Auto mode. In Auto mode, the
function will automatically activate when a user-determined value is met and deactivate or shut down
when other conditions described here, such as a certain amount of time passing, occur.
When an AUX MODE is in AUTO, 12VDC is available at the AUX terminals and a condition, such as a voltage
set point, is met. Other modes can be programmed in lieu of the specific ones listed here, but the Vent Fan
mode is most easily changed (e.g., to activate an alarm instead of a fan). Here are the default AUX modes:
• Vent Fan— when the Vent Fan voltage set point is exceeded, the vent fan will run for at least 15 seconds
(the fan helps remove hydrogen from battery enclosure), even if the set point is exceeded for only a few
seconds due to a surge. If the set point is exceeded for longer than 15 seconds, the fan will stay on until
the voltage drops below the set point. It then takes 15 seconds before the fan shuts off. This is an optional
external fan and not to be confused with the Charge Controller’s internal, thermally activated fan which
cools the unit.
• PV Trigger*—activates an alarm or relay (that disconnects the array); when the PV input exceeds the
user-determined voltage set point (to avoid damage, do not go over 150VDC), the PV Trigger disconnects
after a minimal adjustable amount of Hold Time.
• Error Output—useful for monitoring remote sites, switches to the Off state if the Charge Controller has
not charged the batteries for 26 hours or more (not an audible alarm, only displayed as a printed message
on Charge Controller AUX Menu) or the battery voltage has fallen below a user-determined set point for
10 continuous minutes. In the No Error state, the AUX output is on.
• Night Light*—after the PV voltage is below a threshold voltage for a user-determined time period, a
user-provided light illuminates as long as the Charge Controller remains sleeping or as determined by the
user-established time limit.
• Float—powers a load if the Charge Controller is producing power in the Float stage
• Diversion Relay*—diverts excess power away from batteries when a wind or hydro generator is
connected directly to the batteries.
• Diversion Solid St—same as Diversion Relay, but applies when a solid state relay is used rather than a
mechanical relay
• Low Batt Disconnect—activates/deactivates the AUX load(s) when a user-determined voltage and time
levels are reached.
• Remote—allows OutBack MATE control of the AUX MODE (see MATE manual for details).
* These functions support AUX polarity.
26
9. Programming the AUX MODES
VENT FAN
AUX MODE On Press the <MODE> soft key to manually activate

Vent Fan or deactivate (On or Off) the Vent Fan; if set to Auto,
Off the Vent Fan will turn on when a user-determined
Output: Off Off
voltage is met. Press the <SET> soft key to view
EXIT NEXT SET MODE Auto
the Vent Fan screen. To view other screens, con-
tinue to press the <NEXT> soft key.
AUX MODE The Vent Fan helps remove hydrogen from the
Vent Fan battery box. The ventilation fan referred to here is
not the same as the Charge Controller cooling fan.
Press the <VOLT> soft key to determine the bat-
EXIT VOLT
tery voltage that will activate the AUX MODE and
start the fan.
VENT FAN VOLTS Adjust the voltage level using the < - > and < + >
> 14.4 soft keys. Press the <BACK> soft key to return to
the Vent Fan screen.
BACK - +
27
AUX MODE
Press the <EXIT> soft key return to the main Vent
Vent Fan
Fan screen.
EXIT VOLT
AUX MODE
Press the <NEXT> sot key to view the PV Trigger
Vent Fan
screen
Output: Off Off
EXIT NEXT SET MODE
PV TRIGGER
AUX MODE On When the PV input exceeds the user-determined

PV Trigger VOLT set point, the AUX MODE PV Trigger activates in
Output: Off Off Off Auto Mode. Press the <MODE> soft key to establish
EXIT NEXT SET MODE Auto another PV Trigger mode (On, Off, or Auto).
28
AUX MODE
PV Trigger Press the <SET> soft key to open the PV Trigger’s TIME
Output: On On and VOLT(age) set menus.
EXIT NEXT SET MODE
AUX MODE
PV Trigger
To adjust the voltage, press the <VOLT> soft key.
EXIT TIME VOLT
PV VOLTS Adjust the voltage within a range of 20V-145V by

>140 pressing the < - > or < + > soft key. When finished,
press the <BACK> soft key to return to the PV Trigger
BACK - + screen
AUX MODE
PV Trigger To adjust the minimum amount of time the PV voltage
must remain high before deactivating the AUX MODE,
EXIT TIME VOLT press the <TIME> soft key.
29
Press the < - > or < + > soft key to adjust the Hold
Hold Time Sec Time, then press the <BACK> soft key to return to the
01.1 PV Trigger screen. In this example, the AUX MODE will
remain active for 1.1 seconds after the PV voltage is
BACK - + below the PV Trigger voltage before deactivating the PV
Trigger and reconnecting to the array.
Press the <EXIT> soft key to return to the initial

AUX MODE
PV Trigger screen
PV Trigger
EXIT TIME VOLT
AUX MODE Press the <NEXT> soft key to view the ERROR OUTPUT
PV Trigger screen.
Output: On On
EXIT NEXT SET MODE
30
ERROR OUTPUT
The ERROR OUTPUT default state is On, meaning 12
AUX MODE VDC is present at the AUX terminal. If the Charge
ERROR OUTPUT Controller has not charged the batteries for 26
Output: On On On
hours or more continuously, the inaudible ERROR
EXIT NEXT SET MODE Off OUTPUT goes into an Off state. The ERROR OUTPUT
is intended for remote locations to signal (e.g., a
Auto telecommunication signal to a computer) when the
Charge Controller has not charged the battery for 26
hours or more. Press the <SET> soft key to advance
AUX MODE to the ERROR OUTPUT volt screen.
ERROR OUTPUT
01 hrs The ERROR OUTPUT screen displays the number of
EXIT VOLT hours the Charge Controller has not been producing
any power (the number of hours in Sleep Mode). Press
the <VOLT> soft key to adjust the ERROR LOW BATT
VOLTS screen.
ERROR LOW BATT VOLTS User-determined value—not less than 10V—will

<11.5 trigger an alarm or, through a user-supplied modem,
send a signal from a remote installation indicating
the battery charge has reached this value. This
BACK - +
informs the user of a low battery problem. Use the
< - > and < + > soft keys to change this value. Press
the <BACK> soft key to return to the AUX MODE
ERROR OUTPUT screen.
AUX MODE
ERROR OUTPUT
01 hrs
Press the <EXIT> soft key to bring up the original
EXIT VOLT ERROR OUTPUT screen.
AUX MODE Press the <NEXT> soft key to view the Night Light
ERROR OUTPUT screen.
Output: On On
EXIT NEXT SET MODE
31
NIGHT LIGHT
AUX MODE On The Night Light illuminates a user provided low-wattage

Night Light light when the PV voltage falls below a user-determined
Output: Off Off Off
voltage. Off is the default value. Press the <MODE> soft
EXIT NEXT SET MODE Auto key to change the Night Light MODE (Off, On, or Auto).
AUX MODE This example shows Auto MODE selected. Press the
Night Light <SET> soft key to open the Hysteresis and PV Voltage
Output: Off Auto screens.
EXIT NEXT SET MODE
AUX MODE Press the <HYST> soft key to open the On Hysteresis
Night Light Time screen.
EXIT HYST TIME VOLT
Use the < - > and < + > soft keys to adjust the time
Night Light
On Hysteresis Time required for the PV input voltage to be below the
Minutes 000 threshold voltage before the Night Light is enabled.
Press the <OFF> soft key to view the Off Hysteresis Time
BACK - + OFF screen.
32
Use the < - > and < + > soft keys to adjust the time
Night Light
Off Hysteresis Time required for the PV input voltage to be above the thresh-
Minutes 000 old voltage before the Night Light is disabled. Press the
<BACK> soft key twice to return to the Night Light screen.
BACK - +
AUX MODE
Night Light Press the <TIME> soft key to adjust the length of time
the Night Light remains on. If the time is set to 0, the Night
Light remains on until the off condition is met.
EXIT HYST TIME VOLT
Night Light On Time

Hours 23
Use the < - > and < + > soft keys to adjust the number of
hours the Night Light remains on. Press the <BACK> soft
BACK - + key to return to the previous Night Light screen.
AUX MODE
Night Light
Press the <VOLT> soft key.
EXIT HYST TIME VOLT
Night Light
Threshold Voltage
Press the < - > or < + > soft keys to adjust the Threshold
010
Voltage value. When finished, press the <BACK> soft key
BACK - + to return to the Night Light screen.
33
AUX MODE
Night Light Press the <EXIT> soft key to return to the Night Light
AUX mode.
EXIT HYST TIME VOLT
AUX MODE
Night Light Press the <NEXT> soft key ro view the AUX Float
Output: Off Auto screen.
EXIT NEXT SET MODE
FLOAT
AUX MODE On The AUX MODE is active when the Charge Controller
Float is in Float and producing power. Press the <NEXT>
Output: Off Off Off
soft key to advance to the Diversion screen.
When external DC sources (wind, hydro) are

directly connected to a battery bank, any excess
RELAY
power should be sent to a diversion load, such as
a heating element, via a mechanical or solid state
AUX MODE On
relay. In Diversion, which features Relay and Solid
Diversion: Relay
Output: Off Off Off State screens, the user programs set points—from
-5.0 volts to 5.0 volts relative to the Absorb, Float and
EQ voltages—to activate the AUX MODE. With wind
or hydro generator applications, keep the Charge
Controller’s diversion voltage slightly above its
Absorb and Float voltages for efficient functioning.
This is primarily an off-grid function. Pressing the

<MODE> soft key displays Auto and On modes in
addition to Off. Pressing the <SET> soft key displays
the Diversion: Relay TIME and VOLT screen.
34
AUX MODE Press the <TIME> soft key to advance to the Time
Diversion: Relay screen which allows the user to adjust the minimum
time the AUX MODE is active after the battery voltage
EXIT TIME VOLT falls below the Hysteresis voltage.
Hold Time shows how long the AUX MODE stays active
Hold Delay
after the battery voltage has fallen below the HYST
01.0 Time 00
seconds (Hysteresis) set point. The user can adjust the Hold Time
from 0.1 to 25 seconds.
BACK - + DLY+
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. Pressing the <BACK> soft key
returns to the AUX MODE Diversion: Relay TIME and
VOLT screen.
AUX MODE
Diversion: Relay
Press the <VOLT> soft key.
EXIT TIME VOLT
Use this screen to establish the set points for starting

and ending the AUX MODE relative to the Absorb, Float,
Absorb--Float--EQ
Relative Volts and EQ voltages. The < - > and < + > soft keys set the
0.0 00.2 Diversion set points. The <HYST> (Hysteresis) set point
establishes when the AUX MODE becomes inactive after
BACK - + HYST the battery voltage falls below the Relative Volts voltage
minus the HYST value. After establishing these values,
press the <BACK> soft key to return to the Diversion:
Relay TIME and VOLT screen.
35
AUX MODE
Diversion: Relay
Press the <EXIT> soft key.
EXIT TIME VOLT
AUX MODE
Diversion: Relay If a Solid State Relay is used, press the <NEXT> soft key to
Output: Off On access the Diversion Solid St screen.
EXIT NEXT SET MODE
To adjust the time and voltage when a solid state relay is

AUX MODE used, press the <TIME> and <VOLT> soft keys respectively
Diversion: Solid St and follow the same steps as for the Diversion:Relay screen.
Output: On On Note the values are displayed as percentages when a
solid state relay is used. When any adjustments are com-
EXIT NEXT SET MODE pleted, return to the Diversion: Solid St screen and press the
<NEXT> soft key to view the AUX MODE Low Batt Discon-
nect screen.
Example of Diversion
AUX MODE Absorb—Float—EQ Hold Delay

Diversion Relative Volts 15.0 Time 10
Off 00.2 00.3 Seconds
EXIT NEXT TIME VOLT BACK - + HYST + BACK - + DLY +
Each recharging state—Absorb, Float, or EQ—has a recharging voltage set point. 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. The user can determine these voltages and times.
In the example above, when the RE source (wind or hydro) raises the battery voltage 00.2v above the
chosen set point for a Delay time of 10 seconds—the AUX Output will be active. When the battery
voltage falls 00.3v below the HYST voltage set point for a Hold time of 15 sec – the AUX Output will be
inactive (Off). See Figure 5, next page, for Diversion Load and AUX Wiring Set-Up.
36
Figure 5 Diversion Load and AUX Wiring Set-Up Illustrated
37
LOW BATTERY DISCONNECT
When the battery voltage falls below the disconnect

AUX MODE volts, the AUX connected loads only are disconnected;
Low Batt Disconnect
the AUX connected loads only are connected when
Output: On On On
the battery voltage rises above the reconnect volts.
EXIT NEXT SET MODE Off To adjust these set points, press the <TIME> and
<VOLT> soft keys.
Auto
AUX MODE
Low Batt Disconnect Press the <TIME> and <VOLT> soft keys to adjust the
set points.
EXIT TIME VOLT
Press either the < - > or < + > soft key to adjust
the delay time. This is the time period the Charge
Delay Time Sec
Controller waits before either activating or deactivating
01 Timer
the AUX MODE when either the disconnect or
001
reconnect voltages are reached. When the low voltage
BACK - + occurs, the timer shows the seconds remaining before
disconnecting. When the reconnect voltage is reached,
the timer shows the user-determined time before
connecting. Press the <BACK> soft key to return to the
Low Batt Disconnect screen.
38
AUX MODE In the Low Batt Disconnect screen, press the <VOLT> soft
Low Batt Disconnect key to adjust the battery voltage disconnects
set point.
EXIT TIME VOLT
DISCONNECT VOLTS Press either the < - > or the < + > soft key to adjust the
< 13.6 disconnect voltage. Press the <ReCon> soft key to open
the RE-CONNECT VOLTS screen.
BACK - + ReCon
Press either the < - > or the < + > soft key to adjust the
RE-CONNECT VOLTS RE-CONNECT VOLTS value. The AUX Output activates
> 14.4 when the voltage goes above this setting after the timer
has counted back to zero. Press the <BACK> soft key
BACK - + DisV to return to the Low Batt Disconnect screen. Press the
<DisV> soft key to return to the Disconnect Volts screen.
39
AUX MODE
Low Batt Disconnect
Press the <EXIT> soft key.
EXIT TIME VOLT
AUX MODE
Low Batt Disconnect Press the <NEXT> soft key to view the Remote screen.
Output: Off On
EXIT NEXT SET MODE
REMOTE
AUX MODE
Remote In Remote AUX MODE, the OutBack MATE can
Output: Off On On control the Charge Controller’s AUX MODE. Press
the <EXIT> soft key twice to return to the MAIN
EXIT NEXT SET MODE Off
Menu screen.
Auto
Charger Aux Light Press the < > soft key to move the ” ” to the Light op-
Eq Misc Advanced tion. When the is in front of Light, press the <GO> soft
Logging Stats key.
EXIT GO
40
10. Backlight
On Auto (default) leaves backlight and soft keys on for
BACKLIGHT CONTROL up to nine minutes whenever any soft key is pressed
Off
Auto Time 2 Minutes (pressing any soft key when the LCD is not lighted
Auto Auto does not change any settings). Minutes are adjustable
using the < -> and < + > soft keys.
EXIT - + MODE
On or Off states are also available.
Press the <EXIT> soft key twice to return to the MAIN

Menu screen
Charger Aux Light

Press the < > soft key to move the “ “ to the EQ
EQ Misc Optimize
Logging Stats option. When the is to the left of EQ, press the
<GO> soft key.
EXIT GO
11. EQ—Battery Equalize
The intent of an equalization charge is to bring all battery cells to an equal voltage. Sealed batteries
should not be equalized unless specifically instructed by the manufacturer. Shut off or minimize all
loads on the battery. When equalizing, be sure the EQ voltage will not damage any still energized DC
load. If possible, ensure the EQ cycle starts and stops the same day it is initiated or unnecessary battery
gassing will occur.
• Occasional equalization extends the life of flooded electrolyte batteries.

• Proceed with caution! A vent fan is recommended in enclosed spaces.
• The Charge Controller allows the user to set voltages and times of equalization process.
• Both manual and auto modes are available.
• EQ voltage is not battery temperature compensated.
• Always check the electrolyte level in the batteries before and after equalizing.
41
BATTERY EQUALIZE Press either the < –EQV> or <+EQV > soft key to change
Volts the EQ voltage, following your battery manufacturer’s
15.0 recommendations. Note that the factory default EQ
voltage is set low, the same as the factory default Absorb
EXIT NEXT -EQV +EQV
voltage. Press the <NEXT> soft key to view the BATTERY
EQUALIZE Time screen.
Press either the <-HRS> or <+HRS> soft key to set

BATTERY EQUALIZE
the desired equalization time, up to a seven hour
Time
01 Hours maximum, always following your battery manufacturer’s
recommendations. Press the <NEXT> soft key to view
EXIT NEXT -HRS +HRS the battery equalization start screen.
Manual Mode (default mode)
• Press the <START> soft key to manually begin an

equalization cycle. To stop the cycle, press the <STOP>
BATTERY EQUALIZE soft key.
1 Hours 15.0 Volts • EQ-MPPT display indicates the Charge Controller is
Check water level
trying to reach the target equalize set point.
BACK AUTO START STOP • Equalize time EQ 0:00 in Hours:Minutes displays after
the equalize set point is reached.
• The incomplete equalization cycle continues into the
next day unless the Charge Controller is powered off
or manually stopped. The remaining EQ time can be
viewed in the Stats menu.
• EQ cycle terminates when EQ time period is reached.
• After equalizing, an EQ DONE message displayed and
a Float cycle begins. This message remains displayed
until a soft key is pressed.
Press the <AUTO> soft key to view the auto equalization

screen.
42
AUTO MODE
Use the <-DAY> and <+DAY> soft keys to preset the

COUNT EQ INTERVAL interval day to initiate an automatic equalization cycle.
00 000
The EQ INTERVAL displays the number of days in the
interval between cycles and COUNT displays how many
EXIT -DAY +DAY days of the interval have passed. To view the MAIN EQ
screens, press the <EXIT> soft key.
NOTE:
• Auto Mode initiates when a preset interval day (1-250 days) is reached.
• The default equalize interval (EQ INTERVAL) setting is 000 day leaving the auto eq disabled.
• EQ-MPPT display indicates the Charge Controller is trying to reach the target equalize set point.
• The equalize time EQ 0:00 in Hours:Minutes displays after the equalize set point is reached.
• An incomplete equalization cycle continues into the next day unless the Charge Controller is
powered off or manually stopped. The remaining EQ time can be viewed in the Stats Menu.
• The COUNT value will be cleared to 000 when an EQ is started, manually stopped, or Charge
Controller has been powered off.
• 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 MATE.
BATTERY EQUALIZE
Volts Press the first soft key twice to return to the MAIN Menu.
15.0
EXIT NEXT -EQV +EQV
Charger Aux Light

Eq Misc Advanced Press the < > soft key until the is in front of Misc.
Logging Stats Press the <GO> soft key to view the Misc screen.
EXIT GO
43
12. MISC—Miscellaneous
The MISCELLANEOUS screens display extra settings and technical information, some of which is
useful for OutBack Power Systems Technical Services.
The Grid Tie (GT) value is sent Each MPPT operation is This is the duty cycle of
from G-series inverter through the a state. This number the converter. At 50%, the
MATE and HUB for Grid Tie control is useful for OutBack PV terminals would be
communications. GT means The troubleshooting. twice the battery voltage.
Charge Controller is in grid tie
mode and communicating with The Bulk/Absorb charge
the GT Series Inverter. GT State PWM% ChgT timer counts up to the
255 07 50.0 005 Absorb time limit.
EXIT NEXT RSTRT
Press NEXT to Continue to the RSTRT forces the Charge

Force Bulk/Float Screen. Controller to restart or
wake-up from 5-minute
(default) long Snoozing
mode. Restart and wakeup
are mainly service features.
44
GT State PWM% ChgT
255 07 50.0 005
Press the <NEXT> soft key to view the FORCE FLOAT, or
BULK screen.
EXIT NEXT RSTRT
Pressing the <FLOAT> or <BULK> soft key forces the

Charge Controller to that specific recharging cycle and
returns to the STATUS screen. Forcing a FLOAT or BULK
FORCE recharge will end an EQ cycle. Press the <NEXT> soft key
EXIT NEXT FLOAT BULK to view the third MISCELLANEOUS screen.
• Force FLOAT = float cycle

• Force BULK = bulk cycle
This is the assigned number representing Btmp is a battery temperature sensor reference
the temperature of the internal components value used to compensate the charging voltage.
to control the cooling fan. The lower the This is an arbitrary number between 0 and 255
number, the higher the temperature. 25° C is and is not the actual temperature. An ‘X’ next to
approximately a value of 525. this value indicates a Global external RTS is being
used (system with a HUB and MATE).
The output value of the

PCB Target Btmp CFB internal current sensor is used
The target voltage the 512 14.4v 255 0712 to calculate output amps,
controller is trying to watts, and track the Maximum
reach. EXIT BACK Power Point of the array.
Press the <EXIT> soft key twice to return to the MAIN

MENU.
45
13. Advanced
The ADVANCED MENU allows fine-tuning of the Charge Controller operations including Snooze
periods and Maximum Power Point limits. In order of appearance, the following modes occur in
the ADVANCED Menu selections:
• 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?
From the MAIN Menu, choose Advanced and press

the <GO> soft key.
Snoozing occurs if the recharging current does not

ADVANCED MENU reach the user-selected cutoff current set point as
Snooze Mode shown in this screen. Press the <AMP> soft key to
< .6 amp
adjust the amp setting. Press the <NEXT> soft key
EXIT NEXT AMP for the Wakeup Mode screen.
Amp Values
0.2
0.4
0.6
0.8
1.0
46
Wakeup Mode selects how often the Charge Controller
ADVANCED MENU does a “Wakeup” during “Snoozing” periods. Since
Wakeup Mode environmental conditions impact the open circuit
1.5V 05m voltage (Voc) of an array, a user selectable Voc rise in
value will allow the controller to “wakeup” sooner or later
EXIT NEXT +VOC +Min based on the last measured Voc value. A selectable delay
time in minutes will also allow the controller to “Wakeup”
sooner or later if the measured Voc did not meet the
user selectable Voc rise in value. Before changing these
values, monitor your system for a week or so using the
factory defaults and then gradually adjust the set points.
If they’re set too high, the Charge Controller might not
wake up soon or often enough, which means a loss of
power production. Note: +VOC ranges from 1.5V up to
9.5V. +MIN ranges from 5 up to 15 minutes. Press the
<NEXT> soft key to go to the MPPT Mode screen.
U-Pick %Voc and Auto This screen allows the user to choose one of these
Track are the two modes modes:
appearing on this screen.
• Auto Track MPPT Mode (the default and preferred
mode) automatically tracks the PV upon wakeup and
ADVANCED MENU then tracks the MPP of the array. If the Auto Restart is
MPPT Mode set to 1 or 2, the Charge Controller awakes every 1.5
Auto Track hours and does an initial tracking.
EXIT NEXT nonGT MODE • U-Pick % (Voc) MPPT mode operates the PV voltage at a
user-selected percentage of the Voc. This percentage is
displayed in the Park Mpp % Voc screen along with the
current output wattage. The wattage value changes as
the user adjusts the Voc percentage, allowing the user
to 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.
Press the <MODE> soft key to choose an MPPT mode. If

you have an OutBack G-series inverter system with a HUB
and MATE, press the <nonGT> soft key to activate the
charge controller’s grid-tie mode.
Press the <NEXT> soft key to view the Park Mpp screen.
47
ADVANCED MENU ADVANCED MENU
Park Mpp Park Mpp
77 % Voc Watts 0251 77 % Voc
EXIT NEXT -% +% EXIT NEXT -% +%
As the user changes the %Voc value using the

<-%> and <+%> soft keys, the displayed Watts
value also changes.
Watts appears when U-Pick is selected.
Press the <NEXT> soft key to view the Park

Mpp screen.
U-Pick % (Voc) MPPT mode operates the PV voltage at a

ADVANCED MENU user-selected percentage of the VOC which is displayed
Mpp Range Limit %Voc in the Park Mpp % Voc screen. Press the <NEXT> soft key
Min Max to view the Mpp Range Limit % screen.
EXIT NEXT 1/2 90% The Mpp Range Limit % Voc adjusts the upper Mpp limit of
the VOC. The default Charge Controller MPP voltage limit
is set at 90% of the VOC and is normally left alone for an
array. Setting min to 1/2 reduces the initial tracking time
on a high input voltage array and also tracks one-half the
Use ½ value for high input arrays
to speed up initial tracking. VOC voltage.
The MPP adjustable Charge Controller limits are 80%,

85%, 90%, and 99% of the VOC. The min range limit set-
ting may be set to FULL if something other than a PV
array is connected to the input of the Charge Control-
ler, such as a micro-hydro generator (see page 58), but
the VOC cannot exceed 150 VDC at any time. Press the
<min> or <max> soft key to adjust the MPP range limit.
When done, press the <NEXT> soft key to view the
Absorb Time screen.
48
14. Charging-Related Screens
In the Absorb Time Limits screen, the user can set the
ADVANCED MENU duration the Charge Controller stays in the Absorb
Absorb Time Limits recharge cycle.
01.0 hours
• Absorb Time is adjustable from 0 to 24 hours (consult
EXIT NEXT - + your battery manufacturer’s recommendations).
• A Bulk cycle starts each morning (see chart next page).

The charge timer (ChgT) is preset to zero.
• The ChgT counts up to the Absorb Time Limit after the

Absorb voltage is reached.
• If the system cannot maintain the Absorb voltage

set point during the Absorb cycle, the timer will stop
counting up.
• If the battery voltage is greater than or equal to 12.4V,

24.8V, 37.2V, 49.6V 62.0V and less than the absorb
voltage, the ChgT timer does not change.
• If the battery voltage is less than 12.4 V, 24.8V, 37.2V,

49.6V or 62.0V, the ChgT timer counts down to zero
in minutes—for every minute elapsed, one minute is
subtracted from the timer.
• If the battery voltage is less than 12.0V, 24.0V, 36.0V,

48.0V or 60.0V, the ChgT timer counts down to zero at
twice as fast—for every minute elapsed, two minutes
is subtracted from the timer.
• If the battery voltage is less than 11.6V, 23.2V, 34.8V,

46.6V, or 58.0V, the ChgT timer counts to zero four
times as fast—for every minute elapsed, four minutes
is subtracted from the timer.
• 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 F(Float)-MPPT function.
To adjust the Absorb Time limit, press either the

< + > or < -> soft key. When finished, press the <NEXT>
soft key to view the next screen.
49
Charge Controller Multi-Stage Battery Charging
Figure 6 NOTE: In BULK, the Charge Controller will charge as long as necessary to complete
the cycle, regardless of the timer’s set points
An Absorb charge cycle normally ends when a battery

ADVANCED MENU voltage is maintained at the Absorb set point for the
Absorb End Amps user-determined time period. Use the < -> or < + > soft
00 A keys to adjust the Absorb End Amps to an optimal value
(the default value is 00). While the battery voltage is at or
EXIT NEXT - + above the Absorb target and the Absorb End Amps value
is reached for a time delay of 15 seconds, the Charge
Controller will switch to the Float stage regardless of
the charger time minutes as shown in the Misc menu
under ChgT. The charger timer will be cleared. This is an
optional set point and is used for few installations.
When finished with any adjustments, press the <NEXT>

soft key to view the Rebulk Voltage screen.
ADVANCED MENU In Float, if the battery voltage falls below the ReBulk
Rebulk Voltage Voltage set point for at least 90 seconds, the Charge
Controller will automatically reinitiate a Bulk charge cycle.
12.6 V
The default is set to 6 volts, a very low value that will
EXIT NEXT - + disable this function. The Rebulk Voltage value can be
adjusted by pressing the < - > or < + > soft keys. Press
the <NEXT> soft key to view the Vbatt Calibration screen.
50
A quality calibrated voltmeter will provide even more
ADVANCED MENU accurate Charge Controller battery readings if an undesir-
Vbatt Calibration able voltage drop occurs. When measuring battery volt-
14.1 V 0.0 V age, ensure a good connection is made to the four wire
lugs. Check the battery temperature compensation volt-
EXIT NEXT - +
ages if the voltages are much different than you expect
from the charger setup Absorb and Float voltage settings.
Use the <-> and <+> soft keys to match the readings
from the voltmeter (use of appropriate wire gauge
will minimize voltage drop). When finished, press the
<NEXT> soft key to view the RTS Compensation screen.
RTS Compensation* During cold weather, a battery often requires a higher
recharging voltage. Lower quality inverters might not
ADVANCED MENU accommodate these higher voltages and can shut down
RTS Compensation during recharging, cutting off power to their loads. The
A 14.1 V F 13.8V Charge Controller allows the user to lower the compen-
sated voltage in the Absorb cycle so these inverters will
EXIT NEXT WIDE remain operating. Also, some batteries have an abso-
lute voltage limit that should not be exceeded and the
WIDE/LMIT option allows the user to control this during
recharging. WIDE allows the RTS full control over recharg-
ing; LIMIT sets the ceiling and floor voltages for the RTS.
During hot weather, the LIMIT feature set point assures

recharging will continue at a high enough voltage rather
than dropping too low in reaction to a higher ambient
temperature. This assures the recharging voltage ad-
equately charges, but should be monitored according to
the battery manufacturer’s recommendations.
ADVANCED MENU
RTS Compensation The RTS default compensated voltages apply if the WIDE/
A 14.1 V F 13.8 V LIMIT option is set to WIDE. To change these values, press
the <WIDE> soft key to bring up the next screen which
EXIT NEXT LIMIT SET
allows user-determined limits. Press the <SET> soft key
to adjust these values.
RTS COMPENSATION Press the < > soft key to choose the limit value you
Upper LIMIT 14.1 V want to adjust. Press the < - > and < + > soft keys to
Lower LIMIT 13.2 V adjust the chosen value(s). When finished, press the
<BACK> soft key to return to the RTS Compensation
BACK - + screen.
*Optional OutBack RTS must be installed
51
ADVANCED MENU
RTS Compensation Press the <NEXT> soft key to view the Auto Restart
A 14.4 V F 13.8V screen.
EXIT NEXT LIMIT SET
AUTO RESTART
ADVANCED MENU Pressing the fourth soft key selects among the three
Auto ReStart Charge Controller Auto ReStart modes: 0 (default), 1, and
MODE 2 2. Auto ReStart allows the Charge Controller to perform
internal recalibrations.
EXIT NEXT MODE
ADVANCED MENU
Auto ReStart
MODE 0 • Mode 0— Auto ReStart mode is disabled; the Charge
Controller recharges continuously from an available
EXIT NEXT MODE
source and never Restarts. Mode 0 would be chosen
to avoid spinning a microhydro generator every 1.5
hours.
• Mode 1—once every 1.5 hours, when the Charge
Controller is in Bulk, it will briefly Restart and initiate a
full panel tracking. This will not reset any counters or
ADVANCED MENU charging stages or statistics.
Auto ReStart • Mode 2— Auto ReStart every 1.5 hours; in Bulk, Absorb,
MODE 1 and Float modes, it will briefly Restart and initiate a
full panel tracking. This will not reset any counters or
EXIT NEXT MODE
charging stages or statistics.
52
ADVANCED MENU
Auto ReStart From the Auto Restart MODE 2 screen, press the <NEXT>
MODE 2 soft key to view the Aux Polarity screen.
EXIT NEXT MODE
When the AUX function is ON, 12 volts is present at

the AUX terminal; when it’s OFF, 0 volts are present
ADVANCED MENU at the terminal. Aux Polarity allows the user to reverse
Aux Polarity the availability of this voltage for the Night Light, PV
Active High Trigger, or Diversion Relay functions. In Active High, the
user establishes certain conditions for these functions.
EXIT NEXT MODE Pressing the <MODE> soft key brings up the Active Low
screen which allows the user to reverse these conditions.
ADVANCED MENU In the Active Low zero voltage will be available for a
Aux Polarity function that in Active High would normally have voltage.
Active Low When one of the three functions— Night Light, PV Trigger,
or Diversion Relay—has been chosen as the AUX function,
EXIT NEXT MODE an arrow in the right hand corner of the screen will reflect
the Aux Polarity state. An arrow pointing up means Active
High while an arrow pointing down means Active Low.
Press the <NEXT> soft key to view the Reset to Defaults?
screen.
EXAMPLE
AUX MODE AUX MODE
PV Trigger PV Trigger
Output: Off Off Output: Off Off
EXIT NEXT SET MODE EXIT NEXT SET MODE
PV Trigger Active High PV Trigger Active Low
ADVANCED MENU
In this screen, a user can press the <RESET> soft key
Reset to Defaults? to return the Charge Controller to the factory default
settings.
(If you do not need to reset, press the <EXIT> soft key to
EXIT NEXT RESET
return to the STATUS screen.)
53
Are you sure?
Pressing the <YES> soft key brings up a Reset to Defaults
Reset to Defaults screen momentarily before returning to the Reset to
Defaults? screen
YES NO
ADVANCED MENU
Reset to Defaults? Press the <EXIT> key twice to return to the MAIN Menu
screen.
EXIT NEXT RESET
Charger Aux Light From the MAIN Menu, press the < > soft key to move
Eq Misc Advanced the arrow next to the Logging function and then press
Logging Stats the <GO> soft key. This leads to the End of the Day
Summary screen, which is a log of the daily statistics and
EXIT GO can be viewed at any time.
54
15. Logging
A user can clear either the daily or accumulated statistics

Today 0000Ah 00.0 KWH
of the Charge Controller by pressing the second button
011Vp 00.0Ap 0.00kWp
from the left in this screen. This will bring up the CLEAR
MAX 14.7V ABS 01:00 LOG screen.
MIN 14.6V FLT 00:00
The CLEAR LOG screen offers the option of clearing up

CLEAR LOG to 128 days of accumulated statistics or the total in the
secondary STATS screen (page 56). Press and hold either
the <TOTL> (total) or <DAILY >key to clear those specific
statistics.
BACK TOTL DAILY
Are you sure?

The Are you sure? screen appears. Pressing the <YES> soft
key returns to the CLEAR LOG screen; pressing the <NO>
soft key returns to the Logging screen.
NO YES
Pressing the third and fourth soft keys changes the

Today 0000Ah 00.0 KWH displayed day’s statistics, by moving either forward or
011Vp 00.0Ap 0.00kWp backward within the 128 days of available statistics that
MAX 14.7V ABS 01:00 are viewable.
MIN 14.6V FLT 00:00
NOTE: 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.
55
16. Stats
Charger Aux Light

From the MAIN Menu, press the < > soft key to move
Eq Misc Advanced
the arrow next to the Stats function and then press the
Logging Stats <GO> soft key
EXIT GO
The STATS screen displays additional voltage and time

information.
The highest Voc seen by the

Daily high
Charge Controller
VOC value
In a stand alone Charge
Maximum battery Controller—one that is not
voltage seen by the connected to a MATE—
Max Bat Voc MaxVoc Sunrise shows how long
Charge Controller
14.9 036.6 133.0 ago the Charge Controller
Max Watt seen MaxWatt 0000 Sunrise woke up for the first time
by the Charge each day and when the
Controller EXIT NEXT 01:30:33 daily and total logged
values were updated and
cleared from the STATUS
screen. If the Charge
Controller is connected to a
MATE, the logging occurs at
midinght.
Press the <NEXT> soft

to view the second STATS
screen.
56
Secondary STATS screen
Total 0000 kWH The Secondary Stats screen shows the total accumulated
Total 000.0 kAH DC and AC kilowatt hours and kiloamp hours of the
Charge Controller.
BACK DCkWH Pressing the <DCkWH> soft key switches the screen
between DC kilowatt hours and AC kilowatt hours
• DCkWH shows the DC kilowatthours and should be

used in a non-grid-tied system
• ACkWH is used with a grid-tied system. This measure is
Total 0000 kWHAC based on a 90% inverter efficiency (1 kWH DC= 0.9 kWH
Total 000.0 kAH AC)
BACK ACkWH Pressing the first soft key three times returns to the MAIN
Menu screen.
57
17. Micro-Hydro and Fuel Cell Applications
The Charge Controller is designed to work with solar arrays. Although it will work with micro-hydro
turbines and fuel cell, OutBack Power Systems can only offer limited technical support for these
applications because there is too much variance in micro-hydro and fuel cell generator specifications.
When used for micro-hydro or fuel cell applications, the Charge Controller warranty will be honored
only if the manufacturer and turbine model have been approved by OutBack Power Systems. Please
check with one of the following manufacturers or OutBack Power Systems before employing the
Charge Controller with these applications:
• Harris Hydroelectric
(831) 425-7652
www.harrishydro.com
• Alternative Power & Machine

(541) 476-8916
www.apmhydro.com
• Energy System & Design

(506) 433-3151
www.microhydropower.com
The Charge Controller is not compatible with wind turbine applications and OutBack cannot
warranty its use in these applications.
MICRO-HYDRO AND FUEL CELL SYSTEMS PERFORMANCE OPTIMIZATION

Micro-hydro and fuel cell systems are different than PV systems, whose VOC output is more subject to
change due to weather and time of day. A PV system normally finds its Maximum Power Point voltage
between 50-90% of its VOC. A micro-hydro or fuel cell system’s MPP voltage can be outside of this
range.
The Charge Controller allows a user to experiment and find more appropriate set points to best
capture the MPP voltage using U-Pick mode. Otherwise, Auto Track begins tracking the VOC and works
its way down until the optimum percentage of input voltage yields the MPP voltage. If U-Pick % Voc is
chosen, the MPP is calculated by whatever value is found in Park Mpp, even if it’s not the optimal value
for determining the MPP voltage. For this reason, OutBack normally suggests leaving the system in
Auto Sweep mode.
58
18. Advanced Menu (Micro-Hydro and Fuel Cell Applications)
Mpp Range Limit % (Auto Track Mode only)
The Charge Controller searches for the MPP voltage by tracking the input voltage up to one half
(default) of the Voc, which is based on values appropriate for a solar array. Micro-hydro and fuel cell
systems can require a broader range, normally on the lower end. Adjusting the lower limit, expressed
as 1/2 on the display screen, for FULL allows the Charge Controller to track the input voltage close to
the battery voltage instead of 1/2 (or 50%) of the Voc.
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 Charge Controller.
To adjust the Lower Mpp Range Limit:

Charger Aux Light
Eq Misc Advanced
From the MAIN Menu, with the arrow in front of
Logging Stats
Advanced, press the <GO> soft key.
EXIT GO
In the ADVANCED MENU screen, press the <NEXT> soft

ADVANCED MENU key until the Mpp Range Limit % Voc screen appears. Press
Mpp Range Limit %Voc the <1/2> soft key until FULL appears. When finished,
Min Max press the <NEXT> soft key until the MPPT Mode screen
appears.
EXIT NEXT 1/2 90%
To pick between Auto Track or U-Pick % MPPT Mode

ADVANCED MENU and determine the Charge Controller’s operating Voc
MPPT Mode percentage, press the <MODE> soft key to interchange
Auto Track between the two modes. Re-entering the password
might be required. After choosing a mode, press the
EXIT NEXT nonGT MODE <NEXT> soft key in the ADVANCED MENU to view the
Park Mpp screen (only applicable for U-Pick mode).
ADVANCED MENU Press the <-VOC> or <+VOC> soft key to select one of
Park Mpp the percentage values; U-Pick always uses the Park Mpp
Watts 0000 77 % VOC value.
EXIT NEXT –% +%
59
19. Abbreviated Menu Map
Much of the Charge Controller activity takes place around the MAIN screen. From this screen, the user
can access other screens to both observe system activiy and make adjustments to certain critical func-
tions.
Charger Aux Light The Light feature con-

EQ Misc Advanced trols the backlighing of
Logging Stats the Charge Controllers
LCD screen and soft
key buttons
EXIT GO
Misc offers additional

settings and service
information
Adjusts the Current AUX control includes:

Limit, Absorb, and Float • Vent Fan
recharging voltage set • PV Trigger Stats shows time-
points • Error Output based information
• Night Light regarding the Charge
• Float Controller
• Diversion: Relay
• Diversion: Solid State
• Low Battery Disconnect
• Remote
EQ allows manual or The Advanced menu allows the user to fine-

automatic battery tune the Charge Controller using the following
equalization recharging screens:
• Snooze Mode
• Wakeup Mode
• MPPT Mode
• Park Mpp
• Mpp Range Limit % VOC
The Logging screens display • Absorb Time
primary and secondary power • Absorb End Amps
production information, including • Rebulk Voltage
power peaks • Vbatt Calibration
• RTS Compensation
• Auto Restart
• Aux Polarity
• Reset to Defaults?
60
20. Application Notes
OutBack Power System GTFX/GVFX Grid-tie settings

In a GTFX/GVFX Series Inverter/Charger, Charge Controller, HUB, and MATE installation set the Charge
Controller to GT mode in the ADVANCED MENU. GT mode allows the GTFX/GVFX to manage the
Charge Controller float setting ensuring the Charge Controller is always keeping the battery above the
sell voltage of the GTFX/GVFX.
Grid-tie applications (non-OutBack inverter/chargers)

When selling electricity back to the grid, keep the inverter Sell/Float voltage below the Charge Control-
ler float voltage. Appropriate values: 0.5 Volts difference for 24V battery system or 1.0 volt difference for
48V battery systems.
Positive grounded systems

Telcom applications frequently require a positive grounded system. The Charge Controller switches the
POSITIVE PV and battery leads. Keep these separate. If code allows, ground ONLY the battery positive
lead in this case. Do not connect the Charge Controller’s battery plus to the PV plus input while the
Charge Controller is running. The OutBack HUB cannot be used in a positive grounded system.
61
21. Charge Controller EFFICIENCY vs. INPUT POWER GRAPH
Charge Controller Efficiency vs Input Power
INPUT= 17V, 34V, 51V, 68V, 85V, 100 V OUTPUT = 12V Nominal
Figure 7 12V Battery System

Efficiency Curve

INPUT= 34V, 51V, 68V, 85V, 100 V OUTPUT = 24V Nominal

Efficiency Curve

INPUT= 68V, 85V, 100 V OUTPUT = 48V Nominal

Efficiency Curve
62
22. Understanding the Various Operational Modes
The Charge Controller modes of operation will change occasionally during the day based on the
PV array output and the battery system state of charge. The Charge Controller operating modes are
displayed at the bottom right hand corner of the STATUS screen.
Absorbing The Charge Controller is in the Absorb (constant voltage) charge stage, regulating the
battery voltage at the Absorb voltage set point (modified by battery temperature compensation
if installed). During this cycle, the ChgT counter in the Misc menu is counting up towards the user
defined Absorb Time Limit. If the system cannot regulate the battery voltage at the Absorb voltage set
point, then the Charge Controller reverts back to the Bulk charge stage, display MPPT Bulk, and the
ChgT counter may start counting down towards zero minutes or until the Absorb target is met. See
page 49 for more information.
AutoStart (Auto Re-Start) Mode 1—Once every 1.5 hours in Bulk cycle and in Mode 2, once every
1.5 hours in the Bulk, Absorb and Float recharging modes, the Charge Controller will start over from
sleeping and re-track (full track) and re-calibrate the current sensor. Mode 0 is disabled completely.
(See Stats menu). Note: If enabled, AutoStart also occurs during the MPPT EQ cycle.
BatTmpErr The battery temperature sensor is shorted or damaged. The charging voltage will not be
temperature compensated and the cooling fan will continuously operate.
BatTooHot The battery temperature sensor has detected a battery temperature of over 50°C. The
Charge Controller will stop charging the battery and wait for the battery to cool below 50°C.
Charged There is an external DC source other than solar keeping the battery above the Float voltage
set point-- the Charge Controller will stop charging. The display may also appear when the charge
cycle is transitioning from Absorbing (upper target voltage) to Floating (lower target voltage).
EQ 0:00 This is the time elapsed in hours and minutes since the Equalization voltage set point was met.
If the EQ voltage set point is not maintained, the controller will revert back – the EQ timer will pause
until the batteries are regulated at the EQ voltage set point again. The paused time can be viewed in
the Stats menu.
EQ Done Once the set EQ time (between 1 and 7 hours) has successfully completed, EQ Done will be
displayed either until a button is pressed, or the next morning’s wakeup. The Charge Controller will
transition to Float cycle at the end of the completed EQ cycle.
EX-Absorb There is an external DC source other than solar keeping the battery above the Absorb
voltage set point. The Charge Controller will stop charging.
Floating The Charge Controller is in the Float (constant voltage) charge stage and is regulating the
battery at the Float voltage set point (modified by battery temperature compensation, if installed). If
the system cannot maintain the Float voltage set point, (e.g. AC and/or DC loads are on), the Charge
Controller will employ the MPPT function, display MPPT Float, and try its best to regulate the batteries
to the Float voltage set point.
63
GT Mode In a system with an OutBack FX Grid-Tie Series Inverter(s), HUB and MATE, the Charge
Controller will display GT Mode if and only if the inverter is in Sell mode and the Charge Controller is
in Bulk (MPPT BULK) or Float (MPPT FLOAT) cycle. This is also a good indicator for establishing proper
Grid-Tie mode communication between the FX G-Series Inverter(s) and Charge Controller. GT must be
selected in the MPPT Mode Advanced menu in order to be viewed.
High VOC This indicates the PV array’s open circuit voltage is too high for the controller to
safely operate. This should only occur with systems using 72 VDC nominal PV arrays in very cold
temperatures (below 5° F / -15° C). The controller will automatically restart operation once the PV
array’s open circuit voltage falls to a safe level (145 VDC or lower). 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 controller starts in the morning within a few minutes of
the PV array being in direct sunlight.
Low Light / Snoozing During the initial tracking (see Wakeup and Tracking), if it is determined to
be too late (or too early) in the day, the Charge Controller will display Low Light for a few seconds and
then display Snoozing for 5 minutes (default). This reduces energy usage and unnecessary powering of
the Charge Controller. This message is also displayed in extremely cloudy weather.
MPPT Bulk The Charge Controller is in Maximum Power Point Tracking mode trying to regulate the
battery voltage towards the Absorb voltage set point. If the Charge Controller transitioned from
Absorbing to MPPT Bulk, the Charge Timer (ChgT) counter may start counting down towards zero
minutes or until the Absorb target is met. See page 49 for more information.
MPPT Float The Charge Controller is in Maximum Power Point Tracking mode trying to regulate the
battery voltage towards the Float voltage set point. Note: Charge Timer (ChgT) is inactive in the Float
state.
MPPT EQ The equalization cycle has started and the Charge Controller is trying to regulate at the
Equalization voltage set point. EQ is not battery temperature compensated. During an equalization
cycle, EQ 0:00 will be displayed along with the EQ time in hours and minutes. The AC/DC loads should
be turned off/minimized and the battery charged so the Charge Controller can quickly reach the EQ
voltage set point. Otherwise, the Charge Controller may not reach or maintain the EQ cycle.
New VOC The Charge Controller is acquiring a new open circuit panel voltage (VOC).
OvrCurrent If more than 6A flowing from the battery or more than 100A flowing to the battery. To reinitiate
power production, press ”RSTRT” in the “Misc” menu.
Over Temp (Very rare) Either the Charge Controller is too hot or its internal temperature sensor is shorted.
If this message appears, carefully check if the Charge Controller’s heat sink is extremely hot. The heat
generated by the Charge Controller, and therefore its losses, is proportional to input voltage times output
current. To help control its operating temperature, avoid installing the Charge Controller in direct sunlight
Re-Cal There are certain abnormal conditions that can confuse the current measuring method in the
Charge Controller. When and if one happens, the Charge Controller will temporarily stop and re-calibrate.
This may happen because of negative current, i.e., current flowing from the battery, or a tripped PV breaker.
A new VOC is also acquired during a Re-Cal.
64
Sleeping The PV voltage is two volts less than the battery voltage. This may also appear during the day
when the Charge Controller is transitioning between certain states, or due to other conditions.
SysError (Very rare) System Error indicates an internal non-volatile memory error. The unit will stop
operating when this message is displayed. Call the factory if you see this message (360-435-6030).
Tracking In Auto-Sweep MPPT mode, the Charge Controller is doing an initial tracking of the panel voltage
from VOC towards battery voltage after wakeup. This display also appears when the controller transitions
from a target set point (Absorbing/ Floating/EQ 0:00) to the MPPT state (MPPT Bulk/ MPPT Float/ MPPT EQ).
Unloaded The battery terminals abruptly unload. Unloaded is also displayed if the battery breaker trips
while MPPTing or the battery voltage is set too low.
Wakeup As the PV open circuit voltage (VOC) rises above the battery system voltage by two volts, the
Charge Controller prepares to deliver power to the batteries. During this period, the Charge Controller is
calculating the pulse width modulation (PWM) duty cycles, turning on power supply voltages in the proper
sequences, and making internal calibrations. At wakeup, the Charge Controller closes its relays and then
starts tracking the input voltage (the “initial” tracking) towards the battery voltage. At dawn and dusk this
may happen many times until there is (or is not) enough power from the PV array to keep going. Wakeup is
also a time when the Charge Controller acquires a new VOC.
Zzzzz... At night (after 3 hours of continuous Sleeping) the Charge Controller will display Zzzzz... until
the next wakeup. At the next wakeup, (usually the next morning), the daily statistics of a single Charge
Controller, (AmpHours, KWh, etc.), will accumulate into the total statistics and then the displayed daily
statistics and End of Day summary will clear. A Bulk charge will automatically initiate at the next Wakeup. A
Charge Controller combined with a HUB and a MATE will log at midnight.
65
23. MATE-Displayed Charge Controller Screens
Status Mode Screens
The Charge Controller STATUS MODE Screens displayed on the optional OutBack MATE (Rev 4.0.4 or
greater) include MODE, METER, and SET (SETPOINT). In STATUS Mode, these functions can be viewed
by the MATE, but not changed. Please see the MATE Installation and User Manual for more information.
MAIN------------------------------ STATUS--------------------------- STATUS/CC/PAGE 1-----------

12:00:30P choose product:
SUM STATUS SETUP ADV FX CC DC MAIN MODE METER SETP PG2
STATUS/CC/MODE---------P02 STATUS/CC/MODE---------P02 STATUS/CC/MODE--------P02

charger mode: Absorb aux relay mode: aux relay state: ON
Night Light
DOWN STATUS PORT DOWN UP TOP PORT DOWN UP TOP PORT
STATUS/CC/MODE-------------- STATUS/CC/MODE---------P02 Press the <STATUS> soft key

end of mode menu charger mode: Silent
to return to the STATUS menu.
UP TOP STATUS DOWN STATUS PORT
Then press <METER> to view
the CC METER screens.
Charge Controller MODE Screens

• charger mode: displays one of five charging stages (Bulk, Absorption, Float, Silent, or Equalization)
• aux relay mode: displays one of nine Charge Controller AUX modes (Vent Fan, PV Trigger, ERROR OUT-
PUT, Night Light, FLoat, Diversion: Relay, Diversion: Solid St, Low Batt(ery) Disconnect, Remote)
• aux relay state: indicates if the AUX is ON or OFF
66
MATE-Displayed Charge Controller Status Meter Screens
mode: Silent P02 STATUS/CC/METER--------P02 STATUS/CC/METER-----P02

in 10.2 vdc 0 adc charger 0w charger 0.0 kwh
out: 13.4 vdc 0 adc watts kwhrs
DOWN STATUS PORT DOWN UP TOP PORT DOWN UP TOP PORT
STATUS/CC/METER-------P02 STATUS/CC/METER---------P02 STATUS/CC/METER--------P02

charger +000 adc battery 13.5 vdc panel 10.2 vdc
amps dc voltage voltage
DOWN UP TOP PORT DOWN UP TOP PORT DOWN UP TOP PORT
STATUS/CC/METER---------P02 STATUS/CC/METER----- STATUS/CC/PAGE 1-------------

CC firmware revision end of meter menu
001.008.009
DOWN UP TOP PORT UP TOP STATUS MODE METER SETP PG2
Press <SETP> to view the

SETPOINT screens
FLEXmax METER Screens

• mode/pv/in/bat/out: displays the charger mode, the PV array voltage, the incoming PV amps, the
battery voltage, and the outgoing amps to the battery
• charger watts: charger output measured in watts
• charger kwhrs: kilowatt hours produced today by the Charge Controller
• charger amps dc: the amount of amperage the Charge Controller is sending to the battery
• battery voltage: current battery voltage
• panel voltage: current voltage from the PV array
67
MATE-Displayed Charge Controller STATUS SETPT (SET POINT) Screen
STATUS/CC/SETPT---------P00 STATUS/CC/SETPT---------P00
Absorb 28.8 VDC Float 27.2 VDC
DOWN STATUS PORT DOWN UP TOP PORT
STATUS/CC/METER------
end of setpoint
Press the first two soft keys simultaneously
menu to return to the MAIN Menu.
UP TOP STATUS
CC SETP(OINT) Screens
• Absorb: displays the voltage that initiates and maintains the Absorb cycle
• Float: displays the voltage that begins the Float cycle and is maintained during this cycle
MATE-Displayed Charge Controller Advanced Screens

The Charge Controller Advanced Screens displayed on the optional OutBack MATE include CHGR
(CHARGER), CCADV (ADVANCED), EQ, AND AUX. The Advanced screens allow the user to change various
values and set points.
MAIN------------------------------ ADV/SETTINGS/WARNING ADV/PASSWORD-------------

enter the password
12:00:30P changes made could adversely 132
SUM STATUS SETUP ADV effect system performance ENTER INC DEC EXIT
ADV/PASSWORD------------- ADV------------------------------ ADV/CC/PAGE 1 ----------------

enter the password
141 choose device: choose category:
ENTER INC DEC EXIT FX CC DC MATE ADV CHGR CCADV PG2
ADV/CC/CHGR--------------P01 ADV/CC/CHGR--------------P01 ADV/CC/CHGR--------------P01

output current 80.0A
limit absorb voltage 14.4V float voltage 13.6V
DOWN INC DEC PORT DOWN INC DEC PORT DOWN INC DEC PORT
ADV/CC/CHGR------------------ ADV------------------------------
end of charger menu choose device:
TOP ADV MAIN FX CC DC MATE
68
24. Charge Controller Advanced Menu
ADV/CC/ADVANCED--------P01 ADV/CC/ADVANCED--------P01 ADV/CC/ADVANCED--------P01

snooze now wakeup mode wakeup mode
< 0.6 amp VOC change 1.5 V time 5 minutes
ADV/CC/ADVANCED--------P01 ADV/CC/ADVANCED--------P01 ADV/CC/ADVANCED--------P01

MPPT mode grid tie mode park MPP 77.0
auto track non GT
ADV/CC/ADVANCED------P01 ADV/CC/ADVANCED------P01 ADV/CC/ADVANCED------P01

Mpp range limit %VOC Mpp range limit %VOC absorb time
minimum 1/2 maximum 90% 1.0 hours

absorb end amps rebulk voltage vbatt calibration
0A 12.4 vdc 13.3 vdc 0.0 V

RTS compensation RTS comp limit RTS comp limit
wide upper limit 14.1 vdc lower limit 13.2 vdc

auto restart AUX output polarity
mode 2 active high reset CC to factory defaults
DOWN INC DEC PORT DOWN INC DEC PORT DOWN NO YES PORT
ADV/CC/ADVANCED--------- ADV------------------------------ ADV/CC/PAGE 1 ----------------

end CC advanced menu choose device: choose category:
TOP ADV MAIN FX CC DC MATE ADV CHGR CCADV PG2
ADV/CC/PAGE2----------------
choose category:
PG1 EQ AUX MAIN
69
Charge Controller EQ Screens
ADV/CC/EQ-----------------P01 ADV/CC/EQ-----------------P01 ADV/CC/EQ-----------------P01
auto eq interval
eq voltage 14.4 vdc eq time 1 hrs 0 days
ADV/CC/EQ----------------------
end of CC eq menu
TOP ADV MAIN
Charge Controller AUX Screens

ADV/CC/AUX/MODE--------P01 ADV/CC/AUX/--------------P01 ADV/CC/AUX/-----------------
Night Light aux output OFF
control end of menu
DOWN INC SET PORT DOWN ON OFF PORT TOP ADV MAIN
Charge Controller Displayed Screens
Charge Controller LOGGING Screens

011Vp 00.0Ap 0.00kWp CLEAR LOG Are you sure?
MAX 14.7V ABS 01:00
MIN 14.6V FLT 00:00 BACK TOTL DAILY NO YES

011Vp 00.0Ap 0.00kWp
MAX 14.7V ABS 01:00
MIN 14.6V FLT 00:00
Charge Controller STATS Screens

Max Bat Voc MaxVoc Total 0000 kWH Total 0000 kWHAC
14.9 036.6 133.0
MaxWatt 0000 Sunrise Total 000.0 kAH Total 000.0 kAH
EXIT NEXT 01:30:33 BACK DCkWH BACK ACkWH
70
25. ABBREVIATED CHARGER SET-UP
OutBack 12V Current Limit 80.0 A AUX MODE COUNT EQ INTERVAL

Power Absorbing 14.4 V Diversion: Solid St 000 000
Systems Float 13.8 V Output: Off Off
Charge Controller EXIT - + EXIT NEXT SET MODE EXIT -DAY +DAY
PUSH TWICE PRESS MODE KEY FOR PUSH THREE TIMES
OFF, ON,and AUTO
Select Version Charger Aux Light AUX MODE Charger Aux Light
EliJa la Version EQ Misc Advanced Low Bat Disconnect EQ Misc Advanced
USA Logging Stats Output: Off Off Logging Stats
NEXT ENTER ENTRA SEL EXIT GO EXIT NEXT SET MODE EXIT GO
PUSH THE ARROW KEY PRESS MODE KEY FOR PUSH THE ARROW KEY
AND THEN PUSH GO OFF, ON,and AUTO AND THEN PUSH GO
PASSWORD Charger Aux Light AUX MODE GT State PWM% ChgT

CONTRASENA EQ Misc Advanced Remote 255 00 98.0 0000
***150*** Logging Stats Output: Off Off
ENTRA - + ENTER EXIT GO EXIT NEXT SET MODE EXIT NEXT RETRY
AUX MODES PUSH TWICE PRESS MODE KEY FOR
OFF, ON,and AUTO
Select Version AUX MODE Charger Aux Light

EliJa la Version Vent Fan EQ Misc Advanced
English Output: Off Logging Stats FORCE
NEXT ENTER ENTRA SEL EXIT NEXT SET MODE EXIT GO EXIT NEXT FLOAT BULK
PRESS MODE KEY FOR PUSH THE ARROW KEY
OFF, ON,and AUTO AND THEN PUSH GO
ARE YOU SURE AUX MODE BACKLIGHT CONTROL PCB Target Btmp CFB
USA PV Trigger 514 14.4v 255 0000
Output: Off Off On
NO YES EXIT NEXT SET MODE EXIT MODE EXIT BACK
PRESS MODE KEY FOR PUSH TWICE PRESS MODE KEY FOR PUSH TWICE
OFF, ON,and AUTO OFF, ON,and AUTO
SYSTEM VOLTAGE AUX MODE Charger Aux Light Charger Aux Light
12 24 36 48 60 ERROR OUTPUT EQ Misc Advanced EQ Misc Advanced
Output: Off Off Logging Stats Logging Stats
ENTER EXIT NEXT SET MODE EXIT GO EXIT GO
PRESS MODE KEY FOR PUSH THE ARROW KEY PUSH THE ARROW KEY
OFF, ON,and AUTO AND THEN PUSH GO AND THEN PUSH GO
AUX MODE ADVANCED MENU

Are you sure? BATTERY EQUALIZE
12 24 36 48 60 Night Light Volts Snooze Mode
Output: Off Off 14.4 < .6 Amp
NO YES EXIT NEXT SET MODE EXIT NEXT -EQV +EQV EXIT NEXT +AMP
PRESS MODE KEY FOR
OFF, ON,and AUTO
In 11.6 V 0.0 A AUX MODE BATTERY EQUALIZE ADVANCED MENU

Out 14.1 V 0.0 A Float TIME Wakeup Mode
0.000kW 0.0 kWH Output: Off Off 1 Hours 1.5V 05m
Aux: OFF Zzzzz............. EXIT NEXT SET MODE BACK NEXT - HRS +HRS EXIT NEXT +VOC +Min
PRESS MODE KEY FOR
MAIN MENU OFF, ON,and AUTO
Charger Aux Light AUX MODE BATTERY EQUALIZE ADVANCED MENU

EQ Misc Advanced Diversion: Relay 1 Hours 14.4 Volts MPPT Mode
Logging Stats Output: Off Off Check water level Auto Track
EXIT GO EXIT NEXT SET MODE BACK AUTO START STOP EXIT NEXT nonGT MODE
PRESS MODE KEY FOR
OFF, ON,and AUTO
71
ADVANCED MENU ADVANCED MENU
REVISION
Park Mpp Reset to Defaults?
77% VOC 001.008.009
EXIT NEXT +VOC +Min EXIT NEXT RESET
PUSH TWICE
ADVANCED MENU Charger Aux Light EXTENDED PLAYMODE

Mpp Range Limit %Voc EQ Misc Advanced
Min Max Logging Stats Charger Aux Light
EXIT NEXT 1/2 90% EXIT GO EQ Misc Advanced
PUSH THE ARROW KEY
AND THEN PUSH GO
Logging Stats
EXIT GO
ADVANCED MENU Today 0000AH 00.0kWH
PRESS AND HOLD THE FIRST KEY AND THEN PRESS AND HOLD
Absorb Time 012Vp 00.0Ap 0.00KWp THE THIRD KEY. RELEASE THE THIRD KEY AND PRESS AGAIN TO
TOGGLE THE EXTENDED PLAYMODE ON AND OFF.
01.0 hours MAX 14.9V ABS 00:00
EXIT NEXT - + MIN 14.8V FLT 00:00 X on
PUSH ONCE
ADVANCED MENU In 11.6 V 0.0 A

Absorb End Amps Out 14.1 V 0.0 A
00 A 0.000kW 0.0 kWH
EXIT NEXT - + Aux: OFF Zzzzz............. X off
ADVANCED MENU Charger Aux Light

Rebulk Voltage EQ Misc Advanced
12.4V Logging Stats
EXIT NEXT - + EXIT GO
PUSH THE ARROW KEY
AND THEN PUSH GO
ADVANCED MENU Max Bat Voc MaxVoc

Vbatt Calibration 15.0 000.0 030.4
14.9V 0.0V MaxWatt 0000 Sunrise
EXIT NEXT -V +V EXIT NEXT 00:31:50
ADVANCED MENU Total 0307 kWH

RTS Compensation Total 000.0 kAH
A 14.4V F 13.6V
EXIT NEXT WIDE BACK DCkWH
TO VIEW SOFTWARE
ADVANCED MENU
REVISION
Auto Restart
MODE 2
Charger Aux Light
EQ Misc Advanced
EXIT NEXT MODE
Logging Stats
EXIT GO
ADVANCED MENU PUSH AND HOLD THE
FIRST SOFT KEY
Aux Polarity
Active High
EXIT NEXT MODE
72
26. Troubleshooting Guide
Be sure to check out the OutBack customer
and user forum at www.outbackpower.
Charge Controller does not boot/power-up (blank LCD) com/forum/ for more Charge Controller
information.
• Check the battery connection and polarity.

- Reverse polarity or an improper connection will cause power-up issues.
• Check the battery breaker.
- Ensure that the battery breaker is sized appropriately.
• A battery voltage below 10.5VDC may not power up the Charge Controller (measure the battery-
side of wire lugs).
• If the Charge Controller still does not power up, call the factory for additional support.
Charge Controller is always SLEEPING
• If the battery voltage is at or above the ABSORB voltage set point (compensated ABSORB
voltage), the Charge Controller will not wake up.
• The PV voltage has to be at least two volts greater than the battery voltage for the initial wakeup.
• Check the PV array breaker (or fuse).
• Confirm the PV array breaker (or fuse) is sized appropriately.
• Which State (in MISC Menu) is it at? Is it transitioning between 00 and 01? Is it in GT mode and
connected to a MATE?
- GT mode is only applicable with a HUB 4 or HUB 10 installations with a grid-tie compatible
MATE.
• Does the PV array voltage on the display rise with the PV breaker OFF, but reads 000 with the PV
breaker on?
- If so, the PV array polarity connection on the Charge Controller maybe reversed or the PV
lines could be shorted.
• Does the PV voltage still read 000 with the PV breaker off after a minute?
- Call the factory for support.
• Have you checked the short circuit current of the PV array?
- Use a multi-meter to determine if a short circuit current is detected. The short circuit
current test will not harm the array.
Charge Controller not producing expected power
• Clouds, partial shading, or dirty panels can cause poor performance.

• The lower current limit set point in the Charger menu will yield a loss of power or poor
performance symptoms.
73
• Are the batteries charged? Is the Charge Controller in the Absorbing or Float stage? If either case
is true, the Charge Controller will produce enough power to regulate the voltage at the ABSORB
or FLOAT set point voltage, therefore, requiring less power in these modes.
• What is the short circuit current of the PV array? Use a multi-meter to determine if a short circuit
current is as expected. There might be a loose PV array connection.
• If the PV array voltage is close to the battery voltage, the panels could be warm/hot causing the
Maximum Power Point to be at or lower than the battery voltage.
• Is it in U-Pick mode?
Charge Controller is not equalizing
• Has the EQ cycle been initiated?

- In the EQ Menu, press START to begin process. When the EQ cycle has been initiated,
EQ-MPPT will be displayed.
• The EQ cycle has been initiated, but the battery is not equalizing.
- The EQ cycle will begin when the target EQ set point voltage has been reached. A small
array or cloudy weather will delay the EQ cycle. Accordingly, running too many AC and/or
DC loads will delay the EQ cycle, too.
• An EQ set point that is too high relative to the battery voltage will delay the EQ cycle.
• If the PV array voltage is close to the battery voltage, the panels could be warm/hot causing the
Maximum Power Point to be at or lower than the battery voltage which can delay the EQ cycle.
Charge Controller Battery Temperature Compensated Voltage
• Only the OutBack RTS (remote temperature sensor) can be used with the Charge Controller.
• The battery voltage can rise above the ABSORBING and FLOAT voltage set points if the battery
temperature is < 77°F or fall below the ABSORBING and FLOAT voltage if the battery temperature
is > 77°F.
• Why does the Charge Controller show BatTmpErr on the STATUS screen?
- The RTS is faulty or damaged. Disconnect the RTS from the RTS jack to resume
normal operation.
74
Charge Controller Internal Fan
• 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.
Charge Controller is beeping
• When the Charge Controller is in Extended Play mode, the array is very hot, and the MPP is close to
the battery voltage, or the nominal PV voltage is higher than the nominal battery voltage, beeping
can occur. To disable the Extended Play feature, go to the MAIN Menu and press and hold the #1 soft
key until the Charge Controller’s software version appears on the screen. Continue pressing the #1
soft key and press the #3 soft key at the same time until X Off displays on the screen. To reactivate
Extended Play, repeat these steps and hold the #3 soft key until X On displays. Extended Play is meant
to optimize the performance of a hot array, but isn’t critical to efficient Charge Controller operations.
To enable/open the FLEXmax SELECT VERSION screens:
• Turn off the DC and array breakers

• Press and hold the first and third soft keys
• Turn on the battery breaker
• Follow the SELECT VERSION screen instructions from the beginning of the manual
• Rebooting the Charge Controller like this will return all the values and set points to the factory
defaults.
DC Breakers /
Battery Breaker
Press and hold the first

and third soft keys
Figure 9
75
27. Typical Array Sizing Guide
Below is a list of recommended array sizing for the Charge Controller for various nominal voltage
batteries:
Nominal Battery Voltage Recommended Array Size

(in watts, Standard Test Conditions)
FLEXmax 80 FLEXmax 60
12V 1250W 800W
24V 2500W 1600W
36V 3750W 2400W
48V 5000W 3200W
60V 6250W 4000W
The Charge Controller PV MPPT Charge Controller is capable of an input open circuit voltage (VOC) of
up to 150 VDC. Cooler climates can cause the VOC to rise above the panel VOC rating. In climates that
observe temperatures less than approximately 5° F, a VOC greater than 125 VDC is not recommended.
When sizing an array, it is recommended that the nominal array voltage be higher than the nominal
battery voltage. Below is a list of recommended nominal array sizing:
Nominal Battery Voltage Nominal Array Voltage (recommended)

12V 24V (or higher)*
48V 60 V (or higher)*
60V 60V (low temp is less than 5°F) or
72V (low temp is greater than 5°F)
* When sizing an array to charge controller with a distance of 70 feet or greater, OutBack recommends
the nominal array voltage be slightly higher than the recommended nominal array voltage. Example:
A 36VDC nominal array recharging a 12V nominal battery with an array to charge controller distance
of about 70 feet or greater. Sizing the nominal array voltage higher than the nominal battery voltage
ensures that the Maximum Power Point is always above the battery voltage. The Maximum Power
Point will decrease as the panels warm up, thus lowering the output of the array. The Charge Controller
Charge Controller will not be able to boost the output if the Maximum Power Point of the array is at or
lower than the battery voltage.
76
28. STANDARD vs. AUSTRALIAN DEFAULT SETTINGS
The Australian version Charge Controller has a few default settings that differ from the Standard ver-
sion default settings. However, there are no differences in performance and efficiency between the
two versions. The Standard and Australian version can be identified as follows:
OutBack 12V OutBack 12V

Power Power
Systems Systems
Charge Controller Charge Controller-AU
Standard Version Australian Version
Below are a few default setting differences between the Standard and Australian version.
Settings Standard Australian

Charger Absorb Float Absorb Float
12V 4.4V 13.6V 14.4V 13.8V
24V 28.8V 27.2V 28.8V 27.6V
36V 43.2V 40.8V 43.2V 41.4V
48V 57.6V 54.4V 57.6V 55.2V
60V 72.0V 68.0V 72.0V 69.0V
Equalize Equalize Volts Equalize Volts

12V 14.4 14.7
24V 28.8 29.4
36V 43.2 44.1
48V 57.6 58.8
60V 72.0 73.5
Equalize Time 01 Hours 03 Hours
77
29. Wire Distance Chart
To meet NEC compliance (North America), the largest PV array that can be connected to a FLEXmax 80
must have a rated short-circuit current of 64 amps or less and 48 amps or less for a FLEXmax 60. The
following charts show the maximum distance of various gauge two-conductor copper wire from the
PV array to the Charge Controller with a 1.5% maximum voltage drop. Temperature and conduit fill cor-
rections may be required. Using a higher voltage PV array with a low voltage battery system allows you
to use a much smaller wire size or go up to 5 times as far with the same gauge wire.
FLEXmax 60 and FLEXmax 80 (The figures below assume THWN 750 C two-conductor copper wire
and allow for a 1.5% voltage drop)
12V PV ARRAY (16v Vmp)
WIRE GAUGE #8 #6 #4 #3 #2 #1 #1/0 #2/0 #3/0 #4/0
10 15 24 39 49 62 78 98 124 157 197

20 8 12 19 24 31 39 49 62 78 99
30 5 8 13 16 21 26 33 41 52 66
40 4 6 10 12 15 19 25 31 39 49
AMPS
50 3 5 8 10 12 16 20 25 31 39 METRIC
60 3 4 6 8 10 13 16 21 26 33
#8…8.37mm2
70 2 3 6 7 9 11 14 18 22 28
#6…13.30mm2
80 2 3 5 6 8 10 12 16 20 25
#4…21.15mm2
24V PV ARRAY (32v Vmp) #3…26.7mm2
#2…33.6mm2
WIRE GAUGE #8 #6 #4 #3 #2 #1 #1/0 #2/0 #3/0 #4/0
#1/0…53.5mm2
10 31 49 78 98 124 156 197 248 313 395 #2/0…67.4mm2
20 15 24 39 49 62 78 98 124 157 197 #4/0…107mm2
30 10 16 26 33 41 52 66 83 104 132
40 8 12 19 24 31 39 49 62 78 99
AMPS
50 6 10 16 20 25 31 39 50 63 79
60 5 8 13 16 21 26 33 41 52 66
70 4 7 11 14 18 22 28 35 45 56
80 4 6 10 12 15 19 25 31 39 49

WIRE GAUGE #8 #6 #4 #3 #2 #1 #1/0 #2/0 #3/0 #4/0
10 46 73 117 147 186 234 295 372 470 592

20 23 37 58 73 93 117 148 186 235 296
30 15 24 39 49 62 78 98 124 157 197
40 12 18 29 37 46 58 74 93 117 148
AMPS
50 9 15 23 29 37 47 59 74 94 118
60 8 12 19 24 31 39 49 62 78 99
70 7 10 17 21 27 33 42 53 67 85
80 6 9 15 18 23 29 37 47 59 74
NOTE: Numbers in bold might not meet NEC requirements
78
WIRE GAUGE #8 #6 #4 #3 #2 #1 #1/0 #2/0 #3/0 #4/0
10 62 98 156 196 247 312 393 496 627 789
20 31 49 78 98 124 156 197 248 313 395
30 21 33 52 65 82 104 131 165 209 263
40 15 24 39 49 62 78 98 124 157 197
50 12 20 31 39 49 62 79 99 125 158
AMPS
60 10 16 26 33 41 52 66 83 104 132
70 9 14 22 28 35 45 56 71 90 113
80 8 12 19 24 31 39 49 62 78 99

WIRE GAUGE #8 #6 #4 #3 #2 #1 #1/0 #2/0 #3/0 #4/0
10 77 122 195 245 309 390 492 620 783 987
20 39 61 97 122 155 195 246 310 392 493
30 26 41 65 82 103 130 164 207 261 329
40 19 31 49 61 77 97 123 155 196 247
AMPS
50 15 24 39 49 62 78 98 124 157 197

60 13 20 32 41 52 65 82 103 131 164
70 11 17 28 35 44 56 70 89 112 141
80 10 15 24 31 39 49 61 78 98 123

WIRE GAUGE #8 #6 #4 #3 #2 #1 #1/0 #2/0 #3/0 #4/0
10 93 147 234 294 371 468 590 745 940 1184
20 46 73 117 147 186 234 295 372 470 592
30 31 49 78 98 124 156 197 248 313 395
40 23 37 58 73 93 117 148 186 235 296
AMPS
50 19 29 47 59 74 94 118 149 188 237

60 15 24 39 49 62 78 98 124 157 197
70 13 21 33 42 53 67 84 106 134 169
80 12 18 29 37 46 58 74 93 117 148
METRIC
NOTE: Numbers in bold might not meet NEC requirements #8…8.37mm2
#6…13.30mm2
#4…21.15mm2
#3…26.7mm2
#2…33.6mm2
#1/0…53.5mm2
#2/0…67.4mm2
#4/0…107mm2
79
30. WIRE AND DISCONNECT SIZING
FLEXmax 80
The Charge Controller is a buck type converter with the following properties:
• 80 amp DC output current limit (default setting)
• Listed to operate continuously at 80 amps (40°C/104° F)
With an 80 amp Charge Controller output current limit and PV array output higher than 80 amps offers
little, if any, current boosting or Maximum Power Point Tracking advantage; in effect, any excess power
beyond 80 amps is lost.
For NEC* compliance and the Charge Controller’s 80 amp output rating / MPPT capabilities, the largest
PV array input must not exceed a rated short-circuit current of 64 amps.
Battery Side of the Controller
• All OutBack Power circuit breakers (OBB-XX) are 100% continuous-rated type breakers
• The conductors connected to the breakers must have a 125% safety factor applied (i.e., an 80 amp
breaker must have a 100-amp conductor connected when used at its full 80-amp rating)
PV Side of the Controller
• UL* requires a 125% safety multiplier (before NEC calculations)

• NEC* requires a 125% safety multiplier (after UL calculations).
• The 156% safety multiplier is specific in the NEC* to PV applications only – this “dual” 125% multiplier
is used because a PV array can produce above its rated output in some conditions.
NEC Compliance
• When the 156% safety multiplier is applied, the resulting conductor amperage required is still 100-
amps (1.56 X 64A) and an 80 amp breaker may be used (100% continuous duty rated breaker).
• When a PV array is configured for a higher nominal input voltage (such as 72V PV array), the PV input
conductor can be sized smaller depending on the step-down ratio and the maximum short circuit
current available.
NOTE: The input breaker must also be sized smaller; it cannot be the normal 80 amp with conductor
smaller than #4 AWG. (21.1mm2)
* North America
80
WIRE AND DISCONNECT SIZING
FLEXmax60
The MX60 has a 60 amp current output limit (default) and is listed to operate continuously at 60 amps
depending on the nominal PV array voltage and the nominal battery voltage. There is no 80%
de-rating as required by the NEC* for fuses, conductors, and most circuit breakers.
The MX60 is a buck type converter and cannot boost the output current when the PV array peak
power point voltage is at or below the battery voltage as may happen on hot days in 24 VDC PV and
a 24 VDC battery system or a 48 VDC PV and a 48 VDC battery system.
To meet minimum NEC requirements (NEC 310.15, 690.8, 9), the output conductor should have an
ampacity of 75 amps after any temperature and conduit fill corrections. This would normally indicate
that the output conductors be 6 AWG (5.83 mm), but a larger size may be required if there are temper-
ature and/or conduit fill corrections required. With an output conductor rated at 75 amps (1.25 X the
continuous output current), the OutBack OBB-60 breaker—rated for continuous 100% duty at 60 amps
—can be used to provide the code-required disconnect and output circuit over current protection.
The PV array output connected to the MX60 input may be as high 60 amps, but at this current level,
there is very little (if any) current boosting or maximum power-point tracking due to the 60-amp
output current limit. Additionally, the input current may exceed 60 amps on bright sunny days and
any excess power would be lost. The size and ampacity of the input conductors must be selected to
handle 1.56 times the short-circuit current of the PV array. Any disconnect or circuit breaker connected
to the input conductors must also be rated at 1.56** times the short-circuit current for the PV array
unless the breaker is rated for 100% duty in its enclosure. If that is the case, the circuit breaker may be
rated at 1.25 times the PV array short-circuit current. OutBack OBB-XX breakers are 100% duty rated
breakers.
In terms of NEC compliance and the MX60’s 60-amp output rating, the largest PV array it can connect
to should have a rated short-circuit current of 48 amps. This meets NEC requirements and allows the
MX60 to perform maximum power-point tracking functions. The following charts show maximum dis-
tance in feet of various gauge two-conductor copper wire from the PV array to the MX60 with a 1.5%
maximum voltage drop. Temperature and conduit fill corrections may be required.
*When NEC does not apply, see local code requirements.
81
31. WIRING COMPARTMENT
The wiring terminals and compartment of the Charge Controller Charge Controller are fully compli-
ant with all NEC and UL requirements. The following summary is specific for North American applications
where NEC and UL standards govern installations.
Recommended Conductor and Breaker Sizes for the Charge Controller
Output Rating at 80 amps
If the output current of the Charge Controller is expected to reach the maximum output level of 80
amps:
• #3 or #2 AWG conductor must be used with an 80 amp breaker (100% continuous duty rated breaker)
• The minimum recommended battery conductor is #3* AWG
METRIC
• The maximum recommended battery conductor is #2** AWG
#4…21.15mm
2
#3…26.7mm2
#2…33.6mm2
* #3 AWG conductor can be installed through the side, back or bottom knockouts
** #2 AWG conductor must be installed on the side or back knockout to meet the specific UL
requirements for wire bending room standards
- 1” conduit knockout is approved for up to three #2 AWG conductors
- For short conduit runs (less than 24”), a higher conduit fill is acceptable* —three #2 AWG wires
Please reference the NEC Appendix “C” in the back of the book. You must refer to the table representing
the type of conduit you will be using to find the maximum number of conductors allowed within the
conduit you will be using.
Output Rating less than 64 amps
If the output current of the Charge Controller is expected to be less than 64 amps:
• An 80 amp breaker and #4 AWG conductors can be used on the battery side.
• The PV array short circuit current must be less than 48 amps and the #4 conductor will be acceptable
with an 80 amp breaker.
82
32. Charge Controller MULTI-STAGE BATTERY CHARGING
The Charge Controller 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 Charge Controller has a preset
recharging voltage set points (Absorb & Float) for the selected nominal battery voltage, however,
always follow the battery manufacturer’s recommended charging regulation voltages. The Charge
Controller charging regulation stages correspond to the chart in Figure 10.
Charge Controller Multi-Stage Battery Charging
Figure 10
NOTE: In BULK, the Charge Controller will charge as long as necessary to complete the cycle,
regardless of the timer’s set points.
83
BULK cycle provides the maximum power to the battery –the voltage increases while recharging.
A Bulk cycle is automatically initiated when the battery voltage is below the Absorb and Float* recharge
voltage set points. The Bulk cycle will continue until the Absorb voltage set point is achieved. MPPT Bulk
is displayed on the screen.
ABSORBING cycle limits the amount of power going to the battery—the voltage is held constant.
The Absorb cycle will continue for the duration of the Bulk cycle or until the 2 hour (default) Absorb
time limit is reached. For example, if a Bulk cycle takes 1 hour to reach the Absorb voltage set point,
then the Absorb cycle will continue for 1 hour as well. However, if a Bulk cycle takes 3 hours to reach
the Absorb voltage set point, then the Absorb cycle will continue for 2 hours only. A Bulk cycle will be
re-initiated if the battery voltage is not sustained at the Absorb voltage set point. Absorbing is displayed
on the screen at this time.
FLOAT cycle reduces the recharging voltage to prevent overcharging of the batteries.
A Float cycle follows after the Absorb cycle is completed; Float is displayed on the screen. The
Charge Controller will not re-initiate another Bulk cycle if the Float voltage set point is not sustained*.
FMPPT is displayed. However, it will continue to recharge the battery until the Float voltage set point is
reached.
* A Bulk cycle can be auto-initiated if the battery voltage falls below the Float voltage set point and the
Re-Bulk voltage option is set.
84
33. BATTERY TEMPERATURE COMPENSATED VOLTAGE SET POINT
The temperature of a battery has an impact on the recharging process—in higher ambient
temperatures, the regulation set points (Absorb and Float) need to be reduced to prevent overcharging
of the batteries. In lower ambient temperature conditions, the voltage regulation set points need to be
increased to ensure complete recharging of the batteries.
The default charger settings of the Charge Controller are based on typical lead acid battery systems.
Always ensure the Absorb and Float voltage regulation set points are set to the recommended battery
manufacturer’s recharging regulation voltages.
Non-Battery Temperature Compensated System

If a battery remote temperature sensor is not available the Absorb and Float voltage regulation
set points can be adjusted for the expected weather conditions. The following table shows the
appropriate adjustments for both Absorb and Float voltage regulation set points for weather conditions
above or below 77˚F / 25 C
EXPECTED TEMPERATURE ADJUST SET POINT 12V 24V 48V

Average = 95˚F / 35˚C Subtract 0.30V 0.60V 1.20V
Average = 86˚F / 30˚C Subtract 0.15V 0.30V 0.60V
--------------------------------------------------------------------------------------------------------------------------------
Average = 68 F / 20˚C Add 0.15V 0.3 V 0.60V
Average = 59˚F / 15˚C Add 0.30V 0.60V 1.20V
Battery Temperature Compensated System

A battery remote temperature sensor (RTS) will automatically compensate the Absorb and Float
voltage relative to the Absorb and Float set points in the Charger menu. Please reference page 49 of
this manual for adjusting the upper and lower battery compensated limits.
Battery temperature compensation with other slopes

The Charge Controller uses a 5mV per degree C per cell (2V) compensation slope required by UL. For
other slopes, you may be able to pick a different battery voltage and change the charger Absorb and
Float voltage settings to achieve a more or less aggressive slope. If going lower in voltage, reduce
the Float voltage first, since the Absorb voltage will not be adjustable below the Float voltage setting.
If going higher in voltage, increase the Absorb setting first before raising the Float voltage above
the present setting. Here is a table of Charge Controller compensation based on system voltage for
reference:
12V system -30mV/degree C

85
34. SUGGESTED BATTERY CHARGER SET POINTS
The battery manufacturer should provide you with specific instructions on the following maintenance
and voltage set point limits for the specific batteries. The following information can be used when the
manufacturer’s information is not available.
SEALED LEAD ACID – AGM / GEL 12V 24V 48V

ABSORB voltage set point 14.4V 28.8V 57.6V
FLOAT voltage set point 13.4V 26.8V 53.6V
NON-SEALED LEAD ACID 12V 24V 48V

ABSORB voltage set point 14.8V 29.6V 59.2V
FLOAT voltage set point 13.8V 27.6V 55.2V
NOTE: Higher settings can be used with non-sealed batteries, but water consumption will be greater
and excessive temperatures when recharging may occur.
Battery Voltage and State of Charge

A battery’s voltage can be used as a guideline to estimate the amount of power stored in the battery
that is available for use. When referencing the battery voltage on the display, be sure the battery is not
under significant recharging or heavy loads. Otherwise, the DC voltage is not reflective of the battery
state of cycle. Often the best time to check the battery voltage is in the morning (pre-charging) or at
night (post-charging), with the battery disconnected from charging sources and loads and a rest for at
least three hours.
Operation of a battery below 50% state of cycle will adversely affect the long term health of the
battery system and will result in premature failure. Keeping the battery above the 50% level and
recharging it completely once a month will ensure proper operation and good performance.
STATE OF CHARGE
Nominal Battery Charged Good (~75%) Average (~50%) Low (~25%) Discharged
Voltage
12V over 12.6V 12.3V 12.0V 11.7V under 11.4V
86
35. CALLING THE FACTORY FOR ASSISTANCE
When calling OutBack Power for product assistance, please have the following information ready:
• Charge Controller Serial number and software version (the software version can be viewed by press-
ing the #1 soft key on the STATUS screen and then pressing a second time and holding the soft key
down).
• The nominal PV array and battery voltage.
• The PV array operating voltage and battery current and any Status screen operational mode displays,
such as MPPT BULK, MPPT FLOAT, Absorbing, or Floating.
36. SPECIFICATIONS
Output Current Rating, FLEXmax 80 80 amps continuous @ 40°C ambient
Output Current Rating, FLEXmax 60 60 amps continuous @ 40°C ambient
Default Battery System Voltage 12, 24, 36, 48 or 60VDC (adjustable)
PV open circuit voltage 150VDC Maximum (ETL Rating for UL1741
Standard); operational max = 145VDC
temperature corrected VOC
Standby power consumption Less than 1 watt typical
Recharging regulation methods Five stage—Bulk, Absorption, Battery Full, Float,
and Equalization
Voltage regulation set points 13-80VDC
Temperature compensation With optional RTS sensor 5 millivolts °C per 2V cell
Voltage step down capability Down convert from any PV array voltage within
PV VOC limits of 145VDC to any battery system
voltage. Examples: 72V array to 24V; 60V array to 48V
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 de-rated above 40°C
Environmental Rating Indoor type 1
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 FLEXmax 80–16.25”H x 5.75”W x 4”D
Boxed–21”H x 10.5”W x 9.75”D
FLEXmax 60–13.5”H x 5.75” W x 4” D
Boxed–18” H x 11” W x 8” D
Weight FLEXmax 80–12.20 lbs; Boxed–15.75 lbs
FLEXmax 60–11.6 lbs; Boxes–14 lbs
Options Remote Temperature Sensor (RTS), HUB 4,
HUB 10, MATE, MATE2
Menu Languages English and Spanish
*The Charge Controller automatically limits the current if the temperature rises above the allowable limit.
87
FIVE YEAR LIMITED WARRANTY INFORMATION
FLEXmax Products
OutBack Power Systems, Inc. (“OutBack”) provides a five year (5) limited warranty (“Warranty”) against
defects in materials and workmanship for its FLEXmax products (“Products”) if installed in fixed location
applications.
For this Warranty to be valid, the Product purchaser must complete and submit the applicable Product
registration card within ninety (90) days of the eligible Product’s first retail sale. 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 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; or
• 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.
Revision.2007-10-02
88
To request warranty service, you must contact OutBack Technical Services at (360) 435-6030 or
support@outbackpower.com within the effective warranty period. If warranty service is required,
OutBack will issue a Return Material Authorization (RMA) number. A request for an RMA number
requires all of the following information:
1. 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;
2. Description of the problem; and
3. Shipping address for the repaired or replacement equipment.
After receiving the RMA number, pack the Product(s) authorized for return, along with a copy of the
original purchase invoice and warranty certificate, in the original Product shipping container(s) or
packaging providing equivalent protection and mark the outside clearly with the RMA number. The
sender must prepay all shipping charges, and insure the shipment, or accept the risk of loss or damage
during shipment. 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 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 to the
purchaser freight prepaid, non-expedited, using a carrier of OutBack’s choice within the continental
United States, where applicable
Shipments to other locations will be made freight collect. The warranty period of any repaired or
replacement Product is twelve (12) months from the date of shipment from OutBack, or the remainder
of the initial warranty term, which ever is greater.
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. 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.
Revision.2007-10-02
89
max TM
60
max TM
80
Limited Warranty Registration
Complete this form to request a Limited
Warranty, and return it to:
Outback Power Systems Inc.
19009 62nd Ave. NE
Arlington, WA 98223
NOTE: A Limited Warranty Certificate will only be issued if this Registration Card is received by OutBack
within 90 days of the date of the first retail sale of the eligible Product. Please submit a copy (not the
original) of the Product purchase invoice, which confirms the date and location of purchase, the price
paid, and the Product Model and Serial Number.
Five Year Limited FLEXmax Warranty Registration

System Owner
Name: _______________________________ Country: ______________________________
Address: ______________________________ Telephone Number:______________________
City, State, Zip Code: ____________________ E-mail_________________________________
Product
Product Model Number: _________________ Sold by: _______________________________
Product Serial Number: __________________ Purchase Date: __________________________
Optional Extended Warranty* Coverage? (circle one): Yes No
Please circle the three most important factors affecting your purchase decision:
• Price • Product Reputation • Product Features
• Reputation of OutBack Power Systems • Value
System
System Install/Commission Date: ______________ Number of FLEXmax Products in System: __________
FLEXmax Charging Source(i.e. Solar): ____________ System Array Size: ___________________________
System Array Nominal Voltage: ________________ Type of PV Modules: __________________________
DC Input Wiring Size and Length: ______________ System Battery Bank Size (Amp Hours): ___________
Type of Batteries: ___________________________
Installer
Installer: ______________________________ Contractor Number: ______________________
Installer Address: _______________________ Installer City, State, Zip: ____________________
Installer E-mail: _________________________
*Extended Warranty
OutBack Power Systems offers an optional five(5) year extension to the standard five(5) year Limited Warranty in North
America for the Charge Controller product. To request a 5-year Limited Warranty extension for a total effective warranty
coverage period of ten(10) years; include a check or money order in the amount of $250USD payable to OutBack Power
Systems, Inc. along with your Warranty Registration.
Revision.2007-10-02
90
EU DECLARATION OF CONFORMITY
According to ISO / IEC Guide 22 and EN 45014
Product Type: Photovoltaic Charge Controller

Product Model Number: Charge Controller
This product complies with the following EU directives:

Electromagnetic Compatibility 89/336/EEC, “Council Directive of 3 May 1989
On the approximation of the laws of member States relating to Electromagnetic compatibility”
Low Voltage Directive 73/23/EEC, “Council Directive of 19 February 1973 on the harmonization of
the laws of Member States relating to electrical equipment for use within certain voltage limits”
The compliance of the above mentioned product with the directives and the following essential
requirements is hereby confirmed:
Emissions Immunity Safety
EN 61000-6-3 (2001) EN 61000-6-1 (2001) EN 60335-1 Battery Chargers
EN 60335-2-29Battery Chargers
All associated technical files are located in the Engineering Department at OutBack Power Systems Inc.,
Arlington, Washington, USA.
As the manufacturer, we declare under our sole responsibility that the above-mentioned product
complies with the above-named directives.
19009 62nd Ave. NE

Arlington, WA. 98223 USA
(360) 435-6030
91
OWNER’S SYSTEM INFORMATION
Date of Purchase: __________________________________________________________________
Vendor: __________________________________________________________________________
Date of Installation: _________________________________________________________________
Installer: _________________________________________________________________________
Installer Contact Information: _________________________________________________________
Charge Controller Serial Number: ______________________________________________________
Battery Voltage: ____________________________________________________________________
PV Voltage: _______________________________________________________________________
PV Module Type and Manufacturer: ____________________________________________________
Array Wattage: _____________________________________________________________________
NOTES: __________________________________________________________________________
_________________________________________________________________________________
92
Corporate Office European Sales Office
19009 62nd Avenue NE C/ Castelló, 17
Arlington, WA USA 08830 - Sant Boi de Llobregat
Phone: (+1) 360-435-6030 BARCELONA, España
Phone: +34.93.654.9568
www.outbackpower.com 900-0009-01-00 REV A
max
max
max 80
80
80 TM
TM
TM
FLEXmax 80
The FLEXmax 80 is the latest innovation in Maximum Power Point Tracking (MPPT) charge
controllers from OutBack Power Systems. The FLEXmax 80’s innovative MPPT algorithm is both
continuous and active, increasing your renewable energy yield up to 30%. Thanks to enhanced
cooling, the FLEXmax 80 can operate at its full 80 amp maximum current rating in ambient
temperatures as high as 104°F (40°C).
Included in the FLEXmax 80 are all of the features first developed by OutBack Power in the
revolutionary MX60, such as support for a wide range of nominal battery voltages and the ability
to step-down a high voltage solar array to recharge a low voltage battery. A built-in backlit display
shows status information at the touch of a button. Enhanced network communications allow the
FLEXmax 80 to be remotely programmed via the optional MATE system display and controller.
The new FLEXmax 80 is the only choice when you demand a high performance, efficient and
customizable charge controller for your advanced power system.
FLEXmax™ 80 Specifications
Nominal Battery Voltages 12, 24, 36, 48, or 60 VDC (Single model - selectable via field programming at start-up)
Maximum Output Current 80 amps @ 104º F (40ºC) with adjustable current limit
Maximum Solar Array STC Nameplate 12 VDC systems 1250 Watts / 24 VDC systems 2500 Watts / 48 VDC systems 5000 Watts / 60 VDC Systems 7500 Watts
NEC Recommended Solar Array STC Nameplate 12 VDC systems 1000 Watts / 24 VDC systems 2000 Watts / 48 VDC systems 4000 Watts / 60 VDC Systems 5000 Watts
PV Open Circuit Voltage (VOC) 150 VDC absolute maximum coldest conditions / 145 VDC start-up and operating maximum
Standby Power Consumption Less than 1 Watt typical
Power Conversion Efficiency 97.5% @ 80 Amps in a 48 VDC System - Typical
Charging Regulation Five Stages: Bulk, Absorption, Float, Silent and Equalization
Voltage Regulation Set points 10 to 80 VDC user adjustable with password protection
Equalization Charging Programmable Voltage Setpoint and Duration - Automatic Termination when completed
Battery Temperature Compensation Automatic with optional RTS installed / 5.0 mV per °C per 2V battery cell
Voltage Step-Down Capability Can charge a lower voltage battery from a higher voltage PV array - Max 150 VDC input
Programmable Auxilary Control Output 12 VDC output signal which can be programmed for different control applications (Maximum of 0.2 amps DC)
Status Display 3.1” (8 cm) backlit LCD screen - 4 lines with 80 alphanumeric characters total
Remote Display and Controller Optional Mate or Mate2 with RS232 Serial Communications Port
Network Cabeling Proprietary network system using RJ 45 Modular Connectors with CAT 5e Cable (8 wires)
Data Logging Last 128 days of Operation - Amp Hours, Watt Hours, Time in Float , Peak Watts, Amps, Solar Array Voltage,
Max Battery Voltage Min Battery Voltage and Absorb for each day along with total Accumulated Amp Hours,
and kW Hours of production
Hydro Turbine Applications Consult factory for approved Turbines
Positive Ground Applications Requires two Pole Breakers for switching both positive and Negative Conductors on both Solar Array
and Battery Connections (HUB-4 and HUB-10 can not be used for use in positive ground applications)
Operating Temperature Range Minimum -40° to maximum 60° C (Power capacity of the controller is automatically derated when operated above 40° C)
Environmental Rating Indoor Type 1
Conduit Knockouts One 1” (35mm)on the back; One1” (35mm) on the left side; Two 1” (35mm) on the bottom
Warranty Standard 5 year
Weight - Unit 12.20 lbs (5.56 kg)
- Shipping 15.75 lbs (7.10 kg)
Dimensions - Unit 16.25” x 5.75” x 4” (41.3 x 14 x 10 cm) - (H x W x D)
- Shipping 21” x 10.5” x 9.75” (53 x 27 x 25 cm)
Options Remote Temperature Sensor (RTS), HUB 4, HUB 10, MATE, MATE 2
Menu Languages English & Spanish
* Specifications subject to change without notice.

Use appropriate wire size in accordance with NEC.
7
Morningstar TS-60 - TriStar 60 Amp 12/24/48 Volt PWM Charge Controller http://www.ecodirect.com/Morningstar-TriStar-TS-60-60-Amp-12-24-48...
Contact Us | Bookmark Us | Send Feedback Toll Free:(888) 899-3509 Local: (760) 597-0498
Quote | Your Account | Help
0 ITEMS: $0.00
HOME CUSTOMER SERVICE QUOTE REQUEST KNOWLEDGE BASE INTERNATIONAL ORDERS MANUFACTURERS
Accessories Home > Charge Controllers > Morningstar Charge Controllers > Morningstar TriStar >
Morningstar TS-60 > TriStar 60 Amp 12/24/48 Volt PWM Charge Controller
Charge Controllers
Our Price: $186.95
Apollo Solar Charge Controllers
Blue Sky Charge Controllers Warranty: 5 Years
BZ Products Charge Controllers
Product Code: MORNINGSTAR-TRISTAR-TS-60
MidNite Solar
Morningstar Charge Controllers
OutBack Charge Controllers
Phocos Charge Controllers No Meter
PowerMax Charge Controllers Add Attached Meter [Add $80.95]
Specialty Concepts Controllers Add Remote Meter [Add $110.75]
Steca Charge Controllers
SunForce Charge Controllers
Qty:
Xantrex Charge Controllers
Electrical & Safety Supplies
LED Lights
Portable Solar Power
Power Inverters
SHURflo Pumps
Solar Attic Fans

Accessories for this product...
Solar Thermal Average Customer Review: Based on 5 reviews | Read Reviews |
Write a review. MorningStar Remote Temp
Solar Panels Sensor 33' > RTS
Description Data Sheet Our Price: $25.89
Solar Panel Mounts Add
Tankless Water Heaters MorningStar TriStar 60 Amp Volt 12/24/48 PWM Charge
Transfer Switches
Controller Morningstar Communications
Adapter > RSC-1
Manufacturer Part Number: TS-60 Our Price: $53.00
Tubular Skylights
Add
Wind Turbines Morningstar’s TriStar Controller is a three-function controller that provides
reliable solar battery charging, load control or diversion regulation. The controller
operates in one of these modes at a time and two or more controllers may be MorningStar Meter Hub >
used to provide multiple functions. HUB-1
Our Price: $88.00
The TriStar uses advanced technology and automated production to provide Add
exciting new features at a competitive cost. The optional TriStar meter is the
most sophisticated and informative controller meter on the market. The
controller is UL listed and is designed for both solar home systems and
Morningstar Relay Driver >
professional applications.
RD-1
Our Price: $120.79
Features Add
Highest Reliability
Large heat sink (1) and conservative design enables operating at full
ratings to 60°C. No need to de-rate.
Related Products...
More Power Morningstar TriStar Digital
Remote Meter > TS-RM 2
Ratings to 60A at 48VDC will handle solar arrays up to 4kW. Our Price: $110.75
Add
Communications Capability
RS-2312 (2) connects to a personal computer for custom settings, data

logging and remote monitoring and control. Morningstar TriStar MPPT 45,
45 Amp 12/24/28 Volt
Fully Adjustable Our Price: $399.95
Add
DIP switch (3) provides user with a choice of 7 different digital presets and
custom settings via RS-232.
1 of 9 6/27/2012 9:50 AM
Extensive Electronic Protections
Fully protected against reverse polarity, short circuit, overcurrent, high

temperature and overvoltage. Morningstar TriStar MPPT 60,
60 Amp 12/24/28 Volt
Our Price: $510.95
Add
Morningstar TriStar TS-45 ,

45 Amp 12/24/48 Volt
Our Price: $142.95
Add
Morningstar Relay Driver >

RD-1
Our Price: $120.79
Add
Simple Mechanical Interface
Larger power terminals (4) and conduit knockouts (5). Extra space for wire
turns. Fits on power panels.
Better Battery Charging
Connecting battery sensor wires (6) and optional remote temperature sensor
(7) will improve control accuracy. Constant voltage series PWM algorithm
increases battery capacity and life.
More Information
3 LED’s (8) to indicate status, faults and alarms.Optional meter (9)

displays extensive system and controller information, automatic self-test
and reset capabilities. Meter connection via RJ-11 phone jack (10).
Easy to Reset
Pushbutton (11) provides manual reset and stop/start battery equalization

or load disconnect.
Low Telecom Noise
DIP switch setting will change PWM to "On-Off" battery charging.
Specifications
Electrical
TriStar-45 TriStar-60
Rated solar, load or diversion current: 45 Amps 60 Amps
System Voltage 12-48V
12/24V: 0.1% +/-50mV
Accuracy
48V: 0.1% +/-100mV
Min. voltage to operate 9V
Max. solar voltage (Voc) 125V
Controller > 20mA
Self-consumption:
Meter 7.5mA
Environmental
Operating ambient temperature: Controller –40°C to +60°C
2 of 9 6/27/2012 9:50 AM
Meter –40°C to +60°C

Storage temperature: –55°C to +85°C
Humidity: 100% (non-condensing)
Tropicalization: Conformal coating on both sides of all printed circuit
boards
Electronic Protections
Reverse polarity protection (any combination)

Short-circuit protection
Overcurrent protection
Lightning and transient surge protection using 4500W transient voltage
suppressors
High temperature protection via automatic current reduction or complete
shut down
Prevents reverse current from battery at night
TriStar Options:
Digital Meters
Two digital meters can be added to the TriStar at any time during or after
installation. One version is mounted on the controller (TS-M), the other is
suitable for remote locations (TS-RM):
TriStar Meter (TS-M) — 2 x 16 display mounts to controller and

provides system and controller information, data logging, bar
graphs and choice of 5 languages
TriStar Remote Meter(TS-RM) — Includes 30 meters of cable for
mounting meter away from the controller
The display is a 2x16 LCD meter with backlighting. Four pushbuttons are
used to scroll through the displays and to execute manual functions.
There are a series of display screens that provide information such as:
operating information and data

operating bar charts (voltage and current)
alarms and faults
diagnostics
settings
In addition, there are various manual functions built into the meter. For
example, the meter can be used to reset Ah data or start/stop
equalizations. One of 5 languages can be selected for the meter.
Remote Temperature Sensor
Provides temperature compensated charging by measuring temperature

at the battery (10 meter cable)
If the temperature of the system battery varies more than 5°C (9°F)
during the year, temperature compensated charging should be
considered. Because the battery’s chemical reactions change with
temperature, it can be important to adjust charging to account for the
temperature effects. The RTS will measure the battery temperature, and
the TriStar uses this input to adjust the charging as required.
The battery charging will be corrected for temperature as follows:
12 V battery 0.030 Volts per °C (–0.017V per °F)

The RTS should be used only for battery charging and diversion control.
Do not use the RTS for load control. The charging parameters that are
adjusted for temperature include:
PWM regulation
Equalization
Float
High Voltage Disconnect
Mechanical
Dimensions: Height: 26.0cm/10.3 inch

Width: 12.7cm/5.0 inch
Depth: 7.1cm/2.8 inch
Weight: 1.6 kg/3.5 lb
3 of 9 6/27/2012 9:50 AM
Largest Wire: 35mm2/2 AWG

Conduit Knockouts: Eccentric 2.5/3.2 cm (1.0/1.25 inch)
Enclosure: Type 1, indoor rated
Certifications
CE Compliant
UL Listed (UL 1741)
cUL (CSA-C22.2 No.107.1-95)
Complies with U.S. National Electric Code
Manufactured in a certified ISO 9001 facility
Detailed Description
Versions
There are two standard versions of TriStar controllers:
TriStar-45:
Rated for maximum 45 amps continuous current (solar, load or diversion

load)
Rated for 12, 24, 48 Vdc systems
TriStar-60
Rated for maximum 60 amps continuous current (solar, load or diversion

load)
Rated for 12, 24, 48 Vdc systems
To comply with the National Electric Code (NEC), the current rating of the
controller for solar charging must be equal or greater than 125% of the solar
array’s short circuit current output (Isc). Therefore, the maximum allowable solar
array input to the TriStar controller for compliance with the NEC is:
TS-45: 36 amps Isc

TS-60: 48 amps Isc
Operating Modes:
There are three distinct and independent operating modes programmed into
each TriStar. Only one mode of operation can be selected for an individual
TriStar. If a system requires a charging controller and a load controller, two
TriStars must be used.
Charge Control/Solar Battery Charging
The energy output of a solar array is used for recharging the system battery.
The TriStar manages the charging process to be efficient and to maximize the
life of the battery. Charging includes a bulk charging stage, PWM absorption,
float and equalization.
Constant voltage series PWM design to provide highly efficient battery

charging
4-stage charging to increase battery capacity and life: bulk charge, PWM
regulation, float and equalize
Parallel for larger solar arrays up to 300 amps or more
Load & Lighting Control
4 of 9 6/27/2012 9:50 AM
When set for load control, the TriStar powers loads from the battery, and
protects the battery from over-discharge with a current compensated LVD (low
voltage load disconnect). Lighting control is a special function of Load control
where the load is switched On and Off based on the solar array voltage.
Starts large loads including motors and pumps with no damage to

controller
Allows inrush current to 300 amps
Electronic short-circuit and overload protection with automatic reconnect
LVD is current compensated and has a delay to avoid false disconnects
Diversion Charge Control
In diversion mode, the TriStar will manage battery charging by diverting energy
from the battery to a dedicated diversion load. The energy source is typically
wind or hydro.
May be used for solar, wind or hydroelectric

To protect against battery overcharge, excess energy is diverted from
primary battery to a secondary battery or alternate DC resistive load
PWM reduces power into diversion load during overcurrent conditions
Adjustability
Eight DIP switches permit the following parameters to be adjusted at the

installation site:
5 of 9 6/27/2012 9:50 AM
DIP switch Solar Battery Charging

1 Battery charge control mode
2-3 Select battery voltage
4-6 Standard battery charging programs
7 Manual or automatic equalization
8 PWM charging or on-off charging
DIP switch Load & Lighting Control

1 DC load control mode
4-6 LVD/LVR settings or lighting programs
7 not used for load control
8 enable/disable Lighting Control
DIP switch Diversion Charge Control

1 DC load control mode
4-6 Standard diversion charge control programs
7 Select diversion charge control mode
8 Manual or automatic equalization
In addition to the DIP switches, the TriStar provides for additional adjustments
using a PC program. An RS-232 connection between the TriStar and a personal
computer will enable extensive adjustments using PC software from
Morningstar’s website.
General
The TriStar is suitable for a wide range of solar applications including homes,
telecom and industrial power needs.
TriStar controllers are configured for negative ground systems. There are no
parts in the controller’s negative leg. The enclosure can be grounded using the
ground terminal in the wiring compartment.
The TriStar is protected from faults electronically with automatic recovery. There
are no fuses or mechanical parts inside the TriStar to reset or change. Solar
overloads up to 130% of rated current will be tapered down instead of
disconnecting the solar. Over-temperature conditions will also taper the solar
input to lower levels to avoid a disconnect.
The NEC requires overcurrent protection externally in the system. There are no
system disconnects inside the TriStar enclosure.
Any number of TriStars can be connected in parallel to increase solar charging

current. TriStars can be paralleled ONLY in the battery charging mode. DO NOT
parallel TriStars in the load mode, as this can damage the controller or load.
The TriStar enclosure is rated for indoor use. The controller is protected by
conformal coated circuit boards, stainless steel hardware, anodized aluminum,
6 of 9 6/27/2012 9:50 AM
and a powder coated enclosure, but it is not rated for corrosive environments or
water entry.
The construction of the TriStar is 100% solid state.
Battery charging is by a series PWM constant current charging, with bulk

charging, PWM absorption, float and equalization stages.
The TriStar will accurately measure time over long intervals to manage events
such as automatic equalizations or battery service notification.
Day and night conditions are detected by the TriStar, and no blocking diodes are
used in the power path.
LED’s, a pushbutton, and optional digital meters provide both status information
and various manual operations.
The date of manufacture can be found on the two bar code labels. One label is
on the back of the TriStar, and the other is in the wiring compartment. The year
and week of manufacture are the first four digits of the serial number:
year week serial #
03 36 0087
Safety and Regulatory Information
The TriStar controller is intended for installation by a qualified technician

according to electrical rules of each country in which the product will be installed.
TriStar controllers comply with the following EMC standards:
Immunity: EN61000-6-2:1999
Emissions: EN55022:1994 with A1 and A3 Class B1
Safety: EN60335-1 and EN60335-2-29 (battery chargers)
A means shall be provided to ensure all pole disconnection from the power
supply. This disconnection shall be incorporated in the fixed wiring. Using the
TriStar grounding terminal (in the wiring compartment), a permanent and reliable
means for grounding shall be provided. The clamping of the earthing shall be
secured against accidental loosening. The entry openings to the TriStar wiring
compartment shall be protected with conduit or with a bushing.
FCC requirements:
This device complies with Part 15 of the FCC rules. Operation is subject to the
following two conditions:
1. This device may not cause harmful interference

2. this device must accept any interference received, including interference
that may cause undesired operation. Changes or modifications not
expressly approved by Morningstar for compliance could void the user’s
authority to operate the equipment.
PWM Battery Charging
PWM (Pulse Width Modulation) battery charging is the most efficient and
effective method for recharging a battery in a solar system. Refer to "Why
PWM?" on Morningstar’s website for more information.
Selecting the best method for charging your battery together with a good
maintenance program will ensure a healthy battery and long service life.
Although the TriStar’s battery charging is fully automatic, the following
information is important to know for getting the best performance from your
TriStar controller and battery.
1. Bulk Charging: In this stage, the battery will accept all the current
provided by the solar system. The LED’s will display an indication of the
battery charge state as the battery is being recharged.
2. PWM Absorption: When the battery reaches the regulation voltage, the
PWM begins to hold the voltage constant. This is to avoid over-heating
and over-gassing the battery. The current will taper down to safe levels
as the battery becomes more fully charged. The green LED will blink
once per second.
3. Equalization: Many batteries benefit from a periodic boost charge to stir
the electrolyte, level the cell voltages, and complete the chemical
reactions. The green LED will blink rapidly 2-3 times per second.
4. Float: When the battery is fully recharged, the charging voltage is
reduced to prevent further heating or gassing of the battery. The green
LED will blink slowly once every 2 seconds.
7 of 9 6/27/2012 9:50 AM
Battery Charging Notes
The TriStar manages many different charging conditions and system configu
rations. Some useful functions to know follow below.
Solar Overload: Enhanced radiation or "edge of cloud effect" conditions

can generate more current than the controller’s rating. The TriStar will
reduce this overload up to 130&37; of rated current by regulating the
current to safe levels. If the current from the solar array exceeds
130&37;, the controller will interrupt charging.
Battery Voltage Sense: Connecting a pair of voltage sense wires from
the controller to the battery is recommended. This allows a precise
battery voltage input to the controller and more accurate battery
charging.
Temperature Compensation: All charging setpoints are based on 25°C
(77°F). If the battery temperature varies by 5°C, the charging will change
by 0.15 volts for a 12 volt battery. This is a substantial change in the
charging of the battery, and a remote temperature sensor is
recommended to adjust charging to the actual battery temperature.
Day-Night Detection: The TriStar will automatically detect day and night
conditions. Any functions that require measuring time or starting at dawn,
for example, will be automatic.
PWM Noise: In some installations, the PWM charging may cause audible
noise in certain equipment. If this occurs, the PWM can be changed to
"On- Off" solar charging to reduce the noise. This requires DIP switch
number 8 to be turned On. However, it is strongly recommended to try to
remedy the noise problem with grounding or filtering first, because the
benefits from PWM battery charging are significant.
Battery Types: The TriStar’s standard battery charging programs are
suitable for a wide range of lead-acid battery types.
Warranty: Five year warranty period. Contact Morningstar for complete terms.
Customer Reviews:
1 of 1 people found the following review helpful:

Great service September 12, 2011
Reviewer: David Griffin from Goldendal, WA United States
Thanks for the great service within two days it was at my door and installed immediately. We will definitely be
doing more business. Thanks again and God Bless.....Dave
Was this review helpful to you?

Morningstar TriStar TS-60 August 6, 2011
Reviewer: Wayne Hill from Gormley, ON Canada
Consistent quality, good documentation, good packaging.

TriStar June 13, 2011
Reviewer: creeky from Kemptville, ON Canada
Like the fact that it handles higher current as am inputting 150 volts.

Thanks June 7, 2011
Reviewer: Jerry Harkley from Miami, FL United States
works with no problems. good documentation.

TriStar TS-60 May 16, 2011
Reviewer: Mike Elli8son from Yucca, AZ United States
awsome, works great, excellent product and simple to install.
Browse for more products in the same category as this item:
8 of 9 6/27/2012 9:50 AM
Charge Controllers > Morningstar Charge Controllers > Morningstar TriStar

Charge Controllers > Morningstar Charge Controllers
Charge Controllers
PWM
51-60A
12V
24V
48V
Xantrex C40 > 40 Amp 12/24/48 Volt PWM Charge Controller $115.25
Xantrex C35 > 35 Amp 12/24 Volt PWM Charge Controller $88.50
Morningstar TS-45 > TriStar 45 Amp 12/24/48 Volt PWM Charge Controller $142.95
Company Info Company Policies My Account

Toll free: (888) 899-3509
Local / intl: +1 (760) 597-0498 Employment Product Returns New Accounts
Contact Us Payment FAQ Order Status
Fax: (888) 215-6374
Request a Quote Privacy Policy My Cart
Press 1 for Sales Product Index Shipping Policy Become an Affiliate
Category Index Terms of Use Gov't & Edu
Press 2 for Customer Service
We're ShopWiki
Approved!
Will call / pickup orders are available for customers in the San Diego area, La Jolla, Carlsbad, Encinitas, Rancho Santa Fe, & northern Mexico who can drive to our warehouse. Please call in
advance for will call availability. We also ship from distribution centers in Southern California, New York, Chicago, Atlanta, Houston & Miami for reduced transit times.
Copyright © 2012 EcoDirect. All Rights Reserved.
9 of 9 6/27/2012 9:50 AM
TRISTAR MPPT
SOLAR CONTROLLER
45 or 60 amps at
up to 150 volts
Solar Controller with Maximum open circuit
Power Point Tracking Product shown with optional meter.
Morningstar’s TriStar MPPT solar controller with TrakStar Technology™ is an advanced maximum power point
tracking (MPPT) battery charger for off-grid photovoltaic (PV) systems up to 3kW. The controller provides the
industry’s highest peak efficiency of 99% and significantly less power loss compared to other MPPT controllers.
The TriStar MPPT features a smart tracking algorithm that maximizes the energy harvest from the PV by rapidly
finding the solar array peak power point with extremely fast sweeping of the entire I-V curve. This product is the
first PV controller to include on-board Ethernet for a fully web-enabled interface and includes up to 200 days of
data logging.
Key Features and Benefits
Maximizes Energy Harvest Extensive Networking and

Our TrakStar MPPT Technology features: Communications Capabilities
• Better peak power point tracking than other MPPT Enables system monitoring, data logging and adjustability.
controllers Uses open standard MODBUS™ protocol and Morningstar’s
• Very fast sweeping of the entire I-V curve MS View software.
• Recognition of multiple power points during shading • Meterbus: communications between compatible
or mixed PV arrays Morningstar products
• Excellent performance at sunrise and low solar • Serial RS-232: connection to a personal computer
insolation levels • EIA-485: communications between multiple devices
on a bus
Extremely High Reliability • Ethernet: fully web-enabled interface to a local
•R obust thermal design and no cooling fans network or internet; view from a web browser or
• Parallel circuit design provides less stress and longer send email/text messages.
life for electronic components
• No mechanical relays Metering and Data Logging
• Extensive electronic protections including PV short •O ptional TriStar meter and remote meter provides
circuit protection detailed operating data, alarms and faults
• Epoxy encapsulated inductors and conformally • Three LED’s display system status
coated printed circuit boards • Up to 200 days of data logging via meters or
communications ports
Very High Efficiency System Status:
•P eak efficiency of 99% 53.60V 28C 54.2A
• Proprietary tracking algorithm minimizes
power losses 2867W MPPT
• Low self-consumption Data Logging:

• Continuous operation at full power to 45°C Today Batt Day: -1 Batt
without need to de-rate 46.4 Vmin 47.2 Vmin
• Selected electronic devices with higher ratings to
Today Solar Day: -1 Solar
minimize losses from heating
58.9 Amax 56.8 Amax
Today Solar Day: -1 Solar
107.2 Vmax 105.5 Vmax
T S RI TAR MPPT
TM
SOLAR CONTROLLER
SOLAR CONTROLLER
T E C H N I C A L S P E C I F I C ATIO N S
Electrical Environmental
TS-MPPT-45 TS-MPPT-60 • Ambient Temperature –40°C to +45°C
• Maximum Battery Current 45 amps 60 amps • Storage Temperature –55°C to +100°C
• Nominal Maximum • Humidity 100% non-condensing
Solar Input 12 Volt 600 Watts 800 Watts • Tropicalization Epoxy encapsulation
24 Volt 1200 Watts 1600 Watts Conformal coating
48 Volt 2400 Watts 3200 Watts Marine rated terminals

TS-MPPT-45 and TS-MPPT-60
• Peak Efficiency 99%
• Nominal System Voltage 12, 24, 36 or 48 volts DC EMAIL
• Max. Solar Open Circuit Voltage 150 volts DC
• Battery Operating Voltage Range 8-72 volts DC
• Maximum Self-consumption 2.7 Watts
• Transient Surge Protection 4500 Watts/port WEB
INTERNET PAGE
Electronic Protections
• Solar: Overload, Short Circuit, High Voltage
• Battery: High Voltage
• High Temperature TEXT
MESSAGE
• Lightning and Transient Surges (SMS)
• Reverse Current at Night
Battery Charging Communication Ports

• Charging algorithm 4-stage TS-MPPT-45 TS-MPPT-60
• Charging stages Bulk, Absorption, Float, Equalize • MeterBus Yes Yes
• Temperature Compensation • RS-232 Yes Yes
Coefficient –5mV/°C/cell (25° ref) • EIA-485 No Yes
Range –30°C to +80°C • Ethernet No Yes
Set points Absorption, Float, Equalize, HVD
Note: Remote Temperature Sensor is included. Options
• TriStar Meter-2 (TS-M-2)
Mechanical • TriStar Remote Meter-2 (TS-RM-2)
• Dimensions 29.1 x 13.0 x 14.2 cm • Meter Hub (HUB-1)
11.4 x 5.1 x 5.6 inch • Relay Driver (RD-1)
• Weight 4.2 kg / 9.2 lbs.
• Max. Wire Size 35 mm² / 2 AWG Certifications
• Conduit knockouts M20; ½, 1, 1 ¼ inch • CE Compliant
• Enclosure Type 1 (indoor and vented) • ETL Listed (UL1741)
IP20 • cETL (CSA C22.2 No. 107.1-01)
• FCC Class B Part 15 Compliant
• Complies with (NEC) U.S. National Electric Code
• RoHS Compliant
• Manufactured in a certified ISO 9001 facility
Warranty: Five year warranty period. Contact Morningstar or your authorized distributor for complete terms.
Authorized Morningstar Distributor:
8 Pheasant Run
Newtown, PA 18940 USA
Tel: +1 215-321-4457 fax: +1 215-321-4458
e-mail: info@morningstarcorp.com
website: www.morningstarcorp.com
© 2010 morningstar corporation Printed in USA 224E-R2-1/10
List of Manufacturers for Solar Charge Controller in India
MAHARASHTRA
 Bharat Industries - India
Manufacturer of solar charge controller
Business Type: Manufacturer
Address: Wada Road, RAJGURUNAGAR, Maharashtra India
Contact Person: RAHUL.K.SANDBHOR
Mobile: 91^9850138638, Phone: India - 91-02135-224870
 Aura Emergency Systems - India
Manufacturer / Wholesale Suppliers of solar charge controllers
Business Type: Manufacturer / Wholesale Suppliers
Address: 2012-sadshiv Peth, Pune-30, Maharashtra India
Contact Person: Atul P. Nahar
Mobile: 91 9271984835, Phone: India - 91-20-24481008
 Maxenergy - India
Wholesale Suppliers of solar charge controllers
Business Type: Wholesale Suppliers
Address: 101, Prime Plaza, Jv Patel Compound, Bs Madurkar Marg, Elphinstone (w),,
Mumbai, Maharashtra India
Contact Person: Mr Prashant Menon
Mobile: +91-9819880198/9322383736, Phone : India - +91-98-19880198

 K B Electronics - India
Manufacturer of solar charge controllers
Address: Prabhadevi, mumbai, Maharashtra India
Contact Person: Siddharth Kambe
Mobile: 9920791222, Phone: India - 91-9920791222-9920791222
 Sadhana Energy Devices - India
Address: Samruddhi, Ajinkyatara Industrial Estate, Sinhagad Road, Pune, Maharashtra

India
Contact Person: Dnyaneshwar Rajkuntwar
Mobile: +91-9823 11 66 55, Phone: India - 91-20-24391151
 Prachi Solar - India
Manufacturer / Exporters / Wholesale Suppliers of solar products, solar battery charge

controller, solar lanterns, solar cfl lantern, solar led lantern, solar lights, solar cfl home
light, solar led home lighs, solar cfl street light, solar led street light, solar panel, solar
power pack, power led lantern
Business Type: Manufacturer / Exporters / Wholesale Suppliers
Address: E-12, Yadav Nagar, Samaypur, New Delhi India
Website: http://www.prachisolar.com
Contact Person: Rahul Tyagi
Mobile: 8826359242
Phone: India - +91-11-64723013

 Tilak International - India
Manufacturer / Wholesale Suppliers / Exporters of solar charge controllers
Business Type : Manufacturer / Wholesale Suppliers / Exporters
Address: J-1/162 A, Rajouri Garden (iind) Floor, New Delhi -110027 India
Website: http://www.tilaksolar.com
 Nextech Control - India
Manufacturer / Exporters / Wholesale Suppliers of solar charge controller
Address: F-90/33, Okhla Industrial Area, Phase-I, New Delhi India
Website: http://www.balukenergy.com
Contact Person: D. K. Sirohi -9811960035
Mobile: +91-9910175416-pradeep, Phone: India - +91-11-32312388
 Easy Solar Industries - India
Manufacturer / Exporters of solar charge controllers, solar inverter solar charge

controllers
Business Type : Manufacturer / Exporters
Address: H-17, First Floor, Office No 104, Vikas Marg, Laxminagar, delhi India
Contact Person: Lokesh Vats

ANDHRA PRADESH
 Sneha Enterprises - India
Wholesale Suppliers / Exporters / Manufacturer of solar charge controller
Business Type: Wholesale Suppliers / Exporters / Manufacturer
Address: 411, My Home Mount Veiw Apartments, Navodaya Colony, Yellareddy Guda,
Hyderabad, Andhra Pradesh India
Website: http://www.snehaenterprizes.com
Contact Person: Jagdeesh / Mr. Suresh
Mobile: +91-9491664345 / 9393834499, Phone: India - +91-40-40121718
 Nt Power Systems - India
Manufacturer / Wholesale Suppliers / Exporters of solar charge controllers
Business Type: Manufacturer / Wholesale Suppliers / Exporters
Address: 354 Bavani Nagar, Street No 9, Kapra, Ecil, Hyderabad, Andhra Pradesh India
Website: http://www.ntpowersystems.com
Contact Person: Ms Sukanya Nidiginti
Mobile: 9866286112
Phone: India - +91-98662-86112

RAJASTHAN
 Rahul infocomm - India
Exporters of solar charge controller
Business Type: Exporters
Address: jabalpur, Rajasthan India
Contact Person: robin
 Raydean Industries - India
Business Type : Manufacturer
Address: G1-22,Riico industriel area,Bindayaka, Jaipur, Rajasthan India
Contact Person: Sanjeev.Dakshini
Mobile: 09829277657, Phone: India - +91-0141-2240903// 0141- 224090
 Gears Energy Solutions Pvt Ltd - India
Address: 103/87, Patel Marg, Mansarovar, Jaipur, Rajasthan India
Contact Person: Raj Bhutra

UTTAR PRADESH
 Steca Bergen Solar Products Pvt Ltd - India
Address: J-11, Sdf, Nsez, Phase Ii, Noida, Uttar Pradesh India
Contact Person: Prashant
Mobile: 9871122307, Phone: India - +91-120-4745002
 Unique Solar Power Systems - India
Manufacturer / Exporters / Wholesale Suppliers of solar charge controllers
Address: The Corenthum, Tower-a, 6th Floor, 167, A-41, Sector-62, Noida, UP India
Website: http://www.uniquesolarpower.com
Contact Person: Pankaj Kumar Singh
PUNJAB
 Suryodaya Energies - India
Exporters / Wholesale Suppliers / Manufacturer of solar charge controller
Address: 5411, St. No.-3, New Shivaji Nagar, Ludhiana, PB India
Contact Person: Puneet Kalra
Phone: India - +91-99155-68500

HARYANA
 National Controlling Equipment Industries - India
Manufacturer / Exporters / Wholesale Suppliers of solar charge controller
Address: 65 Laxmi Vihar, Jandli, Ambala City, Harayana India
Website: http://www.nacei.com
Contact Person: Amarjit Singh/ Rita
Phone: India - +91-171-2801711 / 3291897
WEST BENGAL
 Solace - India
Address: 20, Kankulia Road, Kolkata, West Bengal India
Contact Person: Samrat Laha
GUJARAT
 Soni Group of Electronics - India
Address: Highway, Kalol, Gujarat India
Contact Person: Dipan

 Benstar Powetronics Limited - India
Address: #19/2d, J. C.industrial Estate, Bangalore, Karnataka India
Contact Person: Jyothi.c
Mobile: 9019614299
 Digital Solar - India
Address: E -62, Sector 9, Noida, Uttar Pradesh India
Contact Person: Vikrant Verma
KARNATAKA
 Imax Industries Pvt Ltd - India
Manufacturer / Exporters of solar charge controllers
Business Type: Manufacturer / Exporters
Address: Jaraganahalli, Rajiv Gandhi Road, Bangalore, Karnataka India
Contact Person: Kalyan

Charge Controllers Data

Uploaded by

Charge Controllers Data

Uploaded by

An Introduction to Charge Controllers

Page Topics How do MPPT controllers work?

If you are using a PV array only to trickle-charge Overload Protection

Apollo Solar Midnite Solar Outback Power

Dear OutBack Customer,

About OutBack Power Systems

Date and Revision

This product is intended to be installed as part of a permanently grounded electrical system

For routine, user-approved maintenance:

Standards and Requirements

DC and Battery-Related Installation Requirements:

BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL OPERATION. Design the

PERSONAL PRECAUTIONS DURING INSTALLATION

The Charge Controller is designed to attach

NOTE: Install the Charge Controller in an upright

To mount directly to a FLEXware DC enclosure:

• Remove the fan cover and bottom cover from

The Conduit Nipple Assembly creates a sealed

Bushing Use 1 5/8” wood screws to secure the Charge

Maximum Open Circuit Voltage (VOC)

• As every brand of panel is different, be sure to know the manufacturer’s specifications.

Wire and Disconnect Sizing

• The output current limit of the FLEXmax 80 is 80 amps

• The output current limit of the FLEXmax 60 is 60 amps

Figure 1 Charge Controller wiring compartment

Screw holes for attaching Charge Controller

Solid black indicates key is to be pressed:

Down arrow will lead to the next screen:

Up arrow points to one or more keys that will change a value:

The keys correspond to any text immediately above them.

OFF SCREEN (this screen is initially blank at power up)

With the PV array and battery breakers off, turn on the

The Charge Controller will show the system battery

Press the “ – “ soft key until the password 141 shows on

Press the <NEXT> to choose the desired screen

The Charge Controller auto detects the system’s battery

Are you sure?

NOTE: Repeating the Powering Up sequence resets the

The PV voltage will slowly rise to the

PV Input Voltage PV Input Current

Day (up to 128 days) Accumulated KWh total

Minimum batt Accumulated float time

7. Recharging Using the PV Array

Turn the PV input breaker on. The Charge Controller

The Charge Controller enters a “Wakeup” stage, transitions

Press the <GO> soft key after aligning the arrow in

Press or to move the " “ to

From the MAIN screen, press or < > to move

NOTE: If a battery remote temperature sensor (RTS)

When the preferred mode is

Pressing the <NEXT> soft key

PASSWORD AUX MODE

To access the AUX Output Menu:

AUX MODE AUX MODE AUX MODE

AUX MODE AUX MODE AUX MODE

AUX MODE AUX MODE AUX MODE

* These functions support AUX polarity.

AUX MODE On Press the <MODE> soft key to manually activate

EXIT NEXT SET MODE

AUX MODE On When the PV input exceeds the user-determined

EXIT TIME VOLT

PV VOLTS Adjust the voltage within a range of 20V-145V by

Press the <EXIT> soft key to return to the initial

EXIT TIME VOLT

ERROR LOW BATT VOLTS User-determined value—not less than 10V—will

EXIT NEXT SET MODE

AUX MODE On The Night Light illuminates a user provided low-wattage

EXIT NEXT SET MODE

EXIT HYST TIME VOLT

Night Light On Time

EXIT NEXT SET MODE

When external DC sources (wind, hydro) are

This is primarily an off-grid function. Pressing the

EXIT TIME VOLT

Use this screen to establish the set points for starting

EXIT TIME VOLT