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OutBack Power FLEXmax 100 - User Manual

OutBack Power FLEXmax 100
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FLEXmax 100
Charge Controller
Owner’s Manual

Table of Contents

Questions and Answers

  • L
    lozanoleeSep 9, 2025
    What does 'Shorted RTS' mean on my OutBack Power FLEXmax 100 Controller?
    • E
      Edward ParkerSep 9, 2025
      A 'Shorted RTS' message indicates that the Remote Temperature Sensor (RTS) is damaged. To test, remove or replace the RTS.
  • C
    Christopher PotterAug 23, 2025
    What to do if OutBack Power Controller unit does not power up upon initial connection?
    • S
      Shelby MarshallAug 23, 2025
      If your OutBack Power Controller unit doesn't power up, check the battery connection and polarity, ensuring it's properly connected. Also, inspect the battery circuit breaker or device to ensure it's appropriately sized. Confirm the battery voltage at the FLEXmax 100 terminals, as a voltage below 15 Vdc may prevent power-up. If a rapid shutdown device caused this, reset the external rapid shutdown device.
  • A
    aduncanAug 25, 2025
    What does it mean when my OutBack Power Controller displays 'VOC Too High'?
    • B
      braunlynnAug 25, 2025
      If the open-circuit voltage (Voc) is too high, the FLEXmax 100 cannot safely operate. The controller will automatically restart operation once the Voc decreases to a safe level. You should also check the controller temperature.
  • J
    James GardnerAug 27, 2025
    What to do if my OutBack Power FLEXmax 100 is in over current fault?
    • W
      William TylerAug 27, 2025
      An over current fault occurs if more than 80 amps flow from the battery to the FLEXmax 100, or if more than 120 amps flow from the controller to the battery. To restart the FLEXmax 100, remove all power from the controller and then reconnect the batteries.
  • A
    Alyssa JacksonAug 27, 2025
    What to do if my OutBack Power Controller shows a GFDI Fault?
    • E
      Eric ButlerAug 28, 2025
      A GFDI Fault indicates a ground fault where the detection circuit has sensed an open connection on the GFDI fuse. Check the fuse and make certain it is installed according to the instructions.
  • T
    Tara RichardsSep 22, 2025
    Where should FN100-00.bin file be located on microSD card for OutBack Power Controller?
    • E
      Eric AdkinsSep 22, 2025
      Ensure the FN100-00.bin file is located in the root directory of the microSD card.
  • S
    Shawn MillerSep 16, 2025
    What to do if STATUS LED indicator flashes rapid green, but does not flash slowly within a few seconds on OutBack Power FLEXmax 100 Controller?
    • D
      Dr. Russell WilliamsSep 16, 2025
      If the STATUS LED indicator flashes rapid green, but does not flash slowly within a few seconds, there may be a problem with the microSD card or a file on it. Disconnect the battery and try connecting it up to six more times.
  • P
    Paul Rodriguez IISep 18, 2025
    What to do if STATUS LED indicator does not flash, but startup LED indicator sequence runs when pressing RESET button while connecting battery to OutBack Power Controller?
    • M
      Mitchell VargasSep 18, 2025
      If the STATUS LED indicator does not flash, but the startup LED indicator sequence runs when pressing the RESET button while connecting the battery, the button may not be fully pressed when powering up. Ensure the button is fully pressed when powering up.
  • L
    Larry ThompsonSep 7, 2025
    What does it mean if my OutBack Power FLEXmax 100 Controller displays 'Over Temperature'?
    • C
      calebdavisSep 7, 2025
      An 'Over Temperature' message indicates a high temperature fault. Check the controller temperature (see page 38).
  • H
    hcarterSep 4, 2025
    What to do if my OutBack Power Controller displays 'Fault Input Active'?
    • J
      Jeanette GonzalezSep 4, 2025
      A 'Fault Input Active' message indicates a deliberate action due to a rapid shutdown condition, which is not a controller error. Resetting this condition requires resetting the external rapid shutdown device.

Summary

IMPORTANT SAFETY INSTRUCTIONS

General Safety

Covers essential safety precautions for operating the equipment.

Installation

Wiring

Provides instructions and requirements for connecting the charge controller to the system.

Grounding

Explains grounding requirements and methods for system safety.

Ground Fault Detection and Interruption (GFDI)

Describes the internal GFDI circuit and its function for fault protection.

Wiring Size and Requirements

Specifies correct wire gauges and cable ampacities for system connections.

Power Up

Outlines the step-by-step procedure for powering on the charge controller.

Resetting to Factory Defaults

Explains how to restore the controller to its original factory settings.

Status and Information

Error Screen

Details fault conditions, error messages, and troubleshooting steps.

Programming the FLEXmax 100

Menu Structure in the MATE3 S

Presents the menu hierarchy for configuring settings via the MATE3S display.

MATE3 S Screens

Troubleshooting

Specifications

Applications

OutBack Power FLEXmax 100 Specifications

General IconGeneral
Maximum PV Input Voltage150 VDC
Maximum Charge Current100 A
Maximum Output Current100 A
Efficiency98%
Operating Temperature-40°C to +60°C
Battery Voltage12 VDC
CommunicationRS-232
ProtectionOvervoltage, Overcurrent, Short Circuit, Reverse Polarity

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