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OutBack Power FLEXmax Series User Manual

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36 pages
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Board Replacement Instructions for
FLEXmax Charge Controllers
Including Control Board, Button Board,
Power Board, and FLEXmax 60 Fan
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OutBack Power FLEXmax Series Specifications

General IconGeneral
ModelFLEXmax 60, FLEXmax 80
Operating Temperature Range-40°C to +60°C
Weight12.5 lbs (5.7 kg)
Rated Output Current60A, 80A
Maximum PV Input Voltage150 VDC
Nominal Battery Voltages12V, 24V, 48V
Maximum Output Current60A, 80A

Summary

Important Safety Instructions

Symbols Used

Explains symbols for warnings and important information found in the manual.

Audience

Defines the qualified personnel for whom the instructions are intended.

Definitions

Provides a glossary of terms and acronyms used in the manual.

Personal Safety

Outlines essential safety precautions for personnel working with the equipment.

PV Safety

Details safety considerations specific to photovoltaic (PV) array connections.

Equipment Safety

Lists critical safety instructions related to equipment handling and operation.

Introduction

Overview

Provides a general summary of the guide's scope and purpose.

Tools Required

Lists the necessary tools for performing the board replacement procedures.

Preliminary

Covers essential preliminary steps and warnings before starting the procedure.

Summary List of Instructions

Provides a roadmap of the procedures covered in the document.

FLEXmax Charge Controller Disassembly

Removing Chassis Screws

Explains how to remove the screws securing the controller's chassis.

Removing the FLEXmax 80 Fan Cable

Details the process for disconnecting the fan cable from the unit.

Removing the Heat Sink

Guides on safely detaching the heat sink assembly from the main unit.

Removing the FET Bar

Describes the steps to remove the FET mounting bar.

Separating the Heat Sink from the Power Board

Outlines how to detach the heat sink from the power board.

Fan and Button Board

Replacing the FLEXmax 60 Fan

Step-by-step instructions for replacing the cooling fan.

Removing the Fan

Details the procedure for removing the fan from its mounting.

Replacing the Fan

Instructions on installing a new fan, including connector alignment.

Fan Test Procedures

Explains how to test the functionality of the replacement fan.

Replacing the Button Board

Guides on how to remove and replace the button board assembly.

Control Board and Power Board

Removing the Control Board

Details the process for safely disconnecting and removing the control board.

Replacing the Control Board or Power Board

Provides instructions for installing new control or power boards.

Reassembly

Reseating the Control or Power Board

Instructions for properly seating the control or power board.

Reconnecting the Heat Sink to the Power Board

Guides on reattaching the heat sink to the power board assembly.

Reconnecting the Heat Sink to the Chassis

Details how to reinstall the heat sink assembly into the chassis.

Reinstalling FLEXmax 80 Fan Plug

Steps for reconnecting the fan cable plug for the FLEXmax 80.

System Functional Test

Outlines the final testing procedure to verify system operation.

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