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OUTBACK FLEXmax 80 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 conguration sections (see pages 12-14) 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important restrictions apply unless superseded by local or national codes: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 FLEXmax 80 should
never be positive
grounded (see page 60, Applications Notes).
• The FLEXmax 80 equipment ground is marked with this symbol:
• If damaged or malfunctioning, the FLEXmax 80 should only be disassembled and repaired by a
qualied service center. Please contact your renewable energy dealer/installer for assistance.
Incorrect reassembly risks malfunction, electric shock or re.
•
The FLEXmax 80 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 o 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 NEC standards.
• Shut o all DC breakers before connecting any wiring.
• Torque all the FLEXmax 80’s wire lugs and ground terminals to 35 inch-pounds (4 Nm).
• All wiring must be rated at 75° C or higher.
• Use up to 2 AWG (33.6 mm
2
) to reduce losses and ensure high performance of FLEXmax 80 (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 ttings to allow the inductive
currents to cancel.
• DC battery over-current protection must be used as part of the installation. OutBack oers both