FlexMax FM100 AFCI Installation

Troubleshooting
58 900-0253-01-00 Rev A
Troubleshooting Error Messages
Error messages are caused by known faults. These are defined by a list of messages in the Charge
Controller Error screen of the system display. See page 38. See the system display literature for
instructions on navigating to this screen.
Table 8 shows the messages available in the system display. One or more messages will display Y to
indicate an error. If a message says N, it is not the cause of the error.
See Table 7 to troubleshoot symptoms not necessarily represented by error messages.
NOTE: Most errors shown in Table 8 are not regularly accompanied by the red F
AULT LED indicator.
The exceptions are GFDI Fault and Arc Fault.
Table 8 Error Messages
Message Symptom Problem
VOC Too High 24-volt system ≥ 275 V
oc
36-volt system ≥ 283 V
oc
48-volt system ≥ 290 V
oc
If the open-circuit voltage (V
oc
) is too high, the unit
cannot safely operate. It will automatically restart
operation once the V
oc
decreases to a safe level.
Over Temperature Controller is hot to the touch. High temperature fault. Check controller temperature
(see page 38). The FLEXmax 100 will stop
functioning at an Output FETs reading of 90°C.
Shorted RTS Charging is not temperature-
compensated.
Remote Temperature Sensor (RTS) damaged.
To test, remove or replace the RTS.
GFDI Fault
Red (F
AULT) LED indicator
illuminated (see page 30).
Ground fault. The detection circuit has sensed an
open connection on the GFDI fuse. Check the fuse
and bonding jumper (see pages 12, 13 and 56).
Make certain it is installed according to the
instructions. Inspect the rest of the system for
grounding problems or shorted connections.
Fault Input Active LED indicator(s) illuminated on
rapid shutdown device; red
(F
AULT) LED indicator (page 30)
will flash twice before this occurs.
Rapid shutdown condition. This is not a controller
error but a deliberate action. See pages 18 and 24
for more information. Resetting this condition
requires resetting the external rapid shutdown device.
Reduced
Performance
Temperature reading is greater
than 142°C or less than –40°C.
Internal temperature sensor failed. If a failure is
detected, the controller will operate with a maximum
output of 20 Adc.
Over Current Fault Controller has shut down. This occurs if more than 120 Adc flows from the
controller to the batteries (or more than 80 Adc flows
from the array to the controller).

To restart the FLEXmax 100, remove all power from the
controller and then reconnect the batteries.

If the problem recurs, contacts may be loose or shorted.

The PV array may also be oversized.
Arc Fault
Red (F
AULT) LED indicator
blinking (see page 30).
Arc fault. The detection system has sensed an arc on
the PV wiring. This may indicate incorrect installation.
(See pages 16 and 21.) Remove battery power and
wait for all indicators to turn off. Apply power again.
The arc fault card will perform a self-test. If the fault
is still indicated, it may be necessary to troubleshoot
the PV array wiring to find a physical problem.
If the message is Arc Fault but the F
AULT indicator is
solid, a GFDI fault is present at the same time.