eFlex Max battery-inverter integration guide

eFlex Max battery-inverter integration guide


Important notice
This Quick Guide does not exempt the installer or User from reading each product manual. Failure to do so may risk damaging both Fortress Power equipment and other manufacturers and void warranty.

Abbreviations

Connection diagrams
      Connection overview

Fortress Power Envy integration


Closed loop and pinout definitions
If making a communication cable, please refer to the pin out diagram for an RJ45 cable below. Type B format ethernet cable may also be used. 





Commissioning
1. Put the inverter disconnect into “OFF” position (if there is any). Make sure the eFlex MAX battery and any charge controllers are off/disconnected as well.
2. Turn On the all the DC Battery Breaker and Hybrid inverter DC Battery Breaker.
3. Press and hold the Power Button on the Master battery (the battery communicating directly with the inverter) until you hear a beep, then release. Notice the Fortress Power Logo LED will turn on all batteries if connection is successful. Under normal operation, the eFlex MAX LEDs will show state of charge after the diagnostic is complete. The red BMS light should not be on.

Inverter protocol selection
To select the inverter protocol to achieve closed loop communication, you must press and hold the power button for 5 seconds, then release it. Immediately the LED 6&7 will start flashing following the current inverter protocol status. In this stage, press the button once until you select the correct protocol as shown in the images below. Once selected wait for less than 10seconds until the LED indicator returns to normal operation. You must do this with all batteries in the field.

Programming the inverter
Fortress Power Envy
Before setting the parameters, make sure the system is in Standby. Make sure to press SET for each setup. Confirm the battery is doing Closed Loop Communications with the inverter under the Battery of the Data Section.

Battery setup

Self-consumption mode

Back up

Off-grid

Time of use

Sol-Ark
Share Sol-Ark Monitoring w/Fortress
Set up Wi-Fi with Sol-Ark Inverter using Sol-Ark’s My Sol-Ark App and have your site name and Wi-Fi dongle serial number handy to register the system online with Sol-Ark. After registering, use a laptop to log into MySolArk via a web browser at http://mysolark.com
Note: For certain circumstances, temporarily use the batteries in open-loop communication mode, please follow the following link for open-loop settings: 

Programming:
      1. To program the inverter using the Sol-Ark inverter screen, go to battery setup menu:

      2. Program the 'Batt' tab first. Enter the settings as shown below and tap on 'OK' in the bottom of the menu afterwards:


Confirm closed loop communication was established by going to the Home screen and selecting Li-BATT INFO

Open loop settings

Note: 
      a) If closed loop communication is set up correctly, enabling 'BMS Lithium Batt 00' will adjust some values automatically. In this tab, those would be 'Batt Capacity' and 'Tempco'.
      b) If the total charge/discharge current capacity of the batteries exceeds the inverter's capabilities, use the maximum current settings of the inverter. 
For example, if you have four eFlexes and one Sol-Ark 12K inverter, based on the size of the battery bank, 'Max A Charge' and 'Max A discharge' should be 240A each. But Sol-Ark 12K can only carry 185A DC going to or coming from the battery. So, in this case, both 'Max A Charge' and 'Max A Discharge' would be set to 185A.
      c) If recovering a deeply discharged battery, adjust the above charge amps to 10A.

      3. Next, program the 'Charge' tab in the 'Battery Setup' menu:

Note:
      a) The settings shown in the latter screenshot are the most conventional ones, hence, adjustments may be required (please see the table below).
The approach described in the note "2b" applies while programing this tab as well. Additionally, current set point (A) must not exceed the generators’ capability.
      b) Larger generators are commonly tied into the grid side of the inverter rather than the dedicated generator input. Make check-marks and current adjustments accordingly. This fact was kept in mind while creating the last two rows of the table above.
      c) Fortress batteries may be discharged to its full rated capacity without voiding the warranty, but for best overall experience and battery life, limit the discharge to 80% except for very rare occasions. Here is a list of our suggested triggers:
      d) It is acceptable to raise the grid or generator start triggers to increase the reserve capacity of the system.

      4. Program the Discharge tab:

Note:
      a) At 'Shutdown' state of charge (battery bank charge percentage), inverter prevents battery from powering the loads. The battery(s) will renew/continue providing power to the loads when the battery bank is recharged to 'Restart' state of charge. 'Shutdown' and 'Restart' state of charge set-points can be increased to increase the "reserve capacity" of the system, but that will cause less battery charge usage. The correct shutdown level is specific to the project site.
      b) Low battery is an alarm also specific to the project site, integrated with the Sol-Ark monitoring app. We suggest a 20% state of charge as a low battery alarm level. But it is a good idea to increase it if the 'Shutdown' and 'Restart' set-points are increased.
      c) The battery empty voltage should not be lower than 48V. The last statement from the previous note applies to the 'Batt Empty V'. Usually this set-point does not exceed 50V

Grid Setup / Time-of-Use
Time-of-use settings are specific to each end user but also important to having system behavior meeting customer expectations. system to behave as the end user wants it to behave.  There are a few important things to know when programming Sol-Ark's time-of-use settings:
1) Checking the "charge" column boxes will force a grid charge to that battery. 
2) Leaving the "charge" column boxes unchecked will act as a low battery cut-off. 
3) Enabling "grid-sell" will allow the battery to sell back to the grid when it is otherwise 100% full.
4) Solar will charge the battery to 100% if there is enough sunlight available and all the loads are otherwise met. 
5) Additional settings worth exploring in the Grid Setup Menu are the frequency ranges and grid profile settings useful for generator compatibility. 

Back-up Only Customers:
Batteries work better and last longer if they are used, rather than staying 100% full. Our recommendation is to allow the battery to drop to 70% during the early morning hours and then have it go to 100% during the day. You do not need to enable a grid-charge for this functionality. You may want to increase the grid start % or voltage in the battery setup menu.

Time-of-use Customers:
1) To maintain solar tax credit compliance, you will want to prioritize battery charging in the hours before the time-of-use period so that the battery is 100% going into the time frame. 
2) You may also want to enable a grid charge the hour before the time-of-use period to ensure the battery reaches 100%
3) You may not want to discharge the battery too aggressively. Sticking to no more than 9kW per eVault or 3.3kW per eFlex Max is optimal for maximizing battery life under time-of-use grid sell-back. Likewise, selling back at less than the full rated value of the inverter is healthy for inverter life. So for example, if you can identify that the battery and inverter will be fully utilized over the time of use rate period by discharging at 5kW rate instead of the full rated capacity of the inverter, it will extend battery life.
4) That said, the mantra is "use it or lose it" - it is more economically advantageous for the end user to use the battery when it is financially advantageous to do so, rather than to keep the battery at 100% always.

Bad Utility Buyback Rates aka "no net-metering" aka "bad net-metering":
Allow the battery to discharge to a 20% state-of-charge over night, so that it can absorb as much solar power as possible during the day rather than having that energy sold back to the grid.  Staggering the step down percentages throughout the night so that the battery so that the battery hits 20% right in the early morning will mitigate the risk of power outage between sun up and sun down. Maintain the final 20% time-of-use step with a grid charge to make sure the battery does not go below 20% (which would trigger a full grid recharge at 15% per prior steps).  During the day, it does not matter if you prioritize the grid or the battery first when recharging with solar power.
Note: Change the programming from Percentage to Voltage in the Battery setup menu. (Use Batt % Charge / Use Batt  V charge).
Here are more aggressive settings for minimizing sell-back to the grid (but allowing grid-sellback when the batteries are full).

Solo 6.5
Operation and display panel
The operation and display panel of the inverter includes one LCD screen, three indicators, and four physical buttons.
 
Physical button
LED indicator
Physical button
Description
Indicator
Color
Description

Enter/Exit the setup menu 
AC/INV 

Normally ON: Grid 
bypass output 

Flash: inverter output 

Go to the next option 
CHARGE 

Normally ON: charging completed

Flash: charging 

Go to the previous option 
FAULT 

Normally ON: level-1 fault 

Flash: level-2 fault 

OFF: level-3 or level-4 fault

Confirm/Enter the option in setup menu


ICON
DESCRIPTION
ICON
DESCRIPTION

PV panel 

Grid

Battery

Generator

The inverter is working 

Load

The inverter is communicating with the data collector 

The buzzer is in mute mode 

Power flow direction 



The inverter is in standby mode 

The inverter is working normally 

There is a fault 

Settings 

Load power: 80%−100% 

SOC: 80%−100% 

Load power: 60%−79% 

SOC: 60%−79% 

Load power: 40%−59% 

SOC: 40%−59% 

Load power: 20%−39% 

SOC: 20%−39% 

Load power: 5%−19% 

SOC: 5%−19% 

Battery under-voltage 

Battery over-discharge 

Overload 

BMS fault

System communication error 

System undervoltage 

System overvoltage 

System under temperature 

System overtemperature 

System overcurrent 

Battery full power 

User-defined battery 

Sealed lead-acid battery 

Flooded lead-acid battery 

Gel lead-acid battery 

Ternary Li-ion battery 

LFP Li-ion battery 
ECO
Energy-saving mode 
PVLOAD 
PV power is loading 
PVCHG 
PV power is charging the battery 
ACCHG 
AC input power is charging the battery 
GRID FIRST
The output mode of the inverter is Grid first 
BYPASS 
The output mode of the inverter is Grid bypass
SOLAR FIRST
The output mode of the inverter is PV first 
BATT FIRST
The output mode of the inverter is battery first 


Real-time parameters view 
On the screen, press the UP/DOWN button to view real-time data of the inverter in operation

PAGE
PV
BATTERY
AC INPUT
LOAD
GENERAL
1
PV input voltage 
Battery voltage 
Grid input voltage 
Single-phase voltage 
Current time 
2
PV input current 
Battery current 
Grid input current 
Single-phase current 
Current date 
3
PV input power 
Battery voltage 
Grid total input power 
Single-phase active power 
PV gross generation 
4
PV generation for the day 
Battery current 
Grid charging capacity for the day 
Single-phase apparent power 
Total load consumption 
5
PV heat sink temperature  
Heat sink temperature Grid frequency 
Inverter output frequency 
RS485 address 
6
Rated open circuit voltage 
Rated battery voltage 
Bus voltage 
Rated output frequency 
Software version 
7
Maximum PV charge current 
Maximum battery charges current 
Maximum Grid charge current 
Total output active power 
/
8
/
/
/
Total output apparent frequency 
/

Settings
Notice
If you use lithium battery which has communication with Inverter, please skip all Battery Voltage setting (04~07)

INVERTERT MODE OF OPERATION DESCRIPTION
00
Exit
ESC
Exit the setup menu 
01
ESS Operation mode
UTI(Default)

Backup Mode
Backup Mode (Load Source Priority: PV → Grid → Battery)  
 
If PV power is insufficient, the system uses both PV and grid power to support the load. 
When PV power exceeds the demand, the excess energy charges the battery. 
Grid power is only used for charging when the battery is over-discharged (if setting 06 is PV-only charging, the grid will not charge the battery). 
The battery discharges only in off-grid mode 

SBU  
Self-Consumption 
Mode (Recommend) 
Self-Consumption Mode (Load Source Priority: PV → Battery → Grid) 
 
PV Power Priority – The system first uses solar (PV) power to supply the load. 
Battery Backup – If PV power is insufficient, the system draws power from the battery to support the load. 
Grid as Last Resort – The system switches to grid power only when the battery voltage drops below the set threshold (Parameter ④). 
Return to PV/Battery – Once the battery voltage recovers above the set threshold (Parameter ⑤), the system switches back to PV or battery power for load supply. 
SOL
Self-Consumption Mode (Load Source Priority: PV → Battery → Grid) 
The PV mode is to be applied first and when the PV power is unavailable or the battery voltage is lower than the set value in the item 4, it will switch to the Grid mode 
SUB 
Battery  
Charging Priority Mode 
PV and Grid prioritize Charging the Battery 
 
PV Priority for Charging – The system prioritizes PV power to charge the battery. 
Grid-Assisted Charging – If PV power is insufficient, the system uses both PV and grid power for charging (except when Parameter 06 is set to PV-only charging, in which case the grid will not charge the battery). 
Grid Powers the Load – While the battery is charging, the grid supplies power to the load when PV alone is not sufficient. 
Hybrid Load Supply – If PV power is enough for charging but insufficient for the load, the system will use both PV and grid power to support the load. 
Battery Discharges Only in Off-Grid Mode – The battery does not discharge when the system is connected to the grid; it is reserved for off-grid operation only. 

FN
PARAMETER
EFLEX MAX/EFLEX
04
Battery Low Cut of Voltage
51.2V
WHEN PARAMETER ITEM 01 IS SET TO SBU (SOLAR-BATTERY UTILITY) OR SOL (SOLAR ONLY) MODE, THE SYSTEM PRIORITIZES PV AND BATTERY POWER. HOWEVER, IF THE BATTERY VOLTAGE DROPS BELOW THE SET CUT-OFF POINT, THE POWER SOURCE AUTOMATICALLY SWITCHES FROM THE INVERTER TO THE GRID TO PREVENT BATTERY OVER-DISCHARGE
06
Grid Charge Setting
SNU (RECOMMENDED)
SNU (DEFAULT): BOTH PV AND GRID CAN CHARGE THE BATTERY, WITH PV AS THE PRIORITY CHARGING SOURCE 
OSO: GRID POWER WILL NOT CHARGE BATTERY 
07
Battery Charge Current 
60Adc per eFlex MAX/eFlex
08
Battery Type
L16
09
Battery boost charge voltage (Bulk & Absorption)
55.2V
10
Boost Charge duration
60min
11
Battery floating charge voltage 
54V
12
Battery over-discharge Protection voltage (delayed shutdown)
48V
13
Battery over-discharge delay time 
50s
WHEN THE BATTERY VOLTAGE DROPS BELOW THE THRESHOLD SET IN PARAMETER ITEM 12, THE INVERTER WILL WAIT FOR THE DELAY TIME SET IN THIS PARAMETER BEFORE SHUTTING OFF THE OUTPUT. 

SETTING RANGE: 5S – 50S 

ADJUSTMENT STEP: 5S 

PURPOSE: THIS DELAY PREVENTS UNNECESSARY SHUTDOWNS DUE TO TEMPORARY VOLTAGE DIPS, ENSURING STABLE SYSTEM OPERATION WHILE STILL PROTECTING THE BATTERY FROM OVER-DISCHARGE
14
Battery under-voltage alarm threshold
51.2
WHEN THE BATTERY VOLTAGE IS LOWER THAN THE THRESHOLD, IT WILL GIVE AN UNDER-VOLTAGE ALARM AND THE OUTPUT WILL NOT SHUT DOWN. SETTING RANGE: 40 V−52 V, WITH A STEP OF 0.4 V
15
Battery over discharge protection voltage
48
16
Battery equalization charge
DIS (Default)
DIS: DISABLE EQUALIZATION CHARGE 

ENA: ENABLE EQUALIZATION CHARGE, ONLY AVAILABLE FOR FLOODED LEAD-ACID BATTERIES, SEALED LEAD-ACID BATTERIES, AND USER-DEFINED ONES 
32
RS485 Communication Function
CAN
33
BMS communication
FOR
35
Battery under-voltage recovery threshold 
51.2
37
Battery Recharge Voltage
51.2
39
Charge current limit (Communicate with BMS) 
LCBMS (default)
LCSET: THE MAXIMUM BATTERY CHARGE CURRENT IS NOT GREATER THAN THE SET VALUE OF “07” 

LCBMS (DEFAULT): THE MAXIMUM BATTERY CHARGE CURRENT IS NOT GREATER THAN THE MAXIMUM BMS ALLOWED CURRENT 

LCINV: THE MAXIMUM BATTERY CHARGE CURRENT IS NOT GREATER THAN INVERTER ALLOWED CURRENT 
40-45
Start and End Charge time 1,2,3,
00:00:00
46
Timed battery charge function
DIS
DIS (DEFAULT): DISABLE THE FUNCTION 

ENA: WHEN THE TIMED GRID CHARGING/LOAD SUPPLY FUNCTION IS ENABLED, THE POWER SUPPLY MODE WILL OPERATE BASED ON THE CONFIGURED TIME PARAMETERS AND BATTERY STATE (RANGE  0:00:00−23:59:00)

1. OPERATING MODES 

SBU MODE ACTIVATION: THE SYSTEM WILL OPERATE IN SBU MODE WHEN TIMED GRID CHARGING IS ENABLED. THE INVERTER WILL PRIORITIZE SOLAR (S) AND BATTERY (B) POWER, SUPPLYING LOADS FROM THESE SOURCES. WHEN THE SYSTEM REACHES THE CONFIGURED CHARGING PERIOD OR THE BATTERY ENTERS AN OVER-DISCHARGE STATE, IT WILL SWITCH TO GRID (U) POWER FOR BATTERY CHARGING. 

UTI MODE ACTIVATION (WITH TIMED DISCHARGE ENABLED): IF THE TIMED DISCHARGE FUNCTION IS ALSO ENABLED, THE SYSTEM WILL SWITCH TO UTI MODE. IN THIS MODE, THE INVERTER: USES GRID POWER FOR BATTERY CHARGING ONLY DURING THE SET CHARGING PERIOD. SWITCHES TO BATTERY INVERTER OPERATION DURING THE CONFIGURED DISCHARGE PERIOD OR IF THE GRID POWER IS LOST. 
47-52
Start and End discharge time 1,2,3
00:00:00
53
Timed battery discharge function
DIS
DIS (DEFAULT): DISABLE THE FUNCTION 
ENA: AFTER THE TIMED BATTERY DISCHARGE FUNCTION IS ENABLED, THE POWER SUPPLY MODE WILL BE CHANGED INTO UTI, WHERE THE SYSTEM ONLY SWITCHES TO THE POWER SUPPLY OF BATTERY INVERTER DURING THE SET DISCHARGE PERIOD OR GRID FAILURE
58
SOC setting for discharge alarming 
25%
WHEN THE CAPACITY IS LESS THAN THE SET VALUE, THE SOC ALARMS (UNIT: %, ONLY AVAILABLE DURING NORMAL BMS COMMUNICATION)
59
SOC setting for discharge cutoff
20%
WHEN THE CAPACITY IS LESS THAN THE SET VALUE, THE DISCHARGE STOPS (UNIT: %, ONLY AVAILABLE DURING NORMAL BMS COMMUNICATION)
60
SOC setting for charge cutoff
100%
WHEN THE CAPACITY IS GREATER THAN THE SET VALUE, THE CHARGE STOPS (UNIT: %, ONLY VALID DURING NORMAL BMS COMMUNICATION)
61
SOC setting for switching to grid 
25%
WHEN THE CAPACITY IS LESS THAN THE SET VALUE, IT SWITCHES TO GRID (UNIT: %, ONLY AVAILABLE DURING NORMAL BMS COMMUNICATION)
62
SOC setting for Switching to inverter Output
100
WHEN THE CAPACITY IS GREATER THAN THE SET VALUE, IT SWITCHES TO THE INVERTER OUTPUT MODE (UNIT: %, ONLY AVAILABLE DURING NORMAL BMS COMMUNICATION)
73
Max charging current by generator 
80Adc

Schneider
Note: Master battery will not have frames 6&7 ON even when successfully connected.
      
      1. Make sure your Insight home has firmware v1.17
      2. Make sure that Insight Home is reading the battery internal parameters.

      3. Associate Battery as House Battery Bank 1

Parameter settings

PARAMETER
VALUE
CHARGER SETTINGS
RECHARGE VOLTAGE
51.2V
RECHARGE SOC
20%
RECHARGE DELAY
60s
BATTERY SETTINGS
BATTERY TYPE
LI-ION
CHARGE CYCLE
EXTERNAL BMS
SOC CONTROL ENABLE
ENABLED
BATTERY BANK CAPACITY
105aH per eFlex/eFlex MAX
MAXIMUM CHARGE RATE
100%
MAXIMUM BULK CHARGE CURRENT
55A per eFlex, 63A per eFlex Max
MAXIMUM ABSORPTION CHARGE CURRENT
55A per eFlex, 63A per eFlex Max
MAXIMUM FLOAR CHARGE
55A per eFlex, 63A per eFlex Max
DEFAULT BATTERY TEMPERATURE
WARM
ABSORPTION TIME
3600
BULK/BOOST VOLTAGE
55.2V
ABSORPTION VOLTAGE SET POINT
55.2V
MAXIMUM DISCHARGE CURRENT
60A per eFlex /84A Per eFlex Max
MAXIMUM DISCHARGE TIME INTERVAL
8s
LOW BATTERY CUT OUT
48V
LOW BATTERY CUT OUT DELAY
10s
LOW BATTERY CUT OUT HYSTERESIS
2
LOW BATTERY CUTOUT WARNING OFFSET
2
HIGH BATTERY CUT OUT
58V
CHARGE CYCLE TIMEOUT
1440s
HIGH SOC CUT OUT
99%
HIGH SOC CUT OUT DELAY
2s
LOW SOC CUT OUT
15%
LOW SOC CUT OUT DELAY
60s

Victron
Setup steps

OUTBACK INVERTER INTEGRATION GUIDE
Share Your OpticsRE online monitoring with Fortress Power. Sharing OpticsRE with Fortress Power Log into OpticsRE and Click on “My Profiles” in the side menu. Click on the Gear icon next to the site name. 


Add “techsupport@fortresspower.com as an Admin profile


Unpack batteries and check voltage
      1. Unpack the batteries and turn each battery on by itself. 
      2. Note the voltage of each battery and serial number. The serial numbers are useful during warranty submittal.
      3. The batteries must be within +/-0.5V of each other before commissioning. Groups of 4 batteries or more may require a narrower voltage range to commission properly.
      4. Turn off the batteries and install them in parallel.

Notes:
If the battery voltages are significantly different, one technique is to finish battery installation and only turn on the lowest voltage battery using the push button. Charge the battery, and when the charging voltage is ~0.2V above the resting voltage of the next lowest battery, turn it on too. Proceed until all batteries are turned on and at the same voltage level. If the batteries are below 51V, keep charging amperages below 10A per battery. 
If the batteries are slightly more than +/-0.5V from each other, turning on the highest voltage batteries will only reduce their voltages, and turning on the lowest voltage batteries will only lower the highest voltage. Likewise, turning on the lowest voltage batteries as a group will raise the lowest voltage. Then, all the batteries can be turned on within a 0.5/V difference. 
Use of the Fortress firmware update tool can help speed up commissioning times. Fortress installers should request a firmware update tool by filling out a support ticket at https://support.fortresspower.com 

Radian Inverter Settings
Inverter
80% DoD, 6000 cycles 
Absorb Voltage and Time 
55.2 Vdc/ 2.0hr 
Float Voltage and Time 
54.4 Vdc / 0.0 hr 
*Only float with w/inverter if charge controllers unavailable 
Re-float Voltage 
52.4 Vdc 
*Increase by 1V if charge controllers unavailable 
Re-Bulk Voltage 
51.2 Vdc 
*Increase by 1V if charge controllers unavailable 
AC Input Mode  
Grid Tied (default, adjust as needed) 
AC Charger Limit in AC 
eFlex:50Aac per battery
Low Battery Cut- Out Voltage
51V *user adjustable 
LBCO Delay 
130 seconds *user adjustable 
Low Battery Cut-in Voltage 
51.8 *user adjustable 
High Battery Cut-Out Voltage
56V 
HBCO Delay 
10 seconds 
High Battery Cut-in Voltage 
55.2V 
SellRE (Offset) Voltage Max
51.6V for “zero-outflow”, 53.6V for selling at “100% full” 
Temp Sensors
Do not use temperature sensors / reduce any temperature coefficients to as close to zero as allowed 

FM60/80/100 Charge Controller Settings
Charge Controller 
Absorb Voltage and Time 
55.2, 1 hours 
Float Voltage 
54.4 
Rebulk Voltage 
52.5
DC Current Limit  
eFlex Max: 55A per battery ÷ # of controllers 
Absorb End Amps
1A 

FlexNET DC Settings
FLEXnet DC (FN-DC) 
If FLEXNET DC display voltage is not within 0.1V of inverter terminal voltage, calibrate Outback equipment  
Battery Amp hour 
eFlex Max:105Ah per battery 
Charged Voltage 
54.0V 
Charged Time 
15 minutes 
Charged Return Amps 
1A 
Battery Charge 
96% 
Relay Invert Logic 
No *User adjustable 
Relay Voltage 
High = 53.8 ; Low = 51.2 *User adjustable 
Relay Delay 
High = 1, Low = 0 *User adjustable 
MATE3/MATE3s 

FLEXnet DC Advanced
Low SOC Warning = 20% *User adjustable 
FLEXnet DC Advanced 
Critical SOC Warning = 10%*User adjustable 

Calibrating Outback Systems
Calibrating the battery literally means charging the battery 100% full and confirming the battery resting voltage is above 54V.  This can be done onsite or remotely. 
Calibration is not a regular task. Good times to calibration are:

System commissioning
Occasionally when batteries are kept 80-100% full 
deep discharge recovery 
extended periods of overcast / low production days 
anytime when the % state-of-charge says 100% but battery voltage is below 54V  

Conforming calibration is easiest to do online but can be done onsite.
1) Go to OpticsRE.
2) Reduce all system loads and charging to a bare minimum, including charge controllers.  
3) Determine the battery voltage on the inverter terminals. 
4) Calibrate the charge controllers to match the inverter terminals.
5) Determine if the FlexNET DC also needs calibration and follow this link for further instructions: