Instruction/ maintenance manual of the product MX60 Outback Power Systems
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MX60 PV MPPT (Maximum P ow er P oint T racking) Charge C ontroller Installation, Prog ramming and User ’ s Manual.
2 W arranty Summar y Dear OutBack Customer , Thank you for y our purchase of OutBack pr oducts. W e make ever y e or t to assure our power conversion pr oducts will give you long and r eliable ser vice for your r enewable energy system.
3 The OutBack P ower Systems MX60 PV MPPT Charge C ontroller is ETL listed to UL1741 (Inver ters, C onvert- ers, Contr ollers, and Interconnection System Equipment f or Use with Distributed Energy Resources). It is also in compliance with European Union standards EN 61000-6-1 and EN 61000-6-3 (see page 87).
4 T ABLE OF C ONTENTS INTRODUC TION .................................................................................................................. ...................................................................... 6 INST ALLA TION GUIDELINES AND SAFE T Y INSTRUC TIONS .
5 Absorb Time Limits ........................................................................................................... ..........................................................47 W akeup Mode ................................................
6 SC OPE The manual provides saf ety guidelines and installation information for the MX60 PV MPPT Charge Controller . I t does not provide inf ormation about speci c brands of solar panels and supplies limited information on batteries . Contact the supplier or manufacturer of the solar panels or batteries for further information.
7 INST ALLA TION GUIDELINES AND IMPORT ANT SAFET Y INSTRUC TIONS SA VE THESE INSTRUC TIONS This product is intended to be installed as part of a permanently grounded electrical system as shown in the .
8 W ARNING - WORKING IN THE VICINIT Y OF A LEAD ACID BA T TERY IS DANGEROUS. BA T TERIES GENERA TE EXPL OSIVE GASES DURING NORMAL OPERA TION. Design the battery enclosure to prevent accumulation and concentration of h ydrogen gas in “pockets ” at the top of the enclosur e.
9 OPEN CIRCUIT VOL T A GE/WIRE AND DISC ONNEC T SIZING Maximum Open Circuit V oltage ( V oc) • V oc is the unloaded voltage generated by the solar array .
10 Use up to 2 A WG (6.54 mm) wire and torque to 30-inch pounds/3.38 Nm at terminals. MA TE/HUB RJ45 jack If attaching to ply- wood, use a 1 5/8” wood screw to secur e the MX60 at the top slotted hole and other screws as needed at interior bottom holes.
11 NO TES • An optional battery Remote T emperature Sensor (RTS) is recommended for accurate batter y rechar ging (only one RTS is needed for multiple OutBack Series Inverter/Chargers and MX60 units when an OutBack HUB and a MA TE are parts of the system).
12 Figur e 2 MX60 WIRING DIAGRA M without ground fault pr otection—the ground conductors tie into the negative..
13 Figur e 3 MX60 WIRING DIAGRA M with ground fault pr otection—the GFP/2 requires a separate g round bus bar ..
14 BA T TERY SYSTEM VOL T AGE • The MX60’ s default setting is for a 12 VDC battery. • Change the setting after powering up the MX60 if a di erent battery voltage is used. • The PV array voltage—which must not exceed 150 VDC open cir cuit—is automatically detected .
15 POWERING UP The MX60 power-up sequence rst activates the unit and brings up a series of screens; some screens allow the user to change the batt er y voltage. NO TE: Be sure the PV input and batter y breakers are o before starting the power-up sequence.
16 P ower-Up Screen Release both soft ke ys when the OutBack P ower Syst ems screen appears. The selected batter y voltage appears in the upper right hand corner . The B A T TERY VOL T A GE screen will appear next. NO TE : The MX60 designation in the lo wer left corner will read MX60A U for A ustralian versions and MX60ES f or Spanish versions.
17 Battery Voltage Screen Pr ess the “ soft ke y to select a battery voltage. The MX60’ s default values are based on a 12 VDC system. Selecting a higher voltage system will change all the default values (e.g ., the values will double with a 24 VDC system, triple with a 36 VDC system, etc .
18 ST A TUS SCREEN The ST A TUS screen displays system inf ormation. See page 67 for detailed inf ormation of the di erent Operational Modes. The optional OutBack MA TE displays MX ST A TUS screens f or convenient distant viewing from the installation location of the MX60.
19 PREP ARING FOR RECHARGING T urn the PV input breaker on. The MX60 automatically detects the PV input voltage. (NO TE: If P V voltage r egisters “000V ” when the breaker is on, please check the polarity of the P V wires .
20 AC CESSING THE MAIN MENU The MAIN Menu allows the user to adjust and calibrate the MX60 f or maximum per formance . F rom the ST A TUS screen, press soft key #1 to open the MAIN Menu screen. Pr ess the < GO > soft key af ter aligning the ast erisk in front of the selected menu choice.
21 CHARGER SETUP This screen allows changes to the MX60’ s recharging v oltage set points (Current Limit, Absorb, F loat): • The pr esently selected numerical value will have an asterisk “ * ” to the left of it. • P ressing selects the value to be changed.
22 A UX MODE The AUX i s a secondary control circuit—essentially , a small power supply that pr ovides a 12 VDC (up to 200 milliamps) output current. It is either ac tive (12 VDC on) or inac tive (12 VDC o ). • T o access the AUX MODE from the MAIN Menu , press the < >soft key until the asterisk is in front of the A UX selection.
23 A UX MODE P ath • Press the #1 soft key once from the ST A TUS Menu to open the MAIN Menu. • Press either of the arro w soft ke ys until the “*” is to the left of Aux.
24 A UX modes in order of appearance on the MX60 display: • Manual • V ent F an • PV T rigger • Float • Error Alarm • Diversion • L ow Battery Disconnect • Remote The most commonly use.
25 Pr ogramming the A UX MODES Pr ess the < ON > or < OFF > soft keys to manually ac tivate or deactivate AUX MODE . P r ess the < NEXT > soft k ey to view the V ent F an scr een. T o view other screens, continue to press the < NEXT > soft key.
26 Pr ess the < NEXT > soft k ey to advance to the PV T rigger sof t screen. When the PV input is too high and exceeds the user- determined VOL T set point, the AUX MODE PV T rigger activates. P ress the < VOL T > soft key to adjust the voltage.
27 T o adjust the minimum amount of time the PV voltage must remain high bef ore deactivating the A UX MODE , press the < TIME > soft key. Pr ess the < - > or the < + > soft key to adjust the Hold Time, then press the < BA CK > soft key to return to the PV T rigger screen.
28 The default state of the ERROR ALARM is On, meaning 12 VDC is present at the A UX terminal. If the MX60 has not charged the batteries f or 26 hours or more continuously , the inaudible ERROR ALARM goes into an O state. The ERROR ALARM is intended for remote locations t o signal (e.
29 Pr ess the < TIME > soft key to advance to the Time screen which allows the user to adjust the minimum time the A UX MODE is active after the batter y voltage falls below the Hysteresis voltage. Hold T ime shows how long the AUX MODE stays active after the batter y voltage has fallen below the HYST (Hysteresis) set point.
30 Figur e 5 Diversion L oad and AUX Wiring Set-Up Illustrated.
31 Pr ess the < NEXT > soft ke y to view the L ow Batt(ery) Disconnect screen. When the batter y voltage falls below the disconnect volts, the A UX c onnected loads only are disconnected; the loads are On when the batt er y voltage rises above the reconnect volts.
32 In the Lo w Batt Disconnect screen, press the < VOL T > soft key to adjust the batter y voltage disconnects set point. Pr ess either the < - > or the < + > soft key to adjust the disconnect voltage. P ress the <ReC on> soft key to open the RE-CONNECT VOL T S screen.
33 Pr ess the < NEXT > soft ke y to view the Remote screen. In Remote A UX MODE, the OutBack MA TE can control the MX60’ s AUX MODE . P ress the EXIT soft key twice to return to the MAIN Menu screen. Pr ess the < > soft key to move the asterisk to the Light option.
34 BACKLIGHT AU TO (default) leaves backlight and soft k eys on for 60 seconds whenever any soft key is pressed (pressing an y soft ke y when the L CD is not lighted does not change any settings).
35 Pr ess either the < –EQV > or < +EQV > soft key to change the EQ voltage, f ollowing your battery manufac turer’ s rec- ommendations. Note that the factory default EQ voltage is set low , the same as the factor y default Absorb voltage.
36 Use the < -DA Y > and < +DA Y > soft keys to preset the inter val day to initiat e an automatic equalization cycle. The EQ INTER V AL displays the number of days in the inter val between cycles and COUNT displays how many days of the interval have passed.
37 MISC—MISCELLANEOUS The MISCELLANEOUS screens display extra settings and technical inf ormation, some of which is useful for OutBack P ow er Systems T echnical Ser vices. The GT (Grid-tie) value is sent from GT series inverter through the MA TE and HUB for Grid-tie control com- munications.
38 WIDE/LMIT Batter y T emperature Compensat ed Limits During cold weather , a batter y often requires a higher rechar ging voltage . Low er quality inverters might not accommodate these higher voltages and can shut down during rechar ging , cutting o power to their loads .
39 Setting LMIT Upper and Low er Set Points In the DISCONNECT VOL TS screen, press the < -> or <+ > soft ke y to adjust the battery voltage range limits.
40 When the Upper Limit is displayed , the desired compen- sated voltage has been stor ed and the < - > and < + > soft ke ys can be released . After setting these limits, A UX MODE should be set to Manual (default setting) if not used. NO TE: WIDE/LMIT voltages are not applicable in the Equalize charg ing mode.
41 After con rming the Upper Limit and L ow er Limit voltages, pr ess the < > soft key in the MAIN M enu. Pr ess the < GO > soft key to advance to the rst MISC screen. F rom this screen, y ou can access MISCELLANEOUS Screen 2 . F rom the MISC scr een, press the < NEXT > soft key to view the FORCE, FL OA T , or BULK scr een.
42 MISCELLANEOUS Screen 3 This is the assigned number representing the t emperature of the internal components to control the cooling fan. The lower the number , the higher the temperature . 25° C is ap- proximat ely a value of 525. The Err(or) count increas- es hourly if the MX60 has not charged the batteries for 26+ hours continuously .
43 ADV ANCED The ADV ANCED Menu allows ne -tuning of the MX60 operations including “Snooze ” periods and Maximum Po wer P oint limits. In order of appearance, the f ollowing modes occur in the.
44 Auto Sweep MPPT Mode (see page 46) seeks the solar array ’ s maximum available voltage to rechar ge the batteries. The MX60 is best lef t in this default mode f or most recharg ing purposes.
45 The Sweep Interval mode or mini-sweep determines how often a sweep occurs, rang ing from 0-15 minutes . A sweep is a search f or the best MPP for the array . At zero minutes, the MPPT mini-sw eep function is disabled (this is not recommended f or PV arrays).
46 L ow Cuto sets the batter y charger ’ s lowest allowable current limit the MX60 will charge in MPPT mode bef ore stopping and returning to Snoozing . The Low C uto is adjustable from .2 amps to 1 amp; .6 amps is the default L ow Cuto cur rent.
47 In the Absorb T ime Limits screen, the user can set the minimum and maximum times the MX60 stays in the Absorb recharge cycle. MAXimum is adjustable from 0 to 4 hours . MINimum is adjustable from 0 minutes (the default) up to the MAX Absorb T ime Limit minus 10 minutes.
48 W akeup Mode selects how often the MX60 does a W akeup during “Snoozing” per iods. Since en vironmental condition impact the open circuit voltage ( V oc) of an array , a user selectable V oc rise in value will allow the controller to W akeup sooner or later based on the last measur ed V oc value.
49 (DA T A) L OGGING The MX60 records batt er y oat and daily k ilowatt-hour (kWh) inf ormation for the previous 64 da ys. This data can be compared, f or instance, with w eather reports to con r m the MX60’ s per formance.
50 Clearing T otals and Daily Stats • Pr essing and holding <T O TL> for thr ee seconds brings up the Are you sure? screen, pr ompting you to clear the total accumulated kWh and kAh statistical values in the MX60.
51 L OG2 The Lo g 2 screen displays additional voltage and time inf ormation. Daily high Vo c value Daily peak batter y voltage Operational mode The Hi(ghest) V oc seen by the MX60 Sunrise shows how long ago the MX60 woke up for the rst time each day and when the daily and total logged values wer e updated and cleared fr om the ST A TUS screen.
52 Auto Restart Pr essing and holding the #4 soft key for several seconds selects among the three MX60 Auto ReStar t modes: 0, 1, and 2 (default). Auto ReStar t allows the MX60 to per form internal r ecalibrations and eliminate any pos- sibility of soft ware errors .
53 Secondar y L OG2 S creen The Secondary Log2 scr een shows the basic recharg ing state of the MX60 (EQ , FL OA T ) time in minutes, and the daily maximum (HighW atts) wattage seen by the MX60 during the day . When initiated, EQ information will be displayed her e.
54 MICRO-HYDRO , WIND TURBINE, AND FUEL CELL APPLICA TIONS The MX60 is designed to work with solar arrays . Although it will work with micro-hydro and fuel cell , OutBack P ower Systems can only o er limited technical support for these applications because there is too much variance in micro-hydr o and fuel cell generator speci cations.
55 T o adjust these values and enhance the per formance of these systems , use the MX60 ADV ANCED MENU to make changes. T o determine your micro-hydro or fuel cell system ’ s best settings for MPP voltage, do the f ollowing: 1. Use Auto Sweep and record the watts yielded .
56 ADV ANCED MENU (M icro-Hydro) Mpp R ange Limit % (A uto Sw eep Mode only) The MX60 searches f or the MPP voltage by sweeping the input v oltage up to one half (default) of the V oc, which is based on values appr opriate for a solar array . M icro-hydr o and fuel cell systems can require a br oader range, normally on the lower end .
57 In the ADV ANCED MENU screen, press the < NEXT > soft key until the M pp Range Limit % VOC screen appears. Pr ess the < 1/2 > soft key until FULL appears. When nished, press the < NEXT > soft key to go to the Sweep Interval screen.
58 Pr ess the < -VOC > or < +VOC > soft key to select one of the 13 xed percentage values. P ark M pp applies to Auto Sweep Mode if the output current is less than 5 amps; U-Pick always uses the P ark M pp v alue. P ress the < NEXT > soft k ey until the MPPT Mode screen appears.
59 In the ST A TUS screen, press the #3 and #4 soft keys simul- taneously to per form a Mini-Sweep. The MX60 will track the new MPP based on the xed percentage value. P er- form a Mini-Sweep any time a change to the input sys- tem or the P ark Mpp xed percentage value is changed.
60 * Charger Aux Light EQ Misc Advanced Logging Log2 EXIT GO Adjusts the Curr ent Limit, Absorb , and Float recharg ing voltage set points A UX control includes: • Manual • Vent F an • PV T rigg.
61 APPLICA TION NO TES OutBack P ower S ystem GTFX/GVFX Grid-tie settings In a GFX/GVFX series inver ter , MX60, HUB, and MA TE installation set the MX60 to GT mode in the ADV ANCED MENU.
62 CALLING THE F ACTOR Y FOR ASSIST ANCE When calling OutBack P ower f or product assistance, please have the f ollowing inf ormation ready : • MX60 serial number and sof tware version ( The software version can be viewed by pr essing the #1 soft ke y on the ST A TUS screen and then pressing a second time and holding the soft key down.
63 SPECIFICA TIONS Output Current Rating 60 amps continuous @ 25°C ambient Default Batter y System V oltage 12, 24, 36, 48 or 60 VDC (adjustable) PV open circuit voltage 150 VDC Maximum (ETL R ating .
64 *The MX60’ s maximum current output at 25°C is 60 amps. In higher ambient temperatures, the MX60’ s current limit should be reduced in or der to prev ent possible damage to the unit.
65 MX60 Curr ent V s T emperature (all temps C elsius) Ambient T emperature Maximum Current (amps) 25 60.00 30 57.45 35 54.77 40 51.96 45 48.99 50 45.83 55 42.43 60 38.73 65 34.64 70 30.00 75 24.49 80 17.32 T able 1 An easy de -rating rule to use in lieu of the abov e table is “1 amp per degree C.
66 MX60 EFFICIENCY vs. INPUT POWER GRAPH Figur e 6 24V and 48V Batter y System E ciency Curve.
67 UNDERST ANDING THE V ARIOUS OPERA TIONAL MODES The MX60 modes of operation will change occasionally during the day based on the PV array output and the batter y system state of char ge. The MX60 operating modes are displayed at the bottom right hand corner of the ST A TUS screen.
68 Bat T mp Err The batter y temperatur e sensor is shor ted or damaged. EQ 0:00 This is the time elapsed in hours and minutes since the Equalization v oltage was met. If the EQ voltage set point is not maintained, the controller will r ever t back to EQ-MPPT – the EQ timer will pause until the batteries are regulat ed at the EQ target again.
69 Low Light / Snoo zing During the initial sweep (see W akeup and Sweeping) , if it is det ermined to be too late (or too early) in the day , the MX60 will display Low Light f or a few seconds and then display Snoozing f or 5 minutes (default). This reduces energy usage and unnecessar y powering of the MX60.
70 W akeup As the PV open circuit v oltage ( Voc) rises above the batt er y system voltage by two volts , the MX60 prepares t o deliver power t o the batteries. During this period, the MX60 is calculating the pulse width modulation (PWM) duty c ycles, turning on power supply voltages in the pr oper sequences, and making inter nal calibrations.
71 MA TE-DISPLA YED MX60 ST A TUS MODE Screens The MX60 ST A TUS MODE Screens displayed on the optional OutBack M A TE include MODE, METER , and SET (SETPOINT ). I n ST A TUS Mode, these MX functions can be viewed by the MA TE, but not changed. Please see the MA TE Installation and User Manual for more information.
72 MA TE-DISPLA YED MX60 ST A TUS METER Screens MX METER S creens • mode/pv/in/bat/out: displays the charger mode, the PV array voltage , the incoming PV amps, the batter y voltage , and the outgoin.
73 MA TE-DISPLA YED MX60 ST A TUS SETPT (SE TPOINT ) S creens Pr ess the rst two soft k eys simultaneously to return to the MAIN Menu or press < ST A TUS > and then press < MAIN > on the S T A TUS screen.
74 TROUBLESHOO TING GUIDE MX60 does not boot/power-up (blank L CD) • Check the batter y connection and polarity. Reverse polarity or an improper connection will cause power-up issues. • Check the batter y breaker . Ensure that the battery breaker is sized appropriately .
75 MX60 not producing expected power • Clouds, par tial shading, or dirty panels can cause poor per formance. The lower current limit set point in the Char ger menu will yield a loss of power or poor per formance symptoms .
76 • The EQ cycle has been initiated, but the battery is not equalizing. T he EQ cycle will begin when the target EQ set point voltage has been r eached. A small array or cloudy weather will delay the EQ cycle. Accor dingly , running too man y AC and/or DC loads will delay the EQ c ycle, too .
77 T YPICAL ARRA Y SIZING GUIDE Below is a list of recommended array sizing f or the MX60 for various nominal voltage batteries: Nominal Batter y V oltage Recommended Array Size (in watts, Standard T .
78 ST ANDARD v s. A USTRALIAN DEF A UL T SE T TINGS The Australian version MX60 has a f ew default settings that di er from the Standard version default settings. However , there are no di erences in performance and e cienc y between the two versions.
79 T o meet NEC compliance, the largest PV array that can be connected to the MX60 should hav e a rated short- circuit current of 48 amps . The f ollowing char ts show the maximum distance of various gauge two- conductor copper wire from the PV array to the MX60 with a 1.
80 60 V olt PV Array 80V MPP T ypical 12, 24 or 48 V olt Battery System 72 V olt PV Array 96V MPP T ypical 12, 24 or 48 V olt Battery System METRIC #8…8.
81 WIRE AND DISC ONNEC T SIZING The MX60 has a 60 amp current output limit (default) and is listed to operate continuously at 60 amps depending on the nominal PV array voltage and the nominal batter y voltage . There is no 80% de -rating as requir ed by the NEC* for fuses , conductors, and most circuit br eakers.
82 Figur e 7 MX60 MUL TI-ST AGE BA T TERY CHARGING The MX60 Charge Contr oller is a sophisticated, multi-stage battery charger that uses several regulation stages to allow fast rechar ging of the battery system while ensuring a long batter y life. This process can be used with both sealed and non-sealed batteries.
83 BULK cycle provides the maximum pow er to the battery –the voltage increases while recharg ing. A Bulk cycle is automatically initiated when the batter y voltage is below the Absorb and F loat* recharge v oltage set points. The Bulk c ycle will continue until the Absorb voltage set point is achieved .
84 BA T TERY TEMPERA TURE C OMPENSA TED VOLA T GE SET POINT The temperature of a batt er y has an impact on the recharging pr ocess—in higher ambient temperatures , the regulation set points (Absorb & F loat) need to be reduced t o prevent over charg ing of the batteries.
85 SUGGESTED BA T TERY CHARGER SET POINTS The batter y manufacturer should pro vide you with speci c instructions on the following maintenance and voltage set point limits for the speci c batteries. The f ollowing information can be used when the manufacturer ’ s information is not available.
86 OWNER’S SYSTEM INFORM A TION Date of P urchase: ____________________________________________________________ V endor: ____________________________________________________________________ Date of .
87 EU DECLARA TION OF CONFORMITY According t o ISO / IEC Guide 22 and EN 45014 Pr oduct T ype: Photovoltaic Char ge Controller Pr oduct Model Number : MX60 This product complies with the following EU .
88 T WO YEAR LIMITED W ARRANT Y INFORMA TION MX60 P roducts OutBack P ower Systems, Inc. (“OutBack”) provides a two year (2) limited warranty (“ Warranty ”) against defects in materials and workmanship for its MX60 products (“Products ”) if installed in xed location applications .
89 T o request warranty ser vice, you must contact OutBack T echnical Ser vices at (360) 435-6030 or suppor t@ outbackpower .com within the e ec tive warranty period. If warrant y service is required, OutBack will issue a Return Material Authorization (RMA) number .
90 T wo Y ear Limited MX60 W arranty Registr ation Sy stem Owner Name: _______________________________ Countr y : ______________________________ Address: ______________________________ T elephone Numb.
91.
ww w .outback power .com 900-0028-01-00 REV D Corpora te Headquarters 19009 62nd Av enue NE Arlington, W A 98223 USA Phone: (+1) 360.435.6030 European Sales O c e C/ Castelló , 17 08830 - Sant Boi de Llobregat BARCEL ONA, España Phone: +34.93.654.
An important point after buying a device Outback Power Systems MX60 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Outback Power Systems MX60 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Outback Power Systems MX60 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Outback Power Systems MX60 you will learn all the available features of the product, as well as information on its operation. The information that you get Outback Power Systems MX60 will certainly help you make a decision on the purchase.
If you already are a holder of Outback Power Systems MX60, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Outback Power Systems MX60.
However, one of the most important roles played by the user manual is to help in solving problems with Outback Power Systems MX60. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Outback Power Systems MX60 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
