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Outback Power Systems MX60 User's Manual

1. TotalKWh AC is based on a 90 inverter efficiency 1kWH DC 0 9kWH AC Note Float time does not accumulate 1 when the MX60 is sleeping or 2 when an external power source keeps the battery above float voltage OutBack Power Systems Inc 54 MICRO HYDRO WIND TURBINE AND FUEL CELL APPLICATIONS The MX60 is designed to work with solar arrays Although it will work with micro hydro and fuel cell OutBack Power Systems can only offer limited technical support for these applications be cause there is too much variance in micro hydro and fuel cell generator specifications When used for micro hydro or fuel cell applications the MX60 warranty will be honored only if the manufac turer and turbine model have been approved by OutBack Power Systems Please check with one of the following manufacturers or OutBack Power Systems before employing the MX60 Harris Hydroelectric 831 425 7652 www harrishydro com Alternative Power amp Machine 541 476 8916 www apmhydro com Energy Systems amp Design 506 433 3151 www microhydropower com The MX60 is not compatible with wind turbine applications and OutBack cannot warranty its use in these applications MICRO HYDRO AND FUEL CELL SYSTEMS PERFORMANCE OPTIMIZATION Micro hydro and fuel cell systems are different than PV systems whose Voc output is more subject to change due to weather and time of day A PV system normally finds its Maximum Power Point voltage between 50 90
2. No sweeping occurs if the output current is under five amps because it operates at the Park Mpp value Sweeping does occur when the output current is higher than five amps or to maintain user current limit and to track the MPP of the array throughout the day A mini sweep is an accurate but less exten sive version of the full initial sweep done at wakeup Press the lt MIN gt soft key to decrease minisweep interval minutes or press the lt MIN gt soft key to increase the minutes Press the lt NEXT gt soft key to view the Vbatt Calibration screen A quality calibrated voltmeter will provide even more accurate MX60 battery voltage readings if an un desirable voltage drop is present When measuring battery voltage ensure a good connection is made to the Four Position Terminal Block Check the bat tery temperature compensation voltages if voltages are much different than you expect from the charger setup Absorb and Float voltage settings Use the lt V gt and lt V gt soft keys to match the readings from the voltmeter When finished press the lt NEXT gt soft key to view the next screen 45 ADVANCED MENU Low Cutoff lt 6 Amp EXIT NEXT AMP OOOO v A ADVANCED MENU MPPT Mode Auto Sweep EXIT NEXT nonGT MODE OO Oo y A A The default value is nonGT or non grid tied Select GT mode if you have a GVFX or GTFX inverter MATE and HUB connected to the MX60 Selecting GT estab lishes the proper grid
3. 62 ct CALLING THE FACTORY FOR ASSISTANCE When calling OutBack Power for product assistance please have the following information ready X60 Serial number and software version The software version can be viewed by pressing ot he 1 soft key on the STATUS screen and then pressing a second time and holding the soft key down D eat he nominal PV array and battery voltage he PV array operating voltage and battery current and any Status screen operational mode displays such as B MPPT F MPPT Absorbing or Float OutBack Power Systems Inc SPECIFICATIONS Output Current Rating gt Default Battery System Voltage gt PV open circuit voltage ___ gt Standby power consumption gt Recharging regulation methods gt Voltage regulation set points gt Temperature compensation _ gt Voltage step down capability gt Digital Display ____ gt Remote Interface _ gt Operating Temperature Range _ gt Environmental Rating _______ gt Conduit knockouts __ _ Warranty cb Dimensions _ gt Weight iH gt OutBack Power Systems Inc 60 amps continuous 25 C ambient 12 24 36 48 or 60 VDC adjustable 150 VDC Maximum ETL Rating for UL1741 Standard operational max 141 VDC tempera
4. INFORMATION THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER S RISK Date and Revision January 29 2007 REV 7 0 Software REV 5 10 and 5 11 Contact Information OutBack Power Systems 19009 62nd Ave NE Arlington WA 98223 Phone 360 435 6030 Fax 360 435 6019 www outbackpower com OutBack Power Systems Inc TABLE OF CONTENTS INTRODUCTION 6 INSTALLATION GUIDELINES AND SAFETWVINSTRUCTIONS 7 EE EE SUNS EE 8 OPEN CIRCUIT VOLTAGE WIRE AND DISCONNECT SIZING ssssssssessssussssessssssessusssssssunssessusssssusssssstansssssinssssee 9 BRECH GARE E E 14 EWERS 15 STATUS SG BEEN WE 18 PREPARING EO Ri RECHARGIN ees 19 ACCESSING THE MAIN MENU 20 CHARGER SETUP EE EN O 22 PINAL EE Ee 23 AUX Modes Desci DEO euena IESS EEEIEE Programming the AUX MODES ET EE TE 25 O dns inn 26 FLA A e E OO IA 27 Bee e 28 o APP 28 EP e rea EN O OE 31 eeeee er eer 33 E EE 34 A In 34 MISC MISCELLANEOOS cion ense 37 WIDE LMIT Battery Temperature Compensated Uimfts 38 ADVANCED encacccconacos Snooze Mode FAIA O S AA y E 44 MPPRaNO Elle A a EEEE eo 44 EE ENEE 45 Voa ol A A E E 45 ebe 46 MASSA o Pp Pe 46 O aa 47 Wakeup Si aso anna 48 OutBack Power Systems Inc LO e Secondary LOG2 Screen MICRO HYDRO WIND TURBINE AND FUEL CELL APPLICATIONS conocio 54 ADVANCED MENU MiCro Hyr0 cinco enero 56 MAOO ABBREVIATED MENU MAP e 60 EE el ECHTEN ee 61 FACTORY ASSISTANCE rr da 62 SE Ee 63 UNDERS
5. Name Address City State Zip Code Country Telephone Number E mail Sold by Installer Purchase Date Serial Number Check all that apply Model Number gt Off Grid Installation Grid Tie Installation Residential Installation gt Commercial Installation EXTENDED WARRANTYAPPLICATION OutBack Power Systems offers an optional three year extension to the standard two year limited warranty Purchase of extended warranty coverage is available on products listed below provided conditions shown are met Extended warranty coverage must be purchased within 90 days of the original sale ofthe product covered WA state residents please add 8 5 sales tax PRODUCT All FX Series Inverter Chargers MX60 MATE HUB 4 HUB 10 Products Covered OutBack Power Systems Inc REQUIRED SURGE PROTECTION AC Input AC Output DC Input DC Input DC Output NA NA NA Serial Number EXTENDED WARRANTY COST 300 00 100 00 50 00 35 00 50 00 Extended Warranty Cost Total 91 Ciut Back Power Systems 19009 62nd Avenue NE European Sales Office Arlington WA USA Barcelona Espana 1 360 435 6030 34 600 843 845 www outbackpower com 900 0028 01 00 REV B
6. Off EXIT NEXT AUX MODE Low Batt Disconnect On EXIT NEXT TIME VOLT 23 24 AUX modes in order of appearance on the MX60 display Manual gt Vent Fan e PV Trigger gt Float Error Alarm e Diversion e Low Battery Disconnect e Remote The most commonly used AUX modes e Vent Fan Diversion e Low Battery Disconnect When an AUX MODE is ON 12 VDC is available at the AUX terminals and a condition such as a voltage set point is met Other modes can be programmed in lieu of the specific ones listed here but the Vent Fan mode is most easily changed e g to activate an alarm instead of a fan Here are the default AUX modes Manual pressing either the lt ON gt or lt OFF gt soft key manually activates or deactivates AUX Vent Fan when the Vent Fan voltage set point is exceeded the vent fan will run for at least 15 seconds the fan helps remove hydrogen from battery enclosure even if the set point is exceeded for only a few seconds due to a surge If the set point is exceeded for longer than 15 seconds the fan will stay on until the voltage drops below the set point It then takes 15 seconds before the fan shuts off This is an external fan and not to be confused with the MX60 s internal thermally activated fan which cools the unit PV Trigger activates an alarm or relay that disconnects the array when the PV input is too high and exceeds the user determined vol
7. bottom right hand corner of the STATUS screen Absorb EX There is an external DC source other than solar keeping the battery above the Absorb set point The MX60 will not be producing power Absorbing The MX60 is in the Absorb constant voltage charge stage regulating the battery volt age at the Absorb set point modified by battery temperature compensation if installed During this cycle the ChgT counter in the Misc menu is counting down towards zero If the system cannot regulate the battery voltage at the Absorb voltage set point then the MX60 reverts back to the Bulk charge stage display B MPPT and the ChgT counter will start counting up again towards the MAX Absorb time set point or until the Absorb target is met AutoStart Auto Re Start Mode 1 Once every 1 5 hours in Bulk cycle and in Mode 2 once every 1 5 hours in the Bulk Absorb and Float recharging modes the MX60 will start over from sleeping and re sweep full sweep and re calibrate the current sensor Mode 0 is disabled completely It is recommended that this mode be left to mode 2 Auto Re Start in all 3 recharging cycles See Log2 screen Bat gt Abs When the PV voltage exceeds the battery voltage by 2V and the battery voltage exceeds the absorb set point the MX60 has no need to recharge This can also unintentionally occur if the user inputs a lower battery voltage than is actually in use e g establishing set points for a 12V system when a 24V battery bank is use
8. of its Voc The default value for the MX60 is 77 of a solar array s Voc and is displayed on the Park Mpp screen A microhydro or fuel cell system s MPP voltage can be outside of this range The MX60 allows a user to experiment and find more appropriate set points to best capture the MPP voltage If the output current is under five amps Auto Sweep will park the voltage using whatever percentage value is displayed in the Park Mpp screen Otherwise Auto Sweep begins sweeping the Voc output and works its way down until the optimum percentage of input voltage yields the MPP voltage If U Pick Voc is chosen the MPP is calculated by whatever value is found in Park Mpp even if it s not the optimal value for determining the MPP voltage For this reason OutBack normally suggests leaving the system in Auto Sweep mode and the 77 default percent age value but recommends experimenting with changing this value when a micro hydro or fuel cell system is in use OutBack Power Systems Inc To adjust these values and enhance the performance of these systems use the MX60 ADVANCED MENU to make changes To determine your micro hydro or fuel cell system s best settings for MPP voltage do the following 1 Use Auto Sweep and record the watts yielded This value should be in line with your generator capacity 2 Switch to U Pick Voc mode and input different Park Mpp percentage values checking the watts value for each This will require some
9. 1 and 2 default Auto ReStart B MPPT Sunrise Se EXIT NEXT 00 06 12 allows the MX60 to perform internal recalibrations and eliminate any possibility of software errors To O O O O change the mode release the 4 soft key and press and hold again y A A Mode O Auto ReStart mode is disabled the 0 Auto Restart MX60 recharges continuously from an available source and never Restarts Mode 0 would be chosen to avoid spinning a microhydro generator every 1 5 hours Mode 1 once every 1 5 hours when the MX60 is Wiere in Bulk it will briefly Restart and initiate a full panel sweep This will not reset any counters or charging Stages or statistics Mode 2 Auto ReStart every 1 5 hours in Bulk 2 Auto Restart Absorb and Float modes it will briefly Restart and initiate a full panel sweep This will not reset any counters or charging stages or statistics The MX60 sunrise related activity can be influenced During certain days of the year the sun never sets in parts of Alaska for instance and the PV output is constant The MX60 responds to these situations by generating its own sunrise reading at either 24 or 25 hours with 25 hours being the default value After this 24 or 25 hour period the MX60 automatically initiates a BULK cycle and logs the daily KiloWattHour AmpHour statistics and Float Time to be logged and accumulated in the Logging screen Pressing down and holding the third soft key then releasing and pre
10. Auto Sweep or U Pick MPPT Mode and determine the MX60 s operating Voc per centage press the lt NEXT gt soft key until the MPPT Mode Menu appears Press the lt MODE gt soft key to interchange between Auto Sweep and U Pick Voc modes Re entering the password might be required Press the lt NEXT gt soft key in the ADVANCED MENU until the Park Mpp screen appears 57 58 Press the lt VOC gt or lt VOC gt soft key to select one ADVANCED MENU of the 13 fixed percentage values Park Mpp applies Park Mpp to Auto Sweep Mode if the output current is less 17 VOC EXIT NEXT Voc Voc than 5 amps U Pick always uses the Park Mpp value Press the lt NEXT gt soft key until the MPPT Mode O O o screen appears y A A Note After adjusting the Park Mpp values the user must perform a mini sweep to activate these new values OutBack Power Systems Inc In the STATUS screen press the 3 and 4 soft keys simultaneously to perform a Mini Sweep The MX60 PV 087 V Bat 12 0 V 05 0 A 35 84 Watts 0430 Aux Off will track the new MPP based on the fixed percent kWHrs 00 0 B MPPT age value Perform a Mini Sweep any time a change to the input system or the Park Mpp fixed percent O O amp e age value is changed In U Pick Voc mode press the 3 and 4 soft keys and the New Voc is displayed in j j Auto Sweep mode press the 3 and 4 soft keys until Sweeping is displayed A user might want an MPP tha
11. is set to WIDE in the MISC menu The upper and lower LMIT settings can be viewed in the second menu of the Log2 screen when LMIT is selected The LMIT set points can be set in the AUX MODE menu To set the LMIT upper and lower set points press the 1 soft key once and return to the MAIN Menu From the MAIN Menu access the AUX MODE screens and then the Low Batt Disconnect screen Path for Setting the LMIT Upper and Lower Set Points using AUX Charger Aux Light EQ Misc Advance Charger Aux Light EQ Misc Advance Logging Log2 EXIT E GO Logging Log2 EXIT GO OOo 8 o O OO AUX MODE DISCONNECT VOLTS Low Batt Disconnect lt 13 6 On EXIT NEXT TIME VOLT BACK ReCon O O O O O Press lt NEXT gt until Low Batt Disconnect appears then press lt VOLT gt OutBack Power Systems Inc Setting LMIT Upper and Lower Set Points DISCONNECT VOLTS lt 13 6 BACK ReCon DISCONNECT VOLTS lt 13 2 Lower Limit BACK ReCon RE CONNECT VOLTS gt 14 8 BACK DisV OutBack Power Systems Inc In the DISCONNECT VOLTS screen press the lt gt or lt gt soft key to adjust the battery voltage range limits This should be the lowest Absorb voltage when the battery temperature is highest When the desired low voltage is reached simultaneously press and hold the lt gt and lt gt soft keys until Lower Limit displays on the screen When Lower Limit is displayed the
12. only deep cycle lead acid lead antimony lead calcium gel cell or absorbed glass mat type rechargeable batteries Other types of batteries may burst causing personal injury and damage Never charge a frozen battery PERSONAL PRECAUTIONS Someone should be within range of your voice to come to your aid if needed Keep plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eyes e Wear complete eye protection Avoid touching eyes while working near batteries Wash your hands with soap and warm water when done e If battery acid contacts skin or clothing wash immediately with soap and water If acid enters an eye flood the eye with running cool water at once for at least 15 minutes and get medical attention immediately following e Baking soda neutralizes lead acid battery electrolyte Keep a supply on hand in the area of the batteries NEVER smoke or allow a spark or flame in vicinity of a battery or generator Be extra cautious to reduce the risk of dropping a metal tool onto batteries lt could short circuit the batteries or other electrical parts that can result in fire or explosion Remove personal metal items such as rings bracelets necklaces and watches when work ing with a battery or other electrical current A battery can produce a short circuit current high enough to weld a ring or the like to metal causing severe burns OutBack Power Systems Inc OPEN CIRCUIT VOLTAGE WIRE AN
13. overcharging of the batteries In lower ambient temperature conditions the voltage regulation set points need to be increased to ensure complete recharging of the batteries The default charger settings of the MX60 are based on typical lead acid battery systems Always ensure that the Absorb amp Float voltage regulation set points are set to the recommended battery manu facturer s recharging regulation voltages Non Battery Temperature Compensated System If a battery remote temperature sensor is not available the Absorb and Float voltage regulation set points can be adjusted for the expected weather conditions The following table shows the appro priate adjustments for both Absorb and Float voltage regulation set points for weather conditions above or below 77 F 25 C EXPECTED TEMPERATURE ADJUST SETPOINT 12V 24V 48V Average 95 F 35 C Subtract 0 30 V 0 60 V 1 20 V Average 86 F 30 C Subtract 0 15 V 0 30 V 0 60 V Average 68 F 20 C Add 0 15 V 0 30 V 0 60 V Average 59 F 15 C Add 0 30 V 0 60 V 1 20 V Battery Temperature Compensated System A battery remote temperature sensor RTS will automatically compensate the Absorb amp Float voltage relative to the Absorb and Float set points in the Charger menu Please reference page 38 of this manual for adjusting the upper and lower battery compensated limits OutBack Power Systems Inc 85 SUGGESTED BATTERY CHARGER SET POINTS The battery manufa
14. proper operation and good performance STATE OF CHARGE Nominal Battery Charged Good 75 Average 50 Low 25 Discharged Voltage 12v over 12 6v 12 3v 12 0v 11 7v under 11 4v 24v over 25 2v 24 6v 24 0v 23 4v under 22 8v 48v over 50 4v KEE 48 0v 46 8v under 45 6v 60v over 63 0v 61 5v 60 0v 58 5V under 57 0v OutBack Power Systems Inc Ciut Back Power Systems TWO YEAR LIMITED WARRANTY INFORMATION OutBack Power Systems Inc warrants that the products it manufacturers will be free from defects in materials and workmanship for a period of two 2 years subject to the conditions set forth below The limited warranty is extended to the original user and is transferable The limited warranty term begins on the date of invoice to the original user of the product The limited warranty does not apply to any product or part thereof damaged by a alteration or disassembly b accident or abuse c corrosion d lightning e reverse polarity f repair or service provided by an unauthor ized repair facility g operation or installation contrary to instructions pertaining to the product OutBack Power Systems liability for any defective product or any part thereof shall be limited to the repair or replacement of the product at OutBack Power Systems discretion OutBack Power Systems does not warrant or guarantee the workmanship performed by any person or firm nstalling its products THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIG
15. screens charger kwhrs kilowatt hours produced in the last 60 minutes by the MX60 gt charger amps dc the amount of amperage the MX60 is sending to the battery battery voltage current battery voltage panel voltage current voltage from the PV array OutBack Power Systems Inc MATE DISPLAYED MX60 STATUS SETPT SETPOINT Screens STATUS MX SETPT POO Absorb 28 8 VDC STATUS MX SETPT P00 Float 27 2 VDC DOWN STATUS PORT DOWN UP TOP PORT d ooo ooo gt STATUS MX METER Press the first two soft keys simultaneously to return ta SSC to the MAIN Menu or press lt STATUS gt and then UP TOP STATUS press lt MAIN gt on the STATUS screen MX SETP OINT Screens Absorb displays the voltage that initiates and maintains the Absorb cycle Float displays the voltage that begins the Float cycle and is maintained during this cycle OutBack Power Systems Inc 73 TROUBLESHOOTING GUIDE MX60 does not boot power up blank LCD user forum at www outbackpower com forum for more MX60 information Be sure to check out the OutBack customer and e Check the battery connection and polarity Reverse polarity or an improper connection will cause power up issues Check the battery breaker gt Ensure that the battery breaker is sized appropriately A battery voltage below 10 5 VDC may not power up the MX60 measure the battery side of Four Position Terminal Block e Ifthe MX6O0 sti
16. setting screen Press NEXT to This soft key covers normal and RSTRT forces the MX60 to restart or Continue to the limited battery compensation wake up from 5 minute default Force Bulk Float voltage range Press WIDE and long Snoozing mode Restart and Screen LMIT mode appears which limits wakeup are mainly service features the Upper and Lower battery compensated voltage range OutBack Power Systems Inc 37 38 WIDE LMIT Battery Temperature Compensated Limits During cold weather a battery often requires a higher recharging voltage Lower quality inverters might not accommodate these higher voltages and can shut down during recharging cutting off power to their loads The MX60 allows the user to lower the compensated voltage in the Absorb cycle so these inverters will remain operating Also some batteries have an absolute voltage limit that should not be exceeded and the WIDE LMIT option allows the user to control this during re charging WIDE allows the RTS full control over recharging LMIT sets the ceiling and floor voltages for the RTS During hot weather the LMIT feature set point assures recharging will continue at a high enough voltage rather than dropping too low in reaction to a higher ambient temperature This assures the recharging voltage adequately charges but should be monitored according to the battery manufacturer s recommendations The RTS default compensated voltages apply if the WIDE LMIT option
17. soft key to return to the Low Batt Discon nect screen OutBack Power Systems Inc AUX MODE Low Batt Disconnect On EXIT NEXT TIME VOLT AUX MODE Remote Off EXIT NEXT Se Charger Aux Light Eq Misc Advanced Logging Log2 EXIT lt gt GO OOO hoy OutBack Power Systems Inc Press the lt NEXT gt soft key to view the Remote screen In Remote AUX MODE the OutBack MATE can control the MX60 s AUX MODE Press the EXIT soft key twice to return to the MAIN Menu screen Press the lt gt soft key to move the asterisk to the Light option When the asterisk is in front of Light press the lt GO gt soft key 33 34 BACKLIGHT AUTO default leaves backlight and soft keys on for BACKLIGHT CONTROL 60 seconds whenever any soft key is pressed press ing any soft key when the LCD is not lighted does not ALWAYS EXIT AUTO ON OFF change any settings O O ON or OFF states are also available y Press the 1 soft key twice to return to the MAIN Menu screen Press the lt gt soft key to move the asterisk to the Charger Aux Light EQ option When the asterisk is to the left of EQ press EQ Misc Optimize the lt GO gt soft key Logging Log2 EXIT e gt GO OOO A y EQ BATTERY EQUALIZE The intent of an equalization charge is to bring all battery cells to an equal voltage Sealed batter ies should not be equalized unless specifically instructed by the manufa
18. state Absorb Float or EQ has a recharging voltage set point The Diversion AUX MODE can be active On when the battery voltage is raised above one of these set points for a certain amount of time or inactive Off when it falls below The user can determine these voltages and times In the example above when the RE source wind or hydro raises the battery voltage 00 2v above the chosen set point for a Delay time of 10 seconds the AUX Output will be active When the battery voltage falls 00 3v below the HYST voltage set point for a Hold time of 15 sec the AUX Output will be inactive Off See Figure 5 for Diversion Load and AUX Wiring Set Up OutBack Power Systems Inc 29 ino xnv Y3TMOYLNO9 ADYVHO O9XIA Adv OdA P XA 3431V349 90 XVW div 08 RA y3AvV348 90 XVW dg 08 y3NV3Y8 90 Vv BAILISOd HALYSANI OL QVO1NOISHSAAIC BAILVOIN YSLYSANI OL TERMINAL BUS BAR YOLVI3N39 ANIM DOA pZ HOLIMS dOLS Nas no g Av idw Ad 90A P Figure 5 Diversion Load and AUX Wiring Set Up Illustrated OutBack Power Systems Inc 30 AUX MODE Diversion Off EXIT NEXT TIME VOLT OO Oo v AUX MODE Low Batt Disconnect On EXIT NEXT TIME VOLT OO o y Delay Time Sec 01 Timer 001 BACK 0 ooo y A OutBack Power Systems Inc Press the lt NEXT gt soft key to view the Low Batt ery Disconnect screen When the battery voltage falls below t
19. the lt NEXT gt soft key to view the battery equalization start screen Press the lt START gt soft key to manually begin an equalization cycle To stop the cycle press the lt STOP gt soft key EQ MPPT display indicates the MX60 is trying to reach the target equalize set point Equalize time EQ 0 00 in Hours Minutes displays after the equalize set point is reached The incomplete equalization cycle continues into the next day unless the MX60 is powered off or manually stopped The remaining EQ time can be viewed in the Log2 Menu EQ cycle terminates when EQ time period is reached After equalizing an FQ DONE message displayed and a Float cycle begins Press the lt AUTO gt soft key to view the auto equaliza tion screen 35 36 Auto Mode EQ INTERVAL 000 DAY DAY ooo y AA Use the lt DAY gt and lt DAY gt soft keys to preset the interval day to initiate an automatic equalization cycle The EQ INTERVAL displays the number of days in the interval between cycles and COUNT displays how many days of the interval have passed Auto Mode initiates when a preset interval day 1 250 days is reached e The default equalize interval EQ INTERVAL setting is 000 day leaving the auto eq disabled EQ MPPT display indicates the MX60 is trying to reach the target equalize set point e The equalize time EQ 0 00 in Hours Minutes displays after the equalize set point is
20. tie mode communications between the G series FX and the MX60 46 Low Cutoff sets the battery charger s lowest allow able current limit the MX60 will charge in MPPT mode before stopping and returning to Snoozing The Low Cutoff is adjustable from 2 amps to 1 amp 6 amps is the default Low Cutoff current Raising this value will assist the MX60 in entering Sleeping mode at night Press the lt tAmp gt soft key to raise this limit When finished press the lt NEXT gt soft key to view the MPPT Mode screen This screen allows the user to choose one of these modes e Auto Sweep MPPT Mode the default and preferred mode which sweeps the PV upon wakeup and then does mini Sweeps from that point on at the selected Sweep Interval If the sweep interval is set at 0 minutes the MX60 awakes every 1 5 hours and does a full sweep Auto Restart applies here as well see LOG2 Auto Restart page 52 gt U Pick Voc MPPT mode operates the PV voltage at a user selected percentage of the Voc which is displayed in the Park Mpp Voc screen U_Pick acquires a new Voc value every Sweep Interval If the mini sweep interval is set to 0 minutes a new Voc may be acquired once every 1 5 hrs depend ing on the Auto Restart setting see LOG2 Auto Restart page 52 This is an alternative to the Auto Sweep mode and may also be useful for micro hy dro applications Press the lt MODE gt soft key to choose an MPPT mode and t
21. 0 in the Absorbing or Float stage If either case is true the MX60 will produce enough power to regulate the voltage at the ABSORB or FLOAT set point voltage therefore requiring less power in these modes e What is the short circuit current of the PV array Use a multi meter to determine if a short circuit current is as expected There might be a loose PV array connection If the PV array voltage close to the battery voltage the panels could be warm hot causing the Maximum Power Point to be at or lower than the battery voltage e If the SWEEP INTERVAL is set to 00 mins the MX60 will not periodically find the Maximum Power Point of the array A sweep interval of seven to ten minutes is suggested OutBack Power Systems Inc 75 76 MX60 is not equalizing Has the EQ cycle been initiated Inthe EQ Menu press START to begin process When the EQ cycle has been initiated EQ MPPT will be displayed The EQ cycle has been initiated but the battery is not equalizing The EQ cycle will begin when the target EQ set point voltage has been reached A small ar ray or cloudy weather will delay the EQ cycle Accordingly running too many AC and or DC loads will delay the EQ cycle too An EQ set point that is too high relative to the battery voltage will delay the EQ cycle e If the PV array voltage is close to the battery voltage the panels could be warm hot causing the Maximum Power Point to be at or lower than the battery vol
22. 4 36V 43 2 44 1 48 V 57 6 58 8 60 V 72 0 73 5 Equalize Time 01 Hours 03 Hours OutBack Power Systems Inc To meet NEC compliance the largest PV array that can be connected to the MX60 should have a rated short circuit current of 48 amps The following charts show the maximum distance of various gauge two conductor copper wire from the PV array to the MX60 with a 1 5 maximum voltage drop Temperature and conduit fill corrections may be required Using a higher voltage PV array with a low voltage battery system allows you to use a much smaller wire size or go up to 5 times as far with the same gauge wire Wire Distance Chart 12 Volt PV Array 16V MPP Typical Distance in Feet Two Wires 1 5 Voltage Drop 12 Volt Battery System 24 Volt PV Array 32V MPP Typical Distance in Feet Two Wires 1 5 Voltage Drop 12 or 24 Volt Battery System 48 Volt PV Array 64V MPP Typical Distance in Feet Two Wires 1 5 Voltage Drop 12 24 or 48 Volt Battery System 80 1 0 2 0 4 0 145 180 290 115 145 230 76 96 150 2 180 145 Wire Gauge 8 6 22 35 18 28 12 19 9 14 6 9 4 7 3 5 Wire Gauge 8 6 45 71 36 57 24 38 18 29 12 19 9 14 7 11 Wire Gauge 8 6 90 142 72 114 48 76 36 58 24 38 18 28 14 22 182 120 90 60 46 36 2 360 290 192 144 96 72 58 1 0 2 0 4 0 580 720 1160 460 580 920 306 384 600 230 290 464 154 194 308 116 144 224 92 116 172 OutBack Power Systems I
23. BSORBING cycle limits the amount of power going to the battery the voltage is held constant The Absorb cycle will continue for the duration of the Bulk cycle or until the 2 hour default Ab sorb time limit is reached For example ifa Bulk cycle takes 1 hour to reach the Absorb voltage set point then the Absorb cycle will continue for 1 hour as well However ifa Bulk cycle takes 3 hours to reach the Absorb voltage set point then the Absorb cycle will continue for 2 hours only A Bulk cycle will be re initiated if the battery voltage is not sustained at the Absorb voltage set point Absorbing is displayed on the screen at this time FLOAT cycle reduces the recharging voltage to prevent overcharging of the batteries A Float cycle follows after the Absorb cycle is completed Float is displayed on the screen The MX60 will not re initiate another Bulk cycle if the Float voltage set point is not sustained F MPPT is displayed However it will continue to recharge the battery until the Float voltage set point is reached Note A Bulk cycle can be auto initiated if the battery voltage falls below the Float voltage set point and the Re Bulk ReBV voltage option is set OutBack Power Systems Inc BATTERY TEMPERATURE COMPENSATED VOLATGE SET POINT The temperature of a battery has an impact on the recharging process in higher ambient tem peratures the regulation set points Absorb amp Float need to be reduced to prevent
24. Ciut Back Power Systems MX60 PV MPPT Maximum Power Point Tracking Charge Controller Installation Programming and User s Manual Warranty Summary Dear OutBack Customer Thank you for your purchase of OutBack products We make every effort to assure our power conversion products will give you long and reliable service for your renewable energy system As with any manufactured device repairs might be needed due to damage inappropriate use or unintentional defect Please note the following guidelines regarding warranty service of OutBack products gt Any and all warranty repairs must conform to the terms of the warranty gt All OutBack equipment must be installed according to their accompanying instructions and manuals with specified over current protection in order to maintain their warranties e The customer must return the component s to OutBack securely packaged properly addressed and shipping paid We recommend insuring your package when shipping Packages that are not securely packaged can sustain additional damage not covered by the warranty or can void warranty repairs e There is no allowance or reimbursement for an installer s or user s labor or travel time required to disconnect service or reinstall the damaged component s e OutBack will ship the repaired or replacement component s prepaid to addresses in the conti nental United States where applicable Shipments outside the U S will be sent freigh
25. D DISCONNECT SIZING Maximum Open Circuit Voltage Voc e Voc is the unloaded voltage generated by the solar array 141 VDC gt MX60 suspends operation to protect components gt 150VDC gt max open circuit voltage with the coldest environment although the MX60 shuts down at 141 VDC it can absorb up to 150 VDC from the array anything higher than 150 VDC will damage the MX60 As every brand of panel is different be sure to know the manufacturer s specifications Local temperatures vary seasonally and will affect panel voltage Hot weather lower open circuit voltage lower maximum power point voltage Cold weather higher open circuit voltage higher power point voltage Allow for ambient temperature correction using the following table 25 to 10 C 77 to 50 F multiply by 1 06 9 to 0 C 49 to 32 F multiply by 1 10 1 to 10 C 31 to 14 F multiply by 1 13 11 to 20 C 13 to 4 F multiply by 1 17 21 to 40 C 5 to 40 F multiply by 1 25 Check the PV array voltage before connecting it to the MX60 Wire and Disconnect Sizing e The output current limit of the MX60 is 60 amps e Use a minimum of 6 AWG wire for the output between the MX60 and the batterry bus bar con ductors a larger size might be required due to temperature and or conduit fill corrections Install OutBack OBDC 60 or OBDC 80 amp breakers for disconnect and over current protection The largest PV array
26. HTS AND YOU MAY ALSO HAVE OTHER RIGHTS THAT VARY FROM STATE TO STATE OR JURISDICTION TO JURISDICTION OUTBACK POWER SYSTEMS RESPONSIBILITY FOR MALFUNCTIONS AND DEFECTS IN HARDWARE IS LIMITED TO REPAIR AND REPLACEMENT AS SET FORTH IN THIS LIMITED WARRANTY STATEMENT ALL EXPRESS AND IMPLIED WARRANTIES FOR THE PRODUCT INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF AND CONDITIONS OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PUR POSE ARE LIMITED IN DURATION TO THE LIMITED WARRANTY PERIOD SET FORTH ABOVE AND NO WARRANTIES WHETHER EXPRESS OR IMPLIED WILL APPLY AFTER SUCH PERIOD SOME STATES OR JURISDICTIONS DO NOT ALLOW LIMITATIONS ON HOW LONG IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU OUTBACK POWER SYSTEMS DOES NOT ACCEPT LIABILITY BEYOND THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY STATEMENT OR LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAM AGES INCLUDING WITHOUT LIMITATION ANY LIABILITY FOR PRODUCTS NOT BEING AVAILABLE FOR USE SOME STATES OR JURISDICTIONS DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE EXCLUSION OR LIMITATION MAY NOT APPLY TO YOU OutBack Power Systems Inc 87 88 During the two year period beginning on the invoice date OutBack Power Systems will repair or replace products covered under this limited warranty that are returned to OutBack Power Systems facility orto an OutBack Power Systems aut
27. Log2 function and then Eq Misc Advanced press the lt GO gt soft key Logging Log2 EXIT GO GC A OutBack Power Systems Inc LOG2 The Log2 screen displays additional voltage and time information Daily high Voc value The highest Voc seen by the MX60 Daily peak Sunrise shows how long battery voltage PkBatv Voc HiVoc 012 2 070 2 076 9 Operational mode gt _ B MPPT Sunrise EXIT NEXT 00 06 12 ago the MX60 woke up for the first time each day and when the daily and total logged values were O O O O updated and cleared from the STATUS screen Pressing and holding the 3 soft key toggles 24 25 hour save mode Soft key 4 addresses Auto RESTART mode PkBatV logs the peak battery voltage and operational mode simultaneously updating daily at first wakeup it can also be reset to the present battery voltage by powering off the controller This helps determine any degree of voltage overshooting The peak battery voltage should not be used to identify that the controller has charged the battery to a higher voltage than its regulation set point Note If controller power is disconnected the BatTmpErr becomes the default operational mode until the controller wakes up OutBack Power Systems Inc 51 52 Auto Restart Pressing and holding the 4 soft key for several PkBatV Voc HiVoc seconds selects among the three MX60 Auto 012 2 070 2 076 9 ReStart modes 0
28. MODE is active when the MX60 is in Float and producing power Press the lt NEXT gt soft key to advance to the ERROR ALARM screen 27 AUX MODE ERROR ALARM On EXIT NEXT OO oo v AUX MODE Diversion Off EXIT NEXT TIME VOLT OOO Absorb Float EQ Relative Volts 00 0 00 2 BACK HYST 0 ooo YO A A A 28 The default state of the ERROR ALARM is On meaning 12 VDC is present at the AUX terminal If the MX60 has not charged the batteries for 26 hours or more continuously the inaudible ERROR ALAR goes into an Off state The ERROR ALARM is intended for remote locations to signal e g a telecommunica tion signal to a computer when the MX60 has not recharged for 26 hrs or more See MISCELLANEOUS Screen 3 Err for a display of the hourly countdown Press the lt NEXT gt soft key to advance to the Diversion screen When external DC sources wind hydro are directly connected to a battery bank any excess power should be sent to a diversion load such as a heating element In Diversion the user programs set points from 5 0 volts to 5 0 volts relative to the Absorb Float and EQ voltages to activate the AUX MODE This is primarily an off grid function Pressing the lt VOLT gt soft key advances to the Absorb Float EQ screen to adjust the voltage set points Use this screen to establish the set points for starting and ending the AUX MODE relative to the Absorb Float
29. Power Systems Inc ADVANCED The ADVANCED MENU allows fine tuning of the MX60 operations including Snooze periods and Maximum Power Point limits In order of appearance the following modes occur in the ADVANCED Menu selections Snooze Mode Park Mpp Voc gt MPP Range Limit Voc Sweep Interval Vbatt Calibration Low CutOff MPPT Mode gt Absorb Time Limits Wakeup Mode Charger Aux Light Eq Misc Advanced Logging Log2 EXIT gt GO OOO ADVANCED MENU Snooze Mode lt Lowcutoff EXIT NEXT MODE a NOTE There are four Low Cutoff options From the MAIN Menu choose Advanced and press the lt GO gt soft key The MX60 wakes up when an optimal amount of open circuit voltage Voc is available The Voc varies with external conditions primarily the weather and time of day which affect solar panels If the Voc is insufficient the MX60 enters Snoozing until either a five minute default period passes or there is a 1 5 volt default increase in Voc at which point the MX60 reevaluates the Voc for recharging purposes What is the optimal amount The MX60 tries to recharge when the Voc is greater than the battery voltage by 2 volts but voltage alone isn t sufficient An array might have a big increase in voltage first thing in the morn ing more than 2 volts difference but not enough ampacity to recharge Snoozing also occurs if the recharging current does not reach the user selecte
30. TANDING THE VARIOUS OPERATIONAL MODES ccccssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssesssuueeeeeeeee 67 MATE DISPLAYED MX60 STATUS MODE SCTeenS EE 71 MATE DISPLAYED MX60 STATUS METER Screen 72 MATE DISPLAYED MX60 STATUS SETP OINT Green 73 TROUBLES FOOTING GUIDE be 74 TYPICAL ARRAY SIZING OUDE si sisiisasicdssadtassssssssssasaddlessssssssssssssltselilscsssssssassssssssssssssssssssssiiensiissss Tie STANDARD vs AUSTRALIAN DEFAULT SETTINGS WIREDISTANCE EE WIRE AND DISCONNECT SIN mee 82 MULTI STAGE BATTERY CHARGING cnica 83 BATTERY TEMPERATURE COMPENSATED VOLTAGE SET POINT coccion 85 SUGGESTED BATTERY CHARGER El EE 86 WARRANTY INFORMATION cin A 87 OWNER S S YSTEMINFORMATION eenegen 90 PRODUCT REGISTRATION AND OPTIONAL EXTENDED WARRANTY cnc 91 OutBack Power Systems Inc SCOPE The manual provides safety guidelines and installation information for the MX60 PV MPPT Charge Controller It does not provide information about specific brands of solar panels and supplies limited information on batteries Contact the supplier or manufacturer of the solar panels or batteries for further information INTRODUCTION MX60 PV MPPT Maximum Power Point Tracking Charge Controller The OutBack MX60 PV MPPT Charge Controller offers an efficient safe multi stage recharging process that prolongs battery life and assures peak performance from a solar array This component allows customized battery rechar
31. W SNH 24 VDC BATTERY BANK AYILLV8 TERMINAL BUS BAR y3AvV3Y8 90 XV dV 08 asuvo lt _ D 4 Ad Ad Ad Ad 13 Figure 3 MX60 WITH GFP 2 WIRING DIAGRAM The GFP 2 requires a separate ground bus bar OutBack Power Systems Inc BATTERY SYSTEM VOLTAGE gt The MX60 default setting is for a 12 VDC battery e Change the setting after powering up the MX60 if a different battery voltage is used e The PV array voltage which must not exceed 150 VDC open circuit is automatically detected gt KEY TO THE EXAMPLE DIAGRAMS lt softkeys O O 1 2 3 4 Solid black indicates key isto be pressed CY O QQ O Down arrow will lead to the next screen es amp 3 gt y Up arrow points to one or more keys that will change a value amp gt amp Cc A The keys correspond to any text immediately above them OutBack Power Systems Inc POWERING UP The MX60 power up sequence first activates the unit and brings up a series of screens some screens allow the user to change the battery voltage Note Be sure the PV input and battery breakers are off before starting the power up sequence OFF SCREEN this screen is initially blank at power up With the PV array and battery breakers off press and hold soft keys 1 and 3 and then turn on the battery breaker see Figure 4 Battery Breaker Figure 4 Note The battery voltage must be at least 10 5 V or higher to power up
32. Watts 0000 Aux On to LMIT in the Misc Menu EXIT NEXT 00 03 43 kWHrs 00 0 Sleeping d CC lt gt 2 OutBack Power Systems Inc After confirming the Upper Limit and Lower Limit voltages press the lt gt soft key in the MAIN Menu Press the lt GO gt soft key to advance to the first MISC screen From this screen you can access MISCELLANEOUS Screen 2 From the MISC screen press the lt NEXT gt soft key to GT State PWM ChgT view the FORCE FLOAT or BULK screen 255 07 50 0 005 Tmp Comp al4 4 f13 6 EXIT NEXT WIDE RSTRT SA Pressing the lt FLOAT gt or lt BULK gt soft key forces the MX60 to that specific recharging cycle and returns to the STATUS screen Forcing a FLOAT or BULK recharge FORCE l NEXT FLOAT BULK will end an EQ cycle Press the lt NEXT gt soft key to view the third MISCELLANEOUS screen O D O C3 e Force FLOAT float cycle v A d e Force BULK bulk cycle OutBack Power Systems Inc MISCELLANEOUS Screen 3 This is the assigned number representing the temperature of the internal components to control the cooling fan The lower the number the higher the temperature 25 C is ap proximately a value of 525 In Float if the battery volt age falls below the ReBulk vo least 90 seconds the MX60 automatically reinitiate tage set point for at wi a Bulk charge cycle The default is set to a very low value 6 volts and there fore the function will be
33. age close to the battery voltage instead of 1 2 or 50 of the Voc This adjustment only affects the initial sweep at the beginning of the day and any subsequent sweeps caused by Auto Restart or any forced restart of the MX60 In addition to adjusting the Mpp Range Limit changing the Sweep Interval from its default three minute setting to zero minutes will also enhance the performance and reliability of some applica tions voltage input system To adjust the Lower Mpp Range Limit and disable the Sweep Interval From the MAIN Menu with the asterisk in front of Charger Aux Light Eq Misc Advanced Logging Log2 EXIT gt GO Advanced press the lt GO gt soft key OutBack Power Systems Inc ADVANCED MENU Mpp Range Limit Voc min max EXIT NEXT 1 2 90 OO O Yo A ADVANCED MENU Sweep Interval 03 Minutes EXIT NEXT MIN MAX OO OO Yo A ADVANCED MENU MPPT Mode Auto Sweep EXIT NEXT nonGT MODE Ooo A OutBack Power Systems Inc In the ADVANCED MENU screen press the lt NEXT gt soft key until the Mpp Range Limit VOC screen appears Press the lt 1 2 gt soft key until FULL appears When finished press the lt NEXT gt soft key to go to the Sweep Interval screen In the Sweep Interval screen press the lt MIN gt soft key to adjust the sweep interval from 03 minutes default to 00 minutes Press the lt NEXT gt soft key until the MPPT Mode screen appears To pick between
34. ally adjust the set points If they re set too high the MX60 might not wake up soon or often enough which means a loss of power production Note VOC ranges from 1 5V up to 9 5V MIN ranges from 5 up to 15 minutes Press the lt EXIT gt soft key to return to the MAIN Menu From the MAIN Menu press the lt gt gt soft key to move the asterisk next to the Logging function and then press the lt GO gt soft key OutBack Power Systems Inc DATA LOGGING The MX60 records battery float and daily kilowatt hour kWh information for the previous 64 days This data can be compared for instance with weather reports to confirm the MX60 s performance When 64 days are reached for every new day of data recorded a day is eliminated from the front end of the count in the order they were recorded The minutes the MX60 Total power production spent floating the bat may be viewed as amp teries for each of the hours or kilowatt hours last 64 days The pres depending on display ent day s Float time can setting in the STATUS screen The TotalKWh or be found in the Log2 DAILY KWhours Float time mins 0000 TotalKWh 0000 01 EXIT CLR DAY screens TotalKAh accumulates the daily values and Day 01 is yesterday and continue beyond 64 Day 02 is two days ago days of data Cy CC E etc ER OSOS Pressing CLR takes you to the CLEAR Press DAY goes back one day Press DAY DALY DAILY and TOTL TOTAL Menu goes fo
35. and EQ voltages The lt gt and lt gt soft keys set the Diversion set points The lt HYST gt Hysteresis set point establishes when the AUX MODE becomes inactive after the battery voltage falls below the Relative Volts voltage minus the HYST value After establishing these values press the lt BACK gt soft key to return to the Diversion screen see example on next page OutBack Power Systems Inc Press the lt TIME gt soft key to advance to the Time AUX MODE Diversion screen which allows the user to adjust the minimum Off time the AUX MODE is active after the battery volt EXIT NEXT TIME VOLT age falls below the Hysteresis voltage rd old Time shows how long the AUX MODE stays active after the battery voltage has fallen below the Hold Delay YST Hysteresis set point The user can adjust the 01 0 Time 00 Hold Time from 0 1 to 25 seconds If a solid state relay seconds BACK DLY s used set the Hold time to 0 1 seconds and the Delay time to zero O 0 YOA A 4A The Delay Time shows how long the battery voltage must be above the Relative Volts before the AUX MODE is activated It can be adjusted from 0 to 24 seconds but is rarely required Pressing the lt BACK gt soft key returns to the AUX MODE DIVERSION screen Example of Diversion AUX MODE Diversion Absorb Float EQ Relative Volts off EXIT NEXT TIME VOLT 00 2 00 3 HYST Each recharging
36. battery system or 1 0 volt difference for 48V battery systems Diversion using hydro or wind power With wind or hydro generator applications keep the MX60 s diversion voltage slightly above its Absorb and Float voltages for efficient functioning Positive grounded systems Telcom applications frequently require a positive grounded system The MX60 switches the POSI TIVE PV and battery leads Keep these separate If code allows ground ONLY the battery positive lead in this case Do not connect the MX60 s battery plus to the PV plus input while the MX60 is running The OutBack HUB cannot be used in a positive grounded system Battery temperature compensation with other slopes The MX60 uses a 5mV per degree C per cell 2V compensation slope required by UL For other slopes you may be able to pick a different battery voltage and change the charger Absorb and Float voltage settings to achieve a more or less aggressive slope If going lower in voltage reduce the Float voltage first since the Absorb voltage will not be adjustable below the Float voltage setting If going higher in voltage increase the Absorb setting first before raising the Float voltage above the present setting Here is a table of MX60 compensation based on system voltage for reference 12V system 30mV degree C 24V system 60mV degree C 36V system 90mV degree C 48V system 120mV degree C 60V system 150mV degree C OutBack Power Systems Inc 61
37. be changed You may need to re enter the password to change these settings e The default charger output current limit setting is 60 amps and is adjustable up to 70 amps At 70 amps a 70A or 80A breaker must be used between the battery and the MX60 Change Absorb and Float set points using this screen if the battery manufacturer s recommen dations are different than the default values Otherwise see page 79 for suggested recharging voltage set points Ifa battery remote temperature sensor RTS is used its Compensated voltage values can be viewed in the MISCELLANEOUS Misc screen under the Tmp Comp heading Please Note If an RTS is used set the ABSORB EEE es FLOAT and FLOAT setting voltage based on a 25 C 77 F Amps Volts Volts 60 0 14 4 13 6 setting These are typically the manufacturer s set EXIT gt points always consult the battery manufacturer s recommendations If an RTS is not in use please see the Non Battery Temperature Compensated System values page 85 and adjust the ABSORB FLOAT values accordingly OutBack Power Systems Inc 21 ER AUX MODE The AUX is a secondary control circuit essentially a small power supply that provides a 12 VDC up to 200 milliamps output current It is either active 12 VDC on or inactive 12 VDC off To access the AUX MODE from the MAIN Menu press the lt gt soft key until the asterisk is in front of the Aux selection A 200 milliamps or less 12 VDC d
38. cturer Shut off or minimize all AC and or DC loads when equalizing and be sure the EQ voltage will not damage any DC load If possible ensure the EQ cycle starts and stops the same day it is initiated or unnecessary battery gassing can occur Occasional equalization extends the life of flooded electrolyte batteries e Proceed with caution A vent fan is recommended in enclosed spaces The MX60 allows the user to set voltages and times of equalization process Both manual and auto modes are available EQ is not battery temperature compensated Always check the electrolyte level in the batteries before and after equalizing OutBack Power Systems Inc BATTERY EQUALIZE Volts 15 0 EXIT NEX EQV EQV OOOO YO AA BATTERY EQUALIZE Time 01 Hours EXIT NEXT HRS HRS OOOO In Manual Mode BATTERY EQUALIZE 01 Hrs 15 0 Volts Check water level BACK AUTO START STOP OOOO YO AA OutBack Power Systems Inc Press either the lt EQV gt or lt EQV gt soft key to change the EQ voltage following your battery man ufacturer s recommendations Note that the factory default EQ voltage is set low the same as the factory default Absorb voltage Press the lt NEXT gt soft key to view the BATTERY EQUALIZE Time screen Press either the lt HRS gt or lt HRS gt soft key to set the desired equalization time up to a seven hour maximum always following your battery manufac turer s recommendations Press
39. cturer should provide you with specific instructions on the following mainte nance and voltage set point limits for the specific batteries The following information can be used when the manufacturer s information is not available SEALED LEAD ACID AGM GEL 12V 24V 48V ABSORB voltage set point 14 4 V 28 8 V 57 6 V FLOAT voltage set point 13 4 V 26 8 V 53 6 V NON SEALED LEAD ACID 12v 24v 48v ABSORB voltage set point 14 8 V 29 6 V 59 2 V FLOAT voltage set point 13 8 V 27 6 V 55 2V Note Higher settings can be used with non sealed batteries but water consumption will be greater and excessive temperatures when recharging may occur Battery Voltage and State of Charge A battery s voltage can be used as a guideline to estimate the amount of power stored in the battery that is available for use When referencing the battery voltage on the display be sure the battery is not under significant recharging or heavy loads Otherwise the DC voltage is not reflec tive of the battery state of cycle Often the best time to check the battery voltage is in the morning pre charging or at night postcharging with the battery disconnected from charging sources and loads and a rest for at least three hours Operation of a battery below 50 state of cycle will adversely affect the long term health of the battery system and will result in premature failure Keeping the battery above the 50 level and recharging it completely once a month will ensure
40. d In this case the MX60 will always sense a higher 24V voltage than a 12V system would require for recharging Bat Full There is an external DC source other than solar keeping the battery above the Float set point The MX60 is transitioning from Absorb upper target voltage to Float lower target voltage or it will not be producing power B MPPT The MX60 is in Maximum Power Point Tracking mode trying to regulate the battery volt age towards the Absorb voltage set point If the MX60 is in the Bulk charge stage the Charge Timer ChgT will count up to the max Absorb time OutBack Power Systems Inc 67 68 Bat Tmp Err The battery temperature sensor is shorted or damaged EQ 0 00 This is the time elapsed in hours and minutes since the Equalization voltage was met If the EQ voltage set point is not maintained the controller will revert back to EQ MPPT the EQ timer will pause until the batteries are regulated at the EQ target again The paused time can be viewed in the Log2 menu EQ DONE Once the set EQ time between 1 and 7 hours has successfully completed EQ DONE will be displayed either until a button is pressed or the next morning s wakeup The MX60 will tran sition to Float cycle at the end of the EQ cycle EQ MPPT The equalization process has started and the MX60 is trying to regulate towards the Equalization voltage set point EQ is not battery temperature compensated After the EQ voltage has bee
41. d cutoff current set point in the Lowcutoff menu Press the lt MODE gt soft key for Snooze Mode options Press the lt NEXT gt soft key for the Park Mpp screen lt 90 Voc MXG60 snoozes if Voc does not rise to greater than 90 of last measured Voc during a full sweep lt 50 Voc snoozes if Voc does not rise to greater than 50 of last measured Voc during a full sweep e lt Lowcutoff default snooze mode snoozes if initial sweep does not reach Low Cutoff Amps during a full sweep e Disabled no snoozing MX60 will cycle on and off many times not recommended due to ongoing relay clicking OutBack Power Systems Inc ADVANCED MENU Park Mpp 77 Voc EXIT NEXT Voc Voc OO oo y f A ADVANCED MENU Mpp Range Limit Voc min max EXIT NEXT 1 2 90 OOOO YO A 4 Use value for high input arrays to speed up initial sweep Auto Sweep MPPT Mode see page 46 seeks the solar array s maximum available voltage to recharge the batteries The MX60 is best left in this default mode for most recharging purposes If the output current is below five amps e g overcast day or early mornings and late evenings the MX60 will operate at the percentage of the Voc shown on the Park Mpp Maximum Power Point screen The 77 Voc default is close to the MPP for most arrays A higher value may be necessary for different applications such as a 12 VDC array to a 12 VDC battery To change the per ce
42. desired compensated voltage has been stored and the lt gt and lt gt soft keys can be released pressing the lt BACK gt soft key will return to the previous screen Press the lt ReCon gt soft key to adjust the upper battery compensated voltage Press the lt gt or lt gt soft key to adjust the voltage When finished simultaneously press and hold the lt gt and lt gt soft keys until Upper Limit is dis played This should be the highest Absorb voltage when the battery temperature is coolest 39 When the Upper Limit is displayed the desired com RE CONNECT VOLTS pensated voltage has been stored and the lt gt and gt 14 8 lt gt soft keys can be released Upper Limit BACK DisV After setting these limits AUX MODE should be set to Manual default setting if not used O y Note WIDE LMIT voltages are not applicable in the Equalize charging mode Pressing the lt BACK gt soft key returns to the Low Batt Disconnect screen To confirm the Upper Limit and Lower Limit voltages Charger Aux Light EQ Misc Advance 0000 floatTmin 0850 HighWatts Lo 13 2 Hi 14 8 BACK DCkWh PkBatV Voc HiVoc 014 7 021 2 022 1 Logging Log2 EXIT lt GO B MPPT Sunrise EXIT NEXT 00 03 43 OOO O Woo PkBatV Voc HiVoc PV 011 V Bat 13 4 V Limit Set Points visible and 014 7 021 2 022 1 00 0 A 00 0 A active when WIDE LMIT is set B MPPT Sunrise
43. disabled ReBV increments the ReBulk Voltage It will return to a 6 volt value when a 69 volt value is reached The Err or count increases hourly if the MX60 has not charged the batteries for 26 hours continuously The first hour begins at sleeping PCB Err 398 000 ReBulk 06 V Btmp 233 End 0 EXIT ReBV AMP AMP End AMP AMP Norma 00A Btmp is a battery temperature sensor reference value used to compensate the charging volt age This is an arbitrary number between 0 and 255 and is not the actual temperature An X next to this value indicates a Global external RTS is being used system with a HUB and MATE The output value CFB 760 of the internal cur rent sensor is used to calculate output amps watts and track the Maximum Power Point of the array ly an Absorb charge cycle is ter minated because the battery voltage was regulated at the Absorb set point for the m AMP or increasing AM aximum time period Decreasing P sets an optional end current level While the battery vo tage is at or above the Absorb target and the End current level is reached at a time delay of 15 seconds the MX60 will switch to the Float charge stage regardless of the charger time minutes The charger timer ChgT will be cleare d This is an optional set point and its adjustment is not required in most installations 00 Absorb End amps is the default OutBack
44. e nominal array voltage be slightly higher than the recommended nominal array voltage Example A 36 VDC nominal array recharging a 12 V nominal battery with an array to charge controller distance of about 70 feet or greater Sizing the nominal array voltage higher than the nominal battery voltage ensures that the Maximum Power Point is always above the battery voltage The Maximum Power Point will decrease as the panels warm up thus lowering the output of the array The MX60 Charge Controller will not be able to boost the output if the Maximum Power Point of the array is at or lower than the battery voltage OutBack Power Systems Inc STANDARD vs AUSTRALIAN DEFAULT SETTINGS The Australian version MX60 has a few default settings that differ from the Standard version default settings However there are no differences in performance and efficiency between the two ver sions The Standard and Australian version can be identified as follows OutBack 12V OutBack 12V Power Power Systems Systems MX60 MX60 AU Standard version Australian version Below are a few default setting differences between the Standard and Australian version Settings Standard Australian Charger Amps Absorb Float Amps Absorb Float 12V 60 144V 13 6V 60 14 4V 13 8V 24V 60 28 8 V 27 2V 60 8 8 V 27 6V 36V 60 43 2V 40 8V 60 43 2V AT AV 48V 60 57 6V 544V 60 57 6V 55 2V 60 V 60 720V 68 0 V 60 720V 69 0 V Equalize Equalize Volts Equalize Volts 12V 14 4 14 7 24V 28 8 29
45. ed up to 1000 feet by the optional OutBack Power Systems MATE display OutBack Power Systems Inc OUTBACK MX60 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 configuration sections of this manual with the following important restrictions 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 e With the exception of certain telcom applications the MX60 should never be positive grounded see page 61 Applications Notes The equipment ground on the MX60 is marked with this symbol E If damaged or malfunctioning the MX60 should only be disassembled and repaired by a qualified service center Please contact your renewable energy dealer installer for assistance Incorrect reassembly risks malfunction electric shock or fire The MX60 is designed for indoor installation or installation inside a weatherproof enclosure lt must not be exposed to rain and should be installed out of direct sunlight e For routine user approved maintenance gt Disconnect all circuit breakers and related electrical connections before doing any cleaning or adjustments gt Solar modules may produce hazardous voltages when exposed to light unless servicing them at night cover the modules wi
46. er Chargers and MX60 units when an OutBack HUB and a MATE are parts ofthe system When one RTS is used it must be connected to the component plugged into the Port 1 of the HUB AUX modes include powering a relay LED indicator and Piezo buzzer or brushless fan gt The OutBack MATE can display a single MX60 or multiple MX60s if connected to a HUB e Surge protection on the input PV side of the MX60 and on the battery side is required for extended warranty protection A dwelling rooftop array requires ground fault protection OutBack OBDC GFP 2 recommended Always install the MX60 in an upright position The MX60 must be secured for a safe installation and to retain warranty protection Use a 1 5 8 wood screw through the slotted hole at the top of the MX60 and at least two screws in the internally located holes at the bottom of the MX60 s enclosure OutBack Power Systems Inc OutBack Power Systems Inc Siu 90A 9 xog AY3L1V8 YINVIYG 90 YILAIANI Y434W3Y9 90 Y31Y3ANI AY3LIva S LVW SNH H v2ug 90 XVW dy 08 M xv2ug 90 XV dw 08 DC NEGATIVE BUS BAR 24 VDC BATTERY BANK as LVO Tf JVM z ist y anH lva 8 Ad Ad 3LYW 8NH ONNOYO O9XIN Figure 2 MX60 WIRING DIAGRAM WITHOUT A GFP 2 the ground conductors tie into the negative terminal bus bar 12 O O O Y3IAV3Y8 90 XVN dWY 08 mm l Caas 90 YILSIANI de ANS AYLILV9 SLLV
47. er power to the batteries During this period the MX60 is calculating the pulse width modulation PWM duty cycles turning on power supply voltages in the proper sequences and making internal calibrations At wakeup the MX60 closes its relays and then starts sweeping the input voltage the initial sweep towards the battery voltage At dawn and dusk this may happen many times until there is or is not enough power from the PV array to keep going Wakeup is also a time when the MX60 acquires a new Voc Zzzz At night 3 hours of Sleeping the MX60 will display Zzzz until the next wakeup At the next wakeup usually the next morning the daily statistics AmpHours KWh etc will accumulate into the total statistics and then the displayed daily statistics will clear A Bulk charge will automatically initiate at the next Wakeup OutBack Power Systems Inc MATE DISPLAYED MX60 STATUS MODE Screens The MX60 STATUS MODE Screens displayed on the optional OutBack MATE include MODE METER and SET SETPOINT In STATUS Mode these MX functions can be viewed by the MATE but not changed Please see the MATE Installation and User Manual for more information STATUS aia STATUS MX 12 00 30P choose product SUM STATUS SETUP ADV FX MX MODE METER SETP MAIN Oe OO Oe 00 0 ooo gt gt STATUS MX MODE P00 charger mode Silent STATUS MX MODE P00 aux relay Low Batt mode DOWN UP TOP PORT STATUS MX MODE P00 aux relay sta
48. erisk in front of the Amps LIMIT ABSORB FLOAT selection default is 60 0 and adjust this figure using Amps Volts Volts the and soft keys using the figures in follow 60 0 14 4 13 6 ing MX60 Current vs Temperature Chart Remember EXIT gt to change the current limit when the ambient tempera ture changes OutBack Power Systems Inc MX60 Current Vs Temperature all temps Celsius Ambient Temperature Maximum Current amps 25 60 00 30 57 45 35 54 77 40 51 96 45 48 99 50 45 83 55 4243 60 38 73 65 34 64 70 30 00 75 2449 80 17 32 Table 1 An easy de rating rule to use in lieu of the above table is 1 amp per degree C Altitude should also be factored into de rating Use the following table to determine altitude related values Altitude Meters Feet Factor 0 sea level 1 00 1000 3 000 0 95 1500 5 000 0 90 2000 7 000 0 86 3000 10 000 0 80 3500 12 000 0 75 Table 2 OutBack Power Systems Inc 66 MX60 EFFICIENCY vs INPUT POWER GRAPH MX60 Efficiency vs Input 40 65 and 95 volts nominal input 26 5 volts nominal output H T r Figure 6 24V and 48V Battery System Efficiency Curve OutBack Power Systems Inc UNDERSTANDING THE VARIOUS OPERATIONAL MODES The MX60 modes of operation will change occasionally during the day based on the PV array output and the battery system state of charge The MX60 operating modes are displayed at the
49. ertain abnormal conditions that can confuse the current measuring method in the MX60 When and if one happens the MX60 will temporarily stop and re calibrate This may happen because of negative current Le current coming out of the input terminals instead of into the input terminals or a tripped PV breaker A new Voc is also acquired during a Re Cal Sleeping The PV voltage is two volts less than the battery voltage This may also appear during the day when the MX60 is transitioning between certain states or due to other conditions Sweeping In Auto Sweep MPPT mode the MX60 is either 1 doing an initial sweep of the panel voltage from Voc towards battery voltage after wakeup 2 doing a periodic mini sweep to stay within its acquired Maximum Power Point voltage or 3 sweeping to maintain the current limit Below 5 amps of battery output current Sweeping briefly flashes on the display as the MX60 operates at the Park Mpp voltage SysError Very rare System Error indicates an internal non volatile memory error The unit will stop operating when this message is displayed Call the factory if you see this message Unloaded The battery terminals abruptly unload Unloaded is displayed if the battery breaker trips while MPPTing or the battery voltage is set too low OutBack Power Systems Inc 69 70 Wakeup As the PV open circuit voltage Voc rises above the battery system voltage by two volts the MX60 prepares to deliv
50. evice can be wired directly to the AUX terminal higher out put DC loads require a 12 VDC coil relay also rated up to 200 milliamps or less for the DC coil which itself is connected to the AUX output An internal re settable Positive Temperature Coefficient PTC fuse protects the AUX internal components e For certain AUX control applications the use of a solid state relay is preferred This is particularly beneficial with applications such as the Diversion mode where fast switching often called PWM control allows a more constant battery voltage to be maintained Both DC and AC load switching solid state relays are widely available from many sources Eurotherm and Power lO are two suggested solid state relay manufacturers e Most AUX modes or functions are designed for specialized applications and are infrequently used Only one AUX MODE can operate at a time even if other modes have been preset gt Press the lt EXIT gt soft key to initiate the chosen AUX MODE See Figure 5 page 30 for an Aux set up wiring diagram In this Menu ON and OFF indicators show the The second line indicates AUX MODE the present mode for the Manual present state of the Aux Aux Output Off EXIT NEXT terminals Pressing the ON lt ON gt or lt OFF gt soft key When the preferred mode changes this value eS F B is displayed press the n t lt EXIT gt soft key to select ON indicates 12 VDC is it ll poe P
51. experimentation The MX60 can operate at any of the following fixed percentages selected in the Park Mpp screen in the ADVANCED MENU selection 40 50 67 70 72 75 76 77 78 80 81 83 or 85 ofthe measured open circuit voltage e The user will have to experiment with each of the 13 fixed percentage values to determine an appropriate fixed percentage value Typical fixed values between 67 up to 78 have provided optimal results however each system is different and these fixed percentage values should be used as guidelines only 3 Compare the Auto Sweep and U Pick Voc values and determine which will best fit your system In addition to establishing the best mode and percentage values for determining the MPP voltage a user can also adjust the sweep interval and the range of values the MX60 uses to search for the MPP voltage If necessary re enter the system password 141 at any point while optimizing the system s performance OutBack Power Systems Inc 55 56 ADVANCED MENU Micro Hydro Mpp Range Limit Auto Sweep Mode only The MX60 searches for the MPP voltage by sweeping the input voltage up to one half default of the Voc which is based on values appropriate for a solar array Micro hydro and fuel cell systems can require a broader range normally on the lower end Adjusting the lower limit expressed as 1 2 on the display screen for FULL allows the MX60 to sweep the input volt
52. ging The MX60 features include gt 60 amps maximum continuous output current e Engineered to work with 12 24 36 48 and 60 VDC battery voltages Backlit LCD display screen with 80 characters 4 lines 20 characters per line e Last 64 days of operational data are logged for review Voltage step down capability allowing a higher PV array voltage configuration anual and auto equalize cycle The following are the maximum recommended wattage for the most common solar arrays under Standard Test Conditions 1000 watts per square meter of solar panel at 25 C or 77 F 12 VDC battery systems up to 800 watts of solar panels 24VDC battery systems up to 1600 watts of solar panels 48 VDC battery systems up to 3200 watts of solar panels The MX60 also features Maximum Power Point Tracking MPPT which seeks out the maximum power available from a solar array and uses it to recharge the batteries Without this feature the solar array does not operate at the ideal operating voltage and can only recharge at the level of the battery voltage itself The MX60 sweeps the array s operating voltage at user determined sweep intervals to track the Maximum Power Point MPP of the PV array This manual covers the wiring installation and use of the MX60 including explanations of all the Menus displayed on the LCD screen The MX60 is designed to seamlessly integrate with other OutBack components and can be remotely monitor
53. he lt nonGT gt soft key if you have an Out Back G series inverter system with a HUB and MATE Press the lt NEXT gt soft key to view the Absorb Time Limits screen OutBack Power Systems Inc In the Absorb Time Limits screen the user can set the ADVANCED MENU minimum and maximum times the MX60 stays in the Absorb Time Limits Absorb recharge cycle 000m 2hr EXIT NEXT MIN MAX gt MAXimum is adjustable from 0 to 4 hours gt MINimum is adjustable from 0 minutes the O O O default up to the maximum absorb time limit y n n minus 10 minutes EX Maximum Absorb time 2 hours or 120 minutes Minimum Absorb time adjusted up to 110 minutes To adjust the limits press either the lt MIN gt or lt MAX gt soft key When finished press the lt NEXT gt soft key to view the next screen A Bulk cycle starts each morning The charge timer ChgT is preset to the minimum Absorb time limit zero minutes while the Bulk Absorb Charge Timer counts up in minutes The timer stops when it reaches the Maximum Absorb Time or the Absorb voltage set point is met The ChgT counts down to zero after the Absorb voltage is reached At zero the MX60 goes into Float stage and may briefly display Bat Full Battery Full then Float e When the battery voltage drops below the float voltage set point the MX60 recharges to main tain this set point employing the F Float MPPT function Ifthe system can
54. he disconnect volts the AUX connected loads only are disconnected the loads are On when the battery voltage rises above the reconnect volts To adjust these set points press the lt TIME gt and lt VOLT gt soft keys Press either the lt gt or lt gt soft key to adjust the delay time This is the time period the MX60 waits before either activating or deactivating the AUX MODE when either the disconnect or reconnect volt ages are reached When the low voltage occurs the timer shows the seconds remaining before discon necting When the reconnect voltage is reached the timer shows the userdetermined time before con necting Press the lt BACK gt soft key to return to the Low Batt Disconnect screen 31 ER AUX MODE Low Batt Disconnect On EXIT NEXT TIME VOLT OOO y DISCONNECT VOLTS lt 13 6 BACK ReCon O OO E E RE CONNECT VOLTS gt 14 4 BACK DisV 0 ooo LOA 4 In the Low Batt Disconnect screen press the lt VOLT gt soft key to adjust the battery voltage disconnects set point Press either the lt gt or the lt gt soft key to adjust the disconnect voltage Press the lt ReCon gt soft key to open the RE CONNECT VOLTS screen Press either the lt gt or the lt gt soft key to adjust the RE CONNECT VOLTS value The AUX Output activates when the voltage goes above this setting after the timer has counted back to zero Press the lt BACK gt
55. horized repair facility or that are repaired on site by an OutBack Power Systems authorized repair technician To request limited warranty service you must contact OutBack Power Systems at 360 435 6030 within the limited warranty period If limited warranty service is required OutBack Power Systems will issue a Return Material Authorization RMA Number Mark the outside of the package with the RMA number and include a copy of the purchase invoice in the package You must ship the products back to OutBack Power Systems in their original or equivalent packaging prepay shipping cycles and insure the ship ment or accept the risk of loss or damage during shipment OutBack Power Systems will ship the repaired or replacement products to you freight prepaid if you use an address in the continental United States where applicable Shipments to other locations will be made freight collect OutBack Power Systems Inc EU DECLARATION OF CONFORMITY According to ISO IEC Guide 22 and EN 45014 Product Type Photovoltaic Charge Controller Product Model Number MX60 This product complies with the following EU directives Electromagnetic Compatibility 89 336 EEC Council Directive of 3 May 1989 On the approximation of the laws of member States relating to Electromagnetic compatibility Low Voltage Directive 73 23 EEC Council Directive of 19 February 1973 on the harmonization of the laws of Member States relating to e
56. ions This would normally indicate that the output conductors be 4 AWG but a larger size may be required if there are temperature and or conduit fill corrections required With an output conductor rated at 75 amps 1 25 X the continuous output current the OutBack OBDC 60 breaker rated for continuous 100 duty at 60 amps can be used to provide the code required disconnect and output circuit over current protection The PV array output connected to the MX60 input may be as high 60 amps but at this current level there is very little if any current boosting or maximum power point tracking due to the 60 amp output current limit Additionally the input current may exceed 60 amps on bright sunny days and any excess power would be lost The size and ampacity of the input conductors must be selected to handle 1 56 times the short circuit current of the PV array Any disconnect or circuit breaker connected to the input conductors must also be rated at 1 56 times the short circuit current for the PV array unless the breaker is rated for 100 duty in its enclosure If that is the case the circuit breaker may be rated at 1 25 times the PV array short circuit current OutBack OBDC XX breakers are 100 duty rated breakers In terms of NEC compliance and the MX60 s 60 amp output rating the largest PV array it can con nect to should have a rated short circuit current of 48 amps This meets NEC requirements and allows the MX60 to perform maxi
57. just the voltage level using the lt gt and lt gt soft keys Press the lt BACK gt soft key to return to the Vent Fan screen 25 26 AUX MODE Vent Fan On EXIT NEXT AUX MODE PV Trigger Off EXIT NEXT TIME VOLT PV VOLTS gt 140 Press the lt NEXT gt soft key to advance to the PV Trigger soft screen When the PV input is too high and exceeds the user determined VOLT set point the AUX MODE PV Trigger activates Press the lt VOLT gt soft key to adjust the voltage Adjust the voltage within a range of 20V 150V by pressing the lt gt or lt gt soft key Press the lt BACK gt soft key when finished to return to the PV Trigger screen OutBack Power Systems Inc AUX MODE PV Trigger On EXIT NEXT TIME VOLT Hold Time Sec 01 1 AUX MODE PV Trigger Off EXIT NEXT TIME VOLT AUX MODE Float Off EXIT NEXT OutBack Power Systems Inc To adjust the minimum amount of time the PV volt age must remain high before deactivating the AUX MODE press the lt TIME gt soft key Press the lt gt or the lt gt soft key to adjust the Hold Time then press the lt BACK gt soft key to return to the PV Trigger screen In this example the AUX ODE will remain active for 1 1 sec after the PV volt age is below the PV Trigger voltage before deactivat ing the PV Trigger and reconnecting to the array Press the lt NEXT gt soft key to view the Float screen The AUX
58. lectrical equipment for use within certain voltage limits The compliance of the above mentioned product with the directives and the following essential requirements is hereby confirmed Emissions Immunity Safety EN 61000 6 3 2001 EN 61000 6 1 2001 EN 60335 1 Battery Chargers EN 60335 2 29Battery Chargers All associated technical files are located in the Engineering Department at OutBack Power Systems Inc Arlington Washington USA As the manufacturer we declare under our sole responsibility that the above mentioned product complies with the above named directives 19009 62nd Ave NE Qu t Back Arlington WA 98223 USA Power Systems 360 435 6030 OutBack Power Systems Inc 89 90 OWNER S SYSTEM INFORMATION Date of Purchase EE Vendor gt gt Date of Installation Installer GE Installer Contact Information MX60 Serial Number Battery Voltage PV Voltage AAA PV Module Type and Manufacturer Array Wattage ee NOTES E OutBack Power Systems Inc Product Registration Please take a moment to register and provide us with some important information Registering your products will help us maintain the standard of excellence you expect from us in terms of performance quality and reliability Send check or money order payable to OutBack Power Systems Include a completed copy of this application to OutBack Power Systems 19009 62nd Avenue NE Arlington WA 98223 USA
59. ll does not power up call the factory for additional support MX60 is always SLEEPING Ifthe battery voltage is at or above the ABSORB voltage set point Compensated ABSORB voltage the MX60 will not wake up The PV voltage has to be at least two volts greater than the battery voltage for the initial wakeup e Check the PV array breaker or fuse e Confirm the PV array breaker or fuse is sized appropriately e Which State in MISC Menu is it at Is it transitioning between 00 and 01 Is it in GT mode and connected to a MATE GT mode is only applicable with a HUB 4 or HUB 10 installations with a grid tie compatible MATE Does the PV array voltage on the display rise with the PV breaker OFF but reads 000 with the PV breaker on gt If so the PV array polarity connection on the MX60 maybe reversed or the PV lines could be shorted Does the PV voltage still read 000 with the PV breaker off after a minute Call the factory for support e Have you checked the short circuit current of the PV array gt Use a multi meter to determine if a short circuit current is detected The short circuit current test will not harm the array OutBack Power Systems Inc MX60 not producing expected power e Clouds partial shading or dirty panels can cause poor performance gt The lower current limit set point in the Charger menu will yield a loss of power or poor performance symptoms Are the batteries charged Is the MX6
60. mum power point tracking functions The following charts show maximum distance in feet of various gauge two conductor copper wire from the PV array to the MX60 with a 1 5 maximum voltage drop Temperature and conduit fill corrections may be required UL requires Isc to be multiplied by 125 for the conductor rating OutBack Power Systems Inc EE P Bulk cycle begins gt Absorb charge is reached P At zero MX60 goes into FLOAT P Timer starts gt Timer begins counting to zero Figure 7 MX60 MULTI STAGE BATTERY CHARGING The MX60 charge controller is a sophisticated multi stage battery charger that uses several regula tion stages to allow fast recharging of the battery system while ensuring a long battery life This process can be used with both sealed and non sealed batteries The MX60 has a preset recharg ing voltage set points Absorb amp Float for the selected nominal battery voltage however always follow the battery manufacturer s recommended charging regulation voltages The MX60 charging regulation stages correspond to the chart in Figure 7 OutBack Power Systems Inc 84 BULK cycle provides the maximum power to the battery the voltage increases while recharging A Bulk cycle is automatically initiated when the battery voltage is below the Absorb and Float recharge voltage set points The Bulk cycle will continue until the Absorb voltage set point is achieved BMPPT is displayed on the screen A
61. n reached EQ 0 00 will be displayed along with the EQ time in hours and minutes The AC DC loads should be turned off and the battery should be charged so the MX60 can reach the EQ voltage set point Otherwise the MX60 may not reach or maintain the EQ cycle Float The MX60 is in the Float charge stage and is regulating the battery at the Float voltage set point If the system cannot keep up with the Float voltage set point e g AC and or DC loads are on the MX60 will employ the MPPT function display F MPPT and try its best to regulate the bat teries to the Float set point F MPPT The MX60 is in Maximum Power Point Tracking mode trying to regulate the battery volt age towards the Float voltage set point Note Charge Timer ChgT is inactive in the Float state GT Mode In a system with an OutBack FX G series Inverter Charger HUB and MATE the MX60 will display GT Mode if and only if the inverter is in Sell mode and the MX60 is in Bulk B MPPT or Float F MPPT cycle This is also a good indicator for establishing proper Grid tie mode communication between the FX G Series Inverter s and MX60 High Voc This indicates the PV array s open circuit voltage is too high for the controller to safely operate This should only occur with systems using 72 VDC nominal PV arrays in very cold tem peratures below 50 F 150 C The controller will automatically restart operation once the PV array s open circuit voltage falls to a safe le
62. nc 60 Volt PV Array 80V MPP Typical Distance in Feet Two Wires 1 5 Voltage Drop 12 24 or 48 Volt Battery System 72 Volt PV Array 96V MPP Typical Distance in Feet Two Wires 1 5 Voltage Drop 12 24 or 48 Volt Battery System OutBack Power Systems Inc Amps Wire Gauge 8 6 112 177 90 142 60 95 45 72 30 47 225 35 175 27 Wire Gauge 8 6 140 221 113 178 Z5 119 56 90 37 59 28 44 4 285 227 150 112 75 57 45 4 356 284 188 140 94 71 2 450 362 240 180 120 90 72 2 562 453 300 225 150 112 1 0 725 575 382 287 192 145 115 2 0 900 725 480 362 230 180 145 2 0 1125 906 600 452 287 225 4 0 1812 1437 937 725 481 350 81 82 WIRE AND DISCONNECT 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 battery voltage There is no 80 de rating as required by the NEC for fuses conductors and most circuit breakers The MX60 is a buck type converter and cannot boost the output current when the PV array peak power point voltage is at or below the battery voltage as may happen on hot days in 24 VDC PV and a 24 VDC battery system or a 48 VDC PV and a 48 VDC battery system To meet minimum NEC requirements NEC 310 15 690 8 9 the output conductor should have an ampacity of 75 amps after any temperature and conduit fill correct
63. not maintain the Absorb voltage set point during the Absorb cycle the timer will stop counting down and begin counting up towards the Max Absorb time as the MX60 transitions to Bulk BMPPT This up and down counting will continue until the charge timer counts down to zero The Absorb cycle can be disabled by setting the maximum to Ohr 50 ABSORB 45 404 SLEEP Z222 35 PV ARRAY VOLTAGE _ 304 25 20 P Bulk cycle begins gt Absorb charge is reached P At zero MX60 goes into FLOAT Timer starts P Timer begins counting to zero NOTE In BULK the MX60 will charge as long as necessary to complete the cycle regardless of the timer s set points OutBack Power Systems Inc 48 ADVANCED MENU Wakeup Mode 01 5v 05m EXIT NEXT VOC Min ooo v A Charger Aux Light Eq Misc Advanced Logging Log2 EXIT gt GO GE A Wakeup Mode selects how often the MX60 does a Wakeup during Snoozing periods Since environ mental condition impact the open circuit voltage Voc of an array a user selectable Voc rise in value will allow the controller to wakeup sooner or later based on the last measured Voc value A selectable delay time in minutes will also allow the control ler to Wakeup sooner or later if the measured Voc did not meet the user selectable Voc rise in value Before changing these values monitor your system for a week or so using the factory defaults and then gradu
64. nt Output current j 00 0 A 00 0 A le Instantaneous Watts Watts 0000 Aux Off Aux Status ON or OFF Daily accumulated kWHrs 00 0 Sleeping Operational Mode kiloWatt Hours CI OO NOTES Pressing the first soft key opens the MAIN Menu screen e Pressing soft key 2 toggles between Amp Hours and kW Hours displays OutBack Power Systems Inc PREPARING FOR RECHARGING Turn the PV input breaker on The MX60 PV 113 V Bat 12 5 V automatically detects the PV input voltage 00 0 A 00 0 A aN Watts 0000 Aux Off Note If PV voltage registers OOOV when the breaker kWHrs 00 0 Sleeping is on please check the polarity of the PV wires ESPE G2 After 5 seconds of stable input voltage the MX60 PV 087 V Bat 12 5 V enters a Wakeup stage transitions to Sweeping 05 0 A 32 9 A and prepares to charge the batteries by tracking the Watts 0412 Aux Off kWHrs 00 0 B MPPT MPP of the solar array Cc O 2 E OutBack Power Systems Inc 20 ACCESSING THE MAIN MENU The MAIN Menu allows the user to adjust and calibrate the MX60 for maximum performance From the STATUS screen press soft key 1 to open the MAIN Menu screen Charger Aux Light Press the lt GO gt soft key after aligning the asterisk EQ Misc Advanced in front of the selected menu choice Logging Log2 EXIT GO Pressing the lt EXIT gt soft key in the MAIN Menu returns to the STATUS Menu Press the lt EXIT gt
65. ntage of Voc press either the lt VOC gt or lt VOC gt soft key Press the lt NEXT gt soft key to view the next ADVANCED MENU screen The Mpp Range Limit Voc adjusts the upper Mpp limit of the Voc The default MX60 MPP voltage limit is set at 90 of the Voc and is normally left alone for an array If an MX60 sweep finds an MPP voltage out side of this range it will revert to the Park Mpp value Setting to 1 2 reduces the initial sweep time on a high input voltage array The MPP adjustable MX60 limits are 80 85 90 and 99 of the Voc The min range limit setting may be set to FUL if something other than a PV array is connected to the input of the MX60 such as a Micro Hydro generator see page 54 but the Voc cannot exceed 150 VDC at any time Press the lt min gt or lt max gt soft key to adjust the MPP range limit When done press the lt NEXT gt soft key to view the Sweep Interval screen OutBack Power Systems Inc ADVANCED MENU Sweep Interval 07 Minutes EXIT NEXT MIN MAX OOOO Yo AA ADVANCED MENU Vbatt Calibration 12 8v 0 0v EXIT NEXT V V The present Vbatt meter reading is displayed here for convenience OutBack Power Systems Inc The Sweep Interval mode or mini sweep deter mines how often a sweep occurs ranging from 0 15 minutes A sweep is a search for the best MPP for the array At zero minutes the MPPT mini sweep function is disabled this is not recommended for PV arrays
66. pears on the screen Con tinue pressing the 1 soft key and press the 3 soft key at the same time until X Off displays on the screen To reactivate Extended Play repeat these steps and hold the 3 soft key until X On displays Extended Play is meant to optimize the performance of a hot array but isn t critical to efficient MX60 operations OutBack Power Systems Inc TYPICAL ARRAY SIZING GUIDE Below is a list of recommended array sizing for the MX60 for various nominal voltage batteries Nominal Battery Voltage Recommended Array Size in watts Standard Test Conditions 12V 800 W 24V 1600 W 36V 2400 W 48 V 3200 W 60 V 4000 W The MX60 PV MPPT Charge Controller is capable of an input open circuit voltage Voc of up to150 VDC Cooler climates can cause the Voc to rise above the panel Voc rating In climates that observe temperatures less than approximately 5 F a Voc greater than 125 VDC is not recommended When sizing an array it is recommended that the nominal array voltage be higher than the nomi nal battery voltage Below is a list of recommended nominal array sizing Nominal Battery Voltage Nominal Array Voltage recommended 12V 24 V or higher 24V 36 V or higher 36V 48 V or higher 48 V 60 V or higher 60 V 60 V low temp is less than 5 F or 72v low temp is greater than 5 F When sizing an array to charge controller with a distance of 70 feet or greater OutBack recommends th
67. reached An incomplete equalization cycle continues into the next day unless the MX60 is powered off or manually stopped The remaining EQ time can be viewed in the Log2 Menu The COUNT value will be cleared to 000 when an EQ is started manually stopped or MX60 has been powered off After recharging an FQ DONE message displayed and a Float cycle begins To view the MAIN EQ screens press the 1 soft key To view the MAIN EQ screens press the 1 soft key OutBack Power Systems Inc MISC MISCELLANEOUS The MISCELLANEOUS screens display extra settings and technical information some of which is useful for OutBack Power Systems Technical Services The Grid Tie GT value is sent from G Each MPPT operation is This is the duty cycle of series inverter through the MATE and a state This number the converter At 50 HUB for Grid Tie control communica is useful for OutBack the PV terminals would tions GT X means MX60 is in grid tie troubleshooting be twice the battery mode and communicating with the G voltage Series Inverter The battery temperature The Bulk Absorb GT State PWM ChgT lt ch l 255 07 50 0 005 charge timer counts Tmp Comp al4 4 f13 6 EXIT NEXT WIDE RSTRT compensated Absorb a and Float f set points up in Bulk and counts rise and fall with tem down in Absorb perature If no RTS is used these settings will be S ZE age Ee ED the same as those in the charger
68. ressing the lt NEXT gt soft key terminals OFF indicates changes to the next mode OVDC Terms e AUX MODE what is displayed on the Menu e Aux Output 12 VDC is either available or unavailable at the Aux Terminal Aux Terminal the jack to which a relay is wired OutBack Power Systems Inc AUX MODE Path Charger Aux Light EQ Misc Advance Log2 Logging EXIT PASSWORD Charger AUX Light EQ Misc Advance Logging Log2 EXIT AUX MODE AUX MODE Manual On EXIT NEXT ON OFF O OO KKK ik Manual Off EXIT NEXT ON OFF OoOO O O Press the 1 soft key once from the STATUS Menu to open the MAIN Menu Press either of the arrow soft keys until the is to the left of Aux Press the lt GO gt soft key If more than ten minutes have passed since any activity the PASSWORD screen becomes active requiring the user to input the 141 PASSWORD and press lt ENTER gt This screen will also appear after first booting up the MX60 even though the password was entered when setting the battery voltage AUX MODE Vent Fan Off EXIT NEXT AUX MODE ERROR ALARM On EXIT NEXT AUX MODE Remote Off EXIT NEXT d ooo OutBack Power Systems Inc AUX MODE PV Trigger Off EXIT NEXT TIME VOLT O Oo AUX MODE Diversion Off EXIT NEXT TIME VOLT O O O PV 005 V Bat 12 5 V 00 0A 00 0A Watts 0000 Aux Off kWHrs 00 0 Sleeping Ca LS AUX MODE Float
69. rward one day and EXIT takes you back to the main STATUS screen If starting on Day 01 and DAY is pressed the value from 64 days ago is presented CLEAR TOTL DALY Pressing and holding the TOTL or DALY TO TAL AND DAILY soft key will prompt you to erase those total accumulated values Press ing BACK returns to the Logging screen OutBack Power Systems Inc 50 Clearing Totals and Daily Stats e Pressing and holding TOTL for three seconds brings up the Are you sure screen prompting you to clear the total accumulated kWh and kAh statistical values in the MX60 Pressing and holding DALY for three seconds will bring up the Are you sure screen for clearing all of the 64 Daily logged values After Yes is confirmed the values will be cleared It may take a few seconds for all 64 daily values to be cleared before the confirmation screen goes away e Pressing BACK brings back the Logging screen Note If two or more MX60s are used in the same system and are started up or cleared on different days their numeric dates will not be the same This can lead to some misunderstand ings when looking back and comparing data between the two or more units A user looking back at day 12 on both units would find very different results To return to the MAIN Menu press the 1 soft key from any screen From the MAIN Menu press the lt gt gt soft key to Charger Aux Light move the asterisk next to the
70. s 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 indicates the chosen voltage The MX60 will automat ically accept the selected battery voltage if left unat tended for 5 minutes in this screen After choosing the voltage press the lt ENTER gt soft key to proceed Press the lt YES gt soft key to proceed if the selected battery voltage is correct If incorrect press lt NO gt to re enter the correct voltage The MX60 briefly returns to the Power Up screen and then automatically opens the STATUS screen which displays information regarding the recharging status Confirm the battery voltage displayed in the upper right corner is correct Note Repeating the Powering Up sequence resets the MX Charge Controller to its factory default settings STATUS SCREEN The STATUS Screen displays system information See page 67 for detailed information of the dif ferent Operational Modes The optional OutBack MATE displays MX STATUS screens for convenient distant viewing from the installation location of the MX60 Please see page 71 to view the MX screens displayed on the MATE The PV voltage will slowly rise to the battery voltage level even when the PV breaker is off this is normal as the PV capacitor charges up PV Input Voltage Battery voltage PV 005 V Bat 12 5V PV Input Curre
71. soft Cc O ee O ey in your chosen menu to return to the STATUS screen Press amp or gt to move the asterisk to the left of the desired screen The asterisk allows access to any screen to its right From the MAIN asterisk Charger CH Menu a user can choose among the following MX60 functions by aligning the ARGER SETUP gt Adjusts the Current Limit Absorb and Float recharging voltage set points e Aux AUX O Secondary lt Light BACK UTPUT CONTROL control circuit for a vent fan error alarm and other system related additions LIGHT CONTROL gt Adjusts the backlighting of LCD screen and soft key buttons e EQ BATTERY EQUALIZE gt Activates b attery equalization recharging manually or automatically e Misc MISCELLANEOUS Additional settings and service information Advanced Optimizing the user ha ADVANCE MENU fine tuning the MX60 these are advanced Menus that should be left alone until s a good working knowledge of the MX60 and its operations Logging DATA LOGGING P Displays recorded power production information e Log2 LOG 2 P Displays recorded peak system information OutBack Power Systems Inc CHARGER SETUP This screen allows changes to the MX60 s recharging voltage set points Current Limit Absorb Float The presently selected numerical value will have an asterisk to the left of it e Pressing gt selects the value to
72. ssing and holding again for a few seconds will toggle the value between 24 and 25 hours Mini sweeps at the selected sweep interval will initiate on time in either of these modes Press the lt NEXT gt soft key to view the secondary Log2 screen After 3 hours of sleeping the MX60 displays Zzzz This means that the next wakeup will cause the daily KiloWattHour AmpHour statistics and Float Time to be logged and accumulated in the Logging screen This the next wakeup will also initiate a Bulk charge cycle OutBack Power Systems Inc Secondary LOG2 Screen The Secondary Log2 screen shows the basic recharging state of the MX60 EQ FLOAT time in min utes and the daily maximum HighWatts wattage seen by the MX60 during the day When initiated EQ information will be The present day s time in minutes spent in displayed here Float stage 0000 float Tmin 0705 HighWatts Lo 13 2 Hi 14 8 DCkWh The lower and upper This value is the peak battery temperature BACK daily Watts seen by the compensation voltage MX60 is visible and active O O O O only when the mode is set to LMIT nee Press soft key 3 to display the accumulated total kWh reading in AC or DC the Data Logging screen e DCkWh default shows DC kiloWatthours and should be used in a non grid tied system e ACkWh is used with a grid tied system The heading in the logging screen will change to TotalkKWh AC
73. t collect In the event of a product malfunction OutBack cannot bear any responsibility for consequential losses expenses or damage to other components Please read the full warranty at the end of this manual for more information OutBack Power Systems Inc Ciut Back Power Systems The OutBack Power Systems MX60 PV MPPT Charge Controller is ETL listed to UL1741 Inverters Converters Controllers and Interconnection System Equipment for 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 89 About OutBack Power Systems OutBack Power Systems is a leader in advanced energy conversion technology Our products include true sine wave inverter chargers a maximum power point charge controller system com munication components as well as breaker panels breakers accessories and assembled systems Notice of Copyright MX60 PV MPPT Maximum Power Point Tracking Charge Controller Installation Programming and User s Manual Copyright 2007 All rights reserved Disclaimer UNLESS SPECIFICALLY AGREED TO IN WRITING OUTBACK POWER SYSTEMS a MAKES NO WARRANTY AS TO THE ACCURACY SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION b ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE WHETHER DIRECT INDIRECT CONSEQUENTIAL OR INCIDENTAL WHICH MIGHT ARISE OUT OF THE USE OF SUCH
74. t falls outside of the fixed percentages available in Park Mpp With the MX60 a user can manually adjust these values by single percentage points while observing a change in the instantaneous watts made available with these adjustments To manually track and change the MPP voltage in either the Auto Sweep or U Pick Voc MPPT Modes Press and hold the 3 soft key to decrease the power PV 087 V Bat 12 0 V 05 0 A 35 8A point voltage PV voltage Press and hold the 4 soft Watts 0430 Aux Off key to increase the power point voltage PV voltage kWHrs 00 0 B MPPT Observe the changes in the Watts value to determine O O es gt whether increasing or decreasing the PV voltage will A A improve the available power to the system Press either soft key to adjust PV voltage OutBack Power Systems Inc 59 60 THIS PAGE INTENTIONALLY LEFT BLANK OutBack Power Systems Inc APPLICATION NOTES OutBack Power System GTFX GVFX Grid tie settings In a GFX GVFX series inverter MX60 HUB and MATE installation set the MX60 to GT mode in the ADVANCED MENU The GT mode allows the GFX GVFX series inverter to manage the MX60 float setting ensuring the MX60 is always keeping the battery above the sell voltage of the GFX GVFX Grid tie applications non OutBack inverter chargers When selling electricity back to the grid keep the inverter Sell Float voltage below the MX60 float voltage Appropriate values 0 5 Volts difference for 24V
75. tage set point should not go over 150 VDC the PV Trigger disconnects after a minimal adjustable amount of Hold Time Float powers a load if the MX60 is producing power in the Float stage Error Alarm useful for monitoring remote sites switches to the Off state if the MX60 has not charged the batteries for 26 hours or more not an audible alarm only displayed as a printed message on MX60 AUX Menu e Diversion diverts excess power away from batteries when a wind or hydro generator is con nected directly to the batteries Low Batt Disconnect activates deactivates the AUX load s when a user determined voltage and time levels are reached e Remote allows OutBack MATE to control the operation of the AUX MODE see MATE manual for details OutBack Power Systems Inc Programming the AUX MODES AUX MODE Manual On EXIT NEXT ON OFF AUX MODE Vent Fan On EXIT NEXT VOLT VENT FAN VOLTS gt 14 4 OutBack Power Systems Inc Press the lt ON gt or lt OFF gt soft keys to manually activate or deactivate AUX MODE Press the lt NEXT gt soft key to view the Vent Fan screen To view other screens continue to press the lt NEXT gt soft key The Vent Fan helps remove hydrogen from the bat tery room The ventilation fan referred to here is not the same as the MX60 cooling fan Press the lt VOLT gt soft key to determine the battery voltage that will activate the AUX MODE and start the fan Ad
76. tage which can delay the EQ cycle MX60 Sweeping frequently A short sweep interval time will cause the MX60 to sweep frequently A sweep interval of seven to ten minutes is recommended e When the current limit set point is achieved the MX60 will continue to sweep to maintain the targeted current limit OutBack Power Systems Inc MX60 Battery Temperature Compensated Voltage Only the OutBack RTS remote temperature sensor can be used with the MX60 The battery voltage can rise above the ABSORB and FLOAT voltage set points if the battery tem perature is lt 77 F or fall below the ABSORB and FLOAT voltage if the battery temperature is gt 77 F e Why does the MX60 show BatTmpErr on the STATUS screen gt The RTS is faulty or damaged Disconnect the RTS from the RTS jack to resume normal operation MX60 Internal Fan e The internal fan will only run when the internal temperature has reached approximately 115 F The internal fan will run as needed In the MISC Menu the fan will run if and only if the value of PCB is lower than the value 350 Note that the value 350 represents a temperature count value it does not itself equal 350 F MX60 is beeping When the MX60 is in Extended Play mode the array is very hot and the MPP is close to the bat tery voltage beeping can occur To disable the Extended Play feature go to the MAIN Menu and press and hold the 1 soft key until the MX60 s software version ap
77. te ON DOWN STATUS PORT ooo DOWN UP TOP PORT O o g gt gt STATUS MX MODE STATUS MX sseesecascaccnss d of d diia dci Press lt METER gt to view e TAPA MODE METER SETP MAIN the MX METER screens gt MX MODE Screens e charger mode displays one of five charging stages Bulk Absorption Float Silent or Equalization aux relay mode displays one of eight MX60 AUX modes Manual Vent Fan PV Trigger Float ER ROR ALARM Diversion Low Batt ery Disconnect or Remote e aux relay state indicates if the AUX is ON or OFF OutBack Power Systems Inc 71 72 MATE DISPLAYED MX60 STATUS METER Screens mode Silent POO pv 10 0v STATUS MX METER P00 charger bat 26 0v in 0a out 0a DOWN STATUS PORT d oooO watts DOWN UP STATUS MX METER P00 STATUS MX METER P00 charger 000 adc battery 26 5 vdc amps dc voltage DOWN UP TOP PORT DOWN UP TOP PORT 0 ooo ooo gt STATUS MX METER end of meter menu UP TOP STATUS MODE METER SETP MAIN OOO OO 8 oO gt MX METER Screens mode pv in bat out displays the charger mode the PV array voltage the incoming PV amps the battery voltage and the outgoing amps to the battery charger watts charger output measured in watts STATUS MX METER P00 charger D kwh kwhrs DOWN UP TOP PORT 0 ooo STATUS MX METER P00 panel 10 2 vdc voltage DOWN UP TOP PORT d ooo Press lt SETP gt to view the SETPOINT
78. th opaque material before servicing any connected equipment Standards and Requirements All installations must comply with national NEC and local electrical codes professional installation is recommended DC and Battery Related Installation Requirements All DC cables must meet NEC standards Shut off all DC breakers before connecting any wiring Torque the four position terminal block and ground terminals to 30 inch pounds 4Nm All wiring must be rated at 75 C or higher Use up to 2 AWG to reduce losses and ensure high performance of MX60 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 fittings to allow the inductive currents to cancel DC battery over current protection must be provided as part of the installation OutBack offers both breakers and fuses for over current protection OutBack Power Systems Inc WARNING WORKING IN THE VICINITY OF A LEAD ACID BATTERY IS DANGEROUS BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL OPERATION Design the battery enclosure to prevent accumulation and concentration of hydrogen gas in pockets at the top of the enclosure Vent the battery compartment from the highest point to the outside A sloped lid can also be used to direct the flow of hydrogen to the vent opening CAUTION To reduce risk of injury charge
79. that can connect to an MX60 should have a rated short circuit current of 48 amps STC Standard Test Conditions Input conductors and circuit breakers must be rated at 1 56 times the short circuit current of the PV array OutBack OBDC 100 duty continuous breakers only need to be rated at 1 25 times the short circuit current Please see the wire Distance Chart and complete Wire and Disconnect Sizing on pages 80 82 for other suitable conductor wire sizing OutBack Power Systems Inc Figure 1 Field Wiring Connections and Surge Protection Use up to 2 AWG wire and torque to 30 inch pounds at terminals MATE HUB RJ45 jack If attaching to plywood use a 1 5 8 wood screw to secure the MX60 at the top slotted hole and other screws as needed at interior bottom holes IRA PV PV BAT BAT Four Position Terminal Block Battery Remote Temp Sensor RTS RJ11 jack Programmable AUX Output Jack supplies up to 200mA 12 VDC Chassis Equipment Ground Lug The PV and BAT terminals are connected internally Only one negative wire may be needed to connect to the Four Position Terminal Block if the PV and BAT conductors are bonded at the negative bus bar See Figures 2 and 3 for sample wiring diagrams OutBack Power Systems Inc NOTES An optional battery Remote Temperature Sensor RTS is recommended for accurate battery recharging only one RTS is needed for multiple OutBack Series Invert
80. the MX60 If the screen reads Got Battery please see the Troubleshooting Guide on page 74 OutBack Power Systems Inc 15 Power Up Screen OutBack 12V Power Systems E IES E BATTERY VOLTAGE 12 24 36 48 60 AN EXIT ENTER OO O yy Press Either Key Password Screen PASSWORD ENTER O oO y A Release both soft keys when the OutBack Power Systems screen appears The selected battery voltage appears in the upper righthand corner The BATTERY VOLTAGE screen will appear next Note The MX60 designation in the lower left corner will read MX60AU for Australian versions and MX60ES for Spanish versions AN indicates the selected battery voltage Press the or lt ENTER gt soft keys to proceed to the PASSWORD screen which prevents unauthorized changes to the system Press the soft key until the password 141 shows on the screen Press the lt ENTER gt soft key to return to the BATTERY VOLTAGE Note 141 is the password for all OutBack products displayed on a screen OutBack Power Systems Inc Battery Voltage Screen BATTERY VOLTAGE 12 24 36 48 60 AN EXIT gt ENTER OO 4 y Verification Screen Are you sure 12 24 36 48 60 AN NO Yes GC CC i Power Up Screen OutBack 12V Power Systems Map ESE Ee Ke OutBack Power Systems Inc Press the gt soft key to select a battery voltage The MX60 default value
81. ture corrrected VOC Less than 1 watt typical Five stage Bulk Absorption Battery Full Float and Equalization 13 80VDC With optional RTS sensor 5 millivolts C per 2V cell PV voc limits of 141 VDC to any battery system voltage Examples 72V array to 24V 60V array to 48V 4 line 20 character per line backlit LCD display RJ45 modular connector Cat 5 cable 8 wire 40 to 60 C de rated above 25 C ndoor type 1 Two 1 2 3 4 on the back one 3 4 1 on each side two 3 4 1 on the bottom Two years parts and labor optional extended warranty available MX60 13 5 H x 5 75 W x A Boxed 18 H x 11W x 8 D MX60 12 pounds Boxed 15 pounds Down convert from any PV array voltage within 63 64 The MX60 maximum current output at 25 C is 60 amps In higher ambient temperatures the MX60 current limit should be reduced in order to prevent possible damage to the unit Realisti cally given that the solar array also reduces its current output when the ambient temperature increases a user will probably never have to adjust the MX60 current limit To do so go to the STATUS screen and choose the Charger function Press the lt GO gt soft key after aligning the asterisk in Charger Aux Light EQ Misc Advanced front of the selected menu choice Logging Log2 EXIT gt GO GE ee Press E or gt to move the asterisk to the left ofthe Charger function Press gt to move the ast
82. vel 141 VDC The amount of time required to reset is dependent on the module type ambient temperature and the amount of sunlight directly on the PV array Normally the controller starts in the morning within a few minutes of the PV array being in direct sunlight OutBack Power Systems Inc Low Light Snoozing During the initial sweep see Wakeup and Sweeping if it is determined to be too late or too early in the day the MX60 will display Low Light for a few seconds and then display Snoozing for 5 minutes default This reduces energy usage and unnecessary powering of the MX60 This message is also displayed in extremely cloudy weather The Snoozing mode can be disabled and has two basic modes to choose from one based on the speed of the PV to charge the input capacitors and the second looks at the initial wakeup sweep current to see if it reached the Low cutoff default current set point MX 2 Hot Very rare Either the MX60 is too hot or its internal temperature sensor is shorted If this message appears carefully check if the MX60 heat sink is extremely hot The heat generated by the MX60 and therefore its losses is proportional to input voltage times output current Avoid installing the MX60 in direct sunlight to help control its operating temperature New Voc The MX60 is acquiring a new open circuit panel voltage Voc periodically in the UPick MPPT mode or it found a new Voc during an initial sweep Re Cal There are c

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