Outback Power Systems MX60 User Manual 2

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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 e ort 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:

• Any and all warranty repairs must conform to the terms of the warranty.

• All OutBack equipment must be installed according to their accompanying instructions and

manuals with speci ed over-current protection in order to maintain their warranties.

• 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.

• 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).

• OutBack will ship the repaired or replacement component(s) prepaid to addresses in the continental

United States, where applicable. Shipments outside the U.S. will be sent freight 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.

The OutBack Power Systems MX60 PV MPPT Charge Controller is ETL listed to UL1741 (Inverters, Convert-

ers, 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 87).

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 communication

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

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

INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER’S RISK.

Date and Revision

April, 2008 REV D 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

TABLE OF CONTENTS

INTRODUCTION ........................................................................................................................................................................................ 6

INSTALLATION GUIDELINES AND SAFETY INSTRUCTIONS ............................................................................................. 7

Standards and Requirements ................................................................................................................................................. 8

OPEN CIRCUIT VOLTAGE/WIRE AND DISCONNECT SIZING ............................................................................................ 9

BATTERY SYSTEM VOLTAGE ..............................................................................................................................................................14

POWERING UP .........................................................................................................................................................................................15

STATUS SCREEN .......................................................................................................................................................................................18

PREPARING FOR RECHARGING ......................................................................................................................................................19

ACCESSING THE MAIN MENU .........................................................................................................................................................20

CHARGER SETUP ....................................................................................................................................................................................21

AUX MODE .................................................................................................................................................................................................22

AUX MODE Path ............................................................................................................................................................................23

AUX Modes Described ..............................................................................................................................................................24

Programming the AUX MODES ...........................................................................................................................................25

Manual ......................................................................................................................................................................................25

Vent Fan ...................................................................................................................................................................................25

PV Trigger ................................................................................................................................................................................26

Float ............................................................................................................................................................................................27

Error Alarm..............................................................................................................................................................................28

Diversion ..................................................................................................................................................................................28

Low Battery Disconnect .................................................................................................................................................31

Remote .....................................................................................................................................................................................33

BACKLIGHT.................................................................................................................................................................................................34

EQ (Equalize) .............................................................................................................................................................................................34

MISC-MISCELLANEOUS ......................................................................................................................................................................37

WIDE/LMIT Battery Temperature Compensated Limits .................................................................................................38

ADVANCED ................................................................................................................................................................................................43

Snooze Mode..................................................................................................................................................................................43

Park Mpp ...........................................................................................................................................................................................44

Mpp Range Limit % Voc ...........................................................................................................................................................44

Sweep Interval ...............................................................................................................................................................................45

Vbatt Calibration ...........................................................................................................................................................................45

Low Cuto ........................................................................................................................................................................................46

MPPT Mode .....................................................................................................................................................................................46

Absorb Time Limits .....................................................................................................................................................................47

Wakeup Mode ................................................................................................................................................................................48

(DATA) LOGGING ....................................................................................................................................................................................49

Clearing Total and Daily Stats ...............................................................................................................................................50

LOG2 ..............................................................................................................................................................................................................51

Secondary LOG2 Screen ..........................................................................................................................................................53

MICRO-HYDRO, WIND TURBINE, AND FUEL CELL APPLICATIONS............................................................................54

ADVANCED MENU (Micro-Hydro) ...............................................................................................................................................56

MX60 ABBREVIATED MENU MAP..................................................................................................................................................60

APPLICATION NOTES ...........................................................................................................................................................................61

FACTORY ASSISTANCE ........................................................................................................................................................................62

SPECIFICATIONS ......................................................................................................................................................................................63

UNDERSTANDING THE VARIOUS OPERATIONAL MODES ..............................................................................................67

MATE-DISPLAYED MX60 STATUS MODE Screens ...............................................................................................................71

MATE-DISPLAYED MX60 STATUS METER Screens ...............................................................................................................72

MATE-DISPLAYED MX60 STATUS SETP(SETPOINT) Screens .........................................................................................73

TROUBLESHOOTING GUIDE ............................................................................................................................................................74

TYPICAL ARRAY SIZING GUIDE ......................................................................................................................................................77

STANDARD vs. AUSTRALIAN DEFAULT SETTINGS ...............................................................................................................78

WIRE DISTANCE CHART ......................................................................................................................................................................79

WIRE AND DISCONNECT SIZING ..................................................................................................................................................81

MULTI-STAGE BATTERY CHARGING .............................................................................................................................................82

BATTERY TEMPERATURE COMPENSATED VOLTAGE SET POINT .................................................................................84

SUGGESTED BATTERY CHARGER SET POINTS ......................................................................................................................85

OWNER’S SYSTEM INFORMATION ...............................................................................................................................................86

EU DECLARATION OF CONFORMITY........................................................................................................................................ 87

WARRANTY INFORMATION ..............................................................................................................................................................88

PRODUCT REGISTRATION .................................................................................................................................................................90

SCOPE

The manual provides safety guidelines and installation information for the MX60 PV MPPT Charge

Controller. It does not provide information about speci c brands of solar panels and supplies

limited information on batteries. Contact the supplier or manufacturer of the solar panels or

batteries for further information.

INTRODUCTION

MX60 PV MPPT (Maximum Power Point Tracking) Charge Controller

The OutBack MX60 PV MPPT Charge Controller o ers an e cient, safe, multi-stage recharging

process that prolongs battery life and assures peak performance from a solar array. This component

allows customized battery recharging. The MX60 features include:

• 60 amps maximum continuous output current

• 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)

• Last 64 days of operational data are logged for review

• Voltage step-down capability allowing a higher PV array voltage con guration

• Manual and auto-equalize cycles

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

• 24 VDC 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 monitored (up to 1000 feet) by the optional OutBack

Power Systems MATE display.

INSTALLATION GUIDELINES AND IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

This product is intended to be installed as part of a permanently grounded electrical system

as shown in the system con guration 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 (Ground Fault Protector) is present, the battery negative and ground are not bonded.

• 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:

• If damaged or malfunctioning, the MX60 should only be disassembled and repaired by a

quali ed service center. Please contact your renewable energy dealer/installer for assistance.

Incorrect reassembly risks malfunction, electric shock or  re.

• The MX60 is designed for indoor installation or installation inside a weatherproof enclosure. It must not be

exposed to rain and should be installed away from direct sunlight.

• For routine, user-approved maintenance:

Disconnect all circuit breakers and related electrical connections before doing any cleaning

or adjustments.

Solar modules may produce hazardous voltages when exposed to light; unless

servicing them at night, cover the modules with opaque material before servicing any

connected equipment.

Standards and Requirements

All installations must comply with national (NEC) and/or local electrical codes; professional installation

is recommended.

DC and Battery-Related Installation Requirements:

• All DC cables must meet NEC standards or applicable local code standards.

• Shut o 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 (6.54 mm) 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  ttings to allow the inductive cur-

rents to cancel.

• DC battery over-current protection must be provided as part of the installation. OutBack o ers both

breakers and fuses for over-current protection.

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  ow of hydrogen to the vent

opening.

CAUTION - To reduce risk of injury, charge 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.

• Wear complete eye protection. Avoid touching eyes while working near batteries. Wash your hands with soap and warm water when done.

• If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters an eye,  ood the eye with running cool water at once for at least 15 minutes and get medical attention immediately following.

• 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  ame in vicinity of a battery or generator.

• Be extra cautious to reduce the risk of dropping a metal tool onto batteries. It could shortcircuit the batteries or other electrical parts that can result in  re or explosion.

• Remove personal metal items such as rings, bracelets, necklaces, and watches when working 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.

OPEN CIRCUIT VOLTAGE/WIRE AND DISCONNECT SIZING

Maximum Open Circuit Voltage (Voc)

• Voc is the unloaded voltage generated by the solar array.

141 VDC MX60 suspends operation to protect components

150 VDC 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 di erent, be sure to know the manufacturer’s speci cations.

• Local temperatures vary seasonally and will a ect 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

• The output current limit of the MX60 is 60 amps.

• Use a minimum of 6 AWG (4.11 mm) wire for the output between the MX60 and the battery bus

bar conductors; a larger size might be required due to temperature and/or conduit  ll corrections.

• Install OutBack OBB-60 or OBB-80 amp breakers for disconnect and over current protection.

• The largest PV array 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 OBB 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 81-83 for

other suitable conductor/wire sizing.

Figure 1 Field Wiring Connections and Surge Protection

Use up to 2 AWG (6.54 mm) wire and torque to 30-inch pounds/3.38 Nm 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.

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.

NOTE: Each MX 60 requires its own PV array. DO NOT PARALLEL MX 60 PV+ AND PV- TERMINALS TO THE INPUT OF THE MX60. This can cause problems with the MPPT and can cause an MX60 failure.

NOTES

• An optional battery Remote Temperature Sensor (RTS) is recommended for accurate

battery recharging (only one RTS is needed for multiple OutBack Series Inverter/Chargers

and MX60 units when an OutBack HUB and a MATE are parts of the 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.

• The OutBack MATE can display a single MX60 or multiple MX60s if connected to a HUB.

• 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 OBB-GFP-80D-125VDC-PNL 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.

Figure 2 MX60 WIRING DIAGRAM without ground fault protection—the ground conductors tie into the

negative.

Figure 3 MX60 WIRING DIAGRAM with ground fault protection—the GFP/2 requires a separate ground

bus bar.

BATTERY SYSTEM VOLTAGE

• The MX60’s default setting is for a 12 VDC battery.

• Change the setting after powering up the MX60 if a di erent battery voltage is used.

• The PV array voltage—which must not exceed 150 VDC open circuit—is automatically detected.

KEY TO THE EXAMPLE DIAGRAMS

Soft keys:

(#1) (#2) (#3) (#4)

Solid black indicates key is to be pressed:

Down arrow will lead to the next screen:

Up arrow points to one or more keys that will change a value:

The keys correspond to any text immediately above them.

POWERING UP

The MX60 power-up sequence  rst activates the unit and brings up a series of screens; some

screens allow the user to change the battery voltage.

NOTE: Be sure the PV input and battery breakers are o before starting the power-up sequence.

OFF SCREEN (this screen is initially blank at power up)

With the PV array and battery breakers o , 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 the MX60. If the screen reads “Got Battery?” please see the Troubleshooting Guide on page 74.

Power-Up Screen

OutBack 12V

Power Systems MX60

Release both soft keys when the OutBack Power Systems

screen appears. The selected battery voltage appears in

the upper right hand 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.

BATTERY VOLTAGE 12 24 36 48 60 ^^ EXIT ENTER

Press Either Key

Password Screen

PASSWORD

***150***

ENTER - +

“^^” indicates the selected battery voltage. Press

the “ ” or <ENTER> 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 <ENTER> soft key to return to the

BATTERY VOLTAGE.

NOTE: 141 is the password for all OutBack products dis- played on a screen.

Battery Voltage Screen

BATTERY VOLTAGE 12 24 36 48 60 ^^ EXIT ENTER

Veri cation Screen

Are you sure? 12 24 36 48 60 ^^ NO Yes

Press the “ soft key to select a battery voltage. The

MX60’s default values are based on a 12 VDC system.

Selecting a higher voltage system will change all the

default values (e.g., the values will double with a 24 VDC

system, triple with a 36 VDC system, etc.). “^^” indicates

the chosen voltage. The MX60 will automatically accept

the selected battery voltage if left unattended for 5 min-

utes in this screen. After choosing the voltage, press the

<ENTER> soft key to proceed.

Press the <YES> soft key to proceed if the selected

battery voltage is correct. If incorrect, press <NO> to

re-enter the correct voltage.

Power-Up Screen

OutBack 12V

Power Systems MX60

The MX60 brie y returns to the Power-Up screen and

then automatically opens the STATUS screen which

displays information regarding the recharging status.

Con rm the battery voltage displayed in the upper right

corner is correct.

NOTE: Repeating the Powering Up sequence resets the MX60 Charge Controller to its factory default settings.

STATUS SCREEN

The STATUS screen displays system information. See page 67 for detailed information of the di erent

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 dis-

played on the MATE.

The PV voltage will slowly rise to the battery

voltage level even when the PV breaker

is o – this is normal as the PV capacitor

charges up.

PV Input Voltage

PV Input Current

PV 005 V Bat 12.5 V

00.0 A 00.0 A

Instantaneous Watts

Daily accumulated

kiloWatt Hours

NOTES

• Pressing the  rst soft key opens the MAIN Menu screen.

• Pressing soft key #2 toggles between Amp Hours and kW Hours displays.

Watts 0000 Aux Off kWHrs 00.0 Sleeping

Battery voltage

Output current

AUX. Status (ON or OFF)

Operational Mode

PREPARING FOR RECHARGING

PV 113 V Bat 12.5 V

00.0 A 00.0 A Watts 0000 Aux Off kWHrs 00.0 Sleeping

PV 087 V Bat 12.5 V

05.0 A 32.9 A Watts 0412 Aux Off kWHrs 00.0 B-MPPT

Turn the PV input breaker on. The MX60

automatically detects the PV input voltage.

(NOTE: If PV voltage registers “000V” when the breaker is

on, please check the polarity of the PV wires.)

After 5 seconds of stable input voltage, the MX60 enters

a “Wakeup” stage, transitions to “Sweeping” and prepares

to charge the batteries by tracking the MPP of the solar

array.

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.

Press the <GO> soft key after aligning the asterisk

*Charger Aux Light EQ Misc Advanced Logging Log2

EXIT GO

Press or to move the asterisk “*” to the left of the desired screen. The asterisk allows access to any screen to its right.

From the MAIN Menu, a user can choose among the following MX60 functions by aligning the

asterisk:

in front of the selected menu choice.

Pressing the <EXIT> soft key in the MAIN Menu

returns to the STATUS Menu. Press the <EXIT> soft

key in your chosen menu to return to the STATUS

screen.

• Charger—CHARGER SETUP

Adjusts the Current Limit, Absorb, and Float recharging voltage set points

• Aux—AUX OUTPUT CONTROL

Secondary control circuit for a vent fan, error alarm, and other system-related additions

• Light—BACKLIGHT CONTROL

Adjusts the backlighting of LCD screen and soft key buttons

• EQ—BATTERY EQUALIZE

Activates battery equalization recharging (manually or automatically)

• Misc—MISCELLANEOUS

Additional settings and service information

• Advanced —ADVANCE MENU

Optimizing/ ne-tuning the MX60 (these are advanced Menus that should be left alone unti

the user has a good working knowledge of the MX60 and its operations)

• Logging—DATA LOGGING

Displays recorded power production information

• Log2—LOG 2

Displays recorded peak system information

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.

• Pressing selects the value to be changed.

• You may need to re-enter the password to change these settings.

• 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

recommendations are di erent than the default values. Otherwise, see page 80 for suggested

recharging voltage set points.

• If a battery remote temperature sensor (RTS) is used, its compensated voltage values can be viewed

in the MISCELLANEOUS (Misc) screen under the Tmp Comp heading.

NOTE: If an RTS is used, set the ABSORB and FLOAT setting

LIMIT ABSORB FLOAT Amps Volts Volts *60.0 14.4 13.6 EXIT - +

voltage based on a 25°C / 77°F setting. These are typically the manufacturer’s set 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 86) and adjust the ABSORB/FLOAT values accordingly.

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 o ).

• To access the AUX MODE from the MAIN Menu, press the < >soft key until the asterisk is in front of

the AUX selection.

• A 200 milliamps or less, 12 VDC device can be wired directly to the AUX terminal; higher output 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 Coe cient (PTC) fuse

protects the AUX internal components.

• For certain AUX control applications the use of a solid state relay is preferred. This is particularly

bene cial 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-IO are two suggest-

ed solid state relay manufacturers.

• 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).

• Press the <EXIT> 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

present state of the Aux

terminals. Pressing the

<ON> or <OFF> soft key

changes this value.

ON indicates 12 VDC is

present at the Aux output

terminals. OFF indicates

0 VDC.

Off EXIT NEXT ON OFF

AUX MODE

Manual

Pressing the <NEXT> soft key changes to the next mode.

Term s

The second line indicates

the present mode for the

Aux Output.

When the preferred mode

is displayed, press the

<EXIT> soft key to select it.

• AUX MODE: what is displayed on the Menu

• Aux Output: 12 VDC is either available or unavailable at the Aux Terminal

• Aux Terminal: the jack to which a relay is wired

AUX MODE Path

*Charger Aux Light EQ Misc Advance Logging Log2 EXIT GO

PASSWORD

***150***

ENTER - +

Charger *Aux Light EQ Misc Advance Logging Log2 EXIT GO

AUX MODE

Manual Off EXIT NEXT ON OFF

AUX MODE

Manual On EXIT NEXT ON OFF

• 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 <GO> 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< ENTER>. This

screen will also appear after  rst booting up the MX60 even though the password was entered

when setting the battery voltage.

AUX MODE

Vent Fan Off EXIT NEXT VOLT

AUX MODE

ERROR ALARM On EXIT NEXT

AUX MODE

Remote Off EXIT NEXT

AUX MODE

PV Trigger Off EXIT NEXT TIME VOLT

AUX MODE

Diversion Off EXIT NEXT TIME VOLT

PV 005 V Bat 12.5 V

00.0 A 00.0 A Watts 0000 Aux Off kWHrs 00.0 Sleeping

AUX MODE

Float Off EXIT NEXT

AUX MODE

Low Batt Disconnect On EXIT NEXT TIME VOLT

AUX modes in order of appearance on the MX60 display:

• Manual

• Vent Fan

• PV Trigger

• Float

• Error Alarm

• Diversion

• Low Battery Disconnect

• Remote

The most commonly used AUX modes:

• Vent Fan

• Diversion

• 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 speci c 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 < ON> or <OFF> 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

o . 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 voltage 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 O 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).

• Diversion—diverts excess power away from batteries when a wind or hydro generator is connected

directly to the batteries.

• Low Batt Disconnect—activates/deactivates the AUX load(s) when a user-determined voltage and

time levels are reached.

• Remote—allows OutBack MATE to control the operation of the AUX MODE (see MATE manual for

details).

Programming the AUX MODES

AUX MODE

Manual On EXIT NEXT ON OFF

AUX MODE

Vent Fan On EXIT NEXT VOLT

Press the <ON> or <OFF> soft keys to manually activate

or deactivate AUX MODE. Press the <NEXT> soft key to

view the Vent Fan screen. To view other screens, continue

to press the <NEXT> soft key.

The Vent Fan helps remove hydrogen from the battery

room. The ventilation fan referred to here is not the same

as the MX60 cooling fan. Press the <VOLT> soft key to

determine the battery voltage that will activate the AUX

MODE and start the fan.

VENT FAN VOLTS

> 14.4

BACK - +

Adjust the voltage level using the < - > and < + > soft

keys. Press the <BACK> soft key to return to the Vent Fan

screen.

AUX MODE

Vent Fan On EXIT NEXT VOLT

Press the <NEXT> soft key to advance to the PV

Trigger soft screen.

AUX MODE

PV Trigger Off EXIT NEXT TIME VOLT

PV VOLTS

> 140

BACK - +

When the PV input is too high and exceeds the user-

determined VOLT set point, the AUX MODE PV Trigger

activates. Press the <VOLT> soft key to adjust the voltage.

Adjust the voltage within a range of 20V - 150V by

pressing the < - > or < + > soft key. Press the <BACK>

soft key when  nished to return to the PV Trigger screen

AUX MODE

PV Trigger On EXIT NEXT TIME VOLT

To adjust the minimum amount of time the PV voltage

must remain high before deactivating the AUX MODE,

press the <TIME> soft key.

Hold Time Sec

01.1

BACK - +

AUX MODE

PV Trigger Off EXIT NEXT TIME VOLT

AUX MODE

Float Off EXIT NEXT

Press the < - > or the < + > soft key to adjust the Hold

Time, then press the <BACK> soft key to return to the

PV Trigger screen. In this example, the AUX MODE will

remain active for 1.1 sec after the PV voltage is below the

PV Trigger voltage before deactivating the PV Trigger and

reconnecting to the array.

Press the <NEXT> soft key to view the Float screen.

The AUX MODE is active when the MX60 is in Float and

producing power. Press the <NEXT> soft key to advance

to the ERROR ALARM screen.

AUX MODE

ERROR ALARM On EXIT NEXT

AUX MODE

Diversion Off EXIT NEXT TIME VOLT

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 ALARM goes into an O state. The

ERROR ALARM is intended for remote locations to signal

(e.g., a telecommunication 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 <NEXT> soft key to advance to the

Diversion screen.

When external DC sources (wind, hydro) are directly con-

nected 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—

Absorb—Float—EQ

Relative Volts

00.0 00.2 BACK - + HYST+

to activate the AUX MODE.

This is primarily an o -grid function. Pressing the <VOLT>

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, and EQ

voltages. The < - > and < + > soft keys set the Diversion

set points. The <HYST> (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

<BACK> soft key to return to the Diversion screen (see

example on next page).

AUX MODE

Diversion Off EXIT NEXT TIME VOLT

Hold Delay

01.0 Time 00

seconds

BACK - + DLY+

Press the <TIME> soft key to advance to the Time screen

which allows the user to adjust the minimum time the

AUX MODE is active after the battery voltage falls below

the Hysteresis voltage.

Hold Time shows how long the AUX MODE stays active

after the battery voltage has fallen below the HYST

(Hysteresis) set point. The user can adjust the Hold Time

from 0.1 to 25 seconds. If a solid state relay is used, set

the Hold time to 0.1 seconds and the Delay time to zero.

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 <BACK> soft key returns to

the AUX MODE DIVERSION screen.

Example of Diversion

AUX MODE

Diversion Off EXIT NEXT TIME VOLT

Each recharging 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 (O ) 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 (O ). See Figure 5 for Diversion Load and AUX Wiring Set-Up.

Absorb—Float—EQ

Relative Volts

00.2 00.3

BACK - + HYST +

Hold Delay

15.0 Time 10 Seconds

BACK - + DLY +

Figure 5 Diversion Load and AUX Wiring Set-Up Illustrated

AUX MODE

Diversion Off EXIT NEXT TIME VOLT

AUX MODE

Low Batt Disconnect On EXIT NEXT TIME VOLT

Delay Time Sec 01 Timer 001 BACK - +

Press the <NEXT> soft key to view the Low Batt(ery)

Disconnect screen.

When the battery voltage falls below the 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

<TIME> and <VOLT> soft keys.

Press either the < - > or < + > 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 voltages are reached. When the

low voltage occurs, the timer shows the seconds remain-

ing before disconnecting. When the reconnect voltage

is reached, the timer shows the user-determined time

before connecting. Press the <BACK> soft key to return

to the Low Batt Disconnect screen.

AUX MODE

Low Batt Disconnect On EXIT NEXT TIME VOLT

In the Low Batt Disconnect screen, press the <VOLT> soft

key to adjust the battery voltage disconnects set point.

Press either the < - > or the < + > soft key to adjust the

DISCONNECT VOLTS

<13.6

BACK - + ReCon

RE-CONNECT VOLTS

>14.4

BACK - + DisV

disconnect voltage. Press the <ReCon> soft key to open

the RE-CONNECT VOLTS screen.

Press either the < - > or the < + > 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 <BACK> soft key to

return to the Low Batt Disconnect screen.

AUX MODE

Low Batt Disconnect On EXIT NEXT TIME VOLT

Press the <NEXT> soft key to view the Remote screen.

AUX MODE

Remote Off EXIT NEXT

Charger *Aux Light Eq Misc Advanced Logging Log2 EXIT GO

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 < > soft key to move the asterisk to the Light

option. When the asterisk is in front of Light, press the

<GO> soft key.

BACKLIGHT

AUTO (default) leaves backlight and soft keys on for 60

BACKLIGHT CONTROL

ALWAYS

EXIT AUTO ON OFF

Charger Aux *Light EQ Misc Optimize Logging Log2 EXIT GO

seconds whenever any soft key is pressed (pressing any

soft key when the LCD is not lighted does not change

any settings).

ON and OFF states are also available.

Press the #1soft key twice to return to the MAIN Menu

screen

Press the < > soft key to move the asterisk to the EQ

option. When the asterisk is to the left of EQ, press the

<GO> soft key.

EQ—BATTERY EQUALIZE

The intent of an equalization charge is to bring all battery cells to an equal voltage. Sealed batteries

should not be equalized unless speci cally instructed by the manufacturer. Shut o 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  ooded electrolyte batteries.

• 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.

BATTERY EQUALIZE

Volts

15.0

EXIT NEX -EQV +EQV

BATTERY EQUALIZE

Time

01 Hours

EXIT NEXT -HRS +HRS

Manual Mode

BATTERY EQUALIZE

01 Hrs 15.0 Volts

Check water level

BACK AUTO START STOP

Press either the < –EQV> or <+EQV > soft key to change

the EQ voltage, following your battery manufacturer’s rec-

ommendations. Note that the factory default EQ voltage

is set low, the same as the factory default Absorb voltage.

Press the <NEXT> soft key to view the BATTERY EQUALIZE

Time screen.

Press either the <-HRS> or <+HRS> soft key to set the

desired equalization time, up to a seven hour maximum,

always following your battery manufacturer’s recommen-

dations. Press the <NEXT> soft key to view the BATTERY

EQUALIZE start screen

• Press the <START> soft key to manually begin an

equalization cycle. To stop the cycle, press the <STOP>

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 o 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 EQ DONE message displayed and a

Float cycle begins.

Press the <AUTO> soft key to view the Auto Equalization

screen.

Auto Mode

COUNT EQ INTERVAL 00 000

Use the <-DAY> and <+DAY> soft keys to preset

the interval day to initiate an automatic equalization

cycle. The EQ INTERVAL displays the number of days

EXIT -DAY +DAY

• Auto Mode initiates when a preset interval day (1-250 days) is reached.

• 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.

• The equalize time “EQ 0:00” in Hours:Minutes displays after the equalize set point is reached.

• An incomplete equalization cycle continues into the next day unless the MX60 is powered o 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 o .

• After recharging, an EQ DONE message displayed and a Float cycle begins. To view the MAIN EQ

screens, press the #1 soft key.

in the interval between cycles and COUNT displays

how many days of the interval have passed.

To view the MAIN EQ screens, press the #1 soft key.

MISC—MISCELLANEOUS

The MISCELLANEOUS screens display extra settings and technical information, some of which is

useful for OutBack Power Systems Technical Services.

The GT (Grid-tie) value is sent from

GT series inverter through the MATE

and HUB for Grid-tie control com-

munications. GT X means the MX60 is

in grid-tie mode and communicating

with the G Series Inverter.

The battery temperature

compensated Absorb (a)

and Float (f) set points

rise and fall with tem-

perature. If no RTS is used,

these settings will be

the same as those in the

charger setting screen.

GT State PWM% ChgT 255 07 50.0 005 Tmp Comp a14.4 f13.6 EXIT NEXT WIDE RSTRT

Each MPPT operation is

a state. This number

is useful for OutBack

troubleshooting.

This is the duty cycle of

the converter. At 50%,

the PV terminals would

be twice the battery

voltage.

The Bulk/Absorb

charge timer counts

up in Bulk and counts

down in Absorb.

Press <NEXT> to

Continue to the

Force Bulk/Float

screen.

This soft key covers normal and

limited battery compensation

voltage range. Press WIDE and

LMIT mode appears, which limits

the Upper and Lower battery-

compensated voltage range.

RSTRT forces the MX60 to restart or

wake-up from 5- minute (default)

long Snoozing mode. Restart and

wakeup are mainly service features.

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 o

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 recharging.

WIDE allows the RTS full control over recharging; LMIT sets the ceiling and  oor 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 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 Logging Log2 EXIT GO

AUX MODE

Low Batt Disconnect On EXIT NEXT TIME VOLT

Charger *Aux Light EQ Misc Advance Logging Log2 EXIT GO

DISCONNECT VOLTS

<13.6

BACK - + ReCon

Press <NEXT> until Low Batt Disconnect appears, then press <VOLT>

Setting LMIT Upper and Lower Set Points

DISCONNECT VOLTS

<13.6

BACK - + ReCon

DISCONNECT VOLTS

<13.2

Lower Limit

BACK - + ReCon

In the DISCONNECT VOLTS screen, press the < -> or <+ >

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 < - > and < +

> soft keys until Lower Limit displays on the screen. When

Lower Limit is displayed, the desired compensated volt-

age has been stored, and the < - > and < + > soft keys

can be released (pressing the <BACK> soft key will return

to the previous screen).

Press the <ReCon> soft key to adjust the upper battery

compensated voltage.

RE-CONNECT VOLTS

>14.8

BACK - + DisV

Press the < - > or < + > soft key to adjust the voltage.

When  nished, simultaneously press and hold the

< - > and < + > soft keys until Upper Limit is displayed.

This should be the highest Absorb voltage when the

battery temperature is coolest.

When the Upper Limit is displayed, the desired compen-

RE-CONNECT VOLTS

>14.8

Upper Limit

sated voltage has been stored and the < - > and < + >

soft keys can be released.

BACK - + DisV

After setting these limits, AUX MODE should be set to

Manual (default setting) if not used.

NOTE: WIDE/LMIT voltages are not applicable in the

Equalize charging mode.

Pressing the <BACK> soft key returns to the Low Batt

Disconnect screen.

To con rm the Upper Limit and Lower Limit voltages

*Charger Aux Light EQ Misc Advance Logging *Log2 EXIT GO

PkBatV Voc HiVoc

014.7 021.2 022.1 B-MPPT Sunrise EXIT NEXT 00:03:43

PkBatV Voc HiVoc

014.7 021.2 022.1 B-MPPT Sunrise EXIT NEXT 00:03:43

PV 011 V Bat 13.4 V

00.0 A 00.0 A Watts 0000 Aux On kWHrs 00.0 Sleeping

0000 ﬂ oatTmin

0850 HighWatts

Lo 13.2 Hi 14.8

BACK DCkWh

Limit Set Points (visible and active when WIDE/LMIT is set to LMIT in the Misc Menu)

After con rming the Upper Limit and Lower Limit voltages, press the < > soft key in the MAIN Menu.

Press the <GO> soft key to advance to the  rst MISC screen. From this screen, you can

access MISCELLANEOUS Screen 2.

GT State PWM% ChgT 255 07 50.0 005 Tmp Comp a14.4 f13.6 EXIT NEXT WIDE RSTRT

FORCE EXIT NEXT FLOAT BULK

From the MISC screen, press the <NEXT> soft key to view

the FORCE, FLOAT, or BULK screen.

Pressing the <FLOAT> or <BULK> soft key forces the

MX60 to that speci c recharging cycle and returns to the

STATUS screen. Forcing a FLOAT or BULK recharge will end

an EQ cycle. Press the <NEXT> soft key to view the third

MISCELLANEOUS screen.

• Force FLOAT =  oat cycle

• Force BULK = bulk cycle

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

voltage set point for at

least 90 seconds, the MX60

will automatically reinitiate

a Bulk charge cycle. The

default is set to a very low

value (6 volts) and there-

fore the function will be

disabled.

The Err(or) count increas-

es hourly if the MX60

has not charged the

batteries for 26+ hours

continuously. The  rst

hour begins at sleeping.

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).

PCB Err Btmp CFB 398 000 255 0760 ReBulk 06 V End 00 A EXIT +ReBV –AMP +AMP

The output value

of the internal

current sensor is

used to calculate

output amps,

watts, and track the

Maximum Power

Point of the array.

+ReBV increments the ReBulk

Voltage. It will return to a 6 volt

value when a 69 volt value is

reached.

(End, -AMP, +AMP) Normally, an Absorb charge cycle is

terminated because the battery voltage was regulated

at the Absorb set point for the maximum time period.

Decreasing (-AMP) or increasing (+AMP) sets an optional

end current level. While the battery voltage 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 cleared. This is an optional

set point and its adjustment is not required in most

installations. “00” Absorb End amps is the default.

•

ADVANCED

The ADVANCED Menu allows  ne-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) • MPP Range Limit % Voc • Sweep Interva

• Vbatt Calibration • Low CutO • MPPT Mode • Absorb Time Limits • Wakeup Mode

From the MAIN Menu, choose Advanced and press the

Charger Aux Light Eq Misc *Advanced Logging Log2 EXIT GO

<GO> 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 a ect solar panels. If the Voc is insu cient,

the MX60 enters Snoozing until either a  ve-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 su cient. An array might have a big increase

ADVANCED MENU

Snooze Mode

in voltage  rst thing in the morning— more than 2 volts

di erence—but not enough ampacity to recharge.

< Lowcutoff EXIT NEXT MODE

NOTE: There are four Low Cuto options:

• <90% Voc—MX60 snoozes if Voc does not rise to greater than 90% of last measured Voc during a full sweep

• <50% Voc—snoozes if Voc does not rise to greater than 50% of last measured Voc during a full sweep

• <Lowcuto —default snooze mode, snoozes if initial sweep does not reach Low Cuto Amps during a full sweep

• Disabled—no snoozing, MX60 will cycle on and o many times (not recommended due to ongoing relay-clicking)

Snoozing also occurs if the recharging current does not

reach the user-selected cuto current set point in the

Lowcuto menu. Press the <MODE> soft key for Snooze

Mode options. Press the <NEXT> soft key for the Park

Mpp screen

ADVANCED MENU

Park Mpp

77 % Voc

EXIT NEXT -Voc +Voc

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

 ve 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 di erent ap-

plications such as a 12 VDC array to a 12 VDC battery. To

change the percentage of VOC press either the <-VOC>

or <+VOC> soft key. Press the <NEXT> 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%

ADVANCED MENU Mpp Range Limit %Voc min max EXIT NEXT 1/2 90%

Use ½ value for high input arrays to speed up initial sweep.

of the VOC and is normally left alone for an array. If an

MX60 sweep  nds an MPP voltage outside 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 <min> or <max> soft key to adjust the

MPP range limit. When done, press the <NEXT> soft key

to view the Sweep Interval screen.

ADVANCED MENU

Sweep Interval 07 Minutes EXIT NEXT -MIN MAX+

The Sweep Interval mode or mini-sweep determines 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). No sweeping occurs if

the output current is under  ve amps because it operates

at the Park Mpp value. Sweeping does occur when the

output current is higher than  ve 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

extensive version of the full initial sweep done at wakeup.

Press the <–MIN> soft key to decrease minisweep

interval minutes or press the <+MIN> soft key to increase

the minutes. Press the <NEXT> soft key to view the Vbatt

Calibration screen.

ADVANCED MENU

Vbatt Calibration

12.8v 0.0v EXIT NEXT -V +V

The present Vbatt meter reading is displayed here for convenience.

A quality calibrated voltmeter will provide even more

accurate MX60 battery voltage readings if an undesirable

voltage drop is present. When measuring battery

voltage, ensure a good connection is made to the Four-

Position Terminal Block. Check the battery temperature

compensation voltages if voltages are much di erent

than you expect from the charger setup Absorb and Float

voltage settings. Use the <-V> and <+V> soft keys to

match the readings from the voltmeter. When  nished,

press the <NEXT> soft key to view the next screen.

ADVANCED MENU Low Cutoff < .6 Amp EXIT NEXT +AMP

Low Cuto sets the battery charger’s lowest allowable

current limit the MX60 will charge in MPPT mode before

stopping and returning to Snoozing. The Low Cuto is

adjustable from .2 amps to 1 amp; .6 amps is the default

Low Cuto current. Raising this value will assist the MX60

in entering Sleeping mode at night. Press the <+Amp>

soft key to raise this limit. When  nished, press the

<NEXT> soft key to view the MPPT Mode screen.

This screen allows the user to choose one of these

modes:

ADVANCED MENU

MPPT Mode Auto Sweep EXIT NEXT nonGT MODE

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 establishes the proper grid-tie mode communications between the G-series FX and the MX60.

• 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).

• 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. depending 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-hydro applications.

Press the <MODE> soft key to choose an MPPT mode

and the <nonGT> soft key if you have an OutBack GT

series inverter system with a HUB and MATE. Press the

<NEXT> soft key to view the Absorb Time Limits screen

In the Absorb Time Limits screen, the user can set the

ADVANCED MENU

Absorb Time Limits 000m 2hr EXIT NEXT MIN+ MAX+

minimum and maximum times the MX60 stays in the Absorb recharge cycle.

MAXimum is adjustable from 0 to 4 hours. MINimum is adjustable from 0 minutes (the

default) up to the MAX Absorb Time Limit minus 10 minutes. (EX: MAX Absorb Time = 2 hours or 120 minutes; MIN Absorb Time adjusted up to 110 minutes)

To adjust the limits, press either the <MIN+> or <MAX+> soft key. When  nished, press the <NEXT> 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 brie y display “Bat Full” (Battery Full) then “Float.”

• When the battery voltage drops below the  oat voltage set point, the MX60 recharges to maintain this set point, employing the F(Float)-MPPT function.

• If the system cannot 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 0hr.

SLEEP

BULK

N O O Z E

ZZZ

PV ARRAY VOLTAGE

ABSORB

FLOAT

S N O O Z E

SLEEP

ZZZ

Bulk cycle begins Absorb charge is reached At zero, MX60 goes into FLOAT Timer starts 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.

ADVANCED MENU

Wakeup Mode

01.5v 05m EXIT NEXT +VOC +Min

Wakeup Mode selects how often the MX60 does a Wakeup

during “Snoozing” periods. Since environmental 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 controller 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 gradually

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 <EXIT> soft key to return to the MAIN Menu.

Charger Aux Light Eq Misc *Advanced Logging Log2 EXIT GO

From the MAIN Menu, press the < > soft key to move the

asterisk next to the Logging function and then press the

<GO> soft key.

(DATA) LOGGING

The MX60 records battery  oat and daily kilowatt-hour (kWh) information for the previous 64 days. This

data can be compared, for instance, with weather reports to con rm 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.

Total power production

may be viewed as amp

hours or kilowatt-hours

depending on display

setting in the STATUS

DAILY KWhours 00.0

screen. The TotalKWh or

TotalKAh accumulates

the daily values and

continue beyond 64

days of data.

Pressing <CLR> takes you to the CLEAR,

DALY (DAILY), and TOTL (TOTAL) Menu

and EXIT takes you back to the main

STATUS screen.

Float time mins 0000 TotalKWh 0000 01 EXIT CLR +DAY -DAY

The minutes the MX60

spent  oating the batteries

for each of the last 64 days.

The present day’s Float time

can be found in the Log2

screens.

Day 01 is yesterday and Day

02 is two days ago, etc.

Press – DAY: goes back one day Press +DAY:

goes forward one day

If starting on Day 01 and <+DAY> is pressed, the

value from 64 days ago is presented.

CLEAR BACK TOTL DALY

Pressing and holding the <TOTL> or <DALY>

(TOTAL AND DAILY) soft key will prompt you to

erase those total accumulated values. Pressing

BACK returns to the Logging screen.

Clearing Totals and Daily Stats

• 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 con rmed, the values will be cleared. It may take a few

seconds for all 64 daily values to be cleared before the con rmation screen goes away.

• 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

di erent 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  nd very di erent results.

To return to the MAIN Menu, press the #1 soft key from any screen.

From the MAIN Menu, press the < > soft key to

Charger Aux Light Eq Misc Advanced *Logging Log2

move the asterisk next to the Log2 function and then

press the <GO> soft key.

EXIT GO

LOG2

The Log2 screen displays additional voltage and time information.

Daily peak

battery voltage

Daily high Voc value

PkBatV Voc HiVoc

The Hi(ghest) Voc seen by the MX60

Sunrise shows how long

ago the MX60 woke up

012.2 070.2 076.9

Operational mode

B-MPPT Sunrise EXIT NEXT 00:06:12

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  rst

for the  rst time each day

and when the daily and

total logged values were

updated and cleared from

the STATUS screen.

wakeup; it can also be reset to the present battery voltage by powering o 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.

Auto Restart

PkBatV Voc HiVoc

012.2 070.2 076.9 B-MPPT Sunrise EXIT NEXT 00:06:12

Pressing and holding the #4 soft key for several

seconds selects among the three MX60 Auto ReStart

modes: 0, 1, and 2 (default). Auto ReStart allows the MX60

to perform internal recalibrations and eliminate any pos-

sibility of software errors. To change the mode, release

the #4 soft key and press and hold again.

• Mode 0— Auto ReStart mode is disabled; the MX60

recharges continuously from an available source and

0 Auto Restart

1 Auto Restart

2 Auto Restart

The MX60’s sunrise-related activity can be in uenced. 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

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 in

Bulk, it will brie y 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, Absorb,

and Float modes, it will brie y Restart and initiate a full

panel sweep. This will not reset any counters or

charging stages or statistics.

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 pressing 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 <NEXT> 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.

Secondary LOG2 Screen

The Secondary Log2 screen shows the basic recharging state of the MX60 (EQ, FLOAT) time in

minutes, and the daily maximum (HighWatts) wattage seen by the MX60 during the day.

When initiated, EQ

information will be

displayed here.

The lower and upper

battery temperature

compensation voltage

is visible and active

only when the mode

is set to LMIT (5.11

Rev).

0000 ﬂ oat Tmin

0705 HighWatts

Lo 13.2 Hi 14.8

BACK DCkWh

Press soft key #3 to display the accumulated total

kWh reading in AC or DC the Data

Logging screen.

• DCkWh (default) shows DC kiloWatthours and

should be used in a non-grid-tied system.

• ACkWh is used with a grid-tied system. The

The present day’s time—

in minutes—spent in

Float stage.

This value is the peak

daily Watts seen by the

MX60.

heading in the logging screen will change to

TotalKWh AC.

• TotalKWh AC is based on a 90% inverter

e ciency (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  oat voltage.

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 o er limited technical support for these applications because there is

too much variance in micro-hydro and fuel cell generator speci cations. When used for micro-hydro or

fuel cell applications, the MX60 warranty will be honored only if the manufacturer and turbine model

have been approved by OutBack Power Systems. Please check with one of the following manufactur-

ers or OutBack Power Systems before employing the MX60:

Harris Hydroelectric

•

(831) 425-7652

www.harrishydro.com

Alternative Power & Machine

•

(541) 476-8916

www.apmhydro.com

•

Energy Systems & 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 di erent than PV systems, whose Voc output is more subject to

change due to weather and time of day. A PV system normally  nds its Maximum Power Point voltage

between 50-90% 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  nd more appropriate set points to best capture the MPP

voltage. If the output current is under  ve 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 percentage value, but recommends experiment-

ing with changing this value when a micro-hydro or fuel cell system is in use.

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 di erent Park Mpp percentage values, checking the watts

value for each. This will require some experimentation.

• The MX60 can operate at any of the following  xed 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% of the measured

open circuit voltage

• The user will have to experiment with each of the 13  xed percentage values to

determine an appropriate  xed percentage value. Typical  xed values between 67% up to

78% have provided optimal results; however, each system is di erent and these  xed

percentage values should be used as guidelines only

3. Compare the Auto Sweep and U-Pick % Voc values and determine which will best  t

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.)

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 voltage close to the battery voltage

instead of 1/2 (or 50%) of the Voc.

This adjustment only a ects 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 applications’

voltage input system.

To adjust the Lower Mpp Range Limit and disable the Sweep Interval:

Charger Aux Light Eq Misc *Advanced Logging Log2 EXIT GO

From the MAIN Menu, with the asterisk in front of

Advanced, press the <GO> soft key.

ADVANCED MENU Mpp Range Limit %Voc min max EXIT NEXT 1/2 90%

In the ADVANCED MENU screen, press the <NEXT> soft

key until the Mpp Range Limit % VOC screen appears.

Press the <1/2> soft key until FULL appears. When

 nished, press the <NEXT> soft key to go to the Sweep

Interval screen.

In the Sweep Interval screen, press the <-MIN> soft key to

ADVANCED MENU

Sweep Interval 03 Minutes EXIT NEXT -MIN MAX+

ADVANCED MENU

MPPT Mode Auto Sweep EXIT NEXT nonGT MODE

adjust the Sweep Interval from 03 minutes (default) to 00

minutes. Press the <NEXT> soft key until the MPPT Mode

screen appears.

To pick between Auto Sweep or U-Pick % MPPT Mode and

determine the MX60’s operating Voc percentage, press

the <NEXT> soft key until the MPPT Mode menu appears.

Press the <MODE> soft key to interchange between Auto

Sweep and U-Pick%Voc modes. Re-entering the password

might be required. Press the <NEXT> soft key in the

ADVANCED MENU until the Park Mpp screen appears.

Press the <-VOC> or <+VOC> soft key to select one

ADVANCED MENU

Park Mpp 77 % VOC EXIT NEXT –Voc +Voc

NOTE: After adjusting the Park Mpp values, the user must perform a mini-sweep to activate these new values.

of the 13  xed percentage values. Park Mpp applies

to Auto Sweep Mode if the output current is less than

5 amps; U-Pick always uses the Park Mpp value. Press

the <NEXT> soft key until the MPPT Mode screen

appears.

In the STATUS screen, press the #3 and #4 soft keys simul-

PV 087 V Bat 12.0 V

05.0 A 35.8A Watts 0430 Aux Off kWHrs 00.0 B-MPPT

A user might want an MPP that falls outside of the  xed 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:

taneously to perform a Mini-Sweep. The MX60 will track

the new MPP based on the  xed percentage value. Per-

form a Mini-Sweep any time a change to the input sys-

tem or the Park Mpp  xed percentage value is changed.

In U-Pick %Voc mode, press the #3 and #4 soft keys and

the New Voc is displayed; in Auto Sweep mode, press the

#3 and #4 soft keys until Sweeping is displayed.

PV 087 V Bat 12.0 V

05.0 A 35.8A Watts 0430 Aux Off kWHrs 00.0 B-MPPT

Press either soft key to adjust PV voltage

Press and hold the #3 soft key to decrease the power

point voltage (PV voltage). Press and hold the #4 soft key

to increase the power point voltage (PV voltage).

Observe the changes in the Watts value to determine

whether increasing or decreasing the PV voltage will

improve the available power to the system.

Abbreviated Menu Map

Much of the MX60 activity takes place around the MAIN screen. From this screen, the user can access other screens to both observe system activiy and make adjustments to certain critical functions.

Adjusts the Current Limit, Absorb, and Float recharging voltage set points

EQ allows manual or automatic battery equalization recharging

The Logging screens display the daily kW hours,  oat time minutes, and the total kW hours.

AUX control includes:

• Manual

• Vent Fan

• PV Trigger

• ERROR ALARM

• Diversion

• Low Battery Disconnect

• Remote

* Charger Aux Light EQ Misc Advanced Logging Log2

EXIT GO

The Advanced menu allows the user to  ne-tune the MX60 using the following screens:

• Snooze Mode

• Park Mpp

• MPPT Range Limit% VOC

• Sweep Interval

• Vbatt Calibration

• Low Cuto

• MPPT Mode

• Absorb Time Limits

• Wakeup Mode

The Light feature con- trols the backlighing of the MX60s LCD screen and soft key buttons

Misc o ers additional settings and service information including

ReBulk Voltage and Absorb End Amps

Log2 shows time-

based information regarding the MX60

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 GTFX/GVFX series inverter to manage the MX60 Float

setting ensuring the MX60 is always keeping the battery above the sell voltage of the GTFX/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 di erence for 24V battery system or 1.0 volt di erence 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 e cient functioning.

Positive grounded systems

Telcom applications frequently require a positive grounded system. The MX60 switches the POSITIVE

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 di erent 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

 rst, since the Absorb voltage will not be adjustable below the Float voltage setting. If going higher

in voltage, increase the Absorb setting  rst 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

CALLING THE FACTORY FOR ASSISTANCE

When calling OutBack Power for product assistance, please have the following information

ready:

• MX60 serial number and software version (The software version can be viewed by pressing

the #1 soft key on the STATUS screen and then pressing a second time and holding the soft

key down.)

• The nominal PV array and battery voltage

• The PV array operating voltage and battery current and any STATUS screen operational mode

displays, such as B-MPPT, F-MPPT, Absorbing, or Float

SPECIFICATIONS

Output Current Rating 60 amps continuous @ 25°C ambient

Default Battery System Voltage 12, 24, 36, 48 or 60 VDC (adjustable)

PV open circuit voltage 150 VDC Maximum (ETL Rating for UL1741

Standard); operational max = 141 VDC

temperature corrrected VOC

Standby power consumption Less than 1 watt typical

Recharging regulation methods Five stage—Bulk, Absorption, Battery Full, Float,

and Equalization

Voltage regulation set points 13-80VDC

Temperature compensation With optional RTS sensor 5 millivolts °C per

2V cell

Voltage step down capability Down convert from any PV array voltage within

PV voc limits of 141 VDC to any battery system

voltage

Examples: 72V array to 24V; 60V array to 48V

Digital Display 4 line 20 character per line backlit LCD display

Remote Interface RJ45 modular connector Cat 5 cable 8 wire

Operating Temperature Range* -40° to 60°C de-rated above 25°C

Environmental Rating Indoor type 1

Conduit knockouts Two 1” on the back; one 1” on each

side; two ” on the bottom

Warranty Two years parts and labor, optional extended

warranty available

Dimensions MX60—13.5”H x 5.75”W x 4”D

Boxed—18”H x 11W x 8”D

Weight MX60—12 pounds Boxed—15 pounds

*The MX60’s maximum current output at 25°C is 60 amps. In higher ambient temperatures, the MX60’s

current limit should be reduced in order to prevent possible damage to the unit. Realistically, 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’s current limit. To do so, go to the STATUS screen and choose

the Charger function.

*Charger Aux Light EQ Misc Advanced Logging Log2 EXIT GO

Press or to move the asterisk “*” to the left of the Charger function.

LIMIT ABSORB FLOAT Amps Volts Volts *60.0 14.4 13.6 EXIT - +

Press the <GO> soft key after aligning the asterisk in

front of the selected menu choice.

Press to move the asterisk in front of the Amps

selection (default is 60.0) and adjust this  gure using

the “ –“ and “ + “ soft keys using the  gures in follow-

ing MX60 Current vs. Temperature Chart. Remember

to change the current limit when the ambient tempera-

ture changes.

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 42.43

60 38.73

65 34.64

70 30.00

75 24.49

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

MX60 EFFICIENCY vs. INPUT POWER GRAPH

Figure 6 24V and 48V Battery System E ciency Curve

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 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 voltage

at the Absorb set point (modi ed 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>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 used). 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 voltage

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.

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 transition 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 Equal-

ization voltage set point. EQ is not battery temperature compensated. After the EQ voltage has been

reached, EQ 0:00 will be displayed along with the EQ time in hours and minutes. The AC/DC loads

should be turned o 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 batteries to the

Float set point.

F-MPPT The MX60 is in Maximum Power Point Tracking mode trying to regulate the battery voltage

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 GT-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 GT-Series Inverter(s) and MX60.

High Voc This indicates the PV array’s open circuit voltage is too high for the controller to safely oper-

ate. This should only occur with systems using 72 VDC nominal PV arrays in very cold temperatures

(below 50 F / -150 C). The controller will automatically restart operation once the PV array’s open

circuit voltage falls to a safe level (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.

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 cuto (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’s heat sink is extremely hot. The heat generated by

the MX60, and therefore its losses, is proportional to input voltage times output current. Avoid install-

ing 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 certain 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, i.e., 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 volt-

age 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” brie y  ashes 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.

Wakeup As the PV open circuit voltage (Voc) rises above the battery system voltage by two volts, the

MX60 prepares to deliver 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.

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.

MAIN------------------------

12:00:30P

SUM STATUS SETUP ADV

STATUS/MX/MODE---P00 charger mode: Silent

DOWN STATUS PORT

STATUS/MX/MODE------end of mode menu

UP TOP STATUS

MX MODE Screens

STATUS……………………… choose product:

FX MX

STATUS/MX/MODE---P00 aux relay Low Batt mode DOWN UP TOP PORT

STATUS/MX-----------------

MODE METER SETP MAIN

STATUS/MX-----------------

MODE METER SETP MAIN

STATUS/MX/MODE---P00 aux relay state: ON

DOWN UP TOP PORT

Press <METER> to view

the MX METER screens.

• charger mode: displays one of  ve charging stages (Bulk, Absorption, Float, Silent, or Equalization)

• aux relay mode: displays one of eight MX60 AUX modes (Manual, Vent Fan, PV Trigger, Float, ERROR

ALARM, Diversion, Low Batt(ery) Disconnect, or Remote)

• aux relay state: indicates if the AUX is ON or OFF

MATE-DISPLAYED MX60 STATUS METER Screens

mode: Silent P00 pv 10.0v bat 26.0v in 0a out 0a DOWN STATUS PORT

STATUS/MX/METER--P00 charger +000 adc amps dc DOWN UP TOP PORT

STATUS/MX/METER----end of meter menu

UP TOP STATUS

MX METER Screens

STATUS/MX/METER--P00 charger 0 w watts DOWN UP TOP PORT

STATUS/MX/METER--P00 battery 26.5 vdc voltage DOWN UP TOP PORT

STATUS/MX-----------------

MODE METER SETP MAIN

STATUS/MX/METER--P00 charger .0 kwh kwhrs DOWN UP TOP PORT

STATUS/MX/METER--P00 panel 10.2 vdc voltage DOWN UP TOP PORT

Press <SETP> to view the

SETPOINT 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

• charger kwhrs: kilowatt hours produced in the last 60 minutes by the MX60

• 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

MATE-DISPLAYED MX60 STATUS SETPT (SETPOINT) Screens

STATUS/MX/SETPT----P00 Absorb 28.8 VDC

DOWN STATUS PORT

STATUS/MX/METER-----end of setpoint menu UP TOP STATUS

STATUS/MX/SETPT---P00 Float 27.2 VDC

DOWN UP TOP PORT

Press the  rst two soft keys simultaneously to return

to the MAIN Menu or press <STATUS> and then press

<MAIN> 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

TROUBLESHOOTING GUIDE

MX60 does not boot/power-up (blank LCD)

• Check the battery connection and polarity.

Reverse polarity or an improper connection will cause power-up issues.

• Check the battery breaker.

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 the

Four- Position Terminal Block).

• If the MX60 still does not power up, call the factory for additional support.

Be sure to check out the OutBack customer and user forum at www.outbackpower.com/forum/ for more MX60 information.

MX60 is always SLEEPING

• If the 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.

• Check the PV array breaker (or fuse).

• Con rm the PV array breaker (or fuse) is sized appropriately.

• 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?

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 o after a minute?

Call the factory for support.

• Have you checked the short circuit current of the PV array?

Use a multi-meter to determine if a short circuit current is detected. The short circuit current

test will not harm the array.

MX60 not producing expected power

• Clouds, partial shading, or dirty panels can cause poor performance.

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 MX60 in the ABSORB 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.

• 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.

• If the Sweep Interval is set to 00 mins, the MX60 will not periodically  nd the Maximum Power

Point of the array. A Sweep Interval of seven to ten minutes is suggested

MX60 is not equalizing

• Has the EQ cycle been initiated?

In the 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.

array 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.

• 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 voltage which can delay the EQ cycle.

he EQ cycle will begin when the target EQ set point voltage has been reached. A small

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.

• When the current limit set point is achieved, the MX60 will continue to sweep to maintain the targeted current limit.

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

temperature is < 77° F or fall below the ABSORB and FLOAT voltage if the battery temperature is

> 77° F.

• Why does the MX60 show BatTmpErr on the STATUS screen?

The RTS is faulty or damaged. Disconnect the RTS from the RTS jack to resume

normal operation.

MX60 Internal Fan

• 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 appears on the screen.

Continue pressing the #1 soft key and press the #3 soft key at the same time until X O 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

e cient MX60 operations.

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)

12 V 800 W

24 V 1600 W

36 V 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

nominal battery voltage. Below is a list of recommended nominal array sizing:

Nominal Battery Voltage Nominal Array Voltage (recommended)

12 V 24 V (or higher)*

24 V 36 V (or higher)*

36 V 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 the 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.

STANDARD vs. AUSTRALIAN DEFAULT SETTINGS

The Australian version MX60 has a few default settings that di er from the Standard version default

settings. However, there are no di erences in performance and e ciency between the two

versions. The Standard and Australian version can be identi ed as follows:

OutBack 12V

Power Systems MX60

OutBack 12V

Power Systems MX60-AU

Standard version Australian version

Below are a few default setting di erences between the Standard and Australian version.

Settings Standard Australian

Charger Amps Absorb Float Amps Absorb Float

12 V 60 14.4 V 13.6 V 60 14.4 V 13.8 V

24 V 60 28.8 V 27.2 V 60 8.8 V 27.6 V

36 V 60 43.2 V 40.8 V 60 43.2 V 41.4 V

48 V 60 57.6 V 54.4 V 60 57.6 V 55.2 V

60 V 60 72.0 V 68.0 V 60 72.0 V 69.0 V

Equalize Equalize Volts Equalize Volts

12 V 14.4 14.7

24 V 28.8 29.4

36 V 43.2 44.1

48 V 57.6 58.8

60 V 72.0 73.5

Equalize Time 01 Hours 03 Hours

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  ll 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 12 Volt Battery System

24 Volt PV Array

32V MPP Typical 12 or 24 Volt BatterySystem

Wire Gauge

Amps

#8 #6 #4 #2 #1/0 #2/0 #4/0

8 22 35 57 90 145 180 290

10 18 28 45 72 115 145 230

15 12 19 30 48 76 96 150

20 9 14 22 36 57 72 116

30 6 9 15 24 38 48 77

Distance in Feet

40 4 7 11 18 29 36 56

50 3 5 9 4 23 29 46

Wire Gauge

Amps

#8 #6 #4 #2 #1/0 #2/0 #4/0

8 45 71 114 180 290 360 580

10 36 57 91 145 230 290 460

METRIC

#8…8.37mm

#6…13.30mm

#4…21.15mm

#3…26.7mm

#2…33.6mm

#1/0…53.5mm

#2/0…67.4mm

#4/0…107mm

48 Volt PV Array

64V MPP Typical 12, 24 or 48 Volt Battery System

15 24 38 60 96 153 192 300

20 18 29 45 72 115 145 232

30 12 19 30 48 77 97 154

Distance in Feet

40 9 14 23 36 58 72 112

50 7 11 18 29 46 58 86

Wire Gauge

Amps

#8 #6 #4 #2 #1/0 #2/0 #4/0

8 90 142 228 360 580 720 1160

10 72 114 182 290 460 580 920

15 48 76 120 192 306 384 600

20 36 58 90 144 230 290 464

30 24 38 60 96 154 194 308

Distance in Feet

40 18 28 46 72 116 144 224

50 14 22 36 58 92 116 172

60 Volt PV Array

80V MPP Typical 12, 24 or 48 Volt Battery

System

72 Volt PV Array

96V MPP Typical 12, 24 or 48 Volt Battery System

Wire Gauge

Amps

#8 #6 #4 #2 #1/0 #2/0 #4/0

8 112 177 285 450 725 900 1450

10 90 142 227 362 575 725 1150

15 60 95 150 240 382 480 750

20 45 72 112 180 287 362 580

30 30 47 75 120 192 230 385

Distance in Feet

40 22.5 35 57 90 145 180 280

50 17.5 27 45 72 115 145 215

Wire Gauge

Amps

#8 #6 #4 #2 #1/0 #2/0 #4/0

8 140 221 356 562 906 1125 1812

10 113 178 284 453 719 906 1437

15 75 119 188 300 478 600 937

20 56 90 140 225 359 452 725

METRIC

#8…8.37mm

#6…13.30mm

#4…21.15mm

#3…26.7mm

#2…33.6mm

#1/0…53.5mm

#2/0…67.4mm

#4/0…107mm

30 37 59 94 150 240 287 481

Distance in Feet

40 28 44 71 112 181 225 350

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  ll corrections. This would normally indicate

that the output conductors be 4 AWG (5.83 mm), but a larger size may be required if there are temper-

ature and/or conduit  ll corrections required. With an output conductor rated at 75 amps (1.25 X the

continuous output current), the OutBack OBB-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 OBB-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 connect

to should have a rated short-circuit current of 48 amps. This meets NEC requirements and allows the

MX60 to perform maximum power-point tracking functions. The following charts show maximum dis-

tance 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  ll corrections may be required.

*When NEC does not apply, see local code requirements.

**UL requires Isc (short circuit current) to be multiplied by 125% for the conductor rating.

S N O O Z E

BULK

ABSORB

FLOAT

S N O O

SLEEP

PV ARRAY VOLTAGE

SLEEP

Bulk cycle begins Absorb charge is reached At zero, MX60 goes into FLOAT Timer starts 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 regulation

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 recharging voltage set

points (Absorb & 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.

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.

ABSORBING 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) Absorb

time limit is reached. For example, if a Bulk cycle takes 1 hour to reach the Absorb voltage set point,

then the Absorb cycle will continue for 1 hour as well. However, if a 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.

BATTERY TEMPERATURE COMPENSATED VOLATGE SET POINT

The temperature of a battery has an impact on the recharging process—in higher ambient

temperatures, the regulation set points (Absorb & Float) need to be reduced to prevent 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 & Float voltage regulation set points are set to the recommended battery manufacturer’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

appropriate adjustments for both Absorb and Float voltage regulation set points for weather

conditions above or below 77˚ F / 25˚ C

EXPECTED TEMPERATURE ADJUST SETPOINT 12 V 24 V 48 V

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 & 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.

SUGGESTED BATTERY CHARGER SET POINTS

The battery manufacturer should provide you with speci c instructions on the following maintenance

and voltage set point limits for the speci c batteries. The following information can be used when the

manufacturer’s information is not available.

SEALED LEAD ACID – AGM / GEL 12 V 24 V 48 V

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 12 V 24 V 48 V

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 signi cant recharging or heavy loads. Otherwise, the DC voltage is not re ective 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 a ect 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 proper operation and good performance.

STATE OF CHARGE

Nominal Battery Charged Good (~75%) Average (~50%) Low (~25%) Discharged

Voltage

12 V over 12.6 V 12.3 V 12.0 V 11.7 V under 11.4 V

24 V over 25.2 V 24.6 V 24.0 V 23.4 V under 22.8 V

48 V over 50.4 V 49.2 V 48.0 V 46.8 V under 45.6 V

60 V over 63.0 V 61.5 V 60.0 V 58.5 V under 57.0 V

OWNER’S SYSTEM INFORMATION

Date of Purchase: ____________________________________________________________

Vendor: ____________________________________________________________________

Date of Installation: ___________________________________________________________

Installer: ___________________________________________________________________

Installer Contact Information: ____________________________________________________

____________________________________________________________________________

MX60 Serial Number: _________________________________________________________

Battery Voltage: ______________________________________________________________

PV Voltage: _________________________________________________________________

PV Module Type and Manufacturer: ______________________________________________

Array Wattage: _______________________________________________________________

NOTES: ____________________________________________________________________

___________________________________________________________________________

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 electrical equipment for use

within certain voltage limits”

The compliance of the above mentioned product with the directives and the following

essential requirements is hereby con rmed:

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  les 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 Arlington, WA. 98223 USA (360) 435-6030

TWO YEAR LIMITED WARRANTY INFORMATION

MX60 Products

OutBack Power Systems, Inc. (“OutBack”) provides a two year (2) limited warranty (“Warranty”) against defects in

materials and workmanship for its MX60 products (“Products”) if installed in  xed location applications.

For this Warranty to be valid, the Product purchaser must complete and submit the applicable Product

registration card within ninety (90) days of the eligible Product’s  rst retail sale. This Warranty applies to the

original OutBack Product purchaser, and is transferable only if the Product remains installed in the original use

location. The warranty does not apply to any Product or Product part that has been modi ed or damaged by the

following:

• Installation or Removal;

• Alteration or Disassembly;

• Normal Wear and Tear;

• Accident or Abuse;

• Corrosion;

• Lightning;

• Repair or service provided by an unauthorized repair facility;

• Operation contrary to manufacturer product instructions;

• Fire, Floods or Acts of God;

• Shipping or Transportation;

• Incidental or consequential damage caused by other components of the power system;

• Any product whose serial number has been altered, defaced or removed; or

• Any other event not foreseeable by OutBack.

OutBack’s liability for any defective Product, or any Product part, shall be limited to the repair or replacement of

the Product, at OutBack’s discretion. OutBack does not warrant or guarantee workmanship performed by any

person or  rm installing its Products. This Warranty does not cover the costs of installation, removal, shipping

(except as described below), or reinstallation of Products.

Revision.2008-02-26

To request warranty service, you must contact OutBack Technical Services at (360) 435-6030 or support@

outbackpower.com within the e ective warranty period. If warranty service is required, OutBack will issue

a Return Material Authorization (RMA) number. A request for an RMA number requires all of the following

information:

1. Proof-of-purchase in the form of a copy of the original Product purchase invoice or receipt con rming the

Product model number and serial number;

2. Description of the problem; and

3. Shipping address for the repaired or replacement equipment.

After receiving the RMA number, pack the Product(s) authorized for return, along with a copy of the original

purchase invoice and warranty certi cate, in the original Product shipping container(s) or packaging providing

equivalent protection and mark the outside clearly with the RMA number. The sender must prepay all shipping

charges, and insure the shipment, or accept the risk of loss or damage during shipment. OutBack is not

responsible for shipping damage caused by improperly packaged Products, the repairs this damage might

require, or the costs of these repairs. If, upon receipt of the Product, OutBack determines the Product is defective

and that the defect is covered under the terms of this Warranty, OutBack will then and only then ship a repaired

or replacement Product to the purchaser freight prepaid, non-expedited, using a carrier of OutBack’s choice

within the continental United States, where applicable.

Shipments to other locations will be made freight collect. The warranty period of any repaired or replacement

Product is twelve (12) months from the date of shipment from OutBack, or the remainder of the initial warranty

term, which ever is greater.

THIS LIMITED WARRANTY IS THE EXCLUSIVE WARRANTY APPLICABLE TO OUTBACK PRODUCTS. OUTBACK

EXPRESSLY DISCLAIMS ANY OTHER EXPRESS OR IMPLIED WARRANTIES OF ITS PRODUCTS, INCLUDING BUT

NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

OUTBACK ALSO EXPRESSLY LIMITS ITS LIABILITY IN THE EVENT OF A PRODUCT DEFECT TO REPAIR OR

REPLACEMENT IN ACCORDANCE WITH THE TERMS OF THIS LIMITED WARRANTY AND EXCLUDES ALL LIABILITY

FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING WITHOUT LIMITATION ANY LIABILITY FOR

PRODUCTS NOT BEING AVAILABLE FOR USE OR LOST REVENUES OR PROFITS, EVEN IF IT IS MADE AWARE OF SUCH

POTENTIAL DAMAGES. SOME STATES (OR JURISDICTIONS) MAY NOT ALLOW THE EXCLUSION OR LIMITATION OF

WARRANTIES OR DAMAGES, SO THE ABOVE EXCLUSIONS OR LIMITATIONS MAY NOT APPLY TO YOU.

Revision.2008-02-26

Two Year Limited MX60

Warranty Registration

and return it to: Outback Power Systems Inc. 19009 62nd Ave. NE

Arlington, WA 98223

Complete this form to request a Limited Warranty,

NOTE: A Limited Warranty Certi cate will only be issued if this Registration Card is received by OutBack

within 90 days of the date of the  rst retail sale of the eligible Product. Please submit a copy (not the original) of the Product purchase invoice, which con rms the date and location of purchase, the price paid, and the Product Model and Serial Number.

Two Year Limited MX60 Warranty Registration

System Owner

Name: _______________________________ Country: ______________________________ Address: ______________________________ Telephone Number: ______________________ City, State, Zip Code: ____________________ E-mail: ________________________________

Product

Product Model Number: _________________ Sold by: _______________________________ Product Serial Number: __________________ Purchase Date: __________________________ Optional Extended Warranty* Coverage? (circle one): Yes No

Please circle the three most important factors a ecting your purchase decision:

• Price • Product Reputation • Product Features

• Reputation of OutBack Power Systems • Value

System

System Install/Commission Date: __________ MX60 Charging Source(i.e. Solar): ___________ System Array Nominal Voltage: ____________ DC Input Wiring Size and Length: ___________ Type of Batteries: _______________________ Number of MX60 Products in System: ________ System Array Size: ______________________ Type of PV Modules: _____________________ System Battery Bank Size (Amp Hours)

: _________

Installer

Name: _______________________________ Address: ______________________________ City, State, Zip: _________________________ E-mail: ________________________________ Contractor Number:_____________________

*Extended Warranty OutBack Power Systems o ers an optional three (3) year extension to the standard two (2) year Limited Warranty in North America for the MX60 product. To request a 3-year Limited Warranty extension for a total e ective warranty coverage period of  ve (5) years; include a check or money order in the amount of $100USD payable to OutBack Power Systems, Inc. along with your Warranty Registration.

Revision.2008-02-26

Corporate Headquarters

19009 62nd Avenue NE Arlington, WA 98223 USA Phone: (+1) 360.435.6030

European Sales O ce

C/ Castelló, 17

08830 - Sant Boi de Llobregat

BARCELONA, España

Phone: +34.93.654.9568

www.outbackpower.com

900-0028-01-00 REV D

Outback Power Systems MX60 User Manual 2

Specifications and Main Features

Frequently Asked Questions

User Manual