aerl CoolMax SRX 600/55-48 User manual

CoolMax SRX
Charge Controller
Installation and Operation User Manual
Models
SRX 600/55-48
SRX 600/70-48
SRX 600/35-120

USER MANUAL
COOLMAX SRX – Wall Mount
Australian Energy Research Labs
AER09 – Rev 1.1
12th March 2022
2
AER09 REV 1.1
About Australian Energy Research Laboratories
Australian Energy Research Laboratories (AERL) was founded by Stuart Watkinson (BE Elec. Eng., Grad. M.I.E.A) in
1985 to commercialize the “Power Optimizer”, a revolutionary solution to a complex problem, developed while studying at
the University of Queensland in Brisbane, Australia.
Unlike many inventors, Stuart possessed not only a great idea, but also the entrepreneurial skill to turn it in to a
commercially viable product. The “Power Optimizer” would eventually come to be known as the AERL MAXIMIZER™, the
world’s first truly Universal Maximum Power Point Tracker (MPPT).
Today, AERL manufactures a range of highly reliable and efficient specialised power electronic controllers for use in Solar,
Micro Hydro, Micro Wind and Cathodic Protection applications.
Contact Information
Address: Unit 2, 75 Bluestone Circuit,
Seventeen Mile Rocks, 4073,
Queensland, Australia
Phone: [phone]
Email: [email protected]u
Website: https://www.aerl.com.au
Disclaimer
UNLESS SPECIFICALLY AGREED TO IN WRITING, AUSTRALIAN ENERGY RESEARCH LABORATORIES:
(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.
Notice of Copyright
CoolMax SRX Charge Controller Owner’s Manual © 2022 by Australian Energy Research Laboratories Pty. Ltd. All Rights
Reserved.
Trademark
AERL and the AERL logo are trademarks owned and used by Australian Energy Research Laboratories Pty. Ltd.
These trademarks may be registered in Australia and other countries.
Effective Date
March 2022 (03/2022)

USER MANUAL
COOLMAX SRX – Wall Mount
Australian Energy Research Labs
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12th March 2022
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Table of Contents
Warranty Conditions .......................................................................................................................................5
Specifications..................................................................................................................................................6
Introduction .....................................................................................................................................................7
Features......................................................................................................................................................7
Firmware.....................................................................................................................................................7
Installation .......................................................................................................................................................8
Standards & Requirements.......................................................................................................................8
Grounding..................................................................................................................................................8
Mounting the Controller ............................................................................................................................9
Mounting Clearances.........................................................................................................................10
Wiring Information...................................................................................................................................11
Wire and Disconnect Sizing..............................................................................................................11
CoolMax 600/55-48...........................................................................................................................................11
CoolMax 600/70-48...........................................................................................................................................11
CoolMax 600/35-120......................................................................................................................................... 11
Wiring Compartment..........................................................................................................................12
Wiring Polarity....................................................................................................................................13
Operation .......................................................................................................................................................14
Powering Up.............................................................................................................................................14
Programming the Device.........................................................................................................................14
Device Status Indicator ...........................................................................................................................15
Battery Charge Profile.............................................................................................................................16
Charge Profile Configuration ............................................................................................................17
Setting the Battery Charge Profile with AERL Link.........................................................................18
Battery Temperature Compensation.................................................................................................20
Connecting the Temperature Sensor.............................................................................................................20
Temperature Sensor Location ........................................................................................................................20
Communications Protocols ....................................................................................................................21
Troubleshooting –Error Codes....................................................................................................................22

USER MANUAL
COOLMAX SRX – Wall Mount
Australian Energy Research Labs
AER09 – Rev 1.1
12th March 2022
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Important Safety Information
This Installation Manual contains important safety information and installation instructions for the
AERL COOLMAX SRX MPPT Solar Charge Controller.
The following symbols are used throughout this user manual to indicate ideal installation methods,
potentially dangerous conditions and important operational information.
•This User Manual provides detailed installation and usage instructions for the COOLMAX SRX unit. It is
recommended that all of the Instructions and Cautions in this User Manual be read before beginning
installation.
•Only qualified electricians and technicians should install the COOLMAX SRX. This manual is intended for
all installation technicians and the system owner.
•Do not disassemble or attempt to repair the COOLMAX SRX unless you are a qualified technician and
have authority in writing from AERL to do so.
•AERL will not be held responsible in any way for the mishandling of this product or for installation of the
product in a manner that does not follow the instructions in this manual or as advised by an AERL
technician.
IMPORTANT
Indicates information that must be followed to ensure proper operation of the
COOLMAX SRX.
Indicates a critical procedure for the safe installation of the COOLMAX SRX. Use
extreme caution when performing this task.
CAUTION
About this Manual
IMPORTANT

USER MANUAL
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Note: Warranty conditions remain current until the next revision of this document is published. Proof of purchase is required when
making a warranty claim.
1 Warranty Duration from the Date of Purchase
Warranty Requirements
Total Warranty Duration
1. You are the original purchaser of the CoolMax SRX.
3 Years
2. You are the original purchaser and registered your warranty
online within 60 days of installation.
5 Years
Our goods come with guarantees that cannot be excluded under the Australian Consumer Law.
You are entitled to a replacement or refund for a major failure and compensation for any other reasonably
foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be
of acceptable quality and the failure does not amount to a major failure.
AERL will bear the cost of parts and labour to repair any manufacturing faults found within the terms and
period of this warranty. For claims under warranty, the faulty product(s) must be returned to AERL’s facility at
2/75 Bluestone Circuit, Seventeen Mile Rocks, Australia, after contacting AERL and receiving the appropriate
RMA documentation from AERL.
No allowance is made for labour or travelling time required to disconnect or reinstall faulty parts. AERL will pay
the cost of freight to return the repaired charge controller to the customer within Australia or New Zealand only.
The method of freight will be determined by AERL.
All installation and user conditions as set down in the instruction manual must be strictly adhered to as failure
to do so may void your warranty. Any faults or like faults caused by lightning, water or moisture ingress, vermin
infestation, improper voltage, faulty installation, use of the product in a manner for which it is not intended,
alterations which affect the reliability or performance of the unit but are not attributable to faulty manufacture,
failure to act on service warning from the AERL charge controller, or damage caused by other system
components will not be covered under warranty.
In the event of the product being out of service, AERL shall bear no responsibility for any consequential loss or
expense. AERL will not be held responsible for any misleading or incorrect information conveyed by anyone
not directly employed by AERL.
Visit https://core.aerl.com.au/register-product/ and fill out the associated form to activate your full AERL warranty.
Warranty Conditions

USER MANUAL
COOLMAX SRX – Wall Mount
Australian Energy Research Labs
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General Specifications
Parameter
Typical
Weight
5 kg
Dimensions (L x W x H)
432 x 192 x 89 mm
Enclosure Type
Indoor Type 1 / IP20
Input / Output Power Connectors
Screw Terminals (8 mm2 -> 42mm2)
Characteristics
SRX 600/55-48
SRX 600/70-48
SRX 600/35-120
Nominal Battery Voltage / Vdc
Range
24 V | 48 V / 20 - 60
24 V | 48 V / 20 - 60
120 V / 90 – 170
Max Charge Current
55 A
70A
35 A
Nominal PV Power
3168 W @ 48 V
1584 W @ 24 V
4032 W @ 48 V
2016 W @ 24 V
5040 W @ 120 V
Max PV Input Current
12 A
12 A
12 A
Max PV Short Circuit Current
18 A
18 A
18 A
Max PV Input Voltage
600 V
600 V
600 V
MPP Voltage Range
170 – 540 V
170 – 540 V
215 – 540 V
Max Conversion Efficiency
97.3%
97.3%
98.7%
Overload Behaviour
Operating Point Shift
(Power Limitation)
Operating Point Shift
(Power Limitation)
Operating Point Shift
(Power Limitation)
PV Reverse Polarity Protection
Yes
Yes
Yes
Earth Leakage Current Detection
Yes
Yes
Yes
Safety Protection Class
I
I
I
Pollution Degree (Internal)
I
I
I
Pollution Degree (External)
III
III
III
Ambient Operating Range
(Full Rated Output up to 40 ° C)
-20 to 60 °C
-20 to 60 °C
-20 to 60 °C
Storage Temperature
-30 to 70 °C
-30 to 70 °C
-30 to 70 °C
Self-Consumption (Idle)
3 W
3 W
3 W
Allowable Relative Humidity
4 – 95% (Non-Condensing)
4 – 95% (Non-Condensing)
4-95% (Non-Condensing)
Cooling Method
Active (User Serviceable)
Active (User Serviceable)
Active (User Serviceable)
Display
Indication LED Strip
Indication LED Strip
Indication LED Strip
Required Cabinet Air Exchange
Rate (Intake @ 40°C)
14 m3/hour
14 m3/hour
14 m3/hour
Heatsink Temperature @ Full
Power
30°C Rise @ STC (25°C)
30°C Rise @ STC (25°C)
35°C Rise @ STC (25°C)
Communications
RS485 / CAN Bus
RS485 / CAN Bus
RS485 / CAN Bus
Certifications
IEC62109-1:2010
IEC62509:2010
EN61000.6.3:2012
EN61000.6.4:2012
IEC62109-1:2010
IEC62509:2010
EN61000.6.3:2012
EN61000.6.4:2012
IEC62109-1:2010
IEC62509:2010
EN61000.6.3:2012
EN61000.6.4:2012
Specifications

USER MANUAL
COOLMAX SRX – Wall Mount
Australian Energy Research Labs
AER09 – Rev 1.1
12th March 2022
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Thank-you for purchasing an Australian made CoolMax Series Charge Controller.
CoolMax Charge Controllers offer an efficient and reliable charging process that not only maintains battery
efficiency and life but maximizes power generation by utilizing the full potential of your PV array.
Features
CoolMax Charge Controllers utilize an advanced form of Maximum Power Point Tracking (MPPT)
technology to extract the maximum power available from your PV array, efficiently charging your batteries
and maximizing power generation.
AERL’s Maximum Power Point Tracking (MPPT) algorithm has been proven to be highly robust, resistant to
local extremes, and results in power losses of less than 0.5% over the whole operating temperature range
of a PV Array.
•High Input Voltage for Ease of Install
•On Board Ground Fault Detection
•PV Array Oversizing Support (+33%)
•Superior Peak Power Efficiency
•Built-In Overload and Thermal Protection
•Reverse Polarity and Current Protection
•Master/Slave Operational Mode
•Designed for Long Term Reliability
•Australian Made
Firmware
This installation and operating manual covers CoolMax SRX Control Firmware Revisions v1.00 and above.
Introduction

USER MANUAL
COOLMAX SRX – Wall Mount
Australian Energy Research Labs
AER09 – Rev 1.1
12th March 2022
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Standards & Requirements
All installations must comply with national and local electrical standards and codes of practice. AERL
recommends professional installation.
Grounding
CoolMax Charge Controllers are designed to be installed in floating systems but contain provisions for positive
functional earthing for telecom applications if required.
Installation
IMPORTANT
CAUTION – Equipment Damage
The CoolMax SRX must be installed in a clean, dry location away from direct sunlight.
Optimal cooling is achieved when the COOLMAX SRX is mounted vertically. A minimum of 15cm
should be kept clear above the COOLMAX SRX to allow for cooling.
CoolMax Charge Controllers are not designed to be used in parallel with other Third-
Party Charge Controllers and this will void your warranty.
IMPORTANT
The Chassis Ground (located inside the enclosure) is marked with the following symbol:
CAUTION – Hazard
If damaged or malfunctioning, the AERL controller should only be disassembled and
repaired by a qualified service centre. Please contact the local renewable energy
dealer/installer for assistance.
Incorrect reassembly risks malfunction, electric shock, or fire.
DO NOT FUNCTIONALLY EARTH THE ARRAY if a negative earth is used for the batteries, load or DC
system.
CAUTION – Hazard

USER MANUAL
COOLMAX SRX – Wall Mount
Australian Energy Research Labs
AER09 – Rev 1.1
12th March 2022
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Mounting the Controller
Use the mounting plate included with the controller to mount the SRX on a vertical surface as demonstrated in Figure
1A below.
Figure 1A: SRX Mounting Hole Locations

USER MANUAL
COOLMAX SRX – Wall Mount
Australian Energy Research Labs
AER09 – Rev 1.1
12th March 2022
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Mounting Clearances
When mounting the SRX, a clearance zone around the device must be adhered to for optimal cooling of the
controller under full load. Please refer to the Figure 1B below.
Figure 1B: SRX Mounting Clearances
15 CM
10 CM
10 CM
10 CM

USER MANUAL
COOLMAX SRX – Wall Mount
Australian Energy Research Labs
AER09 – Rev 1.1
12th March 2022
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Wiring Information
This section will provide information and instructions for safely wiring up the CoolMax SRX.
Wire and Disconnect Sizing
Use a minimum of #6 AWG (16 mm2) wire for the output between the CoolMax and the battery bus bar or
termination, and we recommend you use an appropriately sized insulated crimp ferrule when terminating
both the input and output connections.
Torque all CoolMax wire and ground terminals to 1.7 Nm (15 in-lb).
CoolMax 600/55-48
•The output current limit of the CoolMax 600/55-48 is 55 amps.
•Use a 63A Non-Polarized DC Circuit Breaker between the controller output and load.
oRecommended Option: Beny BB1-63 63A 600V 2-Pole Circuit Breaker
CoolMax 600/70-48
•The output current limit of the CoolMax 600/70-48 is 70 amps.
•Use a 125A Non-Polarized DC Circuit Breaker between the controller output and load.
oRecommended Option: Beny BD-125 125A 1000V 4-Pole Circuit Breaker
CoolMax 600/35-120
•The output current limit of the CoolMax 600/35-120 is 35 amps.
•Use a 50A Non-Polarized DC Circuit Breaker between the controller output and load.
oRecommended Option: Beny BB1-63 50A 600V 2-Pole Circuit Breaker
Please refer to the relevant IEC or AS/NZS electrical code for recommendations on PV array cable sizing,
length and ampacity.
IMPORTANT
•Wire sizes must comply with local and national standards. Input conductors and
circuit breakers must be rated at 1.56 times the short-circuit current of the PV array.
•Copper wiring must be rated at 75°C or higher.

USER MANUAL
COOLMAX SRX – Wall Mount
Australian Energy Research Labs
AER09 – Rev 1.1
12th March 2022
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To install cabling, the access panel of the COOLMAX SRX must be removed. This is done by removing the
two M4 countersunk Phillips screws on the bottom of the enclosure and the four M3 countersunk Phillips
screws on either side of the access panel. Refer to Figure 2 below.
Figure 2: SRX Access Panel Screw Locations
CAUTION – Hazard
All CoolMax SRX wiring must enter the unit through the entry ports located in the base
and rear of the enclosure.
Under absolutely no circumstances should holes be drilled anywhere into the unit to
make other cable entry points. Doing so can cause metal swarf or fillings to enter the
internal electronics and damage the unit once powered up.
Drilling any holes into the unit will void all product warranty.
Wiring Compartment

USER MANUAL
COOLMAX SRX – Wall Mount
Australian Energy Research Labs
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With the access cover removed, the internal I/O terminals will be visible. Refer to Figure 3 below.
Figure 3: SRX Access Cover Removed
CAUTION – Equipment Damage
Reversing the polarity of either the input or output may damage the CoolMax SRX and
void product warranty.
Confirm polarity with a multi-meter prior to closing the input and output circuit breakers.
Wiring Polarity

USER MANUAL
COOLMAX SRX – Wall Mount
Australian Energy Research Labs
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Powering Up
The CoolMax SRX will power up when a PV voltage above 50Vdc is applied.
When the COOLMAX SRX is first powered the on, the device will run a self-test and then the LED Indication
strip will appear yellow to indicate no charge profile has been configured.
Programming the Device
The CoolMax SRX is programmed via USB-C port located inside the access cover.
The AERL Link Software that can be downloaded at the URL below with instructions for setting the charge
profile located on Page 18.
https://link.aerl.com.au
Figure 4: USB-C Programming Port
Operation

USER MANUAL
COOLMAX SRX – Wall Mount
Australian Energy Research Labs
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Device Status Indicator
Green
OK
Blue
START-UP
Yellow
WARNING
Red
FAULT
Figure 5: LED Indication States

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Australian Energy Research Labs
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Battery Charge Profile
The CoolMax SRX charge output will not automatically activate for safety reasons. Prior to activating the
charge output, the charge profile must be configured for the relevant battery solution being utilized.
The SRX operates using an advanced three-stage charging process and has pre-set charge voltage profiles
for each supported nominal battery voltage. That said, AERL always recommends referring to the battery
manufacturers specifications regarding charge voltages for optimal battery life and performance.
These voltages can be adjusted in the charge profile settings. Refer to Page 18 for instructions.
Figure 6: Battery Charge Profile Illustrated
IMPORTANT
The CoolMax SRX default charge profile is intended for a generic LiFePo4 battery solution.
AERL supports most other battery chemistries that do not require external BMS communications.
AERL is working with various battery manufacturers to expand out-of-the-box comms support for
Lithium batteries that require communication with the Charge Controller.
Please contact AERL support to confirm compatibility prior to installation. Additional battery
support will be rolled out via Over-The-Air firmware updates.
Battery Voltage
Time
Absorb
Time
Absorb Voltage
Float Voltage
Rebulk Voltage
Falls Off Float
New Charge Cycle

USER MANUAL
COOLMAX SRX – Wall Mount
Australian Energy Research Labs
AER09 – Rev 1.1
12th March 2022
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Charge Profile Configuration
The CoolMax SRX allows for extensive flexibility when it comes to charge profile parameters to suit numerous
different modern battery chemistries and manufacturers requirements.
Our programmable charge profile allows for the configuration of the Battery Charge Rate, and the Absorb,
Float, Re-Bulk, and Equalization voltage points.
The default charge profile is suitable for most applications but to determine the optimal charge profile for your
application, please refer to your battery manufacturer’s user manual or datasheet.
The CoolMax SRX Default Charge Profiles are as follows:
SRX 600/55-48
SRX 600/70-48
Nominal Battery voltage
48 V
48 V
Max Charge current
55 A
70 A
Absorption voltage
57.6 V
57.6 V
Absorption time
2 Hours
2 Hours
Float Voltage
55.2 V
55.2 V
Re-Bulk Voltage
52 V
52 V
SRX 600/35-120
Nominal Battery voltage
120 V
Max Charge current
35 A
Absorption voltage
144 V
Absorption time
2 Hours
Float Voltage
138 V
Re-Bulk Voltage
126 V
IMPORTANT
An Equalization is only normally required for Flooded Lead-Acid cells that experience
sulfation as a result of poor charging practices over the lifetime of said cell.
Equalization is not required, nor recommended for LiFePo4 or other lithium-based
battery solutions and will likely cause damage unless otherwise advised by the
battery manufacturer.

USER MANUAL
COOLMAX SRX – Wall Mount
Australian Energy Research Labs
AER09 – Rev 1.1
12th March 2022
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Setting the Battery Charge Profile with AERL Link
Connect to the USB-C Port on the CoolMax and Select the Device from the available local devices list.
Select the Settings button to access the battery charging settings. Charge settings are changed by clicking on
the setting value and using the plus/minus arrows or the keyboard to enter a new value.

USER MANUAL
COOLMAX SRX – Wall Mount
Australian Energy Research Labs
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Once the required settings have been set, Apply the Changes to the CoolMax SRX by clicking on the Apply
button.
Note - Further instructions for more complex functionality can be found in the AERL Link User Manual.

USER MANUAL
COOLMAX SRX – Wall Mount
Australian Energy Research Labs
AER09 – Rev 1.1
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Battery Temperature Compensation
Temperature compensation measures the temperature of the batteries and adjusts the float and absorb voltage
set points to the ideal voltage for batteries at that temperature.
Using the temperature of the batteries, the COOLMAX SRX adjusts voltages by a user specified factor in
millivolts per C. The temperature compensation factor can be set using the AERL Link Software. The
compensation factor is per bank, not per cell.
Please refer to Page 18 of this User Manual for instructions on how to edit settings in the charge profile.
Connecting the Temperature Sensor
To connect your remote temperature sensor to the CoolMax SRX, plug the sensor into one of the CAN RJ45
ports labelled “CAN” and located between the power terminals.
Insert the remote temperature sensor connector into the RJ45 connection (Make sure the orientation is correct
and do not force the connection).
Once the connector is inserted, it will click into place.
Temperature Sensor Location
The CoolMax SRX remote temperature sensor must be in close proximity to the battery cells for accurate
results. Securing the temperature sensor in a central location near the top of the bank is recommended.
IMPORTANT
To utilize the CoolMax SRX battery temperature compensation functionality, an AERL
Battery Sense Remote Temperature and Voltage Sensor will be required.
Part Number: BATT-SENSE
IMPORTANT
A temperature compensation value must be set in the charge profile before the CoolMax
SRX will begin to utilize the battery temperature.
CAUTION – Equipment Damage
Do not place the Battery Sense Remote Temperature and Voltage Sensor in a location
where it may be exposed to water, moisture, direct sunlight or chemical material.