GSL electronics MPPT60-1HV User manual

Page 1 of 8
Model:
MPPT60-1HV
Unit 2, 110 Station Road, Seven Hills ,NSW, 2147, Australia
Operating Instructions
Please read these instructions before use
This revolutionary maximum power point tracker solar charger was
designed using the technology that won GSL Electronics the prestigious
“2008 EDN Innovation award”. A simple, compact and low cost
alternative. Ideal for charging batteries with the new low cost and high
efciency grid type panels.
MPPT60-1HV Unit
3500W Solar Battery Charger
Maximum Power Point Tracker
MPPT60-1HV-R8
PATENT APPLIED FOR - 2010901565

Page 2 of 8
Model:
MPPT60-1HV 3500W Solar Battery Charger
Maximum Power Point Tracker
Operating Instructions
Please read these instructions before use
Unit 2, 110 Station Road, Seven Hills ,NSW, 2147, Australia
96%
Input voltage 20V to 160V
Output voltage Float SLA 13.5V/27V/54V VLA 13.5V/27V/54V Li 13.9V/27.8V/55.6V
Absorption SLA 14.2V/28.4V/56.8V VLA 14.5V/29V/58V Li 14.8V/29.6V/59.2V
Output power 3500W @ 59.2V / 1750W @ 29.6V / 875W @ 14.8V / 60A MAX
Quiescent current 0.05A
Thermal protection Multilevel Type
Dimensions (mm) 308 X 145 X 67mm
Indications LED display – OUTPUT STATUS
Basic Wiring Instructions:
MPPT60-1HV-R8
Disconnected Connected
Panel +
Panel -
Battery +
Battery -
* Optional Diode
Note: First start up may take up to one minute.
MIHV Remote LED
MIHV
MPPT

Page 3 of 8
Model:
MPPT60-1HV
Unit 2, 110 Station Road, Seven Hills ,NSW, 2147, Australia
Operating Instructions
Please read these instructions before use
3500W Solar Battery Charger
Maximum Power Point Tracker
MPPT60-1HV General Information:
• Green LED On – Battery on Float
• Green LED Flashing – Battery on Charge.
• This MPPT is designed to auto detect 12V, 24V or 48V battery systems and select a
suitable charge regime.
• The MPPT 60-1 is shipped in a sealed battery setting which is the safest setting but if your
batteries are vented or lithium then, BEFORE wiring the MPPT, follow the CHANGING
BATTERY TYPE SETTING PROCEDURE on page 5.
• The Absorption Mode is entered following a “low battery condition” at dawn and that mode is
maintained for the remainder of the day. If the battery is not in a “low condition” at dawn then
the Maintenance (Float) Mode is entered and that mode is maintained for the remainder of
the day.
• Custom oat and absorption voltages and thresholds are possible but minimum orders apply.
• This MPPT has a built in multilevel over temperature protection to improve product reliability
while maximising output power availability.
• The maximum continuous output power is 3500W in 48V systems, 1750W in 24V systems
and 875W in 12V systems. The output current is limited to 60A.
• You may use higher power panels safely but the output current will be limited to 60A per unit.
• If over 60A is required you may parallel the outputs of multiple units but each unit must be
supplied from a separate solar panel bank.
The MPPT60-1HV is designed to charge sealed and vented lead acid batteries
and lithium batteries from photovoltaic panels. Silicon based panels such as
monocrystalline, polycrystalline and amorphous are suitable.
MPPT60-1HV-R8

Page 4 of 8
Model:
MPPT60-1HV
Operating Instructions
Please read these instructions before use
Unit 2, 110 Station Road, Seven Hills ,NSW, 2147, Australia
3500W Solar Battery Charger
Maximum Power Point Tracker
Important notes:
• This MPPT should only be operated with a suitable battery connected.
• To enhance Battery and load protection the use of the MIHV or equivalent is recommended
• Before any maintenance ensure that the panels are disconnected or de-energised.
• Use only PV Systems with open circuit voltage below 160V
• This equipment must be installed by qualied personnel only and incorrect wiring can cause
re, injury or death – GSL will accept no responsibility for MPPT misconnection or misuse.
• Use only sealed, vented or lithium 12V, 24V or 48V lead acid batteries and conrm the MPPT
settings charge voltages and currents are correct for your battery system – if in any doubt seek
qualied advice!
• Use wires suitable for at least 80A, but if wire runs are over 3m then larger wires are
recommended to limit voltage drop and losses.
• Install the unit in a dry place out of direct sunlight and away from ammable liquids or gases.
• Battery fuse ( BF ) is always required and must be located as close to the battery as possible,
its sizing depends on the wire size and load ratings. Typically a 80A 60VDC fuse would do.
• Before connecting the battery always check the battery and PV panel polarity.
• Optional Diode A suitably heatsinked schottky diode rated at or above 80A 60V (its anode
connected to the + panel and cathode to the MPPT + input white wire) may be used, see wiring
diagram. This diode will protect against panel short and block any voltage on the panel but will
slightly decrease the battery charge current.
• The lowest Maximum Power Point system voltages are 18V for 12V batteries, 36V for 24V batteries
and 72V for 48V batteries to ensure full output power.
• To enhance Battery and Load protection the MIHV or equivalent and a suitable BMS rated to the
maximum panel power and 170% of nominal battery voltage is highly recommended.
MPPT60-1HV-R8
WARNING
• DO NOT Disconnect battery and/or load whilst charger is operating. Disconnect charger
from the PV rst
• IF the optional Diode is not installed then shorting the panels when the batteries are
connected may damage the MPPT

Page 5 of 8
Model:
MPPT60-1HV
Unit 2, 110 Station Road, Seven Hills ,NSW, 2147, Australia
Operating Instructions
Please read these instructions before use
3500W Solar Battery Charger
Maximum Power Point Tracker
Changing Battery Type Setting Procedure
1.Ensure all the MPPT wires are disconnected. Disconnecting PV rst.
2.Remove the 5 front panel screws and the move the front panel ajar. Then remove 1 middle rear screw on
the back panel (bottom middle below fan) then slide out bottom cover – see Figure 1.
3.Locate connector J4 – see zoom window in Figure 1.
4.Move link on J4 to vented position or for Lithium mode completly remove link– see Figure 2.
5.Slide in the cover and t front panel carefully, secure the front panel again with the 5 screws and the 1 rear
screw.
• The above procedure can be repeated to revert to sealed mode – see Figure 3.
MPPT60-1HV-R8
Figure 1.

Page 6 of 8
Model:
MPPT60-1HV
Operating Instructions
Please read these instructions before use
Unit 2, 110 Station Road, Seven Hills ,NSW, 2147, Australia
3500W Solar Battery Charger
Maximum Power Point Tracker
Figure 2 (Above): Vented Battery Setting
Figure 3 (Above): Sealed Battery Setting
MPPT60-1HV-R8

Page 7 of 8
Model:
MPPT60-1HV
Unit 2, 110 Station Road, Seven Hills ,NSW, 2147, Australia
Operating Instructions
Please read these instructions before use
3500W Solar Battery Charger
Maximum Power Point Tracker
MPPT FAQs
Q: What is an MPPT?
MPPT stands for Maximum Power Point Tracker and is a specialized converter designed to maintain the PV
voltage at the level in which it delivers maximum power to the load or battery. The panel’s nominal output
power can only be obtained with the use of an MPPT.
Q: What are the GSL MPPT’s advantages compared to standard solar regulators?
1. Suitable for lower cost non battery type PV since the MPPT can efciently charge the
batteries from relatively high voltage, say 24V batteries from 40Vmp panels.
2. Less interference and more accurate voltages during absorption and oat.
Q: What sorts of loads can I power with the MPPT60-1HV?
1.The maximum bulk charge current with the MPPT60-1HV on a 12V battery and 800W panel is
approximately 60A, so you can expect about 200Ah per day which means a 200W load for
about 10 hours daily.
2. Following the same reasoning with a 24V 1600W panel the MPPT60-1HV will supply a daily
load of 400W for about 10 hours.
3. Following the same reasoning with a 48V 3200W panel the MPPT60-1HV will supply a daily
load of 800W for about 10 hours.
Q: Why are MPPT not more common in standalone solar systems?
Until now and despite their overwhelming advantages MPPTs have not been commonly used in standalone
solar systems because of cost. The new GSL MPPT specically addresses this issue making economic
sense in a wide range of solar systems.
Q: What sort of batteries should I use?
1. A deep cycle battery is a must due to the cyclical nature of the solar system with a
recommended battery capacity of at least 180Ah.
2. A larger battery will not only give longer run time during low light but also will be able to
avoid available PV power being unstored such as when the battery reaches the oat stage.
MPPT60-1HV-R8

Page 8 of 8
Model:
MPPT60-1HV
Operating Instructions
Please read these instructions before use
Unit 2, 110 Station Road, Seven Hills ,NSW, 2147, Australia
3500W Solar Battery Charger
Maximum Power Point Tracker
Q: Is interference possible? and If so what do I do?
GSL’s MPPTs produce far less interference than a conventional solar regulator during the absorption and oat
stages, that is during most of its operating time, and its designed to comply with local and international EMI
standards however some interference is still possible. If interference occurs rst try and reorient the aerial or
move the sensitive equipment away from the MPPT wires. Ensure the MPPT chassis is grounded.
Grounding a battery terminal may also help and nally you can try adding ferrite clamps.
MPPT60-1HV-R8
Warranty Conditions: Our products come with guarantees that cannot be excluded under the Australian Consumer Law.
The customer is entitled to a replacement or refund for a major failure and compensation for any other reasonably foreseeable loss or damage.
The customer is also entitled to have the products repaired or replaced if the products fail to be of acceptable quality and the failure does not
amount to a major failure.
GSL Electronics (GSL) warrants that its products will, under normal use and service, be free of defects in material and workmanship for a
period of two (2) years from the date of the original purchase by the customer as marked on the customer’s original invoice. Please refer to our
website for full warranty and return information which can be found at http://www.gsl.com.au/faq.html
Q: How do PV temperatures affects charge current?
Temperature increase brings down the PVs maximum power point voltage reducing the MPPTs current
gain available. In principle at 25C it is possible to achieve 30% gain but at 40C, a more realistic average
temperature, about 20% is still available.
Q: What happens at low PV currents?
The MPPT will outperform the conventional regulator above 3% of nominal panel power. Below 3%, about
10W in a 400W panel, the MPPT will have a slightly lower output current than a non MPPT.