GSL electronics MPPT60-2 User manual

Page 1 of 8
Model:
MPPT60-2
Unit 2, 110 Station Road, Seven Hills ,NSW, 2147, Australia
3400W Solar Battery Charger
Maximum Power Point Tracker
Operating Instructions
Please read these instructions before use
MPPT60-2-R7
This revolutionary maximum power point tracker solar charger was designed using the
technology that won GSL Electronics the prestigious EDN Innovation Awards 08’ and 09’
and the Greentech Consensus Awards 09’. A simple, compact and low cost alternative.
Ideal for charging batteries from new low cost and high efciency panels.
The MPPT 60-2 is designed to automatically charge 12V, 24V and 48V sealed and vented lead
acid batteries from silicon based pv panels such as monocrystalline, polycrystalline and thin lm.
It has a built in Load Low Voltage Disconnect congurable as a Dawn to Dusk switch. It can be
connected to the MCM for remote control and full system parameter logging and display.
PATENT APPLIED FOR - 2010901565

Page 2 of 8
Model:
MPPT60-2 3400W 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
MPPT60-2-R7
Important notes:
• 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 or vented 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 only PV Systems with open circuit voltage below 95V.
•Use wires suitable for at least 40A, 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.
•The lowest Maximum Power Point system voltages are 18V for 12V batteries, 36V for 24V
batteries and 72V for 48V batteries to ensure full power.
MPPT60-2 Specications
Efciency typical 96%
Input voltage 16V to 95V
Output voltage
Float 13.5V / 27V / 54V
Absorption - Vented LA Batteries 14.5V / 29V / 58V
Sealed - LA Batteries 14.2V / 28.4V / 56.8V
Output power 3400W / 60A MAX
Quiescent current 0.05A
Thermal protection Multilevel Type
Dimensions (mm) 260 X 145 X 67mm
Indications LED display – OUTPUT STATUS
MPPT60-2 General Information:
• Green LED On – Battery Ok.
• Green LED Flashing – Battery Low.
• This MPPT is designed to auto detect 12V, 24V or 48V battery systems and select a
suitable charge regime.
• The MPPT 60-2 is shipped in a sealed battery setting which is the safest setting but if your
batteries are vented then, BEFORE wiring the MPPT in, follow the
CHANGING BATTERY TYPE SETTING PROCEDURE.
• The maximum absorption voltage is 14.5V, 29V or 58V and the oat voltage is 13.5V, 27V
or 54V for 12V, 24V or 48V batteries respectively.
•The absorption phase is entered following a low battery condition or dawn and is
maintained until the battery demand falls below 2A.
• 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 3400W in 48V systems, 1700W in 24V systems
and 850W in 12V systems. The output current is limited to 60A.

Page 3 of 8
Unit 2, 110 Station Road, Seven Hills ,NSW, 2147, Australia
3400W Solar Battery Charger
Maximum Power Point Tracker
Operating Instructions
Please read these instructions before use
Model:
MPPT60-2
BASIC WIRING OPTIONS:
Permanent Load Connection
(Figure 1):
Simplest wiring option where the
load is permanently connected
and the batteries are not
protected from over discharge.
Wiring With Low Voltage
Disconnect (Figure 2) :
This option protects the
battery from over discharge by
disconnecting the load. The
LVD option disconnects the
load when the battery voltage
drops below 0.85 of nominal
voltage to protect the battery
from damage. The load
reconnects when the battery
voltage exceeds 0.95 of
nominal voltage. This feature
will not trigger during short
transients. LVD load is 60A
continuous or 100A transient.
MPPT60-2-R7
Figure 1.
Figure 2.
Figure 3.
Panel +
Panel -
Battery -
Battery +
Panel +
Panel -
Battery -
Battery +
Load -
Panel +
Panel -
Battery -
Battery +
Load -

Page 4 of 8
3400W 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
Model:
MPPT60-2
Wiring With Critical And Non Critical Loads (Figure 3):
Critical loads are generally light loads which are powered under any condition. Non critical loads are
loads which can be disconnected to ensure maximum on time for critical loads as well as to extend
the life expectancy and reliability of the system. The non critical load can be set up as LVD or Dawn
to Dusk loads.
Wiring with MCM option:
Connecting the optional MCM to the MPPT will allow various system parameter display, output
voltage and alarm settings and enable the programmable dawn to dusk or remote load control
options. For more details please refer to MCM Manual.
MPPT60-2-R7
Figure 1.
Figure 2.
Figure 3.
Panel +
Panel -
Battery -
Battery +
Panel +
Panel -
Battery -
Battery +
Load -
Panel +
Panel -
Battery -
Battery +
Load -

Page 5 of 8
Unit 2, 110 Station Road, Seven Hills ,NSW, 2147, Australia
3400W Solar Battery Charger
Maximum Power Point Tracker
Operating Instructions
Please read these instructions before use
Model:
MPPT60-2
MPPT60-2-R7
VOC
VMP
12V Charging 24V Charging
48V Charging
21 16
42 32 
63 48 
84 64 
42 32 
84 64 
Grid Connect Panel
(size = no. cells in grid)
1x18 Cell Grid 10 8
1x48 Cell Grid 28 23 
2x48 Cell Grid 56 46 
3x48 Cell Grid 84 69 
1x52 Cell Grid 31 25 
2x52 Cell Grid 62 50 
3x52 Cell Grid 93 75 
1x54 Cell Grid 32 26 
2x54 Cell Grid 64 52 
3x54 Cell Grid 96 78 
1x60 Cell Grid 36 29 
2x60 Cell Grid 72 58 
1x72 Cell Grid 44 36 
2x72 Cell Grid 88 72 
1x96cgsp 65 55 
For optimal performance from panel and MPPT please use the following table to
determine the best setup for your situation.

Page 6 of 8
3400W 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
Model:
MPPT60-2
Changing Battery Type Setting Procedure
1.Ensure all the MPPT wires are disconnected.
2.Remove 7 front panel screws and the front panel and slide out cover – see Figure 4.
3.Locate connector J4 – see Figure 4.
4.Shift link on J4 to vented position – see Figure 5.
5.Slide back cover and t in front panel carefully, insuring led ts properly into housing,
and screw back the 7 mounting screws.
• The above procedure can be repeated to turn back to sealed mode – see Figure 6.
Figure 4.
MPPT60-2-R7

Page 7 of 8
Unit 2, 110 Station Road, Seven Hills ,NSW, 2147, Australia
3400W Solar Battery Charger
Maximum Power Point Tracker
Operating Instructions
Please read these instructions before use
Model:
MPPT60-2
Figure 5 (Above): Vented Battery Setting Figure 6 (Above): Sealed Battery Setting
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 MPPTs advantages compared to standard solar regulators?
1. About 20% higher current in a typical application which can be used for higher loads or longer
run times or cutting PV system cost.
2. Suitable for lower cost non battery type PV since the MPPT can efciently charge the batteries
from relatively high voltage, say 12V batteries from 40V MPP panels.
3. Less interference and more accurate voltages during absorption and oat.
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.
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.
MPPT60-2-R7

Page 8 of 8
3400W 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
Model:
MPPT60-2
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 360AH.
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 battery reaches the oat stage.
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 sorts of loads can I power with the MPPT60?
1. The maximum bulk charge current with the MPPT60 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 will supply a daily load of
400W for about 10 hours.
3. Following the same reasoning with a 48V 3200W panel the MPPT60 will supply a daily load of
800W for about 10 hours.
Q: Is interference possible? and If so what do I do?
GSL’s MPPTs produce far less interference than 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.
MPPT60-2-R7
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