aerl CoolMax SRX, Installation And Operation User Manual

Page 1: ...CoolMax SRX Charge Controller Installation and Operation User Manual Models SRX 600 55 48 SRX 600 70 48 SRX 600 30 120 ...

Page 2: ... Micro Wind and Cathodic Protection applications Contact Information Address 2 75 Bluestone Circuit Seventeen Mile Rocks 4073 Queensland Australia Phone 61 1800 950 865 Email sales aerl com au 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...

Page 3: ...e and Disconnect Sizing 11 CoolMax 600 55 48 11 CoolMax 600 70 48 11 CoolMax 600 30 120 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 Tem...

Page 4: ...is 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 th...

Page 5: ...ill be determined by AERL An allowance is made for the labour required to disconnect or reinstall faulty parts up to the value of 220 AUD excluding GST 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 vo...

Page 6: ...ting 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 Int Ext III III III Ambient Operating Range Maximum Charge Current derates by up to 10 Per C above 80 Ambient C 20 to 50 C 20 to 50 C 20 to 50 C Storage Temperature 30 to 70 C 30 to 70 C 30 to 70 C Self Consumption Idle 3 W 3 W 3 W ...

Page 7: ...logy 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 Grou...

Page 8: ...NT CAUTION Equipment Damage The SOLAR DC ISOLATOR BREAKER at the input side must be in the OFF position before connecting or disconnecting the MPPT Charge Controller 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 symbo...

Page 9: ... Research Labs AER09 Rev 1 2 3 31st October 2022 9 AER09 REV 1 2 3 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 ...

Page 10: ...3 31st October 2022 10 AER09 REV 1 2 3 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 ...

Page 11: ...controller output and load o Recommended 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 o Recommended Option Beny BD 125 125A 1000V 4 Pole Circuit Breaker CoolMax 600 30 120 The output current limit of the CoolMax 600 30 120 is 30 amp...

Page 12: ...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 inte...

Page 13: ...nternal PV Input and Battery Output 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 ...

Page 14: ...ation strip will flash yellow to indicate no charge profile has been configured The CoolMax SRX is programmed via the USB C port located inside the access cover as demonstrated in Figure 4 to the right The AERL Link Software for Windows 10 11 can be downloaded at the URL QR below Instructions for setting the charge profile located on Page 18 Operation Figure 4 USB C Programming Port CAUTION Equipm...

Page 15: ...OOLMAX SRX Wall Mount Australian Energy Research Labs AER09 Rev 1 2 3 31st October 2022 15 AER09 REV 1 2 3 Device Status Indicator Green OK Blue START UP SLEEP Yellow WARNING Red FAULT Figure 5 LED Indication States ...

Page 16: ...es 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 va...

Page 17: ...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 30 120 Nominal Battery voltage 120 V Max Charge current 30 A Absorption voltage...

Page 18: ...attery 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 ...

Page 19: ...abs AER09 Rev 1 2 3 31st October 2022 19 AER09 REV 1 2 3 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 ...

Page 20: ... 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 near the battery cells for accurate results Securing...

Page 21: ...dation during the device s start up routine The device chassis must be connected to the same earth as the PV array for the ground fault detection to function The chassis earth point is located inside the access cover and indicated with the symbol demonstrated below Figure 10 Chassis Earth Point IMPORTANT The system earth configuration Ground Fault Mode must be adjusted in the AERL Link software fo...

Page 22: ...sitivity The SRX ground fault detection offers three levels of sensitivity all of which are compliant with the Australian PV installation standards Low 100kΩ Medium 50kΩ High 30kΩ The sensitivity of the ground fault detection can be configured in AERL Link as demonstrated in Figure 11 below Figure 11 Ground Fault Sensitivity Adjustment ...

Page 23: ...ocols for remote monitoring and control functionality The relevant protocol registry maps for integration are available from AERL on request Both networking protocols can be accessed via the RJ45 connectors located inside the access cover The pin outs for these connections are demonstrated in Figure 12 below Pin RS485 Connector 1 5V 4 RS485 B 5 RS485 A 8 GND Pin CAN Connector 1 5V 4 CAN High 7 CAN...

Page 24: ...53 Solid Blue Low Input Voltage Detected Sleep Mode The PV Voltage is below the minimum allowed PV Voltage or not adequate to charge the connected battery Confirm PV String Configuration is appropriate for the device and the sun is shining Note This code may be shown during sunrise and sunset conditions 1304 N A Battery Sense Not Detected The remote voltage and temperature sensor is either unplugg...

Page 25: ...damage The device will automatically restart when it s safe to do so 1159 2 Flashes Red Low Output Voltage Low output voltage has been detected Confirm the battery is connected to the controller 1154 3 Flashes Red High Output Voltage High output voltage has been detected Battery may be being charged from a secondary source Confirm all system battery charge parameters 1157 4 Flashes Red High Output...

Page 26: ... temperature will greatly reduce its lifespan Consider increasing the battery temperature compensation factor with the AERL Link Software or reducing the ambient environment temperature 1103 9 Flashes Red Low Battery Temperature Detected The battery temperature sensor has detected a low battery temperature Operating the battery at a low temperature may greatly reduce its lifespan Consider a temper...

Page 27: ...t Australian Energy Research Labs AER09 Rev 1 2 3 31st October 2022 27 AER09 REV 1 2 3 Note The CoolMax troubleshooting guide and documentation is being improved regularly If the relevant situation is not documented please contact AERL ...