Sigineer Power MPPT48120 120A MPPT Solar Charger Controller User Manual

Sigineer Power MPPT48120 120A MPPT Solar Charger Controller

Manufacturer Information
Sigineer Power Limited
Email: info@sigineer.com
TEL: +86 769 82817616
US Warehouse:

Please record the Sigineer Power unit’s model and serial number in case you need to provide this information in the future. It is much easier to record this information now than try to gather it after the unit has been installed.

• Order Number:
• Model Number:
• Serial Number:

Important Safety Information

Save This Manual! Read this manual before installation, it contains important safety, installation and operating instructions. Keep it in a safe place for future reference.

All wiring must follow the National Electric Code, Provincial or other codes in effect at the time of installation, regardless of suggestions in this manual. This off grid solar inverter should be connected to a grounded wiring system. If the system ground is floating, please follow the codes in effect.

MISTAKES TO AVOID

1. Don’t reverse the PV input polarity.
2. Don’t use any third-party accessories, BTS, communication cables on the solar charger.
3. Only ground the charger via its ground lug.
4. Don’t connect it to solar panels without batteries.

General Safety Precautions

1. Before installing and using the solar charger, read the manual and cautionary markings on the enclosure. Be sure to read all instructions and cautionary markings for any equipment attached to this unit. Installers must be certified technicians or electricians.
2. This product is designed for indoor/compartment installation. Do not expose the charger to rain, snow, spray, bilge or dust. To reduce the risk of hazard, do not cover or obstruct the ventilation openings. Do not install it in a zero-clearance compartment. Overheating may result. Allow at least 30CM (11.81 inches) of clearance around the charger for air flow. Make sure that the air can circulate freely around the unit. A minimum air flow of 145CFM is required.
3. To avoid a risk of fire and electronic shock. Make sure that existing wiring is in good electrical condition; and that wire size is not undersized. Do not operate the charger with damaged or substandard wiring.
4. This equipment contains components which can produce arcs or sparks. To prevent fire or explosion do not install in compartments containing batteries or flammable materials or in locations which require ignition protected equipment. This includes any space containing gasoline-powered machinery, fuel tanks, or joints, fittings, or other connection between components of the fuel system. See Warranty for instructions on obtaining service.
5. Do not dis-assemble the charger. It contains no user serviceable parts. Attempting to service the charger yourself may result in a risk of electrical shock or fire. Internal capacitors remain charged after all power is disconnected.
6. To reduce the risk of electrical shock, disconnect DC power from the charger before attempting any maintenance or cleaning. Turning off power switch will not reduce this risk

Precautions When Working with Batteries

1. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eye, immediately flood eye with running cold water for at least 20 minutes and get medical attention immediately.
2. Never smoke or allow a spark or flame in the vicinity of battery or engine.
3. Do not drop a metal tool on the battery. The resulting spark or short-circuit on the battery of other electrical part may cause an explosion.
4. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a lead-acid battery. A lead-acid battery produces a short-circuit current high enough to weld a ring or the like to metal, causing a severe burn.
5. To reduce the risk of injury, charge only rechargeable batteries accepted by our inverter such as deep-cycle lead acid, lead antimony, lead calcium gel cell, absorbed mat, NiCad/NiFe or Lithium battery. Other types of batteries may burst, causing personal injury and damage. NEVER charge a frozen battery.
6. Don’t install the inverter near batteries, the inverter may heat battery electrolyte and cause corrosive fumes to vent and damage/corrode nearby electronics or metals.

Target Group

This document is intended for qualified persons and end users.
Tasks that do not require any particular qualification can also be performed by end users.
Qualified persons must have the following skills: Knowledge of how an inverter works and is operated
Training in how to deal with the dangers and risks associated with installing and using electrical devices and installations
Training in the installation and commissioning of electrical devices and installations
Knowledge of the applicable standards and directives
Knowledge of and compliance with this document and all safety information

Introduction

General Information

Thank you for purchasing the M48120 Solar Charger.
This MPPT solar controller is an advanced 120A maximum power point tracking solar battery charger.
The controller features a smart tracking algorithm that finds and maintains operation at the solar array peak power point, maximizing energy converting efficiency.
It has two separate 60A MPPT trackers, they also work in parallel to accept a max of 7KW input power from a single solar array at 120A.
The MPPT solar controller charging process has been optimized for long battery life and improved system performance. Self-diagnostics and electronic error protections prevent damage when installation mistakes or system faults occur. The Wi-Fi / GPRS module is a plug-and-play monitoring device which allow users to monitor the status of the PV system from the mobile phone or from the website anytime anywhere.

Mechanical Design

Port(For RS485/CAN Protocol)

Features

• 12V/24V/48V battery voltage automatic detection
• Two Separate 60A MPPT Solar Trackers
• Capable of accepting a max of 7KW 120A PV input
• Parallel Operation up to 2 pcs
• Multi-stage charging optimizes battery performance
• MPPT tracking efficiency >99.5%, peak conversion efficiency 98%
• Compatible with GEL, AGM flooded, sealed lead acid and lithium battery
• Comprehensive protections
• Wi-Fi/GPRS Monitoring

Installation

Location

• Follow all the local regulations to install the charger.
• Please install the equipment in a dry, clean, cool location with good ventilation.
• Working temperature: ‐10℃ to 55℃(14℉ to 131℉)
• Storage temperature: ‐15℃ to 60℃(5℉to 140℉)
• Relative Humidity: 5% to 95%, non-condensing

Cooling: Forced air
Warning! Operation in a condensing environment will invalid warranty.

Unpacking and Inspection

Before installation, please inspect the unit.
Be sure that nothing inside the package is damaged.

You should have received the following items in the package:

• • The charger x 1
• • User manual x 1
• • Communication cable x 1

Mounting the Unit
Before connecting all wiring, please take off bottom cover by removing two screws as shown below.

Consider the following points before selecting where to install:

• Do not mount the inverter on flammable construction materials.
• Mount on a solid surface
• Install this inverter at eye level in order to allow the LCD display to be read at all times.
• The ambient temperature should be between 0°C and 55°C to ensure optimal operation.
• The recommended installation position is to be adhered to the wall vertically.
• Be sure to keep other objects and surfaces as shown in the right diagram to guarantee sufficient heat dissipation and to have enough space for removing wires.

SUITABLE FOR MOUNTING ON CONCRETE OR OTHER NON-COMBUSTIBLE SURFACE ONLY Install the unit by screwing the six sets of screws.

Install the unit by screwing three screws. It’s recommended to use M4 or M5 screws.
Note: For proper air circulation to dissipate heat, allow a clearance of approx. 20cm to the side and approx. 50 cm above and below the unit. Be sure to install each unit in the same level.

Battery Wiring

CAUTION: For safety operation and regulation compliance, it’s requested to install a separate DC
over-current protector or disconnect device between battery and controller. It may not be requested to have a disconnect device in some applications, however, it’s still requested to have over-current protection installed. Please refer to typical amperage in below table as required fuse or breaker size.

Ring terminal:
WARNING! All wiring must be performed by a qualified person.
WARNING! It’s very important for system safety and efficient operation to use appropriate cable for battery connection.
To reduce risk of injury, please use the proper recommended cable and terminal size as below.

Note: For the lead acid battery, the recommended charge current is 0.2C(C-battery capacity).
Please follow below steps to implement lead-acid battery connection:
Assemble battery right terminal based on recommended battery cable and terminal size.
Connect all battery packs as units requires. It’s suggested to connect at least 550Ah capacity battery for 48V/120A model to operate at full power.

Insert the ring terminal of battery cable flatly into battery connector of controller and make sure the bolts are tightened with torque of 2-3Nm. Make sure polarity at both the battery and the controller is correctly connected and ring terminals are tightly screwed to the battery terminals.

For the M48120 solar charger, there are 6 screws, the sizes are

• M682PCS
• M584PCS

WARNING: Shock Hazard
Installation must be performed with care due to high battery voltage in series.

CAUTION!! Do not place anything between the flat part of the controller terminal and the ring terminal. Otherwise, overheating may occur.
CAUTION!! Do not apply anti-oxidant substance on the terminals before terminals are connected tightly.
CAUTION!! Before making the final DC connection or closing DC breaker, be sure positive (+) must be connected to positive (+) and negative (-) must be connected to negative (-).

Recommended cable size:

Note ：When the solar charger is powered on batteries without PV input, it will automatically power off in one minute to save power.

Lithium Battery Connection

If choosing lithium battery for the controller, you are allowed to use the lithium battery only which have configured.
There’re two connectors on the lithium battery, RJ45 port of BMS and power cable.

Please follow below steps to implement lithium battery connection:
Assemble battery ring terminal based on recommended battery cable and terminal size (same as Lead acid, see section Lead-acid Battery connection for details) .
Insert the ring terminal of battery cable flatly into battery connector of inverter and make sure the bolts are tightened with torque of 2-3Nm. Make sure polarity at both the battery and the inverter/charge is correctly connected and ring terminals are tightly screwed to the battery terminals.
Connect the end of RJ45 of battery to the communication port of the controller.

The other end of RJ45 insert to battery comma port.
Note: If choosing lithium battery, make sure to connect the BMS communication cable between the battery and the controller.
You need to choose battery type as “lithium battery”

Lithium battery communication and setting
In order to communicate with battery BMS, you should set the battery type to “LI” in Program 2. Then the LCD will switch to Program 21, which is to set the protocol type. There are several RS485 protocols in the controller which can match some customized battery, please consult with supplier first before you choosing the battery model.

Connecting the communication port between the controller and battery Make sure the lithium battery BMS port connects to the controller is Pin to Pin, the controller communication port pin assignment shown as below (“COM” port on the controller, support RS485 or CAN protocol).

LCD setting
To connect battery BMS, need to set the battery type as “LI” in Program 02. After set “LI” in Program 02, it will switch to Program 21 to choose battery type. There will be some options under Program 21.
RS485 communication protocol is L01 to L49，The CAN communication protocol is L51 to L99.

Flooded
User-Defined If “User-Defined” is selected, battery charge voltage and low DC cut-off voltage can be set up in program 05, 06 and 07.
User-Defined 2 Suitable for lithium battery when inverter not communicated with BMS. If “US2” is selected, battery charge voltage and low DC cut-off voltage can be set up in program 05,06 and 07.
Lithium Only suitable for lithium battery when inverter communicated with BMS.
The lithium battery BMS communication protocol options: ……

When the battery type set to Li, the setting option 07 will change to display percent.
Note: When the battery type set as “Li”, the Maximum charge current can’t be modified by the Low DC cut-off SOC. If “Li” is selected in program 2, this program can be set up.

Default 20%, 5%~50% Settable.

user. When the communication fail , the inverter will cut off output.

Inverter Connection
Sigineer off grid inverters and this controller can communicate to summarize data.
Make sure the inverter connect to the controller Pin to Pin as below by communication port (“COM” port on the controller).

There will be 2 options to connect with inverter in Program 08. Set to mode CL1 if you select RS485 communication, set to CL2 if you select CAN communication. Details as below:

08| Communication model| SIG    (default), used to communicate with upper computer
---|---|---
CL1, used to communicate through RS485
CL2, used to communicate through CAN.
09| RS485

Communication Address

| Address 1    (default)

Used to communicate with controller in CL1 or CL2, or used to communicate with upper computer in SIG

one controller
Set parameters on the controller: Program 08 as CL1, Program 09 as Protocol 2.

Communication operation between one inverter and two controllers
Set parameters on the first controller: Program 08 as CL1, Program 09 as Protocol 2.

Set parameters on the second controller: Program 08 as CL1, Program 09 as Protocol 3.
There will be a RS485/CAN Hub needed to converge the communication cables from the controllers to the inverter.

RS485/CAN Hub:

PV Connection

CAUTION: Before connecting to PV modules, please install separately a DC circuit breaker between controller and PV modules.
WARNING! All wiring must be performed by qualified personnel.
WARNING! It’’ very important for system safety and efficient operation to use appropriate cable for PV module connection.
To reduce risk of injury, please use the proper recommended cable size as below.
WARNING! Don’t connect it to solar panels without batteries.

PV Module Selection:
When selecting proper PV modules, please be sure to consider below parameters:
Open circuit Voltage (Voc) of PV modules should not exceed max PV array open circuit voltage of controller.
Open circuit Voltage (Voc) of PV modules should be higher than min. battery voltage.

• Please follow below steps to implement PV module connection:
• Remove insulation sleeve 10 mm for positive and negative conductors.
• Check correct polarity of connection cable from PV modules and PV input connectors.
• Peel the plastic tube 10mm from the positive polarity end of the wire.
• Insert the wire into the ring terminal and crimp the edges by tools.
• Then connect the wire to the PV Input port “PV+” of the controller.
• Also use the same method to connect the PV Input port “PV-“.
• Make sure the wires are securely connected.

There are two 60A PV tracker built inside the solar charger, they can be paralleled to accept 120A 7Kw PV input from one PV array.

Operation

Operation and Display Panel

The operation and display panel, shown in below chart, is on the front panel of the controller.
It includes three indicators, three function keys and a LCD display, indicating the operating status and input/output power information.

• Power ON/OFF
• Press the “ON/OFF” button to turn on or turn off the system.
  Note: When there is NO PV input, the solar charger will cut off to save power.

LED Indicator

CHARGING

| Green| Solid On| System is running fine, but not charging now
Flashing| During charging now

FAULT

| Red| Solid On| An error occurs
Flashing| A warning occurs
WIRING FAULT| Red| Solid On| Battery wiring reversed

Function Buttons

LCD Display Icons

System Parameters Information
BAAT| Indicates the battery
PV| Indicates the PV input
| Indicate PV voltage, battery voltage, charging current etc.
Configuration Program and Fault Information
| Indicates the setting programs.
| Warning: flashing with warning code.
| Fault: lighting with fault code
System Status Information
| Indicates battery level by 0-24%, 25-49%, 50-74% and 75-100% in battery mode and charging status in line mode.
SLA| Indicates SLA battery
LI| Indicates Lithium battery
| Indicates unit connects to the PV panel.
| Indicates the DC/DC circuit is working.
| Indicates unit alarm is disabled.

After pressing and holding ENTER button for 3 seconds, the unit will enter setting mode.
Press “UP/DOWN” button to select setting programs. And then, press “ENTER” button to confirm the selection or ESC button to exit.

model: Default 60A, 10A~100A Settable 80A model: Default 60A, 10A~80A Settable 60A model: Default 60A, 10A~60A Settable
(If Li is selected in program 2, this program can’t be set up)
| | AGM (default)
| |
| | Flooded
| |
| | User-Defined
| |
| | If “User-Defined” is selected, battery charge voltage and low DC cut-off voltage can be set up in program 05,06 and 07.
| | User-Defined 2
02| Battery type| Suitable for lithium battery when inverter not communicated with BMS.
If “US2” is selected, battery charge voltage and low DC cut-off voltage can be set up in program 05,06 and 07.
| | Lithium
| |
| | Only suitable for lithium battery when inverter communicated with BMS.
The lithium battery BMS communication protocol options:
| |
| | ……
| |
03| Buzzer| Buzzer on (default)

| Buzzer off

---|---|---|---
04| Backlight Control| Backlight on (default)

| Backlight off

05| Bulk charging voltage (C.V voltage)| 48V mode: default 56.4V, 48.0V~58.4V Settable 24V mode: default 28.2V, 24.0V~29.2V Settable 12V mode: default 14.1V, 12.0V~14.6V Settable

If “Li” is selected ,it can’t be set up

06| Floating charging voltage| 48V mode: default 54.0V, 48.0V~58.4V Settable 24V mode: default 27.0V, 24.0V~29.2V Settable 12V mode: default 13.5V, 12.0V~14.6V Settable If “Li” is selected ,it can’t be set up
07| Low DC cut-off voltage| 48V mode: default 42.0V, 40.0V~48.0V Settable 24V mode: default 21.0V, 20.0V~24.0V Settable 12V mode: default 10.5V, 10.0V~12.0V Settable
48V Li model: default 20%,5%~50% Settable
08| Communication mode| SIG    (default), used to communicate with upper computer
CL1, used to communicate through RS485
CL2, used to communicate through CAN.
09| RS485
Communication Address| Protocol 1 (default)
Used to communicate with controller in CL1 or CL2, or used to communicate with upper computer in SIG
---|---|---
10| Battery equalization| |
If ”Flooded” or ”User-Defined” is selected in program this program can be set up.
11|

Battery equalization voltage

| 48.0V model: default 58.0V,48~60V Settable
12| Battery equalization time| Setting range is from 5 min to 900 min. Increment of each click is 1 min.
13| Battery equalization timeout| Setting range is from 5 min to 900 min. Increment of each click is 1 min.
14| Equalization    interval| Setting range is from 1 to 30 days. Increment of each dick is 1 day.
15| Equalization activated immediately| |
If equalization function is enabled in program 10, this program can be set up. If “Enable” is selected in this program, It’s to activate battery equalization immediately and LCD main page will show ”Eq”, If “Disable” is selected, it will cancel equalization    function until next activated equalization time arrives based on program 14 setting. At this time, “Eq” will not be shown in LCD main page.

LCD Display Information

The LCD display information will be switched in turns by pressing “UP/DOWN” key. The selectable information is switched as below order.

For 48V100/48V100-M and 48V120/48V120-M
PV generated power|
Total PV generated energy|
PV controller temperature|
Battery level| Battery SOC=42%
---|---
Battery Equalization|

Fault Code

Warning Code

Battery Equalization
Equalization function is added into charge controller.
It reverses the buildup of negative chemical effects like stratification, a condition where acid concentration is greater at the bottom of the battery than at the top.

Equalization also helps to remove sulfate crystals that might have built up on the plates.
If left unchecked, this condition, called solation, will reduce the overall capacity of the battery.
Therefore, it’s recommended to equalize battery periodically.

How to Apply Equalization Function
You must enable battery equalization function in monitoring LCD setting program 10 first.
Then, you may apply this function in device by either one of following methods:

1. Setting equalization interval in program 14.
2. Active equalization immediately in program 15.

When to Equalize
In float stage, when the setting equalization interval (battery equalization cycle) is arrived, or equalization is active immediately, the controller will start to enter Equalize stage.

Equalize charging time and timeout
In Equalize stage, the controller will supply power to charge battery as much as possible until battery voltage raises to battery equalization voltage. Then, constant-voltage regulation is applied to maintain battery voltage at the battery equalization voltage. The battery will remain in the Equalize stage until setting battery equalized time is arrived.

However, in Equalize stage, when battery equalized time is expired and battery voltage doesn’t rise to battery equalization voltage point, the charge controller will extend the battery equalized time until battery voltage achieves battery equalization voltage. If battery voltage is still lower than battery equalization voltage when battery equalized timeout setting is over, the charge controller will stop equalization and return to float stage.

Trouble Shooting

Use the table below to solve minor problems.

Check the date code of the battery. If the batteries are too old, replace the batteries.
No LED display on the front panel when PV/battery is working| No LED display.| Battery/PV is not connected well.| Return to repair center.
Buzzer beeps continuously and red LED is on.| Fault code 01| Fan fault| Replace the fan.

Fault code 02

| Internal temperature of controller component is over 90°C.| Check whether the air flow of the unit is blocked or whether the ambient temperature is too high.
Fault code 03| Battery is over-charged.| Return to repair center.
The battery voltage is too high.| Check if spec and quantity of batteries are meet requirements.
Warning code 04| The battery voltage is too low.| Connect with PV to charge, the problem will be solved.
Warning code 06| PV input voltage is too high| Return to repair center.
Fault code 20| BMS Communication failed| Check the BMS communication wire to see if it’s well connected Check the transceiver signal
Fault code 63| Inverter Communication failed| Check the communication wire to see if it’s well connected Check the transceiver signal

If any unlisted abnormal situations occur, please call the service people for professional examination.

Specifications

Electrical
PV operating voltage| 15 ~75Vdc@12V 30~150Vdc@24V 60~245Vdc@48V| 15 ~75Vdc@12V 30~150Vdc@24V 60~245Vdc@48V| 15 ~75Vdc@12V 30~150Vdc@24V 60~245Vdc@48V| 15 ~75Vdc@12V 30~150Vdc@24V
60~245Vdc@48V
Max. PV open circuit voltage| 250Vdc| 250Vdc| 250Vdc| 250Vdc

Max. PV input power

| 1000W@12V| 1250W@12V| 1500W@12V| 1750W@12V
---|---|---|---|---
2000W@24V| 2500W@24V| 3000W@24V| 3500W@24V
4000W@48V| 5000W@48V| 6000W@48V| 7000W@48V
Number of MPPT trackers| 1| 1| 2| 2
Max. charging current| 60A| 80A| 100A| 120A
Self Consumption| 3W| 3W| 5W| 5W
MPPT Efficiency| 99.5%| 99.5%| 99.5%| 99.5%
Conversion Efficiency| 97%| 97%| 97%| 97%
Protection| High voltage, high temperature protection
Battery Charging
Battery Type| Sealed, AGM, Gel, Flooded, Lithium, User define
Charging Algorithm| Bulk, Absorption, Float, Equalize
Bulk charge voltage| Sealed:14.4V AGM Gel:14.1V Flooded:14.6V User define:12-14.6V (For 24V system, total voltage2; for 48V system, total voltage4)
Float charge voltage| Sealed/Gel/AMG:13.7V Flooded:13.6V User define :12-14.6V (For 24V system, total voltage2; for 48V system, total voltage4)
Low DC Warning SOC (Only Li)| Low DC Cut-off SOC+5%
Low DC Warning Return SOC (Only Li)| Low DC Cut-off SOC+15%
Temperature compensation| -5mV/℃with BTS(Optional)
Communication
Communication Port| USB
Mechanical
Net weight| 3KG| 3.2KG| 4KG| 4.2KG
Dimensions| 295180100| 295180100| 320200105| 320200105
Cooling| Fan cooling
Enclosure| IP20
Environment
Ambient Temperature| -20~55℃ ( Derating from 45℃)
Storage Temperature| -40℃~+60℃
Humidity| 100% non-condensing

*Cold start voltage is the minimal battery voltage for the inverter to power on without PV or AC input.

Errors and omissions reserved. Specifications in this manual are subject to change without prior notice.

SAVE THIS MANUAL!
READ THIS MANUAL BEFORE INSTALLATION, IT CONTAINS IMPORTANT SAFETY, INSTALLATION AND
OPERATING INSTRUCTIONS. KEEP IT IN A SAFE PLACE FOR FUTURE REFERENCE.

Sigineer Power Limited
Email: info@sigineer.com
TEL: +86 769 82817616
US Warehouse: 4415 S 32nd St, Phoenix AZ 85040

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