Controllers Series 20A MPPT Solar Charge Controller User Manual

Controllers Series 20A MPPT Solar Charge Controller

LCD display

As follow is the MPPT controller’s LCD digital tube display number corresponding meaning.

In order to check clearly, as follow is the digital tube display character and the English comparison table for reference:

Important safety instructions (for the convenience of future use, please keep this handbook. Please read all the instructions and notes in the manual carefully before you install it).

This manual contains all the safety, installation and operation instructions of the series solar charge controller (hereinafter referred to as “controller”):

• Please install it in the room to avoid the exposure of the components and prevent the water from entering the controller.
• Install the controller in well-ventilated places, the controller’s case temperature may become very hot during operation.
• It is recommended that safety or circuit breakers be connected to the input, load and battery terminals to prevent the danger of electric shock in use.
• After installation, check all connections are firm, to avoid the false connection caused by heat accumulation and dangerous.
• If the display is not displayed for the first time, please cut off the fuse or circuit breaker immediately and check whether the line is connected correctly.
• If the system needs to connect the inverter, please connect the inverter directly to the battery, and do not connect with the load end of the controller.
• When the controller is in the normal charge state, do not disconnect the battery connection, otherwise the DC load may be damaged.

MPPT Controller General Information

Overview

Thank you for choosing the MPPT solar charging controller! The series has high conversion efficiency, soft LCD backlight display, efficient MPPT algorithm, neat internal structure, and beautiful appearance design. With the continuous optimization of the products, the series has its unique advantages:

• The various sampling data have shown on the screen, convenient user access.
• The PV input voltage range up to 150V, suitable for various specifications of solar panels.
• The power supply uses an ultra-low power chip, reducing static standby power consumption, and reduce energy loss.
• Continuous optimization design, super high-cost performance.

Features

• It has an efficient MPPT algorithm, MPPT effciency 299.5%, and converter efficiency up to 98%
• Charge mode: three stages (constant current, constant voltage, floating charge), it prolongs service life of the batteries.
• Four types of load mode selection: ON/OFF, PV voltage control, Dual Time control, PV+ Time control.
• Battery system voltage automatic recognition.
• Three kinds of commonly used lead-acid battery (SeallGel\Flooded) parameter setings fcan be selected by the user, and the user can also custo mize the parameters for other battery charging.
• It has a current limiting charging function. When the power of PV is too large, the controller automatically keeps the charging power, and the charging current will not exceed the rated value.
• High definition LCD display function to check the device runing data and working status, also can support modify the controller display parameter
• RS485 communication, we can offer communication protocol to convenient user’s integrated management and secondary development.
• Support PC software monitoring and WIFi module to realize APP cloud monitoring. CE, RoHS, FCC certifications approved, we can assist clients to pass various certifications.

Characteristics

Accessories Instruction

Remark: Extra accessories can be purchased

1. RS485 to USB cable
2. RS485 to wifi modular

If there is any part missing. please contact your dealer.

Maximum Power Point Tracking Technology

• The MPPT controller can detect the generation voltage of the solar panel in real time and track the maximum voltage and current value (V-l), so that the system can charge the battery with the maximum power output.
• Under the assumption that the conversion efficiency of the system is 100%, the following formula is established.

Normally, the VMpp IS always higher than VBat, Due to the principle of conservation of energy, the l8at IS always higher than Ipv. The greater the discrepancy between VMpp &VBat. the greater the discrepancy between Ipv&leat. The greater the discrepancy between array and battery. This is also the simplest way to distinguish whether the real MPPT controller.
As the Figure shown below, is the maximum power point curve, the shadow is the working range of the PWM controller, it can obviously diagnose that the MPPT mode can improve the usage of the solar energy resource. According to our test, our company’s MPPT controller can improve the utilization of solar array 206-60% ( The efficiency may be different due to the environment)

In actual application, as shading from cloud, tree and snow, the panels may have multiple MPPT points, but there is only one real Maximum Power Point. As the below Figure shows:

If there are multiple MPPT points, if there is no good algorithm, it will lead to work on the unreal MPPT point. Our product can track the actual MPPT point quickly and accurately, improve the utilization of array energy and avoid the waste of resources.

Battery Charging Stage

The controller has 3 stages of charge mode, Constant Current Charging(Bulk Charging), Constant Voltage Charging(CV) and Floating Charging(CF) for rapid, efficient, and safe battery charging.

Constant Current Charging_CC(Bulk Charging)

In this stage, the battery voltage has not yet reached constant voltage (Constant or Boost Voltage), the controller operates in constant current mode, delivering its maximum current to the batteries (MPPT Charging).

Constant Voltage Charging_CV( Constant and Boost Charging)

When the battery voltage reaches the constant voltage set point, the controller will start to operate in constant voltage charging mode, this process the charging current will drop gradually. The constant charge voltage will increase 0.2V on the basis of constant voltage at 1st of each month, charge time is 60 mins.(The data of boost charge voltage can be set via PC software and APP)

Floating Charging_ CF

After the constant voltage stage, the controller will reduce charging current to maintaining the battery voltage on the Floating Voltage set point. Charging the battery with a smaller current and voltage on Floating Voltage stage, while maintaining full battery storage capacity. In Floating charging stage, loads are able to obtain almost all power from solar panel. If loads exceed the power, the controller wil no longer be able to maintain battery voltage in Floating charging stage. If the battery voltage remains below the Recharge Voltage, the system will leave the Floating charging stage and return to the Bulk charging stage.

Installation Instructions

Selecting the Mounting Location

• The position should be taken into consideration of the weight and size of the controller.
• The ambient temperature of the position should be within the range of -20C-50C.
• A good ventilation environment should be maintained in the position. Install position should avoid direct sunlight.

Safe distance

Refer to the following safety clearance to ensure that other equipment or objects are not within this range to ensure that there Is sufficient space for heat dissipation.

Dimensions and Weight

Precautions for controller installation

Please read the safety instructions of the title page carefully before installing the controller!

MPPT Controller Connection

Connection of the PV Power System

Serial connection (string) of PV modules

As the core component of PV systems, controllers could be suitable for various types of PV modules and maximize conversation solar energy into electrical energy. According to the open circuit voltage(Voc) and the maximum power point voltage(VMpp) of the MPPT controller, the series number of different types of PV modules can be calculated. The below table is for reference only.

PVinput <DC 150V    Prohibit the total input voltage greater than 150V

System Voltage| 36cell Voc<23V| 48cell Voc<31V| 54cell Voc<34V| 60cell Voc<38V
Max.| Best| Max.| Best| Max.| Best| Max.| Best
12V| 6| 2| 4| 1| 4| 1| 3| 1
24V| 6| 3| 4| 2| 4| 2| 3| 2
36V| 6| 4| 4| 3| 4| 3| 3| 3
48V| 6| 5| 4| 4| 4| 3| 3| 3
PVinput <DC 150V     Prohibit the total input voltage greater than 150V
System Voltage| 72cell Voc<46V| 96cell Voc<62V| Thin-Fim Module 80V<Voc<150V
Max.| Best| Max.| Best| Max.| Best
12V| 3| 1| 2| 1| 1| 1
24V| 3| 2| 2| 1| 1| 1
36V| 3| 2| 2| 1| 1| 1
48V| 3| 2| 2| 2| 1| 1

NOTE: The above parameter values are calculated under standard test conditions (STC (Standard Test Condition): Irradiance 1000W/m, Module Temperature 25C, Air Mas 1.5)

PV Array Input Total Power

This MPPI controller has a limiting function of charging current, the charging current ill be limited Within rated range. Iherefore, the controller will charge the battery with the rated charging power even it the input power at the PV exceeds. Such as: for 12V Solar System with 30A controller, no matter the input power of the solar panel is greater than the rated number, the charging Current will not be more than 30A.

The actual operation power of the PV array conforms to the conditions below

1. PV power S controller rated power, the maximum power of the controller is equal to the actual power of the PV array.
2. PV power> controller rated power, the maximum charge power of the controller is equal to the rated power. If the PV array higher than rated power, the charging time at rated power to battery will be longer, more energy to battery yields. Meanwhile, it will waste the power under the fierce sunshine due to the limitation of current.

Note : for the rated power of different types of products, please refer to the technical parameters form.

System Voltage and Battery Type

1. The controller can charge the DC12V, DC24V, DC36V and DC48V batteries. The controller recognised the system according to the voltage of the first connected battery and reidentified after the power failure was restarted. Therefore, please confirm whether the LCD display system is consistent with the actual system when starting, otherwise, it is necessary to recheck the battery voltage.
   Note: battery group detailed system identification voltage please refer to the technical parameters table!

2. The controller has been set up to charge 3 kinds of conventional battery parameters for the following forms. If you need to charge for other special batteries, please choose “User” type, then set up by PC software or APP. (parameters is in 12V system at 25C, please use double value in 24v, use three times value in 36V and use four times value in 48V.)
   Battery type| Constant voltage| Floating voltage
   ---|---|---
   Flooded| 14.6V| 13.8V
   Sealed| 14.4V| 13.8V
   Gel| 14.2V| 13.8V
   User (setting)| C(9V~15V)| F(9V~15V)

DC Load Output Voltage and Max. Discharge Current

The controller has DC LOAD output function, and its output voltage range is the same as the battery group. If the battery’s voltage is 48.6V, then DC can output a voltage of 48.6V at this moment.

Specifications for Cables and Breakers

The wiring and installation methods must conform to all national and local electrical code requirements.

PV array specification of Wiring

Since PV aray output can vary due to the PV module size, connection method or sunlight angle, the minimum wire can be calculated by the Isc of PV array. Please refer to the value of Isc in PV module specitication. (When the PV modules connect in series, the Isc is equal to the PV module’s Isc. when the PV modules connect in parallels, the Isc is equal to the sum of PV module’s Isc.) And in order to facilitate the opening and closing of the machine and safety, it is recommended to install the circuit breaker. Please reter to the specitication selection of the next table wire and circuit breaker.

Model

| Rated charge current| Rated discharge current| Battery wire (mm2/AWG)| Load wire (mm2/AWG)|

Breaker

---|---|---|---|---|---
20A| 20A| 40A| 4/10| 14/7| >40A
30A| 30A| 40A| 8/8| 14/7| >50A
40A| 40A| 40A| 14/7| 14/7| >63A
50A| 50A| 60A| 16/6| 20/5| >100A
60A| 60A| 60A| 20/5| 20/5| >100A

Before you connect the wire, please open the product case. After done it, please close and locked them,It is helpfu to protect the connection port.

Steps of Switch on and off

Make sure that the controller is installed and connected as above

Opening process

• Step 1 : open the circuit breaker on the battery side(breaker D), make sure that the controller is connected with the battery (the LCD of the controller will display the content), and set the battery type.
• Step 2 : if you need to use the DC load output, then set the output control mode first, and then open the DC output circuit breaker(breaker).
• Step 3 : open the circuit breaker on the input side of the solar panel PV(breaker ®), if the PV input voltage is in the charge range of the controller, then the controller will enter the charging state.

Closing process: turn off the circuit breaker in turn: 3.2.1.

Warning

if the system needs to connect the inverter, please connect the inverter directly to the batery, and do not connect with the load end of the controller. When the controller is in the normal charge state, do not disconnect the battery connection, otherwise the DC load may be damaged.Therefore, the damage to the controller will not be within the warranty.

Communication port description

• The communication port of the controller can match our RS485-USB communication line to achieve PC terminal monitoring software communication. It can also match our WIFI module products to achieve remote APP cloud monitoring
• The communication port is the standard 8 line RJ45 intertace, and the pin is defined as follows
  PIN| Function
  ---|---
  1| RS485-A
  2| RS485-B
  3| Empty
  4| Empty
  5| GND
  6| GND
  7| +5V
  8| +5V

( Note : the definition of the foot is only applicable to the related products of Our company!)

Operation

Button Function

LCD Display

Browse Interface

Setting Interface

( Remark : please refer to the set mode description of the key operation in the 4.1 chapter)
On the controller, users can set date and time, set up to display daily, monthly or total power generation and electricity consumption, load switch mode can be set, battery type can be set, temperature display unit can be set, and power generation can be cleared. (Note: it is suggested that the parameters be set in the state of stopping charging in order to avoid breakdown).

Parameters

**r  uct cate  r**

| Controller Properties| MPPT (maximum power point tracking)
MPPT efficiency| 99 5%
Standby power| 0 5W~1 2W
System voltage| Automatic recognition
 eat-dissipating method| Intelligent fan cooling

Range of system voltage identification

| 12V system| DC9V~DC15V
24V system| DC18V~DC30V
36V system| DC32V~DC40V
48V system| DC42V~DC60V

Input Characteristics

| Max PV input voltage(VOC)| DC150V
Start the charge voltage point| Battery voltage + 3V
Low input voltage protection point| Battery voltage + 2V
Over voltage protection point| DC150V
Over voltage recovery point| DC145V

Rated PV power

| 12V system| 260W| 390W| 520W| 650W| 780W
24V system| 520W| 780W| 1040W| 1300W| 1560W
36V system| 780W| 1170W| 1560W| 1950W| 2340W
48V system| 1040W| 1560W| 2080W| 2600W| 3120W

Char e Characteristics

| Selectable Battery Types

(Default Gel battery)

| Sealed lead acid, Gel battery, Flooded

(Other types of the batteries also can be defined)

Charge rated current| 20A| 30A| 40A| 50A| 60A
Temperature Compensation| -3mV/C/2V (default)
Charge Method| 3-Stage: constant current(fast charging)-constant voltage- floating charge
Output Voltage Stability Precision| :5±1 5%

LOAD

Characteristics

| Load voltage| The same as the battery voltage
Load rated current| 40A| 60A
Load control mode| On\Off mode, PV voltage control mode, Dual-time control mode, PV + Time control mode
Low voltage protection| The default protection point is 10 5V, and it is restored to 11V (can be set)
Setup mode| PC software /APP/ controller display

Displa &

C mmunicati n

| Display mode|  igh-definition LCD segment code backlight display

Communication mode

| 8-pin RJ45 port/RS485/support PC software monitoring/

support WiFi module to reali e APP cloud monitoring

Other arameters

| ****

Protect function

| Input-output over \ under voltage protection,

Prevention of connection reverse protection,battery shedding protection etc

Operation Temperature| -20C~+50C
Storage Temperature| -40C~+75C
IP(Ingress protection)| IP21
Noise| :540dB
Altitude| 0~3000m
Max connection si e| 20mm2| 30mm2
Net Weight (kg)| 2 3| 2 6
Gross Weight (kg)| 3| 3 5
Product Si e  mm| 240 168 66| 270 180 85
Packing Si e(mm)| 289 204 101| 324 223 135

maintenance and cleaning

replacement fuse

• If the insurance is caused by high temperature or other faults, the fuse needs to be replaced correctly.
• Remove the broken fuse from the interface, install the new fuse, check whether the connection is correct, and install the equipment.

clean air vent radiator

Clean the fan vent and internal heat sink regularly and wipe with dry or wet cloth.
Note : no washing liquid or corrosive solvent can be used, and liquid is not allowed to flow into the machine to ensure that the ventilation holes of the equipment are not blocked.

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