PowMr M60 Solar Charge Controller User Manual

Product Type
POW-M60-MAX
SOLAR CHARGE CONTROLLER
User Manual

Important Safety Instructions

WARNING: CAREFULLY READ AND FOLLOW ALL SAFETY INSTRUCTIONS

• Carefully read the manual before the controller is installed and operated; retain the manual in a safe place for future reference.

• The controller must not be installed or operated by any of the following persons, unless they are under strict instruction and supervision:
  a. Anyone who lacks the appropriate knowledge, experience or competence, required for safe installation and/or usage.
  b. Anyone with compromised/reduced physical, sensory or mental capabilities, which may effect safe installation and/or usage (including children).

• Controller installation and operation
  a. There are no serviceable parts for this controller. Do NOT disassemble or attempt to repair the controller.
  b. Install the controller in a location with good natural airflow/ventilation and sufficient unobstructed space around it; refer to the “2 Installation and Connection” section for more detail.
  c. Install the controller on a non-flammable substrate and ensure there are no heat-sensitive items in the immediate vicinity; it is normal for the controller to become hot during operation.
  d. Install the controller in a location where it is protected from environmental conditions such as direct sunlight, water, high moisture and dust, and also located well away from any flammable liquids or gasses. Controller is for indoor use only.
  e. Do not install or place/operate the controller on top of the battery, directly above the battery, or in a sealed compartment with the battery; batteries can emit explosive gasses.
  f. Do not cover or place any other items on top of the controller.

• Battery installation and charging
  a. Install and charge the battery in a location with good natural airflow/ventilation.
  b. Ensure that there are no ignition sources near the battery; batteries can emit explosive gasses.
  c. Battery acid is corrosive; if battery acid comes into contact with skin immediately rinse with water.
  d. Do not charge non-rechargeable batteries or Li-ion batteries if the battery temperature is below 0°C. Never charge a frozen battery.
  e. Ensure that the unit is properly set up for the type of battery intended to be charged.

• Battery DC connections
  a. Ensure that the DC system is fully shut down/isolated prior to disconnection of any existing cabling and/or new connections are made to the battery/DC system.
  b. Use flexible multi stranded copper cable with sufficient cross sectional area, line with an appropriate fuse or circuit breaker; refer to the”2.4 DC Breaker Type” section for more detail.
  c. NEVER connect the solar panel array to the controller without a battery. Battery must be connected first.

• Controller setup
  a. Refer to the battery manufacturers instructions and specifications to ensure the battery is suitable for use with this controller and confirm the recommended charge settings.
  b. The integrated charge modes combined with adaptive charge logic are well suited for most common battery types; such as flooded lead-acid, Gel and LiFePO4.

Production Instructions

Thank you for choosing the 0 layer Series of Solar Power Controllers. The controller uses numerical control technology design, LCD display, automatic operation. Its maximum power point tracking (MPPT) type battery charging mode, as well as control technology, will greatly extend the battery life.
The controller features a smart tracking algorithm that maximizes the energy from the solar PV module(s) and charge the battery.
This controller is suitable for the solar energy system (independent system), control the charging and discharging process automatically. The battery charging and discharging process of the controller is optimized, which can prolong the battery life and improve the system performance. Its self- diagnostics function and electronic protection function can avoid controller damage due to installation errors and system failures.
The 0 layer series has a humanized LCD screen display algorithm, one interface to complete all parameters display. Data can be monitored and configured in one layer of pages. At the same time, the MAX model has been optimized and upgraded in several aspects compared to its previous generation. The continuous growth of the POW-M60 series aims to embody the action philosophy of developing user-friendly products that meet user needs and optimize user experience.
1.1 Features

• Integrated charge presets
  Integrated charge presets combined with adaptive charge logic are well suited for most common battery types, such as LiFePO4, Gel and flooded lead-acid.

• Flexible Application
  Compatible with 12V/24V/36V/48V system voltage.

• Multi-stage charge algorithm
  The multi-stage charge algorithm is specifically engineered to optimise each recharge cycle and charge maintenance over extended periods.

• MPP Tracking Technology
  The Maximum Power Point Tracking (MPPT) technology will track the array’s maximum power point voltage (Vmp) as it varies with weather conditions, ensuring that the maximum power is harvested from the array throughout the course of the day.

• High efficiency
  Innovative MPPT technology with high tracking efficiency up to 99% and peak conversion efficiency of 98%; resulting in lower power usage, less heat generated and cooler operation.

• Adaptive boost charge
  Adaptive boost charge monitors the battery’s response during initial charging and intelligently determines the appropriate boost charge duration for each individual charge cycle. This ensures that the battery is fully recharged regardless of the discharge level or capacity and avoids excessive time at the elevated boost charging voltage (that can accelerate battery aging).

• Durable and safe
  i. Limit the maximum charging current. Protect battery performance and prolong battery life.
  ii. PV array short circuit protection.
  iii. PV input overcurrent protection.
  iv. Controller overload protection.
  v. Load short circuit protection.
  vi. PV reverse polarity protection. No damage to the controller will result.
  vii. Battery reverse polarity protection.
  viii. Over-temperature protection. If the temperature of the controller heat sink exceeds 65℃, the controller will automatically start reducing the charging current and shut down when temperature exceeds 80℃.

• Silent operation
  Almost silent operation since there is no cooling fan or moving parts, cooling is via natural convection.

• Lithium battery activation
  Compatible with Li-ion (LiFePO₄) batteries; when the battery type parameter is set to Lithium battery the charge cycle settings are altered to suit. Moreover, when the connected lithium battery is in a protected state, the controller will activate the lithium battery using the energy from the solar panel with a current that does not exceed the lithium battery’s protection voltage and current range.
  Warning: Do not charge Li-ion batteries if the battery temperature is below 0°C.

• Enhanced User Interface with a Large Screen
  The POW-M60-MAX features an expanded LCD display interface, significantly enhancing the user experience of the operating interface.

• Built-in Dedicated Wiring Terminals
  Convenient plug-and-play design saves approximately 60% of installation time. It greatly enhances wiring safety and completely avoids errors caused by reverse connection to the controller ports.

• Alarm Function
  The battery controller is equipped with an integrated alarm function. For details about protection and fault alarm, see “5.2 Troubleshooting” section.

1.2 Production Overview

Installation and Connection

2.1 Unpacking and Inspection
Before unpacking the controller, check whether the package is damaged. After unpacking, check whether the contents of the package are damaged or missing. You should have received the following items inside of package:

• Controller
• User manual
• Screws / bolts
• Special cable with terminals
• Special cable terminals

2.2 Preparing for Installation
The controller range is designed to be wall mounted using the flanges which protrude from either side of the heatsink.
Select the Mount Location:
Before mounting, the following aspects should be considered to identify/provide a suitable and safe location:
a. Install the controller in a location with good natural airflow/ventilation.
b. Ensure there is sufficient unobstructed space around the controller; a minimum clearance of 75mm above and below is recommended. c. Install the controller on a non-flammable substrate and ensure there are no heat-sensitive items in the immediate vicinity; it is normal for the controller to become hot during operation.
d. Install the controller in a location where it is protected from environmental conditions such as water, high moisture and dust, and also located well away from any flammable liquids or gasses.
e. DO NOT install or place/operate the controller on top of the battery, directly above the battery, or in a sealed compartment with the battery; batteries can emit explosive gasses.
f. DO NOT cover or place any other items on top of the controller.
g. Install the unit by screwing four screws. It’s recommended to use M5 screws.

2.3 Things You Need
Make sure you have all the parts you need to install the controller:

DC-cable to connect the positive DC connection (+) of the controller to the positive
pole of the DC-distribution| 3
DC-cable to connect the negative DC connection (-) of the controller to the negativepole of the DC-distribution| 3
DC breaker| 3
Screws / bolts (Ø 5mm) to mount the cabinet to a surface. Use mounting materialswhich are suitable to carry the weight of the controller.| 4
PV array. See section “2.5 PV Module Selection” for the configuration of solar panels| 1
Battery pack.| 1

NOTICE

• For all wirings and circuits specifications see section “2.4 DC Breaker Type”.

2.4 DC Breaker Type
➢ PV input circuit breaker type: Determine the maximum PV input current based on the configured system voltage and by referring to “6 Technical Specification”.
Note: The voltage in series shall not exceed maximum PV input open-circuit voltage.
➢ Recommended specifications for the DC circuit breakers for load output circuit:

➢ The DC circuit breakers of the battery should be selected based on the maximum charging current of the battery you connected.

2.5 PV Module Selection
When selecting proper PV modules, please be sure to consider below parameters:

1. Open circuit Voltage (Voc) of PV modules not exceeds max. PV array open circuit voltage of controller.
   Controller mode| POW-M60-MAX
   ---|---
   Max. PV array open circuit voltage of controller| 160V
2. Open circuit Voltage (Voc) of PV modules should be higher than Min. battery voltage.

2.6 Wiring Precautions
a. Let installation and connection work be done by a licensed electrician.
b. Loose connections can cause dangerous overheating of the cables and/or terminals. Therefore, tighten all connections well, in order to limit transition resistance as far as possible. Use cables of the correct size. Please refer “2.4 DC Breaker Type” section for details.
c. Please install separate circuit breakers for each circuit, which will not only enhance the safety of the circuits but also facilitate easy disconnection of the circuits for safe operation during future cleaning and maintenance.
d. Do not connect the inverter to the load side of the controller. Otherwise, irreversible damage may be caused to the device. If you need to install an inverter, see the following system application diagram of the controller. 2.7 Installation and Connection Step-By-Step

1. Mark the position of the mounting spots on the wall based on the mount holes of the controller.
   Then make 4 mounting holes in the wall with an electric drill according to the spots. Refer to the ” 2.2 Preparing for Installation” section for installation locations.

2. Insert the expansion rubber screw plug into the mounting holes.

3. Mount the controller vertically to the ground with terminals facing down; secure using the 4 mounting holes/slots on the base. To aid installation, it is recommended to ‘hang’ the unit using the 2 upper screws and then add the 2 lower screws, before fully securing all 4 screws.
   Recommend screws size is M5.

4. Battery Connection: Connect the battery to the controller with the cables.
   NOTICE
   • All wiring must be performed by a qualified personnel.
   • For safe operation and standard application, a circuit breaker of the corresponding specifications must be installed on the cable connecting to the controller. And confirm that the wire used is thick enough. Please refer “2.4 DC Breaker Type” section for selection of wiring and circuit breaker specifications.
   • Ensure that all circuit breakers are open until all cables are connected.
   • The positive end of the cable shall be connected to the positive port (+), and the negative end shall be connected to the negative port (-).
   • The above precautions also apply to the wiring of the PV side and the load side.

5. PV Connection: Connect the PV array to the controller with the cables.

6. DC Output Connection: Connect the load to the controller with the cables.

7. Check before starting up: See figure as shown below for wiring details. If everything is all right, and all the wires are firmly connected, close the circuit breakers at the battery side, PV module side, and load side in sequence to startup controller.

WARNING: Risk of electric shock!

• Make sure that all the power is turned off before above operations, and then follow the corresponding inspections and operations.

Charging Mode

The charging controller is equipped with an intelligent 3-stage charge characteristic which takes care of an optimal charge of your batteries. When switched on, the controller always starts at Bulk stage. There are 3 integrated charge modes (Bulk, constant, float). Through the three stages of fast, efficient and safe battery charging mode, the system can effectively extend the battery life.
The integrated charge modes combined with adaptive charge logic are well suited for most common battery types; such as flooded lead-acid, Gel and LiFePO4.
The charging mode parameters can be set as required via LCD screen. Please refer to the “4.3 Browse and Configuration Step-By-Step” section for more information.
Any setting made are stored and will not be lost when the controller is disconnected from battery or PV module.
The multi-stage charge algorithm includes the individual charge stages described below:

➢ Bulk charge:
The battery is charged at maximum charge current until the voltage increases to the configured boost charge voltage. The bulk stage duration is dependent on the battery’s level of discharge, the battery capacity and the charge current. When the battery voltage reaches the preset value of the Boost charging voltage, it starts to boost charging.
➢ Boost charge:
The battery is charged at the configured boost charging voltage, with the charge current slowly decreasing as the battery approaches full charge.
The default boost stage duration is adaptive and intelligently varied depending on the battery’s level of discharge – this is determined from the duration of the bulk charge stage.
When the photovoltaic module is reconnected, a new round of charging cycle will be started. If the battery is in full state, the charging stage will directly enter stage B, which is the boost charging voltage stage, and the battery voltage in this stage will not be higher than the set voltage of stage B. Currently, the duration of stage B is 30 minutes.
➢ Float charge:
At the end of the boost charging stage, the controller will reduce the battery voltage by reducing the charging current and keep the battery continuously at the floating charging voltage set value to maintain the full charge state of the battery.
In Float charging stage, loads are able to obtain almost all power from solar panel. If loads exceed the power, the controller will no longer be able to maintain battery voltage in Float charging stage. If the battery voltage remains below the Recharge Voltage, the system will leave Float charging stage and return to Bulk charging stage.

Operation Instruction

4.1 Icon Display on LCD Screen

Troubleshooting” section for details.)
⑤| Indicate PV input voltage/power
⑥| Indicate Current battery voltage/Charging current/Equipment temperature/Battery calibration voltage/Battery type/Boost charging voltage/Float charging voltage/Low DC cut-off recovery voltage/ Low DC cut-off voltage.
⑦| Indicate working mode of load.

4.2 Function Keys

option.
| Confirm and reserve the settings.

4.3 Browse and Configuration Step-By-Step
After cables are connected and the device is started, perform the initial configuration according to the following steps based on the actual situation.
NOTICE

• The screen will automatically turn off the backlight after about 25 seconds without pressing a button to save power consumption. The backlight display can be activated by operating the key again.

4.3.1 PV side
Step 1. Checking PV input Information
Press “ ” key to switch PV information, which is PV input voltage and PV input power in sequence. 4.3.2 Battery side
Step 1. Checking Battery Information
Press “ ” key to switch battery information, which is current battery voltage, charging current, equipment temperature, battery calibration voltage, battery type, boost charging voltage, float charging voltage, low DC recovery cut-off voltage, low DC cut-off voltage in sequence. Step 2. Calibrate battery voltage
The battery calibration voltage parameter is used to correct the current battery voltage measured by the controller. The specific operations are as follows:
a. Once the parameter switches to “battery calibration voltage” item, press and hold “ ” key to enter the battery voltage calibration setting. b. Then press the “ ” or “ ” keys to calibrate the battery voltage parameters of the controller according to the battery voltage measured by the multimeter. Finally press “ ” to confirm.
Step 3. Select the Battery Type
Adjust battery type parameters based on the battery you connected:
a. Once the parameter switches to the battery type item, press and hold “ ” key to enter the battery type adjustment setting.
b. Then press “ ” or “ ” adjust battery type, finally press “ ” to confirm. The operating voltage varies according to battery types.
c. For details, please refer “4.5.2 Battery parameters of different types” section.

Step 4. Customize configured voltage parameters

NOTICE

• This step is required only when the battery type is set to “USE”.
  a. Once the battery type is set to “USE”, the configurable parameters are presented in the following order. Increment of each click is 0.1V.

b. Press “ ” key to select parameter item which you need to adjust.
c. Then press and hold “ ” key to enter related parameter, then press “ ” or “ ” adjust voltage value.
d. Finally press “ ” to confirm. Refer “4.5 Key Points Battery Parameter Settings” section for the logic for setting battery voltage parameters.

NOTICE

•  The 5 parameters as shown above can be set only when the battery type is “USE”. If “USE” is selected, you need to manually set the system voltage.

CAUTION

• The preceding parameter ranges apply to the 12V battery. When the connected battery voltage is 24V/36V/48V, the range values are 2/3/4 times of this range, respectively. And the LCD only display the voltage of the 12V battery.

WARNING

• The above Settings must follow the following logic: Boost charging voltage > Float charging voltage > Low DC cut-off recovery voltage > Low DC cut-off voltage.

4.3.3 Load side
Step 1. Configurate load enable duration
a. Press and hold “ ” key to enter the load mode setting.
b. Then press “ ” or “ ” adjust load state or load enable duration
c. Finally press “ ” to confirm.

• 00H: The solar light control mode. (When the solar energy is sufficient, enable the DC output.)
• 24H (Default): Turn on load immediately.
• 01H~23H: Adjust the load enable duration.

Setting range is from 0 hour to 24 hours. Increment of each click is 1 hour.

4.4 Working Mode

4.5 Key Points Battery Parameter Settings
4.5.1 The logic for setting battery voltage parameters

1.  Before you customize battery parameters, confirm the following parameters of the connected battery:
   . Max charging voltage
   . Discharging protection voltage

2. After confirming the battery information, you can set the 4 key parameters according to the following logic:

Max. charging voltage > Boost charging voltage > Float charging voltage > Low DC cut-off recovery voltage > Low DC cut-off voltage > Discharge protection voltage
4.5.2 Battery parameters of different types
For lead-acid battery & User define:

For Ternary lithium battery：

Lithium iron phosphate battery：

 Protection

5.1 Protection Provided

charging. Clear it to resume normal operation
PV Input Overcurrent| The controller will limit the battery charging current to the maximum battery current rating. Therefore, an overcurrent solar array will not operate at peak power.
Controller Overload| If the current exceeds the maximum load current rating of 21A, the controller will disconnect the load. Overloading must be cleared up by reducing the load and restarting the controller.
Load Short Circuit| Fully protected against the load wiring short-circuit. Once the load short circuit (more than quadruple rated current), the load short circuit protection will start automatically. After 5 automatic load
reconnect attempts, the faults must be cleared by restarting the controller.
PV Reverse Polarity| The controller will not operate if the PV wires reverse polarity. Wire them correctly to resume normal controller operation.
Battery Reverse Polarity| The controller will not operate if the battery wires reverse polarity.
Wire them correctly to resume normal controller operation.
Over-Temperature| If the temperature of the controller heat sink exceeds 65℃, the controller will automatically start reducing the charging current and shut down when temperature exceeds 80℃.

5.2 Troubleshooting
In case of a failure, the controller display shows an error signal to help you find its source.

increase the photovoltaic input voltage value in series.
60| Over-temperature protection| When the temperature of the device is cooled below the recovery temperature, normal charge and discharge control is resumed.
63| Battery voltage is high| Measure whether the battery voltage exceeds the rated voltage and turn off the photovoltaic array air switch.
65| Battery voltage is low| Charge the battery and wait until the battery voltage is higher than the low voltage cut-off voltage recovery point, refer to “4.5.2 Battery parameters of different types” section for detail.
71| Input PV voltage is high| Reduce the number of PV panels connected to the controller to reduce the PV input; or reduce the voltage or current value by changing the series or parallel mode
73| Over-charging current

5.3 Maintenance
The following inspections and maintenance tasks are recommended at least two times per year for best performance.

• Make sure controller firmly installed in a clean and dry ambient.
• Make sure no block on air-flow around the controller. Clear up any dirt and fragments on radiator.
• Check all the naked wires to make sure insulation is not damaged for serious solarization, frictional wear, dryness, insects or rats etc. Repair or replace some wires if necessary.
• Tighten all the terminals. Inspect for loose, broken, or burnt wire connections.
• Confirm that all the system components are ground connected tightly and correctly.
• Confirm that all the terminals have no corrosion, insulation damaged, high temperature or burnt/discolored sign, tighten terminal screws to the suggested torque.
• Check for dirt, nesting insects and corrosion. If so, clear up in time.

WARNING: Risk of electric shock!

• Make sure that all the power is turned off before above operations, and then follow the corresponding inspections and operations.

Technical Specification

PV Spot
Max Open Voltage of PV Module| 160Vdc
Max. Input Power: For 12V system For 24V system For 36V system For 48V system| 720W 20-80Vdc: 1440W 37-105Vdc; 2100W 50-160Vdc; 2600W 72-160Vdc.
Charge Mode
Charging Technology| MPPT
Charge Algorithm| 3-Stage
Nominal System Voltage| 12V/24V/36V/48V
Battery Voltage Range| 9-70V
Rated Charging Current| 60A
Conversion Efficiency| a98%
MPP Tracking Efficiency| >99%
Self-consumption| 0.7W-1.2W
DC output
Rated Output Current| 6A
Max. DC Output Current| 8A
Max. Capacitive Load Capacity| 10000pF
Environment
Operating Temperature Range| -35t-+45t
Humidity Range| s95%, Non-condensing
Altitude| <3000m
General Specification
Protection Class| IP32
Dimension| 230’165’72mm (9.1’6.5’2.8in)
Net We ht| 1.33kg (2.9Ibs)

SHENZHEN HEHEJIN INDUSTRIAL CO.,LTD
Tel/Fax: +86 755-28219903
Email:support@powmr.com
Web:www.powmr.com
Add: Henggang Street Longgang District Shenzhen, Guangdong, China

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