Biall MPK Series MPPT Solar Charge Controller User Manual

Biall MPK Series MPPT Solar Charge Controller User Manual

Safety Instruction:

1. The controller is only used for off-grid solar system.It offers the management of charging and discharging for lead-acid and lithium battery from 12V to 48V.
2. The controller only can be used in dry conditions,please avoid direct sunlight.

Dimensions(mm):

30A/40A dimensions:

• Mounting hole pitch : 86mm*186mm
• Mounting hole pitch : 126mm*186mm
• Mounting hole pitch : 166mm*186mm
• Mounting hole diameter : Φ5mm
• LengthWidthThickness : 220mm200mm83mm
• Connecting terminal : Maximum 16mm²
  

50A/60A dimensions:

• Mounting hole pitch : 131mm*206mm
• Mounting hole pitch : 171mm*206mm
• Mounting hole pitch : 211mm*206mm
• Mounting hole diameter : Φ5mm
• LengthWidthThickness : 265mm220mm88mm
• Connecting terminals : Maximum 16mm²
  

80A/100A dimensions:

• Mounting hole pitch : 206mm*226mm
• Mounting hole pitch : 246mm*226mm
• Mounting hole pitch : 286mm*226mm
• Mounting hole diameter : Φ5mm
• LengthWidthThickness: 340mm240mm108mm
• Connecting terminals : Maximum 25mm²
  

Attentions

1. Please confirm the polarity before wiring the solar panel,reverse connection may damage the controller;
2. Don’t disconnect the battery while the controller is charging,otherwise may damage the controller;If need disconnect the battery,please disconnect the solar panel first,and then disconnect the battery;
3. Don’t connect the solar panel to the battery terminal,or may damage controler. Please check the wiring carefully and power on;
4. When connect the controller, be sure to tighten the terminal screws.Do notpress the wire and check the wiring tightly.

Wiring

Connection diagram:

Installation process:

Note: Please switch off the breakers of battery, solar panels array before install ing the controller. Do not touch the positive and negative pole of solar panels or battery at the same time when installing, otherwise there is danger of electric shock!

1. Mount the controller on the wall and fasten the screws.
2. Check whether the battery voltage and solar panels array voltage is within the requested range
3. Switch off the over-current breaker or fuse of the battery, solar panels array and load.
4. Connect the battery to the battery terminal on the controller by cables and fasten the screws.
5. Connect the load to the load terminal on the controller by cables and fasten the screws.
6. Connect the solar panel to the solar panel terminals on the controller with cables.
7. Switch on the breaker or fuse of the battery, then LCD display the system status.
8. Switch on the breaker or fuse of the battery, then the controller starts to charge the battery

Overview

MPK solar charge controller is Multi-stage Maximum Power Point Tracking (MPPT) photovoltaic battery charge controller with our own technology. It’s main topology adopts in Buck conversion circuit, and uses MCU to adjust the solar panels working point intelligently in order to make the solar panels output is maximum power. When the circumstances change, the working point of solar panels deviate from the maximum power point, MCU will adjust the solar panels working point based on MPPT calculation to make the solar panels back to the maximum power point again. Compared with PWM controller, MPPT can increase the output power of solar panels by 5%-30%. The output power increasing proportion is affected by the factors such as solar panel property, humidity and light intensity. The controller uses wall-mount installing.Connecting terminal makes the wiring area bigger and wiring lossless.

Instruction

1. LCD Display Screen
2. Button
3. Communication port
4. Grounding terminal
5. Load terminal
6. Battery terminal
7. Solar panel terminal
8. Temperature sensor

Functions

1. Maximum Power Point tracking technology.
   The controller uses Buck conversion circuit and MCU technology to track the maximum power point to implement the maximum output power of solar panels in different illumination intensity and temperature.The MPPT algorithm increases efficiency of your PV system and decreases the quantity of solar panels

2. Multi-stage
   The starting charging voltage of battery is different; the controller will use different charging strategies to finalize the charging process. When starting charging voltage is lower than12.6v
   (for 12V battery), the battery will go through three stages as Bulk, Absorption and Float charging , when starting charging voltage of battery is higher than 12.6V (for 12V battery),battery will gothrough two stages as Bulk and Float charging.
   Bulk Charge
   The controller charges the battery at the maximum output current. At this stage, it is in the maximum power point tracking state.
   Absorption Charge
   The controller begins to limit the charging current to make the battery voltage at a settled absorption voltage (this voltage has temperature compensation) for two hours. It increases the charging saturation level of battery and prevents battery from leaking gas, and can increase the lifetime of battery.
   Floating Charge
   The battery is at saturation state, and the controller charges the battery at a trickle current to make the battery voltage fixed at the settled float charging voltage (this voltage has temperature compensation)
   

3. Charge Voltage Temperature-compensated
   The controller will compensate the Float charging voltage and Absorption charging voltage b

   • 4Mv/Cell/¡æ according to the current battery temperature.
   • For 12V battery, the compensated voltage U= (t-25)6(-0.004)V
   • For 24V battery, the compensated voltage U= (t-25)12(-0.004)V
   • For 48V battery, the compensated voltage U= (t-25)24(-0.004)V

4. Discharge control
   The controller records the battery voltage all the time. The load will be switched off when the voltage lower than the Low Voltage Disconnect (LVD) point, and it won’t be switched on until the voltage higher than the Low Voltage Reconnect (LVR) point.

5. Battery Reverse Connection Protection
   Connecting the battery to the controller by reversed polarity (with the solar panel disconnected) will not damage the controller. The controller will work normally when it is correct connected.

6. Solar Panel Reverse Connection Protection
   Connecting the solar panel to the controller by reversed connection will not damage controller (with the battery disconnected). The controller will work normally when it is correct connected.

7. Reverse Current Protection
   The controller prevents reverse current from flowing into the solar panel at night

8. Overheating Protection
   When the controller detects that the temperature of the internal power module is higher than a certain value, the controller stops charging the battery. When the temperature drops to acertain value, the controller will restart charging the battery.

9. Solar panel Over voltage Protection
   If the input voltage of the solar panel exceeds the maximum voltage allowed by thecontroller, it will enter into protection state automatically and stops charging. When the input voltage returns to the normal range, the controller will restart charging the battery.

10. Solar panel input power limit
    When the solar panels are too powerful, the controller will deviate from the maximum power point to limit the output current to prevent the controller being damaged

Introduction to Maximum Power Point Tracking Technology

Maximum Power Point Tracking (MPPT) is an advanced charging technology that enables the solar panel to output more power by adjusting the electric module’s operating status. Due to the nonlinearity of solar arrays, there exists a maximum energy output point (maximum power point) on their curves. Unable to continuously lock onto this point to charge the battery, conventional controllers (employing switching and PWM charging technologies) can’t get the most of power from the solar panel. But a solar charge controller featuring MPPT technology can continuously track arrays’ maximum power point so as to get the maximum amount of power to charge battery Take a 12V system as an example.As the solar panel’s peak voltage (Vpp) is approximately 17V while the battery’s voltage is around 12V,when charging with a conventional charge controller,the solar panel’s voltage will stay at around 12V,failing to deliver the maximum power. However,the MPPT controller can overcome the problem by adjusting the solar panel’s input voltage and curre nt in real time, realizing a maximum input power.Compared with conventional PWM controllers, the MPPT controller can make the most of the solar panel’s max. power and therefore provide larger charging current. Generally speaking, the latter can raise the energy utilization ratio by 15% to 20% in contrast with the former.

Solar panel output characteristic curve

Meanwhile, due to changing ambient temperature and illumination conditions, the max.power point var ies frequently, and our MPPT controller can adjust parameter settings according to the environmental conditions in real time,so as to always keep the system close to the max.operating point. The whole process is entirely automatic without the need of human intervention.

Operation Instruction

Symbols：
Icons Explanation:

1. Solar panel
2. Working status
3. System voltage
4. Charge display
5. Battery capacity
6. Discharge display
7. Battery type
8. Load working mode&status
9. Parameters unit
10. Day or Night
11. Parameters display

Startup page
Working page

1. Startup page: the interface when system is powered on by which you check whether the LCD is in good condition.
2. Working page: By pressing bottom to switch load on/off.The battery is properly connected to the controller, rated charging and discha-rging current, battery voltage, system voltage, battery type etc. can be checked in this page.

LCD Main Interface display

By pressing or to circulate interfaces. It will switch automatically to fault interface after 15s if something is out of work.By pressing or to cancle “error code” interface.

※Reamrks: Below situation valid only for products with loading control function

Solar panel input voltage display

By Long pressing over 3s to check PV input voltage value

Time Setting:

• Day.Month Hour:Minute Week
  

• Day.Month Hour:Minute Year.Week
  

By long pressing M over 3s to set Real Time Clock and Date.Above screen from left to right, it means Day,Month, Hour, Minute,Year and week
By pressing M to switch value you want to set and long pressing and to set parameters you need,finally pressing M over to save parameters you set.

※Reamrks: For Monthe display,O means Oct.,N means Nov.,D means Dec

After charging discharging AH value up to 65KAH, the controller starts counting again from 0Ah.
※Reamrks: By long press   botton to clear the value.

Adjustment of sound volume:

By long press the button at the time page to adjust the sound volume.

Restore factory setting:

By press the button to second page and long press botton M to restore factory settings.

Parameters setting:

※Reamrks:Explanation of the above pages:

00 :Working page

1. 01 :Battery type(lithium,lead acid)
2. 02 :System volt.(12/24/48V Auto.)
3. 03 :Battery capacity
4. 04 :Battery floating charge volt. setting
5. 05 :Battery absorption Charge volt. setting
6. 06 :Battery absorption Charging time setting
7. 07 :Battery equalizing charge volt. setting
8. 08 :Battery equalizing Charging time setting
9. 09 :Lithium battery constant Volt. setting
10. 10 :Lithium battery recover charging volt.
11. 11 :Battery low volt. disconnection
12. 2: Battery low volt. recovery charing
13. 13 :Load working mode setting
14. 14 :Load working time set after dark
15. 15 :Load working time set before dawn
16. 16-23 : Load time control and time setting
17. 24 :Temperature compensation coefficient
18. 25 :Communication Address Setting
19. 26 :Serial port communication baud rate set

Battery Types and setting:

Battery types:

b00 : lead-acid custom;
b01 : sealed battery (sealed);
b02 :flooded battery;
b03 : Gel battery (gel);
b05 : 3.2V4 series of LiFePO4;
b06 : 3.2V5 series of LiFePO4;
b07 : 3.7V3 series polymer lithium battery;
b08 : 3.7V4 series polymer lithium battery;

※Reamrks: Charging parameters cannot be set from b05 to b08

b04 :Be applied to custom lithium batteries： include 4 custom types:
3.7V3 series；3.7V4 series； 3.2V4 series； 3.2V5 series

※Reamrks: In this mode, users need to set the CV and RCV volt. by themselves.

Battery voltage setting:

By press and to switch battery voltage you need.
※ Reamrks: System voltage:12/24/36/48V Auto.

Load working mode:

• LO1 :Regular mode(The load continues working for 24hs a day)
• LO2 :Light control mode(The load works only at night)
• L03 :Reverse light control mode(The load works only during )
• L04 :Dual time control mode(light control first)
• L05 :Time control mode(Set load works time)
• L06 :Charge only mode

Serial port communication baud rate setting:

Faults and Remedies:

Error Code and Correction:

battery with a charger
Ex2| When battery voltage more
than rated HVD value| hi voltage is very                   rygh| Check the battery voltage setting is correct or not
check the parameters setted is correct or not
Ex3| When the load current
exceeds the rated current
of the controller| outp  ut overload protection
and stop to output| Reduce the load output, and switch on load
manually or wait 6 minutes for auto switch-on by
controller
Ex4| The pluses and minuses
are straight through| Load short circuit protection| Check load wiring or rehiring
Ex5| The controller temperature
exceeds the rated
temperature| Controller Overheat
Protection and stop charging| The controller automatically resumes charging
when the temperature drops
Ex6| Input current is higher than
rated value of controller| Input overcurrent protection ut         onand stop working| ifVery that the input current of the solar panel is within .wit the rated value specified by the controller.Please reduce the number of panels in parallel.
Ex8| After saving modified parameters| restart controller 10/12

Technical Data：

Model| MPK60| MPK40| MPK80|
---|---|---|---|---
Input
Maximum PV open circuit rains| 15.011 (DI the lowest Temperature)
138V (al a glands d Temperature of 2S•)
Minimum PV voltage| Battery current voltage +2V
Rated Charge Current| 30A    40A| 50A| 60A| 80 A    100 A
Output|
System Voltage| 12V/24V/36V/48V Auto
Rated Discharge Current|

1. 40A
2. 30A
3. 20A

Own consumption| 435mA116V)
MPPT highest accuracy| 99%
Maximum charging efficiency| 97%
Charging Control mode| Multi-stage(MPPT, Absorption, Float, Equalization,CV)
Float Charge| 13. 8V/27. 6V/41.4V/55.2V
Absorption charge| 14.4V/28. 8V/43. 2V/57.6V
Equalization charge| 14. 6V/29.2V/43.8V/58.4V
Load disconnection(LVD)| 10. 8V/21. 6V/32.4V/43. 2V
Load reconnection (LVR)| 12. 6V/25.2V/37. 8V/50. 4V
Load control mode| Normal, light control, light and timing control, timing control, reverse light control
Light Control point voltage| 5V/10V/15V/20V
Battery Type| GEL, SLD,FLD and USR(default), Lithium batteries customization 3series 3.7V,4 series 3.7V,4series 3.2V,5series 3.2V
Others|
Human interface| Color LCD with backlight, 3 buttons
Cooing mode| AL alloy heat sink and cooling fan
Wiring| High current copper terminals25 mm² (3AWG)
Temperature probe| 10K, line length 3 meters
Communication mode| RS485, RJ45 port
Working temperature range| -20~+55 C
Storage Temperature range| -30 +80° C
surname| 10% 90% No condendation
Size| 22220085mm| 26822095mm| 340240108mm
Net Weight| 2500g| 3500g| 4700g

※Reamrks:
Please operate at the ambient temperature allowed by the controller.If the ambient temperature exceeds the allowable range of the controller, please derate it

*36V is not automatically recognized and can be set as a fixed system voltage;
** There is no equalizing charging method for colloidal batteries.

After sales service:

1. One-month warranty of free replacement is provided for this product commencing from the date of purchase.
2. One-year warranty of free repair is provided for this product commencing from the date of purchase.
3. Lifetime warranty of payable repair is provided for this product commencing from the date of purchase. Free guarantee service will not be provided to the said equipment if
4. It has been damaged through transportation or storage or
5. It has been operated otherwise than in accordance with the instructions or
6. Any unauthorized repair or modification has been carried out on the unit or
7. It has been damaged through natural calamities

Return & Repaire:

Please contact customer service before return controller for repair and send controller together with original invoice and associated information like controller model, SN, cause. After receiving return controller, customer service will contact you to confirm cost and time etc. Please note any cost of transportation is on the account of purchaser.

Hi Dear Customers,
All Rayfey Item is with 1 Year Warranty.
Please contact our technical team with any issues about items during
installation and use. We will provide professional tech supports.
service@rayfey.com
In order to better solve problems for customers, please inform the order
number when contact the technical team.
So thanks for supports.

References

• work.by

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