PowMr 209-HHJ60-PRO Solar Charge Controller User Manual

PowMr 209-HHJ60-PRO Solar Charge Controller

Product Information

• Specifications:
  • Indoor use only
  • Well-ventilated installation environment
  • Non-combustible walls for installation
  • Protected from direct sunlight, rain, humidity, and dust
  • Battery charging in well-ventilated areas
  • Installation by trained individuals only

Product Usage Instructions

• Controller Installation and Operation:
  • Before installing the controller, ensure that you are well-versed with the safety instructions provided in the user manual. Only trained individuals should perform the installation and operation.
  • This controller has no user-serviceable components; refrain from disassembling or repairing it yourself.
  • Install the controller in a well-ventilated area with ample space around it.
  • Mount the controller on non-combustible walls and keep it away from flammable materials.
  • Place the controller in an environment shielded from direct sunlight, rain, humidity, and dust. Avoid contact with flammable liquids or gases.
  • Avoid installing or operating the controller near batteries emitting explosive gases. Do not place any objects on top of the controller.
• Battery Installation and Charging:
  • When installing and charging batteries, make sure to follow these guidelines:
  • Install and charge batteries in well-ventilated or exhaust-ventilated environments.
  • Avoid open flames near batteries as they emit explosive gases.
  • If battery acid contacts the skin, rinse immediately with clean water.
  • Do not charge non-rechargeable or lithium batteries improperly.
• Controller Configuration:
  • To configure the controller correctly:
  • Refer to the battery manufacturer’s guide for compatibility and recommended charging settings.
  • Utilize integrated charging modes, including adaptive charging logic suitable for various battery types.
• Warranty Services:
  • The controller is covered by warranty under normal usage conditions. If malfunctioning within 2 years of purchase, it will be repaired at no cost by authorized technical personnel.

FAQs

• Q: Can I disassemble and repair the controller myself?
  • A: No, this controller does not have user-serviceable components. Unauthorized disassembly voids the warranty.
• Q: What should I do if battery acid comes into contact with my skin?
  • A: Rinse immediately with clean water and seek medical attention if necessary.
• Q: Can I charge non-rechargeable batteries with this controller?
  • A: No, do not charge non-rechargeable batteries with this controller.

Important Safety Instructions

WARNING: Carefully read and adhere to all safety

• Before installing and operating the controller, please read the user manual thoroughly and keep it for future reference.
• The installation or operation of the controller should only be performed by individuals who have received proper training and supervision.
  • a. Anyone lacking the necessary knowledge, experience, or capabilities for the safe installation and operation requirements.
  • b. Individuals (including children) who may have physical, sensory, or intellectual impairments that could affect the safe installation and operation.

Controller Installation and Operation

• a. This controller product does not have user-serviceable components; do not disassemble or attempt to repair the controller yourself.
• b. Install the controller in a well-ventilated environment with adequate clearance around it.
• c. Install the controller on non-combustible walls and ensure there are no flammable materials nearby; it is normal for the controller to generate heat during operation.
• d. Place the controller in an environment that is protected from direct sunlight, rain, humidity, and dust, and keep it away from any flammable liquids or gases. The controller is for indoor use only.
• e. Do not install or operate the controller on top of, directly above, or in an enclosed space above batteries, as batteries emit explosive gases.
• f. Do not place any objects on top of the controller.

Battery Installation and Charging

• a. Install and charge batteries in well-ventilated or exhaust ventilated environments.
• b. Ensure there are no open flames in the vicinity of the batteries, as batteries emit explosive gases.
• c. Battery acid is corrosive; if battery acid comes into contact with the skin, rinse immediately with clean water.
• d. Do not charge non-rechargeable batteries. Do not charge lithium batteries when the temperature is below 0°C. Charging frozen batteries is prohibited.
• e. Ensure that the equipment is properly configured for the type of battery connected to it.

DC Battery Connections

• a. Ensure that the DC system is fully off/powered down by disconnecting all cables and/or new ports from the battery/DC system.
• b. Use flexible, multi-strand copper cables with an appropriate cross-sectional area, and connect them to matching fuses or circuit breakers.
• c. Connecting the photovoltaic array to the controller is prohibited until the battery is connected first.

Controller Configuration

• a. Refer to the battery manufacturer’s guide and specifications to ensure the battery is suitable for the controller and confirm the recommended charging settings.
• b. Integrated charging modes include adaptive charging logic, which is suitable for most battery types.

Warranty Services

Dear Customer,

• Thank you for choosing g the HHJ series solar controller.
• Please carefully read this manual as it will help you maximize the many advantages the controller offers for your solar system.
• This manual provides important recommendations regarding installation and usage. For your benefit, please read and pay close attention to the safety advice within.
• By the instructions, repair services may be provided to users for any damaged units resulting from incorrect installation, disassembly, or improper use of this product.

Warranty Terms:

• Within 30 days from the date of purchase, a malfunctioning controller will be replaced at no charge, provided that it has been used under normal circumstances and authorized by the company’s technical personnel.
• Within 2 years from the date of purchase, a malfunctioning controller will be repaired at no charge.
• NOTE: Unauthorized disassembly voids the warranty.

Declaration

Under the following circumstances, our company reserves the right not to assume any quality warranty responsibilities:

• Damage caused by improper transportation.
• Damage resulting from incorrect storage, installation, or usage.
• Damage caused by non-professionals or untrained personnel installing and operating the equipment.
• Damage resulting from noncompliance with the instructions and safety warnings in this document.
• Damage caused by operation in environments that do not meet the requirements specified in this document.
• Damage due to operation beyond the parameter ranges specified in applicable technical specifications.
• Damage resulting from unauthorized disassembly, product alteration, or software code modification.
• Damage caused by abnormal natural conditions (force majeure), such as lightning, earthquakes, fires, storms, etc.
• Any damage resulting from failure to adhere to local standards and regulations during the installation and operation processes.
• Products outside the warranty period.

Product Introduction

• Welcome to the HHJ series solar controller. This controller represents advanced innovation in the field of solar technology and is designed to provide exceptional performance and reliability for your solar energy system.
• The controller is equipped with advanced CNC technology, an LCD, automated operation, and a Maximum Power Point Tracking (MPPT) battery charging mode. Combined with advanced control technology, it significantly extends the lifespan of your batteries.
• The HHJ series solar controller is designed to meet the diverse needs of various solar energy systems, whether in standalone systems or other application scenarios. It automatically controls the charging and discharging processes. Optimizing the control lets battery charging and discharging processes, not only prolong the battery’s lifespan but also enhance the overall system’s performance. The controller features self-diagnostic functions and electronic protection, effectively preventing damage to the controller or batteries during installation errors or system faults, ensuring system reliability and stability.
• Our HHJ series solar controllers are suitable for a wide range of solar energy applications. We offer a user-friendly custom open program configuration interface, making the configuration process of solar energy systems quicker and smoother. It also provides more possibilities for expanding solar energy systems. Whether you are setting up a small-scale residential standalone solar system or expanding your solar energy project, the HHJ series solar controller will be an indispensable partner.
• By choosing the HHJ series solar controller, you will gain an efficient, sustainable, and secure energy management solution that provides strong support for future energy needs. We are committed to advancing solar technology and delivering outstanding products and services to you.

Features

• Integrated Charging Presets
  • Integrated charging modes include adaptive charging logic, suitable for most battery types such as flooded lead acid batteries, gel-sealed lead acid batteries, and lithium batteries. Specific charging parameters for each battery type can be found in Section 3.5
• Versatile Application
  • Compatible with 12V/24V/36V/48V system voltages.
• Multi Stage Charging Algorithm
  • The multi-stage charging algorithm is designed to optimize each charging cycle. After the batteries are fully charged, it maintains battery capacity by applying preset charging parameters in specific charging stages.
• Maximum Power Point Tracking (MPPT) Technology
  • MPPT technology tracks the maximum power point voltage (Vmp) of the array as it varies with weather conditions, ensuring the collection of maximum power from the array throughout the day.
• High Efficiency Charging
  • Innovative MPPT technology with a tracking efficiency of up to 99.9% and a peak conversion efficiency of up to 97%, reducing power consumption, minimizing heat generation, and lowering operating temperatures.
• Supports Up to 12 Units in Parallel
  • The parallel operation function allows for easy expansion of the solar panel configuration and energy storage capacity limits, thus increasing the scale of energy storage. For detailed parallel operation guidelines, refer to Section 7
• Adaptive Boost Charging
  • During the initial charging phase, adaptive boost charging monitors battery response and automatically determines the duration of the boost stage for each independent charging cycle, ensuring that the battery is fully charged at any discharge level or capacity while avoiding overcharging during the boost charging stage (extends battery life).
• Durable and Secure
  • a. Photovoltaic input overcurrent
  • b. Photovoltaic array short circuit
  • c. Reversed photovoltaic polarity
  • d. Overvoltage protection for batteries
  • e. Overdischarge protection for batteries
  • f. Over temperature protection
• External Temperature Probe Configuration
  • Precisely monitor battery temperature. When the battery temperature exceeds 65°C, charging is stopped, and when the battery temperature drops below 55°C, charging is resumed to protect the battery.
• Forced Air Cooling
  • Built-in cooling fan for forced heat dissipation, improving overall device operational efficiency.
• Lithium Battery Activation
  • Compatible with lithium batteries. When the battery type parameter is set to lithium batteries, the charging cycle will be adjusted to accommodate the needs of lithium battery charging.
  • Additionally, when connected lithium batteries are in a protected stat e, the controller will activate the lithium batteries with the energy from the solar panels, with current not exceeding the lithium battery protection voltage and current range.
  • Warning: Do not charge lithium batteries when the temperature is below 0°C.

Product Appearance

Installation and Wiring

Unpacking and Inspection
Before unpacking, inspect the packaging for any signs of damage. After unpacking, check the contents to ensure nothing is damaged or missing. Inside the package, you will find the following items:

• Controller
• User Manual
• Installation screws
• Parallel connector
• External temperature sensor

Choosing the Installation Location

Before installation, several aspects should be considered to determine or provide a suitable and safe installation location:

Wiring Precautions

1. Installation and wiring work should be carried out by a certified electrician.
2. Wiring should follow the sequence of Battery > PV Input > Load.
3. To avoid short circuits and polarity reversal, pay attention to connecting the positive (+) cable to the device’s positive (+) terminal and the negative ( (–) cable to the device’s negative (–) terminal.
4. Loose and/or incomplete connections can lead to cable or terminal overheating. Therefore, tighten all cables to minimize transition resistance, using cable sizes appropriate for the specific circuit’s current rating.
5. Do not connect the inverter to the load terminal of the controller, as doing so may result in irreversible damage to the equipment. If it is necessary to connect the inverter, please follow the battery connection steps outlined in Section 2.4, as indicated in the wiring.

Installation and Wiring Guidelines

• Please refer to the following steps to complete the installation and wiring of the controller.
• Alternatively, scan the QR code on the right to access the operating guide.

NOTE: For parallel connection wiring, please refer to Chapter 7

• Step 1. Install the controller vertically with its ports facing downward, securing it to the wall through the four mounting holes using screws. For ease of installation, it is recommended to use two upper screws for initial “hanging” of the device, followed by the addition of two lower screws, and then fully tighten all four screws.
• Step 2.
  • Battery Wiring: Connect the battery to the controller using cables.
  • Attention: Do not connect the inverter to the load terminal of the controller; otherwise, it may cause irreversible damage to the equipment. If it is necessary to connect the inverter, please refer to the diagram below.
  • NOTE
  • All wiring work must be carried out by professionals.
  • For safe operation and proper application, circuit breakers of the appropriate specifications must be installed on the cables connected to the controller, and ensure that the connections are tight.
  • Ensure that all circuit breakers are in the off position before completing all wiring.
  • Connect the positive cable terminal to the positive terminal port, and the negative cable terminal to the negative terminal port.
  • The above notes also apply to the PV ports and DC output ports.
• Step 3.
  • PV Wiring: Connect the photovoltaic array to the controller using cables.
• Step 4.
  • DC Output Wiring: Connect the load to the controller using cables.
• Step 5.
  • Temperature Probe Connection: Connect the temperature probe wire to the controller and securely fix the probe end to the battery using insulation tape.
• Step 6.
  • Pre Startup Check: Refer to the wiring diagram below. If all connections are accurate, and all wiring is securely connected, close the circuit breakers in the order of Battery, PV Input, and Load terminals.
  • WARNING: Risk of Electric Before wiring, ensure that all power sources are turned off and follow the relevant inspection and operation procedures.

Operation Guide

Key Introduction

Main Page Overview

Operating Modes

Overview of the Settings Page

• On the main screen, press the PRG button to access the settings page.
• Use the and buttons to navigate through the settings items, then press the ENT button to enter the settings for the selected item.
• Within a setting item, use the or buttons to adjust the numerical values or toggle options.
• Finally, press the ENT button to save the settings. After configuring all the settings items, press the ESC button to exit the settings page.

Setting Guidelines

• D00 Load Operation Mode Setting
  • Configure the mode and duration for enabling the load output.
  1. 00H: Light control mode. (Loads start to supply power after dark and stop working after dawn.)
  2. 24H (Default): Immediate load activation.
  3. 01H~23H: Adjust the duration for load activation.
• D01 Float Charge Voltage Setting
  • After the boost charge phase, the controller will reduce the battery voltage by decreasing the charging current and maintaining the battery at the float charge voltage setting value to keep the battery in a fully charged state.
  • Please adjust this setting based on the charging parameters of the connected batteries.
• D02 Boost Charge Voltage Setting
  • During the boost charge phase, the battery will be charged at a constant preset voltage value. Please set this value according to the specific charging parameters of your batteries.
• D03 Low Voltage Disconnect Setting
  • When the battery voltage falls below the value set in D03, the controller will stop discharging the battery to prevent over-discharging.
• D04 Voltage Calibration Setting
  • This setting allows you to calibrate the displayed battery voltage when there is a difference between the controller’s detected voltage and the voltage measured with a multimeter. Please note that using excessively long or thin cables can affect the controller’s ability to accurately read the battery voltage.
• D05 Parallel Communication Code Setting
  • NOTICE: This program requires no configuration if you are not operating in parallel mode.
  • After completing the parallel wiring, you can use the D05 setting program to define the master and slave controllers.
  • The controller with the lowest communication code value will be the master. In parallel operation, if the master encounters an issue, the system will automatically select the controller with the next code value as the new master.
  • For example, if the No. 01 master fails, the system will designate No. 02 as the new master.
  • Assuming six controllers are operating in parallel:
• D06 Battery Type Setting**
  Display| Battery Type**
  ---|---
  SEL| Lead-acid Battery (Default)
  GEL| Gel Sealed Lead-acid Battery
  FLd| Flooded Lead-acid Battery
  L04| 4-Cell Lithium Iron Phosphate Battery
  L08| 8-Cell Lithium Iron Phosphate Battery
  L15| 15-Cell Lithium Iron Phosphate Battery
  L16| 16-Cell Lithium Iron Phosphate Battery
  USE| Custom Battery Type
• Battery Charging Voltage Reference****

  ---

Battery Type

| Float Charging Voltage| Boost Charging Voltage| Undervoltage Protection Voltage
---|---|---|---
SEL| 13.8| 14.4| 11.0
GEL| 13.8| 14.2| 11.0
FLd| 13.8| 14.6| 11.0
L04| 13.8| 14.5| 11.2
L08| 27.6| 29.0| 22.4
L15| 51.8| 54.4| 42.0
L16| 55.2| 58.0| 44.8
USE| User-defined

• D07 System Voltage Setting
  • If D0 6 is set to USE, it will enter D0 7 to select the system voltage.
  • If D0 6 is not set to USE, the system will automatically detect the system voltage of the connected battery and will not enter the D0 7 setting program.
  • The system voltage configuration range is 12V/24V/36V/48V.

Protection

Protection Function

current to the maximum battery current rating. Consequently, an overcurrent from the photovoltaic array input will not allow it to operate at peak power.
Photovoltaic Array Short Circuit| When a short circuit occurs in the photovoltaic array, the controller will stop charging, and operation can be restored by eliminating the short circuit fault.
Photovoltaic Polarity Reversal| If the photovoltaic input wiring polarity is reversed, the controller will not operate, and it will not damage the controller. After proper reconnection, the controller will operate normally.
Battery Overvoltage| When the battery voltage exceeds 15.5/31.0/46.5/62.0V, the controller will stop charging to protect the battery from overcharging damage. Please note that stopping the charging means the charging current is very low.
Battery Over-discharge| When the battery voltage drops to the low-voltage disconnect setpoint, the controller will stop discharging to protect the battery from over-discharge damage.
Over-temperature Protection| When the battery voltage drops to the low-voltage disconnect setpoint, the controller will stop discharging to protect the battery from over-discharge damage.

Troubleshooting

voltage by changing the series-parallel connection or adding more solar panels.
60| Over-temperature Protection| In case of over-temperature, the fan will start automatically to provide efficient forced cooling.
63| Battery Overvoltage| Charging will automatically stop, and it will resume when the battery voltage returns to normal levels.
65| Battery Undervoltage| Discharging will automatically stop, and it will resume when the battery voltage rises to normal levels.
71| Photovoltaic Input Voltage Too High| Reduce the photovoltaic array voltage by changing the series-parallel connection or reducing the number of solar panels.
73| Overcharging Current| Reduce the photovoltaic input power by decreasing the number of solar panels.

Maintenance

We recommend conducting the following checks and maintenance at least twice a year to ensure optimal performance:

1. Ensure the controller is securely mounted in a clean and dry environment.
2. Ensure proper airflow around the controller and clean any dust or debris from the heat sinks.
3. Inspect all exposed wires for insulation damage, such as severe sun exposure, friction wear, dryness, and insect or rodent damage. Repair or replace any damaged wires as necessary.
4. Tighten all terminals and check for loose, broken, or burnt cable connections.
5. Confirm that all system components are properly grounded.
6. Ensure all terminals are free from corrosion, insulation damage, high temperatures, or signs of burning/discolouration, and tighten terminal screws.
7. Check for dirt, nesting insects, and corrosion. If present, clean promptly.

WARNING: Risk of electric

• Before performing the above operations, ensure that all power sources are turned off and then follow the relevant check and operation guidelines.

Specification Parameters

Solar Input Parameters
Max. Solar Array Open-Circuit Voltage| 160V
Maximum Input Power:| 720W

1440W

2100W

2800W

For 12V System
For 24V System
For 36V System
For 48V System
Input Voltage Range:| 20V~80V

37V~105V

50V~160V

72V~160V

For 12V System
For 24V System
For 36V System
For 48V System
Battery Charging Parameters
Charging Technology| MPPT
Charging Algorithm| 3 stages
Battery Voltage Auto-Detection| DC9V~DC15V DC18V~DC29V DC30V~DC39V DC40V~DC60V
12V System
24V System
36V System
48V System
Overcharge Protection Voltage| 60V
Charging Limit Current| 61A
Maximum Efficiency| ≥98. 1%
Solar Utilization Rate| ≥99%
Load Terminal Output
Rated Output Current| 6A
Maximum DC Output Current| 8A
---|---
Protection
Temperature Protection| 75℃ / 167 ℉
Fan Start Temperature| >45℃ / 104℉
Fan Shutdown Temperature| <40℃ / 95℉
General Specification
Dimensions| 215x130x85mm /8.46×5.12×3.35in
Net Weight| 990g / 2.18lb
Electromagnetic Compatibility| EN61000, EN55022, EN55024
Protection Level| IP21
Operating Temperature| -20℃ ~ +55℃ / -4℉ ~ 131℉
Storage Temperature| -40℃ ~ +75℃ / -40℉ ~ 167℉

Parallel Operation Guide

Parallel Operation Schematic

Main Modules:

• Controller
  • The controller device is capable of standalone operation for individual units and can also support a maximum of 12 units in parallel operation.
  • When operating in parallel, communication between the parallel controllers is achieved through communication lines. The parallel controllers are installed at the same horizontal height.
• Solar Array
  • Each controller must be connected to a separate solar array. One solar array cannot be simultaneously connected to more than one controller. The input power connected to each controller should not exceed the rated input power of a single controller.
• Battery Bank
  • Parallel controllers are connected to the same battery bank.

Parallel Installation and Wiring

You can view the parallel operation guide by scanning the QR code in the upper right corner.

• Step 1. Install parallel devices at the same height level with a minimum distance of approximately 75mm between devices.
• Step 2. Connect communication lines.
• Step 3. Connect all parallel controllers to the same battery bank in sequence.
• Step 4. Then, individually connect each controller to its respective photovoltaic array.
• Step 5. Finally, connect each controller to the DC load. Step 6.
• Step 6: Set the parallel operation code for each controller, as detailed in Section 3.5 of the Setting Guidelines under the explanation for Setting D05.

CONTACT

• 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
• Product Model HHJ60-PRO

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