MPP Solar 4024MT Solar Inverter Charger User Manual

PIP4024MT/PIP6048MT
SOLAR INVERTER / CHARGER
Version: 1.3

ABOUT THIS MANUAL

Purpose
This manual describes the assembly, installation, operation and troubleshooting of this unit. Please read this manual carefully before installations and operations. Keep this manual for future reference.
Scope
This manual provides safety and installation guidelines as well as information on tools and wiring.

SAFETY INSTRUCTIONS

WARNING : All safety instructions in this document must be read, understood and followed. Failure to follow these instructions will result in death or serious injury.

1. Before using the unit, read all instructions and cautionary markings on the unit, the batteries and all appropriate sections of this manual.

2. CAUTION –To reduce risk of injury, charge only deep-cycle lead acid type rechargeable batteries.
   Other types of batteries may burst, causing personal injury and damage.

3. Do not disassemble the unit. Take it to a qualified service center when service or repair is required.
   Incorrect re-assembly may result in a risk of electric shock or fire.

4. To reduce risk of electric shock, disconnect all wirings before attempting any maintenance or cleaning.
   Turning off the unit will not reduce this risk.

5. CAUTION – Only qualified personnel can install this device with battery.

6. NEVER charge a frozen battery.

7. For optimum operation of this inverter/charger, please follow required spec to select appropriate cable size. It’s very important to correctly operate this inverter/charger.

8. Be very cautious when working with metal tools on or around batteries. A potential risk exists to drop a tool to spark or short circuit batteries or other electrical parts and could cause an explosion.

9. Please strictly follow installation procedure when you want to disconnect AC or DC terminals. Please refer to INSTALLATION section of this manual for the details.

10. One piece of 150A fuse is provided as over-current protection for the battery supply.

11. GROUNDING INSTRUCTIONS -This inverter/charger should be connected to a permanent grounded wiring system. Be sure to comply with local requirements and regulation to install this inverter.

12. NEVER cause AC output and DC input short circuited. Do NOT connect to the mains when DC input short circuits.

13. Warning!! Only qualified service persons are able to service this device. If errors still persist after following troubleshooting table, please send this inverter/charger back to local dealer or service center for maintenance.

14. WARNING: Because this inverter is non-isolated, only three types of PV modules are acceptable: single crystalline, poly crystalline with class A-rated and CIGS modules. To avoid any malfunction, do
    not connect any PV modules with possible current leakage to the inverter. For example, grounded PV modules will cause current leakage to the inverter. When using CIGS modules, please be sure NO
    grounding.

15. CAUTION: It’s requested to use PV junction box with surge protection. Otherwise, it will cause damage on inverter when lightning occurs on PV modules.

INTRODUCTION

This is a multi-function inverter, combining functions of inverter, solar charger and battery charger to offer uninterruptible power support in a single package. The comprehensive LCD display offers user-configurable and easy- accessible button operations such as battery charging current, AC or solar charging priority, and acceptable input voltage based on different applications.

Features

• Pure sine wave inverter
• Configurable input voltage ranges for home appliances and personal computers via LCD control panel
• Configurable battery charging current based on applications via LCD control panel
• Configurable AC/Solar Charger priority via LCD control panel
• Compatible to utility mains or generator power
• Auto restart while AC is recovering
• Overload / Over temperature / short circuit protection
• Smart battery charger design for optimized battery performance
• Cold start function
• Removable LCD control module
• Multiple communication ports for BMS (RS485, CAN-BUS, RS232)
• Built-in WiFi for mobile monitoring (Requires App), OTG USB function, dusk filters
• Configurable AC/PV Output usage timer and prioritization

Basic System Architecture

The following illustration shows basic application for this unit. It also required the following devices to have a complete running system:

• Generator or Utility mains.
• PV modules

Consult with your system integrator for other possible system architectures depending on your requirements.
This inverter can power various appliances in home or office environment, including motor-type appliances such as tube light, fan, refrigerator and air conditioners.

Product Overview

(refer to OPERATION/Operation and Display Panel section for details) and USB
function setting reminder (refer to OPERATION/Function Setting for the details)
9. PV input|

INSTALLATION

Unpacking and Inspection
Before installation, please inspect the content. Be sure that nothing inside the package is damaged. You should have received the following items inside the package:

• Inverter x 1
• User manual x 1
• RS232 Communication cable x 1
• Software CD x 1
• DC Fuse x 1

Preparation

Before connecting all wirings, please take off the bottom cover by removing two screws as shown below.
Detach the cables from the cover.

Mounting the Unit

Consider the followings before selecting your placements:

• Do not mount the inverter on flammable construction materials.
• Mount on a solid surface
• Install the inverter at eye level in order to allow easy LCD display readout.
• For proper air circulation and heat dissipation, allow a clearance of approx. 20 cm to the side and approx. 50 cm above and below the unit.
•  The ambient temperature should be between 0°C and 55°C to ensure optimal operation.
• The recommended orientation is to adhered to the wall vertically.
  Be sure to keep other objects and surfaces as shown in the diagram to guarantee sufficient heat dissipation and to have enough space for wirings.

SUITABLE FOR MOUNTING ON CONCRETE OR OTHER NON-COMBUSTIBLE SURFACE ONLY.

Battery Connection

CAUTION : For safety operation and regulation compliance, it’s requested to install a separate DC over-current protector or disconnection device between battery and the inverter. It may not be necessary to have a
disconnection device in some applications, however, it’s still recommended to have over-current protection installed. Please refer to typical amperage as required.

WARNING! All wiring must be performed by a qualified electrical technician.
WARNING! It’s very important for system safety and efficient operation to use appropriate cables for battery connection. To reduce risk of injury, please use the proper recommended cable in the table below.

Ring terminal:

Recommended battery cable size:

Please follow below steps to implement battery connection:

1. 4KW model supports 24VDC system and 6KW model supports 48VDC system. Connect all battery packs as below chart. It is recommend to connect minimum of 100Ah capacity battery for 4KW model and 200Ah capacity battery for 6KW model.
2. Prepare four battery wires for 4KW model and two or four battery wires for 6KW model depending on cable size (refer to recommended cable size table). Apply ring terminals to your battery wires and secure it to the battery terminal block with the bolts properly tightened. Refer to battery cable size for torque value.
   Make sure polarity at both the battery and the inverter is correctly connected and ring terminals are secured to the battery terminals.

WARNING : Shock Hazard
Installation must be performed with care due to high battery voltage in series.
CAUTION!! Do not place anything between inverter terminals and the ring terminals.
Otherwise, overheating may occur.
CAUTION!! Do not apply anti-oxidant substance on the terminals before terminals are securely tightened.
CAUTION!! Before making final DC connection or closing DC breaker/disconnector, be sure that the positive (+) must be connected to positive (+) and negative (-) connected to negative (-).

AC Input/Output Connection

CAUTION!! Before connecting to AC input power source, please install a separate AC breaker between the inverter and the AC input power source. This will ensure that the inverter can be safely disconnected during
maintenance and fully protected from over-current. The recommended spec of AC breaker is 32A
CAUTION!! There are two power terminal blocks with “IN” (Input) and “OUT” (Output) markings. DO NOT mistakenly connect to the wrong connectors.
WARNING! All wiring must be performed by a qualified personnel.
WARNING! It’s very important for system safety and efficient operation to use appropriate cable size for AC input connection. To reduce risk of injury, please use the proper recommended cable size as below.
Suggested cable requirement for AC wires

Please follow these steps to implement AC input/output connection:

1. Before making AC input/output connection, be sure to enable DC protector or disconnector first.

2. Remove insulation sleeves for about 10mm for the five screw terminals.

3. Insert AC input wires according to polarities indicated on terminal block and tighten the terminal screws. Be sure to connect the grounding wire ( ) first.
   →Ground (yellow-green)
   L→LINE (brown or black)
   N→ Neutral (blue) WARNING:
   Be sure that AC power source is disconnected before attempting to hardwire it to the unit.

4. This inverter is equipped with dual-output. There are four terminals (L1/N1, L2/N2) available on output port.
   It’s set up through LCD program or monitoring software to turn on and off the second output. Refer to “LCD
   setting” section for the details.
   Insert AC output wires according to polarities indicated on terminal block and tighten terminal screws. Be
   sure to connect PE protective conductor ( ) first.
   →Ground (yellow-green)
   L1→LINE (brown or black)
   N1→Neutral (blue)
   L2→LINE (brown or black)
   N2→Neutral (blue)

5. Make sure the wires are securely connected.
   CAUTION : Appliances such as air conditioner required at least 2~3 minutes to spool up because it needs to have enough time to balance refrigerant gas inside of circuits. If a power shortage occurs and recovers in a short period of time, it may cause damage to your connected appliances. To prevent this from happening, please check with manufacturer of air conditioner if it has time-delay function before installation. Otherwise, this inverter will trigger overload fault and cut off output to protect your appliance but sometimes it may still causes damage to the air conditioner.

PV Connection
CAUTION : Before connecting to PV modules, please install a separately DC circuit breaker between the inverter and PV modules.
WARNING! It’s 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 shown below.

WARNING : Because this inverter is non-isolated, are accepted: single crystalline, poly crystalline with class A-rated and CIGS modules. To avoid any malfunctions, do not connect any PV modules with possible current leakage to the inverter. For example, grounded PV modules will cause current leakage to the inverter. When using CIGS modules, please be sure NO grounding connection.
CAUTION : It’s requested to use PV junction box with surge protection. Otherwise, it will cause damage on inverter when lightning occurs on PV modules.
PV Module Selection:
When selecting proper PV modules, please be sure to consider the following parameters:

1. Open circuit Voltage (Voc) of PV modules not to exceeds maximum PV array open circuit voltage of the inverter.
2. Open circuit Voltage (Voc) of PV modules should be higher than the start-up voltage.
   INVERTER MODEL| 4024MT| 6048MT
   ---|---|---
   Max. PV Array Power| 5000W| 6000W
   Max. PV Array Open Circuit Voltage| 500Vdc
   PV Array MPPT Voltage Range| 60Vdc-450Vdc
   Start-up Voltage| 60Vdc +/- 10Vdc
   Max. PV Current| 27A

Take the 250Wp PV module as an example. After considering above two parameters, the recommended module configurations are listed in the table below.

Solar Panel Spec. (reference)
– 250Wp
–  Vmp: 30.1Vdc
– Imp: 8.3A
– Voc: 37.7Vdc
– Isc: 8.4A
– Cells: 60| SOLAR INPUT| Q’ty of panels| Total input
power
---|---|---|---
Min in series: 2 pcs, max. in series: 12 pcs.
2pcs in series| 2 pcs| 500W
4pcs in series| 4 pcs| 1000W
6 pcs in series| 6 pcs| 1500W
8 pcs in series| 8 pcs| 2000W
12 pcs in series| 12 pcs| 3000W
8 pieces in series and 2 sets in parallel| 16 pcs| 4000W
10 pieces in series and 2 sets in parallel| 20 pcs| 5000W
11 pieces in series and 2 sets in parallel
(only for 6KVA model)| 22 pcs| 5500W
12 pieces in series and 2 sets in parallel
(only for 6KVA model)| 24 pcs| 6000W

Take the 555Wp PV module as an example. After considering above two parameters, the recommended module configurations are listed in the table below.

Solar Panel Spec.
(reference)
– 555Wp
– Imp: 17.32A
– Voc: 38.46Vdc
– Isc: 18.33A
–  Cells: 110| SOLAR INPUT| Q’ty of panels| Total input
power
---|---|---|---
Min in series: 2 pcs, max. in series: 11 pcs.
2pcs in series| 2 pcs| 1110W
4pcs in series| 4 pcs| 2220W
6 pcs in series| 6 pcs| 3330W
8 pcs in series| 8 pcs| 4440W
10 pcs in series
(only for 6KVA model)| 10 pcs| 5550W
11 pcs in series
(only for 6KVA model)| 11 pcs| 6000W

PV Module Wire Connection

Please take the following to implement PV module connection:

1. Remove insulation sleeve for about 7 mm on your positive and negative wires.
2. We recommend using bootlace ferrules on the wires for optimal performance.
3. Check polarities of wire connections from PV modules to PV input screw terminals. Connect your wires as illustrated below. Recommended tool: 4mm blade screwdriver

Final Assembly

After connecting all wirings, replace the bottom cover as shown below.

Remote Display Panel Installation
The LCD module can be removable and installed in a remote location with an optional communication cable.
Please take the follow steps to implement this remote panel installation.
Step 1. Remove the screw on the bottom of LCD panel and pull down the module from the case. Detach the cable from the remote communication port. Be sure to replace the retention plate back to the inverter.

Step 2. Prepare your mounting holes in the marked locations as shown in the illustration below. The LCD module then can be securely mounted to your desired location.

Note : Wall installation should be implemented withthe proper screws to the right.

Step 3. Connect LCD module to the inverter with an optional RJ45 communication cable as shown below.

Communication Options

Serial Connection
Please use the supplied serial cable to connect between the inverter and your PC. Install the monitoring software from the bundled CD and follow the on- screen instructions to complete your installation. For detailed
software operation, refer to the software user manual on the bundled CD.
Wi-Fi Connection
This unit is equipped with a Wi-Fi transmitter. Wi-Fi transmitter can enable wireless communication between off-grid inverters and monitoring platform. Users can access and control the monitored inverter with
downloaded APP. You may find “Watch Power” app from the Apple ®Store or “Watch Power Wi-Fi” in Google ® Play Store. All data loggers and parameters are saved in iCloud. For quick installation and operation,  please check Appendix C.

BMS Communication

It is recommended to purchase a special communication cable if you are connecting to Lithium-Ion battery banks. Please refer to Appendix B- BMS Communication Installation for details.
Dry Contact Signal
There is one dry contact (3A/250VAC) available on the rear panel. It could be used to deliver signal to external device when battery voltage reaches warning level.

Battery voltage > Setting value in Program 13 or battery charging reaches floating stage| Close| Open
Program 01 is set as SBU (SBU priority)| Battery voltage < Setting value in Program 12| Open
Close|
Battery voltage > Setting value in Program 13 or battery charging reaches floating stage| Close| Open

OPERATION

Power ON/OFF
Once the unit has been properly installed and the batteries are connected well, simply press On/Off switch (located on the display panel) to turn on the unit.

Inverter Turn-on
After this inverter is turned on, WELCOME light show will be started with RGB LED BAR. It will slowly cycle through entire spectrum of nine colors (Green, Sky blue, Royal blue, Violet, Pink, Red, Honey, Yellow, Lime yellow) about 10-15 seconds. After initialization, it will light up with default color.
RGB LED BAR can light up in different color and light effects based on the setting of energy priority to display the operation mode, energy source, battery capacity and load level. These parameters such as color, effects, brightness, speed and so on can be configured through the LCD panel. Please refer to LCD settings for the details.

Operation and Display Panel
The operation and the LCD module, shown in the chart below, includes six indicators, six function keys, on/off switch and a LCD display, indicating the operating status and input/output power information.

Indicators

Function Keys

the output source
Timer setting for the Charger source priority| Setup the timer for prioritizing the charger source
| Select| To next selection
| Enter| To confirm/enter the selection in setting mode
| Press these two keys at the time to switch RGB LED bar for output source priority and battery discharge/charge status

LCD Display Icons

Function description
| Indicates the AC input.
| Indicates the PV input
| Indicate input voltage, input frequency, PV voltage, charger current,
charger power, battery voltage.
Configuration Program and Fault Information
| Indicates the setting programs.
| Indicates the warning and fault codes.
Warning:  flashing with warning code.
Fault: lighting with fault code
Output Information
| Indicate output voltage, output frequency, load percent, load in VA, load in Watt and discharging current.
Output| The ICON flashing that indicate the unit with AC output and setting Programs 60, 61 or 62 different to default setting.
Battery Information
| Indicates battery level by 0-24%, 25-49%, 50-74% and 75-100% in battery mode and charging status in line mode.

When battery is charging, it will present battery charging status.

turns.
—  2 2.083V/cell| The right bar will be on and the other three bars will flash in turns.
2.083 — 2.167V/cell| The right two bars will be on and the other two bars will flash in turns.

  2.167 V/cell| The right three bars will be on and the left bar will flash.
Floating mode. Batteries are fully charged.| 4 bars will be on.

In battery mode, it will present battery capacity.

Load Information

| Indicates overload.
---|---
| Indicates the load level by 0-24%, 25-49%, 50-74% and 75-100%.
0%~24%| 25%~49%
|
50%~74%| 75%~100%
|

Mode Operation Information

| Indicates unit connects to the mains.
---|---
| Indicates unit connects to the PV panel.
| Indicates load is supplied by utility power.
| Indicates the utility charger circuit is working.
| Indicates the solar charger circuit is working.
| Indicates the DC/AC inverter circuit is working.
| Indicates unit alarm is disabled.
| Indicates USB disk is connected.
| Indicates timer setting or time display

LCD Setting

General Setting
After pressing and holding “ ” button for 3 seconds, the unit will enter the Setup Mode. Press “ ” button to select setting programs. Press “ ” button to confirm you selection or “ ” button to exit.

Setting Programs:

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