FUTURE SOLUTIONS A1.0 Charge Controller User Manual

FUTURE SOLUTIONS A1.0 Charge Controller

Product Information

• Specifications
  • Product: SP series MPPT solar charge controller
  • Design: Safe and reliable
  • Features: Electrical performance and protection mechanisms
  • Origin: Made in China

Product Usage Instructions

• General Safety Instruction
  • Safety Instruction: Ensure all safety precautions are followed during installation and operation.
  • General Precaution: Handle the controller with care to avoid damage.
  • Precaution regarding battery operation: Follow battery safety guidelines to prevent accidents.
• Introduction
  • Brief Introduction
  • General Description: Provides an overview of the controller’s functions and capabilities.
  • Model Name Rule: Explains the naming convention used for the controller models.
  • Appearance
  • Front View: Describes the layout of buttons, indicators, and displays on the front panel.
• Connectors & Ports
  • Illustrates the various input and output ports on the controller for proper connection.
• Dip Switch
  • Explains the functionality of the dip switch settings and how to configure them for specific requirements.
• Dimension
  • Provides the physical dimensions of the controller for installation purposes.

FAQs

• Q: Can I disassemble the controller for servicing?
  • A: No, disassembling the controller will void the warranty as there are no field serviceable parts inside.
• Q: What should I do if there is a reverse polarity on the BAT connection?
  • A: Ensure that the positive and negative terminals are correctly connected to avoid reverse polarity situations.
• Q: How should I handle changes to the product design?
  • A: The manufacturer reserves the right to make changes at any time due to product and technology updates, please refer to updated manuals or guidelines.

Preface

Thank you for choosing the SP series MPPT solar charge controller which is safe and reliable in design and usage. This manual includes information on the solar controllers’ electrical performance and protection mechanisms. Please read this manual carefully before installing and operating the controller. Following the guidelines outlined in this manual will extend the controller’s service life. The installation, operation, and maintenance of this series of controllers should be carried out by trained technical person. The following requirements MUST be verified:

• PV input voltage MUST be less than the nominal working voltage of the controller.
• Please ensure that the positive and negative of the DC output are correctly connected; Avoid the reverse polarity on the BAT.
• Please ensure that the connection cable between the controller and the battery is as short as possible and avoid short circuits on the connection.
• There are no internal parts that are field serviceable. Disassembling the controller will VOID warranty.

Statement:

• Please understand due to the continuous update and improvement of products and technology, the manufacturer reserves the right to make changes to the product at any time.

General Safety Instruction

Safety Instruction

• As dangerous voltage and high temperature exist within the charge controller, only qualified and authorized maintenance personnel are permitted to open and repair it.
• This manual contains information concerning the installation and operation of the charge controller. All relevant parts of the manual should be read before commencing the installation. Please follow the local stipulation meantime.
• Any operation against safety requirements or design, manufacture, and safety standards, is out of the manufacturer’s warranty.

General Precaution

• Do not expose to rain, snow or liquids of any type, it is designed for indoor use.
• This solar controller must be installed in a dry location. Ventilation requirements must also be met to prevent the controller from overheating.
• To avoid fire and electric shock, please ensure all cables are properly sized, and have good insulation. Do NOT use damaged or undersized cables.
• Do not install the controller near flammable or explosive material.
• Never touch uninsulated cable ends.
• Use only insulated tools.
• In final usage, an isolation measure can be implemented on the communication port for extra-level safety.

Precaution regarding battery operation

• If the skin and clothing are contaminated with battery acid, wash them immediately with soap and water. If acid splashes into your eyes, flush with cold water for at least 20 minutes and seek medical attention immediately.
• Do not smoke or set a fire near the battery or engine.
• Do not place metal tools on the battery, otherwise, there is a risk of explosion caused by sparks or short circuits.
• Do not wear jewellery such as rings, bracelets, necklaces, watches, etc. when operating the battery. The short-circuited current will generate high heat, which can melt metal objects and cause severe burns.

Introduction

Brief Introduction General Description

With MPPT technology, the SP series solar charge controller enables maximum energy tracking for solar charging. This technology allows the controller to track the maximum power point of an array quickly and accurately in any environment, obtain the maximum energy of solar panels in real time, and charge the battery at maximum current. The controller has a built-in multi- stage battery charging algorithm, along with an MPPT algorithm that allows for wide voltage input ranges. This makes this controller suitable for charging various types of batteries, including GEL, AGM, LFP, and WET batteries. The main features are as follows:

• Wide MPPT voltage range
• High MPPT efficiency, the Max. efficiency≥99.9%
• Built-in battery temperature compensation feature
• Support RS485, CAN and Bluetooth communication
• Low self-consumption on battery: 1mA@12VDC,3mA@24VDC
• Support wide operation temperature, charging during -40~70℃
• Support 365 days of real-time data recording, event recording and power statistics
• Nature cooling design without noise

Model Name Rule

e.g. SP100-50 is an MPPT charge controller with BT; max. Voc at 100V, max. output current at 50A.

Appearance Front View

l  Steady On during charging

Warning| l  Flash during the warning
Fault| l  Flash during fault and stop charging

Connectors & Ports

Table 2-2 Connectors & Ports Definition

Table 2-3 COM Port Definition

Table 2-4 RV-C Connector Definition

Dip Switch

Table 2-5 Addr Definition

Table 2-6 Dip Switch i n Connection Compartment Definition

Dimension

Functions

Maximum Power Point Tracking

• Photovoltaic output power is determined by the intensity of light irradiation and weather and climate, and the maximum power point of photovoltaics varies greatly under different weather and climates.
• The maximum power point tracking technology can maximize the energy harvested from the photovoltaic array to charge the battery.
• The MPPT software algorithm will continuously adjust according to the light intensity and climate change, find the maximum power point of the photovoltaic array, and effectively use the energy of the photovoltaic array.

Multistage Charging Algorithm

• The SP is designed with a multi-stage charging algorithm, bulk-absorption-float-recycle, which can ensure that the battery is fully charged quickly.
• Float and cycle charging options ensure the battery is properly maintained during extended connection time.
  • Note 1: At this moment, the external load current of the battery is greater than the maximum charging current of the controller and the battery voltage starts to drop.
  • Note 2: When the battery voltage is lower than 12.5V for 5 minutes, the charging state of the controller changes from floating charging to constant current charging. At this moment, the external load current of the battery is less than the maximum charging current of the controller, and the battery voltage starts to rise.

Battery Temperature Compensation

• Battery temperature is a key factor affecting battery charging. The battery charging voltage must be adjusted in real-time according to the battery temperature to ensure that the battery is fully charged and will not be overcharged or undercharged. Battery temperature compensation range is -10°C~50°C.
• BTS (battery temperature sensor) can measure the battery temperature, and the SP series controller can adjust the charging voltage in real-time according to the measured battery temperature. The temperature compensation is based on 25°C, and the default compensation coefficient is -3mV/℃/cell.
• The factory default setting on the battery temperature compensation function is “OFF” status. The user can enable this feature on the APP and the temperature compensation coefficient can be set as well. For details, check the APP parameter settings.
• Note: BTS is an optional accessory.

Battery Type

• There are various types of batteries, and the absorption charge voltage and floating charge voltage of different batteries are different. The SP controller can support the charging of GEL, AGM, LFP, WET and other batteries.
• You can set the battery type, maximum charging current, absorption charging voltage, floating charging voltage, etc. on the APP according to different batteries to match different battery types and ensure the battery can be charged accurately without overcharging or undercharging.

System Integration Interface RS485 communication

• The SP controller supports RS485 communication and can accept centralized monitoring of the system through the COM interface to view real-time information.

CAN communication

• The SP controller supports CAN communication and can accept centralized monitoring of the system through the RV C interface to view real-time information.

Bluetooth Communication

• The SP controller supports bluetooth communication, monitoring can be carried out through mobile apps.

Protections

• PV input reversed polarity protection
• When the polarity of the PV array is reversed, the controller will shut down; the short circuit current can’t exceed Max. PV short circuit current See Table 3 1 )); the normal operation will continue after the wiring error is corrected

PV overvoltage protection

• When the PV voltage of the SP controller is too high and exceeds the operable voltage range, the controller will turn off the output and prompt with an audible and visual alarm.
• When the PV voltage exceeds the maximum PV open circuit voltage range, beyond specification use may cause damage to the controller.
• Any damage caused by the user’s improper operation will be VOID warranty.

Output short circuit protection

• When the PV input power is within the limit, and the output is short-circuited, the controller will reliably protect and give an alarm.
• After the short circuit fault is removed, the controller will resume normal charging.

Controller over temperature protection

• When the internal temperature of the controller exceeds the threshold (the parameter sheet as reference), the controller will derate and reduce the output power.
• When the external environment temperature is too high and the internal environment temperature still exceeds the threshold after derating, the controller will turn off the output to prevent internal damage.

Battery over temperature protection

• During the charging process, the controller will sample the battery temperature in real-time when the battery temp sensor is connected and enabled.
• Once the battery temperature is too high, the controller will reduce the charging current until shutting down; a fault alarm will be prompted to protect the battery from overtemperature.

Multiple machines in parallel

• Through the RV C ports, the S P controller can support 4 devices wired in parallel.

Forced Charging

• The SP controller has a forced charging function, which is turned on by default when it is set to the LFP lithium battery mode and can be turned on manually for other battery types.
• When the SP battery side is connected to the battery, the battery will be charged after 30s.
• When the battery is not connected, the battery side will start the output after 5.5 minutes.
• If the PV energy is not enough to maintain the output voltage at this time, the output will be cut off and 30 minutes later to output again.

Installation

Pre-installation Inspection Packing Inspection

• Before unpacking, please check whether the outer packaging is damaged and whether the controller model is correct. If there is any abnormality, please contact your dealer.
• After unpacking, please check whether the number of accessories is complete and whether the accessories are damaged. If there is any abnormality, please contact your dealer.

Package

No.| Component| Qty
1| SP Controller| 1
2| Manual| 1

Select installation location Installation Position Requirements

• Indoor installation only.
• Do not install the controller near flammable or explosive items.
• During the operation of the controller, the temperature of the chassis and radiator will be relatively high. Please do not install it in a place where it is easy to touch.
• The controller should be installed in a well-ventilated area.
• Ensure that the mounting surface is strong enough for reliable installation.
• Do not install the SP in a sealed compartment with batteries.

Installation Space Requirements

• The controller MUST have adequate room on all sides for airflow. Refer to Figure 3 1 for minimum spacing requirements.

Installation Guide

• Ensure the controller is flush with the mounting material.
• Drills the holes based on the lock hole requirements. See Figure 3-2; lock hole size:160150mm,4φ5.5.
• Please install the SP controller as close to the battery as possible to reduce the voltage drop and line loss between the controller and the battery.
• It supports horizontal and vertical installation, prefers vertical installation way.
• Make sure all screws of the controller are firmly locked and the controller is installed well.

Preparation Before Wiring PV module configuration

• Each SP controller must be connected to one PV module separately.
• Please configure and connect the photovoltaic modules according to the maximum specifications of the PV as shown in Table 3-1.

Table 3-1 SP PV Module Configuration Requirements

Max. PV input

power

| 12VDC| 800W| 500W
24VDC| 1600W| 1000W

• The maximum PV short circuit current allowed by the controller is referred to in the table above. When configuring PV modules, please ensure that the maximum short circuit current of PV modules is less than the Max. PV short circuit current
• Please ensure that the configuration of the PV module is correct and the positive and negative wiring is correct.
• Please ensure that the maximum open circuit voltage output of the PV module is within the MPPT voltage range, the controller can be charged normally.

Circuit Breaker Preparation

• A fuse or circuit breaker with a current greater than 120% of the rated current must be connected to the battery side of the controller.
• Please refer to Table 3 2 for the specification requirements of the DC circuit breakers on the battery side.

Table 3-2 Breaker requirements

1

| ****

Battery Breaker

| SP100-50| Rated current requirement ≥60A.
SP100-30| Rated current requirement ≥40A.

Cable Preparation

• The temperature resistance of the wire is required to be greater than 90°C (194 °F )
• For wire diameter requirements, see Table 3 3.

Table 3-3 DC Wire Requirement

Single Unit Wiring

Perform the following steps to connect cables.

• Step 1: Shown as Figure 3 3, remove the wiring cover plate
• Step 2: Select the appropriate wire according to section 3.4.3, and make sure the breaker is in the OFF status before wiring.
• Step 3: Connect BAT to the battery negative terminal and connect BAT+ to the battery positive terminal, see Figure 3 4
• Step 4: Connect PV to PV panel negative port and connect PV+ to PV panel positive port, see Figure 3 4.
• Step 5: Make sure the wire is connected correctly and reliably.
• Step 6: After the wiring connection, cover the plate to the connection

Multiple Unit Wiring

• The following figure 3-5 setup is the largest configuration which is used to connect up to 4 SP controllers to charge the battery pack.
• The controllers use parallel communication cables for communication, which can be centrally monitored by the system.
• When used in parallel, the addresses of devices need to be set to 1~4 through the Addr dip switch.

Start-up and Run

Check Before Operation
Please check the following items before starting up

• The SP controller is installed correctly and securely, with a clean installation environment and sufficient space.
• The cable routing and layout are correct.
• Make sure the ground connection is correct and reliable.
• Please make sure that the battery circuit breaker is open.
• Please ensure that the wiring between the battery and PV is correct and secure.

Start-up Inspection

• Please make sure that the battery voltage and PV module voltage do not exceed the S P controller specifications.

Follow the steps below to start up:

• Step 1: Close the circuit breaker between the battery and the SP controller.
• Step 2: After waiting for 30 seconds, observe the running information on the LED indicator to confirm that the device is charging normally.

Power OFF

• After the MPPT controller is powered OFF, there is still residual power and heat in the chassis, which may lead to electric shock or burn.
• Therefore, after the MPPT controller is powered off for 5 minutes, you should wear protective gloves before removing the MPPT controller
• Please turn off the circuit breaker between the battery and the MPPT controller.

Maintenance

Routine Maintenance
To ensure the long-term good operation of the SP controller, this chapter mainly introduces the routine maintenance requirements.

a year
Operation| Ø  The appearance is clean

Ø  There is no abnormal sound during the operation

Ø  The  parameters  are  correct  during the operation

| Once a year
Wiring| Ø  Wiring connection is firm

Ø  The cable insulation shall be free from damage and aging

| Half a year or once a year
Grounding| The ground wire is firmly connected| Half a year or once a year

Quick Fault Inspection Fault level definition:

• Fault: The SP controller has a serious fault and cannot continue charging and the Fault light flashes.
• Warning: The SP controller is abnormal, and the Warning light flashes.

Type| Code| Name| Description| Fault LED| Troubleshooting
---|---|---|---|---|---
Fault|

01

| U_Bus_OV| PV voltage is too high| Flash 1 time| Ø  Check the string of the PV array.

Ø  Make sure the PV open circuit voltage is lower than the maximum range of the MPPT controller.

Ø  If it happens frequently, please contact your dealer.

02| U_BAT_OV| Battery over voltage| Flash 2 times| Ø  Check whether the controller matches the battery voltage.

Ø  If it happens frequently, please contact your dealer.

03| U_Bat_OV_HD| Flash 3

times

04| Buck_ShortCut| Battery short circuit| Flash 4 times| Ø  Check and restore the wiring to see if the controller can operate normally.

Ø  If there is no wiring error, please contact your dealer.

 | 05| I_Buck1_OC| Output over-current| Flash 5 times| Ø  Check the output connection.

Ø  If there is no wiring error, please contact your dealer.

---|---|---|---|---|---
07| T_Board_OT| Over-temperature inside| Flash 7 times| Ø  Check whether the ambient temperature is over the limitation of the controller.

Ø  Check the installation ambient ventilation.

Ø  If the ambient temperature and ventilation are normal, please contact your dealer.

09| PSU_LV| Auxiliary power under-voltage| Flash 9 times| Ø  Please contact your dealer.
10| PSU_LV_HD| Flash 10 times
11| Sam_HD_Fault| Sampling

failure

| Flash 11 times
12| EEPROM_Fail| ROM abnormal| Flash 12

times

Type| Code| Name| Description| Warning

LED

| Troubleshooting
---|---|---|---|---|---
Warning| 04| BAT_UnConnect| Battery connection failure|

Flash 4 times

| Ø  Check whether the battery circuit breaker is off.

Ø  Check whether the battery power

cable is in good connection.

06| T_BAT_OT| Battery over temperature| Flash 6 times| Ø  Check whether the installation ambient temperature is too high.

Ø  Check whether the battery wiring is tight and reliable.

Ø  Check whether the battery cable

matches the requirement.

08| TypeSet

_Mismatch_Err

| The controller model error| Flash 8 times| Ø  Check whether the model is correct.

Ø  Please contact your dealer.

14| NTC_Board

_Fault

| The NTC of the controller is

fault

| Flash 14 times| Ø  Please contact your dealer.

Specification

Electrical
Nominal battery voltage| 12/24VDC
Maximum charging current| 50A| 30A
Maximum charging

power

| 12VDC| 735W| 441W
24VDC| 1470W| 882W
48VDC| NA| NA
Maximum PV input power| 12VDC| 800W| 500W
24VDC| 1600W| 1000W
48VDC| NA| NA
Max. PV open circuit voltage| 100VDC
PV Start Voltage| 21V±5V@12VDC/ 33±5V@24V
MPPT voltage range| (Vbat+6VDC)~90VDC
Max. PV short circuit

current

| 50A| 30A
Max efficiency| ≥97%
Max MPPT efficiency| ≥99.9%
Self-consumption| Less than 1mA@12VDC/ 3mA@24VDC
Charge voltage ‘absorption’| Default setting: 14.1VDC/28.2VDC
Charge voltage ‘float’| Default setting: 13.5VDC/27VDC
Temperature compensation| Default setting: -3mV/℃/cell
Others
Display| LED indicator
Communication| RS485, CAN, Bluetooth
Data logging| 365-day historical records, including daily, monthly, and annual power generation, total power generation records, historical operation event records, user operation logs, etc.
Storage temperature| -40~70℃
Operating temperature| -40~70℃ (power derating over 40℃)
Humidity| 5%~95% non-condensing
Altitude| 3000m (>2000m power derating)
Max wire sizes| 16 mm2
IP rating| IP20
Dimension (mm)| 19916094| 19916074
Weight| 1.85kg| 1.4kg
Cooling| Natural cooling

CONTACT

• [email protected].
• www.fsi-solutions.com.
• 574-262-3688
• www.fsi-solutions.com.

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