PowMr POW-48140A Solar Charge Controller User Manual

PowMr POW-48140A Solar Charge Controller

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: This chapter contains important safety and operating instructions. Read and keep this manual for future reference.

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 charger, please follow required spec to select appropriate cable size. It’s very important to correctly operate this 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 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. NEVER cause DC input short circuited.
12. Warning:  Only qualified service persons are able to service this device. If errors still persist after following troubleshooting table, please send this charger back to local dealer or service center for maintenance.

INTRODUCTION

This is a solar charger. Its comprehensive LCD display offers user- configurable and easy-accessible button operation such as battery charging current.

Features

• Configurable battery charging current based on applications via LCD setting
• Over temperature protection
• Smart battery charger design for optimized battery performance
• Cold start function

Basic SystemArchitecture

The following illustration shows basic application for this solar charger.

• PV modules

Product Overview

1. LCD display
2. Charging indicator
3. Fault indicator
4. Function buttons
5. PV input
6. Ground Connection
7. Battery input
8. Anti dust kit

INSTALLATION

Unpacking and Inspection

Before installation, please inspect the unit. Be sure that nothing inside the package is damaged. You should have received the following items inside of package:

• The unit x 1
• User manual x 1

Preparation

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

Mounting the Unit

Consider the following points before selecting where to install:

• Do not mount the charger on flammable construction materials.
• Mount on a solid surface
• Install this charger at eye level in order to allow the LCD display to be read at all times.
• For proper air circulation to dissipate heat, 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 installation position is to be 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 removing wires .

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

Install the unit by screwing two screws. It’s recommended to use M 6 screws.

Battery Connection

CAUTION: For safety operation and regulation compliance, it’s requested to install a separate DC over-current protector or disconnect device between battery and charger. It may not be requested to have a disconnect device in some applications, however, it’s still requested to have over-current protection installed. Please refer to typical amperage in below table as required fuse or breaker size.

WARNING

• All wiring must be performed by a qualified personnel.
• It’s very important for system safety and efficient operation to use appropriate cable for battery connection. To reduce risk of injury, please use the proper recommended cable as below.

Recommended battery cable size:

24V/140A

48V/140A

| 1 x 2AWG| 25| 2 Nm

Please follow below steps to implement battery connection:

1. Remove insulation sleeve 18 mm for positive and negative conductors.
2. Suggest to put bootlace ferrules on the end of positive and negative wires with a proper crimping tool.
3. Connect all battery packs as below chart.
4. Insert the battery wires flatly into battery connectors of charger and make sure the bolts are tightened with torque of 2 Nm in clockwise direction. Make sure polarity at both the battery and the charge is correctly connected and conductors are tightly screwed into the battery terminals. Recommended tool: #2 Pozi Screwdriver

WARNING: Shock Hazard

• Installation must be performed with care due to high battery voltage in series.

CAUTION!! Before making the final DC connection or closing DC breaker/disconnector, be sure positive (+) must be connected to positive (+) and negative (-) must be connected to negative (-).

PV Connection

• CAUTION: Before connecting to PV modules, please install separately a DC circuit breaker between charger and PV modules.
• WARNING! System safety and efficient operation need to use appropriate cable for PV module connection. To reduce risk of injury, please use the proper recommended cable size as below.

Model| Wire Size| Cable ( mm 2 )| Torque value C max)
---|---|---|---
24V/140A

48V/140A

| 1 x 12AWG| 4| 1.2 Nm

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 charger
2. Open circuit Voltage (Voc) of PV modules should be higher than min. battery voltage.

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

Solar Panel Spec.| SOLAR INPUT| Q’ty of panels| Total input|
---|---|---|---|---
(reference)

– 250Wp

– Vmp: 30.1Vdc

| power|
(Min in serial: 6 pcs, max. in serial: 13 pcs)|
6 pcs in serial| 6 pcs| 1500W|
8 pcs in serial| 8 pcs| 2000W|
–  Imp: 8.3A

–  Voe: 37.Ndc

|
12 pcs in serial| 12 pcs| 3000W|
13 pcs in serial| 13 pcs| 3250W|
– Isc: 8.4A|
8 pieces in serial and 2 sets in parallel| 16 pcs| 4000W|
– Cells: 60|
10 pieces in serial and 2 sets in parallel| 20 pcs| 5000W|
 | 10 pieces in serial and 2 sets in parallel| 20 pcs| 6200W|
 | 12 pieces in serial and 2 sets in parallel| 24 pcs| 6500W|

PV Module Wire Connection

Please follow below steps to implement PV module connection:

1. Remove insulation sleeve 10 mm for positive and negative conductors.
2. Suggest to put bootlace ferrules on the end of positive and negative wires with a proper crimping tool.
3. Check correct polarity of wire connection from PV modules and PV input connectors. Then, connect positive pole (+) of connection wire to positive pole (+) of PV input connector. Connect negative pole (-) of connection wire to negative pole (-) of PV input connector. Recommended tool: 4mm blade screwdriver

Final Assembly

After connecting all wirings, please put bottom cover back by screwing two screws as shown below.

OPERATION

Operation and Display Panel

The operation and display panel, shown in below chart, is on the front panel of the inverter. It includes two indicators, two function keys and a LCD display, indicating the operating status and PV power information.

LED Indicator

Green

| Solid On| Battery is fully charged.
Flashing| Battery is charging.
|

Red

| Solid On| Fault occurs in the charger
Flashing| Warning condition occurs in the charger

Function Keys

LCD Setting

• After pressing and holding ENTER button for 3 seconds, the unit will enter setting mode.
• Press “DOWN” button to select setting programs. And then, press “ENTER” button to confirm the selection or press “ENTER” button second to exit.

Setting Programs:

Display

The LCD display information will be switched in turns by pressing “UP” or “DOWN” key. The selectable information is switched as below order: PV voltage, charging current, charging power, battery voltage, main CPU Version.

Battery Equalization Description

Equalization function is added into charge controller. It reverses the buildup of negative chemical effects like stratification, a condition where acid concentration is greater at the bottom of the battery than at the top. Equalization also helps to remove sulfate crystals that might have built up on the plates. If left unchecked, this condition, called sulfation, will reduce the overall capacity of the battery. Therefore, it’s recommended to equalize battery periodically.

How to Apply Equalization Function

You must enable battery equalization function in monitoring LCD setting program 05 first. Then, you may apply this function in device by either one of following methods:

1. Setting equalization interval in program 09.
2. Active equalization immediately in program 10.

When to Equalize

In float stage, when the setting equalization interval (battery equalization cycle) is arrived, or equalization is active immediately, the controller will start to enter Equalize stage.

Equalize charging time and timeout

In Equalize stage, the controller will supply power to charge battery as much as possible until battery voltage raises to battery equalization voltage. Then, constant-voltage regulation is applied to maintain battery voltage at the battery equalization voltage. The battery will remain in the Equalize stage until setting battery equalized time is arrived.

However, in Equalize stage, when battery equalized time is expired and battery voltage doesn’t rise to battery equalization voltage point, the charge controller will extend the battery equalized time until battery voltage achieves battery equalization voltage. If battery voltage is still lower than battery equalization voltage when battery equalized timeout setting is over, the charge controller will stop equalization and return to float stage.

Fault Reference Code

Warning Indicator

CLEARANCE AND MAINTENANCE FOR ANTI-DUST KIT

Overview

Every charge is already installed with anti-dusk kit from factory. Charge will automatically detect this kit and activate internal thermal sensor to adjust internal temperature. This kit also keeps dusk from your charge and increases product reliability in harsh environment.

Clearance and Maintenance

• Step 1: Please loosen the screw in counterclockwise direction on the top of the charge.
• Step 2: Then, dustproof case can be removed and take out air filter foam as shown in below chart.
• Step 3: Clean air filter foam and dustproof case. After clearance, re-assemble the dust-kit back to the charger.

NOTICE: The anti-dust kit should be cleaned from dust every one month.

CHARGE MODE SPECIFICATIONS

MPPT Solar Charging Mode

I M N O V E D R EL TE R MODEL| 24V| 48V
Max. PV Array Power| 4200W| 6500W
Nominal PV Voltage| 180Vdc| 280Vdc
PV Array MPPT Voltage Range| 60Vdc~450Vdc
Max. PV Array Open Circuit Voltage| S00Vdc
Max Charging Current

(AC charger plus solar charger)

| 140Amp| 140Amp
Charging Curve

TROUBLESHOOTING

Problem| LCD/LED/Buzzer| Explanation / Possible cause| What to do
---|---|---|---
Unit shuts down automatically during startup process.| LCD/LEDs and buzzer will be active for 3 seconds and then complete off.| The battery voltage is too low (<1.91V/Cell)| ****

1.   Re-charge battery.

2.  Replace battery.

No response after power on.

| ****

No indication.

| 1.   The battery voltage is far too low. ( <l.4V/Cell)

2. Internal fuse tripped.

| 1.  Contact repair center for replacing the fuse.

2.  Re-charge battery.

3.  Replace battery.

Red LED is on.

| ****

Fault code 02

| ****

Internal temperature of charger component is over 70 °C.

| Check whether the air flow of the unit is blocked or whether the ambient temperature is too high.

Fault code 03

| Battery is over-charged.| Return to repair center.

The battery voltage is too high.

| Check if spec and quantity of

batteries are meet requirements.

Fault code 01| Fan fault| Replace the fan.

Fault code 52

| ****

Bus voltage is too low.

| Restart the unit, if the error happens again, please return to repair center.

Contact

SHENZHEN HEHEJIN INDUSTRIAL CO.,LTD

• Tel/Fax: +86755-28219903
• Email: support@powmr.com
• Web: www.powmr.com
• Add: Henggang Street, Longgang District, Shenzhen, Guangdong, China

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