MPPT2024Z User`s Manual - YSmart Technology Co.,Ltd
Contents
1. Faults and Remedies YSMART TECHNOLOGY CO LTD website www ysmart tech com Phone 86 755 85232255 6 1 Protection Remedies Fault Phenomenon Cause Remedy Check the battery voltage and manually Load off recharge the battery if necessary Loads Charging on directly connected to the battery can cause deep discharge Battery Load off Check installation Check the battery voltage Charging off voltage and check any additional charging Battery voltage too low too high sources if present Load on Check the PV system configuration The PV PV voltage Charging off open circuit voltage increases while the ambient temperature decreases Excessive Load off Reduce the load current at the load output load current Charging on The load may cause current peaks too high Load output Load off Rectify short circuit Disconnect and short circuit Charging on reconnect the load Allow the controller to cool down Check for Controller l l Load on possible causes of overheating mounting Charging off location other heat sources Possibly reduce the charge current Make sure the inside temperature too high l l controller is adequately ventilated Inside Disconnect the load solar modules and temperature Load on battery Re install the controller If the error sensor Charging on recurs then please contact your specialist error dealer Load Disconnect the load solar modules and Self test charging battery Re insta2. Installation Process cccecccccccccescssseeeecceeessssseeceeeessesaees 13 Operation INStructions oc ccccccceeesscecescccceeessseessssseeeeeseeeees 13 9 1 B tt n FU CEO IN oacossseonanitaicehesacschathdeasdoicanaccsinsntndeiecesnienoneeniaas 13 9 2 LED B 6 FV nannies Rv 14 5 3 System Voltage Indication 0 cc ccceccccesessseececeeeesesseees 14 Faults and REMEAIEGS cece cccceeesccccceccsssssseeeccceessseeeeceesenssneeeeees 14 6 1 Protection REMEAIECS cece cccccsssssceececcesssseeeeeeeeessseeeeeees 15 6 2 Common Faults and Remedies eeesseerrerrrssrrrrrssse 16 Technical Data cccccccccccccccsssscecceecsssssceeeeecesssseeeeeeeserseeeeees 17 Quality ASSULANCE ccc ccecesscecceeesscecceeesseecceeessseceeeesaseseesesaeees 18 YSMART TECHNOLOGY CO LTD website www ysmart tech com Phone 86 755 85232255 Dear Consumer Thank you very much for using our product We will offer you the permanent and reliable service for your solar system The manual gives important recommendations for installing and using the MPPT controller Please read the manual carefully and thoroughly before using this product YSMART TECHNOLOGY CO LTD website www ysmart tech com Phone 86 755 85232255 1 Safety Instructions 1 The controller is only designed to be connected to the off grid solar system It offers the management of charging and discharging for the lead acid battery of flooded gel
3. Silicon solar panels and also Thin film solar panels When configuring the system make sure the open circuit voltage of solar panels array is not higher than the maximum voltage permitted by the controller Table 3 2 introduces the models of Single Crystalline Silicon solar panels and Thin film solar panels and their parameters Table 3 3 shows the configuration solution for 12V 24V and 48V system for solar panels YSMART TECHNOLOGY CO LTD website www ysmart tech com Phone 86 755 85232255 Single STP140D 12 Crystalli ye aagw 22 4V 8 33A 17 6V 7 95A TEA e Silicon Module Thin film MS140GG 02 140W 29 0V 7 12A 23 0V 6 52A Module single STP190S 24 Crystalli ee agqw 45 2V 5 654 36 6V 5 24 Ad e Silicon Module Thin film NS F130G5 130W 60 4V 3 41A 46 1V 2 82A Module The above parameters are for condition of 25 C AM1 5 spectrum and 1000W m illumination intensity Table 3 2 Solar Panels Model and Parameters For 12V System For 24V System For 48V System STP140D 12 T two in series four in series N in parallel l l EA N in parallel N in parallel two in series four in series MS140GG 02 N in parallel l N in parallel N in parallel STP190S 24 A two in series N in parallel N in parallel d N in parallel l two in series NS F130G5 N in parallel N in parallel N in parallel N means the quantity number required by the output current Table 3 3 Solar Panels Model and
4. This working point is the state when using normal controller and the solar panels voltage is clamped to 13V by battery Working point B Output voltage is 17 6V output power is 92W This point is the state when using MPPT controller Because of using power conversion technology the solar panels voltage is not clamped by battery and still works at maximum power point Compare working point A amp B it is easy to find using MPPT controller can increase the using efficiency of solar panels Compared to normal controller MPPT controller can generate more power Figure 2 4 Voltage Current Curve YSMART TECHNOLOGY CO LTD website www ysmart tech com Phone 86 755 85232255 P W 100 oy AAAA te EE pT 80 70 60 50 40 30 20 10 0 2 4 6 8 10 12 14 16 18 20 agU V Figure 2 5 Voltage Power Curve 3 PV System Planning Reference 3 1 System Voltage The common system voltage of solar system has 3 types 12V 24V and 48V The higher the system voltage the more power the system can handle In reality application user should consider the load power and the voltage scope permitted by load and then confirms which system voltage you should use The power range for each system voltage is as follows System Voltage Recommended Power Range lt 800W 24V lt 2000W 48V lt 6000W Table 3 1 System voltage vs Power range 3 2 Solar Modules Configuration MPPT1024Z controller can be connected with Single Crystalline
5. Connect the load with the load terminal on the controller by cables and fasten the screws 3 Connect the solar panels array with the solar panel terminal on controller by cables and fasten the screws E Switch on the breaker or fuse of the battery then the 3 indicators indicate the system status Switch on the breaker or fuse of the load more information about the indicators see Chapter 5 2 and 5 3 F Switch on the breaker or fuse of the battery then the controller starts to charge the battery 5 Operation Instructions 5 1 Button Function There is only one concealed button on the controller which used to restart the load when the controller is in overload protection state The second function of the button is to control the load Press the button and hold about 3 seconds then the load will be switched off This can also switch on the load YSMART TECHNOLOGY CO LTD website www ysmart tech com Phone 86 755 85232255 5 2 LED Displays PV Voltage Low off MPPT Charge illuminates Absorption Charge Float Charge SUUU T 1s PV Overvoltage Protection JUUUUUU T 0 5s Battery Disconnect off Load Short circuit Protection 5 3 System Voltage Indication The MPPT1024Z controller adjusts itself to 12V or 24V system voltage automatically The system type indicates by the green led when the controller startup every time Details show as follows pss 24V 15s oss 12V Figure 5 3 System Voltage Indication Diagram 6
6. MPPT10242Z Solar Charge Controller with Maximum Power Point Tracking Installation amp Operation Manual YSMART TECHNOLOGY CO LTD website www ysmart tech com Phone 86 755 85232255 Content Safety MVS Ul UCTIONS fisisceccvasssiadccsonsnasaccresneudessctneiengdcsbsenaveduceasndeiouvenssiadeusovencs 3 MPPT Controller Instructions 0 0000 cc cccccessccecceeesssseeeeeeessssssees 3 2 1 OV GIVI OW viesicsseixdoviscaciavtvnssanspiencnebeanasivadeinnxcssusintinrbctisiantesseinatelassbnsnnsieptovsmae 3 PAPINE 10 y EE EEE EEE ne ee eee errr 4 KOFUN ENON S eea E E 4 2 4 MPPT technology Instructions 6 PV System Planning Reference eeeesesserrrressrrrrrrsssrrrerrsssrereress 8 3 1 System VOI AGC og cieiciscscssctncasncscoancancen veamassgudanciinaacesdusaeleneiadaiaeistecteiansaees 8 3 2 Solar Modules Configuration 000ccccccccccecsssseeeeceeeesssseeeeeees 8 3 3 We SIZO eeo OR en ee rer ED 9 3 4 Over Current Protection i ccceccccccceceessceecceeesssssseseeeeeens 10 3 5 Lightning PLOTECU ON sosacscecisicasetaicissisabnicrasedssnenccioveadsdaaredseciaaomeimeneinne 10 3 6 SE OUI CII eare cess cet cca EEES EEEE EOE T 11 3 7 System Expansionen eeen MM ccs ceessccescessesesseneee 11 Installation i lll 11 4 1 DIMEMSIONG ccccccccccccccssseceecccsees s A 11 4 2 Connecting Diagram cece cccccccsssseceecceeessneeeeeceesesssaees 12 4 3 Wirin S e a POO E a A 12 4 4
7. System Configuration Solution 3 3 Wire Sizing The maximum input and output current of MPPT1024Z is 10A To ensure the cable temperature does not exceed the safety range the copper cable s area must be at least 2 5mm In reality application user can choose the appropriate cables according to the system voltage permitted cable YSMART TECHNOLOGY CO LTD website www ysmart tech com Phone 86 755 85232255 temperature cable voltage drop and also cable material We suggest customer to control the maximum battery voltage loss under 1 5 and control the maximum voltage loss of solar panels under 2 5 The following is the cable length between controller and battery and the suggested copper cables Voltage Loss Battery Voltage Loss Cable Size Cable Size at 10A in AWG 12V a pair 4V 2 0 60 10 Table 3 4 Cable Length amp Cable Voltage Drop The following is the cable length between solar panels and controller and also the suggested copper cables Voltage Loss Solar Panels Cable Size Size in 5 hues at 10A Voltage Loss In nt a pair 11AWG 018V 0 53 0 26 omm 14 0 8V 3 2m am Table 3 5 Cable Length amp Cable Voltage Drop 3 4 Over Current Protection The electrical equipment used in power circuit must be equipped with over current and short circuit protection devices and there is no exception for MPPT1024Z controller The controller adopts in the design of common positive pole inside We s
8. and AGM chemistries from 12V to 24V nominal only Do not connect this controller to other system such as mains supply and windmill generator 2 The controller is intended for indoor use only Protect it from direct sunlight and place it in a dry environment 3 Batteries generate explosive gases during normal operation It is important never allow a spark or flame in vicinity of battery 4 Be sure to always keep children away from batteries and acid 5 Do not disassemble the MPPT controller it does not have any user serviceable parts 6 The controller warms up during normal operation Do not touch the heat sink at the bottom of the controller Note It is important that the battery is fully charged frequently at least monthly Otherwise the battery will be permanently damaged 2 MPPT Controller Instructions 2 1 Overview MPPT1024Z 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 its 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 refer to Chapter 2 4 about MPPT technology intr
9. ll the controller If the error error indefinite recurs then please contact your specialist dealer YSMART TECHNOLOGY CO LTD website www ysmart tech com Phone 86 755 85232255 6 2 Common Faults and Remedies The battery is Check the fuse LEDs no connected to the Disconnect the battery and reconnect indication controller with the it to the controller with the correct wrong polarity The polarity fuse burns out Battery over The controller Disconnect the load solar modules voltage adjusts to the and battery Waiting for about 10 protection wrong system seconds and then re install the when startup voltage controller Stay in direct The PV MPP It s normal If possible you can charging voltage too low re configure the PV system to enlarge mode the PV open circuit voltage YSMART TECHNOLOGY CO LTD website www ysmart tech com Phone 86 755 85232255 T ooo Data MPPT10242Z Maximum Maximum charging current current 144V 28 8V for 2 hours Temperature eons ae Passive cooling Ambient temperature range St t t orage temperature 30 to 80 C range Note Technical data at 25 C 77 F YSMART TECHNOLOGY CO LTD website www ysmart tech com Phone 86 755 85232255 8 Quality Assurance 8 1 Quality assurance should be carried out according to the following rules e The product is guaranteed of replacement returning and repairing within 7 days after Sale e The product is guaranteed of replaceme
10. ng Bulk Charge The controller charges the battery by its maximum output current It is at maximum power point tracking state at this phrase Absorption Charge The controller begins to limit the charging current to make the battery voltage fixed at a settled absorption voltage this voltage has temperature compensation for 2 hours It increases the charging saturation level of YSMART TECHNOLOGY CO LTD website www ysmart tech com Phone 86 755 85232255 battery and prevents battery from leaking gas and this can increase the lifetime of battery Float Charge The battery is at saturation state and the controller charges the battery ata trickle current to make the battery voltage fixed at the settled float charging voltage this voltage has temperature compensation U 2h Absorption Float Float Bulk Bulk 12 4V 12 0V t t Figure 2 2 Three stage Charge Figure 2 3 Two stage Charge 3 Charge Voltage Temperature compensated The controller will compensate the Float charging voltage and Absorption charging voltage by 4mV Cell C based on 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 4 Discharge Control The controller monitors the battery voltage all the time The load will be switched off when the voltage less than the Low Voltage Disconnect LVD point and it won t be switched on until the voltage more than
11. ns 6 Solar Battery load Reset H arte 0 BOOOO Figure 4 1 Dimensions Unit mm YSMART TECHNOLOGY CO LTD website www ysmart tech com Mounting hole pitch 6 0mm 178mm Mounting hole diameter 5mm Height Width Thickness 92 5mm 188mm 55 3mm Connecting terminals Maximum 6mm 4 2 Connecting Diagram Temperature Sensor N Solar Battery load oO Reset A 65 BOOODD Figure 4 2 Connecting Diagram 4 3 Wiring Phone 86 755 85232255 A Choose the appropriate cables requested as Chapter 3 Prepare 4 sets of M5 screws used to fix the controller on the wall or other vertical plane B Prepare cutting pliers cross screwdriver and multi meter etc YSMART TECHNOLOGY CO LTD website www ysmart tech com Phone 86 755 85232255 4 4 Installation Process Note Please switch off the breakers of battery solar panels array before installing the controller Do not touch the positive and negative pole of solar panels or battery at the same time when installing otherwise you have the risk of electrical shock A Mount the controller on the wall and fasten the screws B Check whether the battery voltage and solar panels array voltage is within the requested range C Switch off the over current breaker or fuse of the battery solar panels array and load D Wiring 1 Connect the battery with the battery terminal on the controller by cables and fasten the screws 2
12. nt and repairing within 1 month after sale e The product is guaranteed of repairing within 12 months after sale 8 2 If it is impossible to identify the using date of the controller we would refer to the ex work date and prescribe 18 months as the warranty period We need to charge beyond the warranty period The controller can be repaired for life no matter when and where you use it 8 3 If the controller is damaged by the following causes we need to charge even if it is in the guarantee period e Do not operate according to the user s manual e Use the controller under the condition which is beyond the using standard and technical requirements e Repair by yourself or reform by yourself e The improper environmental condition which can cause the breakdown and aging of the apparatus e Improper carrying or storage e Regarding to the service of replacement returning and repairing you need to retreat the product to our company and we decide whether to replace or repair after we make clear who should be responsible 8 4 We will not notice if there is any change of this product
13. oduction Compared with PWM controller MPPT controller can increase the output power of solar panels by 5 30 The output power increasing proportion is affected by the factors such as solar panels property humidity and light intensity The controller uses wall mount installing refer to Chapter 4 1 Connecting terminal makes the wiring area bigger and wiring loss less YSMART TECHNOLOGY CO LTD website www ysmart tech com Phone 86 755 85232255 2 2 Structure Bottom Heatsink Indicators and Reset key Solar Terminal Block Battery Terminal Block Load Terminal Block Figure 2 1 Controller Structure Diagram 2 3 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 Charge Control The starting charging voltage of battery is different the controller will use the different charging strategies to finalize the charging process When starting charging voltage of battery is lower than 12 4V for 12V battery battery will go through three stages as Bulk Absorption and Float charging When starting charging voltage of battery is higher than 12 4V for 12V battery battery will go through two stages as Bulk and Float chargi
14. ower point to limit the output current to prevent the controller being damaged 11 Load Output Overload Protection If the permissible load current is exceed then the load output is switched off The overload current vs duration shows as follows Rate of Current Duration s 11Irate lt I lt 1 2Irate 1 2lrate lt l lt 1 5lrate 1 5lrate lt l lt 1 8lrate Note lrate 10A nominal load current The controller restarts the load every 3 minutes automatically but the user can also restart the load by the Restart key 2 4 MPPT technology Instructions Solar panels are nonlinear materials and the output power is mainly affected by illumination intensity solar panels temperature and load impedance When the illumination intensity and solar panels temperature are fixed the output power of solar panels is only affected by load impedance Different load impedance will make the solar panels work at different point and put out the different power The following figure will mark the four working points A B C D and the working point features as follows YSMART TECHNOLOGY CO LTD website www ysmart tech com Phone 86 755 85232255 Working point D Output voltage is 22 3V output power is OW This point is the open circuit point of solar panels Working point C Output voltage is OV output power is OW This point is the short circuit working point of solar panels Working point A Output voltage is 13V output power is 74W
15. the Low Voltage Reconnect LVR point 5 Protection against Reverse Connected Battery Connecting the battery to the controller by reversed polarity under the circumstances of solar panels disconnected will not damage the controller The controller will work normally after connecting with correct polarity 6 Protection against Reverse Connected Solar Modules Connecting the solar modules with the controller by reserved connection will not damage the controller The controller will work normally after connecting with correct polarity 7 Reverse Current Protection The controller prevents reverse current from flowing into the solar modules YSMART TECHNOLOGY CO LTD website www ysmart tech com Phone 86 755 85232255 at night An additional reverse current diode is not required 8 Overtemperature Protection If the temperature inside the controller becomes too high then the controller will stop charging to the battery and it will restart charging the battery again when the temperature decreases to a certain value 9 PV Overvoltage Protection If the input voltage of solar panels exceeds the maximum voltage permitted by the controller it will enter into protection state automatically and stop charging When the input voltage recovers to the normal range the controller will start charging again 10 Current limited for Excessive Charging Current If the permissible charge current is exceed the controller will deviate from the maximum p
16. uggest users to install over current breaker or fuse on the negative loop of solar panels input and also the negative loop of battery output The capacity of over current breaker or fuse is 1 25 times of the rated current 3 9 Lightning Protection It is the same as other electrical devices that MPPT1024Z controller will be damaged by lightning The controller has limited surge absorption capacity We strongly suggest users to install lightning surge absorption devices to increase the reliability of the system YSMART TECHNOLOGY CO LTD website www ysmart tech com Phone 86 755 85232255 3 6 Grounding Use 4 mm yellow and green cable to connect any of the positive terminal of the controller to the ground bus of the system This can decrease the electromagnetic interference in a certain value 3 System Expansion lf you want to deploy a bigger system you can expand the system by paralleling several sets of the same controller More controllers can share with one battery group but each controller must be connected with the independent solar panels array and the independent load Please contact the local distributor for further information 4 Installation 1 Protect the controller from direct sunlight or other source of heat 2 Place the controller in a dry environment 3 A free space of at least 15cm on all side of the controller must be provided 4 Mount the controller as close as possible to the batteries 4 1 Dimensio
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