User Manual MPPT SOLAR CHARGER 3KW
Contents
1. 14 S 2 Eduallz Stages stique aa Eo Mu v Ves FU OE c ibo Mea e e eins 16 5 3 Setting Parameter and Default 19 TROUBLE SHOOTING ws cui TT 20 Fe ON ee ea 21 1 ABOUT THIS MANUAL 1 1 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 1 2 Scope This manual provides safety and installation guidelines as well as information on tools and wiring 1 3 SAFETY INSTRUCTIONS 1 10 WARNING This chapter contains important safety and operating instructions Read and keep this manual for future reference Before using the unit read all instructions and cautionary markings on the unit the batteries and all appropriate sections of this manual 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 To reduce risk of electric shock disconnect all wirings before attempting any maintenance or cleaning Turning off the unit will not reduce this risk CAUTION Only qualified personnel can install this device with battery NEVER charge a frozen battery For optimum operation of this charger2. LED Indicator Solid On The controller is on The controller is charging POWER ON Bulk charge stage flashing every 0 5 second reen CHARGING Flashing Absorption stage flashing every second Equalize stage flashing every 3 seconds Float stage flashing every 5 seconds 11 Solid On Fault occurs FAULT WARNING Solid on Flashing Warning situation occurs WIRING FAULT Solid On Battery polarities are not connected correctly Operation Button Function Action Description Press the button until LCD backlight is on If equalization function is enabled press the button for 3 seconds Equalization until LCD shows 7 to activate battery equalization immediately enable disable If battery equalization is activated press the button for 3 seconds until the disappeared to cancel it Backlight on Press shortly 4 2 LCD Display Icons ioa 0101001 OU INPUT SOLAR PANEL em am am Volt wIRINGFAULT Ll A AA BATTERY VOLTAGE BATT CAPACITY CHARGING CURRENT den Function description Input Source Information C cu L4 LI LI Indicates the PV input voltage INPUT SOLAR PANEL Configuration Program and Fault Information EV Indicates battery equalization is activated Indicates fault codes BH Indicates warning codes Output Information 1010105 1 7 1 H Indicate battery voltage BATTERY VOLTAGE t
3. MPPT SOLAR CHARGER PCM60X CONTENTS 1 ABOUT MATS MANUAL n Ra aS A DIOE LL PUES 1 emp ID DR 1 1 2 tudin s eu mE d c E MUI ed EE 1 SAFEERC INSTRUCTIONS exis eui toe on 1 Z INTRODUCTION MP E 2 2 F eatre et a Ecc NOD t UD elie a totale C DOO ICE NCC 2 2 2 Product 3 cM CIDIBE RIS CL 4 3 1 UnpackIhng INSHSCHOM etait cv i Cc i Da stt ua d a P Duda 4 SPAN E UU te T EN 4 Cie UNIE ey carotid uc uoa eri ov md Rl Darei a riis au 4 aN 5 3 5 Grounding and Ground Fault Interruption 7 2 0 Remote Temperature SENSON tee ees one 7 3 7 Battery Voltage Sense sessanta os CN QU d 8 3 0 Communicalloh COnrecbloris x ses ccs Ea v ar eei e eem a eoe bei 9 dT OPERATION beau M IS C DIM E On M den DUE 11 izle e c ET 11 4 2 Operation and Display Panel sese nnn nnn 11 42 LCD RE T TT 12 753 Reference COGG xo oo oe xe ndo Mea De Vo ir ed a Elie Urn ulti pdt Da 13 5 CHARGING LOGIC 14 JLo Sage Charn
4. _ l f Hm Indicate charging power 111 Tur Indicate charging current CHARGING C Ll Indicates battery level by 0 24 25 49 50 74 and 0 LLL 75 100 in battery mode and charging status in line BATT CAPACITY mode Battery Charging Status Battery voltage LCD Display lt 2 1 4 4barswillflash Will flash in turns Constant ED LE ht bar will be on and the 2 2 083V cell Current other three bars will flash in turns mode The two right bars will be on and 2 083 2 167V cell the other two bars will flash in turns Voltage PAM gt 2 167 V cell The three right bars will be on and the left bar will flash Floating Batteries are fully 4 bars will be on mode charged 4 3 Reference Code coe MN Constant 06 Battery temperature is too low Battery temperature is too high PV is low loss UC Output derating caused from high PV voltage arning Output derating caused from high temperature Low alarm for battery temperature 5 CHARGING LOGIC 5 1 3 stage Charging In general this solar charge controller is designed with 3 stage battery charging algorithm for fast efficient and safe battery charging The following picture shows the sequence of charging stages 1 Bulk charge stage In bulk charge stage charge current begins to flow typically at the maximum rate of the charge source The controller will supply solar pow
5. charging current of Equalization mmm 17 If solar charge controller is working in float stage but at this time setting equalization interval battery equalization cycle is arrived it will transfer to equalize stage Equalize Voltage Float Voltage Equalize charging time and timeout In Equalize stage based on maximum charging current of battery equalization the controller will supply solar 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 Equalize Equalize Voltage Absorption Voltage Float Voltage EQUALIZE However in Equalize stage when battery equalized time is expired and battery voltage doesn t rise to battery equalization voltage point the solar 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 solar charge control will stop equalization and transfer to float stage 18 Equalize Charging Timeout Equalize Voltage Absorption Voltage Float Voltage EQU ALIZE 5 3 Setting Parameter and Default Value Recommended and default
6. Recommended wire size Typical Amperage Wire Type 75 C Wire 90 C Wire 4 AWG 25 mm 6 AWG 16 mm 2 AWG 35 mm 4 AWG 25 mm Overcurrent Protection and Disconnects CAUTION Circuit breakers or fuses must be installed in both battery and solar Circuits The battery circuit breaker or fuse must be rated to 125 of the maximum current or more The recommended breaker fuse rating for use with the charger is listed in the below table Recommended breaker rating Minimum battery circuit breaker fuse rating 1 25 x 60 Amps 75 0 Amps A disconnect is required for the battery and solar circuits to provide a means for removing power from the charger Double pole switches or breakers are convenient for disconnecting both solar and battery conductors simultaneously Connect the Power Wires WARNING Shock Hazard The solar modules can produce open circuit voltages in excess of 100 Vdc when in sunlight Verify if solar input breaker or disconnect has been opened disconnected before connecting system wires Battery Solar Solar Battery common negative Connect terminals by following below steps Refer to diagram above Make sure that system input and output disconnect switches are both turned off before connecting power wires to the charger There are no disconnecting switches inside the charger Make 4 power wires first Remove insulation sleeve 10 5mm and the conductor should be
7. earth ground The grounding terminal is identified by the ground symbol shown below that is stamped into the wiring box just below the terminal The minimum size of the copper grounding wire is 8 AWG 10 mm2 WARNING Risk of Fire DO NOT bond system electrical negative to earth ground at the controller 3 6 Remote Temperature Sensor The included Remote Temperature Sensor RTS is recommended for effective temperature compensated charging Connect the RTS to the 2 pole terminal see figure as below The RTS is supplied with 33 ft 10 m of 22 AWG 0 34 mm2 cable There is no polarity so either wire or can be connected to either screw terminal 7 The RTS cable may be pulled through conduit along with the power wires Tighten connector screws with 5 in Ib 0 56 Nm torque NOTE The RTS is optional package Please check local dealer for the details CAUTION The controller will not activate temperature compensate charging function if the RTS Is not used CAUTION Equipment Damage Never place the temperature sensor inside a battery cell Both the RTS and the battery Wil be darnaged NOTE The RTS cable may be shortened if the full length is not needed 3 7 Battery Voltage Sense The voltage at the battery connection on the controller may differ slightly from the voltage directly at the battery bank terminals due to connection and cable resistance The Battery Voltage Sense connection enables the controller to me
8. please follow required spec to select appropriate cable size It s very important to correctly operate this charger 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 Please strictly follow installation procedure when you want to disconnect PV or battery terminals Please refer to INSTALLATION section of this manual for the details GROUNDING INSTRUCTIONS This charger should be connected to a permanent grounded wiring system Be sure to comply with local requirements and regulation to install this charger NEVER cause short circuited on battery output 11 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 2 INTRODUCTION Thank you for selecting this solar charge controller This solar charge controller is an advanced solar charger with maximum power point tracking Applying intelligent MPPT algorithm it allows solar charge controller to extract maximum power from solar arrays by finding the maximum power point of the array The MPPT battery charging process has been optimized for long battery life and improved system performance Self diagnostics and electronic error protections prevent damage when installation errors o
9. D x 1 3 2 Preparation Before connecting all wirings please take off wiring box cover by removing screws as shown below 3 3 Mounting the Unit Consider the following points before selecting where to install This solar charge controller is designed in IP31 for indoor applications only Do not mount the unit 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 Install the unit to wall by screwing four screws Refer to right chart 2 2 2 2 2 2 A 4 3 4 Power Connection Wire size The four large power terminals are sized for 14 2 AWG 2 5 35 mm wire The terminals are rated for copper and aluminum conductors Use UL listed Class B 300 Volt stranded wire only Good system design generally requires large conductor wires for solar module and battery connections that limit voltage drop losses to 2 or less Minimum Wire Size The table below provides the recommended minimum wire size allowed for the charger Wire types rated for 75 and 90 are listed
10. SPECIFICATIONS Table 1 Electrical Specifications MODEL MPPT 3KW Nominal System Voltage 12 24 or 48 VDC Auto detection Maximum Battery Current 60 Amps Maximum Solar Input 145V Voltage PV Array MPPT Voltage 60 115VDC Range 12 Volt 800 Watts Maximum Input Power 24 Volt 1600 Watts 48 Volt 3200 Watts 7 0 60 0 5 PV Array voltage amp Battery current 3 Battery Current Amps A eo 0 20 10 0 110 115 120 125 130 135 140 145 150 Array Voltage Volts 70 60 50 Heatsink temperature amp Battery current T Battery Current Amps 20 10 0 60 65 70 75 80 85 90 955 Heatsink Temperature degrees C Transient Surge Protection 4500 Watts port 21 Solar high voltage disconnect Solar high voltage reconnect Battery high voltage disconnect Protections Battery high voltage High temperature disconnect High temperature reconnect Table 2 Battery Charging MODEL MPPT 3K Charging Algorithm 3 Step Charging stages Bulk Absorption Float Temperature compensation 5 mV cell 25 C ref coefficient Temperature 0 C to 50 C compensation range Temperature Absorption Float compensated set points Charging Set points Absorption Stage Float Stage Flooded Battery 14 6V 29 2V 58 4V 13 5V 27V 54V AGM Gel Battery 14 1V 28 2V 56 4V 13 5V 27V 54V Default Over charging voltage 15V 30V 60V Over charging 14 5
11. V 29V 58V comeback voltage Battery defect voltage 8 5V 17V 34V Battery defect 9V 18V 36V comeback voltage 22 Battery Voltage per cell Charging Current 96 Voltage Charging Curve 10 TO mini ins imu 3 Bulk Absorption Constant Current Constant Voltage Table 3 Mechanical and Environment Charger MODEL MPPT 3K Product size W x H x D 315 x 165 x 128 pee Ta Ambient Temperature 0 to 55 C Range Storage Temperature 40 C to 75 C Humidity 0 90 RH No condensing 23
12. asure the battery terminal voltage precisely with small gauge wires that carry very little current and thus have no voltage drop Both battery voltage sense wires are connected to the 2 pole terminal inside of wiring box see figure as below Be careful to connect the battery positive terminal to the voltage sense positive terminal and battery negative terminal to the voltage sense negative terminal No damage will occur if the polarity is reversed but the controller cannot read a reversed sense voltage A battery voltage sense connection is not essential required to operate your controller but it is recommended for best performance The battery voltage sense will ensure that the voltage display in LCD is very accurate The voltage sense wires should be cut to length as required to connect the battery to the voltage sense terminal The wire size can range from 16 to 24 AWG 1 0 to 0 25 mm2 A twisted pair cable is recommended but not required Use UL rated 300 Volt conductors The voltage sense wires may be pulled through conduit with the power conductors Tighten the connector screws with 5 in lb 0 56 Nm torque The maximum length allowed for each battery voltage sense wire is 98 ft 30 m 3 8 Communication Connections The default communication of the controller is RS232 port You can use supplied cable to connect RS 232 port of the controller to PC It can be used for monitoring or upgrade the firmware in sh
13. er to charge battery as much as possible 2 Absorption stage When battery charging voltage is reached to Absorption voltage point the charging stage changes from bulk charge to Absorption Constant voltage regulation is used to maintain battery voltage at the Absorption stage If the charging current drops to one tenth of the maximum charging current setting point the charging status will change to Float stage ABSORPTION Voltage Current If the elapsed time of absorption stage is over setting value for C V charging time it will also transfer to Float stage Absorption Voltage 3 Float Stage After the battery is fully charged in the Absorption stage the controller will reduces the battery voltage to the setting point of Float voltage Once in Float stage constant voltage regulation is used to maintain battery voltage at setting point of float voltage e Float timeout If the battery voltage remains lower than the Float voltage for 30 minutes the controller will return to Bulk charging stage ABSORPTION 15 e Float cancel voltage Once the battery voltage drops to setting point of Float cancel voltage the controller also returns to Bulk charging stage Float cancel voltage Floating charging voltage 1V x battery numbers in series Float Voltage L R et ee Float Cancel Voltage ABSORPTION 5 2 Equalize Stage Equalizat
14. ion function is added into solar 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 16 How to Apply Equalization Function You must enable battery equalization function in monitoring software first Battery type pply Rated battery voltage Auto Battery absorption charging voltage pply BTS temperature compensation ratio Battery Floating charging voltage ply Battery C V charge time Max charging current Battery equalization Enable Disable Battery equalized time din 990 Battery equalized timeout The max current of battery equalization A Apply Battery equalization voltage Equalization interval Apply ssing key for 3 second Then you may apply this function in device by either one of following methods 1 Setting equalization interval 1 2 Or press the button for 3 seconds until LCD shows C 1 e When to Equalize In Absorption stage if the charging current drops lower than the maximum charging current of battery equalization the controller will start to enter Equalize stage The Max
15. ort distance Intelligent slot allows the controller to use different communication methods except RS232 Slot can support SNMP USB MODBUS cards and so on You can follow the below figure to install the card if you had purchased for it Insert bundled software CD into a computer and follow on screen instruction to install the monitoring software For the detailed software operation please check user manual of software inside of CD 10 4 4 1 Power Up WARNING Risk of Damage Connecting the solar module to the battery connector will permanently damage the controller e Confirm that the solar and battery polarities are correctly connected to the controller A battery must be connected to the controller before operating it The controller will not operate only with solar input Solar input can trigger the controller to start up when the battery is connected without pressing the button e Turn on battery disconnect switch first And press operation button for a while Then it will indicate a successful start up in LCD display e Turn on solar disconnect switch If the solar module is in full sunlight the controller will begin charging 4 2 Operation and Display Panel The operation and display panel shown in below chart is on the front panel of the controller It includes three indicators one operation button and a LCD display indicating the operating status and input output power information
16. parameter settings are listed below Parameter Battery Absorp Float Equalize Equlize Absorp Equalize Equalize Equalize pe Em E ERN EE pum Time pem n vot En Disable Minutes Minutes Minutes Dass ome we 19 6 TROUBLE SHOOTING Situation Fault Fault Event Solution Code 1 Restart the charger 01 Over charge current 2 If the problem remains please contact your installer 1 Keep charger the cool environment Over temperature 2 If the problem remains please contact your installer 1 Check the battery wire connection Battery voltage under 2 If the wire connection is ok please contact your installer 1 Reconnect the battery to the charger Battery voltage high 2 If the problem remains please contact your installer 4 1 Please check the voltage of the solar panel it 05 PV high loss should be less than 140V 2 If the voltage is ok please contact your installer 1 Check your remote temperature sensor and Battery temperature your battery ambient temperature too low 2 If the problem remains please contact your installer 1 Check your remote temperature sensor and Battery temperature your battery ambient temperature too high 2 If the problem remains please contact your installer 1 Check battery wire connection No display in LCD screen 2 Push the button if the problem remains please contact your installer 0 20 7
17. plated Tin Refer to the chart below 10 5mm Pull all wires into the wiring box The Remote Temperature Sensor and Battery Tin Plating Sense wires can be inside the conduit with the power conductors It is easier to pull RTS and Sense wires before the power cables WARNING Risk of Damage Be sure that the battery connection is made with correct polarity Turn on the battery breaker disconnect and measure the voltage on the open battery wires BEFORE connecting to the controller Disconnect the battery breaker disconnect before wiring to the controller 4 Connect positive terminal of battery to the battery positive terminal on the controller 5 Connect negative terminal of battery to one of the Common Negative terminals on the controller WARNING Risk of Damage Be sure that solar connection is made with correct polarity Turn on the solar breaker disconnect and measure the voltage on the open wires BEFORE connecting to the controller Disconnect solar breaker disconnect before wiring to the controller 6 Connect positive wire of solar module to the solar positive terminal on the controller 7 Connect negative wire of solar module to one of the Common Negative terminals on the controller 8 Screw four 4 power terminals tightly with 50 in lbs torque 5 65 Nm 3 5 Grounding and Ground Fault Interruption Use a copper wire to connect the grounding terminal in the wiring box to
18. r system faults occur This charger also features multifunctional LCD with communication ports for remote battery temperature and voltage measurement 2 1 Features eIntelligent Maximum Power Point Tracking technology increases efficiency 25 30 eCompatible for PV systems in 12V 24V or 48V eThree stage charging optimizes battery performance eMaximum charging current up to 60A eMaximum efficiency up to 98 eBattery temperature sensor BTS automatically provides temperature compensation eAutomatic battery voltage detection eSupport wide range of lead acid batteries including wet AGM and gel batteries eIntegrated intelligent slot compatible with SNMP MODBUS communication 2 2 Product Overview POWER ON FAULT WIRING FAULT CHARGING WARNING LCD display Power On Charging indicator Fault and warning indicator Wiring fault indicator Operation button PV connectors Battery connectors Remote temperature sensor terminal Se e Battery voltage sense terminal NN C Wiring box cover E E Communication port a N Intelligent slot FN CJ Grounding terminal 3 INSTALLATION 3 1 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 e Solar charge controller x 1 e User manual x 1 e Communication cable x 1 e Battery Voltage Sense x 1 e Software C
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