Max48 series Solar Controller User Manual
Contents
1. 3 Dimensions 35 ventilated 10 Avoid touching or short circuiting wires or terminals Be aware that the voltages on special terminals or wires can be as much as ooo0 o 127 i twice the battery voltage Use isolated tools stand on dry ground and keep your hands o TEE 10 dry os kKeep children away from batteries and the 189 47 charge controller NE 2 2 Liability Exclusion The manufacturer shall not be liable for damages especially on the battery caused by use other than as intended or as 4 1 Remote display unit mentioned in this manual or if the Remote display unit can display system information recommendations of the battery failure information and one year s charge and discharge manufacturer are neglected The data manufacturer shall not be liable if there has been service or repair carried out by 4 2 Remote temperature sensor any unauthorized person unusual use Acquisition the ambient temperature of the battery wrong installation or bad system design which can be accurate compensation charge values standard wire length is 2 meters can also be customized according to user needs LN SN 4 Optional Page1 13 Pages 5 Installation 5 1 Mounting location requirements Do not mount the solar charge controller outdoors or in wet rooms Do not subject the solar charge controller to direct sunshine or other sources of heat Protect the solar charge cont2. Timer Default Auto Day Night threshold Day Night threshold Sunset a Sunrise gt Le Auto Dusk to dawn mode Light on Light off Light off Standard Load on mode Day Night threshold Day Night threshold Sy Sunsets Sunrise Timer Double time mode Night timer1 Night timer Light on Light on Light off Figure3 Load mode The time delay of load open settings Press the OK button to enter the menu press A Y to change the value tight on delay The solar charge controller can control night lighting automatically by evaluating 00 00 the density of outside light with the help of the solar PV module array Depending on the PV array alignment or shading it may well be that night recognition is activated even though twilight has not yet come to an end By the programmable time adjustment Light on delay the night light switch on may be shifted to a later time Possibilities for programming 00 00 02 00 Interval 5min Default 00 00 The delay time of load close settings Press the OK button to enter the menu press Lightoff delay A Y to change the value 00 00 After setting Light off delay the light can remain on a period of time after dawn Possibilities for programming 00 00 02 00 Internal 5min Default 00 00 Note When the controller is set to Standard Light on delay and Light off delay have no effect on it but when the controller is set to Auto and Timer
3. Dimensions Weiht Max wire size 127 189 47mm 550g 25mm Max power consumption 7mA Temp Range during operation 10 C 60 C Storage temperature Relative humidity 25 C 80 C 10 90 Non condensation Case protection IP32 Page13 13 Pages
4. the delay time settings work Page8 13 Pages Night timer 1 00 00 Night timer 2 00 00 Night time 1 settings Press the OK button to enter the menu press A W to change the value When the Load control is set to Timer Night timer 1 is the first part light on time when dusk coming If set to Auto or Standard Night timer 1 setting is invalid Possibilities for programming 00 00 09 00 Interval 15min Default 00 00 Night time 2 setting Press the OK button to enter the menu press A Y to change the value When the Load control is set to Timer Night timer 2 is the second part light on time before dawn If set to Auto or Standard Night timer 2 setting is invalid Possibilities for programming 00 00 09 00 Interval 15min Default 00 00 7 6 Menu Logg Inquiry of internal data logger Press MENU button to enter the menu you can recall stored data values from today to the last 7 days at the same time you can view the accumulated value in and out of the system since the controller installed Day in 100 Ah out 80 Day 1 in 12 Ah out 90 Total in 1200 KAh out 880 From this menu window you can read the actual daily value of amp hours in and out of the system Press OK to toggle the display from today s current running data values to the stored data values for the last 7 days You can choose the desired day to view with the arrow key A Y The values can not
5. 0 30 0V Default 12 0V Low voltage disconnect settings Press the OK button to enter the menu press A Y to change the value Note 1 The difference between disconnect and reconnect threshold must be at least 20 If you wish disconnect at higher state of charge you have to first adjust the reconnect threshold as per below to 20 above the desired disconnect threshold 2 When you configure voltage regulation you will find in this window voltage values instead of SOC values for programming the disconnection voltage level The solar charge controller allows the smallest difference between reconnect and disconnect is 3 2V If you want to program a high level for disconnection you must first increase the reconnection level Possibilities for programming by SOC 20 70 Default 30 Possibilities for programming by voltage regulation 44 0 50 0V Default 44 4V Low voltage reconnected settings Press the OK button to enter the menu press A Y to change the value Possibilities for programming by SOC 40 90 Default 50 Possibilities for programming by voltage regulation 47 2 53 2V Default 50 4V Page7 13 Pages 7 5 Menu Load Load mode settings We can set load mode and time in this menu Figure 3 Load mode press the OK button to enter this menu Load mode settings Press the OK button to enter the menu and press A W to eae change the load mode AUTO Possibilities for programming Auto Standard
6. be changed Note Day simply stands for today and Day 1 for the day before Day 2 means two days ago When a new day of logging starts the data for each of Day to Day 6 will be shifted to the previous day i e the 7th day data will be replaced with the data for the 6th day 6th day replaced by 5th day etc View the accumulated value in and out of the system since the controller installed this data can not be changed Note The minimum value is 1KAh Note All historical data will be deleted only when the device been reset to factory settings Page9 13 Pages 7 7 Example of configuration 7 7 1 Battery type By pressing the MENU key you leave the online status display and go to the main menu By pressing the key below the corresponding abbreviation Conf System module settings Prog System parameter settings Load Load mode settings and Logg Inquiry of internal data logger you can enter the corresponding menu In the case of this example you have to press the first key from left labelled A which is below the abbreviation Conf This is how you get into the window for programming the Battery type Figure 4 Change the battery type Note If you have pressed the wrong key by accident press MENU to get back to the main menu and start all over again 7 7 2 Reset to Factory Pre Set Configuration In the previous section it is described how to enter the window Battery type The next window up press A is
7. of many advantages the controller can provide your solar system This manual gives important recommendations for installing program using and so on Read it carefully in your own interest please 1 Description of function 2 Safety instructions and waiver of liability With your new Max48 series controller you own a state of the art device which was developed according to the 54 Safety latest available technical standards It comes with a number of outstanding features such as The solar charge controller may only be used in PV systems in accordance with this user manual and the specifications of other modules manufacturers No energy source other than a solar generator may be connected to the solar charge controller Batteries store a large amount of energy never short circuit a battery under all circumstances We strongly recommend connecting a fuse directly to the battery to protect any short circuit at the battery wiring Batteries can produce flammable gases Avoid making sparks using fire or any naked flame Make sure that the battery room is E LCD display E One year s data memory E 48V system voltage E External temperature sensor make the temperature compensation more accurate E Perfect EMC design E Many choices of battery type working mode and protection E Four stage PWM charge way fast boost equalization float E Full automatic electronic protect function
8. I accu 8 3A A V OK MENU O00 Q Conf Load Prog Logg A V OK MENU Battery type Float charge Load control Day in ta Liquid 54 8V AUTO Ah out 80 Nominal capacity Boost charge Light on delay Total in 1200 300Ah 58 0V 00 00 KAh out 880 Regulation Equal charge Light off delay SOC 59 2V 00 00 Factory adjust D N threshold Night timer 1 Press OK MENU 12 0V 00 00 Disconnect Nighttimer2 30 00 00 Reconnect 50 Page5 13 Pages 7 3 Menu Conf System module settings In this menu you can configure the system modules including battery type battery nominal capacity Liquid Battery type Nominal capacity 300Ah Regulation Soc Factory adjust Press OK MENU Battery type selection Press the OK button to enter the menu you may toggle between A Y Gel to liquid electrolyte Possibilities for programming Liquid Gel Default Liquid Battery nominal capacity Press the OK button to enter the menu press arrow keys A Y for changing the nominal capacity and press OK for entering the new value Possibilities for programming 10Ah 9990Ah Default 300Ah Note The nominal capacity must be consistent with the actual battery capacity when the controller is installed Low voltage protection mode Soc or voltage control settings Press the OK button to enter the menu and switch with the keys A Y between SOC and Voltage Possibilities for programming Soc Voltage Default Soc Factory pre set P
9. Low voltage Switches off Over temp switches off the load if the temperature reaches the set value 1 Controller can not protect itself in a 48V system when polarity of battery or solar is reversed 2 Controller can protect itself but loads might be damaged 3 Battery must be protected by fuse or battery will be permanently damaged 4 The solar panel voltage should not exceed this limit for a long time as voltage protection is done by a varistor Warning The combination of different error conditions may cause damage to the controller Always remove the error before you continue connecting the controller Pagel11 13 Pages 9 Malfunctions and Errors The solar charge controller is protected against damage by various measures Nevertheless always take utmost care in the proper operation of the solar charge controller Short hints of the malfunctions are indicated with the help of the LCD display However errors are only properly indicated in which the system has been properly installed If there are other malfunctions than the ones described below please check first of all if the solar charge controller has been connected to the battery the module and the loads correctly in the right polarity Afterwards check the safety fuses Error message The cause of the malfunction Remedy Short circuit Short circuit Over current The load current is too high and the output is disconnected Either the whole c
10. Max 48 series Solar Charge Controller 10A 20A 30A User Manual User Manual_Max48 series 23 CE Rohs 1S09001 2008 Subject to change e witho ut notic Contents 1 Description of function 2 Safety Instructions and Waiver of Liability 2 1 Safety 2 2 Liability Exclusion 3 Dimensions 4 Optional 4 1 Remote display unit 4 2 Remote temperature sensor 5 Installation 5 1 Mounting location requirements 5 2 Fastening the solar charge controller 5 3 Preparation of wiring 5 4 Connection 5 5 Grounding 6 Indication of Status 7 Operating the solar charge controller 7 1 Factory Pre Set configurations 7 2 Main Menu 7 3 Menu Conf System module settings 7 4 Menu Prog System parameter settings 7 5 Menu Load Load mode settings 7 6 Menu Logg Inquiry of internal data logger 7 7 Example of configuration 7 7 1 Battery type 7 7 2 Reset to Factory Pre Set Configuration 8 Safety Measures 8 1 Electronic Short Circuit Safety 8 2 Hardware Safety 8 3 Safety Features 9 Malfunctions and Errors 10 Technical Data 10 1 Performance Data 10 2 Controlling Data 25 C 10 3 Parameter settings P1 Pi Pa P1 P1 P1 P1 P1 P2 P2 P2 P2 P2 P3 P4 P3 PS PS P6 P6 P8 P9 P 10 P 10 P10 P11 P11 P11 P11 P12 P 13 P 13 P 13 P13 Dear Clients Thanks for selecting the Max 48 series solar controller Please take the time to read this user manual this will help you to make full use
11. battery negative on the chassis loads connected to the controller must not have an electric connection to the car body otherwise the low voltage disconnect and electronic fuse functions of the controller are short circuited Page3 13 Pages 6 Indication of Status The two line display indicates all present system values in short form on the top line and the values are without units Volt Amp etc due to a lack of space The printing above each value serves as a reminder SOC State of charge Battery voltage Charging currents Discharge currents BAT IN OUT SOC means state of charge and indicates how much remaining capacity the battery still has The SOC is never 100 as due to technical reasons it is easier to indicate a two digit number BAT shows the battery s actual voltage IN is the sum of the charging currents flowing into the battery OUT is the sum of discharge currents flowing out of the battery The second line constantly changes its information All values and system information are indicated alpha numerically The following displays can only be seen during regular operation not while programming SOC BAT IN OUT 88 50 8 26 18 I accu 8 3A Laccu is the balance of all charging and discharging currents As long as the charging current is higher than the discharging current the value is position in the opposite case it is
12. for resetting the solar charge controller to the factory pre set configuration Factory adjust By pressing OK you can enter the Factory adjust window The instruction to press the MENU key plus the OK key appears immediately Only by pressing both of these keys simultaneously will the factory pre set configurations be set Then the second line shows Done means successfully restore the factory settings Figure 5 Reset to Factory Pre Set configuration 88 50 8 26 18 88 50 8 26 18 lt K I accu 8 3A I accu 8 3A 90090 0000 Conf Load Conf Load Prog Logg Prog Logg CA yY OK MENU O O gt Batterytype Battery type A V OK MENU A V OK MENU MRK AE Factory adjust Liquid 7 OK MENU A V OK MENU Battery type Factory adjust Gel A V OK MENU eee rr Battery type F 5 w Liquid actory adjust A V OK MENU Done _ A V OK MENU Figure 4 Change the battery type Figure 5 Reset to Factory Pre Set configuration Note 1 If you want to make sure that you have programmed correctly press only OK and move through all submenu items to check the values Do not press the arrow keys while checking or you will change the values 2 If you have programmed a wrong value you will reach the window with the undesired value again and press OK to change the value to the correct one by pressing the arrow keys A Y Page10 13 Pages 8 Safety Measu
13. negative Lin shows the charging current at the moment When the voltage of the battery is getting near the final charge voltage the solar charge controller will regulate the Iin in order to protect the battery from being overcharged The charge current lin is lower than the module current Temp displays the environment temperature of the solar charge controller The solar charge controller status such as Fast charging Equal charging Boost charging Float charging and No Charging indicate which stage of charging is in process After a certain period of time of operation in Load on 88 50 8 26 00 lin 264A 88 50 8 00 15 Temp 25 C 88 50 8 17 15 Boost charging 88 50 8 00 15 the Boost and Equal charging modes the Float charge mode is resumed The content displays the current load state Load on means the load has been opened Load off means the load is in a closed state Page4 13 Pages 7 Operating the solar charge controller 7 1 Factory Pre Set configurations With the factory pre set configurations the solar charge controller can be used in most applications without further programming On delivery the controller is always set with these pre set basic configurations that enable immediate use of most typical solar systems after installation The solar charge controller can be reset to the factory pre se
14. oltage feed from the battery current operating temperature is too high or too low above below the operating temperature causing LCD not to function e Check the battery connections and fuses e Check the working temperature Reinstall the controller disconnect everything and connect it again in the right order Pagel12 13 Pages 10 Technical Data Max1048 Max10HV System voltage 48 V Fixed Max solar current or load current Float voltage 10A 51 7 58 0V Default 54 8V 25 C Fast voltage 56 0V 25 C Boost voltage 51 8 64 0V Default 58 0V 25 C Equal voltage 53 0 64 0V Default 59 2V 25 C Day Night threshold 12 0 30 0V Default 12V Load disconnect voltage Voltage 20 70 Default 30 44 0 50 0V Default 44 4V Load reconnect Soc 40 90 Default 50 voltage Voltage 47 2 53 2V Default 50 4V Battery type Nominal capacity Low voltage protection mode Load mode Liquid Gel 10Ah 9990Ah Default 300Ah Soc Voltage Auto Standard Timer Light on delay 00 00 02 00 Internal 5min Light off delay Night time 1 00 00 02 00 Internal 5min 00 00 09 00 Internal 15min Night time 2 Temperature compensation 00 00 09 00 Internal 15min 4 17 mV K per cell Boost and Equal charge 3 33 mV K per cell Float charge Max solar voltage 110V Max battery voltage 80V
15. onsumption exceeds the max discharge currents or the max Pulse currents were exceeded by using high surge appliances Switch off all loads Remove the fault the controller will switch on load automatically after 1 minute Low voltage Battery has low capacity To protect the battery all loads powered by the solar charge controller will be disconnected The maximum allowable temperature has been exceeded In order to reduce further heat generation the loads are disconnected automatically As soon as the solar charge controller has cooled down normal operation will resume e Reduce loads or hours of operation of loads to keep the battery from being discharged deeply or increase solar array to add energy to the system e Connect all loads through the controller to avoid strong discharge of the battery e It will restore only when the battery being recharged and the voltage reaching the reconnect voltage e Check the ventilation at the back heat sink and clean it if necessary Protect the controller from direct sunshine e Reduce warming caused by appliances near the controller e Reduce the loads or PV modules In particular the recharge process through back up generators or chargers tied directly to the battery causes battery voltages higher than 66 0V Disconnect external chargers when the battery voltage is lower than 62 0V controller automatically restored LCD has no display e There is no v
16. r programming 51 8 64 0V Default 58 0V Page6 13 Pages Equal charge 59 2V D N threshold 12 0V Disconnect Soc 30 econnect Soc 50 Equal voltage settings Press the OK button to enter the menu press A Y to change the value Note 1 The equalisation charging can only be adjusted for batteries with liquid electrolyte since high equalising voltages are harmful for sealed batteries The maximum equalising voltage value should be stated on the battery manufacturer s data sheet 2 This window is deactivated if you have selected Gel with the menu CONF 3 Battery charging voltage is passed on directly to the loads by the solar charge controller Therefore during equal charging high charging voltages can be programmed that may damage some loads Please select this equal charge voltage very carefully and compare the desired value to the battery and load appliance manufacturers data sheets Possibilities for programming 53 0 64 0V Default 59 2V Note The fast charge voltage is fixed at 56 0V users do not have their own set Day Night threshold settings Press the OK button to enter the menu press A Y to change the value The controller recognizes day and night based on the solar array open circuit voltage only functional in street light mode This day night threshold can be modified according to local light conditions and the solar array used Possibilities for programming 12
17. res We urgently recommend the installation of a safety device on the battery pole in order to prevent damage from short circuits between battery and the solar charge controller 8 1 Electronic Short Circuit Safety An electronic short circuit safety device is built into the solar charge controller and prevents both destruction of the solar charge controller and the blowing of the safety fuse in case of short circuits on the load terminals The second line of the LCD display indicates this error as Short circuit After elimination of this fault the solar charge controller automatically switches back to normal operation after about 60 seconds 8 2 Hardware Safety In addition to the electronic fuse device mentioned above the solar charge controller has also been protected by regular fuses which have been rated far beyond nominal currents to prevent false blowing of the fuses during surges The safety fuses are wired in parallel In order to prevent fuses from blowing in the case of high currents over a short period of time a high value has been selected Before the fuses blow the electronic safety fuse should prevent any excessive current flow 8 3 Safety Features Solar terminal Battery terminal Load terminal Reverse polarity Protected 1 Protected 1 Protected 2 Short circuit Protected Protected 3 Switches off immediately Over current Switches off with delay Reverse Current Protected Over voltage Max 110V 4 Max 80V
18. ress the OK button to enter the menu and press the OK MENU button simultaneously to reset the solar charge controller Note If you press OK MENU all settings and values will be reset and the execution will be confirmed by Done 7 4 Menu Prog System parameter settings In this menu you can set the charging parameters Day Nigh threshold LVD and LVR data Press to enter the menu Note We have tried to insure that the values are limited within ranges that do not damage the battery immediately However certain skills are needed as far as battery behaviour is concerned to prevent long term damage or poor system performance If you are unsure about any of these settings please refer to your authorised dealer or leave the pre set configurations as they are Float charge 54 8V Boost charge 58 0V Float voltage settings Press the OK button to enter the menu press A Y to change the value Note The float voltage serves for maintaining the charge in the battery for long periods and preventing self discharge This voltage should not be too high since this may lead to permanent gassing which damages the battery Maximum values are stated on the battery data sheet of your battery For most types of liquid battery this float value is 54 8V Possibilities for programming 51 7 58 0V Default 54 8V Boost voltage settings Press the OK button to enter the menu press A W to change the value Possibilities fo
19. roller from dirt and moisture Mount upright on the wall on a non flammable substrate Maintain a minimum clearance of 10cm below and around the device to ensure unhindered air circulation Mount the solar charge controller as close as possible to the batteries 5 2 Fastening the solar charge controller Mark the position of the solar charge controller fastening holes on the wall drill 4 holes and insert dowels fasten the solar charge controller to the wall with the cable openings facing downwards 5 3 Preparation of wiring Mode Max current Diamete mm Max1048 1 OA 10 Max2048 20A 16 Max3048 30A 16 5 4 Connection We strongly recommend connecting a fuse directly to the battery to protect any short circuit at the battery wiring Solar PV modules create current whenever light strikes them The current created varies with the light intensity but even in the case of low levels of light full voltage is given by the modules So protect the solar modules from incident light during installation Never touch uninsulated cable ends use only insulated tools and make sure that the wire diameter is in accordance with the solar charge controller s expected currents Connections must always be made in the sequence described below Figure 1 System wiring diagram 1st step Connect the battery Connect the battery connection cable with the correct polarity to the middle pair of terminals on the solar charge controller with the bat
20. t configurations at any time with the Menu CONF 7 2 Main Menu Set values and functions can be adjusted with the four control keys on the panel By pressing the key under the MENU a Main Menu appears in the display Conf System module settings Prog System parameter settings Load Load mode settings and Logg Inquiry of internal data logger By pressing the key below the corresponding abbreviation you can enter the corresponding menu Figure 2 Programming Menu After entering the corresponding menu the following actions can be set or viewed the appropriate information yYou can use the keys A Y to select sub menu and press the OK button to enter the sub menu After entering the sub menu press A Y to change the value After setting press the OK button to save the set value and return to the previous menu level Pressing the MENU key will exit the setting bring the display back to the normal Main Menu P Note LIf you did not carry out any operation within 60s after entering the setup menu the controller will automatically exit the menu programming and the normal indication of running status appears 2 If there are no adjustments on an activated submenu value being changed the display indication jumps to the main menu and the adjustment in the open window is not stored or applicable Figure 2 Programming Menu 88 50 8 26 18
21. tery symbol If the system is 48V please make sure that the battery voltage is within 40V 64V If the polarity is correct the LCD screen on the controller will begin to show 2nd step Connect the solar module Ensure that the solar module is protected from incident light Ensure that the solar module does not exceed the maximum permissible input current Connect the solar module connection cable to the correct pole of the left pair of terminals on the solar charge controller with the solar module symbol 3rd step Connect loads Connect the load cable to the correct pole of the right pair of terminals on the solar charge controller with the lamp symbol To avoid any voltage on the wires first connect the wire to the load then to the controller Ath step Final work Fasten all cables with strain relief in the direct vicinity of the solar charge controller clearance of approx 10cm Page2 13 Pages 5 5 Grounding Be aware that the positive terminals of the controller are connected internally and therefore have the same electrical potential If any grounding is required always do this on the positive wires Figure 1 System wiring COM TEM Fema SOC BAT IN OUT O O A V OK MENU Max series Solar charge controller O O Smo m2 94 Remark If the device is used in a vehicle which has the
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