MPPT MPPT-DC Series - User Manual

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Summary

Safety and Liability

Safety Instructions

Guidelines for safe operation and handling of the solar charge controller and batteries.

Liability Exclusion

Details the manufacturer's limitations of responsibility for improper use or installation.

Installation

Connection Sequence

Step-by-step instructions for correctly connecting the solar panel, battery, and load.

Transportation Mode

Open Circuit Protection

Controller enters transport mode if only battery is connected and no solar/load for 5 minutes.

Test Key in Transport Mode

How to activate or confirm transport mode using the remote controller's test key.

Exit Transportation Mode

Procedure to terminate transport mode by connecting load and solar panel.

Remote Controller Settings

Test Function

Activates the load for 10 seconds using the remote controller's test key.

Read Parameters

Accessing and viewing the controller's configured setting parameters via the remote.

Read Running Status

Monitoring the controller's operational status and parameters using the remote.

Controller Startup

Self Test

The controller performs a self-test upon connection to the battery.

Battery Type

Specifies compatibility with single Lithium rechargeable batteries.

0°C Charging Protection

Settings for charging at or below 0°C ambient temperature.

Streetlight Functionality

Dusk to Dawn (D2 D)

Enables automatic load operation from sunset to sunrise based on light detection.

Five-stage Night Mode

Configurable five-stage dimming profiles for nighttime lighting control.

T0 T Mode

Allows setting specific load-on times before morning, independent of dusk/dawn.

Voltage Thresholds and Dimming

Low Voltage Disconnect (LVD)

Sets the battery voltage at which the load is disconnected to prevent deep discharge.

Low Voltage Reconnect (LVR)

Sets the battery voltage required to reconnect the load after LVD.

Day;Night Threshold & Delay

Defines light levels for day/night detection and adds a delay for load switching.

Auto Dimming

Automatic adjustment of load output based on battery voltage.

LED Indicators and Faults

LED Display Explanation

Description of status and functions indicated by Green, Yellow, and Red LEDs.

Faults and Alarms

Lists common faults, their reasons, and recommended remedies for troubleshooting.

The MPPT-DC series solar charge controller with a built-in LED driver is designed for solar street light systems, offering advanced features for efficient power management and lighting control. This intelligent controller utilizes innovative Maximum Power Point Tracking (MPPT) technology to maximize energy harvest from solar panels, boasting a tracking efficiency greater than 99% and a conversion efficiency of up to 93% with full digital technology.

Function Description

The primary function of this device is to manage the charging of a single lithium battery from a solar panel and to control an LED load with constant current output. It operates in a boost mode, ensuring that the LED driver can maintain a constant current even when the battery voltage fluctuates. The controller is programmable, allowing users to customize various operational parameters to suit specific lighting requirements.

One of its key features is the integrated LED driver, which provides a constant current output to the LED load. This ensures stable and consistent lighting performance. The device supports a five-stage time and dimming adjustment, enabling precise control over the lighting schedule and intensity throughout the night. This flexibility allows for energy savings and optimized lighting based on environmental conditions or specific needs.

The controller also includes several intelligent functions to enhance system reliability and battery longevity. It can automatically adjust the dimming level if the battery voltage drops below a set threshold, helping to prevent deep discharge and extend battery life. The day/night threshold can be automatically adjusted, ensuring accurate detection of dusk and dawn for reliable lighting activation and deactivation.

For enhanced safety and convenience during transportation, the controller features an auto-sleeping function. In transport mode, the load has no output, and power consumption is significantly reduced (by about 60%), preventing the lithium battery voltage from becoming too low. The system can be activated or deactivated from transport mode through specific button presses on a remote controller or by connecting the solar panel.

Usage Features

The MPPT-DC series controller is designed for ease of use and configuration, primarily through a remote unit with an LCD display. This remote unit allows users to read parameters, monitor running status, and configure settings without direct interaction with the controller itself.

Lighting Control Modes:

Dusk to Dawn (D2D) Mode: In this mode, the load turns on at dusk and remains on until dawn. The dimming settings are still valid, allowing for customized brightness during the night.
Five-stage Night Mode: This advanced mode allows for up to five distinct time periods with independent dimming percentages. Users can set specific durations and brightness levels for different parts of the night, optimizing energy use and lighting effectiveness.
TOT Mode: This mode enables users to set the load on time before morning, providing flexibility for specific lighting schedules that might not fit the standard D2D or multi-stage profiles.

Dimming Functionality:

Manual Dimming: Users can set specific dimming percentages for each stage of the night, providing granular control over light intensity.
Auto Dimming: The controller can automatically dim the load when the battery voltage falls below a user-defined threshold. The dimming percentage can be set, and the load current will decrease proportionally, with a minimum output current of 10% of the setting. This feature helps to conserve battery power and extend the lighting duration during periods of low battery charge.

Battery Management:

Low Voltage Disconnect (LVD) and Reconnect (LVR): The controller has programmable LVD and LVR settings to protect the battery from over-discharge. If the battery voltage drops to the LVD point, the load is disconnected. It will only restore when the battery is recharged to the LVR voltage. The LVR must be at least 0.2V higher than the LVD.
Low Temperature Charging Protection: The device includes a 0°C charging protection feature, which can be configured to "Yes," "Slow," or "No." If the ambient temperature is below 0°C, the charging function can be normal, limited to 20% of the rated current, or completely disabled, depending on the user's selection. This protects the lithium battery from damage due to charging at low temperatures.
BMS Activation: If the Battery Management System (BMS) powers off due to low voltage disconnect (LVD), the controller can automatically activate the system, ensuring seamless operation.
Charging Target and Recovery Voltage: Users can set specific charging target and recovery voltages, allowing for fine-tuning of the charging process to match battery specifications and optimize performance.

Monitoring and Diagnostics:

The remote unit allows users to read various parameters and running statuses, including battery voltage, load current, load voltage, PV voltage, PV current, total generating capacity (AH), over-discharge times, and fully charge times. Historical data, such as the highest and lowest voltages for the past three days, is also accessible.

Safety Features:

The controller incorporates comprehensive safety features to protect itself, the battery, and the solar panel:

Reverse Polarity Protection: Protects the solar terminal, battery terminal, and load terminal from damage due to incorrect wiring.
Short Circuit Protection: Automatically switches off the load immediately in case of a short circuit. For the PV array, it is protected if a short circuit occurs when not charging, but it is forbidden to short-circuit the PV array during charging.
Over Current Protection: Switches off the load with a delay if an overcurrent condition is detected.
Over Voltage Protection: Protects against excessive voltage from the solar panel (up to 25V for MPPT2050-DC32Li and 34V for MPPT3050-DC32LIG) and the battery (up to 10V).
Under Voltage Protection: Switches off the load if the battery voltage drops below a safe threshold.
Over Temperature Protection: Cuts off the load if the controller's internal temperature reaches a set value, preventing damage from overheating.

LED Indications and Faults & Alarms:

The controller provides clear LED indications for various operational statuses and fault conditions.

Green LED: Indicates solar panel connection (on), MPPT charging (fast flash), or normal charging (slow flash). An off state signifies over voltage protection.
Yellow LED: Indicates battery status (normal when on, low voltage when slow flash, low voltage protection when fast flash). An off state means normal operation.
Red LED: Indicates output power (on for 0 output), open circuit or transport mode (slow flash), over temperature protection (flash), or short circuit/over current protection (fast flash). Detailed fault information can also be read via the S-Unit remote controller.

Maintenance Features

The MPPT-DC series controller is designed for durability and minimal maintenance. It features an IP67 rating, indicating strong protection against dust and water ingress, making it suitable for outdoor installations. The robust aluminum case further contributes to its longevity.

While the device itself requires little maintenance, the manual emphasizes the importance of proper installation and adherence to safety guidelines to ensure long-term reliability. Users are advised to:

Ensure the wire length between the battery and controller is as short as possible to minimize voltage drop.
Use recommended minimum wire sizes for optimal performance and safety.
Connect a fuse directly to the battery to protect against short circuits.
Ensure adequate ventilation in the battery room to prevent the accumulation of flammable gases.
Avoid touching or short-circuiting wires or terminals, especially those with high voltages.
Keep children away from batteries and the charge controller.

In case of faults or alarms, the LED indications provide immediate feedback. For more detailed diagnostics and troubleshooting, the S-Unit remote controller can be used to read specific fault information. The manual also provides a table of common faults, their reasons, and recommended remedies, such as checking battery capacity, switching off loads, or inspecting wiring and connections. It is crucial to address and remove any error conditions before continuing to connect the controller to prevent potential damage.

The controller's ability to automatically adjust day/night thresholds and dimming based on battery voltage helps to reduce the need for manual intervention and ensures optimal system performance over time. The low temperature charging protection further enhances battery life by preventing charging under conditions that could cause damage.