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Maximum Power Point Tracking (MPPT) Series

MPPT40

Solar Charge Controller

User Manual

More information https://www.caravansplus.com.au

Summary of Contents for 500-06222

Page 1: ...Maximum Power Point Tracking MPPT Series MPPT40 Solar Charge Controller User Manual More information https www caravansplus com au ...

Page 2: ... it before reading this manual carefully and completing safety operation training 2 The controller has no internal components that need maintenance or service thus do not attempt to disassemble or repair the controller 3 Install the controller indoors and avoid component exposure and water intrusion 4 During operation the radiator may reach a very high temperature therefore install the controller ...

Page 3: ...d you should get properly prepared before proceeding Note means the operation in question may cause damage Tips means advice or instruction for the operator Table of Contents 1 Product Introduction 4 1 1 Product Overview 4 1 2 Product Features 5 1 3 Exterior and Interfaces Error Bookmark not defined 1 4 Introduction to Maximum Power Point Tracking Technology 8 1 5 Charging Stages Introduction 10 2...

Page 4: ...king the highest voltage and current values VI in real time enabling the system to charge the battery in maximum power It s designed to be used in off grid solar photovoltaic systems to coordinate operation of the solar panel battery and load functioning as the core control unit in off grid photovoltaic systems This product features an LCD screen which can dynamically display the operating status ...

Page 5: ...tracking efficiency of up to 99 9 Advanced digital power supply technologies raise the circuit s energy conversion efficiency to as high as 98 Charging program options are available for different types of batteries including gel DEFAULT Setting sealed open lithium batteries etc The controller features a limited current charging mode When the solar panel power exceeds a certain level and the chargi...

Page 6: ...perature protection mechanism When temperature surpasses the set value the charging current will decline in linear proportion to the temperature so as to curb the temperature rise of the controller effectively keeping the controller from being damaged by overheating Featuring a temperature compensation function the controller can automatically adjust charging and discharging parameters in order to...

Page 7: ...ad interface 5 LCD screen 14 External temperature sampling interface 6 Operating keys 15 RS232 communication interface 7 Installation hole 8 Solar panel interface No Definition 1 Transmitting terminal TX 2 Receiving terminal RX 3 Power supply grounding Signal grounding 4 Power supply grounding Signal grounding 5 Power supply positive 6 Power supply positive More information https www caravansplus ...

Page 8: ...Take a 12V system as an example As the solar panel s peak voltage Vpp is approximately 17V while the battery s voltage is around 12V when charging with a conventional charge controller the solar panel s voltage will stay at around 12V failing to deliver the maximum power However the MPPT controller can overcome the problem by adjusting the solar panel s input voltage and current in real time reali...

Page 9: ...he environmental conditions in real time so as to always keep the system close to the max operating point The whole process is entirely automatic without the need of human intervention Fig 1 3 Relation between solar panel output characteristics and illumination 光照降低电流减小光照降低开路电压减小 U V I A Current decreases with dwindling light Open circuit voltage decreases with dwindling light More information ...

Page 10: ...izing charging etc to complete charging the battery A complete charging process includes fast charging sustaining charging and floating charging The charging curve is as shown below 20 50 70 60 40 30 太阳板温度 I A U V 温度降低电流不变功率增大温度升高开路电压减小 With temperature dropping current stays stable and power increases Solar panel temperature Open circuit voltage decreases with rising temperature More info...

Page 11: ... begin b Sustaining charging When the battery voltage reaches the set value of sustaining voltage the controller will switch to constant voltage charging In this process no MPPT charging will be performed and meanwhile the charging current will also gradually decrease The sustaining charging stage itself consists of two sub stages i e equalizing charging and boost charging the two of which are not...

Page 12: ...quipment damage Overcharge or too much gas generated may damage battery plates and cause active material on the battery plates to scale off Equalizing charging to an excessively high level or for too long a period may cause damage Read carefully the actual requirements of the battery deployed in the system Some types of batteries benefit from regular equalizing charging which can stir the electrol...

Page 13: ...ocess very light charging is carried out for the battery to maintain it at full state At this stage the loads can access almost all the solar power If the loads consume more power than the solar panel could provide the controller will not be able to keep the battery voltage at the floating charging stage When the battery voltage drops to the set value for returning to boost charging the system wil...

Page 14: ...to be done be sure to use insulation tools and keep hands dry The wiring terminals on the controller can be connected with a single battery or a pack of batteries Following descriptions in this manual apply to systems employing either a single battery or a pack of batteries Follow the safety advice given by the battery manufacturer When selecting connection wires for the system follow the criterio...

Page 15: ...s may produce a very high open circuit voltage Open the breaker or fuse before wiring and be very careful during the wiring process Note when installing the controller make sure that enough air flows through the controller s radiator and leave at least 150 mm of space both above and below the controller so as to ensure natural convection for heat dissipation If the controller is installed in an en...

Page 16: ... Step 2 first place the installation guide plate at a proper position use a marking pen to mark the mounting points then drill 4 mounting holes at the 4 marked points and fit screws in Step 3 fix the controller Aim the controller s fixing holes at the screws fit in Step 2 and mount the controller on Hot air Cold air Fig 2 1 Installation and heat dissipation More information https www caravansplus ...

Page 17: ... and then begin wiring operation In order to guarantee installation safety we recommend the following wiring order however you can choose not to follow this order and no damage will be incurred to the controller More information https www caravansplus com au ...

Page 18: ... finally the solar panel When wiring follow the order of first and then 4 Power on After connecting all power wires solidly and reliably check again whether wiring is correct and if the positive and negative poles are reversely connected After confirming that no faults exist first close the fuse or breaker of the battery then see whether the LED indicators light up and the LCD screen displays info...

Page 19: ...on distance be not more than 150mm 2 If no remote temperature sensor is connected to the controller the battery temperature value will stay at 25 C 3 If an inverter is deployed in the system directly connect the inverter to the battery and do not connect it to the controller s load terminals 3 Product Operation and Display 3 1 LED Indicators 1 PV array indicator Indicating the controller s current...

Page 20: ... 2s with on and off each lasting for 0 1s Equalizing charging 5 Double flashing a cycle of 2s with on for 0 1s off for 0 1s on again for 0 1s and off again for 1 7s Current limited charging 6 Off No charging 常亮最大功率充电慢闪提升充电单闪浮充充电快闪均衡充电双闪限流充电 1 2 3 4 5 Steady on charging in max power Slow flashing boost charging Single flashing floating charging Quick flashing equalizing charging Double fla...

Page 21: ...0 2s with on and off each lasting for 0 1s Battery over voltage LOAD indicator Indicator state Load state Off Load turned off Quick flashing a cycle of 0 2s with on and off each lasting for 0 1s Load overloaded short circuited Steady on Load functioning normally ERROR indicator Indicator state Abnormality indication Off System operating normally More information https www caravansplus com au ...

Page 22: ...n Return to previous menu exit without saving Set Enter into sub menu set save Turn on off loads in manual mode 3 3 LCD Startup and Main Interface Nighttime Daytime Solar panel Charging Battery Discharging Load Parameter value Charging stage System voltage Setting Serial port Bluetooth Abnormality Battery type Unit More information https www caravansplus com au ...

Page 23: ...lash successively and after self inspection the LCD screen starts and displays the battery s voltage level which will be either a fixed voltage selected by the user or a voltage automatically recognized 3 3 2 Main interface More information https www caravansplus com au ...

Page 24: ...hen no sunlight is present the solar panel voltage is lower than the light control on voltage and after a time delay the controller will switch on the load The load will be switched off after working for a preset period of time 15 Manual mode Default In this mode the user can switch the load on or off by the keys no matter whether it s day or night This mode is designed for some specially purposed...

Page 25: ...main interface 3 5 System Parameter Settings Under any interface other than load modes press and hold the Set key to enter into the parameter setting interface After entering into the setting interface tap the Set key to switch the menu for setting and tap the Up or Down key to increase or decrease the parameter value in the menu Then tap the Return key to exit without saving parameter setting or ...

Page 26: ... flooded Sealed Gel Li GEL 2 VOLT OF SYS System voltage 12V 24V AUTO 3 EQUALIZ CHG Equalizing charging voltage 9 0 to 17 0V 4 BOOST CHG Boost charging voltage 9 0 to 17 0V 14 2V 5 FLOAT CHG Floating charging voltage 9 0 to 17 0V 13 8V 6 LOW VOL RECT Over discharge recovery voltage 9 0 to 17 0V 12 6V 7 LOW VOL DISC Over discharge voltage 9 0 to 17 0V 11 0V Table 3 4 Product Protection Function and ...

Page 27: ...lved normal operation will resume Load overpower protection When the load power exceeds the rated value the load will enter into delay protection Load short circuit protection When the load is short circuited the controller can implement protection in a quick and timely manner and will try to switch on the load again after a time delay This protection can be carried out up to 5 times a day Users c...

Page 28: ...isplayed errors and take corrective measures if necessary Check all wiring terminals for any sign of corrosion insulation damage overheat combustion discoloration and tighten the terminal screws firmly Check if there are any dirt nesting insects or corrosion and clean as required If the lightening arrester has lost its efficacy replace it with a new one timely to prevent the controller and even ot...

Page 29: ...cator steady on 5 E4 Load short circuit LOAD indicator flashing quickly ERROR indicator steady on 6 E5 Load overloaded LOAD indicator flashing quickly ERROR indicator steady on 7 E6 Over temperature inside controller ERROR indicator steady on 9 E8 Photovoltaic component overloaded ERROR indicator steady on 11 E10 Photovoltaic component over voltage ERROR indicator steady on 12 E13 Photovoltaic com...

Page 30: ...rent 40A Rated load current 20A Max capacitive load capacity 10000uF Max photovoltaic system input power 260W 12V 520W 24V 400W 12V 800W 24V 550W 12V 1100W 24V Conversion efficiency 98 MPPT tracking efficiency 99 Temperature compensation factor 3 0mv C 2V default Operating temperature 35 C to 45 Protection degree IP32 Weight 2kg Communication method RS232 Altitude 3000m Product dimensions 238 173 ...

Page 31: ... 6V 10 6V 10 6V 9 to 17V Over discharge time delay 5s 5s 5s 1 to 30s Equalizing charging duration 120 minutes 120 minutes 0 to 600 minutes Equalizing charging interval 30 days 0 days 30 days 0 to 250D 0 means the equalizing charging function is disabled Boost charging duration 120 minutes 120 minutes 120 minutes 10 to 600 minutes When selecting User the battery type is to be self customized and in...

Page 32: ... Discharging limit voltage Boost return voltage Low voltage cut off return voltage 6 Conversion Efficiency Curve 6 1 12V System Conversion Efficiency MPPT 12V conversion efficiency 12V battery Output power W Conversion efficiency More information https www caravansplus com au ...

Page 33: ...ency 7 Product Dimensions MPPT40 MPPT 24V conversion efficiency 24V battery Output power W Conversion efficiency Product dimensions Hole positions Hole diameter Applicable wire max 8 AWG More information https www caravansplus com au ...

Page 34: ...schedules 3 2 The claim listed in clause 3 1 may be made in person or the claim may be sent to the address listed on this form including the particulars required under clauses 3 1 i and 3 1 ii 3 3 The appropriate form for making a claim for warranty is as attached 4 DURATION OF WARRANTY 4 1 This warranty will cease i where the Goods are purchased already fitted in or as a component of a vehicle or...

Page 35: ...vice or use the Goods in accordance with the specifications and instructions provided by the Manufacturer including a failure to comply with the relevant maintenance schedule where applicable ii the Supplier cannot establish any Defect in the Goods after testing iii the Goods have been used other than for the purpose for which they were designed iv the Goods have been subject to abnormal condition...

Page 36: ...Description of defects Give as much detail as possible Use a separate page if required Date of purchase services provided I hereby declare that the information provided above is true and correct and to the best of my knowledge and belief and I have complied with all the conditions of the warranty Signed Name please print Dated Please note the issue or completion of this form by the Client does not...

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