Equalizing charging
Warning:
risk of explosion!
In equalizing charging, an open lead-acid battery can produce explosive gas, therefore the
battery chamber shall have good ventilation conditions.
Note:
risk of equipment damage!
Equalizing charging may raise the battery voltage to a level that may cause damage to sensitive
DC loads. Check and make sure that allowable input voltages of all the loads in the system are
greater than the set value for battery equalizing charging.
Note:
risk of equipment 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 electrolyte,
balance the battery voltage and finish the electrochemical reaction. Equalizing charging raises the
battery voltage to a higher level than the standard supply voltage and gasify the battery
electrolyte. If the controller then automatically steers the battery into equalizing charging, the
charging duration is 120 minutes (default). In order to avoid too much generated gas or battery
overheat, equalizing charging and boost charging won’t repeat in one complete charging cycle.
Note:
1) When due to the installation environment or working loads, the system can't continuously
stabilize the battery voltage to a constant level, the controller will initiate a timing process, and 3
hours after the battery voltage reaches the set value, the system will automatically switch to
equalizing charging.
2) If no calibration has been done to the controller clock, the controller will perform equalizing
charging regularly according to its internal clock.
Floating charging
When finishing the sustaining charging stage, the controller will switch to floating charging in
which the controller lowers the battery voltage by diminishing the charging current and keeps the
battery voltage at the set value of floating charging voltage. In the floating charging process, 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 will
exit floating charging and reenter into fast charging.
2. Product Installation
2.1 Installation Precautions
Be very careful when installing the battery. For open lead-acid batteries, wear a pair of goggles
during installation, and in case of contact with battery acid, flush with water immediately.
In order to prevent the battery from being short-circuited, no metal objects shall be placed near
the battery.
Acid gas may be generated during battery charging, thus make sure the ambient environment is
well ventilated.
Keep the battery away from fire sparks, as the battery may produce flammable gas.
When installing the battery outdoors, take sufficient measures to keep the battery from direct
sunlight and rain water intrusion.
Loose connections or corroded wire may cause excessive heat generation which may further melt
the wire's insulation layer and burn surrounding materials, and even cause a fire, therefore make
sure all connections are tightened securely. Wires had better be fixed properly with ties, and
when needs arise to move things, avoid wire swaying so as to keep connections from loosening.
When connecting the system, the output terminals' voltage may exceed the top limit for human
safety. If operation needs 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 criterion that the current density is
not larger than 4A/mm2.
Connect the controller's earth terminal to the ground.
2.2 Wiring Specifications
Wiring and installation methods must comply with national and local electrical specifications.
The wiring specifications of the battery and loads must be selected according to rated currents,
and see the following table for wiring specifications:
Model
ML4860
Rated charging
current
Rated discharging
current
Battery wire
diameter (mm2)
Load wire
diameter (mm2)
Battery voltage
compensation wire
60A
20A
>
15
<5
No requirements
2.3 Installation and Wiring
Warning:
risk of explosion! Never install the
controller and an open battery in the same
enclosed space! Nor shall the controller be
installed in an enclosed space where battery gas
may accumulate.
Warning:
danger of high voltage! Photovoltaic
arrays 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 enclosed box,
make sure the box delivers reliable heat
dissipation effect.
≥
150mm
Hot air
≥
150mm
Cold air
Fig. 2.1 Installation and heat dissipation
5
6
!
!
!
