POWLSOJX MPPT Solar Charge Controller User Manual

1. Introduction

The POWLSOJX MPPT Solar Charge Controller is an advanced power management unit designed to efficiently charge 12V and 24V battery systems from solar photovoltaic (PV) panels. Utilizing Maximum Power Point Tracking (MPPT) technology, it optimizes energy harvesting from your solar array, ensuring maximum power delivery to your batteries. This controller is compatible with various battery types, including Lead-Acid, AGM, Gel, FLD, and Lithium (LiFePO4), and features comprehensive protection functions to safeguard your solar system.

It also includes dual USB outputs (5V/3A max) for convenient charging of mobile devices.

Figure 1: Front view of the POWLSOJX MPPT Solar Charge Controller

2. Key Features

• Innovative MPPT Design: Tracking efficiency up to 99%, peak conversion efficiency up to 98%.
• Automatic Identification: Compatible with 12V and 24V battery systems.
• Versatile Battery Compatibility: Supports Lead-Acid, AGM, Gel, FLD, and Lithium (LiFePO4) batteries.
• 4-Stage Charging: Bulk charge, boost charge, float charge, and equalization for optimal battery health.
• Comprehensive Protection: Overcharge, over-discharge, reverse polarity, short circuit, overheating, overpower, overload, and TVS lightning protection.
• Efficient Heat Dissipation: Features aluminum profiles and dual fan cooling for stable operation.
• Dual USB Output: 5V/3A (max) for charging external devices.

3. Setup and Installation

3.1 Package Contents

Before installation, please verify that all components are present:

• POWLSOJX MPPT Solar Charge Controller
• User Manual (this document)
• Mounting Screws

Figure 2: Package Contents

3.2 Connection Diagram

Follow the connection order carefully to prevent damage to the controller or other components. Always connect the battery first, then the solar panels, and finally the load.

1. Connect the Battery: Connect the battery to the controller's battery terminals. Ensure correct polarity (+ to + and - to -). The controller will automatically detect 12V or 24V system voltage.
2. Connect the Solar Panels: Connect the solar panels to the controller's PV terminals. Ensure correct polarity. The controller supports PV input voltage from 18V to 100V.
3. Connect the DC Load (Optional): Connect your DC loads to the controller's load terminals. Ensure correct polarity.

Figure 3: System Connection Diagram

3.3 Battery Type Selection

The controller is compatible with various battery types. Ensure you select the correct battery type in the settings to optimize charging and prolong battery life.

Figure 4: Compatible Battery Types

4. Operating Instructions

4.1 LCD Display Interface

The LCD display provides real-time information about your solar system's status. Key indicators include:

• PV: Solar panel voltage and power.
• BATT: Battery voltage, charge status, and percentage.
• LOAD: Load voltage and power consumption.
• Indicators: Daytime/Nighttime, Solar panel charging, Battery discharging, Load status, Temperature, Faults, Battery type, System voltage.

Figure 5: LCD Browsing Interface

4.2 Button Functions

The controller features four buttons for navigation and settings:

• ESC: Exit current menu or return to the previous screen.
• Up Arrow (▲): Navigate up through menu options or increase values.
• Down Arrow (▼): Navigate down through menu options or decrease values.
• SET: Enter menu, confirm selection, or save settings.

Figure 6: Setup Buttons

4.3 Charging Process (4-Stage)

The controller employs a 4-stage charging algorithm to ensure efficient and safe battery charging:

1. Bulk Charge: Delivers maximum current to rapidly charge the battery.
2. Boost Charge: Once the battery reaches a certain voltage, the controller applies a higher voltage for a set period to ensure a full charge.
3. Float Charge: After the boost charge, the voltage is reduced to a lower level to maintain the battery at full capacity without overcharging.
4. Equalization: Periodically, a higher voltage is applied to equalize the charge across all battery cells, especially beneficial for flooded lead-acid batteries.

5. Maintenance

To ensure optimal performance and longevity of your POWLSOJX MPPT Solar Charge Controller, follow these maintenance guidelines:

• Regular Cleaning: Keep the controller clean and free from dust and debris. Use a dry, soft cloth for cleaning.
• Ventilation: Ensure the controller is installed in a well-ventilated area. The dual cooling fans activate automatically when needed to dissipate heat. Do not block the fan vents.
• Connection Checks: Periodically inspect all wiring connections for tightness and corrosion. Loose connections can lead to power loss or overheating.
• Environmental Conditions: Avoid exposing the controller to direct sunlight, excessive moisture, or extreme temperatures outside its operating range.

Figure 7: Dual Fan Cooling System

6. Troubleshooting

The POWLSOJX MPPT Solar Charge Controller is equipped with multiple protection features to prevent damage. If you encounter issues, refer to the following:

6.1 Protection Features

The controller includes the following built-in protections:

• Reverse Current Protection: Prevents current from flowing back to the solar panels at night.
• Reverse Polarity Protection: Protects against incorrect battery or solar panel wiring.
• Short-circuiting Protection: Safeguards against short circuits in the load or wiring.
• Overtemperature Protection: Shuts down or reduces power if the internal temperature exceeds safe limits.
• Overpower Protection: Prevents damage from excessive input power from solar panels.
• Overcharging Protection: Stops charging when the battery is full to prevent damage.
• Overload Protection: Disconnects the load if current exceeds the rated capacity.
• Over-discharging Protection: Disconnects the load to prevent deep discharge of the battery.
• TVS Lightning Protection: Provides protection against lightning strikes.

Figure 8: Certified Protection Features

6.2 Common Issues & Solutions

• No Display/Power: Check battery connections and ensure the battery has sufficient voltage.
• No Charging: Verify solar panel connections, ensure sufficient sunlight, and check for any fault indicators on the LCD.
• Load Not Working: Check load connections, ensure the battery is charged, and verify that the load current does not exceed the controller's rating.
• Fault Indicator On: Refer to the LCD display for specific fault codes and consult the manual's detailed troubleshooting section (if available in a full PDF manual) or contact support.

7. Specifications

The following table outlines the technical specifications for the POWLSOJX MPPT Solar Charge Controller:

Figure 9: Technical Specifications

7.1 Dimensions

Figure 10: Product Dimensions (Note: 40A/60A models share the same dimensions)

8. Warranty and Support

The POWLSOJX MPPT Solar Charge Controller comes with a 12-month warranty from the date of purchase. This warranty covers manufacturing defects and malfunctions under normal use. Please retain your proof of purchase for warranty claims.

For technical support, troubleshooting assistance, or warranty inquiries, please contact POWLSOJX customer service through your retailer or the official brand website.

9. User Tips

• Not an Inverter: This device is a solar charge controller, designed to manage power flow from solar panels to batteries. It does not convert DC power to AC power (it is not a pure sine wave inverter). An external inverter is required for AC loads.
• No Wi-Fi Connectivity: This model does not feature Wi-Fi connectivity for remote monitoring or control. All settings and monitoring are done directly via the onboard LCD and buttons.
• Optimal Placement: Install the controller in a cool, dry, and well-ventilated location to maximize its lifespan and efficiency, especially considering its dual fan cooling system.
• Correct Battery Type: Always ensure the correct battery type is selected in the controller's settings to prevent under- or over-charging, which can damage your batteries.