POWLSOJX MPPT Solar Charge Controller User Manual

1. Introduction

The POWLSOJX MPPT Solar Charge Controller is designed to efficiently manage power flow from your solar panels to your battery bank, ensuring optimal charging and system protection. Featuring advanced Maximum Power Point Tracking (MPPT) technology, it maximizes energy harvest even under varying light conditions. This controller is compatible with 12V and 24V battery systems and supports various battery types, including lead-acid, AGM, gel, FLD, and lithium batteries.

2. Safety Instructions

• Ensure all wiring is correct and secure before connecting power.
• Do not attempt to repair the controller yourself. Contact qualified personnel for service.
• Install the controller in a well-ventilated area, away from flammable materials.
• Avoid direct sunlight and moisture exposure.
• Always connect the battery first, then the solar panel, and finally the load. Disconnect in reverse order.
• Wear appropriate personal protective equipment (PPE) when working with electrical systems.

3. Setup and Installation

3.1 Package Contents

Verify that all items are present in the package:

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

3.2 Mounting the Controller

Mount the controller vertically on a flat, non-flammable surface in a dry, well-ventilated indoor area. Ensure sufficient clearance around the controller for proper heat dissipation, especially for the cooling fans.

3.3 Wiring Connection Diagram

Follow the wiring sequence 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 to the controller's battery terminals. Ensure correct polarity (+ to + and - to -).
2. Connect the solar panels to the controller's PV terminals. Ensure correct polarity.
3. Connect the DC load to the controller's load terminals. Ensure correct polarity.

The controller automatically identifies 12V or 24V system voltage upon battery connection.

4. Operating Instructions

4.1 Display Interface

The controller features an intuitive display that provides real-time information about your solar system's performance. The display shows various parameters for PV (solar panel), BATT (battery), and LOAD (output) sections.

Key indicators and their meanings:

• PV: Solar panel voltage, current, and power.
• BATT: Battery voltage, charge current, and state of charge (%).
• LOAD: Load current and power consumption.
• Settings: Indicates access to configuration menus.
• Load time: Configurable load operating hours.
• Abnormality/Fault: Alerts for system errors or protection activations.
• Battery type: Currently selected battery chemistry (e.g., USE, FLD, GEL, SLD, LI).
• System voltage: Detected system voltage (12V, 24V, 36V, 48V - though product states 12/24V auto).

4.2 Setup Buttons

The controller has four buttons for navigation and parameter adjustment:

• ESC: Exits current menu or cancels an operation.
• Up Arrow: Navigates up through menu options or increases a value.
• Down Arrow: Navigates down through menu options or decreases a value.
• SET: Enters a menu, confirms a selection, or saves a setting.

Refer to the full manual (if available) for detailed instructions on navigating menus and adjusting parameters like battery type, load control modes, and charging voltages.

4.3 4-Stage Charging Algorithm

The controller employs a 4-stage charging process to optimize battery health and longevity:

1. Bulk Charge: Delivers maximum current to rapidly charge the battery until it reaches a set voltage.
2. Boost Charge: Continues charging at a higher voltage for a limited time to ensure full charge absorption.
3. Float Charge: Maintains the battery at a lower voltage to compensate for self-discharge and keep it fully charged.
4. Equalization: Periodically overcharges flooded lead-acid batteries to balance cell voltages and prevent sulfation (not applicable to all battery types).

4.4 USB Output

The controller includes dual USB outputs (5V/3A max) for charging mobile phones, tablets, and other USB-powered devices.

5. Maintenance

Regular maintenance ensures the longevity and optimal performance of your solar charge controller.

• Cleanliness: Keep the controller clean and free from dust. Use a dry cloth to wipe the exterior.
• Connections: Periodically check all wiring connections for tightness and corrosion. Loose connections can cause overheating and poor performance.
• Ventilation: Ensure the installation area remains well-ventilated. The controller uses dual cooling fans for efficient heat dissipation. Blocked vents can lead to overheating.
• Fan Operation: The cooling fans start automatically when the internal temperature is high. Ensure they are not obstructed and are operating correctly.

6. Troubleshooting

The controller is equipped with comprehensive protection features to prevent damage. If an issue occurs, the "Abnormality/Fault" indicator on the display may activate.

6.1 Common Protections and Solutions

• Reverse Current Protection: Prevents current from flowing back to the solar panels at night. (Automatic)
• Reverse Polarity Protection: Protects against incorrect battery or solar panel wiring. Check and correct wiring.
• Short-circuiting Protection: Shuts down output if a short circuit is detected on the load or battery terminals. Identify and remove the short circuit.
• Overtemperature Protection: Reduces power or shuts down if the controller overheats. Ensure proper ventilation and clear any obstructions from cooling fans.
• Overpower Protection: Limits input power from solar panels if it exceeds the controller's capacity. (Automatic)
• Overcharging Protection: Stops charging when the battery is full to prevent overcharge. (Automatic via 4-stage charging)
• Overload Protection: Shuts down load output if the connected load exceeds the controller's rated load current. Reduce the load.
• Over-discharging Protection: Disconnects the load when battery voltage drops below a safe level to prevent deep discharge. Recharge the battery.
• TVS Lightning Protection: Provides protection against lightning strikes. (Built-in)

If the issue persists after checking these points, contact customer support.

7. Specifications

Detailed technical specifications for the POWLSOJX MPPT Solar Charge Controller.

Note: The "Rated Load Current" of 20A appears to be a general specification for the load output, not directly tied to the controller's main current rating (40A/60A) which refers to the charging current capacity.

7.1 Dimensions

8. User Tips

• Proper Sizing: Ensure your solar panel array and battery bank are appropriately sized for your controller's capacity (e.g., 40A or 60A model) to maximize efficiency and prevent overload.
• Battery Type Selection: Always select the correct battery type in the controller's settings to ensure accurate charging profiles and prevent battery damage.
• Monitor Performance: Regularly check the display for PV input, battery state, and load output to ensure your system is operating as expected.
• Ventilation is Key: Good airflow around the controller is vital, especially in warmer climates, to allow the dual cooling fans to work effectively and prevent thermal derating.
• USB Charging: Utilize the dual USB ports for convenient charging of small electronic devices, but be mindful of the total load on the system.

9. Warranty and Support

The POWLSOJX MPPT Solar Charge Controller comes with a 12-month warranty from the date of purchase, covering manufacturing defects.

For technical support, warranty claims, or any questions regarding your product, please contact the seller or manufacturer directly through your purchase platform. Please have your purchase details and model number ready when contacting support.