ECGSOLAX 60A MPPT Solar Charge Controller

1. Introduction

This manual provides important safety, installation, and operating instructions for the ECGSOLAX 60A MPPT Solar Charge Controller (Model EG4860). This advanced Maximum Power Point Tracking (MPPT) technology controller is designed for solar systems, offering a conversion efficiency of up to 97%. It supports 12V, 24V, 36V, and 48V battery banks and features a 3-stage charging process to optimize battery performance.

Please read this manual carefully before installation and operation to ensure safe and proper use of the controller and to maximize its benefits for your solar system.

2. Important Safety Instructions

Please save these instructions. This manual contains important safety, installation, and operating instructions for the charge controller. The following symbols are used throughout the manual to indicate potentially dangerous conditions or important safety information:

• WARNING: Indicates a potentially dangerous condition. Use extreme caution when performing this task.
• CAUTION: Indicates a critical procedure for safe and proper operation of the controller.
• NOTE: Indicates a procedure or function that is important to the safe and proper operation of the controller.

2.1 General Safety Information

• Read all instructions and cautions in the manual before beginning installation.
• There are no serviceable parts for this controller. DO NOT disassemble or attempt to repair the controller.
• DO NOT allow water to enter the controller.
• Make sure all connections going into and from the controller are tight.
• When making connections, ensure there are no flammable materials or gases near the installation area, and ensure the area is cool. Sparks may occur during connections.

2.2 Charge Controller Safety

• WARNING: NEVER connect the solar panel array to the controller without a battery. The battery must be connected first.
• Ensure input voltage does not exceed 190 VDC to prevent permanent damage. Use the Open Circuit Voltage (Voc) to make sure the voltage does not exceed this value when connecting panels together.
• WARNING: Connect battery terminals to the charge controller BEFORE connecting the solar panel(s) to the charge controller. NEVER connect solar panels to the charge controller until the battery is connected.
• WARNING: DO NOT connect any inverters or battery chargers into the load terminal of the charge controller.
• Once equalization is active in battery charging, it will not exit this stage unless there is adequate charging current from the solar panel. There should be NO load on the batteries when in the equalization charging stage.

2.3 Battery Safety

• Use only sealed lead-acid, flooded, gel, or lithium batteries which must be deep cycle.
• Explosive battery gases may be present while charging. Be certain there is enough ventilation to release the gases.
• Be careful when working with large lead-acid batteries. Wear eye protection and have fresh water available in case there is contact with battery acid.
• Carefully read battery manuals before operation.
• DO NOT let the positive (+) and negative (-) terminals of the battery touch each other. Recycle the battery when it is replaced.
• Over-charging and excessive gas precipitation may damage battery plates and activate material shedding on them. Too high of an equalizing charge or too long of one may cause damage. Carefully review the specific requirements of the battery used in the system.
• Equalization is carried out only for non-sealed / vented / flooded / wet cell lead-acid batteries.
• DO NOT equalize VRLA type AGM / Gel / Lithium cell batteries UNLESS permitted by the battery manufacturer.

3. Setup and Installation

Follow these steps for proper installation of your MPPT Solar Charge Controller.

3.1 Physical Dimensions and Mounting

The controller has dimensions of 214mm x 115mm x 50mm (8.43 x 4.53 x 1.97 inches). Ensure adequate space for ventilation, leaving a minimum of 5.91 inches (15 cm) around the controller.

• CAUTION: Use only the provided screws for mounting. Using other screws may damage the internal PCB.
• CAUTION: Apply proper torque when pushing screws into the casing to avoid damaging the internal PCB.

3.2 Wiring Instructions

Always connect components in the specified order to prevent damage.

1. 1st step: Connect the batteries

   Connect the battery connection cable with the correct polarity to the middle pair of terminals on the solar charge controller (marked with the battery symbol). If the system is 12V, ensure your battery voltage is more than 12V for the controller to boot up.

   NOTE: It is recommended to connect two wires to each BAT+ and BAT- terminal for optimal performance, similar to PV connections.

2. 2nd step: Connect the solar panel

   Ensure that the PV modules are protected from incident light during connection. Ensure the solar panel's maximum permissible input current is not exceeded. Connect the PV modules connection cable to the correct polarity of the left pair of terminals on the solar charge controller (marked with the PV modules symbol).

   NOTE: It is recommended to connect two wires to each PV+ and PV- terminal for optimal performance.
3. 3rd step: Connect loads

   Connect the load cable to the correct polarity of the right pair of terminals on the solar charge controller (marked with the lamp symbol). To avoid any voltage on the wires, connect the wire to the load before connecting to the controller.

4. 4th step: Finalize connections

   Tighten all cables connected to the controller and remove all debris around the controller, ensuring the recommended clearance of approximately 5.91 inches (15 cm) is maintained for proper ventilation.

3.3 Air Circuit Breaker Installation

We strongly recommend connecting a fuse directly to the battery to protect against short circuits. Solar PV modules generate current when exposed to light, so protect them from incident light during installation. Never touch uninsulated cable ends, use only insulated tools, and ensure wire diameter matches expected currents.

Installation Sequence for Air Circuit Breakers:

1. Install an air circuit breaker between the controller and batteries. Turn off the circuit breaker, then connect batteries to the controller with correct polarity.
2. Install an air circuit breaker between the controller and PV modules. Turn off the circuit breaker, and ensure the PV polarity is correct, then connect wires between PV modules and the controller.
3. Turn on the air circuit breaker between the controller and batteries.
4. Turn on the air circuit breaker between the controller and PV modules.
5. The controller will enter self-test mode. Its LCD will display parameters if all connections are correct. The RUN lamp (under the fan inside the casing) will flash every one second. If the controller does not respond, refer to the troubleshooting section or contact support.

4. Operation

This section details how to operate your ECGSOLAX MPPT Solar Charge Controller, including understanding the LCD display and manual settings.

4.1 LCD Display and Main Interface

The controller features a backlight LCD screen that displays various system parameters and allows for configuration.

4.2 Function Keys

The controller has three function keys for navigation and setting adjustments:

Function Key	System Mode	Operation	Operation Indication
ENTER	Setting Mode	Long Press	Exit from setting & saving the present settings data
ENTER	Setting Mode	Short Press	Enter the next setting page
UP	Setting Mode	Short Press	Adjust the parameter by increase the value
DOWN	Setting Mode	Short Press	Adjust the parameter by decrease the value
PRG/ESC	Setting Mode	Short Press	Exit SET Mode without saving data

4.3 Working Modes

The controller operates in several working modes:

• 3.0 Night Mode: No charging occurs.
• 4.0 MPPT Mode: Maximum Power Point Tracking for efficient charging.
• 7.0 Absorption Mode: Battery charging stage to fully charge the battery.
• 8.0 Floating Mode: Maintains battery at a full state of charge.

4.4 Manual Settings (LCD Display)

Reminder: The controller will work fine under default settings except for lithium batteries.

CAUTION: All steps must be carried out when the PV modules are disconnected from the controller.

1. Step 1: D00 (Load Working Time)

   Press the PRG button. The LCD displays D00. This setting is for load working time (Default is 24 hours). Press ENT until numbers flash, then press UP/DOWN to set the desired time. Long-press ENT to confirm. The output voltage is the same as the battery voltage. This load setting is only for small DC loads less than 5A current. If no load, leave it.

2. Step 2: D01 (Floating Charging Voltage)

   Press the UP button. The LCD shows 13.8 (default value). This is the default value for floating charging. Press ENT until numbers flash, then press UP/DOWN to set the desired voltage. Long-press ENT to confirm.

   CAUTION: This value is for one 12V battery. If there are multiple batteries in series, the controller will automatically multiply them in proportion, and the LCD will only display the voltage of one battery (e.g., for a 4x12V battery system, setting 14.1V will result in a 4x14.1V charge voltage, but the LCD will still show 14.1V).

3. Step 3: D02 (Absorption Charging Voltage)

   Continue to press the UP button. The LCD shows 14.5. This is the highest absorption charging voltage for the battery. Press ENT until numbers flash, then press UP/DOWN to set the desired voltage. Long-press ENT to confirm.

   CAUTION: This value is for one 12V battery. If there are multiple batteries in series, the controller will automatically multiply them in proportion, and the LCD will only display the voltage of one battery.
4. Step 4: D03 (Battery Discharge Protection)

   Continue to press the UP button. The LCD shows 10.0. This is the protection value for battery discharge. Press ENT until numbers flash, then press UP/DOWN to set the desired voltage. Long-press ENT to confirm. This means the output power from OU+ and OU- will be cut off when a 12V battery is less than 10.0V.

5. Step 5: D04 (Battery Type Setting)

   Continue to press the UP button. The LCD shows 00.00, which is the default for acid batteries. If you are using a lithium battery, press ENT until numbers flash, then press UP/DOWN to choose 01. Long-press ENT to confirm. Note that Step 2 (D01) is not applicable when 01 is chosen for lithium batteries. The voltage set in Step 3 (D02) will be the highest charging voltage for lithium batteries.

To exit the setting menu: Press ESC.

Reminder: When you set up all steps, please disconnect the battery. And reconnect the controller to see if all settings are successful. When all settings are OK, then connect PV modules to the controller.

4.5 Battery Charge Voltage Reference

5. Troubleshooting and Protections

This section provides information on common issues and the protective features of the controller.

5.1 Troubleshooting Guide

5.2 Protection Functions

• PV Over Current: The controller will limit charging power to its rated charge power. An oversized PV array will not operate at maximum power point.
• PV Short Circuit: When a PV short circuit occurs, the controller will stop charging. Remove the short circuit to resume normal operation.
• PV Reverse Polarity: Full protection against PV reverse polarity is provided, with no damage to the controller. Correct the connection to start normal operation.
• Battery Over Voltage: If other energy sources charge the battery, and the battery voltage exceeds 15.5V (for 12V system), 31.0V (for 24V system), 46.5V (for 36V system), or 62.0V (for 48V system), the controller will stop charging to protect the battery from overcharging damage. (Note: "Stop charging" means the charging current becomes very low).
• Battery Over Discharge: When battery voltage drops to the set low voltage disconnect point, the controller will stop discharging to protect the battery from over-discharging damage.
• Load Over Current Protection: If the load current exceeds 1.25 times the maximum rated load current, the controller will disconnect the load.
• Load Short Circuit Protection: If a load short circuit occurs, the load short circuit protection will activate automatically.
• Over Temperature Protection: The internal fan will activate to reduce temperature if it exceeds 45°C, and the controller will protect itself if the temperature reaches 75°C.

6. Technical Specifications

Detailed specifications for the ECGSOLAX EG4860 MPPT Solar Charge Controller.

7. Warranty and Support

7.1 Warranty Regulations

The manufacturer provides the following warranty for the MPPT series solar charge controller:

• Within 30 days from the date of purchase: A faulty controller will be replaced free of charge under normal use (with authorization from technical personnel).
• Within 2 years from the date of purchase: A faulty controller will be repaired free of charge.

Notes: Disassembled privately, no warranty. Any damaged unit caused by the user's failure to install, disassemble, or incorrect use of this product may void the warranty.

7.2 Liability Disclaimer

The manufacturer shall not be liable for damages, especially to the battery, caused by use other than as intended or as mentioned in this manual, or if the recommendations of the battery manufacturer are neglected. The manufacturer shall not be liable if there has been service or repair carried out by any unauthorized person, unusual use, wrong installation, or bad system design.

7.3 User Manual (PDF)

A detailed user manual in PDF format is available for download. You can access it here: ECGSOLAX MPPT Solar Charge Controller User Manual (PDF).

8. User Tips

• For optimal performance, ensure proper ventilation around the controller to prevent overheating, especially in warm environments. The fan activates automatically above 45°C.
• Always double-check wiring polarity before powering on the system to avoid damage.
• If the controller is unresponsive after installation, re-verify all connections and settings, especially the battery voltage and PV input.
• When setting parameters for lithium batteries, remember to select the correct battery type (01 in D04 setting) as default settings are for acid batteries.

9. Package Contents

The package includes the following items:

• 1x MPPT Solar Charge Controller (Model EG4860)
• 4x Corner connections
• 4x Screws for controller casing
• 1x English manual