ECGSOLAX EG4860 MPPT 60A Solar Charge Controller User Manual

1. Introduction

Thank you for choosing the ECGSOLAX MPPT series solar charge controller. This manual provides important safety, installation, and operating instructions to help you make full use of the controller's advantages in your solar system. The MPPT series solar charge controller is based on advanced Maximum Power Point Tracking (MPPT) technology, dedicated to solar systems, achieving a charge controller conversion efficiency of up to 97%.

Please read this user manual carefully before installation and operation, paying close attention to all safety recommendations.

2. Important Safety Instructions

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.

2.2 Charge Controller Safety

• 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 ensure the voltage does not exceed this value when connecting panels together.

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. Ensure adequate ventilation to release gases.
• Be careful when working with large lead-acid batteries. Wear eye protection and have fresh water available in case of 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. Review specific requirements of the battery used.
• 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.

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.
• DO NOT connect any inverters or battery charger 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 during the equalization charging stage.

3. Product Features

• MPPT 60A solar charge controller
• 100% MPPT technology
• Built-in DSP controller with high performance
• Automatic switch for 12V/24V/36V/48V battery bank
• 3-stage charging optimizes battery performance
• Overcharge protection, input PV polarity reverse protection, output limited current protection, over-temperature protection
• Troubleshooting promotion function
• Suitable for battery types such as sealed lead acid, vented gel, and lithium battery.
• Easy to be mounted

Image: Product characteristics and protection icons including MPPT technology, overcharge protection, 180VDC, overtemperature protection, and heat dissipation.

4. Package Contents

The product package includes the following items:

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

Image: MPPT Solar Charge Controller, its packaging box, and the included user manual.

5. Dimensions

The physical dimensions of the ECGSOLAX EG4860 MPPT Solar Charge Controller are as follows:

• Size (L x W x H): 214mm x 115mm x 50mm (8.43in x 4.53in x 1.97in)
• Net Weight: 1.1 kg / 2.43 lbs
• Gross Weight: 1.2 kg / 2.65 lbs

Image: Diagram illustrating the physical dimensions of the solar charge controller with measurements of 21.4cm, 11.5cm, and 5cm.

6. Setup and Installation

6.1 Instruction Notes

Important:

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

6.2 Connection Steps

1. Step 1: 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 above 12V for the controller to boot up.

2. Step 2: Connect the solar panel

   Ensure that the PV modules are protected from incident light. 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).

3. Step 3: 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. Step 4: Final work

   Tighten all cables connected to the controller and remove all debris around the controller, leaving a space of approximately 5.91 inches (15 cm) for ventilation.

6.3 Air Circuit Breaker Installation

We strongly recommend connecting a fuse directly to the battery to protect against any short circuit at the battery wiring. Solar PV modules generate current when exposed to light. The current varies with light intensity, but full voltage is always present. Protect solar modules from incident light during installation. Never touch uninsulated cable ends, use only insulated tools, and ensure the wire diameter is appropriate for the expected currents of the solar charge controller. Connections must always be made in the sequence described below.

Image: System connection diagram showing solar panels, a breaker, the MPPT solar charge controller, a battery, and a load.

Connection Sequence:

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, please re-read the manual or contact support.

6.4 Air Circuit Breaker and Wires Requirement

7. Operation

7.1 Button Introduction

Image: Close-up view of the controller's front panel, introducing the functions of the UP (+), DOWN (-), ESC (switch load setting to exit), and ENTER (Setting) buttons.

7.2 LCD Display

The LCD display provides real-time information about the system's status. The main interface shows PV voltage/output power, battery voltage/charging current, working mode/temperature, and fault codes. Sub-interfaces provide details on load timer, floating voltage, absorption voltage, calibration voltage, and under-voltage disconnection voltage.

Image: Flowchart diagram of the LCD display's main interface and sub-interfaces, showing various system parameters.

7.3 Working Modes

8. Manual Settings

8.1 Batteries Charge Voltage Reference

NOTICE:

• When selecting SEL, GEL, and FLd battery types, the controller automatically detects the system voltage.

8.2 Manual Setting Procedure

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, then the LCD displays D00. This setting is for load working time (default is 24-hour). Press ENT until numbers flash, then use UP/DOWN to set the desired time. Long-press ENT to confirm. This output voltage is the same as the battery. The load 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 for floating charging). Press ENT until numbers flash, then use 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 proportionally. The LCD will only display the voltage for one battery (e.g., for a 4x12V battery, if you set 14.1V, the charge voltage will be 4x14.1V automatically, but the LCD will only display 14.1V).

3. Step 3: D02 (Absorption Charging Voltage)

   Continue to press the UP button, the LCD shows 14.5 (highest absorption charging voltage for battery). Press ENT until numbers flash, then use 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 proportionally. The LCD will only display the voltage for one battery.

4. Step 4: D03 (Under-voltage 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 use UP/DOWN to set the desired voltage. Long-press ENT to confirm. This means it's protected when a 12V battery is less than 10.0V, and there is no output power from OU+ and OU-.

5. Step 5: D04 (Battery Voltage Calibration)

   Continue to press the UP button, the LCD shows C12.2. This setting item is used to calibrate the battery voltage by adjusting the value, ensuring that the battery voltage detected by the controller matches the actual battery voltage.

6. Step 6: D05 (Battery Type Setting)

   Continue to press the UP button, the LCD shows the setting program for battery type. The default option is USE. The available battery types are:

   Type Code	Battery Type
   SEL	Sealed Lead-Acid Battery
   GEL	Gel Sealed Lead-Acid Battery
   FLd	Flooded Lead-Acid Battery
   L04	4-series Lithium Iron Phosphate Battery
   L08	8-series Lithium Iron Phosphate Battery
   L15	15-series Lithium Iron Phosphate Battery
   L16	16-series Lithium Iron Phosphate Battery
   USE	User-defined Battery Type

   CAUTION! When selecting SEL, GEL, and FLd battery types, the controller automatically detects the system voltage.

7. Step 7: D06 (User-defined System Voltage)

   If you choose the USE option in the D05 battery type setting, you will need to manually configure the system voltage in the D06 setup program. The configuration range is 12V/24V/36V/48V.

Press ESC to exit the setting menu.

Reminder:

When you set up all steps, please disconnect the battery. Then reconnect the controller to see if all settings are successful. Once all settings are confirmed, connect the PV modules to the controller.

9. Troubleshooting and Protections

9.1 Troubleshooting Guide

9.2 Protection Functions

1. 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.

2. PV Short Circuit

   When a PV short circuit occurs, the controller will stop charging. Remove the short circuit to resume normal operation.

3. PV Reverse Polarity

   Full protection against PV reverse polarity ensures no damage to the controller. Correct the connection to start normal operation.

4. 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).

5. Battery Over Discharge

   When the battery voltage drops to the set low voltage disconnect point, the controller will stop discharging to protect the battery from over-discharging damage.

6. Load Over Current Protection

   If the load current exceeds 1.25 times the maximum load current rating, the controller will disconnect the load.

7. Load Short Circuit Protection

   Once a load short circuit happens, the Load Short Circuit protection will start automatically.

8. Over Temperature Protection

   The controller is equipped with over-temperature protection. If the internal temperature exceeds safe limits, the fan will activate, and charging/discharging may be reduced or stopped until the temperature returns to normal.

10. Technical Specifications

11. User Tips

• Lithium Battery Compatibility: This controller is compatible with various battery types, including Lithium Iron Phosphate (LiFePO4) batteries. When using LiFePO4 batteries, select the appropriate series setting (L04, L08, L15, L16) in the D05 menu for optimal performance and protection.
• Voltage Scaling: Remember that when setting voltages for multi-series battery banks (e.g., 4x12V), the controller automatically scales the voltage. The LCD will display the voltage for a single 12V battery, but the actual charge voltage applied will be proportional to your battery bank's total voltage.

12. Warranty and Support

12.1 Warranty Regulations

According to the prescription, any damaged unit caused by the user's failure to install, disassemble, or incorrect use of this product may void maintenance.

1. Within 30 days from the date of purchase, a faulty controller will be replaced free of charge under normal usage conditions (with authorization from technical personnel).
2. Within 2 years from the date of purchase, a faulty controller will be repaired free of charge.

Note: Disassembled privately, no warranty.

12.2 Contact Information

For any questions or support, please contact us:

• Tel/Fax: +86 755-28219903
• Email: support@powmr.com
• Web: www.powmr.com
• Address: Henggang Street, Longgang District, Shenzhen, Guangdong, China

13. Frequently Asked Questions (FAQ)

Q: Is this controller compatible with lithium iron phosphate batteries?

A: Yes, the ECGSOLAX EG4860 MPPT Solar Charge Controller is compatible with lithium iron phosphate batteries. The manual provides specific settings (L04, L08, L15, L16) for 4-series, 8-series, 15-series, and 16-series Lithium Iron Phosphate Batteries, which can be configured in the D05 setting menu.

14. PDF User Manual Reference

A comprehensive user manual in PDF format is available for download. This document contains detailed instructions and diagrams for the ECGSOLAX EG4860 MPPT Solar Charge Controller.

For the official PDF user manual, please refer to the following link: ECGSOLAX MPPT Solar Charge Controller User Manual (PDF)