PowMr 80A PWM Solar Charge Controller User Manual

1. Introduction

This manual provides essential instructions for the safe and efficient operation of your PowMr 80A PWM Solar Charge Controller. This controller is designed to manage the power flow from your solar panels to your battery bank, ensuring optimal charging and protecting your batteries from overcharge and over-discharge. It is compatible with 12V, 24V, 36V, and 48V systems and supports various battery types including AGM, Gel, Flooded, Lead-Acid, and Lithium batteries.

2. Safety Information

Please read all instructions carefully before installation and operation. Failure to follow these instructions may result in serious injury, damage to the controller, or damage to other components in your solar system.

• Ensure all connections are tight and correct to avoid loose connections that can cause excessive heat.
• Always connect the battery first, then the solar panel, and finally the load. Disconnect in the reverse order.
• Do not attempt to repair or modify the controller yourself. Contact qualified personnel for service.
• Install the controller in a well-ventilated area, away from flammable materials and moisture.
• Use appropriate circuit breakers and fuses for all connections to protect against overcurrent.
• Wear protective eyewear and clothing when working with batteries and solar panels.

3. Product Features

• Automatic System Voltage Detection: Automatically detects 12V, 24V, 36V, or 48V battery systems.
• High Charging Current: Rated charging current of 80A.
• Wide PV Input Voltage: Maximum PV input voltage up to 100V.
• Dual USB Outputs: Built-in 2 USB ports providing 5V and 2A output for charging devices.
• LCD Display & Keypad: User-friendly interface for real-time monitoring and parameter configuration.
• 3-Stage PWM Charging: Features Bulk charge, Boost charge, and Float charge modes for optimized battery performance and extended battery life.
• Broad Battery Compatibility: Adaptable to User, Flooded, AGM, GEL, LifePO4, Lithium, and other customized battery types.
• Multiple Protection Functions: Includes overcharge, over-discharge, overload, short circuit, reverse polarity, and over-temperature protection.

4. Product Overview and Interface Description

The PowMr 80A PWM Solar Charge Controller features a clear LCD display and intuitive controls for easy monitoring and adjustment.

Figure 4.1: Controller Interface Description
This image shows the front panel of the PowMr solar charge controller, highlighting its USB ports, LCD display, function keys, mounting holes, PV input port, battery port, load port, and heat sink.

Figure 4.2: LCD Display Screen Details
This image details the backlit LCD screen, showing indicators for Day/Night State, PV Parameter, Battery Capacity, Battery Parameter, Normal/Fault State, and DC Parameter, each numbered for easy identification.

LCD Display Indicators:

1. Day/Night State: Indicates whether it's day or night, affecting load output.
2. PV Parameter: Displays solar panel voltage and current.
3. Battery Capacity: Shows the current battery charge level.
4. Battery Parameter: Displays battery voltage and charging status.
5. Normal/Fault State: Indicates normal operation or displays fault codes.
6. DC Parameter: Shows load voltage and current.

Function Keys:

• PV/A: View PV parameters.
• BAT/V: View battery parameters.
• SET/O: Enter settings menu or confirm selection.

5. Setup and Installation

Proper installation is crucial for the performance and longevity of your solar charge controller. Follow these steps carefully:

5.1 Mounting the Controller

Mount the controller vertically on a wall or a sturdy surface in a dry, well-ventilated area, away from direct sunlight and heat sources. Ensure there is adequate space around the controller for air circulation.

5.2 Wiring Connections

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

1. Connect the Battery: Connect the battery cables to the battery terminals on the controller. Ensure correct polarity (+ to + and - to -).
2. Connect the Solar Panels: Connect the solar panel cables to the PV input terminals on the controller. Verify correct polarity.
3. Connect the DC Load: Connect your DC load to the load terminals on the controller. Ensure correct polarity.

Figure 5.1: Controller Connection Diagram
This diagram illustrates the correct wiring order for the solar charge controller: first the battery bank, then the PV array, and finally the DC load. It also shows an optional inverter for AC loads.

Important: Ensure all connections are secure and insulated. Incorrect wiring can cause damage and void warranty.

6. Operating Instructions

Once installed, the controller will automatically begin operating. Use the LCD display and function keys to monitor system status and configure parameters.

6.1 Monitoring System Status

Press the PV/A button to cycle through solar panel parameters (voltage, current). Press the BAT/V button to view battery parameters (voltage, charge status). The SET/O button is used for entering and confirming settings.

6.2 Parameter Configuration

To enter the parameter settings menu, press and hold the SET/O button for a few seconds. Use the PV/A and BAT/V buttons to navigate through options and adjust values. Press SET/O again to confirm changes and exit the menu.

Key configurable parameters include:

• Battery Type: Select the appropriate battery type (Flooded, AGM, GEL, LifePO4, Lithium, User-defined).
• Load Control Mode: Configure how the DC load output operates (e.g., always on, dusk to dawn, timed).
• Charge/Discharge Voltage Limits: Adjust these values according to your battery manufacturer's recommendations for optimal battery health.

6.3 Supported Battery Types

The controller is highly versatile and supports a wide range of battery chemistries:

Figure 6.1: Compatible Battery Types
This image displays the various battery types compatible with the PowMr solar charge controller, including Sealed Lead-Acid (SEL), Gel Sealed Lead-Acid (GEL), Flooded Lead-Acid (FLD), LiFePO4 Battery (LI), Lithium-ion Battery (LN), and User-defined (USE).

6.4 3-Stage PWM Charging Technology

The controller utilizes a 3-stage Pulse Width Modulation (PWM) charging algorithm to efficiently and safely charge your batteries:

• Bulk Charge: Charges the battery at the maximum current until its voltage rises to the absorption level.
• Boost Charge: Continues charging at a constant voltage to ensure the battery is fully charged.
• Float Charge: Maintains the battery at a fully charged state by providing a small, constant voltage.

7. Protection Functions

The PowMr 80A PWM Solar Charge Controller is equipped with multiple electronic protection features to ensure the safety and reliability of your solar system:

Figure 7.1: Multi-Protection Functions
This image highlights the various protection features of the PowMr solar charge controller, including short-circuit protection, over-load protection, over-current protection, over-discharge protection, reversed polarity protection, and over-temperature protection.

• Short-Circuit Protection: Protects against short circuits in the solar panel, battery, or load circuits.
• Over-Load Protection: Prevents damage from excessive current draw by the load.
• Over-Current Protection: Safeguards against currents exceeding the controller's rated capacity.
• Over-Discharge Protection: Prevents batteries from being discharged below a safe voltage level, extending battery life.
• Reversed Polarity Protection: Protects the controller and system components from damage due to incorrect wiring of battery or solar panel polarity.
• Over-Temperature Protection: Shuts down the controller if internal temperatures exceed safe operating limits.

8. Specifications

9. Troubleshooting

This section addresses common issues you might encounter with your solar charge controller. For more complex problems, please contact customer support.

10. Maintenance

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

• Inspect Connections: Periodically check all wiring connections for tightness and corrosion.
• Clean the Controller: Keep the controller clean and free from dust and debris. Use a dry cloth for cleaning.
• Ventilation: Ensure the installation area remains well-ventilated to prevent overheating.
• Battery Inspection: Regularly inspect your batteries for any signs of damage, corrosion, or swelling.

11. Warranty and Support

For warranty information and technical support, please refer to the documentation included with your purchase or contact PowMr customer service. Keep your purchase receipt as proof of purchase for warranty claims.

Contact Information: Please visit the official PowMr website or refer to your product packaging for the most up-to-date contact details.