PowMr POW-M60-PRO MPPT Solar Charge Controller User Manual

Important Safety Instructions

WARNING: CAREFULLY READ AND FOLLOW ALL SAFETY INSTRUCTIONS

• Carefully read the manual before the controller is installed and operated; retain the manual in a safe place for future reference.
• The controller must not be installed or operated by any of the following persons, unless they are under strict instruction and supervision:
  • Anyone who lacks the appropriate knowledge, experience or competence, required for safe installation and/or usage.
  • Anyone with compromised/reduced physical, sensory or mental capabilities, which may affect safe installation and/or usage (including children).

Controller installation and operation

• There are no serviceable parts for this controller. Do NOT disassemble or attempt to repair the controller.
• Install the controller in a location with good natural airflow/ventilation and sufficient unobstructed space around it; refer to the "2 Installation and Connection" section for more detail.
• Install the controller on a non-flammable substrate and ensure there are no heat-sensitive items in the immediate vicinity; it is normal for the controller to become hot during operation.
• Install the controller in a location where it is protected from environmental conditions such as direct sunlight, water, high moisture and dust, and also located well away from any flammable liquids or gasses. Controller is for indoor use only.
• Do not install or place/operate the controller on top of the battery, directly above the battery, or in a sealed compartment with the battery; batteries can emit explosive gasses.
• Do not cover or place any other items on top of the controller.

Battery installation and charging

• Install and charge the battery in a location with good natural airflow/ventilation.
• Ensure that there are no ignition sources near the battery; batteries can emit explosive gasses.
• Battery acid is corrosive; if battery acid comes into contact with skin immediately rinse with water.
• Do not charge non-rechargeable batteries or Li-ion batteries if the battery temperature is below 0°C. Never charge a frozen battery.
• Ensure that the unit is properly set up for the type of battery intended to be charged.

Battery DC connections

• Ensure that the DC system is fully shut down/isolated prior to disconnection of any existing cabling and/or new connections are made to the battery/DC system.
• Use flexible multi stranded copper cable with sufficient cross sectional area, line with an appropriate fuse or circuit breaker; refer to the "2.4 Wiring Specification and Breaker Type" section for more detail.
• NEVER connect the solar panel array to the controller without a battery. Battery must be connected first.

Controller setup

• Refer to the battery manufacturers instructions and specifications to ensure the battery is suitable for use with this controller and confirm the recommended charge settings.
• The integrated charge modes combined with adaptive charge logic are well suited for most common battery types; such as flooded lead-acid, Gel and LiFePO4.

1 Production Instructions

Thank you for choosing the 0 layer Series of Solar Power Controllers. The controller uses numerical control technology design, LCD display, and automatic operation. Its Maximum Power Point Tracking (MPPT) type battery charging mode, along with its control technology, will greatly extend battery life. The controller features a smart tracking algorithm that maximizes energy harvested from the solar PV module(s) to charge the battery.

This controller is suitable for solar energy systems (independent systems), controlling the charging and discharging process automatically. The battery charging and discharging process is optimized, which can prolong battery life and improve system performance. Its self-diagnostics function and electronic protection features help avoid controller damage due to installation errors and system failures.

The 0 layer series features a user-friendly LCD screen display algorithm, allowing all parameters to be displayed and configured on a single interface.

1.1 Features

• Integrated charge presets: Combined with adaptive charge logic, these presets are well-suited for most common battery types, including LiFePO4, Gel, and flooded lead-acid.
• Flexible Application: Compatible with 12V/24V/36V/48V system voltages.
• Multi-stage charge algorithm: Specifically engineered to optimize each recharge cycle and charge maintenance over extended periods.
• MPP Tracking Technology: The Maximum Power Point Tracking (MPPT) technology tracks the array's maximum power point voltage (Vmp) as it varies with weather conditions, ensuring maximum power is harvested from the array throughout the day.
• High efficiency: Innovative MPPT technology offers tracking efficiency up to 99% and peak conversion efficiency of 98%, resulting in lower power usage, less heat generation, and cooler operation.
• Adaptive boost charge: Monitors the battery's response during initial charging and intelligently determines the appropriate boost charge duration for each cycle, ensuring full recharge regardless of discharge level or capacity and avoiding excessive time at elevated boost charging voltage that can accelerate battery aging.
• Durable and safe:
  • Limits maximum charging current to protect battery performance and prolong battery life.
  • PV array short circuit protection.
  • PV input overcurrent protection.
  • Controller overload protection.
  • Load short circuit protection.
  • PV reverse polarity protection (no damage to the controller).
  • Battery reverse polarity protection.
  • Over-temperature protection: If the controller heat sink temperature exceeds 65°C, charging current is reduced; it shuts down when temperature exceeds 80°C.
• Silent operation: Achieved through natural convection, as there is no cooling fan or moving parts.
• Lithium battery activation: Compatible with Li-ion (LiFePO4) batteries. When set to Lithium battery, charge cycle settings are adjusted. If a connected lithium battery is in a protected state, the controller activates it using solar panel energy at a current that does not exceed the battery's protection voltage and current range.

  Warning: Do not charge Li-ion batteries if the battery temperature is below 0°C.

1.1 Production Overview

The PowMr POW-M60-PRO controller features:

• LCD display screen: For monitoring and configuration.
• Function keys: For navigating menus and settings.
• PV input terminal: For connecting the solar panel array.
• Battery terminal: For connecting the battery.
• Load terminal: For connecting DC loads.
• Mount hole: For wall mounting.
• Heat sink: For thermal management.

2 Installation and Connection

2.1 Unpacking and Inspection

Before unpacking, check the package for damage. After unpacking, verify that all contents are present and undamaged. Expected items include: Controller, User manual, Screws/bolts.

2.2 Preparing for Installation

The controller is designed for wall mounting using flanges on the heatsink.

Select the Mount Location:

Consider the following for a suitable and safe location:

• Install in a location with good natural airflow/ventilation.
• Ensure sufficient unobstructed space around the controller; a minimum clearance of 75mm above and below is recommended.
• Install on a non-flammable substrate, away from heat-sensitive items. Note: The controller may become hot during operation.
• Protect from environmental conditions like direct sunlight, water, high moisture, and dust. Keep away from flammable liquids or gasses. The controller is for indoor use only.
• Do NOT install or operate the controller on top of, directly above, or in a sealed compartment with the battery, as batteries can emit explosive gasses.
• Do NOT cover or place any other items on top of the controller.
• Install using four screws; M5 screws are recommended.

2.3 Things You Need

Ensure you have the following items for installation:

2.4 Wiring Specification and Breaker Type

PV input cable specifications and circuit breaker type: Determine the maximum PV input current based on the configured system voltage and refer to "6 Technical Specification". Note: The voltage in series shall not exceed the maximum PV input open-circuit voltage.

Recommended input wire diameter and switch type for DC output (DC load):

The cables and circuit breakers for the battery should be selected based on the maximum charging current of the battery you connected.

2.5 PV Module Selection

When selecting PV modules, consider the following parameters:

1. The open circuit Voltage (Voc) of PV modules must not exceed the controller's maximum PV array open circuit voltage.

2. The open circuit Voltage (Voc) of PV modules should be higher than the minimum battery voltage.

2.6 Wiring Precautions

• Let installation and connection work be done by a licensed electrician.
• To avoid short circuit and reverse polarity connection, ensure the positive cable is connected to the positive polarity port (+) and the negative cable to the negative polarity port (-).
• Too-thin cables and/or loose connections can cause dangerous overheating. Tighten all connections well to limit transition resistance. Use cables of the correct size. Refer to "2.4 Wiring Specification and Breaker Type" for details.
• Do not connect an inverter to the load side of the controller, as this may cause irreversible damage. If an inverter is needed, consult the system application diagram.

System Application Diagram:

Diagram showing a PV Array connected via a breaker and fuse to the MPPT Solar Charge Controller. The controller is connected to a Battery (36V/48V) via a fuse, and to a Load via a fuse. An Inverter is shown connected to a 220V AC output.

2.7 Installation and Connection Step-By-Step

1. Mark mounting spot positions on the wall based on the controller's mount holes. Drill 4 mounting holes. Refer to "2.2 Preparing for Installation" for location guidance.
2. Insert expansion rubber screw plugs into the mounting holes.
3. Mount the controller vertically with terminals facing down, securing it with the 4 mounting holes/slots. For easier installation, it is recommended to 'hang' the unit using the 2 upper screws first, then add the 2 lower screws before fully securing all 4. M5 screws are recommended.
4. Battery Connection: Connect the battery to the controller using the cables.

5. PV Connection: Connect the PV array to the controller with cables.
6. DC Output Connection: Connect the load to the controller with cables.
7. Check before starting up: Verify all wiring is correct and firmly connected. Close the circuit breakers at the battery side, PV module side, and load side in sequence to startup the controller.

WARNING: Risk of electric shock! Make sure that all power is turned off before operations, and then follow the corresponding inspections and operations.

Diagram: A simplified diagram shows the PV Array connected to the controller, which is connected to the Battery, and the Battery is connected to the Load. Numbers 1, 2, 3 indicate Battery, PV Array, and Load respectively.

3 Charging Mode

The charging controller features an intelligent 3-stage charge characteristic for optimal battery charging. Upon activation, it begins at the Bulk stage.

There are 3 integrated charge modes: Bulk, Boost, and Float. These stages provide fast, efficient, and safe battery charging, extending battery life. The integrated modes, combined with adaptive charge logic, are suitable for common battery types like flooded lead-acid, Gel, and LiFePO4.

Charging mode parameters can be set via the LCD screen. Refer to "4.3 Browse and Configuration Step-By-Step" for details. Settings are stored and retained even when the controller is disconnected from the battery or PV module.

The multi-stage charge algorithm includes the following stages:

Bulk charge: The battery is charged at maximum current until the voltage reaches the configured boost charge voltage. The duration depends on the battery's discharge level, capacity, and charge current. Charging transitions to Boost when the preset boost voltage is reached.

Boost charge: The battery is charged at the configured boost charging voltage, with the charge current gradually decreasing as the battery approaches full charge. The default boost stage duration is adaptive, based on the bulk charge stage duration. If the PV module is reconnected, a new charging cycle begins. If the battery is full, it enters Stage B (boost charging voltage) for a set duration (currently 30 minutes).

Float charge: At the end of the boost charging stage, the controller reduces battery voltage by decreasing charging current and maintains the battery at the floating charging voltage set value to keep it fully charged. In Float charging stage, loads can draw almost all power from the solar panel. If loads exceed available power, the controller may not maintain battery voltage in Float charging stage. If battery voltage drops below the Recharge Voltage, the system will exit Float charging stage and return to Bulk charging stage.

3.1 Alarm Function

The battery controller has an integrated alarm function. For details on protection and fault alarms, see the "5.2 Troubleshooting" section.

4 Operation Instruction

4.1 Icon Display on LCD Screen

The LCD screen displays various icons and data:

• Icon 1: Day or night indicating icon.
• Icon 2: Indicates the remaining battery capacity.
• Icon 3: Displays the working mode (See "4.4 Working Mode" for details).
• Icon 4: Shows periodic running status of the load and warning state (See "5.2 Troubleshooting" for details).
• Display 5: Indicates PV input voltage/power (e.g., kW, V).
• Display 6: Indicates Current battery voltage/Charging current/Equipment temperature/Battery calibration voltage/Battery type/Boost charging voltage/Float charging voltage/Low DC cut-off recovery voltage/ Low DC cut-off voltage.
• Display 7: Indicates the working mode of the load.

4.2 Function Keys

The controller has four function keys:

• PV/ ⌂: To switch PV input parameters information.
• BAT / ▲: To switch charging information / Return to the previous option.
• DC / ▼: To adjust DC output mode and DC output operation duration / Enter the next option.
• SET / ⚙️: Confirm and reserve the settings.

4.3 Browse and Configuration Step-By-Step

After cables are connected and the device is started, perform initial configuration based on the actual situation.

4.3.1 PV side

Step 1. Checking PV input Information

Press " PV / ⌂ " key to cycle through PV input voltage and PV input power information.

PV input voltage ➡️ PV input power

4.3.2 Battery side

Step 1. Checking Battery Information

Press " BAT / ▲ " key to cycle through battery information: current battery voltage, charging current, equipment temperature, battery calibration voltage, battery type, boost charging voltage, float charging voltage, low DC recovery cut-off voltage, and low DC cut-off voltage.

Current Battery Voltage ➡️ Boost Charging Voltage ➡️ Float Charging Voltage ➡️ Low DC Recovery Cut-off Voltage

Charging Current ➡️ Battery Type ➡️ Low DC Cut-off Voltage

Equipment Temperature ➡️ Battery Calibration Voltage

Step 2. Calibrate battery voltage

This parameter corrects the current battery voltage measured by the controller.

• Once the parameter switches to "battery calibration voltage", press and hold " BAT / ▲ " key to enter the calibration setting.
• Then press the " BAT / ▲ " or " DC / ▼ " keys to calibrate the battery voltage parameters according to a multimeter reading. Finally, press " SET / ⚙️ " to confirm.

Step 3. Select the Battery Type

Adjust battery type parameters based on your connected battery:

• Once the parameter switches to the battery type item, press and hold " BAT / ▲ " key to enter the battery type adjustment setting.
• Then press " BAT / ▲ " or " DC / ▼ " to select the battery type, and finally press " SET / ⚙️ " to confirm. The operating voltage varies by battery type.
• For details, refer to "4.5.2 Battery parameters of different types" section.

Step 4. Customize configured voltage parameters

Once the battery type is set to "USE", the following configurable parameters are presented in order (increment of each click is 0.1V):

Nominal system voltage ➡️ Boost charging voltage ➡️ Float charging voltage ➡️ Low DC cut-off recovery voltage ➡️ Low DC cut-off voltage

• Press " BAT / ▲ " key to select the parameter item to adjust.
• Then press and hold " BAT / ▲ " key to enter the related parameter, then press " BAT / ▲ " or " DC / ▼ " to adjust the voltage value.
• Finally, press " SET / ⚙️ " to confirm. Refer to "4.5 Key Points Battery Parameter Settings" section for the logic for setting battery voltage parameters.

4.3.3 Load side

Step 1. Configurate load enable duration

• Press and hold " DC / ▼ " key to enter the load mode setting.
• Then press " BAT / ▲ " or " DC / ▼ " to adjust load state or load enable duration.
• Finally, press " SET / ⚙️ " to confirm.
• 00H: The solar light control mode (When solar energy is sufficient, enable DC output).
• 24H (Default): Turn on load immediately.
• 01H~23H: Adjust the load enable duration.

Setting range is from 0 hour to 24 hours. Increment of each click is 1 hour.

4.4 Working Mode

4.5 Key Points Battery Parameter Settings

4.5.1 The logic for setting battery voltage parameters

1. Before customizing battery parameters, confirm the following parameters of the connected battery:
   • Max charging voltage
   • Discharging protection voltage
2. After confirming the battery information, set the 4 key parameters according to the following logic: Max. charging voltage > Boost charging voltage > Float charging voltage > Low DC cut-off recovery voltage > Low DC cut-off voltage > Discharge protection voltage

4.5.2 Battery parameters of different types

For lead-acid battery & User define:

For Ternary lithium battery:

Lithium iron phosphate battery:

5 Protection

5.1 Protection Provided

5.2 Troubleshooting

In case of a failure, the controller display shows an error signal to help you find its source.

5.3 Maintenance

The following inspections and maintenance tasks are recommended at least twice per year for best performance:

• Make sure the controller is firmly installed in a clean and dry ambient.
• Ensure no blockages to airflow around the controller. Clear any dirt and fragments on the radiator.
• Check all exposed wires for insulation damage due to solarization, frictional wear, dryness, insects, or rats. Repair or replace wires if necessary.
• Tighten all terminals. Inspect for loose, broken, or burnt wire connections.
• Confirm that all system components are ground connected tightly and correctly.
• Confirm that all terminals show no corrosion, insulation damage, high temperature, or burnt/discolored signs. Tighten terminal screws to the suggested torque.
• Check for dirt, nesting insects, and corrosion. If present, clear them up promptly.

WARNING: Risk of electric shock! Make sure that all power is turned off before operations, and then follow the corresponding inspections and operations.

6 Technical Specification

Contact Information

Shenzhen Hehejin Industrial Co., LTD

Tel/Fax: +86 755-28219903

Email: support@powmr.com

Web: www.powmr.com

Add: Henggang Street, Longgang District, Shenzhen, Guangdong, China