PowMr Solar Charge Controller User Manual

Important Safety Instructions

WARNING: Carefully read and adhere to all safety instructions.

Before installing and operating the controller, please read the user manual thoroughly and keep it for future reference.

The installation or operation of the controller should only be performed by individuals who have received proper training and supervision:

• Anyone lacking the necessary knowledge, experience, or capabilities for the safe installation and operation requirements.
• Individuals (including children) who may have physical, sensory, or intellectual impairments that could affect the safe installation and operation.

Controller Installation and Operation

• This controller product does not have user-serviceable components; do not disassemble or attempt to repair the controller yourself.
• Install the controller in a well-ventilated environment with adequate clearance around it.
• Install the controller on non-combustible walls and ensure there are no flammable materials nearby; it is normal for the controller to generate heat during operation.
• Place the controller in an environment that is protected from direct sunlight ☀️, rain, humidity, and dust, and keep it away from any flammable liquids or gases. The controller is for indoor use only.
• Do not install or operate the controller on top of, directly above, or in an enclosed space above batteries ?, as batteries emit explosive gases.
• Do not place any objects on top of the controller.

Battery Installation and Charging

• Install and charge batteries ? in well-ventilated or exhaust-ventilated environments.
• Ensure there are no open flames in the vicinity of the batteries ?, as batteries emit explosive gases.
• Battery acid is corrosive; if battery acid comes into contact with the skin, rinse immediately with clean water.
• Do not charge non-rechargeable batteries. Do not charge lithium batteries when the temperature is below 0°C. Charging frozen batteries is prohibited.
• Ensure that the equipment is properly configured for the type of battery connected to it.

DC Battery Connections

• Ensure that the DC system is fully off/powered down by disconnecting all cables and/or new ports from the battery/DC system.
• Use flexible, multi-strand copper cables with an appropriate cross-sectional area, and connect them to matching fuses or circuit breakers.
• Connecting the photovoltaic array to the controller is prohibited until the battery is connected first.

Controller Configuration

• Refer to the battery manufacturer's guide and specifications to ensure the battery is suitable for the controller and confirm the recommended charging settings.
• Integrated charging modes include adaptive charging logic, which is suitable for most battery types.

Declaration

Under the following circumstances, PowMr reserves the right not to assume any quality warranty responsibilities:

• Damage caused by improper transportation.
• Damage resulting from incorrect storage, installation, or usage.
• Damage caused by non-professionals or untrained personnel installing and operating the equipment.
• Damage resulting from non-compliance with the instructions and safety warnings in this document.
• Damage caused by operation in environments that do not meet the requirements specified in this document.
• Damage due to operation beyond the parameter ranges specified in applicable technical specifications.
• Damage resulting from unauthorized disassembly, product alteration, or software code modification.
• Damage caused by abnormal natural conditions (force majeure), such as lightning ⚡, earthquakes ?, fires ?, storms ⛈️, etc.
• Any damage resulting from failure to adhere to local standards and regulations during the installation and operation processes.
• Products outside the warranty period.

1 Product Introduction

Welcome to the POW-M80 and POW-M100 series solar controllers, representing cutting-edge innovation in the field of solar technology. Designed to deliver outstanding performance and reliability to your solar system, PowMr's meticulously crafted controllers feature advanced CNC technology, an LCD screen, and user-friendly button design, expanding configuration capabilities for real-time monitoring of operational data and system status. Additionally, the controllers support Maximum Power Point Tracking (MPPT) battery charging mode, maximizing energy utilization efficiency.

The POW-M80 and POW-M100 series solar controllers are designed to meet the diverse needs of various solar systems, whether in standalone systems or other applications. They automatically control the battery charging and discharging processes, optimizing these processes to extend battery life while enhancing overall system performance. The controllers come equipped with self-diagnostic and electronic protection functions, effectively preventing damage during installation errors or system failures, ensuring system reliability and stability.

PowMr's POW-M80 and POW-M100 series solar controllers offer expanded customization options for a quicker and smoother solar system configuration process. Whether you are building an independent solar system or expanding a solar energy project, these controllers will be your indispensable partner. With their compact size, lightweight design, and a combination of air-cooling and natural heat dissipation technology using aluminum alloy backplates, they further enhance operational safety, stability, and versatility across various scenarios. The parallel operation feature allows users to effortlessly expand the scale of their solar energy sources.

The POW-M80 and POW-M100 series solar controllers provide a high current charging function of up to 80A or 100A, ensuring efficient capture and storage of energy for your solar system. Whether seeking an efficient, sustainable, and secure energy management solution or providing solid support for future energy needs, these controllers are your ideal choice. PowMr is committed to advancing solar technology, offering excellent products and services to support your solar system construction.

1.1 Features

Integrated Charging Presets

Integrated charging modes include adaptive charging logic, suitable for most battery types such as flooded lead-acid batteries, gel-sealed lead-acid batteries, and lithium batteries. Specific charging parameters for each battery type can be found in Section 3.5.

Versatile Application

Compatible with 12V/24V/36V/48V system voltages.

Multi-Stage Charging Algorithm

The multi-stage charging algorithm is designed to optimize each charging cycle. After the batteries are fully charged, it maintains battery capacity by applying preset charging parameters in specific charging stages.

Maximum Power Point Tracking (MPPT) Technology

MPPT technology tracks the maximum power point voltage (Vmp) of the array as it varies with weather conditions, ensuring the collection of maximum power from the array throughout the day.

High-Efficiency Charging

Innovative MPPT technology with a tracking efficiency of up to 99.9% and a peak conversion efficiency of up to 97%, reducing power consumption, minimizing heat generation, and lowering operating temperatures.

Supports Up to 12 Units in Parallel

The parallel operation function allows for easy expansion of the solar panel configuration and energy storage capacity limits, thus increasing the scale of energy storage. For detailed parallel operation guidelines, refer to Section 7.

Adaptive Boost Charging

During the initial charging phase, adaptive boost charging monitors battery response and automatically determines the duration of the boost stage for each independent charging cycle, ensuring that the battery is fully charged at any discharge level or capacity while avoiding overcharging during the boost charging stage (extends battery life).

Durable and Secure

• Photovoltaic input overcurrent
• Photovoltaic array short circuit
• Reversed photovoltaic polarity
• Overvoltage protection for batteries
• Overdischarge protection for batteries
• Over-temperature protection

External Temperature Probe Configuration

Enhance precision in battery temperature monitoring by configuring an external temperature probe. This ensures accurate temperature compensation for optimal system performance.

Forced Air Cooling

Built-in cooling fan for forced heat dissipation, improving overall device operational efficiency.

Lithium Battery Activation

Compatible with lithium batteries. When the battery type parameter is set to lithium batteries, the charging cycle will be adjusted to accommodate the needs of lithium battery charging. Additionally, when connected lithium batteries are in a protected state, the controller will activate the lithium batteries with the energy from the solar panels, with current not exceeding the lithium battery protection voltage and current range.

Warning: Do not charge lithium batteries when the temperature is below 0°C.

1.2 Product Appearance

Description of the PowMr MPPT Solar Charge Controller:

• 1. LCD Display Screen: Shows operational data and system status.
• 2. Function Keys: Used for navigation and setting adjustments.
• 3. Photovoltaic Input Interface: Connection point for the solar array.
• 4. Battery Interface: Connection point for the battery bank.
• 5. Temperature Probe Port: For connecting an external temperature sensor.
• 6. Parallel Communication Port: For connecting multiple controllers in parallel.
• 7. Port Cover Plate: Protects unused ports.
• 8. Heat Dissipation Vent: Allows for airflow to cool the unit.

2 Installation and Wiring

2.1 Unpacking and Inspection

Before unpacking, inspect the packaging for any signs of damage. After unpacking, check the contents to ensure nothing is damaged or missing. Inside the package, you will find the following items:

• Controller
• User Manual
• Installation screws
• Parallel connector
• External temperature sensor

2.2 Choosing the Installation Location

Before installation, several aspects should be considered to determine or provide a suitable and safe installation location:

• Install the controller in a space with good natural ventilation/exhaust ?️.
• Avoid direct sunlight ☀️.
• Ensure there is ample clearance around the controller. The minimum clearance at the top, bottom, and both sides of the controller is 75mm ?.
• Install the controller on a non-combustible wall ? and ensure there are no flammable materials nearby; an increase in temperature during controller operation is a normal occurrence.
• Install the controller in an environment that avoids direct sunlight ☀️, rain ?️, humidity ?, and dust ?, and keep it away from any flammable liquids or gases. The controller is for indoor use only.
• Do not install or operate the controller on top of, directly above, or in an enclosed space above batteries ?, as batteries emit explosive gases.
• When running multiple controllers in parallel, ensure they are installed at the same horizontal height, with a minimum spacing of 200mm ↔️ between controllers.

2.3 Wiring Precautions

1. Installation and wiring work should be carried out by a certified electrician.
2. Wiring should follow the sequence of Battery ? > PV Input.
3. To avoid short-circuits and polarity reversal, pay attention to connecting the positive (+) cable to the device's positive (+) terminal and the negative (-) cable to the device's negative (-) terminal.
4. Loose and/or incomplete connections can lead to cable or terminal overheating. Therefore, tighten all cables to minimize transition resistance, using cable sizes appropriate for the specific circuit's current rating.

2.4 Installation and Wiring Guidelines

Please refer to the following steps to complete the installation and wiring of the controller. Alternatively, scan the QR code on the right to access the operating guide.

NOTE: For parallel connection wiring, please refer to Chapter 7.

Step 1. Install the controller vertically with its ports facing downward, securing it to the wall through the four mounting holes using screws. For ease of installation, it is recommended to use two upper screws for initial "hanging" of the device, followed by the addition of two lower screws, and then fully tighten all four screws.

Step 2. Battery Wiring: Connect the battery ? to the controller using cables.

ATTENTION: If an inverter connection is required, please refer to the diagram below.

Diagram description: A wiring diagram shows an inverter connected to a battery (36V/48V) via a fuse and circuit breaker, and the battery is connected to the MPPT Solar Charge Controller via a fuse and circuit breaker. The inverter also has an AC output.

NOTE:

• All wiring work must be carried out by professionals.
• For safe operation and proper application, circuit breakers of the appropriate specifications must be installed on the cables connected to the controller, and ensure that the connections are tight.
• Ensure that all circuit breakers are in the off position before completing all wiring.
• Connect the positive cable terminal to the positive terminal port, and the negative cable terminal to the negative terminal port.
• The above notes also apply to the PV ports.

Step 3. PV Wiring: Connect the photovoltaic array to the controller using cables.

Diagram description: A PV array is shown connected via a breaker to the PV input terminals of the MPPT Solar Charge Controller.

Step 4. Temperature Probe Connection: Connect the temperature probe wire to the controller and securely fix the probe end to the battery ? using insulation tape.

Step 5. Pre-Startup Check: Refer to the wiring diagram below. If all connections are accurate, and all wiring is securely connected, close the circuit breakers in the order of Battery ? and PV Input circuitry.

WARNING: Risk of Electric Shock!

• Before wiring, ensure that all power sources are turned off and follow the relevant inspection and operation procedures.

3 Operation Guide

3.1 Operation Interface Overview

Display Interface:

The LCD display shows various parameters. The interface includes:

• 1. Day/Night Indicator Icon: Indicates the presence of photovoltaic input.
• 2. Battery Remaining Capacity Indicator: Shows the current charge level of the battery.
• 3. Charging in Progress Indicator: Visually indicates when charging is active.
• 4. Photovoltaic Input Voltage/Power/Operating Mode/Fault Codes: Displays real-time PV input data or error codes.
• 5. Current Battery Voltage/Charging Current/Device Temperature/Battery Calibration Voltage/Parallel Communication Code/Battery Type/Boost Charging Voltage/Float Charging Voltage/MPP Tracking Return Voltage: Displays detailed battery and system parameters.

Button Functions

The controller has three buttons: PV/SET, BAT/▲, and BAT/▼.

Note: "Setup Mode" refers specifically to the setting mode for battery parameters.

3.2 Overview of Photovoltaic Parameters

A short press of the PV/SET key cycles through the following data on the display:

• PV Input Voltage: Displays the voltage from the solar array.
• PV Input Power: Displays the power generated by the solar array.
• Operating Mode/Fault Codes: Displays the current operating mode or any fault codes.

Operating Modes:

Note: In the event of a fault, the Operating Mode section will display a fault code. Please refer to Section 4.2 for details.

3.3 Overview of Battery Parameters

In browsing mode, use the BAT/▲ and BAT/▼ keys to scroll through battery parameters. To adjust a parameter, long-press the BAT/ key to enter setting mode. Use BAT/▲ and BAT/▼ to adjust values or toggle options. Press PV/SET to confirm.

Parameters include:

• Current Battery Voltage
• Charging Current
• Device Temperature
• Battery Type
• Parallel Communication Code
• Calibrated Battery Voltage
• Boost Charging Voltage
• Float Charging Voltage
• MPP Tracking Return Voltage

3.4 Battery Parameter Settings

Calibrated Battery Voltage

Use this setting to calibrate the battery voltage if there is a difference between the controller's reading and a multimeter measurement. Long-press BAT/▲ to enter, adjust with BAT/▲ and BAT/▼, and save with PV/SET.

Parallel Communication Code Setting

In parallel operation mode, each controller needs a unique communication code (01-06). If not operating in parallel, this setting is not needed.

The controller with the smallest code acts as the host. If the host fails, the next controller in sequence becomes the new host.

Battery Type Setting

Select the battery type based on the connected batteries:

Long-press BAT/▲ to enter setup, use BAT/▲ and BAT/▼ to toggle options, and PV/SET to save.

Custom Configuration of Charging Voltage

If "USE" (User-defined mode) is selected for battery type, the following parameters can be manually set:

Setting Steps:

1. Use the BAT/▲ and BAT/▼ keys to select the parameter.
2. Long-press the BAT/▲ key to enter the setting mode.
3. Use the BAT/▲ and BAT/▼ keys to adjust the value.
4. Press the PV/SET key to confirm and save.

NOTE: The parameters apply to 12V batteries. For 24V/36V/48V, ranges are multiplied by 2/3/4 respectively. The LCD only displays 12V values.

Logic for setting custom battery voltage parameters: Maximum Charging Voltage > Boost Charging Voltage > Float Charging Voltage > MPP Tracking Return Voltage

3.5 Default Parameters for Different Battery Types

For Lithium-Ion Batteries and User-defined Batteries:

For Lithium-Ion Batteries:

For LiFePO4 Batteries:

4 Protection

4.1 Protection Function

4.2 Troubleshooting

When a fault occurs, the controller will display a fault code to assist you in finding a solution.

5 Maintenance

PowMr recommends conducting the following checks and maintenance at least twice a year to ensure optimal performance:

1. Ensure the controller is securely mounted in a clean and dry environment.
2. Ensure proper airflow around the controller and clean any dust or debris from the heat sinks.
3. Inspect all exposed wires for insulation damage, such as severe sun exposure, friction wear, dryness, insect or rodent damage. Repair or replace any damaged wires as necessary.
4. Tighten all terminals and check for loose, broken, or burnt cable connections.
5. Confirm that all system components are properly grounded.
6. Ensure all terminals are free from corrosion, insulation damage, high temperatures, or signs of burning/discoloration, and tighten terminal screws.
7. Check for dirt, nesting insects, and corrosion. If present, clean promptly.

WARNING: Risk of electric shock!

• Before performing the above operations, ensure that all power sources are turned off and then follow the relevant check and operation guidelines.

6 Specification Parameters

Solar Input Specification

Battery Charging Specification

Environment Specification

General Specification

7 Parallel Operation Guide

Parallel Operation Schematic

Diagram description: Shows multiple controllers (#01, #02, #n) connected to separate solar arrays and a common battery pack. Lines indicate Parallel Communication Cable, Positive Power Cable, and Negative Power Cable.

Main Modules:

• Controller: Designed for standalone and parallel operation. Communication between controllers is via communication lines. Parallel controllers should be installed at the same horizontal level.
• Solar Array: Each controller must connect to a separate solar array. One solar array cannot connect to multiple controllers. Input power to each controller should not exceed its rated input power.
• Battery Bank: Parallel controllers connect to the same battery bank ?.

Parallel Installation and Wiring

You can view the parallel operation guide by scanning the QR code in the upper right corner.

Step 1. Install parallel devices at the same height level with a minimum distance of approximately 75mm ↔️ between devices.

Diagram description: Shows three controllers spaced apart with 200mm ↔️ gaps between them and 200mm ↔️ clearance above and below.

Step 2. Connect communication cables.

Step 3. Connect all parallel controllers to the same battery bank ?.

Step 4. Connect each controller to its respective photovoltaic array.

Step 5. After completing the wiring, power on by closing the battery circuit breaker. Once powered on, set the master and slave configurations as defined in Section 3.5. Then, proceed to configure the entire parallel system through the master controller.

NOTE:

• All wiring tasks must be performed by professionals.
• For safety and compliance, the cables connected to the controller must have corresponding circuit breakers installed, ensuring tight connections.
• Before completing all wiring, ensure that all circuit breakers are in the off position.
• Connect the positive cable terminal to the positive port and the negative cable terminal to the negative port.