PowMr MPPT-60A Solar Charge Controller Manual

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.

General Safety Information

• Read all of the instructions and cautions in the manual before beginning the 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.

Charge Controller Safety

• NEVER connect the solar panel array to the controller without a battery. 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.

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 the battery acid.
• Carefully read battery manuals before operation.
• Do NOT let the positive [+] and negative [-] terminals of the battery touch each other.
• Recycle battery when it is replaced.
• Over-charging and excessive gas precipitation may damage the battery plates and activate material shedding on them. Too high of an equalizing charge or too long of one may cause damage. Please 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 battery manufacturer.

Connect battery terminals to the charge controller BEFORE connecting the solar panel(s) to the charge controller. NEVER connect solar panels to 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 the 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 equalization charging stage.

Warranty

Dear Customers,

Thanks for choosing the MPPT series solar charge controller. Please take time to read this user manual carefully; it will help you to make full use of many advantages the controller can provide your solar system. This manual gives important recommendations for installing and using, and so on. Read it carefully in your own interest and pay attention to the safety recommendations in it, please.

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

1.1 Warranty regulations:

• Within 30 days from the date of purchase, the faulty controller will be free to be replaced under normal using (with the authorized technical personnel authorized by the company).
• Within 2 years from the date of purchase, the faulty controller will be free to be repaired.

Notes: Disassembled privately, no warranty.

General Safety Information and Waiver Liability

1. Read all of the instructions and cautions in the manual before beginning the installation.
2. There are no serviceable parts for this controller. Do NOT disassemble or attempt to repair the controller.
3. Make sure all connections going into and from the controller are tight. There may be sparks.
4. When making connections, therefore, make sure there are not flammable materials or gases near installation and cool place.
5. Red wire connected positive Pole of controller and black wire connected positive Pole of controller.
6. Contact PowMr first if you have any questions.

Liability Disclaimer

PowMr shall not be liable for damages, especially on 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. PowMr 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.

Overview

The MPPT series solar charge controller is based on an advanced maximum power point tracking (MPPT) technology developed, dedicated to the solar system. The charge controller conversion efficiency is up to 97%.

It comes with a number of outstanding features, such as:

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

Dimensions

A line drawing of the PowMr MPPT-60A Solar Charge Controller unit, showing its front panel with terminals, vents, and branding. The diagram indicates the physical dimensions: 21.4cm length, 11.5cm width, and 5cm height, with mounting brackets and screws.

Notes:

• Please use the provided screws only, as using other screws may damage the internal PCB.
• Apply proper torque when screwing to avoid damaging the internal PCB by excessive force.

Installation

Instruction Notes

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, please ensure your battery voltage is more than 12V for the controller to boot up.
2. 2nd step: Connect the solar panel Ensure that the PV modules are protected from incident light. Ensure that the solar panel does not exceed the maximum permissible input current. 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. 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, please connect the wire to the load before connecting to the controller.
4. 4th step: Final worked Tighten all cables connected to the controller and remove all debris around the controller, leaving a space of approximately 5.91 inches (15 cm).

Notes:

When the reading data of PV or battery is constantly changing, do not worry. The controller is finding the MPP point. This is caused by insufficient PV input power or voltage. Please contact PowMr soon; their technological team will assist you.

Air circuit Breaker Installation

PowMr strongly recommends connecting a fuse directly to the battery to protect against short circuits in the battery wiring. Solar PV modules create current whenever light strikes them. The current created varies with light intensity, but even in low light conditions, full voltage is provided by the modules. Therefore, protect the solar modules from incident light during installation.

Never touch uninsulated cable ends. Use only insulated tools, and ensure that the wire diameter is in accordance with the expected currents of the solar charge controller. Connections must always be made in the sequence described below.

Air Circuit Breaker and Wires Requirement

Connection Sequence and Operation

Reminder: It's better to connect two wires to two PV+ and another two wires to two PV-. For BAT+ and BAT-, it's the same way to connect wires.

A schematic diagram shows the connection layout: PV modules connect to the controller's PV terminals (with circuit breaker), batteries connect to the controller's Battery terminals (with circuit breaker), and DC loads connect to the controller's Load terminals.

1. Install air circuit breaker between controller and batteries. Turn off the circuit breaker, then connect batteries to the controller with correct polarity.
2. Install air circuit breaker between controller and PV modules. Turn off the circuit breaker, and ensure the PV polarity is correct, then connect wires between PV modules and 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 goes into the self-test mode. Its LCD displays the parameters if all is correct. The RUN lamp (under the fan inside the casing) will flash every one second. If the controller is unresponsive, please read the full manual again for reinstalling or contact PowMr for help.

Operation

LCD display

Diagrams of the controller's LCD display interfaces:

• Main Interface: Shows Battery Voltage, Charging Current, Working Mode, Temperature, and Protection Mode.
• Sub-interface: Displays Load Time, Floating Voltage, Absorption Voltage, and Battery Type.

Item Descriptions

Working mode

Manual Setting

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.

Step 1: D00

Press the PRG button, then the LCD displays D00. This is for setting the load working time (Default is 24-hour). Press ENT until numbers flash, then press UP/DOWN to set the desired time, and 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 there is no load, just leave it.

Step 2: D01

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

Caution! This value is for one 12V battery. If there are multiple batteries in series, the controller will multiply them in proportion automatically, and the LCD will only display the voltage of one battery. For example, if your battery bank is 4x12V, and you set the voltage at 14.1, the charge voltage will be 4x14.1 automatically, but the LCD will only display 14.1.

Step 3: D02

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, and long-press ENT to confirm.

Caution! This value is for one 12V battery. If there are multiple batteries in series, the controller will multiply them in proportion automatically, and the LCD will only display the voltage of one battery.

Step 4: D03

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, and long-press ENT to confirm. It means it's protected when a 12V battery is less than 10.0V, and there is no output power from OU+ and OU-.

Step 5: D04

Continue to press the UP button. The LCD shows 00.00, which is the default for acid batteries. If it's for a lithium battery, please press ENT until numbers flash, then press UP/DOWN to choose 01, and long-press ENT to confirm. Step 2 (D01) is not useful when you choose 01 for a lithium battery. And the voltage set in Step 3 (D02) will be the highest charging voltage for the lithium battery.

Press ESC to exit the setting menu.

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

Troubleshooting and Protections

Troubleshooting

Protections

• PV Over Current: The controller will limit charging power to the rated charge power. An over-sized PV array will not operate at maximum power point.
• PV Short Circuit: When PV short circuit occurs, the controller will stop charging. Remove the short to start normal operation.
• PV Reverse Polarity: Fully protected against PV reverse polarity, causing no damage to the controller. Correct the connection to start normal operation.
• Battery Over Voltage: If there are other energy sources to charge the battery, when the battery voltage exceeds 15.5V (12V system) / 31.0V (24V system) / 46.5V (36V system) / 62.0V (48V system), the controller will stop charging to protect the battery from overcharging damage. (Pay attention: the stop charging means charging current is very low).
• Battery Over Discharge: When battery voltage drops to the setting voltage point of low voltage disconnect, the controller will stop discharging to protect the battery from over discharging damage.
• Load Over Current protection: If the load current exceeds the maximum load current rating by 1.25 times, the controller will disconnect the load.
• Load Short Circuit Protection: Once a load short circuit happens, the Load Short Circuit Protection will start automatically.
• Over Temperature Protection: The controller will stop operation if the internal temperature exceeds the limit.

Technical Date

Properties

Content Included

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