Felicity Solar MPPT Charge Controller User Guide

1. About This Manual

This manual describes the assembly, installation, operation, and troubleshooting of the MPPT solar charge controller. Please read it carefully before installation and operation. Keep it for future reference.

1.1 Purpose

To provide comprehensive guidance for the safe and effective use of the MPPT solar charge controller.

1.2 Scope

This manual includes safety and installation guidelines, as well as information on tools and wiring.

1.3 Safety Instructions

WARNING: Read all instructions and cautionary markings before use. Incorrect installation or operation can lead to electric shock or fire.

• Do not disassemble the unit. Seek qualified service for repairs.
• Disconnect all wiring before maintenance or cleaning.
• Only qualified personnel should install this device with batteries.
• Never charge a frozen battery.
• Use appropriate cable sizes as specified.
• Be cautious when working with metal tools around batteries to avoid sparks or short circuits.
• Follow installation procedures carefully when disconnecting PV or battery terminals.
• Ensure the charger is connected to a permanent grounded wiring system, complying with local regulations.
• Never short-circuit the battery output.
• If errors persist after troubleshooting, contact a qualified service center.

2. Introduction

Thank you for choosing the Felicity Solar MPPT charge controller. This advanced controller utilizes an intelligent MPPT algorithm to extract maximum power from solar arrays, optimizing battery life and system performance. It includes self-diagnostics, electronic error protections, and a multifunctional LCD with communication ports.

2.1 Features

• Intelligent Maximum Power Point Tracking (MPPT) technology increases efficiency by 25%-30%.
• Compatible with 12V, 24V, or 48V PV systems.
• Three-stage charging optimizes battery performance (two-stage for lithium batteries).
• Maximum charging current options: 30A, 45A, 60A, 80A, 100A, 120A.
• Maximum efficiency up to 98%.
• Automatic battery voltage detection (Lithium battery voltage requires manual setting).
• Supports lithium, lead-acid, AGM, and gel batteries.
• Integrated intelligent slot for MODBUS communication.

2.2 Product Overview

The controller features an LCD display (1), Power On/Charging indicator (2), Fault and warning indicator (3), Wiring fault indicator (4), and an Operation button (5). Power terminals include PV Positive + (6), PV Negative - (7), Battery Negative - (8), Battery Positive + (9), and a Communication Port (10).

3. Installation

3.1 Unpacking and Inspection

Inspect the unit upon arrival. Ensure all items are present: Solar charge controller (x1), User manual (x1), Installation hole map (x1).

3.2 Preparation

Prepare mounting holes according to the provided installation hole diagram.

3.3 Mounting the Unit

Consider the following for mounting:

• The unit is designed for indoor applications (IP31).
• Do not mount on flammable materials.
• Mount on a solid surface at eye level for easy LCD viewing.
• Allow clearance: approx. 20 cm (8 inches) to the sides and 50 cm (20 inches) above and below for heat dissipation.
• Optimal ambient temperature range: 0°C to 55°C (32°F to 131°F).
• Mount vertically on a wall.

3.4 Power Connection

Wire Size

Power terminals accommodate 14 - 2 AWG (2.5 - 35 mm²) wire. Use UL-listed Class B 300 Volt stranded wire. For optimal performance, limit voltage drop to 2% or less.

Recommended Minimum Wire Size

Overcurrent Protection and Disconnects

CAUTION: Install circuit breakers or fuses in both battery and solar circuits. The battery circuit breaker/fuse should be rated at 125% of the maximum current.

Recommended Breaker Rating

• 30A: 37.5A
• 45A: 56.3A
• 60A: 75.0A
• 80A: 100.0A
• 100A: 125A
• 120A: 150A

Use double-pole switches or breakers for convenient disconnection of both solar and battery circuits.

Connect the Power Wires

WARNING: Shock Hazard. Solar modules can produce high open-circuit voltages. Ensure solar input breaker/disconnect is OFF before connecting wires.

1. Ensure system input and output disconnect switches are OFF.
2. Prepare power wires: strip insulation 10.5mm and plate conductors with tin.
3. Pull wires into the wiring box. Remote Temperature Sensor (RTS) and Battery Sense wires can be pulled with power conductors.
4. WARNING: Risk of Damage. Ensure correct battery polarity. Turn on the battery breaker/disconnect and measure voltage on open wires BEFORE connecting to the controller. Disconnect before wiring.
5. Connect the positive (+) terminal of the battery to the controller's battery positive terminal (+).
6. Connect the negative (-) terminal of the battery to one of the controller's common negative terminals (-).
7. WARNING: Risk of Damage. Ensure correct solar connection polarity. Turn on the solar breaker/disconnect and measure voltage on open wires BEFORE connecting to the controller. Disconnect before wiring.
8. Connect the positive (+) wire of the solar module to the controller's solar positive terminal (+).
9. Connect the negative (-) wire of the solar module to one of the controller's common negative terminals (-).
10. Tighten all four power terminals to 50 in-lbs (5.65 Nm).

3.5 Grounding and Ground Fault Interruption

Connect the grounding terminal in the wiring box to earth ground using a copper wire (minimum 8 AWG / 10 mm²). The grounding terminal is marked with the ground symbol.

WARNING: Risk of Fire. DO NOT bond system electrical negative to earth ground at the controller.

3.6 Remote Temperature Sensor (RTS)

Connect the RTS to the 2-pole terminal for temperature-compensated charging. The RTS cable (33 ft / 10 m, 22 AWG / 0.34 mm²) has no polarity. Tighten connector screws to 5 in-lb (0.56 Nm).

NOTE: RTS is optional. Check with your dealer.

CAUTION: Temperature-compensated charging will not activate without the RTS.

CAUTION: Equipment Damage. Never place the temperature sensor inside a battery cell.

NOTE: RTS cable can be shortened if necessary.

3.7 Battery Voltage Sense

Connect the Battery Voltage Sense wires to the 2-pole terminal for accurate battery voltage readings. Connect positive (+) to positive (+) and negative (-) to negative (-). Polarity reversal will not cause damage but will prevent accurate readings.

NOTE: This connection is recommended for best performance and accurate LCD voltage display.

Wire size: 16 to 24 AWG (1.0 to 0.25mm²). Twisted pair cable is recommended. Maximum wire length: 98 ft (30 m). Tighten connector screws to 5 in-lb (0.56 Nm).

4. Operation

4.1 Power-Up

1. WARNING: Risk of Damage. Connecting the solar module directly to the battery connector will permanently damage the controller.
2. Ensure correct solar and battery polarities are connected.
3. A battery must be connected for the controller to operate.
4. Turn on the battery disconnect switch first. Press the operation button briefly to power on.
5. Turn on the solar disconnect switch. If sufficient sunlight is available, the controller will begin charging.

4.2 Operation and Display Panel

The panel includes LED indicators, an operation button, and an LCD display.

LED Indicators

• Power On/Charging (Green): Solid On = Controller is on. Flashing = Controller is charging (rate of flashing indicates charge stage).
• Fault/Warning (Red): Solid On = Fault occurs. Flashing = Warning situation.
• Wiring Fault (Red): Solid On = Incorrect battery polarity.

Button Operation

• Power On: Press until LCD backlight turns on.
• Backlight On: Short press.
• Enter LCD Setting Mode: Press for 3 seconds.
• Select/Modify Parameter: Short press.
• Confirm/Return: Press for 1.5 seconds.
• Exit Setting Mode: Wait 10 seconds without action.

4.3 LCD Display Icons

The LCD displays PV input voltage, fault/warning codes, battery voltage, charging power, charging current, and battery capacity status.

Battery Charging Status

• Constant Current Mode: Displays battery level with flashing bars.
• Constant Voltage Mode: Displays battery level with bars indicating charge progress.
• Floating Mode: All 4 bars are on, indicating full charge.

4.4 LCD Setting

Enter setting mode by pressing the button for 3 seconds. Use short presses to navigate programs and modify parameters. Confirm with a 1.5-second press. Exit automatically after 10 seconds of inactivity.

Setting Programs

4.5 Reference Code

Fault Codes

• 01: Over charge current
• 02: Over temperature
• 03: Battery voltage too low
• 04: Battery voltage too high
• 05: PV high loss
• 06: Battery temperature too low
• 07: Battery temperature too high

Warning Codes

• 20: PV low loss
• 21: Output derating due to high PV voltage
• 22: Output derating due to high temperature
• 23: Low alarm for battery temperature

5. Charging Logic

5.1 3-Stage Charging

The controller uses a 3-stage charging algorithm: Bulk, Absorption, and Float.

• Bulk Charge Stage: The controller supplies maximum possible solar power to charge the battery.
• Absorption Stage: Constant voltage is applied to maintain battery voltage. Charging transitions to Float stage when current drops to one-tenth of the maximum setting or after a set C.V. charging time.
• Float Stage: Battery is maintained at a lower voltage. If battery voltage drops below Float voltage for 30 minutes, it returns to Bulk stage.

5.2 Equalize Stage

The equalization stage helps reverse negative chemical effects and remove sulfate crystals, improving battery capacity. It can be triggered in Absorption stage if charging current is high enough, or if the equalization interval is reached while in Float stage.

Equalize Charging Time and Timeout: The controller charges at equalization voltage until the set time is reached. If the battery voltage does not reach the equalization voltage within the set time, the equalization time may be extended. If the timeout is reached before the target voltage, equalization stops and the controller enters Float stage.

5.3 Setting Parameter and Default Value

6. Troubleshooting

7. Specifications

Table 1: Electrical Specifications

Table 2: Battery Charging

Table 3: Mechanical and Environment

8. MPPT Charger Controller Match to the Inverter

This feature limits the inverter's charging current to prevent overcharging when both the MPPT controller and inverter charge the battery simultaneously. The inverter's charging current is limited based on the MPPT charging current.

• Functionality: Enable/disable inverter matching with MPPT function, and limit inverter charging current.
• Current Limiting Logic:
  • If MPPT charging current ≥ inverter setting charging current, inverter's maximum allowable charging current = 0.
  • If MPPT charging current < inverter setting charging current, inverter's maximum allowable charging current = inverter setting charging current - MPPT charging current.

8.1 Match the Inverter to the MPPT Controller

1. Ensure both inverter and MPPT controller are powered on and communication lines are connected.
2. Press and hold the inverter's "Down" button for over 2.5 seconds until the MPPT charger icon flashes, indicating communication attempt.
3. Release the button. The icon stops flashing after 10 seconds. Successful communication enables the function.
4. The matching MPPT function flag is saved in EEPROM and persists after restarts.
5. Once enabled, the inverter's LCD will display MPPT PV voltage and power information.

8.2 Matching MPPT Function is Prohibited

1. Turn off the MPPT or disconnect communication lines.
2. Press and hold the inverter's "Down" button for over 2.5 seconds until the MPPT charger icon flashes.
3. Release the button. The icon stops flashing after 10 seconds. Communication failure indicates successful prohibition.

8.3 Matching MPPT Function Successfully Enabled

If MPPT is charging or PV voltage is >30V and the unit is starting up, the MPPT icon will appear on the inverter's LCD if the function is successfully enabled.

8.4 Matching MPPT Function is Prohibited Successfully

If the matching MPPT function is prohibited successfully, the MPPT icon will no longer be displayed on the inverter's LCD.

Judgment:

• If MPPT function is enabled: LCD interface displays PV voltage, power, etc.
• If MPPT function is prohibited: LCD interface does not display PV voltage, power, etc.