iTechworld 12/24V 40Amp MPPT Solar Charge Controller

Contents

• 1. Safety Precautions
• 2. Product Overview
•     2.1. Introduction
•     2.2 Key Features
•     2.3 Product Appearance
• 3. Installation
•     3.1 Wiring the solar charge controller
•     3.2 Fuse Specifications
• 4. Unit Operation
•     4.1 Menu Navigation
•     4.2 Settings Menu
•     4.3 Changing Parameters
•     4.4 Battery Selection Menu
•         4.4.1 Lithium Battery Profiles (4-3.2, 5-3.2, 3-3.7, 4-3.7, Usr2)
•     4.5 System Voltage Setting
•     4.6 Load Control
•         4.6.1 Manually Controlling the load
•         4.6.2 Load Control Modes
•     4.7 Solar Input Voltage
•     4.8 Setting equalisation charging voltage and duration
•     4.9 Setting Absorption Charging Voltage and Duration
• 5. Troubleshooting
• 6. Specifications
•     6.1 Operating Parameters
•     6.2 Protections
•     6.3 Charging Profiles
• 7. Maintenance and Warranty

1. Safety Precautions

For safe operation and ideal performance, the iTechworld 40A MPPT Solar Charge Controller must be correctly installed and operated correctly. Please carefully read, understand, and follow all instructions and guidelines in this User Guide. iTechworld recommends that all wiring and installation be done by a certified technician to ensure all applicable electrical wiring regulations and installation codes are met.

Failure to follow these instructions may result in damage to the unit and could also result in death or serious injury.

Disclaimer: While iTechworld has taken every precaution to ensure the accuracy of the contents of this user guide, iTechworld assumes no responsibility for any errors or omissions. Furthermore, all specifications and functionality may change at any time without notice.

Important: Please read and understand the entirety of this user guide before using your iTechworld solar charge controller. Any misuse may result in damage to the unit and/or cause harm or serious injury to the user.

SAFETY PRECAUTIONS

1. WARNING: People with physical disabilities, visual, sensory, or mental impairments (including children) should not use this device. Children should be supervised to ensure they do not play with battery chargers.
2. DANGER: Do not disassemble or modify the solar charge controller, doing so may result in a risk of electrical shock, fire, death, or serious injury.
3. DANGER EXPLOSION HAZARD: Do not use this solar charge controller in an environment where flammable fumes or gases are present (such as gas bottles, petrol engines or lead acid battery compartments).
4. DANGER: This solar charge controller is only suitable for battery types listed in the manual. Do not use it for other purposes.
5. WARNING: Please select the correct battery charging profile applicable to the battery being charged. If the incorrect battery charging profile is selected, it may cause damage to your battery or result in fire. If you are unsure of the correct battery charging profile to use, please consult your battery's manufacturer.
6. WARNING: External solar and battery disconnects/fuses are required, otherwise, it may result in damage to the charger, risk of electrical shock, fire, death, or serious injury.
7. WARNING: Ensure that the selected battery charging profile's charge voltage does not exceed the battery's recommended maximum charging voltage. If you are unsure of the maximum charging voltage of your battery, please consult your battery's manufacturer.
8. WARNING: Ensure that the continuous output current of the solar charge controller does not exceed the battery's recommended maximum charging current. If you are unsure of the maximum charging current of your battery, please consult your battery's manufacturer.
9. Warning: When using the solar charge controller to charge a lithium battery, ensure that the battery contains an inbuilt battery management system (BMS) that features under and over voltage protection with cell balancing. Failure to do so may result in fire, death, or serious injury.
10. DANGER: Never smoke or allow a spark or flame in vicinity of battery or engine. This may cause the battery to explode.
11. LIMITATIONS OF USE: Do not use in connection with life support systems or other medical equipment or devices.

2. Product Overview

2.1. Introduction:

The iTechworld 40 Amp MPPT Solar Charge Controller is designed to enhance any solar and battery combination, it works especially well with the iTECH120X lithium battery and iTechworld solar panels. This controller and its charging algorithm are patented by iTechworld. Thanks to the innovative technology in the iTechworld 40 Amp MPPT Solar Charge Controller, you can access the maximum power of your solar panel(s) which will significantly improve your system. The iTechworld 40 Amp MPPT Solar Charge Controller has a Liquid-Crystal Display (LCD) which is used to dynamically display the operation data and working status of the solar charge controller. Suitable for indoor use only.

2.2 Key Features:

• Advanced Maximum Power Tracking (MPPT) technology, with efficiency of 99.5%
• Maximum conversion efficiency of 97%
• Rapid maximum power point tracking.
• Automatic voltage identification (12V or 24V)
• Suitable for charging most common types of automotive or recreational 12-Volt lead acid batteries, such as Gel, Sealed Lead Acid, Flooded Lead Acid, LiFePO4 (Lithium Iron/Ferro Phosphate, such as the iTECH120X) and Li (NiMnCo)O2(Li-po/NMC) Chemistry 12-Volt Lithium batteries containing a BMS.
• 40A MPPT Solar Regulator
• Constant and reliable maximum input power of the solar panel to ensure safety when charging.
• Wide solar panel operating voltage up to 100VDC.
• An intelligent control point for your solar panel system. With an intuitive LCD, you are in control of your solar panel system.
• Power statistics recording functionality, the controller will log the power put into the battery.
• Using the buttons, you can program the controller to your preferences and monitor your solar system in real time.
• Easy to read display icons and indicators will tell you the operating status of your solar panels.

2.3 Product Appearance

Figure 1 Solar Controller Features shows the front panel of the iTechworld solar charge controller. It includes an LCD screen (1), terminals for external temperature probe (2), solar input (3), battery connection (4), and load output (5). It also shows two buttons labeled A (6) and B (7).

3. Installation

The iTechworld 40 Amp MPPT Solar Charge Controller should be installed as close as possible to the battery being charged, this allows for more efficient charging of your battery. The solar charge controller is best mounted vertically with 4 screws (Not included) there are cut outs on the heatsink of the charger where the screws are hooked on. Below is the screw template, the maximum screw head diameter is 5mm.

The solar charge controller should be installed in a dry location, please ensure no liquids (such as water) can enter the solar charge controller. For proper air flow to cool the solar controller, please allow at least 15cm of space above and below the controller and 5cm at the sides.

Figure 2 Mounting Diagram shows a template for mounting the solar charge controller. It indicates dimensions of 131mm vertically and 133mm horizontally, with screw hole positions.

3.1 Wiring the solar charge controller

Figure 3 Connection Diagram illustrates the wiring of the solar charge controller. It shows connections from the PV Array, through a breaker and fuse, to the battery (with a fuse) and then to the Load output. Polarity markings (+/-) are indicated.

When wiring the solar charge controller, please use flexible, multi-stranded copper wire, with a current rating of at least 50Amps.

1. Connect your components to the solar charge controller in the sequence as shown in figure 3(1,2,3) and make sure the polarity is correctly connected. Do not insert fuses or turn on the breaker during the installation. When disconnecting, the order will be reversed (3,2,1).
2. A battery fuse must be used, the battery fuse should be installed as close to the battery as possible. The suggested distance is within 15cm of the battery. Please refer to fuse specifications.
3. Always connect the battery first, as this allows the solar charge controller to recognise the system voltage.
4. Power up the controller by installing the battery fuse first, then switching on/connecting the solar array.

Warning: If using the load output on the solar charge controller, do not exceed 40Amps, large loads such as inverters should only be connected to the battery directly.

Warning: This solar charge controller is a common positive controller. Directly connect the solar panel + & - connections to the solar charge controller only.

3.2 Fuse Specifications

All recommended fuses should be connected in series in circuit, and as close as possible to power sources. Bolt down fuses are preferred as they ensure a low resistance connection.

Blade type fuses are not recommended as they can result in a high resistance connection which can cause excess heat generation and may damage the fuse holder and/or the wiring. Self-resetting circuit breakers are not recommended as they may prematurely trip due to the heat generated by the large current flowing through the wires.

Please refer to the table below for the recommended fuses.

(PLEASE NOTE FUSES ARE NOT SUPPLIED)

Figure 4 Bolt Down Fuse Holder illustrates a bolt-down fuse holder.

4. Unit Operation

Solar Controller Status

Figure 5 Display Icons illustrates various status indicators on the solar controller's LCD screen, including PV Array status (Day/Night, Charging), Battery status (State of Charge, Lithium Battery Type), and Load status (On/Off).

Boot Sequence

Figure 6 Boot Sequence shows the startup process of the controller, displaying the initial boot screen, battery system voltage, controller rated charge current, and software revision.

4.1 Menu Navigation

Figure 7 Main Navigation Flow Chart details the navigation through different parameters on the LCD screen, such as Home Screen, Ambient Temperature, Charge Current, Discharge Current, Accumulated Charging AH, Internal Temperature, and Accumulated Discharging AH. It also explains how to switch between ambient and internal temperature readings.

After the controller is powered on, the display will enter the main navigation flow chart. At this time, short press button A or B to navigate between the parameters. When on the Ambient Temperature screen, you can switch between the ambient temperature and the solar charge controller's internal temperature (denoted by the letter H under the °C) by pressing and hold button B for longer than 3 seconds.

4.2 Settings Menu

Figure 8 Settings Flow Chart outlines the process to enter the settings menu by holding Button A on the Home Screen. It shows various adjustable parameters like Re-Bulk Voltage, Bulk Voltage, Equalisation Voltage, Absorption Voltage, System Voltage, Battery Type, Low Voltage Recovery, Low Voltage Cut-off, Float Voltage, Temperature Compensation, Load Control Mode, and Remote Communication Number.

4.3 Changing Parameters

Figure 9 Changing Parameters illustrates how to modify user-changeable settings. It shows holding Button A to make a parameter flash, using Buttons A or B to adjust the value, and holding Button A again to save or Button B to discard changes.

To change user changeable parameters, press and hold button A until the parameter value starts to flash, then short pressing button A or B will alter the parameter, once the desired value is reached, press, and hold button A for more than 3 seconds to save the data. Otherwise, press and hold button B to not save the change and return to the Home Screen.

4.4 Battery Selection Menu

Figure 10 Battery Selection Flow Chart guides the user through selecting the appropriate battery charging profile. It lists various battery types including User Modes (Usr1, Usr2), Gel, Sealed, Flooded, and multiple Lithium profiles (LiFePO4, LiPo) with different cell configurations and capacities (e.g., 100Ah, 200Ah).

To change the battery charging profile, on the home screen, press and hold button A for more than 3 seconds to access the settings Menu, then short press button B until you are on the Battery Type (refer to Settings Menu), once on the Battery Type menu, press and hold button A for more than 3 seconds to access the Battery Selection Menu.

Then short pressing buttons A or B to toggle through each of the different battery charging profiles (Usr1, Gel, Sld, Fld and lithium batteries.)

When the desired charge profile is on the display flashing, press and hold button A for more than 3 seconds to save the selection.

4.4.1 Lithium Battery Profiles (4-3.2, 5-3.2, 3-3.7, 4-3.7, Usr2)

When a lithium profile is selected, the display will prompt for the total capacity of your lithium battery, use buttons A or B to set the value to the closest number as it is adjusted in increments of 5Ah. Once the correct battery capacity is flashing on the display, press and hold button A for more than 3 seconds to save the selection.

NOTE: When using any of iTechworld's lithium batteries, such as the iTECH120X, please ensure ONLY the 4-3.2 (Lithium Battery, 3.2V/Cell, 4 in series) lithium profile is selected.

4.5 System Voltage Setting

Figure 11 System Voltage Setting shows how to manually set the system voltage to 12V or 24V, overriding the default auto-sensing.

The solar charge controller system voltage is set to auto sensing by default, although if required you can set it manually to be either 12 Volts or 24 Volts. To change the system voltage, enter the Settings Menu (refer to Settings Menu) and scroll to the System Voltage screen, then press and hold button A until the parameter value starts to flash, then short pressing button A or B will alter the parameter, once the desired value is reached, press, and hold button A for more than 3 seconds to save the data. Once the system voltage is saved, the solar controller will automatically restart after a few seconds.

4.6 Load Control

4.6.1 Manually Controlling the load

Figure 12 Load Control shows how to manually turn the load on or off by pressing Button B on the Home Screen, indicated by a light bulb symbol with rays coming out or off.

On the Home Screen, short pressing button B will turn on or off the load as denoted by the light bulb symbol with rays coming out or off.

4.6.2 Load Control Modes

LD1 Manual Load Control: The controller will not automatically turn on or off the load based on solar input (See above (manually controlling the load).

LD2 Light/Load Control Mode: The controller will automatically turn off the load when there is solar input detected (day) and turns on the load when there is no solar input detected (night). (Detection time of day and night is about 30 seconds).

Dual Time Mode

Figure 13 Dual Time Mode Flow Chart explains Load Control Modes LD3 (Dual Time Mode) and LD4 (Inverted Light/Load Control Mode). LD3 allows setting specific ON times for night and day. LD4 turns the load on during the day (solar input) and off at night (no solar input).

LD3 Dual Time Control Mode: The controller will turn on the load automatically for the set amount of time during night and day, it will then turn the load off after the elapsed time. When LD3 is selected the above additional settings will be prompted for input, the parameter will be flashing, use buttons A and B to increase or decrease the desired runtime.

LD4 Inverted Light/Load Control Mode: The controller will automatically turn on the load when there is solar input detected (day) and turns off the load when no solar input is detected (night). (Detection time of day and night is about 30 seconds).

4.7 Solar Input Voltage

Figure 14 Solar Input Voltage shows how to toggle between displaying Solar Input Voltage and Battery Voltage on the Home Screen by holding Button B.

To toggle between the Solar Input Voltage and Battery Voltage, on the Home Screen, press and hold Button B for more than 3 seconds.

4.8 Setting equalisation charging voltage and duration

(Only adjustable on the Usr 1 battery charging profile)

Figure 15 Equalisation Voltage Settings details how to adjust the equalization charging voltage and duration. This is only adjustable for the Usr1 battery profile. The process involves navigating to the screen, holding Button A to flash the value, using Buttons A/B to adjust, and holding Button A to save.

Navigate to the Equalisation Voltage screen (refer to Figure 8), then press and hold Button A for more than 3 seconds until the value starts to flash, then using buttons A or B to increase or decrease the Equalisation Voltage, once the desired voltage is set, press, and hold Button A for more than 3 seconds to advance to the duration setting, once again use Buttons A or B to adjust. Finally press and hold Button A for more than 3 seconds to save all changes.

4.9 Setting Absorption Charging Voltage and Duration

(Only adjustable on Usr1 battery charging profile)

Navigate to the Absorption Voltage screen (refer to figure 8), then press and hold Button A for more than 3 seconds until the value starts to flash, then using buttons A or B to increase or decrease the Absorption Voltage, once the desired voltage is set, press, and hold Button A for more than 3 seconds to advance to the duration setting, once again use Buttons A or B to adjust. Finally press and hold Button A for more than 3 seconds to save all changes.

5. Troubleshooting

6. Specifications

6.1 Operating Parameters

6.2 Protections

6.3 Charging Profiles

NOTE: Values with (Adjustable) next to them indicates user adjustable values. For iTechworld Lithium Batteries, please use LiFePO4(4-3.2) only, please refer to section 4.4.1.

7. Maintenance and Warranty

Maintenance

Make sure that the solar charge controller is turned off while performing any maintenance.

To keep your solar charge controller operating properly, there is very little maintenance required.

You should clean the exterior periodically with a dry cloth to prevent the build-up of dust and dirt. Also check and tighten the fasteners on the DC input terminals.

Warranty

iTechworld guarantees this product against defects in materials and workmanship for a period of 12 months from the date of purchase. This warranty will be considered void if the unit has been misused, altered, or accidentally damaged. iTechworld will not be liable for any amount of damage in excess of the retail purchase price of the unit under any circumstances. Incidental and consequential damages are specifically excluded from coverage under this warranty.

This solar charge controller is not intended for commercial use. This warranty does not apply to damage to units from misuse or incorrect installation/connection. Misuse includes wiring or connecting to improper polarity sources.

Return/Repair Policy

In the unlikely event that technical problem arises, please contact iTechworld customer service on 1300 483 249 or email service@itechworld.com.au before returning the solar charge controller back to the store.

If such a unit is returned within the warranty period, iTechworld will repair the unit or, at its discretion, replace it, free of charge. If the unit is repaired, new or reconditioned replacement parts may be used, at the manufacturer's discretion. A unit may be replaced with a new or reconditioned unit of the same or comparable design. The repaired or replaced unit will then be warranted under these terms for the remainder of the warranty period. The customer is responsible for the shipping charges on all returned items back to iTechworld.

Limitations

This warranty does not cover accessories, such as adapters and batteries, defects or damage resulting from normal wear and tear (including but not limited to chips, scratches, abrasions, discoloration or fading due to usage or exposure to sun or environmental elements), accidents, damage during shipping to iTechworld's service facility, alterations unauthorized use or repair, neglect, misuse, abuse, failure to follow instructions for care and maintenance, fire, and flood.

Contact

iTechworld
281 Great Eastern Hwy
Burswood WA 6100
Phone: 1300 483 249
Website: www.itechworld.com.au
E-Mail: service@itechworld.com.au