PowMr POW-M60-MAX MPPT Solar Charge Controller

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 DC 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, automatic operation. Its maximum power point tracking (MPPT) type battery charging mode, as well as control technology, will greatly extend the battery life. The controller features a smart tracking algorithm that maximizes the energy from the solar PV module(s) and charge the battery.

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

The 0 layer series has a humanized LCD screen display algorithm, one interface to complete all parameters display. Data can be monitored and configured in one layer of pages. At the same time, the MAX model has been optimized and upgraded in several aspects compared to its previous generation. The continuous growth of the POW-M60 series aims to embody the action philosophy of developing user-friendly products that meet user needs and optimize user experience.

1.1 Features

• Integrated charge presets: Integrated charge presets combined with adaptive charge logic are well suited for most common battery types, such as LiFePO4, Gel and flooded lead-acid.
• Flexible Application: Compatible with 12V/24V/36V/48V system voltage.
• Multi-stage charge algorithm: The multi-stage charge algorithm is specifically engineered to optimise each recharge cycle and charge maintenance over extended periods.
• MPP Tracking Technology: The Maximum Power Point Tracking (MPPT) technology will track the array's maximum power point voltage (Vmp) as it varies with weather conditions, ensuring that the maximum power is harvested from the array throughout the course of the day.
• High efficiency: Innovative MPPT technology with high tracking efficiency up to 99% and peak conversion efficiency of 98%; resulting in lower power usage, less heat generated and cooler operation.
• Adaptive boost charge: Adaptive boost charge monitors the battery's response during initial charging and intelligently determines the appropriate boost charge duration for each individual charge cycle. This ensures that the battery is fully recharged regardless of the discharge level or capacity and avoids excessive time at the elevated boost charging voltage (that can accelerate battery aging).
• Durable and safe:
  • Limit the maximum charging current. 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 will result.
  • Battery reverse polarity protection.
  • Over-temperature protection. If the temperature of the controller heat sink exceeds 65°C, the controller will automatically start reducing the charging current and shut down when temperature exceeds 80°C.
• Silent operation: Almost silent operation since there is no cooling fan or moving parts, cooling is via natural convection.
• Lithium battery activation: Compatible with Li-ion (LiFePO4) batteries; when the battery type parameter is set to Lithium battery the charge cycle settings are altered to suit. Moreover, when the connected lithium battery is in a protected state, the controller will activate the lithium battery using the energy from the solar panel with a current that does not exceed the lithium battery's protection voltage and current range. Warning: Do not charge Li-ion batteries if the battery temperature is below 0°C.
• Enhanced User Interface with a Large Screen: The POW-M60-MAX features an expanded LCD display interface, significantly enhancing the user experience of the operating interface.
• Built-in Dedicated Wiring Terminals: Convenient plug-and-play design saves approximately 60% of installation time. It greatly enhances wiring safety and completely avoids errors caused by reverse connection to the controller ports.
• Alarm Function: The battery controller is equipped with an integrated alarm function. For details about protection and fault alarm, see “5.2 Troubleshooting" section.

1.2 Production Overview

The PowMr POW-M60-MAX MPPT Solar Charge Controller features a clear interface and robust design. The main components and their functions are:

• 1. LCD display screen: Shows real-time operating data, status, and parameters.
• 2. Function keys: Four buttons used for navigating menus, adjusting settings, and confirming operations.
• 3. PV input terminal: Connection point for the solar panel array.
• 4. Battery terminal: Connection point for the battery bank.
• 5. Load terminal: Connection point for DC loads.
• 6. Mount hole: Points for securing the controller to a mounting surface.
• 7. Heat sink: Dissipates heat generated during operation.

2 Installation and Connection

2.1 Unpacking and Inspection

Before unpacking the controller, check whether the package is damaged. After unpacking, check whether the contents of the package are damaged or missing. You should have received the following items inside of package:

• Controller
• User manual
• Screws / bolts
• Special cable with terminals
• Special cable terminals

2.2 Preparing for Installation

The controller is designed to be wall-mounted using the flanges that protrude from either side of the heatsink.

Select the Mount Location:

Before mounting, consider the following aspects to identify/provide a suitable and safe location:

• Install the controller in a location with good natural airflow/ventilation.
• Ensure there is sufficient unobstructed space around the controller; a minimum clearance of 75mm above and below is recommended. Diagram showing the PowMr MPPT Solar Charge Controller with arrows indicating recommended minimum clearances of 75mm on all sides (top, bottom, left, right) for proper airflow.
• 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.
• 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.
• Install the unit by screwing four screws. It's recommended to use M5 screws.

2.3 Things You Need

Make sure you have all the parts you need to install the controller:

NOTICE: For all wirings and circuits specifications see section “2.4 DC Breaker Type”.

2.4 DC Breaker Type

PV input circuit breaker type: Determine the maximum PV input current based on the configured system voltage and by referring to "6 Technical Specification”.

Note: The voltage in series shall not exceed maximum PV input open-circuit voltage.

Recommended specifications for the DC circuit breakers for load output circuit:

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

2.5 PV Module Selection

When selecting proper PV modules, please be sure to consider below parameters:

1. Open circuit Voltage (Voc) of PV modules not exceeds max. PV array open circuit voltage of controller.

2. Open circuit Voltage (Voc) of PV modules should be higher than Min. battery voltage.

2.6 Wiring Precautions

• Let installation and connection work be done by a licensed electrician.
• Loose connections can cause dangerous overheating of the cables and/or terminals. Therefore, tighten all connections well, in order to limit transition resistance as far as possible. Use cables of the correct size. Please refer “2.4 DC Breaker Type” section for details.
• Please install separate circuit breakers for each circuit, which will not only enhance the safety of the circuits but also facilitate easy disconnection of the circuits for safe operation during future cleaning and maintenance.
• Do not connect the inverter to the load side of the controller. Otherwise, irreversible damage may be caused to the device. If you need to install an inverter, see the following system application diagram of the controller.

System wiring diagram illustrating the connections. It shows a PV Array connected via a breaker to the controller's PV input terminal. The controller's battery terminal is connected to a battery via a fuse. The controller's load terminal is connected to a load via a fuse. An inverter is shown connected to the AC output, separate from the load side of the controller.

2.7 Installation and Connection Step-By-Step

1. Mark the position of the mounting spots on the wall based on the mount holes of the controller. Then make 4 mounting holes in the wall with an electric drill according to the spots. Refer to the "2.2 Preparing for Installation" section for installation locations.
2. Insert the expansion rubber screw plug into the mounting holes.
3. Mount the controller vertically to the ground with terminals facing down; secure using the 4 mounting holes/slots on the base. To aid installation, it is recommended to 'hang' the unit using the 2 upper screws and then add the 2 lower screws, before fully securing all 4 screws. Recommend screws size is M5. Diagram illustrating the mounting process. It shows the controller being mounted on a wall with four screw holes indicated. Arrows suggest using the top two screws for initial hanging, followed by the bottom two, and then fully securing all four.
4. Battery Connection: Connect the battery to the controller with the cables.

NOTICE:

• All wiring must be performed by a qualified personnel.
• For safe operation and standard application, a circuit breaker of the corresponding specifications must be installed on the cable connecting to the controller. And confirm that the wire used is thick enough. Please refer “2.4 DC Breaker Type” section for selection of wiring and circuit breaker specifications.
• Ensure that all circuit breakers are open until all cables are connected.
• The positive end of the cable shall be connected to the positive port (+), and the negative end shall be connected to the negative port (-).
• The above precautions also apply to the wiring of the PV side and the load side.

5. PV Connection: Connect the PV array to the controller with the cables.
6. DC Output Connection: Connect the load to the controller with the cables.
7. Check before starting up: See figure as shown below for wiring details. If everything is all right, and all the wires are firmly connected, close the circuit breakers at the battery side, PV module side, and load side in sequence to startup controller.

WARNING: Risk of electric shock!

Make sure that all the power is turned off before above operations, and then follow the corresponding inspections and operations.

Wiring diagram for startup sequence. It shows the battery (1) connected to the controller, the PV array (2) connected to the controller, and the load (3) connected to the controller. The diagram emphasizes connecting the battery first, then the PV array, and finally the load.

3 Charging Mode

The charging controller is equipped with an intelligent 3-stage charge characteristic which takes care of an optimal charge of your batteries. When switched on, the controller always starts at Bulk stage.

There are 3 integrated charge modes (Bulk, constant, float). Through the three stages of fast, efficient and safe battery charging mode, the system can effectively extend the battery life. 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.

The charging mode parameters can be set as required via LCD screen. Please refer to the "4.3 Browse and Configuration Step-By-Step" section for more information. Any setting made are stored and will not be lost when the controller is disconnected from battery or PV module.

The multi-stage charge algorithm includes the individual charge stages described below:

• Bulk charge: The battery is charged at maximum charge current until the voltage increases to the configured boost charge voltage. The bulk stage duration is dependent on the battery's level of discharge, the battery capacity and the charge current. When the battery voltage reaches the preset value of the Boost charging voltage, it starts to boost charging.
• Boost charge: The battery is charged at the configured boost charging voltage, with the charge current slowly decreasing as the battery approaches full charge. The default boost stage duration is adaptive and intelligently varied depending on the battery's level of discharge – this is determined from the duration of the bulk charge stage. When the photovoltaic module is reconnected, a new round of charging cycle will be started. If the battery is in full state, the charging stage will directly enter stage B, which is the boost charging voltage stage, and the battery voltage in this stage will not be higher than the set voltage of stage B. Currently, the duration of stage B is 30 minutes.
• Float charge: At the end of the boost charging stage, the controller will reduce the battery voltage by reducing the charging current and keep the battery continuously at the floating charging voltage set value to maintain the full charge state of the battery. In Float charging stage, loads are able to obtain almost all power from solar panel. If loads exceed the power, the controller will no longer be able to maintain battery voltage in Float charging stage. If the battery voltage remains below the Recharge Voltage, the system will leave Float charging stage and return to Bulk charging stage.

Two graphs illustrating the 3-stage charging process. The top graph shows 'Battery Voltage' over 'Time', depicting three stages: 'A Bulk Charge', 'B Boost Charge', and 'C Float Charge'. The bottom graph shows 'Battery Current' over 'Time', illustrating 'Max Current' during Bulk charge, decreasing current during Boost charge, and a lower, stable current during Float charge.

4 Operation Instruction

4.1 Icon Display on LCD Screen

The LCD screen displays various icons to indicate the controller's status and operating parameters:

4.2 Function Keys

The controller is operated using four function keys located below the LCD screen:

4.3 Browse and Configuration Step-By-Step

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

NOTICE: The screen will automatically turn off the backlight after about 25 seconds without pressing a button to save power consumption. The backlight display can be activated by operating the key again.

4.3.1 PV side

Step 1. Checking PV input Information

Press " PV / ☀️ " key to switch PV information, which is PV input voltage and PV input power in sequence.

Flow diagram showing the sequence for checking PV input information (PV input voltage, then PV input power).

4.3.2 Battery side

Step 1. Checking Battery Information

Press " BAT / ▲ " key to switch battery information, which is current battery voltage, charging current, equipment temperature, battery calibration voltage, battery type, boost charging voltage, float charging voltage, low DC recovery cut-off voltage, low DC cut-off voltage in sequence.

Flow diagram showing the sequence for checking battery information, including Current Battery Voltage, Boost Charging Voltage, Float Charging Voltage, Charging Current, Battery Type, Low DC Recovery Cut-off Voltage, Equipment Temperature, Battery Calibration Voltage, and Low DC Cut-off Voltage.

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 / ▼ " adjust load state or load enable duration.
• Finally press " SET / ⚙️ " to confirm.
  • 00H: The solar light control mode. (When the solar energy is sufficient, enable the 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 you customize battery parameters, confirm the following parameters of the connected battery:
   • Max charging voltage
   • Discharging protection voltage
2. After confirming the battery information, you can 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 two times per year for best performance.

• Make sure controller firmly installed in a clean and dry ambient.
• Make sure no block on air-flow around the controller. Clear up any dirt and fragments on radiator.
• Check all the naked wires to make sure insulation is not damaged for serious solarization, frictional wear, dryness, insects or rats etc. Repair or replace some wires if necessary.
• Tighten all the terminals. Inspect for loose, broken, or burnt wire connections.
• Confirm that all the system components are ground connected tightly and correctly.
• Confirm that all the terminals have no corrosion, insulation damaged, high temperature or burnt/discolored sign, tighten terminal screws to the suggested torque.
• Check for dirt, nesting insects and corrosion. If so, clear up in time.

WARNING: Risk of electric shock!

Make sure that all the power is turned off before above operations, and then follow the corresponding inspections and operations.

6 Technical Specification

Company 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