BZ Products
BZ PRODUCTS INC. U.S.A
MODEL MPPT1000пЈЄ
пЈЄ
12, 24 AND 48 VOLT 1000 WATT MAXIMUM TACKING POWER POINT SOLAR CONTROL
INSTALLATION MANUAL V 1.0
CARFULLY READ ALL INSTRUCTIONS PRIOR TO INSTALLING OR USING THIS EQUIPMENT
DESCRIPTION: The model MPPT1000 is a high performance current boosting, voltage converting maximum power point solar
control. Through the use of advanced microprocessor control and high efficiency power converter, power wasted by the old PWM
style solar controls is converted into higher battery charge current. The MPPT1000 allows for input voltage conversion from a higher
input voltage (from the solar panels) to a lower battery voltage. This voltage conversion along with accurate tracking of the maximum
power point of the solar panel greatly increases battery charging current. The MPPT1000 is ideally suited for use in off grid
stand-alone systems.
The digital volt and amp meter of the MPPT1000 displays battery voltage, solar panel current and battery charge current.
Proper battery charging is maintained over a wide temperature range with battery temperature compensation. Battery charging voltage
is accurately regulated.
OPERATION: The MPPT1000 may feel warm when operating. Operation of the MPPT1000 is fully automatic. No adjustments are
required for most installations. The MPPT1000 automatically turns on when power is available from the solar panel. The internal
microprocessor measures the output power of the solar panel and determines the optimum operating point that produces the highest
possible charge current to the battery.
The float voltage of the MPPT1000 is calibrated to 14.1 volts. 14.1 volts is well suited to flooded batteries. When the battery
is charged to 14.1 volts the red float led blinks. At this point, charge current to the battery will gradually diminish to maintain the 14.1
float voltage. If a load is turned on maximum charge current is again applied to the battery. Temperature compensation automatically
adjusts the battery float voltage to properly charge the battery over a wide temperature range. When the temperature is warm, the float
voltage drops to a lower voltage and not over charge the battery. When the temperature is cold, the float voltage rises to ensure full
charge to the battery. MPPT1000 is well suited for flooded, deep cycle and sealed gel type batteries. There is no interaction between
the MPPT1000 and other battery charging systems.
SAFETY INSTRUCTIONS: Refer installation and service to qualified service personnel. Incorrect installation may result in risk
of fire. Remove all sources of electrical power, photovoltaic and battery before servicing this equipment. Never charge a frozen
battery. Warning! Batteries produce explosive gasses. Install batteries in a well-ventilated area. Follow the battery
manufacturer’s maintenance and charging recommendations. Install properly type and rated fuses as required. Do not connect
controller to generators or alternators. Caution high voltages may be present. Do not disturb any components on the circuit board.
SYSTEM PLANNING: Carefully plan your installation. Determine proper fuse type, ratings and wire size using the guides below.
Install the MPPT1000 near the battery bank. Avoid installing the controller in wet, damp or small confined locations. Do not install
the MPPT1000 in direct sunlight. Use short direct wiring. Install the controller in accordance with state, local and national electrical
codes. Securely fasten the controller to a wall or other suitable structure. Provide support for all wiring. Place the battery temperature
sensor on or near the battery. Install suitable type and rated fuses. Install suitable earth ground to the MPPT1000 enclosure.
INSTALLATION: Remove the four # 6 black Phillips screws to gain access to the interior of theMPPT1000. Install the two wire
bushings in the wire conduit holes if conduit is not used. Do not touch or disturb any components of the MPPT1000. Use high quality
stranded wire only. Solid wire is not recommended.
The MPPT1000 wire connector will accept up to # 2 AWG wire. Install the battery fuse near the battery. See the wiring diagram for
more details. Make certain no installation debris falls onto the MPPT1000 circuit board or inside of the enclosure.
1
Do not to modify the MPPT1000 enclosure. Modifying the enclosure may cause metal debris to fall onto the
circuit board and damage the control. Any metal debris found in the control will void the warranty.
Protect wiring from damage. If wire conduit is not used, install the wire bushings (supplied) to protect the wiring from damage.
Clearly labeling all wiring with permanent wire markers will simplify installation and help prevent wiring errors. Write the wire
designations on the MPPT1000 wiring diagram. Documenting the installation will help troubleshoot any problems in the future.
Permanent wire labels are available from most electrical parts suppliers. Route wiring as directly as possible to the solar panel and
battery. Take care to follow the wiring diagram exactly.
GROUNDING: Proper earth ground is required in all installations. The earth ground connection is located inside the MPPT1000
control on the bottom right side of the enclosure (near the BATTERY – terminal). Use suitably sized wire lug and wire to make the
connection to earth ground.
BATTERY VOLTAGE SELECTION: SW-1 on the MPPT1000 circuit board selects the battery voltage. The switch is marked 12,
24 and 48 corresponding to the battery voltage. Select the battery voltage by depressing the required battery voltage white switch to
the right. As shipped SW-1 is set for 12 volt and flooded battery. To change the battery from 12 volts to 24 volts, press SW-1 position
4 (marked 12) to the left and press SW-1 position 3 (marked 24) to the right. For 48 volt operation, press SW-1 position 2 (marked 48)
to the right. Position 1 on SW-1 open (as shipped) is set for flooded batteries. For sealed batteries depress position 1 rocker to the
closed (right) position. The float voltage will reset to13.8 volts.
WIRE SIZING: For proper operation of the MPPT1000 use the wire size specified. Refer to the wire size chart to determine
minimum wire size. Wire sizes specified are the minimum required, a larger wire size than specified may be used.
SOLAR CIRCUIT WIRE SIZING CHART
NINIMUM RECOMMENDED WIRE SIZE
TOTAL
SOLAR
INPUT
WATTS
2
1-10 FT
11-20 FT
21-30 FT
31-40 FT
41-50 FT
UP TO 500
WATTS
24 TO 150 VDC
# 10 AWG
# 8 AWG
# 6 AWG
# 4 AWG
# 2 AWG
501 TO 1000
WATTS
24 TO 150 VDC
# 8 AWG
# 6 AWG
# 4 AWG
# 2 AWG
# 2 AWG
USE CAUTION WHEN CHANGING FUSES
FUSES: Separate fuses are required for the solar panel and battery circuits. Use proper type and rated fuses in all circuits. See
wiring diagram for more information. Properly rated fuses are required in all installations. Refer to the fuse selection chart and wiring
diagram to determine the proper fuse ratings.
SOLAR CIRCUIT FUSE SIZING CHART
SOLAR PANEL VOLTAGE
12 VOLTS
NOT RECOMENDED
24 TO 48 VOLTS
48 TO 88 VOLTS
88 TO 150 VOLTS
INPUT POWER
UP TO 500 WATTS
INPUT POWER
501 TO 1000 WATTS
30 AMPS
25 AMPS
15 AMPS
40 AMPS
30 AMPS
20 AMPS
BATTERY CIRCUIT FUSE SIZING CHART
BATTERY VOLTAGE
12 VOLTS
24 VOLTS
48 VOLTS
INPUT POWER
100 TO 500 WATTS
50 AMPS
30AMPS
20 AMPS
INPUT POWER
101 TO 500 WATTS
50 AMPS
50 AMPS
30 AMPS
BATTERY CIRCUIT WIRE SIZE: Use # 2 wire in the battery circuit.
BATTERY TEMPERATURE SENSOR: Position the battery temperature sensor (the gray wire on the bottom of the MPPT1000) on
or near the main battery.
FLOAT VOLTAGE CALIBRATION: Battery float voltage is pre-calibrated to 14.1 volts.
In most installations the float voltage needs no adjustment. Check battery manufacturer’s specifications for proper float voltage
setting.
To adjust the battery float voltage locate the float voltage control on the MPPT1000. Let the battery charge up to 14.1 volts
(the red float LED will blink) before adjusting the float control. Adjust the float voltage counter clockwise to lower the float voltage
and clockwise to increase the voltage. Adjust the float control in small increments until the desired voltage is displayed on the
MPPT1000 volt meter. SW-1 position 1changes the float voltage between 14.1 volts (flooded batteries) and 13.8 volts (sealed
batteries).
BATTERY VOLTAGE TEMPERATURE COMPENSATION: To properly charge the battery over a wide temperature range the
battery float voltage is temperature compensated. Battery voltage will increase in cold temperatures and decrease in warm
temperatures. Secure battery temperature on or near the main battery.
3
SOLAR PANEL VOLTAGE: The advanced microprocessor control of the MPPT1000 allows a higher input voltage from the solar
panels to charge the battery. In many installations higher boost current over a greater operating range may be achieved by wiring the
solar panels in series. For example, wiring solar panels in series to producer 24 volts for charging a 12 volt battery will generally
produce a higher maximum battery charging current.
MPPT1000 WIRE CONNECTIONS: Connect the MPPT1000 wiring in the following order. Connect battery + and - to the MPPT
1000. The LCD meter will display the battery voltage. Connect the solar panel + and - to the MPPT1000. In a few seconds the
controller will turn on and begin charging the battery.
MAINTENANCE: The MPPT1000 requires little maintenance. Clean the MPPT1000 with a damp cloth. Recalibrate the float voltage
if required. Visually inspect the entire system for damage. Tighten any loose wire connections. Keep the photovoltaic array clean and
properly aligned to the sun. Follow battery manufacturer’s maintenance recommendations.
WARRANTY: BZ PRODUCTS, INC. Model MPPT1000 is warranted to be free of defects in material and workmanship for five
years from the date of purchase. Failure to provide correct installation, operation or care for this product, in accordance with the
instruction manual, will void the warranty. Product liability shall be limited to repair or replacement, at the discretion of the
manufacturer. The manufacturer is not responsible for the labor or other charges necessitated by the removal, transportation, or
reinstallation of any defective product. Warranty does not cover damage due to, mishandling, abusive conditions, lightning, or
exposure to weather. No specific claim of merchantability shall be assumed or implied beyond what is printed in this manual. No
liability shall exist from circumstances arising from the inability to use this product, or it’s inappropriateness for any specific purpose.
In all cases, it shall be the responsibility of the customer to insure a safe installation in compliance with local, state and national
electrical codes.
RETURN PROCEDURE: If return a model MPPT1000 for warranty service is required. Include the following. Name/Company
name, return address, telephone phone number, a brief description of the problem, a copy of sales receipt. Include$14.00 for return
shipping/handling and insurance. For technical assistance call or email BZ Products Inc.
BZ PRODUCTS, INC.
8801 Gravois Road. St. Louis MO 63123 U.S.A
(314)644-2490
[email protected] www.bzproducts.net
MADE IN St. LOUIS MISSOURI U.S.A.
SPECIFICATIONS
SOLAR INPUT POWER 12 VOLT BATTERY SYSTEMS 500 WATTS MAXIMUM
SOLAR INPUT POWER 24 VOLT BATTERY SYSTEMS 1000 WATTS MAXIMUM
SOLAR INPUT POWER 48 VOLT BATTERY SYSTEMS 1000 WATTS MAXIMUM
SOLAR PANEL INPUT VOLTAGE 150 VOLTS MAXIMUM
SOLAR PANEL INPUT POWER 1000 WATS MAXIMUM
BATTERY FLOAT VOLTAGE IS PRE SET TO 14.1 VOLTS.
Solar input voltage 12 volt battery
Solar input voltage 24 volt battery
Solar input voltage 48 volt battery
Output current 12 volts
Output current 24 volts
Output current 48 volts
Float regulation
Float voltage sealed battery
Float voltage range
Float voltage range
Float voltage range
Operating temperature
Storage temperature
Mounting
Efficiency
Size
100 volts max.
Surge current
150 volts max.
Digital meter
150 volts max.
DC volts range
40 amps continuous
DC current range
40 amps continuous
Input power min.
25 amps continuous
Battery capacity
В±.1 volts nominal
Min battery voltage
13.8 /27.6 /55.2 volts
Float voltage flooded battery
12.5 to 15.5 volts
Tempered Compensation
25 to 31 volts
Reverse current
50 to 60 volts
Operating current
-20 to + 60Вє
Wire size
- 30 to + 70Вє C
Conduit size
Four # 6 screws (not supplied)
Lightning protection
> 97% @ 40 amps
Finish
6” X 8 ½” X 3 3/8”
Weight
Specifications are subject to change without notice. 10/2014
120% for 10 min.
½” LCD display
0-99.9 volts В± .5%
0-99.9 amps В± .5%
100 watts
100 AH minimum
0.0 volts
14.1 /28.2 /56.4 volts
-18mV/ВєC cell
.02 amps max.
.15 amps max.
# 2 AWG max.
ВЅ inch two each
1000 watt MOV
Beige powder coat
3 pounds
INSTALLATION SUGGESTIONS:
Do not use glass type fuses or standard size ATO automotive style fuses. Only use fuses or circuit breakers specified for solar
applications. Use cartridge style solar fuses or solar rated circuit breakers. Always instal a fuse in the solar and the battery circuits.
Wire lugs and splices should be crimped properly. With no loose wire strands or uneven crimps. Provide proper weather sealing as
required. It is highly recommended to use larger sized wire than specified in the wire sizing chart.
Only use high quality stranded wire. Leave enough wire at the solar panel and charge controller ends to allow for easy servicing.
The battery temperature sensor (the black tip at the end of the grey wire) may be glued to the battery.
4
BZ PRODUCTS, INC.
MPPT1000 WIRING DIAGRAM v1
SW-1 BATTERY VOLTAGE SELECTION
12 VOLTS
1
2
3
4
24 VOLTS
F/S
48
24
12
1
2
3
4
48 VOLTS
F/S
48
24
12
1
2
3
4
F/S
48
24
12
FLOAT
ADJ.
J1
PV-
BATT+
BATT-
BATTERY TEMP.
SENSOR
PV FUSE
EARTH
GROUND
+ BATTERY 12, 24 OR 48
VOLTS
PV ARRAY
150 VOLTS
- MAX +
PV+
FLOAT
LED
BATTERY FUSE
9" FROM BATTERY
SOLAR PANEL BASIC WIRING
CONFIGURATIONS
NOT
RECOMMENDED
DO NOT USE
+
100
WATTS
-
+
-
-
+
-
225 WATTS
36 VOLTS
-
+
-
- 675 WATTS +
108 VOLTS
+
24 VOLTS +
400 WATTS
100
WATTS
-
+
-
100
WATTS
-
-
-
+
100
WATTS
+
-
225 WATTS
36 VOLTS
-
225 WATTS
36 VOLTS
+
-
48 VOLTS +
500 WATTS
-
+
-
12 VOLTS
300 WATTS
PV-
+
125 WATTS
12 VOLTS
125
WATTS
75
WATTS
100
WATTS
PV+
125 WATTS
12 VOLTS
+
125 WATTS
12 VOLTS
+
125 WATTS
12 VOLTS
+
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