Renogy CTRL-PWM20DB User manual

Renogy CTRL-PWM20DB User manual
Duo Battery Charge Controller
RENOGY 10A | 20A
Pulse Width Modulation Solar Charge Controller Manual
1
2775 E. Philadelphia St., Ontario CA 91761
1-800-330-8678
Version: 1.2
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.
WARNING: Indicates a potentially dangerous condition. Use extreme caution when
performing this task.
CAUTION: Indicates a critical procedure for safe and proper operation of the controller
NOTE: Indicates a procedure or function that is important to the safe and proper operation
of the controller.
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.

Disconnect the solar module and fuse/breakers near to battery before installing or
adjusting the PWM1020CC-DB.

Install external fuses/breakers as required.

Do NOT allow water to enter the controller.

Confirm that the power connections are tightened to avoid excessive heating from a
loose connection.
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 30 VDC (for 12V system) or 55VDC (for 24V
system) to prevent permanent damage. Use the Open Circuit (Voc) to make sure the
voltage does not exceed this value when connecting panels together.

Do not exceed 10A (PWM10DB) or 20A (PWM20DB). The Short Circuit (Isc) of the solar
array should be less than 10A (PWM10DB) or 20A (PWM20DB).
2
Battery Safety

Use only sealed lead-acid, flooded, or gel 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 sealed / VRLA type AGM / Gel cell batteries UNLESS permitted by
battery manufacturer.
WARNING: 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.
WARNING: Do NOT connect any inverters or battery charger into the load terminal of the charge
controller.
WARNING: 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.
3
Table of Contents
General Information ...................................................................................................................................................5
Optional Components ...............................................................................................................................................6
Identification of Parts .................................................................................................................................................7
Installation........................................................................................................................................................................8
Operation....................................................................................................................................................................... 13
Troubleshooting......................................................................................................................................................... 15
Maintenance ................................................................................................................................................................ 15
Fusing.............................................................................................................................................................................. 15
Technical Specifications ....................................................................................................................................... 16
Dimensions .................................................................................................................................................................. 17
4
General Information
The Renogy PWM1020CC-DB features dual battery charging capability making it great for RVs,
caravans, and boats. With its advanced PWM charging technology, your batteries will be
protected from discharging and over-charging.
This controller is specifically designed for mobile off-grid applications supporting 12V deep cycle
battery varieties such as sealed lead acid, gel, and flooded. The built-in RJ45 connector gives
you the freedom of monitor the voltage, current and temperature of your system via MT-1 remote
meter (sold separately).
Key Features

12V / 24V auto recognition

Micro controller digital accuracy

High efficient PWM charging, increase the battery lifetime and improve the solar system
performance.

Dual battery charging

Sealed, Gel, and Flooded battery option.

Remote temperature sensor (sold separated)

Corrects the charging and discharging parameters automatically based on temperature
compensation, improving battery lifetime.

Short circuit protection

Battery reverse polarity protection

Overcharging or discharging protection

Overload protection
PWM Technology
The PWM 10A/20ACC-Dual Battery utilizes Pulse Width Modulation (PWM) technology for battery
charging. Battery charging is a current based process so controlling the current will control the
battery voltage. For the most accurate return of capacity, and for the prevention of excessive
gassing pressure, the battery is required to be controlled by specified voltage regulation set points
for Absorption, Float, and Equalization charging stages. The charge controller uses automatic
duty cycle conversion, creating pulses of current to charge the battery. The duty cycle is
proportional to the difference between the sensed battery voltage and the specified voltage
regulation set point. Once the battery reached the specified voltage range, pulse current charging
mode allows the battery to react and allows for an acceptable rate of charge for the battery level.
5
Optional Components
*The PWM10A/20A-Dual Battery charge controller is shipped by itself, without any
additional components.
Optional components that require a separate purchase:
Remote Temperature Sensor (TS-R): Measures the temperature
at the battery and uses this data for very accurate temperature
compensation. The sensor is supplied with a 6.6ft cable length that
connects to the charge controller. (Figure 1)
Figure 1
LCD Display Tracer Meter (MT-1): Allows for real time monitoring
of the charge controller. Perfect for circumstances where the user
cannot easily access the controller or modify its parameters. It is
supplied with a mounting frame and a cable that connects to the
RJ45 port on the Dual Battery Charge Controller. (Figure 2)
Figure 2
6
Identification of Parts
1
2
4
5
3
6
7
Figure 3
Key Parts
1. Local Temp. Sensor—Measures ambient temperature. Battery regulation is adjusted
accordingly.
2. Batt #1 status LED—Provides charging & battery status and errors
3. Batt #2 status LED—Provides charging & battery status and errors
4. Setting Indicator LEDs and Digital Display
5. SET Button
6. Remote Temp. Sensor (sold separately) — a connection point for RTS (optional) to remotely
monitor battery temperature.
7. Remote Meter Connection (RJ45) — a communication port for the remote meter MT-1 (sold
separately).
7
Installation
General Installation Notes









Read through the entire installation section first before beginning installation.
Be very careful when working with batteries. Wear eye protection. Have fresh water
available to wash and clean any contact with battery acid.
Uses insulated tools and avoid placing metal objects near the batteries.
Explosive battery gasses may be present during charging. Be certain there is sufficient
ventilation to release the gasses.
Avoid direct sunlight and do not install in locations where water can enter the controller.
Loose power connections and/or corroded wires may result in resistive connections that
melt wire insulation, burn surrounding materials, or even cause fire. Ensure tight
connections and use cable clamps to secure cables and prevent them from swaying in
mobile applications.
Use with Gel, Sealed or Flooded batteries only.
Battery connection may be wired to one battery or a bank of batteries. The following
instructions refer to a single battery, but it is implied that the battery connection can be
made to either one battery or a group of batteries.
Mounting
NOTE: When mounting the PWM1020CC-DB, ensure free airflow through the controller heat sink
fins. There should be at least 100mm of clearance above and below the controller to allow for
cooling. If mounted in an enclosure, ventilation is highly recommended.
WARNING: Risk of explosion! Never install the PWM1020CC-DB in a sealed enclose with flooded
batteries! Do not install in a confined area where battery gas can accumulate.
Step 1: Choose mounting location
Locate a vertical or horizontal surface protected from direct sunlight, high temperature, and
water.
Step 2: Check for Clearance
Place the PWM1020CC-D in the location where it will be mounted. Verify that there is sufficient
room to run wires and that there is sufficient room above and below the controller for airflow.
Step 3: Mark Holes
Use a pencil or pen to mark the four (4) mounting hole locations on the mounting surface.
Step 4: Drill Holes
Remove the controller and drill four sizeable holes in the marked locations.
Step 5: Secure Controller
Place the controller on the surface and align the mounting holes with the drilled holes in step
4. Secure the controller in place using mounting screws.
8
Wiring
Recommended tools to have before installation:
Flathead Screwdriver
Multi-Meter
WARNING: Connect battery terminal wires to the charge controller FIRST then connect the solar
panel(s) to the charge controller. NEVER connect solar panel to charge controller before the battery.
CAUTION: Do not over-torque or over tighten the screw terminals. This could potentially break the
piece that holds the wire to the charge controller.
CAUTION: Refer to the technical specifications for max wire sizes on the controller and for the
maximum amperage going through wires.
CAUTION: For mobile applications, be sure to secure all wiring. Use cable clamps to prevent cables
from swaying when the vehicle is in motion. Unsecured cables create loose and resistive
connections, which may lead to excessive heating and/or fire.
You are now ready to begin connecting your battery to your charge controller.
Figure 4 Connection order
9
Battery
2
1
3
Connect Battery 1: Refer to Figure 4, Connect the negative terminal of Battery 1 to the
negative terminal of the charge controller under the Battery 1 logo. Then connect the positive
terminal of Battery 1 to the positive terminal of the charge controller under the Battery 1 logo.
Connect Battery 2: Repeat the process described in last step for Battery 2. Figure 4 shows
the connections. If you are not planning on installing a second battery you can skip this step.
10
Solar Panels
2
1
3
Connect the solar panel(s): Connect the negative PV lead of the solar panel to the negative
terminal of the charge controller under the solar array logo. Then connect the positive lead of
solar to the positive terminal of the charge controller under the solar array logo. Make sure the
solar module(s) voltage and current do not exceed the ratings of the charge controller.
11
Temperature Sensor (if applicable)
1
Connect the Remote Temperature Sensor (Optional): If you purchased the remote
temperature for your batteries, you can connect it in the remote temperature terminals depicted
in Figure 4. If you are not planning on using this sensor, you can skip this step.
Note: When the RTS is not present, the controller will calculate the data from the local
temperature sensor. The controller will obtain data from RTS automatically when present.
MT-1 Tracer (If applicable)
1
2
Connect Remote Meter MT-1 (Optional): The remote meter MT-1 is sold separately and can
be connected in the RJ45 communication port. Again, if you are not planning on using this meter,
you can skip this step.
12
Operation
Battery Type
To select the battery type press the SET button on the controller a few times until the “Battery
Type” LED lights up. Press the setting button again and hold it for 5 seconds until the digits
start flashing. Press the setting button again to choose the battery type as described in Table
1. Leave it in this position, and it will stop flashing after a few seconds. The controller has
recorded the battery setting.
Battery Type
Sealed lead acid battery
Gel battery
Flooded battery
Digital Display
1
2
3
Table 1 Battery type setting
Charging Priority
To adjust the charging priority of the batteries press the setting button on the controller a few
times until the “Charging priority” LED lights up. Press the setting button again and hold it for 5
seconds until the digits start flashing. Press the setting button again to choose the percentage
level listed on Table 2. Leave it in this position, and it will stop flashing after a few seconds.
The controller has recorded the Charging priority setting.
Number
0
1
2
3
4
5
6
7
8
9
Battery #1
0%
10%
20%
30%
40%
50%
60%
70%
80%
90% (pre-set)
Battery #2
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
Table 2 Charging priority settings
Note: In the normal charging conditions, the controller will distribute the charge for the selected
setting. When Battery 1 is fully charged, charge will be diverted to Battery 2, and return to the no. 4
charging priority setting automatically when Battery 1 is low on voltage. When the controller detects
that Battery 1 is the only battery connected, all the charge will go to the Battery 1 automatically.
Charging frequency
To change the charging frequency press the setting button on the controller a few times until
the “Charging frequency” LED lights up. Press the setting button again and hold it for 5 seconds
until the digits start flashing. Press the setting button again to choose a charging frequency
listed on Table 3. Leave it in this position, and it will stop flashing after a few seconds. The
controller has recorded the Charging priority setting.
13
Number
0
1
2
PWM Charging Frequency
25 Hz (pre-set)
50 HZ
100 HZ
Table 3 Charging frequency settings
Battery #1 Status LED Indicator
Battery #2 Status LED Indicator
Figure 5 Charge controller LED indicators
Battery Indicators
The LED indicator shown in Figure 5-2 will turn on whenever sunlight is available for battery
charging. Under normal charging conditions, the charging LED will lit Green at all times.
Color
Green
Green
Green
Green
Indication
Solid
Slowly Flashing
Frequent Flashing
Quickly Flashing
Green
Off
Operating State
Charging
Full
Not Charging*
Short-circuit*
Battery not Connected
/ Overvoltage*
Table 4 Battery LED indicators
*Please refer to the following section for trouble shooting
*Please note older version indicators light will be RED
14
Troubleshooting







Check all connections to ensure they are secure and clean
Check polarity of the battery connection and make sure the battery generates at least 6V
Ensure the solar panels are exposed to sufficient light – ideally position them to face the
sun directly
If charge controller states that there is short-circuit, please ensure that the panels are
connected correctly, and that the wires at the terminals are not touching each other.
If one of the status LED is off and a battery is connected, check that the battery terminals
have good connection and that the polarity is correct. Check that the voltage doesn’t
exceed the rated input voltage shown in Table 7-1 on Section 7.
If the charge controller is not charging, ensure that the panel’s polarity, and check for loose
connections.
Maintenance
For best controller performance, it is recommended that these tasks be performed from time to
time.
1. Check that controller is mounted in a clean, dry, and ventilated area.
2. Check wiring going into the charge controller and make sure there is no wire damage or
wear.
3. Tighten all terminals and inspect any loose, broken, or burnt up connections
4. Make sure readings in the LEDs are consistent.
Fusing
Fusing is a recommended in PV systems to provide a safety measure for connections going from
panel to controller and controller to battery. Remember to always use the recommended wire
gauge size based on the PV system and the controller.
NEC Maximum Current for different Copper Wire Sizes
AWG
16
14
12
10
8
6
4
2
0
Max.
10A 15A 20A 30A 55A 75A 95A 130A 170A
Current
Table 5
15
Fuse from Controller to Battery
Controller to Battery Fuse = Current Rating of Charge Controller
Ex. 20A Dual Battery CC = 20A fuse from Controller to Battery
Fuse from Solar Panel(s) to Controller
Ex. 200W; 2 X 100 W panels
Series:
Total Amperage = Isc1 = Isc2 = 5.75A * 1.56
Fuse = minimum of 5.75A * 1.56 = 8.97A = 9A fuse
Parallel
Total Amperage = Isc1 + Isc2 = (5.75A + 5.75A) * 1.56
Fuse = minimum of 11.5 * 1.56 = 17.94 = 18A fuse
Technical Specifications
Charge Controller
Description
Nominal System Voltage
Rated Charge Current
Rated Discharge Current
Maximum Battery Voltage
Max. Solar Input Voltage
Max. PV Input Power (10A Model)
Max. PV Input Power (20A Model)
Operating Temperature
Self-consumption
Terminals
Parameter
12VDC/24VDC Auto recognition
10A
10A
30V
30V (12V), 55V (24V)
120W (12V), 240W (24V)
240W (12V), 480W (24V)
−31°F to +131°F
4mA (idle), 10mA (charging)
4mm2
Table 6
Battery Parameters (Temp: 25°C)
Battery Charging setting
Equalization Voltage
Boost Voltage
Float Voltage
Boost Duration
Control Parameter
Gel
Seared
14.8V
14.4V
14.6V
14.2V
13.7V
13.7V
30 min
30 min
Table 7
Flooded
14.6V
14.4V
13.7V
30 min
16
Dimensions
Note: All dimensions are in inches
Renogy reserves the right to change the contents of this manual without notice.
Revision: 5/9/2017
17
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