Renogy RNG-CTRL-CMD60 User manual

Renogy RNG-CTRL-CMD60 User manual
Commander Series
RENOGY 60A
Maximum Power Point Tracking Solar Charge Controller
0
2775 E. Philadelphia St., Ontario, CA 91761
1-800-330-8678
Version 2.5
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.

Do NOT allow water to enter the controller.

Make sure all connections going into and from the controller are tight.
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 150 VDC 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 60A for the charge controller The Short Circuit (Isc) of the solar array
should be less than 60A.
1
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 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.
2
Table of Contents
General Information .................................................................................................................................... 4
Additional Components .............................................................................................................................. 8
Optional Components ................................................................................................................................. 8
Identification of Parts ................................................................................................................................. 9
PV Array Requirements ............................................................................................................................ 10
PV Strings .............................................................................................................................................. 10
PV Max Power ....................................................................................................................................... 10
Installation ................................................................................................................................................. 11
Operation ................................................................................................................................................... 17
1. Monitoring ......................................................................................................................................... 18
2. Log Info .............................................................................................................................................. 19
3. Clock Set............................................................................................................................................ 20
4. Local Para Set ................................................................................................................................... 20
5. Control Para Set ................................................................................................................................ 21
6. Sys Password ................................................................................................................................... 23
7. Default Set ......................................................................................................................................... 23
8. Dev Msg ............................................................................................................................................. 23
System Status Icons ................................................................................................................................. 24
LED Indicators ........................................................................................................................................... 24
Commander Protections .......................................................................................................................... 25
System Status Troubleshooting .............................................................................................................. 26
Maintenance .............................................................................................................................................. 27
Fusing......................................................................................................................................................... 27
Technical Specifications .......................................................................................................................... 28
Electrical Parameters ........................................................................................................................... 28
Charging Parameters ........................................................................................................................... 29
Charging Parameters Glossary ........................................................................................................... 29
Mechanical Parameters ........................................................................................................................ 31
Environment Parameters ..................................................................................................................... 31
Conversion Efficiency Curves ............................................................................................................. 31
PC Software ............................................................................................................................................... 34
Dimensions ................................................................................................................................................ 36
3
General Information
The RENOGY Commander MPPT controller is suitable for off-grid solar applications. It
protects the battery from being over-charged by the solar modules and over-discharged
by the loads. The controller features a smart tracking algorithm that maximizes the energy
from the solar PV module(s) and charge the battery.
The MPPT Charge Controller charging process has been optimized for long battery life
and improved system performance. The comprehensive self-diagnostics and electronic
protection functions can prevent damage from installation mistakes or system faults. In
addition, the controller is a high-end industrial class product based on multiphase
synchronous rectification technology and has features of high efficiency and reliability.
Key Features












LCD display with 6 button combination for easy operation.
12V / 24V / 36V / 48V DC systems.
Advanced maximum power point tracking technology with the tracking efficiency
as high as 99.5%
Multiphase synchronous rectification technology ensuring peak conversion
efficiency up to 98%
Excellent heat dissipation with integration of the cast aluminum radiator shell. The
controller can be natural cooling.
Unique dual timer function; enhance the flexibility lighting systems.
Deep cycle Sealed, Gel, Flooded or User battery option.
Adopting temperature compensation and correcting the charging and discharging
parameters automatically, improving battery lifetime.
Electronic protection: Overcharging, over-discharging, overload, and short circuit.
Protection against over-temperature, over-charging, PV short, reverse polarity,
and over current.
RS-232, RS-485, and CAN port compatible for extra features.
Remote Temperature Sensor adaptable and Battery Voltage Sensor adaptable
MPPT Technology
The Commander MPPT Charge Controller utilizes Maximum Power Point Tracking
technology to extract maximum power from the solar module(s). The tracking algorithm
is fully automatic and does not require user adjustment. 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.
Current Boost
In many cases, the Commander MPPT charge controller will “boost” up the current
in the solar system. The current does not come out of thin air. Instead, the power
4
generated in the solar panels is the same power that is transmitted into the battery bank.
Power is the product of Voltage (V) x Amperage (A). Therefore, assuming 100%
efficiency:
Power In = Power Out
Volts In * Amps In = Volts out * Amps out
Although MPPT controllers are not 100% efficient, they are very close at about 92-95%
efficient. Therefore, when the user has a solar system whose Vmp is greater than the
battery bank voltage, then that potential difference is proportional to the current boost.
The voltage generated at the solar module needs to be stepped down to a rate that could
charge the battery in a stable fashion by which the amperage is boosted accordingly to
the drop. It is entirely possible to have a solar module generate 8 amps going into the
charge controller and likewise have the charge controller send 10 amps to the battery
bank. This is the essence of the MPPT charge controllers and their advantage over
traditional charge controllers. In traditional charge controllers, that stepped down voltage
amount is wasted because the controller algorithm can only dissipate it as heat. The
following demonstrates a graphical point regarding the output of MPPT technology.
Current vs. Voltage (12V System)
Typical Battery
Voltage Range
Maximum
Power Point
Output Power (12V System)
Traditional
Controller
Operating
Range
Maximum
Power Point
Limiting Effectiveness
Temperature is a huge enemy of solar modules. As the environmental temperature
increases, the operating voltage (Vmp) is reduced and limits the power generation of the
solar module. Despite the effectiveness of MPPT technology, the charging algorithm will
possibly not have much to work with and therefore there is an inevitable decrease in
performance. In this scenario, it would be preferred to have modules with higher nominal
voltage, so that despite the drop in performance of the panel, the battery is still receiving
a current boost because of the proportional drop in module voltage.
5
Four Charging Stages
The Commander MPPT charge controller has a 4-stage battery charging algorithm for a
rapid, efficient, and safe battery charging. They include: Bulk Charge, Boost Charge, Float
Charge, and Equalization*.
Bulk Charge: This algorithm is used for day to day charging. It uses 100% of available
solar power to recharge the battery and is equivalent to constant current. In this stage the
battery voltage has not yet reached constant voltage (Equalize or Boost), the controller
operates in constant current mode, delivering its maximum current to the batteries (MPPT
Charging)
Constant Charging: When the battery reaches the constant voltage set point, the
controller will start to operate in constant charging mode, where it is no longer MPPT
charging. The current will drop gradually. This has two stages, equalize and boost and
they are not carried out constantly in a full charge process to avoid too much gas
precipitation or overheating of the battery.
 Boost Charge: Boost stage maintains a charge for 2 hours by default. The user
can adjust the constant time and preset value of boost per their demand.
Float Charge: After the constant voltage stage, the controller will reduce the battery
voltage to a float voltage set point. Once the battery is fully charged, there will be no more
6
chemical reactions and all the charge current would turn into heat or gas. Because of this,
the charge controller will reduce the voltage charge to smaller quantity, while lightly
charging the battery. The purpose for this is to offset the power consumption while
maintaining a full battery storage capacity. In the event that a load drawn from the battery
exceeds the charge current, the controller will no longer be able to maintain the battery
to a Float set point and the controller will end the float charge stage and refer back to bulk
charging.
Equalization: Is carried out every 28 days of the month. It is intentional overcharging
of the battery for a controlled period of time. Certain types of batteries benefit from
periodic equalizing charge, which can stir the electrolyte, balance battery voltage and
complete chemical reaction. Equalizing charge increases the battery voltage, higher than
the standard complement voltage, which gasifies the battery electrolyte.
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.
WARNING: Over-charging and excessive gas precipitation may damage the battery
plates and activate material shedding on them. Too high of equalizing charge or for
too long may cause damage. Please carefully review the specific requirements of
the battery used in the system.
WARNING: Equalization may increase battery voltage to a level damaging to
sensitive DC loads. Ensure that all load allowable input voltages are greater than
the equalizing charging set point voltage.
7
Additional Components
Remote Temperature Sensor (TS-R): Measures the
temperature at the battery and uses this data for very accurate
temperature compensation. It is not polarity sensitive.
Remote Battery Voltage Sensor (RBVS): Measures battery
voltage accurately. The voltage detected at the battery terminals
on the controller may differ from the real battery voltage due to
the connection and cable resistance. Therefore, this sensor,
though not required, is recommended for best performance. It IS
polarity sensitive
USB to RS-485 Converter: The USB to RS-485 converter is
used to monitor each controller on the network using Solar
Station Monitor PC software and update the firmware. It
connects to the RS-485 port on the controller. Download the
PC software through Renogy’s website under the “Downloads”
section
Optional Components
Optional components that require a separate purchase:
External Battery (RTC): Allows for the access to the charge controller’s saved settings,
charge accumulation, and discharge accumulation without connecting to a deep cycle
battery. It keeps track of the date/time (once set) for automatic equalization processes.
8
Identification of Parts
3
2
4
5
6
1
7
Top View
12
13
14
11
10
9
7
8
7
7
7
Front View (Hatch Removed)
9
Key Parts
1.
2.
3.
4.
5.
6.
7.
8.
9.
Grounding Bolt
LCD Display
Battery LED
PV LED
Fault LED
Navigation Buttons
RS-485 port—monitor controller through PC and update firmware
RTC Battery Slot—model is CR2032
Remote Temperature Sensor Port—optional accessory to remotely monitor battery
temperature
10. Remote Battery Voltage Sensor Port—Provides accurate battery voltage
measurement
11. Reserved Port—Reserved port for future development. Special accessory currently
not sold.
12. RS-232 port—monitor controller through PC and update firmware
13. PV Terminal
14. Battery Terminal
PV Array Requirements
PV Strings
The commander is suitable for various types of PV configurations to maximize electrical
energy. Configurations are dependent on the open circuit voltage (Voc) and maximum
power point voltage (Vmp) located in solar panel specifications. The following table is to
serve as a reference only.
System Voltage
12V
24V
48V
36 Cell Module
(Voc < 23V)
60 Cell Module
(Voc < 38V)
72 Cell Module
(Voc < 46V)
Max
4
6
6
Max
2
3
3
Max
2
3
3
Best
2
3
5
Best
1
2
3
Best
1
2
2
Note: The above parameter values are calculated under the STC conditions: Irradiance 1000W/m 2,
Temperature 25°C, Air Mass 1.5
PV Max Power
The Commanders have a limiting current function, where the current is limited within a
range, and therefore allows battery charging at the correct value despite oversized input
power. The power operation follows the following conditions:
10
1. PV Actual Power ≤ controller rated charge power, the controller charge battery at
the actual maximum power point.
2. PV Actual Power ≤ controller rated charge power, the controller charges the
battery at the rated power.
WARNING: The Commander will be damaged if the PV array is 3X greater than the
actual operating power of the controller.
WARNING: The Commander’s reverse polarity is no longer warranted if the PV
array size is 1.5X greater than the rated power of the controller.
The following tables serves as the reference guide for the statements above:
Model
Commander
Rated Charge
Current
60A
Rated Charge
Power
Max PV Array
Power
800W @ 12V
2400W @ 12V
1600W @ 24V
4800W @ 24V
2400W @ 36V
7200W @ 36V
3200W @ 48V
9600W @ 48V
Max PV Voc
Input
150V @
minimum
operating
environmental
temperature
OR
138V @ 25°C
environmental
temperature
Installation
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.
11
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.
You are now ready to begin connecting your battery to your charge controller.
Battery
2
1
3
4
Solar Panels
12
1
2
Computer connection
1
2
13
Battery remote sensor (Polarity Sensitive)
1
2
3
4
14
Temperature sensor (Not Polarity Sensitive)
1
3
2
4
15
Mounting Recommendations
NOTE: The Commander MPPT 60 controller requires at least 6 inches(150mm) of
clearance above and below for proper air flow. Ventilation is highly recommended
if mounted in an enclosure.
WARNING: Never install the controller in a sealed enclosure with flooded batteries.
Gas can accumulate and there is a risk of explosion.
1. Choose Mounting Location—place the controller on a vertical surface protected
from direct sunlight, high temperatures, and water. Make sure there is good
ventilation.
2. Check for Clearance—verify that there is sufficient room to run wires, as well as
clearance above and below the controller for ventilation. The clearance should be
at least 6 inches (150mm).
3. Mark Holes—Mark the four mounting holes locations on the mounting surface.
4. Drill Holes—Remove the controller and drill four sizeable holes at the marked
locations.
5. Secure the charge 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
the mounting screws.
16
Operation
After connecting the battery to the charge controller, the controller will turn on
automatically. The user will be prompted by an initialization screen, followed by the
charge controller’s rated parameters, and finally the default monitoring screen.
Rated Parameters
Rat.Volt
Charg.Cur
Disc.Curr
48.0V
60.0A
60.0A
Use the following buttons to maneuver through the menu:

Cycle through the menu

Cycle through the menu
ESC
Return to main menu in any monitoring interface
+
Modify any value and set period of Log to browse
-
Modify any value and set period of Log to browse
OK
Selecting certain parameters
ESC
Select
to display the menu screen selection. The user will have 9 interfaces to
choose from.
1.
2.
3.
4.
5.
6.
7.
8.
Monitoring
Log Info
Clock Set
Local Para Set
Control Para
Sys Password
Default Set
Device Msg
NOTE: You might be prompted to enter a password. Simply put “0” all the way
through by pressing
OK
NOTE: To customize charge parameters, BATT TYPE must be set to USER under
5. Control Param
17
NOTE: The values found in your controller are default values and will not
necessarily match the ones listed. The values on this table are to show the user
what the different screens are used for.
NOTE: You do NOT have to program the control. These parameters are for extra
features. Once you connect the battery the settings are automatically synced.
1. Monitoring

Use the
menu

keys to maneuver through the screens and
0.00A 12.65V 0.00A
Jan 12:12: 12
ESC
to access the
Default monitoring screen displaying charge controller
system status through icons.
10

Batt Volt.
12.6 V
Batt Cur.
0.0 A
Indicates battery voltage and battery current

Batt Day’Max
12.8 V
Batt Day’Min
12.6 V
Indicates the maximum and minimum battery values
since the charge controller has been turned on. When
battery is charging, the values are expected to
change.

Batt State
Normal
Batt SOC
51%
Displays the battery state as well as the state of
charge of the battery.

Charge State
No Charge
PV Volt
0.0 V
Displays the charging state of the battery as well as
the voltage coming from the PV module(s).
NOTE: Make sure PV input is not more than 150 VDC

18
Generated Energy
55 kWh/D
PV Power
0.0 W
Indicates the amount of energy that has been
generated for the day in terms of kilowatt-hours per
day. The PV power indicates how much power the PV
modules have generated.

Total Generated
55 kWh/D
Indicates the total amount of energy generated and in
kilowatt-hours per day.

Batt Temp
25.0 °C
Temp Coefficient
-3mV / °C / 2V

Local Temperature
23.4 oC
Indicates the batteries temperature as well as the
temperature compensation. Temperature fluctuation
can affect performance in the system. The purpose of
temperature compensation is to adjust the
performance of the system to keep the system
functioning normally.
Indicates the local temperature of the charge
controller.
2. Log Info
Use the
menu


keys to maneuver through the screens and
<1>Work Log
<2> Alarm Log
OK
Work Log Query
From 2015-01-23
To
2015-02-01
Total:
121
ESC
to access the
Users will be able to see segments of how
Commander is performing when the whole system is
connected through the work log. Any time there is a
change in voltage or amperage it will be logged onto
the Work Log Query. It is recommended that the date
and time be set correctly so that a range of dates can
be selected and analyze solar performance.

No. 1/121
2015-01-23 1:01
Batt Vol 51.6 V
Batt Curr 0.0A
Depending on the total amount of Work Logs, users
can cycle through the logs using the (up) and (down)
arrows. Press ESC to go back to the previous log
menu. The logs display battery voltage and battery
current.
ESC
19
The Alarm Log will display any kind of faults or
warnings that the charge controller experienced while
having the solar system connected. As in the previous
Log, users can cycle through how many alarm logs
are available and observe the data.
<1>Work Log
<2> Alarm Log
OK
Alarm Log Query
From 2015-01-23
To
2015-02-01
Total:
0
3. Clock Set
Press
OK
+
to highlight the month in the clock set menu and use the
to change the parameter. Press
OK
-
keys
to confirm and save the settings.
Users can set the date and time. The clock uses a 24
hour clock.
Clock Set
Aug-05-2015
13:16:51
NOTE: In some models, users might be prompted to
enter a password. Simply put “0” all the way through
and press OK.
4. Local Para Set
Use the
Menu
Press

OK

keys to maneuver through the screens and
to highlight the parameter and use the
parameters. Press
OK
Local ID
T03-0001
+
-
ESC
to access the
keys to change the
to confirm and save the settings.
The Local ID number is the charge controller’s unique
ID when identifying it in a network or utilizing the PC
software to search for the charge controller.

Backlight Time
60 s
Storage Interval
10 min
The charge controller’s LCD interface is backlit and
this interface lets you know the amount of seconds the
LCD will be illuminated once the last button is
pressed. The range is from 1-90 seconds and the “–
“symbol indicates the backlight is never off. The
storage log is from 1-30 minutes. It relates to how
often the charge controller collects data and inputs
into the Work Log or Alarm log.
20
NOTE: In some models, users might be prompted to
enter a password. Simply put “0” all the way through
and press OK.
5. Control Para Set
Use the
Menu
Press

OK

keys to maneuver through the screens and
to highlight the parameter and use the
parameter. Press
OK
+
-
ESC
to access the
keys to change the
to confirm and save the settings.
Batt Type
SEALED
Batt AH
10 AH
Choose between SEALED, FLOODED, GEL, or
USER for Battery type.

Temp Coefficient
-3mV / C ° / 2V
Rated Volt
AUTO

Over Volt. Disc.
16.0 V
Charge Limit
15.0 V
Indicates Temperature Compensation. Temperature
fluctuation can affect performance in the system.
Therefore, the purpose of temperature compensation
is to adjust the performance of the system to keep the
system functioning normally.
Choose 12V, 24V, 36V, 48V or AUTO for Rated
voltage.
Parameters for
Charging Limit.
Over-Voltage
Disconnect
and
Parameters for Over-Voltage
Equalization Charge Voltage
Reconnect
and

Over Volt. Rect.
15.0 V
Equalize Charge
14.6 V

Boost Charge
14.4 V
Float Charge
13.8 V
Parameters for Boost Charge and Float Charge
voltage
21

Boost Rect Vol
13.2 V
Low Volt Rect
12.6 V
Parameters for Boost Voltage Reconnect and Boost
Under-Voltage Reconnect.

Under Volt Rect
12.2 V
Under Volt Warn
12.0 V
Parameters for under voltage reconnect and under
voltage warning.

Low Volt Dis
11.1 V
Discharge Limit
10.6 V
Parameters for low voltage disconnect and the
discharging limit.

Equalize Time
120 min
Boost Time
120 min
Parameters for the equalization duration time and the
boost duration time.

Batt. Manag.
Char.SOC
100%
Disc.SOC:
30%
Vol.Com.
SOC
Parameters for what constitutes the range for state of
charge and users can select battery managing mode
to be using voltage compensation or SOC.
ESC
NOTE:
It is not possible to measure actual SOC, but rather express it as a percentage of some reference.
In this case it is voltage alone (VC) or battery capacity over a time span (SOC).
VC. converts a reading from battery voltage to determine SOC by utilizing the charge controller’s
algorithm for known discharge. It is highly sensitive to temperature changes and battery
disturbances thus having less accurate battery charge statuses.
SOC is more accurate by keeping track of the voltage and current flow in and out of the battery
when reporting battery charge status. The SOC is determined by multiplying current by the time
for which it flowed.
22
6. Sys Password
Use the
Menu

OK
Press

keys to maneuver through the screens and
to highlight the parameter and use the
parameter. Press
OK
+
-
ESC
to access the
keys to change the
to confirm and save the settings.
Sys Password
Ori.PSW: 000000
NewPSW: 000000
Setting a password for the controller prohibits the user
from programming the controller unless the password
is set.
NOTE: Default Password is “000000” if it prompts the
user to enter a password before they set one.
7. Default Set
Use the
Menu
Press

OK

keys to maneuver through the screens and
to highlight the parameter and use the
parameter. Press
OK
+
-
ESC
to access the
keys to change the
to confirm and save the settings.
Default Set
No
Yes
Clr Log Record
Retain Clear
This interface restores the charge controller to factory
settings which is mainly for user parameters that might
have been set. The second option is to clear the Work
Log which the controller has been keeping track of
thus far.
NOTE: Once parameters are reset, they cannot be
recovered.
8. Dev Msg
ARM Msg.
Type: IT6415ND
Ver: v01.00+v02.60
SN: 0420131210000001

This screen provides information regarding the model
type of the charge controller. It includes the model,
software, and SKU number.
DSP Msg.
Type: IT6415ND
Ver: v01.00+v02.60
SN: 0420131210000001
23
System Status Icons
PV
BATTERY
SYSTEM
Day/ PV
Charging
Battery
Charging
System
Normal
Night/ PV
Not
Charging
Battery
Level Full
System
Fault
Battery Over
Discharge
LED Indicators
Charging LED
Indicator
Status
Charging
Green (Blinking)
Not Charging
Green (Off)
Battery LED
Indicator
Green (Solid)
Green (Slow Blinking)
Orange (Solid)
Status
Normal
Battery Full
Under voltage warning
24
Low voltage disconnect
Red (Solid)
Battery over temperature
Red (Blinking)
Green (Fast Blinking)
High voltage disconnect
Fault LED
Indicator
Red (Off)
Red (Blinking)
Status
Normal
Current is abnormal
Charging overcurrent
PV Overvoltage
The following LED indicators must be occurring at the same time for the Charging LED and
Battery LED
Charging LED
Status
Battery LED
System Voltage Error
Green (Blinking)
Red (Blinking)
Green (Blinking)
Orange (Blinking)
Controller Over Temperature
Commander Protections
Protection
Behavior
PV Array Short
Circuit
When PV shot circuit occurs, the controller will stop charging.
Clear it to resume normal operation
PV Overvoltage
If the PV voltage is larger than maximum input open voltage
150VDC, PV will remain disconnected and warning until the
voltage falls safely below 145V. PV voltage cannot be too high,
otherwise it may damage the controller.
PV Overcurrent
The controller will limit the battery charging current to the
maximum battery current rating. Therefore an over-sized solar
array will not operate at peak power.
PV Reverse Polarity
The controller will not operate if the PV wires are switched. Wire
them correctly to resume normal controller operation.
25
Battery Reverse
Polarity
The controller will not operate if the battery wires are switched.
Wire them correctly to resume normal controller operation.
Over-Temperature
If the temperature of the controller heat sink exceeds 85OC, the
controller will automatically start the protection and recover
once conditions are below 75OC
System Status Troubleshooting
Description
Charging LED off during
daylight.
Battery LED orange (solid)
Battery LED orange
(blinking)
Troubleshoot
Ensure that the PV wires are correctly and tightly secured inside
the charge controller PV terminals. Use a multi-meter to make
sure the poles are correctly connected to the charge controller.
Use a multi-meter to check the battery voltage to confirm reading.
NEVER disconnect battery without disconnecting the solar
panels first. Turn off all loads connected to the battery (if
applicable) and let the battery charge.
The charge controller is operating above the maximum
temperature range. Change the location of the charge controller
to a cooler environment. Follow proper installation procedures to
not damage the system.
Battery LED is green and
blinking fast. LCD is
displaying “OVD”
Battery voltage may be larger than over voltage disconnect
voltage. Use a multi-meter to check the battery voltage and
disconnect the PV modules for a more accurate reading.
Fault LED is blinking red
and LCD displays “Over
Volt”
The solar input may be too high. Use a multi-meter to determine
whether the solar panels are sized appropriately to the controller
and battery bank. The charge controller will pause all activity and
resume work activity once it detects a proper voltage range.
Users cannot connect RS485 cable
Check that the correct cable is being used and the correct port is
being used. Verify that the correct software is installed.
26
Maintenance
WARNING: Risk of Electric Shock! Make sure that all power is turned off before
touching the terminals on the charge controller.
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 LCD and LED are consistent. Take necessary corrective
action.
5. Check to make sure none of the terminals have any corrosion, insulation damage,
high temperature, or any burnt/discoloration marks.
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.
18A 25A 30A 40A 55A 75A 95A 130A 170A
Current
Note: The NEC code requires the overcurrent protection shall not exceed 15A for 14AWG, 20A
for 12 AWG, and 30A for 10AWG copper wire.
Fuse from Controller to Battery
Controller to Battery Fuse = Current Rating of Charge Controller
Ex. 60A MPPT CC = 60A fuse from Controller to Battery
Fuse from Solar Panel(s) to Controller
Ex. 200W; 2 X 100 W panels
**Utilize 1.56 Sizing Factor
27
Series:
Total Amperage = Isc1 = Isc2 = 5.75A * 1.56
Fuse = minimum of 5.75 * 1.56 = 8.97 = 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
Electrical Parameters
Model
Commander 60A MPPT
Nominal system
voltage
Rated Battery Current
Max. Input Short
Current
Battery Voltage Range
Max Solar Input
Voltage
MPPT Voltage Range
Max. Solar Input Power
Self-Consumption
Grounding
Communication
PV Wire Size
12v/24v/36v/48v/ Auto Recognition
60A
75A
8-68V
150 VDC @ Minimum Working Temperature
138 VDC @ 25°C
Vbattery + 2V ~ 108V
12V @ 800W | 24V @ 1600W | 36V @ 2400W | 48V @ 3200W
1.4W to 2.6W
Negative
RS485 Cable
4 AWG
Charging Parameters
NOTE: Under the USER battery setting, the parameters can be adjusted within the boundaries of
the max and min values listed below. All of the following coefficients assume 25oC Standard Testing
Conditions (STC). The following parameters will be (x2) for 24V systems, (x3) for 36V systems, and
(x4) for 48V systems.
Battery Type
SEALED
GEL
FLOODED
USER
High Volt Disconnect
Charging limit
voltage
Over Voltage
Reconnect
Equalization voltage
Boost voltage
16V
15V
16V
15V
16V
15V
9~17V
9~17V
15V
15V
15V
9~17V
14.6V
14.2V
——
14.4V
14.8V
14.6V
9~17V
9~17V
28
Float voltage
Boost return voltage
Low voltage
reconnect
Under voltage
recover
Under voltage
warning
Low Voltage
Disconnect
Discharging Limit
Voltage
Equalize duration
Boost duration
13.8V
13.2V
12.6V
13.8V
13.2V
12.6V
13.8V
13.2V
12.6V
9~17V
9~17V
9~17V
12.2V
12.2V
12.2V
9~17V
12V
12V
12V
9~17V
11.1V
11.1V
11.1V
9~17V
10.6V
10.6V
10.6V
9~17V
120min
120min
——
120min
120min
120min
0~180min
10~180min
NOTE: The following rules MUST be obliged when setting custom parameters.
Rule 1: High Volt Disconnect > Charging limit voltage ≥ Equalization voltage ≥ Boost
voltage ≥ Float voltage > Boost return voltage;
Rule 2: High Volt Disconnect > Over Voltage Reconnect;
Rule 3: Charging Limit Voltage > Low voltage reconnect > Low voltage disconnect;
Rule 4: Charging Limit Voltage > Under voltage recover > Under voltage warning;
Rule 5: Boost return voltage > Low voltage reconnect;
Charging Parameters Glossary
High Volt Disconnect—users can use the default parameters or assign a rated voltage
value that the charge controller will operate. When and if the charge controller
experiences a voltage higher than what is assigned, it will disconnect itself from the circuit;
ceasing charge.
Charging Limit Voltage—depending on the batteries used, there might be a battery
charging limit voltage that is recommended for the battery. This parameter ensures that
the charge controller does not exceed the default or assigned rated charging limit voltage.
This is usually put into play to optimize and extend the life of the battery. Relatively
speaking, the higher the charging voltage then there is a correlation for reduced battery
efficiency. (Likewise the lower the discharge voltage affects battery efficiency.
Over-voltage Reconnect—In the event a charge controller experiences an over-voltage
condition set by the previous two parameters, then this reconnecting parameter is put into
play to direct the controller when it can connect and safely charge again. Typically overvoltage reconnection is achieved when time has passed (ex. The sun setting), or when
29
the over-voltage condition is remedied ultimately reducing the voltage to a user defined
charging voltage.
Equalization Voltage—equalization voltage is a corrective over-charge of the battery.
The user should consult their battery manufacturer regarding specific battery equalization
capacity. This parameter sets the equalization voltage to set the battery at when it reaches
the equalization state.
Boost Voltage—users should check with their battery manufacturer for proper charging
parameters. In this stage, users set the boost voltage where the battery will reach a
voltage level and remain there until the battery undergoes an absorption stage
Float Voltage—once the charge controller recognizes the set float voltage, it will
commence floating. The battery is supposed to be fully charged in his state, and the
charge current is reduced to maintain battery stability levels.
Boost Return Voltage—if at any point, the battery voltage levels registers to be below
the boost return voltage for an extended period amount of time, then the charge controller
will commence the boost stage once again.
Low Voltage Reconnect—this parameter allows loads connected to the system will be
able to operate (not fully) again.
Under-voltage Recover—deals with the loads connected to the system. When batteries
are determined to be low due to them approaching low voltage disconnect, then the loads
will be shut off to give the batteries time to recover. This parameter sets the controller to
shut off the loads until it can reach the low voltage reconnect stage.
Under-voltage Warning—this parameter deals with the batteries themselves
approaching the under-voltage recovery state. The user should minimize loads before the
charge controller approaches a level where it will do this automatically to protect the
battery from discharging
State of Charge
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0
12 V Battery
12.7
12.5
12.42
12.32
12.20
12.06
11.9
11.75
11.58
11.31
10.5
Volts per Cell
2.12
2.08
2.07
2.05
2.03
2.01
1.98
1.96
1.93
1.89
1.75
30
Mechanical Parameters
Model
Commander 60A MPPT
Overall Dimension
Mounting
Max Terminal
Net Weight
Mounting Holes
449mm x 208mm x 107mm | 17.7in x 8.2in x 4.2in
430mm x 180mm | 16.9in x 7.1in
2 AWG
5.5 kg | 12.1 lbs.
Φ10
Environment Parameters
Model
LCD Temperature
Working
Temperature
Storage
Temperature
Humidity
Enclosure
Altitude
Commander 60A MPPT
-20°C to +70°C | -4oF to 158oF
-25°C to +55°C | -13oF to 131oF
-30°C to +85°C | -22oF to 185oF
≤95% N.C.
IP20
< 5000m (Derate to operate according to IEC60146 at a height
exceeding 1000m)
Conversion Efficiency Curves
1. Solar MPPT Voltage (36V, 54V, 72V) / System Voltage (12V)
31
2. Solar MPPT Voltage (36V, 54V, 72V) / System Voltage (24V)
3. Solar MPPT Voltage (54V, 72V, 90V) / System Voltage (36V)
32
4. Solar MPPT Voltage (72V, 90V, 108V) / System Voltage (48V)
PC Software
The Commander MPPT charge controller has a special feature where users are able to
remotely monitor the status of their charge controller through the USB connection cable
provided. Remote monitoring can be applied to more than one Commander MPPT charge
controller with their unique identification numbers. Simply plug the USB into your PC and
follow the downloadable instructions.
NOTE: For PC monitoring users will need to enter a username and password.
Username: administrator
Password: 111111
33
Globe Monitoring
Real Time Monitoring
34
Control Parameter
Load Configuration
35
Dimensions
Renogy reserves the right to change the contents of this manual without notice.
Revision: 12/1/16/2016
36
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