Lumiax Magic Series User Manual
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www.lumiax.com 1.03.02.10038-1 Lumiax Magic your solar life Magic series MPPT Solar Controller 12/24/48V,750/1500/3000W User Manual User Manual_Magic series_KC CE, Rohs, ISO9001:2015 Subject to change without notice! Contents 1.Safety instructions and waiver of liability ..............................................................................2 1.1 Safety Instructions 1.2 Liability Exclusion 2.Pruduct Overview.......................................................................................................................3 3.Dimensions..................................................................................................................................4 4.Structure & Accessory ...............................................................................................................5 4.1 Structure 4.2 Accessories(Included) ....................................................................................................................................7 4.3 Accessories(Optional) ....................................................................................................................................7 5.Installation ..................................................................................................................................8 5.1 Installation Notes 5.2 Battery cables and battery fuse 5.3 PV cables ............................................................................................................................................................9 5.4 Mounting ...........................................................................................................................................................11 6.Operation ....................................................................................................................................14 6.1 LED indicator 6.2 Key function 6.3 Status display 6.4 Menu structure.................................................................................................................................................15 6.5 Operation status display...............................................................................................................................17 6.6 Main menu display .........................................................................................................................................18 6.7 Fault indication.................................................................................................................................................23 7.Troubleshooting,Protections and Maintenance.....................................................................24 7.1 Troubleshooting 7.2 Protection ..........................................................................................................................................................26 7.3 Maintenance .....................................................................................................................................................27 8.Technical Data.............................................................................................................................28 8.1 Electrical Parameters 8.2 Mechanical Parameters .................................................................................................................................29 8.3 Environmental Parameters 1 Dear Clients, Thanks for selecting the Magic series solar controller. Please take the time to read this user manual, as it will help you take full advantage of the controller's features. This manual gives important recommendations for installing, programming, using and so on. Read it carefully in your own interest and pay attention to the safety recommendations in it please. 1, Safety instructions and waiver of liability 1.1 Safety Instructions WARNING: Danger of explosion from sparking. Danger of electric shock. CAUTION: Indicates a critical procedure for safe and proper operation of the controller. 1) There are no user serviceable parts inside the controller. Do not disassemble or attempt to repair the controller. 2) Keep children away from batteries and the charge controller. (1) It is advised to read this manual carefully before the product is installed and put into use. (2) There are no user serviceable parts inside the controller. Do not disassemble or attempt to repair the controller. (3)Install the controller at well ventilated places, the controller's heat sink will be very hot during operation. (4)Refer to the specifications provided by the manufacturer of the battery to ensure that the battery is suitable for use with this product. The battery manufacturer's safety instructions should always be observed. (5)Protect the solar modules from incident light during installation, e.g. cover them. (6)Ensure that the connection cables are provided with fuses or circuit breakers. (7)Please make sure to switch off all connections of the PV array and the fuse/breakers which close to the battery before the controller installation and adjustment. (8)Power connections must remain tight to avoid excessive heating from the loose connection. (9)The installer of the product must provide a means for cable strain relief to prevent the transmission of stress to the connections. (10)Do not open the controller casing. Only the terminal cover may be removed by a technical professional for installation. 1.2 Liability Exclusion The manufacturer shall not be liable for damages, especially on the battery, caused by use other than as intended or as mentioned in this manual or if the recommendations of the battery manufacturer are neglected. The manufacturer shall not be liable if there has been service or repair carried out by any unauthorized person, unusual use, wrong installation, or bad system design. 2 2, Product Over view Magic series solar controller is based on an advanced maximum power point tracking (MPPT) technology developed, dedicated to the solar system, the controller conversion efficiency up to 98%. The controller can rapidly track the maximum power point(MPP) of PV array to obtain the maximum energy of the panel, especially in case of a clouded sky, when light intensity is changing continuously, an ultra fast MPPT controller will improve energy harvest by up to 30% compared to PWM charge controllers. The limitation function of the charging power and current, and automatic power reduction function fully ensure the stability when works with oversize PV modules and operate under high temperature environment. 2.1 Outstanding features Innovative Max Power Point Tracking(MPPT) technology, tracking efficiency >99.9% Full digital technology, high charge conversion efficiency up to 98% LCD display design, read operating data and working condition easily LCD can display lastest daily/monthly/yearly charging data, total 5 years 12/24/48V automatic recognition Liquid, Gel, AGM and Lithium battery for selection The separate ports for remote temperature sensor and voltage sensor, make battery temperature compensation and voltage detection more accurate Automatic power reduction when over-temperature Relay control the switching signals of external loads and chargers for hybrid power supply system like solar energy with utility electricity or gas generation Dual automatic restriction function when exceeding rated charging power and charging current 5-year memory battery voltage and historical charging data Android APP version for Bluetooth communication IoT wireless or RS485 communication functions optional Monthly charging data can be calculated and displayed by grouping and graphs Modbus protocol based on RS485 standard for remote communication need Multi-functional AUX port can meet customized requirements Common positive design, suitable for telecom applications Perfect EMC & thermal design Full automatic electronic protect function 2.2 MPPT MPPT profile The full name of the MPPT is maximum power point tracking. It is an advanced charging way which could detect the real-time power of the solar Modulel and the maximum point of the I-V curve that make the highest battery charging efficiency. Current Boost Under most conditions, MPPT technology will "boost" the solar charge current. MPPT Charging:Power Into the controller (Pmax)=Power out of the controller (Pout) Iin x Vmp= Iout x Vout * Assuming 100% efficiency. Actually, the losses in wiring and conversion exist. If the solar module's maximum power voltage (Vmp) is greater than the battery voltage, it follows that the battery current must be proportionally greater than the solar input current so that input and output power are balanced. The greater the difference between the Vmp and battery voltage, the greater the current boost. Current boost can be substantial in systems where the solar array is of a higher nominal voltage than the battery as described in the next section. 3 High Voltage Strings and Grid-Tie Modules Another benefit of MPPT technology is the ability to charge batteries with solar arrays of higher nominal voltages. For example, a 12 Volt battery bank may be charged with a 12-, 24-, 36-, or 48-Volt nominal off-grid solar array. Grid-tie solar modules may also be used as long as the solar array open circuit voltage (Voc) rating will not exceed the maximum input voltage rating at worst-case (coldest) module temperature. The solar module documentation should provide Voc vs. temperature data. Higher solar input voltage results in lower solar input current for a given input power. High voltage solar input strings allow for smaller gauge solar wiring. This is especially helpful and economical for systems with long wiring runs between the controller and the solar array. An Advantage Over Traditional Controllers Traditional controllers connect the solar module directly to the battery when recharging. This requires that the solar module operate in a voltage range that is usually below the module's Vmp. In a 12 Volt system for example, the battery voltage may range from 10.8-15 Vdc,but the module's Vmp is typically around 16 or 17V. Because traditional controllers do not always operate at the Vmp of the solar array, energy is wasted that could otherwise be used to charge the battery and power system loads. The greater the difference between battery voltage and the Vmp of the module, the more energy is wasted. I(A) P(W) MPP MPP VI curve 0 VP curve Typical Battery Voltage Range 10.8V 15V 17V Pmax-Px Px PWM Controller Operating Range V(V) 0 10.8V 15V 17V V(V) Nominal 12 Volt Solar Module I-V cur ve and output power graph. Contrast with the traditional PWM controller, MPPT controller could play a maximum power of the solar panel so that a larger charging current could be supplied. Generally speaking, the MPPT controller's energy utilization efficiency is 15%~20% higher than PWM controller. Conditions That Limit the Effectiveness of MPPT The Vmp of a solar module decreases as the temperature of the module increases. In very hot weather, the Vmp may be close or even less than battery voltage. In this situation, there will be very little or no MPPT gain compared to traditional controllers. However, systems with modules of higher nominal voltage than the battery bank will always have an array Vmp greater than battery voltage. Additionally, the savings in wiring due to reduced solar current make MPPT worthwhile even in hot climates. 2.3 MPPT—Four Charging Stage Magic series controller has a 4-stage battery charging algorithm for rapid, efficient, and safe battery charging. U(V) Equalize Charge 14.8V 14.5V 13.7V Night MPPT Charge Boost Charge Float Charge Night TIME MPPT Charge In this stage, the battery voltage has not yet reached boost voltage and 100% of available solar power is used to recharge the battery. Boost Charge When the battery has recharged to the Boost voltage setpoint, constant-voltage regulation is used to prevent heating and excessive battery gassing. The Boost stage remains 120 minutes and then goes to Float Charge. Every time when the controller is powered on, if it detects neither over discharged nor overvoltage, the charging will enter into boost charging stage. Float Charge After the Boost voltage stage, the controller will reduce the battery voltage to Float voltage setpoint. When the battery is fully recharged, there will be no more chemical reactions and all the charge current transmits into heat and gas at this time. Then the controller reduces the voltage to the floating stage, charging with a smaller voltage and current. It will reduce the temperature of battery and prevent the gassing, also charging the battery slightly at the same time. The purpose of Float stage is to offset the power consumption caused by self consumption and small loads in the whole system, while maintaining full battery storage capacity. In Float stage, loads can continue to draw power from the battery. In the event that the system load(s) exceed the solar charge current, the controller will no longer be able to maintain the battery at the Float setpoint. Should the battery voltage remains below the boost reconnect charging voltage, the controller will exit Float stage and return to Bulk charging. Equalization Charge 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. If it detects that the battery is being over discharged, the solar controller will automatically turn the battery to equalization charging stage, and the equalization charging will be 120mins. Equalizing charge and boost charge are not carried out constantly in a full charge process to avoid too much gas precipitation or overheating of battery. Risk of explosion! Equalizing flooded batter y can produce explosive gases, so well ventilation of batter y box is necessar y. 3,Dimensions Unit:mm 109 230 Φ6 40 7 Φ10 339 Φ6 3 40 109 4 4.1 Structure ① ② ③ ⑤ + MENU ④ OK ⑥ ⑫ ⑦ ⑧ ⑨ ⑩⑪ RS485 AUX IoT RLY1 RLY2 ⑬ ⑭ ⑮ ⑯ ⑰ Component 1 Heat Sink Description Dissipate controller heat 2 Sheet metal case Internal PCBA protection 3 LCD Display settings and operating status 4 Operating keys MENU OK 5 Indicator lights Operating state indication of controller 6 Grounding point If a grounding point is not already present then this must be created Terminal cover The case to cover the terminals and wires connections 8 Solar module terminals Connected solar modules 9 Battery terminals Connected the battery 7 10 External temperature sensor Collect temperature information for temperature compensation 11 Battery voltage sensor Connect the cable directly to the battery for checking the 12 Button Cell Data can still be saved after the battery is disconnected 13 RS485 interface 14 AUX Multi-functional AUX port can meet customized battery voltage Communication through RS485 interface requirements 15 IoT interface 16 Load Control Relay1 Connect with IoT module 17 Utility/Generator Relay2 Control Utility/Generator ON/OFF Control Load ON/OFF 5 4.1.1 Battery voltage sensor For compensating possible cable losses during charging, two sense wires can be connected to measure voltage directly on the battery. Use wire with a cross-section of 0.75mm² and insert a 0.1 Amp fuse close to the battery. During battery charging, the charger will compensate the voltage drop over the DC cables up to a maximum of 3 Volt. If the voltage drop threatens to become larger than 3V, the charging current is limited in such a way that the voltage drop remains limited to 3V. The "Bat.ext.volt" on the LCD will display "--- " if the voltage drop exceeds 3 Volt. At this time, you need to connect the voltage sensor or check whether the wiring is correct. 4.1.2 Load control relay1 and Utility/Generator relay2 The relay outputs are potential-free, normally-open contacts. Rated Value:3A/30VDC. (1) Load control relay1 The initial state of the contacts is normally-open. The relay outputs can be used for switching devices or loads. Heavy loads connected directly to the battery can be switched using an additional power relay connected to this relay. When the battery voltage is lower than the low-voltage protection voltage, the relay will be turned off. When the battery voltage is higher than the low-voltage recovery voltage, the relay will be opened again. (2)Utility/Generator relay2 The initial state of the contacts is normally-close. The relay outputs can be used for connecting power generation equipment, such as diesel engine and so on. When the battery voltage is lower than the low-voltage protection voltage + 0.2V, the relay will be turned on to access to external power generation equipment. When the battery voltage is higher than the low-voltage recovery voltage, the relay will be turned off again. You can choose whether to start the automatic maintenance function of the diesel engine. For specific operations, please refer to 6.6 Main menu display. The working time of the diesel shall not be less than 15 minutes each time it is started. 4.1.3 AUX Multi-functional AUX port can meet customized requirements. Aux is defined as current sensor by default. Please customize it if you need other functions. The current of the external equipment is calculated by setting the parameters of the current sensor such as the maximum measuring current and the maximum output voltage. After the correct setting, the external current will be displayed on the LCD screen of the controller. For specific operations, please refer to 6.6 Main menu display. 6 4.1.4 RS485 The charger is equipped with a RS485 port with RJ11 sockets, the RJ11 interface is defined as follows: Pin No. Definition NC 2 NC 3 RS485-A 4 5 RS485-B NC 6 NC 1 2 3 4 5 6 NC NC RS485-B RS485-A NC NC 1 RJ11 for controller The RS485 interface on this charger is not galvanically isolated and can not be grounded. Do not short circuit unused pin (Note NC). 4.2 Accessories(Included) Item Accessory Model Number 1 Local temperature sensor 2P-3.81mm 1Pcs 2 Battery voltage sensor terminal 2P-5.08mm 1Pcs 3 AUX terminal 2P-3.81mm 1Pcs 4 Load control relay1 terminal 2P-3.81mm 1Pcs 5 Utility/Generator relay2 terminal 2P-3.81mm 1Pcs 6 Mounting screws M8*40mm 4Pcs 7 RS485 interface cable RJ11*1m 1Pcs 4.3 Accessories(Optional) 4.3.1 Remote Temperature Sensor The controller is shipped with a temperature sensor of length 80mm. If you need other components you need to purchase separately. The remote temperature sensor can measure the temperature at the battery and use this data for very accurate temperature compensation. The standard length of the cable is 3m (length can be customized). The temperature sensor connected via interface ⑩. 1. The connection polarity is irrelevant. 2. If the external temperature sensor is not connected or damaged, the internal temperature will be used for temperature compensation during charging. 3. If the controller and battery are not located in the same room then an external temperature sensor for measuring the battery temperature must be installed. 4.3.2 IoT module After the controller is connected with the IoT module through the IoT interface, the operating status and related parameters of the controller can be changed and monitored by the mobile APP software or PC program. Please contact with our sales about IoT wireless communication information. 7 5, Installation Please read all instructions and precautions in the manual before installing. It is recommended to remove the acrylic protective film covering the LCD screen before installation. 5.1 Installation Notes (1)Do not open the controller sheet metal case, only the terminal cover may be removed by a technical professional for installation. (2)Before wiring installation and adjustment of controller, Always disconnect the solar modules and insurance or circuit breaker of battery terminal. (3)Only to comply with the range of the battery charge controller. (4)Batteries store a large amount of energy, never short circuit a battery under all circumstances. We strongly recommend connecting a fuse directly to the battery to avoid any short circuit at the battery wiring. (5)Batteries can produce flammable gases. Avoid making sparks, using fire or any naked flame. Make sure that the battery room is ventilated. (6)Uses insulated tools and avoid placing metal objects near the batteries. (7)Be very careful when working with batteries. Wear eye protection. Have fresh water available to wash and clean any contact with battery acid. (8)Avoid touching or short circuiting wires or terminals. Be aware that the voltages on special terminals or wires can be as much as twice the battery voltage. Use isolated tools, stand on dry ground, and keep your hands dry. (9)Prevent water from entering the internal controller, outdoor installation should avoid direct sunlight and rain penetration. (10)After installation check that all connections are tight line, avoid heat accumulation caused by virtual access danger. (11)Multiple same models of controllers can be installed in parallel on the same battery bank to achieve higher charging current. Each controller must have its own solar module(s). (12)Select the system cables according to 5A/mm² or less current density. 5.2 Battery cables and battery fuse Cable strain relief must be provided, close to battery and PV connectors. In order to utilize the full capacity of the product, battery cables with sufficient cross section and a fuse of sufficient current rating should be used. Rated charge current 60A Battery Fuse Rating 80A Cable Length Wire Size 2 * 1.5m 16mm²/5AWG 2 * 2.5m 25mm²/3AWG 2 * 5.0m Not recommended !1.The battery wire size recommended is for battery terminal without inverter. 2.Please consult local regulations regarding maximum allowed current carrying capacity of cables. 8 5.3 PV Array The voltage on the PV input should never exceed 200V under any condition. The charger will be permanently damaged if the input voltage is too high. Cable strain relief must be provided, close to PV and battery connectors. 5.3.1 PV cables As the core component of PV system, controller could be suitable for various types of PV modules and maximize converting solar energy into electrical energy. According to the open circuit voltage (Voc) and the maximum power point voltage (Vmpp) of the MPPT controller, the series number of different types PV modules can be calculated. The required PV cable cross section depends on array power and voltage. The table below assumes that maximum PV power has been installed. Cable cross section can be reduced in case of smaller solar arrays.The best efficiency is reached at a PV input voltage that is twice the battery voltage. DC circuit breakers or fuses must be installed in the positive and negative PV cables, to enable isolation of the charger during installation or maintenance. Solar array MPP-Voltage[V] 12V System(Solar array up to 750W) Solar array Cable Length Cable Length MPP-Current[A] 2 * 5m 2 * 10m Cable Length 2 * 20m 18 42 16mm²/5AWG 35mm²/2AWG Not recommended 36 21 10mm²/7AWG 16mm²/5AWG 25mm²/3AWG 54 14 6mm²/10AWG 16mm²/5AWG 25mm²/3AWG 72 10 4mm²/11AWG 6mm²/10AWG 16mm²/5AWG 90 8 2.5mm²/13AWG 4mm²/11AWG 6mm²/10AWG 108 7 2.5mm²/13AWG 4mm²/11AWG 6mm²/10AWG ≥126 6 2.5mm²/13AWG 4mm²/11AWG 6mm²/10AWG Solar array MPP-Voltage[V] 24V System(Solar array up to 1500W) Solar array Cable Length Cable Length MPP-Current[A] 2 * 5m 2 * 10m Cable Length 2 * 20m 36 42 16mm²/5AWG 35mm²/2AWG Not recommended 54 28 16mm²/5AWG 25mm²/3AWG 35mm²/2AWG 72 21 10mm²/7AWG 16mm²/5AWG 35mm²/2AWG 90 17 6mm²/10AWG 16mm²/5AWG 25mm²/3AWG 108 14 6mm²/10AWG 10mm²/7AWG 25mm²/3AWG ≥126 12 4mm²/11AWG 6mm²/10AWG 16mm²/5AWG 9 48V System(Solar array up to 3000W) Solar array MPP-Voltage[V] Solar array MPP-Current[A] Cable Length 2 * 5m Cable Length 2 * 10m 72 42 16mm²/5AWG 35mm²/2AWG Not recommended 90 34 16mm²/5AWG 35mm²/2AWG Not recommended 108 28 16mm²/5AWG 25mm²/3AWG 35mm²/2AWG ≥126 24 10mm²/7AWG 16mm²/5AWG 35mm²/2AWG Cable Length 2 * 20m !please consult local regulations regarding maximum allowed current carr ying capacity of cables. 5.3.2 PV array maximun power The MPPT controller has the function of current/power-limiting, that is during the charging process, when the charging current or power exceeds the rated charging current or power, the controller will automatically limit the charging current or power to the rated charging current or power, which can effectively protect the charging parts of controller, and prevent damages to the controller due to the connection of some over-specification PV modules. !If "Actual charging power of PV array>Rated charging power of controller" or "Actual charging current of PV array>Rated charging current of controller" ,the controller will carry out the charging as per the rated current or power. According to "Peak Sun Hours diagram", if the power of PV array exceeds the rated charging power of controller, then the charging time as per the rated power will be prolonged, so that more energy can be obtained for charging the battery. However, in the practical application, the maximum power of PV array shall not be greater than 1.2 x the rated charging power of controller. If the maximum power of PV array exceeds the rated charging power of controller too much, it will not only cause the waste of PV modules, but also increase the open-circuit voltage of PV array due to the influence of environmental temperature, which may increase the probability of damage to the controller rise. Therefore, it is very important to configure the system reasonably. 10 5.4 Mounting Step 1: Determination of Installation Location and Heat-dissipation Space Do not mount the solar charge controller outdoors or in wet rooms. Do not subject the solar charge controller to direct sunshine or other sources of heat. Protect the solar charge controller from dirt and moisture. Mount upright on the wall on a non-flammable substrate. Maintain a minimum clearance of 15cm below and around the device to ensure unhindered air circulation. Mount the solar charge controller as close as possible to the batteries. Mark the position of the solar charge controller fastening holes on the wall, drill 4 holes and insert dowels, fasten the solar charge controller to the wall with the cable openings facing downwards. If the controller is to be installed in an enclosed box, it is important to ensure reliable heat dissipation through the box. >15CM WARM AIR COOL AIR >15CM Step 2: Preparing the cables (1)Label the cable ends with M+, M-, B+ and B-. (2)Lay the battery and module cables directly next to each other. Do not yet connect the cables. (3)Connect the external battery fuse to the "B–" battery cable, in an easily accessible position close to the battery. (4)Switch off the external battery fuse: Remove the fuse insert from the fuse holder (safety fuse) or switch off the DC line circuit breaker and secure it against being switched on again. (5)Connect the DC load circuit breaker to the module cables "M-" , in an easily accessible position close to the controller. (6)Switch off the DC load circuit breaker and secure it against being switched on again. (7)Remove the terminal cover (release the 4 fastening screws with a screwdriver). Step 3: Connecting the battery Connect the battery cable and external battery fuse to the battery connection of the controller and to the battery. We recommend installing the external battery fuse in the "B–" cable and the current is 1.25 to 2 times the rated current of the controller. 11 Step 4: Connecting the battery voltage sensor The external battery voltage sensor cable allows the controller to directly measure the voltage at the battery. This voltage value can be used for compensation of voltage drops across the battery cables. This means that the voltage measurement is not affected by powerdependent voltage drops across the battery cables. A 2-pin plug with screw terminals for connecting the sensor cable is supplied with the device. A cable with a cross-section of 0.14-1.5 mm² (AWG 28-16) can be used. The battery voltage sensor cable is not supplied with the device. 1. The connection polarity is irrelevant. 2. Install a fuse(< 1A) in the connection between the battery voltage sensor cable and the battery. This protects the cable from burning in the case of a short-circuit in the battery voltage sensor cable. Step 5: Grounding This product is a common-positive controller, if any of one positive is grounded, all the positive terminals of PV and battery will be grounded simultaneously. However, according to the practical application, all the positive terminals of PV array and battery can also be ungrounded, but the grounding terminal on its case must be grounded, which may effectively shield the electromagnetic interference from the outside, and prevent some electric shock to human body due to the electrification of the case. The positive pole of the controller and the shell cannot be grounded at the same time Step 6: Connecting the solar module (1)Safely cover the module (ensure that wind cannot blow off the covering). (2)Connect the module cable with the (open) DC load circuit breaker to the solar module connection of the controller and the solar module. (3)Remove the covering from the solar module. Step 7: Connecting accessories (1)Connect the remote temperature sensor cable Connect the remote temperature sensor cable to the interface ⑪ and place the other end close to the battery. (2)Connect the accessories for RS485 or IoT communication, refer to the accessories list. Step 8: Supplying the controller with voltage (1)Please make sure the battery and the solar module have been connected as described previously. (2)Fit the terminal cover. (3)Fit the fastening screws. (4)Switch on the external battery fuse: Insert the fuse insert into the fuse holder (safety fuse) or switch on the DC line circuit breaker. The controller automatically starts operating and then displays the system states. (5)Switch on the DC load circuit breaker of the solar module, if the PV is charging, the green charge indicator will flash. If the controller is not operating properly or the battery indicator on the controller shows an abnormality, please refer to "7.2 Troubleshooting". 12 + MENU OK RS485 AUX IoT RLY1 RLY2 Utility/Generator Relay2 Grounding DC Breaker Load Relay1 DC/AC Inverter AC/DC Charger Fuse Fuse Remote Batter y Voltage sensor cable Remote Temperature sensor cable Wiring Diagram 13 6, Operation 6.1 LED indicator LED Status Green (PV Panel) Yellow (Battery) Function On Solar panel is connected, but not charged Off PV reverse connection or PV overvoltage protection Fast flash(0.1/0.1s) Flash(0.5/0.5s) MPPT charging Equal or Boost Charging Slow flash(0.5/2s) On Float Charging Battery is normal Off Over voltage protection Fast flash(0.1/0.1s) Low voltage protection Slow flash(0.5/2s) Battery voltage is low 6.2 Key function Key MENU OK Function Enter or exit settings menu. Stop blinking the selected number to confirm the change Navigates one menu level down. Causes the selected numeral to blink so that it can be modified. Moves the selection bar or the display content upwards/downwards. Increases/decreases a setting value by 1 step. 6.3 Status display The status display consists of data, time, communication mode, PV power/ current and battery voltage. ② The figures show the respective basic settings when 2019-01-01 12:30 ① 485 battery chargingis switched on and when the charging ③ ④ is switched off. ①Date and time can be set. ②Communication mode can be set, default RS485. ⑤ ⑥ ⑦ 2000W 21.8A 59.2V If Bluetooth is connected to the mobile phone, the LCD will display the Bluetooth icon. 2019-01-01 12:30 485 ③The solar module is illuminated , the controller ③ recognizes as daytime. The solar module is not illuminated , the controller recognizes as nighttime. ④The arrow symbol indicates charging of the battery. 0W 0.0A 52.0V ⑤Actual charging power. ⑥Actual charging current. ⑦Battery voltage. 14 6.4 Menu structure Main menu Static display Bat.ext.volt. Bat. volt. Bat. Curr. Bat. power : : : : 28.0V 28.0V 37.5A 1050W PV volt. : Accumulation : Running days : Temperature : Relay01 Relay02 Ext.curr. 1.System setting 2.Battery setting 3.Data logger 4.Information OK 1.System settings MENU 54.0V 80KWH 60D 30℃ : : : 10WH MENU ON OFF 30A MENU 1.1 Language 1.2 Set time 1.3 Communication mode 1.4 Backlight time 1.5 Set diesel 1.6 Set AUX 1.7 Factory reset MENU 2.1 Bat. type 2.2 Bat. volt 2.3 LVD 2.4 LVR : : : : LIQ AUTO 11.2V 12.0V MENU 2.5 Equal volt 2.6 Boost Volt 2.7 Float volt : : : 14.8V 14.5V 13.7V OK 2.Battery setting OK Next page OK Next page Total: 600WH 10 8 6 4 2 H 0 4 8 12 100WH 16 20 24 Total: 25KWH 10 OK 3. Data logger 8 6 MENU 4 D 2 0 5 10 15 20 25 OK Next page 30 OK 4. Information MENU ! 3.1 Total in 3.2 Battery volt For the sake of clarity, only the OK, MENU and 15 MT6020-Pro APP: V1.3.5 SYS : V1.5.1 HW: V1.0 operating keys are illustrated. 1.System settings OK MENU 1.1 Language 1.2 Set time 1.4 Backlight time Language : English OK OK 1.1 Language 1.3 Communication mode MENU MENU MENU 1.2 Set time Set time 2019-01-01 12:30 OK MENU MENU MENU OK MENU OK 1.5 Set diesel MENU MENU OK Backlight time MENU 030s OK Diesel generator Auto maint. : ON MENU 1.6 Set AUX OK MENU OK MENU OK 3. Data logger MENU Communication set Comm. mode:RS485 Device ID : 001 1.4 Backlight time MENU 1.5 Set diesel 1.6 Set AUX 1.7 Factor y reset 1.3 Communication mode 1.7 Factor y reset MENU AUX setting Max in curr. :1000A Max out volt.: 10.0V Clear data Reset BLE password Reset 10WH 3.1 Total in 3.2 Batter y voltage OK OK 3.1 Total in 8 6 MENU MENU Total: 600WH 10 4 2 H 0 8 4 12 100WH 16 20 24 Total: 25KWH 10 MENU 8 6 4 D 2 0 10 5 15 10KWH 20 25 30 Total: 300KWH 10 MENU 8 6 4 D 2 0 60 120 180 100KWH 240 300 360 Total: 1.5MWH 35 MENU 28 21 14 Y 7 0 2023 2022 2021 2020 2019 MENU 16 3.2 Batter y voltage OK MENU DATE 08/31 08/30 08/29 08/28 08/27 08/26 08/25 MAX 28.8V 28.8V 28.6V 28.8V 27.6V 28.0V 28.8V MIN 25.0V 24.9V 24.5V 24.6V 23.5V 24.0V 24.5V 6.5 Operation status display Press or to enter this operation status interface. Bat.ext.volt. Bat. volt. Bat. C urr. Bat. power : 28.0V : 28.0V : 37.5A : 1050W PV volt. : 54.0V Accumulation : 80KWH Running days : 60D Temperature : 30℃ Relay01 Relay02 Ext.curr. : : : 10WH ON OFF 30A Total: 600WH 10 8 6 4 2 0 H 4 8 12 100WH 16 20 24 Total: 25KWH 10 8 6 4 2 0 D 5 10 15 20 25 30 Bat.ext.volt Battery voltage measured via the battery voltage sensor cable, in volts (V). If the battery voltage sensor is not connected or the voltage drop exceeds 3V, this item will display "--- ". At this time, you need to connect the voltage sensor or check whether the wiring is correct. Bat. volt The battery voltage measured at connection "B+/B–", in volts (V). Bat.curr The current flowing from the controller to the battery, in Amperes(A). Bat. Power Actual power being used for charging the battery, in watts (W). PV volt Voltage present at PV array connection, in volts(V). Accumulation Actual power being used for charging the battery after the controller is working, in watt-hour (WH) or kilowatt-hour(KWH). Running days Number of operating days since initial commissioning of the device. Temperature This temperature is tested by external sensor for battery temperature compensation. If no external temperature sensor is connected, the temperature inside the controller will be displayed and used for temperature compensation during charging, in Celsius degree(℃). Relay 01 Switching state of load control relay 1. Relay 02 Switching state of Utility/Generator relay 2. Ext.curr Aux interface is connected with current transformer to display the detected current of external equipment. Graphical overview representing the energy input in the last 24 hours. Memory of the information on the amount of input energy in WH or KWH, the vertical axis of the figure varies according to the maximum charging energy. Graphical overview representing the energy input in the last 30 days. Memory of the information on the amount of input energy in WH or KWH, the vertical axis of the figure varies according to the maximum charging energy. 17 6.6 Main menu display Press the MENU key to enter the main menu interface, the interface menu is shown below. 1.System setting 2.Batter y setting 3.Data logger 4.Information Press the MENU key to enter the main menu interface, the interface menu is shown as left, press and to browse the menu. Press OK to enter the current menu settings 6.6.1 System settings 1.1 Language 1.2 Set time 1.3 Communication mode 1.4 Backlight time 1.1 Language OK MENU Language : English 1.2 Set time OK MENU Set time 2019-01-01 12:30 1.3 Communication mode OK MENU Communication set Comm. mode : RS485 Device ID : 001 1.4 Backlight time OK MENU Backlight time 030s If the cursor indicates "System settings", you can press OK and the interface displayed as shown on the left. English is set as the default menu language at the factory, now Chinese and English are available. 1.Press OK to enter the language settings interface, pressing the OK key again, the language item will flash. 2.Press to select the appropriate language. 3.Press OK or MENU to confirm. 4.Press MENU again to exit the current settings. 1.Press OK to enter the time setting interface and the year is selected. 2.Press OK, the year display flashes. 3.Press to change the year. 4.Press OK. The year stops blinking and the month flashes. 5.Press to change the month. 6.Repeat steps 4 and 5 for the day, hour and minutes. 7.Press MENU again to exit the current settings. 1.Press OK to enter the communication setting interface and the communication mode is selected. 2.Press OK, the communication mode display flashes. 3.Press to change the comm. mode, you can select RS485 or IoT. 4.Press OK. The comm. mode stops blinking and the device ID flashes. 5.Press to change the device ID, the setting range is 1~247. 6.Press OK or MENU to confirm. 7.Press MENU again to exit the current settings. 1.Press OK to enter the backlight time setting interface. 2.Press OK, the backlight time display flashes. 3.Press to change the backlight time, the setting range is 0~600. 4.Press OK or MENU to confirm. 5.Press MENU again to exit the current settings. 18 1.5 Set diesel OK MENU Diesel generator Auto maint. : ON 1.Press OK to enter the diesel setting interface. 2.Press OK, the auto maintain setting item flashes. 3.Press to select the auto maintain item from ON and OFF. 4.Press MENU to confirm. 5.Press MENU again to exit the current settings. If "ON" is selected, the automatic maintenance function of the diesel will be started. If the diesel has not been started within 60 days, the diesel will be started at night. The working time of the diesel shall not be less than 15 minutes each time it is started. If "OFF" is selected, the diesel engine will not start until Utility/Generator relay2 is turned on. Aux is defined as current sensor by default. The current of the external equipment is calculated by setting the parameters of the current sensor such as the maximum measuring current and the maximum output voltage. After the correct setting, the external current will be displayed on the LCD screen of the controller. 1.6 Set AUX OK MENU AUX setting Max in curr. : Max out volt. : 1000A 10.0V 1.7 Factor y reset OK MENU Clear data Reset BLE password Reset Clear data 1.Press OK to enter the AUX setting interface. 2.Press OK, the max input current setting item flashes. 3.Press to change the max input current from 10A to 1000A. 4.Press OK. The max input current stops blinking and the max output voltage flashes. 5.Press to change the max output voltage from 0.1V to 10V. 6.Press MENU to confirm. 7.Press MENU again to exit the current settings. 1.Press OK to enter the factory reset setting interface and the clear data is selected. 2.Press OK, the clear log data dialogue appears. 3.Press OK, all log data is deleted and the LCD display "Clear done". 4.Press MENU again to exit the current settings. 5. Repeat steps 3 and 4 for "ReSet BLE password" and "Reset". Refer to the following figure for the operation steps. OK MENU ReSet BLE password OK MENU Reset OK MENU Clear log data Are you sure? Menu Reset BLE password Are you sure? Menu 19 Clear done OK Clear done OK Clear done OK Reset factor y Are you sure? Menu OK OK OK 6.6.2 Batter y setting 2.1 Bat. type 2.2 Bat. V olt 2.3 LVD 2.4 LVR : : : : LIQ AUTO 11.2V 12.0V : : : 14.8V 14.5V 13.7V OK 2.5 Equal volt 2.6 Boost V olt 2.7 Float volt The batter y type is LiQ, AGM or GEL. If the cursor indicates "Battery setting", you can press OK and the interface displayed as shown on the left. 2.1 Bat. type (Battery Type) This item can change the battery type, press the OK key to enter the menu, you may press to change the battery type. Possibilities for programming: GEL, AGM, LIQ, LI.(default : GEL) 2.2 Bat. Volt (Battery Voltage) This item suitable for Gel, AGM and LIQ battery, the controller can be set to identify only fixed system voltage or automatically system voltage. Possibilities for programming: 12V, 24V, 48V, AUTO. (default : AUTO) 2.3 LVD (Low Voltage Disconnect) This item can change the low voltage disconnect data, press the OK key to enter the menu, you may press to change the value. Possibilities for programming: 10.8~11.8V/21.6~23.6V/43.2~47.2V(default : 11.2V/22.4V/44.8V). Possibilities for programming: 12V, 24V, 48V, AUTO. 2.4 LVR (Low Voltage Reconnect) This item can change the low voltage reconnect data, press the OK key to enter the menu, you may press to change the value. Note: The solar charge controller allows the smallest difference between LVD and LVR is 0.6/1.2/2.4V. If you want to program a high level for disconnection you must first increase the reconnection level. Possibilities for programming: 11.4~12.8V/22.8~25.6V/45.6~51.2V(default: 11.8V/23.6V/47.2V) 2.5 Equal volt (Equalization voltage) This item can change the equalization voltage, press the OK key to enter the menu, you may press to change the value. Note: 1.The equalization charging can only be adjusted for batteries with liquid electrolyte, since high equalising voltages are harmful for sealed batteries. The maximum equalising voltage value should be stated on the battery manufacturer's data sheet. 2.This window is deactivated if you have selected "GEL" battery. Possibilities for programming: 14.0~15.0V/28.0~30.0V/56~60.0V(default: 14.8V/29.6V/59.2V) 2.6 Boost volt (Boost voltage) This item can change the boost voltage, press the OK key to enter the menu, you may press to change the value. Possibilities for programming: 14.0~14.8V/28.0~29.6V/56.0~59.2V(default: 14.5V/29.0V/58.0V) 2.7 Float volt (Float voltage) This item can change the float voltage, press the OK key to enter the menu, you may press to change the value. Possibilities for programming: 13.0~14.5V/26.0~29V/52.0~58.0V(default: 13.7V/27.4V/54.8V) 20 2.1 Bat. Type (Battery Type) Press to change the battery type as LI. 2.2 0℃ charge (0℃ charging) "0℃ Charge" can be set to "Yes", "Slow" or "No". When the OK controller detects that the ambient temperature is higher than 0℃, the charging function is normal. when the ambient temperature is 2.5 LVD : 42.4V 2.6 LVR : 48.0V low than 0℃, if the "0℃ Charge" is set to “Yes”, the charging function is normal, else if the "0℃ Charge" is set to “slow”, the max The batter y type is LI. charging current is 20% of the rated current, else if the "0℃ Charge" is set to “No”, the controller does not charge the battery. Possibilities for programming: Yes, No, Slow. (default : Yes) 2.3 CVT (Charging target voltage) This item can change the charging target voltage, press the OK key to enter the menu, you may press to change the value. Possibilities for programming: 10.0~64.0V.(default : 57.6V) 2.4 CVR (Charging recovery voltage) This item can change the charging recovery voltage, press the OK key to enter the menu, you may press to change the value. Possibilities for programming: 9.2~63.8V.(default : 56.0V) 2.5 LVD (Low Voltage Disconnect) This item can change the low voltage disconnect data, press the OK key to enter the menu, you may press to change the value. Possibilities for programming: 9.0~60.0V.(default : 42.4V) 2.6 LVR (Low Voltage Reconnect) This item can change the low voltage reconnect data, press the OK key to enter the menu, you may press to change the value. Note: The solar charge controller allows the smallest difference between LVD and LVR is 0.6V. If you want to program a high level for disconnection you must first increase the reconnection level. Possibilities for programming: 9.6~62.0V.(default : 48.0V) 2.1 Bat. Type 2.2 0℃charge 2.3 CVT 2.4 CVR : : : : LI Yes 57.6V 56.0V 6.6.3 Data logger 3.1 Total in 3.2 Batter y voltage 3.1 Total in Memory of the information on the amount of input energy in Wh/KWh. Graphical overview representing the last 24 hours. 10WH Total: 600WH 10 8 6 4 2 0 H 4 8 21 12 16 20 24 Memory of the information on the amount of input energy in Wh/KWh. Graphical overview representing the last 30 days. 100WH 10 Total: 25KWH 8 6 4 2 D 0 10 5 15 20 25 30 Memory of the information on the amount of input energy in Wh/KWh. Graphical overview representing the last 360 days. 10KWH Total: 300KWH 10 8 6 4 2 D 0 60 120 180 240 300 360 Memory of the information on the amount of input energy in Wh/KWh. Graphical overview representing the last 5 years. 100KWH Total: 1.5MWH 35 28 21 14 7 0 3.1 Total in 3.2 Batter y volt Y 2023 2022 2021 2020 2019 3.2 Battery voltage Record of the minimum and maximum battery voltage for each day over the last 60 days. Date 08/31 08/30 08/29 08/28 08/27 08/26 08/25 Max 28.8V 28.8V 28.6V 28.8V 27.6V 28.0V 28.8V Min 25.0V 24.9V 24.5V 24.6V 23.5V 24.0V 24.5V 22 Date 07/09 07/08 07/07 07/06 07/05 07/04 07/03 Max 28.4V 28.8V 28.6V 28.8V 27.6V 28.0V 28.8V Min 24.0V 24.9V 24.5V 24.6V 23.5V 24.0V 24.5V 6.6.4 Information MT6020-Pro APP: V1.3.5 SYS : V1.5.1 HW: V1.0 This item displays the system of the controller. MT6020-Pro: Product name APP: Software version of the display unit. SYS: Software version of the power unit. HW: Hardware version of the power unit. 6.7 Fault indication Status Icon Description Batter y over discharged Low VD Batter y level shows empty, fault icon display, batter y frame flashes, the LCD screen displays " Low VD " Batter y over voltage Over VP Batter y level shows full, fault icon display, batter y frame flashes, the LCD screen displays " Over VP " PV reverse polarity PV Reverse Fault icon display, the LCD screen displays " PV Reverse " PV over voltage PV Over Volt. Fault icon display, the LCD screen displays " PV Over Volt. " Over temperature Charge Over TD Fault icon display, the LCD screen displays " Charge Over TD " Controller does not correctly identify system voltage C ontroller does not correctly identify Undefined Voltage system voltage, fault icon display, the LCD screen displays "Undefined Voltage" Communication failure Comm. Error Display board failed to obtain controller data, fault icon display, the LCD screen displays "Comm. Error" 23 7, Protections,Troubleshooting and maintenance 7.1 Protection Protection Description PV Over Current The controller will limit charging power in rated charge power. An over-sized PV array will not operate at maximum power point. PV Short Circuit When not in PV charging state, the controller will not be damaged in case of a short-circuiting in the PV array. PV Reverse Polarity When the polarity of the PV array is reversed, the controller may not be damaged and can continue to operate normally after the polarity is corrected. Night Reverse Charging Prevents the battery from discharging through the PV module at night. Battery Over voltage If there are other energy sources to charge the battery, when the battery voltage exceeds 15.8/31.3/62.3V, the controller will stop charging to protect the battery from overcharging damage. Battery Reverse Polarity Fully protection against battery reverse polarity, no damage to the controller. Correct the connection to start normal operation. When battery voltage drops to the setting voltage of low voltage Battery Over discharge disconnect ,the controller will turn off the load control relay1 to protect the battery from over discharging damage. Battery Over Temperature Protection The controller can detect the battery temperature through an external temperature sensor.The controller stops working when its temperature exceeds 65 °C and restart to work when its temperature is below 55 °C. Controller Over Temperature Protection * The controller detects the internal temperature through internal sensor, when the temperature exceeds the setting value, the charging current will lower down followed by the decrease of temperature, so as to control the controller's temperature rise, when the internal temperature exceeds 85℃, the controller stops working and restores after the temperature is below 75℃. TVS High Voltage Transients The internal circuitry of the controller is designed with Transient Voltage Suppressors (TVS) which can only protect against highvoltage surge pulses with less energy. If the controller is to be used in an area with frequent lightning strikes, it is recommended to install an external surge arrester. 24 *When the internal temperature exceeds 65℃, the mode of charging power reduction is started, and the charging power decreases 10% for every 5℃ increase of internal temperature. If the internal temperature is higher than 85℃, the controller will stop charging. But when the temperature drops below 75℃, the controller will resume working at 70% of rated power. When the internal temperature decreases by 5℃, the charging power increases by 10%. When the internal temperature is lower than 60℃, the full power can be recovered. Reduce Charging Mode 100 90 Charging Ratio(%) 80 70 60 50 40 30 20 10 0 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 Internal temperature(℃) Recover charging from over temperature protection 100 90 Charging Ratio(%) 80 70 60 50 40 30 20 10 0 86 84 82 80 78 76 74 72 70 68 66 64 62 60 58 Internal temperature(℃) X-axis is the internal temperature, Y-axis is the charging ratio. For example, the full charging power of the controller is 1000W, when the temperature rises to 75 ℃, the charging ratio drops to 80%, which is 800W. When the controller recovers after over temperature protection, when the temperature drops to 70 ℃, the charging power recovers to 80%, which is 800W. 25 7.2 Troubleshooting Faults Battery over discharged Battery over voltage Possible reason Battery excessively discharged by loads (deep-discharge protection not installed). Battery is defective. Troubleshooting Charge the battery with an external charger. Replace the battery. Additional charging sources in system may be causing an excessively high voltage. Check the external charging devices and adjust if necessary. Controller possibly defective. Contact your installer. Battery voltage too low. Pre-charge the battery. External fuse/circuit breaker for the Replace the external battery fuse for the battery or reset the circuit battery has blown/triggered. breaker. No display Battery is not being charged Over temperature Battery is not connected. Battery is defective. Battery reverse connection. 1. Unclamp all connections. 2. Connect a (new) battery with the correct polarity. 3. Reconnect the solar module. The LCD is mechanically defective. Contact your installer. The device must be replaced. Solar module not connected. Connect the solar module. Short circuit at solar module connection. Rectify short circuit. Incorrect solar module voltage. Use a solar module of a suitable voltage. Solar module defective. Replace the solar module. The temperature of the battery or controller is too high. The controller will automatically turn the system off. When the temperature declines to be below 55 ºC, the controller will resume. The system voltage is set at 12V, Setting "2. Battery Setting" --> Controller does not 24V or 48V, but the battery voltage "2.2 Batt. Volt" to AUTO or to correctly identify is not consistent with the setting match the battery voltage. system voltage system voltage. 26 7.3 Maintenance The following inspections and maintenance tasks are recommended at least two times per year for best performance. 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. Repair or replace some wires if necessary. Tighten all the terminals. Inspect for loose, broken, or burnt wire connections. Check and confirm that LCD is consistent with required. Pay attention to any troubleshooting or error indication .Take corrective action if necessary. 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. Risk of electric shock! Make sure that all the power is turned off before above operations, and then follow the corresponding inspections and operations. 27 8, Technical Data 8.1 Electrical Parameters Item MT6020-Pro Max charging current 60A System voltage 12/24/48V System voltage setting Automatic/12V/24V/48V MPPT charging voltage before boost or equalization charging stage Boost voltage@25℃ 14.0~14.8V/28.0~29.6V/56.0~59.2V(default: 14.5/29.0/58.0V) Equalization voltage@25℃ 14.0~15.0V/28.0~30.0V/56.0~60.0V (default: 14.8/29.6/59.2V) Float voltage@25℃ 13.0~14.5V/26.0~29.0V /52.0~58.0V(default: 13.7/27.4/54.8V) Low voltage disconnect 10.8~11.8V/21.6~23.6V/43.2~47.2V(default: 11.2/22.4/44.8V) Low voltage reconnect 11.4~12.8V/22.8~25.6V/45.6~51.2V(default: 12.0/24.0/48.0V) Overcharge protect 15.8/31.3/62.3V Temp. Compensation -4.17mV/K per cell (Boost, Equalization), -3.33mV/K per cell (Float) Charging target voltage 10.0~64.0V(Lithium, default: 29.4V) Charging recovery voltage 9.2~63.8V(Lithium, default: 28.7V) Low voltage disconnect 9.0~60.0V(Lithium, default: 21.0V) Low voltage reconnect 9.6~62.0V(Lithium, default: 22.4V) Battery type Gel, AGM, Liquid, Lithium(default: Gel) Max volt on Bat. Terminal 65V Max volt on PV terminal 190V(@-20℃), 170V(@25℃) Max input power 750/1500/3000W MPPT tracking range (Battery Voltage + 2.0V)~Voc*0.9 Max tracking efficiency >99.9% Max charge conversion 98.0% Efficiency at full load 97.5% Self consumption <5W Grounding Common Positive *1 *2 Data memory 5 years Relay 3A/30VDC Communication BLE, IoT, RS485(Default, RJ11 interface) *1.The maximum PV open circuit voltage must never exceed 170V at 25℃ environment temperature. *2.Voc means the open circuit voltage of the solar panel. *3.Around oblique line value separately on behalf of 12/24/48V system's value. 28 8.2 Mechanical Parameters Item MT6020-Pro Dimensions 339 * 230 * 109mm Mounting Dimensions 220*215mm Mounting hole size φ6mm Weight 5Kg Terminal size 2AWG(35mm²) Recommended cable 6AWG(16mm²) 8.3 Environmental Parameters Item Operating temperature MT6020-Pro -20 ~ +60℃ Derating From >65℃ internal Fan Internal, temperature controlled LCD temperature range -20 ~ +70℃ Storage temperature -25 ~ +80℃ Ambient humidity 5 ~ 95%RH(No condensation) Protection degree IP20 Max Altitude 4000m 29 Lumiax Magic your solar life! Qingdao Skywise Technology Co., Ltd. NO.192, Zhuzhou Road, Qingdao Tel:0086-532-80776031 Fax: 0086-532-80776757 E-mail: [email protected] website: www.lumiax.com ">

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