PolarPlus P20LWMBT User Manual

www.PolarPlus.no
PolarPlus
MPPT Solar Controller
12/24V, 260/520W
User Manual
CE, Rohs, ISO9001:2015
Subject to change without notice!
Contents
1 Safety instructions and waiver of liability........................................................................................................................2
1.1 Safety Instructions.....................................................................................................................................................................2
1.2 Liability Exclusion.......................................................................................................................................................................2
2 Pruduct Overview........................................................................................................................................................................3
2.1 MPPT .............................................................................................................................................................................................3
2.2 MPPT-Four Charging Stage ...................................................................................................................................................4
3 Dimensions.....................................................................................................................................................................................5
4 Structure & Accessory...............................................................................................................................................................6
5 Installation......................................................................................................................................................................................7
5.1 Installation Notes.......................................................................................................................................................................7
5.2 Mounting Location Requirements........................................................................................................................................7
5.3 Wiring Specifications................................................................................................................................................................8
5.4 Connection...................................................................................................................................................................................8
5.5 Grounding.....................................................................................................................................................................................8
6 Bluetooth.........................................................................................................................................................................................9
6.1 Bluetooth Communication......................................................................................................................................................9
6.2 Battery Type.................................................................................................................................................................................9
7 LED indications, Protections and Maintenance...........................................................................................................10
7.1 Led Display.................................................................................................................................................................................10
7.2 Faults & Alarms........................................................................................................................................................................10
7.3 Protection...................................................................................................................................................................................11
7.4 Maintenance..............................................................................................................................................................................11
8 Technical Data.............................................................................................................................................................................12
1
Dear Clients,
Thanks for selecting the Win series solar controller.
Please take the time to read this user manual, this will help you to make full use of many advantages the
controller can provide your solar system. This manual gives important recommendations for installing and
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 the 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)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 batter y, caused by use other
than as intended or as mentioned in this manual or if the recommendations of the batter y
manufacturer are neglected. The manufacturer shall not be liable if there has been ser vice or
repair carried out by any unauthorized person, unusual use, wrong installation, or bad system
design.
2
2,Over view
Win 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.
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%
LED indicator for easy to read charging state and battery information
12/24V automatic recognition
Liquid, Gel, AGM and Lithium battery for selection
The separate ports for remote temperature sensor, make battery temperature compensation more
accurate
Four stages charge way: MPPT, boost, equalization, float
Automatic over-temperature power reduction function
Dual automatic restriction function when exceeding rated charging power and charging current
Android APP version for Bluetooth communication
Common negative design
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.
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.
3
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
VP curve
Typical
Battery
Voltage
Range
VI curve
Pmax-Px
Px
PWM
Controller
Operating
Range
0
10.8V
15V 17V
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
Win series controller has a 4-stage battery charging algorithm for rapid, efficient, and safe battery
charging.
U(V)
Equalization
Charge
14.8V
14.5V
13.7V
Night
MPPT
Charge
Boost
Charge
Float
Charge
Night
TIME
4
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.
WARNING: 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
4.5
20
φ4
64
107
164
32
5
4,Structure & Accessor y
①Aluminum case
—dissipate controller heat, Internal
②
③
④
⑤
protection.
②Temperature Sensor Port
—Collect temperature information.
Temperature compensation.
③Solar module terminals
—Connected solar modules.
④Battery Terminals
—Connect the battery.
⑤LED Display
—Display the status of the controller.
①
Remote Temperature Sensor(Accessor y)
T h e controller i s s h i p p e d with a temperature sensor of length 80mm. If you need longer remote
temperature sensor, you need to p u r c h a s e s e p a r a t e ly.
The remote temperature sensor can measure the temperature at the batter y and use this data for
ver y accurate temperature compensation. The standard length of the cable is 3m (length can be
customized). The temperature sensor connected via interface ②.
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.
6
5,Installation
Please read all instructions and precautions in the manual before installing.
5.1 Installation Notes
⑴The solar charge controller may only be used in PV systems in accordance with this user manual and
the specifications of other modules manufacturers. No energy source other than a solar generator may be
connected to the solar charge controller.
⑵Before wiring installation and adjustment of controller, Always disconnect the solar modules and
insurance or circuit breaker of battery terminal.
⑶Only to comply with the range of the battery charge controller.
⑷Batteries 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.
⑸Batteries can produce flammable gases. Avoid making sparks, using fire or any naked flame. Make sure
that the battery room is ventilated.
⑹Uses insulated tools and avoid placing metal objects near the batteries.
⑺Be very careful when working with batteries. Wear eye protection. Have fresh water available to wash
and clean any contact with battery acid.
⑻Avoid 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.
⑼Prevent water from entering the internal controller, outdoor installation should avoid direct sunlight
and rain penetration.
⑽After installation check that all connections are tight line, avoid heat accumulation caused by virtual
access danger.
5.2 Mounting Location Requirements
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.
>15CM
WARM AIR
COOL AIR
>15CM
7
5.3 Wiring Specifications
Wiring and installation methods must comply with national and local electrical specifications.
The wiring specifications of the solar, battery must be selected according to rated currents, and see the
following table for wiring specifications:
Rated charging current
Solar wire diameter(mm²/AWG)
Batter y wire diameter(mm²/AWG)
5/10
5/10
20A
!
The wire size is only for reference. If there is a long distance between the PV array and the
controller or between the controller and the battery, larger wires can be used to reduce the voltage
drop and improve performance.
5.4 Connection
We strongly recommend connecting a fuse directly to the battery to protect any short circuit at the
battery wiring. Solar PV modules create current whenever light strikes them. The current created varies
with the light intensity, but even in the case of low levels of light, full voltage is given by the modules. So,
protect the solar modules from incident light during installation. Never touch uninsulated cable ends, use
only insulated tools, and make sure that the wire diameter is in accordance with the expected currents of
solar charge controller. Connections must always be made in the sequence described below.
Fuse
③
④ ①
②
WARNING: Risk of electric shock! Exercise caution when handing solar wiring. The solar
PV array can produce open-circuit voltages in excess of 100V when in sunlight. Pay more
attention to it.
WARNING: Risk of explosion! Once the battery's positive and negative terminals or leads
that connect to the two terminals get short-circuited, a fire or explosion will occur. Always
be careful in operation.
1st step: Connect the battery
Connect the battery connection cable with the correct polarity to the middle pair of terminals on the
solar charge controller (with the battery symbol). If the system is 12V, please make sure that the battery
voltage is within 5V~15.5V, else if the system is 24V, the battery voltage should between 20V~31V.
2nd step: Connect the solar module
Ensure that the solar module is protected from incident light. Ensure that the solar module does not
exceed the maximum permissible input current. Connect the solar module connection cable to the correct
polarity of the left pair of terminals on the solar charge controller (with the solar module symbol).
3th step: Final work
Tighten all cables connected to the controller and remove all the debris around the controller (leaving a
space of approx. 15 cm).
5.5 Grounding
Be aware that the negative terminals of controller are connected together and therefore have the same
electrical potential. If any grounding is required, always do this on the negative wires.
For common-negative system, such as motorhome, it is recommended to use a commonnegative controller, but if in the common-negative system, some common-positive
equipment are used, and the positive electrode is grounded, the controller may be
damaged.
8
6.Bluetooth
6.1 Bluetooth Communication
Bluetooth communication has the following characteristics：
1.Support Android mobile phone APP.
2.Realize wireless monitoring function of solar controller.
3.Use high performance, ultra-low power consumption Bluetooth dedicated chip.
4.Adopt Bluetooth 4.2 and BLE technology.
5.communication distance up to 10m.
Refer to Bluetooth APP instructions for detailed operation of mobile APP.
6.2 Battery Type
The controller applies to Liquid, Gel, AGM and Lithium battery, the factory default setting is suitable for
Gel battery.
6.2.1 Liquid, GEL, AGM
When choosing Liquid, GEL or AGM for battery type, the parameters of boost, equalization and float
charging voltage can be set by mobile phone APP. The range of parameters is as follows. The following
voltage parameters are 25℃/12V system parameters, 24V system automatically multiplied by 2.
Charging stage
Boost
Equalization
Charging voltage range
14.0~ 14.8V
14.0~ 15.0V
13.0~ 14.5V
Default charging voltage
14.5V
14.8V
13.7V
Float
Low voltage disconnect and low voltage reconnect can also be set by Bluetooth app of mobile phone.
Low voltage disconnect(LVD) setting range: 10.8-11.8V/21.6-23.6V(default: 11.2/22.4V)
Low voltage reconnect(LVR) setting range: 11.4~12.8V/22.8~25.6V(default: 12.0/24.0V)
6.2.2 Lithium
① Parameters setting
When choosing lithium battery type, the charge target voltage, charge recovery voltage, low voltage
disconnect and low voltage reconnect of lithium battery can be set by mobile phone APP, the setting
range is as follow.
Charge target voltage(CVT) setting range: 10.0-32.0V (default: 14.4V)
Charge recovery voltage(CVR) setting range: 9.2-31.8V (default: 14.0V)
Low voltage disconnect(LVD) setting range: 9.0-30.0V (default: 10.6V)
Low voltage reconnect(LVR) setting range: 9.6-31.0V (default: 12.0V)
② 0℃ Charging
"0℃ Charging" function is only applicable for lithium battery, it can be set to "Yes", "Slow" or "No". When
the controller detects that the ambient temperature is higher than 0℃, the charging function is normal.
when the ambient temperature is low than 0℃, if the "0℃ Charging" is set to "Yes", the charging function
is normal, else if the "0℃ Charging" is set to "slow", the max charging current is 20% of the rated current,
else if the "0℃ Charging" is set to "No", the controller does not charge the battery.
The user can select the appropriate charging method.
The low voltage reconnect(LVR) should be higher than the low voltage disconnect (LVD) at
least 0.6/1.2V, if you want to improve LVD, you should first improve LVR.
(Charge recovery voltage+1.5V)≥Lithium Charge target voltage≥(Charge recovery
voltage+0.2V)
Mobile App does not support parameters beyond this range.
Warning: The required accuracy of BMS shall be at least 0.2V. If the deviation is higher than
0.2V, the manufacturer will assume no liability for any system malfunction caused by this.
9
7, LED indications, Protections and Maintenance
7. 1 LED Display
Solar LED
Batter y LED
Batter y Capacity LED
Soc1 Soc2 Soc3 Soc4
LED
Solar LED
(Red)
Batter y LED
( Blue)
Batter y Capacity
LED
(Red, Orange,
Green, Green)
Status
Function
On
Solar panel is correctly connected,
but not charged
Fast Flash(0.1s/0.1s)
MPPT charging
Flash( 0.5s/0.5s)
Equal or Boost charging
Slow Flash(0.5s/2s)
Float charging
Off
Night
On
Batter y is normal
Flash( 0.2s/0.2s)
Over temperature
Soc1 Flash( 0.2s/0.2s, Red)
Low voltage protection
Soc4 Flash( 0.2s/0.2s, Green)
Over voltage protection
Soc1 On
Batter y capacity < 20%
Soc2 On
20% < Batter y capacity < 50%
Soc3 On
50% < Batter y capacity < 90%
Soc4 On
Batter y capacity > 90%
7.2 Faults & Alarms
Fault
Reason
Troubleshooting
High voltage at
battery terminal
Batter y voltage is too high
Check if other sources overcharge the battery.
If not, controller is damaged.
Can't recognize
bluetooth
Communication failure
Reconnect after disconnecting the batter y
for about 1 minute and reconnect the
Bluetooth device.
Can't recognize
system voltage
Batter y voltage is abnormal
at start-up
Charge or discharge the batter y so that the
batter y voltage is within the normal
operating range (5~15.5V or 20~31V).
Batter y can't
be charged
during daytime
PV panel fault or reverse
connection
Check panels and connection wires.
10
7.3 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 PV short circuit occurs, the controller will stop charging.
Remove it to start normal operation.
PV Reverse Polarity
Fully protection against PV reverse polarity, no damage to the
controller. Correct the connection to start normal operation.
Batter y Reverse Polarity
Fully protection against batter y reverse polarity, no damage to the
controller. Correct the connection to start normal operation.
Batter y Over voltage
If there are other energy sources to charge the batter y, when the
batter y voltage exceeds 15.8 / 31.3V, the controller will stop charging
to protect the batter y from overcharging damage.
Batter y Over discharge
W h e n b a t t e r y v o l t a g e drops t o t h e s e t ting v o l t a g e p o i n t o f
lo w vo l t a g e di s c o n n e c t , the low voltage protection indicator of
the controller will flash.
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 the setting over temperature protection
threshold, the controller stops working and restores after the
temperature is lowered.
Damaged Remote
Temperature Sensor
If the temperature sensor is shor t-circuited or
d a m a g e d , the controller will use the internal temperature for
charging temperature compensation.
7.4 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 necessar y.
Tighten all the terminals. Inspect for loose, broken, or burnt wire connections.
Pay attention to any troubleshooting or error indication .Take corrective action if necessar y.
Confirm that all the system components are ground connected tightly and correctly.
Confirm that all the terminals have no corrosion, insulation damaged, high temperature or
burnt/discolored sign, tighten terminal screws to the suggested torque.
Check for dirt, nesting insects and corrosion. If so, clear up in time.
WARNING：Risk of electric shock!
Make sure that all the power is turned off before above operations,
and then follow the corresponding inspections and operations.
11
8, Technical Data
Batter y
Parameters
Item
P20LWMBT
System voltage
12/24V automatical recognization
Max charging current
20A
MPPT charging voltage
before boost or equalization charging stage
Boost voltage
14.0~14.8V/28.0~29.6V(default:14.5/29.0V@25℃）
Equalization voltage
14.0~15.0V/28.0~30.0V(default:14.8/29.6V@25℃）
Float voltage
13.0~14.5V/26.0~29.0V(default:13.7/27.4V@25℃）
Low voltage disconnect
10.8~11.8V/21.6~23.6V(default: 11.2/22.4V)
Low voltage reconnect
11.4~12.8V/22.8~25.6V(default: 12.0/24.0V)
Temperature compensation
-4.17mV/K per cell (Boost, Equalization)，
-3.33mV/K per cell (Float)
Panel
Parameters
System
Parameters
Charging target voltage
10.0~32.0V(Lithium, default: 14.4V)
Charging recover y voltage
9.2~31.8V(Lithium, default: 14.0V)
Low voltage disconnect
9.0~30.0V(Lithium, default: 10.6V)
Low voltage reconnect
9.6~31.0V(Lithium, default: 12.0V)
Max volt on bat. terminal
35V
Batter y type
Gel, AGM, Liquid, Lithium(default: Gel)
Max voltage on PV(-20℃)
55V
Max voltage on PV(25℃)
50V
*1
Max input power
260/520W
MPPT tracking range
（Batter y Voltage + 1.0V）~Voc*0.9
Max tracking efficiency
>99.9%
Max conversion efficiency
98.0%
Dimensions
164 * 107 * 32mm
Weight
700g
Communication
BLE
Grounding
Common Negative
Power terminals
10 AWG(5mm²)
Ambient temperature
-20 ~ +55℃
Storage temperature
-25 ~ +80℃
Ambient humidity
0 ~ 100%RH
Protection degree
IP54
Max Altitude
4000m
*2
*1.This value represents the maximum voltage of the solar panel at the minimum operating
ambient temperature.
*2.Voc means the open circuit voltage of the solar panel.
*3.Around oblique line value separately on behalf of 12V and 24V system's value.
12
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