User Manual MA-4025 Solar
Contents
1. Charger not running battery and source Table 3 LED status information Notes Blinking speed is based on power delivered to the battery 0 8 to 7 blinking cycles per second for an output current range of 0 2 to 4 Amps Preliminary Www apecor com MA 4025 Solar Charger User Manual Trouble Shooting Condition Possible Causes Solutions No lights on MA 4025 Solar ready to be connected to battery Connect to battery to charge No or very little input power available Check connection to solar panel Wait for more sunshine Orient panel perpendicular to sun Fault light blinking for a longer period of time Input power may be low Wait for more sunshine Orient panel perpendicular to sun Table 4 General Trouble Shooting Condition Possible Causes Solutions The MA 4025 Solar finishes charge but battery doesn t seem to be fully charged Battery temperature got too high because ambient temperature was above 38 C 100 F therefore charge was terminated early to protect the battery Find a cool and ventilated place to charge the battery Battery temperature needs to be below 40 C 104 F for the MA 4025 Solar to start charging again Fault light blinking Temperature of battery is below 0 C 32 F or above 40 C 104 F Leave MA 4025 Solar connected to battery the charger will start charging once the battery temperature is okay2. Preliminary Www apecor com MA 4025 Solar Charger User Manual Maximum Output Current vs Heatsink Temperature sdwiy uang yndjno Xen 100 90 80 75 70 Heatsink Temperature Figure 8 Max Output Current vs Internal Heatsink Temperature Maximum Output Current vs Input Voltage sdwiy juaung indjno xe Input Voltage V Figure 9 Max Output Current vs Input Voltage WWww apecor com Preliminary MA 4025 Solar Charger User Manual Maximum Output Current vs Battery Temperature sdwy uana yndjno xe MA 4025 Battery Temperature C Figure 10 Max Output Current vs MA 4025 Battery Temperature For further technical information please consult the datasheet of the MA 4025 Solar Charger WWww apecor com Preliminary Ath ir EDR MA 4025 Solar Charger User Manual Warranty Statement The MA 4025 Solar Charger is warranted to be free from defects in material and workmanship for a period of TWO 2 years from the date of shipment to the original end user ApECOR will at its option repair or replace any such defective products Claim Procedure e Before requesting warranty service check the User Manual to be certain that there is a problem with the controller Contact ApECOR to request Returned Material Authorization RMA Return the defective product to your authorized ApECOR distributor with shipping charges prepa
3. Table 5 Trouble Shooting related to the MA 4025 Battery Preliminary www apecor com psi COR MA 4025 Solar Charger User Manual Maintenance The MA 4025 Solar has 2 spring pins that can be pulled out and replaced by new ones if necessary Besides that it has no other serviceable parts Check for broken corroded or otherwise damaged cable or battery contacts Make sure that all battery contacts are straight and that the two smaller pins spring pins can be pushed in and come out again if released If a defect has been found replace the MA 4025 Solar The cable to the solar panel may be repaired however do NOT attempt to repair battery contacts Make sure that all contacts are free of mud dirt dust oil and grease If found dirty they can be cleaned with a damp non abrasive cloth and allowed to air dry or wiped with a clean dry non abrasive cloth In case of oils and grease use a mild soap water solution to dampen the cloth Features The MA 4025 Solar has many features that enhance its core functions make it safer to operate and increase its reliability Fast Maximum Power Point Tracking MPPT A solar panel has a unique characteristic that is derived from the fact that as more current is drawn from the solar panel the more the voltage will decrease The respective curves IV Current vs Voltage PV Power vs Voltage in Figure 6 show that at a certain voltage the available power has a maximum Typical batter
4. E iE eii 15 Warranty Exclusions and Limitations eeeesseeeesseseessestesrestssresteststesrestesesrersesrerserreesrsreeseseees 15 Preliminary www apecor com liie LOR MA 4025 Solar Charger User Manual General Information Specification Summar Maximum Input Voltage 60V Rated Charge Current 4A Maximum Ambient Temperature 60 C The solar panel s open circuit voltage Voc must not exceed the maximum input voltage Safety This manual contains important safety and operating instructions for the MA 4025 Solar Battery Charger Read all the instructions and cautions of this manual and on the label of the MA 4025 Solar before using it To reduce the risk of electrical shock fire or injury operate charger in only the prescribed manner and use only with recommended items General Safety Guidelines e Only use recommended accessories with the MA 4025 e Do not exceed the maximum input voltage and only charge recommended batteries not doing so may result in fire electrical shock or injury e Do not charge battery if the ambient temperature is outside of the recommended battery temperature limits e Disconnect the MA 4025 Solar from panel by pulling on the plug not the cord e Do not use the MA 4025 Solar with damaged cables or connector pins e Check for proper electrical connections to the panel and battery to avoid excessive heating and power loss from a loose connection e Do not try to operate the MA 4025
5. Protection Electrically and Mechanicall In order to protect the entire system the MA 4025 Solar has a reverse polarity protection RPP on the solar panel and battery side If there is no positive voltage seen on the terminals of the MA 4025 Solar it won t allow any current to flow which is the electrical RPP In addition there is a mechanical RPP which means that the solar panel and battery cannot be plugged in the wrong way Temperature Protection The MA 4025 Solar provides the full charge current up to a certain internal temperature After that it will linearly de rate the charge current up to a maximum allowable internal temperature in order to protect its circuitry to safe limits For the respective graph refer to Figure 8 in paragraph Technical Specifications Over Current Protection The MA 4025 Solar is protected against over current and short circuit conditions Normally it will limit the maximum charge current to 4A If under some condition the current still comes up higher a fault may be triggered After that the software of the MA 4025 Solar can successfully reset the fault in case it was only temporarily If the high current could not be stopped because the circuitry of the MA 4025 Solar is damaged an internal fuse will break and disconnect from the battery In that case the MA 4025 Solar would be permanently non operational This behavior is preferred as the battery is protected from short circuit currents that could have l
6. basically two main methods to power the MA 4025 Solar for charging the battery Solar panels see Figure 1 and Figure 2 or a DC source such as other batteries Figure 3 and Figure 4 The most common setup is with one solar panel connected To increase charging speed or if clouds are limiting available power solar panels can be paralleled If available the MA 4025 Solar will use up to 8O0W input power to charge the MA 4025 battery at its maximum charge current Other batteries can be used as power sources as long as they fulfill the input voltage and power requirements of the MA 4025 Solar A 24V vehicle bus or two 12V lead acid batteries in series could serve as a power source Figure 1 Charger Setup 1 with one Solar Panel as power source Figure 2 Charger Setup 2 with two Solar Panels in parallel as power source gt Preliminary Www apecor com Figure 4 Charger Setup 4 with two 12V batteries in series as power source r using optional accessories Preliminary www apecor com Ath ir EDR MA 4025 Solar Charger User Manual Charging Procedures Connect the MA 4025 Solar to the power source to be used and the battery to be charged in any order If LEDs on top of the charger are still lit up from a previous charge wait until all lights are off before connecting to another battery Once everything is connected together the Charging LED blinks at a low rate meaning
7. that the MA 4025 is analyzing the connected battery If there was no fault the Charging LED will continue to blink and the other two LEDs would be off The charge is finished once the Done LED is on Then the battery and or power source can be disconnected or another battery can be charged General Considerations for Maximum Charging and Battery Performance Align solar panel perpendicular to the sun and avoid shading of the panel whenever possible for maximum power Move the MA 4025 Solar with the battery in the shade wherever possible especially at high ambient temperatures Even though the MA 4025 Solar won t be damaged when exposed to full sun while charging the battery has lower maximum temperature limits while being charged that are typically around 38 C 100 F Special Considerations for Charging the MA 4025 NiCd Battery The MA 4025 battery has an internal temperature sensor which allows the MA 4025 Solar to charge the battery more accurately and protect it from over charge Prior to charging the battery should be kept in a cool place because the charge cannot be started if its temperature is already above 40 C 104 F in order to protect the battery from over temperature Therefore it is also not recommended to repeatedly unplug the MA 4025 Solar from the battery and put it back on This is because once the battery s temperature during charge is above 40 C 104 F the MA 4025 will not start charging the battery agai
8. FAULT CHARGING anced Powe err DONE 4025 S0 LAR pa BATTERY CHARGER MAD ANUN P OWER PO WAT TRAC KING S IN 12 0001 POWER SOURCES BATTERIES SOLAR Vuaxrwr ITV 45V Voc lt GOV MA 4025 A DC SOURCE Vin 20V GOV gt 100 MA 4025 D User Manual Issue 2 March 15 2013 EOR 3267 Progress Dr Orlando FL 32826 Wwww apecor com a Preliminary Www apecor com General Information cccccccccccsccccccccessssssecscssccccsecescssssessssssuccceecessessesssssssueceecesscsseeeeeusesneness 3 Specification Summary seen setne saicenivasdeseacnsasaeandecesa snsbe dumuwtatsauiasnaaheasenceponansceasepnnneawiezeneaatasnian 3 SY e O E E E E E E E 3 Introduction eenegen e E r e E E E E ETa 3 What SMT DOR kissret aeiee ei E a e raar a EE Ea pa ESES 4 Optional Accessories sssessseseseesseesetessseeseeeseesestsstesseesesessessesssteseeeseessetssseesseesesetessseeseeeseeseeese 4 Solar Panel Selection amp Input Power Considerations esseesssessssssssssseseseesserssresseesseressesssrse 4 Battery Selection and Typical Operating Temperatures during Charging eesesreeecesereseee 4 Operationen E E N EEE EN 5 Connection GOO LIB UI AION x sas cacachaasentonsiedneenacnaianyscaisl ameitiensoessaneaaadeescensnsudacaaanannevecnysoatauateensnens 5 Charoing FProced re Ssenari ss E A EEEE OEE KERE A AEN EEEE S T7 General Considerations for Maximum Charging and Battery Performance eeeeeseeeeeeee 7 Special Co
9. ed to a catastrophic failure of the battery Preliminary Www apecor com Ath ie EDR MA 4025 Solar Charger User Manual Technical Specifications Converter Efficienc Figure 7 shows typical efficiency numbers of the MA 4025 Solar as a function of total output current with two different input voltages and with an output battery voltage of 15V at 25 C 77 F ambient temperature The 20V input voltage case represents the maximum power voltage of a 12V solar panel whereas 40V represents the maximum power voltage of a 24V solar panel both at 25 C 77 F panel temperature MA 4025 Solar Efficiencies 20V input voltage 40V input voltage Efficiency 0 0 5 1 1 5 2 2 5 3 3 5 4 Output Current Amps Figure 7 MA 4025 Efficiencies When charging the MA 4025 battery with a certain solar panel and at a particular power level the MA 4025 Solar operates at certain points on the efficiency curve Some configuration examples can be seen in Table 6 the last column then shows the expected converter efficiency for each case Panel System Maximum Power Charge Current Current per MA 4025 Solar Voltage Voltage of Panel Level Battery String Efficiency 12V 20V Full current 4A 94 3 24V 40V Full current 4A 94 2 12V 20V Half current 2A 94 5 24V 40V Half current 2A 92 5 Table 6 Typical MA 4025 Solar Efficiencies while charging the MA 4025 battery
10. id Provide proof of date and place of purchase e To obtain service under this warranty the returned products must include the model serial number and detailed reason for the failure the module type solar panel size type of batteries This information is critical to a rapid disposition of your warranty claim e ApECOR will pay the return shipping charges if the repairs are covered by the warranty Warranty Exclusions and Limitations This warranty does not apply under the following conditions Damage by accident negligence abuse or improper use PV or load currents exceeding the ratings of the product Unauthorized product modification or attempted repair Damage occurring during shipment THE WARRANTY AND REMEDIES SET FORTH ABOVE ARE EXCLUSIVE AND IN LIEU OF ALL OTHERS EXPRESSED OR IMPLIED APECOR SPECIFICALLY DISCLAIMS ANY AND ALL IMPLIED WARRANTIES INCLUDING WITHOUT LIMITATION WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE No ApECOR distributor agent or employee is authorized to make any modification or extension to this watranty APECOR IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND INCLUDING BUT NOT LIMITED TO LOST PROFITS DOWNTIME GOODWILL OR DAMAGE TO EQUIPMENT OR PROPERTY 3267 Progress Dr Orlando FL 32826 Email ask apecor com Website www apecor com Preliminary Www apecor com
11. if any visible damages can be seen on it e Make sure all contacts are clean before use Introduction The MA 4025 Solar Charger is a portable solar battery charger capable of charging MA 4025 rechargeable batteries The charger features advanced digital control which enables automatic battery detection maximum power point tracking MPPT of the solar panel and value added features such as a fixed DC input mode The charger is able to operate from any solar panel configuration with V apen circuit lt 60V The charger directly plugs onto the top of the supported batteries and the only wiring needed is the connection to the solar panel or DC source using a polarized SAE plug The implementation of high speed MPPT delivers maximum charging current even in low light or poor weather conditions The simple LED interface informs the user when the battery has been completely charged and if there are any fault conditions Preliminary Www apecor com Abs na EGR MA 4025 Solar Charger User Manual What s in the box 1x MA 4025 Solar Charger Optional Accessories 1x Adapter to charge from Lead Acid batteries 1x 48 SAE Extension Cable 1x SAE Y Parallel Cable Solar Panel Selection amp Input Power Considerations Use 12V or 24V solar panels or any other panel as long as its maximum power voltage Vip is greater than 17V and its open circuit voltage Voc is below 60V If available the MA 4025 Solar will use up to 80W t
12. n unless its temperature has dropped below that point Preliminary Www apecor com Abs na EDR MA 4025 Solar Charger User Manual Label on top of charger and LED Status Indicator A ECOAH AWA Red LED PE LUF WIAVNAG Green LED 1 Advanced Pawar Electronics Corporation KODE Green LED 2 4025 SOLAR pattery cuarcer MAXIMUM POWER POINT TRACKING S N 12 XXXX POWER SOURCES BATTERIES SOLAR Vuaxpwr 17V 45V Voc lt GOV MA 4025 A DC SOURCE Vin 20V GOV gt 100W MA 4025 D Figure 5 Label on top of charger and LED location Red Green Green LED LED1 LED2 Meanin Action to take Off Off Off Ready to connect Connect battery off Blinking off Analyzing battery 7 slowly chemistry Off Blinking Off Charging Off Off On Finished charging Disconnect battery Temporary Fault The MA 4025 Solar is trying to reset faults Monitor the MA 4025 Solar since it might not be able to clear the current fault which would lead to a latched fault condition Charger was not running before Temporary Fault The MA 4025 Solar is trying to reset faults Monitor the Blinking Blinking Off condition Charger MA 4025 Solar since it might not be able to clear the Blinking Off Off was running before current fault which would lead to a latched fault Check connections make sure that operation of converter Latched Fault a On is within the maximum ratings unplug and plug in again
13. nsiderations for Charging the MA 4025 NiCd Battery 00 eee eeeeesseeeeneeeneeeeeneeees 7 Label on top of charger and LED Status Indicator 00 eee eeeseeesnneeeseceeseeeeseeeceseeeeneeentneeesaees 8 Trouble Shooting aco sess nrteeehces extra lacrena cas ticbacw cae en ninoi is rE ESEE EEA A ENEA na ESN ETATE EEk 9 IVA TTR ANIA sssini o a a a E a aE A E 10 Featire Sen eriin isa a a a a Ea EE aeaea aa OEE aE 10 Fast Maximum Power Point Tracking MPPT sisccccssscssscessesssecccedsscesseanseesesonecercdesssssuacetsenseae 10 Reverse Polarity Protection Electrically and Mechanically sessseesseeeeessessessseesreserssssrssren 11 Temperature POUCH OM acas5siianccaesapssscucsus iiis a a ERSE E EN E E Ei 11 Over C rrent Protections ierre ien ae Ee E e S AEOS K EEEE rR Erena 11 Technical Sp cificati NSsccssstieisiissssirninis neiise ain ere E E E e E AEE a 12 Converter LMCI Y scactcs5esawencsaadenas ncipawe teree iiinis nesr E EEE ES EEA OEP N EATE E r aE 12 Maximum Output Current vs Heatsink Temperature cccciscscictscsssssseaonssstedeccetacsansusnees sonsnnes 13 Maximum Output Current vs Input Voltage eeeeeseseeeseseeereseeseesresresrrrresrersenrersesreesrrreesresees 13 Maximum Output Current vs Battery Temperature eee eeeseeessceesceeseceeseecesneeceseeeeneeees 14 Wa ttanty Statement seniiti oreiro esa sta e eee a E E E e e a OREERT nE 15 Claim Procedur zacizsss ecaieccnsyeses ecceedsapdeacutane iere e onii ne Er EER ET EK
14. o charge the MA 4025 battery with its maximum rated charge current The optional SAE Y cable can be used to parallel two solar panels in order to increase charge speed There is no minimum input power requirement only charge speed will decrease when used with lower power solar panels A list of recommended panels is shown in Table 1 below Company Part Max Power 25 C Nominal System Voltage P3 124W 12V 124W 12V P3 124W 24V 124W 24V P3 62W 12V 62W 12V Global Solar Energy Inc P3 62W 24V 62W 24V P3 55W 12V 55W 12V P3 48W 12V 48W 12V P3 48W 24V 48W 24V Table 1 Recommended Solar Panels Battery Selection and Typical Operating Temperatures during Charging Table 2 shows the batteries that can be charged with the MA 4025 Solar Make sure that the battery is charged at its allowable ambient temperature range which is typically between 5 C 41 F and 38 C 100 F Refer to the label on each battery for exact values Please note that the data sheet of most of the batteries lists only the operating and storage temperature ranges which are more extended and not the same as the charging temperature range Company Part Chemistry Voltage MA 4025 A NiCd 12 0 Mathews Associates Inc MA 4025 D NiCd 172 0 Table 2 Recommended Batteries Preliminary Www apecor com seam a GR MA 4025 Solar Charger User Manual Operation Connection Configuration There are
15. y chargers use the battery s voltage to select where the solar panel is operating on the curve and this point of operation is mostly lower than the maximum power point MPP 40 30 S 5 3 S 20 10 0 0 10 20 30 40 50 Voltage in Y Figure 6 IV and PV curves for a typical solar panel Preliminary Www apecor com Ath ir EDR MA 4025 Solar Charger User Manual The MA 4025 Solar uses an advanced version of MPPT which is constantly running to make sure that it always operates at the MPP of the panel This makes the MA 4025 Solar superior to other MPPT battery chargers that look for the MPP every once in a while This is because the MA 4025 Solar finds the new MPP very quickly during changing conditions whereas other MPPT chargers don t operate at the new MPP until their next scan This is especially important during days with lots of clouds and wind which lead to fast variations in available power Since the MA 4025 Solar can operate longer at the maximum power than other chargers it can charge the battery faster The changes in available solar power reaching the panel is usually shading caused by objects blocking the sun such as clouds people or trees If there is more power available from the solar panel than needed to charge the battery then the MA 4025 Solar will drop out of MPPT mode This can happen if there is a higher power solar panel connected or it could mean that the battery is nearly full Reverse Polarity
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