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PCM-924 thin film
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1. lt lt to O qu X 75 Ss S as O ame Na Mm Y o gt D e lcl T o IV gt ER 2 O dig mi3 8 i35 O sell c o cio pS o amp SIi3 l28 n la 3 u O D edd s o nH a amp 5 i Os 5 OS e CU 9 e E ES Is 5 O 2 C D pa gt 2 O l UO D a CD c o D ct cr mD Q v Absorption charge 14 4 28 8 V 13 65 27 3 V 11 22 V 12 3 24 6 V Float charge Low voltage load disconnect Low voltage load reconnect m 5 Appendix A Wire Charts 12 Volt Nominal Wire Chart One way Wire Distance feet One way Wire Distance meters Wire Gauge AWG Wire Gauge mm ej eff so CEEE spp E RID B EE mj mp 2 5 v 2 9 8 e 510 t nio yj ef ej sp Pp ty 9 3 Voltage drop Annealed copper wire at 20 C 24 Volt Nominal Wire Chart One way Wire Distance feet One way Wire Distance meters Wire Gauge AWG Wire Gauge mm ou z D 2 ES EI ou O05 3 Voltage drop Annealed copper wire at 20 C 16
2. battery or battery bank 4 5 Protections Solar Overload The unit will limit battery current to the 7A and 80Vdc maximum ratings A over sized solar panel array will not operate at peak power The solar panel array Volts x Amps should be less than the unit s normal maximum input power rating for the optimal performance Load Overload Status LED light LVD On Solid If the load current accessed the maximum load current rating the unit will disconnect the load The unit will attempt to reconnect the disconnect load automatically Night Time Solar Short Circuit Solar input power wires of the controller has short circuited to prevent the battery voltage re flow back to the solar panel due to the solar panel voltage lower than battery voltage in the night time High Voltage Transients In lightning prone areas additional external suppression is recommended 4 6 Inspection and Maintenance Recommend at least two times per year for best controller performance e Tight all connectors Inspect for loose broken or corroded connotations e Verify that all wire clamps and tie downs are secure e Check and ensure the controller is mounted in a clean ventilated environment and no covering of the solar panel array e Verify LED indication is consistent with the present system conditions 5 Troubleshooting 5 1 Error Indications Status LED Error Indications Battery Empty or System damage All LED OFF Battery un recognize not
3. 12V or 24V ERR On Solid Battery voltage error ERR On Solid Over power input 12V 24V On Solid Load over current LVD On Solid Battery low voltage no error occur LVD On Solid 13 5 2 Common Problems Problems No LED indications Solutions With a multi meter check the voltage at the battery terminals the battery voltage must be at least 11V 22V to power the unit Problems The unit is not charging the battery Solutions If the status LED ERR is solid see section 5 1 Error Indication If the status LED is off measure the voltage across the solar input terminals of the controller Input voltage must be greater than battery voltage Check the fuses and solar wiring connections Check the solar panel array for shading 14 6 Detail Specifications PCM 924 c 2 250 24V 125 12V Input Voltage Range 36 80 24V 18 80 12V DC voltage 12 24 Automatic 9 e ee ime ees AJ G Olalia lio o 4 2 o x x x ums h Q 0 CY Sm ise Se 012 cic c Si S 3 3 3 oly 8 g 2 s5 lE amp mD TF o amp EC uO VES U O I2 OTIO o I0 o o i 8 D 5 et e Self consumption in active status mA Weight kg C nn OO U1 J 3 D 5 dm O 5 Un 3 3 190 125 L with connectors Ul Ul IP67 Outdoor Use 40 55 0 100 Natural Convection 0 2000 Humidity non condensing Cooling Altitude V maximum load 7A db i del Ed On Red hs tab Or SE S
4. CN Vi Solar uying Solar should be this easy UJ User Manual PCM 924 9A 80Voc Input MPPT Controller for Thin Film PVs IP67 Weather Resistant CE Ver 10 Physical Dimension 25mm 0 98 3 25mm 0 98 1g amp 9mm 5 eomm ED 9B8 E t S4 5mm LAS s 1 in i TATEA gama C0 98 Y F l 25mm 0 98 Max input DC power Max input solar panel DC voltage 0 089 0 Max inputsolarpanelDC cunent A 7 Maxcchargeladingcurent A 9 The voltage of solar panel array can not be higher than the max input voltage of controller The solar pon components voltage of system could not be lower than voltage of battery and not be higher than max input power The output of Load voltage depends on the output of battery voltage As reference of solar panel components to calculate open circuit voltage highest values under the lowest temperature circumstance of installation The values could not over the max input voltage 80Vdc When irradiation solar panel components will be produced voltage and current in the input line The capacity of the battery pack is unlimited it will only affect the charging rate Follow the following guide to use the product otherwise they may damage equipment 6 Category Important Safety Instruction 1 1 common information General Information 2 1 Summary Installation 3 1 Note 3 2 Installation 3 3 Wiring Connectio
5. atteries Explosive battery gasses may be present during charging Be certain there is 5 sufficient ventilation to release the gasses e Donot install in locations where water can enter the controller Loose power connections and or corroded wires may result in resistive connections that melt wire insulation burn surrounding materials or even cause fire Ensure tight connections and use cable clamps to secure cables and prevent them from swaying in mobile applications e Only charge lead acid batteries e The controllers battery connection may be wired to one battery or a bank of batteries The following instructions refer to a singular battery but it is implied that the battery connection can be made to either one battery or a group of batteries in a battery bank 3 2 Mounting Note When mounting the MPPT controller ensure free air flow E s through the controller heat sink fins There should be at least 150mm of clearance above and below the controller to allow for cooling If mounted in an enclosure ventilation is highly recommended Warning Risk of explosion Never install the controller in a sealed enclosure with vented flooded batteries Do not install in a confined area where battery gasses can accumulate Step 1 Choose Mounting Location Locate the controller on a vertical surface protected from direct sun high temperatures and water Step 2 Check for Clearance Place the controller in the location w
6. e working voltage should be located between the battery voltage and maximum out put voltage of solar systems i Fig 5 Solar penal array connecting method Step 4 Recheck all connecting points and confirm all poles at right connecting positions check all connecting terminals are fixed 9 Positive pex Negative L Ex Fig 6 Reconfirm all connecting points Step 5 Fuse inserting Insert a 15A DC fuse as follow steps 1 Loads circuit 2 Battery circuit Step 6 Electrify Confirmation Please confirm the following electrify steps when the battery electrify the power to controller the LED lights on unit will flash in order and detect the voltage of battery automatically The charge LED light will flash in charging Please check chapter 5 Trouble Shooting if the unit did not work or the LED lighting shows the wrong identifications 4 Operation 4 1 Status LED Indicator Status indicator The status LED indicator charging status and any existing solar input error conditions The status LED will off whenever an error conditions exists The status LED 12V 24V shows the battery voltage types the status LED will be flashing in charging status in the day time and the light will be on solid in the night time The LVD will be on solid in status load off if the voltage of the battery is too low Table 1 gives lists of the status LED indications Indicator Status Indicat
7. er point and before and after this point the output power is reduced shown in Fig 7 Because traditional controllers do not operate at the Vmp of the solar panel energy is wasted that could otherwise be used to charge the battery voltage and the Vmp of the panel the more energy is wasted The MPPT technology will always operate at the Vmp resulting in less wasted energy compared to traditional controllers and transfer all the power from solar penal to loads or battery 4 3 Information of Battery Charging The MPPT unit has a 3 stages battery charging algorithm for rapid efficient and safe battery charging e BULK CHARGE In this stage the battery voltage has not yet reached absorption voltage and 10096 of available solar power is used to recharge the battery e ABSORPTION When the battery has recharged to the absorption voltage set point constant voltage regulation is used to prevent heating and excessive battery gassing e FLOAT After the battery is fully charged the unit reduces the battery voltage to a float charge which is sometimes call trickle charge 4 4 Information of Load Control The primary purpose of the load control function is to disconnect system loads when the battery has discharged to a low state of charge and reconnect system loads when the battery is sufficiently recharged 12 CAUTION Do not wire a AC inverter of any size to the load terminals of the controller Wire inverters directly to the
8. ery voltage to system loads such as lights pumps motors and electronic devices The voltage of the loads should be depended on the voltage of the battery Positive Negative Figure 3 Load wiring As shown in figure 3 connect load positive and negative load wires to the system load s or load distribution panel An in line fuse holder should be wired in series in the load positive wire as shown DO NOT INSERT A FUSE AT THIS TIME If wiring the load connection to a load distribution panel each load circuit should be fused separately The total load draw should not exceed the 7A load rating 8 Step 2 Battery Wiring Positive Positive Fuses Negative Negative Figure 4 Battery wiring Before connecting the battery measure the battery voltage It must be over 11 volts to switch on the controller For 24 volt systems the battery voltage must be greater than 22 volts The battery detection is automatic and the check is only performed at start up Wire an in line fuse holder no more than 150mm from the battery positive terminal DO NOT INSERT A FUSE AT THIS TIME Step3 Solar Panel Array Connecting Caution Danger Electrical Shock High voltage will occur from the solar panel please covering the solar panel before wiring This MPPT controller is suitable for 12V and 24V off grid solar systems also suitable for the connecting array which the Voc lower than 80V Th
9. here it will be mounted Verify that there is sufficient room to run wires and that there is ample room above and below the controller for air flow Figure 2 Mounting and cooling t4 dues COOL AIR Step 3 Fasten the Flat Fasten flats on the three back holes of controller RSmm CRO 2 125mm 4 92 80mm 3 15 15mm 0 59 i Step 4 Drill Holes Drill dimension 9mm holes spacing 220mm in the mounting location 29mm 80 3547 Step 5 Secure Controller Then put the the back end bracket mounting holes of the controller on the solar panel bracket aligning the hole drilled in step 4 using screws and nuts fixed controller and indeed the case ground wire connected 3 3 Wiring Note A recommended connection order has been provided for maximum safety during installation The controller will not be damaged regardless of the sequence of connections 7 I 97 Note The MPPT controller is a negative grounding controller Caution the total current draw of all system loads connected to the controller s load terminals cannot exceed the 7A load current rating N Caution For mobile applications be sure to secure all wiring Use cable clamps to prevent cables from swaying when the vehicle is in motion Unsecured cables create loose and resistive connections which may lead to excessive heating and or fire Step 1 Load Wiring The controller s load output connection will provide batt
10. ions Loads Remarks light On Solid Battery Voltage Error Voltage Status Error On Solid Flashinc Stand by Charginc 12V Batter On Solid Flashing Stand by Charging 24V Battery Low Voltage Protection Table 1 Status LED definition 10 4 2 Maximum Power Point Tracking Technology This controller utilizes maximum power point tracking technology MPPT to extract maximum power Vmp from the solar panel array The tracking algorithm is fully automatic and does not require user adjustment The MPPT technology will track the solar panel array maximum power point voltage Vmp as it varies with weather conditions ensuring that maximum power is harvested from the solar panel array through the course of the day In most cases the MPPT technology will boost the solar charge current For example a solar system may have 5A of solar current flowing into the unit and 7A to charge current flowing out to the battery This controller does not create current Rest assured that the power into the unit is the same as the power out from the unit Since power is the product of voltage and current Volts x Amps Power the following is true 1 Power into the unit Power out of unit 2 Volts In x Amps In Volts Out x Amps Out Assuming 10096 efficiency Losses in wiring and conversion exist If the solar panel array s Vmp is greater than the battery voltage it follows that the battery current must be proportionally great than the solar in
11. n Manual 4 1 Status Indicator LED 4 2 Max Power Point Tracking 4 3 Battery Charging Information 4 4 Loading Control Information 4 5 Protection 4 6 Inspection amp Maintenance Trouble Shooting 5 1 Error Instruction 52Q amp A Specific Technical Reference Appendix A Cable Dimension 1 Important Safety Instruction Save These Instructions This manual contains important safety installation and operating instructions for the MPPT solar controller The following symbols are used throughout this manual to indicate potentially dangerous conditions or mark important safety instructions WARNING Indicates a potentially dangerous condition Use extreme caution when performing this task 4 CAUTION Indicates a critical procedure for safe and proper operation of the controller E g NOTE Indicates a procedure or function that is important for the safe and proper operation of the controller 1 1 General Safety Information e Read all of the instructions and cautions in the manual before beginning installation e There are no user serviceable parts inside the MPPT Do not disassemble or attempt to repair the controller e Disconnect all sources of power to the controller before installing or adjusting the MPPT e There are no fuses or disconnects inside the MPPT e Prohibition of water into the controller e Confirm that power connections are tightened to avoid excessive heating from a loose connection 2 Ge
12. neral Information 2 1 Summary Thanks for selecting the MPPT charge controller This MPPT controller is an advanced maximum power point tracking solar battery charger and loading device for stand alone PV systems The controller features a smart tracking algorithm that maximizes the energy from the solar module and also provides load control to prevent over discharge of the battery The process of MPPT battery charger has been optimized for long battery life and improved system performance Although the MPPT is very simple to operate and use please take the time to read this operator s manual and become familiar with the controller It will help you make full use of many advantages which MPPT can provide for your PV system Features of the MPPT controller is shown as below 1 Status LED Indicator Four LED Indicator show charging status and battery input and low voltage fault condition 2 Solar Input Connector The connecting terminal of systems solar panel components input 3 Battery Input amp Loading Output Connector Systems battery components input and loading out terminals 3 Installation Instructions 3 1 Installation Note Read through the entire installation section first before beginning installation e Bevery careful when working with batteries Wear eye protection Have fresh water available to wash and clean any contact with battery acid Use insulated tools and avoid placing metal objects near the b
13. put current so that input and output power are balanced The great the difference between the maximum power voltage and battery voltage the greater the current boost Another benefit to the MPPT technology is the ability to charge lower volt battery with solar panel array of higher normal voltages For example a 12V battery bank can be charged with 15 18 Vdc normal solar penal array Certain grid tie solar penal array may also be used as long as the solar penal array open circuit voltage Voc rating will not exceed the controller s 80Vdc maximum input rating at coldest panel temperature The solar panel documentation should provide Voc vs temperature data to users Higher solar input voltage results in lower solar input current for a given input power High voltage solar input strings allow fro smaller gauge solar wiring This is especially helpful for systems with long wiring runs between the solar panel array and the controller Traditional controllers connect the solar panel directly to the battery when recharging This requires that the solar panel operate in a voltage range that is below the panel s Vmp For example in a 12V system the battery voltage may range from 11 15Vdc but the panel s Vmp is around 17Vdc Fig 7 shows a typical current vs voltage output curve for a normal solar panel 11 Current Power Battery Voltage Range V mp mp O 1v 15V Valtage Fig 7 Normal solar panel I V curve The panel Vmp is the max pow
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