WATTUNEED ML Series Manuel utilisateur

ML Maximum Power Point Tracking (MPPT) Series

ML2420—ML2430—ML2440

Solar Charge an Discharge Controller User Manual

Mo el ML2420 ML2430 ML2440

Battery voltage 12V/ 24V

Max. solar panel voltage 100V (25°C), 90V (-25°C)

Charging current 20A 30A 40A

Discharging current 20A

Dear users,

Thank you for choosing our pro uct!

Safety Instructions

1. As this controller deals with voltages that exceed the top limit for human safety, do not

operate it before reading this manual carefully and completing safety operation training.

2. The controller has no internal components that need maintenance or service, thus do

not attempt to disassemble or repair the controller.

3. Install the controller indoors, and avoid component exposure and water intrusion.

4. During operation, the radiator may reach a very high temperature, therefore install the

controller at a place with good ventilation conditions.

5. It's recommended that a fuse or breaker be installed outside the controller.

6. efore installing and wiring the controller, make sure to disconnect the photovoltaic

array and the fuse or breaker close to the battery terminals.

7. After installation, check if all connections are solid and reliable so as to avoid loose

connections that may give rise to dangers caused by heat accumulation.

Warning: means the operation in question is angerous, an you

shoul get properly prepare before procee ing.

Note: means the operation in question may cause amage.

Tips: means a vice or instruction for the operator.

Table of Contents

1.1 Product Overview...............................................................................................................................................................2

1.2 Product Features.................................................................................................................................................................3

1.3 Exterior and Interfaces.......................................................................................................................................................4

1.4 Introduction to Maximum Power Point Tracking Technology..........................................................................................5

1.5 Charging Stages Introduction.............................................................................................................................................6

2. Product Installation.......................................................................................................................................................................8

2.1 Installation Precautions......................................................................................................................................................8

2.2 Wiring Specifications ........................................................................................................................................................9

2.3 Installation and Wiring ......................................................................................................................................................9

3. Product Operation and Display..................................................................................................................................................13

3.1 LED Indicators.................................................................................................................................................................13

3.2 Key Operations.................................................................................................................................................................14

3.3 LCD Startup and Main Interface......................................................................................................................................15

3.4 Load Mode Setting Interface............................................................................................................................................16

3.5 System Parameter Settings...............................................................................................................................................17

4. Product Protection Function and System Maintenance.............................................................................................................18

4.1 Protection Functions.........................................................................................................................................................18

4.2 System Maintenance.........................................................................................................................................................19

4.3 Abnormality Display and Warnings.................................................................................................................................19

5. Product Specification Parameters...............................................................................................................................................20

5.1 Electric Parameters...........................................................................................................................................................20

5.2 attery Type Default Parameters (parameters set in monitor software)..........................................................................21

6. Conversion Efficiency Curve.....................................................................................................................................................22

6.1 12V System Conversion Efficiency.................................................................................................................................22

6.1 24V System Conversion Efficiency.................................................................................................................................22

7. Product Dimensions....................................................................................................................................................................23

1.1 Pro uct Overview

This product can keep monitoring the solar panel's generating power and tracking the

highest voltage and current values (VI) in real time, enabling the system to charge the

battery in maximum power. It's designed to be used in off-grid solar photovoltaic

systems to coordinate operation of the solar panel, battery and load, functioning as the

core control unit in off-grid photovoltaic systems.

This product features an LCD screen which can dynamically display the operating

status, operating parameters, controller logs, control parameters, etc. Users can

conveniently check parameters by the keys, and modify control parameters to cater to

different system requirements.

The controller utilizes standard Modbus communication protocol, making it easy for

users to check and modify system parameters on their own. esides, by providing free

monitoring software, we give users the maximum convenience to satisfy their varied

needs for remote monitoring.

With comprehensive electronic fault self-detecting functions and powerful electronic

protection functions built inside the controller, component damage caused by

installation errors or system failures can be avoided to the greatest extent possible.

1.2 Pro uct Features

◆With the advanced dual-peak or multi-peak tracking technology, when the solar panel

is shadowed or part of the panel fails resulting in multiple peaks on the I-V curve, the

controller is still able to accurately track the maximum power point.

◆A built-in maximum power point tracking algorithm can significantly improve the

energy utilization efficiency of photovoltaic systems, and raise the charging efficiency

by 15% to 20% compared with the conventional PWM method.

◆A combination of multiple tracking algorithms enables accurate tracking of the

optimum working point on the I-V curve in an extremely short time.

◆The product boasts an optimum MPPT tracking efficiency of up to 99.9%.

◆Advanced digital power supply technologies raise the circuit's energy conversion

efficiency to as high as 98%.

◆Charging program options are available for different types of batteries including gel

batteries, sealed batteries, open batteries, lithium batteries, etc.

◆The controller features a limited current charging mode. When the solar panel power

exceeds a certain level and the charging current is larger than the rated current, the

controller will automatically lower the charging power and bring the charging current to

the rated level.

◆Instantaneous large current startup of capacitive loads is supported.

◆Automatic recognition of battery voltage is supported.

◆LED fault indicators and an LCD screen which can display abnormality information

help users to quickly identify system faults.

◆Historical data storage function is available, and data can be stored for up to a year.

◆The controller is equipped with an LCD screen with which users can not only check

device operating data and statuses, but also modify controller parameters.

◆The controller supports standard Modbus protocol, fulfilling the communication needs

of various occasions.

◆The controller employs a built-in over-temperature protection mechanism. When

temperature surpasses the set value, the charging current will decline in linear

proportion to the temperature so as to curb the temperature rise of the controller,

effectively keeping the controller from being damaged by overheat.

◆Featuring a temperature compensation function, the controller can automatically adjust

charging and discharging parameters in order to extend the battery's service life.

◆TVS lighting protection

1.3 Exterior an Interfaces

No. Definition

Transmitting terminal TX

Receiving terminal RX

Power supply grounding /Signal grounding

Power supply positive

Fig. 1-1 Product appearance and interfaces

No. Item No. Item

Charging indicator attery "+" interface

attery indicator attery "-" interface

Load indicator Load "+" interface

Abnormality indicator Load "-" interface

LCD screen External temperature

sampling interface

Operating keys RS232 communication

interface

Installation hole

Solar panel "+"

interface

Solar panel "-"

interface

1.4 Intro uction to Maximum Power Point Tracking Technology

Maximum Power Point Tracking (MPPT) is an advanced charging technology that

enables the solar panel to output more power by adjusting the electric module's

operating status. Due to the nonlinearity of solar arrays, there exists a maximum

energy output point (maximum power point) on their curves. Unable to

continuously lock onto this point to charge the battery, conventional controllers

(employing switching and PWM charging technologies) can't get the most of the

power from the solar panel. ut a solar charge controller featuring MPPT

technology can continuously track arrays' maximum power point so as to get the

maximum amount of power to charge the battery.

Take a 12V system as an example. As the solar panel's peak voltage (Vpp) is

approximately 17V while the battery's voltage is around 12V, when charging with a

conventional charge controller, the solar panel's voltage will stay at around 12V,

failing to deliver the maximum power. However, the MPPT controller can

overcome the problem by adjusting the solar panel's input voltage and current in

real time, realizing a maximum input power.

Compared with conventional PWM controllers, the MPPT controller can make the

most of the solar panel's max. power and therefore provide larger charging current.

Generally speaking, the latter can raise the energy utilization ratio by 15% to 20%

in contrast with the former.

Fig. 1-2 Solar panel output characteristic curve

Meanwhile, due to changing ambient temperature and illumination conditions, the

max. power point varies frequently, and our MPPT controller can adjust parameter

settings according to the environmental conditions in real time, so as to always keep

the system close to the max. operating point. The whole process is entirely

automatic without the need of human intervention.

光照降低，电流减小

光照降低，开路电压减小

U(V)

I(A)

Fig. 1-3 Relation between solar panel output characteristics and illumination

20℃

50℃

70℃

60℃

40℃

30℃

太

阳

板

温

度

I(A)

U(V)

温度降低，电流变，

功率增大

温度升高，开路电压减小

Fig. 1-4 Relation between solar panel output characteristics and temperature

1.5 Charging Stages Intro uction

As one of the charging stages, MPPT can not be used alone, but has to be used

together with boost charging, floating charging, equalizing charging, etc. to

complete charging the battery. A complete charging process includes: fast charging,

sustaining charging and floating charging. The charging curve is as shown below:

Fig. 1-5 attery charging stages diagram

a) Fast charging

At the fast charging stage, as the battery voltage has not reached the set value of full voltage (i.e. equalizing/ boost

voltage) yet, the controller will perform MPPT charging on the battery with the maximum solar power. When the

battery voltage reaches the preset value, constant voltage charging will begin.

b) Sustaining charging

When the battery voltage reaches the set value of sustaining voltage, the controller

will switch to constant voltage charging. In this process, no MPPT charging will be

performed, and meanwhile the charging current will also gradually decrease. The

sustaining charging stage itself consists of two sub-stages, i.e. equalizing charging

and boost charging, the two of which are not carried out in a repeated manner, with

the former getting activated once every 30 days.

Boost charging

y default, boost charging generally lasts for 2h, but users can adjust preset values

of duration and boost voltage point according to the actual needs. When the

duration reaches the set value, the system will then switch to floating charging.

Equalizing charging

Warning: risk of explosion!

In equalizing charging, an open lead-acid battery can produce explosive gas, therefore

the battery chamber shall have good ventilation conditions.

Note: risk of equipment damage!

Equalizing charging may raise the battery voltage to a level that may cause

damage to sensitive DC loads. Check and make sure that allowable input

voltages of all the loads in the system are greater than the set value for battery

equalizing charging.

Note: risk of equipment damage!

Overcharge or too much gas generated may damage battery plates and cause

active material on the battery plates to scale off. Equalizing charging to an

excessively high level or for too long a period may cause damage. Read carefully

the actual requirements of the battery deployed in the system.

Some types of batteries benefit from regular equalizing charging which can stir the

electrolyte, balance the battery voltage and finish the electrochemical reaction.

Equalizing charging raises the battery voltage to a higher level than the standard supply

voltage and gasify the battery electrolyte. If the controller then automatically steers the

battery into equalizing charging, the charging duration is 120 mins (default). In order to

avoid too much generated gas or battery overheat, equalizing charging and boost

charging won’t repeat in one complete charging cycle.

Note:

1) When due to the installation environment or working loads, the system can't

continuously stabilize the battery voltage to a constant level, the controller will initiate a

timing process, and 3 hours after the battery voltage reaches the set value, the system

will automatically switch to equalizing charging.

2) If no calibration has been done to the controller clock, the controller will perform

equalizing charging regularly according to its internal clock.

Floating charging

When finishing the sustaining charging stage, the controller will switch to floating

charging in which the controller lowers the battery voltage by diminishing the

charging current and keeps the battery voltage at the set value of floating charging

voltage. In the floating charging process, very light charging is carried out for the

battery to maintain it at full state. At this stage, the loads can access almost all the

solar power. If the loads consume more power than the solar panel could provide, the

controller will not be able to keep the battery voltage at the floating charging stage.

When the battery voltage drops to the set value for returning to boost charging, the

system will exit floating charging and reenter into fast charging.

2. Pro uct Installation

2.1 Installation Precautions

◆e very careful when installing the battery. For open lead-acid batteries, wear a pair

of goggles during installation, and in case of contact with battery acid, flush with

water immediately.

◆In order to prevent the battery from being short-circuited, no metal objects shall be

placed near the battery.

◆Acid gas may be generated during battery charging, thus make sure the ambient

environment is well ventilated.

◆Keep the battery away from fire sparks, as the battery may produce flammable gas.

◆When installing the battery outdoors, take sufficient measures to keep the battery

from direct sunlight and rain water intrusion.

◆Loose connections or corroded wire may cause excessive heat generation which

may further melt the wire's insulation layer and burn surrounding materials, and even

cause a fire, therefore make sure all connections are tightened securely. Wires had

better be fixed properly with ties, and when needs arise to move things, avoid wire

swaying so as to keep connections from loosening.

◆When connecting the system, the output terminal's voltage may exceed the top limit

for human safety. If operation needs to be done, be sure to use insulation tools and

keep hands dry.

◆The wiring terminals on the controller can be connected with a single battery or a

pack of batteries. Following descriptions in this manual apply to systems employing

either a single battery or a pack of batteries.

◆Follow the safety advice given by the battery manufacturer.

◆When selecting connection wires for the system, follow the criterion that the

current density is not larger than 4A/mm2.

◆Connect the controller's earth terminal to the ground.

2.2 Wiring Specifications

Wiring and installation methods must comply with national and local electrical

specifications.

The wiring specifications of the battery and loads must be selected according to rated

currents, and see the following table for wiring specifications:

Model Rated

charging

current

Rated

discharging

current

attery wire

diameter

(mm2)

Load wire

diameter

(mm2)

ML2420 20A 20A 5 5

ML2430 30A 20A 6 5

ML2440 40A 20A 10 5

2.3 Installation an Wiring

Warning: risk of explosion! Never install the controller an an open

battery in the same enclose space! Nor shall the controller be installe in an

enclose space where battery gas may accumulate.

Warning: anger of high voltage! Photovoltaic arrays may pro uce a

very high open-circuit voltage. Open the breaker or fuse before wiring, an be

very careful uring the wiring process.

Note: when installing the controller, make sure that enough air flows

through the controller's ra iator, an leave at least 150 mm of space both above

an below the controller so as to ensure natural convection for heat issipation.

If the controller is installe in an enclose box, make sure the box elivers

reliable heat issipation effect.

Step 1: choose the installation site

Do not install the controller at a place that is subject to irect sunlight,

high temperature or water intrusion, an make sure the ambient

environment is well ventilate .

Step 2: first place the installation gui e plate at a proper position, use a

marking pen to mark the mounting points, then rill 4 mounting holes at the

4 marke points, an fit screws in.

Step 3: fix the controller

Aim the controller's fixing holes at the screws fit in Step 2 an mount the

controller on.

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