EmergoPlus PowerXtreme XS20 User manual

User manual
MPPT Solar charge controller
PowerXtreme XS20
EmergoPlus BV
Informaticastraat 20
NL 4538 BT Terneuzen
Tel. [phone]
www.emergoplus.com
[email protected]

User manual MPPT Solar charge controller PowerXtreme XS20
E18-XS20-EN00 www.emergoplus.com Page 2of 44
Dear customer,
Thank you for purchasing the high quality MPPT Solar charge controller
from PowerXtreme! This product has been developed using the most
modern technologies and quality systems. We assure you that we make
every effort to ensure trouble-free operation so that you are happy with
your purchase. Our ultimate goal is a satisfied customer.
If you have any questions, please contact one of our dealers or our service
department.
We hope you enjoy your MPPT Solar charge controller!
Cordial greetings,
EmergoPlus BV

User manual MPPT Solar charge controller PowerXtreme XS20
E18-XS20-EN00 www.emergoplus.com Page 3of 44
Table of contents
1. Product description .........................................................................5
1.1 Product information ................................................................5
1.2 Producteigenschappen...........................................................5
1.3 Introduction to Maximum Power Point Tracking (MPPT)
technology .............................................................................................6
1.4 Introduction of charging phases..........................................8
2. Safety instructions........................................................................ 12
2.1 Explanation of safety instructions..................................... 12
2.2 General instructions ............................................................. 12
2.3 Installation precautions....................................................... 13
2.4 Wiring specifications............................................................ 14
3. Description and functioning........................................................ 15
3.1 LED-indicators ....................................................................... 15
3.2 Function control buttons..................................................... 17
3.3 Functions on LCD screen .................................................... 18
3.3.1 Starting interface................................................................. 18
3.3.2 Main menu............................................................................ 19
3.4 Charging mode setting Interface....................................... 20
3.4.1 Charge modes introduction........................................ 20
3.4.2 Activating and deactivating of charging manually 21
3.5 System parameter settings ................................................ 21
4. Unpacking and mounting/installation....................................... 24
4.1 Compontents in packaging................................................. 24

User manual MPPT Solar charge controller PowerXtreme XS20
E18-XS20-EN00 www.emergoplus.com Page 4of 44
4.2 Mounting MPPT Solar lader................................................ 24
5. Operation ........................................................................................ 30
6. Maintenance................................................................................... 33
7. Decommissioning ......................................................................... 33
8. Technical parameters................................................................... 34
8.1 Electrical parameters ........................................................... 34
8.2 Standard settings.................................................................. 35
8.3 12V system efficiency.......................................................... 37
8.4 24V System efficiency ......................................................... 37
9. BT-1 Bluetooth Connector (Optional) ........................................ 38
9.1 General.................................................................................... 38
9.2 Product specifications......................................................... 38
9.3 Mounting ................................................................................ 38
9.4 Technical data ....................................................................... 39
9.5 App data.................................................................................. 39
10. Fault finding table ..................................................................... 41
11. Warranty conditions ................................................................. 42
12. Liability ........................................................................................ 42
13. EG-declaration of conformity.................................................. 43

User manual MPPT Solar charge controller PowerXtreme XS20
E18-XS20-EN00 www.emergoplus.com Page 5of 44
1.1 Product information
The MPPT Solar charger is a fully automatic battery charger that converts
the energy, generated by the Solar panel, into a regulated battery voltage.
MPPT stands for Maximum Power Point Tracking. Using this technology,
the charger continuously searches for the maximum deliverable capacity
or the Solar panel. This to ensure to get maximum return from your Solar
panel. This return is 15 –20 % higher than for conventional systems.
The charger has an LCD-screen and 4 operating buttons that you can use
to go through all menus and settings and adjust them where necessary.
1.2 Product properties
▪The charger has a dual-peak or multi peak tracking technology.
This will always monitor the maximum power point, if the solar
panel is partly in the shade or partly dysfunctional.
▪The charger can be set for the following types or batteries: gel-
batteries, low-maintenance batteries, lead batteries, lithium
batteries, etc.
▪The charger is protected against too high currents. In case the
capacity of the solar panel exceeds a certain level and the
charging current is higher than the rated current, the charger will
automatically assume downward adjustment and align the
charging current to the rated level.
▪High start-up currents or capacitive loads do not cause failures.
▪The charger will automatically set to 12 or 24V-DC battery
voltage.
▪The charger has a data log function. Details can be stored for up
to a year.
▪The charger has built-in temperature monitoring. When the
temperature exceeds the set value, the charging current will
linearly drop to reduce the temperature increase of the charger.
1. Product description

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E18-XS20-EN00 www.emergoplus.com Page 6of 44
This is to prevent the charger from getting damaged by
overheating.
▪During the charging of lead batteries, in can of a temperature
increase, the charger will automatically reduce the charging
voltage to lengthen the life span of the battery.
1.3 Introduction to Maximum Power Point Tracking (MPPT)
technology
Maximum Power Point Tracking (MPPT) is an advanced charging
technology in which the solar panel generates more output capacity, due
the adjustment of the settings of the electrical module. Due to the non-
linear character of solar panels there is a maximum output capacity
(maximum power point) on the power curve. As conventional PWM
chargers do not continuously follow this point, they do not get the
maximum capacity of the solar panel. But a solar charger with MPPT-
technology will continuously monitor the maximum power point to get the
maximum quantity of energy from the panel.
Take a 12V Solar system for example. The maximum peak voltage (Vmpp)
of the solar panel is approximately 17V, whereas the battery voltage is
approximately 12V. When using a conventional charger, the voltage of the
solar panel will remain around 12V, not being able to provide the
maximum capacity. The MPPT-charger solves this problem by
continuously adjusting the input voltage and current of the solar panel
continue and, as such, realise maximum input power.
In comparison with conventional PWM-chargers, the MPPT-charger uses
the maximum capacity of the solar panel and, as a consequence, it be able
to provide a higher charging current. In general, the MPPT charger is able
to increase the energy consumption by 15% to 20%, compared to
conventional chargers.

User manual MPPT Solar charge controller PowerXtreme XS20
E18-XS20-EN00 www.emergoplus.com Page 7of 44
20℃
50℃
70℃
60℃
40℃
30℃
太
阳
板
温
度
I(A)
U(V)
温度降低，电流不变，
功率增大
温度升高，开路电压减小
Image 2. Relation between solar panel output and temperature
Image 1 Typical output curve solar panel
As a consequence of the changing ambient temperature and light
intensity, the maximum power point will vary significantly. Our MPPT-
charger will adjust the parameter settings, based on the conditions so that
the system will always function close to the max. operational point. The
entire process is fully automatic.
In case of dropping
temperature, the current
will remain stable and
capacity will increase.
Voltage will decrease in case of an increase in temperature
Voltage will decrease in case of an increase in temperature

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E18-XS20-EN00 www.emergoplus.com Page 8of 44
1.4 Introduction of charging phases
The MPPT charger makes use of a 3-step charging curve for the charging
of the battery. A full charging process includes:
A] consistent current charging
B] consistent voltage charging and
C] floating charging.
The charging curve as shown below:
Image 3. Relation between solar panel output and light intensity
光照降低，电流减小
光照降低，开路电压减小
U(V)
I(A)
Current will decrease in case of an increase in
dusk
Current will decrease in case of
an increase in dusk

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E18-XS20-EN00 www.emergoplus.com Page 9of 44
Image 4. Charging diagram
A] consistent current (CC) charging
During CC charging, if the battery voltage hasn’t yet reached the set value
of charged voltage, the charger will charge the battery with maximum
MPPT Solar energy capacity. When the battery voltage reaches the pre-
set value, charging at consistent voltage will start.
B ] consistent voltage (CV) charging
During this phase in the charging process no MPPT charging is used.
During this phase the charging current will gradually reduce. The
consistent voltage charging consists of two sub-phases, i.e. equalizing
charging and boost charging. These two phases are not executed

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E18-XS20-EN00 www.emergoplus.com Page 10 of 44
CAUTION!
Overcharging, or situations where too much gas is
being generated, may cause damage to the battery.
Equalizing charging up to an excessively high level
or during too long a period of time may cause
damage. Carefully read the instructions of the
battery that is applied in the system.
alternately, but equalizing is activated once every 30 days. This does not
happen in the charger is in Lithium mode.
B.1] Boost charging
As a rule, the boost charging takes approximately 2 hours. Users can
adjust the pre-defined values of duration and boost voltage point for lead
batteries to suit their own needs.
When the time set has been reached, the system will switch to floating
charging.
B.2] Equalizing charging.
WARNING!
During the equalizing charging, an open lead
battery could produce explosive gas. For that
reason, the battery should be charged in a well-
ventilated location!
CAUTION!
During the equalizing charging, the battery voltage
could reach values high enough to cause damage
to the sensitive DC users. Check and ensure that
all permitted input voltages of all users in the
system are higher than the voltage set for battery
equalizing charging.

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E18-XS20-EN00 www.emergoplus.com Page 11 of 44
Some types of batteries benefit from frequent equalizing charging as this
ensure mixing of the electrolyte, balancing of the battery voltage and the
cessation of the electro-chemical reaction. Equalizing charging increases
the battery voltage to a higher level than the standard supply voltage and
ensure the electrolyte to start gasifying. If subsequently the charger
automatically sets the battery to equalizing charging, the charging will
take 120 minutes (standard). In order to prevent that too much gas is
being generated or that the battery becomes overheated, equalizing
charging and boost charging will not be repeated during a full charging
cycle.
Remarks:
1. If, as a consequence of the installation or load of the battery, the
system is not able to continuously stabilise the battery voltage at
a consistent level, the charger will start a timing-process and after
3 hours, when the battery voltage reaches the set value, the
system will automatically switch to the equalizing charging.
C ] Floating charging
When the consistent voltage charging phase is finished, the charger will
switch to floating charging. In this case the charger reduces the battery
voltage by decreasing of the charging current and keeps the battery
voltage at the set value of floating battery voltage. During the floating
charging process, the battery is lightly charged to keep it fully charged. In
this stage all solar energy is available for users. When the load requires
more capacity than the solar panel is able to generate, the charger will not
be able to keep the battery voltage at the floating charging level. When the
battery voltage reaches a value below the set value for CC charging, the
system will cease the floating charging and start the CC charging again.

User manual MPPT Solar charge controller PowerXtreme XS20
E18-XS20-EN00 www.emergoplus.com Page 12 of 44
2.1 Explanation of safety instructions
The safety instructions will help you avoid risks while carrying out
activities. The safety instructions are sub-divided into the following
categories:
2.2 General instructions
▪As the charger may have loads with voltages that exceed the limit
for human safety, it is not permitted to work with the charger
unless you have carefully read this manual.
▪The charger does not have internal parts that require
maintenance or service. You are not permitted to open the
charger or disassemble it, with the exclusion of the connectors
on the terminal strip.
▪The charger must be installed indoors. Avoid exposure to and
penetration of water, rain, snow, moisture, highly polluting
conditions and condensation.
2. Safety instructions
WARNING!
Means that the relevant activity is hazardous and
you must prepare well before proceeding.
CAUTION!
Means that relevant implementation could cause
damage.
NOTE!
Means advice or instruction for the operator.

User manual MPPT Solar charge controller PowerXtreme XS20
E18-XS20-EN00 www.emergoplus.com Page 13 of 44
▪While in operation the charger may reach a high temperature.
Therefore, place the charger in a well-ventilated room and ensure
that ventilation channels are not covered or obstructed.
▪We highly recommend the use of a fuse (25A) outside the
charger. Position this as close as possible to the positive pole of
the battery. The same goes for the connection of the consumer.
Also make use of a suitable fuse, as close as possible to the
positive pole.
▪Regarding installation and wiring of the charger, you must ensure
that the connection with the Solar panel and the fuse are
disconnected.
▪After the installation check if all connections are fixed solidly and
reliably. Loose connection cause heat which may lead to
extremely dangerous situations.
2.3 Installation precautions
▪Be very careful when positioning the battery. When working with
open lead-acid batteries always wear safety glasses. In case of
contact with battery acid, rinse with water for a long time.
▪In order to prevent short circuit, do not place any metal objects
on or near the battery.
▪During charging gas may be generated. Always ensure a well-
ventilated room.
▪Keep the battery away from sparks and fire, because the battery
may produce highly flammable gas.
▪In case of installation in the open, protect the battery against
direct sunlight and penetration of rain water.
▪Loose connection or corroded wire will lead to excessive heat
development. This may result in melting of the insulation layer of
the wire and surrounding materials and even cause fire.
Therefore, make sure that all connections are firmly fixed or
tightened.
▪When connecting the system, the output voltage may exceed the
upper limit for human safety. Therefore, make use of insulated
tools at all times and keep your hands dry.

User manual MPPT Solar charge controller PowerXtreme XS20
E18-XS20-EN00 www.emergoplus.com Page 14 of 44
▪Always observe the safety recommendations of the
manufacturer.
2.4 Wiring specifications
Wiring and installation methods must meet the national and local
electrical specifications.
The specifications of the wiring of the battery and the load must be
selected in accordance with the rated currents, refer to the following table
for wiring specifications:
Model
Rated
charging
current
Rated
discharge
current
Diameter
battery
cable
(mm²)
Diameter
charge
cable
(mm²)
XS20
20A
20A
≥4
≥4
Image 5. Prescribed cable diameter

User manual MPPT Solar charge controller PowerXtreme XS20
E18-XS20-EN00 www.emergoplus.com Page 15 of 44
3.1 LED-indicators
Solar panel indicator
Indication present charge mode
of the charger.
BAT indicator
Indicates present status of the
battery.
Consumer indicator
Indication of the load On/Off and
status.
Error indicator
Indication whether the charger is
functioning normally.
Solar panel indicator:
No.
Diagram
Indicator
Charging status
1
On
MPPT charging
2
Flashes
slowly
Boost charging
3
Single flash
Float charging
4
Fast
flashing
Equalizing
5
Double
flash
Charging
constant current
6
Off
No charging
3. Description and functioning

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E18-XS20-EN00 www.emergoplus.com Page 16 of 44
BAT indicator:
Indicator status
Battery status
On
Normal battery voltage
Slowly flashing (a cycle of 2s on and
1s off)
Battery discharged too far
Fast flashing (a cycle of 0.2s on and
0,1s off)
Over-voltage of the battery
Consumer indicator:
Indicator status
Load status
Off
Load disconnected
Fast flashing (a cycle of 0.2s on and
0,1s of)
Overload / short circuit
On
Normal charging
Error indicator:
Indicator status
Error indication
Off
System functions normally
On
System defect

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E18-XS20-EN00 www.emergoplus.com Page 17 of 44
3.2 Function control buttons
▲Up
PGUP; increase the value of the parameter
setting
▼Down
PGDN; decrease the value of the parameter
setting
◄Back
Back to previous menu (without saving)
►Set
Enter of submenu; set / save
Switching load on/off (in manual mode)

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E18-XS20-EN00 www.emergoplus.com Page 18 of 44
3.3 Functions on LCD screen
Functions to be read from the LCD screen.
3.3.1 Starting interface
During start-up the 4 battery charging indicators will successively start to
flash, and after the self-inspection the LCD-screen will be started and the
battery voltage level will be displayed. This is a fixed voltage value chosen
by the user or a voltage that is automatically recognised.
Day
Charge
Discharge
Night
Solar panel
Battery
Load
System
Voltage
Warning
Serial
port
Charger
status
Battery
model
Setting
Bluetooth

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E18-XS20-EN00 www.emergoplus.com Page 19 of 44
3.3.2 Main menu
Hoofdscherm Gebruiker voltage Laadstroom
Main screen
Error code
Charge current
Solar voltage
SOC Battery
Voltage Battery
Charge capacity
Charge current
Discharge capacity
Panel Temperature
Charging mode

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E18-XS20-EN00 www.emergoplus.com Page 20 of 44
3.4 Charging mode setting Interface
3.4.1 Charge modes introduction
The charger has 5 charging operation modes that are described below:
Nr.
Modus
Description
0
Only light control (on
during the night, off
during the daytime)
When sunlight appears, the voltage
of the solar panel will become higher
than where there is no light, and
after a delay the charger will activate
the charging. When the sun goes
down, the opposite takes place.
1 to
14
Light + time control 1
to 14 hours
When sunlight appears, the voltage
of the solar panel will be higher than
where there is no light, and after a
delay the charger will activate the
charging. The load will be turned off
after a pre-set time.
15
Manual mode
In this mode, the user can activate
or deactivate charging by use of the
buttons, regardless whether it is day
or night. This mode was designed
for some specially intended loads,
and is also used during the
debugging process.
16
Troubleshooting mode
Used for the debugging of the
system. The charging is deactivated
with light signals, the charging is
activated without light signals. This
mode makes it possible to quickly
check the proper functioning of the
installation during troubleshooting.