FSP Technology MPPT 5KW User manual

User Manual
Solar Charger Controller 5KW

CONTENTS
1.ABOUT THIS MANUAL........................................................................1
1.1 Purpose.............................................................................................................1
1.2 Scope................................................................................................................1
1.3 Safety Instructions............................................................................................1
2.INTRODUCTION...................................................................................1
2.1 Features............................................................................................................2
2.2 Product Overview.............................................................................................3
3.INSTALLATION.....................................................................................4
3.1 Unpacking and Inspection.................................................................................4
3.2 Preparation.........................................................................................................4
3.3 Mounting the Unit..............................................................................................4
3.4 Power Connection..............................................................................................5
3.5 Grounding and Ground Fault Interruption.........................................................7
3.6 Remote Temperature Sensor...............................................................................7
3.7 Communication Connections.............................................................................8
4.OPERATION..........................................................................................11
4.1 Power-Up.........................................................................................................11
4.2 Operation and Display Panel............................................................................11
4.3 LCD Display Icons...........................................................................................12
4.4 LCD Setting......................................................................................................13
4.5 Reference Code................................................................................................16
5.CHARGING LOGIC..............................................................................17
5.1 3-stage Charging...............................................................................................17
5.2 Equalize Stage..................................................................................................19
5.3 Setting Parameter and Default Value................................................................22
6.PARALLEL CHARGING FUNCTION.................................................23
7.SPECIFICATIONS................................................................................26

1.ABOUT THIS MANUAL
1.1 Purpose
This manual describes the assembly, installation, operation and troubleshooting
of this unit. Please read this manual carefully before installations and operations.
1.2 Scope
This manual provides safety and installation guidelines as well as information on
tools and wiring.
The following cases are not within the scope of warranty:
(1) Out of warranty.
(2) Series number was changed or lost.
(3) Battery capacity was declined or external damaged.
(4) Solar charger controller was damaged caused of transport shift, remissness,
ect external factor.
(5) Solar charger controller was damaged caused of irresistible natural disasters.
(6) Not in accordance with the electrical power supply conditions or operate
environment caused damage.
1.3 Safety Instructions
WARNING: This chapter contains important safety and operating
instructions. Read and keep this manual for future reference.
1. Before using the unit,read all instructions and cautionary markings on the unit,the
batteries and all appropriate sections of this manual.
2. Do not disassemble the unit. Take it to a qualified service center when service or
repair is required. Incorrect re-assembly may result in a risk of electric shock or fire.
3. To reduce risk of electric shock, disconnect all wirings before attempting any
maintenance or cleaning. Turning off the unit will not reduce this risk.
4. CAUTION- Only qualified personnel can install this device with battery.
5. NEVER charge a frozen battery.
6. For optimum operation of this charger,please follow required spec to select
appropriate cable size. It’s very important to correctly operate this charger.
7. Be very cautious when working with metal tools on or around batteries. A potential
risk exists to drop a tool to spark or short circuit batteries or other electrical parts and
could cause an explosion.
8. Please strictly follow installation procedure when you want to disconnect PV or
battery terminals.Please refer to INSTALLATION section of this manual for the
details.
9. GROUNDING INSTRUCTIONS- This charger should be connected to a
permanent grounded wiring system.Be sure to comply with local requirements and

regulation to install this charger.
10. NEVER cause short circuited on battery output.
11. Warning!! Only qualified service persons are able to service this device. If errors
still persist after following troubleshooting table, please send this charger back to
local dealer or service center for maintenance.
2. INTRODUCTION
Thank you for selecting this solar charge controller. This solar charge controller is an
advanced solar charger with maximum power point tracking. Applying intelligent
MPPT algorithm, it allows solar charge controller to extract maximum power from
solar arrays by finding the maximum power point of the array.
The MPPT battery charging process has been optimized for long battery life and
improved system performance. Self-diagnostics and electronic error protections
prevent damage when installation errors or system faults occur. This charger also
features multifunctional LCD with communication ports for remote battery
temperature and voltage measurement.
2.1 Features
Intelligent Maximum Power Point Tracking technology increases efficiency
25%~30%
Compatible for PV systems in 12V, 24V, 36V or 48V
Three-stage charging optimizes battery performance
Maximum charging current up to 80A
Maximum efficiency up to 98%
Battery temperature sensor(BTS) automatically provides temperature
compensation
Automatic battery voltage detection
Support wide range of lead-acid batteries including flooded, AGM,
GEL,LEAD,Lithium Ion, User-Defined batteries.
Integrated intelligent slot compatible with 485/USB communication

2.2 Product Overview
1.LCD display
2.Power ON/Charging indicator
3.Fault and warning indicator
4.Wiring fault indicator
5.Operation button
6.PV connectors
7.Battery connectors
8.Battery temperature sensor terminal
9.Wiring box cover
10.RS485 communication port
11.USB
3. INSTALLATION
3.1 Unpacking and Inspection
Before installation, please inspect the unit. Be sure that nothing inside the package is
damaged. You should have received the following items inside of package:
Solar charge controller×1

User manual×1
Communication cable×1
Battery Temperature Sense×1
Software CD ×1
3.2 Preparation
Before connecting all wirings, please take off wiring box cover by removing screws
as shown below.
3.3 Mounting the Unit
Consider the following points before selecting where to install:
This solar charge controller is designed in IP20 for indoor applications only.
Do not mount the unit on flammable construction materials.
Mount on solid surface
Install this charger at eye level in order to allow the LCD display to be read at all times.
For proper air circulation to dissipate heat, allow a
clearance of approx. 300 mm to the side and approx.
300 mm above and below the unit.
The ambient temperature should be between -10℃and 55℃
to ensure optimal operation.
The recommended installation position is to be adhered to
The wall vertically.
Install the unit to the wall by screwing two screws.
Refer to right chart.

3.4 Power connection
Wire size
The four large power terminals are sized for 14-2AWG(2.5-3.5mm2) wire. The terminals are rated
for copper and aluminum conductors. Use UL-listed Class B 300 Volt stranded wire only. Good
system design generally requires large conductor wires for solar module and battery connections
that limit voltage drop losses to 2% or less.
Minimum Wire Size
The table below provides the recommended minimum wire size allowed for the charger. Wire
types rated for 75℃and 90℃are listed.
Recommended wire size:
Typical Amperage
Wire Type
75℃Wire
90℃Wire
80A
Copper
4 AWG(25 mm2)
6 AWG(16 mm2)
Aluminum
2 AWG(35 mm2)
4 AWG(25 mm2)
Overcurrent Protection and Disconnects
CAUTION: Circuit breakers or fuses must be installed in both battery and solar circuits.
The battery circuit breaker or fuse must be rated to 125% of the maximum current or more. The
recommended breaker/fuse rating for use with the charger is listed in the below table.
recommended breaker rating:
Minimum battery circuit breaker / fuse rating
1.25×80Amps=100.0Amps
A disconnect is required for the battery and solar circuits to provide means for removing power
from the charger. Double pole switches or breakers are convenient for disconnecting both solar
and battery conductors simultaneously.
Connect the Power Wires
WARNING:Shock Hazard
The solar modules can produce open-circuit voltage in excess of 100Vdc when in sunlight. Verify
if solar input breaker or disconnect has been opened(disconnected) before connecting system
wires.
（common negative）
Connect terminals by following below steps(Refer to diagram above):
1. Make sure that the system input and output disconnect switches are both turned off before
connecting power wires to the charger. There are no disconnecting switches inside the charger.
2. Make 4 power wires first. Remove insulation sleeve 10.5mm and the conductor should be

plated Tin.Refer to the chart below.
3. Pull all wires into the wiring box. The Remote Temperature Sensor and Battery Sense wires
can be inside the conduit with the power conductors. It is easier to pull RTS and Sense wires
before the power cables.
WARNING:Risk of Damage
Be sure that the battery connection is made with correct polarity. Turn on the battery
breaker/disconnect and measure the voltage on the open battery wires BEFORE connecting to the
controller. Disconnect the battery breaker/disconnect before wiring to the controller.
4. Connect positive terminal(+) of battery to the battery positive terminal(+) on the controller.
5. Connect negative terminal(-) of battery to one of the common negative terminals(-)on the
controller.
WARNING:Risk of Damage
Be sure that solar connection is made with correct polarity. Turn on the solar breaker/disconnect
and measure the voltage on the open battery wires BEFORE connecting to the controller.
Disconnect solar breaker/disconnect before wiring to the controller.
6. Connect positive wire(+) of solar module to the solar positive terminal(+) on the controller.
7. Connect negative wire(-) of solar module to one of the common negative terminals(-)on the
controller.
8. Screw four(4) power terminals tightly with 50 in-lbs torque.(5.65Nm)
3.5 Grounding and Ground Fault Interruption
Use a copper wire to connect the grounding terminal in the wiring box to earth ground. The
grounding terminal is identified by the ground symbol shown below that is stamped into the
wiring box just below the terminal:
The minimum size of the copper grounding wire is 8AWG(10mm2).
WARNING:Risk of Fire
Do NOT bond system electrical negative to earth ground at the controller.
3.6 Battery Temperature Sensor
The included Battery Temperature Sensor(BTS) is recommended for effective temperature
compensated charging. Connect the BTS to the 2-pole terminal(see figure as below). The BTS is

supplied with RJ11,33ft(1m) of 22AWG(0.34mm2) cable.
NOTE: The BTS is optional package. Please check local dealer for the details.
CAUTION: The controller will not activate temperature compensate charging function if the BTS
is not used.
CAUTION:Equipment Damage
Never place the temperature sensor inside a battery cell. Both the BTS and the battery will be
damaged.
NOTE: The BTS cable may be shortened if the full length is not needed.
3.7 Communication Connections
The default Communication of the controller is RS485 port. You can use supplied cable to connect
RS-485,USB port of controller to PC. It can be used for monitoring or upgrade the fireware in
short distance.
Insert bundled software CD into a computer and follow on-screen instruction to install the
monitoring software. For the detailed software operation, please check user manual of software
inside of CD.
4.OPERATION
4.1 Power-up

WARNING: Risk of Damage
Connecting the solar module to the battery connector will permanently damage the controller.
Confirm that the solar and battery polarities are correctly connected to the controller.
A battery must be connected to the controller before operating it. The controller will not
operate only with solar input. Solar input can trigger the controller to start up when the
battery is connected without pressing the button.
Turn on battery disconnect switch first. And press operation button for a while. Then , it will
indicate a successful start-up in LCD display.
Turn on solar disconnect switch. If the solar module is in full sunlight, the controller will
begin charging.
4.2 Operation and Display Panel
The operation and display panel, shown in below chart, is on the front panel of the controller. It
includes three indicators, one operation button and a LCD display, indicating the operating status
and input/output power information.
LED Indicator
LED Indicator
Messages
POWER
ON/CHARGING
Green
Solid On
The controller is on.
Flashing
The controller is charging.
Bulk charge stage : flashing every 0.5 second
Absorption stage : flashing every second
Equalize stage : flashing every 3 seconds
Float stage : flashing every 5 seconds
FAULT/WARNING
Red
Solid On
Fault occurs.
Flashing
Warning situation occurs.
WIRING FAULT
Red
Solid On
Battery polarities are not connected correctly.
Function Keys
Function Keys
Description.
ON/MENU
Enter reset mode or setting mode go to previous selection.

UP
Increase the setting data.
DOWN
Decrease the setting data.
ENTER
Enter setting mode and Confirm the selection in setting mode go to next
selection or exit the reset mode.
4.3 LCD Display Icons
Icon
Function description
Input Source Information
Indicates the PV input voltage, battery voltage.
Configuration Program and Fault Information
Indicates battery equalization is activated.
Indicates the setting programs.
Indicates the warning and fault codes.
Warning: flashing with warning code.
Fault: lighting with fault code.
Output Information
Indicates the output charging current.
Indicate output power.
Indicates battery level by 0-24%,25-49%,50-74%,and 75-100% in
battery mode and charging status in line mode.
Indicates MPPT solar charge controller work pattern.

Battery Charging Status
status
Battery Voltage
LCD Display
Constant Current
mode/ Constant
Voltage mode
<2V/cell
4 bar will flash in turns.
2V/cell~2.083V/cell
The right bar will be on and the
other bars will flash in turns.
2.083V/cell~2.167V/cell
The two right bars will be on and
the other two bars will flash in
turns
>2.167V/cell
The three right bars will be on
and the left bar will flash.
Floating mode
Batteries are fully charged.
4 bars will be on.
4.4 LCD setting
After pressing and holding "ENTER" button for 3 seconds, the unit will enter setting mode. Press
"UP" or "DOWN" button to select setting programs. And then, press "ENTER" or "MENU" button
to confirm the selection and exit.
Setting Programs:
Program
Description
Options
00
Exit setting mode
Escape
01
Maximum
charging current
Setting range is form 10.0A to 80.0A.
Increment of each click is 1A.
02
Battery type
AGM(Default)
Flooded
GEL
LEAD
Lithium Ion
User-Defined
If "User-Defined" LI is selected, battery charge voltage can be set
up in program 03 and 04.
03
Absorption
voltage
The setting range is from 12.0V to 16.0V.
The setting range is from 24.0V to 32.0V.

The setting range is from 36.0V to 48.0V.
The setting range is from 48.0V to 64.0V.
04
Float voltage
The setting range is from 12.0V to 16.0V.
The setting range is from 24.0V to 32.0V.
The setting range is from 36.0V to 48.0V.
The setting range is from 48.0V to 64.0V.
05
Battery rated
voltage
Auto(Default)
If “AUO” is selected, connected battery
voltage system will be automatically
detected.
If “12V” is selected, the unit is considered
as 12V battery system.
If “24V” is selected, the unit is considered
as 24V battery system.
If “36V” is selected, the unit is considered
as 36V battery system.
If “48V” is selected, the unit is considered
as 48V battery system.
06
Battery C.V.
Charging
duration
(Default)
The setting range is form 5 minutes to
900 minutes.
Increment of each short press is 5
minutes. It will jump back to 5 minutes
after 900 is achieved.
07
BTS temperature
compensation
ratio
0mV(Default)
The setting range is from 0mV to 60.0mV.
Increment of each short press is 0.1mV.
The value will jump back to 0mV after
60.0mV is achieved.
For each 12V Battery, the derated battery
charging voltage is followed the below
formula:
(Battery temperature-25℃)
*BTS ratio
08
Battery
equalization
enable/disable
Disable(Default)
Enable
09
Battery
equalization
voltage
The setting range is from 12.0V to 16.0V.
The setting range is from 24.0V to 32.0V.

The setting range is from 36.0V to 48.0V.
The setting range is from 48.0V to 64.0V.
10
The maximum
current of battery
equalization
15A(Default)
The setting range is from 5A to
80A.Increment of each short press is
1A.The value will jump back to 5A after
80A is achieved.
11
Battery
equalization time
60minutes(Default)
The setting range is form 5 minutes to
900 minutes.
Increment of each short press is 5
minutes. The value will jump back to 5
minutes after 900 minutes is achieved.
12
Battery
equalization
overtime
120minutes(Default)
The setting range is form 5 minutes to
900 minutes.
Increment of each short press is 5
minutes. The value will jump back to 5
minutes after 900 minutes is achieved.
13
Equalization
interval
30days(Default)
The setting range is from 0 day to 90
days.
14
Equalization
activated
immediately
Disable(Default)
If “Enable”is selected in this program, it’s
to activate battery equalization
immediately and LCD main page will
shows“ ”.
If “Disable”is selected, it will cancel
equalization function until next activated
equalization time arrives based on
program 13 setting. At this time,“ ”
will be shown in LCD main page too.
Enable
15
Auto turn page
(default)
If selected, the display screen will auto
turn the display page.
If selected, the display screen will stay at
latest screen user finally switches.
16
Backlight control
Backlight on
Backlight off(Default)

After pressing and holding “MENU” button for 6 seconds, the unit will enter reset model. Press
“UP” and “DOWN” button to select programs. And then, press “ENTER” button to exit.
(default)
Reset setting disable
Reset setting enable
4.5 Reference Code
Fault Code
Fault Cause
LCD Indication
01
Battery voltage class error
02
Hardware protection
03
Over current
04
Battery voltage is too low
05
Battery voltage is too high
06
Current is uncontrollable
07
Over temperature
08
Current sensor error
09
PV voltage is too high
10
Fan fault
11
Voltage point setting error
5.CHARGING LOGIC
5.1 3-stage Charging
In general, this solar charge controller is designed with 3-stage battery charging algorithm for fast,
efficient, and safe battery charging. The following picture shows the sequence of charging stages.

1) Bulk charge stage
In bulk charge stage, charge current begins to flow, typically at the maximum rate of The
controller will supply solar power to charge battery as much as possible.
2) Absorption stage
When battery charging voltage is reached to Absorption voltage point, the charging stage changes
from bulk charge to Absorption. Constant-voltage regulation is used to maintain battery voltage at
the Absorption stage. If the charging current drops to one-tenth of the maximum charging current
setting point, the charging status will change to Float stage.
If the elapsed time of absorption stage is over setting value for C-V charging time, it will also
transfer to Float stage.

3) Float stage
After the battery is fully charged in the Absorption stage, the controller will reduces the battery
voltage to the setting point of Float voltage.
Once in Float stage, constant-voltage regulation is used to maintain battery voltage at setting point
of float voltage.
Float timeout
If the battery voltage remains lower than the Float voltage for 30 minutes, the controller will
return to Bulk charging stage.
Float cancel voltage
Once the battery voltage drops to setting point of Float cancel voltage, the controller also returns
to Bulk charging stage.
Float cancel voltage=Floating charging voltage -- (1V × battery numbers in series)

5.2 Equalize Stage
Equalization function is added into solar charge controller. It reverses the buildup of negative
chemical effects like stratification, a condition where acid concentration is greater at the bottom of
the battery than at the top. Equalization also helps to remove sulfate crystals that might have built
up on the plates. If left unchecked, this condition, called sulfation, will reduce the overall capacity
of the battery. Therefore, it's recommended to equalize battery periodically.
How to Apply Equalization function
You must enable battery equalization function in monitoring software first.

Then, you may apply this function in device by either one of following methods:
1. Setting equalization interval.
2. Or, press the button for 3 seconds until LCD shows“ ”
When to Equalize
In Absorption stage, if the charging current drops lower than the maximum charging current of
battery equalization, the controller will start to enter Equalize stage.
If solar charge controller is working in float stage, but at this time, the setting equalization interval
(battery equalization cycle) is arrived, it will transfer to equalize stage.
Equalize charging time and timeout
In Equalize stage, based on maximum charging current of battery equalization, the controller will
supply solar power to charge battery as much as possible until battery voltage raises to battery
equalization voltage. Then, constant-voltage regulation is applied to maintain battery voltage at
the battery equalization voltage. The battery will remain in the Equalize stage until setting battery

equalized time is arrived.
However, in Equalize stage, when battery equalized time is expired and battery voltage doesn't
rise to battery equalization voltage point, the solar charge controller will extend the battery
equalized time until battery voltage achieves battery equalization voltage. If battery voltage is still
lower than battery equalization voltage when battery equalized timeout setting is over, the solar
charge control will stop equalization and transfer to float stage.
5.3 Setting parameter and Default Value
Recommended and default parameter setting are listed below.
Parameter
Battery type
Absorp.
Stage
Float
Stage
Equalize
Stage
Equalize
Activation
Absorp.
Time
Equalize
Time
Equalize
Timeout
Equalize
Interval
Unit
volt
volt
volt
En/Disable
Minutes
Minutes
Minutes
Days
Default
AGM/Gel/L
EAD
14.4V
13.7V
14.6V
Disable
150
60
120
30
Option
Flooded
14.2V
13.7V
14.6V
Disable
150
60
120
30