iTechworld 40Amp MPPT User manual

12/24V 40Amp MPPT Solar Charge
Controller
USER GUIDE

Contents
1.Saftey Precautions................................................... - 2 -
2. Product Overview ...................................................- 5 -
2.1. Introduction: .............................................................................- 5 -
2.2 Key Features:..............................................................................- 5 -
2.3 Product Appearance...................................................................- 6 -
3. Installation ............................................................- 7 -
3.1 Wiring the solar charge controller..............................................- 8 -
3.2 Fuse Specifications ....................................................................- 9 -
4. Unit Operation ..................................................... - 10 -
4.1 Menu Navigation...................................................................... - 10 -
4.2 Settings Menu .......................................................................... - 11 -
4.3 Changing Parameters: .............................................................. - 11 -
4.4 Battery Selection Menu:........................................................... - 12 -
4.4.1 Lithium Battery Profiles (4-3.2, 5-3.2, 3-3.7, 4-3.7, Usr2) ... - 13 -
4.5 System Voltage Setting: ........................................................... - 13 -
4.6 Load Control:............................................................................ - 14 -
4.6.1 Manually Controlling the load ........................................... - 14 -
4.6.2 Load Control Modes .......................................................... - 14 -
4.7 Solar Input Voltage................................................................... - 16 -
4.8 Setting equalisation charging voltage and duration ................. - 16 -
4.9 Setting Absorption Charging Voltage and Duration.................. - 17 -
5. Troubleshooting ................................................... - 18 -
6. Specifications....................................................... - 19 -
6.1 Operating Parameters .............................................................. - 19 -
6.2 Protections............................................................................... - 20 -
6.3 Charging Profiles ...................................................................... - 20 -
7. Maintenance and Warranty.................................... - 21 -

1.Saftey Precautions
For safe operation and ideal performance, the iTechworld 40A MPPT Solar
Charge Controller must be correctly installed and operated correctly. Please
carefully read, understand, and follow all instructions and guidelines in this
User Guide. iTechworld recommends that all wiring and installation be done
by a certified technician to ensure all applicable electrical wiring regulations
and installation codes are met.
Failure to follow these instructions may result in damage to the unit and
could also result in death or serious injury.
Disclaimer:
While iTechworld has taken every precaution to ensure the accuracy of the
contents of this user guide, iTechworld assumes no responsibility for any errors
or omissions.
Furthermore, all specifications and functionality may change at any time
without notice.
Important:
Please read and understand the entirety of this user guide before using
your iTechworld solar charge controller. Any misuse may result in damage
to the unit and/or cause harm or serious injury to the user.
- 2 -

SAFETY PRECAUTIONS
1. WARNING: People with physical disabilities, visual, sensory, or mental
impairments (including children) should not use this device. Children
should be supervised to ensure they do not play with battery
chargers.
2. DANGER: Do not disassemble or modify the solar charge controller,
doing so may result in a risk of electrical shock, fire, death, or
serious injury.
3. DANGER EXPLOSION HAZARD: Do not use this solar charge controller
in an environment where flammable fumes or gases are present(such
as gas bottles, petrol engines or lead acid battery compartments)
4. DANGER: This solar charge controller is only suitable for battery
types listed in the manual. Do not use it for other purposes.
5. WARNING: Please select the correct battery charging profile
applicable to the battery being charged. If the incorrect battery
charging profile is selected, it may cause damage to your battery
or result in fire. If you are unsure of the correct battery charging
profile to use, please consult your battery's manufacturer.
6. WARNING: External solar and battery disconnects/fuses are required,
otherwise, it may result in damage to the charger, risk of electrical
shock, fire, death, or serious injury.
7. WARNING: Ensure that the selected battery charging profile's
charge voltage does not exceed the battery's recommended maximum
charging voltage. If you are unsure of the maximum charging
voltage of your battery, please consult your battery's manufacturer.
8. WARNING: Ensure that the continuous output current of the solar
charge controller does not exceed the battery's recommended
maximum charging current. If you are unsure of the maximum
charging current of your battery, please consult your battery's
manufacturer.
9. Warning: When using the solar charge controller to charge a lithium
battery, ensure that the battery contains an inbuilt battery
management system (BMS) that features under and over voltage
protection with cell balancing. Failure to do so may result in fire,
death, or serious injury.
- 3 -

10. DANGER: Never smoke or allow a spark or flame in vicinity of
battery or engine. This may cause the battery to explode
11. LIMITATIONS OF USE: Do not use in connection with life support
systems or other medical equipment or devices.
- 4 -

2. Product Overview
2.1. Introduction:
The iTechworld 40 Amp MPPT Solar Charge Controller is designed to enhance
any solar and battery combination, it works especially well with the iTECH120X
lithium battery and iTechworld solar panels. This controller and its charging
algorithm are patented by iTechworld. Thanks to the innovative technology in
the iTechworld 40 Amp MPPT Solar Charge Controller, you can access the
maximum power of your solar panel(s) which will significantly improve your
system. The iTechworld 40 Amp MPPT Solar Charge Controller has a Liquid-
Crystal Display (LCD) which is used to dynamically display the operation data
and working status of the solar charge controller. Suitable for indoor use only.
2.2 Key Features:
• Advanced Maximum Power Tracking (MPPT) technology, with
efficiency of 99.5%
• Maximum conversion efficiency of 97%
• Rapid maximum power point tracking.
• Automatic voltage identification (12V or 24V)
• Suitable for charging most common types of automotive or
recreational 12-Volt lead acid batteries, such as Gel, Sealed Lead
Acid, Flooded Lead Acid, LiFePO4(Lithium Iron/Ferro Phosphate,
such as the iTECH120X) and Li (NiMnCo)O2(Li-po/NMC) Chemistry
12-Volt Lithium batteries containing a BMS.
• 40A MPPT Solar Regulator
• Constant and reliable maximum input power of the solar panel to ensure
safety when charging.
• Wide solar panel operating voltage up to 100VDC.
• An intelligent control point for your solar panel system. With an intuitive
LCD, you are in control of your solar panel system.
• Power statistics recording functionality, the controller will log the power
put into the battery.
• Using the buttons, you can program the controller to your preferences
and monitor your solar system in real time.
• Easy to read display icons and indicators will tell you the operating status
of your solar panels.
- 5 -

2.3 Product Appearance
Figure 1 Solar Controller Features
1
LCD Screen
2
External Temperature Probe
3
Solar Input Terminals
4
Battery Connection Terminals
5
Load Output Terminals
6
Button A
7
Button B
- 6 -

3. Installation
The iTechworld 40 Amp MPPT Solar Charge Controller should be installed as
close as possible to the battery being charged, this allows for more efficient
charging of your battery. The solar charge controller is best mounted
vertically with 4 screws (Not included) there are cut outs on the heatsink of
the charger where the screws are hooked on. Below is the screw template,
the maximum screw head diameter is 5mm.
The solar charge controller should be installed in a dry location, please ensure
no liquids (such as water) can enter the solar charge controller. For proper air
flow to cool the solar controller, please allow at least 15cm of space above and
below the controller and 5cm at the sides.
Figure 2 Mounting Diagram
- 7 -- 7 -

3.1 Wiring the solar charge controller
When wiring the solar charge controller, please use flexible, multi-stranded copper
wire, with a current rating of at least 50Amps.
1. Connect your components to the solar charge controller in the sequence as
shown in figure 3(1,2,3) and make sure the polarity is correctly connected. Do
not insert fuses or turn on the breaker during the installation. When
disconnecting, the order will be reversed (3,2,1)
2. A battery fuse must be used, the battery fuse should be installed as close to
the battery as possible. The suggested distance is within 15cm of the battery.
Please refer to fuse specifications.
3. Always connect the battery first, as this allows the solar charge controller to
recognise the system voltage.
4. Power up the controller by installing the battery fuse first, then switching
on/connecting the solar array.
Warning: If using the load output on the solar charge controller, do not exceed
40Amps, large loads such as inverters should only be connected to the battery directly.
Warning: This solar charge controller is a common positive controller. Directly connect
the solar panel + & - connections to the solar charge controller only.
- 8 -
Figure 3 Connection Diagram

3.2 Fuse Specifications
All recommended fuses should be connected
in series in circuit, and as closeas possible to
power sources. Bolt down fuses is preferred
as they ensure a low resistance connection.
Blade type fuses are not recommended as
they can result in
a high resistance connection which can cause excess heat generation
and may damage the fuse holder and/or the wiring. Self-resetting circuit
breakers are not recommended as they may prematurely trip due to the
heat generated by the large current flowing through thewires.
Please refer to the table below for the recommended fuses.
(PLEASE NOTE FUSES ARE NOT SUPPLIED)
Minimum Fuse
Rating
Maximum Fuse
Rating
Battery to solar charge controller
45A
50A
Solar input to solar charge
controller
45A 50A
Solar Charge Controller to Load
45A
50A
- 9 -
Figure 4 Bolt Down Fuse Holder

4. Unit Operation
Boot Sequence
4.1 Menu Navigation
After the controller is powered on, the display will enter the main navigation flow
chart. At this time, short press button A or B to navigate between the parameters.
When on the Ambient Temperature screen, you can switch between the ambient
temperature and the solar charge controller’s internal temperature (denoted by
the letter H under the °C) by pressing and hold button B for longer than 3 seconds.
- 10 -
Figure 5 Display Icons
Solar Controller Status
Item
Icon
Status
PV
Array
Day Night
Charging
Battery
Battery State of
Charge
Lithium Battery
Type
Load On Off
Initial Boot Screen
Battery System
Voltage
Controller Rated
Charge Current
Software Revision
Figure 6 Boot Sequence
Figure 7 Main Navigation Flow Chart

4.2 Settings Menu
To enter the settings menu of the solar charge controller, on the Home Screen,
press and hold button A for more than 3 seconds then using buttons, A or B to
scroll thorough the values. To alter the parameter, refer to “Changing Parameters”
4.3 Changing Parameters:
Figure 9 Changing Parameters
To change user changeable parameters, press and hold button A until the
parameter value starts to flash, then short pressing button A or B will alter the
parameter, once the desired value is reached, press, and hold button A for more
than 3 seconds to save the data. Otherwise, press and hold button B to not save
the change and return to the Home Screen.
- 11 -
Figure 8 Settings Flow Chart

4.4 Battery Selection Menu:
To change the battery charging profile, on the home screen, press and hold
button A for more than 3 seconds to access the settings Menu, then short press
button B until you are on the Battery Type (refer to Settings Men u), once on the
Battery Type menu, press and hold button A for more than 3 seconds to access
the Battery Selection Menu.
Then short pressing buttons A or B to toggle through each of the different battery
charging profiles (Usr1, Gel, Sld, Fld and lithium batteries.)
When the desired charge profile is on the display flashing, press and hold button
B for more than 3 seconds to save the selection.
- 12 -
Figure 10 Battery Selection Flow Chart

4.4.1 Lithium Battery Profiles (4-3.2, 5-3.2, 3-3.7, 4-3.7, Usr2)
When a lithium profile is selected, the display will prompt for the total capacity of
your lithium battery, use buttons A or B to set the value to the closest number as
it is adjusted in increments of 5AH. Once the correct battery capacity is flashing
on the display, press and hold button B for more than 3 seconds to save the
selection.
NOTE: When using any of iTechworld’s lithium batteries,
such as the iTECH120X, please ensure ONLY the 4-3.2
(Lithium Battery, 3.2V/Cell, 4 in series) lithium profile is
selected.
4.5 System Voltage Setting:
Figure 11 System Voltage Setting
The solar charge controller system voltage is set to auto sensing by default,
although if required you can set it manually to be either 12 Volts or 24 Volts.
To change the system voltage, enter the Settings Menu(refer to Settings Menu)
and scroll to the System Voltage screen , then press and hold button A until the
parameter value starts to flash, then short pressing button A or B will alter the
parameter, once the desired value is reached, press, and hold button A for more
than 3 seconds to save the data, once the system voltage is saved, the solar
controller will automatically restart after a few seconds.
- 13 -

4.6 Load Control:
Figure 12 Load Control
4.6.1 Manually Controlling the load
On the Home Screen, short pressing button B will turn on or off the load as
denoted by the light bulb symbol with rays coming out or off.
4.6.2 Load Control Modes
LD1 Manual Load Control: The controller will not automatically turn on or off the
load based on solar input (See above (manually controlling the load)
LD2 Light/Load Control Mode: The controller will automatically turn off the load
when there is solar input detected(day) and turns on the load when there is no
solar input detected(night). (Detection time of day and night is about 30
seconds)
-14 -
Mode
Function Description
(LD1)
Manual load control
(LD2)
Light control mode
(LD3)
Dual Time Mode
(LD4)
Inverted light control mode

Dual Time Mode
Figure 13 Dual Time Mode Flow Chart
LD3 Dual Time Control Mode: The controller will turn on the load automatically
for the set amount of time during night and day, it will then turn the load off after
the elapsed time. When LD3 is selected the above additional settings will be
prompted for input, the parameter will be flashing, use buttons A and B to increase
or decrease the desired runtime.
LD4 Inverted Light/Load Control Mode: The controller will automatically turn on
the load when there is solar input detected(day) and turns off the load when no
solar input is detected(night). (Detection time of day and night is about 30
seconds)
- 15 -
Load Control Mode LD3
Night duration of Load On,
(1-13Hrs)
Day duration of Load On,
(0-5Hrs)
Debug Switch
(Not Used, leave as is)

4.7 Solar Input Voltage
Figure 14 Solar Input Voltage
To toggle between the Solar Input Voltage and Battery Voltage, on the Home
Screen, press and hold Button B for more than 3 seconds.
4.8 Setting equalisation charging voltage and duration
(Only adjustable on the Usr 1 battery charging profile)
Figure 15 Equalisation Voltage Settings
Navigate to the Equalisation Voltage screen (refer to Figure 8), then press and
hold Button A for more than 3 seconds until the value starts to flash, then using
buttons A or B to increase or decrease the Equalisation Voltage, once the desired
voltage is set, press, and hold Button A for more than 3 seconds to advance to
the duration setting, once again use Buttons A or B to adjust. Finally press and
hold Button A for more than 3 seconds to save all changes.
- 16 -

4.9 Setting Absorption Charging Voltage and Duration
(Only adjustable on Usr1 battery charging profile)
Navigate to the Absorption Voltage screen (refer to figure 8), then press and hold
Button A for more than 3 seconds until the value starts to flash, then using
buttons A or B to increase or decrease the Absorption Voltage, once the desired
voltage is set, press, and hold Button A for more than 3 seconds to advance to
the duration setting, once again use Buttons A or B to adjust. Finally press and
hold Button A for more than 3 seconds to save all changes.
- 17 -

5. Troubleshooting
- 18 -
Fault Code/Symptom
Cause
Correction
Solar Charge controller is
not charging battery when
there is enough sunlight
1. Solar input is
disconnected
2. Solar input voltage is
lower than the battery
voltage
1. Check that all solar input
connections and
fuses/breakers are correct.
2. The voltage of the solar
panel should be more than
the battery voltage.
Nothing is displaying on the
LCD
Battery voltage is less than 8
Volts. Or incorrect
connections.
Check battery voltage,
connections, and fuses. The
controller will only turn on if
the battery is above 8 Volts.
(Ex1)
Battery is over discharged;
low voltage protection has
been triggered
The load output is turned
off automatically and will
recover when the battery
voltage rises above the Low
voltage recovery voltage.
(Ex2)
Battery is over charged.
Over voltage detected.
Check that the selected
battery profile is correct for
the battery connected.
(Ex3)
Overload detected
Reduce the load on the load
output of the solar charge
controller.
(Ex5)
Solar charge controller over
temperature.
Make sure the solar charge
controller has adequate
ventilation, and none of the
heat sink fins are blocked.
Allow the regulator to cool
down, once it has cooled
down it will restart charging
automatically.
(Ex6)
Input voltage of solar panels
is too high
Check voltage of the solar
input and reduce the
number of panels
connected in series.

6. Specifications
6.1 Operating Parameters
- 19 -
Input
System Rated Voltage
12/24VDC Auto sensing
Max Open Voltage of
Solar Panel
100VDC (at the lowest temperature)
92VDC (at standard temp of 25°C)
Max Solar Input Power
12VDC System
520W
24VDC System
1040W
Battery Voltage Range
8V DC – 32VDC
Output
Rated Charge Current
40A
Battery Types
Sealed Lead Acid, Flooded Lead Acid, Gel,
LiFePO4(i.e. iTECH120X), LiNiMnCoO2(LiPO)
Static Loss
≤50mA
Temperature
Compensation
Coefficient
-4mV/°2V(25°C)
LCD Temperature
-20°C~+70°C
Operating
Temperature
-20°C~+55°C
Storage Temperature
-30°C~+80°C
Working Humidity
≤90% non-condensing
Grounding
Common Positive
Dimensions H x W x D
215mm x 145mm x 75mm
Wire Terminal Size
16mm2/6AWG
Weight
1.30KG