Phocos CML05-2 User manual

Solar Charge Controller CML05-2, CML08-2, CML10-2, CML15-2, CML20
User Manual English, Page 1
Dear Client,
Thank you very much for buying a Phocos product. With your new CML controller
you own a state-of-the art device which was developed according to the latest
available technical standards. It comes with a number of outstanding features, like:
Clear, readable display of the state of charge
Acoustic signal when the state of charge changes
Low voltage disconnect regulated by state of charge or voltage
16 mm² connector clamps
Complete electronic protection
This manual gives important recommendations for installing, using and programming as
well as remedies in case of problems with the controller. Read it carefully in your own
interest and mind the safety and usage recommendations at the end of this manual.
Description of Functions
The charge controller protects the battery from being overcharged by the solar
array and from being deep discharged by the loads. The charging characteristics
include several stages which include automatic adaptation to the ambient tempera-
ture.
The charge controller adjusts itself automatically to 12V or 24V system voltage.
The charge controller has a number of safety and display functions.
Mounting and Connecting
The controller is intended for indoor use only. Protect it from direct sunlight and place
it in a dry environment. Never install it in humid rooms (like bathrooms).
The controller measures the ambient temperature to determine the charging voltage.
Controller and battery must be installed in the same room.
The controller warms up during operation, and should therefore be installed on a non
flammable surface only.
REMARK: Connect the controller by following the steps described below to avoid
installation faults.
1
Mount the controller to the wall with screws that fit to the wall
material. Use screws with 4 mm shaft and max. 8 mm head
diameter, no counter sunk. Mind that the screws have to carry
also the force applied by the wiring.
Make sure that the ventilator slits on the sides are unob-
structed.
A DIN Rail mounting plate is available as an accessory (CX-DR2). This allows mount-
ing the controller on a standard 35mm DIN rail. Remove the screws at the backside of
the controller and screw the mounting plate with the (long) fastening screw onto the
backside of the controller.
2
Connect the wires leading to the battery with correct polarity.
To avoid any voltage on the wires, first connect the controller,
then the battery. Mind the recommended wire length (min 30
cm to max approx. 100 cm) and the wire size:
CML05: min 2.5 mm²
CLM08: min 4 mm²
CML10: min 6 mm²
CML15, CML20: min 10 mm²
Wrong polarity will cause a permanent warning sound.
WARNING: If the battery is connected with reverse polarity, the load terminals
will also have the wrong polarity. Never connect loads during this condition!
REMARK: Mind the recommendations of your battery manufacturer. We strongly
recommend connecting a fuse directly to the battery to protect any short circuit at the
battery wiring. The fuse must take the charge controller nominal current:
CML05: 20A, CML08: 20A, CML10: 30A, CML15: 30A, CML20: 40A
3
Connect the wires leading to the solar array with correct
polarity. To avoid any voltage on the wires, first connect the
controller, then the solar array. Mind the recommended wire
size:
CML05: min 2.5 mm²
CLM08: min 4 mm²
CML10: min 6 mm²
CML15, CML20: min 10 mm²
REMARK: Place positive and negative wire close to each other to minimize electro-
magnetic effects.
REMARK: Solar panels provide voltage as soon as exposed to sun light. Mind the solar
panel manufacturer’s recommendations in any case.
4
Connect the wires leading to the loads with correct polarity.
To avoid any voltage on the wires, first connect the wire to the
load, then to the controller. Mind the recommended wire size:
CML05: min 2.5 mm²
CLM08: min 4 mm²
CML10: min 6 mm²
CML15, CML20: min 10 mm²
Grounding the Solar System
Be aware that the positive terminals of the
CML controller are connected internally and
therefore have the same electrical potential. If
any grounding is required, always do this on
the positive wires.
REMARK: If the device is used in a vehicle which has the battery negative on the
chassis, loads connected to the controller must not have an electric connection to the
car body, otherwise the Low Voltage Disconnect and electronic fuse functions of the
controller are short circuited.
Starting up the Controller
Self Test
As soon as the controller is supplied with power either from the battery or the solar
array, it starts a self test routine. Then the display changes to normal operation.
System Voltage
The controller adjusts itself automatically to 12 V or 24 V system voltage.
As soon as the voltage at the time of start-up exceeds 20.0 V, the controller implies a
24 V system.
If the battery voltage is not within the normal operation range (ca. 12 to 15.5 V or ca.
24 to 31 V) at start-up, a status display according to the section ERROR DESCRIP-
TION occurs.
Battery Type
The controller is preset to operate with lead acid batteries with liquid electrolyte. If
you intend to use a lead-acid battery with solid electrolyte ('gel' type or 'fleece' type)
you can adjust the charging characteristics (see "Settings"). The equalization charge is
deactivated then.
In case of any doubts consult your dealer.
Recommendations for Use
The controller warms up during normal operation.
The controller does not need any maintenance or service. Remove dust with a dry
tissue.
It is important that the battery gets fully charged frequently (at least monthly). Other-
wise the battery will be permanently damaged.
A battery can only be fully charged if not too much energy is drawn during charging.
Keep that in mind, especially if you install additional loads.
Display Functions
The controller is equipped with 5 LEDs and an acoustic warning signal.
Charge display
State of charge display
Load status display
In normal operation, the controller shows the state of charge of the battery and the
charge from the solar panels. Any change of the state of charge (SOC) to a lower
status is additionally signaled acoustically.
Charge display
Solar array supplies electricity Solar array does not supply electricity
State of charge display
>75% 25-75% <25% flashes: <10%
The percentage corresponds to the available energy until Low Voltage Disconnect in
relation to a fully charged battery.
Acoustic signals
A change in the state of charge (SOC) to a lower status is indicated by an acoustic
signal.
1x 3x 5x 25x
The loads are disconnected approx. 1 minute after a series of 25 signals.
Load status display
In case of deep discharge or overload/short-circuit of load, the load output is switched
off. This is indicated by:
Normal operation Low voltage disconnect Overload or Short-circuit of load

Solar Charge Controller CML05-2, CML08-2, CML10-2, CML15-2, CML20
User Manual English, Page 2
Low Voltage Disconnect Function (LVD)
The controller has 2 different modes to protect the battery from being deeply
discharged:
1. State of charge controlled: Disconnect at 11.4 V (at nominal load current) up to
11.9 V (at no load current). Normal operation mode for good battery protection.
2. Voltage controlled: Disconnect at 11.0 V fixed setting. Appropriate if bypass loads
draw current directly from the battery.
The controller is preset to Mode 1 from the factory. Changing the mode setting is
described below.
In case of doubts which mode to choose, consult your dealer because this has to be
evaluated depending on the battery used.
Settings
The controller can be configured for special operation. For this purpose, open the
cover of the controller by removing the screws on the back side.
WARNING: The controller should not be opened while connected and in opera-
tion!
When the controller is opened, there are 3 jumpers on the electronic board:
For changing, put the jumper either on
both contact pins or only on one
contact pin:
Closed jumper
1
3
2
Open
jumper
With these jumpers, the following settings can be configured:
Jumper GEL (1) LVD (2) BUZ (3)
Function Battery type Function of low voltage
disconnect
Acoustic alarm signal
Setting jumper
open
Liquid
electrolyte
State of charge con-
trolled
Alarm off
Setting jumper
closed
GEL (VRLA
battery)
Voltage controlled Alarm on
Factory setting Jumper open
(liquid electro-
lyte)
Jumper open state-of-
charge controlled
Jumper closed
Alarm on
After completing the setting, replace the cover and tighten it with the screws.
Safety Features
The controller is protected against wrong installation or use:
At the solar termi-
nal
At the battery
terminal At the load terminal
Battery connected
with correct polarity
Unrestricted Normal operation Unrestricted
Battery connected
with wrong polarity Unrestricted Unrestricted. Acous-
t
ic Warning Unrestricted
Reverse polarity Yes, not at 24V
system voltage.
Yes, if only the
battery is connected.
Acoustic Warning
Load output is
protected. Loads
might be damaged.
Short circuit Unrestricted
Unrestricted.
CAUTION: Battery
must be protected
by fuse.
Unrestricted
Overcurrent No protection ----------------------- Controller switches
off load terminal.
Thermal overload No protection ----------------------- Controller switches
off load terminal.
No connection Unrestricted Unrestricted Unrestricted
Reverse Current Unrestricted ----------------------- -----------------------
Overvoltage Varistor 56 V, 2,3 J Max. 40 V Controller switches
off load terminal.
Undervoltage Normal operation Controller switches
off load terminal.
Controller switches
off load terminal.
WARNING: The combination of different error conditions may cause damage to
the controller. Always remove the error before you continue connecting the
controller!
Error Description
Error Display Reason Remedy
Battery is low
Load will reconnect as
soon as battery is
recharged.
Overcurrent/ Short
circuit of loads
Switch off all loads.
Remove short circuit.
Controller will switch
on load automatically
after max 1 minute.
Battery voltage too
high (>15.5 / 31.0 V)
Check if other sources
overcharge the battery.
If not, controller is
damaged.
Loads are not
supplied
Battery wires or
battery fuse damaged,
battery has high
resistance
Check battery wires,
fuses and battery.
Battery is empty
after a short
time
Battery has low
capacity Change battery
Battery is not
being charged
during the day
Solar array faulty or
wrong polarity
Remove faulty connec-
tion/reverse polarity
Battery wrong
polarity
Permanent
sound
Battery is connected
with reverse polarity
Remove reverse
polarity
General Safety and Usage Recommendations
Intended Use
The charge controller is intended exclusively for use in photovoltaic systems with 12 V
or 24 V nominal voltage and in conjunction with vented or sealed (VRLA) lead acid
batteries only.
Safety Recommendations
Batteries store a large amount of energy. Never short circuit a battery under all
circumstances. We recommend connecting a fuse (slow acting type, according to
the nominal controller current) directly to the battery terminal.
Batteries can produce flammable gases. Avoid making sparks, using fire or any naked
flame. Make sure that the battery room is ventilated.
Avoid touching or short circuiting wires or terminals. Be aware that the voltages on
specific terminals or wires can be up to double the battery voltage. Use isolated
tools, stand on dry ground and keep your hands dry.
Keep children away from batteries and the charge controller.
Please observe the safety recommendations of the battery manufacturer. If in doubt,
consult your dealer or installer.
Liability Exclusion
The manufacturer shall not be liable for damages, especially on the battery, caused by
use other than as intended or as mentioned in this manual or if the recommendations
of the battery manufacturer are neglected. The manufacturer shall not be liable if
there has been service or repair carried out by any unauthorized person, unusual use,
wrong installation, or bad system design.
Technical Data
Nominal voltage 12 / 24 V, automatic recognition
Boost voltage 14.5 / 29.0 V (25°C), 2 h
Equalization voltage 14.8 / 29.6 V (25°C), 2 h
Float voltage 13.7 / 27.4 V (25°C)
Low Voltage Disconnect
Function
11.4-11.9 / 22.8-23.8 V controlled by state of charge
11.0 / 22.0 V controlled by voltage
Load reconnect voltage 12.8 / 25.6 V
Temperature compensa-
tion
-4 mV/cell*K
Max. solar panel current 5 / 8 / 10 / 15 / 20 A according to model number @
50°C
Max. load current 5 / 8 / 10 / 15 / 20 A according to model number @
50°C
Dimensions 80 x 100 x 32 mm (w x h x d)
Weight 180 gr
Max. wire size 16 mm² (AWG #6)
Self consumption 4 mA
Ambient temperature
range
-25 to + 50 °C
Case protection IP 20
Subject to change without notice. Version: CML041214
Made in one of the following countries: Germany – China – Bolivia - India
Phocos AG – Germany www.phocos.com