PowMr POW-Boost 10A User manual

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Important Safety Instructions
WARNING: CAREFULLY READ AND FOLLOW ALL SAFETY INSTRUCTIONS
⚫Carefully read the manual before the controller is installed and operated; retain the manual in a
safe place for future reference.
⚫The controller must not be installed or operated by any of the following persons, unless they are
under strict instruction and supervision:
a. Anyone who lacks the appropriate knowledge, experience or competence, required for safe
installation and/or usage.
b. Anyone with compromised/reduced physical, sensory or mental capabilities, which may effect
safe installation and/or usage (including children).
⚫Controller installation and operation
a. There are no serviceable parts for this controller. Do NOT disassemble or attempt to repair the
controller.
b. Install the controller in a location with good natural airflow/ventilation and sufficient unobstructed
space around it.
c. Install the controller on a non-flammable substrate and ensure there are no heat-sensitive items
in the immediate vicinity; it is normal for the controller to become hot during operation.
d. Install the controller in a location where it is protected from environmental conditions such as
direct sunlight, water, high moisture and dust, and also located well away from any flammable
liquids or gasses. Controller is for indoor use only.
e. Do not install or place/operate the controller on top of the battery, directly above the battery, or
in a sealed compartment with the battery; batteries can emit explosive gasses.
f. Do not cover or place any other items on top of the controller.
⚫Battery installation and charging
a. Install and charge the battery in a location with good natural airflow/ventilation.
b. Ensure that there are no ignition sources near the battery; batteries can emit explosive gasses.
c. Battery acid is corrosive; if battery acid comes into contact with skin immediately rinse with water.
d. Do not charge non-rechargeable batteries. And Do Not charge Li-ion batteries if the battery
temperature is below 0°C. Never charge a frozen battery.
e. Ensure that the unit is properly set up for the type of battery intended to be charged.

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⚫Battery DC connections
a. Ensure that the DC system is fully shut down/isolated prior to disconnection of any existing
cabling and/or new connections are made to the battery/DC system.
b. Use flexible multi stranded copper cable with sufficient cross sectional area, inline with an
appropriate fuse or circuit breaker.
c. NEVER connect the solar panel array to the controller without a battery. Battery must be
connected first.
⚫Controller setup
a. Refer to the battery manufacturers instructions and specifications to ensure the battery is
suitable for use with this controller and confirm the recommended charge settings.
b. The integrated charge modes combined with adaptive charge logic are well suited for most
common battery types; such as flooded lead-acid, Gel and LiFePO4.

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Important Safety Instructions........................................................................................1
1 General Information ....................................................................................................4
1.1 Function .............................................................................................................5
1.2 Product Overview...............................................................................................7
1.3 Product Dimension.............................................................................................8
2 Installation..................................................................................................................10
2.1 Unpacking and Inspection ................................................................................10
2.2 Preparing for Installation ..................................................................................10
2.3 Installation Steps..............................................................................................11
3 Connection.................................................................................................................12
3.1 Things You Need..............................................................................................12
3.2 Wiring Precautions ...........................................................................................12
3.3 Connection Steps.............................................................................................13
4 Operation....................................................................................................................14
4.1 Operation Interface Introduction.......................................................................14
4.2 Viewing and Configuration Guide for Parameters ............................................15
5 Protection and Troubleshooting ..............................................................................18
5.1 Protection .........................................................................................................18
5.2 Troubleshooting................................................................................................18
5.3 Maintenance.....................................................................................................19
6 Technical Specification.............................................................................................20
Table of Contents

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1 General Information
The core of the PowMr Boost-Type Solar Charge Controller lies in its adoption of cutting-edge
boost converter circuitry. This sophisticated circuit intelligently elevates the voltage output from
solar panels and matches the optimal charging voltage for batteries. By precisely adjusting the
voltage, the controller maximizes energy transfer efficiency, capturing every available watt of solar
power.
The PowMr controller incorporates advanced Maximum Power Point Tracking (MPPT) technology
to ensure that solar panels operate at their highest power output. Through continuous monitoring
and adjustment of the operating voltage point of the photovoltaic input, MPPT optimizes energy
capture under varying environmental conditions. This results in superior charging efficiency and
increased power generation, maximizing the utilization of solar energy for battery charging.
While focusing on high-efficiency operation, PowMr also prioritizes safety and protection. The
Boost-Type Solar Charge Controller integrates multiple protection mechanisms, including
overcharge, short circuit, and reverse current protection. These measures safeguard your
equipment and batteries from damage, providing reliable and secure charging performance.
The design of an LCD display allows for comprehensive monitoring of the controller's charging
status and real-time data. The display supports configuration of specific operational programs via
user-friendly operation buttons, catering to specific application requirements. Real-time data on
photovoltaic input voltage, battery charge status, charging current, voltage, and more are easily
accessible. This enables users to monitor system performance from various angles and make
informed decisions to optimize energy management.
General Information

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1.1 Function
⚫Boost Voltage Charging Controller
Designed for scenarios where the photovoltaic input voltage is lower than the battery voltage, this
controller effectively boosts the voltage to match the battery's charging requirements. It overcomes
limitations caused by insufficient voltage from a single photovoltaic panel, ensuring reliable battery
charging.
⚫Integrated charge presets
Integrated charge presets combined with adaptive charge logic are well suited for most common
battery types, such as LiFePO4, Gel and flooded lead-acid.
⚫Flexible Application
Compatible with 24V/36V/48V/60V/72V system voltage.
⚫Multi-stage charge algorithm
The multi-stage charge algorithm is specifically engineered to optimize each recharge cycle and
charge maintenance over extended periods.
⚫Adaptive boost charge
Adaptive boost charge monitors the battery’s response during initial charging and intelligently
determines the appropriate boost charge duration for each individual charge cycle. This ensures
that the battery is fully recharged regardless of the discharge level or capacity and avoids excessive
time at the elevated boost charging voltage (that can accelerate battery aging).
⚫Durable and safe
i. Protection against overheating: When the equipment temperature exceeds 85℃, the control
automatically stops charging. Resume charging when the equipment temperature is 75 ℃.
ii. Protection against output short circuit.
iii. Protection against reverse polarity connection: No damage to the controller will result, when
polarity is reversed. And the controller will not work.
iv. Limit the maximum charging current. Protect battery performance and prolong battery life.
⚫Silent operation
Almost silent operation since there is no cooling fan or moving parts, cooling is via natural
convection.
⚫Lithium battery activation
Compatible with Li-ion (LiFePO₄) batteries; when the battery type parameter is set to Lithium battery
the charge cycle settings are altered to suit. Moreover, when the connected lithium battery is in a

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protected state, the controller will activate the lithium battery using the energy from the solar panel
with a current that does not exceed the lithium battery's protection voltage and current range.
Warning: Do not charge Li-ion batteries if the battery temperature is below 0°C.

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1.2 Product Overview
1. LCD display
2. Function Keys
3. PV Input port
4. Battery port
5. Install holes
6. Heat sink

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1.3 Product Dimension
NOTICE
⚫Dimensional measurement tolerance is ±0.5mm.

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2 Installation
2.1 Unpacking and Inspection
Before unpacking the controller, check whether the package is damaged. After unpacking, check
whether thecontents of the package are damaged ormissing. Youshould have received the following
items inside of package:
⚫Controller
⚫User manual
2.2 Preparing for Installation
The Controller range is designed to be wall mounted using the flanges which protrude from either
side of the heatsink backplane.
Select the Mount Location:
Before mounting, the following aspects should be considered to identify/provide a suitable and safe
location:
a. Install the controller in a location with good natural airflow/ventilation.
b. Ensure there is sufficient unobstructed space around the controller. The minimum spacing
between the top, bottom, and sides of the controller is 150mm.
c. Install the controller on a non-flammable substrate and ensure there are no heat-sensitive items
in the immediate vicinity; it is normal for the controller to become hot during operation.
Installation

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d. Install the controller in a location where it is protected from environmental conditions such as
water, high moisture and dust, and also located well away from any flammable liquids or gasses.
e. DO NOT install or place/operate the controller on top of the battery, directly above the battery, or
in a sealed compartment with the battery; batteries can emit explosive gasses.
f. DO NOT cover or place any other items on top of the controller.
g. Install the unit by screwing four screws. It’s recommended to use M5 screws.
2.3 Installation Steps
Step 1. Strictly adhere to the requirements and recommendations outlined in section 2.2 to select
the installation location.
Step 2. Inspect the surroundings and spatial environment of the installation location.
Step 3. Mark the installation holes.
Step 4. Drill the holes.
Step 5. Secure the controller using four M5 screws.

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3 Connection
3.1 Things You Need
Make sure you have all the parts you need to install and connect the Pstar Controller:
Item
Quantity
Controller (included)
1
DC-cable to connect the positive DC connection (+) of the Pstar Controller to the
positive polarity of DC input or DC output
2
DC-cable to connect the negative DC connection (-) of the Pstar Controller to the
negative polarity of DC input or DC output
2
DC breaker
2
PV array
1
Battery pack
1
3.2 Wiring Precautions
1. All wiring must be carried out by qualified professionals with appropriate qualifications.
2. Prioritize connecting the battery before connecting the photovoltaic array.
3. Do not install the controller and lead-acid batteries in an enclosed environment as the batteries
release explosive gases, which may pose a risk of explosion due to gas accumulation.
4. The controller can handle photovoltaic input voltage within the specified range. Exceeding the
maximum input voltage can damage the equipment, so please inspect the system before making
connections.
5. When considering wiring and circuit breaker configuration, refer to the relevant specifications to
determine the maximum current of the connected circuit. Choose the appropriate cable and
circuit breaker accordingly. Thicker cables enhance boost performance, while thinner cables
may reduce it. It is recommended to select cables that are both thick and short to minimize
resistance and avoid voltage drop.
6. Install separate DC circuit breakers for each circuit during the wiring process to facilitate safe
disconnection of the controller during maintenance or repair and provide adequate protection
against circuit overcurrent. The specifications of the circuit breakers should be configured based
on the maximum current of each circuit.
7. The ports of the controller are labeled with polarity markings for the photovoltaic input and
battery charging ports. Strictly follow the markings when connecting the cables to the
Connection

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photovoltaic and battery ends, ensuring that the positive (+) terminal is connected to the positive
(+) terminal and the negative (-) terminal is connected to the negative (-) terminal.
8. Keep each circuit breaker in the open position during the wiring process.
9. Tighten the port screws to avoid loose connections that can cause overheating at the ports,
posing a risk of circuit damage and potentially leading to a fire.
10.Before closing the circuit breakers, check if the cable terminals are securely connected and
ensure there are no reverse connections or errors.
3.3 Connection Steps
Step 1. Battery Wiring
Prioritize connecting the battery module before connecting the photovoltaic array. Install a separate
DC circuit breaker for the battery charging circuit.
Step 2. Photovoltaic Wiring
After confirming that the configured photovoltaic array voltage falls within the acceptable range of
the controller, connect the photovoltaic array. Install a separate DC circuit breaker on the
photovoltaic input line.
Step 3. Controller Startup
Once the battery and photovoltaic array are connected, check for any reverse connections or loose
connections in the cables. After confirming everything is correct, sequentially close the circuit
breakers for the battery charging circuit and photovoltaic input circuit to start the controller.

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4 Operation
4.1 Operation Interface Introduction
Icon
Description
LCD display
①
1. On the main screen, display the photovoltaic input data and operating
mode.
2. In the settings interface, display the setting options.
3. In the event of a fault state, display "ERR".
②
1. On the main screen, display the battery charging parameters and device
temperature.
2. In the settings interface, display the setting codes.
3. In the event of a fault state, display the fault codes, refer to section 5.2
"Troubleshooting" for details.
③
Indicate the battery charge status.
Function key
PRG/ESC
Used to enter or exit the setup program.
Navigate to the next screen or setting item/increase the setting value.
Go back to the previous screen or setting item/decrease the setting value.
ENTER
In the setup interface, enter a setting item or confirm the setting value.
Operation

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4.2 Viewing and Configuration Guide for Parameters
After successfully starting the device, please refer to the following guide to view and configure the
controller parameters based on your specific requirements.
4.2.1 Browsing Interface Data
On the main interface, use the " " and " " keys to toggle between different screen information.
Page
Left Side Parameters on the
Interface
Right Side Parameters on the Interface:
1
Photovoltaic Input Voltage
Current Battery Voltage
2
Photovoltaic Input Power
Charging Current
3
Operating Mode
Device Temperature
➢Operation Mode
Mode Code
Description
3.0
Standby state
4.0
MPPT State
7.0
Content Voltage charging state
8.0
Flooded charging state
4.2.2 Configuration Setup Program
To access the setup program interface, press the "PRG/ESC" key. Use the " " and " " keys to
navigate through the setting options. Press "ENTER" to enter a specific setting option. Adjust the
parameter values using the " " and " " keys, and press "ENTER" to confirm the settings.
Item
Program
Description
D01
Open Circuit Voltage of PV Input
The maximum voltage value of the photovoltaic
input sets the limit for the solar panel's input
voltage that the controller will allow. This
configuration is based on the maximum open-
circuit voltage of the solar panels.
D02
Bulk Charging Voltage
Specific to charging lithium batteries. This
parameter sets the maximum charging voltage for
lithium batteries.
D03
Float Charging Voltage
Specific to charging lead-acid batteries. After the
battery is fully charged, it will be maintained at a
weak current to keep the battery voltage at the
float charging voltage value.

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D04
Return-to-MPPT Charging
Voltage
When the battery voltage drops to this value, the
controller will enter a new charging cycle to charge
the battery.
D05
Maximum Charging Current
The maximum charging current of the controller.
Set according to the charging parameters of the
connected battery.
D06
Battery Voltage Calibration
Used to calibrate the battery voltage measured by
the controller when it does not match the voltage
measured by other devices such as a multimeter.
4.2.3 Charging P arameter Configuration Reference
Please refer to the table below for the appropriate charging parameters based on the battery type
you have connected.
For lead-acid battery:
System Voltage
Voltage control parameters
24V
36V
48V
60V
72V
Sealed
Boost charging voltage
28.8V
43.2V
57.6V
72V
86.4V
Float charging voltage
27.6V
41.4V
55.2V
69V
82.8V
Boost reconnect
charging voltage
26.4V
39.6V
52.8V
66V
79.2V
GEL
Boost charging voltage
28.4V
42.6V
56.8V
71V
85.2V
Float charging voltage
27.6V
41.4V
55.2V
69V
82.8V
Boost reconnect
charging voltage
26.4V
39.6V
52.8V
66V
79.2V
FLD
Boost charging voltage
29.2V
43.8V
58.4V
73V
87.6V
Float charging voltage
27.6V
41.4V
55.2V
69V
82.8V
Boost reconnect
charging voltage
26.4V
39.6V
52.8V
66V
79.2V

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Lithium iron phosphate battery:
Voltage control
parameters
Boost charging voltage
Float charging
voltage
Boost reconnect
charging voltage
7S
25.2V
24.5V
22.4V
8S
28.8V
28V
25.6V
11S
39.6V
38.5V
35.2V
12S
43.2V
42V
38.4V
15S
54V
52.5V
48V
16S
57.6V
56V
51.2V
18S
64.8V
63V
57.6V
19S
68.4V
66.5V
60.8V
22S
79.2V
77V
70.4V
23S
82.8V
80.5V
73.6V
For Ternary lithium battery:
Voltage control
parameters
Boost charging
voltage
Float charging
voltage
Boost reconnect
charging voltage
6S
25.2V
24.6V
22.8V
7S
29.4V
28.7V
26.6V
9S
37.8V
36.9V
34.2V
10S
42V
41V
38V
12S
50.4V
49.2V
45.6V
13S
54.6V
53.3V
49.4V
16S
67.2V
65.6V
60.8V
17S
71.4V
69.7V
64.6V
19S
79.8V
77.9V
72.2V
20S
84V
82V
76V

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5 Protection and Troubleshooting
5.1 Protection
No.
Protection
Description
1
Reverse Polarity
Fully protected against reverse polarity; no damage to the
controller will result. Correct the miswire to resume normal
operation
2
Maximum Charging
Current limit
Ensure safe charging current to prevent battery damage.
Protect battery performance and prolong battery life.
3
Short Circuit Protection
The controller shuts down output for one minute.
4
Controller Overheating
When the temperature exceeds 85 ℃, the control
automatically stops charging. Resume charging when the
temperature is 75℃.
5.2 Troubleshooting
In case of a failure, the Controller display shows an error signal to help you find its source.
Fault Code
Possible Cause
What to do
60
Temperature Too High
Once the device temperature cools down below the
recovery temperature, normal charging and
discharging will resume.
63
High Battery Voltage
Reconfigure parameters or verify if the battery voltage
exceeds the rated voltage, and also, consider shutting
off the photovoltaic array circuit breaker.
71
High PV Voltage
Reconfigure parameters or lower the voltage by
adjusting the series and parallel connections.
73
Excessive Charging
Current
Reduce the number of photovoltaic arrays connected
to the controller.
Protection and Troubleshooting

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5.3 Maintenance
The following inspections and maintenance tasks are recommended at least two times per year for
best performance.
⚫Make sure controller firmly installed in a clean and dry ambient.
⚫Make sure no block on air-flow around the controller. Clear up any dirt and fragments on heat
sink.
⚫Check all the naked wires to make sure insulation is not damaged for serious solarization,
frictional wear, dryness, insects or rats etc. Repair or replace some wires if necessary.
⚫Tighten all the terminals. Inspect for loose, broken, or burnt wire connections.
⚫Confirm that all the system components are ground connected tightly and correctly.
⚫Confirm that all the terminals have no corrosion, insulation damaged, high temperature or
burnt/discolored sign, and tighten terminal screws.
⚫Check for dirt, nesting insects and corrosion. If so, clear up in time.
WARNING: Risk of electric shock!
⚫Make sure that all the power is turned off before above operations, and then follow the
corresponding inspections and operations.

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6 Technical Specification
Model
POW-Boost 10A
PV Input
PV Input Voltage
15~25V
25~48V
48~60V
PV Input Power
≤150W
≤250W
≤400W
System Voltage
24/36/48/60/72V
48/60/72V
60/72V
Charging Mode
Charging technology
MPPT
Charge Algorithm
3-Stage
Self-consumption
<2W
Nominal System Voltage
24V/36V/48V/60V/72V
Battery Voltage Range
20~88V
Environment
Operating Temperature
Range
-35℃~+65℃
Humidity Range
≤95%
General Specification
Protection Class
IP32
Dimension
140*85*50mm
Net weight
305g
Technical Specification