PowMr Pstar-30A 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; refer to the “2 Installation and Connection” section for more detail.
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; refer to the “2.4 Wiring Specification and Breaker Type”
section for more detail.
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 Production Instructions......................................................................................................... 4
1.1 Features ...................................................................................................................... 5
1.2 Production Overview.................................................................................................... 6
2 Installation and Connection .................................................................................................. 7
2.1 Unpacking and Inspection............................................................................................ 7
2.2 Preparing for Installation .............................................................................................. 7
2.3 Things You Need.......................................................................................................... 8
2.4 Wiring Specification and Breaker Type ......................................................................... 9
2.5 PV Module Selection.................................................................................................... 9
2.6 Wiring Precautions..................................................................................................... 10
2.7 Installation and Connection Step-By-Step ...................................................................11
3 Operation Mode.................................................................................................................... 13
3.1 Charge Algorithm ....................................................................................................... 13
3.2 Alarm Function........................................................................................................... 14
4 Operation Instruction........................................................................................................... 15
4.1 Operation Interface Introduction................................................................................. 15
4.2 Browse and Configuration Parameter Step-By-Step................................................... 16
4.3 Key Points of Battery Parameter Settings................................................................... 20
5 Protection ............................................................................................................................. 22
5.1 Protection Provided.................................................................................................... 22
5.2 Troubleshooting ......................................................................................................... 22
5.3 Maintenance .............................................................................................................. 23
6 Technical Specification........................................................................................................ 24
Table of Contents

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1 Production Instructions
Thank you for choosing the Pstar Series of Solar Power Controllers. The controller uses numerical
control technology design, LCD display, automatic operation. Its pulse-width modulation (PWM) type
battery charging mode, as well as control technology, will greatly extend the battery life.
This controller is suitable for the solar energy system (independent system), control the charging and
discharging process automatically. The battery charging and discharging process of the controller is
optimized, which can prolong the battery life and improve the system performance. Its self-test
function and electronic protection function can avoid controller damage due to installation errors and
system failures.

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1.1 Features
⚫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
Automatic identification of 12V/24V/36V/48V system voltage.
⚫Multi-stage charge algorithm
The multi-stage charge algorithm is specifically engineered to optimise 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 over discharging.
iv. Protection against reverse polarity connection: No damage to the controller will result, when
polarity is reversed. And the controller will not work.
v. 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 compatible
Compatible with Li-ion (LiFePO₄) batteries; when the battery type parameter is set to Lithium battery
the charge cycle settings are altered to suit.
Warning: Do not charge Li-ion batteries if the battery temperature is below 0°C.

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1.2 Production Overview
1
LCD display
5
Load port
2
Function keys
6
USB port
3
PV input port
7
Mounting hole (4 x Ø5mm)
4
Battery port
8
Heat sink

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2 Installation and Connection
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 Pstar 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.

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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 Things You Need
Make sure you have all the parts you need to install and connect the Pstar Controller:
Item
Quantity
Pstar 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
3
DC-cable to connect the negative DC connection (-) of the Pstar Controller to the
negative polarity of DC input or DC output
3
DC breaker
3
Screw fitting (Ø 5mm) to mount the controller to a surface. Use mounting materials
which are suitable to carry the weight of the Pstar Controller.
4
PV array. See section “2.5 PV Module Selection” for the configuration of solar panels
1
Battery pack.
1
NOTICE
⚫For all wirings and circuits breaker specifications see section “2.4 Wiring Specification and
Breaker Type”.

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2.4 Wiring Specification and Breaker Type
➢PV input cable specifications and circuit breaker type: Determine the maximum PV input
current based on the configured system voltage and by referring to “6 Technical Specification”.
Note: The voltage in series shall not exceed maximum PV input open-circuit voltage.
➢Recommended wire diameter and breaker type for DC output (DC load side):
Model
Max. DC output Current
Wire Diameter
Circuit Breaker Spec
Pstar-30A
20A
10AWG
2P-20A
Pstar-60A
35A
8AWG
2P-35A
Pstar-80A
50A
6AWG
2P-50A
➢The cables and circuit breakers of the battery should be selected based on the maximum
charging current of the battery you connected.
2.5 PV Module Selection
When selecting proper PV modules, please be sure to consider below parameters:
1. Open circuit Voltage (Voc) of PV modules not exceeds max. PV array open circuit voltage of
controller.
2. Open circuit Voltage (Voc) of PV modules should be higher than Min. battery voltage.
Controller Model
Pstar-30A
Pstar-60A
Pstar-80A
Max. PV array open circuit voltage
of controller
100Vdc
100Vdc
100Vdc

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2.6 Wiring Precautions
a. Let installation and connection work be done by a licensed electrician.
b. To avoid short circuit and reverse polarity connection, ensure that the positive cable is
connected to the positive polarity port (+) of the device, and the negative cable is connected to
the negative polarity port (-) of the device.
c. Too-thin cables and/or loose connections can cause dangerous overheating of the cables
and/or terminals. Therefore, tighten all connections well, in order to limit transition resistance as
far as possible. Use cables of the correct size. Please refer “2.4 Wiring Specification and
Breaker Type” section for details.
d. Do not connect the inverter to the load side of the controller. Otherwise, irreversible damage
may be caused to the device. If you need to install an inverter, see the following system
application diagram of the controller.

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2.7 Installation and Connection Step-By-Step
1. Mark the position of the mounting spots on the wall based on the mount holes of the controller.
Then make 4 mounting holes in the wall with an electric drill according to the spots. Refer to the
" 2.2 Preparing for Installation" section for installation locations.
2. Insert the expansion rubber screw plug into the mounting holes.
3. Mount the controller vertically to the ground with terminals facing down; secure using the 4
mounting holes/slots on the base. To aid installation, it is recommended to 'hang' the unit using
the 2 upper screws and then add the 2 lower screws, before fully securing all 4 screws.
Recommend screws size is M5.
4. Battery Connection: Connect the battery to the controller with the cables.
NOTICE
⚫All wiring must be performed by a qualified personnel.
⚫For safe operation and standard application, a circuit breaker of the corresponding
specifications must be installed on the cable connecting to the controller. And confirm that
the wire used is thick enough. Please refer “2.4 Wiring Specification and Breaker Type”
section for selection of wiring and circuit breaker specifications.
⚫Ensure that all circuit breakers are open until all cables are connected.
⚫Connect the positive cable terminal to the positive port and the negative cable terminal to the
negative port.
⚫The above precautions also apply to the wiring of the PV side and the load side.

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5. PV Connection: Connect the PV array to the controller with the cables.
6. DC Output Connection: Connect the load to the controller with the cables.
7. Check before starting up: See figure as shown below for wiring details. If everything is all right,
and all the wires are firmly connected, close the circuit breakers at the battery side, PV module
side, and load side in sequence to startup controller.
WARNING: Risk of electric shock!
⚫Make sure that all the power is turned off before connection, and then follow the
corresponding inspections and operations.

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3 Operation Mode
3.1 Charge Algorithm
The battery charging controller is equipped with an intelligent 3-stage charge characteristic which
takes care of an optimal charge of your batteries. When switched on, the Pstar Controller always
starts at Bulk stage.
There are 3 integrated charge modes (Bulk, boost, float). Through the three stages of fast, efficient
and safe battery charging mode, the system can effectively extend the battery life.
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.
The charging mode parameters can be set as required via LCD screen. Please refer to the “4.2
Browse and Configuration Parameter Step-By-Step” section for more information.
30mins

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Any setting made are stored and will not be lost when the controller is disconnected from battery or
PV module.
The multi-stage charge algorithm includes the individual charge stages described below:
➢Bulk charge:
The battery is charged at maximum charge current until the voltage increases to the configured
boost charging voltage. The bulk stage duration is dependent on the battery’s level of discharge,
the battery capacity and the charge current. When the battery voltage reaches the preset value of
the Boost charging voltage, it starts to boost charging.
➢Boost charge:
The battery is charged at the configured boost charging voltage, with the charge current slowly
decreasing as the battery approaches full charge.
The default boost stage duration is adaptive and intelligently varied depending on the battery’s level
of discharge –this is determined from the duration of the bulk charge stage.
When the photovoltaic module is reconnected, a new round of charging cycle will be started. If the
battery is in full state, the charging stage will directly enter stage B, which is the boost charging
voltage stage, and the battery voltage in this stage will not be higher than the set voltage of stage
B. Currently, the duration of stage B is 30 minutes.
➢Float charge:
At the end of the boost charging stage, the controller will reduce the battery voltage by reducing the
charging current and keep the battery continuously at the floating charging voltage set value to
maintain the full charge state of the battery.
In Float charging stage, loads are able to obtain almost all power from solar panel. If loads exceed
the power, the controller will no longer be able to maintain battery voltage in Float charging stage. If
the battery voltage remains below the Recharge Voltage, the system will leave Float charging stage
and return to Bulk charging stage.
3.2 Alarm Function
The battery controller is equipped with an integrated alarm function. For details about protection
and fault alarm, see “5 Protection” section.

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4 Operation Instruction
4.1 Operation Interface Introduction
Icon
Description
LCD Display
Indicates the PV input state: daytime state/night state.
Indicates the PV input voltage/ PV input current/ PV input power.
Indicates the remaining battery capacity.
Indicates the current battery voltage/ equipment temperature/ battery calibration
voltage/ battery type/ boost charging voltage/ float charging voltage/ low DC cut-off
recovery voltage/ low DC cut-off voltage.
Indicates DC output mode and DC output operation duration.
Indicates the fault codes.

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Function Keys
To switch the PV input parameters information/ Return the previous option.
To switch the charging information/ Enter the next option.
To adjust DC output mode and DC output operation duration/ Confirm and reserve
the settings.
4.2 Browse and Configuration Parameter Step-By-Step
After cables are connected and the device is started, perform the initial configuration according to
the following steps based on the actual situation.
4.2.1 PV side
Step 1. Checking PV input Information
Press “ ” key to switch PV information, which is PV input voltage, PV input current, and PV
input power in sequence.
NOTICE
⚫The screen will automatically turn off the backlight after 20 seconds without pressing a button
to save power consumption. The backlight display can be activated by operating the key
again.
⚫No matter how users switch display screen, it will automatically return to default display
screen (PV input voltage & current battery voltage & load enable duration) after no button is
pressed for 100 seconds.
PV Input Voltage PV Input Current PV Input Power

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4.2.2 Battery side
Step 1. Checking Battery Information
Press “ ” key to switch battery information, which is current battery voltage, equipment
temperature, battery calibration voltage, battery type, boost charging voltage, float charging voltage,
low DC cut-off recovery voltage, low DC cut-off voltage in sequence.
Step 2. Calibrate battery voltage
The battery calibration voltage parameter is used to correct the current battery voltage measured by
the controller. The specific operations are as follows:
a. Once the parameter switches to “the battery calibration voltage”item, press and hold “ ”
key to enter the battery voltage calibration setting.
b. Then press the “ ” or “ ” keys to calibrate the battery voltage parameters of the
controller according to the battery voltage measured by the multimeter. Finally press
“ ” to confirm.
Current Battery
Voltage
Equipement
Temperature
Battery Calibration
Voltage Battery Type
Boost Charging
Voltage
Float Charging
Voltage Low DC Cut-off Recovery Voltage
Low DC Cut-off
Voltage

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Step 3. Select the Battery Type
Adjust battery type parameters based on the battery you connected:
a. Once the parameter switches to the battery type item, press and hold “ ” key to enter
the battery type adjustment setting.
b. Then press “ ” or “ ” adjust battery type, finally press “ ” to confirm.
The operating voltage varies according to battery types.
c. For details, please refer “4.3.2 Battery parameters of different types” section.
Sequence
Display
Battery Type
1
SEL
Sealed lead acid battery
2
USE
User-defined
3
N14
Ternary lithium battery 14 strings
4
N13
Ternary lithium battery 13 strings
5
N07
Ternary lithium battery 7 strings
6
N06
Ternary lithium battery 6 strings
7
N03
Ternary lithium battery 3 strings
8
L16
Lithium iron phosphate battery 16 strings
10
L15
Lithium iron phosphate battery 15 strings
11
L08
Lithium iron phosphate battery 8 strings
12
L04
Lithium iron phosphate battery 4 strings
13
FLd
Vented lead acid battery
14
GEL
Colloidal lead acid battery
Step 4. Customize configured voltage parameters
a. Once the battery type is set to “USE”, the configurable parameters are presented in the following
order. Increment of each click is 0.1V.
NOTICE
⚫This step is required only when the battery type is set to “USE”.

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Item
Setting Range
Nominal system voltage
12V/24V/36V/48V (optional)
Boost charging voltage
9~17V
Float charging voltage
9~17V
Low DC cut-off recovery voltage
9~17V
Low DC cut-off voltage
8.4~17V
b. Press “ ” key to select parameter item which you need to adjust.
c. Then press and hold “ ” key to enter related parameter, then press “ ” or
“ ” adjust voltage value.
d. Finally press “ ” to confirm. Refer “4.3 Key Points of Battery Parameter Settings”
section for the logic for setting battery voltage parameters.
4.2.3 Load side
Step 1. Configurate load enable duration
a. Press and hold “ ” key to enter the load mode setting.
b. Then press “ ” or “ ” adjust load state or load enable duration
c. Finally press “ ” to confirm.
Nominal
system
voltage
Boost
charging
voltage
Float
charging
voltage
Low DC cut-
off recovery
voltage Low DC cut-
off voltage
NOTICE
⚫The 5 parameters as shown above can be set only when the battery type is “USE”. If “USE”
is selected, you need to manually set the system voltage.
CAUTION
⚫The preceding parameter ranges apply to the 12V battery. When the connected battery
voltage is 24V/36V/48V, the range values are 2/3/4 times of this range, respectively. And the
LCD only display the voltage values of the 12V battery.
WARNING
⚫The above Settings must follow the following logic: Boost charging voltage > Float charging
voltage > Low DC cut-off recovery voltage > Low DC cut-off voltage.