Renogy MPPT Series User manual

MPPT40CC
RENOGY 40A Maximum Power Point Tracking Solar
Charge Controller Manual
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14288 Central Ave., Suite A Chino, CA 91710
1-800-330-8678

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Contents
1. Important Safety Information 2
2. General Information 3
2.1 Overview 3
2.2 Optional Accessories 5
3. Installation Instructions 6
3.1 General Installation Notes 6
3.2 Mounting 6
3.3 Wiring 7
4. Operation 10
4.1 MPPT Technology 10
4.2 Battery Charging Information 12
4.3 LED Indications 13
4.4 Setting Operation 15
5. Protections, Troubleshooting and Maintenance 19
5.1 Protection 19
5.2 Troubleshooting 20
5.3 Maintenance 21
6. Warranty 22
7. Technical Specifications 23

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1.Important Safety Information
Save These Instructions
This manual contains important safety, installation and operating instructions for
the MPPT40CC controller. The following symbols are used throughout this
manual to indicate potentially dangerous conditions or mark important safety
instructions. Please take care when meeting these symbols.
WARNING: Indicates a potentially dangerous condition. Use extreme
caution when performing this task.
CAUTION: Indicates a critical procedure for safe and proper operation
of the controller
NOTE: Indicates a procedure or function that is important for the safe
and proper operation of the controller.
General Safety Information
•Read all of the instructions and cautions in the manual before beginning
installation.
•There are no user serviceable parts inside the MPPT40CC. Do not
disassemble or attempt to repair the controller.
•Disconnect the solar module and fuse/breakers near to battery before
installing or adjusting the MPPT40CC.
•Install external fuses/breakers as required.
•Do not allow water to enter the controller.
•Confirm that the power connections are tightened to avoid excessive
heating from a loose connection.

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2.General Information
2.1 Overview
The RENOGY MPPT series controller is suitable for off-grid solar applications. It
protects the battery from being over-charged by the solar modules and over-
discharged by the loads. The controller features a smart tracking algorithm that
maximizes the energy from the solar PV module(s) and charge the battery. At the
same time, the low voltage disconnect function (LVD) will prevent the battery
from over discharging.
The MPPT40CC controller charging process has been optimized for long battery
life and improved system performance. The comprehensive self-diagnostics and
electronic protection functions can prevent damage from installation mistakes or
system faults. In addition, the MPPT40CC controller has a RJ45 interface to
allow communication with a meter for remote monitoring. The MPPT40CC has
the following features:
•12V / 24V auto recognition.
•Advanced maximum power point tracking technology to optimize the use
of the PV system.
•Peak conversion efficiency of 97 %, high Tracking efficiency of 99%.
•Fast sweeping of the entire I-V curve, several seconds tracking speed.
•Widely used, automatic recognition of day and night.
•Timer function with 1-15 hour option for streetlight.
•Unique dual timer function; enhance the flexibility lighting systems.
•Sealed, Gel and Flooded battery option.
•Adopting temperature compensation and correcting the charging and
discharging parameters automatically, improving battery lifetime.
•Electronic protection: Overcharging, over-discharging, overload, and short
circuit.
•Reverse protection: Any combination of solar module and battery, without
causing damage to any component.
•Excellent thermal design and natural air-cooling.
•RJ45 interface for use with the remote meter MT-5, convenient to check
operating parameters of controllers.
Although the MPPT40CC controller is very simple to configure and use, please
take your time to read the operator's manual and become familiar with the
controller. This will help you make full use of all the functions and improve your
solar PV system.

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Description of MPPT40CC controller:!
Figure 2-1 MPPT40CC Characteristics
1. Charging Status LED indicator
2. Battery Status LED indicator
3. Temperature Sensor
4. Setting Indicators
5. LED Digital Display the load work mode and status.
6. Setting Button (in manual mode used for load ON/OFF)
7. Solar Module Terminals
8. Battery Terminals
9. Load Terminals
10. RJ45 Communication Interface (for remote meter MT-5)

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2.2 Optional Accessories
Remote Meter (Model: MT-5)
The digital remote meter displays system operating information, error indications,
and self-diagnostics read-out. Information is displayed on a backlit LCD display.
The large numerical display and icons are easy to read and large buttons make
navigating the meter menus easy. The meter can be flush mounted in a wall or
surface mounted using the mounting frame (included). The MT-5 is supplied with
2 m of cable and a mounting frame. The MT-5 connects to the RJ45 port on the
MPPT40CC.

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3.Installation Instructions
3.1 General Installation Notes
•Read through the entire installation section first before beginning
installation.
•Be very careful when working with batteries. Wear eye protection. Have
fresh water available to wash and clean any contact with battery acid.
•Uses insulated tools and avoid placing metal objects near the batteries.
•Explosive battery gasses may be present during charging. Be certain
there is sufficient ventilation to release the gasses.
•Avoid direct sunlight and do not install in locations where water can enter
the controller.
•Loose power connections and/or corroded wires may result in resistive
connections that melt wire insulation, burn surrounding materials, or even
cause fire. Ensure tight connections and use cable clamps to secure
cables and prevent them from swaying in mobile applications.
•Use with Gel, Sealed or Flooded batteries only.
•Battery connection may be wired to one battery or a bank of batteries. The
following instructions refer to a single battery, but it is implied that the
battery connection can be made to either one battery or a group of
batteries.
•Select the system cables according to 3A/mm2 current density.
3.2 Mounting
NOTE: When mounting the MPPT40CC, ensure free airflow through
the controller heat sink fins. There should be at least 150mm of clearance
above and below the controller to allow for cooling. If mounted in an
enclosure, ventilation is highly recommended.
WARNING: Risk of explosion! Never install the MPPT40CC in a sealed
enclose with flooded batteries! Do not install in a confined area where
battery gas can accumulate.

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Step 1: Choose mounting location
Locate the MPPT40CC on a vertical surface protected from direct sunlight, high
temperature, and water.
Step 2: Check for Clearance
Place the MPPT40CC in the location where it will be mounted. Verify that there is
sufficient room to run wires and that there is sufficient room above and below the
controller for airflow.
Step 3: Mark Holes
Use a pencil or pen to mark the four (4) mounting hole locations on the mounting
surface.
Step 4: Drill Holes
Remove the controller and drill four sizeable holes in the marked locations.
Step 5: Secure Controller
Place the controller on the surface and align the mounting holes with the drilled
holes in step 4. Secure the controller in place using the mounting screws.
3.3 Wiring
NOTE: A recommended connection order has been provided for
maximum safety during installation.
NOTE: The MPPT40CC is a negative ground controller. Any negative
connection of the solar module, battery or load can be earth grounded.
CAUTION: Don’t connect the loads with surge power exceeding the
ratings of the controller.
CAUTION: For mobile applications, be sure to secure all wiring. Use
cable clamps to prevent cables from swaying when the vehicle is in motion.
Unsecured cables create loose and resistive connections, which may lead
to excessive heating and/or fire.

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Step 1: Battery Wiring
WARNING: Risk of explosion or fire! Never short circuit battery
positive (+) and negative (-) or cables
Figure 3-1 Battery wiring
Before connecting the battery, measure the battery voltage. It must be over 9V to
power the controller. For 24V, the voltage must be greater than 18V to properly
detect a 24V battery. The 12/24V battery detection is automatic and the check is
only performed at start-up.
Wire an in-line fuse holder no more than 150mm from the battery positive
terminal. Do not insert a fuse at this time. Confirm the connection correct and
then turn on the power.
Step 2: Load Wiring
The MPPT40CC load output can connect DC electronic devices of which the
rated voltage is the same as the battery. MPPT40CC will provide battery the
voltage to the loads. See Section 4.4 Setting Operation for more details about the
load control.
Figure 3-2 Load wiring
Connect load positive (+) and negative (-) to the MPPT40CC load output as
shown in figure 3-2. Exercise caution when connecting to the load terminals,
there may be an existing voltage, which may cause a short circuit. An in-line fuse
holder should be wired in series in the load positive (+) or negative (-) wire as

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shown. Do not insert a fuse at this time. Confirm the connection is correct and
then turn on the power.
If wiring the load connection to a load distribution panel, each load circuit should
be fused separately. The total load draw should not exceed the 20A load rating.
Step 3: Solar Module Wiring
WARNING: Risk of electric shock! Exercise caution when handling
solar wiring. The solar module(s) high voltage output can cause severe
shock or injury. Cover the solar module(s) from the sun before installing
solar wiring.
The MPPT40CC can accept 12V or 24V nominal off-grid solar module arrays.
Grid-tie solar module(s) may be used if the open circuit voltage does not exceed
the maximum solar input rating. The solar module(s) nominal voltage must be
equal to or greater than the nominal battery voltage.
Figure 3-3 Solar Module wiring
Step 4: Accessories (option)
Install Remote Meter (purchased separately) if required. Refer to the instructions
provided for detailed installation procedures.
Step 5: Confirm Wiring
Double-check the wiring in step1 through 4. Confirm correct polarity at each
connection. Verify that all power terminals are tightened.
Step 6: Confirm Power-up
When battery power is applied and the MPPT40CC powers up, the battery led
indicator will be green. If the MPPT40CC does not power-up or battery status
LEDs error exists, refer to Section 5 “Troubleshooting”

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4. Operation
4.1 MPPT Technology
The MPPT40CC utilizes Maximum Power Point Tracking technology to extract
maximum power from the solar module(s). The tracking algorithm is fully
automatic and does not require user adjustment. MPPT technology will track the
array’s maximum power point voltage (Vmp) as it varies with weather conditions,
ensuring that the maximum power is harvested from the array throughout the
course of the day.
Current Boost
In many cases, MPPT40CC MPPT technology will boost the solar charge
current. For example, a system may have 8 Amps of solar current flowing into the
charge controller and 10 Amps of charge current flowing out to the battery. The
MPPT40CC does not create current! Rest assured that the power into the charge
controller is the same as the power out of the MPPT40CC. Since power is the
product of voltage and current (Volts ×Amps), the following is true*:
•Power Into the controller = Power Out of the controller
•Volts In ×Amps In = Volts Out ×Amps Out
*Assuming 100% efficiency. Actually, the losses in wiring and conversion exist. If
the solar module’s Vmp is greater than the battery voltage, it follows that the
battery current must be proportionally greater than the solar input current so that
input and output power are balanced. The greater the difference between the
maximum power voltage and the battery voltage, the greater the current
boost.Current boost can be substantial in systems where the solar array is of a
higher nominal voltage than the battery.
An Advantage Over Traditional Controllers
Traditional controllers connect the solar module directly to the battery when
recharging. This requires that the solar module operate in a voltage range that is
below the module’s Vmp. In a 12V system for example, the battery voltage may
range from 11-15Vdc but the module’s Vmp is typically around 16 or 17V.Figure
4-1 shows a typical current vs. voltage output curve for a nominal 12V off-grid
module.

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Figure 4-1 Nominal 12V Solar Module I-V curve and output power graph
The array Vmp is the voltage where the product of current and voltage (Amps ×
Volts) is greatest, which falls on the knee of the solar module I-V curve as shown
in Figure 4-1. Because Traditional controllers do not operate at the Vmp of the
solar modules(s), energy is wasted that could otherwise be used to charge the
battery and power system loads. The greater the difference between battery
voltage and the Vmp of the module, the more energy is wasted.
MPPT40CC MPPT technology will always operate at the Vmp resulting in less
wasted energy compared to traditional controllers.
Conditions that Limits the Effectiveness of MPPT
The Vmp of a solar module decreases as the temperature of the module
increases. In very hot weather, the Vmp may be close or even less than battery
voltage. In this situation, there will be very little or no MPPT gain compared to
traditional controllers. However, systems with modules of higher nominal voltage
than the battery bank will always have an array Vmp greater than battery voltage.
Additionally, the savings in wiring due to reduced solar current make MPPT
worthwhile even in hot climates.
Typical Battery
Voltage Range
Maximum
Power Point
Traditional
Controller
Operating
Range
Maximum
Power Point
Current vs. Voltage (12V System)
Output Power (12V System)

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4.2 Battery Charging Information
Four Charging Stages
The MPPT40CC has a 4-stage battery-charging algorithm for rapid, efficient, and
safe battery charging.
Figure 4-2 MPPT40CC MPPT charging algorithm
Bulk Charge
In this stage, the battery voltage has not yet reached boost voltage and 100% of
available solar power is used to recharge the battery.
Boost Charge
When the battery has recharged to the Boost voltage set point, constant-voltage
regulation is used to prevent heating and excessive battery gassing. The Boost
stage remains 120 minutes and then goes to Float Charge. Each time when the
controller is powered on, it checks if the battery is over-discharged or
overvoltage. If none of these conditions are encountered, the controller will enter
into boost charging stage.
Float Charge
After the Boost voltage stage, MPPT40CC will reduce the battery voltage to float
voltage set point. When the battery is fully recharged, there will be no more
chemical reactions and all the charge current transforms into heat and gas at this
point. The controller reduces the voltage to the floating stage, charging with a
smaller voltage and current. It will reduce the temperature of battery and prevent
gassing, but charging the battery slightly at the same time. The purpose of Float
stage is to offset the power consumption caused by self-consumption and small
loads in the whole system, while maintaining full battery storage capacity.
In Float stage, loads can continue to draw power from the battery. In the event
that the system load(s) exceed the solar charge current, the controller will no
longer be able to maintain the battery at the Float set point. Should the battery
voltage remains below the boost reconnect charging voltage, the controller will
exit Float stage and return to Bulk charging.

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Equalize
WARNING: Risk of explosion! Equalizing flooded batteries can
produce explosive gases, so a well-ventilated battery box is necessary.
NOTE: Equipment damage! Equalization may increase battery
voltage to a level damaging to sensitive DC loads. Ensure that all load
allowable input voltages are greater than the equalizing charging set point
voltage.
NOTE: Equipment damage! Over-charging and excessive gas
precipitation may damage the battery plates and activate material shedding
on them. Too high an equalizing charge or for too long may cause damage.
Please carefully review the specific requirements of the battery used in the
system.
Certain types of batteries benefit from periodic equalizing charge, which can stir
the electrolyte, balance battery voltage and complete chemical reaction.
Equalizing charge increases the battery voltage, higher than the standard
complement voltage, which gasifies the battery electrolyte.
If it detects that the battery is being over discharged, the solar controller will
automatically turn the battery to equalization charging stage, and the equalization
charging will be 120 minutes. Equalizing charge and boost charge are not carried
out constantly in a full charge process to avoid too much gas precipitation or
overheating of battery.
4.3 LED Indications
Figure 4-3 Charge controller LED indicators
LED Digital Display
Battery Indicator
Charging Indicator

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Charging Indicator
The green LED indicator will turn on whenever sunlight is available for battery
charging. Under normal charging conditions, the green charging LED will stay on
at all times. The charging LED indicator flashes when the battery reaches over-
voltage. Please refer to section 5 for troubleshooting.
Color
Indication
Operating State
Green
On Solid
Charging
Green
Flashing
Battery over-voltage
Table 4-1 Charging LED indicators
Battery Indicator
Color
Indication
Operating State
Green
On Solid
Normal (battery)
Green
Flashing
Full (battery)
Orange
On Solid
Low (battery)
Red
On Solid
Over Discharged (battery)*
Table 4-2 Battery LED indicators
*Please refer to Chapter 5 for troubleshooting
PV Overvoltage Display
If the solar input open circuit voltage (Voc) exceeds the maximum rating, the
array will remain disconnected until the Voc falls safely below the maximum
rating.
Color
Indication
Operating State
Red
LED Digital Display shows letter “P"
PV Overvoltage
Table 4-3 PV Overvoltage LED Display
PV Overcurrent Display
If the solar input current exceeds the maximum rating, the array will be
disconnected automatically.
Color
Indication
Operating State
Red
LED Digital Display shows letter “C"
PV Overcurrent
Table 4-4 PV Overcurrent LED Display

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Load indicator
When the load amperage is 1.25 times of rated current for 60 seconds, 1.5 times
of rated current for 5 seconds (overload), or there is a load short circuit, the
Battery LED indicator will be flashing RED. Please refer to section 5 for
troubleshooting.
Color
Indication
Load Status
Red
Battery indicator flashing red
Overload or Short circuit
Table 4-5 Load LED indicators
4.4 Setting Operation
Dual Timer Function
Figure 4-4 Dual timer function diagram
The default night length is 10 hours. The controller can learn the night length
referring to the previous night so as to adapt to the different seasons. However, it
will take some time to learn it.
Notes: When the “OFF” time set on Timer 2 is later than local sunrise
time, the controller will turn off the load output at sunrise.
Load Control Settings
1. Dusk-to-Dawn (Light ON + Light OFF)
When solar module voltage goes below the point of NTTV (Night Time Threshold
Voltage) at sunset, the solar controller will recognize the starting voltage and turn
on the load after 10 minutes delay; When solar module voltage goes above point
of DTTV (Day Time Threshold Voltage), the solar controller will recognize the
starting voltage and turn off the load after 10 minutes delay.
2. Light ON + Timer (1-15H on)
When solar module voltage goes below the point of NTTV (Night Time Threshold
Voltage) at sunset; the solar controller will recognize the starting voltage and turn

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on the load after 10 minutes delay for several hours which users set on the timer.
The timer setting operation is referred to as “Load Work Mode Setting”.
3. Test Mode
It is used to test the system and the same as Dusk to Dawn. But there is no 10-
minute delay when controller recognizes the starting voltage. When below the
starting voltage, the controller will turn on the load, if higher, it will turn off load.
The test mode makes it easy to check the system installation.
4. Manual Mode
This mode is to turn on/off the load by the Setting button.
Load Work Mode Setting
Figure 4-5 Instruction figure on setting
Press the setting button once and the setting indicators will be changed once
among Timer 1, Timer 2 and battery type.
When Timer 1 setting indicator is on, press the setting button for more than 5
seconds until the LED digital display flashes. Then press the setting button until
the desired number appears according to the Table 4-6. The setting is finished
when the digital display stops flashing.
Likewise, Timer 2 set-up instructions are the same as Timer 1 using Table 4-7 as
reference.

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Timer 1
LED Digital No.
Disable
n
Dusk-to-Dawn, Load will be on all night
0
Load will be on for 1 hour after a ten minute delay since sunset
1
Load will be on for 2 hours after a ten minute delay since sunset
2
Load will be on for 3 hours after a ten minute delay since sunset
3
Load will be on for 4 hours after a ten minute delay since sunset
4
Load will be on for 5 hours after a ten minute delay since sunset
5
Load will be on for 6 hours after a ten minute delay since sunset
6
Load will be on for 7 hours after a ten minute delay since sunset
7
Load will be on for 8 hours after a ten minute delay since sunset
8
Load will be on for 9 hours after a ten minute delay since sunset
9
Load will be on for 10 hours after a ten minute delay since sunset
10
Load will be on for 11 hours after a ten minute delay since sunset
11
Load will be on for 12 hours after a ten minute delay since sunset
12
Load will be on for 13 hours after a ten minute delay since sunset
13
Load will be on for 14 hours after a ten minute delay since sunset
14
Load will be on for 15 hours after a ten minute delay since sunset
15
Test mode
16
ON/OFF mode
17
Table 4-6 Load work mode
Timer 2
LED Digital No.
Disable
n
Load will be on for 1 hour before sunrise
1
Load will be on for 2 hours before sunrise
2
Load will be on for 3 hours before sunrise
3
Load will be on for 4 hours before sunrise
4
Load will be on for 5 hours before sunrise
5
Load will be on for 6 hours before sunrise
6
Load will be on for 7 hours before sunrise
7
Load will be on for 8 hours before sunrise
8
Load will be on for 9 hours before sunrise
9
Load will be on for 10 hours before sunrise
10
Load will be on for 11 hours before sunrise
11
Load will be on for 12 hours before sunrise
12
Load will be on for 13 hours before sunrise
13
Load will be on for 14 hours before sunrise
14
Load will be on for 15 hours before sunrise
15
Table 4-7 Load work mode
Notes: If Timer 1 is Dusk-to-Dawn (0), Test mode (16) or ON/OFF
mode (17), Timer 2 will be disabled (n).

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Battery Type Setting
When the Battery setting indicator is on, press the “Setting” button and hold on 5
seconds until the battery type LED turns on. The led will be flashing. Continue to
hold and the number will repeat from 1 to 3, and stop pressing until the desired
number appears according to the following setting table:
Battery type
Digital display
Sealed lead acid battery
1
Gel battery
2
Flooded battery
3
Table 4-8 Battery type setting

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5. Protections, Troubleshooting and
Maintenance
5.1 Protection
PV Array Short Circuit
If PV array short circuit occurs, clear it to resume normal operation.
PV Overvoltage
If PV Overvoltage occurs, the array will remain disconnected until the voltage
falls safely below the maximum rating.
PV Overcurrent
If PV Overcurrent occurs, the array will be disconnected automatically.
Load Overload
If the load current exceeds the maximum load current rating, the controller will
disconnect the load. Reapplying power or pressing the setting button will clear up
the overloading fault.
Load Short Circuit
Fully protected against load wiring short-circuit. After one automatic load
reconnect attempt. Reapplying power or pressing the setting button will clear the
fault.
PV Reverse Polarity
Full protection against PV reverse polarity, no damage to the controller will result.
Correct the wire connection to resume normal operation.
Battery Reverse Polarity
Full protection against battery reverse polarity, no damage to the controller will
result. Correct the wire connection to resume normal operation.
Damaged Local Temperature Sensor
If the temperature sensor short-circuited or damaged, the controller will be
charging or discharging at the default temperature 25°C to prevent the battery
damaged from overcharging or over discharged.