TBB power MPPT User manual

MPPT charge controller User Manual

MPPT charge controller User Manual
WARNING: HIGH VOLTAGE INSIDE
CAUTION: THE DC FUSE MUST HAVE BEENTURNED OFF BEFORE SERVICING
MADE IN CHINA

MPPT charge controller User Manual
Disclaimer
Unless specially agreed in writing, TBB Power Co.,Ltd
Take no warranty as to the accuracy, sufficiency of suitability of any technical or other
information provided in this manual or other documentation.
Assumes no responsibility or liability for loss or damage, whether direct, indirect, consequential
or incidental, which might arise out of the use of such information.
TBB offer standard warranty with its products, taking no responsibility for direct or indirect loss
due to equipment failure.
About this Manual
This manual describes our product features and provides procedure of installations. This manual is
for anyone intending to install our equipment.
General Instruction
Thanks for choosing our products and this manual were suitable for Solar Mate series MPPT.
This chapter contains important safety and operation instructions. Read and keep this User Guide
well for later reference.
MPPT charge controller will have high voltage inside, Solar Mate MPPT charge controller needs to
be installed by professionals and only authorized electrician can open the case.

MPPT charge controller User Manual
C Co on nt te en nt ts s
1. General Safety Instruction........................................................................................................ 1
1.1 Safety Instruction................................................................................................................1
1.2 General Precaution ............................................................................................................1
1.3 Precaution regarding battery operation...............................................................................1
2. Instruction .................................................................................................................................2
2.1 Brief Instruction ..................................................................................................................2
2.1.1 General Description ..................................................................................................2
2.1.2 Naming Rules ...........................................................................................................2
2.2 Structure ............................................................................................................................3
2.2.1 Front.........................................................................................................................3
2.2.2 Connection compartment.......................................................................................... 4
2.2.3 Dimension ................................................................................................................5
2.3 Function .............................................................................................................................5
2.3.1 Maximum Power Point Tracking ...............................................................................5
2.3.2 Battery charging control............................................................................................5
2.3.3 Auxiliary Output ........................................................................................................6
2.3.4 TBB premium II charging algorithm........................................................................... 6
2.3.5 Comprehensive Protection........................................................................................7
2.3.6 Equalization Charging (EQ charging)........................................................................8
3. Installation and Wiring............................................................................................................ 10
3.1 Pre-installation inspection................................................................................................. 10
3.1.1 Check outer packing ............................................................................................... 10
3.2 Select installation location ................................................................................................10
3.2.1 Requirement...........................................................................................................10
3.3.2 Installation space requirements .............................................................................. 11
3.3 Installation........................................................................................................................ 11
3.4 Preparation Before Wiring ................................................................................................12
3.4.1 PV Array Preparation .............................................................................................. 12
3.4.2 Breaker Preparation................................................................................................ 12
3.4.3 Cable Preparation................................................................................................... 13

MPPT charge controller User Manual
3.5 Wiring...............................................................................................................................14
4. Configuration ..........................................................................................................................16
4.1 Check Before Operation ...................................................................................................16
4.2 Power ON Test .................................................................................................................16
4.3 Power OFF.......................................................................................................................16
4.4 Setup Wizard....................................................................................................................16
5. Operation................................................................................................................................. 17
5.1 Menu introduction.............................................................................................................17
5.2 Initial interface ..................................................................................................................18
5.3 Real-time information interface......................................................................................... 18
5.4 Information query interface...............................................................................................18
5
5. .5 5 P Pa ar ra am me et te er r s se et tt ti in ng g i in nt te er rf fa ac ce e ..............................................................................................20
5.6 User Control .....................................................................................................................24
6. FAQ ..........................................................................................................................................25
6.1 Fault code ........................................................................................................................25
7. Specification............................................................................................................................27

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1. General Safety Instruction
1.1 Safety Instruction
As dangerous voltage and high temperature exist within the charge controller, only qualified and
authorized maintenance personnel are permitted to open and repair it.
This manual contains information concerning the installation and operation of the charge controller.
All relevant parts of the manual should be read prior to commencing the installation. Please follow
the local stipulation meantime.
Any operation against safety requirement or against design, manufacture, safety standard, and are
out of the manufacturer warranty.
1.2 General Precaution
Do not expose to rain, snow or liquids of any type，it is designed for indoor use.
To avoid fire and electric shock, make sure all cables selected with right gauge and being
connected well. Smaller diameter and broken cable are not allowed to use.
Please do not put any inflammable goods near to charge controller.
Never place unit directly above batteries, gases from a battery will corrode and damage the
charge controller.
Do not place battery over charge controller.
1.3 Precaution regarding battery operation
Use plenty of fresh water to clean in case battery acid contacts skin, clothing, or eyes and
consult with doctor as soon as possible.
The battery may generate flammable gas during charging. Never smoke or allow a spark or
flame in vicinity of a battery.
Do not put the metal tool on the battery, spark and short circuit might lead to explosion.
Remove all personal metal items such as rings, bracelets, necklaces, and watches while
working with batteries. Batteries can cause short-circuit current high enough to make metal
melt, and could cause severe burns.

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2. Instruction
2.1 Brief Instruction
2.1.1 General Description
Solar Mate is a solar charge controller with built in Maximum Power Point Tracking (MPPT)
technology, which can optimize the PV’s output eliminate the fluctuation due to shading or
temperatures variables. It tracked the maximum power point of a PV array to deliver the maximum
charging current for battery, enabling PV array to increase the output by as much as 30% compared
with PWM design.
Solar Mate is a multi-voltage MPPT with built in sophisticated battery charging algorithm for various
kinds of lead acid batteries, including AGM, GEL, Traction. Data management with a year of history
record was offered as well. Meantime, version for Lead-Carbon battery and lithium ion battery were
available upon request.
Maximum MPPT efficiency up to 99.9%.
Maximum efficiency up to 98.2%.
Excellent performance at sunrise and low solar insulation levels.
High reliability with electronic protections.
Wide MPPT operating voltage range.
Easy installation and commissioning.
Built in TBB premium II battery charging algorithm for lead acid battery.
Self-consumption: Less than 1mA@12VDC,3mA@24VDC,5mA@48VDC.
Data logging 365 days.
With LCD display.
Communication: Auxiliary contact, RS485 support T-bus.
Bluetooth connectivity is available.
Self cooling design for high reliability.
2.1.2 Naming Rules
Field
Character
Description
SP SP SP series MPPT solar charge controller
XXX 100 PV open circuit voltage:(V) 100
YYY 40 Maximum output current:(A) 40
20 20
SP XXX - YY
PV open circuit voltage
Maximum output current
Series
SP 100 - 40

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2.2 Structure
2.2.1 Front
Figure 2-1 MPPT charge controller structure in front view
Table 2-1 Control Buttons
Button Function

Cancel the selection.

Display the previous level of menu.

Display the previous page.
Increase the value of the selected item.

Press the button for more than 2 seconds to scroll the page up.

Display the next page.
Decrease the value of the selected item.

Press the button for more than 2 seconds to scroll the page down.
Enter into this menu, displaying the next level.

Select and confirm the selection of a menu item.
Table 2-2 LED directive function
LED Definition Function
Solar It illuminate when SP is power on.
Charge It Flash when SP is in float charging state.
It illuminate when SP is perform charging.
Fault It Flash when SP have warning.
It illuminate when SP have error.

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2.2.2 Connection compartment
External interface terminal as shown in Figure 2-2.
Figure 2-2 Connection terminals
Table 2-3 Connection terminal introduction
Silk-screen
Definition
PV
+
Connection terminal for PV array Positive
-
Connection terminal for PV array Negative
BAT
+
Connection terminal for Battery Positive
-
Connection terminal for Battery Negative
EPO
EPO contacts, defined for remote on/off.
NC
Output dry contacts.
C
NO
RS485
Connection terminal for RS485 communication.
Temp. Sensor
Connection terminal for battery temperature sensor.
Table 2-4 Pin definition of Temp. Sensor
Pin Definition
Pin1 Battery Positive
Pin2 Battery Negative
Pin3 Temperature sensor
Pin4
Battery Negative
Table 2-5 Pin definition of RS485 communication port
Pin
Definition
Pin1
Pin2
Pin3
RS485_A
Pin4
Pin5
Pin6
RS485_B
Pin7
Pin8

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2.2.3 Dimension
Figure 2-3 Dimension of Solar Mate MPPT charge controller
2.3 Function
2.3.1 Maximum Power Point Tracking
The output power of PV array was affected by sun irradiation level and environment temperature.
The max power point varies a lot under different weather condition.
Max Power Point Tracking allows the maximum harvest of energy from PV array and delivered it
into battery. The MPPT software will continuously adjusts the operating points in an attempt to find
the maximum power point of the array no matter how the weather changes. With MPPT, we can
maximize the usage of the PV array, increasing the system efficiency by maximum 30%.
2.3.2 Battery charging control
With built in TBB premium III charging algorithm, SP automatically regulated the voltage and current
according to the DC source available from PV array.
The SP is able to charge a lower nominal voltage battery from a higher nominal voltage array. For
example, a 75VDC PV array to charge a 48VDC battery. This gives the flexibility to use longer wires
without compromising the efficiency of PV system.
The SP was not able to charge a higher voltage battery from a lower voltage array.

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2.3.3 Auxiliary Output
The SP has a configurable auxiliary output (relay contact, nominal switching capacity is 2A up to
30VDC), of which can be used for default wake up, or remote switch devices such as alarm . Only
one function can be designed at a time. Please refer to chapter 5.5.
The auxiliary contact output was designed to energize a low current circuit.
Connecting to a high amperage device will possibly damage the equipment and it is
out of warranty.
2.3.4 TBB premium II charging algorithm
Adaptive charging
Fitted with multistage charging algorithm (bulk-absorption-float-recycle), the TBB premium II
charging algorithm is designed to charge battery quickly and fully. Microprocessor controlled
charging algorithm with variable absorption charging timer guarantee the optimal charging for
batteries of different discharged state.
Float charging and Recycle charging program guarantee your battery could get proper maintenance
in case of long time connected.
Battrry Voltage
Charging Current
Soft Start Bulk Absorption Float Recycle
Icc
11.5V
10 days 1h 5
mins
½ Icc
12.5V
1
2
Figure 2-4 TBB standard battery charging curve
Note1: At this moment, the external load current of the battery is greater than the maximum
charging current of the charger, and the battery voltage starts to drop.
Note2: When the battery voltage is lower than 12.5V for 5 minutes, the charging state of the charger
changes from floating charging to constant current charging. At this moment, the external load
current of the battery is less than the maximum charging current of the charger, and the battery
voltage starts to rise.
Battery temperature compensation
Battery temperature is a key factor in correct charging, the charging formula must be adjusted
(automatically and in real time) according to the actual battery temperature to ensure that battery
are fully charged but not overcharged or undercharged. All charging voltages recommended by

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battery manufacture are in fact only applied at 20℃-25℃.
The BTS (Battery Temperature Sensor) supplied with SP measures the temperature of battery and
automatically makes adjustments at real time to properly charge your batteries at the default
compensation rate of – 3mV/℃/cell.
In case of BTS was not present, the SP will use 25℃as default setting.
Remark：The BTS is optional.
Figure 2-5 Battery Temperature Sensor(BTS)
Multi battery chemical available
Commonly encountered lead acid battery chemicals include AGM, GEL, Traction. The voltage
required for a proper charging of different battery varies. SP offer premium charging for above
commonly encountered battery categories, of which you can set through the LCD and control
button.
2.3.5 Comprehensive Protection
The equipment is being protected against many failures through hardware and software making it
robust and reliable.
PV array reverse polarity protection
When PV reverse polarity is detected, SP will not work, the maximum PV short-circuit current
cannot exceed 20A. When the PV returns to normal wiring, the SP will work normally.
PV over voltage protection
When PV voltage is beyond the scope of operating voltage, the SP will shut down output, and by
light alarm prompt, to ensure that the SP will not damage.
When the PV voltage exceeds the highest PV open circuit voltage range of SP
street light controller, beyond specification use may cause damage, if the customer
use undeserved cause damage, do not provide warranty service.

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Ambient temperature derating curve
Figure 2-6 Temperature derating curve
Battery over temperature protection
During charging, The SP in the process of charging battery temperature real time acquisition, when
the battery temperature is too high, it will reduce the charging current and shutdown, and fault
warning , in order to prevent thermal runaway of battery.
2.3.6 Equalization Charging (EQ charging)
It is strongly recommended to read this section carefully before you start the EQ
charging and Don’t leave battery unattended while performing desulfuration.
Always check if your battery supplier recommended EQ charging. Only start when it
is suitable.
If battery type was set at AGM, GEL or Lead-Carbon , this charging can’t be
triggered on.
Over a period of time, the cells in a traction battery can develop uneven chemical states. This will
result in a weak cell which in turn can reduce the overall capacity of battery. To improve the life and
performance of these non sealed battery, SP include a manual equalization program that can be
used, if recommended by battery manufacturer.

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Through this page, you can initiate the desulfuration program manually. After entering this page,
please press “ENTER” button to trigger on the EQ charging. Detailed operation, please refer to
chapter 5.5 ‘’Para_Battery’’.
After 30 minutes, it will quit EQ and enter into float charge.
Check electrolyte level and refill battery with distilled water if necessary.
If you want to come to normal charging, you need stop equalization charging and switch off the
unit.
Switch on the unit again, then you will have your equipment back to normal charging.
During equalization, the battery generates potentially flammable gases. Follow all
the battery safety precautions listed in this guide. Ventilate the area around the
battery thoroughly and ensure that there are no sources of flame or sparks in the
vicinity
Turn off or disconnect all loads on the battery during equalization. The voltage
applied to the battery during equalization may be above the safe levels for some
loads.
Frequency: Maximum once a month, for heavily used battery, you may wish to equalize your
battery. For battery with light service only need to be equalized every 2-3 months.
Important:
1) Equalization can damage your batteries if it is not performed properly. Always check
battery fluid before and after equalization. Fill batteries only with distilled water.
2) Always check the equalization switch is set back to OFF after each time’s equalization.
3) Battery manufactures’ recommendations on equalization vary. Always follow the battery
manufacturer’s instructions so batteries are properly equalized. As a guide, a heavily used
battery may require equalization once a month while a battery in light duty service, only
needs equalizing once every 2 to 4 months.
Battery type: As a protection, equalization charging can be performed if and Only if you set the
battery to be traction, Flooded /OPzS batteries. If you choose AGM, GEL or
Lead-Carbon, EQ charging can’t be performed.

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3. Installation and Wiring
3.1 Pre-installation inspection
3.1.1 Check outer packing
Please check the outer packing for damage before unpacking, and check the machine model. If
there have something wrong, please don’t open it and contact your dealer.
After unpacking, please check the deliverable for completeness and any apparent damage.
If any item is missing or there is any damage, please contact your dealer.
Table 3-1 Packing list
Packing list
Description NO.
MPPT charge controller 1
User manual 1
3Pin connector 1
2Pin connector 1
3.2 Select installation location
3.2.1 Requirement
The protection level of charger is IP31, which can only be installed indoors.
During the operation of the radiator, the temperature of the chassis and radiator will be relatively
high. Please do not install it in the place where it is easy to touch.
Do not install in the place where inflammable and explosive articles are stored.
Do not install in the place where children can touch it.
Do not install on flammable building materials
Please ensure that the mounting surface is firm enough to meet the load bearing requirements
of charger installation
Do not install SP in a sealed compartment containing batteries.

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3.3.2 Installation space requirements
A good ventilation can guarantee the normal operation of equipment. Please always guarantee the
enough clearance around SP upon installation. Please refer to following Figure 3-1 for minimum
clearance.
Figure 3-1 Requirement of minimum clearance
3.3 Installation
Please choose a flat surface and with 4xM5 supplied to install following Figure 3-2.
Install the SP as close to the batteries as possible reducing the voltage drop on cable for the
better performance of the equipment.
Please install four feet supplied in the accessory pack on side of the charge controller.
Please place the SP on your preference location and mark the location of four feet.
Screw tight the four screws afterwards
Figure 3-2 Illustration of installation
Please double check the SP is securely installed.

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3.4 Preparation Before Wiring
3.4.1 PV Array Preparation
Each SP must be connected to its own PV array. Please find following maximum PV array can be
connected under various DC systems.
Table 3-2 PV allowance for SP
SP100-40 SP100-20 SP50-40 SP50-20
Max. open circuit
voltage(VDC) 100 100 50 50
Max. short circuit
current (A)
Normal operation:40A
PV polarity reversed:20A
20 20 20
Max. PV
input power
12VDC 600W 300W 560W 300W
24VDC 1200W 600W 1200W 600W
48VDC 2400W 1200W NA NA
The Voc of PV array must never exceed 100 ;The PV array Isc must not exceed 20A
when PV polarity is reversed.
The Voc or Vmpp of solar panel was rated at 25℃with normal weather condition. Along
with temperature reduced, the Voc/Vmpp of solar array will increase. Please consult with
PV manufacturer for Voc/Vmpp of the lowest possible environment temperature and
making sure it is below 100VDC for SP100 and 50VDC for SP50.
3.4.2 Breaker Preparation
An over current protection devices DC fuse or DC circuit breaker needs to be installed on
positive cable, of which rated for 125% of the nominal rating.
The voltage resistance of DC circuit breaker on the battery side should be greater than 63V.
Voltage withstand of PV array side DC circuit breaker should be greater than PV open circuit
voltage.
Circuit breaker requirements are shown in the Table 3-3

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Table 3-3 Breaker Requirement
NO. Parts Description Requirement
1 Battery breaker
SP100-40 (1) The voltage requirement is greater than 63V.
(2) The current requirement is greater than 63A.
SP100-20 (1) The voltage requirement is greater than 63V.
(2) The current requirement is greater than 32A.
SP50-40 (1) The voltage requirement is greater than 63V.
(2) The current requirement is greater than 63A.
SP50-20 (1) The voltage requirement is greater than 63V.
(2) The current requirement is greater than 32A.
2 PV array breaker
SP100-40 (1) The voltage requirement is greater than100V.
(2) The current requirement is greater than 40A.
SP100-20 (1) The voltage requirement is greater than 100V.
(2) The current requirement is greater than 32A.
SP50-40 (1) The voltage requirement is greater than 50V.
(2) The current requirement is greater than 40A.
SP50-20 (1) The voltage requirement is greater than 50V.
(2) The current requirement is greater than 32A.
3.4.3 Cable Preparation
Cable with minimum 90℃(194F) insulation rating was recommended to be used for SP
installation.
Minimum wire size requirements are shown in the Table 3-4
Table 3-4 Recommended DC wiring
Model
Recommended DC wiring
2 meters 3 meters 5 meters 7 meters
10A 12AWG 4mm² 12AWG 4mm² 10AWG 6mm² 8AWG 10mm²
20A 10AWG 6mm² 10AWG 6mm² 8AWG 10mm² 6AWG 16mm²
30A 10AWG 6mm² 8AWG 10mm² 6AWG 16mm² 6AWG 16mm²
40A 8AWG 10mm² 6AWG 16mm² 6AWG 16mm²

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3.5 Wiring
Figure 3-3-a Figure 3-3-b
Figure3-3 Remove wiring cover plate
Step1：Shown as above Figure 3-3-a, by removing wiring cover plate follows the arrow, then
you will see as Figure 3-3-b.
Table 3-5 toggle switch definition on cover plate
Pin Definition
Pin1 NA
Pin2 NA
Pin3 NA
Pin4
OFF- Low power consumption mode (after PV power
is turned off, the charger will shut down
automatically) ON- Normal mode (Charger can be
turned on by battery power）
Default setting ：OFF