TBB power Solar Mate User manual

MPPT charge controller User Manual

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
Contents Contents
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............................................................................................................3
2.2 Structure..............................................................................................................................3
2.2.1 Front
2.2.1 Front..........................................................................................................................3
2.2.2 Control panel
2.2.2 Control panel.............................................................................................................4
2.2.3 Connection compartment...........................................................................................5
2.2.4 Dimension..................................................................................................................6
2.3 Function...............................................................................................................................7
2.3.1 Maximum Power Point Tracking.................................................................................7
2.3.2 Battery charging control.............................................................................................7
2.3.3 Auxiliary Output..........................................................................................................7
2.3.4 TBB premium III charging algorithm...........................................................................8
2.3.5 Comprehensive Protection.........................................................................................9
2.3.6 Equalization Charging (EQ charging).......................................................................10
3. Installation and Wiring................................................................................................................11
3.1 Pre-installation inspection..................................................................................................11
3.1.1 Check outer packing.................................................................................................11
3.1.2 Check deliverables...................................................................................................11
3.2 Instrument Preparation......................................................................................................11
3.3 Select installation location.................................................................................................12
3.3.1 Requirement............................................................................................................12
3.3.2 Installation space requirements...............................................................................12
3.3.3 Installation Angle......................................................................................................13
3.4 Installation.........................................................................................................................14
3.5 Preparation Before Wiring.................................................................................................15
3.5.1 Wiring Diagram
3.5.1 Wiring Diagram........................................................................................................15
3.5.2 PV Array Preparation
3.5.2 PV Array Preparation...............................................................................................15
3.5.3 Breaker Preparation
3.5.3 Breaker Preparation.................................................................................................17
3.5.4 Cable Preparation
3.5.4 Cable Preparation....................................................................................................18
3.5.5 Preparation before wiring.........................................................................................19

MPPT charge controller User Manual
3.6 Grounding Connection.......................................................................................................20
3.7 PV Array Connection.........................................................................................................20
3.8 Battery Connection............................................................................................................21
3.9 Communication Connection...............................................................................................22
3.10 Connecting the multiple units...........................................................................................22
4. Configuration..............................................................................................................................24
4.1 Check Before Operation....................................................................................................24
4.2 Power ON Test...................................................................................................................24
4.3 Power OFF........................................................................................................................25
4.4 Setup Wizard
4.4 Setup Wizard.....................................................................................................................25
5. Operation...................................................................................................................................26
5.1 Menu introduction
5.1 Menu introduction..............................................................................................................26
5.2 Initial interface
5.2 Initial interface...................................................................................................................27
5.3 Real-time information interface
5.3 Real-time information interface..........................................................................................27
5.4 Information query interface
5.4 Information query interface................................................................................................28
5.5 Parameter setting interface
5.5 Parameter setting interface................................................................................................30
5.6 User Config
5.6 User Config........................................................................................................................34
6. FAQ............................................................................................................................................35
6.1 Fault code..........................................................................................................................35
7. Specification...............................................................................................................................38

1
MPPT charge controller User Manual
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.

2
MPPT charge controller User Manual
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.
SP can operate at their full rating in ambient temperatures as high as 40℃.
Maximum MPPT efficiency up to 99.9%, Maximum dynamic MPPT efficiency up to 99%.
Maximum efficiency up to 98%, and European weighted efficiency up to 97.3%.
Maximum charging current up to 120A.
High reliability with electronic protections.
Wide MPPT operating voltage range.
℃Up to 6720W of charging power at 40 .
Parallel function, up to 4 units can operate in parallel.
Easy installation and commissioning.
Flexible charge algorithm.
Extensive networking and communication capabilities.
Auxiliary contact RS485 : communication among TBB products or with other.

3
MPPT charge controller User Manual
2.1.2 Naming Rules
Field Characte Description
SP SP SP series MPPT solar charge controller
XXX 150 PV open circuit voltage:(V) 150
250 250
YYY
120
Maximum output current:(A)
120
100 100
80 80
70 70
60 60
2.2 Structure
2.2.1 Front
2.2.1 Front
SPXXX-YYY
PV open circuit voltage
Maximum output current
Series
SP 150-120

4
MPPT charge controller User Manual
Figure 2-1 MPPT charge controller structure in front view
2.2.2 Control panel
2.2.2 Control panel
Fig
Figure ure 2-2 MPPT Control buttons 2-2 MPPT Control buttons
Tab
Table le 2-1 Control Buttons 2-1 Control Buttons
Button
Button Function 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
Table 2-2 LED directive function
LED
LED Function Function
Charge It Flash when SP is in standby.
It Flash when SP is in float charging state.
It illumirate when SP is perform charging .
Warning It Flash when SP have warning.

5
MPPT charge controller User Manual
Fault It Flash when SP have error.

6
MPPT charge controller User Manual
2.2.3 Connection compartment
External interface terminal as shown in Figure 2-3.
Figure 2-3 Connection terminals
Table
Table 2-3 Connection terminal introduction
Silk-screen Definition
A Com In Connection terminal for parallel communication input.
B Com Out Connection terminal for parallel communication output.
C EPO EPO contacts, defined for remote on/off.
D Relay Output dry contacts.
E RS485 Connection terminal for RS485 communication.
F BAT+ Battery Connection Positive
G BAT- Battery Connection Negative
H PV- PV array Negative
I PV+ PV array Positive
L BTS Connection terminal for battery temperature sensor.
Table 2-4 Pin definition of PCB Connector A,B
Pin Definition
Pin1 --
Pin2 RS485_A
Pin3 RS485_B
Pin4 --
Table 2-5 Pin definition of PCB Connector E
Pin Definition
Pin1 RS485_B
Pin2 RS485_A
Pin3 GND
Pin4 RS485_A
Pin5 RS485_B
Pin6 GND
Pin7 RS485_A

7
MPPT charge controller User Manual
Pin8 RS485_B
2.2.4 Dimension
Figure 2-4 Dimension of Solar Mate MPPT charge controller
(SP250-70、SP150-100、SP150-80、SP150-60)

8
MPPT charge controller User Manual
Figure 2-5 Dimension of Solar Mate MPPT charge controller( only SP250-100)

9
MPPT charge controller User Manual
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
110VDC 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.
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.
Default
Default
The auxiliary contact can be configured to default wake up, if the connection is detected in the DC
Coupling system, take one puff every 5 minutes to wake up Kinergier Pro (Connected to the input
dry contacts of the Kinergier Pro).
Alarms
Alarms
The auxiliary contact can be configured to switch the alarm circuit or indicator light on upon preset
condition occurs, such as MPPT failure, battery low voltage, high PV input voltage etc.

1
MPPT charge controller User Manual
2.3.4 TBB premium III charging algorithm
Adaptive charging
Adaptive charging
Fitted with multistage charging algorithm (bulk-absorption-float-recycle), the TBB premium III
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.
Figure 2-6 TBB standard battery charging curve
Figure 2-6 TBB standard battery charging curve
Battery temperature compensation
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
℃ ℃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 – 3 ℃mv/ /cell.
℃In case of BTS was not present, the SP will use 25 as default setting.
Figure 2-7Battery Temperature Sensor(BTS)

1
1
MPPT charge controller User Manual
Multi battery chemical available
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
PV array reverse polarity protection
When PV reverse polarity is detected, SP will shut down, send out alarm and will resume output
upon corrected the connection.
PV over voltage protection
PV over voltage protection
When SP charger PV voltage is too high, is beyond the scope can be operating voltage, the charger will shut down
output, and by sound and light alarm prompt, to ensure that the charger will not damage.
When the PV voltage exceeds SP charger allows the highest PV open circuit
voltage range, beyond specification use may cause damage, if the customer use
undeserved cause damage, do not provide warranty service.
Ambient temperature derating curve
.
0%
20%
40%
60%
80%
100%
120%
40 45 50 55 60
Percent of rated current
Ambient temperature/℃65
SP150-120
SP250-100
SP250-70
SP150-80
SP150-60
Figure 2-7 Temperature derating curve
Battery over temperature protection
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.

1
MPPT charge controller User Manual
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.
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 7.5 ‘’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-

1
MPPT charge controller User Manual
Carbon, EQ charging can’t be performed.

1
MPPT charge controller User Manual
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.
Please check the quantity of accessories, if there have something wrong, please contact your
dealer.
3.1.2 Check deliverables
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.
3.2 Instrument Preparation
Please prepare tools and instruments following the Table 3-1 in advance.
Table 3-1 tools and instruments
Classify Tools and instruments
Installing
Percussion drill (φ6mm) Diagonal pliers Wire stripper
Wire cutters
（25mm²~35mm²）
Hydraulic
pliers（25mm²~35mm²
）
Cross screwdrivers
（M4、M6）
Universal
meter（600V）Heat-shrinkable tubing Heat gun
Personal
safety
equitment
Protective gloves Protective shoes

1
MPPT charge controller User Manual
3.3 Select installation location
3.3.1 Requirement
The protection level of charger is IP21, 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.
Solar Mate MPPT charge controller should be installed in a well-ventilated environment to
ensure good heat dissipation.
Please install vertically so that the charger can dissipate heat. Do not place the charger
horizontally.
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.
3.3.2 Installation space requirements
A good ventilation can gurantee 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