Srne ML4860 User Manual

4860 Maximum Power Point Tracking

(MPPT) Series

CYNETIC 12-24-36-48V 60A 150V

User Manual

Model

Batte ry vol ta ge

Max. so la r panel v ol tage

Max. in pu t power

Charg ing curre nt

Disch arging cu rrent

ML486 0

12V/2 4V /36V/48 V

150V (2 5° C), 145 V (- 25 °C)

800W/ 12 V; 1600 W/ 24 V; 2400 W/ 36 V; 3200 W/ 48V

60A

20A

Spe cific ation ve rsio n numbe r:V1. 02 If the re is any c hange , witho ut noti ce

Cod e:1.1 .24.0 1492

Dear users, Thank you for choosing our product!

Safe ty Instructions

1. As thi s co nt rolle r de al s wi th voltag es t ha t excee d th e to p limit for h um an s af ety,

do not op er at e it before r eading th is m an ua l caref ul ly a nd comple ti ng s af ety

opera ti on t ra ining.

2. The co nt roller has no i nt ernal com po ne nt s that need m ai nt enance or s er vice ,

thus do n ot a tt empt to d is as se mble or rep air the con tr oller.

3. Inst al l th e co ntrol le r in doors, and av oi d co mponent e xp os ure and wat er

intru si on .

4. Duri ng o pe ra tion, the r ad ia tor may rea ch a ver y hi gh t emperat ur e, theref ore

insta ll t he c on troll er a t a pl ace with go od v en tilatio n co nd it ions.

5. It's reco mm en de d that a fuse o r br eaker b e in st alled out si de t he c ontro ll er.

6. Befo re i nstalling a nd w ir ing the con tr ol ler, make sure to d isconnect t he

photo vo ltaic arr ay a nd t he f use or brea ker clo se t o th e batte ry termi na ls .

7. After in st al la tion, che ck i f al l connectio ns a re solid an d re liable so as to a vo id

loose c on ne ct ions that m ay g iv e rise to d an ge rs c au sed by heat a cc um ulation.

War ni ng : means the operati on i n qu estion is dangero us , an d

you should get p ro pe rl y prepar ed b efore proceedin g.

Note: mean s th e op er ation in questi on m ay c au se damage.

Tips: mean s ad vi ce or instructi on f or t he o perator.

Table of Contents

1. Pr oduct I ntrod uc tio n

1.1 P roduc t Ove rvie w

1.2 P roduc t Fea tures

1.3 E xteri or a nd In ter face s

1.4 I ntrod uct ion to Ma ximum P owe r Poi nt Tra cki ng Tec hno lo gy

1.5 C hargi ng St age s Intro ducti on

2. Pr oduct I nstal latio n

2.1 I nstal latio n Preca uti ons

2.2 W iring S pecif icati ons

2.3 I nstal latio n and Wir ing

3. Pr oduct O perat ion and D ispla y

3.1 L ED Indi cator s

3.2 K ey Oper ati ons

3.3 L CD Di splay a nd O per ation s

3.3 .1 Menu B lock Di agram

3.3 .2 Main M enu 23

3.3 .3 Real -Ti me Moni torin g

3.3 .4 Para met er Se tting s

3.3 .5 Cont rolle r Cha rging a nd Disc hargi ng Re lat ed Paramet ers S ettin g Descr iptio ns

3.3 .6 LCD Sc ree n Bac kligh t Time Se tting

3.3 .7 "Cle ar Hist orica l Dat a" and "R ese t to Facto ry Set tings "

3.3 .8 Load M ode

3.3 .9 Stat ist ic Data

3.3 .10 His toric al Data o f the C urren t Day

3.3 .11 Dev ice Inf ormat ion

3.3 .12 Blu etoot h Conne cti on Stat us

4. Pr oduct P rotec tion Fu nctio n and System M ain tenan ce

4.1 P rotec tio n Funct ions

4.2 S yst em Main tenan ce

5. Pr oduct S pecif icati on Para met er s

5.1 E lectr ic Para met er s

5.2 B atter y Type De fau lt Para met er s

6. Co nvers ion Eff icien cy Cur ve

6.1 1 2V Syst em Co nvers ion Eff icien cy

6.1 2 4V Syst em Co nvers ion Eff icien cy

6.3 4 8V Syst em Co nvers ion Eff icien cy

7. Pr oduct D imens ions

1. Produ ct Introd uctio n

1.1 P ro du ct Ov er view

Thi s produ ct can kee p monit oring t he sola r panel 's gener ating p ower an d track ing the h ighes t volta ge

and c urren t value s (VI ) in real t ime , enabl ing t he syst em to cha rge t he ba tte ry i n max imum po wer. It's des igned t o be used i n off-gr id ph otovo lta ic syst ems t o coord ina te op erati on of the so lar pan el, bat tery and l oad, fu nctio ning as t he core c ont rol uni t in off- grid ph otovo ltaic s ystem s. Thi s produ ct feat ures an LC D scree n whi ch can dy namic ally di splay t he oper ating s tatus , opera ting par amete rs, c ontro ller lo gs, his toric al da ta, con trol par amete rs, etc . Users c an chec k param eters u sin g the key s, and mo dif y contr ol para met ers to ca ter to dif feren t syste m requi remen ts. The c ontro ller ut ilize s stand ard Mod bus c ommun icati on pr oto col, ma king it e asy for u ser s to chec k and mod ify sys tem par amete rs on the ir own. B eside s, with t he free m oni torin g sof tware w e pro vid e, user s' var ied rem ote m oni torin g nee ds can be w ell sat isfie d. Wit h compr ehens ive ele ctr oni c fault s elf-de tecti ng func tions a nd powe rfu l elect ronic p rotec tio n fun ction s built i nside t he cont rolle r, com ponen t damag e cause d by inst allat ion err ors or sy stem fa ilu res can b e avoid ed to the g reates t exten t possi ble.

1.2 P ro du ct Fe at ures

1.3 E xt er ior and I nt er faces

Wit h the adv anc ed dual -peak o r multi -peak t racki ng tech nol ogy, whe n the sol ar pane l is sh adowe d or par t of the pa nel fai ls resu lti ng in mul tiple p eak s on the I- V curv e, th e contr oll er is sti ll ab le to acc urate ly trac k the max imum po wer poi nt. A bui lt-in ma ximum p ower po int tra cking a lgori thm can s ignif icant ly impr ove t he en ergy ut ili zatio n eff icien cy of pho tov olt aic sys tems, a nd rais e the cha rgi ng ef ficie ncy by 15 % to 20% co mpa red w ith t he con venti onal PW M metho d. A com binat ion of mu lti ple tra cking a lgori thms en ables a ccura te trac kin g of the op tim um work ing p oint on th e I-V cur ve in an e xtr eme ly shor t time. The p roduc t boast s an op timum M PPT tra cki ng effi cienc y of up to 99. 9%. Adv anced d igi tal pow er supp ly tech nol ogies r aise th e circu it's e nergy c onver sion ef ficie ncy to as h igh as 98 %. Dif feren t charg ing p rogra m opt ions in cludi ng thos e for g el batt eri es, sea led bat ter ies a nd open bat terie s, cu stomi zed one s, etc. a re ava ilabl e. The c ontro ller fe ature s a lim ited cu rre nt ch argin g mod e. When t he sola r panel p owe r exc eeds a ce rtain lev el and th e charg ing c urren t is la rger th an th e rated c urr ent , the con troll er wi ll auto matic all y lower the c hargi ng powe r and b ring th e charg ing c urren t to th e rat ed leve l. Ins tanta neous l arge cu rrent s tar tup of ca pacit ive l oads is s upp orted . Aut omati c recog nit ion of bat tery v oltag e is supp or ted . LED f ault in dicat ors and a n LCD scre en whic h can dis play ab norma lity in forma tion he lp user s to quic kly ide ntify s ystem f aults . His toric al data s torag e fun ction i s avail abl e, and da ta can be s tored fo r up to a yea r. The c ontro ller is e quipp ed with a n LCD scre en with w hich us ers can n ot only c heck de vice op erati ng dat a and sta tuses , but als o modif y contr oller p arame ter s. The c ontro ller su pport s stand ard Mod bus pro tocol , ful filli ng the co mmuni catio n needs of v ariou s occ asion s. All c ommun icati ons are e lectr icall y isola ted, so u ser s can res t ass ured in u sag e. The c ontro ller em ploys a b uilt-i n over-te mpera ture pr otect ion m echan ism. Wh en temp eratu re sur passe s the set v alu e, th e charg ing c urren t wil l decli ne in lin ear pro por tion to t he temp eratu re and dis charg ing wil l be halt ed so a s to curb t he te mpera ture ri se of th e contr oller, e ffe ctive ly keepi ng the con troll er from b ein g damag ed by ove rhe at. Wit h the hel p of an ext ern al batte ry vol tage sa mplin g funct ion, ba tte ry volt age sam pling i s exemp ted fro m the eff ect of lin e loss, m aking c ontro l more pr eci se. Fea turin g a tempe ratur e com pensa tion fu nctio n, the co ntrol ler c an auto mat icall y adjus t charg ing a nd dis charg ing par ame ters in o rder to ex tend th e batte ry's se rvic e life. The c ontro ller al so feat ures a bat tery o ver-tem perat ure pro tecti on func tion, a nd wh en the ex terna l bat tery te mpera ture ex ceeds t he set va lue , charg ing a nd di schar gin g will be s hut off s o as to p rote ct com ponen ts from b eing da maged b y overh eat . TVS l ighti ng prot ectio n

RS485

③

④

①

②

①

② ③ ④

12V

GND

D-

D+

No.

Def initi on

Battery Sampling

①

②

No. No.

Def initi on

①

②

Controller communication port RJ12 (6-pin)

RS232

①

② ③ ④ ⑤ ⑥

No. Definition

Transm ittin g termi nal TX Recei ving te rmina l RX Power sup ply grou nding/

signal g roundi ng

Power s upply g round ing/ sign al grou nding

Power s upply p ositi ve Power s upply p ositi ve

Fig . 1-1 Pro duct ap peara nc e and i nterf aces

1.4 I nt ro duc ti on to Max im um Po we r Poi nt Tra ck ing Technol og y

Max imum Po wer Po int Trac kin g (MPPT ) is an adv anced c hargi ng te ch nol ogy tha t en abl es the

sol ar pane l to ou tput mo re powe r by a dju st ing t he e lec tric mo dule's o per ating s ta tus . Due to

the n onlin earit y of sola r array s, ther e exi sts a max imum en ergy ou tp ut po in t (ma xi mum p ower

poi nt) on th eir cur ves. U nab le to con tinuo usly lo ck onto t hi s poi nt to cha rge t he batt er y,

con venti on al co ntrol lers (e mp loy ing swi tchin g and PWM c hargi ng tech nolog ie s) ca n't g et th e

mos t of the po wer f rom the s ol ar pa nel . But a sol ar char ge c ont rolle r featu ri ng MP PT

tec hn olo gy can co nt inu ously t rack ar rays' m aximu m po wer p oi nt so a s to get th e ma xim um

amo unt of po wer t o charg e the bat ter y.

Para llel ope ratio n

Blac k

Yello w

Red

No. Ite m No. Ite m

Cha rging i ndica tor

Bat tery i ndi cator

Loa d indic ato r

Abn ormal ity ind icato r

LCD s cre en

Ope ratin g keys

Ins talla tion ho le

Sol ar pane l "+" int er fac e

Sol ar pane l "-" int er fac e

Bat tery " -" in terface

Loa d "-" int er fac e

Bat tery " +" in terface

Loa d "+" int er fac e

Ext ernal t emp eratu re samp ling in terfa ce

Bat tery v olt age com pensa tion in terfa ce

RS4 85 comm unica tion in terfa ce

RS2 32 comm unica tion in terfa ce

㈠

        





 



  

 



 



Take a 12 V sys tem as an e xampl e. As the s olar pa nel 's peak v olt age (Vpp) is a ppr oxima tel y 17V

whi le the ba tte ry's v olt ag e is ar oun d 12V, when c hargi ng w ith a c onven tio nal cha rge con tro ller, th e

sol ar pane l's v olt age wil l stay at a round 1 2V, fa ili ng to d elive r the max imum po wer. Howe ver, the

MPP T contr oller c an ov ercom e the pro ble m by adju sting t he sola r panel 's in put v oltag e an d cur ren t

in re al time , rea lizin g a maxim um inpu t power.

Com pared w ith c onven ti ona l PW M con troll er s, th e MP PT co ntrol ler c an make t he mo st of the s ola r

pan el's max . power a nd ther efore p rov ide l arger c hargi ng cu rrent . Ge ner ally sp eak ing, th e latte r can

rai se the en ergy ut iliza tio n ratio b y 15% to 20 % in cont rast wi th the fo rmer.

MPP T point

VP cu rve

VI cu rve

Mea nwhil e, due to c ha ngi ng ambi ent t emper ature a nd illu min ation c ondit ions, t he max. p ower

poi nt vari es fr equen tly, and o ur MPPT c ontro lle r can adj ust par am ete r set tings a ccord in g to th e

env ironm ental c ond ition s in real t ime, so a s to alwa ys ke ep the sy ste m close t o the max . opera ti ng

poi nt. The w hole pr oce ss is ent irely a utoma tic wit hou t the nee d of huma n inter venti on.

U(V

)

I(A

)

20℃

50℃

70℃

60℃

40 ℃

30℃

I (A)

U( V)

Cur rent dec rease s with dw indli ng ligh t

Ope n-circ uit vol tage de creas es with d windl ing lig ht

Wit h temper ature d roppi ng, cur rent sta ys stab le and powe r incre ases

Sol ar panel t emper ature

Ope n-circ uit vol tage de creas es with r ising t emper ature

Fig . 1-3 Rel ati on betw een sol ar pane l out put cha racte risti cs and il lumin ation

Fig . 1-4 Rel ati on betw een sol ar pane l out put cha racte risti cs and te mp era tu re

Fig . 1-2 Sol ar pane l outpu t chara cteri stic cu rve

1.5 C ha rg ing S tages I nt roduc ti on

As on e of the ch arg ing sta ge s, MP PT can’ t be us ed alon e, but ha s to be use d toget her wit h

boo st char gin g, floa ting ch argin g, eq ualiz ing cha rging , etc . to comp le te ch arg in g the b att er y. A

com plete c ha rgi ng pr ocess i ncl udes: f ast cha rging , su sta ining c har ging an d float ing c hargi ng .

The c hargi ng cur ve is a s shown b elo w:

Bat tery v olt age

Tim e

Max. c urren t

Cumu lativ e time: 3 h

Dura tion: 2 h

(ran ge: 10 to 6 00min )

Fast c hargin g

Boos t

Bulk

Cha rging c urren t

Tim e

Sust ainin g charg ing

Floa ting ch argin g

Equa lizin g charg ing vol tage

Boos t charg ing vol tage

Floa ting ch argin g volta ge

Char ging re turn vo ltage

Fig . 1-5 Bat tery c har ging st ages di agram

a) Fa st char gi ng

At th e fast ch arg ing sta ge , as th e bat tery v olt age has n ot reac hed t he set va lue o f fu ll vo lta ge (i.e .

equ alizi ng/ boo st volt ag e) ye t, th e contr oller w ill per form MP PT char ging on t he ba tter y wit h the

max imum so lar pow er. When t he ba tte ry vol tag e reach es th e prese t value , con stant v ol tag e

cha rging w ill beg in.

b) Su st ai ning ch ar gin g

Whe n the bat ter y volt age r eache s the set v alu e of sust ain ing vol tage, t he cont rolle r wil l switc h to

con stant v oltag e ch arg ing . In this p roces s, no M PPT cha rging w il l be pe rf orm ed, and m eanwh ile

the c hargi ng cu rrent w ill als o gradu ally de creas e. Th e susta ining c hargi ng stag e its elf con sists o f

two s ub-st ages, i .e. equ alizi ng char gin g and boo st char ging, t he tw o of whic h are n ot carr ied out i n

a rep eated m ann er, with t he fo rmer ge tting a ctiva ted o nce eve ry 3 0 days.

 B oost ch ar gin g

By de fault , boost c hargi ng ge neral ly last s for 2h, b ut user s can adj ust pre set val ues o f dur ation

and b oost vo ltage p oi nt ac cordi ng to t he ac tual ne eds. Wh en the du ratio n reach es t he se t val ue,

the s ystem w il l the n switc h to fl oat ing cha rging .

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Srne ML4860 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual