mppt75hv maximum power point tracking solar battery

MPPT75HV MAXIMUM POWER POINT
TRACKING SOLAR BATTERY CHARGE
CONTROLLER
The Intronics Power Inc. MPPT75HV Solar Charge Controller continually tracks the
maximum power point of the solar panel array, adjusting the circuit parameters
approximately two times per second to maximize energy transfer from the array to the
battery bank.
FEATURES
• Automatic tracking of solar panel maximum
power point
• One, two or three stage charging (selectable)
• High energy conversion efficiency (94-97%)
• Tracking of MPPT to within 2%
• Temperature compensated
• LCD display and LED status indicators
• User selectable set points
• 12/24/36/48 Volt system capability
(selectable)
• 75 amp output rating
• Maximum panel input voltage 80 VDC
• Maximum battery voltage 65 VDC
• 25 amp auxiliary load rated output
• Output current automatically limited to 78
amps
• Self Consumption <1 Watt
• All common grounds
• MCU controlled ventilation fan
• All stainless steel hardware
1400 PROVIDENCE HIGHWAY • BUILDING 2 NORWOOD, MASSACHUSETTS 02062-5015
PHONE: 781-551-5500 FAX: 781-551-5555 www.intronicspower.com
CHARGING SEQUENCE
DISPLAY
BULK CHARGE
The blue button on the top of the controller is used to
navigate between LCD display pages.
Page 1 shows:
Panel voltage (Vp) Panel current (Ip)
Battery voltage (Vb) Battery current (Ib)
The MPPT75HV delivers the maximum power
available from the solar array to the battery bank until
the battery voltage reaches one of the following
setpoints, as determined by the dipswitch settings.
FLOAT
Pushing the blue button once and holding it down will
change the display from the normal display to Page 2,
which shows:
The controller maintains the battery voltage at the float
voltage set point. There are two float voltage set points Aux Output Mode (Pump or Lights)
(selectable).
System nominal voltage (12/24/36/48 volts)
Float Voltage at 25 degrees C (13.5/27/40.5/54 or
ABSORPTION (If enabled)
13.9/27.8/41.7/55.6 volts)
Controller temperature in degrees C
The fourth leftmost (SW5) is used to enable or disable
the Absorbtion function.
Pushing it again and holding it down while the display
UP Absorb Enabled
shows Page 2 will change the display to Page 3 which
DOWN Absorb Disabled
shows:
If Absorption is enabled, the controller will raise the
battery voltage to the Absorption voltage (Float voltage Absorb enabled/disabled
plus .75/1.5/2.25/3 volts) for a total of 2 hours per day. Equalize enabled/disabled
After the battery has been maintained at the Absorption Absorb charge time so far this day
voltage for 2 hours in the current day, the controller
Equalize time deficit
will maintain it at the float voltage.
Pushing it again and holding it down while the display
EQUALIZATION (If enabled)
shows Page 3 will change the display to Page 4 which
The controller will raise the battery voltage to the
shows diagnostic information for troubleshooting,
Equalization set point for a total of one hour per month including software revision, PWM duty cycle, and
to ensure that all batteries and cells in the battery bank float/absorb/equalize voltage limits.
are at an equal state of charge. Not recommended for
gel or AGM batteries.
Pushing the button after Page 4 will display Page 5,
which shows the amp hours so far today, plus the amp
hours for each of the previous five days.
Pushing the button after Page 5 will display Page 6,
which shows the maximum amps so far today, plus the
maximum amps for each of the previous five days.
Releasing the pushbutton will return the display to Page
1 after a few seconds delay.
1400 PROVIDENCE HIGHWAY • BUILDING 2 NORWOOD, MASSACHUSETTS 02062-5015
PHONE: 781-551-5500 FAX: 781-551-5555 www.intronicspower.com
LEDs
The leftmost LED shows the battery state of
charge:
Steady Green:
Fully charged, above 13.5/27.0V/40.5/54 volts
Blinking Green:
Nearly full above 12.5/25.0/37.5 volts
Steady Yellow:
Partial charge above 12.0/24.0/36/48 volts
Blinking Yellow:
Partial charge above 11.75/23.5/35.25/47 volts
Steady Red:
Low charge above 11.5/23/34.5/46 volts
Blinking Red:
Low charge less than 11.5/23/34.5/46 volts
The third leftmost switch (SW6) sets the nominal
float voltage for HIGH or LOW float:
UP is HIGH float:
13.8/27.8/41.2/55.5 volts at 25 degrees C
DOWN is LOW float:
13.5/27.0/40.5/54.0 volts at 25 degrees C
High Float is recommended for flooded batteries.
Low Float is recommended for sealed, gel and AGM
batteries. You may need to experiment to find the
appropriate setting for your batteries.
The nominal float voltage for 25 degrees C can be
seen on Page 2 of the LCD display.The actual float
voltage will be different from the displayed value if
the temperature is not 25 degrees C.
EQUALIZE
Note: these indications are only approximate
guides to the battery state of charge, due to the
effects of system loads, temperature, battery
condition, etc.
The middle LED (white) is on if the auxiliary
output is on.
The rightmost LED (blue) indicates that the panel
is connected and is charging the battery bank.
.DIP SWITCHES
The DIP switches are visible in the small cutout
in the end panel of the controller. Set them
appropriately for your application.
The fifth leftmost switch (SW4) is used to enable or
disable the Equalize function.
UP
Equalize Enabled
DOWN Equalize Disabled
If Equalization is enabled, the controller will raise
the battery voltage to the Equalization voltage (Float
voltage plus 1.25/2.5/3.75/5 volts) for a total of 1.5
hours per month. It will do this in increments when
the panels are able to supply sufficient current to do
so, while keeping track of the equalization time. You
can see the total running deficit of equalization time
on Page 3 of the LCD. If the deficit is zero, the
battery is fully equalized.
SYSTEM VOLTAGE
The leftmost two switches (SW8 and SW7)
determine the system voltage:
SW8
SW7
System Voltage
DOWN
DOWN
12V
UP
DOWN
24V
DOWN
UP
36V
UP
UP
48V
The system voltage can be seen on Page 2 of the
display.
1400 PROVIDENCE HIGHWAY • BUILDING 2 NORWOOD, MASSACHUSETTS 02062-5015
PHONE: 781-551-5500 FAX: 781-551-5555 www.intronicspower.com
AUXILIARY OUTPUT
The sixth leftmost switch (SW3) is used to set the
aux mode to Pump or Light mode
UP Pump Mode
DOWN Light mode
The Auxiliary output is used for DC loads, such as
DC lights, radios, and water pumps. It should NOT
be connected to any inverters or refrigerators.
Inverters and DC refrigerators generally include low
and high voltage battery protection, and should be
connected directly to the battery bank.
There are two setup options for the auxiliary output,
Lights and Pumps. Loads such as lights must have
power available at all times if possible.
Therefore, if the Auxiliary Output is set up in Lights
mode, the output will be on unless the battery voltage
falls below the Low Voltage Disconnect voltage of
11.25V/22.5/33.75/45 volts for more than one
minute.
When the battery voltage rises above the Reconnect
Voltage of 12V/24/36/48 volts, the output is again
turned on.
This ensures power is always available, assuming the
batteries are not excessively discharged.
However, loads such as water pumps can be run
when more power is available during the day, and
not at night when power may be more necessary for
essential loads such as lights.
If the controller is set up in Pump mode, the output
will go on when the battery voltage is above
13/26/39/52 volts, and will stay on for a minimum of
15 minutes. If the voltage then falls below
13/26/39/52 volts, the output will go off.
The 15 minute delay ensures that the pump does not
cycle excessively, which can damage the motor, and
consume more energy.
Also the higher connect and disconnect voltages
help ensure that the load will tend to run during the
day when there is more energy available, while
conserving battery charge for the priority loads
(generally supplied by an inverter) at night.
Whether in Lights or Pump mode, if the DC loads
can draw more than 15 amperes, you should use the
Auxiliary Output to control a relay which in turn
runs the loads. This will protect the controller from
possible over current problems, and also conserve
energy.
The last two switches (SW2 and SW1) are not used.
This will protect the controller from possible over
current problems, and also conserve energy. Some
refrigerators have a Low Battery Disconnect and
Reconnect feature incorporated in them. These can
be connected directly to the battery bank.
INSTALLATION
MOUNTING
The controller can be mounted on a flat surface or
on a wall. Be sure it is in a dry, protected location. If
it is not close to the battery bank, be sure to use
heavy cable to reduce voltage loss in the cables. #10
gauge or 2.5mm wire or heavier is recommended.
The connector will accept up to #4 gauge (5mm)
wire.
Be sure the batteries are in a protected area with
good ventilation. Install the controller far enough
from the batteries that it will not be exposed to
battery acid splashes or fumes.
1400 PROVIDENCE HIGHWAY • BUILDING 2 NORWOOD, MASSACHUSETTS 02062-5015
PHONE: 781-551-5500 FAX: 781-551-5555 www.intronicspower.com
CONNECTIONS
1. Loosen all the terminals on the connector by
turning the screws counterclockwise. Look inside the
wire entry holes while doing so to familiarize your
self as to how the connector functions. Tightening the
screw raises the bottom of the contact and clamps the
wire against the top of the connector assembly. If you
don't make a good connection, the high currents can
heat and destroy the connector.
2. Connect any 12/24/36 or 48V auxiliary loads to
the AUX+ and AUX- terminals on the controller. DO
NOT CONNECT ANY INVERTERS TO THE AUX
OUTPUT. INVERTERS SHOULD BE
CONNECTED DIRECTLY TO THE BATTERY
BANK.
See the Auxiliary Output section.
Measure the voltage between the BAT- terminal on the
controller and the + cable from the battery bank to
verify that you have not made any errors. Be sure the
polarity is correct. Then connect the + cable from the
battery bank to the BAT+ terminal on the controller.
With a pen or similar item, press the reset button
through the small hole on the end panel near the DIP
switches. The controller fan should go on, and the
controller will sweep through the PWM ratio to find the
Maximum Power Point of the panel array and battery
bank. The blue LED and fan will go on and the other
LEDs will go off. After about 20 seconds, the battery
charge indicator will go on and the controller will
operate normally.
After a few hours, retighten the connections to be sure
they are good and tight. Also, check and retighten them
again after a month or so, and at least every few months
after that.
3. Identify the + and - cables from the panel array.
Make any parallel or series connections of the panels
separately from the controller. There should be only
two wires from the panels connected to the
controller. Do not use the controller terminals to
make connections between panel strings.
Connect the - cable from the panels to the PANterminal on the controller.
TEMPERATURE COMPENSATION
The Float, Absorb and Equalize voltage set points are
temperature compensated at -5 mV per degree
Centigrade per cell.
4. Identify the + and - cables from the battery bank.
Make any parallel or series battery connections
separately from the controller. Do not use the
controller terminals to make connections between
battery strings. Connect the battery- cable to the
BAT- terminal on the controller.
The controller will work with panel arrays with
maximum open circuit voltages up to 65 volts. Check
the specs of your panels to find their ratings. Higher
voltage panels need smaller cable sizes and lose less
energy in the cabling. Lower voltage panels can be
connected in series for higher output voltages.
Industrial style panels often have ratings of 200-300
watts and max power voltages of 30-60 volts. The
Intronics MPPT75HV will work well with such panels,
individually or in series/parallel arrays.
If your panels can generate enough power to produce
more than 80 amperes of battery charge current, it is
not a problem. The MPPT75HV will automatically
limit the output to 78 amps. That way, you can oversize
your panel array so as to be sure to have the necessary
power during periods of less than optimal sun.
Measure the voltage between the PAN- terminal and
the + cable from the panels to verify that you have
not made any errors. Be sure the polarity is correct.
Then connect the + cable from the panels to the
PAN+ terminal on the controller. The controller
should now start operating.
RECOMMENDATIONS
Panels
1400 PROVIDENCE HIGHWAY • BUILDING 2 NORWOOD, MASSACHUSETTS 02062-5015
PHONE: 781-551-5500 FAX: 781-551-5555 www.intronicspower.com
System Voltage
Batteries
For small systems, 12V has the advantages of readily
available DC lights and radios, etc. For larger systems,
24 or 48 volts is recommended, as the controller can
supply more power, and the cable sizes can be
smaller. Inverters for 12, 24 and 48 volts are readily
available. Some specialized systems including small
electric vehicles use 36 volt systems.
There are as many opinions on battery choices and
the proper settings for battery charging as there are
experts. Consult the battery manufacturer's
recommendations for more information, and
suggestions as to appropriate settings.
If you use AGM, sealed, or gel batteries, we suggest
Low Float, Absorb disabled, and Equalize disabled.
For batteries other than lead acid, consult the battery
manufacturer's recommendations.
We recommend flooded batteries for consumer
stationary applications because they tend to be
more robust, less costly, and the electrolyte levels
can be checked and topped up.
If you use flooded batteries, (preferably deep cycle,
or golf cart types), we suggest you try using the
Low Float setting with Absorb and Equalize
enabled. If the battery will be used only
occasionally, we suggest disabling Absorb and
enabling Equalize. If it seems like the battery is not
being fully charged, try using the High Float
setting. If the liquid level in the battery does not
need topped up more than twice a year, High Float
will keep the battery somewhat more fully charged.
If excessive gassing and loss of electrolyte occurs,
move back to Low Float, and/or disable Absorb
and/or Equalize.
1400 PROVIDENCE HIGHWAY • BUILDING 2 NORWOOD, MASSACHUSETTS 02062-5015
PHONE: 781-551-5500 FAX: 781-551-5555 www.intronicspower.com
MPPT75HV
98
97
96
E
F
F
I
C
%
I
E
N
C
Y
95
94
93
92
91
90
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
45.0
50.0
55.0
60.0
65.0
70.0
75.0
OUTPUT AMPERES (Ib)
Vp-Vb = 15 VOLTS
Vp-Vb = 30 VOLTS
1400 PROVIDENCE HIGHWAY • BUILDING 2 NORWOOD, MASSACHUSETTS 02062-5015
PHONE: 781-551-5500 FAX: 781-551-5555 www.intronicspower.com