LCD MPPT

User Documentation

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 Contents

1. INTRODUCTION ......................................................................................................... 2

2. MPPT SPECIFICATIONS ........................................................................................... 5

4. SAFETY INSTRUCTION ............................................................................................. 9

5. CABLE CONNECTIONS ............................................................................................ 9

6. BASIC MPPT WIRING DIAGRAM ............................................................................ 10

7. MPPT LCD OPERATION .......................................................................................... 11

8. DATA LOGGING OPERATION ................................................................................ 15

9. PROGRAMMABLE OPERATION ............................................................................ 16

10. EXTERNAL CONNECTIONS.................................................................................... 21

11. CLARIFICATION AROUND THE PURPOSE AND CONNECTION OF AN MPPT.. 24

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1. INTRODUCTION

1.1. General Description

The Microcare Maximum Power Point Tracker Charge Controller is designed to

provide maximum power from the panels into the batteries. Using this system up to
30% more power can be extracted from the panels than using shunt or series pass
PWM controllers. The Microcare MPPT is able to charge batteries of a lower voltage
than the panel system. A Liquid Crystal Display shows the status of the system and
the data logging information. The unit has various programmable charge regimes
which automatically adjust the charge levels when first starting up or if the battery falls
below the minimum voltage. The MPPT will read the battery voltage when first
starting up and select whether it is a 12v, 24v, 36v, or 48 volt battery system. It will
then read the panel voltage and find the optimum power point. The charging, battery
values and charge modes are then adjusted. This series features a durable and
continuous 24 hour operation. The compact and modular design makes installations
easy and cost effective. It is a high quality product that offers the best
price/performance ratio in the industry.

1.2. Key Features

1. 4 X 20 LCD Display.
2. Optional Input and Output circuit breaker protection.
3. RS232 and Ethernet connectivity.
4. Fully programmable.
5. 63 Days logger.
6. High efficiency design with greater than 96% conversion.
7. Low heat dissipation.
8. Variable Fan cooling.
9. Suitable for any battery set between 12 and 48 Volt with 12V increments.
10. Electronically limited charge current 20, 40, 60, 100 Amps. (Dependent on the
MPPT type)
11. Maximum open circuit PV Array voltage 150 VOC (Open Circuit Voltage).
12. Manual or Auto Equalise selection.
13. Wall mounted.

1.3. Important Notices

Read the instructions carefully before operating the MPPT.

The unit must only be installed in a clean dry environment.

The unit should only be opened by skilled personnel.

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1.4. Recommended Array Sizes:

The following should be used as a guide to the maximum array size that can be
connected to the MPPT. The current limits to the specified level of the MPPT model
so any array larger than these will simply waste power:

Recommended Photovoltaic Array Sizes in Watts

Battery Set 20 Amp MPPT 40 Amp MPPT 60 Amp MPPT 100 Amp MPPT
12V 250W 500W 750W 1300W
24V 500W 1000W 1500W 2500W
36V 750W 1500W 2200W 3600W
48V 1000W 2000W 3000W 5000W

1.5. LCD MPPT Description:

6 2

3
4
1
5

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1. LCD Display: This indicates the MPPT’s operation including Panel voltage,
charge condition, charge amps, battery voltage and output power.
2. The <DATA>and<CHARGE> buttons are used to access the different menus and
displays.
3. The Green LED indicates panel power.
4. The Green LED indicates charging.
5. The Green LED indicates battery in float condition.
6. The RJ12 connections at the top of the unit are for programming and RS232
signals.
7. Circuit Breakers (Isolators Installed on 100A MPPT Unit’s).

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1.6. MPPT Operation Description:

This simple real world illustration (above) shows how an MPPT functions during the course of a day
as well as a simple schematic (below). In the morning, as soon as the MPPT detects that the Panel
Voltage is at a useable level (MPPT charge entry voltage); it starts to charge the batteries at
maximum efficiency in a BOOST mode which has a nominal voltage of 14.5V per 12V battery bank. If
however the batteries are detected to not be uniformly discharged, the MPPT will go into EQUALISE
mode to restore battery bank balance before switching to BOOST mode as its primary charge mode.
The MPPT maintains this mode until the batteries reach the boost voltage and the charge current
decreases to a level below a nominal changeable level of 6Amps.

The MPPT then steps down the charge voltage to a nominal voltage of 13.8V per 12V battery bank in
FLOAT mode. The MPPT will attempt to maintain FLOAT mode for as long as the panel voltage is
present. If no panel voltage is present, the MPPT goes into a sleep state until it detects a rise in
panel voltage indicating a new day for charging.

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2. MPPT SPECIFICATIONS

Nominal Battery Multi-Voltage (Automatic/Manual selection of voltage -

Voltage 12/24/36/48V battery set)

PV Input Voltage Open Circuit Absolute Maximum 150VDC

Charge Algorithm 5-stage, 3-level Equalize/Boost/Float

Equalize Voltage Charges12V to 15V per 12V DC battery pack for 1hour

Boost Voltage Charges to 14.5V and switches when charge current is <
10Amps for 1hour

Float Voltage 13.8v per battery

Power Conversion DC/DC Switch Mode

Output Efficiency Peak greater than 96 % conversion efficiency

Voltage Step dow n Can charge a lower voltage battery from a higher voltage
Capability PV array.

Status display 4 Line LCD Screen with Backlight

• Battery Voltage
• Charge mode-charge current (Equalize/Boost/Float)
and
Charge current
• Panel Voltage
• Output Power
• State of charge of battery

Data Logger • 24hr Average

• 63 day history

Power Consumption Less than 1 Watt

Environmental Rating 0 – 40˚C

Protection System • Lightning Protection

• Reverse polarity Panel/Battery

Warranty 36 months

Recommended Circuit Breaker sizes:

MPPT Type Input Amp Output Amp
20 Amp 20A 25A
40 Amp 40A 50A
60 Amp 63A 63A
100 Amp 100A 125A

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 3. MPPT SYSTEM INSTALLATION

3.1. MPPT Installation Instructions:

• Do not place the MPPT on a rugged or inclined surface.

• The MPPT must be mounted in a vertical position against a solid wall.
• Do not install the MPPT near water or in damp environments.
• Do not install the MPPT where it would be exposed to direct sunlight or near
heat.
• Do not install the MPPT on a wooden surface. Only install the MPPT on flat
concrete, stone or metal surfaces.
• Do not block off the aluminium heat sink and don’t leave objects on top of the
MPPT.
• Do not expose the MPPT to corrosive battery gases.
• MPPT operating environment temperature should not exceed: 0˚C - 40˚C.
• Ensure that connecting cables are of adequate thickness. Consult the
reference table for recommended thicknesses in Cable Connections.
Refer to the cable design sheet for correct PV cable thickness.

150mm Airflow

4x ANSI B18.6.5M -
M6x1 x 20
Cross Recessed Pan
Head Self Tapping
Screws

143mm

40 Amp LCD MPPT

150mm
Installation Diagram
204mm

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 MPPT Mounting Hole Dimensions
Height Width
20 Amp LCD MPPT 143mm 204mm
40 Amp LCD MPPT 143mm 204mm
60 Amp LCD MPPT 227mm 204mm
100 Amp LCD MPPT 278mm 204mm

3.2. MPPT Setup Diagrams

A simple PV system setup is illustrated with 48V DC Battery Set.

This setup may be extended to suit the needs of the user. 150V is the maximum voltage
the MPPT may accept, therefore, PV arrays may not have a voltage greater than 150V
else the MPPT will be damaged. Battery Sets may not exceed a voltage of 48V. Ensure
that the current strength leading into the MPPT from the PV Array does not exceed that
of the maximum allowed by the specific MPPT model that is installed.

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A complex PV-MPPT setup can have arrayed PV and Battery Sets all connected in
parallel. The voltage of the PV array may not exceed 150V and depending on the MPPT
model, a specified current strength. The Battery Set array is however unlimited in size
although an increase in Batter Set array length will increase the amount of time needed
to fully charge the batteries.

This complex setup diagram of a PV-MPPT System illustrates two 120V DC PV Arrays
connected in parallel and two 48V DC Battery Sets connected in parallel.

Try not to exceed a voltage ratio of 1:4. (Battery Bank Voltage – PV Panel Voltage)

Battery Bank Size PV Panel Voltage (Voc)

12V 48V
24V 96V
36V 135V
48V 135V
Please remember that the Standard MPPT will only
support 150Voc per PV Panel String.

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4. SAFETY INSTRUCTION
1. Route cable so that no one can step on them.
2. Batteries may cause electric shock and have a high short-circuit current. Please
take the precautionary measures specified below and any other measures
necessary when working with batteries.
• Remove wristwatches, rings and other metal objects.
• Use only tools with insulated grips and handles.

5. CABLE CONNECTIONS
The PV (Photo Voltaic) panels should always be connected in the highest voltage
configuration. The advantage of this is that panel current will always be at its minimum so
that thinner connecting wires may be used which reduces voltage drops with loading and
improves cost efficiency.

The cable length from the batteries to the MPPT should not exceed 3m. The cable
lengths connecting the PV panels to the MPPT should not exceed 30m.

As an example, if there are two 40 volt panels rated at 5 amps each and they are
connected in parallel, then the output voltage would be 40 volts at 10 amps. If they were
connected in series the output would be 80 volts at 5 amps. In both cases the power
would be the same but in the parallel configuration a thicker power cable must be used to
reduce the volt drop from the array to the MPPT as well as from the MPPT to the
batteries.

Cable thicknesses listed are recommended thicknesses that have voltage drops
accounted for up to a distance of 3m for connecting the MPPT and the batteries together
and the bottom table lists recommender cable thicknesses for cables connecting the
MPPT to the panels up to a distance of 30m.

Recommended Connecting Cables up to 3m from MPPT to batteries

(Single Stranded Copper Specifications)
Overall Cable
MPPT Type Cable Core Area Diameter
20 Amp 6mm²-10mm² 5.4mm-6.3mm
40 Amp 10mm²-16mm² 6.3mm-7.5mm
60 Amp 20mm²-30mm² 8mm-9.5mm
100 Amp 40mm²-55mm² 10mm-13mm
Recommended Connecting Cables up to 30m from MPPT to PV
panels
(Single Stranded Copper Specifications)
MPPT Type Cable Core Area Cable Core Diameter
20 Amp 3mm²-4mm² 1.8mm-2.2mm
40 Amp 6.8mm²-9mm² 2.8mm-3.2mm
60 Amp 16mm²-21mm² 4.4mm-5mm
100 Amp 25mm²-32mm² 6mm-6.8mm

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6. BASIC MPPT WIRING DIAGRAM

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 7. MPPT LCD OPERATION
7.1 Check Prior to Start Up
1. Ensure the MPPT is mounted vertically.
2. Check input output cables are secured.
3. Check the polarity of the panel and battery and they are correct.
4. Check if the Panel Voltage meets the MPPT rating required.

7.2 MPPT Start-up Procedure

1. Always turn on battery breaker first.
2. Wait until MPPT Display states that the MPPT is sleeping.
3. Turn on Panel Breaker.
4. MPPT will track the PV Panels.
5. MPPT will start charging the batteries.

7.3 Basic LCD Operation Procedure

Please follow the instructions below for basic MPPT operation.

1. Turn ON the battery circuit breaker. The following screen should appear:

Supplied by
Supplier Details
Supplier Tel Number
Serial No = MC *****

This shows the name of the supplier, contact number and serial number.

The screen will then change to:

...Start up...
Checking Batteries
48 volt system
....................

This shows the unit automatically measuring the batteries and displaying the result.
Should the battery voltage shown be incorrect it is possible to force the MPPT to accept
a new battery value.

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Turn ON the Panel Circuit Breaker. The following screen should appear:

TRACKING
MAXIMUM POWER POINT
V power point...xxxV

This shows the MPPT measuring the open circuit panel voltage and calculating the initial
power point voltage.

The screen then changes to:

BATTERY..........= 12.0 V
BOOST at.........= 10.0 A
PANEL............= 24.0 V
OUTPUT POWER.....= 120.0W
W…………………

This is the screen that will normally be displayed showing the system operating correctly.
There are other details that will appear on the screen that will assist the user to read at
what point the MPPT and batteries are:

BATTERY.........*= 13.8 V
FLOAT AT ....... = 1.0 A
PANEL........... = 24.0 V
OUTPUT POWER.... = 138.0 W
13…………………54v

The * flashing next to the batteries indicates that the MPPT is in FLOAT mode and the
batteries are full.

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 BATTERY......... = 12.0 V
BOOST at........ = 10.0 A
PANEL...........*= 24.0 V
OUTPUT POWER.... = 120.0W
W…………………

The * flashing next to the PANEL indicates that the PV panels are limiting the amount of
energy delivered to the MPPT to charge the batteries.

BATTERY........ = 12.5V
EQUALISE AT....! = 10.0A
PANEL........... = 24.0V
OUTPUT POWER.... = 125.0W
W.0…………………

The ‘!’ sign next to the EQUALISE AT line indicates that the batteries are being charged in
the Equalise mode and the batteries have not reached the equalise voltage, for every 12volt
in the battery pack, system this would be 15 volts.

Once the batteries have reached the EQUALISE VOLTAGE then the display will change to:

BATTERY....* = 15.0V
EQUALISE at. = 10.0A
PANEL....... = 24.0V
OUTPUT POWER =150.0W

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This shows that the battery is at the EQUALISE Voltage, and that the MPPT is in the 1 hour
bulk charge mode. When this is complete the charger switches to the BOOST mode and will
hold the voltage at the programmable value say 14.5 volts until the charge current has fallen
below the programmable BOOST amps, say 5.0 amps.

BATTERY....* = 14.5V
BOOST at.... = 5.0A
PANEL....... = 24.0V
OUTPUT POWER = 72.5W
72.5owerpoint…………………54v

When the charge current falls below the programmed value of say 5.0 amps, the screen
will then change to:

BATTERY........* = 13.8 V
FLOAT at.........= 1.0 A
PANEL............= 28.0 V
OUTPUT POWER.....= 13.8 W

This shows that the battery is in FLOAT mode and is indicated by the flashing ‘*’at the
end of the BATTERY line.

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7.4 Checking MPPT Firmware

To determine the MPPT’s firmware, make sure the LCD display is at the main screen:

Now hold in the <CHARGE> button for 3 seconds and the following screen will appear
for 2 seconds and then automatically revert to the main screen:

FIRMWARE V4.55
DOC’S AND SUPPORT at
www.Microcare.CO.ZA

Check the Microcare website for the latest firmware available for your specific MPPT. To
request a firmware upgrade for the MPPT, visit Microcare at www.microcare.co.za and
contact them via the online email.

7.5 Turning the MPPT Off.

1. Turn off the panel breaker first. (Never Turn Off The Battery Breaker First.)
2. Wait until MPPT Display states that the MPPT is sleeping.
3. Turn off the battery breaker.
4. This will allow the MPPT to discharge any remaining power in the coil into the
batteries and will eliminate the possibility of damage to the MPPT.

8. DATA LOGGING OPERATION

By pushing the DATA button the following screen will appear:

0: 2.234 4: 0.000
1: 0.000 5: 0.000
2: 0.000 6: 0.000
3: 0.000 7: 0.000

This shows the energy accumulated since the charger started. The 24Hr is the daily
average for the no of days shown. Should you wish to CLEAR the DATA then hold the
<CHARGE> button in for 6 seconds and the values will reset to 0.

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 To view the next 8 days of DATA LOGGING push the <DATA> button and the screen will
change to:

8 : 2.234 12: 0.000

9 : 0.000 13: 0.000
10: 0.000 14: 0.000
11: 0.000 15: 0.000

Day 0 shows the power accumulated for the current day. Up to 31 days of data is stored
and may be viewed by pushing the <DATA> button. To clear the screen, hold in the
<CHARGE> button in for 10 seconds or until the data has been cleared.

To return to the main screen, the <DATA> button must be pressed until the end of the
Data Log Menu has been reached. Alternatively, the MPPT will automatically revert to
the normal charge display after 1minute.

If a Battery Temperature and Battery Voltage Sensor is connected to the MPPT, the
<DATA>button needs to be repeatedly pressed to return to the main screen.

9. PROGRAMMABLE OPERATION
To enter the programming mode the panel circuit breaker must be turned OFF and the
MPPT must be in the SLEEP MODE.
Hold in the <CHARGE> button for 6 seconds and the following screen will appear:

9.1 Float Voltage:

FLOAT CHARGE VOLTAGE

PER BAT PACK = 13.8v
press CHRG to save
press DATA to change

To change the battery pack FLOAT VOLTAGE push the <DATA> button and the voltage
can be changed from 13.2 to 14.5 volts with 0.1 volt increments.
Default Value is 13.8V.

Press <CHARGE> button to save the changed voltage.

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 The screen will now change to:

9.2 Boost Voltage:

BOOST VOLTAGE
PER BAT PACK = 14.5v
press CHRG to save
press DATA to change

The Boost voltage can be changed between 13.5 and 16.0 volts with 0.1 volt increments.
Press <CHARGE> to save. The screen will now change to:
Default Value is 14.5V.

9.3 Boost to Float Voltage:

BOOST TO FLT CHANGE

INTERVAL SCAN = 30mn
press CHRG to save
press DATA to change

This screen changes the time that the BOOST mode takes to switch to FLOAT mode
once the batteries have reached the BOOST voltage level. The time can be 30minutes –
1 hour – 2 hours. Press <CHARGE> to save. The screen will then change to:
Default Value is 1 Hr.

BOOST TO FLT CHANGE

IF CHARGE < 6 amps
press CHRG to save
press DATA to change

This changes the charge current at which the BOOST mode after timing out changes to
FLOAT. This can be 3 – 6 – 15 - 30 amps or Disabled. Press <CHARGE> to save. The
screen will then change to:
Default Value is < 6 Amps.

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9.4 Equalise Voltage:

EQUALISE CHARGE MODE

AUTO ENABLED
press CHRG to save
press DATA to change

In this mode the Regulator will automatically go into EQUALISE mode if the battery pack
voltage falls below 10.8 volts. This enables or disables the EQUALISE Charge mode.
The screen will now change to:
Default Value is AUTO.

9.5 Battery Set Voltage:

BATTERY PACK SELECT

12 – 48 AUTO SELECT
press CHRG to save
press DATA to change

This allows the user to leave the battery system selection to the MPPT or the selection
can be PRESET. Pushing the <CHARGE> button will change the battery selection from
AUTO to 6 cells 12 volts through to 24 cell 48 volt battery pack. The screen will now
change to:
Default Value is 12 – 48 AUTO SELECT.

9.6 Charge Limit:

Charge LIMIT IS @
= 95%
press CHRG to save
press DATA to change

This allows the user to limit the MPPT current. 100 % will be 20 amps or if the limit must
be 18 amps then set the % to 90 % for a 20Amp MPPT as an example. This can be
extended to any LCD MPPT type accordingly.
Default Value is 95%.
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9.7 External Output Connections:

EXTERNAL OUTPUT IS A
UNUSED OUTPUT N/C
press CHARGE to save
press DATA to change

Please refer to Section 10 on External Output Connections.

9.8 Set Operation Mode:

SET OPERATION MODE

F MODE0
press CHRG to save
press DATA to change

MODE 0 is the Low Frequency Setting – 34MHz.

MODE 1 is the High Frequency Setting – 77MHz.
MODE 2 – 5 Is Currently Not Used.
Default Value is MODE 0.

9.9 Solar or Wind Settings:

SOLAR OR WIND MPPT ?

MODE = SOLAR
press CHRG to save
press DATA to change

This Setting allows the MPPT to be changed between a solar MPPT and a Wind Turbine
MPPT. Please confirm that these settings are not adjusted as a standard.
Confirm with support before adjusting these settings.
Default Value is SOLAR.

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9.10 Change Time Settings:

SET HOUR OF THE DAY

= 14: 4
press CHRG to save
press DATA to change

This allows the user to change the time settings of the MPPT. The Hour of the day is
changed in this screen through a 24hour time format with 1 hour increments. By pressing
the <DATA> button, the display wills then change to change the minute’s settings of the
MPPT:

SET MIN OF THE HOUR

= 14: 4
press CHRG to save
press DATA to change

In this screen, the clock’s minutes are adjusted in a similar fashion to that of the hour
settings. Pressing the <DATA> button again will exit the settings menu and the MPPT will
then reset itself with all adjusted settings loaded and normal MPPT operation will
continue as soon as the PANEL breaker is reset.

Note: Time settings do not affect any MPPT operations and are purely for user
convenience. Time settings are lost when the batteries are disconnected from the MPPT.

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 10. EXTERNAL CONNECTIONS
This allows the user to program the external output to operate the RELAY INTERFACE.
This is plugged into the RJ12 port.

EXTERNAL OUTPUT IS A
UNUSED OUTPUT N/C
press CHARGE to save
press DATA to change

Pushing the <CHARGE> button will change the external output from being an UNUSED
output to a:
• SOLAR ASSIST SIGNAL
• DAY NIGHT SIGNAL
• LOAD SHED SIGNAL (also known as a Low Battery Disconnect)
• SOLAR ASSIST SIGNAL V2
• SOLAR AST UPS CNTR1
• WIND TURBINE BRAKE

Note: The external output is only to be used with MICROCARE MPPT CHARGER
accessories.
Finally:
Pressing the <CHARGE> button twice (pressing it once will display the time settings) will
save the changes made to the MPPT. The MPPT will then reset itself and normal
operation will continue as soon as the user resets the PANEL breaker.

10.1 The SOLAR ASSIST SIGNAL switches the relay for 10 seconds when the regulator
switches from BOOST to FLOAT.

10.2 If DAY NIGHT SIGNAL mode is selected, it switches the relay when the panel power is
LOW and stays ON until the panel reconnects.

10.3 If LOAD SHED DISCONNECT is selected (by pressing <CHARGE>to save)

EXTERNAL OUTPUT IS A
LOAD SHED DISCONNECT
press CHARGE to save
press DATA to change

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 The following screen will appear:

LOAD DISCONNECTING @
= 11.0V PER BAT PACK
press CHARGE to save
press DATA to change

The user can program the Voltage at which the RELAY operates. This is between 10-12
volts per pack and increments in steps of 0.1 volts. If the system is 48 volts, multiply the
settings by 4. If this is complete then the LOAD SHED RECONNECT voltage can be
programmed which can be between 12-14 volts per pack:

LOAD RECONNECTING @
= 13.0V PER BAT PACK
press CHARGE to save
press DATA to change

10.4 The SOLAR ASSIST SIGNAL V2 switches the relay for 10 seconds when the battery
voltage is limiting the current into the system. This is when the * is flashing next to the
Battery display.

10.5 If SOLAR AST UPS CNTR1 is selected (by pressing <CHARGE> to save).

EXTERNAL OUTPUT IS A
LOAD SHED DISCONNECT
press CHARGE to save
press DATA to change

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 The following screen will appear:

LOAD DISCONNECTING @
= 11.0V PER BAT PACK
press CHARGE to save
press DATA to change

The user can program the Voltage at which the RELAY operates. This is between 10-12
volts per pack, in 0.1 volt steps. If the system is 48 volts multiply the settings by 4.

If this is complete then the LOAD RELAY RECONNECT voltage may be programmed
which can be between 12-14 volts per pack.

LOAD RECONNECTING @
= 13.0V PER BAT PACK
press CHARGE to save
press DATA to change

10.6 Wind Turbine Brake is not used in the solar MPPT.

10.7 If the Battery Temperature and Battery Voltage Sensor is plugged into the RJ12
connector then the following screen will show:

REMOTE BVT CONNECTED

VOLTAGE MPPT = xx.xV
BV= 0.00V ADJ- xx.xV
BT=25.0’C ADJ+ xx.xV

This shows the battery temperature and voltage. Should there be a problem with the
cable or a poor connection then the screen will flash ERROR.
• Voltage MPPT shows the battery voltage at the output of the MPPT.
• The BV shows the voltage at the battery terminals. The correction is shown as
either +/-.
• The Battery Temperature (BT) is then shown with the ADJ compensation.
If the Battery Voltage Temperature is disconnected, the MPPT will revert back to stand
alone readings.

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 11. TO RESET THE MPPT TO FACTORY SETTINGS

11.1. To reset the MPPT to factory defaults you need to make sure the MPPT Battery and
Panel Breaker is off.
11.2. Push and hold the DATA and CHARGE Button and turn on the battery breaker.
11.3. The Following screen will appear:

11.4. Once the countdown completes then the MPPT will have been reset to the default
values.
11.5. Switch off the battery breaker and restart the MPPT as described under step 7.2 in
the manual.

12. CLARIFICATION AROUND THE PURPOSE AND CONNECTION

OF AN MPPT.
What is the main Idea of an MPPT:
A MPPT allows you to take advantage of the mathematics behind power conversion and allows
maximum power delivery from the panel.

Let’s look at a typical solar panel (the values will be adjusted to make reading/maths easier).
Open circuit voltage = 22v (Voc)
Power point voltage = 17v (Vmp)
Short Circuit current = 10.1 Amp (Icc)
Max Charge current = 10.0 Amp (Imp)
Max Power = 170w

What do these values mean?

Open circuit voltage:
If the panel is exposed to sunlight while the panel is not connected to anything the voltage will
be 22v.
Power point voltage:
If we connect the panel to an MPPT the panel will be kept around 17v (depending on
temperature of panel, angle of sun…) as long as the MPPT has a flat battery to charge. This is
the point at which panel voltage multiplied by panel current = max wattage (not max amps or
max voltage but the combination of the two).
Short Circuit current:
If the panel + and panel – touch this current will flow. The panel will be at 10amp when panel
voltage is at 17v, if the panel voltage is forced lower the current will increase as voltage
decreases, when the panel voltage reaches 0v then the current will = 10.1amps.
Max Charge current:
As long as the sun gives you 1000wm2 and the panel is kept at 25° C (P.S. panel temp rises
when current is flowing) and the panel voltage is kept at Vmp then the Imp will = 10amps.
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Max Power:
Vmp x Imp = 170w

What Happens When You Charge a Battery.

Remember that power cannot be created out of nothing and cannot be destroyed so input =
output so Vbat x Ibat must = Vpan x Ipan.
With the MPPT the panel voltage is controlled independently from battery voltage and the panel
voltage is kept at Vmp allowing Imp to flow, with PWM the panel is connected to the Battery
while charging, forcing Vpan to = Vbat, a current slightly higher than Imp will flow, because the
panel is directly connected to battery the current must be equal in both, if the current is limited
to Imp then the power is limited to Vpan (or Vbat) x Imp.

MPPT PWM
Vbat Ibat Vpan Ipan Power Vbat Ibat Vpan Ipan Power
10v 17 Amp 17v 10 Amp 170w 10v 10.05 Amp 10v 10.05 Amp 100w
12v 14.2 Amp 17v 10 Amp 170w 12v 10.05 Amp 12v 10.05 Amp 120w
14v 12.2 Amp 17v 10 Amp 170w 14v 10.05 Amp 14v 10.05 Amp 140w

So here you can see that the PWM can give you as low as 100w from a 170w panel under full
sunlight condition and a max of about 140w in ideal conditions (battery V, temp, radiation …).
The MPPT will always give you 170w in ideal conditions (temp, radiation …) no matter what the
battery voltage is.

So now that you know the 1st and foremost importance of an MPPT we can discuss some
added advantages.
It is true that a MPPT helps to improve system efficiency by allowing a higher panel voltage to
be used, because power stays the same and power = V x I it means that the panel array current
will decrease, resulting in less volt drop in the cable, resulting in les power loss in cable. What is
important here is that this is only true if you keep the cable / conductor diameter the same when
or as you increase the voltage, if you use thinner cable because the current is less then you’re
only saving on system installation cost and not gaining any efficiency. This gain in efficiency in
any ways is normally almost insignificant when compared to the 1st most important reason for
using an MPPT gain of up to 70% increase in power (normally around 30% because battery
voltage does not always stay at 10v).
So my point here is, do not use an MPPT to increase panel voltage, increase panels voltage to
make your installation easier and more economical but what is very important to note is that
there is a limit to how much you can increase the panel voltage on the MPPT.

Why is this so?

A MPPT (all step down MPPT battery chargers) uses a Buck regulator circuit to do the power
conversion, these circuits do not operate at max efficiency when the input output voltage ratio is
very high, try to not exceed a ratio of 1:4, this is especially true on 12v systems. For examples is
you charge a 12v battery do not connect 120v of panels to the MPPT, the ratio = 1:10 the MPPT
will give you a “High Panel voltage” Warning meaning that the MPPT is now operated out of
speck. For a 12v system your max Charge is 15v so use a panel array with a power point
voltage (Vmp not Voc) between 15v and 60v (1:4 = 15v x 4 = 60v), then your MPPT will be
happy and you will get maximum power transfer efficiency from your MPPT. In essence your
MPPT has 2 paths where the power flow, 1 path steps down and divides the voltage and the
other increases and multiplies the current, if your ratio is 1:10 then each circuit has to work 10
times harder then what it would have worked if the ratio was 1:1, having too dived the voltage
by 10 and boosting the current 10 fold (turn 1 amp from panel into 10 amps into the battery), the
difference in efficiency between 1:1 and 1:4 is minuscule and not worth stressing about but
when the ratio becomes greater than 1:6 then the efficiency is notably lower.

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13. Fault Finding Support:
When Problems are experienced with the MPPT’s please refer to this section to confirm the
procedure to follow in order to correct the fault.

13.1. When the display is showing the following:

BATTERY.......... = 13.8V
BOOST at......... = LOW
PANEL............ = 28.0V
OUTPUT POWER..... = LOW

This would be the general error experienced when connecting the MPPT.

This fault can be checked through any of the following tests on the MPPT:
13.1.1. Turn off the MPPT Panel breaker and measure the voltage using a multi-
meter. Turn on the Panel circuit breaker and confirm if the voltage is
immediately dropping to the battery voltage or if the voltage is slowly
decreasing. (If the voltage is immediately dropping to the battery voltage
then the MPPT needs to be sent to Microcare for repair.)
13.1.2. If the voltage is not adjusting then you need to open up the MPPT and
check the internal cables to confirm if the circuit breaker attachments are
tight. Tighten the circuit breaker internally and externally.
13.1.3. If this does not solve the error then you would be required to test your PV
Panels independently to confirm if you have a Panel short circuit that is
causing the PV voltage to be low.

13.2. When the display is showing the following:

. . . WARNING . . .
MEMORY FAILURE
HAS BEEN DETECTED
CONTACT MICROCARE!!!

The Internal PIC (Memory Chip) in the MPPT is becoming full and is starting to detect
that it is full. This warning can be overcome by restarting the MPPT, however the
problem will start occurring more often.

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When the screen below is seen:

. . . ERROR . . .
MEMORY FAILURE
HAS BEEN DETECTED
CONTACT MICROCARE!!!

This means that the PIC has become saturated and will no longer be able to store
information.

The MPPT needs to be sent in to the Microcare offices in order to get replaced with a
new PIC to gather the information for the MPPT LOG’s.

13.3. When the display is showing the following:

. . . WARNING . . .

HIGH PANEL VOLTAGE

V POWER POINT = xV

This error will display when the PV Voltage is exceeding the 4:1 Ratio between the
battery voltage and the PV Panel Voltage used to charge the batteries.
(Refer to List Below)

Battery Bank Size PV Panel Voltage (Voc)

12V 48V
24V 96V
36V 135V
48V 135V
Please remember that the Standard MPPT will only
support 150Voc per PV Panel String.

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13.4. When the display is showing the following and all LED Lights are flashing:

ERR DETECTED! PANEL

OPEN CIRCUIT VOLTAGE
GREATER THAN 100vDC
MPPT CHARGE DISABLED

Your PV Panel array is connected in series and is exceeding the 150Voc capacity
of the MPPT

13.5. When the display is showing the following:

ERR DETECTED!BATTERY
OPEN CIRCUIT VOLTAGE
GREATER THAN 60vDC
MPPT CHARGE DISABLED

The Battery Voltage is exceeding the supported Voltage range of the MPPT.

13.6. When the display is showing the following:

ERR DETECTED!
MPPT OUTPUT
SHORT CIRCUIT
MPPT CHARGE DISABLED

This error message will be displayed if the load being drawn from the batteries is
exceeding the amount of power that the MPPT is capable of supplying.

If the load being drawn from the batteries is 63A and you only have a 40A MPPT
then this error will display on the MPPT.

If this error is detected, open up the MPPT and check the left ribbon cable and
confirm that the ribbon cable is securely fastened between the Display and the
power card.

If the Ribbon Cable is secure then reduce the Load being drawn from the battery
bank to clear the error. (Restart the MPPT once the load has been reduced.)

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 J & J ELECTRONICS LIMITED WARRANTY

J&J Electronics warrants its full range of products against defects in workmanship and
materials, fair wear and tear accepted, for a period of three (3) years from the date of
delivery/collection for all equipment and are based on a bring-in-basis. Where the installation of
the product makes it impractical to bring-in to our workshops, J&J Electronics reserves the right
to charge for travel time and kilometres travelled to and from the site where the product is
installed.

During this warranty year period, J&J Electronics will, at its own discretion, repair or replace the
defective product free of charge. This warranty will be considered void if the unit has suffered
any physical damage or alteration, either internally or externally, and does not cover damages
arising from improper use such as, but not exclusive to:

• Reverse of battery polarity.

• Inadequate or incorrect connection of the product and/or of its accessories.
• Mechanical shock or deformation.
• Contact with liquid or oxidation by condensation.
• Use in an inappropriate environment (dust, corrosive vapour, humidity, high temperature,
biological infestation).
• Breakage or damage due to lightning, surges, spikes or other electrical events.
• Connection terminals and screws destroyed or other damage such as overheating due to
insufficient tightening of terminals.
• When considering any electronic breakage except due to lightning, reverse polarity, over-
voltage, etc. the state of the internal control circuitry determines the warranty.

This warranty will not apply where the product has been misused, neglected, improperly
installed, or repaired by anyone else than J&J Electronics or one of its authorised Qualified
Service Partners. In order to qualify for the warranty, the product must not be disassembled or
modified. Repair or replacement are our sole remedies and J&J Electronics shall not be liable
for damages, whether direct, incidental, special, or consequential, even caused by negligence
or fault. J&J Electronics owns all parts removed from repaired products. J&J Electronics uses
new or re-conditioned parts made by various manufacturers in performing warranty repairs and
building replacement products. If J&J Electronics repairs or replaces a part of a product, its
warranty term is not extended. Removal of serial nos. may void the warranty.

All remedies and the measure for damages are limited to the above. J&J Electronics shall in no
event be liable for consequential, incidental, contingent or special damages, even if having been
advised of the probability of such damages. Any and all other warranties expressed or implied
arising by law, course of dealing, course of performance, usage of trade or otherwise, including
but not limited to implied warranties of merchantability and fitness for a particular purpose, are
limited in duration to a period of three (3) years from the date of purchase.

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Life Support Policy:
As a general policy, J&J Electronics does not recommend the use of any of its products in life
support applications where failure or malfunction of the J&J Electronics product can be
reasonably expected to cause failure of the life support device or to significantly affect its safety
or effectiveness. J&J Electronics does not recommend the use of any of its products indirect
patient care. J&J Electronics will not knowingly sell its products for use in such applications
unless it receives in writing assurances satisfactory to J&J Electronics that the risks of injury or
damage have been minimised, the customer assumes all such risks, and the Liability of J&J
electronics is adequately protected under the circumstances.

Caution:
Our products are sensitive. While all care is taken by us to dispatch goods with adequate
packaging, J&J Electronics is not responsible for any damage caused to products after they
have left our premises. Semi-sealed batteries have to be transported upright and must not be
put on their side. Please ensure that your transport company or delivery team is aware of the
sensitivity of the products they are collecting.

Goods return policy

The following terms apply to return of items purchased from J&J Electronics, and we require the
following information:

1. Details of the item(s) you would like to return.

2. Our invoice number.
3. The reason for the return.
4. J&J Electronics must be notified within 7 days of your intention to return the goods which
were purchased.
5. All items returned will be inspected prior to refund. If our technicians are not immediately
available, the goods will have to be left with us until such time as a technician is available
to check the items.
6. Proof of purchase is required for all returns.
7. The price paid by the customers is the price on which the refund is based.
8. Items purchased can be returned for a refund, replacement or exchange, provided proof
of purchase is provided and subject to all other conditions as set down here.
9. All returns may be subject to an administration and handling fee of 10% of purchase
price plus VAT.
10. Returns are based on a bring-in basis; all return shipment costs are for customer’s
account.
11. Returns will be refused in the following circumstances:
a. Where an item has been tampered with, altered or damaged in any way, or
b. Where a return is deemed unreasonable, this will be referred to management.

Severability:
If a part of the terms and conditions set out above is held invalid, void, or unenforceable due to
any particular national or international legislation, it shall not affect other parts of the terms and
conditions remaining.
_______________________________________________________________

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 J&J ELECTRONICS’ TERMS AND CONDITIONS OF SALE

• Payment Terms:

o On placing an order your unit/s is/are booked on the production line, and a Pro Forma invoice is
sent to you with our banking details.
o A 50% deposit is required to secure the order, with the balance payable prior to despatch of the
goods.
o Payment is accepted in South African Rands (ZAR) only, and by Electronic Funds Transfer
(EFT) into J&J Electronics’ bank account.
o The issuing of a quotation or a Pro Forma invoice issued as a quotation represents no obligation
by J&J Electronics until such time that the customer’s official purchase order has been accepted.

• Pricing:

o Prices are quoted ex-works Port Elizabeth, and do not include delivery.
o Prices are quoted excluding VAT. VAT is payable on all invoices except on exports where J&J
Electronics is arranging the export transport.
o Prices are valid for 30 calendar days from the date of quotation.
o Prices quoted are based on the quantities specified in the quotation and J&J Electronics reserves
the right to revise prices quoted in the event of the quantities being reduced or increased.

• Delivery/Packaging:

o Delivery times where specified are estimated. J&J Electronics will endeavour to adhere to
estimated delivery times; however, should any delays which are beyond J&J Electronics control
occur, J&J Electronics will not be liable for any costs or losses incurred by the customer through
such a delay.
o J&J Electronics requires all customers to arrange their own shipping/courier when orders are
placed as all orders are Ex-Port Elizabeth; when repairs as per the J&J Electronics Carry In
Warranty are sent to J&J Electronics, the onus on the return of the goods to the customers lays
with the customer in terms of arranging shipping/courier services.
o Goods are packaged in corrugated packaging; if the customer requires any specific type of
packaging such as crates or pallets, this will be an additional cost for the customer.
o Where the goods are not delivered by J&J Electronics or are collected by the customer, but are
collected or delivered by and independent carrier, the collection/delivery by the carrier shall be
deemed to be delivery to the customer. Where the goods have been delivered by the carrier, J&J
Electronics is not responsible for goods lost or damaged in transit.

• Carry-In Warranty and Returns:

o Carry-In Warranty is 36 months (three years).

o Goods are warranted against faulty workmanship and components for a period of thirty six months
(three years) from the date of supply. A copy of our full warranty policy and returns policy is
available on request or from our home page on our website.
o While J&J Electronics provides professional advice regarding the usage of goods supplied, the
suitability of the goods supplied for the use contemplated by the customer is the sole responsibility
of the customer.
o J&J Electronics shall in no way be responsible for the suitability of the goods sold on for any
particular end use.

• General:

o Any item not specified is excluded from the quotation. Delivery, commissioning, installation and
electrical work are excluded unless specifically quoted.

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