user manual solar generators
TRANSCRIPT
USER MANUAL — SOLAR GENERATORS
The warnings, precautions, and instructions discussed in this instruction guidelines cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this prod- uct, but must be supplied by the operator. While Cutting Edge Power is proud to be an American company dedicated to producing a high quality product, we are not responsible for any property or personal damage to you or your device(s) due to use/misuse of this product. Always use good judgement and never try to modify or disassemble this product.
TABLE OF CONTENTS Page #
1. Safety Information………………………………………………………………… 1
2. General Information……………………………………………………………… 2
2.1 Common Parts Among the Designs……………………………..…….. 2
2.2 Quick Start………………………………………………………………………. 3
3. About the Charge Controller………………………………………………….. 4
4. About the Solar Panels……………………………………………….………….5-6
5. Battery Recommendations………………………………………………….….7
6. Blue MPPT Charge Controller…………………….……….……………….…8
6.1 Specifications…………………………………………………………………..…9
6.2 Safety Precautions………………………………………………………….….10
6.2.1 National Electrical Code……………………………………………………11-12
6.3 How does it work…………………………………………………………………13
6.4 Solar Cell I-V Curve in Varying Sunlight…………………….………….14
6.5 Connections……………………………………………………………..………..15
6.6 Button Guide………………………………………………………………………16
6.7“Load”Output Function………………………………………………………16
6.8 Screen Guide……………………………………………………………………..17-18
6.9 Troubleshooting………………………………………………………………….19
7. CEP200 Black MPPT Charge Controller…………………………………..20
7.1 Overview…………………..……………………………………………………….21
7.2 Instructions for Use…………………………………………………………….21
7.2.1 MPPT Charging introduction……………………………………………..21-22
7.2.2 Sleep and wake-up…………………………………………………………..23
7.2.3 Indicator and remote control status…………………………………….24
7.2.4 Intelligent Power……………………………………………………………….24
7.2.5 Remote control CU-ALL5…………………………………………………..25-28
7.3 Technical Parameters………………………………………………………….29
7.4 Protections…………………………………………………………………………30
7.5 Electrical Wiring Diagram………………………………………….…………31
7.6 Common Exceptions and Handling Methods…………….……………32
1. SAFETY INFORMATION
• This product is not waterproof. It is designed to be used indoors, or outdoors temporarily without
rain or water ingress. Except for the Fortress Solar Generator which is waterproof and designed
to be used indoors or outdoors.
• Some wires may be supplied in parallel sets. Do not separate them. Doing so will void the Solar
Generator warranty.
• Note: when connecting the charge controller to batteries, a small initialization spark is typical.
• Follow the directions for the charge controller and the inverter. Manuals are included in your
package.
• Please check the output voltage specifications “Voc”: of the solar panels. It must be the same
or less input voltage of the charge controller. Not following these guidelines could result in
damage to the charge controller.
• Keep away from any combustible material.
• Allow adequate ventilation. This unit generates heat; without proper ventilation it may overheat,
potentially causing a fire hazard. Think of it like a small space heater; just leave a few inches of
cleareance all around and avoid enviroments over 86°F (30°C)
• Leave the inverter power switch “off” whenever the box is not in use to help prevent draining the battery.
• Switch any device to be powered “off” before plugging into this device.
• Keep away from children.
• Use as intended only.
1
2. GENERAL INFORMATION
A solar generator is merely a battery or a bank of batteries being charged by solar panels. All
batteries must use a charge controller, and typically an inverter is required for using the power
stored in the battery bank.
Cutting Edge Power Solar Generators always include the charge controller, and depending
on the user’s choices: the batteries, the inverter and the solar panels.
2.1 COMMON PARTS AMONG THE DESIGNS
2
12V Socket:
- Input and Output.
- Plug a Cutting Edge Power Mini Wind Turbine, and/or a car charger,
to charge your battery or batteries.
- Power any device up to 30A (360W max output)
30A Circuit Breaker:
- Protects the socket(s): It automatically disconnects the 12V sockets
when current AMP exceeds 30A (Total combined including all 12V
sockets). To turn them back on, wait a couple of minutes until the
Circuit Breaker cools down, then press the button. (No need to take
the cap off)
Terminal Posts:
- Input/Output
- Meant for connecting extra batteries, powering external inverters,
connecting battery chargers, others devices, etc.
- To connect additional battery in Parallel: Remove the caps, connect
negative wire to black post, and positive to red. We highly recommend
using a Cutting Edge Power Series/Parallel Kit.
- Use 6 AWG 90°C Wire. Ideally larger wire size. If in doubt, use larger
size wire or additional Parallel sets.
Series/Parallel Kit
- For wiring extra batteries.
2.2 QUICK START
1.Connect the red cable(s) to the positive terminal of the
battery bank. Then, connect the black cable(s) to the
negative terminal of the battery bank.
• When connecting the charge controller to batteries, a
small initialization spark is typical.
• Battery connection types may vary. As long as the ring
terminals are fastened tight (snug) and cannot
accidentally be pulled off the battery, the connection is
acceptable.
• Solar generators equipped with battery switches (Rebel,
Trailblazer, Scout and Fortress): turn the black knob
clockwise. Tighten as much as possible by hand. Not
tightening this switch may cause intermittent issues with
solar generator output. If you are experiencing
connection issues, check this switch first. Do not use a
hand tool to tighten the battery switch as overtightening
could damage it.
2. Plug the solar panel(s).
3. Plug devices to the inverter and turn the
inverter on.
3
3. ABOUT THE CHARGE CONTROLLER
Cutting Edge Power Solar Generators use two different MPPT charge controllers. They are
always prewired, and preset for 12V Lead Acid Batteries (Blue Charge Controller) , or
Lithium ion batteries if equipped (CEP200 Black MPPT charge controller)
Please refer to the manuals respectively for further information. Manuals are supplied with
the solar generators, and published in the Drawings and Instructions page on our website:
CuttingEdgePower.com
Blue MPPT Charge Controller CEP200 Black MPPT Charge Controller
Please check the specifications of your solar panels before plugging to Charge Controller.
• Maximum solar panel voltage: 23VDC for
charging 12V battery/batteries.
• It is rated for 1,200W of solar panel charging
max.
Go to page 8 for complete User Manual
Charger input
• Maximum solar panel voltage: 92VDC
(@25C ambient) for charging 12V battery/
batteries.
• Maximum solar panel current: 20A
• It is rated for up to 520W of solar panel in-
put (520W @ 12V DC)
Go to page 20 for complete User Manual
4
4. ABOUT THE SOLAR PANELS
When using the Blue MPPT Charge Controller:
First, make sure your Voc Solar Panel Voltavge is under 23V DC. If so, use any size solar panel,
(ex: 100W, 200W), up to 100A (0-1200W) whichever limitation comes first. If using multiple solar
panels, please wire them in parallel (++ --). Wiring the solar panels in series will void your warranty
and most likely damage the solar charge controller.
When using the CEP200 Black MPPT Charge Controller:
Use any size solar panel, any combination, up to 520W of solar panel input (520W @ 12V DC) If
using multiple solar panels, wiring in series or in parallel is fine as long as the maximum voltage
input is 92V DC.
Parallel Series
• Best for beginners when dealing with solar
power and wind power.
• Allows wiring to remain at a safe, low voltage.
Typically we consider anything under about
30V DC to be “safe”. Of course all electricity
should be respected but the risk of getting hurt
is lower when your voltage is under 30V.
• Requires larger gauge wiring due to low
voltage, which can get expensive.
• Requires longer “parallel” runs of wire which
can be costly and labor intensive.
• Less risk of damaging components due to
lower voltage
• Generally more compatible with mainstream
components.
• For advanced users that are familiar with
Ohm’s Law (see below)
• May be less safe when the resultant voltage
is over 30V DC. 30V DC is widely regarded
as the point at which you will be able to be
shocked at a dangerous level. Especially
high voltages (60+ V DC) can be even more
dangerous.
• Can save time and money by consolidating
all wiring into one single circuit (basically one
wire for all panels)
• Higher risk of damaging
components. Generally as a rule of thumb,
components that can withstand higher
voltages are more expensive.
• Can be a huge advantage because you can
use smaller gauge wire. An easy way to
calculate this is with Ohm’s law
Power (P) = Voltage (V) x Current (A)
5
Solar Panels wired in
Parallel
Voltage stays the same
as a single panel, while
current and power
increases.
Solar Panels wired in
Series
Voltage and power
increases while current
remains the same.
If you need to change your charge controller from onw model to another, please contact
[email protected] for retrofit options.
6
5. BATTERY RECOMMENDATIONS
• Battery connection types may vary. As long as the ring terminals are fastened tight (snug)
and cannot accidentally be pulled off the battery, the connection is acceptable.
• Solar generator equipped with battery switches (Rebel, Trailblazer, Scout and Fortress):
turn the knob clockwise. Tighten as much as possible by hand. Not tightening this switch
may cause intermittent issues with solar generator output. If you are experiencing
connection issues, check this switch first. Do not use a hand tool to tighten the battery
switch as overtightening could damage it.
• When wiring batteries in parallel, be sure to use a cutting edge power parallel kit, or
minimum 6AWG wire. If in doubt, it never hurts to add more (or thicker) wires. Adding
more and thicker wires will increase the overall efficiency of your system because the
lower resistance in the wires will produce less waste heat.
• Do not wire batteries in series unless your product specifically instructs you to do so. The
only Cutting Edge Power products that may be wired in series are clearly marked by the
factory at Cutting edge power.
• When connecting the charge controller to batteries, a small initialization spark is typical.
7
6. BLUE MPPT CHARGE CONTROLLER
COMPONENTS
Display screen USB output Temperature sensor
Load connection
Battery connection
Solar panel input connection
Charger input
8
6.1 SPECIFICATIONS
BATTERY VOLTAGE 12V 24V
MAXIMUM SOLAR INPUT
23V VOC
46V VOC
EQUALIZATION 14.4V 28.8V
FLOAT CHARGE
13.7V DEFAULT,
ADJUSTABLE
27.4V DEFAULT,
ADJUSTABLE
DISCHARGE CUT OFF
10.7V DEFAULT,
ADJUSTABLE
21.4V DEFAULT,
ADJUSTABLE
DISCHARGE RECONNECT
12.6V DEFAULT,
ADJUSTABLE
25.2V DEFAULT,
ADJUSTABLE
LOAD “ON”, AKA NIGHT MODE
8V SOLAR INPUT
16V SOLAR INPUT
LOAD “OFF”, AKA DAY MODE
8V SOLAR INPUT
16V SOLAR INPUT
MAXIMUM CHARGE CURRENT
100A
USB OUTPUT 5V / 2.5A MAX
POWER CONSUMPTION
<10mA
OPERATING TEMPERATURE
WITHOUT FORCED CONVECTION
50°C
SIZE 6-7/16” L X 3-3/4” W X 1-11/16” H
9
6.2 SAFETY PRECAUTIONS
1. Make sure your battery has enough voltage to register on the charge
controller (8V DC minimum).
2. Make sure you have the right size wire. Wire sizing typically includes 2
considerations:
A. NEC minimum wire size to avoid overheating the wire, based on
insulation material.
The following is an excerpt from the National Electrical Code . It can be used as
a general guideline for wire sizes. Take note of the materials listed
(copper/aluminum) and temperature rating. Many of Cutting Edge Power’s wire
is not included in this table because we use very special, high
temperature/current rated 200°C silicone insulated tinned copper wire.
Silicone Wire Parameter Table
10
6.2.1 National Electrical Code
Allowable Ampacities of Insulated Conductors Rated up to 2000 Volts. 60°C - 90°C. No More Than Three Current-Carrying Conduc- tors in Raceway, Cable or Earth. Based on Ambient Temperature of 30°C (86°F)
Temp Rated
Conductor
Types
60°C TW, UF
75°C RHW, THHW, THW, THWN, XHHW, USE,ZN
90°C
TBS, SA, SIS, FEP, FEPB, MI, RHH, RHW-2, THHN, THHW,
THW-2, THWN-2, USE-2, XHH, XHHW, XHHW-2, ZW-2
COPPER CONDUCTORS ALUMINUM CONDUCTORS
SIZE 60°C 75°C 90°C 60°C 75°C 90°C SIZE
11
B. Voltage drop, to avoid low voltage / high current issues.
Voltage drop is a phenomenon that can affect low voltage (under 60V) systems
quite a bit. We recommend checking with the voltage drop calculator from
calculator.net found here. One of the biggest problems with having a voltage
drop too low, is that it proportionally increases the current of the system,
which can have a tendency to overheat wiring or components. You can read
more about this on our blog. As a general rule of thumb, 2% voltage drop is
considered good, and 3% voltage drop is considered acceptable.
When in doubt, bigger wire is better.
Note: the largest practical size wire that can be used in this charge controller’s
terminals is 10AWG. 10AWG silicone insulat- ed tinned copper wire is rated for
140.6A maximum.
3. This charge controller is suitable for charging lead acid 13.7V nominal
batteries (deep cycle, AGM, Gel, SLA) as well as Lithi- um Iron Phosphate
(LiFePO4) 4S 12.8V nominal batteries.
It can be used to charge Nickel Oxide based lithium batteries, but it isn't
recommended because you won’t be able to use the full voltage range of these
batteries.
12
6.3 How does it work?
MPPT is a fascinating technology. MPPT stands for Maximum power point
tracking. Basically, it is a charging control technique that determines the point
at which a solar panel’s maximum voltage and current (thus, power) can be
used to charge your battery. A visual graph of a typical solar panel is shown
below. The line which follows the “knee” of the curves indicates the maximum
power point. As you can see, the maximum power point will change depending
on the amount of sunlight. The abil- ity of this charge controller to adapt and
harvest the maximum amount of power with any given amount of sunlight is
what makes it almost 99% efficient.
13
6.4 Solar Cell I-V Curve in Varying Sunlight
DON’T BELIEVE US??
Perform your own precise tests using our Smart Tech Power Meter. Designed
specifically for wind and solar, our Smart Tech Power Me- ter is perfect for all of your
testing needs. Easy pairing through your standard WiFi router or phone's hotspot,
you can view the measured voltage, current (amps) and the power output (Watts).
Available at CuttingEdgePower.com
14
6.5 CONNECTIONS
1. Always connect the battery first, then the solar panels. This is
to prevent a voltage surge or spike from damaging the sensitive
electronics in the charge controller.
2. Connect the solar panels second.
23V maximum solar panel Open Circuit Voltage (VOC)
input for charging 12V battery/batteries.
46V DC maximum solar panel Open Circuit Voltage
input (VOC) for charging 24V batteries.
See “Specifications” for more details.
3. If applicable, connect “load” last.
4. Reversing the polarity will result in a damaged charge controller
and will void the warranty.
15
6.6 BUTTON GUIDE
Menu button: short press to scroll through settings. Long press to
modify settings.
Up button: Short and long press does nothing from home
screen. Use to adjust settings after long pressing the
menu button.
Down button: Short press turns on/off the “load” output.
Use to adjust settings after long pressing the menu button.
Long press at home screen to engage or disengage the
“load” function.
6.7 “LOAD” OUTPUT FUNCTION
The load function is typically used for lighting applications, hence the light bulb
icon. It can commonly be set to turn on a load out- put after dusk (when the
charge controller detects 8V or less, it assumes it’s night time). The time aspect
(24h, 1-15h, 0h) is the time the load output will remain engaged. After this time
is elapsed, the load output will be disengaged.
Important: The load voltage settings and time settings must be satisfied in order
for the load output to engage.
16
6.8 SCREEN GUIDE
Settings that are adjusted will be automatically saved, even if power is
removed.
17
Home Screen:
Default display which shows the battery voltage,
if the solar panels are charging, and if the load
output is engaged.
From the home screen, short press “menu” to view the status of all parameters.
When you get to a setting you want to change, long press “menu” for 3 seconds
to enter “edit mode”. After the setting is adjusted, to save: short press “menu” or
just wait for the screen to time out.
PV OFF:
The voltage at which solar charging will be
disconnected. PV OFF should be the maxi- mum
voltage you want your battery/ batteries to be
charged. (Typ.
Note: this MUST be modified for LiFePO4
batteries!! Refer to your battery specifica- tions!
LOAD ON (Voltage):
The voltage at which the load output will
be engaged (if allowed by time setting).
LOAD OFF:
The voltage at which the load output will be
disconnected. This is a protective setting to
prevent the battery from over- discharging.
LOAD ON (Time):
The time at which the load output can be
engaged. 24h means the load will always be on as
long as the voltage doesn't drop below “LOAD
OFF”. 1-15h means the load output will be
engaged for this many hours after the charge
controller no long- er detects the solar panel
(sunset). 0h activates the “dusk to dawn” setting;
load will be set to engage at dusk and disen- gage
at dawn.
These are preset settings and can be dis- b1, b2, b3, b4
regarded.
The other displays are status indicators/parameters.
18
6.9 TROUBLESHOOTING
PROBLEM CAUSE SOLUTION
Charge icon is not
on when it’s
sunny
Solar panel polarity (+/-)
reversed
Solar panel not connected
Solar panel defective Wire(s)
cut or disconnected
Use a multimeter to ver-
ify continuity and volt- age
output from solar panel(s)
Load icon off
Mode setting wrong
Battery low
Refer to load settings
earlier in this document
Load icon flash-
ing slowly
Overload
Short circuit on load output
Reduce load output or
correct short circuit. Try
again after 1 minute.
No display on
screen
Battery voltage too low or
battery polarity (+/-) incor-
rect
Check battery and / or
connection
Odd characters
on screen / in-
correct voltage
displayed
(verified with
multimeter)
Defective charge controller
Contact
Support
@CuttingEdgePower
.com
19
7. CEP200 BLACK MPPT CHARGE
CONTROLLER
Models Applications
DM200 All-in-one constant current MPPT charge controller
DM200-U All-in-one constant current MPPT charge controller with IoT function (built-in communication module)
DM200-C All-in-one constant current MPPT charge controller with IoT function (external communication module)
Version : V1.01 The above information is subject to change without prior notice.
20
SR-DM200 series waterproof all-in-one constant current MPPT charge controller integrates
MPPT solar charging management, LED step-up constant current drive, remote networking
communication and other functions, ideal for lead-acid battery/lithium battery / gel battery
etc. With high reliability, high efficiency, high precision and ease of installation and
maintenance, it has found wide applications in solar street lights, solar garden lights, etc.
Features:
MPPT technology, tracking efficiency up to 99.5%, charging conversion efficiency up to 96%;
Applicable to both lead-acid battery and lithium battery, operating parameters can be set by
remote control;
Very low sleep current, more energy efficient and convenient for long distance transportation
and storage;
Lead-acid battery constant voltage charging with multi-stage temperature compensation;
10-period programmable load power/time control;
Battery charge and discharge high and low temperature protection, with working
temperature settable;
Multiple intelligent power modes are available for selection, and load power can be adjusted
automatically according to the battery level;
High-precision digital step-up constant current control algorithm ensures high efficiency and
high constant current accuracy;
Infrared wireless communication allows for parameters setting/reading, status reading, etc.;
Multiple protections including battery/PV polarity reverse protection, LED short circuit/open
circuit/limited power protection and more;
Extensible to provide IoT remote communication monitoring function (-U/-C series);
All aluminum housing with up to IP68 waterproof rating meets the requirements of use in a
variety of harsh environments
7.2.1 MPPT charging introduction:
Common controller working point
Maximum power point
Voltage
(take 12V battery system as an example)
21
7.1 Overview
7.2 Instructions for Use
Cu
rren
t
MPPT (Maximum Power Point Tracking) is an advanced charging method. The MPPT
controller detects the generation power of solar panel in real time and tracks the highest
voltage and current value (VI), allowing the system to charge the battery with maximum
efficiency. Compared to traditional PWM controller, the MPPT controller can maximize the
power of solar panel and thus can provide a larger charging current. In general, the MPPT
controller can improve the energy utilization by 15% -20% compared with the PWM
controller.
Peak voltage (Vpp) of the solar panel is about 17V, while the battery voltage is about 12V.
In general, when the controller is charging the battery, the voltage of solar panel is about
12V and does not fully reach its maximum power. But, MPPT controller can overcome this
problem. It constantly adjusts the input voltage and current of the solar panel to achieve
the maximum input power.
Also, the maximum power point often changes due to different ambient temperature and
lighting conditions. The MPPT controller adjusts the parameters from time to time
according to different conditions, so that the system is always near the maximum
operating point.
MPPT cannot be used alone as a stage of charging. It is usually used to combine boost
charge, floating charge, equalizing charge and other charging methods to charge the
battery.
When the controller starts working, it will make a judgment of the battery voltage. If the
battery voltage is higher than 13.2 V (×2 / 24V), the controller will consider that the
battery is fully charged and will directly enter the floating charge stage without equalizing
charge or boost charge.
When the initial charging voltage of the battery is lower than 13.2V (×2 / 24V), the
charging process is:
MPPT charge – boost charge (equalizing charge) – floating charge, where the equalizing
charge interval is 30 days.
Voltage/current 1-hour equalizing charge Battery voltage (full charge)
Battery voltage (not full) Charge current
Voltage
Current MPPT
MPPT charge stage
4-hour boost charge
Floating charge to night
Time
Dawn Daytime Nighttime
Four-stage charging curve
22
Equalizing/boost charge stage
Floating charge stage
7.2.2 Sleep and wake-up:
Enter sleep:
Press the [OFF] button on the CU remote control or mini remote control. The controller will
turn off all external control devices, and then enters the sleep state of very low power
consumption, to avoid the lithium battery feed caused by not use for a long time;
Wake up from sleep:
1. Press the [ON] button on the CU remote control or mini remote control to wake up
the controller in a sleep state and turn it back to normal work;
2. PV wakeup:
A. If the option [Yes] is selected for the [PV wakeup] function, the controller entering sleep
mode, as connected to a PV panel, will be awakened in the daytime to charge the battery for
more than 30 minutes when the charging conditions are met. The load will be automatically
turned on at night. If the charging time is less than 30 minutes, the lights will not light up at
night, and the controller will continue to sleep;
B. If the option [No] is selected for the [PV wakeup] function, the controller entering sleep
mode, as connected to a PV panel, will be awakened in the daytime to charge the battery
when the charging conditions are met. But at night, the controller will continue to sleep.
(Note: [PV wakeup] function can be selected by CU remote control)
Controller Wake-up status method
Sleep Wakeup Charge Discharge
CU-ALL5 OFF button ON button -- --
CU-mini2 OFF button ON button -- --
PV Wakeup [Yes] -- PV charging for 1 minute
Normal charging in the daytime
If charged for 30 minutes in the daytime, battery can discharge at night
PV Wakeup [No] -- PV charging for 1 minute
Normal charging in the daytime
Battery does not discharge at night, controller continues to sleep
23
7.2.3 Indicator and remote control status:
DM200 CONTROLLER HAS THREE RED INDICATORS
Three red indicators:
Indicators Status Descriptions Remote control system status
PV indicator
Steady on Solar panel voltage is higher than
light control voltage Free
Off Solar panel voltage is lower than light
control voltage Free
Slow flash In charging Charging
Quick flash
BMS protection or full charge Or BAT overvoltage
Or PV overvoltage
Or over temperature (Ambient temperature) Or limited power/current charging
Full charge BAT overvoltage PV overvoltage Over temperature
Overcurrent
BAT indicator
Steady on Battery works properly Free
Off Battery is not connected or lithium battery over discharge protection
Quick flash Battery over discharge Over discharge
LOAD indicator
Steady on Load is turned on Discharge
Off Load is turned off Free
Slow flash Load open circuit Open circuit
Quick flash Load short circuit Short circuit
7.2.4 Intelligent power:
The SR-DM200 controller can select an appropriate intelligent power mode according to
the actual battery capacity, the number of rainy days and other factors. Specific intelligent
power modes include: High, Medium, Low, Auto, USE (custom), No (off).
Intelligent power modes:
High - The battery capacity at the starting point of power reduction is high, and the load
lighting time is the longest. This mode is suitable for use in areas with more rainy days or
poor lighting conditions;
Medium - The battery capacity at the starting point of power reduction is moderate, and
the load lighting time is moderate. This mode is suitable for use in scenarios where both
brightness and the number of rainy days are required to be considered;
Low - The battery capacity at the starting point of power reduction is low, and the load
lighting time is the shortest. This mode is suitable for use in scenarios where lighting effect
is highly required;
Intelligent power curve
24
30
25
20
15
10
22:2
3:2
0
23:0
7:5
0 23:5
2:2
0 0:3
6:5
0 1:2
1:2
0 2:0
5:5
0
2:5
0:2
0 3:3
4:5
0 4:1
9:2
0 5:0
3:5
0 5:4
8:2
0
6:3
2:5
0 7:1
7:2
0 8:0
1:5
0 8:4
6:2
0
9:3
0:5
0 10:1
5:2
0 11:0
0:2
0 11:4
4:5
0 12:2
9:2
0
13:1
3:5
0 13:5
8:2
0 14:4
2:5
0
15:2
7:2
0
Intelligent power experiment data
Comparison of intelligent power consumption and the number of rainy days
Intelligent power mode Power consumption per day Number of continuous working days
No 100% 1
Low 50% 2
Medium 25% 4
High 15% 6
Test descriptions: 1. The test battery is fully charged, and loads are consistent in the maximum power and
working time. 2. Assume that the power consumption is 100% when intelligent power mode is turned off. 3. Test result is the data obtained under a single condition (the charge amount is 0 per day).
Actual use may be different from the test condition, and the test result is for reference only.
Auto - High/medium/low intelligent power mode is automatically selected according to the
parameters such as charge amount and power consumption on the day;
For example, in summer, more charge amount is needed, so the controller will run in the
intelligent power mode - low, and lighting effect is better; in winter, however, less charge
amount is needed, so the controller will run in the intelligent power mode - high, and the load
works in a power saving mode, and can keep working in more rainy days.
USE (User-defined) - The user defines the voltage at the starting point of intelligent power
derating, the voltage at the ending point of power derating and the minimum load current
value;
Load current (mA) Derating starting point voltage
Derating ending point voltage
Minimum load current
150mA
12.7V 12.0V Battery voltage(V)
No (Off) —The intelligent power is turned off, and the load power is output according
to set time period.
7.2.5 Remote control operation:
Remote control CU-ALL5:
The communication between the controller and the handheld remote control CU-ALL5 can be
operated wirelessly or by IR. Press the [+] and [-] buttons on the remote control to select a
[Remote Control Type] (Infrared/Wireless) for remote operations. In actual use, the infrared
remote control signal is easy to attenuate under outdoor strong light, so the remote
communication distance is 5-6m, and the remote communication distance at night is 8-10m;
the wireless remote control signal can penetrate the plastic housing or aluminum housing,
and the wireless remote control distance can be adjusted in 0.3m to 20m.
25
Specific [Parameter settings] and [Run status] of remote control are as follows:
Parameter settings:
Items Default Range
Battery type Lead Lead / lithium 12V / lithium 24V
Sensing delay No No
PV wakeup Yes No/Yes
Light control voltage 5V 3V-11V
Light control delay 10s 5s-60min
Over discharge voltage 11.0V 9.00V-17.0V
Over discharge return voltage 12.6V 9.00V-17.0V
Boost charge voltage 14.4V 9.00V-17.0V
Floating charge voltage 13.8V 9.00V-17.0V
Low temperature charge -35℃ -35℃-0℃
High temperature working 65℃ 40℃-90℃
Load current 0.33A 0.15A-7.0A
Intelligent power Medium No/High/Medium/Low/Auto/*USE
*Derating start 12.4V 9.00V-17.0V
*Derating end 11.4V 9.00V-17.0V
*Minimum current 0.15A 0.05A-1.00A
Load parameter setting
Nth period of time 00:00-15:00
Power with person
detected 0%-100%
Power without person detected 0%-100%
Reset Yes No/Yes
Load parameter setting default value
Period H/M Power
1 00:30 50%
2 00:30 70%
3 02:00 100%
4 00:30 70%
5 00:30 50%
6 04:00 30%
7
00:00
0% 8
9
Predawn period
Status data:
Press the [Status] button on the remote control at any interface to read the [Run Status]
data of the controller;
Press and hold the [Status] button on the remote control at any interface to enter the
[Status Data] submenu, where you can choose to read [Run Status] / [History Data]. After
selecting the [Run Status] or [History Data], press the [Status] button to read corresponding
status data.
26
Run Status:
Status Instance Status value description
System status Discharge Current run status: discharge / charge / idle / full / over discharge, etc.
Battery voltage 12.3V Current battery voltage
PV voltage 17.6V Current PV panel voltage
Charge current 0.0A Current charge current
Charge power 0.0W Current charge power
Charge AH 0.01AH Charge AH in the daytime
Load voltage 27.1V Current load voltage
Load current 1.00A Current load current
Load power 27.2W Current load power
Lighting-up time 05:20 Total lighting-up time of loads in the nighttime
Sensing time 01:10 The lighting-up time of loads in the nighttime with
person sensed
Discharge AH 2.05AH Discharge AH in the nighttime
Ambient temperature 23℃ Current internal temperature
Running days 15D Cumulative running days
Number of times of over discharge 2N
Total number of times of lithium battery over discharge
Number of times of full charge 10N Total number of times of lithium battery full charge
Production Date 1810 Production date of controller
Software version 1000 Software version number of controller
History Data:
The controller can read the running data of controller in the past 30 days through the remote control, and the number of days to read can be selected.
Status Instance Status value description
---->Past N days<---- Number of days can be selected, N= 0-30
Minimum voltage 11.2V The minimum voltage of battery before N days
Maximum voltage 14.2V The maximum voltage of battery before N days
Maximum temperature 38℃ The maximum ambient temperature before N days
Minimum temperature 23℃ The minimum ambient temperature before N days
Charge power 205W The maximum charge power before N days
Lighting-up time 07:10 Night lighting-up time before N days
Charge AH 55AH Total charge AH before N days
Discharge AH 49AH Total discharge AH before N days
Charge WH 408WH Total charge WH before N days
Discharge WH 350WH Total discharge WH before N days
27
Remote control CU-mini2: (Optional)
The small remote control CU-mini2 is used for power on/off and testing.
A total of 7 buttons: [ON], [OFF], [70%], [50%], [30%], [+10%], [-10%]; button icons and descriptions are as follows:
Icon Description
ON Controller is awakened from sleep mode
OFF Controller enters a low power sleep mode
70% Controller runs for 1 minute at 70% of the set load current
50% Controller runs for 1 minute at 50% of the set load current
30% Controller runs for 1 minute at 30% of the set load current
+10%
Each time you press it, the test current increases by 10% and the controller runs for 1 minute.
-10 %
Each time you press it, the test current decreases by 10% and the controller runs for 1 minute.
7.3 Installation method: Installation method and size:
Controller dimensions are as follows:
Outline dimensions: 155*114.4*34mm
Installation size: 102*123mm
Hole diameter: φ3.5mm
Controller dimensions diagram:
90.4
28
Green power is changing our life.
ON OFF
70% 50% 30%
114.4
102
15
5
16
1
23
1
6
7
34
Items Values Adjus table Default
Models DM200 DM200-U DM200-C
Controller type All-in-one constant
current MPPT charge controller
All-in-one constant current MPPT charge controller with IoT function
System voltage 12V/24V Lead acid
Static power consumption ≤10mA/12V;≤5mA/24V
Sleep power consumption ≤1 mA
Load current 150mA ~ 7000mA √ 330mA
Load voltage 15V ~ 75V
Max. load power 100W/12V;200W/24V
Load conversion efficiency 98% (Typical efficiency: 85%-98%)
Load current accuracy ≤3%
Intelligent power High / Medium / Low / Auto / Custom / No √ Medium
Load working period 9 periods + predawn working period
Period adjustment range 1min. / 10min.
Power adjustment range 1% / 10%
Max. solar input power 260W/12V;520W/24V
Max. charge current 20A
Max. solar input voltage 95V (at minimum temperature);92V (at standard 25° C)
Overvoltage Pb-16.0V; Li- Overcharge voltage +2V;×2,24V system 16.0V
Charging limit voltage Pb-15.5V; Li- Overcharge voltage +1V;×2,24V system 15.5V
Equalizing charge voltage Pb-14.6V;Li-none;×2,24V system 14.6V
Equalizing charge interval 30 days 30D
Boost charge voltage (Lead-acid)
8.5V ~ 17.0V; ×2,24V system
√
14.4V Charge voltage (lithium battery)
Floating charge voltage (Lead-acid)
8.5V ~ 17.0V; ×2,24V system
√
13.8V Charge return voltage (lithium battery)
Over discharge voltage 8.5V ~ 17.0V; ×2,24V system √ 11.0V
Over discharge return voltage 8.5V ~ 17.0V; ×2,24V system √ 12.5V
Temperature compensation coefficient
Pb: -3.0mv/℃/2V; (Lithium battery without temperature compensation)
Light control voltage 3V ~ 11V;×2,24V system √ 5V
Light control delay 0s~60s/2min ~ 60min √ 10S
High temperature working 40℃ ~ +90℃ √ 65℃
Low temperature charging 0℃ ~ -35℃ √ -35℃
Operating temperature -35℃ ~ +65℃
IP rating IP68
Protections
Battery polarity reverse protection, solar panel polarity reverse protection, solar panel overvoltage protection, lithium battery overcharge and over discharge protection, lithium battery BMS overcharge detection protection, over temperature protection, load open circuit and short circuit protection, load overcurrent protection, etc.
Weight 770g
Controller dimensions 155*114.4*34mm
Controller installation size 102*123mm
Installation hole diameter φ3.5
29
7.3 Technical Parameters
● Waterproofing protection
Rating: IP67
● Lithium battery BMS overcharge detection protection
When the controller detects a BMS overcharge protection, it stops charging immediately, preventing the high voltage of PV panel from being applied to both ends of the BMS for a long time, which may cause damage of the battery.
● Lithium battery low temperature charge protection
When ambient temperature drops to the set value, the controller stops charging to protect the lithium battery from an irreversible damage caused by low temperature.
● High temperature protection
When ambient temperature is above the set value, the controller stops charging and discharging to protect the lithium battery from being damaged by excessive temperature.
● Battery reverse polarity protection
When the battery polarity is reversed, the system will not work but it will not burn out the controller.
● PV input end over voltage protection
When the voltage at the PV input end is too high, the controller will automatically shut off PV input.
● PV input end short circuit protection
When the voltage at the PV array input end is short circuited, the controller will turn off charging; after short circuit is removed, charging will automatically recover.
● PV input reverse polarity protection
When the polarity of PV array is reversed, the controller will not be damaged, and normal operation will continue after wiring error is corrected.
● Load power limit protection
When the power of LED lights that customer uses is too large, or the load current is adjusted to be too large, the controller will limit the load power output to less than the rated value, to ensure that the controller and LED load will not be damaged.
● Load overload and short circuit protection
When the number of connected LEDs in series is insufficient (3 or less), the controller will stop output immediately to protect LED loads or controller from damage;
When a short circuit occurs, the controller immediately turns off load output to prevent control damage. After the load short-circuit condition is removed, controller output automatically restores within 1 minute (if it is short-circuited for a long time, output will automatically restore once every 1 hour), or press and hold the test button on the remote control (CU or mini2) for 10S to automatically restore output.
● Load open-circuit protection
If wiring is suddenly disconnected while the LED load is normally running, the controller can immediately turn off load output and protect the controller from damage. After the load wiring is restored, the controller will automatically restore load output within 10 seconds (if the circuit is open for a long time, it will automatically restore output once every 1 hour), or press and hold the test button on the remote control (CU or mini2) for 10S to automatically restore output.
● Night reverse charging protection
Prevent battery discharge through the solar panel at night.
● TVS lightning protection
30
7.4 Protections
260W 520 W
17V ~72 V 34V ~72 V
100V
20A
100W 200 W
15V ~75 V 30V ~75 V
Note: controllers with antennas are of the Internet-of-Things version
1. Wiring sequence: Firstly connect the load, then the battery and finally the solar panel.
31
7.5 Electrical Wiring Diagram
No. Exceptions Problems Handling methods
1
Remote control cannot work
A. Remote control password is incorrect
B. Remote control working mode (infrared or wireless) is not selected properly
C. Wireless remote control distance is set too short
D. Remote control battery is low
B1. Press the “+” and “-” buttons at the same time to enter the [Remote Control Settings] interface and set a correct password. B2. Press the “+” and “-” buttons at the same time to enter the [Remote Control Settings] interface, and then select [Infrared Remote Control] or [Wireless Remote Control]. C1. Press the “+” and “-” buttons at the same time to enter the [Remote Control Settings] interface, and then increase the [Remote Control Distance] before testing. D1. Replace 2 AA (No. 5) batteries
2
The controller has no response after connected to the battery. Indicator does not light up and the remote control has no response.
A. There is a problem with
battery power supply B. The controller is in sleep
mode
A1. Check if battery wiring is intact. A2. Check if there is voltage on the battery and if the protection board is working. If there is no voltage on the battery, it indicates that the protection board has protected, and the battery can be charged to activate. B1. Press the "ON" button on the remote control to activate the controller B2. Connect the solar panel to charge the battery.
3
Charge is normal in the daytime, but the load does not light up at night, and the LED indicator on the controller does not light up.
A. The controller is in sleep state
A1. Press the “ON” button on the remote control to activate the controller. A2. Select <PV Wakeup> as Yes, and the controller will be automatically activated if charged in the daytime.
4
The battery indicator flashes quickly and the load LED does not light up.
A. The battery is low
A1. Check if the solar panel is charging properly and if the solar panel is covered. A2. Check if the wiring between battery and solar panel wiring is disconnected or loose.
5
Load lighting-up time is short
A. The battery is low B. The load power is too
large
A1. Check if the solar panel for proper charging and correct configuration. A2. Check if the lithium battery has a single-cell protection. A3. Open the "Intelligent Power" option B1. Check if the controller current is properly set and if the load power is right.
6
Load lighting-up current does not reach the set value
A. Intelligent power regulation of load current
B. LED power exceeds rated value
A1. Turn "Intelligent Power" off and test load current again B1. Lower the set value or replace the lamp with less number of LEDs in series.
7
Load indicator flashes and load LED does not light up.
A. Load open circuit B. LED load wiring is shorted
or the number of LEDs in series is less
A1. Check if load wiring is correct, and if the LED positive and negative poles are reversed. B1. Check if there is a short circuit in the load wiring, and if the LED positive and negative poles are reversed. B2. Check if the LED string is correct, and replace the lamp with appropriate number of LEDs in series and parallel.
8
LED load cannot be dimmed
A. There is a problem with the number of LEDs in series; a 3-LED (in series) or step- down lamp is used
A1. Replace a step-up (more than 5 LEDs in series) lamp
9
LED load lights up in the daytime or only lights up for one night
A. The solar panel is not connected
B. The solar panel polarity is reversed
A1. Check if the solar panel is connected properly and the wiring is reliable. B1. Reverse the solar panel wiring in the daytime to see if the charging indicator flashes.
10
Charging indicator does not flash slowly during charging when there is sunlight in the daytime.
A. Solar panel fault or wiring error.
A1. Check if the solar panel wiring is correct and reliable, and if the solar panel is covered.
11
LED load does not light up and the battery indicator is steady on.
A. The voltage of solar panel is not lower than the light control voltage or the delay time is not up. B. The controller runs out of time
A1. Wait for reduction of solar panel voltage, and then, LED load automatically lights up
B1. Controller recharge reset timer
12
Charging indicator flashes quickly and there is no charging current.
A. Lithium battery BMS overcharge protection
A1. Please wait, when the lithium battery voltage lowers to the overcharge return voltage, charging automatically restores.
32
7.6 Common Exceptions and Handling Methods
"Innovative Renewable Energy Solutions"
OUR STORY
Cutting Edge Power Inc. was founded in 2014 by a father and son in Dallas, TX. Jim and Bobby
are two engineers, still in their prime, who wanted to start a company with two requirements. True
to their engineering spirit, they decided the company had to 1) be related to the latest cutting edge
technology, and 2) only design really cool products!
Jim and Bobby learned that the true key to success would only come by helping other people
achieve their own success. Thus their conclusion was that Cutting Edge Power must
provide Innovative Renewable Energy Solutions to as many customers around the world as
possible. To accomplish this we developed a unique, rigorous design process so that we ALWAYS
remain cutting edge.
We are aware that to participate in this new global economy, companies must be lean, extremely
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We're the first to admit, independence is an American thing. Wait, maybe it's more of a Texas
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We won't stop until EVERYONE has Energy Independence!
CONTACT INFORMATION
1320 FM 100
Honey Grove, TX 75446
United States
(281) 786-4337
CuttingEdgePower.com
"Innovative Renewable Energy Solutions"