Manual - Renogy
PWM1020CC-D
Dual Battery PWM Charge Controller Manual
RNG Group Inc. (Renogy)
14288 Central Ave., Suite A Chino, CA 91710
1-800-330-8678
Contents
1. Important Safety Information
2
2. General Information
3
2.1 Overview
3
2.2 PWM Technology
3
2.3 Product Description
4
3. Installation Instructions
5
3.1 General Installation Notes
5
3.2 Mounting
5
3.3 Wiring
6
4. Settings
8
4.1 Battery Type
8
4.2 Charging Priority
8
4.3 Charging frequency
9
5. LED Indicators
5.1 Battery Indicators
9
9
6. Troubleshooting
10
7. Technical Specifications
10
7.1 Charge Controller
10
7.2 Battery Parameters
10
7.3 Dimensions
11
8. Warranty
12
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1. Important Safety Information
Save These Instructions
This manual contains important safety, installation and operating instructions for the
PWM1020CC-D controller. The following symbols are used throughout this manual to
indicate potentially dangerous conditions or mark important safety instructions. Please
take care when meeting these symbols.
WARNING: Indicates a potentially dangerous condition. Use extreme caution
when performing this task.
CAUTION: Indicates a critical procedure for safe and proper operation of the
controller
NOTE: Indicates a procedure or function that is important for the safe and
proper operation of the controller.
General Safety Information
Read all of the instructions and cautions in the manual before beginning
installation.
There are no user serviceable parts inside the PWM1020CC-D. Do not
disassemble or attempt to repair the controller. Disconnect the solar module and fuse/breakers near to battery before installing
or adjusting the PWM1020CC-D. Install external fuses/breakers as required. Do not allow water to enter the controller.
Confirm that the power connections are tightened to avoid excessive heating
from a loose connection.
Although the PWM1020CC-D controller is very simple to configure and use, please take
your time to read the operator's manual and become familiar with the controller. This will
help you make full use of all the functions and improve your solar PV system.
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2. General Information
2.1 Overview
The Renogy PWM1020CC-D features dual battery charging capability making it great for
RVs, caravans, and boats. With its advanced PWM charging technology, your batteries
will be protected from discharging and over-charging. The PWM1020CC-D has the
following features:
12V / 24V auto recognition
High efficient PWM charging, increase the battery lifetime and improve the solar
system performance.
Dual battery charging Sealed, Gel and Flooded battery option
Remote Temperature Sensor (sold separately)
Corrects the charging and discharging parameters automatically based on
temperature compensation, improving battery lifetime. This controller is specifically designed for mobile off-grid applications supporting 12V deep
cycle battery varieties such as sealed lead acid, gel, and flooded. The built-in RJ45
connector gives you the freedom of monitor the voltage, current and temperature of your
system via MT-1 remote meter (sold separately).
2.2 PWM Technology
The charge controller is based on advanced Pulse Width Modulation (PWM) charging
technology. With a charging range of 0-100%, it can charge a battery quickly and safely
under any condition of the solar photovoltaic system.
When charging, the controller utilizes automatic duty cycle conversion, creating pulses of
current to charge the battery. Intermissions make the oxygen and hydrogen generated by
chemical reactions combine again and become absorbed. This process can naturally
eliminate both concentration polarization and ohm polarization, and can also reduce the
internal pressure of the battery; thus, the battery will absorb more power. Pulse current
charging mode allows the battery more time to react, which reduces the gassing volume
and makes the battery improve the acceptance rate of the charging current.
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2.3 Product Description
Local Temp. Sensor
Setting Indicator LEDs
and Digital Display
Batt #1 Status LED
SET Button
Batt #2 Status LED
Remote Temp. Sensor
(Sold separately)
Remote Meter Connection
(RJ45)
Figure 2-1 Charge Controller detailed description
Remote Temperature Sensor (RTS)
A connection point for RTS (optional) to remotely monitor battery temperature.
Local Temperature Sensor
Measures ambient temperature. Battery regulation is adjusted accordingly.
Battery 1 Status LED
Provides charging & battery status and errors
Battery 2 Status LED
Provides charging & battery status and errors
Remote meter connection
A communication port for the remote meter MT-1 (sold separately).
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3. Installation Instructions
3.1 General Installation Notes
Read through the entire installation section first before beginning installation. Be very careful when working with batteries. Wear eye protection. Have fresh
water available to wash and clean any contact with battery acid.
Uses insulated tools and avoid placing metal objects near the batteries.
Explosive battery gasses may be present during charging. Be certain there is
sufficient ventilation to release the gasses. Avoid direct sunlight and do not install in locations where water can enter the
controller. Loose power connections and/or corroded wires may result in resistive
connections that melt wire insulation, burn surrounding materials, or even cause
fire. Ensure tight connections and use cable clamps to secure cables and prevent
them from swaying in mobile applications.
Use with Gel, Sealed or Flooded batteries only. Battery connection may be wired to one battery or a bank of batteries. The
following instructions refer to a single battery, but it is implied that the battery
connection can be made to either one battery or a group of batteries.
3.2 Mounting
NOTE: When mounting the PWM1020CC-D, ensure free airflow through the
controller heat sink fins. There should be at least 100mm of clearance above and
below the controller to allow for cooling. If mounted in an enclosure, ventilation is
highly recommended.
WARNING: Risk of explosion! Never install the PWM1020CC-D in a sealed
enclose with flooded batteries! Do not install in a confined area where battery
gas
can accumulate.
Step 1: Choose mounting location
Locate a vertical or horizontal surface protected from direct sunlight, high temperature,
and water.
Step 2: Check for Clearance
Place the PWM1020CC-D in the location where it will be mounted. Verify that there is
sufficient room to run wires and that there is sufficient room above and below the controller
for airflow. 5
Step 3: Mark Holes
Use a pencil or pen to mark the four (4) mounting hole locations on the mounting surface.
Step 4: Drill Holes
Remove the controller and drill four sizeable holes in the marked locations.
Step 5: Secure Controller
Place the controller on the surface and align the mounting holes with the drilled holes in
step 4. Secure the controller in place using mounting screws.
3.3 Wiring
NOTE: A recommended connection order has been provided for maximum
safety during installation. Figure 3-1 shows the correct order.
CAUTION: For mobile applications, be sure to secure all wiring. Use cable
clamps to prevent cables from swaying when the vehicle is in motion. Unsecured
cables create loose and resistive connections, which may lead to excessive heating
and/or fire.
Remote Meter Connection
(RJ45)
Remote Temp. Sensor
Figure 3-1 Connection order
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Step 1
Connect Battery 1: Refer to Figure 3-1. Connect the negative
terminal of Battery 1 to the negative terminal of the charge
controller under the Battery 1 logo. Then connect the positive
terminal of Battery 1 to the positive terminal of the charge
controller under the Battery 1 logo.
Step 2
Connect Battery 2: Repeat the process described in Step 1
for Battery 2. Figure 3-1 shows the connections. If you are not
planning on installing a second battery you can skip this step.
Step 3
Connect the solar panel(s): Refer to Figure 3-1.Connect the
negative PV lead of the solar panel to the negative terminal of
the charge controller under the solar array logo. Then connect
the positive lead of solar to the positive terminal of the charge
controller under the solar array logo. Make sure the solar
module(s) voltage and current do not exceed the ratings of the
charge controller.
Step 4
Connect the Remote Temperature Sensor (Optional): If you purchased the remote
temperature for your batteries, you can connect it in the remote temperature terminals
depicted in Figure 3-1. If you are not planning on using this sensor, you can skip this
step.
Note: When the RTS is not present, the controller will calculate the data from the local
temperature sensor. The controller will obtain data from RTS automatically when
present.
Step 5
Connect Remote Meter MT-1 (Optional): The remote meter MT-1 is sold separately
and can be connected in the RJ45 communication port. Again, if you are not planning
on using this meter, you can skip this step.
Once you finish the installation, the charge controller should be charging the
battery or batteries automatically with the current preset values. To adjust these
settings, please read Section 4.
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4. Settings
4.1 Battery Type
To select the battery type press the SET button on the controller a few times until the
“Battery Type” LED lights up. Press the setting button again and hold it for 5 seconds until
the digits start flashing. Press the setting button again to choose the battery type as
described in Table 4-1. Leave it in this position, and it will stop flashing after a few
seconds. The controller has recorded the battery setting.
Battery type
Sealed lead acid battery
Gel battery
Flooded battery
Digital display
1
2
3
Table 4-1 Battery type setting
4.2 Charging Priority
To adjust the charging priority of the batteries press the setting button on the controller a
few times until the “Charging priority” LED lights up. Press the setting button again and
hold it for 5 seconds until the digits start flashing. Press the setting button again to choose
the percentage level listed on Table 4-2. Leave it in this position, and it will stop flashing
after a few seconds. The controller has recorded the Charging priority setting.
Number
0
1
2
3
4
5
6
7
8
9
Battery #1
0%
10%
20%
30%
40%
50%
60%
70%
80%
90% (pre-set)
Battery #2
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
Table 4-2 Charging priority settings
Note: In the normal charging conditions, the controller will distribute the charge for the
selected setting. When Battery 1 is fully charged, charge will be diverted to Battery 2, and
return to the no. 4 charging priority setting automatically when Battery 1 is low on voltage.
When the controller detects that Battery 1 is the only battery connected, all the charge will
go to the Battery 1 automatically.
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4.3 Charging frequency
To change the charging frequency press the setting button on the controller a few times
until the “Charging frequency” LED lights up. Press the setting button again and hold it for
5 seconds until the digits start flashing. Press the setting button again to choose a charging
frequency listed on Table 4-3. Leave it in this position, and it will stop flashing after a few
seconds. The controller has recorded the Charging priority setting.
Number
0
1
2
PWM Charging Frequency
25 Hz (pre-set)
50 Hz
100 Hz
Table 4-3 Charging frequency settings
5. LED Indicators
Battery #1 Status LED Indicator
Battery #2 Status LED Indicator
Figure 5-2 Charge controller LED indicators
5.1 Battery Indicators
The LED indicator shown in Figure 5-2 will turn on whenever sunlight is available for
battery charging. Under normal charging conditions, the charging LED will lit red at all
times
Color
Red
Red
Red
Red
Red
Indication
Solid
Slowly Flashing
Frequent Flashing
Quickly Flashing
Off
Operating State
Charging
Full
Not Charging*
Short-circuit*
Battery not connected/Overvoltage*
Table 5-1 Battery LED indicators
*Please refer to Section 6 for troubleshooting
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6. Troubleshooting
Check all connections to ensure they are secure and clean
Check polarity of the battery connection and make sure the battery generates at
least 6V
Ensure the solar panels are exposed to sufficient light – ideally position them to
face the sun directly
If charge controller states that there is short-circuit, please ensure that the panels
are connected correctly, and that the wires at the terminals are not touching each
other.
If one of the status LED is off and a battery is connected, check that the battery
terminals have good connection and that the polarity is correct. Check that the
voltage doesn’t exceed the rated input voltage shown in Table 7-1 on Section 7.
If the charge controller is not charging, ensure that the panel’s polarity, and check
for loose connections.
7. Technical Specifications
7.1 Charge Controller
Description
Nominal System Voltage
Rated Charge Current
Rated Discharge Current
Maximum Battery Voltage
Max. Solar Input Voltage
Max. PV Input Power (10A Model)
Max. PV Input Power (20A Model)
Operating Temperature
Self-consumption
Terminals
Parameter
12VDC/24VDC Auto recognition
10A
10A
30V
30V (12V), 55V (24V)
120W (12V), 240W (24V)
240W (12V), 480W (24V)
−31°F to +131°F
4mA (idle), 10mA (charging)
4mm2
Table 7-1 Charge controller parameters
7.2 Battery Parameters (Temp: 25°C)
Battery Charging setting
Equalization Voltage
Boost Voltage
Float Voltage
Boost Duration
Control Parameter
Gel
14.8V
14.6V
13.7V
30 min.
Sealed
14.4V
14.2V
13.7V
30 min.
Flooded
14.6V
14.4V
13.7V
30 min.
Table 7-2 Battery Parameters
Note: Data is for 12V, for 24V, please use 2x.
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7.3 Dimensions [mm (inches)]
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7. Warranty
By acquiring the products of RNG Group Inc. ("Renogy"), you have purchased quality. As
a sign of confidence in this quality, we are pleased to grant you the following warranties
and guarantees for our photovoltaic products.
LIMITED WARRATNY: Renogy warrants this product will be free from defects in material
and manufacturer for the following periods from the date of purchase:
One (1) year on charge controllers
This warranty extends only to the original purchaser. The Customer’s sole and exclusive
remedy and the entire liability of Renogy, its suppliers and affiliates for breach of the
warranty is, either to replace the Product or component parts or to refund the purchase
price of the Product. This warranty does not cover labor. Repaired or replaced products
are warranted for the remainder of the original warranty period only. No employee, agent,
dealer or other person is authorized to give any warranties on behalf of Renogy not
expressly set forth in this limited warranty.
The warranty does not cover failures result from incorrect handling, product modifications,
installation, conversion or additions, supplements, operation, natural elements, excessive
or deficient energy supply, chemicals, the effect of solid bodies or deliberate damage. If
Renogy determines that the problem with the Product is not due to a manufacturing defect
in Renogy’s workmanship or materials, or otherwise does not qualify for warranty repair,
then the Customer will be responsible for the costs of all necessary repairs and expenses
incurred by Renogy.
The warranty shall be asserted with Renogy in writing enclosing a copy of the invoice and
a description of the defect/loss of performance within the warranty period. Renogy shall
accept no returns of modules without the previous written request for this. Within five (5)
business days of the date of notification, Renogy will provide the Customer with an RMA
number and the location to which the Customer must return the defective Product. Any
Product returned for warranty service shall be shipped at the expense and risk of the
Customer. The Customer must return the entire Product (or, if authorized by Renogy, the
defective component parts), within fifteen (15) days after issuance of the RMA number.
Renogy will be under no obligation to accept any returned Product that does not have a
valid RMA number. All parts that Renogy replaces shall become Renogy’s property on the
date Renogy ships the repaired Product or part back to the Customer. Renogy will use all
reasonable efforts within thirty (30) days of receipt of the defective Product to repair or
replace such Product. If a warranty claim is invalid for any reason, the Customer will be
charged at Renogy’s then-current rates for services performed and will be charged for all
necessary repairs and expense incurred by Renogy. If Renogy determines that a warranty
claim is valid, it will ship the repaired or replaced Product to Customer at Renogy’s cost.
RENOGY MAKES NO OTHER WARRANTIES OR CONDITIONS, EXPRESS OR
IMPLIED, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OR
CONDITION OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE
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OR ANY IMPLIED WARRANTY OR CONDITION ARISING OUT OF A COURSE OF
DEALING, CUSTOMER OR USAGE OF TRADE.
LIMITATION OF LIABILITY
UNDER NO CIRCUMSTANCES WILL RENOGY OR ITS AFFILIATES OR SUPPLIERS
BE LIABLE OR RESPONSIBLE FOR ANY LOSS OF USE, INTERRUPTION OF
BUSINESS, LOST PROFITS, LOST DATA, OR INDIRECT, SPECIAL, INCIDENTAL, OR
CONSEQUENTIAL DAMAGES OF ANY KIND REGARDLESS OF THE FORM OF
ACTION, WHETHER IN CONTRACT, TORT (INCLUDING NEGLIGENCE), STRICT
LIABILITY OR OTHERWISE, EVEN IF RENOGY OR ITS AFFILIATE OR SUPPLIER
HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGE.
Some states do not allow the exclusion or limitation of incidental or consequential
damages, so these limitations may not apply to you. Neither Renogy nor its affiliates or
suppliers will be held liable or responsible for any damage or loss to any items or products
connected to, powered by or otherwise attached to the Product. The total cumulative
liability to Customer, from all causes of action and all theories of liability, will be limited to
and will not exceed the purchase price of the Product paid by Customer. This warranty
gives you specific legal rights and you may also have other legal rights that vary from state
to state.
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