Solarmate charger controller user manual
Contents
1. 4 Connect the terminal marked battery positive on solar charge controller to the positive battery terminal and tighten the screws 5 Connect the terminal marked load negative on solar charge controller to the negative load terminal and tighten the screws 6 Connect the terminal marked load positive on solar charger controller to the positive battery terminal and tighten the screws 7 Connect a cable from controller s other terminal marked load negative to the negative terminal of your DC load and tighten the screws 8 Connect a cable from controller s other terminal marked load positive to the positive terminal of your DC load and tighten the screws Figure 1 9 PV charge control mode wiring Load negative PV negative Load positive PAP ee eth POON PV Array Positive Negative Controller DC Wiring BTS Wire eu og DC Load 2 10 Easily install in parallel connection In order to get more than 40A charge current Output of solar charger controller can be connected in parallel For example connecting 2 solar charger controller in parallel can get 80A charger current and connecting 3 solar charger controller in parallel can get 120A charger current Figure 1 10 Parallel connection 21 DV Array 1 DC Wiring Positive Negative C BTS Wire Controller Lighting ka 2 11 Battery type selector Please2. 2s 6s Off 0 all Over temperature 10 Blink green 1s 1s Blink red 1s 1s PV over voltage 11 Blink green 1s 1s Blink orange 1s 1s PV under voltage 12 Blink green 1s 6s Blink red 0 all BAT over voltage PB when solar charger controller starts wait for 3s if the start time is over 3s then mean that the BAT voltage 13 Blink green All O Blink red O all is out of the range Table 1 6 The LED indicators NOTE When solar charger controller is charging the green LED will be solid green 1 Low voltage disconnect When connected with DC load if voltage remains below low voltage disconnect setting controller will disconnect after a 1 minute delay period And controller waits until voltage rises above low voltage recovery setting 2 Over voltage of load If controller detects an over voltage of load it will disconnect load 3 Over temperature Temperature of the controller s transistors is continuously monitored This protects charge controller from damage in high temperature environments if excessive temperatures are detected While operating in charge mode controller will decrease charge current to reduce transistor temperature and the green led will be solid green If solar charger controller connected with DC load load is disconnected before transistors reach an excessive temperature and the green LED flashes Once temperature has dropped load
3. Automotive and truck batteries are designed for high cranking power not deep cycling Do not use them unless no other battery type is available They simply will not last long in a cycling application 6 3 Maintenance free batteries This type of battery is often sold as a RV or marine battery but is rarely appropriate for use with a PV system They typically have an additional reserve of electrolyte but are vented This is not the same as a sealed battery 6 4 Deep cycle batteries Best suited for use with PV systems this type of battery is designed to be more deeply discharged before being recharged Deep cycle batteries are available in many sizes and types The most common is vented liquid electrolyte battery Vented batteries usually have battery caps The caps may appear to be sealed but are not The caps should be removed periodically to check level of electrolyte When a cell is low distilled water should be added after battery is fully charged If level is extremely low add only enough distilled water to cover plates before recharging Electrolyte volume increases during charging process and battery will overflow if it is filled all of way up before recharging Use only distilled water because impurities will reduce battery performance A popular and inexpensive deep cycle battery is golf cart battery It is a 6 volt design typically rated at 220amphours RV and marine deep cycle batteries are also popular for small systems They
4. are usually referred to as group 24 or group 27 batteries and are rated at 80 to 100 amp hours at 12volts Many larger systems use L16 batteries which are usually rated at 350amp hours at 6 volts each They are 17 inches high and weigh about 130pounds 8D batteries are available with either cranking or deep cycle construction Purchase only deep cycle version 8D is typically rated at 220 amp hours at 12 volts 6 5 Sealed batteries Another type of battery construction is sealed gel cell They do not use battery caps Electrolyte is in form of a gel rather than a liquid which allows batteries to be mounted in any position The advantages are no maintenance long life 800 cycles claimed and low self discharge Absorbed glass mat AGM electrolyte batteries are also acceptable Their electrolyte is contained in mats between battery plates Sealed batteries reduce maintenance requirements for system and are good for remote applications They are much more sensitive to charging process and can be ruined in as little as a day of overcharging 6 6 Battery sizing Batteries are fuel tank of system The larger the batteries the longer the system can operate before recharging is necessary An undersized battery bank results in short battery life and disappointing system performance To determine proper battery bank size compute number of amp hours that will be used between charging cycles Once required amp hours are known size batteries at approximately
5. B SELECT Battery type selector CHG MODE Charge mode PV Photovoltaic MPPT Maximum power point tracking PWM Pulse width modulation RE Renewable energy 1 Product description 1 1 General description Solar charger controller is a 40 amp 12 24 voltage maximum power point tracking MPPT photovoltaic PV battery charge controller Through use of MPPT technology solar charger controller can increase charge current up to 30 or more compared to conventional controllers Solar charger controller s sophisticated three stage charge control system can be configured to optimize charge parameters to precise battery requirements The unit is fully protected against voltage transients over temperature over current reverse battery and reverse PV connections An automatic current limit feature allows use of full 40 amp capability without worrying about overload from excessive current voltage or amp hour based load control Solarmate passes pulse width modulation PWM charge voltage control combined with a multistage charge control algorithm leads to superior charging and enhanced battery performance Filtered PWM power control system uses highly efficient and reliable power MOSFET transistors MOSFET s are turned on and off at high frequency to precisely control charge voltage and MPPT Fully automatic temperature compensation of charge voltage is available to further improve charge control and battery performance Optional battery temperature se
6. Both conditions can be corrected by an equalization charge A proper equalization charge will not damage a vented liquid electrolyte type battery It may however cause significant electrolyte usage and require that battery be refilled with distilled water to correct level This may be a problem with unattended systems in remote areas which do not receive regular maintenance Consult battery manufacturer for their recommendations 6 8 Equalization setting points non sealed batteries only Table 1 10 Battery equalization Battery type Bulk volts Float volts Equalizing charge Default settings 14 0VDC 13 5VDC Disabled Sealed GEL battery 14 1VDC 13 6VDC Not recommended consult battery manufacturer AGM lead acid battery 14 4VDC 13 4VDC Charge to 15 5VDC or per manufacturer Maintenance free 14 4VDC 13 4VDC Limited appropriateness RV marine if water level can be checked Deep cycle liquid 14 6VDC 13 4VDC Charge to 15 5VDC or electrolyte lead antimony per antimony battery battery manufacturer NiCad or NiFe alkaline 16 0VDC 14 5VDC Not recommended battery consult battery manufacturer 32
7. reverse polarity solar charger controller will be protected by inner fuse and fuse will be open If PV array is connected reverse polarity charge control system will not turn on 1 8 Electrostatic handling precautious All electronic circuits may be damaged by static electricity To minimize likelihood of electrostatic damage discharge yourself by touching a water faucet or other electrical ground prior to handling the unit and avoid touching components on circuit boards Risk of electrostatic damage is the highest when relative humidity is below 40 1 9 Solar charger controller setup 1 9 1 Factory default settings Table 1 1 Factory shipping settings Basic settings Charge mode 3 stage Absorption voltage 14 4 28 8V Bulk voltage 14 6 29 2V Float voltage 13 4 26 8V Equalize 14 28V 1 10 Three stage charge control Solar charger controller is typically configured for a three stage charging process bulk absorption and float The three stage charge process provides a somewhat higher charge voltage to charge the battery quickly and safely Once battery is fully charged a somewhat lower voltage is applied maintain battery in a fully charged state without excessive water loss The three stage charge process charges battery as quickly as possible while minimizing battery water loss and maintenance Figure 1 1 Bulk charge curve Bulk Stage Absorption Stage Float Stage Charging Bulk Volts Setting Started
8. to a battery charging at 12 volts module still provides approximately the same current But because output voltage is now at 12 volts rather than 17 volts module power production is artificially limited and 75W module only delivers 53 watts This wastes 22 watts of available power Solar charger controller s MPPT technology operates in a very different fashion Under these conditions solar charger controller calculates the maximum power voltage V at which PV module delivers maximum power in this case 17 volts It then MPPT operates module 17 volts which extracts maximum available power from module Solar charger controller continually recalculates the maximum power voltage as operating conditions change Input power from the maximum power tracking controller in this case 75 watts feeds a switching type power converter which reduces the 17 volt input to battery voltage at output The full 75 watts which is now being delivered at 12 volts would produce a current of 6 25 amps A charge current increase of 1 8 amps or 40 is achieved by converting the 22 watts that would have been wasted into useable charge current Note that this example assumes 100 efficiency to illustrate principal of operation In actual operation boost will be somewhat less 1 7 Over voltage reverse polarity protection Solar charger controller is fully protected against reverse polarity and high voltage transients for both PV and battery connections If battery is connected
9. to provide explanations and procedures for installing operating maintaining and troubleshooting solar charge controller Scope This manual provides safety guidelines detailed planning and setup information procedures for installing solar charger controller as well as information about operating and troubleshooting the unit It does not provide details about particular brands of batteries You need to consult individual battery manufacturers for this information Audience This manual is intended for anyone who needs to install and operate solar charger controller Installers should be certified technicians or electricians Organization This manual is organized into six chapters Chapter 1 Product description Chapter 2 Installation Chapter 3 Operation Chapter 4 Troubleshooting Chapter 5 Specification Chapter 6 Battery Important safety instructions Save these instructions This manual contains important instructions for solar charger controller that shall be followed during installation and maintenance General 1 Refer installation and servicing to qualified service personnel Incorrect installation or use may result in risk of fire No user serviceable parts in this unit 2 Remove all sources of power photovoltaic and battery before servicing or installing 3 Warning risk of explosive gases 1 When solar charger controller is working please DO NOT touch it because temperature is too high 2 Working in v
10. 7 5 SpecificatiONS iaiia aaa Banana AN RAN BER Ra nan an ana ana 28 DENIS E eae aa Re eal Ba RAG BAAR AR EE 28 5 2 Environmental ecwcn cai wien ee ena Ren een A Ren een a Reh EE Geena Renan aul 28 5 2 1 Temperature ooooooooWoW W WWW W manakala 28 5 3 Safety and EM 28 5 3 2 European market CEA 29 SEET ea 29 5 4 1 Operating humidity 2 0 0 0 eect eee eee JW llnnnaknn nakal 29 5 4 2 Non operating huMidity ooooo WoWoW Wo WWW m Jallnnakaan nakal 29 5 5 Mechanical features 29 5 6 Detailed dimension drawing WWW WWW o Wo Wc WWW 30 Bare eeh 31 6 1 Battes Nb rss Nan NN 31 6 2 Automotive batteries Woo Wo WWW Wanna 31 6 3 Maintenance free baiterles WWW WWW ombak 31 6 4 Deep cycle batteries WWW Wo W oa 31 6 5 Sealed batere dd naa na an aa an in alan inna oi aan 31 6 6 Battery SiZing ooooooo W Wo eee eee eee WWW W Waka 31 6 7 EqualiZatiom CMarging evict eit eae SN te eat arena aan See eee agan sak 31 6 8 Equalization setting points non sealed batteries only 32 Tables Table 1 1 Factory shipping settings oooooooW Wc oom WWW WWW bakalan 10 Table 1 2 Battery type selector switch eettngs Woo Wo Wo W oo 16 Table 1 3 Temperature compensation calculatiON oo oW Woo W Wo W oo oom 18 Table 1 4 Battery compensation Coeiftdent WWW WWW o WoWoW Wanna 18 Table 1 5 Minimum Wire size 20 Table 1 6 The LED indicators oooo W
11. Absorption Time Float Vois Setting DC Voltage Constant Voltage Reduced Voltage 1 10 1 Bulk charge When charge starts solar charger controller attempts to apply bulk charge voltage to battery The system will switch to bulk charge if battery is sufficiently discharged and or insufficient charge current is available to drive battery up to bulk voltage setting point During bulk charge stage the unit delivers as much charge current as possible to rapidly recharge battery Once charge control system enters absorption or float the unit will again switch to bulk charge if battery voltage drops below the present charge voltage setting point 1 10 2 Absorption charge During this stage the unit changes to a constant voltage mode where absorption voltage is applied to battery 10 When charge current decreases to float transition current setting battery is fully charged and the unit switches to the float stage 1 10 3 Float charge During this stage float voltage is applied to battery to maintain it in a fully charged state When battery voltage drops below float setting for a cumulative period a new bulk cycle will be triggered 1 11 Battery temperature sensor BTS Charge voltage required by batteries changes with battery temperature Temperature compensation of charge voltage enhances battery performance and life and decreases battery maintenance Automatic temperature compensation can be provided through use of optional battery temperat
12. Beban Hanan Dejan binaan Bajang Banua bapa asa ik 14 2 1 Pre InstallatiOn aa aa na ene A A a 14 2 2 Removing the top Cover 14 2 3 Mounting the solar charger controller oooooooooWooW WWW Wc 14 2 3 Mounting the solar charger controller oooooooWooW WWW WWW 15 2 3 1 Mount the solar charge controller om Wcom 15 2 4 Configuring the solar charge controller Wo o Wo WWW WWW allnnaakann 16 2 4 1 Battery type selector can apply different charger method 16 2 5 Temperature compensation siiin a a Ed EENEG 17 2 5 1 Automatic battery temperature COMPENSATION Woo WWW 18 PAEROA ILAE PEN oa ananda mean an aan tandan nana Banana Badan 19 2 7 DC terminal connector Jocattons WWW Wc WWW WWW 19 2 8 Wire Size and over current protection requirements Woo WWW Woo 19 281 er n t Cl EE 19 2 8 2 SUrge Protecto Nitis na a a E A E E E 20 2 8 9 Over current PFOLSCHION TEE 20 2 9 PV Charge and load control mode wirimg nnne 20 2 10 Easily install in parallel connection oo ooooWooWoW Woo Wc WWW 21 211 Battery e EE 22 2 12 Installing optional accessorieS oooo oWW Woo WWW Wo WWW Wen 23 2 13 Reinstalling the faceplate Woo WoW WWW WWW Jaana 23 Os Operat onn aen an en na Bean an SENERE na eee 25 311 BaSid OPSLAUOM 222 Maa han an Nan pe Nan na En ana 25 3 2 LED Status ue ee EE 25 3 2 1 Charge control indications oooo Woo WWW 25 4 Troubleshooting 2 bean sama aa aa aa EN Ra na an Ran aa anna 2
13. LLECT Table 1 2 Battery type selector switch settings 12 volt 24 volt Charge function Switch D ipti position SC P 0 Float voltage Bulk equalize Float voltage Bulk egualize Equalize Equalize V voltage V V voltage V charge rate time Equalize 1 equalizes at a rate equal to Depend on g he banery 13 2 15 26 4 30 M ax 40Amp battery bank capacity in amp capacity hours divided by 40 Equalize 2 depend on 1 customer Reserved Reserved Reserved Reserved reset Provides an additional float and bulk settings Deep cell for deep cycle lead acid 2 lead GE 2 13 3 15 26 6 30 batteries Refer to battery manufacturer recommendation for float and bulk settings Provides an additional 3 Not specified 13 6 14 3 27 2 28 6 setting of bulk and float voltages Recommended for GEL cell batteries that specify 4 GEL cell 2 13 7 14 4 27 4 28 8 high float voltages Check with battery manufacturer 5 GEL cell 1 13 5 14 1 27 28 2 Typical gel cell setting Use this setting for 6 pene 13 2 14 3 26 4 28 6 sealed type car batteries AA o Factory setting for 7 default 13 4 14 6 26 8 29 2 typical deep cycle lead acid batteries setting Use for NiCad battery 8 NiCad 1 14 16 28 32 systems Recommended for use S SES 14 5 18 SS ee with nickel iron batteries lt Important 1 Switch positions 0 and 1 are for
14. Solarmate charger controller user manual LOAD BATTERY Contents Important safety instructions oooooooocooWoWoWcoWo WWW mma 6 1 Product deSCFIpI TEE 8 Ie General ON AA ATA SA ANN AN RN AA NE NN EN NN NN NS un 8 EA ETO EESE AA Ka ana bana ana ana Mn ana em ed ena Tan ea aa 8 1 3 Maximum setting point voltage mt 9 1 4 Temperature and output power iioooooo o Wo WoWoWo W W W W makananenak 9 1 5 Maximum power point tracking MPPT iooo oo o WoWoWoW oo Wanna 9 1 6 HOW MPPT WOKS nba an aan aa aa maa mn ana 9 1 7 Over voltage reverse polarity protection o oooooo Woo Woo WWW mmm 9 1 8 Electrostatic handling preCa utiouS WooWoWo WoW WWW Wc WWW 10 1 9 Solar charger controller setup ooooocoWoWoWo WoW WWW WWW benak 10 1 9 1 Factory default settmges Woo WWW anna 10 1 10 Three stage charge Control 10 EE 1051 Cen EE 10 1 10 2 Absorption charge 10 110 3 Float Charge E 11 1 11 Battery temperature sensor DIE 11 1 12 Equalization Charge oooooooWooW Wo oWo W ombak 11 1 12 1 Photovoltaic charge and load controller Woo WWW 11 1 12 2 Automatic PV array night disconnect oooo oW Woo Wo W WWW Wana 12 1 12 3 Solar charger controller load Control 12 1 12 4 Low voltage deconmec Wana 12 1 12 5 Low voltage reconnect eed eeeaaaaeeeeeeesgeecaaaeeeeeeeeeseecnaeeeeeees 12 1 13 Optional acceseorles Wo Woo manakala 13 2 InstallatiON44 3 Bana ears sage aps aa an Hamas
15. Surge protection Since PV arrays are often mounted on an elevated structure and thus are more susceptible to lightning strikes protection from lightning induced power surges and other transient power disturbances between PV array and solar charge controller are strongly recommended Because solar charger controller has wider input voltage range 15 55VDC 2 8 3 Over current protection If controller detects an overload it will automatically resets over current protection system every 6 minutes If the default is still present controller will shut off and wait another 6 minutes This will occur continuously until the problem is corrected Table 1 5 Minimum wire size Controller Minimum wire size 12 24VDC 8AWG 2 9 PV charge and load control mode wiring The procedure below is illustrated in Figure 1 9 s WARNING Shock hazard PV arrays generate voltage whenever light strikes surface of array Before connecting solar charge controller cover or disconnect array to prevent any current from being generated 1 Connect the PV array s positive output to the terminal marked PV positive on solar charge controller and tighten the screws 2 Connect the PV array s negative output to the terminal marked PV negative on solar charge controller and tighten the screws 3 Connect the terminal marked battery negative on solar charge controller to the negative battery terminal and tighten the screws
16. When temperature rises above 25 C regulation battery voltage setting automatically decreases 18 2 6 Grounding Solar charge controller is designed to work with grounded electrical systems In solar charger controller ground is not connected to input terminal and output terminal so customer can connect ground to battery or batter But don t connect battery terminal and PV output terminal with ground at same time Figure 1 7 Safety earth ground en Safety earth ground 2 7 DC terminal connector locations Terminal connectors for DC wiring are located on the lower edge of circuit board Terminal torque requirements Once wires have been installed torque terminals as follows Be careful not to over tighten Figure 1 8 DC terminal connector locations Load negative PV negative Load positive PV positive Battery negative Battery positive 2 8 Wire size and over current protection requirements The wiring over current protection devices fuses and installation methods used must conform to all national and local electrical code requirements Wiring should be protected from physical damage with conduit or a strain relief clamp 2 8 1 Current rating Solar charge controller is rated for a rating continuous current of 40 amps Since PV outputs can vary due to array size or sunlight striking it the safe minimum wire size should be based on the maximum current ratings 19 2 8 2
17. d controller solar charger controller will disconnect load from batteries when it reaches LVD setting There will be a 1 minute delay after voltage drops below low voltage disconnect LVD setting before controller actually disconnects load 1 12 5 Low voltage reconnection It can also provide automatic reconnection of loads at the low voltage reconnect LVR setting Reconnection of load is allowed once battery voltage has exceeded low voltage reconnect LVR setting Loads are either automatically when battery voltage exceeds low voltage reconnect LVR setting for 1 minutes Figure 1 3 Load controller Important When using solar charger controller load control 1 Do not temperature compensate these settings 12 2 Do not install optional battery temperature compensation sensor 1 13 Optional accessories The follow accessories can be purchased for use with solar charger controller Battery temperature sensor BTS BTS is installed on the side of battery and attaches to RS232 port inside solar charger controller It provides accurate sensing of battery temperature and uses this reading to control charging Using this accessory can extend battery life and improve overall charging 13 2 Installation 2 1 Pre installation The instructions that follow are applicable to typical installation For special applications consult a qualified electrician or your certified dealer Installation procedures will vary according to your sp
18. ecific application lt Important Installations should meet all local codes and standards Installations of this equipment should only be performed by skilled personnel such as qualified electricians and certified renewable energy RE system installers 2 2 Removing top cover 1 Access inside of solar charger controller by removing the four screws M3 6 on cover of the unit 2 Remove top cover of solar charger controller Figure 1 4 Removing top cover Dmna tt Remove these screws M3 6 4 from top cover to access heat sink of controller Remove top cover 14 2 3 Mounting solar charger controller Solar charger controller is designed for indoor mounting Care should be taken in selecting a location and when mounting enclosure Avoid mounting it in direct sunlight to prevent heating of enclosure Enclosure should be mounted vertically on a wall In outdoor installations solar charge controller must be installed in a rainproof enclosure to eliminate exposure to rain mist or water spray lt Caution Damage to solar charge controller install solar charge controller in a dry protected location away from sources of high temperature moisture and vibration Exposure to saltwater is particularly destructive Corrosion is not covered by warranty 2 3 1 Mount solar charge controller 1 Place controller on desired mounting surface and mark location of keyhole slots on wall 2 Move controller out of way and secure t
19. icinity of lead acid batteries is dangerous Batteries produce explosive gasses during normal battery operation 3 To reduce risk of battery explosion follow these instructions and those published by battery manufacturer and manufacturer of any equipment you intend to use in vicinity of battery 4 Personal precautions 1 Someone should be within range of your voice or close enough to come to your aid when you work near a lead acid battery 2 Have plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eyes 3 Wear complete eye protection and clothing protection Avoid touching eyes while working near battery 4 If battery acid contacts skin or clothing wash immediately with soap and water If acid enters eye immediately flood eye with running cold water for at least 10 minutes and get medical attention immediately 5 NEVER smoke or allow a spark or flame in vicinity of battery 6 Be extra cautious to reduce risk of dropping metal tool onto battery It might spark or short circuit battery or other electrical part that may cause explosion 7 Remove personal metal items such as rings bracelets necklaces and watches when working with a lead acid battery A lead acid battery can produce a short circuit current high enough to weld a ring or the like to metal causing a severe burn 5 Preparing to charge 1 Never charge a frozen battery 2 Be sure battery is mounted in a well ventilated compart
20. ion for solar charge controller 5 1 Specifications Table 1 8 Electrical specification Rated voltage 12 24VDC a w current include load 40Amp Load current 15Amp Input voltage range 15 55VDC Max PV open circuit array voltage 55VDC Overload protection DC load 2 0 Inom gt 5s 1 5 Inom gt 20s 1 25 Inom temperature controlled Typical idle consumption At idle lt 10mA Bulk charge 14 6VDC default 29 2VDC default Floating charge 13 4VDC default 26 8VDC default Equalization charge 14 0VDC default 28 0Vdc default Over charge disconnection 14 8VDC 29 6VDC Over charge recovery 13 6VDC 27 2VDC Over discharge disconnection 10 8VDC default 21 6VDC default Over discharge reconnection 12 3VDC 24 6VDC Temperature compensation 13 2mV C 26 4mV C Lead acid battery settings Adjustable NiCad battery settings Adjustable Load control mode 1 Low voltage reconnect LVR adjustable 2 Low voltage disconnect LVD automatic disconnection 3 Reconnection includes warning flash before disconnect and reconnection Low voltage reconnect 12 0 14 0VDC 24 0 28 0VDC Low voltage disconnect 10 5 12 5VDC 21 0 25 0VDC Ambient temperature 0 40 C full load 40 60 C de rating Altitude Operating 5000 m Non operating 16000 m Protection class IP21 Battery temperature sensor BTS optional remote battery temperature sensor fo
21. ment 3 Add distilled water in each cell until battery acid reaches level specified by battery manufacturer This helps purge excessive gas from cells Do not overfill For a battery without cell caps carefully follow manufacturers charging instructions 6 Charger location amp installation 1 Controller employs components that tend to produce arcs or sparks NEVER install in battery compartment or in presence of explosive gases 2 Protect all wiring from physical damage vibration and excessive heat 3 Insure that controller is properly setup for battery being charged 4 Do not expose controller to rain or snow 5 Insure all terminating connections are clean and tight to prevent arcing and overheating 6 Charging system must be properly installed as described in these instructions prior to operation 7 Do not connect to a PV array capable of producing greater than 40 amps of short circuit current 25 C 8 Do not connect input to DC source directly with load solar charger controller need to be powered by solar panel 9 Do not short circuit DC output port it will damage solar charger controller Symbol A Warning A Dangerous Voltage Alternative Current Direct Current D Protective Earth A de Esp Abbreviations and Acronyms BTS Battery temperature sensor DC Direct current LED Light emitting diode LVD Low voltage disconnect LVR Low voltage reconnect
22. monthly battery maintenance only Equalize voltages are displayed in the table with an asterisk Switch positions 0 and 1 only 2 Switch position 7 is default values as shipped from factory 3 Always refer to battery manufacturer s specifications for equalization 2 5 Temperature compensation For optimal battery charging bulk and float charge rates should be adjusted according to temperature of battery When battery charging voltages are compensated based on temperature charge voltage will vary depending on temperature around batteries 2 5 1 Temperature compensation based on battery type Charge voltage required by batteries changes with battery temperature Temperature compensation of charge voltage enhances battery performance and life and decreases battery maintenance Automatic temperature compensation can be provided through use of optional battery temperature sensor The following table describes approximately how much voltage may vary depending on temperature of the batteries Temperature compensation is based on battery type 5mv cell for lead acid type batteries and 2mv cell for alkaline type batteries NiCad or NiFe Temperature compensation calculations are derived from the following table Table 1 3 Temperature compensation calculation Battery type 12 volt 24 volt Lead acid Do volts 30mv per degree Celsius 0 06 volts 60mv per degree Celsius 0 04 volts 40mv per degree 0 02 volt
23. nsor is built for long term reliability The sensor element is environmentally sealed and encapsulated into a plastic lug which adheres to directly to battery terminal and by RJ11 port connect with the unit and solar charger controller also includes an isolated RS232 port for connection to a PC computer for data logging and system monitoring Solar charger controller can easily install in parallel connection of output so it also suitable for large system current application condition 1 2 Features ADC Load output port An optional battery temperature sensor ensures precise battery charging LED displays to indicate the status of charge Lightning protection Reverse current at night Three stage battery charging bulk absorption and float with optional temperature compensation Automatic overload protection Microprocessor controlled Silent pulse width modulated PWM high efficiency operation OONDARWND 1 3 Maximum setting point voltage limit Very cold batteries combined with high charge voltage setting points can produce voltages high enough to disrupt or damage other equipment connected to battery To minimize possible damage a maximum voltage setting point limit feature is provided Factory defaults can be adjustable using software Regardless of what setting point values result from temperature compensation solar charger controller will never attempt to apply a charge voltage greater than the maximum voltage
24. ntains information about operation of solar charge controller 3 1 Basic Operation Solar charge controller has one blue and multicolor LED status indicator one battery type selector Figure 1 14 LED status indicator Single color LED indicator Multicolor LED indicator 3 2 LED Status Indicator Solar charger controller has one multicolor LED and one green LED to indicate operating status The green LED indicates whether charging source is functioning properly when it display solid green or type of fault when it flash And the multi color LED indicates particular operating mode and batteries capacity level 3 2 1 Charge control indications LED1 LED2 Operation State On Off State On Off Description mode 1 Solid green All 0 Solid red All 0 Charge ON PV gt BV BAT lt LVD Charge ON PV gt BV Normal 2 Solid green All 0 Solid orange All 0 LVD lt BAT lt LVR 3 Solid green All 0 Solid green All 0 Charge ON PV gt BV BAT gt LVR Solid green All 0 Blinkred 1s 1s Charge ON PV gt BV BAT lt LVD Charge ON PV gt BV Derated 5 Solid green All 0 Blink orange 1s 1s LVD lt BAT lt LVR 6 Solid green All 0 Blink green 1s 1s Charge ON PV gt BV BAT gt LVR 7 Off 0 all Blink orange 1s 6s BAT under voltage Fault DC load overcurrentor dc 8 Blink green 3s 6s Off 0 all load voltage out of the range 9 Blink green
25. o Wo WoWoWo W oo WWW mall 26 Table 1 7 Troubleshooting West 27 Table 1 8 Electrical specificatiOn o ooooooooooWoW Woo oo WWW manakala 28 Table 1 9 Mechanical specification Woo Woo WWW W Wek 29 Table 1 10 Battery equalization o ooooooooWooWoW WWW WWW Wanna 32 Figures Figure 1 1 Bulk charge cume WWW nana 10 Figure 1 2 PV charge and load controller ooooooWo WoWoWoWo Woo WWW Waka 12 Figure 1 3 Load Controller ooooooooooWo W W W nnnnnaka nakal 12 Figure 1 4 Removing the topCOVeT ooooWoWooWooWoWo WWW 14 Figure 1 5 Mounting the solar charge controller oooooWoo WWW oom Wc 15 Figure 1 6 Battery type selector D GEI 16 Figure 1 7 Safety earth ground oom WWW 19 Figure 1 8 DC terminal connector locations ooooooooWoWcoWoW WWW kanan 19 Figure 1 9 PV charge control mode wiring oooo WoWWoW Woo Wcom Wanna 20 Figure 1 10 Parallel connection oo WWW mc nnaknnlnn kkn 21 Figure 1 11 battery type selector oooooo Wo WWW oWoWo Wc WWW 22 kigure 1 5412 Install EB TS ENEE 23 Figure 1 13 Reinstalling the faceplate nerne nn nr Wakai 24 Figure 1 14 LED status indicator oooo oWW WWW WWW Wanna 25 Figure 1 15 Solar charger controller dimension drawing ooooooWoWoooWoWoWoW Woo 30 About manual Purpose The purpose of this manual is
26. on but no output charge current Battery voltage greater than charge voltage setting point Battery voltage too low This is normal operation Output is off due to high battery voltage which may be caused by other charging systems Battery voltage must be at least 9VDC for the unit to operate Charge current is lower than expected PV current may be low as well Battery is highly charged Worn out PV modules Low isolation PV connected to BAT Nominal PV voltage has changed from 24VDC to 12VDC Normal operation current is reduced if battery voltage is at setting point Replace or use as it Atmospheric haze PV s dirty sun low on horizon etc PV amp BAT must be separate for proper operation PV must receive earth ground via shunts inside the Solar charger controller which internally connect PV to BAT External connection prevents proper operation of internal shunts and current measurement system If PV voltage is changed from 24VDC to 12VDC battery and PV power must be removed momentarily to reboot the unit and load initial 12VDC PV control values The unit considers PV s to 24VDC if PV voltage ever goes above 30VDC Charge OFF at high temperature System temporarily shuts down due to high heat sink temperature Improve ventilation or reduce PV power Sufficient ventilation to prevent over temperature shut down 2 27 5 Specifications Specifications provide specificat
27. ower vs temperature characteristic is such that a cool PV array can produce a higher voltage and more power than a hot PV array When PV voltage is sufficiently high for MPPT to operate a constant power output is delivered to battery Since output power is constant while MPPT is operating a decrease in battery voltage produces corresponding increase in charge current This means that the greatest current increase occurs with a combination of cool ambient temperature and low battery voltage The unit delivers the greatest charge current increase when you need it most in cold weather with a discharged battery Additionally anything that can be done to lower PV array temperature will also lead to increased charge current by increasing PV power production In cool comfortable temperatures and typical battery states of charge most systems see about 10 20 increase Charge current increase can go to zero in hot temperatures whereas charge current increase can easily exceed 30 with a discharged battery and freezing temperatures 1 6 How MPPT works A PV module is a constant current type device As shown on a typical PV module voltage vs current curve current remains relatively constant over a wide range of voltage A typical 75 watt module is specified to deliver 4 45 amps 17 volts 25 C cell temperature Conventional PV controllers essentially connect PV array directly to battery when battery is discharged When a 75 watt module is connected directly
28. r increased charging precision Terminal size fine single wire 8AWG 5 2 Environmental 5 2 1 Temperature 5 2 1 1 Operating Temperature 0 C to 40 C 40 C to 60 C de rating 5 2 1 2 Transit temperature 25 C to 70 C 5 2 1 3 Storage temperature 25 C to 70 C 5 3 Safety and EMC 28 5 3 2 European market CE 5 3 2 1 Compliant with EN 60335 1 5 3 2 2 Compliant with EN61000 6 1 2001 5 3 2 3 Compliant with EN61000 6 3 2001 5 4 Humidity 5 4 1 Operating humidity 20 to 80 relative humidity non condensing 5 4 2 Non operating humidity 5 to 95 relative humidity 38 7 C maximum wet bulb temperature with no cosmetic damage 5 5 Mechanical features Table 1 9 Mechanical specification tems JL Sorten Depth lt 202 mm Dimension H x W x D Height lt 66 mm Width lt 140 mm Mounting Vertical wall mount indoor only 29 5 6 Detailed dimension drawing Figure 1 15 Solar charger controller dimension drawing SS e fr NN III 30 6 Batteries 6 1 Battery Types Batteries come in different sizes types amp hour capacity voltages and chemistries Here are a few guidelines that will help in battery selection and ensure that the batteries are properly maintained The best source of the most appropriate settings for solar charger controller will be from manufacturer or supplier of the batteries 6 2 Automotive batteries
29. s 20mv per degree Celsius Celsius 2 5 2 Automatic battery temperature compensation Temperature compensation can be accomplished automatically by using a battery temperature sensor BTS The sensor attaches directly to the side of one of batteries in bank and provides precise battery temperature See Installing the battery temperature sensor for detailed instructions on how and where to install BTS If a BTS is installed charge controlling process will be automatically adjusted for battery temperature When using a BTS set bulk and float voltage for a battery at normal room temperature for 25 C Table 1 4 Battery compensation coefficient SEN 12 volt 24 volt Celsius Fahrenheit Za 10 cells 12 cells 20 cells 60 140 1 05 0 7 2 1 1 4 55 131 0 9 0 6 1 8 1 2 50 122 0 75 0 5 1 5 1 45 113 0 6 0 4 1 2 0 8 40 104 0 45 0 3 0 9 0 6 35 95 0 3 0 2 0 6 0 4 30 86 0 15 0 1 0 3 0 2 25 77 0 0 0 0 20 68 0 15 0 1 0 3 0 2 15 59 0 3 0 2 0 6 0 4 10 50 0 45 0 3 0 9 0 6 5 41 0 6 0 4 1 2 0 8 0 32 0 75 0 5 1 5 1 5 23 0 9 0 6 1 8 1 2 10 14 1 05 0 7 2 1 1 4 15 5 1 2 0 8 24 1 6 20 4 1 35 0 9 27 1 8 25 13 1 5 1 3 2 30 22 1 65 1 1 3 3 2 2 35 31 1 8 1 2 3 6 2 4 40 40 1 95 1 3 3 9 2 6 If using a BTS when battery temperature drops below 25 C regulation voltage setting automatically increases
30. s are reconnected 4 Over current of load If controller detects an overload or short circuit of load it will automatically resets over current protection system every 6 minutes If the default is still present controller will shut off and wait another 6 minutes This will occur continuously until the problem is corrected 26 4 Troubleshooting Table 1 7 Troubleshooting list Symptom Probable cause Items to examine or correct Completely dead no display No battery power Battery disconnected overly discharged or connected reversely no display polarity Battery powers system not PV Unit will not turn on charge status LED off display if attached is OK PV disconnected PV reverse polarity PV connected to BAT external to controller PV disconnected PV must supply at least 0 25Amp at 3V more than battery voltage to begin charge PV reverse polarity reverse polarity PV will cause heat sink to heat PV amp BAT must be separate for proper operation PV must receive earth ground via shunts inside the solar charger controller which internally connect PV to BAT External connection prevents proper operation of internal shunts and current measurement system Battery voltage is determined automatically when the unit first receives power Voltage must be less than 30VDC for 12VDC battery or greater than 30VDC for 24VDC battery Apply battery quickly and crisply Charge status LED
31. see 2 5 1 section which you find the different one of 10 positions stand for different battery types specified You can select solar charger controller for proper float and bulk voltage levels These levels are selected depending on type of batteries used Refer to the table below for charge voltages in various switch positions Consult battery manufacturer for optimum battery voltage charging settings Figure 1 11 Battery type selector Please use truss screwdriver to select proper position 22 2 12 Installing optional accessories The following sections describe how to install optional accessories available for solar charge controller To install battery temperature sensor BTS 1 Install BTS on the side of battery below electrolyte level It is best to place the sensor between batteries and place batteries in an insulated box to reduce influence of ambient temperature outside battery enclosure 2 Insert RJ 11 plug on the other end of the BTS into BTS port on solar charge controller Figure 1 12 Install BTS RJ 11 Port Accept BTS to the side of the battery 2 13 Reinstalling the faceplate To reinstall the faceplate on solar charge controller 1 Align top cover so that two screw holes in corners line up 2 Insert screws into screw holes and tighten 223 Figure 1 13 Reinstalling the faceplate CSE Align these screw holes replace the screw to secure the top cover 294 3 Operation Chapter 3 co
32. setting point limit value 1 4 Temperature and output power Over temperature protection is provided to protect the unit from damage due to high output power at high ambient temperatures When mounted vertically as described in installation section the unit can deliver full output in a temperature of up to 40 C and the unit will de rate output in 40 60 C While operating in charge mode controller will decrease charge current to reduce transistor temperature and the green led will be blinking green reducing average power delivery to within safe limits During thermal shutdown charge status indicator will display an Off condition Over temperature shutdown occurs when ambient temperature reaches 60 C 1 5 Maximum power point tracking MPPT MPPT and associated current boost operation is fully automatic and will function whenever sufficient PV voltage and current are available Percent increase in output charge current relative to PV current is variable and will change with operating conditions When conditions are such that insufficient PV power is available to produce an increase in output current the unit will stop it s internal DC DC power conversion and operate as a series pass PWM controller with very low forward voltage drop Principal operating conditions which affect current boost performance are PV array temperature and battery voltage At constant solar intensity available PV power changes with PV temperature A PV array s p
33. ts DC for charging batteries at the same time solar charger controller can provide the maximum 15Amp current to DC load but the rating 40Amp current is shared battery with DC load When PV voltage is lower battery will provide power to DC load In load control condition solar charger controller controls when to remove load from system when an over discharge or over load situation occurs Solar charger controller uses software setting points to determine when to disconnect or reconnect loads depending on battery voltage Solar charger controller prevents damage to battery from over discharge during periods of poor weather or excessive loads Solar charger controller can charge batteries when in this function 11 Figure 1 2 PV charge and load controller E Diversion d Load D Bateren SES AA V Aer gt Tag Fa Ge A ec h eg i 1 12 2 Automatic PV array night disconnect When using PV charge control mode PV array is automatically disconnected from battery at night to prevent reverse leakage of power and protect PV 1 12 3 Solar charger controller load control Solar charger controller can operate as a low voltage disconnect LVD for DC loads to prevent over discharge to batteries during periods of poor charging or excessive loads Solar charger controller uses software setting points to determine when to disconnect or reconnect loads depending on battery voltage 1 12 4 Low voltage disconnect When configured as a loa
34. twice this amount Doubling expected amp hour usage ensures that batteries will not be overly discharged and will extend battery life 6 7 Equalization charging Approximately every month some batteries may need to be equalized Since individual cells of battery are not identical some cells may not be fully charged when charging process is completed If batteries have been left in a discharged condition for long periods of time plates will have sulfates on them from electrolyte If sulfate remains on plates for an extended period of time it will harden and seal off a percentage of plate area reducing capacity of battery By equalizing batteries before sulfate hardens the sulfate is removed from plates Batteries with liquid electrolyte may become stratified Stratification concentrates sulfuric acid into the bottom of cell while the top becomes diluted This corrodes lower portion of plates reducing battery life Mixing of 31 electrolyte by formation of gas bubbles during equalization process reduces stratification Two methods can be used to determine if a battery needs to be equalized If possible measure voltage of each individual cell while battery is at rest not being charged or discharged A variation of 0 05 volts between cells indicates an imbalance exists If battery construction prevents measurement of individual cell voltages use a hydrometer A variation of 0 020 in specific gravity between cells is considered significant
35. ure sensor The following table describes approximately how much voltage may vary depending on temperature of batteries 1 12 Equalization charge Equalize charging is a special mode of battery charging During use battery s cells can become unequal in voltage and current they can deliver This is due to a buildup of sulfate on plates as well as stratified electrolyte Sulfate prevents cells from receiving or delivering full power If sulfate is left on plates it will harden and permanently reduce battery s capacity Stratification separates heaver acid from water and concentrated acid remains at lower portion of plates eventually corroding them Equalizing batteries every month or two depending on usage prolongs life of batteries and provides better battery performance To set the equalize charge 1 Remove all DC loads connected to batteries 2 Remove all battery vent caps 3 Check battery water level it should be just over the top of plates do not over fill Use only distilled water for filling batteries 4 Set BATTERY TYPE SELECTOR switch to position 0 or 1 position 1 is reserved 5 Reset BATTERY TYPE SELECTOR potentiometer to an appropriate setting for system batteries when equalize charge has completed 1 12 1 Photovoltaic charge and load controller Solar charger controller can operate as a PV charge controller It can regulate up to 40amps of continuous photovoltaic PV array current at 12 24 vol
36. wo mounting screws in the locations marked Leave screw heads backed out approximately 1 4inch 6 mm or less 3 Place controller onto the screws and pull it down into the keyhole slots 4 Then insert the two screws provided to secure enclosure onto the wall lt Warning Explosion corrosion hazard and don t mount solar charger controller on flammable wall for example wooden all and so on Do not locate solar charge controller in a sealed compartment with batteries Batteries can vent hydrogen sulfide gas which is corrosive to electronic equipment Batteries also generate hydrogen and oxygen gas that can explode when exposed to a spark Figure 1 5 Mounting solar charge controller Additional mounting holes 2 15 2 4 Configuring the solar charge controller Before making any wiring connections to solar charge controller it must be configured for desired mode of operation The following sections describe how to configure the unit for desired application and function 2 4 1 Battery type selector can apply different charger method Battery type selector is a 10 position rotary switch used to set solar charger controller for proper float and bulk voltage levels These levels are selected depending on type of batteries used Refer to the table below for charge voltages in various switch positions Consult battery manufacturer for optimum battery voltage charging settings Figure 1 6 Battery type selector B SEL BAT SE
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