Solar charger controller User`s Manual
Contents
1. 2 1 Charge control indications trie ode nete re nana Nanas 22 4 Troubleshooting eroe oret teet eee b bo ibo rb anna 24 5 Sp cifications ee eere e e ARR RC nuwun 25 STREIT 25 3 2 Environmental din ederet ete tod ei ang Sh Sth des cot P and abaikan 25 5 2 1 Temperature eere eere rte ete eee ere e an uda 25 5 3 Safety and BE MG oe Uh AN AN ena itia idonee it geste BEE tor re E has dne 26 5 32 European markets E 26 E re eu II EU He 54T Operating Humidity E 26 5 4 2 Non Operating Humidity EE 26 5 5 Mechanical features ne ettet re eie Pete dere dei ana Ro ies cot Pe Naa akan 26 5 6 Detailed dimension drawing eter eerta eet rete estre KENEEN dee rte ee epe sons 27 6 run T ah ea ane ea Ea as Bana bhn aki 28 6 T Battery Py pes aan enam sangan anang en NN ngan 28 6 2 Automotive Batteries ona eer ee be ve naa nan tanu nga vt sone aes aan 28 6 3 Maintenance Free Batteries oie ete ettet eee te eren eee enne rete d ee eee e err edes 28 6 4 Deep Cycle Batteries isse UD ERROR OE E D CADO RE De ERU 28 6 3 Sealed Batteries Masakan menda Ia TU e NN AE NN 28 6 6 Battery SIZIBB oo E NAN EN RN Ran 28 6 7 Equalization Charging Iki tree ttp eene tb dr Mon tee Pu eo eee pea anna nahan Sains 28 6 8 Equalization Setpoints Non Sealed Batteries Only 20 Tables Table 1 1 Factory shipping settings ENEE 10 Table 1 2 Battery type selector switch setngs moon 15 Table 1 3 Minimum Wire2. SIZe i ederet ret peer ne Bidan ea ie itr ee eer ee Rn 17 Tabl T 4 The ED indicators e eee eere ER EDO ERES 22 Table 1 5 Troubleshooting bet 24 Table 1 6 Electrical specifiCation uec etie rer tenter t ea cepere rre BE anna an 25 Table 1 7 Mechanical specification sisne niseni anna E rr Ee PR eR 26 Table 1 8 Battery equalizati n i eren o ee eege Eege Ed Epi Kesha naik 29 Figures Prove I 1 Bulk charge EE 10 Figure 1 2 PV charge and load controller o ooooWWoWoW om mmk 11 Ergure 1 3 Load controller 2 5 o NN Si ee pan 12 Figure 1 4 Removing the tOpCOover esiri eee Tee enina sie Een ne E Ee EnS KE SEa nE ETE eiea 13 Figure 1 5 Mounting the Solar charge controller sese 14 Figure 1 6 Battery type selector OB SI 15 Figure 1 7 Safety Earth eround aon ena asa nee re rerit roe hee Rer 16 Figure 1 8 DC terminal connector location nana 17 Figure 1 9 PV charge control mode wimg oom 18 Figure 1 10 Parallel connection ote Rees alas ERREUR VR ERR LR NN 19 Figure 1 11 battery type Selector e inerte terreno eer irent nan ie a NS 20 Figure 1 12 Reinstalling the faceplate moon 21 Figure 1 13 LED status indicator nennen nennen nennen enne testen ennt nennen enne 22 Figure 1 14 Solar charger controller dimension drawing sees 27 About This Manual Purpose The purpose of this manual is to p
3. Slots 2 for mounting Additional Mounting Holes 2 2 4 Configuring the Solar charge controller Before making any wiring connections to the Solar charge controller it must be configured for the desired mode of operation The following sections describe the how to configure the unit for the desired application and function 2 4 Battery type selector can apply different charger method The battery type selector is a 10 position rotary switch used to set the Solar charger controller for the proper float and bulk voltage levels These levels are selected depending on the type of batteries used Refer to the table below for the charge voltages in the various switch positions Consult the battery manufacturer for optimum battery 14 voltage charging settings Figure 1 6 Battery type selector B SEL BAT SELLECT Table 1 2 Battery type selector switch settings 12 volt 24 volt Charge Function Switch Descrinti Position S TP Float voltage Bulk Equalize Float voltage Bulk Equalize Equalize Equalize V voltage V V voltage V charge rate time Equalize 1 equalizes at a rate equal to Depend on O the battery 13 2 15 26 4 30 Max 40Amp battery bank capacity capacity in amp hours divided by 40 Equalize 2 depend on 1 customer reserved reserved reserved reserved reset Provides an additional Float and Bulk settings for deep cycle lead acid gp Pepe 133 15 26 6 30
4. battery voltage exceeds the low voltage reconnect LVR setting for 1 minutes Figure 1 3 Load controller Diversion Load Important When using the Solar charger controller load control Do not temperature compensate these settings Do not install the optional battery temperature compensation sensor 12 2 Installation 2 1 Pre Installation The instructions that follow are applicable to the typical installation For special applications consult a qualified electrician or your Certified Dealer Installation procedures will vary according to your specific 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 the top cover 1 Access the inside of the solar charger controller by removing the four screws M3 6 on the cover of the unit 2 Remove the top cover of Solar charger controller Figure 1 4 Removing the topcover Remove these screws M3 6 4 from the topcover to access the heatsink of controller A131 4 544222444444 E E Men anna k ei Remove the topcover 13 2 3 Mounting the Solar charger controller The Solar charger controller is designed for indoor mounting Care should be taken in selecting a location and when mounting the enclosure Avoid mounting it in direct sunligh
5. electrostatic damage discharge yourself by touching a water faucet or other electrical ground prior to handling the unit and avoid touching components on the circuit boards The risk of electrostatic damage is 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 the battery is fully charged a somewhat lower voltage is applied maintain the battery in a fully charged state without excessive water loss The three stage charge process charges the 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 Started Float Volts Setting Dc Voltage Reduced Voltage DC Current Camps Time 1 10 1 Bulk charge When charge starts the Solar charger controller attempts to apply the bulk charge voltage to the battery The system will switch to Bulk charge if the battery is sufficiently discharged and or insuf
6. the Solar charger controller for the proper float and bulk voltage levels These levels are selected depending on the type of batteries used Refer to the table below for the charge voltages in the various switch positions Consult the battery manufacturer for optimum battery voltage charging settings Figure 1 11 battery type selector Please use truss screwdriver to select proper position e LOAD BATTERY PV M 20 2 11 Reinstalling the Faceplate To reinstall the faceplace on the Solar charge controller 1 Align topcover so that two screw holes in the corners line up 2 Insert the screws into the screw holes and tighten Figure 1 12 Reinstalling the faceplate Align these screw holes replace the screw to secure the top cover D 3 Operation Chapter 3 contains information about the operation of Solar charge controller 3 1 Basic Operation The Solar charge controller has one blue and multicolor LED status indicator one battery type selector Single color LED indicator Figure 1 13 LED status indicator Multicolor LED indicator 3 2 LED Status Indicator LOAD BATTERY The Solar charger controller has one multicolor LED and one green LED to indicate the operating status of the controller The green LED indicates whether the charging source is functioning properly when it display solid green or the type of the fault when it flash And the multi color LED indicates the part
7. use battery caps The electrolyte is in the form of a gel rather than a liquid which allows the 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 the battery plates Sealed batteries reduce the maintenance requirements for the system and are good for remote applications They are much more sensitive to the charging process and can be ruined in as little as a day of overcharging 6 6 Battery Sizing Batteries are the fuel tank of the 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 the proper battery bank size compute the number of amp hours that will be used between charging cycles Once the required amp hours are known size the batteries at approximately twice this amount Doubling the expected amp hour usage ensures that the 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 the individual cells of the battery are not identical some cells may not be fully charged when the charging process is completed If the batteries 28 have been left in a discharged condition for long p
8. Solar charger controller User s Manual LOAD BATTERY Contents Important safety instructions eere e Yen acronis ete scones ere EE 6 1 Product descripti n eR RO anna naek ata 8 Ve I General desctiption zie eee titer ter irre ute rete tret na an bre ri E repe UR du 8 1 2 Features cetero oe Re PO PR REED 8 1 3 Maximum setpoint voltage limit eene nennen eere nne nennen enne nennen enne nne 8 1 4 Temperature and output power 8 1 5 Maximum power point tracking MDDI 8 1 6 HowAMPET WOEKS 5E erede tenti eer tee e eet e eet Berau ee a una nan 9 1 7 Over voltage reverse polarity protection oooooooooomooWoWoW Woo Woman 9 1 8 Electrostatic handling precautpousg nennen nen eere nee nennen nre e nennen eren 9 1 9 Solar charger controller Setup 4 4 er em PRU e RE Nanah 9 1 9 1 Factory default Settings ae ena anna EE EO Tan ERR FERAI dee aksen 9 1 10 Three stage charge Control misemi teme teen nan p Hi eo te e Pe eh bre eerte ek onn 10 RI EE 10 1 10 2 Absorption Charge et Re tetro eoe eere eere eive er o Eve AE 10 110 3 Float charge nte ntt etre tede keganasan 10 LI Equalization charge its AG AA AA eere eire iere eer hp nan nana 11 1 11 1 Photovoltaic charge and load controller 11 1 11 2 Automatic PV array night disconnect osese marinarii enia eNEAN A REA ENEA AEA aa 12 1 11 3 Solar charger controller load Control 12 1 11 4 Low voltage disconnect 4 ettet eer rr verter eR eei
9. at same time Figure 1 7 Safety Earth ground Safety Earth ground 2 6 DC terminal connector locations Terminal connectors for DC wiring are located on the lower edge of the circuit board Terminal Torque Requirements Once the wires have been installed torque the terminals as follows Be careful not to over tighten Figure 1 8 DC terminal connector location BATTERY zs Load Negative PV Negative Load Positive 4 PV Positive Battery Negative Battery Positive 2 7 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 7 1 Current Rating Solar charge controller is rated for a rating continuous current of 40 amps Since PV outputs can vary due to the array size or sunlight striking it the safe minimum wire size should be based on the maximum current ratings 2 7 2 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 the PV array and the Solar charge controller are strongly recommended Because the Solar charger controller have wider input voltage range 15 55VDC 2 7 3 Over current Pr
10. batteries Refer to the Lead Acid 2 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 15 Recommended for gel cell batteries that specify 4 Gel Cel 2 13 7 14 4 27 4 28 8 high float voltages Check with the battery manufacturer 5 Gel Cell 1 13 5 14 1 27 28 2 Typical gel cell setting 6 PcCa lead 132 143 264 28 6 Use this setting for sealed Calcium type car batteries n NE Factory setting for typical 7 13 4 14 6 26 8 29 2 deep cycle lead acid Default i batteries Setting e NiCad 1 14 16 28 32 Use for NiCad battery systems 9 NiCad 2 14 5 16 29 32 Na sue with nickel iron batteries lt Important 1 Switch positions 0 and 1 are for 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 the default values as shipped from the factory 3 Always refer to the battery manufacturer s specifications for equalization 2 5 Grounding The 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
11. charger controller prevents damage to the battery from over discharge during periods of poor weather or excessive loads The solar charger controller can charge the batteries when in this function Figure 1 2 PV charge and load controller ren Hr e P r Diversion Load PV Array 1 11 2 Automatic PV array night disconnect When using PV Charge Control mode the PV array is automatically disconnected from the battery at night to prevent reverse leakage of power and protect PV 1 11 3 Solar charger controller load control The 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 The Solar charger controller uses the software setpoints to determine when to disconnect or reconnect loads depending on battery voltage 1 11 4 Low voltage disconnect When configured as a load controller the Solar charger controller will disconnect the load from the batteries when it reaches the LVD setting There will be a 1 minute delay after the voltage drops below the Low Voltage Disconnect LVD setting before the controller actually disconnects the load 1 11 5 Low voltage reconnect It can also provide automatic reconnection of the loads at the low voltage reconnect LVR setting Reconnection of the load is allowed once the battery voltage has exceeded the low voltage reconnect LVR setting Loads are either automatically when
12. efault 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 14V 27 2N dc 28V Over discharge disconnection 10 8Vdc default 21 6Vdc default Over discharge reconnection 12 3Vdc 24 6V dc 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 Terminal size fine single wire 8 AWG 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 25 power Sufficient ventilation to prevent over temperature shut down 5 3 Safety and EMC 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 H
13. ene onus 12 LITS Low voltage EE 12 2 Install tion rotos nOD enr ee o nina Man ate p e rte onde ERE PP rong 13 2 1 Pre Installation ooo ete e ene teet te rene Nan NN RA Nda 13 2 2 Removing thetop COVer ce eee aee de eee 13 2 3 Mounting the Solar charger controller eese AE AEA ennt enne tn nennen ene 13 2 3 Mounting the Solar charger controller oom 14 2 3 1 Mount the Solar charge controller oo 14 2 4 Configuring the Solar charge controller eee ees ceeceseesecseeseceseesessecsecesecsessesesesaecseseseaeeaesseeneeegs 14 2 4 1 Battery type selector can apply different charger method 14 2 5 Grroundin eege ee ea ert eit EN Ba ANA EN NBA nd Nan 16 2 6 DC terminal connector locations 4 5 reet den eh ee Rn Suasana 17 2 7 Wire Size and Over current Protection Reguirements o oooooooooWooooWoWo Wo 17 LIA Current Rating EE EN ds an Iya bukan 17 2 1 2 Surge Protection eei etatem oet ree OUR GIRO Ee Dr eee Ts 17 21 3 Overc trent Protection uite tette etri tet ine una ee LE esi ues Eu oed 17 2 8 PV Charge And Load Control Mode Wumg nana 18 2 9 Easily install in parallel connecton sses e esesten sE e Ens eSEE Seo CSS EVSEN ESEE EES Sa osi es 19 2 10 Battery type SelectOE Js irren ere te tpe E RR RR ana 20 2 11 Reinstalling the Faceplat eere tenete agunan anggun 21 Ds POP U CE i EE 22 Sidi Basic Operation seen namu una akan nan NN 22 32 LED StatuS IndidatOt MP 22 3
14. eriods of time the plates will have sulfates on them from the electrolyte If the sulfate remains on the plates for an extended period of time it will harden and seal off a percentage of the plate area reducing the capacity of the battery By equalizing the batteries before the sulfate hardens the sulfate is removed from the plates Batteries with liquid electrolyte may become stratified Stratification concentrates the sulfuric acid into the bottom of the cell while the top becomes diluted This corrodes the lower portion of the plates reducing battery life Mixing of the electrolyte by the formation of gas bubbles during the equalization process reduces stratification Two methods can be used to determine if a battery needs to be equalized If possible measure the voltage of each individual cell while the battery is at rest not being charged or discharged A variation of 0 05 volts between cells indicates an imbalance exists If the battery construction prevents measurement of the individual cell voltages use a hydrometer A variation of 0 020 in the specific gravity between cells is considered significant 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 the battery be refilled with distilled water to the correct level This may be a problem with unattended systems in remote areas whic
15. ery 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 the use of MPPT technology Solar charger controller can increase charge current up to 3096 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 n automatic current limit feature allows use of the full 40 amp capability without worrying about overload from excessive current voltage or amp hour based load control Series pass Pulse Width Modulation PWM charge voltage control combined with a multistage charge control algorithm leads to superior charging and enhanced battery performance The filtered PWM power control system uses highly efficient and reliable power MOSFET transistors The MOSFET s are turned on and off at high frequency to precisely control charge voltage and MPPT The Solar charger controller can easily install in parallel connection of output so it also suitable for large system current application condition 1 2 Feat
16. ficient charge current is available to drive the battery up to the bulk voltage setpoint During the Bulk charge stage the unit delivers as much charge current as possible to rapidly recharge the battery Once the charge control system enters Absorption or Float the unit will again switch to Bulk charge if battery voltage drops below the present charge voltage setpoint 1 10 2 Absorption charge During this stage the unit changes to a constant voltage mode where the absorption voltage is applied to the battery When charge current decreases to the float transition current setting the battery is fully charged and the unit switches to the float stage 1 10 3 Float charge During this stage the float voltage is applied to the battery to maintain it in a fully charged state When battery voltage drops below the float setting for a cumulative period a new bulk cycle will be triggered 10 1 11 Equalization charge Equalize charging is a special mode of battery charging During use the battery s cells can become unequal in the voltage and current they can deliver This is due to a buildup of sulfate on the plates as well as stratified electrolyte Sulfate prevents the cells from receiving or delivering full power If the sulfate is left on the plates it will harden and permanently reduce the battery s capacity Stratification separates the heaver acid from the water and the concentrated acid remains at the lower portion of the plates eventuall
17. h do not receive regular maintenance Consult the battery manufacturer for their recommendations 6 8 Equalization Setpoints Non Sealed Batteries Only Table 1 8 Battery equalization Battery Type Bulk Volts Float Volts Equalizing Charge Default Settings 14 0 Vdc 13 5 Vdc Disabled Sealed Gel Lead Acid 14 1 Vdc 13 6 Vdc Non recommended Battery Consult Battery manufacturer AGM Lead Acid Battery 14 4 Vdc 13 4 Vdc Charge to 15 5Vdc or per manufacturer Maintenance Free 14 4 Vdc 13 4 Vdc Limited appropriateness if RV Marine water level can be checked Deep Cycle Liquid 14 6 Vdc 13 4 Vdc Charge to 15 5Vdc or per Electrolyte Lead Antimony Battery battery Antimony Battery manufacturer NiCad or NiFe Alkaline 16 0 Vdc 14 5 Vdc Not recommended A Battery Consult battery manufacturer 29
18. howing the de rating status During thermal shutdown the charge status indicator will display off condition Over temperature shutdown occurs when the ambient temperature reaches 60 C or higher 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 The 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 The 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 power 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 the 8 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 un
19. icular operating mode and the batteries capacity level 3 2 1 Charge control indications Table 1 4 The LED indicators LEDI LED2 Operation State On Off State On Off Description mode Solid Charge ON PV gt BV green all 0 Solid red all 0 BAT lt LVD Solid Solid Charge ON PV gt BV Nen 2 green all 0 orange all 0 LVD lt BAT lt LVR Solid Charge ON PV gt BV 3 green all 0 Solid green all 0 BAT gt LVR Solid Charge ON PV gt BV 4 green all 0 Blink red Is Is BAT lt LVD Solid Blink Charge ON PV gt BV Derated 9 green all 0 orange Is Is LVD lt BAT lt LVR Solid Charge ON PV gt BV 6 green all 0 Blink green Is Is BAT gt LVR Pk Fault 7 Off 0 all orange ls 6s BAT under voltage 222 DC load over current or Blink dc load voltage out of the 8 green 3s 6s Off 0 all range Blink 9 green 2s 6s Off 0 all Over Temperature Blink 10 green Is 1s Blink red Is Is PV over voltage Blink Blink 11 green Is Is orange Is 1s PV under voltage Blink 12 green Is 6s Blink red 0 all BAT over voltage when Solar charger controller starts wait for 3s 1f the start time is over 3s Blink then mean that the BAT 13 green all 0 Blink red 0 all voltage is out of the range NOTE When the solar charger c
20. is designed to be more deeply discharged before being recharged Deep cycle batteries are available in many sizes and types The most common is the 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 the level of electrolyte When a cell is low distilled water should be added after the battery is fully charged If the level is extremely low add only enough distilled water to cover the plates before recharging The electrolyte volume increases during the charging process and the battery will overflow if it is filled all of the way up before recharging Use only distilled water because impurities will reduce battery performance A popular and inexpensive deep cycle battery is the 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 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 the deep cycle version The 8D is typically rated at 220 amp hours at 12 volts 6 5 Sealed Batteries Another type of battery construction is the sealed gel cell They do not
21. it 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 3096 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 the PV array directly to the battery when battery is discharged When a 75 watt module is connected directly to a battery charging at 12 volts the 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 the 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 the PV module del
22. ivers maximum power in this case 17 volts It then MPPT operates the module 17 volts which extracts maximum available power from the 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 the 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 the 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 the PV and the battery connections If the battery is connected reverse polarity Solar charger controller will be protected by inner fuse and fuse will be open If the PV array is connected reverse polarity the charge control system will not turn on Over voltage protection System voltage Over voltage point 12V battery system 30V 24V battery system 55V 1 8 Electrostatic handling precautious All electronic circuits may be damaged by static electricity To minimize the likelihood of
23. ked load positive on the Solar charger controller to the positive battery terminal and tighten the screw 7 Connect a cable from the controller s other terminal marked load negative to the negative terminal of your DC load and tighten the screw 8 Connect a cable from the controller s other terminal marked load positive to the positive terminal of your DC load and tighten the screw Figure 1 9 PV charge control mode wiring Load Negative PV Negative Load Positive PV Positive Battery Negative Battery Positive 4 18 PV Array DC Wiring Positive CT Controller Negative ayeuu os DC Load 2 9 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 19 PV Array 1 DC Winng Positive ES Oo Negative e Controller 2 x Lem 2 S Lighting D 1 00 9 mo Controller 2 ye ULE IOS b CH DCLoad 2 10 Battery type selector Please see 2 5 1 section which you find the different one of 10 positions stand for the different battery type specified You can select
24. l ventilated compartment Add distilled water in each cell until battery acid reaches level specified by battery manufacturer This helps purge excessive gas from the cells Do not overfill For a battery without cell caps carefully follow manufacturers charging instructions 6 Charger location amp installation 999999 Controller employs components that tend to produce arcs or sparks NEVER install in battery compartment or in the presence of explosive gases Protect all wiring from physical damage vibration and excessive heat Insure that the controller is properly setup for the battery being charged Do not expose controller to rain or snow Insure all terminating connections are clean and tight to prevent arcing and overheating Charging system must be properly installed as described in these instructions prior to operation Do not connect to a PV array capable of producing greater than 40 amps of short circuit current 25 C Do not connect input to DC source directly with load Solar charger controller need to be powered by solar panel Do not short DC output port otherwise it will damage Solar charger controller Symbol A Warning A Dangerous Voltage Alternative Current Direct Current 5 Protective Earth A de von Abbreviations and Acronyms DC Direct Current LED Light Emitting Diode LVD Low Voltage Disconnect LVR Low Voltage Reconnect BAT SELECT Batt
25. ne or correct Completely dead no display No battery power Battery disconnected overly discharged or connected reverse dead no display polarity Battery powers the 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 12V dc battery or greater than 30Vdc for 24Vdc battery Apply battery quickly and crisply Charge status LED on but no output charge current Battery voltage greater than charge voltage setpoint 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 OV dc 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 in
26. o high Working in the vicinity of lead acid batteries is dangerous Batteries produce explosive gasses during normal battery operation 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 9 KA Someone should be within range of your voice or close enough to come to your aid when you work near a lead acid battery Have plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eyes Wear complete eye protection and clothing protection Avoid touching eyes while working near battery 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 NEVER smoke or allow a spark or flame in vicinity of battery 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 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 Never charge a frozen battery Be sure battery is mounted in a wel
27. ontroller is charging the green LED will be solid green 1 Low voltage disconnect When connected with DC load if voltage remains below the Low Voltage Disconnect setting the controller will disconnect after a 1 minute delay period And the controller waits until the voltage rises above the Low Voltage Recovery setting 2 Over voltage of load If the controller detects an over voltage of load it will disconnect the load 3 Over temperature The temperature of the controller s transistors is continuously monitored This protects the charge controller from damage in high temperature environments if excessive temperatures are detected while operating in charge mode the controller will decrease the charge current to reduce the transistor temperature and the green led will be solid green If the Solar charger controller connected with DC load the load is disconnected before the transistors reach an excessive temperature and the green LED flashes Once the temperature has dropped the loads are reconnected 4 Over current of the load If the controller detects an overload or short circuit of the load it will automatically resets the over current protection system every 61 minutes If the default is still present over 3 times the controller will shut off loading function This function will be enable unless the machine restarts 03s 4 Troubleshooting Table 1 5 Troubleshooting list Symptom Probable cause Items to exami
28. otection If the controller system detects the overload status it will automatically reset the over current protection system every 6 minutes If the default is still present the controller will shut off and wait for another 6 minutes This will occur continuously until the problem is corrected Table 1 3 Minimum wire size Controller Minimum Wire Size 12 24 VDC 88AWG 17 2 8 PV Charge And Load Control Mode Wiring The procedure below is illustrated in Figure 1 9 WARNING Shock Hazard PV arrays generate voltage whenever light strikes the surface of the array Before connecting the Solar charge controller cover or disconnect the array to prevent any current from being generated 1 Connect the PV array s positive output to the terminal marked PV positive on the Solar charge controller and tighten the screw 2 Connect the PV array s negative output to the terminal marked PV negative on the Solar charge controller and tighten the screw 3 Connect the terminal marked battery negative on the Solar charge controller to the negative battery terminal and tighten the screw 4 Connect the terminal marked battery positive on the Solar charge controller to the positive battery terminal and tighten the screw 5 Connect the terminal marked load negative on the Solar charge controller to the negative load terminal and tighten the screw 6 Connect the terminal mar
29. rovide explanations and procedures for installing operating maintaining and troubleshooting the Solar charge controller Scope This manual provides safety guidelines detailed planning and setup information procedures for installing the 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 the 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 When Solar charger controller is working Please DO NOT touch it because the temperature is to
30. solation PV connected to BAT Nominal PV voltage has changed from 24Vdc to 12Vdc Normal operation current is reduced if battery voltage is at setpoint Replace or use as is 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 unit and load initial 12Vdc PV control values Unit considers PV s to 24Vdc if PV voltage ever goes above 30Vdc Charge OFF at high temperature System temporarily shuts down due Improve ventilation or reduce PV 2 d S to high heat sink temperature 5 Specifications Specifications provide the specifications for the Solar charge controller 5 Specifications Table 1 6 Electrical specification Rated Voltage 12 24V dc Has pe current include load 40Amp Load current 15Amp Input voltage range 15 55 Vdc Max PV open circuit array voltage 55Vdc Overload protection DC load 2 0 Inom 5s 1 5 Inom gt 20s 1 25 Inom temperature controlled Typical idle consumption At idle lt 10mA Bulk charge 14 6Vdc default 29 2V dc d
31. t to prevent heating of the enclosure The enclosure should be mounted vertically on a wall In outdoor installations the 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 the 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 the warranty 2 3 1 Mount the Solar charge controller 1 Place the controller on the desired mounting surface and mark the location of the keyhole slots on the wall 2 Move the controller out of the way and secure two mounting screws in the locations marked Leave the screw heads backed out approximately 1 4inch 6 mm or less 3 Place the controller onto the screws and pull it down into the keyhole slots 4 Then insert the two screws provided to secure the enclosure onto the wall amp Warning Explosion Corrosion Hazard and don t mount solar charger controller on the flammable material for example wooden wall and so on Do not locate the Solar charge controller in a sealed compartment with the 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 the Solar charge controller Keyhole
32. umidity 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 7 Mechanical specification Items Specification Depth x 202 mm Dimension H x W x D Height lt 66 mm Width lt 140 mm Unit Weight Warranty Mounting Cooling 26 5 6 Detailed dimension drawing Figure 1 14 Solar charger controller dimension drawing zs 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 the Solar charger controller will be from the manufacturer or supplier of the batteries 6 2 Automotive Batteries 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
33. ures A DC Load output port 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 000000020 1 3 Maximum setpoint voltage limit Very cold batteries combined with high charge voltage setpoints can produce voltages high enough to disrupt or damage other eguipment connected to the battery To minimize possible damage a maximum voltage setpoint limit feature is provided The factory defaults can be adjustable using software Regardless of what setpoint values result from temperature compensation the Solar charger controller will never attempt to apply a charge voltage greater than the maximum voltage setpoint 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 temperature When mounted vertically as described in the installation section the unit can deliver full power output under the temperature of 40 C and the unit will de rate output from 40 C to 60 C While operating in charge mode the controller will decrease the charge current to reduce the temperature of transistor and also reduce the average power delivery within safe limits At the mean time the green LED will blink for s
34. y corroding them Equalizing the batteries every month or two depending on usage prolongs the life of the batteries and provides better battery performance To set the Equalize Charge amp Remove all DC loads connected to the batteries Remove all battery vent caps Check the battery water level it should be just over the top of the plates do not over fill Use only distilled water for filling batteries Set the BATTERY TYPE SELECTOR switch to position 0 or 1 position 1 is reserved Reset the BATTERY TYPE SELECTOR potentiometer to the appropriate setting for the system batteries when the Equalize charge has completed 1 11 1 Photovoltaic charge and load controller The Solar charger controller can operate as a PV charge controller the solar charger controller can regulate up to 40amps of continuous photovoltaic PV array current at 12 24 volts DC for charging batteries at the same time the Solar charger controller can provide the maximum 15Amp current to DC load but the rating 40Amp current is shared battery with DC load When the PV voltage is lower the battery will provide the power to the DC load In the load control condition the Solar charger controller controls when to remove load from the system when an over discharge or over load situation occurs The Solar charger controller uses the software setpoints to determine when to disconnect or reconnect loads depending on battery voltage Solar
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