Morningstar SUNSAVER DUO Manual de usuario

SUNSAVER DUOTM

Installation and Operation Manual

….

Dual Battery Charging Solar Controller

for RVs, Caravans, and Boats

….

Ratings

……………………………….…………

Nominal Voltage 12 Volts

Rated Solar Current 25 Amps

www.morningstarcorp.com

SUNSAVER DUO DIMENSIONS

Contents

1.0 Important Safety Information .................................................................................4

2.0 General Information................................................................................................5

2.1 Overview..............................................................................................................5

2.2 Morningstar Accessories......................................................................................7

3.0 Installation ...............................................................................................................8

3.1 General Installation Notes....................................................................................8

3.2 Adjusting DIP Switches........................................................................................9

3.3 Mounting............................................................................................................11

3.4 Wiring.................................................................................................................12

4.0 Operation ...............................................................................................................19

4.1 LED Indications..................................................................................................19

4.2 Charging Information .........................................................................................20

4.3 Protections.........................................................................................................21

4.4 Inspection and Maintenance..............................................................................22

5.0 Troubleshooting....................................................................................................23

5.1 Error Indications.................................................................................................23

5.2 General Problems..............................................................................................23

6.0 Limited Warranty...................................................................................................25

7.0 Technical Specifications ......................................................................................26

1.0 Important Safety Information

SAVE THESE INSTRUCTIONS:

This manual contains important safety, installation and operating instructions for the

SunSaver Duo solar controller.

The following symbols are used throughout this manual to indicate potentially

dangerous conditions or important safety instructions.

WARNING: Indicates a potentially dangerous condition. Use extreme caution when

performing this task.

CAUTION: Indicates a critical procedure for safe and proper operation of the

controller.

NOTE: Indicates a procedure or function that is important for the safe and proper

operation of the controller.

General Safety Information

Read all of the instructions and cautions in the manual before starting the

installation.

There are no user serviceable parts inside the SunSaver Duo. Do not disassemble

or attempt to repair the controller.

Disconnect all sources of power to the controller before installing or adjusting the

SunSaver Duo. Ensure that both batteries and the solar power have been

disconnected before opening the access cover.

There are no fuses or disconnects in the SunSaver Duo. Power must be removed

externally.

Do not allow water to enter the controller.

Confirm that the power wires are tightened to avoid excessive heating from a loose

connection.

2.0 General Information

2.1 Overview

Thank you for selecting the SunSaver Duo solar charge controller. The SunSaver Duo

is an advanced PWM dual-battery charge controller for RV’s, caravans, boats, and other

installations that require simultaneous battery charging of two separate (isolated)

batteries. The controller features a solar input connection and two battery connections.

The SunSaver Duo will charge one battery or two batteries simultaneously using an

advanced multi-stage charging algorithm.

A Status LED indicates charging progress and controller operating state. Battery

charging and operating parameters are adjusted using five (5) Settings DIP Switches.

The SunSaver Duo also features self-diagnostics and electronic error protection.

Corrosion resistant power terminals and an epoxy-encapsulated circuit board provide

maximum environmental protection. The SunSaver Duo also provides connections for a

Remote Temperature Sensor (RTS) and Remote Meter (RM-1).

The major features of the SunSaver Duo are shown in figure 1 below. An explanation of

each feature is provided.

Remote Temperature Sensor (RTS)

Terminals Settings

DIP Switches

RemoteMeter

Connection

(RJ-11)

Local Temperature

Sensor Status LED

Indicator

Battery #1

Power Terminals Battery #2

Power Terminals

Solar Input

Power Terminals

Figure 1. SunSaver Duo features

Remote Temperature Sensor (RTS) Terminals

A connection point for a Morningstar RTS (optional) to remotely monitor battery

temperature.

Local Temperature Sensor

Measures ambient temperature. Battery regulation is adjusted accordingly.

Status LED Indicator

Provides system status and error indication.

Settings DIP Switches

Adjustment switches that define the operating parameters of the SunSaver Duo.

Battery #1 Power Terminals

Power connections for battery #1.

Solar Input Power Terminals

Power connections for solar module(s).

Battery #2 Power Terminals

Power wire connections for battery #2.

Remote Meter Connection (RJ-11)

A communication port for the Morningstar Remote Meter.

2.2 Morningstar Accessories

Remote Temperature Sensor (Model: RTS)

The RTS measures battery temperature for accurate temperature compensation.

Use when the ambient battery temperature differs from the ambient controller

temperature by +/- 5 degrees C or more. An RTS can be attached to the

SunSaver Duo at any time. The SunSaver Duo will automatically use the RTS for

battery temperature compensation when installed. The standard cable length is

25 ft (7.6 m), and this can easily be extended to 100 ft (30 m) or longer.

Installation instructions are provided with the RTS.

Remote Meter (Model: RM-1)

The digital Remote Meter displays system operating information, error

indications, and self-diagnostic read-out. Information is displayed on a backlit 4-

digit custom LCD display. The large numerical display and icons are easy to read

and large buttons make navigating the meter menus easy. Additionally, a status

LED and three (3) battery SOC LEDs provide a quick reference to system

operation.

The meter can be mounted in a wall or on the surface of a wall in a frame. The

RM-1 is supplied with 32.8 ft (10.0 m) of cable, a mounting frame, and mounting

screws. The RM-1 connects to the MeterBus port on the SunSaver Duo.

PC MeterBus Adapter (Model: MSC)

The MSC converts the MeterBus RJ-11 electrical interface to a standard RS-232

interface which allows communication between the SunSaver Duo and a PC. The

MSC is required for programming custom charging setpoints and for logging

data. Visit Morningstar’s website for more information.

3.0 Installation

3.1 General Installation Notes

Read through the entire installation section before beginning installation.

Be very careful when working with batteries. Wear eye protection. Have fresh

water available to wash and clean any contact with battery acid.

Use insulated tools and avoid placing metal objects near the batteries.

Explosive battery gasses may be present during charging. Be certain there is

sufficient ventilation to release the gasses.

Do not install in locations where water can enter the controller.

Loose power connections and/or corroded wires can melt wire insulation, burn

surrounding materials, or even cause fire. Ensure tight connections and use

cable clamps to secure cables in mobile applications.

Only charge lead-acid batteries.

Each of the two SunSaver Duo Battery connections may be wired to one battery

or a bank of batteries. The following instructions refer to a singular battery, but it

shall be implied that each battery connection can be made to either one battery

or a group of batteries wired in parallel to form a 12 volt battery bank.

3.2 Adjusting DIP Switches

Battery #1 Type

Battery #2 Type

Battery Charging Priority

Custom Setpoints

Regulation Type

OFF

Figure 2. Setting DIP switch definitions

DIP Switches 1 & 2 –Battery Type Select

The SunSaver Duo charges both sealed and flooded lead-acid batteries per the

charging specifications in table 1 below. Sealed batteries are typically

maintenance-free batteries that do not require water. Flooded batteries have

removable caps that allow the addition of water when needed. DIP switches 1 &

2 select the battery type for Battery #1 and Battery #2 respectively. Choose the

correct battery type for each battery.

DIP Switch OFF: Sealed battery type (factory pre-set)

DIP Switch ON: Flooded battery type

Setpoint

Battery Type

Sealed

Flooded

Absorption Voltage

14.1 V

14.4 V

Float Voltage

13.7 V

Boost Voltage

14.8 V

Boost Time

2 hrs

Boost Interval

28 days

Table 1. Standard battery charging programs

DIP Switch 3 –Battery Charging Priority

Select the percentage of available charge current to each battery.

The 90% / 10% priority setting allows Battery #1 to receive 90% of available

charging current, while Battery #2 receives 10% of charging current. This setting

is ideal for RV and boat systems where a “house” bank requires most of the

available charge current and a separate engine starter battery requires only a

“trickle charge” to remain topped-off. When Battery #1 reaches full charge, more

charge current will be diverted to Battery #2 as needed.

The 50% / 50% priority setting splits available charge current equally between

two battery banks. This priority setting is ideal for systems with two equal-sized

battery banks that require simultaneous charging. If one battery bank reaches full

charge before the other, more charge current will be diverted to the lower state-

of-charge battery.

DIP Switch 3 OFF: 90% / 10% Priority (factory pre-set)

DIP Switch 3 ON: 50% / 50% Priority

DIP Switch 4 –Custom Setpoints

If the standard battery type settings are not suitable, custom charging setpoints

can be programmed using a PC and a Morningstar Serial to Meterbus adapter

(not included). See Morningstar’s website for more information.

DIP Switch 4 OFF: Factory settings (factory pre-set)

DIP Switch 4 ON: Custom programmed settings

DIP Switch 5 –Regulation Type

The SunSaver Duo is a PWM charge controller. Some systems with sensitive

equipment may experience noise interference from PWM charging. Refer to the

FAQ in section 4.0 Troubleshooting for tips on how to reduce or eliminate PWM

noise.

If the noise cannot be satisfactorily reduced, place DIP switch 5 in the ON

position. While less efficient, Slow Switching regulation will significantly reduce or

eliminate PWM noise.

DIP Switch 5 OFF: PWM Regulation (factory pre-set)

DIP Switch 5 ON: Slow Switching Regulation

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