Morningstar SunSaver SS-6 Manual de usuario

PHOTOVOLTAIC SYSTEM CONTROLLERS

PERATOR

’

ANUAL

SUNSAVER MODELS

INCLUDED IN THIS MANUAL

•

SS-6 / SS-6L

6A / 12V

•

SS-10 / SS-10L

10A / 12V

•

SS-10-24V / SS-10L-24V

10A / 24V

•

SS-20L

20A / 12V

•

SS-20L-24V

20A / 24V

1098 Washington Crossing Road

Washington Crossing, PA 18977 USA

Website: www.morningstarcorp.com

SPECIFICATION SUMMARY

SS-6 SS-10 SS-20 24 Volt

System Volts

(V) 12 12 12 24

Maximum PV Volts

(V) 25 25 25 44

Rated PV Input

(A) 6.5 10 20 n/a

Rated Load

(A) 6 10 20 n/a

Maximum array short

(A) 8.1 12.5 25 n/a

circuit current

Setpoints:

Sealed PWM (V) 14.1 14.1 14.1 28.2

Flooded PWM (V) 14.4 14.4 14.4 28.8

LVD (V) 11.5 11.5 11.5 23.0

LVD Reconnect (V) 12.6 12.6 12.6 25.2

Ambient Temp Range

(°C)

–40 to 60 –40 to 60 –40 to 60 –40 to 60

Temp Compensation

(mV/°C)

–28 –28 –28 –56

0.50

(13)

1.32

(34)

4 MOUNTING HOLES ø0.20 (5.0)

2.18

(55)

1.00

(25)

6.00 (152)

5.50 (140)

DIMENSIONS INCHES (MM)

CONTENTS

1.0 G

ENERAL

NFORMATION

.............................................. 4

2.0 I

MPORTANT

AFETY

NSTRUCTIONS

.............................. 4

2.1 Installations in Hazardous

(Classified) Locations .............................................. 4

3.0 Q

UICK

TART

NSTRUCTIONS

........................................ 5

4.0 LED I

NDICATORS

.............................................................. 6

5.0 I

NSTALLATION

NSTRUCTIONS

............................................ 7

5.1 Ratings and Limits ............................................ 7

5.2 Polarity Protection ............................................ 8

5.3 Installation Procedure ...................................... 8

6.0 O

PERATION

................................................................10

6.1 Operator Tasks ................................................10

6.2 Operation and Functions ................................11

6.3 Inspection and Maintenance ............................12

7.0 T

ESTING AND

ROUBLESHOOTING

................................13

7.1 Testing with a Power Supply ............................13

7.2 Troubleshooting................................................13

8.0 S

PECIFICATIONS

..........................................................16

1.0 GENERAL INFORMATION

Thank you for selecting the SunSaver™ PV controller. The

SunSaver is a sophisticated controller using advanced tech-

nology and series switching PWM charging. The battery

charging process has been optimized for longer battery life

and improved system performance.

Many specifications of the SunSaver are unique. Although the

SunSaver is very simple to use, please take the time to read

this operator’s manual and become familiar with the controller.

This will help you to make full use of the many advantages the

SunSaver can provide to your PV system.

2.0 IMPORTANT SAFETY INSTRUCTIONS

•SAVE THESE INSTRUCTIONS—This manual contains impor-

tant instructions that should be followed during installation

and maintenance of the SunSaver controller.

• WARNING—Be very careful when working with batteries.

Lead acid batteries can generate explosive gases, and short

circuits can draw thousands of amps from the battery. Read

all instructions provided with the battery.

• Do not exceed the voltage or current ratings of the con-

troller. Use only with a 12 volt or 24 volt battery.

•

DO NOT

short circuit the PV array or load while connected

to the controller. This will

DAMAGE

the controller.

• The controller should be protected from direct sunlight.

Ensure adequate space for air flow around the controller.

• Pressure terminal connectors are not required. Use only cop-

per wire with minimum 75˚C insulation rating and between

10 AWG (5.2 mm2) and 14 AWG (2.1 mm2) gage.

• The negative system conductor should be properly

grounded. Grounding should comply with local codes.

2.1 I

NSTALLATIONS IN

AZARDOUS

LASSIFIED

) L

OCATIONS

The SunSaver family of charge controllers have been listed to

UL1604 and CSA 22.2 No. 213-M1987 for use in Class I, Division

2, Groups A, B, C and D hazardous locations. In order to comply

with the UL and CSA standards, the installation should follow the

requirements of the National Electrical Code Article 501-4(b)

and/or Canadian Electrical Code Article 18-156 when installing a

SunSaver in a Hazardous (Classified) Location.

WARNING:Do not disconnect while the circuit is alive

unless the area is known to be nonhazardous.

AVERTISSEMENT: Risque D’explosion—Avant De

Deconnecter L equipment; Couper Le

Courant Ou S’assurer Que L’emplacement

Est Designe Non Gereux.

3.0 QUICK START INSTRUCTIONS

This section provides a brief overview of how to get started

using the SunSaver controller. However, please review the

entire manual to ensure best performance and years of trouble-

free service.

1. Mount the SunSaver to a vertical surface. Allow space above

and below the controller for air flow.

2. Make sure the PV and load currents will not exceed the

ratings of the SunSaver model being installed.

3. The 6 system connections to the SunSaver terminals

are numbered on the label. It is recommended that the

connections be made in order from 1 to 6.

4. Connect the

BATTERY

first. Use care that bare wires do not

touch the metal case of the controller.

+–

BATTERYSOLAR LOAD

+–+–

3 2 1 6 5

{

PHOTOVOLTAIC CONTROLLER

12 Volts

6.5A Solar

6.0A Load

LOAD

DISCONNECT

CHARGING

Remove

Jumper

Wire for

Flooded

Battery

TEMP. SENSE

MORNINGSTAR

SEALED

FLOODED

SELECT

BATTERY

5. Connect the

SOLAR

(PV array) next. The green LED indicator

will light if sunlight is present.

6. Connect the

LOAD

last. If this model includes an LVD and

the red LED indicator lights, the battery capacity is low and

should be charged before completing the system installation.

(Refer to Section 5.3)

7. The controller is shipped with a jumper installed. This sets

the controller for charging

SEALED

batteries.

If a

FLOODED

battery is being used, simply remove the

jumper to optimize the battery charging for a flooded bat-

tery. If the jumper is connected again, the charging will return

to the setpoints for a sealed battery. (Refer to Section 5.3)

8. For most effective surge protection, it is recommended that

the battery negative conductor be properly grounded.

4.0 LED INDICATORS

REEN

LED:

The green LED indicator will light whenever sunlight is avail-

able for battery charging. The green LED will turn off at night.

Because the SunSaver uses a PWM constant voltage charging

process, there is usually some amount of energy going into the

battery at all times. Although the charging current falls to very

low levels when the battery reaches full charge, the green LED

will continue to stay ON (during the daytime). This is to indi-

cate that the controller is working and that energy is available

from the PV array for charging.

LED:

If your SunSaver model includes an automatic load disconnect

(LVD) feature, a red LED indicator is also provided. Whenever

the battery charge state falls below the LVD setpoint, the load

will be disconnected and the red LED will light. This indicates

that the controller has disconnected the load to protect the

battery from further discharge and possible damage.

After some period of recharging the battery such that it recov-

ers to approximately 40 to 50 percent of its rated capacity, the

load will automatically be reconnected and the red LED will

turn off.

5.0 INSTALLATION INSTRUCTIONS

5.1 R

ATINGS AND

IMITS

•The SunSaver is rated for 12 volt (or 24 volt) PV systems. Do

not connect to a PV array with open circuit voltage (Voc)

greater than 25 (or 44) volts.

• Maximum array short circuit current rating:

AVER

-6

8.1 amps

AVER

-10

12.5 amps

AVER

-20

25.0 amps

• Because the SunSaver is a series controller, the PV current

rating is specified at the PV array’s peak power (Ipp). The

SunSaver does NOT short the PV array for regulation, and

it is not necessary to derate the controller for short-circuit

current (Isc) as is commonly done with shunt controllers.

• SunSaver models with an automatic low voltage load discon-

nect function (LVD) are rated for either 6, 10 or 20 amp loads

depending on the model.

•

SunSaver models without an LVD capability are rated for a

maximum load of 10 amps. All loads connected to the SunSaver

LOAD

terminals should not exceed 10 amps of current.

OTE

It is not necessary to use the SunSaver load

terminals. Loads that exceed the load rating of the

SunSaver can be connected directly to the battery.

• The rated PV input current and the rated load current can

both be exceeded by 25% for up to 5 minutes. This 25%

overload will reduce the safety margins for surges and will

cause heating that can shorten the life of the controller.

For the reasons noted above, these higher overload ratings

should

NOT

be used for routine operation. They are only to

note overload capability for system design purposes.

• The SunSaver is designed to operate continuously in 60°C

ambient temperatures. However, do not install the controller

near heat generating sources or in direct sun. This could

cause the temperature rating to be exceeded and damage

the controller.

• The date of manufacture can be found on the serial number

(bottom of case). The first 4 digits are the year and week.

5.2 P

OLARITY

ROTECTION

The SunSaver is generally protected from reversed connec-

tions, but the system operator and other equipment will be at

risk when polarities (+ and –) are reversed. Carefully check

before making each connection to be certain the polarity is

correct.

5.3 I

NSTALLATION

ROCEDURE

OTES

•The SunSaver prevents reverse current leakage at night, so

a blocking diode is not required in the system.

• The connector terminals will accept a maximum wire size

of AWG #10 (up to 5.2 mm2). A flathead screwdriver is

required. (Some #10 spade connectors may not fit in this

terminal.)

• Tighten each terminal clamping screw to 20 inch-pounds of

torque.

• The SunSaver is designed to regulate power from a PV

array. Other generators can be connected directly to the

battery, however, with no effect on the SunSaver.

• Do not connect any system wires (Solar, Battery, Load) to

the

SEALED OR FLOODED SELECT

terminal.

•The installation should follow the requirements of the U.S.

National Electric Code, Section 690.

• The installation should follow the requirements of the

National Electrical Code Article 501-4(b) and/or Canadian

Electrical Code Article 18-156 when installing a SunSaver in

a Hazardous (Classified) Location.

Refer to the connection diagram on page 5 to illustrate each of

the following installation steps.

1. Inspect the controller for shipping damage. If possible,

mount the SunSaver to a vertical surface.

Allow a minimum of 5 cm (2 inches) space above and below

the controller for air flow. Protect the controller from direct

sunlight or other heat sources.

The SunSaver can be mounted outdoors. Avoid mounting in

in direct rain such that water could collect under the cover. If

installed in an enclosure, some ventilation is recommended

to minimize operating temperatures.

OTE

The SunSaver is very corrosion resistant. The case

is hard coat anodized, cover screws are stainless

steel, the circuit is encapsulated, and the termi-

nals are copper and nickel plated brass.

2. Confirm that the PV array and loads will not exceed the

current ratings of the SunSaver model being installed

(see specifications on page 2).

OTE

Multiple SunSavers can be connected in parallel

to charge a single battery. Make sure each PV

sub-array does not exceed the solar rating of the

SunSaver, and be careful not to connect a load

that exceeds a single SunSaver’s load rating.

Separate loads can be connected to different

SunSavers.

CONNECTION ORDER

The label has each system connec-

tion numbered from 1 to 6. This is the recommended order

of system connections. However, a different order will not

damage the controller.

BATTERY

Connect the 12-volt (or 24-volt) system battery.

The green LED will not light. If a red LED (LOAD DISCON-

NECT) is provided with this model and it lights, the battery

charge state is low and should be recharged before

completing the installation.

OTE

If the battery voltage is below 11.5 volts (or

23.0 volts), the load has been automatically

disconnected due to a very low battery charge

condition, and the battery must be recharged.

OTE

If the battery voltage is between 11.5 and 12.0

(or 23 and 24) volts, the SunSaver will sometimes

power-up during initial installation in the LVD

(load disconnected) state. This will automatically

clear when the battery voltage rises above 12.6

(or 25.2) volts. The LVD can also be reset manual-

ly (only if the battery voltage is above 11.5 (or 23)

volts). First connect the SOLAR array (see step 5

below). Next disconnect and then reconnect the

BATTERY positive wire. The red LED will turn off

to indicate that the LVD has been reset.

SOLAR

First, be certain the battery (+ and –) is connected

correctly. Then connect the PV array to the

SOLAR

terminals.

CERTAIN

that the PV + and – wires are connected

correctly. The green LED will light if the array is connected

during the daytime.

AUTION

Remember that the PV array will generate

power whenever in sunlight. Also, be careful

not to SHORT-CIRCUIT the PV array while

connected to the controller, since this will

DAMAGE the controller.

LOAD

Turn the load off. Connect the load to the

LOAD

terminals, and then turn the load on.

If the load causes the red LED to turn on (for models with

LVD) soon after the load was activated, the battery must be

recharged. (see Section 6.2)

SEALED OR FLOODED SELECT

The SunSaver is shipped

with a jumper installed between the

LOAD

-negative terminal

(connection 5) and the

SEALED OR FLOODED SELECT

ter-

minal. With this jumper installed, the SunSaver is configured

for charging

SEALED

batteries.

If your PV system has a

FLOODED

battery, simply remove

the jumper to change the SunSaver to a flooded battery

charger. (see Section 6.2)

The SunSaver can be changed between SEALED and

FLOODED as many times as you wish by using the jumper.

Save the jumper for future use in case your battery type is

changed. If the jumper is lost, a wire can also be used.

8. For safety and the most effective lightning protection, the

negative conductor of the PV system should be properly

grounded. The SunSaver connects the PV-negative, Battery-

negative and Load- negative internally per UL recommenda-

tions. No switching is done in the negative current path.

6.0 OPERATION

6.1 O

PERATOR

ASKS

The SunSaver is a fully automatic PV system controller that

includes electronic functions to protect both the controller and

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