Morningstar SUNSAVER SS-10-12V, Installation And Operation Manual

Page 1: ...US See Operator s Manual Nominal Rating 12 Volts dc Max Input 30 V Solar 20 0A Battery 20 0A Load 20 0A Max Ambient 65 ºC indoor use only Use 75 ºC Copper Conductors Only CONFORMS TO ISA 12 12 01 CERTIFIE D TO CAN C SASTD C22 2 NO 213 1992 Class I Division 2 GroupsA B C D Hazardous Loc Tem p Code T5 RoHS MORNINGSTAR S S 20L UN AVER SOLAR CONTROLLER SS 20L 12V SunSaver Models Included in this Manua...

Page 2: ...rmine the highest expected array Voc as defined by the lowest expected ambient temperature for the system location CONTENTS 1 0 Safety Information 4 2 0 General Information 10 2 1 Overview 10 2 2 Features 11 2 3 Regulatory Information 12 3 0 Installation Instructions 15 3 1 General Installation Notes 15 3 2 User Selections 17 3 3 Mounting 20 3 4 Wiring 22 4 0 Operation 31 4 1 LED Indications 31 4 ...

Page 3: ... SunSaver Do not attempt to repair Install external fuses breakers as required WARNING These servicing instructions are for use by qualified personnel only To reduce the risk of electric shock do not perform any servicing other than that specified in the operating instructions unless you are qualified to do so WARNING EXPLOSION HAZARD DO NOT DISCONNECT WHILE CIRCUIT IS LIVE UNLESS AREA IS KNOWN TO...

Page 4: ... of same type make and age Do not smoke in the vicinity of the battery bank Mount the controller at least 3 ft 1 m away from vented batteries unless separated by a barrier or located in a separate compartment Informations de sécurité Lisez toutes les instructions et les avertissements figurant dans le manuel avant de commencer l installation Le SunSaver ne contient aucune pièce réparable par l uti...

Page 5: ...ans le contrôleur Installez le SunSaver dans un endroit qui empêche le con tact occasionnel Le dissipateur de chaleur SunSaver peut devenir très chaude pendant le fonctionnement Utilisez des outils isolés pour travailler avec les batteries Évitez le port de bijoux pendant l installation Le groupe de batteries doit être constitué de batteries du même type fabricant et âge Ne fumez pas à proximité d...

Page 6: ...gure 1 below An explanation of each feature is provided SEALED OR FLOODED SELECT LOAD BATTERY SOLAR Remove Jumper Wire for Flooded Battery 12 V BATTERY STATUS TEMP SENSOR CHARGING STATUS See Operator s Manual Nominal Rating 12 Volts dc Max Input 30 V Solar 6 5A Battery 6 5A Load 10 0A indoor use only Use Copper Conductors Only CONFORMS TO UL STD 1604 CERTIFIED TO CAN CSASTD C22 2 NO 213 M1987 Clas...

Page 7: ... modifications not expressly approved by Morningstar for compliance could void the user s authority to operate the equipment NOTE This equipment has been tested and found to comply with the limits for a Class B digital device pursuant to Part 15 of the FCC rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment gene...

Page 8: ...ufficient ventilation to release the gases Do not install in locations where water can enter the controller Loose power connections and or corroded wires may result in resistive connections that melt wire insulation burn surrounding materials or even cause fire Ensure tight connections and use cable clamps to secure cables and prevent them from swaying in mobile applications The SunSaver charging ...

Page 9: ...ualification de type requise 3 2 User Selections Select a Battery Type The SunSaver provides a Battery Select Jumper to choose the battery type See Section 7 0 Technical Specifications for detailed charging information for each battery type The battery select jumper is secured in the terminal block between terminal 6 and terminal 7 as shown in figure 2a The second column in table 1 specifies wheth...

Page 10: ... enable Slow Switching regulation do the following 1 Remove all four screws that secure the faceplate on the SunSaver See Figure 2b 2 Gently pry the faceplate off the SunSaver Occasionally epoxy encapsulant will cause the faceplate to stick Use a small flat head screw driver to separate the faceplate from the SunSaver body See Figure 2c 3 A loop of wire protrudes from the epoxy Cut the loop with w...

Page 11: ...battery Locate the controller within 10 ft 3 M of the battery bank Mounting the controller on a horizontal surface does not provide optimal airflow and could lead to overheating Step 2 Check for Clearance Place the SunSaver in the location where it will be mounted Verify that there is sufficient room to run wires and that there is ample room above and below the controller for air flow WARM AIR COO...

Page 12: ...during charging may cause a brief spike in load voltage above the 15V regulation limit which may damage sensitive equipment ATTENTION Unité bénéficie d aucune protection de retrait de batterie Débrancher la batterie pendant la charge peut entraîner un bref pic de tension de charge au dessus du 15V limite de règlement qui peuvent endommager les équipement sensibles Step 1 Load Wiring The SunSaver l...

Page 13: ...or correct wire size Use 75 C copper wire If required the negative battery connection may be earth grounded Use appropriate gauge wire and proper grounding methods for the installation site Wire an in line fuse holder no more than 6 inches 150 2 3 0 mm from the battery positive terminal DO NOT INSERT A FUSE AT THIS TIME A circuit breaker may be used in lieu of a fuse Keep the breaker in the open d...

Page 14: ... voltage of the 24V array must be less than 60V SEALED OR FLOODED SELECT LOAD BATTERY SOLAR Remove Jumper Wire for Flooded Battery 12 V BATTERY STATUS TEMP SENSOR CHARGING STATUS See Operator s Manual Nominal Rating 12 Volts dc Max Input 30 V Solar 20 0A Battery 20 0A Load 20 0A Max Ambient 65 ºC indoor use only Use 75 ºC Copper Conductors Only CONFORMS TO ISA12 12 01 CERTIFIED TO CAN CSASTD C22 2...

Page 15: ...L 12V 2 1 3 Figure 7 System Wiring Review Step 5 Install the Terminal Cover The terminal cover prevents contact with the power terminals when energized If local code and regulations require certification terminal cover must be installed otherwise terminal cover use is optional Begin by removing the two 2 lower faceplate screws as shown in figure 8a Set the screws aside Figure 8a Remove 2 faceplate...

Page 16: ...r a flashing LED error sequence exists refer to Section 5 0 Troubleshooting 4 0 OPERATION 4 1 LED Indications STATUS LED The Status LED indicates charging status and any existing solar input error conditions The Status LED is on when charging during the day and off at night The Status LED will flash red whenever an error condition s exists Table 2 lists the Status LED indications Color Indication ...

Page 17: ...S On Battery Missing Load Off Table 3 Battery SOC LED definitions NOTE An error condition exists if multiple Battery SOC LEDs are flashing See Section 5 1 Error Indications for more information 4 2 Battery Charging Information The SunSaver has a 4 stage battery charging algorithm for rapid efficient and safe battery charging Figure 9 shows the sequence of the stages NIGHT NIGHT BULK CHARGE ABSORPT...

Page 18: ...s a special charging function to recover batteries that have discharged too low If the terminal voltage of the battery is greater than 1 Volt the SunSaver will detect the battery and provide approximately 85 of available charge current until the battery reaches the minimum operating voltage of the controller When the battery has recharged to the minimum operating voltage of the SunSaver 100 of ava...

Page 19: ...amage the load Always re check load connections before applying power The SunSaver will go straight to LVD on start up if the battery voltage is at or below 11 7V 23 4V 4 0 4 4 Protections Solar Overload Charging Status LED Red flashing If the solar current exceeds the maximum solar rating the SunSaver will stop charging until the solar current returns to within its operational rating See Section ...

Page 20: ...eatsink temperature has exceeded 85 C and the solar and load is disconnected The SunSaver will automatically reconnect when the heatsink cools to 80 C High Voltage Disconnect Battery Status LED R G sequencing The battery voltage has exceeded the controller s maximum regulation limit The solar and load will be disconnected until the battery voltage decreases to the SunSaver s High Voltage Reconnect...

Page 21: ...e Yellow LED is on then Red and Green LED are on 5 2 Common Problems Problem No LED indications Solution With a multi meter check the voltage at the Battery terminals on the SunSaver and the Solar terminals on the SunSaver The solar module must be in good sun and battery voltage must be at least 1 V to power the SunSaver and activate the dead battery charging function Problem The SunSaver is not c...

Page 22: ...TABILITY AND FITNESS FOR A PARTICULAR PURPOSE No Morningstar distributor agent or employee is authorized to make any modification or extension to this warranty MORNINGSTAR IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES OF OF ANY KIND INCLUDING BUT NOT LIMITED TO LOST PROFITS DOWN TIME GOODWILL OR DAMAGE TO EQUIPMENT OR PROPERTY 6 0 WARRANTY and CLAIM PROCEDURE WARRANTY CLAIM PROCEDURE ...

Page 23: ...ery Set points 25 C Sealed 12 V or 24 V Flooded AGM 12 V or 24 V Absorption Voltage1 14 1 V or 28 2 V 14 6 V or 29 2 V Absorption Duration2 3 hr 3 hr Float Voltage 13 7 V or 27 4 V 13 7 V or 27 4 V Equalize Voltage none 14 9 V or 29 8 V Equalize Duration none 3 hrs Equalize Calendar none 28 days Max Regulation Voltage3 15 V or 30 V Low Voltage Disconnect 11 5 V or 23 0 V Low Voltage Reconnect 12 6...

Page 24: ...orp com support library Under Type choose Declaration of Conformity DOC to view list of product DOCs Tables Fusing Chart Wire Gauge AWG Max Fuse Size 14 15 Amps 12 20 Amps 10 30 Amps per 2011 NEC NFPA 70 Article 240 For copper wire only Refer to the wire charts on page 47 for appropriate wire size 12 VOLT NOMINAL WIRE CHART Amps One way Wire Distance feet Wire Gauge AWG One way Wire Distance meter...

Page 25: ...44 228 10 16 26 42 69 10 29 45 72 115 182 8 12 21 34 55 12 24 38 60 96 152 7 10 17 28 46 14 20 32 51 82 130 6 9 15 24 39 16 18 28 45 72 114 5 8 13 21 34 18 16 25 40 64 101 4 7 11 19 30 20 14 23 36 57 91 4 6 10 17 27 3 Voltage drop Annealed copper wire at 20 C www morningstarcorp com MORNINGSTAR World s Leading Solar Controllers Inverters Specifications subject to change without notice Designed in ...

Page 26: ...onmental specifications CSA C22 2 107 1 POWER CONVERSION EQUIPMENT EMC Directives Immunity EN 55024 Emissions EN 55032 Hazardous Locations for IECEx ATEX Applications IECEx ETL 20 0060X ITS20ATEX35891X IECEx Ex ec IIC TX Gc ATEX II 3G Ex ec IIC TX Gc T4 40 C Tamb 60 C T5 40 C Tamb 45 C Sunsaver Gen 3 must be verified with di electric strength test specified by the relevant industrial standard The ...