P H O T O V O LTA I C S Y S T E M C O N T R O L L E R S OPERATOR’S MANUAL SUNSAVER MODELS INCLUDED IN THIS MANUAL • • • • • SS-6 / SS-6L SS-10 / SS-10L SS-10-24V / SS-10L-24V SS-20L SS-20L-24V 6A 10A 10A 20A 20A 1098 Washington Crossing Road Washington Crossing, PA 18977 USA Website: www.morningstarcorp.
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 circuit current (A) 8.1 12.5 25 n/a 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.
CONTENTS 1.0 GENERAL INFORMATION .............................................. 4 2.0 IMPORTANT SAFETY INSTRUCTIONS .............................. 4 2.1 Installations in Hazardous (Classified) Locations .............................................. 4 3.0 QUICK START INSTRUCTIONS ........................................ 5 4.0 LED INDICATORS .............................................................. 6 5.0 INSTALLATION INSTRUCTIONS ............................................ 7 5.
1.0 GENERAL INFORMATION Thank you for selecting the SunSaver™ PV controller. The SunSaver is a sophisticated controller using advanced technology 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.
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.
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.
5.0 INSTALLATION INSTRUCTIONS 5.1 RATINGS AND LIMITS • 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: SUNSAVER-6 SUNSAVER-10 SUNSAVER-20 8.1 amps 12.5 amps 25.0 amps • Because the SunSaver is a series controller, the PV current rating is specified at the PV array’s peak power (Ipp).
5.2 POLARITY PROTECTION The SunSaver is generally protected from reversed connections, 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 INSTALLATION PROCEDURE NOTES: • 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).
NOTE: The SunSaver is very corrosion resistant. The case is hard coat anodized, cover screws are stainless steel, the circuit is encapsulated, and the terminals 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). NOTE: Multiple SunSavers can be connected in parallel to charge a single battery.
5. SOLAR First, be certain the battery (+ and –) is connected correctly. Then connect the PV array to the SOLAR terminals. Be CERTAIN that the PV + and – wires are connected correctly. The green LED will light if the array is connected during the daytime. CAUTION: 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. 6. LOAD Turn the load off.
the PV system. Battery charging is managed by a constant voltage PWM algorithm that has been optimized for PV systems. The only manual tasks performed by the operator are: a. Installation (see Section 5.3 ) b. Battery type selection (see Section 5.3-7) c. Maintenance (see Section 6.3) 6.2 OPERATION AND FUNCTIONS The PV system operator should become familiar with the following operating functions and design of the SunSaver controller. Refer to the Technical Specifications (Section 8.
• Low Voltage Disconnect (LVD) The automatic load disconnect is an option. If the battery falls below 11.5 (or 23.0) volts, the load is disconnected from the battery to protect against harmful deep discharges. A 2-second delay prevents load disconnects from transients. The load is automatically reconnected when the battery voltage recovers to 12.6 (or 25.2) volts. • Battery Disconnect If the battery is disconnected during the daytime, the PV array will continue to provide power to the controller.
2. Confirm that the current levels of the PV array and load do not exceed the SunSaver ratings. 3. Tighten all the terminals. Inspect for loose, broken, or burnt wire connections. Be certain no loose strands of wire are touching other terminals. 4. Check that the controller is securely mounted in a clean environment. Inspect for dirt, insects, and corrosion. 5. Check that air flow around the controller is not blocked. 6. Protect from direct sun and rain. Confirm that water is not collecting under the cover.
CAUTIONS: 1. Troubleshooting should be done by qualified personnel only. 2. Remember that a battery can cause serious damage if shorted. 3. There are no user serviceable parts, fuses or circuit breakers inside the SunSaver. 4. Observe all normal precautions when working with energized circuitry. 1. BATTERY IS NOT CHARGING a. Check the green LED indicator. The green CHARGING LED should be on if it is daytime. b. Check that the proper battery type (sealed or flooded) has been selected. c.
at 0°C the controller will regulate at about 15.1 volts (for 12 volt flooded batteries). b. Check that the proper battery type (sealed or flooded) has been selected. c. Check that all wire connections in the system are correct and tight. d. Disconnect the PV array and momentarily disconnect the lead from the BATTERY positive terminal. Reconnect the battery terminal and leave the PV array disconnected. The Green charging light should not be lit.
8.0 TECHNICAL SPECIFICATIONS RELIABILITY MECHANICAL 5-year failure rates at a 95% confidence level • Dimensions: (inches) .... 6.0 x 2.2 x 1.3 (W•H•D) • SunSaver-6 ........................................ < 0.1% (mm) ........ 152 x 56 x 33 (W•H•D) • SunSaver-10 ...................................... < 0.2% • Weight (oz)............ 8 (kg) .......... 0.23 PERFORMANCE / ELECTRICAL • Wire terminals: • Accuracy: Wires per terminal...... 1 or 2 wires Sealed...........................................
