SUNKEEPER TM Solar Charge Controller Installation and Operation Manual …. Junction Box ( J-Box) Mounted Solar Controller …. Models ……………………………….………… SunKeeper-6 6A / 12V SunKeeper-12 12A / 12V 1098 Washington Crossing Road Washington Crossing, PA 18977 USA www.morningstarcorp.
Table of Contents 1.0 Safety Instructions 2.0 Installation 2.1 Installation Notes 2.2 Mounting to a J-box 2.3 Surface Mounting 3.0 LED Indications 4.0 Operation 4.1 Operator’s Tasks 4.2 Charging Algorithm 4.3 Charging Features 4.4 Protections 5.0 Inspection and Maintenance 6.0 Troubleshooting 6.1 Testing for Correct Operation 6.2 Flashing Red LED 6.3 Solid Red LED 7.0 Warranty 8.
1.0 Safety Instructions SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be followed for proper installation and maintenance. Read all of the instructions and cautions in the manual before starting the installation. WARNING – Be very careful when working with batteries. Lead-acid batteries can generate explosive gases, and short circuits can potentially draw hundreds or thousands of amps from the battery. Do not exceed the voltage or current ratings of the controller.
2.0 Installation 2.1 Installation Notes Hazardous Locations: The SunKeeper family of charge controllers has been listed to UL1604 and CSA 22.2 No.213-M1987 for use in Class 1, 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 SunKeeper in a Hazardous (Classified) Location.
Temperature Compensation Select: The SunKeeper has three temperature compensation options. The blue Temperature Compensation Loop can be configured for the following temperature compensation options: ♦ ♦ ♦ Loop not cut: Internal temperature sensor used for temperature compensation (factory default). Loop cut, left open: No temperature compensation. Insulate/cap loose ends. Loop cut, connected to RTS: Remote Temperature Sensor (RTS)* used for temperature compensation.
2.2 Mounting to a J-box NOTE: Complete steps 1 through 7 before mounting the solar module. SOLAR MODULE ( BOTTOM VIEW ) J-BOX CONDUIT FUSE - + RTS BATTERY Figure 1. Typical System 1. Remove the solar module j-box cover (refer to solar module documentation if necessary). 2. Unscrew the SunKeeper locknut and remove the plastic mounting feet. Store the mounting feet in a safe place. They are not needed when mounting to a j-box.
3. On the solar module j-box: choose knockouts or drill 7/8 inches (22.2 mm) holes for the SunKeeper and ½” conduit entry into the j-box. If drilling holes, choose locations that will allow easy wiring access to the solar module power terminals and easy exit into the ½” conduit. 4. Insert the SunKeeper leads into the chosen knockout or drilled hole. 5. Thread the SunKeeper leads through the locknut and slide the locknut down to meet the threaded neck of the SunKeeper. 6.
Figure 2.
b. Strip ½” (13 mm) of insulation off each of the leads. c. Crimp or splice the two (2) blue wire leads to the two RTS wires (red & black). Polarity is not important. Refer to section 2.1: Installation Notes - System Wiring. 9. Wire the SunKeeper as shown in Figure 2. Wiring may differ slightly depending on the solar module manufacturer. Terminal locations and the number of terminals may also differ. Splices may not be necessary if extra junction terminals are provided.
1. Plastic mounting feet are included with the SunKeeper to allow for surface mounting. Figure 3. Mounting Feet Assembly 2. Assemble the SunKeeper, mounting feet, and locknut as shown in Figure 3. 3. Place the SunKeeper on the surface where it will be mounted and determine where the wires will be routed. Be sure there is sufficient bending room for the wires. With a pen or pencil, mark the location of the screws. 4.
5. Place the SunKeeper onto the surface and align the two (2) mounting feet slots with the pilot holes. Use #10 (M5) pan-head screws (not supplied) to secure the SunKeeper to the surface. 6. On the SunKeeper: select the temperature compensation configuration required (Refer to section 2.1: Installation Notes - Temperature Compensation Select) . If using an RTS: a. Cut the blue Temperature Compensation Loop on the SunKeeper in the middle of the loop creating two (2) equal length wire leads. b.
3.0 LED Indications Green LED (blinks 3 times): Indicates correct installation. Displayed at installation start up (when solar or battery power is first applied). Green LED (ON): Bulk charging stage. Solar power is available and the battery is being charged. A single blink of the green LED every 5 seconds indicates that the SunKeeper is still operational. Green LED (fast blinking): Regulation / Float stage. The battery has charged to Regulation voltage, solar power is being limited to prevent over-charge.
4.0 Operation 4.1 Operator’s Tasks The SunKeeper is a fully automatic solar charge controller that includes many electronic functions to protect both the controller and the system. The only manual tasks performed by the operator are: a. Installation (see section 2.0) b. Temperature Compensation selection (see section 2.1 – Temperature Compensation Select) c. Routine Maintenance (see section 5.0) 4.2 Charging Algorithm The SunKeeper battery charging algorithm is optimized for sealed lead-acid batteries.
solar charging current to prevent battery overcharge while bringing the battery to full state-of – charge. Float – The battery has reached full state-ofcharge and the SunKeeper has reduced battery voltage to the lower Float setpoint. 4.3 Charging Features Temperature Compensation - Lead-acid battery chemistry changes with temperature. The SunKeeper adjusts the Regulation and Float voltage setpoints as temperature changes so that the battery is correctly charged.
4.4 Protections The SunKeeper is fully protected against system faults listed below. Recovery is automatic except where noted below. Refer to section 3.0 for fault LED indications. Reverse Polarity Solar (LED OFF) – no charging, disconnects solar module until wired with correct polarity. Reverse Polarity Battery (red blinking LED) – no charging, displays fault until battery wired with correct polarity.
5.0 Inspection and Maintenance The following inspections and maintenance tasks are recommended at least once per year for best controller performance. 9 Inspect for loose or broken connections at the battery. If an RTS is installed, be sure the RTS terminal lug is secured to a battery terminal. 9 Check the wires and cables for frays, pinches, or other insulation damage. 9 Inspect the SunKeeper plastic case for damage. 9 Verify that the o-ring still maintains a seal against the j-box outside wall.
6.0 Troubleshooting The SunKeeper continuously monitors for system faults (blinking red LED) and critical SunKeeper internal circuit faults (solid red LED). This section explains how to test a SunKeeper for correct operation and provides troubleshooting checklists for both types of faults. 6.1 Testing for Correct Operation The SunKeeper operation can be verified by simply measuring a few voltages. You will need a volt or multimeter to take voltage measurements.
battery voltage, there is a problem with the SunKeeper. 4. Disconnect the battery. 5. Connect the solar module (in full sun) to the SunKeeper Solar input leads. The LED should blink 3 times. After a few seconds the LED should begin blinking green (Regulation). 6. Measure the output voltage on the open Battery leads (Battery + to Common -). Voltage should exist on the Battery leads, however the output voltage will NOT be 14.1V. The output voltage is a pulsed waveform.
6.2 Flashing Red LED Installation Error or Operation Fault (SunKeeper is not damaged) A red flashing LED indicates that a fault exists in the system or the SunKeeper faulted during operation. Corrective action is needed. Check the system for the following conditions: Reverse Battery – The battery connection is reversed at the SunKeeper or at the battery terminals. Disconnect the battery connection at the SunKeeper and measure the voltage with a voltmeter. Verify correct polarity.
the SunKeeper internal temperature has cooled to a safe operating temperature. 6.3 Solid Red LED Critical Faults (SunKeeper may be damaged) If the SunKeeper Status LED indicates a Solid Red critical fault, the SunKeeper should be removed from service immediately. Internal Temperature Sensor Failure – The internal temperature sensor has failed. The SunKeeper can no longer monitor internal temperature, which is critical for proper battery charging.
7.0 Warranty The SunKeeper is warranted to be free from defects in material and workmanship for a period of FIVE (5) years from the date of shipment to the original end user. Morningstar will, at its option, repair or replace any such defective products. CLAIM PROCEDURE Before requesting warranty service, check the Operator’s Manual to be certain that there is a fault with the SunKeeper. Return the defective product to your authorized Morningstar distributor with shipping charges prepaid.
8.0 Technical Specifications Electrical Nominal System Voltage Maximum Solar Input Voltage Rated Solar Input: SK-6 SK-12 Self-consumption Current 12 V 30 V 6A 12 A < 7.0 mA (charging) ~2.0 mA (night) 0 – 15 V Battery Operating Range Battery Charging Setpoints: Regulation Voltage Float Voltage Temperature Compensation Maximum Charge Voltage Limit 14.10 V (@ 25C) 13.70 V (@ 25C) -30 mV / C 15V Mechanical 2 Power Wires (red-yellow-black) 2.0 mm / 14 AWG 2 RTS Wire Loop (blue) 0.
Protections Reverse Polarity – Solar and Battery Short Circuit Solar Charging Over-current High Temperature shut-down Temperature Sensor Failure Nighttime Reverse Current Leakage (no blocking diode needed) Certifications CE UL 1604 and CSA 22.2 No. 213-M1987 for use in Class 1, Division 2, Groups A,B,C,D hazardous locations Specifications subject to change without notice.
