SOLAR LIGHTING CONTROLLER OPERATOR’S MANUAL SUNLIGHT MODELS INCLUDED IN THIS MANUAL • SL-10 10A / 12V • SL-10-24V 10A / 24V • SL-20 20A / 12V • SL-20-24V 20A / 24V 1098 Washington Crossing Road Washington Crossing, PA 18977 USA Website: ww.morningstar.
SPECIFICATION SUMMARY SL-10 SL-20 24 Volt System Voltage 12 12 24 V Maximum Voltage 30 30 50 V Rated Solar Input 10 20 n/a A 12.5 25 n/a A Rated Load 10 20 n/a A 25% Current Overload 5 5 n/a minutes Sealed PWM 14.1 14.1 28.2 V Flooded PWM 14.4 14.4 28.8 V LVD 11.7 11.7 23.4 V LVD Reconnect 12.8 12.8 25.
CONTENTS 1.0 2.0 3.0 4.0 5.0 6.0 GENERAL INFORMATION ................................................ IMPORTANT SAFETY INSTRUCTIONS .................................. QUICK START INSTRUCTIONS .......................................... LIGHTING CONTROL OPTIONS ........................................ LED INDICATORS ................................................................ INSTALLATION INSTRUCTIONS .............................................. 6.1 Ratings and Limits ..................................
will help you to make full use of the many advantages the SunLight can provide to your solar lighting system. 2.0 IMPORTANT SAFETY INSTRUCTIONS • SAVE THESE INSTRUCTIONS—This manual contains important instructions that should be followed during installation and maintenance of the SunLight 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.
3 LOW VOLTAGE DISCONNECT CHARGING SOLAR LIGHTING CONTROLLER D/D 6/2 TEMP. SENSE 2 12 Volts 10A Solar 10A Light SOLAR BATTERY 4 3 – + 2 LIGHT 1 12 V – + 6 5 – + LIGHTING CONTROL SEALED OR FLOODED SELECT OFF 1 2 4 6 4/2 3/1 10 8 TEST Õ UP 9 MORNINGSTAR MADE IN USA 7 4 10 6 5 8 6. 7. 8. 9. Connect the LIGHT last. If the red LED indicator lights, the battery capacity is low and should be charged before completing the system installation (Refer to Section 6.4).
5.0 LED INDICATORS GREEN LED: The green LED indicator will light whenever sunlight is available for battery charging. The green LED will turn off at night. Because the SunLight 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 all day.
• Because the SunLight is a series controller, the PV current rating is specified at the PV array’s peak power (Ipp). The SunLight 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. • The rated PV input current and the rated load current can both be exceeded by 25% for up to 5 minutes.
• Tighten each terminal clamping screw to 20 inch-pounds of torque. • The SunLight is designed to regulate power from a PV array. Other generators can be connected directly to the battery, however, with no effect on the SunLight. • Do not connect any system wires (Solar, Battery, Light) to the SEALED OR FLOODED SELECT terminal. Refer to the connection diagram on page 3 to illustrate each of the following installation steps. 1. Inspect the controller for shipping damage.
NOTE: If the battery voltage is below 11.7 (or 23.4) volts, the load has been automatically disconnected due to a very low battery charge condition, and the battery must be recharged. NOTE: A battery below 10 volts may not start the microcontroller properly. Make sure the battery is charged before installing the system. 5. SOLAR First, be certain the battery (+ and –) is connected correctly. Then connect the solar array to the SOLAR terminals.
8. For safety and the most effective lightning protection, the negative conductor of the battery should be properly grounded. The SunLight connects the PV-negative, Battery-negative and Loadnegative internally per UL recommendations. No switching is done in the negative current path. 7.0 OPERATION 7.1 SELECT LIGHTING CONTROL OPTION After completing the system connections, select the desired LIGHTING CONTROL option. Refer to Section 4.
Switch Setting # of Flashes Switch Setting # of Flashes OFF 2 4 6 8 0 1 2 3 4 10 3/1 4/2 6/2 D/D 5 6 7 8 9 NOTE: Rotate the rotary switch one full cycle if there is an incorrect or no LED flash (except for OFF setting). b. Turn system lights on Pressing the TEST button will turn the system lights on to verify correct installation or for troubleshooting a system problem. The lights will be turned on anytime (day or night) for 5 minute intervals.
• Battery Charge Regulation SunLight uses an advanced series PWM charge control for constant voltage battery charging. A true 0 to 100% PWM duty cycle is very fast and stable for positive charge control under all system conditions. • Day-Night Transition The SunLight uses the solar array to detect day and night. The transition to night requires a solar insolation level less than 2 percent. The transition back to day requires a high solar array open-circuit voltage.
• Sealed / Flooded Select Flooded batteries require more vigorous charging to avoid stratification, and sealed batteries require precise control to avoid outgassing. The SunLight constant voltage setpoints are 14.4 volts for flooded batteries, and 14.1 volts for 12 volt sealed batteries. See Section 6.4-7 for more information. • LED Indicators See Section 5.0 • Low Voltage Disconnect (LVD) If the battery falls below 11.7 (or 23.
7.5 INSPECTION AND MAINTENANCE The following inspections and maintenance tasks are recommended at least once per year for best controller performance. 1. Confirm that the correct battery type has been selected (sealed or flooded with the jumper). 2. Confirm that the current levels of the Solar array and load do not exceed the SunLight 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.
8.2 TROUBLESHOOTING The SunLight is very rugged and designed for the most extreme operating conditions. Most PV system problems will be caused by connections, voltage drops, and loads. Troubleshooting the SunLight controller is simple. Some basic troubleshooting procedures are listed below. CAUTIONS: 1. Troubleshooting should be done by qualified personnel only. 2. Remember that a battery can cause serious damage if shorted. 3.
2. BATTERY VOLTAGE IS TOO HIGH a. First check the operating conditions to confirm that the voltage is higher than specifications. Consider the temperature compensation of the controller’s PWM setpoint. For example, 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.
