SUNSAVER PV SYSTEM CONTROLLERS Installation and Operation Manual SunSaver Models Included in this Manual: • • • • SS-6-12V / SS-6L-12V SS-10-12V SS-10L-12V / SS-10L-24V SS-20L-12V / SS-20L-24V MORNINGSTAR World’s Leading Solar Controllers & Inverters www.morningstarcorp.
CONTENTS SunSaver Dimensions Inches [Millimeters] 1.0 Safety Information 2.0 General Information 10 2.1 Overview 10 2.2 Features 11 2.3 Regulatory Information 12 3.0 Installation Instructions 15 3.2 User Selections 16 3.3 Mounting 19 3.4 Wiring 21 4.1 LED Indications Ratings System Voltage SS-6/6L SS-10/10L SS-20L 12 V 12V or 24V 12V or 24V Min. Battery Voltage 6V 6V 6V Max. Solar Voltage 30 V 30V or 60V 30V or 60V Max. Solar Current 6 .5 A 10 A 20 A Max.
1.0 IMPORTANT SAFETY INSTRUCTIONS ! This manual contains important safety, installation and operating instructions for the SunSaver solar controller. NOTE: PROPER DISPOSAL OF BATTERIES IS REQUIRED. REFER TO YOUR LOCAL CODES FOR DISPOSAL REQUIREMENTS; The following symbols are used throughout this manual to indicate potentially dangerous conditions or mark important safety instructions: WARNING: These servicing instructions are for use by qualified personnel only.
Installation in Hazardous Locations 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’utilisateur. Ne démontez pas ni ne tentez de réparer le contrôleur. Déconnectez toutes les sources d’alimentation du contrôleur avant d’installer ou de régler le SunSaver. Le SunSaver ne contient aucun fusible ou interrupteur. Ne tentez pas de réparer.
• • • • Direct Current Symbol AVERTISSEMENT: L’appareil n’est pas fourni avec un dispositif GFDI. Ce contrôleur de charge doit être utilisé avec un dispositif GFDI externe tel que requis par l’Article 690 du Code électrique national de l’emplacement de l’installation. • • • • • • • • 8 • Le contrôleur SunSaver doit être installé par un technicien qualifié conformément aux règlementations électriques du pays où est installé le produit.
2.0 GENERAL INFORMATION 2.2 Features The features of the SunSaver are shown in Figure 1 below. An explanation of each feature is provided. 2.1 Overview Thank you for selecting the SunSaver solar charge controller. The SunSaver is an advanced PWM solar battery charger and load controller for stand-alone PV systems. Although the SunSaver is very simple to install and use, please take the time to read this operator’s manual and become familiar with the controller. 5 2 6 2 .
5 - Battery Status LEDs Provides approximate battery state-of-charge indication and also indicates when a system or load fault condition exists. 6 - Mounting Holes Four (4) mounting holes NOTE: This section contains important information for safety and regulatory requirements. The SunSaver controller should be installed by a qualified technician according to the electrical regulations of the country in which the product will be installed.
This Class B digital apparatus complies with Canadian ICES-003. Cet appareil numerique de la classe B est conforme a la norme NMB-003 du Canada. 3.0 INSTALLATION INSTRUCTIONS 3.1 General Installation Notes 3 .0 • Read through the entire installation section before beginning installation. • Be very careful when working with batteries. Wear eye protection. Have fresh water available to wash and clean any contact with battery acid. • Use insulated tools and avoid placing metal objects near the batteries.
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. Battery Type Battery Jumper Absorption Float Equalize Sealed Inserted 14.10V 13.70V N/A Flooded Removed 14.40V 13.70V 14.90V Table 1. Battery Type selection Slow Switching regulation should only be selected if noise or interference exists in the system due to PWM charging.
3.3 Mounting ! CAUTION: Equipment Damage When installing the SunSaver in an enclosure, ensure sufficient ventilation. Installation in a sealed enclosure will lead to over-heating and a decreased product lifetime. ! PRUDENCE: Endommagement de l’équipement ou risque d’explosion N’installez jamais le SunSaver dans une enceinte avec des batteries à évent/à électrolyte liquide. Les vapeurs des batteries sont inflammables et corroderont et détruiront les circuits du SunSaver.
3.4 Wiring AT LEAST 2” (51 mm) NOTE: A recommended connection order has been provided for maximum safety during installation. When disconnecting, solar input must be removed first before disconnecting battery. See caution below. WARM AIR SOLAR CONTROLLER SS-20L-12V CHARGING STATUS Nominal Rating 12 Volts dc Max. Input 30 V Solar 20.0 A Battery 20.0 A Load 20.0 A Max. Ambient 65 ºC ! NOTE: The SunSaver is a negative ground controller. Any one negative conductor can be earth grounded as required.
! 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 load output connection will provide battery voltage to system loads such as lights, pumps, motors, and electronic devices. See Section 4.3 Load Control Information for more details about load control. CONFORMS TO ISA 12.12.
Step 2: Battery Wiring WARNING: Shock Hazard Fuses, circuit breakers, and disconnect switches should never open grounded system conductors. Only GFDI devices are permitted to disconnect grounded conductors. ! 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.
NOTE: Battery circuit fuse / breaker not included. Fuse must be purchased separately. CONFORMS TO ISA 12.12.01 CERTIFIED TO CAN/CSA STD C22.2 NO.213-1992 SUNSAVER-20L SOLAR CONTROLLER SS-20L-12V ! AVERTISSEMENT : Risque d’endommagement La connexion du réseau solaire sur la borne de la batterie endommagera le SunSaver de façon permanente. Class I, Division 2 Groups A,B,C,D Hazardous Loc. Temp. Code: T5 CHARGING STATUS TEMP. SENSOR BATTERY STATUS BATTERY SOLAR Nominal Rating 12 Volts dc Max.
Connect the solar module(s) to the SunSaver. Refer to the wire gauge chart on page 30 of this manual for correct wire size. Use 75 °C copper wire. If required, the negative solar connection may be earth grounded. Use appropriate gauge wire and proper grounding methods for the installation site. Step 4: Confirm Wiring Re-check the wiring in steps 1 through 3. Confirm correct polarity at each connection. Verify that all seven (7) SunSaver power terminals are tightened. CONFORMS TO ISA 12.12.
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. Figure 8c. Secure the Terminal Block Cover with 2 screws.
4.2 Battery Charging Information Three (3) battery “state-of-charge” (SOC) LEDs indicate the level of charge on the battery. The SOC indication is based only on battery voltage setpoints, which only provides an approximation of the actual state-of-charge of the battery. Table 3 lists the SOC LED indications. The SunSaver has a 4-stage battery charging algorithm for rapid, efficient, and safe battery charging. Figure 9 shows the sequence of the stages.
absorption stage for 3 or 4 hours before transitioning to the float stage. Equalize (flooded battery type only) The SunSaver will equalize a flooded battery for three (3) hours every 28 days. Equalize charging raises the battery voltage above the standard absorption voltage so that the electrolyte gases. This process prevents electrolyte stratification and equalizes the individual cell voltages within the battery. WARNING: Risk of Explosion Equalizing vented batteries produces explosive gases.
will depend on many factors including: • rate of discharge (amount of load draw) • capacity of the battery • health of the battery • LVD set-point If the battery discharges to the LVD set-point the load will disconnect and a solid red Battery Status LED indication will be displayed. 4.4 Protections General Load Control Notes • Only SS-6L/10L/20L models provide load control. • Regulated voltage due to temperature compensation is limited to a maximum of 15V (30V @ 24V nominal).
Battery Reverse Polarity (No LED indication) Fully protected against reverse battery connection. No damage to the controller will result. Correct the mistake to resume normal operation. Damaged Local Temperature Sensor (Battery Status LED: R - Y - G sequencing, Charge Status LED: R on solid) The local ambient temperature sensor is short-circuited or damaged. Charging stops to avoid over- or under-charging. This is a critical error. Contact your authorized Morningstar dealer for service.
5.0 TROUBLESHOOTING 5.1 Error Indications Status LED Error Indications • • • • • • • Solar overload High Voltage Disconnect High Temperature Disconnect Damaged local temp. sensor Damaged heatsink temp. sensor Damaged input MOSFETs Firmware Error Flashing Red Flashing Red Flashing Red Solid Red1 Solid Red1 Solid Red1 Solid Red1 1 - A heartbeat indication flickers the Status LED off briefly every 5 seconds. A solid red Status LED indicates that a critical fault has been detected.
6.0 WARRANTY AND CLAIM PROCEDURE 6.0 WD CLAIM PROCEDURE LIMITED WARRANTY Morningstar Solar Controllers and Inverters SunSaver controllers are 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.
7.0 TECHNICAL SPECIFICATIONS Battery Set-points (@ 25°C) Sealed 12 V or 24 V Flooded 12 V or 24 V 14.1 V or 28.2 V 14.4 V or 28.8 V Electrical Absorption Voltage Nominal system voltage Max. solar input voltage Max. solar current Battery voltage range Self-consumption Voltage Accuracy Transient Surge Protection 12 or 24 Vdc 30 or 60V 6.5 or 10 or 20A 6 -15V or 6-30V < 8 mA 1.0 % 1500W per connection Absorption Duration 3 hr 3 hr 13.7 V or 27.4 V 13.7 V or 27.4 V Equalize Voltage none 14.
Mechanical 12 VOLT NOMINAL WIRE CHART Power terminals wire size (max.) Solid Multistrand Fine strand Terminal Diameter Power terminals torque (max.) Dimensions Weight (unpacked) #10 AWG / 5 mm2 #10 AWG / 5 mm2 #10 AWG / 5 mm2 0.210 in / 5.4 mm 10.6 in-lb / 1.2 Nm See inside front cover 8 oz / 0.23 kg Certifications RoHS UL1741 INVERTERS, CONVERTERS, AND CONTROLLERS AND INTERCONNECTION SYSTEM Amps 2 Compliant 2002/95/EC INCLUDING NOV 7, 2005 CSA C22.2 No. 107.1-01 3094762 ISA 12.12.
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