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 www.morningstarcorp.
SunSaver Dimensions Inches [Millimeters] Specification Summary 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 6A 10 A 20 A Max. Load Current 6A 10 A 20 A See Section 7.0 for full technical specifications ** Array voltage should never exceed maximum input voltage.
CONTENTS 1.0 Important Safety Information 1.0 Safety Information 2.0 General Information 4 4 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 16 3.3 Mounting 19 3.4 Wiring 21 4.0 Operation 31 4.1 LED Indications 31 4.2 Battery Charging Information 33 4.3 Load Control Information 35 4.4 Protections 37 4.5 Inspection and Maintenance 39 5.
1.0 Important Safety Instructions SAVE THESE INSTRUCTIONS This manual contains important safety, installation and operating instructions for the SunSaver solar controller. The following symbols are used throughout this manual to indicate potentially dangerous conditions or mark important safety instructions: WARNING: Indicates a potentially dangerous condition. Use extreme caution when performing this task. ! CAUTION: Indicates a critical procedure for safe and proper operation of the controller.
NOTE: PROPER DISPOSAL OF BATTERIES IS REQUIRED. REFER TO YOUR LOCAL CODES FOR DISPOSAL REQUIREMENTS; 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 BE NON-HAZARDOUS.
Installation in Hazardous Locations THIS EQUIPMENT IS SUITABLE FOR USE IN CLASS I, DIVISION 2, GROUPS A,B,C and D OR NON-HAZARDOUS LOCATIONS ONLY. 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.
! 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. Installation Safety Precautions WARNING: This unit is not provided with a GFDI device. This charge controller must be used with an external GFDI device as required by the Article 690 of the National Electrical Code for the installation location.
• • • Power connections must remain tight to avoid excessive heating from a loose connection. Use properly sized conductors and circuit interrupters This charge controller is to be connected to DC circuits only. These DC connections are identified by the symbol below. Direct Current Symbol AVERTISSEMENT: L’appareil n’est pas fourni avec un dispositif GFDI.
• • • MORNINGSTAR CORPORATION 9 1.0 • Le contrôleur SunSaver doit être installé par un technicien qualifié conformément aux règlementations électriques du pays où est installé le produit. Un moyen d’assurer la déconnexion de tous les pôles de l’alimentation doit être fourni. Cette déconnexion doit être incorporée dans le câblage fixe. À l’aide de la borne de mise à la masse du SunSaver (dans le compartiment de câblage), un moyen permanent et fiable de mise à la terre doit être fourni.
2.0 General Information 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. The SunSaver battery charging process has been optimized for long battery life and improved system performance. Self-diagnostics and electronic error protection prevent damage when installation mistakes or system faults occur.
2.2 Features The features of the SunSaver are shown in Figure 1 below. An explanation of each feature is provided. 4 1 5 2 SUNSAVER-6 CONFORMS TO UL STD 1604 CERTIFIED TO CAN/CSA STD C22.2 NO.213-M1987 SOLAR CONTROLLER SS-6-12V CHARGING STATUS Nominal Rating 12 Volts dc Max. Input 30 V Solar 6.5 A Battery 6.5 A Load 10.0 A ! SOLAR 2 .0 6 For the Risk of Explosion Only Operating Temp. Code: T5 TEMP.
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 (mounting screws provided) 2.3 Regulatory Information 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 rules of the country in which the product will be installed.
The entry openings to the SunSaver wiring compartment shall be protected with conduit or with a bushing. FCC requirements: 2 .0 This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including 2 interference that may cause undesired operation.
• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. • Consult the dealer or an experienced radio/TV WWtechnician for help. 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. 14 2.
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. 2 • Explosive battery gasses may be present during charging. Be certain there is sufficient ventilation to release the gasses.
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 whether the jumper should be removed or remain in place, depending on the desired battery type.
Choose Regulation Method (optional) Choose between Pulse Width Modulation (PWM) charging or Slow Switching charging. PWM charging is the default regulation method and is the method recommended for most systems. 3 .0 Slow Switching regulation should only be selected if noise or interference exists in the system due to PWM charging. This regulation method limits the switching frequency to 10 Hz (maximum), which can eliminate noise issues in some 2 systems. PWM charging is selected by default.
Figure 2b. Remove faceplate screws. Figure 2c. Remove faceplate. CUT Figure 2d. Cut the Regulation Select wire loop. 18 3.
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.
AT LEAST 2” (51 mm) WARM AIR SUNSAVER-20L CONFORMS TO ISA 12.12.01 CERTIFIED TO CAN/CSA STD C22.2 NO.213-1992 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 ! TEMP. SENSOR SOLAR BATTERY 12 V BATTERY STATUS LOAD Class I, Division 2 Groups A,B,C,D Hazardous Loc. Temp.
3.4 Wiring 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. NOTE: The SunSaver is a negative ground controller. Any combination of negative connections can be earth grounded as required. Grounding is recommended, but not required for correct operation.
! 22 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. 3.
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. SUNSAVER-20L CONFORMS TO ISA 12.12.01 CERTIFIED TO CAN/CSA STD C22.2 NO.213-1992 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 ! TEMP.
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. AVERTISSEMENT: Risque de décharge électrique Les fusibles, coupe-circuits et interrupteurs ne doivent jamais ouvrir les conducteurs du système mis à la terre. Seuls les dispositifs GFDI sont autorisés à déconnecter les conducteurs reliés mis à la terre.
! 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. 3 .
NOTE: Battery circuit fuse / breaker not included. Fuse must be purchased separately. SUNSAVER-20L CONFORMS TO ISA 12.12.01 CERTIFIED TO CAN/CSA STD C22.2 NO.213-1992 SOLAR CONTROLLER SS-20L-12V CHARGING STATUS BATTERY STATUS BATTERY SOLAR 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 ! TEMP. SENSOR LOAD 12 V Class I, Division 2 Groups A,B,C,D Hazardous Loc. Temp.
WARNING: Risk of Damage Connecting the solar array to the battery terminal will permanently damage the SunSaver. AVERTISSEMENT : Risque d’endommagement La connexion du réseau solaire sur la borne de la batterie endommagera le SunSaver de façon permanente. 12 V OR 24 V NOMINAL (DEPENDS ON MODEL) 12 Volt MODULE 12 Volt MODULE SUNSAVER-20L CONFORMS TO ISA 12.12.01 CERTIFIED TO CAN/CSA STD C22.2 NO.213-1992 SOLAR CONTROLLER SS-20L-12V CHARGING STATUS Nominal Rating 12 Volts dc Max. Input 30 V Solar 20.
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. SUNSAVER-6 CONFORMS TO ISA 12.12.
Figure 8a. Remove 2 faceplate screws. Figure 8b. Place the Terminal Block Cover. Last, secure the terminal cover with the two (2) screws included with the cover. MORNINGSTAR CORPORATION 29 3.0 Next, place the terminal cover over the terminal block as shown in Figure 8b. The cover mounting holes should align with the two (2) faceplate screw holes.
Figure 8c. Secure the Terminal Block Cover with 2 screws. Step 6: Install Fuses or Close Breakers Install a properly sized DC-rated fuse in each fuse holder in the following order: 1. Load circuit 2. Battery circuit Refer to the fuse table on page 38 for appropriate fuse sizes If using circuit breakers, close the Load breaker first followed by the battery breaker. Step 7: Confirm Power-up The SunSaver should begin the power-up LED sequence when battery power is applied.
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. Indication Operating State None Off (with heartbeat¹) Night Green On Solid ( with heartbeat² ) Charging Red Flashing Error Red On Solid ( with heartbeat2 ) Critical Error 4.
BATTERY SOC LEDS 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. SOC LED Indication Battery Status Load Status Green Fast Flashing (2 Flash / sec) Full Battery: Equalize Charge Load On Green Med.
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. VOLTAGE EQUALIZE NIGHT BULK CHARGE ABSORPTION FLOAT NIGHT TIME Figure 9. SunSaver charging algorithm. Absorption When the battery has recharged to the Absorption voltage setpoint, constant-voltage regulation is used to prevent heating and excessive battery gassing.
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 gasses. 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 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 available charge current will flow to the battery and normal operation will resume. 4.
time between a green SOC indication and load disconnect 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. General Load Control Notes • Only SS-6L/10L/20L models provide load control.
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 7.0 Technical Specifications for more information. Load Overload (Battery Status LEDs: G&R - Y sequencing) If the load current exceeds the maximum load current rating, the SunSaver will disconnect the load.
Battery Reverse Polarity (Battery Status LED: G&R - Y) 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.
4.5 Inspection and Maintenance The following inspections and maintenance tasks are recommended at least two times per year for best controller performance. MORNINGSTAR CORPORATION 39 4.0 • Tighten all terminals. Inspect for loose, broken, or corroded connections. • Verify that all wire clamps and tie-downs are secure. • Check that the controller is mounted in a clean, protected environment; free of dirt, insects, nests, and corrosion.
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.
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 charging the battery. Solution: If the Status LED is solid or flashing red, see Section 5.1 Error Indications.
6.0 Warranty and Claim Procedure LIMITED WARRANTY Morningstar Solar Controllers and Inverters All of Morningstar’s products except the SureSine™ inverter and SHS™ controller 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.
WARRANTY CLAIM PROCEDURE 1. Before proceeding, please refer to product manual, including troubleshooting section. 2. Contacting your authorized Morningstar distributor or dealer from whom you purchased the unit is the first step in the warranty process. Local dealers can often address warranty issues quickly. 3. If supplier is unable to address the issue, please contact Morningstar by e-mail (support@morningstarcorp.
7.0 Technical Specifications Electrical Nominal system voltage Max. solar input voltage Max. solar current Battery voltage range Self-consumption Voltage Accuracy Transient Surge Protection 12 V or 24 Vdc 30 V or 60 V 6.5 A or 10 A or 20 A 6 V – 15 V or 30 V < 8 mA 1.0 % 1500 W per connection Protections (Solar & Load): short circuit, over-current, reverse polarity, high temperature, high voltage Battery Charging Regulation Method Temp.
Battery Set-points (@ 25°C) Absorption Voltage Absorption Duration 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 3 hr 3 hr 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 Float Voltage 15 V or 30 V Low Voltage Disconnect 11.5 V or 23.0 V Low Voltage Reconnect 12.6 V or 25.2 V High Voltage Disconnect 15.3 V or 30.6 V High Voltage Reconnect 1 28 days Max.
Mechanical 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.
12 Volt Nominal Wire Chart One-way Wire Distance (feet) Wire Gauge (AWG) Amps One-way Wire Distance (meters) Wire Gauge (mm2) 14 12 10 8 6 2.0 3.0 5.0 8.0 13.
www.morningstarcorp.com Specifications subject to change without notice. Designed in the U.S.A. Assembled in Taiwan. © 2015 Morningstar Corporation MS-001272 v03.
