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SPECIALTY CONCEPTS MODEL 1

(

SC1

)

Photovoltaic Battery Charge Controller

Installation and Operation Manual

SPECIALTY CONCEPTS, INC.

8954 Mason Ave.

Chatsworth, CA 91311 USA

GENERAL DESCRIPTION

The SPECIALTY CONCEPTS CHARGER MODEL 1 (SC1) is a versatile, industrial quality charge

controller for the efficient use of photovoltaic energy and the protection of expensive batteries. It

is available for 12, 24, 36, and 48 volt negative ground systems with models for 30 amps of

charge current (optional 50 amps available) .

The SC1 consists of a series-relay battery charge controller in a wall mount chassis with low

voltage load disconnect, a load circuit breaker, and system status lights. The lights indicate

"CHARGE MODE" and "LOAD DISCONNECTED" conditions. The SC1 is housed in an anodized

aluminum chassis and has a terminal block that accepts up to 10 gauge wire. A terminal adapter

kit is included to increase wire size to #6.

FEATURES

CHARGE REGULATION

• 30 amp charge current, 12, 24, 36 or 48 volt

• 50 amp charge current (optional), 12 or 24 volt

• Two-step, series charging, 12,24 v

• Single step, series charging, 36,48 v

• Adjustable charging set-points (option)

• Temperature compensation (option)

LOW-VOLTAGE LOAD DISCONNECT (LVD)

• 30 amp LVD, 12 volt

• 20 amp LVD, 24 volt

• 15 amp LVD, 36 and 48 volt

• Adjustable disconnect set-points

• Manual override switch

DESIGN FEATURES

• Maximum array usage

• Over-current protection - load circuit breaker

• Reverse polarity protection

• Reverse leakage protection

• Lightning protection

• Input noise suppression

• Remote battery voltage sense

MONITORING and MOUNTING

• “CHARGE MODE” light

• ”LOAD DISCONNECTED” light

• Analog volt/amp meters (option)

• Indoor wall mount

• Outdoor enclosure (accessory)

Summary of content (22 pages)

PAGE 1
SPECIALTY CONCEPTS MODEL 1 ( SC1 ) Photovoltaic Battery Charge Controller Installation and Operation Manual SPECIALTY CONCEPTS, INC. 8954 Mason Ave. Chatsworth, CA 91311 USA Copyright 8 / 1997 Specialty Concepts, Inc. GENERAL DESCRIPTION The SPECIALTY CONCEPTS CHARGER MODEL 1 (SC1) is a versatile, industrial quality charge controller for the efficient use of photovoltaic energy and the protection of expensive batteries.
PAGE 2
SPECIFICATIONS PARAMETERS UNITS Charge Current, Continuous (1) Charge Current, Max (60 seconds) (2) Load Current, Continuous (3) Load Current, Max (60 seconds) (2) Array Voltage, Max Voc Operating Voltage @ Battery, Minimum 34.0 Quiescent Current (4) Current Consumption, Charging (5) Current Consumption, Load Disconnected (6) Current Consumption, Metering, Typ. (7) Voltage Drop, Typ. (Array to Battery) Voltage Drop, Typ.
PAGE 3
RELATED SYSTEM EQUIPMENT The SC1 is an integral part of a solar electric power system that includes a PV solar array, a battery and a load. These items should be installed in accordance with the National Electrical Code, and with the instructions provided by the equipment supplier. SOLAR ARRAY PANELS: The SC1 is compatible with all makes and models of PV panels.
PAGE 4
INSTALLATION WARNINGS / CAUTIONS WARNING: Electricity, even low-voltage electricity, can be dangerous. Installation should be performed by a licensed electrical contractor or other qualified personnel only. The requirements of the U.S. National Electrical Code should be followed. WARNING: Follow all safety precautions of the battery manufacturer. Proper ventilation must be provided for vented batteries. Most vented batteries produce hydrogen gas when charging, which is extremely explosive.
PAGE 5
INSTALLATION INSTRUCTIONS: 1. LOCATION: - A suitable location must be found for mounting the SC1. The unit should be mounted on a vertical surface and be as close as possible to the batteries to avoid errors in battery voltage reading. DO NOT block the ventilation holes on the top and bottom of the SC1. On units with temperature compensation (Option A), the sensor wire is 10 feet long and should reach the battery bank if possible.
PAGE 6
9. NOTE WIRE POLARITY: - Insure that the polarity of the wires is correctly marked, using colored wires or tags. Incorrect polarity should not damage the SC1, but incorrect operation would result. 10. COMPLETE ARRAY AND BATTERY CONNECTIONS: - Connections to the SC1 terminal block should be made with just the bare wire (not crimped spade or ring lugs unless the lugs are crimped AND soldered) 11. COMPLETE LOAD CONNECTIONS: - Refer to wiring diagram (FIGURE 1).
PAGE 7
16. RECONNECT BATTERY AND ARRAY POWER position the load circuit breaker on. Reconnect both power sources, then POWER CONNECT SEQUENCE It is recommended that the power is supplied to the system using this sequence. Some of the circuits within the SC1 must be reset to their "start state" and this is automatically accomplished if the power is supplied in this order. If the order is not followed, a period of up to 24 hours may have to elapse before the electronics are fully reset.
PAGE 8
FIGURE 1 SPECIALTY CONCEPTS CHARGE CONTROLLER MODEL 1 SOLAR ARRAY PANEL SPECIALTY CONCEPTS CHARGER MODEL 1 BATT SENSE (-) + BATTERY (-) 30 amp fuse (or 50 amp with Option P) SOLAR PANEL(-) LOAD (-) Temperature compensation (Optional) LOAD (+) + SOLAR PANEL (+) BATTERY (+) BATT SENSE (+) BATTERY + Jumpers: This jumper and the jumper on the negative terminal, should remain as shown unless a Battery Voltage Sense Connection is needed.
PAGE 9
SETTINGS / ADJUSTMENTS FULL CHARGE VOLTAGE ADJUSTMENT (Option T) : If the controller is supplied with this option, the charge termination voltage set-point may be adjusted. Refer to the OPTIONS section (“OPTION T”). LOW-VOLTAGE LOAD DISCONNECT (LVD) SETTINGS: The Load Disconnect and Reconnect set-points are factory set as listed in the specifications section, and are adjustable. NO LVD: - For an override of the load disconnect function, push the switch up.
PAGE 10
OPERATION CHARGE REGULATION (12 and 24 volt units): The two-step control circuit regulates the charging of storage batteries by monitoring battery and solar panel voltage. STEP 1: CONSTANT CURRENT (FULL) CHARGE MODE: At sunrise, the charging relay energizes and closes, connecting the solar panel directly to the battery and lighting the "CHARGE MODE" light. The battery will accept as much current as the solar panel will provide, and battery voltage will rise.
PAGE 11
MONITORING “CHARGE MODE” LIGHT: The "CHARGE MODE" light will be on when the controller is in the full charge mode. In this mode, the charging relay is closed, connecting the solar panel directly to the battery. This light should go on first thing in the morning. When the battery reaches the "Full Charge Termination" set-point, the SC1 will switch from Full-Charge mode to Float-Charge mode and the CHARGE MODE light will go out.
PAGE 12
OPTIONS The following are the options available with the SC1. Options cannot be added to units after production. Some of the features and functions described in this manual are not included on all of the units. Check the model number and voltage/current ratings of your unit and compare with the specifications and option descriptions to determine what your particular model's capabilities are.
PAGE 13
OPTION F - VOLT / AMP METERS These meters monitor the battery voltage and charging current of the system. The battery voltage meter is an expanded scale meter with red, yellow and green indication of state of charge. These are 5% meters and are intended to give an indication of system status, but are not designed to give highly accurate readings of voltage and current. The Specialty Concepts Digital Monitor (DM3) is available if higher accuracy is required.
PAGE 14
TROUBLE SHOOTING: GENERAL NOTES IF THE CONTROLLER IS NEWLY INSTALLED, CHECK THESE THINGS FIRST: 1) Re-check system wiring to insure proper installation and polarity . 2) Check all system fuses and circuit breakers. Before replacing a blown fuse, locate and correct the cause. 3) Check to be sure that there is a connection (voltage input) to the "BATTERY VOLTAGE SENSE" terminals from the battery.
PAGE 15
TROUBLE SHOOTING: SC1 PROBLEM DESCRIPTIONS BATTERY UNDER CHARGED CONTROLLER NOT CHARGING AT ALL, ALWAYS IN FLOAT MODE ("CHARGE MODE" LIGHT OFF) Check to see that the controller is receiving voltage (at least about nominal system voltage) from the battery and the solar panels. If it is, momentarily disconnect the panels, using an solar panel disconnect switch if available, then reconnect. The controller should reset into the full charge mode ("CHARGE MODE" light on).
PAGE 16
to be on for a few hours each evening. Also, the light will stay on during the night of the first day of installation or if the solar panel has been manually disconnected that day. If the light stays on all night every night, the timer may be defective. BATTERY OVERCHARGING CONTROLLER ALWAYS IN FULL CHARGE ("CHARGE MODE" LIGHT ON) See General Note #6 above: The battery may not be reaching the charge termination setpoint.
PAGE 17
LOAD DISCONNECT CIRCUIT NOT OPERATING CORRECTLY LOADS ALWAYS DISCONNECTED, LVD LIGHT ON, EVEN WHEN BATTERY VOLTAGE IS HIGH See General Note #6 above: No voltage at the BATTERY VOLTAGE SENSE terminals tells the controller that the battery voltage is low and loads need to be disconnected. Install a connection from the battery to "BATTERY VOLTAGE SENSE" terminals to resolve.
PAGE 18
TROUBLE SHOOTING: BATTERIES Refer to this section to help diagnose potential problems based on battery observations.
PAGE 19
TROUBLE SHOOTING: SOLAR PANELS Refer to this section to help diagnose potential problems based on panel performance. CASE PANELS 1 → Less charge than expected SEE NOTE(S) See Panel note 1 Panel Note 1 - The panels should generate a charge close to their rated load current as presented in their specifications. To reach this level assumes that all conditions are ideal. If the panel performance as measured at the panel inputs on the SC1 controller is much lower, consider the following potential problems.
PAGE 20
FIELD TEST PROCEDURE: SC1 Test equipment required: Digital Multimeter Conditions: Sunny or bright overcast if possible This procedure assumes that the solar panels are installed and operational and capable of producing at least 17.5 volts open circuit (for a 12 volt system). Proportionately higher for higher voltage systems. Systems should be equipped with disconnects or switches to facilitate connecting and disconnecting the batteries and solar panel as described in this procedure.
PAGE 21
BENCH TEST PROCEDURE: SC1 Test equipment required: Digital Multimeter, Adjustable Power supply Nominal Voltage 12 24 36 48 Power Supply Range 10-18 Vdc 20-36 Vdc 30-48 Vdc 40-64 Vdc All measurements described in this procedure should be made at the controller terminals. 1) Make sure that there is a jumper between Battery(+) and Battery Voltage Sense(+) and one between Battery(-) and Battery Voltage Sense(-). 2) Check continuity between Battery(-),Solar Panel(-) and Load(-).
PAGE 22
LIMITED FIVE YEAR WARRANTY SPECIALTY CONCEPTS, INC. 1. Specialty Concepts, Inc. warrants all its products for a period of five (5) years from the date of shipment from its factory. This warranty is valid against defects in materials and workmanship for the five (5) year warranty period. It is not valid against defects resulting from, but not limited to: A. Misuse and/or abuse, neglect or accident. B. Exceeding the unit's design limits. C.