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SPECIALTY CONCEPTS SYSTEM

(

SCS

50, SCS

)

Photovoltaic Battery Charge Controller

Installation And Operation Manual

SPECIALTY CONCEPTS, INC.

8954 Mason Ave.

Chatsworth, CA 91311 USA

GENERAL DESCRIPTION

The SPECIALTY CONCEPTS SYSTEM (SCS) is a versatile, industrial quality charge

controller for the efficient use of photovoltaic energy and the protection of expensive

batteries.

The SCS is a series-relay battery charge controller using mercury relays, remote

temperature compensation, adjustable charging set-points, low-voltage load

disconnect, circuit breakers, and digital metering. Lights indicate "CHARGING" and

"LOAD DISCONNECT" conditions and the meter displays battery voltage, charging and

load current, and current from an external shunt.

FEATURES

CHARGE REGULATION

• Available for 12,24,36 or 48 volt systems

• 50 amp charge current: SCS/50

• 90 amp charge current: SCS/90

• Two-step, series charging, 12,24 v

• Single step, series charging, 36,48 v

• Adjustable charging set-points

• Temperature compensation

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

MOUNTING

• Indoor wall mount enclosure (standard)

• Outdoor enclosures (optional)

MONITORING

• Digital volt / amp meter

• “CHARGING” light

DESIGN FEATURES

• Mercury Relays

• Array, battery and load circuit breakers

(providing over-current protection and

manual disconnects)

• Maximum array usage

• Reverse polarity protection

• Reverse leakage protection

• Lightning protection

• Input noise suppression

• Remote battery voltage sense

• “LOAD DISCONNECTED” light

Summary of content (23 pages)

PAGE 1
SPECIALTY CONCEPTS SYSTEM (SCS/ 50, SCS/ 90) Photovoltaic Battery Charge Controller Installation And Operation Manual SPECIALTY CONCEPTS, INC. 8954 Mason Ave. Chatsworth, CA 91311 USA Copyright 10 / 1997 Specialty Concepts, Inc. GENERAL DESCRIPTION The SPECIALTY CONCEPTS SYSTEM (SCS) 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 (Amps) Charge Current, Max. (60 seconds) (Amps) Load Current, Continuous (1) (Amps) Load Current, Max. (60 seconds) (2) (Amps) Array Voltage, Max. Voc (Volts) Operating Voltage @ Battery, Min. (Volts) Quiescent Current (3) (Milliamps) Current Consumption, Charging, SCS/50 (4) (Amps) .5 Current Consumption, Charging, SCS/90 (4) (Amps) 1 Current Consumption, Load Disconnected (5) (Amps) 1 Voltage Drop, Max. (Array to Battery),SCS/50 (Volts @ Max.
PAGE 3
RELATED SYSTEM EQUIPMENT The SCS 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 (NEC) or other applicable code, and with the instructions provided by the equipment supplier. SOLAR ARRAY PANELS: The SCS is compatible with all makes and models of PV panels, provided the voltage and current specifications of the SCS are not exceeded.
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. It is recommended that the requirements of the U.S. National Electrical Code (NEC) or other applicable code should be followed. WARNING: Follow all safety precautions of the battery manufacturer and the NEC. Proper ventilation must be provided for vented batteries.
PAGE 5
INSTALLATION INSTRUCTIONS: 1. LOCATION: - A suitable location must be found for mounting the SCS. The unit features mercury relays that require the unit to be mounted on a vertical surface. This unit should also be as close as possible to the batteries to avoid errors in battery voltage reading. The temperature sensor wire is 10 feet long and should reach the battery bank if possible. 2.
PAGE 6
INSTALLATION INSTRUCTIONS (continued): 8. RUN SYSTEM WIRING: - After disconnecting the power sources, refer to wiring diagram (FIGURE 1) and run the system wiring to the location of the SCS. The wires should reach the location of the SCS with a little extra for strain relief loops. 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 SCS, but incorrect operation would result. 10.
PAGE 7
16. AUX CURRENT CONNECTION (using external shunt): - If needed. The SCS can be modified to allow the user to monitor a current to or from another source, such as a charger or alternator or for monitoring loads such as a DC source center or an inverter. This requires an external shunt to be added to the system and connected to the circuitry behind the plate. Contact a technical representative for information. 17. MAKE NEEDED ADJUSTMENTS TO SETTINGS: - See Setting/Adjustments section 18.
PAGE 8
FIGURE 1 SCS Wiring Diagram SOLAR ARRAY #1 SCS LOW + HIGH SOLAR ARRAY #2 TO ALARMS + Temp. Comp. A B + BATTERY Jumpers: These jumpers (2) should remain as shown unless a Battery Voltage Sense Connection is needed. See INSTALLATION INSTRUCTIONS: BATTERY VOLTAGE SENSE CONNECTIONS + LOAD + DC LOAD CENTER Note: A load with low-voltage disconnect (LVD) should be wired to the SCS. A load without LVD may be wired to the SCS or directly to the battery.
PAGE 9
TEMPERATURE COMPENSATION DESCRIPTION: - The SCS has a small sensor on a ten foot cable that is wired into the controller to adjust the charging thresholds according to battery temperature. The rate of compensation is -5mv/°C per battery cell in series from 25° C.
PAGE 10
SETTINGS / ADJUSTMENTS ADJUSTABLE CHARGE TERMINATION SET-POINTS (“CHARGE SET-POINT SELECT”): Four different charge termination voltage set-points are available with this switch. Table 2 : Charge termination set-points by switch position CONTROLLER VOLTAGE 12 VOLT 24 VOLT 36 VOLT 48 VOLT A 15.3 30.6 45.9 61.2 B 14.8 29.6 44.4 59.2 SWITCH POSITION C D 14.3 13.8 28.6 27.6 42.9 41.4 57.2 55.2 The controller is factory set at position B.
PAGE 11
CIRCUIT BREAKERS LOAD CIRCUIT BREAKER : - A 15 amp load circuit breaker is included with the SCS. This provides over-current and short-circuit protection for the load and can be used as an on/off switch for the load. ARRAY CIRCUIT BREAKER : - A 50 amp array circuit breaker is included with the SCS. This provides over-current and short-circuit protection for the SCS from the array and can be used as an on/off switch for the array in order to stop additional charging.
PAGE 12
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 13
MONITORING "CHARGING" LIGHT: The "CHARGING" light will be on when the controller is in the full charge mode. In this mode, the charging relay is closed, connecting the array directly to the battery. This light should go on first thing in the morning, and will go off if the battery reaches the Full Charge Termination voltage set-point. If the light is off after morning, the batteries have reached the full charge voltage some time that day.
PAGE 14
OPTIONS OPTION H - GENERATOR START : The generator start option is for systems designed with a stand-by generator that has an autostart circuit. A voltage-free contact closure is provided to signal the generator to start and stop charging, based on battery voltage. Access to the relay contacts is via a terminal block on the face plate. The start and stop set-points are factory set at 11.5 volts start and 13.5 volts stop (for a 12 volt system) and are adjustable.
PAGE 15
TROUBLE SHOOTING: GENERAL NOTES IF THE CONTROLLER IS NEWLY INSTALLED, CHECK THESE FIRST: 1) Re-check system wiring to insure proper installation and polarity . 2) Check all system fuses and circuit breakers. A 1 amp AGC fuse is located behind the front plate on the display circuit board. Before replacing a blown fuse, locate and correct the cause. 3) Check to be sure that there is a connection (voltage input) to the " VOLTAGE SENSE" terminals from the battery.
PAGE 16
TROUBLE SHOOTING: SCS PROBLEM DESCRIPTIONS BATTERY UNDER CHARGED CONTROLLER NOT CHARGING AT ALL, ALWAYS IN THE FLOAT MODE ("CHARGING" LIGHT OFF) Check to see that the circuit breakers are all on, and that the controller is receiving voltage (at least about nominal system voltage) from the battery and the solar panels. If it is, momentarily disconnect and reconnect the panels, using the array circuit breaker. The controller should reset into the full charge mode ("CHARGING" light on).
PAGE 17
BATTERY OVERCHARGING CONTROLLER ALWAYS IN FULL CHARGE ("CHARGING" LIGHT ON) See number 6 above: The battery may not be reaching the charge termination setpoint. See number 3 above: No voltage at the battery sense terminals tells the controller that the battery voltage is low and needs to be charged more. Install a connection from battery to "BATTERY SENSE" terminals to resolve.
PAGE 18
MONITOR DISPLAY NOT READING CORRECTLY DISPLAY BLANK, ALARMS DO NOT FUNCTION Check the fuse on the backside of the front plate on the display circuit board. If it is blown, replace with a new 1 amp type agc fuse. If it continues to blow, this indicates that the SCS probably needs servicing. Inspect the wire connections to and from the display circuit board on the back of the unit and confirm all connections are sound. ALARMS DO NOT FUNCTION PROPERLY Check alarm calibration. See Voltage Alarms section.
PAGE 19
TROUBLE SHOOTING: BATTERIES Refer to this section to help diagnose potential problems based on battery observations.
PAGE 20
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.
PAGE 21
FIELD TEST PROCEDURE: SCS Test equipment required: digital multimeter, jumper wires Conditions: Sunny or bright overcast if possible Precautions: This procedure assumes that the system panels are installed and operational, or at least capable of producing at least 15 volts for a 12 volt system (proportionately higher for higher nominal system voltages).
PAGE 22
BENCH TEST PROCEDURE: SCS This procedure provides a basic bench test to check the operation and calibration for the SCS. This procedure is designed specifically for experienced electronic technicians. Equipment required: Digital multimeter: 0-80 volt 500 ma power supply The SCS printed circuit board is coated with a water resistant coating. Use a sharp pointed probe and enough pressure to pierce the coating when making measurements. 1) Inspect temperature compensation sensor and cable for damage.
PAGE 23
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.