Morningstar SunSaver Gen 3 Manuel utilisateur

Marque: Morningstar

Modèle: SunSaver Gen 3

Taper: Manuel utilisateur

Installation and Operation Manual

www.morningstarcorp.com

MORNINGSTAR

World’s Leading Solar Controllers & Inver ters

AVER

PV SYSTEM CONTROLLERS

SEALED

FLOODED

SELECT

LOAD

BATTERY

SOLAR

Remove

Jumper

Wire for

Flooded

Battery

{

12 V

BATTERY STATUSTEMP. SENSORCHARGING STATUS

See Operator’s

Manual

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

indoor use only

Use 75 ºC Copper

Conductors Only

CONFORMS TO ISA 12.12.01

CERTIFIED TO CAN/CSA STD

C22.2 NO.213-1992

Class I, Division 2

Groups A,B,C,D

Hazardous Loc.

Temp. Code: T5

RoHS

MORNINGSTAR

S S

20L

UN AVER-

SOLAR CONTR OLLER SS-20L-1 2V

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 CORPORATION

SunSaver Dimensions

Inches [Millimeters]

Specication Summary

Ratings SS-6/6L SS-10/10L SS-20L

System Voltage 12 V 12 or 24V 12 or 24V

Min. Battery Voltage 6 V 6 V 6 V

Max. Solar Voltage 30 V 30 or 60V 30 or 60V

Max. Solar Current 6 .5 A 10 A 20 A

Max. Load Current 6 A 10 A 20 A

See Section 7.0 for full technical specications

** Array voltage should never exceed maximum input voltage. Refer to the

solar module documentation to determine the highest expected array V

dened by the lowest expected ambient temperature for the system location.

CONTENTS

1.0 Safety Information 4

2.0 General Information 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 17

3.3 Mounting 20

3.4 Wiring 22

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

5.0 Troubleshooting 40

5.1 Error Indications 40

5.2 Common Problems 41

6.0 Warranty and Claim Procedure 42

7.0 Technical Specications 44

MORNINGSTAR CORPORATION

1.0 SAFETY INFORMATION

1.0

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:

Indicates a procedure or function that is important for

the safe and proper operation of the controller.

Safety Information

• Read all of the instructions and cautions in the manual before

beginning installation.

• There are no user serviceable parts inside the SunSaver. Do

not disassemble or attempt to repair the controller.

• Disconnect all sources of power to the controller before

installing or adjusting the SunSaver.

• There are no fuses or disconnects inside the SunSaver. Do

not attempt to repair.

• Install external fuses/breakers as required.

WARNING:

These servicing instructions are for use by qualied

personnel only. To reduce the risk of electric shock,

do not perform any servicing other than that specied

in the operating instructions unless you are qualied

to do so.

WARNING:

EXPLOSION HAZARD - DO NOT DISCONNECT WHILE

CIRCUIT IS LIVE UNLESS AREA IS KNOWN TO BE NON-

HAZARDOUS.

CAUTION:

A BATTERY CAN PRESENT A RISK OF ELECTRICAL

SHOCK, BURN FROM HIGH SHORT-CIRCUIT

CURRENT, FIRE OR EXPLOSION FROM VENTED GASES.

OBSERVE PROPER PRECAUTIONS

CAUTION:

To reduce the risk of re, connect only to a circuit

provided with a maximum branch-circuit overcurrent

protection rating not to exceed the model current rating

on page 2 and in accordance with the National Electrical

Code, ANSI/NFPA 70.

CAUTION:

Unit has no battery removal protection.

Disconnecting battery during charging may cause a

brief spike in load voltage (above the 15V

regulation limit) which may damage sensitive equipment.

NOTE:

PROPER DISPOSAL OF BATTERIES IS REQUIRED.

REFER TO YOUR LOCAL CODES FOR DISPOSAL

REQUIREMENTS

.0 Important Safety Information 4

1.0 IMPORTANT SAFETY INSTRUCTIONS

MORNINGSTAR CORPORATION

1.0 SAFETY INFORMATION

1.0

ATTENTION:

Pour diminuer le risque d’incendie, ne connectez

l’alimentation qu’à un circuit équipé d’une protection

maximum par dérivation contre les surintensités ne

dépassant pas le courant nominal du modèle de la

page 2, conformément à la norme du Code National de

l’Électricité (NEC), ANSI/NFPA 70.

ATTENTION:

Unité bénécie 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.

• Mount the SunSaver indoors. Prevent exposure to the

elements and do not allow water to enter the controller.

• Install the SunSaver in a location that prevents casual

contact. The SunSaver heatsink can become very hot during

operation.

• Use insulated tools when working with batteries.

• Avoid wearing jewelry during installation.

• The battery bank must be comprised of batteries of same

type, make, and age.

• Do not smoke in the vicinity of the battery bank.

• Mount the controller at least 3 ft (1 m) away from vented

batteries unless separated by a barrier or located in a

separate compartment.

Informations de sécurité

• Lisez toutes les instructions et les avertissements gurant

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.

• Installez des fusibles/coupe-circuits externes selon le besoin.

AVERTISSEMENT:

Ces instructions d’entretien sont exclusivement réservé-

es à des techniciens qualiés. Pour réduire le risque de

choc électrique, ne réalisez aucun entretien autre que

celui stipulé dans les instructions de fonctionnement, à

moins que vous ne possédiez les qualications néces-

saires en la matière.

ATTENTION:

UNE BATTERIE PEUT PRÉSENTER UN RISQUE ÉLEVÉ

DE CHOC ÉLECTRIQUE, DE BRÛLURES SUITE À UN

COURANT DE COURT-CIRCUIT ÉLEVÉ, À UN INCENDIE

OU À UNE EXPLOSION PROVENANT DE GAZ REJETÉS

DANS L’AIR. VEUILLEZ PRENDRE LES PRÉCAUTIONS

NÉCESSAIRES.

AVERTISSEMENT:

RISQUE D’EXPLOSION. NE PAS DEBRANCHER TANT

QUE LE CIRCUIT EST SOUS TENSION, A MOINS QU’lL

NE S’AGISSE D’UN EMPLACEMENT NON DANGEREUX.

1.0 SAFETY INFORMATION

MORNINGSTAR CORPORATION

1.0

• 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 identied by the symbol below:

Direct Current Symbol

Précautions de sécurité d’installation

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.

• Montez le SunSaver à l’intérieur. Empêchez l’exposition aux

éléments et la pénétration d’eau dans le contrôleur.

• Installez le SunSaver dans un endroit qui empêche le con-

tact occasionnel. Le dissipateur de chaleur SunSaver peut

devenir très chaude pendant le fonctionnement

• Utilisez des outils isolés pour travailler avec les batteries.

• Évitez le port de bijoux pendant l’installation.

• Le groupe de batteries doit être constitué de batteries du

même type, fabricant et âge.

• Ne fumez pas à proximité du groupe de batteries.

• Monter le régulateur au moins 3 pi (1 m) de batteries ventilés

sauf séparées par une barrière ou situé dans un comparti-

ment séparé.

• Les connexions d’alimentation doivent rester serrées pour

éviter une surchauffe excessive d’une connexion desserrée.

• Utilisez des conducteurs et des coupe-circuits de dimensions

adaptées.

• Ce contrôleur de charge ne doit être connecté qu’à des cir-

cuits en courant continu. Ces connexions CC sont identiées

par le symbole ci-dessous:

Symbole courant continu

MORNINGSTAR CORPORATION

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.

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.

2.2 Features

The features of the SunSaver are shown in Figure 1 below.

An explanation of each feature is provided.

SEALED

FLOODED

SELECT

LOAD

BATTERY

SOLAR

Remove

Jumper

Wire for

Flooded

Battery

{

12 V

BATTERY STATUSTEMP. SENSORCHARGING STATUS

See Operator’s

Manual

Nominal Rating

12 Volts dc

Max. Input 30 V

Solar 6.5 A

Battery 6.5 A

Load 10.0 A

indoor use only

Use Copper

Conductors Only

CONFORMS TO UL STD 1604

CERTIFIED TO CAN/CSA STD

C22.2 NO.213-M1987

Class 1 Division 2

Groups A,B,C,D

Hazardous Loc.

For the Risk of Explosion Only

Operating Temp. Code: T5

MORNINGSTAR

S S

UN AVER-

SOLAR CONTROLLER SS-6-12V

Figure 1. SunSaver features.

1 - Status LED

An LED indicator that shows charging status and also

indicates when a solar input fault condition exists.

2 - Power Terminal Block

Power terminations for system Solar, Battery, and Load

connections.

3 - Battery Select Jumper

A removable jumper to select the battery type.

4 - Local Temperature Sensor

Measures ambient temperature. Battery regulation is

adjusted based on ambient temperature changes.

2 .0

2.0 GENERAL INFORMATION

MORNINGSTAR CORPORATION

132.0 GENERAL INFORMATION12

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

2.3 Regulatory Information

NOTE:

This section contains important information for safety

and regulatory requirements.

The SunSaver controller should be installed by a qualied

technician according to the electrical regulations of the

country in which the product will be installed.

SunSaver controllers comply with the following EMC

standards:

• Immunity: EN61000-6-2:1999

• Emissions: EN55022:1994 with A1 and A3 Class B1

• Safety: EN60335-1 and EN60335-2-29 (battery

chargers)

FCC requirements:

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

interference that may cause undesired operation.

Changes or modications not expressly approved by

Morningstar for compliance could void the user’s authority to

operate the equipment.

Note:

This equipment has been tested and found to comply

with the limits for a Class B digital device, pursuant to Part

15 of the FCC rules. These limits are designed to provide

reasonable protection against harmful interference in a

residential installation. This equipment generates, uses, and

can radiate radio frequency energy and, if not installed and

used in accordance with the instruction manual, may cause

harmful interference to radio communication. However,

there is no guarantee that interference will not occur in a

particular installation. If this equipment does cause harmful

interference to radio or television reception, which can be

determined by turning the equipment on and off, the user is

encouraged to try to correct the interference by one or more

of the following measures:

• Re-orient or relocate the receiving antenna.

• Increase the separation between the equipment and

receiver.

• 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

technician for assistance.

2 .0

MORNINGSTAR CORPORATION

2.0 GENERAL INFORMATION14

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

• 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.

• Explosive battery gases may be present during

charging. Be certain there is sufcient ventilation to

release the gases.

• Do not install in locations where water can enter the

controller.

• Loose power connections and/or corroded wires

may result in resistive connections that melt wire

insulation, burn surrounding materials, or even cause

re. Ensure tight connections and use cable clamps

to secure cables and prevent them from swaying in

mobile applications.

• The SunSaver charging algorithm is compatible with

lead-acid or NiCd batteries. NiMH, Li-ion, and other

battery chemistries are not compatible with the

SunSaver charging algorithm.

• The SunSaver Battery connection may be wired

to one battery or a bank of batteries. The following

instructions refer to a singular battery, but it is implied

that the battery connection can be made to either one

battery or a group of batteries in a battery bank.

3 .0

MORNINGSTAR CORPORATION

3.0 INSTALLATION

Installation in Hazardous Locations

THIS EQUIPMENT IS ONLY SUITABLE FOR USE IN CLASS

I, DIVISION 2, GROUPS A,B,C and D OR NON-HAZARDOUS

LOCATIONS.

CAUTION:

For hazardous locations, device must be

installed inside an appropriately type rated tool secured

enclosure. Consult with local authority having jurisdiction for

type rating required.

ATTENTION:

Pour les endroits dangereux, le dispositif doit être

installé à l’intérieur un convenablement qualication de type

outil sécurisé enceinte. Consultez les autorités locales

compétentes pour la qualication de type requise.

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

Specications 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 gure 2a.

The second column in table 1 species whether the jumper

should be removed or remain in place, depending on the

desired battery type.

Battery Type Battery Jumper Absorption Float Equalize

Sealed Inserted 14.10V 13.70V N/A

Flooded/

AGM

Removed 14.60V 13.70V 14.90V

1. Flooded/AGM absorption value effective with unit serial nos.

2038 0001 and higher

Table 1. Battery Type selection

Figure 2a. Removing the Battery Select jumper.

3 .0

MORNINGSTAR CORPORATION

3.0 INSTALLATION

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.

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

systems.

PWM charging is selected by default. To enable Slow

Switching regulation do the following:

1. Remove all four screws that secure the faceplate on

the SunSaver. See Figure 2b.

2. Gently pry the faceplate off the SunSaver.

Occasionally, epoxy encapsulant will cause the

faceplate to stick. Use a small at-head screw driver

to separate the faceplate from the SunSaver body.

See Figure 2c.

3. A loop of wire protrudes from the epoxy. Cut the loop

with wire clippers to switch the regulation method to

Slow Switching. See Figure 2d.

4. Tape the cut ends with electrical tape to prevent

contact with the faceplate.

5. Replace the faceplate and secure with the four

screws.

Figure 2b. Remove faceplate screws.

Figure 2c. Remove faceplate.

CUT

Figure 2d. Cut the Regulation Select wire loop.

3 .0

MORNINGSTAR CORPORATION

3.0 INSTALLATION

3.3 Mounting

CAUTION: Equipment Damage or Risk of Explosion

Never install the SunSaver in an enclosure with vented/

ooded batteries. Battery fumes are ammable and will

corrode and destroy the SunSaver circuits.

CAUTION: Equipment Damage

When installing the SunSaver in an enclosure, ensure

sufcient ventilation. Installation in a sealed enclo-

sure 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 inammables et corroderont et détru-

iront les circuits du SunSaver.

PRUDENCE: Endommagement de l’équipement

Assurez une ventilation sufsante en cas d’installation

du SunSaver dans une enceinte. L’installation dans une

enceinte hermétique entraîne une surchauffe et une

réduction de la durée de vie du produit.

Step 1: Choose Mounting Location

Locate the SunSaver on a vertical surface protected from

direct sun, high temperatures, and water. The unit should

be located in the same ambient temperature as the battery.

Locate the controller within 10 ft (3 M) of the battery bank.

Mounting the controller on a horizontal surface does not

provide optimal airow and could lead to overheating.

Step 2: Check for Clearance

Place the SunSaver in the location where it will be

mounted. Verify that there is sufcient room to run wires and

that there is ample room above and below the controller for

air ow.

WARM AIR

COOL AIR

AT LEAST

2” (51 mm)

AT LEAST

2” (51 mm)

SEALED

FLOODED

SELECT

LOAD

BATTERY

SOLAR

Remove

Jumper

Wire for

Flooded

Battery

{

12 V

BATTERY STATUSTEMP. SENSORCHARGING STATUS

See Operator’s

Manual

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

indoor use only

Use 75 ºC Copper

Conductors Only

CONFORMS TO ISA 12.12.01

CERTIFIED TO CAN/CSA STD

C22.2 NO.213-1992

Class I, Division 2

Groups A,B,C,D

Hazardous Loc.

Temp. Code: T5

RoHS

MORNINGSTAR

S S

20L

UN AVER-

SOLAR CONTROLLER SS-20L-12V

Figure 3. Mounting and cooling.

Step 3: Mark Holes

Use a pencil or pen to mark the four (4) mounting hole

locations on the mounting surface.

Step 4: Drill Holes

Remove the controller and drill 3/32” (2.5 mm) holes in the

marked locations.

Step 5: Secure Controller

Place the controller on the surface and align the mounting

holes with the drilled holes in step 4. Secure the controller in

place using mounting screws (not included).

3 .0

MORNINGSTAR CORPORATION

3.0 INSTALLATION

3.4 Wiring

NOTE: A recommended connection order has been

provided for maximum safety during installation. When

disconnecting, solar input must be removed rst before

disconnecting battery. See caution below.

NOTE: The SunSaver is a negative ground controller.

Any one negative conductor can be earth grounded as

required. Grounding is recommended, but not required

for correct operation.

NOTE:

To comply with the NEC, the SunSaver must be installed

using wiring methods in accordance with Article 690 of

the latest edition of the National Electric Code, NFPA 70.

NOTE:

The total current draw of all system loads connected

to the SunSaver LOAD terminals cannot exceed the

controller’s load current rating.

NOTE:

For mobile applications, be sure to secure all wiring.

Use cable clamps to prevent cables from swaying when

the vehicle is in motion. Unsecured cables create loose

and resistive connections which may lead to excessive

heating and/or re.

WARNING:

EXPLOSION HAZARD - DO NOT DISCONNECT WHILE

CIRCUIT IS LIVE UNLESS AREA IS KNOWN TO BE NON-

HAZARDOUS.

AVERTISSEMENT:

RISQUE D’EXPLOSION. NE PAS DEBRANCHER TANT

QUE LE CIRCUIT EST SOUS TENSION, A MOINS QU’lL

NE S’AGISSE D’UN EMPLACEMENT NON DANGEREUX.

CAUTION: Unit has no battery removal protection.

Disconnecting battery during charging may cause a brief

spike in load voltage (above the 15V regulation limit)

which may damage sensitive equipment.

ATTENTION:

Unité bénécie 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.

LOAD

POSITIVE (+)

LOAD

NEGATIVE (-)

FUSE

SEALED

FLOODED

SELECT

LOAD

BATTERY

SOLAR

Remove

Jumper

Wire for

Flooded

Battery

{

12 V

BATTERY STATUSTEMP. SENSORCHARGING STATUS

See Operator’s

Manual

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

indoor use only

Use 75 ºC Copper

Conductors Only

CONFORMS TO ISA 12.12.01

CERTIFIED TO CAN/CSA STD

C22.2 NO.213-1992

Class I, Division 2

Groups A,B,C,D

Hazardous Loc.

Temp. Code: T5

RoHS

MORNINGSTAR

S S

20L

UN AVER-

SOLAR CONTRO LLER SS-20L-12 V

Figure 4. Load wiring.

Connect load positive (+) and negative (-) load wires to

the system load(s) or load distribution panel as shown in

gure 4. 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 load connection may be

earth grounded. Use appropriate gauge wire and proper

grounding methods for the installation site.

3 .0

MORNINGSTAR CORPORATION

3.0 INSTALLATION

An in-line fuse holder should be wired in series in the load

positive (+) wire as shown. DO NOT INSERT A FUSE AT

THIS TIME. A circuit breaker may be used in lieu of a fuse.

Keep the breaker in the open (disconnected) position at this

time.

If wiring the load connection to a distribution panel, each

load circuit should be fused separately. The total load draw

should not exceed the the SunSaver’s maximum load rating.

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.

The nominal battery voltage must match the SunSaver

voltage rating. For 12V SunSaver models, only a 12V

battery may be used. Connect only 24V batteries (or two

12V batteries in series) to 24V SunSaver models.

Before connecting the battery, measure the battery

voltage. Battery voltage must be greater than 6 volts to

power the SunSaver (12V or 24V models).

Connect the battery to the SunSaver. Refer to the wire

gauge chart on page 43 of this manual for correct wire size.

Use 75 °C copper wire.

If required, the negative battery connection may be

earth grounded. Use appropriate gauge wire and proper

grounding methods for the installation site.

Wire an in-line fuse holder no more than 6 inches (150

3 .0

mm) from the battery positive terminal. DO NOT INSERT

A FUSE AT THIS TIME. A circuit breaker may be used in

lieu of a fuse. Keep the breaker in the open (disconnected)

position at this time.

CAUTION: Unit has no battery removal protection.

Disconnecting battery during charging may cause a brief

spike in load voltage (above the 15V regulation limit) which

may damage sensitive equipment.

ATTENTION:

Unité bénécie 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.

SEALED

FLOODED

SELECT

LOAD

BATTERY

SOLAR

Remove

Jumper

Wire for

Flooded

Battery

{

12 V

BATTERY STATUSTEMP. SENSORCHARGING STATUS

See Operator’s

Manual

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

indoor use only

Use 75 ºC Copper

Conductors Only

CONFORMS TO ISA 12.12.01

CERTIFIED TO CAN/CSA STD

C22.2 NO.213-1992

Class I, Division 2

Groups A,B,C,D

Hazardous Loc.

Temp. Code: T5

RoHS

MORNINGSTAR

S S

20L

UN AVER-

SOLAR CONTROLLER SS-20L-12V

6 in (150 mm)

MAX.

BATTERY

NEGATIVE (-)

BATTERY

POSITIVE (+)

FUSE

12V / 24V

BATTERY

EARTH

GROUND

Figure 5. Battery wiring.

MORNINGSTAR CORPORATION

3.0 INSTALLATION

3.0

Step 3: Solar Wiring

WARNING: Shock Hazard

The solar PV array can produce open-circuit voltages

in excess of 40 Vdc when in sunlight. Verify that the

solar input breaker or disconnect has been opened

(disconnected) before installing the system wires.

AVERTISSEMENT: Risque de décharge électrique

Le réseau PV solaire peut produire des tensions de cir-

cuit ouvert supérieures à 40 V cc à la lumière du soleil.

Vériez que le coupe-circuit ou l’interrupteur d’entrée

solaire a été ouvert (déconnexion) avant d’installer les

câbles du système.

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 bat-

terie endommagera le SunSaver de façon permanente.

The nominal solar module voltage must match the

SunSaver voltage rating. For 12V SunSaver models, only

a 12 V nominal solar module having a maximum open

circuit voltage of 30V may be used. Connect only 24V

nominal solar modules (or two 12V arrays in series) to 24V

SunSaver models. The maximum open circuit voltage of the

24V array must be less than 60V.

SEALED

FLOODED

SELECT

LOAD

BATTERY

SOLAR

Remove

Jumper

Wire for

Flooded

Battery

{

12 V

BATTERY STATUSTEMP. SENSORCHARGING STATUS

See Operator’s

Manual

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

indoor use only

Use 75 ºC Copper

Conductors Only

CONFORMS TO ISA 12.12.01

CERTIFIED TO CAN/CSA STD

C22.2 NO.213-1992

Class I, Division 2

Groups A,B,C,D

Hazardous Loc.

Temp. Code: T5

RoHS

MORNINGSTAR

S S

20L

UN AVER-

SOLAR CONTRO LLER SS-20L-12 V

12 Volt

MODULE

12 Volt

MODULE

SOLAR

POSITIVE (+)

SOLAR

NEGATIVE (-)

(+)

(-)

12V OR 24V NOMINAL

(DEPENDS ON MODEL)

EARTH

GROUND

Figure 6. Solar input wiring.

NOTE:

Higher voltage PV modules designed for on-grid PV

applications should not be used with the SunSaver or

any PWM controller. Only use high voltage modules with

maximum power point tracking (MPPT) controllers.

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: Conrm Wiring

Re-check the wiring in steps 1 through 3. Conrm

correct polarity at each connection. Verify that all seven (7)

SunSaver power terminals are tightened.

MORNINGSTAR CORPORATION

3.0 INSTALLATION

3.0

SEALED

FLOODED

SELECT

LOAD

BATTERY

SOLAR

Remove

Jumper

Wire for

Flooded

Battery

{

12 V

BATTERY STATUSTEMP. SENSORCHARGING STATUS

See Operator’s

Manual

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

indoor use only

Use 75 ºC Copper

Conductors Only

CONFORMS TO ISA 12.12.01

CERTIFIED TO CAN/CSA STD

C22.2 NO.213-1992

Class I, Division 2

Groups A,B,C,D

Hazardous Loc.

Temp. Code: T5

RoHS

MORNINGSTAR

S S

20L

UN AVER-

SOLAR CONTRO LLER SS-20L-12 V

(+)

Figure 7. System Wiring Review.

Step 5: Install the Terminal Cover

The terminal cover prevents contact with the power

terminals when energized. UL / ETL Listed systems must

install the terminal cover. The terminal cover installation is

optional for systems that are not listed to UL / ETL.

Begin by removing the two (2) lower faceplate screws as

shown in gure 8a. Set the screws aside.

Figure 8a. Remove 2 faceplate screws.

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 8b. Place the Terminal Block Cover.

Last, secure the terminal cover with the two (2) screws

included with the cover.

Figure 8c. Secure the Terminal Block Cover with 2 screws.

MORNINGSTAR CORPORATION

3.0 INSTALLATION

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

3. Solar circuit

Refer to the fuse table on page 46 for appropriate fuse sizes

If using circuit breakers, close the load breaker rst

followed by the battery breaker, then the solar breaker.

Step 7: Conrm Power-up

The SunSaver should begin the power-up LED sequence

when battery power is applied. Observe that the Battery

Status LEDs blink in sequence one time.

If the SunSaver does not power up or a ashing LED error

sequence exists, refer to Section 5.0 Troubleshooting.

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 ash red whenever an error condition(s) exists.

Table 2 lists the Status LED indications.

Color Indication

Operating

State

None Off (with heartbeat¹) Night

Green

On Solid

( with heartbeat² )

Charging

Red Flashing Error

Red

On Solid

( with heartbeat

)

Critical Error

¹ Status LED heartbeat indication flickers ON briefly every 5 seconds

² Status LED heartbeat indication flickers OFF briefly every 5 seconds

Table 2. Status LED denitions

For more information on Status LED errors, see Section

5.1 Error Indications.

4.0

MORNINGSTAR CORPORATION

4.0 OPERATION

4.0

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. Flashing

(1 Flash / sec)

Full Battery:

Absorption Charge

Load On

Green

Slow Flashing

(1 Flash / 2 sec)

Full Battery:

Float Charge

Load On

Green On solid Battery Nearly Full Load On

Yellow On solid Battery Half Full Load On

Red

Flashing

(1 Flash / sec)

Battery Low

LVD Warning

(Load On)

Red On solid Battery Empty

LVD

(Load Off)

None No LEDS On Battery Missing Load Off

Table 3. Battery SOC LED denitions

NOTE:

An error condition exists if multiple Battery SOC LEDs

are ashing. See Section 5.1 Error Indications for more

information.

4.2 Battery Charging Information

The SunSaver has a 4-stage battery charging algorithm

for rapid, efcient, and safe battery charging. Figure 9

shows the sequence of the stages.

NIGHT

BULK

CHARGE

ABSORPTION

FLOAT

EQUALIZE

VOLTAGE

TIME

Figure 9. SunSaver charging algorithm.

Bulk Charge

In this stage, the battery voltage has not yet reached

absorption voltage and 100% of available solar power is

used to recharge the battery.

Absorption

When the battery has recharged to the Absorption voltage

setpoint, constant-voltage regulation is used to prevent

heating and excessive battery gassing.

Float

After the battery is fully charged the SunSaver reduces

the battery voltage to a oat charge which is sometimes

called a trickle charge.

Depending on battery history, the battery remains in the

MORNINGSTAR CORPORATION

4.0 OPERATION

absorption stage for 3 or 4 hours before transitioning to the

oat stage.

Equalize (ooded battery type only)

The SunSaver will equalize a ooded 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

stratication and equalizes the individual cell voltages within

the battery.

WARNING: Risk of Explosion

Equalizing vented batteries produces explosive gases.

The battery bank must be properly ventilated.

CAUTION: Equipment Damage

Excessive overcharging and gassing too vigorously

can damage the battery plates and cause shedding of

active material from the plates. An equalization that is

too high or for too long can be damaging. Review the

requirements for the particular battery being used in

your system.

AVERTISSEMENT: Risque d’explosion

Les batteries à évent et compensation produisent des

gaz explosifs. Le groupe de batteries doit être correcte-

ment ventilé.

ATTENTION: Endommagement de l’équipement

Une surcharge excessive et un dégagement gazeux

trop vigoureux peuvent endommager les plaques de

batteries et provoquer l’élimination du matériau actif des

plaques. Une compensation trop élevée ou trop longue

peut provoquer des dégâts. Examinez les exigences

pour la batterie particulière utilisée dans votre système.

Dead Battery Charging

The SunSaver has a special charging function to recover

batteries that have discharged too low. If the terminal

voltage of the battery is greater than 1 Volt, the SunSaver

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 ow to

the battery and normal operation will resume.

4.3 Load Control Information

The primary purpose of the load control function is to

disconnect system loads when the battery has discharged

to a low state-of-charge and reconnect system loads when

the battery is sufciently recharged. System loads may be

lights, pumps, motors, DC appliances, and other electronic

devices. The total current draw of all loads must not exceed

the SunSaver maximum load rating.

NOTE:

Do not wire an AC inverter of any size to the load termi-

nals of the SunSaver. Damage to the load control circuit

may result. Connect inverters directly to the battery or

battery bank.

Load Control Settings

Load control is fully automatic. The load will be

disconnected and reconnected based upon the Low Voltage

Disconnect (LVD) and Low Voltage Reconnect (LVR) voltage

thresholds. The LVD and LVR thresholds are listed in the

back of the manual.

LVD Warning

As the battery discharges the Battery Status LEDs will

transition from green to yellow and then from yellow to

ashing red. The ashing red indication is a warning that a

low voltage disconnect event will occur soon. The amount of

time between a green SOC indication and load disconnect

4.0

MORNINGSTAR CORPORATION

4.0 OPERATION

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.

• Regulated voltage due to temperature compensation

is limited to a maximum of 15V (30V @ 24V nominal).

This protects certain DC loads that may be damaged

by high regulated input voltage.

• The load connection is NOT a regulated voltage

output. The load terminal voltage is approximately the

same as battery voltage unless the controller is in LVD

condition (load turned off).

• Do not wire multiple SunSaver load outputs together in

parallel to power DC loads with a current draw greater

than the lowest rated controller’s maximum load rating.

Equal current sharing cannot be guaranteed and an

over-load condition will likely occur on one or more

controllers.

• Exercise caution when connecting loads with specic

polarity to a live load circuit. A reverse polarity con

nection may damage the load. Always re-check load

connections before applying power.

• The SunSaver will go straight to LVD on start-up if the

battery voltage is at or below 11.7V / 23.4V.

4.0

4.4 Protections

Solar Overload

(Charging Status LED: Red ashing) 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 Specications

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.

The SunSaver will attempt to reconnect the load two

(2) times approximately 10 seconds apart. If the overload

remains after the rst two (2) attempts, the fault must be

cleared by removing and reapplying power.

Solar Short Circuit

(Charging Status LED: off) Solar input power wires are

short-circuited. Charging automatically resumes when the

short is cleared.

Load Short Circuit

(Battery Status LEDs: G&R - Y sequencing) Fully

protected against load wiring short-circuits. After two (2)

automatic load reconnect attempts (10 seconds apart), the

fault must be cleared by removing and reapplying power.

PV Reverse Polarity

(Charge Status LED: off) Fully protected against reverse

solar connection. No damage to the controller will result.

Correct the mistake to resume normal operation.

4.0 OPERATION

MORNINGSTAR CORPORATION

4.0

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.

Damaged Internal Temperature Sensor

(Battery Status LED: R - Y - G sequencing, Charge Status

LED: R on solid) The internal heatsink temperature sensor

is damaged. This is a critical error. Contact your authorized

Morningstar dealer for service.

High Temperature

(Battery Status LED: R - Y sequencing) The heatsink

temperature has exceeded 85 °C and the solar and load is

disconnected. The SunSaver will automatically reconnect

when the heatsink cools to 80 °C.

High Voltage Disconnect

(Battery Status LED: R - G sequencing) The battery

voltage has exceeded the controller’s maximum regulation

limit. The solar and load will be disconnected until

the battery voltage decreases to the SunSaver’s High

Voltage Reconnect threshold. See Section 7.0 Technical

Specications for more information.

4.5 Inspection and Maintenance

The following inspections and maintenance tasks are

recommended at least two times per year for best controller

performance.

• 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.

• If applicable, check enclosure ventilation and air ow

holes for obstructions.

• Verify LED indication is consistent with the present

system conditions.

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Morningstar SunSaver Gen 3 Manuel utilisateur

Marque: Morningstar

Modèle: SunSaver Gen 3

Taper: Manuel utilisateur

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