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Table of Contents
Related Manuals for Invertek SUNSTAR SERIES
Summary of Contents for Invertek SUNSTAR SERIES
- Page 2 RICH ELECTRIC CO.,LTD. INVERTEK SUNSTAR SERIES ® SOLAR CHARGE CONTROLLER SS-30C/ SS-45C/ SS-60C Installation and Operation Manual USER MANUAL Solar Battery Charging Load Control Diversion Charge Control...
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Page 3: Table Of Contents
CONTENTS Specifications ..........................I Chapter 1 SunStar Description....................1-1 1.1 Versions and Ratings ..................1-1 1.2 Operating Modes....................1-2 1.3 Adjustability ..................... 1-2 1.4 General Use....................... 1-3 1.5 Optonal Available .................... 1-4 Chapter 2 SunStar Installation....................2-1 2.1 General Information..................2-1 2.2 Installation Overview.................. - Page 4 4.5 Float........................4-6 Chapter 5 Load Control ......................5-1 5.1 Load Control Settings..................5-1 5.2 Inductive Loads (Motors)................5-1 5.3 General Load Control Notes ................5-2 5.3.1 Inverters....................5-2 5.3.2 Parallel SunStar ..................5-2 5.3.3 Reverse Polarity ..................5-2 Chapter 6 Diverson Charge Control ..................6-1 6.1 Diversion Charge Control ................
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Page 5: Specifications
Specifications MODEL SS-30C SS-45C SS-60C ELECTRICAL System voltage ratings 12, 24, 48 Vdc Current ratings-Battery Charge Control Current ratings-Load Control Current ratings-Diversion Charge Control Diversion load Diversion load Diversion load 12/24V:≦0.1 % ± 50 mV Accuracy 48V:≦0.1 % ± 100 mV Min. -
Page 6: Chapter 1 Sunstar Description
Chapter 1 SunStar Description The SunStar is a technically advanced solar system controller. There are three operating modes programmed into each SunStar. The manual describes solar battery charging, DC diversion charge control or DC Load control instructions are inserted where required. The manual will help you to become familiar with the SunStar’s features and capabilities. -
Page 7: Operating Modes
1.2 Operating Modes There are three distinct and independent operating modes programmed into each SunStar. Only one mode of operation can be selected for an individual SunStar. If a system requires a charging controller and a load controller, two SunStars must be used. Solar Battery Charging The energy output of a solar array is used for recharging the system battery. -
Page 8: General Use
DIP switch Load control Standard low voltage disconnects and reconnects 7 (OFF) Manual reconnect for Dip Switch 4~6 standard low voltage (ON) Auto reconnect for Dip Switch 4~6 standard low voltage 8 (OFF) Operating from Dip Switch 4~6 standard low voltage disconnects and reconnects (ON) VR1 and VR2 settings for user define low voltage disconnects... -
Page 9: Optonal Available
1.5 Optional Available Three optional components can be added to the standard SunStar controller at any time. ※ Battery Temperature Sensor (BTS) If the temperature of the system battery varies more than 5°C during the year, temperature compensated charging should be considered. Because the battery’s chemical reactions change with temperature, it can be important to adjust charging to account for the temperature effects. -
Page 10: Chapter 2 Sunstar Installation
Chapter 2 SunStar Installation The installation instructions describe solar battery charging. Specific instructions for the load control and diversion modes are provided as notes. 2.1 General Information The mounting location is important to the performance and operating life of the controller. The environment must be dry and protected as noted below. -
Page 11: Control Terminal Connection
2.3 Control Terminal Connection Name Description Battery + Battery cable Positive connection PV+ / Load + Connecting terminal for Solar Array or DC Load Positive PV—/Load— Connecting terminal for Solar Array or DC Load Negative Battery— Battery cable Negative connection Earth Connecting terminal for Ground ON or OFF to choose battery charge control mode or load control... - Page 12 PV+/ BAT+ G ND LOA D+ D C Load Solar Array BATTERY Ground Installation wiring for solar charging or DC load control Solar charging or DC load control: Step 1: Open the access cover Step 2: Mount the SunStar using the enclosed template. Step 3: Adjust the 8 switches in the DIP switch.
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Page 13: Installation Steps
DC diversion charge control: Step 1: Open the access cover Step 2: Mount the SunStar using the enclosed template. Step 3: Adjust the 8 switches in the DIP switch. Each switch must be in the correct position. Step 4: Attach the BTS if battery charging will be temperature compensated Step 5: Connect the battery power wires to the SunStar. -
Page 14: Mounting
2.4.1 Mounting Unit: mm Mounting Dimensions Locate the SunStar on a wall protected from direct sun, high temperatures, and water. Do not install in a confined area where battery gasses can accumulate. When mounting the SunStar, make sure the air flow around the controller and heat sink is not obstructed. - Page 15 D IP O F F C o n tro l M o d e (1 ) B a tte ry C h a rg in g (d iv e rs io n c h a rg e c o n tro l) S y s te m V o lta g e (2 ,3 ) B a tte ry C h a rg in g a lg o rith m (4 ,5 ,6 ) M a n u a l/A u to E q u a liz a tio n (7 )
- Page 16 DIP Switch Number 2, 3-System voltage Switch 2 Switch 3 System Voltage 48V system 24V system 12V system DIP Switch Number 4, 5, 6-Battery charging algorithm Equalize Equalize Bulk Float Equalize DIPSW-4 Time Interval SW-5 SW-6 voltage voltage Voltage (hours) (days) 14.0V 13.4V...
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Page 17: Load Control Dip Switch Setting
for the timer to start counting-the voltage may not reach the equalization voltage setting. To manually stop the equalization process, press the reset pushbutton and the status LED will stop, if the equalization process was shorter than one hour, the controller will continue with a bulk charge cycle and then hold the battery at the bulk setting for one hour (the absorption voltage) before returning to the float setting. - Page 18 D IP O F F C o n tro l M o d e (1 ) D C L o ad C o n tro l S y stem V o ltag e (2 ,3 ) L V D / L V R (4 ,5 ,6 ) A u to / M an u al L V R (7 ) U ser D efin e L V D /L V R (8 ) Load Control DIP Switch Functions...
- Page 19 DIP Switch Number 4, 5, 6-Load Control Algorithm DIPSW-4 DIP SW-5 DIP SW-6 12.6V 25.2V 50.4V 11.1V 22.2V 44.4V 12.8V 25.6V 51.2V 11.3V 22.6V 45.2V 13.0V 26.0V 52.0V 11.5V 23.0V 46.0V 13.2V 26.4V 52.8V 11.7V 23.4V 46.8V 13.4V 26.8V 53.6V 11.9V 23.8V 47.6V 13.6V 27.2V...
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Page 20: Diversion Charge Control Dip Switch Settings
2.4.4 Diversion Charge Control DIP Switch Setting Diversion charge control DIP switch settings are exactly the same as solar battery charging DIP switch setting which can be referred to 2.4.2 description. 2.4.5 Battery Temperature Sensor (BTS) For solar battery charging and diversion load control, a Battery Temperature Sensor (BTS) is recommended for effective temperature compensated charging. - Page 21 Notes: The specified wire length is for a pair of conductors from the solar, load or battery source to the controller (1-way distance). Figures are in meters (m) and feet (ft). For 24 volt systems, multiply the 1-way length in the table by 2. For 48 volt systems, multiply the 1-way length in the table by 4.
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Page 22: Finish Installation
CAUTION: The solar PV array can produce open-circuit voltages over 100 Vdc when in sunlight. Verify that the solar input breaker has been opened (disconnected) before installing the system wires (if the controller is in the solar charging mode). Using the diagram on the previous pages, connect the four power conductors in the following steps: 1. -
Page 23: Communication With Combiplus/Supercombi
2.5 Communication with CombiPlus/SuperCombi SunStar Series can not only operate alone when the BCD Switch is placed at 0 but also communicate with CombiPlus/SuperCombi up to 10 units together when BCD Switch is placed at 1~A. The example of how to wire 1 unit of the SunStar and how to wire 2~10 units to CombiPlus/SuperCombi is demonstrated in the following. - Page 24 The Wiring of 2~10 units of SunStar to Communicate with CombiPlus/ SuperCombi COMBI PLUS / SUPERCOMBI POS+ PORT A PORT B PORT C (IN) (OUT) (EXT) AC INPUT BREAKER V-SENS CHARGE NEG- SUN STAR AC IN AC OUT SOLAR BAT+ PV+A PANEL RJ-45 Cable...
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Page 25: Chapter 3 Front Cover Of Sunstar Operation
Chapter 3 Front Cover of SunStar Operation There are 4 LEDs, 1 LCD Meter of 16 x 2 characters and 2 pushbuttons on SunStar front cover. The details are described as follows: SunStar-60C Unit SunStar-60C Display Panel... - Page 26 3.1 LED Status Indicators Four LED indicate operating status of the controller. When the controller is in Charge Control Mode (or Diversion Charge Control Mode), the charge mode (green) LED will blink. When in Load Control Mode, the Load Control Mode (red) LED will blink. When battery equalization is in process, the Equalization (orange) LED is blinking.
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Page 27: Led Status Indicator
“Load Control Mode LED” Blinking Red: As battery voltage approaches the LVD setting, the LED will blink red several times (up to five) and then pause providing an indication of battery voltage. Refer to Table 2 to determine the battery voltage. Battery Voltage (Using LED Status Indicator) LED Status Red LED (Load Control Mode) -
Page 28: Lcd Meter Displays
Blinking Red: In DC Load Control Mode, the controller is in the status of battery low voltage disconnect. Details of the fault messages could be referred to 3.6.2 Fault Messages. 3.6 LCD Meter Displays Two optional LCD digital meter displays are available for SunStar controllers: The SS-D LCD Meter Displays is standard faceplate on the SunStar Controller and the other SS-RD can be mounted remotely. -
Page 31: Chapter 4 Solar Battery Charging
Chapter 4 Solar Battery Charging 4.1 PWM Battery Charging PWM (Pulse Width Modulation) battery charging is the most efficient and effective method for recharging a battery in a solar system. Selecting the best method for charging your battery together with a good maintenance program will ensure a healthy battery and long service life. -
Page 32: Standard Battery Charging Programs
Some useful functions to know follow below. Solar Overload: Enhanced radiation or “edge of cloud effect” conditions can generate more current than the controller’s rating. The SunStar will reduce this overload up to 130% of rated current by regulating the current to safe levels. If the current from the solar array exceeds 150%, the controller will interrupt charging. -
Page 33: Temperature Effects
A. Battery Type– These are generic lead-acid and Ni-cad battery types. See Section 8.0 for more information about battery types and appropriate solar charging. B. BULK Voltage–This is the PWM Absorption stage with constant voltage charging. The “PWM voltage” is the maximum battery voltage that will be held constant. As the battery becomes more charged, the charging current tapers down until the battery is fully charged. -
Page 34: Equalization
Float Float is less affected by temperature changes, but it may also undercharge or gas too much depending on how much the temperature changes. The BTS corrects the three charging setpoints noted above by the following values: • 12 volt battery: –0.030 volts per °C (–0.017 volts per °F) •... -
Page 35: Standard Equalization Programs
battery is fully recharged. However, a solar battery is seldom completely recharged, so the soft lead sulfate crystals harden over a period of time. Only a long controlled overcharge, or equalization, at a higher voltage can reverse the hardening sulfate crystals. In addition to slowing or preventing lead sulfation, there are also other benefits from equalizations of the solar system battery. -
Page 36: Typical Equalization
mode. 4.4.2 Typical Equalizations The automatic equalizations will occur at the selected charging program from Dip Switch 4~6. When an equalization begins (auto or manual), the battery charging voltage increases up to the equalization voltage (Veq). The battery will remain at Veq for the time specified in the selected charging program. -
Page 37: Chapter 5 Load Control
Chapter 5 Load Control This section describes the user selectable load control settings (5.1) and the low voltage load disconnect (LVD) warning indications (5.2). Load information and general cautions are provided in the remaining sections. 5.1 Load Control Settings The primary purpose of a low voltage load disconnect function (LVD) is to protect the system battery from deep discharges that could damage the battery. -
Page 38: General Load Control Notes
PV+/LOAD+ DC Motor SUNSTAR Figure 5.3 Diode Protection The specifications for the diode follow: • a power diode • rated equal or greater than 80 volts • rated equal or greater than 45 amps (SS-45C) or 60 amps (SS-60C) For large inductive loads, a heat sink for the diode may be necessary. 5.3 General Load Control Notes In addition to the inductive loads discussed above, there are a few other load issues that require attention:... - Page 39 damaged. CAUTION: Carefully verify the polarity (+ and –) of the load connections before applying power to the controller.
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Page 40: Diversion Charge Control
Chapter 6 Diversion Charge Control The SunStar’s third mode of operation is diversion load battery charge control. As the battery becomes fully charged, the SunStar will divert excess current from the battery to a dedicated diversion load. This diversion load must be large enough to absorb all the excess energy, but not too large to cause a controller overload condition. -
Page 41: Selecting The Diversion Load
All values are 25ºC (77ºF). Equalize Equalize Switches Bulk Float Equalize Time Interval (4-5-6) Voltage Voltage Voltage (hours) (days) off-off-off 14.0 13.4 None off-off-on 14.1 13.4 14.2 off-on-off 14.3 13.4 14.4 off-on-on 14.4 13.4 15.1 on-off-off 14.6 13.4 15.3 on-off-on 14.8 13.4 15.3... -
Page 42: Definition Of Terms
elements are reliable and widely available. Heating elements are also easy to replace, and the ratings are stable. NOTE: Do not use light bulbs, motors, or other electrical devices for diversion loads. These loads will fail or cause the SunStar to disconnect the load. Only heating elements should be used. -
Page 43: Maximum Diversion Load
6.4.4 Maximum Diversion Load The diversion load should never exceed the SunStar’s current rating (30A or 45A or 60A). Note that the load is not limited by the source (wind, hydro), and will draw its rated current from the battery. The following table specifies the absolute maximum diversion loads that can be used with each SunStar version. - Page 44 SS-45C will not provide the 150% diversion load margin, and the SS-45C is only rated for 30A of source current. The SS-45C will not provide enough margin for wind gusts and overloads, so a SS-60C should be used. The diversion load should be sized for 52.5A (150% of the source current) up to 60A (the rating of the SS-60C).
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Page 45: Chapter 7 Trouble Shooting
Chapter 7 Trouble Shooting The SunStar performs a continuous self-test to monitor controller and system operation. Detected problems are classified as either faults or alarms. Typically, faults are problems that stop the normal operation of the controller and require immediate attention. Alarms indicate an abnormal condition, but will not stop the controller’s operation. - Page 46 Troubleshooting Load Control No power to the load DIP switch settings may be wrong (check each switch position carefully) Controller is in LVD (check the LEDs) Load circuit breaker or disconnect may be open Check the load cables for continuity and good connection An over-temperature condition may have caused the load to be disconnected Troubleshooting Diversion Control Diversion load is too small so PWM reaches 99%...
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Page 47: Chapter 8 Battery Information
Chapter 8 Battery Information The standard battery charging programs in the SunStar controller, as described in Section 4.2, are typical charging algorithms for four battery types: • sealed (VRLA) • flooded (vented) • L-16 group • Nicad and NiFe Other battery chemistries of special voltages such as 36V, can be charged using a custom charging algorithm modified with the potentiometers VR2 and VR1. -
Page 48: Flooded Batteries
may be needed to balance the individual cell voltages. Other Sealed Batteries: Automotive and “maintenance-free” batteries are also sealed. However, these are not discussed here because they have very poor lifetimes in solar cycling applications. NOTE: Consult the battery manufacturer for the recommended solar charging settings for the battery being used. -
Page 49: Cells
low antimony and selenium plates can offer fairly good cycling performance, long life, and reduced watering needs. NOTE: Consult the battery manufacturer for the recommended solar charging settings for the battery being used. 8.3 L-16 Cells One particular type of flooded battery, the L-16 group, is often used in larger solar systems. The L-16 offers good deep-cycle performance, long life, and low cost. - Page 50 Appendix B...
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