Blue Sky 2512iX-HV User Manual

SOLAR BOOST™ 2512i(X)-HV

20/25AMP 12VDC MAXIMUM POWER POINT TRACKING

PHOTOVOLTAIC CHARGE CONTROLLER

INSTALLATION AND OPERATION

MANUAL

THIS MANUAL INCLUDES IMPORTANT SAFETY INSTRUCTIONS FOR MODELS

SB2512i-HV and SB2512iX-HV, SAVE THESE INSTRUCTIONS.

THIS MANUAL DOES NOT APPLY TO EARLIER MODELS SB2512i OR SB2512iX

COVERED UNDER ONE OR MORE OF THE FOLLOWING US PATENTS

6,111,391 • 6,204,645

Blue Sky Energy - Solar Boost 2512i-HV and 2512iX-HV

TABLE OF CONTENTS

IMPORTANT SAFETY INSTRUCTIONS ................................................................................................................................ 2

PRODUCT DESCRIPTION...................................................................................................................................................... 3

Features Omitted in the Solar Boost 2512i-HV ...................................................................................................... 3

Part Numbers and Options ..................................................................................................................................... 3

OPERATION ......................................................................................................................................................................... 3

Charge Status Indicator .......................................................................................................................................... 3

Auxiliary Output Indicator ....................................................................................................................................... 3

Optional Remote Displays or Internet Communication .......................................................................................... 3

3-Stage Charge Control ......................................................................................................................................... 4

Bulk Charge ................................................................................................................................... 4

Absorption Charge ......................................................................................................................... 4

Float Charge .................................................................................................................................. ..4

2-Stage Charge Control ......................................................................................................................................... 4

Equalization ............................................................................................................................................................ 4

Current Limit ........................................................................................................................................................... 5

Optional Temperature Compensation .................................................................................................................... 5

Maximum Setpoint Voltage Limit ............................................................................................................................ 5

Maximum Power Point Tracking (MPPT) ............................................................................................................... 5

Panel Temperature and Output Power ................................................................................................................... 5

Multiple Charge Controllers On The IPN Network .................................................................................................. 5

INSTALLATION ....................................................................................................................................................................... 5

Electrostatic Handling Precautions ......................................................................................................................... 6

Selecting PV Modules ............................................................................................................................................ 6

As Shipped Factory Default Settings ...................................................................................................................... 6

Equalize Enable ..................................................................................................................................................... 6

Battery Temperature Sensor .................................................................................................................................. 6

Battery and PV Wiring ............................................................................................................................................ 7

Auxiliary Output ...................................................................................................................................................... ..7

Auxiliary Battery Charge ................................................................................................................ 8

Load Controller ............................................................................................................................... 8

Dusk-to-Dawn Lighting Control ...................................................................................................... 8

Installing a Multi-Controller System ........................................................................................................................ 8

Multi-Controller Wiring And Setup .................................................................................................. 8

IPN Network Address ..................................................................................................................... 9

Mounting ................................................................................................................................................................. 9

TROUBLESHOOTING GUIDE ................................................................................................................................................ 10

SPECIFICATIONS ................................................................................................................................................................... 11

5-YEAR LIMITED WARRANTY .............................................................................................................................................. 11

TABLES AND FIGURES

Table 1 Charge Status Indicator ................................................................................................................. 3

Table 2 Maximum Conductor Length - 3% Voltage Drop ............................................................................ ..7

Figure 1 Front Panel Indicators .................................................................................................................... 4

Figure 2 Factory Charge Voltage Setpoint -vs.- Battery Temperature ......................................................... 5

Figure 3 Setup and Wiring Diagram ............................................................................................................. 7

Figure 4 Auxiliary Output Wiring ................................................................................................................... 8

Figure 5 IPN Network Wiring ........................................................................................................................ 9

Figure 6 Detailed Dimensional Drawing ....................................................................................................... 9

Installation and Operation Manual

IMPORTANT SAFETY INSTRUCTIONS

This manual contains important instructions for Models SB2512i-HV and SB2512iX-HV

SAVE THESE INSTRUCTIONS

1. Refer installation and servicing to qualified service personnel. High voltage is present inside unit. Incorrect installation or use may result in risk of electric shock or fire. No user serviceable parts in this unit.

2. To reduce the risk of electric shock, fire or personal injury, the following symbols are placed throughout this manual to indicate dangerous conditions, or important safety or operational instructions.

WARNING CAUTION IMPORTANT

)

Indicates dangerous conditions or electric

shock potential. Use extreme caution.

Indicates items critical to safe installation or

operation of the unit.

3. PERSONAL PRECAUTIONS a) Working in the vicinity of lead-acid batteries is dangerous. Batteries produce explosive gasses during normal operation. b) To reduce risk of battery explosion, follow these instructions and those published by battery manufacturer and manufacturer of any equipment you intend

to use in vicinity of battery. c) Someone should be within range of your voice or close enough to come to your aid when you work near a lead-acid battery. d) Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing or eyes. e) Wear complete eye protection and clothing protection. Avoid touching eyes while working near battery. f) If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eye, immediately flood eye with running cold water for at

least 15 minutes and get medical attention immediately. g) NEVER SMOKE or allow a spark or flame in vicinity of battery. h) Be extra cautious to reduce risk of dropping metal tool onto battery. It might spark or short circuit battery or other electrical part that may cause explosion. i) Remove personal metal items such as rings, bracelets and watches when working with a lead-acid battery. A lead-acid battery can produce a short circuit

current high enough to weld a ring or the like to metal, causing a severe burn. j) Remove all sources of power, photovoltaic and battery before servicing or installing.

4. CHARGER LOCATION & INSTALLATION

a) This unit is designed to charge 12V (6 cell) flooded or sealed type lead-acid chemistry batteries within the range of 10 to 2,000 amp-hours. Follow battery

manufacturers charging recommendations when considering this unit for use with other battery chemistry.

b) This unit employs components that tend to produce arcs or sparks. NEVER install in battery compartment or in the presence of explosive gases. c) This unit must be installed and wired in accordance with National Electrical Code, ANSI/NFPA 70. d) Over current protection for the battery must be provided externally. To reduce the risk of fire, connect to a circuit provided with 30 amperes maximum

branch-circuit over current protection in accordance with National Electrical Code, ANSI/NFPA 70.

e) Over current protection for the auxiliary load control output or auxiliary battery charge output must be provided externally. To reduce the risk of fire,

connect to load or auxiliary battery with 30 amperes maximum over current protection in accordance with National Electrical Code, ANSI/NFPA 70.

f) Insure that unit is properly configured for the battery being charged. g) This unit is not water tight. Do not expose to rain, snow or excessive moisture. h) Insure all terminating connections are clean and tight. Battery, PV and Auxiliary Output terminals are to be tightened to 9 in-lb (1 nm). IPN Network and

battery temperature sensor compression terminals are to be tightened to 2.1 in-lb (0.24 nm).

i) Do not connect to a PV array capable of producing greater than 20 amperes of short circuit current @ STC. j) This unit is not provided with a GFDI (ground-fault detector/interrupter) device and must be used with an external GFDI device as required by Article 690

of National Electrical Code for the installation location.

5. PREPARING TO CHARGE

a) Never charge a frozen battery. b) Be sure battery is mounted in a well ventilated compartment. c) Add distilled water in each cell of a lead-acid battery until battery acid reaches level specified by battery manufacturer.

Follow these instructions closely for proper

operation of the unit.

Blue Sky Energy - Solar Boost 2512i-HV and 2512iX-HV

PRODUCT DESCRIPTION

Solar Boost™ 2512i-HV and 2512iX-HV are improved versions of the original SB2512i and SB2512iX 12 volt 25 amp Maximum Power Point Tracking

(MPPT) photovoltaic (PV) battery charge controllers. The new HV versions retain their original 25 amp 340 watt rating when used with conventional 12 volt 36 cell PV modules, but are also able to operate up to 270 watts of higher voltage 60 cell “grid tie” type modules. The full featured SB2512iX-HV includes all the features described in this manual. The SB2512i-HV omits certain features to reduce cost.

The 2512’s patented MPPT technology can increase charge current up to 30% or more compared to conventional controllers. MPPT also allows the use of higher voltage 60 cell modules by converting higher PV voltage down to charge a 12 volt battery. The 2512’s sophisticated 3-stage charge control system improves battery performance and life while minimizing battery maintenance. The unit is fully protected against voltage transients, over temperature, over current and reverse polarity. The IPN Network display connector provided in both versions allow use of optional remote displays or a UCM.

Additional features included in the SB2512iX-HV version of the product include a battery temperature sensor input, equalization capability, full IPN Network interface, and an auxiliary output. The versatile auxiliary output can operate as either a 2 amp battery charger for a second battery, or serve as a 25 amp load controller or 25 amp variable Dusk-to-Dawn lighting controller. The full IPN Network interface included in the SB2512iX-HV allows multiple charge controllers to communicate with each other and coordinate their activity to charge the battery as a single coordinated charging machine.

FEATURES OMITTED IN THE SOLAR BOOST 2512i-HV

The following features described in this manual are omitted in the lower cost Solar Boost 2512i-HV version of the product.

• Battery Temperature sensor input • Battery equalization capability

• Full IPN Network interface (multi-controller coordination) • Auxiliary Output (25A load & lighting control, or 2A auxiliary battery charge)

PART NUMBERS AND OPTIONS

• SB2512i-HV ....... Basic Solar Boost 2512i-HV charge controller • SB2512iX-HV ..... Full featured Solar Boost 2512iX-HV charge controller

• IPNPRO-S .......... IPN-ProRemote display & battery monitor w/shunt • IPNPRO .............. IPN-ProRemote w/o required 500A/50mV shunt

• CS-500 ............... 500A/50mV current shunt • IPNREM ............. IPN-Remote display

• 930-0022-20 ....... Battery temperature sensor • UCM ................... Universal Communication Module

OPERATION

Charge control and MPPT operations are fully automatic. At night when PV power production stops, the PV array is disconnected from the battery to

prevent unwanted current drain. There is a 5 second turn-on delay, and a 45 second turn-off delay.

¾ WARNING: The 2512 operates on battery power, not PV power. A battery must be connected with a minimum voltage of 9V for the unit to operate. Battery voltage on the battery terminals of the 2512 must be the same as actual battery voltage within a few 10ths of a volt for proper operation. DO NOT disconnect the battery with PV power applied as appliances still attached to the output of the 2512 may be damaged by voltage spikes resulting from sudden removal of the battery, particularly when used

CHARGE STATUS INDICATOR

A charge status indicator is provided on the face of the 2512, and on the optional remote displays. If net battery charge current is greater than ≈3 to 5 amps per 100 amp-hours of battery capacity the charge status indicator can provide a rough indication of battery state of charge.

RAPID BLINKING • 0.2 SEC ON / 0.2 SEC OFF

AUXILIARY OUTPUT INDICATOR (Omitted on SB2512i-HV)

An Auxiliary Output indicator labeled “LOAD” is provided on the face of the SB2512iX-HV, and is omitted on the SB2512i-HV. The indicator will be ON when the auxiliary output is ON providing power to a load, or charging an auxiliary battery. Default operation of the auxiliary output is Auxiliary Battery Charge and the indicator may turn ON even though an auxiliary battery may not be connected. Auxiliary Output status can also be viewed on the IPN-ProRemote.

OPTIONAL REMOTE DISPLAYS OR INTERNET COMMUNICATION

There are two available remote displays, the low cost IPN-Remote and the full featured IPN-ProRemote. The IPN-Remote is a basic 3-digit LED type voltage, current and charge mode display without setup or control capability. The full featured IPN-ProRemote provides setup capability and enhanced monitoring of charge controllers on the IPN network. It also provides a complete battery system monitor with various amp-hour counters and a highly accurate “fuel gage” type battery level indicator. A Universal Communication Module (UCM) may also be used for communication with other devices or to access the charge control system remotely over the Internet.

with higher voltage 60 cell PV modules. ALWAYS remove PV power first before disconnecting the battery.

CHARGE STATUS INDICATOR

CHARGE STATUS INDICATOR CHARGE MODE APPROXIMATE CHARGE LEVEL

OFF CHARGE OFF

CONTINUOUSLY ON BULK <70% FULL

BLINKING • 1 SEC ON / 1 SEC OFF

BLINKING • 0.2 SEC ON / 1 SEC OFF

ABSORPTION 70% - 95% FULL

FLOAT FULLY CHARGED

EQUALIZE

TABLE 1

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