Blue Sky 3000i User Manual

SOLAR BOOST™ 3000i

12 VOLT 30/22 AMP MAXIMUM POWER POINT TRACKING

PHOTOVOLTAIC CHARGE CONTROLLER

INSTALLATION AND OPERATION

MANUAL

THIS MANUAL INCLUDES IMPORTANT SAFETY INSTRUCTIONS FOR MODEL SB3000i

SAVE THESE INSTRUCTIONS.

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Blue Sky Energy – Solar Boost 3000i

TABLE OF CONTENTS

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

PRODUCT DESCRIPTION...................................................................................................................................................... 2

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

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

Charge Status Indication ........................................................................................................................................ 3

Digital Display ......................................................................................................................................................... 3

Solar Charge Amp-Hour Counter ........................................................................................................................... 3

Battery Level Graphic ............................................................................................................................................. 4

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

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

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

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

Two Stage Charge Control ..................................................................................................................................... 5

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

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

Equalization ............................................................................................................................................................ 5

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

Maximum Power Point Tracking ............................................................................................................................. 6

Panel Temperature and Thermal Protection .......................................................................................................... 6

Multiple Charge Controllers On The IPN Network .................................................................................................. 6

INSTALLATION ....................................................................................................................................................................... 6

Charge And Load Control Settings ......................................................................................................................... 6

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

Restoring As Shipped Factory Default Settings ............................................................................. 7

Changing Charge And Load Control Settings ................................................................................ 7

Selecting PV Modules ............................................................................................................................................ 8

Mounting ................................................................................................................................................................. 8

Battery and PV Wiring ............................................................................................................................................ 9

Optional Battery Temperature Sensor .................................................................................................................... 9

Auxiliary Output ...................................................................................................................................................... 10

Auxiliary Battery Charge ................................................................................................................ 10

Load Controller ............................................................................................................................... 10

Dusk–To–Dawn Lighting Control ................................................................................................... 11

Battery & PV Power Connect/Disconnect Order .................................................................................................... 11

Connecting The Battery ................................................................................................................. 11

Connecting PV Modules ................................................................................................................. 11

Installing A Multi-Controller System Using The IPN Network ................................................................................. 11

Multi-Controller Wiring And Setup .................................................................................................. 12

TROUBLESHOOTING GUIDE ................................................................................................................................................ 12

SPECIFICATIONS ................................................................................................................................................................... 15

FIVE YEAR LIMITED WARRANTY......................................................................................................................................... 15

TABLES AND FIGURES

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

Table 2 Charge And Load Control Settings ................................................................................................ 7

Table 3 Maximum Conductor Pair Length – 3% Voltage Drop ................................................................... 9

Figure 1 Front Panel Operation & Indicators ................................................................................................ 4

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

Figure 3 Detailed Dimensional Drawing ....................................................................................................... 8

Figure 4 Wiring Diagram .............................................................................................................................. 9

Figure 5 Auxiliary Output Wiring Diagram .................................................................................................... 10

Figure 6 IPN Network Wiring ........................................................................................................................ 12

Installation and Operation Manual

IMPORTANT SAFETY INSTRUCTIONS

This manual contains important instructions for Model SB3000i

SAVE THESE INSTRUCTIONS

1. Refer installation and servicing to qualified service personnel. 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 12 volt (6 cell) flooded or sealed type lead-acid chemistry batteries within the range of 20 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 40 amp maximum branch-

circuit over current protection in accordance with National Electrical Code, ANSI/NFPA 70 with 36 cell modules, or 30 amp maximum with 60 cell modules. Do not connect a PV array capable of delivering greater than 24 amps of short circuit current I with 60 cell modules.

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 25 amp maximum over current protection in accordance with National Electrical Code, ANSI/NFPA 70.

f) Insure that charge parameters are properly configured for the battery being charged as recommended by the battery manufacturer. 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. Tighten Battery and PV compression terminals to 15.9 in-lb (1.80 nm), battery temperature sensor

and IPN Network compression terminals to 2.1 in-lb (0.24 nm), and auxiliary output compression terminals to 6 in-lb (0.67 nm).

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.

PRODUCT DESCRIPTION

The Solar Boost 3000i is a Maximum Power Point Tracking (MPPT) solar charge controller able to charge 12V batteries at up to 30 amps from 36 cell 12V PV modules. Patented MPPT technology operates the modules electrically in a manner that harvests all available PV power and can increase charge current up to 30% or more compared to conventional PWM type controllers. The voltage step-down operation of the MPPT power converter also allows use higher voltage 60 cell grid-tie PV modules at up to 22 amps of output current producing a charge current increase approaching 200% with 60 cell modules.

The 3000i’s sophisticated and fully adjustable 3-stage plus equalization charge control system optimally charges flooded, GEL and AGM lead-acid chemistry batteries. Electronic protection is provided against voltage transients, over temperature, over current, short circuit, swapped battery & PV, and reverse battery & PV polarity. A very low power LED display is provided to monitor PV charge performance and includes a resettable amp-hour counter which computes total PV amp-hours produced. A user configurable auxiliary output is also provided which can serve as either a 20 amp LVD load controller, a 20 amp lighting controller with LVD, or a 2 amp auxiliary battery charger for a second battery such as the engine start battery in an RV.

Follow these instructions closely for proper

operation of the unit

at STC with 36 cell modules, or 11.8 amps

Blue Sky Energy – Solar Boost 3000i

To allow easy system expandability the 3000i may also operate as an IPN Network Master controlling up to 7 Blue Sky Energy IPN compatible charge controllers such as the SB3024iL. Blue Sky Energy’s IPN Network allows multiple charge controllers to communicate with each other and coordinate their activities to charge the battery as a single coordinated charging machine.

PART NUMBERS AND OPTIONS

• SB3000i ............... Solar Boost 3000i solar charge controller • 930-0022-20 ..................... Optional battery temperature sensor

• IPNPRO-S ........... Optional IPN-ProRemote battery system monitor • 720-0011-01 ..................... Optional wall mounting box, black powder coated

• UCM .................... Optional Universal Communication Module for system access over the Internet

OPERATION

Basic charge control operations are fully automatic and require no operator intervention. When sufficient PV power is available the 3000i will switch to a Charge ON state and begin charging the battery. The particular charge mode the 3000i will operate in will vary depending on the needs of the battery and available PV charge current. When insufficient PV current is available to charge the battery the 3000i will switch to a Charge Off state and the PV array will be 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 The 3000i operates on battery power, not PV power. Insure that voltage on the battery terminals of the 3000i is always the

)

same as actual battery voltage within a few 10 serves as a heatsink for power control devices and may become quite warm during normal operation.

¾ CAUTION: Do not disconnect the battery while the 3000i is in a Charge ON state. A healthy battery is a key component of the charge voltage control system and provides charge voltage filtering. Sudden removal of the battery while the 3000i is charging will produce voltage spikes at the 3000i’s battery terminals which may damage 12 volt appliances still connected to the 3000i, especially when using higher voltage 60 cell PV modules.

IF THE BATTERY MUST BE DISCONNECTED, REMOVE PV POWER FIRST.

CHARGE STATUS INDICATION

Present charge status of the 3000i is indicated using two charge status LED’s, Absorption & Float. If net battery charge current is greater than about 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.

CHARGE STATUS LED’s CHARGE MODE APPROXIMATE CHARGE LEVEL

ABSORPTION & FLOAT OFF CHARGE OFF

ABSORPTION & FLOAT ON BULK <70% FULL ABSORPTION ON – FLOAT OFF ABSORPTION 70% - 95% FULL ABSORPTION OFF – FLOAT ON FLOAT FULLY CHARGED

ABSORPTION & FLOAT ALTERNATELY BLINKING

DIGITAL DISPLAY

When the 3000i completes self-test the VOLT/AMP display mode is active. This mode displays Battery Voltage continuously if the 3000i is in a Charge Off state, or alternates between Battery Voltage & Output Charge Current if the 3000i is charging the battery. The AMPS indicator in the upper left of the display will be on solid when displaying 3000i output current, or blinking when displaying PV input current. To provide good readability yet minimize the likelihood of the display being objectionably bright at night an automatic night time dimming feature dims the display at night when the 3000i is in a Charge Off state.

Other display modes may be selected using the Display Select push-button. Each brief press of Display Select selects the next display mode as shown on the front panel graphic of Figure 1. VOLT shows Battery Voltage, AMP-OUT shows 3000i Output Charge Current, AMP-IN shows PV Input Current, and AMP-HRS shows total PV Amp-Hours produced since the amp-hour counter was last cleared. If the 3000i is part of a multi-controller system using the IPN Network the 3000i’s display will show the total of all controllers on the network.

AUX-VOLT shows voltage on 3000i’s the auxiliary output. When the auxiliary output is configured for Auxiliary Battery Charge (factory default) and the 2 amp auxiliary charge output is connected to an auxiliary battery (such as the engine start battery in a Motorhome) the voltage of the auxiliary battery is displayed. If the auxiliary output is configured for Load Control, the voltage displayed is that applied to the load.

SOLAR CHARGE AMP-HOUR COUNTER

The battery essentially serves as a “storage tank”, with the battery storing electrical energy in units referred to as amp-hours. Amp-hours are

computed by multiplying current in amps X time in hours. For example 20 amp-hours may be a current of 10 amps flowing for 2 hours, or may be 1 amp

flowing for 20 hours. The battery receives and stores amp-hours when being charged, and then delivers those stored amp-hours when being discharged.

The amp-hour counter displays total solar charge amp-hours accumulated since the last time the counter was cleared up to a maximum count of 999 amp-hours. Amp-hour production varies widely with operating conditions, but as a very broad brush approximation 100 watts of PV modules can deliver up to

ths

of a volt and greater than 9 volts for proper operation. Note that the front panel

CHARGE STATUS

EQUALIZE

TABLE 1

Installation and Operation Manual

a maximum of about 30 amp-hours per day. Any partial shading, lower sun intensity, shorter days, or time spent in Absorption or Float will decrease amphours produced. The present amp-hour count may be cleared by pressing Display Select for 5 seconds while viewing amp-hours on the display.

BATTERY LEVEL GRAPHIC

The 3000i provides a battery level graphic on the front panel which indicates approximate battery level versus battery voltage. Generally a higher voltage is better than a lower voltage. A battery that is being charged will typically range in voltage from about 12.5 volts after charge commences, to 14.0 volts or greater when the battery is highly charged. Once charge stops and the battery begins discharging and delivering power to a load it is normal for battery voltage to drop. A battery under a light load of about 1 amp per 100 amp-hours of battery capacity may range between about 12.5 volts when the battery is full, down to perhaps 12.0 volts when the battery is about 50% discharged. Battery voltage during discharge will tend to be higher under light load and lower under a heavier load.

Do not think of these voltage values as absolutes but rather as a broad brush indication of approximate battery charge level. Voltage at a particular state of charge will vary with battery size, age, construction, temperature, and with the level of charge or discharge current. Most battery manufacturers recommend not discharging below about 50% DOD (depth of discharge) to promote improved battery performance and life. Avoid allowing battery voltage to drop below about 11.5 volts, and NEVER allow battery voltage to drop below 10.0 volts. If a highly accurate battery charge level indication is desired, consider installing an optional IPNProRemote display.

Digital Display May show battery voltage, input/output charge current, solar charge amp-hours or auxiliary output voltage. AMP indicator will be on solid for output current or blinking for PV input current. Display automatically dims at night.

FRONT PANEL OPERATION & INDICATORS

Auxiliary Output LED Indicates when the auxiliary output is ON, either charging an auxiliary battery or powering a load.

Charge Status LED’s Shows present charge mode.

Setup Push-Button Display Select Push-Button Selects display mode. May also be used to clear solar

Used with Display Select to

view or change all setup

parameters. charge amp-hours or start/stop Equalize.

Front Panel Heating

Panel serves as a heatsink Battery Level Graphic Shows approximate battery level vs. battery voltage.

3-STAGE CHARGE CONTROL

FIGURE 1

for power control devices,

may become quite warm

during normal operation.

The 3000i is factory configured for a 3-stage charging process, Bulk, Absorption and Float, which is fully automatic and requires no operator intervention. The 3-stage charge process applies a somewhat higher Absorption charge voltage to charge the battery quickly and safely. Once the battery is fully charged a somewhat lower Float voltage is applied to maintain the battery in a fully charged state without excessive water loss.

¾ The charge control system always starts in Absorption and will return to Absorption upon exiting Current Limit or Equalization.

)

Following a 10 second delay in Absorption the 3000i may move on to other charge modes based on battery and system needs.

Bulk Charge

The 3000i will switch to Bulk charge when battery voltage remains below the present Charge Voltage setpoint. During Bulk the 3000i delivers as much charge current as possible to rapidly recharge the battery. During Bulk it is a combination of battery size, state of charge and available charge current that determine battery voltage, not the 3000i.

Absorption Charge

Once the battery recovers sufficient charge for battery voltage to rise to the Absorption Charge Voltage setpoint (factory set to 14.4V), charge current is reduced as necessary to hold the battery at the Absorption Voltage. The 3000i will return to Bulk should battery voltage remain below the Absorption Voltage setpoint for more than 10 seconds. The 3000i remains in Absorption until the battery is fully charged as determined by either;

1) The 3000i remains continuously in Absorption for the Absorption Charge Time period (factory set to 2 hours).

− OR −

2) With the optional IPN-ProRemote display and battery system monitor, net battery charge current decreases to the Float Transition Current

(factory set in the ProRemote to 1.5 amps per 100 amp-hours of battery capacity).

Float Charge

Once the battery is fully charged a somewhat lower Float Voltage (factory set to 13.2V) is applied to maintain the battery in a fully charged state without excessive water loss. The 3000i will return to Absorption should battery voltage remain below the Float Voltage setpoint for more than 10 seconds.

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