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3024iL DUO-Option
User Manual
4 pgs221.22 Kb0

Blue Sky 3024iL DUO-Option User Manual

SB3024iL DUO-Option Manual Addendum
For Models; SB3024i, SB3024Di, SB3024iL, SB3024DiL
Purpose
This manual addendum applies to the Solar Boost 3024i family of charge controllers which have received the DUO-Option upgrade part number Upgrade/3024DUO
The DUO-Option
What is Diversion type charge control?
The core purpose of any charge controller is to prevent battery voltage from exceeding a certain charge voltage setting during charging by reducing charge current delivered to the battery. A battery will charge if PV modules or a wind generator was connected directly to a battery without a charge controller, but as battery state of charge rises so does battery voltage. Without a charge controller voltage can rise so high once the battery is charged that the battery or attached systems may be damaged.
The Series Pass type charge control in the 3024’s MPPT system reduces current delivered to the battery when necessary to control battery voltage by reducing the current it draws in from the PV and “passes through” to the battery. By contrast Diversion type charge control has the power source connected directly to the battery. When charge current needs to be reduced to control battery voltage the Diversion controller “diverts or redirects” a portion of the power source charge current away from the battery as the means it uses to limit net battery charge current and control battery voltage. The diverted current is typically dissipated as heat in a resistive dump load.
Diversion charge control operation
When multiple 3024’s are networked together without the Diversion control upgrade they essentially operate as separate PV power controllers under the direction of a single charge control system. Charge voltage setpoints and all charge control “smarts” reside within
the charge control system. If one or more PV power controllers receives PV input power the charge control system starts and directs the activities of the one or more PV power controllers to deliver the 3024’s sophisticated multi-stage battery charge control.
The Diversion control upgrade creates a completely separate 100Hz Pulse Width Modulation (PWM) Diversion type power controller within the 3024 using the 3024’s existing 20 amp auxiliary output. The Diversion power controller has it’s own turn on criteria which is when battery voltage reaches the present charge voltage setpoint (typically 14.4/28.8V). When this battery voltage threshold is reached Diversion turns on (whether PV power is present or not) and the Diversion power controller as directed by the charge control system begins to divert current to a resistive dump load as necessary to reduce net charge current and control battery voltage. The charge control system then progresses through it’s normal multi-stage charge process to precisely control battery charge.
Min-Power / Max-Power modes
A key aspect of the Diversion control upgrade is it’s coordinated interaction with PV charge control. This interaction allows the user to select whether minimum or maximum possible power is delivered to the dump load. Note that this coordinated interaction occurs within a 3024 only and not among multiple 3024’s on the IPN network. Min-Power / Max-Power mode is selected with 3024 Dip #4.
Diversion
Operating
Mode
DIP
Switch
#4
OFF
Min-Power
Mode
(formerly
Aux Bat
Chg)
ON
Max-Power
Mode
(formerly
Load
Control)
. This addendum should be used in conjunction with the standard product manuals.
Diversion Control Operation
When battery voltage climbs to the present charge voltage setpoint in the Min-Power mode the PV power controller reduces current delivered to the battery to control battery voltage in the same manner as a standard 3024. The Diversion power controller remains off until the PV power controller is unable to reduce current enough to control battery voltage. Once PV output is at a minimum, the Diversion power controller begins to divert current to the dump load to further reduce net charge current and control battery voltage. Min-Power mode is typically selected when dump load power is not directed towards a useful purpose and minimum dump load heating is desired. If no generator is present in Min-Power mode a dump load is unnecessary as the PV power controller alone controls all charge current. When battery voltage climbs to the present charge voltage setpoint in the Max-Power mode the PV power controller continues deliver maximum PV power. While maximum PV power production continues, the Diversion power controller diverts current to the dump load to reduce net charge current and control battery voltage. If the Diversion power controller is unable to divert enough current to control battery voltage, the PV power controller will reduce current to assist in controlling battery voltage while the system as a whole delivers as much power as possible to the dump load. Max-Power mode is typically selected when dump load power is directed towards a useful purposes such as heating water. The Max­Power mode may be used with PV power alone if the user wishes to divert PV power not required for battery charging to a useful purpose. Note that a dump load must be present in Max-Power mode to ensure stable battery voltage control.
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Microprocessor installation (required for field upgrade only)
¾ WARNING:
standard electrostatic handling precautions. At a minimum discharge yourself by touching grounded metal prior to handling the microprocessor or touching circuits in the 3024. Touch the “BAT-” terminal in
The microprocessor or 3024 may be damaged by static electricity. Observe industry
the 3024 just prior to removing the old microprocessor or inserting the new microprocessor. The risk of electrostatic damage increases greatly if relative humidity is below 40%.
The Microprocessor must be inserted in the proper Pin-1 orientation and all pins must be properly seated into the socket.
1. Remove all sources of power, battery and PV.
2. Carefully remove the old microprocessor with a suitable tool. Take care not to damage the microprocessor socket or other components.
3. Carefully place the new microprocessor p/n 590-0009-01 onto the socket, but do not press into place. Confirm that the Pin-1 end of the microprocessor is in the proper orientation closest to the case wall and that all pins are properly placed into the socket.
4. With one finger on each end of the microprocessor, carefully and evenly press the microprocessor to fully seat it into the socket. Confirm all pins are properly seated into the socket with no bent pins, and again confirm Pin-1 orientation.
5. Reapply battery power. Confirm that the microprocessor operates by viewing the charge voltage setting value (V
) as described in the
CHG
3024 manual.
Place Microprocessor into socket with Pin 1 orientation where shown.
Confirm that each pin is properly placed into socket prior to pressing microprocessor into place.
Dump Load selection and installation
¾ WARNING:
reduce the risk of fire, connect the auxiliary output to 25 ampere maximum over current protection in accordance with National Electrical Code, ANSI/NFPA 70. Do not connect the auxiliary output to a dump
Over current protection for the 3024’s auxiliary output must be provided externally. To
load capable of drawing more than 20 amperes at the highest battery charge voltage. For dump load current up to 40 amperes use current booster module part number CBM4070. Over current protection for CBM4070 must be provided externally. To reduce the risk of fire, connect CBM4070 to 50 ampere maximum over current protection in accordance with National Electrical Code, ANSI/NFPA 70. Do not connect CBM4070 to a dump load capable of drawing more t han 40 amperes the highest battery charge voltage. Install and wire the dump load in accordance with the dump load manufacturer’s installation and safety instructions and National Electrical Code, ANSI/NFPA 70. For dump load wiring clarity these instructions omit standard 3024 installation. These instructions show generalized connections only and are not intended to show all wiring, circuit protection and safety requirements.
For proper battery voltage control the dump load resistor value should be just low enough consume full generator current, but not so low as to exceed the maximum current ratings of the 3024’s auxiliary output or the CBM4070. Since any charging source that drives battery voltage up to or above the 3024’s charge voltage setpoint will cause current to be delivered to the dump toad, care must be taken in the selection of both the 3024’s charge voltage setpoints and the charge voltage setpoints of other charging sources. To prevent the Diversion control system from diverting current to the dump load from other charging sources such as an AC powered charger or engine driven alternator, the 3024’s charge voltage setpoint must ALWAYS be greater than the voltage applied by these other chargers. This may necessitate eliminating the 3024’s lower voltage Float charge stage by setting the 3024 for 2-stage charge.
Minimum dump load resistor value may calculated as follows:
R
DUMP-MIN
V
I
= V
BAT-MAX
÷ I
DUMP-MAX
Where: R
DUMP-MIN BAT-MAX
DUMP-MAX
= Minimum value of dump load resistor in Ohms (Ω)
= Maximum expected battery charge voltage in Volts (V) = Maximum dump load current in Amperes (A)
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