Invertek SUNSTAR SERIES, SS-60C, SS-45C, SS-30C Installation And Operation Manual
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
RICH ELECTRIC CO.,LTD.
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.......................................................................................2-1
2.3 Control Terminal Connection.........................................................................2-2
2.4 Installation Steps..............................................................................................2-4
2.4.1 Mounting ................................................................................................2-5
2.4.2 Solar Battery Charging DIP Switch Settings.......................................2-5
2.4.3 Load Control DIP Switch Setting..........................................................2-8
2.4.4 Diversion Charge Control DIP Switch Settings...................................2-11
2.4.5 Battery Temperature Sensor (BTS)................................................. ... ..2-11
2.4.6 System Wiring and Power-Up ...............................................................2-11
2.4.7 Finish Installation ...................................................................................2-13
2.5 Communication with CombiPlus/SuperCombi.............................................2-14
Chapter 3 Front Cover of SunStar Operation........................................................................3-1
3.1 LED Status Indicator.......................................................................................3-2
3.2 Charge Control or Diversion Control Mode Indicatons ..............................3-2
3.3 Load Control Indications................................................................................3-2
3.4 Equalization Mode Indication ........................................................................3-3
3.5 Fault Mode Indication.....................................................................................3-3
3.6 LCD Meter Displays........................................................... .............................3-4
3.6.1 LCD Displays Flow.................................................. .. .............................3-5
3.6.2 Fault Messages ........................................................................................3-6
Chapter 4 Solar Battery Charging...........................................................................................4-1
4.1 PWM Battery Charging..................................................................................4-1
4.1.1 Four Stages of Solar Charging...............................................................4-1
4.1.2 Battery Charging Notes..........................................................................4-1
4.2 Standard Battery Charging Programs...........................................................4-2
4.3 Temperature Effects........................................................................................4-3
4.3.1 Battery Temperature Sensor (BTS)......................................................4-3
4.4 Equalization......................................................................................................4-4
4.4.1 Standard Equalization Programs..........................................................4-5
4.4.2 Typical Equalization...............................................................................4-6
4.4.3 When to Equalize....................................................................................4-6
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...............................................................................6-1
6.2 Diversion Current Ratings..............................................................................6-1
6.3 Stanadrd Diversion Battery Charging Programs.........................................6-1
6.4 Selecting the Diversion Load...........................................................................6-2
6.4.1 Suitable Load for Diversion...................................................................6-2
6.4.2 Definition of Terms.................................................................................6-3
6.4.3 Load Power Ratings................................................................................6-3
6.4.4 Maximum Diversion Load.....................................................................6-4
6.4.5 Minimum Diversion Load Definition of Terms....................................6-4
Chapter 7 Trouble Shooting .....................................................................................................7-1
Chapter 8 Battery Information.................................................................................................8-1
8.1 Sealed Batteries................................................................................................8-1
8.2 Flooded Batteries .............................................................................................8-2
8.3 L-16 Cells..........................................................................................................8-3
8.4 Nicad and NiFe Batteries.................................................................................8-3
Appendix A EMC Certificate
Appendix B C-tick Certificate
Specifications
Ⅰ
MODEL SS-30C SS-45C SS-60C
ELECTRICAL
System voltage ratings 12, 24, 48 Vdc
Current ratings-Battery Charge
Control
30A 45A 60A
Current ratings-Load Control 30A 45A 60A
Current ratings-Diversion Charge
Control
30A
Diversion load
45A
Diversion load
60A
Diversion load
Accuracy
12/24V:≦0.1 % ± 50 mV
48V:≦0.1 % ± 100 mV
Min. voltage to operate 9 V
Max. solar array Voc 140 V
Max. operating voltage 68 V
Total current consumption While operating -25mA, at idle -3mA
High temp shutdown
90ºC disconnect solar
90ºC disconnect load / diversion l oa d
70ºC reconnect solar / load / diversion load
Transient surge protec tion
pulse power rating 4500 watts
response < 5 nanosec
BATTERY CHARGING / BTS
Charge algorithm PWM, constant voltage
Temp comp. coefficient –5mV/ºC / cell (25ºC ref)
Temp comp. range 0ºC to +50ºC
Temp comp. setpoints PWM, float, equalize (wit h BTS o p tion)
MECHANICAL
Dimensions (mm)
H: 65 / W: 236 /
D: 35
H: 266 / W: 127 / D: 75
Weight 0.8 kg 1.5 kg
Power terminals 30A Rated 45A Rated 60A Rated
BTS / Sense terminals
wire sizes 1.0 to 0.25 m m
2
/ 16 to 24 AWG
torque 0.40 Nm / 3.5 in-lb
ENVIRONMENTAL
Ambient temperature –40 to +45ºC
Storage temperature –55 to +85ºC
Humidity 100% (NC)
Enclosure Indoor & vented, (powder coated steel)
Specifications subject to change without notice
1-1
Chapter 1 SunStar Description
The SunStar is a technically advanced solar system controller. Th ere are three operating
modes programmed into each SunSta r. The m anual describes solar battery charging, DC
diversion charge control or DC Load control instruc tions are inse rte d whe re requ ire d.
The manual will help you to become familiar with the SunStar’s features and capabilities.
This operation manual is applicable to the software version V1.05 and later versio n of the
SunStar units. Some of these follow:
z Solid-state Pulse Width Modulated (PWM) charging process with four-stage control,
temperature compensation, and manual or automatic equalization to maximizes system
performance and increase battery life.
z Electric overload and short circuit protection with automatic and manual reset
capability increase the reliability of unattended systems by eliminating blown fuses
and tripped circuit breakers.
z Optional external battery temperature com pensation (BTS) for automatic adjustment of
charge setpoints.
z Over-temperature protection f or the electronic circuitry when used in hot envi ronment
(over 80℃)
z LCD meter with easy to read mode/status messages.
z LCD meter for remote or direct mounting on the controller. May be mounted up to 500
feet away.
z An 8-position DIP switch to set up the controller for its intended use. All major
functions can be set with DIP switches.
z Rated for 12, 24, 48 volt systems, and 30, 45 or 60 amps current.
z Eight standard charging or Load programs selected with DIP switches.
z Continuous self-testing with fault notification.
z LED indications and pushbutton functions.
z Complies with EMC and LVD standards for CE marking.
1.1 Versions and Ratings
There are three standard versions of SunStar controllers:
SunStar-60 (SS-60C):
Rated for maximum 60 amps continuous current
(solar, load or diversion load)
Rated for 12, 24, 48 Vdc systems
SunStar-45 (SS-45C):
Rated for maximum 45 amps continuous current
(solar, load or diversion load)
Rated for 12, 24, 48 Vdc systems
SunStar-30 (SS-30C):
Rated for maximum 30 amps continuous current
(solar, load or diversion load)
Rated for 12, 24, 48 Vdc systems
※LCD meter (optional)
1-2
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 f or re c harging the system battery.
The SunStar manages the charging process to be efficient and to maximize the life of the
battery. Charging includes a bulk charging stage, PWM absorption, float and equalization.
DC Load Control
When set for DC load control, the SunStar powers loads from the battery, and protects the
battery from over-discharge with a current compensated LVD (low voltage load
disconnect).
DC Diversion Charge Control
In DC diversion mode, the SunSta r will manage battery charging by diverting energy from
the battery to a dedicated diversion load. The energy source is typi cally wind or hydro.
1.3 Adjustability
Eight DIP switches permit the following parameters to be adjusted at the installation site:
DIP switch Solar battery charging (Diversion charge control)
1 (OFF) Battery charge control mode (Diversion charge control mode)
2 3 Select Battery Voltage
OFF OFF 48V system
ON OFF 24V system
OFF ON 12V system
4~6 Standard battery charging programs
7 (OFF) Manual Equalization
(ON) Auto Equalization
8 (OFF) Operating from Dip Switch 4~6 battery charging programs settings
(ON) VR1 and VR2 settings f or use r define battery charging progr ams
DIP switch Load control
1 (ON) Load control mode
2 3 Select Battery Voltage
OFF OFF 48V system
ON OFF 24V system
OFF ON 12V system
1-3
DIP switch Load control
4~6 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
and reconnects
1.4 General Use
NOTE: This manual describes solar battery charging. Specific instructions for the DC load
control and DC diversion charge control modes are provided as notes throughout
this manual.
z The SunStar is suitable for a wide range of solar applications including homes, telecom
and industrial power needs.
z The SunStar controllers are configured for negative ground systems. There are no parts
in the controller’s negative leg. The enclosure can be grounded using the ground
terminal in the wiring compartment.
z The SunStar is protected from faults electronically with automatic recovery. There are
no fuses or mechanical parts inside the SunStar to reset or change.
z Solar overloads up to 130% of rate d cu rre nt will be tapered down instead of
disconnecting the solar. Over-temperature conditions will also taper the solar
input to lower levels to avoid a discon nect.
z Any number of SunStars can be connected in parallel to increase solar charging current.
SunStars can be paralleled ONLY in the battery charging mode. DO NOT parallel
SunStars in the load mode, as this can dama ge the controller or load.
z The SunStar is rated for indoor use. The controller is protected by conformal coated
circuit boards, stainless steel hardware, anodized aluminum , and a p owder coated
enclosure, but it is not rated for corrosive environm ents or water entry.
z The construction of the SunStar is 100% solid state.
z Battery charging is by a series PWM constant current charging, with bulk charging,
PWM absorption, float and equalization stages.
z The SunStar will accurately measure time over long intervals to manage events
such as automatic equalizations or battery servic e notification.
z Day and night conditions are detected by the SunStar, and no blocking diodes are used
in the power path.
z LED’s, a pushbutton, and LCD meters provid e both status information and various
manual operations.
1-4
1.5 Optional Available
Three optional components can be added to the standard SunStar controller at an y time.
※ Battery Temperature Sensor (BTS)
If the temperature of the syst em battery varies more than 5°C dur in g t h e y ear,
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. The BTS will measure the battery temperature, and
the SunStar uses this input to adjust the charging as required.
The battery charging will be corrected for temperature as follows:
Charger Setpoint Temperature Compensation Chart
System Voltage
Battery Type
12VDC 24VDC 48VDC
Lead Acid –30mV/ºC –60mV/ºC –120mV/ºC
Nicad –20mV/ºC –40mV/ºC –80mV/ºC
The BTS should be used only for batte r y c h arging and diversion control. Do not use the
BTS for load control. The charging parameters that are adjusted for temperature include:
• PWM regulation
• Equalization
• Float
• High Voltage Disconnect
※ Remote LCD Meter
One Remote LCD Meter can be added to the SunStar at any time during or after
installation. The display is a 2x16 LCD meter with backlighting. One pushbuttons is
used to scroll through the displays function.
There are a series of display screens that provide information such as:
• Operating information and data
• Reset Amp-Hours
※ RJ-45 Communication Cable
RJ-45 Communication Cable is used to connect the SunStars to CombiPlus or
SuperCombi Inverter/Charger. T he c o nnection of CombiPlus or SuperCombi and
SunStars can become a power management control system of standalone PV charger.
When connecting CombiPlus or SuperC ombi to SunStars in parallel, the maximum units
can go up to 10 SunsStars. The optiona l RJ-45 Communication Cables can be supplie d
in the following length.
• RJ-45-01 (1 Meter long Com munication Cable)
• RJ-45-03 (3 Meter long Com munication Cable)
• RJ-45-05 (5 Meter long Com munication Cable)
• RJ-45-10 (10 Meter long Com munication Cable)
2-1
Chapter 2 SunStar Installation
The installation instructions describe solar battery charging. Specific ins tructions for the
load control and diversion modes are prov ided as notes.
2.1 General Information
The mounting location is importa n t t o the performance and operating life of the contro lle r .
The environment must be dry and protected as noted below. The controller may be installed
in a ventilated enclosure with sealed batteries, but never in a sealed battery enclosure or
with vented batteries.
If the solar array exceeds the current rating of the controller, multiple SunStars can be
installed in parallel. Additional parallel controllers can also be added in the future. The load
controllers cannot be used in parallel.
If solar charging and load control are both required, two separate controllers must be used.
2.2 Installation Overview
The installation is straightforward, but it is important that each step is done c o rre ctly and
safely. A mistake can lead to dangerous voltage and current levels. Be sure to carefully
follow each instruction in Section 2.3 and observe all cautions and warnings.
The following diagrams provide an overview of the connections and the proper order:
Battery
Positive +
PV+ /
Load +
PV—/
Load—
Battery
Negative—
Earth
Dip Switches
VR2
VR1
BCD
Switch
Communication Port
BTS+ BTS—
2-2
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 Sola r Array or DC Load Negative
Battery—
Battery cable Negative connection
Earth Connecting terminal for Ground
Dip Switch 1
ON or OFF to choose battery charge control mode or load control
mode
Dip Switch 2, 3 Selection of battery voltage for 12V o r 24V or 48V system
Battery charge control mode: Battery charging algorithm
Dip Switch 4, 5, 6
Load control mode: Load control disconnect/reconnect algorithm
Battery charge control mode: Auto / Manual Equalization
Dip Switch 7
Load control mode: Auto / Manual Reconnect
Dip Switch 8
ON: Potentiometer of VR1, VR2 setting range
OFF: Dip switch 4~6 setting range
VR1, VR2
User define battery charging pr ogra m s or user define sta n dard low
voltage disconnect and reconnect
BCD Switch 0
SunStar unit is operating alone.
*When the BCD Switch is not placed at 0 and the fault m e ssa ge of
“ Alarm: CPF01 Wait for Combi” will be displayed if the SunStar unit
is not communicating with CombiPlus/SuperCombi
BCD 1~A
1
st
~10th SunStar units are communicating with CombiPlus
/SuperCombi
BCD B~F They are operating as the 10th SunStar unit
Communication IN Communication port for CombiPlus/SuperCombi
Communication OUT Com m unica ti on port for th e ne xt SunStar unit
BTS+ Connecting terminal for Battery Temperature Sensor Positive
BTS—
Connecting terminal for Battery Temperature Sensor Negative
2-3
Ground
BTS
BATTERY
Solar A rray
DC Load
or
GNDGND
PV+/
LOAD+
BAT+
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 enclose d 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 (not for load
control).
Step 5: Connect the battery power wires to the SunStar. Then connect the solar array wires
(or DC load wires).
Step 6: Close the cover.
※ Step 4 is optional.
DIVERSION
LOAD
Ground
BTS
BATTERY
Hydro
Wind
Solar
GNDGND
PV+/
LOAD+
BAT+
Installation wiring for DC diversion charge control
2-4
DC diversion charge control:
Step 1: Open the access cover
Step 2: Mount the SunStar using the enclose d 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. Then co nnect the diversion load
wires.
Step 6: Close the cover.
※ Step 4 is optional.
2.4 Installation Steps
The SunStar controller must be installed properly and in accordance with the local and
national electrical codes. It is also important that the installation be done safely, correctly
and completely to realize all the benefits that the SunStar can provide for your solar system.
Before starting the installation, review these safety notes:
z Do not exceed a battery voltage of 48V (nominal). Do not use a battery less than 12V.
z Do not connect a solar input greater than a nominal 48V array for battery charging.
Never exceed a Voc (open-circuit voltage) of 140V.
z Charge only 12, 24, or 48 volt lead-aci d ba tteries when using the standard battery
charging programs or NI-CAD batteries when DIP switch number 4~6 is ON position
in the SunStar.
z Verify the nominal charging voltage is the same as the nominal battery voltage.
z Do not install a SunStar in a sealed compartment with batteries.
z Never open the SunStar access cover unl es s both the solar and battery power has been
disconnected.
z Never allow the solar array to be connected to the SunStar with the battery
disconnected. This can be a dangerous condition with high open-circuit solar voltages
present at the terminals.
2-5
2.4.1 Mounting
Unit: mm
Mounting Dimensions
z Locate the SunStar on a wall protected from direct su n, hig h temperatures, and water.
Do not install in a confined area where battery gasses can accumulate.
z When mounting the SunStar, make sure the air flow around the controller and heat sink
is not obstructed. There should be open space above and below the heat sink, and at
least 75 mm (3 inches) clearance around the heat sink to allow free air flow for
cooling.
z Before starting the installation, place the SunStar on the wall where it will be mounted
and determine where the wires will enter the controller.
2.4.2 Solar Battery Charging DIP Switch Settings
The 8 DIP switches are located on the right of the Earth terminal. Each switch is numbered.
The solar battery charging functions that can be adjusted with the DIP switches follow:
2-6
M anual/Auto Equalization (7)
B atte ry C h a rg ing a lg or ithm (4 ,5 ,6)
Sy s tem V o lta g e (2 ,3 )
(diversion charge control)
Control Mode (1)
B atte ry C h a rg ing
OFF
ON
DIPON
8
7
6
5
4
3
21
U se r D e fin e C h arg in g alg o rith m (8)
DIP Switch Functions
※ As shown in the diagram, all the positions are in the “OFF” position except switch
number 3 and 7 which are in the “ON” position.
NOTE: The DIP switches should be changed only when there is no power to the
controller. Turn off disconnect switches and remove all power to the
controller before changing a DIP switch. A fault will be indicated if a switch is
changed while the controller is powered.
CAUTION 1: The SunStar is shipped with all the switches in the “OFF” position.
Each switch position must be confirmed during installation. A wrong
setting could cause damage to the battery or other system components.
CAUTION 2: To configure your SunStar for the battery charging and control you
require, follow the DIP switch adjustments described below. Before
changing any switch, make sure the BCD switch is placed at number 0
for the SunStar settings. To change a switch from OFF to ON, slide the
switch up toward the top of the controller. Make sure each switch is
fully in the ON or OFF position.
DIP Switch Number 1-Control Mode: Solar battery charging
Switch 1 Control Mode
ON Load control mode
OFF
Solar charging mode
(Diversion charge control m ode )
For the solar battery charging c o ntrol mode, leave the DIP switch in the OFF positi on.
2-7
DIP Switch Number 2, 3-System voltage
Switch 2 Switch 3 System Voltage
OFF OFF 48V system
ON OFF 24V system
OFF ON 12V system
DIP Switch Number 4, 5, 6-Battery charging algo rithm
DIPSW-4
DIP
SW-5
DIP
SW-6
Bulk
voltage
Float
voltage
Equalize
Voltage
Equalize
Time
(hours)
Equalize
Interval
(days)
OFF OFF OFF 14.0V 13.4V None - OFF OFF ON 14.1V 13.4V 14.2V 1 28
OFF ON OFF 14.3V 13.4V 14.4V 2 28
OFF ON ON 14.4V 13.4V 15.1V 3 28
ON OFF OFF 14.6V 13.4V 15.3V 3 28
ON OFF ON 14.8V 13.4V 15.3V 3 28
ON ON OFF 15.0V 13.4V 15.3V 3 14
ON ON ON 16.0V 14.5V - - -
Select one of the 7 standard battery charging algorithms, or select NiCad to determine the
charging of the battery.
※ The above setting voltage value is in the condition of 12V system. The voltage will be
twice of above values in the 24V system and it will be four times of above values in t he
48V system.
※ Refer to section 8.0 of the manual for battery charging information.
※ The 7 standard charging algorithms above are described in section 4.2-standard battery
charging programs.
DIP switch number 7- Battery Equaliz ation
Switch 7 Battery Equalization
ON Auto Equalization
OFF Manual Equalization
※ In the Auto Equalization Mode (Switch number 7 ON), the SunStar contr oller can
automatically triggering of the equalization process. When automatic has been selected,
an equalization charge will occur at set voltage and time (hours and days).
During the equalization process, the status LED indicates equalization (Equalization is
not recommended for NiCad batte ries and is disabled). The equalization pro cess will
continue until the voltage has been held above the bulk setting for a cumulative period of
set hours as shown above. This might ta ke several days on larger system with big
batteries and small solar arrays. The battery voltage only needs to exceed the bulk setting
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