INSTALLATION and OPERATION MANUAL
for the
ASC
AUTOMATIC SEQUENCING CHARGER
Photovoltaic (Solar) Charge Controller
The ASC is a highly reliable charge controller ideal for small to
mid-sized photovoltaic systems. It will efficiently charge your
batteries and provide years of protection from over-charging.
Units with the low-voltage disconnect (LVD) option will provide
additional protection from low-voltage. This protective care
will prolong your battery life and reduce maintenance
requirements.
SPECIALTY CONCEPTS, INC.
8954 Mason Ave.
Chatsworth, CA 91311, USA
Web-site: www.specialtyconcepts.com
ASC - Specifications
12 / 2001
PARAMETERS UNITS NOMINAL VOLTAGES
6 v 12 v 24 v 36 v 48 v
Charge Current, Short Circuit, Continuous Refer to Serial Number Tag (available in 1 – 20 amps)
Charge Current, Short Circuit, Max.(60 sec) 1.30% of rated charge current
Load Current, Continuous (1)(2) (Amps) N/A 10 10 N/A N/A
Load Current, Max (60 seconds) (1)(2)(3) (Amps) N/A 13 13 N/A N/A
Array Voltage, Max Voc (Volts) 26 26 46 69 92
Voltage @ Battery for Charging, Minimum (Volts) 0 0 0 0 0
Voltage @ Battery for LVD, Minimum (1) (Volts) N/A 8.5 17 N/A N/A
Quiescent Current (Milliamps) 10 10 10 10 10
Current Consumption, Charging, Typ. (Milliamps) 15 15 15 15 15
Current Consumption,
Load Disconnected, Typ. (1)(4) (Milliamps) N/A 40 40 N/A N/A
Voltage Drop, Array to Battery, Typ. (Volts) .30 .30 .30 .60 .60
Voltage Drop, Array to Battery, Max. (Volts) .55 .55 .55 .70 .70
Voltage Drop, Battery to Load, Typ. (1) (Volts) . 06 .06 .06 N/A N/A
Charge Termination (5) (Volts) 7.1 + .1 14.3 + .2 28.6 + .4 42.9 + .6 57.2 + .8
Charge Resumption (5) (Volts) 6.75 + .2 13.5 + .3 27.0 + .6 40.5 + .6 54.0 + 1.2
Load Disconnect (LVD) (1) (5) (Volts) N/A 11.5 + .2 23.0 + .4 N/A N/A
Load Reconnect (1) (5) (Volts) N/A 13.0 + .3 26.0 + .6 N/A N/A
Operating Temp. Range (°C) -40 to 50 -40 to 50 -40 to 50 -40 to 50 -40 to 50
Storage Temp. Range (°C) -55 to 85 -55 to 85 -55 to 85 -55 to 85 -55 to 85
Temperature Comp. Coef. (from 25
Notes: (1) Low-voltage disconnect option. 10 amp load.
(2) Non-inductive.
(3) Carry only, Non-switching
(4) LVD relay energized, red L.E.D. on, typical value.
(5) Value adjustable with Adjust. Voltage Set-point option. Charge Termination / Resumption
(and Load Disconnect / Reconnect (Option E)) span is fixed
(6) Temperature compensation option
C) (6) (Volts/
°
C) - .015 -.03 -.06 -.09 -1.2
°
PART NUMBERING KEY
Model
EXAMPLE: Nominal Voltage
Nominal Current
Option
ASC- 12 / 8 - A
OPTIONS
A - Temperature Compensation
E - Low-voltage Disconnect (LVD)/
Generator Start
F - Adjustable Voltage Set-point(s)
S - Special or Custom unit
FEATURES
•
IDEAL SOLAR CHARGING
Efficient – Over 99% efficiency when
•
charging
Full Charging – Ensures that the batteries
•
are always topped off
Battery Safe – Charging method maximizes
•
battery life
Reduced Maintenance – from healthy
•
charging and reliable operation
Temperature Compensation – (Option)
•
Remote sensor provides best charging for
hot or cold locations
OVER-CHARGE PROTECTION
High Voltage “Shut-off” - shuts off only
•
when battery is full
Robust Circuitry – Control function 100%
•
solid state.
HIGH RELIABILITY
Simple, rugged electronics – low
•
component count and streamlined design
ensure long term reliability
Maximum environmental protection –
•
Ideal for outdoor mounting
No Minimum Voltage Required – Can
•
charge a dead battery.
Lightning protection – Survives most
•
indirect strikes
FEATURES
Reverse leakage protection – Prevents
•
power loss at night.
Terminal Block – for sound and easy wire
•
connections.
Status Light(s) – “Charging” and LVD
•
“Activated” (with LVD option)
LOW-VOLTAGE PROTECTION (Option)
Automatic Load Shutoff – Protects battery
•
from deep discharge.
Generator Start or Alarm – Includes N/O,
•
N/C, COM voltage free contacts
SYSTEM COMPATIBILITY
Minimum RF Noise – Low switching
•
frequency lessens electronic noise
Protection from External RF Noise – Can
•
operate with noisy invertors
CERTIFICATIONS
Not all units are certified. Refer to logos on product (front or back) for certifications.
FM
APPROVAPPROVEDED
Recognized by Underwriters Laboratories (UL)
Meets all requirements for UL 1741.
Factory Mutual (FM) approved
For Class 1, Div 2, Groups A, B, C and D hazardous locations
Canadian Standards Association (CSA) approved
For Class 1, Div 2, Groups A, B, C and D hazardous locations
•
Do not disconnect wiring while circuits are live unless area is known to be
•
non-hazardous.
Substitution of components may impair suitability for classification 2.
RELATED SYSTEM EQUIPMENT
The ASC is an integral part of a solar electric power system that includes a
photovoltaic (PV) solar array and a battery.
SOLAR ARRAY PANELS: The ASC is compatible with all makes and models of PV
panels, provided the open circuit voltage and short circuit current do not exceed the
Array (Voc) Max. and the short circuit current (ISC), max., specification ratings for
the ASC being used. See Specifications section. Install all modules with the
correct series-parallel configuration to insure proper system voltage and current.
The ASC includes a blocking diode to eliminate leakage of the battery power into
the solar panels at night. No additional protection is needed.
FOR LARGER SYSTEMS: Systems with large arrays and higher charging
currents can divide up the array into 2 or more parallel sub-arrays. An ASC should
be wired to each sub-array, provided that each sub-array does not exceed the
rating of the individual ASC. This method allows higher currents, an ideal charging
method and a degree of redundancy to increase overall system reliability.
OTHER CHARGING SOURCES: Systems with an additional source of charging
(alternator, battery charger, wind power, etc.) can operate with a solar array and an
ASC. All charging sources need to connect directly to the battery on independent
lines and have their own form of over-charge protection.
ASC FOR NON-SOLAR APPLICATIONS: The ASC will only operate with solar
panels (PV). Do not use with other power sources, such as a hydro or wind
generators/alternators or AC battery chargers. These charging sources can
damage the ASC and/or the generating equipment because the ASC regulates
charging by short circuiting the input.
BATTERIES: The ASC is designed to be used with standard lead-acid batteries.
These include wet-cell batteries, sealed maintenance-free batteries and gel-cell
batteries. Vented pocket plate nickel-cadmium (NiCad) batteries may also be used
provided the number of battery cells in series is a multiple of 5 (for a 12 volt
system, 10 cells). Consult with the battery manufacturer for specific recommended
set-points. Install all batteries with the correct series-parallel configuration to insure
proper system voltage and current
LOADS: System loads such as lights, radios, DC/AC inverters, etc. must be rated for
the proper DC input voltage. If the ASC is equipped with low-voltage disconnect
(LVD) (Option-E), DC loads not exceeding 10 amps can be connected to the ASC.
These loads will disconnect automatically when the battery voltage is low. Higher
current loads, or inductive loads such as pumps, motors or invertors should be
connected directly to the battery and be properly fused.
INSTALLATION
WARNINGS
WARNING: Electricity, even low voltage electricity, can be dangerous. Installation should
be performed by a licensed electrical contractor or other qualified personnel only. The
requirements of the U.S. National Electrical Code should be followed.
WARNING: Follow all safety precautions of the battery manufacturer. Proper ventilation
must be provided for the batteries. Most batteries produce hydrogen gas when
charging, which is extremely explosive. Provide adequate battery ventilation. DO NOT
expose the battery to open flame, matches, cigarettes or sparks.
CAUTIONS:
CAUTION: DO NOT EXCEED THE ASC’S VOLTAGE AND CURRENT RATINGS:
• Do not exceed the maximum voltage rating of the ASC (see SPECIFICATIONS).
Compare the ASC’s rating of the open circuit voltage (Voc) to the array, or the sum
of the Voc of all modules in series.
• Do not exceed the maximum current rating of the ASC (see SPECIFICATIONS).
Compare the ASC’s rating of the short circuit currents (Isc) to the array, or the
sum of all the modules in parallel. Remember that cold temperatures increase
the charging current from the modules. Refer to the temperature chart with the
module specifications.
CAUTION: DO NOT DEVIATE FROM THE RECOMMENDED WIRING INSTRUCTIONS:
• Do not reverse Battery(+) and Battery(-) connections to the ASC. Any reverse polarity
from the battery can damage the unit.
• Do not reverse the Battery and Array connections to the ASC. A battery connected to
the array terminals can damage the unit.
• Do not connect the array directly to the battery when the array is connected to the
ASC at the same time. This will damage the ASC when the battery voltage reaches
the Charge Termination set-point.
• Do not wire the ASC in such a way that it can be connected to an alternator (or other
charging source) while the battery is disconnected. Other charging sources should
have independent connections to the battery.
• Do not wire the ASC in such a way that it can be connected to a load without a
battery connected. (Example: Do not connect the loads directly to the ASC BATT
terminals. This will damage the ASC if the battery is disconnected.)
CAUTION: DO NOT OVER-TIGHTEN SCREWS:
• Do not exceed 8 inch pounds of torque on the terminal block screws during
installation. The screws are corrosion resistant nickel plated brass, and are softer
than standard steel screws.
INSTALLATION INSTRUCTIONS:
10‘/3m
20’/6m
30’/9m
40’/12m
10‘/3m
20’/6m
30’/9m
40’/12m
Distance round trip (feet / meter)
1. LOCATION / MOUNTING: - The ASC may be mounted in almost any indoor or outdoor
location. The unit should be mounted as close as possible to the batteries to avoid errors in
battery voltage reading. The ASC may be mounted on the rear of the solar panels using
outdoor-type double-stick foam tape. On units with temperature compensation (Option-A), the
ASC should be mounted within 10 feet (3m) of the batteries to enable the sensor cable to
reach the battery.
2. PROTECTION REQUIREMENTS: - The circuitry of the ASC is encased within hard epoxy
resin that offers substantial protection from the environment.
HEAT: - The unit should not be mounted in direct sunlight or close to any heat generating
•
source to avoid extreme temperature increases. The rear of the unit should not be blocked to
allow air flow for adequate cooling.
CORROSION: - The exposed terminal block is made of corrosion resistant nickel plated
•
brass. This will endure most outdoor environments. When the ASC is in an excessively
corrosive location, a coating of an oxide inhibitor should be applied to the terminals.
TEMPERATURE COMPENSATION CABLE (for units with Option-A): - The optional
•
sensor and cable need to be protected from damage (cuts, impacts, rodents). If the sensor
or cable is damaged, the ASC will not operate. (Refer to Options section: OPTION - A)
3. SELECT WIRE:
WIRE TYPE: - When possible, use stranded wire rather than solid wire. Stranded wire is less
likely to fail and cause loose connections over time. Consider using wires of different colors
to indicate source or polarity. Also, select a wire that offers the appropriate insulation for the
condition of the location. (Refer to the U.S. National Electrical Code)
WIRE SIZE: - Select wire of sufficient gauge to safely handle the rated current of the system
and to limit voltage drop. The ASC terminals accept up to 10 gauge stranded bare wire (and
12 gauge solid wire). (When using 10 gauge stranded wire, divide the end wires into two
equal sections and straddle the terminal screw). An alternative to using larger wire is to use
two wires in parallel for each connection.
Large Wires: To connect large wire to the ASC, use crimp connectors or connect the
larger wire to a short, thinner wire using a wire nut (solder these connections).
Wire Size: Minimum wire gauge (AWG) - (based on ASC at maximum current)
Model (V/C)
ASC-6/4 14 10 10 8* 14 14 12 10
ASC-12/1 14 14 14 14 14 14 14 14
ASC-12/4 14 14 12 10 14 14 14 14
ASC-12/8 14 10 10 8* 14 14 12 10
ASC-12/12 12 10 8* 6* 14 12 10 10
ASC-12/16 10 8* 6* 4* 14 10 10 8*
ASC-24/8 14 14 12 10 14 14 14 14
ASC-24/16 14 10 10 8* 14 14 12 10
* Wire gauge larger than unit can accept directly. See WIRE SIZE / Large Wires above.
Battery Connection
Distance round trip (feet / meter)
Solar Array Connection
+
BATTERY
+
+
BATTERY
+
(Optional)
(Optional)
BATT (-)
ARRAY (-)
ARRAY (+)
BATT
FIGURE 1 ASC Controller
SOLAR PANEL ARRAY
A
B
Temp.Sensor
+
LOAD
FUSE RATINGS:
A = Rated for ASC
B = Rated for load
BATT (-)
ARRAY (-)
ARRAY (+)
BATT (+)
COM
N / C
N / O
FIGURE 2 ASC Controller with Option-E (LVD)
SOLAR PANEL ARRAY
+
LOAD
A
C
FUSE RATINGS:
A = Rated for ASC
C = Rated for load,
Temp.Sensor
up to 10 amps max.
INSTALLATION INSTRUCTIONS (continued) :
4. COMPLETE THE INSTALLATION OF ARRAY, BATTERIES AND LOAD: - Follow the
manufacturer's instructions for mounting and wiring the solar panel, batteries and the
load. Install with the correct series-parallel configuration to insure proper system
voltage and current
5. REMOVE POWER FROM BATTERY / PANELS (if needed): - Prior to running the
wires to the ASC, be sure that power is disconnected from the batteries and
panels
6. RUN SYSTEM WIRING: - Run the wires from the battery and solar panel to the
ASC controller. The wires should reach the location of the ASC and be secured
with a little extra for strain relief loops.
7. NOTE WIRE POLARITY: - Make sure to correctly note the source and polarity of
the wires using colored wires or tags. Incorrect polarity may damage the
ASC.
8. ASC CONNECTION: - Wire the ASC according to Figure 1. Do not use a jumper
across the Array(-) and Batt(-) terminals. If using crimp connections, be sure to
crimp and solder.
9. INSTALL TEMPERATURE COMPENSATION (OPTION-A): - If included. The
cable’s sensor needs to mount onto the side of the batteries. Refer to
“OPTIONS” section.
10. COMPLETE LVD CONNECTION (OPTION-E): - Refer to Figure 2 to complete
the load connection for low-voltage load disconnect. Be sure to run a separate wire
from the battery (+) terminal to the ASC’s COM terminal. Do not use a jumper from the
ASC’s BATT(+) terminal to the COM position. Refer to “OPTIONS” section.
11. INSTALL FUSING AS NEEDED: - Add circuit protection where needed. A
fuse and disconnect switch, rated for the nominal current of the ASC, should be
installed on the Battery (+) run of the ASC. See Figures 1 or 2.
12. CONNECT BATTERY AND ARRAY POWER
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