Specialty Concepts SC1 User Manual

SPECIALTY CONCEPTS MODEL 1

SC1

(

Photovoltaic Battery Charge Controller

Installation and Operation Manual

SPECIALTY CONCEPTS, INC.

8954 Mason Ave.

Chatsworth, CA 91311 USA

Copyright 8 / 1997 Specialty Concepts, Inc.

GENERAL DESCRIPTION

)

The SPECIALTY CONCEPTS CHARGER MODEL 1 (SC1) is a versatile, industrial quality charge
controller for the efficient use of photovoltaic energy and the protection of expensive batteries. It
is available for 12, 24, 36, and 48 volt negative ground systems with models for 30 amps of
charge current (optional 50 amps available) .

The SC1 consists of a series-relay battery charge controller in a wall mount chassis with low
voltage load disconnect, a load circuit breaker, and system status lights. The lights indicate
"CHARGE MODE" and "LOAD DISCONNECTED" conditions. The SC1 is housed in an anodized
aluminum chassis and has a terminal block that accepts up to 10 gauge wire. A terminal adapter
kit is included to increase wire size to #6.

FEATURES

CHARGE REGULATION

•30 amp charge current, 12, 24, 36 or 48 volt

•50 amp charge current (optional), 12 or 24 volt

•Two-step, series charging, 12,24 v

•Single step, series charging, 36,48 v

•Adjustable charging set-points (option)

•Temperature compensation (option)

LOW-VOLTAGE LOAD DISCONNECT (LVD)

•30 amp LVD, 12 volt

•20 amp LVD, 24 volt

•15 amp LVD, 36 and 48 volt

•Adjustable disconnect set-points

•Manual override switch

DESIGN FEATURES

•Maximum array usage

•Over-current protection - load circuit breaker

•Reverse polarity protection

•Reverse leakage protection

•Lightning protection

•Input noise suppression

•Remote battery voltage sense

MONITORING and MOUNTING

•“CHARGE MODE” light

•”LOAD DISCONNECTED” light

•Analog volt/amp meters (option)

•Indoor wall mount

•Outdoor enclosure (accessory)

SPECIFICATIONS

PARAMETERS UNITS NOMINAL VOLTAGES

12 v 24 v 36 v 48 v

Charge Current, Continuous (1) (Amps) 30 30 30 30
Charge Current, Max (60 seconds) (2) (Amps) 39 39 39 39
Load Current, Continuous (3) (Amps) 30 20 15 15
Load Current, Max (60 seconds) (2) (Amps) 39 26 20 20
Array Voltage, Max Voc (Volts) 22 44 66 88
Operating Voltage @ Battery, Minimum (Volts) 8.5 17.0 25.5

34.0
Quiescent Current (4) (Milliamps) 10 10 10 10
Current Consumption, Charging (5) (Milliamps) 160 160 80 80
Current Consumption,

Load Disconnected (6) (Milliamps) 140 100 70 70
Current Consumption, Metering, Typ. (7) (Milliamps) . 5 .5 .5 .5
Voltage Drop, Typ. (Array to Battery) (Volts @ Max rating) .15 .15 .15 .15
Voltage Drop, Typ. (Battery to Load) (Volts @ Max rating) .40 .40 .40 .40
Full Charge Termination (8) (Volts) 14.8 + .2 29.6 + .4 44.4 + .6 59.2 + .8
Full Charge Resumption (Volts) 12.8 + .2 25.6 + .4 38.4 + .6 51.2 + .8
Load Disconnect (9) (Volts) 11.5 + .2 23.0 + .4 34.5 + .6 46.0 + .8
Load Disconnect Adjustment Range (Volts) 11.0 to 12.0 22.0 to 24.0 33.0 to 36.0 44.0 to 48.0
Load Reconnect (Volts) 13.0 + .3 26.0 + .6 39.0 + .9 52.0 + 1.2
Float Voltage (Volts) 14.1 + .2 28.2 + .4 NA NA
Float Current, Max (Amps) 3 1 NA NA
Temp. Compensation coef. (from 25°C) (10) (Volts/°C) -.03 -.06 -.09 -.12
Operating Temp. Range (°C) 0 to 50 0 to 50 0 to 50 0 to 50
Storage Temp. Range (°C) -55 to 85 -55 to 85 -55 to 85 -55 to 85

Notes:
(1) 50 amp option available.
(2) Carry only, Non-switching
(3) Non-inductive.
(4) Both relays unenergized, red L.E.D.s off, typical value.
(5) Charge relay energized, red L.E.D. on, typical value.
(6) LVD relay energized, red L.E.D. on, typical value.
(7) Metering option
(8) Adjustable set-point is available. Refer to table.

PART NUMBERING KEY

EXAMPLE: Model

SC1 - 12 - AF

NOMINAL

MODEL VOLTAGE OPTIONS

SC1 12 A - Remote Temperature Compensation

24 F - Volt Meter / Amp Meter
36 P - 50 Amp charge current (12 & 24 volt)
48 T - Adjustable Full Charge Termination Set-point

FULL CHARGE TERMINATION SET- POINTS (OPTION)

Control SWITCH POSITIONS

Voltage A B C D

12 15.3 14.8 14.3 13.8
24 30.6 29.6 28.6 27.6
36 45.9 44.4 42.9 41.4
48 61.2 59.2 57.2 55.2

Nominal Voltage
Options

ACCESSORIES

INDOOR ENCLOSURE (NEMA 13)
OUTDOOR ENCLOSURE (NEMA 4X)

Specifications and product availability subject to change without notice.

RELATED SYSTEM EQUIPMENT

The SC1 is an integral part of a solar electric power system that includes a PV solar array, a
battery and a load. These items should be installed in accordance with the National Electrical
Code, and with the instructions provided by the equipment supplier.

SOLAR ARRAY PANELS: The SC1 is compatible with all makes and models of PV panels. The

open circuit voltage of the array should not exceed the maximum open circuit voltage of the
SC1(See SPECIFICATIONS: “Array Voltage, Max Voc”) and the maximum power current of
the panels should not exceed 30 amps (or 50 amps with P-Option).
HIGHER CHARGING CURRENTS: For arrays exceeding the maximum power current of the
SC1, the array can be divided into smaller parallel sub-arrays. A SC1 can be wired in parallel
to each sub-array, provided the sub-arrays do not exceed the rating of the individual SC1.

BATTERIES: The standard SC1 is designed to be used with the most common lead-acid

batteries. These are wet cell batteries using pure lead, lead antinomy and/or lead calcium
grids. Adjustments in voltage set-points may be made on SC1 models with the adjustable set­point option (Option T). For sealed, maintenance free batteries, or vented pocket plate nickel­cadmium batteries, the charging set-points should be adjusted to maximize performance and
battery life. For sealed, maintenance free batteries or nickel cadmium batteries, consult the
battery manufacturer for recommended set-points and refer to Table 1 (OPTIONS section) for
appropriate settings.

LOADS: The load is considered the item or equipment that the PV system is powering. System

loads such as lights, radios, DC/AC inverters, etc. must be rated for the proper DC input
voltage. DC loads not exceeding the rated SC1 load current (See SPECIFICATIONS “Load
Current, Continuous”) can be connected to the load terminals of the SC1 and they will
automatically be disconnected in the event of a low-voltage condition. Higher current, or
inductive loads such as pumps, motors or inverters should be connected directly to the
battery, using properly rated over-current protection devices (fuses or circuit breakers).

OTHER CHARGING SOURCES: Do not use the SC1 to regulate a power source other than a

photovoltaic array, such as a hydro or wind generator/alternator or an AC battery charger.
This could result in damage to the SC1 and/or the generating equipment. Connect other
charging sources with their own regulation devices directly to the battery, using properly rated
over-current protection devices.

The SC1 and solar panel can remain connected to a battery being charged by other sources,
(alternator, battery charger, etc.) without damage to the controller or solar panel.

INSTALLATION

WARNINGS / CAUTIONS

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 vented batteries. Most vented batteries produce hydrogen gas when charging,
which is extremely explosive. DO NOT expose the battery to open flame, matches, cigarettes
or sparks.

WARNING: Install properly DC rated, high interrupt current limiting over-current protection and

disconnect equipment between the SC1 and the battery. Suitable fused disconnect switches
are low cost and provide protection from fire and damage due to over-current. Refer to the
National Electrical Code or your local alternative energy vendor for recommendations.

CAUTION: DO NOT subject the controller to voltages greater than the "Array Voltage, Max Voc"

as stated in the SC1 specifications. This is the open circuit voltage (Voc) of the solar panel, or
the sum of the open circuit voltages of all modules connected in series.

CAUTION: DO NOT exceed the maximum current rating ("Charge Current, Max") of 30 amps (or

50 amps with P-Option). This is the sum of the maximum power currents of all the modules in
parallel.

CAUTION: On higher voltage units (36, 48 volt), exercise extreme care during installation. These

voltages can be extremely dangerous in that they can create large arcs, which can burn or
cause other injuries.

INSTALLATION INSTRUCTIONS:

1. LOCATION: - A suitable location must be found for mounting the SC1. The unit should be

mounted on a vertical surface and be as close as possible to the batteries to avoid errors in
battery voltage reading. DO NOT block the ventilation holes on the top and bottom of the SC1.
On units with temperature compensation (Option A), the sensor wire is 10 feet long and
should reach the battery bank if possible. For installation details on temperature

compensation, refer to OPTIONS section.

2. PROTECTION REQUIREMENTS: - The unit should not be placed in direct sunlight or close to
any heat generating source to avoid extreme temperature increases. It must receive adequate
protection from rain, dust and insects. The SC1 is NOT designed to be mounted outdoors or in
high humidity environments unless protected by a suitable enclosure.

3. MOUNTING: - Secure the SC1 to the selected location using the four mounting holes on the
chassis and proper fasteners.

4. COMPLETE THE INSTALLATION OF THE PANELS, BATTERIES AND LOAD: - Follow the
manufacturer's instructions for mounting and wiring the solar panel, batteries and the load.

5. SELECT WIRE:

WIRE TYPE: - It is recommended that stranded wire rather than solid wire be used

whenever possible, because stranded wire does not fatigue and cause loose
connections over time as easily as solid wire does.

WIRE SIZE: - The SC1 terminal block accepts bare wire up to 10 AWG. (The 50 amp

model accepts up to 6 AWG). Wire should be sized of sufficient gauge to safely handle
the rated current of the system and to limit voltage drop. Consult wire sizing tables and
local alternative energy system suppliers for information on wire sizing.

6. REMOVE POWER FROM BATTERY / PANELS: - Disconnect power from the batteries and
panels prior to running the wires to the SC1 to prevent accidental damage or bodily harm.

7. SET CIRCUIT BREAKER TO “OFF”: - Make sure the load circuit breaker on the SC1 is
“OFF”.

8. RUN SYSTEM WIRING: - After disconnecting the power sources, refer to wiring diagram
(FIGURE 1) and run the system wiring to the location of the SC1. The wires should reach the
location of the SC1 with a little extra for strain relief loops.

9. NOTE WIRE POLARITY: - Insure that the polarity of the wires is correctly marked, using
colored wires or tags. Incorrect polarity should not damage the SC1, but incorrect operation
would result.

10. COMPLETE ARRAY AND BATTERY CONNECTIONS: - Connections to the SC1 terminal
block should be made with just the bare wire (not crimped spade or ring lugs unless the lugs
are crimped AND soldered)

11. COMPLETE LOAD CONNECTIONS: - Refer to wiring diagram (FIGURE 1). DC loads not
exceeding the rated SC1 load current (see specification section “Load Current, Continuous”)
can be connected to the load terminals of the SC1 and they will automatically be disconnected
in the event of a low-voltage condition. Higher current, or inductive loads such as pumps,
motors or inverters should be connected directly to the battery, using properly rated over­current protection devices (fuses or circuit breakers).

12. BATTERY VOLTAGE SENSE CONNECTIONS: - The factory has installed two jumpers onto
the terminal block. They connect the "BATTERY VOLTAGE SENSE" (positive and negative)
terminal to their respective "BATTERY" terminals. These jumpers should remain in place if
the SC1 is located within 5-10 feet of the batteries and if large enough wire is used to
minimize voltage drops to less than 2%.

If the SC1 is at a greater distance from the batteries and/or if the voltage drop in the
battery wires exceeds 2%, then the jumpers should be removed and replaced with another
circuit running directly to the battery terminals. This is a low current, voltage sensing circuit
that can be wired in 16 AWG wire. Proper over-current protection should be added on the
positive side. This connection will allow the SC1 to accurately measure battery voltage.

13. INSTALL FUSING AS NEEDED: - Add circuit protection where needed. A 30 amp fuse
(or 50 amp with Option P) should be installed on the Battery (+) run of the SC1. Fusing is also
advised for the battery voltage sense connection, if included. The load is already protected by
the built-in circuit breaker of the SC1.

14. ATTACH TEMPERATURE COMPENSATION CABLE (OPTION A): - If included. See
Temperature Compensation section

15. MAKE NEEDED ADJUSTMENTS TO VOLTAGE SET-POINT (OPTION T): - If included.

See Setting/Adjustments section

16. RECONNECT BATTERY AND ARRAY POWER - Reconnect both power sources, then

Step 8 Battery Voltage Sense(+)( # 1): To Battery (+) (Remove #1-#2 jumper)

position the load circuit breaker on.

POWER CONNECT SEQUENCE

It is recommended that the power is supplied to the system using this sequence.
Some of the circuits within the SC1 must be reset to their "start state" and this is
automatically accomplished if the power is supplied in this order. If the order is not
followed, a period of up to 24 hours may have to elapse before the electronics are
fully reset.

Step 1 Battery (-) (terminal # 7): To Battery (-)
Step 2 Battery (+)( # 2): To Battery (+)
Step 3 Solar Panel (-)( # 6): To Solar Panel Array (-)
Step 4 Solar Panel (+)( # 3): To Solar Panel Array (+)

Optional (see “COMPLETE LOAD CONNECTION” above)
Step 5 Load (-)( # 5): To Load (-)
Step 6 Load (+)( # 4): To Load (+)

If Needed (see “BATTERY VOLTAGE SENSE CONNECTIONS” above)
Step 7 Battery Voltage Sense(-) ( # 8): To Battery (-). (Remove #7-#8 jumper)

17. OPERATION: - Operation of the charge controller is now fully automatic. If the battery

voltage is below the Full Charge Termination set-point (see SPECIFICATIONS) and power is
available from the array and the Power Connect Sequence (above) was followed, the SC1
should start up in the full-charge mode. If the battery voltage is above the Load Disconnect
voltage, the loads connected to the LOAD terminals should go on.

During float charging (12 or 24 volt units) it is normal for the unit to feel warm. This is due to
power dissipation of the voltage regulated float circuit.

18. CHECK FOR VOLTAGE DROP (OPTIONAL): - Once the system is installed and operational,
a check on the battery connection is recommended. A poor battery connection will result in a
voltage loss that will cause the batteries to be under-charged and/or result in excessive heat
generated at the location of poor connection (wire connection or terminal block). A voltage
multi-meter is required and the SC1 must be in Full Charge mode with maximum expected
charge current.

First, note the voltage at the battery terminals. Select the positive and negative terminals that
are used for the SC1 connection. Then note the voltage at the SC1 terminals labeled “BATT
(+)” and “BATT (-)”. The difference in voltage should be no more than ¼ volt (for a 12 volt
system). If the voltage drop is more, suspect crimp connections that have not been soldered
or loose terminals. If no location of voltage drop is found, consider using larger wires for your
run or run a separate wire for the Battery Sense connection. See “BATTERY VOLTAGE
SENSE CONNECTION” (above).

FIGURE 1

BATTERY VOLTAGE SENSE

BATTERY

++

++

+

+

(Optional)

SPECIALTY CONCEPTS CHARGE CONTROLLER MODEL 1

SPECIALTY CONCEPTS

CHARGER MODEL 1

BATT SENSE (-)

BATTERY (-)

SOLAR PANEL(-)

LOAD (-)

Temperature compensation

LOAD (+)

SOLAR PANEL (+)

BATTERY (+)

SOLAR
ARRAY

PANEL

30 amp fuse

(or 50 amp with

Option P)

BATT SENSE (+)

Jumpers: This jumper and the

jumper on the negative terminal,
should remain as shown unless a
Battery Voltage Sense Connection
is needed.

See WIRING INSTRUCTIONS:

Note: This connection from the load can be

wired to the SC1 directly (as shown) for
low-voltage load disconnect or the load can
connect directly to the battery.

See WIRING INSTRUCTIONS:

COMPLETE LOAD CONNECTIONS

ADDITIONAL

LOAD

LOAD

SETTINGS / ADJUSTMENTS

FULL CHARGE VOLTAGE ADJUSTMENT (Option T) : If the controller is supplied with this
option, the charge termination voltage set-point may be adjusted. Refer to the OPTIONS

section (“OPTION T”).

LOW-VOLTAGE LOAD DISCONNECT (LVD) SETTINGS: The Load Disconnect and Reconnect

set-points are factory set as listed in the specifications section, and are adjustable.
NO LVD: - For an override of the load disconnect function, push the switch up. No load

disconnect will occur with the switch in the "NO LVD" position.

AUTO LVD: - When the “Load Disconnect” switch is in the "AUTO" position, the load control

circuit will operate automatically. Refer to the “OPERATION: LOW-VOLTAGE
DISCONNECT” section for a description of this operation. If a load disconnect occurs, the
loads will be automatically reconnected when the batteries charge up to the Load
Reconnect voltage, or they can be reconnected manually with the “Load Disconnect”
switch.

MANUAL RESET: - For a temporary reset, push the switch down. The battery voltage must

remain above the Load Disconnect voltage for the load to stay connected after reset.

ADJUSTING LVD SET-POINTS : To alter the voltage at which the load disconnect and reconnect

occur, turn the adjustment pot on the front of the unit labeled “LOAD DISCONNECT ADJUST”
clockwise to decrease and counter-clockwise to increase (for the range of adjustment, refer to
the specifications section: “Load Disconnect Adjustment Range”). Both set-points will change,
with the span value fixed.

CAUTION : When adjusting this controller, it is important to use the proper size screwdriver.
Do not force the adjustment beyond the end stops, it will damage the controller.

If problems develop, refer to the "TROUBLE SHOOTING" section of this book.

OPERATION

CHARGE REGULATION (12 and 24 volt units): The two-step control circuit regulates the

charging of storage batteries by monitoring battery and solar panel voltage. STEP 1:
CONSTANT CURRENT (FULL) CHARGE MODE: At sunrise, the charging relay energizes
and closes, connecting the solar panel directly to the battery and lighting the "CHARGE
MODE" light. The battery will accept as much current as the solar panel will provide, and
battery voltage will rise. STEP 2: CONSTANT VOLTAGE (FLOAT) CHARGE MODE: When
the battery reaches the full charge termination voltage, the charging relay will open and the
"CHARGE MODE" light will go out. At this point the float controller takes over to keep the
battery below the float voltage and supply limited current (maximum float current). As the
battery approaches the float voltage, the current will taper off, eventually falling to the
battery's maintenance current.

CHARGE REGULATION (36 and 48 volt units): The operation of a 36 and 48 volts unit is

identical with the exception that no float circuit is included.

MAXIMUM SOLAR PANEL USAGE : If a load is applied when the controller is in the float mode,

the controller will supply up to its maximum float current to maintain the battery charge. If the
load is less than the maximum float current the batteries will still be receiving a net charge
from the float controller. If the load current is more, the battery will supply what the float
controller cannot and the battery voltage will fall. When it falls below the full charge
resumption voltage, the charging relay will re-close, re-initiating the full charge mode. This
insures that if a large load is applied during the day, maximum use will be made of the power
available from the solar panel.

LOW-VOLTAGE DISCONNECT : The low-voltage disconnect (LVD) of the SC1 prevents damage

from deep discharge of the batteries by automatically disconnecting the loads. The disconnect
threshold is load current compensated by a factor of 10 mv/amp, and a minimum time of 3
seconds is applied to prevent false disconnect. When a disconnect occurs, the load relay is
energized and opens, and a red "LOAD DISCONNECTED" light, visible on the front panel, will
light to indicate that the loads have been disconnected. Normal battery charging will continue.
When the battery voltage rises to the reconnect threshold, the loads will automatically be
reconnected to the battery and the red light will go off. The LVD function has a reset/disable
switch and user adjustable set-points.

Note: The amount of time required to recharge the battery sufficiently to reconnect the loads
depends upon the battery size, solar panel current and weather conditions. In some cases, it
can take several days or longer. The loads can be manually reset prior to the reconnect
voltage by pressing the "MANUAL RESET" switch.

REVERSE CURRENT PROTECTION : The SC1 uses a timing circuit to disconnect the solar

panel from the battery at night, preventing reverse leakage current loses through the solar
panel. About 12 hours after sunrise the charging relay will open. If the battery is below the
reconnect threshold and voltage is still available from the solar panel, the relay will re-close
and continue charging. It will open again about every 2 hours thereafter to determine if power
is still available for charging. The relay will stay open after the 12 hour period if the battery is
above the reconnect threshold or if there is no power available from the solar panel. This
results in the relay being open every night. Note: The relay may be closed ("CHARGE MODE"
light on) for a few hours in the evening after the sun has gone down.

MONITORING

“CHARGE MODE” LIGHT: The "CHARGE MODE" light will be on when the controller is in the

full charge mode. In this mode, the charging relay is closed, connecting the solar panel
directly to the battery. This light should go on first thing in the morning. When the battery
reaches the "Full Charge Termination" set-point, the SC1 will switch from Full-Charge mode to
Float-Charge mode and the CHARGE MODE light will go out. The light may go on again if the
battery drops below the reconnect voltage and the controller goes into the full charge mode
again. It is not uncommon for the light to remain on, for several hours after dark. Refer to the

operation section for details on controller operation.

“LOAD DISCONNECTED” LIGHT: When the "LOAD DISCONNECTED " light is on, the Low-

voltage Load Disconnect (LVD) circuit is activated and any DC loads connected to the "LOAD"
terminals will be disconnected. This occurs at the LVD set-point voltage. The light will go out
when the voltage rises above the reconnect voltage and the load is reconnected
automatically, or if the reset switch is pushed to LVD "MANUAL RESET" or "NO LVD". Refer

to the operation section for details on LVD operation.

CIRCUIT BREAKER

“LOAD CIRCUIT BREAKER” - A load circuit breaker is included with the SC1. This provides

over-current protection for the load circuit (SC1 and load connections) and provides protection
from a short circuit at the load. This also can be used as an on/off switch for the load.

OPTIONS

The following are the options available with the SC1. Options cannot be added to units after
production. Some of the features and functions described in this manual are not included on all of
the units. Check the model number and voltage/current ratings of your unit and compare with the
specifications and option descriptions to determine what your particular model's capabilities are.

OPTION A - TEMPERATURE COMPENSATION

Temperature compensation is recommended for stand alone systems with sealed batteries, or for

systems that have no regular charging source other than PV AND where prolonged
temperature extremes will be experienced during periods of charging. Temperature extremes
would be when the battery will be exposed to average temperatures below 50°F (10°C) or
above 90°F (32°C). Systems with other sources of charging, (alternators on RVs) or
applications where the battery is on maintenance charge, normally do not need this option.

DESCRIPTION: On units equipped with temperature compensation, a small sensor on a ten
foot cable is wired into the controller to adjust the charging thresholds according to battery
temperature. The rate of compensation is -5mv/°C per battery cell in series from 25° C.

CAUTION: SENSOR CABLE: If the sensor is damaged or the cable is cut, the controller will

no longer function.

INSTALLATION INSTRUCTIONS

Provision must be made to attach the sensor unit to the battery. This must be done properly to
insure that accurate temperature readings are made. It is important that ambient temperature
not influence the sensor. To minimize this, attach the sensor to the battery as follows:

1. RUN SENSOR TO BATTERIES: Run the sensor to the batteries, taking care to prevent

damage to the actual sensor itself. When pulling the sensor through conduit, do not pull
on the rubber-coated sensor, but instead on the gray cable just behind the sensor. Do not
force the sensor. The sensor itself is made of glass, but it is encased in an aluminum
tube, then coated with plastic. If the tube should pull off of the glass sensor, and if the
sensor is not damaged, the tube can be slipped back over the sensor.

2. ATTACH SENSOR: Use the adhesive sided foam (included) to cover the sensor (the

plastic coated unit at the end of the cable) and attach it to the side of the battery
approximately half-way up the side of the battery. Choose a battery that is shielded from
drafts or sunlight by other batteries or by the battery shelter. DO NOT immerse the sensor
directly in the battery's electrolyte, it will be severely damaged. Temperature
compensation of charging voltage is now automatic.

OPTION F - VOLT / AMP METERS

These meters monitor the battery voltage and charging current of the system. The battery voltage

meter is an expanded scale meter with red, yellow and green indication of state of charge.
These are 5% meters and are intended to give an indication of system status, but are not
designed to give highly accurate readings of voltage and current. The Specialty Concepts
Digital Monitor (DM3) is available if higher accuracy is required.

OPTION P - 50 AMP CHARGE CURRENT

This option provides 50 amps of charging current capabilities. The terminal accepts up to 6 AWG

wire. Load ratings and other specifications remain as stated in the "SPECIFICATIONS"
section.

OPTION T - ADJUSTABLE FULL CHARGE TERMINATION SET-POINT

This option allows for the adjustment of the high voltage charge termination set-point on SC1’s

equipped with this option. All other set-points remain fixed and as stated in the
"SPECIFICATIONS " section.

Four different voltage set-points are available when using the selection switch. See Table 1

TABLE 1: VOLTAGE SET-POINT SELECTION (values + 2%)

CONTROLLER SWITCH POSITION

VOLTAGE A B C D

12 VOLT 15.3 14.8 14.3 13.8
24 VOLT 30.6 29.6 28.6 27.6
36 VOLT 45.9 44.4 42.9 41.4
48 VOLT 61.2 59.2 57.2 55.2

The controller is factory set at position B. To change the set-point, locate the adjustment
switch. The switch is located on the bottom or top of the controller in one of the vent slots, and
can be identified by the label. Using a slotted screwdriver, turn the switch until the slot is
pointing at the desired position.

SET-POINT RECOMMENDATIONS:

POSITION A: NiCad batteries or for occasional equalization charging
POSITION B: Wet cell lead acid batteries
POSITION C: Sealed maintenance free batteries (heavy use)
POSITION D: Sealed maintenance free batteries (float applications)
Contact the battery manufacturer for recommended settings

TROUBLE SHOOTING: GENERAL NOTES

IF THE CONTROLLER IS NEWLY INSTALLED, CHECK THESE THINGS FIRST:

1) Re-check system wiring to insure proper installation and polarity .

2) Check all system fuses and circuit breakers. Before replacing a blown fuse, locate and correct
the cause.

3) Check to be sure that there is a connection (voltage input) to the "BATTERY VOLTAGE
SENSE" terminals from the battery. This would be either a factory installed jumper strip on the
controller terminal block from the "BATTERY VOLTAGE SENSE" terminals to the "BATTERY"
terminals, or a connection from the sense terminals directly to the battery itself.

4) Check to see that modules and batteries are in the correct series-parallel configuration for
proper system voltage and current.

5) Review controller specifications relating to solar panel output, load ratings and system sizing
to insure that ratings are not exceeded.

6) Review the controller specifications relating to operation and set-points, particularly the charge
termination and reconnect voltage set-points. If possible, check this with the operation of the
controller, monitoring the battery voltage with a multi-meter.

7) Some types of loads (fluorescent lights, inverters) can generate electronic "noise" that
sometimes interferes with the operation of the controller. Check to see if strange behavior can
be traced to operation of a certain appliance.

8) If the unit is equipped with temperature compensation, inspect the temperature sensor and
sensor wire. Check for a broker sensor or a cut or frayed sensor wire.

9) If possible, perform the "FIELD TEST PROCEDURE" and /or "BENCH TEST PROCEDURE"
that follows.

10) The SC1 with Option F are equipped with a colored scale volt meter. This meter is 5%
accurate (about .5 volt in a 12 volt system) and is designed to give a general state of charge,
not to determine voltages accurately.

IF THE CONTROLLER HAS BEEN INSTALLED AND WORKING PROPERLY
FOR AWHILE, CHECK THESE THINGS FIRST:

11) Check all system fuses and circuit breakers. Before replacing a blown fuse, locate and
correct the cause.

12) Confirm that all connections are clean and tight. Particularly check crimp connections that
have been crimped but not soldered as these connections tend to deteriorate over time.

13) Some types of loads (fluorescent lights, inverters) can generate electronic "noise" that
sometimes interferes with the operation of the controller. Check to see if strange behavior can
be traced to operation of a certain appliance.

14) If you have an accurate digital volt meter, check for voltage drop between the controller and
the battery by measuring voltage at the battery and at the controller when maximum charging
is occurring. Drops often occur through old fuses, fuse holders or circuit breaker boxes and at
loose or corroded connections.

15) High voltage from nearby lightning strikes or unregulated charging sources can damage the
controller. The built-in lightning protection provides substantial protection, but it is sometimes
overwhelmed.

16) If the unit is equipped with temperature compensation, inspect the temperature sensor and
sensor wire. Check for a broker sensor or a cut or frayed sensor wire.

17) Check output from the solar panel, and that it is not partially shaded or dirty.

18) If possible, perform the "FIELD TEST PROCEDURE" and /or "BENCH TEST PROCEDURE"
that follows.

TROUBLE SHOOTING: SC1

PROBLEM DESCRIPTIONS

BATTERY UNDER CHARGED

CONTROLLER NOT CHARGING AT ALL, ALWAYS IN FLOAT MODE ("CHARGE MODE"
LIGHT OFF)

Check to see that the controller is receiving voltage (at least about nominal system voltage)

from the battery and the solar panels. If it is, momentarily disconnect the panels, using an
solar panel disconnect switch if available, then reconnect. The controller should reset into
the full charge mode ("CHARGE MODE" light on). If it does not reset, the controller may
be defective.

See General Note #8 above. A damaged sensor or wire will cause the controller to

malfunction.

CONTROLLER STOPS CHARGING TOO SOON, AT TOO LOW A VOLTAGE

See General Note #6 above: Try to monitor the voltage at the "BATTERY VOLTAGE SENSE"

terminals when the controller actually switches. Most often, when a controller is
operational, it is switching the correct voltage. If the battery is not reaching the charge
termination set-point voltage before the controller switches, it is usually an error in the
voltage that the controller is sensing, not a controller failure.

See General Notes #12 and #14 above: A poor connection between the battery and the

controller results in a voltage drop during charging periods (larger drop for higher current)
that disappears when charging stops. This voltage drop results in a higher voltage being
sensed at the controller than is actually at the battery.

CONTROLLER CLICKS AND CHATTERS, PARTICULARLY IN THE MORNING AND EVENING

See General Notes #12 and #14 above: Check the connection to the battery. A poor

connection at the battery will cause the relay to chatter under low light conditions and the
controller to remain in float mode during full sun.

CONTROLLER NOT CHARGING, "CHARGING" LIGHT DIM, BATTERY VOLTAGE VERY LOW

See LVD trouble shooting section (“LOAD DISCONNECT CIRCUIT NOT OPERATING

CORRECTLY”) . If the LVD circuit is not operating, the battery can be discharged to a very
low voltage. If the battery is extremely low, there might not be enough voltage to operate
the controller. The charging relay requires a minimum operating voltage to engage and
allow charging. If the battery is down to 9 volts or lower on a 12 volt system, (17 on a 24
volt) connect the battery directly to the array (or use an auxiliary charging source) until
sufficient charging has occurred to increase the voltage. Note: Battery life depends on the
number, time and the depth of the discharges. Severe battery damage can result when
batteries are deeply discharged and not recharged immediately.

"CHARGE MODE" LIGHT ON AT NIGHT

Review the "REVERSE CURRENT PROTECTION" and "CONNECTION SEQUENCE"

sections of this manual. The reverse leakage timer may cause the "CHARGE MODE" light

to be on for a few hours each evening. Also, the light will stay on during the night of the
first day of installation or if the solar panel has been manually disconnected that day. If the
light stays on all night every night, the timer may be defective.

BATTERY OVERCHARGING

CONTROLLER ALWAYS IN FULL CHARGE ("CHARGE MODE" LIGHT ON)

See General Note #6 above: The battery may not be reaching the charge termination set-

point.

See General Note #3 above: No voltage at the BATTERY VOLTAGE SENSE terminals tells

the controller that the battery voltage is low and needs to be charged more. Install a
connection from battery to "BATTERY VOLTAGE SENSE" terminals to resolve..

See General Note #8 above: A damaged temperature sensor or wire will cause the controller

to malfunction and requires immediate replacement.

CONTROLLER NOT IN CHARGE MODE ("CHARGE MODE" LIGHT OFF)

Disconnect solar panel, then reconnect. Listen for relay to click and for “CHARGE MODE"

light to come back on. If the light goes on but you hear no click, the relay or controller may
be defective.

Check for other charging sources that are not properly regulated, causing the battery to

overcharge.

LOAD DISCONNECT CIRCUIT NOT OPERATING CORRECTLY

LOADS ALWAYS DISCONNECTED, LVD LIGHT ON, EVEN WHEN BATTERY VOLTAGE IS
HIGH

See General Note #6 above: No voltage at the BATTERY VOLTAGE SENSE terminals tells

the controller that the battery voltage is low and loads need to be disconnected. Install a
connection from the battery to "BATTERY VOLTAGE SENSE" terminals to resolve.

LOADS DISCONNECTED TOO SOON OR NOT RECONNECTING

See General Note #6 above: The battery may not be reaching the reconnect voltage set-point.
See General Note #12 and #14 above: A poor connection between the controller and the

battery results in a voltage drop when heavy loads are turned on that disappears when the
loads are turned off. The heavier the loads are, the larger the voltage drop will be. This
voltage drop results in the controller seeing a lower voltage than what the battery voltage
actually is.

LOADS NOT DISCONNECTING ON LOW VOLTAGE, LVD LIGHT OFF

Check the position of the "LVD" switch. If the switch is in the "NO LVD" position the load will

not be disconnected.

LOADS ALWAYS DISCONNECTED, LVD LIGHT OFF, BATTERY VOLTAGE IS HIGH

Check the load circuit breaker on the front of the controller. If the breaker is tripped, the load

will not operate.

TROUBLE SHOOTING: BATTERIES

Refer to this section to help diagnose potential problems based on battery observations.

CASE BATTERY SEE NOTE(S)

1 →
2 →

Battery Note 1 - BATTERY OVER-CHARGING: If there is evidence that the batteries have

been over-charging, consider these points:

• Normal Battery Condition: The batteries may not be over-charging but only be

• Controller Problem: The SC1 could be defective. Refer to the field test procedure.

• Battery Type: The batteries may be a type that require a lower full-charge voltage than what

• Other Charging Sources: Another charging source could be the cause. If the SC1

•• A Hot Battery - Hot temperatures can affect the battery charging, a hot location for

Seems to be over-charging See Battery Note 1
Does not fully charge batteries See Battery Note 2

experiencing normal water loss and normal levels of gassing. Check the “BATTERY
VOLTAGE” reading. Normal battery voltage for a wet cell battery can be up to 14.8 volts
(12v system).

the SC1 is set to. Refer to SETTINGS / ADJUSTMENTS Section.

“CHARGING” light is off and the “ARRAY CURRENT” reading is 0, then the solar system is
off and overcharging can be from another source. Some 110 volt battery chargers are not
well regulated and could over-charge batteries if left unattended.

batteries will tend to over-charge the batteries.

Battery Note 2 - BATTERY UNDER-CHARGED: If the battery voltage is low and they are not

able to be charged sufficiently, consider one of the following problems:

•• Solar Panels Problem - Panel may be dirty, not aligned or other problem.

•• Bad Connection to the Solar Panel.

•• SC1 Controller Problem. - Refer to the FIELD TEST PROCEDURE

•• A Bad Battery - The batteries may be going bad. TEST: If the battery is going bad, a little

charging or discharging will cause a large change in the battery voltage.

•• A Cold Battery - Cold temperatures can affect the battery charging. If the battery is cold

much of the time, the battery’s long-term performance and life may suffer.

•• System not sized correctly - For too much usage, try charging the battery with another

charging source (engine alternator, generator or AC battery charger). If the batteries are
OK and hold the charge, an increase in the number batteries and panels may be needed
to support the usage.

TROUBLE SHOOTING: SOLAR PANELS

Refer to this section to help diagnose potential problems based on panel performance.

CASE PANELS SEE NOTE(S)

1 →

Panel Note 1 - The panels should generate a charge close to their rated load current as

presented in their specifications. To reach this level assumes that all conditions are ideal. If
the panel performance as measured at the panel inputs on the SC1 controller is much lower,
consider the following potential problems.

•• Solar Panels Problem - Panels may be dirty, not aligned or other problem. TEST: Monitor

•• Bad Connection to the Solar Panel. TEST: Measure the voltage up at the solar panel, and

•• Solar Panels may be defective - TEST: Disconnect the array by switching the array circuit

Less charge than expected See Panel note 1

the "ARRAY CURRENT" reading before and after cleaning of the solar panels and
orientation. Locate panel where no shadows will cross it.

then down at the battery itself during a sunny period of maximum charging. These voltage
readings should not be more than 1 to 1.5 volts different. More than that would indicate a
bad connection or other voltage drop in the system. Suspect crimp connections that have
not been soldered.

breaker off, and measure the solar array voltage between the array(+) and the array(-). In
sunny conditions, this should be 18-24 volts (in a 12 volt system). A lower value could
indicate problems with the solar panel.

FIELD TEST PROCEDURE: SC1

Test equipment required: Digital Multimeter
Conditions: Sunny or bright overcast if possible

This procedure assumes that the solar panels are installed and operational and capable of
producing at least 17.5 volts open circuit (for a 12 volt system). Proportionately higher for higher
voltage systems. Systems should be equipped with disconnects or switches to facilitate
connecting and disconnecting the batteries and solar panel as described in this procedure. If
performing this procedure without approved disconnects, care should be taken since arcing may
occur. On bright days it may be advisable to partially cover the solar panel to reduce the current
produced.

Warning: Most batteries produce hydrogen gas when charging, which is extremely explosive.

Avoid making sparks in the vicinity of batteries and provide adequate battery ventilation.

All measurements described in this procedure should be made at the controller terminals.

1) Disconnect Load(+), Array(+), Battery(+), and Battery Sense(+)(jumper or wire) from the
controller. Secure each wire away from any possible contact with other wires, metal chassis,
enclosures etc.

2) Measure the resistance between the Battery(+) and Solar Panel(+) terminals on the controller.
It should be open (more than 10M ohm). Turn on load circuit breaker and measure the
resistance between Load(+) and Battery(+). It should be less than 1 ohm. Turn off load circuit
breaker and re-measure. It should be open.

3) Reconnect the solar panel to the controller. (On 36 volt or 48 volt chargers, briefly connect a
jumper wire between Solar Panel(+) and Battery(+). When the charge light comes on, remove
the jumper).The charge light should go on, and after a few moments the load disconnected
light should come on.

4) Measure the voltage between Solar Panel(+) and Solar Panel(-). It must be at least 17.5 volts
for a 12 volt system (proportionately higher for higher voltage systems).

5) Measure the voltage between Battery(+) and Battery(-). It should be the same as the voltage
measured in step 4.

6) Turn on load circuit breaker and measure the voltage between Load(+) and Load(-). It should
be zero.

7) For 12 volt or 24 volt chargers, go to step 8. For 36 volt or 48 volt chargers, install a jumper
wire between Battery(+) and Solar Panel(+) then go to step 8.

8) Install a jumper between Battery(+) and Battery Sense(+). The charge mode light should turn
off. Move the LVD switch to manual reset and observe that the load disconnected light turns
off. Note: A few seconds after the jumper is installed, the LVD will automatically reset. If this
happens before you test the manual reset, remove the jumper, wait for the light to come on,
reinstall the jumper and try the switch again.

9) For 12 volt and 24 volt controllers only; Measure the voltage between Battery(+) and Battery(­). It should be approximately equal to the float voltage. (Refer to the SPECIFICATIONS for
actual values. 10) If the controller fails any of these tests, it is defective. If all tests are passed,
the problem is most likely elsewhere in the system.

BENCH TEST PROCEDURE: SC1

Test equipment required: Digital Multimeter, Adjustable Power supply

Nominal Voltage Power Supply Range

12 10-18 Vdc
24 20-36 Vdc
36 30-48 Vdc
48 40-64 Vdc

All measurements described in this procedure should be made at the controller terminals.

1) Make sure that there is a jumper between Battery(+) and Battery Voltage Sense(+) and one
between Battery(-) and Battery Voltage Sense(-).

2) Check continuity between Battery(-),Solar Panel(-) and Load(-).

3) Turn off the load circuit breaker and measure the resistance between Load(+) and Battery(+).
It should be open (more than 10M ohm). Turn on the load circuit breaker and re-measure. It
should be less than 0.2 ohm.

4) Measure the resistance between Solar Panel(+) and Battery(+). It should be open.

5) Set the power supply to the nominal system voltage. Connect the power supply negative to the
controller Battery(-) terminal. Connect the power supply positive to the controller Solar
Panel(+) terminal. For 36 volt and 48 volt chargers, briefly connect a jumper between Solar
Panel(+) and Battery(+). When the charge mode light turns on, remove the jumper.

6) Verify that the charge mode light is on. Measure and note the voltage between Solar Panel(+)
and Solar Panel(-).

7) Measure the voltage between Battery(+) and Battery(-). It should be the same as the voltage
measured in step 6 to within +/- 0.1 volt. Measure the voltage between Load(+) and Load(-). It
should be the same as the voltage measured in step 6 to within +/- 0.1 volt.

8) Install a jumper between Battery(+) and Solar Panel(+).

9) Verify the charge termination and charge resumption set-points by changing the power supply
voltage up and down and observing the activation of the “CHARGE MODE” light.

10) Set the LVD switch to AUTO LVD. Verify the load disconnect and load reconnect set-points
by changing the power supply voltage up and down and observing the activation of the load
disconnected light. There is a time delay on the load disconnect circuit. The set-points must
be approached slowly to avoid overshooting. With the controller in the load disconnected
mode, press the MANUAL RESET and verify that the light goes off momentarily. Set the LVD
switch to NO LVD and verify that the load disconnect does not activate.

11) For 12 and 24 volt controllers only; remove the jumper between Battery(+) and Solar
Panel(+). Increase the power supply voltage to 18 volts for a 12 volt system or 36 volts for a
24 volt system. Measure the voltage between Battery(+) and Battery(-). It should be about the
float voltage.

LIMITED FIVE YEAR WARRANTY

SPECIALTY CONCEPTS, INC.

1. Specialty Concepts, Inc. warrants all its products for a period of five (5) years from the date of shipment from its factory. This

warranty is valid against defects in materials and workmanship for the five (5) year warranty period. It is not valid against
defects resulting from, but not limited to:

A. Misuse and/or abuse, neglect or accident.
B. Exceeding the unit's design limits.
C. Improper installation, including, but not limited to, improper environmental protection and improper hook-up.
D. Acts of God, including lightning, floods, earthquakes, fire and high winds.
E. Damage in handling, including damage encountered during shipment.

2. This warranty shall be considered void if the warranted product is in anyway opened or altered. The warranty will be void if any

eyelets, rivets, or other fasteners used to seal the unit are removed or altered, or if the unit's serial number is in any way
removed, altered, replaced, defaced or rendered illegible.

3. The five (5) year term of this warranty does not apply to equipment where another manufacturers' warranty is available. An

example of such equipment may be, but is not limited to, an electronic enclosure. The time limit for this warranty may be for
less than the Specialty Concepts limited warranty. Specialty Concepts will assist the claimant in attempts to seek warranty
claims for such equipment, where appropriate.

4. Specialty Concepts cannot assume responsibility for any damages to any system components used in conjunction with

Specialty Concepts products nor for claims for personal injury or property damage resulting from the use of Specialty
Concepts' products or the improper operation thereof or consequential damages arising from the products or use of the
products.

5. Specialty Concepts cannot guaranty compatibility of its products with other components used in conjunction with Specialty

Concepts products, including, but not limited to, solar modules, batteries, and system interconnects, and such loads as
inverters, transmitters, and other loads which produce "noise" or electromagnetic interference, in excess of the levels to which
Specialty Concepts products are compatible.

6. Warranty repair and/or evaluation will be provided only at Chatsworth, California facility of Specialty Concepts. Units for such

repair and/or evaluation must be returned freight prepaid to Specialty Concepts with a written description of any apparent
defects. Specialty Concepts will not be required at any time to visit the installation site wherein Specialty Concepts' products
are subject to warranty repair and/or evaluation.

7. Only Specialty Concepts is authorized to repair any of its products, and they reserve the right to repair or replace any unit

returned for warranty repair. The party returning a unit for repair is responsible for proper packaging and for shipping and
insurance charges, as well as any other charges encountered, in shipping to and from Specialty Concepts.

8. This warranty supersedes all other warranties and may only be modified by statement in writing, signed by Specialty

Concepts.

Warranty terms effective as of April 1, 1993

REPAIR INFORMATION

Directions for returning units needing repair.

1. Write up a note with the following information:
Name / Company Name
Return Address : (For USA/Canada: UPS Deliverable. Avoid PO Boxes)
Daytime Phone
Description the failure
Specify amount of repair charges preapproved (we will contact you if repair charges are larger than

this amount.)

2. Box up unit with copy of sales receipt (if available).

3. Send by UPS or Parcel Post to :

Specialty Concepts, Inc.
Attn : Repair Dept.
8954 Mason Ave
Chatsworth, CA 91311 USA

If the Repair is not covered under warranty, the repair charges will not exceed 30% of the value of a new unit. (shipping
and handling not included) Domestic charges are collected via UPS-COD.
For non-warranty repairs, repaired portion features an additional one-year warranty.

SPECIALTY CONCEPTS, INC.

8954 MASON AVE., CHATSWORTH, CA 91311 USA PH: [phone], FAX: [phone]