Morningstar SunSaver-10 User manual

Installation and Operation Manual

www.morningstarcorp.com

MORNINGSTAR

World’s Leading Solar Controllers &Inverters

SUNSAVER

PV SYSTEM CONTROLLERS

SEALED

FLOODED

SELECT

LOAD

BATTERY

SOLAR Remove

Jumper

Wire for

Flooded

Battery

{

12 V

BATTERY STATUSTEMP. SENSORCHARGING STATUS

See Operator’s

Manual

NominalRating

12Voltsdc

Max. Input 30 V

Solar 20.0A

Battery20.0A

Load 20.0A

Max. Ambient 65ºC

indooruse only

Use75 ºCCopper

ConductorsOnly

CONFORMSTO ISA12.12.01

CERTIFIEDTO CAN/CSASTD

C22.2 NO.213-1992

Class I, Division2

GroupsA,B,C,D

HazardousLoc.

Temp.Code: T5

RoHS

MORNINGSTAR

S S

20L

UN AVER-

SOLAR CONTROLLER SS-20L-12V

SunSaver Models Included in this Manual:

•SS-6-12V / SS-6L-12V

•SS-10-12V

•SS-10L-12V / SS-10L-24V

•SS-20L-12V / SS-20L-24V

MORNINGSTARCORPORATION 3

SunSaver Dimensions

Inches [Millimeters]

Specication Summary

Ratings SS-6/6L SS-10/10L SS-20L

System Voltage 12 V 12 or 24V 12 or 24V

Min. Battery Voltage 6 V 6 V 6 V

Max. Solar Voltage¹ 30 V 30 or 60V 30 or 60V

Max. Solar Current 6 .5 A 10 A 20 A

Max. Load Current 6 A 10 A 20 A



1. Array voltage should never exceed maximum input voltage. Refer to the

solar module documentation to determine the highest expected array Voc as

dened by the lowest expected ambient temperature for the system location.

CONTENTS

1.0 Safety Information 4

2.0 General Information 10

2.1 Overview 10

2.2 Features 11

2.3 Regulatory Information 12

3.0 Installation Instructions 15

3.1 General Installation Notes 15

3.2 User Selections 17

3.3 Mounting 20

3.4 Wiring 22

4.0 Operation 31

4.1 LED Indications 31

4.2 Battery Charging Information 33

4.3 Load Control Information 35

4.4 Protections 37

4.5 Inspection and Maintenance 39

5.0 Troubleshooting 40

5.1 Error Indications 40

5.2 Common Problems 41

6.0 Warranty and Claim Procedure 42

7.0 Technical Specications 44

MORNINGSTAR CORPORATION 5

1.0 SAFETY INFORMATION4

1.0

SAVE THESE INSTRUCTIONS.

This manual contains important safety, installation and operating

instructions for the SunSaver solar controller.

The following symbols are used throughout this manual to

indicate potentially dangerous conditions or mark important safety

instructions:

WARNING:

Indicates a potentially dangerous condition. Use

extreme caution when performing this task.

CAUTION:

Indicates a critical procedure for safe and proper

operation of the controller.

NOTE:

Indicates a procedure or function that is important for

the safe and proper operation of the controller.

Safety Information

• Read all of the instructions and cautions in the manual before

beginning installation.

• There are no user serviceable parts inside the SunSaver. Do

not disassemble or attempt to repair the controller.

• Disconnect all sources of power to the controller before

installing or adjusting the SunSaver.

• There are no fuses or disconnects inside the SunSaver. Do

not attempt to repair.

• Install external fuses/breakers as required.

WARNING:

These servicing instructions are for use by qualied

personnel only. To reduce the risk of electric shock,

do not perform any servicing other than that specied

in the operating instructions unless you are qualied

to do so.

WARNING:

EXPLOSION HAZARD - DO NOT DISCONNECT WHILE

CIRCUIT IS LIVE UNLESS AREA IS KNOWN TO BE NON-

HAZARDOUS.

CAUTION:

A BATTERY CAN PRESENT A RISK OF ELECTRICAL

SHOCK, BURN FROM HIGH SHORT-CIRCUIT

CURRENT, FIRE OR EXPLOSION FROM VENTED GASES.

OBSERVE PROPER PRECAUTIONS

CAUTION:

To reduce the risk of re, connect only to a circuit

provided with a maximum branch-circuit overcurrent

protection rating not to exceed the model current rating

on page 2 and in accordance with the National Electrical

Code, ANSI/NFPA 70.

CAUTION:

Unit has no battery removal protection.

Disconnecting battery during charging may cause a

brief spike in load voltage (above the 15V

regulation limit) which may damage sensitive equipment.

NOTE:

PROPER DISPOSAL OF BATTERIES IS REQUIRED.

REFER TO YOUR LOCAL CODES FOR DISPOSAL

REQUIREMENTS

.0 Important Safety Information 4

1.0 IMPORTANT SAFETY INSTRUCTIONS

MORNINGSTAR CORPORATION 7

1.0 SAFETY INFORMATION6

1.0

ATTENTION:

Pour diminuer le risque d’incendie, ne connectez

l’alimentation qu’à un circuit équipé d’une protection

maximum par dérivation contre les surintensités ne

dépassant pas le courant nominal du modèle de la

page 2, conformément à la norme du Code National de

l’Électricité (NEC), ANSI/NFPA 70.

ATTENTION:

Unité bénécie d’aucune protection de retrait de batterie.

Débrancher la batterie pendant la charge peut entraîner

un bref pic de tension de charge (au-dessus du 15V limite

de règlement) qui peuvent endommager les équipement

sensibles.

Installation Safety Precautions

WARNING:

This unit is not provided with a GFDI device. This

charge controller must be used with an external

GFDI device as required by the Article 690 of

the National Electrical Code for the installation

location.

• Mount the SunSaver indoors. Prevent exposure to the

elements and do not allow water to enter the controller.

• Install the SunSaver in a location that prevents casual

contact. The SunSaver heatsink can become very hot during

operation.

• Use insulated tools when working with batteries.

• Avoid wearing jewelry during installation.

• The battery bank must be comprised of batteries of same

type, make, and age.

• Do not smoke in the vicinity of the battery bank.

• Mount the controller at least 3 ft (1 m) away from vented

batteries unless separated by a barrier or located in a

separate compartment.

Informations de sécurité

• 

dans le manuel avant de commencer l’installation.

• Le SunSaver ne contient aucune pièce réparable par

l’utilisateur. Ne démontez pas ni ne tentez de réparer le

contrôleur.

• Déconnectez toutes les sources d’alimentation du contrôleur

avant d’installer ou de régler le SunSaver.

• Le SunSaver ne contient aucun fusible ou interrupteur. Ne

tentez pas de réparer.

• Installez des fusibles/coupe-circuits externes selon le besoin.

AVERTISSEMENT:

Ces instructions d’entretien sont exclusivement réservé-

es à des techniciens qualiés. Pour réduire le risque de

choc électrique, ne réalisez aucun entretien autre que

celui stipulé dans les instructions de fonctionnement, à

moins que vous ne possédiez les qualications néces-

saires en la matière.

ATTENTION:

UNE BATTERIE PEUT PRÉSENTER UN RISQUE ÉLEVÉ

DE CHOC ÉLECTRIQUE, DE BRÛLURES SUITE À UN

COURANT DE COURT-CIRCUIT ÉLEVÉ, À UN INCENDIE

OU À UNE EXPLOSION PROVENANT DE GAZ REJETÉS

DANS L’AIR. VEUILLEZ PRENDRE LES PRÉCAUTIONS

NÉCESSAIRES.

AVERTISSEMENT:

RISQUE D’EXPLOSION. NE PAS DEBRANCHER TANT

QUE LE CIRCUIT EST SOUS TENSION, A MOINS QU’lL

NE S’AGISSE D’UN EMPLACEMENT NON DANGEREUX.

1.0 SAFETY INFORMATION8 MORNINGSTAR CORPORATION

1.0

• Power connections must remain tight to avoid excessive

heating from a loose connection.

• Use properly sized conductors and circuit interrupters

• This charge controller is to be connected to DC circuits only.



Direct Current Symbol

Précautions de sécurité d’installation

AVERTISSEMENT:

L’appareil n’est pas fourni avec un dispositif GFDI.

Ce contrôleur de charge doit être utilisé avec un

dispositif GFDI externe tel que requis par l’Article

690 du Code électrique national de l’emplacement de

l’installation.

• Montez le SunSaver à l’intérieur. Empêchez l’exposition aux

éléments et la pénétration d’eau dans le contrôleur.

• Installez le SunSaver dans un endroit qui empêche le con-

tact occasionnel. Le dissipateur de chaleur SunSaver peut

devenir très chaude pendant le fonctionnement

• Utilisez des outils isolés pour travailler avec les batteries.

• Évitez le port de bijoux pendant l’installation.

• Le groupe de batteries doit être constitué de batteries du

même type, fabricant et âge.

• Ne fumez pas à proximité du groupe de batteries.

• Monter le régulateur au moins 3 pi (1 m) de batteries ventilés

sauf séparées par une barrière ou situé dans un comparti-

ment séparé.

• Les connexions d’alimentation doivent rester serrées pour

󰀨

• Utilisez des conducteurs et des coupe-circuits de dimensions

adaptées.

• Ce contrôleur de charge ne doit être connecté qu’à des cir-



par le symbole ci-dessous:

Symbole courant continu

MORNINGSTAR CORPORATION 11

2.1 Overview

Thank you for selecting the SunSaver solar charge

controller. The SunSaver is an advanced PWM solar battery

charger and load controller for stand-alone PV systems.

The SunSaver battery charging process has been

optimized for long battery life and improved system

performance. Self-diagnostics and electronic error protection

prevent damage when installation mistakes or system faults

occur.

Although the SunSaver is very simple to install and use,

please take the time to read this operator’s manual and

become familiar with the controller.

NOTE: Product photos are only intended for use in general

depiction, and for purposes of wiring illustration – refer to

manual addendums and website declarations of conformity

for exact certication listings.

2.2 Features

The features of the SunSaver are shown in Figure 1 below.

An explanation of each feature is provided.

SEALED

FLOODED

SELECT

LOAD

BATTERY

SOLAR Remove

Jumper

Wire for

Flooded

Battery

{

12 V

BATTERY STATUSTEMP. SENSORCHARGING STATUS

See Operator’s

Manual

Nominal Rating

12 Volts dc

Max. Input 30 V

Solar 6.5A

Battery 6.5 A

Load 10.0 A indoor use only

Use Copper

Conductors Only

CONFORMS TO UL STD 1604

CERTIFIED TO CAN/CSA STD

C22.2 NO.213-M1987

Class 1 Division 2

GroupsA,B,C,D

Hazardous Loc.

For the Risk of Explosion Only

Operating Temp. Code: T5

MORNINGSTAR

S S 6

UN AVER-

SOLAR CONTROLLER SS-6-12V

Figure 1. SunSaver features.

1 - Status LED

An LED indicator that shows charging status and also

indicates when a solar input fault condition exists.

2 - Power Terminal Block

Power terminations for system Solar, Battery, and Load

connections.

3 - Battery Select Jumper

A removable jumper to select the battery type.

4 - Local Temperature Sensor

Measures ambient temperature. Battery regulation is

adjusted based on ambient temperature changes.

2 .0

2.0 GENERAL INFORMATION

MORNINGSTAR CORPORATION 132.0 GENERAL INFORMATION12

5 - Battery Status LEDs

Provides approximate battery state-of-charge indication

and also indicates when a system or load fault condition

exists.

6 - Mounting Holes

Four (4) mounting holes

2.3 Regulatory Information

NOTE:

This section contains important information for safety

and regulatory requirements.



technician according to the electrical regulations of the

country in which the product will be installed.

SunSaver controllers comply with the following EMC

standards:

• Immunity: EN61000-6-2:1999

• Emissions: EN55022:1994 with A1 andA3 Class B1

• Safety: EN60335-1 and EN60335-2-29 (battery

chargers)

FCC REQUIREMENTS:

This device complies with Part 15 of the FCC rules.

Operation is subject to the following two conditions: (1)

This device may not cause harmful interference, and (2)

this device must accept any interference received, including

interference that may cause undesired operation.



Morningstar for compliance could void the user’s authority to

operate the equipment.

NOTE:

This equipment has been tested and found to comply

with the limits for a Class B digital device, pursuant to Part

15 of the FCC rules. These limits are designed to provide

reasonable protection against harmful interference in a

residential installation. This equipment generates, uses, and

can radiate radio frequency energy and, if not installed and

used in accordance with the instruction manual, may cause

harmful interference to radio communication. However,

there is no guarantee that interference will not occur in a

particular installation. If this equipment does cause harmful

interference to radio or television reception, which can be

󰀨

encouraged to try to correct the interference by one or more

of the following measures:

• Re-orient or relocate the receiving antenna.

• Increase the separation between the equipment and

receiver.

• Connect the equipment into an outlet on a circuit

󰀨

• Consult the dealer or an experienced radio/TV

technician for assistance.

2 .0

MORNINGSTARCORPORATION 15

2.0 GENERAL INFORMATION14

This Class B digital apparatus complies with Canadian

ICES-003.

Cet appareil numerique de la classe B est conforme a la

norme NMB-003 du Canada.

3.0 INSTALLATION INSTRUCTIONS

3.1 General Installation Notes

• Read through the entire installation section before

beginning installation.

• Be very careful when working with batteries. Wear

eye protection. Have fresh water available to wash

and clean any contact with battery acid.

• Use insulated tools and avoid placing metal objects

near the batteries.

• Explosive battery gases may be present during

󰀩

release the gases.

• Do not install in locations where water can enter the

controller.

• Loose power connections and/or corroded wires

may result in resistive connections that melt wire

insulation, burn surrounding materials, or even cause

re. Ensure tight connections and use cable clamps

to secure cables and prevent them from swaying in

mobile applications.

• The SunSaver charging algorithm is compatible with

lead-acid or NiCd batteries. NiMH, Li-ion, and other

battery chemistries are not compatible with the

SunSaver charging algorithm.

• The SunSaver Battery connection may be wired

to one battery or a bank of batteries. The following

instructions refer to a singular battery, but it is implied

that the battery connection can be made to either one

battery or a group of batteries in a battery bank.

3 .0

MORNINGSTAR CORPORATION 17

3.0 INSTALLATION16

Installation in Hazardous Locations

THIS EQUIPMENT IS ONLY SUITABLE FOR USE IN CLASS

I, DIVISION 2, GROUPS A,B,C and D OR NON-HAZARDOUS

LOCATIONS.

CAUTION:

For hazardous locations, device must be

installed inside an appropriately type rated tool secured

enclosure. Consult with local authority having jurisdiction for

type rating required.

ATTENTION:

Pour les endroits dangereux, le dispositif doit être

installé à l’intérieur un convenablement qualication de type

outil sécurisé enceinte. Consultez les autorités locales

compétentes pour la qualication de type requise.

3.2 User Selections

Select a Battery Type

The SunSaver provides a Battery Select Jumper to

choose the battery type. See Section 7.0 Technical

Specications for detailed charging information for each

battery type.

The battery select jumper is secured in the terminal block





should be removed or remain in place, depending on the

desired battery type.

Battery Type Battery Jumper Absorption Float Equalize

Sealed Inserted 14.10V 13.70V N/A

Flooded/

AGM1Removed 14.60V 13.70V 14.90V

1. Flooded/AGM absorption value effective with unit serial nos.  and higher

Table 1. Battery Type selection

Figure 2a. Removing the Battery Select jumper.

3 .0

MORNINGSTAR CORPORATION 19

3.0 INSTALLATION18

Choose Regulation Method (optional)

Choose between Pulse Width Modulation (PWM) charging

or Slow Switching charging. PWM charging is the default

regulation method and is the method recommended for most

systems.

Slow Switching regulation should only be selected if noise

or interference exists in the system due to PWM charging.

This regulation method limits the switching frequency to 10

Hz (maximum), which can eliminate noise issues in some

systems.

PWM charging is selected by default. To enable Slow

Switching regulation do the following:

1. Remove all four screws that secure the faceplate on

the SunSaver. See Figure 2b.

2. 󰀨

Occasionally, epoxy encapsulant will cause the

 

to separate the faceplate from the SunSaver body.

See Figure 2c.

3. A loop of wire protrudes from the epoxy. Cut the loop

with wire clippers to switch the regulation method to

Slow Switching. See Figure 2d.

4. Tape the cut ends with electrical tape to prevent

contact with the faceplate.

5. Replace the faceplate and secure with the four

screws.

Figure 2b. Remove faceplate screws.

Figure 2c. Remove faceplate.

CUT

Figure 2d. Cut the Regulation Select wire loop.

3 .0

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