background image

LEGEND

3

2

SunSaver Solar Controller

Quick Start Guide

(+)

(–)

(+)

(–)

Solar Disconnect* 

(PV GFP required per 

NEC 690)

Photovoltaic (PV) Array

Battery / Battery Bank

Battery 

Disconnect*

DC Load 

Disconnect*

Power UP Sequence:

1. Connect

 

Battery/Battery

 

Bank.

2. Connect

 

Solar.

Power DOWN Sequence:

1. Disconnect

 

Solar.

2. Disconnect

 

Battery/Battery

 

Bank.

Mounting:

#2

Minimum Clearance Requirements:

CAUTION:  Equipment Damage

Do

 

not

 

expose

 

the

 

SunSaver

 

CC

 

to

 

weather.

  

Locate

 

in

 

a

 

dry,

 

protected

 

area

 

to

 

prevent

 

equipment

 

damage.

  

Ensure

 

the

 

minimum

 

clearance

 

requirements

 

are

 

followed

 

to

 

provide

 

adequate

 

ventilation

 

and

 

prevent

 

the

 

unit

 

from

 

overheating.

IMPORTANT: 

 

Example

 

only.

  

Actual

 

wiring

 

may

 

vary.

  

READ

 

the

 

SunSaver

 

Installation,

 

Operations,

 

and

 

Maintenance

 

Manual

 

for

 

mandatory

 

safety

 

requirements.

  

All

 

configuration

 

must

 

comply

 

with

 

local

 

and

 

national

 

electric

 

codes.

  

Consult

 

your

 

local

 

electric

 

authority

 

to

 

ensure

 

compliance.

 

Negative (–)

Positive (+)

Ground

See

 

the

 

Morningstar

 

PV

 

String

 

Calculator

 

at:

http://string

calculator.morningstarcorp.com/

Component

Load

 

Terminals

Wire

 

Size

 

(Solid)

#10

 

AWG

5.2

 

mm

2

 

(Maximum)

Tool

 

Required

3/16"(5

 

mm)

 

Flathead

 

Screwdriver

Battery

 

Terminals

 

WIRING AND TORQUE REQUIREMENTS

Torque

 

(Maximum)

10.6

 

in

lbs.

 

(1.2

 

Nm)

Solar

 

Terminals

Securing

 

hardware

 

not

 

shown.

WARNING:  Explosion Hazard

Never

 

install

 

the

 

SunSaver

 

in

 

an

 

enclosure

 

with

 

vented/

flooded

 

batteries.

  

Battery

 

fumes

 

are

 

flammable

 

and

 

will

 

corrode

 

and

 

destroy

 

the

 

SunSaver

 

circuits.

 

Ensure

 

sufficient

 

ventilation.

 

Step 1: Choose Mounting Location

Locate

 

the

 

SunSaver

 

on

 

a

 

vertical

 

surface

 

within

 

10

 

feet

 

(3

 

m)

 

of

 

the

 

battery

 

bank

 

that

 

is

 

protected

 

from

 

direct

 

sun,

 

high

 

temperatures,

 

and

 

water.

Step 2: Check for Clearance and Ventilation

Place

 

the

 

SunSaver

 

in

 

the

 

location

 

where

 

it

 

will

 

be

 

mounted.

 

Verify

 

that

 

there

 

is

 

sufficient

 

room

 

to

 

run

 

wires

 

and

 

that

 

there

 

is

 

ample

 

room

 

above

 

and

 

below

 

the

 

controller

 

for

 

air

 

flow.

Step 3: Mark Holes

Use

 

a

 

pencil

 

or

 

pen

 

to

 

mark

 

the

 

four

 

(4)

 

mounting

 

hole

 

locations

 

on

 

the

 

mounting

 

surface.

Step 4: Drill Holes

Remove

 

the

 

controller

 

and

 

drill

 

3/32”

 

(2.5

 

mm)

 

holes

 

in

 

the

 

marked

 

locations.

Step 5: Secure Controller

Place

 

the

 

controller

 

on

 

the

 

surface

 

and

 

align

 

the

 

mounting

 

holes

 

with

 

the

 

drilled

 

holes

 

in

 

step

 

4.

  

Secure

 

the

 

controller

 

in

 

place

 

using

 

the

 

Mounting

 

screws

 

(included).

3/32"

 

(2.5

 

mm)

Battery

 

(+)

Battery

 

(—)

2

Wire

 

Size

 

(multistrand)

#10

 

AWG

5.2

 

mm

2

 

(Maximum)

 

Wire

 

Size

(fine

 

strand)

#10

 

AWG

5.2

 

mm

2

 

(Maximum)

Recommended

 

Order

 

of

 

Installation

1
2
3

4

4

DC Load(s)*

Communications

Security

Lighting

Industrial

Residential

Primary

 

System

 

Ground

3

1

2"

 

(51

 

mm)

Fuses

 

or

 

Disconnects

*Fuse

 

or

 

breaker

 

sizing

 

must

 

be

 

based

 

on

 

required

 

wire

 

ampacity.

If

 

using

 

a

 

fuse,

 

do

 

NOT

 

insert

 

the

 

fuse

 

in

 

the

 

fuse

holder

 

until

 

after

 

all

 

the

other

 

connections

 

have

 

been

 

completed.

(+)

(–)

12

 

Vdc

 

Module

12

 

Vdc

 

Module

30

 

Voc

 

Max

 

@

 

12

 

V

 

battery

 

/

 

60

 

Voc

 

@

 

24

 

V

 

battery

Status

 

LED

Battery

 

SOC

 

LEDs

IMPORTANT:  

Array

 

Voltage

 

should

 

NEVER

 

exceed

 

the

 

maximum

 

input

 

voltage.

BATTERY STATE-OF-CHARGE (SOC) LED

Green

Green

Green

Green

Indication

Battery 

Status

SOC 

LED

Fast

 

Flashing

 

(2

 

Flash

 

/

 

sec)

Medium

 

Flashing

 

(1

 

Flash

 

/

 

sec)

Slow

 

Flashing

 

(1

 

Flash

 

/

 

2

 

sec)

ON

 

Solid

Equalize

 

Charge

Absorption

 

Charge

Float

 

Charge

Nearly

 

Full

Load 

Status

Load

 

ON

Load

 

ON

Load

 

ON

Load

 

ON

Yellow

Red

Red

ON

 

Solid

Flashing

 

(1

 

Flash

 

/

 

sec)

ON

 

Solid

Half

 

Full

Battery

 

Low

Battery

 

Empty

Load

 

ON

LVD

 

Warning

 

(Load

 

ON)

LVD

 

(Load

 

OFF)

WARNING:  Shock Hazard

Fuses,

 

circuit

 

breakers,

 

and

 

disconnect

 

switches

 

never

 

open

 

grounded

 

system

 

conductors

.

 

Only

 

GFDI

 

devices

 

are

 

permitted

 

to

 

disconnect

 

grounded

 

conductors.

WARNING:  Shock Hazard

Test

 

between

 

all

 

terminals

 

and

 

ground

 

before

 

touching.

Power

 

or

 

accessory

 

terminals

 

are

 

NOT

 

electrically

 

isolated

 

from

 

DC

 

input

 

and

 

may

 

be

 

energized

 

with

 

hazardous

 

solar

 

voltage.

  

IMPORTANT:  

Ensure

 

there

 

is

 

only

 

1

 

DC

 

Negative

to

Ground

 

Bond

 

in

 

the

 

entire

 

system.

4

2"

 

(51

 

mm)

STATUS LED

None

Green

Red

Red

Indication

Operating 

State

Color

OFF

 

(with

 

heartbeat

1

)

ON

 

Solid

 

(with

 

heartbeat

2

)

Flashing

ON

 

Solid

 

(with

 

heartbeat

2

)

Night

Charging

Error

Critical

 

Error

¹

 

heartbeat

 

indication

 

flickers

 

the

 

Status

 

LED

 

ON 

briefly

 

every

 

5

 

seconds

2

 

heartbeat

 

indication

 

flickers

 

the

 

Status

 

LED

 

OFF 

briefly

 

every

 

5

 

seconds

(12-volt or 24-volt*)

*SunSaver

 

Model

 

Dependent

4

WARNING:  Shock Hazard

The

 

solar

 

PV

 

array

 

can

 

produce

 

open

circuit

 

voltages

 

in

 

excess

 

of

 

40

 

Vdc

 

when

 

in

 

sunlight.

 

Verify

 

that

 

the

 

solar

 

input

 

breaker

 

or

 

disconnect

 

has

 

been

 

opened

 

(disconnected)

 

before

 

installing

 

the

 

system

 

wires.

None

No

 

LEDs

 

ON

Battery

 

Missing

Load

 

OFF

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