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SOLAR BOOST™ 3048

30A 24/48V MAXIMUM POWER POINT TRACKING

PHOTOVOLTAIC CHARGE CONTROLLER

INSTALLATION AND OPERATION

MANUAL

THIS MANUAL INCLUDES IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

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Содержание SOLAR BOOST 3048

Страница 1: ...ER POINT TRACKING PHOTOVOLTAIC CHARGE CONTROLLER INSTALLATION AND OPERATION MANUAL THIS MANUAL INCLUDES IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS COVERED UNDER US PATENTS 6 111 391 6 204 645 RV Power Products Inc 2001 430 0013 B ...

Страница 2: ...l System Voltage 11 Charge Mode 11 Float Transition Current Measurement Shunt 11 Float Transition Current Setpoint 12 Maximum Power Voltage 12 Optimizing MPPT 13 Temperature Compensation 13 Acceptance Charge Voltage 13 Float Charge Voltage 13 Solar Boost 3048 Installation 14 Battery and PV Wiring 15 Optional Battery Temperature Sensor 15 Optional External Current Shunt 16 Optional Digital Display ...

Страница 3: ... a spark or flame in vicinity of battery f Be extra cautious to reduce risk of dropping metal tool onto battery It might spark or short circuit battery or other electrical part that may cause explosion g Remove personal metal items such as rings bracelets necklaces and watches when working with a lead acid battery A lead acid battery can produce a short circuit current high enough to weld a ring o...

Страница 4: ...tage control system and continually turning on and off as with other PV controllers They simply turn on in the morning and off in the evening and in this application have a life expectancy in excess of 10 5 operations Since Solar Boost 3048 is a high efficiency series pass buck type power converter with current limit the battery can be charged from any power source with a voltage greater than the ...

Страница 5: ...t systems or 36 volts in 48 volt systems is required for Solar Boost 3048 to operate OPTIONAL DIGITAL DISPLAY An optional digital display is available to monitor PV charge performance The display is available in the Solar Boost 3048 controller chassis and as a remotely mounted panel Both the chassis display and the remote display may be installed and used simultaneously The digital display can be ...

Страница 6: ... In the bulk stage the battery is typically at a low state of charge of less than 70 full Bulk charge is initiated when 1 Charge current during acceptance or float increases above the Float Transition Current or 2 Insufficient power is available from the PV array to hold the battery at the desired acceptance or float voltage Maximum available charge current during bulk varies with the number and s...

Страница 7: ...the battery Note that the three stage charge technique matched to battery size type and temperature provided by Solar Boost 3048 minimizes the need for equalization as the battery is properly and fully charged on each cycle A proper equalization cycle is a substantial over charging of the battery at relatively high voltages with significant battery gassing Solar Boost 3048 features a manually oper...

Страница 8: ...s are such that sufficient PV voltage and current are not available to produce an increase in output current Solar Boost 3048 will operate as a high performance series pass PWM controller Current boost performance can be easily monitored using the digital display Whenever output charge current is greater than solar panel current current boost is functioning A minimum PV current of just under two a...

Страница 9: ...ng delivered at 24 volts would produce a current of 6 25 amps A charge current increase of 1 8 amps or 40 is achieved by converting the 44 watts that would have been wasted into useable charge current Note that this example assumes 100 efficiency to illustrate the principal of operation In actual operation boost will be somewhat less as some available power is lost in wiring connections and in Sol...

Страница 10: ...sed circuits may be damaged by electrostatic discharge during installation and handling Discharge yourself by touching a water faucet or other electrical ground prior to handling the unit and avoid touching components on the circuit boards Keep the Digital Display in it s electrostatic protective bag until it is installed All electronic circuits may be damaged by static electricity and these instr...

Страница 11: ...ompensation Disabled Float transition current measurement Internal shunt measuring output charge current Float transition current 5 0A Charge mode Three stage Acceptance voltage 57 2V Float voltage 53 2V MPPT operating point VOC VMP 4 4V single 36 cell module SETUP AND WIRING DIAGRAM Figure 3 ...

Страница 12: ...o stage charge equalization still operates as described SWITCH 10 SWITCH 11 CHARGE MODE ON OFF THREE STAGE BULK ACCEPTANCE FLOAT OFF OFF TWO STAGE BULK ACCEPTANCE ON ON TWO STAGE BULK FLOAT Float Transition Current Measurement Shunt Solar Boost 3048 measures charge current during acceptance to determine when the battery is fully charged A lead acid battery is considered fully charged when charge c...

Страница 13: ...S 500 500A 50mV 0 01V PER AMP 400 AMP When using the internal shunt measuring Output Charge Current the Float Current potentiometer is also set for a voltage on the I Float relative to Com test point of 0 1V per amp of desired Float Transition Current However if battery load is a constant 10 amps add 10 amps to the setting For example if the battery capacity is 500 amp hours requiring a Float Tran...

Страница 14: ...ut current if temperature compensation is enabled with the SensorLug connection open not installed or if the SensorLug is shorted or installed reverse polarity SWITCH 6 SWITCH 7 24V CURVE 48V CURVE TEMPERATURE COMPENSATION OFF OFF N A N A DISABLED ON ON 60mV ºC 12 cells 120mV ºC 24 cells ENABLED LEAD ACID ON OFF 40mV ºC 20 cells 80mV ºC 40 cells ENABLED NiCd Acceptance Charge Voltage The factory s...

Страница 15: ... reduce average output power to prevent damage due to over temperature A variety of conduit knockouts are provided for wiring Figure 3 identifies field connections and connection locations Figure 4 provides a detailed dimensional drawing For best thermal performance and reliability mount the controller to a vertical surface free of air flow restrictions Orient the heatsink fins vertically to promo...

Страница 16: ...sizes will improve boost performance whereas smaller wire sizes will reduce boost performance When considering wiring fuse and connection options think big and short as larger heavier components and shorter wire lengths offer less resistance and voltage drop Note that the lengths shown in Table 3 are for a total PV short circuit current of 24 amps If current is halved length can be doubled If the ...

Страница 17: ... suitable for lengths up to 40ft 12 2m Longer lengths should use standard Category 5 computer network cable wired pin to pin with no swap Typical Category 5 unshielded twisted pair UTP cable wiring used for the remote display is shown in Figure 5 With a Category 5 UTP cable up to 300ft 91 4m of cable may be used Longer lengths are possible and can be evaluated on an individual basis The remote dis...

Страница 18: ...e separate for proper operation PV must receive earth ground via shunts inside the SB3048 which internally connect PV to BAT External connection prevents proper operation of internal shunts and measurement system Charge status LED on in Bulk but no output charge current Dip switches set for incorrect system voltage Temp sensor installed reverse polarity or sensor failed short Double check dip swit...

Страница 19: ...ot available from PV array It is normal for boost to decrease as temperature rises Verify dip switch 5 verify proper MPPT setup and MPPT trim See Maximum Power Voltage and Optimizing MPPT sections System appears OK but will not correctly switch between Accept Float Not set for 3 stage charge System will not switch out of Bulk and into Acceptance or Float System will not switch from Float to Accept...

Страница 20: ...d is not extended to any other party 2 The limited warranty period commences on the date the product is sold to original consumer purchaser 3 This limited warranty does not apply to any product or part thereof damaged by a alteration or disassembly b repair or service not rendered by an RVPP authorized repair facility c accident or abuse d corrosion or e operation or installation contrary to instr...

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