sbc-6100 user manual..
Contents
1. be cut off When the battery voltage becomes higher than Low Voltage Reconnect LVR setting the controller will automatically reconnect the load again The following chart shows the night light mode selections LCD Display Explanation SUNSET NIGHT SUNRISE OFF OFF 2 HR ON 2 HOURS ON 4 HR ON 4 HOURS ON 6 HR ON 6 HOURS ON 8 HR ON 8 HOURS ON 10 HR ON 10 HOURS ON 3 OFF 1 3 OFF 1 4 OFF 2 4 OFF 2 6 OFF 2 6 OFF 2 DK DN Dusk to Dawn Table 5 DESCRIPTION OFF Load remain turned off X Hours On Load is turned on for X hours after sunset Y OFF Z Load is turned on after for Y hours after sunset turned off during the night then turned on again Z hours before sunrise Dusk to Dawn Load is turned on all night Measure Night Length The load timer options that turn the load on again before sunrise require that the PV charge controller to measure the length of the night The default value of night length is 12 hours after installation or disconnect then reconnect the battery The local length of night will take the moving average of 4 consecutive nights If the solar array is disconnected during service the controller will then record premature night duration This wrong night length data will be outdated after another 4 days of normal service Alternatively the above error can be corrected by disconnect then reconnect the battery Verify Night Light Mode selection To verify the night light2. mode selection During night light mode press the reset button once The green LED will flash once per second Count these LED flashes to confirm the correct selection P 7 Each of the 10 night light mode options has a unique number of flashes These are as follows Switch Setting of Flashes OFF 0 2 Hours On l 4 Hours On 2 6 Hours On 3 8 Hours On 4 10 Hours On 5 3 OFF 1 6 4 OFF 2 7 6 OFF 2 8 Dusk to Dawn 9 Table 6 Note Do not press the reset button when the LED is flashing during the verification 4 4 Temperature Sensor Optional When an external temperature sensor optional accessory is installed the controller will adjust the Bulk and Float Charge Voltage according to the temperature of the battery type The regulation setpoint is 25 C The Controller adjusts the BULK and FLOAT setpoints 0 03 V C Only the factory provided temperature sensor optional accessory can be used If no temperature sensor is installed the controller will set the temperature of the battery at 25 C p _ ded a ws z i om _ ui La S 5 g e ia Ko m E s p OHA a 5 Temperature Sensor Connection Terminal Stereo Jack Figure 4 4 5 Over Temperature Protection The operation temperature of the transistors of the PV Charge Controller is also continuously monitored If excessive temperature is detected the charge controller transistors will repeatedly and rapidly turn On and Off to reduce the charging ra
3. Green BAT V gt 12 6V Green BAT V Bulk Charging V BAT Full 0 Orange BAT V lt LVD V Load Cut Off WET TYPE BAT ONLY CO Red Gre Equalization Charging 12V DC Load rated current 8SA SBC 6108 12A SBC 6112 6120 P FUSE To AC Appliances 12V Battery Inverter Figure 2 Connection of PV Charge Controller CHARGING FLOATING CHARGE ABSORPTION CH 6 BULK 1 CHARGE PV Panel Open Circuit Voltage 17 23V Short Circuit Current 10A SBC 6108 14A SBC 6112 22A SBC 6120 This controller has Electronic Blocking feature therefore it is not necessary to connect a diode between the PV module and the Controller The recommended wire size is 12A WG SBC 6108 6112 10AWG SBC 6120 It is recommended that the PV Charge Controller should be installed in a dry sheltered location away from sources of high temperature and moisture 3 2 LED Indicator Battery Voltage is lower than 12 6V Battery Voltage has reached Low Voltage Disconnect LVD Battery Voltage is higher than 12 6V Battery Voltage has reached Bulk Charging Setting Fully Charged Battery Voltage is lower than Low Voltage Disconnect LVD Voltage Setting and load has been disconnected P 3 Table 1 LED Indications 3 3 Charging LED Indicator It shows 3 charging modes Bulk Absorption and Float Charge Charging LED Indicator Charging Status Fast Flashing Green Bulk Charg
4. ION CHARGING BECAUSE DIP SWITCH 2 IS AT ON POSITION Equalization Eq charging is only for wet type Lead Acid Battery When Auto Equalization Charging is set at ON mode Equalization charge will occur for 2 hours once every thirty days P 4 Use the dip switch to select equalization charging and night light mode as below AUTO Equalization Night Light Mode Dip Switch Settings Charging Dip switch 3 OFF Dip switch 2 ON Dip switch 1 OFF L Preset a Dp wich 2 ON Dip switch 2 ON Dip switch 1 OFF OFF ON Dip switch 3 OFF OFF Dip switch 2 OFF Dip switch 1 OFF Dip switch 3 ON ON Dip switch 2 OFF Dip switch 1 OFF Table 4 Dip Switch Functions 4 PV Charge Control Mode The SBC 6100 Series PV Charge Controller can operate in the several modes This includes the 3 stage Charge Control Equalization Charging Mode DC Load Control Mode NIGHT LIGHT mode Temperature Sensing and Over Temperature Protection features 4 1 3 Stage Charge Control The main function of charge controller is to regulate the flow of electricity from the photovoltaic panels to the batteries In PV systems with batteries the batteries must be protected from overcharging and be maintained at fully charged state The PV Charge Controller uses the Micro Processor and PWM Pulse Width Modulation to give optimal and safe charging It makes varying On Off pulses of electrical energy from the photovoltaic PV panel i
5. PV Charge Controller SBC 6108 6112 6120 User s Manual NOTE Please note that features 10 Night light mode see Section 4 3 are available for products manufactured after Oct 2004 PY CHARGE CONTROLLER Lighting 29 Sky a Programmer O BATTERY STATE y Y Ak oi 6 0 Red BAT V lt 12 6V Red BAT V LVD ONLY FOR 12V PV SYSYEM Green BAT V gt 12 6V E LOAD CHARGING O Green BAT V Bulk za FLOATING Charging V BAT Full CHARGE O Orange BAT V lt ABSORPTION LVD V Load Cut Off 9 CHARGE WET TYPE BAT ONLY X BULK Sua QOQOGS Equalization Charging EILIEIE ICI A A Table of Contents Precautions and Specifications 1 Introduction 4 PV Charge Control M Od E 4 1 3 Stage Charge OOM TO nmmiiinnininiininsininininnnnininnnnninnnn 4 2 Equalization Charging Mode Automatic or Manual 4 2 1 Automatic Equalization Charging 4 2 2 Manual Equalization Charging 4 3 12V DC Load Terminal Control Mode 4 3 3 Night Light Mode Programs 4 4 Temperature Sensor Optional BHF HNAAAAAAA AA inst Shh WW WN NWN Precautions 1 Before using the charge load controller read all the instructions and cautionary markings on the charge load controller the batteries and the photovoltaic panels 2 Do not attempt to repair the controller Incorrect re assembly may result in a risk of electric shock or fire 3 To reduce risk of electric shock disconnect all wiring before attempti
6. e Slow Flashing Green Absorb Charge Constant Green Float Charge LED off No Charging Table 2 Charging LED Indicator 3 4 The Dip Switch The dip switch are used to select the AUTO MANUAL equalization charging night light mode ON OFF selection and WET SEALED type Lead Acid battery selection amp L a Mia DIP Switch 1 2 amp 3 RESET button Figure 3 Temperature sensor Factory Preset The following table shows the factory preset values of the PV Charge Controller Bulk Voltage 14 3V Sealed type lead acid battery Float Voltage 13 5V Low Voltage Disconnect 11 5V Low Voltage Reconnect 12 5V Night Light Mode Option Off refer to section 4 3 3 table 5 Table 3 Preset values of the adjustable parameters 3 4 1 Bulk Voltage Setting for Sealed and Wet type Lead Acid Battery The bulk voltage of sealed gel type and wet type lead acid battery are different The preset Bulk Setpoint 14 3V is for typical Sealed Gel type Lead Acid Battery The Dip switch 1 is set to OFF position For typical Wet type Lead Acid Battery set the Dip switch to ON position The bulk voltage is 14 6V for Wet type Lead Acid battery 3 4 2 Select the Auto Equalization Charging and Night Light Mode The dip switch 3 1s for Night Light Mode switch 2 for Equalization Charging mode and switch l is always set at off position THE PV CHARGE CONTROLLER IS FACTORY PRESET FOR USE WITH SEAL TYPE BATTERY THAT IS NO AUTO EQUILIZAT
7. erminal Control Mode The 12V DC load terminal is designed for low power DC load such as street light It prevents over discharging the battery and has 10 Night Light timer programs 4 3 1 Low Voltage Disconnect LVD When the battery voltage is lower than the Low Voltage Disconnect LVD setting the LED will blink orange once every 2 seconds After it has flashed several times up to 5 the load will be cut off After the load is cut off user can press the Reset button once to switch on the load fora grace period of 10 minutes for emergency purpose 4 3 2 Low Voltage Reconnect LVR When the battery voltage is higher than Low Voltage Reconnect LVR setting the controller will automatically reconnect the load 4 3 3 NIGHT LIGHT Mode Programs In the night light mode we have 10 selections To Activate the NIGHT LIGHT Mode switch the dipswitch 3 to ON position Then use the lighting programmer to select one of the night light mode selections see Table 5 P 6 After activating when the PV panel voltage is lower than 3 5V for 10 minute the Controller will turn on the light for a preset period of time according to the option selected When the PV panel voltage is higher than 3 5V for 1Ominute the Controller will turn off the light In NIGHT LIGHT Mode press and hold the Reset button can switch on the Light to test the light Also when the battery is lower than the Low Voltage Disconnect LVD for 2 minutes the load will
8. n charging the battery according to the battery state It has 3 stages of charging as follows a BULK CHARGE At this mode a preset maximum constant amount of current amps is fed into the battery as no PWM 1s present As the battery 1s being charged up the voltage of the battery increases gradually b ABSORPTION CHARGE After the preset voltage is reached approximately 14 3 volts for a 12 volt system the voltage is then held constant As the battery continues to be charged at constant voltage the charging current decreases The charging voltage is held at the Bulk Voltage Setting for one full hour with various rapid On Off pulses PWM It then switches to Float Charge Mode c FLOAT CHARGE The controller will maintain the battery voltage at the float voltage setting by giving shorter On pulse charge to make up for any detected self discharge of the battery When the battery voltage drops below the Float Voltage Setting for a total period of 10 minutes a new charging cycle is activated in Bulk or Absorption Charge PS The three stages charging method works well with the chemical reaction that occurs as a battery is being charged When a battery is more discharged a regulated maximum current can be applied since there is a lot of material available for the reactions to occur As the battery refills less and less chemical material is available for the reaction By using PWM to slowly reducing the charge current while maintai
9. ng any maintenance or cleaning Turning off controls will not reduce this risk PV panels produce power when exposed to light cover them with opaque material before servicing 4 Working in Vicinity of a Lead Acid Battery is dangerous Batteries generate EXPLOSIVE gases during normal operation Provide ventilation to outdoors from the highest point of the battery compartment 5 This charge load controller is intended to be used with a battery supply of 12 VDC nominal voltage 6 Be extra cautious to reduce the possibility of dropping a metal tool onto batteries It might spark or short circuit batteries or other electrical parts that may cause explosion Cover wrench handles with plastic tape or vinyl dip coating material Specifications SBC 6100 Series Models 6108 6112 6120 Battery voltage 12V Maximum PV panel open circuit voltage 26V Continuous load charge current 12A Maximum charge current 5 mins Maximum load current 5 mins Operation current no Load and no PV Voltage across terminals PV to Battery Voltage across terminals Battery to Load Electronic Blocking To protect against reverse polarity connection of PV panel and to block current from battery to PV panel when voltage of battery is higher than PV panel Battery reverse polarity protection Overcharge amp Over discharge protection i avel a Battery status LED indication 5 State LED Indications Charging status indication 3 State LED Indications Rec
10. ning a preset high voltage the battery is more closely refilled at the reaction rate of the chemicals Finally the Float voltage keeps the battery fully charged at all times taking care of the self discharge 4 2 Equalization Charging Mode Automatic or Manual WARNING Equalization Charging is only for Wet type Lead Acid Battery The Equalization Charging Voltage is factory pre set to the Bulk Voltage 1 Volt The battery manufacturer should be consulted Clean distilled water will need to be added to the battery AFTER the equalization process 4 2 1 Automatic Equalization Charging Automatic Equalization charge is only available when battery voltage is higher than the Low Voltage Disconnect LVD voltage see 4 3 1 To set Automatic Equalization Charging set the dip switch 2 to OFF position The PV Charge Controller will perform Equalization charging for 2 hours once every 30 days During equalization charge it can be stopped any time by pressing the Reset button once and the controller will return to the charging mode before the Equalization charge 4 2 2 Manual Equalization Charging Set the Night Light Mode dip switch 3 to off position Press and hold the Reset button for 10seconds and the equalization charge will go on for two hour During equalization charge it can be stopped any time by pressing the Reset button once and the controller will return to the charging mode before the Equalization charge 4 3 12V DC Load T
11. ommended wire size 12AWG Weight 0 44 kg Dimension WxDxH 150 x 85 x 45 mm Fuse 15A 20A Operating ambient temperature 10 to 50 C Over temperature protection Battery charging float voltage setting Factory Preset 13 5V i P Battery charging bulk voltage setting Factory Preset 14 3V DC load control mode For DC load terminal Low Voltage Disconnect LVD Factory Preset 11 5V Low Voltage Reconnect LVR Factory Preset 12 5V P 1 i Introduction The SBC 6108 6112 6120 PV Charge Controller is designed for use with all types of 12V photovoltaic PV panels systems and different types of 12V batteries such as wet or sealed lead acid lead calcium lead antimony battery Numerous features are provided to maximize the performance of the system eee Se a T Electronic Blocking To protect against reverse polarity connection of PV panel and block current from battery to PV Panel when voltage of Battery is higher than PV panel Suitable for PV panels with Open Circuit Voltage from 17 to 23V Rated charging load current 8A SBC 6108 12A SBC 6112 20A SBC 6120 PWM Charging Build In Microprocessor for PV charge control to maximize the charging efficiency Overcharge and Over discharge Protection 3 stage Charge Control Bulk Absorption amp Float to allow battery be left unattended for long period Over Temperature Protection Night Light Mode 10 selections Short Circuit Protection at load terminal am
12. p Battery Reverse Polarity Protection at Battery Connection Terminal Tri Color LED indication of system and battery conditions Optional Temperature Sensor for compensated battery charging Optional Remote Signal Terminal Control and Indicator The following diagram shows the hardware interface of the PV Charge Controller PY CHARGE CONTROLLER m 4 Lighting ie sce a Programmer BATTERY STATE E v i os Red BAT V lt 12 6V Red BAT V LVD ONLY FOR 12V PV SYSYEM Green BAT V gt 12 6V aot LOAD CHARGING 0 Green BAT V Bulk z Charging V BAT Full Aee se Orange BAT V lt E O ABSORPTION LVD V Load Cut off s CHARGE WET TYPE BAT ONLY Ot BULK CO Red Gre CHARGE Equalization Charging ee ee E E Figure 1 Front view of PV Charge Controller Battery LED Indicator Lighting Programmer Night Light Mode Selections Charging LED Indicator Reset button see Section 3 4 Temperature Sensor Optional 12V DC Load terminal with Low Voltage Disconnect NIGHT LIGHT mode Section 4 3 12V Battery connection terminal PV Panel connection terminal Remote Signal Terminal Optional P 2 3 Installation and Indication 3 1 Connection The PV Charge Controller should be connected as follow PY CHARGE CONTROLLER O BATTERY STATE e O A Lighting 29 as 4 Programmer fle j ONLY FOR 12V PV SYSYEM E LOAD O Red BAT V lt 12 6V Red BAT V LVD
13. rol of Equipment Connected to Battery 87654321 Remote RJ 45 Remote Signal Terminal Figure 8 Connection diagram of RJ 45 to Equipments On Off Control Signal synchronized with Night light Mode High Low control signal 12V OV up to 1A synchronized with Night Light mode Shows the battery status Red LED See Section 3 2 Shows the battery status Green LED See Section 3 2 Table 7 Pins configuration Note Pin 3 and 5 are not used in Remote Signal Terminal Rev 1 0 11 2004 7673 6112 0562 END
14. te so as to reduce the transistors temperature In case the charging current from the solar panel is reduced to zero and over temperature condition still persists the load will also be disconnected When the temperature has dropped to the working range the PV panel and the load will be connected again 5 Remote Signal Terminal Optional The PV controller has a remote signal output terminal Optional which can 1 control the ON OFF operation of equipment such as inverter hooked up to the battery bank to operate along with the night light mode program and share the safeguard function such as low battery disconnect and reconnect 2 make extension connection of the battery status LED to allow remote monitoring Battery bank status see Section 3 2 P 8 Activate the feature Please follow the steps below 1 Open the case of the controller there should be a small control board near the Remote Signal Terminal as shown in figure 5 Figure 5 2 On the small control board there is a sky blue color dip switch Turn the dip switch 1 and 2 to ON position as shown in figure 6 FHL A 7 Ti in ee 4541 7112 2012 3 REU O my CONS i nas i 7 CON4 A E MASSUSE i a f40 3 005 1ZS Figure 6 Connection Use the RJ 45 connector 8 pin to make extension of Battery status LED and control ON OFF of the Equipments The pins configuration and connection are as follow RJ 45 PIN PIN Remote ON OFF Cont
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