Product Manual
Contents
1. The GP PWM 30 should be e Mounted as close to the battery as possible e Mounted on a vertical surface to optimize cooling of the unit e Indoors protected from the weather In a RV the most common controller location is above the refrigerator The wire from the solar array most commonly enters the RV through the fridge vent on the roof PV connections should connect directly to the controller Positive and negative battery connections must connect directly from the controller to the batteries Use of a positive or negative distribution bus is allowed between the controller and battery as long as it is properly sized electrically safe and an adequate wire size is maintained 7 2013 Carmanah Technologies Corporation GP PWM 30 E MAXIMUM POWER BOOST TECHNOLOGY 5 0 Installation Instructions L Prepare for mounting Use the template provided at the end of the manual to mark the four mounting holes and the cutting line for flush mounting Complete the installation of the solar modules If this GP PWM 30 was purchased as part of a Go Power Solar Power Kit follow the Installation Guide provided Otherwise follow manufacturer s instructions for solar module mounting and wiring Select wire type and gauge If this GP PWM 30 was purchased as part of a Go Power Solar Power Kit appropriate wire type gauge and length is provided Please continue to Section 6 Operating Instructions If the GP PWM 30 was pur2. Solar Controller GP PWM 30 MAXIMUM POWER BOOST TECHNOLOGY Go Power e carmanah Owner s Manual MAXIMUM POWER BOOST TECHNOLOGY gt camanan gqpelectric com 4 O 2013 Carmanah Technologies Corporation GP PWM 30 E MAXIMUM POWER BOOST TECHNOLOGY 2 2013 Carmanah Technologies Corporation GP PWM 30 E MAXIMUM POWER BOOST TECHNOLOGY CONTENTS 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 10 0 11 0 Installation Overview 1 1 Introduction 1 2 Specifications Warnings Tools and Materials Needed Choosing a Location Installation Instructions Operating Instructions Frequently Asked Questions FAQs Troubleshooting 8 1 Problems with the Display 8 2 Problems with Voltage 8 3 Problems with Current Limited Warranty 9 1 Repair and Return Information Installation Template Wiring Diagram 10 16 17 17 18 18 20 20 20 211 3 2013 Carmanah Technologies Corporation GP PWM 30 E MAXIMUM POWER BOOST TECHNOLOGY 1 0 Installation Overview 1 1 Introduction A Solar Controller or Charge Controller Regulator is an essential component of your photovoltaic solar system The Controller maintains the life of the battery by protecting it from overcharging When your battery has reached a 100 state of charge the Controller prevents overcharging by limiting the current flowing into the batteries from your solar
3. array The GP PWM 30 is a 12 volt flush mounted photovoltaic PV charge controller rated for a continuous solar current input of 30 amps The GP PWM 30 uses Pulse Width Modulation PWM technology and a unique four stage charging system that includes an optional equalize setting to charge and protect your battery bank The GP PWM 30 features an LCD digital display that shows solar array charge current system battery voltage and battery capacity The GP PWM 30 also features Maximum Power Boost Technology for manual bulk charge at any stage of the charge cycle 4 2013 Carmanah Technologies Corporation GP PWM 30 E MAXIMUM POWER BOOST TECHNOLOGY 1 2 Specifications Description Value Nominal System Voltage 12V Max Solar Array Current 30 amps Battery Voltage Range 6V 15 5V Max Solar Voltage 28V Operating Consumption 6mA Display Consumption 10mA Bulk Absorption Voltage 14 1 14 4V 25 C 77 F 1 2h Day Float Voltage 13 7 25 C 77 F Equalization Voltage 14 8V 259C 77 F 2h 28 Day or V lt 12 1 Temperature Compensation 4mV cell K Operating Temperature 40 to 85 C 40 to 1859F Display Operating 20t05590 4to 1319F Temperature Humidity 99 N C Protection Battery Reverse Polarity Solar Array Reverse Polarity Over Temperature PV Short Circuit Over Current The total rated Maximum Power Current Imp of the PV
4. MPBT is designed to be used before the end of the day if you Know you will require a lot of loads through the night The MPBT feature can also be used when you have just installed the solar controller to put batteries on a boost charge up to 14 4 right away IMPORTANT Do not use the Maximum Power Boost function more than twice a day Max Power Boost To activate the Maximum Power Boost Technology hold the A Button for 5 seconds to put Controller into Max Power Boost As long as there is full sunlight present your batteries flooded only will be boosted to 14 4V for 30 minutes Icons Displayed 4 dois at bottom right of display 12 O 2013 Carmanah Technologies Corporation GP PWM 30 E MAXIMUM POWER BOOST TECHNOLOGY Battery Charge Profile Chart Battery Type FLOODED AGM GEL Float Charge 25 C 13 7V 0 1V Bulk Absorption Charge 25 C men 14 4V 4 0 1V OAV Applied for 1h each morning 0 1V Boost Charge 14 1V Applied for 2 hours if the battery voltage drops 14 44 0 74 0 1 V below 12 3 volts Equalization Charge 14 8V Applied for 2 hours every 28 days and if the 0 1V N A N A battery voltage drops below 12 1 volts The Boost Charge will occur in addition to the Bulk Charge The Equalization Charge will occur in addition to the Boost Charge If a charging cycle is unable to complete in a single day it will continue the following day The terms FLOODED AGM an
5. N O MS O Go Power powered by ce carmanah 2012 GO POWER By Carmanah Technologies MOBI MAN GP PWM 30 vD gelectric com
6. V the controller will stop operating and the display will begin to flash The controller will resume operating when the error is cleared E MAXIMUM Icons Displayed Battery Volt Symbol Lightning Bolt Low Voltage If the GP PWM 30 experiences the battery state of charge reaching O a lightning bolt symbol will begin to flash in the lower right corner of the display The controller will continue operating The controller will only stop operating if the voltage drops below 6 volts MAXIMUM Icons Displayed Battery Percent Symbol Lightning Bolt 15 2013 Carmanah Technologies Corporation GP PWM 30 E MAXIMUM POWER BOOST TECHNOLOGY 7 0 Frequently Asked Questions FAQs Before a problem is suspected with the system read this section There are numerous events that may appear as problems but are in fact perfectly normal Please visit gpelectric com for the most up to date FAQs It seems like my flooded batteries are losing water over time Flooded batteries may need to have distilled water added periodically to replace fluid loss during charging Excessive water loss during a short period of time indicates the possibility of overcharging or aging batteries When charging my flooded batteries are emitting gas During charging hydrogen gas is generated within the battery The gas bubbles stir the battery acid allowing it to receive a more full state of charge Ensure they are in a well ventilat
7. an one solar module you will need to conduct this test between the positive and negative terminals of each module junction box with either the positive or negative wires disconnected from the terminal Remedy 2 Reconnect in correct configuration Tighten all connections Check wire gauge and length of wire run Refer to Suggested Minimum Wire Gauge in Section 5 3 Clean modules clear obstruction or wait for conditions to clear 4 If the open circuit voltage of a non connected 12 volt module is lower than the manufacturer s specifications the module may be faulty Check for blown diodes in the solar module junction box which may be shorting the power output of module 19 2013 Carmanah Technologies Corporation GP PWM 30 E MAXIMUM POWER BOOST TECHNOLOGY 9 0 Limited Warranty 1 Carmanah warrants the GP PWM 30 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 e Misuse and or abuse neglect or accident e Exceeding the unit s design limits e Improper installation including but not limited to improper environmental protection and improper hook up e Acts of God including lightning floods earthquakes fire and high winds e Damage in handling including damage encountered during shipment 2 This warranty sha
8. ation Section are followed Even if it appears the system is not functioning it should be treated as a fully functioning system generating live power 8 1 Problems with the Display Display Reading Blank Time of Day Daytime Nighttime Possible Cause 1 Battery or fuse connection and or solar array connection Daytime only 2 Battery or fuse connection Nighttime only How to tell 1 amp 2 Check the voltage at the controller battery terminals with a voltmeter and compare with a voltage reading at the battery terminals If there is no voltage reading at the controller battery terminals the problem is in the wiring between the battery and the controller If the battery voltage is lower than 6 volts the controller will not function For the solar array repeat steps 1 and 2 substituting all battery terminals with solar array terminals Remedy 1 amp 2 Check all connections from the controller to the battery including checking for correct wire polarity Check that all connections are clean tight and secure Ensure the battery voltage is above 6 volts 17 2013 Carmanah Technologies Corporation GP PWM 30 E MAXIMUM POWER BOOST TECHNOLOGY 8 2 Problems with Voltage Voltage Reading Inaccurate Time of Day Daytime Nighttime Possible Cause 1 Excessive voltage drop from batteries to controller due to loose connections small wire gauge or both How to tell 1 Check the voltage at the cont
9. chased separately follow the instructions included here Wire type is recommended to be a stranded aluminium UV resistant wire Wire fatigue and the likelihood of a loose connection are greatly reduced in stranded wire compared to solid wire Wire gauge should be able to sustain rated current as well as minimizing voltage drop Suggested Minimum Wire Gauge Cable length 25 ft max from solar array to battery bank 50 Watt 14 Wire Gauge 80 Watt 12 Wire Gauge 95 Watt 10 Wire Gauge 110 Watt 10 Wire Gauge 125 Watt 10 Wire Gauge 160 Watt 10 Wire Gauge 240 Watt 10 Wire Gauge Terminal Screw Torgue 16 inch pounds 1 8N m IMPORTANT Identify the polarity positive and negative on the cable used for the battery and solar module Use colored wires or mark the wire ends with tags Although the GP PWM 30 is protected a reverse polarity contact may damage the unit 8 O 2013 Carmanah Technologies Corporation GP PWM 30 E MAXIMUM POWER BOOST TECHNOLOGY 4 Wiring the GP PWM 30 Wire the GP PWM 30 according to the wiring schematic in Section 11 Run wires from the solar array and the batteries to the location of the GP PWM 30 Keep the solar array covered with an opaque material until all wiring is completed 5 Torque all terminal screws to 16 inch pounds 1 8N m Connect the battery wiring to the controller first and then connect the battery wiring to the battery IMPORTANT Always use appropriate circuit protection on an
10. cking for correct wire polarity Check that all connections are clean tight and secure Continue with the solutions below for additional help on low current readings 18 O 2013 Carmanah Technologies Corporation GP PWM 30 E MAXIMUM POWER BOOST TECHNOLOGY Current Reading Less than expected Time of Day Daytime clear sunny skies Possible Cause 1 Current is being limited below 1 Amp as per normal operation 2 Incorrect series parallel configuration and or wiring connections and or wire gauge 3 Dirty or shaded module or lack of sun 4 Blown diode in solar module when two or more modules are connected in parallel How to tell 1 Battery State of Charge screen is close to 100 and the Sun and Battery icon are present with an arrow in between 2 Check that the modules and batteries are configured correctly Check all wiring connections 3 Modules look dirty overhead object is shading modules or it is an overcast day in which a shadow cannot be cast Note Avoid any shading no matter how small An object as small as a broomstick held across the solar module may cause the power output to be cut to almost nil Overcast days may also cut the power output of the module to almost nil 4 Disconnect one or both array wires from the controller Take a voltage reading between the positive and negative array wire A single 12 volt module should have an open circuit voltage between 17 and 22 volts If you have more th
11. d GEL are generic battery designations Choose the charging profile that works best with your battery manufacturer s recommendations Auto Equalize The GP PWM 30 has an automatic equalize feature that will charge and recondition your batteries once a month at a higher voltage to ensure that any excess sulfation is removed This feature is recommended for Flooded batteries only Check with your battery manufacturer IMPORTANT This feature is only available for wet cell or flooded batteries Charging Profile 1 13 2013 Carmanah Technologies Corporation GP PWM 30 E MAXIMUM POWER BOOST TECHNOLOGY Viewing the Controller display information To toggle between State of Charge SOC Battery Voltage and PV Charging Current press the B Button The battery state of charge is shown as a percentage SOC oe MAXIMUM on Ka Icons Displayed Baitery Percent Symbol Push the B Button to show the battery voltage a MAXIMUM FORTE RO TRES Icons Displayed Battery Volt Symbol V Push the B Button to show the PV charging current The GP PWM 30 will begin to limit the current as the battery reaches a full charge i ss MAXIMUM on POE NALA KSA a A Icons Displayed Sun Battery Current Symbol A 14 2013 Carmanah Technologies Corporation GP PWM 30 E MAXIMUM POWER BOOST TECHNOLOGY Errors Over Voltage If the GP PWM 30 experiences a battery over voltage 15 5
12. ed space My voltmeter shows a different reading than the GP PWM 30 display The meter value on the GP PWM 30 display is an approximate reading intended for indication purposes only There is an approximate 0 1 volt inherent error present that may be accentuated when compared with readings from another voltmeter There may be a slight difference between the battery voltage displayed on the GP PWM 30 display and the battery voltage measured at the battery terminals When troubleshooting using a voltmeter check both the battery voltage at the GP PWM 30 controller terminals and battery voltage at the battery terminals If a difference of more than 0 5 volts is noted this indicates a large voltage drop possibly caused by loose connections long wire runs small wire gauge faulty wiring a faulty voltmeter or all the above Consult the Suggested Minimum Wire Gauge chart in Section 5 for wiring suggestions and check all connections 16 2013 Carmanah Technologies Corporation GP PWM 30 E MAXIMUM POWER BOOST TECHNOLOGY 8 0 Troubleshooting Problems How to read this section Troubleshooting Problems is split into three sub sections grouped by symptoms involving key components Components considered irrelevant in a diagnosis are denoted Not Applicable N A A multimeter or voltmeter may be required for some procedures listed It is imperative all electrical precautions stated in the Warning Section and outlined in the Install
13. input should not exceed 30 Amps The GP PWM 30 will limit PV current above 30 Amps Although the GP PWM 30 will accept PV current greater than 30 Amps for a short duration damage may occur if the GP PWM 30 operates continuously with greater than 30 Amps of PV input Dimensions H x W x D 107 x 190 x 35 mm 4 25 x 7 5 x 1 38 in Weight 172 grams 6 oz Maximum Wire Gauge 6 AWG Warranty 5 years e PWM Charging e 3 Battery Charging profiles e 4 Stage Charging e Monthly Equalize option e Displays Charging Current Battery Voltage and Battery State of Charge e Reverse Polarity protected e Temperature Compensated e RoHS Compliant environmentally safe e Accepts up to 495 watts of solar at 12 volts e Maximum Power Boost Technology 5 2013 Carmanah Technologies Corporation GP PWM 30 E MAXIMUM POWER BOOST TECHNOLOGY 2 0 Warnings Disconnect all power sources Battery and wiring safety Wiring connections Work safely Observe correct polarity Do not exceed the GP PWM 30 Amp current and max voltage ratings Electricity can be very dangerous Installation should be performed only by a licensed electrician or qualified personnel Observe all safety precautions of the battery manufacturer when handling or working around batteries When charging batteries produce hydrogen gas which is highly explosive Ensure all connections are tight and secure Loose connections may ge
14. ll be considered void if the warranted product is in any way opened or altered The warranty will be void if any eyelet 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 9 1 Repair and Return Information Visit www gpelectric com to read the frequently asked questions section of our website to troubleshoot the problem If trouble persists 1 Call your Go Power Technical Support team 1 866 247 6527 2 Return defective product to place of purchase 10 0 Installation Template see last page 20 2013 Carmanah Technologies Corporation GP PWM 30 E MAXIMUM POWER BOOST TECHNOLOGY 11 0 Wiring Diagram The GP PWM 30 is based on a 30 amp max input from the solar modules Solar Array yN E G Three modules in parallel with an input of a ia b 7 amps each equal a total input of 21 amps Most solar modules list the input amps on their specifications label O Solar Panel Solar Panel Baitery o Battery Fuse Battery Bank Note The fuse or breaker used should be no larger than 30 amps 21 O 2013 Carmanah Technologies Corporation GP PWM 30 E MAXIMUM POWER BOOST TECHNOLOGY 22 2013 Carmanah Technologies Corporation GP PWM 30 MAXIMUM POWER BOOST TECHNOLOGY Cut line for flus ount _ o ee 5 O O
15. nerate sparks and heat Be sure to check connections one week after installation to ensure they are still tight Wear protective eyewear and appropriate clothing during installation Use extreme caution when working with electricity and when handling and working around batteries Reverse polarity of the battery terminals will cause the controller to give a warning tone Reverse connection of the array will not cause an alarm but the controller will not function Failure to correct this fault could damage the controller The current rating of the solar system is the sum of the Maximum Power Current Imp of the solar PV strings in parallel The resulting system Imp current is not to exceed 30A The voltage of the array is the rated open circuit voltage Voc of the PV array and is not to exceed 28V If your solar system exceeds these ratings contact your dealer for a suitable controller alternative 6 2013 Carmanah Technologies Corporation GP PWM 30 E MAXIMUM POWER BOOST TECHNOLOGY 3 0 Tools and Materials Needed e Phillips Screwdriver If the GP PWM 30 Controller was purchased with a Go Power RV Solar Power Kit then UV resistant wire is included For instructions regarding the Go Power RV Solar Power Kit installation please refer to the Installation Guide provided with the Kit 4 0 Choosing a Location The GP PWM 30 is designed to be mounted flush against a wall out of the way but easily visible
16. roller battery terminals with a voltmeter and compare with the voltage reading at the battery terminals If there is a voltage discrepancy of more than 0 5 V there is an excessive voltage drop Remedy 1 Check all connections from the controller to the battery including checking for correct wire polarity Check that all connections are clean tight and secure Shorten the distance from the controller to battery or obtain larger gauge wire It is also possible to double up the existing gauge wire i e two wire runs to simulate a larger gauge wire 8 3 Problems with Current Current Reading O A Time of Day Daytime clear sunny skies Possible Cause 1 Current is being limited below 1 Amp as per normal operation 2 Poor connection between solar array and controller How to tell 1 The State of Charge SOC screen is close to 100 and the Sun and Battery icon are present with an arrow between 2 With the solar array in sunlight check the voltage at the controller solar array terminals with a voltmeter If there is no reading at the controller solar array terminals the problem is somewhere in the wiring from the solar array to the controller Remedy 2 Hold down the A Button for approximately 5 seconds to activate Maximum Power Boost This will allow the controller to charge batteries to 14 4 0 1V with all current the solar array is producing 2 Check all connections from the controller to the array including che
17. y conductor attached to a battery With battery power attached the controller should power up and display information Connect the solar wiring to the controller and remove the opaque material from the solar array The negative solar array and battery wiring must be connected directly to the controller for proper operation Do not connect the negative solar array or negative battery controller wiring to the chassis of the vehicle 6 Mounting the GP PWM 30 Mount the GP PWM 30 to the wall using the included four mounting screws IMPORTANT You must set the battery type on the GP PWM 30 before you begin to use the controller The default battery setting is for AGM batteries Congratulations your GP PWM 30 should now be operational If the battery power is low and the solar array is producing power your battery should begin to charge 7 Re torgue After 30 days of operation re torque all terminal screws to ensure the wires are properly secured to the controller 9 O 2013 Carmanah Technologies Corporation GP PWM 30 E MAXIMUM POWER BOOST TECHNOLOGY 6 0 Operating Instructions Power Up When the GP PWM 30 is I MAXIMUM connected to the battery the GP PWM 30 will go into Power PN A Up mode Icons Displayed Three horizontal dashes Setting the Battery Type Charging Profile Set the Battery Type Charging ce MAXIMUM Profile by holding down the B i Button for 5 seconds When the displa
18. y shows a single digit number release the B Button Set the Battery Type by toggling CD through the Charging Profile numbers 1 2 or 3 by pressing the B Button NOTE Non volatile memory Any settings made on the GP PWM 30 will be saved even when the power has been disconnected from the controller 10 O 2013 Carmanah Technologies Corporation GP PWM 30 EE MAXIMUM POWER BOOST TECHNOLOGY Refer to the Battery WN Charge Profile Chart on mem nomes page 13 for details on each profile FLOODED Battery o Confirm the Baitery Type Charging Profile selection by pressing the A Button Depending on the battery voltage when the GP PWM 30 Power Up occurs the GP PWM 30 may do a Boost Charge or quickly go into Float Charge The Charging Profile selected will commence the following day after a Power Up 11 O 2013 Carmanah Technologies Corporation GP PWM 30 E MAXIMUM POWER BOOST TECHNOLOGY Maximum Power Boost Technology Maximum Power Boost Technology MPBT is a new feature on the GP PWM 30 that allows you to override the normal charging algorithm of the solar controller This feature will make the GP PWM 30 go into a boost mode bringing the voltage up to 14 4 VOC for 30 minutes regardless of the batteries state of charge This feature should not be used more than twice a day as it could cause your batteries to require more distilled water top ups due to more gassing of the batteries
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