AIMS Power SCC-20A MPPT User manual

AIMS Power www.aimscorp.net
Solar Charge Controller
Installation and Operation Manual
SCC60-100A
AIMS POWER™
Headquarters
9550 Gateway Drive
Reno, NV 89521
Telephone: [phone]
Email:
[email protected]
[email protected]

2
Contents
1. Important Safety Instructions .........................................................................................................................3
2. Getting Familiar with Display..........................................................................................................................5
3. Installation..................................................................................................................................................10
4. Operation ........................................................................................................................................................15
5.Troubleshooting..............................................................................................................................................20
6. Warranty Claim Procedure and Datasheet...................................................................................................21

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1. Important Safety Instructions
This manual contains important safety, installation and operating instructions for the
MPPT 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 the instructions and cautions in the manual before beginning installation.
There are no user serviceable parts inside the MPPT charger. Do not disassemble
or attempt to repair the controller.
Disconnect all sources of power to the controller before installing or adjusting the
controller setting.
Mount the controller indoors. Prevent exposure to the elements and do not
allow water to enter the controller.
Install the controller in a location that prevents casual contact. The controller 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 near the battery bank.

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Power connections must remain tight to avoid excessive heating from a loose
connection.
Use properly sized conductors and circuit interrupters.
WARNING: A battery can present a risk of electrical shock or burn from
large amounts of short-circuit current, fire, or explosion from vented gases. Observe
proper precautions.
CAUTION: When replacing batteries, use properly specified sizes, type
and rating based on application and system design.
About this Manual
This manual provides detailed installation and usage instructions for the
MPPT solar charge controller. Only qualified electricians and technicians
who are familiar with solar system design and wiring practices should install
the MPPT controller. The usage information in this manual is intended for the
system owner/operator.

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2. Getting Familiar with Display
Monitoring
Function Keys
Function Key
Description
BACK / LEFT
To exit setting mode
UP
To go to previous selection
DOWN
To go to next selection
ENTER / RIGHT
To confirm the selection in setting mode or enter setting
ON(RIGHT)/OFF(LEFT
Press for 2 seconds it will turn on/off the DC load

6
Setting Battery Type

7
Overview
The MPPT controller is an advanced maximum power point tracking solar battery
charger. The controller features a smart tracking algorithm that finds and maintains
operation at the solar array’s peak power point, maximizing energy harvest.
The MPPT controller charging process has been optimized to prolong battery life and
improve system performance. Self-diagnostics and electronic error protections prevent
damage when installation errors or system faults occur. The controller also features
four adjustable setting switches, RS485 communication port and terminal for remote
battery temperature monitoring.
Please take the time to read this operator’s manual and become familiar with the
controller. This will help you utilize the many advantages of the MPPT Controller for your
PV system.
Versions and Rating
Model Rated Current Solar Input Voc System voltage DC Load Cooling type Casing
SCC-20A MPPT 20A 18～100Vdc 12V/24V 30A Heatsink
Metal
casing
SCC-30A MPPT 30A 18
～
100Vdc 12V/24V 30A Heatsink
Metal
casing
SCC-40A MPPT 40A 18
～
150Vdc 12V/24V/36V/48V 40A Heatsink
Metal
casing
SCC-60A MPPT 60A 18
～
150Vdc 12V/24V/36V/48V 60A Heatsink
Metal
casing
SCC-80A MPPT 80A 18～150Vdc 12V/24V/36V/48V 60A Heatsink
Metal
casing
SCC-100A MPPT 100A 18
～
150Vdc 12V/24V/36V/48V 60A Heatsink
Metal
casing
Features
The features of the MPPT controller are shown in figure below. An explanation of each
feature is provided.
.

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1. Heatsink
Aluminum heatsink to dissipate controller heat
2. Mounting hole
Predrilled slot for mounting
3. Setting switches
Four setting switches to configure operation of the MPPT controller
4. Solar positive terminal
Power connection for solar (+) Solar
negative terminal
Power connection for solar (-)
5. Battery outputs. Positive port to connect to positive battery terminal (+). Negative port to
connect to negative battery (-) terminal.
6. DC load output
7. LCD screen
Indicate the operating status
8. LED indicators
LED indicators show charging status and controller faults
9. Wiring box cover
Box cover to protect power connections
10. Battery temperature sensor
Terminal for battery temperature. Controls charge current if battery is too hot.
11. RS-485 Port
Terminal for RS-485 communication

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10
3. Installation
General Information
The mounting location is important to the performance and operating life of the
controller. The environment must be dry and protected from water sources. If required,
the controller may be installed in a ventilated enclosure with sufficient air flow. Never
install the controller in a sealed enclosure. The controller may be mounted in an
enclosure with sealed batteries, but never with vented/flooded batteries. Battery
fumes from vented batteries will corrode and destroy the controller’s circuits.
Multiple controllers can be installed in parallel to the same battery bank to achieve
higher charging current. Additional controllers, connected in parallel, may be added in
the future. Each controller must have its own solar array and sized the same.
CAUTION: Equipment Damage or Risk of Explosion
Never install the controller in an enclosure with vented/flooded batteries. Battery fumes
are flammable and will corrode and destroy the controller circuits.
CAUTION: Equipment Damage
When installing the controller in an enclosure, ensure proper ventilation. Installation in
a sealed enclosure will lead to over-heating and lessen controller’s overall life.
The installation is straight-forward, but it is important each step is done correctly and
safely. A mistake can lead to dangerous voltage and current levels. Be sure to carefully
follow each instruction. Read all instructions first before beginning installation.
Recommended Tools:
Wire strippers
Wire cutters
Phillips screwdriver
Slotted screwdrivers
Pliers
Drill
Drill bit
Level
Hacksaw (cutting conduit）

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Controller Installation
Step 1-Remove the wiring box cover to access inside of charge controller.
Step 2 – Punch out perforated hole slots to feed cables through bottom of charge controller.
CAUTION: Shock Hazard
Disconnect all power sources to the controller before removing the wiring box cover.
Never remove the cover when voltage exists on any of the power connections.
Use a #4 Phillips screw driver to remove the screws that secure the wiring box cover
as show in figure below.

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Power Connections
The six large power terminals are sized for up to 4 AWG wire. The terminals are rated
for copper and aluminum conductors. Good system design generally requires large
conductor wires for the solar and battery connection that limit voltage drop losses to
2% or less.
Minimum Wire Size
The wire recommendation below is based on an ambient temperature of 113 F
or 45 C. Adjust cable size for more extreme temperatures.
Model
Copper Wire Type
Recommended Size
Minimum Size
20A
Copper
12AWG
14AWG
30A
Copper
10AWG
12AWG
40A
Copper
6AWG
8AWG
60A
Copper
5AWG
6AWG
80A
Copper
4AWG
5AWG
100A
Copper
4AWG
5AWG
Power Wire Connection
WARNING: Shock Hazard
The solar PV array cannot produce open-circuit voltages exceeding 155V DC
when in sunlight. If using breakers or disconnect switches, verify that the solar
input breaker or disconnect switch has been opened (disconnected) before
installing the system wires.
Model: 60A 80A 100A
1. Insert the wires through the bottom of the charge controller via the punch out
holes.
④Solar Input ⑤Battery Input ⑥DC Load Output (#6 is not required)
BTS Sensor
RS485 Port

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If using input and output disconnect switches or breakers, ensure they are turned off
before connecting the power wires to the controller.
WARNING: Risk of Damage
Do not reverse the polarity on the connections. If using a breaker or disconnect switch,
turn on the battery breaker or disconnect switch to ensure correct polarity and voltage
with a multi meter BEFORE connecting to charge controller. Final connection should
be made with breakers in the off position.
2. Connect the battery+ (Positive) wire to the battery+ terminal on the controller,
Connect the battery- (Negative) wire to the battery- terminal on the controller.
3. Connect the Solar+ (Positive) wire to the PV+ terminal on the controller,
Connect the Solar- (Negative) wire to the PV-terminal on the controller.
4. Connect the DC load+ (Positive) wire to the Load+ terminal on the controller,
Connect the DC load- (Negative) wire to the Load - terminal on the controller.
5. If using the battery temperature sensor, connect sensor. Attach the battery
temp sensor to the side of the battery (s) closest to the charge controller, near
the negative terminal.
6. If using RS485 monitoring, connect a RS485 cable.
*NOTE – Do not connect the battery (s) to the DC load port. Only
connect battery (s) to the “Battery Port”.

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Powering Up
WARNING: Risk of Damage
Connecting the solar array to the battery terminal will permanently damage the
controller.
WARNING: Risk of Damage
Connecting the solar array or battery connection with reverse polarity will permanently
damage the controller.
Confirm that the Solar and Battery polarities are correct.
Turn the battery disconnect switch on first (if using one). Ensure the LCD screen
powers on.
Note that a battery bank must be connected to the controller to start and operate
the controller. The controller will not operate from solar input only.
Turn the solar disconnect switch on (if using one). If the solar array is in full
sunlight. The controller will begin charging.
Powering Down
WARNING: Risk of Damage
Only disconnect the battery from the controller AFTER the solar input has been
disconnected. Damage to the controller may result if the battery is removed while the
controller is charging.
To prevent damage, power-down must be done in the reverse order as power- up.

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4. Operation
The MPPT controller is fully automatic. After installation is completed, there are few
operator tasks to perform. However, the operator should be familiar with the operation
and care of the controller as described in this section.
The MPPT controller utilizes Solar Maximum Power Point Technology
Tracking (MPPT) technology to extract maximum power from the solar array. The
tracking algorithm is fully automatic and does not require user adjustment. MPPT
technology tracks the array maximum power point as it varies with weather conditions,
ensuring that maximum power is harvested from the array throughout the course of
the day.
Current Boost
Under most conditions, MPPT technology will “boost” the solar charge current. For
example, a system may have 36 Amps of solar current flowing into the controller
and 44 Amps of charge current flowing out to the battery. The controller does not
create current! Rest assured that the power into the controller is the same as the
power out of the controller. Since power is the product of voltage and current (Volts
x Amps), the following is true*:
(1) Power into the MPPT 150V = Power Out of the MPPT 150V
(2) Volts In x Amps In = Volts Out x Amps Out
* Assuming 100% efficiency. Losses in wiring and conversion exist.
If the solar module’s maximum power voltage (Vmp) is greater than the battery
voltage, it follows that the battery current must be proportionally greater than the
solar input current so that input and output power are balanced. The greater the
difference between the Vmp and battery voltage, the greater the current boost.
Current boost can be substantial in systems where the solar array is of a higher
nominal voltage than the battery as described in the next section.
Battery Charging Information
The MPPT controller has 4-stage battery charging algorithm for rapid, efficient,
and safe battery charging. Figure 4-1 shows the sequence of the stages.
Figure4-1. MPPT Controller Charging Algorithm

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Battery Charging Settings
It is important to select the correct battery setting for the battery type used in the solar
system. Refer to the specifications provided by the battery manufacturer and choose
a setting that best fits the recommended charging profile.
There are 4 charging stages:
Bulk Charging: This is the initial stage of charging. While Bulk Charging, the charger
supplies the battery with controlled constant current. The charger will remain in Bulk
charge until the Absorption charge voltage (determined by the Battery Type selection)
is achieved. The green LED will blink once every 0.5 seconds during bulk charging.
Absorb Charging: This is the second charging stage and begins after the
battery has recharged to the set absorption voltage. Absorb Charging provides
the batteries with a constant voltage and reduces the DC charging current,
maintaining the absorb voltage setting. This prevents heating and excessive
battery gassing. The green/blue Led will blink once per every two seconds
during absorption charging.
Float Charging:The third charging stage occurs at the end of the Absorb Charging
time. While Float Charging, the charge voltage is reduced to the float charge voltage
(determined by the Battery Type selection). In this stage, the batteries are kept fully
charged. The float stage provides a very low rate of maintenance charging while
reducing the heating and gassing of a fully charger battery. This protects the battery
from long term over charger. The green/blue LED will keep green during float charging
Equalize Stage
Equalize charging will charge in a higher voltage to kick start battery activity, usually
this cycle lasts about 30 minutes depending on battery type. Only for open lead acid
batteries and this stage occurs every 30 days.
Network Connections
Network connections allow the MPPT controller to communicate with computers. A
network can be as simple as one controller and one PC, or as complex as dozens of
controllers monitored via the Internet. RS485 cable needed and not included.
WARNING: Risk of Explosion
Equalizing vented batteries produce explosive gases. The battery bank must be
properly ventilated.
Battery type Bulk charge stage Absorption charge
stage
Float charge stage
Gel
14.2
14.4
13.7
AGM
14.3
14.5
13.7
Sealed
14.4
14.6
13.7
Flooded
14.6
14.8
13.5
Lithium/Lifepo4
13.7-15
Same as bulk charge voltage-
Same as bulk charge voltage
User define
10.0-15V
10.0-15V
10.0-15

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CAUTION: Equipment Damage
Equalization increases the battery voltage to levels that may damage sensitive DC
loads. Verify all system loads are rated for the temperature compensated Equalize
voltage before beginning an Equalization charge. Excessive overcharging and gassing
too vigorously can damage the battery plates and cause shedding of active material
from the plates. An equalization that is too high or for too long can be damaging.
Review the requirements for the battery being used in your system.
Temperature Compensation
All charging setting are based on 25°C (77°F). If the battery temperature varies by 5°C,
the charging setting will change by 0.15 volts from a 12V battery. This is a substantial
change in the charging of the battery, and the use of the battery sensor is
recommended to adjust charging to the actual battery temperature.

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Protections, Faults and Alarms
The MPPT controller protections and automatic recovery are important features that
ensure the safe operation of the system. Additionally, the controller features real-time
self-diagnostics that report Fault and Alarm conditions as they occur.
Faults are events or conditions that require the controller to cease operation. A Fault
usually occurs when a limit such as voltage, current, or temperature has been
surpassed. Fault conditions are indicated with unique LED sequences and are also
displayed on the LCD screen.
-Solar overload
The controller will limit battery current to the maximum battery current rating. An over-
sized solar array will not operate at peak power. The solar array should be less than
the controller nominal maximum input power rating for optimal performance.
-Solar short circuit
The controller will disconnect the solar input if a short circuit is detected in the solar
wiring. Charging automatically resumes when the short is cleared.
-Very Low battery Voltage
If battery discharge below 9Volts the controller will go into brownout and shut down.
When the battery voltage rises above the 10 Volts minimum operating voltage, the
controller will restart.
-High temperature current limit
The MPPT controller will limit the solar input current if the heatsink temperature
exceeds safe temperature. Solar charge current will be tapered back (to 0 amps if
needed) to reduce the heatsink temperature. The controller is designed to operate at
full rated current at the maximum ambient temperature. This alarm indicates that there
is insufficient airflow and that the heatsink temperature is approaching unsafe limits. If
the controller frequently reports this alarm condition, corrective action must be taken
to provide better air flow or to relocate the controller to a cooler spot.
-High Input voltage current limit
The MPPT controller will limit the solar input current as the solar array Voc approaches
the maximum input voltage rating. The array Voc should never exceed the
maximum input voltage (100VDC or 155VDC).
Current Limit
The array power exceeds the rating of the controller, this alarm indicates that the
controller is limiting battery current to the maximum current rating.

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Uncalibrated
The controller was not factory calibrated. Return the controller to an authorized dealer
for service.
Inspection and Maintenance
The following inspections are recommended two times per year for best long-term
performance.
System Inspection
Confirm the controller is securely mounted in a clean and dry environment.
Confirm that the air flow around the controller is not blocked. Clean the
heatsink of any dirt or debris.
Inspect all exposed conductors for insulation damage due to sun damage,
rubbing on nearby objects, dry rot, insects, or rodents. Repair or replace
conductors as necessary.
Tighten all power connections per the manufacturers’ recommendations.
Verify the LED and LCD indications are consistent with the equipment operation.
Note any fault or error indications. Take corrective action if necessary.
Inspect the battery bank. Look for cracked or bulging cases and corroded
terminals.
Inspect the system earth grounding for all components. Confirm all grounding
conductors are appropriately secured to earth ground.
Inside the MPPT Controller Wiring Box
CAUTION: Shock Hazard
Disconnect all power sources to the controller before removing the wiring box cover.
Never remove the cover when voltage exists on the controller power connections.
Check all wire terminals. Inspect connection for corrosion, damaged insulation,
signs of high temperature or burning/discoloration. Tighten the terminal screws to
the recommended torque.
Inspect for dirt, nesting insects, and corrosion. Clean as required.

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5.Troubleshooting
Battery Charging and Performance Issues
Problem: No LCD or LED indications, controller does not appear to have
power.
Solution:
With a multi-meter, check the voltage at the battery terminals on the controller. Battery
voltage must be 9 VDC or greater. If the voltage on the battery terminals of the
controller is between 9 and 60 VDC and no LED or LCD indicate, contact your
authorized dealer for service. If no voltage is measured, check wiring connections,
fuses
Problem:
The controller is not charging the battery.
Solution:
If the LCD indicator is normal, check the fuses, breakers and wiring connections in the
solar array wiring. With a multi-meter, check the array voltage directly at the controller
solar input terminals. Input voltage must be greater than the minimum start- up voltage
before charging will begin.
Network and Communication Issues.
Problem:
Cannot connect to the controller via communication port.
6.1 Communication port pinout
Make sure that your cable matches the RS485 communication port. The
communication port is RS485.