Apollo Solar TurboCharger T80 User manual

23 Francis J. Clarke Circle, Bethel, CT 06801 USA
[phone]
www.ApolloSolar.com
TurboCharger™
(For T80 & T80HV models)
Installation and Operation Manual

TurboCharger™ Installation and Operation Manual Page 1
TABLE OF CONTENTS
Revision History ...........................................................................................2
Important Safety Instructions........................................................................3
Overview ......................................................................................................4
Theory of Operation …………………………………………………………… 5
Planning Your System..................................................................................6
Loads ................................................................................................6
Determining Battery Voltage..............................................................6
Determining PV Array Voltage...........................................................7
Maximum Voc....................................................................................7
Conversion Efficiency ........................................................................8
Wire Sizing ........................................................................................8
Determining Maximum Current..........................................................9
Circuit Protection ...............................................................................9
Lightning Protection...........................................................................10
Installation ....................................................................................................11
Initialization ..................................................................................................14
Front Panel LED Status Indicator.................................................................18
Restarting the TurboCharger
™
.....................................................................18
Operating the TurboCharger
™
.....................................................................19
Status Screens ..................................................................................19
Data Screens.....................................................................................20
Setup .................................................................................................21
Setup Selections Screen ...................................................................22
Main EQ Setup Screen......................................................................23
Main Miscellaneous Setup Screen ....................................................25
Aux Relay Setup Screen ...................................................................28
Emonitor Setup Screen .....................................................................32
Wiring Diagram with Batteries ......................................................................33
Networking (Stacking) Multiple TurboChargers
™
…………………………….34
Warranty Information....................................................................................37
Appendix A – Wire Sizing Table for 1.5% Voltage Drop...............................38
Appendix B – Bootloader Function...............................................................44

TurboCharger™ Installation and Operation Manual Page 2
Revision History
Manual Revision Applies to Firmware Revision Date BY
1.7 3.20 12/12/06 KMV
1.8 3.20, 4.00, 4.03 4/24/07 KMV
1.9 3.20, 4.00, 4.03, 4.04, 5.00 6/29/07 KMV
1.91 5.00 7/16/07 KMV
2.0 5.04 7/23/07 KMV
2.1 6.03 10/19/07 KMV
2.11 6.06 1/31/08 KMV
3.0 6.10, 6.11 3/27/08 KMV
3.1 7.08, 7.09, 7.10 7/21/09 HF
3.2 7.08, 7.09, 7.10 11/12/09 KMV
3.3 7.17 2/9/10 HF
3.4 7.18 3/1/10 HF
3.5 8.00 8/1/2010 JS
3.6 8.00 12/17/10 HF
3.7 8.00 4/7/11 HF

TurboCharger™ Installation and Operation Manual Page 3
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
The TurboCharger™ is capable of processing over 4.8 kW of DC power. These Safety Instructions are to
ensure safe installation and operation of the TurboCharger™ and the equipment it is connected to. Be sure to
read the instructions which came with the TurboCharger™ and all other connected equipment carefully. Inspect
the TurboCharger™ and all other equipment and read all cautionary and instructive markings on all equipment.
Be sure to follow all cautions and instructions when installing all equipment. Save this manual, it has important
maintenance and operation information.
The TurboCharger™ Battery System Controller is designed to be permanently connected to a DC electrical
system. The TurboCharger™ must be provided with an equipment-grounding conductor connected to the DC
input ground.
THIS IS THE SYMBOL FOR GROUND:
⇒Use a minimum of #8 AWG conductors rated for at least 75º
C.
⇒The input/output and ground terminals on the TurboCharger™ will accept #8 to #3 AWG wire.
The lugs are rated to accept a single conductor.
⇒Torque all connections to 50 lb-in (5.65 N-m)
Apollo Solar recommends that all wiring be done by an electrician or certified technician in accordance to all
local and national electrical codes applicable in your jurisdiction. Do not perform electrical work you do not feel
qualified to do.
To avoid a risk of fire and electric shock, make sure that existing wiring is in good condition and that wire is not
undersized. Do not operate the TurboCharger™ or any other system components with damaged or substandard
wiring. Use only attachments recommended or sold by Apollo Solar or our Authorized Distribution Partners,
doing otherwise may result in a risk of fire, electric shock, or injury to persons. To reduce the risk of electrical
shock, disconnect all sources of DC power from the TurboCharger™ before attempting any maintenance or
cleaning or working on any components connected to the controller.

INTENDED USE
The TurboCharger™ is designed to charge lead acid batteries of flooded, gel and AGM chemistries from 12 to
48 Vdc nominal. For all other battery types follow specific voltage, current, and time settings provided by the
manufacturer of the batteries.

WARNING
The TurboCharger™ is designed for use in a controlled environment (i.e. for indoor use only). Do not
expose this unit to rain, snow, or liquids of any type. Damp environments will significantly shorten the life of this
product and installation in damp environments may affect the product warranty. (For information about damp
environment warranty exclusions see the Warranty section at the end of this manual).
Do not operate the TurboCharger™ if it has been damaged in any way. If the unit is damaged follow the product
return directions in the Warranty section at the end of this manual. Do not disassemble the TurboCharger™.
The TurboCharger™ does not have any user-serviceable parts. Internal capacitors remain charged after all
power is disconnected and attempting to service the unit may result in a risk of electrical shock or fire. Always
use insulated tools to reduce the chance of short-circuits when installing or working with the TurboCharger™,
the batteries, PV arrays and any other connected equipment. To further reduce the risk of exposure to live
circuits remove all jewelry while installing this system. A battery can present a risk of electrical shock, burn from
high short circuit current, fire or explosion from vented gas. Observe proper precautions.

EXPLOSIVE GAS PRECAUTIONS
Working in the vicinity of lead acid batteries is dangerous. Batteries generate explosive gases during normal
operation. Follow all Explosive Gas Safety procedures. To reduce the risk of battery explosion, follow these
instructions and those published by the battery manufacturer and supplier.
Proper Disposal of Batteries is required. Refer to your local codes for disposal requirements.

TurboCharger™ Installation and Operation Manual Page 4
OVERVIEW
The Apollo TurboCharger™ is essentially a smart DC to DC converter which has been optimized to
harvest maximum energy from the PV array in battery based solar electric systems by using a variety of
maximum power point tracking (MPPT) strategies. The controller’s secondary objective is to ensure that
the batteries receive a full charge without becoming overcharged. This is accomplished through a five
stage charging process. Built into the unit is a comprehensive data logging system which tracks battery
state of charge (SOC) and power produced by the PV array.
The DC to DC converter feature allows for a wide variety of input and battery voltage configurations.
Batteries may be configured from 12 to 48 Vdc nominal (12, 24, 36, and 48 are the factory default
settings). This feature allows system designers considerable flexibility with respect to wire sizing and
module location. At this time there are 2 models of the TurboCharger the T80 and the T80HV. The two
models operate exactly the same with only one difference, the maximum input voltage. For the T80 the
PV arrays may be wired in up to 112 Vdc nominal, with the actual constraint being the maximum
allowable Voc at worse case conditions, 150 Voc. (The T80 automatically shuts down above 140 Voc.)
For the T80HV the PV arrays can be wired in up to 160 Vdc nominal, with the actual constraint being the
maximum allowable Voc at worse case conditions, 200 Voc. (The T80HV automatically shuts down above
180 Voc.) The T80HV model is not recommended for 12V systems, the T80 version should be
considered instead (see “Determining Battery Voltage” below).
The TurboCharger™ features two auxiliary relays. These relays have a host of control uses and
functions and can be custom programmed to suit the system operator’s needs (refer to the Aux relay
setup screen section of operating instructions for more information).
Please carefully read the Planning Your System section of this manual and all warnings before beginning
your installation. To ensure best performance follow all installation instructions and wiring guidelines.
Always install equipment in accordance to local codes and bylaws. We recommend that external lightning
protection be installed along with the TurboCharger™.

TurboCharger™ Installation and Operation Manual Page 5
THEORY OF OPERATION
Bulk: In the Bulk Mode the Controller is trying to get the battery voltage up to the Absorb Voltage Setting
(B). It will use all the power it can get from the panels limited only by the Maximum Charge setting (A).
When the Absorb Voltage is reached on the batteries, the charger switches into Absorb Mode.
Absorb: In this mode the Charger will supply just enough current to maintain the Absorb Voltage setting.
This current will gradually decrease over time with a constant load but can vary due to outside loads. The
charger stays in absorb until the Absorb Timer counts down to 0 or for as long as the batteries were in
Bulk Mode that day which ever time is shorter. The timer is suspended if the Battery Voltage drops 1 V
below the Absorb Voltage Setting due to loading. When the Timer counts down to 0 the Charger goes
into Float Mode (D). At this point, the Charger will output a minimum current (C), unless a load requires
more.
Float: When first switching to this mode the Charger may experience a short period of 0 Amps output.
This is because the Absorb Voltage is usually set higher than the Float Voltage and the controller waits
for the battery voltage to drop. In this mode the Charger will supply just enough current (F) to maintain
the Float Voltage setting (E). The current required to maintain the battery at this voltage is usually fairly
small but as loads are applied the current will rise to try to maintain the voltage level.
Standby: The Charger will go into the Standby mode whenever the PV Voltage applied to the input is
less than the Battery Voltage on the output +10%. Example: If the Battery Voltage = 49.0V then the PV
Voltage must be at least 53.9V or the unit will stop charging and go into Standby Mode.

TurboCharger™ Installation and Operation Manual Page 6
PLANNING YOUR SYSTEM
Loads
Congratulations on choosing a solar electric system, when designed and installed properly it should give
you decades of service life. The TurboCharger™ is a key component in your PV system. From a system
planners perspective it is very flexible with the ability to accept a wide range of input voltages and
produce a similarly wide range of output voltages. Never-the-less some planning and choice is required
when deciding on the components and configuration of your PV system.
The first step in planning a PV system is to know something about the load. What is the power intended
for? How much power will be required? There are many resources available in print and on-line to help
determine average and peak load requirements we recommend using these resources to calculate
anticipated load requirements. We also recommend that planners design for load growth. Experience has
shown that loads rarely remain static and are reduced even less frequently. Once the load characteristics
are determined the system planner may move to make decisions about the appropriate battery voltage.
Determining Battery Voltage
A major factor in making this decision is how much power will be required from the batteries. As power
demands increase it is advisable to raise the battery voltage. A limiting factor in system design is current
– it is expensive to move and provide circuit protection for large amounts of current (amps). A basic rule
of electricity states “current = power/voltage”. This means that the higher the battery voltage the lower the
current will be for any given load. For example a 96 watt load at 12 Volts draws 8 amps the same load at
48 Volts draws only 2 amps of current.
The table below shows rule-of-thumb recommendations for battery system voltage choices and maximum
inverter sizes.
Load in kWh per day Battery Voltage Suggested Inverter
Size
Under 2 kWh per day 12 Vdc Up to 2.5 kW
2 to 6 kWh per day 24 Vdc 2-4 kW
Over 6 kWh per day 48 Vdc 3 kW and larger
Other factors in making this decision will include the size of the inverter.
A final factor in this decision is how much power will be required from the PV array. The TurboCharger™
is designed to produce 80 amps of output current. The amount of power this represents will be dependent
on the output voltage (battery bank voltage). At 12 Vdc output 80 amps is 960 watts of power, at 48 Vdc
output 80 amps is 3840 watts of power. The example above demonstrates that the amount of current or
input power the TurboCharger™ will accept is limited by the system battery voltage.
Note: Although it supports 12V, the T80HV is not recommended for 12V systems, the T80 should
be considered instead as it is more efficient in 12V applications.

TurboCharger™ Installation and Operation Manual Page 7
Determining PV Array Voltage
One of the great advantages of the DC to DC converter design of the TurboCharger™ is that PV array
voltages are no longer dictated by the battery voltage. Sizing a PV array for the is much like sizing a grid-
tie inverter, the same questions apply: What is the max and min Vmp and Voc of each string, how many
strings will be needed.
Sellback Operation
When used in a system with a grid connected inverter. Set the sellback voltage on the inverter to just
below the absorb voltage setting. This will ensure that the TurboCharger™ will deliver full current from
the PV array. It is advised that sellback be turned off occasionally to allow the batteries to float.
Maximum Voc
Each PV module has specific ratings for voltage and current at standard test conditions and
temperatures, the manufacturers also publish current and temperature coefficients. The Voc for any PV
module increases in cold temperatures. Modules are rated with an assumed cell temperature of 25
o
C,
when calculated at 0
o
C there may be as much as a 25% increase in the rated Voc. The Voc voltage
temperature coefficient for the specific location of the installation must be calculated from known weather
data. Once the maximum Voc of the module is found a series string voltage may be determined.
T80 model: The maximum operating voltage of the T80 is 140 Vdc. Above this, the unit will shut down to
avoid damage. The absolute maximum applied input voltage the controller can accept without damage is
150 Vdc.

WARNING
The Voc maximum on the coldest brightest day of the year must not exceed 150 Vdc for the T80. Input
voltage in excess of 150 Vdc will result in internal damage which is NOT covered by warranty. We
recommend a maximum design Voc of 140 Vdc. This will result in the most effective energy harvest.
T80HV model: The maximum operating voltage of the T80HV is 180 Vdc. Above this, the unit will shut
down to avoid damage. The absolute maximum applied input voltage the controller can accept without
damage is 200 Vdc.

WARNING
The Voc maximum on the coldest brightest day of the year must not exceed 200 Vdc for the T80HV.
Input voltage in excess of 200 Vdc will result in internal damage which is NOT covered by warranty. We
recommend a maximum design Voc of 180 Vdc. This will result in the most effective energy harvest.

TurboCharger™ Installation and Operation Manual Page 8
Conversion Efficiency
The conversion efficiency of the TurboCharger™ in the proposed configuration must be considered.
While it is possible to input 72 Vdc and output 12 Vdc, it is not the most efficient configuration for the
controller. A system which had 36 Vdc input and 12 Vdc output would run more efficiently from the
T80HV’s perspective. The most efficient configuration is with 60 Vdc input and 48 Vdc output. Never-the-
less, in many cases the savings in wire costs and the slight advantage of earlier wake up and shut down
make the “inefficient” higher voltage to low voltage conversion the best system choice. Many systems
input 72 Vdc for 24 and 48 Vdc batteries. The table below shows some recommended input to output
configurations for a system using the T80 model.
Battery Voltage Array Vmp Range
12 Vdc 16 - 83 Vdc
24 Vdc 32 – 136 Vdc
48 Vdc 70 – 150 Vdc*
* Never exceed 140 Voc in any T80 system design.
Wire Sizing
The distance between the PV array and the controller will be a factor in choosing an optimum string
voltage for the TurboCharger™. The higher the input voltage the smaller the wire can be for any given
amount of power. For example a system with a 12 volt battery and a PV array consisting of four 6.5 amp
12 Vdc nominal modules located at a distance of 40’ from the batteries could have the modules wired in
series, parallel or series and parallel. Input configuration possibilities in this example are 12, 24, and 48
Vdc. If the array was configured with the modules wired in parallel the input voltage would be 12 Vdc with
an input current of 26 A. The same array wired in series would have an input voltage of 48 Vdc and an
input current of 6.5 amps. In this example #1, the 26 amp 12 Vdc array #1/0 wire, which is prohibitively
expensive, would be required to limit voltage drop to 2% which is recommended for 12 Vdc systems. The
same array wired for 48 Vdc would only require a #8 wire. With the #8 wire the 12 Vdc array would have
to be within 7’ of the batteries. The distance that #8 cable can be used is over five times greater at 48 Vdc
than 12 Vdc. (Refer to Wire Sizing Table for 2% Voltage Drop Appendix A)
Of course, a final determining factor will be the number of modules available for installation. For example
the optimum system design might call for six 12 V nominal modules in series, but the actual system to be
installed consists of only 10 modules. It is not possible to wire strings of differing voltages to the
TurboCharger™; therefore the number of modules available must be divided into even numbers. In the
example given above each string would consist of 5 modules for a nominal voltage of 60 Vdc. The above
noted system could be expanded by adding one module to each string for a nominal voltage of 72 Vdc or
by adding an additional string of 5 modules and maintaining the 60 Vdc nominal input voltage.

TurboCharger™ Installation and Operation Manual Page 9
Determining Maximum Current
The TurboCharger™ is designed to handle a maximum input current of 70 amps and a maximum output
current of 80 amps – both of these ratings are continuous at 45
0
C. The Input voltage will be higher than
output voltage hence input current (amps) will be lower than output current. For example twelve 6.5 amp
12 Vdc nominal PV modules wired in series and parallel to produce 36 Vdc would equate to an input
current of 26 amps – the rated current of each string times 4. (In series wiring the voltage increases and
the current remains constant.) The output current of the controller will be dependent on the voltage of the
battery bank. If the array in this example was connected to a 12 Vdc battery system the output current
would be 78 amps. (Current in x V nom / V Bat = Current out).
When calculating the maximum input or output current, remember to add 25% to the rated current of the
PV array, this is the NEC required “headroom” to account for the PV’s ability to produce more than the
rated output under some conditions.
Circuit Protection
All electrical circuits require protection from over current and shorts and the TurboCharger™ is no
exception. The unit should be installed with a circuit breaker or a fused disconnect on the input and
output. The TurboCharger™ has a maximum current limit of 80 amps on the output. It is designed and
listed to run at its maximum rating continuously. The continuous rating does not reflect the 80% derating
required by the NEC for conductors, fuses, and many circuit breakers.
The NEC requires that the output conductors have an amperage capacity of 1.25 X the rated current after
all temperature and fill corrections are calculated. This means conductors must be rated to carry 100
amps. The minimum cable necessary to carry the full rated output of both the T80 and T80HV is #3AWG,
corrections for conduit fill and temperature could result in a large wire size being necessary.
Since the TurboCharger™ T80HV can accept a higher PV input voltage, a high voltage circuit breaker
must be used. Apollo Solar offers circuit breakers that can accept up to 250VDC.
T80 model:
In summary Apollo Solar recommends that the input breaker be 90 amps rated for 150 Vdc and the
output breaker be 100 amps rated at a minimum of 80 Vdc. Apollo Solar and it’s distribution partners offer
90 and 100 amp breakers which are compatible with widely available PV system DC service entrance
enclosures.
T80HV model:
In summary Apollo Solar recommends that the input breaker be 50 amps rated for 250 Vdc and the
output breaker be 100 amps rated at a minimum of 80 Vdc. Apollo Solar and it’s distribution partners offer
50 and 100 amp breakers which are compatible with widely available PV system DC service entrance
enclosures.

TurboCharger™ Installation and Operation Manual Page 10
Wiring Diagram
The simplified single-line drawing below shows the appropriate location and amperage capacity rating of
circuit breakers. Please note that all circuit protection devices must be installed inside UL recognized
enclosures. Follow all applicable electrical codes.
Use #3 to #8 AWG wire
rated for 75º C for Battery,
PV and Ground
connections. Torque all
terminals to 50 lb-in (5.64
N-m).
The Aux Relay screw
terminals accept #14 to 22
AWG wire. Torque all
signal terminals to 4.4 lb-in
(0.5 N-m).
Only use circuit protection
equipment which is DC
rated for the appropriate
amperage capacity and DC
voltage.
Lightning Protection
Like any other electronic device the TurboCharger™ may be damaged during lightning storms. We
strongly recommend that external lightning protection devices be included as part of the circuit protection
equipment.
TURBOCHARGER BASIC SYSTEM
WIRING DIAGRAM
Input from PV Array
or Combiner Box
+
+
_
_
+_
GND
MODULAR CABLE WITH 3
TWISTED PAIRS.
FOR CURRENT SHUNT,
BATTERY VOLTAGE
SENSE AND BATTERY
TEMPERATURE.
USE SEPARATE CONDUIT
AND KEEP CLEAR OF
HIGH VOLTAGE WIRING.
90
0
100 AMP
DC RATED
BREAKER
DC RATED BREAKER
100
0
BATT+
Apollo Solar
+BAT+ -BAT- +PV+- PV -
TurboCharger
TEMPERATURE
SENSOR
SHUNT
50mV
500AMP
APOLLO
SHUNT BOARD
BATTERY
VOLTAGE
SENSE WIRES
+Bat
Temp
-Bat
FUSE
SYSTEM
EARTH
GROUND

TurboCharger™ Installation and Operation Manual Page 11
INSTALLATION
Controller
To minimize voltage drop and keep wiring and circuit protection costs down the TurboCharger™ should
be located as close to the batteries as possible while still maintaining suitable distance to prevent any risk
of fire from sparks and battery gasses. The minimum distance between the TurboCharger™ and batteries
should be 4’ (1.2 meters).
The TurboCharger™ has one external mounting tab on top and four mounting screw locations in the
wiring access area. Use #10 wood screws of sufficient length to penetrate ¾” into framing members or
other solid wood materials. Screw locations are: Top Center (external) and inside wire access area.
Locate the unit and install the top mounting screw first, remove wiring access cover and install the
remaining mounting screws. Most installations will utilize conduit to house the wires entering and leaving
TurboCharger™. The unit is designed to accept conduit between ½ and 1 ¼ inches. Follow all applicable
codes and regulations during installation
Once securely mounted with all conduit installed the unit is ready for wiring. Before attempting any wiring
make sure that all disconnects (or circuit breakers) for the PV array and batteries are in the OFF position.

IMPORTANT
Keep all breakers in the OFF position until ready to initiate the TurboCharger™. When you are ready to
start, turn on ONLY the Battery breaker. Do NOT turn on the PV breaker until instructed during the
TurboCharger™ initialization. The unit will not be damaged if the PV breaker is turned on first, but it will
not operate. The internal power supply can only be powered by the batteries.
Batteries give off explosive gasses during charging. All battery enclosures should be vented to the
outside. Never locate the TurboCharger™ in a poorly ventilated battery area. Do not locate the unit within
4’ (1.2 meters) of the batteries.
The illustration below shows a view of the wiring access area.
There are six large lugs for the power
conducting cables; Bat +, Bat -, PV -,
PV + and Ground. Use #3 to #8 AWG
wire rated for 75ºC in each of these
terminals. Torque each terminal to 50
lb-in (5.64 N-m).
AA
TURBOCHARGER WITH WIRING BOX COVER
REMOVED SHOWING CONNECTORS
+BAT+ -BAT- +PV+ - PV -
AUXILIARY
RELAY 2
NORMALLY OPEN RELAY
CONTACTS (50VDC @ .5A max)
TO CONTROL EXT EQUIPMENT
6 PIN MODULAR JACK FOR
CABLE TO APOLLO BATTERY
SHUNT ASSEMBLY
OPTION CARD SLOT
AUX 1 AUX 2
N. O. RELAYS
AUXILIARY
RELAY 1
B - KNOCK OUTS FOR 1" or 1-¼” CONDUIT
A - KNOCK OUTS FOR 1/2" or 3/4” CONDUIT
A
B B
B
C - KNOCK OUTS FOR OPTIONAL RF ANTENNA
C
C
4 PIN MODULAR JACKS FOR
NETWORKING (STACKING)
MULTIPLE TURBOCHARGERS
PIN HEADER –
REMOVE WHEN 2
NETWORK CABLES
ARE CONNECTED
4 PIN MODULAR JACK
DO NOT USE

TurboCharger™ Installation and Operation Manual Page 12
Apollo Shunt
The TurboCharger™ is designed to utilize a specially made shunt assembly. The Apollo Shunt is
essential to operate at optimal levels and it serves as a hub for connecting critical measurement sensors.
The main purpose of the shunt is to allow the TurboCharger™ to measure current flowing into and out of
the battery. The circuit board attached to the shunt has two “modular“-type jacks (the larger jack is also
known as RJ-12 and the smaller RJ-9) and one voltage sense wire jack. The modular jack marked “T80”
(J3) accepts the grey cable which carries information between the shunt and the TurboCharger™. The
modular jack marked “TEMP” (J5) accepts the black battery temperature sensor cable. The small white
jack near the top of the T80 Shunt circuit board marked “BATT” (J4) accepts the voltage sense wires. The
voltage sense wires transmit accurate battery voltage information to the TurboCharger™. Accurate
voltage information is critical to perform advanced the charge control functions and for the Energy Monitor
to operate properly. Warning: The modular jacks must never be connected to telephone equipment.
Locating the Shunt—for safety and practicality the DC load center is the recommended location for the
Shunt. Most popularly available DC load centers have provisions to accept the shunt. If no load center is
available or there is no room in the load center, install the shunt in a code compliant electrical enclosure.
DC Cable Installation—the shunt has two large brass bolts which thread into the top of the shunt, these
are the connection location for the DC power cables. The cables which attach to the shunt should have
ring terminals with a 3/8” (9.5 mm) size hole. It is very important that the shunt be installed in the correct
direction. It must be installed so that the cable which connects battery negative to the shunt is connected
to the shunt post marked closest to the connector labeled “BATT”.
Temperature Sensor Cable Installation—After installing the battery temperature compensation sensor
(see instructions Battery Temperature Sensor on the following page) route the black cable to the Apollo
Shunt and plug it into the RJ9 jack marked “TEMP”.
TurboCharger™ Cable Installation—Route this cable between the TurboCharger™ and the Apollo Shunt
location. (It may be necessary to route cable through a few electrical boxes located between the shunt
and controller.) Note: This is a low voltage cable, and must not come in contact with either the
battery or PV cables, nor should it be run in the same conduit. Plug one end into the Apollo Shunt
modular jack marked “T80”. When routing the cable through conduit wrap the modular plug with electrical
tape to protect it from damage.

TurboCharger™ Installation and Operation Manual Page 13
Voltage Sense Wire Installation— Push
the white connector on the wire assembly
onto the white connector on the Apollo
Shunt circuit board after connecting the
red wire to a battery positive buss and the
black wire to a battery negative buss
within the DC load center. Be sure to
observe correct polarity when installing
voltage sense wires or damage will result.
Note: Fuse on positive battery terminal
(1/2A 5mm x 20mm fuse).
Battery Temperature Sensor

WARNING
Batteries give off explosive gasses during charging. All battery enclosures should be vented to
the outside. Never locate the TurboCharger™ in a poorly ventilated battery area. Do not locate
the unit within 4’ (1.2m) of batteries.

WARNING
The TurboCharger™ has an external temperature sensor which adjusts charging voltage up or
down according to the temperature read by the sensor. Altering factory temperature
compensation settings may result in overheated batteries which in turn could cause a fire.
The TurboCharger™ requires that the Battery Temperature Compensation Sensor (hereafter referred to
as “the sensor”) be connected for all charging features to be available. The controller will operate without
the sensor but the Absorption Trigger set points will be lower and equalization will be disabled.
The sensor is designed to be mounted on batteries one of two ways, onto a battery terminal or onto the
side of a battery case. The method chosen will depend on the type of battery. If the battery is of single-
wall construction the sensor should be located approximately half-way down the battery near the center of
the battery bank. If the battery is of double-wall construction or is housed in an exterior case the sensor
should be located on a battery terminal. When mounting the sensor on battery terminal be sure that the
sensor is in direct contact with the terminal by installing it on the opposite side of the terminal from the DC
power connection cables. Mount only on flag type terminals.
SHUNT WIRING DETAIL
MODULAR CABLE WITH 6 PIN RJ-11
AT BOTH ENDS PLUGS INTO THE
CONTROL PC BOARD IN THE T80.
TEMPERATURE SENSOR
(Stick between batteries below
top of the electrolyte level.)
OUTPUT TO DC
LOAD BREAKER
+
_
APOLLO
SHUNT
BOARD
BATTERY VOLTAGE
SENSE WIRES WITH FUSE
(Must be connected across
the full battery voltage.)
FROM THE
TurboCharger
BATTERY TERMINALS
+_
This diagram shows a
pair of 12 volt batteries.
The T80 works with 12,
24 or 48 volt battery
systems.
SHUNT 50mV
500AMP
+Bat
-Bat
FUSE
Temperature
NOTE: The Shunt must
be the only item wired
directly to the battery
negative terminal.

TurboCharger™ Installation and Operation Manual Page 14
INITIALIZATION
Each TurboCharger™ requires initialization when it is first installed and commissioned. The initialization
process is the way that it “gets introduced” to its new environment. A series of screens take the installer
through the installation process in a simple step-by-step manner. The TurboCharger™ has a four line
display which uses “soft keys” as a means of user interface. Under the display are four keys, the functions
of the keys change in accordance with what is displayed above the key.
Once all mechanical and electrical connections are completed the unit is ready for commissioning. To
start the initializing process, simply turn the battery breaker to the ON position. Before turning on the
battery breaker please make sure that all connections are tight and secure. Make sure that the PV
breaker (or other DC input source) is turned OFF. When the initialization process is complete the on
screen instructions will tell the installer when to turn the PV breaker on.
Once the battery breaker is turned on a welcome screen will be displayed.
1 Welcome Screen
The Welcome screen provides information on the model (T80 or T80HV), the numeric software revision
(REV:X.XX), alphabetic hardware revision of the Power Board(P:XX) and Control Board(C:XX), serial
number (S/N:XXXXXX), and option card installed (ASNET). This screen will be displayed for seven
seconds while battery voltage is determined. After seven seconds the battery confirmation screen will be
displayed.
2 Battery Voltage Confirmation Screen
This screen displays the nominal battery voltage that the TurboCharger™ has detected and asks the
installer to confirm that the voltage found is correct. In almost all circumstances the correct battery voltage
will be detected. If the battery voltage displayed is different from the installed batteries immediately
undertake appropriate troubleshooting procedures to ensure that the battery is wired correctly and has
sufficient charge to be within its nominal voltage range.
If NO is pressed a Change Battery Voltage screen will appear.
If YES is pressed a Second Battery Voltage Confirmation screen will appear.
A P O L L O S O L A R
T u r b o C h a r g e r T 8 0 H V
R E V : X . X X P : X X C : X X
S / N : X X X X X X A S N E T
A P O L L O S O L A R
B A T T E R Y F O U N D
N O M I N A L X X V O L T S
C O N F I R M : N O Y E S

TurboCharger™ Installation and Operation Manual Page 15
3 Change Battery Voltage Screen
This screen will only display if NO is selected in the Confirm Voltage screen and is used to manually set
nominal battery voltage. The default value displayed will be the voltage found by the TurboCharger™,
selecting the – or + keys will raise or lower the battery voltage displayed in twelve volt increments.
If NEXT is selected the Second Battery Voltage Confirmation screen will appear.
4 Second Confirm Voltage Screen
It is critical to the safe operation of the entire electrical system that the correct battery voltage setting be
entered. This screen is a safeguard and provides a second chance to review the selection and confirm it
is correct.
If NO is selected the Battery Voltage Confirmation screen will appear
If YES is selected the Battery Setup screen #1 will appear.
1B Battery Setup Screen #1
This screen allows the installer to “tell” the TurboCharger™ what type of batteries it is connected to
(Flooded, Gel, AGM or Flooded NiCAD) and what the capacity of the batteries are.
The default “BATTERY TYPE” is GEL; choose other battery types by scrolling up or down the list. Please
be sure to select the type which matches the system’s batteries. This setting controls battery charging
voltages.
This setting controls battery charging amperages and other settings. The default setting for CAPACITY is
1600 amp hours. At full output capacity a TurboCharger™ can deliver 80 amps to a battery, this amount
of amperage (current) is equal to the C/20 (capacity divided by twenty) rate of a 1600 amp hour battery
and, as such meets most manufacturers recommendations for minimum PV charging capacity. In
applications with battery banks under 1600 amp hours it is recommended to lower the Maximum Charge
Rate setting from the default 80 amps to the C20 rate of the battery bank. Note: Where multiple
capacities are listed in the battery manufacturer’s specifications; use the 20 Hr capacity.
S E T B A T T E R Y V O L T A G E
S C R O L L W I T H - O R + K E Y
S E L E C T E D X X V O L T S
- + N E X T
B A T T E R Y C O N F I R M A T I O N
Y O U S E L E C T E D : X X V O L T S
N O Y E S
B A T T E R Y T Y P E = X X X X X X X
C A P A C I T Y = X X X 0 A H R
B A C K - + N E X T

TurboCharger™ Installation and Operation Manual Page 16
The installer will prompted to enter a capacity. Once this is entered the NEXT key will display the
first in a series of Battery Setup screens. These screens offer a manual override of the default
generic settings for each battery type selected. Not all setting adjustments will be available
depending upon Battery Type. (For example Auto Equalization is not available for Gel batteries.).
In most cases the default settings provided for each battery type and capacity are appropriate and the
installer will simply scroll through the screens confirming each setting value provided. It is not
recommended to change default settings unless advised so by the battery manufacturer or supplier.
2B Battery Setup Screen #2
B A T T E R Y S E T U P 2
M A X C H A R G E A M P S = X X A
B A C K - + N E X T
This screen allows the installer to limit the maximum charge amps allowed to the batteries. The default
setting is based on the Battery Capacity entered in the previous screen.
3B Battery Setup Screen #3
B A T T E R Y S E T U P 3
A B S = X X . X V F O R H H : M M
F L T = X X . X V
B A C K - + N E X T
This screen allows the installer to adjust the Absorption and Float voltages, as well as the length of time
the TurboCharger™ will charge at the Absorption voltage before switching to float mode. The default
values are based on the battery type and capacity selected. It is not advisable to change default settings
unless advised so by the battery manufacturer or supplier.
Note: When used in a system with a grid connected inverter. Set the sellback voltage on the inverter to
just below the absorb voltage setting. This will ensure that the TurboCharger™ will deliver full current
from the PV array. It is advised that sellback be turned off occasionally to allow the batteries to float.
4B Auto Equalize Screen
E Q U A L I Z E V O L T S = X X . X V
M A X E Q T I M E = H H : M M
D A Y S B E T W E E N E Q = X X X
B A C K - + N E X T
This screen is only displayed if Flooded is selected as Battery Type. It allows the installer to override
default values for equalize volts, time of equalization charge and the number of days between
equalization charges. The default values are based on the battery type and capacity selected. It is not
recommended to change default settings unless advised so by the battery manufacturer or supplier.

TurboCharger™ Installation and Operation Manual Page 17
5B Set Clock Screen
S E T C L O C K M O D E = X X H r
T I M E = H H : M M : S S A M
D A T E = M M / D D / Y Y
B A C K - + N E X T
This screen is the final battery set up screen for all battery type and/or brand choices. It allows the
installer to enter the correct time and date as well as select the time format. The installer will be prompted
to select either 12 hour (AM/PM) or 24 hour clock display format. Once this selection is made the time will
display 12 noon in the selected mode. Enter the correct time using the – and + keys to move the hour and
minutes values up and down. Enter the correct date in the same manner.
6B Save Battery Setting Screen
This screen confirms that the battery settings are complete and asks the installer if they want to save the
settings entered. The possible choices are DFLT (default), RCLL (recall), and SAVE.
If SAVE is selected the controller will save the entered settings and operate with them.
If DFLT is selected the controller will revert to and operate at default settings based on the
original voltage, battery type and capacity entered in the initialization process. Pressing
Pressing the RCLL key will return to the last settings prior to entering setup.
8B Final Battery Setup Screen
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This screen confirms that the TurboCharger™ is ready to receive power from the PV array. Now is the
time to turn on the breaker from the PV array. This screen will stay active until the input breaker is closed
and the unit senses incoming power from the PV array. This is the end of Battery Setup, Pressing the
next key will display the Main Status Screen. Please refer to the next section of this manual, “Operating
the TurboCharger™” for information about Status screens.
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TurboCharger™ Installation and Operation Manual Page 18
FRONT PANEL STATUS INDICATOR LED
The Light Emitting Diode (LED) status indicator works in conjunction with the status screens. It is a three
color LED (Green, Amber, Red) whose color indicates the following:
•Steady Amber: When the voltage from the PV array is first applied, the unit is preparing to
charge.
•Flashing Green: The unit is in charge mode. This also serves as a “heartbeat” to indicate that
the TurboCharger™ is functioning properly.
•Alternating Green and Amber: The unit is in equalization mode.
•Steady Red: Error indicator. This draws attention to error conditions displayed on the status
screen:
oHigh Input Voltage – Displayed if the PV voltage exceeds the maximum Input Voltage.
E R R O R ! ! !
H I G H I N P U T V O L T A G E
C L E A R
After the error condition is corrected, pressing CLEAR will return to normal operation.
RESTARTING THE TurboCharger
From time to time there will be occasion to shut the TurboCharger™ down, which is accomplished by
turning off the PV breaker and the Battery breaker thus disconnecting power. Reasons to shut down the
controller include; battery or PV array maintenance, changes or additions to the system and
troubleshooting. When the unit is restarted it first displays the Welcome Screen (1) for seven seconds. It
then displays a screen which asks the operator to verify that the retained settings are still correct.
9B Retained Battery Setting Confirmation
B A T S E T U P X X V X X X X X H
B E T T E R Y T Y P E = X X X X X X X
A B S = X X . X V F L T = X . X X V
C H A N G E K E E P
This screen is used when the TurboCharger™ is restarted to verify battery voltage, type, make and
capacity settings. If the settings displayed are correct pressing KEEP will turn the controller on at the last
retained settings. If CHANGE is selected the controller will default to Initialization Setup routine. The first
screen displayed will be Battery Voltage Confirmation Screen (2).
Pressing the CHANGE key will return to the Battery Setup routine
Pressing the KEEP key will confirm the displayed settings, turn the controller on and advance to
display the Set Clock screen (5B), as the clock setting is not retained when battery voltage is
removed.
Note: If neither key is pressed, the unit will time out and return to the main screen, retaining the
previously saved settings. In the event of a power interruption, the settings will always revert to the last
retained settings.