Go Power GP-PWM-30 User manual

Solar Controller
GP-PWM-30
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© 2012 Carmanah Technologies Corporation
September 2012
Owner’s Manual

Solar Controller
GP-PWM-30
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© 2012 Carmanah Technologies Corporation
September 2012

Solar Controller
GP-PWM-30
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© 2012 Carmanah Technologies Corporation
September 2012
CONTENTS
1.0 Installation Overview 4
1.1 Introduction 4
1.2 Specifications 5
2.0 Warnings 6
3.0 Tools and Materials Needed 7
4.0 Choosing a Location 7
5.0 Installation Instructions 8
6.0 Operating Instructions 10
7.0 Frequently Asked Questions (FAQs) 15
8.0 Troubleshooting Problems 16
8.1 Problems with the Display 16
8.2 Problems with Voltage 17
8.3 Problems with Current 17
9.0 Limited Warranty 19
9.1 Repair and Return Information 19
10.0 Glossary 20
11.0 Installation Template 21
12.0 Wiring Diagram 23

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GP-PWM-30
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© 2012 Carmanah Technologies Corporation
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1.0 Installation Overview
1.1 Introduction
A Charge Controller is an essential component of your photovoltaic (PV)
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 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 technology and a unique four
stage charging system and 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.

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GP-PWM-30
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© 2012 Carmanah Technologies Corporation
September 2012
1.2 Specifications
Description
Value
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
PWM Charging
3 Battery Charging profiles
4 Stage Charging
Monthly Equalize option
Displays Charging Current,
Battery Voltage and Battery
State of Charge
Reverse Polarity protected
Temperature Compensated
RoHS Compliant,
environmentally safe
Accepts over 400 Watts of
solar at 12 volts
Nominal System Voltage
12V
Max. Solar Array Current
30 amps
Battery Voltage Range
6V –15.5V
Max. Solar Voltage
28V
Operating Consumption
Display Consumption
6mA
10mA
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 (25°C / 77°F),
2h / 28 Day or V < 12.1
Temperature
Compensation
- 4mV/cell*K
Operating Temperature
Display Operating
Temperature
- 40 to 85°C / - 40 to 185°F
- 20 to 55°C / - 4 to 131°F
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
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.

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GP-PWM-30
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© 2012 Carmanah Technologies Corporation
September 2012
2.0 Warnings
Disconnect all power
sources
Electricity can be very dangerous.
Installation should be performed
only by a licensed electrician or
qualified personnel.
Battery and wiring
safety
Observe all safety precautions of
the battery manufacturer when
handling or working around
batteries. When charging, batteries
produce hydrogen gas, which is
highly explosive.
Wiring connections
Ensure all connections are tight
and secure. Loose connections
may generate sparks and heat. Be
sure to check connections one
week after installation to ensure
they are still tight.
Work safely
Wear protective eyewear and
appropriate clothing during
installation. Use extreme caution
when working with electricity and
when handling and working around
batteries.
Observe correct
polarity
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.
Do not exceed the
GP-PWM-30 Amp
current and max
voltage ratings
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.

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GP-PWM-30
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© 2012 Carmanah Technologies Corporation
September 2012
3.0 Tools and Materials Needed
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.
The GP-PWM-30 should be:
mounted as close to the battery as possible.
mounted on a vertical surface to optimize cooling of the unit.
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.
Drill with 3/32” and 3/8 bits
UV Wire (Solar Array to
GP-PWM-30)*
Keyhole or Jigsaw
Battery Wire (GP-PWM-
30 to Battery)*
Phillips Screwdriver
Wire Cutters
Pencil or Marking Implement
Wire Strippers
Torque wrench (optional)
Electrical Tape

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GP-PWM-30
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© 2012 Carmanah Technologies Corporation
September 2012
5.0 Installation Instructions
1. 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.”
2. 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.
3. 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
purchased separately, follow the instructions included here.
Wire type is recommended to be a stranded copper 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 Torque
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.

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GP-PWM-30
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© 2012 Carmanah Technologies Corporation
September 2012
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.
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 any
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.
5. 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. If the battery type is not
selected, the GP-PWM-30 will only flash 3 dashes (---) on the screen
and will not operate correctly. See section 6.0 for instructions on
setting battery type.
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.
6. Re-torque:
After 30 days of operation, re-torque all terminal screws to
ensure the wires are properly secured to the controller.

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GP-PWM-30
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© 2012 Carmanah Technologies Corporation
September 2012
6.0 Operating Instructions
Power Up
When the GP-PWM-30 is
connected to the battery, the
GP-PWM-30 will go into Power
Up mode.
Icons Displayed: Three
horizontal dashes
Setting the Battery Type / Charging Profile
Set the Battery Type / Charging
Profile by holding down the B
Button for 5 seconds. When the
display begins blinking you may
set the Battery Type by toggling
through the Charging Profile
numbers 1, 2 or 3 by pressing
the B Button.

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GP-PWM-30
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© 2012 Carmanah Technologies Corporation
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Refer to the Battery Charge
Profile Chart on the following
page for details on each
profile.
Confirm the Battery 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.

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GP-PWM-30
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© 2012 Carmanah Technologies Corporation
September 2012
Battery Charge Profile Chart
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.
NOTE: This feature is only available for Charging Profile 1.
Battery Type
FLOODED
AGM
GEL
Charging Profile #
1
2
3
Float Charge @ 25°C:
13.7V
Bulk/Absorption Charge @ 25°C:
Applied for 1h each morning
14.4V
14.1V
Boost Charge
Applied for 2 hours if the battery voltage drops
below 12.3 volts.
14.4V
14.1V
Equalization Charge
Applied for 2 hours every 28 days and if the
battery voltage drops below 12.1 volts.
14.8V
N/A
N/A
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 and GEL are generic battery designations. Choose the
charging profile that works best with your battery manufacturer’s recommendations.

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GP-PWM-30
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© 2012 Carmanah Technologies Corporation
September 2012
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.
Icons Displayed: Battery,
Percent Symbol
Push the B Button to show
the battery voltage.
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.
Icons Displayed: Sun, Battery, Current Symbol (A)
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.

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GP-PWM-30
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© 2012 Carmanah Technologies Corporation
September 2012
Errors
Over Voltage
If the GP-PWM-30 experiences
a battery over voltage (15.5V),
the controller will stop operating
and the display will begin to
flash. The controller will resume
operating when the error is
cleared.
Icons Displayed: Battery, Volt Symbol, Lightning Bolt
Low Voltage
If the GP-PWM-30 experiences
the battery state of charge
reaching zero, 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.
Icons Displayed: Battery, Percent Symbol, Lightning Bolt

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GP-PWM-30
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© 2012 Carmanah Technologies Corporation
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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.
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 ventilated 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 battery 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.

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© 2012 Carmanah Technologies Corporation
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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 Installation 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) & (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) & (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.

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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 controller 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: 0 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) Check all connections from the controller to the array including checking 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.

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© 2012 Carmanah Technologies Corporation
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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 than 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.

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© 2012 Carmanah Technologies Corporation
September 2012
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:
Misuse and/or abuse, neglect or accident
Exceeding the unit’s design limits
Improper installation, including, but not limited to, improper
environmental protection and improper hook-up
Acts of God, including lightning, floods, earthquakes, fire,
and high winds
Damage in handling, including damage encountered during
shipment
2. This warranty shall 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

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10.0 Glossary
Ampere: A unit of electrical current. Designates the number of electrons flowing per
second through a conductive material.
Array: One or more photovoltaic (PV) modules electrically connected to produce a single
electrical output.
Battery: Two or more electrochemical cells connected to provide energy storage.
May be used to designate one cell. PV system batteries may be “sealed” or “wet acid”.
Charge Controller: The PV system component that controls the battery’s state of charge.
It may also provide other system control functions. Also referred to as a controller.
Charge Rate: The current applied to a battery to restore its energy capacity. The battery
manufacturer will usually have a recommended charge rate for their product. The rate is
typically 10 –20 percent of the amp hour capacity at the 20-hour rate.
Current: DC or Direct Current is the type of electron flow provided by a battery or solar
cell, which flows in one direction. The unit for current is ampere or amp for short and
designated by the letter A.
Deep Cycle Battery: Batteries that are designed to discharge as much as 80% of their
capacity as opposed to engine-starting or “shallow cycle” batteries which are designed for
heavy cranking but will not stand up to repeated deep discharges.
Equalization: The process that equalizes the specific gravity of all the cells in a battery by
means of a controlled overcharge that breaks down sulfation on the battery plates. Most
inverter/chargers and some charge controllers are equipped with this feature.
Maximum Power: Also referred to as peak power. The point of a solar array, panel or
module output where the product of “Imp” and “Vmp” (“Pmax”, measured in watts) is
maximized. The points used to calculate Pmax are Imp (current @ max power) and Vmp
(voltage @ max power).
Solar Module: A number of solar cells electrically connected, and protected from the
environment usually by an aluminum frame covered with a pane of glass. A module is self-
contained and not sub dividable, therefore providing a single electrical output.
Open-Circuit Voltage (Voc): Refers to a photovoltaic device’s voltage potential when it is
disconnected from the rest of the PV system.
Parallel Connection: Electrical connection where the positive terminals of a number of
devices are connected together, as are their negative terminals. The output voltage is
usually limited to the device with the lowest voltage, and the total current is the sum of the
current of all the devices.
Photovoltaic (PV): Capable of producing a voltage when exposed to radiant energy,
especially light.
Sealed Batteries: Electrolyte will not spill out and gassing is kept to a minimum. A sealed
battery is maintenance free and may be installed in several orientations. GEL and AGM are
two common types of sealed batteries.