Invertek SUNSTAR SERIES Owner's manual

INVERTEK® SUNSTAR SERIES
SOLAR CHARGE CONTROLLER
SS-30C/ SS-45C/ SS-60C
Installation and Operation Manual
USER MANUAL
Solar Battery Charging
Load Control
Diversion Charge Control
RICH ELECTRIC CO.,LTD.

CONTENTS
Specifications..................................................................................................................................I
Chapter 1 SunStar Description.................................................................................................1-1
1.1 Versions and Ratings.......................................................................................1-1
1.2 Operating Modes..............................................................................................1-2
1.3 Adjustability.....................................................................................................1-2
1.4 General Use.......................................................................................................1-3
1.5 Optonal Available ............................................................................................1-4
Chapter 2 SunStar Installation.................................................................................................2-1
2.1 General Information........................................................................................2-1
2.2 Installation Overview.......................................................................................2-1
2.3 Control Terminal Connection.........................................................................2-2
2.4 Installation Steps..............................................................................................2-4
2.4.1 Mounting ................................................................................................2-5
2.4.2 Solar Battery Charging DIP Switch Settings.......................................2-5
2.4.3 Load Control DIP Switch Setting..........................................................2-8
2.4.4 Diversion Charge Control DIP Switch Settings...................................2-11
2.4.5 Battery Temperature Sensor (BTS)......................................................2-11
2.4.6 System Wiring and Power-Up...............................................................2-11
2.4.7 Finish Installation...................................................................................2-13
2.5 Communication with CombiPlus/SuperCombi.............................................2-14
Chapter 3 Front Cover of SunStar Operation........................................................................3-1
3.1 LED Status Indicator.......................................................................................3-2
3.2 Charge Control or Diversion Control Mode Indicatons..............................3-2
3.3 Load Control Indications................................................................................3-2
3.4 Equalization Mode Indication ........................................................................3-3
3.5 Fault Mode Indication.....................................................................................3-3
3.6 LCD Meter Displays........................................................................................3-4
3.6.1 LCD Displays Flow.................................................................................3-5
3.6.2 Fault Messages ........................................................................................3-6
Chapter 4 Solar Battery Charging...........................................................................................4-1
4.1 PWM Battery Charging..................................................................................4-1
4.1.1 Four Stages of Solar Charging...............................................................4-1
4.1.2 Battery Charging Notes..........................................................................4-1
4.2 Standard Battery Charging Programs...........................................................4-2
4.3 Temperature Effects........................................................................................4-3
4.3.1 Battery Temperature Sensor (BTS)......................................................4-3
4.4 Equalization......................................................................................................4-4
4.4.1 Standard Equalization Programs..........................................................4-5
4.4.2 Typical Equalization...............................................................................4-6
4.4.3 When to Equalize....................................................................................4-6

4.5 Float...................................................................................................................4-6
Chapter 5 Load Control............................................................................................................5-1
5.1 Load Control Settings......................................................................................5-1
5.2 Inductive Loads (Motors)................................................................................5-1
5.3 General Load Control Notes...........................................................................5-2
5.3.1 Inverters...................................................................................................5-2
5.3.2 Parallel SunStar......................................................................................5-2
5.3.3 Reverse Polarity......................................................................................5-2
Chapter 6 Diverson Charge Control........................................................................................6-1
6.1 Diversion Charge Control...............................................................................6-1
6.2 Diversion Current Ratings..............................................................................6-1
6.3 Stanadrd Diversion Battery Charging Programs.........................................6-1
6.4 Selecting the Diversion Load...........................................................................6-2
6.4.1 Suitable Load for Diversion...................................................................6-2
6.4.2 Definition of Terms.................................................................................6-3
6.4.3 Load Power Ratings................................................................................6-3
6.4.4 Maximum Diversion Load .....................................................................6-4
6.4.5 Minimum Diversion Load Definition of Terms....................................6-4
Chapter 7 Trouble Shooting .....................................................................................................7-1
Chapter 8 Battery Information.................................................................................................8-1
8.1 Sealed Batteries................................................................................................8-1
8.2 Flooded Batteries .............................................................................................8-2
8.3 L-16 Cells..........................................................................................................8-3
8.4 Nicad and NiFe Batteries.................................................................................8-3
Appendix A EMC Certificate
Appendix B C-tick Certificate

Specifications
Ⅰ
MODEL SS-30C SS-45C SS-60C
ELECTRICAL
System voltage ratings 12, 24, 48 Vdc
Current ratings-Battery Charge
Control 30A 45A 60A
Current ratings-Load Control 30A 45A 60A
Current ratings-Diversion Charge
Control 30A
Diversion load 45A Diversion load 60A Diversion load
Accuracy 12/24V:≦0.1 % ± 50 mV
48V:≦0.1 % ± 100 mV
Min. voltage to operate 9 V
Max. solar array Voc 140 V
Max. operating voltage 68 V
Total current consumption While operating -25mA, at idle -3mA
High temp shutdown 90ºC disconnect solar 90ºC disconnect load / diversion load
70ºC reconnect solar / load / diversion load
Transient surge protection
pulse power rating 4500 watts
response < 5 nanosec
BATTERY CHARGING / BTS
Charge algorithm PWM, constant voltage
Temp comp. coefficient –5mV/ºC / cell (25ºC ref)
Temp comp. range 0ºC to +50ºC
Temp comp. setpoints PWM, float, equalize (with BTS option)
MECHANICAL
Dimensions (mm) H: 65 / W: 236 /
D: 35 H: 266 / W: 127 / D: 75
Weight 0.8 kg 1.5 kg
Power terminals 30A Rated 45A Rated 60A Rated
BTS / Sense terminals
wire sizes 1.0 to 0.25 mm2/ 16 to 24 AWG
torque 0.40 Nm / 3.5 in-lb
ENVIRONMENTAL
Ambient temperature –40 to +45ºC
Storage temperature –55 to +85ºC
Humidity 100% (NC)
Enclosure Indoor & vented, (powder coated steel)
Specifications subject to change without notice

1-1
Chapter 1 SunStar Description
The SunStar is a technically advanced solar system controller. There are three operating
modes programmed into each SunStar. The manual describes solar battery charging, DC
diversion charge control or DC Load control instructions are inserted where required.
The manual will help you to become familiar with the SunStar’s features and capabilities.
This operation manual is applicable to the software version V1.05 and later version of the
SunStar units. Some of these follow:
zSolid-state Pulse Width Modulated (PWM) charging process with four-stage control,
temperature compensation, and manual or automatic equalization to maximizes system
performance and increase battery life.
zElectric overload and short circuit protection with automatic and manual reset
capability increase the reliability of unattended systems by eliminating blown fuses
and tripped circuit breakers.
zOptional external battery temperature compensation (BTS) for automatic adjustment of
charge setpoints.
zOver-temperature protection for the electronic circuitry when used in hot environment
(over 80℃)
zLCD meter with easy to read mode/status messages.
zLCD meter for remote or direct mounting on the controller. May be mounted up to 500
feet away.
zAn 8-position DIP switch to set up the controller for its intended use. All major
functions can be set with DIP switches.
zRated for 12, 24, 48 volt systems, and 30, 45 or 60 amps current.
zEight standard charging or Load programs selected with DIP switches.
zContinuous self-testing with fault notification.
zLED indications and pushbutton functions.
zComplies with EMC and LVD standards for CE marking.
1.1 Versions and Ratings
There are three standard versions of SunStar controllers:
SunStar-60 (SS-60C):
Rated for maximum 60 amps continuous current
(solar, load or diversion load)
Rated for 12, 24, 48 Vdc systems
SunStar-45 (SS-45C):
Rated for maximum 45 amps continuous current
(solar, load or diversion load)
Rated for 12, 24, 48 Vdc systems
SunStar-30 (SS-30C):
Rated for maximum 30 amps continuous current
(solar, load or diversion load)
Rated for 12, 24, 48 Vdc systems
※LCD meter (optional)

1-2
1.2 Operating Modes
There are three distinct and independent operating modes programmed into each SunStar.
Only one mode of operation can be selected for an individual SunStar. If a system requires a
charging controller and a load controller, two SunStars must be used.
Solar Battery Charging
The energy output of a solar array is used for recharging the system battery.
The SunStar manages the charging process to be efficient and to maximize the life of the
battery. Charging includes a bulk charging stage, PWM absorption, float and equalization.
DC Load Control
When set for DC load control, the SunStar powers loads from the battery, and protects the
battery from over-discharge with a current compensated LVD (low voltage load
disconnect).
DC Diversion Charge Control
In DC diversion mode, the SunStar will manage battery charging by diverting energy from
the battery to a dedicated diversion load. The energy source is typically wind or hydro.
1.3 Adjustability
Eight DIP switches permit the following parameters to be adjusted at the installation site:
DIP switch Solar battery charging (Diversion charge control)
1 (OFF) Battery charge control mode (Diversion charge control mode)
2 3 Select Battery Voltage
OFF OFF 48V system
ON OFF 24V system
OFF ON 12V system
4~6 Standard battery charging programs
7 (OFF) Manual Equalization
(ON) Auto Equalization
8 (OFF) Operating from Dip Switch 4~6 battery charging programs settings
(ON) VR1 and VR2 settings for user define battery charging programs
DIP switch Load control
1 (ON) Load control mode
2 3 Select Battery Voltage
OFF OFF 48V system
ON OFF 24V system
OFF ON 12V system

1-3
DIP switch Load control
4~6 Standard low voltage disconnects and reconnects
7 (OFF) Manual reconnect for Dip Switch 4~6 standard low voltage
(ON) Auto reconnect for Dip Switch 4~6 standard low voltage
8 (OFF) Operating from Dip Switch 4~6 standard low voltage
disconnects and reconnects
(ON) VR1 and VR2 settings for user define low voltage disconnects
and reconnects
1.4 General Use
NOTE: This manual describes solar battery charging. Specific instructions for the DC load
control and DC diversion charge control modes are provided as notes throughout
this manual.
zThe SunStar is suitable for a wide range of solar applications including homes, telecom
and industrial power needs.
zThe SunStar controllers are configured for negative ground systems. There are no parts
in the controller’s negative leg. The enclosure can be grounded using the ground
terminal in the wiring compartment.
zThe SunStar is protected from faults electronically with automatic recovery. There are
no fuses or mechanical parts inside the SunStar to reset or change.
zSolar overloads up to 130% of rated current will be tapered down instead of
disconnecting the solar. Over-temperature conditions will also taper the solar
input to lower levels to avoid a disconnect.
zAny number of SunStars can be connected in parallel to increase solar charging current.
SunStars can be paralleled ONLY in the battery charging mode. DO NOT parallel
SunStars in the load mode, as this can damage the controller or load.
zThe SunStar is rated for indoor use. The controller is protected by conformal coated
circuit boards, stainless steel hardware, anodized aluminum, and a powder coated
enclosure, but it is not rated for corrosive environments or water entry.
zThe construction of the SunStar is 100% solid state.
zBattery charging is by a series PWM constant current charging, with bulk charging,
PWM absorption, float and equalization stages.
zThe SunStar will accurately measure time over long intervals to manage events
such as automatic equalizations or battery service notification.
zDay and night conditions are detected by the SunStar, and no blocking diodes are used
in the power path.
zLED’s, a pushbutton, and LCD meters provide both status information and various
manual operations.

1-4
1.5 Optional Available
Three optional components can be added to the standard SunStar controller at any time.
※Battery Temperature Sensor (BTS)
If the temperature of the system battery varies more than 5°C during the year,
temperature compensated charging should be considered. Because the battery’s
chemical reactions change with temperature, it can be important to adjust charging to
account for the temperature effects. The BTS will measure the battery temperature, and
the SunStar uses this input to adjust the charging as required.
The battery charging will be corrected for temperature as follows:
Charger Setpoint Temperature Compensation Chart
System Voltage
Battery Type 12VDC 24VDC 48VDC
Lead Acid –30mV/ºC –60mV/ºC –120mV/ºC
Nicad –20mV/ºC –40mV/ºC –80mV/ºC
The BTS should be used only for battery charging and diversion control. Do not use the
BTS for load control. The charging parameters that are adjusted for temperature include:
• PWM regulation
• Equalization
• Float
• High Voltage Disconnect
※Remote LCD Meter
One Remote LCD Meter can be added to the SunStar at any time during or after
installation. The display is a 2x16 LCD meter with backlighting. One pushbuttons is
used to scroll through the displays function.
There are a series of display screens that provide information such as:
• Operating information and data
• Reset Amp-Hours
※RJ-45 Communication Cable
RJ-45 Communication Cable is used to connect the SunStars to CombiPlus or
SuperCombi Inverter/Charger. The connection of CombiPlus or SuperCombi and
SunStars can become a power management control system of standalone PV charger.
When connecting CombiPlus or SuperCombi to SunStars in parallel, the maximum units
can go up to 10 SunsStars. The optional RJ-45 Communication Cables can be supplied
in the following length.
• RJ-45-01 (1 Meter long Communication Cable)
• RJ-45-03 (3 Meter long Communication Cable)
• RJ-45-05 (5 Meter long Communication Cable)
• RJ-45-10 (10 Meter long Communication Cable)

2-1
Chapter 2 SunStar Installation
The installation instructions describe solar battery charging. Specific instructions for the
load control and diversion modes are provided as notes.
2.1 General Information
The mounting location is important to the performance and operating life of the controller.
The environment must be dry and protected as noted below. The controller may be installed
in a ventilated enclosure with sealed batteries, but never in a sealed battery enclosure or
with vented batteries.
If the solar array exceeds the current rating of the controller, multiple SunStars can be
installed in parallel. Additional parallel controllers can also be added in the future. The load
controllers cannot be used in parallel.
If solar charging and load control are both required, two separate controllers must be used.
2.2 Installation Overview
The installation is straightforward, but it is important that each step is done correctly and
safely. A mistake can lead to dangerous voltage and current levels. Be sure to carefully
follow each instruction in Section 2.3 and observe all cautions and warnings.
The following diagrams provide an overview of the connections and the proper order:
Battery
Positive + PV+ / Load + PV—/
Load—Battery
Negative—Earth
Di
p
Switches VR2 VR1
BCD
Switch
Communication Port
IN
OUT
BTS+ BTS—

2-2
2.3 Control Terminal Connection
Name Description
Battery + Battery cable Positive connection
PV+ / Load + Connecting terminal for Solar Array or DC Load Positive
PV—/Load—Connecting terminal for Solar Array or DC Load Negative
Battery—Battery cable Negative connection
Earth Connecting terminal for Ground
Dip Switch 1 ON or OFF to choose battery charge control mode or load control
mode
Dip Switch 2, 3 Selection of battery voltage for 12V or 24V or 48V system
Battery charge control mode: Battery charging algorithm
Dip Switch 4, 5, 6 Load control mode: Load control disconnect/reconnect algorithm
Battery charge control mode: Auto / Manual Equalization
Dip Switch 7 Load control mode: Auto / Manual Reconnect
Dip Switch 8 ON: Potentiometer of VR1, VR2 setting range
OFF: Dip switch 4~6 setting range
VR1, VR2 User define battery charging programs or user define standard low
voltage disconnect and reconnect
BCD Switch 0
SunStar unit is operating alone.
*When the BCD Switch is not placed at 0 and the fault message of
“ Alarm: CPF01 Wait for Combi” will be displayed if the SunStar unit
is not communicating with CombiPlus/SuperCombi
BCD 1~A 1st~10th SunStar units are communicating with CombiPlus
/SuperCombi
BCD B~F They are operating as the 10th SunStar unit
Communication IN Communication port for CombiPlus/SuperCombi
Communication OUT Communication port for the next SunStar unit
BTS+ Connecting terminal for Battery Temperature Sensor Positive
BTS—Connecting terminal for Battery Temperature Sensor Negative

2-3
Ground BTS
BATTERY
Solar Array
DC Load
or
GNDGND
PV+/
LOAD+
BAT+
Installation wiring for solar charging or DC load control
Solar charging or DC load control:
Step 1: Open the access cover
Step 2: Mount the SunStar using the enclosed template.
Step 3: Adjust the 8 switches in the DIP switch. Each switch must be in the correct position.
Step 4: Attach the BTS if battery charging will be temperature compensated (not for load
control).
Step 5: Connect the battery power wires to the SunStar. Then connect the solar array wires
(or DC load wires).
Step 6: Close the cover.
※Step 4 is optional.
DIVERSION
LOAD
Ground
BTS
BATTERY
Hydro
Wind
Solar
GNDGND
PV+/
LOAD+
BAT+
Installation wiring for DC diversion charge control

2-4
DC diversion charge control:
Step 1: Open the access cover
Step 2: Mount the SunStar using the enclosed template.
Step 3: Adjust the 8 switches in the DIP switch. Each switch must be in the correct position.
Step 4: Attach the BTS if battery charging will be temperature compensated
Step 5: Connect the battery power wires to the SunStar. Then connect the diversion load
wires.
Step 6: Close the cover.
※Step 4 is optional.
2.4 Installation Steps
The SunStar controller must be installed properly and in accordance with the local and
national electrical codes. It is also important that the installation be done safely, correctly
and completely to realize all the benefits that the SunStar can provide for your solar system.
Before starting the installation, review these safety notes:
zDo not exceed a battery voltage of 48V (nominal). Do not use a battery less than 12V.
zDo not connect a solar input greater than a nominal 48V array for battery charging.
Never exceed a Voc (open-circuit voltage) of 140V.
zCharge only 12, 24, or 48 volt lead-acid batteries when using the standard battery
charging programs or NI-CAD batteries when DIP switch number 4~6 is ON position
in the SunStar.
zVerify the nominal charging voltage is the same as the nominal battery voltage.
zDo not install a SunStar in a sealed compartment with batteries.
zNever open the SunStar access cover unless both the solar and battery power has been
disconnected.
zNever allow the solar array to be connected to the SunStar with the battery
disconnected. This can be a dangerous condition with high open-circuit solar voltages
present at the terminals.

2-5
2.4.1 Mounting
Unit: mm
Mounting Dimensions
zLocate the SunStar on a wall protected from direct sun, high temperatures, and water.
Do not install in a confined area where battery gasses can accumulate.
zWhen mounting the SunStar, make sure the air flow around the controller and heat sink
is not obstructed. There should be open space above and below the heat sink, and at
least 75 mm (3 inches) clearance around the heat sink to allow free air flow for
cooling.
zBefore starting the installation, place the SunStar on the wall where it will be mounted
and determine where the wires will enter the controller.
2.4.2 Solar Battery Charging DIP Switch Settings
The 8 DIP switches are located on the right of the Earth terminal. Each switch is numbered.
The solar battery charging functions that can be adjusted with the DIP switches follow:

2-6
Manual/Auto Equalization (7)
Battery Charging algorithm (4,5,6)
System Voltage (2,3)
(diversion charge control)
Control Mode (1)
Battery Charging
OFF
ON DIPON
8
7
6
5
4
3
21
User Define Charging algorithm (8)
DIP Switch Functions
※ As shown in the diagram, all the positions are in the “OFF” position except switch
number 3 and 7 which are in the “ON” position.
NOTE: The DIP switches should be changed only when there is no power to the
controller. Turn off disconnect switches and remove all power to the
controller before changing a DIP switch. A fault will be indicated if a switch is
changed while the controller is powered.
CAUTION 1: The SunStar is shipped with all the switches in the “OFF” position.
Each switch position must be confirmed during installation. A wrong
setting could cause damage to the battery or other system components.
CAUTION 2: To configure your SunStar for the battery charging and control you
require, follow the DIP switch adjustments described below. Before
changing any switch, make sure the BCD switch is placed at number 0
for the SunStar settings. To change a switch from OFF to ON, slide the
switch up toward the top of the controller. Make sure each switch is
fully in the ON or OFF position.
DIP Switch Number 1-Control Mode: Solar battery charging
Switch 1 Control Mode
ON Load control mode
OFF Solar charging mode
(Diversion charge control mode)
For the solar battery charging control mode, leave the DIP switch in the OFF position.

2-7
DIP Switch Number 2, 3-System voltage
Switch 2 Switch 3 System Voltage
OFF OFF 48V system
ON OFF 24V system
OFF ON 12V system
DIP Switch Number 4, 5, 6-Battery charging algorithm
DIPSW-4 DIP
SW-5 DIP SW-6 Bulk voltage Float voltage Equalize Voltage
Equalize
Time
(hours)
Equalize
Interval
(days)
OFF OFF OFF 14.0V 13.4V None - -
OFF OFF ON 14.1V 13.4V 14.2V 1 28
OFF ON OFF 14.3V 13.4V 14.4V 2 28
OFF ON ON 14.4V 13.4V 15.1V 3 28
ON OFF OFF 14.6V 13.4V 15.3V 3 28
ON OFF ON 14.8V 13.4V 15.3V 3 28
ON ON OFF 15.0V 13.4V 15.3V 3 14
ON ON ON 16.0V 14.5V - - -
Select one of the 7 standard battery charging algorithms, or select NiCad to determine the
charging of the battery.
※ The above setting voltage value is in the condition of 12V system. The voltage will be
twice of above values in the 24V system and it will be four times of above values in the
48V system.
※Refer to section 8.0 of the manual for battery charging information.
※The 7 standard charging algorithms above are described in section 4.2-standard battery
charging programs.
DIP switch number 7- Battery Equalization
Switch 7 Battery Equalization
ON Auto Equalization
OFF Manual Equalization
※In the Auto Equalization Mode (Switch number 7 ON), the SunStar controller can
automatically triggering of the equalization process. When automatic has been selected,
an equalization charge will occur at set voltage and time (hours and days).
During the equalization process, the status LED indicates equalization (Equalization is
not recommended for NiCad batteries and is disabled). The equalization process will
continue until the voltage has been held above the bulk setting for a cumulative period of
set hours as shown above. This might take several days on larger system with big
batteries and small solar arrays. The battery voltage only needs to exceed the bulk setting

2-8
for the timer to start counting-the voltage may not reach the equalization voltage setting.
To manually stop the equalization process, press the reset pushbutton and the status LED
will stop, if the equalization process was shorter than one hour, the controller will
continue with a bulk charge cycle and then hold the battery at the bulk setting for one
hour (the absorption voltage) before returning to the float setting. Once a manual
equalization has been triggered, the period to the next automatic equalization will be
restarted.
In the Manual Equalization Mode (Switch number 7 OFF), equalization will occur only
when manually started with the push button. The equalization status LED indicator will
begin to equalization enabled. The equalization process will continue until the batteries
have been held at or above the set Equalize Voltage for set Equalize Time of accumulated
time. During the equalization process, the battery voltage will be limited to the set
Equalize Voltage setting. Once the battery voltage has been at or above the set Equalize
Voltage for a cumulative period of set Equalize Time, the SunStar will return to the float
stage of the charge process. To stop the equalization process, press the reset push button,
the status LED will stop. If the equalization process was shorter than one hour, the
controller will continue with a bulk charge cycle and hold the battery at bulk setting for
one hour (the absorption stage) before returning to the float setting.
DIP switch number 8-User define battery select
Switch 8 Charge Control algorithm
ON User define (VR1, VR2)
OFF Dip Switch 4~6 selection
The battery voltage setting range of VR2 BULK Voltage potentiometer is 13.0V~15.0V
The battery voltage setting range of VR1 FLOAT Voltage potentiometer is 12.5V~14.5V
※ The above setting voltage value is in the condition of 12V system. The voltage will be
twice of above values in the 24V system and it will be four times of above values in the
48V system.
The latest LCD Meter display will show the voltage setting value of VR2 and VR1 and the
user can adjust those values directly.
2.4.3 Load Control DIP Switch Setting
The Load Control functions that can be adjusted with the DIP switches follow:

2-9
User Define LVD/LVR (8)
LVD / LVR (4,5,6)
System Voltage (2,3)
Control Mode (1)
DC Load Control
OFF
ON DIP
ON
87
6
5
4321
Auto / Manual LVR (7)
Load Control DIP Switch Functions
※As shown in the diagram, all the positions are in the “OFF” position except switch
number 1, which is in the “ON” position.
NOTE: The DIP switches should be changed only when there is no power to the controller.
Turn off disconnect switches and remove power to the controller before changing a DIP
switch. A fault will be indicated if a switch is changed with the controller powered.
CAUTION 1: The SunStar is shipped with all the switches in the “OFF” position.
Each switch position must be confirmed during installation. A wrong
setting could cause damage to the load or other system components.
CAUTION 2: To configure your SunStar for the Load Control you require, follow the
DIP switch adjustments described below. Before changing any switch,
make sure the BCD switch is placed at number 0 for the SunStar
settings. To change a switch from OFF to ON, slide the switch up toward
the top of the controller. Make sure each switch is fully in the ON or
OFF position.
DIP Switch Number 1-Control Mode: Load Control
Switch 1 Control Mode
ON Load control mode
OFF Solar charging mode
For the load control mode, move the DIP switch to the ON position.
DIP Switch Number 2, 3-System Voltage
Switch 2 Switch 3 System Voltage
OFF OFF 48V system
ON OFF 24V system
OFF ON 12V system

2-10
DIP Switch Number 4, 5, 6-Load Control Algorithm
LVR LVD
DIPSW-4 DIP SW-5 DIP SW-6 12V 24V 48V 12V 24V 48V
OFF OFF OFF 12.6V 25.2V 50.4V 11.1V 22.2V 44.4V
OFF OFF ON 12.8V 25.6V 51.2V 11.3V 22.6V 45.2V
OFF ON OFF 13.0V 26.0V 52.0V 11.5V 23.0V 46.0V
OFF ON ON 13.2V 26.4V 52.8V 11.7V 23.4V 46.8V
ON OFF OFF 13.4V 26.8V 53.6V 11.9V 23.8V 47.6V
ON OFF ON 13.6V 27.2V 54.4V 12.1V 24.2V 48.4V
ON ON OFF 13.8V 27.6V 55.8V 12.3V 24.6V 49.2V
ON ON ON 12.0V 24.0V 48.0V 10.5V 21.0V 42.0V
Select 1 of the 8 standard load control algorithms.
Dip Switch Number 7-Auto Reconnect or Disconnect standard low voltage
Switch 7 Selection
ON Auto Reconnect after low voltage returning to Dip Switch 4~6
standard LVR setting
OFF Manual Reconnect after low voltage disconnect (LVD)
Manual reconnect of the loads is allowed when voltage has not exceeded the LVR setting.
To reconnect the loads, press the reset button on the front panel of the unit. If the voltage is
below the LVR level, the DC load can be reconnected from approximately 6 minutes.
Multiple reconnects are allowed, but the “on” time duration will vary with battery voltage.
( Approximately 5 seconds when the battery voltage is under 10V).
When Dip Switch 7 is ON position, it allows the controller to be set for Auto reconnect of
the DC load when the voltage exceeds the LVR setting.
DIP switch number 8-User define LVR, LVD
Switch 8 Load Control algorithm
ON User define (VR1, VR2)
OFF Dip Switch 4~6 selection
The latest LED Meter display will show the voltage setting value of LVR (VR2) and LVD
(VR1) and the user can adjust those values directly.
LVR range set by VR2: 12.0V~14.0V (12V system)
24.0V~28.0V (24V system)
48.0V~56.0V (48V system)
LVD range set by VR1: 10.5V~12.5V (12V system)
21.0V~25.0V (24V system)
42.0V~50.0V (48V system)

2-11
2.4.4 Diversion Charge Control DIP Switch Setting
Diversion charge control DIP switch settings are exactly the same as solar battery charging
DIP switch setting which can be referred to 2.4.2 description.
2.4.5 Battery Temperature Sensor (BTS)
For solar battery charging and diversion load control, a Battery Temperature Sensor (BTS)
is recommended for effective temperature compensated charging.
This Battery Temperature Sensor should not be installed for DC load control. The BTS is
supplied with 10 meters (33 ft) of 0.34 mm2 (22 AWG) cable. There is +/- polarity so pay
attention to connecting the polarity. Reverse of the polarity may damage the BTS.
2.4.6 System Wiring and Power-Up
Wire Size:
The five large power terminals are sized for 35 - 2.5 mm2(2-14 AWG) wire. The terminals
are rated for copper and aluminum conductors. Good system design generally requires large
conductor wires for the solar and battery connections that limit voltage drop losses to 3% or
less. The following table provides the maximum wire length (1-way distance / 2-wire pair)
for connecting the battery, solar array or load to the SunStar with a maximum 3% voltage
drop.
Wire Size 60Amps 45 Amps 30 Amps
95 mm2
(3/0 AWG) 12.86 m (42.2 ft.) 17.15 m (56.3 ft.) 25.72 m (84.4 ft.)
70 mm2
(2/0 AWG) 10.19 m (33.4 ft.) 13.58 m (44.6 ft.) 20.38 m (66.8 ft.)
50 mm2
(1/0 AWG) 8.10 m (26.6 ft.) 10.80 m (35.4 ft.) 16.21 m (53.1 ft.)
35 mm2
(2 AWG) 5.12 m (16.8 ft.) 6.83 m (22.4 ft.) 10.24 m (33.6 ft.)
25 mm2
(4 AWG) 3.21 m (10.5 ft.) 4.27 m (14.0 ft.) 6.41 m (21.0 ft.)
16 mm2
(6 AWG) 2.02 m (6.6 ft.) 2.69 m (8.8 ft.) 4.04 m (13.2 ft.)
10 mm2
(8 AWG) 1.27 m (4.2 ft.) 1.70 m (5.6 ft.) 2.54 m (8.3 ft.)
6 mm2
(10 AWG) 1.06 m (3.5 ft.) 1.60 m (5.2 ft.)
4 mm2
(12 AWG)
1.00 m
(3.3 ft.)
2.5 mm2
(14 AWG)
Maximum 1-Way Wire Distance (12 Volts)