Morningstar SunGuard User manual

SOLAR BATTERY CHARGE CONTROLLER
O PERATOR ’ S M ANUAL
1098 Washington Crossing Road
Washington Crossing, PA 18977 USA
Website: www.morningstarcorp.com
1.0 SPECIFICATION SUMMARY
System Volts 12 V PWM Setpoint 14.1 V
Max. Solar Volts 30 V Accuracy +/–60 mV
Rated Solar Input 4.5 A Min. Operating Volts 6V
Max. Input (5 min.) 5.5 A Self-consumption 6mA
Max. Solar Short Circuit Rating 5.5 A
PWM Temp Compensation –28 mV/˚C
Reverse Current Leakage <10 uA
Ambient Temperature Range –40 to +60 ˚C
Relative Humidity 100%

2.0 SAFETY INSTRUCTIONS
•Follow these instructions carefully during installation.
•WARNING - Be very careful when working with batteries. Lead
acid batteries can generate explosive gases, and short circuits
can draw thousands of amps from the battery. Read all instruc-
tions provided with the battery.
• Do not exceed the voltage or current ratings of the controller.
Use only with a 12 volt battery.
•Do not SHORT CIRCUIT the solar array while connected to
the controller. This will DAMAGE the controller.
• The negative system conductor should be properly grounded
for most effective lightning protection.
3.0 OPERATION AND FUNCTIONS
•100% SOLID STATE: All power switching is done with
MOSFETs. No mechanical relays are used.
• The SunGuard wires are rated for outdoor use, size 16 AWG,
with Hypalon insulation.
•BATTERY CHARGE REGULATION: SunGuard uses an
advanced series PWM charge control for constant voltage
charging. A true 0 to 100% PWM duty cycle is very fast and
stable for highly efficient charging.
• TEMPERATURE COMPENSATION: A sensor measures ambient
temperature and corrects the constant voltage setpoint by
–28 mV per ˚C with a 25˚C reference. This works best if the
SunGuard and battery are in a similar thermal environment.
• The SunGuard prevents the battery from discharging through
the solar array at night. There is no need to install a blocking
diode for this purpose.

4.0 INSTALLATION
1. SunGuard can be mounted in any position. It is best to mount
to a vertical surface and allow space for air flow through the
controller.
2. First connect the Battery
BLACK wire (negative) to the battery.
Use either black wire since they are connected together inside
the controller.
3. Connect the
RED Battery positive wire to the battery.
4. Connect the Solar array using the other
BLACK wire and the
YELLOW Solar positive wire. Be very careful not to short circuit
the solar array, or the controller will be damaged.
5. SunGuard prevents reverse current leakage at night, so a
blocking diode is not required in the system.
6. A negative earth ground at the battery is recommended for
most effective lightning protection.
7. SunGuard can be mounted outdoors. Do not expose to ambi-
ent temperatures above 60˚C. Make sure that water will drain
from inside the case.
+–
SOLAR
YELLOW
SOLAR
BLACK
BATTERY
BLACK +
BATTERY
RED
–
SOLAR CONTROLLER
12 V 12 V
Made in Singapore
RATED 4.5A 12V
SOLAR BATTERY

5.0 INSPECTION AND MAINTENANCE
At least once per year, inspect the controller to ensure best
performance.
• Confirm that the solar array is not exceeding the SunGuard rating.
•Inspect the wire connections.
• Inspect for dirt, insects and corrosion. Clean as required.
• Check that the air flow through the SunGuard is not blocked.
• Confirm that water is not collecting inside the case.
6.0 TROUBLESHOOTING
The SunGuard can be tested with a power supply used in
place of either the solar array or the battery. Observe the
following cautions:
•Current limit the power supply to 2 amps.
• Set the power supply to 15 volts DC.
• Connect only one power supply to the controller.
I FTHE BATTERY IS NOT CHARGING :
If the SunGuard is regulating (in PWM), then the controller is
charging and operating correctly. If the battery voltage is low
(under 12.5V - this test will not work if the SunGuard is regu-
lating in PWM), then measure the solar voltage and battery
voltage close to the SunGuard. If the voltages are within a few
tenths of volts, the array is charging the battery. If the solar
voltage is close to 20 volts and the battery voltage is low, the
controller is not charging the battery and may be damaged.
I FTHE BATTERY VOLTAGE IS TOO HIGH :
First account for the temperature compensation (for exam-
ple: 0˚C = 14.8 charging volts). Next, disconnect the solar
array and measure the voltage at the SunGuard solar yellow
and black leads. If battery voltage is measured at the solar
leads, the controller may be damaged.
N OTE : For more detailed testing instructions, contact the
Morningstar website.
105E-R1-2/99