sunsei CC20000D User manual

The Ideal Charge Controller for Home, RV & Marine Solar Systems
The SunseiTM CC20000D is a highly reliable charge controller that is ideal for
the SunseiTM SolarCharger SE-4000, SE-6000 and SE-8000 solar panels. It will
efficiently charge your batteries and provide years of protection from
overcharging. This protective care will prolong your battery life and reduce
maintenance requirements.
FEATURES
IDEAL SOLAR CHARGING
•Compatible – Works with almost all
types of batteries and solar panels
•Efficient – Over 95% efficiency when
charging
•Full Charging – Ensures that the
batteries are always topped off
•Battery Safe – Charging method
maximizes battery life
•Reduced Maintenance – From
healthy charging and reliable
operation
OVER-CHARGE PROTECTION
•High Voltage “Shut-off” – Shuts off
only when battery is full
•Robust Circuitry – Control function
100% solid state
HIGH RELIABILITY
•Simple, rugged electronics – Low
component count and streamlined
design ensure long-term reliability
•No Minimum Voltage Required –
Can charge a dead battery
FEATURES
•Digital Voltage and Current – Accurate
readout for battery and solar panels
•Status Lights – Colored BATTERY
condition bar-graph with “CHARGING”
and “CHARGED” lights
•Adjustable Set-point – Easily adjusts
to higher or lower voltages
•Reverse leakage protection –
Prevents power loss at night.
•Over-current & Incorrect Wiring
Protection – ARRAY and BATTERY
fuse
•Terminal Block – For sound and easy
wire connections
•Mounting Options – Can mount flush
or onto a wall (with accessory)
•Environmental Protection – Front
plate and circuitry have moisture
protection
SYSTEM COMPATIBILITY
•Minimum RF Noise – Low-switching
frequency minimizes electronic noise
•Protection from External RF Noise –
Can operate with noisy inverters
SYSTEM COMPATIBILITY
•Minimum RF Noise – Low-switching
frequency minimizes electronic noise
•Protection from External RF Noise –
Can operate with noisy inverters

2
Specifications
PARAMETERS UNITS SunseiTM
C20000D
C
Nominal Voltage Volts 12
Array Voltage, Max (Voc) Volts 26
CERTIFICATIONS
Not all units are certified. Refer to logos on product (back) for certifications.
Charging Current, Continuous (Isc) Amps 20
Charging Current, Max (60 seconds) Amps 25
Operating Voltage at Battery, Min
Charge Control Volts 0
LCD Metering Volts 7.8
LED Bar-graph Volts 10.5
Current Consumption
Quiescent (Tare) Milliamps 8.8
Charging (with LED Bar-graph off) Milliamps 12.8
LED Bar-graph Milliamps per LED 5
Charge Termination, Factory Set (1) Volts 14.4 + .2
Charge Termination, Adjustable Range (2) Volts 13.6 – 15.3
Charge Resumption, Factory Set (2) Volts 13.0 + .2
Voltage Drop, Array to Battery
Controller Volts per Amp 0.05
Controller and 2 fuses Volts per Amp 0.08
LCD Meter Accuracy
DC Voltage 0.5 %
DC Current 1 %
Operating Temperature Range °C (°F) -30 to 50 (-22 to 122)
Storage Temperature Range °C (°F) -40 to 70 (-40 to 158)
Notes:
(1) This is not a constant voltage controller.
The batteries will drop below this
voltage when completely charged.
(2) The Charge Termination / Resumption
span is fixed. The Resumption set-point
changes as the Termination set-point is
adjusted.
4x7 BOX (ACCESSORY)
In Inches (cm)
5.0 (12.7)
Dia:
.275 (.7) 3.75
(9.5)
1.75
(4.4)
7.0 (17.8)
Recognized by Underwriters Laboratories (UL)
Meets all requirements for UL 1741.

3
RELATED SYSTEM EQUIPMENT
The SunseiTM CC20000D is an integral part of a solar electric power system that includes a
solar panel, a battery and a load.
SOLAR PANELS - (“photovoltaic (PV) array”, “solar modules”):
The SunseiTM CC20000D is compatible with all makes and models of photovoltaic solar
panels.
The entire solar array’s open circuit voltage (Voc) cannot exceed 26 volts (the sum of the Voc
of all solar panels in series). Also, the solar array’s short circuit current (Isc) cannot exceed 20
amps. (This is the sum of the short circuit currents (Isc) of all the solar panels in parallel).
Install all panels with the correct series-parallel configuration to insure proper system voltage
(12 volts) and current.
The SunseiTM CC20000D includes a blocking diode to eliminate leakage of the battery power
into the solar panels at night. No additional protection is needed.
OTHER CHARGING SOURCES: Systems with an additional source of charging (alternator,
battery charger, etc.) can operate with a solar array and a SunseiTM CC20000D. All charging
sources need to connect directly to the battery on independent lines and have their own form
of over-charge protection.
SunseiTM CC20000D FOR NON-SOLAR APPLICATIONS: These units will only operate with
solar electric panels. Do not use to regulate other power sources, such as a hydro or wind
generators/alternators or AC battery chargers. These charging sources can damage the
controller and/or the generating equipment because the SunseiTM CC20000D stops charging
by short-circuiting the input.
BATTERIES: The SunseiTM CC20000D provides the proper charging of standard lead-acid
batteries that are normally used in recreational vehicles, boats and remote stand alone
systems. These include wet cell batteries (with filler caps), sealed, maintenance-free and gel-
cell batteries. Automobile batteries can also be charged, but these batteries are rarely used as
the primary battery in a solar system. Install all batteries with the correct series-parallel
configuration to insure proper system voltage and current.
SYSTEMS WITH TWO BATTERY BANKS: When solar charging two separate battery banks,
a switch can be installed to allow manual selection of one battery or the other.
BATTERY ISOLATORS: In installations that use a diode battery isolator with two batteries,
the SunseiTM CC20000D needs to connect directly to one of the batteries or an output from
the isolator. The SunseiTM CC20000D will not operate if it is connected to the input of the
isolator.
LOADS:System loads such as lights, radios and DC/AC inverters must be 12 volts DC (unless
an inverter is being used).

4 INSTALLATION
WARNINGS
WARNING: Electricity, even low voltage electricity, can be dangerous. Installation should be
performed by a licensed electrical contractor or other qualified personnel only. The
requirements of National Electrical Codes should be followed.
WARNING: Follow all safety precautions of the battery manufacturer. Proper ventilation must
be provided for the batteries. Most batteries produce hydrogen gas when charging, which is
extremely explosive. Provide adequate battery ventilation. DO NOT expose the battery to
open flame, matches, cigarettes or sparks.
CAUTIONS (The following can cause a fuse to blow and may damage the unit)
CAUTION: DO NOT EXCEED THE UNIT’S VOLTAGE AND CURRENT RATINGS
•Do not exceed the maximum open circuit voltage (voc) rating of 26 volts. This is the sum
of the Voc of all solar panels in series.
•Do not exceed the maximum current rating 20 amps. This is the sum of the short circuit
currents (Isc) of all the solar panels in parallel.
CAUTION: DO NOT DEVIATE FROM THE RECOMMENDED WIRING INSTRUCTIONS:
•Do not reverse BATTERY (+) and BATTERY (-) connections to the SunseiTM CC20000D.
Any reverse polarity to the battery may damage the unit.
•Do not reverse the BATTERY and Solar ARRAY connections to the SunseiTM
CC20000D. A battery connected to the array terminals may damage the unit.
•Do not connect the array directly to the battery when the array is connected to the
SunseiTM CC20000D at the same time. This will cause the fuse to blow when the battery
reaches full charge voltage.
•Do not wire the SunseiTM CC20000D in such a way that it can be connected to an
alternator (or other charging source) while the battery is disconnected. Other charging
sources should have independent connections to the battery.
•Do not wire the SunseiTM CC20000D in such a way that it can be connected to a load
without a battery connected. (Example: Do not connect the loads directly to the
SunseiTM CC20000D BATT terminals. This may damage the controller if the battery is
disconnected.)

5
INSTALLATION INSTRUCTIONS
1. MOUNTING CONSIDERATIONS
The SunseiTM CC20000D is designed to be mounted flush against a wall. It can be mounted
onto a wall by adding the optional knockout box (4x7 BOX). Flush mounting or wall
mounting require different installation and mounting considerations.
FLUSH MOUNT: The flush mounted unit requires a rectangular cutout in the mounting
surface with sufficient space (2-3 inches) immediately behind to accommodate the
controller.
WALL MOUNT: The wall-mounted unit (SunseiTM CC20000D with the 4x7 BOX) is
installed onto a wall surface using four mounting screws. Electrical connections are
made through knockouts in the box to the back of the controller. Wiring can be run down
the wall or through a hole in the wall directly below the controller.
2. ACQUIRE TOOLS AND MATERIALS
TOOLS AND MATERIALS NEEDED:
•Slotted screwdriver
•Wire cutter/strippers
•Keyhole saw or saber saw
•Pencil, scratch awl or other marker
•Wire of proper gauge to run from the panels, to the SunseiTM CC20000D, to the
battery (See INSTALLATION INSTRUCTIONS 6: WIRE TYPE / SIZE)
•Mounting fasteners of appropriate type for wall material
•Included are four 3/4 - #6 screws and a spare fuse, 25 amp AGC for the SunseiTM
CC20000D
Also for Flush Mounting:
•Drill with 3/32" and 3/8" bits
Also for wall mounting: (SunseiTM CC20000D with 4X7 BOX):
•1/2 inch Romex strain relief clamps
3. LOCATION
The SunseiTM CC20000D should be mounted where it can be easily seen and reached as
needed. Carefully consider how the wires are to be run from the solar panel to the controller
and from the controller to the battery. The SunseiTM CC20000D should be mounted as close
to the battery as possible, and should be mounted on a vertical surface to aid in cooling.
4. PROTECTION REQUIREMENTS
The unit should be mounted indoors, out of the weather, unless a weatherproof enclosure is
used. Avoid mounting in direct sunlight or in a hot environment or where exposed to
excessive moisture. Locations near refrigerators may pose a moisture problem.

INSTALLATION INSTRUCTIONS (continued)
6
5. PREPARE THE LOCATION PRIOR TO WIRING
FLUSH MOUNT: Use the template provided to position and mark the cutout and the four
mounting holes. Make the cutout using a keyhole or saber saw. Start by drilling holes in the
corners, and then saw between the holes.
WALL MOUNT: Mount the knockout box to the wall using suitable fasteners.
6. SELECT WIRE
WIRE TYPE: When possible, use stranded wire instead of solid wire. Stranded wire does not
fatigue and cause loose connections over time as easily as solid wire. Use red wire for (+)
and black for (-).
WIRE SIZE: Refer to the “WIRE SIZE” chart below to determine the minimum size wire
needed for each connection. Note that the bigger the wire, the lower the AWG. When using
large stranded wire, you may need to divide the ends into two groups and straddle the screw
on the terminal block.
SunseiTM CC20000D: Accepts one wire at 6 AWG (stranded) or two wires at 8 AWG.
Large Wires: To connect large wires to the SunseiTM CC20000D, use crimp connectors or
connect the larger wire to a short, thinner wire using a wire nut (solder these connections).
Wire Size: Minimum wire gauge (AWG) - (based on maximum current)
Model 10’/3m 20’/6m 30’/9m 40’/12m 10’
/
3m 20’/6m 30’/9m 40’/12m
SunseiTM
CC20000D 10 8 6 4* 12 10 8 6
* Wire gauge larger than unit can accept directly. See WIRE SIZE / Large Wires above.
Battery Connection
Distance round trip (feet/meters) Solar Array Connection
Distance round trip (feet/meters)
7. COMPLETE THE INSTALLATION OF PANELS, BATTERY AND LOAD
Follow the manufacturer's instructions for mounting and wiring the solar panel, batteries and
the load. Install with the correct series-parallel configuration to insure proper system voltage
and current.
8. REMOVE POWER FROM BATTERY / PANELS (if needed)
Before running the wires to the SunseiTM CC20000D be sure that power is disconnected from
the batteries and panels.
9. RUN SYSTEM WIRING
After disconnecting the power sources, run the wires from the battery and solar panel to the
location selected for the controller.
WALL MOUNT: Run the array and battery wires into the box through the knockouts,
using a 1/2 inch Romex cable clamp for strain relief.

7
INSTALLATION INSTRUCTIONS (continued)
10. NOTE WIRE POLARITY
Make sure to correctly mark the polarity of the wires using colored wires or tags. Incorrect
polarity may blow a controller fuse or damage the SunseiTM CC20000D.
CAUTION: Some vehicles or solar kits use black and white wires for connection to the
battery. These kits will label the black wire as battery negative and the white wire as
battery positive (please verify with your manual). Black and red wiring systems will label
the black wire as negative and the red wire as positive. When these systems
interconnect, the black wire does not connect to the black wire.
CAREFULLY NOTE BATTERY POLARITY AND WIRE COLORS!
11. PREPARE WIRES
Using a wire stripper, carefully remove approximately ½ inch of insulation from the
controller end of each wire, being careful not to nick or break any wire strands.
12. SunseiTM CC20000D CONNECTION
Wire the SunseiTM CC20000D according to Figure 1. The wires should be connected
directly to the SunseiTM CC20000D screw terminals (no spade or ring lugs). Tighten
securely.
Any wiring variation can affect the performance and operation of the system.
CAUTION: The two negative connections (ARRAY (-) & BATTERY (-)) must be
separated. Do not install a jumper across the terminal block.
CAUTION: The battery negative connection should not come from a frame or chassis.
This wire needs to originate directly from the battery.
CAUTION: Do not connect any loads to the SunseiTM CC20000D terminals.
13. INSTALL FUSING AS NEEDED
Add circuit protection where needed. A 25 amp fuse and disconnect switch should be
installed on the BATTERY (+) run of the SunseiTM CC20000D.
WARNING: A good system design calls for circuit protection to be added to all wire
runs from the battery. This will provide protection from fire and damage due to over-
current from the battery. Also, disconnect switches in-line between the components
allow you to isolate power during installation and maintenance. Recommended:
Install properly DC rated, high interrupt, current limiting, over-current protection and
disconnect equipment between the SunseiTM CC20000D and the battery. Refer to the
National Electrical Code or your local alternative energy vendor for
recommendations.
14. SunseiTM CC20000D MOUNTING
Mount the SunseiTM CC20000D to the wall or box front using the four screws provided, or
other suitable fasteners. Do not remove the four rubber spacers, they provide a gap for
added cooling.

INSTALLATION INSTRUCTIONS (continued)
15. RECONNECT BATTERY AND ARRAY POWER
16. OPERATION
Operation of the charge controller is now fully automatic. If the battery voltage is below the
Full Charge Termination set-point (14.4 volts) and power is available from the array, the
SunseiTM CC20000D should start up “CHARGING”.
17. CHECK FOR VOLTAGE DROP (OPTIONAL)
Once the system is installed and operational, a check on the connections is recommended.
A poor connection will result in a voltage loss that will distort the battery voltage reading
and cause the charging to stop too soon. To check the onnections, an accurate voltmeter is
required, The SunseiTM CC20000D must be charging with maximum expected charge
current (very sunny conditions).
Battery Connection:First, note the voltage at the battery. Then, immediately note the
voltage at the SunseiTM CC20000D battery terminals. Ideally, the difference in voltage
should be no more than ¼ volt.
Array Connection:Note the voltage at the panel. Then, immediately note the voltage at
the SunseiTM CC20000D Array terminals. Ideally, the difference should be no more than
½ volt.
If the voltage drop is more, suspect crimp connections that have not been soldered, in-line
fuses or fuse holders, or loose terminals. If no location of voltage drop is found, consider
using larger wires (or double up the wires) for your run.
Example: You record these readings:
Battery terminals: 13.65 volts
SunseiTM CC20000D battery connection: 13.95 volts →“.30 volt difference too
large. Decrease voltage drop”
SunseiTM CC20000D panel connection: 14.10 volts
Panel(s): 14.30 volts →“Connection OK”
8

9
FIGURE 1 SunseiTM CC20000D CHARGE CONTROLLER
FUSE RATINGS
A = Fuse / Disconnect switch
SunseiTM CC20000D = 25 amp
B = Rated for load
Array (+)
++
FIGURE 2 SunseiTM CC20000D - BACK VIEW
Charge Set-Point Adjust
Adjust the pot here to modify the charge set-
point. Refer to the front display (CHARGE
SET-POINT) to view setting. Turn counter-
clockwise to increase voltage and clockwise to
decrease voltage.
Bar-graph selector
For “Bar” readings, place jumper across both
pins.
For “Dot” readings, place jumper across only
one of the pins (“storage position”).
Fuses
SunseiTM CC20000D:
Access from rear
LOAD
BATTERY
+
A
Batt
(
-
)
Batt
(
+
)
Array (-)
B
SOLAR PANEL ARRAY
←

10 OPERATION
The operation of the SunseiTM CC20000D is completely automatic. This controller will regulate the
charging of batteries during conditions of heavy usage, or when left unattended for long periods of time.
During operation, it is normal for the front plate to feel warm.
CHARGING METHOD – Low Frequency Pulse Width Modulation: The SunseiTM CC20000D
provides pulses of charging current at varying durations to maintain the batteries at a full state of
charge and insure the long-term health on the batteries. The “on” and “off” cycle time is wide
enough to eliminate electronic noise and short enough to insure the batteries are always topped off.
This method allows the batteries to reach a higher voltage with the “on” cycle and protect the
batteries from gassing in the “off” cycle. This will provide the benefits of the higher voltage (reduced
sulfation and stirred up electrolyte) and prevent excessive gassing and excessive water loss.
A TYPICAL DAY: A typical daily cycle will be as follows. As the charging starts for the day and battery
state of charge is low, charging will be continuous and the “CHARGING” light will be on all the time.
As the battery charges up, current will pass into the battery for a while and eventually stop. Later,
charging will resume and the system will continue this cycle throughout the day. During the course
of the day, the duration of the charging period of each cycle will get shorter (cycling on for shorter
periods and staying off longer). When the battery is close to full charge, it will pulse current into the
battery to achieve and maintain full charge. The “CHARGING” light occasionally turning on and off
indicates this pulse charging.
ARRAY AND BATTERY FUSES
ARRAY FUSE: An array fuse is included on the SunseiTM CC20000D. It will protect the controller from
over-current from the solar panels, battery short circuit and incorrect wiring problems with the
system. If the fuse continued to blow after all external problems have been corrected, then this may
indicate a defective unit.
Fuse type: SunseiTM CC20000D: 25 amp AGC
BATTERY FUSE: A battery fuse is included on the SunseiTM CC20000D. This will protect the controller
from over-current from the solar panels, reverse polarity from the batteries and a battery short circuit
and incorrect wiring problem in the system. If the fuse continued to blow after all external problems
have been corrected, then this may indicate a defective unit.
Fuse type: SunseiTM CC20000D: 25 amp AGC.
MAINTENANCE
AVOID DISCONNECTING BATTERY: Do not leave the battery disconnected from the SunseiTM
CC20000D for an extended period of time (weeks or months). If you need to, then disconnect both
battery and array.
RECOMMENDED ANNUAL CARE: Any solar system, when designed correctly, should provide years
of reliable charging with very little user involvement. To assure system reliability, an annual routine
of checking the electrical connections is recommended. Especially on a moving vehicle exposed to
road vibrations. Over time, electrical connections can deteriorate or corrode causing a voltage drop
and possible hot-spots at the problem area.
WHAT TO CHECK: Check to confirm all wire connections are sound and free from corrosion.
Tighten terminal block screws, inspect any fuse connections in-line, the array connections and
battery terminals. Also, consider checking for a voltage drop. See INSTALLATION INSTRUCTIONS
– Step 17: CHECK FOR VOLTAGE DROP ( Page 8).