sunsei CC25000 User manual

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Operating Instructions
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CHARGECONTROLLER CC25000
TheSunsei™CC25000isahighlyreliablechargecontrollerthat
is ideal for Sunsei™ SolarChargers up to 25A. 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.
PRODUCT FEATURES
IDEAL SOLAR CHARGING
>Compatible – Works with almost all types of batteries
>and solar panels in 12V and 24V configurations
>Efficient – Over 98% efficiency at full current
>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 Limiting – Floats battery at safe voltage
>when battery is full
>Robust Circuitry – Control function 100% solid state
HIGH RELIABILITY
>Simple, rugged electronics – Low component count &
>streamlined design ensure long-term reliability
FEATURES
>Two stage charging – Boost and float charge using pulse
>width modulation (PWM) control
>12V and 24V systems – Operation for batteries and solar
>panels, automatic voltage detection
>Temperature compensation – Adjusts battery voltage limits
>with temperature
>LED display – Built-in battery voltage and charge function
>indicator by LED display
>Advanced digital control – Uses pulse width modulation
>(PWM) control
>Reverse leakage protection – Prevents power loss at night
>Incorrect Wiring Protection – Reverse battery and solar
>panel protected, surge protection
>Terminal Block – For sound and easy wire connections
1Array voltage of 50V can only be applied with a 24V battery,
otherwise the unit will be damaged.
2If the battery is lower than 17V, the charger will recognize it
as a 12V battery.
RELATED SYSTEM EQUIPMENT
The SunseiTM CC25000 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 CC25000 is compatible with all makes and
models of photovoltaic solar panels.
The entire solar array’s open circuit voltage (Voc) cannot
exceed 30V with a 12V battery or 50V with a 24V battery (the
sum of the Voc of all solar panels in series). Also, the solar
array’s peak operating current (Ip) cannot exceed 25A. (This
is the sum of the peak operating currents (Ip) of all the solar
panels in parallel).
Install all panels with the correct series-parallel configuration
to ensure proper system voltage and current.
The SunseiTM CC25000 circuitry uses a MOSFET transistor 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 CC25000. All
charging sources need to connect directly to the battery on
independent lines and have their own form of over-charge
protection.
SunseiTM CC25000 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 orAC battery chargers. These charging
sources can damage the controller and/or the generating
equipment.
BATTERIES: The SunseiTM CC25000 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
usedastheprimarybatteryinasolarsystem.Installallbatteries
with the correct series-parallel configuration to ensure 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 CC25000
needs to connect directly to one of the batteries or an output
from the isolator.
PARAMETERS
Nominal Voltage
Array Voltage, Max (Voc)
Charging Current, Continuous (Ip)
Operating Voltage at Battery,
Min Charging starts at :
Current Consumption
Quiescent (Night)
Boost Charge Voltage (2 hours)
Float Charge Voltage
Regulation Accuracy
Voltage Drop, Array to Battery
Operating Temperature Range
Dimensions
Weight
UNITS
Volts
Volts
Amps
Volts
Milliamps
Volts
Volts
Volts
Volts
ºC (ºF)
inches (mm)
lbs. (kg)
Sunsei™ CC25000
12 or 24
30 or 501
25
7 or 172
<4
14.5 or 29
13.7 or 27.4
±0.150
< 220 mV
-40 to 50 (-40 to 122)
3.1x3.9x1.25 (80x100x32)
0.40 (0.18)

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Operating Instructions
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CHARGECONTROLLER CC25000
LOADS: System loads such as lights, radios and DC/AC
inverters must be 12V or 24V DC (unless an inverter is being
used).
INSTALLATION
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.
CAUTION: DO NOT EXCEED THE UNIT’S VOLTAGE AND
CURRENT RATINGS
Do not exceed the maximum open circuit voltage (Voc) rating
of 30V for 12V operating systems or 50V for 24V operating
systems. This is the sum of the Voc of all solar panels in
series.
Do not exceed the maximum current rating 25A. This is the
sum of the peak operating current (Ip) of all the solar panels
in parallel.
Do not deviate from the recommended wiring instructions.
INFORMATION
>The charge controller SHOULD NOT BE USED in direct
>sunlight or temperatures exceeding 122ºF (50ºC) or below
>-40ºF (-40ºC). It should be installed within 5 feet (1.5m)
>of the battery in a cool, dry and well ventilated area.
>Intended for indoor use.
>DO NOT USE MORE THAN 25A (400W for 12V or 800W
>for 24V) of solar power with the Sunsei™ CC25000.
>ALL connections should be in PARALLEL (Positive to
>Positive, Negative to Negative). Ensure that connections
>are clean and solid.
>Always CONNECT the BATTERY FIRST, and
>DISCONNECT
•
the BATTERY LAST. It is recommended
>connecting a fuse close to the battery on wires extending
>from it, especially for longer runs. Follow electrical codes
>where applicable.
>For all additions or longer distances, use up to #6
>(gauge) wires. Always CONNECT the BATTERY FIRST,
>and DISCONNECT the BATTERY LAST.
PROCEDURE
Mount charger on a dry non-flammable surface. Use mounting
holes.
1. CONTROLLER TO BATTERY CONNECTION: Connect
positive and negative wires into designated positive and
negative terminals of the controller. Then carefully connect
wires to battery and/or fuse terminal (see wire selection table
below).
2. CONNECT PANELS: If connecting more than one solar
panel, connect the solar panels to the master cable in parallel,
+ to + and - to -.
3.CONTROLLERTOPANELCONNECTION:Connectpositive
and negative master cable wires to designated positive and
negative terminals of the charge controller.
4. 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 (-).
5. WIRE SIZE: Refer to the “WIRE GAUGE” charts 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.
RECOMMENDED WIRE GAUGE CHARTS
6. COMPLETE THE INSTALLATION OF PANELS, BATTERY
AND LOAD
LOCATION
The SunseiTM CC25000 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 CC25000
should be mounted as close to the battery as possible to
reduce voltage drop in the wires. Wires extending from the
battery should be fused. Respect local electrical codes where
applicable.
Recommended Wire Gauge (AWG) Chart to limit voltage drop to 0.5V
Panel to Charge Controller
Cable Length (ft.)
0 to 10
10 to 20
20 to 30
30 to 40
40 to 50
50 to 60
SE-1200
14
14
14
14
14
12
SE-4000
14
14
12
12
10
10
SE-6000
14
12
10
10
8
8
SE-8000
14
12
10
8
8
6
Cable Length (ft.)
0 to 5
5 to 10
10 to 15
15 to 20
SE-1200
14
14
14
14
SE-4000
14
14
14
12
SE-6000
14
14
12
10
SE-8000
14
12
10
8
Recommended Wire Gauge (AWG) Chart to limit voltage drop to 0.3V
Charge Controller to Battery

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Operating Instructions
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CHARGECONTROLLER CC25000
OPERATION
TheoperationoftheSunseiTMCC25000iscompletelyautomatic.
This controller will regulate the charging of batteries during
conditions of heavy usage, or when left unattended for long
periods of time.
CHARGING STATUS LIGHTS:There are three (3) LED status
lights that indicate the charging status of the CC25000:
Red = low battery indicator, Yellow = good battery voltage
indicator, Green = charging status.
HOW TO READ THE LIGHTS:
NOTE: Double the values for 24V systems.
1) All LED lights off: Insufficient voltage from solar panel and
battery to activate the controller.
2) Green “Charging” LED
lit constant: Solar panel is
charging the battery. When
battery voltage falls goes
below 12.5V, the charger will
charge the battery in boost
mode up to 14.5V maintaining
for two hours and then go into
float mode of 13.7V using
PWM.
3) Green “Charging” LED
flashing: Charger is in PWM
mode either in boost mode or
float mode which means that
the battery is being topped off
or full.
4) Yellow LED on: Yellow LED
is a battery state of charge
indicator based on voltage,
day or night. LED “On” means
the battery is 12V or above;
“Off” means the battery is
below 12V. The yellow LED
works in conjunction with the
red LED, so when the yellow
LED turns off, the red LED turns on and vice-versa.
5) Red “Low battery” LED lit constant: Battery is very low
voltage, between 11.5V and 12V. Load must be reduced.
6) Red “Low battery” LED flashing: Battery has extremely low
voltage, below 11.5V. Load must be disconnected and battery
allowed to recharge.
ATYPICALDAY:Atypical 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. Battery will be charged up to 14.5V or 29V,
the Boost voltage, and kept at this level for two hours using
PWM control. Then, the controller goes into float mode and
will maintain the battery at 13.7V or 27.4V indefinitely as long
as the load current does not surpass the charging current.
WHAT TO CHECK: Check to confirm all wire connections are
sound and free from corrosion. Tighten terminal particularly at
the battery. Also, consider checking for a voltage drop in the
cables which should be less than 0.5V between the
solar panel and the controller and less than 0.3V between the
controller and the battery.
MAINTENANCE
RECOMMENDED CARE: Any solar system, when designed
correctly, should provide years of reliable charging with very
little user involvement. To assure system reliability, a regular
routineofcheckingtheelectricalconnectionsisrecommended.
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.
TROUBLESHOOTING
These sections can assist
in the troubleshooting of a
solar system. If a problem
is suspected, please verify
all components (solar panel,
battery and controller).
SOLAR PANEL
To verify the solar panel,
disconnect it from the controller.
In full sun, it should give its
rated open circuit voltage (Voc).
Measure across the two wires
extending from the solar panels
with a DC voltmeter. Then
measure the output current by
connecting the panel directly
to the battery. Put the DC
ampmeter in one of the lines
and verify that the panel can
put out its rated current (in full
sun).
BATTERY
With the panel connected to the battery as above, the battery
voltage should be within the maximum values indicated by the
manufacturer.
CHARGE CONTROLLER
Reconnect the working panel and good battery and the charge
controller should turn on as indicated by the charging LED
lighting up.
FRANÇAIS
ITALIANOESPAÑOL
DEUTSCH NEDERLANDS
> Contrôleur de charge intelligent
garanti à la batterie une
puissance de charge maximale
> Indicateur LED intégré
affiche instantanément l’état
de la charge
> Connexions intégrées
facilitent l’installation
> Limiteur de charge
évite les surcharges et
les inversions de polarité
> Control de carga inteligente
Asegura potencia de batería máxima
> Indicador a diodo LED integral
Indica estado de carga
inmediatemente
> Conectores a tornillo incorporados
Para una instalación rápida y sencilla
> Interruptor de circuito a rearma
automático
Para inversión de polaridad y
protección contra picos de voltaje
> Controllo di carica intelligente
assicura la massima potenza della
batteria
> Indicatore a LED incorporato
visualizza lo stato di carica istante
per istante
> Connettori a vite integrati
per un’installazione facile e rapida
> Interruttore automatico di protezione
per inversioni di polarità e
sovraccarichi
> Intelligente Aufladung Steuerung
stellt maximale Batterieleistung sicher
> Eingebaute LED Anzeige
zeigt sofort aufladenstatus an
> Integrierte Schraube
Anschlußanschlüsse
für schnelle und einfache Installation
> Automatische-reset Schutzschalter
für Rückpolarität und Schwankung
Schutz
> Doordachte laadcontrole
garandeert maximaal accuvermogen
> Ingebouwde LED-indicator
toont continue de laadstatus
> Geïntegreerde schroefaansluitingen
voor snelle en makkelijke installatie
> “Auto-reset” stroomonderbreker
t.b.v. ompool- en vermogens
schommelingbeveiliging

Need help?
www.sunseisolar.com
+1 514.270.5770
Operating Instructions
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CHARGECONTROLLER CC25000
WARRANTY
ICP Solar Technologies grants the original purchaser of the
Sunsei™ CC25000 Charge Controller a 2-year warranty
against any defects of materials or workmanship. This warrant
not be responsible for any costs due to removal, shipment,
re-installation or any other loss due to warranty servicing. The
maximum liability to ICP under this warranty shall not exceed
the purchase price of this controller. This warranty does not
cover a controller that has been damaged by misuse, neglect
or improper installation. ICP shall not be responsible for any
damagetopersonsorpropertycausedbyimproperinstallation,
misuse or improper handling of this product. Some states do
not allow exclusion or limitation of accidental or consequential
losses so the exclusions may not apply to the purchase.
This warranty gives you specific legal rights and you may
have other rights, which vary from one state (or province) to
another. Please note that ICP will not accept returns without
prior authorization. The original proof of purchase is required
for warranty validation.