WESTECH SeaStar SS1024 User manual

SS1024 / SS1524 / SS2024
—— Moisture proof solar controller
Thank you very much for selecting our product!
This manual offers important information and suggestions with
respect to installation, use and troubleshooting, etc. Please read this
manual carefully before using the product and pay attention to the
safety recommendations in it.
INSTRUCTION
MANUAL

SS1024 / SS1524 / SS2024
—— Moisture proof solar controller
Specification Summary
Nominal system voltage 12 / 24VDC*
Maximum PV input voltage 50V
Nominal charge / discharge current
SS1024 10A
SS1524 15A
SS2024 20A
* The controller will recognize the system rated voltage when start up. If the battery
voltage is lower than 18V, it will recognize the system as 12V. If the battery voltage is
greater than 18V, it will recognize the system as 24V.
SeaStar

Contents
1 Important Safety Information................................................... 1
2 General Information................................................................. 2
2.1 Product Overview........................................................ 2
2.2 Product Features.......................................................... 3
3 Installation Instructions............................................................ 4
3.1 General Installation...................................................... 4
3.2 Mounting..................................................................... 5
3.3 Wiring ......................................................................... 6
4 Operation................................................................................ 10
4.1 PWM Technology...................................................... 10
4.2 Battery Charging Information.................................... 10
4.3 LED Indicators .......................................................... 12
4.4 Setting Operation....................................................... 15
5 Protection, Troubleshooting and Maintenance........................ 16
5.1 Protection .................................................................. 16
5.2 Troubleshooting......................................................... 17
5.3 Maintenance .............................................................. 19
6 Warranty ................................................................................ 20
7 Technical specifications ......................................................... 21

1
1 Important Safety Information
Save These Instructions
This manual contains important safety, installation and operating instructions.
The following symbols are used throughout this manual to indicate potentially dangerous
conditions or mark important safety instructions，please take care when meeting these
symbols.
WARNING: Indicates a potentially dangerous condition.
Use extreme caution when performing this task.
CAUTION: Indicates a critical procedure for safe and
Proper operation of the controller.
NOTE: Indicates a procedure or function that is important
for the safe and proper operation of the controller.
General Safety Information
Read all of the instructions and cautions in the manual before beginning installation.
There are no user serviceable parts inside the controller. Do not disassemble or attempt
to repair it.
Install external fuses/breakers as required.
Disconnect the solar module and fuse/breakers near to battery before installing or
adjusting the controller.
Do not allow water to enter the controller.
Confirm that power connections are tightened to avoid excessive heating from loose
connection.

2
2 General Information
2.1 Product Overview
Thank you for selecting SeaStar series Moisture proof solar controller
that adopts the most advanced digital technique and operates fully automatically. The
Pulse Width Modulation (PWM) battery charging can greatly increase the lifetime of
battery. It has various unique functions and quite easy to use, such as:
With aluminum case, circuit board encapsulation. Ideal for marine application
12/24V automatic recognition
High efficient Series PWM charging, increase the battery lifetime and improve the solar
system performance.
Use MOSFET as electronic switch, without any mechanical switch.
Gel, Sealed and Flooded battery type option.
Adopt temperature compensation, correct the charging and discharging parameters
automatically and improve the battery lifetime.
Electronic protection: Overheating, over charging, over discharging, overload, and short
circuit.
Reverse protection: any combination of solar module and battery.
The controller is for off-grid solar system, and protects the battery from being over
charged by the solar module and over discharged by the loads. The charging process has
been optimized for long battery life and improved system performance. The
comprehensive self-diagnostics and electronic protection functions can prevent damage
from installation mistakes or system faults.
Though the controller is easy to operate and use, please take your time to read this manual
and become familiar with it. This will help you make full use of all the functions and
improve your solar PV system.

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2.2 Product Features
Figure 2-1 SeaStar characteristics
1–Temperature Sensor
Measure ambient temperature and make temperature compensation for charging and
discharging.
2–Charging status LED indicator
An LED indicator that shows charging status and also indicates when battery voltage is
higher than over voltage disconnec t v oltage.
3–Battery status LED indicator
An LED indicator that shows battery status
4–Battery type indicator
Corresponding indicator will be on when select Sealed, Gel or Flooded battery.
1
2
3
4
5
6
7
8
9

4
5–Load status indicator
Display the load status.
6–Setting button
Control the load ON / OFF and select the battery type.
7–Solar Module Terminals
Connect solar modules.
8–Battery Terminals
Connect batteries.
9–Load Terminals
Connect loads.
3 Installation Instructions
3.1 General Installation Notes
Read through the entire installation section first before beginning installation.
Be very careful when working with batteries. Wear eye protection. Have fresh water
available to wash and clean any contact with battery acid.
Uses insulated tools and avoid placing metal objects near the batteries.
Explosive battery gasses may be present during charging. Be certain there is sufficient
ventilation to release the gasses.
Avoid direct sunlight and do not install in locations where water can enter the controller.
Loose power connections and/or corroded wires may result in resistive connections that
melt wire insulation, burn surrounding materials, or even cause fire. Ensure tight
connections and use cable clamps to secure cables and prevent them from swaying in
mobile applications.
Use with Gel, Sealed or Flooded batteries only.
Battery connection may be wired to one battery or a bank of batteries. The following
instructions refer to a singular battery, but it is implied that the battery connection can
be made to either one battery or a group of batteries in a battery bank.
Select the system cables according to 3A/mm2current density.

5
3.2 Mounting
NOTE: When mounting the controller, ensure free air through the
controller heat sink fins. There should be at least 6 inches (150 mm)
of clearance above and below the controller to allow for cooling. If
mounted in an enclosure, ventilation is highly recommended.
WARNING: Risk of explosion! Never install the controller in a sealed
enclose with flooded batteries! Do not install in a confined area where
battery gassed can accumulate.
Step 1: Choose Mounting Location
Locate the controller on a vertical surface protected from direct sun, high temperature,
and water. And make sure good ventilation.
Step 2: Check for clearance
Place the controller in the location where it will be mounted. Verify that there is sufficient
room to run wires and that there is sufficient room above and below the controller for air
flow.
Figure 3-1 Mounting and cooling
Warm air
Cool air
150mm(5.9inches)
150mm(5.9inches)

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Step 3: Mark Holes
Use a pencil or pen to mark the four (4) mounting hole locations on the mounting surface.
Step 4: Drill Holes
Remove the controller and drill 4mm holes in the marked locations.
Step 5: Secure Controller
Place the controller on the surface and align the mounting holes with the drilled holes in
step 4.
Secure the controller in place using the mounting screws.
3.3 Wiring
NOTE: A recommended connection order has been provided for
maximum safety during installation.
NOTE: The controller is a common positive ground controller.
CAUTION: Don’t connect the loads with surge power exceeding the
ratings of the controller.
CAUTION: For mobile applications, be sure to secure all wiring.
Use cable clamps to prevent cables from swaying when the vehicle is
in motion. Unsecured cables create loose and resistive connections
which may lead to excessive heating and/or fire.
Step1: Battery Wiring
WARNING: Risk of explosion or fire! Never short circuit battery
positive (+) and negative (-) or cables.

7
Figure 3-2 Battery connecting
Before battery is connected, make sure that battery voltage is greater than 6V so as to
start up the controller. If system is 24V, make sure battery voltage is not less than 18V.
System voltage can only be automatically recognized when controller start up for the first
time. When install fuse, make sure that the biggest distance between the fuse holder and
the positive terminal of battery is 150mm. Do not insert a fuse at this time. Confirm the
connection correct and turn on the power.
Step 2: Load Wiring
The controller loads can be connected to such electrical equipments as lights, pumps,
motors and others. Controller offers power to loads through the battery voltage.
Figure 3-3 Load Wiring
Battery
Fuse
Fuse
Load

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Connect the positive (+) and negative (-) of loads to controller load terminals as shown in
Figure 3-3. The load terminal may exist voltage, connect carefully to avoid short circuit.
An in-line fuse holder should be wired in series in the load positive (+) or negative (-)
wire as show in Figure 3-3. Do not insert a fuse at this time. Confirm the connection
correct and turn on the power.
If wiring the load connection to a load distribution panel, each load circuit should be
fused separately. The total load draw should not exceed the load rated current of
controller.
Step 3: Solar wiring
WARNING: Risk of electric shock! Exercise caution when handling
solar wiring. The solar module(s) high voltage output can cause
severe shock or injury. Be careful operation when installing solar
wiring.
The controller can accept12V, 24V nominal off-grid solar module(s). Grid-tie solar
module(s) may be used if the open circuit voltage of solar module doesn’t exceed the
Maximum PV input voltage of the controller.
The solar module(s) work voltage must be equal to or greater than the system voltage.
Figure 3-4 Solar wiring
Solar Module

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Step 4: Confirm Wiring
Double-check the wiring in step1 through 3. Confirm correct polarity at each connection.
Verify that all six terminals are tightened.
Figure 3-5 System wiring review
Step 5: Install Fuse
Install a suitable fuse in each fuse holder in the following order:
1. Battery circuit
2. Load circuit
Step 6: Confirm power on
When battery power is applied and the controller starts up, the battery LED indicator will
be green.
If the controller doesn't start up, or the battery status LED error exists, please refer to
section 5 for troubleshooting.
Solar Module
Fuse
Load
Fuse
Battery

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4 Operation
4.1 PWM Technology (Series Pulse Width Modulation)
The controller adopts the advanced series pulse width modulation (PWM) charging mode.
With range of 0-100%, it can charge the battery quickly and stably under any condition of
solar photovoltaic system.
PWM charging mode use automatic conversion duty ratio pulses current to charge the
battery. The battery can be fully charged safety and rapidly with the pulse current.
Intermissions make some oxygen and hydrogen generated by chemical reaction
chemically combined again and absorbed. It can eliminate concentration polarization and
ohm polarization naturally and reduce the internal pressure of the battery so that the
battery can absorb more power. Pulse current charging mode makes battery have more
time to react, which reduces the gassing volume and makes battery improve the
acceptance rate of charging current.
4.2 Battery Charging Information
Figure 4-1 PWM Charging mode
·Bulk Charge
In this stage, the battery voltage has not yet reached boost voltage and 100% of available
solar power is used to charge the battery.

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·Boost Charge
When the battery has recharged to the Boost voltage setpoint, constant- current regulation
is used to prevent heating and excessive battery gassing. The Boost stage remains 120
minutes and then goes to Float Charge.
·Float Charge
After the battery is fully charged in Boost voltage stage, the controller reduces the battery
voltage to Float voltage set point. When the battery is fully recharged, there will be no
more chemical reactions and all the charge current transmits into heat and gas at this time.
Then the controller reduces the voltage to the floating stage, charging with a smaller
voltage and current. It will reduce the temperature of battery and prevent the gassing, also
charging the battery slightly at the same time. The purpose of Float stage is to offset the
power consumption caused by self consumption and small loads in the whole system,
while maintaining full battery storage capacity.
In Float stage, loads can continue to draw power from the battery. In the event that the
system load(s) exceed the solar charge current, the controller will no longer be able to
maintain the battery at the Float setpoint. Should the battery voltage remains below the
boost reconnect charging voltage, the controller will exit Float stage and return to Bulk
charge.
·Equalize Charge
WARNING: Risk of explosion!
Equalizing flooded battery can produce explosive gases, so well
ventilation of battery box is necessary.
NOTE: Equipment damage!
Equalization may increase battery voltage to the level damaging to
sensitive DC loads. Ensure that all load allowable input voltages are
greater than the equalizing charging set point voltage.

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NOTE: Equipment damage!
Over-charging and excessive gas precipitation may damage the
battery plates and activate material shedding on them. Too high an
equalizing charge or for too long may cause damage. Please
carefully review the specific requirements of the battery used in the
system.
Certain types of batteries benefit from periodic equalizing charge, which can stir the
electrolyte, balance battery voltage and complete chemical reaction. Equalizing charge
increases the battery voltage, higher than the standard complement voltage, which
gasifies the battery electrolyte.
If the battery is being over discharged, the solar controller will automatically turn to
equalize charging stage, and the equalize stage remain 120mins. Equalize charge and
boost charge are not carried out constantly in a full charge process to avoid too much gas
precipitation or overheating of battery.
4.3 LED Indicators
Charging Status LED indicator Battery Status LED indicator
Figure 4-2 LED indicators

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Charging Status indicator
GREEN ON whenever sunlight is available for battery charging,
GREEN FAST FLASHING when battery over voltage.
Please refer to section 5 for troubleshooting.
Charging Status LED indicator Table 4-1
Color
Indicator
Charging Status
Green
On Solid
Charging
Green
Fast Flashing
Battery over voltage
Battery Status indicator
GREEN ON when battery voltage in normal range
GREEN SLOWLY FLASHING when battery full
ORANGE ON when battery under voltage
RED ON when battery over discharged
Please refer to section 5 for troubleshooting.
Battery status LED indicator Table 4-2
Color
Indicator
Battery Status
Green
On solid
Normal
Green
Slowly Flashing
Full
Orange
On solid
Under voltage
Red
On solid
Over discharged

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Load status indicator:
When the load current is 1.25times of rated current for 60 seconds, or the load current is
1.5 times of rated current for 5 seconds (overload); or load current is more than 3.5
times of rated current(Short Circuit) ,the load status indictor will be red and flashing.
Please refer to section 5 for trouble shooting.
Load status indicator Table 4-3
Color
indictor
Load status
Red
flashing
Overload or short circuit
Overheating protection indicator:
When heat sink of the controller exceeds 85 ℃, the controller will automatically cut input
and output circuit, Sealed, Gel, Flooded indicator will be red and flashing simultaneously.
Please refer to section 5 for trouble shooting.
Overheating protection indicator Table 4-4
Color
indictor
System status
Red
Sealed、Gel、Flooded
flashing simultaneously
Controller overheating

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4.4 Setting Operation
Sealed Setting indicator Load Status LED indicator
Figure 4-3 Setting operation indicating
·Load Work Mode Setting
When the controller is powered on, press the setting button to control the load output.
Press the button once, the ON/OFF status will be changed corresponding.
·Battery Type Setting
Press the setting button for more than 5 seconds, the original battery type indicator will be
flashing. Then press the setting button to choose Sealed, Gel, and Flooded battery type.
The setting is finished till the digital tube stop flashing.
Battery type selection Table4-5
Battery type
LED indicator
Sealed lead acid battery
Sealed
Gel battery
Gel
Flooded battery
Flooded
Gel
Setting indicator
Flooded
Setting Indicator
Setting button

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5 Protection, Troubleshooting and Maintenance
5.1 Protection
·PV Array Short Circuit
If PV array short circuit occurs, clear it to resume normal operation.
·Load Overload
If the load current exceeds the maximum load current rating, the controller will
disconnect the load. Overloading must be cleared up through reapply power or pressing
the setting button.
·Load Short Circuit
Fully protected against load wiring short-circuit. After one automatic load reconnect
attempt, the fault must be cleared by reapply power or pressing the setting switch.
·PV Reverse Polarity
Fully protection against PV reverse polarity, no damage to the controller will result.
Correct the miswire to resume normal operation.
·Battery Reverse Polarity
Fully protection against battery reverse polarity, no damage to the controller will result.
Correct the miswire to resume normal operation.
·Damaged Local Temperature Sensor
If the temperature sensor short-circuited or damaged, the controller will be charging or
discharging at the default temperature 25℃to prevent the battery damaged from
overcharging or over discharged.
·Overheating Protection
If the temperature of the controller heat sink exceeds 85C, the controller will
automatically start the overheating protection.
·High Voltage Transients
PV is protected against high voltage transients. In lightning prone areas, additional
external suppression is recommended.

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5.2 Troubleshooting
Trouble Shooting Table 5-1
Faults
Possible reasons
Troubleshooting
Charging LED indicator off
during daytime when sunshine
falls on PV modules properly.
PV
array
disconnection
Check that PV and battery
wire connections are
correct and tight.
Green charging LED indicator
fast flashing
Battery voltage
higher than over
voltage disconnect
voltage(OVD)
Check if battery voltage
over high. Disconnect the
solar module
Battery
LED indicators orange
Battery
under voltage
Load output is normal,
charging LED indicator
will return to green
automatically when fully
charged.
Battery LED indicators RED
color and loads not working.
Battery
over discharged
The controller cut off the
output automatically, LED
indicator will return to
green automatically when
fully charged.