WINDY NATION CHC-1224-10 User manual

CHC-1224-xx User Manual
Revision 1.0
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07/19/2013
windynation)
)
Solar Panel Charge Controller
CHC-1224-10
CHC-1224-30
User’s Manual

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Table of Contents
1!Introduction ................................................................................................................................................. 3!
1.1!Features ............................................................................................................................................ 3!
1.2!System Diagram ................................................................................................................................ 3!
1.3!Safety Information ............................................................................................................................. 4!
1.4!Specifications .................................................................................................................................... 4!
1.4.1!Electrical Specifications................................................................................................................. 4!
1.4.2!Physical Specifications .................................................................................................................. 4!
2!Installation ................................................................................................................................................... 4!
2.1!Electrostatic (ESD) Precautions ........................................................................................................ 4!
2.2!Mounting............................................................................................................................................ 5!
2.3!Connections....................................................................................................................................... 5!
3!Operation .................................................................................................................................................... 6!
3.1!Power ................................................................................................................................................ 6!
3.2!LED Indicators ................................................................................................................................... 7!
3.2.1!Charge LED................................................................................................................................... 7!
3.2.2!Battery LED ................................................................................................................................... 7!
3.2.3!Load LED....................................................................................................................................... 8!
3.3!Setting Modes.................................................................................................................................... 8!
3.3.1!Normal Control .............................................................................................................................. 8!
3.3.2!Night ON+ Day OFF Control Mode ............................................................................................... 8!
3.3.3!Night ON + Set Time Delay OFF Mode......................................................................................... 8!
3.3.4!Common Controller Mode ............................................................................................................. 9!
3.3.5!Test Mode...................................................................................................................................... 9!
3.3.6!Functional Matrix ........................................................................................................................... 9!
4!Application .................................................................................................................................................. 9!
4.1!Wire Gauge Reference...................................................................................................................... 9!
4.1.1!Wire Thickness .............................................................................................................................. 9!
5!Troubleshooting And Support ................................................................................................................... 10!
5.1!Maintenance & Care........................................................................................................................ 10!
5.2!Troubleshooting............................................................................................................................... 10!
5.3!Support............................................................................................................................................ 10!
5.4!Warranty.......................................................................................................................................... 11!
5.4.1!Restrictions.................................................................................................................................. 11!
5.4.2!Warranty Claims & Return Procedures ....................................................................................... 11!
5.4.3!Disclaimer.................................................................................................................................... 11!
5.4.4!Limitation of Liability .................................................................................................................... 12!

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1 INTRODUCTION
The WindyNation Solar Panel Charge Controller provides a reliable charging and power management
solution for solar power battery systems with many of the features that you would expect in a much higher
priced controller. This is made possible by the board microprocessor and embedded intelligent software
control.
The controller featuresautomatic a 12V or 24V DC detect function that will identify the battery voltage upon
initial charge and uses Pulse-Width Modulation (PWM) for automatic charge management and high
efficiency. A built in temperature sensor provides software controlled charge compensation that accurately
adjusts the over-discharge voltage and maximizes your batteries life.
Built in protection includes overload, short circuit, reverse connection, lightning/surge, PV panel reverse
current, over charging, and discharging protection. In the event of a short circuit or overload event, the
system will be protected and remain undamaged.
The enclosure is made of durable plastic with LED lights to provide status indications of charge, battery
status, and system faults as well a user selectable Work Mode/timing interval that willpower various DC
powered systems for specified time intervals after dusk such as night/street lighting.
Please read this manual carefully before installing or using the controller and keep it for future reference.
1.1 FEATURES
Compact size is easy to mount on wall or panel.
Charge controller maintains batteries and extends battery life.
Auto sensing for 12 or 24V systems
Built-in battery test function
Convenient screw terminals for wiring
Separate connections for PV panel, battery,and load
Built-in overload and short circuit protection
Automatic self-recovery after fault removal
LED system status indicators
Requires no adjustments
User selectable on, off, and time modes
Wide operating temperature range -35˚C to +55˚C (-31˚F to +131˚F)
1.2 SYSTEM DIAGRAM
The MCU controller takes sample measurements from the storage battery voltage, discharge current, and
ambient temperature to calculate and control the discharge rate.

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1.3 SAFETY INFORMATION
Please read the installation and operating instructions carefully prior to use. Pay special attention to the
IMPORTANT and WARNING statements in the manual.
WARNING:
Never install during a lightning storm or where unsafe voltages are present.
Solar panels produce power when exposed to light. Use caution when handling copper wiring.
Do not use with equipment that exceeds the rated power for this device.
1.4 SPECIFICATIONS
1.4.1 Electrical Specifications
Parameter
CHC-1224-10
CHC-1224-30
Rated Charge Current
10 Amps
30 Amps
Rated Load Current
10 Amps
30 Amps
Typical Idle Consumption
At idle < 5mA
Overvoltage Protection
15.6V
31.2V
Low Voltage Indication
12.0V
24.0V
Overload Protection (DC load)
1.25 x Inom>60s
1.5 x Inom >5s
Short Circuit Protection
3x Inom
Boost Charge
14.6V
29.2V
Float Charge Voltage
13.6V
27.2V
Equalization Charge
14.4V
28.8V
Overcharge Disconnection
14.8V
29.6V
Overcharge Recovery
13.2V
26.4 V
Over-discharge Disconnection
11.1V
22.2V
Over-discharge Reconnection
12.5V
25.0V
Temperature Compensation
-4.0 mV/oC/2V
1.4.2 Physical Specifications
Parameter
Value
Dimension (H x W x D)
5.26” (133.5mm)x 2.76” (70mm)x 1.34” (34mm)
Unit Weight
0.3 lb. (142g)
Operating Temperature
-31oF to 131oF(-35oC to 55oC)
Operating Humidity
20 to 80% relative humidity (non-condensing)
Wire Size
Up to 6mm2
Battery Type
Lead Acid including AGM and Flooded
2 INSTALLATION
Insure all terminating connections are clean and tight to prevent arcing and overheating.
The controller must be installed in an area that satisfies all of the following conditions:
1. Dry: Avoid any location where water can contact the controller
2. Cool: Ambient air temperature between 30°F and 105°F (0°C and 40°C)
3. Ventilated: Allow at least 2in (50 mm) of clearance above and below and at least 1 in (25 mm)
on each side for proper air flow.
2.1 ELECTROSTATIC (ESD) PRECAUTIONS
All electronic circuits may be damaged by static electricity. To minimize the likelihood of electrostatic
damage, discharge yourself by touching an electrical ground (e.g.: copper pipe) prior to handling the unit and

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avoid touching components on the circuit boards. The risk of electrostatic damage is highest when relative
humidity is below 40%.
2.2 MOUNTING
Mounting is optional;however, the environment must be dry and protected from water.
1. The controller can be mounted on a vertical or horizontal surface. If mounted vertically, the unit
should be oriented such that neither end is at the top so foreign material cannot settle into the
unit.
2. Install four user-supplied fasteners through the four mounting slots and into the mounting
surface.
3. Tighten all the fasteners to ensure the controller cannot slide in any direction.
IMPORTANT: For best results, mount the charge controller and batteries as close to the panels as practical.
2.3 CONNECTIONS
WARNING: Loose connectors result in excessive voltage drop and may cause over heated wires and melted
insulation, which can lead to electrical fires.
IMPORTANT: The NEC requires that the wires carrying the system current never exceed 80% of the
conductor’s current rating (sizing recommendations are located in Section 4).
IMPORTANT: The screw-down terminals on the charge controller accept 10~26AWG wire.
IMPORTANT: Strip the wire ends approximately 0.2” (5mm) before connecting to the charge controller. Use
caution when handling the stripped wires to avoid electric shock.

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1) Connect the Battery
Connect the battery wiring to the battery terminals on the charge controller. Note the polarity on the screw-
down terminals. The charge controller self-protection feature will prevent damage from reverse polarity
connections, but the charge controller will not function until the battery is connected properly.
IMPORTANT: A properly sized fuse needs to be placed in the positive wire connecting the charge controller
to the battery.
2) Connect the Solar Panel Array
Connect the wires from the solar panel array to the PV port on the charge controller. Note the polarity on the
screw-down terminals. The charge controller self-protection feature will prevent damage from reverse polarity
connections, but the charge controller will not function until the solar panel array is connected properly.
The green LED indicator will light up if there is enough sunlight.
IMPORTANT: A properly sized fuse needs to be placed in the positive wire connecting the solar panel(s) to
the charge controller.
WARNING: High voltages may be present on the solar panel output wiring. Solar panels produce electricity
when exposed to light. Use caution and avoid touching any conductors in the system circuit to avoid electric
shock.
3) Connect the Load (Optional)
If you have a 12VDC application, connect the wires from the appliance to the load port on the charge
controller. Note the polarity on the screw-down terminals. The charge controller self-protection feature will
prevent damage from reverse polarity connections, but the charge controller will not function until the load is
connected properly.
IMPORTANT: A properly sized fuse needs to be placed in the positive wire connecting the load (e.g. light
bulb, etc.) to the charge controller.
If the red LED indicator light turns on, the battery capacity is low and needs to be charged before completing
the system installation.
Press the Power/Mode button to turn on power to the load terminals.
3 OPERATION
3.1 POWER
Once properly connected to a battery and solar panel array, the charge controller will immediately begin
operating. When first connected, the Load LED will be off, indicating that the power to the load is off.
Press the Power/Mode button to turn on power to the load.
Note: The solar power charge controller can only be used with lead acid type batteries.
To test the system for proper connections, press the Power/Mode button on the charge controller until you
see the number 7. (or 17; see description below).
IMPORTANT: Make sure the solar module(s) voltage and current do not exceed the ratings of the charge
controller.

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3.2 LED INDICATORS
LED
State
Description
OFF
No Charge (Nighttime)
Solid Green
Solar power is charging the battery
Charge
Blinking Green
The system is over voltage
Solid Green
Battery level is in the right range
Slow Flash Green
Battery level is full
Solid Yellow
Battery level is low
Battery
Solid Red
Load cut-off
Solid Red
The output is on
Slow Flash Red
Overload
Load
Blinking Red
Load is short circuit
Note: The load output will shut off once there is an overload or short circuit. Disconnect all of the equipment
and then wait a few seconds before reconnecting everything. Press the Power/Mode button and the
controller will resume working after approximately 10 seconds, or in some instances, it may take a few
moments longer.
3.2.1 Charge LED
When the connected solar panel is exposed to sunlight, the Charge LED will be green, indicating that the
system is charging normally.
The Charge LED will flash green when an overcharge condition or an open battery circuit exists.
PWM mode is used during charging. If an over-discharge of the battery has occurred, the charger will switch
to boost voltage for 10 minutes, then will return to direct voltage for at least 10 minutes to activate the
battery, and finally to the float voltage state where it will remain to maintain the best state of the battery. This
multistep charging process will help bring the battery to full charge and maximize its life span.
3.2.2 Battery LED
The Battery LED is green when the battery voltage is in normal condition. It will blink green slowly when the
battery finishes its charge.
The LED is yellow when the voltage of the battery is below normal.

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When the battery voltage goes down continuously into an over-discharge condition, the Battery LED will turn
red and the Load output will switch off.
The system will automatically resume normal operation and switch on the load output and when the battery
voltage recovers to the over-discharge return voltage.
3.2.3 Load LED
The load LED is red when a load output is operating normally.
If the load current is 1.25 times higher than the rated current of the controller for 60 seconds or 1.5 times
higher than the rated current for 5 seconds, then the controller will shut down the output and the Load
LED will blink red slowly to indicate that an overload condition occurred.
To resume normal operation, disconnect the load at fault and press the Power/Mode button. The charge
controller will resume normal operation after 30 seconds.
The Load LED will blink red rapidly to indicate that a short circuit condition occurred. If a load short circuit
occurs, the controller will shut down the output. If this happens, verify load connections. To resume normal
operation, remove the short circuit at the load and press the Power/Mode button. The charge controller will
resume normal operation after 30 seconds.
3.3 SETTING MODES
The charge controller has a mode setting function to set specific operation parameters. It is preset to the
factory default of normal control. The load will draw from the battery at all times, and the PV panel will charge
the battery when sunlight is available.
To set modes, press and hold the Power/Mode Button until the number on the LED display begins to flash
(~5 seconds). Press the button repeatedly to choose the desired mode number. When the desired number is
selected, stop pressing the button and wait for number to stop flashing, indicating that the setting is
completed. The display will turn off after several seconds. Press the button to check the value.
IMPORTANT: Settings 10 through 17 may appear as a single digit and have a dot (.) after the mode number.
IMPORTANT: The controller requires about 10 minutes of continuous transition values before it starts
working properly. These constraints avoid false transitions due to lighting or shading.
3.3.1 Normal Control
This is the default setting. The load will draw from the battery at all times, and the PV panel will charge the
battery when sunlight is available. When selecting this mode (16 or 6-dot), press the Power/Mode button
again after the mode is set to turn on the load output.
Note: In this mode only, the Power/Mode button will turn the load output on and off when pressed. After
selecting this mode, make sure the load LED is on, indicating load output.
3.3.2 Night ON+ Day OFF Control Mode
The load will start working when it gets dark until it gets light. There is a 10 minute delay before turning on
the load in order to make sure it is really dark and not a passing cloud etc.
3.3.3 Night ON + Set Time Delay OFF Mode
The load will switch on same as above, and remain on for a set duration. Once the selected time has
elapsed, the load will switch off. The duration setting is listed in mode setting table. 1 to 15 hour delays can
be selected, in increments of 1 hour. If the time setting overlaps with the occurrence of light control, then light
control takes priority.
Press!and!hold!
un-l!LED!
Flashes!
Press!to!Select!
Mode!Number!
Release!at!
desired!mode,!
wait!for!blinking!
to!stop!
Mode!is!set.!
Mode!display!
turns!off!
automa-cally!

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3.3.4 Common Controller Mode
The controller will work as a common controller, without light and time control, and no ON and OFF delay
time. The load turns on immediately when there is no light, and off immediately when light is present on the
PV panel.
3.3.5 Test Mode
This is used for the testing the system by directly turning on the load output. If there is light signal (sunlight),
the load will be turned off (closed). If there is no light signal (sunlight),the load will be turned on (opened). It
is convenient for checking the correctness of the system during installation and debugging.
3.3.6 Functional Matrix
MODE
LED
MODE
LED
Night ON + Day OFF
00
Night ON + 10 Hours delay OFF
10 or 0.
Night ON + 1 Hour delay OFF
01
Night ON + 11 Hours delay OFF
11 or 1.
Night ON + 2 Hours delay OFF
02
Night ON + 12 Hours delay OFF
12 or 2.
Night ON + 3 Hours delay OFF
03
Night ON + 13 Hours delay OFF
13 or 3.
Night ON + 4 Hours delay OFF
04
Night ON + 14 Hours delay OFF
14 or 4.
Night ON + 5 Hours delay OFF
05
Night ON + 15 Hours delay OFF
15 or 5.
Night ON + 6 Hours delay OFF
06
Normal Control
16 or 6.
Night ON + 7 Hours delay OFF
07
Test (no delay)
17 or 7.
Night ON + 8 Hours delay OFF
08
Night ON + 9 Hours delay OFF
09
4 APPLICATION
4.1 WIRE GAUGE REFERENCE
4.1.1 Wire Thickness
AWG
Diameter
inches (mm)
Ohms per
1000ft
Break
Force
Square
mm2
16
0.051 (1.29)
4.016
75 lbs
1.30
14
0.064 (1.63)
2.525
119 lbs
2.08
12
0.081 (2.05)
1.588
197 lbs
3.30
10
0.102 (2.59)
0.999
314 lbs
5.26
8
0.129 (3.26)
0.628
480 lbs
8.30
6
0.162 (4.11)
0.395
760 lbs
13.30
4
0.204 (5.19)
0.249
1210 lbs
21.15
2
0.258 (6.54)
0.156
1930 lbs
33.62
1
0.289 (7.35)
0.124
2430 lbs
42.41
0 (1/0)
0.325 (8.25)
0.098
3060 lbs
53.49
00 (2/0)
0.365 (9.27)
0.078
3860 lbs
67.43
000 (3/0)
0.410 (10.4)
0.062
4860 lbs
85.01
0000 (4/0)
0.460 (11.68)
0.049
6120 lbs
107.22

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5 TROUBLESHOOTING AND SUPPORT
The Controller requires minimal care. It is recommended to inspect all the connections at least two times per
year for insulation damage or corrosion and to ensure all connections are tight and secure.
5.1 MAINTENANCE &CARE
Clean the area around the controller of any dirt or debris with a moistened cloth.
Tighten the screws on the DC input terminals. Inspect for loose, broken, or burnt wire connections.
Inspect any batteries for cracked or bulging cases and corroded terminals.
Make sure the PV array is clean and remove any debris.
5.2 TROUBLESHOOTING
Problem
Possible Remedies
The charge LED indicator
doesn't light green when
the solar panel is exposed
to sunlight.
1. Check if the solar panel cables are connected properly.
2. Check to make sure the correct battery is being used.
3. Check all wiring connections to make sure they are in their designated
locations and make sure that there are no loose connections.
4. Measure the PV array open-circuit voltage and confirm it is within its normal
limits.
5. Measure the PV voltage and the battery voltage at the controller terminals.
a. If the voltage at the terminals is within proper specifications, the PV array is
charging the battery properly.
b. If the PV voltage is within specifications to the open circuit voltage rating of
the panels, but the battery voltage is low, the charge controller may not be
charging the battery and it may be damaged.
The charge LED indicator
flashes rapidly.
1. System over voltage protection is active.
2. Check for open circuit in battery, faulty battery connections to the system, or
system charging circuit failure.
3. Check the operating conditions to confirm that the voltage is higher than the
specifications.
a. Consider temperature compensation. For example, at 0°C the charge
controller will regulate at about 15 volts.
The load LED indicator is
on but there is no power
output.
1. Load open circuit.
2. Check cables and connections and any other load switches.
3. Over discharge of the battery. The controller will resume normal operation
after the battery has finished charging.
The load LED indicator
light flashes and there is
no power output.
1. Check the output circuit for load short circuit or over load condition
2. Remove the load and push the button; the controller will resume its work
after 30 seconds.
5.3 SUPPORT
If you are experiencing technical problems, and cannot find a solution in this manual, you can contact Windy
Nation Inc. for further assistance.
•Call: [phone]
•Email: [e-mail]
•Write: 398 South Kalorama Street, Unit C, Ventura, CA 93001
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