Zamp Solar ZS-8A User manual

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Solar Controller / Battery Charger
Input: DC12V Solar panel (Max. 25V)
Output: DC12V 8A
Model Number: ZS-8A
User’s Manual

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●Advanced MCU control pulse width modulated (PWM) technology, high efficiency
operation.
●Target for Gel, AGM, Conventional lead-acid (WET) and Calcium Batteries.
●Built in regulator to prevent your battery from being overcharged. Overcharging
occurs when the charge voltage is unregulated. This can result in premature battery
failure.
●Come with regulator to prevent your battery from being under charged, in the solar
energy field, battery undercharge always occurs, especially on some Conventional
lead –acid or Calcium batteries; The unit provides an automatic Equalization feature
for deeply drained Conventional lead acid battery or Calcium battery.
●Can be connected to the battery permanently to keep the battery fully charged by
using a process called “floating”. This means the controller will stop charging when
the battery is full and will automatically start charging the battery as required. This
process will also reduce water loss and help prevent the battery from ‘drying out’.
●Protects your battery from discharge at night. Under low light or no light conditions
the solar panel voltage could be less than the battery voltage. The unit contains a
special circuit which prevents current flowing back from the battery and into the
solar panel.
●Colored LED’s to easily indicate the charging status and battery conditions and
system faulty.
●Multi charging protections against reverse polarity, short circuit, over temperature,
over voltage, etc.
●Conformal-coating circuit boards and plated terminals apply to hostile environments.
●Waterproof with IP67 .
For use with 12Volt Solar Panel Only
Suitable for Solar panels up to 135 Watts
FEATURE

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Figure 1.1
●This charger is designed for indoor use or outdoor use.
●Do not disassemble the controller. Take to a qualified person if the unit
requires repairing.
●Lead acid batteries can be dangerous. Ensure no sparks or flames are
present when working near batteries.
●Eye protection should always be used. Never short circuit the battery
●Given sufficient light solar panels always generate energy even when they
are disconnected.
●Accidental ‘shorting’ of the terminals or wiring can result in sparks causing
personal injury or a fire hazard. We recommend that you cover up the
panel(s) with some sort of soft cloth so you can block all incoming light
during the installation. This will ensure that no damage is caused to the
Solar Panel or Battery if the wires are accidentally short circuited.
●Always install a battery fuse on each circuit including the solar controller
●Do not reverse connect the wires to the solar panel or battery
WARNING – IMPORTANT PLEASE READ
MOUNTING THE DEVICE
The Solar Controller is mounted as below
The quickest and easiest way to mount the unit is to use the three plastic
spacers and self tapping screws supplied and mount the unit to a flat surface,

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To protect the Battery and the Solar Panel, we strongly recommend that you place a
inline fuse on the positive wire on both the “Solar” and “Battery” Circuits. A 15A fuse
for ZS-8A, (As close to the Battery /Panel as possible)
The Solar Controller has 4 terminals which are clearly marked ‘Solar’ and ‘Battery’.
There is a (12V) and earth (GND) terminal for each circuit.
Refer to the wiring diagram below.
Figure 2.1
Battery Connection
Solar Array Connection
Length of
Wire
< 1m
6m 9m 12m
Size (AWG)
14
14 12* 10*
* If the wire length is beyond 9 meter, the wire dimension must be over 2.4 mm2
please slim the end of wire prior to installation.
1. Using the string wires, screw tightly the wires to the “Solar” terminal on the back of
controller and connect to the Solar Panel like shown.
2. Using the string wires, screw tightly the wires to the “Battery” terminal on the back
of controller and connect to the Battery like shown.
When the connections are completed, the Solar Controller will start working
automatically.
Please check your battery manufacturer’s specifications to select correct battery type.
The unit provides 4 battery types for selections: Gel, AGM, WET (conventional lead
acid), and Calcium.
There is a DIP switch at the back of the solar charge controller, this Dip switch is used
for presetting your battery type. Please refer to Figure 3.1 to make DIP switch setting
for the proper battery chemical; the factory default setting is at AGM battery type.
Note: Once the Dip switch setting is finished, do not freely change the DIP
switch; otherwise it may damage your battery.
Correct Wire Size:
Please refer to the wire size chart
below to determine the minimum
size wire needed for each
connection. This will also ensure
you get the best performance out
of your solar regulator.
WIRING CONNECTIONS
Battery type setting – via DIP Switch

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.
Figure-3.1
The unit has a 5 stage charging algorithm.
Soft Charge (Level 1) –Bulk Charge (Level 2)-Absorption charge (Level 3) –
Equalizing Charge* (Level 4) - Float Mode (Level 5)
Soft Charge- When batteries suffer an over-discharge, the controller will softly ramps
the battery voltage up to 10V.
Bulk Charge-Maximum current charging until batteries rise to Absorption level
Absorption Charge-Constant voltage charging and battery is over 85%.
Equalization Charge*-Only for WET battery or Calcium battery type, when the battery
is deeply drained below 11.5V, it will automatically run this stage to bring
the internal cells as an equal states and fully complement the loss of
capacity.(Gel and AGM battery do not run Equalization charge)
Float Charge-Battery is fully charged and maintained at a safe level.
A fully charged battery has a voltage of more than 13.6 Volts.
The 3 LED’s indicate the
charging status and
Fault connection
Fault
Charge
Full
Red
Blue
Green
Solar Power Present-No
battery connected
ON
Slow flash
Slow flash
Battery reversed
ON
Fast flash
Fast flash
Solar panel reversed
OFF
OFF
OFF
Soft start charging
OFF
Slow flash
OFF
Bulk, Absorption,
Equalization charging
OFF
ON
OFF
Float charging
OFF
OFF
ON
Solar panel weak
Slow flash
OFF
OFF
At night no charge
OFF
OFF
OFF
Slow flash = Slow flash = 1Hz flash; Fast flash = 3 Hz flash
OPERATION - L.E.D. INDICATION
CHARGE STAGE

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1
Electrical Parameters
1-1
Rated solar panel amps
8
Max.
AMP
1-2
Normal input Solar cell array voltage
15-22
VDC
1-3
Max. solar cell array voltage (output has no load)
25
Max.
VDC
1-4
The controller lowest operating voltage (at solar or
battery side )
9V
Min
VDC
1-5
Standby current consumption at night
2
Max
mA
1-6
Maximum voltage drop-Solar panel to battery
0.25
Max.
VDC
2
Charging characteristics
2-1
Minimum battery start charging voltage
3
Min
VDC
2-2
Soft start charging voltage
3-10
+/-0.2
VDC
2-3
Soft start charging current (50% PWM duty)
Up to 4
AMP
2-4
Bulk charge voltage
10-14.0
+/-0.2
VDC
2-5
Absorption charging voltage at 25*C
--Gel type battery
14.1
+/-0.2
VDC
--AGM type battery (default setting)
14.4
+/-0.2
VDC
--WET type battery
14.7
+/-0.2
VDC
--Calcium type battery
14.9
+/-0.2
VDC
2-6
Absorption transits to Equalizing or Float condition:
--Charging current drops to
0.8
+/0.1
AMP
-- or Absorption charging timer timed out
4
Hour
2-7
Equalization charging active
--Only for WET or Calcium battery
--Battery voltage discharged to less than
11.5
+/-0.2
VDC
2-8
Equalization charging voltage at 25*C
15.5
+/-0.2
VDC
2-9
Equalization charging timer timed out
2
Hour
2-10
Float charging voltage at 25*C
13.6
+/-0.2
VDC
2-11
Voltage control accuracy
+/- 1%
2-12
Battery temperature compensation coefficient
-24
mV/*C
2-13
Temperature compensation range
-20 ~ +50
*C
3
Protection
3-1
Against reverse polarity or short circuit at panel side
3-2
Against reverse polarity or short circuit at battery side
3-3
No reverse current from battery to solar at night
3-4
Over temperature protection during charging
65
*C
4
Electrical parts
4-1
Input output terminal
M4 terminals
4-2
Temperature sensor port or DIP switch
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Physical Parameters
5-1
Controller material
Plastic, Standard ABS
5-2
Power terminal maximum stranded wire size
#12AWG stranded-3 mm2
5-3
Mounting
Vertical wall mounting
5-4
IP grade
IP22 or IP67,
5-5
Net weight
Approx. 200g
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Environmental characteristics
6-1
Operating temperature
-25 ~ 50*C
6-2
Storage temperature
-40 ~ 85*C
6-3
Operating Humidity range
100% no condensation
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