Zamp Solar Pulse Tech CINDER 40 PWM User manual

CINDER™40 PWM Charge
Controller
CINDER 40 PWM
Part # SCC1005
Input: DC12V or DC24V solar panel (Max 50Voc)
Output: DC 12V 40A
DC 24V 40A
User Manual

CINDER 40 PWM Charge Controller User Manual Zamp Solar
THIS MANUAL CONTAINS IMPORTANT INSTRUCTIONS FOR
INSTALLATION AND MAINTENANCE OF THE
SCC1005 CHARGE CONTROLLER
Contents
1) IMPORTANT SAFETY INSTRUCTIONS - PLEASE READ 3
2) Overview 4
Intro 4
PulseTech 4
Bluetooth 4
Load Output Circuit 4
3) Features 5
4) Wiring and Installation 6
Important Installation Notes - Please Read 6
Device Connections 7
Installation Guide 12-Volt and 24-Volt 8
12-Volt Installation Specifics 9
24-Volt Installation Specifics 11
Load Output Circuit Details 13
5) Zamp Solar Mobile Application 14
Status Page 15
History Page 17
Settings Page 17
6) PulseTech Functionality 20
7) Charging Profiles 21
8) LED Operation 23
9) Troubleshooting 24
10) Specifications 25
11) Contact Us 26
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CINDER 40 PWM Charge Controller User Manual Zamp Solar
Figure 1: CINDER 40 Top View
Figure 2: Front face of CINDER 40 showing all connections
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CINDER 40 PWM Charge Controller User Manual Zamp Solar
1) IMPORTANT SAFETY INSTRUCTIONS -
PLEASE READ
●THIS DEVICE IS INTENDED FOR INDOOR USE ONLY AND SHOULD NEVER
BE EXPOSED TO RAIN, MOISTURE OR OUTDOOR ELEMENTS.
●"WARNING: WHEN A GROUND FAULT IS INDICATED, BATTERY
TERMINALS AND CONNECTED CIRCUITS MAY BE UNGROUNDED AND
HAZARDOUS."
●LEAD-ACID, AGM, LITHIUM, AND LTO BATTERIES CAN BE DANGEROUS.
ENSURE NO SPARKS OR FLAMES ARE PRESENT WHEN WORKING NEAR
BATTERIES.
●NEVER SHORT CIRCUIT THE BATTERY.
●SOLAR PANELS WILL GENERATE ENERGY WHEN THEY ARE EXPOSED TO
LIGHT EVEN WHEN DISCONNECTED. ANY CONTACT WITH WIRES CAN
CAUSE INJURY.
●NEVER USE THIS DEVICE WITH A LITHIUM BATTERY THAT DOES NOT
HAVE A BMS. A BMS IS CRITICAL FOR LITHIUM BATTERY SAFETY.
●Eye protection should always be used when working near batteries.
●Accidental shorting of the wiring during installation can result in sparks
causing personal injury or a fire hazard. Zamp Solar recommends
covering the solar panels to block all light from reaching the surface
during installation.
●Use 6 AWG, 90°C copper wire for the Solar and Battery connections.
●Always install a battery fuse (50-amp recommended) between the battery
and the solar controller. (see Section 4 for more details on fusing).
●Be very careful not to connect the wires to the solar panel or battery in
reverse. (See Figure 2 above for connection layout)
●Do not disassemble the CINDER 40. Please contact Zamp Solar Customer
Service if you have any problems with your device. 541-728-0924 or
[email protected].
●Device has overcurrent protection up to 50 amps on both the Solar and
Battery terminals.
●Zamp Solar recommends not exceeding 40-amps of short circuit current
(Isc)for your solar input.
●Audible noise during charging is normal, particularly during absorption
and float modes. The noise is due to the PWM charging functionality of
the device and not an indication of a device failure.
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CINDER 40 PWM Charge Controller User Manual Zamp Solar
2) Overview
Intro
The Zamp Solar CINDER 40 solar charge controller automatically controls the
attached solar input to charge the connected battery and keep it at optimal battery
health. The CINDER 40 also monitors, regulates and protects the attached solar and
battery components. Equipped with advanced, high efficiency, pulse width
modulated (PWM) technology and temperature compensation, batteries safely
charge to 100% every time.
PulseTech
Patented PulseTech pulsing technology increases the life of lead-acid batteries.
PulseTech works by removing and hindering the natural sulfation (corrosion) that
occurs in all lead-acid/AGM batteries that eventually leads to a dead battery.
PulseTech patented desulfating technology has been proven to increase the life of
lead-acid/AGM batteries by up to three times their normal life. This technology is
built into the CINDER 40 and can be turned on for any lead-acid/AGM battery
charging profile.
Bluetooth
Use our Android and iOS apps with our built-in Bluetooth technology to program,
control and monitor your battery(s). Get real-time charging and battery statistics at
the touch of a button on your smart device. Check the history page for long term
performance data and statistics. Program when the load output circuit should turn
on and off and set low voltage disconnects. See Section 5 for more details on the
Zamp Solar application.
Load Output Circuit
Power and control DC devices using our Load Output Circuit. The CINDER 40 load
circuit will power devices that run on 12-volt or 24-volt, depending on battery
configuration. The load circuit is not for use with any DC/AC power inverters. Use our
Android or iOS app to turn this circuit On/Off or program to run at certain times
during the day.
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CINDER 40 PWM Charge Controller User Manual Zamp Solar
3) Features
1. Premium 40-amp Pulse Width Modulation (PWM) Solar Charge Controller
2. Charge 12-volt and 24-volt battery systems using 12-volt or 24-volt solar panels
3. Preprogrammed and customizable battery charging profiles
a. AGM, WET, GEL and Calcium lead-acid type batteries
b. Lithium (LiFeP04/Lithium Ion) and lithium titanate oxide (LTO) type
batteries
c. Customize any charging profile for specific battery needs. (see Section 7
for more detail on custom charging profiles)
4. PulseTech pulsing technology increases the life of all lead-acid battery
types (see Section 6 for more details on the PulseTech functionality)
5. Built-in Bluetooth technology allows remote monitoring and control of the
battery and load output circuit. Change battery settings, charging profiles and
toggle the load output circuit all from our mobile app. Available for both
Android and iOS. (see Section 5 for more details on the Zamp Solar
Application)
6. Robust safety and protection
a. Protects battery from over-voltage or over-current scenarios
b. Protection from reverse polarity or reverse current
c. Battery temperature protection (see Section 7 for more information)
d. Load output short circuit protection.
7. Load output circuit
a. App controlled - Turn a circuit on/off on demand or automatically at
programmed times
b. Smart monitoring and low voltage cutoff to prevent battery from being
discharged to unsafe levels.
c. Ideal for lighting and other small loads
d. Fuse protected at 25-amps.
e. Not for use with a DC/AC inverter
8. Battery temperature compensation
a. External battery temperature sensor included with device.
b. Improves charging accuracy for all lead acid battery types.
c. Prevents damage during temperature extremes for all lead acid battery
types.
9. LED lights indicate battery status, solar panel status, load status, Bluetooth
status and PulseTech status.
10. RV-C Capable
a. Receive charging data
b. Request specific Data
c. Control Load circuit
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CINDER 40 PWM Charge Controller User Manual Zamp Solar
4) Wiring and Installation
See the following six pages for the installation guides for both 12-volt and
24-volt systems. See the mounting diagram in Section 10 for detailed
dimension information.
Important Installation Notes - Please Read
1. Use 6-AWG, 90°C copper wire for the Solar and Battery connections.
2. Ensure that your solar input has a maximum short circuit current (Isc) of
less than 40 amps.
3. To protect the battery and the solar panel, a 50-amp inline fuse must be
placed between the charge controller and the battery. This fuse should
be located as close to the battery as possible for optimal performance.
4. The maximum overcurrent of the CINDER 40 is 50 amps.
5. Use up to 6-AWG wire for Load connections (see Load Output Circuit
Details Section below for specific wire size recommendations).
6. It is important to use the external temperature sensor to ensure proper
battery charging for all lead acid battery types. Please use the supplied
flathead screwdriver to connect the sensor to the charge controller
(polarity does not matter) and either tape the ring terminal end to your
battery or connect it to the positive battery post.
7. Immediately after connecting the battery to the charge controller, use the
Zamp Solar Mobile App to set the proper battery charging profile or use
the custom profile settings to adjust the charging profile. Do this before
connecting your solar panels to the device. - Follow the battery
manufacturer’s recommendations when using the custom profile
setting.
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CINDER 40 PWM Charge Controller User Manual Zamp Solar
Device Connections
Figure 4: Bottom of CINDER 40 Showing All Connections
The CINDER 40 charge controller has 10 separate connection points which are detailed
below. Note the orientation of each terminal; it does not follow the same polarity (+/-) pattern.
Connect the battery first, then the solar panels. It is very important that you connect
your CINDER 40 with the proper polarity for each of the terminals or you can cause
significant damage to the device. Be very careful not to connect solar panels to the
battery terminals and vice versa.
A removable service panel is located on the front of the charge controller for LOAD, BATTERY,
SOLAR and TEMPERATURE connections. A standard flat head screwdriver is required to
secure all of the following wired connections Please use the supplied smaller flat head
screwdriver to attach the Temperature sensor wires
LOAD
Connect these terminals to any DC circuit up to 20 amps you wish to power off your
battery. These terminals are internally fuse protected at 20A. (-) goes to the negative
side of the load. (+) goes to the positive side of the load.
BATTERY
Battery connection terminals. (-) goes to the negative side of the battery. (+) goes to
the positive side of the battery. Zamp Solar strongly recommends installing a 50-amp
fuse inline on the positive wire leading to the battery. Connect the battery wiring first,
then the solar panel wiring.
SOLAR
Solar connection terminals. (-) goes to the negative side of the solar panel. (+) goes to
the positive side of the solar panel. Connect the Battery wiring first, then the Solar
Panel wiring second.
TEMP
These terminals are for connecting the included temperature sensor. NOTE: This
sensor is not polarized, it does not require a specific orientation for proper
installation. Insert wires and screw tight. Tape ring terminal to the top of the battery
or connect it to the positive battery post. (Do not use for Lithium batteries)
DISP & AUX
These terminals are RJ45 connectors for RV-C functionality as well as for future
interconnectivity and development.
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CINDER 40 PWM Charge Controller User Manual Zamp Solar
Installation Guide 12-Volt and 24-Volt
Charge Controller to Battery Wiring
Connect the charge controller to the battery using 10 feet (or less) of 6-AWG, 90oC copper
wire. The shorter the wire run, the better. This is due to the voltage drop that occurs in the
wires when the device is charging. When connecting the charge controller to the battery,
ensure there is a 50-amp fuse between the charge controller and the battery on the positive
side, as shown in Figures 5 and 7 below. Place the fuse as close to the battery as possible.
Battery Fusing
Examples of fuses to use are a terminal fuse block, manual resetting breaker or an ANL type
fuse. A 50-amp fuse is recommended for all installations.
Automatic resetting breakers are NOT recommended.
Temperature Sensor
The CINDER 40 comes with a 10-foot temperature sensor that has a ring terminal on one end
and two exposed leads on the other end. If using a lead acid battery, connect the
temperature sensor leads to the charge controller’s TEMP terminals. Note that there is no
polarity with this connection. Once tight, give each lead a light tug to ensure that they are
properly connected. Then, tape the ring terminal side of the temperature sensor to the side
or the top of your battery. This is recommended over connecting it to one of the battery
terminals because it will give a better gauge of the actual temperature of your battery. It is
important to use the temperature sensor as described to accurately charge your lead acid
battery bank over all temperature ranges. Do not use the temperature sensor for lithium
batteries. (See the Section 7 for information on temperature behavior during charging).
12-Volt and 24-Volt Load
Connect your 12-Volt DC circuits to the load terminal to enable remote control and
monitoring of these devices. Please see the Load Details section for a full load description,
examples and load wiring recommendations.
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CINDER 40 PWM Charge Controller User Manual Zamp Solar
12-Volt Installation Specifics
Table 1: 12-Volt Installation Quick information
Maximum Nominal Panel Wattage
800W (<= 40A Isc)
Battery to Charge Controller Wire Size
6-AWG
Battery to Charge Controller Fuse Size
50A
Battery to Charge Controller Maximum Wire Length with 6-AWG
10 Ft
Solar Panel to Charge Controller Wire Size
6-AWG
Solar Panel to Charge Controller Maximum Wire Length with 6-AWG
10 Ft
Solar Panel Configuration
Parallel (12V)
Temperature Sensor
Tape to top or side of the Battery if lead
acid
Load Output Voltage
12V
Load Output Current
20A
Figure 5: 12-Volt Installation Diagram
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CINDER 40 PWM Charge Controller User Manual Zamp Solar
Figure 6: 12-Volt Charge Controller to Solar Panel Wiring example
Figure 6 demonstrates how to connect two panels in parallel using a Zamp solar parallel
connecting roof cap to create a 12-volt charging system. This configuration should be used
when your battery is 12-volts. Please see the Device Connections Section above for a
description of all the Cinder 40 inputs to help you during installation.
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CINDER 40 PWM Charge Controller User Manual Zamp Solar
24-Volt Installation Specifics
Table 2: 24-Volt Installation Quick information
Maximum Nominal Panel Wattage
1600W (<= 40A Isc)
Battery to Charge Controller Wire Size
6-AWG
Battery to Charge Controller Fuse Size
50A
Battery to Charge Controller Maximum Wire Length with 6-AWG
20 Ft
Solar Panel to Charge Controller Wire Size
6-AWG
Solar Panel to Charge Controller Maximum Wire Length with 6-AWG
20 Ft
Solar Panel Configuration
2x12V panels in Series
or
24V Panel
Temperature Sensor
Tape to top or side of the Battery if lead
acid
Load Output Voltage
24V
Load Output Current
20A
Figure 7: 24-Volt Installation
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CINDER 40 PWM Charge Controller User Manual Zamp Solar
Figure 8: 24-Volt Charge Controller to Solar Panel Wiring example
Figure 8 demonstrates how to connect 4 panels in a 2x2 series configuration using Zamp
solar series connecting roof caps to create a 24-volt charging system. This configuration
should be used when your battery is 24-volts. Please see the Device Connections Section
above for a description of the CINDER 40 inputs and outputs.
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CINDER 40 PWM Charge Controller User Manual Zamp Solar
Load Output Circuit Details
Description
The load terminals give a user-controlled, 20-amp, fuse protected output circuit that
discharges from the battery. The Zamp Solar app allows you to turn your load on/off as well as
monitor the load output at all times so you can see how much power is being used by your
attached electronics.
The load terminals will automatically turn off when the CINDER 40 senses that your battery
system has dropped below the “Load Disconnect Voltage” to protect your battery from
discharging too far (see the Settings Page for more information on the “Load Disconnect
Voltage”)
IMPORTANT: The load voltage matches the battery voltage. Ensure that your electronics
match your battery voltage. i.e. DO NOT connect 12-volt electronics to the load if your battery
voltage is 24-volt.
Examples
The best use of the Load is to connect LED lighting to these terminals so that you can turn
on/off your lighting with the Zamp Solar App.
These terminals could also be run to a DC fuse block to run other devices such as LED light
bars, fans, USB chargers, refrigerators, heaters, small water pumps and other battery driven
devices. Ensure that the total current of your loads does not exceed 20-amps.
IMPORTANT: It is very important that you do NOT connect your inverter to these terminals.
Inverters require significant start up current that can cause damage to the device.
Keep in mind that the circuit can only handle 20 amps at one time. If you have a device that
should never turn off regardless of the battery voltage, connect this device directly to the
battery instead of through the load circuit.
Load Wiring Recommendations
Please see the chart below for information on recommended wire gauge size for the load
terminals. Please note that these recommendations assume that the wires connected are
carrying the full 20A load output and keeping the voltage drop below 5%. Note: it is
recommended to use larger wire as there will be less power loss in the wires.
Table 3: Load Wiring Recommendations (for a Maximum 20-amp Load Current)
Length of Wire Run
Wire Size to Use
5 Ft
10 AWG or larger
10 Ft
10 AWG or larger
15 Ft
10 AWG or larger
20 Ft
8 AWG or larger
25 Ft and greater
8 AWG or larger
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CINDER 40 PWM Charge Controller User Manual Zamp Solar
5) Zamp Solar Mobile Application
Find the Zamp Solar App on the Google Play Store or on the iOS App Store by searching
“Zamp Solar”.
The CINDER 40 PWM controller can be controlled using the Zamp Solar application available
on both Android and iOS devices.
There are three main pages in the application:
●Status
●History
●Settings
These allow you to view important information about the status or your device and to change
the way it behaves. Each app page is shown below. See the following three pages for a
detailed description of each page.
STATUS
HISTORY
SETTINGS
Figure 9: 3 Main App Screens (Status, History and Settings)
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CINDER 40 PWM Charge Controller User Manual Zamp Solar
Status Page
●Real Time Data
Graph Select Buttons: These two buttons are labeled “Real Time Solar” and “Real
Time Load”. The option that is highlighted in green will be displayed below on the
graph.
Solar Input: This value gives either the real time current in amps or the real time
power in watts from the solar panels depending on your settings for the real time
status graph. This value will always be shown even if the Real Time Load option is
selected for the graph. See Table 4 below for a description of the indicator next to
this value.
Real Time Graph: This graph shows solar input data or load output data over the
last 2 hours. The graph will automatically scale its vertical axis to the highest value.
●Load Control
ON: turns the Load output circuit on until it is turned off.
OFF: turns the Load output circuit off.
TIMED: allows you to turn on the load for a defined time range (e.g. 8AM - 8PM)
●Load Disconnect Voltage
If the battery voltage drops below this value, the load will disconnect in order to
preserve the health of the battery. It can be set to any value between 10.2V ~ 12.6V
for 12V systems (20.4V ~ 25.2V for 24V systems).
●Load Output Current
Gives real time current going from the battery through the load terminals in amps.
●Real Time Information
Battery Voltage: Shows the real time voltage of the battery in volts. See Table 4
below for a description of the indicator.
Battery Temperature: Shows the temperature of the battery taken from the
external temperature sensor. The app will show “not connected” if the external
temperature sensor is not connected. Change from C to F in the settings under
“Temperature Setting”. See Table 4 below for a description of the indicator.
Charging Current: Shows real time solar current in amps going to the battery
from the solar input. See Table 4 below for a description of the indicator next to
this value.
Solar Wattage: Shows real time solar wattage going to the battery from the solar
input. See Table 4 below for a description of the indicator next to this value.
Solar Voltage: Shows real time solar voltage of the solar input. See Table 4 below
for a description of the indicator next to this value.
System Voltage - This shows the nominal system voltage (either 12V or 24V). If this
value does not match your nominal battery voltage adjust this value in the
settings under “System Voltage”.
Charge Profile - This shows the current battery profile being used by the system
to charge the battery. This can be changed in the settings under “Battery Profile”.
Charge State: This shows the current charging state of the controller. The state
can be any of the following: Start, Soft, Bulk, Absorption, Float or Idle
PulseTech: This shows if the PulseTech Pulsing Technology is active or not.
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CINDER 40 PWM Charge Controller User Manual Zamp Solar
Status Indicator Light Descriptions
Table 4: Status LED Descriptions
Indicator LED Status
Bulk/Soft (CC)
Absorption/Float (CV)
Idle/Start
Solar Input (Charging
Current) Green
<=40A
<0.3 A
Solar Input (Charging
Current) Red
>40A OR Negative Current
>0.3A OR Negative Current
Battery Temp Green
-15oC~32oC
Battery Temp Yellow
-20oC~-15oC or 32oC~37oC
Battery Temp Red
<-20oC or >37oC
Battery Voltage Green
● 12V: 11.8V~Absorption Voltage
● 24V: 23.6V~Absorption Voltage
Battery Voltage Yellow
● 12V: 8V~11.8V or Absorption Voltage~16V
● 24V: 16V~23.6V or Absorption Voltage~32V
Battery Voltage Red
● 12V: <8V or >16V
● 24V: <16V or >32V
Solar Wattage Green
If both Solar Voltage and Solar Current are Green
Solar Wattage Yellow
If one or both of Solar Voltage and Solar Current are Yellow
Solar Wattage Red
If one or both of Solar Voltage and Solar Current are Red
Solar Voltage Green
If Charging
● 12V: Solar Voltage~23V
● 24V: Solar Voltage~46V
“Solar is not connected” = yellow
● 12V: 10V~28V
● 24V: 30V~50V
Solar Voltage Yellow
If Charging
● 12V: <Solar Voltage or 23V~50V
● 24V:<Solar Voltage or 46V~50V
“Solar is not connected” = yellow
● 12V: <=10V or
28V~50V
● 24V: <30V
● “Solar is not
connected” = yellow
Solar Voltage Red
● 12V: >50V OR Negative Voltage
● 24V: >50V OR Negative Voltage
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CINDER 40 PWM Charge Controller User Manual Zamp Solar
History Page
●System History
Historical Data Options: This button allows you to change the History graph to
any of the following options:
●Solar Energy Production
●Max Daily Wattage
●Max Daily Amperage
●Wattage Average
●History Graph
The top buttons can change the time scale of the graph. This can be 7 days, 15
days and 30 days.
●Records and Statistics
Here you can view any of the following historical statistics:
●10 Day Total Energy Generation (kWh)
●30 Day Average Daily Energy Generation (Wh)
●Maximum Daily Energy Production (Wh)
●Highest Recorded Amperage (A)
●Average 10 Day Battery Percentage (%)
●Average 10 Day Battery Voltage (V)
●Average 24 Hour Battery Voltage (V)
●Average 24 Hour Wattage (W)
●Average 24 Hour Amperage (A)
●Lowest Battery Voltage (V)
Choose Records and Statistics - This button allows you to change the
displayed Records and Statistics. The order in which these statistics are
presented can also be adjusted here.
Settings Page
●Set Battery Profile
Select to change the active battery profile. It is very important that you set this
profile to match your battery type. (See Section 7 for a description of all the
default profiles.)
Check your specific battery datasheet for recommended absorption and float
voltages.
If the specific values of your battery differ from the default profile, create a
customized profile one of the three Custom Profiles. Follow the steps below to
create a custom profile.
1. Select an available custom profile.(1-3)
2. Choose a battery type to base this profile on that best matches your
battery type.
3. You will then be taken to a screen where you can edit the absorption
voltage and float voltage according to your battery spec sheet. The
“Float” option allows you to enable or disable the float stage entirely.
4. Once your custom values match those given by your battery
manufacturer, press “set” to enable your new custom profile.
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CINDER 40 PWM Charge Controller User Manual Zamp Solar
●Battery Profile Details
Select to view the details of the active Battery Profile.
If Float is not active, then it will not appear in the details section.
●Load Configuration Settings
Load Disconnect Voltage: If the battery voltage drops below this value, the
load will disconnect in order to preserve the health of the battery. This value
can be adjusted from 10.2V ~ 12.6V for 12V systems (20.4V ~ 25.2V for 24V
systems).
●System Voltage
This value is the nominal voltage of the battery you are charging. It is
automatically detected by default but can be changed. Unless the system
voltage value in the Real Time Battery Data section does not match your
nominal battery voltage, do not change the system voltage.
●Status Graph Options
Select to change the Status Graph between Watts and Amps
●PulseTech Technology
Select to turn the PulseTech Pulsing Technology on or off (see Section 6 for a
description of this function)
For all Lithium-based profiles this option will be greyed out because PulseTech
cannot be used with Lithium batteries.
●Time Format
Select to change between 12-hour and 24-hour clock formats.
●Temperature Setting
Select to change the displayed temperature between Fahrenheit and Celsius.
●Device Enable
Device Enable State: If enabled is selected, the device will run as normal. If
disable is selected, the device will stop all charging until enable is selected.
When disabled, the CINDER 40 will slowly blink the battery LED orange.
Default Device Enable State: This field determines what the Device Enable
State will be when the device is started or restarted.
●RV-C
○Select Enable to enable RV-C Communication capabilities
○NOTE: If not actively using RV-C, it is recommended to keep this disabled to
reduce self-consumption
●Rename Device
Select to change the name of the device as it appears on your App. The name
you select must be 10 characters or less.
●Device Info
Select for a description of the App and Firmware versions of the device. Update
device firmware by following instructions on the next page.
●Report a Problem
Select to send an email to our developers describing the issue.
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CINDER 40 PWM Charge Controller User Manual Zamp Solar
Updating Device Firmware
If you need to update the Device Firmware (FW) for any reason, follow the instructions below.
●Use the Zamp Solar App to connect to your CINDER 40
●Navigate to the Settings Page
●Click “Device Info”
●Click “Check FW Version”
●If a new update is available, install it.
●If the update has begun successfully, all LEDs except the Blue Bluetooth LED will turn
off.
●Ensure that you keep your phone close to the CINDER 40 device for the entirety of the
update.
Note: The app will search for firmware updates when it first connects to the CINDER 40 and
you will be alerted if there is an update available.
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