Zamp Solar ZS-10A User manual

SOLAR POWER - THE NEW WAY TO RV!
IMPORTANT! - YOU'RE SOLAR READY
www.zampsolar.com
#1 In Mobile Solar Solutions
CONGRATULATIONS!
Thank you for purchasing your NEW Forest River RV.
Your RV is PRE-WIRED for SOLAR POWER!
Benefits of Solar
Maximize Battery Life
Electrical Independence
Green, Clean & Quiet
Safe & Reliable
Virtually Maintenance Free
Reduce Generator Use & Hook-Up fees
We are constantly looking for ways to create a better product for you, our
customer. That's why we went the extra mile and pre-wired your RV with a
Zamp Solar pre-wired solar port. Solar is a great way to keep batteries fully
charged and cut the cord giving you freedom to explore.
Zamp Solar - POWER to EXPLORE!
If you have questions regarding solar and the best solar system for your
requirements contact your nearest Zamp Solar Dealer or Zamp Solar directly.
Zamp Solar Portable Solar Kit
Have one of these? You're ready for solar!

Contact Your Selling Dealer or Call Us
1-855-567-8031
We Can Help You!
I M P O R T A N T
Thank you for purchasing your new R-Pod Recreational Vehicle. If you
have any questions concerning The Zamp Solar Prewire Kit, service
or component compatibility, please call Zamp Solar at our toll-free
number listed above. Or you may email us on the internet at: support
@ zampsolar.com. Our office hours are Mon-Fri 8:00am-5:00pm
(PST). We value our customers and are pleased to address any
questions or concerns.
CONGRATULATIONS!
On The Purchase Of Your New R-Pod
.
This Recreational Vehicle
Has Been Prewired For
A Zamp Solar Charging
System

Zamp Solar is the expert in the recreational vehicle solar b
attery charging industry. Zamp
Solar is leading the charge in RV solar charging technology. They have created some of
the best and most innovated products available today exclusively for the RV
owner, some
of which are the portable charging systems pictured below.
Made of the same durable and dependable roof mounted solar panels, Zamp Portable
Charging Systems will give your customer the ability to charge their batteries easily,
affordably, and portably.
Complete and ready to use! Zamp folding solar kits feature A+ Monocrystaline solar
panel technology, are ground mounted, have adjustable tilt legs for optimum reflection
angle, comes standard with a built in charge controller, equipped with16ft lead wire with
battery clips for easy hook up, can be folded up and stored safely in a ballistic nylon
padded carrying case. When your customer arrives at their destination, the set up process
takes less than 5 minutes. Unpack the bag, unfold the panels, adjust the tilt legs, set on
the ground in a sunny location pointing south and simply connect the optional quick
battery plug (Part# ZS-BDC-C) to the Zamp Solar battery Charging Port on the side of
the RV.
Available through your manufacturer in 40 & 80 watt
versions (larger units are available). These units are
compact and easy to store. Increase your dealerships
profitability, with this new and exciting option. Factory
direct savings will allow your parts, sales and service
departments to increase the deal gross as well as increase
your aftermarket sales with past customers.
Contact your factory sales rep for more information
regarding this program.

1
Solar Controller / Battery Charger
Input: DC12V Solar panel (Max. 25V)
Output: DC12V 10A / DC12V 15A
Model Number: ZS-10A / ZS-15A
User’s Manual

2
●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, as well as
provides a cycling automatic Equalizing feature every 28 days.
●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 operational status and battery conditions.
●Digital LCD to directly display battery voltage, charging current, charging capacity
(Amp hour), battery types, full charge and faulty codes.
●Provides external battery temperature sensor (Optional).
●Multi charging protections against reverse polarity, short circuit, over temperature,
over voltage, etc.
●Surface Mount or Flush Panel Mount options.
●Conformal-coating circuit boards and plated terminals apply to hostile environments.
●Waterproof and non-waterproof selectable.
For use with 12Volt Solar Panel Only
Suitable for Solar panels up to 170 / 255 Watts for ZS-10A / ZS-15A
FEATURE

3
●This charger is designed for indoor use (non-waterproof type ) or outdoor
Use (waterproof type).
●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 two plastic
spacers and self tapping screws supplied and mount the unit to a flat surface,

4
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. 20A fuse for
ZS-10A, 30A fuse for ZS-15A (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.
Battery Connection Solar Array Connection
Length of
Wire < 0.9m 6m 9m 12m
Size (AWG) 18 or 16 14 12 12
1. Using the stranded 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 stranded 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.
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
OPERATION - LCD DISPLAY

5
.
Press BATTERY TYPE button and hold for 3 seconds to go into your battery type
selection mode, the battery type you select will be shown on the LCD meter, the
default setting is AGM Battery; the controller will automatically memorize your battery
type setting.
Caution: Incorrect battery type setting may damage your battery.
When the controller powers on, the unit will run self-qualify mode and automatically
show below items on LCD before going into charging process
Self-test starts, digital meter segments test
Software version test
Rated voltage and current test
External battery temperature sensor test (if connected)
After going into charging process, the LCD displays the charging statues as below:
Press VOLT / AMP button in sequence, the LCD will display in turn with
Battery Voltage, Charging Current, Charged capacity (Amp-hour) and Battery
Temperature (if external temperature sensor connected)
Display in the day time-
Display during the night-
Display when battery fully charged
Press VOLT / AMP button in sequence, the LCD will display in turn with
Battery Voltage, Charging Current, if you do not press the button, the LCD will
alternatively display the FUL and VOLT or FUL and AMP every 2 seconds
or
The VOLT / AMP button can be changed at any time during charging process.
The LCD also can be treated as an independent voltage meter or thermometer.
A voltage less than 11.5V Volts indicates that the battery is discharged and needs
re-charging.
CHARGING STAGES

6
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 10V, 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 6 LED’s indicate the
charging status and the
battery condition
Red Blue Green Green Yellow Red
Solar Power Present-No
battery connected
ON OFF OFF OFF OFF Flash
Soft charging ON Flash OFF OFF OFF ON
Bulk charging ON ON OFF Subject to battery voltage
Absorption charging ON ON OFF ON OFF OFF
Equalization charging ON ON OFF ON OFF OFF
Float charging ON OFF ON OFF OFF OFF
Solar panel weak Flash OFF OFF Subject to battery voltage
At night no charge OFF OFF OFF Subject to battery voltage
Battery Voltage below 11.5V
(+/-0.2V) ON ON OFF OFF OFF ON
Battery Voltage between
11.5V - 12.5V(+/-0.2V) ON ON OFF OFF ON OFF
Battery Voltage above 12.5V
(+/-0.2V) ON ON OFF ON OFF OFF
.
OPERATION - L.E.D. INDICATION

7
.
Solar panel abnormal
mode
LCD display LED indication LCD backlight
Solar panel weak
Flash
ON
Solar panel reverse
connection
Flash Flash
Solar panel over voltage
(> 26.5V)
Flash Flash
Battery abnormal mode
LCD display LED indication LCD backlight
Battery disconnected or
less than 3.0V
Flash Flash Flash Flash
Battery reverse
connection
Flash Flash
Battery over voltage than
> 17.5V
Flash Flash
Battery temperature over
65C
Flash Flash Flash Flash
The solar controller
abnormal mode LCD display LED indication LCD backlight
The controller over
temperature protection
Flash
.
The controller provides an optional devices (excludes in the packaging box).
Optional external Battery temperature sensor:
As an option, the unit provides a port to connect the external battery temperature sensor; If the
external battery temperature sensor is connected, the unit will optimize the charging performance
subjected to the battery temperature detected and also provide the battery over temperature
protection, in some case, if battery over temperature occurs, the controller will automatically stop
charging.
ABNORMAL OPERATION MODE
OPTIONAL EXTERNAL DEVICE

8
1Electrical Parameters
1-1 Rated solar panel amps for ZS-15A 15 Max. AMP
1-2 Rated solar panel amps for ZS-10A 10 Max. AMP
1-3 Normal input Solar cell array voltage 15-22 VDC
1-4 Max. solar cell array voltage (output has no load) 25 Max. VDC
1-5 The controller lowest operating voltage (at solar or battery
side )
8V Min VDC
1-6 Standby current consumption at night 5 Max mA
1-7 Maximum voltage drop-Solar panel to battery 0.25 Max. VDC
2Charging 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 15 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 0.5 +/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 10 +/-0.2 VDC
--Automatic equalizing charging periodical 28 Day
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
3-5 Transient over voltage protection with TVS or varistor
4 Electrical parts
4-1 Input output terminal M4 terminals
4-2 Temperature sensor port (Press and Release type) DA 250-350 2P
5 Physical Parameters
5-1 Controller material Plastic, Standard ABS
5-2 Power terminal maximum stranded wire size #12 AWG stranded-3 mm2
5-3 Mounting Vertical wall mounting
5-4 IP grade IP22 or IP66,
5-5 Net weight Approx. 250g
6 Environmental characteristics
6-1 Operating temperature -25 ~ 50*C
6-2 Storage temperature -40 ~ 85*C
6-3 Operating Humidity range 100% no condensation
SPECIFICATIONS