Zamp Solar ZS-30AD User manual

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Dual Battery Solar Controller
Nominal Voltage: 12Volts
Rated Solar Current: 30Amps
Model Number: ZS-30AD
User’s Manual

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WARNING – IMPORTANT PLEASE READ
●Fully independent dual battery charging control, reduce the extra cost of two
separated solar charging system, ideal for Caravans, RVs, Boats and Cottages, etc.
●Charging priority preset, can select the percentage of available charge current to
each battery.
●Provide a wide range of Battery type setting for each battery: Gel, AGM,
Conventional lead-acid (WET), Calcium, LiFePO4, LTO (Lithium Titanium Oxide)
Battery types selection.
●Industrial grade MCU control, Pulse width modulated (PWM) technology, high
efficiency operation.
●Ensure charge current is not wasted, if the first battery is fully charged, more charge
current will be divided to the second battery, and return to the setting charging
automatically when the first battery is in low voltage.
●Built in regulator to prevent two battery from being overcharged. Overcharging
occurs when the charge voltage is unregulated. This can result in premature battery
failure.
●Come with regulator to prevent two 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.
●Protects two 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 each battery and into
the solar panel.
●Colored LED’s to easily indicate the operational status and each battery conditions.
●Digital LCD to directly display each battery voltage, charging current, charging
capacity, percentage preset, battery type, ambient temperature and faulty codes.
●Provides plug-in remote digital display meter (Optional).
●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-coated circuit boards and plated terminals apply to hostile environments.
FEATURE

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● This charger is designed for indoor use only and should never be exposed
to rain.
● Do not disassemble the controller. Take to a qualified person if the unit
requires repairing.
● Lead acid batteries, LiFePO4 or LTO 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
MOUNTING THE DEVICE
The Solar Controller has two mounting options.
1. Surface mount:
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,
2. Flush (panel) mount:
Before deciding to use this mounting method, please ensure there is sufficient
depth behind the controller or in the cavity. (Refer to Diagram below)
Using the dimensions shown in the following diagram, mark a 105mm x
130mm rectangle where you wish to mount the controller and cut-out the panel
opening then use the two self- tapping screws supplied to secure the unit.

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WIRING CONNECTIONS
Refer to the wiring diagram below.
Battery Connection Solar Array Connection
Length of
Wire < 1m 6m 9m 12m
Size (AWG) 8 or 6 10 8 6
Installation procedure:
1. Using the Terminals supplied, crimp the terminals on your Battery wires.
2. Connect together the Negative polarity of solar controller “-“, BAT1 “-“ and BT2 “-“
3. Connect the solar controller “BT1+” to the Positive polarity of Battery “BT1+”
Connect the solar controller “BT2+” to the Positive polarity of Battery “BT2+”
4. Using the Terminals supplied, crimp the terminals on your Solar Array wires and
connect to the Solar Panel “+” to the solar controller “+” like shown.
NOTE: The 40Amp inline fuses must be connected into the positive wires as shown.
Caution 1: If BT1 and BT2 are different battery type or setting, please do not
confuse or reverse the connection of BT1 or BT2 to the controller, otherwise
may damage your battery.

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Caution 2: The dual battery controller installation must be made by
specialized technique person, any wrong size of wires used or loose power
connections or corroded wires can melt wire insulation, burn surrounding
materials or even cause a fire. Ensure tight all connections and use cable
clamps to secure cables.
NOTE: The dual battery controller has a common negative, it does not matter which
Negative terminal is grounded.
When the connections are completed, the Controller will start working automatically.
Charging priority setting: The dual battery controller provides the priority charging
setting for Battery 1# and Battery 2#; the user can select the percentage of available
charge current to each battery.
Press the Button BT1 and hold for 3 seconds until the number flashing, you can
select 10% into 90% setting via clicking BT1 button until you want, it will
automatically save the data after you complete the percentage setting, or you go
into the next Battery type setting by pressing and holding the button for 5 seconds.
Only need to set the charge rate percentage you want for Battery 1#, the controller
will automatically calculate the rest for the Battery 2#:
For example: Battery 1# is set at the charging rate percentage of 50%.
LCD will be shown % and indicated the pattern
Note: in the normal charging condition, the controller will divide the charging current
as your setting, while Battery 1# is fully charged; more charging current will be
diverted to Battery 2#, and return to the former setting automatically when the
Battery 1# is in need of charge.
When the controller detects there is only Battery 1# connected, the entire charging
current will go into the Battery 1# automatically.
Battery type settings:
Please check your battery manufacturer’s specifications to select correct battery
type. The unit provides six (6) battery types setting for selections: Gel, AGM, WET
(conventional lead acid), Calcium, LiFePO4 and LTO battery. Allow the different
battery type for each battery setting.
OPERATION - LCD DISPLAY

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.
Press Battery type button BT1 and hold for 5 seconds to go into your battery 1# type
selection mode, the battery 1# type you select will be shown on the LCD meter, the
default setting is AGM Battery; the controller will automatically memorize your battery
1# type setting; Press Battery type button BT2 and hold for 5 seconds to go into your
battery 2# type selection mode.
Caution 1: Incorrect battery type setting may damage your battery.
Caution 2: Do not confuse or reverse the Battery 1# or Battery 2# when you
select the battery type setting.
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
V
Rated voltage test
A
Rated current test
ºC
External battery temperature sensor test (if connected)
After going into charging process, the LCD displays the charging statues as below:
Press BT1 or BT2 button in sequence, the LCD will indicate or , and
display in turn with Battery Voltage, Charging Current, Charged capacity
(Amp-hour), charge rate percentage setting and Battery Temperature (if external
temperature sensor connected)
V
A

AH
%
ºC
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.
You also can visually monitor your battery charging condition for each battery; there
is a LCD bar to show how many percentage capacities are charged, you can easily
see the battery is charged around 25%, 50%, 75% or 100%.
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)
CHARGING STAGES
%

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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, AGM,LiFePO4 and LTO 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 Red Blue Green Blue Green
Soft charging ON OFF Fast
Flash OFF Fast
Flash OFF
Bulk charging ON OFF ON OFF ON OFF
Absorption charging ON OFF ON OFF ON OFF
Equalization charging ON OFF Slow
Flash OFF Slow
Flash OFF
Float charging
Fully charged ON OFF OFF ON OFF ON
Solar panel weak Flash OFF OFF OFF OFF OFF
For example with BT1:
OPERATION - L.E.D. INDICATION
ABNORMAL OPERATION MODE

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.Solar panel abnormal
mode LCD
display
LED indications
LCD backlight
Solar panel reverse
connection Flash OFF OFF OFF Flash
Solar panel over voltage
(Vs > 26.5V) Flash ON OFF OFF Flash
Solar panel weak
(Vs < Vbt1 or Vbt2) Flash ON OFF OFF ON
Battery abnormal mode LCD
display
LED indications
LCD backlight
Battery disconnected or
less than 3.0V ON OFF Flash Flash Flash
Battery reverse
connection ON ON Flash Flash Flash
Battery over voltage
than > 17.5V OFF ON Flash Flash Flash
Battery temperature
over 65C ON ON Flash Flash Flash
The solar controller
abnormal mode LCD
display LED indication LCD backlight
The controller over
temperature protection Flash
.
The controller provides two optional devices (excludes in the packaging box).
Optional external Battery temperature sensor:
As an option, the unit provides a port to connect an external battery temperature sensor; if
the temperature sensor is connected, the unit will optimize the charging performance
subjected to the battery temperature and also provide the battery over temperature
protection; in some cases, if battery over temperature occurs, the controller will automatically
stop charging.
Optional external Remote display meter:
OPTIONAL EXTERNAL DEVICE

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As an option, the unit also provides a port to connect the external Remote display meter
for some special location needed. The display content on the Remote meter is same as
the display on the controller.
1 Electrical Parameters
1-1 Rated solar panel amps 30 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 ) 8V Min VDC
1-5 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 15 AMP
2-4 Bulk charge voltage 10-14.0 +/-0.2 VDC
2-5 Absorption charging voltage at 25*C
--LTO type battery ((Lithium Titanium Oxide battery) 14.0 +/-0.2 VDC
--Gel type battery 14.1 +/-0.2 VDC
--LiFePO4 battery 14.4 +/-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 charge active --- only for the battery type 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 Reverse polarity or short circuit protections
3-2 No reverse current from battery to solar at night
3-3 Over temperature protection during charging 65 *C
3-4 Transient over voltage protection with TVS or varistor
4 Electrical parts
4-1 Input output terminal M5 terminals
4-2 Remote port RJ-45 (8 pins)
5 Physical Parameters
5-1 Controller material Plastic, Standard ABS
5-2 Power terminal maximum stranded wire size #6 AWG stranded-16 mm
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5-3 Power terminal torque Up to 17 in-lb (0.2n-m)
5-4 Mounting Vertical wall mounting
5-5 IP grade IP22,
5-6 Net weight Approx. 300g
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