Go Power Dura Lite Portable Solar Kits

Solar Controller Overview

Introduction
A Solar Controller (or Charge Controller / Regulator) is an essential component of your photovoltaic solar system. The Controller maintains the life of the battery by protecting it from overcharging. When your battery has reached a 100% state of charge, the Controller prevents overcharging by limiting the current flowing into the batteries from your solar array.
The solar controller used in the DURALITE-100 kit features an LCD digital display that shows the charge current of the solar array, system battery voltage and battery state of charge.

System Voltage and Current
This controller is intended for use at 12 VDC system voltage and is rated for a maximum continuous DC input current of 37.5A and input voltage of 35VDC.
Per National Electrical Code (NEC) article 690.7 and 690.8, PV module nameplate ratings must be multiplied by required values (typically 1.25 for both voltage and current) to obtain the maximum voltage and continuous current available from the module.
Applying NEC factors, the maximum allowable nameplate PV Panel rated Isc is 30A (30A x 1.25 = 37.5A), and the maximum voltage, Voc is 28VDC (28VDC x 1.25 = 35VDC).
The voltage and current ratings of all equipment connected to PV panels must be capable of accepting the voltage and current levels available from PV panels installed in the field.

Battery Type
This solar controller is suitable for use with lead acid batteries (vented, GEL, or AGM type) as well as some lithium iron phosphate (LiFePO4) batteries that are supplied with a Battery Management System (BMS).
Use the Sealed battery profile for AGM

Regulatory Information

Specifications

Description| Value| Dimensions (H x W x D): 178.5 × 105.5 × 48.3mm

7.02 x 4.15 x 1.90 in

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Weight: 300g / 10.6 oz

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Recommended Wire Gauge:

8 AWG

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Warranty: 5 years

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·   PWM Charging

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·   4 Battery Charging profiles

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·   4 Stage Charging

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·   Displays Charging Current, Battery Voltage and Battery State of Charge

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·   Reverse Polarity protected

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·   Temperature Compensated

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·   RoHS Compliant, environmentally safe

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·   Accepts up to 3 DuraLite Kits (300 watts of solar at 12 volts)

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Nominal System Voltage| 12 VDC
Charging Output Voltage Range Battery 1| 9.0 – 14.9 VDC
Battery Input Voltage Range| 8V～32V
Rated Charge Current| 30A
Max. PV Short Circuit Current| 30A
Max. PV Open Circuit Voltage| 50V
Battery Type| Sealed (AGM), Gel, Flooded, Lithium 1 (12V), and Lithium 2 (24V)
Self-consumption| ≤4.2mA/12V;≤2.6mA/24V
Temperature Compensate Coefficient| -3mV/℃/2V(Default)
Charge Circuit Voltage Drop| 0.21V
Operating Consumption (Display backlight on)| 15mA
Operating Consumption (Display backlight off)| 6mA
Battery Types Supported| Vented and Sealed (GEL, AGM etc.) Lead Acid
Protections| Battery Reverse Polarity, PV Reverse Polarity, Over Temperature, PV Short Circuit, PV Over Current, PV Over Voltage,

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS
THIS MANUAL CONTAINS IMPORTANT INSTRUCTIONS FOR THE DURALITE KIT AND SOLAR CONTROLLER THAT SHOULD BE FOLLOWED DURING KIT USE AND MAINTENANCE.

• Read this manual in its entirety before using the DuraLite kit for the first time.
• DO NOT GET WET. Bring in the DuraLite kit when it rains.
• Use only with approved DuraLite connections and harnessing.
• Please cut off all connections of the PV array, fuses or breakers which close to the battery before the controller installation and adjustment.
• Power connections should remain tight to avoid excessive overheating
• No user serviceable component inside the controller. DO NOT disassemble or attempt to repair the controller.

| Disconnect all power sources| Electricity can be very dangerous. Installation should be performed only by a licensed electrician or qualified personnel.
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Battery and wiring safety

| Observe all safety precautions of the battery manufacturer when handling or working around batteries. When charging, batteries produce hydrogen gas, which is highly

explosive.

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Wiring connections

| Ensure all connections are tight and secure. Loose connections may generate sparks and heat. Be sure to check connections one week after installation to ensure they are still tight.
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Work safely

| Wear protective eyewear and appropriate clothing during installation. Use extreme caution when working with electricity and when handling and working around batteries.

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Observe correct polarity

| Reverse polarity of the Battery 1 terminals will cause the controller to give a warning tone.

Reverse connection of Battery 2 terminals will not cause an alarm. However, the controller will not charge or display information for Battery 2 on the LCD. The controller will not function unless Battery 1 terminals are connected to a battery with proper polarity.

Failure to correct this fault could damage the controller.

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Do not exceed the SOLAR CONTROLLER max

current ratings

| The maximum current of the solar system is the sum of parallel-connected PV module– rated short circuit Currents (Isc) multiplied by

1.25. The resulting system current is not to exceed 37.5A. If your solar system exceeds

this value, contact your dealer for a suitable controller alternative.

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Do not exceed max voltage ratings

| The maximum voltage of the array is the sum of the PV module–rated open- circuit voltage of the series connected modules multiplied by

1.25 (or by a value from NEC 690.7 provided in Table 690.7 A). The resulting voltage is not to exceed 35V. If your solar system exceeds this value, contact your dealer for a suitable

controller alternative.

Choosing a Battery

The SOLAR CONTROLLER is suitable for use with lead acid batteries (vented, GEL, or AGM type) as well as some lithium iron phosphate (LiFePO4) batteries that are supplied with a Battery Management System (BMS). If using lithium ion, it must be lithium iron phosphate (LiFePO4) chemistry with a BMS. No other chemistries are compatible.
Lithium batteries typically have maximum allowed charge currents. These maximums typically decrease in cold temperatures. SOLAR CONTROLLER does not limit current for these restrictions, and system design of the solar array must account for this.
Be sure to follow all battery manufacturer safety instructions.

DuraLite Kit Wiring Diagram
The SOLAR CONTROLLER Maximum 37.5A rating is based on a 30-amp total maximum short circuit current rating (Isc) from the solar modules nameplate ratings. The National Electric Code specifies the PV equipment/system rating to be 125% of the maximum Isc from the PV module ratings (1.25 times 30 = 37.5A). E.G. Three modules in parallel with an Isc of 7 amps each equal a total Isc input of 21 amps. When selecting PV modules for use with the SOLAR CONTROLLER do not exceed a total nameplate Isc current of 30A. Solar modules list the Isc amps on their nameplate label.

Note: The controller will not work unless there is a battery connected to the Battery 1 terminals.

WARNING: When the photovoltaic (solar) array is exposed to light, it supplies a dc voltage to this equipment.

Operating Instructions

1. Automatic cycle interface
   Display: PV voltage, PV current, PV power, Battery voltage and Battery temperature

2. Clear the generated energy Operation:
   Step 1: Press the “SET” button and hold 5s under the PV power interface and the value is flashing.
   Step 2: Press the “SET” button to clear the generated energy

3. Switch the battery temperature unit
   Press the “SET” button and hold 5s under the battery temperature interface.

4. Battery type

5. Battery type
   Sealed Gel Flooded User⑴

6. Set battery type by LCD⑴
   Operation:
   Step1: Press the “SET” button and hold 5s under the battery voltage interface. Step2: Press the “MENU” button when the battery type interface is flashing. Step3: Press the “SET” button to confirm the battery type.

Battery Charging Profile Chart

1. When the battery type is sealed, gel, flooded, the adjusting range of equalizing duration is 0 to180min and boost duration is 10 to180min.
2. When setting a lithium battery type, (for example: a LiFePO4) use these rules when setting voltage parameters.
   • Over Voltage Disconnect Voltage > Charging Limit Voltage ≥ Equalize Charging Voltage ≥ Boost Charging Voltage ≥ Float Charging Voltage > Boost Reconnect Charging Voltage.
   • Over Voltage Disconnect Voltage > Over Voltage Reconnect Voltage
   • Low Voltage Reconnect Voltage > Low Voltage Disconnect Voltage ≥ Discharging Limit Voltage.
   • Under Voltage Warning Reconnect Voltage > Under Voltage Warning Voltage ≥ Discharging Limit Voltage.
   • Boost Reconnect Charging voltage > Low Voltage Disconnect Voltage.

Errors & Troubleshooting

No Power to LCD Screen
Solution 1
Check the connection between the DuraLite Kit and the controller, and the controller and the battery. The controller requires a minimum voltage of 8v to run.

Solution 2
Your battery may be too far discharged to accommodate the controller. Keep the solar kit plugged in and placed in full sun for a few hours and try the controller again.

Flashing
Solution
This is an Overvoltage Error. The battery voltage is too high. Disconnect the DuraLite kit and plug in a power draw to lessen the voltage in the battery.

Flashing
Solution
This is an Over Discharge Error. The battery voltage is too low. Connect the DuraLite kit to charge the battery.

Display Symbols

Flashing

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Battery Over Discharge

Frequently Asked Questions (FAQs)

Before a problem is suspected with the system, read this section. There are numerous events that may appear as problems but are in fact perfectly normal. Please visit https://gpelectric.com/support/ for the most up-to-date FAQs and troubleshooting videos.
It seems like my flooded batteries are losing water over time.

Flooded batteries may need to have distilled water added periodically to replace fluid loss during charging. Excessive water loss during a short period of time indicates the possibility of overcharging or aging batteries.
When charging, my flooded batteries are emitting gas.
During charging, hydrogen gas is generated within the battery. The gas bubbles stir the battery acid allowing it to receive a fuller state of charge.

Important: Ensure batteries are in a well-ventilated space.

My voltmeter shows a different reading than the SOLAR CONTROLLER display.
The meter value on the SOLAR CONTROLLER display is an approximate reading intended for indication purposes only. There is an approximate 0.1 VDC inherent error present that may be accentuated when compared with readings from another voltmeter.
There may be a slight difference between the battery voltage displayed on the SOLAR CONTROLLER display and the battery voltage measured at the battery terminals. When troubleshooting using a voltmeter, check both the battery voltage at the SOLAR CONTROLLER terminals and battery voltage at the battery terminals. If a difference of more than 0.5 VDC is noted, this indicates a large voltage drop possibly caused by loose connections, long wire runs, small wire gauge, faulty wiring, a faulty voltmeter or all the above. Consult the Suggested Minimum Wire Gauge chart in Section 6 for wiring suggestions and check all connections.

For advanced users:
The SOLAR CONTROLLER makes voltage measurement adjustments based on resistance it detects at the battery terminals. In addition to resistance in the wires, batteries also have an internal resistance due to chemical properties. The controller cannot distinguish between these two sources of resistance. It will compensate up to 250mV in the displayed value.

Why does the voltage fluctuate so much when charging with the LITHIUM setting?
Lithium batteries contain smaller battery cells. The voltages of these individual cells must be balanced during the charging process by the Battery Management System (BMS). Imbalances will cause fluctuations in the battery voltage measurement, but this will stabilize as the cells are charged and balanced.
Additionally, lithium batteries have higher resistance than lead acid batteries. This affects the charge controller’s battery voltage measurements and its compensation for wire resistance.
Reduce wire inductance which may also cause voltage fluctuations. Keep battery wires close together, or gently twist positive and negative wires together.

Troubleshooting Problems

How to Read this Section
Troubleshooting Problems is split into three sub-sections, grouped by symptoms involving key components. A multimeter or voltmeter may be required for some procedures listed.
It is imperative all electrical precautions stated in the Warning Section and outlined in the Installation Section are followed. Even if it appears the system is not functioning, it should be treated as a fully functioning system generating live power.

Problems with the Display

• Display Reading: Blank

• Time of Day : Daytime/Nighttime

• Possible Causes:
  Battery or fuse connection and/or solar array connection
  (Daytime only) or battery or fuse connection (Nighttime only).

• How to tell:
  Check the voltage at the controller battery terminals with a voltmeter and compare with a voltage reading at the battery terminals.
  If there is no voltage reading at the controller battery terminals, the problem could be a fuse, or the wiring between the battery and the controller. If the battery voltage is lower than 6 volts the controller will not function.
  For the solar array, repeat steps 1 and 2 substituting all battery terminals with solar array terminals.

Check all connections from the controller to the battery including checking for correct wire polarity. Check that all connections are clean, tight, and secure. Ensure the battery voltage is above 6 volts.

• Display Reading : Nighttime

• Time of Day: Daytime

• Possible Causes:
  Panel is covered by something; PV panel is too dirty to supply a high enough voltage to charge the battery; PV panel is not connected.

• Remedy:
  Check the panel and to ensure it is not obscured. Clean the panel if it is dirty. Check that PV cables are connected to the controller.

Problems with Voltage

• Voltage Reading: Inaccurate

• Time of Day: Daytime/Nighttime

• Possible Cause:
  Excessive voltage drop from batteries to controller due to loose connections, small wire gauge or both.
  How to tell:
  Check the voltage at the controller battery terminals with a voltmeter and compare with the voltage reading at the battery terminals.
  If there is a voltage discrepancy of more than 0.5 VDC, there is an excessive voltage drop.

• Remedy:
  Check all connections from the controller to the battery including checking for correct wire polarity. Check that all connections are clean, tight, and secure. Shorten the distance from the controller to battery or obtain larger gauge wire. It is also possible to double up the existing gauge wire (i.e. two wire runs) to simulate a larger gauge wire.

Problems with Current

• Current Reading: 0 A

• Time of Day: Daytime, clear sunny skies

• Possible Cause:
  Current is being limited below 1 Amp as per normal operation or
  poor connection between solar array and controller.

• How to tell:
  The State of Charge (SOC) screen is close to 100% and the Sun and Battery icon are present with an arrow between.
  With the solar array in sunlight, check the voltage at the controller solar array terminals with a voltmeter.
  If there is no reading at the controller solar array terminals, the problem is somewhere in the wiring from the solar array to the controller.

• Remedy:
  Hold down the MAX BOOST Button for approximately 3 seconds to activate Maximum Power Boost. This will allow the controller to charge batteries to 14.4 +/- 0.1 VDC (14.1 +/- 0.1 VDC Sealed/Gel) with all current the solar array is producing.
  Check all connections from the controller to the array including checking for correct wire polarity. Check that all connections are clean, tight, and secure. Continue with the solutions below for additional help on low current readings.

• Current Reading: Less than expected

• Time of Day: Daytime, clear sunny skies

• Possible Causes:

1. Current is being limited below 1 Amp as per normal operation.
2. Incorrect series/parallel configuration and/or wiring connections and/or wire gauge.
3. Dirty or shaded module or lack of sun.
4. Blown diode in solar module when two or more modules are connected in parallel.
5. The battery is full.

• How to tell:

1. Battery State of Charge screen is close to 100% and the Sun and Battery icon are present with an arrow in between.
2. Check that the modules and batteries are configured correctly. Check all wiring connections.
3. Modules look dirty, overhead object is shading modules or it is an overcast day in which a shadow cannot be cast.  

Note Avoid any shading no matter how small. An object as small as a broomstick held across the solar module may cause the power output to be significantly reduced. Overcast days may also cut the power output of the module.

4. Disconnect one or both array wires from the controller. Take a voltage reading between the positive and negative array wire. A single 12 volt module should have an open circuit voltage between 17 and 23 VDC. If you have more than one solar module, you will need to conduct this test between the positive and negative terminals of each module junction box with either the positive or the negative wires disconnected from the terminal.

Remedy:

1. Reconnect incorrect configuration. Tighten all connections. Check wire gauge and length of wire run. Refer to Suggested Minimum Wire Gauge in Section 6.
2. Clean modules, clear obstruction or wait for conditions to clear.
3. If the open circuit voltage of a non-connected 12 volt module is lower than the manufacturer’s specifications, the module may be faulty. Check for blown diodes in the solar module junction box, which may be shorting the power output of the module.

Limited Warranty
Go Power! warrants the SOLAR CONTROLLER for a period of five (5) years from the date of shipment from its factory. This warranty is valid against defects in materials and workmanship for the five (5) year warranty period. It is not valid against defects resulting from, but not limited to:

• Misuse and/or abuse, neglect or accident
• Exceeding the unit’s design limits
• Improper installation, including, but not limited to, improper environmental protection and improper hook-up
• Acts of God, including lightning, floods, earthquakes, fire, and high winds
• Damage in handling, including damage encountered during shipment

This warranty shall be considered void if the warranted product is in any way opened or altered. The warranty will be void if any eyelet, rivets, or other fasteners used to seal the unit are removed or altered, or if the unit’s serial number is in any way removed, altered, replaced, defaced, or rendered illegible.

Repair and Return Information

Visit https://gpelectric.com/support/ to read the “frequently asked questions” section of our website to troubleshoot the problem. If trouble persists:

1. Fill out our online Contact Us form or Live Chat with us
2. Email techsupport@gpelectric.com
3. Return defective product to place of purchase

© 2019 GO POWER!®
201 – 710 Redbrick St,
Victoria, British Columbia
Canada, V8T 5J3
MOBI_MAN_SOLAR CONTROLLER _RevF
gpelectric.com

References

• Complete Mobile Power Solutions | Solar, Batteries & Inverters | Go Power
• Home - Go Power! - powered by HappyFox

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