AIMS POWER SCC60-100A Solar Charge Controller User Manual
- June 6, 2024
- AIMS Power
Table of Contents
SCC60-100A Solar Charge Controller
User Manual
Important Safety Instructions
This manual contains important safety, installation, and operating
instructions for the MPPT solar controller.
The following symbols are used throughout this manual to indicate potentially
dangerous conditions or mark important safety instructions.
WARNING:
Indicates a potentially dangerous condition. Use extreme caution when
performing this task.
CAUTION:
Indicates a critical procedure for the safe and proper operation of the
controller.
NOTE:
Indicates a procedure or function that is important for the safe and proper
operation of the controller.
Safety Information
- Read all the instructions and cautions in the manual before beginning installation.
- There are no user-serviceable parts inside the MPPT charger. Do not disassemble or attempt to repair the controller.
- Disconnect all sources of power to the controller before installing or adjusting the controller setting.
- Mount the controller indoors. Prevent exposure to the elements and do not allow water to enter the controller.
- Install the controller in a location that prevents casual contact. The controller can become very hot during operation.
- Use insulated tools when working with batteries.
- Avoid wearing jewelry during installation.
- The battery bank must be comprised of batteries of the same type, make and age.
- Do not smoke near the battery bank.
- Power connections must remain tight to avoid excessive heating from a loose connection.
- Use properly sized conductors and circuit interrupters.
WARNING: A battery can present a risk of electrical shock or burn from
large amounts of short-circuit current, fire, or explosion from vented gases.
Observe
proper precautions.
CAUTION: When replacing batteries, use properly specified sizes, types,
and ratings based on application and system design.
About this Manual
This manual provides detailed installation and usage instructions for the MPPT solar charge controller. Only qualified electricians and technicians who are familiar with solar system design and wiring practices should install the MPPT controller. The usage information in this manual is intended for the system owner/operator.
Getting Familiar with Display
Monitoring
Function Keys
Function Key | Description |
---|---|
BACK / LEFT | To exit the setting mode |
UP | To go to the previous selection |
DOWN | To go to the next selection |
ENTER / RIGHT | To confirm the selection in setting mode or enter setting |
ON(RIGHT)/OFF(LEFT | Press for 2 seconds it will turn on/off the DC load |
Setting Battery Type
Overview
The MPPT controller is an advanced maximum power point tracking solar battery
charger. The controller features a smart tracking algorithm that finds and
maintains operation at the solar array’s peak power point, maximizing energy
harvest.
The MPPT controller charging process has been optimized to prolong battery
life and improve system performance. Self-diagnostics and electronic error
protections prevent damage when installation errors or system faults occur.
The controller also features four adjustable setting switches, an RS485
communication port, and a terminal for remote battery temperature monitoring.
Please take the time to read this operator’s manual and become familiar with
the controller. This will help you utilize the many advantages of the MPPT
Controller for your PV system.
Versions and Rating
Model| Rated Current| Solar Input Voc| System voltage| DC Load| Cooling type|
Casing
---|---|---|---|---|---|---
SCC-20A MPPT| 20A| 18 — 100Vdc| 12V/24V| 30A| Heatsink| Metal
casing
SCC-30A MPPT| 30A| 18 — 100Vdc| 12V/24V| 30A| Heatsink| Metal
casing
SCC-40A MPPT| 40A| 18 — 150Vdc| 12V/24V/36V/48V| 40A| Heatsink| Metal
casing
SCC-60A MPPT| 60A| 18 — 150Vdc| 12V/24V/36V/48V| 60A| Heatsink| Metal
casing
SCC-80A MPPT| 80A| 18 — 150Vdc| 12V/24V/36V/48V| 60A| Heatsink| Metal
casing
SCC-100A MPPT| 100A| 18-150Vdc| 12V/24V/36V/48V| 60A| Heatsink| Metal
casing
Features
The features of the MPPT controller are shown in the figure below. An
explanation of each feature is provided.
-
Heatsink
Aluminum heatsink to dissipate controller heat -
Mounting hole
Predrilled slot for mounting -
Setting switches
Four setting switches to configure the operation of the MPPT controller -
Solar positive terminal
Power connection for solar (+) Solar negative terminal
Power connection for solar (-) -
Battery outputs. Positive port to connect to positive battery terminal (+). Negative port to
connect to negative battery (-) terminal. -
DC load output
-
LCD screen
Indicate the operating status -
LED indicators
LED indicators show charging status and controller faults -
Wiring box cover
Box cover to protect power connections -
Battery temperature sensor
Terminal for battery temperature. Controls charge current if the battery is too hot. -
RS-485 Port
Terminal for RS-485 communication
Installation
General Information
The mounting location is important to the performance and operating life of
the controller. The environment must be dry and protected from water sources.
If required, the controller may be installed in a ventilated enclosure with
sufficient airflow. Never install the controller in a sealed enclosure. The
controller may be mounted in an enclosure with sealed batteries, but never
with vented/flooded batteries. Battery fumes from vented batteries will
corrode and destroy the controller’s circuits.
Multiple controllers can be installed in parallel to the same battery bank to
achieve a higher charging current. Additional controllers, connected in
parallel, may be added in the future. Each controller must have its own solar
array and be sized the same.
CAUTION: Equipment Damage or Risk of Explosion Never install the controller in an enclosure with vented/flooded batteries. Battery fumes are flammable and will corrode and destroy the controller circuits.
CAUTION: Equipment Damage
When installing the controller in an enclosure, ensure proper ventilation.
Installation in a sealed enclosure will lead to over-heating and lessen the
controller’s overall life.
The installation is straightforward, but it is important each step is done
correctly and safely. A mistake can lead to dangerous voltage and current
levels. Be sure to carefully follow each instruction. Read all instructions
first before beginning installation.
Recommended Tools:
- Wire strippers
- Wire cutters
- Phillips screwdriver
- Slotted screwdrivers
- Pliers
- Drill
- Drill bit
- Level
- Hacksaw (cutting conduit)
Controller Installation
Step 1-Remove the wiring box cover to access the inside of the charge
controller.
Step 2 – Punch out perforated hole slots to feed cables through the bottom of
the charge controller
CAUTION: Shock Hazard
Disconnect all power sources to the controller before removing the wiring box
cover.
Never remove the cover when voltage exists on any of the power connections.
Use a #4 Phillips screwdriver to remove the screws that secure the wiring box
cover as shown in the figure below.
Power Connections
The six large power terminals are sized for up to 4 AWG wires. The terminals
are rated for copper and aluminum conductors. Good system design generally
requires large conductor wires for the solar and battery connection that limit
voltage drop losses to 2% or less.
Minimum Wire Size
The wire recommendation below is based on an ambient temperature of 113̊ F or 45̊ C. Adjust cable size for more extreme temperatures.
Model | Copper Wire Type | Recommended Size | Minimum Size |
---|---|---|---|
20A | Copper | 12AWG | 14AWG |
30A | Copper | 10AWG | 12AWG |
40A | Copper | 6AWG | 8AWG |
60A | Copper | 5AWG | 6AWG |
80A | Copper | 4AWG | 5AWG |
100A | Copper | 4AWG | 5AWG |
Power Wire Connection
WARNING: Shock Hazard
The solar PV array cannot produce open-circuit voltages exceeding 155V DC when in sunlight. If using breakers or disconnect switches, verify that the solar input breaker or disconnect switch has been opened (disconnected) before installing the system wires.
-
Insert the wires through the bottom of the charge controller via the punch-out holes.
④Solar Input ⑤Battery Input ⑥DC Load Output (#6 is not required)
If using input and output disconnect switches or breakers, ensure they are turned off before connecting the power wires to the controller.
WARNING: Risk of Damage
Do not reverse the polarity of the connections. If using a breaker or disconnect switch, turn on the battery breaker or disconnect switch to ensure correct polarity and voltage with a multimeter BEFORE connecting to the charge controller. The final connection should be made with breakers in the off position. -
Connect the battery+ (Positive) wire to the battery+ terminal on the controller,
Connect the battery- (Negative) wire to the battery- terminal on the controller. -
Connect the Solar+ (Positive) wire to the PV+ terminal on the controller, Connect the Solar- (Negative) wire to the PV- terminal on the controller.
-
Connect the DC load+ (Positive) wire to the Load+ terminal on the controller,
Connect the DC load- (Negative) wire to the load – terminal on the controller. -
If using the battery temperature sensor, connect the sensor. Attach the battery temp sensor to the side of the battery (s) closest to the charge controller, near the negative terminal.
-
If using RS485 monitoring, connect an RS485 cable.
*NOTE – Do not connect the battery (s) to the DC load port. Only connect the battery (s) to the “Battery Port”.
Powering Up
WARNING: Risk of Damage Connecting the solar array to the battery terminal will permanently damage the controller.
WARNING: Risk of Damage
Connecting the solar array or battery connection with reverse polarity will permanently damage the controller.
- Confirm that the Solar and Battery polarities are correct.
- Turn the battery disconnect switch on first (if using one). Ensure the LCD screen powers on.
- Note that a battery bank must be connected to the controller to start and operate the controller. The controller will not operate from solar input only.
- Turn the solar disconnect switch on (if using one). If the solar array is in full sunlight. The controller will begin charging.
Powering Down
WARNING: Risk of Damage
Only disconnect the battery from the controller AFTER the solar input has been
disconnected. Damage to the controller may result if the battery is removed
while the controller is charging.
To prevent damage, a power-down must be done in the reverse order as a power-up.
Operation
The MPPT controller is fully automatic. After installation is completed, there are a few operator tasks to perform. However, the operator should be familiar with the operation and care of the controller as described in this section.
The MPPT controller utilizes Solar Maximum Power Point Technology
Tracking (MPPT) technology to extract maximum power from the solar array. The tracking algorithm is fully automatic and does not require user adjustment. MPPT technology tracks the array’s maximum power point as it varies with weather conditions, ensuring that maximum power is harvested from the array throughout the course of the day.
Current Boost
Under most conditions, MPPT technology will “boost” the solar charge current.
For example, a system may have 36 Amps of solar current flowing into the
controller and 44 Amps of charge current flowing out to the battery. The
controller does not create current! Rest assured that the power into the
controller is the same as the power out of the controller. Since power is the
product of voltage and current (Volts x Amps), the following is true*:
- Power into the MPPT 150V = Power Out of the MPPT 150V
- Volts In x Amps In = Volts Out x Amps Out
- Assuming 100% efficiency. Losses in wiring and conversion exist.
If the solar module’s maximum power voltage (Vmp) is greater than the battery voltage, it follows that the battery current must be proportionally greater than the solar input current so that input and output power are balanced. The greater the difference between the Vmp and battery voltage, the greater the current boost. The current boost can be substantial in systems where the solar array is of a higher nominal voltage than the battery as described in the next section.
Battery Charging Information
The MPPT controller has a 4-stage battery charging algorithm for rapid, efficient, and safe battery charging. Figure 4-1 shows the sequence of the stages.
Battery Charging Settings
Battery type| Bulk charge stage| Absorption charge
stage| Float charge stage
---|---|---|---
Gel| 14.| 14.| 14.
AGM| 14.| 15.| 14.
Sealed| 14.| 15.| 14.
Flooded| 15.| 15.| 14.
Lithium/Lifepo4| 13.7-15| Same as bulk charge voltage-| Same as bulk charge
voltage
User define| 10.0-15V| 10.0-15V| 10.0-15
It is important to select the correct battery setting for the battery type used in the solar system. Refer to the specifications provided by the battery manufacturer and choose a setting that best fits the recommended charging profile.
There are 4 charging stages:
Bulk Charging: This is the initial stage of charging. While Bulk Charging, the charger supplies the battery with a controlled constant current. The charger will remain in Bulk charge until the Absorption charge voltage (determined by the Battery Type selection) is achieved. The green LED will blink once every 0.5 seconds during bulk charging.
Absorb Charging: This is the second charging stage and begins after the battery has recharged to the set absorption voltage. Absorb Charging provides the batteries with a constant voltage and reduces the DC charging current, maintaining the absorb voltage setting. This prevents heating and excessive battery gassing. The green/blue Led will blink once every two seconds during absorption charging.
Float Charging: The third charging stage occurs at the end of the Absorb Charging time. While Float Charging, the charge voltage is reduced to the float charge voltage (determined by the Battery Type selection). In this stage, the batteries are kept fully charged. The float stage provides a very low rate of maintenance charging while reducing the heating and gassing of a full charger battery. This protects the battery from long-term over the charger. The green/blue LED will keep green during float charging
Equalize Stage
Equalize charging will charge in a higher voltage to kick start battery
activity, usually, this cycle lasts about 30 minutes depending on battery
type. Only for open lead-acid batteries and this stage occurs every 30 days.
Network Connections
Network connections allow the MPPT controller to communicate with computers. A
network can be as simple as one controller and one PC, or as complex as dozens
of controllers monitored via the Internet. RS485 cable needed and not
included.
WARNING: Risk of Explosion
Equalizing vented batteries produce explosive gases. The battery bank must be
properly ventilated.
CAUTION: Equipment Damage
Equalization increases the battery voltage to levels that may damage sensitive
DC loads. Verify all system loads are rated for the temperature compensated
Equalize voltage before beginning an Equalization charge. Excessive
overcharging and gassing too vigorously can damage the battery plates and
cause shedding of active material from the plates. An equalization that is too
high or for too long can be damaging. Review the requirements for the battery
being used in your system.
Temperature Compensation
All charging settings are based on 25°C (77°F). If the battery temperature
varies by 5°C, the charging setting will change by 0.15 volts from a 12V
battery. This is a substantial change in the charging of the battery, and the
use of the battery sensor is recommended to adjust charging to the actual
battery temperature.
Protections, Faults, and Alarms
The MPPT controller protections and automatic recovery are important features
that ensure the safe operation of the system. Additionally, the controller
features real-time self-diagnostics that report Fault and Alarm conditions as
they occur.
Faults are events or conditions that require the controller to cease
operation. A Fault usually occurs when a limit such as voltage, current, or
temperature has been surpassed. Fault conditions are indicated with unique LED
sequences and are also displayed on the LCD screen.
-Solar overload
The controller will limit battery current to the maximum battery current rating. An oversized solar array will not operate at peak power. The solar array should be less than the controller nominal maximum input power rating for optimal performance. -Solar short circuit
The controller will disconnect the solar input if a short circuit is detected
in the solar wiring. Charging automatically resumes when the short is cleared.
-Very Low battery Voltage
If the battery discharges below 9Volts the controller will go into brownout
and shut down.
When the battery voltage rises above the 10 Volts minimum operating voltage,
the controller will restart.
-High-temperature current limit
The MPPT controller will limit the solar input current if the heatsink
temperature exceeds safe temperature. Solar charge current will be tapered
back (to 0 amps if needed) to reduce the heatsink temperature. The controller
is designed to operate at a full rated current at the maximum ambient
temperature. This alarm indicates that there is insufficient airflow and that
the heatsink temperature is approaching unsafe limits. If the controller
frequently reports this alarm condition, corrective action must be taken to
provide better airflow or to relocate the controller to a cooler spot.
-High Input voltage current limit
The MPPT controller will limit the solar input current as the solar array Voc
approaches the maximum input voltage rating. The array Voc should never exceed
the maximum input voltage (100VDC or 155VDC).
Current Limit
The array power exceeds the rating of the controller, this alarm indicates
that the controller is limiting battery current to the maximum current rating.
Uncalibrated
The controller was not factory-calibrated. Return the controller to an
authorized dealer for service.
Inspection and Maintenance
The following inspections are recommended two times per year for best long- term performance.
System Inspection
-
Confirm the controller is securely mounted in a clean and dry environment.
-
Confirm that the airflow around the controller is not blocked. Clean the heatsink of any dirt or debris.
-
Inspect all exposed conductors for insulation damage due to sun damage, rubbing on nearby objects, dry rot, insects, or rodents. Repair or replace conductors as necessary.
-
Tighten all power connections per the manufacturers’ recommendations.
-
Verify the LED and LCD indications are consistent with the equipment operation.
Note any fault or error indications. Take corrective action if necessary. -
Inspect the battery bank. Look for cracked or bulging cases and corroded terminals.
-
Inspect the system earth grounding for all components. Confirm all grounding conductors are appropriately secured to earth ground.
Inside the MPPT Controller Wiring Box
CAUTION: Shock Hazard
Disconnect all power sources to the controller before removing the wiring box
cover.
Never remove the cover when voltage exists on the controller power
connections.
- Check all wire terminals. Inspect connection for corrosion, damaged insulation, signs of high temperature or burning/discoloration. Tighten the terminal screws to the recommended torque.
- Inspect for dirt, nesting insects, and corrosion. Clean as required.
Troubleshooting
Battery Charging and Performance Issues
Problem: No LCD or LED indications, controller does not appear to have power.
Solution:
With a multimeter, check the voltage at the battery terminals on the controller. Battery voltage must be 9 VDC or greater. If the voltage on the battery terminals of the controller is between 9 and 60 VDC and no LED or LCD indicates it, contact your authorized dealer for service. If no voltage is measured, check wiring connections, fuses
Problem:
The controller is not charging the battery.
Solution:
If the LCD indicator is normal, check the fuses, breakers, and wiring
connections in the solar array wiring. With a multi-meter, check the array
voltage directly at the controller solar input terminals. Input voltage must
be greater than the minimum start-up voltage before charging will begin.
Network and Communication Issues.
Problem:
Cannot connect to the controller via the communication port.
Communication port pinout
Make sure that your cable matches the RS485 communication port. The
communication port is RS485.
Warranty Claim Procedure and Datasheet
All AIMS Power™ products come with warranty coverage against defects as follows, from the date of purchase, unless otherwise indicated:
- 2-Years for ETL (Extract, Transform and Load) Solar Charge Controllers
Within the warranty coverage period, AIMS Power™ will either repair or replace, at its sole discretion, the defective product.
Any shipping charges that occur as a result of a warranty return or exchange are NOT covered by the warranty and are the responsibility of the customer.
The warranty does not cover the following:
- Products that AIMS Power™ determine, in its sole discretion, to be free of any material or workmanship defects or flaws
- Products evidencing excessive wear, misuse or alteration
- Products with missing or defaced labels, stickers, or other identifying information
- Improper care or storage (e.g. water damage, exposure to extreme heat or cold temperatures, unsanitary environment)
- Alterations or customizations
- Items that were purchased second hand, or from an unauthorized seller
- Items outside of the covered warranty period
TO RETURN MERCHANDISE: It is our goal at AIMS Power™ to provide a comprehensive and hassle-free return and exchange process. As such, please review the below process before initiating a warranty claim.
-
Contact AIMS Power™ via phone or email to submit your warranty return request and obtain a Return Merchandise Authorization (RMA) number.
Note: Be sure to provide the name from the original order as well as the original order number. -
An automated email will then be sent to the address indicated on the warranty return request containing further instructions regarding packing, shipping, and documentation to include when returning the product as well as an RMA authorization number.
-
Once the return is received and inspected an e-mail will be sent informing you that the return has been approved and processed. If there are any issues with the return, an additional e-mail will be sent notifying you of such.
Other Items of note:
-
AIMS Power™ DOES NOT cover return shipping. Any product that is returned and deemed to be of working condition or was returned without all of the required information, and the customer has not paid for return shipping, may be disposed of or destroyed after 90 days.
-
Any requested information that is not provided in a timely manner could result in delayed processing of your return.
-
When shipping the product for a return:
o Ensure the product is packed accordingly to avoid being damaged in transit.
Include original packaging. Use proper protective material to ensure package arrives without damage.
o Ensure some form of shipment tracking is used.
o It is strongly recommended to insure the shipment.
o AIMS Power™ is not liable for products that are lost or damaged in transit. -
The RMA authorization email will indicate what, if any, other product contents need to be sent in with the returned product.
-
For any other questions please contact us via phone or email.
Except as provided above, AIMS makes no warranty of any kind, express or implied, including without limitation the implied warranties of merchantability and fitness for a particular purpose. In no event shall AIMS be liable for indirect, special or consequential damages. This warranty only applies to AIMS Power branded products. All other name brand products are warranted by and according to their respective manufacturer. Please do not attempt to return non-AIMS Power branded products to AIMS Power.
For additional products such as:
- Modified Sine Wave Inverters
- Pure Sine Wave Inverters
- Low-Frequency Inverters
- Solar Charge Controllers
- Inverter Chargers and Automatic Transfer Switches
- Converters AC-DC and DC-DC
- Custom Cut Cables
- Batteries
- Solar Panels & Racks
Please visit our web site: www.aimscorp.net
To find out where to buy any of our products, you may also e-mail: sales@aimscorp.net or call (775)359-6703
SPECIFICATION | SCC20A | I SCC30 | SCC40 | I SCC60 | I SCC80 | I SCC100 | |
---|---|---|---|---|---|---|---|
Solar System Voltage | 12V/24V | 12V/24V/36V/48V |
Electrical
PV operating voltage| 18-100Vdc@12V
34-100Vdc@24V| 15-155Vdc 12V
34-155Vdc 24V
60-155Vdc 36V
Max. PV open circuit voltage| | 100Vdc| 155Vdc
Rated PV input| | 12V 400W
24V 800W| 12V 500W 24V 1000W 36V 1500W 48V 2000W| 12V 800W 24V 1700W 36V 2400W
48V 3400W| 12V 1200W 24V 2400W 36V 3600W 48V 4800W| 12V 1400W 24V 2800W 36V
4200W 48V 5600W
Max. charging current| 20A| | I 30A| 40A| 60A| 80A| 100A
Max. DC load current| | 30A| 40A| 60A
Self-Consumption| | <2W| <4W
Conversion Efficiency| 97%| | I 97%| 98.%| 98%| I 98.5%
Protection| | Overload, short circuit, high voltage, high-temperature
protection
| Battery Charging
Battery Type| | Gel, Sealed, AGM, Flooded, Lithium, User define
Charging Algorithm| 3-stage: Bulk, Absorption, Float I 4-stage: Bulk,
Absorption, Float, Equalize
Bulk charge voltage| | Sealed:14.4V AGM Ge1:14.2V Flooded:14.6V User
define:10-15V
Float charge voltage| | Sealed/Gel/AMG:13.7V Flooded:13.6V User define :10-15V
Equalize charge voltage| | Sealed:14.6V AGM:14.8V Flooded:14.8V User define
:10-15V
Low voltage reconnect voltage| | 12.5V
Low voltage disconnect voltage| | 10.5V (10.5-12.5 Adjustable)
Temperature compensation| | -5mViC /2V with BTS(Optional)
| Communication
Communication Pon| | NONE| RS485
| Mechanical
Net weight| 4.7 lb| | 4.71b| 9 lb| 171b| 20 lb| 21 lb
Gross weight| 6 lb| | 6 lb| 12 lb| 21 lb| 24 lb| 26 lb
Dimensions| 825×7.5×3.25′| 825×7.5×3.2″| 11×8.25×3.75′| 14.5×10.5×4.5-|
17×10.5×5-| 18.25×10.5×5′
Packing box| 13x13x4.5′| 13x13x4.5″| 18x12x6″| 23x16x9-| 23x16x9″| 23x16x9″
Cooling| | Heatsink cooling
Enclosure| | IP43
| Environment
Ambient Temperature| | -25-60’C (Derating from 45’C) I -11′ F to 140’F
Storage Temperature| | 40’C’ ’80’C I -140 F to 176 F
Humidity| | 100% non-condensing
Warranty| | Two Year
References
Read User Manual Online (PDF format)
Read User Manual Online (PDF format) >>