SUNFORGE SB3024iL, SB3024DiL 24V Maximum Power Point Tracking Solar

Charge Controller

This manual includes important safety instructions for the SB3024iL & SB3024DiL. Save these instructions.

Safety Instructions

Refer installation and servicing to qualified service personnel. No user- serviceable parts in this unit.

PERSONAL PRECAUTIONS

• Working in the vicinity of lead-acid batteries is dangerous. Batteries produce explosive gases during normal operation.
• To reduce the risk of battery explosion, follow these instructions and those published by the battery manufacturer and manufacturer of any equipment you intend to use in the vicinity of the battery.
• Someone should be within range of your voice or close enough to come to your aid when you work near a lead-acid battery.
• Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.
• Wear complete eye protection and clothing protection. Avoid touching your eyes while working near the battery.
• If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters the eye, immediately flood the eye with running cold water for at least 15 minutes and get medical attention immediately.
• NEVER SMOKE or allow a spark or flame in the vicinity of the battery.
• Be extra cautious to reduce the risk of dropping metal tools onto the battery. It might spark or short circuit battery or other electrical part that may cause explosion.
• Remove personal metal items such as rings, bracelets, and watches when working with a lead-acid battery. A lead-acid battery can produce a short circuit current high enough to weld a ring or the like to metal, causing a severe burn.
• Remove all sources of power, photovoltaic, and battery before servicing or installing.

CHARGER LOCATION & INSTALLATION

• This unit is designed to charge 12 V or 24 V nominal lithium, flooded, or sealed type lead-acid chemistry batteries within the range of 20 to 10,000 amp-hours. Follow battery manufacturers’ charging recommendations when considering this unit for use with other battery chemistry.
• This unit employs components that tend to produce arcs or sparks. NEVER install in a battery compartment or in the presence of explosive gases.
• This unit must be installed and wired by the National Electrical Code, ANSI/NFPA 70.
• Over-current protection for the battery must be provided externally. To reduce the risk of fire, connect to a circuit provided with 50 A maximum branch circuit over current protection by National Electrical Code, ANSI/NFPA 70.
• Over-current protection for the auxiliary load control output or auxiliary battery charge output must be provided externally. To reduce the risk of fire, connect to load or auxiliary battery with 25 A maximum over current protection by National Electrical Code, ANSI/NFPA 70.
• Ensure that the unit is properly configured for the battery being charged.
• The unit is not watertight. Do not be exposed to rain or snow.
• Ensure all terminating connections are clean and tight. Battery and PV compression terminals are to be tightened to 45 in-lb (5 nm). IPN Network and battery temperature sensor compression terminals are to be tightened to 2.1 in-lb (0.24 nm). Auxiliary output compression terminals are to be tightened to 6 in-lb (0.67 nm).
• Do not connect to a PV (Panel) array capable of producing greater than 32 A short circuit current for 12 V nominal PV modules, or 24 A short circuit for PV modules greater than 12 V nominal. Limit input short circuit current to 12 A if the 24 V input 12 V output mode is used.
• This unit is not provided with a GFDI (ground-fault detector/interrupter) device and must be used with an external GFDI device as required by Article 690 of the National Electrical Code for the installation location.

PREPARING TO CHARGE

• Never charge a frozen battery.
• Be sure the battery is mounted in a well-ventilated compartment.
• Add distilled water in each cell of a lead-acid battery until battery acid reaches the level specified by the battery manufacturer.

Product Description

Solar Boost™ 3024iL/3024DiL is a multi-stage Maximum Power Point Tracking (MPPT) photovoltaic battery charge controller capable of delivering up to 30 A or 40 A depending on PV modules and battery voltage. The auxiliary output can serve as either a 2 A auxiliary battery charger or as a 20 A Low Voltage Disconnect (LVD) output with or without variable Dusk-to-Dawn lighting control. The SB3024 includes an IPN Network interface which allows multiple charge controllers to communicate with each other and operate as a single charging unit.

Part Numbers and Options

• SB3024iL Solar Boost 3024iL charge controller
• SB3024DiL Solar Boost 3024iL charge controller with volt/amp display
• IPNPRO IPN ProRemote display & battery monitor
• 930-0022-20 Battery temperature sensor
• IPNPRO-S IPN ProRemote with required 500 A / 50 mV current shunt
• IPNREM IPN Remote display
• BT Connect Bluetooth adaptor
• ProTouch 3.5” Touch-Screen display
• Upgrade DUO DUO-Option Software

Product Certifications

CONFORMS TO:
UL STD. 1741

CERTIFIED TO:
CAN/CSA STD. E335-1/2E

CONFORMS TO:

• EN 61326-1:2006 (*)
• EN 60335-1:2002 + A11:2004 + A1:2004 (*)
• EN 60335-2-29:2004 (*)

*FCC CFR 47 Part 15 Subpart B ()**
This device complies with part 15 of the FCC rules. Operation is subject to the following two conditions: 1) This device may not cause harmful interference, and 2) This device must accept any interference received, including interference that may cause undesired operations.

COVERED UNDER ONE OR MORE OF THE FOLLOWING US PATENTS
6,111,391 • 6,204,645

Operation

Charge control and MPPT operation are fully automatic. At night, when PV (Panel) power production stops, the PV array is disconnected from the battery to prevent unwanted current drain. There is a 5-second turn-on delay and a 45-second turn-off delay.

NOTE:
The SB3024 operates on battery power, not PV power. A battery must be connected with a minimum voltage of 9 V for the unit to operate.

Charge Status Indicator
Shows present charge mode and approximate battery state of charge.

A charge status indicator is provided on the face of the SB3024, and the optional remote displays. If net battery charge current is greater than about 3 to 5 A per 100 amp-hours of battery capacity the charge status indicator can provide a rough indication of the battery state of charge.

Optional Digital Display, Remote Displays, and Bluetooth adapter
The SB3024DiL includes a digital display of battery voltage and output charge current. The display alternates between voltage and current when charging. Current is displayed when the “AMPS” indicator is on and can be the total of all controllers on the IPN network (factory default), or the current of a single controller on the IPN network. An automatic nighttime dimming feature reduces display brightness when the PV (Panel) charge is OFF. The SB3024iL can be converted into an SB3024DiL by replacing the front panel with the p/n 3024PDL. Four remote displays are available. The IPN Remote has the same display functionality as the SB3024DiL. The full-featured IPN ProRemote provides setup capability and enhanced monitoring of charge controllers on the IPN network. It also provides a complete battery system monitor (when utilized with an external shunt) with various amp-hour counters and a highly accurate “fuel gage” type battery level indicator. The ProTouch 3.5″ touch-screen display provides enhanced monitoring of charge controllers and setup capability by 5 preset configurations (Lead-Acid and Lithium). The BT Connect provides a setup capability and monitoring through the detailed app (Android and iOS). See Figure 6 and Table 3.

Multi-Stage or 2-Stage Charge Control for Lithium Battery
The SB3024 can be programmed for any type of Lithium battery via one of the following accessories: IPN ProRemote display, BT Connect, ProTouch display, or UCM. the SB3024 can also be programmed to a limited degree via its internal DIP switches. Consult the manual of the battery manufacturer for the appropriate charge profile. When programming the SB3024 for Lithium, the battery temperature compensation must be disabled and/or the Battery Temperature Sensor (p/n 930-0022-20) removed. See the manual of the specific accessory for more information.

Multi-Stage Charge Control for Sealed Lead-Acid batteries (Default)

BULK CHARGE
The SB3024 will be in Bulk charge when the battery voltage is below the Absorption (Acceptance) Charge Voltage setpoint. During Bulk the SB3024 delivers as much charge current as possible to rapidly recharge the battery. The automatic current limit prevents output current from exceeding the SB3024’s maximum current rating.

ABSORPTION VOLTAGE
When the battery recovers sufficient charge for voltage to rise to the Absorption Voltage setpoint, (factory set to 14.4/28.8 V) current is reduced as necessary to maintain the Absorption Voltage. The 3024 remains in Absorption until the battery is fully charged as determined by either:

• The SB3024 has remained in Absorption Voltage for the Absorption period (factory set to 2 hours), or
• With the IPN ProRemote display, the net battery charge current while in Absorption (Acceptance) decreases to the Float Transition Current setting (factory set to 1.5 A per 100 amp-hours of battery capacity).

FLOAT CHARGE
Once the battery is fully charged, a somewhat lower Float Voltage (factory set to 13.2/26.4 V) is applied to maintain the battery in a fully charged state without excessive water loss.

2-STAGE CHARGE CONTROL
Certain battery types (including lithium) or system configurations may require 2-stage charge control. The SB3024 can be configured for two-stage Bulk/Absorption charge control by setting the Float Voltage to “No Float” with the DIP switches (see Figure 3) or by the IPN ProRemote, BT Connect, and the UCM. Refer to the IPN ProRemote, BT Connect, or UCM operators manual for their settings.

Equalization (only for lead-acid battery)

WARNING:
Not all batteries can be safely equalized. Equalization should only be performed on vented liquid electrolyte lead-acid batteries. Always follow battery manufacturers’ recommendations about equalization. Equalization applies a high voltage, producing significant battery gassing. Disconnect equipment that cannot tolerate the high equalization voltage which is temperature-compensated.

Periodic equalization improves battery performance and life by bringing all battery cells up to the same specific gravity and eliminating electrolyte stratification. Equalization parameters are factory set to 15.2/30.4 V for 2 hours every 30 days. A minimum net charge current of approximately 3 A per 100 amp-hours of battery capacity is required for proper equalization. If insufficient current is available equalization may have to be canceled manually since the equalization time accumulator may not complete the countdown.

The equalization timer is a “time at voltage” time accumulator that counts in 3-minute increments. The equalization timer will not count down unless the battery is at the equalization voltage setpoint. Unless manually disabled the SB3024 will stay in equalize for as long as necessary to accumulate the required time at voltage. If equalize does not complete by the end of the charging day it will resume where it left off the next charging day, automatically canceling the equalize cycle if unable to complete in the normal manner within 24 hours.

AUTOMATIC EQUALIZATION
If DIP switch #5 is turned ON before the application of battery power, automatic equalization is enabled. The SB3024 will perform automatic equalization after the set number of days has elapsed. (factory set to 30 days).

MANUAL EQUALIZATION
If DIP switch #5 is turned OFF, equalization is completely disabled. A manual equalization can be performed by turning DIP switch #5 ON after battery power is applied. Following completion of a manually initiated equalization cycle, turn DIP switch #5 OFF. If DIP switch #5 remains ON automatic equalization is enabled. Equalization can also be controlled from the IPN ProRemote, BT Connect, or UCM if DIP switch #5 is ON.

Output Current Limit
The automatic current limit prevents output current from exceeding 40 A with 12 V batteries and 12 V PV’s (Panel). If PV (Panel) open circuit voltage (VOC) ever exceeds 30 V which would occur with PV (Panel) voltage greater than 12 V nominal, the current limit will become 30 A until the SB3024 reboots. Note that when the SB3024 exits the current limit, it will briefly enter Absorption (Acceptance) on its way back to MPPT even though battery voltage may be low.

Temperature and Output Power
When mounted vertically as described in the installation section, the SB3024 can deliver full output in an ambient temperature of up to 40 0C (104 0F). If an over-temperature condition exists, the SB3024 will cycle on/off, reducing average power delivery to within safe limits. During thermal shutdown, the Charge Status Indicator will display an OFF condition.

Optional Temperature Compensation (only for lead-acid battery)
The optional battery temperature sensor automatically adjusts charge voltage setpoints based on battery temperature which enhances battery performance and life and decreases maintenance.

Maximum Setpoint Voltage Limit
Regardless of the setpoint values entered by the user or result from temperature compensation, the SB3024 will not apply a charge voltage setpoint greater than the maximum voltage setpoint limit (factory configured to 15.5/31.0 V). Note that actual battery voltage may briefly exceed this value by 0.1 – 0.2 V as the voltage control servo responds to changes in load.

Maximum Power Point Tracking (MPPT)
Patented MPPT technology can extract more power and increase charge current by up to 30% or more compared to conventional controllers. The principal operating conditions that affect current boost performance are PV (Panel) array temperature and battery voltage. At constant solar intensity, available PV (Panel) voltage and power increase as PV (Panel) temperature decreases but it takes an MPPT controller to access this extra power. When PV (Panel) voltage is sufficiently high in Bulk for MPPT to operate, constant power output is delivered to the battery. Since output power is constant a decrease in battery voltage produces a further increase in charge current. This means that the SB3024 provides the greatest charge current increase when you need it most, in cold weather with a discharged battery. In cool comfortable temperatures, most systems see about a 10 – 20% increase. Charge current increase can go to zero in hot temperatures, whereas charge current increase can easily exceed 30% with a discharged battery and freezing temperatures. For a more complete MPPT description see “What Is MPPT and how does it work?” on the FAQ page at https://sunforgellc.com/learning-center.

Multiple Charge Controllers on the IPN Network
The IPN network architecture allows multiple charge controllers to operate as a single charging machine. Up to 8 IPN compatible charge controllers can reside on a single network and can share a single display or battery temperature sensor. Charge controllers can be added to grow a small system into a large system and have this large system operate from the user’s standpoint as a single charge controller.

Detailed Dimensional Drawing

Installation

WARNING:
Read, understand, and follow the Important Safety Instructions at the beginning of this manual before proceeding. This unit must be installed and wired by the National Electrical Code, ANSI/NFPA 70. Over-current protection must be provided externally. To reduce the risk of fire, connect to a circuit provided with 40 A maximum branch-circuit over current protection (50 A with 12 V battery and 12 V PV (Panel) modules) by National Electrical Code, ANSI/NFPA 70. Do not connect a PV (Panel) array capable of delivering greater than 24 A of short circuit current ISC at STC (32 A with 12 V battery and 12 V PV modules). Do not connect BAT– and PV– together external to the unit. The unit is not provided with a GFDI (ground-fault detector/interrupter) device and must be used with an external GFDI device as required by Article 690 of NEC for the installation location. To reduce the risk of electric shock, remove all sources of power before installing or servicing. Figures 3, 4, and 5 show generalized connections only and are not intended to show all wiring, circuit protection, and safety requirements for a photovoltaic electrical system.

CAUTION:
The SB3024 is protected against reverse battery and PV (Panel) polarity, and swapped PV (Panel) and battery connections, but will be damaged by reverse battery to the PV (Panel) terminals. Transient voltage lightning protection is provided, but steady state voltage over 57 VDC on the battery or PV (Panel) terminals will damage the unit. Damage of either type voids the limited warranty.

Electrostatic Handling Precautions
To minimize the likelihood of damage, discharge yourself by touching a water faucet or other electrical ground before handling the 3024 and avoid touching circuit board components. The risk of electrostatic damage is highest when relative humidity is below 40%.

Selecting PV Modules
Voltage, current, and power produced by Photovoltaic (PV) modules fluctuate widely with operating conditions. As a result a set of test conditions referred to as Standard Test Conditions (STC) are used to rate modules in a meaningful manner and accurately predict real-world performance. STC ratings are not maximum or optimal ratings. Conditions can be present where VOC and ISC approach 1.25 times STC ratings which is why the National Electrical Code and our recommendations call for 1.25 derating of both VOC and ISC. Yet in real-world conditions, IMP is commonly only about 75 – 80% of IMP at STC.

Key PV module specifications

• PMAX Maximum power in watts (PMAX = VMP x IMP)
• VOC Voltage with module open circuit (typically about 20–22 V for 12 V nominal 36 cell modules)
• VMP Voltage where the module produces Maximum Power (typically about 17–18 V for 12 V nominal 36 cell modules)
• IMP Current where the module produces Maximum Power
• ISC Current with module Short Circuit

The SB3024 will provide the best MPPT current boost performance if all PV (Panel) modules are identical. If module types are mixed, do not put dissimilar modules in series. Dissimilar modules in parallel should have VMP values within about 0.5 V or better for 12 V modules, and be of the same basic cell technology so their VMP will tend to track as operating conditions change. If module types are very different consider using a separate charge controller for each module type to obtain the best MPPT current boost performance. Select PV (Panel) modules that do not exceed the maximum ratings shown below, and preferably produce at least 3 A of IMP per 100 amp-hours of battery capacity.

Nominal Battery Voltage| Automatic Current Limit| Max PV

Power @ STC

| Max PV Isc @ STC| Max PV VOC @ STC| Recommended range of

VMP at STC

---|---|---|---|---|---
Nominal 12V PV| Nominal 18V PV| Nominal 24V PV
12 V| 40 A| 540 W| 32 A| 24.0 V*| 16.5 /

18.5 V

| –| –
12 V| 30 A| 400 W| 16 A| 45.6 V| –| 24.8 /

27.8 V

| –
12 V| 30 A| 400 W| 12 A| 45.6 V| –| –| 33.0 /

37.0 V

24 V| 30 A| 800 W| 24 A| 45.6 V| –| –| 33.0 /

37.0 V

(*) The current rating and current limit are 40 A when charging a 12 V battery from nominal 12 V PV (Panel) modules. If PV (Panel) VOC ever exceeds 30 V (>12 V nominal PV modules) current rating and current limit become 30 A.

NOTE:
The SB3024 has various setup parameters all of which are preconfigured at the factory. Confirm that the SB3024’s charge parameter settings are within the ranges specified by the battery manufacturer. Default settings are typically suitable for most flooded or sealed lead-acid batteries and likely require no changes. For lithium batteries, check the charge settings recommended by the manufacturer.

Setup parameters are divided into two categories, Basic and Advanced. Basic parameters can be configured with the SB3024 alone within limited steps and ranges as shown in Figure 3. Advanced parameters require the IPN ProRemote, UCM, or BT Connect to access. The IPN ProRemote, BT Connect, and UCM also allow basic settings to be configured in smaller steps and over wider ranges. All setup parameters are retained if power is lost, or the IPN ProRemote/BT Connect/ProTouch/UCM is used as a setup tool only and removed.

As-Shipped Factory Default Settings

Basic Settings

• Charge mode 3-stage
• Absorption (Acceptance) voltage 14.4/28.8 V
• Float voltage 13.2/26.4 V
• Charge time 2.0 hours
• Equalize Disabled
• IPN Network address 0 (zero)
• Auxiliary Output mode Aux. bat. charger
• All DIP switches OFF
• Current display (SB3024DiL) IPN network total

Advanced Settings

• Equalize voltage 15.2/20.4 V
• Equalize time 2.0 hours
• Auto equalize days 30 days
• Maximum voltage setpoint limit 15.5/31.0 V
• Float Transition Current 1.5 A/100 amp-hours
• Temperature compensation factor -5.00 mV/0C/cell
• Load control ON voltage 12.6/25.2 V
• Load control OFF voltage 11.5/23.0 V
• Dusk-to-Dawn lighting control Disabled

RESTORING AS-SHIPPED DEFAULT SETTINGS

1. Remove PV (Panel) and battery power.
2. Turn ALL 8 power board DIP switches shown in Figure 3 ON.
3. Restore battery power for 10 seconds, then remove battery power.
4. Return ALL 8 power board DIP switches to their default OFF position.
5. If the display is present, set display DIPs to #4 ON, #1-3 OFF
6. The unit is now set to as shipped factory default settings.

BATTERY AND PV VOLTAGE

NOTE:
Nominal battery and PV (Panel) voltage are determined automatically. The battery is considered to be 12 V if the battery voltage when first connected is less than 16 V, or 24 V if the battery voltage is greater. PV (Panel) voltage is also determined automatically. If nominal PV (Panel) voltage is changed following installation power must be momentarily removed to reboot the SB3024.

ABSORPTION VOLTAGE, FLOAT VOLTAGE, & ABSORPTION TIME
Absorption Voltage, Float Voltage, and Absorption Time setpoints can be viewed or changed using the parameter setup leds and DIP switch shown in Figure 3. Operate only one switch at a time. To view the present setting turn the appropriate DIP switch ON momentarily (AbsV #8, FloatV #6, or AbsT #7). For a 24 V battery, the actual voltage setpoints are doubled.

To change a setting, turn the appropriate DIP switch ON, OFF, and then back ON before the LEDs turn OFF. The SB3024 will enter setup mode and scan through available settings. Turn the DIP switch off at the desired setting to store the new value. If Float Voltage is set to “No Float” the SB3024 operates as a two-stage charger, will remain in Absorption, and will not display Absorption Time on the setup leds. For more details, visit the Learning Center page at https://sunforgellc.com/learning-center/ and watch the video “Solar Boost 3024iL Basic Settings”.

Setup and Wiring Diagram

12 OUTPUT CURRENT DISPLAY (SB3024DiL ONLY)

NOTE:
The display can show the total output current from all networked controllers, or the output current of a single controller. To show output current from a single controller IPN network address of the display and charge controller must match.

DISPLAY BOARD

DIP SWITCH

| IPN ADDRESS – OUTPUT CURRENT OF SINGLE CHARGER UNIT| TOTAL OUTPUT CURRENT OF ALL CHARGERS ON THE IPN NETWORK
---|---|---
0| 1| 2| 3| 4| 5| 6| 7

1 (A2)| OFF| OFF| OFF| OFF| ON| ON| ON| ON| Don’t care

2 (A1)| OFF| OFF| ON| ON| OFF| OFF| ON| ON| Don’t care

3 (A0)| OFF| ON| OFF| ON| OFF| ON| OFF| ON| Don’t care

4 (IPN Total)| OFF| OFF| OFF| OFF| OFF| OFF| OFF| OFF| ON

Table 2

Battery and PV (Panel) Wiring

CAUTION:
Battery and PV (Panel) compression terminals accept #14–2 AWG wire and are tightened to 45 in-lb (5 nm). IPN network compression terminals accept #24–14 AWG wire and are tightened to 2.1 in-lb (0.24 nm). Auxiliary Output compression terminals accept #24–12 AWG wire and are tightened to 6 in-lb (0.67 nm). DO NOT connect Bat– and PV– together external to the SB3024 or improper operation will result. Bat– and PV– connect internally.

A desirable installation would produce a total system wiring voltage drop of 3% or less. The lengths shown in the Table below are one way from the PV to the battery with the SB3024 located along the path. The wire length can be increased inversely proportional to the actual current. If the current was reduced by ½, wire lengths could doubled and still provide a 3% voltage drop.

Maximum Conductor Pair Length – 3% Voltage Drop

Wire Gauge AWG| 12 Volt System @ 32 A FEET/METERS| 24 Volt System @ 24 A FEET/METERS
---|---|---
12| 4.0 / 1.2| 10.7 / 3.3
10| 6.4 / 2.0| 16.9 / 5.2
8| 10.1 / 3.1| 26.9 / 8.2
6| 16.1 / 4.9| 42.8 / 13.0
4| 25.5 / 7.8| 68.1 / 20.7
2| 40.6 / 12.4| 108.2 / 33.0
1/0| 64.6 / 19.7| 172.2 / 52.5

Electromagnetic Compatibility
To comply with electromagnetic compatibility requirements the SB3024’s battery and PV (Panel) wiring must be installed in grounded metallic conduit, and the two clamp-on type ferrite suppressors supplied must be installed. Clamp one suppressor around both Bat+ and Bat– cables. Clamp the second suppressor around both the battery temperature sensor and remote display cables with the cables looped to pass through the core 3 times.

If both sensor and display cables are used, the sensor cable outer cover must be stripped back ~12 inches (30 cm) so both cables will fit through the core 3 times. Ensure that the two suppressors are restrained so they will not damage circuit board components. Additional suppressors can be ordered as p/n 523-0005-01.

Optional Battery Temperature Sensor (only for lead-acid batteries)
Installation of the optional battery temperature sensor enables temperature compensation of all charge voltage setpoints to improve performance and extend the battery’s longevity. In a multi-controller system, a single temperature sensor must connect to the IPN master. Do not attach sensors or components other than the Blue Sky Energy battery temperature sensor (p/n 930-0022-20) to the temp sensor terminal block. Be certain to observe proper RED/BLK polarity.

Auxiliary Output
The auxiliary output can serve one of three functions; 1) a 2 A auxiliary battery charger, 2) a 20 A load controller with Low Voltage Disconnect (LVD), or 3) a 20 A variable Dusk-to-Dawn lighting load controller with Low Voltage Disconnect (LVD). The Charge/Load function is selected by DIP switch #4 shown in Figure 3. The IPN ProRemote, BT Connect, or UCM is required to adjust LVD thresholds or enable Dusk-to-Dawn lighting control. Auxiliary outputs in a multi-controller system will function normally, but only the auxiliary output in the master can be configured or monitored using the IPN ProRemote. The auxiliary output “Load” LED will illuminate whenever the auxiliary output is ON (*).

*NOTE ():**
The LOAD indicator light will be ON whenever power is available at the Load and Auxiliary Battery Charge terminals.

Auxiliary Output Wiring

CAUTION:
The auxiliary output cannot perform both auxiliary battery charge and load control functions at the same time. Do not connect to the 20 A Load terminal for auxiliary battery charge.

AUXILIARY BATTERY CHARGE – DIP #4 OFF
The auxiliary charge function is used to charge an auxiliary battery of the same voltage as the primary battery. If the primary battery is charging in Absorption (Acceptance) or Float, up to 2 A is diverted to the auxiliary battery at roughly the same charge voltage. Auxiliary battery charge is disabled during bulk or equalization. Use 14 AWG wire to minimize voltage drop and 25 A over current protection. The auxiliary battery negative must connect to the primary battery negative.

LOAD CONTROLLER – DIP #4 ON
The load controller can deliver up to 20 A (increased to 70 A w/ the CBM4070) of continuous output from the battery. Default settings are for LVD operation with ON at VBAT ≥12.6/25.2 V, and OFF at VBAT ≤11.5/23.0 V, which can be changed using the IPN ProRemote, BT Connect, or UCM. The operation can also be based on net battery amp-hours if an IPN ProRemote (with an external shunt) is present. The ON/OFF condition must be valid for 20 seconds before switching will occur. If the higher/lower values are reversed the output control logic is inverted. Load negative must connect to battery negative.

CAUTION:
25 A maximum over-current protection for load control output must be provided externally. If the load control output is configured to operate based on net battery amp-hours, configure ON/OFF voltage thresholds as well. If an amp-hour from full data is not available, the voltage-based operation will resume. Voltage or amp-hour ON/OFF thresholds must not be the same value or improper operation will result.

DUSK-TO-DAWN LIGHTING CONTROL – DIP #4 ON
A BT Connect, or UCM, or IPN ProRemote with software version V2.00 or later is required to enable lighting control. Refer to the operator’s manual for lighting control setup instructions. Variable time settings are available to turn lighting ON after Dusk (Post-Dusk timer) and/or ON before Dawn (Pre-Dawn timer). If both timers are set to DISABLED (factory default), the lighting control feature is disabled. If either the Post-Dusk or Pre-Dawn timers are set to a time value the lighting control feature is enabled. When lighting control is enabled the auxiliary output is controlled by both the normal load (LVD) control function and the lighting control function such that whichever function wants the auxiliary output OFF prevails.

Dusk or nighttime begins when the charge control system turns OFF, which occurs when the PV (Panel) module current drops below about 50 mA at battery voltage. Dawn or daytime begins when the charge control system turns ON which occurs when the PV module current rises to about 100 mA at battery voltage. If the Post-Dusk timer was set to 1.0 hours and the Pre-Dawn timer was set to 2.0 hours, lights would turn ON at Dusk, remain ON for one hour, and then turn OFF. Two hours before Dawn the lights would again turn ON and remain ON until Dawn. For full Dusk to Dawn lighting set the Post-Dusk timer to 20 hours. Lights will always be OFF when the charge control system is ON. When the SB3024 first receives battery power it does not know when Dawn is expected to occur. As a result, Pre-Dawn control does not operate for the first night. Once a nighttime period of 4 hours or more is detected, this nighttime period is stored and Pre-Dawn control will operate. Each subsequent night period greater than 4 hours is added to a filtered average of nighttime.

Installing a Multi-Controller System
A communication link is established between controllers by daisy chaining a twisted pair cable from the IPN Network terminal block, controller to controller (A-to-A, B-to-B) as shown in Figure 5. Up to 8 IPN-based charge controllers can be connected in a multi-controller system. Device address 0 (zero) is the master and 1 – 7 are followers. The master controls the charging process and directs the activities of the followers. The charge control system will start whenever one or more controllers receive PV (Panel) input power.

MULTI-CONTROLLER WIRING AND SETUP

CAUTION:
A multi-controller system requires the following specialized installation and setup:

1. Each controller must connect to and charge the same battery or batteries.
2. One controller must be set to IPN address 0 (zero) and the others be set to addresses 1 – 7 with no controllers set the same.
3. Charge parameters are set in the master only.
4. While outputs connect in parallel to a common battery, PV (Panel) inputs must be completely separate, with separate PV+ and PV– wiring.
5. All controllers must be connected to the IPN network as shown in the wiring figure.

IPN Network Wiring

IPN NETWORK ADDRESS

NOTE:
A single controller must be set to IPN network address 0 (zero). In a multi- controller system, one controller must be set to address 0 (zero) to serve as the master. The other controllers must be set to address 1-7 with no two controllers set the same.

POWER BOARD DIP SWITCH| MASTER|  |  | FOLLOWERS|  |
---|---|---|---|---|---|---
0| 1| 2| 3| 4| 5| 6| 7

1 (A2)| OFF| OFF| OFF| OFF| ON| ON| ON| ON

2 (A1)| OFF| OFF| ON| ON| OFF| OFF| ON| ON

3 (A0)| OFF| ON| OFF| ON| OFF| ON| OFF| ON

Mounting

CAUTION:
Mount the unit with heatsink fins oriented vertically to promote cooling and not enclose in a confined space. The SB3024 is not waterproof and must be protected from rain, snow, and excessive moisture.

Installing Optional Accessories (Remote Displays and BT Connect)
The SB3024iL/DiL can communicate via IPN cable with different accessories for full monitoring and advanced programming. More accessories with different capabilities can be connected simultaneously to the SB3024 via RJ-11 cables (see Figure 6), as, a remote display (IPN Remote, IPN ProRemote, or ProTouch), the Bluetooth adapter BT Connect, and the UCM. See Table 3.

Mounting

Table 3

Troubleshooting Guide

No battery power

| Battery disconnected, overly discharged (<9 V), or connected reverse polarity. Battery powers unit, not PV (Panel).
The unit will not turn on (charge status LED off ), Display if present may be OK| PV (Panel) disconnected| PV (Panel) must supply at least 0.15 A at just above battery voltage to begin charging.
PV reverse polarity| Reverse polarity PV will cause heat sink to heat.
IPN network address set wrong| A single unit must be set to IPN network address 0 (zero). One unit of a multi-unit network must be set to IPN network address 0 (zero), AND all other units must be set to different addresses.
Low battery power| Battery overly discharged (<9 V). Battery powers unit, not PV (Panel).
Extreme voltage fluctuations or interference has caused microprocessor lock- up|

Reboot the microprocessor by momentarily removing all power. Reattach the power crisply.

Unit cycles on/off

|

PV- connected to BAT- external to the unit

| PV- & BAT- must be separate external to the unit for proper operation and cannot connect to a common location. External connection prevents the proper operation of internal shunts and the current measurement system.
 | Battery voltage greater than charge voltage setpoint| This is a normal operation. Output is off due to high battery voltage which may be caused by other charging systems.
---|---|---
Charge status LED on, but no output charge| Battery voltage too low| Battery voltage must be at least 9 V for the unit to operate.
current| Unit recognized battery voltage to be 12 V when it is 24 V| Battery voltage is determined automatically when the unit first receives power. Voltage must be greater than 16 V to recognize the battery as 24 V. Remove all power and reapply the battery quickly and crisply.
Charge status LED blinks rapidly| System in equalized mode| Disable equalize via IPN ProRemote, or by turning DIP switch #5 off.
The charge current is lower than expected, PV current may be low as well| The battery is highly charged| In normal operation, the current is reduced if the battery voltage is at a point.
Worn-out PV modules| Replace, or use as is.
Low insolation| Atmospheric haze, PV’s (Panel) dirty, sun low on the horizon, etc.

PV- connected to BAT-

| PV- & BAT- must be separate external to the unit for proper operation and cannot connect to a common location. External connection prevents the proper operation of internal shunts and the current measurement system.
Nominal PV (Panel) voltage has changed from 18 V or 24 V to 12 V| If the PV (Panel) voltage is changed to 12 V, all power must be removed momentarily to reboot unit and load initial PV (Panel) control values.
The current limit has switched to 30 A| Normal operation. The current limit will change to 30 A if PV VOC has exceeded 30 V which will occur with greater than 12 V nominal PV’s. Reconfigure PV’s for 12 V and reboot SB3024 to resume the 40 A current limit.
PV’s with low VMP. PV’s with higher VMP produce greater power and current boost potential. PV’s

PV (Panel) maximum            with VMP ≥ 17 V work best.

power voltage (VMP) is

not much higher than

battery voltage, leaving

| Excessive PV (Panel) wiring voltage drop due to undersize wiring, poor connections etc.

MPPT Current boost is less than expected

| little extra power to be extracted| Battery is nearly charged and battery voltage is high. Output during MPPT operation is “constant power”, higher battery voltage reduces charge current increase.
 |

PV’s hot

| VMP and available power decrease with increasing PV cell temperature. Cooler PV’s will produce greater boost. It is normal for boost to decrease as temperature rises.
 | Nominal PV (Panel) voltage has changed from 18 V or 24 V to12 V| If PV (Panel) voltage is changed from to 12 V, all power must be removed momentarily to reboot unit and load initial PV (Panel) control values.
Auxiliary battery not charging (Cont’d…)| Auxiliary output not configured for auxiliary battery charge| Confirm dip switch #4 is OFF.

Specifications

1. 36-cell panels are typically referred to as “12 V panels” providing Vmp/Voc of ~18 V / 22 V at STC, 60-cell panels refer to as “20 V panels” (Vmp/Voc ~30 V / 37 V), 72-cell panels refers to “24 V panels” (Vmp/Voc ~36 V / 44 V).
2. Factory default voltages unless programmed via DIP switches or with IPN ProRemote, ProTouch, BT Connect, or UCM.

5-year limited warranty

Visit https://sunforgellc.com/product/sb3024(d)il/ for more information and terms of the warranty.

Copyright © 2022 Sunforge LLC. All rights reserved. Changes are periodically made to the information herein which will be incorporated in revised editions of this publication. Sunforge may make changes or improvements to the product(s) described in this publication at any time and without notice.

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