Warning!
While there is no shock hazard with low voltage DC systems, be aware of any conductive material nearby. Any conductive material such as an uninsulated wire, tool, ring, watch band, etc. can short a high current source like the battery. If this material shorts the battery it could overheat or explode, potentially harming the battery or the operator.
Step 1: Confirm correct wiring
The majority of issues this unit encounters are related to a battery issue. Many units are returned and turn out to simply have wiring issues or battery discharge issues. Refer to the wiring diagrams below and cross reference with the installation guide to double check that the wiring is correct.
If wiring is incorrect: DC Controller Installation Guide
If the wiring is correct, move onto the next steps. If it is incorrect, refer to the DC Controller Installation Guide linked above.
Step 2: LED guide for voltage doubler troubleshooting:
The voltage doubler has an LED that is located in the bottom left of the circuit board. During normal operation, this light should remain solid. If there is an error with the wiring or battery, the LED will flash accordingly.
Fast Blinking (3-4 blinks per second) = Unit in error state, blinks below define error
Slow Blinking (Blink lasts 1 second) = Unit is out of error state and is in 10-minute timeout before turning power on, blinks below define error
2 blinks = under voltage
3 blinks = over voltage
4 blinks = battery charge low
Constant blinking = over current
No LED = no power or Voltage Doubler is bad
Solid LED = power is on and functioning normally
Step 3: Voltage levels for unit
If the LED has identified an error, test the various connections for the error using a multimeter. Use the list of acceptable voltages available below and the values listed in the wiring diagram to diagnose what connection is causing the error.
CurrentMax: about 3 amps
VoltageMax: maximum voltage with no delay (20v)
VoltageMin: minimum voltage with no delay (7v)
VoltageHigh: maximum voltage during operation (17v)
VoltageLow: minimum voltage during operation (11v)
VoltageLowBatTest: minimum voltage during battery test (11.5v)
VoltageHighGood: maximum voltage before powering controller (16v)
VoltageLowGood: minimum voltage before powering controller (12v)
Fully charged battery: 13.7V
Excessively discharged battery: less than 11V
Once you have identified the error, power down the controller by reversing the order of the installation instructions that were linked in step 2 of this guide, stopping after step 10 of the installation instructions. From there, replace the faulty part or rewire the faulty connection. Then, reinstall the cables and fuses according to the instructions, resuming at step 10 of the installation instructions.
Note
When uninstalling fuses, we recommend keeping one side of the fuse in the clip. This helps avoid mixing up fuses, and reduces the possibility for clattering during reinstallation. See the picture in step 4 of this guide for an example.
Step 4: Power-cycle Fuses
Error conditions require a 10 min timeout; the power needs to discharge from the microcontroller to shut off and reset, otherwise it will contain that error timer, which needs to be <.5V before measuring voltage.
This ten minutes can be circumvented by removing the fuse for 20 seconds and reinstalling the fuse. Avoid chattering the fuse while installing or a new fault will be introduced. Chattering can be reduced by removing only one side of the fuse, waiting the 20 seconds, then swinging the other side down into it's connection in one motion.
You can verify that the board is fully discharged by using a multimeter to check if there is DC power running between pin 1 & 2 (labeled J5) on terminal board
Step 5: Check Battery:
If nothing else fixes the error, pull the battery and have it tested to verify if it has either:
a) full charge power capacity (~13.7V)
b) excessive discharge (< ~11V)
c) Power min:
A batteries’ lifespan is reduced if deeply discharged frequently or for long periods of time. The voltage doubler stops battery drainage beyond 11V but if it didn’t fully charge before winterization or bad fuse didn’t fully charge battery, then it may be below that min voltage. In that case, it is likely that you need to replace the battery. Return to the install guide and work in reverse to uninstall the battery stopping after step 7, then replace the battery and finish the installation guide resuming from step 7.
If none of the above steps helped solve the issue, refer to the SunSaver website for documentation on the device.
SunSaver Solar Charge Controller documentation and user manuals can be found on the manufacturer's website: https://www.morningstarcorp.com/products/sunsaver/
Quick start guide (including SunSaver LED information): https://www.morningstarcorp.com/wp-content/uploads/quick-start-guide-sunsaver-en.pdf