SunKeeper SK-6

Morningstar SunKeeper solar charge controllers

Morningstar’s SunKeeper solar controller provides a low cost regulated output directly from the solar module to maximize battery life in small solar power applications. The SunKeeper is epoxy encapsulated and rated for outdoor use. By mounting directly to the module junction box and wiring through the junction box knockout, the connection is weather-proof. This eliminates the need for an additional housing for the controller.

The SunKeeper is available in a 6 amp or 12 amp version (both at 12 volts DC). To withstand the high temperatures at the solar module, the controller has been designed using extremely efficient power electronics and is rated to 70°C. The SunKeeper is also certified for use in Class 1, Division 2 hazardous locations, making it an ideal controller for solar powered oil/gas applications.

Key Features and Benefits :

• High Reliability
Rated to 70°C to operate in high temperatures at the solar module. More reliable than controllers mounted inside the junction box. Uses very low on-resistance power MOSFET’s. No need to re-rate.
Outdoor Rated ETL approved for outdoor use without an additional enclosure. Rugged IP65, UV resistant case. Epoxy encapsulated printed circuit board and watertight connection to the module junction box.

• Extensive Electronic Protections Fully protected against reverse polarity, short circuit, overcurrent, lightning and transient surges, high temperature and reverse current at night.

• Longer Battery Life
Series PWM with 3 stage charging: bulk, PWM regulation and float. Includes temperature compensation at the controller or alternatively at the battery when using optional remote temperature sensor. Able to charge a zero voltage battery.

• Rated for Hazardous Locations
Specifically designed for solar power systems in the oil/gas industry. Approved for use in Class 1, Division 2, Groups A,B,C,D.

• More Information
Bi-color LED is easy to read from the ground when the solar module is pole-mounted. Indicates solar charging, regulation, normal nighttime operation and any controller or system faults.

• Easy to Install
Fits standard half inch conduit knockout (PG 13.5, M20) in module junction box. Quickly fastens with included locknut. Wires have fork connectors for easy connection to solar module terminals.

Morningstar SunKeeper SK-6
# 04-27-018
SK-6, 6A, MODULE MOUNT CONTROLLER 4.5 AMP REGULATOR, 12V

Morningstar - SunKeeper SK6 pdf download brochures

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Electrical Specifications • Rated Solar Input:
SK-6 6 A
• Nominal System Voltage 12 Volts
• Min. Battery Voltage 0 Volts
• Max. Solar Voltage 30 Volts
• Self-Consumption Charging...7 mA
   Night ........2 mA
• Voltage Accuracy ± 150 mV
Mechanical Specifications • Dimensions 99 x 51 x 13 mm
(3.9 x 2.0 x 0.5 inches)
• Weight 0.11 kg / 0.25 lbs
• Enclosure IP65
• Fitting to Module J-box PG 13.5, M20, 1/2 inch conduit
• Wire Size 2.0 mm2 (#14 AWG)
• Wire Terminations #8 fork connectors
Battery Charging

 


• Regulation Voltage 14.1 Volts (at 25°C)
• Float Voltage 13.7 Volts (at 25°C)
• Type of Charging Series PWM
3 stage: bulk, PWM and float
• Temperature Compensation (3 choices)
Reading temp at controller –30 mV / °C
Attaching remote temp sensor –30 mV / °C
Disable temp comp Defaults to 25°C
• Ability to Charge a Zero Voltage Battery
Bi-color LED • Green Blink 3 Times Successful installation
• Green On Solar charging battery
• Green Blink Fast In regulation
• Green Blink Slow Normal nighttime operation
• Red On Controller damaged
• Red Blink System problem
• LED Off No power
Electronic Protections • Reverse Polarity
• Short Circuit
• Overcurrent
• Lightning and Transient Surges
• High Temperature
• Reverse Current at Night
Options • Remote Temperature Sensor (RTS)
Environmental Specifications • Operating Temperatures – 40°C to +70°C
• Humidity 100%
• Tropicalization Encapsulated in epoxy
UV resistant plastic enclosure
Conduit connection with
rubber gasket seal
Certifications •CE Compliant
• Hazardous Locations: Class 1, Division 2, Groups A-D,
UL 1604
CSA 22.2 No. 213-M1987
• Complies with U.S. National Electric Code
• Manufactured in a Certified ISO 9001 Facility

 

Charge Controllers

TriStar Charge ControllerControllers, or charge regulators, prevent excessive overcharge of the batteries within a remote power system. Two different methods of charge control are generally used, Series and Shunt type, though both typically use battery voltage (set point) to determine when charging should be reduced or stopped completely.

Unlike other types of generators, solar modules can be short circuited or open circuited without causing damage to them. In a Series type controller the current flowing into a battery will occasionally be broken by opening the circuit between the array and the battery. In a Shunt type controller, this same array current is directed to a resistor of some type effectively short circuiting the solar modules. We generally do not recommend the use of shunt controllers in our solar installations since partial shading of any cells may cause overheating even if bypass diodes are used.

Series relay controllers

Depending upon the size of the solar array single or multiple relay controllers can be used. These controllers simply open one or more relays depending upon battery voltage to stop or reduce the current flowing to a battery and are suitable for array currents up to 40 - 50 amps. These relays open and close based upon preset high and low voltages. In multiple series controllers one relay may always remain closed to maintain a full charge, by passing some current to the battery via a linear current device or power transistor.

For systems with output currents exceeding 50 amps, controllers should contain more than one (mercury) relay connected to one or more individual controllers offering the benefits of individual or stepped voltage setting and failsafe operation.

Solid state switching controllers (Pulse Width Modulation)

These controllers use MOSFET or power transistors at very high frequencies to pulse the charge current on and off in order to maintain a constant battery voltage. Used in a series or shunt configuration the duration of the cycle will vary depending upon the battery voltage and the available charge current. These controllers offer excellent charging characteristics for solar arrays of up to 40 amps, however, due to their high switching frequency may cause noise on some telecommunications equipment.

The relays used within these controllers offer some limitations which affect performance and useful life. To extend life, relay's on/off range will be widened to reduce their cycling though this results in less efficient battery charging. Where currents are high, these relays may have a bypass circuit to temporarily handle the current during the cycle. Solid state switching devices will cycle almost endlessly without damage to them, however, the resultant voltage drop will lead to some heat generation.

Maximum Power Point Trackers

MPPTs are smart DC to DC converters that optimize the match between the solar array and the battery bank. While gains of 50% in solar module output are possible the typical wattage gain using an MPPT is 10 15% vs. a PWM controller. For example, Shell Solars SP75 is rated at 4.4 amps @ 17 volts that is 4.4 times 17 = 74.8 watts. But this 75 watts does NOT equal 75 watts of charging capacity since your battery is only charging near 13.5 V. The output of a solar module is controllers characterized by a performance curve of voltage versus current known as its I-V curve. For crystalline modules, the current remains fairly constant as the voltage changes relative to the voltage of battery it is charging. A battery charging at 13 V is only using 57.2 watts of power not the full 75 watts a loss of about 24%. In an extreme case, such as a fully discharged battery at 10.5 volts, you would get nearly 7 amps at 10.5 volts from the MPPT into the battery! MPPT's are most effective under these conditions: Cloudy or hazy days - when the extra power is needed the most. Cold weather - solar module output increases in cold temperatures during the winter when sun hours are low and you need the most power. Low battery charge - the lower the state of charge in your battery, the more current a MPPT puts into them - another time when the extra power is needed the most. With higher voltage solar arrays of 300 Wp or more. Below this size, it may be more cost effective to simply add another solar module.

Diode Protection only

Self regulating systems

Solar systems may be operated without a regulator, using only a blocking diode to prevent reverse current flow, under the following conditions:

• The load on the battery coincides with the solar array's output, including, allowances for temperature, throughout the period of use.
• Temperature is relatively constant.
• The battery is at least 30 times greater than the maximum short circuit array current.
• The solar array`s open output voltage is no more than 18.0 V. A blocking diode of sufficient current capacity provides reverse current protection.

Zenor Diode

Early, small PV systems used Zenor diodes to shunt array current. This means of control is used in limited applications stemming from variations in their performance due to temperature and difficulty matching diodes to the specific voltage required for battery charging.

Choosing a Voltage Regulator or Charge Controller

TriStar Charge Controller 45, 60 AThe choice of a regulator is contingent upon three main factors - charge voltage, current and ambient temperature. Regarding current capability, the controller should be sized 30% higher than the short circuit current of the solar array (ie) If Isc is 4.8A the controller must have rated capacity of 6.24 A.

A number of options are available:

* Adjustable voltage setpoints or voltage by battery type.
* Temperature compensation should be used only unless both the battery and charge controller will remain within a few degrees of the 25 C STC. Typically, the controllers output voltage will vary 5 mV/cell/C.
* Low voltage disconnect (LVD) is used to prevent the battery from excessive discharge via a prefixed or adjustable low voltage set point.
* Auto equalization is available on certain controllers. Set at about 14 V on 12 V nominal systems, this feature injects a higher than normal voltage to the battery to avoid stratification and reduce battery sulfation. Equalization should not be applied to batteries with gelled electrolyte.
* LED indicators for charge and/or load status.
* Digital monitoring to indicate array voltage and charge current, battery voltage and/or load current.
* Remote system monitoring and communications for remote sites.
* Reverse polarity protection.

Charge Controllers: PWM vs MPPT download brochure

 

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