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Zamp Solar ZS-30A - User Manual

Zamp Solar ZS-30A
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Solar Controller / Battery Charger
ZS-30A / ZS-40A
Input: DC12V Solar panel (Max. 25V)
Output: DC 12V 30A (ZS-30A)
DC 12V 40A (ZS-40A)
Users Manual
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Summary

Solar Controller; Battery Charger Overview

Product Features

Advanced MCU and PWM Technology

Utilizes advanced MCU control with PWM technology for high efficiency operation.

Battery Compatibility and Protection

Supports multiple battery types and includes overcharge/undercharge protection.

Charging Modes and Safety

Features automatic equalization, floating charge, and nighttime discharge prevention.

Display and Optional Features

Includes LED indicators, LCD display, and optional remote display/temperature sensor.

Important Safety Warnings

Environmental and Repair Safety

Designed for indoor use only; avoid rain and entrust repairs to qualified personnel.

Battery and Electrical Safety

Handle batteries with care, use eye protection, avoid sparks, and prevent short circuits.

Installation Precautions

Install battery fuses, avoid reverse connections, and cover solar panels during installation.

Mounting the Device

Surface Mount Method

Quick installation on a flat surface using provided spacers and screws.

Flush Panel Mount Method

Involves cutting a panel opening and securing the unit with screws.

Wiring Connections

Fuse and Terminal Guidance

Recommends inline fuses for protection and identifies controller terminals for wiring.

Wire Size and Connection Procedure

Provides wire size chart and step-by-step instructions for connecting solar array and battery.

Operation - LCD Display

Battery Type Selection and Self-Test

Guide to selecting battery type and details the controller's self-test sequence upon power-up.

Charging Status and Display Modes

Explains how the LCD shows charging status, voltage, current, and capacity.

Detailed Charging Information

How to cycle through voltage, current, capacity, and temperature readings on the LCD.

Charge Level Monitoring

Using the LCD bar to visually track battery charge percentage and identify low voltage.

Charging Stages

Five-Stage Charging Algorithm

Details the 5-stage algorithm: Soft, Bulk, Absorption, Equalizing, and Float modes.

Stage Descriptions

Explains each charging stage: Soft, Bulk, Absorption, Equalization, and Float charge.

LED Status Indication

Charging Status LEDs

Describes how 6 LEDs indicate charging status and battery condition.

Battery Voltage Indicators

LED indications for different battery voltage levels, including low voltage warnings.

Abnormal Operation Modes

Solar Panel Abnormalities

Displays and LED indications for solar panel weak signal, reverse connection, and over voltage.

Battery Abnormalities

Displays and LED indications for battery disconnected, reverse connection, over voltage, and temp.

Controller Over-Temperature Protection

Indicates controller over-temperature protection status.

Optional External Devices

External Battery Temperature Sensor

Connects an external sensor to optimize charging based on detected battery temperature.

External Remote Display Meter

Allows connection of a remote display meter for monitoring at a different location.

Specifications

Electrical Parameters

Details rated amps, input voltage, voltage drop, and charging characteristics.

Charging Characteristics

Specifies voltages and currents for various charging stages and battery types.

Protection Features

Lists protections against reverse polarity, short circuit, over-temperature, and transient over-voltage.

Physical and Environmental Parameters

Covers controller material, terminals, mounting, IP grade, net weight, and operating conditions.

Summary

Solar Controller; Battery Charger Overview

Product Features

Advanced MCU and PWM Technology

Utilizes advanced MCU control with PWM technology for high efficiency operation.

Battery Compatibility and Protection

Supports multiple battery types and includes overcharge/undercharge protection.

Charging Modes and Safety

Features automatic equalization, floating charge, and nighttime discharge prevention.

Display and Optional Features

Includes LED indicators, LCD display, and optional remote display/temperature sensor.

Important Safety Warnings

Environmental and Repair Safety

Designed for indoor use only; avoid rain and entrust repairs to qualified personnel.

Battery and Electrical Safety

Handle batteries with care, use eye protection, avoid sparks, and prevent short circuits.

Installation Precautions

Install battery fuses, avoid reverse connections, and cover solar panels during installation.

Mounting the Device

Surface Mount Method

Quick installation on a flat surface using provided spacers and screws.

Flush Panel Mount Method

Involves cutting a panel opening and securing the unit with screws.

Wiring Connections

Fuse and Terminal Guidance

Recommends inline fuses for protection and identifies controller terminals for wiring.

Wire Size and Connection Procedure

Provides wire size chart and step-by-step instructions for connecting solar array and battery.

Operation - LCD Display

Battery Type Selection and Self-Test

Guide to selecting battery type and details the controller's self-test sequence upon power-up.

Charging Status and Display Modes

Explains how the LCD shows charging status, voltage, current, and capacity.

Detailed Charging Information

How to cycle through voltage, current, capacity, and temperature readings on the LCD.

Charge Level Monitoring

Using the LCD bar to visually track battery charge percentage and identify low voltage.

Charging Stages

Five-Stage Charging Algorithm

Details the 5-stage algorithm: Soft, Bulk, Absorption, Equalizing, and Float modes.

Stage Descriptions

Explains each charging stage: Soft, Bulk, Absorption, Equalization, and Float charge.

LED Status Indication

Charging Status LEDs

Describes how 6 LEDs indicate charging status and battery condition.

Battery Voltage Indicators

LED indications for different battery voltage levels, including low voltage warnings.

Abnormal Operation Modes

Solar Panel Abnormalities

Displays and LED indications for solar panel weak signal, reverse connection, and over voltage.

Battery Abnormalities

Displays and LED indications for battery disconnected, reverse connection, over voltage, and temp.

Controller Over-Temperature Protection

Indicates controller over-temperature protection status.

Optional External Devices

External Battery Temperature Sensor

Connects an external sensor to optimize charging based on detected battery temperature.

External Remote Display Meter

Allows connection of a remote display meter for monitoring at a different location.

Specifications

Electrical Parameters

Details rated amps, input voltage, voltage drop, and charging characteristics.

Charging Characteristics

Specifies voltages and currents for various charging stages and battery types.

Protection Features

Lists protections against reverse polarity, short circuit, over-temperature, and transient over-voltage.

Physical and Environmental Parameters

Covers controller material, terminals, mounting, IP grade, net weight, and operating conditions.

Overview

The Zamp Solar ZS-30A / ZS-40A is a solar controller and battery charger designed for use with 12V solar panels, capable of handling up to 510 Watts for the ZS-30A and 680 Watts for the ZS-40A. It features advanced MCU control with pulse width modulated (PWM) technology for high-efficiency operation.

Function Description:

This device acts as a regulator to prevent both overcharging and undercharging of batteries in solar energy systems. It supports a wide range of battery types, including LiFePO4, LTO (Lithium Titanium Oxide), Gel, AGM, Conventional lead-acid (WET), and Calcium Batteries. The controller can be permanently connected to the battery, maintaining a full charge through a "floating" process where it stops charging when the battery is full and resumes as needed. This process helps reduce water loss and prevents battery "drying out." It also protects the battery from discharge at night by preventing current from flowing back from the battery into the solar panel when the solar panel voltage is lower than the battery voltage. The unit employs a 5-stage charging algorithm: Soft Charge (Level 1), Bulk Charge (Level 2), Absorption Charge (Level 3), Equalizing Charge (Level 4), and Float Mode (Level 5). The Equalizing Charge stage is specifically for WET and Calcium battery types when deeply drained, aiming to equalize internal cells and fully complement lost capacity. LiFePO4, LTO, Gel, and AGM batteries do not utilize the Equalization charge.

Important Technical Specifications:

  • Input: DC12V Solar panel (Max. 25V)
  • Output: DC 12V 30A (ZS-30A) / DC 12V 40A (ZS-40A)
  • Rated Solar Panel Amps: 30/40 Max. AMP
  • Normal Input Solar Cell Array Voltage: 15-22 VDC
  • Max. Solar Cell Array Voltage (output has no load): 25 Max. VDC
  • Controller Lowest Operating Voltage (solar or battery side): 8V Min VDC
  • Maximum Voltage Drop (Solar panel to battery): 0.25 Max. VDC
  • Minimum Battery Start Charging Voltage: 3 Min VDC
  • Soft Start Charging Voltage: 3-10 +/-0.2 VDC
  • Soft Start Charging Current: Up to 15/20 AMP (ZS-30A / ZS-40A)
  • Bulk Charge Voltage: 10-14.0 +/-0.2 VDC
  • Absorption Charging Voltage at 25°C:
    • LTO type battery: 14.0 +/-0.2 VDC
    • Gel type battery: 14.1 +/-0.2 VDC
    • LiFePO4 battery: 14.4 +/-0.2 VDC
    • AGM type battery (default setting): 14.4 +/-0.2 VDC
    • WET type battery: 14.7 +/-0.2 VDC
    • Calcium type battery: 14.9 +/-0.2 VDC
  • Absorption Transits to Equalizing or Float Condition: Charging current drops to 1.0 +/-0.1 AMP or Absorption charging timer timed out (4 Hour).
  • Equalization Charging Active (Only for WET or Calcium battery):
    • Battery voltage discharged to less than: 10 +/-0.2 VDC
    • Automatic equalizing charging periodical: 28 Day
    • Equalization charging voltage at 25°C: 15.5 +/-0.2 VDC
    • Equalization charging timer timed out: 2 Hour
  • Float Charging Voltage at 25°C:
    • For LTO and LiFePO4 battery: 13.4 +/-0.2 VDC
    • For Gel, AGM, WET, Calcium battery: 13.6 +/-0.2 VDC
  • Voltage Control Accuracy: +/- 1%
  • Battery Temperature Compensation Coefficient: -24 mV/°C
  • Temperature Compensation Range: -20~+50 °C
  • Over Temperature Protection During Charging: 65 °C
  • Input Output Terminal: M5 terminals
  • Remote Port: RJ-11 (6 pins)
  • Controller Material: Plastic, Standard ABS
  • Power Terminal Maximum Stranded Wire Size: #6 AWG stranded-16 mm²
  • Power Terminal Torque: Up to 17 in-lb (0.2n-m)
  • Mounting: Vertical wall mounting
  • IP Grade: IP22
  • Net Weight: Approx. 0.3kg / 0.66lb
  • Operating Temperature: -25~50°C / -13~122 °F
  • Storage Temperature: -40~85°C / -40~185 °F
  • Operating Humidity Range: 100% no condensation

Usage Features:

The controller offers both surface mount and flush (panel) mount options for installation. For safety, it is recommended to install a 40A inline fuse for ZS-30A (60A fuse for ZS-40A) on the positive wire of both the "Solar" and "Battery" circuits, as close to the battery/panel as possible. The unit features a digital LCD display and colored LEDs to easily indicate operational status and battery conditions. The LCD directly displays battery voltage, charging current, charging capacity (Amp-hour), battery types, and fault codes. Users can select the correct battery type (LiFePO4, LTO, Gel, AGM, WET, Calcium) by pressing and holding the "BATTERY TYPE" button for 3 seconds. The default setting is AGM Battery, and the controller memorizes the selection. The LCD also shows a percentage bar (25%, 50%, 75%, 100%) to visually monitor battery charging condition. A voltage less than 11.5V indicates a discharged battery needing recharging. The "VOLT / AMP" button allows users to cycle through displayed information (Battery Voltage, Charging Current, Charged capacity, Battery Temperature) during the charging process.

Maintenance Features:

The device includes multiple charging protections against reverse polarity, short circuit, over temperature, and over voltage. It also prevents reverse current from the battery to the solar panel at night and offers transient over voltage protection with TVS or varistor. Conformal-coating circuit boards and plated terminals are applied for hostile environments. The controller provides ports for optional external devices:

  • External Battery Temperature Sensor: When connected, the unit optimizes charging performance based on detected battery temperature and provides over-temperature protection. If the battery temperature exceeds a safe limit, the controller will automatically stop charging.
  • Remote Digital Display Meter: This optional meter can be connected for special location needs, displaying the same information as the controller's built-in LCD.

Safety Warnings:

  • Designed for indoor use only; never expose to rain.
  • Do not disassemble the controller; refer to qualified personnel for repairs.
  • Lead acid, LiFePO4, LTO batteries can be dangerous; ensure no sparks or flames are present when working near batteries.
  • Always use eye protection.
  • Never short circuit the battery.
  • Solar panels generate energy even when disconnected; cover panels with a soft cloth during installation to block light and prevent accidental shorting of terminals.
  • Always install a battery fuse on each circuit.
  • Do not reverse connect wires to the solar panel or battery.
  • Incorrect battery type setting may damage your battery.

Zamp Solar ZS-30A Specifications

General IconGeneral
BrandZamp Solar
ModelZS-30A
CategoryBattery Charger
LanguageEnglish

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