Troubleshooting guide, Installation and operation manual – Blue Sky Solar Boost 2512iX-HV User Manual

Page 11

Installation and Operation Manual

TROUBLESHOOTING GUIDE

SYMPTOM

PROBABLE CAUSE

ITEMS TO EXAMINE OR CORRECT

Completely dead,
optional display blank

No battery power

Battery disconnected, overly discharged, or connected reverse polarity. Battery powers the 2512,
not PV.

Unit will not switch to a
Charge ON (charge
status indicator OFF),
Remote display if
attached turns ON.

PV disconnected or low in voltage

PV reverse polarity

IPN network address set wrong

Microprocessor lockup

PV must supply 0.10 amps at greater than battery voltage to begin charge.

Reverse polarity PV will cause front panel to heat.

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.

Momentarily remove all power (battery & PV) to reboot.

Charge status indicator
ON., but no output
charge current

Battery voltage greater than charge voltage
setpoint

Battery voltage too low

PV- connected to BAT- external to controller

This is normal operation. Output is off due to high battery voltage which may be caused by other
charging systems.

Battery voltage must be at least 9V for the 2512 to operate.

PV- & BAT- must be separate for proper operation. PV- must receive earth ground via shunts
inside the 2512 which internally connect PV- to BAT-. External connection prevents proper
operation of current measurement system.

Charge status indicator
blinks rapidly

System in equalize mode

Disable equalize via IPN-ProRemote, or by turning DIP switch #4 off.

Charge OFF at high
ambient temperature

System temporarily shuts down due to high
heat sink temperature

Improve ventilation or reduce PV power. Sufficient ventilation to prevent over temperature shut
down will improve reliability. See Technical Bulletin #100206.

Charge current is lower
than expected, PV
current may be low as
well

Battery is highly charged

Worn out or dissimilar PV modules

Low insolation

PV- connected to BAT-

Normal operation, current is reduced if in Absorption or Float to control battery voltage.

Replace, or use as is.

Atmospheric haze, PV’s dirty or shaded, sun low on horizon, etc.

MPPT Current boost is
less than expected

PV maximum power voltage (V

) is not

much higher than battery voltage, leaving
little extra power to be extracted

PV’s hot

Worn out or dissimilar PV modules

PV’s with low V

PV’s with V

≥ 17V work best, PV’s with <36 cells tend to work poorly.

Excessive PV wiring voltage drop due to undersize wiring, poor connections etc.

Battery is nearly charged and battery voltage is high. Output during MPPT operation is “constant
power” such that higher battery voltage reduces charge current increase.

and available power decrease with increasing PV cell temperature. Cooler PV’s will produce

greater boost. It is normal for % increase to drop or even go to zero as PV temperature rises.

Replace, use as is, or use different controller for different PV modules.

Auxiliary battery not
being charging

Not configured for auxiliary battery charge

Primary battery not highly charged

Load on Auxiliary battery too high

Confirm dip switch #3 is OFF.

Auxiliary battery will not receive charge unless primary battery is in Absorption or Float.

Maximum auxiliary charge current is roughly 2 amps. Load may need to be reduced.

System appears OK,
but will not correctly
switch between Bulk,
Absorption & Float

Not set for 3 stage charge

Will not switch out of Bulk and into
Absorption or Float

Will not switch from Absorption to Float

Double check Float voltage setpoint.

Battery is so discharged that available net charge current cannot bring battery voltage up to the
desired charge voltage setpoint. PV power may be too low or loads too high.

Battery not fully charged. Unit will not switch to Float until battery voltage remains at the
Absorption voltage setpoint continuously for the Charge Time period (or net battery current drops
to the Float Transition Current setpoint if using IPN-ProRemote).

Load control not
working properly

Auxiliary output not set for load control

Output may have shut off due to low battery
charge

ON/OFF thresholds set incorrectly

Confirm dip switch #3 is ON.

Load will shut off if battery voltage drops below OFF threshold (default 11.5V). Once shut off, the
load will not come back on until battery voltage is above ON threshold (default 12.6V).

Correct ON/OFF threshold settings.

Dusk-to-Dawn feature,
lights will not turn ON or
remain ON

Auxiliary output not set for load control

Output may have shut off due to low battery
charge

Charge control system ON

Timers set incorrectly

Valid night time period not seen

Confirm dip switch #3 is ON and Dusk-to-Dawn enabled.

Load will shut off if battery voltage drops below OFF threshold (default 11.5V). Once shut off, the
load will not come back on until battery voltage is above ON threshold (default 12.6V).

Lights will not turn on if charge control system is ON and charging as this is day time.

Check time settings Post-Dusk or Pre-dawn timer.

Pre-Dawn lighting will not operate until a valid night time period of

≥4 hours detected. If PV was

removed/reconnected, night time period may be inaccurate. Remove & restore power to reboot

Dusk-to-Dawn feature,
lights will not turn OFF

Auxiliary output not set for load control

Timers set incorrectly

Charge control does not turn ON

Confirm dip switch #3 is ON and Dusk-to-Dawn enabled.

Either Post-Dusk or Pre-dawn timers must be set to time value to enable Dusk-to-Dawn feature.

Check charge control system related items