GP-SB-PWM-30BT & GP-SB-PWM-10: Troubleshooting
How to Read this Section
- Troubleshooting Problems are split into sub-sections, grouped by symptoms involving key components.
- Components considered irrelevant in a diagnosis are denoted ‘Not Applicable’ (N/A). A multimeter or voltmeter may be required for some procedures listed.
- It is imperative that all electrical precautions stated in the Warning Section and outlined in the Installation Section are followed. Even if it appears the system is not functioning, it should be treated as a fully functioning system generating live power.
6.1 PROBLEMS WITH DISPLAY
Display Reading:
Blank Or LUE error
Time of Day:
Daytime/Nighttime
Possible Causes:
The controller requires battery power to run. If the controller I not getting battery power the display may be blank or show a low battery error (LUE). This could be from a loose battery or a blown fuse connection or low batteries.
How to tell:
- Check the voltage at the controller battery terminals with a voltmeter and compare with the voltage reading at the battery terminals.
- If there is no voltage reading at the controller battery terminals, the problem is in the wiring between the battery and the controller. If the battery voltage is lower than 6 volts, the controller will not function and will show a LUE error. If low, charge up the battery bank and repeat the above steps.
Remedy:
Check all connections from the controller to the battery, including checking for correct wire polarity. Check that all connections are clean, tight, and secure. Ensure the battery voltage is above 6 volts.
Display Reading:
Low Solar Voltage
Time of Day:
Daytime
The voltage from the panel in good sun conditions should be 16 to 23 VDC. The image above shows low solar voltage.
Possible Causes:
The panel is covered by something; the PV panel is too dirty to supply a high enough voltage to charge the battery; the PV panel is not connected with the output of the solar panel. Problem with the wiring between the controller and the solar panel.
Remedy:
Check the panel to ensure it is not obscured. Clean the panel if it is dirty. Check that PV cables are connected to the controller. Measure the input voltage at the panel and at the back of the controller. If the controller is not getting voltage and current from the panel it will not charge the batteries.
See link below for soalr panel testing
https://support.gopowersolar.com/support-center/solar-panel-troubleshooting
6.2 PROBLEMS WITH VOLTAGE
Voltage Reading:
Inaccurate
Time of Day:
Daytime/Nighttime
Possible Causes:
Excessive voltage drops from batteries to controller due to loose connections, small wire gauge or both.
How to tell:
- Check the voltage at the controller battery terminals with a voltmeter and compare with the voltage reading at the battery terminals.
- If there is a voltage discrepancy of more than 0.5 V, there is an excessive voltage drop.
Remedy:
Check all connections from the controller to the battery including checking for correct wire polarity. Check that all connections are clean, tight, and secure. Shorten the distance from the controller to battery or obtain larger gauge wire. It is also possible to double up the existing gauge wire (i.e. two wire runs) to simulate a larger gauge wire.
6.3 PROBLEMS WITH CURRENT
Current Reading:
0 A
Time of Day:
Daytime, clear sunny skies
Possible Cause:
Current is being limited below 1 Amp as per normal operation or poor connection between solar array and controller.
How to tell:
- The State of Charge (SOC) screen is close to 100% and the Sun and Battery icon is present with an arrow between.
- With the solar array in sunlight, check the voltage at the controller solar array terminals with a voltmeter.
- If there is no reading at the controller solar array terminals, the problem is somewhere in the wiring from the solar array to the controller.
Remedy:
Check all connections from the controller to the array including checking for correct wire polarity. Check that all connections are clean, tight, and secure. Continue with the solutions below for additional help on low current readings.
Current Reading:
Less than expected.
Time of Day:
Daytime, clear sunny skies
Possible Causes:
- Current is being limited below 1 Amp as per normal operation.
- Incorrect series/parallel configuration and/or wiring connections and/or wire gauge.
- Dirty or shaded module or lack of sun.
- 4. Output issue with one or more solar panels
- The battery is full
How to tell:
- Battery State of Charge screen is close to 100% and the Sun and Battery icon are present
- Check that the modules and batteries are configured correctly. Check all the wiring and connections.
- Modules look dirty, an overhead object is shading modules, or it is an overcast day in which a shadow cannot be cast.
- Disconnect one or both array wires from the controller. Take a voltage and current reading between the positive and negative array wire. A single 12-volt module should have an open circuit voltage between 17 and 22 volts. Amperage can range from 2-7 to 9 amps depending on size of panel and the sun conditions. If you have more than one solar module, you will need to conduct this test between the positive and negative terminals of each module junction box with either the positive or the negative wires disconnected from the terminal.
Remedy:
- Reconnect in correct configuration. Tighten all connections. Check wire gauge and length of wire run. Refer to Suggested Minimum Wire Gauge in Section 5.
- Clean modules, clear obstruction or wait for conditions to clear.
- If the open circuit voltage of a non-connected 12-volt module is lower than the manufacturer’s specifications, the module may be faulty. Check for blown diodes in the solar module junction box, which may be shorting the power output of module.
Temperature issues Internal and PCB
Possible causes:
- Controller is mounted I such a way that there is no air flow and there is no way the controller can cool itself.
- Controller reading at a higher-than-normal temperature.
Remedy:
- Improve air flow around the controller so it dissipates heat better.
- Replace the controller if the temperature is lower than the recorded controller temperature.
Note: there are two types of temperature errors both pertain to the internal temperature of the controller
Battery and solar polarity issue
Possible causes:
Positive and negative connections reversed from the batteries of the solar panels.
Remedy:
Determine which cables are connected incorrectly by measuring the back of the solar controller with a multimeter. If showing a negative voltage this will indicate the polarity is reversed. Swapping the wires around to the correct position will clear this error state.
Battery and Solar over Voltage errors
Possible Causes:
- Charing source putting too high a voltage to the battery. This can be from a solar controller or any other charging source in the vehicle. (Alternator, Converter /charger, Solar controller?)
- Incorrect wiring. The solar panel outputs a higher voltage if these wires have been placed on the battery connections then an over Voltage error can occur.
Remedy :
- If an alternate source is spiling the battery to much than the source will need to be eliminated or repaired so it does not provide this voltage spike or raise the battery voltage above the error threshold.
- I wiring is incorrect check the back of the controller with a multimeter to determine what the voltage is on each connection point. If the battery connections are between 15 to 23 volts and the solar connections are sitting at battery voltages (10-14) There is a reasonable chance the wires have been placed in the incorrect position. Swapping the wires will solve this problem.
- If there is a solar over voltage error and the controller reads correctly on the battery connections, make sure that the roof panels only input 27 VDC at the most to the controller. A panel that is too large or multiple panels wired is series produce to high a voltage for the controller and produce this same over voltage error.
Solar over voltage error
