Specialty Concepts MARK/22 - Manual (Page 6)

T R O U B L E S H O O T I N G
These sections can assist in the troubleshooting of a solar system.
• HELP NOTES: - lists some common problems with a solar system.
• MARK/(15,20,22) Problems: - If a problem is suspected based on the observations of the MARK/(15,20,22) controller, find the condition on the
MARK/(15,20,22) PROBLEMS chart. It will direct you to a “MARK/(15,20,22) NOTE”.
• Fuse Removal Test: - provides a simple test to confirm operation.
• Battery Problems: - If you feel your batteries are not being adequately charged or are consistently being over-charged, refer to the section BATTERY
PROBLEMS.
• Solar Panels Problems: - If you feel that the solar panels are not performing adequately, refer to the section SOLAR PANEL PROBLEMS.
NORMAL CONDITIONS
:
1. “ALWAYS CHARGING” or “NEVER CHARGING” - Depending on your system, it may be normal for the MARK/(15,20,22) to go for long periods of
constant charging or long periods with no charging. The function of the MARK/(15,20,22) is to prevent over-charging of the battery. Therefore, it will
charge continuously when the battery voltage is low and stop all charging as long as the battery voltage is high.
2. BATTERY WATER LOSS - It is normal for unsealed batteries to need some water from time to time. Minor water loss is not a problem; just add to the top
level when needed. Excessive water loss (a quart or more in a period of a month depending on battery size) may indicate a more serious problem.
3. BATTERY GASSING - In vented batteries, some gassing is good. Gassing stirs up the battery acid and allows the battery to fully charge. A little bubbling
in the batteries is not necessarily a problem. Refer to BATTERY WATER LOSS above.
4. TEMPERATURE - Temperature can affect the performance of batteries. They will tend to over-charge easier when hot, and will not have as much capacity
when cold. Temperature can also affect the performance of the solar panels. The charging current can be substantially higher in cold conditions. When
sizing the system, consider the current at cold conditions. Most panel specifications include a temperature chart.
PROBLEM CONDITIONS:
5. SYSTEM IS NOT SIZED CORRECTLY - The system batteries will tend to be under-charged if the solar array is too small, or if the battery bank is too
small, or if the usage is too high. Some systems contain small hidden loads that can slowly draw down the battery.
6. PROBLEMS WITH SOLAR PANELS - Solar panel output is dependent upon the amount of sun-energy reaching the panel. This can be seriously affected by
the angle of the panel and sun (as in winter months), minor shading, high level haze (barely visible) and dust on the panel. At the time of installation, a solar
array can have an incorrect series-parallel configuration for the proper system voltage and current. A panel can also become less productive or defective
over time. TEST: Disconnect the MARK/(15,20,22) from the panel, and measure the voltage at panel(+) and panel(-). In sunny conditions, this should be 18-
24 volts. A lower value may indicate a problem with the panel. To check the panel’s current output, contact a local solar dealer.
7. PROBLEMS WITH BATTERIES - At the time of installation, a battery bank can have an incorrect series-parallel configuration for the proper system voltage
and current. A battery can also go bad and be unable to maintain a charge. If the battery is going bad, a little charging or discharging will cause a large
change in the battery voltage. Also, a shorted battery cell will cause the battery to gas heavily and the system will charge constantly will no notable increase
in voltage. If the condition of the battery is suspect, a battery capacity test is recommended.
8. BAD CONNECTION: PANEL - The solar panel connection to the controller may be weak or completely out. Problems can be found at the
MARK/(15,20,22) connection (ARRAY(+) & ARRAY(–) terminals), both panel connections (“+” or “–”), the Array Fuse on MARK/(15,20,22) (either blown
or defective), or fuses and unsoldered crimp connectors in these lines. Also, wire that is too small for the length of the run may cause a problem. Refer to
INSTALLATION INSTRUCTIONS, step #17: CHECK FOR VOLTAGE DROP (Page 3).
9. BAD CONNECTION: BATTERIES - The battery connection to the controller may be weak or completely out. The MARK/(15,20,22) needs to read an
accurate battery voltage to regulate the charging correctly. Therefore, you need to minimize the voltage drop from the battery. Problems can be found
with the MARK/(15,20,22) connection (BATT(+) and BATT(–) terminals), both battery terminals (“+” or “–”), the Battery Fuse on MARK/(15,20,22) (either
blown or defective), or fuses and unsoldered crimp connectors in these lines. Also, small wire or incorrect wiring may cause a voltage drop. Refer to
INSTALLATION INSTRUCTIONS, step #12: MARK/(15,20,22) CONNECTION (Page 3) and step #17: CHECK FOR VOLTAGE DROP (Page 3).
10. CONTROLLER MISWIRED - This may include reversing the polarity from the panels or batteries, or switching the array and battery connections. This may
also include a deviation from the wiring instructions, such as using a jumper across the BATTERY(-) & ARRAY(-) connections or by having your
battery(–) connection run to a frame or chassis and not the actual battery itself. Refer to INSTALLATION INSTRUCTIONS, step #12: MARK/(15,20,22)
CONNECTION (Page 3).
11. INCORRECT VOLTAGE SET-POINT - The MARK/(15,20,22) may be functional but the charge termination set-point may not be correct for your
batteries. The factory set-point is 14.4 volts and is designed to work for the majority of batteries. Set the front panel switch position to “CHARGE SET-
POINT” and verify set-point. Refer to the ‘CHARGE SET-POINT ADJUSTMENT” section (Page 4) and consider if an adjustment may be necessary.
12. SYSTEM NOISE - The MARK/(15,20,22) can be affected by electrical noise from a converter or inverter. This will not affect the charging function but will
cause erratic meter readings. If the MARK/(15,20,22) is connected to a buss that is connected to a converter, try connecting the MARK/(15,20,22)
directly to the battery instead.
13. CONTROLLER DEFECTIVE - The MARK/(15,20,22) may no longer be functional. A defective unit can overcharge the battery or stop all charging. A faulty
unit can not drain a battery. It may have been exposed to high voltage or current, reverse polarity from the batteries or other wiring problem.
HELP NOTES :
Normal Conditions and Common Problems
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