EcoBoost MPPT TM Solar Charging System Controller Installation, Operation and Maintenance Manual For the most recent manual revisions, see the version at: www.morningstarcorp.com www.morningstarcorp.
DIMENSIONS (centimeters) TABLE OF CONTENTS ( 19.6 ) ( 17.0 ) 1.0 Important Safety Instructions............................ 1 2.0 General Information..... .................................... ... 5 2.1 2.2 2.3 (14.8 ) (18.1 ) Overview................................................................. 5 Features.................................................................. 6 Optional Accessories............................................... 8 3.0 Installation.........................................
.....Continued 1.0 IMPORTANT SAFETY INSTRUCTIONS 5.0 Troubleshooting...........................................35 SAVE THESE INSTRUCTIONS. 5.1 5.2 This manual contains important safety, installation, operating and maintenance instructions for the EcoBoost MPPT solar controller. LED Fault Indications...................................................35 Battery Charging and Performance Issues.................39 6.0 Warranty .................................................... 40 7.
Installation Safety Precautions • Mount the EcoBoost MPPT indoors. Prevent exposure to the elements and do not allow water to enter the controller. • Install the EcoBoost MPPT in a location that prevents casual contact. The EcoBoost MPPT heatsink can become very hot during operation. • Use insulated tools when working with batteries. • Avoid wearing jewelry during installation. • The battery bank must be comprised of batteries of same type, make, and age.
4 Important Safety Instructions 2.0 GENERAL INFORMATION 2.1 Overview Thank you for choosing the EcoBoost MPPT charge controller with TrakStarTM MPPT Technology. The EcoBoost MPPT is an advanced maximum power point tracking solar battery charger. The controller features a smart tracking algorithm that finds and maintains operation at the power source's peak power point, maximizing energy harvest.
2.2 Features The features of the EcoBoost MPPT are shown in Figure 2-1 below. An explanation of each feature is provided below. 2.0 2 - Heatsink / Grounding Screw (M4 screw for grounding heatsink) Aluminum heatsink (underneath) to dissipate controller heat (the EcoBoost MPPT is 100% passively cooled for reliability) 3 - Meter Display Digital LCD monitoring and programming display 13 1 12 2 1 - Charging Status / Error LED Indicates charging and error condition statuses.
2.3 Optional Accessories 3.0 The following accessories are available for purchase separately from your authorized Morningstar dealer: 3.1 General Installation Notes • Read through the entire installation section first before beginning installation. • Be very careful when working with batteries. Wear eye protection. Have fresh water available to wash and clean any contact with battery acid. • Use insulated tools and avoid placing metal objects near the batteries.
• The EcoBoost MPPT is designed to regulate ONLY solar (photovoltaic) power. Connection to any other type of power source e.g. wind turbine or generator may void the warranty. However, other power sources can be connected directly to the battery. • The maximum power terminal wire size is #6 AWG / 16 mm2 (solid/multi-strand) or #8 AWG / 10 mm2 (fine strand). Use a flathead insulated screwdriver, and torque tightly up to 3.95 Nm.
Switches 2, 3: System Voltage Three (3) system voltage configurations are available as shown in the table below: System Voltage Switch 2 Switch 3 Auto OFF OFF 12 OFF ON 24 ON OFF Generally, the specfic system voltage is known, and it is best to set DIPs 2,3 accordingly; the auto-detect setting should be used only in rare circumstances. Switches 4, 5, 6: Battery Type Selection Preset EcoBoost MPPT battery charging options are shown in table 3-1 below.
3.3 Mounting 3.4 Wiring Inspect the controller for shipping damage. Mount the EcoBoost MPPT to a vertical surface (4-#8 self-tapping screws are included). Tighten the mounting screws, using care not to crack the plastic case. Do not install directly over an easily combustible surface since the heat sink may get hot under certain operating conditions. 3 3.0 NOTE: The heat sink must be in a vertical position (fins up and down).
STEP 1: Check Controller Limitations Verify that the highest temperature compensated solar array open-circuit voltage (Voc), and load current do not exceed the ratings of the EcoBoost MPPT version being installed. STEP 2: Remote Temperature Sensor WARNING: Risk of Fire. If no Remote Temperature Sensor (RTS) is connected, use the EcoBoost MPPT within 3m (10 ft) of the batteries. Internal Temperature Compensation will be used if the RTS is not connected. Use of the RTS is strongly recommended.
Per IEC 62109, minimum sizes for equipment copper grounding wire are: • EcoBoost MPPT-20 • EcoBoost MPPT-30 • EcoBoost MPPT-40 10 mm2 10 mm2 10 mm2 STEP 4: Battery Connections - see diagram below Be sure that DIP switches 2 and 3 are set for 12 or 24V, as described in Section 3.2 NOTE: Before connecting the battery, measure the open-circuit voltage. It must be over 10 volts to start the controller. If the system voltage Settings Switches are set to Auto-detect, battery voltage over 15.
120Voc Maximum 40 Volt MODULE 40 Volt MODULE 40 Volt MODULE LOAD (+) 3.0 SOLAR (+) Fuse or breaker sizing based on required wire ampacity Solar Disconnect (- ) (+) (- ) (+) (- ) Fuse or breaker sizing based on required wire ampacity (+) LOAD (-) SOLAR (-) STEP 7: Power-Up and Verify System Operation STEP 6: Load Connections - see diagram below CAUTION: Equipment Damage Do not wire any AC inverter to the load terminals of the EcoBoost MPPT. Damage to the load control circuit may result.
• • • • the EcoBoost MPPT is in LVD (red LED on) there is a short circuit in the load (LEDs blinking R/G – Y) there is an overload condition (LEDs blinking R/Y - G) the load is not connected, not working, or turned off After all connections have been completed, observe the LEDs to make sure the controller is operating normally for system conditions. If the optional digital meter is used, observe that the display is scrolling with proper voltage and current values.
VOLTAGE NOTE: These settings are general guidelines for use at the operator’s discretion. The EcoBoost MPPT can be programmed to satisfy a wide range of charging parameters. Consult the battery manufacturer for optimal battery charge settings. EQUALIZE DIP Switch Settings 4-5-6 NIGHT BULK CHARGE ABSORPTION FLOAT NIGHT Figure 4-1. EcoBoost MPPT Charging Algorithm Float Stage (volts) off-off-off 1 - Sealed* 14.00 13.50 off-off-on 2 - Sealed* 14.15 13.50 14.40 off-on-off 3 - Sealed* 14.
4.3 Load Control Information The primary purpose of the load control function is to disconnect system loads when the battery has discharged to a low state of charge, and to reconnect system loads when the battery is sufficiently recharged. System loads may be lights, DC appliances, or other electronic devices. The total current draw of all loads must not exceed maximum load ratings of 20 Amps (EB-20/M) or 30 Amps (EB- 30/M or EB40/M).
4.4 LED Indications KEY: G = green Y = yellow R = red G - Y - R = flashing sequencially G/Y = flashing together G / Y - R = G and Y flashing together, alternating with R flash NOTES: 1) R flashing is generally a user addressable fault / error 2) R charging status LED ON with heartbeat blink OFF every 5 secs is a critical fault that generally requires service. See, "Solid Charging Status LED with Self-test (R-Y-G) SOC Faults", in Section 5.1. 4.4.1. Power-up 4.4.
High Temperature Current Limit The EcoBoost MPPT will limit the solar input current if the heatsink temperature exceeds safe limits. Solar charge current will be tapered back (to 0 amps if needed) to reduce the heatsink temperature. The EcoBoost MPPT is designed to operate at full rated current at the maximum ambient temperature. This alarm indicates that there is insufficient airflow and that the heatsink temperature is approaching unsafe limits.
For metered models, see the included complete meter map insert, also available in the EcoBoost MPPT support documents at: www.morningstarcorp.com 4.6.2 Meter Display Operation 4.6.2.1 Directional Key Use and Operation / Navigating the Meter Map 4.6.2.2 Adjusting the Meter Display The display setting options, as shown in Figure 4-2, are adjustable by using the directional keys to locate and edit a desired setting or variable. 4.
Maintenance Items 2 weeks after installation Re-tighten power terminal connections to specified torque values. 3 months after installation Re-tighten power terminal connections to specified torque values. Monthly or After Each Equalization Inspect the battery bank. Look for cracked or bulging cases, and corroded terminals. For wet cell (flooded type) batteries, make sure the water level is correct. Wet cell water levels should be checked monthly or according to the manufacturer’s recommendations.
Load Short Circuit Error status LED: Flashing red. Battery status LEDs: R/G-Y sequencing. Fully protected against load wiring shortcircuits. After two (2) automatic load reconnect attempts (10 seconds between each attempt) the EcoBoost MPPT will wait, and then automatically reconnect the load, once the short is cleared. High Solar Voltage Disconnect Charging Status LED: R flashing. No battery status errors.
Firmware Update Failure 5.2 Battery Charging and Performance Issues The firmware update was not successfully programmed. The controller will not indicate the full power-up LED sequence of G-Y-R when power to the controller is reset. Instead, the controller will display green, and then stop on yellow. The yellow LED will continue to be lit and the controller will not complete start up or begin charging. Problem: No LED indications, controller does not appear to be powered Re-try the firmware update.
6.0 7.0 WARRANTY LIMITED WARRANTY Morningstar Solar Controllers and Inverters TECHNICAL SPECIFICATIONS EB-MPPT-20/M EB-MPPT-30/M EB-MPPT-40/M Electrical: The EcoBoost MPPT is warrantied to be free from defects in material and workmanship for a period of TWO (2) years from the date of shipment to the original end user. Morningstar will, at its option, repair or replace any such defective products.
Battery Charging Set-points (@ 25°C): Lighting Control (DIP 1 ON): [multiply voltages by (2) for 24 volt systems] Lighting Timer Setting Lighting Test Timer DIP Switch Settings 4-5-6 Float Stage (volts) off-off-off 1 - Sealed* 14.00 13.50 off-off-on 2 - Sealed* 14.15 13.50 14.40 150 60 120 28 11.30 12.80 off-on-off 3 - Sealed* 14.30 13.50 14.60 150 60 120 28 11.50 13.00 off-on-on 4- AGM/Flooded Equalize Stage (volts) Absorp.
8.0 CERTIFICATIONS IEC 62109-1 EN 62109-1 ® TUVRheinland CERTIFIED www.tuv.com ID 0007000000 ALL COMPONENTS REACH COMPLIANT Registration, Evaluation and Authorization of Chemicals EcoBoost MPPT TM Régulateur de charge solaire Solarladesystem-Regler Controlador del sistema de carga solar Manuel de l’utilisateur...46 Bedienerhandbuch.........87 Manual del operador......128 Le présent document est un manuel abrégé.
