Morningstar EC-10 Allgemeine Anweisungen

Solar Charging System Controller

Installation, Operation, and Maintenance Manual

Languages: English, French, German, Spanish

www.morningstarcorp.com

EcoPulse

MODELS

EC-10

EC-10M

EC-20

EC-20M

EC-30

EC-30M

For the most recent manual revisions, see the

version at: www.morningstarcorp.com

TABLE OF CONTENTS

6.30

160

4.33

110

5.51

140

3.54

2.04

DIMENSIONS [inches (millimeters)]

1.0 Important Safety Instructions.............................1

2.0 General Information...........................................6

2.2 Features

...............................................................6

2.3 Optional Accessories

............................................7

3.0 Installation..........................................................8

3.1 General Installation Notes.....................................8

3.2 Configuration

...............................................................9

3.3 Mounting

....................................................................11

3.4 Wiring

.........................................................................13

3.5 Custom Settings

....................................................... 19

3.5.1 Adjusting the Meter Display

....................................19

3.5.2

Directional Key Use and Operation /

Navigating the Meter Map..................................... 19

3.5.3 Using the Meter Display to Program Charging

Set-points and Load Control......................................19

4.0 Operation.........................................................20

4.1 Battery Charging Information.............................20

4.2 Load Information.........................................................22

4.3 LED Indcations............................................................ 22

4.3.1 Power-up..................................................................... 22

4.3.2 Status LED...................................................................23

4.3.3 State-of-charge LEDs................................................. 23

Continued

SPECIFICATION SUMMARY

10/M 20/M 30/M

Nominal Battery voltage 12 / 24V 12 / 24V 12 / 24V

Max. PV Open- Circuit Voltage* 60V 60V 60V

Max. Battery Charging Current 10A 20A 30A

Rated Load Current 10A 20A 30A

* Array voltage should never exceed this limit

iv EcoPulse Operator’s ManualImportant Safety Instructions

1.0

TABLE OF CONTENTS (Cont.)

4.4

Protections, Faults & Alarms................................. 24

4.4.1 Protections...................................................................24

4.4.2 LED Fault Indication.....................................................24

4.4.3 Alarms..........................................................................25

4.5 Inspection and Maintenance.......................................26

5.0 Warranty.................................................................28

6.0 Technical Specifications......................................... 29

Appendix - Certifications.................................................30

SAVE THESE INSTRUCTIONS.

This manual contains important safety, installation,

operating and maintenance instructions for the EcoPulse

solar charge controller.

The following symbols are used throughout this manual

to indicate potentially dangerous conditions or mark

important safety instructions:

WARNING: Indicates a potentially dangerous

condition. Use extreme caution when performing

this task.

CAUTION: Indicates a critical procedure for safe

and proper operation of the controller.

NOTE: Indicates a procedure or function that is

important to the safe and proper operation of the

controller.

Safety Information

• Read all of the instructions and cautions in the

manual before beginning installation.

• There are no user serviceable parts inside the

EcoPulse. Do not disassemble or attempt to repair

the controller.

1.0 IMPORTANT SAFETY INSTRUCTIONS

2EcoPulse Operator’s ManualImportant Safety Instructions

1.0

• Use properly sized conductors and circuit

interrupters.

• This charge controller is to be connected to DC

circuits only. These DC connections are identiﬁed by

the symbol below:

Direct Current Symbol

The EcoPulse controller must be installed by a qualiﬁed

technician in accordance with the electrical regulations

of the country where the product is installed.

A means of disconnecting all power supply poles must

be provided. These disconnects must be incorporated

in the ﬁxed wiring.

The EcoPulse negative power terminals are common,

and must be grounded as instructions, local codes,

and regulations require.

Battery Safety

WARNING: A battery can present a risk of

electrical shock or burn from large amounts

of short-circuit current, ﬁre, or explosion from

vented gases. Observe proper precautions.

WARNING: Risk of Explosion.

Proper disposal of batteries is required. Do

not dispose of batteries in ﬁre. Refer to local

regulations or codes for requirements.

WARNING: Risk Of Electrical Shock.

NO POWER OR ACCESSORY TERMINALS ARE

ELECTRICALLY ISOLATED FROM DC INPUT,

AND MAY BE ENERGIZED WITH HAZARDOUS

SOLAR VOLTAGE. UNDER CERTAIN FAULT

CONDITIONS, BATTERY COULD BECOME OVER-

CHARGED. TEST BETWEEN ALL TERMINALS AND

GROUND BEFORE TOUCHING.

• External solar and battery disconnects are required.

• Disconnect all sources of power to the controller

before installing or adjusting the EcoPulse.

• There are no fuses or disconnects inside the

EcoPulse Do not attempt to repair.

Installation Safety Precautions

• Mount the EcoPulse indoors. Prevent exposure to

the elements and do not allow water to enter the

controller.

• Install the EcoPulse in a location that prevents

casual contact. The EcoPulse 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.

• UL/IEC 62109 certified for use in negative ground or

floating systems only

• Do not smoke near the battery bank.

• Power connections must remain tight to avoid

excessive heating from a loose connection.

4EcoPulse Operator’s ManualImportant Safety Instructions

1.0

CAUTION: When replacing batteries, use

properly speciﬁed number, sizes, types, and

ratings based on application and system

design.

WARNING: Do not open or mutilate

batteries. Released electrolyte is harmful

to skin, and may be toxic.

Servicing of batteries should be performed, or

supervised, by personnel knowledgeable about

batteries, and the proper safety precautions.

• Be very careful when working with large lead-acid

batteries. Wear eye protection and have fresh water

available in case there is contact with the battery

acid.

• Remove watches, rings, jewelry and other metal

objects before working with batteries.

•

Wear rubber gloves and boots

• Use tools with insulated handles and avoid placing

tools or metal objects on top of batteries.

• Disconnect charging source prior to connecting or

disconnecting battery terminals.

• Carefully read the battery manufacturer's

instructions before installing / connecting to, or

removing batteries from, the EcoPulse.

• Be very careful not to short circuit the cables

connected to the battery.

• Have someone nearby to assist in case of an

accident.

• Explosive battery gases can be present during

charging. Be

certain there is enough ventilation to

release the gases.

• Never smoke in the battery area.

• If battery acid comes into contact with the skin,

wash with

soap and water. If the acid contacts

the eye, ﬂood with fresh water and get medical

attention.

• Be sure the battery electrolyte level is correct before

starting charging. Do not attempt to charge a frozen

battery.

• Recycle the battery when it is replaced.

General Information EcoPulse Operator’s Manual 7

2.0

2.1 Features

1 - Charging Status / Error LED

2 - Meter Display (optional)

3 - Battery Status / Fault LED Indicators

4 - Solar Positive and Negative Terminals

5 - Remote Temperature Sensor Terminals (RTS)

6 - Battery Positive and Negative Terminals

7 - DIP Switches

8 - Load Positive and Negative Terminals

9 - Heatsink

10 - Meter Directional Buttons

11 - Local Temperature Sensor

12 - Mini-screwdriver for DIP switch adjustments

and RTS screws

2.0 GENERAL INFORMATION

Figure 2.1. EcoPulse Features

2.2 Optional Accessories

The following accessory is available for purchase

separately from your authorized Morningstar dealer:

Remote Temperature Sensor (Model: RTS)

The RTS measures battery temperature for accurate

temperature compensation, and is recommended

when the ambient battery temperature differs from the

ambient controller temperature by +/- 5ºC or more.

When installed, the EcoPulse will automatically use the

RTS for battery temperature compensation.

Installation EcoPulse Operator’s Manual 9

3.0

3.0 INSTALLATION

3.1 General Installation Notes

• Read through the entire installation section ﬁrst

before beginning installation.

• Do not install in locations where water can enter

the controller.

• Loose power connections and/or corroded wires

may result in resistive connections that melt wire

insulation, burn surrounding materials, or even

cause ﬁre. Ensure tight connections.

• F

or good service life, extreme temperatures and

marine environments should be avoided.

WARNING: Solar and battery fuses or DC

breakers are required in the system. These

protection devices are external to the EcoPulse

controller, and must be a maximum of 15

Amps for the EcoPulse-10/M, 30 Amps for

the EcoPulse-20/M, and 40 Amps for the

EcoPulse-30/M.

WARNING: All breakers must be properly rated

for wire ampacity, which may require less than

the maximum breaker sizes referenced above.

WARNING: Minimum over-current protection

device interrupt ratings must be 2000A

for 12V systems, and 4000A for 24V systems.

NOTE: Carefully observe the LEDs after

each connection. The LEDs will indcate

proper polarity, and a secure connection.

3.2 Conﬁguration

The DIP switch block shown below is used to set the

operating parameters for the EcoPulse.

Switch 1: Lighting Control

With DIP 1 ON, a light connected to the load

terminals will be ON from dusk-dawn.

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

NOTE: Before connecting the battery, measure

the open-circuit voltage. It must be over 10 Volts

tostart the controller. (Cont.)

Installation EcoPulse Operator’s Manual 11

3.0

Switch 7: Battery Equalization

Mode Switch 7

Manual Equalization OFF

Auto Equalization ON

NOTE: Regardless of DIP 7 setting, manual EQ can be initiated using

the on-board meter command, "Start Equalize". For non-meter

versions, DIP 7 only enables or disables auto equalization - manual EQ

is not available.

Switch 8: Current Switching

Mode Switch 8

PWM switching OFF

Slow switching ON

The default (PWM) switching setting (OFF / down) operates

at 300Hz. If load or system noise is an issue, DIP 8 can be set

(ON-up) for slow switching at 1Hz. Standard PWM switching is

recommended when system noise is not a problem.

3.3 Mounting

Inspect the controller for shipping damage. Mount

the EcoPulse to a vertical surface (4-#8 stainless steel

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.

NOTE: The heat sink must be in a vertical

position (ﬁns up and down).

Table 3.1. Battery charging settings for each selectable battery type

If the system voltage DIP Settings Switches are set

to Auto-detect, battery voltage over 15.5V will be

detected as a 24V nominal battery, and the unit will

charge accordingly.

The 12/24V auto selection is done only at start-up,

and the detected system voltage will never change

during operation. It is recommended to set DIPs 2

and 3 to the correct system voltage setting. Only use

the default auto-detect setting if the nominal system

voltage is not known.

Switches 4, 5, 6: Battery Type Selection

Preset EcoPulse battery charging options are shown

in table 3-1 below. All voltage settings listed are

for nominal 12 Volt batteries. Multiply the voltage

settings by two (2) for 24 Volt systems.

NOTE: These settings are general guidelines for use

at the operator’s discretion. Consult the battery

manufacturer for optimal battery charge settings.

DIP

Switch

Settings

4-5-6

Battery

Type

Absorp.

Stage

(volts)

Float

Stage

(volts)

Equalize

Stage

(volts)

Absorp.

Time

(mins)

Equalize

Time

(mins)

Equalize

Timeout

(mins)

Equalize

Interval

(days)

Equalize

Interval

(days)

Equalize

Interval

(days)

off-off-off 1 - Sealed* 14.00 13.50 150

off-off-on 2 - Sealed* 14.15 13.50 14.40 150 60 120 28

off-on-off 3 - Sealed* 14.30 13.50 14.60 150 60 120 28

off-on-on 4- AGM/Flooded 14.40 13.50 15.10 180 120 180 28

on-off-off 5 - Flooded 14.60 13.50 15.30 180 120 180 28

on-off-on 6 - Flooded 14.70 13.50 15.40 180 180 240 28

on-on-off 7 - L-16 15.40 13.40 16.00 180 180 240 14

on-on-on 8 - Custom Custom Custom Custom Custom Custom Custom Custom

Custom Custom

Custom

* “Sealed” baery type includes gel and AGM baeries

Custom

LVD

(volts)

LVR

(volts)

Custom

12.30 13.80

12.10 13.60

11.90 13.40

11.50 13.00

11.70 13.20

11.30 12.80

11.50 12.60

Installation EcoPulse Operator’s Manual 13

3.0

For proper air ﬂow, allow at least 15 cm (6 in) of space

above and below the controller, and 50 mm (2 in) at

the sides - see Figure 3-1 below. Install in an area

protected from direct rain and direct sun.

If the controller is installed in an enclosure, some

ventilation is recommended. Do not locate in an

enclosure where battery gases can accumulate.

6 in / 150 mm

2 in /

50 mm

Figure 3-1. Proper Clearances for Passive Cooling

3.4 Wiring

To battery for

temperature

sensing

Not used in this illustration

To battery (+)

and (-)

terminals

To load (+)

and (-)

terminals

To properly

sized array

REFER TO FIGURE 3.2 WHEN USING THE FOLLOWING

WIRING INSTRUCTIONS

Figure 3-2. Wiring the EcoPulse

Installation EcoPulse Operator’s Manual 15

3.0

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 EcoPulse version being

installed.

STEP 2: Remote Temperature Sensor

WARNING: Risk of Fire.

If no Remote Temperature Sensor (RTS)

is connected, use the EcoPulse 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.

Connect the RTS to the 2-position terminal located

(see ﬁgure). There is no polarity, so the (+) or (-) can

be connected to either screw terminal.

WARNING: Equipment Damage.

Never place the temperature sensor inside

abattery cell. Both the RTS and the battery

will be damaged.

CAUTION: The EcoPulse will use the local

temperature sensor for compensation if the RTS

is not used.

STEP 3:

Grounding

NOTE: Depending on the country of

installation, conductors identiﬁed by the

color green, or a combination of green /

yellow, shall only be used for earthing

conductors.

For safety, and effective lightning protection, it is

recommended, and may be locally required, that

the negative conductor of the charging system be

properly grounded. Use only one system earth

ground. For conductor sizing requirements, refer to

the U.S. National Electrical Code, or applicable local

regulations or code.

STEP 4: Battery Connections

(at battery

OR solar side,

but NOT both)

System Ground

6 in (150 mm)

Max.

Battery (-)

Battery (+)

12V or 24V

Battery

Fuse or breaker sizing

based on required wire

ampacity

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