Blue Sky Energy SOLAR BOOST 3024DiL User manual

SB3024iL / SB3024DiL
(SOLAR BOOST™ 3024(D)iL MPPT)
30AMP 24VDC / 40AMP 12VDC MAXIMUM POWER POINT TRACKING
SOLAR CHARGE CONTROLLER
INSTALLATION AND OPERATION MANUAL
THIS MANUAL INCLUDES IMPORTANT SAFETY INSTRUCTIONS FOR MODELS SB3024iL, SB3024DiL
SAVE THESE INSTRUCTIONS
COVERED UNDER ONE OR MORE OF THE FOLLOWING US PATENTS
6,111,391 •6,204,645
© Blue Sky Energy, Inc. 2017 430-0024 F (EN)
2003167
CONFORMS TO:
UL STD. 1741
CERTIFIED TO:
CAN/CSA STD. E335-1/2E
FCC CFR 47 Part 15 Subpart B
This device complies with part 15 of the FCC
rules. Operation is subject to the following two
conditions: 1) This device may not cause
harmful interference, and 2) This device must
accept any interference received, including
interference that may cause undesired
operations.
CONFORMS TO:
EN 61326-1:2006
EN 60335-1:2002 + A11:2004 + A1:2004
EN 60335-2-29:2004

Blue Sky Energy - Solar Boost 3024(D)iL
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TABLE OF CONTENTS
IMPORTANT SAFETY INSTRUCTIONS .................................................................................................................. 2
PRODUCT DESCRIPTION...................................................................................................................................... 3
Part Numbers and Options .................................................................................................................. 3
OPERATION ........................................................................................................................................................ 3
Charge Status Indicator........................................................................................................................ 4
Optional Digital Display........................................................................................................................ 3
Optional Remote Displays.................................................................................................................... 3
Multi-Stage Charge Control ................................................................................................................. 3
Bulk Charge .................................................................................................................... 3
Absorption (Acceptance) Charge ................................................................................... 3
Float Charge................................................................................................................... ..4
Equalization ......................................................................................................................................... 4
Automatic Equalization.................................................................................................. 4
Manual Equalization ...................................................................................................... 4
Current Limit........................................................................................................................................ 4
Temperature and Output Power ......................................................................................................... 4
Optional Temperature Compensation................................................................................................. 5
Maximum Setpoint Voltage Limit ........................................................................................................ 5
Maximum Power Point Tracking (MPPT) ............................................................................................. 5
Multiple Charge Controllers On The IPN Network ............................................................................... 5
INSTALLATION..................................................................................................................................................... 5
Electrostatic Handling Precautions ...................................................................................................... 5
Selecting PV Modules .......................................................................................................................... 6
Solar Boost 3024i Setup....................................................................................................................... 6
As Shipped Factory Default Settings............................................................................... 6
Restoring As Shipped Default Settings ........................................................................... 6
Battery And PV Voltage.................................................................................................. 7
Charge Voltage, Float Voltage & Charge Time ............................................................... 7
Output Current Display .................................................................................................. 8
Battery and PV Wiring ......................................................................................................................... 8
Electromagnetic Compatibility............................................................................................................. 8
Battery Temperature Sensor ............................................................................................................... 8
Auxiliary Output................................................................................................................................... 8
Auxiliary Battery Charge................................................................................................. 9
Load Controller .............................................................................................................. 9
Dusk-to-Dawn Lighting Control...................................................................................... 9
Installing a Multi-Controller System .................................................................................................... 10
Multi-Controller Wiring And Setup ................................................................................ 10
IPN Network................................................................................................................... 10
Mounting ............................................................................................................................................. 11
TROUBLESHOOTING GUIDE ................................................................................................................................ 12
SPECIFICATIONS .................................................................................................................................................. 14
TWO YEAR LIMITED WARRANTY ........................................................................................................................ 15
TABLES AND FIGURES
Table 1 Charge Status Indicator.................................................................................................. 3
Table 2 Maximum Conductor Length - 3% Voltage Drop............................................................ 8
Figure 1 Front Panel and Remote Display Indicators ................................................................... 4
Figure 2 Factory Charge Voltage Setpoint -vs.- Battery Temperature ......................................... 5
Figure 3 Setup and Wiring Diagram ............................................................................................. 7
Figure 4 Auxiliary Output Wiring.................................................................................................. 9
Figure 5 IPN Network Wiring ....................................................................................................... 10
Figure 6 Detailed Dimensional Drawing....................................................................................... 11

Installation and Operation Manual
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IMPORTANT SAFETY INSTRUCTIONS
This manual contains important instructions for Models SB3024iL and SB3024DiL
SAVE THESE INSTRUCTIONS
1. Refer installation and servicing to qualified service personnel. No user serviceable parts in this unit.
2. To reduce the risk of electric shock, fire or personal injury, the following symbols are placed throughout this manual to indicate dangerous
conditions, or important safety or operational instructions.
WARNING
CAUTION
IMPORTANT

Indicates dangerous conditions or electric
shock potential. Use extreme caution.
Indicates items critical to safe installation
or operation of the unit.
Follow these instructions closely for
proper operation of the unit
3. PERSONAL PRECAUTIONS
a) Working in the vicinity of lead-acid batteries is dangerous. Batteries produce explosive gasses during normal operation.
b) To reduce risk of battery explosion, follow these instructions and those published by battery manufacturer and manufacturer of any
equipment you intend to use in vicinity of battery.
c) Someone should be within range of your voice or close enough to come to your aid when you work near a lead-acid battery.
d) Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing or eyes.
e) Wear complete eye protection and clothing protection. Avoid touching eyes while working near battery.
f) If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eye, immediately flood eye with running
cold water for at least 10 minutes and get medical attention immediately.
g) NEVER SMOKE or allow a spark or flame in vicinity of battery.
h) Be extra cautious to reduce risk of dropping metal tool onto battery. It might spark or short circuit battery or other electrical part that
may cause explosion.
i) Remove personal metal items such as rings, bracelets and watches when working with a lead-acid battery. A lead-acid battery can
produce a short circuit current high enough to weld a ring or the like to metal, causing a severe burn.
j) Remove all sources of power, photovoltaic and battery before servicing or installing.
4. CHARGER LOCATION & INSTALLATION
a) This unit is designed to charge 12V (6-cell) or 24V (12-cell) flooded or sealed type lead-acid chemistry batteries within the range of 20 to
10,000 amp-hours. Follow battery manufacturers charging recommendations when considering this unit for use with other battery
chemistry.
b) This unit employs components that tend to produce arcs or sparks. NEVER install in battery compartment or in the presence of
explosive gases.
c) This unit must be installed and wired in accordance with National Electrical Code, ANSI/NFPA 70.
d) Over current protection for the battery must be provided externally. To reduce the risk of fire, connect to a circuit provided with 50A
maximum branch-circuit over current protection in accordance with National Electrical Code, ANSI/NFPA 70.
e) Over current protection for the auxiliary load control output or auxiliary battery charge output must be provided externally. To reduce
the risk of fire, connect to load or auxiliary battery with 25A maximum over current protection in accordance with National Electrical
Code, ANSI/NFPA 70.
f) Insure that unit is properly configured for the battery being charged.
g) Unit is not water tight. Do not expose to rain or snow.
h) Insure all terminating connections are clean and tight. Battery and PV compression terminals are to be tightened to 45 in-lb (5 nm). IPN
Network and battery temperature sensor compression terminals are to be tightened to 2.1 in-lb (0.24 nm). Auxiliary output
compression terminals are to be tightened to 6 in-lb (0.67 nm).
i) Do not connect to a PV array capable of producing greater than 32A short circuit current for 12V nominal PV modules, or 24A short
circuit for PV modules greater than 12V nominal. Limit input short circuit current to 12A if the 24V input 12V output mode is used.
j) This unit is not provided with a GFDI (ground-fault detector/interrupter) device and must be used with an external GFDI device as
required by Article 690 of National Electrical Code for the installation location.
5. PREPARING TO CHARGE
a) Never charge a frozen battery.
b) Be sure battery is mounted in a well ventilated compartment.
c) Add distilled water in each cell of a lead-acid battery until battery acid reaches level specified by battery manufacturer.

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PRODUCT DESCRIPTION
Solar Boost™ 3024iL is multi-stage Maximum Power Point Tracking (MPPT) photovoltaic battery charge controller capable delivering up to
30A or 40A depending on PV modules and battery voltage. The auxiliary output can serve as either a 2A auxiliary battery charger, or as a
20A load controller with or without variable Dusk-to-Dawn lighting control. The 3024 includes an IPN Network interface which allows
multiple charge controllers to communicate with each other and operate as a single charging machine.
PART NUMBERS AND OPTIONS
•SB3024iL .......... Solar Boost 3024iL charge controller •SB3024DiL.........Solar Boost 3024iL controller with volt/amp display
•IPNPRO ............ IPN ProRemote display & battery monitor •IPNPRO-S..........IPN ProRemote with required 500A/50mV current shunt
•CS-500.............. 500A/50mV current shunt •IPNREM.............IPN Remote display
•930-0022-20 .... Battery temperature sensor
OPERATION
Charge control and MPPT operation are fully automatic. At night when PV power production stops, the PV array is disconnected from the
battery to prevent unwanted current drain. There is a 5 second turn-on delay, and a 45 second turn-off delay.
➢The 3024 operates on battery power, not PV power. A battery must be connected with a minimum voltage of 9V
for the unit to operate.
CHARGE STATUS INDICATOR
A charge status indicator is provided on the face of the 3024, and on the optional remote displays. If net battery charge current is greater than
3 to 5A per 100 amp-hours of battery capacity the charge status indicator can provide a rough indication of battery state of charge.
CHARGE STATUS INDICATOR
CHARGE STATUS INDICATOR
CHARGE MODE
APPROXIMATE CHARGE LEVEL
OFF
CHARGE OFF
CONTINUOUSLY ON
BULK
<70% FULL
BLINKING •1 SEC ON / 1 SEC OFF
ABSORPTION (ACCEPTANCE)
70% - 95% FULL
BLINKING •0.2 SEC ON / 1 SEC OFF
FLOAT
FULLY CHARGED
RAPID BLINKING •0.2 SEC ON / 0.2 SEC OFF
EQUALIZE
TABLE 1
OPTIONAL DIGITAL DISPLAY
The SB3024DiL includes a digital display of battery voltage and output charge current. The display alternates between voltage and current
when charging. Current is displayed when the “AMPS” indicator is on and can be the total of all controllers on the IPN network (factory
default), or the current of a single controller on the IPN network. An automatic night time dimming feature reduces display brightness when
PV charge is OFF.
OPTIONAL REMOTE DISPLAYS
Two remote displays are available. The IPN Remote has the same display functionality as the SB3024DiL. The full featured IPN ProRemote
provides setup capability and enhanced monitoring of charge controllers on the IPN network. It also provides a complete battery system
monitor with various amp-hour counters and a highly accurate “fuel gage” type battery level indicator.
MULTI-STAGE CHARGE CONTROL
Bulk Charge
The 3024 will be in Bulk charge when battery voltage is below the Absorption (Acceptance) Charge Voltage setpoint. During Bulk the 3024
delivers as much charge current as possible to rapidly recharge the battery. Automatic current limit prevents output current from
exceeding the 3024’s maximum current rating.
Absorption (Acceptance) Charge
When the battery recovers sufficient charge for voltage to rise to the Absorption (Acceptance) Charge Voltage setpoint (factory set to
14.4/28.8V) current is reduced as necessary to control at the Absorption (Acceptance) Voltage. The 3024 remains in Absorption
(Acceptance) until the battery is fully charged as determined by either;
1. The 3024 has remained in Absorption (Acceptance) for the Charge Time period (factory set to 2 hours).
–OR –
2. With the IPN ProRemote display, net battery charge current while in Absorption (Acceptance) decreases to the Float
Transition Current setting (factory set to 1.5A per 100 amp-hours of battery capacity).


Installation and Operation Manual
Blue Sky Energy | USA | www.blueskyenergyinc.com 4
Float Charge
Once the battery is fully charged a somewhat lower Float Voltage (factory set to 13.2/26.4V) is applied to maintain the battery in a
fully charged state without excessive water loss.
2-STAGE CHARGE CONTROL
Certain battery types or system configurations may require 2-stage charge control. The 3024 can be configured for two stage
Bulk/Absorption charge control by setting the Charge Voltage to "No Float" with the DIP switches, the IPN ProRemote or the UCM.
Refer to the IPN ProRemote or UCM operators manual for their settings.
FRONT PANEL AND REMOTE DISPLAY INDICATORS
Solar Boost 3024iL Solar Boost 3024DiL
FIGURE 1
EQUALIZATION
➢WARNING: Not all batteries can be safely equalized. Equalization should only be performed on vented liquid
electrolyte lead-acid batteries. Always follow battery manufacturers recommendations pertaining to equalization.
Equalization applies a high voltage producing significant battery gassing. Disconnect equipment that cannot
tolerate the high equalization voltage which is temperature compensated.
Periodic equalization improves battery performance and life by bringing all battery cells up to the same specific gravity and eliminating
electrolyte stratification. Equalization parameters are factory set to 15.2/30.4V for 2 hours every 30 days. A minimum net charge current of
approximately 3A per 100 amp-hours of battery capacity is required for proper equalization. If insufficient current is available equalization may
have to be canceled manually since the equalization time accumulator may not complete count down.
The equalization timer is a “time at voltage” time accumulator which counts in 3 minute increments. The equalization timer will not count down
unless the battery is at the equalization voltage setpoint. Unless manually disabled the 3024 will stay in equalize for as long as necessary to
accumulate the required time at voltage. If equalize does not complete by end of the charging day it will resume where it left off the next
charging day.
Automatic Equalization
If DIP switch #5 is turned ON prior to the application of battery power, automatic equalization is enabled. The 3024 will perform
automatic equalization after the set number of days has elapsed. (factory set to 30 days).
Manual Equalization
If DIP switch #5 is turned OFF, equalization is completely disabled. A manual equalize can be performed by turning DIP switch #5 ON,
after battery power is applied. Following completion of a manually initiated equalization cycle, turn DIP switch #5 OFF. If DIP switch #5
remains ON automatic equalize is enabled. Equalization can also be controlled from the IPN ProRemote if DIP switch #5 is ON.
CURRENT LIMIT
Automatic current limit prevents output current from exceeding 40A with 12V batteries and 12V PV’s. If PV open circuit voltage (VOC) ever
exceeds 30V which would occur with PV voltage greater than 12V nominal, current limit will become 30A until the 3024 reboots. Note that
when the 3024 exits current limit, it will briefly enter Absorption (Acceptance) on it’s way back to MPPT even though battery voltage may
be low.
TEMPERATURE AND OUTPUT POWER
When mounted vertically as described in the installation section, the 3024 can deliver full output in an ambient temperature of up to 40C
(104F). If an over temperature condition exists, the 3024 will cycle on/off, reducing average power delivery to within safe limits. During thermal
shutdown the Charge Status Indicator will display an OFF condition.
Charge Status Indicator
Indicator shows present charge
mode and approximate battery
state of charge
AMPS Indicator
Display shows output
current when ON

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OPTIONAL TEMPERATURE COMPENSATION
The optional battery temperature sensor automatically adjusts charge voltage setpoints based on battery temperature which enhances
battery performance and life, and decreases maintenance. The default compensation factor of 5.00mV/C/cell is suitable for most lead-
acid chemistry batteries.
FACTORY DEFAULT CHARGE VOLTAGE SETPOINT -VS.- BATTERY TEMPERATURE
FIGURE 2
MAXIMUM SETPOINT VOLTAGE LIMIT
Regardless of setpoint values entered by the user or result from temperature compensation the 3024 will not apply a charge voltage setpoint
greater than the maximum voltage setpoint limit factory configured to 15.5/31.0V. Note that actual battery voltage may briefly exceed this
value by 0.1 –0.2V as the voltage control servo responds to changes in load.
MAXIMUM POWER POINT TRACKING (MPPT)
Patented MPPT technology can extract more power and increase charge current up to 30% or more compared to conventional controllers.
The principal operating conditions which affect current boost performance are PV array temperature and battery voltage. At constant solar
intensity, available PV voltage and power increase as PV temperature decreases but it takes an MPPT controller to access this extra power.
When PV voltage is sufficiently high in Bulk for MPPT to operate, a constant power output is delivered to the battery. Since output power is
constant a decrease in battery voltage produces a further increase in charge current. This means that the 3024 provides the greatest charge
current increase when you need it most, in cold weather with a discharged battery. In cool comfortable temperatures most systems see about
10 –20% increase. Charge current increase can go to zero in hot temperatures, whereas charge current increase can easily exceed 30% with a
discharged battery and freezing temperatures. For a more complete MPPT description see www.blueskyenergyinc.com.
MULTIPLE CHARGE CONTROLLERS ON THE IPN NETWORK
The IPN network architecture allows multiple charge controllers operate as a single charging machine. Up to 8 IPN compatible charge
controllers can reside on a single network and can share a single display or battery temperature sensor. Charge controllers can be added to
grow a small system into a large system and have this large system operate from the users standpoint as a single charge controller.
INSTALLATION
➢WARNING: Read, understand and follow the Important Safety Instructions in the beginning of this manual before
proceeding. This unit must be installed and wired in accordance with National Electrical Code, ANSI/NFPA 70. Over
current protection must be provided externally. To reduce the risk of fire, connect to a circuit provided with 40A
maximum branch-circuit over current protection (50A with 12V battery and 12V PV modules) in accordance with
National Electrical Code, ANSI/NFPA 70. Do not connect a PV array capable of delivering greater than 24A of short
circuit current ISC at STC (32A with 12V battery and 12V PV modules). Do not connect BAT–and PV–together external
to the unit. The unit is not provided with a GFDI (ground-fault detector/interrupter) device and must be used with an
external GFDI device as required by Article 690 of NEC for the installation location. To reduce risk of electric shock,
remove all sources of power before installing or servicing. Figures 3, 4 and 5 show generalized connections only and
are not intended to show all wiring, circuit protection and safety requirements for a photovoltaic electrical system.
➢CAUTION: The 3024 is protected against reverse battery and PV polarity, and swapped PV and battery connections,
but will be damaged by reverse battery to the PV terminals. Transient voltage lightning protection is provided, but
steady state voltage in excess of 57VDC on the battery or PV terminals will damage the unit. Damage of either type
voids the limited warranty.
ELECTROSTATIC HANDLING PRECAUTIONS
To minimize the likelihood of damage, discharge yourself by touching a water faucet or other electrical ground prior to handling the 3024 and
avoid touching circuit board components. The risk of electrostatic damage is highest when relative humidity is below 40%.

Installation and Operation Manual
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
SELECTING PV MODULES
Voltage, current and power produced by Photovoltaic (PV) modules fluctuate widely with operating conditions. As a result a set of test
conditions referred to as Standard Test Conditions (STC) are used to rate modules in a meaningful manner and accurately predict real world
performance. STC ratings are not maximum or optimal ratings. Conditions can be present where VOC and ISC approach 1.25 times STC ratings
which is why National Electrical Code and our recommendations call for 1.25 derating of both VOC and ISC. Yet in real world conditions IMP is
commonly only about 75 –80% of IMP at STC.
Key PV module specifications;
PMAX Maximum power in watts (PMAX = VMP x IMP)
VOC Voltage with module open circuit (typically 20 –22V for 12V modules)
VMP Voltage where module produces Maximum Power (typically 17 –18V for 12V modules)
IMP Current where module produces Maximum Power
ISC Current with module Short Circuit
The 3024 will provide the best MPPT current boost performance if all PV modules are identical. If module types are mixed, do not put
dissimilar modules in series. Dissimilar modules in parallel should have VMP values within 0.5V or better for 12V modules, and be of the
same basic cell technology so their VMP will tend to track as operating conditions change. If module types are very different consider using a
separate charge controller for each module type to obtain the best MPPT current boost performance.
Select PV modules that do not exceed the maximum ratings shown below, and preferably produce at least 3A of IMP per 100 amp-hours of
battery capacity.
Nominal
Battery
Voltage
Automatic
Current
Limit
Maximum
PV Power
@ STC
Maximum
PV
Isc @ STC
Maximum
PV
VOC @ STC
Recommended range of VMP at STC
Nominal 12V PV
Nominal 18V PV
Nominal 24V PV
12V
40A*
540W
32A*
24.0V*
16.5 –18.5V
-
-
12V
30A
400W
16A
45.6V
-
24.8 –27.8V
-
12V
30A
400W
12A
45.6V
-
-
33.0 –37.0V
24V
30A
800W
24A
45.6V
-
-
33.0 –37.0V
(*) Current rating and current limit are 40A when charging a 12V battery from nominal 12V PV modules. If PV VOC ever exceeds 30V (>12V nominal PV
modules) current rating and current limit become 30A.
SOLAR BOOST 3024 SETUP
➢The 3024 has various setup parameters all of which are preconfigured at the factory. Confirm that the 3024’s
charge parameter settings are within the ranges specified by the battery manufacturer. Default settings are
typically suitable for most flooded or sealed lead-acid batteries and likely require no changes.
➢Setup parameters are divided into two categories, Basic and Advanced. Basic parameters can be configured with
the 3024 alone within limited steps and ranges as shown in Figure 3. Advanced parameters require the IPN
ProRemote to access. The IPN ProRemote also allows basic settings to be configured in smaller steps and over
wider ranges. All setup parameters are retained if power is lost, or the IPN ProRemote is used as a setup tool only
and removed.
As Shipped Factory Default Settings
Basic Settings Advanced Settings
•Charge mode ....................................... 3-stage •Equalize voltage ............................................... 15.2/30.4V
•Absorption (Acceptance) voltage ...... 14.4/28.8V •Equalize time .................................................... 2.0 hours
•Float voltage ........................................ 13.2/26.4V •Auto equalize days ........................................... 30 days
•Charge time ......................................... 2.0 hours •Maximum voltage setpoint limit ...................... 15.5/31.0V
•Equalize................................................. Disabled •Float Transition Current ................................... 1.5A/100 amp-hours
•IPN Network address ........................... 0 (zero) •Temperature compensation factor ................. 5.00mV/C/cell
•Auxiliary Output mode......................... Aux. bat. charger •Load control ON voltage ............................... . 12.6/25.2V
•All DIP switches..................................... OFF •Load control OFF voltage .............................. . 11.5/23.0V
•Current display (SB3024Di) .................. IPN network total •Dusk-to-Dawn lighting control ...................... . Disabled
Restoring As Shipped Factory Default Settings
1. Remove PV and battery power. 4. Return ALL 8 power board DIP switches to their default OFF position.
2. Turn ALL 8 power board DIP switches shown in Figure 3 ON. 5. If display is present, set display DIP’s to #4 ON, #1-3 OFF
3. Restore battery power for 10 seconds, then remove battery power. 6. The unit is now set to as shipped factory default settings.

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Battery and PV Voltage
➢Nominal battery and PV voltage are determined automatically. The battery is considered to be 12V if battery
voltage when first connected is less than 16V, or 24V if battery voltage is greater. PV voltage is also determined
automatically. If nominal PV voltage is changed following installation power must be momentarily removed to
reboot the 3024.
Charge Voltage, Float Voltage & Charge Time
Absorption (Acceptance) Charge Voltage, Float Charge Voltage and Charge Time setpoints can be viewed or changed using the parameter
setup LED’s and DIP switch shown in Figure 3. Operate only one switch at a time. To view the present setting turn the appropriate DIP
switch ON momentarily ( VCHG #8, VFLOT #6 or TCHG #7). For a 24V battery the actual voltage setpoints are doubled.
To change a setting, turn the appropriate DIP switch ON, OFF, and then back ON before the LED’s turn OFF. The 3024 will enter setup
mode and scan through available settings. Turn the DIP switch off at the desired setting to store the new value. If Float Charge Voltage is
set to “No Float” the 3024 operates as a two stage charger, will not switch to Float, and will not display Charge Time on the setup LED’s.
SETUP AND WIRING DIAGRAM
FIGURE 3

Caution: Do not connect PV-
& Bat- together external to
the 3024, improper
operation will result. PV- &
Bat- are connected together
internally.
Optional Battery
Temperature Sensor
Power Board
DIP Switch
Parameter Setup LED’s
Display Board
DIP Switch
40A / 50A Maximum
Battery
Charge Status LED
Auxiliary Output LED

Installation and Operation Manual
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
Output Current Display (SB3024DiL only)
➢The display can show total output current from all networked controllers, or the output current of a single
controller. To show output current from a single controller IPN network address of the display and charge
controller must match.
DISPLAY BOARD
DIP SWITCH
IPN ADDRESS –OUTPUT CURRENT OF SINGLE CHARGER UNIT
TOTAL OUTPUT CURRENT OF ALL
CHARGERS ON IPN NETWORK
0
1
2
3
4
5
6
7
# 1 (A2)
OFF
OFF
OFF
OFF
ON
ON
ON
ON
Don’t care
# 2 (A1)
OFF
OFF
ON
ON
OFF
OFF
ON
ON
Don’t care
# 3 (A0)
OFF
ON
OFF
ON
OFF
ON
OFF
ON
Don’t care
# 4 (IPN Total)
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
BATTERY AND PV WIRING
➢CAUTION: Battery and PV compression terminals accept #142 AWG wire and are tightened to 45 in-lb (5 nm).
IPN network compression terminals accept #2414 AWG wire and are tightened to 2.1 in-lb (0.24 nm). Auxiliary
Output compression terminals accept #2412 AWG wire and are tightened to 6 in-lb (0.67 nm).
➢CAUTION: DO NOT connect Bat–and PV–together external to the 3024 or improper operation will result. Bat–
and PV–connect together internally.
A desirable installation would produce a total system wiring voltage drop of 3% or less. The lengths shown in Table 2 are one way from the PV to
the battery with the 3024 located along the path. Wire length can be increased inversely proportional to actual current. If current was reduced
by ½, wire lengths could doubled and still provide 3% voltage drop.
MAXIMUM CONDUCTOR PAIR LENGTH - 3% VOLTAGE DROP
WIRE GAUGE
AWG
12 VOLT SYSTEM @32A
FEET / METERS
24 VOLT SYSTEM @24A
FEET / METERS
12 AWG
4.0 / 1.2
10.7 / 3.3
10 AWG
6.4 / 2.0
16.9 / 5.2
8 AWG
10.1 / 3.1
26.9 / 8.2
6 AWG
16.1 / 4.9
42.8 / 13.0
4 AWG
25.5 / 7.8
68.1 / 20.7
2 AWG
40.6 / 12.4
108.2 / 33.0
1/0 AWG
64.6 / 19.7
172.2 / 52.5
TABLE 2
ELECTROMAGNETIC COMPATIBILITY
To comply with electromagnetic compatibility requirements the 3024’s battery and PV wiring must be installed in grounded metallic conduit,
and the two clamp on type ferrite suppressors supplied must be installed. Clamp one suppressor around both Bat+ and Bat–cables. Clamp the
second suppressor around both the battery temperature sensor and remote display cables with the cables looped to pass through the core 3
times. If both sensor and display cables are used, the sensor cable outer cover must be stripped back 12” (30cm) so both cables will fit
through the core 3 times. Ensure that the two suppressors are restrained so they will not damage circuit board components. Additional
suppressors can be ordered as BSE p/n 523-0005-01.
BATTERY TEMPERATURE SENSOR
Installation of the optional battery temperature sensor enables temperature compensation of all charge voltage setpoints. In a multi-
controller system a single temperature sensor must connect to the IPN master. Do not attach a sensor or connections other than Blue Sky
Energy battery temperature sensor p/n 930-0022-20. Be certain to observe proper RED/BLK polarity.
AUXILIARY OUTPUT
The auxiliary output can serve one of three functions; 1) a 2A auxiliary battery charger, 2) a 20A load controller with Low Voltage Disconnect
(LVD), or 3) a 20A variable Dusk-to-Dawn lighting load controller. The Charge/Load function is selected by DIP switch #4 shown in Figure 3. The
IPN ProRemote is required to adjust LVD thresholds or enable Dusk-to-Dawn lighting control. Auxiliary outputs in a multi-controller system will
function normally, but only the auxiliary output in the master can be configured or monitored using the IPN ProRemote. The auxiliary output
“Load” LED will illuminate whenever the auxiliary output is ON (*).
➢CAUTION: The auxiliary output cannot perform both auxiliary battery charge and load control functions at the same
time. Do not connect to the 20A Load terminal for auxiliary battery charge.
➢(*) The LOAD indicator light will be ON whenever power is available at the Load and Auxiliary Battery Charge
terminals.


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1) AUXILIARY BATTERY CHARGE –DIP #4 OFF
The auxiliary charge function is used to charge an auxiliary battery of the same voltage as the primary battery. If the primary battery is
charging in Absorption (Acceptance) or Float, up to 2A is diverted to the auxiliary battery at roughly the same charge voltage. Auxiliary
battery charge is disabled during bulk or equalization. Use 14awg wire to minimize voltage drop and 25A over current protection. Auxiliary
battery negative must connect to primary battery negative.
AUXILIARY OUTPUT WIRING
2A Auxiliary Battery Charger 20A Load Controller
FIGURE 4
2) LOAD CONTROLLER –DIP #4 ON
The load controller can deliver up to 20A of continuous output from the battery. Default settings are for LVD operation with ON at VBAT
≥12.6/25.2V, and OFF at VBAT ≤11.5/23.0V, which can be changed using the IPN ProRemote. Operation can also be based on net battery
amp-hours if an IPN ProRemote is present. The ON/OFF condition must be valid for 20 seconds before switching will occur. If the
higher/lower values are reversed the output control logic is inverted. Load negative must connect to battery negative.
➢CAUTION: 25A maximum over current protection for load control output must be provided externally. If the load
control output is configured to operate based on net battery amp-hours, configure ON/OFF voltage thresholds as
well. If amp-hour from full data is not available, voltage based operation will resume. Voltage or amp-hour
ON/OFF thresholds must not be the same value or improper operation will result.
3) DUSK-TO-DAWN LIGHTING CONTROL –DIP #4 ON
An IPN ProRemote with software version V2.00 or later is required to enable lighting control. Refer to IPN ProRemote operators manual
for lighting control setup instructions. Variable time settings are available to turn lighting ON after Dusk (Post-Dusk timer) and/or ON
before Dawn (Pre-Dawn timer). If both timers are set to DISABLED (factory default), the lighting control feature is disabled. If either the
Post-Dusk or Pre-Dawn timers are set to a time value the lighting control feature is enabled. When lighting control is enabled the auxiliary
output is controlled by both the normal load control function and the lighting control function such that whichever function wants the
auxiliary output OFF prevails.
Dusk or night time begins when the charge control system turns OFF which occurs when PV module current drops below 50mA at battery
voltage. Dawn or day time begins when the charge control system turns ON which occurs when PV module current rises to 100mA at
battery voltage. If the Post-Dusk timer was set to 1.0 hour and the Pre-Dawn timer was set to 2.0 hours, lights would turn ON at Dusk,
remain ON for one hour, and then turn OFF. Two hours before Dawn the lights would again turn ON and remain ON until Dawn. For full
Dusk to Dawn lighting set the Post-Dusk timer to 20 hours. Lights will always be OFF when the charge control system is ON.
When the 3024 first receives battery power it does not know when Dawn is expected to occur. As a result Pre-Dawn control does not
operate for the first night. Once a night time period of 4 hours or more is detected this night time period is stored and Pre-Dawn control
will operate. Each subsequent night time period greater 4 hours is added to a filtered average of night time.
INSTALLING A MULTI-CONTROLLER SYSTEM
A communication link is established between controllers by daisy chaining a twisted pair cable from the IPN Network terminal block, controller
to controller (A-to-A, B-to-B) as shown in Figure 5. Up to 8 IPN based charge controllers can be connected together in a multi-controller system.
Device address 0 (zero) is the master and 1 –7 are slaves. The master controls the charging process and directs the activities of the slaves.
The charge control system will start whenever one or more controllers receives PV input power.
Equivalent Circuit
Battery
Load +
20A Maximum
20A
Load
2A
Charge
2A Current
Limiter
Bat+
25A
25A Maximum
Auxiliary
Output LED

Installation and Operation Manual
Blue Sky Energy | USA | www.blueskyenergyinc.com 10
MULTI-CONTROLLER WIRING AND SETUP
➢CAUTION: A multi-controller system requires the following specialized installation and setup:
1) Each controller must connect to and charge the same battery.
2) One controller must be set to IPN address 0 (zero) and the others be set to addresses 1 –7 with no controllers set
the same.
3) Charge parameters are set in the master only.
4) While outputs connect in parallel to a common battery, PV inputs must be completely separate. A large PV array
must be divided into sub-arrays, each with separate PV+ and PV–wiring.
5) All controllers must be connected to the IPN network as shown in Figure 5.
IPN NETWORK WIRING
Master Slave Slave
Address 0 Address 1 Address 2
FIGURE 5
IPN Network Address
➢A single controller must be set to IPN network address 0 (zero). In a multi-controller system one controller must
be set to address 0 (zero) to serve as the master. The other controllers must be set to address 1-7 with no two
controllers set the same.
IPN NETWORK ADDRESS
POWER BOARD
DIP SWITCH
MASTER
SLAVES
0
1
2
3
4
5
6
7
# 1 (A2)
OFF
OFF
OFF
OFF
ON
ON
ON
ON
# 2 (A1)
OFF
OFF
ON
ON
OFF
OFF
ON
ON
# 3 (A0)
OFF
ON
OFF
ON
OFF
ON
OFF
ON
MOUNTING
➢CAUTION: Mount the unit with heatsink fins oriented vertically to promote cooling and do not enclose in a
confined space. The 3024 is not watertight and must be protected from rain, snow and excessive moisture.
Twisted Pair, 18 –22 awg
To Other Slaves


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DETAILED DIMENSIONAL DRAWING
FIGURE 6
TROUBLESHOOTING GUIDE:
SYMPTOM
PROBABLE CAUSE
ITEMS TO EXAMINE OR CORRECT
Completely dead,
no display
No battery power
Battery disconnected, overly discharged (<9V), or connected reverse
polarity. Battery powers unit, not PV.
Unit will not turn
on (charge status
LED off), Display if
present may be OK
PV disconnected
PV reverse polarity
IPN network address set wrong
Low battery power
Extreme voltage fluctuations or
interference has caused
microprocessor lock-up
PV must supply at least 0.15A at just above battery voltage to begin
charge.
Reverse polarity PV will cause heat sink 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.
Battery overly discharged (<9V). Battery powers unit, not PV.
Reboot microprocessor by momentarily removing all power. Reattach
power crisply.
This knockout symmetrically
duplicated in opposite wall
(cabinet top)
Combination ½ - ¾ inch
conduit knockouts, 3 places

Installation and Operation Manual
Blue Sky Energy | USA | www.blueskyenergyinc.com 12
SYMPTOM
PROBABLE CAUSE
ITEMS TO EXAMINE OR CORRECT
Unit cycles on/off
PV- connected to BAT- external to
unit
PV- & BAT- must be separate external to the unit for proper operation and
cannot connect to a common location. External connection prevents
proper operation of internal shunts and current measurement system.
Charge status LED
on., but no output
charge current
Battery voltage greater than charge
voltage setpoint
Battery voltage too low
Unit recognized battery voltage to be
12V when it is actually 24V
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 unit to operate.
Battery voltage is determined automatically when the unit first receives
power. Voltage must be greater than 16V to recognize battery as 24V.
Remove all power, and reapply battery quickly and crisply.
Charge status LED
blinks rapidly
System in equalize mode
Disable equalize via IPN ProRemote, or by turning DIP switch #5 off.
Charge current is
lower than
expected, PV
current may be
low as well
Battery is highly charged
Worn out PV modules
Low insolation
PV- connected to BAT-
Nominal PV voltage has changed
from 18V or 24V to 12V
Current limit has switched to 30A
Normal operation, current is reduced if battery voltage is at setpoint.
Replace, or use as is.
Atmospheric haze, PV’s dirty, sun low on horizon, etc.
PV- & BAT- must be separate external to the unit for proper operation and
cannot connect to a common location. External connection prevents
proper operation of internal shunts and current measurement system.
If PV voltage is changed to 12V, all power must be removed momentarily
to reboot unit and load initial PV control values.
Normal operation. Current limit will change to 30A if PV VOC has exceeded
30V which will occur with greater than 12V nominal PV’s. Reconfigure PV’s
for 12V and reboot 3024 to resume 40A current limit.
MPPT Current
boost is less than
expected
PV maximum power voltage (VMP) is
not much higher than battery
voltage, leaving little extra power to
be extracted
PV’s hot
Nominal PV voltage has changed
from 18V or 24V to 12V
PV’s with low VMP.PV’s with higher VMP produce greater power and
current boost potential. PV’s with VMP 17V work best.
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”, higher battery voltage reduces charge
current increase.
VMP and available power decrease with increasing PV cell temperature.
Cooler PV’s will produce greater boost. It is normal for boost to decrease
as temperature rises.
If PV voltage is changed from to 12V, all power must be removed
momentarily to reboot unit and load initial PV control values.
Auxiliary battery
not charging
Auxiliary output not configured for
auxiliary battery charge
Primary battery not highly charged
Load on Auxiliary battery too high
Confirm dip switch #4 is OFF.
Auxiliary battery will not receive charge unless primary battery is highly
charged in Absorption (Acceptance) or Float.
Maximum auxiliary charge current is roughly 2A. Load may need to be
reduced.

Blue Sky Energy - Solar Boost 3024(D)iL
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SYMPTOM
PROBABLE CAUSE
ITEMS TO EXAMINE OR CORRECT
System appears
OK, but will not
correctly switch
between Bulk,
Absorption(Accept
ance) & Float
Not set for 3 stage charge
System will not switch out of Bulk
and into Absorption (Acceptance) or
Float
System will not switch from Float to
Bulk or Absorption (Acceptance)
System will not switch from
Absorption (Acceptance) to Float
System shows Absorption
(Acceptance) at times but battery
voltage is low and current is very high
near max. rating.
Check Float voltage setpoint.
Battery is highly discharged or very large relative to relative to available
net charge current. PV power may be too low or loads too high.
Normal operation. Unit will stay in Float and not switch to Bulk or
Absorption (Acceptance) until it is unable to hold the battery at the Float
voltage setpoint.
Battery not fully charged. Unit will not switch to Float until battery voltage
remains at the Absorption (Acceptance) voltage setpoint continuously for
the Charge Time period (or net battery current drops to the Float
Transition Current setpoint if using IPN ProRemote).
Normal operation. If the unit enters current limit, it will pass through
Absorption (Acceptance) for about 10 seconds upon exiting current limit
and returning to Bulk/MPPT.
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 to
inappropriate values
Dusk-to-Dawn feature enabled
Confirm dip switch #4 is ON.
Load will shut off if battery voltage drops below OFF threshold (default
11.5/23.0V). Once shut off, the load will turn on until battery voltage is
above ON threshold (default 12.6/25.2V).
Correct settings.
Disable Dusk-to-Dawn control.
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
First valid night time not seen yet
Confirm dip switch #4 is ON and Dusk-to-Dawn enabled.
Load will shut off if battery voltage drops below OFF threshold (default
11.5/23.0V). Once shut off, the load will not come back on until battery
voltage is above ON threshold (default 12.6/25.2V).
Lights will not turn on if charge control system is ON and charging.
Check Post-Dusk and Pre-dawn timer settings
Pre-Dawn lighting will not operate until a valid night time of greater than 2
hours is detected to initialize the night time period.
Dusk-to-Dawn
feature, lights will
not turn OFF or
remain OFF
Auxiliary output not set for load
control
Dusk-to-Dawn feature not enabled.
Timers set incorrectly
Charge control does not turn ON
Confirm dip switch #4 is ON and Dusk-to-Dawn enabled.
Post-Dusk and Pre-dawn timers both set to DISABLED. One or both timers
must be set to enable Dusk-to-Dawn feature.
Correct Post-Dusk and Pre-dawn timer settings.
Check charge control operation
Networked units
do not seem to
coordinate action
or slaves do not
turn on
IPN network address set wrong
Network wiring problem
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.
Confirm wiring. Use IPN ProRemote to View Charge Unit Status and
confirm communication.
Temperature
related functions
do not work.
Temperature sensor missing, failed or
installed reverse polarity
Temperature sensor not installed on
master
If sensor is open, short, reverse polarity or missing unit will operate as if
sensor was at 25C. Sensor voltage when connected should be 2.98V at
25C, changing at +10mV/C.
Temperature sensor must be installed on the master in a multi-controller
system.

Installation and Operation Manual
Blue Sky Energy | USA | www.blueskyenergyinc.com 14
SYMPTOM
PROBABLE CAUSE
ITEMS TO EXAMINE OR CORRECT
Display turns on,
but battery voltage
displays “– ––“
rather than a
number
Display not communicating with
charge controller
Cable faulty
One charge controller only must be Master.
Poor or missing Bat –connections preventing communication
When charger
turns on, output
current displays “–
––“ rather than a
number
Output current display selection set
for an address not present on the IPN
network
Configure display IPN network address to a charger present on the IPN
network.
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.
When charger
turns on, output
current displays
but the value
seems incorrect
Output current display selection set
for wrong IPN network address
Bat–connected to PV–outside
charge controller
Configure display IPN network address DIP switch to read desired output
current.
PV- & BAT- must be separate external to the unit for proper operation and
cannot connect to a common location. External connection prevents
proper operation of internal shunts and current measurement system.
Voltage or current
value displayed
seems to be stuck
and does not
change
Display or charge controller IPN
network addressed has changed
Display not communicating with
charge controller
Configure display IPN network address DIP switch to properly read output
current of a charger present on the IPN network
Intermittent display cable.
Specifications:
SB3024(D)iL @12V
SB3024(D)iL @24V
Maximum PV Power:
540W with 36-cell PV panel(*)
800W with 72-cell PV panel(*)
400W with 60/72-cell PV panel(*)
Rated Battery (Output) Current:
40A with 36-cell PV panel(*)
30A with 72-cell PV panel(*)
30A with 60/72-cell PV panel(*)
Conversion Efficiency:
97% (typical @28V / 24A output)
Power Consumption:
0.35W (typical standby)
Recommended Max Panel Voc at STC:
45.6V (Max Panel Input 57V)
Charge Profile:
Multi-Stage plus Manual or Automatic Equalization
Absorption Voltage:
14.4V(1)
28.8V(1)
Float Voltage:
13.2V(1)
26.4V(1)
Equalization Voltage (if enabled):
15.2V(1)
30.4V(1)
Auxliary Output (option A, B, or C):
A) Auxiliary Battery Charge 2A (2nd battery)
B) Load Control
C) Dusk-to-Dawn (by IPN ProRemote)
Load (LVD) Disconnect/Reconnect Voltage:
11.5V12.6V (1)
23.0V/25.2V(1)
Maximum Auxiliary Output current (option B or C):
20A
Display:
Only version SB3024DiL
Temperature Compensation (by optional Battery Temp. Sensor):
-5.00mV/°C/cell correct factor (Range 0.00 to -8.00mV/°C/cell) (1)
Operating Temperature:
-40°C –40°C
Maximum Full Power Ambient:
40°C
Environmental Protection:
IP20
Weight:
3.95 lb. (1.8 Kg)
Dimensions:
6.86 x 6.6 x 3.38" (17.4 x 16.8 x 8.6 cm)
(*) 36-cell panels are typically referred to as “12V panels” providing Vmp/Voc of ~18V/22V at STC, 60-cell panels refers to "20V panels" (Vmp/Voc ~30V/37V),
72-cell panels refers to "24V panels" (Vmp/Voc ~36V/44V) -(1) Factory default voltages unless programmed via DIP switches or with an IPN ProRemote
display or UCM.
NB. As a part of our continuous improvement process specifications are subject to change without prior notice.

Blue Sky Energy - Solar Boost 3024(D)iL
15 Blue Sky Energy | USA | www.blueskyenergyinc.com
FIVE (5) YEAR LIMITED WARRANTY
Blue Sky Energy, Inc. (hereinafter BSE), hereby warrants to the original consumer purchaser, that the product or any part thereof shall be
free from defects due to defective workmanship or materials for a period of five (5) years subject to the conditions set forth below.
1. This limited warranty is extended to the original consumer purchaser of the product, and is not extended to any other party.
2. The limited warranty period commences on the date the product is sold to the original consumer purchaser. A copy of the original
purchase receipt identifying purchaser and date of purchase, must accompany the product to obtain warranty repairs.
3. This limited warranty does not apply to, and future warranty shall become void, for any product or part thereof damaged by; a)
alteration, disassembly or application of a foreign substance, b) repair or service not rendered by a BSE authorized repair facility, c)
accident or abuse, d) corrosion, e) lightning or other act of God, f) operation or installation contrary to instructions pertaining to the
product, or g) cosmetic aging.
4. If BSE’s examination of the product determines that the product is not defective the consumer shall be charged a test and evaluation
fee of $40 and be responsible for all transportation costs and insurance related to returning the product to the consumer. The
consumer is ultimately responsible for proper installation and operation of the product and BSE’s prior troubleshooting assistance shall
not serve as a waiver of the test and evaluation fee. The test and evaluation fee is subject to change without prior notice.
5. If within the coverage of this limited warranty, BSE shall repair or replace the product at BSE’s sole discretion and return the product
via standard ground transportation of BSE’s choosing within the continental US. The consumer shall be responsible for all
transportation costs and insurance to return the product outside the continental US, and for all transportation costs and insurance
related to expedited return of the product. BSE’s liability for any defective product or any part thereof shall be limited to the repair or
replacement of the product. BSE shall not be liable for any loss or damage to person or property, or any other damages, whether
incidental, consequential or otherwise, caused by any defect in the product or any part thereof.
6. Any implied warranty for merchantability or fitness for a particular purpose is limited in duration to the length of this warranty.
7. To obtain warranty repairs, contact BSE at 760-597-1642 or [e-mail] to obtain a Returned Goods
Authorization (RGA) number. Mark the outside of the package with the RGA number and return the product, postage prepaid and
insured to the address below. The consumer is responsible for all transportation costs and insurance related to returning the product
to BSE, and for any shipping damage which may void the warranty or increase the cost of repairs.