Morningstar EC-10 General instructions

Solar Charging System Controller
Installation, Operation, and Maintenance Manual
Languages: English, French, German, Spanish
www.morningstarcorp.com
EcoPulse
TM
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

ii
TABLE OF CONTENTS
6.30
160
4.33
110
5.51
140
3.54
90
2.04
52
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

1
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

3
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.

5
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
6
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
1
2
3
78
9
4
56
10
12
11
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
8
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
10
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
Equalize
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
12
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
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
1
5
6
2
3
4
REFER TO FIGURE 3.2 WHEN USING THE FOLLOWING
WIRING INSTRUCTIONS
Figure 3-2. Wiring the EcoPulse

Installation EcoPulse Operator’s Manual 15
14
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