SITECNO EQX 500-DC Manuel utilisateur

MATRIX Inverter System User Manual

C/ Can Balmes 1-3, Sta. M. de Palautordera, 08460 Barcelona, Spain. T: +34 938482544, F: +34 938480439, E-mail: info@spanishsolar.com, www.spanishsolar.com

EQX 500-DC Solar Charger

User’s Manual

MATRIX Inverter System User Manual

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Contents

Important safety instructions................................................................................................................................. 6

1. Product description ............................................................................................................................................. 8

1.1 General description...................................................................................................................................... 8

1.2 Features........................................................................................................................................................ 8

1.3 Maximum setpoint voltage limit.................................................................................................................. 8

1.4 Temperature and output power.................................................................................................................... 8

1.5 Maximum power point tracking (MPPT) .................................................................................................... 9

1.6 How MPPT works....................................................................................................................................... 9

1.7 Over voltage / reverse polarity protection ................................................................................................... 9

1.8 Electrostatic handling precautions............................................................................................................... 9

1.9 EQX 500-DC solar charger setup.............................................................................................................. 10

1.9.1 Factory default settings................................................................................................................... 10

1.10 Three stage charge control....................................................................................................................... 10

1.10.1 Bulk charge................................................................................................................................... 10

1.10.2Absorption charge......................................................................................................................... 10

1.10.3 Float charge................................................................................................................................... 10

1.11 Battery temperature sensor (BTS) ........................................................................................................... 11

1.12 Equalization charge ................................................................................................................................. 11

1.12.1 Photovoltaic charge and load controller.........................................................................................11

1.12.2Automatic PV array night disconnect........................................................................................... 12

1.12.3 EQX 500-DC solar chargerload control........................................................................................ 12

1.12.4 Low voltage disconnect................................................................................................................ 12

1.12.5 Low voltage reconnect.................................................................................................................. 12

1.13 Optional accessories ................................................................................................................................ 13

2. Installation.......................................................................................................................................................... 14

2.1 Pre-Installation........................................................................................................................................... 14

2.2 Removing the topcover.............................................................................................................................. 14

2.3 Mounting the EQX 500-DC solar chargercontroller.................................................................................. 15

2.3.1 Mount the EQX 500-DC solar charger charge controller............................................................... 15

2.4 Configuring the EQX 500-DC solar charger charge controller................................................................. 16

2.4.1 Battery type selector can apply different charger method............................................................... 16

2.5 Temperature compensation........................................................................................................................ 17

2.5.1 Temperature compensation based on battery type.......................................................................... 18

2.5.2Automatic battery temperature compensation................................................................................. 18

2.6 Grounding.................................................................................................................................................. 19

2.7 DC terminal connector locations ............................................................................................................... 19

2.8 Wire Size and Over-current Protection Requirements............................................................................... 19

2.8.1 Current Rating ................................................................................................................................ 19

2.8.2 Surge Protection.............................................................................................................................. 20

2.8.3 Over-current Protection .................................................................................................................. 20

2.8.4 Long-distance wire runs.................................................................................................................. 20

2.9 PV Charge And Load Control Mode Wiring............................................................................................. 20

2.10 Easily install in parallel connection......................................................................................................... 22

2.11 Battery type selector................................................................................................................................ 22

2.12 Installing Optional Accessories............................................................................................................... 23

2.13 Reinstalling the Faceplate........................................................................................................................ 23

3. Operation............................................................................................................................................................ 25

3.1 Basic Operation ......................................................................................................................................... 25

3.2 LED Status Indicator ................................................................................................................................. 25

3.2.1 Charge control indications.............................................................................................................. 25

4. Troubleshooting................................................................................................................................................. 27

5. Specifications...................................................................................................................................................... 28

5.1 Specifications............................................................................................................................................. 28

5.2 Environmental............................................................................................................................................ 28

5.2.1 Temperature.................................................................................................................................... 28

5.3 Safety......................................................................................................................................................... 29

5.3.1American market............................................................................................................................. 29

5.3.2 European market............................................................................................................................. 29

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5.4 Humidity.................................................................................................................................................... 29

5.4.1 Operating Humidity........................................................................................................................ 29

5.4.2 Non-Operating Humidity................................................................................................................ 29

5.5 Mechanical features................................................................................................................................... 29

5.6 Detailed dimension drawing...................................................................................................................... 30

6. Batteries.............................................................................................................................................................. 31

6.1 Battery Types............................................................................................................................................. 31

6.2 Automotive Batteries................................................................................................................................. 31

6.3 Maintenance-Free Batteries....................................................................................................................... 31

6.4 Deep-Cycle Batteries................................................................................................................................. 31

6.5 Sealed Batteries ......................................................................................................................................... 31

6.6 NiCad and NiFe Batteries.......................................................................................................................... 31

6.7 Battery Sizing ............................................................................................................................................ 31

6.8 Equalization Charging............................................................................................................................... 32

6.9 Equalization Setpoints (Non-Sealed Batteries Only)................................................................................. 32

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Tables

Table 1 –1: Factory shipping settings ............................................................................................................. 10

Table 1 –2: Battery type selector switch settings............................................................................................ 16

Table 1 –3: Temperature compensation calculation........................................................................................ 18

Table 1 –4: Battery compensation coefficient................................................................................................. 18

Table 1 –5: Minimum wire size...................................................................................................................... 20

Table 1 –6: The LED indicators...................................................................................................................... 26

Table 1 –7: Troubleshooting list ..................................................................................................................... 27

Table 1 –8: Electrical specification................................................................................................................. 28

Table 1 –9: Mechanical specification ............................................................................................................. 29

Table 1 –10: Battery equalization................................................................................................................... 32

Figures

Figure 1 –1: Bulk charge curve....................................................................................................................... 10

Figure 1 –2: PV charge and load controller.................................................................................................... 12

Figure 1 –3: Load controller........................................................................................................................... 12

Figure 1 –4: Removing the topcover .............................................................................................................. 14

Figure 1 –5: Mounting the EQX 500-DC solar charger charge controller...................................................... 15

Figure 1 –6: Battery type selector (B.SEL) .................................................................................................... 16

Figure 1 –7: Safety (Earth) ground................................................................................................................. 19

Figure 1 –8: DC terminal connector locations................................................................................................ 19

Figure 1 –9: PV charge control mode wiring.................................................................................................. 21

Figure 1 –10: Parallel connection................................................................................................................... 22

Figure 1 –11: battery type selector.................................................................................................................. 22

Figure 1 –12: Install BTS ............................................................................................................................... 23

Figure 1 –13: Reinstalling the faceplate......................................................................................................... 24

Figure 1 –14: LED status indicator................................................................................................................. 25

Figure 1 –15: EQX 500-DC solar charger dimension drawing....................................................................... 30

MATRIX Inverter System User Manual

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About This Manual

Purpose

The purpose of this manual is to provide explanations and procedures for installing, operating, maintaining, and

troubleshooting the Solar Charge Controller.

Scope

This manual provides safety guidelines, detailed planning and setup information, procedures for installing the

Solar Charge Controller, as well as information about operating and troubleshooting the unit. It does not provide

details about particular brands of batteries. You need to consult individual battery manufacturers for this

information.

Audience

This manual is intended for anyone who needs to install and operate the Solar Charge Controller. Installers should

be certified technicians or electricians.

Organization

This Manual is organized into six chapters.

Chapter 1. Product description

Chapter 2. Installation

Chapter 3. Operation

Chapter 4. Troubleshooting

Chapter 5. Specification

Chapter 6. Battery

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Save these instructions

This manual contains important instructions for EQX 500-DC solar charger that shall be followed during

installation and maintenance.

General

1. Refer installation and servicing to qualified service personnel. High voltage is present inside unit. Incorrect

installation or use may result in risk of electric shock or fire. No user serviceable parts in this unit.

2. Remove all sources of power, photovoltaic and battery before servicing or installing.

3. Warning –risk of explosive gases

When EQX 500-DC solar charger is working, Please DO NOT touch it because the temperature is

too high.

Working in the vicinity of lead-acid batteries is dangerous. Batteries produce explosive gasses

during normal battery operation.

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.

4. Personal precautions

Someone should be within range of your voice or close enough to come to your aid when you work

near a lead-acid battery.

Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing or eyes.

Wear complete eye protection and clothing protection.Avoid touching eyes while working near

battery.

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.

NEVER smoke or allow a spark or flame in vicinity of battery.

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.

Remove personal metal items such as rings, bracelets, necklaces, 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.

5. Preparing to charge

Never charge a frozen battery.

Be sure battery is mounted in a well-ventilated compartment.

Add distilled water in each cell until battery acid reaches level specified by battery manufacturer.

This helps purge excessive gas from the cells. Do not overfill. For a battery without cell caps,

carefully follow manufacturers charging instructions.

6. Charger location & installation

Controller employs components that tend to produce arcs or sparks. NEVER install in battery

compartment or in the presence of explosive gases.

Protect all wiring from physical damage, vibration and excessive heat.

Insure that the controller is properly setup for the battery being charged.

Do not expose the controller to rain or snow.

Insure all terminating connections are clean and tight to prevent arcing and overheating.

Charging system must be properly installed as described in these instructions prior to operation.

Do not connect to a PV array capable of producing greater than 40 amps of short circuit current @

25°C.

Do not connect input to DC source directly with load, EQX 500-DC solar charger need to .be

MATRIX Inverter System User Manual

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Symbol

--Warning

--Dangerous Voltage

--Alternative Current

--Direct Current

--Protective Earth

--ESD

Abbreviations and Acronyms

BTS

Battery Temperature Sensor

Direct Current

LED

Light Emitting Diode

LVD

Low Voltage Disconnect

LVR

Low Voltage Reconnect

B.SEL

Battery type selector

CHG.MODE

Charge mode

Photovoltaic

MPPT

Maximum Power Point Tracking

PWM

Pulse Width Modulation

Renewable Energy

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EQX 500-DC solar charger is a 40 amp 12/24 voltage Maximum Power Point Tracking (MPPT) photovoltaic (PV)

battery charge controller. Through the use of MPPT technology, EQX 500-DC solar charger can increase charge

current up to 30% or more compared to conventional controllers. Solar Charge Controller’s sophisticated three

stage charge control system can be configured to optimize charge parameters to precise battery requirements. The

unit is fully protected against voltage transients, over temperature, over current, reverse battery and reverse PV

connections. An automatic current limit feature allows use of the full 40 amp capability without worrying about

overload or nuisance fuse blow from excessive current, voltage or amp-hour based load control.

Series pass Pulse Width Modulation (PWM) charge voltage control combined with a multistage charge control

algorithm leads to superior charging and enhanced battery performance. The filtered PWM power control system

uses highly efficient and reliable power MOSFET transistors. The MOSFET’s are turned on and off at high

frequency to precisely control charge voltage and MPPT.

Fully automatic temperature compensation of charge voltage is available to further improve charge control and

battery performance. The optional battery temperature sensor is built for long term reliability. The sensor element

is environmentally sealed and encapsulated into a plastic lug which adheres to directly to the battery terminal and

by RJ11 port connect with the unit, and the EQX 500-DC solar charger also includes an isolated RS232 port for

connection to a PC computer for data logging and system monitoring.

The EQX 500-DC solar charger can easily install in parallel connection, so it also suitable for large system current

application condition.

High converting efficiency up to 97% for minimizing energy loss

Build-in MPPT tracker for optimizing the power transformation

Reversed current protection with fuse

Automatic battery temperature compensation for long-term reliability

Capable of selecting different charging mode for various type of batteries

Capable of connecting additional DC load for wider applications

Three stage charge control system (bulk, absorption, and float mode) with temperature

compensation

LED indicators display charge status in real time

Pulse Width Modulation (PWM) topology combined with a multi-stage charge control

algorithm leads to superior charging and enhanced battery performance

Very cold batteries combined with high charge voltage setpoints can produce voltages high enough to disrupt or

damage other equipment connected to the battery. To minimize possible damage a maximum voltage setpoint limit

feature is provided. The factory defaults can be adjustable using software. Regardless of what setpoint values

result from temperature compensation, the EQX 500-DC solar charger will never attempt to apply a charge

voltage greater than the maximum voltage setpoint limit value.

Over temperature protection is provided to protect the unit from damage due to high output power at high ambient

temperatures. When mounted vertically as described in the installation section, the unit can deliver full output in a

temperature of up to 40ºC, and the unit will de-rate output in 40 –60ºC. While operating in charge mode, the

controller will decrease the charge current to reduce the transistor temperature and the green led will be solid

green. If the EQX 500-DC solar charger connected with DC load, the load is disconnected before the transistors

reach an excessive temperature and the green LED flashes. Once the temperature has dropped, the loads are

reconnected., reducing average power delivery to within safe limits. During thermal shutdown the charge status

indicator will display an “off” condition. Over temperature shutdown occurs when the ambient temperature

reaches 60ºC.

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(

)

MPPT and associated current boost operation is fully automatic and will function whenever sufficient PV voltage

and current are available. The percent increase in output charge current relative to PV current is variable, and will

change with operating conditions. When conditions are such that insufficient PV power is available to produce an

increase in output current, the unit will stop it’s internal DC-DC power conversion and operate as a series pass

PWM controller with very low forward voltage drop.

The principal operating conditions which affect current boost performance are PV array temperature and battery

voltage. At constant solar intensity available PV power changes with PV temperature. A PV array’s power vs.

temperature characteristic is such that a cool PV array can produce a higher voltage and more power, than a hot

PV array. When PV voltage is sufficiently high for MPPT to operate, a constant power output is delivered to the

battery. Since output power is constant while MPPT is operating, a decrease in battery voltage produces

corresponding increase in charge current. This means that the greatest current increase occurs with a combination

of cool ambient temperature and low battery voltage. The unit delivers the greatest charge current increase when

you need it most, in cold weather with a discharged battery. Additionally, anything that can be done to lower PV

array temperature will also lead to increased charge current by increasing PV power production. In

cool/comfortable temperatures and typical battery states of charge, 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.

A PV module is a constant current type device. As shown on a typical PV module voltage vs. current curve,

current remains relatively constant over a wide range of voltage. A typical 75 watt module is specified to deliver

4.45 amps @ 17 volts @ 25 C cell temperature. Conventional PV controllers essentially connect the PV array

directly to the battery when battery is discharged. When a 75 watt module is connected directly to a battery

charging at 12 volts, the module still provides approximately the same current. But, because output voltage is now

at 12 volts rather than 17 volts, module power production is artificially limited and the 75W module only delivers

53 watts. This wastes 22 watts of available power.

Solar Charge Controller’s MPPT technology operates in a very different fashion. Under these conditions EQX

500-DC solar charger calculates the maximum power voltage (V) at which the PV module delivers maximum

power, in this case 17 volts. It then MPPT operates the module 17 volts which extracts maximum available power

from the module. EQX 500-DC solar charger continually recalculates the maximum power voltage as operating

conditions change. Input power from the maximum power tracking controller, in this case 75 watts, feeds a

switching type power converter which reduces the 17 volt input to battery voltage at the output. The full 75 watts

which is now being delivered at 12 volts would produce a current of 6.25 amps. A charge current increase of 1.8

amps or 40% is achieved by converting the 22 watts that would have been wasted into useable charge current.

Note that this example assumes 100% efficiency to illustrate the principal of operation. In actual operation, boost

will be somewhat less.

EQX 500-DC solar charger is fully protected against reverse polarity and high voltage transients for both the PV

and the battery connections. If the battery is connected reverse polarity, EQX 500-DC solar charger will not

operate. If the PV array is connected reverse polarity the charge control system will not turn on.

All electronic circuits may be damaged by static electricity. To minimize the likelihood of electrostatic damage,

discharge yourself by touching a water faucet or other electrical ground prior to handling the unit and avoid

touching components on the circuit boards. The risk of electrostatic damage is highest when relative humidity is

below 40%.

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-D

1.9.1 Factory default settings

Table 1 –1: Factory shipping settings

Basic settings

Charge mode

3 stage

Absorption voltage

14.4/28.8V

Bulk voltage

14.6/29.2V

Float voltage

13.4/26.8V

Equalize

14/28V

EQX 500-DC solar charger is typically configured for a three stage charging process, Bulk, Absorption and Float.

The three stage charge process provides a somewhat higher charge voltage to charge the battery quickly and safely.

Once the battery is fully charged a somewhat lower voltage is applied maintain the battery in a fully charged state

without excessive water loss. The three stage charge process charges the battery as quickly as possible while

minimizing battery water loss and maintenance.

Figure 1 –1: Bulk charge curve

1.10.1 Bulk charge

When charge starts the EQX 500-DC solar charger attempts to apply the bulk charge voltage to the

battery. The system will switch to Bulk charge if the battery is sufficiently discharged and/or insufficient

charge current is available to drive the battery up to the bulk voltage setpoint. During the Bulk charge

stage the unit delivers as much charge current as possible to rapidly recharge the battery. Once the charge

control system enters Absorption or Float, the unit will again switch to Bulk charge if battery voltage

drops below the present charge voltage setpoint.

1.10.2Absorption charge

During this stage, the unit changes to a constant voltage mode where the absorption voltage is applied

to the battery. When charge current decreases to the float transition current setting, the battery is fully

charged and the unit switches to the float stage.

1.10.3 Float charge

During this stage, the float voltage is applied to the battery to maintain it in a fully charged state.

When battery voltage drops below the float setting for a cumulative period, a new bulk cycle will be

triggered.

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