Volt Polska Green Boost 4000 Bypass Solar Controller

1. Important Safety Instructions

Read this user manual carefully before installing and using the MPPT solar electric heating controller. Keep this manual for future use.

The following symbols are used in this manual:

• WARNING! ⚠️ This mark indicates a danger when performing operations.
• CAUTION! ⚠️ This mark indicates key operation steps for safe controller operation.
• NOTE! ? This mark indicates safe operation and correct procedures for the controller.

Security Information:

• Read instructions and precautions carefully before starting installation.
• Do not disassemble the controller for private maintenance.
• Before installing or moving the controller, disconnect all power supplies.
• The controller emits heat during operation, which may cause skin burns. Install in a location not easy to touch.
• Use insulated tools when connecting the power cord.
• Do not wear jewelry when installing the controller.
• Ensure power cord connections are fastened to prevent overheating and fire hazards.
• Use wires and circuit breakers of appropriate specifications.

About the manual

This manual provides detailed installation and operating instructions for the MPPT solar electric heating controller. The installer should have qualified electrical skills and be familiar with solar system design and wiring rules. Installation information is for professional operators.

2. Introduction

2.1 Overview

The MPPT solar electric heating controller provides electric energy generated by solar panels to the electric heating rod with maximum efficiency using MPPT technology. It converts PV direct current into square wave alternating current, suitable for connecting directly to traditional utility water heaters. The controller features intelligent control, and intelligent solar and AC switching.

Read this manual to maximize the advantages of the controller for an optimal solar photovoltaic electric heating system.

2.2 Appearance feature

The controller's appearance and function descriptions are shown in the figure below:

[Controller Front Panel] A green unit with a display screen showing temperature and status indicators (NORMAL, FAULT). It has control buttons: ESC, UP, DOWN, ENTER. Below the screen are terminals labeled L, N, PE, +, -, and numbered 1 through 5.

[Controller Rear Panel] A diagram showing various terminals and connection points.

2.3 Datasheet

Photovoltaic characteristics

AC characteristics

Load requirement

Machine characteristics

2.4 System diagram

2.4.1 Working principle diagram

[Working principle diagram] A schematic showing PV input (+/-), AC input (L, N, PE), and AC output (LOAD L, LOAD N, PE) connected through an MPPT inverter, control power supply unit, CPU control unit, and LED display operation interface. It also shows an OUTPUT Relay and ground connections.

2.4.2 System wiring diagram

[System wiring diagram] An illustration showing the MPPT Water Heating Controller connected to a 230 Vac AC Grid, a Solar Panel, and a Load. The load can be an Electric water heater, Heating element, or Incandescent bulb. Temperature monitoring is also indicated.

3. Installation notes

3.1 Getting started

The installation environment is critical for controller performance and service life. Install in a dry environment, prevent water infiltration, and ensure sufficient ventilation and airflow.

• Never install the controller in a sealed box!
• This controller cannot be used in parallel!
• Warning: Risk of equipment damage! If installed in a box, ensure sufficient ventilation inside and outside. A closed environment can cause overheating and reduce service life.

Read all installation instructions carefully and operate strictly according to requirements. Improper operation may cause damage.

Install spare tools:

• Wire stripper
• Wire cutter
• Phillips screwdriver
• Crimping tool
• Inflatable drill
• Level
• Hacksaw (for cutting pipelines with protective wires)
• Wall nail

3.2 Installation

3.2.1 Wire diameter selection

Choose a suitable cable diameter to ensure voltage drop is less than 2% of the system voltage between the controller, solar panel, heating rod, and water dispenser.

Minimum wire diameter requirements at 45°C ambient temperature:

3.2.2 Heating rod selection

Output interface: heating load power no more than 230V/4000W, resistance value not less than 13 ohms.

Wall mount installation

Note: Wall-mounted installation is important! The wall or mounting frame must bear the controller's weight to prevent injury and damage from falling.

3.2.3 Wall mounted installation

The controller must be perpendicular to the mounting surface. Deviation over 45 degrees from vertical can cause poor heat dissipation and affect power output.

[Wall mounting diagram] Two views of the controller showing mounting hole dimensions (100.00 mm, 43.00 mm, 201.40 mm, 185.40 mm). Instructions indicate to choose any set of mounting holes and install vertically with expansion screws.

3.2.4 Remove the wiring cover

[Diagram showing wiring cover removal] An illustration depicting the controller with the front panel and the wiring cover being detached.

Warning: Electric DANGER! Before removing the wiring cover, ensure all power sources are disconnected and the controller has stood for at least 5 minutes for residual power discharge. Live operation can be dangerous.

3.2.5 Power cord connection

Warning: Risk of electric shock! The maximum open circuit voltage of the solar panel array should not exceed 420VDC. Ensure solar panels and cables are disconnected before installation.

Follow these steps for terminal connections:

• Ensure all breakers connected to the controller are OFF.
• There is no breaker inside the controller.
• Warning! Note that the positive and negative poles of the solar panel cannot be reversed!
• Warning! Note that it must be ensured that the ground is wired correctly!

1. Connect the solar panel + (positive) wire to the PV+ terminal. Connect the solar panel - (negative) wire to the PV- terminal.
2. Connect the LOAD wire to the OUTPUT terminal. Select LOAD with correct power (not more than 230V/4000W, resistance ≥ 13 ohms). Connect Load L to OUTPUT L, Load N to OUTPUT N, Load PE to OUTPUT PE.
3. Warning! The controller is suitable only for resistance heating components using solar power. Load connection is for resistance heating equipment with mains heating power within 230V/4000W (e.g., AC water heaters, heating wires, heating rods, PTC). Capacitive or inductive loads may damage the controller.
4. AC input connection: Connect the AC Grid line to the AC IN terminal. Connect AC Grid L to AC IN L, AC Grid N to AC IN N, AC Grid PE to AC IN PE.

3.2.6 POWER-ON

Warning! Pay attention to the terminal mark! Connecting PV to AC IN/OUT, or AC IN to PV/AC OUT can cause irreversible damage.

Warning! Note that the polarity is correct! Reversed solar cell array poles will prevent normal operation.

Warning! Note that before powering on, you must ensure that the ground is wired correctly. Poor ground wiring affects mains leakage protection and can endanger the user!

• Confirm solar cell array polarity is correct.
• Confirm the mains plug ground wire is in good condition.
• Close the PV input breaker. If solar panel voltage is suitable, the controller will use solar energy for heating.
• Close the AC input breaker. If solar panel voltage is unavailable, it will switch to AC in and AC out.

3.2.7 POWER-OFF

Warning! Pay attention to the power-off sequence! After ensuring AC and solar panel connections are completely disconnected, other cables can be removed.

4. Operation instructions

After installation, the MPPT controller operates smartly. Solar is the priority source; if insufficient, it switches to AC automatically.

4.1 Maximum power point tracking technology

MPPT technology detects and tracks the maximum power generated by the solar panel in real-time, ensuring the solar cell array operates at its maximum power point. This is achieved automatically through DSP calculations.

4.2 Maximum water temperature setting

Maximum PV heating water temperature setting: On the operation panel, press the UP key ⬆️, then the ENTER key ↵. The PV temperature setting number will flash. Use UP ⬆️ and DOWN ⬇️ keys to select the desired temperature (55°C - 80°C). Press ENTER ↵ to confirm. Press ESC ⎋ to cancel. When PV heating reaches the set temperature, PV heating stops. If the temperature drops by 3°C, PV heating resumes.

Maximum AC heating water temperature setting: On the operation panel, press the UP key ⬆️, then the ENTER key ↵. The AC temperature setting number will flash. Use UP ⬆️ and DOWN ⬇️ keys to select the desired temperature (30°C - 80°C). Press ENTER ↵ to confirm. Press ESC ⎋ to cancel. When AC heating reaches the set temperature, AC heating stops. If the temperature drops by 3°C, AC heating resumes.

4.3 Protection function

• Solar panel power is too high: The controller limits output current to the rated value. If the solar array power exceeds the maximum rated value, the controller will limit output power, potentially not operating at the maximum power point, reducing solar cell utilization.
• Solar panel input line short circuit: A short circuit is equivalent to no solar input. Normal operation resumes after the short circuit is removed.
• Over temperature protection: If ventilation is poor, the controller's temperature may exceed the normal operating range. The controller will reduce photovoltaic output power until it stops. Output automatically restores when the body temperature drops below the protection temperature.

4.3 Alarm function

• AC input voltage high alarm: When AC voltage exceeds 260VAC, the Fault indicator lights up, and AC output is cut off. Operation recovers when voltage drops below 260VAC.
• PV input voltage high alarm: The open circuit voltage of the solar cell array connected to the controller should not exceed the rated maximum value. If it exceeds the specified maximum input voltage, the controller will stop working or be damaged.

4.4 Inspection and Maintenance

Perform the following inspections twice a year to extend the controller's service life.

4.4.1 System check

• Confirm the controller is firmly installed and the surrounding environment is clean.
• Ensure good ventilation around the controller and clean dust/debris from its surface.
• Check external power cords for damage (aging, rubbing, bites from insects/animals). Replace if damaged.
• Check external power cords for looseness and tighten if necessary.
• Verify LED indications are consistent with equipment operation. Address any faults or wrong indications promptly.
• Check that all system grounding wires are properly grounded.

4.4.2 Inspection of controller wiring cover

Note: Danger of electric shock! Before removing the wiring cover, ensure all power supplies are disconnected. Do not open the cover until 5 minutes after disconnection.

• Check power cords in the junction box for damage (aging, rubbing, insect/animal bites). Repair or replace if damaged.
• Check power cords in the junction box for looseness and tighten if necessary.

5. Common trouble shooting

1. No LED indicator, controller does not turn on:
   • Solution: Measure PV terminal voltage with a multimeter. Must be above 160 VDC for operation. If voltage is between 160V and 350V and no LED display, contact your local dealer. Measure AC socket L-N voltage; must be above 180VAC. If between 180V and 260V, check AC plug insertion. If no LED display, contact your local dealer. If no voltage at PV terminals, check PV cable condition, fuse, or circuit breaker. If AC socket has no voltage, check AC source.
2. Red fault light is indicator:
   • Solution: Check if the controller triggered a protection condition (Section 4.2) or alarm function (Section 4.3). If not, contact your local dealer.

6. Warranty service regulations and Repair process

6.1 Warranty service regulations

Warranty service: For non-human performance failures within 15 months from the production date, contact your local dealer.

Non-warranty regulations: The following situations are not covered by warranty:

• Human-made damage (accident, negligence, improper installation/use).
• Damage from solar cell voltage, power, or load current exceeding rated values.
• Damage due to selection of over-specification heating rods.
• Unauthorized modification or repair.
• Damage during transportation.
• Damage from natural disasters (lightning, extreme weather).
• Damage from irresistible factors (fire, flood).

The specified scope of use is unique. Over-range applications without manufacturer authorization will not be recognized. Unauthorized modifications or extensions to the warranty are not permitted. The manufacturer is not responsible for economic losses caused by these actions.

WARRANTY CARD

DATE OF PURCHASE:

SHIPPING ADDRESS:

SIGNATURE / STAMP:

DAMAGE DESCRIPTION:

SERVICE COMMENTS:

FILL IN IF NEEDED:

(*) Cross incorrect

I agree to pay the cost of inverter repair due to: expiration of the warranty period / warranty void.

Before repair, service will inform by phone about costs. Attach a copy of the purchase document (receipt or invoice) to the complaint. Full service regulations are on www.voltpolska.pl.

Proper disposal of the product (waste electrical and electronic equipment)

This marking indicates the product should not be disposed of with household waste. To prevent environmental harm, separate this product from other waste and recycle responsibly. For recycling information, contact the retailer or local government authority. Business users should contact their supplier. This product should not be disposed of with commercial waste.

[CE marking] [WEEE symbol]