User Manual - PVPower.com
Contents
1. An Advantage Over Traditional Controllers Traditional controllers connect the solar module directly to the battery when recharging This requires that the solar module operate in a voltage range that is below the module s Ve In a 12 V system for example the battery voltage may range from 10 15 Vdc but the module s Vab is typically around 17 V Figure 8 shows a typical current vs voltage output curve for a nominal 12V off grid module MAXIMUM POWER POINT BATTERY VOLTAGE RANGE 10V 15v 17v VOLTAGE Figure 8 Nominal 12 V Solar Module I V curve The array Mao is the voltage where the product of current and voltage Amps x Volts is greatest which falls on the knee of the solar module l V curve as shown in Figure 8 Because Traditional controllers do no operate at the Mop of the solar array energy is wasted that could otherwise be used to charge the battery and power system loads The greater the difference between battery voltage and the Vmp of the module the more energy is wasted TrakStar MPPT technology will always operate at the os resulting in less wasted energy compared to traditional controllers 4 3 Battery Charging Information The SunSaver MPPT has a 4 stage battery charging algorithm for rapid efficient and safe battery charging Figure 9 shows the sequence of the stages BULK FLOAT CHARGE Figure 9 SunSaver MPPT charging algorithm Bulk Charge In this stage the battery voltage has not yet2. 1 Power Into the SS MPPT Power Out of the SS MPPT 2 Volts In x Arrps In Volts Out x Arrps Out assuming 100 efficiency losses in wiring and conversion exist If the solar module s V is greater than the battery voltage it follows that the battery current must be proportionally greater than the solar input current so that input and output power are balanced The greater the difference between the maximum power voltage and battery voltage the greater the current boost Current boost can be substantial in systems where the solar array is of a higher nominal voltage than the battery as described in the next section High Voltage Strings and Grid tie Modules Another benefit of TrakStar MPPT technology is the ability to charge 12 Volt or 24 Volt batteries with solar arrays of higher nominal voltages A 12V battery bank can be charged with a 12 V 24 V or 36 V nominal off grid solar array Certain grid tie solar modules may also be used as long as the solar array open circuit voltage V rating will not exceed the SS MPPT 75 V maximum input voltage rating at worst case coldest module temperature The solar module documentation should provide V vs temperature data Higher solar input voltage results in lower solar input current for a given input power High voltage solar input strings allow for smaller gauge solar wiring This is especially helpful for systems with long wiring runs between the solar array and the SS MPPT
3. Regulation Voltage 15V 30V Low Voltage Disconnect 11 5V 11 0V Low Voltage Reconnect 12 6V 12 1V 1 Not temperature compensated 15 V 12 V nominal 30 V 24 V nominal Adjustable by switch not temperature compensated 11 0 V 12 1 V setting N can be modified in custom settings i21 NOTE Temperature compensation increases regulation sensitive DC loads Environmental Ambient Temperature Range Storage temperature Humidity Enclosure voltage in cold temperature A 15 V 30 V 24 V nominal maximum battery voltage limit prevents damage to 40 C to 60 C 55 C to 100 C 100 N C IP10 indoor Mechanical Power terminals wire size max Solid 6 AWG 16 mm2 Multistrand 6 AWG 16 mm2 Fine strand 8 AWG 10 mm2 Terminal Diameter 0 210 in 5 4 mm Power terminals torque max 35 in lb 4 Nm RTS terminals wire size max Wire gauge min 322 AWG 0 3 mm2 Wire gauge max 12 AWG 3 0 mm2 RTS terminals torque max 0 4 Nm 3 5 in Ib Dimensions see inside front cover Weight 1 3 lbs 0 60 kg Efficiency and Deratings SS MPPT Efficiency 12 Volts Efficiency o 5 so 7 100 E 150 175 20 Output Power Watts Figure 10 SS MPPT 12 Volt Efficiency Curves SS MPPT Efficiency 24 Volt 51 Vmp sms a ee psu 35 Vmp 2 E x z 4 z zd 3 L4 Pa s la uo 7 ex E x 1 m a z5 ET 350 Power Out Watts Figure 11 SS MPPT 24 Vol
4. Battery Jumper Switch1 Flooded REMOVED OFF 1 1 Setpoints for this battery type can be modified with custom program ming See Section 4 7 Programming Custom Setpoints for more informa tion Table 1 Battery Type selection Figure 2 Removing the Battery Select jumper Load Control Low Voltage Disconnect Reconnect Choose between two 2 load control Low Voltage Discon nect Reconnect settings SWITCH 2 OFF 1 SWITCH 2 ON 1 LVD 11 50 V LVR 12 60 V LVD 11 00 V LVR 12 10 V 2 These values can be modified with custom programming See Section 4 7 Programming Custom Setpoints for more information Enable or Disable Auto Equalization Turn the auto equalize feature OFF or ON The auto equalize feature will administer an equalization charge flooded battery type only every 28 days or if the battery discharges too low the previous night There is no equalization charge for the gel or sealed battery type SWITCH 3 OFF AUTO EQUALIZE OFF SWITCH 3 ON 7 AUTO EQUALIZE ON agm flooded battery type only Communication Meter MODBUS Choose the desired communication protocol for the RJ 11 meter connection Select the Meter protocol to communicate with a Morningstar Remote Meter optional accessory Select the MODBUSO protocol to communicate with a PC and Morningstar s MSView software MODBUS is an open communication protocol standard used by Morningstar s MSView PC software a
5. Fuses Install a 25 Amp DC rated fuse in each fuse holder in the following order 1 Load circuit 2 Battery circuit Step 7 Confirm Power up The SS MPPT should begin the power up LED sequence when battery power is applied Observe that the Battery Status LEDs blink in sequence one time If the SS MPPT does not power up or a flashing LED error sequence exists refer to Section 6 0 Troubleshooting 4 1 LED Indications STATUS LED The Status LED indicates charging status and any existing solar input error conditions The Status LED is on when charging during the day and off at night The Status LED will flash red whenever an error condition s exists Table 2 lists the Status LED indications Operating State ff with heartbeat Night On Solid eae with heartbeat Charging Flashing Error On Solid i as with heartbeat Critical Error 1 heartbeat indication flickers the Status LED on briefly every 5 seconds heartbeat indication flickers the Status LED off briefly every 5 seconds Table 2 Status LED definitions For more information on Status LED errors see Section 5 1 Error Indications BATTERY SOC LEDS Three 3 battery state of charge LEDs indicate the level of charge on the battery The SOC indication is based on battery voltage setpoints alone which only provides an approximation of the actual state of charge of the battery Table 3 lists the SOC LED indications SOC LED Indication Battery
6. Status Load Status Fast Flashing 2 Flash sec Equalize Charge Load On Med Flashing 1 Flash sec Absorption Charge Load On Slow Flashing 1 Flash 2 sec Float Charge Load On On solid Nearly Full Load On Yellow On solid Half Full Flashing LVD Warning Red 1 Flash sec Battery Low Load On LVD Red On solid Battery Empty Load Off Table 3 Battery SOC LED definitions SOC LEDs are flashing See Section 5 1 Error Indications N CAUTION An error condition exists if multiple Battery for more information 4 2 TrakStar MPPT Technology The SS MPPT utilizes Morningstar s TrakStar Maximum Power Point Tracking technology to extract maximum power from the solar module s The tracking algorithm is fully automatic and does not require user adjustment Trakstar technology will track the array maximum power point voltage Vinp as it varies with weather conditions ensuring that maximum power is harvested from the array through the course of the day Current Boost In many cases TrakStar MPPT technology will boost the solar charge current For example a system may have 2 Amps of solar current flowing into the SS MPPT and 5 Amps of charge current flowing out to the battery The SS MPPT does not create current Rest assured that the power into the SS MPPT is the same as the power out of the SS MPPT Since power is the product of voltage and current Volts x Amps the following is true
7. controller and drill 3 32 2 5 mm holes in the marked locations Step 5 Secure Controller Place the controller on the surface and align the mounting holes with the drilled holes in step 4 Secure the controller in place using the mounting screws included 3 4 Wiring gt gt y NOTE A recommended connection order has been provided for maximum safety during installation The controller will not be damaged regardless of the sequence of connnections NOTE The SS MPPT is a negative ground controller Any REY combination of negative connections can be earth o grounded as required Grounding is recommended but not required for correct operation CAUTION The total current draw of all system loads connected to the SS MPPT LOAD terminals cannot exceed the 15A load current rating CAUTION For mobile applications be sure to secure all wiring Use cable clamps to prevent cables from swaying when the vehicle is in motion Unsecured cables create loose and resistive connections which may lead to excessive heating and or fire Step 1 Load Wiring The SS MPPT load output connection will provide battery voltage to system loads such as lights pumps motors and electronic devices See Section 4 4 Load Control Information for more details about load control LOAD POSITIVE NEGATIVE Figure 4 Load wiring Connect load positive and negative load wires to the system load s or load distribution panel
8. reached absorption voltage and 100 of available solar power is used to recharge the battery Absorption When the battery has recharged to the Absorption voltage setpoint constant voltage regulation is used to prevent heating and excessive battery gassing Float After the battery is fully charged the SS MPPT reduces the battery voltage to a float charge which is sometimes called a trickle charge Depending on battery history the battery remains in the absorption stage for 3 or 4 hours before transitioning to the float stage Equalize flooded battery type only If the auto equalize feature is enabled the SS MPPT will equalize a flooded battery for three 3 hours every 28 days Equalize charging raises the battery voltage above the standard absorption voltage so that the electrolyte gasses This process prevents electrolyte stratification and equalizesthe individual cell voltages within the battery 4 4 Load Control Information The primary purpose of the load control function is to disconnect system loads when the battery has discharged to a low state of charge and reconnect system loads when the battery is sufficiently recharged System loads may be lights pumps motors DC appliances and other electronic devices The total current draw of all loads must not exceed the SS MPPT 15 Amp maximum load rating load terminals of the SunSaver MPPT Damage to the load control circuit may result Wire inverters directly to i CAU
9. requirements that are not met using the factory default charge and load control settings The factory default settings will be sufficient for the vast majority of users Custom charging and load setpoints can be programmed into SS MPPT non volatile memory using a PC with Morningstar MSView software installed and a Meterbus to Serial Adapter model MSC Refer to the MSView help files for detailed instructions MSView PC software is available for free on our website at http www morningstarcorp com A setup wizard will guide you through the setpoint configuration process Refer to MSView help files for more information To use custom setpoints the Settings Switches must be adjusted as follows SWITCH 1 ON 1 TO USE CUSTOM CHARGING SETPOINTS USE THE BATTERY SELECT JUMPER TO SELECT BETWEEN TWO SETS OF CUSTOM CHARGING SETPOINTS SWITCH 2 ON 1 TO USE CUSTOM LOAD CONTROL SETPOINTS NOTE Programming custom setpoints will overwrite the Cg default Gel and AGM battery type values programmed into custom memory at the factory Document the new custom values in this manual for future reference 5 0 Troubleshooting 5 1 Error Indications NOTE If an optional Morningstar Remote Meter is Fs attached to the SunSaver MPPT use the self diagnostic feature to determine the cause of the error indication Refer to the Remote Meter Operator s Manual for more information Status LED Error Indications PVHigh Voltage Disco
10. solar wiring The solar array high voltage output can cause severe shock or injury Cover modules from the sun before installing solar wiring The SunSaver MPPT can accept 12 V 24 V or 36 V nominal off grid solar module arrays Grid tie solar module s may be used if the open circuit voltage V does not exceed the SS MPPT 75 Volt maximum solar input rating The solar module s nominal voltage must be equal to or greater than the nominal battery voltage For 24 V systems a 24 V or 36 V nominal solar array must be used 36 V NOMINAL MAX 12 Volt 12 Volt 12 Volt MODULE MODULE MODULE SOLAR POSITIVE SOLAR NEGATIVE be AAAS Figure 6 Solar input wiring Connect the solar module s to the SS MPPT Refer to the wire gauge chart on page 41 of this manual for correct wire size If required the negative solar connection may be earth grounded Use appropriate gauge wire and proper grounding methods for the installation site Step 4 Accessories optional Install the Remote Temperature Sensor and Remote Meter both purchased separately if required Refer to the instructions provided with each accessory for detailed installation procedures Step 5 Confirm Wiring Double check the wiring in steps 1 through 4 Confirm correct polarity at each connection Verify that all seven 7 SS MPPT power terminals are tightened Figure 7 System Wiring Review Step 6 Install
11. FIVE 5 years from the date of shipment to the original end user Morningstar will at its option repair or replace any such defective products CLAIM PROCEDURE Before requesting warranty service check the Operator s Manual to be certain that there is a problem with the controller Return the defective product to your authorized Morningstar distributor with shipping charges prepaid Provide proof of date and place of purchase To obtain service under this warranty the returned products must include the model serial number and detailed reason for the failure the module type array size type of batteries and system loads This information is critical to a rapid disposition of your warranty claim Morningstar will pay the return shipping charges if the repairs are covered by the warranty WARRANTY EXCLUSIONS AND LIMITATIONS This warranty does not apply under the following conditions Damage by accident negligence abuse or improper use PV or load currents exceeding the ratings of the product Unauthorized product modification or attempted repair Damage occurring during shipment THE WARRANTY AND REMEDIES SET FORTH ABOVE ARE EXCLUSIVE AND IN LIEU OF ALL OTHERS EXPRESS OR IMPLIED MORNINGSTAR SPECIFICALLY DISCLAIMS ANY AND ALL IMPLIED WARRANTIES INCLUDING WITHOUT LIMITATION WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE No Morningstar distributor agent or employee is authorized to make any modificatio
12. SUNSAVER MPPT WITH TRAKSTAR MPPT TECHNOLOGY Installation and Operation Manual Z TIRAKSTARS MAXIMUM POWER POINT TRACKING Model SS MPPT 15L MORNINGSTAR 1098 Washington Crossing Road Washington Crossing PA 18977 USA www morningstarcorp com SunSaver MPPT Dimensions 6 10 6 64 169mm 155mm 2 73mm i 44 gun T m Ne BERT OB t tumm Specification Summary System Voltage Rated Battery Current Rated Load Current Max Input Voltage Nominal Input Power 12 Volt System 24 Volt System 12 Volts 24 Volts 15 Amps 15 Amps 75 Volts 200 Watts 400 Watts see Section 7 0 for full technical specifications Array voltage should never exceed maximum input voltage Refer to the solar module documentation to determine the high est expected array V as defined by the temperature for the system location lowest expected ambient 1 0 Important Safety Information 2 0 General Information 2 1 Overview 2 3 Optional Accessories 3 0 Installation Instructions 3 1 General Installation Notes 3 2 Configuration 3 3 Mounting 3 4 Wiring 4 0 Operation 4 1 LED Indications 4 2 TrakStar MPPT Technology 4 3 Battery Charging Information 4 4 Load Control Information 4 5 Protections 4 6 Inspection and Maintenance 4 7 Programming Custom Setpoints 5 0 Troubleshooting 5 1 Error Indications 5 2 Comm
13. TION Do not wire an AC inverter of any size to the the battery or battery bank Load Control Settings Load control is fully automatic Choose between two 2 factory Low Voltage Disconnect LVD and Low Voltage Reconnect LVR settings by adjusting switch 2 See Section 3 2 Configuration for more information Current Compensation All LVD and LVR setpoints are current compensated Under load the battery voltage will sag in proportion to the current draw of the load A short term large load could cause a premature LVD without the current compensation feature LVD and LVR setpoints are adjusted lower per the following table System Voltage Current Compensation 12Volt 15 nV per anp of load 24 volt 30 nV per anp of load Table 4 Current compensation values LVD Warning As the battery discharges the Battery Status LEDs will transition from green to yellow and then from yellow to flashing red The flashing red indication is a warning that a low voltage disconnect event will occur soon The amount of time between a green SOC indication and load disconnect will depend on many factors including rate of discharge amount of load draw capacity of the battery health of the battery LVD setpoint If the battery discharges to the LVD setpoint the load will disconnect and a solid red Battery Status LED indication will be displayed General Load Control Notes A 15 V maximum regulation voltage limit 30 V 24 V nom
14. and the load is disconnected The load will automatically reconnect when he heatsink cools to a safe temperature Remote Temperature Sensor RTS Battery Status LED R Y G Y sequencing A bad RTS connection or a severed RTS wire has disconnected the emperature sensor during charging Charging automatically resumes when the problem is fixed To resume operation without a RTS disconnect all power to the SunSaver MPPT and then reconnect High Voltage Transients Solar battery and load power connections are protected against high voltage transients In lightning prone areas additional external suppression is recommended 4 6 Inspection and Maintenance The following inspections and maintenance tasks are recommended at least two times per year for best controller performance Tighten all terminals Inspect for loose broken or corroded connections Verify that all wire clamps and tie downs are secure Check that the controller is mounted in a clean protected environment free of dirt insects nests and corrosion If applicable check enclosure ventilation and air flow holes for obstructions Verify LED indication is consistent with the present system conditions Verify that the Remote Temperature Sensor if used is securely attached to the RTS terminals 4 7 Programming Custom Setpoints CAUTION This feature should only be used by advanced users who have very specific charging and or load control
15. as shown in figure 4 Refer to the wire gauge chart on page 41 of this manual for correct wire size If required the negative load connection may be earth grounded Use appropriate gauge wire and proper grounding methods for the installation site An in line fuse holder should be wired in series in the load positive wire as shown DO NOT INSERT A FUSE AT THIS TIME If wiring the load connection to a load distribution panel each load circuit should be fused separately The total load draw should not exceed the 15 A load rating Step 2 Battery Wiring BATTERY BATTERY POSITIVE NEGATIVE oE 6 in 150 mm MAX Figure 5 Battery wiring Before connecting the battery measure the battery voltage It must be over 7 volts to power the controller For 24 volt systems the battery voltage must be greater than 15 5 volts to properly detect a 24V battery The 12 24 volt battery detection is automatic and the check is only performed at start up Connect the battery to the SS MPPT Refer to the wire gauge chart on page 41 of this manual for correct wire size If required the negative battery connection may be earth grounded Use appropriate gauge wire and proper grounding methods for the installation site Wire an in line fuse holder no more than 6 inches 150 mm from the battery positive terminal DO NOT INSERT A FUSE AT THIS TIME Step 3 Solar Wiring WARNING Risk of electric shock Exercise caution when handling
16. charge controller with TrakStar Technology The SunSaver MPPT SS MPPT is an advanced maximum power point tracking solar battery charger and load controller for stand alone PV systems The controller features a smart tracking algorithm hat maximizes the energy from the solar module s and also provides load control to prevent over discharge of the battery UKA The SS MPPT battery charging process has been optimized for long battery life and improved system performance Self diagnostics and electronic error protection prevent damage when installation mistakes or system faults occur The controller also features four 4 settings switches or adjustability a meter port and terminals for remote battery temperature measurement optional Although the SS MPPT is very simple to configure and use please take the time to read this operator s manual and become familiar with the controller This will help you make ull use of the many advantages the SS MPPT can provide or your PV system The features of the SunSaver MPPT are shown in Figure 1 below An explanation of each feature is provided Figure 1 SunSaver MPPT features 1 Status LED An LED indicator that shows charging status and also indicates when a solar input fault condition exists 2 Power Terminal Block Power terminations for system Solar Battery and Load connections 3 Battery Select Jumper A removable jumper to select the battery type 4 Meter Con
17. disconnected until power is removed and reapplied Solar Short Circuit Charging Status LED OFF Solar input power wires are short circuited Charging automatically resumes when the short is cleared Load Short Circuit Battery Status LEDs R Y G sequencing Fully protected against load wiring short circuits After two 2 automatic load reconnect attempts 10 seconds between each attempt the fault must be cleared by removing and reapplying power High Voltage Input Charging Status LED R flashing If the solar input open circuit voltage V exceeds the 75 volt maximum rating the array will remain disconnected until the V falls safely below the maximum rating Battery Reverse Polarity No LED indication not powered Fully protected against reverse battery connection No damage to the controller will result Correct the miswire to resume normal operation Damaged Local Temperature Sensor Charging Status LED R on solid The local ambient temperature sensor is short circuited or damaged Charging stops to avoid over or under charging This is a critical error Contact your authorized Morningstar dealer for service Damaged Internal Temperature Sensor Charging Status LED R on solid The internal heatsink emperature sensor is damaged This is a critical error Contact your authorized Morningstar dealer for service High Temperature Battery Status LED R Y sequencing The heatsink emperature has exceeded safe limits
18. em operating information error indications and self diagnostic read out Information is displayed on a backlit 4 digit custom LCD display The large numerical display and icons are easy to read and large buttons make navigating the meter menus easy Additionally a status LED and three 3 battery SOC LEDs provide system status at a glance The meter can be flush mounted in a wall or surface mounted using the mounting frame included The RM 1 is supplied with 33 ft 10 0 m of cable a mounting frame and mounting screws The RM 1 connects to the RJ 11 Meter port on the SunSaver MPPT PC MeterBus Adapter Model MSC The MSC converts the MeterBus RJ 11 electrical interface to an isolated standard RS 232 interface which enables communication between the SunSaver MPPT and a personal computer PC The MSC is required for programming custom charging setpoints and for logging data See Section 4 7 Programming Custom Setpoints or visit Morningstar s website for more information 3 0 Installation Instructions 3 1 General Installation Notes Read through the entire installation section first before beginning installation Be very careful when working with batteries Wear eye protection Have fresh water available to wash and clean any contact with battery acid oE Use insulated tools and avoid placing metal objects near the batteries Explosive battery gasses may be present during charging Be certain there is sufficient ventilatio
19. inal exists for all battery types This limit ensures that the battery and load terminal voltages will never exceed 15 V 30 V This protects certain DC loads that may be damaged by high input voltage Do not wire multiple SunSaver MPPT load outputs together in parallel to power DC loads with a current draw greater than 15A Equal current sharing cannot be guaranteed and an over load condition will likely occur on one or more controllers Exercise caution when connecting loads with specific polarity to a live load circuit A reverse polarity connec tion may damage the load Always double check load connections before applying power 4 5 Protections Solar Overload No LED indication The SunSaver MPPT will limit battery current to the 15 Amp maximum rating An over sized solar array will not operate at peak power The solar array should be less than the SS MPPT nominal max input power rating for optimal performance See Section 7 0 Technical Specifications for more information Load Overload Battery Status LEDs R Y G sequencing If the load current exceeds the maximum load current rating the SS MPPT will disconnect the load The greater the overload the faster the load will be disconnected A small overload could take a few minutes to disconnect The SS MPPT will attempt to reconnect the load two 2 times Each attempt is approximately 10 seconds apart If the overload remains after two 2 attempts the load will remain
20. n or extension to this warranty MORNINGSTAR IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND INCLUDING BUT NOT LIMITED TO LOST PROFITS DOWNTIME GOODWILL OR DAMAGE TO EQUIPMENT OR PROPERTY 1098 Washington Crossing Road Washington Crossing PA 19877 USA Email info momningstarcorp com Website www morningstarcorp com 7 0 Technical Specifications Electrical Battery Setpoints 25 C Nominal system voltage Max battery current Battery voltage range Max solar input voltage Nominal Max Input Power 12 Volt 24 Volt Self consumption Accuracy Voltage Current Meter Connection Transient Surge Protection Battery Charging Regulation Method Temp Compensation Coefficient Temp Compensation Range Temp Compensated Setpoints Battery Status LEDs Falling V Rising V GtoY 12 1 13 1 YtoFlashR 11 7 12 6 Flash RtoR 11 5 12 6 Note Multiply x2 for 24 Volt systems 12 or 24 Vdc 15A 7V 36V 75V 200 Watts 400 Watts 35 mA 1 0 96 2 0 6 pin RJ 11 4x 1500 W 4 stage 5 mV C cell 25 C reference 30 C to 60 C Absorption Float Equalize YtoG Flash R to Y RtoY m a amp Absorption Voltage 14 0V 14 1 V 14 3V 14 4 V Float Voltage 13 7V 13 7 V 13 7V 13 7 V Time until Float 3hr 3hr 3hr 3hr Equalize Voltage N A N A 145V 14 9 V Equalize Duration N A N A 3 hrs 3 hrs Equalize Calendar N A N A dai die Max
21. n to release the gasses 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 and use cable clamps to secure cables and prevent them from swaying in mobile applications Only charge lead acid or NiCd batteries The SunSaver MPPT Battery connection may be wired to one battery or a bank of batteries The fol lowing instructions refer to a singular battery but it is implied that the battery connection can be made to either one battery or a group of batteries in a bat tery bank 3 2 Configuration The four 4 Settings Switches and the Battery Select Jumper adjust the SS MPPT battery type load control equalization and communication settings This section details the configuration for each setting Select a Battery Type The SS MPPT provides four 4 different battery types as shown in table 1 below Use Settings Switch 1 and the Battery Select Jumper to choose the battery type See Section 7 0 Technical Specifications for detailed charging information for each battery type The battery select jumper is secured in the terminal block between terminal 6 and terminal 7 as shown in figure 2 The second column in table 1 specifies whether the jumper should be removed or remain in place depending on the desired battery type Battery Type
22. nd other 3rd party hardware software SWITCH 4 OFF MORNINGSTAR REMOTE METER SWITCH 4 ON 7 MODBUS PROTOCOL FOR MSVIEW 3RD PARTY DEVICES 2 Morningstar PC Meterbus Adapter Model MSC required Not included See Morningstar s website for more information www morningstarcorp com MODBUSSG is a registered trademark of Modbus IDA www modbus ida org 3 3 Mounting NOTE When mounting the SunSaver MPPT ensure free Fs air flow through the controller heat sink fins There should be at least 6 inches 150 mm of clearance above and below the controller to allow for cooling If mounted in an enclosure ventilation is highly recommended WARNING Risk of explosion Never install the SunSaver MPPT in a sealed enclosure with vented flooded batteries Do not install in a confined area where battery gasses can accumulate oE Step 1 Choose Mounting Location Locate the SunSaver MPPT on a vertical surface protected from direct sun high temperatures and water Step 2 Check for Clearance Place the SunSaver MPPT in the location where it will be mounted Verify that there is sufficient room to run wires and that there is ample room above and below the controller for air flow AT LEAST 6 150 mm WARM AIR AT LEAST 6 150 mm COOL AIR Figure 3 Mounting and cooling Step 3 Mark Holes Use a pencil or pen to mark the four 4 mounting hole locations on the mounting surface Step 4 Drill Holes Remove the
23. nection A communication port for the Morningstar Hemote Meter or Personal Computer PC connection A MSC adapter is required available separately 5 Settings Switches Adjustment switches that define the operating parameters of the SunSaver MPPT UKA 6 Remote Temperature Sensor RTS Terminals Connection point for a Morningstar RTS optional to remotely monitor battery temperature 7 Local Temperature Sensor Measures ambient temperature Battery regulation is adjusted based on ambient temperature unless an optional RTS is installed 8 Battery Status LEDs Provides approximate battery state of charge indication and also indicates when a system or load fault condition exists 2 3 Optional Accessories The following accessories are 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 5 degrees C or more An RTS can be attached to the SunSaver MPPT at any time The SunSaver MPPT will automatically use the RTS for battery temperature compensation when installed The standard cable length is 33 ft 10 m and can be extended to 100 ft 30 m if required Installation instructions are provided with the RTS Remote Meter Model RM 1 The digital Remote Meter displays syst
24. nnect Flashing Red RTS Shorted Flashing Red RTS Disconnected Flashing Red Damaged local temp sensor Solid Red Damaged heatsink temp sensor Solid Red Damaged input MOSFETs Solid Red Firmware Error Solid Red 1 heartbeat indication flickers the Status LED off briefly every 5 seconds Battery Status LED Error Indications Load High Voltage Disconnect R G Sequencing High Temperature Disconnect R Y Sequencing Remote Temp Sensor Error YIR G Y Sequencing External Wiring Error G R Y Sequencing Load Overcurrent Y R G Sequencing Load Short Circuit G R Y Sequencing Custom Setpoints Update G YIR Flashing Self test Error R Y G Sequencing 5 2 Common Problems Problem No LED indications Solution With a multi meter check the voltage at the battery terminals on the SS MPPT Battery voltage must be at least 7V to power the SS MPPT Problem The SS MPPT is not charging the battery Solution If the Status LED is solid or flashing red see Section 5 1 Error Indications If the Status LED is off measure the voltage across the Solar input terminals of the SS MPPT Input voltage must be greater than battery voltage Check fuses and solar wiring connections Check solar array for shading Full testing documentation is available on our website at http support morningstarcorp com 6 0 Warranty The SunSaver MPPT charge controller is warranted to be free from defects in material and workmanship for a period of
25. on Problems 6 0 Warranty 7 0 Technical Specifications Appendix A Wire Charts oonan A 13 15 20 20 22 25 27 29 31 32 33 33 34 35 36 41 1 0 Important Safety Information Save These Instructions This manual contains important safety installation and operating instructions for the SunSaver MPPT solar 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 A CAUTION Indicates a critical procedure for safe and proper operation of the controller NOTE Indicates a procedure or function that is important for the safe and proper operation of the controller General Safety Information Read all of the instructions and cautions in the manual before beginning installation There are no user serviceable parts inside the SunSaver MPPT Do not disassemble or attempt to repair the controller Disconnect all sources of power to the controller before installing or adjusting the SunSaver MPPT There are no fuses or disconnects inside the SunSaver MPPT Install external fuses breakers as required Donotallow water to enter the controller Confirm that power connections are tightened to avoid excessive heating from a loose connection 2 0 General Information 2 1 Overview Thank you for selecting the SunSaver MPPT
26. t Efficiency Curves Output Current vs Heatsink Temperature a 184 15 N 14 134 gu a HI Ea Ba n E EE 05 at a4 2 14 o 6 62 64 08 68 70 72 74 78 78 80 82 8 86 88 90 Heatsink Temperature degrees C Figure 12 Output Current vs Heatsink Temperature Output Current vs Array Voltage 18 5 u 3 2 Output Current Amps 80 ei 62 63 44 65 68 67 8 6 amp 0 70 T 72 Array Voltage Volts Figure 13 Output Current vs Array Voltage Specifications subject to change without notice Designed in the U S A Assembled in Taiwan 2008 Morningstar Corporation CE MS ZMAN SSPPT A v02 Appendix A Wire Charts 12 Volt Nominal Wire Chart vay Wire Distance meters Wire Gauge mm 3 Voltage drop Annealed copper wire at 20 C 24 Volt Nominal Wire Chart One way Wire Distance feet One way Wire Distance meters Wire Gauge AWG Wire Gauge mm 3 Voltage drop Annealed copper wire at 20 C 36 Volt Nominal Wire Chart ance meters Wire Gauge mm 3 Voltage drop Annealed copper wire at 20 C
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