SUNSAVER MPPT TM WITH TRAKSTARTM MPPT TECHNOLOGY Installation and Operation Manual Model: SS-MPPT-15L www.morningstarcorp.
SunSaver MPPT Dimensions Specification Summary System Voltage Rated Battery Current Rated Load Current Maximum Input Voltage* Nominal Maximum 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.
Contents 1.0 Important Safety Information 1.0 Important Safety Instructions 2.0 General Information 4 4 9 2.1 Overview 9 2.2 Features 10 2.3 Optional Accessories 12 2.3 Regulatory Information 13 3.0 Installation Instructions 15 4.0 Operation 28 5.0 Troubleshooting 41 6.0 Warranty 7.0 Technical Specifications Appendix A - Wire Chart 43 44 49 3.1 General Installation Notes 15 3.2 Configuration 16 3.3 Mounting 19 3.4 Wiring 21 4.
1.0 Important Safety Instructions 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. CAUTION: Indicates a critical procedure for safe and proper operation of the controller.
NOTE: PROPER DISPOSAL OF BATTERIES IS REQUIRED. REFER TO YOUR LOCAL CODES FOR DISPOSAL REQUIREMENTS; WARNING: These servicing instructions are for use by qualified personnel only. To reduce the risk of electric shock, do not perform any servicing other than that specified in the operating instructions unless you are qualified to do so. WARNING: EXPLOSION HAZARD - DO NOT DISCONNECT WHILE CIRCUIT IS LIVE UNLESS AREA IS KNOWN TO BE NON-HAZARDOUS.
Informations de sécurité • • • • • Lisez toutes les instructions et les avertissements figurant dans le manuel avant de commencer l’installation. Le SunSaver ne contient aucune pièce réparable par l’utilisateur. Ne démontez pas ni ne tentez de réparer le contrôleur. Déconnectez toutes les sources d’alimentation du contrôleur avant d’installer ou de régler le SunSaver. Le SunSaver ne contient aucun fusible ou interrupteur. Ne tentez pas de réparer.
1.0 Installation Safety Precautions WARNING: This unit is not provided with a GFDI device. This charge controller must be used with an external GFDI device as required by the Article 690 of the National Electrical Code for the installation location. • • • • • • • • • • Mount the SunSaver-MPPT indoors. Prevent exposure to the elements and do not allow water to enter the controller. Install the SunSaver in a location that prevents casual contact. The SunSaver heatsink can become very hot during operation.
AVERTISSEMENT: L’appareil n’est pas fourni avec un dispositif GFDI. Ce contrôleur de charge doit être utilisé avec un dispositif GFDI externe tel que requis par l’Article 690 du Code électrique national de l’emplacement de l’installation. • • • • • • • • • • • • Montez le SunSaver à l’intérieur. Empêchez l’exposition aux éléments et la pénétration d’eau dans le contrôleur. Utilisez des outils isolés pour travailler avec les batteries. Évitez le port de bijoux pendant l’installation.
2.0 General Information 2.1 Overview 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 for adjustability, a meter port, and terminals for remote battery temperature measurement (optional).
2.2 Features The features of the SunSaver MPPT are shown in Figure 1 below. An explanation of each feature is provided. 8 7 1 6 5 2 4 3 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. 2.
4 - Meter Connection A communication port for the Morningstar Remote Meter or Personal Computer (PC) connection. A MSC adapter is required, available separately. 6 - Remote Temperature Sensor (RTS) Terminals Connection point for a Morningstar RTS (optional) to remotely monitor battery temperature. NOTE: The use of a Remote Temperature Sensor is strongly recommended. Controller location, air flow, and system power can drastically affect the local temperature sensor reading.
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.
2.3 Regulatory Information NOTE: This section contains important information for safety and regulatory requirements. 2.0 The SunSaver-MPPT controller should be installed by a qualified technician according to the electrical rules of the country in which the product will be installed.
Changes or modifications not expressly approved by Morningstar for compliance could void the user’s authority to operate the equipment. Note: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation.
3.0 Installation Instructions 3.1 General Installation Notes • Read through the entire installation section first before beginning installation. • Use insulated tools and avoid placing metal objects near the batteries. • Explosive battery gasses may be present during charging. Be certain there is sufficient ventilation to release the gasses. • Do not install in locations where water can enter the controller.
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.
3.0 Figure 2. Removing the Battery Select jumper. Load Control – Low Voltage Disconnect / Reconnect Choose between two (2) load control Low Voltage Disconnect / Reconnect settings. SWITCH 2 OFF (↓): SWITCH 2 ON (↑): LVD = 11.50 V, LVR = 12.60 V LVD = 11.00 V, LVR = 12.10 V 2 (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.
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 MODBUS® protocol to communicate with a PC2 and Morningstar’s MSView software. MODBUS® is an open communication protocol standard used by Morningstar’s MSView PC software and other 3rd party hardware / software.
3.3 Mounting CAUTION: Equipment Damage or Risk of Explosion Never install the SunSaver-MPPT in an enclosure with vented/flooded batteries. Battery fumes are flammable and will corrode and destroy the SunSaver circuits. PRUDENCE: Endommagement de l’équipement ou risque d’explosion N’installez jamais le SunSaver-MPPT dans une enceinte avec des batteries à évent/à électrolyte liquide. Les vapeurs des batteries sont inflammables et corroderont et détruiront les circuits du SunSaver.
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 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.
3.4 Wiring NOTE: A recommended connection order has been provided for maximum safety during installation. The controller will not be damaged regardless of the sequence of connections. NOTE: To comply with the NEC, the SunSaver-MPPT must be installed using wiring methods in accordance with Article 690 of the latest edition of the National Electric Code, NFPA 70. NOTE: The total current draw of all system loads connected to the SunSaver-MPPT LOAD terminals cannot exceed the controller’s load current rating.
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 (+) 25 AMP FUSE LOAD NEGATIVE (-) Figure 4. Load wiring Connect load positive (+) and negative (-) load wires to the system load(s) or load distribution panel as shown in figure 4. Refer to the wire gauge chart on page 41 of this manual for correct wire size.
Step 2: Battery Wiring WARNING: Shock Hazard Fuses, circuit breakers, and disconnect switches should never open grounded system conductors. Only GFDI devices are permitted to disconnect grounded conductors. BATTERY NEGATIVE (-) BATTERY POSITIVE (+) 25 AMP FUSE 6 in (150 mm) MAX. + - 12V / 24V BATTERY EARTH GROUND Figure 5. Battery wiring. Before connecting the battery, measure the battery voltage. It must be over 7 volts to power the controller.
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. 3.
Step 3: Solar Wiring WARNING: Shock Hazard The solar PV array can produce open-circuit voltages in excess of 60 Vdc when in sunlight. Verify that the solar input breaker or disconnect has been opened (disconnected) before installing the system wires. WARNING: Risk of Damage Connecting the solar array to the battery terminal will permanently damage the SunSaver-MPPT. AVERTISSEMENT : Risque d’endommagement La connexion du réseau solaire sur la borne de la batterie endommagera le SunSaver de façon permanente.
36 V NOMINAL MAX. 12 Volt MODULE 12 Volt MODULE 12 Volt MODULE SOLAR POSITIVE (+) (-) (+) ( -) (+) (-) SOLAR NEGATIVE (-) (+) EARTH GROUND 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. 3.
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. 3 + - 2 1 Figure 7. System Wiring Review Step 6: Install 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.
4.0 Operation 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.
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. Indication Battery Status Load Status Green Fast Flashing (2 Flash / sec) Equalize Charge Load On Green Med.
4.2 TrakStarTM 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 (Vmp) as it varies with weather conditions, ensuring that maximum power is harvested from the array through the course of the day.
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 Vmp. In a 12 V system for example, the battery voltage may range from 10 - 15 Vdc but the module’s Vmp is typically around 17 V. Figure 8 shows a typical current vs. voltage output curve for a nominal 12V off-grid module.
The array Vmp is the voltage where the product of current and voltage (Amps x Volts) is greatest, which falls on the “knee” of the solar module I-V curve as shown in Figure 8. Because Traditional controllers do no operate at the Vmp 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.
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. 4.0 VOLTAGE EQUALIZE NIGHT MPPT CHARGE ABSORPTION FLOAT NIGHT TIME Figure 9. SunSaver MPPT charging algorithm Bulk Charge In this stage, the battery voltage has not yet reached absorption voltage and 100% of available solar power is used to recharge the battery.
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 Control Settings Load control is fully automatic.
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.
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. Solar Short Circuit (Charging Status LED: OFF) Solar input power wires are short-circuited. Charging automatically resumes when the short is cleared.
High Voltage Input (Charging Status LED: R flashing) If the solar input open circuit voltage (Voc) exceeds the 75 volt maximum rating the array will remain disconnected until the Voc 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.
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 • Tighten all terminals. Inspect for loose, broken, or corroded connections. • Verify that all wire clamps and tie-downs are secure.
4.7 Programming Custom Set-Points CAUTION: This feature should only be used by advanced users who have very specific charging and/or load control 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 set-points can be programmed into SSMPPT non-volatile memory using a PC with Morningstar MSView software installed and a Meterbus to Serial Adapter (model: MSC).
5.0 Trouble Shooting 5.1 Error Indications NOTE: If an optional Morningstar Remote Meter is 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 PV High Voltage Disconnect RTS Shorted RTS Disconnected Damaged local temp. sensor Damaged heatsink temp.
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.
6.0 Warranty The SunSaver MPPT charge controller is warranted to be free from defects in material and workmanship for a period of 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.
7.0 Technical Specifications Electrical Nominal system voltage Max. battery current Battery voltage range Max. solar input voltage Nominal Maximum Input Power* 12 Volt 24 Volt Self-consumption Accuracy Voltage Current Meter Connection Transient Surge Protection 12 or 24 Vdc 15 A 7 – 36 V 75 V 200 Watts 400 Watts 35 mA 1.0 % 2.0 % 6-pin RJ-11 4 x 1500 W Battery Charging Regulation Method Temp. Compensation Coefficient Temp.
Battery Setpoints (@ 25°C) Gel Sealed AGM Flooded Absorption Voltage 14.0 V 14.1 V 14.3 V 14.4 V Float Voltage 13.7 V 13.7 V 13.7 V 13.7 V Time until Float 3 hr 3 hr 3 hr 3 hr Equalize Voltage N/A N/A 14.5 V 14.9 V Equalize Duration N/A N/A 3 hrs 3 hrs Equalize Calendar N/A N/A 28 days 28 days Max. Regulation Voltage1 15 V / 30 V Low Voltage Disconnect 2 11.5 V / 11.0 V 2 12.6 V / 12.1 V Low Voltage Reconnect Not temperature compensated.
Mechanical Power terminals wire size (max.) Solid Multistrand Fine strand Terminal Diameter Power terminals torque (max.) RTS terminals wire size (max.) Wire gauge (min) Wire gauge (max) RTS terminals torque (max.) Dimensions Weight #6 AWG / 16 mm2 #6 AWG / 16 mm2 #8 AWG / 10 mm2 0.210 in / 5.4 mm 35 in-lb / 4 Nm #22 AWG / 0.3 mm2 #12 AWG / 3.0 mm2 0.4 Nm / 3.5 in-lb see inside front cover 1.3 lbs / 0.60 kg Efficiency and Deratings Figure 10.
Figure 11. SS-MPPT 24 Volt Efficiency Curves 7.0 Figure 12. Output Current vs.
Figure 13. Output Current vs. Array Voltage Certifications EMC Directives • Immunity: EN61000-6-2:1999 • Emissions: EN55022:1994 with A1 and A3 Class B1 • Safety: EN60335-1 and EN60335-2-29 (battery chargers) Specifications subject to change without notice. Designed in the U.S.A. Assembled in Taiwan © 2013 Morningstar Corporation MS-ZMAN-SSPPT-C v03 7.
Appendix A - Wire Charts 12 Volt Nominal Wire Chart One-way Wire Distance (feet) Wire Gauge (AWG) amps One-way Wire Distance (meters) Wire Gauge (mm2) 14 12 10 8 6 2.0 3.0 5.0 8.0 13.
