SUNSAVER MPPT TM WITH TRAKSTARTM MPPT TECHNOLOGY Installation, Operation and Maintenance Manual For the most recent manual revisions, see the version at: www.morningstarcorp.com MAXIMUM POWER POINT TRACKING SS-MPPT-15L www.morningstarcorp.
Contents SunSaver MPPT Dimensions 1.0 Important Safety Information 1.0 Important Safety Instructions 2.0 General Information 15 16 18 20 3.0 Installation Instructions 22 4.0 Operation System Voltage Rated Battery Current Rated Load Current Maximum Input Voltage* Nominal Maximum Input Power** 12 Volt System 24 Volt System 12 / 24 Volts 15 Amps 15 Amps 60 Volts 200 Watts 400 Watts See Section 7.0 for full technical specifications * Array Voltage should never exceed maximum input voltage.
SAVE THESE INSTRUCTIONS. This manual contains important safety, installation, operating and maintenance 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.
Informations de Sécurité • Le SunSaver-MPPT ne contient aucune pièce réparable par l’utilisateur. Ne démontez pas ni ne tentez de réparer le contrôleur. AVERTISSEMENT: RISQUE DE CHOC ÉLECTRIQUE. NON ALIMENTATION OU AUX BORNES D’ACCESSOIRES SONT ISOLÉS ÉLECTRIQUEMENT DE L’ENTRÉE DE C.C ET DOIT ÊTRE ALIMENTÉS À UNE TENSION DANGEREUSE SOLAIRE. SOUS CERTAINES CONDITIONS DE DÉFAILLANCE, LA BATTERIE POURRAIT DEVENIR TROP CHARGÉE. TEST ENTRE TOUTES LES BORNES ET LA MASSE AVANT DE TOUCHER.
• Utilisez des outils isolés pour travailler avec les batteries. • Évitez le port de bijoux pendant l’installation. The SunSaver-MPPT controller must be installed by a qualified technician in accordance with the electrical regulations of the country where the product is installed. A means of disconnecting all power supply poles must be provided. These disconnects must be incorporated in the fixed wiring.
Battery Safety WARNING: A battery can present a risk of electrical shock or burn from large amounts of short-circuit current, fire, or explosion from vented gases. Observe proper precautions. AVERTISSEMENT: Une batterie peut présenter a risque de choc électrique ou de brûlure de grandes quantités de court-circuit curlouer, incendie ou explosion de ventilé gaz. Observer précautions appropriées. WARNING: Risk of Explosion. Proper disposal of batteries is required. Do not dispose of batteries in fire.
• If battery acid comes into contact with the skin, wash with soap and water. If the acid contacts the eye, flood with fresh water and get medical attention. • Be sure the battery electrolyte level is correct before starting charging. Do not attempt to charge a frozen battery. • Recycle the battery when it is replaced. • Entretien des batteries devrait être effectué ou supervisé, par un personnel bien informé sur les piles et les précautions de sécurité appropriées.
2.0 General Information • Recyclez la batterie quand elle est remplacée. 2.1 Overview Thank you for selecting the SunSaver MPPT charge controller with TrakStar TechnologyTM. 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 that maximizes the energy from the solar module(s) and also provides load control to prevent over-discharge of the battery.
2.2 Features The features of the SunSaver MPPT are shown in Figure 1 below. An explanation of each feature is provided. 4 - Meter Connection A communication port for the Morningstar Remote Meter or personal computer (PC) connection. A MSC or UMC-1 adapter is required, available separately. 7 1 6 6 - Remote Temperature Sensor (RTS) Terminals Connection point for a Morningstar RTS (optional) to remotely monitor battery temperature.
2.3 Optional Accessories The following accessories are available for purchase separately from your authorized Morningstar dealer. 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. A RTS will provide optimal charging performance. Remote Meter (Model: RM-1) The digital Remote Meter displays system operating information, error indications, and a self-diagnostic read-out.
2.4 Regulatory Information NOTE: This section contains important information for safety and regulatory requirements. SunSaver-MPPT controllers comply with the following EMC standards: • Immunity: EN61000-6-2:1999 • Emissions: EN55022:1994 with A1 and A3 Class B1 • Safety: EN60335-1 and EN60335-2-29 (battery chargers) FCC requirements: This device complies with Part 15 of the FCC rules.
3.0 Installation 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. • Solar and battery fuses or DC breakers are required in the system. These protection devices are external to the SunSaver-MPPT controller, and must be a maximum of 22.5 Amps.
3.2 Configuration The four (4) Settings Switches and the Battery Select Jumper are used to adjust the SS-MPPT battery type, load control, equalization, and communication settings. This section details the configuration for each setting. Battery Type Battery Jumper Switch 1 Gel1 INSERTED ON (↑) Sealed INSERTED OFF (↓) AGM1 REMOVED ON (↑) Flooded REMOVED OFF (↓) (1) Set-points for this switch setting can be modified with custom programming. For more information, see Section 4.
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.
3.4 Wiring AT LEAST 6” (150 mm) AT LEAST 6” (150 mm) WARM AIR COOL AIR NOTE: A recommended connection order has been provided for maximum safety during installation. NOTE: The SunSaver-MPPT is a negative ground controller. Any combination of negative connections can be earth grounded as required. Grounding is recommended, but not required for correct operation. 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 1: Load Wiring The SS-MPPT load output connection will provide battery voltage to system loads such as lights and other electronic devices. Do not connect inductive loads such as inverters, motors, pumps, compressors, generators to the load terminals. Connect inductive loads directly to the battery. See Section 4.4 - Load Control Information for more details about load control.
Connect the battery to the SS-MPPT. Refer to the wire gauge chart on page 65 of this manual for correct wire sizing. If required, the negative battery connection may be earth grounded. Use appropriate gauge wire and proper grounding methods for the installation site. Grounding wires must be of the same, or greater, cross-sectional area as the PV wires. WARNING: Shock Hazard The solar PV array can produce open-circuit voltages in excess of 60 Vdc when in sunlight.
Step 4: Optional Accessories 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. 36 V NOMINAL MAX. 12 Volt MODULE 12 Volt MODULE 12 Volt MODULE SOLAR POSITIVE (+) (-) (+) (-) (+) (-) SOLAR NEGATIVE (-) (+) Figure 6. Solar input wiring. Connect the solar module(s) to the SS-MPPT. Refer to the wire gauge chart on page 65 of this manual for correct wire sizing.
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. 3 + - 2 1 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.
4.2 TrakStarTM MPPT Technology 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 set-points 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.
High Voltage Strings and Grid-tie Modules Another benefit of TrakStar MPPT technology is the ability to charge 12 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 (Voc) rating will not exceed the SS-MPPT 60V maximum input Voltage rating at worstcase (coldest) module temperature.
4.3 Battery Charging VOLTAGE 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. EQUALIZE BULK CHARGE ABSORPTION FLOAT NIGHT 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 gases.
! PRUDENCE: Endommagement de l’équipement Une surcharge excessive et un dégagement gazeux trop vigoureux peuvent endommager les plaques de batteries et provoquer l’élimination du matériau actif des plaques. Une compensation trop élevée ou trop longue peut provoquer des dégâts. Examinez les exigences pour la batterie particulière utilisée dans votre système. 4.
• 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 connection may damage the load. Always double check load connections before applying power. 4.
additional external suppression is recommended. Battery Reverse Polarity (No LED indication) 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 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.
AVERTISSEMENT: Risque de décharge électrique Un moyen de déconnexion de tous les poteaux d'alimentation doit être fourni. Ceux-ci se déconnecte doit être intégrée dans le câblage fixe. Ouvrir que toutes les source d'énergie se déconnecte avant de retirer le couvercle de la contrôleur, ou accès au câblage. The following inspections and maintenance tasks are recommended at least two times per year for best controller performance. • Verify that all wire clamps and tie-downs are secure.
4.8 Data-logging 5.0 Troubleshooting The SS-MPPT creates a thirty day internal data log of key PV system information. The log can be accessed and viewed by downloading and running MSView PC software, available at no charge at: www.morningstarcorp.com Internal data logged: Daily min. and max. battery voltages Daily Ah charge to battery Daily Ah charge to load Daily array faults Daily load faults Max.
AVERTISSEMENT: Risque de décharge électrique. Un moyen de déconnexion de tous les poteaux d’alimentation doit être fourni. Ceux-ci se déconnecte doit être intégrée dans le câblage fixe. Ouvrir que toutes les source d’énergie se déconnecte avant de retirer le couvercle de la contrôleur, ou accès au câblage. 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.
6.0 Warranty and Policies The SunSaver MPPT charge controller is warrantied 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. 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.
MORNINGSTAR TECHNICAL SUPPORT POLICIES (Cont.) WARRANTY CLAIM PROCEDURE ♦ Please visit the Tech Support section at www.morningstarcorp.com for any documentation or specification needs before requesting support. The site also offers an array sizing tool (String Selector), product comparison tool (Product Comparator) and articles on solar charging technologies and other design considerations. 1. Before proceeding, please refer to product manual, including Troubleshooting section.
Battery Set-points Gel Sealed AGM Flooded 7.0 Technical Specifications Absorption Voltage 14.0V 14.1V 14.3V 14.4V Float Voltage 13.7V 13.7V 13.7V 13.7V 3 hr 3 hr 3 hr 3 hr 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 15A 7 – 36V 60V Time until Float 200 Watts 400 Watts 35 mA 1.0 % 2.
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 10.6 in-lb / 1.2 Nm #22 AWG / 0.3 mm2 #12 AWG / 3.0 mm2 3.5 in-lb / 0.4 Nm See inside front cover 1.3 lbs / 0.60 kg Efficiency and De-ratings Figure 11. SS-MPPT 24 Volt Efficiency Curves 7.0 Figure 10.
APPENDIX 12 Volt Nominal Wiring Chart One-way Wire Distance (feet) Wire Gauge (AWG) Amps 2 One-way Wire Distance (meters) Wire Gauge (mm2) 14 12 10 8 6 2.0 3.0 5.0 8.0 13.
Certifications RECOGNIZED COMPONENT ® TUVRheinland CERTIFIED 3094762 THIS PAGE IS LEFT BLANK INTENTIONALLY • ETL Certified to UL 1741 - Recognized Component • CSA-C22.2 No. 107.
