Transcript Solar Charge Controller - e

Morningstar
Solar Controller and Inverter
Overview
Morningstar’s Mission
Morningstar is the world’s leading supplier of Solar Controllers.
In 2010 we sold over 250,000 controllers through 164 distributors
in 73 countries throughout the world.
Our goal is to continue to lead the controller market in terms of
quality, reliability and customer service as well as expand our
products in the PV inverter market.
Morningstar’s Company Advantages
• Reliability - our failure rates are less then 2 units per 1000 sold.
• 100% in-house design – we only put our name on a product that
we’ve built from scratch, one resistor at a time.
• Morningstar sells only through the world’s PV distribution
channels.
• Supporting our distribution network is our #1 priority. We send
sales leads directly through our distribution network and do not sell
directly to OEM’s, dealers or end-users.
Morningstar Product Advantages
Highest Quality – Manufactured in a fully automated ISO 9001 factory. Quality control using
the latest computerized test equipment. Every unit is digitally calibrated, tested and logged.
Superior Lightning Protection – Use of large transient voltage suppressors provide faster
response to transients and do not degrade over time.
No need to De-rate – Designed with a 25% safety margin, controllers may be used up to their
full “nameplate” ratings.
Expected 15 Year Life – Controllers carry a full 5-year warranty, with an expected operating life
of 15 years or more.
Easy to Use – Detailed manuals, technical support by phone or internet, large clearly-marked
wire terminals, electronic protections and good front panel indicators. Controllers are easily
utilized at multiple experience levels.
Morningstar Product Advantages
Tropicalization is the process by which
we condition our hardware for use in
extreme environmental conditions.
Conformal Coating – Dupont Humiseal –
a UL listed protective spray that will seal
out moisture and prevent corrosion from the
effects of salt air and high humidity.
Epoxy Encapsulation – a 2-part epoxy
resin that protects the board as well as acts
to conduct heat away from the power
carrying components on the circuit board.
It acts like a liquid heat sink.
Terminal plating - to resist corrosion.
Technical Support
Fast Response – Same day response on emails. Live people
answering the phone. Fast tracking to our engineering office for high
level assistance. Searchable tech support library.
Applications Knowledge – We can interpret specifications,
certifications, sizing and other requirements for your projects to give
you a quick review of the controller options that are right for you.
Industry Leading Warranty Support – We work to provide
quick warranty replacement. Morningstar doesn’t require complicated
approvals, so we are able to provide warranty service easily through
our distribution network, or directly if necessary.
ProStar
Rating: 15A or 30A at 12/24V or
15A at 48V
Negative or Positive Ground
Applications: Mid-Range professional or consumer systems.
Major Benefits
Extensive Protections: Electronic short-circuit, overload
and reverse polarity protected with automatic recovery.
More Information: LED’s indicate various battery and system
status while digital meter (optional) displays 9 different
controller status parameters.
ProStar
Rating: 15A or 30A at 12/24V or
15A at 48V
Negative or Positive Ground
Self-Test: Digital meter displays any detected faults, making it
very easy to troubleshoot the PV system.
Tropicalization: For protection against corrosion and nesting
insects. Includes conformal coating on circuit boards,
stainless-steel screws and anodized aluminum heat sink.
Low Telecom Noise: PWM has been modified to reduce
interference and any noise may be easily eliminated in the field.
SunSaver
Rating: 6.5A,10A or 20A at
12V or 24V
Applications: Small professional or consumer systems. Oil/Gas
projects located in hazardous locations.
Major Benefits
Tropicalization: Epoxy encapsulation, marine rated terminal
block and Anodized aluminum enclosure.
Hazardous Locations: Approved for use in Class 1, Division 2
Groups A,B,C,D
SunSaver
Rating: 6.5A,10A or 20A at
12V or 24V
Temperature Extremes: Rated for operating
temperatures of -40°C to +60 °C up to full
“nameplate” current ratings.
Series PWM Design: Less heating and longer life
compared to shunt controllers.
SunGuard
Rating: 4.5A at 12V
Applications: single module
professional or consumer systems.
Major Benefits
Charging: Circuitry is the same as SunSaver (series PWM).
Tropicalization: Epoxy encapsulation, ABS plastic case
and outdoor rated wires.
Economics: Low cost controller.
Power Usage: Minimal self-consumption (6 mA).
SunLight
Rating: 10A or 20A at 12V
10A at 24V
Applications: Solar lighting controller used for street
lighting, bus stations, telephone booths, billboards,
signs and parking lots.
Major Benefits
Combines the SunSaver charging circuit and case
with a micro controller for automatic lighting control
functions.
SunLight
Rating: 10A or 20A at
12V or 24V
Functionality: Choice of 10 different lighting control
options including ON-OFF-ON options.
Test button to check light during installation and
confirm correct lighting option selection.
TriStar Solar Charge Controller
TriStar – Solar Charge Controller
• 3 Operating modes – Solar charging, load control
or diversion control for wind/hydro
• 45A or 60A versions, both with automatic
detection of 12/24/48V system modes
• Optional front panel and remote meters display
system information
• Conduit ready enclosure designed for installation
onto a Power Panel
Main Features
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Optional remote sensor provides temperature compensation
Battery sense connection for accurate voltage readings
Self test algorithm runs continuously to locate faults
All electronic protections
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Reverse polarity and short circuit on all connections
All faults have auto reset
Lightning surge protection with 4500W TVS’s
PWM current limiting for high temp and over current states
Reliability by Design
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100% solid state power electronics
All functions microprocessor controlled with non-volatile Flash-RAM
Conformally coated circuit board
Robust Heatsink
Morningstar SunKeeper
• 12V Controller available in 6A and 12A versions.
• Conduit gasket connection mounts directly to the PV module
junction box to form a weather-proof seal
• Bulk, PWM absorption and float stages
• Full electronic protections from wiring errors
Morningstar SunKeeper
•Bi-Color LED confirms proper installation and shows the
charging state as well as any fault info or evidence of damage.
•The SunKeeper has the ability to restart from zero voltage to
recover the system in the case of a fully depleted battery.
• Epoxy potting and very low resistance power MOSFET's
allow for extremely high temp operation to 70C.
SunSaver / SunKeeper
Hazardous Location Rating
• UL 1604 - UL Standard for Safety Electrical Equipment
for Use in Class I and II, Division 2, and Class III
Hazardous (Classified) Locations
• CSA C22.2 NO 213-M1987 - Non-Incendive Electrical
Equipment for Use in Class I, Division 2 Hazardous
Locations
Morningstar SunKeeper
Fits PG 13.5, M20, ½ Inch conduit knockout
SureSine Inverter
Rating: 300W Continuous, 600W Surge
12VDC Input
115V/220V versions available
Listed to UL 458
Applications: Rural electrification, telecom, mobile/marine markets.
Extensive Protections: Electronic short-circuit, overload
and reverse polarity protection.
High Power Surge: 200% surge allows a 600W output for up to 15 minutes.
Rugged Chassis Design: Cast aluminum heat sink, epoxy encapsulated
transformer, fanless convection cooling.
SureSine Inverter
Rating: 300W Continuous, 600W Surge
12VDC Input
115V/220V versions available
Listed to UL 458
Low Power Consumption: Peak efficiency of 91.5% makes more solar energy
available for the loads. Search mode turns the inverter off when no
AC load is present to further reduce power draw.
More Information: LED’s indicate various battery, system
and AC output status. Interpretation is easy. Green LED’s show operational
status while Red LED’s indicate a fault.
Remote Power Switch: Remote power terminal allows an external switch
or another device (like a solar controller) to turn on the inverter.
Popular Uses for the SureSine 300
• Sine wave power for AV equipment (mobile market)
• Rural electrification and remote cabins
• Networking and Security equipment
• AC lighting systems (the remote on/off terminal may be used
with the SunLight to provide automatic control)
• Adds sine wave capability to a larger wattage modified
square-wave system.
SunSaver Duo
Rating: 25A total charging current
12VDC System Voltage
Isolated Charging for 2 Batteries
Combination Product - charge controller and remote meter package.
Designed For Easy Installation - Controller mounts near battery. Meter display
mounts up to 30ft. away.
Robust Design - Builds on the proven design of the SunSaver. Cast aluminum
case, heat sink and epoxy encapsulation provide efficient and cool operation.
Dual Battery Charging - splits solar current between house and cabin batteries.
SunSaver Duo Meter Display
• Meter mounts on surface with
included frame or can be inset into the
vehicle wall
• Voltage and Current information
shown separately for each battery
without the need for external shunts
• Min/Max voltage
• Instantaneous Amps from solar and
each battery’s Ah shown separately
• Room temperature and battery
temperature display
• Automatic backlight settings
SunSaver MPPT
System Voltage:
12/24V
Max. Battery Current:
15A
Max. Voc:
75V
Max. PV Input:
200Wp (12V Battery)
400Wp (24V Battery)
•Provides an estimated 5-25% boost of amps from the PV array into the battery.
Actual boost depends on PV cell temperature and battery state-of-charge.
•Enables the use of high voltage PV modules (designed for on-grid applications) for
off-grid 12V or 24V battery charging.
•Provides a means to use a 12-36V nominal PV array to charge a 12V battery,
reducing power losses in systems with a long wire run between the PV array and
the battery.
RM-1 Remote Meter (New)
Compatible with:
SunSaver MPPT
SureSine
SunSaver Duo
-Array Voltage/Vmp
-Temperature
-Solar Charge Amps
-Faults and Alarms
-Load Amps
-Displays daily logging information on supported
-Battery Voltage with Max/Min
products.
-Solar/Load Ah accumulation
MSC MeterBus Adapter (New)
• Allows any meter port enabled Morningstar
product to be given RS-232 serial port data
communications.
• Includes DB-9 Serial cable and RJ11 cable.
• List price of $39
TriStar Firmware Upgrade (coming soon)
• Firmware update to support Hub functions on previously produced TS
units.
• To enable 30 day data logging feature on TS-M.
Morningstar
TriStar MPPT
TriStar MPPT Ratings
• Two Models
•45A Battery Charge Current.
•60A Battery Charge Current.
• 8-68V battery range (12/24/48V or Auto)
• Rated -40 to +45C at 100% continuous power.
•150V maximum open circuit PV voltage.
• Peak efficiency of 99%
• Options:
• TriStar Meter 2 (TS-M-2)
• TriStar Remote Meter 2 (TS-RM-2)
• Relay Driver (RD-1)
• Meter Hub (HUB-1)
• Remote Temp Sense (RTS)
TriStar MPPT Mechanicals
• Extruded aluminum heatsink for efficient cooling
• Tri-Phase DC-DC design. 3 x 20A MPPT
• Fanless– uses less power, more reliable and
runs without drawing in dust and dirt.
• Solid state controls – no relays
• Enclosure allows the use of
- 4 standard 1” or 1.25” conduit knockouts
- 8 metric knockouts (M20) for Europe
• All circuit boards are conformally coated to
prevent corrosion.
• All inductors are potted for cool operation and
environmental protection.
TriStar MPPT Protections
• Electronic Protections
• PV Short circuit protection (solid state)
• Automatic current limiting to max rating
• High temperature protection
• Lightning protection (fast acting Transient
Voltage Suppressors)
• High Voltage PV Voc Backoff
TriStar MPPT Certifications
• UL 1741 - Pending
• cUL (CSA-C22.2 No. 107.1-95) – Pending
• FCC Class B Part 15 Compliant
• CE Compliant
• RoHS Compliant
• ISO 9001 Certified production
TriStar MPPT Setup
• Same established simple and quick setup as the original TriStar
• DIP switch configuration gives you 7 preset battery profiles
• One DIP preset is reserved for complete customization using MS View.
• Controller automatically determines
• System Voltage
• Array configuration
• Sense Voltage presence
• RTS presence
TriStar MPPT Setup
Common battery profiles are available as presets. Values
are for all charging values, float/absorption times and
equalization schedule.
TriStar MPPT Sizing
With the MPPT controller, you can size in pure watts
since the controller provides the maximum current
available from the system. Wattages in excess of those
below will be held to controller current limit.
Battery
TS – MPPT-45
TS – MPPT-60
12 Volt
600 Watts
800 Watts
24 Volt
1200 Watts
1600 Watts
48 Volt
2400 Watts
3200 Watts
Maximum Power Point Tracking
The Technology behind maximum energy harvest.
1. The controller needs to keep the module operating at the Vmp
to ensure rated output in watts of the PV module.
2. Accounts for changes in temperature and irradiance through the day.
3. Ensures grid-tie modules (i.e. 54 and 72 cell) are optimized in voltage
for effective battery charging regardless of their nominal voltage.
Even the largest and most efficient controller can give up crucial power if
not tracking the power point of the module correctly. Speed and logic in
the tracking algorithm yield gains that pure size and efficiency cannot
make on their own.
Maximum Power Point Tracking
The Technology behind maximum energy harvest.
IV Curve
Power Graph
MPPT Benefits
Boost – 10-30% gain in charging amps out of the same module used on a PWM
controller. The greater the gap between Vmp and battery voltage, the more the
boost in current the battery receives.
-Cold modules increase the gain due to higher Vmp
-low battery voltages increase the gain when needed most
High Voltage Wire Runs – smaller wire can be used and greater distances
achieved using higher voltage PV input.
Shading and cloud irradiance effects – Cloud edge effect can cause the
module to exceed it’s rated wattage for a short time. Shading can cause tricky IV
curve shapes. MPPT can follow both these changes to ensure maximum power
during these conditions.
Low Battery Protection – when the battery is very low, a high voltage difference
between the PV Vmp and the battery voltage causes an even greater power
boost. This can prevent an LVD at a time when the power is most needed.
MPPT Economics
MSRP
TS-60 PWM + RTS
TS MPPT-60 + RTS
Incremental cost of MPPT
PV Module Cost/Wp
Boost Needed to cover MPPT cost (Wp)
Boost Needed to cover MPPT cost (%):
500 Wp PV array
1kWp PV array
1.5 kWp PV array
$258
$669
$411
$4
103 Watts
21%
10%
7%
Maximum Power Point Tracking
MPPT Tracking Algorithms on the market:
Full Sweep - scans entire PV array from 0-150V.
Pros: Sees everything on the IV curve, not easily fooled.
Cons: Slow, sometimes takes an extended time for a full sweep
during which charging is far from the true Vmp.
Dynamic Tracking – stays near Vmp and makes minor rapid
adjustments.
Pros: Faster
Cons: Can get hung up on a local peak and miss the true peak
power point.
Maximum Power Point Tracking
Morningstar TrakStar Technology –
- Full array sweeps from 0-150V in ¼ second! Others can take
up to 30 seconds during which much has happened.
- The TS-MPPT offers full sweep and dynamic adjustments
continuously.
- Dual chipset provides specialized control
-DSP – high speed MPPT, charge control and data logging
-Main Processor – Ethernet and serial communications
TS MPPT Data Logging
Up to 6 months of internal data logging of key daily values.
Max Battery Voltage
Min Battery Voltage
Max Array Voltage
Amp Hours
Watt Hours
Faults
Alarms
Daily Absorption Stage Time (mins)
Daily Equalization Stage Time (mins)
Daily Float Stage Time (mins)
TriStar MPPT
Communications
TriStar MPPT
Communications
Meterbus – RJ11 connection
- Connection of local or remote TriStar Meter-2
- Allows combining of TriStars into network with HUB-1
- Sum all controller data for system level information
Total Charge Amps into the battery
Total Load Amps drawn out of the battery
Net gain/loss of amps from/to the battery
TriStar MPPT
Communications
RS-232 – for a single connection between a PC
or other device and the TriStar MPPT. Allows
for data logging, program changes and
firmware upgrades.
- easiest way to connect to the TriStar for PC data
- included on all TriStar versions
- uses standard MODBUS protocol
- optically isolated for safe power system grounding
TriStar MPPT
Communications
RS-485 – for networked (multi-unit) connections between a
PC or other devices and many Morningstar products. Allows
for data logging and program changes.
- for larger or industrial PV systems with many devices
- uses MODBUS protocol
- supports long distances
- can be used on original TriStars with RSC adapter
- optically isolated for safe power system grounding
TriStar MPPT
Communications
Ethernet* – for TCP/IP connection for internet
applications. IP makes it compatible with wireless
protocols, cellular systems and existing networking
equipment.
Allows for the use of:
- web page view directly from the TS MPPT
- email and text message notifications and alarms
- remote connection anywhere on the internet (MODBUS IP)
- SNMP functions for networking service providers
- integration with third party software developers
writing in HTML, XML and Java.
*Ethernet available on 60A TS-MPPT only.
TriStar MPPT Communications
TriStar MPPT Live view
allows the direct webpage
viewing of solar and charge
data from the controller
itself.
Compatible with any Java
enabled web browser (Mac,
PC or Smartphone).
MPPT Economics
MSRP
TS-60 PWM + RTS
TS MPPT-60 + RTS
Incremental cost of MPPT
PV Module Cost/Wp
Boost Needed to cover MPPT cost (Wp)
Boost Needed to cover MPPT cost (%):
500 Wp PV array
1kWp PV array
1.5 kWp PV array
$258
$669
$411
$4
103 Watts
21%
10%
7%
TriStar MPPT Industry Leading Efficiency
12V
10
Controller Self Consumption in Watts
8
48V
6
24V
4
2
OB
XW
TriStar
0
24V
48V
12V
MPPT Controller Price Comparison
M Star
Outback
TS MPPT
FM-60
Xantrex
%
XW
%
TriStar MPPT-45
531
699
-24%
685
-22%
TriStar MPPT-60
669
699
-4%
685
-2%
TriStar MPPT-45 with RTS
531
731
-27%
685
-22%
TriStar MPPT-60 with RTS
669
731
-8%
685
-2%
TriStar MPPT-45 with meter
635
699
-9%
685
-7%
TriStar MPPT-60 with meter
773
699
11%
685
13%
TriStar MPPT-45 with RTS and meter
TriStar MPPT-60 with RTS and meter
635
773
731
731
-13%
6%
685
685
-7%
13%
Note: You can view TS MPPT-60 from a web browser and oftentimes will not need a
meter
TriStar MPPT Summary
The TriStar MPPT brings many advantages:
- Superior MPPT Tracking technology
- Highest efficiency with the lowest power loss during operation
- Lower cost with 45A version and choice of meter option.
- Powerful communications with open protocols, including Ethernet.
- Easy setup for a quick installation (sometimes no setup at all)
- Backed by Morningstar’s controller expertise and 5 year warranty
- Delivers technology and simplicity for residential use, built to
survive the remote and industrial market’s harshest environments.
TS HUB (Sept 2009)
•Allows TS Meter to show summed
data including:
•Net System Data
•Individual Controller Data
•Supports up to 15 Devices
TS, TS-MPPT, RD-1, TS-M
•Provides complete isolation from
ground. (will work with both Positive
and Negative Ground systems.)
Morningstar String Calculator
-Allows for quick and simple array string configurations to be displayed
for any Morningstar charge controller.
-Works with a variety of common industry PV modules or allows you to
input your own specifications.
-Accounts for ambient temperatures at the site and compensates for
expected battery voltages in the system.
-Prevents maximum current and Voc figures from exceeding the
controller rating at any time during the year.
Morningstar String Calculator
SunLights used
in a rural
streetlight
installation in
Indonesia.
SHS’s used in a
rural installation
in Ecuador.
Dual TriStar
system used in
mountaintop
repeater in
Norway.
Norway in Summer
Norway in Winter
Application Photos
Application Photos
Application Photos
Application Photos
Thank you
for your
business!