Morningstar SunSaver MPPT [SS-MPPT-15L] Manuel utilisateur

Marque: Morningstar

Modèle: SunSaver MPPT [SS-MPPT-15L]

Taper: Manuel utilisateur

Ce manuel convient également à

Installation, Operation and

Maintenance Manual

AVER MPPT

WITH TRAKSTAR

MPPT TECHNOLOGY

www.morningstarcorp.com

SS-MPPT-15L

For the most recent manual revisions, see the

version at: www.morningstarcorp.com

MAXIMUM POWER POINT TRACKING

MORNINGSTAR CORPORATION

SunSaver MPPT Dimensions

Specication Summary

System Voltage 12 / 24 Volts

Rated Battery Current 15 Amps

Rated Load Current 15 Amps

Maximum Input Voltage* 60 Volts

Nominal Maximum Input Power**

12 Volt System 200 Watts

24 Volt System 400 Watts

See Section 7.0 for full technical specications

* Array Voltage should never exceed maximum input voltage. Refer

to the solar module documentation to determine the highest expected array

as dened by the lowest expected ambient temperature for the system

location.

** These power levels refer to the maximum wattage the SS-MPPT-15L

can process at a certain system voltage. Higher power arrays can be

used without damaging the controller.

Contents

1.0 Important Safety Information 4

1.0 Important Safety Instructions 4

2.0 General Information 15

2.1 Overview 15

2.2 Features 16

2.3 Optional Accessories 18

2.4 Regulatory Information 20

3.0 Installation Instructions 22

3.1 General Installation Notes 22

3.2 Conguration 24

3.3 Mounting 27

3.4 Wiring 29

4.0 Operation 37

4.1 LED Indications 37

4.2 TrakStar

MPPT Technology 39

4.3 Battery Charging 42

4.4 Load Control Information 44

4.5 Protections 46

4.6 Inspection and Maintenance 49

4.7 Programming Custom Set-points 51

4.8 Data-logging 52

5.0 Troubleshooting 53

5.1 Error Indications 54

5.2 Common Problems 55

6.0 Warranty and Policies 56

7.0 Technical Specications 60

Appendix - Wire Sizing Charts 65

Certications 67

MORNINGSTAR CORPORATION

1.0 IMPORTANT SAFETY INSTRUCTIONS

1.0

PRUDENCE: Indique une procédure critique pour

l’utilisation sûre et correcte du contrôleur.

REMARQUE: Indique une procédure ou fonction

importante pour l’utilisation sûre et correcte du

contrôleur.

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.

WARNING: RISK OF ELECTRICAL

SHOCK. NO POWER OR ACCESSORY

TERMINALS ARE ELECTRICALLY ISOLATED FROM DC

INPUT, AND MAY BE ENERGIZED WITH HAZARDOUS

SOLAR VOLTAGE. UNDER CERTAIN FAULT

CONDITIONS, BATTERY COULD BECOME OVER-

CHARGED. TEST BETWEEN ALL TERMINALS AND

GROUND BEFORE TOUCHING.

• External solar and battery disconnects are required.

• 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 Do not attempt to repair.

1.0 Important Safety Instructions

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.

NOTE: Indicates a procedure or function that is

important to the safe and proper operation of the

controller.

CONSIGNES IMPORTANTES DE SÉCURITÉ

CONSERVEZ CES INSTRUCTIONS.

Ce manuel contient des instructions importantes de sécurité,

d’installations et d’utilisation du contrôleur solaire.

SunSaver-MPPT. Les symboles suivants sont utilisés dans ce

manuel pour indiquer des conditions potentiellement

dangereuses ou des consignes importantes de sécurité.

AVERTISSEMENT: Indique une condition

potentiellement dangereuse. Faites preuve d’une

prudence extrême lors de la réalisation de cette tâche.

MORNINGSTAR CORPORATION

1.0 IMPORTANT SAFETY INSTRUCTIONS

1.0

• Mount the SunSaver-MPPT indoors. Prevent exposure

to the elements and do not allow water to enter the

controller.

• Install the SunSaver-MPPT in a location that prevents

casual contact. The SunSaver-MPPT heatsink can

become very hot during operation.

• Use insulated tools when working with batteries.

• Avoid wearing jewelry during installation.

• The battery bank must be comprised of batteries of same

type, make, and age.

• UL/IEC 62109 certified for use in negative ground or

floating systems only

• Do not smoke near the battery bank.

• Power connections must remain tight to avoid excessive

heating from a loose connection.

• Use properly sized conductors and circuit interrupters.

• The grounding terminal is located in the wiring

compartment and is identied by the symbol below:

Ground Symbol

• This charge controller is to be connected to DC circuits

only. These DC connections are identied by the symbol

below:

Informations de Sécurité

• Lisez toutes les instructions et les avertissements gu-

rant dans le manuel avant de commencer l’installation.

• 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 ÉLEC-

TRIQUE. 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 POUR-

RAIT DEVENIR TROP CHARGÉE. TEST ENTRE TOUTES

LES BORNES ET LA MASSE AVANT DE TOUCHER.

• External solaire et la batterie se déconnecte sont néces-

saires.

• Déconnectez toutes les sources d’alimentation du con-

trôleur avant d’installer ou de régler le SunSaver-MPPT.

• Le TriStar MPPT ne contient aucun fusible ou interrupt-

eur. Ne tentez pas de réparer.

• Installez des fusibles/coupe-circuits externes selon le

besoin.

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 Article 690 of the

National Electrical Code for the installation location.

MORNINGSTAR CORPORATION

1.0

1.0 IMPORTANT SAFETY INSTRUCTIONS

Direct Current Symbol

The SunSaver-MPPT controller must be installed by

a qualied 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

xed wiring.

A permanent, reliable earth ground must be established

with connection to the SunSaver-MPPT wiring compartment

ground terminal.

The grounding conductor must be secured against any

accidental detachment. The knock-outs in the SunSaver-

MPPT wiring compartment must protect wires with conduit

or rubber rings.

Précautions de Sécurité D’installation

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-MPPT à l’intérieur. Empêchez

l’exposition aux éléments et la pénétration d’eau dans le

contrôleur.

• Installez le MPPT ProStar dans un endroit qui empêche

le contact occasionnel. Le dissipateur de chaleur

SunSaver-MPPT peut devenir très chaud pendant le

fonctionnement.

• Utilisez des outils isolés pour travailler avec les batteries.

• Évitez le port de bijoux pendant l’installation.

• Le groupe de batteries doit être constitué de batteries du

même type, fabricant et âge.

• UL/IEC 62109 certié pour utilisation au négatif à la

masse ou les systèmes ottants seulement.

• Ne fumez pas à proximité du groupe de batteries.

• Les connexions d’alimentation doivent rester serrées

pour éviter une surchauffe excessive d’une connexion

desserrée.

• Utilisez des conducteurs et des coupe-circuits de dimen-

sions adaptées.

• La borne de mise à la terre se trouve dans le comparti-

ment de câblage et est identiée par le symbole

ci-dessous estampillé dans le boit:

• Ce contrôleur de charge ne doit être connecté qu’à

des circuits en courant continu. Ces connexions CC sont

identiées par le symbole ci-dessous:

MORNINGSTAR CORPORATION

1.0

1.0 IMPORTANT SAFETY INSTRUCTIONS

Le contrôleur SunSaver-MPPT doit être installé par un

technicien qualié conformément aux règlementations élec-

triques du pays où est installé le produit.

Un moyen d’assurer la déconnexion de tous les pôles de

l’alimentation doit être fourni. Cette déconnexion doit être

incorporée dans le câblage xe.

À l’aide de la borne de mise à la masse du SunSaver-MPPT

(dans le compartiment de câblage), un moyen permanent

et able de mise à la terre doit être fourni. La xation de la

mise à la terre doit être xée contre tout desserrage

accdentel. Les ouvertures d’entrée au compartiment de

câblage du doivent être protégées avec conduit ou anneaux.

Battery Safety

WARNING: A battery can present a risk of

electrical shock or burn from large amounts of

short-circuit current, re, 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 re. Refer to local regulations

or codes for requirements.

AVERTISSEMENT: Risque d’Explosion.

Au rebut des piles est nécessaire. Ne pas jeter

les piles dans le feu. Se référer aux réglementations locales

ou des codes pour les exigences.

CAUTION: When replacing batteries, use

properly specied number, sizes, types, and rat-

ings based on application and system design.

PRUDENCE: Lorsque le remplacement des

piles, utilisez correctement nombre spécifié,

tailles, types et les évaluations basées sur conception de

système et d’application.

CAUTION: Do not open or mutilate batteries.

Released electrolyte is harmful to skin, and

may be toxic.

PRUDENCE: Ne pas ouvrir ou mutiler les piles.

L’électrolyte est nocif pour la peau et peut être

toxique.

• Servicing of batteries should be performed, or supervised, by

personnel knowledgeable about batteries, and the proper safety

precautions.

• Be very careful when working with large lead-acid

batteries. Wear eye protection and have fresh water

available in case there is contact with the battery acid.

• Remove watches, rings, jewelry and other metal objects

before working with batteries.

• Wear rubber gloves and boots

• Use tools with insulated handles and avoid placing tools or

metal objects on top of batteries.

•

Disconnect charging source prior to connecting or

disconnecting battery terminals.

•

Determine if battery is inadvertently grounded. If so,

remove the source of contact with ground. Contact with

any part of a grounded battery can result in electrical

MORNINGSTAR CORPORATION

1.0

1.0 IMPORTANT SAFETY INSTRUCTIONS

shock. The likelihood of such a shock can be reduced if

battery grounds are removed during installation and

maint enance (applicable to equipment and remote battery

supplies not having a grounded supply circuit).

• Carefully read the battery manufacturer’s instructions

before installing / connecting to, or removing batteries

from, the SunSaver-MPPT.

• Be very careful not to short circuit the cables connected

to the battery.

• Have someone nearby to assist in case of an accident.

• Explosive battery gases can be present during charging.

certain there is enough ventilation to release the

gases.

• Never smoke in the battery area.

•

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.

• Soyez très prudent quand vous travaillez avec des grandes

batteries au plomb. Portez des lunettes de protection et ayez

de l’eau fraîche à disposition en cas de contact avec

l’électrolyte.

• Enlevez les montres, bagues, bijoux et autres objets mé

talliques avant de travailler avec des piles.

• Porter des bottes et des gants de caoutchouc

• Utiliser des outils avec poignées isolantes et évitez de placer

des outils ou des objets métalliques sur le dessus de batteries.

• Débrancher la source de charge avant de brancher ou

disreliant les bornes de la batterie.

• Utilisez des outils isolés et évitez de placer des objets

métalliques dans la zone de travail.

• Déterminer si batterie repose par inadvertance. Dans

l’afrmative, supprimer la source du contact avec le sol.

Contact avec n’importe quelle partie d’une batterie mise

à la terre peut entraîner un choc électrique. La probabilité

d’un tel choc peut être réduite si des motifs de batterie

sont supprimés pendant l’installation et maintentretien

(applicable à l’équipement et les fournitures de pile de la

télécommande n’ayant ne pas un circuit d’alimentation

mise à la terre).

• Lisez attentivement les instructions du fabricant de la

batterie avant d’installer / connexion à ou retrait des

batteries du SunSaver-MPPT.

• Veillez à ne pas court-circuiter les câbles connectés à la

batterie.

• Ayez une personne à proximité qui puisse aider en cas

d’accident.

• Des gaz explosifs de batterie peuvent être présents

pendant la charge. Assurez-vous qu’une ventilation suf-

sante évacue les gaz.

• Ne fumez jamais dans la zone des batteries

2.0

MORNINGSTAR CORPORATION

1.0 IMPORTANT SAFETY INSTRUCTIONS

2.0 General Information

2.1 Overview

Thank you for selecting the SunSaver MPPT 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

that maximizes the energy from the solar module(s) and

also provides load control to prevent over-discharge of the

battery.

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).

Using MSView

PC software, the SS-MPPT can be

programmed with custom settings to function as a lighting

controller to turn the system loads on and off at specied

intervals throughout the day and night. See Section 4.7 for

more information.

Although the SS-MPPT is very simple to congure and

use, please take the time to read this operator’s manual and

become familiar with the controller. This will help you make

full use of the many advantages the SS-MPPT can provide

for your PV system.

• En cas de contact de l’électrolyte avec la peau, lavez

avec du savon et de l’eau. En cas de contact de

l’électrolyte avec les yeux, rincez abondamment avec de

l’eau fraîche et consultez un médecin.

• Assurez-vous que le niveau d’électrolyte de la batterie

est correct avant de commencer la charge. Ne tentez

pas de charger une batterie gelée.

• Recyclez la batterie quand elle est remplacée.

2.0

MORNINGSTAR CORPORATION

2.0 GENERAL INFORMATION

2.2 Features

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 Connection

A communication port for the Morningstar Remote Meter

or personal computer (PC) connection. A MSC or UMC-1

adapter is required, available separately.

5 - Settings Switches

Adjustment switches that dene the operating parameters

of the SunSaver MPPT.

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 ow, and

system power can drastically affect the local temperature

sensor reading. A RTS will provide optimal charging

performance.

7 - Local Temperature Sensor

Measures ambient temperature. Battery regulation is

adjusted based on ambient temperature unless the 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.

2.0

MORNINGSTAR CORPORATION

2.0 GENERAL INFORMATION

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.

NOTE: The use of a Remote Temperature Sensor is

strongly recommended. Controller location, air ow, 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.

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 ush-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 (or UMC-1) is required

for programming custom charging set-points, and for viewing

logged data. See Sections 4.7 - Programming Custom

Set-points, and 4.8 - Data-logging, for details

Ethernet MeterBus Converter (EMC-1)

This product is an Ethernet gateway that provides web

monitoring services, a Modbus TCP/IP server, and a local

web page server. End users can collect information about

their off-grid PV system remotely. The EMC-1 supports all

products with MeterBus ports by bridging MODBUS TCP/IP

requests to serve LiveView pages for each product.

USB Communications Adapter (UMC-1)

A modular unit that uses a USB-B plug, usually from a

USB A-B computer cable, and an RJ-11 plug to connect with

a Morningstar controller’s MeterBus port, for monitoring and

programming using MSView PC software.

2.0

MORNINGSTAR CORPORATION

2.0 GENERAL INFORMATION

2.4 Regulatory Information

NOTE:

This section contains important information for safety

and regulatory requirements.

The SunSaver-MPPT controller should be installed by a

qualied technician according to the governing electrical

regulations of the country in which the product will be

installed.

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.

Operation is subject to the following two conditions: (1)

This device may not cause harmful interference, and (2)

this device must accept any interference received, including

interference that may cause undesired operation.

Changes or modications 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. This equipment generates, uses,

and can radiate radio frequency energy and, if not installed

and used in accordance with the instruction manual,

may cause harmful interference to radio communication.

However, there is no guarantee that interference will not

occur in a particular installation. If this equipment does

cause harmful interference to radio or television reception,

which can be determined by turning the equipment on and

off, the user is encouraged to try to correct the interference

by one or more of the following measures:

• Re-orient or relocate the receiving antenna.

• Increase the separation between the equipment and

receiver.

• Connect the equipment into an outlet on a circuit

different from that to which the receiver is connected.

• Consult the dealer or an experienced radio/TV techni-

cian for help.

This Class B digital apparatus complies with Canadian

ICES-003. Cet appareil numerique de la classe B est

conforme a la norme NMB-003 du Canada.

MORNINGSTAR CORPORATION 23

3.0

3.0 INSTALLATION

3.0 Installation

3.1 General Installation Notes

• Read through the entire installation section rst 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.

• Use insulated tools and avoid placing metal objects

near the batteries.

• Explosive battery gases may be present during charging.

Be certain there is sufcient ventilation to release the

gases.

• 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 re. 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 following

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 battery bank.

• Stranded wires to be connected to the SunSaver-MPPT

terminals should be prepared rst with e.g. clamped

copper heads, etc., to avoid the possibility of conductor

strands coming free out of the connection screw, and

possible contact with the metal enclosure.

• 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.

• Maximum battery short-circuit current rating must be less

than the interrupt current rating of the battery over-current

protection device referenced above.

MORNINGSTAR CORPORATION 25

3.0

3.0 INSTALLATION

3.2 Conguration

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 conguration 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 Specications 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 species whether the jumper

should be removed or remain in place, depending on the

desired battery type.

Battery Type Battery Jumper Switch 1

Gel

INSERTED ON (↑)

Sealed INSERTED OFF (↓)

AGM

REMOVED ON (↑)

Flooded REMOVED OFF (↓)

(1) Set-points for this switch setting can be modified with custom

programming. For more information, see Section 4.7 - Programming

Custom Set-points.

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

Disconnect / Reconnect settings.

SWITCH 2 OFF (↓): LVD = 11.50 V, LVR = 12.60 V

SWITCH 2 ON (↑): LVD = 11.00 V, LVR = 12.10 V

(2) These values can be modified with custom programming. For more

information, see Section 4.7 - Programming Custom Set-points.

Enable or Disable Auto-Equalization

Turn the auto-equalize feature OFF or ON. The auto-

equalize feature will administer an equalization charge

(ooded battery type only) every 28 days. There is no

equalization charging for gel or sealed battery types.

SWITCH 3 OFF (↓): AUTO-EQUALIZE OFF

SWITCH 3 ON (↑): AUTO-EQUALIZE ON

(AGM, ooded battery types

only)

MORNINGSTAR CORPORATION 27

3.0

3.0 INSTALLATION

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 PC

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.

SWITCH 4 OFF (↓): MORNINGSTAR REMOTE METER

SWITCH 4 ON (↑): MODBUS® PROTOCOL FOR

MSVIEW, 3RD PARTY DEVICES

(2) Morningstar PC Meterbus Adapter (Model: MSC) required. Not in-

cluded. See Morningstar’s website at: www.morningstarcorp.com for more

information. .

MODBUS® is a registered trademark of Modbus-IDA (www.modbus-ida.org)

3.3 Mounting

CAUTION: Equipment Damage or Risk of Explosion

Never install the SunSaver-MPPT in an enclosure with

vented/ooded batteries. Battery fumes are ammable

and will corrode and destroy the SunSaver circuits.

CAUTION: Equipment Damage

When installing the SunSaver-MPPT in an enclosure,

ensure sufcient ventilation. Installation in a sealed

enclosure will lead to over-heating and a decreased

product lifetime.

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 inammables et corroderont

et détruiront les circuits du SunSaver.

PRUDENCE: Endommagement de l’équipement

Assurez une ventilation sufsante en cas d’installation

du SunSaver-MPPT dans une enceinte. L’installation

dans une enceinte hermétique entraîne une surchauffe et

une réduction de la durée de vie du produit.

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 sufcient room to run wires and

that there is ample room above and below the controller for

air ow.

MORNINGSTAR CORPORATION 29

3.0

3.0 INSTALLATION

WARM AIR

COOL AIR

AT LEAST

6” (150 mm)

AT LEAST

6” (150 mm)

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).

3.4 Wiring

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.

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.

NOTE:

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 re.

WARNING:

EXPLOSION HAZARD - DO NOT DISCONNECT WHILE

CIRCUIT IS LIVE UNLESS AREA IS KNOWN TO BE

NON-HAZARDOUS.

AVERTISSEMENT:

RISQUE D’EXPLOSION. NE PAS DEBRANCHER TANT

QUE LE CIRCUIT EST SOUS TENSION, A MOINS QU’lL

NE S’AGISSE D’UN EMPLACEMENT NON DANGEREUX.

MORNINGSTAR CORPORATION 31

3.0

3.0 INSTALLATION

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.

LOAD

POSITIVE (+)

LOAD

NEGATIVE (-)

Fuse or breaker sizing

based on required wire

ampacity

Figure 4. Load wiring

Connect 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 65 of this manual

for correct wire sizing.

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 15A load rating.

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.

AVERTISSEMENT: Risque de décharge électrique

Les fusibles, coupe-circuits et interrupteurs ne doivent

jamais ouvrir les conducteurs du système mis à la terre.

Seuls les dispositifs GFDI sont autorisés à déconnecter

les conducteurs reliés mis à la terre.

6 in (150 mm)

MAX.

BATTERY

NEGATIVE (-)

BATTERY

POSITIVE (+)

Fuse or breaker

sizing based on

required wire

ampacity

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.

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.

MORNINGSTAR CORPORATION 33

3.0

3.0 INSTALLATION

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.

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: 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.

AVERTISSEMENT: Risque de décharge électrique

Le réseau PV solaire peut produire des tensions de cir-

cuit ouvert supérieures à 60 V cc à la lumière du soleil.

Vériez que le coupe-circuit ou l’interrupteur d’entrée

solaire a été ouvert (déconnexion) avant d’installer les

câbles du système.

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 bat-

terie endommagera le SunSaver de façon permanente.

The SunSaver MPPT can accept 12, 24, or 36V 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 60 Volt maximum solar input rating. The solar

module(s) nominal voltage must be equal to or greater than

the nominal battery voltage. For 24 Volt systems, a 24, or

36V nominal solar array must be used.

MORNINGSTAR CORPORATION 35

3.0

3.0 INSTALLATION

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.

If required, the negative solar connection may be

earth grounded. Use appropriate gauge wire and proper

grounding methods for the installation site.

SOLAR

POSITIVE (+)

SOLAR

NEGATIVE (-)

(+)

(-)

60 VOLT MAX. INPUT

EARTH

GROUND

Step 4: Optional Accessories

Install the Remote Temperature Sensor and Remote Meter

(both purchased separately) if required. For detailed

installation procedures, refer to the instructions provided

with each accessory.

WARNING: Risk of Fire.

If no Remote Temperature Sensor (RTS) is

connected, use the SunSaver-MPPT within 3m (10 ft) of the

batteries. Internal temperature compensation will be used

if the RTS is not connected. Use of the RTS is strongly

recommended.

AVERTISSEMENT

: Risque d’incendie.

Si non Capteur de température distant (RTS) est

connecté, utilisez le MPPT ProStar moins de 3m (10 pi) de

les batteries. Compensation de la température interne sera

utilisée si la RTS n’est pas connecté. Utilisation de la RTS

est fortement recommandé.

MORNINGSTAR CORPORATION

3.0 INSTALLATION

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 ash red whenever an error condition(s) exists.

Table 2 lists the Status LED indications.

Color Indication

Operating

State

None Off (with heartbeat¹) Night

Green

On Solid

( with heartbeat² )

Charging

Red Flashing Error

Red

On Solid

( with heartbeat

)

Critical Error

¹ heartbeat indication flickers the Status LED on briefly every 5 seconds

² heartbeat indication flickers the Status LED off briefly every 5 seconds

Table 2. Status LED denitions

For more information on Status LED errors, see Section

5.1 - Error Indications.

Step 5: Conrm Wiring

Double-check the wiring in steps 1 through 4. Conrm

correct polarity at each connection. Verify that all seven (7)

SS-MPPT power terminals are tightened.

Figure 7. System Wiring Review

Step 6: Install Fuses

Install a properly sized DC-rated fuse in each fuse holder

in the following order:

1. Load circuit

2. Battery circuit

Step 7: Conrm 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 ashing LED

error sequence exists, refer to Section 6.0 - Troubleshooting.

4.0

MORNINGSTAR CORPORATION

4.0 OPERATION

4.0

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.

SOC LED Indication Battery Status Load Status

Green

Fast Flashing

(2 Flash / sec)

Equalize Charge Load On

Green

Med. Flashing

(1 Flash / sec)

Absorption Charge Load On

Green

Slow Flashing

(1 Flash / 2 sec)

Float Charge Load On

Green On solid Nearly Full Load On

Yellow On solid Half Full Load On

Red

Flashing

(1 Flash / sec)

Battery Low

LVD Warning

(Load On)

Red On solid Battery Empty

LVD

(Load Off)

Table 3. Battery SOC LED denitions

NOTE:

An error condition exists if multiple Battery SOC LEDs

are ashing. See Section 5.1 Error Indications 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

) 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 owing into the SS-MPPT and 5 Amps

of charge current owing 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*:

(1) Power Into the SS-MPPT = Power Out of the SS-MPPT

(2) Volts In x Amps In = Volts Out x Amps 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.

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