Morningstar PS-MPPT-25 Installation, Operation And Maintenance Manual
Prostar mppt series solar charging system controller
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Table of Contents
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Summary of Contents for Morningstar PS-MPPT-25
- Page 1 ProStar MPPT Solar Charging System Controller Installation, Operation and Maintenance Manual For the most recent manual revisions, see the version at: www.morningstarcorp.com www.morningstarcorp.com MODELS PS-MPPT-25 PS-MPPT-25M PS-MPPT-40 PS-MPPT-40M MAXIMUM POWER POINT TRACKING...
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Page 2: Table Of Contents
4.0 Operation ( 7.0 ) .............35 TrakStar MPPT Technology ........35 Battery Charging Information ........37 SPECIFICATION SUMMARY Load Control Information ........47 LED Indications............ .49 PS-MPPT-25 PS-MPPT-40 4.4.1 Power-up..............49 Nominal Battery 12/24V 12/24V 4.4.2 Status LED.............. 49 Voltage 4.4.3... -
Page 3: Important Safety Instructions
4.7.4 Using the Meter Display to Program Charging IMPORTANT SAFETY INSTRUCTIONS Set-points, Load Control, Communications, and Advanced Settings............55 SAVE THESE INSTRUCTIONS. 4.7.5 Lighting Control / Programming Overview....55 This manual contains important safety, installation, operating 4.7.6 Lighting Programming Using Meter Display.....56 and maintenance instructions for the ProStar MPPT solar Inspection and Maintenance........ - Page 4 Safety Information AVERTISSEMENT: Risque De Choc Électrique. NON ALIMENTATION OU AUX BORNES • Read all of the instructions and cautions in the manual D'ACCESSOIRES SONT ISOLÉS ÉLECTRIQUEMENT DE before beginning installation. L'ENTRÉE DE C.C ET DOIT ÊTRE ALIMENTÉS À UNE TENSION •...
- Page 5 • The battery bank must be comprised of batteries of same permanent, reliable earth ground must be established type, make, and age. with connection to the ProStar MPPT ground terminal. • UL/IEC 62109 certified for use in negative ground or The grounding conductor must be secured against any floating systems only.
- Page 6 • Ce contrôleur de charge ne doit être connecté qu’à WARNING: Risk of Explosion. Proper disposal of batteries is required. Do not des circuits en courant continu. Ces connexions CC sont dispose of batteries in fire. Refer to local identifiées par le symbole ci-dessous: regulations or codes for requirements.
- Page 7 if battery grounds are removed during installation and • Utilisez des outils isolés et évitez de placer des objets maint enance (applicable to equipment and remote métalliques dans la zone de travail. battery supplies not having a grounded supply circuit). •...
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Page 8: General Information
Changes or modifications not expressly approved occur. The controller also features eight (8) adjustable set- by Morningstar for compliance could void the user’s tings switches, several communication ports, and terminals authority to operate the equipment. -
Page 9: Versions And Ratings
2.3 Versions and Ratings • Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. PS-MPPT-25 • Consult the dealer, or an experienced radio/TV • Rated for maximum 25 amps continuous current technician for help. -
Page 10: Features
13 - Battery Sense Terminals Connection points for battery voltage sensing wires 14 - Remote Temperature Sensor Terminals (RTS) Connection points for a Morningstar RTS to remotely monitor battery Figure 2-1. PS-MPPT Features temperature 15 - Wire Box for ProStar-MPPT... -
Page 11: Optional Accessories
The RM-1 connects to the RJ- 11 Meter A-B computer cable, and an RJ-11 plug to connect with a port on the ProStar MPPT. Morningstar controller's MeterBus port, for monitoring and programming using MSView PC software. RelayDriver (RD-1) -
Page 12: Installation
INSTALLATION INSTRUCTIONS • Do not install in locations where water can enter the controller. 3.1 General Installation Notes • Loose power connections and /or corroded wires • Read through the entire installation section first before may result in resistive connections that melt wire beginning installation. -
Page 13: Configuration
These protection devices are external to the ProStar MPPT controller, and must be a maximum of 30 amps for the PS-MPPT-25/M and 50 amps for the PS-MPPT-40/M. Figure 3.1. DIP Switch Block to set charging parameters AVERTISSEMENT: Solaire et batterie fusibles ou disjoncteurs DC sont nécessaires dans le système. -
Page 14: Installation Instructions
Switch 8: Meterbus / MODBUS Settings Switches 4, 5, 6: Battery Type Selection Preset ProStar MPPT battery charging options are shown in Mode Switch 8 table 3-1 below. All voltage settings listed are for nominal Meterbus 12 volt batteries. MODBUS Multiply the voltage settings by two (2) for 24 volt systems. -
Page 15: Mounting
3.3 Mounting 3.4 Wiring Inspect the controller for shipping damage. Mount the ProStar MPPT to a vertical surface (4-#8 stainless steel self-tapping screws are included). Tighten the mounting screws, using care not to crack the plastic case. Do not install directly over an easily combustible surface since the heat sink may get hot under certain operating conditions. - Page 16 STEP 1: Check Controller Limitations the true battery voltage would only be 14.1 volts, if there is a 0.3 volt drop between the controller and battery. Verify that the highest temperature compensated solar array open-circuit voltage (Voc), and load current do not exceed Note that the battery sense wires will not power the the ratings of the ProStar MPPT version being installed.
- Page 17 STEP 3: Remote Temperature Sensor CAUTION: The ProStar MPPT will use the local temperature sensor for compensation if the RTS is not WARNING: Risk of Fire. used. If no Remote Temperature Sensor (RTS) is connected, PRUDENCE: Le ProStar MPPT MPPT ne compense pas use the ProStar MPPT within 3m (10 ft) of the batteries.
- Page 18 The grounding point may be located in the solar, or the battery circuit. For system grounding electrode conductor sizing requirements, refer to the NEC Section 690.47, or applicable local regulations or code. STEP 5: Battery Connections - see diagram below Be sure that DIP switches 2 and 3 are set for 12 or 24V, as Figure 3-4.
- Page 19 STEP 6: Solar Connections - see diagram below STEP 7: Load Connections - see diagram below Turn the loads off, and connect the load wires to the load WARNING: Shock Hazard terminals. DO NOT CLOSE THE BREAKER AT THIS TIME. The solar PV array can produce open-circuit voltages in excess of 120 Vdc when in sunlight.
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Page 20: Operation
• there is an overload condition (LEDs blinking R/Y - G) • the load is not connected, not working, or turned off The ProStar MPPT utilizes Morningstar’s TrakStar Maxi- mum Power Point Tracking technology to extract maximum power from the solar module(s). The tracking algorithm After all connections have been completed, observe the is fully automatic and does not require user adjustment. -
Page 21: Battery Charging Information
High Voltage Strings and Grid-tie Modules 4.2 Battery Charging Information Another benefit of TrakStar MPPT technology is the ability to charge 12 or 24 volt batteries with solar arrays of higher 4-Stage Charging nominal voltages. A 12 volt battery bank can be charged The ProStar MPPT has a 4-stage battery charging algorithm with a 12, 24, 36 or 48V nominal off-grid solar array. - Page 22 The battery must remain in the Absorption charging Equalization Stage stage for a cumulative 120 - 150 minutes, depending on battery type, before transition to the Float stage will occur. WARNING: Risk of Explosion However, Absorption time will be extended by 30 minutes Equalizing vented batteries produces explosive gases.
- Page 23 the battery voltage above the standard absorption voltage Only a long controlled overcharge, or equalization, at a so that the electrolyte gases. The green SOC LED will blink higher voltage can reverse the hardening of sulfate crystals. rapidly two (2) times per second during equalization charg- When to Equalize? ing.
- Page 24 gel, have charging requirements up to 14.4V (12V battery). Shared Settings Value Units Depending on the battery manufacturer’s recommendation, Absorption Extension Voltage 12.50 Volts the “boost” cycle for sealed cells can be disabled by setting Absorption Extension Time Absorption Time + 30 minutes the equalize setting switch to manual, if required.
- Page 25 If battery voltage discharges below 12.50 volts (25.00 volts Float Cancel Voltage @ 24V) the previous night, Absorption charging will be extended on the next charge cycle as shown in figure 4-3 Bulk Absorption above. 30 minutes will be added to the normal Absorption duration.
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Page 26: Load Control Information
4.3 Load Control Information Equalize Time-out The primary purpose of the load control function is to disconnect system loads when the battery has discharged Bulk Equalize Float to a low state of charge and reconnect system loads when the battery is sufficiently recharged. System loads may be Equalize V lights, pumps, motors, DC appliances, and other electronic devices. -
Page 27: Led Indications
The amount of time between a green SOC indication and 4.4 LED Indications load disconnect will depend on many factors including: KEY: • rate of discharge (amount of load draw) G = green G - Y - R = flashing sequencially •... -
Page 28: State-Of-Charge Leds
Lighting Control Mode (DIP 1 ON) NOTES: 1) R flashing is generally a user addressable fault / error • A quick press and release will clear any faults or reminders that are present. A second quick press will then conduct 2) R charging status LED ON with heartbeat blink OFF a lighting test. -
Page 29: Custom Settings
Input Voltage The heatsink temperature sensor is damaged. Return the Manual Insert Factory Reset Last Equalization Graphs Hour Meter Reset Control controller to an authorized Morningstar dealer for service. Serial No. SYSTEM Firmware Version Records Battery Type Absorption Voltage Float Voltage... -
Page 30: Programming In Msview
4.7.2 Programming in MSView 4.7.3 Meter Display Operation Beyond the preset DIP switch options, the Prostar MPPT's 4.7.3.1 Directional Key Use and Operation / Navigating charging profile and all other settings are customizable the Meter Map using MSView PC software available at: The ProStar MPPT's meter map consists of two main axes: www.morningstarcorp.com The horizontal top level daily monitoring screens, and... -
Page 31: Lighting Programming Using Meter Display
With DIP switch 1 ON (up), a dusk-dawn lighting program 4.8 Inspection and Maintenance is enabled, if lighting timing hasn't been programmed in MSView or using the meter; with DIP 1, 4, 5, 6 ON, and the Table 4-6 below lists the recommended maintenance unit programmed, custom timing will be in effect. -
Page 32: Troubleshooting
TROUBLESHOOTING Schedule Maintenance Items Re-tighten power terminal WARNING: RISK OF ELECTRICAL SHOCK. 2 weeks after installation connections to specified NO POWER OR ACCESSORY TERMINALS ARE ELEC- torque values. TRICALLY ISOLATED FROM DC INPUT, AND MAY BE ENER- GIZED WITH HAZARDOUS SOLAR VOLTAGE. UNDER CERTAIN FAULT CONDITIONS, BATTERY COULD BECOME OVER- Re-tighten power terminal CHARGED. - Page 33 disconnected. A small overload could take a few minutes to A metered model, an RM-1 meter, or MSView PC software disconnect. The ProStar MPPT will attempt to reconnect the can be used to determine if the RTS is working properly. load two (2) times.
- Page 34 Verify that nothing has been mis-wired. If not, the error is The fault is generally related to fast, large battery voltage likely critical. Contact an authorized Morningstar dealer for transients (connecting a very heavy or capacitive load like support.
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Page 35: Battery Charging And Performance Issues
If no voltage is measured, check wiring connections, fuses, period of TWO (2) years from the date of shipment to the original and breakers. end user. Morningstar will, at its option, repair or replace any such defective products. Problem: The ProStar MPPT is not charging the battery. -
Page 36: Warranty And Policies
- including the String Calculator array design tool (at www. morningstarcorp.com) - are available to assist in these areas. Morningstar can help refer customers to a nearby autho- rized distributor, dealer, or installer if assistance is required in designing a renewable energy system that best suits your specific needs. -
Page 37: Technical Specifications
/ #14 - 6* AWG requested by Morningstar Warranty Dept. (maximum torque) 35 in-lb 5. If instructed by Morningstar, after warranty replacement Battery/Temp. Sense 0.25 - 1.0 mm / #24 - 16 AWG shipment has been received, return of failed unit(s) is Knock-outs (wire box option only) M20, 1/2", 1"... - Page 38 Battery Charging Set-points (@ 25°C) Data & Communications: [multiply voltages by (2) for 24 volt systems] Communication Port MeterBus Comm. Protocols Morningstar MeterBus; MODBUS Absorp. Float Equalize Absorp. Equalize Equalize Equalize Equalize Equalize Equalize Equalize Switch Battery Stage Stage Stage...
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Page 39: Certifications
EN 61000- 4-6: 2009 • Emissions: CISPR 22: 2008 ProStar MPPT , MeterBus are trademarks of Morningstar Corporation MODBUS and MODBUS TCP/IP are trademarks of Modbus IDA. www.modbus-ida.org © 2016 Morningstar Corporation. All rights reserved. MS-001537 v1.4 Certifications ProStar MPPT Operator’s Manual... -
Page 40: Appendix B - De-Rating Graphs
APPENDIX B - De-rating Graphs Battery Current vs. Array Voltage (Vmp) Array Voltage (Volts) Battery Current vs. Ambient Temperature 100Vmp 80Vmp 60Vmp 40Vmp 20Vmp 25 30 32 33 34 35 36 37 38 39 40 41 42 43 45 46 47 48 49 50 51 52 53 54 55 56 57 60 61 Ambient Temperature (degrees C) -
Page 41: Appendix C - Wire Sizing Charts
APPENDIX C - Wire Sizing Charts 2% Voltage Drop Charts for 75°C Solid Copper Wire 1-Way Wire Distance (feet), 12 Volt System 2% Voltage Drop Charts for 75°C Stranded Copper Wire Wire Size 1-Way Wire Distance (feet), 12 Volt System (AWG) Wire Size 2/0 *... - Page 42 *Wires sizes larger than 2 AWG (35 mm ) must be terminated at a splicer 2% Voltage Drop Charts for 90°C Stranded Copper Wire block located outside of the ProStar MPPT wiring box. Use 2 AWG (35 mm ) or smaller wire to connect to the ProStar MPPT to the splicer 1-Way Wire Distance (feet), 12 Volt System block.
- Page 43 *Wires sizes larger than 2 AWG (35 mm ) must be terminated at a splicer 2% Voltage Drop Charts for 90°C Solid Copper Wire block located outside of the ProStar MPPT wiring box. Use 2 AWG (35 mm ) or smaller wire to connect to the ProStar MPPT to the splicer 1-Way Wire Distance (feet), 12 Volt System block.
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