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ROGUE MPT-3024 Installation Manual And Owner's Manual

30a - 12/24vdc mppt photovoltaic charge controller
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Enlarged version
MPT-3024
30A - 12/24VDC MPPT
Photovoltaic Charge Controller
Installation Guide
and
Owner's Manual
Rogue Power Technologies, Ashland, OR 97520
www.roguepowertech.com
© Copyright 2011, Revision C1, 05/18/11
1

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  • Page 1 MPT-3024 30A - 12/24VDC MPPT Photovoltaic Charge Controller Installation Guide Owner’s Manual Rogue Power Technologies, Ashland, OR 97520 www.roguepowertech.com © Copyright 2011, Revision C1, 05/18/11...
  • Page 2 Warranty and Liability Information Rogue Power Technologies (hereafter RPT) warrants the MPT-3024 to be free from defects in materials and workmanship for a period of five (5) years from date of purchase. Warranty applies only to the original purchaser. RPT will, at its option, either repair or replace a unit found to be defective under the terms of this warranty.

  • Page 3: Table Of Contents

    Table of Contents 1. Introduction and Overview................... 2. Safety Information....................2.1 General safety precautions..............3. Front Panel and LCD Display................4. System design considerations................4.1 Distance of wire runs................. 4.2 Wire size..................4.3 Optimal PV array voltage..............4.4 Optimal PV array power..............4.5 PV array location................
  • Page 4 Tables, Graphs, and Diagrams Tables 4.1.1. Copper wire resistance & power loss vs. gauge......4.2.1. Wire distance vs. gauge & voltage drop for 12V......4.2.2. Wire distance vs. gauge & voltage drop for 24V......4.3.1. Typical voltage drop and power loss..........4.4.1.

  • Page 5: Introduction And Overview

    Either of these methods can result in more downtime and less power being delivered to the batteries. Boost of over 40% may be achieved with the MPT-3024 when the batteries are in a low state of charge, the PV array is cold, and the sun is bright.

  • Page 6: Safety Information

    Additionally, it offers an auxiliary output relay that can be set to turn on at a specific battery voltage. A RS-485 communication port is also standard on the MPT-3024. It may be connected to a PC through the optional DCV-0001data converter, and may also be directly connected to remote monitoring and interface devices that may be available from Rogue.
  • Page 7 3) Lead-acid batteries contain an electrolytic mixture of water and sulfuric acid. Wear suitable eye and skin protection while working with batteries. Make sure you have access to running water and a supply of baking soda nearby to neutralize any spilled or splashed acid. Should acid contact eyes, wash immediately with running water for at least ten minutes and get medical attention.

  • Page 8: Front Panel And Lcd Display

    3. Front Panel and LCD Display 1 - Array voltage (volts) 2 - Array current (amps) 3 - Array power (watts) 4 - Battery voltage (volts) 5 - Battery current (amps) 6 - Charger operating mode • MPPT - bulk power tracking mode •...

  • Page 9: System Design Considerations

    4.1 Minimize the distance of wire runs Place the PV array and battery bank as close as practical to the MPT-3024. This will limit the power loss associated with long wire runs. Longer lengths of wire will cause an increase in power loss, especially at higher currents.
  • Page 10 NEC 310-15 restricts the minimum wire size for a 30-amp circuit to 10-gauge. 12-gauge may be used for installations of 20 amps or less, provided that the length of the wire does not cause a significant voltage drop. Ideally the voltage drop in any of your wiring runs should be 2% or less of the system voltage: for example, this would be approximately 0.24 volts for a 12-volt system, or 0.48 volts for a 24-volt system.

  • Page 11: Optimal Pv Array Voltage

    6-gauge is required to meet the maximum voltage drop, a junction box may be used, in which a short run of 6-gauge wire from the MPT-3024 is terminated at the larger gauge wire.

  • Page 12: Optimal Pv Array Power

    Conversely, an array that is oversized will consistently push the MPT-3024 to its maximum limit of 30A. At and beyond this limit the power from the array is constrained and the MPPT algorithm is overridden so that the controller does not exceed its maximum current output.

  • Page 13: Pv Array Location

    * = PV input limited by NEC 690-8. ** = PV input limited by maxi- mum 30A output of MPT-3024. Rows 1 and 6 suggest the maximum array sizes that are feasible without regard to NEC 690-8, using maximum 30A out- put limit for constraint.

  • Page 14: Matching Array Modules

    4.6 Match the modules of an array Although the individual PV modules of an array need not necessarily be of the same make or model, you will achieve better tracking performance from an array in which all of the modules have the same maximum power point (V This is best accomplished by choosing modules of the same make and model.

  • Page 15: Charging Modes

    MPT-3024. 5.2 Charging modes The MPT-3024 employs six distinct modes of charger operation. 1) MPPT: This is the default charging mode, also called the BULK mode, which commences when the controller first has power applied and when it first wakes up after sleeping.
  • Page 16 The absorb mode will be re-enabled (FLOTM will be reset to its default of 180 minutes or 3 hours) if power is disconnected from the MPT-3024 while absorb is disabled. 3) FULL: In this mode, the charger has been turned off so that no power is being supplied to the batteries.
  • Page 17 PV array is disconnected, the microprocessor operates at a reduced speed, and only essential circuit elements continue to receive power. These measures ensure that the MPT-3024 consumes minimal power while sleeping. In this mode the controller will check the open-circuit voltage (V ) of the PV array every five minutes.

  • Page 18: Maximum Power Point Tracking

    normal charger operation (see Section 15 for instructions). Upon selecting this mode the controller will resume operation in the MPPT mode (if it’s presently in any other mode, it will exit that mode and enter MPPT mode), and will begin an attempt to charge the batteries until their voltage reaches the value determined by the EQLZ setpoint.
  • Page 19 Figure 5.2.1. A typical day of operation for the MPT-3024 with 24-volt nominal array and 12-volt battery bank.
  • Page 20 48.0 watts (12.0 x 4.0) – a 21.6 watt loss. The MPT-3024 is capable of operating the array at its maximum power point voltage while charging a battery of substantially less voltage. It does this by rapidly switching on and off (many thousands of times per second) the connection between the array and the battery.
  • Page 21 The efficiency of the charger will also have a limiting effect on boost. The MPT-3024, like any DC-DC converter, is not 100% efficient. This is due to the resistance of circuit elements, the switching losses of the conversion, and the small amount of energy used in simply powering the electronics that operate the converter.
  • Page 22 There are no nominal MPPT adjustments to make or controls to adjust. The MPT-3024 will conduct a full sweep of the PV array’s power curve when the power is first applied, after sleeping, when transitioning from float mode back to MPPT mode, and occasionally when transitioning from equalize mode during an abort.
  • Page 23 Figure 6.1.2. Efficiency curves for various PV / battery combinations at 25...

  • Page 24: Remote Battery Temperature Sensor

    MPPT algorithm to locate and track the maximum power point. 7. Remote Battery Temperature Sensor The remote temperature sensor included with the MPT-3024 will automatically alter absorb and float setpoints based on the temperature of the batteries being charged. For each degree Celsius above 25 degrees, the setpoints will be lowered approximately 5mV per 2 volt cell (30mV for a 12-volt battery, or 60mV for a 24-volt battery).

  • Page 25: Remote Battery Voltage Sense

    9. Auxiliary Output / Relay The MPT-3024 offers an auxiliary output that can be used to turn on external devices (a vent fan, for example) when the battery voltage meets a predeter- mined setpoint (as adjusted by the user).

  • Page 26: Installation

    11.1 Mounting & thermal considerations With the preceding guidelines in mind, choose a suitable location to mount the MPT-3024. The unit must be mounted vertically against a hard, flat surface (i.e. drywall or plywood) for proper ventilation and cooling. This will also discourage foreign matter from entering the controller through the vents on the front panel.
  • Page 27 Figure 11.1.1. Removing the four screws that secure the front panel to the base of the controller (at arrows). Figure 11.1.2. Disconnecting the ribbon cable from the front panel. When reconnect- ing, make certain that key on connector aligns with keyslot in the socket.

  • Page 28: Wiring

    6-gauge is required to meet the maximum voltage drop, a junction box may be used, in which a short run of 6-gauge wire from the MPT-3024 is terminated at the larger gauge wire.
  • Page 29 Figure 11.2.2. Suggested wiring diagram.

  • Page 30: Grounding

    11.3 Grounding The enclosure of the MPT-3024 is floating with respect to all circuit voltages and may be used with either negatively or positively grounded systems. It may also be used with systems in which neither negative or positive are grounded, as allowed by NEC 690-41 for systems of less than 50 volts.

  • Page 31: Disconnects And Overcurrent Protection

    Pursuant to National Electric Code requirements (and others which may have jurisdiction in your locale), disconnects and/or overcurrent protection devices are required for both the input and output of the MPT-3024. It is recommended that the PV disconnect should be rated for 30 amps to comply with NEC requirements.

  • Page 32: Remote Battery Voltage Sense Connection

    Route the sensor cable to the MPT-3024 and through a knockout in the enclosure, using a cable clamp or suitable bushing.

  • Page 33: Auxiliary Output / Relay Connection

    The RE-CONN communication port uses standard Cat.5/Cat.6 four-pair cable wired straight-through with RJ-45 connectors on either end. Compatible devices may be attached to the port at any time. Contact Rogue for a list of devices that are compatible with the MPT-3024.

  • Page 34: Final Assembly

    12.1 Initialization With power applied, a welcome screen will appear for approximately five seconds. The MPT-3024 will then verify that a battery of suitable voltage has been connected, and will display the results on the next screen. You may confirm the result and commence charger operation (OK), or you may choose to enter SETUP.

  • Page 35: Setpoint Adjustments

    as a 12-volt nominal battery; banks measuring between 20 and 30 volts will automatically be configured as a 24-volt nominal bank. Batteries measuring outside of these ranges will cause a fault to be displayed (see Table 17.1.1). The unit must be powered down and the fault corrected before continuing.
  • Page 36 Figure 12.1.1. Operational flowchart.
  • Page 37 FLOTM value to its minimum value of zero minutes. The absorb mode will be re-enabled (FLOTM will be reset to its default of 180 minutes or 3 hours) if power is disconnected from the MPT-3024 while absorb is disabled. Changing the value of FLOTM while the charger is operating in the absorb mode will have no effect until the next time the charger transitions into the absorb mode.

  • Page 38: Operation

    See Figure 12.1.1. 13. Operation The normal operation of the MPT-3024 is fully automatic and requires no user intervention, except for battery equalization (see section 15). Setpoints may be changed at any time while the charger is operating by pressing the SETUP key.
  • Page 39 Data logging will not operate properly in regions that receive 24-hour sunlight during the summer months, if there is insufficient darkness to cause the MPT-3024 to sleep once in a 24-hour period. In these situa- tions, data will continue to accrue until the maximum values have been reached (9.99kWh and 999.9Ah), and no log entries will be made.

  • Page 40: Battery Equalization

    The data log may be accessed from the main status display at any time by pressing the “DATA” key. It may also be accessed once the MPT-3024 has entered sleep mode by pressing any key. “Wh” is the accumulated PV watt-hours for that day. If the value is greater than 999, the number will appear as kilowatt-hours (kWh).
  • Page 41 The MPT-3024 features a built-in equalize mode which must be initiated by the user. Automatic equalization can be potentially harmful to the batteries if they are not properly prepared to accept the overcharge.
  • Page 42 7) Check frequently on the batteries once the equalize mode begins. Always wear protective clothing and eye protection when checking on the condition of your batteries. Initialize equalization by pressing the EQLZ key while the charger is in normal operation. You will be prompted to read these instructions; you may then press either OK to proceed, or EXIT to resume normal charger operation.

  • Page 43: Use Of Multiple/Other Charging Sources

    EQLZ key again. 16. Use of Multiple and Other Charging Sources The MPT-3024 has been designed for use only with PV modules. Although it may possibly be used with other sources, it has not been tested with them, and will not be warranted when used with non-PV sources.

  • Page 44: Fault Messages

    MPT-3024 to enter sleep mode. 17. Fault Messages The MPT-3024 is designed with a variety of sensing capabilities that are meant to make the microprocessor aware of a fault condition and allow it to shut the controller down before damage results.
  • Page 45 Lower ambient C (120 temperature if possible. Table 17.1.1. Fault messages that are displayed on the MPT-3024’s LCD when an abnormal condition is detected. Shut down the MPT-3024, correct the fault, and wait 30 seconds before reapplying power.

  • Page 46: Specifications

    19. Specifications Output Current 30 amps Battery Voltage 12V or 24V nominal PV Voltage 12V or 24V nominal Max PV Open-circuit Voltage 60 volts Power Consumption in Sleep ~53mW (2.2mA @ 24V) Power Consumption at Idle w/backlight ~600mW (25mA @ 24V) Battery Temperature Compensation 5mV/ C per 2-volt cell...
  • Page 47 Problem Possible Cause(s) Possible Solution(s) • Battery voltage is insuffi- • Ensure that battery volt- Controller will not power up - display is blank cient age is greater than 10 volts • Improper wiring • Check integrity of wiring and connections •...
  • Page 48 Problem Possible Cause(s) Possible Solution(s) • Insufficient current from • Array may be undersized Controller never enters full mode PV array to fully charge bat- for system. Re-evaluate and tery increase array size if neces- sary / possible. • Array might not be receiv- ing enough sunlight.
  • Page 49 Problem Possible Cause(s) Possible Solution(s) • Array may be undersized • PV array output insuffi- Equalize never starts cient for system. Re-evaluate and increase array size if neces- sary / possible. • Array might not be receiv- ing enough sunlight. Con- sider relocating array for better exposure.
  • Page 50 NOTES...
  • Page 51 NOTES...
  • Page 52 NOTES...

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