MORNINGSTAR SUNSAVERMPPT Operation Manual
TM
MAXIMUM POWER POINT TRACKING
UNSAVER MPPT
S
WITH TRAKSTARTM MPPT TECHNOLOGY
Installation and Operation Manual
Model: SS-MPPT-15L
1098 Washington Crossing Road
Washington Crossing, PA 18977 USA
www.morningstarcorp.com
SunSaver MPPT Dimensions
Specication Summary
System Voltage 12 Volts / 24 Volts
Rated Battery Current 15 Amps
Rated Load Current 15 Amps
Max. Input Voltage** 75 Volts
Nominal Input Power
12 Volt System 200 Watts
24 Volt System 400 Watts
see Section 7.0 for full technical specications
** Array voltage should never exceed maximum input voltage.
Refer to the solar module documentation to determine the high-
est expected array Voc as dened by the lowest expected ambient
temperature for the system location.
Contents
34
1.0 Important Safety Information 4
2.0 General Information 5
2.1 Overview 5
2.3 Optional Accessories 8
3.0 Installation Instructions 9
3.1 General Installation Notes 9
3.2 Conguration 10
3.3 Mounting 13
3.4 Wiring 15
4.0 Operation 20
4.1 LED Indications 20
TM
4.2 TrakStar
4.3 Battery Charging Information 25
4.4 Load Control Information 27
4.5 Protections 29
4.6 Inspection and Maintenance 31
4.7 Programming Custom Setpoints 32
5.0 Troubleshooting 33
5.1 Error Indications 33
5.2 Common Problems 34
6.0 Warranty 35
7.0 Technical Specications 36
Appendix A - Wire Charts 41
MPPT Technology 22
MORNINGSTAR CORPORATION 3
1.0 Important Safety Information
Save These Instructions
This manual contains important safety, installation and operating
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 for the safe and proper operation of
the controller.
General 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.
• 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. Install external fuses/breakers as required.
• Do not allow water to enter the controller.
• Conrm that power connections are tightened to avoid
excessive heating from a loose connection.
2.0 General Information
2.1 Overview
Thank you for selecting the SunSaver MPPT charge
controller with TrakStar Technology
(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).
TM
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 specied
intervals throughout the day and night. See section 4.7 for
more information.
Although the SS-MPPT is very simple to congure 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.
TM
. The SunSaver MPPT
2.0
1.0 IMPORTANT SAFETY INFORMATION
MORNINGSTAR CORPORATION 5
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 adapter is
required, available separately.
2.0
8
7
1
2
3
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.
5 - Settings Switches
Adjustment switches that dene the operating parameters
of the SunSaver MPPT.
6 - Remote Temperature Sensor (RTS) Terminals
6
Connection point for a Morningstar RTS (optional) to
remotely monitor battery temperature.
5
4
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 an 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 GENERAL INFORMATION
MORNINGSTAR CORPORATION 7
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 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 AdapterTM (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 is required for programming custom charging setpoints and for
logging data. See Section 4.7 Programming Custom Setpoints.
3.0 Installation Instructions
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 gasses may be present during
charging. Be certain there is sufcient ventilation to
release the gasses.
• 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.
3.0
2.0 GENERAL INFORMATION
MORNINGSTAR CORPORATION 9
3.2 Conguration
The four (4) Settings Switches and the Battery Select
Jumper adjust the SS-MPPT battery type, load control,
equalization, and communication settings. This section
details the conguration 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 Specications 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 gure 2.
The second column in table 1 species whether the jumper
should be removed or remain in place, depending on the
desired battery type.
Battery Type Battery Jumper Switch 1
1
Gel
Sealed INSERTED OFF (↓)
1
AGM
Flooded REMOVED OFF (↓)
(1) Setpoints for this battery type can be modified with custom programming. See Section 4.7 Programming Custom Setpoints for more information.
Table 1. Battery Type selection
INSERTED ON (↑)
REMOVED ON (↑)
Figure 2. Removing the Battery Select jumper.
Load Control – Low Voltage Disconnect / Reconnect
Choose between two (2) load control Low Voltage Discon-
nect / 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. See Section 4.7
Programming Custom Setpoints for more information.
2
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 or if the battery
discharges too low the previous night. There is no
equalization charge for the gel or sealed battery type.
SWITCH 3 OFF (↓): AUTO-EQUALIZE OFF
SWITCH 3 ON (↑): AUTO-EQUALIZE ON
(agm, ooded battery type only)
3.0
3.0 INSTALLATION INSTRUCTIONS
MORNINGSTAR CORPORATION 11
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.
SWITCH 4 OFF (↓): MORNINGSTAR REMOTE METER
SWITCH 4 ON (↑): MODBUS® PROTOCOL FOR
MSVIEW, 3RD PARTY DEVICES
3.3 Mounting
NOTE: When mounting the SunSaver MPPT, ensure free
air ow through the controller heat sink ns. There
should be at least 6 inches (150 mm) of clearance above
and below the controller to allow for cooling. If mounted
in an enclosure, ventilation is highly recommended.
WARNING: Risk of explosion! Never install the SunSaver
MPPT in a sealed enclosure with vented (ooded)
batteries! Do not install in a conned area where battery
gasses can accumulate.
Step 1: Choose Mounting Location
Locate the SunSaver MPPT on a vertical surface
protected from direct sun, high temperatures, and water.
3.0
(2) Morningstar PC Meterbus Adapter (Model: MSC) required. Not included.
See Morningstar’s website for more information. www.morningstarcorp.com.
MODBUS® is a registered trademark of Modbus-IDA (www.modbus-ida.org)
3.0 INSTALLATION INSTRUCTIONS
Step 2: Check for Clearance
Place the SunSaver MPPT in the location where it will be
mounted. Verify that there is sufcient room to run wires and
that there is ample room above and below the controller for
air ow.
AT LEAST
6” (150 mm)
AT LEAST
6” (150 mm)
Figure 3. Mounting and cooling
WARM AIR
COOL AIR
MORNINGSTAR CORPORATION 13
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