Solar Regulators - MPPT

Solar Regulators

What are Solar Regulators / Solar Charge Controllers?

Solar electric power systems are essentially very simple. You have a device which converts sunlight into electrical energy (a photovoltaic panel or 'solar panel') and this is used to charge up a battery. The battery allows you to collect energy when the sun is shining and store it until needed.

This simple picture is complicated by the limitations of the battery. If you leave the photovoltaic panel connected to a battery, the battery will slowly charge up. If you are putting in more energy than you are taking out, then the battery will eventually become fully charged. If this continues, the battery will become overcharged and be damaged by corrosion of it's plates and loss of electrolyte. To avoid this, some sort of charge regulator / solar regulator is used to stop the charging when the battery is full.

Some charge controllers / solar regulators have additional features, such as a low voltage disconnect (LDV), a separate circuit which powers down the load when the batteries become overly discharged (some battery chemistries are such that over-discharge can ruin the battery).Some charge controllers may also monitor battery temperature to prevent overheating. Some charge controller systems also display data, transmit data to remote displays, and data logging to track electric flow over time.

Pulse width modulation (PWM) and maximum power point tracker (MPPT) technologies are more electronically sophisticated, adjusting charging rates depending on the battery's level, to allow charging closer to its maximum capacity.

Series Regulator vs MPPT

The MPPT versus series regulated question is not always straight forward as it very much depends on the conditions under which charging is taking place.

MPPT is good if you need to run cables from an array over a long distance as it allows higher voltage panel strings (therefore lower power loss due to cable resistance, because of lower currents).

Other than that, MPPT is useful if you don’t want to (or can’t) match the panel specifications to the battery (e.g. on a motorhome you may want to use some uncommon, high output panels since the roof space is limited).

Be aware that the % gains claimed for MPPT (other than the above couple of examples) are not likely to be ‘real world’ (e.g. How many hours during the day do your panels work at 25°C or less ?!). The hotter the panels become –the maximum power point voltage decreases and gets close to a typical battery voltage, therefore wiping out most (if not all) the gain an MPPT unit will give.

The other issues with MPPT (particularly for boats at sea) is that it’s not always easy to bypass the regulator should a fault occur (e.g. due to lightning) since the panels and battery are not matched (e.g. high voltage panels and lower voltage battery). With a series regulated system (like the Plasmatronics regulators), the system can be kept running by connecting the panels directly to the battery and manually regulating.

Morningstar MPPT Regulators

Morningstar SunSaver MPPT 15L

Morningstar’s SunSaver MPPT solar controller with TrakStar Technology™ is an advanced maximum power point tracking (MPPT) battery charger for off-grid photovoltaic (PV) systems.

The controller features a smart tracking algorithm that maximizes the energy harvest from the PV and also provides load control to prevent over discharge of the battery.

The SunSaver MPPT is well suited for both professional and consumer PV applications including automatic lighting control. Its charging process has been optimised for long battery life and improved system performance.

This product is epoxy encapsulated for environmental protection, may be adjusted by the user via four settings switches or connection to a personal computer, and has an optional remote meter and battery temperature sensor.

Key Features and Benefits:

Maximizes Energy Harvest: - Our TrakStar MPPT Technology features:
- peak efficiency of over 97%
- Almost no power losses
- Recognition of multiple power peaks during shading or mixed PV arrays
- Excellent performance at low solar insolation levels
Use of High Voltage Modules
- Enables the use of high voltage and thin film modules for off-grid battery charging
Converts 36V or 24V PV Arrays
- Provides a means to use up to a 36V PV array to charge either a 24V or 12V battery.
Lower System Cost
- Less expensive than other MPPT controllers and is affordable in smaller PV systems up to 400Wp. Allows system costs to be reduced by down-sizing the PV array, using on-grid or thin film modules and decreasing cable sizes.
Automatic Lighting Control
- Up to four programmable timer sequences for PV lighting applications
Smaller Size
- Mechanical dimensions are less than other MPPT controllers, making it easier to install in equipment enclosures.
Highly Reliable
- Efficient electronics, a conservative thermal design and tropicalization result in high reliability and long life.
Fully Adjustable
- User selection via on-board switches or PC connection.
Extensive Electronic Protections
- Fully protected against most system errors and faults.
Longer Battery Life
- Efficient MPPT tracking and 4-stage charging increases battery life.
More Information
- The status LED’s and optional meter provide extensive controller and system data.
Data Logging
- Records key operating parameters of the PV system and includes 30 days of data logging.

Specifications
Peak Efficiency:	97.5%	Humidity:	100% non-condensing
Nominal Battery Voltage:	12 or 24 volts	Tropicalisation:	Epoxy EncapsulationConformal Coating Marine Rated Terminals
Maximum Battery Charging Current:	15 amps	Electronic Protections:	PV: Overload, Short Circuit, High Voltage Load: Overload, Short Circuit Reverse Polarity: Battery, PV and Load Lightning and Transient Surges High Temperature Reverse Current at Night
Battery Voltage Range:	7-36 volts	Battery Types:	Gel, Sealed, AGM, Flooded
Nominal Maximum Operating Power*:	12 Volt Battery: 200w 24 Volt Battery: 400w	4 Stage Charging:	Bulk, absorption, float, equalize (optional)
Maximum PV Open Circuit Voltage**:	75 volts	Temperature Compensation:	Coefficient: –5mV/°C / cell (25°C ref) Range: –30°C to +60°C Set points: Absorption, float, equalize
Rated Load Current:	15 amps	Dimensions cm (HxWxD) :	16.9 x 6.4 x 7.3 cm (6.6" x 2.5" x 2.9' in)
Self Consumption:	35 milliamps	Weight:	0.60 kg / 1.3 lbs
Transient Surge Protection:	4 x 1500 Watts	Power Terminal :	16 mm2 / #6 AWG
Operating Temperature :	-40°c to +60°c	Enclosure:	Die cast aluminum with plastic cover
Storage Temperature:	-55°c to +100°c

Optional Extras	Remote Meter, Remote Temperature Sensor, USB MeterBus Adapter (UMC-1), PC MeterBus Adapter for RS-232, DIN Rail Mounting Clips
Certifications:	CE Compliant, RoHS Compliant, UL 1741 / CSA 107.1-01 Recognised Component, Manufactured in a Certified ISO 9001 Facility

*Input power can exceed Nominal Maximum Operating Power, but controller will limit and provide its rated continuous maximum output current into batteries. This will not harm the controller (reminder: do not exceed Voc).
**Exceeding Maximum PV Open Circuit Voltage may damage the controller

Morningstar ProStar MPPT 25 & 40

The NEW ProStar MPPT™ is a mid-range MPPT solar charge controller with TrakStar Technology™ that provides maximum power point tracking (MPPT) battery charging for off-grid photovoltaic (PV) systems up to 1100 watts.

Available with and without advanced built-in meter.

This device is ideal for industrial and residential applications.

A Wire Box for ProStar MPPT accessory to reduce hazards associated with exposed wires and connections can be purchased separately.

This controller allows multiple modules in series for 12V and 24V battery systems.

Detailed battery programming options allow for advanced battery support for the latest Lithium, Nickel Cadmium, and Lead Acid battery types.*

*Note: some battery types require a compatible battery management system.

KEY FEATURES AND BENEFITS

High Reliability – conformally coated circuit board and corrosion resistant terminals.
Automatic PV-based lighting load control
Charges all battery types including Lithium Ion
Continuous charging and no damage from PV array oversizing
Up to 190 days of data logging
Built-in self diagnostics
Highly durable polycarbonate case
3⁄4 Maximizes Energy Harvest – using TrakStar MPPT Technology to determine and adjust to the true maximum power point as solar insolation changes throughout the day.
3⁄4 High Efficiency – at low, medium, and high power levels.
3⁄4 Data Logging – up to 256 days of detailed power and load data.
3⁄4 Low Noise Design – meets US Federal Communications Commission Class B specifications.
3⁄4 Automatic PV Based Lighting Control – field adjustable, multi-event load control enables powerful options for PV lighting systems.
3⁄4 MODBUS Communications – Solar Industry Standard MODBUS communications protocol allows for easy programming, control, remote data access and charge synchronization.
3⁄4 High Strength – polycarbonate case and extruded aluminum heatsink.
3⁄4 Self Diagnostics – continuous monitoring and reporting of any errors through its status LED’s, optional display or communication port.

Specifications
	PS-MPPT-25, PS-MPPT-25M	PS-MPPT-40, PS-MPPT-40M
Max. Battery Current:	25 Amps	40 Amps
Load Current Rating :	25 Amps	40 Amps
Max. PV Open Circuit Voltage (Voc):	120 Volts (without damage to unit)
Nominal Battery Voltage:	12V or 24V
Nominal Maximum Operating Power*:	12 Volt Battery: 350W @45C 24 Volt Battery: 700W @60C	12 Volt Battery: 550W @45C 24 Volt Battery: 1100W @60C
Peak Efficiency:	98%
Battery Voltage Range:	10-35V
Voltage Accuracy:	<= 0.1% +/- 50mV
Self-Consumption:	normal: 0.6W; maximum: 1W
LED Indication:	(1) status, (3) Battery S.0.C
Transient Surge Protection:	solar, battery, load
Meter Operating Temperature Range:	-40°C to +60°C
Storage Temperature:	-20°C to +60°C
Humidity:	-40°C to +80°C
Tropicalization:	Conformal coating, marine-rated terminals
Load & Lighting Control:	Low Voltage Disconnect, Low Voltage Reconnect Settings: 11.4V/12.6V or custom (x2 for 24 volt systems) Lighting Settings: Dusk-dawn or custom
Electronic Protections:	Automatic recovery without fuses Solar Input: overload, short-circuit, high voltage warning, reverse polarity, high temperature, nighttime reverse current Load Output: overload, short-circuit, high temperature, reverse polarity Battery: reverse polarity (no battery removal)
Battery Charging:	4-stage charging: Bulk, Absorption, Float, Equalize
Temperature Compensation:	Coefficient: -5 mV / C /cell (25 C / 77 F ref.) Range: -30 C to +60 C / -22 F to +140 F Setpoints: Absorption, Float, Equalize
Data & Communications:	Communication Port: MeterBus Protocols: Morningstar MeterBus, MODBUS Datalogging: 256 days, daily records PC Software: MSView
Dimensions:	Standard: 20 x 17 x 7 cm (w/ Wire Box: 20 x 28.5 x 9.2 cm)
Weight:	Standard: 1.4 kg / 3.1 lbs (w/ Wire Box: 1.8 kg / 4.0 lbs)
Battery/Temp. sense:	0.25 - 1.0 mm2 / 24 - 16 AWG

Optional Extras	Ground Fault Protection Device (GFPD-150), Remote Temperature Sensor (RTS), Remote Meter (RM-1), Wire Box (PS-MPPT-WB), PC MeterBus Adapter (MSC), USB Communications Adapter (UMC-1), Meter Hub (HUB-1), Relay Driver (RD-1)
Certifications:	CE; RoHS; ETLListed (UL1741,UL62109); cETL(CSA-C22.2No.107.1), TUV (IEC 62109-1); FCC Part-15 Class B compliant, Manufactured in a certified ISO 9001 facility

*Input power can exceed Nominal Operating Power. Controller will limit and provide its rated continuous maximum output current into batteries.

Morningstar TriStar MPPT 30, 45 & 60

Morningstar’s TriStar MPPT solar controller with TrakStar Technology™ is an advanced maximum power point tracking (MPPT) battery charger for off-grid photovoltaic (PV) systems up to 3kW.

The controller provides the industry’s highest peak efficiency of 99% and significantly less power loss compared to other MPPT controllers.

The TriStar MPPT features a smart tracking algorithm that maximizes the energy harvest from the PV by rapidly finding the solar array peak power point with extremely fast sweeping of the entire I-V curve.

This product is the first PV controller to include on-board Ethernet for a fully web-enabled interface and includes up to 200 days of data logging

Key Features and Benefits:

Maximizes Energy Harvest
- Better peak power point tracking than other MPPT controllers
- Very fast sweeping of the entire I-V curve
- Recognition of multiple power points during shading or mixed PV arrays
- Excellent performance at sunrise and low solar insolation levels
Extremely High Reliability
- Robust thermal design and no cooling fans
- Parallel circuit design provides less stress and longer life for electronic components
- No mechanical relays
- Extensive electronic protections including PV short circuit protection
- Epoxy encapsulated inductors and conformally coated printed circuit boards
Very High Efficiency
- Peak efficiency of 99%
- Proprietary tracking algorithm minimizes power losses
- Low self-consumption
- Continuous operation at full power to 45°C without need to de-rate
- Selected electronic devices with higher ratings to minimize losses from heating
Extensive Networking and Communications Capabilities
- Enables system monitoring, data logging and adjustability.Uses open standard MODBUS™ protocol and Morningstar’s MS View software.
- Meterbus: communications between compatible Morningstar products
- Serial RS-232: connection to a personal computer
- EIA-485: communications between multiple devices on a bus
- Ethernet: fully web-enabled interface to a local network or internet; view from a web browser or send email/text messages.
Metering and Data Logging
- Optional TriStar meter and remote meter provides detailed operating data, alarms and faults
- Three LED’s display system status
- Up to 200 days of data logging via meters or communications ports

Specifications
	TS-MPPT-30	TS-MPPT-45	TS-MPPT-60
Max. Battery Current:	30 Amps	45 Amps	60 Amps
Nominal Maximum Operating Power:*	12 Volt Battery: 400w 24 Volt Battery: 800w 48 Volt Battery: 1600w	12 Volt Battery: 600w 24 Volt Battery: 1200w 48 Volt Battery: 2400w	12 Volt Battery: 800w 24 Volt Battery: 1600w 48 Volt Battery: 3200w
Max. PV Open Circuit Voltage (Voc):**	150 volts DC
Nominal System Voltage:	12, 24, 36 or 48 volts DC
Peak Efficiency:	99%
Battery Voltage Range:	8-72 volts DC
Maximum Self-consumption:	2.7 Watts
Transient Surge Protection:	4500 Watts/port
Ambient Temperature:	-40°C to +45°C
Storage Temperature:	-55°C to +100°C
Humidity:	100% non-condensing
Tropicalization:	Epoxy encapsulation, Conformal coating, Marine rated terminals
Electronic Protections:	Solar: Overload, Short Circuit, High Voltage Battery: High Voltaget High Temperature, Lightning and Transient Surges, Reverse Current at Night
Battery Charging:	4-stage charging: Bulk, Absorption, Float, Equalize
Temperature Compensation:	Coefficient: –5mV/°C/cell (25° ref) Range: -30 C to +80 C Setpoints: Absorption, Float, Equalize, HVD
Communication Ports MeterBus: RS-232: EIA-485: Ethernet:	TS-MPPT30 Yes Yes No No	TS-MPPT45 Yes Yes No No	TS-MPPT60 Yes Yes Yes Yes
Dimensions:	29.1 x 13.0 x 14.2 cm (11.4 x 5.1 x 5.6 in)
Weight:	4.2 kg / 9.2 lbs

Optional Extras:	TriStar Meter-2 (TS-M-2), TriStar Remote Meter-2 (TS-RM-2), Meter Hub (HUB-1), Relay Driver (RD-1)
Certifications:	CE and RoHS Compliant, ETL Listed (UL1741), cETL (CSA C22.2 No. 107.1-01), FCC Class B Part 15 Compliant, U.S. National Electrical Code (NEC) 690.5 Compliant, Manufactured in a certified ISO 9001 facility

Morningstar TriStar MPPT 600v

Morningstar’s TriStar MPPT 600V charge controller leverages Morningstar’s innovative TrakStar™ MPPT technology and our 20+ years of power electronics engineering excellence, to enable the widest input operating voltage range available from a solar array, wind turbine or hydro input.

This controller’s standard and DB versions are for off-grid applications, and the TR versions were developed to enable retrofitting grid-tied systems with battery backup:

TS-MPPT-60-600V-48 (Standard)

TS-MPPT-60-600V-48-DB (With Disconnect Box)

TS-MPPT-60-600V-48-DB-TR (With DC Transfer Switch)

TS-MPPT-60-600V-48-DB-TR-GFPD (Pre-wired with Ground Fault Protection Device)

Rated for 60 Amps, the TriStar MPPT 600V controller does much more than efficiently charge batteries; it also provides remote communications, data logging, adjustability and metering. In fact, the TriStar MPPT 600V controller is the only 600-volt PV controller to offer open communication protocols and true Ethernet-enabled functionality.

Key Features & Benefits

The TriStar MPPT 600V charge controller delivers high reliability and excellent performance and features:

97.9% peak efficiency.
Morningstar’s advanced 4-stage charging algorithm to optimize battery health
Robust thermal, mechanical and electrical design
Environmentally optimized and equipped with extensive electronic protections
Industry standard open communication protocols and interfaces for system networking, monitoring and communications
Superior lightning protection from nearby lightning-induced voltage/current spikes
Fewer combined circuits and lower current for long wire runs from the array to the controller

Applications

The TriStar MPPT 600V charge controller’s high voltage capability and flexible design enable several application scenarios including:

Adding modules incrementally with no string sizing issues
Off-grid PV systems greater than 150 Voc with long wire runs from the array to the controller
New installation grid-tie PV systems with battery back-up
Retrofitting string PV inverter systems to later add battery back-up without changing the PV array configuration
Supplementary charging for AC Coupled PV systems
Battery-based Wind systems
Water pumping applications

High Voltage Capacity

Maximum input voltage of 600V
Operates with PV array Voc voltages up to 525 Voc
Wind, hydro operating voltages up to 500 Vdc
Pre-set for 48 Vdc battery systems
Programmable for 24V, 36V and 60V battery systems
Allows long wire runs from the array to the controller
Higher voltage reduces voltage drop and wire costs
No combiner boxes required for single or two string systems
Better enables grid-tie PV systems with battery back-up
Enables easier PV array expansion than lower voltage systems and accommodates increasing loads
Supports battery based solar PV, wind, hydro and other high voltage DC power systems

Extremely High Reliability

Robust thermal design and no cooling fans
No moving parts
Superior lightning protection from nearby lightning induced voltage/current spikes
Extensive electronic protections
Epoxy encapsulated inductors and conformally coated printed circuit boards

Very High Efficiency

97.9 % peak efficiency
Proprietary tracking algorithm minimizes power losses
Low self-consumption
Continuous operation at full power to 45°C ambient temperatures without need to de-rate
Electronic devices with higher ratings to minimise losses from heating

Maximises Energy Harvest
Our TrakStarTM MPPT Technology features:

Better peak power point tracking than other MPPT charge controllers
Very fast sweeping of the entire PV array
Recognition of multiple power points during shading or mixed PV arrays
Low input voltage operation
Excellent performance at sunrise and low solar insolation levels

Communications Capabilities

Enables system monitoring, data logging and adjustability.
Uses open standard MODBUSTM protocol and Morningstar’s MS View software
Meterbus: Communications between compatible Morningstar products
Serial RS-232 and EIA-485 serial connectivity
Ethernet: fully web-enabled interface to a local network or internet; view from a web browser or send email

Other Features

High-Low voltage barrier improves safety
Available with optional Disconnect Box: 600V PV disconnect switch, battery breaker and prewired input/output bus bars
Available with DC Transfer Switch option for switching from a GT string inverter to battery backup charging during a utility outage. Multiple controllers and GFPDs may be added later, on an as-needed basis

Specifications

Peak Efficiency:	97.9%
Maximum Battery Current:	60A
Maximum Input Operating Current:	15A (self limiting)
Maximum Solar Open Circuit Voltage:	600V
Nominal Maximum Operating Power****	3200Wp, 48 Volt
Nominal System Voltage:	48 Vdc (custom programmable to 24V, 36V and 60V)
Battery Operating Voltage Range:	16-72 Vdc
PV Input Operating Voltage Range:	100V to Voc = 525V
Wind/Hydro Input Operating Voltage Range:	Battery Voltage to 500V
Self-Consumption:	1.75 - 2.50 W
Transient Surge Protection:	4500 Watts/port
Electronic Protections:	Input: Overload, high voltage Battery: High voltage, battery sense disconnected, remote temperature sense disconnected General Operation: High temperature, reverse current at night, lightning and transient surges
Ambient Temperature:	-40°C to +45°C
Storage Temperature:	-55°C to +85°C
Humidity:	100% non-condensing
Tropicalization:	Epoxy encapsulation, Conformal coating, Marine-rated terminals
Battery Charging:	Charging Stages: MPPT, absorption, float, equalize
Temperature Compensation:	Coefficient: -5 mV / C /cell (25 C / 77 F ref.) Range: -30 C to +60 C / -22 F to +140 F Setpoints: Absorption, Float, Equalize
Communication:	Ports: Ethernet, EIA-485, RS-232, MeterBus Supported Protocols: MeterBus, MODBUS RTU, MODBUS TCP/ IP, HTTP, SNMP v2, SMTP
Dimensions:	Standard Version: 39.2 x 22.1 x 14.9 cm / 15.4 x 8.7 x 5.9 in DB & TR Version: 54.2 x 22.1 x 14.9 cm / 21.4 x 8.7 x 5.9 in
Weight:	Standard: 9.0 kg / 19.8 lbs DB & TR Version: 12.8 kg / 28.1 lbs

Optional Extras:	TriStar 600V Meter (TS-M-2-600V), TriStar Remote Meter (TS-RM-2), Meter Hub (HUB-1), Relay Driver (RD-1), 600V Ground Fault Protection Device (GFPD-600V)
Certifications:	CE, RoHS, NEC Compliant, ETL Listed: UL-1741 and Canadian CSA C22.2 No. 107.1.01, FCC Class B Part 15 Compliant

Four Versions:

TS-MPPT-60-600V-48 Standard

TS-MPPT-60-600V-48-DB With Disconnect Box (600V; 25A 1-Pole disconnect switch)

TS-MPPT-60-600V-48-DB-TR* With DC Transfer Switch (600V; 30A double pole; double throw DC Transfer Switch)

TS-MPPT-60-600V-48-DB-TR-GFPD**

Pre-wired with Ground Fault Protection Device All non-standard versions include a 1-Pole; 63A PV battery breaker*** and pre-wired PV/Battery busbars TR versions also include a pre-wired String Inverter busbar

* Can be used as a 2-pole version of the Disconnect Box.
** See GFPD-600V datasheet for additional specifications.
*** Can be replaced with 2-pole battery breaker.
**** Input power can exceed Nominal Maximum Operating Power, but controller will limit and provide its rated continuous maximum output current into batteries. This will not harm the controller.