Morningstar ProStar MPPT Series Installation, Operation And Maintenance Manual Download Page 21

Operation

ProStar MPPT Operator’s Manual

37

36

4.0

4.1  TrakStar

TM

 MPPT Technology

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 

is  fully  automatic  and  does  not  require  user  adjustment.                

Trakstar technology will track the array maximum power 

point voltage (Vmp) 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 flowing into the ProStar MPPT and 

5 amps of charge current flowing out to the battery. The 

ProStar MPPT does not create current!  Rest assured that the 

power into the ProStar MPPT is the same as the power out 

of the ProStar MPPT. Since power is the product of voltage 

and current (Volts x Amps), the following is true*: 

(1)  Power Into the ProStar MPPT = Power Out of the ProStar 

MPPT

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

* assuming 100% efficiency i.e. if no losses in wiring and 

conversion existed.
If the solar module’s Vmp 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.

4.0 OPERATION

High Voltage Strings and Grid-tie Modules

Another benefit of TrakStar MPPT technology is the ability 

to charge 12 or 24 volt batteries with solar arrays of higher 

nominal voltages. A 12 volt battery bank can be charged 

with a 12, 24, 36 or 48V nominal off-grid solar array. Certain     

grid-tie solar modules may also be used as long as the 

solar array open circuit voltage (V

oc

) rating will not exceed 

the ProStar MPPT 120V maximum input voltage rating at 

worst-case (lowest) module temperature. The solar module 

documentation should provide V

oc

 vs. temperature data.

Higher solar input voltage results in lower solar input       

current for a given input power. High voltage solar input 

strings allow for smaller gauge solar wiring. This is especially 

helpful for systems with long wiring runs between the solar 

array and the ProStar MPPT. 

An Advantage Over Traditional Controllers

Traditional controllers connect the solar module directly 

to the battery when recharging. This requires that the so-

lar module operate in a voltage range that is below the      

module’s V

mp

.   In a 12V system, for example, the battery 

voltage may range from 10 - 15 Vdc but the module’s V

mp

 is 

typically around 17V. Figure 4.1 shows a typical current vs. 

voltage output curve for a nominal 12V off-grid module.

 

 

   

Figure 4.1.  Nominal 12 volt solar module I-V curve and output power  

                      graph

 

PO

WER

VOLTAGE

10

15 17

TrackStar

Maximum

Power

Point

Traditional

Controller

Operating Range

CURRENT

VOLTAGE

10

15 17

Maximum

Power

Point

Typical Battery

Voltage Range

12 Volt Module

Current vs. Voltage

12 Volt Module

Output Power

Summary of Contents for ProStar MPPT Series

Page 1: ...ation Operation and Maintenance Manual www morningstarcorp com ProStar MPPT TM MODELS PS MPPT 25 PS MPPT 25M PS MPPT 40 PS MPPT 40M MAXIMUM POWER POINT TRACKING For the most recent manual revision see...

Page 2: ...36 4 1 TrakStar MPPT Technology 36 4 2 Battery Charging Information 38 4 3 Load Control Information 48 4 4 LED Indications 50 4 4 1 Power up 50 4 4 2 Status LED 50 4 4 3 State of charge LEDs 51 4 5 Pu...

Page 3: ...d installations et d utilisation du contr leur solaire ProStar MPPT Les symboles suivants sont utilis s dans ce manuel pour indiquer des conditions potentiellement dangereuses ou des consignes importa...

Page 4: ...allow water to enter the controller Install the ProStar MPPT in a location that prevents casual contact The ProStar MPPT heatsink can become very hot during operation Use insulated tools when working...

Page 5: ...with connection to the ProStar MPPT ground terminal The grounding conductor must be secured against any accidental detachment Pr cautions de S curit D installation AVERTISSEMENT L appareil n est pas f...

Page 6: ...Risk of Explosion Proper disposal of batteries is required Do not dispose of batteries in fire Refer to local regulations or codes for requirements AVERTISSEMENT Risque d Explosion Au rebut des piles...

Page 7: ...bagues bijoux et autres objets m talliques avant de travailler avec des piles Porter des bottes et des gants de caoutchouc Utiliser des outils avec poign es isolantes et vitez de placer des outils ou...

Page 8: ...otherwise a maximum of 6 AWG wire Includes battery voltage sense terminals Digital meter display options Optional remote battery temperature sensor 5 year warranty see Section 6 0 2 0 GENERAL INFORMAT...

Page 9: ...la classe B est conforme a la norme NMB 003 du Canada 2 3 Versions and Ratings PS MPPT 25 Rated for maximum 25 amps continuous current battery or load Designed for 12 or 24 VDC systems PS MPPT 25M In...

Page 10: ...Power connections for Load and cable terminations 7 Battery Positive and Negative Terminals Power connections for Battery and cable terminations 8 Local Temperature Sensor Compensates charging based...

Page 11: ...ound fault Protection Device GFPD 150V The GFPD 150V detects power source ground faults and interrupts current as required by the U S National Electrical Code Wire Box for ProStar MPPT A modular wirin...

Page 12: ...nections that melt wire insulation burn surrounding materials or even cause fire Ensure tight connections and use cable clamps to secure cables and prevent them from swaying in mobile applications Pre...

Page 13: ...0 M WARNING Installation must comply with all US National Electrical Code and Canadian Electrical Code requirments Breakers and fuses may require lower ratings than referenced above so as not to excee...

Page 14: ...Float Stage volts Equalize Stage volts Absorp Time mins Equalize Time mins Equalize Timeout mins Equalize Interval days off off off 1 Sealed 14 00 13 50 150 off off on 2 Sealed 14 15 13 50 14 40 150...

Page 15: ...temperature sensing To battery and terminals To load and terminals To properly sized array 2 3 1 7 5 6 4 3 4 Wiring Figure 3 3 Wiring the PS MPPT REFER TO FIGURE 3 3 WHEN USING THE WIRING INSTRUCTION...

Page 16: ...ecommended if the controller is more than three meters 10 ft from the battery Generally accepted wiring practice is to limit voltage drops between the charger and the battery to 2 Even properly sized...

Page 17: ...cated between the battery and chassis ground terminal lugs see figure The RTS is supplied with 33 ft 10 m of 22 AWG 0 34 mm2 cable There is no polarity so either wire or can be connected to either scr...

Page 18: ...syst me la mise la terre au niveau du contr leur Selon les exigences par le code local ou les r f rences le c t n gatif du syst me doit tre mis la terre par un GFPD un seul point For safety and effect...

Page 19: ...way to break the PV connection when necessary DO NOT CLOSE THE BREAKER AT THIS TIME 40 Volt MODULE 40 Volt MODULE 40 Volt MODULE SOLAR Solar Disconnect SOLAR 120Voc Maximum EARTH GROUND STEP 7 Load C...

Page 20: ...r connection LOAD LOAD 40 or 55 Amp Fuse depending on model If the load does not turn on it could be for various reasons the ProStar MPPT is in LVD red LED on there is a short circuit in the load LEDs...

Page 21: ...tems where the solar array is of a higher nominal voltage than the battery as described in the next section 4 0 OPERATION High Voltage Strings and Grid tie Modules Another benefit of TrakStar MPPT tec...

Page 22: ...extended by 30 minutes if the battery discharges below 12 50 volts 12V system the previous night The Absorption set point is temperature compensated through either the on board local temperature sens...

Page 23: ...the electrolyte gases The green SOC LED will blink rapidly two 2 times per second during equalization charging The duration of the equalize charge is determined by the selected battery type See table...

Page 24: ...ings table see table 4 1 in this section shows two sealed battery settings with an Equaliza tion cycles These are minimal boost cycles to level indi vidual cells This is not an equalization and will n...

Page 25: ...Absorption Extension Voltage time hrs Figure 4 3 Absorption Extension Charging Profile If battery voltage discharges below 12 50 volts 25 00 volts 24V the previous night Absorption charging will be ex...

Page 26: ...threshold voltage The diagram shows where Float stage would have occurred if Float was not canceled Equalize Time out 1 00 2 00 3 00 4 00 5 00 6 00 Absorp V Bulk Float Equalize Equalize timeout time...

Page 27: ...sistance Current Compensation All LVD and LVR set points are current compensated Under load the battery voltage will sag in proportion to the current draw of the load A short term large load could cau...

Page 28: ...briefly every 5 seconds heartbeat indication flickers the Status LED off briefly every 5 seconds Table 4 4 Status LED Definitions NOTES 1 R flashing is generally a user addressable fault error 2 R cha...

Page 29: ...h the ProStar MPPT will operate with full rated current as indicated in each graph maximum ambient temperature depends on array input voltage Actual de rating temperatures lower than specified in the...

Page 30: ...Manual Insert Clear Resettable Ah Clear Total Ah Serial No Firmware Version Battery Type Absorption Voltage Float Voltage EQ Voltage Input Mode System Voltage 4 7 2 Programming in MSView Beyond the pr...

Page 31: ...1 4 5 6 ON and the unit programmed custom timing will be in effect With DIP 1 OFF down all lighting control functions are disabled Using either MSView or the meter display four channels are available...

Page 32: ...rie pourrait devenir trop charg e Test entre toutes les bornes et la masse avant de toucher Schedule Maintenance Items 2 weeks after installation Re tighten power terminal connections to specified tor...

Page 33: ...OOTING disconnected A small overload could take a few minutes to disconnect The ProStar MPPT will attempt to reconnect the load two 2 times Each attempt is approximately 10 seconds apart If the overlo...

Page 34: ...ry status LEDs R Y G sequencing While rare if battery current exceeds approximately 130 of the controller s output current rating this fault can occur The fault is generally related to fast large batt...

Page 35: ...oStar MPPT Battery voltage must be 10 vdc or greater If the voltage on the battery terminals of the controller is between 10 and 35 vdc and no LEDs are lit contact your authorized Morningstar dealer f...

Page 36: ...claim Morningstar will pay the return shipping charges if the repairs are cov ered under the warranty WARRANTY EXCLUSIONS AND LIMITATIONS This warranty does not apply under the following conditions D...

Page 37: ...ank you for your business and we look forward to assisting you WARRANTY CLAIM PROCEDURE 1 Before proceeding please refer to product manual including Troubleshooting section 2 Contacting your authorize...

Page 38: ...et points Absorption Float Equalize HVD and HVDR solar 7 0 TECHNICAL SPECIFICATIONS Battery Charging Set points 25 C multiply voltages by 2 for 24 volt systems Current Compensation 12 volt systems 15...

Page 39: ...Humidity 100 n c Tropicalization Conformally coated PCBs Marine rated terminals For hazardous location IECEx ATEX applications see the addendum part no MS 003244 EN to this manual Protections Power up...

Page 40: ...atts E ciency ProStar MPPT E ciency 24 Volt System 62 Vmp 93 Vmp APPENDIX B De rating Graphs Battery Current vs Array Voltage Battery Current vs Array Voltage Array Voltage Volts O V E R V O L T A G E...

Page 41: ...systems solid copper 2 voltage drop 1 Way Wire Distance meters 12 Volt System Wire Size mm2 40A 35A 30A 25A 20A 15A 10A 5A 70 10 24 11 71 13 66 16 39 20 49 27 32 40 98 81 95 50 8 12 9 28 10 83 12 99 1...

Page 42: ...01 6 69 10 03 20 06 10 1 58 1 80 2 10 2 52 3 15 4 21 6 31 12 62 6 0 99 1 13 1 32 1 59 1 98 2 64 3 97 7 93 4 0 62 0 71 0 83 1 00 1 25 1 66 2 50 4 99 2 5 0 39 0 45 0 52 0 63 0 78 1 05 1 57 3 14 Table C...

Page 43: ...0 32 0 36 0 42 0 50 0 63 0 84 1 26 2 52 Table C 6 Maximum 1 way wire distance for 12 Volt systems stranded copper 2 voltage drop 2 Voltage Drop Charts for 90 C Solid Copper Wire 1 Way Wire Distance fe...

Page 44: ...mperature as defined in the following table Wire Ampacity Key Exceeds wire ampacity at 60 C ambient temperature Exceeds wire ampacity at 50 C ambient temperature Exceeds wire ampacity at 40 C ambient...

Page 45: ...0 6 3 CISPR 22 Low Voltage Directive IEC EN 62109 1 MORNINGSTAR CORPORATION 2 1 Hazardous Locations for IECEx ATEX Applications IECEx ETL 20 0066X ITS20ATEX25933X IECEx Ex ec ic IIC TX Gc ATEX II 3G E...

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