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Morningstar ProStar MPPT TRAKSTAR PS-MPPT-15, Installation, Operation And Maintenance Manual, Page: 1 / 85

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Morningstar ProStar MPPT TRAKSTAR PS-MPPT-15 Installation, Operation And Maintenance Manual Download Page 1

Solar  Charging  System  Controller

Installation, Operation and Maintenance Manual

   

www.morningstarcorp.com

  

ProStar MPPT

TM

      MODELS

               

PS-MPPT-15

PS-MPPT-15M

PS-MPPT-25

PS-MPPT-25M 

PS-MPPT-40

PS-MPPT-40M

MAXIMUM POWER POINT TRACKING

For the most recent manual revisions, see the e-version at:  

www.morningstarcorp.com

Summary of Contents for ProStar MPPT TRAKSTAR PS-MPPT-15

Page 1: ...on and Maintenance Manual www morningstarcorp com ProStar MPPT TM MODELS PS MPPT 15 PS MPPT 15M PS MPPT 25 PS MPPT 25M PS MPPT 40 PS MPPT 40M MAXIMUM POWER POINT TRACKING For the most recent manual re...

Page 2: ...4V Max PV Open Circuit Voltage 120V 120V 120V Maximum Operating Power 210 420W 350 700W 550 1100W Max Battery Charging Current 15A 25A 40A Rated Load Current 25A 25A 30A DIMENSIONS inches centimeters...

Page 3: ...24 3 4 Wiring 25 4 0 Operation 35 4 1 TrakStar MPPT Technology 35 4 2 Battery Charging Information 37 4 3 Load Control Information 47 4 4 LED Indications 49 4 4 1 Power up 49 4 4 2 Status LED 49 4 4...

Page 4: ...ramming Overview 55 4 7 6 Lighting Programming Using Meter Display 56 4 8 Inspection and Maintenance 57 5 0 Troubleshooting 59 5 1 LED Fault Indications 59 5 2 Battery Charging and Performance Issues...

Page 5: ...a procedure or function that is important to the safe and proper operation of the controller CONSIGNES IMPORTANTES DE S CURIT CONSERVEZ CES INSTRUCTIONS Ce manuel contient des instructions importantes...

Page 6: ...required Disconnect all sources of power to the controller before installing or adjusting the ProStar MPPT There are no fuses or disconnects inside the ProStar MPPT Do not attempt to repair Informatio...

Page 7: ...r the installation location Mount the ProStar MPPT indoors Prevent exposure to the elements and do not allow water to enter the controller Install the ProStar MPPT in a location that prevents casual c...

Page 8: ...must be incorporated in the fixed wiring The ProStar MPPT negative power terminals are common and must be grounded as instructions local codes and regulations require A permanent reliable earth ground...

Page 9: ...pe de batteries doit tre constitu de batteries du m me type fabricant et ge UL IEC 62109 certifi pour utilisation au n gatif la masse ou les syst mes flottants seulement Ne fumez pas proximit du group...

Page 10: ...y WARNING A battery can present a risk of electrical shock or burn from large amounts of short circuit current fire or explosion from vented gases Observe proper precautions AVERTISSEMENT Une batterie...

Page 11: ...h batteries Wear rubber gloves and boots Use tools with insulated handles and avoid placing tools or metal objects on top of batteries Disconnect charging source prior to connecting or dis connecting...

Page 12: ...z les montres 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...

Page 13: ...erie peuvent tre pr sents pen dant la charge Assurez vous qu une ventilation suffisante vacue les gaz Ne fumez jamais dans la zone des batteries En cas de contact de l lectrolyte avec la peau lavez av...

Page 14: ...ngs switches several communication ports and terminals for remote battery temperature and voltage measurement Please take the time to read this operator s manual to become familiar the many benefits t...

Page 15: ...th the limits for a Class B digital device pursuant to Part 15 of the FCC rules These limits are designed to provide reasonable protection against harmful interference in a residential installation Th...

Page 16: ...cuit different from that to which the receiver is connected Consult the dealer or an experienced radio TV technician for help This Class B digital apparatus complies with Canadian ICES 003 Cet apparei...

Page 17: ...lay Rated for maximum 25 amps continuous current battery or load Designed for 12 or 24 VDC systems PS MPPT 40 Rated for maximum 40 amps of continuous battery current and 30 amps of continuous load cur...

Page 18: ...ral Information 14 2 4 Features The features of the ProStar MPPT are shown in Figure 2 1 below An explanation of each feature is provided 11 10 12 15 16 14 4 2 3 1 5 8 6 13 9 7 Figure 2 1 PS MPPT Feat...

Page 19: ...ctions for Battery and cable terminations 8 Local Temperature Sensor Compensates charging based on ambient temperature not used if Re mote Temperature Sensor is connected 9 Meter Directional Buttons U...

Page 20: ...system operating in formation error indications and self diagnostic read out Information is displayed on a backlit 4 digit custom LCD dis play The large numerical display and icons are easy to read an...

Page 21: ...ernet gateway that provides web monitoring services a Modbus TCP IP server and a local web page server End users can collect information about their off grid PV system remotely One EMC 1 supports all...

Page 22: ...T circuits CAUTION Equipment Damage When installing the ProStar MPPT in an enclosure ensure sufficient ventilation Installation in a sealed enclosure will lead to over heating and a decreased product...

Page 23: ...mplied that the battery connection can be made to either one battery or a group of batteries in a battery bank The ProStar MPPT uses stainless steel fasteners an anodized aluminum heat sink and confor...

Page 24: ...un maximum de 30 amp res pour le PS MPPT 25 M et 50 amp res pour le PS MPPT 40 M WARNING Installation must comply with all US National Electrical Code and Canadian Electrical Code requirments Breaker...

Page 25: ...ating parameters for the ProStar MPPT Figure 3 1 DIP Switch Block to set charging parameters Switch 1 Load Lighting Mode Switch 1 Normal OFF Lighting ON Switches 2 3 System Voltage Three 3 system volt...

Page 26: ...s NOTE These settings are general guidelines for use at the operator s discretion The ProStar MPPT can be programmed to satisfy a wide range of charging param eters but only the battery manufacturer c...

Page 27: ...3 0 ProStar MPPT Operator s Manual 23 Switch 7 Battery Equalization Mode Switch 7 Manual Equalization OFF Auto Equalization ON Switch 8 Meterbus MODBUS Settings Mode Switch 8 Meterbus OFF MODBUS ON...

Page 28: ...may get hot under certain operating conditions NOTE The heat sink must be in a vertical position fins up and down For proper air flow allow at least 15 cm 6 in of space above and below the controller...

Page 29: ...nd 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 INSTRUCTIONS BELOW NOTE THE PS MPPT IS UL 1741 COMPLIANT WHEN USED...

Page 30: ...inals for regulation This voltage may differ from the actual battery bank voltage due to voltage drop Battery Voltage Sense is a high impedance connection that enables the ProStar MPPT to measure the...

Page 31: ...ted 300 Volt conductors The voltage sense wires may be pulled through conduit with the power conductors Observing correct polarity connect both battery voltage sense wires to the ProStar MPPT at the 2...

Page 32: ...in the charging of the battery and the use of the optional Remote Temperature Sensor RTS is recommended to adjust charging to the actual battery temperature The RTS can be added at any time after the...

Page 33: ...est enlev e Cette bobine assure la conformit avec les normes d missions lectromagn tiques STEP 4 Grounding and Ground Fault Interruption WARNING This unit is not provided with a GFDI device This charg...

Page 34: ...mis la terre par un GFPD un seul point Do not connect the system negative conductor to the terminal NEC requires the use of an external ground fault protection device GFPD The ProStar MPPT does not h...

Page 35: ...al 31 STEP 5 Load Connections Turn the loads off and connect the load wires to the load terminals DO NOT CLOSE BREAKER AT THIS TIME 6 in 150 mm MAX BATTERY BATTERY 30 or 50 Amp Breaker depending on mo...

Page 36: ...battery and the unit will charge accordingly The 12 24V auto selection is only done at start up With the battery disconnect open connect the battery and wires from the battery to controller DO NOT CLO...

Page 37: ...EDs will indicate proper polarity and a good connection Close the battery breaker to power on the controller Watch the the charging status and then the three battery state of charge SOC LEDs blink in...

Page 38: ...est can be performed with digital meter units STEP 9 To Power down WARNING Risk of Damage ONLY disconnect the battery from the ProStar MPPT AFTER the solar input has been dis connected Damage to the c...

Page 39: ...ut 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...

Page 40: ...ngs allow for smaller gauge solar wiring This is especially help ful for systems with long wiring runs between the solar array and the ProStar MPPT An Advantage Over Traditional Controllers Traditiona...

Page 41: ...ttery is not at 100 state of charge and battery voltage has not yet charged to the Ab sorption voltage set point The controller will deliver 100 of available solar power to recharge the battery Absorp...

Page 42: ...ions and all the charging cur rent is turned into heat and gasing The float stage provides a very low rate of maintenance charging while reducing the heating and gasing of a fully charged battery The...

Page 43: ...osion Les batteries vent et compensation produisent des gaz explosifs Le groupe de batteries doit tre correctement ventil PRUDENCE Endommagement de l quipement La compensation augmente la tension des...

Page 44: ...he perfor mance and life of a battery particularly in a solar system During battery discharge sulfuric acid is consumed and soft lead sulfate crystals form on the plates If the battery remains in a pa...

Page 45: ...tage will reach 16 75 volts for L 16 batteries with a temperature sensor installed Disconnect any loads at risk of damage due to the high input voltage If Hydrocaps are used be sure to remove them bef...

Page 46: ...e Interval days off off off 1 Sealed 14 00 13 70 150 off off on 2 Sealed 14 15 13 70 14 40 150 60 120 28 off on off 3 Sealed 14 30 13 70 14 65 150 60 120 28 off on on 4 AGM Flooded 14 40 13 70 15 10 1...

Page 47: ...stom set points using MSViewTM PC software Table 4 1 above summarizes the major parameters of the standard charging settings The shared settings in Table 4 2 are common to all battery types The follow...

Page 48: ...0 hrs when the controller is in Float stage runs for one hour and turns off at 5 00 hrs The load current draw is larg er than the charge current causing battery voltage to drop below Float voltage for...

Page 49: ...scharges below 12 30 volts 24 60 volts 24 V the previous night Float charging stage will be cancelled for the next charge cycle Figure 4 5 above illustrates this concept At 0 00 hrs dawn battery volta...

Page 50: ...The timeout timer begins as soon as battery voltage exceeds the Absorption voltage setpoint If there is insufficient charging current or system loads are too large the battery voltage may not reach th...

Page 51: ...inverseur de toute taille de la bornes de charge MPPT ProStar endommage ment de la charge contr le est susceptible d entra ner Ondu leurs de fil directement la batterie ou groupe de batteries Current...

Page 52: ...cation will be displayed General Load Control Notes Do not wire multiple ProStar MPPT load outputs together in parallel to power DC loads with a current draw greater than 25 or 30A depending on the Pr...

Page 53: ...4 4 2 Status LED The Status LED indicates charging status and any exist ing solar input error conditions The Status LED is on when charging during the day and off at night The Status LED will flash r...

Page 54: ...every 2 secs Equalize G flash 2 sec SOC 13 5V G solid 13 5V SOC 13 0V G Y solid 13 0V SOC 12 5V Y solid SOC 12 5V Y R solid Low voltage disconnect warning R flash every sec Low voltage disconnect R s...

Page 55: ...attery keep the push button depressed for 10 secs A Custom Edit Settings fault will occur See p 62 in Section 5 for details The unit will then need to be re powered to resume normal opertation 4 6 Ala...

Page 56: ...controller This alarm indicates that the ProStar MPPT is limiting battery current to the maximum current rating RTS Open The Remote Temperature Sensor is not connected to the controller Use of the RT...

Page 57: ...ay Screens and Programming Models PS MPPT 25M PS MPPT 40M Main Screens Daily Charging Stage Time Daily Charge Transferred Battery and Load Solar Current Battery Current Load Current Daily Max Min Batt...

Page 58: ...ente dans le port de communication de transfert Utilisez 150V valu 4 ou 6 conducteurs c ble de t l phone r pertori UL With a connection to a PC and using the ProStar MPPT Set up Wizard the software is...

Page 59: ...d edit a desired setting or variable 4 7 4 Using the Meter Display to Program Charging Set points Load Control Communications and Advanced Settings Refer to the complete meter map insert for metered P...

Page 60: ...done via on screen instructions The Summary provides a graphical representation of the complete lighting configuration LVD LVR can be specified for use when a lighting program is in operation Sunrise...

Page 61: ...IRES SONT ISOL S LECTRIQUEMENT DE L ENTR E DE C C ET DOIT TRE ALIMENT S UNE TENSION DANGEREUSE SOLAIRE SOUS CERTAINES CONDITIONS DE D FAILLANCE LA BATTERIE POURRAIT DEVENIR TROP CHAR G E TEST ENTRE TO...

Page 62: ...rminals For wet cell flooded type batteries make sure the water level is correct Wet cell water levels should be checked monthly or accord ing to the manufacturer s recommendations Annually Clean the...

Page 63: ...TOUCHER WARNING Shock Hazard A means of disconnecting all power supply poles must be provided These disconnects must be incorporated in the fixed wiring Open all power source disconnects before removi...

Page 64: ...After two 2 automatic load reconnect attempts 10 seconds between each attempt the fault must be cleared by removing and re applying power High Solar Voltage Disconnect Charging Status LED R flashing N...

Page 65: ...ew PC software can be used to determine if the battery sense is working properly Battery Load High Voltage Disconnect HVD Error status LED Flashing red Battery status LEDs R G sequencing This fault is...

Page 66: ...t The controller must be re started to clear the fault and begin operation with the new settings Custom Settings Edit Error status LED Flashing red Battery status LEDs R Y G sequencing A value has bee...

Page 67: ...tery SOC LEDs PV FET Short Solid red R Y G sequencing Load FET Short Solid red R Y G sequencing Load FET Open Solid red R Y G sequencing Damaged local temperature sensor Solid red only if RTS is inval...

Page 68: ...hree 3 battery SOC LEDs If they are flashing in a sequence see Section 4 5 LED indications of this manual to determine the cause A metered model an RM 1 meter or MSView PC software will display active...

Page 69: ...er the following conditions Damage by accident negligence abuse or improper use PV or load currents exceeding the ratings of the product Unauthorized product modification or attempted repair Damage oc...

Page 70: ...s warranty policy 3 Assisting with the operability of all product system features and functions described in Morningstar manuals and datasheets Please be advised The Morningstar Technical Support Grou...

Page 71: ...tool String Selector product comparison tool Product Comparator and articles on solar charging technologies and other design considerations Although emergencies do arise when a phone call is necessar...

Page 72: ...e behavior including LED indications D array configuration panel Pmax Voc Vmp Isc and nominal battery voltage these specifications are needed to receive assistance E multi meter available for field tr...

Page 73: ...ion Efficiency peak 97 3 all Mechanical Dimensions Standard 7 87 W x 6 69 L x 2 76 D in 20 0 W x 17 0 L x 7 0 D cm Wire Box Option 7 87 W x 11 22 L x 3 62 D in 20 0 W x 28 5 L x 9 2 D cm Weight Standa...

Page 74: ...t customizable V_batt Instant LVD Lighting Control DIP 1 ON Lighting Timer Setting Dusk Dawn default Lighting Test Timer 5 minutes DIP Switch Settings 4 5 6 Battery Type Absorp Stage volts Float Stage...

Page 75: ...rature 30C to 80C Environmental Operating Altitude Below 2000 meters Operating Temperature 40C to 45C Storage Temperature 40C to 80C Humidity 100 n c Tropicalization Conformally coated PCBs Marine rat...

Page 76: ...00 82 00 83 00 84 00 85 00 86 00 87 00 88 00 89 00 90 00 91 00 92 00 93 00 94 00 95 00 96 00 97 00 98 00 99 00 100 00 0 50 100 150 200 250 300 350 400 450 500 550 600 E ciency Output Power Watts ProS...

Page 77: ...80 00 81 00 82 00 83 00 84 00 85 00 86 00 87 00 88 00 89 00 90 00 91 00 92 00 93 00 94 00 95 00 96 00 97 00 98 00 99 00 100 00 0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900...

Page 78: ...40 80 85 90 95 100 105 110 115 120 O V E R V O L T A G E R A N G E 0 5 10 20 15 25 30 35 40 45 Ambient Temperature degrees C Battery Current vs Ambient Temperature Battery Current Amps 10 20 25 30 32...

Page 79: ...3 3 4 4 6 6 13 1 14 1 0 1 2 1 4 1 7 2 1 2 8 4 1 8 3 Table C 1 Maximum 1 way wire distance for 12 Volt systems solid copper 2 voltage drop 1 Way Wire Distance meters 12 Volt System Wire Size mm2 40A 3...

Page 80: ...2 1 2 6 3 4 5 1 10 3 Table C 3 Maximum 1 way wire distance for 12 Volt 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 12...

Page 81: ...er 1 way distance For 24 volt systems multiply the 1 way length in the table by 2 Shaded cells in the table indicate that the current exceeds the ampacity of the wire for a given ambient temperature a...

Page 82: ...1 7 2 1 2 8 4 1 8 3 Table C 5 Maximum 1 way wire distance for 12 Volt systems stranded copper 2 voltage drop 1 Way Wire Distance meters 12 Volt System Wire Size mm2 40A 35A 30A 25A 20A 15A 10A 5A 70 1...

Page 83: ...14 1 3 1 5 1 7 2 1 2 6 3 4 5 1 10 3 Table C 7 Maximum 1 way wire distance for 12 Volt systems solid copper 2 voltage drop 1 Way Wire Distance meters 12 Volt System Wire Size mm2 40A 35A 30A 25A 20A 15...

Page 84: ...ce For 24 volt systems multiply the 1 way length in the table by 2 Shaded cells in the table indicate that the current exceeds the ampacity of the wire for a given ambient temperature as defined in th...

Page 85: ...ives Complies with ENs and LVD standards for CE marking Immunity EN 61000 4 3 2006 EN 61000 4 6 2009 Emissions CISPR 22 2008 ProStar MPPTTM MeterBusTM are trademarks of Morningstar Corporation MODBUST...

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