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Morningstar Morningstar Solar Controller and Solar Controller and Inverter Overview Inverter Overview

Morningstar Solar Controller and Inverter Overview Morningstar

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Page 1: Morningstar Solar Controller and Inverter Overview Morningstar

MorningstarMorningstarSolar Controller and Solar Controller and Inverter OverviewInverter Overview

MorningstarMorningstarSolar Controller and Solar Controller and Inverter OverviewInverter Overview

Page 2: Morningstar Solar Controller and Inverter Overview Morningstar

Morningstar is the world’s leading supplier of Solar Controllers.

In 2010 we sold over 250,000 controllers through 164 distributors in 73 countries throughout the world.

Our goal is to continue to lead the controller market in terms of quality, reliability and customer service as well as expand our products in the PV inverter market.

Morningstar’s Mission

Page 3: Morningstar Solar Controller and Inverter Overview Morningstar

Morningstar’s Company Advantages

• Reliability - our failure rates are less then 2 units per 1000 sold.

• 100% in-house design – we only put our name on a product that we’ve built from scratch, one resistor at a time.

• Morningstar sells only through the world’s PV distribution channels.

• Supporting our distribution network is our #1 priority. We send sales leads directly through our distribution network and do not sell directly to OEM’s, dealers or end-users.

Page 4: Morningstar Solar Controller and Inverter Overview Morningstar

Morningstar Product Advantages

Highest Quality – Manufactured in a fully automated ISO 9001 factory. Quality control using the latest computerized test equipment. Every unit is digitally calibrated, tested and logged.

Superior Lightning Protection – Use of large transient voltage suppressors provide faster response to transients and do not degrade over time.

No need to De-rate – Designed with a 25% safety margin, controllers may be used up to their full “nameplate” ratings.

Expected 15 Year Life – Controllers carry a full 5-year warranty, with an expected operating life of 15 years or more.

Easy to Use – Detailed manuals, technical support by phone or internet, large clearly-marked wire terminals, electronic protections and good front panel indicators. Controllers are easily utilized at multiple experience levels.

Page 5: Morningstar Solar Controller and Inverter Overview Morningstar

Morningstar Product AdvantagesTropicalization is the process by which we condition our hardware for use in extreme environmental conditions.

Conformal Coating – Dupont Humiseal – a UL listed protective spray that will seal out moisture and prevent corrosion from the effects of salt air and high humidity.

Epoxy Encapsulation – a 2-part epoxy resin that protects the board as well as acts to conduct heat away from the power carrying components on the circuit board. It acts like a liquid heat sink.

Terminal plating - to resist corrosion.

Page 6: Morningstar Solar Controller and Inverter Overview Morningstar

Technical Support

Fast Response – Same day response on emails. Live people answering the phone. Fast tracking to our engineering office for high level assistance. Searchable tech support library.

Applications Knowledge – We can interpret specifications, certifications, sizing and other requirements for your projects to give you a quick review of the controller options that are right for you.

Industry Leading Warranty Support – We work to provide quick warranty replacement. Morningstar doesn’t require complicated approvals, so we are able to provide warranty service easily through our distribution network, or directly if necessary.

Page 7: Morningstar Solar Controller and Inverter Overview Morningstar
Page 8: Morningstar Solar Controller and Inverter Overview Morningstar

ProStarRating: 15A or 30A at 12/24V or15A at 48VNegative or Positive Ground

Applications: Mid-Range professional or consumer systems.

Extensive Protections: Electronic short-circuit, overload and reverse polarity protected with automatic recovery.

More Information: LED’s indicate various battery and systemstatus while digital meter (optional) displays 9 different controller status parameters.

Major Benefits

Page 9: Morningstar Solar Controller and Inverter Overview Morningstar

ProStarRating: 15A or 30A at 12/24V or15A at 48VNegative or Positive Ground

Self-Test: Digital meter displays any detected faults, making it very easy to troubleshoot the PV system.

Tropicalization: For protection against corrosion and nesting insects. Includes conformal coating on circuit boards, stainless-steel screws and anodized aluminum heat sink.

Low Telecom Noise: PWM has been modified to reduce interference and any noise may be easily eliminated in the field.

Page 10: Morningstar Solar Controller and Inverter Overview Morningstar

SunSaverRating: 6.5A,10A or 20A at 12V or 24V

Applications: Small professional or consumer systems. Oil/Gas projects located in hazardous locations.

Tropicalization: Epoxy encapsulation, marine rated terminal block and Anodized aluminum enclosure.

Hazardous Locations: Approved for use in Class 1, Division 2Groups A,B,C,D

Major Benefits

Page 11: Morningstar Solar Controller and Inverter Overview Morningstar

SunSaverRating: 6.5A,10A or 20A at 12V or 24V

Temperature Extremes: Rated for operating temperatures of -40°C to +60 °C up to full “nameplate” current ratings.

Series PWM Design: Less heating and longer life compared to shunt controllers.

Page 12: Morningstar Solar Controller and Inverter Overview Morningstar

SunGuardRating: 4.5A at 12V

Applications: single module professional or consumer systems.

Charging: Circuitry is the same as SunSaver (series PWM).

Tropicalization: Epoxy encapsulation, ABS plastic caseand outdoor rated wires.

Economics: Low cost controller.

Power Usage: Minimal self-consumption (6 mA).

Major Benefits

Page 13: Morningstar Solar Controller and Inverter Overview Morningstar

SunLightRating: 10A or 20A at 12V10A at 24V

Applications: Solar lighting controller used for streetlighting, bus stations, telephone booths, billboards,signs and parking lots.

Combines the SunSaver charging circuit and case with a micro controller for automatic lighting control functions.

Major Benefits

Page 14: Morningstar Solar Controller and Inverter Overview Morningstar

SunLightRating: 10A or 20A at 12V or 24V

Functionality: Choice of 10 different lighting control options including ON-OFF-ON options.

Test button to check light during installation and confirm correct lighting option selection.

Page 15: Morningstar Solar Controller and Inverter Overview Morningstar

TriStar Solar Charge Controller

Page 16: Morningstar Solar Controller and Inverter Overview Morningstar

TriStar – Solar Charge Controller

• 3 Operating modes – Solar charging, load control or diversion control for wind/hydro

• 45A or 60A versions, both with automatic detection of 12/24/48V system modes

• Optional front panel and remote meters display system information

• Conduit ready enclosure designed for installation onto a Power Panel

Page 17: Morningstar Solar Controller and Inverter Overview Morningstar

Main Features

• Optional remote sensor provides temperature compensation

• Battery sense connection for accurate voltage readings

• Self test algorithm runs continuously to locate faults

All electronic protections

• Reverse polarity and short circuit on all connections• All faults have auto reset• Lightning surge protection with 4500W TVS’s• PWM current limiting for high temp and over current states

Reliability by Design

• 100% solid state power electronics

• All functions microprocessor controlled with non-volatile Flash-RAM

• Conformally coated circuit board

• Robust Heatsink

Page 18: Morningstar Solar Controller and Inverter Overview Morningstar

Morningstar SunKeeperMorningstar SunKeeper

• 12V Controller available in 6A and 12A versions.12V Controller available in 6A and 12A versions.

• Conduit gasket connection mounts directly to the PV module Conduit gasket connection mounts directly to the PV module junction box to form a weather-proof sealjunction box to form a weather-proof seal

• Bulk, PWM absorption and float stagesBulk, PWM absorption and float stages

• Full electronic protections from wiring errorsFull electronic protections from wiring errors

Page 19: Morningstar Solar Controller and Inverter Overview Morningstar

Morningstar SunKeeperMorningstar SunKeeper

•Bi-Color LED confirms proper installation and shows the charging state as well as any fault info or evidence of damage.

•The SunKeeper has the ability to restart from zero voltage to recover The SunKeeper has the ability to restart from zero voltage to recover the system in the case of a fully depleted battery.the system in the case of a fully depleted battery.

• Epoxy potting and very low resistance power MOSFET's allow for Epoxy potting and very low resistance power MOSFET's allow for extremely high temp operation to 70C.extremely high temp operation to 70C.

Page 20: Morningstar Solar Controller and Inverter Overview Morningstar

SunSaver / SunKeeper Hazardous Location Rating

• UL 1604 - UL Standard for Safety Electrical Equipment for Use in Class I and II, Division 2, and Class III Hazardous (Classified) Locations

• CSA C22.2 NO 213-M1987 - Non-Incendive Electrical Equipment for Use in Class I, Division 2 Hazardous Locations

Page 21: Morningstar Solar Controller and Inverter Overview Morningstar

Morningstar SunKeeperMorningstar SunKeeper

Fits PG 13.5, M20, ½ Inch conduit knockout

Page 22: Morningstar Solar Controller and Inverter Overview Morningstar

SureSine InverterRating: 300W Continuous, 600W Surge12VDC Input115V/220V versions availableListed to UL 458

Applications: Rural electrification, telecom, mobile/marine markets.

Extensive Protections: Electronic short-circuit, overload and reverse polarity protection.

High Power Surge: 200% surge allows a 600W output for up to 15 minutes.

Rugged Chassis Design: Cast aluminum heat sink, epoxy encapsulatedtransformer, fanless convection cooling.

Page 23: Morningstar Solar Controller and Inverter Overview Morningstar

SureSine InverterRating: 300W Continuous, 600W Surge12VDC Input115V/220V versions availableListed to UL 458

Low Power Consumption: Peak efficiency of 91.5% makes more solar energyavailable for the loads. Search mode turns the inverter off when no AC load is present to further reduce power draw.

More Information: LED’s indicate various battery, systemand AC output status. Interpretation is easy. Green LED’s show operationalstatus while Red LED’s indicate a fault.

Remote Power Switch: Remote power terminal allows an external switchor another device (like a solar controller) to turn on the inverter.

Page 24: Morningstar Solar Controller and Inverter Overview Morningstar

Popular Uses for the SureSine 300

• Sine wave power for AV equipment (mobile market)

• Rural electrification and remote cabins

• Networking and Security equipment

• AC lighting systems (the remote on/off terminal may be used with the SunLight to provide automatic control)

• Adds sine wave capability to a larger wattage modified square-wave system.

Page 25: Morningstar Solar Controller and Inverter Overview Morningstar

Combination Product - charge controller and remote meter package.

Designed For Easy Installation - - Controller mounts near battery. Meter display mounts up to 30ft. away.

Robust Design - - Builds on the proven design of the SunSaver. Cast aluminum case, heat sink and epoxy encapsulation provide efficient and cool operation.

Dual Battery Charging - splits solar current between house and cabin batteries.

SunSaver DuoSunSaver Duo Rating: 25A total charging current12VDC System VoltageIsolated Charging for 2 Batteries

Page 26: Morningstar Solar Controller and Inverter Overview Morningstar

SunSaver Duo Meter DisplaySunSaver Duo Meter Display

• Meter mounts on surface with included frame or can be inset into the vehicle wall

• Voltage and Current information shown separately for each battery without the need for external shunts

• Min/Max voltage

• Instantaneous Amps from solar and each battery’s Ah shown separately

• Room temperature and battery temperature display

• Automatic backlight settings

Page 27: Morningstar Solar Controller and Inverter Overview Morningstar

SunSaver MPPTSunSaver MPPT

•Provides an estimated 5-25% boost of amps from the PV array into the battery. Actual boost depends on PV cell temperature and battery state-of-charge.

•Enables the use of high voltage PV modules (designed for on-grid applications) for off-grid 12V or 24V battery charging.

•Provides a means to use a 12-36V nominal PV array to charge a 12V battery, reducing power losses in systems with a long wire run between the PV array and the battery.

System Voltage: 12/24V

Max. Battery Current: 15A

Max. Voc: 75V

Max. PV Input:

200Wp (12V Battery)

400Wp (24V Battery)

Page 28: Morningstar Solar Controller and Inverter Overview Morningstar

RM-1 Remote Meter (New)RM-1 Remote Meter (New)

-Array Voltage/Vmp

-Solar Charge Amps

-Load Amps

-Battery Voltage with Max/Min

-Solar/Load Ah accumulation

-Temperature

-Faults and Alarms

-Displays daily logging information on supported

products.

Compatible with:Compatible with:

SunSaver MPPT SureSine

SunSaver Duo

Page 29: Morningstar Solar Controller and Inverter Overview Morningstar

MSC MeterBus Adapter (New)• Allows any meter port enabled

Morningstar product to be given RS-232 serial port data communications.

• Includes DB-9 Serial cable and RJ11 cable.• List price of $39

Page 30: Morningstar Solar Controller and Inverter Overview Morningstar

TriStar Firmware Upgrade (coming soon)

• Firmware update to support Hub functions on previously produced TS units.

• To enable 30 day data logging feature on TS-M.

Page 31: Morningstar Solar Controller and Inverter Overview Morningstar

MorningstarMorningstarTriStar MPPTTriStar MPPTMorningstarMorningstarTriStar MPPTTriStar MPPT

Page 32: Morningstar Solar Controller and Inverter Overview Morningstar

TriStar MPPT Ratings• Two Models

•45A Battery Charge Current. •60A Battery Charge Current.

• 8-68V battery range (12/24/48V or Auto)• Rated -40 to +45C at 100% continuous power.•150V maximum open circuit PV voltage.• Peak efficiency of 99%

• Options:• TriStar Meter 2 (TS-M-2)• TriStar Remote Meter 2 (TS-RM-2)• Relay Driver (RD-1)• Meter Hub (HUB-1)• Remote Temp Sense (RTS)

Page 33: Morningstar Solar Controller and Inverter Overview Morningstar

TriStar MPPT Mechanicals

• Extruded aluminum heatsink for efficient cooling• Tri-Phase DC-DC design. 3 x 20A MPPT • Fanless– uses less power, more reliable and runs without drawing in dust and dirt.• Solid state controls – no relays• Enclosure allows the use of

- 4 standard 1” or 1.25” conduit knockouts

- 8 metric knockouts (M20) for Europe• All circuit boards are conformally coated to prevent corrosion.• All inductors are potted for cool operation and environmental protection.

Page 34: Morningstar Solar Controller and Inverter Overview Morningstar

TriStar MPPT Protections

• Electronic Protections• PV Short circuit protection (solid state)

• Automatic current limiting to max rating

• High temperature protection

• Lightning protection (fast acting Transient Voltage Suppressors)

• High Voltage PV Voc Backoff

Page 35: Morningstar Solar Controller and Inverter Overview Morningstar

TriStar MPPT Certifications

• UL 1741 - Pending• cUL (CSA-C22.2 No. 107.1-95) – Pending• FCC Class B Part 15 Compliant• CE Compliant• RoHS Compliant• ISO 9001 Certified production

Page 36: Morningstar Solar Controller and Inverter Overview Morningstar

TriStar MPPT Setup

• Same established simple and quick setup as the original TriStar• DIP switch configuration gives you 7 preset battery profiles• One DIP preset is reserved for complete customization using MS View.• Controller automatically determines

• System Voltage• Array configuration• Sense Voltage presence• RTS presence

Page 37: Morningstar Solar Controller and Inverter Overview Morningstar

TriStar MPPT SetupCommon battery profiles are available as presets. Values are for all charging values, float/absorption times and equalization schedule.

Page 38: Morningstar Solar Controller and Inverter Overview Morningstar

TriStar MPPT Sizing

Battery TS – MPPT-45 TS – MPPT-60

12 Volt 600 Watts 800 Watts

24 Volt 1200 Watts 1600 Watts

48 Volt 2400 Watts 3200 Watts

With the MPPT controller, you can size in pure watts since the controller provides the maximum current available from the system. Wattages in excess of those below will be held to controller current limit.

Page 39: Morningstar Solar Controller and Inverter Overview Morningstar

Maximum Power Point Tracking

The Technology behind maximum energy harvest.

1. The controller needs to keep the module operating at the Vmp to ensure rated output in watts of the PV module.

2. Accounts for changes in temperature and irradiance through the day.

3. Ensures grid-tie modules (i.e. 54 and 72 cell) are optimized in voltage for effective battery charging regardless of their nominal voltage.

Even the largest and most efficient controller can give up crucial power if not tracking the power point of the module correctly. Speed and logic in the tracking algorithm yield gains that pure size and efficiency cannot make on their own.

Page 40: Morningstar Solar Controller and Inverter Overview Morningstar

Maximum Power Point Tracking

The Technology behind maximum energy harvest.

IV Curve Power Graph

Page 41: Morningstar Solar Controller and Inverter Overview Morningstar

MPPT Benefits

Boost – 10-30% gain in charging amps out of the same module used on a PWM controller. The greater the gap between Vmp and battery voltage, the more the boost in current the battery receives.

-Cold modules increase the gain due to higher Vmp-low battery voltages increase the gain when needed most

High Voltage Wire Runs – smaller wire can be used and greater distances achieved using higher voltage PV input.

Shading and cloud irradiance effects – Cloud edge effect can cause the module to exceed it’s rated wattage for a short time. Shading can cause tricky IV curve shapes. MPPT can follow both these changes to ensure maximum power during these conditions.

Low Battery Protection – when the battery is very low, a high voltage difference between the PV Vmp and the battery voltage causes an even greater power boost. This can prevent an LVD at a time when the power is most needed.

Page 42: Morningstar Solar Controller and Inverter Overview Morningstar

MPPT Economics

MSRP

TS-60 PWM + RTS $258 TS MPPT-60 + RTS $669Incremental cost of MPPT $411PV Module Cost/Wp $4Boost Needed to cover MPPT cost (Wp) 103 WattsBoost Needed to cover MPPT cost (%): 500 Wp PV array 21% 1kWp PV array 10% 1.5 kWp PV array 7%

Page 43: Morningstar Solar Controller and Inverter Overview Morningstar

Maximum Power Point Tracking

MPPT Tracking Algorithms on the market:

Full Sweep - scans entire PV array from 0-150V.Pros: Sees everything on the IV curve, not easily fooled.Cons: Slow, sometimes takes an extended time for a full

sweep during which charging is far from the true Vmp.

Dynamic Tracking – stays near Vmp and makes minor rapid adjustments.

Pros: FasterCons: Can get hung up on a local peak and miss the true

peak power point.

Page 44: Morningstar Solar Controller and Inverter Overview Morningstar

Maximum Power Point Tracking

Morningstar TrakStar Technology –

- Full array sweeps from 0-150V in ¼ second! Others can take

up to 30 seconds during which much has happened.

- The TS-MPPT offers full sweep and dynamic adjustments

continuously.

- Dual chipset provides specialized control -DSP – high speed MPPT, charge control and data logging-Main Processor – Ethernet and serial communications

Page 45: Morningstar Solar Controller and Inverter Overview Morningstar

TS MPPT Data Logging

Up to 6 months of internal data logging of key daily values.

Max Battery VoltageMin Battery VoltageMax Array VoltageAmp HoursWatt HoursFaultsAlarmsDaily Absorption Stage Time (mins)Daily Equalization Stage Time (mins)Daily Float Stage Time (mins)

Page 46: Morningstar Solar Controller and Inverter Overview Morningstar

TriStar MPPT Communications

Page 47: Morningstar Solar Controller and Inverter Overview Morningstar

Meterbus – RJ11 connection

- Connection of local or remote TriStar Meter-2- Allows combining of TriStars into network with

HUB-1- Sum all controller data for system level

informationTotal Charge Amps into the batteryTotal Load Amps drawn out of the batteryNet gain/loss of amps from/to the battery

TriStar MPPT Communications

Page 48: Morningstar Solar Controller and Inverter Overview Morningstar

RS-232 – for a single connection between a PC or other device and the TriStar MPPT. Allows for data logging, program changes and firmware upgrades.

TriStar MPPT Communications

- easiest way to connect to the TriStar for PC data

- included on all TriStar versions- uses standard MODBUS protocol- optically isolated for safe power system

grounding

Page 49: Morningstar Solar Controller and Inverter Overview Morningstar

RS-485 – for networked (multi-unit) connections between a PC or other devices and many Morningstar products. Allows for data logging and program changes.

- for larger or industrial PV systems with many devices

- uses MODBUS protocol- supports long distances- can be used on original TriStars with RSC

adapter- optically isolated for safe power system

grounding

TriStar MPPT Communications

Page 50: Morningstar Solar Controller and Inverter Overview Morningstar

Ethernet* – for TCP/IP connection for internet applications. IP makes it compatible with wireless protocols, cellular systems and existing networking equipment.

TriStar MPPT Communications

Allows for the use of:- web page view directly from the TS MPPT

- email and text message notifications and alarms

- remote connection anywhere on the internet (MODBUS IP)

- SNMP functions for networking service providers

- integration with third party software developers writing in HTML, XML and Java.

*Ethernet available on 60A TS-MPPT only.

Page 51: Morningstar Solar Controller and Inverter Overview Morningstar

TriStar MPPT Communications

TriStar MPPT Live view allows the direct webpage viewing of solar and charge data from the controller itself.

Compatible with any Java enabled web browser (Mac, PC or Smartphone).

Page 52: Morningstar Solar Controller and Inverter Overview Morningstar

MPPT Economics

MSRP

TS-60 PWM + RTS $258 TS MPPT-60 + RTS $669Incremental cost of MPPT $411PV Module Cost/Wp $4Boost Needed to cover MPPT cost (Wp) 103 WattsBoost Needed to cover MPPT cost (%): 500 Wp PV array 21% 1kWp PV array 10% 1.5 kWp PV array 7%

Page 53: Morningstar Solar Controller and Inverter Overview Morningstar

TriStar MPPT Industry Leading Efficiency

Page 54: Morningstar Solar Controller and Inverter Overview Morningstar

MPPT Controller Price ComparisonM Star Outback Xantrex

TS MPPT FM-60 % XW %

TriStar MPPT-45 531 699 -24% 685 -22%

TriStar MPPT-60 669 699 -4% 685 -2%

 

TriStar MPPT-45 with RTS 531 731 -27% 685 -22%

TriStar MPPT-60 with RTS 669 731 -8% 685 -2%

 

TriStar MPPT-45 with meter 635 699 -9% 685 -7%

TriStar MPPT-60 with meter 773 699 11% 685 13%

 

TriStar MPPT-45 with RTS and meter 635 731 -13% 685 -7%TriStar MPPT-60 with RTS and meter 773 731 6% 685 13%

Note: You can view TS MPPT-60 from a web browser and oftentimes will not need a meter

Page 55: Morningstar Solar Controller and Inverter Overview Morningstar

TriStar MPPT Summary

The TriStar MPPT brings many advantages:

- Superior MPPT Tracking technology

- Highest efficiency with the lowest power loss during

operation

- Lower cost with 45A version and choice of meter option.

- Powerful communications with open protocols, including

Ethernet.

- Easy setup for a quick installation (sometimes no setup at

all)

- Backed by Morningstar’s controller expertise and 5 year

warranty

- Delivers technology and simplicity for residential use,

built to survive the remote and industrial market’s

harshest environments.

Page 56: Morningstar Solar Controller and Inverter Overview Morningstar

TS HUB (Sept 2009)•Allows TS Meter to show summed data including:

•Net System Data

•Individual Controller Data

•Supports up to 15 Devices TS, TS-MPPT, RD-1, TS-M

•Provides complete isolation from ground. (will work with both Positive and Negative Ground systems.)

Page 57: Morningstar Solar Controller and Inverter Overview Morningstar

Morningstar String Calculator

-Allows for quick and simple array string configurations to be displayed for any Morningstar charge controller.

-Works with a variety of common industry PV modules or allows you to input your own specifications.

-Accounts for ambient temperatures at the site and compensates for expected battery voltages in the system.

-Prevents maximum current and Voc figures from exceeding the controller rating at any time during the year.

Page 58: Morningstar Solar Controller and Inverter Overview Morningstar

Morningstar String Calculator

Page 59: Morningstar Solar Controller and Inverter Overview Morningstar

SunLights used in a rural

streetlight installation in

Indonesia.

Page 60: Morningstar Solar Controller and Inverter Overview Morningstar

SHS’s used in a rural

installation in Ecuador.

Page 61: Morningstar Solar Controller and Inverter Overview Morningstar

Dual TriStar system used in mountaintop repeater in

Norway.

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Norway in Summer

Norway in Winter

Page 63: Morningstar Solar Controller and Inverter Overview Morningstar

Application Photos

Page 64: Morningstar Solar Controller and Inverter Overview Morningstar

Application Photos

Page 65: Morningstar Solar Controller and Inverter Overview Morningstar

Application Photos

Page 66: Morningstar Solar Controller and Inverter Overview Morningstar

Application Photos

Page 67: Morningstar Solar Controller and Inverter Overview Morningstar

Thank you Thank you for your for your

business!business!