Sunwize MorningstarTriStarMPPT Training

TriStar MPPT Training Program

Brad Berwald

Sr. Sales Engineer

[email protected]

Training Overview

TriStar Family Applications – where is it used?

Product Details – ratings, specs and features.

MPPT Advantages – the benefits of an MPPT controller over

other types.

Competitive Advantages – TriStar MPPT’s features that beat

the competition

Sizing and Setup – how to configure the TS MPPT

Product Communications – all the ways you can communicate

with the TS MPPT

Questions?

TriStar Applications

•With its several operating modes and sizing configurations, the TriStar family of controllers is perfect in the following applications:

• Scalable Telecommunications systems from 1-15kw

• Residential Off-Grid and Grid-Tie with battery

• RV and Boating (Mobile Market)

• Traffic and Highway Telemetry

• Industrial Automation and control systems (SCADA)

• Larger scale Solar Outdoor Lighting

Following are some of the applications the

TriStar has been used in. (TriStar PWM is shown)

Back-Up System Five TS-60’s used in parallel to provide charging for this 10kW

communications building.

Norway Weather Station Dual TriStar System used for Wind and Solar charging in very Northern region.

Portable Power Station Two TriStars used for 5kw system in military application.

Ratings and Features

• 45A and 60A Versions

• 150V Maximum Open Circuit Voltage

• RS-232 on TS-MPPT-45A

• RS-232/485 and Ethernet on TS-MPPT-60A

• MPPT charge control with TrakStar TechnologyTM

Maximizes Energy Harvest

• 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

Robust Thermal Design

• Passively cooled – no fans required • Parallel circuit design provides less stress and longer life for electronic components

• No mechanical relays

• 5 Year Warranty

• Extensive electronic protections including PV short circuit protection

• Epoxy encapsulated inductors and conformally coated printed circuit boards

Electrical Specifications

Specification

Peak Efficiency 99%

Nominal System Voltage 12, 24, 36 or 48 volts DC

Max. Solar Open Circuit

Voltage

150 VDC

Battery Operating Voltage

Range

8-68 VDC

Maximum Self-consumption 2.7 Watts

Transient Surge Protection 4500 Watts/terminal

TriStar MPPT Sizing

Battery TS – MPPT-45 TS – MPPT-60

12 Volt 600 Watts 800 Watts



With the TriStar MPPT you can size in pure watts since

the controller provides the maximum current available

from the system after conversion. Wattages in excess of

those below will be held to controller current limit.

Electronic Protections

Solar: Overload, Short Circuit, High Voltage

Battery: High Voltage

High Temperature

Lightning and Transient Surges – all

terminals

Reverse Current at Night

Certifications

CE Compliant

ETL Listed (UL1741, CSA 22.2)

FCC Class B Part 15 Compliant

Complies with (NEC) U.S. National Electric

Code

RoHS Compliant

Manufactured in a certified ISO 9001 facility

Charge Controllers: MPPT vs. PWM

PWM Charge Control MPPT Charge Control

PV Array and Battery Voltages must match.

Array is sized in Amps based on charge produced at when PV array is operating at battery voltage.

Less expensive

Simpler series switching charge control circuit using 300 Hz PWM pulse charge control.

Array can be higher nominal

voltage than battery and

controller converts power down.

Array is sized in watts

High Frequency charge control

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 charge 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.

MPPT Economics

MSRP

TS-60 PWM + RTS $258

TS MPPT-60 + RTS $669

Incremental cost of MPPT $411

PV Module Cost/Wp $4

Boost Needed to cover MPPT cost (Wp) 103 Watts

Boost Needed to cover MPPT cost (%):

500 Wp PV array 21%

1kWp PV array 10%

1.5 kWp PV array 7%

“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 due to less voltage drop.

Shading and cloud irradiance effects – Cloud edge effect can cause the

module to exceed its 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.

MPPT Benefits


IV Curve Power Graph

Since Vmp and battery voltage levels are in constant change, it is difficult to

calculate boost through out a long period of time. To estimate potential benefit of

MPPT over a PWM controller you can use the following calculation:

MPPT Boost

System Assumptions

12V System

3 PV Modules in system

25C Ambient Temperature

No BOS voltage drops

Perfect controller efficiency

Estimate of charge amps

Between Imp and Isc

130W PV Module

7.39 Imp

17.6 Vmp

21.9 Voc

186W PV Module

6.95 Imp

25.9 Vmp

32.6 Voc

MPPT Boost – Off-Grid Module

130W Sized in Amps TriStar PWM

3 Modules in Parallel (390W)

7.8A x 3 modules in parallel

130W Sized in Watts TriStar MPPT

3 Modules in Parallel

130W x 3 = 390W

390W PV

13V battery

= 23.4A into the battery

(304W)

= 30A into the battery

(390W)

28% more potential power when used with MPPT

MPPT Boost – Grid-Tie Module

186W Sized in Amps TriStar PWM

3 Modules in Parallel (558W)

25.9 Vmp is far greater than 13Vbatt

7.5A x 3 modules in parallel

186W Sized in Watts TriStar MPPT

3 Modules in parallel

186W x 3 = 558W

25.9 Vmp is converted down Vbatt.

558W PV

13V battery

= 22.5A into the battery

(293W) =43A into the battery

(558W)

A PWM controller is really not an option with this type of PV

module. You may lose half your available power!

Maximum Power Point Tracking Techniques

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: Faster

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

power point.

TrakStar MPPT Comparison

Full I-V Curve Sweep

Dynamic Tracking

TrakStar MPPT Comparison

Dynamic tracking alone limits the controller:

-Only sees what is happening locally at the

presumed power point.

-Does not detect what true Voc is.

-Can be fooled by shading effects, mixed module

types or flat IV curves often seen on thin film

modules.

-Takes time to re-track during periods of fast

changing irradiance and temperature levels.

(cool winds on the panel surface or fast moving

clouds).

Dynamic Tracking by itself leaves you in the dark as to

where the best Vmp point is.

By not venturing further up the curve, you may be

missing a big opportunity for more power.


Morningstar TrakStar Technology

- Full array sweeps from 0-150V in ¼ second! Other controllers can

take up to 30 seconds during which light levels could change.

- The TS-MPPT offers the ability to sweep more often to make sure

to not miss any fast changing max power points.

TriStar MPPT – minimal power draw designed

for remote power systems.

0 2 4 6 8 10

Night - 12V

Night - 24V

Night - 48V

Day - 12V

Day - 24V

Day - 48V

Controller Self Consumption in Watts (Ethernet Enabled)

TriStar

XW

OB

TriStar MPPT - Industry Leading Efficiency


Outback FM60 Efficiency Curve


Price Comparison (US Retail Prices in $)

M Star Outback Xantrex

TS MPPT FM-60 % XW %

TriStar MPPT-45 531 749 -29% 685 -22%

TriStar MPPT-60 669 749 -11% 685 -2%

TriStar MPPT-45 with RTS 531 778 -32% 685 -22%

TriStar MPPT-60 with RTS 669 778 -14% 685 -2%

TriStar MPPT-45 with meter 635 749 -15% 685 -7%

TriStar MPPT-60 with meter 773 749 3% 685 13%

TriStar MPPT-45 with RTS and meter 635 778 -18% 685 -7%

TriStar MPPT-60 with RTS and meter 773 778 0.5% 685 13%

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

meter

String Sizing Calculator Morningstar’s string

calculator allows you size

compatible PV strings for

all of Morningstar’s

charge controllers. (both

PWM and MPPT.

You can select from a

pre-populated module

database or enter your

own module ratings.

The calculator also

accounts for ambient

temperature and battery

voltages which affect

temperature

compensation and MPPT

charge levels.

TriStar Charge Settings

Battery voltage detection is automatic for 12, 24 and 48V systems or can be

fixed if desired.

The PV Array requires nothing to be configured. Simply connect the array

and any voltage from Vbatt up to Voc will be detected and charging will begin

automatically and at the most efficient level possible.

DIP Switch Settings Battery Type is the only major decision that has to be made.

We use simple DIP switch combinations to give you a complete battery

charging profile with all the stages, timers and voltages pre-configured for

a given battery type. Usually jumping to just one or two presets will

become second nature for most system installs.

You really only need look at switches 4,5 and 6 to choose the battery type.

You can also choose to enable auto-equalization or not with switch 7.

DIP Switch Settings

If desired, more sophisticated settings can be programmed and an open

preset is available for the user or installer to create their own custom setting

using our free PC software, MS View.

This setting allows editing of very fine details, even allowing you to set

maximum charge ceilings, extended absorption or equalization cycles.

TriStar MPPT Communications

•Networked Controllers Working Together

•Controllers interacting with other site hardware

•Data logging of site data for later retrieval

•Remote monitoring and control

TriStar and TriStar MPPT with HUB

The TriStar MPPT can be paralleled with

other TriStars or TriStar MPPT

controllers when used with the

Morningstar HUB.

This shares the utility and cost of a

single meter with multiple units.

It accumulates data on the meter for the

sum of the system but still lets you view

individual TS unit data (unit 1,2,3 etc.)

Stacking multiple HUBs allows support

for up to 15 total meterbus devices

including controllers, meters and our

relay driver which is used for alarm

contact and genstart functionality.



A single TS-M2 will scan the meter

bus and detect all connected TriStars

and their mode of operation (charge

or load)

You get system power totals as well

as individual controller detail for

specific information and

troubleshooting.

HUB and Meter Economics

MSRP

5 x TS MPPT-60 + RTS $3345

5 x TS-M2 Meter Display $520

TS-M2 + HUB $219

Savings: $301

TS MPPT Internal Data Logging

Internal daily logged values stored in controller memory

show a variety of power information, voltage and current

thresholds in the system. It also logs daily events such as

faults or maintenance cycles.

Max Battery Voltage

Min Battery Voltage

Max Array Voltage

Amp Hours

Watt Hours

Daily Events

-Equalize/Float Stages Triggered

-Alarms

-Faults

Absorption Stage Time (mins)

Equalization Stage Time (mins)

Float Stage Time (mins)

TS MPPT Remote Data Logging with TS Meter 2

The TriStars data logging information can be easily viewed in the

following ways:

1. Viewed locally using any connected TS-M2 meter display (60 days)

TS MPPT Remote Data Logging with MS View

2. Downloaded locally using the serial RS-232/485 connection or

remotely using the Ethernet TCP/IP connection (200 day file)

This log file can be viewed in MS View so you can see and graph up to

the previous 200 days of daily logged values.


3. A continuous internet connection allows for a logging file to record data over

a very long period of time at an interval set by the user. This log file is written to a CSV

format and can be used for very detailed logging of key data occurring at intervals of every

day or every 5 seconds if desired.

This log file can be viewed in MS View graphically so you can also see comparative

graphs to analyze the information or it could analyzed graphically using a spreadsheet

program like MS Excel.


4. The TS MPPT web interface allows you to also view up to 200 days

of the internal data logging information through a simple HTML table interface.

No software is needed and the web page can be viewed with any full web

browser application on any computing platform. Just another simple way the TS

MPPT allows you to get your system data.

TriStar – Notification

Often a remote data connection is not something that can be continually

monitored due to the lack of bandwidth, or the fact that there are two

many sites to effective keep track of in real time. The TS MPPT 60 with

Ethernet offers two solutions to better manage larger controller

deployments.

Email Alerts – Programmable Proactive Alerts

Using comparative logic, the user can setup conditions that the TS MPPT

will watch for and when detected, can send an email with details of the

alert and on which unit it happened.

SNMP – Simple Network Management Protocol

SNMP is a network standard that allows networked equipment to send out

a proactive alert in the event of a problem with the system. A listening

server will detect these alerts and allow for identification to pursue further

information about the problem.

TriStar – Notification Setup

TriStar Notifications

Email and SNMP Alerts –Proactive Alerts

Using comparative logic, the user can setup conditions that the TS MPPT

will watch for and when detected, can send an email or SNMP trap with

details of the alert and on which unit it happened.

TriStar – MODBUS Open Protocol

All of Morningstar’s data enabled controllers use an open industrial data

protocol known as MODBUS. By choosing this type of protocol, we allow

3rd party software and hardware to easily communicate with our

controllers. We do not limit the customer to our proprietary hardware to

use our system information.

MODBUS is continuing to be chosen as the standard of choice for remote

telemetry, power monitoring and inter-device communication. We believe

MODBUS support will allow our products to grow easily with the industry’s

rapid pace of energy technology development.

TriStar – Data Summary

There are many different options for communicating with the TriStar

MPPT. Depending on the level of detail needed, the timeliness of the

need for that data and the communications resources available, a variety

of choices can be used to best meet the needs of the system and user.

Data Type Detail Time Period Proactive or On Demand

MS View PC Software Best Instant and historical On Demand

Web-HTML Good Instant and historical On Demand

TS-M2 Meter Good Instant and historical On Demand

SNMP Basic Instant Proactive

Email Basic Instant Proactive

TriStar MPPT Summary

The TriStar MPPT delivers with Morningstar’s consistent

offering of quality, reliability and unique features.

It offers the latest Solar MPPT charge control, industry

leading efficiency and temperature performance as well

as sophisticated new Ethernet functionality at a

compelling price.

It’s scalability and ease of use should make it another

Morningstar product you can count on to complement

your off-grid product portfolio.

Michelle Bollella, NY, [email protected] (800) 817-6527 x7135

Mark Brown AZ [email protected] (866) 993-5636

Charlie Bachman CO [email protected] (303) 604-1125

Helga Canfield NV [email protected] (800) 232-7652

David Love WA [email protected] (888) 870-9493

David Martindale NY [email protected] (866) 542-7972

Steve Naccarato NY [email protected] (877) 857-6527

Mark Paddison Canada [email protected] (800) 507-2585

Mona Rotkopf NY [email protected] (800) 333-1245

Wayne Robertson CA [email protected] (800) 344-2003

Patrick Rogers MT [email protected] (406) 333-4290

Mike Troutner FL [email protected] (877) 270-2241

Vicki Wallace CA [email protected] (800) 344-2003

Jim Westover CA [email protected] (877) 400-5150

Bruce Wilson MD [email protected] (410) 480-7175

mailto:[email protected]















Documents

Sunwize MorningstarTriStarMPPT Training