TriStar MPPT Training Program

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TriStar MPPT Training Program
Brad Berwald Sr. Sales Engineer bberwald_at_morningst
arcorp.com
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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 MPPTs 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?

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TriStar Applications
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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)

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Back-Up System

• Five TS-60s used in parallel to provide charging
  for this 10kW communications building.

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Norway Weather Station

• Dual TriStar System used for Wind and Solar
  charging in very Northern region.

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Portable Power Station

• Two TriStars used for 5kw system in military
  application.

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Product Details
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Ratings and Features

• 45A and 60A Versions
• 150V Maximum Open Circuit Voltage
• MPPT charge control with TrakStar TechnologyTM

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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

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Robust Thermal Design

• Passively cooled no fans required
• 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

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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 2.3 Watts
Transient Surge Protection 4500 Watts/terminal
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TriStar MPPT Sizing
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.
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
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Electronic Protections

• Solar Overload, Short Circuit, High Voltage
• Battery High Voltage
• High Temperature
• Lightning and Transient Surges all terminals
• Reverse Current at Night

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Certifications

• CE Compliant
• ETL Listed (UL1741)
• FCC Class B Part 15 Compliant
• Complies with (NEC) U.S. National Electric Code
• RoHS Compliant
• Manufactured in a certified ISO 9001 facility

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MPPT Advantages
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Charge Controllers MPPT vs. PWM

• PWM Charge Control

• MPPT Charge Control

• PV Array and Battery Voltages must match.
• Array is sized in Amps based in Imp of modules.
• Less expensive
• Simpler series switching charge control circuit
  using PWM pulse charge control.

• Array can be higher nominal voltage than battery
  and controller converters power down.
• Array is sized in watts
• High Frequency charge control

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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.
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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
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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 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.
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Maximum Power Point Tracking
IV Curve
Power Graph
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MPPT Boost
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
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
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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
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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!
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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.
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TrakStar MPPT Comparison

• Full I-V Curve Sweep

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TrakStar MPPT Comparison

• Dynamic Tracking

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Dynamic tracking alone causes the controller to
-Only see what is happening locally at the
presumed power point. -Not detect what true Voc
is. -Be fooled by shading effects, mixed module
types or flat IV curves often seen on thin film
modules. -Take time to re-track during periods
of fast changing irradiance and temperature
levels. (cool winds on the panel surface or fast
moving clouds).
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Dynamic Tracking by itself leaves you in the dark
as to where the best Vmp point is.
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By not venturing further up the curve, you may be
missing a big opportunity for more power.
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Maximum Power Point Tracking
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 often to make sure to
not miss any fast changing max power points. -
Dual chipset provides specialized control -DSP
high speed MPPT, charge control, protections
and data logging -Secondary Processor
Ethernet and communications
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Competitive Advantages
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TriStar MPPT minimal power draw designed for
remote power systems.
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TriStar MPPT - Industry Leading Efficiency
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TriStar MPPT - Industry Leading Efficiency
Outback FM60 Efficiency Curve
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TriStar MPPT - Industry Leading Efficiency
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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
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TS MPPT sizing and setup
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String Sizing Calculator
Morningstars string calculator allows you size
compatible PV strings for all of Morningstars
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.
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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.
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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.

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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.
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Product Communications
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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

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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.
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TriStar and TriStar MPPT with HUB
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TriStar and TriStar MPPT with HUB
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.
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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
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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)
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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)
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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.
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TS MPPT Remote Data Logging with MS View
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.
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TS MPPT Remote Data Logging with MS View
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.
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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 with Ethernet offers two solutions to
better manage large quantities of sites. 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. 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.
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TriStar Notification Setup
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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.
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TriStar MODBUS Open Protocol
All of Morningstars 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
industrys rapid pace of energy technology
development.
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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
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TriStar MPPT
Summary
The TriStar MPPT delivers with Morningstars
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. Its scalability and ease of use should
make it another Morningstar product you can count
on to complement your off-grid product portfolio.