Morningstar SUNSAVER MPPT Series User manual

1098 Washington Crossing Road
Washington Crossing, PA 18977 USA
www.morningstarcorp.com
Installation and Operation Manual
SUNSAVER MPPT
TM
WITH TRAKSTAR
TM
MPPT TECHNOLOGY
Model: SS-MPPT-15L

SunSaver MPPT Dimensions
Specication Summary
System Voltage 12 Volts / 24 Volts
Rated Battery Current 15 Amps
Rated Load Current 15 Amps
Maximum Input Voltage* 75 Volts
Nominal Maximum Input Power**
12 Volt System 200 Watts
24 Volt System 400 Watts
See Section 7.0 for full technical specications
* Array voltage should never exceed maximum input voltage. Refer
too the solar module documentation to determine the highest expected
array Voc as dened by the lowest expected ambient temperature for the
system location.
** These power levels refer to the maximum wattage the SS-MPPT-15L
can process. Higher power arrays can be used without damaging the
controller, but efciency will be reduced at power levels much beyond
the nominal ratings.

MORNINGSTAR CORPORATION 3
Contents
1.0 Important Safety Information 4
1.0 Important Safety Information 9
2.0 General Information 9
2.1 Overview 9
2.2 Features 10
2.3 Optional Accessories 12
2.3 Regulatory Information 13
3.0 Installation Instructions 15
3.1 General Installation Notes 15
3.2 Conguration 16
3.3 Mounting 19
3.4 Wiring 21
4.0 Operation 28
4.1 LED Indications 28
4.2 TrakStarTM MPPT Technology 30
4.3 Battery Charging Information 33
4.4 Load Control Information 35
4.5 Protections 37
4.6 Inspection and Maintenance 39
4.7 Programming Custom Setpoints 40
5.0 Troubleshooting 41
5.1 Error Indications 41
5.2 Common Problems 42
6.0 Warranty 43
7.0 Technical Specications 44
Appendix A - Wire Chart 49

1.0 IMPORTANT SAFETY INFORMATION
1.0 Important Safety Information
Save These Instructions
This manual contains important safety, installation and operating
instructions for the SunSaver MPPT solar controller.
The following symbols are used throughout this manual to
indicate potentially dangerous conditions or mark important safety
instructions.
WARNING: Indicates a potentially dangerous
condition. Use extreme caution when
performing this task.
CAUTION: Indicates a critical procedure for
safe and proper operation of the controller.
NOTE: Indicates a procedure or function that
is important for the safe and proper operation of
the controller.
General Safety Information
• Read all of the instructions and cautions in the manual
before beginning installation.
• There are no user serviceable parts inside the
SunSaver MPPT. Do not disassemble or attempt to
repair the controller.
• Disconnect all sources of power to the controller before
installing or adjusting the SunSaver MPPT.
• There are no fuses or disconnects inside the SunSaver
MPPT. Install external fuses/breakers as required.
• Do not allow water to enter the controller.
• Conrm that power connections are tightened to avoid
excessive heating from a loose connection.

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1.0
CAUTION:
A BATTERY CAN PRESENT A RISK OF ELECTRICAL
SHOCK, BURN FROM HIGH SHORTCIRCUIT
CURRENT, FIRE OR EXPLOSION FROM VENTED GASES.
OBSERVE PROPER PRECAUTIONS;
NOTE:
PROPER DISPOSAL OF BATTERIES IS REQUIRED. RE-
FER TO YOUR LOCAL CODES FOR DISPOSAL
REQUIREMENTS;
WARNING:
These servicing instructions are for use by qualied
personnel only. To reduce the risk of electric shock,
do not perform any servicing other than that specied in
the operating instructions unless you are qualied
to do so.
WARNING:
EXPLOSION HAZARD - DO NOT DISCONNECT WHILE
CIRCUIT IS LIVE UNLESS AREA IS
KNOWN TO BE NON-HAZARDOUS.
CAUTION:
To reduce the risk of re, connect only to a circuit
provided with a maximum branch-circuit overcurrent
protection rating not to exceed the model current rating
on page 2 and in accordance with the National Electrical
Code, ANSI/NFPA 70.
Installation in Hazardous Locations
THIS EQUIPMENT IS SUITABLE FOR USE IN CLASS I, DIVISION
2, GROUPS A,B,C and D OR NON-HAZARDOUS LOCATIONS
ONLY.

1.0 IMPORTANT SAFETY INFORMATION
Informations de sécurité
• Lisez toutes les instructions et les avertissements gurant dans
le manuel avant de commencer l’installation.
• Le SunSaver ne contient aucune pièce réparable par l’utilisateur.
Ne démontez pas ni ne tentez de réparer le contrôleur.
• Déconnectez toutes les sources d’alimentation du contrôleur
avant d’installer ou de régler le SunSaver.
• Le SunSaver ne contient aucun fusible ou interrupteur. Ne
tentez pas de réparer.
• Installez des fusibles/coupe-circuits externes selon le besoin.
ATTENTION:
UNE BATTERIE PEUT PRÉSENTER UN RISQUE ÉLEVÉ
DE CHOC ÉLECTRIQUE, DE BRÛLURES SUITE À UN
COURANT DE COURT-CIRCUIT ÉLEVÉ, À UN INCENDIE
OU À UNE EXPLOSION PROVENANT DE GAZ REJETÉS
DANS L’AIR. VEUILLEZ PRENDRE LES PRÉCAUTIONS
NÉCESSAIRES.
AVERTISSEMENT:
Ces instructions d’entretien sont exclusivement réservé-
es à des techniciens qualiés. Pour réduire le risque de
choc électrique,
ne réalisez aucun entretien autre que celui stipulé dans
les instructions de fonctionnement, à moins que vous ne
possédiez les qualications nécessaires en la matière.
AVERTISSEMENT:
RISQUE D’EXPLOSION. NE PAS DEBRANCHER TANT
QUE LE CIRCUIT EST SOUS TENSION, A MOINS QU’lL
NE S’AGISSE D’UN EMPLACEMENT NON DANGEREUX.
ATTENTION:
Pour diminuer le risque d’incendie, ne connectez
l’alimentation qu’à un circuit équipé d’une protection
maximum par dérivation contre les surintensités ne
dépassant pas le courant nominal du modèle de la
page 2, conformément à la norme du Code National de
l’Électricité (NEC), ANSI/NFPA 70.

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1.0
Installation Safety Precautions
WARNING:
This unit is not provided with a GFDI device. This
charge controller must be used with an external
GFDI device as required by the Article 690 of
the National Electrical Code for the installation
location.
• Mount the SunSaver-MPPT indoors. Prevent exposure to the
elements and do not allow water to enter the controller.
• Install the SunSaver in a location that prevents casual contact.
The SunSaver heatsink can become very hot during operation.
• Use insulated tools when working with batteries.
• Avoid wearing jewelry during installation.
• The battery bank must be comprised of batteries of same type,
make, and age.
• Do not smoke in the vicinity of the battery bank.
• Mount the controller at least 3 ft (1 m) away from vented bat-
teries unless separated by a barrier or located in a separate
compartment.
• Power connections must remain tight to avoid excessive heating
from a loose connection.
• Use properly sized conductors and circuit interrupters.
• This charge controller is to be connected to DC circuits only.
These DC connections are identied by the symbol below.
Direct Current Symbol

1.0 IMPORTANT SAFETY INFORMATION
AVERTISSEMENT:
L’appareil n’est pas fourni avec un dispositif GFDI.
Ce contrôleur de charge doit être utilisé avec un
dispositif GFDI externe tel que requis par l’Article
690 du Code électrique national de l’emplacement de
l’installation.
• Montez le SunSaver à l’intérieur. Empêchez l’exposition aux élé-
ments et la pénétration d’eau dans le contrôleur.
• Utilisez des outils isolés pour travailler avec les batteries.
• Évitez le port de bijoux pendant l’installation.
• Le groupe de batteries doit être constitué de batteries du même
type, fabricant et âge.
• Ne fumez pas à proximité du groupe de batteries.
• Les connexions d’alimentation doivent rester serrées pour éviter
une surchauffe excessive d’une connexion desserrée.
• Utilisez des conducteurs et des coupe-circuits de dimensions
adaptées.
• Ce contrôleur de charge ne doit être connecté qu’à des circuits
en courant continu. Ces connexions CC sont identiées par le
symbole ci-dessous.
• Le contrôleur SunSaver doit être installé par un technicien
qualié conformément aux règlementations électriques du pays
où est installé le produit.
• Un moyen d’assurer la déconnexion de tous les pôles de
l’alimentation doit être fourni. Cette déconnexion doit être incor-
porée dans le câblage xe.
• À l’aide de la borne de mise à la masse du SunSaver (dans le
compartiment de câblage), un moyen permanent et able de
mise à la terre doit être fourni. La xation de la mise à la terre
doit être xée contre tout desserrage accidentel.
• Les ouvertures d’entrée au compartiment de câblage du Sun-
Saver doivent être protégées avec un conduit ou une bague.

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2.0
2.0 General Information
2.1 Overview
Thank you for selecting the SunSaver MPPT charge
controller with TrakStar TechnologyTM. The SunSaver-MPPT
(SS-MPPT) is an advanced maximum power point tracking
solar battery charger and load controller for stand-alone PV
systems. The controller features a smart tracking algorithm
that maximizes the energy from the solar module(s) and
also provides load control to prevent over-discharge of the
battery.
The SS-MPPT battery charging process has been
optimized for long battery life and improved system
performance. Self-diagnostics and electronic error protection
prevent damage when installation mistakes or system faults
occur. The controller also features four (4) settings switches
for adjustability, a meter port, and terminals for remote
battery temperature measurement (optional).
Using MSViewTM PC software, the SS-MPPT can be
programmed with custom settings to function as a lighting
controller to turn the system loads on and off at specied
intervals throughout the day and night. See section 4.7 for
more information.
Although the SS-MPPT is very simple to congure and
use, please take the time to read this operator’s manual and
become familiar with the controller. This will help you make
full use of the many advantages the SS-MPPT can provide
for your PV system.

2.0 GENERAL INFORMATION
2.2 Features
The features of the SunSaver MPPT are shown in Figure 1
below. An explanation of each feature is provided.
Figure 1. SunSaver MPPT features.
1 - Status LED
An LED indicator that shows charging status and also
indicates when a solar input fault condition exists.
2 - Power Terminal Block
Power terminations for system Solar, Battery, and Load
connections.
3 - Battery Select Jumper
A removable jumper to select the battery type.
1
2
8
7
6
5
4
3

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2.0
4 - Meter Connection
A communication port for the Morningstar Remote Meter
or Personal Computer (PC) connection. A MSC adapter is
required, available separately.
5 - Settings Switches
Adjustment switches that dene the operating parameters
of the SunSaver MPPT.
6 - Remote Temperature Sensor (RTS) Terminals
Connection point for a Morningstar RTS (optional) to
remotely monitor battery temperature.
NOTE: The use of a Remote Temperature Sensor is
strongly recommended. Controller location, air ow, and
system power can drastically affect the local temperature
sensor reading. A RTS will provide optimal charging
performance.
7 - Local Temperature Sensor
Measures ambient temperature. Battery regulation is
adjusted based on ambient temperature unless an optional
RTS is installed.
8 - Battery Status LEDs
Provides approximate battery state of charge indication
and also indicates when a system or load fault condition
exists.

2.0 GENERAL INFORMATION
2.3 Optional Accessories
The following accessories are available for purchase
separately from your authorized Morningstar dealer.
Remote Temperature Sensor (Model: RTS)
The RTS measures battery temperature for accurate temperature
compensation and is recommended when the ambient battery
temperature differs from the ambient controller temperature by
+/- 5 degrees C or more. An RTS can be attached to the SunSaver
MPPT at any time. The SunSaver MPPT will automatically use the
RTS for battery temperature compensation when installed. The
standard cable length is 33 ft (10 m), and can be extended to 100
ft (30 m) if required. Installation instructions are provided with the
RTS.
NOTE: The use of a Remote Temperature Sensor is
strongly recommended. Controller location, air ow, and
system power can drastically affect the local temperature
sensor reading. A RTS will provide optimal charging
performance.
Remote Meter (Model: RM-1)
The digital Remote Meter displays system operating information,
error indications, and self-diagnostic read-out. Information is
displayed on a backlit 4-digit custom LCD display. The large
numerical display and icons are easy to read and large buttons
make navigating the meter menus easy. Additionally, a status LED
and three (3) battery SOC LEDs provide system status at a glance.
The meter can be ush mounted in a wall or surface mounted
using the mounting frame (included). The RM-1 is supplied with 33
ft (10.0 m) of cable, a mounting frame, and mounting screws. The
RM-1 connects to the RJ- 11 Meter port on the SunSaver MPPT.
PC MeterBus AdapterTM (Model: MSC)
The MSC converts the MeterBus RJ-11 electrical interface to an
isolated standard RS-232 interface which enables communication
between the SunSaver MPPT and a personal computer (PC). The
MSC is required for programming custom charging setpoints and for
logging data. See Section 4.7 Programming Custom Setpoints.

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2.0
13
2.3 Regulatory Information
NOTE:
This section contains important information for safety
and regulatory requirements.
The SunSaver-MPPT controller should be installed by a
qualied technician according to the electrical rules of the
country in which the product will be installed.
SunSaver-MPPT controllers comply with the following
EMC standards:
• Immunity: EN61000-6-2:1999
• Emissions: EN55022:1994 with A1 and A3 Class B1
• Safety: EN60335-1 and EN60335-2-29 (battery chargers)
A means shall be provided to ensure all pole
disconnection from the power supply. This disconnection
shall be incorporated in the xed wiring.
Using the SunSaver-MPPT grounding terminal (in the
wiring compartment), a permanent and reliable means for
grounding shall be provided. The clamping of the earthing
shall be secured against accidental loosening.
The entry openings to the SunSaver-MPPT wiring
compartment shall be protected with conduit or with a
bushing.
FCC requirements:
This device complies with Part 15 of the FCC rules.
Operation is subject to the following two conditions: (1)
This device may not cause harmful interference, and (2)

2.0 GENERAL INFORMATION
this device must accept any interference received, including
interference that may cause undesired operation.
Changes or modications not expressly approved by
Morningstar for compliance could void the user’s authority to
operate the equipment.
Note:
This equipment has been tested and found to comply
with 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. This equipment generates, uses, and
can radiate radio frequency energy and, if not installed and
used in accordance with the instruction manual, may cause
harmful interference to radio communication. However,
there is no guarantee that interference will not occur in a
particular installation. If this equipment does cause harmful
interference to radio or television reception, which can be
determined by turning the equipment on and off, the user is
encouraged to try to correct the interference by one or more
of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit 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 appareil numerique de la classe B est conforme a la
norme NMB-003 du Canada.

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3.0
3.0 Installation Instructions
3.1 General Installation Notes
• Read through the entire installation section rst before
beginning installation.
• Be very careful when working with batteries. Wear
eye protection. Have fresh water available to wash
and clean any contact with battery acid.
• Use insulated tools and avoid placing metal objects
near the batteries.
• Explosive battery gasses may be present during
charging. Be certain there is sufcient ventilation to
release the gasses.
• Do not install in locations where water can enter the
controller.
• Loose power connections and/or corroded wires
may result in resistive connections that melt wire
insulation, burn surrounding materials, or even cause
re. Ensure tight connections and use cable clamps
to secure cables and prevent them from swaying in
mobile applications.
• Only charge lead-acid or NiCd batteries.
• The SunSaver MPPT Battery connection may be
wired to one battery or a bank of batteries. The fol-
lowing instructions refer to a singular battery, but it
is implied that the battery connection can be made
to either one battery or a group of batteries in a bat-
tery bank.

3.0 INSTALLATION INSTRUCTIONS
3.2 Conguration
The four (4) Settings Switches and the Battery Select
Jumper adjust the SS-MPPT battery type, load control,
equalization, and communication settings. This section
details the conguration for each setting.
Select a Battery Type
The SS-MPPT provides four (4) different battery types
as shown in table 1 below. Use Settings Switch 1 and the
Battery Select Jumper to choose the battery type. See
Section 7.0 Technical Specications for detailed charging
information for each battery type.
The battery select jumper is secured in the terminal block
between terminal #6 and terminal #7 as shown in gure 2.
The second column in table 1 species whether the jumper
should be removed or remain in place, depending on the
desired battery type.
Battery Type Battery Jumper Switch 1
Gel1INSERTED ON (↑)
Sealed INSERTED OFF (↓)
AGM1REMOVED ON (↑)
Flooded REMOVED OFF (↓)
(1) Setpoints for this battery type can be modified with custom program-
ming. See Section 4.7 Programming Custom Setpoints for more informa-
tion.
Table 1. Battery Type selection

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3.0
Figure 2. Removing the Battery Select jumper.
Load Control – Low Voltage Disconnect / Reconnect
Choose between two (2) load control Low Voltage Discon-
nect / Reconnect settings.
SWITCH 2 OFF (↓): LVD = 11.50 V, LVR = 12.60 V
SWITCH 2 ON (↑): LVD = 11.00 V, LVR = 12.10 V 2
(2) These values can be modified with custom programming. See Section 4.7
Programming Custom Setpoints for more information.
Enable or Disable Auto-Equalization
Turn the auto-equalize feature OFF or ON. The auto-
equalize feature will administer an equalization charge
(ooded battery type only) every 28 days or if the battery
discharges too low the previous night. There is no
equalization charge for the gel or sealed battery type.
SWITCH 3 OFF (↓): AUTO-EQUALIZE OFF
SWITCH 3 ON (↑): AUTO-EQUALIZE ON
(agm, ooded battery type only)

3.0 INSTALLATION INSTRUCTIONS
Communication – Meter / MODBUS®
Choose the desired communication protocol for the RJ-11
meter connection. Select the Meter protocol to communicate
with a Morningstar Remote Meter (optional accessory).
Select the MODBUS® protocol to communicate with
a PC2and Morningstar’s MSView software. MODBUS®
is an open communication protocol standard used by
Morningstar’s MSView PC software and other 3rd party
hardware / software.
SWITCH 4 OFF (↓): MORNINGSTAR REMOTE METER
SWITCH 4 ON (↑): MODBUS® PROTOCOL FOR
MSVIEW, 3RD PARTY DEVICES
(2) Morningstar PC Meterbus Adapter (Model: MSC) required. Not included.
See Morningstar’s website for more information. www.morningstarcorp.com.
MODBUS® is a registered trademark of Modbus-IDA (www.modbus-ida.org)

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3.0
3.3 Mounting
CAUTION: Equipment Damage or Risk of Explosion
Never install the SunSaver-MPPT in an enclosure with
vented/ooded batteries. Battery fumes are ammable
and will corrode and destroy the SunSaver circuits.
CAUTION: Equipment Damage
When installing the SunSaver-MPPT in an enclosure,
ensure sufcient ventilation. Installation in a sealed
enclosure will lead to over-heating and a decreased
product lifetime.
PRUDENCE: Endommagement de l’équipement ou
risque d’explosion
N’installez jamais le SunSaver-MPPT dans une enceinte
avec des batteries à évent/à électrolyte liquide. Les
vapeurs des batteries sont inammables et corroderont
et détruiront les circuits du SunSaver.
PRUDENCE: Endommagement de l’équipement
Assurez une ventilation sufsante en cas d’installation
du SunSaver-MPPT dans une enceinte. L’installation
dans une enceinte hermétique entraîne une surchauffe et
une réduction de la durée de vie du produit.
Step 1: Choose Mounting Location
Locate the SunSaver-MPPT on a vertical surface
protected from direct sun, high temperatures, and water.
Step 2: Check for Clearance
Place the SunSaver-MPPT in the location where it will be
mounted. Verify that there is sufcient room to run wires and
that there is ample room above and below the controller for
air ow.

3.0 INSTALLATION INSTRUCTIONS
WARM AIR
COOL AIR
AT LEAST
6” (150 mm)
AT LEAST
6” (150 mm)
Figure 3. Mounting and cooling
Step 3: Mark Holes
Use a pencil or pen to mark the four (4) mounting hole
locations on the mounting surface.
Step 4: Drill Holes
Remove the controller and drill 3/32” (2.5 mm) holes in the
marked locations.
Step 5: Secure Controller
Place the controller on the surface and align the mounting
holes with the drilled holes in step 4. Secure the controller in
place using the mounting screws (included).