Rich electric INVERTEK SUNSTAR MPPT Series User manual

INVERTEK®
SUNSTAR MPPT SERIES
SOLAR CHARGE CONTROLLER
SS-50C / SS-80C / SS-80CX / SS-160CX MPPT
Installation and Operation Manual
利佳興業股份有限公司
RICH ELECTRIC CO.,LTD.
MANUAL VER.1, 0809

II
CONTENTS
Introduction ............................................................................................................................... Ⅳ
Feature..........................................................................................................................................IV
Specification..................................................................................................................................VI
Dimension ...................................................................................................................................VII
Chapter 1 Installation................................................................................................................1-1
1.1 Loads Requirement..........................................................................................1-1
1.2 Battery Voltage System...................................................................................1-1
1.3 PV Array Voltage.............................................................................................1-1
1.4 Maximum Voc..................................................................................................1-1
1.5 Shunt (BCS)......................................................................................................1-2
1.6 Battery Temperature Sensor (BTS-3)............................................................1-2
1.7 Battery Voltage Sensing (BVS).......................................................................1-2
1.8 Wiring Diagram...............................................................................................1-2
1.9 Installation Steps..............................................................................................1-4
Chapter 2 Wiring.......................................................................................................................2-1
2.1 Front Panel Display .........................................................................................2-1
2.2 Control Terminal Connection.........................................................................2-3
2.3 Parallel Connection..........................................................................................3-6
Capter 3 User Constants ...........................................................................................................3-1
3.1 Structure of User Constants................................................................................3-1
3.2 Initialization Stage Flow Chart...........................................................................3-2
3.3 Operation Stage Flow Chart...............................................................................3-4
Chapter 4 Constants List...........................................................................................................4-1
U Group: Operation ................................................................................................4-1
A Group: Initialize...................................................................................................4-1
B Group: Battery Setup...........................................................................................4-1
C Group: MPPT Setup............................................................................................4-2
D Group: Auxiliary Relay 1....................................................................................4-3
E Group: Auxiliary Relay 2....................................................................................4-4
F Group: Parallel Setup..........................................................................................4-5
O Group: Operator..................................................................................................4-5

III
G Group: Data Log..................................................................................................4-5
Chapter 5 Programming Constants.........................................................................................5-1
U Group: Operation ................................................................................................5-1
A Group: Initialize...................................................................................................5-4
B Group: Battery Setup...........................................................................................5-5
C Group: MPPT Setup............................................................................................5-8
D Group: Auxiliary Relay 1....................................................................................5-9
E Group: Auxiliary Relay 2..................................................................................5-12
F Group: Parallel Setup........................................................................................5-12
O Group: Operator................................................................................................5-13
G Group: Data Log................................................................................................5-14
Chapter 6 Trouble Shooting .....................................................................................................6-1

IV
Introduction
The SunStar MPPT is a highly reliable solar battery charger and its most critical feature is to
maximize the harvest energy from the PV array into the battery by using the advanced technology
of Maximum Power Point Tracking (MPPT). The battery types that the SunStar MPPT charge
include Flooded Lead Acid (FLA), GEL ,AGM chemistries and LiFePo4in the range of 12Vdc,
24Vdc, 36Vdc and 48Vdc nominal. The high efficiency of charging ability can be accomplished
through a 2 or 3 or 4-stage charging depending on the battery type. It is built-in with the protection
to ensure the battery without being overcharged or undercharged.
The wide range of the input array voltage and output battery voltage are well applied to the solar
system to allow system planner to produce the most of the solar energy. The input PV array of the
SS-50C MPPT and SS-80C MPPT may be wired in the range of 16~112Vdc nominal and the
input PV array of the SS-80CX and SS-160CX may be wired in the range of 16~192Vdc nominal.
The output battery voltage is accepted from 12 to 48Vdc nominal.After wiring up and operation,
the built-in intelligent data logging system can track the battery of charge (SOC) and the harvest
power produced over the days.
SunStar MPPT may not only well used in solar systems but also in wind or hybrid systems. With
respect to these systems, the 2 auxiliary relays can be programmed by constants setting. The
functions and programming of the relays helps to control the dump loads. Multiple SunStar MPPT
with cables (up to 16 units) can be connected in the larger power systems. The controller with
optional rectifier and braking unit for wind system is required to control and stop the control from
overload condition caused by over large wind speed.
.
Please carefully read through this manual and all the installation instruction and wiring before
beginning installation of your SunStar MPPT. The protection and installation equipment should be
complied with the local codes. The rated fuses, breakers and external lightning protection should
be installed along with SunStar MPPT.
Features
zIntegrates Maximum Power Point Tracking (MPPT), battery charge management, state of
charge information.
zContinuous output Power Rating without de-rating at up to 50℃ambient temperature.
zBuilt-in Battery Energy Monitor tracks power production and consumption to
calculate the energy remaining in battery state of charge (SOC) is displayed in
percent full, Amp-hours, Watt-hours, and 90 days of energy-harvest history is stored in the
solar charger.
zSupports Flooded Lead Acid (FLA), GEL, Absorbed Glass Mat (AGM) and LiFePO4

V
batteries; 2/3/4-stage charging with adjustable set points for all parameters.
zWire the PV modules in series up to 112VDC normal (140VDC Max) for SS-50C Series,
SS-80C Series and 192VDC normal (240VDC Max) for SS-80CX Series, SS-160CX Series.
zEasy stacking of up to 16 units in parallel for high currents.
zPrecision charging of 12V/ 24V/36V/48V batteries with easy set-up and using battery voltage
sense (BVS) wires.
zBuilt-in temperature compensation function for safe and complete charging.
zThe optional rectifier with braking unit for wind system is required to control and stop the
controller from overload condition caused by over large wind speed.

VI
Specification
Model No. SS-50C MPPT SS-80C MPPT SS-80CX MPPT SS-160CX MPPT
Maximum output current
(Continuous at up 50℃
ambient temperature)
50 Amps 80 Amps 80 Amps 160 Amps
Battery Voltages 12,24,36,48 VDC Normal
Max PV Input Current 40 Amps 70 Amps 70 Amps 140 Amps
16~112VDC Operating 16~192VDC Operating
Input Voltage Range 140VDC Maximum
Open Circuit Voltage
240VDC Maximum
Open Circuit Voltage
Max PVArray Power
3250 Watts
(Maximum
when equalizing
a 48V battery to
64V at 50 Amps)
5200 Watts
(Maximum
when equalizing
a 48V battery to
64V at 80 Amps)
5200 Watts
(Maximum when
equalizing a 48V
battery to 64V at
80 Amps)
10400 Watts
(Maximum when
equalizing a 48V
battery to 64V at
160 Amps)
Charge Regulation Modes Bulk, Absorption, Float, Auto/ Manual Equalization
Battery Temperature
Compensation 5.0 mV per℃, per 2 volt cell
12V Battery: 16~112VDC 12V Battery: 16~192VDC
24V Battery: 32~112VDC 24V Battery: 32~192VDC
36V Battery: 48~112VDC 36V Battery: 48~192VDC
DC to DC Conversion
Capability
48V Battery: 64~112VDC 48V Battery: 64~192VDC
Display Status
Built-in 2-line, 20-character LCD with backlight
LCD status screen displays input voltage and current, output voltage and
current, charge-mode, Battery SOC
Data Logging Logs energy harvested for 90 days, LCD displays WH, KWH,AH
Energy Monitor LCD shows SOC, AH, WH, and present charge or discharge current.A
50mV/ 500Amp shunt is required to use
Auxiliary Relays Two independent relays with fromA(SPST) contacts for control of external
devices. Contact rating is 3 Amps, 50VDC
Operation Temperature Full Power Output to +50℃ambient
Standby Power < 2 Watts < 4 Watts
Dimension 267.6 x 196 x
147 mm
414.8 x 225 x
147 mm
414.8 x 225 x
147 mm
498 x 392.6 x
147 mm
Weight 4.3 Kgs 7.1 Kgs 7.1 Kgs 17 Kgs

VII
Dimension for SS-50C MPPT
Unit: mm
Fig-1

VIII
Dimension for SS-80C MPPT
Dimension for SS-80CX MPPT
Unit: mm
Fig-2

IX
Dimension for SS-160CX MPPT
Unit: mm
Fig-3

1-1
Chapter 1 Installation
1.1 Loads Requirement
The SunStar MPPT series plays a major role in planning your PV system. The first
step in planning an efficient PV system is to calculate the load requirement. In order
to calculate the anticipated load requirement, it is important to determine average and
peak load consumption. The possible load growth should also be taken into
consideration when planning the load requirement because loads hardly remain static
and they grow more frequently than they reduce.
1.2 Battery Voltage System
After the estimate of the power requirement, the required power from the battery will
be the next consideration in planning the system. According to the basic rule of the
electricity, “Current is the power divided by voltage”, when the power amount
increases, it is suggested to raise the battery voltage so the current amount will
decrease. The principle is based on the larger amount of current is, the more expensive
the circuit protection is. In an example of the 96 watt load, it draws 4 amps at 24V
battery system but it draws only 2 amps at 48V system.
1.3 PVArray Voltage
As the SunStar MPPT is a smart DC to DC converter design, the specification of a PV
array is much like sizing a grid tie inverter. Installers choose the max. and min. Vmp
and Voc of each string and how many strings are needed.
1.4 Maximum Voc
The maximum operating voltage of theSS-50C MPPT and SS-80C MPPT is 140 Vdc
and of the SS-80CX MPPT and SS-160CX MPPT is 240Vdc. The protection will be
active to shut down the unit when the operating voltage is higher. PV array
manufacturers has the published data sheet with rated voltage and current as well as
the current and temperature coefficients. The rated Voc is measured in the temperature
of 25℃so when calculated at lower temperature such as 0℃, 25% increase of the
rated Voc is expected. At different temperature location of installation, the maximum
Voc of the module should be determined by the Voc voltage temperature coefficient
and after that, a series string voltage may be determined as well.

1-2
1.5 Shunt (BCS)
The Shunt is an optional component and it is required for the SunStar MPPT to
achieve to the optimal operation levels and it functions as a hub for connecting
measurement sensors. The main purpose of the shunt is to allow the SunStar MPPT to
measure current drawing into and out of the battery.
DC load centers is where the SunStar MPPT Shunt is recommend to be placed at. Or
installing it in an electrical enclosure is also acceptable. Locating the Shunt is
essential for safety. Please note that the capacity of the Shunt is 50mV, 500Amp. See
page 2-3 for wiring connection terminal.
1.6 Battery Temperature Sensor (BTS-3)
The battery temperature sensor BTS-3 is used to compensate charging by adjusting
charging voltage up or down according to the temperature detected by the sensor, see
page 2-3 for wiring connection terminal.
The SunStar MPPT requires BTS-3 to be connected for all charging features to be
available. SunStar MPPT is able to operate without the sensor but Absorption Trigger
set points will be lower and equalization stage will be disabled. BTS-3 can be
mounted on the battery posts.
1.7 Battery Voltage Sensing (BVS)
Connecting the red wire to a battery positive bus and the black wire to a battery
negative bus within the DC load center, see page 2-3 for wiring connection terminal.
Two sense wires may be connected to compensate possible battery cable loss during
charging. Be sure to observe correct polarity when installing voltage sense wires or
damage will result.
1.8 Wiring Diagram
Before starting to initiate the SunStar MPPT, keep all breakers in the OFF position.
When you are ready to start the SunStar MPPT, turn on ONLY the Battery breaker. Do
NOT turn on the PV breaker until the instruction on LCD shows during SunStar
MPPT initialization. The internal electric circuit of the SunStar MPPT can only be
powered by the batteries.
The installation environment of SunStar MPPT should be in an area of good
ventilation. Never locate the SunStar MPPT in a poorly ventilated battery area
because batteries emit the explosive gases. Do not locate the SunStar MPPT within 1
meters of the batteries to ensure the safety condition.
See next page for the wiring diagram of SS-80C as an example.

1-3
Fig-4

1-4
1.9 Installation Steps
Example: SS-80C MPPT
Before starting the SS-80C, keep the breakers, controllers in OFF position.
1. Locate the battery and SunStar MPPT Series and make sure the safety distance is
at least 1 meter long.
2. Install a 100 Amp rated DC breaker and connect it to the Battery + .
3. Install a Shunt of rated 500A/50mV and connect it to the Battery –.
4. Connect the BAT+ terminal of the SunStar MPPT to the DC breaker.
5. Connect the GND terminal (next to BAT+) of the SunStar MPPT to the Shunt.
6. Install a 90 Amp rated DC breaker and connect it to the PV array + and also to the
PV+ terminal of the SS-80C.
7. Connect the PV array – directly to the GND terminal (next to PV+) of the SS-80C.
8. Connect the EARTH terminal of the SS-80C to the system ground.
9. To measure the current drawing into and out of the battery, connect the BCS+
terminal of SS-80C to the Shunt + and connect the BCS- terminal of SS-80C to
the Shunt –.
10. To compensate the battery charging due to the temperature difference, connect the
BTS+ terminal of SS-80C to BTS-3 Battery Temperature Sensor +and connect the
BTS- terminal of SS-80C to BTS-3 Battery Temperature Sensor –.
※ BTS-3 should be located in the battery posts –.
11. To compensate the possible battery cable loss, connect the BVS+ terminal of the
SS-80C to Battery +, connect the BVS- terminal of the SS-80C to Battery – .
12. Finally, connect the DC load+ to the Battery+ and DC load – to Battery – through
the Shunt.

2-1
Chapter 2 Wiring
2.1 Front Panel Display
8 Push Buttons
Push buttons Name Description
PB1 Data write-in key
PB2
UP key to increment setting values.
UP key to go to the next selection or constant.
PB3
DOWN key to decrement setting values.
DOWN key to go to the last selection or constant.
PB 1PB 2PB 3
PB 4
PB 5PB 6PB 7PB 8
LED
Indicator
LCD Meter

2-2
PB4
Reset key to reset the fault.
ESC key to return to the last selection level.
PB5 Quick function key to the Main Menu: Data Log
PB6 Quick function key to the Main Menu: Programming
PB7 Quick function key to the Main Menu: Initialize
PB8 Quick function key to the Main Menu: Operation
4 LED Indicators
LEDs Flashing/
Solid Description
FAULT Solid Red
Read the LCD meter for fault condition displayed.
4 fault conditions could be displayed as follows:
EQUAL Flashing
Orange
SunStar MPPT unit is in equalization mode. Refer to constant
B-09~B-12 for the setting details.
CHARGE Flashing
Green
SunStar MPPT unit is in charge mode. This indicates that it is
functioning properly.
READY Solid Green
When the voltage from the PV array is first received, the SunStar
MPPT is in standby mode to charge.
LCD Meter
1 LCD Meter of 20 x 2 characters is built in each SunStar MPPT unit.
ERROR!!!
High Input Voltage
ERROR!!!
SunStar Over-Temp.
ERROR!!!
Parallel COM Failed
ERROR!!!
Battery Over-Temp.

2-3
2.2 Control Terminal Connection
Fig-4
Connections Details
A BVS- Connecting terminal to Battery Voltage feedback Negative
B BTS- Connecting terminal for Battery Temperature Sensor Negative
C BVS- Connecting terminal for optional Shunt Negative
D BVS+ Connecting terminal to Battery Voltage feedback Positive
E BTS+ Connecting terminal for Battery Temperature Sensor Positive
F BCS+ Connecting terminal for optional Shunt Positive
G Parallel IN Connections for parallel input from last SunStar MPPT
H Parallel OUT Connections for parallel output
I Remote Connecting terminal to Remote Panel Display
P Q R S T
M N O
IHGJKLD E FA B C

2-4
J MA1 Connecting terminal for the contactA of auxiliary 1
K MC1 Connecting terminal for the common contact of auxiliary 1
L MB1 Connecting terminal for the contact B of auxiliary 1
M MA2 Connecting terminal for the contactA of auxiliary 2
N MC2 Connecting terminal for the common contact of auxiliary 2
O MB2 Connecting terminal for the contact B of auxiliary 2
P PV+ Connecting terminal for Solar Array Positive
Q GND Connecting terminal for Solar Array Negative
R BAT+ Connecting terminal for battery cable Positive
S GND Connecting terminal for battery cable Negative
T EARTH Connecting for ground

2-5
2.3 Parallel Connection
The parallel connection of SunStar MPPT series can be up to 16 units (1 Master and 15 Slaves) and in the parallel system, there is only one
Shunt which needs to be connected to the Master unit to measure the total accumulated current.
Fig-5
F-01=Master F-01=Slave
F
-
02
=
2
F-01=Slave
F-02=3

3-1
Chapter 3 User Constants
3.1 The following is the structure of user constants.
U-12 Battery SOC
U-13 Battery Current
U-14 Battery Amp Hours
U-15 Battery Temperature
U-16 Parallel COMM Status
U-17 Serial Number
Initialize A-01 Access Level
A-02 Init Parameters
A-03 Password 1
A-04 Password 2
Programming B Battery Setup B-01 Set Battery Voltage
B-02 Set Battery Type
B-04 Set Battery Capacity
B-05 BAT. MAX Charge Amps
B-06 Set Absorption Voltage
B-07 Set Absorption Time
B-08 Set Float Voltage
B-09 Set Equalize Voltage
B-10 Set MAX EQU. Time
B-11 Set Days Between EQU
B-12 Manual Equalize
C MPPT Setup C-01 Set MPPT Type
C-02 Set Scan Frequency
C-03 Set Percentage VOC
C-04 Percentage EveryTime
C-05 Set Hold Input Volts
D Auxiliary Relay 1 D-01 Set Aux Relay 1 Mode
D-02 Aux RY1 ON Condition
D-03 AuxRY1 OFF Condition
D-04 Aux RY1 MIN. ON time
E Auxiliary Relay 2 E-01 Set Aux Relay 2 Mode
E-02 Aux RY2 ON Condition
E-03 AuxRY2 OFF Condition
E-04 Aux RY2 MIN. ON time
F Parallel Setup F-01 SunStarParallel MODE
F-02 SunStarParallel Addr
O Operator O-01 Set Clock Mode
O-02 Set SunStar Time
O-03 Set SunStar Date
O-04 Model Number
O-05 Turn OFF Backlight T
O-06 FAN Test
O-07 Software Version
O-08 ***Bootloader***
Data Log G-01 EnergyHarvestToday 1
G-02 EnergyHarvestToday 2
G-03 Set Day LOG # (1-90)
G-04 Day LOG # : kWHr
G-05 Day LOG # @ FLOAT
Average Last xx Days
xxxx kWHr xxxx Ahr
Average Last xx Days
FLOAT xx : xx
G-07
G-08

3-2
3. 2 The following is the “Initialization Stage Flow Chart”.