ROGUE MPT-3024 User manual

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MPT-3024
30A - 12/24VDC MPPT
Photovoltaic Charge Controller
Installation Guide
and
Owner’s Manual
Rogue Power Technologies, Ashland, OR 97520
www.roguepowertech.com
© Copyright 2011, Revision C1, 05/18/11

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Warranty and Liability Information
Rogue Power Technologies (hereafter RPT) warrants the MPT-3024 to
be free from defects in materials and workmanship for a period of five
(5) years from date of purchase. Warranty applies only to the original
purchaser. RPT will, at its option, either repair or replace a unit found
to be defective under the terms of this warranty. RPT’s sole liability
shall be said repair or replacement of a defective unit. RPT shall not be
held liable for incidental or consequential damages, or injury, arising
from the installation or use of this unit, nor shall RPT provide reim-
bursement for labor, removal or installation, shipping charges, or other
expenses not directly related to the terms of this warranty. RPT does not
warrant the workmanship of any persons installing this unit.
Conditions that will invalidate this warranty:
• Operation or installation contrary to the instructions provided in this
guide, including but not limited to: damage caused by reverse battery
connection, installation in an unapproved location, improper wiring,
etc.
• Damage caused by lightning or electrostatic discharge.
• Damage caused by abuse, neglect, or accident.
• Any unit which has been modified or repaired by anyone other than
RPT.
• Damage cause by natural disaster, shipping, transportation, or any
other circumstances outside of RPT’s control.
• Damage caused by another component of the power system.
• Any unit that has had its serial number or identification tag removed
or altered.
• Damage resulting from moisture or other environmental elements.
• Cosmetic damage, including scratches, scuffs, dents.
Before returning a unit for warranty service, please verify that the unit
is in fact defective. Shipping must be prepaid and insurance must be
purchased on any unit sent in for warranty service. RPT will pay return
shipping and insurance on units after the validity of the warranty claim
has been confirmed. Units sent in that are outside of their warranty
period, or units that do not qualify for warranty service based on the
above terms, will be returned at the expense of the sender. Units in need
of warranty service should be sent to: Rogue Power Technologies,
15975 Baldy Creek Rd., Ashland, OR 97520. Include a copy of the
original receipt and a detailed description of the problem.

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Table of Contents
1. Introduction and Overview...................................................................................
2. Safety Information...............................................................................................
2.1 General safety precautions................................................................
3. Front Panel and LCD Display...............................................................................
4. System design considerations.............................................................................
4.1 Distance of wire runs.........................................................................
4.2 Wire size..........................................................................................
4.3 Optimal PV array voltage..................................................................
4.4 Optimal PV array power....................................................................
4.5 PV array location..............................................................................
4.6 Matching array modules....................................................................
5. Lead-Acid Battery Charging.................................................................................
5.1 Charging basics................................................................................
5.2 Charging modes................................................................................
6. Maximum Power Point Tracking...........................................................................
7. Remote Battery Temperature Sensor...................................................................
8. Remote Battery Voltage Sense............................................................................
9. Auxiliary Output / Relay.......................................................................................
10. RE-CONN Communications Port.........................................................................
11. Installation........................................................................................................
11.1 Mounting and thermal considerations..............................................
11.2 Wiring.............................................................................................
11.3 Grounding......................................................................................
11.4 Disconnects and overcurrent protection..........................................
11.5 External surge protection................................................................
11.6 External noise filtering....................................................................
11.7 Remote temperature sensor installation...........................................
11.8 Remote battery voltage sense connection........................................
11.9 Auxiliary output / relay connection...................................................
11.10 RE-CONN communication port connection......................................
11.11 Final Assembly..............................................................................
12. Setup and Configuration....................................................................................
12.1 Initialization....................................................................................
12.2 Setpoint adjustments.......................................................................
13. Operation.........................................................................................................
13.1 Backlight and autoexit features.......................................................
14. Data Logging....................................................................................................
15. Battery Equalization..........................................................................................
16. Use of Multiple/Other Charging Sources............................................................
17. Fault Messages.................................................................................................
18. Troubleshooting...............................................................................................
19. Specifications...................................................................................................
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Tables, Graphs, and Diagrams
Tables
4.1.1. Copper wire resistance & power loss vs. gauge.............................
4.2.1. Wire distance vs. gauge & voltage drop for 12V............................
4.2.2. Wire distance vs. gauge & voltage drop for 24V............................
4.3.1. Typical voltage drop and power loss.............................................
4.4.1. Maximum PV array input...............................................................
12.2.1. Default values for setpoints........................................................
17.1.1. Fault messages..........................................................................
Graphs
5.2.1. Typical day of operation...............................................................
6.1.1. Typical PV array power curve........................................................
6.1.2. Efficiency......................................................................................
Diagrams
11.2.2. Wiring diagram...........................................................................
11.9.1. Auxiliary output wiring................................................................
12.1.1. Operational flowchart.................................................................
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1. Introduction and Overview
The Rogue MPT-3024 is a highly efficient 30 amp photovoltaic charge
controller that features a proprietary maximum power point tracking algorithm
for peak performance under a variety of atmospheric conditions. The MPT-
3024 constantly monitors the PV array’s output and automatically readjusts it
as necessary to extract the most power available from it at any given moment.
The array is never disconnected from the battery to make measurements, nor
are periodic sweeps of the array conducted while the controller is operating in
the power tracking stage. Either of these methods can result in more downtime
and less power being delivered to the batteries. Boost of over 40% may be
achieved with the MPT-3024 when the batteries are in a low state of charge,
the PV array is cold, and the sun is bright.
The MPT-3024 is based on a DC-DC buck converter topology. As such, it’s
capable of operating with a PV array input voltage that is higher than the
voltage of the battery it’s charging. The MPT-3024 will accommodate a 24-volt
nominal PV array with either a 12-volt or 24-volt battery bank, or a 12-volt
nominal PV array with a 12-volt battery bank. It will not operate with a PV array
that generates less voltage than that of the battery it’s charging. Output
current is electronically limited to 30 amps.
The MPT-3024 has been designed and built using only the highest quality,
most reliable components available, including ultra-low resistance MOSFETS;
long life, high-temperature capacitors; a 40-MHz microprocessor; and a
heavy-gauge, low resistance inductor. Additionally, the MPT-3024 senses
current without the use of resistive shunts. This results in an output gain of at
least 3 watts over conventional current shunt technology.
The MPT-3024 utilizes an advanced six-stage charge routine to ensure that
batteries are maintained properly for long life and minimal maintenance. All
setpoints are fully adjustable from the front panel and are stored in a
non-volatile memory that retains information even when the power is removed.
Setpoints may be retrieved, viewed, and altered on the LCD display at any time
during normal operation. Also included with the unit is a remote temperature
sensor that will alter the programmed setpoints based on the temperature of
the batteries being charged. This prevents overcharging when the batteries are
warmer, and undercharging when the batteries are cooler.

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The MPT-3024 features remote battery voltage sensing, which results in more
accurate charging. Additionally, it offers an auxiliary output relay that can be set
to turn on at a specific battery voltage. A RS-485 communication port is also
standard on the MPT-3024. It may be connected to a PC through the optional
DCV-0001data converter, and may also be directly connected to remote
monitoring and interface devices that may be available from Rogue.
Thirty days worth of data logging is kept in non-volatile memory. The data log
is retrievable during both normal operation and after the controller has entered
sleep mode. It can be erased at any time.
2. Safety Information
Please take a moment to read this manual and become better acquainted with
the features of the MPT-3024. As you read you will notice the following
symbols. They are meant to alert you of potential hazards, cautions, or
information that will require your attention as you install and use the MPT-
3024. Read the notations accompanying them carefully and understand their
content before continuing.
FPotential hazard to health, life, or property.
!Potential damage to charge controller or other ancillary equipment
if instructions are not followed.
SInformation that is useful in obtaining maximum performance from
the charge controller.
2.1 General safety precautions
1) This charger is intended for use only with lead-acid battery chemistries of
12- or 24-volt nominal system voltage. It may be suitable for other types of
batteries; consult your battery manufacturer for more information.
2) Lead-acid batteries produce small amounts of flammable hydrogen gas
during charging. Always work with batteries in a well-ventilated area and never
allow flames, sparks, or other sources of ignition within the vicinity of batteries
being charged.

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3) Lead-acid batteries contain an electrolytic mixture of water and sulfuric acid.
Wear suitable eye and skin protection while working with batteries. Make sure
you have access to running water and a supply of baking soda nearby to
neutralize any spilled or splashed acid. Should acid contact eyes, wash
immediately with running water for at least ten minutes and get medical
attention.
4) Batteries are capable of producing an extremely large current under short
circuit conditions. This current can generate enough heat to weld metal and
cause severe burns. Be careful when using metal tools around batteries and
remove all metal jewelry before commencing work.
5) Never attempt to move or relocate a battery without first disconnecting it
completely from its circuit.
6) Never charge a frozen battery.
7) Always ensure that the battery’s electrolyte is filled to the level recom-
mended by the manufacturer. Failure to do so may cause permanent damage
to the battery.
8) The electricity generated by a PV array may be of sufficient voltage to cause
electric shock or electrocution. Practice industry-standard safety techniques at
all times when working around electricity and always disconnect electricity
before you begin work on a circuit.

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1 - Array voltage (volts)
2 - Array current (amps)
3 - Array power (watts)
4 - Battery voltage (volts)
5 - Battery current (amps)
6 - Charger operating mode
• MPPT - bulk power tracking mode
• ABSB - absorb mode
• FULL - battery full
• FLOT - float mode
• EQLZ - equalize mode
7 - Accumulated PV Watt-hours (kWh if greater than 999Wh)
8 - Accumulated Amp-hours (as delivered to BATTERY)
9 - Battery temperature (if sensor is connected)
10-13 - Keypad legend
• BKLT - press for backlight on/off
• DATA - press for data log
• EQLZ - press to invoke equalize routine
• SETUP - press to view and alter setpoints
14 - Keypad
3. Front Panel and LCD Display

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4. System Design Considerations
Whether you are planning and installing your energy system for the first time
or retrofitting an existing system, you’ll obtain the best performance if you
follow a few simple guidelines.
4.1 Minimize the distance of wire runs
Place the PV array and battery bank as close as practical to the MPT-3024.
This will limit the power loss associated with long wire runs. Longer lengths of
wire will cause an increase in power loss, especially at higher currents. See
Table 4.1.1 to determine the resistance of selected wire gauges versus wire
length.
4.2 Maximize wire size
The wire used to connect the PV array and battery bank to the MPT-3024
should be of a heavy enough gauge so as not to introduce excessive voltage
drops and/or current limitations. At higher currents, light gauge wire may
introduce a large voltage drop from the PV array, causing an extreme loss of
power and erratic operation of the MPT-3024. Wire of insufficient size may
also constrain charging current to the battery (which is charging at a relatively
constant voltage at any given point in time). The effects of wire size may not
be evident at lower charging currents; they may gradually appear and get
worse as current increases.
Table 4.1.1. Copper wire resistance and power loss versus wire gauge.
Wire Gauge
(copper)
Resistance
(ohms/ft at 25oC)
Power Loss @ 30A (watts/
ft)
#12 0.00162 1.46
#10 0.00102 0.92
#8 0.00064 0.58
#6 0.00040 0.36
#4 0.00025 0.23
#2 0.00016 0.14

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NEC 310-15 restricts the minimum wire size for a 30-amp circuit to 10-gauge.
12-gauge may be used for installations of 20 amps or less, provided that the
length of the wire does not cause a significant voltage drop. Ideally the voltage
drop in any of your wiring runs should be 2% or less of the system voltage: for
example, this would be approximately 0.24 volts for a 12-volt system, or 0.48
volts for a 24-volt system. Refer to Tables 4.2.1 and 4.2.2 for help in
determining the proper gauge of wire when factoring in voltage drop and
distance.
#12 #10 #8 #6 #4 #2
5A 30 47 75 119 190 302
10A 15 24 37 60 95 151
15A 10 16 25 40 63 101
20A 7 1219304775
25A — 9 15 24 38 60
30A — 8 12 20 32 50
Table 4.2.1. Maximum distance (in feet) for wire at a specific gauge and cur-
rent, which will result in no more than a 0.24v (2%) voltage drop when used
with a 12-VOLT nominal system. Divide these distances in half for a round-trip
(both positive and negative) wire run.
#12 #10 #8 #6 #4 #2
5A 59 94 150 238 379 604
10A 30 47 75 119 190 302
15A 20 31 50 79 126 201
20A 15 24 37 60 95 151
25A —19304876121
30A —16254063101
Table 4.2.2. Maximum distance (in feet) for wire at a specific gauge and cur-
rent, which will result in no more than a 0.48v (2%) voltage drop when used
with a 24-VOLT nominal system. Divide these distances in half for a round-trip
(both positive and negative) wire run.