Solar Regulators
What are Solar Regulators / Solar Charge Controllers?
Solar electric power systems are essentially very simple. You have a device which converts sunlight into electrical energy (a photovoltaic panel or 'solar panel') and this is used to charge up a battery. The battery allows you to collect energy when the sun is shining and store it until needed.
This simple picture is complicated by the limitations of the battery. If you leave the photovoltaic panel connected to a battery, the battery will slowly charge up. If you are putting in more energy than you are taking out, then the battery will eventually become fully charged. If this continues, the battery will become overcharged and be damaged by corrosion of it's plates and loss of electrolyte. To avoid this, some sort of charge regulator / solar regulator is used to stop the charging when the battery is full.
Some charge controllers / solar regulators have additional features, such as a low voltage disconnect (LDV), a separate circuit which powers down the load when the batteries become overly discharged (some battery chemistries are such that over-discharge can ruin the battery).Some charge controllers may also monitor battery temperature to prevent overheating. Some charge controller systems also display data, transmit data to remote displays, and data logging to track electric flow over time.
Pulse width modulation (PWM) and maximum power point tracker (MPPT) technologies are more electronically sophisticated, adjusting charging rates depending on the battery's level, to allow charging closer to its maximum capacity.
Series Regulator vs MPPT
The MPPT versus series regulated question is not always straight forward as it very much depends on the conditions under which charging is taking place.
MPPT is good if you need to run cables from an array over a long distance as it allows higher voltage panel strings (therefore lower power loss due to cable resistance, because of lower currents).
Other than that, MPPT is useful if you don’t want to (or can’t) match the panel specifications to the battery (e.g. on a motorhome you may want to use some uncommon, high output panels since the roof space is limited).
Be aware that the % gains claimed for MPPT (other than the above couple of examples) are not likely to be ‘real world’ (e.g. How many hours during the day do your panels work at 25°C or less ?!). The hotter the panels become –the maximum power point voltage decreases and gets close to a typical battery voltage, therefore wiping out most (if not all) the gain an MPPT unit will give.
The other issues with MPPT (particularly for boats at sea) is that it’s not always easy to bypass the regulator should a fault occur (e.g. due to lightning) since the panels and battery are not matched (e.g. high voltage panels and lower voltage battery). With a series regulated system (like the Plasmatronics regulators), the system can be kept running by connecting the panels directly to the battery and manually regulating.
Morningstar Regulator Accessories
Morningstar Ground Fault Protection Device
Morningstar’s Ground Fault Protection Device products are built to provide a superior solution to ground fault protection for both off-grid and on-grid PV systems.
The GFPD products’ are available in two model versions (GFPD-150V and GFPD-600V) to support 150V and 600V PV system breaker stacks.
Morningstar’s GFPD increases safety and design flexibility in off-grid and on-grid PV systems.
Ground fault protection is used in electrical systems to prevent current from following any unintended paths during a ground fault.
It is critical to detect any stray current and to interrupt (break) the circuit until safe operation can be restored.
A current imbalance between the conductors of a circuit indicates a ground fault.
When a ground fault is detected, Morningstar’s GFPD breaks the circuit on both the positive and the negative legs and ensures interruption of the ground fault current better than other solutions on the market.
Key Features & Benefits
- Maintains the integrity of earth bond for battery and loads.
- Trips at lower fault current with greater accuracy.
- Breaks both conductors in the faulted circuit and completely isolates PV source circuits.
- Does not require an extra warning label at the battery as per U.S. National Electric Code requirements.
- Provides design flexibility to meet a wide range of configurations:
- Positive and negative ground
- Large and small arrays
- Makes it easier to locate and troubleshoot ground faults.
- Powered via the PV system’s battery bank.
- Equipped with both visual and audible alarms.
- Built to support both single controller and multiple controllers systems:
- Morningstar’s GFPD will only shut off affected controllers, while maintaining the system earth bond.
- All loads will continue to operate safely with the battery remaining bonded
- Multiple controllers and GFPDs can be added on an as-needed basis
GFPD-150V |
GFPD-600v
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Maximum Solar Voltage (Voc): |
150V |
600V
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Maximum Solar Current: |
85 Amps |
50 Amps
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Supply Voltage Range: |
10-72 Vdc |
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Self-Consumption: |
<0.5W |
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Ground Fault Threshold Current: |
300 mA +/- 10% |
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Number of Poles: |
2 |
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Trip Method: |
Relay |
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Output Trip Signal: |
12V |
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Nominal System Voltage: |
12, 24, 36 or 48 Vdc |
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Electronic Protections: |
Reverse Polarity Disconnected Feedback Signal Circuit Detection |
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Ambient Temperature: |
-40°c to +50°c |
-40°c to +60°c |
Storage Temperature: |
-55°c to +85°c |
-55°c to +85°c |
Humidity: |
Up to 100%, non-condensing |
|
Tropicalization |
PCB Conformal Coating |
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Dimensions: |
26.9 x 12.8 x 11.2 cm (10.6 x 5.1 x 4.4 in) |
35.7 x 22.1 x 10.6 cm (14.1 x 8.7 x 4.2 in) |
Weight: |
2.0 kg / 4.4 lbs |
4.4 kg / 8.9 lbs |
| Certifications: | CE, RoHS and REACH Compliant, UL 1741 and CSA C22.2 No. 107.1-01 Listed, GFPD-150V is UL-489 Listed, GFPD-600V is UL-1077 Listed, Meets EMC Directives (Immunity, Emissions and Safety), FCC Class B Part 15 Compliant, U.S. National Electrical Code (NEC) 690.5 Compliant for use as a GFPD device, Manufactured in a Certified ISO 9001 Facility |
Wire Box for ProStar MPPT
The Wire Box for ProStar MPPT™ (model: PS-MPPT-WB) provides an effective cover for wires and conduit leading to and from the ProStar MPPT controller.
It is an optional two-piece enclosure accessory that can replace the standard wire cover on the bottom of the ProStar MPPT solar charge controlle
This Wire Box accessory provides an effective cover and additional space for #2 AWG wire and conduit leading to and from the ProStar MPPT solar charge controller.
Inspectors may require or recommend this Wire Box to reduce hazards associated with exposed wires, conduits and connections
KEY FEATURES AND BENEFITS
- Dimensions: 20(W) x 17(L) x 9.2(D) cm 7.9(W) x 6.7(L) x 3.6(D) in
- Weight: 0.4 kg / 0.9 lbs
- Material: High strength polycarbonate Lexan
- Enclosure space: accommodates 35mm2 wire
- Meets NEC standards for conduits and wire bending
- Manufactured in an ISO 9001 facility
- Includes: Concentric knockouts (trade size) (4) 1/2” / 3/4” [M15 / M20] (1) 3/4” / 1” [M20 / M25] 4 cover screws for assembling
Morningstar TriStar Meters (RM-2, M-2, M-2-600V)
Digital Displays for TriStar Solar Charge Controllers
The TriStar Meter-2™ (TS-M-2), TriStar Meter-2-600V™ (TS-M-2-600V) and the TriStar Remote Meter-2™ (TS-RM-2) are advanced digital meters. They are nearly identical except that the TS-M-2 and TS-M-2-600V are mounted on the controller and the TS-RM-2 is flush mounted up to 30 meters away from the controller.
The TriStar meters are 2 x 16 character LCD’s that display system and controller information, logged data, bar graph metering, alarms and faults for easy troubleshooting. The information may be shown in English, French, German, Portuguese or Spanish. In multi- controller systems, these are networkable using Morningstar’s MeterHub to allow individual controller data and aggregate system data to be displayed together on a single meter.
Key Features and Benefits:
- Easy to install
- Uses standard 6 conductor RJ-11 connectors
- TS-RM-2 fits a “double gang” electrical box and includes 30 meters (98.4 feet) of cable
- Both data and meterbus power flow over a single cable
- Network supports up to 15 devices and, optionally, more than one meter per system
- Networking capability
- Displays individual controller data from up to 15 TriStars with optional Morningstar MeterHub
- Aggregates system data to show total charge, load and battery charge/discharge state
- Auto detects any device found on the network
- Easy to use
- Four directional pushbuttons for easy navigation of display screens
- Backlighting to enhance readability
- Meter may be added during initial controller installation, added as an upgrade anytime in the future or connected temporarily for troubleshooting with the ability to use this same meter at other site
TriStar Meter-2™ (TS-M-2) |
TriStar Meter-2-600V™ (TS-M-2-600V)
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TriStar Remote Meter-2™ (TS-RM-2)
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Self-Consumption: |
<0.5W 42.5 mA (backlight on) |
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Connector Type |
RJ-11 (6-pin) |
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Cable: |
0.13 m / 5 in - 6 conductor
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0.35 m/ 14 in - 6 conductor |
30 m / 98.4 ft - 6 conductor |
Cable Temperature: |
60°c rating |
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Compatibility:
|
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TriStar TriStar MPPT TriStar MPPT 600V |
Yes Yes No |
No No Yes |
Yes Yes Yes |
Ambient Operating Temperature: |
-40°c to +60°c |
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LCD Temperature Rating: |
-20°c to +70°c |
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Storage Temperature Range: |
-55°c to +85°c |
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Humidity: |
5 to 95 % non-condensing |
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Tropicalization |
Conformal Coating on both sides of circuit board |
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Weight: |
0.23 kg / 0.5 lb |
0.18 kg / 0.4 lb |
0.18 kg / 0.4 lb |
| Certifications: | CE, RoHS and REACH Compliant, ETL Recognised Component FCC Class B Part 15 Compliant, ACMA-EMC Compliant, Manufactured in a Certified ISO 9001 Facility |
Morningstar Sunsaver Duo, Sunsaver MPPT & Prostar MPPT Meter (RM-1)
Morningstar’s Remote Meter™ (RM-1) is a universal, four digit display with custom icons that is compatible with several Morningstar controllers and inverters. This meter provides comprehensive system information for easy monitoring including voltage, current and temperature.
Key Features & Benefits
- Provides Important Information
- The digital meter displays voltage, current, temperature, logged data, settings, alarms and error reporting for easy troubleshooting. Present, cumulative and maximums/ minimums are indicated. The LED’s display battery level and operating state. One or more icon and units indicators are displayed to indicate whether the numerical information relates to solar, load, battery 1 or 2, options, errors or self-test.
- The digital meter displays voltage, current, temperature, logged data, settings, alarms and error reporting for easy troubleshooting. Present, cumulative and maximums/ minimums are indicated. The LED’s display battery level and operating state. One or more icon and units indicators are displayed to indicate whether the numerical information relates to solar, load, battery 1 or 2, options, errors or self-test.
- Easy to Install
- Simply plugs into other Morningstar products via RJ-11 connector. May be mounted in the wall or on the wall using the included frame. Also includes 10 meters of wiring with RJ-11 connectors and mounting screws
- Easy to Use
- Three soft buttons allow for simple navigation of the meter menus. Custom icons and back lighting make the meter easy to read and understand.
- Low Self-Consumption:
- The Remote Meter was designed for low self-consumption to avoid draining the system batteries on even small solar systems. Self-consumption is 6 mA with backlight off and 15 mA with backlight on.
- The Remote Meter was designed for low self-consumption to avoid draining the system batteries on even small solar systems. Self-consumption is 6 mA with backlight off and 15 mA with backlight on.
- Adjustability
- The temperature may be displayed in either °C or °F, the backlight timer may be adjusted for desired running time and the amp-hours and minimum/maximum values may be reset
- Backlight off 6mA
- Backlight on 15mA
- Mount in the wall or on the wall
Self-consumption: |
Backlight Off = 6mA Backlight On = 15mA |
Minimum Operating Voltage: |
8Vdc |
Connector type: |
RJ-11 (6 pin) |
Faceplate dimensions: |
9.5 x 9.5 cm / 3.8 x 3.8 in. |
Faceplate material: |
Powder coated steel |
Meter back dimensions: |
7.4 cm / 2.9 in. diameter 2.8 cm / 1.1 in. deep Fits 7.6 cm / 3 in. round hole |
Frame dimensions: |
11.4 x 11.4 x 3.5 cm 4.5 x 4.5 x 1.4 in. |
Frame material: |
PBT pastic |
Meter cable: |
10 m / 33 ft (6 conductor) May be extended to 30 m / 100 ft |
Meter cable temp. rating: |
60 °c / 140 °f |
Meter weight: |
135 g / 0.3 lbs |
Ambient Temperature: |
-20°c to +60°c (-4°f to +140°f) |
Storage Temperature: |
-30°c to +80°c (-22°f to +176°f) |
Humidity: |
100% non-condensing |
Tropicalization: |
Printed circuit board is conformal coated |
| Compatible With: | Sunsaver Duo, Sunsaver MPPT, Prostar MPPT, Suresine Inverter |
| Certifications: | CE Compliant, RoHS Compliant, Manufactured in a certified ISO 9001 facility |
Morningstar Relay Driver (RD-1)
Morningstar’s RelayDriver™ is a logic module which provides high level system control functions such as high/low voltage alarms, load control and generator start
Morningstar’s Relay Driver is a logic module which provides high level system control functions such as high/low voltage alarms, load control and generator start. The product controls four independent relay driver outputs by reading digital data inputs from Morningstar’s TriStar controller or by reading battery voltage when used in systems with other controllers.
Typical Functions:
- High and Low Alarm Contacts for Industrial Applications
- Load Control Including High Power Applications (pumps and large motors)
- Temperature Controlled Settings for Battery Fans or Cooling Vents
- Generator Start Functions
- Auxiliary AC Backup Charge Control
Data Control Input Options:
- Connected to a TriStar Controller: Battery voltage, charge/load current, battery temperature, TriStar heatsink temperature, PWM duty cycle, PV/load voltage, and all TriStar alarms or faults.
- Used in Systems with Other Controllers: Battery voltage, Relay Driver temperature, input voltages from other sources.
Key Features and Benefits:
- Cost Effective - The four channels provide up to four high level system control functions at a lower cost compared to other alarm and generator start packages.
- High Reliability - Each channel has complete electronic protections for high reliability.
- Flexibility - The system designer may choose the exact relay needed for each application including a wide range of current ratings and solid state, mechanical or mercury displacement relays.
- Fully Programmable - It is easy to program the Relay Driver with the included PC software via serial RS-232 port connection. Data is stored in non-volatile memory. The Relay Driver is pre-programmed with four commonly used settings.
- Advanced Generator Control - Provides flexible parameters to control one, two or three-wire generator schemes and complete control of preheat, crank, ignition and cool-down.
- Industrial Design - Each relay driver output may be controlled directly by MODBUS commands via the RS-232 for use with PLC’s and other industrial hardware. Mounts to a DIN rail or a flat surface.
- LED Indicators - Displays power and status of each channel as well as faults and data sampling intervals.
System Voltage: |
12 to 48 Volts* |
Max. Channel Current: |
750 mA |
Voltage Accuracy: Temperature Accuracy: |
2% ± 50 mV ± 2 ?C |
Min. Operating Voltage: |
8 Volts |
Max. Operating Voltage: |
68 Volts |
Self-consumption: |
< 20 mA |
Temperature Sensor Range: |
-40°c to +85°c |
Transient Surge Protection: |
1500 W / channel |
Comm. Ports (opto-isolated): |
(2) RJ-11 meter bus connections (1) 9-pin serial RS-232 |
Electronic Protections: |
Reverse Polarity Protection, Short-Circuit Protection, Overcurrent Protection, Lightning and Transient Surge Protection |
Dimensions: |
Length: 16.3 cm / 6.4 inch Width: 8.1 cm / 3.2 inch Depth: 3.3 cm / 1.3 inch |
Weight: |
0.2 kg / 0.4 lb |
Largest Wire: |
1.0 to 0.25 mm2 16 to 24 AWG |
Torque Terminals: |
0.4 Nm / 3.5 in-lb |
Enclosure: |
Type 1, indoor rated |
DIN Rail Attachment: |
35 mm standard |
Operating Temperature: |
|
Storage Temperature: |
–55°c to +85°c |
Humidity: |
100% non-condensing |
Tropicalization: |
Conformal coating on both sides of printed circuit board |
| Compatible With: | TriStar MPPT 600V Controller, TriStar MPPT Controller, ProStar MPPT Controller, SunSaver MPPT Controller, TriStar Controller, SunSaver Duo Controller, SureSine Inverter, MeterHub |
| Certifications: | CE Compliant, RoHS Compliant, Manufactured in a certified ISO 9001 facility |
*Voltage of user selected relays must be same as battery voltage
Morningstar Meter Hub (HUB-1)
Morningstar’s MeterHub (HUB-1) allows multiple Morningstar products to communicate over a Meterbus network to provide improved data monitoring, additional capabilities and lower system cost.
The MeterHub allows up to 15 Morningstar products on a single MeterBus network. The product electrically isolates devices that supply power to the network, preventing damage to the network in the event of grounding problems. Five status LED’s indicate the proper network connection to each port. The MeterHub is suitable for either wall or DIN rail mounting.
Typical Functions:
- Enables multiple controllers to share a single TriStar meter and display both single controller data (TriStar #1, TriStar #2…) as well as aggregated data for the entire system.
- Enables multiple controllers to share a single Relay Driver and fully utilize all 4 channels of the Relay Driver for different functions (alarms, load disconnects, generator starts) from multiple products
Included in the Box:
- MeterHub Typical Network Configuration
- Operator’s Manual
- Five Meterbus RJ-11 cables – each 1 meter in length
- Four mounting screws
Minimum Isolation (Ports 1-4): |
500 Volts |
Self-consumption (per port): |
8 mA |
Compatible DIN rail : |
35 mm standard |
Enclosure: |
Type 1 (indoor and vented) |
Port Connections: |
RJ-11, gold plated |
Dimensions: |
13.5 x 10.8 x 3.7 cm (5.3 x 4.3 x 1.5 inch) |
Weight: |
0.2 kg / 0.4 lb |
Operating Temperature: |
|
Storage Temperature: |
–55°c to +85°c |
Humidity: |
100% non-condensing |
Tropicalization: |
Conformal coating-printed circuit board |
| Compatible With: | SunSaver-MPPT, TriStar, TriStar-MPPT, TriStar Meter-2, TriStar Remote Meter-2, Relay Driver |
| Certifications: | CE Compliant, ETL Recognized (UL1741), RoHS Compliant, Manufactured in a certified ISO 9001 facility |
Morningstar Remote Temperature Sensor (RTS)
Morningstar’s Remote Temperature Sensor (RTS) provides improved battery charging in solar systems that experience temperature variations during the year.
The RTS measures temperature at the battery and the controller uses this data for very accurate temperature compensation.
Use of the RTS is recommended whenever the temperature at the battery will be more than 5°C (9°F) different than the temperature at the controller.
The TriStar has no on-board temperature compensation; therefore the use of the RTS is required for temperature compensated charging.
Other Morningstar controllers will default to an on-board temperature sensor if a RTS is not connected.
The RTS is compatible with the following Morningstar controllers:
- ProStar (soldering required) - whenever the temperature at the battery will be more than 5°C (9°F) different than the temperature at the controller.
- TriStar - for battery charging or diversion control modes (not for load control mode).
- SunKeeper
- SunSaver Duo
- SunSaver MPPT
- TriStar MPPT
For maximum protection from harsh environments, the sensor is encapsulated in epoxy inside a power lug housing. The RTS is also protected from lightning surges and short circuits.
Standard Features:
- Highly accurate: +/- 1.5°C (2.7°F)
- Cable length: 10 meters (33 feet)
- User may easily extend cable length up to 30 meters (100 feet) using standard cable
- Corrects for temperatures from -30°C (-22°F) to +80°C (+176°F)
- Wires are non-polarized
Specifications:
- Power lug housing: 9.5 mm (3/8”) screw hole
- 2-conductor copper cable with PVC jacket, 0.34mm2 (#22 AWG)
- Cable rated UL CMR
- UL recognized component when used with TriStar
- CE certified for use with all compatible Morningstar controllers
- Sensor noise is filtered
Morningstar PC MeterBus Adapter (MSC)
Morningstar’s PC Meterbus Adapter (MSC) converts a controller’s meter port (RJ-11 phone type connector) to a standard RS-232 serial connector for connection to a PC or other equipment.
The MSC may be used with any Morningstar controller or inverter equipped with a meter connection that does not also already have a RS-232 port.
By converting to RS-232, the MSC allows Morningstar’s controllers and inverters to communicate with a variety of third party serial enabled devices such as:
- A PC running Morningstar’s MS View software or any other compatible software.
- A serial enabled device such as an internet gateway.
- Another MODBUS enabled hardware device at the site that needs to access solar system information.
Establishing a communications link enables the monitoring or logging of data from the controller or inverter as well as the customizing of any user-adjustable settings. The MSC makes available a wide variety of data stored in Morningstar’s products such as (varies by product):
- Battery Voltage (including minimum and maximum)
- Solar charge current to the battery
- Load current from the battery
- Accumulated solar and load amp hours
- Charge Stage Errors and alarms
- Local and battery temperature
- Data logging files
All data is transmitted in the form of MODBUS protocol. This industry standard was chosen for a high level of compatibility with a variety of equipment. Each Morningstar product has its own data specification (see their website for full details). The MSC is sold as a kit that includes the following:
- PC Meterbus Adapter
- RS-232 cable with connectors: 1.8 meters (5.9 feet)
- RJ-11 cable with connectors: 1 meter (3.3 feet)
Other Technical Specifications:
- Operating Temperature -40C to +60C
- Storage Temperature -55C to +80C
- Humidity 100% N.C.
- Enclosure IP20
- Dimensions 72 x 35 x 22mm 2.83 x 1.37 x 0.87 inches
- Weight 35 g (1.23 oz)
Morningstar EIA-485 / RS-232 Adapter (RSC-1)
Morningstar’s EIA-485 / RS-232 Communications Adapter (RSC-1) enables networking capability by converting a controller or inverter’s RS-232 port to a standard EIA-485 serial connector.
The RSC-1 may be used with any Morningstar controller or inverter equipped with a RS-232 port.
By converting to EIA-485, the RSC-1 allows up to 128 Morningstar products to communicate on the same communication bus and over much greater distances.
Typical configurations include:
- Networking several TriStar and/or TriStar-MPPT controllers
- Adding Morningstar’s PC Meterbus Adapters (MSC) for use with an RJ-11 port in multi-device networks.
- Adding Morningstar’s Relay Driver to a network
- Integrating any compatible Morningstar product into an existing EIA-485 network, such as those used by industrial control or SCADA systems.
All data is transmitted in the form of MODBUS protocol. This industry standard was chosen for its robust design and high level of compatibility with a variety of equipment. Each Morningstar product has its own MODBUS specification (see our website for full details) that covers the data available from each products specific functions.
Key Features:
- Removable four (4) position EIA-485 terminal
- 9-pin RS-232 connector (male)
- Status LED for monitoring and diagnostics
- Molded tabs for attachment to 35mm standard DIN rail
- RS-232 ribbon cable (not shown) with low-profile connectors
Power Input Voltage: |
8V – 16V |
Self Consumption: |
8-16mA |
Baud Rate |
9600 baud |
EIA-485 Network Unit Load: |
1⁄4 |
Dimensions: |
72 x 35 x 23mm (2.83 x 1.37 x 0.90 inches) |
Weight: |
37 g (1.3 oz) |
Enclosure: |
IP20 |
DIN Rail Attachment: |
35 mm standard |
Operating Temperature: |
|
Storage Temperature: |
–55°c to +80°c |
Humidity: |
100% (NC) |
| Compatible With: | TriStar MPPT 600V Controller, TriStar MPPT Controller, ProStar MPPT Controller, SunSaver MPPT Controller, TriStar Controller, SunSaver Duo Controller, SureSine Inverter, MeterHub |
| Certifications: | CE Compliant, RoHS Compliant, Manufactured in a certified ISO 9001 facility |
Morningstar USB MeterBus Adapter (UMC-1)
The USB MeterBus Adapter (model: UMC-1) converts the Morningstar MeterBus RJ-11 electrical interface to a standard USB 2.0 interface.
This allows communication between a PC and Morningstar charge controllers or inverters that have a MeterBus connection, but no serial or other communications port.
This includes the Sunsaver MPPT, SunSaver DUO, and SureSine products.
The UMC-1 is required for:
- Programming custom charging set-points
- Logging data using Morningstar’s MSView PC software
- Communication with any 3rd party hardware that supports MODBUS communication.
Morningstar DIN Rail Clips (DIN-1)
These rugged plastic clips have been custom made to match the mounting holes on the SunSaver controllers and to either snap on to the middle of the rail or to slide on from the end of the rail.
The clips also provide a mechanism to allow easy removal of the controller from the DIN rail without removing the clips.
The DIN Rail Clips are compatible with the following Morningstar solar controllers:
- SunSaver
- SunLight
- SunSaver Duo
- SunSaver MPPT
Key Features and Benefits
- Polypropylene clips
- Fits all 35 mm standard DIN rails
- Mounting screws: M3 x 5mm, black stainless steel