Morningstar Solar Controller and Inverter Overview Morningstar s

Morningstar Solar Controller and Inverter Overview

Morningstar’s Mission Morningstar is the world’s leading supplier of Solar Controllers. In 2010 we sold over 250, 000 controllers through 164 distributors in 73 countries throughout the world. Our goal is to continue to lead the controller market in terms of quality, reliability and customer service as well as expand our products in the PV inverter market.

Morningstar’s Company Advantages • Reliability - our failure rates are less then 2 units per 1000 sold. • 100% in-house design – we only put our name on a product that we’ve built from scratch, one resistor at a time. • Morningstar sells only through the world’s PV distribution channels. • Supporting our distribution network is our #1 priority. We send sales leads directly through our distribution network and do not sell directly to OEM’s, dealers or end-users.

Morningstar Product Advantages Highest Quality – Manufactured in a fully automated ISO 9001 factory. Quality control using the latest computerized test equipment. Every unit is digitally calibrated, tested and logged. Superior Lightning Protection – Use of large transient voltage suppressors provide faster response to transients and do not degrade over time. No need to De-rate – Designed with a 25% safety margin, controllers may be used up to their full “nameplate” ratings. Expected 15 Year Life – Controllers carry a full 5 -year warranty, with an expected operating life of 15 years or more. Easy to Use – Detailed manuals, technical support by phone or internet, large clearly-marked wire terminals, electronic protections and good front panel indicators. Controllers are easily utilized at multiple experience levels.

Morningstar Product Advantages Tropicalization is the process by which we condition our hardware for use in extreme environmental conditions. Conformal Coating – Dupont Humiseal – a UL listed protective spray that will seal out moisture and prevent corrosion from the effects of salt air and high humidity. Epoxy Encapsulation – a 2 -part epoxy resin that protects the board as well as acts to conduct heat away from the power carrying components on the circuit board. It acts like a liquid heat sink. Terminal plating - to resist corrosion.

Technical Support Fast Response – Same day response on emails. Live people answering the phone. Fast tracking to our engineering office for high level assistance. Searchable tech support library. Applications Knowledge – We can interpret specifications, certifications, sizing and other requirements for your projects to give you a quick review of the controller options that are right for you. Industry Leading Warranty Support – We work to provide quick warranty replacement. Morningstar doesn’t require complicated approvals, so we are able to provide warranty service easily through our distribution network, or directly if necessary.

Pro. Star Rating: 15 A or 30 A at 12/24 V or 15 A at 48 V Negative or Positive Ground Applications: Mid-Range professional or consumer systems. Major Benefits Extensive Protections: Electronic short-circuit, overload and reverse polarity protected with automatic recovery. More Information: LED’s indicate various battery and system status while digital meter (optional) displays 9 different controller status parameters.

Pro. Star Rating: 15 A or 30 A at 12/24 V or 15 A at 48 V Negative or Positive Ground Self-Test: Digital meter displays any detected faults, making it very easy to troubleshoot the PV system. Tropicalization: For protection against corrosion and nesting insects. Includes conformal coating on circuit boards, stainless-steel screws and anodized aluminum heat sink. Low Telecom Noise: PWM has been modified to reduce interference and any noise may be easily eliminated in the field.

Sun. Saver Rating: 6. 5 A, 10 A or 20 A at 12 V or 24 V Applications: Small professional or consumer systems. Oil/Gas projects located in hazardous locations. Major Benefits Tropicalization: Epoxy encapsulation, marine rated terminal block and Anodized aluminum enclosure. Hazardous Locations: Approved for use in Class 1, Division 2 Groups A, B, C, D

Sun. Saver Rating: 6. 5 A, 10 A or 20 A at 12 V or 24 V Temperature Extremes: Rated for operating temperatures of -40°C to +60 °C up to full “nameplate” current ratings. Series PWM Design: Less heating and longer life compared to shunt controllers.

Sun. Guard Rating: 4. 5 A at 12 V Applications: single module professional or consumer systems. Major Benefits Charging: Circuitry is the same as Sun. Saver (series PWM). Tropicalization: Epoxy encapsulation, ABS plastic case and outdoor rated wires. Economics: Low cost controller. Power Usage: Minimal self-consumption (6 m. A).

Sun. Light Rating: 10 A or 20 A at 12 V 10 A at 24 V Applications: Solar lighting controller used for street lighting, bus stations, telephone booths, billboards, signs and parking lots. Major Benefits Combines the Sun. Saver charging circuit and case with a micro controller for automatic lighting control functions.

Sun. Light Rating: 10 A or 20 A at 12 V or 24 V Functionality: Choice of 10 different lighting control options including ON-OFF-ON options. Test button to check light during installation and confirm correct lighting option selection.

Tri. Star Solar Charge Controller

Tri. Star – Solar Charge Controller • 3 Operating modes – Solar charging, load control or diversion control for wind/hydro • 45 A or 60 A versions, both with automatic detection of 12/24/48 V system modes • Optional front panel and remote meters display system information • Conduit ready enclosure designed for installation onto a Power Panel

Main Features • • • Optional remote sensor provides temperature compensation Battery sense connection for accurate voltage readings Self test algorithm runs continuously to locate faults All electronic protections • • Reverse polarity and short circuit on all connections All faults have auto reset Lightning surge protection with 4500 W TVS’s PWM current limiting for high temp and over current states Reliability by Design • • 100% solid state power electronics All functions microprocessor controlled with non-volatile Flash-RAM Conformally coated circuit board Robust Heatsink

Morningstar Sun. Keeper • 12 V Controller available in 6 A and 12 A versions. • Conduit gasket connection mounts directly to the PV module junction box to form a weather-proof seal • Bulk, PWM absorption and float stages • Full electronic protections from wiring errors

Morningstar Sun. Keeper • Bi-Color LED confirms proper installation and shows the charging state as well as any fault info or evidence of damage. • The Sun. Keeper has the ability to restart from zero voltage to recover the system in the case of a fully depleted battery. • Epoxy potting and very low resistance power MOSFET's for extremely high temp operation to 70 C. allow

Sun. Saver / Sun. Keeper Hazardous Location Rating • UL 1604 - UL Standard for Safety Electrical Equipment for Use in Class I and II, Division 2, and Class III Hazardous (Classified) Locations • CSA C 22. 2 NO 213 -M 1987 - Non-Incendive Electrical Equipment for Use in Class I, Division 2 Hazardous Locations

Morningstar Sun. Keeper Fits PG 13. 5, M 20, ½ Inch conduit knockout

Sure. Sine Inverter Rating: 300 W Continuous, 600 W Surge 12 VDC Input 115 V/220 V versions available Listed to UL 458 Applications: Rural electrification, telecom, mobile/marine markets. Extensive Protections: Electronic short-circuit, overload and reverse polarity protection. High Power Surge: 200% surge allows a 600 W output for up to 15 minutes. Rugged Chassis Design: Cast aluminum heat sink, epoxy encapsulated transformer, fanless convection cooling.

Sure. Sine Inverter Rating: 300 W Continuous, 600 W Surge 12 VDC Input 115 V/220 V versions available Listed to UL 458 Low Power Consumption: Peak efficiency of 91. 5% makes more solar energy available for the loads. Search mode turns the inverter off when no AC load is present to further reduce power draw. More Information: LED’s indicate various battery, system and AC output status. Interpretation is easy. Green LED’s show operational status while Red LED’s indicate a fault. Remote Power Switch: Remote power terminal allows an external switch or another device (like a solar controller) to turn on the inverter.

Popular Uses for the Sure. Sine 300 • Sine wave power for AV equipment (mobile market) • Rural electrification and remote cabins • Networking and Security equipment • AC lighting systems (the remote on/off terminal may be used with the Sun. Light to provide automatic control) • Adds sine wave capability to a larger wattage modified square -wave system.

Sun. Saver Duo Rating: 25 A total charging current 12 VDC System Voltage Isolated Charging for 2 Batteries Combination Product - charge controller and remote meter package. Designed For Easy Installation - Controller mounts near battery. Meter display mounts up to 30 ft. away. Robust Design - Builds on the proven design of the Sun. Saver. Cast aluminum case, heat sink and epoxy encapsulation provide efficient and cool operation. Dual Battery Charging - splits solar current between house and cabin batteries.

Sun. Saver Duo Meter Display • Meter mounts on surface with included frame or can be inset into the vehicle wall • Voltage and Current information shown separately for each battery without the need for external shunts • Min/Max voltage • Instantaneous Amps from solar and each battery’s Ah shown separately • Room temperature and battery temperature display • Automatic backlight settings

Sun. Saver MPPT System Voltage: 12/24 V Max. Battery Current: 15 A Max. Voc: 75 V Max. PV Input: 200 Wp (12 V Battery) 400 Wp (24 V Battery) • Provides an estimated 5 -25% boost of amps from the PV array into the battery. Actual boost depends on PV cell temperature and battery state-of-charge. • Enables the use of high voltage PV modules (designed for on-grid applications) for off-grid 12 V or 24 V battery charging. • Provides a means to use a 12 -36 V nominal PV array to charge a 12 V battery, reducing power losses in systems with a long wire run between the PV array and the battery.

RM-1 Remote Meter (New) Compatible with: Sun. Saver MPPT Sure. Sine Sun. Saver Duo -Array Voltage/Vmp -Temperature -Solar Charge Amps -Faults and Alarms -Load Amps -Displays daily logging information on supported -Battery Voltage with Max/Min products. -Solar/Load Ah accumulation

MSC Meter. Bus Adapter (New) • Allows any meter port enabled Morningstar product to be given RS-232 serial port data communications. • Includes DB-9 Serial cable and RJ 11 cable. • List price of $39

Tri. Star Firmware Upgrade (coming soon) • Firmware update to support Hub functions on previously produced TS units. • To enable 30 day data logging feature on TS-M.

Morningstar Tri. Star MPPT

Tri. Star MPPT Ratings • Two Models • 45 A Battery Charge Current. • 60 A Battery Charge Current. • 8 -68 V battery range (12/24/48 V or Auto) • Rated -40 to +45 C at 100% continuous power. • 150 V maximum open circuit PV voltage. • Peak efficiency of 99% • Options: • Tri. Star Meter 2 (TS-M-2) • Tri. Star Remote Meter 2 (TS-RM-2) • Relay Driver (RD-1) • Meter Hub (HUB-1) • Remote Temp Sense (RTS)

Tri. Star MPPT Mechanicals • Extruded aluminum heatsink for efficient cooling • Tri-Phase DC-DC design. 3 x 20 A MPPT • Fanless– uses less power, more reliable and runs without drawing in dust and dirt. • Solid state controls – no relays • Enclosure allows the use of - 4 standard 1” or 1. 25” conduit knockouts - 8 metric knockouts (M 20) for Europe • All circuit boards are conformally coated to prevent corrosion. • All inductors are potted for cool operation and environmental protection.

Tri. Star MPPT Protections • Electronic Protections • PV Short circuit protection (solid state) • Automatic current limiting to max rating • High temperature protection • Lightning protection (fast acting Transient Voltage Suppressors) • High Voltage PV Voc Backoff

Tri. Star MPPT Certifications • UL 1741 - Pending • c. UL (CSA-C 22. 2 No. 107. 1 -95) – Pending • FCC Class B Part 15 Compliant • CE Compliant • Ro. HS Compliant • ISO 9001 Certified production

Tri. Star MPPT Setup • Same established simple and quick setup as the original Tri. Star • DIP switch configuration gives you 7 preset battery profiles • One DIP preset is reserved for complete customization using MS View. • Controller automatically determines • System Voltage • Array configuration • Sense Voltage presence • RTS presence

Tri. Star MPPT Setup Common battery profiles are available as presets. Values are for all charging values, float/absorption times and equalization schedule.

Tri. Star MPPT Sizing With the MPPT controller, you can size in pure watts since the controller provides the maximum current available from the system. 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

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 charging 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.

Maximum Power Point Tracking The Technology behind maximum energy harvest. IV Curve Power Graph

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. Shading and cloud irradiance effects – Cloud edge effect can cause the module to exceed it’s 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.

MPPT Economics MSRP TS-60 PWM + RTS TS MPPT-60 + RTS Incremental cost of MPPT PV Module Cost/Wp Boost Needed to cover MPPT cost (Wp) Boost Needed to cover MPPT cost (%): 500 Wp PV array 1 k. Wp PV array 1. 5 k. Wp PV array $258 $669 $411 $4 103 Watts 21% 10% 7%

Maximum Power Point Tracking MPPT Tracking Algorithms on the market: Full Sweep - scans entire PV array from 0 -150 V. 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.

Maximum Power Point Tracking Morningstar Trak. Star Technology – - Full array sweeps from 0 -150 V in ¼ second! Others can take up to 30 seconds during which much has happened. - The TS-MPPT offers full sweep and dynamic adjustments continuously. - Dual chipset provides specialized control -DSP – high speed MPPT, charge control and data logging -Main Processor – Ethernet and serial communications

TS MPPT Data Logging Up to 6 months of internal data logging of key daily values. Max Battery Voltage Min Battery Voltage Max Array Voltage Amp Hours Watt Hours Faults Alarms Daily Absorption Stage Time (mins) Daily Equalization Stage Time (mins) Daily Float Stage Time (mins)

Tri. Star MPPT Communications

Tri. Star MPPT Communications Meterbus – RJ 11 connection - Connection of local or remote Tri. Star Meter-2 - Allows combining of Tri. Stars into network with HUB-1 - Sum all controller data for system level information Total Charge Amps into the battery Total Load Amps drawn out of the battery Net gain/loss of amps from/to the battery

Tri. Star MPPT Communications RS-232 – for a single connection between a PC or other device and the Tri. Star MPPT. Allows for data logging, program changes and firmware upgrades. - easiest way to connect to the Tri. Star for PC data - included on all Tri. Star versions - uses standard MODBUS protocol - optically isolated for safe power system grounding

Tri. Star MPPT Communications RS-485 – for networked (multi-unit) connections between a PC or other devices and many Morningstar products. Allows for data logging and program changes. - for larger or industrial PV systems with many devices - uses MODBUS protocol - supports long distances - can be used on original Tri. Stars with RSC adapter - optically isolated for safe power system grounding

Tri. Star MPPT Communications Ethernet* – for TCP/IP connection for internet applications. IP makes it compatible with wireless protocols, cellular systems and existing networking equipment. Allows for the use of: - web page view directly from the TS MPPT - email and text message notifications and alarms - remote connection anywhere on the internet (MODBUS IP) - SNMP functions for networking service providers - integration with third party software developers writing in HTML, XML and Java. *Ethernet available on 60 A TS-MPPT only.

Tri. Star MPPT Communications Tri. Star MPPT Live view allows the direct webpage viewing of solar and charge data from the controller itself. Compatible with any Java enabled web browser (Mac, PC or Smartphone).

MPPT Economics MSRP TS-60 PWM + RTS TS MPPT-60 + RTS Incremental cost of MPPT PV Module Cost/Wp Boost Needed to cover MPPT cost (Wp) Boost Needed to cover MPPT cost (%): 500 Wp PV array 1 k. Wp PV array 1. 5 k. Wp PV array $258 $669 $411 $4 103 Watts 21% 10% 7%

Tri. Star MPPT Industry Leading Efficiency 1012 V Controller Self Consumption in Watts 8 48 V 6 24 V 4 2 OB 0 XW Tri. Star 24 V 48 V 12 V

MPPT Controller Price Comparison M Star Outback TS MPPT FM-60 Xantrex % XW % Tri. Star MPPT-45 531 699 -24% 685 -22% Tri. Star MPPT-60 669 699 -4% 685 -2% Tri. Star MPPT-45 with RTS 531 731 -27% 685 -22% Tri. Star MPPT-60 with RTS 669 731 -8% 685 -2% Tri. Star MPPT-45 with meter 635 699 -9% 685 -7% Tri. Star MPPT-60 with meter 773 699 11% 685 13% 685 -7% 13% Tri. Star MPPT-45 with RTS and meter Tri. Star MPPT-60 with RTS and meter 635 773 731 -13% 6% Note: You can view TS MPPT-60 from a web browser and oftentimes will not need a meter

Tri. Star MPPT Summary The Tri. Star MPPT brings many advantages: - Superior MPPT Tracking technology - Highest efficiency with the lowest power loss during operation - Lower cost with 45 A version and choice of meter option. - Powerful communications with open protocols, including Ethernet. - Easy setup for a quick installation (sometimes no setup at all) - Backed by Morningstar’s controller expertise and 5 year warranty - Delivers technology and simplicity for residential use, built to survive the remote and industrial market’s harshest environments.

TS HUB (Sept 2009) • Allows TS Meter to show summed data including: • Net System Data • Individual Controller Data • Supports up to 15 Devices TS, TS-MPPT, RD-1, TS-M • Provides complete isolation from ground. (will work with both Positive and Negative Ground systems. )

Morningstar String Calculator -Allows for quick and simple array string configurations to be displayed for any Morningstar charge controller. -Works with a variety of common industry PV modules or allows you to input your own specifications. -Accounts for ambient temperatures at the site and compensates for expected battery voltages in the system. -Prevents maximum current and Voc figures from exceeding the controller rating at any time during the year.

Morningstar String Calculator

Sun. Lights used in a rural streetlight installation in Indonesia.

SHS’s used in a rural installation in Ecuador.

Dual Tri. Star system used in mountaintop repeater in Norway.

Norway in Summer Norway in Winter

Application Photos

Application Photos

Application Photos

Application Photos

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