Morningstar Solar Controller and Inverter Overview

1. Morningstar Solar Controller and Inverter Overview

2. 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.

3. 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.

4. 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.

5. 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.

6. 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.

8. ProStar Rating: 15A or 30A at 12/24V or 15A at 48V Negative or Positive Ground Applications: Mid-Range professional or consumer systems. 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. Major Benefits

9. ProStar Rating: 15A or 30A at 12/24V or 15A at 48V 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.

10. SunSaver Rating: 6.5A,10A or 20A at 12V or 24V Applications: Small professional or consumer systems. Oil/Gas projects located in hazardous locations. 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 Major Benefits

11. SunSaver Rating: 6.5A,10A or 20A at 12V or 24V 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.

12. SunGuard Rating: 4.5A at 12V Applications: single module professional or consumer systems. Major Benefits Charging: Circuitry is the same as SunSaver (series PWM). Tropicalization: Epoxy encapsulation, ABS plastic case and outdoor rated wires. Economics: Low cost controller. Power Usage: Minimal self-consumption (6 mA).

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

14. SunLight Rating: 10A or 20A at 12V or 24V 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.

15. TriStar Solar Charge Controller

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

17. 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 4500W 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

18. Morningstar SunKeeper • 12V Controller available in 6A and 12A 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

19. Morningstar SunKeeper • Bi-Color LED confirms proper installation and shows the charging state as well as any fault info or evidence of damage. • The SunKeeper 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 allow for extremely high temp operation to 70C.

20. SunSaver / SunKeeper 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 C22.2 NO 213-M1987 - Non-Incendive Electrical Equipment for Use in Class I, Division 2 Hazardous Locations

21. Morningstar SunKeeper Fits PG 13.5, M20, ½ Inch conduit knockout

22. SureSine Inverter Rating: 300W Continuous, 600W Surge 12VDC Input 115V/220V 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 600W output for up to 15 minutes. Rugged Chassis Design: Cast aluminum heat sink, epoxy encapsulated transformer, fanless convection cooling.

23. SureSine Inverter Rating: 300W Continuous, 600W Surge 12VDC Input 115V/220V 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.

24. Popular Uses for the SureSine 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 SunLight to provide automatic control) • Adds sine wave capability to a larger wattage modified square-wave system.

25. SunSaver Duo Rating: 25A total charging current 12VDC 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 30ft. away. Robust Design - Builds on the proven design of the SunSaver. Cast aluminum case, heat sink and epoxy encapsulation provide efficient and cool operation. Dual Battery Charging - splits solar current between house and cabin batteries.

26. SunSaver 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

27. SunSaver MPPT System Voltage: 12/24V Max. Battery Current: 15A Max. Voc: 75V Max. PV Input: 200Wp (12V Battery) 400Wp (24V 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 12V or 24V battery charging. •Provides a means to use a 12-36V nominal PV array to charge a 12V battery, reducing power losses in systems with a long wire run between the PV array and the battery.

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

29. MSC MeterBus Adapter (New) • Allows any meter port enabled Morningstar product to be given RS-232 serial port data communications. • Includes DB-9 Serial cable and RJ11 cable. • List price of $39

30. TriStar 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.

31. Morningstar TriStar MPPT

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

33. TriStar MPPT Mechanicals • Extruded aluminum heatsink for efficient cooling • Tri-Phase DC-DC design. 3 x 20A 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 (M20) for Europe • All circuit boards are conformally coated to prevent corrosion. • All inductors are potted for cool operation and environmental protection.

34. TriStar 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

35. TriStar MPPT Certifications • UL 1741 - Pending • cUL (CSA-C22.2 No. 107.1-95) – Pending • FCC Class B Part 15 Compliant • CE Compliant • RoHS Compliant • ISO 9001 Certified production

36. TriStar MPPT Setup • Same established simple and quick setup as the original TriStar • 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

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

38. TriStar 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.

39. 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.

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

41. 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.

42. MPPT Economics

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

44. Maximum Power Point Tracking Morningstar TrakStarTechnology – - Full array sweeps from 0-150V 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

45. 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)

46. TriStar MPPT Communications

47. TriStar MPPT Communications Meterbus– RJ11 connection - Connection of local or remote TriStar Meter-2 - Allows combining of TriStars 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

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

49. TriStar 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 TriStars with RSC adapter - optically isolated for safe power system grounding

50. TriStar 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 60A TS-MPPT only.