Maximum Power Point Tracking (MPPT)
Classic MPPT Charge Controller
The MidNite Classic charge controller maximizes the flexibility and features available in a charge controller. At this time, the Classic the only MPPT charge controller that offers arc fault detection. This will soon be required by the NEC. These charge controllers also include ground fault protection so that a separate GFP breaker assembly is not necessary and leaves those breaker spaces free for other uses. Three models accommodate solar arrays with up to 150, 200, or 250 VDC of operating voltage. Open circuit voltage (Voc) is based on operating voltage plus the battery voltage. This is called the HyperVOC zone. They have MPPT modes for solar, wind or hydro with user adjustable power curves, and a learning mode for self optimization. No hub is required for stacking Classics to act as one large controller. They have two auxiliary outputs, a dry contact relay and a 12V output. Each unit includes snap-on covers and hole plugs for sealing openings in dusty or salt-air environments, but about 20% reduction in output will result when used in sealed mode. The Classic has built-in Ethernet, USB and RS-232 ports for two-way communications. An internal IP address allows the Classic to be a mini web server when hooked up to broadband. It has 32 MB of memory for data storage. A wizard driven setup covers battery bank size, string voltage, wind turbine selection, power and wire loss chart, PV breaker sizing and more. Firmware is user upgradable by downloading files. Works with the MidNite Clipper for wind and hydro applications to protect turbine and Classic from excessive voltage. The MidNite clipper will load the turbine based on one of five parameters: 1-max current; 2-max voltage; 3-max RPM’s; 4-max wind speed; 5-as commanded by the Classic. In addition the Clipper can be programmed to automatically shut the turbine down during high wind conditions and will float the batteries when they are fully charged. Floating the batteries results in much reduced turbine speed. ETL listed and made in the U.S. 5-year warranty.
T100 and T80 PV MPPT Battery Charge Management Systems
The T80 Charge Controllers integrate maximum power point tracking, battery charge management, state-of-charge information and communications into a single device. The T80 can deliver 80 amps continuous output to 12-, 24-, 36 or 48-volt battery systems from PV arrays with open circuit voltage up to 140 VDC (150 volts absolute maximum voltage). The new T80HV allows you to wire modules in series up to 200 Voc max/160 volts nominal.
The T80 and T80HV produce full-rated power without de-rating up to 45 degrees C/113 degrees F ambient temperature. Above that, the output current is reduced gradually to protect the life of the T80, and then automatically ramped up as the temperature decreases. High efficiency power circuits and robust thermal design minimize heat generation. The internal temperature-controlled variable speed fan runs just fast enough to maintain optimum reliability. UL Listed. Dimensions are 15.2″ x 8.5″ x 4.4″ and weight is 22 lbs.
Both controllers include a built-in energy monitor using TriMetric technology from Bogart Engineering. The monitor tracks energy production and consumption to calculate the energy remaining in the battery. State of charge (SOC) is displayed in percent of capacity, amp-hours, watt-hours, and bar-graph format. They store 90 days of energy-harvest history and feature a slot for add-in cards providing system performance, data communication, and firmware updates.
Controllers do not include shunts. Order a 500A/50mV shunt if your system doesn’t have one. Both the T80 and T80HV support flooded lead acid (FLA), GEL and absorbed glass mat (AGM) batteries. Two independently programmable SPST relays can be used to control external devices based on battery voltage, charge or discharge current or battery state of charge. Contact rating is ½ amp at up to 50 VDC.
XW-MPPT60-150 Charge Controller
The XW-MPPT60-150 can be used with PV arrays with voltages ranging from battery voltage to 150 VDC and can support an output of up to 60 amps into the battery for battery voltages of 12 to 60 VDC. The PV open circuit voltage must not exceed 150 VDC.
Maximum power point tracking (MPPT) allows the charge controller to deliver to the batteries the maximum energy available from the PV array. The MPPT algorithm continuously adjusts the operating points in an attempt to find the maximum power point of the array. The algorithm can then determine if it is harvesting more or less power than the previous operating points.
The charge controller has a configurable auxiliary output (producing 5 to 13 volts at 200 mA) to drive a relay for load control or to turn on devices such as vent fans or indicator alarms. The auxiliary output can be configured to perform only one function at a time.
Its large aluminum heat sink allows it to operate at full power with only convection cooling, without the need for a fan. Built-in PV ground fault protection allows code-compliant installation without the need for additional ground fault protection. The XW-MPPT60-150 can be mounted on the side or top of the XW power distribution panel, or used by itself in other PV systems. The front panel features a 2-line 16-character display and four buttons for configuration and system monitoring. A battery temperature sensor is included with the controller.
The XW-MPPT60-150 is able to communicate its settings and activity to other Xanbus-enabled devices, such as the XW Series inverter/charger, the System Control Panel II (SCP), XW Automatic Generator Start (XW-AGS), and other Xantrex XW-MPPT-60-150 solar charge controllers through the Xanbus network.
Array size can be up to 750 watts when charging a 12-volt battery, 1,500 watts when charging at 24 volts and 3,000 watts when charging at 48 volts. See the Xantrex array sizing tool at www.xantrex.com/support. Dimensions are 14 ½”H x 5 ¾”W x 5 ½”D and weight is 12 lbs.
5-year warranty. 10-year warranty optional.
CSA Listed to UL 1741 for the U.S. and Canada
MX60 and FLEXmax80 MPPT Charge Controller
The FLEXmax family of charge controllers is the latest maximum power point tracking (MPPT) charge controllers from OutBack Power Systems. The innovative FLEXmax MPPT software algorithm is both continuous and active, increasing your photovoltaic array power yield up to 30% compared to non-MPPT controllers.
With active cooling and intelligent thermal management, both FLEXmax charge controllers can operate at their full maximum current rating, 60 amps or 80 amps respectively, in ambient temperatures as high as 104°F (40°C). Both controllers can be used with battery systems from 12 to 60 VDC with PV open-circuit voltage as high as 150 VDC. The controller’s set points are fully adjustable to allow use with virtually any battery type, chemistry and charging profile. The OutBack FLEXmax controllers allow you to use a higher output voltage PV array with a lower voltage battery – such as charging a 12 or 24VDC battery with a 48VDC PV array. This reduces wire size and power loss from the PV array to the battery/inverter location and can maximize the performance of your PV system.
The FLEXmax 60 can be used with PV arrays up to 750 watts when charging a 12-volt battery, 1,500 watts when charging at 24 volts, and 3,000 watts when charging at 48 volts.
The FLEXmax 80 can be used with PV arrays up to 1,000 watts when charging a 12-volt battery; 2,000 watts when charging at 24 volts; and 4,000 watts when charging at 48 volts.
Both controllers come standard with a display of PV system performance that is easy to use and understand. The 4-line, 80-character backlit LCD display is also used for programming and monitoring the system’s operation. They can be connected to the OutBack MATE series of system controllers and displays to allow monitoring of up to eight controllers from locations up to 300 feet away. The MATE also includes an opto-isolated RS-232 port for connection to a PC for data logging and system monitoring.
FM60 dimensions: 13.5″H x 5.75″W x 4″D. FM80: 16.25″H x 5.75″W x 4″D. Weight: 12 lbs. ETL Listed to UL 1741, and CSA Listed to C22.2 No. 107.1. 5-year standard warranty. 10-year warranty available.
Blue Sky Energy
Solar Boost MPPT Charge Controllers
The Blue Sky Solar Boost features reverse-polarity protection, MPPT, and selectable-charge voltage for flooded and gel lead-acid batteries. An equalize function periodically conditions liquid electrolyte lead-acid batteries. An optional user-friendly digital display is available to monitor PV charge performance. The display shows battery voltage, solar current, charge current and charge mode, either in the controller, as a remote panel installed up to 300 feet away, or both. Optional temperature compensation of charge voltage is also available to further improve charge controller and battery performance. Solar Boost controllers are available with or without digital display and optional remote display. 3-year limited warranty.
Solar Boost 50L
This charge controller can be used on 12- and 24-volt systems. It can also be used to charge a 12-volt battery from a 24-volt array. Maximum open-circuit PV array voltage is 57 VDC.
Solar Boost 3048
SB3048 is designed to charge 24- and 48-volt battery systems from a 48- to 60-volt array (maximum open-circuit voltage is 140). Maximum charge current is 30 amps output at 24 or 48 VDC. ETL/cETL Listed
Solar Boost 2000E
This 25-amp solar charge controller is for 12-volt systems. It mounts in a 5-11/16″ x 3-15/16″ cut-out and is wired from the rear. This controls some very popular in RV installations and an optional box allows surface mounting.
Solar Boost 2512i , 2512iX, and 2524iX
The Solar Boost 2512i provides a fully automatic 3-stage charge controller system. A partial IPN network interface is included to allow use of the IPN-Remote or IPN Pro-Remote displays. Additional features provided in the Solar Boost 2512iX and 2524iX include automatic or manual equalization, battery temperature sensor input, full IPN network compatibility, and an auxiliary output. The user-configurable auxiliary output can serve as either a 25-amp (15/20 in 2524iX) load controller or a 2-amp auxiliary battery charger. The auxiliary battery charge feature is ideal for charging a separate battery such as the engine battery in an RV.
Solar Boost 3024iL
SB3024iL is designed to charge 12- and 24-volt battery systems from a 24-volt array (maximum open circuit voltage is 57). Maximum charge current is 40 amps output at 12 and 30 amps at 24 VDC. The new IPN network interface coordinates multiple controllers and shares temperature sensors and display. ETL/cETL Listed.
TriStar MPPT Charge Controller
Morningstar’s TriStar TS-MPPT-45 and -60-MPPT solar controllers with TrakStar Technology are advanced maximum power point tracking (MPPT) battery chargers for photovoltaic (PV) systems up to 3kW. Both controllers can be used with arrays with a maximum open circuit voltage of 150 VDC and charge batteries between 8 and 72 VDC. A remote temperature sensor is included.
The controller provides the industry’s highest peak efficiency of 99% and significantly less power loss compared to other MPPT controllers. The TriStar MPPT features a smart tracking algorithm that maximizes the energy harvest from the PV by rapidly finding the solar array peak power point with extremely fast sweeping of the entire I-V curve. The TS-MPPT-60 is the first PV controller to include on-board Ethernet for a fully web-enabled interface and includes up to 200 days of data logging. Optional TriStar meter and remote meter provide detailed operating data, alarms and faults and three LED’s display system status. The chassis on the TriStar TS-MPPT controllers is isolated from the power circuits, allowing use in both negative and positive grounded systems.
Extensive Networking and Communications Capabilities enables system monitoring, data logging and adjustability. Both models offer open standard modbus protocol and Morningstar’s MS View software, Meterbus communications between compatible Morningstar products, and allow Serial RS-232 connection to a personal computer. The TS-MPPT-60 has RS-485 communications between multiple devices on a bus and has a fully web-enabled interface to a local network or internet; you can view data from a web browser and send email/text messages. Weight: 9.2 lbs. Dimensions are 11.4 x 5.1 x 5.6 inches. 5-year warranty. ETL Listed to UL 1741.
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. It 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. HUB-1 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. See Relays subsection here for Relay Driver.
The RSC-1 communications adapter enables networking capability by converting a controller or inverter’s RS-232 port to a standard RS-485 serial connector. The RSC-1 may be used with any Morningstar controller or inverter equipped with an RS-232 port.
SunSaver MPPT Charge Controller
The SunSaver MPPT charge controller is designed for 12V and 24V battery charging from PV modules with a maximum open circuit voltage of 75V. Use up to three 36-cell modules in series. It can be used with 200 watts of PV when charging a 12-volt battery and up to 400 watts when charging a 24-volt 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 grid-tie applications) for off-grid 12V or 24V battery charging. Provides a means to use a 24V PV array to charge a 12V battery, reducing power losses in systems with a long cable run between the PV array and the battery. The controller has electronic protection from short circuit, overcurrent, reverse polarity, high temp, high voltage, lightning and transient surges. An adjustable low battery voltage load disconnect protects the battery from over-discharge. LED indicators indicate charging, low battery and faults. Dimensions are 6.6 x 2.75 x 2.2 inches. DIN rail clips on PWM Morningstar SunSaver Duo RV page. Weight is 1.65 lbs. 5-year warranty.
Pulse Width Modulator (PWM)
SunSaver Charge Controllers
The SunSaver is a very reliable charge controller. It uses the same battery charging algorithm as the ProStar and offers many of the advantages of the ProStar for smaller systems, at a reduced cost. Constant voltage pulse width modulation (PWM) charging is a proven advance compared to the common on/off PV regulators. SunSavers are field-selectable for sealed or flooded batteries. A rugged anodized aluminum case and epoxy encapsulated electronics enhance durability and longevity. A temperature compensation sensor in the charge controller varies full charge voltage with temperature. They have LED charging and load control indicators in LVD models. 5-year warranty.
Dimensions: 6″ x 2.2″ x 1.3″.
MET Listed for the U.S. and Canada.
SunSaver Duo RV Charge Controller
The SunSaver Duo 2-battery controller for RVs, caravans, boats and cottages is rated for 25 amps at 12 volts DC. This product will charge two separate and isolated batteries at the same time, such as a house and an engine battery, based on user selectable priorities. The SunSaver Duo employs Morningstar’s SunSaver controller technology, whose long-term track record for high reliability and improved battery charging is well-recognized in the solar industry.
This controller includes a backlit remote meter which may be mounted in or on a wall, and displays alpha-numeric and graphical information about the solar power system status. The SunSaver Duo is epoxy encapsulated for environmental protection, is user adjustable via DIP switch or connection to a personal computer, and has an optional remote temperature sensor. 5-year warranty.
TriStar Charge Controller
The TriStar pulse width modulated (PWM) controller can operate as a solar charge controller, a load controller, or a diversion regulator in 12-, 24- or 48-volt systems. It can operate in only one of these modes at a time, but two or more controllers can be used to provide multiple functions. PWM operation may be changed to on/off operation to prevent telecom noise.
Two models are available with UL current ratings of 45 and 60 amps. A choice of 7 different set points are easily selectable with DIP switches. An RS-232 communications enables PC connection to adjust control set points and data logging. An optional digital display may be mounted on the front of the controller or up to 100 feet away using 4-conductor phone cable with RJ11 jacks.
Battery temperature compensation may be added with the optional temperature sensor. Knock-outs on the bottom of the charge controller match knock-out spacing on MPPT controllers, allowing easy mounting to available power system components.
Dimensions: 10.25″ H x 5″ W x 2.8″ D; weight is 3.5 lbs. 5-year warranty. UL Listed for U.S. and Canada.
ProStar Charge Controllers
This sophisticated line of PV charge controllers incorporates constant voltage PWM to make maximum use of valuable PV power. They have automatic equalization, temperature compensation and very high efficiency. They can be used on 12-, 24- and 48-volt systems with sealed, gel and wet-cell lead-acid batteries. Front panel LEDs indicate when the batteries are being charged and relative battery state of charge. Reverse polarity protection on input and output. In the event of a load short circuit, the load is automatically disconnected. M models include LCD meter of battery voltage, PV charging current, and load current. Low voltage LVD is current-compensated to prevent false disconnect when the battery is heavily loaded. Units are conformal coated to guard against corrosion. Dimensions: 6.01″ x 4.14″ x 2.2″. 5-year warranty.
SunLight Charge Controller with Lighting Control
The SunLight has all the features of the SunSaver controller. It also has a rotary switch that allows it to turn on the loads after dusk for 2, 4, 6, 8, or 10 hours. One option turns loads on at dusk, off and on again before dawn. In this configuration, you can choose the following settings (in hours): 3/off/1, 4/off/2, or 6/off/2. “On” from dusk to dawn is also possible. A test button turns light on for five minutes. 5-year warranty. Dimensions: 6.6″ x 2.2″ x 1.3″.
SunGuard Charge Controller
The SunGuard uses the same charging circuit as the SunSaver. It is ideal where a 12-volt, low-power controller is needed. It can control up to 75 watts of PV module(s). Since it is epoxy encapsulated, it can be used outdoors in a harsh environment. Dimensions are 2.5″ x 2″ x 1.6″ with wire leads for connecting module and battery. 5-year warranty.
SunKeeper Charge Controller
The SunKeeper is available in 6-amp or 12-amp versions at 12 volts DC. To withstand the high temperatures at the solar module, the controller has been designed using extremely efficient power electronics and is rated to 70C. The SunKeeper is also certified for use in Class 1, Division 2 hazardous locations, making it an ideal controller for solar powered oil/gas applications. Mounts in 1/2″ knockout.
5-year warranty. ETL/cETL Listed to UL 1604. CSA 22.2 Listed.
Pulse Width Modulator (PWM) / Lighting Controllers
C-35, C-40 and C-60 PWM Controllers
The Xantrex C-35, C-40, and C-60 PWM (pulse width modulator) controllers can be used as PV charge controllers, DC load controllers or DC diversion regulators in 12-, 24- and 48-volt systems (only the C-40 can be used in 48-volt systems). They operate in only one mode at a time, so two controllers must be used to provide both PV charge controller and low battery load disconnect. As DC load controllers they disconnect the load at a user-settable low voltage and reconnect at a higher voltage reconnect point. As diversion controllers they send excess power to a “dummy load” (such as a water or space heater) to regulate hydroelectric or wind generators. When used in diversion mode, derate the amperage by 25%. All Xantrex controllers, when used as a charge controller, have field-adjustable bulk and float set points and perform automatic equalization every 30 days or whenever LVD is reached. Equalization can be manually initiated with automatic shut-off. Order the optional temperature sensor for a more accurate battery charge controller. The optional LCD digital display shows battery voltage, array amps and watts, cumulative amp-hours and a separately resettable “trip” amp-hour measurement. The digital display is available for mounting on the front of the charge controller, or with a 50- or 100-foot cable for remote mounting in a double-gang electrical box. UL Listed. 2-year warranty.
This fully waterproof PV charge and lighting controller for area lighting, roadside signs, and warning signs can be used with 12- or 24-volt systems. Available in 15-amp and 40-amp versions, controllers have low-voltage load disconnect and temperature compensation and can be used with sealed or flooded batteries. Pulse action reduces sulfation.
Lighting Controllers with Motion Sensor
This fully waterproof PV charge and lighting controller for area lighting, roadside signs, and warning signs can be used with 12- or 24-volt systems. 15-amp and 40-amp versions are available. Controllers have a motion sensor to activate the light or load when motion is sensed. They have temperature compensation and can be used with sealed or flooded batteries. Pulse action reduces sulfation.
Generator Start Controllers
AGS-RV Auto Generator Start
The Magnum AGS is compatible with most major generators, including Onan, Powertech, Generac, and Weterbeke. Please check with us for specific model compatibility. The Magnum Automatic Generator Start (AGS) is designed to automatically start your coach generator based on low battery condition or the inside temperature of the coach.
You can set the battery start voltage from 10-12 VDC or 20-22 VDC, the start temperature from 65-85°F, the run time from one to five hours, and the quiet time with an easy-to-set clock. Automatic Generator Start settings do not interfere with the manual start/stop operation of the generator. Just use any existing start/stop switch in your coach.
Two models are available. The standalone version of the AGS works well for installation and operation without an inverter. The network version of the AGS allows operation of the AGS via the ME Series remote panel.
The Atkinson GSCM (generator start controller module) is a microprocessor-based generator-starting controller that receives start commands from the 12-volt output from an OutBack FX inverter auxiliary relay, a user-supplied switch, an auxiliary relay in an inverter, a voltage controlled relay, a timer or any user-supplied contact closure. It automatically controls a gas/propane or diesel powered generator or pump, and is totally sealed for harsh environment operation.
The GSCM provides contact signal relays to start the engine and disconnect the starter when a minimum generator frequency output is measured. It monitors the generator operation, shutting it down if one of several fault conditions is detected. LEDs are flashed to indicate the cause of the shutdown. Manually resetting the GSCM removes the lockout and allows the generator to restart if called. The GSCM is powered by 12 to 24 VDC from a battery bank and will start generators for 12 to 48V systems. For 48V systems the GSCM must be powered by a 24V-or-less tap on the 48V battery bank. The GSCM provides a 30-day exercise function which can be synchronized with a photovoltaic input to only start each 30-day period at the beginning of the solar charge day. 2-year limited warranty. Dimensions are 5.5″ x 3.3″ x 1.5″.
Charge Controller Relays
SPDT 12V 40A Relay
SPST N.O. 12V 75A Relay
This enclosed single-pole, single-throw relay has one set of contacts that closes when power is applied to the coil terminals. It can be used to turn on 12-volt loads of up to 75 amps. Power terminals are 10-32 screws and coil terminals are ¼” quick disconnects. 300mA is nominal operating current.
DPDT 30A Relay
These double-pole, double-throw relays can be used for up to 30 amps at 12 or 24 volts DC or 120/240 volts AC. All contact surfaces are silver alloy with gold flashing. Contact terminals are #8-32 screws and coil terminals are #6-32 screws. Relays with 120 VAC or 240 VAC coils can be used to build simple transfer switches. Relays with DC coils can be used for remote operation of pumps and fans. By connecting a relay with a DC coil to a voltage controlled switch, AC or DC loads may be turned on or off based on battery voltage levels.
Charge Controller Diversion Loads
Low-Voltage Water Heating Element
These low-voltage water heating elements are for use as diversion loads for wind or hydroelectric systems. Use one or more of these heating elements with a charge controller designed for load diversion, such as the Xantrex C-40 or C-60, or the Morningstar TS-45 or TS-60 to turn your excess power into hot water. They fit most electric water heaters with screw-in elements. We have one model for 12- and 24-volt systems and another for higher power 24- and 48-volt systems. Each unit has two elements that can be wired in series or parallel or used individually, depending on voltage and desired amp draw. See table to determine what each element will draw at various charging voltages.
If your water heater tank is designed for square flange elements, use one square flange adapter for each element. 1-inch male pipe threads. 2-year warranty.
Air Heating Diversion Loads
These resistive loads enclosed in vented aluminum boxes can be used in 12-, 24 and 48-volt diversion regulation systems. The aluminum box may get very hot in operation. It should be mounted on a nonflammable surface and should be at least 12″ from any flammable material.
HL-100 is shipped as a 4-ohm resistor and can be reconfigured as a 1-, 0.5- or 0.25-ohm resistor by easily changing connections in the terminal block.
HL-75 is shipped as a 3-ohm resistor and can be reconfigured as a 0.75-ohm resistor by changing connections in the terminal block. See table for diverted amps at various voltages. 2-year warranty.