TraditionalPWMvs.

MorningstarsTrakStarMPPT Technology

Introduction:
MorningstarMPPT(MaximumPowerPointTracking)controllersutilizeMorningstarsown advancedTrakStarMaximumPowerPointTrackingtechnologytoharvestthemaximumamountof powerfromyoursolararray.ItisgenerallyacceptedthateventhemostbasicMPPTcontrollerswill provideanadditional1015%ofchargingcapabilitycomparedtoastandardPWMregulator.Inaddition toefficiency,thereareseveralimportantdifferencesbetweenPWMandMPPTtechnologyandunique advantagestoeach.Thesebasicdifferencesareoutlinedbelowandanexplanationisgivenonhowto properlysizesolararraysforeachtypeofcontroller.

PWMCharging:
TraditionalsolarregulatorsfeaturingPWM(pulsewidthmodulation)chargingoperateby connectingthesolararraydirectlytothebatterybank.Whenthearrayisconnecteddirectlytothe batterybank,thearrayoutputvoltageispulleddowntothebatteryvoltage.Thisoccursbecausethe batteriesareaverylargeloadforthelimitedcurrentsourcingcapabilityofasolararray. TheVmp(maximumpowervoltage)ratingisthevoltagewheretheproductoftheoutputcurrent andoutputvoltage(amps*volts)isgreatestandoutputpower(watts=amps*volts)ismaximized. Modulewattageratings(i.e.100W,205W)arenormallyspecifiedattheVmp. Usinganominal12Vsystemasanexample,thebatteryvoltagewillnormallybesomewhere between1015Vdc.However,12VnominalsolarmodulescommonlyhaveaVmpofabout17V.When thearray(havingVmpof17V)isconnectedtothebatteriesforcharging,thebatteriespulldownthe outputvoltageofthearray.Thus,thearrayisnotoperatingatitsmostefficientvoltageof17V,but ratheratsomewherebetween10and15V.Thefollowinggraphsillustratethisphenomenon:

BecausethesetraditionalcontrollersrarelyoperateattheVmpofthesolararray,energyis wastedthatcouldotherwisebeusedtochargethebatteryandpowersystemloads.Thegreaterthe differencebetweenbatteryvoltageandtheVmpofthearray,themoreenergyiswasted.

TrakStarMaximumPowerPointTracking:
MorningstarMPPTcontrollersfeatureTrakStartechnology,designedtoquicklyandaccurately determinetheVmp(maximumpowervoltage)ofthesolararray.TrakStarMPPTcontrollerssweepthe solarinputtodeterminethevoltageatwhichthearrayisproducingthemaximumamountofpower. ThecontrollerharvestspowerfromthearrayatthisVmpvoltageandconvertsitdowntobatteryvoltage, boostingchargingcurrentintheprocess. Becausepowerintothecontrollerisequaltothepoweroutofthecontroller(assuming100% efficiency,neglectingwiringandconversionlosses),itfollowsthatadownconversionofvoltage correspondstoaproportionalincreaseincurrent.Power(watts)isequaltotheproductofvoltageand current,therefore,ifvoltageisreducedcurrentmustbeincreasedtokeeptheinput/outputpower equal. Assuming100%efficiency: InputPower=OutputPower VoltsIn*AmpsIn=VoltsOut*AmpsOut

Forexample:a100Wpanel(Vmpof17V)isusedtochargeabatteryat12VwithaTrakStar MPPTcontroller.Inidealconditions,5.88AofsolarcurrentflowintotheMPPT(100W/17V=5.88A). Buttheoutputvoltage(batteryvoltage)is12V,meaningcurrentflowtothebatteryis8.33A(100W/ 12V=8.33A).YoucanseethatthegreaterthevoltagedifferencebetweentheVmpandthebattery,the moreboostcurrentthebatterywillreceive.Thefollowinggraphillustratestheadvantageofoperating attheTrakStarMaximumPowerPoint:

 Aconsequenceofthisis:thelesschargedthebatteriesare(lowerbatteryvoltage),themore boostcurrenttheywillreceive.Thisispreciselythetimewhenbatterieswillbenefitfromanincreased amountofchargingcurrent.

EnvironmentalConsiderations:
EnvironmentalconditionscancausetheVmpofasolararraytofluctuate.Partialarrayshading andmoduletemperaturewillhavethemostimpactontheVmpofthesolararray.MPPTtechnology allowsthesystemtotrackthechangingVmpandmaximizeenergyharvestinanyenvironmental conditions. Themostnoticeableincreaseinchargingefficiencywillbeseenincoldertemperatures.Assolar modulesdropintemperature,theirVmpincreases(seeAppendix).UsingastandardPWMregulator,a decreaseintemperaturewouldcorrespondtoreducedchargingefficiency(becausethereisan increaseddifferencebetweentheVmpandbatteryvoltage).However,anMPPTcontrollertracksthe increasingVmpandconvertstheexcessvoltagebeingproducedintoadditionalchargingcurrent.In general,anyriseinVmpwillincreaseanMPPTcontrollersharvestrelativetoaPWMcontroller. (Conversely,anydropinVmpwilldecreaseanMPPTcontrollersharvestrelativetoaPWMregulator.) Asseasonschange,theangleofthesunstrikingasolarmodulewillchangeaswell(assuming stationarymodules).Thegreatertheangleofincidence,thelesspoweramodulewillultimately produce.Duringtimesoftheyearwheretheangleofincidenceisgreatest(andrelativepoweroutputis decreased),MPPTtechnologyisveryusefulforharvestingthemaximumamountofenergy.

ArraySizingforPWMRegulators:
ThefirstconsiderationinsizingthearrayforaPWMregulatorisopencircuitvoltage(Voc).Every regulatorhasamaximuminputvoltagerating.Thearraymusthaveatemperaturecompensated(see Appendix)Voclessthanthecontrollersmaximuminputvoltagerating.DuringPWMswitchingcycles,the controllerinputisexposedtothearrayopencircuitvoltage.Usinganarraywithatemperature compensatedVocgreaterthanthecontrollerinputratingwilldamagetheregulator. Next,considerthemaximumpowervoltage(Vmp).TheVmpofthearrayneedstobehigherthan thebatterysmaximumchargingvoltage.RecommendedvaluesforVmparebelow: 12Vsystems: 24Vsystems: 36Vsystems: 48Vsystems: Vmp>15V Vmp>30V Vmp>45V Vmp>60V

Formostsolarmodules,poweroutputdecreasessignificantlyatvoltageshigherthanVmp.Therefore, Vmpmustbehigherthanfullbatteryvoltagetoensureefficientchargingovertheentirebatteryvoltage

range.NOTE:TheVmpofthearrayshouldbehigherthan,butascloseto,themaximumbatteryvoltage aspossible.Vmpsignificantlyhigherthanmaxbatteryvoltagereducesefficiencyandputsmorestresson theswitchingcomponentsoftheregulator.OnlyoffgridmodulesshouldbeusedwithPWM controllers. Finally,thecurrentoutputofthearrayisconsidered.UnlikeMPPTcontrollers,standardPWM regulatorsarenotabletoboosttheamountofchargingcurrentbyconvertingexcessinputvoltage intoamperage.Thismeansthattheinputcurrentfromthesolararraywillbeequaltotheoutput currentdeliveredtothebattery.Thesolararraymustbesizedsothattheshortcircuitcurrent(Isc)does notexceedthenameplatecurrentratingofthecontrollerbeingused.AnarraywithIscgreaterthanthe currentratingoftheregulatorwillconsistentlytripovercurrentprotectionsordamagetheunit. IMPORTANT:ForthesystemtobeNEC(NationalElectricCode)compliantthecurrentratingofthe controllermustbeequaltoorgreaterthan125%ofthearrayshortcircuitcurrentoutput(Isc).Therefore, themaximumallowablesolararrayinputtoa30Acontrollerwouldbe24A(24A*1.25=30A). NOTE:MorningstaroffersaStringSizertooltoassistinthepropersizing/configurationofyour solararraywithMorningstarcontrollers.Usersmaychoosebetweenaselectionofprepopulated moduledataorinputtheirownmodulespecifications.Thistoolalsoallowsadjustmentofdesign parameterssuchasrangeofexpectedbatteryvoltagesandmin/maxtemperaturesexpectedatthe installationsite.AlinktotheStringCalculatorcanbefoundontheMorningstarhomepage: www.morningstarcorp.com.

ArraySizingforMPPTRegulators:
AswithPWMregulators,themostbasicconcernwhensizinganMPPTsolararrayisopencircuit voltage(Voc).Thetemperaturecompensated(seeAppendix)Vocofthearraymustbelessthanthe maximuminputvoltageratingoftheMPPTcontroller.HigherVochasthepotentialtodamagetheunit. ForagivenMPPTcurrentratingandnominalsystemvoltage,thereisaneffectivemaximum solararraywattagethatcanbeused.MorningstarMPPTcontrollershavecurrentratingswhichspecify themaximumbatterychargecurrenttheunitcansupport.NOTE:Thebatterychargecurrentisdifferent fromthesolarinputcurrentduetotheMPPTsabilitytoboostchargingamperage.TheMPPTcurrent ratingmultipliedbythebatteryvoltagewillgivethemaximumsolarpanelwattagewhichcanbeused: Example#1:A15AMPPTcontrollerisbeingusedina12Vnominalsystem(actualbattery voltagebetween10Vand15V).Multiplyingcurrentratingandbatteryvoltagegivesabout200W (15A*13.3V=200W).Themaximumarraywattagethatcanbeusedinthissystemistherefore 200W. Example#2:A15AMPPTcontrollerisnowbeingusedina24Vnominalsystem(actualbattery voltagebetween20Vand30V).Themaximumarraywattagewillthereforebe400W(15A* 26.6V=400W).

Itisimportanttonotethatexceedingthemaximumarraywattageforagivencontroller/ nominalvoltagecombinationwillnotdamagethecontroller.Anywattageinexcessofthemaxarray wattagewillsimplybelost.(i.e.Usinga300WarrayinasystemwherethemaxarrayWisonly200W willnotdamagethecontroller,butthe300Warraywilleffectivelyactlikea200Warrayand100Wof powerwillbelost.) IMPORTANT:MPPTcontrollerscanbeusedwithoffgridorongridmodules.PWMcontrollersshould onlybeusedwithoffgridmodules. MaximizingEfficiency MorningstarTrakStarMPPTcontrollerswilloperateatslightlydifferentefficienciesdepending uponthenominalbatteryvoltagebeingused,theVmpofthearray,andthetotalwattageofthearray. TheseefficiencycurvesareprintedintheappropriatemanualforeveryMorningstarMPPTcontroller. Thisdatacanbeusedtooptimallysizeyoursolararrayforbestperformanceandmaximumenergy harvest. NOTE:MorningstaroffersaStringSizertooltoassistinthepropersizing/configurationofyour solararraywithMorningstarcontrollers.Usersmaychoosebetweenaselectionofprepopulated moduledataorinputtheirownmodulespecifications.Thistoolalsoallowsfortheadjustmentofdesign parameterssuchasrangeofexpectedbatteryvoltagesandmin/maxtemperaturesexpectedatthe installationsite.AlinktotheStringCalculatorcanbefoundontheMorningstarhomepage: www.morningstarcorp.com.

PWMOverMPPT?
TheprecedingdiscussionofPWMvs.MPPTmaycausesometowonderwhyaPWMcontroller wouldeverbechoseninfavorofanMPPTcontroller.ThereareindeedinstanceswhereaPWM regulatorisabetterchoicethanMPPTandfactorswhichwillnegateadvantagestheMPPTmayprovide. Themostobviousconsiderationiscost.MPPTcontrollerswillcostmorethantheirPWMcounterparts. Whendecidingonacontroller,theextracostofMPPTshouldbeanalyzedwithrespecttothefollowing factors. Lowpower(specificallylowcurrent)chargingapplicationsmayhaveequalorbetterenergy harvestwithaPWMcontroller.PWMcontrollerswilloperateatarelativelyconstantharvesting efficiencyregardlessofthesizeofthesystem(allthingsbeingequal,efficiencywillbethesamewhether usinga30Warrayora300Warray).MPPTregulatorscommonlyhavenoticeablyreducedharvesting efficiencies(relativetotheirpeakefficiency)whenusedinlowpowerapplications.Efficiencycurvesfor everyMorningstarMPPTcontrollerareprintedintheircorrespondingmanualsandshouldbereviewed whenmakingaregulatordecision.(ManualsareavailablefordownloadontheMorningstarwebsite www.morningstarcorp.com.) AsexplainedintheEnvironmentalConsiderationssection,thegreatestbenefitofanMPPT regulatorwillbeobservedincolderclimates(Vmpishigher).Conversely,inhotterclimatesVmpis

reduced.AdecreaseinVmpwillreduceMPPTharvestrelativetoPWM.Averageambienttemperatureat theinstallationsitemaybehighenoughtonegateanychargingadvantagestheMPPThasoverthe PWM.ItwouldnotbeeconomicaltouseMPPTinsuchasituation.Averagetemperatureatthesite shouldbeafactorconsideredwhenmakingaregulatorchoice(SeeAppendix). Systemsinwhicharraypoweroutputissignificantlylargerthanthepowerdrawofthesystem loadswouldindicatethatthebatterieswillspendmostoftheirtimeatfullornearfullcharge.Sucha systemmaynotbenefitfromtheincreasedharvestingcapabilityofanMPPTregulator.Whenthe systembatteriesarefull,excesssolarenergygoesunused.TheharvestingadvantageofMPPTmaybe unnecessaryinthissituation.

AppendixTemperatureCompensation
Itisimportanttotakeintoaccounttemperaturecompensationandunderstandhowitrelatesto boththeoutputvoltageandoutputcurrentofasolarmodule. Solarmoduleshaveperformanceratingsunderstandardtestconditions(STC);normallyacell temperatureof25Cand1000W/m2irradiance.Actualoperatingconditionswill,ofcourse,varyfrom STC.Manufacturerspublishtemperaturecoefficientswhichcanbeusedtodeterminemoduleoutput current/voltageunderexpectedconditions.ThetwomostimportantaretheVocandIscTemperature Coefficients. TheVoctempcoefficient,specifiedinvoltsperdegreeC(orF),isanegativevalue.Thisindicates thattheopencircuitvoltageofthemodulehasaninverserelationshipwithtemperature(Vocdecreases withincreasingtemperatureandincreaseswithdecreasingtemperature).WhendeterminingiftheVoc ofanarrayisappropriateforthecontrollersmaximuminputvoltage,itisessentialtotakeintoaccount temperatureeffects.Inwarmweather,theVocofamodulemaybelowenoughtousewithacertain controller.However,asseasonschangeandtemperaturedrops,theVocmayrisepastavoltagesafeto usewiththatcontroller. Worstcasetemperatureeffectsshouldalwaysbeusedwhensizinganarray.Forexample:the VocofamoduleunderSTC(25C)is21V.TheVoctempcoefficientis0.05V/C.Iftherecordlow temperaturefortheareainwhichthemodulewillbeplacedis10C,theworstcase(highest)Vocwillbe 22.75Voc: 10C25C=35C 35C*0.05V/C=1.75V 21V(@STC)+1.75V=22.75V(@10C)

TheIsctempcoefficient,specifiedinampsperdegreeC(orF),isapositivevalue.Thisindicates thattheshortcircuitcurrentwillrisewithincreasingtemperatureandfallwithdecreasingtemperature. Normally,theIsccoefficientissmallenoughtobeneglected.