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Title Type Language Date Version Rating
SunGuard Operator’s Manual application/pdf English 11.13.2009 01
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Marketing 39.47 Kb pdf

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Comprehensive manual covering installation, operation, and maintenance of the SunGuard controller.

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SunGuard Datasheet application/pdf English 08.10.2018 11
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Marketing 1.75 Mb pdf

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Full operating specifications of the SunGuard including:

  • Electrical parameters
  • Mechanical specs
  • Environmental ratings

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SunGuard Quick Test Checklist application/pdf English 05.13.2013 01
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Marketing 510.75 Kb pdf

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A quick checklist for testing the functionality of the SunGuard controller.

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SunGuard Advantages text/plain English 12.11.2007 01
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Marketing 1.00 b txt

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Morningstar's SunGuard is the world's leading single module controller. We have combined all the advantages of our SunSaver charging circuit with less expensive packaging to provide an economical controller for small PV systems.
  • Includes most of the advantages of the SunSaver charge controller. Please refer to the SunSaver product information for more details.

  • Unique SunGuard Features
    • One version only rated for 4.5A solar at 12VDC (LVD not available)
    • Smaller package size (64mm x 51mm x 38mm) for easy mounting
    • Outdoor rated, Hypalon connecting wires instead of a terminal strip
    • ABS plastic case will withstand temperature and humidity extremes

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SunGuard Mechanical Diagram application/pdf English 11.26.2007 01
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Marketing 11.81 Kb pdf

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This document displays the physical dimensions of the SunGuard.

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SunGuard Electrical Diagram application/pdf English 11.26.2007 01
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Marketing 8.20 Kb pdf

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This document shows a basic electrical diagram of the SunGuard.

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SunGuard Field Testing Instructions application/pdf English 10.29.2007 01
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Marketing 14.96 Kb pdf

Description:

This document specifies basic testing instructions for verifying operation of the SunGuard controller when on site and no external power sources are available.

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SunGuard Bench Testing Instructions application/pdf English 10.08.2007 01
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Marketing 141.69 Kb pdf

Description:

Comprehensive testing instructions to verify operation of the SunSaver charge controller.
Test the controller using basic lab equipment:

  • power supply
  • small Ah battery
  • multimeter

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Charging Isolated Battery Banks – 1 controller application/pdf English 09.29.2011 01
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Marketing 172.98 Kb pdf

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There is often a need to charge two or more isolated batteries with the same off-grid solar system. Morningstars SunSaver-Duo charge controller is designed to charge 2 isolated battery banks with an adjustable charging priority. We recommend the use of this controller for isolated battery bank applications.

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Morningstar-Corporation-Traditional-PWM-vs-TrakStar-MPPT-Whitepaper-March-2015 application/pdf English 02.11.2014 01
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WHITEPAPER 1005.40 Kb pdf

Description:

A white paper discussing the advantages and disadvantages of PWM and MPPT charge controller technologies. Sizing, environmental, and cost factors are discussed.

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Declaration of Conformity for Products Under 48V application/pdf English 10.20.2011 01
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Marketing 256.14 Kb pdf

Description:



The EMC Directive 2004/108/EC

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Correct Inverter Wiring application/pdf English 05.13.2013 01
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Marketing 553.82 Kb pdf

Description:

A diagram shows how to properly wire a charge controller and an inverter into the same battery-based PV system.

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Charging with Parallel Controllers application/pdf English 05.13.2013 01
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Marketing 529.56 Kb pdf

Description:

A diagram showing two SunSaver controllers shows how to properly parallel multiple Morningstar controllers into the same battery system. The concepts shown are applicable to all Morningstar controller models.

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Parallel Battery String Wiring application/pdf English 05.28.2013 01
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Marketing 524.89 Kb pdf

Description:

A diagram shows how to correctly wire charge controllers to a battery bank comprised of multiple parallel strings. Correct wiring is important to ensure even and distributed charging of the entire bank.

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Title Type Language Date Version Rating
Will other charging sources backfeed into my controller? text/plain English 09.12.2014 01
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Tech Note 34.00 b txt

Description:

Other charging sources can be used in parallel with the Morningstar charge controller; you do not need to isolate the controller from the battery. For best performance when using other charging sources, ensure the charging source and Morningstar controller are set to charge to the same (or close) voltage. If the supplemental charging source is set to a higher charging voltage than the Morningstar controller, the Morningstar controller may go into a fault state temporarily when the battery voltage rises higher than the controller’s setpoint. The controller will automatically recover from this state when the battery voltage drops to a lower level.

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Reverse discharge protection at night text/plain English 09.12.2014 01
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Tech Note 34.00 b txt

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All Morningstar controllers will automatically prevent reverse discharge of the battery back through the solar array during the night. No external diodes on the input of the controller are required.

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Charging Isolated Battery Banks – 1 Solar Array application/pdf English 09.29.2011 01
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Tech Note 48.64 Kb pdf

Description:

A wiring diagram for charging multiple isolated battery banks using multiple controllers and only one PV array.

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Noise or Interference During PWM Charging text/plain English 09.28.2011 01
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Tech Note 1.00 b txt

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Pulse Width Modulation (PWM) charging may cause interference in sensitive loads in the system during charging. The SunSaver switches current at 300 Hz. PWM switching noise can sometimes be heard in the controller itself, the wiring or wiring connections, or the system loads. AM radios and CB radios are especially prone to PWM interference. Noise in the controller or wiring is caused by mechanical resonance when current is switched through the circuits. There is little that can be done to remedy this issue. However, noise/interference in the system loads can usually be reduced or eliminated by the following:

1) Minimize cable runs between components

2) Twist power pairs(+/-) to reduce radiated noise

3) Good system grounding

4) Add capacitance across load power(at load input, 22000uf or more)

5) Add a line filter. some have had success with car audio filters that eliminate alternator whine. If these measures do not eliminate or reduce interference to acceptable levels, the controller can be modified to reduce the switching frequency. The 3rd generation SunSaver has a wire loop under the faceplate. If this loop is cut, the controller will reduce the switching frequency to ~1 Hz. Refer to the SunSaver Operator’s Manual for more information.

6) Some Morningstar controllers allow for operation in a ‘low-noise’ state. Check your controller documentation for details.

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Testing the SunGuard text/plain English 10.05.2007 01
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Tech Note 1.00 b txt

Description:

The SunGuard can be tested for correct operation as follows: 1. Wire the SunGuard into your system with Solar and Battery attached to the appropriate leads
2. Measure battery voltage
3. Measure solar voltage If the battery is charging up (has NOT reached regulation voltage) the solar voltage and battery voltage will be about the same.
If the battery is fully charged, the battery voltage will be at 14.1V* and the solar voltage will be higher
If solar voltage is greater than battery voltage and the battery is not yet fully charged, there may be a problem with your SunGuard. * The 14.1V regulation voltage setpoint is temperature compensated. If the ambient temperature is warmer than 25C (~78F) the regulation setpoint will be lower. The regulation setpoint will be higher in colder temperatures.

NOTE: Measuring the SunGuard battery voltage leads without the battery attached is not a valid test!

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No output voltage from the SunGuard text/plain English 10.17.2007 01
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Tech Note 1.00 b txt

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When a solar panel is wired to the solar input, no voltage output is measured on the battery leads. The SunGuard is not damaged!
There is no voltage output because the SunGuard requires the battery connection to function properly. Without a battery attached, the SunGuard’s internal circuits cannot power up and allow current to flow from the Solar input to the battery. Refer to the SunGuard testing documents in the Related Documents.

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Wiring multiple controllers to one battery bank? text/plain English 12.10.2007 01
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Tech Note 1.00 b txt

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Yes. There can be as many Morningstar controllers as required in parallel on the same battery bank. For best performance, set each controller to as close a charge setting as possible. Since the controllers will not have direct communication with each other, it is not unusual to see the controllers transition between charging stages at different times. This is generally not a concern.

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What is PWM charging? application/pdf English 12.11.2007 01
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Tech Note 313.43 Kb pdf

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PWM is an acronym for Pulse Width Modulation. When the battery is recharged to regulation voltage, the controller will begin limiting the amount of current into the battery so that the regulation voltage is maintained but not surpassed. The method of regulating the current, referred to as PWM, pulses current into the battery with pulses of a varying width. Wider pulses allow a greater percentage of the input current to flow into the battery, narrower pulses restrict current to a lower percentage. Refer to the accompanying download,  “Why PWM?”, for more technical and detailed information concerning PWM charging.

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Common Reasons Why Power Transistors Fail text/plain English 09.28.2011 01
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Tech Note 1.00 b txt

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The internal switches of a controller, called MOSFETs or power transistors, switch current on and off to control solar current and load current. Because these components are in the power path, the controller will no longer be able to switch current if they fail.

Power transistors can fail for the following reasons:

  • Over-voltage: lightning or other high voltage transients on the PV power cables.
  • Over-current: too much PV for the controller or a short in the PV line pulls too much currentout of the battery through the controller.
  • Extreme temperatures during charging.
  • A premature failure of the component. The transistors are solid state devices that are manufactured in huge volumes with extremely low failure rates. However, no electrical components are 100% defect free and can pass test and then fail after a short period of time.
  • Old age

 

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Charging NiMh Batteries text/plain English 10.16.2007 01
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Tech Note 1.00 b txt

Description:

Our controllers are designed to charge lead-acid batteries which have different charging requirements than NiMh. Please DO NOT use our products with NiMh batteries, it is dangerous to do so.

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Higher voltage array with a lower voltage battery text/plain English 09.28.2011 01
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Tech Note 1.00 b txt

Description:

A higher voltage solar array (e.g. 24V nominal) can only be used with a lower voltage battery bank (e.g. 12V nominal) if the controller used is an MPPT controller.

PWM controllers CANNOT be used to charge a lower-voltage battery bank with a higher-voltage solar array. Please use an MPPT style controller if this is required.

 

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Audible buzzing noise during charging text/plain English 12.07.2009 01
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Tech Note 1.00 b txt

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I sometimes hear a buzzing noise during charging. Is something wrong?

No. The buzzing sound is mechanical resonance created by the switching of current through the circuit board and solid-state devices. This is normal and not indicative of a problem.

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Using multiple controllers with one PV array application/pdf English 09.28.2011 01
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Tech Note 71.50 Kb pdf

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Can I wire multiple controllers in parallel off the same PV array to charge different batteries?

Yes. Refer to the document, “Charging Isolated Battery Banks”. This can ONLY be done with PWM controllers. MPPT controllers cannot be used in this configuration.

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Charge isolated battery banks with one controller application/pdf English 09.28.2011 01
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Tech Note 111.30 Kb pdf

Description:

Can I charge separate battery banks with one Morningstar charge controller?

Yes.  Refer to the document, “Charging Isolated Battery Banks – 1 Controller”.

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Do Morningstar controllers use SOC calculations? text/plain English 09.28.2011 01
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Tech Note 1.00 b txt

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Do Morningstar Controllers regulate according to SOC (State of Charge) calculations?

No. Morningstar Controllers regulate according to battery voltage setpoints. Because battery health and other factors affect charging over time, using voltage setpoints is a way to naturally track these changes and affords the user a complete understanding of the controllers operation. SOC calculations and algorithms may not be precise under all conditions and may leave the user with a “fuzzy” understanding of the workings of the unit.

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Calculating temperature compensation variances application/pdf English 09.28.2011 01
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Tech Note 191.23 Kb pdf

Description:

How do I calculate the effect of temperature compensation on the regulation voltage?

Refer to the accompanying document download, which includes compensation curves for most Morningstar Controllers, or refer to temperature compensation coefficient in the specifications section of the Operator’s Manual.

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Using a DC power supply as a PV panel substitute? text/plain English 03.05.2009 01
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Tech Note 1.00 b txt

Description:

Can I use a power source other than a PV panel to charge my batteries?

We do not recommend using a DC power supply with any of our PWM controllers. While they appear to be similar to PV modules in function, DC power supplies have considerably more output capacitance. Connecting a DC power supply to our PWM controllers may cause excessive heating and premature failure. MPPT controllers can be used for this purpose without issue. In addition, AC powered battery chargers are often the best option for systems requiring AC battery charging.

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Calculating temperature compensated charging application/pdf English 05.17.2011 1
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Tech Note 191.23 Kb pdf

Description:

Here’s a brief explanation on how to calculate the temperature compensated adjustments our controllers make to their charging voltages based on the ambient temperature changes.

The charging voltages listed in the controller operator’s manual are specified at a 25C standard test condition ambient temperature with a -.030V (@ 12V battery) adjustment per degree C change in temperature above or below the 25C reference. The (-) in front of the .030V indicates that voltage adjustment is inverse to the change in temperature. In other words, if the temperature increases above 25C, the controller decreases it’s charging voltage by -.030V per degree C rise above 25C and vice versa. An accurate measurement of the ambient temperature is required for calculating the the controller’s temperature compensated adjustment.

Example:

An ambient temperature of 35C = +10C increase above the 25C base temp = 10 x -.030V compensated adjustment = temperature compensated -.300V decrease in charging voltage.
Therefore, a 14.4V charging voltage specified in the manual @ 25C would be reduced to 14.1V @ 35C or increased to 14.7V @ 15C.

The compensation rate is doubled to .060V/C for 24Vnominal battery systems and quadrupled to .120V/C for 48V nominal battery systems.

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Why PWM? application/pdf English 11.07.2012 01
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Tech Note 231.60 Kb pdf

Description:

Frequently Asked Questions about PWM battery charging are addressed.

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Can I mount the controller horizontally? text/plain English 05.12.2013 01
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Tech Note 1.00 b txt

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Morningstar controllers have been designed to mount vertically. This is the orientation in which the heatsinks are most effective. Mounting the controller horizontally will reduce its passive cooling efficiency, but the risk of overheating will be determined by the ambient temperature and the power level at which the controller will be operating.

All efforts should be made to mount the controller vertically.

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Charging LED staying lit after solar input removed text/plain English 05.12.2013 01
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Tech Note 1.00 b txt

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Most Morningstar controllers will take up to 5 minutes to realize that the solar input voltage is no longer present before transitioning into the ‘night’ state. The controller performs periodic day/nigh checks (about once every 5 minutes). Depending upon where the controller is in this cycle when the input is removed, it may take anywhere from 0-5min for the controller to turn off its Charging LED and go into the ‘night’ state.

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What is the PWM switching frequency? text/plain English 05.13.2013 01
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Tech Note 1.00 b txt

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All Morningstar PWM type controllers have a PWM switching frequency of ~300Hz.

Some Morningstar PWM controllers have a feature which will reduce the switching frequency to ~1Hz (called on/off charging). This on/off charging virtually eliminates switching noise (both radiated and conducted) and can be used when experiencing noise problems with 300Hz switching operation.

Current models with this on/off charging option are:

– SunSaver Generation 3

– SunSaver Duo

– ProStar PWM

– TriStar PWM

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Controller System Sizing with 60 Cell Modules application/pdf English 10.01.2013 01
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Tech Note 290.20 Kb pdf

Description:

This Tech Tip discusses the use of today’s 60 cell PV modules with Morningstar’s solar controllers. It explains why 60 cell modules are not well adapted for meeting the nominal array voltage requirements of PWM controllers. It also shows how Morningstar’s MPPT controllers can be used with great success at higher input voltages.

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Title Type Language Date Version Rating
SunGuard-4 Straight Product Photo image/png English 10.09.2013 01
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Image 252.41 Kb png

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SunGuard-4 Straight Product Photo 253 KB

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SunGuard-4 Angled Product Photo image/png English 10.09.2013 01
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Image 358.09 Kb png

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SunGuard-4 Angled Product Photo 359 KB

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Title Type Language Date Version Rating
Sunguard Declaration of Conformity application/pdf English 08.24.2019 03
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Corporate 122.90 Kb pdf

Description:

Documentation certifying that the Sunguard conforms to the European testing requirements outlined by:

  • EN 61000-6-2:1999 EMC Immunity, Industrial Environments
  • EN 55022:2006 (Class B) EMC Emissions
  • REACH EC 1907/2006 compliant
  • Electromagnetic Compatibility Directive 93/68/EEC

 

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Warranty Claim Procedure application/pdf English 09.11.2014 01
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Corporate 97.76 Kb pdf

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Tech Support Policy application/pdf English 09.11.2014 01
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Corporate 76.48 Kb pdf

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2014-2015 Product Catalog in English application/pdf English 05.14.2014 01
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Corporate 4.70 Mb pdf

Description:

The 2014/2015 Morningstar Product Catalog in English

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RoHS Certification Document application/pdf English 02.19.2014 01
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Corporate 81.08 Kb pdf

Description:

The part numbers listed within are in compliance with Directive 2011/65/EC on the restriction of the use of certain
hazardous substances in electrical and electronic equipment (RoHS directives). This document also certifies that
the product declaration that has been provided by Morningstar Corporation is accurate.

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Intl-Warranty application/pdf English 10.17.2013 01
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Corporate 98.02 Kb pdf

Description:

Morningstar Product Warranty

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Strong R&D Capability and Engineering Excellence application/pdf English 08.02.2013 01
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Corporate 119.38 Kb pdf

Description:

Whitepaper on Morningstar’s s high-level of innovation, R&D and engineering excellence.

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Company Profile (video) video/x-ms-wmv English 10.16.2012 01
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Corporate 70.29 Mb wmv

Description:

Short video highlighting Morningstar Corporation’s history and products.

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Weights and Dims application/pdf English 12.16.2015 02
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Corporate 289.03 Kb pdf

Description:

PDF file of the packed Weights and Dims of Morningstar products.

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