Custom Settings for East Penn Manufacturing Company, Inc.; Deka/MK Batteries

This application note was developed by Morningstar Corporation and is based on information from East Penn Manufacturing Company, Inc.; Deka/ MK Batteries. The information is intended as a guide to help configure custom settings on various Morningstar controllers to charge batteries manufactured by MK Battery/Deka. Performance may vary depending on use conditions and application. East Penn Manufacturing Company, Inc.; Deka/MK Batteries and Morningstar Corporation are separate companies with unaffiliated ownership. Morningstar Corporation does not make any warranties explicit or implied regarding this product information.

The following information is from the MK Battery web site:

“MK Battery is one of the largest sealed lead acid battery suppliers in North America.”

“MK Battery provides the highest quality and most environmentally responsible sealed battery solutions for specialized deep-cycle and standby power applications. We take pride in our dedicated people and in our total commitment to offering the most reliable products, world-class service and support, and maximum overall value to the diverse markets we serve.”

Morningstar controllers have up to seven factory presets and many controller models include custom programming options. Typically, one of the factory presets works perfectly fine for a specific Lead-Acid battery. Battery manufacturers provide voltage regulation set-points that closely match one of the factory preset options.

The custom settings being provided here are similar to several of Morningstar’s factory presets. These settings include much longer cumulative time for the Absorption and Equalize stages. MK Battery has informed us that these longer Absorption times will be more of an advantage in applications where the batteries are traditionally susceptible to undercharging. Also, they indicated that if the charge controller voltage settings are within the recommended range, the batteries will not be overcharged.

The custom settings indicated here would be the maximum duration for the Absorption stage that would be considered. As with any battery charge settings, optimal performance may depend on adjustments that are based on many factors including battery bank size, average daily loads, battery temperatures and daily charge rates which depend on location specific criteria and array sizing. Cumulative Absorption Time adjustments should be considered on a case by case basis for best performance.

Web Sites:

Battery Types and Models:

Recommended products by Morningstar:

Morningstar Custom Settings Overview:

The following configuration information and MSView Setup Wizard custom settings configuration files are designed in accordance with specifications from the manufacturer. These settings have been reviewed by MK Battery and are in accordance to their Technical Bulletin regarding Renewable Energy Charging Parameters.

As with any battery charge settings, optimal performance may depend on adjustments that are based on many factors including battery bank size, average daily loads, battery temperatures and daily charge rates which depend on location specific criteria and array sizing. The Absorption Time might need to be adjusted so that it regularly completes the Absorption stage with the end condition as outlined in the Bulletin so that the change (reduction) in Net charge current is < -0.10 A per Hr.

In addition, the Deka Bulletin indicates the following.
“End condition parameters per charge & Equalize Charge intervals are application specific and will vary dependent upon site specific characteristics such as: temperature, days of autonomy, array to load ratio, etc…”

Options for batteries that are mostly sitting idle for long periods of time would be as follows.

  1. Greatly reduce the daily Absorption Time allowing the Absorption Extension Settings to take over if the battery voltage gets low.
  2. Use reduced Absorption and/or Float Voltages to prevent unnecessary charging.

Please note also that these settings are with the highest voltage settings possible for each battery as indicated in the tables in the Deka Bulletin.

Communications hardware required for programming Custom Settings with MSView:

MSView Software Download

MSView Custom Settings Configuration Files for Deka/ MK Batteries

Recommended Settings; Morningstar Custom Settings Basic Setup Overview:

Morningstar DIP Switch Settings by Product and Type of Settings

General DIP Switch Custom Settings Tables TSMPPT, TS.jpg
General DIP Switch Custom Settings Tables PSMPPT, PS, SSMPPT, SSDuo.jpg

Notes:

  • Custom settings are recommended for best results. However, there are factory PreSets that can be enabled with alternative DIP Switch settings which may be applicable for a particular model, system and environmental conditions.
  • Different controllers will have different options and charging parameters. Please use the information below and adjust as needed. Not all settings are critical and certain conditions may or may require some of the optional settings. Review all the settings and consider what adjustments may be required for your particular system.
  • Max. Charge Limits can be imposed for the TriStar MPPT and ProStar MPPT controllers.
  • All custom settings must be programmed with 12V nominal voltages which will be multiplied accordingly for 24V and 48V battery banks. DIP Switch nominal voltage multiplier settings are recommended whenever possible.

Morningstar Custom Settings Details:

Different controllers will have different options and charging parameters. Please use the information below and adjust as needed. Not all settings are critical and certain conditions may or may not require some of the optional settings. Review all the settings and consider what adjustments may be required for your particular system.

Custom Options for MK/Deka Flooded Monoblock & 2V Flooded Batteries

  • Absorption Voltage14.7 V *
  • Absorption Time6 hr
  • Enable Absorption ExtensionChecked/ 12.5V/ 12 hr
  • Battery Temperature Compensation‐0.018 V/°C
  • Maximum Compensation Temp35°C
  • Minimum Compensation Temp15°C
  • Charge Mode – Float Settings
  • Enable FloatChecked
  • Float Voltage14.1V
  • Float Timeout3 hr **
  • Enable Float CancelChecked/12.3V
  • Enable EqualizeChecked/15.3V
  • Equalize Time6 hr
  • Auto Equalize interval28 days
  • Equalize Timeout12 hr
  • Enable Battery HVDChecked ***
  • High Voltage Disconnect15.6V
  • High Voltage Reconnect14.3V
  • Enable Maximum Regulation LimitOptional
  • Enable Battery Current LimitOptional
  • Battery Current LimitOptional
  • LED transition voltages (Green Only)13.3V
  • LED transition voltages (Green and Yellow)12.9V
  • LED transition voltages (Yellow Only)12.6V
  • LED transition voltages (Yellow and Red)12.3V
  • LED transition voltages (Red Only)
Tristar – TS‐60 (60A), TS-45 (45A) Special Considerations

Chose a TriStar Mode – Solar/ Diversion

  • Solar Charge Controlchecked
  • Charge Mode – Float Settings
  • Transition to Float when duty cycle is98% or less for 6 hrs (Diversion – After 4 h in Absorption (d > 0%)…) ****
  • Exit Float when duty cycle is 100% for3 hr (Diversion – Exit Float if d=0% for a cumulative 2h)
  • Enable Low battery tripEnable, 12.5V, 12 hr
  • Enable Float cancel VoltageEnable. 12.3V

Load Settings (TriStar in Load Control Mode, ProStar, ProStar MPPT, SunSaver MPPT)

  • Low Voltage Disconnect11.5-12V (typically)
  • Low Voltage Reconnect12.5-13V
  • Delay Before LVD5 min
  • Load Current Compensation0.02 ohms (V/A)

* – Settings must be programmed with 12V nominal voltages with all Morningstar controllers and will be multiplied by 2 or 4 for 24V and 48V batteries respectively. Use DIP Switches to set the battery voltages as indicated in the DIP Switch tables above.

** – Float Timeout is the cumulative time that voltage drops below the Float Target Voltage before returning to Bulk/Absorption. If a system drops out of float this setting will attempt to recharge the battery late in the day

*** – High Voltage Disconnect/ Reconnect will disable charging when there is overcharging from other sources.

**** – For TriStar Solar Control Applications: Transition to Float with a lower duty cycle can be considered but Absorption Time should reflect the time it takes to reach the lower duty cycle. (For example … 30% or less for 3 hrs)

Caution: There are few limits to the changes that can be made using Morningstar’s Setup Wizard Tools in MSView. It is the responsibility of the user to be certain all changes are appropriate. Any damages to the controller or the system from setpoint adjustments will not be covered under warranty.

Disclaimer: Morningstar makes no representation, warranty or assumption of liability regarding the use of these custom settings configuration files. These custom settings configuration files are based on information provided by other parties (such as battery specs) and makes calculations based on assumptions which may or may not prove to be valid.

Custom Options for MK/Deka VRLA ( 8A, 8G & Unigy II) Batteries
  • Absorption Voltage14.4 V *
  • Absorption Time6 hr
  • Enable Absorption ExtensionChecked/ 12.5V/ 11 hr
  • Battery Temperature Compensation0.018 V/°C
  • Maximum Compensation Temp 35°C
  • Minimum Compensation Temp 15°C
  • Charge Mode – Float Settings
  • Enable Float Checked
  • Float Voltage 13.5
  • Float Timeout 3 hr **
  • Enable Float Cancel Checked/12.3V
  • Enable Equalize Checked/14.6V
  • Equalize Time 3 hr
  • Auto Equalize interval 28 days
  • Equalize Timeout 4 hr
  • Enable Battery HVD Checked ***
  • High Voltage Disconnect14.9V
  • High Voltage Reconnect 13.8V
  • Enable Maximum Regulation Limit Optional
  • Enable Battery Current Limit Optional
  • Battery Current Limit Optional
  • LED transition voltages (Green Only) 13.3V
  • LED transition voltages (Green and Yellow) 12.9V
  • LED transition voltages (Yellow Only) 12.6V
  • LED transition voltages (Yellow and Red) 12.3V
  • LED transition voltages (Red Only)

See Custom Options for MK/Deka Flooded Monoblock & 2V Flooded Batteries above for TriStar special considerations, Load control settings and * notes and Caution/ Disclaimers.

Custom Options for MK/Deka Sealed (2V Gel) Batteries
  • Absorption Voltage 14.52 V *
  • Absorption Time 6 hr
  • Enable Absorption Extension Checked/ 12.5V/ 11 hr
  • Battery Temperature Compensation -0.018 V/°C
  • Maximum Compensation Temp 35°C
  • Minimum Compensation Temp 15°C
  • Charge Mode – Float Settings
  • Enable Float Checked
  • Float Voltage 13.8V
  • Float Timeout 3 hr **
  • Enable Float Cancel Checked/12.3V
  • Enable Equalize Checked/14.88V
  • Equalize Time 6 hr
  • Auto Equalize interval 28 days
  • Equalize Timeout 12 hr
  • Enable Battery HVD Checked ***
  • High Voltage Disconnect 15.2V
  • High Voltage Reconnect 14V
  • Enable Maximum Regulation Limit Optional
  • Enable Battery Current Limit Optional
  • Battery Current Limit Optional
  • LED transition voltages (Green Only) 13.3V
  • LED transition voltages (Green and Yellow) 12.9V
  • LED transition voltages (Yellow Only) 12.6V
  • LED transition voltages (Yellow and Red) 12.3V
  • LED transition voltages (Red Only)

See Custom Options for MK/Deka Monoblock & 2V Flooded Batteries above for TriStar special considerations, Load control settings and * notes and Caution/ Disclaimers.

Custom Options for MK Battery Small VRLA (ES Series) Batteries
  • Absorption Voltage 15.0 V *
  • Absorption Time 6 hr
  • Enable Absorption Extension Checked/ 12.5V/ 11 hr
  • Battery Temperature Compensation -0.018 V/°C
  • Maximum Compensation Temp 40°C
  • Minimum Compensation Temp -15°C
  • Charge Mode – Float Settings
  • Enable Float Checked
  • Float Voltage 13.8V
  • Float Timeout 3 hr **
  • Enable Float Cancel Checked/12.3V
  • Enable Equalize Checked/15.01V
  • Equalize Time 6 hr
  • Auto Equalize interval 28 days
  • Equalize Timeout 12 hr
  • Enable Battery HVD Checked ***
  • High Voltage Disconnect 15.9V
  • High Voltage Reconnect 14.6V
  • Enable Maximum Regulation Limit Optional
  • Enable Battery Current Limit Optional
  • Battery Current Limit Optional
  • LED transition voltages (Green Only) 13.3V
  • LED transition voltages (Green and Yellow) 12.9V
  • LED transition voltages (Yellow Only) 12.6V
  • LED transition voltages (Yellow and Red) 12.3V
  • LED transition voltages (Red Only)

See Custom Options for MK/Deka Flooded Monoblock & 2V Flooded Batteries above for TriStar special considerations, Load control settings and * notes and Caution/ Disclaimers.