MSRX Polycarbonate Enclosure Charge Controller: Product Manual

MSRx Polycarbonate Enclosure
Charge Controller
Product Manual
Issue. C
Micha Design MSRx Polycarbonate Enclosure Charge Controller 800776-C.DOC
Product Manual
1. INTRODUCTION...............................................................................................................................................................3
2. HEALTH & SAFETY.........................................................................................................................................................4
3. MSRX CONTROL UNIT OPERATION ...........................................................................................................................5
4. MSRX LCD DISPLAY AND CONTROL .........................................................................................................................7
5. INSTALLATION..............................................................................................................................................................18
6. RE-CONFIGURING THE MSRX CHARGE CONTROLLER .......................................................................................23
7. TROUBLESHOOTING GUIDE ......................................................................................................................................25
MF/27th March 2002/Issue C Page 2 of 25 The Micha Design Company Ltd

Product Manual
1. Introduction
The MSRx series of Charge Controllers are designed to provide the charge regulation and supervisory functions necessary
in a solar power system. The controller prevents damage to the battery due to excessive charge or discharge and also
provides a convenient place to interconnect the solar arrays, battery bank and load equipment.
The MSRx series of Charge Controllers use fully solid-state switching of charge and load current and combine this with
the flexibility and advantages of microprocessor control. The basic function of a charge controller is to control the transfer
of energy from the array to the battery and load. The state of charge of the battery is sensed by monitoring the battery
voltage.
The MSRx series of Charge Controllers are available in four basic configurations as shown in the following table:
MSRx2 MSRx4 MSRx6 MSRx8

Number of Array Inputs 2 4 6 8
Total Array Current 60A 120A 180A 240A
Load 1 Current 25A 25A 25A 25A
Load 2 Current 25A 25A 25A 25A
Control Unit Enclosure Yes Yes Yes Yes
Expansion Unit Enclosure No No Yes Yes
An MSRx2 Charge Controller is supplied as a partially populated Control Unit in an enclosure. An MSRx4 Charge
Controller is supplied as a fully populated Control Unit in the same enclosure as an MSRx2. An MSRx6 is supplied as an
MSRx4 Control Unit with a separate partially populated Expansion Unit in its own enclosure. An MSRx8 is supplied as
an MSRx4 Control Unit with a fully populated Expansion Unit in its own enclosure.
1.1. Standard Features of the MSRx Charge Controller

1.1.1. System Voltages available: 12V, 24V and 48 versions
1.1.2. System Polarity: Positive Earth and Negative Earth versions
1.1.3. Microcontroller (MCU) based control circuit
1.1.4. Solid state switching of up to eight array inputs of 30A each maximum
1.1.5. Solid state switching of two load outputs of 25A each maximum
1.1.6. Temperature compensation of the preset levels
1.1.7. LED indication of Regulation Status, Array Connection and Load Connection
1.1.8. LCD 16 x 2 Character Display with Menu, Up, Down and Select switches for user control
1.1.9. High Volts, Low Volts, Load Cut 1, Load Cut 2 Alarm indication and volt-free relay contacts
1.1.10. 40A Array MCBs and 32A Load MCBs fitted as standard
1.1.11. Protection against induced voltage transients
1.1.12. Control Unit: Polycarbonate IP66 Enclosure (600 x 300 x 130mm)
1.1.13. Expansion Unit: Polycarbonate IP66 Enclosure (400 x 300 x 130mm)
1.2. Optional Features of the MSRx Charge Controller
1.2.1. MSRx RS232 communications port to interface to a local PC or remote PC by Modem.

Product Manual
2. Health & Safety
2.1. General
Read this manual thoroughly BEFORE undertaking any work.
Potentially lethal voltages can be present at the terminals within the Unit. Extreme care MUST be taken when
performing any of the actions described in this manual. Remove all metallic personal adornments from the hands,
wrists and neck before commencing work on a live unit. Ensure all tools are insulated.
2.2. Earthing
The MSRx Charge Controller can be used with either a Positive Earth or Negative Earth solar system.

Product Manual
3. MSRx Control Unit Operation
3.1. Analogue Measurements

The on-board micro-controller (MCU) within the MSRx Charge Controller uses an analogue to digital (A/D)
converter to read the battery voltage, the array voltages, the temperature sensor and the array and load currents.
The battery voltage is read every 50ms (20 times a second). When the unit determines a change of mode or alarm
status is necessary, four successive readings will have to be above or below the appropriate set-point (the exception
is the High Volts Alarm) for the change to occur.
To obtain the true array voltages, the MCU needs to first disconnect an array from the battery (if connected) and then
read the array voltage. This is done approximately every 16 seconds
The temperature sensor is used to compensate the battery voltage. If faulty or disconnected, then the A/D converter
will return a value outside of possible air temperature limits in which case the regulator will operate as if the
temperature was sensed as being the Temperature Compensation Null Temperature (zero compensation applied).
3.2. Battery Regulation
If the compensated battery voltage is less than the Reset-to-Boost voltage, the unit will enter the Boost Mode.
During this time the unit will connect the arrays to the battery if the voltage present on each array is greater than the
battery voltage by 2V. If the total array current is greater than the load current, the battery will charge and the
battery voltage will increase.
When the compensated battery voltage reaches the Boost voltage, the unit will enter the Equalisation Mode. In this
mode, the unit will disconnect and reconnect the arrays to the battery to regulate the battery voltage at the Boost
voltage for the Equalisation period. This ensures the battery reaches its optimum state of charge.
After the Equalisation period, the unit will enter the Float Mode. In this mode, the unit will disconnect and
reconnect the arrays to the battery to regulate the compensated battery voltage at the Float voltage.
If the compensated battery voltage decreases below the Reset-to Boost voltage, the unit will reset to Boost Mode.
When there is insufficient sunlight to generate current (at night or on a day with poor light conditions), the regulator
disconnects the arrays from the battery to avoid the battery discharging back through the array. This is referred to as
the Night mode.
When the unit is regulating at either the Boost voltage or Float voltage, it will disconnect the arrays from the battery
when the battery reaches the required voltage. It will re-connect the array to the battery when the compensated
battery voltage falls below the required voltage by 0.15V(12V system), 0.3V (24V system) or 0.6V (48V system).
3.3. Alarms Activation and Reset
If the compensated battery voltage is higher than the High Volts activation voltage, the array will be immediately
disconnected from the battery and the High Volts alarm relay and indicator will be activated. If the compensated
battery voltage is lower than the High Volts reset voltage, the High Volts alarm relay and indicator will be
immediately reset.
If the battery voltage is lower than the Low Volts activation voltage and remains lower for 2 seconds, the Low Volts
alarm relay and indicator will be activated. If the battery voltage is higher than the Low Volts reset voltage, the Low
Volts alarm relay and indicator will be immediately reset.
If the battery voltage is lower than a Load Cut activation voltage and remains lower for 2 seconds, the Load Cut
alarm relay and indicator will be activated. After the Load Cut switch delay period, the Load Cut Switch and
indicator will be activated. If the battery voltage is higher than the Load Cut reset voltage, the Load Cut alarm relay
and indicator and the Load Cut switch and indicator will be immediately reset.

Product Manual
3.4. Status LED
3.4.1. A status LED is mounted on the MSRx Control PCB Assembly and is used to provide basic unit status to
the user as described in the following table:
Mode Status LED Operation

Boost Mode Flash : 0.35 sec on - 0.35 sec off
Equalisation Mode Flash : 1.05 sec on – 0.35 sec off
Float Mode Steady
Night Mode Flash: 0.35 sec on – 2.45 sec off
3.5. Power Up Sequence

3.5.1. Ensure that the jumper link is installed on LK1 in the Disable position on the MSRx PSU/Load PCB
Assembly.
3.5.2. Apply the battery power.
Power-up This screen appears for 2 seconds when the unit has power first applied
MSRx Charge Screen to it, or when the RESET switch on the MSRx Control PCB Assembly is
Controller pressed.
BATTERY: XX.XV Menu 0 Present Regulation Mode = Disabled

Mode - Disabled (Arrays and Loads disconnected from the Battery)

Product Manual
4. MSRx LCD Display and Control
The MSRx Charge Controller has a built in 2x16 character LCD Display Module, which is used to give information to the
user. Four associated switches (Menu, Up, Down, and Select) are used to gain access to the information and in some cases
to control the MSRx Charge Controller operation.
The MSRx display has a power down feature, which operates 4 minutes after the last press of any switch. The display is
re-activated by pressing any switch.
4.1. MSRx Menu Guide

The MSRx display has multiple menus and information screens as shown in Figure 1. The function of each screen is
explained over the following pages. The Menu switch is used to move from one menu to the next in the sequence 0
? 1 ? 2 ? 3 ? 4 ? 5 ? 0. The Up and Down switches are used to navigate through the screens of each menu.
The Select switch is used when instructed.
Menu 0 Menu 1 Menu 2 Menu 3 Menu 4 Menu 5

Menu Menu Menu Menu Menu Menu
BATTERY: XX.XV SYSTEM INFO: SYSTEM SETTINGS: TEST HV ALARM: SHOW ARRAY 1 V: SHOW ARRAY 1 I:
Mode - Boost 12V NEG Earth Boost V: XX.X Press + hold SEL Press + hold SEL Press + hold SEL
Up Down Up Down Up Down Up Down Up Down
BATTERY: XX.XV SYSTEM INFO: SYSTEM SETTINGS: TEST LV ALARM: SHOW ARRAY 2 V: SHOW ARRAY 2 I:
Mode - Equal Batt Temp:+XX.XC Float V: XX.X Press + hold SEL Press + hold SEL Press + hold SEL
BATTERY: XX.XV SYSTEM INFO: SYSTEM SETTINGS: TEST LC1 ALARM: SHOW ARRAY 3 V: SHOW ARRAY 3 I:
Mode - Float Array I: XXX Rst to Bst: XX.X Press + hold SEL Press + hold SEL Press + hold SEL
BATTERY: XX.XV SYSTEM INFO: SYSTEM SETTINGS: TEST LC2 ALARM: SHOW ARRAY 4 V: SHOW ARRAY 4 I:
Mode - Night Load I: XXX Hi V Set V: XX.X Press + hold SEL Press + hold SEL Press + hold SEL
BATTERY: XX.XV SYSTEM INFO: SYSTEM SETTINGS: TEST SN ALARM: SHOW ARRAY 5 V: SHOW ARRAY 5 I:
Mode - Disabled Batt I: XXX Hi V Rst V: XX.X Press + hold SEL Press + hold SEL Press + hold SEL
BATTERY: XX.XV SYSTEM INFO: SYSTEM SETTINGS: TEST AF ALARM: SHOW ARRAY 6 V: SHOW ARRAY 6 I:
Alarm - Hi Volts Array AHr: XXXXXX Lo V Set V: XX.X Press + hold SEL Press + hold SEL Press + hold SEL
BATTERY: XX.XV SYSTEM INFO: SYSTEM SETTINGS: TEST LOAD 1 Sw: SHOW ARRAY 7 V: SHOW ARRAY 7 I:
Alarm - Lo Volts Load AHr: XXXXXX Lo V Rst V: XX.X Press + hold SEL Press + hold SEL Press + hold SEL
BATTERY: XX.XV SYSTEM INFO: SYSTEM SETTINGS: TEST LOAD 2 Sw: SHOW ARRAY 8 V: SHOW ARRAY 8 I:
Alarm - Ld Cut 1 E/Time Hr: XXXXXX LC1 Set V: XX.X Press + hold SEL Press + hold SEL Press + hold SEL
Up Down Up Down Up Down
BATTERY: XX.XV SYSTEM INFO: SYSTEM SETTINGS: TEST ARRAY 1 Sw:

Alarm - Ld Cut 2 Reset AHr -> SEL LC1 Rst V: XX.X Press + hold SEL

Alarm - AYX Fail Reset Alms-> SEL LC2 Set V: XX.X Press + hold SEL

Fault - BY Sense Total Hr: XXXXXX LC2 Rst V: XX.X Press + hold SEL

Fault - Temp Sen Prog XXXXXX VX.X LC1 Delay: XXsec Press + hold SEL
Up Down Up Down
BATTERY: XX.XV SYSTEM SETTINGS: TEST ARRAY 5 Sw:

Arrays: 00000000 LC2 Delay: XXsec Press + hold SEL
Up Down Up Down
SYSTEM SETTINGS: TEST ARRAY 6 Sw:

Equalisation XXm Press + hold SEL
Up Down Up Down
SYSTEM SETTINGS: TEST ARRAY 7 Sw:

No of Arrays: X Press + hold SEL
Up Down
TEST ARRAY 8 Sw:

Press + hold SEL
Figure 1

Product Manual
4.2. Menu 0 – Status
Menu 0 displays the present Regulation Mode of the MSRx Charge Controller as well as Alarms and Faults. The
change of display is automatic for all screens with the exception of Screen 12.
If the unit is in the Disable Mode (user selected by jumper link on the MSRx PSU/Load PCB Assembly) then Screen
4 will be displayed.
When the unit is not in Disable Mode:
If there are no Alarms or Faults to be displayed, then the display will show one of the four possible Regulation
Modes (Screens 0-3). If there is an Alarm active, it will be displayed instead of the Regulation Mode (Screens 5-8)
with the last Alarm to activate being displayed. If there is a Fault active, it will be displayed instead of the
Regulation Mode or Alarm (Screens 9-11).
Pressing the Up or Down switches while in Menu 0 will show the Array Switch Status (Screen 12). This screen
indicates whether the Array Switch is connected (=0) or disconnected (=1) from the battery. Reading left to right the
display indicates Arrays: 12345678 (depending on unit).
Menu 0 Screen Description
BATTERY: XX.XV Screen 0 Present Regulation Mode = Boost Mode

Mode - Boost (Unit will regulate to Boost Voltage)
BATTERY: XX.XV Screen 1 Present Regulation Mode = Equalisation Mode

Mode - Equal (Unit will regulate to Boost Voltage for Equalisation Period)
BATTERY: XX.XV Screen 2 Present Regulation Mode = Float Mode

Mode - Float (Unit will regulate to Float Voltage)
BATTERY: XX.XV Screen 3 Present Regulation Mode = Night Mode

Mode - Night (No Arrays ready for charging)
BATTERY: XX.XV Screen 4 Present Regulation Mode = Disabled

Mode - Disabled (Arrays and Loads disconnected from the Battery)
BATTERY: XX.XV Screen 5 High Volts Alarm active

Alarm - Hi Volts
BATTERY: XX.XV Screen 6 Low Volts Alarm active

Alarm - Lo Volts
BATTERY: XX.XV Screen 7 Load Cut 1 Alarm active

Alarm - Ld Cut 1 (Load 1 Disconnected after delay)
BATTERY: XX.XV Screen 8 Load Cut 2 Alarm active

Alarm - Ld Cut 2 (Load 2 Disconnected after delay)
BATTERY: XX.XV Screen 9 Array X Failure

Alarm - AYX Fail (No Array voltage sufficient for charging for Array Fail Period)
BATTERY: XX.XV Screen 10 Battery Sense Fault

Fault - BY Sense (The Battery Sense is disconnected or faulty)
BATTERY: XX.XV Screen 11 Temperature Sensor Fault

Fault - Temp Sen (The Temperature Sensor is disconnected or faulty)
BATTERY: XX.XV Screen 12 Press Up or Down switches to see the Array Switch Status
Arrays: 00000000 (0 = disconnected 1 = connected)

Product Manual
4.3. Menu 1 – System Information
Menu 1 is entered from any screen of Menu 0 by pressing the Menu switch.
Menu 1 allows the user to view System Information by pressing the Up and Down switches: System Voltage and
System Polarity, Temperature, Array Current, Load Current, Battery Current (by calculation), Array AHrs, Load
AHrs, Elapsed Time, and the software program version number. It is possible to reset either Load Cut conditions
and to reset the AHrs memory.
If Array AHr or Load AHr rolls over 999999 to 000000, the unit will reset the other one and the Elapsed Time
counter.
SYSTEM INFO: Screen 0 System Voltage: 12V / 24V / 36V / 48V

12V NEG Earth System Polarity: POS = Positive Earth / NEG = Negative Earth
SYSTEM INFO: Screen 1 Temperature Sensed by Temperature Sensor

Batt Temp:+XX.XC (A faulty or disconnected sensor will display “---.-C”)
SYSTEM INFO: Screen 2 Total Array Current

Array I: XXXA (Measured across Array Shunt)
SYSTEM INFO: Screen 3 Total Load Current

Load I: XXXA (Measured across Load Shunt)
SYSTEM INFO: Screen 4 Total Battery Current

Batt I: XXXA (Calculated from Array-Load Current)
SYSTEM INFO: Screen 5 Array Current Ampere-Hours

Array AHr: XXXXXA (since last Ampere-Hour reset)
SYSTEM INFO: Screen 6 Load Current Ampere-Hours

Load AHr: XXXXXA (since last Ampere-Hour reset)
SYSTEM INFO: Screen 7 Elapsed Time

E/Time Hr: XXXXXX (since last Ampere-Hour reset)
SYSTEM INFO: Screen 8 Reset Ampere-Hours Counters

Reset AHr -> SEL (Press Select to reset both Array and Load Current Ampere-Hours)
SYSTEM INFO: Screen 9 Reset Load Cut 1 - (Press Select to reset if the battery voltage is above
Reset LC1 -> SEL the trip voltage but below the reset voltage)
SYSTEM INFO: Screen 10 Reset Load Cut 2 - (Press Select to reset if the battery voltage is above
Reset LC2 -> SEL the trip voltage but below the reset voltage)
SYSTEM INFO: Screen 11 Program Filename and Version Number

Prog XXXXXX VX.X

Product Manual
4.4. Menu 2 – System Settings
Menu 2 allows the user to view System Settings by pressing the Up and Down switches: Boost Voltage, Float
Voltage, Reset to Boost Voltage, High Volts Set Voltage, High Volts Reset Voltage, Low Volts Set Voltage, Low
Volts Reset Voltage, Load Cut 1 Set Voltage, Load Cut 1 Reset Voltage, Load Cut 2 Set Voltage, Load Cut 2 Reset
Voltage, Load Cut 1 Delay, Load Cut 2 Delay, Equalisation Period and Number of Arrays.
SYSTEM SETTINGS: Screen 0 Boost Regulation Voltage Set-point

Boost V: XX.X
SYSTEM SETTINGS: Screen 1 Float Regulation Voltage Set-point

Float V: XX.X
SYSTEM SETTINGS: Screen 2 Reset to Boost Voltage

Rst to Bst: XX.X
SYSTEM SETTINGS: Screen 3 High Volts Alarm Trip Voltage Set-point

Hi V Set V: XX.X
SYSTEM SETTINGS: Screen 4 High Volts Alarm Reset Voltage Set-point

Hi V Rst V: XX.X
SYSTEM SETTINGS: Screen 5 Low Volts Alarm Trip Voltage Set-point

Lo V Set V: XX.X
SYSTEM SETTINGS: Screen 6 Low Volts Alarm Reset Voltage Set-point

Lo V Rst V: XX.X
SYSTEM SETTINGS: Screen 7 Load Cut 1 Alarm Trip Voltage Set-point

LC1 Set V: XX.X
SYSTEM SETTINGS: Screen 8 Load Cut 1 Alarm Reset Voltage Set-point

LC1 Rst V: XX.X
SYSTEM SETTINGS: Screen 9 Load Cut 2 Alarm Trip Voltage Set-point

LC2 Set V: XX.X
SYSTEM SETTINGS: Screen 10 Load Cut 2 Alarm Reset Voltage Set-point

LC2 Rst V: XX.X
SYSTEM SETTINGS: Screen 11 Load Cut 1 Delay Period

LC1 Delay: XXsec (Load is cut after the alarm is activated)
SYSTEM SETTINGS: Screen 12 Load Cut 2 Delay Period

LC2 Delay: XXsec (Load is cut after the alarm is activated)
SYSTEM SETTINGS: Screen 13 Equalisation Period

Equalisation XXm
SYSTEM SETTINGS: Screen 14 Number of Arrays in the MSRx unit

No of Arrays: X (MSRx2 = 2, MSRx4 = 4, MSRx6 = 6, MSRx8 = 8)

Product Manual
4.5. Menu 3 - Test
Menu 3 allows the user to test the Alarm relays, the Load solid-state switches and the Array solid-state switches.
The Up and Down switches allow the user to choose the test, and the Select switch changes the present state of the
alarm or solid-state switch.
CAUTION: When testing the Load Switches, power to the Load will be removed or applied by the test.
Screens 7-14 will only be accessible depending on the Number of Arrays in the system.
TEST HV ALARM: Screen 0 Test High Volts Alarm indicator and relay
Press + hold SEL (Press Select to toggle the state of the alarm)
TEST LV ALARM: Screen 1 Test Low Volts Alarm indicator and relay
TEST LC1 ALARM: Screen 2 Test Load Cut 1 Alarm indicator and relay
TEST LC2 ALARM: Screen 3 Test Load Cut 2 Alarm indicator and relay
TEST SN ALARM: Screen 4 Test System Nornal Alarm indicator and relay
TEST AF ALARM: Screen 5 Test Array Failure Alarm indicator and relay
TEST LOAD 1 Sw: Screen 6 Test Load 1 solid-state switch

Press + hold SEL (Press Select to toggle the state of the switch – see Caution above)
TEST LOAD 2 Sw: Screen 7 Test Load 2 solid-state switch

Press + hold SEL (Press Select to toggle the state of the switch – see Caution above)
TEST ARRAY 1 Sw: Screen 8 Test Array 1 solid-state switch

Press + hold SEL (Press Select to toggle the state of the switch)








Product Manual
4.6. Menu 4 – Array Voltages
Menu 4 allows the user to view the open circuit array voltages. The Up and Down switches allow the user to select
the required array.
NOTE: In order to measure the open-circuit voltage on any Array, the MSRx unit needs to turn off the Array solid-
state switch to disconnect it from the battery. When the Select switch is pressed, the Array Switch is turned off and
the voltage measured.
Screens 0-7 will only be accessible depending on the Number of Arrays in the system. For example, an MSRx4 will
only access Screens 0-4.
NOTE: An array voltage will be measured correctly only when there is an array module connected to the
array input, and the array input MCB is turned on.
SHOW ARRAY 1 V: Screen 0 Show Array 1 open-circuit array voltage

Press + hold SEL (Press Select to show the voltage)








Product Manual
4.7. Menu 5 – Array Currents
Menu 5 allows the user to view the Array current flowing from each array. The Up and Down switches allow the
user to select the required array.
NOTE: In order to measure an individual Array current, the MSRx unit will turn on that individual Array Switch to
connect it to the Battery and it will turn off all the other Array Switches, which will disconnect them from the
Battery. This happens only when the Select switch is pressed.
Screens 0-7 will only be accessible depending on the Number of Arrays in the system. For example, an MSRx4 will
only access Screens 0-4.
SHOW ARRAY 1 I: Screen 0 Show Array 1 Current

Press + hold SEL (Press Select to show the current)








Product Manual
4.8. Change Settings Menus
The Change Settings Menus (see next page) exist to allow an authorised user to change the settings of the unit in the
field. The Change Settings Menus can only be entered by doing the following:
Insert the jumper link on LK1 (MSRx PSU/Load PCB Assembly) in the Disable position, hold the Menu, Up and
Down switches pressed and press the Select switch.
4.8.1. Range of Settings
The Change Settings Menu allows the user to change the following settings:
Menu 6: Boost Voltage, Float Voltage, Reset to Boost Voltage, High Volts Set Voltage, High Volts Reset
Voltage, Low Volts Set Voltage, Low Volts Reset Voltage, Load Cut 1 Set Voltage, Load Cut 1 Reset
Voltage, Load Cut 2 Set Voltage, Load Cut 2 Reset Voltage, Load Cut 1 Delay Period, Load Cut 2 Delay
Period, Equalisation Period, Number of Arrays
Menu 7: Temperature Compensation Null Temperature, Temperature Compensation Rate, Load Shunt
Value (60, 100, 150A), Array Fail Period (Hours), and Array Failure feature Enable/Disable for each Array
(OFF = Array Failure feature for that array input is disabled, ON = Array Failure feature for that array input
is enabled).
Menu 8: Accept the changed settings, Re-program factory defaults into the unit.
4.8.2. Changing Settings
The Menu, Up and Down switches are used to select the setting to be changed. Then the Select switch is
pressed and the value will flash. The Up and Down switches are used to vary the value. The Select switch
is pressed and the value will stop flashing. The Menu, Up and Down switches can be used again to select a
setting to be changed or to navigate to the “Accept?” screen.
4.8.3. Accepting Changes to Settings
In order to remember the new settings, the user must navigate to the “Accept ?” screen and press the Select
switch. The unit will not remember any changes to settings unless they are accepted by using this screen.
4.8.4. Default Settings
The Change Settings Menu allows the user to reset all the settings back to one of three default settings:
Default 1 = Fulmen Battery Settings
Default 2 = Vented Cell Battery Settings
Default 3 = VRLA Cell Battery Settings
4.8.5. Exiting the Change Settings Menus
By pressing the Menu switch when looking at one of the Menu 8 screens, the user can exit the Change
Settings Menus without making any changes. The user is taken back to Menu 0.
If changes are made and accepted using the Accept screen then the user is automatically taken back to
Menu 0.
If any of the Default Settings are selected, the user is automatically taken back to Menu 0.

Product Manual
4.8.6. Changing Settings Menus - Diagram
Menu 6 Menu 7 Menu 8

Menu Menu Menu
CHANGE SETTINGS: CHANGE SETTINGS: CHANGE SETTINGS:
Boost V: XX.X Temp Null: XXC Accept ? -> SEL

Float V: XX.X Temp Rate: -X.XmV Def Val 1 -> SEL

Rst to Bst: XX.X Ld Shunt = XXXA Def Val 2 -> SEL

Hi V Set V: XX.X LC1 & LC2: DIFF Def Val 3 -> SEL
Up Down Up Down
CHANGE SETTINGS: CHANGE SETTINGS:

Hi V Rst V: XX.X AY Fail Time XXH
Up Down Up Down

Lo V Set V: XX.X AY1 Fail = OFF
Up Down Up Down

Lo V Rst V: XX.X AY2 Fail = OFF
Up Down Up Down

LC1 Set V: XX.X AY3 Fail = OFF
Up Down Up Down

LC1 Rst V: XX.X AY4 Fail = OFF
Up Down Up Down

LC2 Set V: XX.X AY5 Fail = OFF
Up Down Up Down

LC2 Rst V: XX.X AY6 Fail = OFF
Up Down Up Down

LC1 Delay: XXsec AY7 Fail = OFF
Up Down Up Down

LC2 Delay: XXsec AY8 Fail = OFF
Up Down
CHANGE SETTINGS:
Equalisation XXm
Up Down
CHANGE SETTINGS:
No of Arrays: X

Product Manual
4.9. MSRx Charge Controller Set-points for FULMEN Batteries (Default Values 1)
Controller Set-points Volts / Cell 12V System 24V System 48V System
Boost & Equalise Regulation Voltage 2.45 V 14.70 ± 0.12V 29.40 ± 0.24V 58.80 ± 0.48V
Float Regulation Voltage 2.30 V 13.80 ± 0.12V 27.60 ± 0.24V 55.20 ± 0.48V
Reset to Boost Voltage 2.20 V 13.20 ± 0.12V 26.40 ± 0.24V 52.80 ± 0.48V
High Volts Alarm Trip Voltage 2.50 V 15.00 ± 0.12V 30.00 ± 0.24V 60.00 ± 0.48V
High Volts Alarm Reset Voltage 2.30 V 13.80 ± 0.12V 27.60 ± 0.24V 55.20 ± 0.48V
Low Volts Alarm Trip Voltage 1.95 V 11.70 ± 0.12V 23.40 ± 0.24V 46.80 ± 0.48V
Low Volts Alarm Reset Voltage 2.30 V 13.80 ± 0.12V 27.60 ± 0.24V 55.20 ± 0.48V
Load Cut 1 Alarm Trip Voltage 1.90 V 11.40 ± 0.12V 22.80 ± 0.24V 45.60 ± 0.48V
Load Cut 1 Alarm Reset Voltage 2.15 V 12.90 ± 0.12V 25.80 ± 0.24V 51.60 ± 0.48V
Load Cut 1 Switch Delay N/A 60 seconds 60 seconds 60 seconds
Equalisation Time N/A 30 minutes 30 minutes 30 minutes
Temp Compensation Null Temp N/A 20 ºC 20 ºC 20 ºC
Temp Compensation Rate N/A -5.0mV / cell / ºC -5.0mV / cell / ºC -5.0mV / cell / ºC
4.10. MSRx Charge Controller Set-points for Vented Cell Batteries (Default Values 2)

Product Manual
4.11. MSRx Charge Controller Set-points for VRLA Cell Batteries (Default Values 3)

Product Manual
5. Installation
5.1. MSRx2 / MSRx4 Control Unit Mounting and Position

5.1.1. The MSRx2 and MSRx4 Charge Controllers consist of one Control Unit enclosure which should be
installed using one of the following schemes shown in the diagram below:
A – six mounting points hidden by the cover fixing screws
B – four mounting feet fitted horizontally
C – six mounting feet fitted vertically
5.1.2. Ensure that the surface to which the unit will be attached is flat.
5.1.3. Ensure that the fixing method employed is sturdy enough to support the weight of the Unit.
5.1.4. Position the unit so that it is shaded from direct sunlight, sheltered from extreme weather conditions and
oriented so that the cable glands are pointing downwards.
618.0 mm
600.0 mm
290.0 mm 290.0 mm 130.0 mm

C
C C Heatsink
B B
A A
A
318.0 mm
300.0 mm
280.0 mm
A
A A
B B
C C C
4.5 mm

Product Manual
5.2. MSRx6 / MSRx8 Expansion Unit Mounting and Position
5.2.1. The MSRx2 and MSRx4 Charge Controllers consist of one Control Unit enclosure which should be
installed using one of the following schemes shown in the diagram below:
A – four mounting points hidden by the cover fixing screws
B – four mounting feet fitted horizontally
C – four mounting feet fitted vertically
5.2.2. Ensure that the surface to which the unit will be attached is flat.
5.2.3. Ensure that the fixing method employed is sturdy enough to support the weight of the Unit.
5.2.4. Position the unit so that it is shaded from direct sunlight, sheltered from extreme weather conditions and
oriented so that the cable glands are pointing downwards.
418.0 mm
400.0 mm
380.0mm 130.0 mm
Heatsink
C C
B B
A A
318.0 mm
300.0 mm
280.0 mm
A A
B B
C C
4.5 mm
5.3. Equipment Suitability

5.3.1. Confirm that the System Voltage shown on the MSRx PSU Module (mounted on the MSRx PSU/Load PCB
Assembly) is as required.
5.3.2. Confirm that the System Polarity as shown on the Product Identification Label (on the mounting plate) is as
required:
Common Positive for a Positive Earth system
Common Negative for a Negative Earth system
5.3.3. Do not proceed unless 5.3.1 and 5.3.2 have been confirmed.

Product Manual
5.4. Electrical Connections
COMMON POSITIVE SYSTEM ONLY
CAUTION: SOLAR MODULES AND BATTERIES CAN HAVE POTENTIALLY LETHAL VOLTAGES
PRESENT AT THEIR TERMINALS AND PRESENT AN ENERGY HAZARD.
Ensure the Jumper Link LK1 on the MSRx PSU/Load PCB Assembly is fitted in the DISABLE position.
WARNING - RISK OF EXPLOSION:
The battery cable MUST be connected to the MSRx Control Unit BEFORE connecting to the battery
Make the electrical connections in the order shown in the following table:
COMMON POSITIVE SYSTEM ONLY

Connection 1st Location To Connection 2nd Location
BATT COM (+VE) MSRx Control Unit Battery Positive Terminal Battery
BATT LIVE (–VE) MSRx Control Unit Battery Negative Terminal Battery
Battery Sense BS+ MSRx PSU/Load PCB Battery Positive Terminal Battery
Battery Sense BS- MSRx PSU/Load PCB Battery Negative Terminal Battery
ARRAY 1 COM MSRx Control Unit Array Positive Terminal Array 1 Module
ARRAY 1 LIVE MSRx Control Unit Array Negative Terminal Array 1 Module
Load Positive Terminal Load 1 LOAD 1 COM MSRx Control Unit
Load Negative Terminal Load 1 LOAD 1 LIVE MSRx Control Unit
Load Positive Terminal Load 2 LOAD 2 COM MSRx Control Unit
Load Negative Terminal Load 2 LOAD 2 LIVE MSRx Control Unit
Red wire MSRx Temperature Sensor TEMP SENSE TS+ MSRx PSU/Load PCB
Black wire MSRx Temperature Sensor TEMP SENSE TS- MSRx PSU/Load PCB
High Volts Alarm Relay MSRx PSU/Load PCB Input Terminals Telemetry System
Low Volts Alarm Relay MSRx PSU/Load PCB Input Terminals Telemetry System
Load Cut 1 Alarm Relay MSRx PSU/Load PCB Input Terminals Telemetry System

Product Manual
5.5. Electrical Connections
COMMON NEGATIVE SYSTEM ONLY
CAUTION: SOLAR MODULES AND BATTERIES CAN HAVE POTENTIALLY LETHAL VOLTAGES
PRESENT AT THEIR TERMINALS AND PRESENT AN ENERGY HAZARD.
Ensure the Jumper Link LK1 on the MSRx PSU/Load PCB Assembly is fitted in the DISABLE position.
WARNING - RISK OF EXPLOSION:
The battery cable MUST be connected to the MSRx Control Unit BEFORE connecting to the battery
Make the electrical connections in the order shown in the following table:
COMMON NEGATIVE SYSTEM ONLY

Connection 1st Location To Connection 2nd Location
BATT COM (-VE) MSRx Control Unit Battery Negative Terminal Battery
BATT LIVE (+VE) MSRx Control Unit Battery Positive Terminal Battery
Battery Sense BS+ MSRx PSU/Load PCB Battery Positive Terminal Battery
Battery Sense BS- MSRx PSU/Load PCB Battery Negative Terminal Battery
ARRAY 1 COM MSRx Control Unit Array Negative Terminal Array 1 Module
ARRAY 1 LIVE MSRx Control Unit Array Positive Terminal Array 1 Module
Load Negative Terminal Load 1 LOAD 1 COM MSRx Control Unit
Load Positive Terminal Load 1 LOAD 1 LIVE MSRx Control Unit
Load Negative Terminal Load 2 LOAD 2 COM MSRx Control Unit
Load Positive Terminal Load 2 LOAD 2 LIVE MSRx Control Unit
Red wire MSRx Temperature Sensor TEMP SENSE TS+ MSRx PSU/Load PCB
Black wire MSRx Temperature Sensor TEMP SENSE TS- MSRx PSU/Load PCB
High Volts Alarm Relay MSRx PSU/Load PCB Input Terminals Telemetry System
Low Volts Alarm Relay MSRx PSU/Load PCB Input Terminals Telemetry System

Product Manual
5.6. MSRx Charge Controller Enable
To enable the MSRx Charge Controller, ensure Jumper Link LK1 on the MSRx PSU/Load PCB Assembly is fitted
in the ENABLE position.
5.7. MSRx Charge Controller MCBs
Ensure the Array MCBs (if fitted) are set to their ON positions to allow the arrays to charge the battery.
Ensure the Load MCBs (if fitted) are set to their ON positions to allow the battery to supply current to the load.
5.8. Battery Temperature
To ensure the Battery Temperature Compensation is as accurate as possible, proceed with the following instructions
after the temperature of the batteries has stabilised:
5.8.1. Using the user switches (Menu, Up, Down and Select), navigate to the Battery Temperature screen (Menu
1, Screen 1).
5.8.2. Use a small flat screwdriver to adjust the potentiometer VR1 on the MSRx PSU/Load PCB Assembly (just
above the Temperature Sensor connection terminals) so that the temperature shown on display is the same
as the actual temperature as measured at the battery with a calibrated temperature meter.

Product Manual
6. Re-Configuring the MSRx Charge Controller
6.1. System Voltage

6.1.1. The MSRx Charge Controller requires a power supply module suitable for the system voltage. The
following table lists the appropriate MSRx PSU Module PCB Assemblies for the different system voltages.
System Voltage Description Micha Part Number

12V MSRx 12V PSU Module PCB Assembly 400 501
To change from one system voltage to another:

6.1.2. Disconnect Battery Sense connections from the battery
6.1.3. Disconnect Battery Power connections from the battery
6.1.4. Remove the existing MSRx PSU Module PCB Assembly, which is installed on the MSRx PSU/Load PCB
Assembly, by removing the two nylon nuts securing the Module in place.
6.1.5. Install the replacement MSRx PSU Module PCB Assembly making sure that the connector mates properly
with the header on the MSRx PSU/Load PCB Assembly, and secure the Module with the two nylon nuts.
6.1.6. The MSRx Charge Controller automatically senses the change of system voltage.

Product Manual
6.2. System Polarity
6.2.1. The MSRx Charge Controller requires minimal changes to configure the system for Common Positive or
Common Negative use. The unit will be supplied as requested in the customer order for one polarity or the
other. If it becomes necessary to re-configure the unit, proceed with the following instructions:
To change from Common Positive to Common Negative
6.2.2. The unit MUST be completely disconnected from any external electrical connections.
6.2.3. Identify the cable that is connected from LOAD 1 LIVE (MCB5) to the MSRx PSU/Load PCB Assembly –
it is connected via a ring crimp to J1 (also labelled “SHUNT NE”). Disconnect this cable from J1.
6.2.4. On the MSRx PSU/Load PCB Assembly, disconnect the cable from J2 (also labelled “SHUNT PE”) and
connect it to J1.
6.2.5. Reconnect the cable from LOAD 1 LIVE (MCB5) to J2 on the MSRx PSU/Load PCB Assembly.
it is connected via a ring crimp to J3 (also labelled “SHUNT NE”). Disconnect this cable from J3.
6.2.7. On the MSRx PSU/Load PCB Assembly, disconnect the cable from J4 (also labelled “SHUNT PE”) and
connect it to J3.
6.2.9. On the MSRx Control Unit, remove the label that is mounted below the main battery terminals (by
removing the four 2-part black plastic rivets holding it in place), turn it over (to show the negative common
connections) and replace. Repeat for the MSRx Expansion Unit if used in this application.
6.2.10. On the MSRx PSU/Load PCB Assembly, change the position of switch SW1 to the NE position.
6.2.11. The unit is now configured for Common Negative use (the MSRx Charge Controller automatically senses
the change of system polarity).
To change from Common Negative to Common Positive

6.2.12. The unit MUST be completely disconnected from any external electrical connections.
it is connected via a ring crimp to J2 (also labelled “SHUNT PE”). Disconnect this cable from J2.
6.2.14. On the MSRx PSU/Load PCB Assembly, disconnect the cable from J1 (also labelled “SHUNT NE”) and
connect it to J2.
it is connected via a ring crimp to J4 (also labelled “SHUNT PE”). Disconnect this cable from J4.
6.2.17. On the MSRx PSU/Load PCB Assembly, disconnect the cable from J3 (also labelled “SHUNT NE”) and
connect it to J4.
6.2.19. On the MSRx Control Unit, remove the label that is mounted below the main battery terminals (by
removing the four 2-part black plastic rivets holding it in place), turn it over (to show the positive common
connections) and replace. Repeat for the MSRx Expansion Unit if used in this application.
6.2.20. On the MSRx PSU/Load PCB Assembly, change the position of switch SW1 to the PE position.
6.2.21. The unit is now configured for Common Positive use (the MSRx Charge Controller automatically senses the
change of system polarity).

Product Manual
7. Troubleshooting Guide
Situation Description Action

The display in inactive The MSRx display powers down after 4 Press any key to activate the display
minutes from the last user switch press
The display indicates: The Battery Sense connections are not Check the Battery Sense connections
made correctly
“Fault - BY Sense”
The display indicates: The Temperature Sensor connections are Check the Temperature Sensor
not made correctly connections
“Fault – Temp Sen”
8. Software History
Filename Version Date Released Comments

Number
800532-B V0.2 25-Jul-2001 First Issue of software
800532-C V1.0 29-Nov-2001 Added 36V PSU Module recognition and operation
Added Array Failure Alarm driver and Relay Test Screen.
Added Load Shunt selection and AHr Elapsed Time
RS232 output expanded to include extra features
800532-E V2.0 26-Mar-2002 Load Cut 1 & 2 Switch Delay default time = 60 seconds
Added System Normal Alarm driver and Relay Test Screen.
Added System Normal and Array Failure Relay drivers
Added absolute limits to all Voltage setpoints:
Minimum = 0.75 x Nominal System Voltage
Maximum = 1.50 x Nominal System Voltage
Added Total Controller Run Time to Menu 1
Added LC1 & LC2 settings different/same feature to Menu 7
Changed Reset LC1 and Reset LC2 to Reset all Alarms in Menu 1

MSRX Polycarbonate Enclosure Charge Controller: Product Manual

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MSRx Polycarbonate Enclosure

2. HEALTH & SAFETY.........................................................................................................................................................4

3. MSRX CONTROL UNIT OPERATION ...........................................................................................................................5

4. MSRX LCD DISPLAY AND CONTROL .........................................................................................................................7

6. RE-CONFIGURING THE MSRX CHARGE CONTROLLER .......................................................................................23

7. TROUBLESHOOTING GUIDE ......................................................................................................................................25

MF/27th March 2002/Issue C Page 2 of 25 The Micha Design Company Ltd

MSRx2 MSRx4 MSRx6 MSRx8

1.1. Standard Features of the MSRx Charge Controller

MF/27th March 2002/Issue C Page 3 of 25 The Micha Design Company Ltd

MF/27th March 2002/Issue C Page 4 of 25 The Micha Design Company Ltd

3.1. Analogue Measurements

MF/27th March 2002/Issue C Page 5 of 25 The Micha Design Company Ltd

Mode Status LED Operation

3.5. Power Up Sequence

BATTERY: XX.XV Menu 0 Present Regulation Mode = Disabled

MF/27th March 2002/Issue C Page 6 of 25 The Micha Design Company Ltd

4.1. MSRx Menu Guide

Menu 0 Menu 1 Menu 2 Menu 3 Menu 4 Menu 5

BATTERY: XX.XV SYSTEM INFO: SYSTEM SETTINGS: TEST ARRAY 1 Sw:

BATTERY: XX.XV SYSTEM INFO: SYSTEM SETTINGS: TEST ARRAY 2 Sw:

BATTERY: XX.XV SYSTEM INFO: SYSTEM SETTINGS: TEST ARRAY 3 Sw:

BATTERY: XX.XV SYSTEM INFO: SYSTEM SETTINGS: TEST ARRAY 4 Sw:

BATTERY: XX.XV SYSTEM SETTINGS: TEST ARRAY 5 Sw:

SYSTEM SETTINGS: TEST ARRAY 6 Sw:

SYSTEM SETTINGS: TEST ARRAY 7 Sw:

TEST ARRAY 8 Sw:

MF/27th March 2002/Issue C Page 7 of 25 The Micha Design Company Ltd

Menu 0 Screen Description

BATTERY: XX.XV Screen 0 Present Regulation Mode = Boost Mode

BATTERY: XX.XV Screen 1 Present Regulation Mode = Equalisation Mode

BATTERY: XX.XV Screen 2 Present Regulation Mode = Float Mode

BATTERY: XX.XV Screen 3 Present Regulation Mode = Night Mode

BATTERY: XX.XV Screen 4 Present Regulation Mode = Disabled

BATTERY: XX.XV Screen 5 High Volts Alarm active

BATTERY: XX.XV Screen 6 Low Volts Alarm active

BATTERY: XX.XV Screen 7 Load Cut 1 Alarm active

BATTERY: XX.XV Screen 8 Load Cut 2 Alarm active

BATTERY: XX.XV Screen 9 Array X Failure

BATTERY: XX.XV Screen 10 Battery Sense Fault

BATTERY: XX.XV Screen 11 Temperature Sensor Fault

MF/27th March 2002/Issue C Page 8 of 25 The Micha Design Company Ltd

Menu 1 Screen Description

SYSTEM INFO: Screen 0 System Voltage: 12V / 24V / 36V / 48V

SYSTEM INFO: Screen 1 Temperature Sensed by Temperature Sensor

SYSTEM INFO: Screen 2 Total Array Current

SYSTEM INFO: Screen 3 Total Load Current

SYSTEM INFO: Screen 4 Total Battery Current

SYSTEM INFO: Screen 5 Array Current Ampere-Hours

SYSTEM INFO: Screen 6 Load Current Ampere-Hours

SYSTEM INFO: Screen 7 Elapsed Time

SYSTEM INFO: Screen 8 Reset Ampere-Hours Counters

SYSTEM INFO: Screen 11 Program Filename and Version Number

MF/27th March 2002/Issue C Page 9 of 25 The Micha Design Company Ltd

Menu 2 Screen Description

SYSTEM SETTINGS: Screen 0 Boost Regulation Voltage Set-point

SYSTEM SETTINGS: Screen 1 Float Regulation Voltage Set-point

SYSTEM SETTINGS: Screen 2 Reset to Boost Voltage

SYSTEM SETTINGS: Screen 3 High Volts Alarm Trip Voltage Set-point

SYSTEM SETTINGS: Screen 4 High Volts Alarm Reset Voltage Set-point

SYSTEM SETTINGS: Screen 5 Low Volts Alarm Trip Voltage Set-point

SYSTEM SETTINGS: Screen 6 Low Volts Alarm Reset Voltage Set-point