MSR1-10 Charge Controller

Part Number: 102449

Product Manual

Issue 1
Micha Design MSR1-10 Charge Controller 801973-1.doc
Product Manual
1. Introduction

The MSR1-10 Charge Controller is 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 MSR1-10 Charge Controller uses fully solid-state switching of Array (charge) and Load (discharge) current and
combines 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.

1.1. Technical Specification

Operating Voltage Range 24VDC nominal (18-36VDC)

System Polarity Common Negative
Operating Temperature Range 0-65C
Array Input 1 Array Input rated at 10A continuously (Solid-State MOSFET technology)
Load Output 1 Load Output rated at 5A continuously (Solid-State MOSFET technology)
Battery Regulation 3-Stage Regulation: Boost, Equalisation, Float
Battery Voltage Sense Best accuracy using remote battery sense cables
Battery Settings User Programmable
Temperature Compensation Optional using MSR Temperature Sensor
Alarm Relays 4 Programmable Alarm Relays with LEDs and volt-free changeover contacts
User Display 2 x 16 character LCD Display (High Temperature)
User Control 4 button keypad – Menu, Up, Down, Select
Quiescent Current 15mA at 24VDC (0.36W)
Induced Lightning Protection Metal Oxide Varistors on Battery, Array, Load connections
Battery, Array, Load Connections PCB Terminals - 10mm2 cable entry
Alarm Connections PCB 2-part Terminals – 2.5mm2 cable entry
Dimensions 235mm x 120mm x 55mm
Weight 530g (including DIN rail carrier and fascia cover)
Mounting Carrier to fix to 35mm DIN rail

1.1. Installation
The unit is designed to be mounted within an appropriate enclosure for the environment.
1.2. Connections to be made in this order:
1.2.1. Battery Power Connection (power cables to the battery)
1.2.2. Battery Sense Connection (2-core screened twisted pair connected to the battery)
1.2.3. Temperature Sensor (locate the sensor in the battery enclosure or attached to one pole of the battery)
1.2.4. Array Connection
1.2.5. Load Connection
1.2.6. Alarm Signals

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2. Operation

The MSR1-10 Charge Controller uses a microprocessor to provide control and diagnostic features in the unit. A 2x16
alphanumeric LCD Display is used to indicate parameters and set-points as described below. The following diagram
describes the various screens available to the user:
Controller Menu Guide:

Menu 0 Menu 1 Menu 2 Menu 3 Menu 4 Menu 5 Menu 6

Menu Menu Menu Menu Menu Menu Menu Menu
**** Menu 0 **** **** Menu 1 **** **** Menu 2 **** **** Menu 3 **** **** Menu 4 **** **** Menu 5 **** **** Menu 6 ****
Information Utilities Batt Regulation Alarm Settings Relay Functions Array/Load Tests Time Settings
Up Down Up Down Up Down Up Down Up Down Up Down Up Down

Batt:24.5V +1.2A Reset any Active Boost Regulation High Volts Alarm Relay 1 Function Show Array 1 V: Day Number: 1234
Mode/Alarms Alarms: --> Sel Voltage: 28.8V Set V: 29.4V High Volts Alarm Press --> Select Time: 12:34:56
Up Down Up Down Up Down Up Down Up Down Up Down Up Down

Battery I: 12.3A Test Mode: Equal Regulation High Volts Alarm Test Relay 1 Show Array 1 I: Set Day No: 1234
Battery T: 25°C Disabled Time: 30mins Reset V: 28.8V Press --> Select Press --> Select Time: 12:34:56
Up Down Up Down Up Down Up Down Up Down Up Down Up Down

Array I: 0.0A Auxiliary Input: Float Regulation Low Volts Alarm: Relay 2 Function Test Array 1 Sw: Set Time: 1234
Array Ah: 0 Theft Alarm Voltage: 28.2V Set V: 22.8V Low Volts Alarm Press --> Select Hours: 12:34:56
Up Down Up Down Up Down Up Down Up Down Up Down Up Down

Load I: 0.0A Initial Charge: Reset to Boost Low Volts Alarm: Test Relay 2 Test Load 1 Sw: Set Time: 1234
Load Ah: 0 Array Ah: Voltage: 26.4V Reset V: 24.0V Press --> Select Press --> Select Minutes 12:34:56
Up Down Up Down Up Down Up Down Up Down

Ah Time: 0 Initial Charge Regulation Load Cut Alarm: Relay 3 Function

Run Time: 0 Function: Hysterisis:0.30V Set V: 22.2V Load Cut Alarm
Up Down Up Down Up Down Up Down Up Down

MSR1-10 24V Array Failure Temperature Comp Load Cut Alarm: Test Relay 3
Common Negative Time: 48hours Null Temp: 25°C Reset V: 24.0V Press --> Select
Up Down Up Down Up Down Up Down Up Down

Software: Array Failure Temperature Comp Load Switch Relay 4 Function

801705 Ver 1.0 Function:Disable Rate: -0.066V/°C Act Delay: 10s Theft Alarm
Up Down Up Down Up Down Up Down

Site Reference: Reset Ah Data: Battery Type: Test Relay 4

Press --> Select Vented Press --> Select
Up Down Up Down

Restore Battery Test Reg Mode:

Defaults --> Sel Night --> Select

2.1. Menu Navigation

Navigating the menus is done by using the Menu, Up and Down switches while the Select switch will activate
various functions. Pressing Menu and Down together will take the user back to Menu 0 Screen 0 (Home Screen).
Pressing the Menu switch at any screen in Menu 0 will change the display to show the top screen of Menu 1. In a
similar manner, the user can move to Menus 2, 3, 4 etc and back to Menu 0, by pressing the Menu switch
repeatedly.
The Up and Down Switches will move the user up and down within a menu.
2.2. Parameter and Set-point Adjustment
At the appropriate screen, press Select and the parameter will flash. Use the Up and Down switches to select the
desired value. Press Select again to accept and store the value in non-volatile memory.
2.3. Power Up Screen

LCD Display Screen Description

MSR1-10 Charge Screen 0 The Power Up Screen is shown for 2 seconds after power up
Controller

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2.4. Menu 0 – Information

LCD Display Screen Description

**** Menu 0 **** Screen 0 Menu Identifier (automatically goes to Screen 1 after 2 seconds)
Information

Batt:24.5V +1.2A Screen 1 Battery Voltage and Current (+ for charge, - for discharge)
Mode / Alarms
Present Regulation Mode & Alarms shown one after another

Battery I: +1.2A Screen 2 Battery Current

Battery T: 25oC
Battery Temperature

Array I: 10.0A Screen 3 Array Current

Array Ah: 0
Array Amp-hours

Load I: 5.0A Screen 4 Load Current

Load Ah: 0
Load Amp-hours

Ah Time: 0 Screen 5 Amp-hour Time

Run Time: 0
Total Run Time

MSR1-10 24V Screen 6 Unit Model Number, Voltage

Common Negative
System Polarity

Software: Screen 7 Unit Software Number and Version

801972 Ver 1.0

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2.5. Menu 1 – Utilities

LCD Display Screen Description

**** Menu 1 **** Screen 0 Menu Identifier

Utilities

Reset any Active Screen 1 Reset any Active Alarms

Alarms: --> Sel

Test Mode: Screen 2 Test Mode: Enable or Disable (Auto disable after 30 minutes)
Disabled
Test Mode: Array ready to charge / Equalisation Time = 30 seconds

Auxiliary Input: Screen 3 Auxiliary Input Function:

Not used
Not used / Theft Alarm / Disable Arrays & Loads

Initial Charge: Screen 4 Initial Charge Function:

Array Ah:
Unit will remain in boost until number of Ah of charge achieved

Initial Charge: Screen 5 Initial Charge Function:

Function:
Enable or Disable

Array Failure Screen 6 Array Failure Time:

Time: 48hours
Set the number of hours

Array 1 Failure Screen 7 Array Failure Function:

Function:Disable
Enable or Disable

Reset Ah Data: Screen 8 Reset Amp-hours data (and resets Amp-hour Time)
Press --> Select

2.5.1. Auxiliary Input Function = Theft Alarm

If the Auxiliary Input terminals are open circuit then the Theft Alarm is active
2.5.2. Auxiliary Input Function = Disable Ays,Lds
If the Auxiliary Input terminals are closed circuit on then disconnect the Array and Load from the Battery

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2.6. Menu 2 – Battery Regulation

LCD Display Screen Description

**** Menu 2 **** Screen 0 Menu Identifier

Batt Regulation

Boost Regulation Screen 1 Boost Regulation Voltage Set-point

Voltage: 28.8V

Equal Regulation Screen 2 Equalisation Regulation Time

Time: 30mins

Float Regulation Screen 3 Float Regulation Voltage Set-point

Voltage: 28.2V

Reset to Boost Screen 4 Reset to Boost Voltage Set-point

Voltage: 26.4V

Regulation Screen 5 Regulation Hysterisis

Hysterisis:0.30V

Temperature Comp Screen 6 Temperature Compensation Null Temperature

Null Temp: 25oC

Temperature Comp Screen 7 Temperature Compensation Rate (Volts per oC)

Rate: -0.066V/oC

Battery Type: Screen 8 Battery Type Selection:

VRLA
NiCd KL65 19cell, Vented, VRLA, Absolyte, Gel/OPzV

Restore Battery Screen 9 Restore the Battery Default Settings to the factory settings:
Defaults --> Sel
Press Select to restore Battery Defaults (see sections 2.7 & 2.9)

2.7. Battery Regulation Default Settings (selected in Menu 2 Screens 8 & 9)

Factory Default = VRLA Battery Settings (unless other battery settings are requested by the customer)

Regulation Setting NiCd 19cell Vented VRLA Absolyte Gel/OPzV

Boost Regulation Voltage 29.45V 28.8V 27.6V 28.2V 28.2V
Equalisation Time 30 mins 30 mins 30 mins 30 mins 30 mins
Float Regulation Voltage 27.0V 28.2V 27.0V 27.0V 27.3V
Reset to Boost Voltage 25.65V 26.4V 25.2V 25.2V 25.3V
Temperature Compensation Null °C 20°C 25°C 25°C 25°C 20°C
Temperature Compensation Rate -133mV/°C -132mV/°C -80mV/°C -72mV/°C -120mV/°C

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2.8. Menu 3 – Alarm Settings

LCD Display Screen Description

**** Menu 3 **** Screen 0 Menu Identifier

Alarm Settings

High Volts Alarm Screen 1 High Voltage Alarm Set (Trip) Voltage Set-point
Set V: 29.4V

High Volts Alarm Screen 2 High Voltage Alarm Reset Voltage Set-point
Reset V: 28.8V

Low Volts Alarm: Screen 3 Low Voltage Alarm Set (Trip) Voltage Set-point
Set V: 22.8V

Low Volts Alarm: Screen 4 Low Voltage Alarm Reset Voltage Set-point
Reset V: 24.0V

Load Cut Alarm: Screen 5 Load Cut Alarm Set (Trip) Voltage Set-point
Set V: 22.2V

Load Cut Alarm: Screen 6 Load Cut Alarm Reset Voltage Set-point
Reset V: 24.0V

Load Switch Screen 7 Load Switch Activation Delay Time (seconds)

Act Delay: 10s
(Time between the alarm being activated and the load being cut)

2.9. Alarm Default Settings (selected in Menu 2 Screens 8 & 9)

Factory Default = VRLA Battery Settings (unless other battery settings are requested by the customer)

Alarm Setting NiCd 19cell Vented VRLA Absolyte Gel/OPzV

High Volts Alarm Set Voltage 31.0V 29.4V 28.8V 29.4V 28.8V
High Volts Alarm Reset Voltage 27.0V 28.8V 28.2V 28.8V 25.8V
Low Volts Alarm Set Voltage 23.5V 22.8V 22.8V 23.4V 22.8V
Low Volts Alarm Reset Voltage 26.5V 24.0V 24.0V 27.6V 27.0V
Load Cut Alarm Set Voltage 21.85V 22.2V 22.2V 22.8V 22.2V
Load Cut Alarm Reset Voltage 26.0V 24.0V 24.0V 27.0V 27.0V
Load Switch Activation Delay 10 seconds 10 seconds 10 seconds 10 seconds 10 seconds

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2.10. Menu 4 – Alarm Relays Function and Test

LCD Display Screen Description

**** Menu 4 **** Screen 0 Menu Identifier

Relay Functions

Relay 1 Function Screen 1 Set Alarm Relay 1 Function:

High Volts Alarm
Set to desired function (default High Voltage Alarm)

Test Relay 1 Screen 2 To Test Alarm Relay 1 – press Select

Press --> Select
Pressing Select changes the state of the alarm relay

Relay 2 Function Screen 3 Set Alarm Relay 2 Function:

Low Volts Alarm
Set to desired function (default Low Voltage Alarm)

Test Relay 2 Screen 4 To Test Alarm Relay 2 – press Select

Press --> Select
Pressing Select changes the state of the alarm relay

Relay 3 Function Screen 5 Set Alarm Relay 3 Function:

Load Cut Alarm
Set to desired function (default Load Cut Alarm)

Test Relay 3 Screen 6 To Test Alarm Relay 3 – press Select

Press --> Select
Pressing Select changes the state of the alarm relay

Relay 4 Function Screen 7 Set Alarm Relay 4 Function:

Common Alarm
Set to desired function (default Common Alarm)

Test Relay 4 Screen 8 To Test Alarm Relay 4 – press Select

Press --> Select
Pressing Select changes the state of the alarm relay

Test Reg Mode: Screen 1 Test Regulation Mode Relays / Contacts

Night --> Select
Press Select repeatedly to cycle through Night, Boost, Equal, Float

List of Alarms available on each Programmable Alarm Relay:

Not used Alarm Relay not used
High Volts Alarm High Voltage Alarm
Low Volts Alarm Low Voltage Alarm
Load Cut Alarm Load Cut Alarm (Battery Failure)
Theft Alarm Theft Alarm (if Auxiliary Input is open circuit)
Batt Sense Alarm Battery Sense Alarm (if Battery Sensor is faulty or disconnected)
Temp Sense Alarm Temperature Sense Alarm (if Temp Sensor is faulty or disconnected)
Common Alarm Common Alarm (if any Alarm is active)
System Normal System Normal (if no Alarm is active)
Array Fail Alarm Array Failure Alarm (no voltage from Array for number of hours)

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2.11. Menu 5 – Array and Load Tests

LCD Display Screen Description

**** Menu 5 **** Screen 0 Menu Identifier

Array/Load Tests

Show Array 1 V: Screen 1 To show the open circuit Array Voltage – press Select
Press --> Select

Show Array 1 I: Screen 2 To show the closed circuit Array Current – press Select
Press --> Select

Test Array 1 Sw: Screen 3 To Test Array 1 Switch – press Select

Press --> Select
Pressing Select changes the state of the array switch

Test Load 1 Sw: Screen 4 To Test the Load 1 Switch – press Select
Press --> Select
Pressing Select changes the state of the Load Switch

2.12. Menu 6 – Time Settings

LCD Display Screen Description

**** Menu 6 **** Screen 0 Menu Identifier

Time Settings

Day Number: 1234 Screen 1 Day Number Information

Time: 12:34:56
Time Information

Set Day No: 1234 Screen 2 Set Day Number

Time: 12:34:56

Set Time: 1234 Screen 3 Set Time: Hours

Hours: 12:34:56

Set Time: 1234 Screen 4 Set Time: Minutes

Minutes 12:34:56

The Time Setting Information does not have any function in this unit.
The Day Number and Time can be set but the unit will not retain the information after losing power.

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2.13. Power Up and Configuration Screens

Display Screen Description

MSR1-10 Charge Screen 0 Power Up Screen is shown for 2 seconds after power is turned on
Controller

Configure Unit: Screen 1 The unit is designed to work at 24V only

Voltage: 24V
This cannot be changed

Configure Unit: Screen 2 The unit is designed to work as a Common Negative System
Common Negative
This cannot be changed

Calibrate Zero Screen 3 This screen is used to calibrate the individual controller during the factory
Current: Select testing procedure.

Calibrate Array Screen 4 This screen is used to calibrate the individual controller during the factory
Current: 0.00A testing procedure.

Calibrate Load Screen 5 This screen is used to calibrate the individual controller during the factory
Current: 0.00A testing procedure.

2.13.1. Power Up Screen

The Power Up Screen is shown for 2 seconds after power is applied to the Unit.
To enter the Configuration Screens, the Menu and Select switches should be pressed and held down when
the Power Up Screen is shown. When the first Configuration Screen is shown, the switches may be
released.
Under normal circumstances (when the Menu and Select switches are not pressed) after showing the
Power Up Screen for 2 seconds, the unit will automatically go to Menu 0 Screen 0.
2.13.2. Configuration Screens
IMPORTANT: The Configuration Screens should ONLY be used by authorised persons.
The Configuration Screens are intended to be used at time of manufacture to configure the software
depending on Unit Voltage and Unit Type.
CAUTION: Setting the Configuration Screens incorrectly may cause incorrect operation.
WARNING: Setting the Configuration Screens incorrectly may result in damaging the unit.
2.13.3. Configure Unit Voltage and Polarity (Screens 1-2)
These screens do not cause any change to the controller.
The design is fixed for 24V Common Negative operation.
2.13.4. Calibration Screens (Screens 3-5)
These screens are used for calibration purposes during the factory test and should not be used unless the
user understands the purpose of the screens.
2.13.5. Exiting the Configuration Screens
Pressing Menu at any time will take the user to Menu 0.
If no switches are pressed for 60 seconds then the unit will move to Menu 0.

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3. Software

3.1. Software History

Software Date Product Comments

Version Released Manual

801 972 4th March 801 973 Production Release

2013
Ver 1.0 Issue 1

3.2. Program Port

The Microcontroller can be programmed without removing it from the PCB by using the Program Port J1.
The Microcontroller can be programmed with or without power connected to it.
Remove the fascia cover and connect the PICkit2 Programmer to J1 (look for the arrow indicating pin1) as shown:

Follow the normal programming instructions.

When programming is successful, disconnect the programmer from the unit and replace the fascia cover.
3.3. Installation / Replacement of the MCU
Ensure that anti-static precautions are taken to avoid damage to the Microcontroller when handling (i.e. touch a
conductor that is connected to earth before carrying out the following):
Turn off all power to the Controller.
Remove any Fascia Cover using the plastic thumbscrews. Identify the Microcontroller (the 40 pin integrated
circuit with a label on it showing the software number and version) on the PCB Assembly. Carefully lever out the
Microcontroller presently located there by using a small flat screwdriver on both ends equally. Do this carefully.
Identify the device to be installed. Carefully handle the device without touching the legs of the device. Note the
orientation of the semi-circular notch at one end of the device. Note which end on the PCB socket has a similar
notch. Now insert the Microcontroller into the PCB socket so that the notch in the device is at the same end as the
notch in the socket. Before pressing down on the device to mate it fully in its socket, check that all pins are
properly lined up with the pins in the PCB socket. Press the device fully home into the socket and check that no
leg has been bent or missed its socket.
Replace any Fascia Cover using the plastic thumbscrews.
Restore power to the Controller.

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