Morningstar TS-MPPT-60-600V-48-DB-TR Installation, Operation And Maintenance Manual
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Morningstar TS-MPPT-60-600V-48-DB-TR Installation, Operation And Maintenance Manual

Morningstar TS-MPPT-60-600V-48-DB-TR Installation, Operation And Maintenance Manual

Solar charging system controller
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TriStar MPPT 600V
TM
with
Off-grid / Grid-tie
Transfer Switch
Solar Charging System Controller
Installation, Operation and Maintenance Man ual
For the most recent manual revisions, see the version at:
www.morningstarcorp.com
Solar Battery Charger with
TrakStar
Maximum Power Point Tracking Technology
TM
www.morningstarcorp.com
MODELS
TS-MPPT-60-600V-48-DB-TR
TS-MPPT-60-600V-48-DB-TR-GFPD
MAXIMUM POWER POINT TRACKING

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Summary of Contents for Morningstar TS-MPPT-60-600V-48-DB-TR

  • Page 1 Transfer Switch Solar Charging System Controller Installation, Operation and Maintenance Man ual For the most recent manual revisions, see the version at: www.morningstarcorp.com Solar Battery Charger with TrakStar Maximum Power Point Tracking Technology www.morningstarcorp.com MODELS TS-MPPT-60-600V-48-DB-TR TS-MPPT-60-600V-48-DB-TR-GFPD MAXIMUM POWER POINT TRACKING...

  • Page 2: Table Of Contents

    4.5 Push-button 4.6 LED Indications and Audible Warnings 4.7 Protections, Faults & Alarms 5.0 Networking and Communication 8.70 5.1 Introduction [ 221 ] 5.2 Morningstar MeterBus 5.3 Serial RS-232 5.4 EIA-485 (formerly RS-485) 5.5 Ethernet 3.34 3.06 2.82 [ 85 ]...

  • Page 3: Important Safety Instructions

    1.0 Important Safety Instructions Informations de Sécurité • Lisez toutes les instructions et les avertissements figurant dans le manuel avant de com- SAVE THESE INSTRUCTIONS. mencer l’installation. This manual contains important safety, installation and operating instructions for the • Le TS-MPPT-600V-TR ne contient aucune pièce réparable par l’utilisateur. Ne démontez TS-MPPT-600V-TR solar controller.
  • Page 4 • This charge controller is to be connected to DC circuits only. These DC connections are identified • Ce contrôleur de charge ne doit être connecté qu’à des circuits en courant continu. Ces connex- by the symbol below: ions CC sont identifiées par le symbole ci-dessous: Direct Current Symbol The TS-MPPT-600V-TR controller must be installed by a qualified technician in accordance with the Le contrôleur TS-MPPT-600V-TR doit être installé...

  • Page 5: About This Manual

    • Servicing of batteries should be performed, or supervised, by personnel knowledgeable about • Veillez à ne pas court-circuiter les câbles connectés à la batterie. batteries, and the proper safety precautions. • Ayez une personne à proximité qui puisse aider en cas d’accident. •...

  • Page 6: Getting Started

    (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. Changes or modifications not expressly approved by Morningstar for compliance could void the user’s authority to operate the equipment.

  • Page 7: Versions And Ratings

    This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the TS-MPPT-60-600V-48-DB-TR instruction manual, may cause harmful interference to radio communication. However, there is •...

  • Page 8: Features

    15 - LED Indicators Show battery state-of-charge (SOC) and controller fault conditions 16 - Remote Temperature Sensor Terminals Connection point for a Morningstar RTS to remotely monitor battery temperature 17. Push-button Switch Manually reset from an error or fault. Start/stop a manual equalization.

  • Page 9: Optional Accessories

    A modular unit that uses a USB-B plug, usually from a USB A-B computer cable, and an RJ-11 TriStar Meter 2-600V; TriStar Remote Meter 2 (Models: TS-M-2-600V; TS- plug to connect with a Morningstar controller's MeterBus port, for monitoring and programming RM-2) using MSView PC software.

  • Page 10: Installation

    Installation Recommended Tools: • Wire strippers • Pliers • Wire cutters • Drill3/32” (2.5 mm) drill bit 3.1 General Information • #2 & #0 Phillips screwdriver • Level • slotted screwdrivers • hack saw (cutting conduit) WARNING: Equipment Damage or Risk of Explosion Never install the TS-MPPT-600V-TR in an enclosure with vented/flooded batteries.

  • Page 11: Conduit Knock-Outs And Wire Routing

    3.3 Conduit Knock-Outs and Wire Routing High and Low Voltage Wiring Positions - TS-MPPT-600V-TR Knock-outs are provided for routing cables through conduit or wire glands. Table 3-1 details the knockout sizes and quantity provided on the TS-MPPT-600V-TR wiring box. Knockout placement dimensions are on the inside front cover.

  • Page 12: Controller Installation

    3.4 Controller Installation Step 1 - Remove the Wiring Box Cover CAUTION: Shock Hazard Disconnect all power sources to the controller before removing the wiring box cover. Never remove the cover when voltage exists on any of the TS-MPPT-600V-TR power connections. PRUDENCE : Risque de décharge électrique Déconnectez toutes les sources d’alimentation du contrôleur avant d’enlever le couvercle du boîtier de câblage.
  • Page 13 Step 4 - Mounting to a Vertical Surface The mounting location is important to the performance and operating life of the controller. The environment must be dry and protected from water ingress. If required, the controller may be installed in a ventilated enclosure with sufficient air flow. Never install the TS-MPPT-600V-TR in a sealed enclosure.
  • Page 14 Step 5 - Network Connections Network connections allow the TS-MPPT-600V-TR to communicate with other controllers or computers. A network can be as simple as one controller and one PC, or as complex as dozens of controllers monitored via the internet. Review section 5.0 for more information about networking and the connection(s) required for your system.
  • Page 15 NEC for both TS-MPPT-600V-TR models when the output current equals the full nameplate rating. Wire types rated for 75°C and 90°C are included. * The TS-MPPT-60-600V-48-DB-TR comes pre-wired with #6 AWG copper wire. If replacement Figure 3-9. Removing the EIA-485 socket connector is required, do not exceed #6 AWG wire.
  • Page 16 To Grid-tie Inverter Solar Input To Grid-tie Inverter Solar Input 48 Volt Battery Termination 48 Volt Battery Termination Solar Array Inputs Solar Array Inputs Up to 2 Strings Up to 2 Strings Loose Leads for Termination at a GFPD, or cut to length, and connected at the Controller Solar +/- Terminals (Step G) Figure 3-10.
  • Page 17 Connect the Power Wires WARNING: Risk of Damage WARNING: Shock Hazard Be very certain that the solar connections are made with correct polarity. Turn on the solar array breaker The solar PV array can produce open-circuit voltages in excess of 500 Vdc when /disconnect and measure the voltage on the open wires BEFORE connecting to the TS-MPPT-600V-TR.
  • Page 18 AVERTISSEMENT: Risque d’incendie. Si non Capteur de température distant (RTS) est connecté, utilisez le MPPT ProStar moins de 3m (10 pi) de les batteries. Compensation de la température interne sera utilisée si la RTS n’est pas connecté. Utilisation de la RTS est fortement recommandé. CAUTION: The TS-MPPT-600V-TR will not temperature compensate charging parameters if the RTS is not used.
  • Page 19 If a TriStar meter is installed, check the “TriStar Settings” to confirm the Voltage Sense and the Battery Type - The most common battery type associated with the specified charging settings. RTS (if installed) are both present and detected by the controller. MSView PC software can also be used to confirm the voltage sense is working correctly.
  • Page 20 Use a copper wire to connect the grounding terminal in the wiring box to earth ground. Per NEC CAUTION: Risk of Tampering 690.45 and NEC Table 250.122, the minimum size for copper grounding wire is: The Ethernet Security settings switch does not block write commands to devices bridged via EIA- 485.

  • Page 21: Operation

    Operation Step 11 - Power-Up The TS-MPPT-600V-TR modes are controlled by a manual transfer switch. After installation has WARNING: Risk of Damage been completed, there are few operator tasks to perform. However, the operator should be Connecting the solar array to the battery terminal will permanently damage the familiar with the operation and care of the TS-MPPT-600V-TR as described in this section.

  • Page 22: Trakstar Tm Mppt Technology

    The TS-MPPT-600V-TR has a 4-stage battery charging algorithm for rapid, efficient, and safe battery charging. Figure 4-0 shows the sequence of the stages. The TS-MPPT-600V-TR utilizes Morningstar’s TrakStar Maximum Power Point Tracking (MPPT) technology to extract maximum power from high voltage solar arrays commonly used in grid-tie applications.
  • Page 23 Float Stage Certain battery types benefit from a periodic boost charge to stir the electrolyte, level the cell voltages, and complete the chemical reactions. Equalize charging raises the battery voltage After the battery is fully charged in the Absorption stage, the TS-MPPT-600V-TR reduces the above the standard absorption voltage so that the electrolyte gasses.
  • Page 24 Battery Charging Settings The details of the TS-MPPT-600V-TR battery charging settings are shown in tables 4-1 and 4-2 Preparation for Equalization below. All voltage settings listed are for nominal 48 Volt battery banks. First, confirm that all of the system loads are rated for the equalization voltage. Consider that at 0°C (32°F) the equalization voltage will reach 67.00 Volts for L-16 batteries with a temperature Settings Battery...
  • Page 25 Absorption Extension Float Cancel Voltage Extended Absorption Bulk Absorption Float Bulk Absorption Float cancelled this charge cycle 50.00 V 49.20 V Absorption Extension Voltage Float Cancel Voltage time (hrs) time (hrs) 1:00 2:00 3:00 4:00 5:00 6:00 1:00 2:00 3:00 4:00 5:00 6:00...

  • Page 26: Gfpd-600V Operation

    It is critical to detect any stray current, and to interrupt (break) the circuit until safe operation can be restored. Any current imbalance between the (+) and (-) conductors of a circuit indicates a ground-fault. Morningstar’s GFPD-600V will detect this condition, and break the circuit on both the (+) and (-) legs, ensuring interruption. Operation...

  • Page 27: Led Indications And Audible Warnings

    4.6 LED Indications & Audible Warnings Battery State-of-Charge LED Indications 80% to 95% SOC Valuable information is provided by the three LEDs visible through the front cover. Although 60% to 80% SOC there are many different LED indications, they have similar patterns to make it easier to interpret 35% to 60% SOC each LED display.

  • Page 28: Protections, Faults & Alarms

    4.7 Protections, Faults & Alarms Battery Voltage Sense Failure (R+Y / G+Y) If a fault in the battery sense connection (such as a short circuit, open-circuit or loose terminal) occurs after the battery sense has been working, the LEDs will indicate a failure. If the control- The TS-MPPT-600V-TR protections and automatic recovery are important features that ensure the safe operation of the system.

  • Page 29: Networking And Communication

    Table 5-1 below provides a summary of supported features for each communication interface. Heatsink Temperature Sensor Open / Shorted The heatsink temperature sensor is damaged. Return the controller to an authorized Morningstar dealer for service. Battery Sense Out of Range / Disconnected A battery sense wire is disconnected.

  • Page 30: Morningstar Meterbus

    • view real-time data with MSView PC software **A Morningstar MeterBus Hub (HUB-1) and a TriStar Meter 2 (TS-M-2), TriStar Remote Meter 2 (TS-RM-2) or a TriStar Meter 2 600V (TS-M-2-600V) are required (not included). • log real-time data with MSView PC software •...

  • Page 31: Eia-485 (Formerly Rs-485)

    • program each controller on the network with custom charge settings using MSView the “Morningstar Communications Document” on our website at: http://www.morningstarcorp.com software • connect the TS-MPPT-600V-TR to other Morningstar controllers with the RSC-1 Serial to EIA-485 Adapter (sold separately) • bridge an Ethernet connection through a TS-MPPT-600V-TR to an EIA-485 network The EIA-485 port has four (4) connections: Power, Data A, Data B, and Ground.

  • Page 32: Ethernet

    Yellow LED Green LED This section provides a summary of each of the features. For detailed information about Ethernet Network Connection OK connectivity and networking, refer to the “Morningstar Communications Document” on our Network Activity Blinking website at: http://www.morningstarcorp.com Error...
  • Page 33 For telecom and industrial applications that require SNMP monitoring of deployed systems, the eters. Morningstar’s MSView PC software can connect to any TS-MPPT-600V-TR on the TriStar MPPT will behave as an SNMP agent and supports the following commands: Ethernet network or through a RS-232 serial connection.

  • Page 34: Testing And Troubleshooting

    • The RSC-1 adapter used to connect the PC to the EIA-485 network shows a green LED ler is between 16 and 72 vdc, and no LEDs are lit, contact your authorized Morningstar dealer for and pulses red when a connection is attempted. See the RSC-1 documentation for more service.

  • Page 35: Maintenance And Service

    ♦ Push the test button to perform a system test. Close the breaker to resume normal operation. REMARQUE : ♦ A critical fault indicates a hardware malfunction. Please contact Morningstar for instructions. Indique une procédure ou fonction importante pour l’utilisation sûre et correcte du contrôleur.
  • Page 36 • Install the TS-MPPT-600V-TR in a location that prevents casual contact. The TS-MPPT-600V-TR heatsink can become very hot during operation. WARNING: Shock Hazard Disconnect all power sources to the controller before removing the wiring box cover. • Use insulated tools when working with batteries. Never remove the cover when voltage exists on the TS-MPPT-600V-TR power connections.
  • Page 37 • Évitez le port de bijoux pendant l’installation. AVERTISSEMENT: Risque d’Explosion. • Le groupe de batteries doit être constitué de batteries du même type, fabricant et âge. Au rebut des piles est nécessaire. Ne pas jeter les piles dans le feu. Se référer aux régle •...

  • Page 38: Maintenance Schedule

    7.2 Maintenance Schedule • Porter des bottes et des gants de caoutchouc Table 7-1 below lists the recommended maintenance schedule to keep your TS-MPPT-600V-TR performing optimally. • Utiliser des outils avec poignées isolantes et évitez de placer des outils ou des objets métalliques sur le dessus de batteries.

  • Page 39: Warranty And Policies

    FIVE (5) years from before requesting technical support. the date of shipment to the original end user. Morningstar will, at its option, repair or replace any such defective products.

  • Page 40: Technical Specifications

    1. Before proceeding, please refer to product manual, including Troubleshooting section. Electrical 2. Contacting your authorized Morningstar distributor or dealer from whom you purchased the unit is the first step in the warranty process. Local dealers can often address warranty issues quickly.
  • Page 41 Grid-tie Transfer Terminal Block Solar Input and Grid-tie Output Screws: 10.6 in-lb / 1.2 N-m Mechanical RTS and Battery Sense Terminal Screws: 3.5 in-lb / 0.40 N-m TS-MPPT-60-600V-48-DB-TR TS-MPPT-60-600V-48-DB-TR-GFPD Knock-outs (trade sizes) M20 & 1/2", 3/4”, 1”, 1-1/4” Dimensions: HWD (in.) 21.4 x 8.7 x 5.9...
  • Page 42 De-ratings Output Power vs. Array Input Voltage 60 Amp Battery Current Limit Battery Current vs. Array Voltage Vb = 60 V 3500 60 Amp Battery Current Limit 3000 Array Voltage (Volts) Vb = 50 V 2500 60 Amp Battery Current Limit Vb = 40 V 2000 Array Voltage (Volts)

  • Page 43: Appendix

    10.0 Appendix Efficiency 2% Voltage Drop Charts for 75°C Stranded Copper Wire 200 Vmp, 52 Vbatt 1-Way Wire Distance (feet), 48 Volt System Amps Amps Amps Amps Amps Amps Amps Amps Amps Amps 89.6 97.8 107.5 119.5 134.4 153.6 179.2 215.1 268.9 358.5...
  • Page 44 2% Voltage Drop Charts for 75°C Solid Copper Wire 2% Voltage Drop Charts for 90° Stranded Copper Wire 1-Way Wire Distance (feet), 48 Volt System 1-Way Wire Distance (feet), 48 Volt System Amps Amps Amps Amps Amps Amps Amps Amps Amps Amps Amps...

  • Page 45: Certifications

    Modbus IDA. www.modbus-ida.org • Shaded cells in the table indicate that the current exceeds the ampacity of the wire for a © 2017 Morningstar Corporation. All rights reserved. given ambient temperature as defined in the following table: Wire Ampacity* Key Exceeds wire ampacity at 60°C ambient temperature...

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